Pressure Test & Test Pack Management

Project N° Unit Document Code Serial N° Rev.
Page
076551C 000D PP 813 G 1/38
TECNICAS REUNIDAS SAMSUNG ENGINEERING
The present document or drawing is property of THE BAHRAIN PETROLEUM OWNER B.S.C. (CLOSED) (BAPCO) and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in
Bapco Doc. No. : 000-A-PRO-50102-001
BAPCO MODERNIZATION PROGRAM
PIPING SYSTEM PRESSURE TEST

AND
TEST PACKAGE MANAGEMENT PROCEDURE
Unit No.: 000 – Common

Material Classification: A
Equipment Nos.: N/A
Purchase Order No.: N/A
any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.
ISSUE FOR REVIEW (AFTER OWNER COMMENTS, E. KIM - F.TATA NARDINI –

G 10/09/19
TRANSMITTAL N BMP-DIR-TRE-000523)
G.M. RASCELLI – A.C.CELIK N.KIM – F.TERENZI
A.DI MARIO
F 24/07/19
G.M. RASCELLI – A.C.CELIK N.KIM – F. TERENZI
A.DI MARIO
E 28/06/19
G.M. RASCELLI – A.C.CELIK N.KIM - S.FIDICCI
A.DI MARIO
D 22/03/19
G.M. RASCELLI – A.C.CELIK N.KIM - S.FIDICCI
A.DI MARIO
C 27/02/19 G.M. RASCELLI - J.GUTIERREZ N.KIM - S.FIDICCI
TRANSMITTAL N BMP-DIR-TRE-000404) A.DI MARIO
B 27/11/18 G.M. RASCELLI - J.GUTIERREZ N.KIM - S.FIDICCI
TRANSMITTAL N BMP-DIR-TRE-000155) A.DI MARIO
M.LUCARELLI / E. KIM - F.TATA
A 25/07/18 ISSUE FOR REVIEW G.M. RASCELLI - J.GUTIERREZ N.KIM - S.FIDICCI
NARDINI, A.DI MARIO
REV. DATE STATUS WRITTEN BY CHECKED BY APPROV./AUTHOR. BY
(DD MMM YY) (name & visa) (name & visa) (name & visa)
DOCUMENT REVISIONS
TTSJV W.L.L. – Riffa AlHajiyat – Blk. 939, Rd. 3901, Bldg 98, Flt. 33 – Kingdom of Bahrain
Project N° Unit Document Code Serial N° Rev. Page

076551C 000D PP 813 G 2/38
Bapco Doc. No.: 000-A-PRO-50102-001

PIPING SYSTEM PRESSURE TEST AND TEST PACKAGE MANAGEMENT
INDEX
1 GENERAL.................................................................................................................................. 3
1.1 Scope .................................................................................................................................. 3
1.2 Definitions ........................................................................................................................... 3
1.3 Reference Documents ........................................................................................................ 4
1.4 Acronyms ............................................................................................................................ 5
2 TESTING ACTIVITIES ............................................................................................................... 5
2.1 General ............................................................................................................................... 5
2.2 Test Package (Engineering Phase) .................................................................................. 5
2.2.1 Test Package Folder (TPF) ............................................................................................. 6
2.2.2 Test Package Flow Chart ................................................................................................ 6
2.2.3 Test Package Folder management ................................................................................. 6
2.2.4 Test Package Folder issue .............................................................................................. 7
2.3 Test Preparation (Construction Phase) ............................................................................ 7
2.3.1 Punch Listing ................................................................................................................... 8
2.3.2 QC Reviewing ................................................................................................................. 9
2.3.3 Test Preparation .............................................................................................................. 9
2.4 Test Execution (Construction Phase) ........................................................................... 14
2.4.1 Test Authorization ....................................................................................................... 14
2.4.2 Service Test ................................................................................................................. 15
2.4.3 Visual Inspection Test ................................................................................................ 15
2.4.4 Hydrostatic Test .......................................................................................................... 15

2.4.5 Pneumatic Leak Test................................................................................................... 17
2.5 Pipeworks after Test ....................................................................................................... 18
2.5.2 Reinstatement (Construction/Precommissioning phase) ......................................... 18
3 MODIFICATIONS .................................................................................................................... 19
3.1 Modifications ................................................................................................................... 19
3.2 Tie-in (battery limits) ....................................................................................................... 20
3.3 Golden Joints (Closure Weld) ......................................................................................... 20
4 APPENDIX ............................................................................................................................... 21
4.1 APPENDIX ........................................................................................................................ 22
4.2 APPENDIX ........................................................................................................................ 24
4.3 APPENDIX ........................................................................................................................ 28
4.4 APPENDIX ........................................................................................................................ 31
4.5 APPENDIX ........................................................................................................................ 34
4.6 APPENDIX ........................................................................................................................ 37
076551C 000D PP 813 G 3/38

1 GENERAL
1.1 Scope
1- This procedure defines OWNER, CONTRACTOR and SUBCONTRACTOR duties and
responsibilities on Piping Pressure Test preparation, execution, and reinstatement.
2- The icon highlights those actions which deserves maximum

caution during execution
3- This procedure refers to the Project Specification and Codes listed below in the para.
1.3, giving additional requirements and defining the Management of the Piping Pressure
Test and related Test Flow Diagram.
4- This procedure does not apply the piping services such as HVAC & plumbing and all
piping systems under Building Quality Control Plan, and sewer (under Civil Quality Control
Plan).
5- In the case of conflict and or discrepancies with other applicable documents, the most
stringent requirement shall be applied. Meanwhile, with reference with coordination matters,
this procedure will lead the job.
1.2 Definitions
This procedure applies the following definitions:
 Owner Bahrain Petroleum Company B.S.C. (BAPCO)

 Contractor The TTSJV between Technip USA Inc., Technip Italy
S.p.A., Tecnicas Reunidas S.A., Samsung Engineering
Co. Ltd
 Subcontractor Company that perform the Construction Works
 Test Pack Folder Dossier collecting drawings, QC Reports, and

documents belong to the same piping system (Testing

Circuit) to be pressure tested together;
 Piping System interconnected piping components listed on

mechanical piping list
 Golden Joint welded joint where, for safety, construction, schedule

or other reasons, specific NDE procedure during
construction, can be applied in lieu of pressure test.
 Pressure Test:
o Hydrostatic Leak Test: a pressure test, that uses water or another approved
liquid as test medium, to verify the integrity of the piping system for service at
design pressure.
o Pneumatic Leak Test: a pressure test that uses air or another compressed gas
as test medium.
076551C 000D PP 813 G 4/38

o Hydrostatic-Pneumatic Leak Test: a combination Hydrostatic-Pneumatic Leak

Test according to requirements of para 345.5 of ASME B31.3 and pressure
limits for the liquid filled part of the piping stated in para 345.4.2 of ASME B31.3.
(EXCLUDED)
o Sensitive Leak Test: when the sensitivity test is not less than 10-3 atm·ml/sec
under test conditions. (EXCLUDED)
o Tightness Test: a pressure test to ensure tightness of the piping system (i.e.,
no leaks in the system) at the test pressure.
 Other Test
o Service Test: a pressure test to prove the integrity of the piping system using
the service fluid at the maximum attainable operating pressure.
o Visual Inspection Test: Piping System visually examined when the piping is
operating at atmosphere conditions such as vent, drain and piping downstream
of pressure relieving devices that discharge directly to the atmosphere.
1.3 Reference Documents
This procedure refers to the latest edition and Addenda of the following codes, standards
and specifications.
1.3.1 INTERNATIONAL CODES and STANDARDS

 ASME B31.3 Process Piping
 ASME B31.1 Power Piping
 ASME B16.34 Valves Flanged, Threaded and Welded Ends
 ASME V Non-destructive examination
Code edition as defined in the CONTRACT between OWNER and TTSJV
1.3.2 PROJECT’S PROCEDURES, SPECIFICATIONS AND REQUIREMENTS

 000-A-PRO-50056-001 Inspection Coordination Procedure
 000-L-PQP-50006-001 QCP for Piping Erection
 000-L-MST-50001-001 Construction Specification for Piping

Prefabrication, Erection and Non Destructive
Testing
 000-L-MST-50003-001 Job Specification For Gaskets & Bolts
Installation (Torquing And Tensioning) During
Construction, Precommissioning And
Commissioning
 076551C-000D-NM-0022 (WILL FOLLOW WITH BAPCO CODE)
Mechanical Line List Piping
 000-A-PRO-50064-001 Handover And Punch List Procedure
 BMPS-B3 Piping fabrication, Installation and Testing
 BMPS-B12 Preparation of Test Packages, Hydrotesting
and Pneumatic Testing Guidelines
 P & ID and ISO DWGs (enclosing welding map)
 Project System list
And all the project specifications mentioned along this document
076551C 000D PP 813 G 5/38

1.4 Acronyms
BCJ Bolted Connection Joint

RFI Request For Inspection
GJ Golden Joint
NDE Non Destructive Examination
PL Punch List
PMI Positive Material Identification
PWHT Post Weld Heat Treatment
TPC Test Pack Coordinator
TPF Test Pack Folder
TPTS Test Pack Tracking Sheet
PTW Permit To Work
2 TESTING ACTIVITIES
2.1 General
 The whole Pressure Test execution is split in several main activities and phases, as follows:
 Test Package (Engineering Phase) para2.2

 Test Preparation (Construction Phase) para2.3
 Test Execution (Construction Phase ) para2.4
 Reinstatement (Constr/Precom Phase) para2.5
 Before the Pressure Test Campaign begin, all equipment and necessary materials, e.g.
manifolds, blind flanges, other fittings etc., shall be inventoried and offered to Contractor
inspection to confirm the suitability, including the calibration certificates according to
SUBCONTRACTOR Calibration Procedure. The material availability assessment shall
confirm the schedule.
 All activities related to the hydrotest shall be coordinated by the Test Pack Coordinator
(TPC). The TPC will be responsible to follow up all working phases such as:
 Coordination of the Engineering, Quality Control, and Construction team,
 Coordination of the signature of the involved personnel on TP Tracking Sheet,
 Coordination of the activities of punch list and related clearance,
 Updating the status of test packs,
 Authorization of the Pressure Test,
 Authorization of the Reinstatement,
 Authorization of control/safety valve reinstallation,
 Authorization of Instruments/Components reinstallation,
 Clearance and Closure of the Test Pack Folder,
 Both CONTRACTOR and SUBCONTRACTOR will appoint a Test Pack Coordinator in their
organization.
 Testpackage coordinators shall be experienced Construction professionals, with sufficient
knowledge, expertise and organizational skills to effectively execute the duties of the role
2.2 Test Package (Engineering Phase)
076551C 000D PP 813 G 6/38

2.2.1 Test Package Folder (TPF)

At care of the SUBCONTRACTOR the Test Pack Folder shall be prepared before Test
Execution and will include the following documents:
1. Test Package Flow Chart (from 000-L-PQP-50006-001)
2. Test Pack content (QC Form W510)
3. Test Pack Index
4. P & Id red marked up, with isolation limits identified (blind positioned)
5. Non Standard drawing for support, or special pieces
6. Mechanical Line list with test pressure value to be applied
7. ISO red marked up copy including the weld map, with blind positioned
8. Blind control sheet (QC Form BCS 01)
9. Flange parallelism / alignment & stud bolt tightening (QC Form BTCC 01)
10. Piping prefabrication summary report (form W50)
11. NDT/PMI/PWHT/HT AND MATERIAL TRACEABILITY SUMMARY (QC Form WHS)
12. Golden Joint Report (QC Form W53)
13. Valve Installation Inspection - (QC Form V 01)
14. Reinforcing pad pneumatic test - (QC Form W31B)
15. Slope Survey Report - (QC Form SS 01) Only for gravity line
16. Pipework before test (QC Form PL10)
17. Manifold pressure tested - (QC Form W12)
18. Pressure gauge calibrated – certificate
19. Water test certificate – certificate
20. Piping/Equipment internal cleaning (QC Form IC 01)
21. Pressure Test (QC Form W13)
22. Lay-up Inspection (QC Form LU01)
23. Pipework after test (QC Form PL10)
24. Inspection of Venturi, Restriction Orifice and Flow Orifice (QC Form W31A)
25. Holiday Test (QC Form W18)
26. Excavation & Backfilling (QC Form W61)
27. Pump Prealignment certification signed by construction (see para 2.5.1)
2.2.2 Test Package Flow Chart

The SUBCONTRACTOR will issue one original only of the TP Folder.
The first page of the Folder shall be the Test Package Flow Chart that shall collect all
signatures of the nominated representative of the work phases according to the defined and
planned Test Pack work sequence.
2.2.3 Test Package Folder management
The TP Folder will circulate among all personnel in charge of review or punching.
At care of the TP Coordinator the original TP folder will be transmitted to the appointed
personnel.
To facilitate the coordination of the TP Folders and the pressure testing activities the
SUBCONTRACTOR, CONTRACTOR, and OWNER personnel will attend the daily
pressure testing coordination. Purpose of the meeting is to review the schedule of pressure
testing activities, based on the follow up of the activities previously scheduled.
076551C 000D PP 813 G 7/38

2.2.4 Test Package Folder issue
1- Before issue the TP Folder for CONTRACTOR review, the SUBCONTRACTOR will
identify the complete interconnected piping (Testing Circuit) to be tested based on the Plant
System prepared by CONTRACTOR.
2- The test limits will be shown in the P& Id’s and the position of all temporary testing blinds
for blind-off will be red marked on the ISO.
3- The P& Id’s and ISO (red marked up copy) attached in the TP Folder must be the latest
revision.
4- The lines included in the test shall be listed in the form QCF W13 suitable for test
pressure record.
5- The engineering of the CONTRACTOR will review the TP Folder for:

 confirmation of the last revision of ISO,
 verification of ISO against P & Id (cross check of status revision),
 verification of the feasibility of the test circuits,
 verification of the test limits/blinds position (Blind control sheet QC Form BCS 01),
 verification of specific bolting torque is requested other than the Standard
 verification of the test pressure and medium (mechanical line list),

Warning 1: The effect of the static head of the testing liquid shall be considered within a
tested system.
 verification of additional precautions to be taken such as temporary support and/or
for barrier during pneumatic testing,
Warning 2: particular care shall be taken with large thin-walled piping where stresses due to
the hydrotest load may exceed those calculated for service requirements (MS 1320.52).
6- After review of the TP Folder, the engineering of the CONTRACTOR will sign the
tracking sheet for acceptance or comments.
7- In case of the comment, the SUBCONTRACTOR will revise and re-issue the TP Folder.
2.3 Test Preparation (Construction Phase)
1- Once the construction of the piping system to be tested is completed and the TPF has
been issued and reviewed by the piping engineer, the SUBCONTRACTOR,
CONTRACTOR and OWNER should start the actions needed before test execution, that
are:
 Punch Listing,
 QC reviewing,
 Test Preparation,
2- During the daily meeting for the coordination of the whole testing activities, the Test Pack
Coordinator will assign to the inspectors/supervisors the TP Folders to be punched &
reviewed, and those to be set up for test execution.
076551C 000D PP 813 G 8/38

2.3.1 Punch Listing
1- Once the construction is completed a jointly walk through of the lines pertaining to the
same Test Pack/Test Circuit should be performed by SUBCONTRACTOR, CONTRACTOR
and OWNER Supervisor or Inspectors.
Purpose of this walk through is to verify the construction against the Iso’s and P&Ids
2- All activities not completed or to be rectified, as result of the walk through, shall be listed
in the QC Form PL10 (See Appendix 4.4).
3- All actions listed shall be identified according to 000-A-PRO-50064-001 Handover And

Punch List Procedure
The punched items shall be managed through the QC Form PL10 up to the Test Pack
Folder close-out. through EasyPlant database).
In addition all points must be:
 Clearly identified by line/iso/area and location.

 Clearly identifying the originator
 Clearly identified; generic descriptions/requests are not admitted, such as:
o touch-up to be completed.
o insulation to be done.
o stenciling of line number and flow direction.
o installation of instruments.
 Clearly stated: If there are no punched items, QC Form PL10 shall be filled and
signed.
 Omitted when the reinstatement activity is done by precommissioning team
(see below 5).
 Omitted when there is an other monitoring organization/summary form, such as:
o Item to be reinstalled after pressure test as listed in the QC Form PL10 as
punch points categorized “B”,
o Bolted connection verified/monitored by QC Form BTC 01 and as explained

below (see 2.3.3. 2),
o Spring setting verified/monitored by Precommissioning team
 Cleared by the same organization who detected them.
 Signed off only by the authorized persons.
4- The following reinstatement actions shall not be classed as punch listing because of
under Precommissioning management, such as:
 Line cleaning.
 Line Leak Test.
 Car Seal installation
 Valve Lock Open/Close.
 Spring Hanger Pin removal & setting.
 Orifice Plate installation. (FE, RO, FO)
 Rupture/Burst Disk installation
 Corrosion Probes installation.
 Insulation Kit installation for Cathodic Protection.
076551C 000D PP 813 G 9/38

2.3.2 QC Reviewing
1- The Mechanical SUBCONTRACTOR QC is responsible to collect all information related

to the lines included in the same Test Pack such as:
 Welding map updated with the last ISO revision (red marked up copy),
 Test Pack content against the QC Form W510,
 Welding completed and accepted,
 NDE completed, accepted, and verified against the level control class (QC Form
W09), information coming from NDE SUBCONTRACTOR QC
 PWHT/HT completed, accepted, and verified against the level control class (QC
Form W09),
 PMI (Form QC22) and traceability completed, accepted, and verified against 000-B-
MST-50003-001 (included instruments),
 QC Form WHS and all other QC Forms/certificates completed and signed,
 Shop fabrication QCF W50 completed and signed,
2- The CONTRACTOR QC is responsible to verify the completeness of the Test Pack

Folder that all information/QC Forms and Certificates attached in the Folder.
The QC is also responsible to verify in particular:
 Welding completed and accepted,
 NDE completed, accepted, and verified against the level control class (QC Form
W09),
 PWHT/HT completed, accepted, and verified against the level control class (QC
Form W09),
 PMI and traceability completed, accepted, and verified against 000-B-MST-50003-
001; instruments are included,
 QC Form WHS and all other QC Forms /certificates completed and signed,
 Shop fabrication QCF W50 completed and signed.
2- The CONTRACTOR QC is responsible to verify the completeness of the Test Pack,

which was previously verified by CONTRACTOR Engineering. After all required punch
item have been closed and Test Package has been accepted by OWNER Inspector,
CONTRACTOR QC shall release the piping circuit identified into the TPF as ready for
test.
2.3.3 Test Preparation
1- Isolation Limits- The SUBCONTRACTOR is responsible to install paddle blinds or

spectacle blinds (and rated gasket up/down stream) to isolate the test section provided they
shall be the same class rating of the system or may be fabricated based on appropriate
calculations. Field Valve test reports and Instrument Calibration valid certificates (relevant
to all measurement devices used for pressure test purposes) shall be attached to each test
pack.
Warning 1: Use of the closed block valves (gate, globe, plug, ball to isolate
equipment or piping sections) shall be avoided, unless it is confirmed by
CONTRACTOR engineering and OWNER approval that the involved valves are able
076551C 000D PP 813 G 10/38

to withstand the testing pressure value. In that case, written authorization must be
attached to the test pack folder.
Warning 2: It is strictly forbidden to use Rotating Equipment Nozzles as

isolation limits
Warning 3: Non-return valves, control valves, Pneumatic or Hydraulic operated
valves or other valves which do not provide tight shut-off, must not be used
2- Non Standard Testing Blind Flanges- The SUBCONTRACTOR is responsible to issue
a procedure for classification, identification, validation and handling of the non standard
blind flanges. Non Standard Testing Blind Flanges list shall be provided to OWNER for
INFO.
 Validation: the SUBCONTRACTOR will provide the material test certificate and
calculation for thickness verification/acceptance by CONTRACTOR engineering
department.
 Welding: the SUBCONTRACTOR will issue the applicable WPS with a suitable
Preheating/Post-heating of nozzle welding. The welding joint shall be verified by
PT/MT. A RFI shall be issued.
 Handling: the SUBCONTRACTOR will provide a suitable color code to identify:

o the base material,
o suitable thickness against the test pressure.
 Precaution: the SUBCONTRACTOR cannot use the CS or Ferritic material blind

flanges in contact with austenitic Stainless Steel, Duplex SS, or Inconel 625 piping
material.
3- Gasket & Bolting - The SUBCONTRACTOR for each piping system to be tested shall
identify all bolted connections and issue a “Gasket installation and bolting torque
verification” list (QC Form BTC 01) to ensure that in each bolted connection has been
installed the right final gasket and the permanent bolts are tightened according to 000-L-
MST-50003-001 and BMPS-L14 or torque/tension value defined by the Engineering.
3.1 Tensioning. Bolted connections where bolt/nuts are to be tightened by tensioning

shall be identified prior pressure test campaign by SUBCONTRACTOR engineering,
and confirmed by CONTRACTOR engineering. SUBCONTRACTOR shall issue a
dedicated procedure for job execution including bolt tightening and its traceability in
accordance to 000-L-MST-50003-001
Permanent gasket and bolting must be installed by SUBCONTRACTOR before
the hydro-test . Proper RFI shall be issued to CONTRACTOR after gasket
installation and bolt tightening to verify and validate the BCJ before hydro-test.
The CONTRACTOR Precommissioning Team will monitor that Bolted Connection

Joints are provided with Permanent Gasket and Bolts and ensure the right
076551C 000D PP 813 G 11/38

installation and torque filling and signing off the QC Form BTC 01 already initialized
by the SUBCONTRACTOR.
 Gaskets: the SUBCONTRACTOR shall verify:

o The specification for type, size, material and colour coding,
o The alignment of the flanges,
o The equipment specification for type and material.
 Bolts/Stud bolts: the SUBCONTRACTOR shall verify:

o The specification for type, size, material and dimensions,
o The equipment specifications for the flange bolting torque or tensioning
requirements,
o the stress and yield levels on the bolts or flange and mechanical joint have not
been exceeded,
Stud bolts must have equal projection beyond nuts.
4- Vent & Drain - The SUBCONTRACTOR in addition to the process vent & drain as
requested by the P &Id should install testing vent & drain, as needed:
 Vents: shall be provided at all high points of the piping system under testing.
Warning 1: High points on associated facilities require vents so that the amount of residual
air in the system during hydro testing can be minimized.
Warning 2: Filling the test system shall only be started after it has been verified that the high
point vent is open.
 Drains: shall be provided at all low points of the piping system.
Warning 1: Low points within the system should be avoided at critical areas such as valves,
sphere toes or branch connections. Pipework should allow free drainage away from dead
ends such as tee arrangements, to prevent hydro-test water from collecting.
Warning 2: Draining shall only be started after it has been verified that the high point vents
are open.
Warning 3: The rate of drainage shall be controlled in respect to the inflow of air to the
testing system to prevent formation of a vacuum or partial vacuum.
Warning 4: Tthe piping system should contain a sufficient number of low point drains to
ensure that no water remains trapped after a hydro-test
5- Pressure Gauges - The SUBCONTRACTOR will follow the recommendation given by

spec BMPS-B12 for installation and calibration of the Pressure Gauges. The following
minimum actions/consideration should be taken:
076551C 000D PP 813 G 12/38

 Subcontractor shall prepare and submit for approval a Calibration procedure for
testing gauges
 one test gauge on piping circuit at ground nearby the test pump;
 one or more (according to circuit complexity) along the piping circuit in the highest
portion of the line, anyway at the maximum distance from one another.
Warning 1: Pressure test gauges shall have an adequate scale to the test pressure. The
full-scale value shall be in the range of 1.25 to 2 times the required test pressure.
Warning 2: Pressure test gauges shall be calibrated once a month to ensure accurate
readings.
Warning 3: Pressure test gauges shall be identified by means of a tag with pressure test
gauge item and date of last calibration.
Warning 4: Recording gauges shall be used when where it is necessary to keep a

permanent record.
6- Testing Fluid - The SUBCONTRACTOR will follow the recommendation given by spec
BMPS-B12 for Testing Fluid. The following minimum actions/consideration should be
taken:
Warning 1: During pressure test, fluid thermal expansion shall be foreseen, and then
precautions shall be taken by SUBCONTRACTOR to avoid overpressure.
Warning 2 after test the water shall not re-used for other Austenitic stainless steel, Duplex
and Inconel 625 piping system, unless the chemical and bacteriological properties are
confirmed by adequate testing and certificates (carried out/issued after previous usage) and
proper storage has been established.
Warning 3: The piping system must be drained immediately

after pressure test is completed and accepted. RFI to be
issued.
Warning 4: Lube and seal oil piping shall be hydrotested with its own fluid.
7- Equipment & Components to be excluded - The SUBCONTRACTOR will follow the

recommendation given by spec BMPS-B12 in excluding equipment and/or components.
The following minimum actions/consideration should be taken:
 Components which interfere with filling, venting, draining or flushing shall not be
installed until after line flushing and pressure testing are completed. These include
orifice plates, flow nozzles, sight glasses, venturi, positive displacement and turbine
meters and other in-line equipment.
 Equipment that shall be excluded from the testing:

o Rotating machinery, such as pumps, turbines and compressors.
o Strainers and filter elements.
o Pressure relieving devices, such as rupture disks and pressure relief valves.
076551C 000D PP 813 G 13/38

o Locally mounted indicating pressure gauges.

o Equipment that cannot be drained.
o Instrument Devices.
 Equipment may be included, after CONTRACTOR/OWNER approval, in the test
circuit if the shop test pressure is not exceeded, however it shall be verified that
equipment will not damaged by test. CONTRACTOR shall provide written approval
from Equipment Manufacturer to OWNER, and the relevant note/authorization shall
be enclosed and filed into the TPF.
Warning 1:in accordance with ASME B31.3 clause 345.4.3, 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. 345.4.2(b).
8- Precautions - The SUBCONTRACTOR is requested to take all precautions needed to
minimize the risks due to the failure during the pressure test of the piping system, such as:
 Temporary supports - Piping has to be provided by SUBCONTRACTOR with

additional temporary supports, if necessary, to support the weight of test liquid.
Warning 1: temporary supports shall be never welded to pressure retaining piping; bolted -
type temporary support shall be utilized. Whereas welded additional temporary supports will
be needed they will be used only after CONTRACTOR approval; these welds shall respect
the same weld conditions applied to the rest of piping line. Temporary supports should be
identified by yellow and red strips color painting.
Warning 2: temporary supports shall not be removed until after the system has been fully
drained.
Warning 3: temporary supports shall be identified by color code (above indicated as

yellow and red stripe). The SUBCONTRACTOR will define and implement with engineering
design of support approved. In particular: temporary support design shall be approved by
CONTRACTOR engineering and temporary supports shall be load tested at 1.5 times load
expected during hydrostatic test. Design of larger Temporary Supports (>2500N load) shall
be supported by appropriate, approved calculations. Temporary supports that have been
proof Load Tested shall be clearly, permanently marked showing the maximum safe working
load.
 Check valve - Unless there is a by-pass, the check valve shall be turned to permit
the filling and discharge. Each modified check valve shall be tagged, and such tag
easily identifiable. A record of such modified valves shall be maintained into the
Test Pack as well.
SUBCONTRACTOR under approval of CONTRACTOR could be use a rated hose

to by pass the check valve.
Warning 1: temporary removal of the disc (securely attached to the outside of the body) is
not allowed.
Warning 2: after test the check valve must be re-positioned according to the P & Id with the
final gasket and proper torque.
076551C 000D PP 813 G 14/38

 Temporary connections shall be provided for de-pressurizing and draining of the

system to the sewer or disposal area. Disposal of any/all testing water shall comply
with the requirements specified in section 2.4.4, point 6 “De-Watering”
 Spring hangers or spring supports shall be provided with temporary restraints

where needed to prevent excessive travel or deformation under the test loads
Warning 1: In case of Expansion Joints, the attentions reported at 345.3.3 of ASME B31.3
Code have to be taken into account by SUBCONTRACTOR.
 Overpressure - System being pressure tested shall be protected against the risk of
the overpressure by the following:
Warning 1: Relief valve(s) shall be provided having an

adequate capacity set to relieve no higher than the test
pressure plus the lesser of 345 KPa or 10% of the test
pressure, according to BMPS-B12. The relief valve(s)
shall be tested, dated, and tagged within one week prior
to the pressure test.
Warning 2: In addition to the pressure relieving device, a

bleed valve shall be provided to protect the piping and
equipment from overpressure. The bleed valve shall be
readily accessible in case immediate depressurization is
required.
Warning 3: An isolation valve shall be provided

between the pressure testing manifold and the system
being tested. The isolation valve shall be rated for the
manifold test pressure when in the closed position.
Warning 4: Before employing the pressure testing

manifold in the actual system pressure test, it shall be
separately pressure tested to at least 1.2 times the
system test pressure but not less than the discharge
pressure of the pump used for the pressure testing.
2.4 Test Execution (Construction Phase)
2.4.1 Test Authorization

Only the CONTRACTOR Test Pack Coordinator shall authorize the testing of the piping
system/circuit under construction verification with the OWNER, provided that:
 Punch List”: the SUBCONTRACTOR has cleared

all points classified “A” and CONTRACTOR
Supervisor/Inspector has signed off them.
 Test Package has been reviewed and accepted by
OWNER representative according to BMPS-B12
and this document.
076551C 000D PP 813 G 15/38

 NDE/PWHT/PMI: the SUBCONTRACTOR has

completed all welding activities with related
NDE/PWHT/PMI and CONTRACTOR Inspector
has signed off the QC Form WHS,
 Testing Devices: all of them are available, tested,

calibrated by SUBCONTRACTOR and verified by
CONTRACTOR Supervisor/Inspector,
 Safety Devices: the SUBCONTRACTOR has
implemented all safety precautions and
arrangements as requested by the applicable
Method Statement.
 PTW rules applied according to 000-A-PRO-

50116-001
2.4.2 Service Test

1- The integrity of the piping system shall be ensured by pressurizing the system using the
service fluid at the maximum attainable operating pressure.
2- Plant utility piping in air and inert gases services with a designed pressure and equal to
less than 1035 KPa (ga) (150 psig) should be service tested.
3- CONTRACTOR Engineer will identify piping systems that could be tested as Service
test. The list shall be submitted to OWNER for acceptance.
2.4.3 Visual Inspection Test

1- Pressure Leak Test may be replaced by a Visual Leak Test to ensure the integrity of the
piping system (or portion) when piping system is not working under pressure such as vent,
drain and piping downstream of pressure relieving devices that discharge directly to the
atmosphere/open sewer.
2- Visual Leak Test shall be done in lieu of Pressure Leak Test for circuits for which
internal lining could be affected by the pressure test or it shall be performed when the
pressure test is carried out before internal lining is applied (e.g. galvanization, FBE, rubber,
etc…) after the installation is completed.
3- The Visual Leak Test shall be performed only after clearance of the punched item list.
4- The Visual Leak Test shall be recorded with the same QC Form W13.
2.4.4 Hydrostatic Test

The SUBCONTRACTOR will follow the recommendation given by spec BMPS-B12 for
pressure testing of piping system. The following minimum actions/consideration should be
taken:
1- Final Verifications/Inspections: CONTRACTOR Supervisor/Inspector before test

pressure starting should carry out the final verification:
076551C 000D PP 813 G 16/38

 Test gauges: identified, installed and calibrated by SUBCONTRACTOR.

 Relief valve: identified, installed and calibrated by SUBCONTRACTOR.
 Manifold: identified and pre-tested by SUBCONTRACTOR.
 Water Test Certificate: valid certificate issued by SUBCONTRACTOR.
 Safety barrier: installed by SUBCONTRACTOR.
 Blind Flanges: identified and installed by SUBCONTRACTOR.
 Spring Supports: blocking pins installed by SUBCONTRACTOR
2- Joints: The SUBCONTRACTOR will leave all joints un-insulated and exposed for
examination during the test, unless authorized by CONTRACTOR/OWNER according to
ASME B.31.3.
Joints welds that are painted may be hydro/pneumatic tested without paint removal (ASME
B 31.3 clause 345.3.1).
3- Pressure Test: The SUBCONTRACTOR will connect the filling hose from the pressure
generator to the lowest drain point of the system to minimize entrapped air.
Warning 1: The isolation valve shall be closed immediately after the pressure test is
reached and stabilized and the pressure generator shall be disconnected.
Warning 2: The test pressure shall be verified at the highest point.
Warning 3: The amount of any static head acting in service and in testing must be
considered. (the static pressure caused by the content of the piping during service and/or
testing does not need to be taken into account if it does not increase the stress in the wall by
more than 5%).
Warning 4: In plant areas and shops the test area are marked and warning signs posted to
alert approaching personnel.
4- Test Duration: The final test pressure shall be maintained to permit complete inspection
of all joints for leakage or signs of failure, at least 60 minutes after stabilization.
Warning 1: In case of tests performed during rain period, CONTRACTOR together with
OWNER may, in their unobjectionable opinion, accept or not the testing under execution. In
any case the piping circuit being tested shall remain under pressure, at the testing value,
without the necessity of a further pumping or compression, for a sufficient time (4 hours).
Warning 2: If for justifiable safety reasons underground line piping must be back-filled, the
joints must be 100% radio graphed, otherwise the test shall be a 24 hour recorded test
.
Warning 3 Depressurization will be done slowly and safely after completion of test or
discovery of leaks. Bleed off the system slowly to an approved safe discharge area and
monitor discharge.
5- Test Acceptance: Any connection leaking during a pressure test shall be repaired and
retested to the specified test pressure.
Warning 1: If welds are involved in leaks and/or piping modifications, the entire piping circuit
shall be depressurized, leaks eliminated, NDE performed, certification performed, and the
piping circuit shall be retested.
076551C 000D PP 813 G 17/38

Warning 2: If flanged connections, including those that are part of components (e.g. Valves
body/bonnet and packing), leaks (if the tightening cannot eliminate them), the following shall
be done after hydro test.:
o Test circuit depressurized

o check of flange sealing surface,
o possible repair of such surface,
o replacement of gasket.
6- De-watering: Disposal of test water shall be in accordance with all local laws/regulations
(see in particular local regulatory wastewater effluent discharge requirements), and the
OWNER's facility emission standards, as stated in the appropriate "Project Specifications”.
After testing, test water shall be recovered, to the extent possible, for reuse, according to
BMPS-B12.
7- Lay-Up: Equipment must be laid-up after hydrotesting, unless it can be ensured that it
will be returned to service within 30 days from the first introduction of hydrotest water to the
system.
Lay-Up procedure shall be developed by SUBCONTRACTOR and submitted to
CONTRACTOR for approval prior the hydrotest campaign.
Ambient Lay-Up shall be followed generally as follow:
Remove all water from the circuit. For facilities other than pipes, drain the system
completely, sweep and mop as required to ensure that no visible traces of water remains.
For piping systems, dewatering shall be performed by scraping with a three-or four-cup
displacement scraper (or better) unless system limitation make this option impracticable.
After removal of all water, close the system to prevent the entry of sand or rainwater.
The Lay-up shall be recorded with the same QC Form LU01

2.4.5 Pneumatic Leak Test

The Pneumatic Leak Test shall be performed when specified in the Mechanical Line List
NM022, and the SUBCONTRACTOR will follow the recommendation given by spec
BMPS-B12 (see also appendix 4.3). As recommended, the following minimum
actions/consideration should be taken:
Warning 1: Equipment to be pneumatically tested

shall be thoroughly cleaned and free of oil/grease
deposits.
Warning 2: The required air pressure will be supplied
by a compressor. The air compressor shall be of a
portable type and equipped or provided with a
receiver, after cooler, oil separator and relief valve.
Warning 3: The compressor shall not be left
unattended during the test.
076551C 000D PP 813 G 18/38

Warning 4: Flanged joints shall be prepared for

pneumatic testing, by taping with masking tape and
punching a 1/8” (3mm) dia. Hole through the tape for
soaping (bubble testing).
Warning 5: The PSV should be suitable to release
the maximum compressor flow.
2.5 Pipeworks after Test
2.5.1 Connection with rotating machine (construction phase)
According to 000-K-MST-50001-001 “Job Construction Specification For Machinery And Air

Coolers Installation” the final alignment, free and flanged, shall be executed after pressure
test (construction phase). The relevant QCF, as per following table, shall be reported in the
Test Pack.
Machinery Type QCP Reference QCF applicable

(1)
Centrifugal and Rotary Pumps QCP 6850.01 CR 01A or CR 01B
Centrifugal Compressor QCP 6850.03 (1) CR 10A
Reciprocating Compressor QCP 6850.04 (1) CR 11A
(1) Will Follow with Bapco Code
2.5.2 Reinstatement (Construction/Precommissioning phase)
Once the test pressure is completed and accepted the SUBCONTRACTOR will proceed
with the following activities before transferring monitoring activities from Construction to
Precommissioning team:
 Fully drainage (according to Para 2.4.4 item 4) and air blowing of the piping
system under testing immediately after test completion. Acceptance criteria shall be
given by Contractor for air blowing. According to Para 2.4.4 item 4

recommendations, depressurization will be done slowly and safely to approved safe
disposal area.
Warning 1: special care MUST BE taken on piping system where the material is Austenitic
Stainless Steel (304, 316, and 321), Duplex SS, and Inconel 625. The piping system must
be drained immediately after pressure test is completed and accepted.
Warning 2 piping system drainage shall be certified. The SUBCONTRACTOR will issue a
dedicated RFI to CONTRACTOR.
 Hydrostatic Vent and Drain shall be weld sealed by the SUBCONTRACTOR

according to the applicable job specification.
Warning 1: all seal welds MUST BE PT/MT tested. The SUBCONTRACTOR will issue a
dedicated RFI.
Warning 2: PWHT shall be applied if requested by the applicable job specification (FORM
W09). The SUBCONTRACTOR will issue a dedicated RFI.
076551C 000D PP 813 G 19/38

 Reinstatement 1: SUBCONTRACTOR will provide the whole reinstatement

according to the P & Id with the following considerations/exceptions:
o Static Equipment: the nozzles shall be protected by slip blind/blinds with
gasket.
o Rotating Equipment: the nozzles shall be protected by slip blind/blinds with
gasket.
 All the bolts shall be placed but no tightening performed (at care of the pre-
commissioning machinery during the final alignment)
o Static Mixer:
 Blinded during the hydrotest: still blinded.
 Removed during the hydrotest: shall be reinstalled with nozzles protected by
slip blind/blinds with temporary gasket or returned to the CONTRACTOR
Warehouse.
o Ejectors:
 Blinded during the hydrotest: still blinded.
 Removed during the hydrotest: shall be reinstalled with nozzles protected by
slip blind/blinds with gasket or returned to the CONTRACTOR Warehouse.
o Safety Valves: once the fit-up of the valve is done during the SV inlet and outlet
pipe installation, the PSV must be returned to CONTRACTOR Warehouse
available for calibration by Precommissioning.
 The reinstallation will be performed by Precommissioning.
 The SVs counter flanges on the inlet/outlet piping shall remain protected all
the time after pressure test.
 The valve can be released by Warehouse only through a voucher signed by
Precommissioning
o On Line Instruments (Rotameter, Venturi, Vortex, LV, TV, PV, FV, PCV, XV,
etc…): they must be reinstalled with nozzles protected by slip blind/blinds with
gasket.
Warning 1: this solution allow instruments installation & checks and to execute the Loop
Check verifications.
o Trim lines: trim lines should be tested before installation. After testing and
before installation the trim lines must be precommissioned and certified by

CONTRACTOR Precommissioning/OWNER Team.
Warning1: once time the trim line is installed the SUBCONTRACTOR must protect the
flange (by blind or similar)to be connected with the instrument.
o Tie-in on the Battery Limit: still blinded after the hydrotest.
 Reinstatement 2: the final piping reinstatement activities are listed in previous

chapters/paragraphs and will be led by CONTRACTOR
Precommissioning/Commissioning team (see 2.3.1.4)
3 MODIFICATIONS
3.1 Modifications
3.1.1- After the test, modifications of the piping system could be executed.
076551C 000D PP 813 G 20/38

3.1.2- The CONTRACTOR Engineering will issue the QC Form W16 where will be explained
the reasons of the modification and shall define if the modified piping system should be re-
tested and welding, NDE, PWHT & PMI shall be performed according to the job specification,
or the welding joints (if any) shall not re-hydro tested. In this case the welding procedure and
further inspections shall be done according to the point 3.3 “Golden Joint”.
Warning 1: miss-alignment of flange after test on rotating equipment suction and discharge
shall consider as modification or rework, heating and partial welding on full
circumferential weld in order to align shall not permitted.
3.1.3- The SUBCONTRACTOR will issue an addendum to the original Test Package Folder
with the QC Form W16 and all other inspection forms requested by the rework due to the
revision.
3.2 Tie-in (battery limits)
3.2.1The CONTRACTOR will issue the list of the Plant Tie-in to be implemented and
recorded, as follows:
i. SUBCONTRACTOR to CONTRACTOR: they will be inspected and recorded

through the Test Package Folder organization.
ii. Between OWNER and Public Authority: they will be inspected and recorded as per
applicable local rule/authority .
iii. Between OWNER and Others: they will be inspected and recorded such us
golden joint (see the next 3.3) or bolt connection joint (see 2.3.3. 3)
3.3 Golden Joints (Closure Weld)
3.3.1 Anytime it is impractical to carry out the pressure test for safety or construction reasons
or other the CONTRACTOR will issue the QC Form W16 to perform the welding and related
NDE (according to Appendix 4.5 and 000-L-MST-50001-001), PWHT & PMI as replacement
of the pressure test to be submitted to OWNER for approval of Golden Joint.
3.3.2 The whole construction (welding and related inspection) must be managed as a Hold
Point and the SUBCONTRACTOR is requested to issue a dedicated RFI for each activity.
3.3.3 The CONTRACTOR and SUBCONTRACTOR will perform the same Precommissioning
activity such us cleaning, blowing, etc… before to proceed with the welding and related
inspections.
The CONTRACTOR will issue the Golden Joint list. The SUBCONTRACTOR will maintain a
separate Golden Joint Folder collecting all inspection QC Form W53 duly filled and signed off
by them and CONTRACTOR QC personnel.
The Golden Joint method statement is attached in the appendix 4.5

Project N°
076551C
4 APPENDIX
Unit
000D

PP

Document Code

813
Serial N°
G
Rev.
Page
21/38

Project N°
076551C
(test pack numbering)

Unit
4.1 APPENDIX
000D

PP

Document Code

813
Serial N°
G
Rev.
Page
22/38
076551C 000D PP 813 G 23/38

APPENDIX 4.1
(Test pack numbering)
The Test Package shall be identified by the progressive numbering as clarified below.
1 1 1 1 2 2 2 3 3 4 4 4 5 6 6
(1) System No. or Subsystem No.

(2) Project construction WBS Area – first 3 digits only
(3) Line Service Code – 2 digits only
(4) Numbering sequence starting from 001
(5) Subcontractor’s code
(6) Sub-division numbering sequence starting from 01 (when required)

Project N°
076551C
4.2 APPENDIX
Unit
000D
(duties and responsibilities)

PP

Document Code

813
Serial N°
G
Rev.
Page
24/38
076551C 000D PP 813 G 25/38

1. ENGINEERING PHASE
(preliminary 1st issue)
CONTRACTOR SUBCONTRACTOR
team activity activity
Issue the preliminary TP Folder
Precommissioning Issue the Project System List Define the Test Circuits for each Project System
Engineer Review and sign Issue the Test Package Flow Chart
Engineer Review revision & test limits Issue the P&ID with the identified isolation limits
Engineer Review revision & test limits Issue the ISO with the identified isolation limits
Engineer Review
Hand over Issue the Blind Control Sheet (form BCS 01)
Review
Manager
Review & confirm torque
Engineer Bolt Connection list and torque (form BTC 01)
values
Piping Supervisor Review Pipework after pressure test (form PL10)
(2nd issue)
Construction Appoint Test Pack Coordinator Appoint Test Pack Coordinator
Issue the Final TP Folder
Engineer Review and sign
Issue the Test Package Flow Chart
Supervisor Review and sign
Engineer Confirm last revision & test limits Issue the P&Id/ Iso’s with the test limits
Supervisor Review the test limits
Issue the Blind Control Sheet (form BCS
Hand over
Review 01)
Manager
Engineer Review & confirm torque values Bolt Connection list and torque (form
Supervisor Review split between Constr/Precom BTC 01)
Supervisor Review & confirm
Pipework after pressure test (form PL10)
Precommissioning Review & confirm
1. CONSTRUCTION PHASE – test preparation
(punch listing)
Supervisor or walk through for line check with OWNER
Pipework before test (PL10)
QC Inspector and list of points “A
Supervisor or Verification and signature of all points Clearance of all points “A”, before
QC Inspector “A” cleared testing
Supervisor or
Sign the Test Package Flow Chart Sign the Test Package Flow Chart
QC Inspector
076551C 000D PP 813 G 26/38

(QC reviewing)
Review the completeness of the TP Issue the TP Folder according to QC Form
Quality Control
folder against the QC Form W510 W510
Issue the welding map updated with the
Quality Control Welding completed and accepted
last ISO revision(red marked up copy)
Confirm Welding are completed and Declare the Welding are completed and
Quality Control
accepted accepted
Confirm that NDE completed, Declare the NDE completed, accepted, and
Quality Control accepted, and verified against the level verified against the level control class (QC
control class (QC Form W09) Form W09)
Confirm that PWHT/HT completed, Declare the PWHT/HT completed,
Quality Control accepted, and verified against the level accepted, and verified against the level
control class (QC Form W09) control class (QC Form W09)
Confirm that PMI and traceability Declare the PMI and traceability
completed, accepted, and verified completed, accepted, and verified against
Quality Control
against 000-B-MST-50003-001 000-B-MST-50003-001 53 (included
(included instruments) instruments)
Review that QC Form WHS completed Issue the QC Form WHS completed and
Quality Control
and signed signed
Review that Shop fabrication & related Issue the Shop fabrication & related QC
Quality Control
QC Forms completed and signed Forms completed and signed
Review that all other QC Forms/ and Issue the all other QC Forms and
Quality Control
certificates completed and signed certificates completed and signed
Quality Control Sign the Tracking Sheet (form W510) Sign the Tracking Sheet (form W510)
(test preparation)
Verification of proper Pressure Testing Installation of proper Pressure Testing
Supervisor
Manifold against the Pressure Test Manifold against the Pressure Test
Supervisor/ Verification of tightening of BC Joints & Tightening of Bolted Connection Joints

Quality Control Final gasket installation (form BTC01) with final gasket (form BTC01)
Supervisor/ Verification of implementation of BC Implementation of BC Joint color code
Quality Control Joint color code for identification for identification
Engineer Review of calculation Testing Blind Flange calculation
Verification of Testing Blind Flange
Testing Blind Flange fabrication,
Quality Control fabrication, identification and
identification and segregation
segregation
Supervisor/ Verification of Testing Blind Flange Installation of proper Testing Blind
Quality Control installation Flange
Supervisor/ Verification of water testing certificate – Issue water testing certificate –
Quality Control Periodical check Periodical check
Supervisor/ Verification of Pressure Gauge Issue Pressure Gauge calibration
Quality Control calibration certificate – Periodical check certificate – Periodical check
Verification of testing temporary support Installation of testing temporary support
Supervisor
installation and identification and identification
Verification of safety barrier installation Installation of safety barrier for
Supervisor/HSE
for Pneumatic Leak Test Pneumatic Leak Test
076551C 000D PP 813 G 27/38

Sign the Test Package Flow Chart,

Supervisor/ Issue RFI for Testing and sign the Test
release of Test Package for test by
Quality Control Package Flow Chart
Quality Control.
3. CONSTRUCTION PHASE – test execution

Verification of Bolted Joint retightening
Supervisor/ Bolted Joint retightening before
before pressure test attainment, if
Quality Control pressure test attainment, if necessary
necessary
Supervisor/ Verification of disconnection of pump at Disconnection of pump at pressure test
Quality Control pressure test attainment and stabilized attainment and stabilized
Supervisor/ Verification of joint leaking after Verification of joint leaking after
Quality Control pressure test attainment and stabilized pressure test attainment and stabilized
Supervisor/ Authorization of test circuit
Depressurization of test circuit
Quality Control depressurization
Supervisor/ Test completed and accepted. Signature Test completed and accepted. Signature
Quality Control of the Test Package Flow Chart of the Test Package Flow Chart
4. CONSTRUCTION PHASE – reinstatement

Supervisor Verification of water test disposal Water test disposal
Verification of drainage and blowing Drainage (lay-up) and blowing of test
Supervisor/ Quality
of test circuit and signature of the circuit and signature of the Test
Control
Test Package Flow Chart Package Flow Chart
Verification of tightening of BC
Supervisor/ Quality Tightening of Bolted Connection
Joints & Final gasket installation
Control Joints with final gasket (form BTC01)
(form BTC01)
Supervisor/ Quality Verification of implementation of BC Implementation of BC Joint color code
Control Joint color code for identification for identification
Verification of reinstallation,
Reinstallation of all items included
included items listed on form W14B.
Supervisor those listed on form W14B. Signature
Signature of the Test Package Flow
of the Test Package Flow Chart
Chart
Closure of Test pack Folder and
Test Pack Acceptance and signature
Quality Control signature of the Test Package Flow
of the Test Package Flow Chart
Chart

Project N°
076551C
(pneumatic leak test)

4.3 APPENDIX
Unit
000D

PP

Document Code

813
Serial N°
G
Rev.
Page
28/38
076551C 000D PP 813 G 29/38

APPENDIX 4.3
(pneumatic leak test)
1- Precautions
Pneumatic testing involves the hazard of released energy stored in compressed gas.
Particular care must therefore be taken to minimize the chance of brittle failure during a pneumatic
leak test.
Test temperature is important in this regard and must be considered when the designer chooses
the material of construction.
To set down properly all necessary safety precautions, Subcontractor shall evaluate the energy
contained into the pressurized system and shall report all calculation into the Pneumatic
Calculation sheet (for each pneumatic test). The Pneumatic Calculation sheet shall be attached to
the test package folder.
Reference document applicable is BMPS-B12.
2- Check of Test Equipment before Applying Pressure
The test equipment shall be examined before pressure is applied to ensure that it is tightly
connected.
All items not subjected to the test pressure shall be disconnected or other suitable means.
3- Pressure Relief Device
A pressure relief device shall be provided, having a set pressure not higher than the test pressure
plus the lesser of 345 kPa (50 psi) or 10% of the test pressure.
4- Test Fluid
The gas used as test fluid, if not air, shall be non-flammable and non-toxic.
5- Test Pressure
The test pressure shall be 110% of design pressure.
6- Procedure
The pressure shall be gradually increased until a gage pressure which is the lesser of one-half the
test pressure or 170 kPa (25 psi) is attained, at which time a preliminary check shall be made,
including visual examination of joints in accordance with ASME B 31.3 para. 341.4.1(a).
Thereafter, the pressure shall be gradually increased in steps until the test pressure is reached,
holding the pressure at each step long enough to equalize piping strains.
The pressure shall then be reduced to the design pressure before examining for leakage in
accordance.
076551C 000D PP 813 G 30/38

The leak test shall be maintained for at least 30 min after stabilization, and all joints and
connections shall be examined for leaks.

Project N°
076551C
4.4 APPENDIX
Unit
000D
(Pre-test punch/check list – PL10 )

PP

Document Code

813
Serial N°
G
Rev.
Page
31/38
076551C 000D PP 813 G 32/38

APPENDIX 4.4
(Pre-test punch/check list – PL10 )
Tab. 1: Punch Items Type A

CHECK LIST / ACTION A
0 Check correspondence between ISO & PID
1 check all welding are completed X
2 check that all NDT/Stress relieving done & recorded X
3 check the completeness of the test pack folder X
4 check piping for correct schedule and type X
5 check the file number has been implemented/recorded X
6 check valve/piping materials X
7 check the ratings of forged steel fittings X
8 check that the branch reinforcement is correct X
9 check for correct flow through check valves, globe valves and control valves X
10 check valve identification and its label X
11 check sealant on screwed connections is as per specification X
12 check the valves within test limits to be opened more than 50% X
13 check seat ratings of closed valves X
14 check that the internals of check valves have been removed or restricted X
15 check that all extended spindles required for specified valves have been installed X
16 check that spectacle blinds are in the correct flow position X
17 check the painting cycle applied X
18 check flanges pump parallelism/alignment are verified X
19 check the bolts/gasket and appropriate torque is applied at mechanical joints X
20 check that all pipe supports are completely installed X
21 check if pipe supports are sufficient X
22 check if anchors are installed X
23 check if guides are installed X
24 check if proper shoes installed and welded X
25 check if temporary pipe supports have been properly installed X
check that all gags are properly installed on spring pipe supports & expansion X
26
bellows
27 check if support clips, shoes and guides on lines have been correctly installed X
28 check if insulation welded supports are installed X
29 check clearances for insulation between other lines, conduit tubing, equipment X
30 check that the internal weld penetration of all orifice flanges have been ground X
31 check that all process vents & drains are installed X
32 check if temporary vents & drains for testing are required X
check water test certificate (Cl- max 50 ppm for SS material and 250 ppm for CS
33 X
material)
34 check pressure testing gauges calibration is correct X
35 check relief testing valve calibration is correct X
36 check that orifice flanges have required upstream & downstream clearances X
076551C 000D PP 813 G 33/38

Tab. 2: Punch Items which does not hold the circuit pressure test (could not be A Items)
CHECK LIST / ACTION
1 check for correct flow through filters & strainers, traps

2 check that all process blinds & spades have been correctly installed as per P&ID
3 check that specified block valves have locking devices correctly installed
4 check that chain wheels for specified valves correctly installed
5 check for correct flow through filters and strainers, traps, check valves & globe valves
6 check that all pump suction strainers have been correctly installed
7 check if Form BTC01 for bolted connection joints is issued
8 check orifice valve tap orientation
9 check that control valves have been installed in the correct flow position
10 check that all thermo well have been correctly installed
11 check that valves of pressure gauges have been correctly installed
12 check that valves at meter runs have been correctly installed
13 testing vents & drains to be sealed & NDE/PWHT verified

Project N°
076551C
4.5 APPENDIX
Unit
000D
(method statement for Golden Joint)

PP

Document Code

813
Serial N°
G
Rev.
Page
34/38
076551C 000D PP 813 G 35/38

APPENDIX 4.5
(Method Statement for Golden Joint)
1- The CONTRACTOR Field Engineer will issue and keep updated the list the Golden Joint (or
closure weld). The Golden Joint could be specified after the piping system pressure test due to
some modification.
2- The Field Engineer on the QC Form W16 (Modification after Test Pressure) will assign the
progressive number GJ XXX when the Golden Joint procedure should be implemented when the
hydrotest repetition of the piping system could be waived. The waiver should be based on:
 Safety concerns
 Unavailability of the intercepting valves (too far).
 Criticality of the service (fluid, temperature and pressure).
 Unavailability of the testing medium.
 Criticality of the Construction/Precommissioning stage (i.e. material unavailability).
 Temporary Construction.
 Constructability sequence.
NOTE: golden joints are different than joint executed due to modification after pressure test (see
above). SUBCONTRACTOR Engineering should study the configuration of the Piping System and
prepare a list of proposed GJ to be reviewed by CONTRACTOR/OWNER.
3- The inspections shall be fully witnessed and split in two steps:
 Precommissioning activities:
o Inspection related to the activities could not be performed later the welding,
such us cleaning, blowing, or etc…
o The Precommissioning Manager will define which activities to be performed

in the earlier stage and will sign the QC Form W53 after inspection and
before the welding of the Golden Joint.
 Construction activities.
o Inspection related to the welding activities and their NDE, as applicable.
o The NDE/PWHT shall be as minimum in accordance with project

specification 000-L-MST-50001-001 QC Form W09.
4- The SUBCONTRACTOR shall issue the RFI before Precommissioning and before joint fit-up.
076551C 000D PP 813 G 36/38

5- For each Golden Joint, the following inspections shall be always performed and recorded on QC
Form W53:
 Dimensional check of fit-up,
 PT/MT on bevels of P22 pipe (Chromium-Molybdenum)
 PT/MT after 2nd pass. (cooling and pre-heating shall be executed according to
applicable WPS and shall be strongly monitored)
 PT/MT after welding completion (cooling and post-heating shall be strongly

monitored),
 RT after welding completion. (Advanced UT can be used as alternative, only upon

CONTRACTOR QC Manager authorization, refer to 000-L-MST-50001-001).
 UT after welding completion, in addition to RT for rating  900.
6- The following data shall be verified and recorded on QC Form W53:
 Welding Procedure Specification reference,
 Welder ID,
 Date and starting/completion time,
 Amperes/Volts at beginning and each third of the welding,
 Heat input, each 10mm of piping wall thickness,
 PMI of Filler Metal (test per batch can be accepted),
 PMI of Weld Metal and two adjacent Base Metals,
 Material Traceability or File Number,

 Pre-heating and Post- heating, when applicable,
 PWHT and Hardness Test, when applicable.
 Golden Joint dossier: copy of W 16 only for GJ coming from modifications, P&D red
mark, OWNER approval

Project N°
076551C
4.6 APPENDIX
Unit
000D
(QC Forms applicable list)

PP

Document Code

813
Serial N°
G
Rev.
Page
37/38
076551C 000D PP 813 G 38/38

APPENDIX 4.6
(QC Forms applicable list)
LIST
#
QCF rev DESCRIPTION
1 WHS A NDT/PMI/PWHT/HT AND MATERIAL TRACEABILITY SUMMARY
2 V01 A VALVE INSTALLATION INSPECTION
2 W13 A PIPING PRESSURE TEST REPORT
3 PL10 A PUNCH LIST ITEM
4 W14 A DIMENSIONAL CHECK
5 W16 A MODIFICATIONS AFTER PRESSURE TEST (LINE/ISO CHECK REPORT)
6 W18 A HOLIDAY DETECTOR TEST
7 W31A A INSPECTION OF VENTURI, RENSTRICTION ORIFICE AND FLOW ORIFICE
8 W50 A PIPING PREFABRICATION SUMMARY REPORT
9 W 510 A TEST PACK CONTENT
10 PL10 A PIPEWORK AFTER TEST
11 BCS 01 A BLIND CONTROL SHEET
12 BTC 01 A FLANGE PARALLELISM/ALLIGNMENT & STUD BOLT TIGHTENING
13 W53 A GOLDEN JOINT REPORT
From
14 000-L-PQP- - TEST PACKAGE FLOW CHART
50006-001
15 IC 01 A PIPING/EQUIPMENT INTERNAL CLEANING
16 W 31B A REINFORCING PAD PNEUMATIC TEST
17 SS 01 A SLOPE SURVEY REPORT
18 W 53 A GOLDEN JOINT REPORT
19 W 16 A MODIFICATIONS AFTER PRESSURE TEST
20 W 12 A INSPECTION REPORT
21 W 18 A HOLIDAY DETECTOR TEST
22 W 61 A SECTION EXCAVATION & BACKFILLING
23 VARIOUS - FINAL ALLIGNMENT (fre & flanged) AFTER PIPING P.T. (see para: 2.5.1)
PROJECT: BAPCO MODERNIZATION PROGRAM

OWNER: BAPCO
QUALITY CONTROL FORM W 510 PROJ. No.: 076551C QCF REV. SH. 1 OF 3
TEST PACK CONTENT SUBCONTRACTOR: W 510 N° _____
System Description: Test Package Nr:
POS DESCRIPTION Verified N.A.

1 BMP Test Package Cover Page
2 Test Package Flow Chart
3 Test Pack Content (W510) & Index
4 P & Id red marked up, with isolation limits identified (blind positioned)
5 Test Pack Legend and Diagram
6 Non Standard drawing for support, or special pieces
7 Mechanical Line list with test pressure value to be applied
8 ISO red marked up copy including the weld map, with blind positioned
9 Blind control sheet (QC Form BCS 01)
10 Flange parallelism / alignment & stud bolt tightening (QC Form BTC 01)
11 Piping prefabrication summary report (form W50)
12 NDT/PMI/PWHT/HT and material traceability Summary (QC Form WHS)
13 Golden Joint Report (QC Form W53)
14 Valve Installation Inspection - (QC Form VE 01 and W14)
15 Slope Survey Report - (QC Form SS 01)
16 Pipework before test (QC Form PL10)
17 Inspection of Venturi, Restriction Orifice and Flow Orifice (QC Form W31A)
18 Ready for pressure test
19 Manifold pressure tested - (QC Form W12)
20 Pressure gauge calibrated – certificate
21 Water test certificate
22 Piping/Equipment internal cleaning (QC Form IC 01)
23 Pressure Test (QC Form W13)
24 Pressure Test: DONE
25 Lay-up Inspection
26 Pipework after test (QC Form PL10)
27 Holiday Test (QC Form W18)
28 Final alignment (free and flanged) after Piping Pressure Test (see para. 2.5.1)
29 Excavation & Backfilling (QC Form W61)
TEST PACK CLOSED
INSPECTORS SUBCONTRACTOR CONTRACTOR OWNER

NAME
SIGNATURE
DATE
TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68


OWNER: BAPCO
QUALITY CONTROL FORM W 510 PROJ. No.: 076551C SH. 2 OF 3
TEST PACK LEGEND AND DIAGRAM SUBCONTRACTOR:
TEST MANIFOLD WITH

TM PRESSURE TB TEST BLIND
INDICATOR
FP FILLING POINT HP HIGHEST POINT
TV TEST VENT LP LOWEST POINT
PG PRESSURE GAUGE PSV

PRESSURE RELIEF
VALVE
TR TEMPORARY REMOVE TP TEMPORARY

SPOOL
TO TEST OPEN TC TEST CLOSED
TEMPORARY
TPG TEMPORARY PLUG TI
ASSEMBLY WITH
PRESSURE
INDICATOR
RI REMOVE INTERNALS TEST LIMIT


OWNER: BAPCO
QUALITY CONTROL FORM W 510 PROJ. No.: 076551C QCF Rev SH. 3 OF 3
TEST PACK LEGEND AND DIAGRAM SUBCONTRACTOR:

OWNER: BAPCO
QUALITY CONTROL FORM W 12 PROJ. No.: 076551C QCF REV. SH. 1 OF 1
INSPECTION REPORT SUBCONTRACTOR: W 12 N° ____
CIVIL PIPING MACHINERY ELECTRICAL STEEL STRUCT.
BLDG MECHANICAL TANK/SILOS PAINTING INSTRUMENT
NDT LINING FURNACE INSULATION
INSPECTION REPORT
1. PURPOSE OF THE INSPECTION _________________________________________________________________
2. REF. QCP _________________________ CHECK/INSPECTION Nr. _______________________________
3. AREA _____________________________ UNIT ____________________________
4. ITEM IDENTIFICATION _________________________________________________________________
5. DRAWING & REV. _________________________________________________________________
_________________________________________________________________
TYPE OF INSPECTION
___________________________ TEST / EXAMIN
___________________________ CHECK
___________________________
6. INSPECTION RESULT: ACCEPTED REMARKS:
WITH REMARKS
7. ATTACHMENT:
INSPECTORS SUBCONTRACTOR CONTRACTOR OWNER

NAME
SIGNATURE
DATE
PROJECT: BMP - BAPCO MODERNIZATION PROGRAM
TEST PACK N.:
TYPE OF TEST:
TEST MEDIUM:
TESTING PRESSURE:
MIN TEST PRESSURE/MAX TEST PRESSURE
MINIMUM HOLD TIME WITH TEST CIRCUIT PRESSURIZED
SYSTEM:
SUB-SYSTEM:
REMARKS:
TEST PACK APPROVAL
Subcontractor Contractor Client

Name: Name: Name:
Date: Date: Date:
Signature: Signature: Signature:
RELEASE FOR TEST

Name: Name: Name:
Date: Date: Date:
REINSTATEMENT/FINAL RELEASE AFTER TEST

Name: Name: Name:
Date: Date: Date:
General Note:

Pressure Test &amp; Test Pack Management

Загружено:

Сведения о документе

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Pressure Test &amp; Test Pack Management

Загружено:

Авторское право:

Доступные форматы

Project N° Unit Document Code Serial N° Rev.

Bapco Doc. No. : 000-A-PRO-50102-001

BAPCO MODERNIZATION PROGRAM

PIPING SYSTEM PRESSURE TEST

Unit No.: 000 – Common

ISSUE FOR REVIEW (AFTER OWNER COMMENTS, E. KIM - F.TATA NARDINI –

Project N° Unit Document Code Serial N° Rev. Page

Bapco Doc. No.: 000-A-PRO-50102-001

BAPCO MODERNIZATION PROGRAM

2.4.4 Hydrostatic Test .......................................................................................................... 15

Bapco Doc. No.: 000-A-PRO-50102-001

BAPCO MODERNIZATION PROGRAM

2- The icon highlights those actions which deserves maximum

This procedure applies the following definitions:

 Owner Bahrain Petroleum Company B.S.C. (BAPCO)

 Test Pack Folder Dossier collecting drawings, QC Reports, and

documents belong to the same piping system (Testing

 Piping System interconnected piping components listed on

 Golden Joint welded joint where, for safety, construction, schedule

Bapco Doc. No.: 000-A-PRO-50102-001

BAPCO MODERNIZATION PROGRAM

o Hydrostatic-Pneumatic Leak Test: a combination Hydrostatic-Pneumatic Leak

1.3 Reference Documents

1.3.1 INTERNATIONAL CODES and STANDARDS

Code edition as defined in the CONTRACT between OWNER and TTSJV

1.3.2 PROJECT’S PROCEDURES, SPECIFICATIONS AND REQUIREMENTS

 000-L-MST-50001-001 Construction Specification for Piping

And all the project specifications mentioned along this document

Bapco Doc. No.: 000-A-PRO-50102-001

BAPCO MODERNIZATION PROGRAM

BCJ Bolted Connection Joint

 Test Package (Engineering Phase) para2.2

2.2 Test Package (Engineering Phase)

Bapco Doc. No.: 000-A-PRO-50102-001

BAPCO MODERNIZATION PROGRAM

2.2.1 Test Package Folder (TPF)

2.2.2 Test Package Flow Chart

The SUBCONTRACTOR will issue one original only of the TP Folder.

2.2.3 Test Package Folder management

Bapco Doc. No.: 000-A-PRO-50102-001

BAPCO MODERNIZATION PROGRAM

2.2.4 Test Package Folder issue

5- The engineering of the CONTRACTOR will review the TP Folder for:

 verification of the test pressure and medium (mechanical line list),

2.3 Test Preparation (Construction Phase)

Bapco Doc. No.: 000-A-PRO-50102-001

BAPCO MODERNIZATION PROGRAM

2.3.1 Punch Listing

3- All actions listed shall be identified according to 000-A-PRO-50064-001 Handover And

In addition all points must be:

 Clearly identified by line/iso/area and location.

o Bolted connection verified/monitored by QC Form BTC 01 and as explained

Bapco Doc. No.: 000-A-PRO-50102-001

BAPCO MODERNIZATION PROGRAM

1- The Mechanical SUBCONTRACTOR QC is responsible to collect all information related

2- The CONTRACTOR QC is responsible to verify the completeness of the Test Pack

2- The CONTRACTOR QC is responsible to verify the completeness of the Test Pack,

2.3.3 Test Preparation

1- Isolation Limits- The SUBCONTRACTOR is responsible to install paddle blinds or

Bapco Doc. No.: 000-A-PRO-50102-001

BAPCO MODERNIZATION PROGRAM

Warning 2: It is strictly forbidden to use Rotating Equipment Nozzles as

 Handling: the SUBCONTRACTOR will provide a suitable color code to identify:

 Precaution: the SUBCONTRACTOR cannot use the CS or Ferritic material blind

Pressure Test & Test Pack Management

Pressure Test & Test Pack Management