Pressure Testing Procedure

For JGSCP OSBL Stage 1 Expansion Project

K008

Title : Pressure Piping Procedure

For JGSPC OSBL Stage 1 Expansion Project – K008

Document No. : AG&P-18062- P-E-70-0001.00

Revision : A

Date : 14 December 2018

APPROVALS:

1. Project Manager
Peter F. Connelly Date

2. Department Manager
Florencio C. Ebora Date

3. Customer’s Representative
Date

28th Floor, Tower 2, Insular Life Corporate Centre, Insular Life Drive, Filinvest Corporate City, Alabang, Muntinlupa City 1781, Philippines
Phone: +63 (2) 663 2100 l Fax: +63 (2) 663 2199 l www.agp.ph

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TABLE OF CONTENTS

1. Objective.................................................................................................................... 2
2. Scope......................................................................................................................... 2
3. References.................................................................................................................2
4. Definitions...................................................................................................................3
5. Responsibilities........................................................................................................... 4
6. General Requirements............................................................................................4-9
7. Hydrostatic Pressure Test.....................................................................................9-10
8. Pneumatic Pressure Test.........................................................................................10
9. ServiceTest...............................................................................................................11
10. Pressure Releasing and Draining.............................................................................12
11. Test Records............................................................................................................ 12
12. Notes........................................................................................................................ 13
13. Appendices............................................................................................................... 14

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1. Objective
This procedure describes and establishes the method for the performance and
documentation of tests to demonstrate the integrity of a piping system and conformity
with the specifications, drawings and good construction practice.

2. Scope
This applies to all hydrostatic , pneumatic ,and service testing for both metallic and GRP
piping material to be performed by AG&P.

3. References
Codes, Standards, Legal And Other Regulations
Reference
Description
Title
ASTM American Society for Testing and Materials
API American Petroleum Institute
American Society for Mechanical Engineers (ASME)
ASME B31.3
Chemical Plant and Petroleum Refinery Piping
AWS American Welding Society
ISO 17025 Bench Testing and Calibration of Instrument Standards
A4-
JGS1EP- Piping Design Basis
DB-50-001
A4-
JGS1EP- Fluor Specification for Construction Work of Piping
ES-50-010
A4-
JGS1EP-
Piping Material Specification
A7MI-ES-
50-001
A4-
JGS1EP- Fluor Pipe Support Specification
ES-50-014
A4-
JGS1EP-
RTR Pipes, Fittings & Flanges
A7MI-ES-
50-003
FRP Vendors/ Manufacturers’ Testing Procedure

4. Definitions
Piping System – Those procedure retaining systems and components for which proof
tests are required by ASME Section I, ASME B31.3 and other standards and codes
where required.

Pressure Testing – A method of leak testing in which the component being tested is

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filled completely with a gas or liquid, which is then pressurized. The outside of the
component is examined for the detection of any leaks.

Calibrate – To ascertain the error (if any) in a device by checking it against a standard
to adjust the output of a device to bring it to a desired value (within a specified
tolerance) for particular value of input.

Set point – The point which the controller or instrument is adjusted to regulate the
process.

FRP- Fiber Reinforced Plastic

5. Responsibilities
AG&P – shall supply, install, maintain all test equipment required to carry out the test
programs.
Customer – is responsible for issuing specifications, which prescribe the system and
component test requirements.
Piping Engineer – is responsible for establishing an overall program to ensure that
piping systems are tested in accordance with the Testing Schedule, and all systems
are tested accordingly.
Piping Supervisor – is responsible for carrying out the testing in accordance with the
requirements.
Quality Control Supervisor – is responsible for assigning a QC inspector to conduct
an inspection of the piping system prior to and during testing.

6. General Requirement

6.1 Work Permits

6.1.1 An approved Method Statement / JHA shall be attached with the work
permits for carrying out pressure testing activity.

6.2 Resources
6.2.1 Certified Hydrotest Filling pump

6.2.2 Certified Pressurizingg pump

6.2.3 Certified Air Compressor

6.2.4 Certified Hydrotest manifold with block valves and check valve

6.2.5 Calibrated Pressure gauges at 1.5x to 2x Design pressure

6.2.6 Calibrated PSV at 1.1x above test pressure

6.2.7 Calibrated Pressure-Temperature Recorder

6.2.8 Temporary Blinds, Test Blinds, Slip flanges and end plates

6.2.9 Temporary Bolts and non-asbestos hydrotest gaskets

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6.2.10 Caps,plugs, chicago fittings and connectors

6.2.11 Water Tanks and water Hoses

6.2.12 High pressure hoses

6.2.13 Calibrated Torque wrenches, combination wrenches , spanners and

adjustable wrenches

6.2.14 Anti-whip check

6.2.15 Nitrogen Cylinder tank

6.2.16 Certified lifting gears

Testing Fluid with no more than 50PPM chloride content and PH 6 - 8

6.3 Test package Preparation

6.3.1 Prior to testing, the Piping Engineer shall put together a test package for
each test system. The package shall include:

 Test Boundary Sheet – a colour marked-up P&ID showing the

physical extent of the test.

 Piping isometric drawings marked-up to show all piping and

equipment included in the test system.

 Pressure Test Checklist (Appendix A).

 Pressure Test Report (to be completed during actual test (Appendix

B).

 Punch List Record (Appendix C).

 Valve list & blind register.

6.3.2 The piping isometric drawings in the test package shall contain the following
information:

 Test limits;

 Pressure test flow diagram shall be prepared by Construction

Contractor. These diagrams shall show the system to be tested, the
valves to be opened, and the equipment to be blanked with blind
flanges and necessary instrumentation.

 Location of test blanks and pumps, compressor, control valves and

safety valves;

 Size of blinds and type of gaskets and bolts necessary to withstand

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pressure;

 Requirements for removal of flappers of check valves, or for testing

against them;

 Requirements for removal of instruments, orifice meters, rupture

discs and other piping items, which could be damaged by, or affect
the implementation of the test;

 Location of high point vents and low point drains;

 Location of temporary supports, if needed;

 Location where system will be filled with the test medium and where
pressure will be applied with the test pump;

 Location of calibrated test pressure gauges (minimum of two) and

where temperature is measured for test, if required;

 Location of pressure relief protection devices;

 Test pressure;

 Test medium; and estimated quantity required.

 Test duration.

6.4 Area Preparation

6.4.1 Areas where pressure test are taking place are to be roped off and warning
notices displayed forbidding entry to unauthorized personnel.

6.4.2 Please add exclusion zone considerations in a clear plot plan identifying the
adjacent assets/facilities, access control requirements, safety signage etc.

6.5 Preparation of Piping System

A pipe run inspection shall be conducted to verify the completeness of the system,
its conformity to drawings and specifications, the proper installation of test
accessories and the dismantling of items not to be included in the test.

Any condition or item that does not satisfy the pre-test requirements shall be
recorded in the punch list. The test shall not proceed until the corrective work has
been done and punch list has been cleared. Cleared punch list shall be sign by
assign QC for document purposes.

6.5.1 All welds and bonded joints shall be completely checked visually and all
NDE, stress reliving and hardness test requirements shall be reviewed to
determine if satisfactorily completed.

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6.5.2 Joints and welds to be tested shall not be insulated, painted or covered in
any way, to allow for examination during the test.

6.5.3 Equipment not included in the pressure test shall be disconnected or

isolated by blinding. All compressor and pump suction and discharge
nozzles shall be blinded to prevent water entering the equipments.

6.5.4 Ball valves shall be in the half open position for testing to allow for
pressurization of the body cavity and internals with the exception of
Emergency Shutdown valves that will be fully open.

6.5.5 All instruments, relief valves, bursting discs, and other fragile items shall be
removed or isolated from piping and replaced with blind flanges, dummy
spools and spades as necessary.

6.5.6 When the test cannot be done with the instrument connected, the test shall
be carried out for piping up to the first valve of instrument pressure piping.
In this case, if flange or union is installed at instrument side of teh first
valve, such flange or union shall be kept disconnected during test, to
prevent dust or any other foreign matters from coming into the instrument
pressure piping.

6.5.7 Where check valves are installed in a system, the testing pressurization
point shall be upstream of valve. On completion of the test, pressure shall
be released from the downstream side of the check valve, before the
upstream side is drained. If no suitable connection is available, the check
valve be jacked open or the valve flapper removed.

6.5.8 If a pressure test is to be maintained for a period of time and test medium in
the system is subject to thermal expansions, precautions (such as
surveillance by a QC Inspector throughout the period) shall be taken to
prevent over pressure.

6.5.9 Permanent pipe supports, anchors, guides, clamps and similar shall be
installed as detailed on the drawings prior to pressure testing. The Test
Engineer shall ensure that load pins for spring units are not removed.

6.5.10 End-user’s certificate shall be presented stating that all required Non-
Destructive Tests (NDT) have been completed and cleared for hydro
testing.

6.6 Underground Piping

6.6.1 Hydrostatic pressure test of underground piping shall be performed before
backfilling

6.6.2 In case partial hydraulic pressure test are applied for sections of
underground piping, connection points between the two parts (sections)
may be checked using other inspection method, after obtaining approval of
OWNER/COMPANY.

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6.7 Preparation of Testing Media

The piping system shall be tested with fluid media free from any suspended
solids as shown below:

 Stainless Steel Lines – potable/demineralized water with a

combined fluoride and chloride content of below 50 ppm and a ph
value of between 6.00 and 8.00 or as prescribed in the project
specifications.

 Carbon Steel and Alloy Lines – potable water.

 Special Service – as required by Customer specification.

 Media analysis reports shall be provided for the hydrotesting of

stainless steel lines.

 Pneumatic Testing

The piping systems shall be tested with gaseous media free from oil or
contaminants as shown below:

 Clean, dry, oil free air.

6.8 Blinds and Blanks

6.8.1 Where the piping system is required to be disconnected from equipment in
the test, disconnected end of the piping shall be isolated by blind flange
having the same rating with the piping system to be tested.

6.8.2 Where the piping system to be tested is isolated at a pair of companion

flanges, blank shall be inserted between the companion flanges.  Minimum
thickness of blanks shall be as listed in Table 1.  And a record should be
kept showing the location of all test blinds to assure their removal. These
blanks shall be supplied by Construction Contractor.

6.8.3 No testing shall be down against closed valves, blind flange or blanks.
Instrument block valves shall be exempted from this rule.

6.8.4 For flanged control valves with block valves and a by-pass, if the test
pressure upstream and down stream is the same, the block and by-pass
valve shall be left open, with the control valve removed and blinds.

6.8.5 In case the test pressure upstream and down stream of the control valve is
different, the test on the upstream position shall be made with the by-pass
valve open and blanked-off, upstream block valve open and blanked off and
control valve removed

6.9 Support and Hanger

6.9.1 On hydrostatic pressure test of piping of fluid other than liquid, additional
temporary pipe support shall be installled, if necessary.

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6.9.2 In case of piping supported by spring hanger , it shall be checked, before

the piping is filled with water, the knock for the spring is set. If the hanger is
not of knock type, temporary support shall be provided so that overstress is
avoided. Such temporary support shall be removed after confirming
completion of draining out from the line.

6.10 Pressure Test Gauges

6.10.1 Two calibrated dial indicating pressure gauges, at least, shall be provided at
the pump discharge and other suitable locations.

6.10.2 All gauges used shall be checked for accuracy. All test pressure gauges
shall be calibrated at regular intervals at least every two weeks. Calibration
certificate shall be available at the work site and all gauges shall be properly
identified to enable tractability to the calibration certifications.

6.10.3 The test pressure shall be checked by means of a gauge having a range
from zero up to 1.5 to 2 times the intended maximum test pressure.

6.10.4 Pressure gauge shall be connected at point as near as possible in highest

and lowest point of the piping system to be tested. Where practical, the
static head of the water column shall be taken into account in the test
pressure.

6.10.5 Check the pressure gauges regularly during pressure testing especially
during hot weather. The pressure has tendency to rise if the temperature is
high. If possible provide shading during testing.

6.11Test Pressure
6.11.1 Hydrotestest pressure shall not be less than 1.5 times the minimum design
pressure, but shall not exceed the maximum allowable test pressure for
flanges, according to ASME B16.5 OR ASME B16.47.

6.11.2 All piping to be used in vacuum service shall be hydrostatically tested with
water at test pressure of 2kg/sq.cm, if water filling is applicable .In case
water filling is not applicable, the piping shall be pneumatically tested by air
or nitrogen gas at test pressure of 1 kg/sq.cm

6.11.3 In Pneumatic testing it shall be 1.1 times the minimum design pressure

6.11.4 In case of high pressure line which , due to its specialty, cannot be put
under the stipulated hydrostatic and pneumatic pressure test and therefore
must be tested with actual process gas,a pretesr with air or inert gas at
about 1/3 of the maximum operating pressure shall be performed in
advance.AG&P shall proceed with this work, according to the procedure to
be approved by OWNER/COMPANY, regarding pressure source , method
of test, and etc.

6.11.5 The following points shall be taken into account to determine the test
pressure.

A. The weakest component in the piping system to be tested.

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B. In case that the piping system is tested together with existing

lines of

having lower test pressure than the system.

7. Hydrostatic Pressure Test

7.1 Flushing
7.1.1 A pre-test line cleaning/flushing may be necessary before pressurization is
carried out.

7.1.2 Trash and construction debris shall be removed from the piping
system by flushing with water or by blowing with air or nitrogen in line
with the pressure test medium. All lines shall be completely free of
weld slag and other foreign material and shall be reasonably clean.

7.1.3 Flushing through equipment or machinery is not allowed. Flushing

shall be performed against open pipe ends.

7.1.4 Pressure test shall be carried out in 4 hours or more after welding , so
as to prevent delayed cracking.

7.2 Filling & Venting System

7.2.1 Prior to testing, the system shall be filled with fluid being vented as filling
takes place. The location of fill and vent points will be detailed on the
system isometric.

7.3 Leak Inspection

7.3.1 On completion of filling, the pressurization may commence. The system
shall be gradually pressurised as per project specification maintaining for at
least 3 minutes in each step and no abnormal conditions such as leakage,
etc.

7.3.2 The stipulated test pressure shall be maintained for more than 30 minutes
and then no abnormal conditions such as leakage, etc. Shall be confirmed
at eevry welded part and joint part.

7.3.3 For system rates ANSI class 600 and above, the final test pressure shall be
reached in increments of 25%, 50% and 75%. The system shall be allowed
to stabilize for 15 minutes after each increment and after reaching the final
test pressure.

7.3.4 Each pressure test shall be witnessed and recorder charts (when required)
shall be sign on and off by QC and the Customer, signifying acceptance of
the test.

7.3.5 After pressure test, the pressure value shall be decreased down to
maximum operating pressure x 1.1. Then welded joints shall be checked
against leakage.

7.3.6 Immediately after hydrotesting, water shall be properly drain/flushed

followed by air blowing to ensure the inside dryness. Warm or hot air shall

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not be used for drying 300 series stainless steel. Proper venting shall be
maintained to avoid vacuum conditions.

7.3.7 All pipe open end shall be properly covered/sealed after air blowing. Inside
cleanliness/dryness shall be checked/inspect by QC with the presence of
customer representative.

7.4 Water Disposal

7.4.1 If the Hydrotested water is to be discharged to the storm water drain inside
plant, approval is required from the owner. Quality of discharge water shall
comply with local Environmental Regulations.

7.4.2 First sample of the hydro tested water shall have been tested from an
accredited laboratory.

8. Pneumatic Pressure Test

8.1 General
8.1.1 Pneumatic testing may be substituted for hydrotesting subject to customer
approval when:

 Special supports would be required to support the test medium weight.

 The hydrotest medium may damage, corrode or contaminate piping

components.

 Close joints require testing following cleaning and drying.

 Test vents/drains cannot be added to lines containing hazardous

substance i.e. fuel gas when these lines are located in a non-
hazardous area.

Where line list or line designation table indicate pneumatic testing, no hydro
testing shall be performed.

8.1.2 Each individual pneumatic test areas shall be restricted where possible to
the minimum volume of contained compressed air.

8.1.3 As pneumatic testing presents special risk due to possible release of energy
stored in the compressed gas almost care shall be taken during
pressurization and inspection of the system to prevent any danger to
personnel or equipment and the chances of a brittle failure of piping. Piping
systems to be pneumatically tested shall be protected by a relief valve.

8.1.4 The system being tested shall be inspected during the pressurization period
for visual signs of leakage. Leaks shall be located by applying a leak
detection fluid completely around all connections and welded joints and
FRP Joints.

8.2 Pressurization
8.2.1 After evacuating all personnel from the test area The system shall be
pressurized and held for sufficient time to allow the piping to equalize

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strains (ten minutes minimum). All joints (threaded, socket welded, butt

welded and flanged) shall be preliminary tested for leakage using the test
solution.

8.2.2 Pressurize the system up tp the lesser of 50% of the test pressure or
1.73kg/sq.m and shall be checked for any leak.

8.2.3 The pressure shall be increased gradually in steps providing sufficient time
to allow piping to equalize strains during test and to check for any leaks.

8.2.4 The indicated test pressure shall be held for at least 10 minutesto permit the
testing of all joints, the pressure shall then be reduced to the design
pressure before examining for leakage.

8.3 Leak Inspection

8.3.1 Each reinforcing pad (or each segment thereof) and similar attachments
shall be tested at a designated test pressure with air, a soap solution shall
be used to detect air leaks. Test and vent holes shall be left open upon
completion of the test.

8.3.2 A soap solution shall be applied to all screwed, weld and flanged joints
undergoing pneumatic test.

9. Service Test
9.1.1 Service test may be performed for lines which belong to Inspection Class I-
A in para 5 , Flour Specification for Construction Work of Piping with
OWNER’s approval in lieu of the hydrostatic leak test.

9.1.2 Service Test shall be in accordance with Para. 345.7 of ASME B31.3

10. Pressure Releasing and Draining

10.1Pressure Releasing
10.1.1 After completion of the test, pressure shall be released by opening the valv
gradually so as not to endanger personnel or damage equipment. As a rule,
pressure releasing rate shall be 300 kg/sq.cm per hr.

10.1.2 Special attention shall be paid for pressure releasing of lined piping or
equipment, tower filled with catalyst, etc. And, in these cases, the releasing
rate shall be less than 25 kg/sq.cm per hr.

10.2Draining
10.2.1 After completion of the test, piping and equipment shall be drained
completely.

10.2.2 Vents shall be opened completely before the piping is drained and shall be
kept open during draining to prevent vacuum in the piping.

10.2.3 When water comes into the instrument due to the hydrostatic pressure test,
draining of teh instrument shall be carried out without fail after completion of
the test.

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11. Test Records

11.1 Records shall be made for each piping system during teting and these records shall
include the following items.
A.    Extent of testing and specification

B.    Identification of piping tested

C.    Pressurizing apparatus

D.    Test pressure and test duration

E.    Test fluid

F.    Date of test

G.    Approval signature of witness (Client, owner)

H.    Signature of person in charge of testing

I.     Applicable remarks concerning defects

J.     Water temperature and chloride content

K.    Design temperature and pressure

D. Test flow plan showing blind points, vents/drains, valve, location

of test

gages, pressure inlet, etc..

11.1.1 All tests satisfactory or not shall be record on the test form and complete set
will be made part of the permanent job records.The records will become
part of the pressure test dossier to be filled with the pressure test sheets.

11.1.2 QC Supervisor shall index and file each pressure test document into the
relevant system/sub-system. In some cases the test will incorporate more
than one system and in such cases the documents shall be filed in all
relevant systems.

11.1.3 Piping Engineer shall maintain a set of dedicated marked up P&ID’s to

show the status of lines tested.

11.1.4 The originals of all relevant documentation and recorder charts shall be
maintained by QC.

12. Notes
12.1 Welds or portion of welds that leak during pressure test shall be repaired, cutout,
rewelded, radiographed (if needed) and line shall be hydrostatically tested again.

12.2 Painting and coating for all joints including welded joint shall be performed after
completion if test.

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12.3 Hot and Cold insulation work for welded joint part’s connection shall be performed
after completion of the test.

12.4 All lines which may not require test or leak test (i.e. vent line, open drains and
other lines open to atmosphere) shall be visually inspected.

12.5 Thermoplastic material system shall not be subjected to repeated hydrostatic test.
Weeping joints are not permitted.

13. Appendices
Appendix A – Pressure Test Checklist (F75117)

Appendix B – Pressure Test Report (F82408)

Appendix C – Punchlist (F82415)

Appendix D – Pressure Test Register (F82417)

Appendix E – Basic Hydrostatic Test Manifold Assembly

Appendix F – Basic PneumaticTest Manifold Assembly

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Appendix A

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Appendix B

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Appendix C

Appendix D

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Appendix D

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Appendix E

28th Floor, Tower 2, Insular Life Corporate Centre, Insular Life Drive, Filinvest Corporate City, Alabang, Muntinlupa City 1781, Philippines
Phone: +63 (2) 663 2100 l Fax: +63 (2) 663 2199 l www.agp.ph

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Appendix F

28th Floor, Tower 2, Insular Life Corporate Centre, Insular Life Drive, Filinvest Corporate City, Alabang, Muntinlupa City 1781, Philippines
Phone: +63 (2) 663 2100 l Fax: +63 (2) 663 2199 l www.agp.ph

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