Piping Pressure Test, Flushing ,

Blowing and Reinstatement-1

Procedure
(TIMAS-PR-PI-005)

Contract No :
Project Title : PIPING LINE GAS
Location : PANGKALAN KRINCI - RIAU
Client : PT. PEC – TECH INDONESIA

Issued for Approval

Rev’d Client
Rev. Date Description Prp’d Chk’d Rev’d
(QA) App’d
 Piping Pressure Test, Flushing , Doc.No.: TIMAS-PR-PI-005
Blowing and Reinstatement-1 Rev. : A
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Table of Contents

1. Scope

2. References

3. Procedure

4. Flushing and Air Blowing

5. Reinstatement

6. Attachments

PT. TIMAS SUPLINDO

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1.0 Scope
This Procedure describes the requirements to be conformed in pressure leak
testing on piping for the construction.

2.0 Reference
The related procedures which supplement this procedure are as follows :

2.1 ANSI B31.1 : Power Piping

2.2 Project Tech. Specification

2.3 ANSI B31.3 : Chemical Plant & Petroleum Refinery Piping

3.0 Procedure

3.1 General Requirement

3.1.1 After installation of piping, pressure test required shall be performed as

specified in this Procedure.

3.1.2 All testing shall be conducted by the Piping Supervisor and shall be witnessed
by the QC Piping Inspector and OWNER.

3.1.3 Prior to the scheduled pressure test, the Piping Supervisor shall prepare the
pressure test package including Hydrostatic or Pneumatic Test Report, Line &
ISO DWG. List and P & ID drawings marked up to show the boundaries of the
test and filling. Two copies of the pressure test packages shall be submitted to
OWNER.
3.1.4 The following items shall be shown in the "Pressure Test Package".
1) Limitation of system to be tested on P & ID.
2) Location of temporary blind plate, pressure gauges.
3) Line number and equipment item numbers to be tested.

PT. TIMAS SUPLINDO

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4) Test pressure and test medium.

5) Hydro / Pneumatic Test Report
6) Punch list cleared.
7) Certificate for piping pressure test

3.1.5 Supplier documents, for valves which are intended for use in test boundary
isolation shall be checked by Piping Supervisor and evidence included in
pressure test package to show that the valve are capable of withstanding the
pressure loads applied, likewise, all equipment within the test segment shall be
determined as being capable of withstanding the test.

3.1.6 Valves, equipments, etc., not capable of withstanding test pressure shall not be
used for the pressure tests.

3.1.7 Additional supports shall be temporally installed if the system has not been
designed to support the added weight of the test media.

3.1.8 Any expansion joints in the system shall be restrained or they shall be isolated
from the system during the test.

3.1.9 When pressure testing a system, the test pressure shall not exceed maximum
test pressure for any component in the system.

3.1.10 All components in the system that should not be subjected to pressure test,
such as pumps, tanks, heat exchangers, gauges and instruments, shall be
isolated from the test.

3.1.11 Pressure gauges shall be installed as follows ;

As a minimum, one gauge shall be installed at pump, and one at the Lowest
point. Additional gauges may be installed on the system as required. Pressure
reading taken at the Low point shall be equal to the required test pressure plus
the static head to the high point. However, the test pressure shall not exceed
the maximums as given in para.5.4.2 or the SK Corporation STD ESS-50410.

PT. TIMAS SUPLINDO

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3.1.12 For the other piping except process piping may be used one indicating
pressure gauge.
The gauges shall have a reading range of 1 1/2 to maximum of 4 times the test
pressure and shall be calibrated and certified before the start of each test or
series of tests.

3.1.14 A series of tests is that group of test, using the same pressure gauges, which
are conducted within a period not exceeding two weeks.

3.1.15 Gauges in use shall be installed in a manner visually accessible to personnel

performing the test.

3.1.16 When performing pneumatic test, a pressure relief valve set for 1.06 times the
maximum test pressure shall be installed in the system.

3.1.17 All welding inspection records for field welds, field modification welds, and
pressure boundary attachment welds shall be verified and be completed by
QC.
The ISO DWG's used during pressure test walkdown and the pipe supports
attachment drawings shall be utilized for determining these requirement.

3.1.18 The preliminary walkdown before the pressure test shall be performed by
Piping Supervisor in conduction with Piping QC Inspector.

3.1.19 The punch items found out during preliminary walkdown shall be cleared prior
to the notification of pressure test to OWNER.

3.1.20 NCR Completion Verification

All open NCRs shall have been identified and completed except those that are
not pressure test restraints.

3.1.21 All joints shall be exposed and cleared of insulation and wrapping for easy
inspection.

PT. TIMAS SUPLINDO

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3.1.22 Before the start of the test, the Piping Supervisor shall verify that tags
("DANGER" Tag) are attached on the all valves and components within the
boundaries of the test.
He shall also verify that the test area has been secured for the safety of
personnel.

3.1.23 Piping components or system which cannot be tested or inspected after

completion of erection may be tested prior to the erection.

3.1.24 For low temperature service, it's requested to use air or nitrogen without
moisture content at the test pressure.
When water must not be used for Pressure Test on a vessel for process
reason, pneumatic test shall be employed. In such cases, the Pneumatic Test
shall be performed with due consideration given to safety. The fabricator shall
propose a suitable test procedure for approval by OWNER.

3.1.25 Except for the location to be inspected, the thermal insulation work and
painting work may be done upon completion of the pressure leak tests and
overall air-tightness tests.

3.2 Test Procedure

3.2.1 Air vent shall be opened to allow the elimination of air from the system during
the water fill.

3.2.2 The system shall be gradually filled, venting air from high points.

3.2.3 Vents shall be closed when the system is full.

3.2.4 A gradual and slow filling, combined with the removal of air from the system, is
required to eliminate the danger of water hammering.

3.2.5 The test pressure shall be applied gradually with a suitable hydraulic pump in
increments of 1/3 or less of the test pressure.

PT. TIMAS SUPLINDO

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3.2.6 The test pressure shall not be applied until the system and the pressurizing
medium are at approximately the same temperature.

3.2.7 The system under test shall be held at full test pressure until all joints are
examined. In no case shall the duration of the pressure test be Less than one
hour on each system tested.

3.2.8 Thereafter, the test pressure shall be maintained for examination by the Piping
QC and COMPANY/PMC of all joints, connections and regions and high stress
such as around openings and thicknesses transition sections.

3.2.9 Upon satisfactory completion of the test, the system shall be depressurized
gradually and then drained completely (air blowng, if required).

3.2.10 Action shall be taken to properly vent the system during drainage to prevent
subjecting the system to a vacuum.

3.3 Repair
Should repairing work or additional work necessary as a result of pressure
tests or leak tests, those work shall be conducted after reducing pressure, and
those piping systems which have been affected by such work shall be subject
to additional tests.

4.0 Flushing and Air Blowing

4.1 After the pressure test and leak test, flushing or air blowing shall be conducted
for the tested system to assure the removal of dirts, debris and obstructions
inside piping tested.
Details shall be subject to the field instructions by field supervisor.

5.0 Reinstatement

PT. TIMAS SUPLINDO

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5.1 All temporary blinds, safety relief valves, gaskets, gauges, etc. installed for the
pressure test shall be removed.

5.2 All instruments, equipments, control valves, etc. temporally dismounted for the
pressure test shall be reinstated in accordance with EFD, so that it can be
subject to operational conditions.

6.0 Attachments

6.1 Piping (Hydro / Pneumatic) Pressure Test Flow Chart (Attachment 1)

6.2 Hydro / Pneumatic Test Report (Attachment 2)
6.3 Punch List (For Pressure Test) (Attachment 3)
6.4 Record Sheet Flushing / Blowing (Attachment 4)
6.5 Piping Reinstatement Check List (Attachment 5)
6.6 Field Installation Check List for A/G Piping (Attachment 6)
6.7 Chemical Cleaning Report (Attachment 7)

Attachment 1.

PIPING (HYDRO/PNEUMATIC) PRESSURE TEST FLOW

PT. TIMAS SUPLINDO

 Piping Pressure Test, Flushing , Doc.No.: TIMAS-PR-PI-005
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Attachment 2.

Page of
HYDRO / PNEUMATIC TEST REPORT FOR PIPING Date :

PT. TIMAS SUPLINDO

 Piping Pressure Test, Flushing , Doc.No.: TIMAS-PR-PI-005
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Procedure Page : 10 of 16

Project / No. : Report No. :

Location : Item :

DWG No. Sub-Con.

: :
(Rev. No.) Name

Test Package No. : System No. :

Pressure (KG/cm2) Operating : Design : Test :
Temperature Operating : Design :
Method Hydro Pneumatic Visual
Test Fluid Water Air N2
Pressure Gauge No.
Holding Time
Area Line No. ISO DWG No. Line No. ISO DWG No.

Comments :

Prepared By Witness By Witness By

Sub-Con. Sign/Date CLIENT Sign/Date COMPANY/PMC Sign/Date

PT. TIMAS SUPLINDO

 Piping Pressure Test, Flushing , Doc.No.: TIMAS-PR-PI-005
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Attachment 3-1.
Category Legend
PUNCH LIST - A : Before Mechanical Completion
(For Discipline Completion 11 System Completion 11) - B : After Mechanical Completion

Project : System (Area) :

Subcontractor : Date :
Drawing No./ Category Issued By / Cleared By Verified By Verified By
Item No. Description
Location A/B Date Subcon./Date Cont./Date COMPANY/Date

Attachment 3-2. Page of

PT. TIMAS SUPLINDO

 Piping Pressure Test, Flushing , Doc.No.: TIMAS-PR-PI-005
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Drawing No./ Category Issued By / Cleared By Verified By Verified By

Item No. Description
Location A/B Date Subcon./Date Cont./Date COMPANY/Date

PT. TIMAS SUPLINDO

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Attachment 4.

Project : RECORD SHEET FLUSHING / Page :

System No. :
BLOWING Date :

System Name :
Flushing No. : Hydro Test Pkg No. :
E.F.D. No.s :
Preparation Work

Flushing / Blowing

- Start :
- Finish :

Reinstatement

System Fully Reinstated Sign :

Date :

Flushing Medium Source

Remarks

Checked by Witnessed by

COMPANY

Sign/Date Sign/Date

Attachment 5.

PT. TIMAS SUPLINDO

 Piping Pressure Test, Flushing , Doc.No.: TIMAS-PR-PI-005
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Project :
System No. :
PIPING REINSTATEMENT Date :
Cert. No. :
Test Pkg No. : CHECK LIST

Yes No. NA

Check that correct bolts and gaskets are installed at all reinstalled joints
1.
completed and recorded.

Check that all process blinds and spades have been correctly installed as
2.
indicated on the P & ID.

3. Check that spectacle blinds are in the correct position.

4. Check that control valves have been installed in the correct "Flow" position.
5. Check that specified block valves have locking device correct installed.

Check that all valves are functioning properly and that spindle has been coated
6.
with "Copa-Slip" or equal where specified.
Check that all extended spindles required for specified valves have been
7.
installed.
8. Check that relief valves have been correctly installed.
9. Check that all pump suction strainers have been correctly installed.

Check correct flow through fillers and strainers, trains, check valves and globe
10.
valves.

11. Check Release for final equipment alignment.

12. Check Hydrotest Completed.
Remarks :

Completed by SUBCONTRACTOR CLIENT COMPANY / PMC

Firm
Signature
Name
Date

Attachment 6.
Page of

PT. TIMAS SUPLINDO

 Piping Pressure Test, Flushing , Doc.No.: TIMAS-PR-PI-005
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FIELD INSTALLATION CHECK LIST FOR A/G PIPING Date :

Project / No. : Report No. :

Location : Item :

DWG No.
: Sub-Con. Name :
(Rev. No.)

NO. ITEM TO CHECK RESULT NO. ITEM TO CHECK RESULT

GENERAL VALVES (contd.)
1 Line size correct 22 Bypass installed
2 Material correct 23 Chain wheel installed
3 Flange rating correct 24 Extension stem installed
4 Stress relieving complete 25 Stem oriented properly
5 Welding complete 26 Drain / flush connections in
6 Installation straight and plumb GASKETS AND BOLTS
7 Line slopes per drawing 27 Correct type
8 Branches located correctly 28 Correct material
9 Branches reinforced 29 Studs Tightened
10 Weepholes in reinforcing pad PIPE SUPPORT
11 High point vents in 30 Field supports installed
12 Low point drains in 31 Sufficient supports
13 Reducers located correctly 32 Anchors installed
14 Reducer type correct 33 Guides installed
15 Blinds installed 34 Proper shoes installed and welded
16 NDT complete 35 Spring hangers properly installed
17 Cold springs per drawing INSULATION AND TRACING
18 Clearance for expansion 36 Insulation support clips installed
VALVES 37 Clearances adequate for insulation
Flow direction correct 38 Electric tracing installed
19
20 Stock code no. correct 39 Steam tracing installed
21 Bolts or nuts correct 40 Correct no. of tracers
41 Tracer size correct

Prepared By Witness By Witness By

Sub-Con. Sign/Date CLIENT Sign/Date COMPANY/PMC Sign/Date

Attachment 7.
Page of

PT. TIMAS SUPLINDO

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CHEMICAL CLEANING REPORT Date :

Project / No. : Report No. :

Location : Item :
DWG No.
: Sub-Con. Name :
(Rev. No.)

Flushing Time Results

No. Line No. Remarks
Media Rate Start End ACC. REJ.

Prepared By Witness By Witness By

Sub-Con. Sign/Date CLIENT Sign/Date COMPANY/PMC Sign/Date

PT. TIMAS SUPLINDO