General Piping – Process and Utility Pressure Testing

CHEVRON GEOTHERMAL INDONESIA LTD

CGI-022-PIP-003 Rev. 0

REVISION HISTORICAL SHEET

Rev. Date Page Description

no
0 14/12/11 All Issued for Implementation

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 General Piping – Process and Utility Pressure Testing
CHEVRON GEOTHERMAL INDONESIA LTD
CGI-022-PIP-003 Rev. 0

TABLE OF CONTENTS

SECTION PAGE

1.0 SCOPE............................................................................................................................4

2.0 REFERENCE CODES AND STANDARDS......................................................................4

3.0 TERMINOLOGY ..............................................................................................................5

4.0 CONFLICTING REQUIREMENT…………………………………………..………….…….…6

5.0 GENERAL .......................................................................................................................6

6.0 TEST WATER CRITERIA ................................................................................................7

7.0 TEST METHODS AND PRESSURES .............................................................................8

8.0 ALTERNATIVE TESTS .................................................................................................10

9.0 VESSELS AND EQUIPMENT .......................................................................................11

10.0 INSTRUMENTS ............................................................................................................12

11.0 FIELD PROCEDURES ..................................................................................................12

12.0 PRESSURE TEST BLINDS ...........................................................................................18

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 General Piping – Process and Utility Pressure Testing
CHEVRON GEOTHERMAL INDONESIA LTD
CGI-022-PIP-003 Rev. 0

1.0 SCOPE

This specification defines the requirements and procedures for Field Pressure Testing
of aboveground and underground pressure piping systems, connected equipment and
integral components to assure mechanical strength and tightness. Any deviation from
this Specification requires written approval from Chevron Geothermal Indonesia Ltd.
(CGI) and Chevron Geothermal Salak Ltd. (CGS).

1.1 Exclusions

The following are excluded from the requirements of this specification:

1.1.1 Any package unit previously tested by the manufacturer in

accordance with the applicable codes.

1.1.2 Atmospheric storm drains, which are tested in accordance with

Specification SP-CGI-IN-015 General specification for instrument
installation material.

1.1.3 Plumbing systems, which are tested in accordance with the applicable
plumbing codes.

1.1.4 Lines and systems open to the atmosphere and will not (cannot) be
plugged or capped off later without alteration.

1.1.5 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, which will be
tested in accordance with SP-CGI-IN-017 General specification for
instrument piping field pressure test

1.1.6 Firewater piping systems (see Specification SP-CGI-PR-003).

2.0 REFERENCE CODES AND STANDARDS

2.1 Related Specification

The latest edition and applicable revisions of codes and standards will be used
as referenced in this specification. References beginning with "ST" or "SP" are
Company standard drawings and specifications respectively.

2.2 Code and Standard

This procedure shall refer to the publications listed below. Each publication
shall be the latest revision and addendum. Except as modified by the
requirements specified herein or the details of the drawings. Work included in
this procedure shall according to the applicable provisions on these following
publications:

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CGI-022-PIP-003 Rev. 0

• ASME (American Society of Mechanical Engineers)

a. ASME Section VIII Rules for Construction of Pressure Vessels,

latest edition
b. ASME B31.1 Power Piping, latest edition
c. ASME B31.3 Process Piping, latest edition
d. ASME B31.4 Liquid Transportation System for Hydrocarbon

• ASTM (American Society for Testing and Materials)

e. ASTM A36 Specification for Structural steel

• PIM 600 Piping Construction

3.0 TERMINOLOGY

In this specification, the following words and terms shall have the meanings
hereby assigned to them, unless noted otherwise.

3.1 COMPANY
Refer to Chevron Geothermal Indonesia Ltd. (CGI) and Chevron
Geothermal Salak Ltd. (CGS) as the ultimate user and owner, the
authorized representative of COMPANY or COMPANY third part
inspection.

3.2 CONTRACTOR

Refers to company selected by COMPANY, which may be responsible

for the detailed engineering design, material and equipment
procurement, and construction as specified in Contract, Scope of Work,
or Work Order.

3.3 Vendor

Refers to the company selected by COMPANY or CONTRACTOR,

which is responsible for the purchase agreement or purchase order of
the goods/services specified in this specification

Note:

• For EPC (Engineering, Procurement and Construction) project

purposes:
The terminology shall have the meanings as above.
• For “ Direct Procurement” by COMPANY purposes:

Vendor shall also be responsible as CONTRACTOR.

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4.0 CONFLICTING REQUIREMENT

4.1 In case of conflict between this Specification and its associated Specifications
and the above Codes and Standards, the Vendor shall bring the matter to the
COMPANY’s attention for resolution and approval in writing. However, the most
stringent requirement shall apply.
4.2 Should conflicts exist between this specification and other documents, the
following order of precedence shall govern:
• Scope of Work
• Data Sheets.
• This Specification
• Other COMPANY Specifications
• Other Referenced Publications
• Approved for Construction Drawings
• Vendor’s Code

5.0 DEFINITIONS

5.1 Calculated Test Pressure - The test pressure determined in accordance with
Section 6.0.

5.2 Minimum Test Pressure - The lowest allowable test pressure gauge reading
(the calculated test pressure plus the additional pressure resulting from the
static head of the test fluid).

5.3 Maximum Test Pressure - The highest allowable test pressure gauge reading
(the pressure test rating of the "weakest" component in the test system).

6.0 GENERAL

6.1 This Specification complies with the requirements of ASME B31.3-1993, "Code
for Pressure Piping, Chemical Plant and Petroleum Refinery Piping"' and
ASME B31.1-1992, "Power Piping."

6.2 This specification for inspection and test complies with requirements of ASME
Section VIII, UG-99 to UG-101.

6.3 The minimum test pressure for each line will be specified on the Pipe Line List.

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6.4 Prior to initial operation, all installed piping will be pressure tested except where
otherwise qualified in this Specification.

6.5 The test will be hydrostatic using water except if the operating fluid or piping
material would be adversely affected by water, other suitable liquids will be
used. Testing of feritic piping, however, is limited to the temperature restrictions
in Paragraph 10.2.7.

6.5.1 If a flammable liquid is used, its flash point will not be less than 4gC
and consideration will be given to the test environment. Approval for
use by Company is required for each line.

6.6 In those cases where hydrostatic testing is considered impractical,

recommendations for pneumatic tests shall be made for Companyreview and
approval. Pneumatic tests to be in accordance with Paragraph 6.4 using air or
another nonflammable gas. The following systems are normally considered for
pneumatic testing.

6.6.1 Gas, steam, or vapor lines when the weight of the hydro test liquid
would overstress supporting structures or pipe wall.

6.6.2 Piping with linings subject to damage by the hydro test liquid.

6.6.3 Large piping where available hydro test liquid is limited.

6.7 The instrument air headers will be tested with dry air.

7.0 TEST WATER CRITERIA

7.1 Care will be taken to ensure the use of clean water for these tests. A suitable
filter will be provided in the fill line to the systems if foreign matter such as
sand, rust or other particles are suspected or in evidence in the proposed test
water. Use of sea water or process water is prohibited.

7.2 Water used for hydrostatic testing of austenitic stainless steel piping, vessels
and equipment, including those with austenitic stainless steel claddings, linings
or internals (excluding valve trim) will conform to the requirements listed below.

7.2.1 Water containing more than twenty-five (25) ppm chlorides will not be
used.

7.2.2 Piping, vessels and equipment must be drained thoroughly after testing.
Where complete drainage is impossible, the system will be flushed free
of all test water using boiler condensate or demineralized water
containing less than ten (10) ppm chlorides, alcohol, petroleum distillate
or other suitable flushing solutions. Hot air drying is not acceptable in
lieu of flushing, but water may be blown out of pockets using air.

7.3 Piping that is to be chemically cleaned after installation will be tested and all
repairs made prior to cleaning.

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CGI-022-PIP-003 Rev. 0

8.0 TEST METHODS AND PRESSURES

8.1 Hydrostatic Testing of Piping Designed for Internal Pressure (ASME B31.3,
Resource Production Facility)

8.1.1 The hydrostatic test pressure at any point in the system to be as

follows:

8.1.1.1 Not less than 1-1/2 times the design pressure.

8.1.1.2 For a design temperature above the test temperature, the

minimum test pressure is as calculated by the following equation
except that the value of ST/S shall not exceed 6.5.

1.5P
P T
S
ST

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 A-1, Appendix A, ASME B31.3)

8.2 Where the test pressure as defined above would produce a stress in excess of
the yield strength at test temperature, the test pressure will be reduced to the
pressure at which the stress will not exceed the yield strength at the test
temperature.

The maximum test pressure at which the stress produced will not
exceed the yield strength will be calculated by the following equation:

2St
P M
14.5D

8.3 Where:

PM = Maximum Test Pressure (bar)

S = Minimum Specified Yield (psi)
T = Specified Pipe Wall Thickness Minus Mill Tolerance (in.)
D = Outside Diameter (in.)

8.3.1 If the test pressure of piping attached to a vessel is equal to or less than
the test pressure of the vessel and it is not possible to isolate the piping,
then the piping and vessel may be tested together at the test pressure
of the piping. If the test pressure of piping attached to a vessel is higher
than the vessel test pressure and it is not practical to isolate the vessel
from the piping test, the piping test pressure (with the approval of
theCompany) may be reduced to the vessel test pressure, provided the
vessel test pressure is not less than 77 percent of the piping test
pressure (See Paragraph 6.1.1 for formula definitions). If the test
pressure of the piping after applying the reduced factor is still higher

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than the connected equipment, then it will be isolated and tested

separately in accordance with Paragraph 6.1.1. Company's preference
is that equipment and vessels not be included in pressure testing of
piping systems.

8.4 Hydrostatic Testing of Piping Designed for External Pressure

(ASME B31.1. Power Generation Facility, External Piping, See Section 6.7)

8.4.1 The hydrostatic test pressure at any point in the system to be not less
than 1-1/2 times the design pressure.

8.4.2 Where the test pressure as defined above would produce a stress in
excess of 90% of the yield strength at test temperature, the test
pressure shall be reduced.

The maximum test pressure at which the stress produced will not
exceed 90% of the yield strength will be calculated by the following
equation:

.9X 2sT
P M
14.5d

where:

PM = Maximum Test Pressure (bar)

S = Minimum Specified Yield (psi)
t = Specified Pipe Wall Thickness Minus Mill Tolerance (in.)
D = Outside Diameter (in.)

8.4.3 If the test pressure of piping attached to a vessel is equal to or less than
the test pressure of the vessel and it is not possible to isolate the piping,
then the piping and vessel may be tested together at the test pressure
of the piping. If the test pressure of piping attached to a vessel is higher
than the vessel test pressure and it is not practical to isolate the vessel
from the piping test, the piping test pressure (with the approval of
theCompany) may be reduced to the vessel test pressure. Company's
preference is that equipment and vessels not be included in pressure
testing of piping systems.

8.5 Hydrostatic Testing of Piping Designed for External Pressure

Lines in external service will be subjected to an internal test pressure of 1-1/2

times the external differential design pressure but not less than a gauge
pressure of 1.03 bar.

8.6 Pneumatic Testing

8.6.1 If the piping is tested pneumatically, the minimum test pressure will be
110 percent of the design pressure for piping designed to ASME B31.3.

8.6.2 If the piping is tested pneumatically, the minimum test pressure will be
120 percent and 150 percent maximum of the design pressure for
piping designed to ASME B31.1.

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8.7 Hydrostatic-Pneumatic Testing

For piping designed to ASME B31.3, a combination hydrostatic-pneumatic test

is permissible. The pneumatic test pressure will be in accordance with Section
6.4.1. The pressure in the liquid-filled portion of the piping will not exceed that
given in Section 6.1.

8.8 Sensitive Leak Test

Piping required to have a sensitive leak test, mass-spectrometer of halide test

will be tested in accordance with the applicable code, ASME B31.3 or
ASME B31.1. If a hydrostatic pressure test is used, it will be done after the
sensitive leak test.

8.9 Hydrostatic Testing of Boiler External Piping

8.9.1 The hydrostatic test pressure at any point in the system will be not less
than 1-1/2 times the design pressure.

8.9.2 Pneumatic or other alternative test are not permitted.

9.0 ALTERNATIVE TESTS

9.1 For ASME B31.3 piping, utility systems can be commodity tested in accordance
with ASME B31.3 for category "D" service provided that the fluid is nontoxic,
nonflammable and not damaging to human tissues. The design pressure shall
not exceed 11.2 bar and the design temperature is from -29°C through 186°F.
The following systems meet the requirements of category "D" service and can
be commodity tested.

9.1.1 Cooling water

9.1.2 City or potable water

9.1.3 Instrument air

9.1.4 Plant air

9.2 For ASME B31.1 piping, an initial service test and examination in accordance
with ASME B31.1 is acceptable when other types of tests are not practical or
when leak tightness is demonstrable. An initial service test is not permitted for
boiler external piping.

9.3 Alternative Test Procedure

The commodity test or initial service test is performed with the service fluid.
The pressure shall be gradually increased until half of the operating pressure or
2.58 bar reached, then the joints are visually examined. The pressure is then
increased in steps until the operating pressure is reached and continuously
held for 10 minutes while the joints are examined for leakage.

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10.0 VESSELS AND EQUIPMENT

10.1 The following are excluded from hydrostatic tests:

10.1.1 Vessels or equipment supported by other vessels or equipment or by a

support structure or foundation not capable of supporting the hydro test
load.

10.1.2 Vessels or equipment not capable of sustaining the hydro test load, and
those with internals or linings that would be damaged by the test fluid.

10.1.3 Testing through vessels and equipment shall require Company's

approval.

10.2 The following are excluded from all pressure tests:

10.2.1 Pumps, compressors and turbines.

10.2.2 Equipment and Seller furnished piping previously shop tested

specifically recommended by the manufacturer not to be field tested.

10.2.3 Chemically cleaned and previously tested systems.

10.3 The pressure on any point in vessels or equipment included in the pressure
test will not be greater than the shop test pressure for that equipment as stated
on the vessel drawing, Seller's equipment drawing or specification sheets. In
the event the piping test pressure is greater than the vessel or equipment test
pressure, the piping will be disconnected, blinded and tested separately. If the
piping cannot be disconnected (welded connection) one of the following will be
implemented:

10.3.1 The appropriate commodity engineer will request written approval from
the Seller to test at the required piping test pressure.

10.3.2 Reduce piping test pressure as necessary after review and approval of
Company.

10.4 Certain types of exchangers are specifically designed for a low allowable
differential pressure between shell and tubes, as stated on the Seller drawings
and specification sheets. These will be checked, and if necessary test both
shell and tubes simultaneously as one system with the same pressure or
exclude both sides from the test.

10.5 Pressure vessels with two or more pressure chambers are specifically
designed for a low allowable differential pressure between pressure chambers
as stated on the manufacturers' drawings. These will be checked, and if
necessary test all adjacent pressure chambers simultaneously as one system
with the same pressure or exclude all pressure chambers from the test.

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11.0 INSTRUMENTS

11.1 All instruments will be protected from damage when hydrotesting process and
utility piping systems. Appendix "B" outlines the status of instruments during
testing to insure protection. 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 will be tested by
Company.

11.2 Instruments not listed in Appendix "B" will not be subjected to the pressure test
unless authorization is obtained from the Company Control Systems Engineer.

12.0 FIELD PROCEDURES

12.1 Test Preparation

12.1.1 All joints, including field weld joints, are to be left uninsulated and
exposed for examination during the test, except that joints previously
tested in accordance with this Specification may be insulated or
covered. If a sensitive leak, mass-spectrometer or halide test
(Paragraph 6.6) is required, all field weld joints will also be left unprimed
and unpainted.

12.1.2 Underground portions of piping systems may be tested and covered

prior to testing aboveground portions.

12.1.3 Piping designed for vapor or gas will be provided with additional
temporary supports, if necessary, to support the weight of the test liquid.

12.1.4 Lines which are counterweight supported will 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; if this is not the
case, temporary support will be provided before filling the system.

12.1.5 Before testing:

12.1.5.1 Piping systems will have been completely checked

("punched").

12.1.5.2 All lines, vessels and equipment will be checked to

ensure the entire system can be completely drained after
testing.

12.1.5.3 Vents or other high point connections will be opened to

eliminate air from lines which are to receive a hydrostatic test.

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12.1.6 The field test staff will review all vessels and internals in order to
determine best method to prevent air entrapment when filling and to
prevent vacuum when draining.

12.1.7 Short pieces of piping which must be removed to permit installation of a

blind or blank will be tested separately.

12.1.8 Lines containing check valves will have the source of pressure located
in the piping upstream of the check valve so that the pressure is applied
under the seat. If this is not possible, remove or jack up the check valve
closure mechanism or remove check valve completely and provide
necessary filler piece or blinds.

12.1.9 Systems that include expansion joints will be investigated to verify that
any required temporary restraints, anchors, guides, etc., are installed
prior to test.

12.1.10 When a pressure test is required to be maintained for a period of time

during which the testing medium in the system would be subject to
thermal expansion, provision will be made for relief of any pressure
greater than the maximum test pressure.

12.1.11 Testing of previously installed plant piping is not desired to extend

beyond the closest tie in point of newly attached components.
Company and field contractor shall establish limits and test pressures
prior to field testing each location of tie in to existing systems.

12.1.12 Compliance to Appendix B is mandatory.

12.1.13 Installed open valves in pressure test systems shall be observed for
packing gland leakage. If leaking, packing gland shall be tightened only
enough to stop leakage.

12.2 Hydrostatic Test Procedure

12.2.1 In order to hydrostatic test as much piping as possible at one time, a

systems test may be employed. This test may include one or more
lines.

12.2.2 The minimum test pressure for a system test will be such that each line
in the system is subjected to a test pressure in accordance with
Paragraphs 6.1 or 6.2.

12.2.3 The maximum system test pressure will not exceed the pressure test
rating of any piping component (see Appendix "A") or the shop test
pressure of any vessels or equipment included in the test system.
(Maximum test pressures for flanges and valves conforming to ASME
B16.5 are given in Appendix "A").

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12.2.4 Systems, or sections of systems to be tested, may be isolated by closed

valves provided the valve body and seat are suitable for the test
pressure.

12.2.5 Where a suitable valve is not available, vessels, equipment or other

piping not included in the system pressure test will be either
disconnected from the system or isolated by blinds or other means
during the test.

12.2.6 The normal location for the pressure test gauge is at grade near the
pressure test pump. Readings may be made at higher points providing
the gauge pressure reading plus the static head (.01 bar/meter)
between grade and the point of measurement does not exceed the
maximum test pressure. Pressure test gauges will be calibrated once a
month, using a dead weight tester. The gauge will be tagged with the
date last calibrated and this activity will be recorded.

12.2.7 Hydrostatic test pressure will not be applied until the metal surface and
internal test liquid are at approximately the same temperature. To
minimize the risk of brittle fracture, pressure tests through vessels and
equipment will not be conducted when the test liquid and/or metal
temperature is below 15.6°C. Pressure tests in ferritic and austenitic
stainless steel piping systems that do not include vessels or equipment
may be conducted below 15.6°C but will not be conducted when the
test liquid and/or metal temperature is below 4.4°C.

12.2.8 Hydrostatic test pressure will be maintained for a sufficient length of

time to visually determine if there are any leaks, but not less than ten
minutes. The Field Erection Contractor will not be required to maintain
test pressure in excess of two hours after notification to Company's
authorized inspector.

12.3 Pneumatic Test Procedure Minimum Metal Temperature

At time of testing, the minimum pipe metal temperature will be as

listed below:

Nom. Wall Min.

Thickness Temp
Carbon Steel 1-1/2" & Less 15.6°C
Post-Heat Treated Ferritic Alloy Steels 1" & Less 15.6°C
Austenitic Stainless Steels and Copper 1" & Less 12.2°C
Nickel Alloys

Minimum temperatures for materials not listed above will be

determined by Company l

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Clear test area while bringing line up to and while holding at full
pneumatic test pressure. It may be desirable to conduct test during
the weekend when fewer personnel are present.

12.3.1 During pneumatic testing care will be exercised not to exceed the
specified test pressure by the lesser of ten (10) percent or 3.4 bar for
ASME B31.3 piping and as limited by 6.4.2 for ASME B31.1 piping.

12.3.2 When pneumatic testing at over 1.03 barg, a preliminary check at 1.03
barg will be made to locate major leaks. The pressure will be increased
in gradual steps of .345 barg or 10 percent of the test pressure,
whichever is greater.

12.3.3 A double block and bleed valve arrangement will be included in the
pressurizing line to the system being tested. A test pressure gauge to
be downstream of the double block. After each pressure step has been
reached, close the block valves and open the bleeder to atmosphere. If
after a five minute period the "Step Pressure" is held, proceed to the
next "Step Pressure"; if not, examine the entire system for leakage.

12.3.4 Prior to soaping the joints, the entire line will be "Walked" to determine if
there is any audible evidence of leakage. Any leaks found at the time
will be marked, and repaired after first depressuring the line.

12.3.5 When the system has been brought up to the test pressure shown on
the pipe line list, all joints and welds will be covered with a bubble
forming solution in order to detect any leakage. The solution will be a
commercial preparation made specifically for leak detection.

12.3.6 Bolting will not be tightened while systems being tested are pressured
above 2.07 barg.

12.3.7 Pneumatic test pressures will be maintained for a sufficient length of

time to permit thorough visual inspection of all joints and weld seams
but not less than ten minutes. The Field Erection Contractor will not be
required to maintain test pressure in excess of 2 hours after notification
of Company's authorized inspector. Pressure will be reduced gradually
when depressuring.

12.4 Test Records

12.4.1 Records will be made of each piping system test, utilizing the form titled,
"Field Test Record Piping Pressure Test." These forms, when
completed, will be retained in the Field Quality Control file by Company
as a permanent record. These records to include:

12.4.1.1 Date of test.

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12.4.1.2 Identification of piping system and any vessels or

equipment tested with the piping system.

12.4.1.3 Test medium.

12.4.1.4 Test pressure.

12.4.1.5 Minimum ambient temperature.

12.4.1.6 Test medium temperature.

12.4.1.7 Certification by examiner.

12.4.2 Upon completion of the piping installation, the only retained records will
be a letter of certification by Company's authorized inspector that all
piping has been pressure tested as required by these procedures.
Upon completion of the project, these records will be sent to the
Company home office as specified in the Job Closeout Procedure.

12.5 Test Completion

12.5.1 In the event that repairs or additions are made to ASME B31.3 piping
following the pressure test, the affected piping will be retested at the
pressures originally specified for the test. Testing of minor repairs,
additions or tie-ins to existing lines may possibly be waived provided the
welding is nondestructively examined as follows; however, hydrotest is
still the best assurance of a system integrity:

12.5.1.1 Butt (longitudinal, spiral, and circumferential) and miter

(circumferential) joint groove welds will be 100 percent
radiographed in accordance with Paragraph 344.5.1 of ASME
B31.3.

12.5.1.2 All welds, including structural attachment welds, except

butt (longitudinal, spiral, and circumferential) and miter
(circumferential) joint groove welds, will be liquid penetrant
examined in accordance with Paragraph 344.4 of ASME B31.3
except that magnetic materials may be magnetic particle
examined in accordance with Paragraph 344.3 of ASME B31.3.

12.5.2 Repairs or additions to ASME B31.1 following the pressure test shall be
pressure tested.

12.5.3 After completion of testing, all temporary blanks and blinds will be
removed, all operating blinds returned to proper position and all lines
and piping components (except those tested pneumatically) will be
completely drained. Valves, orifice plates, expansion joints and short
pieces of piping which have been removed will be reinstalled with
proper gaskets in place. All valves that were closed during hydrotest

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will be opened to insure draining the bonnet cavity. Lines being drained
after testing will have all vents open. Piping systems downstream of
check valves will be inspected to insure complete drainage.

12.5.4 Direct connected transmitters at orifice flanges will be disconnected

when replacing orifice plates to avoid distorting the connections.

12.5.5 Care will be exercised in controlling the rate of drainage from vessels
with respect to the inflow of air through the vent to insure that the vessel
is not subjected to vacuum. After vessels are completely drained,
vents, cyclones and other internal closures which were opened prior to
testing will be closed.

12.5.6 After lines have been drained, temporary supports will be removed and
insulation and painting completed. Spring hangers provided with stops
to carry the test load will have these stops removed in accordance with
the "Field instructions" provided on Form E-326, "Constant Support
Spring Hanger," and Form E-327, "Variable Support Spring Hangers,"
for each hanger.

12.5.7 Flanged joints at which test blinds have been removed will not be
retested. Special length bolting and flat non-asbestos gaskets will be
removed and replaced with line class bolts and gaskets.

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

13.0 PRESSURE TEST BLINDS

13.1 Plain test blanks with 1/16 inch flat non-asbestos gaskets will be used for
blanking flat face, raised face, ring joint, male and female, and tongue and
groove type flanges. Full face blanks and gaskets at 125 lb. Cast Iron
connections will be used. However, where permanent operational blinds are
installed, they may be used for field pressure testing.

13.2 Plate material, extra length bolts and gaskets for testing will be furnished by the
field unless directed otherwise by contract requirements. See Appendix "C" for
maximum test pressures at various thicknesses.

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 General Piping – Process and Utility Pressure Testing
CHEVRON GEOTHERMAL INDONESIA LTD
CGI-022-PIP-003 Rev. 0

APPENDIX A
MAXIMUM HYDROSTATIC TEST PRESSURE (PSIG) FOR FLANGES AND VALVES

Carbon Steel Carbon Steel

Carbon Steel Low NI Steel Low NI Steel Chrome-Moly Stainless Steel
(1.1) (1.2) (1.3) 1/2 Cr-1/2Mo (1.7) 304 (2.1) 304L (2.3)
A105 A203, B A203, A 1-1/4Cr-1/2Mo (1.9) 316 (2.2) 316L (2.3)
Material A216, WCB A203, E A203, D 2-1/4Cr-1Mo (1.10) 321 (2.4) Alloy 20 (3.1)
A350, LF2 A216, WCC A352, LCB 5Cr-1/2Mo (1.13) 347 (2.5)
A515, 70 A350, LF3 A515, 65 9Cr-1Mo (1.14) 348 (2.5)
A516, 70 A352, LC2 A516, 65
A352, LC3
Pressure FLG FLG FLG FLG FLG FLG
Class Shell Seat Shell Seat Shell Seat Shell Seat Shell Seat Shell Seat
150 450 314 450 319 400 291 450 319 425 303 350 253
300 1125 814 1125 825 1050 765 1125 825 1100 782 900 660
400 1500 1089 1500 1100 1400 1018 1500 1100 1450 1056 1200 880
600 2225 1628 2250 1650 2100 1529 2250 1650 2175 1584 1800 1320
900 3250 2442 3375 2475 3150 2294 3375 2475 3250 2376 2700 1980
1500 5575 4076 5625 4125 5225 3817 5625 4125 5400 3960 4500 3300
2500 9275 6787 9375 6875 8700 6364 9375 6875 9000 6600 7500 5500

NOTES:
1. The above chart is based on ASME B16.5-1988, and provides the maximum allowable hydrotest pressures
of 1/2 inch through 24 inch flanges (shell test) and flanged and standard class weld end valves (shell test,
with valve open and seat test, with valve closed).
2. Flanged valves manufactured per API-600, API-602 and API-604 may be tested in accordance with the
above chart. 800 lbs. screwed or scoketweld valves manufactured per API-602 and API-606 may be tested
to 3000 lbs. (shell test) or 2200 lbs.
3. For valves not conforming to the above standards or ASME B16.5-1088, the manufacturer's recommended
test pressure limits for both shell and seat will be used.
4. Maximum test pressures for flanges and valves over 24 inches and piping components not covered by this
chart will be provided by the engineering contract as applicable.
5. The maximum test pressure for pneumatic testing will not exceed 75 percent of the stated values.

6. Numbers in parentheses denotes material group number per ASME B16.5-1988.

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 General Piping – Process and Utility Pressure Testing
CHEVRON GEOTHERMAL INDONESIA LTD
CGI-022-PIP-003 Rev. 0

APPENDIX B
STATUS OF INSTRUMENTS DURING PRESSURE TEST

Blow & Blind Include Refer to

Vent Remove Off in Test Notes
1. Analyzers X
2. Control Valves - Pressure Balanced, Regulators X
3. Flow Instruments - D/P Cell & Bellows Types X
4. Flow Instruments – Rotameters X 1.00
5. Flow Meters - Positive Displacement Type X
6. Flow Indicating Switches – Turbine Type X
7. Flow Indicating Switches – Bellows Type X
8. Flow Switches - Vane Type X
9. Gauge Glasses X
10. Level Instruments– Displacer Type X 2.00
11. Level Instruments - D/P Cell and Bellows Type X
12. Level Switches - Float Type X 2.00
13. Orifice Plates X 3.00
14. Pressure Gauges X
15. Pressure Instruments - All Types X
16. Pressure Regulators X
17. Pressure Switches X
18. PSVs X 4, 5, 6
19. PSVs, TSVs - 3/4" and 1" screwed X
NOTES:

1. Caution: do not force reverse flow.

2. Caution: do not overpressure float or displacer. If in doubt, do not test, block or drain instead.
3. Install after hydrotesting and line flushing.
4. Test gag will not be used
5. Blinds not required on PSV outlets discharging into a system being tested at 1.03 barg or less.
6. Where test blinds have been installed for pressure testing PSVs, the Field Erection Contractor will ensure
that blinds are removed upon completion of tests. PSVs may be removed prior to pressure testing where
piping lacks sufficient flexibility to accommodate test blinds.
All instruments will be protected from damage due to freezing. In preparation for cold weather and during cold
weather, all instruments will be drained and process lead lines blown out with air or nitrogen.

Page 19 of 20
 General Piping – Process and Utility Pressure Testing
CHEVRON GEOTHERMAL INDONESIA LTD
CGI-022-PIP-003 Rev. 0

APPENDIX C
SCHEDULE OF MAXIMUM ALLOWABLE HYDROSTATIC TEST PRESSURES (PSIG)
FOR THE LISTED TEST BLIND THICKNESS

Blank NOMINAL PIPE SIZE (N)

Thick-
ness
(IN)
2 3 4 6 8 10 12 14 16 18 20 24 30 36 42 48 54 60
0.250 1862 857 518 239 141 90 64 53 41 32 26 18 11 8 5 4 3 2
0.375 4308 1983 1200 553 326 210 149 123 94 75 60 42 27 18 13 10 8 6
0.500 7764 3576 2162 997 588 378 269 223 171 135 109 76 48 33 24 19 15 12
0.625 12230 5631 3406 1571 927 596 424 351 269 212 172 119 76 53 39 29 23 19
0.750 17707 8153 4932 2275 1342 864 614 509 390 308 249 173 110 77 56 43 34 27
0.875 24195 11140 6739 3109 1834 1180 839 696 533 421 341 236 151 105 77 59 46 37
1.000 31693 14593 8828 4073 2403 1546 1099 912 698 551 446 310 198 137 101 77 61 49
1.125 40201 18511 11198 5166 3048 1962 1394 1158 885 699 566 393 251 174 126 98 77 62
1.250 49721 22894 13849 6389 3770 2426 1725 1430 1095 865 701 486 311 216 158 121 96 77
1,375 60250 27743 16782 7743 4568 2940 2090 1733 1327 1048 849 590 377 262 192 147 116 94
1.500 71791 33056 19997 9226 5443 3504 2491 2066 1581 1249 1012 703 449 312. 229 175 138 112
1.625 84341 38835 23493 10839 6395 4116 2926 2427 1858 1468 1189 825 528 367 269 206 163 132
1.750 97903 45080 27270 12582 7423 4778 3397 2817 2157 1704 1380 958 613 426 313 239 189 153
1.875 112474 51790 31329 11454 8528 5489 3902 3236 2478 1958 1586 1101 704 489 359 275 217 176
20 128057 58965 35670 16457 9709 6250 4443 3685 2821 2229 1805 1254 802 557 409 313 247 200
2.125 144649 66605 40292 18589 10967 7060 5019 4162 3187 2518 2039 1416 906 629 462 354 279 226
2.250 162253 74711 45195 20852 12302 7919 5629 4669 3575 2824 2288 1588 1018 706 518 397 313 254
2.375 180867 83281 50380 23244 13714 8828 6275 5205 3985 3148 2550 1771 1133 787 578 442 349 283
2.500 200491 92318 55846 25766 15202 9786 6956 5769 4417 3490 2827 1963 1256 872 641 490 387 314

NOTES:

1. The Tabulated Pressures above are based on the formula stated in ASME B31.3, Paragraph 304.5.3 using
a. Flat nonasbestos gaskets conforming to ANSI B16.2.1.
b. Structural grade carbon steel plate, ASTM A36 having a minimum specified yield strength of 36,000
psi
2. For plate which is identified as having a lower minimum yield strength, the allowable hydrostatic pressure
must be reduced in accordance with the following formula:

y
Pma = X
y
Where: Pma = Maximum
Y = Minimum Specified Yield Strength, ASTM A36
Yx = Minimum Specified Yield Strength for Material Selected

3. Pneumatic test pressures shall not exceed 50 percent of the values indicated.

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