RECORD OF REVISIONS

Date Revision Details Revision

Number

20.07.2012 Issued for Implementation 0

21.01.2013 Criteria for Pneumatic Testing included 1

Section.7.0: Added applicable codes & standards for

Pneumatic testing,
Section.9.4.4 ‐ Added the following :
 Conditions in which Pneumatic testing is
acceptable
 Requirement for DECs to identify Pneumatic
testing in Line Designation Table (LDT)

16.05.2013 Section.9.7.13: Changed “specified limits” to “specified 2

test pressure limits”
Section.9.10: Added sections 9.10.1, 9.10.11,9.10.12
and 9.10.13 related to stored energy calculation
narrative
Replaced section designation a,b,c…f to 9.10.1, 9.10.2…
9.10.13
Deleted attachment‐4 related to safety distance
calculation
Contents
1. Purpose............................................................................................................................. 1
2. Scope ................................................................................................................................ 1
3. Cost competitive engineering and design........................................................................ 1
4. Conflicts and Deviations................................................................................................... 1
5. Definitions: ....................................................................................................................... 1
6. Abbreviations: .................................................................................................................. 2
7. Codes and Standards:....................................................................................................... 3
8. Basic Methodology........................................................................................................... 4
9. Inspection and Testing: .................................................................................................. 13
10 Preparation for Shipment: ............................................................................................. 26
11 Vendor Data Requirement: ............................................................................................ 27

ATTACHMENT‐1 Aluminium Blind for Blinding Equipment Nozzles ....................................... 30

ATTACHMENT‐2 Alignment of Dowel Pin with Threaded End................................................ 34
ATTACHMENT‐3 Alignment of Dowel Pin with Plain End ....................................................... 38
1. Purpose
This specification is to establish the general requirements for the field installation
and pressure testing of piping systems.
2. Scope
This specification shall be applied to above ground and underground process and
utility piping, including pipework in modules, package units or other sub assemblies,
offshore and onshore. Refer to separate specification for the installation of below
ground pipework.
3. Cost competitive engineering and design
The engineering team shall maintain the cost focus throughout all phases of the
project. This should be done without compromising any specification and design
requirements. From the perspective of erection and testing for piping, efforts shall
be made to optimize usage of modular approach and sub assemblies so that the
variable component of cost could be minimized.
4. Conflicts and Deviations
Process and utility piping shall be fabricated in accordance with codes, drawings,
and other requirements specified herein. Where conflict exists, the order of priority
of documents shall follow in the following sequence:
(i). Local Regulatory and Statutory requirement
(ii). This Specification
(iii). Codes and Standard
5. Definitions:
5.1 Piping Drawings

The primary piping drawings will be line isometrics, and these will be supplemented
with “screen‐dumps” from the 3D PDS model as required. Appropriate standard
detail drawings and other drawings showing typical details will be available. System
isometrics will be produced for IBR coded piping systems.

5.2 Piping and Instrument Diagrams (P&ID)

The Piping and Instrument Diagrams indicate “to and from” routing, service
classification and identification number for each line and which codes or
requirements (other than the Petroleum Refinery Piping Code, ASME B31.3) apply
Page 1 of 41
to various parts of the piping systems as well as the limits of such code or
requirement. They provide a basis for field checks of continuity and completeness
of piping systems.

5.3 Line Designation Table

Mechanical Data Section of the Line Designation Table shows the line number,
description, piping material class, design pressure and temperature, insulation and
tracing requirements and test type and pressure for each line.

5.4 Line Numbers

Line numbers identify each line by plant or unit number, fluid designation, serial
number, line size and piping material class. Line numbers appear on the P&ID’s,
models, and isometrics.

5.5 Material Specification

The Piping Materials Specification includes details for each individual piping
material class. Each class details the pipe, valve, flange, fitting, bolting, gasket and
other specific material requirements for different fluid temperature and pressure
services. The Piping Stock Code Book describes code items shown in specifications
and on drawings. Materials not identified otherwise on drawings or isometrics shall
be strictly as specified in Piping Material Specification for that material class.
5.6 Supplementary Table of Wall Thickness and Branch Reinforcement

The Supplementary Table of Wall Thickness will specify by individual pipeline

number the requirements of wall thickness subject to calculation as specified in the
Piping Material Classes.
5.7 Piping Stock Code Index

The Piping Stock Code Index identifies and describes all piping material item codes
in documents related to piping material.
6. Abbreviations:
SWG Standard Wire Gauge
DVOM Digital Volt Ohm Meter
NPT National Pipe Taper (Thread)

Page 2 of 41
RT Radiography Test
UT Ultrasonic Test
DP Dye Penetration
MPT Magnetic Particle Test
SER Site Engineering Request
DEC Design Engineering Contractor
7. Codes and Standards:
Codes

ASME B31.1 Power Piping

ASME B31.3 Chemical Plant and Petroleum Refinery Piping
ASME PCC‐2, Art 5 Repair of Pressure Equipment & piping
ASME Sec VIII Pressure Vessel
ASME Sec V , Art 10 Leak Testing
API 650, Article 7.3 Welded Steel Tank for Oil storage
API 520 Pressure Relieving Devices
API 620 Design & Construction of LP Storage Tanks
The Indian Boiler Code Regulations (1950) (IBR)
References

10080‐1‐ENGG‐DBD‐PP‐001 Piping Class‐ Design Basis

10080‐1‐SS‐PP‐004
10080‐1‐SS‐PP‐005
10080‐1‐SS‐PP‐006
10080‐1‐SS‐PP‐040
10080‐1‐ENGG‐PRA‐PP‐028
10080‐1‐ENGG‐DBD‐ST‐003
10080‐1‐ENGG‐DBD‐ST‐004
Piping Components‐Technical Supply & Condition
Piping Components‐Colour Coding
Piping Fabrication.
Chemical Cleaning of Pipework
Production of Spool Drawings and Erection
Isometrics
Pipe Supports
Pipe Supports Standard Drawings

Page 3 of 41
10080-1-ENGG-DBD-ST-009 Indian Boiler Regulations-Reference Document
8. Basic Methodology
8.1. Fabrication
The field fabrication and welding shall be in accordance with
10080‐1‐SS‐PP‐006, Specification for Piping Fabrication.
8.2. Installation
8.2.1. All piping shall be installed in accordance with the isometrics and 3D PDS
model.
All pipe‐work, valves, piping specials shall be inspected before installation to ensure
that protective packing, covers, wrapping and internal protective such as silica gel
bags are removed.

Protective covers of pipe and equipment shall not be removed until immediately
prior to installation.

All pipe‐work and valves shall be examined to ensure that no deterioration has
occurred in storage with particular note to valve internals. All manually operated
valves shall be cycled from fully open to fully closed and back again to ensure
operability.

Temporary blinds made from 18 SWG aluminium sheet shall be installed at flanges
of all equipments to prevent entering of dirt and debris during erection/installation
of piping system. Refer Appendix A for detailed dimensions of aluminium blind.

Composite Insulation gasket assembly shall be installed at the mating flanges of

piping spools with the machine flanges of all rotary equipments during welding and
electrical heating for stress relieving to prevent damage to machinery component
from stray currents. Composite insulation gasket is the combination of 18 SWG
aluminium sheet and 0.5 mm thick Teflon sheet used as an assembly. Preferably
coated stud bolts shall be used at flange connection for electrical isolation purpose.
If coated bolts are not available, insulating tape can be wrapped around bolts. For
insulating the nut ebonite washers shall be used. An electrical continuity check
across flange shall be performed to confirm the electrical isolation before
proceeding with the welding and electrical heating for stress relieving work. The
assembly will serve dual purpose of blind preventing entry of debris into machinery
as well as insulating gasket, to prevent damage to machinery component.

Page 4 of 41
8.2.2. Piping shall be supported as indicated on the isometric. When temporary
supports other than those shown on the isometric are required to facilitate
installation, they shall be of the removable type. Temporary supports shall not
transfer detrimental reactions to piping, structural members, or equipment.
Welding to pipe and/or piping supports as a temporary support measure, during
installation, is not permitted. (See 9.7.12).

Temporary supports shall be completely removed upon completion of testing and

prior to commissioning.

Where pipe support attachments are to be permanently welded to the pipework,

the welding shall be in accordance with the project specification employing only
welders qualified in accordance with the relevant code. Galvanised material shall
not be welded to stainless steel, copper nickel or titanium material under any
circumstances.

Where piping is supported using spring supports the locking pins should be in place
during installation, flushing and testing of the piping system. Locking pins shall be
removed prior to start‐up and where necessary, springs adjusted to correct “cold
Setting”.

Locking pins shall be either firmly attached to spring housing by use of a chain or
tagged with the spring identification number and placed in the stores for safe
keeping. A Tagging System shall be defined to identify the spring’s Lock or unlocked
condition.

The spring setting shall be certified by the vendor before commissioning.

8.2.3. All closing dimensions to equipment shall be checked and any field
adjustments made as necessary to assemble pipework.

Equipment piping shall be installed up to a break point between nearest pipe

support and the equipment. The remainder of the piping shall be properly fitted
between the equipment nozzle and this break point. It is essential that this is done
accurately in order to avoid any external loadings on the equipment connections.

Before tightening bolting to equipment flanges, ensure that piping flanges are
concentric and parallel. Manufacturer’s specified maximum allowable forces and
movements on equipment nozzles shall not be exceeded at any stage of installation.
Refer to section 8.5 for flange alignment tolerances.

Page 5 of 41
Cold springing or forcing of piping for the purpose of joint make‐up is not permitted
unless so specified on the drawings. Cold springing is not permitted on strain
sensitive equipment.

When connecting pipework to equipment the Contractor shall ensure that the
manufacturer’s instructions are carefully observed as to removal of external and
internal protective and that the opening is clean and free from obstruction and
foreign matter. Care shall be taken to avoid the ingress of foreign matter during
connecting of pipework to equipment.

Equipment to the piping flange joint shall be connected using alignment machined
pins. A minimum of 3 machined pins (120 degrees apart) to be used for assembly of
piping spool flange with machine flange. The diameter of machined pins shall be
equal to bolt hole diameter on the machine flange with a negative tolerance of 0.2
mm to 0.4 mm max. The flange joint with locating pins in position should be
tightened as per procedure (i.e. sequentially in four rounds). After the flange joint is
tightened, the locating pins should be removed and replaced with bolts like the
adjacent ones, and fully tightened – sequentially in 3 to 4 rounds. However if
locating pins are made of ebonite rods (Insulating Material) then they can be left in
position during welding of field fit up joint and stress relieving operations. Such
machined pins can be with plain end or threaded end. The later type is preferred, as
pins can be jacked out in case of jamming.

For alignment machined pin fabrication and installation details;

Refer Appendix –B for threaded pins.

Refer Appendix –C for plain end pins.

8.2.4. Flange faces shall be cleaned of protective, etc, and checked for mechanical
or corrosion damage to the gasket contact surfaces. Damage shall be repaired prior
to use. No damage shall be repaired where the integrity of the flange design is
impaired.

Flange bolts shall be tightened evenly and diametrically opposite to impose even
pressure on the gaskets and to avoid distortion or overstressing of equipment.

Where hydraulic bolt tensioning is not required bolts shall be installed so as to leave
at least two threads exposed from each nut. Exposed threads on over long bolts
used for hydraulic bolt tensioning shall be protected.

Page 6 of 41
Where hydraulic bolt tensioning is required, the bolts are to be tensioned to give
stresses in the bolts equal to 0.67 x specified Yield strength of the bolt material. A
Bolt tightening Handbook may be made available for this purpose.

Prior to flange joint assembly, bolts shall be lubricated with Molycote 1000 or equal.
For bolt length paragraph no. 335.2.3 of ASME B31.3 shall be referred.

Gaskets shall be installed so that they do not protrude inside the pipe bore.

8.2.5. Gaskets shall not be reused. If a flanged joint must be opened, for example,
for system pressure testing, line flushing, removal of temporary blinds or strainers,
etc, the joint shall be re‐made with new gaskets and with the bolt lubricant
replenished.

Flanged joints at equipment or valves employing tapped holes shall have the thread
depth checked prior to assembly to ensure that cap screws of the correct length are
used.

Connections to flat faced cast iron flanges shall use flat face mating flanges and full
face gaskets. Special care shall be taken to tighten bolts correctly.

No sealing compounds shall be applied to gaskets or flanges faces.

8.2.6. Where insulating flange kits are to be installed, care shall be taken not to
damage the bolt sleeves and gasket. The completed joint shall be tested with a
“Megger”, DVOM or similar device to assure electrical isolation. If both sides of the
flanges are grounded a reading of 1 to 20 ohms will occur. If one or both sides are
not grounded, a reading of 1000 or more Ohms should occur.

Caution: Welding grounds shall not be installed across isolation flanges.

8.2.7. Orifice runs must not contain welds except at the flanges. Pipe ends at
orifice flanges must be cut such that it is perpendicular to the pipe axis. Welds at
the orifice flanges must be ground smooth inside. Pipe tap connections are to be
drilled through the pipewall and be smooth inside. Drawings show the orientation
of orifice flange taps and the locations of pipe taps. Orifice flanges are to be drilled
and tapped for jack screws.

8.2.8. Underground piping shall be installed and inspected as per the Project
Specification.

Page 7 of 41
8.2.9. The handling of coated and wrapped pipe as well as the field coating and
wrapping shall be in accordance with Project Specification 10080‐1‐ SS‐PP‐019 and
10080‐1‐ SS‐PP‐020.

8.2.10. Valves shall be installed with stems oriented as indicated on isometrics.

Split disc check valves shall be installed with the shaft in vertical position. Globe
valves shall be installed with bottom of disc facing the flow direction.

8.2.11. Where seal welding is required, the joints shall be made up without the
application of thread lubricant and threads thoroughly cleaned from grease and oil.
Seal welds shall cover exposed threads completely.

Seal welding is required:‐

a) Between connections to columns, vessels, tanks and exchangers in hydrocarbon

service and the first valve.

b) Orifice flange taps and blanking plugs in those systems where socket welding
small bore piping is specified.

c) Unvalved, plugged hydrostatic test vents and drains in systems where socket
welding small bore piping is specified. Seal welding to be performed post hydro‐
test.

Following items shall never be seal welded:‐

a) Screwed Thermo‐wells

b) Union Nuts

c) Screwed Ends of Gauge Glasses, Gage Cocks

All the plugs/caps used shall be tested as per clause 10, either with piping or
separately.

8.2.12. Reinforced fibreglass pipe and the like shall be installed strictly in
accordance with the vendor’s installation instructions. Personnel doing this work
shall be properly trained by vendor’s representative prior to doing this installation.

8.2.13. For bolt sizes 1 inch and above, a suitable hydraulic torque wrench should
be used.

Page 8 of 41
8.3. Pipe Threads
8.3.1. Threaded joints shall only be used where specified in the relevant Piping
Classes.

All pipe threads shall be NPT type in accordance with either ASME B1.20.1 or API
5B.

Threads shall be cut after any required bending, forming or heat treatment. Where
this is not practical, suitable protection shall be applied to protect the threads.

8.3.2. PTFE or other types of thread tape shall not be used on any threaded joint.
Instead, one of the following thread compounds or equivalent shall be employed:‐

a) Liquid O‐ring 404 (for 2” (50mm) or smaller NB) or Liquid O‐ring 104 (for 2”
(50mm) and larger NB). Manufactured by Oil Centre Research Incorporated of
Lafayette, Louisiana, USA.

b) TFE‐Super (for 1” (25mm) and smaller NB) or TFE‐20 (for 1 “ (40mm) and arger
NB). Manufactured by Ilex Compounds Ltd, Maidenhead, England. Use TFE‐Super
for all sizes in potable water service. Do not use TFE‐20 for potable water.

c) PTF Grease (for 2” (50mm) or smaller NB) or PTF Heavy Duty (for 2” (50mm) or
larger NB). Manufactured by Blacksmith Chemical Services of Aberdeen, Scotland.

d) Ilex ILX35 for high temperature service. Manufactured by Ilex Compounds Ltd,
Maidenhead, England.

e) LOCTITE made by Henkel India Ltd.

In case leak does not stop after applying the thread compound, repair of the joint
shall be done as per qualified procedure.

8.3.3. Where threaded flanges are specified, the pipe shall terminate 1/16”
(1.5mm) short of the flange face.

8.3.4. Adequate threaded flanges shall be included in threaded assemblies to

permit easy assembly and dismantling without the need for rotation of long pipe
legs, especially in the case of pipework connecting to pumps, compressors, etc,
where routine servicing or replacement by a standby unit necessitates
disconnection of the pipe.

Page 9 of 41
 10080‐1‐SS‐PP‐007

Date: 16/05/2013, Rev. 2

Excessive gouging of pipe or fittings by wrenches shall be cause for rejection, this
shall be considered such if the defect extends below the mill tolerance minimum
wall thickness or is more than 1/16” (1.5mm) in depth.

8.4. Field Run Piping

Field run piping is defined as Carbon Steel threaded or socket welded piping 1½
and below.

Long straight runs of butt‐welded piping in pipe racks as shown on stringing

drawings.

8.5. Flange Alignment Tolerances

Proper alignment of all joint members is the essential element of flange joint
assembly. It results in maximum seating surface contact, maximum opportunity for
uniform gasket loading, and improves the effectiveness of all bolt tightening
methods.
Refer below figure for following four types of alignments:

Page 10 of 41
 10080‐1‐SS‐PP‐007

Date: 16/05/2013, Rev. 2

8.5.1. Flange alignment tolerances for Rotary Equipment

For compressor and steam turbine; equipment vendor specified Piping flange
parallelism, flange separation and flange axial offset tolerances will govern.
For pumps flange alignment tolerances, vendor specified values will govern
however in case such values are not given by pump vendor; the following tabulated
values to be used at site.

Rotary Equipment (Pump) Tolerances

Characteristic for all pipe sizes

Flange face axial

1.5 mm
offset

Nozzle Up to Up to Above
Flange face Size (NB) 150 250 250
parallelism offset
Tolerance 0.2mm 0.8mm
0.4mm

Bolt hole offset 1.5 mm (Radially)

(Rotational)

Uncompressed Gasket thk + 1.5 mm

Flange face
max
separation offset

8.5.2. Flange alignment tolerances for Static Equipment

Characteristic Static Equipment Tolerances

Flange face axial

2mm( ≤ 4 in. NPS); 3mm( > 4 in. NPS)
offset
Flange face 0.8 mm max.

Page 11 of 41
 10080‐1‐SS‐PP‐007

Date: 16/05/2013, Rev. 2

parallelism offset

Bolt hole offset

1.5 mm (Radially)
(Rotational)
Flange face
Uncompressed Gasket thk+3 mm
separation offset

8.6. Field Modifications

Modifications to pipe routing may be required in the field. Such modifications shall
be determined by the erector and agreed with the responsible field engineer. All
modifications shall be reflected on “as built” record drawings by the construction
subcontractor or Field Engineer. At the end of the construction phase one set of
these drawings shall be sent to the responsible Design Office. In the case of IBR
piping, no field modifications shall be performed without the prior approval of the
IBR inspectors.

Any field modification shall be properly backed‐up and documented with an SER.

8.7. Cleaning
Refer to 10080‐1‐SS‐PP‐040 ‐ Specification for Chemical Cleaning of Pipework.

8.7.1. General requirements:‐

Piping spools shall be dry, thoroughly cleaned and free from dirt, slag and other
loose foreign materials. Before assembly, they shall be cleaned by “up ending” and
rapping to dislodge any dirt and debris. Hot bends shall be cleaned completely to
remove adherent burned on sand.

Completed systems shall be internally cleaned to remove all remaining dirt and
foreign matter by water flushing or blowing with air or steam. Where special
conditions exist, specific specifications will cover cleaning and preparations.

Flushing shall be done with clean water using hydrostatic test water where possible.
Refer to section 14.0 for the quality of water to be used for both flushing and
testing.

8.7.2. Compressor Suction Piping

Shortly before start up the inside of all compressors suction piping shall be
thoroughly cleaned to remove rust and scale.
Page 12 of 41
 10080‐1‐SS‐PP‐007

Date: 16/05/2013, Rev. 2

Suction piping may require pickling or mechanical cleaning. The extent of such
cleaning shall be shown on P&IDs and on the isometrics. Cleaning shall be carried
out in accordance with project specifications.

8.7.3 Lube Oil Piping

Shortly before start up the inside of all lube oil piping shall be thoroughly cleaned in
accordance with the machinery vendor’s recommendation or with project
specifications whichever is the most stringent to remove rust and scale.

9. Inspection and Testing:

9.1 Inspection for Completeness

Upon completion of erection, piping systems shall be visually inspected for

completeness, proper gasketing, proper valve installation, supporting, proper
control valve installation, etc.

The P&ID and isometrics shall be used for this purpose, essentially before erection.

The pressure safety valve duly calibrated at 1.1 times the test pressure shall be
installed in piping system, as per clause 9.7.13, before commencement of the test.

9.2 Testing Requirements

9.2.1 General

Process and utility pressure piping shall be tested as required by the applicable code
and described herein.

9.2.1.1 Pressure Piping Defined

Pressure piping includes all piping designed to convey or contain process or utility
fluids at either a positive or a negative internal pressure.

Open ended vent, drain and like piping at essentially atmospheric pressure are not
considered as pressure piping.

9.2.1.2 Boiler Code Piping

Piping will be governed by and conform to both The Indian Boiler Regulations 1950
and ASME B31.1 Code for Pressure Piping, Power Piping. Boiler piping shall be
Page 13 of 41
 10080‐1‐SS‐PP‐007

Date: 16/05/2013, Rev. 2

tested hydrostatically to the required standard described within the Indian Boiler
Code and in Paragraph 137 of ASME B31.1 Code for Pressure Piping, Power Piping,
whichever is the most stringent.

IBR Piping will include all steam systems, boiler feed water and selected condensate
systems.

9.2.1.3 Refinery Code Piping

Pressure piping governed by the Petroleum Refinery Piping Code, ASME B31.3 shall
be hydrostatically tested in accordance with Paragraph 345 of that code.

Alternate tests are not permitted unless specifically approved by Project Engineer
and/or Client.

9.3 Test Source Information

9.3.1 Line Designation Tables (LDT’s)

The LDT’s shall be the Controlling Documents in determining the type of test, test
medium and test pressure.

The Line Designation Tables indicate (in the mechanical data section) the line
number, description, piping material service class, design pressure, design
temperature, insulation and tracing requirements and minimum test pressure for
each line. The type of pressure test and test medium, if other than hydrostatic, will
be noted in the table.

9.3.2 Hydrostatic Test Diagrams

The hydrostatic test package will show the block limits for testing a system as well
as the type and test pressure to be applied. This package will generally be prepared
by RIL site engineers in consultation with RIL operation engineer. All hydrostatic
tests related documentation shall be done by sub‐contractors field engineers.

9.4 Tests

9.4.1 Hydrostatic Test

The fluid shall be water unless there is the possibility of damage due to freezing or
to adverse effects of water on the piping or the process.

Page 14 of 41
 10080‐1‐SS‐PP‐007

Date: 16/05/2013, Rev. 2

Refinery Code piping shall be hydrostatically tested to a minimum pressure of 1.5

times the design pressure at any point in the system unless otherwise noted in the
line designation tables.

The test pressure shall be adjusted for elevated design temperature in accordance
with ASME B31.3, Paragraph 345.4.2(b). All liquid lines will be hydrostatically tested
except as outlined in section 9.4.4. Large thin walled lines in vapour service will
require special consideration and temporary pipe supports installed.

If the test pressure as defined above would produce a nominal pressure stress or
longitudinal stress in excess of the yield strength at test temperature, the test
Pressure may be reduced to the maximum pressure that will not exceed the yield
strength at test temperature. In accordance with ASME B31.3, Paragraph 345.4.2(c)

According to the Constructability / Design constraint, it may be necessary to hydro

test the line at grade level with suitable supports. After successful completion of
hydro test, line shall be lifted into position and then closer weld shall be examined
as per closing welds clause 9.4.5.

9.4.2 Initial Service Leak Test

A piping system in Category D fluid service (Design gage pressure does not exceed
150 psi, or 10.5 kg/cm2 and design temp. upto 186˚ C) may be subjected to an initial
service leak test, at the owner’s option, in lieu of the hydrostatic leak test.

The test fluid is the service fluid. During or prior to initial operation, the pressure
shall be gradually increased in steps until the operating pressure is reached, holding
the pressure at each step long enough to equalize piping strains. A preliminary
check shall be made as described in para. 345.5.5 of ASME B31.3, if the service fluid
is a gas or vapour.

9.4.3 Vacuum Piping

Lines in vacuum service, unless governed by specific design conditions, shall be

tested at an internal gage pressure 1.5 times the external differential pressure, but
not less than 15 psig (1.03 barg) as specified in Paragraph 345.2.4 of ASME B31.3.

Page 15 of 41
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Date: 16/05/2013, Rev. 2

9.4.4 Pneumatic Testing

General industry practice is to avoid pneumatic tests to the maximum extent

possible. The main concern with conducting pneumatic testing is that it generates a
considerable amount of stored energy when the system is pressurized for testing.
Pneumatic testing can only be used when the requirement is specified by the EP
contractor and the conditions of code are met. Usage of pneumatic testing as an
alternative to other kinds of test, viz. Hydrostatic tests, etc merely on account of
cost savings is not acceptable.
The gas used as test fluid, if not air, shall be non‐flammable, nontoxic and shall be in
accordance to the specification(s) provided by the EP Contractor.

The test pressure shall be 110% of the design pressure.

In general pneumatic testing should only be considered as leak test for the following
conditions:
 Small diameter tubing (such as impulse lines or steam tracing) where we
don't want moisture left in the tubing after testing.

 Lines where a hydrostatic test could damage the internal lining (such as if a
line is refractory lined and needs to be tested at site)

 Lines specifically designed to be pneumatically tested. (E.g. Overhead vapor

lines, Conveying lines, etc. along with duct work, flare lines and certain lines
where hydraulic testing is impractical)

 Lines involving Piping Metallurgy which may be adversely affected by water

especially if there is apprehension about the quality of water available for
hydro testing.

 Lines that must be completely dry after testing (e.g. oxygen piping)

 Lines, when filled with water, would weigh more than the structure can
bear. This situation could typically be encountered only in existing plants
where the structural steel design never took in to consideration the addition
of future lines.

 Conditions where it is very difficult to remove the water after testing. An

example is when the convection box crossover piping is welded to the

Page 16 of 41
 10080‐1‐SS‐PP‐007

Date: 16/05/2013, Rev. 2

nd then the system is tested. The radiant

section piping runs up and down with 180 degree elbows (u‐bends) at top
and bottom there by making it very difficult to remove the water collected
at the bottom u‐bends. In fact, we typically wait to start‐up the heater so
that the water gets boil out.

 Any additional cases specified by the EP Contractor/Licensors

 Any lines or systems requiring Pneumatic testing shall be identified by the

DECs in the Line Designation Table.

The test shall be well documented and pre‐approved by the concerned authorities
along with the Stored energy and Pressure Testing Safety Distance Calculation as
per ASME PCC‐2‐2011 Article 5.1 Mandatory Appendix II/III.

9.4.5 Closing Welds

Where practical, pressure tests of piping shall include all closing welds between
different parts of the system. Where it is not practical to include a closing weld in
the pressure test, the weld shall be tested and examined 100% by RT/UT and
DP/MPT and its location recorded.

9.4.6 Connections to Equipment

Piping test pressures shall not be applied to pumps or to other equipment except
where specifically approved by the Project field engineer; and provided such
procedure will not cause unsafe loads or other unreasonable hazards.

9.4.7 Test with Equipment

Connecting piping may be tested with pressure vessels or other equipment

requiring field test provided resulting test pressure applied to piping is not greater
than allowable or less than the required piping test pressure.

Where the test pressure of the piping exceeds the vessel test pressure, and it is not
considered practicable to isolate the piping from the vessel, the piping and the
vessel may be tested together at the vessel test pressure, provided the owner
approves and the vessel test pressure is not less than 77% of the piping test
pressure calculated in accordance with Para. 9.4.1 above.

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Care shall be taken when exchangers are included in the test. Both tube and shell
side shall be pressurised to avoid overstressing of tube sheets if these are designed
for a limited differential pressure.

9.4.8 Jacketed Piping

In jacketed lines, the jacket shall be tested as described in Paragraph 345.2.5 of

ASME B31.3.

If the test pressure in the jacket is too high for the internal lines as an external
pressure, the internal line shall be pressurised to minimise the differential pressure.

9.5 System Pressure Test Package

Test conditions shall be specified in LDT. System pressure test package, including a
pressure test diagram based on piping and instrument diagrams showing the extent
of pipework, will generally be prepared by RIL site engineers in consultation with RIL
operation engineer. All hydrostatic tests related documentation shall be done by
sub‐contractors field engineers.

The scope of each separate test shall be the maximum practicable, considering
adequate pressure relief protection, available test fluid.

The diagrams shall show all in line components which are to be replaced with
temporary spools, indicate which internals are to be removed for the test, and
indicate all temporary test blinds and plugs used to isolate the system being tested.

The package shall include a sign off sheet with places for the subcontractor and the
Project Inspection Authorities signatures and date for each of the three stages of
testing: preparation, testing and post test completion (removal of temporary blinds
and supports, replacement of removed internals and valves, air drying, etc.).

The extent of test systems shall be such that the static head of the test medium
does not create a pressure greater than the maximum allowable test pressure.

9.6 Cryogenic Lines

Non‐complex cryogenic piping systems of relatively short runs with limited numbers
of welded in valves and fittings may be hydro‐tested provided they can be
thoroughly dried after testing. Complex cryogenic lines that can not be thoroughly
dried shall have welds subjected to 100% radiograph and then subjected to a
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pneumatic test. Alternatively, spools shall be shop hydro‐tested & closing welds
shall be tested as per Closing weld clause 10.5.

9.7 Preparation of Systems for Testing

9.7.1 Temporary blind flanges and test blinds used to isolate a test system shall be
of an adequate thickness to withstand the test pressure. For minimum thickness of
carbon steel blind plate EPCMD‐P14‐JG000‐167 to be referred. Test blinds shall
include an integral lug or handle, extending at least 4” (100mm) beyond the flange
perimeter, which shall be painted bright red or orange.

Temporary blind flanges and test blinds shall be adequately gasketed to prevent
damage to flange facings.

9.7.2 Instrument connections shall be closed with a properly gasketed blind

flange, or with a threaded plug.

9.7.3 Valves except socket weld valves shall not be used to isolate a test system
except for lines not pressurised in service (for example, flare lines, gravity drain
lines, black and grey sewage systems, etc).

9.7.4 Control valves, thermowells, orifice plates, strainer baskets, filter elements,
expansion bellows, in line instruments and all other in line components unable to
withstand the test pressure shall be removed and replaced with temporary spools
or spacers.

9.7.5 If the pressure is to be applied downstream of check valves, the valves shall
have their internals removed or be securely blocked open in a manner acceptable to
the inspector.

9.7.6 Permanent pressure and thermal relief valves and rupture discs shall not be
included in system pressure tests.

9.7.7 All internal parts and in line items removed for the duration of pressure
testing shall be labeled and the component to which they belong or the position in
the line from which they were removed shall also be labeled, to the satisfaction of
the inspector, to ensure the correct replacement of components following the
testing.

9.7.8 All valves, except as excluded specifically herein, shall be included in the
pressure tests, ball valves shall be in the half open position (for the ball only acts
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against the seal when the ball "floats" into it. this is to make sure that the valve
body is evenly loaded.) recommended by the manufacturer and all other valves fully
open. However, where the test pressure to be applied to lines is greater than the
maximum allowable test pressures specified for the valves, the valves shall be
blinded on the test side or replaced with a temporary spool. Valves shall be
removed prior to flushing.

9.7.9 Where a valve has not been included in a system test, the shop test
certificate shall be reviewed and approved by the RIL/DEC’s authorized inspector.

9.7.10 Expansion joints shall not be included in pressure tests.

9.7.11 All lines in vapour service shall have sufficient temporary supports. Spring
supports for lines in vapour service shall be locked in position for the test using
preset pins or plates or by blocking up the spring. (See 5.2.2)

9.7.12 All temporary supports, spring support restraints, temporary spools,

temporary strainers, blinds and plugs, etc, shall be prominently flagged or painted
bright orange or red to ensure their removal following testing.

9.7.13 Use of pressure safety valve shall be restricted as per following:

A. For hydro testing lines less than or equal to 24” dia. and test pressure less than
or equal to 50 bar, and lines greater than 24” dia. and test pressure less than or
equal to 30 bar, constantly monitor pressure and open vent valve if pressure rises
above specified test Pressure limits (+10%).

B. For hydro testing lines less than or equal to 24” dia. and test pressure greater
than 50 bar, and lines greater than 24” dia. and test pressure greater than 30 bar,
adjustable PSVs must be used set to relieve if pressure rises above specified test
pressure limits (+10%).

C. For all pneumatic testing pressure safety valve must be used (ref API‐520 for
PSV sizing).

9.7.14 Minimum two numbers of pressure gauges, one at high point and other at
low point of the system, shall be used for testing.
Pressure gauges shall have current certification of accuracy. In general, the
calibration frequency shall be 6 months but if any deviations are noticed while

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carrying out pressure test or any mismatch occurs between two gauges (after level
correction, if any) in a loop then the gauges shall be recalibrated.
System flushing can be either before test or after test. This shall be jointly decided
by operation and construction engineer.

9.7.15 Care shall be taken to ensure that dirt and debris cannot be forced into
instrument branches or pockets in lines. Flushing shall proceed in an intermittent
manner allowing time between flushes for debris to be cleared from the line.
Flushing shall continue for sufficient time to ensure that the line is cleaned. Liquid
flushing shall not be employed on systems requiring pneumatic testing.

9.7.16 All orifice plates which interfere with filling, venting or draining shall be
removed prior to testing.

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

test blind shall be tested separately.

9.7.18 All joints in piping shall be accessible during test and shall not be insulated,
backfilled or otherwise covered until satisfactory completion of testing in
accordance with this specification, except joints may be primed and painted prior to
leak testing.

9.7.19 Care shall be taken to avoid overloading any parts of the supporting
structures.

9.8 Test Medium

9.8.1 Clean, fresh water free of suspended solids and other foreign matter shall be
used for hydrostatic testing of piping. For carbon steel and low alloy steel piping,
the limit of water chloride content shall be 300 ppm (max). Also, where the water is
unfiltered and untreated a chemical inhibitor package shall be provided which shall
include the following chemicals:‐

a) Oxygen scavenger to remove dissolved oxygen.

b) Biocide to kill harmful organisms and sulphate reducing bacteria.

c) Corrosion inhibitor to minimise corrosion.

Proposals to use chemical inhibitors shall be agreed between contractor and DEC.

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9.8.2 The minimum water temperature during hydrostatic testing shall be 40°F
(10°C). After testing the piping shall be drained and thoroughly dried and
maintained such that no moisture or chloride laden deposits will enter the piping.

9.8.3 Liquids other than water shall require the approval of the Project Designated
Inspection Authority prior to use.

9.8.4 Pneumatic tests shall use dry (dew‐point ‐40°F (‐40°C) or lower), clean, oil
free air or nitrogen. Oil lubricated compressors shall not be used. Pneumatic testing
temperatures shall not exceed 120°F (50°C).

9.8.5 For testing of austenitic stainless steel and nickel alloy steel piping, the limit
of water chloride content shall be 50 ppm (max).

9.8.6 For austenitic and duplex stainless steel piping, to avoid the possibility of
subsequent failure due to stress corrosion, cracking or pitting, clean de‐mineralized
water, free of chlorides, (50 ppm max) shall be used.

9.9 Testing Procedure

9.9.1 Hydrostatic Tests

9.9.1.2 Prior to filling the system with the test medium, the system shall be
inspected for fabrication completeness and satisfactory test preparation, including
the placement of pressure gauges and suitability of the test rig. The test package
sign off sheet is then signed by the authorized Project Inspector to allow flushing or
purging prior to commencing test. Where valves have been included in the test
circuit, those valves with stainless steel internals shall be removed or the chloride
content of the water shall not exceed 50 ppm.

9.9.1.3 After completion of flushing or purging, the area around the system under
test shall be cleared of unauthorized personnel and warning notices posted during
the time that the piping system is pressurized for the test. The arrangements made
to exclude unauthorized personnel, and the perimeter of the hazard zone, shall be
agreed with the inspector.

9.9.1.4 A preliminary air test to not more than 25 psig (1.7 barg) may be made to
locate major leaks before a hydrostatic test.

9.9.1.5 Liquid testing medium shall be introduced at the system low point to avoid
air pocket formation. Vents at high points shall be left open and not closed until
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test medium flow from the outlet. All air must be removed before pressure greater
than the required to fill the system is applied.

9.9.1.6 Hydrostatic testing with water as a test medium shall not be performed
when there is a falling air temperature of 5°C or less. Should these conditions occur
during a test, the test shall be aborted and the system de‐pressurised.

9.9.1.7 When conducting tests at low metal temperatures (below 5°C) the
possibility of brittle failure shall be considered and the Project Engineer shall be
contacted for special requirements. Do not test when metal temperature is below
5°C. (Caution: Such low temperatures may also be caused by wind chill).

9.9.1.8 Hydrostatic pressure testing shall not commence until the test fluid
temperature is in equilibrium with the pipework system. The rate of pressure
increase in approaching the test pressure shall not exceed 70 psi (5 bar) per minute.

Pressure shall be applied by means of a suitable test pump which shall not be
connected to the system until ready for test. A test gauge shall be provided at the
pump discharge to determine the test pressure of the system and to avoid over‐
pressurizing. The pump shall be attended constantly during pressurizing by an
authorized operator and effectively isolated from the system during the test and
whenever left unattended. In order to prevent pressure in excess of the test
pressure, power operated test pumps shall be equipped with a pressure relief
device which is set to ensure that the test pressure is not exceeded.
9.9.1.9 Pressurise the system to the specified test pressure and hold for 10
minutes to allow piping strain to equalise. Once achieved inspect the complete
system, which will include all joints, threaded, socket‐welded, butt‐welded, flanged
and branch connections. On completion of the check and if no leaks are detected
then leave the system for a further 30 minutes to complete the test

On some large system it may take 2,3 or even 4 hours to check the system out and if
no leaks are detected but the pressure has dropped due to the decrease in
temperature, then bring the pressure back up to the test pressure and leave for a
further 30minutes. If the pressure holds then the test is complete.
Conversely if the test is started during the cool part of the day and pressure
increases beyond the test pressure due to the increases in temperature, then the
system will have to be periodically relieved back to the test pressure. On
completion of the check leave, relieved back to the test pressure, for 30 minutes. If
the pressure holds then the test is complete.

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Testing at night shall be restricted to small systems only and at ground level and
there must be adequate illumination to detect even the smallest leakage. There
shall be no testing of systems in pipe racks or elevated structures between sunset
and sunrise.
9.9.1.10 All lines and equipment shall be completely drained after the hydrostatic
test of a system has been completed. Vents shall be opened first to prevent
excessive vacuum and permit complete draining.

9.10 Pneumatic Tests

9.10.1 Pneumatic testing shall be in accordance with the requirement stipulated

in ASME PCC‐2 Part 5 & associated appendices.
9.10.2 Pressurize to 7 psig (0.5 bar) and hold for a sufficient length of time to
allow piping to equalize strains. All joints (threaded, socket welded, butt‐welded
and flanged) shall be inspected for leaks with soap suds.
9.10.3 Pressurize gradually in 10% steps to 60% of the specified test pressure and
hold for a sufficient length of time to allow piping to equalise strains (10 minutes
minimum).
9.10.4 Reduce pressure to 50% of the specified test pressure and visually inspect
all joints for leaks.
9.10.5 Pressurise in steps (each step to be no more than 10% of the specified test
pressure) until the specified test pressure has been reached, holding for a sufficient
length of time at each step to allow piping to equalise strains (10 minutes
minimum). The test pressure shall be held for two hours and then reduced to
design pressure after which all joints shall be inspected for leaks with soap suds.
9.10.6 The soap suds shall be a solution such as Sherlock, Snoop or equal.
9.10.7 Throughout the test period, the bubble formation properties of soap suds
shall be checked.
Before any remedial work is undertaken on weld defects, leaking flanges etc. the
system shall be depressurised and valves shall remain open to prevent any
accidental re‐pressurising. No work shall be attempted on a pressurising system.

9.10.8 All defects revealed by the test shall, after approval by the inspector, be
repaired and, after inspection, be retested as specified herein. At the discretion of
the inspector and where permitted by the relevant code repaired defects may be
retested by means other than pressure testing, as per clause 10.5.

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9.10.9 Weld joints in shop fabricated spools which have been successfully
pressure tested elsewhere, and for which documentation acceptable to the
inspector is included in the test package, need not be retested in a system test.
Laterals however, which have been hydrostatically tested (see paragraph 10.4) and
which have welded connections to flare headers shall be included in the pneumatic
system test.

9.10.10 A system under test pressure shall never be left unattended. If a test
cannot be completed before the end of a work period, the system shall be
depressurised. The contractor shall be responsible for all safety precautions and
procedures during testing.

9.10.11 Pneumatic testing stored energy calculation as per ASME PCC‐2‐2011

Article 5.1 Mandatory Appendix II

The maximum calculated stored energy of any piping system being pneumatically
pressure tested should not be greater than 271 000 000 J (200,000,000 ft‐lb). If the
calculated stored energy is greater than 271 000 000 J (200,000,000 ft‐lb), then the
system shall be divided into smaller volumes such that each subsystem has a
stored energy not greater than 271 000 000 J (200,000,000 ft‐lb).

9.10.12 The test shall be well documented and pre‐approved by the concerned
authorities along with minimum distance shall be calculated per ASME PCC‐2‐2011
Article 5.1 Mandatory Appendix III

9.10.13 A barricade shall be installed for pressure tests where the risk of injury
from potential fragments, shockwaves, or other consequences of any pressurized
system failure is determined to be unacceptable, a limited access area and pressure
control Point should be established. The minimum distance from the boundary of
this area to the pressurized component should be calculated according to ASME
PCC‐2‐2011 Article 5.1 Mandatory Appendix III. When the spacing requirements
described in Mandatory Attachment‐4 are not achievable, consideration should be
given to the design, fabrication and Installation of an alternative barricade capable
of withstanding the blast of stored energy within the system.

9.11 General Requirements

9.11.1 Special Tools

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9.11.2 Pressure gauges for system testing shall have a range suitable for the
systems test pressure to the satisfaction of the Inspection Authority.

9.11.3 Pressure gauges shall have tag numbers which shall appear on calibration
certificates. The certification documentation shall be a permanent part of the
system pressure test package. No certificate shall be more than one year old and
verified accurate by a recognized authority to the satisfaction of the inspection
authority.

9.11.4 In case of any disagreements between two pressure gauge readings, during
the pressure test cycle, the pressure test shall be stopped and both gauges sent for
for re‐calibration. To complete the test, two fresh gauges shall be used.

10 Preparation for Shipment:

10.1 Following the acceptance of a successful test, the system is to be immediately
depressurised and vented in a gradual and safe manner, thoroughly drained
allowing no pockets of fluid to remain. The system shall then be blown out with dry
filtered air (dew‐point ‐40°F (‐40°C)) at 150°F (60°C) to 170°F (77°C) at a velocity of
100 ft/Sec (30 m/Sec) until dry to the satisfaction of the inspector.

10.2 Replace all items removed for the test and remove all test blinds, temporary
supports, etc. The replacement of piping component internals shall be carefully
controlled to ensure that they are reinstalled in the correct place. Flange joints
opened for these purposes shall be remade with new gaskets. Plugs in unvalved
test vents shall be seal welded.

10.3 The inspector shall reinspect the system for mechanical completeness and
sign off the package as complete. The signed test package shall be retained as part
of the contract documentation.

10.4 Packing and Preservation

10.4.1 Desiccant removed from chemically cleaned piping prior to pressure testing
shall be regenerated or renewed and replaced together with appropriate warning
signs.

10.4.2 All openings in pipework, whether vents or drains to atmosphere or

openings for onsite hook up of modules etc, shall be adequately sealed to prevent
the ingress of foreign matter.

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10.4.3 Exposed machined surfaces such as weld bevels and flange facings shall be
covered with an approved white spirit soluble rust preventative.

10.4.4 Plastic end caps and thread protection plugs shall be secured with Denso or
equal tape.

10.4.5 Flange covers of metal (minimum 3/16” (5mm) thick) or wood (minimum
¾” (20mm) thick) shall be gasket of the same outside diameter as the flange, and
held in place with 50% of the required bolts for the joint (minimum 4 bolts). Covers
held on with wire or steel straps are not acceptable.

10.4.6 Gate and globe valves shall be closed. Ball and plug valves positioned
either full open or full closed, and diaphragm valves opened.

10.4.7 Warning signs noting items to be removed prior to commissioning

(temporary blinds to isolate chemically cleaned pipe, desiccant, etc) shall be
prominently displayed and adequately protected from weather and handling
damage.

10.4.8 All packing and preservation shall be witnessed and approved by the
inspector who will advise the contractor of any systems requiring special protective
measures such as blanketing with dry air or inert gas, etc, when long term storage is
envisaged.

10.5 Testing Contractor Supplied Items

All tools and equipment required for piping system pressure tests, including pumps,
compressors, connecting pipework with strainers and storage reservoirs, pressure
gauges, temporary blinds, plugs, spools, vents and drains, pigging equipment,
gaskets required for test purposes, test fluids and additives, etc, shall be supplied by
the contractor. However separate Scope of Work shall be made for project to
project basis.

The contractor shall demonstrate that all the necessary items are available at site in
advance of commencing testing to ensure the testing is not delayed in any way.

11 Vendor Data Requirement:

11.1 Records shall be made for each system tested which shall include:‐

a) Date of test

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b) Identification of piping test
c) Line Number
d) Test medium
e) Test pressure
f) Test duration /Pressurization Time
g) Cross reference to test gauge certificate
h) Observations Including Leakage etc.
i) Remedial Action
j) Details of Retesting
k) Approval by the Inspector
11.2 Records for piping which require that pressure be held for a specified period
of time shall include any corrections of test pressure due to temperature variations
between the start and finish of the test.

11.3 Records for piping in which a specified leakage rate is permitted shall include
the time at which water was added and the quantity added.

11.4 All test records and authorized Inspectors certifications shall be retained in
the job records.

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 ATTACHMENT - 1
ALUMINIUM BLIND FOR BLINDING EQUIPMENT NOZZLES

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 ATTACHMENT - 2
ALIGNMENT DOWEL PIN WITH THREADED END

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 ATTACHMENT - 3
ALIGNMENT DOWEL PIN WITH PLAIN END

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