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RAPID P0014 0026 PMG PRC 0001 0018

PETRONAS RAPID PROJECT

PACKAGE 14 - UTILITIES, INTERCONNECTING,
OFFSITE UNITS

HYDROSTATIC PRESSURE TESTING

PROCEDURE

OWNER Approval: PRPC Utilities and Facilities Sdn. Bhd.

Name: 
Date (DD-MMM-YY):

Signature:

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Pages modified under this revision: -

B 17-NOV-17 IFR – Issued For Review MIS JM BS

A 26-OCT-16 IFR – Issued For Review MAO HIB JM
DATE WRITTEN BY CHECKED BY APPROVED BY
REV. STATUS – REVISION MEMO
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PETRONAS RAPID PROJECT

PACKAGE 14 - UTILITIES, INTERCONNECTING,
OFFSITE UNITS

Sections changed in last revision are identified by a vertical line in the right margin.

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retrieval system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
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HYDROSTATIC PRESSURE TEST PROCEDURE

HOLD’s

HOLD No. REF. § DESCRIPTION ACTIONS

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HYDROSTATIC PRESSURE TEST PROCEDURE

Table of Contents
1. PURPOSE..................................................................................................................................... 4
2. REFERENCE DOCUMENTS......................................................................................................... 4
3. ACRONYM AND DEFINITIONS....................................................................................................5
4. ORDER OF PRECEDENCE.......................................................................................................... 6
5. PROCEDURE................................................................................................................................ 7
5.1 INTRODUCTION.................................................................................................................. 7
6. TEST MEDIUM.............................................................................................................................. 8
6.1 CRITERIA............................................................................................................................ 8
7. PNEUMATIC TESTING................................................................................................................. 9
NO PNEUMATIC TESTING REQUIRES.......................................................................................9
8. SENSITIVE LEAK TEST ING........................................................................................................9
FOR THE SENSITIVE LEAK TEST, REFERENCE IS MADE TO ASME B31.3 PARA.345.8(B).. .9
9. TEST EQUIPMENT....................................................................................................................... 9
9.1 LIST OF HYDROSTATIC TESTING EQUPMENTS.............................................................9
9.2 CALIBRATION CERTIFICATE.............................................................................................10
10. HYDROSTATIC PRESSURE TESTING......................................................................................10
10.1 PRIOR TO HYDROSTATIC TESTING.................................................................................10
10.2 DURING HYDROSTATIC TESTING....................................................................................11
10.3 COMPLETION OF HYDROSTATIS TESTING.....................................................................12
10.4 FLUSHING AND DRYING....................................................................................................13
11. SAFETY PRECAUTIONS............................................................................................................ 13
12. TEST PACK................................................................................................................................. 14
13. RECORDS................................................................................................................................... 14
14. APPENDIX................................................................................................................................... 15

1.

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system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
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1. PURPOSE
PETRONAS intends to build a grass root integrated Refinery and Petrochemicals Complex by
developing the RAPID PROJECT (Refinery and Petrochemical Integrated Development) to meet
both domestic and Asia's energy and chemicals demand. The RAPID PROJECT consists of a world
scale integrated site which includes Refinery with a deep conversion scheme, 300 000 barrels per
stream day capacity, Naphtha Steam Cracker of 1.28 million tons of ethylene per year capacity;
Petrochemical Derivative Units, utilities, off site and jetty installations.
The RAPID PROJECT is a fundamental component of the Pengerang Integrated Complex (PIC)
which also includes the following major projects; Pengerang Cogeneration Plant (PCP), a new LNG
Regasification Terminal (RGT2), Raw Water Supply Project (PAMER), Pengerang Deep Water
Terminal (PDWT) and Air Separation Unit (ASU) which provides oxygen and nitrogen gases to the
Complex and to the local market.
The RAPID PROJECT is located at Pengerang, Mukim of Pengerang, Kota Tinggi District, Johor
and is in close proximity to the international shipping lane connecting the Straits of Malacca,
Singapore and the South China Sea
The purpose of this document is to provide guidance in hydrostatic pressure testing and
flushing/drying of newly fabricated and erected piping and utilities process lines to ensure that
piping system are clean from debris or unwanted items and the integrity of the system is proven.
The procedure is applicable for the flushing/drying and hydrostatic pressure testing (HT) to confirm
the integrity of new fabricated piping spools and completed piping system.
This covers all the lines piping system and piping spools being tested in either the fabrication
workshop (outside PRPC area and TCF) or at the area 6900-01A, 6900-01B and 6900-01C.

2. REFERENCE DOCUMENTS

RAPID-P0014-OUI-MCI-SPN-0001-0101 Project Specification-Welding of Metal

RAPID-P0014-OUI-PIP-SPN-0001-0005 Piping Pressure Testing Specification

RAPID-P0014-OUI-PIP-SPN-0001-9008 Project Specification – Shop and Field

Fabrication of Piping

RAPID-P0014-OUI-PIP-SPN-0001-9011 Project Specification – Pipe Support

RAPID-P0014-0026-PMG-ITP-0001-0002 Inspection and Test Procedure for Piping

Including ITP

"In accordance with Article 38 of the UIO EPCM Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”
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3. ACRONYM AND DEFINITIONS

OWNER: PRPC Utilities and Facilities Sdn. Bhd.
EPCM CONTRACTOR: OUI JV: Joint venture appointed by OWNER with specified authority
to perform the EPCM Services of the UIO Project.
PROJECT or UIO PROJECT: EPCM of utilities, interconnecting and offsite facilities (UIO) Package
14 for RAPID PROJECT at Pengerang, Johor
EPCM: Engineering, Procurement and Construction Management
PACKAGE WORK: The works, services or supplies, or any or all of the foregoing, to be
undertaken by a PACKAGE CONTRACTOR or PACKAGE
VENDOR, as applicable.
"SCOPE OF WORK" may also be used instead of "PACKAGE
WORK" to facilitate the understanding of all the parties.
PACKAGE: means each package of works or supplies forming part or parts of
the PROJECT.
PACKAGE VENDOR: means any Vendor engaged by OWNER to supply Equipment and
Materials or Spare Parts, which may include associated services.
PACKAGE CONTRACTOR: means any Contractor engaged by OWNER to undertake the
PACKAGE WORKS for a PACKAGE.
PROJECT SPECIFICATION means mandatory documents comprising of specifications,
PETRONAS Technical Standards and Project Procedures.
SUBCONTRACTOR: means any company which EPCM CONTRACTOR has engaged or
proposes to engage (as the context may require) to undertake any
part of the EPCM CONTRACTOR Services
The acronyms used in this document have the meaning defined below:

HT : Hydrostatic Test
ITP : Inspection Test and Plan
ISO : Isometric Drawing

"In accordance with Article 38 of the UIO EPCM Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”
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4. ORDER OF PRECEDENCE

In case of conflicts between the LAWS, PROJECT SPECIFICATION and Codes & Standards, the
following order of precedence shall be considered:

 Malaysia Laws and applicable regulatory requirements;

 PROJECT SPECIFICATION
 Applicable Malaysia Codes & Standards
 Applicable international Codes & Standards.

If a lower level requirement is more stringent than an upper level one in the hierarchy described
above, PACKAGE CONTRACTOR shall raise a request to OWNER for a written decision before
undertaking any related activity for the SERVICES.

In case of conflict between requirements in different documents at the same level of the hierarchy,
the most stringent requirement shall apply. PACKAGE CONTRACTOR shall provide its
interpretation in writing for OWNER’S approval. In all such cases of conflict, OWNER decision shall
be final.

"In accordance with Article 38 of the UIO EPCM Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
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5. PROCEDURE

5.1 INTRODUCTION

5.1.1 The hydrostatic pressure testing (HT) shall be carried-out in accordance with
relevant, specification, codes and standards for this project.

5.1.2 Hydrostatic testing shall be performed after the completion of all required
examination and stress relieving with NDE & Welding verification/release by NEWS.

5.1.3 Hydrostatic testing shall be covered all flanged connections pipe spool and pipe
spools completely installed on the area 6900-01A, 6900-01B and 6900-01C.

5.1.4 Test pack shall be included a complete set of mark-up P & ID and ISO drawings, its
specified the piping line list, test pressure, data & etc. in according to Test pack
check list. It also shall be approved by EPCM’s Engineering.

5.1.5 Line check shall be performed and clearance of pre-punch works prior to Hydrostatic
testing of the piping system or its components.

5.1.6 Pressure testing may be performed on fully painted piping spools (including welds)
provided that:

• The welds consist of at least two layers (root and fill run) for stainless steels,
and three layers for all other materials, in accordance with a Welding
Procedure Specification qualified for the application;

• The test is not considered to be a sensitive leak test in accordance with

ASME B31.3.

• The piping spool has been fully inspected (visual examination, non-
destructive examination and positive material identification, where specified)
and released for pressure test.

5.1.7 No attempt shall be made to repair leaks on system under-going hydrostatic testing.
The system shall be fully depressurized before repairs work are conducted.

"In accordance with Article 38 of the UIO EPCM Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
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6. TEST MEDIUM

6.1 CRITERIA

6.1.1 Care shall be taken to ensure the use of clean water for these testes. A suitable
10µm filter should be provided in the filling line regardless of the water source.
Special precautions shall be taken if weather condition can cause freezing or heating
up of the test water.

6.1.2 Hydrostatic test pressure shall not be applied until the piping and its contents are at
approximately the same temperature. To minimize the risk of the brittle fracture,
pressure tests through piping shall not be conducted when the test medium or metal
temperature is below 16°c.

6.1.3 Carbon steel and low alloy steel piping

• Piping with carbon steel or low alloy steel piping classes may be
hydrostatically tested with portable water having a chloride content of no more
than 250 ppm. The use of brackish or salt water requires OWNER approval.

• If portable water is not used, the test water shall be completely drained and
the piping flush with portable water immediately after testing and thoroughly
dried with air blowing.

6.1.4 Austenitic stainless-steel piping

 Water used for hydrostatic testing of austenitic stainless-steel piping shall be

tested for chloride and MIC (Microbiologically Influenced Corrosion Causing
Bacteria) and shall conform to the requirements listed below.

 To minimize the risk of MIC, austenitic stainless-steel piping shall be clean prior
to final assembly and hydrostatic testing.

 Austenitic stainless-steel piping shall be tested with condensate, boiler feed or

demineralized water having a chloride content of no more than 50 ppm.

 Alternatively, with OWNER approval, it may be tested with portable water

provided that is either drained and mechanically dried immediately after the
testing, or flush with condensate, boiler feed water or demineralized water
immediately after the testing.
"In accordance with Article 38 of the UIO EPCM Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
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 Removing water or drying by blowing with hot air or gas shall be performed
unless the testing or flushing has been done with condensate, boiler feed water
or demineralized water.

 Steam or electricity traced system should be tested or at least properly flushed

with the applicable test medium depending on the material of the piping prior to
the functional testing of the tracing.

6.1.5 General

 After pipe has been tested, it shall be drained and blow dry & witness by Owner,
EPCM, PACKAGE CONTRACTOR AND PRE-COMMISIONSING team. Air
blowing shall be continuing until the output air is free from water vapor and dust.

 Piping that is to be chemically cleaned after installation shall be tested and all
repair made to cleaning.

 After testing, the test medium shall be drained and covered with plastic end cap
or wooden plated after piping thoroughly dried such that relatively low moisture or
chloride laden deposit will enter the piping.

7. PNEUMATIC TESTING

NO PNEUMATIC TESTING REQUIRES

8. SENSITIVE LEAK TEST ING

FOR THE SENSITIVE LEAK TEST, REFERENCE IS MADE TO ASME B31.3 PARA.345.8(B).

9. TEST EQUIPMENT

9.1 LIST OF HYDROSTATIC TESTING EQUPMENTS

 Hydrostatic test pump

 Pressure gauge
 Ball/need valves
 Tube and fittings
 Pressure relief valve
 Temperature and pressure recorder
 Vent release valve
 High pressure hose and fitting air compressor
"In accordance with Article 38 of the UIO EPCM Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
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 Strainer

9.2 CALIBRATION CERTIFICATE

9.2.1 Pressure relief valve, pressure/temperature recorder and pressure gauge shall be
calibrated prior to hydrostatic testing.

10. HYDROSTATIC PRESSURE TESTING

10.1 PRIOR TO HYDROSTATIC TESTING

10.1.1 The system shall be checked and preparedd as the follow, but not limited to;
 Completeness of all piping system and attachments as per P & ID and ISO
drawings.
 Pipe, valve size, flange ratings are in accordance with piping layout and ISO
drawings.
 Low point drains and high point vents are installed as per ISO drawing and
indicated on P & ID.
 Piping is properly supported as per pipe support drawing.
 All flange connection is properly torqued in accordance with approved Flange
Management procedure.
 Gasket, temporary blinds, spectacle blinds, bleed rings, etc. are correctly
installed.
 Instruments connected to the tested line shall be temporary isolated, and it is
recommended to disconnect of isolating all tubing connections.
 All bleed valves, drains or vents shall be provided with plugs or blinds whichever
applicable.
 Verify that any required heat treatment has been performed.

"In accordance with Article 38 of the UIO EPCM Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”
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10.1.2 All piping shall be tested in accordance with ASME B31.3, project specification. The
test pressure shall be according to data stated in the latest edition of piping line list.

10.1.3 Minimum two (2) pressure gauges, i.e. one (1) fitted on the highest point and another
at the lowest point, one (1) temperature/pressure recorder shall be used on each
test.

10.1.4 The recorder rand pressure gauge shall be such test pressure in within 25% to 75%
of full scale. Recorder timer duration shall be a maximum of 8 hours and preferably 4
hours

10.1.5 Location of Hydrostatic testing pump and recorder shall be easily accessible to the
personnel conducting the test. The test pressure shall be recorded on a two (2)
different color pend for pressure and temperature chart recorder.

10.1.6 Gauge and recorders shall be calibrated and witnessed. Gauges used for the
hydrostatic testing shall be calibrated using a dead weight test and selection based
on the minimum 1.5 times to 4 times of test pressure.

10.1.7 Hydrostatic testing test pack shall be reviewed and approved by EPCM
CONTRACTOR. The hydrostatic testing test pack drawing shall be revised if there is
a change to the actual line system under testing.

10.1.8 A suitable sized pressure relief device shall be provided, between the pump and the
piping fills connection, to protect the piping from potential overpressure. The relief
device shall be reset and calibrated with 110% of test pressure.

10.2 DURING HYDROSTATIC TESTING

10.2.1 Fill the system with water preferably at the lowest points in the system.

10.2.2 All vent line valve connection shall be opened and closed only when there is a steady
flow of air-free test water at the vent opening.

10.2.3 The sequence closure shall be from the lowest to the highest system vent points. The
hydrostatic testing water shall be filled prior to introduction into the line.

10.2.4 During the filling, all external surface should be dried and the system examined for
leakage.

10.2.5 Upon completion, pump shall be disconnected from the system and all vents closed.

10.2.6 Connect the hydrostatic testing system, where two (2) numbers of calibrated
pressure gauges shall be installed at the lowest and highest point of the system.

10.2.7 Isolate the recorder initially. Pre-hydrostatic testing the system (system under test) to
check for any leaks. If there is no leak in the system, de-isolate the recorder back in
system and ready to start recording the test pressure.
"In accordance with Article 38 of the UIO EPCM Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
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10.2.8 Gradually pressurized from 0%, 25%, 50% to 75% and 5 minutes interval minimum
for stabilization and leakage check. Upon conforming that there no leakages, the
pressure shall be increase to 100% of the required hydrostatic test pressure

10.2.9 Hydrostatic testing pressure shall be maintained for sufficient time for visually check
for any leaks, but not less than 10 minutes. Test pressure is not requiring to hold
more than 2 hours after notification to EPCM CONTRACTOR.

10.2.10 When the test pressure has been achieved, the test pump shall be isolated or
disconnected from the system.

10.2.11 Hold the system at the requires test pressure and duration shall be minimum
of one (1) hour.

10.2.12 Any pressure drops during testing, PACKAGE CONTRACTOR shall confirm
the test temperature correlation to test pressure, if pressure drop due to cold
temperature, all parties should remark/clarify the reason beside the recorder chart.

10.2.13 The whole system shall be examined for leaks throughout testing duration. If
any leaks discovered the system shall be depressurized for repair and rectification.

10.3 COMPLETION OF HYDROSTATIS TESTING

10.3.1 After hydrostatic testing successfully carried-out, the test pressure should gradually
release from 75%, 50%, 25% to 0% in 5 minutes interval minimum, all vents have to
be opened and kept open in order that no vacuum generated in piping.

10.3.2 After completion of testing the system shall be cleaned/flushed with make use of test
medium (Portable water) to remove dirt, loose rust, mill scale and construction debris
from the pipe internal, drying with air blow shall carry-out immediately as described in
6.1.5. All parties, client and Pre-commissioning team to witness and verify the
cleaning activities,

10.3.3 All temporary blanks and spectacle blinds shall be removed, all operating blinds
returned to proper position, and all lines and piping components shall be completely
drained. Valves, orifice plates, expansion joints, and short pieces of piping that have
been removed shall be reinstalled with proper new gaskets in place. Valves that were
closed during hydrostatic test shall be opened to ensure drainage of the bonnet
cavity.

"In accordance with Article 38 of the UIO EPCM Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
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10.3.4 Direct mounted transmitters at orifice flanges must be disconnected when replacing
orifice plates to avoid distorting the connections.

10.3.5 Instruments which were removed or blocked out for test shall be reinstalled and
blocks placed in the normal operating position.

10.3.6 Check valves that were jacked open or the internals were opened specifically for
pressure testing shall be closed.

10.4 FLUSHING AND DRYING

10.4.1 Flushing will be performed upon completion of hydrotest and make use the drain test
medium (portable water) to remove dirt, loose rust, mill scale and construction debris
from the pipe internal.

10.4.2 Online valve shall be fully in open position during flushing works.

10.4.3 This flush cleaning will be considered acceptable when no rust scale and
construction debris. This step shall be a “Hold Point Inspection” for the EPCM’s
CONTRACTOR & PRE-COMMISIONING.

10.4.4 Dewatering and flushing work shall be completed in a same day if possible to reduce
internal pipe corrosion occurrence.

10.4.5 After flushing, the pipe system shall be completely drained and blowing.

10.4.6 Air blowing shall be continuing until the output air is free from water vapor and dust.

"In accordance with Article 38 of the UIO EPCM Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”
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11. SAFETY PRECAUTIONS

11.1.1 During test pressure build-up, suitable precaution shall be taken to prevent from
excessive pressure and monitor high pressure pump at all time of testing.

11.1.2 Test area shall be barricaded with warning signboards.

11.1.3 PACKAGE CONTRACTOR shall ensure correct pressure rate for ancillary fitting are
used (i.e. temporary piping, hoses, blanks, etc.) which can withstand the flushing and
pressure test.

11.1.4 All system testing will be carried-out in accordance with applicable Codes, Project
Specification requirements and other Standards.

11.1.5 No bolt tightening to be performed during test pressure stabilization.

11.1.6 Only authorized/trained personnel shall be allowed to work in within test area during
testing.

11.1.7 Flushing and blowing activities to be supervised at all times when pump running, a
good communication is to be maintained at all times among co-workers.

11.1.8 PTW, JMS/JSA & tool box shall be prepared and conducted to test crew members
prior to commencement of testing.

12. TEST PACK

12.1.1 Test pack shall be prepared and submitted to EPCM’s CONTRACTOR for review
and approval.

12.1.2 Each test pack shall consist of the following;

 Front cover sheet
 Test pack content sheet
 Test pack sign-off sheet
 NEWS (NDE) – NDE Clearance certificate by Isometric drawing
 Legend sheet
 Plot plan (Pressure test location map)
 P&ID list
 P&ID/Test boundary/Battery limit
 Line list sheet
 Isometric list & Blind list
 Isometrics/GA/As-built Drawings
 Piping punch list/work list
 Special pipe supports
 Other certificates i.e.; Calibration certificates, test certificates.
"In accordance with Article 38 of the UIO EPCM Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”
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 PDCN & NCR’s (if applicable)

 Test pack QCFs

13. RECORDS

13.1.1 Records shall be kept of all parameters specified in this project specification during
each testing.

13.1.2 For each completed piping system test, a final pressure test report shall be compiled.
These reports, when completed, shall be retained in the field QC file as a permanent
record. The contents, as a minimum, shall include the following;

 Date of test
 Identification of piping system and or equipment tested with the piping
system.
 Test medium
 Test pressure
 Minimum ambient temperature
 Test medium temperature
 Test result (pressure test charts)
 Records of weld repairs and procedures, welders employed, any
corrective action undertaken
 Name of test operator
 Minimum metal temperature (if applicable)

"In accordance with Article 38 of the UIO EPCM Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”
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14. APPENDIX

APPENDIX 1: STATUS OF INSTRUMENT DURING PRESSURE TEST

General

• This appendix defines additional requirements for pressure testing of

instrumentation.

• Pressure testing of instrument process piping after the piping root valve
and control pneumatic piping are not covered by this specification.

Specific Requirements

• The status of instruments during pressure testing shall conform to Table

1 below. Instruments not covered in Table 1 shall not be subjected to
pressure testing without OWNER's authorization.

• When flanged instruments are removed from the test, the flange facings
shall be protected over the entire gasket seating surface with hook or
plastic covers, securely attached to the instrument, to exclude dirt and other
foreign matter from the interior of the instrument and to protect the flange
facings.

• When threaded instruments are removed from the test, the threaded ends
shall be closed with metal (of the same basic metallurgy as the instrument
material) or plastic protectors, to exclude dirt and other foreign matter from
the interior of the instrument.

NOTE: Extreme caution should be taken in regards to Stainless Steel

NPT fittings. Do not cap ends with Stainless Steel caps or plugs, without
proper lubrication, as galling will occur. It is recommended to use PVC
threaded caps or plugs.

• If spacer plates are required to be installed during testing, to replace

removed orifice plates, they shall be installed using test gaskets and test
bolting.

• Float type level instruments shall be excluded from pressure testing.

• Displacer type level instruments shall be blocked from the test and drained.

• Pressure instruments shall have their root valve closed and the drain valve
shall be open during testing.

• Analyzer tubing shall be disconnected during testing.

"In accordance with Article 38 of the UIO EPCM Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”
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Table 1 – Status of Instruments During Pressure Testing

Block Include
Instrument Type Remove Blank Off Refer To
and Vent in Test
1. Analyzers (Intrusive Type) X 2.8

2. Analyzers (Extractive Type) X 2.8

3. Control valves (excluding pressure regulators,
X
pressure balanced, and butterfly)
4. Control valves (butterfly) X

5. Flow transmitters (D/P type) X

6. Flow instruments (Metal tube rotameters,
Vortex, Coriolis, Magnetic, Ultrasonic, Flow X
nozzle & Ventura)
7. Flow meters (positive displacement) X

8. Flow meters (turbine) X

9. Flow indicating switches (bellows) X

10. Flow switches (vane) X

11. Level gauges [1] X

12. Level instruments (displacer) [1] X 2.6

13. Level instruments (D/P type) X

14. Level switches (float) [1] X 2.5

15. Orifice plates & restriction orifice plates X 2.4

16. Pressure gauges [2] X

17. Pressure instruments X 2.7

18. PSV’s X

19. PSV’s / TSV’s – 3/4” and 1” screwed X

20. Pressure regulators X

21. Pressure switches X

"In accordance with Article 38 of the UIO EPCM Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”
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Notes:

1. Block, vent for external chamber mounted type. Remove for direct vessel internal
mounted type. Vessel flange to be blinded.

2. Pressure gauges that are contractor material should not be installed after systems testing.
APPENDIX 2: SUMMARY OF THE CALCULATED TEST PRESSURES PER PIPING CLASS
The test pressures listed in Table 2 are computed based on Equation 1 from section 9.3.1.1
of this specification. Unless noted otherwise in the piping line list, the test pressures of the
lines carrying the listed piping classes shall be in accordance with this table.

Table 2 – Summary of the Calculated Test Pressures per Piping Class

Material Size Range Design Pressure Design Temp Test Pressure
Piping Class
(ASTM) [1] (DN) [2] (barg) [3] (°C) [3] (barg)
1C100DA A106 Gr. B All 19.6 -20 / 0 29.4
1C101DA A106 Gr. B All 19.6 -20 / 0 29.4
1C101DA-20 A106 Gr. B 15 – 600 19.6 -20 / 0 29.4
A234 Gr. WPB > 600 7.0 250 11.0
1C102DA A106 Gr. B All 19.6 -20 / 0 29.4
1C102DA-KS A333 Gr. 6 All 19.6 -20 / 0 29.4
1C102DC [8] A106 Gr. B All 19.6 -20 / 0 29.4
1C103DA A106 Gr. B All 19.6 0 29.4
1C108DA A106 Gr. B / 15 – 600 19.6 -20 / 0 29.4
API 5L Gr. B
A234 Gr. WPB > 600 18.4 75 27.6
1C108DB A106 Gr. B All 19.6 -20 / 0 29.4
1C108DC A106 Gr. B / All 19.6 -20 / 0 29.4
API 5L Gr. B
1C114DA A106 Gr. B 15 – 600 19.6 -20 / 0 29.4
A234 WPB > 600 18.4 75 27.6
1C116DA A106 Gr. B All 19.6 0 29.4
1C118DA A106 Gr. B All 19.6 -20 / 0 29.4
1C119DA-20 A333 Gr. 6 15 – 600 19.6 -46 / 0 29.4
A420 Gr. WPL6 > 600 7.0 250 11.0
1C124DA A333 Gr. 6 All 19.6 -46 / 0 29.4
1C124DB [8] A333 Gr. 6 15 – 600 19.6 -46 / 0 29.4
A420 Gr. WPL6 > 600 19.6 -46 / 0 29.4
1C127DA A106 Gr. B All 19.6 0 29.4
1C136DA A106 Gr. B / 15 – 600 19.6 0 29.4
API 5L Gr. B
A234 WPB > 600, ≤ 1400 17.5 75 26.3
A672 Gr. C65 > 1400 17.5 75 26.5
1C136DB A106 Gr. B / 15 – 600 19.6 0 29.4
API 5L Gr. B
A234 WPB > 600, ≤ 1400 13.0 75 19.5
A672 Gr. C65 > 1400 13.0 75 19.7
1C136DC A106 Gr. B All 19.6 0 29.4
1C136DD [8] A106 Gr. B All 19.6 0 29.4
1C139DA A106 Gr. B 15 – 600 19.6 0 29.4
A234 WPB > 600 15.8 150 23.7
1C139DA [5] A106 Gr. B 15 – 600 6.0 175 9.0
A234 WPB > 600 6.0 175 9.0
1C144DA A106 Gr. B All 19.6 0 29.4

"In accordance with Article 38 of the UIO EPCM Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
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1G100DA API 5L Gr. B All 16.0 0 24.0

1G101 [4] A106 Gr. B All 10.0 -20 / 0 15.0
1G101DA [4] A106 Gr. B All 12.0 150 18.0
1G301 API 5L Gr. B All 16.0 0 24.0
1L103DA A335 Gr. P11 All 19.8 0 29.7
1N103DA [4] GRE All 16.0 80 24.0
1N103DB [6] GRE All ATM 60 -
1N103DC [4] GRVE All 16.0 75 24
1N301 [6] PVC-U All ATM 60 -
1N302 [4] PVC-C All 5.5 75 8.25
1N302 [4] [7] PVC-C All 13.0 60 19.5
1N303 [4] HDPE All 3.5 60 5.3
1N304 [8] HDPE All 3.5 60 5.3

Table 2 – Summary of the Calculated Test Pressures per Piping Class

Material Size Range Design Pressure Design Temp Test Pressure
Piping Class
(ASTM) [1] (DN) [2] (barg) [3] (°C) [3] (barg)
1N305 [8] HDPE All 6.5 60 9.8
1N306 [8] HDPE All 14.0 50 21.0
1S105DB A312 Gr. TP316/316L 15 – 300 19.0 -20 / 0 28.5
A358 Gr. 316/316L ≥ 350 19.0 -20 / 0 28.5
1S105DC A312 Gr. TP316/316L 15 – 300 19.0 -20 / 0 28.5
A358 Gr. 316/316L ≥ 350 19.0 -20 / 0 28.5
1S105DD A312 Gr. TP316/316L All 19.0 -20 / 0 28.5
1S105DE A312 Gr. TP316/316L 15 – 300 19.0 -20 / 0 28.5
A358 Gr. 316/316L ≥ 350 19.0 -20 / 0 28.5
1S108DA A312 Gr. TP316/316L All 19.0 -20 / 0 28.5
1S109DA [8] A312 Gr. TP316/316L 15 – 300 19.0 -20 / 0 28.5
A358 Gr. 316/316L ≥ 350 19.0 -20 / 0 28.5
1S113DA A312 Gr. TP304/304L 15 – 300 19.0 -20 / 0 28.5
A358 Gr. 304/304L ≥ 350 19.0 -20 / 0 28.5
1S117DA A312 Gr. TP304/304L 15 – 300 19.0 -20 / 0 28.5
A358 Gr. 304/304L ≥ 350 19.0 -20 / 0 28.5
1S119DA A312 Gr. TP304/304L 15 – 300 19.0 -196 / 0 28.5
A358 Gr. 304/304L ≥ 350 19.0 -196 / 0 28.5
1S301 A312 Gr. TP316/316L 15 – 300 19.0 -100 / 0 28.5
A358 Gr. 316/316L ≥ 350 19.0 -100 / 0 28.5
3C100DA A106 Gr. B All 51.1 -20 / 0 76.7
3C102 [8] A106 Gr. B 15 – 50 51.1 -20 / 0 76.7
80 – 100 51.0 -20 / 0 76.5
≥ 150 42.9 -20 / 0 64.4
3C102DA-KS A333 Gr. 6 15 – 50 51.1 -20 / 0 76.7
80 – 100 51.0 -20 / 0 76.5
≥ 150 42.9 -20 / 0 64.4
3C108DA A106 Gr. B All 50.5 0 75.8
3C108DB A106 Gr. B All 50.5 0 75.8
3C113DA-KS A333 Gr. 6 All 51.1 -46 / 0 76.7
3C114DA A106 Gr. B All 51.1 0 76.7
3C121DA A106 Gr. B All 50.5 0 75.8
3C124DA A333 Gr. 6 15 – 50 51.1 -46 / 0 76.7
80 – 100 51.0 -46 / 0 76.5
≥ 150 50.5 -46 / 0 75.8
3C124DB A333 Gr. 6 All 51.1 -46 / 0 76.7
3C124DC A333 Gr. 6 15 – 250 51.1 -46 / 0 76.7
≥ 300 50.5 -46 / 0 75.8
3C139DA A106 Gr. B 15 – 250 50.8 0 76.2
300 – 600 42.9 200 64.6
A234 Gr. WPB > 600 25.0 350 43.7

"In accordance with Article 38 of the UIO EPCM Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
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3L103DA A335 Gr. P11 15 – 400 51.5 100 83.0

A691 Gr.1-1/4 CR ≥ 450 51.7 0 77.6
3S117DA A312 Gr. TP304/304L 15 – 300 49.6 -20 / 0 74.4
A358 Gr. 304/304L ≥ 350 49.6 -20 / 0 74.4
3S119DA A312 Gr. TP304/304L 15 – 300 49.6 -196 / 0 74.4
A358 Gr. 304/304L ≥ 350 49.6 -196 / 0 74.4
3S301 A312 Gr. TP321 50 – 300 49.6 -20 / 0 74.4
A358 Gr. 321 ≥ 350 49.6 -20 / 0 74.4
6C108DA A106 Gr. B 15 – 450 102.1 0 153.2
A333 Gr. 6 ≥ 500 102.1 0 153.2
6C139DA A106 Gr. B 15 – 450 102.1 0 153.2
A333 Gr. 6 500 – 600 102.1 0 153.2
A420 Gr. WPL6 > 600 97.0 0 145.5
6L103DA A335 Gr. P11 15 – 400 62.0 455 128.6
A691 Gr.1-1/4 CR ≥ 450 62.0 455 114.3
9C139DA A106 Gr. B 15 – 250 130.0 175 195.5
A333 Gr. 6 ≥ 300 130.0 175 195.5

Notes:
1. The material indicated has the lowest allowable stress (weakest component) compared
to the other materials in the piping class for the specified size range.
2. The size range of each piping class is as per RAPID-P0014-OUI-PIP-SPN-0001-0019.
3. The design pressure and temperature is taken from the P-T Ratings of the piping
class. With consideration to the prevalent material (Note 1), the maximum P/S ratio
occurs at this indicated pressure and temperature conditions.
4. For nonmetallic and lined piping systems, the test pressure indicated shall be
reconfirmed with the MANUFACTURER.
5. The test pressure indicated shall be applicable only to boiler feed water (BFW)
service under piping class 1C139DA.
6. Lines using this piping class are open to atmosphere.
7. The test pressure indicated shall be applicable only to lines without valve
components under piping class 1N302.
8. Piping class not used.

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APPENDIX 3: HYDROTEST CONNECTION DIAGRAM

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