TIRERAG PROGRAN-ENONEERNG GENERAL INCOR ) TECHNICAL STANDARD SUN REVISION REVIEW AND APPROVAL No. FIREBAG PROGRAM TECHNICAL STANDARD REVISION REVIEW AND APPROVAL Doc. No. FB-L-5205 Current Rev. No. Document Title: PIPING PRESSURE TESTS Issuing Department: To: From: DESCRIPTION OF CHANGE (Attach the draft/evised Technical Standard) ‘+ Reasons for Change — Creation of a Firebag Program Technical Standard Revisions: (See attached) ‘* Additions: (See attached) ‘* Deletions: (See attached) Comments Approval Date 1. | Originator 5 Roger Bandy : DON IC hee Firebag Piping Program Lead ‘ eee * lente Maro f& amé/n/i8 Frebag Piping Progrem (so stn ont nae of 3. | Reviewer Hv Dave Tullis iniso a fro Frebag Engineering Manager motives | Doc. 2yJole A 4. | Approval Authority \ ul. Ken Hart (Also sigh fror Firebag Operations Manager oo Doc Joe 5. | Return to Rita Lewis Jacobs Canada, Heritage Square ‘ Attachment —Firebag Projects Standard Number FB-L-5205 Rev. 2 Issue Date: 15-Dec-06 INCONTROLLED DOCUMENT WHEN PRINTED (15:0EG-08) CONTROLLED DOCUMENT INEWR FILE ‘fm EWR 109-2008-001 - 2-48. -FB- Rov (ON TortSUNCOR ENERGY Technical Standard No. FB-L-5205 FIREBAG PROGRAM PIPING PRESSURE TESTS SUNCOR ENERGY INC. CANADA v1 15-Dec-06 | Re-Issued for Implementation Bandy [B. Munro Date ‘Document Status 07g “Engineer ‘UNCONTROLLED DOCUMENT WHEN PRINTED (18-Dee-06) CONTROLLED DOCUMENT IN JPIEWR 100.2008001 2-447 Fle Name: FB-L-5205 Rev. 2 Page 1 0f 23,REBAG PROGRAM —PPOG EVGNEERING Su Y c TECHNICAL STANDARD ‘Subiect Resin PIPING PRESSURE TESTS 2 REVISION HISTORY Date Description 2 | 108606 | “Revised 6 match Rav. 7 TOS. Sis. 0206 ‘| ¥-Fet-06 [issued for Ingiementaton 4 ‘B_} 16-Sep-05 | issued for External Squad Check ‘| —26:Ape05 [issued fr intemal Squad Check =| ‘This standard is based on Suncor Energy ns. Standard No. 0205 Rev. 6 and been developed special for use on Frebag Projects “| REV. REVISION HISTORY This Firebag Standard has been generated from the Suncor OSG Standard 0205 Rev 6. All changes made between the Suncor OSG standard and this standard are noted as follows: General Revisions: 1. All references to other Suncor Standards have been changed to indicate the Firebag Standard number. 2. Added metric units where appropriate, Specific Revisions by Section Number: 415 41.9 432 434 442 Accuracy of test pressure gauge changed to 0.5% ‘Added “Leakage allowed past the valve seat shall be verified and measured.” Modified for clarification Modified for clarification ‘Modified for clarification Attachment C — Modified table on Pg 4 to include Firebag piping material classes only. ‘UNCONTROLLED DOCUMENT WHEN PRINTED (15-Dec-06) CONTROLLED DOCUMENT IN JPIEWR 100-2004001 24-47 File Name: FB-5205 Rev 2 Page 2 of 23 Modiegs 55008oR) TREBAG PROGRAN PWG ENGNEERING SUNCOR TECHNICAL STANDARD Saba War Retin PIPING PRESSURE TESTS. FB-L-5205 2 TABLE OF CONTENTS 10 SCOPE 1.4 Purpose 1.2 Application 4.3 Definitions 2.0 REFERENCE CODES AND DOCUMENTS 24 Local Codes 22 Code for Process Piping, ASME B31.3 2.3 For Boiler External Piping, ASME B31.1 2.4 Additional Codes 2.5 Suncor Energy Standards and Documents 3.0 INFORMATION SOURCES 3.41 General 3.2 Piping Drawings 3.3. Piping and Instrument Diagrams (P&ID) 3.4 Line Designation Table (LOT) 35 Tie-In List 4.0 PRESSURE TESTING (SHOP AND FIELD) 44 General 4.2 Special Conditions 43 Test Pressure 4.4 System Package for Pressure Tests 4.5 Preparation of Systems for Testing 46 Test Medium 4.7 Hydrostatic Testing Procedure for B31.3 Piping 48 Pneumatic Tests 4.9 Test Procedure for Boiler External Piping 4.10 Post Test Procedure 5.0 REPORTS AND RECORDS 60 ATTACHMENTS Attachment A — Suncor Firebag Program ~ Field Pressure Test Certificate Attachment B — Test Blind Thickness Requirements — B1 and B2 Attachment C — Summary of Revision “UNCONTROLLED DOCUMENT WHEN PRINTED (15-Dec-08) CONTROLLED DOCUMENT IN JPI EWR 100-2004.007 24.47 File Name: F-52065 Rev_2 Page 3 of 23, ecined onefuer INCOR ) TECHNICAL STANDARD ‘Sabie Namber Ravsion PIPING PRESSURE TESTS FB-1-5205 2 1.0 | SCOPE 1.1 PURPOSE 1.1.4 This Standard js issued to establish uniform procedures for the testing of above ground Process and utlity piping and those pipes extending below ground in the same service, using the same materials. These requirements shall apply to shop, module, vendor packages and on-site work. 1.2 APPLICATION 1.2.1 Process and utility piping shall be pressure tested in strict accordance with the Code(s), drawings, purchase order and other requirements specified herein. Where conflict exists between the referenced documents, the Supplier shall notify the Owner's Engineer in writing. No requirements herein have the effect of waiving the applicable Code unless they are more stringent than the Code. 1.3. DEFINITIONS “Owner” — means Suncor Energy Inc. “Buyer” ~ means Suncor Energy Inc. or its agent designated for that project. “Owner's Engineer” — means the person responsible for the technical integrity of the project. “Owner's inspector” — means the person authorized for inspection. “Supplier” — means the entity, manufacturer, fabricator, vendor or contractor that supplies the ‘material or services. “Local Authorities” — means the governmental regulatory authority controlling laws, codes, rules or regulations for the design, fabrication and testing of industrial piping in the Province of Alberta, ‘UNCONTROLLED DOCUMENT WHEN PRINTED (15-Dec-06) CONTROLLED DOCUMENT IN JPI EWR 1002004001 24.47 File Name: F8-L5205 Rev 2 Page 4023,Suncor) Ra ERE TECHNICAL STANDARD ‘Subjoct 2.0 24 2.2 23 24 25 3.0 34 32 Number Revision: PIPING PRESSURE TESTS FB-L-5205 2 REFERENCED CODES AND DOCUMENTS Note: The latest editions, as of the date of the Purchase Order or Contract, for all referenced Codes and documents shall be used. LOCAL CODES Where local regulations, ordinances, statutes or codes take precedence over ASME codes, ‘such regulations, ordinances, statutes or codes shall govern. CODE FOR PROCESS PIPING, ASME B31.3 Except where specified otherwise, ASME B31.3 Latest Edition, hereinafter referred to as the Code, governs fabrication, installation and testing of all piping. FOR BOILER EXTERNAL PIPING, ASME B31.1 Boiler external piping as defined in ASME B31.1, shall be pressure tested in accordance with section 137.3.1 of ASME B31.1. The extent of such piping shail be indicated on the P&ID's, isometrics and other piping drawings as required. ADDITIONAL CODES In addition to the above mentioned codes and their sub-references, other codes, such as refrigeration, plumbing or national regulations may govern some parts of the piping. Drawings shall indicate the applicable codes in such cases. SUNCOR ENERGY STANDARDS AND DOCUMENTS: A. Manual for Piping and Pressure Vessels ‘Suncor Procedure TCP0004A, “Alternative Test Procedure” Suncor Procedure ENP0014A, "Hydrostatic Testing” INFORMATION SOURCES GENERAL In addition to the above mentioned codes and their sub-references, the following sources contain information pertaining to pressure testing, PIPING DRAWINGS, Piping drawings may be orthographic arrangements and/or line isometrics. UNCONTROLLED DOCUMENT WHEN PRINTED (15-Dec-06) CONTROLLED DOCUMENT IN JPIEWR 160:2004001 24-47 File Name: FBL5205 Rew 2 Page 5 of 23,Suncor) rae Po NS Pueney TECHNICAL STANDARD Subject Namiber Revision PIPING PRESSURE TESTS FB-L-5205 2 3.3 PIPING AND INSTRUMENT DIAGRAMS (P&ID) 34 3.5 40 44 444 41.2 Note: 413 The Piping and Instrument Diagrams indicate "to and from" routing, pipe class, fluid designation and line number for each fine and, which codes or requirements apply to various parts of the piping systems, as well as, the limits of such code or requirement. LINE DESIGNATION TABLE (LDT) The Mechanical Data Section of the Line Designation Table shows the line number, description, pipe material class, design pressure and temperature, insulation and tracing requirements and test type and pressure for each line. TIEN LIST The piping tie-in list shows the tie-in number, existing line number, new line number, type of ‘connection, the party responsible for instailing and testing of the tie-in. PRESSURE TESTING (SHOP AND FIELD) GENERAL Newly installed process and utility pressure piping shall be pressure tested as required by the applicable Code. The test, shall also include the more stringent requirements specified in the LDT oF the piping drawings, and as described herein, Alternatives to pressure tests, if permitted by the applicable Code, shall comply with TCPOO04A, (see Attachment °C") and require prior approval of the Owner's Engineer. For closure welds, the requirements of ASME code for process piping B31.3, PARA 345.2.3 (c) may be applied at the discretion of the Owner's Engineer. However, radiography, ultrasonic, or other alternative testing in lieu of hydrostatic testing shall not be applied to closure welds in critical process services where the design pressure is above 900 psig (6206 Kpa) and the design temperature is above 600°F (316°C). Examples of such services are: Hydratreating processes, Hydrogen production, Ultra-high pressure steam. Pressure tests of Tie-ins into existing piping systems shall meet the limitations of the Potentially corroded system and shall have prior approval of the Owner's Engineer. The Contractor shall be responsible for all safety precautions and procedures during testing and for the safe disposal in an environmentally acceptable manner of any chemicals and additives used during testing. Pressure gauges for system testing, shall have a measurement range of no more than 1-1/2 to 4 times the test pressure with a 0.2% accuracy. Pressure gauges shall be 4” minimum diameter. ‘UNCONTROLLED DOCUMENT WHEN PRINTED (15-0206) CONTROLLED DOCUMENT IN JPIEWR 100-2004001 - 24-47 File Name: FBA-6205 Rev. 2 Page § of 23, oct. oneSuncor) TECHNICAL STANDARD Sak ject ‘Number Revision: PIPING PRESSURE TESTS FB-L-5205 2 4.1.6 Pressure gauges/recorders, shall be recalibrated and certified ta be accurate by a recognized authority, at a minimum of six month intervals. Recalibration may be requested by the ‘Owner's Inspector. The certification documents shai! be a permanent part of the system pressure test package. Each gauge shall have an identifying mark or number, which shall appear on the certification documents. 4.1.7 Two indicating pressure gauges shall be used. One gauge, placed near the lowest point in the system shall be located so that it is easily readable by the operator controlling the applied pressure, The second gauge, shall be located as near to the top of the system being tested, as practical. The test gauges, shall be orientated to minimize injury or damage if failure of the gauge occurs 4.1.8 Alltools, equipment, test fluids and additives required for piping system pressure tests shall be 44 supplied by the Contractor. 9 Valves, shall be in the open position but not backseated to test the packing. Flanged valves located at the end of a system, shall be blanked on the downstream side. Threaded valves located at the end of a system, shall be plugged or capped, Closed valves may only be used in “Existing Piping” and stiaif not be relied upon to be leak proof at the test pressure. When closed vaives must be used at the end of a pressure test system, then the resulting pressure drop and the make-up volume of the test fluid required to restore the test pressure shall be recorded and included in the test report. The maximum pressure that a closed valve may be subjected to when used for isolating a pressure test system shall not exceed 110% of the valve pressure rating at 100°F (38°C), 10 The following items shall not be included in a pressure test: ‘a. Pumps, compressors and turbines. b. Expansion joints. ¢ Strainer baskets and filter elements shall be removed, d. Allisolatable instruments shall be disconnected downstream of the first (second in double valved systems) isolation valve. e. Flanged safety and thermat relief valves shall be blinded or removed. {Threaded relief valves shall be removed and the line connection plugged or capped. g. Control valves shall be removed and replaced with a spool piece unless written approval is obtained from Suncor to leave selected vaives in place. h. Pressure gauges, orifice plates, flow transmitters, rupture dises and steam traps shall be removed, ‘UNCONTROLLED DOCUMENT WHEN PRINTED (15-Dec.06) CONTROLLED DOCUMENT IN JPIEWR 1002004001 24-47 File Name: FB-5205 Rev 2 Page 7 of 23, Medi DecoSuncor) anc PROGR PONG RENEE Twency TECHNICAL STANDARD Satie Namber Revision PIPING PRESSURE TESTS FB-L-5205 2 i. Pressure vessels and exchangers (for exemptions see 4.2.3). 4.1.11 Lines containing check valves, shall have the fill and pressure source located upstream of the check valve. The drain shall be located downstream of the check valve. If that is not practical, then the disc, plug or ball shall be removed or blocked open. 4.1.12 All threaded thermowells shall be installed prior to testing. 42 SPECIAL CONDITIONS 4.2.1 Lines in vacuum service, unless governed by specific design conditions, shall be tested at a minimum of 15 psig (103 Kpag) as specified in Paragraph 345.2.4 of ASME 831.3, 4.2.2 Pressure testing of connected pressure vessels, exchangers, pumps and like equipment is, acceptable only when designed for a test pressure at least equal to the required piping test pressure and only with prior approval of the Owner's Engineer. Note: Heat exchangers shall be checked to verify that the tube sheet maximum differential pressure is not exceeded. 42.3 Connected piping may be tested with pressure vessels or other equipment requiring field test provided resulting test pressure applied to piping is not greater than allowable or less than the required piping test pressure. 4.24 Unless limited by design, the inner and the jacket part of jacketed lines shall be pressure tested independently. If the test pressure in the jacket is too high for the internal lines as an external pressure, the internal line shall be pressurized to minimize the differential pressure. 43 TEST PRESSURE 4.3.1 Piping specified per ASME 831.1 and piping governed by Section 1, Power Boilers of the ‘ASME Boiler and Pressure Vessel Code, shall be tested hydrostatically as described in Paragraph 137 of the Code for Power Piping ASME B31.1 4.3.2 Piping specified per ASME B31.3 shall be hydrostatically tested at 1.5 x maximum allowable working pressure of its limiting component. This limiting component can be flange or pipe maximum allowable working pressure. The hydrostatic test pressure thus calculated shall be shown on the line designation tables in the test pressure column. 43.3. Pneumatic test pressures shall be limited to 1.1 times the design pressure for ASME B31.3 piping systems and 1.2 times the design pressure for ASME B31.1 piping systems. The maximum energy level of 50,000 determined by pressure (psfg) x volume (ft®), shall not be exceeded. ‘UNCONTROLLED DOCUMENT WHEN PRINTED (15-Dec106) CONTROLLED OOCUMENT IN JPIEWR 100-2004001 ~ 24-47 File Name: FB-L-5205_Rev.2 age 8 of 23, Modes. oncor) TRERAG PROGR PPG ENGNEERING SUNCOR TECHNICAL STANDARD abject Number: Revise PIPING PRESSURE TESTS FB-L-5205 2 4.3.4 For piping identified as “Service Test” on the LDT, the test fluid shall be the process fluid. ‘Only fluids that are non flammable and non toxic such as steam, air, water or inert gas shall be considered for service tests. 43.5. ingeneral, piping pressure test shall be per the requirements of AMSE B31.3 & B31.1 However, service pressure tests may be applied to selective services subject to the approval of the Owner's Engineer. Examples of such selective service are: PlantUtiity Air, Utility Water, Potable Water, and Low Pressure Condensate. Service pressure test may also be applied to Nitrogen service, subject to the following conditions: a. The line shall not exceed 3" diameter in size. b. Line design pressure shall not exceed 80 psig (552 Kpag). c. The volumetric energy shall not exceed 50,000. (Volume (ft?) x Pressure (psfg)). d. The line is not destined for purging and/or blanketing of critical equipment, as identified by Process and operations personnel. 4.3.6 Blowdown And Flare Lines For large blawdown and flare lines 14" diameter and above, pneumatic pressure test may be applied subject to the approval of the Owner's Engineer under the following conditions: a. The pneumatic pressure test shall not exceed 30 psig (207 Kpag) unless otherwise specified in the line designation tables, in which case acceptance of the test pressure ‘shall be at discretion of the Owner's Engineer. b. For new systems, prior to the pneumatic pressure test, the records of inspection (visual, ‘adiographic, or otherwise) of all the circumferential and longitudinal line welds made from rolled plate shall be submittad to the Owner's Engineer for review and approval. 4.4 SYSTEM PACKAGE FOR PRESSURE TESTS: 4.4.1. The Supplier shall prepare a system pressure test package for each test system, 4.4.2 The static head created by the test fluid must be considered when making up a test package, The test pressure at the highest elevation must be equal to or greater than the minimum required test pressure. The test pressure at the lowest elevation including static head must be equal to or lower than the maximum allowed test pressure. The test package must indicate how these two pressures relate to the measured pressure at the test gauge elevation. ‘UNCONTROLLED DOCUMENT WHEN PRINTED (75:Dec-06) CONTROLLED DOCUMENT IN JPIEWR 100-2004001 - 24.47 File Name: FB-L-S205_Rev.2 Page 9 of 23 ode seSuncor) [Freencprookar—rincencneeane ‘| Tuenay TECHNICAL STANDARD ‘SobIeeE ‘Nomiter Ravision: PIPING PRESSURE TESTS FB-L-5205 2 4.43 System pressure test package data shall include: Piping Pressure Test Certificate, to include the following: a. Line numbers and pressure test limits taken from the Line Designation Table (LOT's). Pressure limits from the LDT's shall be listed when combining piping of different test pressures into one test. b. Pressure gauge numbers, gauge range and certification date(s), c. Test system number, test medium, test pressure, tes! temperatures and duration of test. d. Stored energy for pneumatic tests. e. Marked up Process and Instrument Diagrams (P&ID's). 4. Marked up Piping 'somettic Drawings (Iso’s) when available. g. Records of weld inspection per 4.3.6b (if applicable). “Field Pressure Test Certificate” (See Attachment “A’).. 4.4.4 Process and Instrument Diagrams (P&1D's) shall be marked up to identity a. Test medium fill point. b. Test medium vent point(s). cc, Test medium drain point(s). 1d. Test blind locations. @. Pressure gauge location(s). f Indine instruments removed for test. g. Limits of pressure test, ‘UNCONTROLLED DOCUMENT WHEN PRINTED (15-Dec‘6) CONTROLLED DOCUMENT IN JPi EWR 100.2008.001 24.47 Fle Name: FB-L-5205_ Rev 2 Page 10 of 23su Tew cor) TECHNICAL STANDARD = Nabe Ravaion PIPING PRESSURE TESTS FB-L-5205 2 4.5 PREPARATION OF SYSTEMS FOR TESTING 4.5.1. Temporary blind flanges and test blinds used to isolate a test system shall be of an adequate thickness to withstand the test pressure. (See Attachment “B" Piping Test Blind Thickness Requirements.) Test blinds shall include a 'T' handle, extending at least 4" beyond the flange perimeter, which shall be painted primer red. Test blinds shall be gasketed on both sides to prevent damage to flange facings. 4.5.2 All internal parts and in-line items removed for the duration of pressure testing shall be 453 454 455 456 457 458 459 46 46.4 labelled and the component to, which they belong or the position in the line from, which they ‘were removed shall also be labelled, to the satisfaction of the Owner's Inspector to ensure the correct replacement of components following the testing, All valves, except as excluded herein, shall be included in the pressure tests, ball valves shall be in the position recommended by the manufacturer and all other valves fully open but not back-seated. ‘Where a valve has not been included in a system test, the valve shall be subjected to a bench hydrotest at the required test pressure of that system, Spring supports shall be locked in position for the test using pre-set pins or plates or by blocking up the spring. (REF: Firebag Projects Standard FB-L-5211) All temporary supports, spring support restraints, temporary spools, blinds and plugs, etc., shall be prominently flagged or painted primer red to ensure their removat following testing, Short pieces of piping, which must be removed to permit installation of a test blind shall be tested separately. All pressure containing joints stall be accessible during test and shall not be insulated, back-filed or otherwise covered until satisfactory completion of the pressure test. Where the test system piping and equipment require painting andlor priming, such priming and/or painting shall not be applied prior to pressure testing, TEST MEDIUM Potable water is preferred. Other water used for hydrostatic testing of piping shall be fresh, clean and free from suspended solids and other foreign matter. Where the quality of available wales is unsatisfactory for testing, a chemical inhibitor package shall be provided, which shall include the following chemicals: a. Oxygen scavenger to remove dissolved oxygen b. Biocide to kill harmful organisms and sulphate producing bacteria. ‘UNCONTROLLED DOCUMENT WHEN PRINTED (15-Dec-06) CONTROLLED DOCUMENT IN JPI EWR 106-2004.001 - 24.4.7 Fle Name: FB-L-5205 Rev. 2 Page 11 of 23, eines: Monetsu fon) Taira me tenets] pone TECHNICAL STANDARD Sijeat Tabor Revsion PIPING PRESSURE TESTS FBL-5205 2 ©. Corrosion inhibitor to minimize corrosion. Note: Proposals to use chemical inhibitors shall be agreed between Contractor and the ‘Owner's Engineer or Inspector. 46.2 The minimum water temperature during hydrostatic testing shall be 40°F (4°C). After testing the piping shall be drained and thoroughly dried and maintained such that no moisture or chloride laden deposits will enter the piping. 46.3 No pressure testing shall be performed below a metal temperature of minus 20°F (-29°C). 464 465 466 a7 ATA 47.2 47.3 The possibility of pritfe failure shall be evaluated and the criteria of acceptance shalt be approved by the Owner's Engineer. ‘A non flammable anti-freeze liquid shall be used when the ambient temperature is below 40°F (4°C). Methanol shall not be used. The use of liquids other than water shall have the prior approval of the Owner's Engineer. Pneumatic tests shall use dry (dewpoint ~40°F (-40°C) or lower), clean, oil free air or nitrogen. Oil lubricated compressors shall not be used without adequate filters and dryers. Pneumatic testing temperatures shall not exceed 120°F (49°C). For testing austenitic stainless and nickel alloy steel piping, the test fluid shall not contain more than 50 ppm chlorides. If plant water is being used, the chloride content shall be checked by laboratory testing. HYDROSTATIC TESTING PROCEDURE FOR B31.3 PIPING Prior to filling the system with the test medium, the system shall be inspected by the Contractor's and the Owner's Inspectors for fabrication completeness and satisfactory test preparation, including the placement of pressure gauges and suitability of the test rig. The test package sign-off sheet is then signed by the Owner's Inspector to allow commencement of the test. Liquid testing medium shall be introduced at the system low point to avoid air pocket formation. Vents at high points shall be left open and not closed until test medium flows from the outlet. All air must be removed before pressure greater than that required to fill the system is applied. Hydrostatic pressure testing shall not commence until the test fluid temperature is in equilibrium with the piping system. ‘UNCONTROLLED DOCUMENT WHEN PRINTED (15-boc-06) CONTROLLED GOGUMENT IN JPIEWR 100-2008001 — 24-47 Fe Name: FB-L-5205 Rev 2 Page 12 0f 23Suncor) Fas POT PPR DT ewensy TECHNICAL STANDARD Sabie Namba Rar | PIPING PRESSURE TESTS FB-1-5205 ae] 4.74 The specified test pressure shail be held for 2 sufficient length of time to allow piping to 48 484 482 48.3 48.4 48.5 equalize strains. The test pressure shall be held until all joints (threaded, socket-welded, butt ‘welded and flanged) have been inspected for leaks but in no case for less than the following: 2. Shop fabricated spools 10 minutes b. Final line hydrotest for systems 30 minutes The rate of pressure increase shall not exceed 50 psig (345 Kpag) per minute and the test pumps shail be disconnectad rom the system before the pipe inspection. PNEUMATIC TESTS The area around the system under test shall be cleared of unauthorized personnel and warning notices posted during the time that the piping system is pressurized for the test. The arrangements made to exclude unautharized personnel and the perimeter of the hazard zone, shail be approved by the Owner's Engineer. ‘The pressurization and inspection sequence shall be a. Pressurize to the lesser of % test pressure or 25 psig (172 Kpag) and hold for a sufficient length of time to allow piping to equalize strains. All joints (threaded, socket welded, butt welded and flanged) shall be inspected for leaks with soap suds. b. Pressurize gradually in 10% steps of the specified test pressure and hold for a sufficient length of time to allow piping to equalize strains (10 minutes minimum). c. The test pressure shall be held as per 4.7.4 with pressure source disconnected and then reduced to design pressure after, which aif joints shall be inspected for feaks with soap suds. ‘The soap suds shall be a solution such as Sherlock, Snoop or equal. Throughout the test periad, the bubble formation properties of the soap suds shall be checked, All defects revealed by the test shall be repaired and retested. Weld joints in shop fabricated spools that have been successfully pressure tested elsewhere and for, which documentation acceptable to the Owner's Inspector is included in the test package, need not be retested in a system test. A system under test pressure shall never be left unattended. If a test cannot be completed before the end of a work period, the system shall be depressurized, ‘UNCONTROLLED DOCUMENT WHEN PRINTED (15-5ec06) CONTROLLED HOCUMENT IN JPI EWR 100-2004001 — 24-47 File Name: FO-L-5205_Rev.2 Page 13 of 23,Sunc ) TECHNICAL STANDARD ‘Subject Number: Revision PIPING PRESSURE TESTS: FB-L-5205 2 | 4.9 TEST PROCEDURE FOR BOILER EXTERNAL PIPING 49. 49: 49, 1 Pressure testing procedures for piping designed according to ASME Section 1 and B31.1 as Boiler External Piping, shall conform to the requirements of ASME B31.1, PARA. 137.3.1. 2 The test medium temperature must be 70° F (21°C) min and a maximum metal temperature of 420° F (49°C), .3 All pressure tests of boiler external piping shall include the involvement of the authorized inspector. 4.10 POST TEST PROCEDURE 4.10.1 Following the acceptance of a successful test, the system shall be immediately depressured, drained and vented in a gradual and safe manner, thoroughly drained allowing no pockets of fluid to remain. The system shall then be blown out with dry filtered air until dry to the Satisfaction of the Owner's Inspector. 4.10.2. All items removed for the test shall be replaced and all test blinds, temporary supports, etc. shall be removed. The replacement of piping component internals shall be carefully controlled to ensure that they are reinstalled in the correct place. Flange joints opened for these Purposes shall be remade with new gaskets. 4.10.3 The system shall be re-inspected for mechanical completeness by the Supplier's and the 5.0 5.4 5.2 ‘Owner's Inspectors and signed off as complete. The signed test package shall be retained as, part of the contract documentation. REPORTS AND RECORDS The "Piping Pressure Test Certificate" shall be completed for each pressure test, Pressure Test Records for each system tested shall include: Date of test. identification of piping test. Cross reference to test gauge certificate, Test medium. Test pressure. Test duration. Pre-test and post-test inspection certificate. e>eange ‘See Attachment ‘A" Piping Pressure Test Certificate. ‘UNCONTROLLED DOCUMENT WHEN PRINTED (16-Dec-06) CONTROLLED DOGUMENT IN JPIEWR 1002006001 - 24.47 Fie Name: FEL-5205 Rev. 2 age 14 0623‘FRESNO PROGR PING EVGREERING SUNCOR TECHNICAL STANDARD ‘Subject Nainber Revision: PIPING PRESSURE TESTS FB-L-5205 2 5.3 Records for piping, which require that pressure be held for a specified period of time shall include any corrections of test pressure due to temperature variations between the start and finish of the test. 5.4 Records for piping in, which a specified leakage rate or leaky valves (see 4.1.9) are permitted shall include the time at which water was added and the quantity added. All test records with the Owner's Inspectors signature shall be retained in the job records. 6.0 ATTACHMENTS Attachment A — Suncor Firebag Program — Field Pressure Test Certificate Attachment 8 - Test Blind Thickness Requirements - 81 and 82 Attachment C — Summary of Revision ‘UNCONTROLLED DOCUMENT WHEN PRINTED (18-Gec) CONTROLLED DOCUMENT In JPI EWR 100200401 - 24.47 Fie Name: FB-L-5205_Rev.2 Page 15 of 23 ate 150008Suncor) Tang PROGRAON- FPNG EXGNEERING TECHNICAL STANDARD ‘Subject Taber Favsion PIPING PRESSURE TESTS FB-L-5205 2 Attachment A Suncor Firebag Program Field Pressure Test Certificate Issued By: Work Order # Location: EWR#: Test Pressure Required: Actual Test Pressure: Test Hold Time Required: Actual Hold Time: Test Medium: Pressure Increase Not to Exceed: Actual Temperature of Test Medium: Gauge Calibration Date: Date: Line # Location Hydro-Test Equip. # From | To Pressure Design Description of Pressure Repairs Notes: Approvals: Date | Contractor ‘Owner's inspector a Released for Testing Tested and Accepted Reinstated after Test Print Name / Initial Local Autherities Approval: (Only When Required) ‘UNCONTROLLED DOCUMENT WHEN PRINTED (15-Dac-26) CONTROLLED DOCUMENT IN JPt EWR 1002004001 - 2-4-7 Fite Name: FB-L-5205 Rev. 2 Page 16 of 23 woot HoneNG ENGNEEAIN Frama Proaraae SUNCOR ) TECHNICAL STANDARD ‘Subject Taber Rawson { PIPING PRESSURE TESTS FB-L-8205 2 Attachment B Test Blind Thickness Requirements Page 1 of 2 1.0 FABRICATION REQUIREMENTS 4.1 Allowable pressure shown in table are based on Formula 15, paragraph 304.5.3, ASME 31.3, where: 3P tn = de 16sE tf c=0 E=1 S = 24,000 psi, based on ASTM A285 Grade C, or ASTM 516 Grade 55, (80% of minimum yield), d,, = inside diameter of gasket or gasket pitch diameter. 1.2 The test blind 0.D. shall equal to the flange raised face diameter specified in ANS! B16.5, 1.3 All test blinds shall be marked by die stamping on the 4” min. “T" handle, welded as an extension, with the material specification, pipe size, test pressure and the words "FOR TESTS ONLY", Example: 4" dia. x 3/8" thick blind would have the following stamped: ASTM A285-C NPS 4; 150# FOR TESTS ONLY @ 862 psig 14 Test blinds must not be used as service blinds. Service blinds are designed for the particular application including temperature, corrosion, pressure, and code. Note: Blinds fabricated and installed according to these requirements shall be removed from the piping system immediately after the piping pressure test. ‘UNCONTROLLED COCUMENT WHEN PRINTED (15-Dec-06) CONTROLLED DOCUMENT IN JPI EWR 100-2004001 — 24.47 Fle Name; FB-L-5205 Rov 2 Page 17 of 23 ocmes: oneSuncor) EEA PROGRAM PPG ENGREERNG TECHNICAL STANDARD j Sabet Taine Fesion PIPING PRESSURE TESTS FB-L-5205 2 Attachment B4 Test Blind Thickness Requirements Page 2 of 2 Test Blind Thickness Table (Pressures shown in psig.) Plate Nominal Pipe Size (Inches) ithickness| 1 [ie] 2 | 3 [a To | a [to { to | i [te | ie 7 20" | 24" T 30" tia" {4325 [2104 | 1344 | 628 | 383 | 177 | 105 | 68 | 48 | 40 | 31 [24 {20 Brie" | 6761 | 3289 | 2101 | 981 | 509 | 277 | 164 | 108 | 75 | 63 {48 {38 | 31 | 27 3/8" | 9730 } 4733 | 3023 | 1412 | 862 | 398 | 273 | 152 | 100 | 90 [60 [54 | 44 | 3i | 20 TAS 6443 | 4115 | 1922 | 1173 [542 | 322 | 207 [148 | 122 | 94 | 74 {60 [42 | 27 11" e415 | 5375 | 2517 | 1532 | 706 _| 421 [ 270 | 193 | 160 | 123 | 97 [79 | 58 | 36 18" 6803 | 3178 | 1939 | 897 | 533 | 342 | 244 | 202 | 155 | 122 | 99 [69 [45 5/8” 9398 | 3923 | 2304 | 1107 | 657 | 422 | 302 [250 | 191 | 151 | 123 | 88 | 85 a4 5649 | 3448 | 1594 | 947 | 608 | 434 | 360 | 276 | 216 | 177 | 123 | 80 7/8" 7689 | 4692 [2170 | 1289 | 823 | 501 | 490 [375 | 206 [240 {167 | 109 Az 6129 | 2834 | 1683 | 1081 | 772 | 640 | 490 [367 | 314 | 218 | 142 Te" 7757 | 3567 | 2130 | 1368 | 977 | 810 | 620 | 490 | 397 | 276 | 180 18" ‘9677 | 4428 | 6230 | 1689 | 1206 | 1000 | 766 _| 605 | 491 | 341 | 222 36" 5358 | 3182 | 2044 | 1460 | 1210 | 926 | 732 | 604 [412 | 269 Tue 6377 | 3787 | 2432 | 4737 | 1440 | 1103 | 671] 707 | 491 | 320 1-5/8 7483 | 4444 | 2854 | 2039 | 1690 | 1294 | 1022 | 829 | 676 [375 1-3/4" 8679 | 5154 | 3311 | 2364 | 1960 | 1507 | 4785 | 962 | 668 | 435 a 6732 {4324 | 3088 | 2560 | 1960 [1548 | 1265 | 872 | 568 ‘UNCONTROLLED DOCUMENT WHEN PRINTED (15-Det-06) CONTROLLED OOCUMENT IN JPI EWR 100-2004-001 - 24-47 File Name: FB-+.5205,Rev 2 Page 18 of 23 cies: 1aor) FREDAG PROGRAN_ HONG ENGREEANG Sun COR TECHNICAL STANDARD ‘Sab Taber Revision { PIPING PRESSURE TESTS FBAL-5205 2 Attachment B2 Test Blind Thickness Requirements Page 2 of 2 Test Blind Thickness Table (Pressures shown in Kpag) Plate ‘Nominal Pipe Size (inches) Thickness| 7 [Tue] 2 | * | #* | 6 tov [ie [aT ie | ie | 20" | ba | a 1/4" |29,820|14,507] 9,266 | 4,330 | 2.640] 7,290) 723 | 468 | 3320 | 275 | 213 | 165 | 137 S716" [46 617|22,677| 14,486] 6,763 | 4,130 | 4,909 | 7,130 | 730 | 517 | 434 | 330 | 262 | 213 | 144 3/8" {67,088|32,634|20,843] 9,735 | 6,043 | 2,744 | 1,882 | 7,048 | 761 | 620 | 475 | 372] 303 | 213 | tar 76" [44,424|28,372|13,252] 8,087 | 3.737 | 2,220 | 1,427 | 1,020 | 841 | 648 | S10 | 413 | 280 | 186 112” '58,021(37,060[17,313[ 10,563] 4,881 | 2,902 | 1,861 | 1,330 [1,103] 848 | 668 | 644 | 379 | 241 oie" 146,906]21,912]13,369] 6,184 | 3,675 | 2,356 | 1,682 | 1,392] 7,068) 841 | 682 | 475 | 310 5/8” '57,904|27,049] 16,506] 7,632 | 4,530 | 2,909 [2,082 [1,723 | 1,316 | 1,041 | 648 | 586 | 379 3/4" 138,949|23,773110,990] 6,529 | 4,192 | 2,992 12.482 | 1,903 | 1,503 | 1,220] 848 | 561 7/8" 53,015|32,351|14,962| 8,887 | 5.674 | 4,074 [3,378 | 2,585 | 2,040 [1,654 |1,151| 751 v 42,259] 19,540|11,604| 7,453 | 5,222 | 4,412 [3,378 | 2,668 | 2,165 | 1,503] 979 Te 53,484]24,732| 14,686] 9,432 | 6.736 | 6,584 | 4.274 | 3.378 | 2.737 | 1,903] 1,241 a 168,033]30,531]42,955] 11,648] 6,315 | 6,895 | 6,281 | 4,171 | 3.385 [2,361 | 1,530 138" [36,94312 1,930]14,003]10.066) 8,342 | 6,384 [5,047 [4,095 12,840] 1,854 ie 43,969|26,111]16,768|1 1,976] 9,926 | 7,605 | 6,005 | 4.874 | 3,385 | 2,206 5/8 51,595/30,641| 19,676) 14,058|11,652| 6,922 5,715 {4,971 | 2,585 7-3/4" '59,841[35,536|22,629|16,209|13,514|10,349) 6,632 | 4,605 | 2,999 2 46,417] 29.813|21,291] 17,651 ]13,514] 10,673] 8,722 16,012] 3.916 ‘UNCONTROLLED DOCUMENT WHEN PRINTED (15-Dec-06) CONTROLLED DOCUMENT IN JPIEWR 100-204-001 - 244.7 File Name: FB-L5205 Rev.2 Page 19 of 23, ope WeDecdeSr) "REEAG PROGRAM PONE ENGNEERING Sunco R TECHNICAL STANDARD Subject Naniber Revision: | PIPING PRESSURE TESTS: FB-L-5205 2 Attachment © ‘Summary of Revision ALTERNATIVE TESTING - PIPING REPAIRS, MODIFICATIONS, AND TIE-INS 4.0 PURPOSE The purpose of this procedure is to detail the requirements for use of alternative testing in tiew of hydrotesting, as required by Code and Suncor Standards for ing repairs, Modifications and tie-ins, 2.0 DEFINITION 21 This procedure applies to pressure piping system repairs, modifications and tie-ins, where application of a hydrotest is deemed impractical, 22 Alternative testing only applies to the field final tie-in weld(s) of the system being repaired or modified. Sub-assemblies and components must be hydrotested before performing the tie-in weld. Altemative testing shall not apply to equipment such as vessels and heat exchangers. 3.0 PROCEDURE All sub-assemblies and components must be hydrotested before performing the field weld. Temporary weided caps or closures may be required to perform this test. Although valves are hydrotested at the time of manufacture, it is recommended they be tested prior to installation to detect packing and bonnet gasket Jeaks. NDE for sub-assemblies must be preformed in accordance with the relevant piping specification per Suncor STD FB-L-5202. 3.4. CODE AND SUNCOR ALTERNATIVE TESTING REQUIREMENTS {tis the intent of Suncor and the Code requirements that hydrotesting be carried out whenever possible and practical. The purpose of a hydrotest is to ensure against leakage and to detect gross defects in the design, materials, welding and assembly. When conditions arise where the waiving of a pressure test is warranted, it is important that alternative testing ensures that the integrity of the system is maintained. CSA Standard B51, Boiler, Pressure Vessel and Piping states that where the application of a hydrostatic pressure test is difficutt or impractical, alternative procedures in lieu of the hydrotesting may be used only after approval by the Engineeer-In-Charge and followed by the notification to the regulatory authorities. UNCGNTROLLED DOCUMENT WHEN PRINTED (18-Hec46) CONTROLLED GOCUMENT IN JPI EWR 100-2004001 - 24-47 Fle Name: FB-L-5205_Rev.2 Page 20 of 23sont) ame TECHNICAL STANDARD ‘Subjeat Rober Ravin 32 33 4.0 44 44 42 PIPING PRESSURE TESTS FB-L-S205 2 CASES FOR APPLICATION OF ALTERNATIVE TESTING in every application, every effort must be made to Pressure Test. The following are cases where tests may not be practical: a. Piping shut off valves are not available for isolating a line and where temporary closures are impractical b. Hydrotesting would have to be carried out against a hot valve or live system. ¢. For systems such as lube oil, recirculating process fluid, seal water, etc. While starting up equipment such as pumps, compressors, and associated process equipment, ample ‘opportunity is provided for examination for leakage prior to the full scale operation. d. Attachment of non-pressure parts such as structural attachments or seal-welding of threaded joints, which were previously hydrotested, fe. Replacement of a single component in a system such as a valve, nipple, elbow etc. where isolation is impractical. The single component shall be closely inspected for defects, and all valves hydrotested as per the attached table. {Where lack of support integrity does nat allow hydrotest of an entire system ALTERNATIVE TESTING REQUIREMENTS ternative testing only applies to the FINAL FIELD WELD(S). The attached table lists the requirements for alternative testing, All alternative testing must be followed by an initial service test. The location must be left bare of insulation for examination during the initial startup of the system. IMPLEMENTATION The Area Maintenance Supervisor and Engineer-In-Charge may identify an application for altemative testing. A drawing/sketch is provided in the job package detailing the location of the field tie-in welds and required alternative testing. ‘An Engineer-In-Charge shall review applications for alternative testing in SEVERE SERVICE (as defined in the attached table) with consideration to safety, design, reliability and service conditions. The Engineer will review and specify the alternative testing required for the application. The Chief Inspector, or designate is responsible for reviewing all applications, prior to start of the job, for compliance with this procedure, Codes, and Suncor standards. The Chief Inspector is responsible for obtaining approval, as required, from the Authorized Inspector. File Name: F8U-5208 Rev.2 UNCONTROLLED DOCUMENT WHEN PRINTED (15-0ec6) CONTROLLED DOCUMENT IN JPI EWR 100-2004001 — 24-47 24 of 23 woones: 1sbaco8= 43 5.0 ‘UNCONTROLLED DOCUMENT WHEN PRINTED (15-Dac-06) CONTROLLED DOCUMENT IN JPI EWR 100-204-001 - 244-7 File Name: F-15305 Rev 2 Suncor) TECHNICAL STANDARD Namber Revision PIPING PRESSURE TESTS B-L-5205 2 ‘The Quality Assurance Area Inspector ensures that all alternative testing is completed as specified. INTERPRETATION AND UPDATING The Manager of Quality Assurance shall ensure interpretation and updating of this procedure.oR RAG PROGR SUNCOR TECHNICAL STANDARD Subject amber Revision PIPING PRESSURE TESTS FB-L-5205 2 Attachment C ‘Summary of Revision ALTERNATIVE TESTING REQUIREMENTS: (APPLIES TO FIELD TIE-IN WELDS ONLY) SERVICE PIPING SPECIFICATION | SHOPHYDROTESY | RT| MT | PT | UT] WI Water, Glycol, Sewage | ADA, ADX, AEC, AED, ALX, | Piping >= 27.5 13 F Condensate, and Slurry | CA, CAB, CAF, CAZ, CB, Capacity All less than ‘CHY, CKY, CS 36°F (186°C), 150psi (1034 Kpa) B31.3 Category D Air, Steam, Fly Ash, | CA, CBA, CS, ES, HS Valves and Piping | B | B ‘le Condensate / Water over F F 336°F (186°C) Hydrocarbons / Chemicals | AEA, AEX, CAB, CAF,CAH, | Valves and Piping | B | B | 8 | + |B <500psi (3448 Kpa), | CA, CAL, CAQ, CAR, CAX, F |r F <=500° F (260°C) | CKX, CLC, CXX, EA, EAU, 4150# /300#/ 600% | EAX, EDB, ELC. EXx Carbon Steel, 304 / 3168S Hydrocarbons / Chemicals | CAG, CBF, EAB, EAG, EDC, | ENGINEERING APPROVAL IS REQUIRED FOR 00psi (3448 Kpa), | EDX, HAG, HAX, HB, HBA, ‘ALL TESTING IN LIEU OF HYRDOTESTING 50°F (260°C) HBD, Hk, LAX, LDA, LLC, 600% / 900% / 1500# | RAA, RAX, RSA, RSB, RTA CS, Alloy Stee! SEVERE SERVICE LEGEND RT ~ 100% Radiography MT - Magnetic Particle PT — Penetrant (Stainless Steels) UT ~ Shearwave Ultrasonic WI- In Process Visual Weld Inspection per ASME B31.3 Section 344.7 * - Large Bore Branch Connections B— Butt Weld F — Fillet or Socket Weld ‘UNCONTROLLED DOCUMENT WHEN PRINTED (15-Dec-06) CONTROLLED DOCUMENT IN JPIEWR 100-2004001 —24.4-7 File Name: FB-L-5208_Rev.2 Page 23 of 23