GP 05-03-01 Pressure Testing of Unfired Pressure Vessels December 2009

Pressure Testing of Unfired Pressure

Vessels
GP 05-03-01

Scope
[I] This Global Practice (GP) covers the pressure testing of pressure vessels, including TEMA type,
double pipe, and air-cooled heat exchangers.

Refining/Chemicals, Downstream
For Company Use Only Version 1.3.0
Imperial Oil

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Copyright Waiver
ExxonMobil Development Company and ExxonMobil Pipeline Company hereby license the use of ExxonMobil Engineering Practices System (EMEPS) Global Practices (GPs) for
use by any ExxonMobil division, subsidiary, or more-than-50%-owned affiliate. The GPs may be downloaded and modified as necessary for project and affiliate use. Written
permission from ExxonMobil Development Company or ExxonMobil Pipeline Company is not required. However, any modified GPs must be renumbered to a project-specific or
affiliate-specific number to distinguish them from the GPs on the EMEPS web site. ExxonMobil operated joint ventures may utilize GPs to create project-specific or location-specific
specifications. It is the responsibility of individual affiliate or joint venture to ensure that the use of GPs and their derivatives is limited to joint venture related business and not
disclosed or used outside the JV without appropriate EM management approval.
 GP 05-03-01 Pressure Testing of Unfired Pressure Vessels December 2009

Table of Contents

1. Required References...............................................................................................3
1.1. Global Practices-ExxonMobil Engineering Practices.....................................3
1.2. ASME-American Society of Mechanical Engineers........................................3
2. Definitions................................................................................................................3

3. Test Procedures.......................................................................................................3
3.1. Pressure Levels..............................................................................................4
3.2. Duration..........................................................................................................5
3.3. Temperature Requirements............................................................................5
Record of Change............................................................................................................6

Attachment: Purpose Codes Definitions......................................................................8

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 GP 05-03-01 Pressure Testing of Unfired Pressure Vessels December 2009

1. Required References
[I] This Section lists the practices, codes, standards, specifications, and publications that shall be used
with this document. Unless otherwise specified herein, use the latest edition.

1.1. Global Practices-ExxonMobil Engineering Practices

GP 18-10-01 Additional Requirements for Materials

1.2. ASME-American Society of Mechanical Engineers

ASME SEC VIII D1 BPVC Section VIII - Rules for Construction of Pressure Vessels -
Division 1
ASME SEC VIII D2 BPVC Section VIII - Rules for Construction of Pressure Vessels -
Division 2 Alternative Rules

2. Definitions
Term [I] Definition

MAWP Maximum Allowable Working Pressure (MAWP) is the maximum

allowable pressure at the design temperature in the corroded condition.
MAWP is determined by calculation using the actual thickness less the
corrosion allowance in accordance with ASME SEC VIII D1, Paragraph
UG-98.
MDMT The MDMT is the Minimum Design Metal Temperature at the MAWP
in accordance with ASME SEC VIII D1.

3. Test Procedures
1) [S] [A] Pneumatic testing with vessels partly or completely filled with air is not permitted unless
approved by Owner. When such testing is approved, the test pressure shall meet the minimum
requirements specified by ASME (ASME SEC VIII D1 and ASME SEC VIII D2), and the testing
procedure shall be submitted to the Owner's Engineer. The test temperature shall be per GP 18-10-
01.
2) [R] Vessels with internal non-metallic linings or protective coatings shall be pressure tested before
the application of such linings or coatings.
3) [R] Vessels shall be pressure tested before external painting of pressure containing welds.
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 GP 05-03-01 Pressure Testing of Unfired Pressure Vessels December 2009

4) [R] All vessels with austenitic stainless steel or high alloy materials exposed to test water shall be
drained immediately after hydrostatic testing, and dried by blowing with air.
5) [R] Water used for hydrostatic pressure testing or wash water shall conform to the quality
requirements of GP 18-10-01.

3.1. Pressure Levels

1) [R] The hydrostatic test pressure, PT, at the top of each section of a vessel shall be no lower than the
pressure determined below. A section of a vessel is defined as an area within the vessel where the
design pressure or ratio t/(t-c) varies from that of another area.
2) [R] In the hydrostatic test condition, the maximum membrane stress in the vessel in the uncorroded or
corroded condition shall not exceed 90 percent of the specified minimum yield strength for ferritic
steels, nor 100 percent of the specified minimum yield strength for austenitic steels or non-ferrous
materials.
3) [R] PT shall be calculated as follows:
a) For vessels designed with ASME (ASME SEC VIII D1) allowable stresses, PT shall be the greater
result of the following formulas:
S rt t
PT  1.5  Design Pressure  
S dt t  c
or
S rt t
PT  1.3  MAWP  
S dt t  c
b) For vessels designed with higher than ASME (ASME SEC VIII D1) allowable stresses, PT shall
be the greater result of the following formulas:
S t
PT  1.25  MAWP  rt 
S dt t  c
or
t
PT  1.43  MAWP 
t c

Note: For all vessels, the ratio Srt/Sdt shall be the lowest ratio for the vessel, not including bolting.
Also, the ratio t/(t-c) shall not be greater than 1.20 for new uncorroded vessels and 1.0 for fully
corroded vessels.

Srt = Allowable design stress at room c= Corrosion allowance

temperature
Sdt = Allowable design stress at design t= Vessel section nominal wall thickness,
temperature including corrosion allowance

3.2. Duration
[R] The test pressure shall be held for at least one hour per in. (25 mm) of vessel thickness, and in no case
for less than one hour. The thickness of either of the heads or the shell, whichever is greatest, shall be
used to determine the length of the test period.
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 GP 05-03-01 Pressure Testing of Unfired Pressure Vessels December 2009

3.3. Temperature Requirements

[S] When the vessel thickness exceeds 1/2 in. (13 mm), the metal temperature of the vessel at time of
hydrostatic test shall be as follows:
1) For vessel thickness 2 in. (50 mm) or less, the temperature shall be at least 10F (6C) above the
MDMT.
2) For vessel thickness greater than 2 in. (50 mm), the temperature shall be at least 30F (17C) above
the MDMT.
3) When the required vessel temperature during hydrostatic test is greater than 70F (21C), this
temperature shall be marked on the vessel nameplate.

Cuando el espesor del recipiente excede 1/2 pulgada (13 mm), la temperatura del metal del recipiente
en el momento de la prueba hidrostática será la siguiente:
1) Para recipientes con un espesor de 2 pulg. (50 mm) o menos, la temperatura debe ser al menos
10F (6 aboveC) por encima del MDMT.
2) Para recipientes de más de 2 pulg. (50 mm) de espesor, la temperatura debe ser al menos 30 ° F (17
° C) por encima del MDMT.
3) Cuando la temperatura requerida del recipiente durante la prueba hidrostática sea superior a 70 ° F
(21 ° C), esta temperatura se marcará en la placa de identificación del recipiente.

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GP 05-03-01 Pressure Testing of Unfired Pressure Vessels December 2009

Record of Change

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GP 05-03-01 Pressure Testing of Unfired Pressure Vessels December 2009

Version 1.0.0 Date: 07/01

Location Action Description
Initial Publish.

Version 1.1.0 Date: 02/02

Section 3.1 Addition Added Purpose Code [R] to item 3).

Version 1.1.0 Date: 09/03

Global Practice version number and format updated to comply with new
process; however, original publish date remains, and no content was
modified.

Version 1.2.0 Date: 03/05

Section 3.1, Modification Stress ratio not to include bolting; thickness ratio for corroded and
Item (3) Note uncorroded vessel specified.

Version 1.3.0 Date: 12/09

General Addition Added purpose codes as needed.
Section 2 Addition Added definition for MDMT.
Section 3, Item Addition Added reference to test/wash water quality requirements.
(5)
Section 3.1, Modification Test pressure calculation for vessels built to higher than ASME D1
Item (3) allowable stresses was modified to reflect changes to ASME D2 test
pressure calculations. (Use of MAWP instead of Design Pressure,
includes an additional calculation.)
Section 3.3, Modification Requirement changed to avoid excessively high test temperatures.
Items (1) & (2)
All Global Modifications To standardize the format of the Global Practices and to meet other
Practices requirements, the following changes have been implemented:
"For ExxonMobil Use Only" has been replaced with "For Company Use
Only."
A copyright waiver has been added in the first page Footer.
The definition of asterisks in the Scope has been deleted. The asterisk is
now defined in the Purpose Code attachment and is used within brackets
as other Purpose Codes.
Multiple paragraphs within a Section have been numbered.
The standard text for Required References has been modified.
The standard text for Additional Requirements has been modified.
The [S] Purpose Code has been modified.
The following Purpose Codes have been added:
[*] for additional information or decision required of Owner's
Engineer.

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GP 05-03-01 Pressure Testing of Unfired Pressure Vessels December 2009

[A] for approval requirements before beginning work or finalizing

design.

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GP 05-03-01 Pressure Testing of Unfired Pressure Vessels December 2009

Attachment: Purpose Codes Definitions

Code Description

* Assigned to paragraphs that require the Owner's Engineer to provide additional information or
make a decision.
A Assigned to paragraphs that require approval from the Owner's Engineer before the work may
proceed or the design is finalized.
C Assigned to paragraphs whose primary purpose is reduced costs. Reduced cost in this context
refers to initial investment cost and does not include life cycle cost considerations. Life cycle
cost considerations are captured under reliability, maintainability, or operability purpose codes.
E Assigned to paragraphs whose primary purpose is driven by environmental considerations.
Environmental considerations typically include specifications intended to protect against
emissions/leakage to the air, water, and/or soil. Deviations from the specifications contained
in such paragraphs require formal review and approval according to local environmental
policy.
I Assigned to paragraphs that provide only clarifying information, such as Scope statements,
definitions of terms, etc.
M Assigned to paragraphs whose primary purpose is to provide for maintainability of equipment
or systems. Maintainability provisions are those that facilitate the performance of maintenance
on equipment/systems either during downtimes or during onstream operations.
O Assigned to paragraphs whose primary purpose is to assure operability of equipment or
systems. Operability is the ability of the equipment/system to perform satisfactorily even
though conditions are off-design, such as during start-ups, process swings, subcomponent
malfunction, etc.
R Assigned to paragraphs whose primary purpose is to improve or assure the reliability of
equipment or systems. Reliability is a measure of the ability of equipment/systems to operate
without malfunction or failure between planned maintenance interventions.
S Assigned to paragraphs containing specifications/guidance where the primary purpose is the
avoidance of incidents impacting personnel safety, process safety, and the public in general
and/or involving responses to emergency situations. Any deviation from the specifications
contained in such designated paragraphs requires formal review and approval according to
local safety policy.
Personnel Safety: Refers to the prevention of incident-related personnel injuries or illness,
e.g., burns, cuts, abrasions, inhalation of or exposure to dangerous
substances, etc., that could result in medical treatment, restricted work,
lost-time incidents, or fatalities.
Process Safety: Refers to the prevention and control of process releases, fires, and/or
explosions that could result in damage to equipment, process disruption,
or personnel injury or illness.

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