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TWO GAS COMPRESSOR STATIONS PROJECT-IGAT IV

DEHAGH & POLKALEH STATIONS


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DP PI SP DEH I 1000 2 Code: 2

FIELD PRESSURE TESTING


SPECIFICATION
(DEHAGH)

Client Approval:
Approved Name: Date: Sign:
Commented
2 27.10.09 APPROVED A.S. M.R.J. M.M.
1 29.08.09 APPROVED A.S. H.G. M.M.
0 05.08.09 ISSUE FOR APPROVAL (ENDORSED) H.G. M.M. M.SH.
PCE-01 86.12.20 ISSUE FOR APPROVAL .M.A.A .N.R.H .G.N.A
Rev. Date Description Prepared By Checked By Approved By
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TABLE OF CONTENTS
TWO GAS COMPRESSOR STATIONS PROJECT-IGAT IV
DEHAGH & POLKALEH STATIONS
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DP PI SP DEH I 1000 2 Code: 2

1. General
2. Site location and conditions
3. Standards and codes
4. Testing mediums
5. Hydrostatic testing calculation for internal pressure piping
6. Pneumatic testing
7. Preparation for pressure testing
8. Procedure for testing of piping
9. Time of test
10. Test records
TWO GAS COMPRESSOR STATIONS PROJECT-IGAT IV
DEHAGH & POLKALEH STATIONS
IGEDC
DOC. TITLE: FIELD PRESSURE TESTING SPECIFICATION
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DP PI SP DEH I 1000 2 Code: 2

1-General
1-1This specification covers the minimum requirements of hydrostatic and pneumatic
testing of piping, equipment and instruments services.
1-2In case of any conflict between this specification, relevant data sheet and related
documents and standards, supplier shall consider the stricter standard and shall confirm with
the CLIENT.
1-3Definitions
I.G.E.D.C Owner:
Purchaser / EPC Contractor: Party which carries out all or part of procurement for the project
.which to be specified later
Vendor: Party which manufactures or supplies equipments & performs the services & duties
.specified by purchaser
2-Site location and conditions
Site location and conditions are given in the Site condition (DEHAGH) No. DP-PE-SP-DEH-
I-1002

3-Standards and codes


ASME B31.8 Gas transmission and distribution piping systems
ASME B31.3 Process piping
IPS-C-PI-350 Construction standard for plant piping systems-pressure testing
4-Testing mediums
4.1Testing shall be hydrostatic, using water unless otherwise noted on the Pressure Test
Flow Diagrams.
4.2In systems where residual moisture cannot be tolerated, oil is the preferred test
medium. If water has to be dried out with hot air special attention should be given to points where
water may be trapped, such as in valve bodies or low points. Stainless steel lines shall not be
tested with water containing more than 30 PPM of chloride.
4.3Where hydrostatic testing would be impractical, pneumatic testing will be specified on
the drawings. The pneumatic test will be performed strictly in accordance with ASME B31.3 and
TWO GAS COMPRESSOR STATIONS PROJECT-IGAT IV
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DP PI SP DEH I 1000 2 Code: 2

all safety conditions are strictly adhered to, prior and during the test for each system. All
pneumatic tests need Prior permission of owner.
4.4The following are usually excluded from hydrostatic testing, and are usually tested with
compressed air and soap suds:
4.4.1Instrument airlines (test with dry and oil free air only).
4.4.2Airlines to air operated valves. (Test with dry and oil free air only).
4.4.3Very large (usually over 24) gas or steam overhead lines (max. design pressure 4.5
barg)
4.4.4Pressure parts of instruments in gas or vapor service.
4.5If investigation determines that testing is required for relief or blow down header
system, they need only be tested for tightness with soapsuds at 0.4 bars (5 psi) air pressure.
4.6Piping with lining subject to damage by water shall be investigated.
5-Hydrostatic testing calculation of internal pressure piping
5.15-1 For pressure piping systems the hydrostatic test pressure shall be 1.4 times
(minimum) the design pressure (DP), where design pressure is maximum operating pressure
(MOP) times 1.1 (MOP X 1.1) or (MOP+30 PSIG) whichever is greater.

5.2The test pressure for utility piping system in accordance with ASME B31.3 shall be
determined by the following equation:
Pt = F*P
Where Minimum hydrostatic test pressure. Kg/cm2 g
=
Pt
P = Internal design pressure Kg/cm2
F = Factor, (1.5 St) / S
St = Allowable stress at 37.8 C (100F)
Allowable stress at design temperature. (See table A-1, appendix A, ASME
S =
B31.3-1996)

Note: See table A-1, APPENDIX A, ASME B 31.3 (The latest version)
TWO GAS COMPRESSOR STATIONS PROJECT-IGAT IV
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5.3Where the pipe work being tested contains flanges, the test pressure as determined in
paragraph 5.2 for piping should be in accordance with Section 8 of steel pipe flanged fittings,
ASME B 16.5.
6-Pneumatic testing
If piping is tested pneumatically, the test pressure shall be 110% of design pressure. When
performing any pneumatic test, pressure shall be increased gradually in steps, allowing sufficient
time for the piping to equalize strains during test. All welded, flanged or screwed joints shall be
swabbed with soap solution during these tests, for detection of leakage. Pneumatic test procedure
shall be according to ASME B31.3.

- The gas used as test fluid, if not air, shall be nonflammable and nontoxic.
- A pressure relief device shall be provided, having a set pressure not higher than 10% of
test pressures.

7-Preparation for pressure testing


7.1At the beginning of hydro test, the contractor shall make sure that all welding works are
completed and the following documentation shall be approved by Employer before construction
contractor starting the hydro test:
7.1.1All reports of NDT shall be prepared and submitted by the Contractor to the Client.
7.1.2Test drawing such as hydro test diagram, marked P&ID according to hydro test
diagram, as-built isometric drawings to indicate joints of welds.
7.1.3For performing the hydro test, a checklist for piping system shall be prepared and
submitted by the Contractor to the Client.
7.2All lines should be cleared of debris by flushing with water or blowing with steam or
air-Precautions should be taken to ensure that debris is not flushed into associated vessels,
equipment or dead ends.
7.3Pressure relief valves shall be excluded from the general pressure tests. Blinds shall be
installed immediately adjacent to their inlet or outlet flanges during tests.
TWO GAS COMPRESSOR STATIONS PROJECT-IGAT IV
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7.4Screwed relief valves shall be removed and the connections temporarily plugged or
capped during the tests.
7.5Pipe supports and anchors should be fitted prior to pressure testing. In certain cases
temporary or additional supporting of pipe-work may be required due to weight of the testing
medium.
7.6Welded, flanged or screwed connections must not be painted or other wise covered
before completion of pressure testing.
7.7Where soft-seated ball valves are in the line, these must be blinds off on the pressure
side of the line at the ball valve flanges if such a valve is within the line being tested it shall be in
the fully open position. Gate and globe valves should be opened until the back seat is fully
engaged. Testing may take place against gate and globe valves; however the Contractor should be
aware that valve seats might not necessarily be bubble tight shut off.
7.8Investigation of check valves should be considered to determine whether or not the
flapper should be removed or jacked up.
7.9Lines that have spring hangers or are counterweight supported shall be temporarily
provided with additional supports during testing in order to sustain the weight of the test fluid.
Sometimes spring hangers are provided with stops for carrying the test load and need not be
blocked up.
7.10Plug and/or temporary pieces shall be installed in place of instrumentation (i.e.
press. /temp. Gauges, control valves, venturi, orifice plates, gauge glasses, etc.) and expansion
joints unless otherwise noted.
7.11All required stress relieving, radiographic test, etc. of field welds must be completed
and accepted before these particular lines are tested.
7.12All joints, including welds are to leave un-insulated and exposed for examination
during the test.
7.13Piping designed for vapor or gas shall be provided with additional temporary
supports, if necessary.
7.14Equipment, which is not to be subjected to the pressure test shall be either
disconnected from the piping or isolated by blinds during the test.
TWO GAS COMPRESSOR STATIONS PROJECT-IGAT IV
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7.15Rupture disks, orifice plates, venture type flow meters (flanged), internal parts of
equipment) trays, level instrument floats, float cages, etc.) If included in the test system, internals
of strainers and filters, steam/air traps shall be removed or blanked off prior to flushing/testing.

8-Procedure for pressure testing of piping


8.1Pressure test system shall be developed by the Contractor, testing as much piping as
possible at one time without exceeding the allowable test pressure of the weakest element in the
system. Alternatively the Contractor may utilize his own established testing procedures. These
shall be submitted to the Employer for approval at the earliest possible date prior to the testing
being carried out.
8.2The test pressure on any section of piping shall not exceed the test pressure permitted
for any vessel, exchanger, heater or other equipment operating with this pipe, when approved by
the Client, and provided the vessel test pressure is not less than 77% of piping pressure test.
8.3For convenience, exchanger and/or vessels may be tested simultaneously with
connected piping, provided, the test pressure of both the connected piping material and equipment
does not exceed the maximum allowable pressure. Vessels shall not be tested with the piping when
the following conditions apply:
8.3.1Large vessels, which would overload the foundation or support, if, filled with water.
8.3.2Large vessels requiring too much water to fill.
8.3.3Vessels with internals, which would be damaged by water.
8.3.4Vessels, which are extremely difficult to drain or vent.
Note: When vessels or tanks are drained, vent shall be opened to avoid pulling any Vacuum.
8.4When conditions require that a pressure test be maintained for a period of time during
which the testing medium in the system would be subject to thermal expansion, provision should
be made for relief of excess pressure.
8.5During hydrostatic testing, care must be exercised to limit the applied pressure to any
particular portion of the system designated on the field pressure test flow diagram.
8.6Care must be taken to avoid overloading any parts of supporting structures.
TWO GAS COMPRESSOR STATIONS PROJECT-IGAT IV
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8.7Vents or other connections shall be opened to eliminate air from lines, which are to
receive a hydrostatic test. Lines shall thoroughly be purged of air before hydrostatic test pressure
is applied. Vents shall be open when systems are drained so not to create buckling from a vacuum
effect.
8.8Short pieces of piping, which must be removed to permit installation of blind or blank,
should be tested separately.
8.9Resetting of lines after repair by welding shall be done at pressure originally specified
for the test.
8.10Lines containing check valves shall have the source of pressure located in the piping
upstream of the check valve so that pressure is applied under the seat. If this is not possible, the
check valve flapper shall be removed or jacked up.
8.11Seats of valves shall not be subjected to a pressure in excess of the maximum cold
working pressure of the valve.
8.12If the test pressure is the same upstream and downstream of a control valve, the block
and by pass valves shall be left open, with the control valve open or closed (whichever is most
convenient).
8.13If the test pressure is different upstream and downstream of a control valve, the test on
the upstream portion shall be made with the by pass valve closed, upstream block valve open,
downstream block closed and control valve open. Control valves and heat exchangers should, be
isolated from the piping until the initial flushing of the system is completed, where flushing passes
through a control valve, the valve seat must afterwards be cleaned under supervision of authorized
personnel. Flushing should not be carried out through machinery, globe and control valves, soft-
seated valves, or through any other equipment, which the flushing might damage.
8.14Test pressure shall be taken at the lowest point of a line or test system
8.15All plain test blanks required for field-testing of lines shall be made in the field.
Allowable test pressure for various thicknesses shall be presented in detail design stage of this
project. Plates of varying thickness will be included in the miscellaneous material, purchased for
construction.
TWO GAS COMPRESSOR STATIONS PROJECT-IGAT IV
DEHAGH & POLKALEH STATIONS
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8.16After completion of hydrostatic testing, all temporary blanks and blinds shall be
removed and all lines completely drained. Valves, orifice plates, expansion joints and short pieces
of piping, which have been removed, shall be reinstalled with proper and undamaged gaskets in
place. Valves, which were closed solely for hydrostatic testing, shall be opened. After lines have
been drained with vents open, temporary- piping supports shall be removed so that insulation and
painting may be completed.
8.17Flanged joints at which blinds are inserted to blank off equipment during the test need
not be tested.
8.18Underground lines shall be tested before back filling.
8.19After completion of the hydrostatic testing, all screwed plugs shall be seal welded,
except noted.
9-Time of test
9.1Tests shall be applied after erection and before equipment is initially placed in service
9.2All joints including welds shall be exposed during test.
9.3All lines shall be tested prior to coating, wrapping or insulation. Lines may be painted
except on welded, screwed, or flanged joints.
9.4The pipe shall be held during test without any loss in pressure prior to requesting
Employer to witness and accept test.
9.5Duration of test for process & utility piping system shall be as follows:
9.5.1Minimum 2 hours for process & utility piping system according to ASME
B31.8.
9.5.2Minimum 60 minutes for utility piping system (ASME B31.3) according to IPS-
C-PI-350.
9.6Rainfall or snow on an exposed line may result in non-acceptance of the test until
outside of the system is sufficiently dry to make an inspection.

10-Test records
TWO GAS COMPRESSOR STATIONS PROJECT-IGAT IV
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Records shall be made of each piping installation during the testing, which will include:
10.1Date and duration of time of test.
10.2Identification of piping and equipment being tested.
10.3Test medium used.
10.4Test pressure.
10.5Approval by the Client's inspector.
10.6Records Shall Include:
Detail of the testing and examination procedure.
Examination personnel qualification.
Certification of satisfactory results by the Client or certifying authority.
Pressure gauge, calibration/ test certificates.
10.7For more accuracy, test gauges graduated in psi units shall be used.
10.8Test gauges shall be selected so that their max. Graded value is 1.5 to 2 times the test
pressure.