Hyd - Test Pro For Metalic Pipoing

Kuwait National Petroleum Company (K.S.C) P6011MAA.000.10.51.
051
Clean Fuels Project (CFP) REV : F11
Conntract No. CFP/EPC/0054-MAA Page 1 of 73
Contractor JOB CODE : 0-6798-20-0000 S-000-3168-0002V
HYDROSTATIC TEST PROCEDURE FOR

METALLIC PIPING
KNPC CFP Project DSN:
Package Center30742
MAA Operation Job Code 14019D
REVIEW BY: DISCIPLINE: DATE:
CODE: 1 BF QCM Center
Operation 11/July/18
Doc No. S-000-3168-0002V
REVIEW CODE: 1: Approved\No Comments; 2: Minor Comments;

3: Comments as Noted; 4: Rejected
F11 08-Jul-18 Issued for Final Stanley Park Henry Park M.H.Kim
F10 29-Jan-18 Issued for Final Stanley Park Henry Park M.H.Kim
F9 19-Oct-17 Issued for Final Bijulal Ahn Byeong Ho M.H.Kim
F8 15-Oct-17 Issued for Final Bijulal Ahn Byeong Ho M.H.Kim
F7 30-Mar-17 Issued for Final F.Gonzales Ahn Byeong Ho M.H.Kim
F6 13-Feb-17 Issued for Final F.Gonzales Ahn Byeong Ho M.H.Kim
F5 06-Feb-17 Issued for Final F.Gonzales Ahn Byeong Ho M.H.Kim
F4 31-Jan-17 Issued for Final F.Gonzales Ahn Byeong Ho M.H.Kim
F3 18-Jan-17 Issued for Final F.Gonzales Ahn Byeong Ho M.H.Kim
F2 28-June-16 Issued for Final F.Gonzales Ahn Byeong Ho M.H.Kim
F1 02-Mar-16 Issued for Final F.Gonzales Ahn Byeong Ho M.H.Kim
O6 14-Feb-16 Issued for Comment SC Shin Joy Kim Felix Jang
O5 04-Feb-16 Issued for Comment SC Shin Joy Kim Felix Jang
O4 25-Jan-16 Issued for Comment SC Shin Joy Kim Felix Jang
REV DATE Description Originated by Checked by Approved by
Kuwait National Petroleum Company (K.S.C)

JGC Corporation / GS Engineering
Clean & Construction
Fuel / SK Engineering & Construction
Project (CFP)
Contract No. Kuwait Document No. Rev
CFP/EPC/0054-MAA P6011MAA.000.10.51.051 F11
CONFIDENTIAL OR PROPRIETARY INFORMATION
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
TROLL
NCON
Kuwait National Petroleum Company (K.S.C) P6011MAA.000.10.51.051
RECORDS OF REVISION
REV DATE Description

O1 18-Jan-16 Issued for Comment
O5 04-Feb-16 Issued for Comment
O6 14-Feb-16 Issued for Comment
F1 02-Mar-16 Issued for Final
F2 28-June-16 Issued for Final
F3 18-Jan-17 Issued for Final
F5 6-Feb-17 Issued for Final
F6 13-Feb-17 Issued for Final
F7 30-Mar-17 Issued for Final
F8 15-Oct-17 Issued for Final
F9 19-Oct-17 Issued for Final
F11 08-Jul-18 Issued for Final
Issued for Final
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
LIST OF HOLDS
Page Section Rev Date DESCRIPTION
5 Table of Contents 18-Jan-17 Add: # 7 Attachment
6 1.0 F3 18-Jan-17 Add: “shop and”
Add: “ in accordance with DEP 74.00.10.10 Clause 3.2.1”
nd
Add: 2 Para. “ ITM, Ferrite, HT”
7 3.3 F3 18-Jan-17
Add: “Special precaution shall be taken if weather condition can cause
freezing of heating up pf the test water.”
Deleted: 6.1.1 Contents and replace “Test Equipment (DEP 74.00.10.10-

Gen)”
11 6.1.1 F3 18-Jan-17
Add Para: Pressure Relief Valve (PRV) shall be calibrated every 6 months
and with the tag of last calibrated date and KNPC approved third
14 6.3.8 F3 party certificate.
Add: Test manifold shall be calibrated every one year by 3rd party inspection.
Deleted the sentence “but only with Company approval”
13 6.3.5 F3 18-Jan-17 Note: Neglected to include this to the previous issued.
Add: Licensor document number

6 2.0 F4 31-Jan-17
ND
Words Correction 2 Para. “ fill or purge” –(incorporator’s comment-GS)
8 3.3.4 F4 31-Jan-17
Re-words “..before submit the request for pressure test” –( incorporator’s

comment-GS)
10 3.7 F4 31-Jan-17
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
Add: sentence to #1) follow as per line list. (PMC comment on F2)
Deleted the Paragraph under # 2) “Application of pressure”.
Add: The system under test shall be held at test pressure until all joints to be
examined. In no case shall the duration of the pressure test be less than one
10 4.1.1 F4 31-Jan-17 hour on each system tested. (PMC comment on F2)
Modify as per KNPC Engineering Standard 93a2 Clause 5.6.1
Deleted: “Only a small-capacity test pump shall be used for pressurization”

rd
(incorporator’s comment-GS)3 Para. Add: NO: 1.5 to 3.0 times
11 6.1.1 F4 31-Jan-17
Re-words: “...shop fabricated joints can be painted before pressure test

except the following” – (incorporator’s comment-GS)
12 6.1.2 F4 31-Jan-17
Add: d) “or licensor requirement”
13 6.2.3 F4 31-Jan-17 Correction spelling: “ensure”
Add: However the contractor providing all test packages to Company for line check
& document check purpose prior to testing. Company will check/verify the test
package contents include the test limits. (Incorporator’s comment- JGC)
6.3.5 ADD: Pressure Relief Valve (PRV) shall be calibrated every 1 year and with the tag of
14 F4 31-Jan-17 last calibrated date and KNPC approved third party certificate.
6.3.8
Deleted: “Test Manifold shall be calibrated every one year by 3rd Party Inspection”
Add: “Test Manifold shall be certified by 3rd Party Inspection”. (Incorporator’s comment-
JGC)
DELETED: The sentence of Para. # 1”Retesting of minor repairs or additions

15 6.4.2 F4 31-Jan-17
may be waived subject to Company’s approval”
8 3.3.4 F5 6-Feb-17 Deleted: “or purge”
Note: 6.3.5. (There is no DEP, PV, Contractual requirement to get “company

approval”.) Otherwise some additional paragraph stated on this
closure.
14 6.3.5 F5 6-Feb-17
Re-word the paragraph Add: “with attachment of the valve technical
data sheet to the test package prior to conducting testing. Normally
during pressure testing valves are left in the fully open position. Valves
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
such as ball valves, which have cavities when fully open, are set in the
half-open/close position”.
“Contractor ensures downstream of valve is open to atmosphere to secure the

out of test limit.”
“Testing against existing valves for tie-in is required Company

approval”. (JGC)
Re-words last paragraph: “Contractor provides all test packages to Company

for line check & document check purpose prior to testing. Company will
check/verify the test package contents include the test limits.”
Deleted Previous Paragraph and change “Per DEP 70.00.10.10-Gen Section

3. Pressure gauges shall be installed at the pump discharge and on
highest point of the equipment being tested. The gauges shall have
accuracy as specified in the applicable code and shall have a scale
14 6.3.8 F5 6-Feb-17
range suitable for the test pressure. Additional guidance for hydro test
equipment may be found in ASME PCC-2.
Deleted: “every 1 year” and incorporate PMC comment “ every 6 months
Deleted the words: “existing”, “for tie –in”
Rewords the sentence: Testing against any valves is

required Company approval as mentioned below
paragraph.
14 6.3.5 F6 13-Feb-17
Rewords the para. : Company will check/verify and approve the test
package contents include the test limits.
Deleted the words: “length/”

11 5.3 F7 30-Mar-17
Add: “only with Company Approval”

14 6.3.5 F7 30-Mar-17
Re-words the paragraph: “If the valve is not available in the system
14 6.3.6 F7 30-Mar-17 for pressure test limit”
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
Add: “ Material to be used is Carbon steel”

11 5.5 F8 15-Oct-17
Re-words: “ Issued for Final ”

1 F9 19-Oct-17
Re-words: “ Issued for Final ”

2 F9 19-Oct-17
Change attachment : Rev.3

Attachment-
17 F9 19-Oct-17
1
Deleted - ANSI B31.3 & ANSI B31.1 and replaced ASME B31.3 & ASME
6 2.0 F10 29-Jan-18
B31.1
Add: ASME BPV Code Sec. VIII Div.1 – Rules for construction of pressure
6 2.0 F10 29-Jan-18
vessels.
Deleted the previous title: PRESSURE TEST BLINDS & INSPECTION

REQUIREMENTS FOR TEST HEAD.
11 5.0 F10 29-Jan-18
Revised title: The test bank and blind for the pressure test
11 5.1- 5.3 F10 29-Jan-18 Update the contents according to new attachment #02 to #04
Deleted the sentence – Material to be used is carbon steel

12 5.6 F10 29-Jan-18
Added – A36 or equivalent material shall be used.
17 7.0 F10 29-Jan-18 Attachment #02 has updated and #03 & #04 have been added.
F11 Duration of Time duration of hydro test revised. Following DEP for new area
12 4.1.1 08-Jul-18 and KNPC standard for revamping (Licensor-7).
All Subcontractors will be using this procedure.
Note: Incorporate all comments both JGSK & PMC comments, revision marked (bar line) indicate as revised
portion.
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
TABLE OF CONTENTS
1.0 SCOPE.................................................................................................................................. 8
2.0 CODES AND REFERENCES .............................................................................................. 8
3.0 GENERAL ............................................................................................................................ 9
4.0 TEST METHODS AND PRESSURES ................................................................................. 12
5.0 THE TEST BLANK AND BLIND FOR THE PRESSURE TEST…....................................... 13
6.0 TEST PROCEDURE ............................................................................................................. 13
7.0 ATTACHMENTS.................................................................................................................... 18
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
1.0 SCOPE
This procedure describes the general requirements and procedures for shop and field
pressure testing of above ground and underground pressure metallic piping system,
connected equipment and integral components to assure mechanical strength and
tightness.
1.1 The following are excluded from the requirements of this procedure:
1.1.1 Any package previously tested by the manufacturer in accordance with the applicable
code.
1.1.2 Instrument piping lead lines between the root valve at the process or utility line and the
connected instrument, and control piping used to connect air or hydraulically operated
control apparatus.
1.2 The following systems shall be checked thoroughly by visual examination after
installation
1.2.1 Atmospheric sewer, drainage system and static head test required as per DEP.
1.2.2 Lines and systems which are open to the atmosphere, such as vents, drains, and open
ended safety valve discharge. As required by the line list.
2.0 CODES AND REFERENCES
ASME B31.3 Process Piping
ASME B31.1 Power Piping
ASME BPV Code Sec.VIII Div.1 Rules for construction of pressure vessels
DEP 31.38.01.31-Gen Shop and Field Fabrication of Piping
DEP 74.00.10.10-Gen Shop and Field Pressure Testing of Piping

System
DEP 31.38.30.11-Gen Protective Steam Heating of Piping System
DEP 31.40.40.38-Gen Hydrostatic Pressure testing of New Pipeline
S-000-3168-0001V Piping Test Package Preparation and

Handling Procedure
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
S-000-1670-0305V Typical Inspection and Test Plan for Piping

Works
S-000-1360-0151V Piping Tie-in Procedure
74.00.10.10-P6000CFP-000-PV Project variation to DEP 74.00.10.10-Gen

Section 4 Exhibit H General Execution
Requirements
LICENSOR DOCUMENT NUMBER
License Agreement CFP2020-(Licensor -0005-CNSL) SRU-151/152-MAA
Amendment 1 for CFP2020-(Licensor -0005-CNSL) SRU-151/152-MAA
Amendment 2 for CFP2020-(Licensor -0005-CNSL) SRU-151/152-MAA
CFP-Licensor -0005-CNSL-ENGG-AGT-SRU-MAA
Amendment 1 CFP-Licensor -0005-CNSL-ENGG-AGT-SRU-MAA
Amendment 2 CFP-Licensor -0005-CNSL-ENGG-AGT-SRU-MAA
3.0 GENERAL
3.1 All lines shall be hydro-statically tested.
3.2 The line list shall indicate the type of test and pressure to use on each line. The
maximum operating pressure of each piece of equipment, including instruments, shall
be checked against the test pressure of the piping system in which the piece of
equipment is included. If the test pressure of the piping system is greater than the
maximum operating pressure of the equipment, the equipment shall be blanked off and
tested separately. Test through the equipment required Company approval.
3.3 Wherever reference is made to hydrostatic pressure testing, the medium shall be water.
The water quality to be used for hydrostatic testing depends on the material(s) from
which the equipment to be tested is manufactured (see below). Whatever the source of
the hydrostatic test water, it shall be filtered through a 10 μm filter when filling the
system in accordance with DEP 74.00.10.10-Gen Claus 3.2.1. The water quality shall
have been tested for chloride and microbiological culture (if required), content within the
last 3 months and certificate available for inspection. The line shall be thoroughly
checked before pressure test as per the Company approved checklists.
The piping spool has been fully inspected prior to hydrostatic test (visual examination,
NDE, heat treatment, and positive material identification, ITM, F errite, HT) and the
package shall be submitted for company review at least 48 hours before the test time.
Water quality certificate should be provided at the time of inspection for the piping
hydrostatic test.
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
Special precaution shall be taken if weather condition can cause freezing or heating up
of the test water.
3.3.1 Carbon Steel and low-alloy steel

Equipment manufactured from carbon steel or low-alloy steel may be hydrostatically
tested with potable water. (Chloride content requirement: no more than 250ppm)
3.3.2 Austenitic stainless steel

The water used for hydrostatic testing shall not contain a concentration of chlorides,
either present originally or resulting from evaporation that may precipitate stress
corrosion cracking or pitting. If biological components are left in systems or introduced
with the testing water, there is also the possibility of microbiologically induced corrosion
(MIC).
The stainless steel shall be clean prior to final assembly and hydrostatic testing.
The equipment and/or piping shall be tested with good quality water that must contain
less than 50ppm chloride and be free from sediment.
In locations where water of required quality is not available (initially or permanently),

temporary facilities shall be used to prepare the test water
Austenitic stainless steel piping sections and components such as valves and
expansion joints that do not allow full draining or mechanical drying and that do not
require field hydro testing should preferably be isolated from the system, and, if still
required, tested separately from the system.
Steam-traced or electrically traced systems should be tested or at least properly flushed

with condensate or demineralized water prior to the functional testing of the tracing.
3.3.3 Ferritic stainless steels and medium/high nickel alloys

Due to the possibility of pitting corrosion, (3.3.2 of DEP 74.00.10.10-Gen.) shall also
apply to ferritic stainless steels and medium/high-nickel alloys.
3.3.4 Duplex stainless steel

Duplex stainless steel is highly susceptible to crevice corrosion when in contact with
oxygen containing water.
The preferred hydrostatic testing method is to use potable water and to carefully rinse
the equipment immediately after the pressure test with condensate; boiler feed water or
demineralized water, followed by thorough drying or dewatering of the equipment and
fill with nitrogen in such a way that all oxygen is removed from the system.
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
3.3.5 9% Nickel alloy steel

When hydrostatically testing equipment manufactured from or containing 9% Ni steel,
the water used shall be of a neutral PH value, clear and free from Sulfide which may
otherwise precipitate stress cracking of the equipment. Complete and thorough draining
and drying of the equipment is required after the removal of the test water.
3.3.6 Aluminum and aluminum alloys

The test water shall be of a neutral pH value and free from ions of heavy metals, e.g.
copper, nickel and iron. These metals are readily deposited on the aluminum surface
and cause severe pitting.
The equipment shall be thoroughly cleaned and dried after removal of the test water.
3.4 Test pressure for hydrostatic test will be 1.5 times of design pressure.
3.5 All piping shall be completely drained after test.
3.6 The minimum temperature of the fluid used for hydrostatic test shall [PS] be 17℃ (30℉)
above the minimum design metal temperature of the piping, unless otherwise approved
by the Company.
Before application of test pressure, the test fluid and piping material shall be allowed to
equalize to approximately the same temperature.
In case metal temperature and/ or test liquid is below +10℃ (+50℉), the minimum
allowable metal temperature shall be determined as per following decision tree.
3.7 Inspection Checklist Prior to Pressure test

Inspection checklist prior to pressure test shall be checked and filled by Subcontractor
and Contractor QC before submit the request for pressure test.
Refer to the attachment #01, Inspection Checklist Prior to Pressure Test
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
4.0 TEST METHODS AND PRESSURES
4.1 Hydrostatic Testing of Piping Designed for Internal Pressure
4.1.1 The hydrostatic test pressure at any point in the system shall be as follows:
1) Not less than 1½ times the design pressure, follow as per approved line list.
2) Application of pressure
The system under test shall be held at test pressure until all joints to be examined.
a) For Revamping areas (Licensor-7), in no case shall the duration of the pressure
test be less than one hour on each system tested.(Ref- KNPC Engineering
Standard 93A2 Clause 5.6.1).
b) For new areas, the full test pressure (+ 1.0 %) shall be held for at least 10
minutes or as long as required to complete the inspection, whichever is greater.
(Ref - DEP 74.00.10.10-Gen. -SHOP AND FIELD PRESSURE TESTING OF
PIPING, clause-3.3.3).
3) For a design temperature above the test temperature, the minimum test pressure
shall be as calculate by the following equation:
1.5 × P × ST
PT = ---------------------
S
Where
PT = minimum hydrostatic gauge pressure (psi)
P = internal design gauge pressure (psi)
ST = allowable stress at test temperature (psi)
S = allowable stress at design temperature (psi)
(See Table 1, Appendix-A, ANSI/ASME B31.3)
4.1.2 Equipment is usually shop tested at vendors shop. It is preferred field practice to isolate
connected equipment from the piping for hydrostatic pressure testing.
4.2 Hydrostatic Testing of Piping Designed for External Pressure
4.2.1 Lines in external pressure service shall be subjected to an internal test pressure of 1½
times the external differential design pressure but not less than a gauge pressure of 1
bar (15psi).
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
4.2.2 In jacketed lines, the jacket shall be pressure tested on the basis of the internal or
external design pressure, whichever is the more critical.
5.0 THE TEST BLANK AND BLIND FOR THE PRESSURE TEST
5.1 Attachment #02 provides the calculated thickness of the test blank and its formula.
For the test blank with a nipple, the dimension “A” in the attachment #04 shall be
complied with the calculated thickness in the attachment #02.
5.2 Attachment #03 provides the calculated thickness of the test blind and its formula.
5.3 All weldments on the test blank and blind shall be examined by any nondestructive
(NDE) method in accordance with ASME B31.1.
5.4 A36 or equivalent material shall be used and the material test certificate shall be
provided at the time of inspection or test.
6.0 TEST PROCEDURE
6.1 Test Preparation
6.1.1 A pressure relief valve shall be installed on the discharge of the test pump. This PRV
shall be set at 110% of test pressure.
Pressure gauges shall be installed at the pump discharge and on highest point of the
equipment being tested.
The gauges shall have accuracy as specified in the applicable code and shall have a
scale range suitable for the No: 1.5 to 3.0 times test pressure. Additional guidance for
hydro test equipment may be found in ASME PCC-2.
Where bellows are installed in the test circuit, special precautions shall be taken to
prevent over pressurizing.
6.1.2 All joints, including welds, shall be left un-insulated, un-coated (ie, un-painted) and
exposed for examination during the test, except that joints previously tested in
accordance with this procedure.
In accordance with approved waiver request “MAA-WR-DD-618”, shop fabricated joints

can be painted before pressure test except the following;
(a) Piping requiring a sensitive leak test also referred to as a sensitive pressure test.
(b) Any piping to be pneumatically tested.
(c) Any piping, where the test pressure is equal to or less than 5 barg.
(d) Or Licensor requirements
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
6.1.3 Underground portions of piping systems may be tested and covered prior to testing of
above ground portions.
6.1.4 Piping designed for vapor or gas shall be provided with additional temporary supports, if
necessary to support the weight of the test liquid. Where required, temporary supports
shall be specified in the pressure test documents
6.1.5 Lines which are counterweight supported shall be temporarily blocked during testing in
order to sustain the weight of the test fluid. Spring hangers which have been provided
with stops for carrying the test load normally do not require additional temporary
supports and should be locked and recorded on punch list, if this is not the case,
temporary support must be provided before filling of test fluid to the system.
6.1.6 Temporary gaskets with an equal pressure rating can be applied in the flanged spool or
the inline item to be reinstated during/after the test. And it is not required to be
distinguished with a color code.
6.1.7 Temporary bolts shall be same diameter as used in service.
6.2 Pre-Hydrostatic test
6.2.1 Test Package Approval

Subcontractor shall prepare and submit test package until approved by Contractor test
team.
When test packages are approved by Contractor shall submit for Company approval.
6.2.2 Line Check and Punch Clearing

Piping systems shall have been completely checked (Punch Items).
Subcontractor will receive the scan copy of approved test package for each piping
system from Contractor test team. The latest drawings (Isometric drawing, PEFS & etc.)
shall be attached on the test package. Subcontractor shall conduct line check and
punch clearing with this scan copy.
Subcontractor shall submit to Contractor for Contractor’s line check after cleared
Subcontractor category (l) punch items. Then, Contractor generate punch list and pass
to Subcontractor for clearing. When Subcontractor cleared all category (l) punch items,
the test package shall be treated as test package line completion. Contractor’s internal
punch will be closed by Contractor, not Company.
Once Contractor closes all punch items, Company shall be called for Company’s punch
inspection.
Company inspection will be cancelled if more than two categories (I) punch items are
found at any time in the inspection and the test pack returned to Contractor for
Contractor’s re-inspection.
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
6.2.3 All lines shall be checked to ensure the entire system can be completely drained after
testing.
6.2.4 Vents, drains and relief valves shall be utilized to prevent damage to the piping system
due to thermal expansion or other hazardous conditions during the test period.
6.2.5 Short pieces of piping which must be removed to permit installation of a blind or blank
shall be tested separately or, where possible, connected to main pipe or manifold by
hose and tested at the same time.
6.2.6 Check valves should be removed for test of piping, if locked open or other record on
punch list. This statement does not consider the lift pressure of check valve. Remove or
jack up the check valve completely and provide necessary filler piece or blinds.
6.2.7 System that include expansion joints shall be investigated to see that any required
temporary restraints, anchors, guides, etc., are installed prior to test.
6.3 Hydrostatic Test
6.3.1 The specific procedure for application of piping pressure test is given in DEP
74.00.10.10-Gen
6.3.2. In order to hydrostatic test as much piping as possible at one time, a system test may
be employed. This test shall include one or more lines and if possible connected
equipment (with Company/ Vendor approval), such as fired heater coils. The extent of
each system test shall be identified by color coding and noting the test number on the
appropriate flow diagram. Color coding on the leak test diagrams should be consistent
with the system limits, as per the commissioning system definition.
6.3.3 The minimum test pressure for test system shall be such that each line in the system is
subjected to a test pressure in accordance with paragraph 3.2 or 3.4.
6.3.4 The maximum system test pressure shall not exceed the pressure test rating of any
piping component included in the test system.
6.3.5 Where systems to be tested are divided at the valves, it should be isolated by blinds in
lieu of valve closing. But where it is impracticable to install blinds (e.g. socket valves),
the valve may be used for isolating of system provided the valve body and seat are
suitable for the testing pressure, with attachment of the valve technical data sheet to the
test package prior to conducting testing, but only with Company approval. Normally
during pressure testing valves are left in the fully open position. Valves such as ball
valves, which have cavities when fully open, are set in the half-open/close position.
Contractor ensures downstream of valve is open to atmosphere to secure the out of test
limit.
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
Testing against any valves is required Company approval as mentioned below

paragraph.
Contractor provides all test packages to Company for line check & document check
purpose prior to testing. Company will check/verify and approve the test package
contents include the test limits.
6.3.6 If the valve is not available in the system for pressure test limit, the other piping not
included in the system pressure test shall be either disconnected from the system or
isolated by blinds or other means during the test.
6.3.7 Inline instruments & equipment such as orifice plates, flow meters, control valves & etc.
shall be removed prior to hydrostatic test.
6.3.8. Per DEP 74.00.10.10-Gen Section 3. Pressure gauges shall be installed at the pump
discharge and on highest point of the equipment being tested. The gauges shall have
accuracy as specified in the applicable code and shall have a scale range suitable for
the test pressure. Additional guidance for hydro test equipment may be found in ASME
PCC-2.
Pressure test gauges shall be calibrated every 6 month, using a dead weight tester.
Gauge shall be tagged with the date last calibrated and this activity shall be recorded.
Pressure Relief Valve (PRV) shall be calibrated every 6 months and with the tag of last
calibrated date and KNPC approved third party certificate.
On all hydrostatic tests at least 2 calibrated gauges should be installed to indicate the
test pressure, these should be located at the high and low points of the system. Test
Manifold shall be certified by 3rd Party Inspection
6.3.9 When the required test pressure is establish, mark the position of pressure gauge arrow
indicator (by providing masking tape) and time to be recorded.
6.3.10 Piping subjected to hydrostatic pressure should be clearly marked "Line under
hydrostatic test", and barricaded.
6.3.11. During hydrostatic test check valve to be separated from the line. If not possible
(Welded type valve), internals to be removed and inspected. Testing shall not be
performed in wet weather.
6.3.12 Water filling and draining
1) Fill the water using the approved temporary hose connection Control rate of filling
so that it will not pressurize the circuit (low supply pressure).
2) Service (process) water pressure, hand operated pump is recommended for filling.
3) Ensure venting of air is done at the highest point.
4) Filling of water shall be carried out from the lowest point.
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
5) Gradually fill the water in the circuit and ensure air pockets are completely
removed inside the pressurize volume.
6) Filling point and air vent shall be of the same size.
7) After reaching the test pressure, pump will be isolated and disconnected from test
manifold.
8) After piping pressure test, the system will be depressurized and completely
drained.
6.4 Post Hydrostatic Test
6.4.1 Test Records

Records shall be made of each piping system test, utilizing the form titled, and
“Pressure test report (JGSK-QC-6000-17). These forms, when completed, shall be
retained in the field QC document as a permanent record.
6.4.2 Test Completion
1) In the event that repairs or additions are made following the pressure test, the
affected piping shall be retested at the pressures originally specified for the test.
2) After completion of testing, all temporary blanks and blinds shall remove, 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 which have been removed shall be reinstalled with proper gaskets in
place. Lines which are being drained after testing shall have all vents open. Piping
systems downstream of check valves should be inspected to insure complete
drainage.
3) Direct connected transmitters at orifice flanges must be disconnected when

replacing orifice plates to avoid distorting the connections.
4) After lines have been drained, temporary supports shall be removed.
5) Flange joints where the test temporary blind has been removed shall not be
retested. As per line class base, gaskets shall be used for hydrostatic test as per
system requirement (See section 5.2). Asbestos type gaskets are strictly prohibited
from use.
6) Instruments which were removed or blocked out for test shall be reinstalled and
blocks placed in the normal operating position after test.
6.4.3 Pre-commissioning Activity

Test package will be handed over to commissioning team for further pre-commissioning
cleaning activity (air blowing & etc.) after reinstatement completed and punch items
cleared unless commissioning team request otherwise.
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
6.4.4 Reinstatement and hand over

After completion of pre-commissioning activity, reinstatement can be started and test
package will be submitted to the Company for confirmation once Contractor confirms all
category (ll) punch are cleared and line is reinstated completely. After confirmation by
Company, test package shall be transferred to hand over team to upload hand over
system. In case a certain punch item can be cleared or after achievement PTOP due to
commissioning reason, category (ll) punch would be changed to category (lll) subject to
agreement between Company and Contractor. Category (lll) punch will be transferred
into system punch and re-categorized as per system punch definition.
7.0 ATTACHMENTS
1) Attachment #01, Inspection check list prior to pressure test --------------------------Page-19.

2) Attachment #02, Test blank thickness table------------------------------------------------Page-21.
3) Attachment #03, Test blind thickness table-------------------------------------------------Page-51.
4) Attachment #04, The schematic diagram of test blank with a nipple-----------------Page-72.
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
Attachment # 01
Inspection check list prior to pressure test
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
Attachment # 02
Test blank thickness table
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
INDEX
FOR TEST BLANK THICKNESS TABLE
CALCULATION BASIS FOR TEST BLANK ------------------------------------------ PAGE 21
RF or FF / CLASS 150 ---------------------------------------------------------------------- PAGE 22
RF or FF / CLASS 900 --------------------------------------------------------------------- PAGE 31
RF or FF / CLASS 1500 ------------------------------------------------------------------- PAGE 34
RF or FF / CLASS 2500 ------------------------------------------------------------------- PAGE 37
RJ / CLASS 900 ----------------------------------------------------------------------------- PAGE 40
RJ / CLASS 1500 --------------------------------------------------------------------------- PAGE 43
RJ / CLASS 2500 --------------------------------------------------------------------------- PAGE 46
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
Attachment # 03
Test blind thickness table
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
INDEX
FOR TEST BLIND THICKNESS TABLE
CALCULATION BASIS FOR TEST BLIND -------------------------------------------- PAGE 51
CLASS 150 ------------------------------------------------------------------------------------ PAGE 52
CLASS 300 ------------------------------------------------------------------------------------ PAGE 55
CLASS 600 ------------------------------------------------------------------------------------ PAGE 58
CLASS 900 ----------------------------------------------------------------------------------- PAGE 61
CLASS 1500 ---------------------------------------------------------------------------------- PAGE 64
CLASS 2500 ---------------------------------------------------------------------------------- PAGE 67
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
Attachment # 04
Schematic Dwg of Test blank with Nipple
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON
D R A
N
I 09-JUL 8
- 2 0 1
D
RINTE
ED WHEN P
T ROLL
NCON

Hyd - Test Pro For Metalic Pipoing

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Hyd - Test Pro For Metalic Pipoing

Uploaded by

Copyright:

Available Formats

Kuwait National Petroleum Company (K.S.C) P6011MAA.000.10.51.

HYDROSTATIC TEST PROCEDURE FOR

REVIEW CODE: 1: Approved\No Comments; 2: Minor Comments;

Kuwait National Petroleum Company (K.S.C)

Contract No. Kuwait Document No. Rev

CFP/EPC/0054-MAA P6011MAA.000.10.51.051 F11

CONFIDENTIAL OR PROPRIETARY INFORMATION

REV DATE Description

Issued for Final

CONFIDENTIAL OR PROPRIETARY INFORMATION

Page Section Rev Date DESCRIPTION

5 Table of Contents 18-Jan-17 Add: # 7 Attachment

6 1.0 F3 18-Jan-17 Add: “shop and”

Add: “ in accordance with DEP 74.00.10.10 Clause 3.2.1”

Deleted: 6.1.1 Contents and replace “Test Equipment (DEP 74.00.10.10-

Deleted the sentence “but only with Company approval”

13 6.3.5 F3 18-Jan-17 Note: Neglected to include this to the previous issued.

Add: Licensor document number

Re-words “..before submit the request for pressure test” –( incorporator’s

CONFIDENTIAL OR PROPRIETARY INFORMATION

Deleted the Paragraph under # 2) “Application of pressure”.

Modify as per KNPC Engineering Standard 93a2 Clause 5.6.1

Deleted: “Only a small-capacity test pump shall be used for pressurization”

Re-words: “...shop fabricated joints can be painted before pressure test

13 6.2.3 F4 31-Jan-17 Correction spelling: “ensure”

DELETED: The sentence of Para. # 1”Retesting of minor repairs or additions

8 3.3.4 F5 6-Feb-17 Deleted: “or purge”

Note: 6.3.5. (There is no DEP, PV, Contractual requirement to get “company

“Contractor ensures downstream of valve is open to atmosphere to secure the

“Testing against existing valves for tie-in is required Company

Re-words last paragraph: “Contractor provides all test packages to Company

Deleted Previous Paragraph and change “Per DEP 70.00.10.10-Gen Section

Deleted: “every 1 year” and incorporate PMC comment “ every 6 months

Deleted the words: “existing”, “for tie –in”

Rewords the sentence: Testing against any valves is

Deleted the words: “length/”

Add: “only with Company Approval”

CONFIDENTIAL OR PROPRIETARY INFORMATION

Add: “ Material to be used is Carbon steel”

Re-words: “ Issued for Final ”

Re-words: “ Issued for Final ”

Change attachment : Rev.3

Deleted the previous title: PRESSURE TEST BLINDS & INSPECTION

Deleted the sentence – Material to be used is carbon steel

All Subcontractors will be using this procedure.

CONFIDENTIAL OR PROPRIETARY INFORMATION

2.0 CODES AND REFERENCES .............................................................................................. 8

3.0 GENERAL ............................................................................................................................ 9

4.0 TEST METHODS AND PRESSURES ................................................................................. 12

6.0 TEST PROCEDURE ............................................................................................................. 13

CONFIDENTIAL OR PROPRIETARY INFORMATION

2.0 CODES AND REFERENCES

ASME B31.3 Process Piping

ASME B31.1 Power Piping

DEP 31.38.01.31-Gen Shop and Field Fabrication of Piping

DEP 74.00.10.10-Gen Shop and Field Pressure Testing of Piping

DEP 31.38.30.11-Gen Protective Steam Heating of Piping System

DEP 31.40.40.38-Gen Hydrostatic Pressure testing of New Pipeline

S-000-3168-0001V Piping Test Package Preparation and

CONFIDENTIAL OR PROPRIETARY INFORMATION

S-000-1670-0305V Typical Inspection and Test Plan for Piping

S-000-1360-0151V Piping Tie-in Procedure