Piping Flushing & Pressure Testing BES-CO-05-003-02

Issuing organisation Rev: 2 / 02.10.2008

PA&E Sheet 1 / 22

PIPING FLUSHING AND

PRESSURE TESTING

BES-CO-05-003

Preparer Date Name/Position

Gino De Landtsheer / Piping Expert
02.10.2008
TSG - PTS

Issuer Date Name/Position

Hennie de Bruyn / Chief Engineer –
02.10.2008
Material Technology, PTS

Process owner Date Name/Position

02.10.2008 Jan-Olav Kvitnes/ Specs PTS

2 General update
1 Approved
Rev. Description

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TABLE OF CONTENTS

1 GENERAL....................................................................................................................................4
1.1 Validity.......................................................................................................................................4
1.2 Review Schedule.......................................................................................................................4
1.3 Group Amendment to the Borealis Engineering Specification...................................................4
1.4 Objective and Scope.................................................................................................................4
2 APPLIED STANDARDS..............................................................................................................4
2.1 Standards and Regulations.......................................................................................................4
2.1.1 European Directives...............................................................................................................5
2.1.2 Applicable Design Codes.......................................................................................................5
2.1.3 Borealis Reference Documents..............................................................................................5
2.1.4 Standards...............................................................................................................................5
3 QUALITY ASSURANCE / QUALITY CONTROL.........................................................................5
3.1 Quality Assurance / Quality Control...........................................................................................5
3.1.1 Inspection Plan.......................................................................................................................5
3.1.2 Inspection Notification............................................................................................................6
3.1.3 Inspector’s Approval...............................................................................................................6
3.2 Documentation..........................................................................................................................6
3.2.1 Quality records.......................................................................................................................6
3.2.2 Filing System..........................................................................................................................7
4 BASIC DESIGN REQUIREMENTS..............................................................................................7
4.1 General.....................................................................................................................................7
5 FLUSHING REQUIREMENTS.....................................................................................................7
5.1 General.....................................................................................................................................7
5.2 Hydro Flushing..........................................................................................................................8
5.3 Pressurised Air Shock Blowing (PAS).......................................................................................9
5.4 Pneumatic Flushing...................................................................................................................9
5.5 Hot Oil Flushing.........................................................................................................................9
5.5.1 General..................................................................................................................................9
5.5.2 Marking................................................................................................................................10
5.5.3 Documentation.....................................................................................................................10
6 PRESSURE TESTING...............................................................................................................10
6.1 General...................................................................................................................................10
6.1.1 Pressure Test Diagrams and Test Procedure.......................................................................10
6.1.2 Pressure Test Packages......................................................................................................10
6.1.3 Test Pressure.......................................................................................................................11
6.2 Preparations for Testing..........................................................................................................11
6.3 Safety and Environmental Control...........................................................................................13
6.4 Test Equipment.......................................................................................................................14
6.5 Test Medium...........................................................................................................................14
6.5.1 For Hydrostatic Testing........................................................................................................14
6.5.2 Austentic Stainless Steel......................................................................................................15
6.5.3 Ferritic Stainless Steels and Medium/High Nickel Alloys......................................................15
6.5.4 Duplex Stainless Steel.........................................................................................................15
6.5.5 9% Nickel Alloy Steel...........................................................................................................16
6.5.6 Aluminium and Aluminium Alloys..........................................................................................16
6.5.7 For Pneumatic Testing.........................................................................................................16
6.5.8 For Alternative Leak Test and for Service Test.....................................................................16
6.6 Disposal..................................................................................................................................16
6.7 Test Procedure........................................................................................................................16
6.7.1 Hydrostatic Testing...............................................................................................................16
6.7.2 Pneumatic Testing................................................................................................................17
6.7.3 Alternative to Hydrostatic or Pneumatic Pressure Testing (Alternative Leak Test)...............19
6.7.4 Initial Service Leak Test (Service Test)................................................................................19

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6.7.5 Draining and Drying..............................................................................................................19

6.7.6 Verification of Cleanliness....................................................................................................20
6.7.7 Reinstatement......................................................................................................................20
7 CHEMICAL CLEANING.............................................................................................................21
8 INSPECTION AND REPORTING.............................................................................................22
9 ATTACHMENTS........................................................................................................................22

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1 GENERAL
1.1 Validity
This specification is valid for all BOREALIS Sites.

1.2 Review Schedule

This specification shall be reviewed at least every three years.

1.3 Group Amendment to the Borealis Engineering Specification

This Borealis Engineering Specification shall consist of the ‘BES-CO-00-001; Group
Amendment to the Borealis Engineering Specifications’ which are incorporated herein and
made part here of by reference.

Content for info: General Definitions, Abbreviations, Objective and Scope, Language, Unit
System, CE-Marking, PED / ATEX / Quality Assurance / Quality Control, General Basic
Design Requirements.

1.4 Objective and Scope

It is CONTRACTOR’s responsibility, after the piping lay-out is completely installed and
before it will be put in to operation, to perform a full flushing (blow out) of the piping lay-out
and/or applicable equipment. This is to allow removal any loose debris. Only after this
action a pressure test can be performed.

A final purging phase with a temporary gas (nitrogen) or with the intended system gas
needs to be performed to assure cleanliness of the piping components.

When any requirement in this specification might violate specific requirements of a

material VENDOR necessary to warrant the integrity of supplied materials, the different
requirements must be discussed and approved by COMPANY.

2 APPLIED STANDARDS
It shall be CONTRACTOR’s responsibility to be, or to become, knowledgeable of the
requirements of the referenced Codes and Standards.

When an edition date is not indicated for a code or standard, the latest edition in force at
the time of CONTRACTOR’s commitment shall apply.

Intermediate changes or updates/revisions of applied codes, standards, regulations or

laws during the course of the project shall be brought to COMPANY’s attention. Possible
implications for the works shall be discussed.

2.1 Standards and Regulations

The design and engineering shall satisfy all laws and regulations of the national and/or
local authorities of the country in which the EQUIPMENT AND MATERIALS will be
located.

The international codes and standards, to the extent specified herein, form a part of this
specification and shall be followed. Some codes or standards (e.g. Euro codes) are still
under development and their final number and identification are given below. If the
referenced code is not yet available, it’s preceding pre-code, draft code or relevant
national codes covering the same subject shall be followed.

In case of conflict, the order of precedence shall be:

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 BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 5 / 22

1. National and/or local Laws and Regulations applicable at the location of the
site.
2. European Directives
3. Applicable Design Codes (ASME BVPC, ASME B31.3, AD2000, BS 5500, EN
13445, EN 13480, etc.)
4. Project specific CATALOGUE DATA SHEETS from the LICENSOR
5. COMPANY specifications
• Project Specification
• Local Amendment
• Common Engineering Specification
Reference to international standards (API, NFPA, etc.)

The more stringent of two conflicting regulations/standards will prevail.

In all cases CONTRACTOR shall inform COMPANY of any deviation from the
requirements in the specifications, which is considered to be necessary in order to comply
with national and/or local laws and regulations.

Deviations from this specification are subject to written approval by COMPANY. After this
approval these specifications are integral part of the contract.

The standards and codes as listed in 2.1.1, 2.1.2, 2.1.3 and 2.1.4 shall be followed.

2.1.1 European Directives

97/23 EC Pressure Equipment Directive (PED) for pressure containing
equipment and assemblies

2.1.2 Applicable Design Codes

ASME B31.3 Code for Pressure Piping: Process Piping
AD2000 Code Technical Rules for Pressure Vessels: AD Merkblätter,
AD2000 Merkblatt HP 100 R
EN 13480 Metallic Industrial Piping

2.1.3 Borealis Reference Documents

BER-CO-05-001 General Design Requirements Piping
BES-CO-00-001 Group Amendment to the Borealis Engineering Specifications
BES-CO-04-013 Mechanical Package Unit General

2.1.4 Standards
ISO 4406 Hydraulic Fluid Power - Fluids – Method for Coding the Level
of Contamination by Solid Particles
ISBN 0717616290 Health Safety & Environment (HSE) Guidance note GS4
Safety in Pressure Testing

3 QUALITY ASSURANCE / QUALITY CONTROL

3.1 Quality Assurance / Quality Control

3.1.1 Inspection Plan

CONTRACTOR shall establish and maintain a documented inspection plan that will provide
adequate, effective Quality Assurance and will provide for the easy identification and
handling of items.

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The flushing activities and the specific pressure test inspections described in this specification
shall be part of the general quality inspection plan related to any piping fabrication and/or
assembly activities.

Each applicable quality inspection plan shall be set up as per recommended project
requirements and in relation with the fabrication sequence.

Inspection points related to the flushing and testing of piping components, piping spools and
piping assemblies, shall be part of the general project inspection plan that shall be sent to
COMPANY for approval prior to contract awarding.

Together with the general project inspection plan, all applicable procedures concerning flushing
and testing of piping components, piping spools and piping assemblies shall be sent to
COMPANY for approval prior to contract awarding.

3.1.2 Inspection Notification

CONTRACTOR shall provide COMPANY with advance notification of certain shop
inspections and tests (when applicable or required according inspection plans); field
inspection and tests, including those of SUBCONTRACTORS and/or SUBVENDORS, as
outlined in the contract or agreements made in the pre-award inspection meeting.

COMPANY shall be informed in advance according to the schedule specified in the

project planning or at least 10 working days before the actual scheduled date.

COMPANY shall have entry - after advance notification - to all CONTRACTOR and
SUBCONTRACTOR’S plants where testing of equipment and/or materials is in progress.

It shall be the responsibility of CONTRACTOR to notify SUBCONTRACTORS,

SUBVENDORS, THIRD PARTY INSPECTORS or NOTIFIED BODIES (in case CE
certification is applicable) of COMPANY’s inspection requirements.

3.1.3 Inspector’s Approval

COMPANY inspector’s approval does not relieve CONTRACTOR from any responsibility.

3.2 Documentation

3.2.1 Quality records

Quality records shall include, but are not limited to:
• Item identification by reference to drawings and revision number
• Operating, design and test conditions by reference to piping lay-out drawings
(isometrics) and revision number
• Approved flushing procedure specifications
• Approved pressure test procedure specifications
• Acceptance criteria by reference to procedures
• Specific inspections performed and results obtained
• Date of inspections and identification of inspection
• Data recording charts, checked and signed after 100% completion of the applicable
test by a representative of CONTRACTOR, SUBCONTRACTORS, SUBVENDORS,
THIRD PARTY INSPECTORS or NOTIFIED BODIES (in case CE certification is
applicable) and the COMPANY’S inspector. (COMPANY’S inspector has the possibility
to waive this inspection)
• Qualification of material, personnel, procedures and equipment.
• Callibration reports of all used inspection equipment used. This is required for the
performance of the quality review.

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• COMPANY final inspection certificate

If deemed necessary by COMPANY inspector, other items may be added. CONTRACTOR may
use its own forms for records but this must be submitted to COMPANY for approval prior
to use.

All previously mentioned data shall be available to COMPANY's representative at all times and
the status of the data content shall be completed together with the assembly progress.

An example of the traceability in relation to pressure testing shall be supplied by

CONTRACTOR together with the quality plan to COMPANY for approval prior to use.

The quality of flushing and the internal cleanliness of the piping spools shall be checked on a
spot check basis by a COMPANY representative. Any indication that COMPANY
requirements are not fulfilled will result in extra inspections. CONTRACTOR will cooperate
without any extra costs to allow COMPANY’S inspector to perform the extra inspections.

All hardcopy documents shall be of good copy quality, allowing a well readable content with no
possibility of wrong interpretation.

If dates of validity are applicable (e.g. calibration test certificates, etc.), these shall be clearly
indicated and checked. If documents are delivered with expired dates of validity, this will
result in a rejection of the final documentation.

All documentation shall be provided to COMPANY in ‘As Built’ version and 100% complete. This
final and ‘As Built’ data shall be send by the CONTRACTOR to the COMPANY both in
hardcopy and scanned format (*.pdf) and compiled on CD-rom.

3.2.2 Filing System

CONTRACTOR shall maintain a systematic filing system of all certificates and reports for all
tests and inspections carried out by him under the applicable specifications, standards
and codes of practice quoted herein.

Originals of all documents are to be sent to COMPANY.

4 BASIC DESIGN REQUIREMENTS

4.1 General
Complete package units delivered by other VENDORS shall not be flushed and pressure
tested unless separately requested by COMPANY, since this has already been performed
during fabrication in VENDOR’s shop.

Flushing and pressure testing of packaged units shall be in accordance to the

requirements outlined in ‘BES-CO-04-013 Mechanical Package Unit General, Section 6
Inspection and Testing’.

Although some test systems may be tested in combination with systems installed by other
CONTRACTORS, each CONTRACTOR is responsible for his own part installed, unless
agreed otherwise.

5 FLUSHING REQUIREMENTS
5.1 General
Procedures for flushing shall be developed by CONTRACTOR prior to start and subjected to the
approval by COMPANY.

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After COMPANY accepted the preparations for flushing, the piping system will be
released for flushing.

The initial flushing shall be carried out prior to pressure testing.

For austenitic steelwork, flushing can be performed after pressure testing, if approved by
COMPANY.

General requirements for flushing for specific systems are listed in Attachment 1; Fluid
List.

All pipe work shall be free from dirt, trash, debris, grease and temporary protective coating
upon completion of flushing.

Flushing through equipment is not allowed unless approved by COMPANY.

During flushing of pump suction/discharge lines, the pipe connections to the pump shall
be turned away and the pump inlet shall be adequately covered to prevent contamination
of pumps. This applies also for equipment nozzles, which shall be blinded off, during the
flushing operation.

To clean the inside of storage tanks water jetting can be applied.

Flushing shall be performed against open pipe ends, not via small openings like vents,
drains, etc.

The system shall be inspected for cleanliness and approved by COMPANY before closing
and reinstatement.

Before closing and reinstatement after the flushing and pressure test activities, the flange
faces of each dismantled flange connection shall be inspected for damage. Any damage
will result in a re-machining of the flange face to meet the required facing tolerances.

5.2 Hydro Flushing

Items of equipment, which would be sensitive to damage during hydro flushing, shall be
removed, blocked off or isolated.

A list shall be prepared and be part of the flush & test procedure.

Ball valves shall be flushed in fully open position.

All piping systems shall be flushed using high-pressure jet flushing equipment, such as
rotating hose or rotating nozzle. Minimum pressure shall be 600 bar(g).

Below 4”, High Velocity Water Flushing (HVWF) may be used. Water velocity shall be a
minimum of 10m/s.

On systems where high pressure jet flushing cannot be used due to complicated shapes
and/or long runs HVWF may be used.

The flushing medium shall in general be fresh water.

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All flushing and hydro testing for carbon-steel and stainless steel systems shall be
performed with clean water (maximum chloride content 100 ppm). Prior to use, the water
shall be analysed and the results reported to COMPANY.

After flushing, the piping systems shall be completely drained and protected against corrosion,
as specified in ‘Attachment 1 Fluid List’.

Also see Section 6.5.2; Austenitic Stainless Steel.

5.3 Pressurised Air Shock Blowing (PAS)

This method may be used as an initial cleaning method for instrument air, plant air and as an
alternative method for initial cleaning of small-bore pipe (less than 2 inch).

This method may also be used when there are problems removing trapped liquid in the circuit,
or to verify cleanliness of small-bore pipe where video inspection is impossible or
inadequate due to pipe dimension or configuration.

When using PAS method for cleaning or verification, the procedure shall be repeated until
cleanliness is acceptable to COMPANY.

The air shocking pressure shall never exceed the working pressure of the system and shall
never be more than 8 bar(g).

Special safety precautions shall be agreed with COMPANY when this method is used.

5.4 Pneumatic Flushing

In cases where water is not desirable in the piping system (e.g. instrument/utility air, nitrogen),
flushing by pressurised air or PAS shall be carried out.

When pressurised air is used, the minimum velocity shall be 35m/s.

Procedure to limit the safety risk for personnel, equipment and environment shall be established
by CONTRACTOR and approved by COMPANY.

5.5 Hot Oil Flushing

5.5.1 General
Required cleanliness for systems subject to hot oil flushing shall be in accordance with
Attachment 1; Fluid List.

A detailed procedure for hot oil flushing shall be developed out prior to start.

Filters used for hot oil flushing shall be:

• 10 µm ABS for hydraulic systems
• 10 – 25 µm ABS for lube and seal oil

Filling of lubricant oil shall take place through filters with 10µm ABS.

Flushing and sampling to verify cleanness shall take place at turbulent flow, upstream any
filters.

The Reynolds number shall be minimum 4000.

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The level of cleanness shall be documented from an automatic particle counter or a membrane
checked in a microscope before a flushing operation is considered finalised.

A flow meter shall be installed to verify flow used during flushing operation.

Maximum water content in oil used for flushing shall be less than 500ppm.

5.5.2 Marking
Piping spools or systems that have been chemical cleaned or hot oil flushed shall be marked in
a unique manner.

5.5.3 Documentation
Relevant laboratory analysis certificates or other acceptable methods shall document the
compliance to ISO 4406 requirements.

6 PRESSURE TESTING
6.1 General

6.1.1 Pressure Test Diagrams and Test Procedure

CONTRACTOR shall prepare Pressure Test Diagrams and Test Procedure.
Piping systems subject to pressure testing shall be indicated on Pressure Test diagrams
that are prepared using P&ID´s.

Prior to testing CONTRACTOR shall obtain approval by COMPANY for:

• Pressure testing-plan outlining lines to be

o Hydro-tested
o Pneumatically tested
o Alternative Leak tested
o Initial Service Leak tested
• Pressure testing procedure

6.1.2 Pressure Test Packages

Based on the approved testing procedure, CONTRACTOR will prepare Pressure Test
Packages.

These packages shall include, but not limited to:

• Review of P&ID to define test packages limits, equipment and instrument to be

included or excluded, the valve position (open / close) and test blinds
• Check of systems to assure that the maximum allowable test pressure of the
weakest point in the system is not exceeded.
• Check of systems applicable to hydro test for static load of the applied test
medium to ensure that the maximum allowable test load of the weakest point in the
system is not exceeded.
• Colour-code of piping system to be tested, outlined in the P&ID, and assigned test
system numbers for identification
• Assembled pressure test packages: The package shall consist of Piping Pressure
Test Record and Isometric drawings with test related information (blinds, valve tested
open or closed, removed instruments etc.)

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6.1.3 Test Pressure

The test pressure shall be accordance with the requirements of the Pressure Equipment
Directive (97/23 EC), as well as the applicable piping design code. Reference is also
made to Attachment 2; Pressure Test – Static Head of Test Medium.

6.2 Preparations for Testing

Before the pressure test, CONTRACTOR shall:

• Perform a visual inspection of the piping (internal and external).

• Inspect piping for completeness and conformity to piping drawings (including P&ID
´s) and specifications (use punch-list).
• Verify that flushing has been performed as required. The inside of all pipe work
shall be clean and free from loose mill scale, weld spatters and any other foreign
matter.
• Verify that all NDT, PWHT, etc. has been completed, documented and approved.
• Verify that the Pressure Test Diagrams and the Pressure Test Packages are up-to-
date and are approved by COMPANY.
• Verify that the test pressure is in accordance with the codes and specifications.
• Verify the quality of the test medium, the testing temperature and whether a
corrosion inhibitor has been added as per product datasheets. The type of corrosion
inhibitor and preparation of the test fluid shall be approved by COMPANY.
• Verify that all testing equipment is in accordance with the specifications, calibrated
etc.
• Verify the location of the test pressure gauges.
• Before pressure testing, all open butt-weld ends on process piping shall be closed
with metal plates, welded into or onto the pipe (thickness and weld size to withstand
applied pressure).
• Before pressure testing, all open flanged ends shall be closed with blind flanges in
corresponding sizes and the pressure ratings. The blind flanges shall have sufficient
thickness to allow pressure testing without any deformation.
• Temporary gaskets shall be used for hydrostatic pressure testing.
• All joints shall be left un-insulated and unlined and exposed for examination during
pressure testing, except that joints and tubes previously tested in accordance with this
specification may be insulated or covered. Painting for corrosion protection is
permitted, provided, it does not prevent the clear examination of the joint under test.
• Verify the location and installation of blinds.
• Verify that all items which cannot sustain the pressure test are removed.
• Verify that spring hangers/supports are blocked where required.
• Verify that supporting structures and piping can sustain the load of the test
medium.
• Verify that all safety precautions are taken and known to all personnel.
• Verify that all air is displaced from the pipe work before applying the test pressure.
• Pipe work under test conditions shall not be subject to any form of shock loading
(e.g. hammer testing).
• The full test pressure value shall be maintained for at least 1 hour.

After the pressure test, CONTRACTOR shall:

• Verify that there is no deterioration resulting from the pressure test.

• Immediately after hydrostatic test, pipe spools shall be dried out by dry, oil free air
or nitrogen. CONTRACTOR shall take all precautions to ensure that piping cleanliness
is maintained.
• No modification to the piping shall be allowed after previously mentioned test.

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• If the pressure test has negative results (leakage), CONTRACTOR shall repair the
system and Pressure Test the system again.
• Verify that all testing equipment is removed.
• Verify that all items, which where removed prior to the pressure test, are
reinstalled. Special attention shall be paid to the connections.
• Installation of final gaskets as per piping classes.
• Assemble all documents concerning NDT, Pressure Testing etc as required. Make
the required Certificates and Declarations (see PED and EN13480-5 Metallic Industrial
Piping - Part 5: Inspection and Testing).

Items to be removed or blanked off prior to flushing/testing shall include, but shall not be limited
to:

• Equipment not included in the test system.

• Any items not designed to withstand the test pressure (all instruments e.g.
pressure gauges, bellows, expansion joints, flexibles, check valves, etc.).
• Safety valves and rupture discs.
• Orifice plates, flow nozzles or other similar restrictions.
• Venturing type flow meters (flanged).
• Internals of equipment (trays, demisters, level instrument floats, float cages, etc.),
if included in the test system.
• Flanged control valves (for welded-in types control valve internals shall be
removed).
• Internals of strainers and filters.

For flanged control valves with block valves and a bypass, the block and bypass valve shall be
left open, with the control valve removed and blinds or spool piece installed, if the test
pressure up and downstream is the same.

CONTRACTOR shall supply spools to replace any item removed.

Blind flanges, blanks, caps or plugs with adequate pressure rating shall be installed to isolate
piping systems and equipment as indicated on the test diagrams. CONTRACTOR shall
supply these items.

All temporary installed items (blanks, gaskets, spools, strainers, etc.) shall be adequately
marked using paint (orange) or tags for easy traceability.

For stainless-steel piping, the duration of the flushing, hydro testing and draining/drying
sequence shall be kept as short as possible; in order to reduce the possibility of chloride
induced corrosion damage.

When flanged valves are present in a test system, testing against a closed valve is only
permitted when the valve and its closing mechanism is suited for the test pressure, and
approved by COMPANY.

Where the test pressure to be applied to the piping is greater than the maximum allowable test
pressure for valves, the valves shall be blinded off on the side to be tested, or removed
and replaced by dummy spools.

Unless otherwise noted, all valves are to be through body tested. First block valve for pressure
instruments shall be included in the test.

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Piping containing check valves shall have the source of test pressure on the upstream side. If
this is not possible, the check valve disc shall be removed or jacked open.

Ball valves shall be pressure tested in the half open position. Other valves shall be tested in the
fully open position.

Test systems without equipment or closed valves may be combined when approved by
COMPANY.

Testing shall not take place with system temperatures 7°C or less, or where ambient
temperature during test falls by 5°C or more, nor during rain or fog unless under suitable
cover. Hydrostatic pressure test may however be performed under a lower temperature
with a proper frost preventive added to the test water after approval of COMPANY.

During the test, the ambient temperature shall be checked. When ambient temperature
increases, test pressure shall be witnessed carefully to avoid any damage to the pipe
spool due to over pressurizing.

Items excluded from pressure tests are:

• All small bore instrument control piping downstream the first piping block valve;
• Open drains and vents to atmosphere (leak test only).

6.3 Safety and Environmental Control

Before starting any pressure test or flushing operation, the adequate measures for safety and
environmental control shall be established. All local regulations and requirements by
COMPANY shall apply.

The test area shall be strictly closed for unauthorised personnel when tests are performed. The
test area shall be marked with yellow / black plastic marking strips and a warning label
stating ‘“NO ENTRY - PRESSURE TEST IN PROGRESS”

Piping systems subject to extended hydrostatic test periods shall be provided with a protective
device to relieve excess pressure due to thermal expansion of the test fluid. The release
pressure shall be agreed with COMPANY.

Care shall be taken that as little test liquid as possible is spilled over the paving to prevent
muddy and/or icy roads, or the damage of equipment, instrumentation or insulation.

As pneumatic testing represents especially high risks, utmost care shall be taken during
pressurisation and inspection of the systems to prevent any danger from personnel,
equipment and environment. Therefore pneumatic testing shall be performed in several
steps.

• Step 1: A preliminary pneumatic test at no more than 1.7 bar(g) shall be performed
according to ASME B31.3 paragraph N345.5.5.

• Step 2: Pneumatic test of all applicable pipe spools at a test pressure of maximum
1.1 times design pressure or otherwise defined according the applicable design code.

Note: Necessary precautions and actions shall be aligned to the national legislation, and the
requirements of the NOTIFIED BODY. Previous steps 1 and 2 shall be seen as a minimal
requirement.

All pneumatic testing has to be authorised by the relevant authorities and COMPANY.

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The use of chemical additives, i.e. wetting agents, biocides, inhibitors, etc., shall only be
allowed when an environmentally acceptable disposal has been agreed with COMPANY
and local authorities.

6.4 Test Equipment

COMPANY shall approve equipment used for testing prior to use.

Purpose built hydrostatic testing equipment, including filters, fills pump, pressurising pump, test
gauges, relief devices, storage tanks, test and flushing medium, and shall be supplied by
CONTRACTOR.

CONTRACTOR shall supply an air compressor suitable to supply dry, clean air at the
pneumatic pressure test level, unless otherwise agreed with COMPANY.

For pneumatic pressure testing a pressure safety valve (PSV) shall be installed to avoid over-
pressuring.

Accuracy of pressure gauge shall be at least 1-2% at full scale. The test pressure shall be within
60% of the gauge range (20% from top and 20% from bottom).

Pressure, temperature and time shall be recorded for all hydrostatic tests. Pressure gauges and
recorders used to indicate and record test pressure shall be calibrated according to
requirements.

Normally minimum one gauge shall be positioned at the highest point of the system. The static
pressure shall be considered (see Piping Specification for allowable pressure).

If there is a deviation of more than 2% between gauges during test, the test shall be stopped
and the equipment recalibrated.
All test pressure gauges shall be calibrated prior to testing. Calibration certificates shall be
available at the worksite and all gauges shall be properly identified to enable traceability to
the calibration certificates.

Calibration of gauges shall be repeated minimum once a year or whenever requested by the
inspection team (representatives from the authorities, COMPANY and CONTRACTOR).

CONTRACTOR shall supply test blanks. Design and dimensions shall be in accordance with
the related pipe class.

6.5 Test Medium

6.5.1 For Hydrostatic Testing

All flushing and hydro testing for carbon-steel and stainless steel systems shall be performed
with clean water (maximum chloride content 100 ppm). The pH value shall be between 6.5
and 7.5.

Prior to use, the water shall be analysed and the results reported to COMPANY.

Use of corrosion preventing chemicals shall be considered and approved by COMPANY when
hydro testing carbon steels. The chemicals shall be compatible with the process

Care shall be taken that flushing and testing water can freeze, neither in the storage tanks nor
in the piping systems. CONTRACTOR has to provide heating or insulation, in case the

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risk of freezing exists. Necessary measures shall be agreed upon with COMPANY
(antifreeze or steam heating).

For hydrostatic testing the test medium shall in general be water, except that other suitable
liquid may be used if:

• The piping or inline equipment would be adversely affected by water;

• If the liquid is flammable, it's flash point shall be at least 49°C and consideration shall
be given to the environment;
• The liquid to be used is approved by COMPANY.

If the test medium cannot be guaranteed clean, it shall be filtered through a 10µm filter when
filling the system.

6.5.2 Austentic Stainless Steel

• Equipment such as shell-and-tube heat exchangers may have crevices, which

prevent proper draining and mechanical drying.
• When flushing with condensate, boiler feed water or demineralised water, it is
essential that all surfaces previously wetted during the test are flushed. The quantity
and velocity of the flushing water depends on the equipment volume and shall be
determined in consultation with COMPANY.
• Removing water or drying by blowing with hot air or gas shall not be performed
unless the testing or flushing has been done with condensate; boiler feed water or
demineralised water.
• In locations where water of the required quality is not available (initially or
permanently), temporary facilities shall be used (e.g. mobile packaged demineralisation
units) to prepare the test water.
• The risk of pitting corrosion is considerably reduced if the time between hydrostatic
testing and start-up is short.
• Clean systems, and the use of boiler feed water or condensate as test water,
minimise the risk of Microbiologically Induced Corrosion.
• Consider the use of biocide to minimise the risk of Microbiologically Induced
Corrosion if all water cannot be drained or dried out (more than three weeks before
start-up).
• Steam-traced or electrically traced systems should be tested or at least properly
flushed with condensate or demineralised water prior to the functional testing of the
tracing. Stainless steel bellows should preferably be isolated from the system during
hydrostatic testing. If this is not possible, the hydrostatic testing shall be done with
condensate; boiler feed water or demineralised water.

6.5.3 Ferritic Stainless Steels and Medium/High Nickel Alloys

Due to the possibility of pitting corrosion, the paragraph above for austenitic stainless steel,
shall also apply to ferritic stainless steels and medium/high-nickel alloys.

6.5.4 Duplex Stainless Steel

Duplex stainless steel is highly susceptible to crevice corrosion when in contact with oxygen-
containing water.

The preferred hydrostatic testing method is to use potable water and to carefully rinse the
equipment immediately after the pressure test with condensate; boiler feed water or
demineralised water, followed by thorough drying the equipment and filling with nitrogen in
such a way that all oxygen is removed from the system.

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6.5.5 9% Nickel Alloy Steel

When hydrostatically testing equipment manufactured from or containing 9% Ni-steel, the water
used shall be clear and free from sulphides which may otherwise precipitate stress
cracking of the equipment.

Complete and thorough draining and drying of the equipment is required after the removal
of the test water.

6.5.6 Aluminium and Aluminium Alloys

The test water shall be of a neutral pH (6 to 7.5) value and free from ions of heavy metals, e.g.
copper, nickel and iron. These metals are readily deposited on the aluminium surface and
cause severe pitting.

The equipment shall be thoroughly cleaned and dried after removal of the test water.

6.5.7 For Pneumatic Testing

Where the test packages indicate that a pneumatic test must be performed, the test media shall
be oil free, dry air or any inert gas. The use of air for testing shall be limited to a maximum
pressure of 7.0 bar(g). Above this pressure nitrogen shall be used.

For instrument/utility air systems, where the introduction of water is undesirable, test media
shall be air or inert gas.

6.5.8 For Alternative Leak Test and for Service Test

These tests shall be performed with the fluid designated for the line.

6.6 Disposal
A wastewater disposal plan, which will specify the handling of the water used for flushing and
pressure testing, shall be prepared and agreed upon by CONTRACTOR and COMPANY.

The disposal of flush and test water via the plant sewer system shall only be allowed after
COMPANY’s written approval at the specified flow rates.

An estimate of the expected quantities flow rate and quality of the wastewater shall be prepared
by CONTRACTOR.

6.7 Test Procedure

6.7.1 Hydrostatic Testing

After acceptance of the preparations for pressure testing by COMPANY, the piping system will
be released for pressure testing.

The test pressure shall be as indicated in the hydrostatic test diagrams provided by
CONTRACTOR and shall be in accordance with PED 97/23 EC or ASME B31.3
requirements defined under paragraph 345.4.

All systems shall be properly vented (at the high points) while filling.

Hydrostatic test pressure shall be applied by means of a suitable test pump or other pressure
source. This pump shall be positively isolated from the system except when being used to
pressurise the system.

A pressure gauge shall be provided at the test pump discharge.

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 BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 17 / 22

The pressure shall be increased gradually. For test pressures over 100 bar(g), the pressure
shall be increased in steps of 25 bar(g), providing sufficient time to check for leaks and to
allow the piping to equalize strains during the test.

In case hydrostatic testing through equipment is required, COMPANY will provide special
instructions (e.g. maximum differential pressures on shell and tube side of heat
exchangers) where applicable.

The minimum number of pressure gauges for a test system is one. For large systems, more
pressure gauges shall be installed at suitable locations in co-ordination with COMPANY
and inspection organisations.

When a union is provided downstream of an instrument block valve, it shall be disconnected

during testing to prevent dirt or foreign matter from being introduced into the instrument.

The outside surface of the test system shall be clean and dry before and during testing.

An authorised person shall constantly attend the test pump during the test.
Whenever the pump is left unattended, it shall be positively disconnected from the system, while
the pressure gauge remains connected to the test system.

The test pressure shall be maintained for at least one hour for systems prior to start of
inspection and long enough to enable inspection of the complete test system by the
inspection team.

Care shall be taken to ensure that over pressuring due to static head does not take place:

• See the relevant Piping Specification for allowable pressure.

• See Attachment 2; Pressure Test – Static Head of Test Medium, for an
explanation on this topic.

Re-testing of a system, if required, shall be performed at the same pressure as originally

specified for the test.

6.7.2 Pneumatic Testing

In general pneumatic pressure testing shall be avoided.

Precautions:

• A calculation/safety evaluation to define stored energy in the equipment and safe

distance from the equipment shall be performed by CONTRACTOR, and be subject to
approval by COMPANY, before any pneumatic test is carried out.

• Formula for Energy (E) is based on HSE Guidance Note GS4 Safety in Pressure
testing ISBN 0717616290.

 Pf 
E =10000 .Pi .V.ln  
 Pi 
Where:

• E= Energy in Joule.
• Pi = initial internal (test) pressure in Bar absolute.
• Pf = final pressure in Bar absolute (1Bar absolute = atm).
• V = volume (contents) in m3.

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 BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 18 / 22

• Formula for safe distance as a function of E is based on:

o If E < 5.000.000J a safety zone with minimum radius = 20m shall be fenced.
o If E >= 5.000.000J and E < 135.000.000J a safety zone with radius = between
20m and 100m (ratio to the energy content) shall be fenced.
o If E>= 135.000. 000J a safety zone with radius = 100m shall be fenced.

• See Attachment 3; Safety Distances for Pneumatic Pressure Test: Example, for an
example graph.

• Within the test area a safe area shall be demarcated for the personnel involved in
pneumatic pressure testing. Personnel may not leave this safe area as long as the test
pressure is above the design pressure (highest allowable pressure) of the pipe
system / equipment subject to this pneumatic test.

• Adjustment of test pressure shall be possible from the safe area.

• Only non-toxic and non-flammable gas shall be used. Air can only be used up to a
maximum of 7 bar(g). Nitrogen is the preferred pneumatic test medium. Above 7 bar(g)
the use of nitrogen is mandatory. When using nitrogen, the testing area shall be
carefully ventilated and all necessary safety precautions shall be taken for pressure
testing using nitrogen.

• The test shall be carried out with the minimum number of personnel in the vicinity.

• CONTRACTOR’s Supervisor in charge shall nominate one person to ensure that no

unauthorised person shall be allowed in the affected area. The area shall be roped-off
and a notice “NO ENTRY - PNEUMATIC TEST IN PROGRESS” shall be placed at
conspicuous locations.

Before the pneumatic testing, a minimum 10 % of all joints have to be checked using either one
or a combination of the following inspection techniques:

• Radiography
• Penetrant testing
• Magnetic particle testing
• Ultrasonic testing

This inspection shall demonstrate system integrity.

The isolation of the equipment/project shall be with full rated blinds and inspected by
CONTRACTOR’s Supervisor in charge to ensure that they are at the right locations.

The whole pressure test operation shall be authorized, witnessed and approved by
CONTRACTOR’s quality personnel, COMPANY representative and Authority
representative (THIRD PARTY INSPECTOR / NOTIFIED BODY).

Testing Procedure:

• Pressurise the system to 50 kPa (0.5 bar(g)) and inspect for leaks
• Pressurise the system to 200 kPa (2 bar(g)) and inspect for leaks. All joints shall
be soap tested
• Gradually raise the pressure to half the test pressure and hold for 15 minutes to
equalise the strain

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 BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 19 / 22

• Thereafter, gradually raise the pressure in steps of 1/10 of the test pressure with
holding time of five (5) minutes between steps until the test pressure is reached and
hold for fifteen (15) minutes
• Thereafter, reduce the pressure to 75% of the final test pressure and inspect the
system. If necessary carry out another soap test to ascertain leaks. If no leaks found
depressurise the system

Flanged joints shall be prepared for pneumatic soap testing by taping with masking tape and
punching a 3mm diameter hole through the tape.

In pneumatic testing, care shall be taken to avoid a temperature drop that could cause failure of
metal and thermoplastics due to embrittlement.

6.7.3 Alternative to Hydrostatic or Pneumatic Pressure Testing (Alternative Leak Test)

Alternative leak test shall normally not replace the normal pressure test where pressure test is
required. However, under special conditions this test can replace the pressure test, but
this must be evaluated on a case by case basis and approved by COMPANY and
Authority representative. Additional NDT will be required.

Lines to be tested shall be suitably indicated on the hydrostatic test diagram.

An alternative leak test shall be performed with the line in service, i.e. with the service medium
and at service pressure.

The testing shall comply with ASME B31.3 Paragraph 345.9.

6.7.4 Initial Service Leak Test (Service Test)

Initial Service leak test applies only to non-critical services, and shall comply with ASME B31.3
Para 345.7.

This type of pressure test shall be subject to approval by COMPANY and AUTHORITY
representative.

6.7.5 Draining and Drying

The tested systems shall be depressurised by opening the depressurising valve in the test rig.

After depressurisation, all vents and low point drain valves shall be opened and the system shall
be thoroughly drained where the test medium is water or another liquid.

Special measures shall be taken to prevent freezing in winter.

All test systems, not subject to chemical cleaning, shall be dried by air (6 bar(g) when the
system operating pressure is above 6 bar(g)) and expanded rapidly.

Where required, trapped liquid shall be removed by blowing dry air or Pressurised Air Shock
Blowing.

Systems with drying requirement as defined in ‘Attachment 1 Fluid List’ shall be dried out after
hydro testing with dry oil free air with a dew point of 5°C below the one day minimum
ambient design temperature. Drying can be terminated when the dew point at the outlet is
equal to the dew point at the inlet.
Other methods, such as vacuum drying or air shocking, may also be used if the same dryness
can be documented.

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 BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 20 / 22

If more than three (3) months to commissioning, drying shall be followed by preservation with
nitrogen (overpressure 0.5 bar(g)) to keep the pipe system completely dry and to avoid
condensation. Other alternatives are subject to approval by COMPANY.

It is important that preservation should be adequate for the purpose intended, yet at the same
time it is equally necessary to ensure that it is justified economically. Whilst the extent of
preservation is primarily a function of the time for which a plant is to be standing idle, there
are other factors which have to be considered simultaneously and it is recommended that
this is best achieved through inter-functional discussions at local management level.

Provision should be made for tagging all equipment after preservation, and for fixing the tags in
a prominent position. For example, where nitrogen pressurisation is applied, the tag may
read (must be in local language):

CAUTION
THIS VESSEL IS BEING PRESERVED WITH NITROGEN AT A PRESSURE OF 1 BAR (G).

IT SHALL NOT BE DISTURBED WITHOUT PRIOR AUTHORITY FROM COMPANY.

IT SHALL NOT BE TAKEN INTO SERVICE WITHOUT INSPECTION DEPARTMENT

AUTHORITY.

Reinstallation of the system shall be performed in accordance with the test procedure.

Where permanent or temporary strainers have remained in place for the hydrostatic pressure
test, they shall be removed following the test and thoroughly cleaned before reinstalling.

Ends of pipes and nozzles shall be fully protected against the ingress of foreign material by the
use of caps, plugs or plate blinds sealed with gaskets. These shall not be removed until
just prior to final assembly.

Flange parallelism and alignment to equipment shall be checked prior to reinstatement.

Vent holes in reinforcing pads shall be sealed upon completion of pressure test.

6.7.6 Verification of Cleanliness

All systems shall be internal visual inspected for acceptable cleanliness by spot check. Internal
visual inspection includes the use of Boroscope, video etc.

If pipe configuration in critical parts of systems as defined in Attachment 1; Fluid List, is too
complicated for visual inspection, the PAS method or other suitable methods shall be
used for verification of cleanliness.

6.7.7 Reinstatement
After the completion of testing, chemical cleaning (where applicable) and drying, all systems
shall be reinstated according to drawings and specifications.
The reinstatement of the system shall include, but shall not be limited to:

• Removal of all temporary auxiliary equipment such as spades, blinds, gaskets,

pipe spools, temporary supports, etc.
• Replacement of all damaged gaskets and all test gaskets
• Positioning of spectacle blinds to the correct position
• Reinstallation of all items previously removed for hydro testing
• Reinstall unions of instrument piping

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 BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 21 / 22

• Inspection of the completed system for correct flow direction of instruments, check
and control valves, etc.

During the pre-commissioning of piping, no dirt, debris, etc., shall be allowed to enter into the
piping system. Each pipe spool shall be inspected for cleanliness prior to installation.

After approval by COMPANY, the system shall be released for further activities, e.g. steam
tracing, painting, insulation, etc.

The "stop" of pipe support springs with "down travel stops" placed prior to flushing, shall be
removed at COMPANY’s request during pre-commissioning.

7 CHEMICAL CLEANING
Lines to be chemical cleaned shall be identified on the P&ID´s and Line Index.

For system overview see Attachment 1; Fluid List.

A procedure shall describe in detail the steps for chemical cleaning.

Chemical cleaning shall include:

• Degassing
• Neutralisation
• Water flushing
• Drying

The end result shall be a clean smooth surface.

Maximum temperatures used during these operations shall not exceed maximum design
temperature for the systems as listed in the Line Index.

For equipment such as turbines, generators, pumps and compressors, the piping to be cleaned
shall have all sensitive items that can be damaged by the cleaning medium removed or
blanked off.

Normally the following items shall not be chemically cleaned if not otherwise agreed with
COMPANY (items shall be identified on chemical cleaning isometrics by CONTRACTOR):

• All instrument tubing downstream the first piping block valve

• Piping systems with copper alloy materials
• Flexible hoses
• Vessels
• Exchangers
• Pumps
• All bolted/screwed valves and instruments
Removed or blanked off items shall be cleaned separately prior to reinstallation.

The systems to be cleaned shall have high and low point vents and drains installed. "Dead legs"
shall be avoided.

Cleaning shall be carried out after pressure testing unless otherwise specified.

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 BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 22 / 22

If the period between chemical cleaning and start of commissioning is expected to be more than
three (3) months, then the system shall be preserved with nitrogen. Overpressure shall be
0.5 bar(g) (see Section 6.7.4; Initial Service Leak Test (Service Test)).

8 INSPECTION AND REPORTING

CONTRACTOR shall prepare a final report, giving positive documented evidence that subject
systems are pressure tested in accordance with agreed requirements.

The test report shall be included in the final piping documentation. The documentation shall as a
minimum include (in principle all documentation required/specified in EN 13480):

• Reference to documents and specifications

• Pressure test diagrams (P&ID)
• Isometrics with identification of:
• Heat numbers of components (only for PED category III, II and I)
• Weld numbers
• Welders identification
• WPS, WPR
• Approval of welders
• NDT reports
• Qualification and certification of NDT personnel
• CE certificates of components
• Agreed punch lists
• All required certificates (material certificates, test certificates, qualification
certificates etc)
• Test results and duration
• A continuous log of operation, if applicable
• Signature of COMPANY representative, CONTRACTOR representative,
AUTHORITY representative (THIRD PARTY INSPECTOR / NOTIFIED BODY)

9 ATTACHMENTS
Attachment 1: Fluid List & Piping Classes
Attachment 2: Pressure Test - Static Head of Test Medium
Attachment 3: Safety Distances for Pneumatic Pressure Test (Example)

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