Attach-9 Work Procedure For Piping Pressure Test

WUHUAN Job. No.
17125
WUHUAN
Talcher Fertilizers Project
ENGINEERING 17125-PC10-PP-002
CO.,LTD
WORK PROCEDURE 1 of 11 Rev. 0
PIPING PRESSURE TEST PROCEDURE
0 For Bidding
REV. DESCRIPTION DEGND CHEKD APPRD DATE
MUST NOT BE COPIED, TRANSMITTED TO OTHERS OR USED WITHOUT PERMISSION OF WUHUAN
ENGINEERING CO. LTD
WUHUAN Talcher Fertilizers Project WUHUAN Job. No.17125
CO.,LTD 2 of 11 Rev. 0
CONTENTS
1. GENERAL ................................................................................................................................ 3
1.1 Purpose ................................................................................................................................. 3
1.2 Scope Of Application ........................................................................................................... 3

2. PRESSURE TEST SYSTEM ................................................................................................... 4
2.1 General ..................................................................................................................................4
2.2 Isolation. ............................................................................................................................... 4
2.3 Exclusions .............................................................................................................................4
2.4 Test Medium .........................................................................................................................5

3. TEST WATER CRITERIA ...................................................................................................... 5
4. TEST PRESSURES .................................................................................................................. 5
5. BLINDS FOR PRESSURE TEST ............................................................................................ 5
6. TEST PACKAGES PREPARATION ...................................................................................... 6
7. FIELD LINE CHECK PROCEDURE FOR TEST PACKAGE ...............................................6
7.1 General ...............................................................................................................................6
7.2 Preparation ............................................................................................................................6
7.3 Contractor inspection ............................................................................................................7
7.4 QC Clearance .....................................................................................................................8

8. HYDROSTATIC TEST PROCEDURE ................................................................................... 8
9. ALTERNATIVE TESTS .......................................................................................................... 9
10. PRESSURE TESTING REPORT .........................................................................................10
11. TEST COMPLETION .......................................................................................................... 10
MUST NOT BE COPIED, TRANSMITTED TO OTHERS OR USED WITHOUT PERMISSION OF WUHUAN ENGINEERING CO. LTD
1. General
1.1 Purpose
This specification specifies pressure test procedure and acceptance criteria of piping works to
perform the required quality level for this Project.
1.2 Scope Of Application
This specification covers pressure-testing requirements, which are to be done by Construction

Team in piping construction works.
In principle, requirements of ASME B31.3 prevails in case of conflict, unless requirements of
this document are stricter.
1.2.1 Service test
The Service test should be after Owner’s approval, and then applied for Category D fluid
service pipe line, (The fluid handled is nonflammable, nontoxic, and not damaging to human
tissues, the design gauge pressure does not exceed 10.55kg/cm2 as a gauge.) The following
systems may be tested by service leak test and flushing/blowing must be done before service
test.
 Instrument air
 Plant air
 Nitrogen
 Potable water
 Demi-water (provide design pressure less than 10.55 kg/cm2)
 Above ground cooling water
 Above ground raw water
 Above ground waste water
1.2.2 Pneumatic Test
The refrigeration system shall be tested by compressed air to reduce the likelihood of water
remaining in the system and causing rust.
The following systems may be tested pneumatically: Gas or vapor lines when the weight of
the hydrostatic test liquid would overstress supporting structures or pipe wall; Piping with
linings subject to damage by the hydrostatic test liquid.
1.2.3 hydro-test:
The hydro-test will be applied for category M (toxic fluid), category D fluid pressure pipe
line underground part, or normal fluid service pipe line except otherwise specified.
1.2.4 References
 ASME B31.3 “PROCESS PIPING”
 ASME SECTION IX “welding and brazing qualifications”
 ASME B31.1 “power piping”

 ASME B16.5 “pipe flanges and flanged fittings”
 Index of Piping Material Classification
 Underground Pipe Installation Procedure
 Piping Test Package formal
 Process Pipe Installation Procedure.
2. Pressure Test System
2.1 General
A piping system with same design pressure should be subjected to hydrotest as an unit, but
345.4.3 of ASME B31.3 also is applicable at some special case.
2.2 Isolation.
The following components shall be completely isolated from the system and this is to prevent
severe mechanical damages except approval from client:
1）Rotating equipment such as pumps, compressors and turbines.
2）Safety valves, rupture discs, flame arresters, and steam traps.
3）Pressure vessels with sophisticated internals.
4）Equipment and piping lined with refractories.
5）Storage tanks
6）Filters, if filter elements is not dismantled
7）Heat exchangers of which tube sheets and internals have been designed for differential
pressure between tube side and shell side.
8) Instruments such as control valves, pressure gages, level gages and flow-meters
(excluding thermocouples)
9) Piping line that is not allowing the hydrostatic lest according to the process requirements.
2.3 Exclusions
The followings are excluded from the requirements of this Specification

1) Any package unit previously tested by the manufacturer in accordance with the applicable
Codes.
2) Plumbing systems, which are tested in accordance with the applicable plumbing Codes
3) Lines and systems which are open to the atmosphere such as drains, vents, open discharge
of relief valve, and atmospheric sewers. For the flare lines to flare stack, the 100%RT
should be required instead of the hydrostatic test. When RT is difficult to perform, UT can
be used instead of RT with owner's QC engineer agreement in project site (before test)
4) Instrument impulse lines between the block valve at the process or utility line and the
connected instrument
5) Any vents or bypasses downstream of the instrument's first block valves shall be opened or
the instrument shall be disconnected during the task to ensure full protection of that
instrument.
6) For pipeline connected to tower, the hydrostatic test could be done on ground or structure
segmentally; and lifted together, then 100%RT should be done for the weld joint(s)
between the hydrostatic tested pipe segments instead of hydrostatic test for the whole pipe
line.
2.4 Test Medium
1) Pneumatic Test medium shall be compressed air.
2) Hydrostatic test shall be water.
3. Test Water Criteria
Raw water could be used for carbon steel material provided that not containing suspended
solids which may plug small lines.
Filter should be used equipped with 100 mesh screen to remove 99% of particles which are
140 microns or more in size.
The chloride content in the water used for the hydrostatic testing of piping manufactured
from or containing parts manufactured from austenitic stainless steel, cladding and duplex
shall be controlled as follow:
a) If the piping metal temperature does not exceed 50°C during commissioning, operation or
non-operation, water containing up to 150 mg/kg (150 mass PPM) chlorides may be used
for the hydrostatic test.
b) If the piping metal temperature exceeds 50°C during commissioning, operation or
non-operation, the piping shall be tested using demineralized water.
4. Test Pressures
The test pressure shall be in accordance with approved line schedule and drawings, which are
supplied by Contractor and / or Applicable Codes.
Pressure test shall follow clause 345.4.2 of ASME B31.3 and indicated in document "Line List"
but Owner's experts at project site have the right to check this data.
Approval of any document by Owner will not repeal EPC contractor's responsibilities to prepare
correct and valid documents. If any discrepancy be found in any time, EPC contractor shall
correct it.
5. Blinds for pressure test
1) Plate material, extra length bolts and gaskets, which are made at the Site, could be used for
testing. For Maximum allowable hydrostatic testing pressure for test blinds, refer to pressure
test package.
2) Temporary spades and blanks installed for testing purposes shall be designed to withstand
the test pressure without distortion.
3) Specification of Blind Flanges/Board as attachment 13 of document “PIPING TEST
PACKAGE”.
6. Test Packages Preparation
Contractor will prepare PIPING TEST PACKAGE for approval.
7. Field Line Check Procedure for Test Package

7.1 General
WUHUAN includes supervisor level and construction level. Contractor means the supervisor
level of WUHUAN. Construction team means the executor level of WUHUAN.
1) Supervisor of Contractor will forward a marked-up P&ID (or drawings just for
underground piping) indicating the test limit to Construction team of Contractor. Based on
this, Construction team of Contractor shall prepare the pressure test package as refer to a
sample test package.
2) Construction team of Contractor shall utilize his own pre-punch work lists to verify that
piping and piping system component installation is completed per piping test packages.
3) Construction team of Contractor shall inspect the piping test Package for its completeness
of installation and review all required documentation for material traceability, all
outstanding work required for the completion of the above mentioned items shall be listed
on a test punch list and be submitted with the referenced memorandum to the Contractor's
Engineer.
4) All Category A punch shall be cleared prior to testing. If no Test Punch List items exist on
a piping test, a test punch list will be issued with the words "No Items" on it.
5) Definition of Punch Categories are: "A" Category punch means that it shall be cleared
before pressure/leak test; "B" Category punch to be completed before pre-commissioning
and commissioning.
7.2 Preparation
(1) All joints, including welds, shall be accessible and left without corrosion or uninsulated,
and exposed for examination during the test.
(2) Piping designed for vapor or gas shall be provided with additional temporary supports, if
necessary, to support the weight of the test liquid. Where required, temporary supports
shall be specified in the pressure test documents.
(3) 7.2.3 Lines, which are counterweight supported, shall be temporarily blocked during
testing in order to sustain the weight of the test fluid. Spring hangers, which have been
provided with stops for carrying the test load normally, it is not require additional
temporary supports；If this is not the case, temporary support must be provided before
filling the system.
(4) Before testing:
1) Piping systems shall have been completely checked for correctness.
2) All lines shall be checked to insure the entire system can be completely drained after
testing.
3) Vents or other high point connections shall be opened to eliminate air from lines, which
are to receive a hydrostatic test.
4) Temporary gaskets may be used, which are not the same as permanent gaskets, provided.
Such use will not lead to damage of the flange faces and temporary gaskets are removed
immediately after completion of tests.
(5) Lines containing check valves shall 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 open the check valve closure mechanism or remove check valve
completely and provide necessary spool piece or blinds.
(6) Systems that include expansion joints:
1) Expansion joints shall be investigated to see that any required temporary restraints,
anchors, guides, etc. are installed prior to test.
2) Expansion joints shall be excluded from pressure testing if the piping test pressure is
greater than the allowable test pressure of the expansion joint.
3) Care shall be taken to remove the water completely out of bellows from horizontal/
vertical expansion joint, if hydro tested.
(7) 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, shall be made for
relief of any pressure greater than the maximum pressure
(8) Holding pins/spring stops shall not be removed from spring supports or hangers until
testing is completed and permission to remove is obtained from the Owner.
(9) Test equipment to be used during testing shall have suitable capacity for the range of test
pressures required. Pressure gauges shall have a full-scale range at least 150 percent of
test pressure. In case any equipment is to be hydro tested along with lines， then
proper care shall be taken to provide PSV, for overpressure protection.
(10) All pressure gauges shall have been calibrated before testing.
(11) The preparation of work should follow the requirements clause 345.3 of ASME B31.3.
7.3 Contractor inspection
(1) After receipt of the above-referred notification, OWNER will inspect the piping system in
reference to the test package and test punch list. They shall list all the remaining punch
list and send to contractor within 3 days since be notified.
(2) The engineers of OWNER should have completed their inspection of piping test package
and have confirmed their inspection as referenced QC clearance in paragraph 7.4 below.
(3) A combined "Master" punch list shall be produced; all pre-hydrostatic test work shall be
indicated on the punch list.
(4) After completion of the remaining Category “A” test punch, then the Contractor Piping
Engineers and OWNER Piping Engineers signature on the piping field test report after
clearance of material certificate and NDT, Construction team/Subcontractor may request
permission to test, a minimum of 24 hours prior to inspection of test. At the time of the
request, Construction team/Subcontractor shall leave a copy of the completed test punch
list.
(5) OWNER Piping Engineers and Contractor Piping Engineers will recheck the remaining
punch list and sign off completed items. This signed punch list shall be distributed for
documentation.
7.4 QC Clearance
During the time of the test punch list is being prepared, the Contractors and Construction
team/Subcontractor shall proceed as follows:
(1) Material Traceability:
1) Construction team/Subcontractor Inspector checks that it is completed
2) After checking the material traceability documents on traceability record sheet, the
Construction team/Subcontractor’s inspector shall submit the documentation to
Contractor’s engineer for checking/verification.
(2) Post Weld Heat treatment (PWHT) and Hardness Testing: when applicable, submission
of data for PWHT and Hardness Testing shall follow that of material traceability.
(3) Non Destructive Testing (NDT):
1) After checking NDT records, the Construction team/Subcontractor's Inspection Group
shall notify Contractor's Engineer that documentation is "Complete" for
checking/verification by Contractor and OWNER.
2) In addition, a visual check shall be carried out in the field by Construction
team/Subcontractor, Contractor and OWNER. Inspection and to ensure all welding has
been correctly performed and that no remedial work is required. If there is remedial
work required it shall be recorded on the punch list.
8. Hydrostatic Test Procedure
1) A systems test may be performed so as to hydrostatic test as much piping as Possible at one
time. This test shall include one or more lines
2) The maximum system test pressure shall not exceed the pressure test rating of any piping
component. Maximum test pressures for flanges and valves shall be conformed to ASME
B16.5.
3) Systems or sections of systems to be tested may be isolated by closed valves provided the
valve seat is suitable for the test pressure.
4) Valves(like check valves), vessels, equipment or other piping not included in the System to
be pressure tested shall be disconnected from the system or isolated by blinds or other
means during the test.
5) A minimum of two (2)certified pressure gauges are to be used for pressure test. The normal
location for the pressure test gauge is at grade near the pressure test pump and at the highest
point of the piping system. Readings may be made at higher points providing the gauge
pressure reading plus the static head (0.097kg/cm2/M) between grade and the point of
measurement does not exceed the maximum test pressure. Pressure test gauges shall be
calibrated to ensure accurate readings with presence of Owner representative. Gauges
should be tagged with the date they were last calibrated.
6) The pressure tests shall not be conducted, when metal temperature is near the ductile-brittle
transition temperature, due to the possibility of the brittle fracture.
7) Piping systems shall be filled from a low point. During filling of the system all air or
gaseous substance shall be vented from high point to the maximum extent possible.
8) Pressurizing to start the pressure tests, pressure shall be increased step by step at 25%, 50%,
75% and 100% of the test pressure. Leaks shall be checked at design pressure. Following
completion of pressurization of the system, the pump shall be isolated from the pressurized
line by means of cut-off valves.
9) Holding time: Whenever reach to 100% of test pressure with its stable state, the test system
shall be held for 10 minutes, then depressurize and maintain at design pressure for a period
required to complete full visual inspection of the test section but not less than 30 minutes.
10) Draining: All vents shall be opened before the system is drained and shall remain open
during draining. Depressurization shall reduce to 75%, then to 50% and then to atmospheric
at a steady rate. The line may drain naturally once the pressure is at atmospheric.
11) After testing, the chart recorder shall be signed off by both the Contractor inspectors and
OWNER Representatives for test acceptance. All charts shall be retained and form part of
the final hand over packages.
12) The hydrostatic test record should follow the requirements clause 345.2.7of ASME B31.3.
Clause 345.5.5 and 345.7.2 of ASME B31.3 also shall be followed.
9. Alternative Tests
Alternative tests may be carried out only with the written approval of OWNER's Engineer.
(1) In circumstances when neither hydrostatic nor pneumatic test are considered practical, an
alternative test in accordance with ASME B31.3 Para. 345.9 may employed, if both of the
following conditions apply.

1) A hydrostatic test would be damaging to linings or internal insulation would
contaminate a process, which would be hazardous, corrosive or inoperative in the
presence of moisture; or would present a danger of brittle fracture from low metal
temperature during test.
2) A pneumatic test would introduce considerable hazard due to possible release of stored
energy in the system or would present a danger of brittle fracture from low metal
temperature during lest.
(2) Under the conditions stated in Paragraph 9.1 all of the following shall be applied Welds,
including those used in the manufacture of welded pipe and fittings, which have not been
subjected to hydrostatic or pneumatic pressure tests in accordance with this Specification,
shall be nondestructively examined as follows:
1) Butt welds, longitudinal and spiral groove welds shall be 100% (RT /UT + PT/MT)
2) All welds, including structural attachment welds, shall be PT/MT.
3) When heat treatment is required, the above examinations shall be performed after heat
treatment.
10. Pressure Testing Report
1) A report shall be made of each piping system test. These records, when completed, shall be
submitted as part of the test and inspection certificates. Which are required for
pre-commissioning and commissioning.
2) Report shall be as attachment 17 of “PIPING TEST PACKAGE”
3) Chart Record with involved party’s signatures shall be as a part of Test Report.
4) All test records with chart records shall be retained in the test package records for turnover
to the Owner.
11. Test Completion

(1) The Pressure Test shall be considered complete when:
1) All defective welds, detective materials, flange leaks, valve gland leaks, or other such
defects have been corrected to the satisfaction of the Owner.
2) All documentation and "test package information is complete and accepted by the
Contractor and audited by Owner.
(2) Sealing materials shall not be used to correct leaks at joints with the exception of threaded
connections, where PTFE tape is used.
(3) Subcontractor/Construction team’s Inspector will verify that all punch list items to be
completed after the test and the line has been reinstated. This will be formally transmitted
to the Contractor.
(4) In the event that repairs or additions are made after the pressure test, the piping shall be
retested at the pressures originally specified for the test.

(5) After completion of testing, all lines and piping components shall completely be drained
except for underground piping system that should be drained at the suitable time. All
temporary blanks and blinds shall be replaced as per design.
(6) Valves, orifice plates, expansion joints and short pieces of piping which have been
removed shall be reinstalled with proper gaskets in place.
(7) Piping systems downstream of check valves shall be inspected to ensure complete
drainage.
(8) Special length bolts and flat asbestos gaskets for pressure test shall be removed and
replaced with line class bolts and gaskets. Flanged joints at which test blinds have been
removed shall not be retested.

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WUHUAN Job. No.

PIPING PRESSURE TEST PROCEDURE

1.1 Purpose ................................................................................................................................. 3

1.2 Scope Of Application ........................................................................................................... 3

2.1 General ..................................................................................................................................4

2.2 Isolation. ............................................................................................................................... 4

2.3 Exclusions .............................................................................................................................4

2.4 Test Medium .........................................................................................................................5

7.1 General ...............................................................................................................................6

7.2 Preparation ............................................................................................................................6

7.3 Contractor inspection ............................................................................................................7

7.4 QC Clearance .....................................................................................................................8

This specification covers pressure-testing requirements, which are to be done by Construction

 ASME B31.1 “power piping”

The followings are excluded from the requirements of this Specification

7. Field Line Check Procedure for Test Package

following conditions apply.

11. Test Completion

retested at the pressures originally specified for the test.

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