Attachment 19-Exterran Pneumatic Pressure Testing Specification

Pneumatic Pressure Testing
PROCEDURE
CONTROLLED COPY
ENG-PRC-1025
VERSION: 2.0
Approved By: Patel, MK; Contasti, Gustavo G

Created By: Sai Quach (Sr. Project Engineer)
ENGINEERING
PROCEDURE
PNEUMATIC PRESSURE TESTING
Version: 2.0 Number: ENG-PRC-1025 Release Date: 11/3/2014
THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN IS CONFIDENTIAL AND PROPRIETARY. FOR INTERNAL USE ONLY.
VERSION INDEX
Version Date Description of Changes Revised By
10-Aug- Converted without change from ENG-PRC-US-IPS-001,
1 Amira Shaikh
2014 ver. 1
2 26-Oct-14 Column 2; Locations Revised to All Locations Kulasekaran R
COPYRIGHT © EXTERRAN HOLDINGS, INC. ALL RIGHTS RESERVED.

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ENGINEERING
PROCEDURE
TABLE OF CONTENTS
1.0 OBJECTIVE ..................................................................................................................................................... 4
2.0 SCOPE ........................................................................................................................................................... 4
3.0 OWNERSHIP STATEMENT ............................................................................................................................. 4
4.0 REFERENCES ................................................................................................................................................ 4
5.0 DEFINITIONS ................................................................................................................................................. 4
5.1 Pneumatic Leak Test ....................................................................................................................................... 4
5.2 Supplier ............................................................................................................................................................. 5
5.3 Owner ................................................................................................................................................................ 5
5.4 Shall .................................................................................................................................................................. 5
5.5 Should ............................................................................................................................................................... 5
6.0 RESPONSIBILITIES ........................................................................................................................................ 5
6.1 Director of Engineering .................................................................................................................................... 5
6.2 Regional Directors of Project Managers, Engineering Manager and Supply Chain Manager for Integrated
Projects ........................................................................................................................................................................ 5
6.3 Project Manager ............................................................................................................................................... 5
6.4 Construction Manager ..................................................................................................................................... 5
6.5 Test Supervisor ................................................................................................................................................. 5
6.6 Safety Representative ...................................................................................................................................... 6
7.0 SAFETY & ENVIRONMENTAL ......................................................................................................................... 6
8.0 PROCEDURE .................................................................................................................................................. 6
8.1 General ............................................................................................................................................................. 6
8.2 Test Preparation ............................................................................................................................................... 7
8.3 Testing .............................................................................................................................................................. 9
8.4 Documentation ............................................................................................................................................... 10

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1.0 OBJECTIVE
The objective of this procedure is to ensure safe pneumatic pressure testing of piping/vessel systems
in accordance with ASME B31.3 Process Piping.
NOTE: The acceptance of pneumatic testing of pressure piping may be done on a case-by-case basis
or may be permitted when the test is conducted in accordance with a standard pneumatic test
procedure for pressure piping systems in accordance with the Exterran QHSE Program. A standard
pneumatic test procedure for pressure piping systems must include stored energy limitations
established in accordance with this requirements document.
Pressure testing, in general, introduces hazards that must be identified and understood. Appropriate
measures to manage the risk of a potential failure must be considered. Pneumatic testing is
inherently more hazardous than a hydrostatic test of the same conditions of volume, pressure and
temperature. Appropriate safety precautions must be taken based on the stored energy contained in
a pneumatic test.
2.0 SCOPE
This procedure provides the definitions and methods to mitigate potentially hazardous situations
typically associated with the pneumatic pressure testing of piping/vessel systems. This procedure
applies to Integrated Projects at field construction.
This document is applicable to the following product lines and locations:
Product Lines: INTEGRATED PROJECTS
Locations: All Locations
3.0 OWNERSHIP STATEMENT

The Director of Engineering Services maintains control of this document and is responsible for
ensuring that this document is necessary and reflects actual practice. Paper copies of this document
are uncontrolled and may not be the most recent version. Paper copies are valid only at the time of
printing. The controlled version of this document is stored on the Exterran intranet web site.
4.0 REFERENCES
ASME B31.3 – Process Piping
5.0 DEFINITIONS
5.1 Pneumatic Leak Test
5.1.1 A pneumatic leak test is the testing of equipment, piping, completed process systems, or portions
thereof, using inert gases as the test medium and where 100 percent of the item(s), equipment,
systems meet the pressure test codes, standards and engineering design of the proposed leak test.

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5.2 Supplier
5.2.1 Contractor/Vendor/Bidder/Business entity offering equipment and/or services for sale
5.3 Owner
5.3.1 Entity that ultimately pays and possesses the exclusive right to hold, use, benefit-from, convey,
transfer, and otherwise dispose of equipment and services
5.4 Shall
5.4.1 The word “shall” indicates a mandatory requirement
5.5 Should
5.5.1 The word “should” indicates a strong recommendation
6.0 RESPONSIBILITIES
6.1 Director of Engineering
6.1.1 The Director of Engineering for Integrated Projects shall maintain responsibility for the revision and
posting of this document for use on Integrated Projects.
6.2 Regional Directors of Project Managers, Engineering Manager and Supply Chain Manager for
Integrated Projects
6.2.1 The Regional Directors of Project Managers, Engineering Manager and the Supply Chain Manager for
Integrated Projects maintains the responsibility for enforcing this procurement specification on
Integrated Projects.
6.3 Project Manager
6.3.1 The Project Manager is responsible for providing the detailed written procedure for the pressure test
in accordance with ASME B31.3 Process Piping, the calculated safe boundary zone, and a set of
applicable drawings and test pressures for the systems to be tested. Project Manager shall ensure
the pneumatic test will not void any equipment or manufacturer’s warranties.
6.4 Construction Manager
6.4.1 The Construction Manager is responsible for the administering and maintaining compliance with the
requirements of this procedure, designating a Test Supervisor for the pneumatic leak test, reviewing
the systems and pre-evaluation plans with the Test Supervisor and Quality Assurance and authorizing
and approval of all pneumatic testing.
6.5 Test Supervisor
6.5.1 The Test Supervisor is responsible for the administering and maintaining compliance with the
requirements of this procedure, planning all aspects of the testing, reviewing systems and pre-
evaluation plans with the Construction Manager, completing the pre-evaluation pneumatic pressure
test form and submit to the Construction Manager for approval and authorization, confirming the test
preparations has been made, notifying affected supervision of the test requirements, directing
pneumatic leak detection activities, directing any retesting related to repairs or additions after
completion of the initial pneumatic pressure testing, documenting the pneumatic pressure test and

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attesting the compliance with this procedure and code, confirming that all gages are calibrated and
certified prior to the pressure test in which they will be used and confirming that the test stand is in
proper working condition.
6.6 Safety Representative
6.6.1 The Safety Representative is responsible for reviewing the test procedure, maintaining compliance
with applicable industry codes and standards, verifying all emergency contact numbers, assuring
adequate means of communications are in place, reviewing the safe boundary zone and determining
the appropriate barricades, designating a muster point, keeping a head count in the event of an
incident, and stopping the test at any time to ensure safety.
7.0 SAFETY & ENVIRONMENTAL

The Supplier shall throughout the progress of the work have the strongest regard for the Health Safety
and Environment (HSE) of all persons and surroundings. Supplier shall provide its personnel, at the
Supplier’s cost, with protective clothing and equipment as may be required for the work.
Supplier shall comply with the latest applicable codes and standards as shown on section 4.0 to
ensure safety in equipment testing and operation.
8.0 PROCEDURE
8.1 General
8.1.1 To perform a pneumatic pressure test in lieu of a hydrostatic test or where the pneumatic test is the
only option, Supplier shall obtain formal Owner approval prior to initiating the pneumatic pressure
testing.
8.1.2 Final Exterran approval for pneumatic pressure testing will be obtained from the Director of
Engineering and the Director of Project Management (NA, LA, or EH as appropriate) with concurrence
from the Director IP Global QHSE. The following information will be included for review in order to
obtain Director approval:
A. An explanation and justification which indicates why hydrotesting cannot be performed, or why
pneumatic testing is preferred.
B. The written authorization from the client
C. The specific test plan including test dates, personnel involved, and testing methodology
including specific piping, systems, and vessels to be tested
D. Description of safeguards to be employed including safe areas and standoff distances,
employee count during testing, barricades and any other equipment to be used for the protection
of personnel.
E. A written certification by the Test Supervisor that all preparations are complete and that the test
is ready to begin (or will be ready by the test start time and date).
8.1.3 Prior to starting the pneumatic pressure test, the Test Supervisor shall obtain all Owner
representatives approvals, Project Manager approval, and Construction Manager approval.

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8.1.4 Before the pneumatic test, the Test Supervisor shall conduct a tailgate safety meeting with all
employees on site about the pneumatic test, hazards, precautions, restricted areas and the
scheduled time/date of the test.
8.1.5 Test Supervisor shall fill out a JHA and conduct a walk through with all employees involved prior to
pneumatic test.
8.1.6 Before the pneumatic pressure test is started, a safe distance shall be evaluated and barricaded off
for non-testing personnel in the test area.
8.1.7 The test area shall be barricaded off using red danger tape. Only the test crew shall enter the
restricted area. Anyone other than the test crew must obtain permission of the test supervisor. Do
not enter a test area to get tools or just to pass through.
8.1.8 The entire perimeter of the testing area shall have “DANGER, DO NOT ENTER” signs.
8.1.9 A sign-in and sign-out log shall be established and maintained at the restricted area during the test.
8.1.10 Particular care must be taken to minimize the chance of brittle failure during a pneumatic leak test.
Pressure vessels will not be pneumatically tested below a minimum test temperature equal to MDMT
(minimum design metal temperature) + 30°F.
8.1.11 Assure all testing equipment, piping, fittings, and appurtenances are rated for the designated
pressure and temperature prior to test.
8.1.12 Where practical, test the highest pressure subsystems first then bleed then bleed down to the next
highest subsystems to minimize the quantity of test medium used.
8.1.13 Keep test sections as small as practical so the volume of test gas is reduced.
8.2 Test Preparation
8.2.1 Test Identification
8.2.1.1 The Project Manager shall provide a set of applicable drawings/flow diagrams for the system to be
tested.
8.2.1.2 Each system shall be defined as to the extent of piping and equipment tested, design pressure, test
pressure and other pertinent information.
8.2.1.3 Drawings shall show the connection points for the supply of the test medium as well as blinds,
jumpers, skillets, etc. required to properly control the test medium pressure between subsystems
with differing design pressures.
8.2.2 Pneumatic Pressure Test Stand
8.2.2.1 Pneumatic testing shall be conducted through a test stand located behind a barricade.
8.2.2.2 The Test Supervisor shall confirm that all items on the test stand are in working order before the start
of test.
8.2.2.3 The test stand shall consist of a test manifold equipped with the following:
A. A regulator suitable for the maximum pressure to be used during the test and of sufficient
number to accommodate the necessary flow rate to efficiently fill the system being tested

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B. A connection suitable for attaching to an air compressor or media supply source

C. A minimum of 2 calibrated pressure gauges of proper range, blow down and block valves are
required on each section of pressure range being tested and the highest reading gauge is to be
followed.
D. Air supplying piping, hoses, connections to the test stand and equipment to be tested bi-annually
8.2.3 Pre-Test Verification
8.2.3.1 Verify that testing will not exceed vendor’s operating specifications. Isolate any equipment or
instruments that may be damaged by the test pressure.
8.2.3.2 The following will not be subject to pneumatic test pressure, unless indicated otherwise by the test
drawing or individually approved by the Construction Manager:
A. Pumps, turbines, and centrifugal/reciprocating compressors

B. Rupture discs and flame arrestors
C. The inlet side of relief valves
D. If a vessel is pressured during a test, care must be taken not to over pressure by adding at least
one pressure gauge of the range being tested to the vessel or as close to the vessel as possible.
E. If a vessel is isolated, there shall be a path for pressure to escape in case of bleed by.
F. Instrument tubing beyond the first process block valve, level controllers and level switches with
floats or displacers, pressure and level gauges pressure switches, any pressure sensing
instruments and analyzers or analyzer sample systems.
G. Jacket water and lube oil systems that will be inspected for leaks when systems are filled to their
normal operating static heads, prior to start-up.
H. Brazed aluminum plate-fin heat exchangers
I. Pressure vessels previously hydrostatic-tested per ASME
8.2.3.3 Equipment, piping and vessels that are not subjected to the test pressure for that system will be
disconnected or blinded from the system being tested. For cases where the required test pressure
changes across the valve and it is not feasible to insert a blind, care must be taken when testing
against the closed valve to ensure that the allowable seat test pressure is not exceeded.
8.2.3.4 If testing through vessels or equipment, and existing PSVs are set for less than the test pressure,
close the block valve upstream of the PSV.
8.2.3.5 All permanent supports, guides and anchors welded directly to pipe or pressure retaining equipment
will be installed prior to testing, if required additional temporary pipe supports or pipe anchors will be
provided. Spring supported lines will be supported on blocks or by stops furnished with the springs.
8.2.3.6 The point of introduction of pressure will be located upstream of check valve and the point of release
downstream. If this is not possible or practical then the check valve piston or clapper must be either
removed or held open for the test.
8.2.3.7 Verify that all automatic valves and manual valves being tested shall always be in the open position,
unless it is provided with a bypass permitting application of the pressure to both sides.

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8.2.3.8 Verify that there are no missing or backed-off nuts on the U-bolts that secure process piping.
8.2.3.9 Verify there are no backed-off nuts on stud bolts and that at the minimum one thread is exposed
beyond the nut.
8.2.3.10 Verify all plastic plugs/thread protectors have been removed and replaced with pressure-rated STEEL
plugs/caps. Plastic thread protectors are sometimes painted over and may be overlooked or
considered to be metal because they are the same color as the equipment.
8.2.3.11 Verify all threaded valves and plugs are tight.
8.2.3.12 Plug all low/high point valves in the open position so that the valve body can be tested with each
system. This will ensure the packing gland has been properly tightened.
8.2.3.13 Prior to the test, ensure all inspection access; ladders, scaffolding, etc. are in place.
8.2.3.14 Tape all flanged connections to facilitate leak detection. Wrap duct tape around the circumference
and make a pinhole at the top.
8.2.3.15 Prepare sprayers with soap solution ahead of time and available for the testing.
8.2.3.16 Ensure any required recording equipment is available and connected to the systems being tested.
8.2.3.17 Prior to starting the initial preliminary pressure test, inspect the system after preparation for testing
to assure that the criteria of the pneumatic pressure test specification have been met. The Test
Supervisor must approve any required deviations in writing to the Construction Manager.
8.3 Testing
8.3.1 The pneumatic test medium shall be a non-flammable, non-toxic gas such as air or nitrogen.
8.3.2 Initial preliminary test will be applied as follows:
A. Start the flow of test medium from the supply source to the test system at a slow rate to verify
that no bleed points were inadvertently left open.
B. If no leaks are found during the initial filling, pneumatic pressure will be gradually raised to an
initial pressure of approximately 25 psig or 25% of the test pressure, whichever is less.
C. Allow time for the system pressure and temperature to stabilize. The time required to achieve
stabilization is dependent on test conditions but must be adequate to allow proper leak testing
based on the correlation of temperature/pressure changes during the test hold period.
D. After stabilization, this initial pressure will be held for at least ten minutes.
E. The isolating valve will be closed on the system under test.
F. The supply hose will be disconnected from the pipe system or equipment.
G. After the required ten minutes hold time, the equipment may be approached by a two person
team working together to identify and list all leaks and problems.
H. Make sure the two person test team are equipped with personnel protection equipment and
have a clear uninterrupted means of communication.
I. Examine all threaded, bolted, and mechanical joints for audible leaks.

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J. All welded, threaded, flanged and packed joints will then be checked using the application of a
fluid mixture of soap and water.
K. Examine all piping and equipment for evidence of defects requiring replacement or repair.
L. The team shall identify and list all leaks and problems, and then leave the area to report their
findings to the Test Supervisor.
8.3.3 If leaks develop during the test:
A. The pressure will be released before any tightening is started.

B. No one is permitted to tighten any type of threaded fitting or flange under pressure.
C. All leaks shall be flagged with ribbon to identify leak.
D. Once the required repairs are made, the effected vessel(s), piping and/or equipment will be
retested in accordance with this section.
E. If leaks are detected during the test, see this section for retesting.
F. Once repairs have been completed, reapply the test pressure in accordance with this section.
8.3.4 When the initial test is completed with all problems fixed and leaks repaired, the pneumatic pressure
test may slowly increase to 50% of the test pressure and repeat the leak detection and repair
activities.
8.3.5 Continue to increase the pressure in steps of approximately 10% of the test pressure until the
required final test pressure is reached.
8.3.6 The final test pressure shall be 1.1 times the design pressure per ASME B31.3, and shall be held for
10 minutes (the hold period). No personnel shall enter the test area while piping or equipment is
pressurized to more than the design pressure.
8.3.7 After the required hold period of the 1.1 times the design pressure, reduce the final max test pressure
to the design pressure of the system. After pressure is reduced, hold at the maximum anticipated
operating pressure while test personnel enter the test area to perform the final leak detection.
8.3.8 Any leaks found during the final leak check will be recorded by test personnel. Repairs shall be made
after the piping is blown down, and these repairs rechecked after the system is placed in service.
8.4 Documentation
8.4.1 The Test Supervisor will complete the Pneumatic Test Report and distribute as directed on the form.
8.4.2 The Project Manager shall maintain the records required by this procedure for a period of three (3)
years.

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Attachment 19-Exterran Pneumatic Pressure Testing Specification

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Pneumatic Pressure Testing

Approved By: Patel, MK; Contasti, Gustavo G

COPYRIGHT © EXTERRAN HOLDINGS, INC. ALL RIGHTS RESERVED.

COPYRIGHT © EXTERRAN HOLDINGS, INC. ALL RIGHTS RESERVED.

This document is applicable to the following product lines and locations:

Product Lines: INTEGRATED PROJECTS

Locations: All Locations

3.0 OWNERSHIP STATEMENT

COPYRIGHT © EXTERRAN HOLDINGS, INC. ALL RIGHTS RESERVED.

5.2.1 Contractor/Vendor/Bidder/Business entity offering equipment and/or services for sale

5.4.1 The word “shall” indicates a mandatory requirement

5.5.1 The word “should” indicates a strong recommendation

6.3 Project Manager

6.4 Construction Manager

6.5 Test Supervisor

COPYRIGHT © EXTERRAN HOLDINGS, INC. ALL RIGHTS RESERVED.

6.6 Safety Representative

7.0 SAFETY & ENVIRONMENTAL

COPYRIGHT © EXTERRAN HOLDINGS, INC. ALL RIGHTS RESERVED.

8.2 Test Preparation

8.2.1 Test Identification

8.2.2 Pneumatic Pressure Test Stand

COPYRIGHT © EXTERRAN HOLDINGS, INC. ALL RIGHTS RESERVED.

B. A connection suitable for attaching to an air compressor or media supply source

A. Pumps, turbines, and centrifugal/reciprocating compressors

COPYRIGHT © EXTERRAN HOLDINGS, INC. ALL RIGHTS RESERVED.

8.2.3.11 Verify all threaded valves and plugs are tight.

8.3.2 Initial preliminary test will be applied as follows:

COPYRIGHT © EXTERRAN HOLDINGS, INC. ALL RIGHTS RESERVED.

A. The pressure will be released before any tightening is started.

COPYRIGHT © EXTERRAN HOLDINGS, INC. ALL RIGHTS RESERVED.

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