Hydrostatic Leak Testing Procedure

Authorized By:

____________________________
Maintenance Manager

Methanex Corporation
Medicine Hat, AB

Copy: 01
Revision Date: October 21, 2003
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 TABLE OF CONTENTS
HYDROSTATIC LEAK TESTING PROCEDURE

1. POLICY ..................................................................................................................................................... 3

2. PURPOSE................................................................................................................................................. 3

3. SCOPE...................................................................................................................................................... 3

4. RESPONSIBILITY .................................................................................................................................... 3

4.1 Legal requirements .............................................................................................................................. 3

5. DEFINITIONS............................................................................................................................................ 4

6. PROCEDURE ........................................................................................................................................... 4

6.1 Test Water Criteria .............................................................................................................................. 5

6.2 Examination and inspection................................................................................................................. 6

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Hydrostatic Leak Testing Procedure

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1. POLICY

Not identified at present; will be addressed at the next review of this document.

2. PURPOSE

The purpose of this policy is to establish a safe practice for hydrostatic leak testing pressure containing
components. Maintenance personnel and contractors shall follow this procedure to ensure minimum code
requirements are met.

3. SCOPE

Not identified at present; will be addressed at the next review of this document.

4. RESPONSIBILITY

A hydrostatic test project co-ordinator will be appointed each time a hydrotest is contemplated using
methanol.

The project co-ordinator as appointed has direct responsibility to ensure all aspects of this guideline are
adhered to.

The project co-ordinator shall ensure that all testing medium is vented, drained and disposed of in a
manner acceptable to Methanex Responsible Care standards.

The project co-ordinator shall ensure special precautions are taken in case of a spill caused by a
component failure.

The quality control inspector is to ensure all code requirements are adhered to.

4.1 Legal requirements

The legal requirements for hydrostatic leak testing are outlined in, but not restricted to the following codes:

· ASME B-31-3 (345)

· ASME B-31-1 (137.4)

· ASME Section VIII Division I (General Requirements)

· ASME Section I (Pg. 99)

· The Methanex QC Manual

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Hydrostatic Leak Testing Procedure

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 NOTE: In all cases the most stringent requirement will apply where this guideline
conflicts with the above codes.

5. DEFINITIONS

Not identified at present; will be addressed at the next review of this document.

6. PROCEDURE

Prior to initial operation, each pressure containing component or system shall be hydrostatic leak tested in
accordance with the applicable code. In certain instances alternative testing may be approved by
inspection as allowed by the appropriate code section.

Suitable precautions shall be taken to eliminate hazards to personnel in the proximity to systems being
tested in the event of a system failure.

Test pressures shall be calculated using applicable code formulas for design conditions.

The test pressure shall be stamped on the work order, indicated on engineering drawings or outlined on
the project quality plan.

Pressure test calculations are the responsibility of the Senior Inspector or his designate for maintenance
work orders and capital projects.

A project quality plan and a hydrostatic test pressure calculation sheet shall accompany every engineering
package where temperature or yield strength impacts the test pressure.

Hydrostatic test pressures in no case shall be less than the design pressure or maximum allowable
working pressure.

If the calculated test pressure produces a stress in excess of the yield strength at the test temperature, the
test pressure may be reduced to the maximum pressure that will not exceed the yield strength.

Minimum metal temperature for all components during a test shall be as specified in the reference code
section.

Equipment not to be tested shall be either disconnected from the piping or isolated by blinds or other
means during the test. At the Inspector’s discretion, a valve may be used for isolation provided the valve
body and the closure mechanism is suitable for the test pressure. Blinds shall be in accordance with
Table 1 Maximum Allowable Hydrostatic Test Pressure (PSIG) for Listed Blank Thickness.

Expansion joints shall be provided with temporary restraint if required for additional pressure load under
test or they may be isolated during the system test.

High point vents are required on all systems to eliminate trapped air. Air may be vented by loosening
flanges if they are at the highest point in the system.

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Dial indicating gauges used in testing should be graduated over a range of about double the intended
maximum test pressure but in no case shall the range be less than one-and-one-half (1 1/2) times nor
more than four (4) times that pressure.

Pressure gauges shall be calibrated using a dead-weight tester and standard practice recognized for this
type of calibration.

Two pressure gauges shall be used on all tests. For vessels and boilers, one of the gauges is to be
mounted directly on the vessel at the highest practical point and one gauge mounted near the pump
operator for test pressure monitoring.

All gauges are to be marked with identification numbers and calibration expiry date.

When specified by the Senior Inspector, a recorder chart indicating temperature and pressure may be
required for hydrostatic testing. The recorder shall be calibrated using a dead-weight tester and standard
practice recognized for this type of calibration.

At the Inspector’s discretion, the capillary bulb (for temperature measurement) may be fastened to the
outside of the component being tested or may be in contact with the test medium.

The test fluid shall be water unless there is a possibility of damage due to freezing. In this case water
and/or methanol may be used. Where possible, a water and methanol solution containing the smallest
concentration of methanol (%) must be considered. This would increase the flash point temperature of
the testing medium. (For methanol/water solutions, see Figure 2 Freezing Points of Methanol - Water
Solutions. For boiling and flash points of the solution, see Figure 1 Boiling and Flash Points of Methanol -
Water Solutions. Consideration to B31.3 Paragraph 445.4.1 is required when testing B31.3 piping using
water/methanol blends.

Hydrostatic testing shall not be carried out using methanol unless approval is obtained from the Senior
Inspector, the Maintenance Manager and the Operations Manager. The environment and quality care co-
ordinator or the responsible care co-ordinator must be notified.

6.1 Test Water Criteria

Care shall be taken to ensure the use of clean water for these tests. A suitable filter should be provided in
the fill line to the systems should foreign matter such as sand, rust or other particles be in evidence in the
proposed test water.

Water used for hydrostatic testing of austenitic stainless steel piping, vessels, and equipment including
those with austenitic stainless steel claddings, linings or internals (including valve trim) shall conform to
the requirements listed below. These requirements apply also to 12% chrome claddings or linings that are
welded with austenitic stainless steel weld filler.

· Water containing more than two hundred (200) ppm chlorides shall not be used.

· Water containing more than fifty (50) but less than two hundred(200) ppm chlorides shall be
treated with an inhibitor of 1.5% soda ash and 0.5% sodium nitrate. The chloride content of
the soda ash and sodium nitrate shall not exceed 500 ppm. These percentages are by
weight.

· Water containing less than fifty (50) ppm chloride does not require inhibitor treatment.

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 · Piping, vessels and equipment must be drained thoroughly after testing. Where complete
drainage is impossible, the system shall be flushed free of all test water using boiler
condensate or demineralized water containing less than five (5) ppm chlorides, alcohol,
petroleum distillate or another suitable flushing solution. Hot air drying is not acceptable in
lieu of flushing, but water may be blown out of pockets using air.

6.2 Examination and inspection

The system or equipment shall be visually examined by the inspector prior to hydrostatic testing.

All joints including welds and bonds are to be left uninsulated and exposed for examination during a
hydrostatic test. All joints are to be left unprimed and unpainted unless specifically approved by the Senior
Inspector.

A hydrostatic leak test shall be maintained for at least ten (10) minutes and all joints and connections shall
be examined for leaks.

The system exclusive of possible pump or valve packing leaks shall show no visible evidence of weeping
or leaking.

Acceptance of valve packing leaks shall be at the inspector’s discretion.

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 Table 1 Maximum Allowable Hydrostatic Test Pressure (PSIG) for Listed Blank Thickness

NOMINAL PIPE SIZE

1.5” 2” 2.5” 3” 4” 6” 8” 10” 12” 14” 16” 18” 20” 24” 30”
PLATE
1/4 2,525 1,507 1,079 713 456 221 135 89 64 53 41 33 27 19 10
3/8 5,680 3,392 2,428 1,603 1,026 496 304 200 143 120 93 73 60 42 23
1/2 6,030 4,317 2,850 1,824 883 540 356 255 213 165 131 107 74 41
5/8 9,421 6,746 4,453 2,850 1,379 844 557 398 333 258 204 166 116 64
3/4 9,714 6,413 4,104 1,986 1,215 802 574 480 371 294 240 167 93
7/8 8,728 5,586 2,703 1,654 1,091 781 653 505 400 326 228 126
1 7,296 3,530 2,161 1,425 1,020 853 660 522 426 298 165
1 1/8 9,234 4,468 2,735 1,804 1,290 1,079 835 661 539 377 209
1 1/4 5,516 3,376 2,227 1,593 1,332 1,031 816 666 465 258
1 3/8 6,674 4,085 2,694 1,928 1,612 1,248 987 806 563 312
1 1/2 7,943 4,861 3,207 2,294 1,919 1,485 1,175 959 670 371
1 5/8 9,322 5,705 3,763 2,692 2,252 1,743 1,379 1,125 786 436
1 3/4 6,617 4,365 3,123 2,612 2,021 1,599 1,305 912 505
1 7/8 7,596 5,010 3,585 2,998 2,320 1,836 1,498 1,047 580
2 8,643 5,701 4,078 3,411 2,640 2,089 1,705 1,191 660
2 1/4 7,215 5,162 4,317 3,341 2,644 2,158 1,507 835
2 1/2 8,907 6,373 5,330 4,125 3,264 2,664 1,861 1,031
2 3/4 7,711 6,449 4,991 3,950 3,223 2,252 1,248
3 9,177 7,675 5,939 4,700 3,836 2,680 1,485
3 1/4 9,007 6,971 5,517 4,501 3,145 1,743

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 NOMINAL PIPE SIZE
1.5” 2” 2.5” 3” 4” 6” 8” 10” 12” 14” 16” 18” 20” 24” 30”
PLATE
3 1/2 8,084 6,398 5,221 3,648 2,021
3 3/4 9,280 7,344 5,993 4,187 2,320
4 8,356 6,819 4,764 2,640

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 Figure 1 Boiling and Flash Points of Methanol - Water Solutions

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Hydrostatic Leak Testing Procedure

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 Figure 2 Freezing Points of Methanol - Water Solutions

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