ZPEC PROCEDURE Procedure No.

:
FOR ZPEC-414-HP (R0)
PRESSURE TEST Dated 15 Nov 2019
QA/QC

1. Title : Procedure for Pressure Test

2. Scope : This document intends to describe the procedure for the shop pressure test,flushing, and draining of
pressure vessels & leak testing of pads

3. References:

a) ASME SEC VIII DIV 1

b) Inspection and Test Plan (Latest Rev.)
c) Drawings (Latest Rev.)
d) Project Specs: 32 – SAMSS – 004 (02 Feb 2018)
e) SAES-D-008

4. Hydrostatic Pressure Test:

a) After completion of fabrication and all inspection activities the production unit shall carry out the necessary
arrangement for conducting the hydrostatic test as detailed in the procedure. The QC unit is responsible to
inspect and to inform client and authorized inspector to witness testing.

b) All related documents like MTC’s, NDE Reports, PWHT charts (if applicable) etc., shall be provided to client
inspector for review prior to hydro test as per the ITP.

c) Telltale holes in internal attachments shall be seal welded prior to the pressure test.

d) The vessel shall be cleaned internally and externally of dirt, debris and welding slag before the pressure test

4.1 Test Equipments:

a) Test Fluid: Only Clean potable water shall be used for pressure testing of CS vessels. For vessels
manufactured from stainless steel, the water shall not contain more than 50 ppm chlorides with pH value not
exceeding 7 at the time of filling vessel. The temperature of water used during hydro test shall be maintained not
less than 15⁰C throughout the testing cycle.

2 No’s pressure gauges with valid Calibration shall be used. The test gauges range approximately 1.5 times and
not more than 4.0 times of the intended test pressure. The calibration Certificate shall be available for reference.

b) Vessel shall be protected from being over pressure ,while pressure tested by use of pressure test relief valve
meeting the following :

1- Relief valve shall be of adequate capacity set to relieve at 10% above the test pressure.
2- The relief valve shall be tested, dated and tagged within one week prior to pressure test.
3- The pressure test relief valve shall be accompanied by test certificate that includes CDTP, test date and
springe range, the CDTP shall be within spring range.
4- Sizing of relief valve shall be according to API RP520, Part I.

c) Pressure Pump: A suitable capacity hydraulic / pneumatic pump to reach the applicable test pressure. The test
pressure shall not be applied until the vessel and the test fluid are at about the same temperature.

d) Air Compressor: A suitable capacity air compressor to flush the complete assembly prior to and after hydrostatic
test.

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ZPEC PROCEDURE Procedure No.:
FOR ZPEC-414-HP (R0)
PRESSURE TEST Dated 15 Nov 2019
QA/QC
5. Test Arrangements / Procedure :

a) One pressure gauge shall be provided at or near the highest point of the assembly directly mounted without any
intermediate valve and the other at the pump discharge. Pressure Gauge shall be calibrated within one year
before the hydro test. Each pressure gauge shall have an identification number and calibration label.

b) All openings such as nozzles, couplings, etc. shall be fitted with blind flanges and plugs of same size.
Note: shellacs, glues, lead shall not be used on gasket joints.

c) Hydrostatic pressure testing shall be performed with gaskets and bolting identical to those required in service and as
specified on the data sheet(for permanent blind flange). These gaskets may be used as service gaskets if the bolted
joint is not disassembled after completion of hydrostatic pressure testing. Temporary gasket and fastener can be
used for other flanges

d) Sufficient and safe access lighting shall be provided for thorough inspection and all the safety precaution have been
completed as per section 12

e) Tell tale holes on the external attachments and pads shall not be plugged during hydro test.

f) Suitable valves shall be provided one at or near the highest point of vent line and another at bottom point of drain
line as necessary to release / vent possible air lock.

g) Complete assembly shall be thoroughly flushed with clean and dry compressed air prior to the test. Flushing
activity shall be carried out before fixing the pressure gauges at the required points.

h) Water can be filled in the vessel from any convenient point; and shall be pumped with a suitable hydraulic /
pneumatic pressure pump to reach the test pressure. Ensure that the vent point at the bottom of drain line is
closed and a top most air vent point is open during the filling of water. Close and open the top most air vent valve
as necessary for the release of possible air locks.

i) Vertical vessels that are tested in the horizontal position shall be adequately supported such that the primary
stresses in any part of the vessel do not exceed 90% of the minimum specified yield strength of the vessel
material

6. Hydrostatic Test Performance :

a) The Hydro Test shall be in accordance with UG-99 of ASME Sec VIII Div.1. Test Pressure shall be as per the
approved drawing and shall be held for a minimum of one hour per 25 mm of vessel thickness and in no case
less than one hour

b) The Vessel metal temperature shall be minimum 17⁰C above warmest MDMT based on the temperature values
on the impact exemption curves of ASME SEC VIII Div.1; not below 15⁰C; the maximum test temperature shall
be 48°C.The temperature during test cycle shall be continuously manually monitored by Inspector.

c) The test shall be carried out in the sequences as follows:

Step 1: The pressure shall be gradually increased in steps of 1/10 th of test

Pressure to the specified test pressure & maintain the pressure for the
Minimum specified holding time. (Note: At pressure test, the applicable test pressure shall be
in accordance with approved General Arrangement drawing.)

Step 2: Then pressure shall be then gradually decreased to MAWP & visually
Inspected entire surface especially joints, corners, knuckle areas etc for any
leak or deformation. If no leak is observed, depressurize the vessel gradually.
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ZPEC PROCEDURE Procedure No.:
FOR ZPEC-414-HP (R0)
PRESSURE TEST Dated 15 Nov 2019
QA/QC
7. Evaluation:

a) ZS QC personnel, Client representative shall witness the Pressure test.

b) Any deformation, loss of pressure, seeps at the weld joints shall be considered as unacceptable.

8. Flushing after test :

a) Ensure that sufficient vents are open at the top most point prior to flushing / draining.

b) After acceptance of test the complete assembly shall be flushed with clean and dry compressed air until the water
traces are thoroughly dried out. The vessel shall be visually inspected to ensure the dryness as per Equipment
Preservation Procedure

9. Repair and Retesting ( if necessary ) :

a) If leakage is observed at any weld joint, water shall be drained prior to the repair welding of the leakage weld
joint. Repair shall be carried out using Approved Repair Procedure

b) If any such Repair done, the same shall be communicated to Client / Saudi Aramco inspector prior to Repair.

c) Repair welding shall be carried out as per the applicable WPS & necessary NDT tests shall be completed and
accepted before the retest.

d) Refilling and Retest shall be carried out as per this procedure.

10. Test Report:

a) ZS QC personnel, client representatives shall sign / certify the enclosed Pressure test report [Form #
ZPEC/QC/12 (Rev.1)] after successful completion of the test.

11. Leak Test on Pads

a) All welded attachment with tell tale hole shall be tested for leak tightness at a pressure of 70 kpa(10 Psi) prior to
PWHT (if applicable) and Vessel Pressure Testing.

b) The test gauges range approximately 1.5 times and no more than 4.0 times the intended test pressure.

c) Compressed air shall be used to establish the required pressure.

d) Bubble forming Solution shall be used to detect leak if any.

e) Form no: ZPEC/QC/13 Rev.0 shall be used to report the leak test.

12. Safety

a) The area where the equipment is to be hydrostatically tested shall be cordoned off. Signs shall be displayed
at roped off areas indicating that hydro test is under progress. Only authorized persons shall be allowed with
in test area during testing.
b) The equipment while under pressure shall not be subjected any form of shock or hammering.

c) When the equipment is at the hydrostatic pressure, it shall be monitored to avoid a pressure rise during the
holding time. A relief valve of adequate capacity shall be provided to protect the vessel
from being over pressured.

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