ANZ Standard Specification

ANZ-SS-P-3007 Rev.0

PRESSURE TESTING OF PIPING SYSTEMS

Approved STEVEN VINING

HEAD OF ENGINEERING

Rev Effective Author Document Checked Description

Date Initial and Date Initial and Date

0 Nov-2014 JWP Nov-2014 JGB Nov-2014 Issued for ANZ Region

This document is uncontrolled if printed or downloaded

Copyright 2014 by Jacobs Engineering Group Inc. All rights reserved. The contents of this document are proprietary and
produced for the exclusive benefit of Jacobs Engineering Group Inc. and its affiliated companies. No part of this document may
be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying,
recording, or otherwise, without the prior written approval of Jacobs Engineering Group Inc.
Page 1 of 13 0000-50-SPE-1100_0.doc
ANZ Standard Specification

ANZ-SS-P-3007 Rev.0

CONTENTS

1. GENERAL ...................................................................................................................... 3

1.1 Scope ......................................................................................................................... 3

1.2 Document Precedence ............................................................................................... 3

2. EXCLUSIONS ................................................................................................................ 3

3. APPLICABLE CODES, STANDARDS AND SPECIFICATIONS..................................... 4

3.1 American Society of Mechanical Engineers (ASME) ................................................... 4

3.2 Project Specifications & Lists ...................................................................................... 4

4. MATERIALS AND EQUIPMENT .................................................................................... 4

5. HYDROSTATIC TESTING .............................................................................................. 5

6. PNEUMATIC TESTING .................................................................................................. 5

7. PREPARATION FOR TEST ........................................................................................... 5

7.1 Planning...................................................................................................................... 5

7.2 Requirements ............................................................................................................. 6

7.3 Physical Checks ......................................................................................................... 8

8. TEST PROCEDURE ....................................................................................................... 8

8.1 Hydrostatic Test .......................................................................................................... 8

8.2 Test Criteria ................................................................................................................ 9

8.2.1 Leaks .................................................................................................................. 9

8.2.2 Pressure ............................................................................................................. 9

8.2.3 Time .................................................................................................................. 10

8.3 Pneumatic Test ......................................................................................................... 10

9. COMPLETION OF TEST .............................................................................................. 11

Page 2 of 13 0000-50-SPE-1100_0.doc
ANZ Standard Specification

ANZ-SS-P-3007 Rev.0

1. GENERAL

1.1 Scope

This specification covers pressure testing of plant piping systems and integral
components for [Enter Project Name] in accordance with the applicable codes
and standards.

No deviation from this specification shall take place without written approval from
The Principal’s Representative.

This specification shall be used in conjunction with the piping and

instrumentation diagrams (P& ID's) and the Project Line List.

All piping systems shall be pressure tested except where otherwise specified in
the Purchaser Project Line List and in Appendix A.

1.2 Document Precedence

In the case of any conflicting requirements in the documents, the order of

precedence shall be:

 Statutory Regulations, Acts of Parliament and Codes and Standards

referenced therein, except when this specification or its referenced
documents impose more stringent requirements.

 Referenced Technical Specifications.

 Client Specifications/Practices, as applicable.

 Local and international codes and standards.

2. EXCLUSIONS

The following items shall not be subject to pressure testing unless specified
otherwise by The Principal’s Representative:

 Piping systems open to the atmosphere, downstream of the last isolation

valve.

 Instrument piping lines between the isolation valve at the process or utility
line and the connected instrument.

 Instrument components as listed in Appendix ‘A’ of this specification.

 Items specifically listed in by The Principal’s Representative.

Page 3 of 13 0000-50-SPE-1100_0.doc
ANZ Standard Specification

ANZ-SS-P-3007 Rev.0

 Non metallic underground piping systems.

3. APPLICABLE CODES, STANDARDS AND SPECIFICATIONS

All codes, standards and specifications referred herein shall be current edition of
such documents.

3.1 American Society of Mechanical Engineers (ASME)

B31.3 Process Piping

3.2 Project Specifications & Lists

[Enter Doc. No] Piping Standard Details

[Enter Doc. No] Specification for Fabrication, Installation, Inspection &

Testing of Steel Piping

[Enter Doc. No] Specification for Flushing and Air Blowing of Pipework

[Enter Doc. No] Specification for Chemical Cleaning of Pipework

[Enter Doc. No] Line List

4. MATERIALS AND EQUIPMENT

The Contractor shall supply all blanks for flanges, plugs, fittings, pipe and valves
and temporary safety valves required for the pressure test procedures additional
to those components which form the piping system being tested.

Materials supplied by the Contractor shall be suitable for the pressure testing of
the piping system.

The Contractor shall supply all pumps, ancillary equipment, pressure gauges,
pressure recorders and any other necessary items required to complete the
tests.

The pressure gauges and recorders shall be test calibrated and certified by a
NATA approved laboratory. The calibration shall be done in accordance with
NATA approved standards.

Recording instruments shall have a minimum of 12 hours per chart revolution

timing and the chart shall be graduated in 15 minute intervals.

Instruments used on a test system shall have an operating range such that the
test pressure is between lower quartile and the upper quartile of the indicated
range of each instrument.

Page 4 of 13 0000-50-SPE-1100_0.doc
ANZ Standard Specification

ANZ-SS-P-3007 Rev.0

5. HYDROSTATIC TESTING

All lines identified for Hydrostatic Testing in the Line List shall be tested to the
pressure specified therein.

Where the test medium is specified as water, it shall be potable water at ambient
temperature with a pH value between 6 and 8 or other sources as directed by
The Principal’s Representative. For stainless steel lines the maximum chloride
content shall not be greater than 30 ppm. Water having a chloride content above
100 ppm shall not be used, and where it is necessary to use water within a range
of 30 to 100 ppm, lines shall be flushed with water having a chloride content of
less than 30 ppm within a short period of testing

Water shall be drained immediately after hydrostatic testing and the line airblown
where nominated on the Line List.

For stainless steel lines the system shall be dried out, using oil free compressed
air at ambient temperature so as to avoid concentration of chlorides.

A report on water analysis including the chloride content and pH value of the
water shall be attached to the test report at all times when austenitic stainless
steel systems are hydrotested. A NATA registered laboratory shall prepare the
analysis and report.

In-line items per appendix “A” of this document shall not be installed until
completion of all hydrostatic testing, flushing and cleaning on the pipework.
Where in-line items are welded in and contain stainless steel internals, then low
chloride water (30 ppm maximum) shall be used.

6. PNEUMATIC TESTING

Where pneumatic testing is specified, the Contractor shall first obtain the
necessary permission of the Statutory Authority and observe all safety
precautions. For pneumatic testing, the test medium shall be dry air which is
clean, oil free and with a dew point below 10°C at the test pressure.

All lines identified for pneumatic testing are designated in Line List. The lines
shall be tested to the pressure specified in the line list.

7. PREPARATION FOR TEST

7.1 Planning

Piping systems to be tested shall be divided into sections. The sections

proposed shall be subject to approval by The Principal’s Representative.

Page 5 of 13 0000-50-SPE-1100_0.doc
ANZ Standard Specification

ANZ-SS-P-3007 Rev.0

The Contractor shall prepare a "Test Pack" for each section in conjunction with
The Principal’s Representative containing the following:

Piping Isometrics Drawings

Limit of the test shown on the appropriate piping and instrumentation diagrams
(P& ID's)

Location and thickness of test spades, and calculations as necessary, to

confirm thickness

Testing medium

Test pressure

Location of vents and drains

Requirements for isolation or removal of instruments and other in line items,

as per Appendix ‘A’.

The test pack shall also make provision for the following information to be
added, following the hydrostatic test:

Pressure test charts

Record of weld repairs and procedures, and welders employed

Any corrective actions.

Review of P & ID’s to identify all pipe material spec breaks at socket, or butt
welded valves

The Principal’s Representative will examine and approve the test pack submitted
by the Contractor, and if desired, conduct a visual inspection of the piping section
to ensure compliance with the specification prior to commencement of the
pressure test.

7.2 Requirements

All joints, including welds, shall be left uninsulated and exposed for examination
during the test, full painting of the welds is acceptable prior to hydrotest.

Piping designed for vapour or gas shall be provided with additional temporary
supports, where nominated, to support the weight of the test liquid.

Stops on spring and constant hangers and supports shall not be removed prior to
testing.

Short pieces of piping, which must be removed to permit installation of blind or

blank, shall be tested separately.

Page 6 of 13 0000-50-SPE-1100_0.doc
ANZ Standard Specification

ANZ-SS-P-3007 Rev.0

Lines containing check valves shall have the flapper removed during testing. The
Contractor shall ensure that all check valve internals are stored securely and
reinstated after all works are completed. The Principal’s Representative shall
witness the reinstatement of all valve internals.

Under no circumstances shall closed valves be used to isolate a line or any

equipment for the purposes of system pressure testing. In a system, all valves
shall be in the open position, and to isolate the system, spades or blinds shall be
used downstream of any valves.

Where a pipe material spec break occurs at a socket, or butt welded valve, the
Contractor shall ensure that a spool piece of the higher class rating has been
welded to the valve. The spool piece shall be blinded/blanked off during the
hydrotest, after which the end closure shall be removed and the spool ends re-
bevelled to match the lower class piping wall thickness. The weld of the spool
piece to the lower class piping shall be hydrostatically tested to the lower class
pressure and contrary to the above the valve may be used as an end closure.

Rotating equipment shall not be included in hydrotest; other equipment shall not
be included in a hydrotest involving a pressure exceeding its design pressure.
Equipment, which is not subject to pressure test, shall be either disconnected
from the piping or blocked off during the test. In all cases testing of equipment
simultaneous with piping systems shall be subject to the approval of The
Principal’s Representative.

In cases where a pipeline being tested extends beyond the battery limit without
flanges, it shall be tested to the first block valve or set of flanges outside the
battery limit. They should have tabs which project at lest 75 mm beyond their
retaining flanges so that they can be readily seen.

Pressure test blinds with gaskets as per pipe specification shall be used for
blanking flat face and raised face type flanges. In cases where the piping class
requires spiral wound gaskets to be used, compressed non-asbestos fibre
gaskets may be substituted at test locations. Where permanent operational
blinds are installed, the Contractor may elect to use these for field pressure
testing. Specification shall be referred for control and tagging of blinds.

Prior to the pressure testing, the Contractor shall be responsible for providing
and installing temporary pipe supports where required or where nominated (e.g.:
for vapour or gas piping). The temporary supports shall be designed to carry the
hydrotest loads.

Before commencing to fill the system, the Contractor shall ensure that all air will
be purged from the system by opening the vents and other connections in the
line and that the system can be completely drained after the testing. Where
additional vents and drains are required, the proposed locations shall be
approved by The Principal’s Representative, and the Contractor shall be
responsible for supply of materials and provide necessary connections in
accordance with the Project Specification. The additional vents/ drains shall be
marked-up on the “as-builts” drawings.

Page 7 of 13 0000-50-SPE-1100_0.doc
ANZ Standard Specification

ANZ-SS-P-3007 Rev.0

To assist in leak detection during pneumatic testing, all flanged joints shall be
circumferentially taped with sealing tape. A small puncture shall be made in the
tape between the mating flanges to localise any leakage from the joints.

Impulse piping to instruments is to be disconnected from the instrument

downstream of the first block valve during flushing and testing of main process
lines. Analyser sampling systems shall also be disconnected.

All sprinkler piping shall be flushed and then plugged for pressure testing; heads,
rosettes and nozzles shall be fitted after pressure testing.

Tests on closing welds in lines which have previously been tested in sections, or
retests due to a cut-in to a line which has already been tested, may be waived at
the Inspector's discretion provided that cases (a) to (c) below are satisfied and
the results are to the Inspector's satisfaction.

(a) Preparation and welding are carried out under the supervision of the
Inspector.

(b) Full (100%) radiography is carried out on closure welds.

(c) Other NDE requirements imposed by the specifying authority and

authorised by the Inspector are met.

7.3 Physical Checks

Piping systems shall have been completely checked ("Punched") and released
for testing. All filaments shall be welded to piping prior to hydrotest.

All lines shall be checked to ensure that the entire system can be completely
drained after testing.

Vents or other high point connections shall be opened to eliminate air from lines,
which are to receive a hydrostatic test.

All air shall be removed from the piping system by venting before hydrostatic test
pressure is applied. Air purging shall be witnessed by The Principal’s
Representative

All elements as listed in Appendix ‘A’ shall be removed.

All equipment not to be pressurised shall have been isolated.

8. TEST PROCEDURE

8.1 Hydrostatic Test

The normal location for the pressure test gauge shall be at grade near the
pressure test pump. Readings may be made at higher points providing static

Page 8 of 13 0000-50-SPE-1100_0.doc
ANZ Standard Specification

ANZ-SS-P-3007 Rev.0

head differential between grade and the point of measurement is subtracted from
the specified pressure.

All pressure test records shall be made using a combined pressure and ambient
temperature chart recorder unless otherwise accepted by The Principal’s
Representative.

All pressure gauges and chart recorders used for testing shall have a valid
calibration certificate issued by a NATA registered organisation. At least two
pressure gauges of a type and range in accordance with the specific
requirements of the above “Materials and Equipment” section, shall be used, one
located at or near the low point of the system being tested and the other near the
test pressure pump.

Test and vent holes in reinforcing pads shall be open during testing, and shall be
left open for operation. The holes shall be sealed with mastic prior to operation.

If a pressure test is to be maintained for a period of time and the test liquid in the
system is subject to thermal expansion, precautions (such as surveillance by a
suitably qualified person throughout this period) shall be taken to avoid excessive
pressure.

Sealing materials shall not be used to correct leaks at joints.

Valve glands shall be tightened as necessary to stop leaks, however valve

glands shall not be tightened to the extent that the valve cannot be operated. If
necessary, valves shall be repacked.

The Contractor shall be responsible for venting piping, vessels and equipment
when filling, testing and draining, to ensure against their collapse by vacuum.

Additional connections for hydrostatic testing vents and drains, if required, shall
be supplied and installed by the Contractor as per the Piping Standard Details
specification [Enter Doc. No].

Hydrostatic tests shall not be performed in the rain, or whilst the piping is wet.

8.2 Test Criteria

8.2.1 Leaks

All welds and flanged joints shall be inspected and found free of leaks.

8.2.2 Pressure

During testing, care shall be exercised not to exceed test pressure specified on
the line list. This shall be achieved by installation of a relief valve at the pressure
source and the set pressure of the relief valve shall be the test pressure plus the
lower of 200 kPa or 5% of the test pressure.

Page 9 of 13 0000-50-SPE-1100_0.doc
ANZ Standard Specification

ANZ-SS-P-3007 Rev.0

Any drop of pressure during the test period shall be investigated and the cause
rectified. (Allowance shall be made for any effect of temperature change). The
test shall be repeated after the cause of the pressure drop has been rectified.

8.2.3 Time

The test pressure shall be maintained for a sufficient time to inspect for small
seeping type leaks but in no case less than a 30 minutes period (or as directed
by the Principal’s Representative), after the test pressure has stabilised, and the
test pump disconnected, and shall be recorded on a pressure recorder. Any
leaks shall be repaired and the lines retested.

8.3 Pneumatic Test

All items in the above section are applicable together with any Statutory Authority
requirements.

Pneumatic tests shall not be performed in the rain, or whilst the piping is wet.
Tests shall be carried out during daylight hours unless specifically approved by
The Principal’s Representative.

The test pressure shall not be applied until the piping system and the
pressurising medium is at about the same temperature.

A relief valve shall be installed at the pressure source and shall be set at the test
pressure plus the lesser of 70 kPa or 7 percent of the test pressure.

A limited access area and pressure control point shall be established. Signs
which read "PNEUMATIC TEST IN PROGRESS - ACCESS BY PERMISSION
ONLY", shall be posted at the perimeter of the limited access area. Only testing
personnel involved in the particular operation being performed may be within the
limited access area e.g. during system pressurising, testing personnel who will
be examining the system shall be outside the limited access area.

One person shall be at the Pressure Control Point monitoring the gauge
whenever the system contains pressure.

The air shall be introduced into the piping system gradually until the pressure is
the lesser of one-half of the test pressure or 170 kPa. At this point the pressure
shall be maintained for a minimum of 10 minutes followed by a preliminary
check.

Leak detection fluid shall be applied (using a chemist’s wash bottle or other
suitable means) to all joints and connections. Ordinary household soaps or
detergents are not permitted. If tightening is required to stop leaks, isolate the
immediate work area from persons not necessary for the tightening operation.
Personnel shall remain clear of the gasket plane projection.

The pressure shall be gradually increased in steps of one-tenth's of the test

pressure until the test pressure is attained. During this pressurising stage, check

Page 10 of 13 0000-50-SPE-1100_0.doc
ANZ Standard Specification

ANZ-SS-P-3007 Rev.0

seals, seats, and gasketed joints for leakage after a specific pressure has been
established for 10 minutes, as required.

When the test pressure has been attained, it shall be held for a minimum of one
hour or as directed by The Principal’s Representative.

Perform a visual inspection of all joints and connections at the test pressure
using leak detection fluid. The Principal’s Representative shall witness this
inspection.

Any bubbles observed as a result of seepage shall be considered sufficient

reason for non-acceptance of the system being tested. The system shall be
retested following repair work.

The maximum rate of depressurising shall be 100 kPa per hour or as directed by
The Principal’s Representative.

9. COMPLETION OF TEST

A pressure test shall be considered complete when the following are finalised
and accepted by The Principal’s Representative:

All defective welds, defective materials, flange leaks, valve gland leaks or other
such defects have been corrected and, where required, retested to the
satisfaction of The Principal’s Representative.

All documentation and "test pack" information is complete. The test pack at this
stage shall include pressure test charts, a record of all repair welding operations
including record of all welding procedures used and welders employed and all
other corrective operations.

Completed systems shall be cleaned, flushed and air blown as required in

accordance with Project Specification OP4.3033.

After completion of test all temporary blanks and blinds shall be removed, all
operating blinds returned to proper position and all lines completely drained and
the correct line class gaskets and bolting installed. Valves, orifice plates,
expansion joints and short pieces of piping which have been removed shall be
reinstalled with correct line class gaskets and bolting. Lines being drained after
testing shall have all vents open. Lines down stream of a check valve shall be
inspected to insure complete drainage. Piping and equipment shall be
completely dried.

Check valve internals shall be replaced.

After lines have been drained, temporary-piping supports shall be removed.

Spring hangers provided with stops to carry the test load shall have these stops
removed after test is complete and prior to putting line in operation.

Lines shall be closed to prevent entry of foreign materials.

Page 11 of 13 0000-50-SPE-1100_0.doc
ANZ Standard Specification

ANZ-SS-P-3007 Rev.0

Instruments and equipment which were removed or blocked out for test shall be
reinstalled and blocks opened or removed.

Hydrostatic vents and drains shall be installed and backwelded in accordance

with specification.

If it has been necessary to use water to test systems in which moisture cannot be
tolerated, special drying techniques may have to be employed, e.g. the use of
hot dry air, and special attention should be paid to places where water may be
trapped, such as valve bodies, low points and dead ends. The use of water in
such situations can only be permitted in extreme cases where another medium is
not available.

Any temporary bolting which has been used shall be replaced to the satisfaction
of the Inspector and any temporary fitments which may have been installed to
limit travel, e.g. in expansion joints and pipe hangers, shall be removed.
Hangers shall be checked and reset as necessary.

Pressure relieving devices shall be replaced to the satisfaction of the Principal’s

Representative.

Where necessary, valves are to be re-packed with the appropriate grade of

material.

Page 12 of 13 0000-50-SPE-1100_0.doc
ANZ Standard Specification

ANZ-SS-P-3007 Rev.0

APPENDIX A: STATUS OF INSTRUMENTS AND IN-LINE ITEMS

PRIOR TO FLUSHING AND PRESSURE TEST
REFER TO NOTES
BLIND-OFF
REMOVE
BLOCK AND VENT
1. Analysers
2. Control Valves and Regulators X X 1/3
3. Flow Instrumentations - D/P Cell and Bellow Types
4. Flow Instruments - Vortex type X
5. Flow Instruments – Rotameters X
6. Flow Meters – positive displacement type. X
7. Flow Meters – turbine type X
8. Gauge Glasses. X X
9. Level Instruments – displacer type X
10. Level Instr. - D/P cell
11. Orifice Plates. X 2
12. Pressure Gauges. 2
13. Pressure Instruments - all types 2
14. Pressure Regulators. X
15. Pressure Switches. 2
16. Safety and Pressure Relief Valves & Bursting Discs. X
17. Expansion Joints and Flexible Hoses. X
18. All Flanged Ball Valves. X 4
19. Duplex and Cartridge Filters. X
20. Truseal & Orbit Valves X
21. Strainers & Filters X X
22. Non-Slam Check Valves X
23. Sight Flow Indicators
24. Flow Nozzles X

NOTES:

1. Welded-in items to be closed during test, bypass to be opened.

2. Install after hydrotesting and line flushing.

3. If valves are to be removed; spool piece for testing whole line to be

considered

4. Ball valves need not be removed, if condensate with less than 1 ppm
chlorides is used for pressure testing.

Page 13 of 13 0000-50-SPE-1100_0.doc