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TABLE OF CONTENTS

1.0

INTRODUCTION

2.0

ABBREVIATIONS, DESCRIPTIONS

3.0

REFERENCES

4.0

PRESSURE TESTING

5.0

QUALITY CONTROL / ASSURANCE

6.0

SAFETY

10

7.0

ASSOCIATED ITPs, WORK INSTRUCTIONS

12

8.0

ATTACHMENTS

13

1.0 INTRODUCTION

The purpose of this MS is to explain the construction procedures and


methodology for the pressure testing of pipework. For the purpose of this method
statement the Hydrostatic, Pneumatic, Service and Alternative testing
procedures shall be described.
All such works shall be performed in full compliance with IFC Drawings,
Specifications, ITPs, Vendors Procedures and all relevant Codes and Standards.

Codes, Standards, Specifications, Procedures, Regulations and References in


the CWP.

ASME B 31.3

60-0000-L-SPE-0003 Specification for Piping and Material Classes

60-0000-L-SPE-0006 Specification for Piping Installation and Testing

60-0000-L-SPE-0020 Specification for Site Piping Material Traceability

60-0000-L-SPE- 0007 Specification for Paint and Protective Coatings

60-0000-W-SPE-0421 Process Plant Piping , Welding PWHT and NDT

60-0000-L-SPE-0014 Specification for Piping Standard Details

60-0000-L-SPE-0002 Specification for Pipe Supports

COMPANY MS-030 Method Statement for the Transport of Spools and


Materials

4.0 PRESSURE TESTING


4.1 COMPANY piping engineers shall prepare test packs for each test system
based upon the appropriate P & ID, isometrics and piping layouts. The
packages shall further comply with all local code requirements.
4.2 In the event that there are inadequate high point vents and/or drains in any
system the COMPANY RE shall agree with PFD the sizing and location(s) of
required additional ones. All such vents and drains shall be installed with
materials compatible with the relevant Piping Class.
4.3 Included within each test pack shall be a marked up P&ID, As Built
isometrics clearly defining the test pressure (as per the Line Designation
Table), the duration of test and the extent of the pipe work to be tested. The

extent of the test shall be such that the static head of the test medium does
not create a pressure greater than the maximum allowable test pressure.
4.4 All in line components or internals which are to be removed , temporary test
blinds, test vents and drains and plugs that shall be utilised for testing the
pipe work are to be recorded on the test diagram.
4.5 Included in the test package will be sign off sheets wherein both COMPANY
and PFD representatives shall duly record their approval of the test
preparations, pre- test/post test punch lists, testing/flushing and post test
completion.
4.6 COMPANY QC supervisor and PFD (NEWS) Engineer shall sign off on the
test package prior to testing as the means of verifying that all welding,
PWHT and NDT has been completed in accordance with the relevent
codes/standards and project specifications. COMPANY QC Engineer shall
verify that all ITP check lists are updated with the relevant approval
signatures.
4.7 The RE and RS shall carry out a pre-test walk down of the pipe system to be
tested with PFD, duly agreeing, classifying and recording punch items that
are to be completed before the test (Category A) or items that may be
completed, at a later date, after test completion (Category B).
4.8 Temporary test blinds shall be of adequate thickness to withstand the test
pressure. They shall have an integral lug or handle which shall be painted
for identification purposes. Suitable gaskets shall be used to prevent
damage to permanent flange faces.
4.9 Instrument connections shall be closed with a properly gasketed blind flange
or plugged off.
4.10 The RE shall confirm the removal of all inline piping components that are
liable to be damaged during the pressure test. Permanent pressure and
thermal relief valves shall not be included in system pressure test.

4.11 All in line items and internals to be removed for the test shall be agreed with
PFD and adequately labelled and the component to which they belong or the
position in the line from which they have been removed shall also be
labelled. These shall be noted on the Release for Test form and signed by
both COMPANY and PFD. (Attachment 8.1)
4.12 Testing, as a general rule, shall not be carried out against closed valves. All
valves in the pressure test should be in the fully open position. Any test to be
performed against a closed valve shall be approved by PFD.
4.13 Weld joints shall be left uninsulated to allow access for visual inspection
during the duration of the pressure test.
4.14 A certified testing rig or manifold shall be used for the pressure testing. The
testing rig shall have a calibrated pressure gauge , pressure relief valve and
bleed valve which shall be located on the upstream side of the rig or
manifold block valve. Test pressure gauges shall also be installed at high
and low points of the piping system in order to accurately monitor test
pressures during the test. A pressure recorder shall be used for the duration
of the test period.
4.15 Water, supplied by PFD, shall be fresh, clean and free from suspended
solids and other foreign matter and with chloride content of not more than
50ppm.
4.16 Prior to filling any system it shall be checked for installation completeness,
including all permanent supports and temporary supports (if required),
satisfactory test preparation, inclusive of system cleaning, the locations of
pressure gauges, installation of test vents and drains and the suitability of
the test rig. All mechanical supports (spring supports) shall be checked to
ensure that the locking pins are installed prior to filling of any system.
4.17 Prior to pressurisation of the piping system, the area shall be monitored ,
cordoned and sign posted with warning notices to prevent unauthorised
personnel from entering the testing area.

4.18 After all preliminary test preparations are complete testing medium shall be
introduced into the piping system from a low point in the system. The
system shall have high point vents left open until test medium flows from the
outlet and then shall be closed.
4.19 Precautions shall be taken to avoid temperature variations between the test
medium and piping system during the winter season and as a minimum the
testing medium shall not be less than 5 C.
4.20 Piping system shall be pressurised at a rate of not more than 5 barg per
minute. Upon attaining the required test pressure, the manifold block valves,
downstream of the test pump shall be tightly closed. The pressure shall be
held for sufficient time to equalise strains in the system.
4.21 Pressure shall be held for such a time as to allow visual inspection of the
complete system for leakage but in any event shall not be less than 10
minutes.
4.22 Drops of test pressure, in one hour, of 3% shall be acceptable for hydrotest
acceptance.
4.23 Upon completion of the pressure test,all high point vents shall be opened
before draining of the system of the test medium. The system shall then be
air flushed and dried with clean, approved air to the satisfaction of the
relevent parties. All components removed for the testing shall be re-instated
and re-inspected by the RE and PFD representative. In particular all flange
faces of removed items and their mating flange shall be carefully checked.
Any post test punch list item shall be duly recorded, catagorised and agreed
between the parties.
4.24 Due to the inherent dangers of pneumatic pressure testing, such testing
shall only be carried out when deemed necessary and with the explicit
approval of the operating authority and project management. Additional
precautions shall be taken to ensure the safety of personnel participating in
the pressure test and personnel adjacent to the piping system being
tested.As a minimum the following shall be adhered to :

Pneumatic test pressure shall not exceed 110% of the design pressure
whether using air or nitrogen as the test medium.

System shall be pressurised to 5 barg and held for sufficient time to


allow equalisation of piping strains and the visual inspection for
leakage using soapy water.

Further pressurisation of the system shall be undertaken in increments


of no more than 10% of the specified test pressure and held for not less
than 10 minutes to allow equalisation of strains.

Test pressure shall be held for the length of time required to examine
the system prior to the depressurisation to design pressure level in
order to carry out soapy water testing of weld joints.

4.25 Special attention shall be taken to ensure against the adverse effects of
brittle fracture occurences from low metal temperature.
4.26 Piping System shall be air flushed to the satisfaction of the relevent parties
prior to re-instatement of the system.
4.27 On completion of re-instatement piping system shall be re-inspected by the
parties for mechanical completeness, duly recorded, categorising any punch
items for inclusion within the test package.
4.28 Category D piping systems (excluding firewater) may be pressure tested
with its own medium at its operating pressure. Testing shall be undertaken
utilising the same parameters for the testing, recording, and safety
precautions as per hydrotesting.
4.29 When deemed necessary and within the guidelines of ASME B31.3 rules for
qualification, alternative test in accordance with same may be employed. In
such cases conditions as stated in para. 345.9 of ASME B31.3 shall apply for
the NDT of welding joints and para. 345.8 for any subsequent leak testing.
The agreement of PFD shall be required prior to the foregoing actions.
5.0 QUALITY CONTROL/ASSURANCE

5.1 Prior to testing the COMPANY QC Welding Engineer shall verify that all the
required welding, PWHT, NDT has been completed and carried out in
accordance with the project specifications. Records for the aforementioned
functions shall be made available for review, upon request, for the relevant
test package prior to the commencement of pressure testing.
5.2 COMPANY QC Engineer shall ensure that all test equipment has been
certified and calibrated for the intended purpose in accordance with
specification requirements. Test records for such calibrated equipment shall
be made available within the relevant test package.
5.3 Test gauges shall be visually inspected prior to each test to verify their
condition and that there is no obvious damage to them. If, during the test,
any of the gauges being used indicate inaccuracies in readings they shall be
replaced with another calibrated one.
5.4 Suitably ranged gauges (1.25 4 x Test Pressure) shall be used to verify
accurate test pressure readings.
5.5 A pressure recorder shall be used for each system test.
5.6 On completion of tests all test blinds, temporary supports etc., shall be
removed and permanent gaskets and fittings re-installed. In line Items and
internals removed for the test shall be reinstated and carefully monitored to
ensure their correct locations. COMPANY and PFD QC Engineers shall
witness these activities.
5.7 Relevant, approved ITPs will be strictly adhered to. All ITP Hold Points shall
be notified to and witnessed by PFD & COMPANY QA/QC Engineers and the
SA, as applicable.
5.8 All tests shall be witnessed and records signed off by COMPANY
QA/QC Inspectors, PFD, Statuatory Authorities and TAs as applicable. Test
documentation shall be used as attached to ITP 451 Pressure Testing of
Piping.

5.9 All originals of test records and inspections shall be retained by COMPANY for
inclusion in the final hand over documentation. Copies of such shall be
made available for PFD and the SA as applicable.
6.0 SAFETY
6.1 All personnel shall adhere to the COMPANY and PFD Safety Programmes.
6.2 COMPANY Management and Supervision shall encourage all personnel to
be pro-active in the promotion of the IIF culture.
6.3 All personnel shall be issued with and shall use the requisite PPE.
6.4 Daily Tool Box talks shall be held with all personnel.
6.5 STA reviews shall be made prior to testing commencing and shall be
reviewed and amended as required on a daily basis.
6.6 The RE shall apply for all necessary permit(s) with all required
documentation and drawings etc.
6.7 All lifting Equipment shall be duly certified / tagged and fit for the intended
purpose.
6.8 All electrical equipment shall be inspected for electrical safety and
appropriately tagged.
6.9 All scaffolding shall be erected by qualified personnel and the Scaff Tag
system of inspection and use shall be used. Inspections shall be carried out
on a weekly basis or as required
6.10 All test equipment shall be of good working order and fit for the intended
purpose. They shall be tested and calibrated by the approved authority per
specification.

6.11 All safety pressure relief devices shall be tested and calibrated by the
approved authority per specification. Valid test certificates shall be available
for inspection.
6.12 .Pressure testing area is to be cordoned and sign posted with suitable
warning signs (two languages).
6.13 Test systems shall be fully attended at all times when under pressure
6.14 On completion of tests the systems shall immediately be depressurised and
vented in a gradual and safe manner. It shall be ensured that all vents have
been opened prior to draining commencing.