TA 2016 AT PPTSB (DEFECT-PIPING)

Date :
ENPROSERVE MALAYSIA 04/01/2016
SDN BHD Document No : EMSB/PPTSB/TA2016/PTP-009 PPT SDN. BHD.
Rev No : 0

Document Title : PRESSURE TESTING PROCEDURE

PRESSURE TESTING
PROCEDURE

REV PREPARED BY REVIEWED BY APPROVED BY

0

Name : Name : Name :
Date : Date : Date :

Page 1 of 6
 TA 2016 AT PPTSB (DEFECT-PIPING)
Date :
ENPROSERVE MALAYSIA 04/01/2016
SDN BHD Document No : EMSB/PPTSB/TA2016/PTP-009 PPT SDN. BHD.
Rev No : 0

Document Title : PRESSURE TESTING PROCEDURE

TABLE OF CONTENT

1.0 GENERAL

1.1 Scope

1.2 Objective

1.3 Codes and Standards

2.0 DEFINITION OF PRESSURE TESTING

3.0 GENERAL REQUIREMENT FOR PRESSURE TESTING

3.1 General requirement

3.2 Test Gauges

3.3 Test Medium

4.0 HYDROSTATIC TESTING PROCEDURE

4.1 Precautions

4.2 Pressure Testing

4.3 Hydrostatic Testing Considerations

4.4 Inspection on Test Pressure

4.5 Test Failure

5.0 TEST RECORD

6.0 SAFETY

Page 2 of 6
 TA 2016 AT PPTSB (DEFECT-PIPING)
Date :
ENPROSERVE MALAYSIA 04/01/2016
SDN BHD Document No : EMSB/PPTSB/TA2016/PTP-009 PPT SDN. BHD.
Rev No : 0

Document Title : PRESSURE TESTING PROCEDURE

1.0 GENERAL

1.1 Scope

This procedure and specification covers the requirements of the hydrostatic and pneumatic pressure test
of piping during TA 2016 at PPTSB (Defect-Piping).

1.2 Objective

The objective of this procedure as a guideline to perform pressure testing safely and in accordance with
the specification.

1.3 Codes and Standards

The related code and standard to be supplement this specification is as follows:

1.3.1 ASME VIII DIV I - UG-99" Standard Hydrostatic Test"

1.3.2 API 570 - Piping Inspection Code

1.3.3 ASME B31.3 - Process Piping

2.0 DEFINITION OF PRESSURE TESTING

Pressure test is defined as pressurizing piping systems to a specified pressure to ascertain its mechanical
strength and integrity. It is categorize by two category;

1) The hydrostatic testing is where the piping completely filled with liquid or water and pressurized to the specified
pressure.

2) The pneumatic leaktest is where the piping is pressurized to the specified pressure with air or inert gases.

3.0 GENERAL REQUIREMENT FOR PRESSURE TESTING

3.1 General requirement

3.1.1 A hydrostatic testing shall be conducted on all pressure piping after ;

a) All fabrication/repair has been completed.

b) All examination have been performed and satisfactory.

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 TA 2016 AT PPTSB (DEFECT-PIPING)
Date :
ENPROSERVE MALAYSIA 04/01/2016
SDN BHD Document No : EMSB/PPTSB/TA2016/PTP-009 PPT SDN. BHD.
Rev No : 0

Document Title : PRESSURE TESTING PROCEDURE

3.2 Test Gauges

3.2.1 All indicating gauges shall be connected directly to the piping. If the indicating gauge is not readily
visible to operator controlling the pressure applied, an additional indicating gauges shall be
provided where it will be visible to the operator throughout the duration of the test.

3.2.2 It is recommended that a recording gauge be used;

a) Dial indicating pressure gauged used in testing shall be graduated over a range of about double
the intended maximum test pressure, but in no case shall the range be less than 1 not more
than 4 times of the test pressure. Digital reading pressure gauges having a wider range of
pressure may be used provided the reading give the same or greater degree of accuracy as
obtained with dial pressure.

b) All gauges shall be calibrated against a standard deadweight tester or calibrated master
gauges. Gauges shall be recalibrated at any time that there is reason to believe that they are in
error or not exceed 12 months as per recommendation.

3.3 Test medium

3.3.1 Hydrostatic pressure test piping having component of type austenitic stainless steel should be
conducted with portable water or steam condensate having a chloride concentration of less than
30 ppm. After the test, the equipment should be completely drained and dried. The medium can be
used in the testing is demineralise water. Chloride contents certificate for portable water shall be
attached before performing the hydrotest.

3.3.2 For the common material like carbon steel can be conduct the hydrostatic with the service
water/plant water.

3.3.3 For the pneumatic test, compressed air from air compressor can be used other than plant service
air or other gases medium as per owner requirement.

4.0 HYDROSTATIC TESTING PROCEDURE

4.1 Precautions

4.1.1 EMSB QA/QC Inspector is responsible for conducting the hydrostatic test which shall be
witnessed by owner / Third Party Inspector and applied as specified on the drawings.

4.1.2 All hydrostatic tests shall be performed using the minimum double gauges method. The gauges
shall be attached directly on the highest point and lowest point (vent point and drain point).

4.1.3 The test pressure should be holding at least 30 minutes minimum for test leaks or as per owner
requirement.

4.1.4 It shall be ensured that, before any test, line test schematic shall be approved by the owner and
design of the system is such that it can withstand the weight of the hydrostatic medium.

4.1.5
All the unnecessary valves, transmitters, gauges that not subjected to hydrotest shall be dismantle.

4.1.6 Ensure all flange connection, the bolting has been tightened properly.

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 TA 2016 AT PPTSB (DEFECT-PIPING)
Date :
ENPROSERVE MALAYSIA 04/01/2016
SDN BHD Document No : EMSB/PPTSB/TA2016/PTP-009 PPT SDN. BHD.
Rev No : 0

Document Title : PRESSURE TESTING PROCEDURE

4.2 Pressure Testing

4.2.1 As per stated in AFC drawing or 1.5 times design pressure for piping.

4.3 Hydrostatics Testing Considerations

4.3.1 EMSB QA/QC is responsible for conducting the hydrostatic test which shall be witnessed by
PPTSB representative and to be informed in advance.

4.3.2 All pressure test equipment, test pump, hoses, fittings which to be used for pressure test should
be checked in good working condition by EMSB QA/QC and verify by PPTSB before using it for
pressure testing.

4.3.3 All joints and welds shall be left uninsulated, unpainted and exposed for examination during test.
Piping which is connect or continues with equipment or line to be tested shall be isolated by using
test blinds, valves or spades.

4.3.4 All vents should be open during water filling from lowest point to ensure that air is vented prior to
applying test pressure to the system.Increase water pressure gradually by using test pump.

4.3.5 Increase pressure until reach 30% of the test pressure and hold for 5 minutes. Check joints and
confirm no leaks.

4.3.6 Gradually increase pressure until reach 60% of the test pressure, hold 5 minutes and check joints
to confirm no leaks.

4.3.7 Thereafter, increase pressure gradually in step until the test pressure is reached, holding the test
pressure for 30 minutes (min).

4.3.8 EMSB QA/QC Inspector shall be visually checked the piping during hydrostatic testing and monitor
the pressure gauges to confirm no leaks.

4.3.9
After holding time at least 30 minutes at the test pressure and no leaking detected during that time,
reduce pressure to 60% of the test pressure for 5 minutes holding time and confirm no leaks.

4.3.10 Then, reduce pressure until reach 30% of test pressure and hold for 5 minutes. Check joints and
confirm no leaks.

4.3.11 Thereafter, reduce pressure gradually in step until the pressure is reached zero.

4.3.12 After testing is completed and approved by PPTSB representative then piping should be drained
from water for a closed examination, pressure shall be released by opening the valve gradually so
as not to endanger personnel or damage piping.

4.3.13 Before water in the piping system is drained, vent shall be opened and shall kept open until water
will be fully drained from equipment or piping system.

4.3.14 When accepted, EMSB QA/QC Inspector and PPTSB representative shall be sign off the result of
hydrostatic test report.

Page 5 of 6
 TA 2016 AT PPTSB (DEFECT-PIPING)
Date :
ENPROSERVE MALAYSIA 04/01/2016
SDN BHD Document No : EMSB/PPTSB/TA2016/PTP-009 PPT SDN. BHD.
Rev No : 0

Document Title : PRESSURE TESTING PROCEDURE

Hydrotest Flow Chart

Pressure (Bar)

Test Pressure Holding Time

Holding Holding
60% Test
Time Time
Pressure
Holding Holding
Time Time

30% Test
Pressure
0 5 min 5 min 30 min 5 min 5 min Time

4.4 Inspection on Test Pressure

4.4.1 The application of the hydrostatic test pressure, an inspection shall be made of all joints and
connection. Except for leakage that might occur at temporary test closures for those opening
intended for welded connection, leakage is not allowed at the time of the required visual
inspection.

4.4.2 Both gauges shall be check to ensure the readings shown on both the gauges do not exceed a
difference of 4% at any time during testing. All gauges and pressure recording equipment shall
have valid calibration certificates.

4.4.3 A temperature gauge shall be placed on the equipment to check the temperature. During testing
the temperature of the vessel and test meter reading shall not be lower than 7C nor more than
50C. No wet surface / rainy day ease of leak detection.

4.4.4 On satisfactory completion of inspection, the pressure shall be released gradually. All vents shall
be opened and temporary blinds shall be removed during draining to prevent the creation of
vacuum. The drying process shall be carried out by means of dry compressed air or other medium
as specified in the drawing / client specification.

4.5 Test Failure

4.5.1 Should a leak be detected, it shall be located and repaired. Regardless of where the failure
occurs, the faulty section shall be marked with its location and shall be delivered to such place as
PPTSB dictates. Re-hydrotest shall be carry out after repair work completed.

5.0 TEST RECORD

Test Record shall be made of each piping system during the testing, including:
a. Date of test.
b. Identification of equipment or piping system tested.
c. Test pressure.
d. Pressure gauges calibration certificates.
e. Certification of test results by examiner

6.0 SAFETY

6.1 The testing area shall be barricaded and signboard noted Pressure Testing in Progress should be
displayed to ensure precautions have been taken.

6.2 Supervisor / foreman must ensure that the work can only be started when no more hazardous gases
detected around the work and covered by approved permit.

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