!

i
rttLl -? ptF
Honrbeni JOB No. DOC. No. REV

Prolect Speeification 0-0800 s-000-1540-601 3B

DATE 22_-_ApR. -!998_ SHEEI__4_OF_ 28
PREP'D Y.IIfATSUYAMA .tlr Y Z=-
CHKD A"KoNpo i;t,H
APP'D K K,r\MfYAf\fA i -/ J*,,

TEST AND INSPECTION PROCEDTJRE

FOR

a
o STEEL PIPING WORK AT SITE

IEIES!!9L
PTSCOXPO I /
ili-E
ffiT7
!354gjg
PCI PAK-ARAB REFINERY LIMITED
FSrt
ffi-
E
@_
MID.CO{'NTRY REFINERY PROJECT

F MAHMOOD KOT. PAKTSTAN

I INDD(

REV. DATE PAGE DESCRPT|ON PREPD CHKD APPD

(o) 22 APR'98 Atl lssusd tor Approval Y.M. A.K K.K
11 AUG 98 Arl lssued for Consffuction/Refer XrJY/PY-13Z & Oarification A-K
<e> Y.M. KK.

o
@
4 DEC98 I, t8
21,2.,A
Revise mistype pad ol 6.6.1, Specified d€hil for item 7.8.1.

W.
IY.M. A"K KK.

-*I\ 24""A
24 MAR 99 Conection of Table 1

LT

8
 0-0800
TEST AND INSPECTION PROCEDURE FOR DOC. NO. S-000-154G601
STEEL PIPING WORK AT SITE SHEET 2 OF ?3

CONTENTS

PAGE

1. scoPE..... 3

2 APPLICABLE CODES AI.{D REFERENCE SPECIFICATIONS 3

3. WELDING QUALIFICATION 4

4 QUALITY CONTROLLER 4

o 5. NON-DESTRUCTTVE EXAI\4MER 5

o 6. INSPECTION OFWELDING 5

7. PRESSURE TEST.... 11

8. WRAPPING INSECTION 19

9. ACCESSORIES l9
10. O\IER ALLTIGIITNESS TEST t9
11. DMUT{ENTS A}.{D RECORDS t9

TABLE I (,-'r--- lrnNLJMBER

t
OF RADIOGRAPHIC FILMS By JOINT SrTF 1.
o rr-"""'
2l

o TABLE 2 TEST BLIND PLATE THICKNESS................ 24

TABLE 3 NON-DESTRUCTTVE TEST (NDT) REQUTREMENTS ............i ?5

FIGURE 1 crAusEs TO BE INDICATED ON FILM CTYPICAL) ......... ...\ n

ATTACHMENT I PRESSI,]RE TEST FI-OW DIAGRAM 28

S{0G154&@l R3Brrf
 G0800
TEST Ar\rD INSPECTION PROCEDURE FOR
D@. NO. Sff&154G601
STEEL PIPING STORK AT SIIE
SHEET 3 OF 28

SCOPE

1.1 This spcification cove's ttre testing and inspection of piping work" which
conducted during and/or after completion of shop fanication and field
will b
installation of
piping.

t2 This spffication shall always be applied in conjunction with relevant paragnphs

in the
applicable code.

13 Any deviations from and/or additions to this procedure, if required in individual

cases,
shall be called to the attention of Manrbni (MC) and approveO in writing
by MC prior to
commencement of the applicable tests and inspections.

At{ q*
a L.4 and inspections thu are not contained in this specification, if required, shall
made in accordance with the instnrctions of the MC penonnel in charge.
be

o Laws and regulations, if applicablg shall take precedence over this specification.

L APPLICABLE CODES AND RETERENCts SPECU'ICATIONS

(1) ASMEB31.3a-r996

'?rocess Piping"

Q) ASME Section V- 1995

'T.Ion-Destructive Examination"

(3) ASME Section D(- 1995

o "Welding and Brazing eualification'

a (4) Reference Specifi cations

s@1360405 General Specification for Piping Material Common

s-00s13@-010 Detailed Specification of Piping Material

s{@13@052 Cold Bending Pipe Fabrication

s{0G316&ml Constnrction Specification for Steel piping

Work at Site
s{&1540-001 Specification for Positive Material Identification
(For Field Constmction)

s{p1540-m2 Field Quality Control hocedure

 0-0800
TEST AND INSPECTION PROCEDURE FOR
DOC. NO. S-00G154G601
STEEL PIPING WORK AT SITE
SHEET 4 OF 28
3. WELDING OUALIFICATION

3.1 Priol starting the worlc, the welding procedure specifications (WpS), procedure
lo
qualific*ion reord (PQR) and welder& welding opratorperforrrance qualification
documents shall be approved-

4. OUALITY CONTROLLER

4.1 The subconhactor shall supenrise the fabrication and installation work and verify
that all
requrements stipulated in this specification are fulfilled throughout the fabricatiln
and
installation work and during test and inspection, and that tfre quality of the work
meets all
the requirements after the constnrction has been completed.

o For this PuPose the subcontractor shall assign qualifred quatity controller(s).

o 42 The quality controller shall be authorized to stop and correct the work that does
not
conform to this specification.

43 The quality controller shall assume the following work responsibilities. When work
that
does not conform to this specification has been foun4 he sidt stop and correct
the work
performed by directing repair, replacement or removal. In each case, he shall
notiry MC
inspector without any delay in writing of the non-conformities and the d,isposition
for
approval.

(l) Supenrision of material stor4ge and handling and verification of material

identification.

(2) Preparation of detailed test and inspection procedure and supervision of work
execution stafits, when required.
o (3) suprvision of welding work and verification of quality in welded products by
o destuctive and non-destructive means.

(4) Preparation for the calibration of instruments, recorders, measuring devices and
testing devices to be used for the testing and inspection of the constnrction work.
Calibration record shall be fumished to MC.

(s) Pre,paration of prsonnel qualification records and supervision of work records.

(6) verification and submission to MC of the welding work record for each weld-

a) Preparation, verification, and submission of all inspection records to MC.

(8) Preparation and submission to MC of non-conformity notices, disposition notices,

and repair confirmation notices.

5{0G,1540601 R3Jrd
t(

G...0800
TEST AND INSPECTION PROCEDUPG FOR DOC. NO. S-00G,154G601
STEEL PIPING WORKAT SITE SHEET 5
OF 28

(9) Verification of tests and inspections that are considered necessary for qualrty control
or tests and inspections directed by MC inspector.

Note : 'Yerification" means that the quality controller himself nor his assistance shall
witness the tests and/or inspections for confirmation of the quality.
And "Suprvision' means ttrat quality controller himself or his assistants shall
ascertain whether the execution of the work conforms to this specification by
conducting spot inspection.

5, OUALIFICATION OF NON.DESTR,UCTIVE PRESONNEL

5.1 The nondestnrctive personnel shall be a person qualified to one of the following items:

o (1) A person qualified in accordance with applicable Codes and/or regulations.

o Q) A person qualified by Pakistan Atomic Energy Commission.
(3) A person who has above capability and subsequently approved by the MC & IPMT
Inspector.

52 The nondestructive personnel who gives unreliable judgment or lrrforms work not
conforming to this specification and/or instuctions by the quality controller or the MC
iqspector, MC QC manager will discharge hirn

6.. INSPECTION OF WELDING

6.1 Inspection of Completed Weld

o Aftercompletion of welding, visual inspection shall be applied to the following:

a All welds shall be 1@7o visually inspected before application of other non-destnrctive
examinations. Visual inspection shall be made for irregular bead, excess or concave
reinforcement, root penetration if possible, leg length of fillet" surface weld defect such as
crach lack of fusion and undercutting, an6 free from slag, spatter, etc.

62 RadiographicBxamination

6.2.1 Radiographic examination shall be applied to the bun-welded portion in piprng. The
minimum examination rate shall be in accordance with Table 3.

622 *l00%oRadiography''
means thx lffiVoof every cornplete girth butt weld in a designated
Iot of piping shall be examined by radiogaphy.

S40G1540-@1 R3Jnf
rI

0-0800
TEST AND INSPECTION PROCEDURE F9R DOC. NO. S-00S154C1601
STEEL PIPING WORK AT SME SHEET 6 OF 28
623 "RandomRadiogr4hf shall apply as follows:

The complete circumference of aspecified percentage of the girttr butt welds in designated
lot of piping shall be examils6 by radiography. This is a random selection for each
welder and each line class.

62.4 "Spot Radiographt'' shall not apply for this project.

62s Application of radiographic examination for P No. 3, 4 and 5 material of Table 3 shall be
performed afterpostweld heat treatrnent when specified.
"Ultrasonic examinzliqn may be made after postweld heat treafrnent instead of
radiographic exam i nation.

62.6 Method
o
o Radiographic examination shall be in accordance with the applicable Code and the
following requirements.

(1) Radiation source to be used shall be Ir-192 or Co.60 in principle.

@ Minimum number of films for each prpe size shall be in accordance with Table 1.
(3) Films to be used shall be fine grain films such as KODAK Type *AA"o FUJI "#lm-,
or equivalent Iead foil sensitive scr@n 0.03 mm or 0.1 mm shall be used-

(4) The film length shall be l0,l2 or 15 inch unless otherwise agreed-
(5) A wire type Image Quality Indicator (IQD or peneffarneter, specified by DIN or JIS
may be used for each film and may b places between the weld and the film.

o The image quality level (sensitivity) shall be equal or lesser the values calculated in
the following mannen
O - Single wall single image : 2Vo of (T + reinforcement)

- Double wall single image : 2Vo of (T + reinforcement)

Double wall double image: 2Vo of (T + reinforcement)

(T is pipe wall thickness.)

(6) The density of the radiograph of the sound metal in the area under examination shall
be within the range of 1.8 - 3.5 for X-ray and 2.0 - 3.5 for T-ray source.

O The radiograph shall be examined in a darkened rooul The brightness of the viewer
should be adjustable so as to allow satisfactory reading.

s-00G1540{01 R3kd
 G,08m
TEST AND INSPECTION PROCEDURE FOR DOC. NO. S-00G154G@r
STEEL PIPING WORK AT SITE SHEET 7 OF 28

(8) For fabricating identification of examined welds and radiographs, alphabetical letters
and numerals shall be affixed on the film as indicated in Fig. 1.

62J Limitation of Imperfections

rimitationof imperfectionsshallbeasstatedinTable 341.3.2|of ASMEB3t.3a- 1996.

62A Prognessive Examination

(l) When the required spot and/or random examination reveals a defect requiring repair,
two additional exeminations of the same t)?e shall be made of other welds maae by
the same welder orwelding oprator.

(2) If the second group of welds examined is acceptable, all welds represented by these
o additional examinations shall be accepted"

o (3) When each of the second goup reveals a defect requiring rcpair, two additional
welds shall be examined. If all of the third groups of welds examined are
acceptable, the welds requiring repair shall be repaired or replaced to meet the
requirements of the Code aod all welds represented by the examined welds shatl be
accepted.

(4) Ifany of the third group of welds examined reveal defects requiring repair, all
comparable welds may be replaced or they shall be fully examined and repaired as
necessary to meet applicable quality requirements.

Defect Repair

(l) 'When
acrack, incomplete penehation or lack of fusion is foun4 the repair work shall
not be started before MC has bn notified and agrees with the rework
o (2) Repair welding shall only be allowed trrice for one lrcrtion of the weld joinr
o (3) AII defects in welds requiring repair, shall be removed by arc gouging, gnnd.ing,
chipping, or machining. Basic principles of the applicable welding procedure shall
be used-

63 Liquid Penetrant Examination

63.1 Uquid penetmnt examination shall be apptied to the fillet welded portion in piping. The
minimum examination ftrte shall be in accordance with Table 3.

632 Methd
(1) Uquid penetrant examination shall be carried out in accordance with Article 6, Sect-
V of the ASME Code.

(2) The solvent removal type using color contrast method shall be used.
lx

G.0800
TEST AI{D INSPECTION PROCEDURE FOR
DOC. NO. S-o&ts4GCIt
STEELPIPINGWORKATSNE SHEET 8 OF 28

633 Application of this exanination shall be perforrred after postweld heat treahnent when
specified"

63./ !otf* preparation by gdnding or other mechanical method is necessary where surface
irregularities could otherwise mask indications of unacceptable discontinuities. prior to
liquid llcDehant examination, the surface to be examined and all adjacent area within at
least 25 mm shall be dry and fre of any dirt, gease, cloth, scale, flux, spafter,
oil, or other
exffineous matter.

635 Drying, der cleaning, of the surfaces to be examined shall be accomplished by normal
evapration for a period of I min. ?s a minimum.

63.6 Penetrant trrne shall be 5 min. at least

o 63-7 Excess lEnetnant in so far a possible, shall be removed by wiping with a cloth, and the

o remaining traces shall be removed by wiping the surface with cloth moistened with solvenl
To minimize rcmoval of penetrant from discontinuities, care shatl be taken to avoid the use
ofexcess solvent

63.8 A wet dwelopr shall be applied as soon as possible after penetrant removal. prior to
applnng the wet developer to the surface, the developer must be thoroughly agitated.
Developingtime forfinal interpretation begins immediately afterfte appti&tion of a dry
develolrr or as soon as a wet developer coating is dry.

63-9 Final interpretation shall be made within 7 to 30 minutes after the procedure of para 6.3.g.

63.10 Liquid penetrant examination record shall be submitted to MC.

63.11 Post Claning

o Aftertestto remove all residual penetrant and developerwhich could interface with
subsequent preessing.
o 64 Inspection of Postweld lleat Treatment

6-4-l The time-temperature chart shall be checked for approval by MC Inspector.

h the case of localized heat treating which will be'High Frequency Induction Heating",
' 'Electric Resistance Heating" or other suitable methods allowed in applicable code, in-ttre
fiel4 the state of insulation, heating procedures, treafinent temperatures, holding times, etc.,
to be spcified for each applicable heating methd" shall be inspected-

s{0G1540{01 R3Jrd
 G0800
TEST AND INSPECTION PROCEDURE FOR DOC. NO. 5-00&1540-601
STEEL PIPING WORK AT SITE SHEET 9 OF 28
65 llardnm Test

65-1 For the welds required PUIIIT by applicable Code hardness shall be measured in
accordance with the Code.

652 Forthe girth butt welds of Wet HzS Service piping, hardness of completed weld depsits
shall be measured with a Telebrineller or equal. Where PWIIT required, the hardness
shall be measured afterPlyHT.

653 The hardness measured shall not exceed following values.

Material Hardness (Max.)

+
Other than Wet HzS Service
o HzS Service Pryrng

o Carbon steel & IIB 2OO

Stainless steel

Alloy steel (P-4) ETB 225

Alloy steel (P-5) HB 241

65.4 Hardness test report shall be submitted to MC.

6.6 Inqlection for Cross of Seam Weld Sections

Cross welding should avoid as much as possible. In case of cross welding is unavoidable
the following inspections shall apply.

o 6.6.1 In case of longitudinal fusion seam weld is covered by pad plate and others:

o (1) Une that random or l@Vo RT is required:

Before install pad plate and others, a ground flush by gnnder shall carry out to
remove excessive weld reinforcement on longitudinal fusion seam weld section
which shall be covered by pad plate and others, then RT shall perform for that seasr
weld-

@ Line that RT is not required:

Before install pad plate and others, gnnding shall be canied out to remove excessive
weld reinforcement on longinrdinal fusion seam weld which shall be covered by pad
plate and others, then PT shall perforrr for that ground surface.

S@.1540{Ol R3trtf
t'

o.,0800
TEST AND INSPECTION PROCEDURE FOR DOC. NO. 5-00&1540-601
STEEL PIPING WORK AT SITE SHEET 10 OF 28

6.62 In case of adjrcent longitudinal fusion seam weld make a cross joint with a circurnferencial
seam weld ormake a nearness (within 5 time of prpe wall thickness) each other.

(1) Line that ICF,VoRTis required:

RT shall be performed to circumferential seam weld (all circurnference) and area of

100 mm (from cnossing point with circurnferential seam weld section) in both sides
of longitudinal fusion seam weld section.

A) Line thatrandomRT is required

RT shall be performed to areas of 100 mm (from each of their crossing points) in

both sides of circumferential seam weld and longitudinal fusion seam weld-

o (3) Line that RT is not required:

o PT shall be prformed to areas of 100 mm (from each of their crossing points) in

both sides of circumferential seam weld section and longitudinal fusion seam weld-
After grinding the rough weld surface.

6-63 In case of nouleinstallation weld section orfillet weld section makes acrossing with
longinrdinal fusion seam weld section orcircumferential seam weld section.

(l) PT shall be performed to areas of l@ mm in both sides (from crossing point or

contact poinQ of longitudinal fusion seam weld.

6:7 Positive Material ldentification (pMfl

PMI test shall be prformed on field welded part of low alloy containing more than O.SVo
total alloying elements, intermediate and high alloy steel, nickel based alloys, coptrEr based
o alloys and other non-ferrous metals in accordance with "specification for PositivJMaterial
Identification (for Field Consrnrction), 5@1540{01.
o

S-00G154060r R3Irtr
 t

G,0800
TEST AND INSPECUON PROCEDURE FOR
DOC. NO. S{0G154G601
STEEL PIPING WORK AT STTE
SHEET 11 OF 28

7. PRESST]RE TEST

7.1 General

1.Ll After completion of the piping installation and NDE work, the field fabricated piping
shall
be subjected to pressure test.

7.12 In case, where hydrostatic nor pneumatic test are considered practical following
examinations shall be applied in lieu of pressure test-

(1) All butt welds shall be l@Voradiographed- Furthemrore, all Cr-Mo butt welds
shall b liquid lnnetrant examined.

(2)
o All fillet welds, including socket welds and anachment welds, shall be liquid
penehant examined.

o Following cases are applicable to this paragraph.

(1) Welded piping connections with equipment

Q) The final connection (oint) with piping for the special case such as piping around the
dress-up towers

Dress Up

Final Connection

a Pressure Tested Separately

o (3) The weld joint at tie-in point to existing lines

7.13 Pressure tests on the piping system shall be conducted in conformity with the flow diagraar
shown in Attachment l.
7.1-4 All joints of piping including welds, shall not be hot or cold insulate4 nor paintd until
completion of the pressure tests.

7.lS Should, as a result of the pressure tests, repair work or additional work is conducted, the
plplng affected by such work shall be subjected to additional pressure tests, except for the
prtion of minor repairs approved by MC authorized engineer.
 G0800
TEST AND INSPECTION PROCEDURE FOR
DOC. NO. S-00C154G601
STEEL PIPING WORK AT SITE
SHEET L2 OF 28

7'l'6 Testpump shall be attended constantly during the test by an experienced opefifior,
who is
to disconnect the pump from the equipment and/or tineJimne,iiately after the test
has
started- The pump shall also b disconnected from equipment
olErator orMC's inspector leaves the pump or equipment site for-d/or lines if the pump
any rea$on.

7'13 The minimum metal temprahrrc during pressure testing shall be in accordance
with the
higher of (a), O) or (c) listed below:
a- 16"C
b- I7.C above the Minimum Desigu Metal remperature (NDlvfD.
c. l7t above the ductile to brittle transition temperature for all of the materials of
construction.
The hansition t€mperature shall b established from impact test data.

72 Pressure Test ptanning

o 72.1
o The prping:o$o* shall prepare the pressure testing procedure and schedule. AIso,
a
markedup flow sheet shall be prepared showing the test number, pressure and a syrrbol
for
the testing medium if the medium is differcnt than fresh warer.

722 The pressure testing prmedures shall contain the following information.

(1) The boundaries of the test including the location of blanla and the valves to be used
as boundaries.

(2) The test Pressue and the reference point at which the pressure is measured-

(3) Thetestingmedium.
(4) The materials required for the test (blinds, gaskets, etc.)

o (5) Special instmctions for the test.

o The qpecial instnrctions shall indicate where the test may be combined with other
tests.

(O The line numbers included in the test-

A The piping material specifications included in the rest.

(8) The equipment included in the tesL

723 The marked-up flow sheet shall indicate the test number, the pressure, and the boundaries,
and the location of test blinds.

The test pressure schedule number, shall have a prefix indicating the testing medium if it is
otherthan fresh water. The prefix shall b as follows:-

P - Pneumatic (Air)

S40G'lsrf&@l R3Jrtf
-:.
 G,0800
TESTAND INSPECTION PROCEDURE FOR
NO.SSGI540{01
DOC.
STEEL PIPING WORK AT SITE
SHEET 13 OF ?A

N - Nitrogen

S - Steam

W - Fresh Water

72'4 Test are numbered for reference only, actual sequence is to satisff
the constnrction
schedule.

725 Prprng that connects to or is continuos with lines already tested

shall be isolated from these
lines by vahes or test blanks (blinas; If it is necessary to include portions
of such lines
in the test" both portions shall be tested to the most severe condition.

o 73 Tetine Mediums
o 73'l Water shall generally be used as the testing medium for Hydrostatic
Testing of piping
Systems. Hydrostatic Testing shall be cauiea out in such a menner so as to
minimize
water consumption. Wherever possible, test water from one system
shall be reused to test
another system. If possible, the water used for testing puqloses, could
be stored in a
suitable storage tanlq and transferred ftom there to the test location,
and drained back to the
tank once the test is completed-

732 The Hydrostatic Test medium shall be fresh water. If the operating
fluid orpiping
marerial would b adversely affected by water test, an alternate testinedium shall be
substinrted.

733 Test warer shall be free of sediments and corrosive substances.

73.4 Hydrostatic Testing of Austentic Stainless Steel, shall b done with potable quality water
O having a Chloride content less than 50ppm.

o If the Chloride content is greater than 50 pprn, a sufFrcient quantity of Sodium Nimte shall
h added to provide a test medium of O.Svo,by weigh! Sodium Nitrate solution.
7.4 Test Pressure

7 A.l The Hydrostatic Test pressure shall be minimun of l-ll2times the design pressure
of the
weakest comPonent in the sysGm- Unless otherwise stated on the testirocedure,
the test
pressures are at the lowest point on the system.

7.42 When a design code other than ASME B 31.3 is applicable, the test shall
be modified
conforming to any requirements of the code, as required.

S{00'I54O{01 R3Jrd
 G0800
TEST AND INSPECTION PROCEDTJRE FOR DOC. NO. S40&154G@l
STEEL PIPING WORK AT SITE SIIEET 14 OF 28

7.43 Test prcsure for Pneumatic Testing shall be ll}Vo of thedesign pressure.

75 Test Gauges

7S.l Two pressure indicating gauges are requird one at the source of pressure and one at the
lowest practical point in the systen

75.2 Thetestpressureshallbecheckedbymeansof gaugeshavinganngeof atleast l-ll2

times the intended maximum test pressure. All giuges shall be calibrated against a
standard dead weigbt tester or a calibrated master gauge. It is preferable ttrat the test
pressure gauge be located at the bottom of the system.

7.6 keparation for hessure Tst

o 7.6.1 Prior to pressrue tesq all-
o l. Flange blts,
2. Pipeplugq erc.,

shall be checked fortightness.

7'62 Equipment not included in the test shall be either disconnected or isolated by blanks.

7-63 Safety and thermal expansion relief valves, rupture discs, and flame arrestors shall be
excluded from the field test Flanged retef valves shall have blanls installed at their
inlets before test, or at their outlet nozzle,in the case of testing the relief header.
Threaded relief valves shall be removed and the line connection capped or plugged-

7.6.4 Line systems which are oIEn to the atrnosphere, such as:-
o t.
a Drains,

2. Vents,

3. Open safety valve discharges, and

4. Gravity sewers,

do not require pressure testing. These lines shall be examinsd to determine all joints are
properly made up.
 0-08@
TEST AND INSPECTION PROCEDI'RE FOR DOC. NO. S40G1s4G60l
STEEL PIPING WORKAT SITE SHEET T5 OF 28

7.65 The test pressure shall be applied by rcans of a suitable test pump or other pressure sour@.
The pressure source which shatl b isolated from the system until ready fortest A
pressure gauge shall be provided at thepump discharge for guidance in bringing the system
up to pressure. The pump shall be asended constantly during the test by an authorized
peaon. The pump shall isolated from the system whenever the pump is to be left
b
unattended

7.6.6 'When testing hydrostaticalln orifice plates, restriction orifices, mixing nozzles, spray
nozzles and all restrictions !o flow shall be removed- Where necessary, items thus shall
be replaced with spool pieces.

7.6.7 Expansion joints shall always b isolated ftom the test orbe installed preset piecas
(shipping locks) during pressure tesL

o 7.68 Spring or counterweight supported lines shall be temporarily blocked up at supports during
o testing.

7.6.9 Lines containing check valves shall have the source pressure locafed upstream of the check
valve so that ttre pressure is applied underthe seat If this is not possible, the flappr shall
b€ removed, jacked up, or the check valve completely isolated from the test.

7.6.10 Vapor and gas liens not designed for liquid load shall be provided with additional
temPorary supporB to support the weight of the test liquid, as indicated on test schedule.

7.6.11 Lines extending byond battery limits shall be tested to the first set of flanges or block
valve outside of the battery limits. The line and flanges outside the battery limits must be
able to withstand the test pressure.

7.6.t2 Seats of valves shall not be subjected to a pressure in excess of the manimum cold working
pressure of the valve.
o 7.6.13 When the test pressure
o exceeds the maximum cold working pressure, closed valves shall
not tle relied upon to wittrstand the test pressure. The valve shall be in the opn position,
but not back sate4 to test the packing. Flanged valves located at the end of a system shall
be blanked on the downstream side. Threaded valves shall be plugged"

7.6.14 Vents, or other connections, shall be opn to eliminate air in lines receiving a Hy&ostatic
' test. Lines shall h thoroughly purged of air before Hydrostatic fssting is applied-
Where venting connections are not available, provide suffrcient water velocity to expel any
entrapFd air.

7.6.15 Pumps, turbines, blowers, and compresson shall not be subjected to Field Pressure Testing.
All such equipment shall be isolated- All connections to and from such equipment shall
be blanked off.

S40G1540{01 R3Jrd
 0-0800
TEST AND INSPECTION PROCEDTJRE FOR
DOC. NO. S-0@154M01
STEEL PIPING WORK AT SITE
SHEET 16 OF 28

7.6.16 The shell side of shelt and tube heat exchangers, shall not be included in the piping
Hydrostatic Test unless a pressure equal to the operating prcssure is also appilA to the tube
side simultaneously.

7.5.17 All joints, including all welds, shall be left un-insulated and exposed during the tesl
hefabricafed piping, previously tested in accordance with Code requirements shall be
tested after erection to assue tightness of all field connections. Att pip joints of
underground prcssure piping except those encased in concrete, n*t,
inaf U" left exposed
until pressure test is completed.

7.6.1E Short lengths of piping removed to install blind flanges shall b tested separately.

7.6-19 Instnrmem take-offpiping, up to the fint block valve, shall be tested with piping or
equipment to whichit is connected-
a 7-6.2fr joints, which had blanks installed for testing shall be service tested only.
o Flanged

7.6-21 Instnrment piping shall be tested together with the piping system up to the blck valve
nearest to the instrument.

When aunion is provided downstream of the block valvg it shall be broken during
cleaning and testingto prevent dirt orforeign matterfrom being inroduced into ttre
instnrment inadvertently.

7-622 In general, all instnrments in the system to be tested shall be excluded from the test by
isolation or remove4 unless otherwise permitted by this Inspection and Testing hoceAure.

lilS Iocally mounted indicating pressure gauges, shall be blocked off or removed and their
connections plugged when the test pressure exceeds the scale range. These gauges shall
also be blocked offduring cleaning.

o 7 -624 If the test Pressure is the same upstream and downstream of a control valve, the block and
o blpass valves shall be left opn, with the control valve open orclosed (whichever is most
convenienQ. If the test pressure is different upstream than downstrream of the control
valve, the test-on the upstrream portion shall be made with the bypass valve close4
upstream block valve open, downstream block valve closed, and control valve opn.
Where control valves arc tested together with the piprng system, no attempt strall be made
' to tighten control valve packing to prevent leakage. Should leakage at a control valve be
excessive to the extent that the pressure test cannot tb canied out, the control valve shall
be blocked out orremoved-

7 -62;5 lrvel instrument floas located inside vessels or float cages shall be removed prior to
Hydrostatic Testing if the allowable external pressure on the float is unknown or it is below
Hydrostatic Testpressure. Untested float cages, shall be tested with the system.

7 -621i If the test is to be held for a period of time and the test liquid
is subject to thennal
expansion, precautions shall be taken to avoid excessive pressure.

s-0@'154G@l R3rrd
 G0800
TEST AND INSPECTION PROCEDURE FOR
DOC.NO. S40G154G601
STEEL PIPING WORK AT SITE
SHEET I7 OF 28

7'627 Thickness and marcrial of test blanks shall be per Table l. Test blanks shatl 6s of the tab
typepainted yellow to make them readily visible and identified
forremoval priorto the
start-up operation A list or location map of all test blanks,
blind flanges, plogt and caps
installed for testing shall be kept and cnecrca offupon removal.

7'628 When testing at a high elevation, strong and safe scaffolding

shall be prepared.

7J heedure of hessure Test

7'7'l The test presslue shall be gradually increased up to the qpecified
test pressure. After the
Pressure has increased to the determined level, the pressue shall be maintained at such
level for more than 10 minutes for confirming the absence of abnormality.
Then,
thorough inspection shall be made of all flu"g"O" and welded joine,
wetiea sezrms, packing
glands, and so forth. The test pressurc shall be maintained
o time required to complete the inspection.
for the sufficient length'of

O 7'72 After comple!91 tests, all high point vents shall be opned to
9f lnevent pulling a vacuum,
all temporary blinds and blanls shall be removed and lines compietely
a*in"o" Valves,
orifice plates, expansion joints, short length of pipe, etc., which were
removed shall be
reinstalled- After lines have been draine{ t"*poury supports and restraints shall
be
removed. All strainers shall be removed, cleaned and reinstalled.

7J3 !r freezins weather, all lines and equipment shall be completely drained of water to prevent
dam4ge from freeze-up after the pressure test is completed-

t
I

S40Gl5,l0{0r R3Jrrf
 a.

G0800
TEST AND INSPECIION
PR@DURE FOR DOC. NO. S-mG154G60l
STEEL PIPINGWORKAT SrIE
SHEET 18 OF 28

7.8 heumatic hessure Test

7'8'1 Pneumatic Pressure test wiu be perforrred in place of hydrostatic

tesg for the following
services and as specified in the relevant line indexes..

(t) utility and other lines defined clearly from its service Namety.

- Air
- hertGas
- Flare

@ Lines 18 inch in diameter and larger in vapor, ar, and lines for catalyst
service in
catalytic cracking process and continuous catalyst regeneration uni6 including
smallerlines orbranches up to fint valve or flange.
a (3)
a Process lines insulared on their inside

(4) Decokinglines

(5) Vacuumlines

(6) Lines carryingcatalyst as specified in line index.

O lines which hydrostatic testing is not recommended due to technical reiasons

as defined in the relevant line index such as rcactor transfer lines
in Unit 300, HzSOe
lines, air lines for hocess use in Merox Unit and pplng connected to furnace,
heafer/sulfir pit in SRU Unir

7'82 When pneumatic pres$re test is qpecified and approved by MC, this procedgre
may by

t
perfornred as follows:

(l) Pressurc d|g shall beprformed gradually, in stages, providing sufficient time to
a equalize strains duing test

@ In the course of raising the test prcs$re, the first check shall be conducted at the
stage where the prcssure does not exceed Zkgctr?G.

' (3) To achieve uniform strress in the piping system and also forchecking leakages,
the
spcified test pressurc shall be maintained for a urinimum l0 minutes frorr-the
attainment of the pressure before starting inspection.

(4) Air leakages shall be checked by the application of soapy water to the joints.

S{0G1540{01 R3Ird
- ; :-
 I,

G0800
TEST ANID INSPECTION PROCEDTJRE FOR
S&154G601
DOC. NO.
STEEL PIPING WORKAT SNE
SHEET 19 OF ?A

8. WRAPPING INSPECTION

Refer to S-@'13q@4, Specification for The Wrapping and Coating of Carbon

Steel
Piping Buried Underground-

9. ACCESSORIES

Expansion joints and supporting hangers shall be inspected by piping

specialists/engineers.

10.

10'1
o Subsequent to the completion of pressure test, air-tigbtness tests shail be conducted
entire system after completing the following procedures:
on the

o 10'1.1 Slag, scale, dust and other foreign mder shall be removed by line flushing using
water
(stated in Para 7 J.n or air blowing, and to be completely aoio"A
and blown dry.

to.lz Shipping bolts for spnng hangen, expansion joints, etc., shall be removed and set bolt
shall
be adjusted so ,rs to alow them to s*isfactorily function.

10.13 ft shall be confirmed that parts (instruments, orifice plates, valves, etc.) which werc
removed for the Preceding pressure t€st are correctlyreinstalled for functioning in
operation.

10.1.4 All test blinds to be removed and slntem reinstalled with operational service gaske1

102 After confirming the completion of the iterns mentioned per l0.l above, overall

I air-tightness test shall be condusted in the following manner conforming to the test flow
sheet which shall be approved by MC bforehand.

I t:02.l Test shall be conducted by pneumatic or nitnogen.

la22 Testpressure shall b 3.5 kg/cm2G, unless otherwise specified.

11. DOCUMENTS AI\ID RECORDS

11.1 Subcontractor shall submit the following documents and records to MC and/or pARCO.

(l) Record of radiographic examination and films

(2) Record of liquid penetranr examination

(3) Chafi of posrweld heat treatment

(4) Record of hardness test

S{)Gl540$l R3Jrrf
 I

G0800
TEST AND INSPECTION PROCEDURE FOR
DOC. NO. $00s154G601
STEEL PIPING WORK AT SITE
sHmT 20 0F 28

(5) Record of pressurc test (hydrostatic and pneumatic)

(6) Record of overall air tightness test

O Non-conformity notice, disposition notice and repair confirmation notice report

rL2 Records of pressure test shall include:

1. Pressure,

2. Test time duration

3. Te,mperate,
O
O 4. Extent of test,

5. Date and signanre of inspctor.

Test pressures shall be subject to approval by the owner or their representative.

113 After the testing of all prprng on the job site is complete, the test records required by
the
Code shall be grven to the owner or their representative.

ll.4 The field Engineer or Inspector will supenrise tests according to:-

l) Establishedschedules,

2) Record allowable deviations, and

o 3) Obtain IPMT approval of each test

o 115 MC shall supply the owner, with the schedule for, Hydrostatic Testing and Flushing of
Piping Systems, not less than two weeks in advance of the test. Testing and Flushing
shall be such that the entire system is left clean to the satisfaction of the owner or his
representative.

11.6 Tests of equal pressure may be combined or divided to suit the schedule, provided
deviations are recorded under'T.,[otes. on the test record-
 TEST AND INSPECTION PROCEDURE FOR
DOC. NO. 5-0@1540-601
STEEL PIPINGWORKATSITE
SHEET 2I OF 28

,a:f,)\

WALLTI{ICKNESS (m)
NTJMBER OF FILMS TO BE TAKEN
i
Min SUEOFFILMTOBEUSED I

Ellipticat - Size cbosen to ensure coverage of weld joint i

Hlipdcal - Size ctosen to ensue ooverage of weld joint

Elliptical - Size cbsen to ensure aovqiage of weld joint

Hlipucal - Size chosen to ensurc coyef,age of weld joint

Elliptical - Size chen o ensure @ver4ge of weld joint

Ellipticat - Size choeen to ensure covenage of weld joint

Hlipqcal - Size chosen to ensure coverage of weld joint

S{@.1540{Ol R3Jrtf
 G0800
TEST AND INSPECTION PRMDURE FOR
DOC. NO. S-mGts4G60l
STEEL PIPINGWORKAT SITE
SHEET 22 OF 28

TABLE 1

WALLTI{ICKNESS (mm)
NT'MBER OF FILMS TO BE TAKEN
Mi!" SZE OF FILM TO BE USED

o J
I

I
I
I

I
I

W1540601 R3trrf
 , tt t
.:

0-08@
TEST AND INSPECTION PROCEDURE FOR
DOC.NO. S-00Gls4G60l
STEEL PIPING WORK AT SITE
SHEET 23 OF 28

TABLE 1 NUTGER OF RAprOGRAprilc FILMS By JOn{r SZE (3/3)

_'----..--

WALLTHICKNESS (n'n)
e
NTJMBER, OFFILMS TO BETAKEN
Min" Srm OF FILM TO BE USED
I
I

i
I
\
I
I

oi

o
o

5-0001540{01 R3Jrd
 o q
o o o
\0 \d oi N
o
\d ol
q q q
€ N €
6l 6l t! (.I
5
\0
A€ ra r q q o q q
o\ .{' 1€ o\ N rro N G GI € €
rn c{ al a.! C'l
F)

ER
ov o\s o\d cOr cio o (\
o v'! c) o q q h
ttl \CJ od c,i C-l 6 hl
,h.(\t+ N (a Ft (r)
v
o
zF{El
ri
rn
E
e
= \0 o\
q o o
(\| \o g\ €
(\
q o e
6lci a (.t
3+
trtr
YtrI* (fr

222
a.t

= q)
l-J o n') o q o q (\l
q
c, s \rt o\ t\ \o g\ € 6 o
t\l 6l FI F!

rn
F
tn
$
q q o o o q o
\o g\ .i \o oi € € .i
q
€
FFfiE
vl q q q o
N 6| FT
@
cr) (n
FHI-
o q q q q
F $ \o o\ o\ \o o\ C.!
(\l @
N
cl (N a
Ft T c't "JZF=
o o q o o q q
O n o q -t-
rIi
r
\o s ld oi o\ \o o\ N €
6l N
@
o.
ci
FI
€
(a

o \0 n
o crl !n
{ q o o o q o
o\ oi \o \o ol
(\ N
od @
(!|
q
c{
F) -
crl
a
ar)

rn tr1 rn o o o q q
r ctr $ oi c ci \o al € O(\ GI c{ €
ol N (o FT Ft

o la !a o o o o o o q q q
vt crl .f rrt oi t\| \d o\ c.i € € (\ 6
(\l N cl ("1 F}

.f o q o o o e q q
rn rn
srn C.t rd g\ N \C' oi (\| @
6l
G
c{ (1 N
(a €
cf)

o la a q o o q q q q
s (a t rg oi cl a
\o o\ N (\ € € N @
6l t\l (\l (\l c') ca

ol rn in q o o q q q q
trl
(r) CQ I oi ci \o \0 CA (\ F
(\I
€
(\ 6l @ €
G| (.!
J crt c.t
e q q o o q q q
o !a
\o oi (\ \c) g
(a € €
o €
!,9
t-. a.t o\ g\ t\.
6l
@
(1 N
C.l F) FT FI

ra e o o o o q q
o ra
N crl $ \d oi 6l \o \o o\ (:l
(\I N
t\
@
c..l
N
(tl
(\ €
(i F) 6
F)

o lt? U?
q
o o q o q q
6l F: \C' g\ ci c{ \0 \o o\ ai (\ € € (:l € @ €
N a.l ol t\ F) FI (.1 G)
R
tt] q
x
I
rn lr:
ct!
n
s g\ g\ N N
o
6 \o oi
o
o\ qi
o
6 ri @ e (1
a.
ld
6l (\ N
(\l (\ |:I c.)
@
(.!

uEt
OF o la o q e q q o elc q
it \o oio\ N N \o \0 \o o\ GI .i @l€ @ oo
Fra N GI c.|IN N 6l

7 !n q o q o q
Xv ra ri \o \o g\ o\ o\ 6i N\r, \o \o o\ o\ o\ (\
H6
H}
N

J lll
zz
V) rr
.\F
SH
6H
6l
N c') rt \0 € 6l t \o o (\l
tc
cl
\o
(\ € o (\ (a
6l (a FI s \o
FI
o
,1 A
{!
ZE 9
,iii slft
nFl
Ft< A
FU) Y
v)
ra ,l

TEST A}ID INSPECTION PROCEDIJRE FOR

DOC. NO. S{@154G601
STEEL PIPING WORKAT SITE
SHEET 25 OF 28
TABLE3 (Lt2)

FAB. USINGFOR P-NT]MBER NDTREQT]IREMENT PWTTT REMARKS

CLASS LINECI.ASS w PT RT YES/NO
cl MSol, Ms02, P-l t00% NONE NONE NO
MS20, MS25
e AlA1, MSll P-l IAOVo NONE 5% NO
AIA2, MSIiA RAI{DOM
AlA3, MSl2
AIA4, MSI2A
A2AI, PRO3
A2AL PR07
42A3, PR08
BIAI.
o BIA2,
B1A2J,
PRZ}
PR3O
PR38

o BIA3,
B2A1,
B2AL
PR39
PR41

A4AI
Al'A2
A4A3 O0" & srnaller)
B4AI
vp,
B4A4 O0" & smaller)
B5Al (10" & smaller)
B5A2
MS13
MSI3A (10" & smaller)
c3 AIAIP, AIA2P P-l l0Wo NONE 5Vo YES
AIA3P, A1A4P RAI\DOM
A2AIP, A2A2P
A4A1B A4A2P
A4A3 (12" & larger)
BIA2P. B4AIP

o B4A4 (12" & larger)

B5Al (12" & largo)
B5AIP
o PR3OP
MSI3A (12" & larger)
u 86A'l (10" & snaller) P-l lOMo l0Wo lMo NO
(l)
c5 86Al (12" & larger) P-l lWVo rw% lMo YES
(l)

NOTES (l) ?T. FOR FILLET WELD PORTION ?T"FORAIIWELDPORTION

(3) "RT FOR BUTT WELD PORTION

S{0G1540-601 R3Jrd
 | (/ I
i

TEST AND INSPEgIION PROCEDURE

FOR
DOC. NO. S{@1s4G601
STEEL PIPING WORK AT SITE
SITEET 26 OF 28
TABLE 3
@2)

FAB. USINGFOR P.NUMBER NDTREQTIIREMENT PNMT REMARKS

CLASS LINECI.A,SS
w PT RT YES/NO
AI E2AI, E2A1A P-4 r$M
B[A1, E/,A2 l@Vo tw% YES
(l-ll4Cr - o)
El.A3, E5A2 rt2Mo)
PR3I, PR31M
M HIAA
rr2A2"
HIA4
Ir2A3
P.5B
(5 Cr-
lWo tw t@% YES
(2)
T]2M, ll2 Mo)
H4ILZ H4A3
H/'e4,
rL14
o A3
t2N
T4A3
(9
P.58
Cr-ll2 Mo)
TOM rn%
(2)
lWo YES

o sl
T5A2
KIAI K4AI P-8 rc$Eo
K2AI NO 5% NO
crP304 SS) RANDOM
PRII
s2 LIAI P-8 tw% NO 5% NO
crP3o4l, SS) RANTTNM
s3 MIAI P-8 rcv% NO 57o NO
PR36 (rP3l6 SS) RANDOM
s4 NIAI P-8 lAWo NO 57o NO
N2AI
c$Bl6LSS) RANDOM
s5 QsAt P-8 lWTo lWo l@Vo NO
Q6Al crr{t2l ss) (l)
s6 PRzT P-8 l0Mo NO 5%
PR33 NO
crP3olH SS) RANDOM

NOTES (1) .PT' FOR

FILLET WELD PORTION (2) ?T" FORALLWEIDPORTTON
o (3) ?T"FORBUTTWELDPORTION

S{00'I54O{01 R3Jnf
tl ?,

TEST AND INSPECTION PROCEDURE FOR

DOC. NO. S-mG1s40-60r
STEEL PIPINGWORKAT SITE
SHEET N OF 28

FIGURE 1

o
o

o_D.4" OR OVER O.D. 3" OR UNDER

o Spool Dwg. No., and welding point

@ Nominal Diameter and Wall Thickness
@ No. of Radiographic Film (Gl, l-Z,z{ll$-B. B-2, C-A)
@ Welder No. (203/152: lst layer/Cover Iayer)
o a\
\s/ Date

o @
@
Arrow with indicate effective area
I.Q.I
@ Repair mark (Rl, R2.....)

S{0S154&601 R3Jrtf
 'l
,t '
r

TEST AI.ID INSPECTION PROCEDURE FOR

DOC. NO. S40G1540-@l
STEEL PIPING WORK AT SITE
SHEET 28 OF 28

ATTACHMENT I PRESSURE TEST FLOW DIAGRAM

The pressure test for piping shall be conducted in conforrrity

with the following flow diagram.

Subconhactor Mambeni Corporation

(Mc)
Overall Test Schedule Approval Inform

Monthly and weekly

Approval Inform
o Test Schedule

o
Preparation for Test
Block Diagram and A I
^yy. laPP uviu
Application Documents
for Line Check

Line Check and Pre-

paration for Pressure
Test

o Application for
o Inspection APPI APPI oval

Pre-Pressure Test

Pressure Test

Application Documents
for Certificate to Acceptance Acceptance
Acceptance

5{@'1540{01 R3J.rf