Job Code 0-7577-20

Owner’s Doc. No.

SONATRACH Contractor’s Doc.

S-3000-3160-002
HASSIR'MEL BOOSTING No.
PHASE III PROJECT Sheet 1 OF 12

SONATRACH
Activité E&P
Pôle Exploitation & Production
Division Production
Direction Régionale Hassi-R’mel

REALISATION DES INSTALLATIONS DE SEPARATION ET DE

COMPRESSION ENTREE BOOSTING PHASE III
Contract N° : E/05/SH/E-P/DP/HR/2016

CONSTRUCTION PROCEDURE
FOR
PIPING PRESSURE TESTING

REV. DATE PAGE ISSUE PURPOSE/DESCRIPTION PREP’D CHK’D APP’D

A 22-MAR-2018 All For Information E. Cristales. S.Seyama T. Sakaue

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Piping Pressure Test Procedure
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INDEX

1 Scope 3
2 Purpose 3
3 Standard Regulation and Codes 3
4 Definition 4
5 Hydrostatic Test Procedure 5
5.1 Documentation 5
5.2 General Requirements for Hydrostatic Pressure Testing 5
5.3 Additional Situation Where Hydrostatic Pressure Testing is Required 6
5.4 Pneumatic in Lieu of Hydrostatic Testing 6
5.5 Alternative Leak Tests 7
5.6 Structural Modifications for Hydrostatic Testing 7
5.7 Test Media 7
5.8 Weather Conditions 9
5.9 Filling 9
5.10 Testing Equipment 10
5.11 Application of Test Pressure 10
5.12 De-pressuring 11
5.13 Retesting 12

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Contractor’s Doc. No. S-3000-3160-002 Rev. A
Piping Pressure Test Procedure
Sheet 3 OF 12

1. SCOPE

This procedure covers the requirements and method of pressure testing of pipe spool
and piping system under the jurisdiction of the latest edition of ASME B31.3 applicable to
HassiR'mel Boosting III Project, Wilayah de Laghouat, Algeria.

The following are excluded from the requirements of this Specification.

a. Any package unit previously tested by the Manufacturer in accordance with the
applicable codes.
b. Atmospheric sewer and drain
c. Plumbing system, which are tested in accordance with the applicable
plumbing codes.
d. Lines and system open to the atmosphere provided it is Category "D" fluid.
e. Instrument piping lead lines between the root valve at the process or utility
line and the connected instrument and control piping used to connect air or
hydraulically operated control apparatus.
f. Liquid petroleum transportation pipelines systems under the jurisdiction of
ASME B31.4.
g. Gas Transmission and distribution pipelines systems under the jurisdiction of
ASME B31.8.

2. PURPOSE

The purpose of this Specification is to prescribe the methods, task, scope, and criteria for
testing pipe spools and installed piping systems for HassiR'mel Boosting III Facilities
Projects.

3. STANDARD REGULATION AND CODES

3.1 Work shall be in accordance with the latest revision of all applicable Codes,
Standards Specification and Regulation listed below . The term "latest
revision" shall be interpreted as the revisions including addenda of the
publications effective on the date of purchase order or contract
award. Except as modified by the requirements specified herein or
the details of the drawings, all Work governed by the Specification shall

D R A comply with the applicable provisions of the referenced publications.

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Piping Pressure Test Procedure
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3.2 American Society of Mechanical Engineers (ASME)

ASME B16.5 Pipe Flanges and Flanged Fittings, NPS 1/2 Through
NPS 24 Metric/Inch Standard
ASME B16.20 Metallic Gaskets for Pipe Flanges
ASME B16.21 Non-metallic Flat Gaskets for Pipe Flanges
ASME B16.34 Valves-Flanged, Threaded, and Welded End
ASME B16.47 Large Diameter Steel Flanges, NPS26 Through
NPS 60
ASME B31.3 Process Piping
ASME BPV Code Sec V Non-destructive Examination

3.3 Standard and Project Specification

S-3000-1360-002 Piping Material Specification

S-3000-1360-011 Specification for Identity of Piping Material
S-3000-1670-001 Field Quality Control Plan and Procedure
S-3000-1670-101 Field Quality Control Plan for Sub-Contractor
S-3000-1670-301 Requirement of Algeria Local Authority
S-3000-1676-501 Inspection and Test Plan for Piping Works
S-3000-3116-001 Construction Specification for UG Piping
Work
S-3000-3160-101 Piping Cleanliness Procedure
S-3000-3160-104 Test Package Handling Procedure

4 DEFINITIONS

Contracting Authority or CA SONATRACH Activite Amont,

Division Engineering et Construction

Contractor JGC Corporation / JGC Algeria S.P.A.

DPEM Direction des Petrimoines Energétiques et Miniers

(Algerian Ministry of Energy and Mines)

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ARH L'Agence Nationale de Controle et de Régulation des

Activités dans le domaine des Hydrocarbures

5 HYDROSTATIC TEST PROCEDURE

5.1 Documentation

5.1.1 A Test Package document will be prepared for each test. Each test will have
the same test pressure throughout and isolated from the adjoining
systems with blind flanges or test blinds, as per Test Diagram referenced.
5.1.2 The hydrostatic test package test result will be documented as per ASME
B31.3-paragraph 345.2.7 which include the following: Date of Test,
Identification of Piping System tested, Test Fluid, Test Pressure and
Certification of result by Examiner
5.1.3 DGM/DMI, CA representative, Contractor and Sub-Contractor
Representative who executed the test shall sign the form-Piping Test
Pressure Certificate. Pressure, temperature and time recordings shall be
incorporated to the certificate which will be included as part of the permanent
record. This applies in the Test System which requires DPEM/ARHI
supervision.
5.1.4 Other Test Systems that are excluded from DPEM/ARH supervision, the
form- Piping Test Pressure Certificate will have no DGM/DMI signature.
Instead N/A or Not applicable will be written.
5.1.5 Contractor Representative shall ensure that the pressure test certificates fully
define the scope of the test, isolated equipment, date executed and results
obtained. This can be achieved by marking on the relevant Test Diagram.

5.2 General Requirements for Hydrostatic Pressure testing

5.2.1 The test pressure stated in the hydrostatic test package should agree with
that stated in the line list. Per ASME B31.3 code, the hydrostatic test
pressure shall be 1.5 times the design pressure. When the design
temperature exceeds the test temperature, the minimum design pressure is
as per Paragraph 345.4.2 of ASME B31.3
5.2.2 All pressure testing operations shall be performed with knowledge of and to
the satisfaction of the CA representative

D R A
5.2.3 Pressure testing may proceed only after all punch items have been
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satisfactorily completed upon the satisfaction of Contractor's and CA

representatives. Instrumentation, control valves, rotating equipment, and
pressure vessels should be removed or isolated and not subjected to
pressure testing.
5.2.4 In case where the vessel is to be included in the test, Contractor's
Representative shall ensure that the test pressure applied at shop shall be
the same if not higher than the test pressure of the piping system. Safety
Instruction Data Sheet of the vessel shall be verified to ensure compliance. In
addition, approval from CA shall be secured for this purpose.
5.2.5 The conditions under which hydrostatic testing takes place will be specified in
the Test Package. These conditions include fluid used for testing, operating
pressure, temperature and service of the system.
5.2.6 A Test Package compose of Isometric drawings, test diagram, including
welding and NDE reports, air blowing or water flushing reports, pressure
gauges calibration report, punch list Items initiated by Contractor and cleared
by subcontractor shall be submitted to CA for final approval prior testing.
5.2.7 The Contractor Representative is to confirm that the details of the isometric,
P&ID and piping plan drawings agree for each line tested.
5.2.8 Underground piping that is subject to a hydrostatic test pressure test shall be
tested by holding the pressure test for 24 hours in lieu of a visual inspection.
Firewater system shall be tested by holding the pressure for 2 hours as
recommended by NFPA. Documentation shall reflect the test duration and all
changes in temperature and pressure shall be recorded.

5.3 Additional Situations Where Hydrostatic Pressure Testing is Required

5.3.1 Hydrostatic pressure tests are to be repeated if any revisions (i.e. heat
treatment, grinding, cutting or welding of piping or equipment) are made after
initial hydrostatic pressure test unless waived by CA Representative.
5.3.2 If piping and/or equipment is subjected to metal temperatures near the
ductile-brittle transition temperature, leak testing is to be performed to identify
the possibility of brittle fracture.

5.4 Pneumatic in Lieu of Hydrostatic Testing

5.4.1 Part of a test package maybe pneumatically pressure tested in accordance

D R A with ASME B31.3-Paragraph 345.5, Pneumatic Test Procedure, when it is

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impracticable to hydrostatically pressure test that part of the package. The

substitution of a pneumatic pressure test shall be subject to the approval of
CA Representative.
5.4.2 Pneumatic test shall be 1.1 times the piping systems design pressure per
paragraph 345.5.4

5.5 Alternative Leak Tests

5.5.1 A low pressure piping system that meets the criteria for "Category D" service
as defined in ASME B31.3-paragraph 345.1a maybe pressure tested with its
own service product at the system's intended operating pressure. The
pressure will be increased at intervals until the test pressure is reached. At
each interval, the pressure level will be held long enough to equalize piping
strains.
5.5.2 Piping systems which maybe classed as "Category D" service include those
in water, air, inert gas, or lubricating oil service (utility piping system
operating at a pressure of 150 psig (10 barg) or less and with a temperature
range of -20°F to 330°F (-29°C to 166°C)

5.6 Structural Modifications for Hydrostatic Testing

5.6.1 A piping spool maybe hydrostatically pressure tested prior to installation

when there is good cause for pre-testing, e.g. to avoid the liquid load of
overhead lines on the vessels and tanks; such pre-testing shall be subject to
the approval of CA Representative.
5.6.2 Piping designed for vapor or gas shall be provided with additional temporary
support, where necessary, to support the weight of the test medium.

5.7 Test Media

5.7.1 The medium employed for the hydrostatic pressure testing of a test package
shall be acceptably clean or de-mineralized water, as specified on the
applicable hydrostatic test diagram provided with the hydrostatic test
packages.
5.7.2 Hydraulic oil system will be pressure tested with medium it contains during
normal operations.

D R A
5.7.3 Water shall not be used as a test medium for instrument air piping; this piping
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shall be pneumatically tested.

5.7.4 Any test fluid that contains suspended solids shall not be used where there is
a possibility that residue might enter and plug small lines.
5.7.5 The medium to be used for testing shall be agreed with the CA
Representative.
5.7.6 Water used for hydrostatic pressure testing shall be corrosion inhibited and
de-oxygenated when the test medium is foreseen to stay longer in the test
system, due to the test system configuration that will prolong final acceptance
until water evacuation from the system takes place
.
A) Where test water is left in test system less than thirty (30) days:
1) Corrosion inhibitors

a) S/N 26-502-341 Corexit 7730-1 gallon/20,000 gallons of test water

b) S/N 26-502-649 Corexit 7711-2X- 1 gallon/30,000 gallons of test water

2) Oxygen Scavenger

a) S/N 26-502-652 kontol 490- 1 gallon/10,500 gallons of test water

b) S/N 26-502-655 Oxygen Scavenger 7790- 1 gallon/10,500 gallons of
test water.

B) Hydrostatic test water remaining in a line more than 30 days shall have the
dosage rates of the inhibitor and the oxygen scavenger double that specified
above.

C) In case draining will take effect less than a week, chemical treatment of the
test medium will not be applied. Instead, a positive pressure in the system
shall be maintained until water evacuation is carried out.

5.7.7 Corrosion inhibition and de-oxygenating chemicals shall be injected into the
system continuously during filling to obtain thorough mixing. If, continuous
injection is not possible, the chemical shall be batched into the test lines in
three equal installments to help spread the inhibitor and oxygen scavenger
throughout the system. The first batch of chemicals shall be injected before

D R A filling begins.
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5.7.8 Diesel fuel maybe used as the pressure test medium where there is a
possibility that the operating fluid or certain pieces of equipment could be
adversely affected by water, unless diesel fuel could also damage equipment
(i.e. desiccant, mole sieve and etc.)
5.7.9 A preliminary air leak test at 25 psig (1.7 barg ) shall be performed to locate
major leaks on any line that is to be pressure tested with a flammable liquid.
5.7.10 The air in any piping system that is to be pressure tested with flammable
liquid shall be purged prior to the introduction of the flammable liquid into the
system. Diesel fuel used for pressure testing shall have a flash point greater
than 120°F ( 49°C ).
5.7.11 De-mineralized water with a chloride content of less than 25 ppm shall be
used for the pressure test medium for chromium-nickel austenitic steel,
stainless steel, aluminum and aluminum alloys piping systems.
5.7.12 De-mineralized water shall be used as the medium for all pressure tests that
require the test medium to be chloride free. De-mineralized water shall not be
mixed with other water.
5.7.13 The CA shall be responsible to supply the hydrostatic test water except for
de-mineralized water which will be supply by Contractor. Contractor shall run
temporary lines as required for flushing and hydrostatic test used.

5.8 Weather Conditions

5.8.1 Due attention shall be paid to the effects of high/low ambient temperatures
occurring during the test.
5.8.2 Outdoor piping system shall not be tested during inclement weather. No
hydrostatic test shall be performed or continued during periods when the
ambient temperature is below 35°F (1.7°C)
5.8.3 Care shall be taken to prevent damage to pipe work by the formation of ice
during freezing or potentially freezing weather. Under these circumstances,
the system may require complete draining before the end of work each day,
even if testing of the system is not complete.

5.9 Filling

5.9.1 When filling a test package, test fluid shall be injected at the lowest point in

D R A the system to minimize the risk of entrapped air. All vents shall be opened to
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ensure the complete displacement of air from the piping.

5.9.2 Extreme care shall be given to remove all entrapped air while filling a system
to minimize pressure fluctuation during testing.
5.9.3 The temperature of the testing medium, piping, vessels and any other
interconnected equipment in a test package shall be equalized prior to the
application of the test pressure.

5.10 Testing Equipment

5.10.1 Pressure test gauges shall be installed at high and low points of the system.
The gauge situated at the highest point shall indicate whether the system
pressure has reached the required hydrostatic test pressure.
5.10.2 For documentation purposes, pressure, temperature and time recordings
shall be used on a regular basis with a calibration record maintained.
5.10.3 All test gauges shall be given an individual reference number. Calibration
period shall be followed manufacturer’s recommendation.

5.11 Application of Test Pressure

5.11.1 To ensure that the required test pressure is not exceeded during
pressurizing, a test manifold shall be provided with pressure gauge and
isolation valve so that a permanent watch man can control and regulate the
valve not to exceed the test pressure.
5.11.2 The operator responsible for applying the test pressure shall be fully
instructed as to the required test pressure and he shall fully understand that
the test pressure is not to be exceeded.
5.11.3 A test package shall be pressurized at a maximum rate of 100 psig (7 barg )
per minute.
5.11.4 When pressuring any system, continuous attendance and supervision shall
be maintained at the test pump. The pressure gauges shall be monitored
throughout the duration of the test .
5.11.5 Access to high pressure test areas should be restricted to those persons
required to conduct the test.
5.11.6 During the hydrostatic test, the test duration shall be held and maintained for
a minimum of 30 minutes up to a maximum of 2 two hours depending on
each Test Package System subject for the approval of CA and or

D R A DPEM/ARH Representatives.
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5.11.7 While the Test System is under test pressure, the test pump shall be isolated
from the system and continuous monitoring for leaks carried out over the
entire system. Every mechanical or welded joints and attachment shall be
checked.
5.11.8 Close visual inspection for leakage during a pressure test shall be made with
caution. There shall be no hammer testing of a system under pressure.
5.11.9 Precaution shall be taken to avoid over-pressuring of a test package due to
thermal expansion of the test medium, throughout the test period. Equipment
filled with testing medium shall not be allowed to stand without venting to the
atmosphere, since temperature changes may build up excessive pressure or
vacuum. Test personnel shall be at the test site at all times during the test
period.
5.11.10 The minimum temperature of the testing medium, piping and equipment in
the test package shall be 40°F(4.5°C) for pipe having a wall thickness of
12.7mm or less, 50°F (10°C) for pipe having a wall thickness of 19.05mm.
This minimum temperature maybe reduced with the approval of CA
Representative.
5.11.11 Two or more lines 24 inches in diameter or greater on the same pipe rack,
which do not normally carry liquid, shall not be hydrostatically pressure tested
at the same time.
5.11.12 Adjacent vessels on a common foundation or structure shall not be filled or
hydrostatically tested simultaneously.
5.11.13 All mechanical joints and weld shall be exposed while testing in progress,
except on buried piping where a 24 hour test is acceptable.

5.12 De-pressuring

5.12.1 When testing is completed to the satisfaction of the DPEM/ARH, the CA and
the Contractor's Representatives, shall witness the gradual release of
pressure and drain down. Test systems shall be depressurized by opening
the de-pressuring valve in the test manifold and drained by opening all the
vents and low point drain valves. Adequate venting should be effected to
avoid vacuum conditions.
5.12.2 All drained lines should be dried by purging with dry oil free air.
5.12.3 The timing and manner for de-pressuring a test package and draining the test
medium shall be subjected to the approval of CA and Contractor's

D R A Representatives.
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5.12.4 Tanks or vessels not equipped with vacuum relief valves may collapse when
drain unless suitable precautions are taken. A pressure gauge reading shall
be recorded for each tank or vessel when it is full but not depressurized. The
test pressure shall not be allowed to fall below this recorded pressure when
the test pressure is released; The top manway cover shall be removed with
the drain valves closed at this initial pressure. After removal of the top
manway cover, the tank or vessel may then be drained.

5.13 Retesting

5.13.1 Any leaks found during pressure testing shall be corrected and approved by
CA and Contractor's Representatives. The specified pressure test shall be
re-applied after the completion of any required corrections or repairs.
5.13.2 The CA's Representative may waive the above re-testing when the repairs or
additions are minor and suitable precautions are taken to assure sound
constructions.
5.13.3 Flanged joints at which a blank is inserted to blind off other equipment during
a pressure test need not be re-tested. All flanged joints broken or damaged
for a test shall be remade with new gaskets.

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