GP 03-19-01 Piping Erection, Leak Testing, Flushing, and Cleaning April 2005

Piping Erection, Leak Testing,

Flushing, and Cleaning
GP 03-19-01

Scope
1) [I] This Global Practice (GP) covers field erection, leak testing, flushing, and cleaning of piping
systems.
2) [I] An asterisk (*) indicates that additional information is required. If a job is contracted, this
additional information is specified in the Job Specification.

Refining/Chemicals, Downstream
For ExxonMobil Use Only Version 2.0.0
Imperial Oil

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 GP 03-19-01 Piping Erection, Leak Testing, Flushing, and Cleaning April 2005

Table of Contents

1. Additional Requirements ...................................................................................... 3

1.1. Global Practices–ExxonMobil Engineering Practices ................................... 3
1.2. ASME–American Society of Mechanical Engineers ..................................... 3
2. Erection .................................................................................................................. 3
2.1. Flange Jointing Practice ............................................................................... 3
3. Additional Requirements for Piping Over NPS 3 (80 mm) Connected to
Rotating Machinery ............................................................................................... 4
3.1. Piping Erection and Flange Alignment.......................................................... 4
4. Testing and Flushing ............................................................................................ 7
4.1. Preparation for Leak Testing ........................................................................ 7
4.2. Instrument Piping and Sampling Connections .............................................. 8
4.3. Leak Test Procedures .................................................................................. 8
4.4. Hydrostatic Leak Testing .............................................................................. 8
4.5. Pneumatic Leak Testing ............................................................................... 9
4.6. Leak Test Pressures..................................................................................... 9
5. Piping System Cleanliness................................................................................... 9

Record of Change ....................................................................................................... 11

Attachment: Purpose Codes Definitions.................................................................. 12

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1. Additional Requirements
* [I] The following Practices and Standards shall be used with this GP as specified by the Owner's
Engineer.

1.1. Global Practices–ExxonMobil Engineering Practices

GP 18-08-01 Precommission Cleaning of Steam Generating Equipment and Piping
Systems for Rotating Equipment
GP 18-10-01 Additional Requirements for Materials

1.2. ASME–American Society of Mechanical Engineers

ASME B16.5 Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24 Metric/Inch
Standard
ASME B31.1 Power Piping
ASME B31.3 Process Piping

2. Erection
1) [R] Field routed small piping (NPS  11/2 [40 mm]) shall be supported in a manner that minimizes
excessive vibration and accommodates thermal expansion of terminal equipment.
2) [R] Temporary shipping braces, stops, or other protective devices for expansion joints shall not be
removed until installation is complete, including any required adjustments to tie-rods, etc.

2.1. Flange Jointing Practice

1) [R] Alignment tolerances of mating flanges shall be per the applicable code (ASME B31.1 or ASME
B31.3) and Figure 1.

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Figure 1: Flange Alignment Tolerances

2

1 2

Total Tolerance Per Flanged Joint

Special Services

Item Normal Service

a. Design Temperature –> 850°F (454°C) or Flange Rating > –
ASME Class 900.
b. Where plastic or elastomeric liner (lapped over the flange
faces) provides the gasket for the joint.

1 Per the applicable Code 1/32 in. (1 mm) maximum out of parallel alignment of flanges,
measured across any diameter.

2 Per the applicable Code 1/8 in. (3 mm) maximum translation of branches or
connections.

2) [R] Flange "makeup" shall be done without the use of gasket sealing compounds.
3) [R] All flange bolting shall be assembled with thread lubricating compound.
4) [R] Regarding flanged pipe joints of cement lined type valves, it may be necessary to grind the lining
at the pipe ends to avoid interference with the action of the valve disc (or plate). In this case, the
lining shall be taper ground and coated with epoxy cement.
5) [R] Flange "bolt-up" procedures shall be approved by the Owner’s Engineer.

3. Additional Requirements for Piping Over NPS 3 (80 mm)

Connected to Rotating Machinery
3.1. Piping Erection and Flange Alignment
1) * [R] A detailed piping erection and alignment procedure shall be prepared for each rotating
equipment machinery category and for each special purpose machinery train. Each procedure shall
include the following and shall be submitted to the Owner's Engineer for review and approval:
a) Piping erection sequence
b) Flange alignment techniques
c) Flange bolt up and driver(s) to driven machine(s) alignment pipe strain checks
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The procedure shall require that flange alignment tolerances and driver to driven machine alignment
change tolerances be satisfied both with and without temporary strainers installed. Where these
criteria cannot be met, the Contractor and machinery vendor shall develop a suitable resolution, such
as installation of piping spools of different length to accommodate temporary strainers.
2) [R] The following considerations shall be addressed as part of final flange alignment and bolt up:
a) Prior to final flange alignment, all hydrostatic leak testing and line cleaning (including chemical
cleaning, hydroblasting, steam blowing, and rupture disk blow downs) shall be complete. The
system shall be clean and dry. Hydrotesting blinds shall be removed.
b) Permanent spring supports shall be locked in the "cold load" position during piping erection, leak
testing, piping alignment to machinery, and piping bolt up.
c) All fixed supports shall be checked with feeler gauges to ensure full contact with piping. All
guides shall be checked to verify that design piping movement is not restricted.
d) No unsupported piping shall be connected to the equipment nozzles.
e) For field-fabricated piping, the makeup of flanged or field welded joints shall be done
progressively towards the machinery (e.g. the last flange bolted shall be the flange to the
machinery).
f) If prefabricated piping sections are used, at least one weld shall be left near the nozzle flanges for
final fitting and alignment.
g) Piping shall be free of load-imposing temporary restraints that may cause "cold springing" of the
piping.
h) Local heating to correct minor misalignment is permitted on piping that does not require post
weld heat treatment. Piping shall be allowed to cool below 150F before bolt up.
i) Machined pins furnished with mating flanges shall be used to align flange boltholes during field
erection of mating piping.
j) Final alignment of the driver to driven machine(s) shall be achieved in accordance with the
required tolerances specified in the alignment procedure. This includes offsets for thermal
growth or movement of the casing prior to final pipe alignment and bolt up.
k) * Final piping alignment and driver to driven casing alignment or web deflection and movement
on bolt up shall be witnessed by the Owner's Engineer. Records of pipe flange misalignment
shall be provided for the following:
i) All special purpose equipment trains
ii) All reciprocating compressors over 200 bhp (150kW)
iii) All machinery bolted to flanges of NPS 10 and larger
iv) When specified by the Owner's Engineer
3) [R] Equipment nozzle and mating flange alignment tolerances shall be within the following maximum
permissible limits:
a) For steam turbines and compressors other than reciprocating types, 1/64 in. (0.4 mm) for all
alignment categories listed in Item b below.
b) For centrifugal pumps, reciprocating compressors and other rotating machinery, refer to Table 1.
4) [R] For liquid service, final adjustments of spring supports shall be performed with the piping full of
process liquid.

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5) [R] After piping alignment is achieved for all machinery except reciprocating compressors, flange
bolt up shall be performed as follows:
a) Dial indicators shall be installed on brackets installed on coupling hubs or shafts to measure
vertical and horizontal movement of the driven machine(s) relative to the driver(s).
b) Starting with the largest flange size to be connected to any casing in the train, bolts and the gasket
shall be installed in the flange.
c) All bolts shall first be finger tightened. Then all bolts shall be tightened to approximately half the
required torque level. Next, bolts shall be tightened to an intermediate torque level, followed by
tightening to the full torque level required.
d) The maximum allowable vertical or horizontal movement of the shaft on the casing to which the
piping is bolted as measured relative to the adjacent shaft is 0.002 in. (0.05 mm).
e) If the shaft movement exceeds 0.002 in. (0.05 mm), all bolts in the flange shall be loosened, the
gasket shall be removed, corrections to the piping or supports shall be made, and the bolt up
procedure shall be repeated.

Table 1: Equipment Flange Alignment Tolerances

Maximum Permissible Misalignment of

Alignment Category Flanged Joints, in.

NPS  12 14  NPS  22 NPS  24

1 1 1
1. Vertical bolt hole offset /8 /16 /64
1 1 1
2. Horizontal bolt hole offset /8 /16 /64
1 1 1
3. Rotational offset /8 /16 /64
1 1 1
4. Flange face parallelism (across diameter) /64 /64 /64
5. Flange face separation, plus space required for gasket 1/8 1/16 1/64

Acceptable Metric Equivalents

1 1 1
in. /64 /16 /8
mm 0.4 1.5 3

6) [R] For reciprocating compressors, flange bolt up shall be performed as follows:

a) Web deflections shall be within the manufacturer's tolerance.
b) Steps (a) through (c) of Item (5) shall be performed.
c) After bolting, rod drop of the cylinder to which the piping is being installed shall be within the
manufacturer's tolerance.
d) After all flange bolting, web deflections shall be within the manufacturer's tolerance.
7) * [R] When specified, alignment of the driver to driven machine(s) shall be witnessed in the hot
condition. Alignment records shall be provided to the Owner's Engineer for review and approval.
8) [I] The following pipe flange misalignment data, showing the effect of the piping connections on the
machinery shaft alignment, shall be provided to the Owner:
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a) Ambient temperature at which flange misalignment is measured

b) Driver to driven machine(s) shaft alignment (readings before, during and after flange bolt
tightening) as follows:
i) Radial alignment (maximum dial gauge runout measured perpendicular to the shaft on the
rim of the coupling hub)
ii) Axial alignment (maximum dial gauge runout measured parallel to the shaft on the face of
the coupling hub near the rim)
c) Flange misalignment: (final "cold" alignment and "hot" alignment when specified)
i) Vertical bolt hole offset
ii) Horizontal bolt hole offset
iii) Rotational offset
iv) Flange face parallelism
v) Flange face separation
vi) Reciprocating compressor web deflections

4. Testing and Flushing

4.1. Preparation for Leak Testing
1) [R] The following piping components and equipment shall not be subjected to piping system leak
testing (pressure testing):
a) Rotating machinery, such as pumps, turbines, and compressors
b) Pressure relieving devices, such as rupture discs and pressure relief valves
c) Expansion joints
d) * Any equipment that does not have a specified test pressure at least as great as the piping test
pressure
e) Vessels that do not satisfy impact requirements at the piping test temperature
f) * Equipment lined with uncured phosphate or chemically bonded castable materials, unless
approved by the Owner
g) Locally mounted instruments and indicating pressure gauges, where the test pressure would
exceed their scale range
h) * Other equipment as designated by the Owner's Engineer
2) [R] Piping containing soft sealed valves shall be flushed and drained before the valves are installed.
3) [R] Control valves shall be excluded from pressure testing and line flushing to protect the valves from
dirt, scale, and foreign objects. The valves may be replaced with spool pieces or the ends of the pipe
blanked off, as appropriate.
4) [R] All restrictions that would interfere with filling, venting, draining or flushing shall not be installed
until after completion of the pressure test and line flushing operations. This includes orifice plates,
flow nozzles, venturi tubes, variable area meters, PD meters, turbine magnetic meters, strainers, and
any other similar in-line equipment.

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5) [R] Joints, including all welds and bonds, shall be left unprimed and unpainted for examination
during leak testing as follows:
a) * Joints located in environmentally sensitive areas, when specified by the Owner's Engineer
b) Joints located in buried piping systems

4.2. Instrument Piping and Sampling Connections

1) [R] Instrument take-off piping and sampling system piping, up to the first block valve, shall be leak
tested with the piping or equipment to which it is connected.
2) [R] Instrument lead lines, between the first block valve and the instruments to which they are
connected, shall be leak tested to the test pressure of the associated piping/equipment. Testing may
be performed separately or at the same time as the piping or equipment is tested, but the instruments
shall be disconnected.

4.3. Leak Test Procedures

1) [I] Calibration records for gauges used for testing shall be provided to the Owner.
2) * [R] Piping shall not be pressure tested at metal temperatures below 35F (2C) or below the piping
design minimum temperature without specific approval by the Owner.
3) * [R] Test fluid quality, draining procedures, and drying procedures shall be in accordance with
Section 5 of GP 18-10-01.
4) * [R] Test procedures and test schedules of lines or systems shall be reviewed by the Owner prior to
the start of the test. Procedures shall include the following:
a) Source and disposition of test fluid
b) Provisions to prevent the creation of significant negative pressure (vacuum) during draining of
the test fluid, etc.
c) Specific lines to be included within a system test
d) Provisions for temporary supports, vent, drain, fill connections, and gauge locations
5) [R] All leak tests shall be witnessed and accepted by the Inspector. The test results shall be recorded
and a copy shall be provided to the Owner.

4.4. Hydrostatic Leak Testing

1) [R] A strainer shall be installed in the fill line to minimize the possibility of foreign matter being
introduced into the system during the leak testing and line flushing operations.
2) [R] The following shall not be tested with water:
a) Instrument air supply lines
b) Air lines to air motor operated valves
c) Hydraulic power piping and tubing
d) Lube, seal, and control oil piping
3) * [R] Lines in HF acid service shall not be tested with water, unless approved by the Owner's
Engineer. When HF acid piping is tested with water, the piping system shall be flushed and dried to
ensure all water is removed prior to pipe commissioning.

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4.5. Pneumatic Leak Testing

1) [R] Pneumatic leak testing of instrument air piping and tubing shall be performed with dry instrument
air. The minimum test pressure shall be 90 psig (620 kPa) for supply systems and 20 psig (138 kPa)
for transmission systems.
2) * [S] Pneumatic testing of other piping is acceptable only if the Owner has approved the test
procedure.
3) [S] Pneumatic testing of spiral welded pipe is not permissible.

4.6. Leak Test Pressures

[R] Hydrostatic leak test pressure shall be determined per the applicable code but shall be at least 100 psig
(690 kPa), except as follows:
1) For ASME B16.5 material groups 1.1 through 2.5, the test pressure for Class 150 piping systems up
through size NPS 24 shall be equal to 1.5 times the working pressure of Class 150 flanges at 100F
(37C).
2) Test pressure for Class 300 piping systems for ASME B16.5 material groups 1.1 through 2.5 and up
through size NPS 24 shall be set equal to the lower of:
a) 1.5 times the working pressure of Class 300 flanges at 100F (37C)
b) 1.5 times the maximum pressure rating of the limiting system component at 100F (37C).
Where a system component limits the maximum working pressure of the piping system,
consideration shall be given to isolating the limiting component from the test circuit so as to
allow for an increase in the test pressure.
3) Underground pressure piping in water service and employing non-welded girth joints (such as bell
and spigot) shall be hydrostatically tested at 1.5 times the system design pressure. The test pressure
shall be maintained for two hours while the leakage rate is measured and the joints are inspected for
leakage.
4) Underground non-pressure sewer piping shall be tested full of water with a static head only, and the
joints shall be inspected for leakage.

5. Piping System Cleanliness

1) [R] The Owner's Engineer shall approve flushing fluids and flushing, draining and drying procedures
and schedules. These procedures shall include complete descriptions of flushing fluids, source of
fluids, proposed use of de-watering devices such as plastic foam pigs, and disposition of fluids. The
requirements for temporary supports, items to be included or excluded, temporary strainers, filling,
and venting of piping systems during flushing shall be specified. All flushing, draining, and drying
shall be witnessed and approved by the Owner.
2) [R] Pre-commission cleaning by chemical or mechanical means per GP 18-08-01 shall be performed
for the following piping serving steam generating equipment and rotating machinery:
a) Boiler feedwater piping downstream of the de-aerator.
b) Piping systems for machinery (carbon and low alloy steels < 5 Cr):

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i) Lube and seal oil systems (field fabricated piping only).

ii) Centrifugal and axial compressor suction piping, from the outlet of the first major vessel
upstream of the compressor to the compressor. Recycle and start-up bypass piping shall be
included.
iii) Reciprocating and rotary compressor suction and interstage piping (including vessels,
exchangers and pulsation suppression devices).
iv) Positive displacement pumps suction piping.
v) Steam turbine inlet piping.
3) [S] If pigs are used for flushing or cleaning, the procedures shall include a description of how
personnel and equipment will be protected from the fluids or other material that may be expelled from
the pipe.
4) * [R] The Owner shall approve procedures and schedules for piping protection after testing, flushing,
draining, drying, and pre-commission cleaning until start-up.

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Record of Change
Version 1.0.0 Date: 07/01
Location Action Description
Initial Publish

Version 1.0.0 Date: 07/03

Global Practice version number and format updated to comply with new
process; however, original publish date remains, and no content was
modified.

Version 2.0.0 Date: 04/05

General Modifications Implemented reference reduction guidelines by deleting reference to
ASME Section I.
Revised test pressure requirements for Class 150 and Class 300 piping
systems.
General editorial revision.

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Attachment: Purpose Codes Definitions

Code Description
C Assigned to paragraphs containing specifications whose primary purpose is reduced costs.
Reduced cost in this context refers to initial investment cost and does not include Life-Cycle
cost considerations. Life-Cycle cost considerations are captured under reliability,
maintainability, or operability purpose codes.
E Assigned to paragraphs containing specifications whose primary purpose is driven by
environmental considerations. Environmental considerations typically include specifications
intended to protect against emissions/leakage to the air, water, and/or soil. Deviations from the
specifications contained in such paragraphs require formal review and approval according to
local environmental policy.
I Assigned to paragraphs that provide only clarifying information such as Scope statements,
definitions of terms, etc.
M Assigned to paragraphs containing specifications whose primary purpose is to provide for
maintainability of equipment or systems. Maintainability provisions are those that facilitate the
performance of maintenance on equipment/systems either during downtimes or during on-
stream operations.
O Assigned to paragraphs containing specifications whose primary purpose is to assure
operability of equipment or systems. Operability is the ability of the equipment/system to
perform satisfactorily even though conditions are off-design, such as during startups, process
swings, subcomponent malfunction, etc.
R Assigned to paragraphs containing specifications whose primary purpose is to improve or
assure the reliability of equipment or systems. Reliability is a measure of the ability of
equipment/systems to operate without malfunction or failure between planned maintenance
interventions.
S Assigned to paragraphs containing specifications whose primary purpose is avoidance of
personnel or operational safety incidents. Any deviation from the specifications contained in
such designated paragraphs requires formal review and approval according to local safety
policy.
Personnel Safety: Refers to the avoidance of recordable personnel injuries; i.e., burns, cuts,
abrasions, inhalation, or exposure to dangerous substances, etc., that
could result in medical treatment, restricted work, lost-time incidents, or
fatalities.
Operational Refers to the prevention and control of process releases, fires, explosions,
Safety: etc.

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