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SPECIFICATION FOR HYDROSTATIC

TEST PROCEDURES (PIPING)

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0 1400/02/06 Issued for Comment M.N. B.M.
Rev. Date Status Prepared. Checked. Approved AC

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Table of Content
1.TERMS AND DEFINITIONS ...................................................................................................4
2.SCOPE………………………. ....................................................................................................4
3.REFERENCED STANDARDS .................................................................................................4
4.TESTING MEDIUMS…………. ...............................................................................................5
5.HYDROSTATIC TESTING CALCULATIONS OF INTERNAL PRESSURE PIPING ...6
6.PNEUMATIC TESTING…………. ..........................................................................................7
7.FLUSHING……………………..................................................................................................8
8.PREPARATION FOR PRESSURE TESTING .......................................................................9
9.LEAK TEST…………………… ..............................................................................................11
10.PROCEDURE FOR PRESSURE TESTING OF PIPING – GENERAL NOTES ...........11
11.COMPLETION OF TESTING .............................................................................................13
12.PRESSURE TESTING THROUGH EQUIPMENT ...........................................................14
13.PRESSURE TESTING OF INSTRUMENTS ......................................................................14
14.TIME OF TEST…………………. .........................................................................................15
15.TEST RECORDS………………… ........................................................................................16

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1. TERMS AND DEFINITIONS

• Owner/Client: Abadan Petrochemical Company

• EPC Contractor: Butane Procurement & Engeneering Services Company, Shall Mean
the Contractor Responsible For Engineering, Procurement & Construction of the Project.

• Vendor: The manufacturer /manufacturer's representative selected by the contractor &

approved by the client to supply equipment tools.

• Will: Is normally used in connection with the action by the "company" rather than by a
contractor, supplier or vendor.

• May: Is used where a provision is completely discretionary.

• Should: Is used where a provision is advisory only.

• Shall: Is used where a provision is mandatory.

2. SCOPE
This specification covers hydrostatic and pneumatic testing of piping, equipment and
instruments. Prior to operation each pressure piping system shall be tested to ensure
tightness. The extent, test pressure and test medium will be specified in the project test
flow diagram and line list.

3. REFERENCED STANDARDS
Piping shall be tested in accordance with this specification and the applicable section of
the Code for Pressure Piping, ASME B31.3, ASME B16.5 Latest edition.

Piping within the scope of steam generation shall be tested in accordance with ASME
Code for Power Boilers Sec. I and ASME B31.1-Latest edition.

Alternatively the Contractor may utilize his own established testing procedures.

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These shall be submitted to the Company for approval at the earliest possible date prior
to the testing being carried out.

Related Engineering and Construction Specifications.

IPS-C-PI-150, IPS-M-PI-350 and other related series of Iran Petroleum Standard.

4. TESTING MEDIUMS
Testing shall be hydrostatic, using water unless otherwise noted on the Pressure Test
Flow Diagram drawings. Temperature of test medium shall not be changed during hydro-
test.

In systems where residual moisture cannot be tolerated, e.g. in SO2 acid, ammonia and
LPG service, and where certain catalysts are used, oil is the preferred test medium. If
water has to be used the system should afterwards be dried out with hot air. Special
attention should be given to points where water may be trapped, such as in valve body or
low points. Stainless steel lines shall not be tested with water containing more than 30
ppm of chloride, 1% soda ash and 0.5% sodium nitrate. Water chemical analysis shall be
approved by Company. Proper precautions should be taken against stress corrosion
cracking.

Where hydrostatic testing would be impractical, pneumatic testing will be specified on

the drawings. The pneumatic test will be performed strictly in accordance with ASME
B31.3 and all safety conditions strictly adhered to, prior and during the test for each
system. All pneumatic tests require prior Company approval.

The following are usually excluded from hydrostatic testing, and are usually tested with
compressed air and soap suds:

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- Instrument air lines (Test with dry air only).

- Air lines to air-operated valves. (Test with dry air only).

Very large (Usually over 24”) gas or steam overhead line. Pressure parts of instruments
in gas or vapor service.

If investigation determines that testing is required for relief or blow down header systems
or individual pipe stacks more than 15.2m in height which are open to atmosphere, they
need only be tested for tightness with soap suds at 0.4 bars (5 psi) air pressure.

Piping with linings subject to damage by water, shall be investigated.

Piping not pressured in service, such as free vents, relief valve open tail pipes and drains
which are open to atmosphere, may be tested by only visual inspection without pressure
test.

Hydrostatic testing shall be performed using clam potable water with a chloride content
of max 50 ppm.

5. HYDROSTATIC TESTING CALCULATIONS OF INTERNAL PRESSURE PIPING

The hydrostatic test pressure for piping systems should be not less than 1-1/2 times the
maximum design pressure. The test medium should be as per Section 3. Instrument air
piping should be tested with dry air at maximum working pressure obtainable in the
instrument air system.

The test pressure shall be determined by the following equation based on ASME B31.3-
Latest edition.

Pt = F x P
Where,
Pt = Minimum hydrostatic test pressure. Barg.

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P = Internal design pressure. Barg. St = Allowable stress at 37.8 (100)

S = Allowable stress at design temperature (See note below).
F = Factor, 1.5 St/S (See Table 1, attached)
Note: See Table A-1, APPENDIX A, ASME B31.3 – Latest edition.
Where the pipe work being tested contains flanges, the test pressure determined in
paragraph 4.2 for piping should be in accordance with Section 8 of Steel Pipe Flanges
and Flanged Fittings, ANSI B16.5-Latest edition.

Hydrostatic Testing of External Pressure and Jacketed Piping

Piping subject to external pressure shall be tested in accordance with ASME B31.3 –
Latest edition.

In jacketed lines the jacket shall be tested in accordance with paragraph 4. on the basis
of jacket design pressure. The internal line shall be tested on basis of external or internal
design pressure, whichever is greater, unless limited by the engineering design
conditions. Limitations will be noted on the Pressure Test Flow Diagram.

6. PNEUMATIC TESTING
The pneumatic test shall be in accordance with ASME B31.3 Code. Any pneumatic test
shall be increased gradually in steps allowing sufficient time for the piping to equalize
strains during test. All joints welded, flanged or screwed shall be swabbed with soap
solution during these tests, for detection of leakage. Pneumatic test uses air, nitrogen, or
any non-flammable and nontoxic gas.

All connection which cannot be tested during the hydro test, shall be pressure tested (air
soap) at 0.5-1.0 barg. Erection Contractor shall repair all leaks detected during the test.

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7. FLUSHING
Item to be removed or blanked off prior to flushing/testing shall include, but shall not be
limited to:

- Check valve internals which shall be removed or locked open. Lines containing check
valves shall be pressurized from the upstream side of the valve.

- Relief valves and rupture discs.

- Orifice plates, flow nozzles or other similar restrictions.

- Venturi type flow meters (flanged).

- Internals of equipment (trays, demisters, level instrument floats, float cages, etc.), if
included in the test system.

- Control valves.

- Expansion joints (or provides temporary restrains).

- Any items not designed to withstand the test pressure, e.g. pressure gauges.

- Internals of strainers and filters, steam/air traps, etc.

Trash and construction debris shall be removed from the piping systems by flushing with
water or by blowing with air or nitrogen in line with the relevant test medium. All lines
shall be completely free of weld slag and other foreign material and shall be reasonably
clean. Any flanged connection may be broken for blow-down.

Flushing through equipment is not allowed unless specifically approved by Owner.

Care shall be taken with flushing of pump suction lines to prevent contamination of
pumps. The elbow close to the pump shall be turned away and the pump inlet shall be
adequately covered to prevent entering water into the pump.
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All flushing operations shall be carried out in the presence of Owner.

Flushing shall be performed against open pipe ends. Flushing against small openings like
vents, drains, etc., is not accepted.

Flushing water shall be drained through hoses to locations as indicated by Owner.

After completion of the flushing operation, welded-in items which are included in the
test system, shall be inspected for internal cleanliness.

8. PREPARATION FOR PRESSURE TESTING

All lines should be cleared of debris by flushing with water or blowing with steam or air.

Precautions should be taken to ensure that debris is not flushed into associated vessels,
equipment or “dead ends”.

Pressure relief and thermal expansion relief valves shall be excluded from the general
pressure tests. Blinds shall be installed immediately adjacent to their inlet or outlet
flanges during tests. Relief valve test gauges may be used in place of blinds. Screwed
relief valves shall be removed and the connections temporarily plugged or capped during
the tests.

All in-line instruments, control valves and expansion joints shall be installed after hydro-
test and temporary spool shall be used during hydro-test.

Pipe supports and anchors should be fitted prior to pressure testing. In certain case
temporary or additional supporting of pipe work may be required due to weight of the
testing medium.

Welded, flanged or screwed connections must not be painted or otherwise covered before
completion of pressure testing for visual inspection.

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Where soft seated ball valves are in the line, these must be blinded off on the pressure
side of the line at the ball valve flange if such a valve is at the end of a tested section. If
such a ball valve is within the line being tested it shall be in the fully open position.

Gate and globe valves should be opened until the back seat is fully engaged. Testing may
take place against gate and globe valves, however the Contractor should be aware that
valve seats may not necessarily be bubble tight shut off.

Investigation of check valves should be considered to determine whether or not the

flapper shall be removed or jacked up.

Lines which have spring hangers or are counterweight supported shall be temporarily
blocked up during testing in order to sustain the weight of the test fluid. Sometimes spring
hangers are provided with stops for carrying the test load and need not be blocked up.

All orifice plates which interfere with filling, venting and draining shall be removed for
the test.

All required stress relieving, radiographic, etc. of field welds must be completed and
accepted before these particular lines are tested.

Piping designation shall be provided with additional temporary supported, if necessary,

to support the weight of the test liquid. Prior to the liquid fill for test of the piping system,
it shall be checked that springs with "down travel stop" have the "stop" inserted. The
"stop" in the spring shall be removed after draining of test fluid from the piping system.

All tests executed with day temperature of 5°C and lower or when frost is expected during
night and system may stay filled overnight shall have antifreeze, which is an ethylene
glycol water solution as per Attachment Il. During flushing, no anti-freeze is required.
Avoid flushing when temperature is below 0°C.

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9. LEAK TEST
Prior to pre-commissioning, each piping system shall be tested to ensure tightness. Air
or steam at 25 psig may be used as preliminary test to detect missing gaskets, etc. As this
avoids the necessity of draining the line to make repairs, however, steam shall not be
used for this purpose, if the steam temperature is more than the design temperature of
line.

10. PROCEDURE FOR PRESSURE TESTING OF PIPING – GENERAL NOTES

Pressure test “system” shall be developed by the Contractor, testing as much piping as
possible at one time without exceeding the allowable test pressure of the weakest element
in the system.

The test pressure on any section of piping shall not exceed the test pressure permitted for
any vessel, exchanger, heater or other equipment operating with this piping.

For convenience, exchangers and/or vessels may be tested simultaneously with

connected piping, provided, the test pressure of both the connected piping material and
equipment does not exceed the maximum allowable pressure.

When conditions require that a pressure test be maintained for a period of time during
which the testing medium in the system would subject to thermal expansion, provision
should be made for relief excess pressure.

During hydrostatic testing, care must be exercised to limit the applied pressure to the
particular portion of the system designated in the field pressure test flow diagram.

Care must also be taken to avoid overloading any parts of support structures.

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Vents or other connections shall be opened to eliminate air from lines which are to
receive a hydrostatic test. Lines shall be thoroughly purged of air before hydrostatic test
pressure is applied. Vents shall be open when systems are drained so not to create
buckling from a vacuum effect.

Short pieces of piping which must be removed to permit installation of blind or blank,
should be tested separately.

Retesting of lines after repair by welding shall be done at pressure originally specified
for the test.

Lines containing check valves shall have the source of pressure located in the piping
upstream of the check valve so that pressure is applied under the seat. If this is not
possible, the check valve flapper shall be removed or jacked up.

Seats of valves shall not be subjected to a pressure in excess of the maximum cold
working pressure of the valve.

Flushing should not be carried out through machinery, globe & control valves, soft seated
valves, or through any other equipment which might be damaged by the flushing.

Test pressures shall be taken at the lowest point of a line or test system.

All plain test blanks required for field testing of lines shall be made in the field. Plates of
varying thickness will be included in the miscellaneous material purchased for
construction.

After completion of hydrostatic testing, all temporary blanks and blinds shall be removed
and all lines completely drained. Valves, orifice plates, expansion joints and short pieces
of piping which have been removed shall be reinstalled with proper and undamaged
gaskets place. Valves which were closed solely for hydrostatic testing shall be opened.

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After lines have been drained with vents open, temporary piping supports shall be
removed so that insulation and painting may be completed.

Flanged joints at which blinds are inserted to blank off equipment during the test need
not be tested.

Underground lines shall be tested, before back filling.

Piping shall be divided into test systems as shown on Pressure Test Flow Diagrams by
using blinds, caps or plugs suitably.

11. COMPLETION OF TESTING

Draining and Drying:

- After completion of the pressure test, the pressure shall be released so as not to
endanger personnel or damage equipment.

- Before draining the system, all vents shall be opened and remain open during draining
to prevent pulling a vacuum in the system.

- Immediately after testing, all lines and systems shall be flushed and completely drained.

- All lines shall be dried by means of air. Special care shall be taken that no freezing can
occur in winter.

- Owner will confirm when a line is considered dried by Erection Contractor.

Reinstatement of Piping Systems:

- After completion of testing, flushing and draining, all systems shall be reinstated as per
drawings and specifications. This includes but shall not be limited to: - Removal of all
temporary pipe spools, temporary supports, temporary materials such as spades, blinds,

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gaskets, etc. - Replacement of all damaged gaskets and/or all test gaskets. - Repositioning
of spectacle blinds to the correct position, as per P&ID. - Reinstallation of all items
removed for hydro testing such as valves, rupture discs, in-line instruments, internals of
strainers and filters, spectacles, traps, etc. - Inspection of the completed system for correct
flow direction of instruments, check and control valves, etc. -Pneumatic leak test shall
be performed to ensure tightness of flanged/screwed joints at the time of pre
commissioning.

- After approval by Owner, the system shall be released for activities like electrical
tracing, painting, insulation, etc.

- The "stop" of pipe support springs with "Down travel stop” placed prior to flushing,
shall be removed at Owner request during pre-commissioning or commissioning stage.

12. PRESSURE TESTING THROUGH EQUIPMENT

All equipment's that tested in construction in accordance with ASME B31.3 or related
standards will not require individual pressure tests at site.

13. PRESSURE TESTING OF INSTRUMENTS

Certain types of instruments with their connecting process lead line shall be tested at the
same pressure as the main pipe lines or the equipment to which they are connected. Such
instruments normally include the following types:

Displacer Type Level Instruments

Control Valves Gage Glasses

Flow Meter Pots

Rotameters

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Other types of instruments shall not be tested at line pressure, but shall have process lead
lines tested to the first block valve or valves nearest the instrument. Care shall be taken
that this equipment is protected by removal, or by blocking the instrument lead line and
disconnecting or venting the instruments. These types will normally include the
following:

Flow Instruments

Pressure Balanced Control Valves

Pressure Indicators

Recorders Pressure

Pressure Switches

Special precautions shall be taken to insure that instruments and instrument lead lines to
be tested are vented and completely filled before testing, and are thoroughly drained after
test.

Hydrostatic testing of instruments and instrument piping shall be coordinated with the
instrument erection subcontractor.

14. TIME OF TEST

Tests shall be applied after erection and before equipment is initially placed in service.

All joints including welds shall be exposed during tests.

All lines shall be tested prior to coating, wrapping or insulation. Lines may be painted
except on welded, screwed, or flanged joints.

Each test shall be held for sixty (60) minutes without any loss in pressure prior to
requesting Company to witness and accept test.

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Rainfall or snow on an exposed line may result in non-acceptance of the test until the
outside of the system is sufficiently dry to make an inspection.

15. TEST RECORDS

Records shall be made of each piping installation during the testing, which will include:

Date and length of time of test.

Identification of piping and equipment being tested.

Test medium used and its temperature during hydro-test.

Test Pressure.

Approval by Company Inspector.

Record shall include:

-Detail of the testing and examination procedures.

-Examination personnel qualification.

-Certification of satisfactory results by the Company inspector or certifying

authority.

-Pressure gauge, calibration / test certificates.

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TABLE 1: “F” TEMPERATURE ADJUSTMENT FACTOR FOR TEST

PRESSURE

Alloy Alloy
Base Material Carbon Steel Stainless Steel
Steel 625

ASTM API ASTM ASTM ASTM

Standard A106 A333 5L A333 A312 A312 B444

Grade B 6 B 3 304 304L 1

Design

Temperature

37.8D 100°F 1.5 1.5 1.5 1.5 1.5 1.5 1.5

93.3D 200°F 1.5 1.5 1.5 1.66 1.5 1.5 1.5

148.9D 300°F 1.5 1.5 1.5 1.66 1.5 1.5 1.5

204.4D 400°F 1.5 1.5 1.5 1.74 1.6 1.59 1.5

260.0D 500°F 1.59 1.59 1.59 1.83 1.71 1.7 1.54

315.6D 600°F 1.73 1.73 1.73 1.94 1.83 1.79 1.58

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