TABLE OF CONTENTS
1.0
INTRODUCTION
3
2.0
ABBREVIATIONS, DESCRIPTIONS
3
3.0
REFERENCES
4
4.0
PRESSURE TESTING
4
5.0
QUALITY CONTROL / ASSURANCE
9
6.0
SAFETY
10
.0
ASSOCIATED ITP!", #OR$ INSTRUCTIONS
12
%.0
ATTAC&'ENTS
13
1.0
INTROD INTRODUCT UCTION ION
The purpose of this MS is to explain the construction procedures and methodology for the pressure testing of pipework. For the purpose of this method statement the Hydrostatic, Pneumatic, Service and lternative testing procedures shall !e descri!ed.
ll such works shall !e performed in full compliance with "F# $rawings, Specifications, "TP%s, &endors% Procedures and all relevant #odes and Standards.
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#odes, Standards, Specifications, Procedures, 'egulations and 'eferences in the #(P.
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SM) * +.+
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-//0/SP)/+ Specification for Piping and Material #lasses
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-//0/SP)/- Specification for Piping "nstallation and Testing
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-//0/SP)/1 Specification for Site Piping Material Tracea!ility
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-//0/SP)/ 2 Specification for Paint and Protective #oatings
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-//(/SP)/31 Process Plant Piping , (elding P(HT and 4$T
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-//0/SP)/3 Specification for Piping Standard $etails
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-//0/SP)/1 Specification for Pipe Supports
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#5MP46 MS/+ Method Statement for the Transport of Spools and Materials
4.0
PRESSURE TESTING
3. #5MP46 piping engineers shall prepare test packs for each test system !ased upon the appropriate P 7 "$, isometrics and piping layouts. The packages shall further comply with all local code re8uirements.
3.1 "n the event that there are inade8uate high point vents and9or drains in any system the #5MP46 ') shall agree with PF$ the si:ing and location;s< of re8uired additional ones. ll such vents and drains shall !e installed with materials compati!le with the relevant Piping #lass.
3.+ "ncluded within each test pack shall !e a marked up P7"$, =s *uilt> isometrics clearly defining the test pressure ;as per the 0ine $esignation Ta!le<, the duration of test and the extent of the pipe work to !e tested. The
extent of the test shall !e such that the static head of the test medium does not create a pressure greater than the maximum allowa!le test pressure.
3.3 ll in line components or internals which are to !e removed , temporary test !linds, test vents and drains and plugs that shall !e utilised for testing the pipe work are to !e recorded on the test diagram.
3.? "ncluded in the test package will !e sign off sheets wherein !oth #5MP46 and PF$ representatives shall duly record their approval of the test preparations, pre/ test9post test punch lists, testing9flushing and post test completion.
3.- #5MP46 @# supervisor and PF$ ;4)(S< )ngineer shall sign off on the test package prior to testing as the means of verifying that all welding, P(HT and 4$T has !een completed in accordance with the relevent codes9standards and proAect specifications. #5MP46 @# )ngineer shall verify that all "TP check lists are updated with the relevant approval signatures.
3.2The ') and 'S shall carry out a pre/test walk down of the pipe system to !e tested with PF$, duly agreeing, classifying and recording punch items that are to !e completed !efore the test ;#ategory < or items that may !e completed, at a later date, after test completion ;#ategory *<.
3.B Temporary test !linds shall !e of ade8uate thickness to withstand the test pressure. They shall have an integral lug or handle which shall !e painted for identification purposes. Suita!le gaskets shall !e used to prevent damage to permanent flange faces.
3.C"nstrument connections shall !e closed with a properly gasketed !lind flange or plugged off.
3. The ') shall confirm the removal of all inline piping components that are lia!le to !e damaged during the pressure test. Permanent pressure and thermal relief valves shall not !e included in system pressure test.
3. ll in line items and internals to !e removed for the test shall !e agreed with PF$ and ade8uately la!elled and the component to which they !elong or the position in the line from which they have !een removed shall also !e la!elled. These shall !e noted on the ='elease for Test = form and signed !y !oth #5MP46 and PF$. ;ttachment B.<
3.1 Testing, as a general rule, shall not !e carried out against closed valves. ll valves in the pressure test should !e in the fully open position. ny test to !e performed against a closed valve shall !e approved !y PF$.
3.+ (eld Aoints shall !e left uninsulated to allow access for visual inspection during the duration of the pressure test.
3.3 certified testing rig or manifold shall !e used for the pressure testing. The testing rig shall have a cali!rated pressure gauge , pressure relief valve and !leed valve which shall !e located on the upstream side of the rig or manifold !lock valve. Test pressure gauges shall also !e installed at Dhigh% and Dlow% points of the piping system in order to accurately monitor test pressures during the test. pressure recorder shall !e used for the duration of the test period.
3.? (ater, supplied !y PF$, shall !e fresh, clean and free from suspended solids and other foreign matter and with chloride content of not more than ?ppm.
3.- Prior to filling any system it shall !e checked for installation completeness, including all permanent supports and temporary supports ;if re8uired<, satisfactory test preparation, inclusive of system cleaning, the locations of pressure gauges, installation of test vents and drains and the suita!ility of the test rig. ll mechanical supports ;spring supports< shall !e checked to ensure that the locking pins are installed prior to filling of any system.
3.2 Prior to pressurisation of the piping system, the area shall !e monitored , cordoned and sign posted with warning notices to prevent unauthorised personnel from entering the testing area.
3.B fter all preliminary test preparations are complete testing medium shall !e introduced into the piping system from a Dlow% point in the system. The system shall have high point vents left open until test medium flows from the outlet and then shall !e closed.
3.C Precautions shall !e taken to avoid temperature variations !etween the test medium and piping system during the winter season and as a minimum the testing medium shall not !e less than ?E #.
3.1 Piping system shall !e pressurised at a rate of not more than ? !arg per minute. pon attaining the re8uired test pressure, the manifold !lock valves, downstream of the test pump shall !e tightly closed. The pressure shall !e held for sufficient time to e8ualise strains in the system.
3.1 Pressure shall !e held for such a time as to allow visual inspection of the complete system for leakage !ut in any event shall not !e less than minutes.
3.11 $rops of test pressure, in one hour, of +G shall !e accepta!le for hydrotest acceptance.
3.1+ pon completion of the pressure test,all high point vents shall !e opened !efore draining of the system of the test medium. The system shall then !e air flushed and dried with clean, approved air to the satisfaction of the relevent parties. ll components removed for the testing shall !e re/instated and re/inspected !y the ') and PF$ representative. "n particular all flange faces of removed items and their mating flange shall !e carefully checked. ny post test punch list item shall !e duly recorded, catagorised and agreed !etween the parties.
3.13 $ue to the inherent dangers of pneumatic pressure testing, such testing shall only !e carried out when deemed necessary and with the explicit approval of the operating authority and proAect management. dditional precautions shall !e taken to ensure the safety of personnel participating in the pressure test and personnel adAacent to the piping system !eing tested.s a minimum the following shall !e adhered to
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Pneumatic test pressure shall not exceed G of the design pressure whether using air or nitrogen as the test medium.
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System shall !e pressurised to ? !arg and held for sufficient time to allow e8ualisation of piping strains and the visual inspection for leakage using soapy water.
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Further pressurisation of the system shall !e undertaken in increments of no more than G of the specified test pressure and held for not less than minutes to allow e8ualisation of strains.
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Test pressure shall !e held for the length of time re8uired to examine the system prior to the depressurisation to design pressure level in order to carry out soapy water testing of weld Aoints.
3.1? Special attention shall !e taken to ensure against the adverse effects of !rittle fracture occurences from low metal temperature.
3.1- Piping System shall !e air flushed to the satisfaction of the relevent parties prior to re/instatement of the system.
3.12 5n completion of re/instatement piping system shall !e re/inspected !y the parties for mechanical completeness, duly recorded, categorising any punch items for inclusion within the test package. 3.1B #ategory D$% piping systems ;excluding firewater< may !e pressure tested with it%s own medium at it%s operating pressure. Testing shall !e undertaken utilising the same parameters for the testing, recording, and safety precautions as per hydrotesting.
3.1C (hen deemed necessary and within the guidelines of SM) *+.+ rules for 8ualification, alternative test in accordance with same may !e employed. "n such cases conditions as stated in para. +3?.C of SM) *+.+ shall apply for the 4$T of welding Aoints and para. +3?.B for any su!se8uent leak testing. The agreement of PF$ shall !e re8uired prior to the foregoing actions.
5.0 QUALITY CONTROL/ASSURANCE
?.Prior to testing the #5MP46 @# (elding )ngineer shall verify that all the re8uired welding, P(HT, 4$T has !een completed and carried out in accordance with the proAect specifications. 'ecords for the aforementioned functions shall !e made availa!le for review, upon re8uest, for the relevant test package prior to the commencement of pressure testing.
?.1 #5MP46 @# )ngineer shall ensure that all test e8uipment has !een certified and cali!rated for the intended purpose in accordance with specification re8uirements. Test records for such cali!rated e8uipment shall !e made availa!le within the relevant test package.
?.+Test gauges shall !e visually inspected prior to each test to verify their condition and that there is no o!vious damage to them. "f, during the test, any of the gauges !eing used indicate inaccuracies in readings they shall !e replaced with another cali!rated one.
?.3Suita!ly ranged gauges ;.1? I 3 x Test Pressure< shall !e used to verify accurate test pressure readings.
?.? pressure recorder shall !e used for each system test.
?.-5n completion of tests all test !linds, temporary supports etc., shall !e removed and permanent gaskets and fittings re/installed. "n line "tems and internals removed for the test shall !e reinstated and carefully monitored to ensure their correct locations. #5MP46 and PF$ @# )ngineers shall witness these activities.
?.2'elevant, approved "TP%s will !e strictly adhered to. ll "TP =Hold Points> shall !e notified to and witnessed !y PF$ 7 #5MP46 @9@# )ngineers and the S, as applica!le.
?.B ll tests shall !e witnessed and records signed off !y #5MP46 @9@# "nspectors, PF$, Statuatory uthorities and T%s as applica!le. Test documentation shall !e used as attached to "TP I 3? I Pressure Testing of Piping.
?.Cll originals of test records and inspections shall !e retained !y #5MP46 for inclusion in the final hand over documentation. #opies of such shall !e made availa!le for PF$ and the S as applica!le.
6.0
SAFETY
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ll personnel shall adhere to the #5MP46 and PF$ Safety Programmes.
-.1
#5MP46 Management and Supervision shall encourage all personnel to !e pro/active in the promotion of the ""F culture.
-.+ ll personnel shall !e issued with and shall use the re8uisite PP).
-.3 $aily Tool *ox talks shall !e held with all personnel.
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ST reviews shall !e made prior to testing commencing and shall !e reviewed and amended as re8uired on a daily !asis.
-.- The ') shall apply for all necessary permit;s< with all re8uired documentation and drawings etc.
-.2 ll lifting )8uipment shall !e duly certified 9 tagged and fit for the intended purpose.
-.B ll electrical e8uipment shall !e inspected for electrical safety and appropriately tagged.
-.C
ll scaffolding shall !e erected !y 8ualified personnel and the =Scaff Tag> system of inspection and use shall !e used. "nspections shall !e carried out on a weekly !asis or as re8uired
-. ll test e8uipment shall !e of good working order and fit for the intended purpose. They shall !e tested and cali!rated !y the approved authority per specification.
-. ll safety pressure relief devices shall !e tested and cali!rated !y the approved authority per specification. &alid test certificates shall !e availa!le for inspection.
-.1 .Pressure testing area is to !e cordoned and sign posted with suita!le warning signs ;two languages<.
-.+ Test systems shall !e fully attended at all times when under pressure
-.3 5n completion of tests the systems shall immediately !e depressurised and vented in a gradual and safe manner. "t shall !e ensured that all vents have !een opened prior to draining commencing.
