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SAIC-A-2010
WBS / BI / JO NUMBER
1-Dec-06
Piping-
CONTRACTOR / SUBCONTRACTOR
EQUIPMENT ID NUMBER(S) LAYOUT DRAWING NUMBER SCHEDULED INSPECTION DATE & TIME SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO INSPECTION LEVEL
EQPT CODE
SYSTEM ID.
PLANT NO.
ACTUAL INSPECTION DATE & TIME SAUDI ARAMCO ACTIVITY NUMBER CONTRACTOR INSPECTION LEVEL
ITEM No.
ACCEPTANCE CRITERIA
REFERENCE
PASS
FAIL
N/A
RE-INSP DATE
NOTE: Use Pre-test Punch List Form, SATR-A-2007, for listing of specific deficiencies, indicating location and/or references A A1 Test Pack Verification & Review* (*Thorough & detailed review of specs for each new system's first package) Test Package has been verified to be approved and to contain the detailed elements of SAEP-1160, Sect 8 as detailed in SAIC-A-2003. Use Attachments 1 & 2 of this checklist (quick reference). Pressure Testing Procedure is approved. Test application meets SA reqmts as checked against Pressure Test Matrix - Attach. 3. Construction & Special Process Control (per SAEP-1160 Database) has been documented as complete* (ready for Punch Listing). Welding, NDT, PWHT, BHT, PMI, Other Testing, is documented in pkg Procedure is followed regarding Test Pkg flow sequence. SAES-A-004, Para. 5.6.1 SAES-A-004, Para. 7.1.1 SAEP-1160, Section 6 Weld Database
A2
A3
B B1
SIS Sheet Data Verification (Safety Considerations & Limiting Factors in Pressure Test Calculations) SIS Sheets contain full code pressure calculations for applicable piping sizes. Limiting Factor listed on SIS Sheet is supported by data On SIS sheets, proposed hydrostatic strength test pressures for NEW plant piping systems are verified against the listed applicable limiting factors by determining the lesser of the following: A) Pressure rating of flanges (per ASME B16.5 or other) B) Pressure rating of any valves used in isolation (ASME B16.34) Note: (Valve pressure ratings for seat closure = tested at 110% when valves are used for isolation) C) Other system components (Internal Coating pressure rating) may result in test pressure reduction APCS 102 = 3,000, others 5,000psi SAES-L-150, Para. 7.1
B2
Test Pressure=2t(0.9)(SMYS)/D where: t= nominal pipe wall thickness minus the specified mill tolerance* *mill tolerance =12.5% (seamless pipe) or .01" for welded plate SMYS= Specified minimum yield strength (psi). Use ASME B31.3 Appendix A Tables for specific material grade used (SIS sheet). Example: SMYS for API 5L Gr X-60 = 60 KSI or 60,000 psi D = Outside piping diameter (OD)* ... Per ASME B36.10 Tables *Note: For nominal piping sizes 14" (& above), actual O.D. = 14" For nominal pipe sizes 12" & below ... See ASME B36.10 Tables
On SIS sheets, proposed hydrostatic strength test pressures for EXISTING PLANT PIPING SYSTEMS (TIE-INS) is the test pressure shall be minimum required by the Code ASME B31.3. Actual min wall thickness of piping shall be verified (PROCEDURE) and used in such calculations. Thickness readings are current (30 days) & flange rating is considered when calculating test pressure (ASME B31.3)
B3
Test Pressure=2t(0.9)(SMYS)/D where: t= ACTUAL PIPING WALL THICKNESS (MINIMUM MEASURED) SMYS= Specified minimum yield strength (psi). Use ASME B31.3 Appendix A Tables for specific material grade used (SIS sheet). Example: SMYS for API 5L Gr X-60 = 60 KSI or 60,000 psi D = Outside piping diameter (OD)* ... Per ASME B36.10 Tables *Note: For nominal piping sizes 14" (& above), actual O.D. = 14" For nominal pipe sizes 12" & below ... See ASME B36.10 Tables
Page 1 of 17
SAIC-A-2010
WBS / BI / JO NUMBER
1-Dec-06
Piping-
CONTRACTOR / SUBCONTRACTOR
ITEM No. C
REFERENCE
PASS
FAIL
N/A
RE-INSP DATE
SPEC CHECK SHALL BE UTILIZED BY SAUDI ARAMCO INSPECTORS FOR FIELD WALK-DOWNS All joints (flange, threaded, welded or mechanical seals) are left exposed for visual leak detection during the strength test. A) External coating & priming of joints is allowed only if approved by Insp Dept Mgr & proponent Organization Representative. B) The pipe itself can be externally primed & coated to a final coat. All permanent flange joints were inspected, gasket mat'l verified & properly torqued. (Review Flange joint report, SAIC-L-2014) Drains shall be provided at all low points of the piping system. Note: Exceptions are submarine & buried* pipelines (*pump-outs) Vents and drain valves, both temporary and permanent, conforms with the piping class or rating. ( Refer SAES-L-108) Supports are installed. Additional temporary support may be installed as required. Expansion joints and spring hangers or spring supports are provided with temporary restraints. Arc strikes, gouges, and other indications of careless workmanship (such as surface porosity, uneven weld profiles, and undercut) shall be removed by grinding and inspected by magnetic particle or liquid penetrant method. Temporary welded attachments to the pipe were ground off and inspected by magnetic particle or liquid penetrant method All threaded joints and faying surfaces shall be seal welded by a continuous fillet weld (required weep holes shall be left unwelded). Isolation valves are verified to have been body and seat tested prior to installation through verification of field test certificates. All in line valves that are not used as test isolation valves are in open position. During filling, permanent vent & drain valves are in open position. Plugging is only AFTER WATER FILL & EFFICIENT AIR VENTING.
C1
C2 C3 C4 C5 C6
SAES-L-450, Para. 9.4 SAES-L-150, Para. 6.2 SAES-L-105, Para. 5.9 SAES-L-150, Para. 6.3 SAES-L-150, Para. 6.4 SAES-W-011, Para. 11.6 SAES-W-011, Para. 11.7 SAES-W-011, Para. 11.15.1 SAES-L-108, Section 4.7 SAES-A-004, Para. 7.3.2 SAES-A-004, Para 8.1.1 SAES-A-004, Para. 7.4.2 SAES-A-004, Para. 7.4.3 SAES-L-110, Para. 8.2 SAES-L-110, Para. 8.2 SAES-A-004, Para. 7.2 SAES-A-004, Para. 5.5.4 SAES-L-450 Appendix C SAES-A-004, Para. 7.1.5 (a) SAES-A-004, Para. 7.3.1 SAES-A-004, Para. 5.5.2
C7
C13 Drains are provided immediately above check valves (vertical lines). C14 Disc of check valve is removed, unless check valve has by-pass. Method for storage (plastic bag & tie) allows visual verification.
C15 Spare taps of orifice flanges are plugged and seal welded. C16 C17 All threaded joints up to the first block valve of hydrocarbon pipeline are seal welded. Thread engagement has been verified & accepted. Process instruments and equipment that may be damaged by the strength test pressure are disconnected.
The pressure testing manifold is separately pressure tested to at least 1.2 C18 times the system test pressure but not less than the discharge pressure of the pump used for the pressure testing. C19 C20 C21 C22 Buried pipeline are adequately bermed or covered to anchor the line during pressure test. Pressure gages and pressure recorders are calibrated within one (1) month before the test. Check stickers at the time of the test. Paddle or spectacle blinds shall be used to isolate test sections. Safety of test "implements" has been checked (SAIC-A-2009) A bleed valve readily accessible is provided in case immediate depressurization is required.
Page 2 of 17
SAIC-A-2010
WBS / BI / JO NUMBER
1-Dec-06
Piping-
CONTRACTOR / SUBCONTRACTOR
ITEM No.
ACCEPTANCE CRITERIA
REFERENCE
PASS
FAIL
N/A
RE-INSP DATE
EVALUATE CLEANING (PROCEDURES) & PROPOSED LAY-UPS: For pipe up to 12-inch NPS - flushed clean of loose scale/debris or scraped prior to commencement of pressure testing per procedure Note 1: If flushing was done with valves in line, cavity cleanliness is highly suspect where no low point drains exist. Verify post-test removal of C23 scale/debris/water in low points (Check valve cavities). Random verification involves Inspection of valve cavities. This is a standard comment or addition to the punchlist. Note 2: Internal Cleaning procedure for pipe size larger than 14 inch shall be submited for review and approval) See SATIP-L-108. Flushing Cert is available in the test package for review All pressure containing components of pipeline, except instruments that C24 may be damaged by the test pressure, were physically verified to be included in test using P&ID, ISOs (Pressure Test Diagram)
C26
Use SAIC-A-2011 along with this checklist (inspection efficiency) whenever walkdown is done on the same day as press. testing
As Referenced
REMARKS: REFERENCE DOCUMENTS: 1. 2. 3. 4. 5. 6. 7. SAES-A-004, General Requirements for Pressure Testing, (30 March, 2005) SAES-L-105, Piping Material Specifications, (30 March, 2005) SAES-L-108, Selection of Valves, (30 March, 2005) SAES-L-110, Limitations on Pipe Joints and Components, (30 March, 2005) SAES-L-150, Pressure Testing of Plant Piping and Pipelines, (30 September, 2003) SAES-L-450, Construction of On-Land and Near-Shore Pipelines, (30 September, 2003) SAES-W-011, Welding Requirements for On-Plot Piping, (30 March, 2005)
Contractor / Third-Party
Construction Representative*
Work is Complete and Ready for Inspection: Name, Initials and Date: Name, Initials and Date:
Saudi Aramco
PMT Representative
T&I Witnessed QC Record Reviewed Work Verified
QC Inspector
Performed Inspection Name, Initials and Date: Work / Rework May Proceed
PID Representative
T&I Witnessed Name, Initials and Date: QC Record Reviewed Work Verified
QC Supervisor
Quality Record Approved: Name, Sign and Date: *Person Responsible for Completion of Quality Work / Test
Y = YES
N = NO F = FAILED
Page 3 of 17
SAIC-A-2010
1-Dec-06
Piping-
Page 4 of 17
Attachment 2 -- TEST PACKAGE FLOW CHART Test Package (or Test System) No
Test Pack Preparation
Engineering
Contractor QC
Construction
Contractor QC
SAPMT
PID
Construction
Contractor QC
SAPMT
PID
Construction
Contractor QC
SAPMT
PID
Pressure Testing
Construction
Contractor QC
SAPMT
PID
Proponent
System Lay-Up
Construction
Contractor QC
SAPMT
PID
Construction
Contractor QC
SAPMT
SAPMT
PID
Proponent
Page 5 of 17
SAIC-A-2010
1-Dec-06
Piping-
Attachment 3 -- Pressure Testing Matrix for On-Plot Piping (Incl. UG Utilities, FW & Plumbing)
SYSTEM Process Piping ON-PLOT NEW B31.1 & B31.3 CODE PRESSURE PIPING (SATIP-A-004 Series) TEST PRESS TEST CONSIDERATIONS & NOTES & DURATION
As Calculated* 30 mins (min) Piping Line Class List (Hydrotest Spec) lists all new process piping line classes (strength test required per code) with exceptions for Service Test and other tests as noted below. NDE in lieu of pressure test may be performed if requested & approved by SA Insp. Dept. Mgr. Process requests per Sect 5 of SAES-A-004, and at a minimum, 30 days ahead of testing.
*Note: Unless limited by flanges, valves or other component (exceptions below), hydrostatic strength test pressures for every section of new constructed line shall produce a hoop stress in pipe of 90% SMYS at test temperature. See Exceptions Below. *Lube & seal oil piping is pressure tested with its own fluid at 1.5 times design pressure or 100 psig, See Notes Lube & Seal Oil whichever is greater. Chemical cleaning precedes pressure testing. Joints shall be completely 30 mins (min) Systems cleaned* (oil free) before testing. *Baby Powder works best to clean/dry joints Note: Leaks are common, difficult to identify as "active" or "non-active". Perform preliminary tests to identify all leaks, especially at flanged and threaded joints. When evaluating leakage, utilize clean dry cloths to identify "active" leaks for repair. Oil residue found after wiping the joints (check low points carefully) is cause for clean and retest. Always wait a minimum of 30 mins after wiping joints before reevaluation.
A) Test prior to backfilling (all joints exposed) & maintain test pressure for a minimum of 2 hrs B) If justifiable (safety) & line must be back-filled, a 24 hr recorded test (Chart Recorder) reqd. Flare lines 24-inch NPS & larger with a design pressure of 75 psig or lower may be strength tested pneumatically (75 psig is tested at 1.1 factor or 82 psig) per Para. 345.5 of ASME B31.3
Note: Test limits shall be downstream of isolation valves (beyond PZVs & locked valves for equipment). Portions of the test may be less than 24 inches from these valves to the flare header branch connection. Flare system Isolation Valves receive a pneumatic seat test at 5 psig in lieu of a high pressure seat hydrotest. Conduct this test on a weekend to minimize personnel exposure. Perform a stored energy calc when requested by Company. Test limits utilize blind flanges at removed isolation valve locations. Follow Pneumatic Testing SATIP.
Vacuum Piping Air & Inert Gas (150 psig max) LP Steam (60 psig max) Weld-Plus-Ends Existing Plant Piping Incl. Tie-Ins RETESTING REQMTS
See Notes 30 mins (min) SERVICE TEST & Soap Bubble Test 30 mins (min) SERVICE TEST 30 mins (min) Soap Bubble Leak Test at 5-10 psig As Calculated* 30 mins (min)
Tested to 1.5 times the differential external pressure, but not less than 15 psig. Perform a preliminary soap bubble test at 5-10 psig after construction is complete & threaded joints are checked for engagement (two full visible thread rule). Coordinate with Compressor and Receiver Service tests and final gasket installation. Coordinate with system Service tests and construction completion. Weld-Plus-Ends shall be subjected to a pneumatic pressure test of 5 to 10 psig in the annulus between the gasket and the seal weld. It shall be examined for leaks using a soap solution. For revalidation purposes of existing plant piping, the test pressure shall be minimum required by the Code ASME B31.3. The actual wall thickness of the piping and flange rating shall be determined and taken into consideration when calculating the test pressure. In case of flanged tie-in connections, a flange tester is utilized to conduct hydrostatic testing of flange butt weld. Systems that already passed a successful pressure test require RETEST IF subjected to new welding activities (Modifications, repair to pressure boundary) OR IF PWHT is reqd*.
See Notes
Note: Seal welds of threaded connections & Attachment welds of non-pressure containing parts, such as wear pads DO NOT REQUIRE RETEST UNLESS THE LINE REQUIRES PWHT (Including attachment welds & seal welds to the pressure boundary).
See Notes
Every existing plant piping & pipeline, after repairs or alterations have been made that affect the integrity of the pressure containing parts, shall successfully pass a hydrostatic test. The test pressure shall be in accordance with the requirements of the applicable code.
Note: SAEP-310 requirements apply as well for pressure testing after Repairs, Upgrades, Refurbishment, etc EXEMPT, VISUAL EXAM Drains, vents & piping downstream of pressure relieving devices that discharge directly to the atmosphere (max internal pressure 10 psig) are EXEMPT from testing. Drain holes installed, etc
Note: Test Package SIS Sheet shows design data & "EXEMPT" under required test pressure. Line(s) shall be visually examined. As Calculated* 30 mins (min) Whether piping or tubing, between the root isolation valve and the instrument isolation shall be pneumatically pressure tested (air or nitrogen) at 1.25 X design pressure of the piping system or process equipment to which it is connected. Test duration shall not be less than 30 minutes.
Note: Instrumentation that could be damaged due to the test shall be disconnected. When pneumatic test is not practical (pressure greater than 1000 psig, physical configuration, etc.) test with liquid or water. (Flush, test & dry clean using a quality of water not harmful to lines).
For internally Fusion Bonded Epoxy (FBE) coated piping system, the test pressure shall not exceed 5,000 psi for APCS 100, 101, 103 systems & 3,000 psi for APCS 102 System
Note: ALL Welding shall be completed (Design Issue), all internal coating and Holiday Testing PRIOR TO pressure testing.
Page 6 of 17
SAIC-A-2010
1-Dec-06
Piping-
Attachment 3 -- Pressure Testing Matrix for On-Plot Piping (Incl. UG Utilities, FW & Plumbing)
ON-PLOT NEW B31.1 & B31.3 CODE PRESSURE PIPING (SATIP-A-004 Series) Sampling Lines Vessel & Tank Trim (Piping) Skid-Mounted Piping (Vendor)
See Note See Note Test as an integral part with the piping or equipment to which it is connected. Test separately (separate package) as required. Exemptions include sight glasses & other instruments. Strength or Service test associated piping based on service
Note: ALL Code Piping construction (in-situ) that is not VENDOR supplied shall be tested. Utility = Service Test, Process = Strength Test EXEMPT IF TESTED BY VENDOR 1. When testing with adjacent Lube oil system piping (no leaks = acceptance). 2. When code repairs are made to skid-mounted piping to correct misalignment, physical per 01-SAMSS-010 damage or any modifications in-situ, pressure test the affected spools. (exceptions noted)
FIELD HYDROTESTING OF NEW VALVES (SAES-L-108, Section 4.7 & SATIP-L-108 & SAIC-L-2042) See Note Location shall be specified by proponent & PID approved. SAIC-A-2031 Sect. J Test Location All new valves designated for isolation service (as specified by the Proponent) shall be See Note Field Testing of subjected to high pressure hydrostatic seat test prior to installation in line. New Valves Low pressure pneumatic seat test at 5 psig shall be substituted for high pressure See Note Exception
hydrostatic seat test for flare system valves. Identify & Segregate Early!!!
Exemption Procedure
(Checklist Item D4)
Buttweld & socketweld end valves in NPS 2 inches and smaller are exempt Test procedures, pressures, durations, & leakage acceptance criteria shall be equal to those that the valves were originally purchased to. All resilient (soft) seated isolation valves shall have zero leakage. See SAIC-L-2042
Note: Proponent specifies those Line Classes and valves subject to field hydrotesting. Valves received shall be carefully identified & given a unique ID number for installation into the correct Line Class based on visual verification of construction stamp. Valves shall be given a unique ID & corresponding test report document upon receipt, Valve ID shall be controlled, documents transferred into appropriate Test Pkg & Database (Piping System, Line Class, Line Number, Location) per SAEP-1160. Procedure identifies all critical aspects of Valve Testing incl Receipt Inspection (internal visual exam by qualified Inspector), pressure test, ambient lay-up (corrosion protection per mfg instructions & follow-up preservation reqmts) & segregation control to prevent "mixing valves". Controlled System for Valve Placement exists.
Page 7 of 17
SAIC-A-2010
1-Dec-06
Piping-
Page 8 of 17
SAIC-A-2010
1-Dec-06
Piping-
Page 9 of 17
SAIC-A-2010
WBS / BI / JO NUMBER
1-Dec-06
Piping-
CONTRACTOR / SUBCONTRACTOR
ITEM No. C
REFERENCE
PASS
FAIL
N/A
RE-INSP DATE
SPEC CHECK SHALL BE UTILIZED BY SAUDI ARAMCO INSPECTORS FOR FIELD WALK-DOWNS All joints (flange, threaded, welded or mechanical seals) are left exposed for visual leak detection during the strength test. A) External coating & priming of joints is allowed only if approved by Insp Dept Mgr & proponent Organization Representative. B) The pipe itself can be externally primed & coated to a final coat. All permanent flange joints were inspected, gasket mat'l verified & properly torqued. (Review Flange joint report, SAIC-L-2014) Drains shall be provided at all low points of the piping system. Note: Exceptions are submarine & buried* pipelines (*pump-outs) Vents and drain valves, both temporary and permanent, conforms with the piping class or rating. ( Refer SAES-L-108) Supports are installed. Additional temporary support may be installed as required. Expansion joints and spring hangers or spring supports are provided with temporary restraints. Arc strikes, gouges, and other indications of careless workmanship (such as surface porosity, uneven weld profiles, and undercut) shall be removed by grinding and inspected by magnetic particle or liquid penetrant method. Temporary welded attachments to the pipe were ground off and inspected by magnetic particle or liquid penetrant method All threaded joints and faying surfaces shall be seal welded by a continuous fillet weld (required weep holes shall be left unwelded). Isolation valves are verified to have been body and seat tested prior to installation through verification of field test certificates. All in line valves that are not used as test isolation valves are in open position. During filling, permanent vent & drain valves are in open position. Plugging is only AFTER WATER FILL & EFFICIENT AIR VENTING. Drains are provided immediately above check valves (vertical lines). Disc of check valve is removed, unless check valve has by-pass. Method for storage (plastic bag & tie) allows visual verification. Spare taps of orifice flanges are plugged and seal welded. All threaded joints up to the first block valve of hydrocarbon pipeline are seal welded. Thread engagement has been verified & accepted. Process instruments and equipment that may be damaged by the strength test pressure are disconnected. The pressure testing manifold is 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. Buried pipeline are adequately bermed or covered to anchor the line during pressure test. Pressure gages and pressure recorders are calibrated within one (1) month before the test. Check stickers at the time of the test. Paddle or spectacle blinds shall be used to isolate test sections. Safety of test "implements" has been checked (SAIC-A-2009) A bleed valve readily accessible is provided in case immediate depressurization is required.
C1
C2 C3 C4 C5 C6
SAES-L-450, Para. 9.4 SAES-L-150, Para. 6.2 SAES-L-105, Para. 5.9 SAES-L-150, Para. 6.3 SAES-L-150, Para. 6.4 SAES-W-011, Para. 11.6 SAES-W-011, Para. 11.7 SAES-W-011, Para. 11.15.1 SAES-L-108, Section 4.7 SAES-A-004, Para. 7.3.2 SAES-A-004, Para 8.1.1 SAES-A-004, Para. 7.4.2 SAES-A-004, Para. 7.4.3 SAES-L-110, Para. 8.2 SAES-L-110, Para. 8.2 SAES-A-004, Para. 7.2 SAES-A-004, Para. 5.5.4 SAES-L-450 Appendix C SAES-A-004, Para. 7.1.5 (a) SAES-A-004, Para. 7.3.1 SAES-A-004, Para. 5.5.2
C7
C18
Page 10 of 17
SAIC-A-2010
WBS / BI / JO NUMBER
1-Dec-06
Piping-
CONTRACTOR / SUBCONTRACTOR
ITEM No.
ACCEPTANCE CRITERIA EVALUATE CLEANING (PROCEDURES) & PROPOSED LAY-UPS: For pipe up to 12-inch NPS - flushed clean of loose scale/debris or scraped prior to commencement of pressure testing per procedure Note 1: If flushing was done with valves in line, cavity cleanliness is highly suspect where no low point drains exist. Verify post-test removal of scale/debris/water in low points (Check valve cavities). Random verification involves Inspection of valve cavities. This is a standard comment or addition to the punchlist. Note 2: Internal Cleaning procedure for pipe size larger than 14 inch shall be submited for review and approval) See SATIP-L-108. Flushing Cert is available in the test package for review All pressure containing components of pipeline, except instruments that may be damaged by the test pressure, were physically verified to be included in test using P&ID, ISOs (Pressure Test Diagram)
REFERENCE
PASS
FAIL
N/A
RE-INSP DATE
C23
C24
C26
Use SAIC-A-2011 along with this checklist (inspection efficiency) whenever walkdown is done on the same day as press. testing
As Referenced
REMARKS: REFERENCE DOCUMENTS: 1. 2. 3. 4. 5. 6. 7. SAES-A-004, General Requirements for Pressure Testing, (30 March, 2005) SAES-L-105, Piping Material Specifications, (30 March, 2005) SAES-L-108, Selection of Valves, (30 March, 2005) SAES-L-110, Limitations on Pipe Joints and Components, (30 March, 2005) SAES-L-150, Pressure Testing of Plant Piping and Pipelines, (30 September, 2003) SAES-L-450, Construction of On-Land and Near-Shore Pipelines, (30 September, 2003) SAES-W-011, Welding Requirements for On-Plot Piping, (30 March, 2005)
Contractor / Third-Party
Construction Representative*
Work is Complete and Ready for Inspection: Name, Initials and Date: Name, Initials and Date:
Saudi Aramco
PMT Representative
T&I Witnessed QC Record Reviewed Work Verified
QC Inspector
Performed Inspection Name, Initials and Date: Work / Rework May Proceed
PID Representative
T&I Witnessed Name, Initials and Date: QC Record Reviewed Work Verified
QC Supervisor
Quality Record Approved: Name, Sign and Date: *Person Responsible for Completion of Quality Work / Test
Y = YES
N = NO F = FAILED
Page 11 of 17
SAIC-A-2010
1-Dec-06
Piping-
SAIC-A-2010
1-Dec-06
Piping-
Attachment 2 -- TEST PACKAGE FLOW CHART Test Package (or Test System) No
Test Pack Preparation
Engineering
Contractor QC
Construction
Contractor QC
SAPMT
PID
Construction
Contractor QC
SAPMT
PID
Construction
Contractor QC
SAPMT
PID
Pressure Testing
Construction
Contractor QC
SAPMT
PID
Proponent
System Lay-Up
Construction
Contractor QC
SAPMT
PID
Construction
Contractor QC
SAPMT
SAPMT
PID
Proponent
Page 13 of 17
SAIC-A-2010
1-Dec-06
Piping-
Attachment 3 - Pressure Testing Matrix for On-Plot Piping (Incl. UG Utilities, FW & Plumbing)
SYSTEM Process Piping ON-PLOT NEW B31.1 & B31.3 CODE PRESSURE PIPING (SATIP-A-004 Series) TEST PRESS TEST CONSIDERATIONS & NOTES & DURATION
As Calculated* 30 mins (min) Piping Line Class List (Hydrotest Spec) lists all new process piping line classes (strength test required per code) with exceptions for Service Test and other tests as noted below. NDE in lieu of pressure test may be performed if requested & approved by SA Insp. Dept. Mgr. Process requests per Sect 5 of SAES-A-004, and at a minimum, 30 days ahead of testing.
*Note: Unless limited by flanges, valves or other component (exceptions below), hydrostatic strength test pressures for every section of new constructed line shall produce a hoop stress in pipe of 90% SMYS at test temperature. See Exceptions Below. *Lube & seal oil piping is pressure tested with its own fluid at 1.5 times design pressure or 100 psig, See Notes Lube & Seal Oil whichever is greater. Chemical cleaning precedes pressure testing. Joints shall be completely 30 mins (min) Systems cleaned* (oil free) before testing. *Baby Powder works best to clean/dry joints Note: Leaks are common, difficult to identify as "active" or "non-active". Perform preliminary tests to identify all leaks, especially at flanged and threaded joints. When evaluating leakage, utilize clean dry cloths to identify "active" leaks for repair. Oil residue found after wiping the joints (check low points carefully) is cause for clean and retest. Always wait a minimum of 30 mins after wiping joints before reevaluation.
A) Test prior to backfilling (all joints exposed) & maintain test pressure for a minimum of 2 hrs B) If justifiable (safety) & line must be back-filled, a 24 hr recorded test (Chart Recorder) reqd. Flare lines 24-inch NPS & larger with a design pressure of 75 psig or lower may be strength tested pneumatically (75 psig is tested at 1.1 factor or 82 psig) per Para. 345.5 of ASME B31.3
Note: Test limits shall be downstream of isolation valves (beyond PZVs & locked valves for equipment). Portions of the test may be less than 24 inches from these valves to the flare header branch connection. Flare system Isolation Valves receive a pneumatic seat test at 5 psig in lieu of a high pressure seat hydrotest. Conduct this test on a weekend to minimize personnel exposure. Perform a stored energy calc when requested by Company. Test limits utilize blind flanges at removed isolation valve locations. Follow Pneumatic Testing SATIP.
Vacuum Piping Air & Inert Gas (150 psig max) LP Steam (60 psig max) Weld-Plus-Ends Existing Plant Piping Incl. Tie-Ins RETESTING REQMTS
See Notes 30 mins (min) SERVICE TEST & Soap Bubble Test 30 mins (min) SERVICE TEST 30 mins (min) Soap Bubble Leak Test at 5-10 psig As Calculated* 30 mins (min)
Tested to 1.5 times the differential external pressure, but not less than 15 psig. Perform a preliminary soap bubble test at 5-10 psig after construction is complete & threaded joints are checked for engagement (two full visible thread rule). Coordinate with Compressor and Receiver Service tests and final gasket installation. Coordinate with system Service tests and construction completion. Weld-Plus-Ends shall be subjected to a pneumatic pressure test of 5 to 10 psig in the annulus between the gasket and the seal weld. It shall be examined for leaks using a soap solution. For revalidation purposes of existing plant piping, the test pressure shall be minimum required by the Code ASME B31.3. The actual wall thickness of the piping and flange rating shall be determined and taken into consideration when calculating the test pressure. In case of flanged tie-in connections, a flange tester is utilized to conduct hydrostatic testing of flange butt weld. Systems that already passed a successful pressure test require RETEST IF subjected to new welding activities (Modifications, repair to pressure boundary) OR IF PWHT is reqd*.
See Notes
Note: Seal welds of threaded connections & Attachment welds of non-pressure containing parts, such as wear pads DO NOT REQUIRE RETEST UNLESS THE LINE REQUIRES PWHT (Including attachment welds & seal welds to the pressure boundary).
See Notes
Every existing plant piping & pipeline, after repairs or alterations have been made that affect the integrity of the pressure containing parts, shall successfully pass a hydrostatic test. The test pressure shall be in accordance with the requirements of the applicable code.
Note: SAEP-310 requirements apply as well for pressure testing after Repairs, Upgrades, Refurbishment, etc EXEMPT, VISUAL EXAM Drains, vents & piping downstream of pressure relieving devices that discharge directly to the atmosphere (max internal pressure 10 psig) are EXEMPT from testing. Drain holes installed, etc
Note: Test Package SIS Sheet shows design data & "EXEMPT" under required test pressure. Line(s) shall be visually examined. As Calculated* 30 mins (min) Whether piping or tubing, between the root isolation valve and the instrument isolation shall be pneumatically pressure tested (air or nitrogen) at 1.25 X design pressure of the piping system or process equipment to which it is connected. Test duration shall not be less than 30 minutes.
Note: Instrumentation that could be damaged due to the test shall be disconnected. When pneumatic test is not practical (pressure greater than 1000 psig, physical configuration, etc.) test with liquid or water. (Flush, test & dry clean using a quality of water not harmful to lines).
For internally Fusion Bonded Epoxy (FBE) coated piping system, the test pressure shall not exceed 5,000 psi for APCS 100, 101, 103 systems & 3,000 psi for APCS 102 System
Note: ALL Welding shall be completed (Design Issue), all internal coating and Holiday Testing PRIOR TO pressure testing.
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Test as an integral part with the piping or equipment to which it is connected. Test separately (separate package) as required. Exemptions include sight glasses & other instruments. Strength or Service test associated piping based on service
Note: ALL Code Piping construction (in-situ) that is not VENDOR supplied shall be tested. Utility = Service Test, Process = Strength Test
Skid-Mounted EXEMPT IF TESTED BY VENDOR 1. When testing with adjacent Lube oil system piping (no leaks = acceptance). 2. When code repairs are made to skid-mounted piping to correct misalignment, per 01-SAMSS-010 Piping (Vendor)
(exceptions noted) physical damage or any modifications in-situ, pressure test the affected spools.
FIELD HYDROTESTING OF NEW VALVES (SAES-L-108, Section 4.7 & SATIP-L-108 & SAIC-L-2042) See Note Location shall be specified by proponent & PID approved. SAIC-A-2031 Sect. J Test Location All new valves designated for isolation service (as specified by the Proponent) shall be See Note Field Testing of subjected to high pressure hydrostatic seat test prior to installation in line. New Valves Low pressure pneumatic seat test at 5 psig shall be substituted for high pressure See Note Exception
hydrostatic seat test for flare system valves. Identify & Segregate Early!!!
Exemption Procedure
(Checklist Item D4)
Buttweld & socketweld end valves in NPS 2 inches and smaller are exempt Test procedures, pressures, durations, & leakage acceptance criteria shall be equal to those that the valves were originally purchased to. All resilient (soft) seated isolation valves shall have zero leakage. See SAIC-L-2042
Note: Proponent specifies those Line Classes and valves subject to field hydrotesting. Valves received shall be carefully identified & given a unique ID number for installation into the correct Line Class based on visual verification of construction stamp. Valves shall be given a unique ID & corresponding test report document upon receipt, Valve ID shall be controlled, documents transferred into appropriate Test Pkg & Database (Piping System, Line Class, Line Number, Location) per SAEP-1160. Procedure identifies all critical aspects of Valve Testing incl Receipt Inspection (internal visual exam by qualified Inspector), pressure test, ambient lay-up (corrosion protection per mfg instructions & follow-up preservation reqmts) & segregation control to prevent "mixing valves". Controlled System for Valve Placement exists.
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SPEC AWARENESS
PIDs ATTENTION TO SPECS & SPEC-Check (Piping Line Class Specs, WPS, NDT Specs, PWHT, PMI, etc) on Projects: Initial Review of SPECS 1. Carefully recheck Contractor Piping Specs (Line Class Summary & Tables) as early as possible during or just after Design is complete (as soon as they are issued and available). 2. This is done by checking Contractors specs against Line Class Material requirements listed in SAES-L-105. Give special attention to critical systems & systems above 300#. 3. Average large projects can have as many as 50 different piping specs & details can be very hard to pick up in the field. Pipelines have fewer specs and are easier to manage. THIS INCLUDES THE MAZE OF GASKETS!!! 4. Time taken for early review only takes an experienced plant inspector 2 days of review. Findings (often human error) can be critical. Help prevent unplanned shutdowns on your projects & find substandard material specs before they are installed or before they enter service. 5. Carefully check Contractor Special Process SPECS (WPS, NDT, PWHT, etc) as early as possible (as soon as they are issued and available). 6. This is done by checking Contractors Special Process Specs against code and SA requirements (SAES-W-011, Sect 17 for NDT & 13 for PWHT). SAES-W-012 is similar to SAES-W-011 in this respect 7. Ensure that notes are included in these SPECS that require increased NDT based on field welding and other code considerations. 8. Clear violations such as our weekly highlight example (such as specs and drawings that use 3000# fittings on a 900# system instead of required 6000# fittings) must be itemized & brought to SAPMT attention early. See attached Sample Weekly Highlight. 9. After all SPECS submitted by Contractor are accepted ... CREATE your custom SPEC-CHECK (sample attached with instructions). Commentary: This is a valuable review and exercise for all inspectors. Have all inspectors trained in this task for self-reliance during future projects. This teaches critical lessons in Materials*, specification requirements* and substandard installation identification*. *FACT: MOST INSPECTORS ARE WEAK REGARDING KNOWLEDGE OF SPECIFICATIONS & ARE UNAWARE OF MANY CRITICAL REQUIREMENTS! SPEC CHECK PUTS THESE DOWN ON PAPER (BY SYSTEM)