CR Asia Group

Work Instruction for

Pressure Testing of pipelines
Revision Record
Issue
No

Revision
No

Date

Page
Edition

01

00

dd.mm.yy

All

Established/ Revised;

( Nitin Karbhari )
Project Engineer

Initial Release

Reviewed;

CRAI-WI-ME-05

Issue Date :

Month DD,YYYY

Approved
by

Nitin Karbhari

Gunavel R

Group Reviewed;

( Swapnil Patil )

Business unit QUENSH

MR.

Document :

Prepared
by

Description of Revision

PERMIT REQUIRED PRIOR TO COPYING

(Dinesh Deogiri)
Group Quality &
performance Manager

DAR
No.

Accepted / Approved;

( General Manager )
General Manager

Revision Number :

00

Copy Number :

Issue Number :

01

Page :

1 of 7

CONTROLLED DOCUMENT

CR Asia Group
Work Instruction for
Pressure Testing of pipelines
1. Objective
This procedure provides the control methods of the hydrostatic test of the pipelines
fabricated in accordance with ASME B 31.3
Piping system open to atmosphere, such as drains, vents and outlet piping for relief valves
discharging to atmosphere and underground sewers shall not require any pressure testing.
These lines shall be examined to determine that all joints are properly made up according to
standard requirements.
2. Scope
This procedure is outlines the scope of requirement for inspection, flushing & testing of piping
system.
3. Reference document

ASME B31.3
API 570.
4. Form
F-CRAI-WI-ME-06-01 Pressure Test Report for Pipelines
5. Definition: For checking integrity of pipelines at designed pressure hydro testing of pipelines is
necessary.
6. Responsibilities:
6.1 Project Manager or Project Engineer has the overall responsibility for the control and
management of the project. Including ensuring that safety, health & environment management
takes priority over all. Responsible for the projects progress, records and contact with the
clients representatives
6.2 Supervisor has responsibility for ensuring that safety is paramount to the job, compliance with
job method statements and work execution in conjunction with the PM or PE
6.3 Safety Supervisor is responsible for all safety, health & environmental matters in conjunction
with the Supervisor and PM or PE.
6.4 Foreman & Technicians must be fully equipped to meet all of the present dangers and have
a clear understanding of safe work procedures plus potential health and environmental risks
applicable to the task at hand.

7.

Procedure Steps:

7.1 Pre-Shutdown Activities

Following steps need to be done in the Pre-shutdown stages.
7.1.1 Documents related to Process of Testing.
Following documents need to be collected from client representative during kick off meeting
a) Pressure testing loops number quantity with designed test pressure.
b) Pressure testing loops blind register
c) Pressure testing medium.
d) P & ID diagram of the respective plant.

Document :

CRAI-WI-ME-05

Issue Date :

Month DD,YYYY

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

00

Copy Number :

Issue Number :

01

Page :

2 of 7

CONTROLLED DOCUMENT

CR Asia Group
Work Instruction for
Pressure Testing of pipelines
7.1.2 Review of the documents :
All the documents received from the client need to be review properly. If any doubts in the
documents observed same will highlight and same will discuss with Engineer incharge EIC of client or
client representative.
7.1.3 Steps of loop tracing on actual site with Client representative:
This is one of the key process need to be carry during the pre-shutdown stages. With the help of
client operation representative and P & ID diagram trace the piping loops which is in the scope.
While tracing the loops all the loop start point & blinding location & end point need to be identify by the
tags.( If possible used color tags e.g. a) Blue for Hydro testing,
b) Yellow for Pneumatic testing,
c) Red for the DM water testing
While surveying the loops following safety measures need to be taken
1) Wear all mandatory PPE while working in the plant process area.
2) Take a cold work permit while working inside the plant area and same has to be displayed if
possible.
3) Do not touch or operate any valves or process equipments.
4) If any leakage or abnormal found in the process plant highlight the same to the concern
engineer in charge.
5) In case emergency or fire alarm condition do not enter in the process area. If inside the process
area leave to the assembly point.
6) Note down temporary spool dropping locations, sizes & make a register copy for our reference.
7) Maintain blind register with gasket requirements for client & our record.
7.1.4 Drawing of the Piping loops:
After every loop trace up Piping loop drawing need to be done on the Isometric sheet and once all the
loop trace up and drawing is over get it certified from the client & TPI representative.
7.2 Shutdown Activities:
7.2.1 Flushing of the Process Pipelines
The following guidelines shall be ensure while carrying out flushing of lines.
Flushing of all lines shall be done before pressure testing. Flushing shall be done by fresh
potable water or dry compressed air( wherever water flushing is not desirable) , to clean the
pipe of all dirts, debris & foreign material.
Required pressure for the water flushing shall meet the fire hydrant pressure or utility water
pressure. For air flushing, the lines/system will be pressurized by compressed air at the required
pressure which shall be 50PSI maximum. The pressure then be release by quick opening of
valve which is already available in the system or installed temporary for the flushing purpose.
This procedure shall be repeated till the inside pipeline is fully cleaned.
In line instrument like control valves,orifice plates, rotameters, strainers ,safety valves and other
instrument like thermowell which may interfere with flushing shall not be included in the flushing
circuit. coordinate with instrument department for the same.
The screen /meshes shall be removed from all the strainers before flushing. Screen/meshes
shall be reinstalled after flushing before testing.
In case an equipment such as column, vessel, exchanger etc. form part of piping circuit during
flushing, this shall be done with the approval of client.
During flushing discharged water/air shall be drained to the place directed by the client
representative.
Care shall be taken during flushing so as not to damage/spoil work of other division. Precaution
shall also be taken to prevent entry of water/foreign particle into equipment, electrical motors,
instruments, electrical installation etc. in vicinity of the lines being flushed.
Following activities need to complete before, during and after the flushing activities.

Document :

CRAI-WI-ME-05

Issue Date :

Month DD,YYYY

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

00

Copy Number :

Issue Number :

01

Page :

3 of 7

CONTROLLED DOCUMENT

CR Asia Group
Work Instruction for
Pressure Testing of pipelines
1)Dropping of valves, distance pipes, inline instruments and any other part before flushing.
The flanges to be disengaged for this purpose shall be envisaged by CRAI and approved
by the client representative. The flanges shall be provided with temporary CAF gasket at
the time of flushing.
2)After flushing is completed and approved, the valves distance pieces, piping etc. shall be
reinstalled by CRAI with gaskets. However, flanges at equipment nozzles and other
places where isolation is required during testing, only temporary gaskets shall be
provided.
7.2.2 Preparation for testing
Testing shall be carried out with permanent gaskets installed unless specified otherwise or
instructed by client representative.
No pressure test shall be carried out against closed valve unless approved by the client.
Before testing, all piping shall be cleaned by flushing to make it free from dirt ,loose debris and
other loose foreign material.
All the piping system to be tested shall be vented at high point.
Whenever in the line any void exists due to any reason,like absence of control valves, safety
valves, check valves etc. it shall be made up with temporary spools.
Where a system is to be isolated at a pair of companion flanges, a blank shall be inserted
between companion flanges. Minimum thickness of the blank shall be designed in accordance
with applicable design code ASME B 31.
Open end of piping system where blanks cannot be used, such as pumps, compressor,
turbines or wherever equipment or pipe spool have to be recovered or disconnected prior to
pressure testing ,shall be blinded of using standard flanges of same rating as the piping
system is being tested.
Pressure gauges used for testing shall be installed as close as possible to the lowest point in
the piping system to be tested, to avoid overstressing of any of the lower portion of the system.
For longer lines & verticle lines two or more pressure gauges need to be installed or as per
client advice.
For the lines containing check valves any of the following alternatives will be adopted for
pressure testing:
- Wherever possible pressurize upstream side of valve.
-replace the valve by temporary spool and reinstall the valve after testing.
-provide blind on valve flanges and test the upstream and downstream of the line separately
and remove the lines after testing. At these flanges, temporary gaskets shall be provided
during testing and shall be replaced by permanent gaskets subsequent completion of hydro
test.
Gas lines when pressure tested shall be provided with additional temporary supports as per
client instruction (if required).
Piping which is spring or count weight supported shall be temporarily supported, where the
weight of fluid would overload the support.
When testing any pipeline system, air or steam at 2kg/cm may be used for the preliminary
checking for missing gaskets etc. as this avoids the necessity of draining the line to make
repair. Avoid the use of steam as a design temperature of line may be less than steam
temperature.

7.2.3 Fluid medium and temperature :

(a) Any pipe system containing Austenitic Stainless Steel piping components shall be
tested with potable water (less than 50 ppm chlorides).
- If chloride content is greater than 50 ppm, up to a maximum of 250 ppm, a sufficient
quantity of sodium nitrate shall be added to provide a test medium of 0.5% by weight
Document :

CRAI-WI-ME-05

Issue Date :

Month DD,YYYY

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

00

Copy Number :

Issue Number :

01

Page :

4 of 7

CONTROLLED DOCUMENT

CR Asia Group
Work Instruction for
Pressure Testing of pipelines
sodium nitrate solution.
- Water with a chloride content of greater than 250 ppm shall not be used for hydro
testing.
- The lines shall be immediately drained after testing and flushed and dried by blowing
air.
(b) Salt water may be permitted for testing non austenitic piping, provided that the
following requirements are met:
- Isolating austenitic SS piping and connected equipment with salt water.
- Steps to be taken to ensure complete removal of water from the system after testing.
- Chemical treatment (inhibitors, oxygen scavengers) to mitigate corrosion if salt water will
remain in the piping for more than 30 days.
(c) It is recommended that the metal temperature during hydrostatic test be maintained
at least to 35 0 F.
(d) The test pressure shall not be applied until the pipeline and its content are at about the same
temperature.
7.2.4 Test Gauges:
(a) Dial indication pressure gauge shall be used in testing pipeline. It should be installed
as close as possible to the lower point of the piping system.
(b) The gauges shall be selected such that the intended maximum test pressure falls in
the midrange of the instrument, but in no case shall the range be less that 1.5 nor
More than 4 times the test pressure.
(c) The gauges shall be calibrated at least every twelve months or at any times with registered
vendors from client.
7.3 Procedure for Pressure testing.
7.3.1 Filling the pipeline with test medium:
(a) Vents shall be provided at all high points of the pipeline in position in which it is tested to purge
possible air pockets which the pipeline is being filled.
(b) The pipeline will be filled with water by any suitable low pressure filling lines.
(c) Before applying pressure, the shop or field operator shall check the test equipment to assure that it is
tight and all low pressure filling lines and other appurtenances that should not be subjected to the test
pressure have been positively isolated.
(d) Control valves and relief valves shall be excluded from the test irrespective of their pressure rating.
7.3.2 Application of pressure
(a)The pressure in the pipeline shall be increased until the required test pressure.i.e.1.5 times designed
pressure has been reached.
(b) All joints, including welds, shall be left un-insulated and exposed for examination during the test for a
minimum total time of 10 minutes or as specified by client.
.
7.3.3 Inspection:
(a) At the pressure described above, inspection for leakage shall be made on the whole pipelines,
especially on weld seam and all areas of high stress concentration.
(b)Any leaks or other defects found during inspection shall be reported. The assembly shall then be
depressurized and the leaks repaired. After repairs have been made, the assembly shall be retested.
Document :

CRAI-WI-ME-05

Issue Date :

Month DD,YYYY

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

00

Copy Number :

Issue Number :

01

Page :

5 of 7

CONTROLLED DOCUMENT

CR Asia Group
Work Instruction for
Pressure Testing of pipelines
(c) The test shall be conducted by the shop and witnessed by concerned inspection authority.
7.4 EMPTYING THE PIPELINE:
After successful completion of the pressure test, vents shall be opened slowly to reduce the pressure to
release and then drain should be kept open to remove the test medium.
Note: As per current practice, pipelines are to be tested as per pressure indicated in the drawings.
However, if the pressure is not mentioned in the drawings, then pipelines should be tested as given
below.

FOR NEW PIPELINES:

Piping Class
150#

Test Pressure in kg/cm(psi)

30(420)

300#

50(720)

600#

100(1420)

FOR EXISTING PIPELINES IN FIELD OR THE EXISTING PIPELINES MODIFIED WITH

NEW PIPELINES CONNECTED TO IT:
Piping Class
Test Pressure in kg/cm(psi)
150#

20(285)

300#

35(500)

600#

70(1000)

8.0 Process flow chart :Hydro testing general setup

Document :

CRAI-WI-ME-05

Issue Date :

Month DD,YYYY

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

00

Copy Number :

Issue Number :

01

Page :

6 of 7

CONTROLLED DOCUMENT

CR Asia Group
Work Instruction for
Pressure Testing of pipelines

Document :

CRAI-WI-ME-05

Issue Date :

Month DD,YYYY

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

00

Copy Number :

Issue Number :

01

Page :

7 of 7

CONTROLLED DOCUMENT