100801SSPP007

J3Program
PipingErectionandTesting Date:16/05/2013,Rev.2

RECORDOFREVISIONS

Date RevisionDetails Revision

Number

20.07.2012 IssuedforImplementation 0

21.01.2013 CriteriaforPneumaticTestingincluded 1

Section.7.0:Addedapplicablecodes&standardsfor
Pneumatictesting,
Section.9.4.4Addedthefollowing:
ConditionsinwhichPneumatictestingis
acceptable
RequirementforDECstoidentifyPneumatic
testinginLineDesignationTable(LDT)

16.05.2013 Section.9.7.13:Changedspecifiedlimitstospecified 2
testpressurelimits
Section.9.10: Added sections 9.10.1, 9.10.11,9.10.12
and 9.10.13 related to stored energy calculation
narrative
Replacedsectiondesignationa,b,cfto9.10.1,9.10.2
9.10.13
Deleted attachment4 related to safety distance
calculation

100801SSPP007
J3Program
PipingErectionandTesting Date:16/05/2013,Rev.2

Contents
1. Purpose............................................................................................................................. 1
2. Scope ................................................................................................................................ 1
3. Costcompetitiveengineeringanddesign........................................................................ 1
4. ConflictsandDeviations................................................................................................... 1
5. Definitions: ....................................................................................................................... 1
6. Abbreviations: .................................................................................................................. 2
7. CodesandStandards:....................................................................................................... 3
8. BasicMethodology........................................................................................................... 4
9. InspectionandTesting: .................................................................................................. 13
10 PreparationforShipment: ............................................................................................. 26
11 VendorDataRequirement: ............................................................................................ 27

ATTACHMENT1AluminiumBlindforBlindingEquipmentNozzles ....................................... 30
ATTACHMENT2AlignmentofDowelPinwithThreadedEnd................................................ 34
ATTACHMENT3AlignmentofDowelPinwithPlainEnd ....................................................... 38

100801SSPP007
J3Program
PipingErectionandTesting Date:16/05/2013,Rev.2

1. Purpose
Thisspecification is to establish the general requirements for the field installation
andpressuretestingofpipingsystems.
2. Scope
This specification shall be applied to above ground and underground process and
utilitypiping,includingpipeworkinmodules,packageunitsorothersubassemblies,
offshoreandonshore.Refertoseparatespecificationfortheinstallationofbelow
groundpipework.
3. Costcompetitiveengineeringanddesign
The engineering team shall maintain the cost focus throughout all phases of the
project. This should be done without compromising any specification and design
requirements.Fromtheperspectiveoferectionandtestingforpiping,effortsshall
be made to optimize usage of modular approach and sub assemblies so that the
variablecomponentofcostcouldbeminimized.
4. ConflictsandDeviations
Process and utility piping shall be fabricated in accordance with codes, drawings,
andotherrequirementsspecifiedherein.Whereconflictexists,theorderofpriority
ofdocumentsshallfollowinthefollowingsequence:
(i).LocalRegulatoryandStatutoryrequirement
(ii).ThisSpecification
(iii).CodesandStandard
5. Definitions:
5.1 PipingDrawings

Theprimarypipingdrawingswillbelineisometrics,andthesewillbesupplemented
with screendumps from the 3D PDS model as required. Appropriate standard
detaildrawingsandotherdrawingsshowingtypicaldetailswillbeavailable.System
isometricswillbeproducedforIBRcodedpipingsystems.

5.2 PipingandInstrumentDiagrams(P&ID)

The Piping and Instrument Diagrams indicate to and from routing, service
classification and identification number for each line and which codes or
requirements(otherthanthePetroleumRefineryPipingCode,ASMEB31.3)apply
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100801SSPP007
J3Program
PipingErectionandTesting Date:16/05/2013,Rev.2

to various parts of the piping systems as well as the limits of such code or
requirement.Theyprovideabasisforfieldchecksofcontinuityandcompleteness
ofpipingsystems.

5.3 LineDesignationTable

Mechanical Data Section of the Line Designation Table shows the line number,
description,pipingmaterialclass,designpressureandtemperature,insulationand
tracingrequirementsandtesttypeandpressureforeachline.

5.4 LineNumbers

Line numbers identify each line by plant or unit number, fluid designation, serial
number, line size and piping material class. Line numbers appear on the P&IDs,
models,andisometrics.

5.5 MaterialSpecification

The Piping Materials Specification includes details for each individual piping
materialclass.Eachclassdetailsthepipe,valve,flange,fitting,bolting,gasketand
other specific material requirements for different fluid temperature and pressure
services.ThePipingStockCodeBookdescribescodeitemsshowninspecifications
andondrawings.Materialsnotidentifiedotherwiseondrawingsorisometricsshall
bestrictlyasspecifiedinPipingMaterialSpecificationforthatmaterialclass.
5.6 SupplementaryTableofWallThicknessandBranchReinforcement

The Supplementary Table of Wall Thickness will specify by individual pipeline

numbertherequirementsofwallthicknesssubjecttocalculationasspecifiedinthe
PipingMaterialClasses.
5.7 PipingStockCodeIndex

ThePipingStockCodeIndexidentifiesanddescribesallpipingmaterialitemcodes
indocumentsrelatedtopipingmaterial.
6. Abbreviations:
SWG StandardWireGauge
DVOM DigitalVoltOhmMeter
NPT NationalPipeTaper(Thread)

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100801SSPP007
J3Program
PipingErectionandTesting Date:16/05/2013,Rev.2

RT RadiographyTest
UT UltrasonicTest
DP DyePenetration
MPT MagneticParticleTest
SER SiteEngineeringRequest
DEC DesignEngineeringContractor
7. CodesandStandards:
Codes

ASMEB31.1 PowerPiping
ASMEB31.3 ChemicalPlantandPetroleumRefineryPiping
ASMEPCC2,Art5 RepairofPressureEquipment&piping
ASMESecVIII PressureVessel
ASMESecV,Art10 LeakTesting
API650,Article7.3 WeldedSteelTankforOilstorage
API520 PressureRelievingDevices
API620 Design&ConstructionofLPStorageTanks
TheIndianBoilerCodeRegulations(1950)(IBR)
References

100801ENGGDBDPP001 PipingClassDesignBasis
100801SSPP004 PipingComponentsTechnicalSupply&Condition
100801SSPP005 PipingComponentsColourCoding
100801SSPP006 PipingFabrication.
100801SSPP040 ChemicalCleaningofPipework
100801ENGGPRAPP028 Production of Spool Drawings and Erection
Isometrics
100801ENGGDBDST003 PipeSupports
100801ENGGDBDST004 PipeSupportsStandardDrawings

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100801SSPP007
J3Program
PipingErectionandTesting Date:16/05/2013,Rev.2

10080-1-ENGG-DBD-ST-009 Indian Boiler Regulations-Reference Document

8. BasicMethodology
8.1. Fabrication
The field fabrication and welding shall be in accordance with
100801SSPP006,SpecificationforPipingFabrication.
8.2. Installation
8.2.1. All piping shall be installed in accordance with the isometrics and 3D PDS
model.
Allpipework,valves,pipingspecialsshallbeinspectedbeforeinstallationtoensure
that protectivepacking,covers,wrappingandinternalprotectivesuchassilicagel
bagsareremoved.

Protective covers of pipe and equipment shall not be removed until immediately
priortoinstallation.

All pipework and valves shall be examined to ensure that no deterioration has
occurred instorage with particularnote to valve internals. All manually operated
valves shall be cycled from fully open to fully closed and back again to ensure
operability.

Temporaryblindsmadefrom18SWGaluminiumsheetshallbeinstalledatflanges
ofallequipmentstoprevententeringofdirtanddebrisduringerection/installation
ofpipingsystem.ReferAppendixAfordetaileddimensionsofaluminiumblind.

Composite Insulation gasket assembly shall be installed at the mating flanges of

pipingspoolswiththemachineflangesofallrotaryequipmentsduringweldingand
electrical heating for stress relieving to prevent damage to machinery component
from stray currents. Composite insulation gasket is the combination of 18 SWG
aluminium sheet and 0.5 mm thick Teflon sheet used as an assembly. Preferably
coatedstudboltsshallbeusedatflangeconnectionforelectricalisolationpurpose.
Ifcoatedboltsarenotavailable,insulatingtapecanbewrappedaroundbolts.For
insulating the nut ebonite washers shall be used. An electrical continuity check
across flange shall be performed to confirm the electrical isolation before
proceeding with the welding and electrical heating for stress relieving work. The
assemblywillservedualpurposeofblindpreventingentryofdebrisintomachinery
aswellasinsulatinggasket,topreventdamagetomachinerycomponent.

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100801SSPP007
J3Program
PipingErectionandTesting Date:16/05/2013,Rev.2

8.2.2. Piping shall be supported as indicated on the isometric. When temporary

supports other than those shown on the isometric are required to facilitate
installation, they shall be of the removable type. Temporary supports shall not
transfer detrimental reactions to piping, structural members, or equipment.
Welding to pipe and/or piping supports as a temporary support measure, during
installation,isnotpermitted.(See9.7.12).

Temporary supportsshall be completely removed upon completion of testing and

priortocommissioning.

Where pipe support attachments are to be permanently welded to the pipework,

the welding shall be in accordance with the project specification employing only
welders qualified in accordance with the relevant code. Galvanised materialshall
not be welded to stainless steel, copper nickel or titanium material under any
circumstances.

Wherepipingissupportedusingspringsupportsthelockingpinsshouldbeinplace
duringinstallation,flushingandtestingofthepipingsystem.Lockingpinsshallbe
removed prior to startup and where necessary, springs adjusted to correct cold
Setting.

Locking pins shall be either firmly attached to spring housing by use of a chain or
tagged with the spring identification number and placed in the stores for safe
keeping.ATaggingSystemshallbedefinedtoidentifythespringsLockorunlocked
condition.

Thespringsettingshallbecertifiedbythevendorbeforecommissioning.

8.2.3. All closing dimensions to equipment shall be checked and any field
adjustmentsmadeasnecessarytoassemblepipework.

Equipment piping shall be installed up to a break point between nearest pipe

supportandtheequipment.Theremainderofthepipingshallbeproperlyfitted
betweentheequipmentnozzleandthisbreakpoint.Itisessentialthatthisisdone
accuratelyinordertoavoidanyexternalloadingsontheequipmentconnections.

Before tightening bolting to equipment flanges, ensure that piping flanges are
concentric and parallel. Manufacturers specified maximum allowable forces and
movementsonequipmentnozzlesshallnotbeexceededatanystageofinstallation.
Refertosection8.5forflangealignmenttolerances.

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100801SSPP007
J3Program
PipingErectionandTesting Date:16/05/2013,Rev.2

Coldspringingorforcingofpipingforthepurposeofjointmakeupisnotpermitted
unless so specified on the drawings. Cold springing is not permitted on strain
sensitiveequipment.

When connecting pipework to equipment the Contractor shall ensure that the
manufacturers instructions are carefully observed as to removal of external and
internal protective and that the opening is clean and free from obstruction and
foreign matter. Care shall be taken to avoid the ingress of foreign matter during
connectingofpipeworktoequipment.

Equipmenttothepipingflangejointshallbeconnectedusingalignmentmachined
pins.Aminimumof3machinedpins(120degreesapart)tobeusedforassemblyof
piping spool flange with machine flange. The diameter of machined pins shall be
equaltoboltholediameteronthemachineflangewithanegativetoleranceof0.2
mm to 0.4 mm max. The flange joint with locating pins in position should be
tightenedasperprocedure(i.e.sequentiallyinfourrounds).Aftertheflangejointis
tightened, the locating pins should be removed and replaced with bolts like the
adjacent ones, and fully tightened sequentially in 3 to 4 rounds. However if
locatingpinsaremadeofeboniterods(InsulatingMaterial)thentheycanbeleftin
position during welding of field fit up joint and stress relieving operations. Such
machinedpinscanbewithplainendorthreadedend.Thelatertypeispreferred,as
pinscanbejackedoutincaseofjamming.

Foralignmentmachinedpinfabricationandinstallationdetails;

ReferAppendixBforthreadedpins.

ReferAppendixCforplainendpins.

8.2.4. Flangefacesshallbecleanedofprotective,etc,andcheckedformechanical
orcorrosiondamagetothegasketcontactsurfaces.Damageshallberepairedprior
to use. No damage shall be repaired where the integrity of the flange design is
impaired.

Flange bolts shall be tightened evenly and diametrically opposite to impose even
pressureonthegasketsandtoavoiddistortionoroverstressingofequipment.

Wherehydraulicbolttensioningisnotrequiredboltsshallbeinstalledsoastoleave
at least two threads exposed from each nut. Exposed threads on over long bolts
usedforhydraulicbolttensioningshallbeprotected.

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100801SSPP007
J3Program
PipingErectionandTesting Date:16/05/2013,Rev.2

Where hydraulic bolt tensioning is required, the bolts are to be tensioned to give
stressesintheboltsequalto0.67xspecifiedYieldstrengthoftheboltmaterial.A
BolttighteningHandbookmaybemadeavailableforthispurpose.

Priortoflangejointassembly,boltsshallbelubricatedwithMolycote1000orequal.
Forboltlengthparagraph no. 335.2.3 of ASME B31.3 shall be referred.

Gasketsshallbeinstalledsothattheydonotprotrudeinsidethepipebore.

8.2.5. Gasketsshallnotbereused.Ifaflangedjointmustbeopened,forexample,
forsystempressuretesting,lineflushing,removaloftemporaryblindsorstrainers,
etc, the joint shall be remade with new gaskets and with the bolt lubricant
replenished.

Flangedjointsatequipmentorvalvesemployingtappedholesshallhavethethread
depthcheckedpriortoassemblytoensurethatcapscrewsofthecorrectlengthare
used.

Connectionstoflatfacedcastironflangesshalluseflatfacematingflangesandfull
facegaskets.Specialcareshallbetakentotightenboltscorrectly.

Nosealingcompoundsshallbeappliedtogasketsorflangesfaces.

8.2.6. Where insulating flange kits are to be installed, care shall be taken not to
damage the bolt sleeves and gasket. The completed joint shall be tested with a
Megger,DVOMorsimilardevicetoassureelectricalisolation.Ifbothsidesofthe
flangesaregroundedareadingof1to20ohmswilloccur.Ifoneorbothsidesare
notgrounded,areadingof1000ormoreOhmsshouldoccur.

Caution:Weldinggroundsshallnotbeinstalledacrossisolationflanges.

8.2.7. Orifice runs must not contain welds except at the flanges. Pipe ends at
orificeflangesmustbecutsuchthatitisperpendiculartothepipeaxis.Weldsat
theorificeflangesmustbegroundsmoothinside.Pipetapconnectionsaretobe
drilledthroughthepipewallandbesmoothinside.Drawingsshowtheorientation
oforificeflangetapsandthelocationsofpipetaps.Orificeflangesaretobedrilled
andtappedforjackscrews.

8.2.8. Underground piping shall be installed and inspected as per the Project
Specification.

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100801SSPP007
J3Program
PipingErectionandTesting Date:16/05/2013,Rev.2

8.2.9. The handling of coated and wrapped pipe as well as the field coating and
wrappingshallbeinaccordancewithProjectSpecification100801SSPP019and
100801SSPP020.

8.2.10. Valves shall be installed with stems oriented as indicated on isometrics.

Split disc check valves shall be installed with the shaft in vertical position. Globe
valvesshallbeinstalledwithbottomofdiscfacingtheflowdirection.

8.2.11. Where seal welding is required, the joints shall be made up without the
applicationofthreadlubricantandthreadsthoroughlycleanedfromgreaseandoil.
Sealweldsshallcoverexposedthreadscompletely.

Sealweldingisrequired:

a) Betweenconnectionstocolumns,vessels,tanksandexchangersinhydrocarbon
serviceandthefirstvalve.

b) Orifice flange taps and blanking plugs in those systems where socket welding
smallborepipingisspecified.

c) Unvalved, plugged hydrostatic test vents and drains in systems where socket
welding small bore piping is specified. Seal welding to be performed post hydro
test.

Followingitemsshallneverbesealwelded:

a) ScrewedThermowells

b) UnionNuts

c) ScrewedEndsofGaugeGlasses,GageCocks

All the plugs/caps used shall be tested as per clause 10, either with piping or
separately.

8.2.12. Reinforced fibreglass pipe and the like shall be installed strictly in
accordance with the vendors installation instructions. Personnel doing this work
shallbeproperlytrainedbyvendorsrepresentativepriortodoingthisinstallation.

8.2.13. Forboltsizes1inchandabove,asuitablehydraulictorquewrenchshould
beused.

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100801SSPP007
J3Program
PipingErectionandTesting Date:16/05/2013,Rev.2

8.3. PipeThreads
8.3.1. Threaded joints shall only be used where specified in the relevant Piping
Classes.

All pipe threads shall be NPT type in accordance with either ASME B1.20.1 or API
5B.

Threadsshallbecutafteranyrequiredbending,formingorheattreatment.Where
thisisnotpractical,suitableprotectionshallbeappliedtoprotectthethreads.

8.3.2. PTFEorothertypesofthreadtapeshallnotbeusedonanythreadedjoint.
Instead,oneofthefollowingthreadcompoundsorequivalentshallbeemployed:

a) Liquid Oring 404 (for 2 (50mm) or smaller NB) or Liquid Oring 104 (for 2
(50mm) and larger NB). Manufactured by Oil Centre Research Incorporated of
Lafayette,Louisiana,USA.

b) TFESuper(for1(25mm)andsmallerNB)orTFE20(for1(40mm)andarger
NB).ManufacturedbyIlexCompoundsLtd,Maidenhead,England.UseTFESuper
forallsizesinpotablewaterservice.DonotuseTFE20forpotablewater.

c) PTFGrease(for2(50mm)orsmallerNB)orPTFHeavyDuty(for2(50mm)or
largerNB).ManufacturedbyBlacksmithChemicalServicesofAberdeen,Scotland.

d) IlexILX35forhightemperatureservice.ManufacturedbyIlexCompoundsLtd,
Maidenhead,England.

e) LOCTITEmadebyHenkelIndiaLtd.

Incaseleakdoesnotstopafterapplyingthethreadcompound,repairofthejoint
shallbedoneasperqualifiedprocedure.

8.3.3. Where threaded flanges are specified, the pipe shall terminate 1/16
(1.5mm)shortoftheflangeface.

8.3.4. Adequate threaded flanges shall be included in threaded assemblies to

permit easy assembly and dismantling without the need for rotation of long pipe
legs, especially in the case of pipework connecting to pumps, compressors, etc,
where routine servicing or replacement by a standby unit necessitates
disconnectionofthepipe.

Page9of41

100801SSPP007
J3Program
PipingErectionandTesting Date:16/05/2013,Rev.2

Excessivegouging of pipe or fittings by wrenchesshall because for rejection, this

shall be considered such if the defect extends below the mill tolerance minimum
wallthicknessorismorethan1/16(1.5mm)indepth.

8.4. FieldRunPiping
Field run piping is defined as Carbon Steel threaded or socket welded piping 1
andbelow.

Long straight runs of buttwelded piping in pipe racks as shown on stringing

drawings.

8.5. FlangeAlignmentTolerances
Proper alignment of all joint members is the essential element of flange joint
assembly.Itresultsinmaximumseatingsurfacecontact,maximumopportunityfor
uniform gasket loading, and improves the effectiveness of all bolt tightening
methods.
Referbelowfigureforfollowingfourtypesofalignments:

Page10of41

100801SSPP007
J3Program
PipingErectionandTesting Date:16/05/2013,Rev.2

8.5.1. FlangealignmenttolerancesforRotaryEquipment

For compressor and steam turbine; equipment vendor specified Piping flange
parallelism,flangeseparationandflangeaxialoffsettoleranceswillgovern.
For pumps flange alignment tolerances, vendor specified values will govern
howeverincasesuchvaluesarenotgivenbypumpvendor;thefollowingtabulated
valuestobeusedatsite.

RotaryEquipment(Pump)Tolerances
Characteristic forallpipesizes

Flangefaceaxial
1.5mm
offset

Nozzle Up to Up to Above
Flangeface Size(NB) 150 250 250
parallelismoffset
Tolerance 0.2mm 0.8mm
0.4mm

Boltholeoffset 1.5mm(Radially)
(Rotational)

Uncompressed Gasket thk + 1.5 mm
Flangeface
max
separationoffset


8.5.2. FlangealignmenttolerancesforStaticEquipment

Characteristic StaticEquipmentTolerances

Flangefaceaxial
2mm(4in.NPS);3mm(>4in.NPS)
offset
Flangeface 0.8mmmax.

Page11of41

100801SSPP007
J3Program
PipingErectionandTesting Date:16/05/2013,Rev.2

parallelismoffset

Boltholeoffset
1.5mm(Radially)
(Rotational)
Flangeface
UncompressedGasketthk+3mm
separationoffset

8.6. FieldModifications
Modificationstopiperoutingmayberequiredinthefield.Suchmodificationsshall
be determined by theerectorandagreed with theresponsible field engineer. All
modifications shall be reflected on as built record drawings by the construction
subcontractor or Field Engineer. At the end of the construction phase one set of
these drawings shall be sent to the responsible Design Office. In the case of IBR
piping,nofieldmodificationsshallbeperformedwithoutthepriorapprovalofthe
IBRinspectors.

AnyfieldmodificationshallbeproperlybackedupanddocumentedwithanSER.

8.7. Cleaning
Referto100801SSPP040SpecificationforChemicalCleaningofPipework.

8.7.1. Generalrequirements:
Piping spools shall be dry, thoroughly cleaned and free from dirt, slag and other
looseforeignmaterials.Beforeassembly,theyshallbecleanedbyupendingand
rappingtodislodgeanydirtanddebris.Hotbendsshallbecleanedcompletelyto
removeadherentburnedonsand.

Completed systems shall be internally cleaned to remove all remaining dirt and
foreign matter by water flushing or blowing with air or steam. Where special
conditionsexist,specificspecificationswillcovercleaningandpreparations.

Flushingshallbedonewithcleanwaterusinghydrostatictestwaterwherepossible.
Refer to section 14.0 for the quality of water to be used for both flushing and
testing.

8.7.2. CompressorSuctionPiping
Shortly before start up the inside of all compressors suction piping shall be
thoroughlycleanedtoremoverustandscale.
Page12of41

100801SSPP007
J3Program
PipingErectionandTesting Date:16/05/2013,Rev.2

Suction piping may require pickling or mechanical cleaning. The extent of such
cleaningshallbeshownonP&IDsandontheisometrics.Cleaningshallbecarried
outinaccordancewithprojectspecifications.

8.7.3LubeOilPiping

Shortlybeforestartuptheinsideofalllubeoilpipingshallbethoroughlycleanedin
accordance with the machinery vendors recommendation or with project
specificationswhicheveristhemoststringenttoremoverustandscale.

9. InspectionandTesting:
9.1 InspectionforCompleteness

Upon completion of erection, piping systems shall be visually inspected for

completeness, proper gasketing, proper valve installation, supporting, proper
controlvalveinstallation,etc.

TheP&IDandisometricsshallbeusedforthispurpose,essentiallybeforeerection.

The pressure safety valve duly calibrated at 1.1 times the test pressure shall be
installedinpipingsystem,asperclause9.7.13,beforecommencementofthetest.

9.2 TestingRequirements

9.2.1 General

Processandutilitypressurepipingshallbetestedasrequiredbytheapplicablecode
anddescribedherein.

9.2.1.1 PressurePipingDefined

Pressurepipingincludesallpipingdesignedtoconveyorcontainprocessorutility
fluidsateitherapositiveoranegativeinternalpressure.

Openendedvent,drainandlikepipingatessentiallyatmosphericpressurearenot
consideredaspressurepiping.

9.2.1.2 BoilerCodePiping

PipingwillbegovernedbyandconformtobothTheIndianBoilerRegulations1950
and ASME B31.1 Code for Pressure Piping, Power Piping. Boiler piping shall be
Page13of41

100801SSPP007
J3Program
PipingErectionandTesting Date:16/05/2013,Rev.2

tested hydrostatically to the required standard described within the Indian Boiler
CodeandinParagraph137ofASMEB31.1CodeforPressurePiping,PowerPiping,
whicheveristhemoststringent.

IBRPipingwillincludeallsteamsystems,boilerfeedwaterandselectedcondensate
systems.

9.2.1.3 RefineryCodePiping

PressurepipinggovernedbythePetroleumRefineryPipingCode,ASMEB31.3shall
behydrostaticallytestedinaccordancewithParagraph345ofthatcode.

Alternate tests are not permitted unless specifically approved by Project Engineer
and/orClient.

9.3 TestSourceInformation

9.3.1 LineDesignationTables(LDTs)

TheLDTsshallbetheControllingDocumentsindeterminingthetypeoftest,test
mediumandtestpressure.

The Line Designation Tables indicate (in the mechanical data section) the line
number, description, piping material service class, design pressure, design
temperature, insulation and tracing requirements and minimum test pressure for
eachline.Thetypeofpressuretestandtestmedium,ifotherthanhydrostatic,will
benotedinthetable.

9.3.2 HydrostaticTestDiagrams

Thehydrostatictestpackagewillshowtheblocklimitsfortestingasystemaswell
asthetypeandtestpressuretobeapplied.Thispackagewillgenerallybeprepared
byRILsiteengineersinconsultationwithRILoperationengineer.Allhydrostatic
testsrelateddocumentationshallbedonebysubcontractorsfieldengineers.

9.4 Tests

9.4.1 HydrostaticTest

Thefluidshallbewaterunlessthereisthepossibilityofdamageduetofreezingor
toadverseeffectsofwateronthepipingortheprocess.

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100801SSPP007
J3Program
PipingErectionandTesting Date:16/05/2013,Rev.2

Refinery Code pipingshall be hydrostatically tested to a minimum pressure of 1.5
timesthedesignpressureatanypointinthesystemunlessotherwisenotedinthe
linedesignationtables.

Thetestpressureshallbeadjustedforelevateddesigntemperatureinaccordance
withASMEB31.3,Paragraph345.4.2(b).Allliquidlineswillbehydrostaticallytested
except as outlined in section 9.4.4. Large thin walled lines in vapour service will
requirespecialconsiderationandtemporarypipesupportsinstalled.

If the test pressure as defined above would produce a nominal pressure stress or
longitudinalstressinexcessoftheyieldstrengthattesttemperature,thetest
Pressuremaybe reducedtothemaximumpressurethatwillnot exceedtheyield
strengthattesttemperature.InaccordancewithASMEB31.3,Paragraph345.4.2(c)

AccordingtotheConstructability/Designconstraint,itmaybenecessarytohydro
test the line at grade level with suitable supports. After successful completion of
hydrotest,lineshallbeliftedintopositionandthencloserweldshallbeexamined
asperclosingweldsclause9.4.5.

9.4.2 InitialServiceLeakTest

ApipingsysteminCategoryDfluidservice(Designgagepressuredoesnotexceed
150psi,or10.5kg/cm2anddesigntemp.upto186C)maybesubjectedtoaninitial
serviceleaktest,attheownersoption,inlieuofthehydrostaticleaktest.

The test fluid is the service fluid. During or prior to initial operation, the pressure
shallbegraduallyincreasedinstepsuntiltheoperatingpressureisreached,holding
the pressure at each step long enough to equalize piping strains. A preliminary
checkshallbemadeasdescribedinpara.345.5.5ofASMEB31.3,iftheservicefluid
isagasorvapour.

9.4.3 VacuumPiping

Lines in vacuum service, unless governed by specific design conditions, shall be

testedataninternalgagepressure1.5timestheexternaldifferentialpressure,but
notlessthan15psig(1.03barg)asspecifiedinParagraph345.2.4ofASMEB31.3.

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100801SSPP007
J3Program
PipingErectionandTesting Date:16/05/2013,Rev.2

9.4.4 PneumaticTesting

General industry practice is to avoid pneumatic tests to the maximum extent

possible.Themainconcernwithconductingpneumatictestingisthatitgeneratesa
considerableamountofstoredenergywhenthesystemispressurizedfortesting.
Pneumatic testing can only be used when the requirement is specified by the EP
contractor and the conditions of code are met. Usage of pneumatic testing as an
alternative to other kinds of test, viz. Hydrostatic tests, etc merely on account of
costsavingsisnotacceptable.
Thegasusedastestfluid,ifnotair,shallbenonflammable,nontoxicandshallbein
accordancetothespecification(s)providedbytheEPContractor.

Thetestpressureshallbe110%ofthedesignpressure.

Ingeneralpneumatictestingshouldonlybeconsideredasleaktestforthefollowing
conditions:
Small diameter tubing (such as impulse lines or steam tracing) where we
don'twantmoistureleftinthetubingaftertesting.

Lineswhereahydrostatictestcoulddamagetheinternallining(suchasifa
lineisrefractorylinedandneedstobetestedatsite)

Linesspecificallydesignedtobepneumaticallytested.(E.g.Overheadvapor
lines,Conveyinglines,etc.alongwithductwork,flarelinesandcertainlines
wherehydraulictestingisimpractical)

LinesinvolvingPipingMetallurgywhichmaybeadverselyaffectedbywater
especially if there is apprehension about the quality of water available for
hydrotesting.

Linesthatmustbecompletelydryaftertesting(e.g.oxygenpiping)

Lines, when filled with water, would weigh more than the structure can
bear. This situation could typically be encountered only in existing plants
wherethestructuralsteeldesignnevertookintoconsiderationtheaddition
offuturelines.

Conditions where it is very difficult to remove the water after testing. An

example is when the convection box crossover piping is welded to the

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radiantsectionofafiredheaterandthenthesystemistested.Theradiant
section piping runs up and down with 180 degree elbows (ubends) at top
andbottomtherebymakingitverydifficulttoremovethewatercollected
at the bottom ubends. In fact, we typically wait to startup the heater so
thatthewatergetsboilout.

AnyadditionalcasesspecifiedbytheEPContractor/Licensors

Any lines or systems requiring Pneumatic testing shall be identified by the

DECsintheLineDesignationTable.

Thetestshallbewelldocumentedandpreapprovedbytheconcernedauthorities
along with the Stored energy and PressureTesting Safety Distance Calculation as
perASMEPCC22011Article5.1MandatoryAppendixII/III.

9.4.5 ClosingWelds

Wherepractical,pressuretestsofpipingshallincludeallclosingweldsbetween
differentpartsofthesystem.Whereitisnotpracticaltoincludeaclosingweldin
thepressuretest,theweldshallbetestedandexamined100%byRT/UTand
DP/MPTanditslocationrecorded.

9.4.6 ConnectionstoEquipment

Pipingtestpressuresshall notbeappliedtopumpsorto other equipmentexcept

where specifically approved by the Project field engineer; and provided such
procedurewillnotcauseunsafeloadsorotherunreasonablehazards.

9.4.7 TestwithEquipment

Connecting piping may be tested with pressure vessels or other equipment

requiringfieldtestprovidedresultingtestpressureappliedtopipingisnotgreater
thanallowableorlessthantherequiredpipingtestpressure.

Wherethetestpressureofthepipingexceedsthevesseltestpressure,anditisnot
considered practicable to isolate the piping from the vessel, the piping and the
vessel may be tested together at the vessel test pressure, provided the owner
approves and the vessel test pressure is not less than 77% of the piping test
pressurecalculatedinaccordancewithPara.9.4.1above.

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Careshallbetakenwhenexchangersareincludedinthetest.Bothtubeandshell
sideshallbepressurisedtoavoidoverstressingoftubesheetsifthesearedesigned
foralimiteddifferentialpressure.

9.4.8 JacketedPiping

In jacketed lines, the jacket shall be tested as described in Paragraph 345.2.5 of

ASMEB31.3.

If the test pressure in the jacket is too high for the internal lines as an external
pressure,theinternallineshallbepressurisedtominimisethedifferentialpressure.

9.5 SystemPressureTestPackage

TestconditionsshallbespecifiedinLDT.Systempressuretestpackage,includinga
pressuretestdiagrambasedonpipingandinstrumentdiagramsshowingtheextent
ofpipework,willgenerallybepreparedbyRILsiteengineersinconsultationwithRIL
operation engineer. All hydrostatic tests related documentation shall be done by
subcontractorsfieldengineers.

The scope of each separate test shall be the maximum practicable, considering
adequatepressurereliefprotection,availabletestfluid.

The diagrams shall show all in line components which are to be replaced with
temporary spools, indicate which internals are to be removed for the test, and
indicatealltemporarytestblindsandplugsusedtoisolatethesystembeingtested.

Thepackageshallincludeasignoffsheetwithplacesforthesubcontractorandthe
Project Inspection Authorities signatures and date for each of the three stages of
testing:preparation,testingandposttestcompletion(removaloftemporaryblinds
andsupports,replacementofremovedinternalsandvalves,airdrying,etc.).

The extent of test systems shall be such that the static head of the test medium
doesnotcreateapressuregreaterthanthemaximumallowabletestpressure.

9.6 CryogenicLines

Noncomplexcryogenicpipingsystemsofrelativelyshortrunswithlimitednumbers
of welded in valves and fittings may be hydrotested provided they can be
thoroughlydriedaftertesting.Complexcryogeniclinesthatcannotbethoroughly
dried shall have welds subjected to 100% radiograph and then subjected to a
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pneumatic test. Alternatively, spools shall be shop hydrotested & closing welds
shallbetestedasperClosingweldclause10.5.

9.7 PreparationofSystemsforTesting

9.7.1 Temporaryblindflangesandtestblindsusedtoisolateatestsystemshallbe
ofanadequatethicknesstowithstandthetestpressure.Forminimumthicknessof
carbon steel blind plate EPCMDP14JG000167 to be referred. Test blinds shall
includeanintegrallugorhandle,extendingatleast4(100mm)beyondtheflange
perimeter,whichshallbepaintedbrightredororange.

Temporary blind flanges and test blinds shall be adequately gasketed to prevent
damagetoflangefacings.

9.7.2 Instrument connections shall be closed with a properly gasketed blind

flange,orwithathreadedplug.

9.7.3 Valvesexcept socket weldvalvesshallnotbeusedtoisolate atestsystem

except for lines not pressurised in service (for example, flare lines, gravity drain
lines,blackandgreysewagesystems,etc).

9.7.4 Controlvalves,thermowells,orificeplates,strainerbaskets,filterelements,
expansion bellows, in line instruments and all other in line components unable to
withstandthetestpressureshallberemovedandreplacedwithtemporaryspools
orspacers.

9.7.5 Ifthepressureistobeapplieddownstreamofcheckvalves,thevalvesshall
havetheirinternalsremovedorbesecurelyblockedopeninamanneracceptableto
theinspector.

9.7.6 Permanentpressureandthermalreliefvalvesandrupturediscsshallnotbe
includedinsystempressuretests.

9.7.7 All internal parts and in line items removed for the duration of pressure
testingshallbelabeledandthecomponenttowhichtheybelongorthepositionin
thelinefromwhichtheywereremovedshallalsobelabeled,tothesatisfactionof
the inspector, to ensure the correct replacement of components following the
testing.

9.7.8 All valves, except as excluded specifically herein, shall be included in the
pressure tests, ball valves shall be in the half open position (for the ball only acts
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against the seal when the ball "floats" into it. this is to make sure that the valve
bodyisevenlyloaded.)recommendedbythemanufacturerandallothervalvesfully
open.However,wherethetestpressuretobeappliedtolinesisgreaterthanthe
maximum allowable test pressures specified for the valves, the valves shall be
blinded on the test side or replaced with a temporary spool. Valves shall be
removedpriortoflushing.

9.7.9 Where a valve has not been included in a system test, the shop test
certificateshallbereviewedandapprovedbytheRIL/DECsauthorizedinspector.

9.7.10 Expansionjointsshallnotbeincludedinpressuretests.

9.7.11 Alllinesinvapourserviceshallhavesufficienttemporarysupports.Spring
supports for lines in vapour service shall be locked in position for the test using
presetpinsorplatesorbyblockingupthespring.(See5.2.2)

9.7.12 All temporary supports, spring support restraints, temporary spools,

temporarystrainers,blindsandplugs,etc,shallbeprominentlyflaggedorpainted
brightorangeorredtoensuretheirremovalfollowingtesting.

9.7.13 Useofpressuresafetyvalveshallberestrictedasperfollowing:

A. Forhydrotestinglineslessthanorequalto24dia.andtestpressurelessthan
orequalto50bar,andlinesgreaterthan24dia.andtestpressurelessthanor
equalto30bar,constantlymonitorpressureandopenventvalveifpressurerises
abovespecifiedtestPressurelimits(+10%).

B. Forhydrotestinglineslessthanorequalto24dia.andtestpressuregreater
than50bar,andlinesgreaterthan24dia.andtestpressuregreaterthan30bar,
adjustablePSVsmustbeusedsettorelieveifpressurerisesabovespecifiedtest
pressurelimits(+10%).

C. Forallpneumatictestingpressuresafetyvalvemustbeused(refAPI520for
PSVsizing).

9.7.14 Minimumtwonumbersofpressuregauges,oneathighpointandotherat
lowpointofthesystem,shallbeusedfortesting.
Pressure gauges shall have current certification of accuracy. In general, the
calibration frequency shall be 6 months but if any deviations are noticed while

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carryingoutpressuretestoranymismatchoccursbetweentwogauges(afterlevel
correction,ifany)inaloopthenthegaugesshallberecalibrated.
Systemflushingcanbeeitherbeforetestoraftertest.Thisshallbejointlydecided
byoperationandconstructionengineer.

9.7.15 Care shall be taken to ensure that dirt and debris cannot be forced into
instrument branches or pockets in lines. Flushing shall proceed in an intermittent
manner allowing time between flushes for debris to be cleared from the line.
Flushingshallcontinueforsufficienttimetoensurethatthelineiscleaned.Liquid
flushingshallnotbeemployedonsystemsrequiringpneumatictesting.

9.7.16 All orifice plates which interfere with filling, venting or draining shall be
removedpriortotesting.

9.7.17 Short pieces of piping which must be removed to permit installation of a

testblindshallbetestedseparately.

9.7.18 Alljointsinpipingshallbeaccessibleduringtestandshallnotbeinsulated,
backfilled or otherwise covered until satisfactory completion of testing in
accordancewiththisspecification,exceptjointsmaybeprimedandpaintedpriorto
leaktesting.

9.7.19 Care shall be taken to avoid overloading any parts of the supporting
structures.

9.8 TestMedium

9.8.1 Clean,freshwaterfreeofsuspendedsolidsandotherforeignmattershallbe
used for hydrostatic testing of piping. For carbon steel and low alloy steel piping,
thelimitofwaterchloridecontentshallbe300ppm(max).Also,wherethewateris
unfilteredanduntreatedachemicalinhibitorpackageshallbeprovidedwhichshall
includethefollowingchemicals:

a) Oxygenscavengertoremovedissolvedoxygen.

b) Biocidetokillharmfulorganismsandsulphatereducingbacteria.

c) Corrosioninhibitortominimisecorrosion.

ProposalstousechemicalinhibitorsshallbeagreedbetweencontractorandDEC.

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9.8.2 The minimum water temperature during hydrostatic testing shall be 40F
(10C). After testing the piping shall be drained and thoroughly dried and
maintainedsuchthatnomoistureorchlorideladendepositswillenterthepiping.

9.8.3 LiquidsotherthanwatershallrequiretheapprovaloftheProjectDesignated
InspectionAuthoritypriortouse.

9.8.4 Pneumatic tests shall use dry (dewpoint 40F (40C) or lower), clean, oil
freeairornitrogen.Oillubricatedcompressorsshallnotbeused.Pneumatictesting
temperaturesshallnotexceed120F(50C).

9.8.5 Fortestingofausteniticstainlesssteelandnickelalloysteelpiping,thelimit
ofwaterchloridecontentshallbe50ppm(max).

9.8.6 For austenitic and duplex stainless steel piping, to avoid the possibility of
subsequentfailureduetostresscorrosion,crackingorpitting,cleandemineralized
water,freeofchlorides,(50ppmmax)shallbeused.

9.9TestingProcedure

9.9.1 HydrostaticTests

9.9.1.2 Prior to filling the system with the test medium, the system shall be
inspectedforfabricationcompletenessandsatisfactorytestpreparation,including
theplacementofpressuregaugesandsuitabilityofthetestrig.Thetestpackage
signoffsheetisthensignedbytheauthorizedProjectInspectortoallowflushingor
purging prior to commencing test. Where valves have been included in the test
circuit,thosevalveswithstainlesssteelinternalsshallberemovedorthechloride
contentofthewatershallnotexceed50ppm.

9.9.1.3 Aftercompletionofflushingorpurging,theareaaroundthesystemunder
testshallbeclearedofunauthorizedpersonnelandwarningnoticespostedduring
thetimethatthepipingsystemispressurizedforthetest.Thearrangementsmade
toexcludeunauthorizedpersonnel,andtheperimeterofthehazardzone,shallbe
agreedwiththeinspector.

9.9.1.4 Apreliminaryairtesttonotmorethan25psig(1.7barg)maybemadeto
locatemajorleaksbeforeahydrostatictest.

9.9.1.5 Liquidtestingmediumshallbeintroducedatthesystemlowpointtoavoid
air pocket formation. Vents at high points shall be left open and not closed until
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testmediumflowfromtheoutlet.Allairmustberemovedbeforepressuregreater
thantherequiredtofillthesystemisapplied.

9.9.1.6 Hydrostatic testing with water as a test medium shall not be performed
whenthereisafallingairtemperatureof5Corless.Shouldtheseconditionsoccur
duringatest,thetestshallbeabortedandthesystemdepressurised.

9.9.1.7 When conducting tests at low metal temperatures (below 5C) the
possibility of brittle failure shall be considered and the Project Engineer shall be
contactedforspecialrequirements.Donottestwhenmetaltemperatureisbelow
5C.(Caution:Suchlowtemperaturesmayalsobecausedbywindchill).

9.9.1.8 Hydrostatic pressure testing shall not commence until the test fluid
temperature is in equilibrium with the pipework system. The rate of pressure
increaseinapproachingthetestpressureshallnotexceed70psi(5bar)perminute.

Pressure shall be applied by means of a suitable test pump which shall not be
connectedtothesystemuntilreadyfortest.Atestgaugeshallbeprovidedatthe
pump discharge to determine the test pressure of the system and to avoid over
pressurizing. The pump shall be attended constantly during pressurizing by an
authorized operator and effectively isolated from the system during the test and
whenever left unattended. In order to prevent pressure in excess of the test
pressure, power operated test pumps shall be equipped with a pressure relief
devicewhichissettoensurethatthetestpressureisnotexceeded.
9.9.1.9 Pressurise the system to the specified test pressure and hold for 10
minutes to allow piping strain to equalise. Once achieved inspect the complete
system,whichwillincludealljoints,threaded,socketwelded,buttwelded,flanged
and branchconnections. On completion of the check and if no leaks are detected
thenleavethesystemforafurther30minutestocompletethetest

Onsomelargesystemitmaytake2,3oreven4hourstocheckthesystemoutandif
no leaks are detected but the pressure has dropped due to the decrease in
temperature,thenbringthepressurebackuptothetestpressureandleavefora
further30minutes.Ifthepressureholdsthenthetestiscomplete.
Conversely if the test is started during the cool part of the day and pressure
increases beyond the test pressure due to the increases in temperature, then the
system will have to be periodically relieved back to the test pressure. On
completionofthecheckleave,relievedbacktothetestpressure,for30minutes.If
thepressureholdsthenthetestiscomplete.

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Testing at night shall be restricted to small systems only and at ground level and
there must be adequate illumination to detect even the smallest leakage. There
shallbenotestingofsystemsinpiperacksorelevatedstructuresbetweensunset
andsunrise.
9.9.1.10 All lines and equipment shall be completely drained after the hydrostatic
test of a system has been completed. Vents shall be opened first to prevent
excessivevacuumandpermitcompletedraining.

9.10 PneumaticTests

9.10.1 Pneumatictestingshall be inaccordancewith the requirementstipulated

inASMEPCC2Part5&associatedappendices.
9.10.2 Pressurize to 7 psig (0.5 bar) and hold for a sufficient length of time to
allow piping to equalize strains. All joints (threaded, socket welded, buttwelded
andflanged)shallbeinspectedforleakswithsoapsuds.
9.10.3 Pressurizegraduallyin10%stepsto60%ofthespecifiedtestpressureand
hold for a sufficient length of time to allow piping to equalisestrains (10 minutes
minimum).
9.10.4 Reducepressureto50%ofthespecifiedtestpressureandvisuallyinspect
alljointsforleaks.
9.10.5 Pressuriseinsteps(eachsteptobenomorethan10%ofthespecifiedtest
pressure)untilthespecifiedtestpressurehasbeenreached,holdingforasufficient
length of time at each step to allow piping to equalise strains (10 minutes
minimum). The test pressure shall be held for two hours and then reduced to
designpressureafterwhichalljointsshallbeinspectedforleakswithsoapsuds.
9.10.6 ThesoapsudsshallbeasolutionsuchasSherlock,Snooporequal.
9.10.7 Throughoutthetestperiod,thebubbleformationpropertiesofsoapsuds
shallbechecked.
Before any remedial work is undertaken on weld defects, leaking flanges etc. the
system shall be depressurised and valves shall remain open to prevent any
accidentalrepressurising.Noworkshallbeattemptedonapressurisingsystem.

9.10.8 All defects revealed by the test shall, after approval by the inspector, be
repairedand,afterinspection,beretestedasspecifiedherein.Atthediscretionof
the inspector and where permitted by the relevant code repaired defects may be
retestedbymeansotherthanpressuretesting,asperclause10.5.

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9.10.9 Weld joints in shop fabricated spools which have been successfully
pressure tested elsewhere, and for which documentation acceptable to the
inspector is included in the test package, need not be retested in a system test.
Lateralshowever,whichhavebeenhydrostaticallytested(seeparagraph10.4)and
whichhaveweldedconnectionstoflareheadersshallbeincludedinthepneumatic
systemtest.

9.10.10 A system under test pressure shall never be left unattended. If a test
cannot be completed before the end of a work period, the system shall be
depressurised. The contractor shall be responsible for all safety precautions and
proceduresduringtesting.

9.10.11 Pneumatic testing stored energy calculation as per ASME PCC22011

Article5.1MandatoryAppendixII

The maximum calculated stored energy of any piping system being pneumatically
pressuretestedshouldnotbegreaterthan271000000J(200,000,000ftlb).Ifthe
calculatedstoredenergyisgreaterthan271000000J(200,000,000ftlb),thenthe
system shall be divided into smaller volumes such that each subsystem has a
storedenergynotgreaterthan271000000J(200,000,000ftlb).

9.10.12 The test shall be well documented and preapproved by the concerned
authoritiesalongwithminimumdistanceshallbecalculatedperASMEPCC22011
Article5.1MandatoryAppendixIII

9.10.13 A barricade shall be installed for pressure tests where the risk of injury
from potential fragments, shockwaves, or other consequences of any pressurized
systemfailureisdeterminedtobeunacceptable,alimitedaccessareaandpressure
control Point should be established. The minimum distance from the boundary of
this area to the pressurized component should be calculated according to ASME
PCC22011 Article 5.1 Mandatory Appendix III. When the spacing requirements
describedinMandatoryAttachment4arenotachievable,considerationshouldbe
giventothedesign,fabricationandInstallationofanalternativebarricadecapable
ofwithstandingtheblastofstoredenergywithinthesystem.

9.11 GeneralRequirements

9.11.1 SpecialTools

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9.11.2 Pressure gauges for system testing shall have a range suitable for the
systemstestpressuretothesatisfactionoftheInspectionAuthority.

9.11.3 Pressuregaugesshallhavetagnumberswhichshallappearoncalibration
certificates. The certification documentation shall be a permanent part of the
systempressuretestpackage.Nocertificateshallbemorethanoneyearoldand
verified accurate by a recognized authority to the satisfaction of the inspection
authority.

9.11.4 Incaseofanydisagreementsbetweentwopressuregaugereadings,during
thepressuretestcycle,thepressuretestshallbestoppedandbothgaugessentfor
forrecalibration.Tocompletethetest,twofreshgaugesshallbeused.

10 PreparationforShipment:
10.1 Followingtheacceptanceofasuccessfultest,thesystemistobeimmediately
depressurised and vented in a gradual and safe manner, thoroughly drained
allowingnopocketsoffluidtoremain.Thesystemshallthenbeblownoutwithdry
filteredair(dewpoint40F(40C))at150F(60C)to170F(77C)atavelocityof
100ft/Sec(30m/Sec)untildrytothesatisfactionoftheinspector.

10.2 Replaceallitemsremovedforthetestandremovealltestblinds,temporary
supports, etc. The replacement of piping component internals shall be carefully
controlled to ensure that they are reinstalled in the correct place. Flange joints
opened for these purposes shall be remade with new gaskets. Plugs in unvalved
testventsshallbesealwelded.

10.3 The inspector shall reinspect the system for mechanical completeness and
signoffthepackageascomplete.Thesignedtestpackageshallberetainedaspart
ofthecontractdocumentation.

10.4 PackingandPreservation

10.4.1 Desiccantremovedfromchemicallycleanedpipingpriortopressuretesting
shall be regenerated or renewed and replaced together with appropriate warning
signs.

10.4.2 All openings in pipework, whether vents or drains to atmosphere or

openingsforonsitehookupofmodulesetc,shallbeadequatelysealedtoprevent
theingressofforeignmatter.

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10.4.3 Exposedmachinedsurfacessuchasweldbevelsandflangefacingsshallbe
coveredwithanapprovedwhitespiritsolublerustpreventative.

10.4.4 PlasticendcapsandthreadprotectionplugsshallbesecuredwithDensoor
equaltape.

10.4.5 Flange covers of metal (minimum 3/16 (5mm) thick) or wood (minimum
(20mm) thick)shallbegasketofthesameoutsidediameterastheflange,and
heldinplacewith50%oftherequiredboltsforthejoint(minimum4bolts).Covers
heldonwithwireorsteelstrapsarenotacceptable.

10.4.6 Gate and globe valves shall be closed. Ball and plug valves positioned
eitherfullopenorfullclosed,anddiaphragmvalvesopened.

10.4.7 Warning signs noting items to be removed prior to commissioning

(temporary blinds to isolate chemically cleaned pipe, desiccant, etc) shall be
prominently displayed and adequately protected from weather and handling
damage.

10.4.8 All packing and preservation shall be witnessed and approved by the
inspectorwhowilladvisethecontractorofanysystemsrequiringspecialprotective
measuressuchasblanketingwithdryairorinertgas,etc,whenlongtermstorageis
envisaged.

10.5 TestingContractorSuppliedItems

Alltoolsandequipmentrequiredforpipingsystempressuretests,includingpumps,
compressors, connecting pipework with strainers and storage reservoirs, pressure
gauges, temporary blinds, plugs, spools, vents and drains, pigging equipment,
gasketsrequiredfortestpurposes,testfluidsandadditives,etc,shallbesuppliedby
the contractor. However separate Scope of Work shall be made for project to
projectbasis.

Thecontractorshalldemonstratethatallthenecessaryitemsareavailableatsitein
advanceofcommencingtestingtoensurethetestingisnotdelayedinanyway.

11 VendorDataRequirement:
11.1 Recordsshallbemadeforeachsystemtestedwhichshallinclude:

a) Dateoftest

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b) Identificationofpipingtest
c) LineNumber
d) Testmedium
e) Testpressure
f) Testduration/PressurizationTime
g) Crossreferencetotestgaugecertificate
h) ObservationsIncludingLeakageetc.
i) RemedialAction
j) DetailsofRetesting
k) ApprovalbytheInspector
11.2 Recordsforpipingwhichrequirethatpressurebeheldforaspecifiedperiod
oftimeshallincludeanycorrectionsoftestpressureduetotemperaturevariations
betweenthestartandfinishofthetest.

11.3 Recordsforpipinginwhichaspecifiedleakagerateispermittedshallinclude
thetimeatwhichwaterwasaddedandthequantityadded.

11.4 All test records and authorized Inspectors certifications shall be retained in
thejobrecords.

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ATTACHMENT - 1
ALUMINIUM BLIND FOR BLINDING EQUIPMENT NOZZLES

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ATTACHMENT - 2
ALIGNMENT DOWEL PIN WITH THREADED END

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ATTACHMENT - 3
ALIGNMENT DOWEL PIN WITH PLAIN END

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