Contract

Number: P1007

File Reference

Page

1007-DISQ-0-L-SS-39024-Rev. 0

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RWE Dea

Disouq Field Development

FEED

Specification for Piping Flushing and Testing

1007-DISQ-0-L-SS-39024

26.02.12 Issued for Client Review

M Magdy

A Fawzy

A Hamdan

RWE

A Abbas
Rev

Date

Description

Issued By Checked By Approved

By

Client
Approval

Onspec Engineering Solutions

Disouq Field Development Project
Specification for Piping Flushing and Testing

Table of Contents
1

INTRODUCTION ....................................................................................................... 4

SCOPE ...................................................................................................................... 5

REFERENCES .......................................................................................................... 5

ABBREVIATIONS ...................................................................................................... 6

FLUSHING ................................................................................................................. 6

GENERAL REQUIREMENTS OF TESTING ............................................................. 7

6.1

Test Fluid ................................................................................................................... 9

6.2

Test Preparation ........................................................................................................ 9

6.2.1

Instrumentation .......................................................................................................... 9

6.2.2

Test Pressure Gauges ............................................................................................. 10

6.3

Procedure for Pressure Testing ............................................................................... 12

6.4

Test Records ........................................................................................................... 12

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Disouq Field Development Project
Specification for Piping Flushing and Testing

Changes List
Rev.

Date
prepared
(DD.MM.YYYY)

Prepared by

Description

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Onsp
pec Engine
eering Solutions
Disouq
q Field Dev
velopment Project
P
Sp
pecification
n for Piping
g Flushing and Testin
ng
1 IN
NTRODUCT
TION
RWE Dea Egyptt has discovvered seven
n natural ga
as reserves in the Diso
ouq Concesssion within
the on
nshore Nile Delta, startting in 2008
8, as shown
n on the con
ncession ma
ap below. Further
F
exploration in the
e concessio
on is ongoin
ng. RWE De
ea Egypt is the operato
or of the Concession
EGAS as a partner.
with E

The sselected devvelopment comprises

c
a central ga
as treatmentt site near NSG-1x,
N
wh
here the
gas iss collected, treated by means
m
of Low Temperrature Sepa
aration utilizing the Joule
Thom
mson effect to
t achieve gas
g quality, and comprressed for export.
e
Trea
ated gas is transferred
t
via a 16 pipeline
e directly intto the GASC
CO NTS pip
peline.
The w
well fluids arre gathered
d and fed to a common inlet separrator at the central
c
plan
nt. All gases
s
and liquids will be separated
d and proce
essed on the
e central tre
eatment site
e into sales gas,
nsate, and free
f
producction water.
stabiliized conden
Treatm
ment of gass is carried out in two trains, while
e treatment of
o condensa
ate is in a single
s
train.
Three
e trains of sa
ales gas co
ompression are installe
ed. Fuel gass for the gass engine drives is
taken from the su
uction of the
e sales gass compresso
ors.

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Onspec Engineering Solutions

Disouq Field Development Project
Specification for Piping Flushing and Testing
2

SCOPE

The purpose of this specification is to define the construction requirements of flushing, testing
and inspection of piping system.
This specification supplements the applicable code requirements/ specifications/ standards for
fabrication, erection, inspection, testing of pipelines.
Engineering drawings/ codes/ standards shall take precedence over this specification if there
are any conflicting clauses.
3

REFERENCES

Throughout this Standard the following standards/codes are referred to. These referenced
documents shall, to the extent specified herein, form a part of this standard. The latest edition
of the referenced documents (including any supplements and amendments) applies.
1.

ASME B31.3

Process Piping

2.

ASME PCC2

3.

ASME VIII

Repair of Pressure Equipment and

Piping
Boiler and Pressure Vessel Code,
Section VIII Rules for construction of
Pressure Vessels, Division 1

4.

API 6A

API standard 6A

5.

ISO 4406

Hydraulic fluid power Fluids

Method for coding the level of
contamination by solid particles

6.

ASME PCC-1

Guidelines for Pressure Boundary

Bolted Flange Joint Assembly

7.

EN 1591

Flanges and their joints

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Onspec Engineering Solutions

Disouq Field Development Project
Specification for Piping Flushing and Testing

4 ABBREVIATIONS
ABBREVIATION
ABS
API
ASME
EN
GRP
He
HVAC
ISO
IX
N2
N2He
NCR
NDE
NPT
O2
OD
P&ID
PAS
PVC
UV
5

DESCRIPTION
Absolute
American Petroleum Institute
American Society of Mechanical Engineers
European Standard
Glass fibre reinforced plastic
Helium
Heating ventilation and air conditioning
International Organisation for Standardisation
Special metallic seal ring
Nitrogen
Nitrogen helium
Non-conformance request
Non-destructive examination
National Pipe Thread Taper
Oxygen
Outside diameter
Piping and instrument diagram
Pressurised air shock blowing
Polyester vinyl chloride
Ultra violet

FLUSHING

Flushing of all lines shall be done before pressure testing. Flushing of all lines shall be
done in the presence and as per the approval of the Company. Flushing of piping
system will be done by fresh potable water or dry compressed air wherever water
flushing is not desirable to clean the pipe of all dirt, debris or loose foreign materials.
The supply of compressed air for flushing will be Contractor's responsibility and it will
be done at his cost.
It will be Contractor's responsibility to provide pumping equipment, compressors,
water / air hoses with accessories etc., Wherever required, instruments such as
pumps, pressure gauges, safety valves etc. spool pieces, temporary gaskets, tools
and tackles and all other arrangements, equipment, materials and consumables etc.
required as aids for completing the flushing as per the directions of the Company.
During flushing, care shall be taken for on line instruments as per clause of this
specification.
The Contractor shall carry out all the activities required before, during and after the
flushing operation arising from the flushing requirement such as but not limited to the
following :

Removing of valves, specials, distance pieces, on line instruments and any

piping part before flushing. The flanges to be broken for this purpose should be
envisaged by the Contractor approved by the Company and should be provided
with temporary gaskets at the time of initial erection.

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Onspec Engineering Solutions

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Specification for Piping Flushing and Testing

After flushing is completed and approved, the valves, distance pieces,

piping specials etc. shall be re-installed by the Contractor with permanent
gaskets. However, flanges at equipment nozzles and other places where
isolation is required during testing, only temporary gaskets will be provided.
Flushing will be continued till the inside of the pipe is fully cleaned to the
satisfaction of the Company
For air flushing the line / system will be pressurised by the compressed air at
the required pressure. Then pressure will be released by quick opening of
a valve already in line or installed temporarily for this purpose.
This procedure will be repeated as many times as required till inside of
the pipe is fully cleaned. The arrangement for raising and releasing the
air pressure will be made by the Contractor as per the approval of the
Company
During the flushing, discharged water / air shall be drained to the place directed
by the Company. Care shall be taken during flushing so as not to damage /
spoil other agencies work. As desired by the Company, proper temporary
drainage for flushing of water shall be provided by the Contractor. Precautions
shall also be taken to prevent entry of water / foreign particles in to equipment,
electrics, motors, instruments, electrical installations etc. in the vicinity of lines
being flushed.
In case where fluid inlet in to the pipe lines through connected equipment such
as columns, vessels, exchangers etc. is unavoidable this shall be done after
having approval of the Company. However, equipment thus included in the
circuit for the flushing shall be completely drained and dried with
compressed air after flushing is completed.
Wherever required as per specification lines will be dried with air after flushing.

GENERAL REQUIREMENTS OF TESTING

The intent of this specification is to provide a basis and guide for carrying out field
testing of piping to ensure leak tightness. This covers the general requirements for
testing of piping after erection as specified by the code of Petroleum Refinery
Piping ASME B.31.3. Chapter VI Inspection and Test - Latest Edition. Upon
completion of installation the piping system shall be inspected to ascertain that each of
the following points has been adhered to:

Proper use of material.

Correct erection of line (in accordance with drawings).
Correct installation of (temporary) blind discs to be employed during testing.
The correct application of pre-established pressure.
Sectioning of the line in correspondence with these materials and / or
equipment, which are not a part of the test.

With the exclusion of instrumentation, piping systems fabricated or assembled in the

field shall be test in the field, irrespective of whether or not that have been pressure
tested prior to site welding or fabrication (Process and Utility piping system).
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Specification for Piping Flushing and Testing
After completion of flushing and testing, draining and drying of lines, the permanent
strainers screens shall be cleaned and re-installed. During flushing temporary strainers
shall be retained. After flushing temporary strainers shall be removed, cleaned and reinstalled before testing. All joints remaining untested during hydro-testing such as
nozzles in columns, vessels, heat exchangers etc. shall be tested pneumatically after
the hydrogenating is over. Pneumatic test pressure will be indicated by the Company
and Contractor shall ensure that this test pressure is not exceeded any time during this
test.
All tests shall be conducted as per the procedure outlined in this specification. Lines
repaired by welding subsequent to the pressure test shall be retested after the repair at
the same test pressure originally applied. However, the Company may waive such
retest in case of minor addition or alteration by taking some precautionary
measure to assure sound construction.
The selection of piping systems for individual test will be based on the following:

Test Pressure required.

Maximum allowable pressure for the Material of Construction of piping.

Depending on the above requirement and based on Construction completed / on

construction progress, maximum length of piping shall be included for each
test. Piping checks incorporating various lines to be tested at the same process
shall be marked on the P&I diagram.
Systems / lines may be tested in sections to facilitate completion of work in that area or
areas, however, such sections so tested shall be capped out, tagged suitably
and subsequently tested as a complete system prior to final acceptance. Such weld
joints (untested) may be exempted from hydraulic testing by the Company subject to
radiography approval of these joints.
Lines, which are directly, open to atmosphere such as vents, drains, safety valves,
discharge shall not be tested but all joints shall be visually inspected. Wherever
necessary, as decided by the Company, such lines shall be tested by continuous flow
of fluid to eliminate the possibility of blockage.
Instrumentation pressure impulse piping shall start beyond the first block valve located
in the process line. During the pressure test this isolation valve must be kept closed to
prevent dirt or any foreign matter entering in to the instrument piping. Temperature
impulse connections shall be blocked off by a blind flange or threaded plug to be
provided by the Contractor.
Locally mounted indicating pressure gauge may be tested with the piping if the test
pressure does not exceed the scale range. However, the gauge shall be blocked off
from the piping during cleaning and flushing. Where lines to which they are connected
will receive a higher test pressure the gauge shall be isolated by closing the gauge
isolation valve.
The Company shall be notified in advance by the Contractor of the testing sequence /
programme to enable him to be present for witnessing the test.
Required number of copies of test certificates in this respect shall be obtained in the
relevant Companys certificate form.

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Specification for Piping Flushing and Testing
6.1

Test Fluid

Fresh potable water shall be used as the testing medium for the hydrostatic testing of
piping unless specified otherwise. Air shall be used as alternate medium wherever
specified in the line list / specification and for drying the lines. In testing of stainless
steel equipment and piping water containing more than 50 ppm of chloride shall not be
used.
In case chloride content of water is less than 50 ppm. Water used for hydrostatic
testing of Stainless steel equipment and / or piping should be drained completely as
soon as test is approved.
Salty water shall never be used for hydrostatic testing under any circumstances.
Pressure testing for certain specific lines will have to be carried out as per piping
specifications.
6.2

Test Preparation

All equipment, materials, consumables, and services mentioned below but not limited
to them, required for carrying out pressure testing of piping shall be provided by the
Contractor at his cost:

Pump sets for pressurisation, air compressor etc.

Hoses for water and other test fluid if any, with accessories and adaptor
flanges.
Supply, fabrication and erection of temporary carbon steel piping valves,
fittings specials etc.
Pressure gauges, safety valves and all such instruments with necessary
connections.
Temporary gaskets wherever required as per specifications and instructions of
the Company.
Soap solution, grease, graphite, white lead, paints etc. all consumables.
Tools, Tackles, pipe wrenches, spanners etc.
All aids not specified here but required for carrying out pressure test of piping.

Before testing all piping shall be cleaned by fresh potable water or blown with
compressed air where water flushing is not desirable to make it free from dirt, loose
scale, debris and other loose foreign material as per the details given in clause thereof.
This should be completed wherever required prior to completion of final weld in order
that visual inspection of interior is possible.
6.2.1

Instrumentation

Any restrictions which interfere with filling of draining such as orifice plates etc. shall
not be installed until flushing is completed. Till such time that orifice plate is installed
orifice flanges shall be provided with temporary gaskets.
Control valves shall be first installed with temporary gaskets. Before flushing is started
control valves shall be removed and reinstalled after completion of flushing and
testing with permanent gaskets. If for any reason control valve is retained in the line
during tests, it shall be isolated by blinking off.
All safety valves and rotameters shall be installed only after flushing and testing is
completed successfully.
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Specification for Piping Flushing and Testing
Wherever in the line any void exists, due to any reasons, for absence of control valves,
safety valves check valves etc. it will be filled with temporary spools.
All joints welded, screwed or flanged shall be left exposed for the examination during
the test .Before pressurising the lines each weld joint shall be cleaned by wire brush to
make it free from rust and any other foreign matter.
The test will be carried out with permanent gaskets installed unless otherwise specified
herein or instructed by the Company.
Vents and drains at the highest and the lowest points in the piping systems shall be
provided.
Pumps, blowers, compressors, in line instruments other equipment and piping
specialities shall be isolated during flushing and pressure testing by metallic blinds,
blanks caps or plugs.
No pressure test shall be carried out against closed valve unless approved by the
Company.
Piping which is spring or counter weight supported shall be temporarily supported
where the weight of the test fluid would overload the supports.
Retaining pins or spring supports shall be removed only after testing is completed and
test fluid is fully drained.
Piping systems subject to extended hydrostatic test period shall be provided with
protective device to relieve excess pressure due to the thermal expansion of the test
fluid.
6.2.2

Test Pressure Gauges

All gauges used for field testing should be of the Bourdon type having a suitable range
and dial scale not less than 4 diameter. Test pressure indication should fall between
40vc % to 80% of the gauge scale range. Gauge shall be of good quality and shall be
in first class working condition.
Prior to the start of test and periodically during the field test programme all test gauges
shall be calibrated using a standard Dead W eight gauge tester or other suitable
approved testing apparatus. Any gauge showing incorrect zero reading, or error of
more than + 2% of full scale range shall be discarded. The Company shall check the
accuracy of water pressure gauge used for calibration. The Contractor shall furnish
documentary
proof of having calibrated each gauge / instrument to the
satisfaction of the Company and shall maintain such records until completion of the
project.
The pressure gauge shall be installed as close as possible to the lowest point of piping
system to be rested to avoid over stressing of any of the lower portion of the system.
For longer lines and vertical lines two or more pressure gauges shall be installed at the
locations decided by the Company. Over and above the pressure gauges installed in
the system being tested, a pressure gauge will be installed on discharge of pumps or
other pressurising source.
For lines containing check valves any of the following alternatives will be adopted for
pressure testing:

Wherever possible pressurise up stream of valve.

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Specification for Piping Flushing and Testing

Replace the valve by a temporary spool and reinstall the valve after testing.
Provide blind on valve flanges and test the up streams and down streams of
the line separately and remove the blind after testing, (in all the above
mentioned cases wherever valves, flanges are required to make and break for
testing, the Contractor shall provide temporary gaskets at the time of initial
installation of check valves. Final gaskets will be provided only after completion
of testing.)

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Utilities Consumption List
6.3

Procedure for Pressure Testing

All pipe lines to be tested are shown in the piping specifications. The medium to be used and
test pressure to be applied is also indicated in the piping specifications provided to
the Contractor for the performance of work.
The minimum hydrostatic / pneumatic test pressure shall be indicated in the piping
specifications or as per instructions of the Company.
The selection of the piping system for one individual test will be based on the following:

Test pressure required as per line list.

Maximum allowable pressure for the material of Construction of piping.

Depending upon the above requirements and based

maximum length of piping shall be included in each test.

on

construction

progress

All vents and other connections used as vents shall be left open while filling the line with test
fluid for complete removal of air, in the lines for pressurising and depressurising the system
temporary isolating valves shall be provided in valve vents, drains do not exist in the systems.
Pressure shall be applied only after the system / line is ready and approved by the Company.
Pressure shall be applied by means of a suitable test pump of other pressure source which
shall be isolated from the system as soon as test pressure is reached and established the
system.
The test pressure shall be retained long enough to facilitate inspection of the
complete system. Duration of the test in each case shall be fixed up by the Company but in
no case it will be less than 2 hours. No leakage of any kind will be permissible. The glands of
the valves in the system being tested shall be tightened by the Contractor, so as to
stop / minimise the leakage, if any. In case leakage is not stopped after adequate tightening
of the glands, the hand wheel of such valves shall be painted red only on the rim to identify
these valves for subsequent repair. The gland packing for replacement shall be supplied by
the Company.
The Contractor shall replace the gland packing on the valve and tighten it to make it leak
proof. Valve gland tightening and hand wheel painting shall be done by the Contractor.
Care shall be taken to avoid increase in pressure due to temperature variation during the test.
After completion of hydro test, the pressure shall be released gradually. All vents and drains
shall be kept open till the lines are fully drained. After draining, lines / systems shall be dried
by air.
Pressure test shall be considered, complete only after approval by the Company. Defects, if
any noticed during testing shall be rectified immediately and retesting immediately and
retesting of the system / line shall be done by the Contractor at his cost.
6.4

Test Records

Records in triplicate shall be prepared and submitted by the Contractor for each
system (line wise) for the flushing and the pressure test done giving following details in the
form approved by the Company.

Date of flushing.
Date of test.
Identification of piping tested, i.e. line no., line diagram no., plant area etc.
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Utilities Consumption List

Flushing medium used.

Test fluid used.
Minimum test pressure required and actual test pressure obtained.
Signature of the Contractor's representative.
Approval signature of the Company.

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