QUALITY PROCEDURE FOR PRESSURE TEST (HYDRO)

QCP-HP110

02 12/09/2018 For approval SHAHZAD KESAVAN ANOOP

01 12/06/2016 For approval SHAHZAD KESAVAN ANOOP
Reason for Checked Approved
Rev. Date Prepared By Sign Sign Sign
Issue By By
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QUALITY PROCEDURE FOR PRESSURE TEST
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TABLE OF CONTENTS

1. Scope

2. References

3. Responsibility

4. General Requirements

5. Safety Requirements of Pressure Testing

6. Test Equipment

7. Test Preparation

8. Test Procedure

9. Lay – Up Procedure

10. Safety

11. Attachment
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1. SCOPE

This quality control procedure has been developed in order to highlighting the quality control activities

during pressure testing of metallic piping system for SATORP Project.

2. REFERENCES

 JERES-L-350 Construction of Plant Piping

 JERES-A-004 General Requirements for Pressure Testing

 JERES-A-007 Hydrostatic Testing Fluids and Lay-Up Procedures

 JERES-L-150 Pressure Testing of Plant Piping and Pipelines

 ASME B 31.3 Process piping

3. RESPONSIBILITES

3.1 The Project Manager / Piping Manager are responsible for the proper implementation of this

procedure. The Execution Supervisor or his designee shall be responsible for preparation and

performance of the hydrostatic test including cleaning in accordance with this procedure and he is

responsible for release from construction.

3.2 QA/QC Manager is responsible for the implementation of all required quality control activities such

as test and inspection for this particular job. QA/QC Engineer is responsible for the proper carrying

out of the inspection and testing details respective to this procedure.QA/QC Engineer shall prepare

hydro test package and submit to SATORP for approval prior to pressure testing.

3.3 Safety Manager / Supervisor will make sure that all the safety requirements are fulfilled prior to

start of the job. Job Safety Analysis / Safety Task Assignments will be strictly implemented. Safety
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personnel should ensure all safety requirements are fulfilled before, during and after testing.

Also they are responsible for enforcing exclusion zone during test.

4. GENERAL REQUIRMENTS

4.1 Every plant piping after construction and prior to initial operation, shall successfully pass a

hydrostatic test. The test pressure shall be in accordance with minimum requirements of ASME

B31.3 as applicable. The test pressure shall be held for a sufficient time to allow detection of any

leaks along the complete length of the piping system under test but in no case less than 30 minutes.

4.2 All joints including welds shall be left exposed for visual leak detection during the test. Coating and

priming of such joints are not allowed unless approved by the Owner. The pipe itself may be primed

and coated to a final coat.

4.3 Vents shall be provided at all high points in the piping system. Cross-country or submarine pipelines

may be exempted if a scraper will be used ahead of the test water to purge air from the lines

before the test pressure is applied.

4.5 Drains shall be provided at all low points of the piping system, excluding submarine and buried

pipelines. They shall be immediately above check valves which are in vertical position.

4.6 All welded attachments such as pipe supports and hanger lugs etc. shall be completely welded as

per the drawing, before pressure testing.

4.7 On completion of piping installation, the system will be walked down by piping engineer/QC

inspector and pretest critical component placement/removal shall be checked. Any outstanding

items identified shall be added to the punch list form

4.8 QC shall ensure that category “A” punch list items have been completed and sign by SATORP

representative prior to pressure testing.

4.9 All pressure gauges, pressure relief valves, test manifolds shall be calibrated in accordance with

JERES-A-004, JERES-L-105.

5. SAFETY REQUIREMENTS OF PRESSURE TESTING

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5.1 Hydro test shall be conducted in strict compliance with the approved test procedure. A copy of

the approved test procedure shall be kept at the job site. Prior to starting the test, the Engineer

in-charge shall obtain all required work permits, adequate working signs etc.

5.2 The system / piping network shall be pressurized slowly and not to exceed 100 PSIG per minute.

The test manifold shall be supported firmly to avoid vibration during the process of pressurization.

5.3 Calibrated pressure gauge along with vent valve on highest point and calibrated PSV and PG shall be

installed at the Manifold location. A responsible person shall be stationed at this point throughout

the duration of test to check and monitor.

5.4 Filling and pressurizing shall be done on the upstream side of check valve

5.5 Should leaks occur on any part of the system being tested, the system shall be de-pressurized to

zero Bar.

5.6 Temperature of water to be used for hydro testing shall not be less than neither 10C nor more than

50C.

5.7 Vent shall be provided at highest point. The vent shall be opened during filling and draining

operations.

5.8 Temperature equilibrium must be attained between test fluid and piping system after filling and

before applying pressure.

5.9 Hammer testing and flange tightening shall not be done while the system is under

pressure.

6. TEST EQUIPMENT

6.1 Pressure gauges and pressure recorders shall be calibrated before the tests. The calibration interval

shall not exceed one (1) month. Calibration Certificates shall be made available to Inspection

personnel prior to commencement of the pressure test. Stickers shall be applied indicating the latest

calibration date. A minimum of two dial indicating pressure gauges shall be provided at both ends

of the pipe line to be tested. All gauges shall have a range such that the test pressure is within 30

to 80% of the full range. A minimum of two pressure gages are required for the test system. One

pressure gage shall be on the test pump and the other(s) on the test system. Their accuracy shall be
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within 5% of one another. Calibration certificates shall be made available at the job site to

Inspection personnel prior to commencement of pressure test.

6.2 Pressure Relief Valve of adequate capacity set to relieve at 5% above the test pressure shall be

installed unless the test pressure is less than 85% SMYS at which time it can be set at 10% above test

pressure. Sizing of these relief valves used for testing shall follow the requirements of API RP 520,

Part 1. The relief valve(s) shall be tested, dated, and tagged within one week prior to the pressure

test. Calibration reports shall be available at the job site for review.

6.3 Hydro test Pump - adequate rating pump to meet test pressure requirements shall be used.

6.4 Hydro test Manifold shall be pressure tested at least 1.2 times of system test pressure but not less

than the discharge pressure of the pump used for the pressure testing before employing the

pressure testing manifold in the actual system pressure test. All pipe, fittings, flanges and

materials used for pressure testing shall be in accordance with the governing piping material

specification for the piping system.

7. TEST PREPARATION

7.1 An approved test procedure shall be available at the site prior to commencing any pressure testing

activities. Test boundaries limit shall be clearly marked on ISO & P&ID. When testing is done in

existing construction/isolation/blinding location shall be tagged and witnessed by area operator.

Each isolation/blinding location shall have unique identification number, which shall be record on

blind control list.

7.2 Each section of the system shall be examined by the assigned QA/QC representative to make sure

it is cleaned by blowing the air / applicable method.

7.3 Soft seated valves and control valves shall not be installed until after the lines have been thoroughly

flushed. All valves, excluding those used for sectioning or blocking test shall be in the open position.

7.4 Components which interfere with filling, venting, draining or flushing shall not be installed until after

line flushing and pressure testing are completed. These include orifice plates, flow nozzles, sight

glasses, ventures, positive displacement and turbine meters and other in-line equipment.

7.5 The following list defines the equipment that shall be excluded from the pressure test loops.

 Strainers and filter elements.

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 Pressure relieving devices, such as rupture disks and pressure relief valves.

 Locally mounted indicating pressure gauges, where the test pressure may exceed their scale

range.

 Equipment that cannot be drained.

7.6 Hydrostatic test diagrams shall be prepared and made available prior to test. The test diagram shall

include the limits of piping and equipment included in each hydro test.

7.7 A test package shall be prepared to confirm the clearance of all NDT and completion of category

“A” punch list and etc. before hydro test.

7.8 Hydro test package shall be submitted to SATORP prior to hydro test for review and

approval.

8. TEST PROCEDURE

8.1 The area around the system to be tested shall be cleared of unauthorized personnel and warning

notices posted during the time that the piping system is pressurized for the test.

8.2 The test fluid shall be injected at the lowest elevation to minimize the entrapped air. The vent

shall be kept open during filling.

8.3 pressure shall be raised at 05 Bar/min slowly up to 50% of the test pressure. Carry out preliminary

checks for leaks. The pressure shall be increased slowly until 100% of test pressure is reached.

Isolation valve between temporary test manifold and piping shall be closed and the test pump

disconnected after the test pressure is reached, before commencement of inspection in the

system.

8.4 Pressure Relief Valve of adequate capacity set to relieve at 5% above the test pressure shall be

installed unless the test pressure is less than 85% SMYS at which time it can be set at 10% above

test pressure. In addition to the pressure relieving device, a bleed valve shall be provided to

protect the piping and equipment from overpressure. The bleed valve shall be readily accessible in

case immediate depressurization is required. An isolation valve shall be provided between the

pressure testing manifold and the system being tested.

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8.4 The test pressure shall be maintained for a minimum of 30 minutes for above ground piping and 2

hrs for underground pipes. The pressure must be maintained for a sufficient time to determine that

there are no leaks.

8.5 Upon successful completion of hydrostatic test, a test report shall be prepared as per enclosed

format and line shall be depressurization of the system shall be carried out in controlled manner.

8.6 The test water shall be disposed safely. During draining vents shall be kept open to avoid any

negative pressure in the system. Vents and drains used only for the pressure test shall be blinded.

8.7 All temporary items installed for testing purpose shall be removed and items that were removed for

testing shall be reinstalled.

9. LAY UP PROCEDURE

9.1 The hydrostatic test and the lay-up procedure must be planned to protect the most corrosion-

susceptible material in the system. The time between introducing hydrostatic test water and

commissioning the equipment must be minimized. The hydrostatic test should be performed as close

as possible to the start-up date.

9.2 The addition of an oxygen scavenger to the hydrostatic test water shall be required where the

equipment contact time with water is likely to exceed 14 days. Treat the water before it enters

the system.

9.3 Equipment must be laid-up after hydro testing unless it can be ensured that it will be returned to

service within 30 days from the first introduction of hydro test water to the system.

9.4 Drying the entire system shall be carried out with hot dry air or by natural drying. Hot Air blowing

shall be performed in the methods of blowing pressurized oil free air, until there remains no scale

in the piping.

10. SAFETY

Al-Amara Safety Supervisor shall carry out the safety site inspections to ensure that safety

requirements laid out in the safe work plan are followed during the testing. Safety sign boards and

proper barricade to be provided for unwanted entry during testing. AL Amara Safety Manager /

Supervisor shall review Safety Action Plan and secure Work Permit if necessary prior to start of any
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activities. JSA /STA to be filled and to be available at site while conducting test.

11. ATTACHMENT