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Issuing organisationPiping Flushing & Pressure Testing BES-CO-05-003-02Rev: 2 / 02.10.2008PA&ESheet 1 / 22PIPING FLUSHING ANDPRESSURE TESTINGBES-CO-05-003Preparer Date Name/Position02.10.

2008Gino De Landtsheer / Piping ExpertTSG - PTSIssuer Date Name/Position02.10.2008Hennie de Bruyn / Chief Engineer Material Technology, PTSProcess owner Date Name/Position02.10.2008 Jan-Olav Kvitnes/ Specs PTS2 General update1 ApprovedRev. DescriptionA print of this document is only valid at the date of printing. For reference, use the actual version available on Borena/Bordocs. BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 2 / 22TABLE OF CONTENTS1 GENERAL ....................................................................................................................................4 1.1 Validity .......................................................................................................................................4 1.2 Review Schedule .......................................................................................................................4 1.3 Group Amendment to the Borealis Engineering Specification ...................................................4 1.4 Objective and Scope .................................................................................................................4 2 APPLIED STANDARDS ..............................................................................................................4 2.1 Standards and Regulations .......................................................................................................4 2.1.1 European Directives ...............................................................................................................5 2.1.2 Applicable Design Codes .......................................................................................................5 2.1.3 Borealis Reference Documents ..............................................................................................5 2.1.4 Standards ...............................................................................................................................5 3 QUALITY ASSURANCE / QUALITY CONTROL .........................................................................5 3.1 Quality Assurance / Quality Control ...........................................................................................5 3.1.1 Inspection Plan .......................................................................................................................5 3.1.2 Inspection Notification ............................................................................................................6 3.1.3 Inspectors Approval ...............................................................................................................6 3.2 Documentation ..........................................................................................................................6 3.2.1 Quality records .......................................................................................................................6 3.2.2 Filing System ..........................................................................................................................7 4 BASIC DESIGN REQUIREMENTS ..............................................................................................7 4.1 General .....................................................................................................................................7 5 FLUSHING REQUIREMENTS .....................................................................................................7 5.1 General .....................................................................................................................................7 5.2 Hydro Flushing ..........................................................................................................................8 5.3 Pressurised Air Shock Blowing (PAS) .......................................................................................9 5.4

Pneumatic Flushing ...................................................................................................................9 5.5 Hot Oil Flushing .........................................................................................................................9 5.5.1 General ..................................................................................................................................9 5.5.2 Marking ................................................................................................................................10 5.5.3 Documentation .....................................................................................................................10 6 PRESSURE TESTING ...............................................................................................................10 6.1 General ...................................................................................................................................10 6.1.1 Pressure Test Diagrams and Test Procedure .......................................................................10 6.1.2 Pressure Test Packages ......................................................................................................10 6.1.3 Test Pressure .......................................................................................................................11 6.2 Preparations for Testing ..........................................................................................................11 6.3 Safety and Environmental Control ...........................................................................................13 6.4 Test Equipment .......................................................................................................................14 6.5 Test Medium ...........................................................................................................................14 6.5.1 For Hydrostatic Testing ........................................................................................................14 6.5.2 Austentic Stainless Steel ......................................................................................................15 6.5.3 Ferritic Stainless Steels and Medium/High Nickel Alloys ......................................................15 6.5.4 Duplex Stainless Steel .........................................................................................................15 6.5.5 9% Nickel Alloy Steel ...........................................................................................................16 6.5.6 Aluminium and Aluminium Alloys ..........................................................................................16 6.5.7 For Pneumatic Testing .........................................................................................................16 6.5.8 For Alternative Leak Test and for Service Test .....................................................................16 6.6 Disposal ..................................................................................................................................16 6.7 Test Procedure ........................................................................................................................16 6.7.1 Hydrostatic Testing ...............................................................................................................16 6.7.2 Pneumatic Testing ................................................................................................................17 6.7.3 Alternative to Hydrostatic or Pneumatic Pressure Testing (Alternative Leak Test) ...............19 6.7.4 Initial Service Leak Test (Service Test) ................................................................................19 A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena/Bordocs. BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 3 / 226.7.5 Draining and Drying ..............................................................................................................19 6.7.6 Verification of Cleanliness ....................................................................................................20 6.7.7 Reinstatement ......................................................................................................................20 7 CHEMICAL CLEANING .............................................................................................................21 8 INSPECTION AND REPORTING .............................................................................................22 9 ATTACHMENTS ........................................................................................................................22

A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena/Bordocs. BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 4 / 221 GENERAL1.1 ValidityThis specification is valid for all BOREALIS Sites.1.2 Review ScheduleThis specification shall be reviewed at least every three years.1.3 Group Amendment to the Borealis Engineering SpecificationThis Borealis Engineering Specification shall consist of the BES-CO-00-001; GroupAmendment to the Borealis Engineering Specifications which are incorporated herein andmade part here of by reference.Content for info: General Definitions, Abbreviations, Objective and Scope, Language, UnitSystem, CE-Marking, PED / ATEX / Quality Assurance / Quality Control, General BasicDesign Requirements.1.4 Objective and ScopeIt is CONTRACTORs responsibility, after the piping lay-out is completely installed andbefore it will be put in to operation, to perform a full flushing (blow out) of the piping lay-outand/or applicable equipment. This is to allow removal any loose debris. Only after thisaction a pressure test can be performed.A final purging phase with a temporary gas (nitrogen) or with the intended system gasneeds to be performed to assure cleanliness of the piping components.When any requirement in this specification might violate specific requirements of amaterial VENDOR necessary to warrant the integrity of supplied materials, the differentrequirements must be discussed and approved by COMPANY.2 APPLIED STANDARDSIt shall be CONTRACTORs responsibility to be, or to become, knowledgeable of therequirements of the referenced Codes and Standards.When an edition date is not indicated for a code or standard, the latest edition in force atthe time of CONTRACTORs commitment shall apply.Intermediate changes or updates/revisions of applied codes, standards, regulations or laws during the course of the project shall be brought to COMPANYs attention. Possibleimplications for the works shall be discussed.2.1 Standards and RegulationsThe design and engineering shall satisfy all laws and regulations of the national and/or local authorities of the country in which the EQUIPMENT AND MATERIALS will belocated.The international codes and standards, to the extent specified herein, form a part of thisspecification and shall be followed. Some codes or standards (e.g. Euro codes) are stillunder development and their final number and identification are given below. If thereferenced code is not yet available, its preceding pre-code, draft code or relevantnational codes covering the same subject shall be followed.In case of conflict, the order of precedence shall be:A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena/Bordocs. BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 5 / 221. National and/or local Laws and Regulations applicable at the location of thesite.2. European Directives3. Applicable Design Codes (ASME BVPC, ASME B31.3, AD2000, BS 5500, EN13445, EN 13480, etc.)4. Project specific CATALOGUE DATA SHEETS from the LICENSOR5. COMPANY specificationsProject SpecificationLocal AmendmentCommon Engineering SpecificationReference to international standards (API, NFPA, etc.)The more stringent of two conflicting regulations/standards will prevail.In all cases CONTRACTOR shall inform COMPANY of any deviation from therequirements in the specifications, which is considered to be necessary in order to complywith national and/or local laws and regulations.Deviations from this specification are subject to written approval by COMPANY. After thisapproval these specifications are integral part of the contract.The standards and codes as listed in 2.1.1, 2.1.2, 2.1.3 and 2.1.4 shall be followed.2.1.1 European Directives97/23 EC Pressure Equipment Directive (PED) for pressure containingequipment and assemblies2.1.2 Applicable Design CodesASME B31.3 Code for Pressure Piping: Process PipingAD2000 Code Technical Rules for Pressure Vessels: AD Merkbltter,AD2000 Merkblatt HP 100 REN 13480

Metallic Industrial Piping2.1.3 Borealis Reference DocumentsBER-CO-05-001 General Design Requirements PipingBES-CO-00-001 Group Amendment to the Borealis Engineering SpecificationsBESCO-04-013 Mechanical Package Unit General2.1.4 StandardsISO 4406 Hydraulic Fluid Power - Fluids Method for Coding the Levelof Contamination by Solid ParticlesISBN 0717616290 Health Safety & Environment (HSE) Guidance note GS4Safety in Pressure Testing3 QUALITY ASSURANCE / QUALITY CONTROL3.1 Quality Assurance / Quality Control3.1.1 Inspection PlanCONTRACTOR shall establish and maintain a documented inspection plan that will provideadequate, effective Quality Assurance and will provide for the easy identification andhandling of items.A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena/Bordocs. BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 6 / 22The flushing activities and the specific pressure test inspections described in this specificationshall be part of the general quality inspection plan related to any piping fabrication and/or assembly activities.Each applicable quality inspection plan shall be set up as per recommended projectrequirements and in relation with the fabrication sequence.Inspection points related to the flushing and testing of piping components, piping spools andpiping assemblies, shall be part of the general project inspection plan that shall be sent toCOMPANY for approval prior to contract awarding.Together with the general project inspection plan, all applicable procedures concerning flushingand testing of piping components, piping spools and piping assemblies shall be sent toCOMPANY for approval prior to contract awarding.3.1.2 Inspection NotificationCONTRACTOR shall provide COMPANY with advance notification of certain shopinspections and tests (when applicable or required according inspection plans); fieldinspection and tests, including those of SUBCONTRACTORS and/or SUBVENDORS, asoutlined in the contract or agreements made in the pre-award inspection meeting.COMPANY shall be informed in advance according to the schedule specified in theproject planning or at least 10 working days before the actual scheduled date.COMPANY shall have entry - after advance notification - to all CONTRACTOR andSUBCONTRACTORS plants where testing of equipment and/or materials is in progress.It shall be the responsibility of CONTRACTOR to notify SUBCONTRACTORS,SUBVENDORS, THIRD PARTY INSPECTORS or NOTIFIED BODIES (in case CEcertification is applicable) of COMPANYs inspection requirements.3.1.3 Inspectors ApprovalCOMPANY inspectors approval does not relieve CONTRACTOR from any responsibility.3.2 Documentation3.2.1 Quality recordsQuality records shall include, but are not limited to:Item identification by reference to drawings and revision number Operating, design and test conditions by reference to piping lay-out drawings(isometrics) and revision number Approved flushing procedure specificationsApproved pressure test procedure specificationsAcceptance criteria by reference to proceduresSpecific inspections performed and results obtainedDate of inspections and identification of inspectionData recording charts, checked and signed after 100% completion of the applicabletest by a representative of CONTRACTOR, SUBCONTRACTORS, SUBVENDORS,THIRD PARTY INSPECTORS or NOTIFIED BODIES (in case CE certification isapplicable) and the COMPANYS inspector. (COMPANYS inspector has the possibilityto waive this inspection)Qualification of material, personnel, procedures and equipment.Callibration reports of all used inspection equipment used. This is required for theperformance of the quality review.A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena/Bordocs.

BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 7 / 22COMPANY final inspection certificateIf deemed necessary by COMPANY inspector, other items may be added. CONTRACTOR mayuse its own forms for records but this must be submitted to COMPANY for approval prior to use.All previously mentioned data shall be available to COMPANY's representative at all times andthe status of the data content shall be completed together with the assembly progress.An example of the traceability in relation to pressure testing shall be supplied byCONTRACTOR together with the quality plan to COMPANY for approval prior to use.The quality of flushing and the internal cleanliness of the piping spools shall be checked on aspot check basis by a COMPANY representative. Any indication that COMPANYrequirements are not fulfilled will result in extra inspections. CONTRACTOR will cooperatewithout any extra costs to allow COMPANYS inspector to perform the extra inspections.All hardcopy documents shall be of good copy quality, allowing a well readable content with nopossibility of wrong interpretation.If dates of validity are applicable (e.g. calibration test certificates, etc.), these shall be clearlyindicated and checked. If documents are delivered with expired dates of validity, this willresult in a rejection of the final documentation.All documentation shall be provided to COMPANY in As Built version and 100% complete. Thisfinal and As Built data shall be send by the CONTRACTOR to the COMPANY both inhardcopy and scanned format (*.pdf) and compiled on CD-rom.3.2.2 Filing SystemCONTRACTOR shall maintain a systematic filing system of all certificates and reports for alltests and inspections carried out by him under the applicable specifications, standardsand codes of practice quoted herein.Originals of all documents are to be sent to COMPANY.4 BASIC DESIGN REQUIREMENTS4.1 GeneralComplete package units delivered by other VENDORS shall not be flushed and pressuretested unless separately requested by COMPANY, since this has already been performedduring fabrication in VENDORs shop.Flushing and pressure testing of packaged units shall be in accordance to therequirements outlined in BES-CO-04-013 Mechanical Package Unit General, Section 6Inspection and Testing.Although some test systems may be tested in combination with systems installed by other CONTRACTORS, each CONTRACTOR is responsible for his own part installed, unlessagreed otherwise.5 FLUSHING REQUIREMENTS5.1 GeneralProcedures for flushing shall be developed by CONTRACTOR prior to start and subjected to theapproval by COMPANY.A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena/Bordocs. BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 8 / 22After COMPANY accepted the preparations for flushing, the piping system will bereleased for flushing.The initial flushing shall be carried out prior to pressure testing.For austenitic steelwork, flushing can be performed after pressure testing, if approved byCOMPANY.General requirements for flushing for specific systems are listed in Attachment 1; FluidList.All pipe work shall be free from dirt, trash, debris, grease and temporary protective coatingupon completion of flushing.Flushing through equipment is not allowed unless approved by COMPANY.During flushing of pump suction/discharge lines, the pipe connections to the pump shallbe turned away and the pump inlet shall be adequately covered to prevent contaminationof pumps. This applies also for equipment nozzles, which shall be blinded off, during theflushing operation.To clean the inside of storage tanks water jetting can be applied.Flushing shall be performed against open pipe ends, not via small openings like vents,drains, etc.The system shall be inspected for cleanliness and approved by COMPANY before closingand reinstatement.Before closing and reinstatement after the flushing and

pressure test activities, the flangefaces of each dismantled flange connection shall be inspected for damage. Any damagewill result in a re-machining of the flange face to meet the required facing tolerances.5.2 Hydro FlushingItems of equipment, which would be sensitive to damage during hydro flushing, shall beremoved, blocked off or isolated.A list shall be prepared and be part of the flush & test procedure.Ball valves shall be flushed in fully open position.All piping systems shall be flushed using high-pressure jet flushing equipment, such asrotating hose or rotating nozzle. Minimum pressure shall be 600 bar(g).Below 4, High Velocity Water Flushing (HVWF) may be used. Water velocity shall be aminimum of 10m/s.On systems where high pressure jet flushing cannot be used due to complicated shapesand/or long runs HVWF may be used.The flushing medium shall in general be fresh water.A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena/Bordocs. BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 9 / 22All flushing and hydro testing for carbon-steel and stainless steel systems shall beperformed with clean water (maximum chloride content 100 ppm). Prior to use, the water shall be analysed and the results reported to COMPANY.After flushing, the piping systems shall be completely drained and protected against corrosion,as specified in Attachment 1 Fluid List.Also see Section 6.5.2; Austenitic Stainless Steel.5.3 Pressurised Air Shock Blowing (PAS)This method may be used as an initial cleaning method for instrument air, plant air and as analternative method for initial cleaning of small-bore pipe (less than 2 inch).This method may also be used when there are problems removing trapped liquid in the circuit,or to verify cleanliness of small-bore pipe where video inspection is impossible or inadequate due to pipe dimension or configuration.When using PAS method for cleaning or verification, the procedure shall be repeated untilcleanliness is acceptable to COMPANY.The air shocking pressure shall never exceed the working pressure of the system and shallnever be more than 8 bar(g).Special safety precautions shall be agreed with COMPANY when this method is used.5.4 Pneumatic FlushingIn cases where water is not desirable in the piping system (e.g. instrument/utility air, nitrogen),flushing by pressurised air or PAS shall be carried out.When pressurised air is used, the minimum velocity shall be 35m/s.Procedure to limit the safety risk for personnel, equipment and environment shall be establishedby CONTRACTOR and approved by COMPANY.5.5 Hot Oil Flushing5.5.1 GeneralRequired cleanliness for systems subject to hot oil flushing shall be in accordance withAttachment 1; Fluid List.A detailed procedure for hot oil flushing shall be developed out prior to start.Filters used for hot oil flushing shall be:10 m ABS for hydraulic systems10 25 m ABS for lube and seal oilFilling of lubricant oil shall take place through filters with 10m ABS.Flushing and sampling to verify cleanness shall take place at turbulent flow, upstream anyfilters.The Reynolds number shall be minimum 4000.A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena/Bordocs. BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 10 / 22The level of cleanness shall be documented from an automatic particle counter or a membranechecked in a microscope before a flushing operation is considered finalised.A flow meter shall be installed to verify flow used during flushing operation.Maximum water content in oil used for flushing shall be less than 500ppm.5.5.2 MarkingPiping spools or systems that have been chemical cleaned or hot oil flushed shall be marked ina unique manner.5.5.3 DocumentationRelevant laboratory analysis certificates or other acceptable

methods shall document thecompliance to ISO 4406 requirements.6 PRESSURE TESTING6.1 General6.1.1 Pressure Test Diagrams and Test ProcedureCONTRACTOR shall prepare Pressure Test Diagrams and Test Procedure.Piping systems subject to pressure testing shall be indicated on Pressure Test diagramsthat are prepared using P&IDs.Prior to testing CONTRACTOR shall obtain approval by COMPANY for:Pressure testing-plan outlining lines to beoHydro-testedoPneumatically testedoAlternative Leak testedoInitial Service Leak testedPressure testing procedure6.1.2 Pressure Test PackagesBased on the approved testing procedure, CONTRACTOR will prepare Pressure TestPackages.These packages shall include, but not limited to:Review of P&ID to define test packages limits, equipment and instrument to beincluded or excluded, the valve position (open / close) and test blindsCheck of systems to assure that the maximum allowable test pressure of theweakest point in the system is not exceeded.Check of systems applicable to hydro test for static load of the applied testmedium to ensure that the maximum allowable test load of the weakest point in thesystem is not exceeded.Colour-code of piping system to be tested, outlined in the P&ID, and assigned testsystem numbers for identificationAssembled pressure test packages: The package shall consist of Piping PressureTest Record and Isometric drawings with test related information (blinds, valve testedopen or closed, removed instruments etc.)A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena/Bordocs. BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 11 / 226.1.3 Test PressureThe test pressure shall be accordance with the requirements of the Pressure EquipmentDirective (97/23 EC), as well as the applicable piping design code. Reference is alsomade to Attachment 2; Pressure Test Static Head of Test Medium.6.2 Preparations for TestingBefore the pressure test, CONTRACTOR shall:Perform a visual inspection of the piping (internal and external).Inspect piping for completeness and conformity to piping drawings (including P&IDs) and specifications (use punch-list).Verify that flushing has been performed as required. The inside of all pipe workshall be clean and free from loose mill scale, weld spatters and any other foreignmatter.Verify that all NDT, PWHT, etc. has been completed, documented and approved.Verify that the Pressure Test Diagrams and the Pressure Test Packages are up-to-date and are approved by COMPANY.Verify that the test pressure is in accordance with the codes and specifications.Verify the quality of the test medium, the testing temperature and whether acorrosion inhibitor has been added as per product datasheets. The type of corrosioninhibitor and preparation of the test fluid shall be approved by COMPANY.Verify that all testing equipment is in accordance with the specifications, calibratedetc.Verify the location of the test pressure gauges.Before pressure testing, all open butt-weld ends on process piping shall be closedwith metal plates, welded into or onto the pipe (thickness and weld size to withstandapplied pressure).Before pressure testing, all open flanged ends shall be closed with blind flanges incorresponding sizes and the pressure ratings. The blind flanges shall have sufficientthickness to allow pressure testing without any deformation.Temporary gaskets shall be used for hydrostatic pressure testing.All joints shall be left un-insulated and unlined and exposed for examination duringpressure testing, except that joints and tubes previously tested in accordance with thisspecification may be insulated or covered. Painting for corrosion protection ispermitted, provided, it does not prevent the clear examination of the joint under test.Verify the location and installation of blinds.Verify that all items which cannot sustain the pressure test are removed.Verify that spring hangers/supports are blocked where required.Verify that supporting

structures and piping can sustain the load of the testmedium.Verify that all safety precautions are taken and known to all personnel.Verify that all air is displaced from the pipe work before applying the test pressure.Pipe work under test conditions shall not be subject to any form of shock loading(e.g. hammer testing).The full test pressure value shall be maintained for at least 1 hour.After the pressure test, CONTRACTOR shall:Verify that there is no deterioration resulting from the pressure test.Immediately after hydrostatic test, pipe spools shall be dried out by dry, oil free air or nitrogen. CONTRACTOR shall take all precautions to ensure that piping cleanlinessis maintained.No modification to the piping shall be allowed after previously mentioned test.A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena/Bordocs. BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 12 / 22If the pressure test has negative results (leakage), CONTRACTOR shall repair thesystem and Pressure Test the system again.Verify that all testing equipment is removed.Verify that all items, which where removed prior to the pressure test, arereinstalled. Special attention shall be paid to the connections.Installation of final gaskets as per piping classes.Assemble all documents concerning NDT, Pressure Testing etc as required. Makethe required Certificates and Declarations (see PED and EN13480-5 Metallic IndustrialPiping - Part 5: Inspection and Testing). Items to be removed or blanked off prior to flushing/testing shall include, but shall not be limitedto:Equipment not included in the test system.Any items not designed to withstand the test pressure (all instruments e.g.pressure gauges, bellows, expansion joints, flexibles, check valves, etc.).Safety valves and rupture discs.Orifice plates, flow nozzles or other similar restrictions.Venturing type flow meters (flanged).Internals of equipment (trays, demisters, level instrument floats, float cages, etc.),if included in the test system.Flanged control valves (for welded-in types control valve internals shall beremoved).Internals of strainers and filters.For flanged control valves with block valves and a bypass, the block and bypass valve shall beleft open, with the control valve removed and blinds or spool piece installed, if the testpressure up and downstream is the same.CONTRACTOR shall supply spools to replace any item removed.Blind flanges, blanks, caps or plugs with adequate pressure rating shall be installed to isolatepiping systems and equipment as indicated on the test diagrams. CONTRACTOR shallsupply these items.All temporary installed items (blanks, gaskets, spools, strainers, etc.) shall be adequatelymarked using paint (orange) or tags for easy traceability.For stainless-steel piping, the duration of the flushing, hydro testing and draining/dryingsequence shall be kept as short as possible; in order to reduce the possibility of chlorideinduced corrosion damage.When flanged valves are present in a test system, testing against a closed valve is onlypermitted when the valve and its closing mechanism is suited for the test pressure, andapproved by COMPANY.Where the test pressure to be applied to the piping is greater than the maximum allowable testpressure for valves, the valves shall be blinded off on the side to be tested, or removedand replaced by dummy spools.Unless otherwise noted, all valves are to be through body tested. First block valve for pressureinstruments shall be included in the test.A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena/Bordocs. BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 13 / 22Piping containing check valves shall have the source of test pressure on the upstream side. If this is not possible, the check valve disc shall be removed or jacked open.Ball valves shall be pressure tested in the half open position. Other valves shall be tested in

thefully open position.Test systems without equipment or closed valves may be combined when approved byCOMPANY.Testing shall not take place with system temperatures 7C or less, or where ambienttemperature during test falls by 5C or more, nor during rain or fog unless under suitablecover. Hydrostatic pressure test may however be performed under a lower temperaturewith a proper frost preventive added to the test water after approval of COMPANY.During the test, the ambient temperature shall be checked. When ambient temperatureincreases, test pressure shall be witnessed carefully to avoid any damage to the pipespool due to over pressurizing.Items excluded from pressure tests are:All small bore instrument control piping downstream the first piping block valve;Open drains and vents to atmosphere (leak test only).6.3 Safety and Environmental ControlBefore starting any pressure test or flushing operation, the adequate measures for safety andenvironmental control shall be established. All local regulations and requirements byCOMPANY shall apply.The test area shall be strictly closed for unauthorised personnel when tests are performed. Thetest area shall be marked with yellow / black plastic marking strips and a warning labelstating NO ENTRY - PRESSURE TEST IN PROGRESSPiping systems subject to extended hydrostatic test periods shall be provided with a protectivedevice to relieve excess pressure due to thermal expansion of the test fluid. The releasepressure shall be agreed with COMPANY.Care shall be taken that as little test liquid as possible is spilled over the paving to preventmuddy and/or icy roads, or the damage of equipment, instrumentation or insulation.As pneumatic testing represents especially high risks, utmost care shall be taken duringpressurisation and inspection of the systems to prevent any danger from personnel,equipment and environment. Therefore pneumatic testing shall be performed in severalsteps.Step 1: A preliminary pneumatic test at no more than 1.7 bar(g) shall be performedaccording to ASME B31.3 paragraph N345.5.5.Step 2: Pneumatic test of all applicable pipe spools at a test pressure of maximum1.1 times design pressure or otherwise defined according the applicable design code.Note: Necessary precautions and actions shall be aligned to the national legislation, and therequirements of the NOTIFIED BODY. Previous steps 1 and 2 shall be seen as a minimalrequirement.All pneumatic testing has to be authorised by the relevant authorities and COMPANY.A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena/Bordocs. BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 14 / 22The use of chemical additives, i.e. wetting agents, biocides, inhibitors, etc., shall only beallowed when an environmentally acceptable disposal has been agreed with COMPANYand local authorities.6.4 Test EquipmentCOMPANY shall approve equipment used for testing prior to use.Purpose built hydrostatic testing equipment, including filters, fills pump, pressurising pump, testgauges, relief devices, storage tanks, test and flushing medium, and shall be supplied byCONTRACTOR.CONTRACTOR shall supply an air compressor suitable to supply dry, clean air at thepneumatic pressure test level, unless otherwise agreed with COMPANY.For pneumatic pressure testing a pressure safety valve (PSV) shall be installed to avoid over-pressuring.Accuracy of pressure gauge shall be at least 1-2% at full scale. The test pressure shall be within60% of the gauge range (20% from top and 20% from bottom).Pressure, temperature and time shall be recorded for all hydrostatic tests. Pressure gauges andrecorders used to indicate and record test pressure shall be calibrated according torequirements.Normally minimum one gauge shall be positioned at the highest point of the system. The staticpressure shall be considered (see Piping Specification for allowable pressure).If there

is a deviation of more than 2% between gauges during test, the test shall be stoppedand the equipment recalibrated.All test pressure gauges shall be calibrated prior to testing. Calibration certificates shall beavailable at the worksite and all gauges shall be properly identified to enable traceability tothe calibration certificates.Calibration of gauges shall be repeated minimum once a year or whenever requested by theinspection team (representatives from the authorities, COMPANY and CONTRACTOR).CONTRACTOR shall supply test blanks. Design and dimensions shall be in accordance withthe related pipe class.6.5 Test Medium6.5.1 For Hydrostatic TestingAll flushing and hydro testing for carbon-steel and stainless steel systems shall be performedwith clean water (maximum chloride content 100 ppm). The pH value shall be between 6.5and 7.5.Prior to use, the water shall be analysed and the results reported to COMPANY.Use of corrosion preventing chemicals shall be considered and approved by COMPANY whenhydro testing carbon steels. The chemicals shall be compatible with the processCare shall be taken that flushing and testing water can freeze, neither in the storage tanks nor in the piping systems. CONTRACTOR has to provide heating or insulation, in case theA print of this document is only valid at the date of printing. For reference, use the actual version available on Borena/Bordocs. BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 15 / 22risk of freezing exists. Necessary measures shall be agreed upon with COMPANY(antifreeze or steam heating).For hydrostatic testing the test medium shall in general be water, except that other suitableliquid may be used if:The piping or inline equipment would be adversely affected by water;If the liquid is flammable, it's flash point shall be at least 49C and consideration shallbe given to the environment;The liquid to be used is approved by COMPANY.If the test medium cannot be guaranteed clean, it shall be filtered through a 10m filter whenfilling the system.6.5.2 Austentic Stainless SteelEquipment such as shell-and-tube heat exchangers may have crevices, whichprevent proper draining and mechanical drying.When flushing with condensate, boiler feed water or demineralised water, it isessential that all surfaces previously wetted during the test are flushed. The quantityand velocity of the flushing water depends on the equipment volume and shall bedetermined in consultation with COMPANY.Removing water or drying by blowing with hot air or gas shall not be performedunless the testing or flushing has been done with condensate; boiler feed water or demineralised water.In locations where water of the required quality is not available (initially or permanently), temporary facilities shall be used (e.g. mobile packaged demineralisationunits) to prepare the test water.The risk of pitting corrosion is considerably reduced if the time between hydrostatictesting and start-up is short.Clean systems, and the use of boiler feed water or condensate as test water,minimise the risk of Microbiologically Induced Corrosion.Consider the use of biocide to minimise the risk of Microbiologically InducedCorrosion if all water cannot be drained or dried out (more than three weeks beforestart-up).Steam-traced or electrically traced systems should be tested or at least properlyflushed with condensate or demineralised water prior to the functional testing of thetracing. Stainless steel bellows should preferably be isolated from the system duringhydrostatic testing. If this is not possible, the hydrostatic testing shall be done withcondensate; boiler feed water or demineralised water.6.5.3 Ferritic Stainless Steels and Medium/High Nickel AlloysDue to the possibility of pitting corrosion, the paragraph above for austenitic stainless steel,shall also apply to ferritic stainless steels and medium/high-nickel alloys.6.5.4 Duplex Stainless SteelDuplex stainless steel is highly susceptible to crevice corrosion when in contact with oxygen-containing water.The preferred hydrostatic testing method is to use potable water and to carefully rinse theequipment immediately

after the pressure test with condensate; boiler feed water or demineralised water, followed by thorough drying the equipment and filling with nitrogen insuch a way that all oxygen is removed from the system.A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena/Bordocs. BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 16 / 226.5.5 9% Nickel Alloy SteelWhen hydrostatically testing equipment manufactured from or containing 9% Ni-steel, the water used shall be clear and free from sulphides which may otherwise precipitate stresscracking of the equipment.Complete and thorough draining and drying of the equipment is required after the removalof the test water.6.5.6 Aluminium and Aluminium AlloysThe test water shall be of a neutral pH (6 to 7.5) value and free from ions of heavy metals, e.g.copper, nickel and iron. These metals are readily deposited on the aluminium surface andcause severe pitting.The equipment shall be thoroughly cleaned and dried after removal of the test water.6.5.7 For Pneumatic TestingWhere the test packages indicate that a pneumatic test must be performed, the test media shallbe oil free, dry air or any inert gas. The use of air for testing shall be limited to a maximumpressure of 7.0 bar(g). Above this pressure nitrogen shall be used.For instrument/utility air systems, where the introduction of water is undesirable, test mediashall be air or inert gas.6.5.8 For Alternative Leak Test and for Service TestThese tests shall be performed with the fluid designated for the line.6.6 DisposalA wastewater disposal plan, which will specify the handling of the water used for flushing andpressure testing, shall be prepared and agreed upon by CONTRACTOR and COMPANY.The disposal of flush and test water via the plant sewer system shall only be allowed after COMPANYs written approval at the specified flow rates.An estimate of the expected quantities flow rate and quality of the wastewater shall be preparedby CONTRACTOR.6.7 Test Procedure6.7.1 Hydrostatic TestingAfter acceptance of the preparations for pressure testing by COMPANY, the piping system willbe released for pressure testing.The test pressure shall be as indicated in the hydrostatic test diagrams provided byCONTRACTOR and shall be in accordance with PED 97/23 EC or ASME B31.3requirements defined under paragraph 345.4.All systems shall be properly vented (at the high points) while filling.Hydrostatic test pressure shall be applied by means of a suitable test pump or other pressuresource. This pump shall be positively isolated from the system except when being used topressurise the system.A pressure gauge shall be provided at the test pump discharge.A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena/Bordocs. BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 17 / 22The pressure shall be increased gradually. For test pressures over 100 bar(g), the pressureshall be increased in steps of 25 bar(g), providing sufficient time to check for leaks and toallow the piping to equalize strains during the test.In case hydrostatic testing through equipment is required, COMPANY will provide specialinstructions (e.g. maximum differential pressures on shell and tube side of heatexchangers) where applicable.The minimum number of pressure gauges for a test system is one. For large systems, morepressure gauges shall be installed at suitable locations in co-ordination with COMPANYand inspection organisations.When a union is provided downstream of an instrument block valve, it shall be disconnectedduring testing to prevent dirt or foreign matter from being introduced into the instrument.The outside surface of the test system shall be clean and dry before and during testing.An authorised person shall constantly attend the test

pump during the test.Whenever the pump is left unattended, it shall be positively disconnected from the system, whilethe pressure gauge remains connected to the test system.The test pressure shall be maintained for at least one hour for systems prior to start of inspection and long enough to enable inspection of the complete test system by theinspection team.Care shall be taken to ensure that over pressuring due to static head does not take place:See the relevant Piping Specification for allowable pressure.See Attachment 2; Pressure Test Static Head of Test Medium, for anexplanation on this topic.Re-testing of a system, if required, shall be performed at the same pressure as originallyspecified for the test.6.7.2 Pneumatic TestingIn general pneumatic pressure testing shall be avoided.Precautions:A calculation/safety evaluation to define stored energy in the equipment and safedistance from the equipment shall be performed by CONTRACTOR, and be subject toapproval by COMPANY, before any pneumatic test is carried out.Formula for Energy (E) is based on HSE Guidance Note GS4 Safety in Pressuretesting ISBN 0717616290. =PiPf ln.V.Pi.10000E Where:E= Energy in Joule.Pi = initial internal (test) pressure in Bar absolute.Pf = final pressure in Bar absolute (1Bar absolute = atm).V = volume (contents) in m3.A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena/Bordocs. BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 18 / 22Formula for safe distance as a function of E is based on:oIf E < 5.000.000J a safety zone with minimum radius = 20m shall be fenced.oIf E >= 5.000.000J and E < 135.000.000J a safety zone with radius = between20m and 100m (ratio to the energy content) shall be fenced.oIf E>= 135.000. 000J a safety zone with radius = 100m shall be fenced.See Attachment 3; Safety Distances for Pneumatic Pressure Test: Example, for anexample graph.Within the test area a safe area shall be demarcated for the personnel involved inpneumatic pressure testing. Personnel may not leave this safe area as long as the testpressure is above the design pressure (highest allowable pressure) of the pipesystem / equipment subject to this pneumatic test.Adjustment of test pressure shall be possible from the safe area.Only non-toxic and non-flammable gas shall be used. Air can only be used up to amaximum of 7 bar(g). Nitrogen is the preferred pneumatic test medium. Above 7 bar(g)the use of nitrogen is mandatory. When using nitrogen, the testing area shall becarefully ventilated and all necessary safety precautions shall be taken for pressuretesting using nitrogen.The test shall be carried out with the minimum number of personnel in the vicinity.CONTRACTORs Supervisor in charge shall nominate one person to ensure that nounauthorised person shall be allowed in the affected area. The area shall be roped-off and a notice NO ENTRY - PNEUMATIC TEST IN PROGRESS shall be placed atconspicuous locations.Before the pneumatic testing, a minimum 10 % of all joints have to be checked using either oneor a combination of the following inspection techniques:RadiographyPenetrant testingMagnetic particle testingUltrasonic testingThis inspection shall demonstrate system integrity.The isolation of the equipment/project shall be with full rated blinds and inspected byCONTRACTORs Supervisor in charge to ensure that they are at the right locations.The whole pressure test operation shall be authorized, witnessed and approved byCONTRACTORs quality personnel, COMPANY representative and Authorityrepresentative (THIRD PARTY INSPECTOR / NOTIFIED BODY).Testing Procedure:Pressurise the system to 50 kPa (0.5 bar(g)) and inspect for leaksPressurise the system to 200 kPa (2 bar(g)) and inspect for leaks. All joints shallbe soap testedGradually raise the pressure to half the test pressure and hold for 15 minutes toequalise the

strainA print of this document is only valid at the date of printing. For reference, use the actual version available on Borena/Bordocs. BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 19 / 22Thereafter, gradually raise the pressure in steps of 1/10 of the test pressure withholding time of five (5) minutes between steps until the test pressure is reached andhold for fifteen (15) minutesThereafter, reduce the pressure to 75% of the final test pressure and inspect thesystem. If necessary carry out another soap test to ascertain leaks. If no leaks founddepressurise the system Flanged joints shall be prepared for pneumatic soap testing by taping with masking tape andpunching a 3mm diameter hole through the tape.In pneumatic testing, care shall be taken to avoid a temperature drop that could cause failure of metal and thermoplastics due to embrittlement.6.7.3 Alternative to Hydrostatic or Pneumatic Pressure Testing (Alternative Leak Test)Alternative leak test shall normally not replace the normal pressure test where pressure test isrequired. However, under special conditions this test can replace the pressure test, butthis must be evaluated on a case by case basis and approved by COMPANY andAuthority representative. Additional NDT will be required.Lines to be tested shall be suitably indicated on the hydrostatic test diagram.An alternative leak test shall be performed with the line in service, i.e. with the service mediumand at service pressure.The testing shall comply with ASME B31.3 Paragraph 345.9.6.7.4 Initial Service Leak Test (Service Test)Initial Service leak test applies only to non-critical services, and shall comply with ASME B31.3Para 345.7.This type of pressure test shall be subject to approval by COMPANY and AUTHORITYrepresentative.6.7.5 Draining and DryingThe tested systems shall be depressurised by opening the depressurising valve in the test rig.After depressurisation, all vents and low point drain valves shall be opened and the system shallbe thoroughly drained where the test medium is water or another liquid.Special measures shall be taken to prevent freezing in winter.All test systems, not subject to chemical cleaning, shall be dried by air (6 bar(g) when thesystem operating pressure is above 6 bar(g)) and expanded rapidly.Where required, trapped liquid shall be removed by blowing dry air or Pressurised Air ShockBlowing.Systems with drying requirement as defined in Attachment 1 Fluid List shall be dried out after hydro testing with dry oil free air with a dew point of 5C below the one day minimumambient design temperature. Drying can be terminated when the dew point at the outlet isequal to the dew point at the inlet.Other methods, such as vacuum drying or air shocking, may also be used if the same drynesscan be documented.A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena/Bordocs. BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 20 / 22If more than three (3) months to commissioning, drying shall be followed by preservation withnitrogen (overpressure 0.5 bar(g)) to keep the pipe system completely dry and to avoidcondensation. Other alternatives are subject to approval by COMPANY.It is important that preservation should be adequate for the purpose intended, yet at the sametime it is equally necessary to ensure that it is justified economically. Whilst the extent of preservation is primarily a function of the time for which a plant is to be standing idle, thereare other factors which have to be considered simultaneously and it is recommended thatthis is best achieved through interfunctional discussions at local management level.Provision should be made for tagging all equipment after preservation, and for fixing the tags ina prominent position. For example, where nitrogen pressurisation is applied, the tag mayread (must be in local language):CAUTIONTHIS VESSEL IS BEING

PRESERVED WITH NITROGEN AT A PRESSURE OF 1 BAR (G).IT SHALL NOT BE DISTURBED WITHOUT PRIOR AUTHORITY FROM COMPANY.IT SHALL NOT BE TAKEN INTO SERVICE WITHOUT INSPECTION DEPARTMENTAUTHORITY.Reinstallation of the system shall be performed in accordance with the test procedure.Where permanent or temporary strainers have remained in place for the hydrostatic pressuretest, they shall be removed following the test and thoroughly cleaned before reinstalling.Ends of pipes and nozzles shall be fully protected against the ingress of foreign material by theuse of caps, plugs or plate blinds sealed with gaskets. These shall not be removed untiljust prior to final assembly.Flange parallelism and alignment to equipment shall be checked prior to reinstatement.Vent holes in reinforcing pads shall be sealed upon completion of pressure test.6.7.6 Verification of CleanlinessAll systems shall be internal visual inspected for acceptable cleanliness by spot check. Internalvisual inspection includes the use of Boroscope, video etc.If pipe configuration in critical parts of systems as defined in Attachment 1; Fluid List, is toocomplicated for visual inspection, the PAS method or other suitable methods shall beused for verification of cleanliness.6.7.7 ReinstatementAfter the completion of testing, chemical cleaning (where applicable) and drying, all systemsshall be reinstated according to drawings and specifications.The reinstatement of the system shall include, but shall not be limited to:Removal of all temporary auxiliary equipment such as spades, blinds, gaskets,pipe spools, temporary supports, etc.Replacement of all damaged gaskets and all test gasketsPositioning of spectacle blinds to the correct positionReinstallation of all items previously removed for hydro testingReinstall unions of instrument pipingA print of this document is only valid at the date of printing. For reference, use the actual version available on Borena/Bordocs. BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 21 / 22Inspection of the completed system for correct flow direction of instruments, checkand control valves, etc.During the pre-commissioning of piping, no dirt, debris, etc., shall be allowed to enter into thepiping system. Each pipe spool shall be inspected for cleanliness prior to installation.After approval by COMPANY, the system shall be released for further activities, e.g. steamtracing, painting, insulation, etc.The "stop" of pipe support springs with "down travel stops" placed prior to flushing, shall beremoved at COMPANYs request during precommissioning.7 CHEMICAL CLEANINGLines to be chemical cleaned shall be identified on the P&IDs and Line Index.For system overview see Attachment 1; Fluid List.A procedure shall describe in detail the steps for chemical cleaning.Chemical cleaning shall include:DegassingNeutralisationWater flushingDryingThe end result shall be a clean smooth surface.Maximum temperatures used during these operations shall not exceed maximum designtemperature for the systems as listed in the Line Index.For equipment such as turbines, generators, pumps and compressors, the piping to be cleanedshall have all sensitive items that can be damaged by the cleaning medium removed or blanked off.Normally the following items shall not be chemically cleaned if not otherwise agreed withCOMPANY (items shall be identified on chemical cleaning isometrics by CONTRACTOR):All instrument tubing downstream the first piping block valvePiping systems with copper alloy materialsFlexible hosesVesselsExchangersPumpsAll bolted/screwed valves and instrumentsRemoved or blanked off items shall be cleaned separately prior to reinstallation.The systems to be cleaned shall have high and low point vents and drains installed. "Dead legs"shall be avoided.Cleaning shall be carried out after pressure testing unless otherwise specified.A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena/Bordocs.

BES-CO-05-003 Rev. 2 / 02.10.2008 Sheet 22 / 22If the period between chemical cleaning and start of commissioning is expected to be more thanthree (3) months, then the system shall be preserved with nitrogen. Overpressure shall be0.5 bar(g) (see Section 6.7.4; Initial Service Leak Test (Service Test)).8 INSPECTION AND REPORTINGCONTRACTOR shall prepare a final report, giving positive documented evidence that subjectsystems are pressure tested in accordance with agreed requirements.The test report shall be included in the final piping documentation. The documentation shall as aminimum include (in principle all documentation required/specified in EN 13480):Reference to documents and specificationsPressure test diagrams (P&ID)Isometrics with identification of:Heat numbers of components (only for PED category III, II and I)Weld numbersWelders identificationWPS, WPRApproval of weldersNDT reportsQualification and certification of NDT personnelCE certificates of componentsAgreed punch listsAll required certificates (material certificates, test certificates, qualificationcertificates etc)Test results and durationA continuous log of operation, if applicableSignature of COMPANY representative, CONTRACTOR representative,AUTHORITY representative (THIRD PARTY INSPECTOR / NOTIFIED BODY)9 ATTACHMENTSAttachment 1: Fluid List & Piping ClassesAttachment 2: Pressure Test - Static Head of Test MediumAttachment 3: Safety Distances for Pneumatic Pressure Test (Example)A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena/Bordocs

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