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*THIS PRINT IS NON-CONTROLLED *

Bechtel France S.A.S.

Reliance Industries Limited Jamnagar Export Refinery Project

Specification 25194-3PS-PL-007 Title

Piping Erection & Testing


This specification is based on 22960-3PS-PL-007 Rev.7

1 0 Rev

9/11/06 27/01/06 Date

Re-Issued for Design Issued for Design Revision

RC PD By

SH PC Chkd

DH SH Appr

PKS

Client

25194-3PS-PL-007

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Reliance Industries Limited Jamnagar Export Refinery Project

*THIS PRINT IS NON-CONTROLLED*

Contents
1. Purpose.............................................................................................................................................3 2. Scope................................................................................................................................................3 3. Associated Codes And Specifications...............................................................................................3 4. Design Information...........................................................................................................................3 5. Fabrication And Installation..............................................................................................................4 6. Field Modifications...........................................................................................................................8 7. Cleaning............................................................................................................................................8 8. Inspection For Completeness............................................................................................................9 9. Testing Requirements.......................................................................................................................9 10. Tests..............................................................................................................................................11 11. System Pressure Test Package......................................................................................................12 12. Cryogenic Lines............................................................................................................................13 13. Preparation Of Systems For Testing.............................................................................................13 14. Test Medium.................................................................................................................................15 15. Testing Procedure.........................................................................................................................15 16. Post Test Procedure......................................................................................................................17 17. Test Records.................................................................................................................................18 18. General Requirements...................................................................................................................18

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Reliance Industries Limited Jamnagar Export Refinery Project

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1.

Purpose
This specification is to establish the general requirements for the field installation and pressure testing of piping systems.

2.

Scope
This specification shall be applied to above ground and underground process and utility piping, including pipework in modules, package units or other sub assemblies, offshore and onshore. Refer to separate specification for the installation of below ground pipework.

3.

Associated Codes And Specifications


3.1. Codes ASME B31.1 ASME B31.3 Power Piping Chemical Plant and Petroleum Refinery Piping

The Indian Boiler Code Regulations (1950) (IBR) 3.2. Specifications 25194-3PS-PL-001 25194-3PS-PL-006 25194-3PS-PL-013 25194-3PS-PL-023 Specification For Piping Material Classes Specification For Piping Fabrication. Specification For Chemical Cleaning of Pipework. Specification For Indian Boiler Regulations

4.

Design Information
4.1. Piping Drawings The primary piping drawings will be line isometrics, and these will be supplemented with screen-dumps from the 3D PDS model as required. Appropriate standard detail drawings and other drawings showing typical details will be available. System isometrics will be produced for IBR coded piping systems. 4.2. Piping And Instrument Diagrams (P&ID) The Piping and Instrument Diagrams indicate to and from routing, service classification and identification number for each line and which codes or requirements (other than the Petroleum Refinery Piping Code, ASME B31.3) apply to various parts of the piping systems as well as the limits of such code or requirement. They provide a basis for field checks of continuity and completeness of piping systems.

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Reliance Industries Limited Jamnagar Export Refinery Project 4.3. Line Designation Table

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Mechanical Data Section of the Line Designation Table shows the line number, description, piping material class, design pressure and temperature, insulation and tracing requirements and test type and pressure for each line. 4.4. Line Numbers Line numbers identify each line by plant or unit number, fluid designation, serial number, line size and piping material class. Line numbers appear on the P&IDs, models, and isometrics. 4.5. Material Specifications The Piping Materials Specification includes details for each individual piping material classes. Each class details the pipe, valve, flange, fitting, bolting, gasket and other specific material requirements for different fluid temperature and pressure services. The Piping Stock Code Book describes code items shown in specifications and on drawings. Materials not identified otherwise on drawings or isometrics shall be strictly as specified in Piping Material Specification for that material class.

5.

Fabrication And Installation


5.1. Fabrication The field fabrication and welding shall be in 25194-3PS-PL-006, Specification For Piping Fabrication. 5.2. Installation accordance with

5.2.1. All piping shall be installed in accordance with the isometrics and 3D PDS model. All pipework, valves, piping specials shall be inspected before installation to ensure that protective packing, covers, wrapping and internal protectives such as silica gel bags are removed. Protective covers of pipe and equipment shall not be removed until immediately prior to installation. All pipework and valves shall be examined to ensure that no deterioration has occurred in storage with particular note to valve internals. All manually operated valves shall be cycled from fully open to fully closed and back again to ensure operability. 5.2.2. Piping shall be supported as indicated on the isometric. When temporary supports other than those shown on the isometric are required to facilitate installation, they shall be of the removable type. Temporary supports shall not

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Reliance Industries Limited *THIS PRINT IS NON-CONTROLLED* Jamnagar Export Refinery Project 5.2.3. transfer detrimental reactions to piping, structural members, or equipment. Welding to pipe and/or piping supports as a temporary support measure, during installation, is not permitted. (see 13.12). Temporary supports shall be completely removed upon completion of testing and prior to commissioning. Where pipe support attachments are to be permanently welded to the pipework, the welding shall be in accordance with the project specification employing only welders qualified in accordance with the relevant code. Galvanised material shall not be welded to stainless steel, copper nickel or titanium material under any circumstances. Where piping is supported using spring supports the locking pins should be in place during installation, flushing and testing of the piping system. Locking pins shall be removed prior to start-up and where necessary, springs adjusted to correct cold Setting. Locking pins shall be either firmly attached to spring housing by use of a chain or tagged with the spring identification number and placed in the stores for safe keeping . 5.2.4. All closing dimensions to equipment shall be checked and any field adjustments made as necessary to assemble pipework. Pump and compressor piping shall be installed up to a break point between nearest pipe support and the equipment. The remainder of the piping shall be properly fitted between the equipment nozzle and this break point. It is essential that this is done accurately in order to avoid any external loadings on the equipment connections. Before tightening bolting to equipment flanges, ensure that piping flanges are concentric and parallel. Manufacturers specified maximum allowable forces and movements on equipment nozzles shall not be exceeded at any stage of installation. Cold springing or forcing of piping for the purpose of joint make-up is not permitted unless so specified on the drawings. Cold springing is not permitted on strain sensitive equipment . When connecting pipework to equipment the Contractor shall ensure that the manufacturers instructions are carefully observed as to removal of external and internal protectives and that the opening is clean and free from obstruction and foreign matter. Care shall be taken to avoid the ingress of foreign matter during connecting of pipework to equipment. 5.2.5. Flange faces shall be cleaned of protectives, etc, and checked for mechanical or corrosion damage to the gasket contact surfaces. Damage shall be repaired prior to use. No damage shall be repaired where the integrity of the flange design is impaired. Flange bolts shall be tightened evenly and diametrically opposite to impose even pressure on the gaskets and to avoid distortion or overstressing of equipment.

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Reliance Industries Limited *THIS PRINT IS NON-CONTROLLED* Jamnagar Export Refinery Project Where hydraulic bolt tensioning is not required bolts shall be installed so as to leave at least two threads exposed from each nut. Exposed threads on over long bolts used for hydraulic bolt tensioning shall be protected. Where hydraulic bolt tensioning is required, the bolts are to be tensioned to give stresses in the bolts equal to 0.67 x specified Yield strength of the bolt material. Prior to flange joint assembly, bolts shall be lubricated with Molycote 1000 or equal. Gaskets shall be installed so that they do not protrude inside the pipe bore. 5.2.6. Gaskets shall not be reused. If a flanged joint must be opened, for example, for system pressure testing, line flushing, removal of temporary blinds or strainers, etc, the joint shall be re-made with new gaskets and with the bolt lubricant replenished. Flanged joints at equipment or valves employing tapped holes shall have the thread depth checked prior to assembly to ensure that cap screws of the correct length are used. Connections to flat faced cast iron flanges shall use flat face mating flanges and full face gaskets. Special care shall be taken to tighten bolts correctly. No sealing compounds shall be applied to gaskets or flanges faces. 5.2.7. Where insulating flange kits are to be installed, care shall be taken not to damage the bolt sleeves and gasket. The completed joint shall be tested with a Megger, DVOM or similar device to assure electrical isolation. If both sides of the flanges are grounded a reading of 1 to 20 ohms will occur. If one or both sides are not grounded, a reading of 1000 or more Ohms should occur. Caution: Welding grounds shall not be installed across isolation flanges. 5.2.8. Orifice runs must not contain welds except at the flanges. Pipe ends at orifice flanges must be machine cut and perpendicular to the pipe axis. Welds at the orifice flanges must be ground smooth inside. Pipe tap connections are to be drilled through the pipewall and be smooth inside. Drawings show the orientation of orifice flange taps and the locations of pipe taps. Orifice flanges are to be drilled and tapped for jack screws. 5.2.9. Underground piping shall be installed and inspected per this Project Specification. 5.2.10. The handling of coated and wrapped pipe as well as the field coating and wrapping shall be in accordance with Project Specification. 25194-3PS-GAW008 5.2.11. Valves shall be installed with stems oriented as indicated on isometrics. Split disc wafer-type check valves shall be installed with the shaft in vertical position. Globe valves shall be installed with bottom of disc facing the flow direction. 5.2.12. Where seal welding is required, the joints shall be made up without the application of thread lubricant and threads thoroughly cleaned from grease and oil. Seal welds shall cover exposed threads completely.
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Reliance Industries Limited Jamnagar Export Refinery Project Seal welding is required:-

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a) Between connections to columns, vessels, tanks and exchangers in hydrocarbon service and the first valve. b) Orifice flange taps and blanking plugs in those systems where socket welding small bore piping is specified. c) Unvalved, plugged hydrostatic test vents and drains in systems where socket welding small bore piping is specified. Seal welding to be performed post hydrotest. Following items shall never be seal welded:a) Screwed Thermowells b) Union Nuts c) Screwed Ends of Gauge Glasses, Gage Cocks 5.2.13. Reinforced fibreglass pipe and the like shall be installed strictly in accordance with the vendors installation instructions. Personnel doing this work shall be properly trained by vendors representative prior to doing this installation. 5.3. Pipe Threads

5.3.1. Threaded joints shall only be used where specified in the relevant Piping Classes. All pipe threads shall be NPT type in accordance with either ASME B1.20.1 or API 5B. Threads shall be cut after any required bending, forming or heat treatment. Where this is not practical, suitable protection shall be applied to protect the threads. 5.3.2. PTFE or other types of thread tape shall not be used on any threaded joint. Instead, one of the following thread compounds or equivalent shall be employed:a) Liquid O-ring 404 (for 2 (50mm) or smaller NB) or Liquid O-ring 104 (for 2 (50mm) and larger NB). Manufactured by Oil Centre Research Incorporated of Lafayette, Louisiana, USA. b) TFE-Super (for 1 (25mm) and smaller NB) or TFE-20 (for 1 (40mm) and arger NB). Manufactured by Ilex Compounds Ltd, Maidenhead, England. Use TFE-Super for all sizes in potable water service. Do not use TFE-20 for potable water. c) PTF Grease (for 2 (50mm) or smaller NB) or PTF Heavy Duty (for 2 (50mm) or larger NB). Manufactured by Blacksmith Chemical Services of Aberdeen, Scotland. d) Ilex ILX35 for high temperature service. Manufactured by Ilex Compounds Ltd, Maidenhead, England.

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Reliance Industries Limited *THIS PRINT IS NON-CONTROLLED* Jamnagar Export Refinery Project 5.3.3. Where threaded flanges are specified, the pipe shall terminate 1/16 (1.5mm) short of the flange face. 5.3.4. Adequate unions shall be included in threaded assemblies to permit easy assembly and dismantling without the need for rotation of long pipe legs, especially in the case of pipework connecting to pumps, compressors, etc, where routine servicing or replacement by a standby unit necessitates disconnection of the pipe. Excessive gouging of pipe or fittings by wrenches shall be cause for rejection, this shall be considered such if the defect extends below the mill tolerance minimum wall thickness or is more than 1/16 (1.5mm) in depth. 5.4. Field Run Piping Field run piping is defined as Carbon Steel threaded or socket welded piping 1 and below. Long straight runs of buttwelded piping in piperacks as shown on stringing drawings.

6.

Field Modifications
Modifications to pipe routing may be required in the field. Such modifications shall be determined by the erector and agreed with the responsible field engineer. All modifications shall be reflected on as built record drawings by the construction subcontractor or Field Engineer. At the end of the construction phase one set of these drawings shall be sent to the responsible Design Office. In the case of IBR piping, no field modifications shall be performed without the prior approval of the IBR inspectors.

7.

Cleaning
Refer to 25194-3PS-PL-013 - Specification for Chemical Cleaning of Pipework.

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Reliance Industries Limited Jamnagar Export Refinery Project 7.1. General requirements:-

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Piping spools shall be dry, thoroughly cleaned and free from dirt, slag and other loose foreign materials. Before assembly, they shall be cleaned by up ending and rapping to dislodge any dirt and debris. Hot bends shall be turbined or otherwise cleaned to completely remove adherent burned on sand. Completed systems shall be internally cleaned to remove all remaining dirt and foreign matter by water flushing or blowing with air or steam. Where special conditions exist, specific specifications will cover cleaning and preparations. Flushing shall be done with clean water using hydrostatic test water where possible. Refer to section 14.0 for the quality of water to be used for both flushing and testing. 7.2. Compressor Suction Piping Shortly before start up the inside of all compressor suction piping shall be thoroughly cleaned to remove rust and scale. Suction piping may require pickling or mechanical cleaning. The extent of such cleaning shall be shown on P&IDs and on the isometrics. Cleaning shall be carried out in accordance with project specifications. 7.3. Lube Oil Piping Shortly before start up the inside of all lube oil piping shall be thoroughly cleaned in accordance with the machinery vendors recommendation or with project specifications whichever is the most stringent to remove rust and scale.

8.

Inspection For Completeness


Upon completion of erection, piping systems shall be visually inspected for completeness, proper gasketing, proper valve installation, supporting, proper control valve installation, etc. The P&IDs and isometrics shall be used for this purpose.

9.

Testing Requirements
9.1. General Process and utility pressure piping shall be tested as required by the applicable code and described herein. 9.1.1. Pressure Piping Defined Pressure piping includes all piping designed to convey or contain process or utility fluids at either a positive or a negative internal pressure. Open ended vent, drain and like piping at essentially atmospheric pressure are not considered as pressure piping. 9.1.2. Boiler Code Piping

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Reliance Industries Limited *THIS PRINT IS NON-CONTROLLED* Jamnagar Export Refinery Project Piping will be governed by and conform with both The Indian Boiler Regulations 1950 and ASME B31.1 Code for Pressure Piping, Power Piping. Boiler piping shall be tested hydrostatically to the required standard described within the Indian Boiler Code and in Paragraph 137 of ASME B31.1 Code for Pressure Piping, Power Piping, whichever is the most stringent. IBR Piping will include all steam systems, boiler feed water and selected condensate systems. Piping Material Service Classes XXXXXM or XXXXXR. 9.1.3. Refinery Code Piping Pressure piping governed by the Petroleum Refinery Piping Code, ASME B31.3 shall be hydrostatically tested in accordance with Paragraph 345 of that code. Alternate tests are not permitted unless specifically approved by Project Engineer and/or Client. 9.2. Test Source Information

9.2.1. Line Designation Tables (LDTs) The LDTs shall be the Controlling Documents in determining the type of test, test medium and test pressure. The Line Designation Tables indicate (in the mechanical data section) the line number, description, piping material service class, design pressure, design temperature, insulation and tracing requirements and minimum test pressure for each line. The type of pressure test and test medium, if other than hydrostatic, will be noted in the table. 9.2.2. Hydrostatic Test Diagrams The hydrostatic test diagram will show the block limits for testing a system as well as the type and test pressure to be applied. These diagrams will generally be prepared by the subcontractors field engineer and shall be reviewed by Reliance/Bechtel Field Engineering.

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Reliance Industries Limited Jamnagar Export Refinery Project

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10.

Tests
10.1. Hydrostatic Test Refinery Code piping shall be hydrostatically tested to a minimum pressure of 1.5 times the design pressure at any point in the system unless otherwise noted in the line designation tables. The test pressure shall be adjusted for elevated design temperature in accordance with ASME B31.3, Paragraph 345.4.2. All liquid lines will be hydrostatically tested. Large thin walled lines in vapour service will require special consideration and temporary pipe supports installed. Acording to the layout of the line, it maybe necessary to hydro test the line at grade with it suitably supported, and then lifted into position with a 100% radiograph of the closing welds. 10.2. Operational Test Low pressure systems may be tested by using the service fluid as the testing medium provided that:a) The fluid is non flammable, non toxic and not harmful to human tissue such as air, water, inert gas etc. The exception to this is steam which shall be tested in accordance with Para 9.1.2. b) The design pressure does not exceed 150 psig, (10.3 bar g) and the design temperature does not exceed 366F (185C). The following test procedure applies:A preliminary check shall be made at not more than 25 psig (1.7 bar g). Thereafter the pressure shall be increased gradually in steps providing sufficient time to allow the piping to equalise strains during the test and to check for leaks. 10.3. Vacuum Piping Lines in vacuum service, unless governed by specific design conditions, shall be tested at a minimum of 15 psig (1.03 barg) as specified in Paragraph 345.2.4 of ASME B31.3. 10.4. Pneumatic Testing Some overhead vapour lines have been specifically designed to be Pneumatically tested. These along with duct work, flare lines and certain lines where hydraulic testing is impratical shall be air tested. In all cases any lines or systems requiring air tests shall be specifically noted in the Line Designation Tables.

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Reliance Industries Limited Jamnagar Export Refinery Project 10.5. Closing Welds

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Where practical, pressure tests of piping shall include all closing welds between different parts of the system. Where it is not practical to include a closing weld in the pressure test, the weld shall be tested and examined by RT/UT and DP/MPT and its location recored. 10.6. Connections to Equipment Piping test pressures shall not be applied to pumps or to other equipment except where specifically approved by the Project field engineer; and provided such procedure will not cause unsafe loads or other unreasonable hazards. 10.7. Test With Equipment Connecting piping may be tested with pressure vessels or other equipment requiring field test provided resulting test pressure applied to piping is not greater than allowable or less than the required piping test pressure. Care shall be taken when exchangers are included in the test. Both tube and shell side shall be pressurised to avoid overstressing of tube sheets if these are designed for a limited differential pressure. 10.8. Jacketed Piping In jacketed lines, the jacket shall be tested as described in Paragraph 345.2.5 of ASME B31.3. If the test pressure in the jacket is too high for the internal lines as an external pressure, the internal line shall be pressurised to minimise the differential pressure. 10.9. Reinforced Pad All reinforcement Pad (RF pad) shall be pneumatic tested at 1.5 Kg/sq.cm using suitable tapped hole.

11.

System Pressure Test Package


The subcontractor shall prepare a system pressure test package for each test system, including a pressure test diagram based on piping and instrument diagrams showing the extent of pipework to be included in each test. The scope of each separate test shall be the maximum practicable, considering adequate pressure relief protection, available test fluid. The diagrams shall show all in line components which are to be replaced with temporary spools, indicate which internals are to be removed for the test, and indicate all temporary test blinds and plugs used to isolate the system being tested. The package shall include a sign off sheet with places for the subcontractor and the Project Inspection Authorities signatures and date for each of the three stages of testing: preparation, testing and post test completion (removal of temporary blinds and supports, replacement of removed internals and valves, air drying, etc.).

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Reliance Industries Limited *THIS PRINT IS NON-CONTROLLED* Jamnagar Export Refinery Project The extent of test systems shall be such that the static head of the test medium does not create a pressure greater than the maximum allowable test pressure.

12.

Cryogenic Lines
Non-complex cryogenic piping systems of relatively short runs with limited numbers of welded in valves and fittings may be hydrotested provided they can be thoroughly dried after testing. Complex cryogenic lines that can not be thoroughly dried shall have welds subjected to 100% radiograph and then subjected to a pneumatic test. Alternatively, spools shall be shop hydrotested with closing welds subjected to 100% radiography.

13.

Preparation Of Systems For Testing


13.1. Temporary blind flanges and test blinds used to isolate a test system shall be of an adequate thickness to withstand the test pressure. Test blinds shall include an integral lug or handle, extending at least 4 (100mm) beyond the flange perimeter, which shall be painted bright red or orange. See Standard Drawing 25194-P14-JG000-045 . Temporary blind flanges and test blinds shall be adequately gasketed to prevent damage to flange facings. 13.2. Instrument connections shall be closed with a properly gasketed blind flange, or with a threaded plug. 13.3. Valves except socket weld valves shall not be used to isolate a test system except for lines not pressurised in service (for example, flare lines, gravity drain lines, black and grey sewage systems, etc). 13.4. Control valves, thermowells, orifice plates, strainer baskets, filter elements, expansion bellows, in line instruments and all other in line components unable to withstand the test pressure shall be removed and replaced with temporary spools or spacers. 13.5. If the pressure is to be applied downstream of check valves, the valves shall have their internals removed or be securely blocked open in a manner acceptable to the inspector. 13.6. Permanent pressure and thermal relief valves and rupture discs shall not be included in system pressure tests. 13.7. All internal parts and in line items removed for the duration of pressure testing shall be labelled and the component to which they belong or the position in the line from which they were removed shall also be labelled, to the satisfaction of the inspector, to ensure the correct replacement of components following the testing. 13.8. All valves, except as excluded specifically herein, shall be included in the pressure tests, ball valves shall be in the half open position recommended by the manufacturer and all other valves fully open. However, where the test pressure to be applied to lines is greater than the maximum allowable test pressures specified for the valves, the valves shall be blinded on the test side or replaced with a temporary spool. Valves shall be removed prior to flushing.

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Reliance Industries Limited *THIS PRINT IS NON-CONTROLLED* Jamnagar Export Refinery Project 13.9. Where a valve has not been included in a system test, the shop test certificate shall be reviewed and approved by the Bechtel authorised inspector. 13.10. Expansion joints shall not be included in pressure tests. 13.11. All lines in vapour service shall have sufficient temporary supports. Spring supports for lines in vapour service shall be locked in position for the test using preset pins or plates or by blocking up the spring. (See 5.2.2) 13.12. All temporary supports, spring support restraints, temporary spools, blinds and plugs, etc, shall be prominently flagged or painted bright orange or red to ensure their removal following testing. 13.13. The test rig shall be provided with relief valves of adequate capacity to contain the system at not more than 10% above the specified test pressure. 13.14. The test pressure gauge shall be located at the high point of the system. A check gauge shall, in addition, be located at the low point of the system if significant vertical legs could cause the static head pressure to over pressure parts of the system. Pressure gauges shall have current certification of accuracy. 13.15. Before testing commences, and after the Project Authorised Inspector has signed the test package signoff sheet, the system shall be flushed with the test medium to remove all dirt and foreign matter. 13.16. Strainers shall be included in the piping system and care shall be taken to ensure that dirt and debris cannot be forced into instrument branches or pockets in lines. Flushing shall proceed in an intermittent manner allowing time between flushes for debris to be cleared from the line. Flushing shall continue for sufficient time to ensure that the line is cleaned. Liquid flushing shall not be employed on systems requiring pneumatic testing. 13.17. All orifice plates which interfere with filling, venting or draining shall be removed prior to testing. 13.18. Short pieces of piping which must be removed to permit installation of a test blind shall be tested separately. 13.19. All joints in piping shall be accessible during test and shall not be insulated, backfilled or otherwise covered until satisfactory completion of testing in accordance with this specification, except joints may be primed and painted prior to leak testing. 13.20. Care shall be taken to avoid overloading any parts of the supporting structures.

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Reliance Industries Limited Jamnagar Export Refinery Project

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14.

Test Medium
14.1. Clean, fresh water free of suspended solids and other foreign matter shall be used for hydrostatic testing of carbon steel piping. Water chloride content shall not exceed 300 PPM. Also, where the water is unfiltered and untreated a chemical inhibitor package shall be provided which shall include the following chemicals:a) Oxygen scavenger to remove dissolved oxygen. b) Biocide to kill harmful organisms and sulphate reducing bacteria. c) Corrosion inhibitor to minimise corrosion. Proposals to use chemical inhibitors shall be agreed between contractor and Bechtel Engineering. 14.2. The minimum water temperature during hydrostatic testing shall be 40F (10C). After testing the piping shall be drained and thoroughly dried and maintained such that no moisture or chloride laden deposits will enter the piping. 14.3. When conducting tests at low metal temperatures (below 5C) the possibility of brittle failure shall be considered and the Project Engineer shall be contacted for special requirements. Do not test when metal temperature is below 5C. (Caution: Such low temperatures may also be caused by wind chill). 14.4. Liquids other than water shall require the approval of the Project Designated Inspection Authority prior to use. 14.5. Pneumatic tests shall use dry (dewpoint -40F (-40C) or lower), clean, oil free air or nitrogen. Oil lubricated compressors shall not be used. Pneumatic testing temperatures shall not exceed 120F (50C). 14.6. For testing low and alloy austenitic stainless(300 series) and nickel alloy steel piping, the test fluid shall not contain more than 30 ppm chlorides.

15.

Testing Procedure
15.1. Hydrostatic Tests 15.1.1. Prior to filling the system with the test medium, the system shall be inspected for fabrication completeness and satisfactory test preparation, including the placement of pressure gauges and suitability of the test rig. The test package sign off sheet is then signed by the authorised Project Authorised Inspector to allow flushing or purging prior to commencing test. Where valves have been included in the test circuit, those valves with stainless steel internals shall be removed or the chloride content of the water shall not exceed 30ppm.

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Reliance Industries Limited *THIS PRINT IS NON-CONTROLLED* Jamnagar Export Refinery Project 15.1.2. After completion of flushing or purging, the area around the system under test shall be cleared of unauthorised personnel and warning notices posted during the time that the piping system is pressurised for the test. The arrangements made to exclude unauthorised personnel, and the perimeter of the hazard zone, shall be agreed with the inspector. 15.1.3. A preliminary air test to not more than 25 psig (1.7 barg) may be made to locate major leaks before a hydrostatic test. 15.1.4. Liquid testing medium shall be introduced at the system low point to avoid air pocket formation. Vents at high points shall be left open and not closed until test medium flow from the outlet. All air must be removed before pressure greater than the required to fill the system is applied. 15.1.5. Hydrostatic testing with water as a test medium shall not be performed when there is a falling air temperature of 5C or less. Should these conditions occur during a test, the test shall be aborted and the system de-pressurised. 15.1.6. Hydrostatic pressure testing shall not commence until the test fluid temperature is in equilibrium with the pipework system. The rate of pressure increase in approaching the test pressure shall not exceed 70 psi (5 bar) per minute. 15.1.7. Pressurise the system to the specified test pressure and hold for 10 minutes to allow piping strain to equalise. Once achieved inspect the complete system, which will include all joints, threaded, socket-welded, butt-welded, flanged and branch connections. On completion of the check and if no leaks are detected then leave the system for a further 30 minutes to complete the test On some large system it may take 2,3 or even 4 hours to check the system out and if no leaks are detected but the pressure has dropped due to the decrease in temperature, then bring the pressure back up to the test pressure and leave for a further 30minutes. If the pressure holds then the test is complete. Conversely if the test is started during the cool part of the day and pressure increases beyond the test pressure due to the increases in temperature, then the system will have to be periodically relieved back to the test pressure. On completion of the check leave, relieved back to the test pressure, for 30 minutes. If the pressure holds then the test is complete. Testing at night shall be restricted to small systems only and at ground level and there must be adequate illumination to detect even the smallest leakage. There shall be no testing of systems in pipe racks or elevated structures between sunset and sunrise. 15.2. Pneumatic Tests 15.2.1. a) Pressurise to 7 psig (0.5 barg) and hold for a sufficient length of time to allow piping to equalise strains. All joints (threaded, socket welded, buttwelded and flanged) shall be inspected for leaks with soap suds.

b) Pressurise gradually in 10% steps to 60% of the specified test pressure and hold for a sufficient length of time to allow piping to equalise strains (10 minutes minimum).

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Reliance Industries Limited *THIS PRINT IS NON-CONTROLLED* Jamnagar Export Refinery Project c) Reduce pressure to 50% of the specified test pressure and visually inspect all joints for leaks. d) Pressurise in steps (each step to be no more than 10% of the specified test pressure) until the specified test pressure has been reached, holding for a sufficient length of time at each step to allow piping to equalise strains (10 minutes minimum). The test pressure shall be held for two hours and then reduced to design pressure after which all joints shall be inspected for leaks with soap suds. e) The pneumatic test pressure shall not exceed 110% of the design pressure. f) The soap suds shall be a solution such as Sherlock, Snoop or equal. g) Throughout the test period, the bubble formation properties of soap suds shall be checked. 15.2.2 All defects revealed by the test shall, after approval by the inspector, be repaired and, after inspection, be retested as specified herein. At the discretion of the inspector and where permitted by the relevant code repaired defects may be retested by means other than pressure testing (for example, 100% radiography and MPI or ultrasonic examination). Weld joints in shop fabricated spools which have been successfully pressure tested elsewhere, and for which documentation acceptable to the inspector is included in the test package, need not be retested in a system test. Laterals however, which have been hydrostatically tested (see paragraph 10.4) and which have welded connections to flare headers shall be included in the pneumatic system test. A system under test pressure shall never be left unattended. If a test cannot be completed before the end of a work period, the system shall be depressurised. The contractor shall be responsible for all safety precautions and procedures during testing.

15.2.3

15.2.4

16.

Post Test Procedure


16.1. Following the acceptance of a successful test, the system is to be immediately depressurised and vented in a gradual and safe manner, thoroughly drained allowing no pockets of fluid to remain. The system shall then be blown out with dry filtered air (dewpoint -40F (-40C)) at 150F (60C) to 170F (77C) at a velocity of 100 ft/Sec (30 m/Sec) until dry to the satisfaction of the inspector. 16.2. Replace all items removed for the test and remove all test blinds, temporary supports, etc. The replacement of piping component internals shall be carefully controlled to ensure that they are reinstalled in the correct place. Flange joints opened for these purposes shall be remade with new gaskets. Plugs in unvalved test vents shall be seal welded. 16.3. The inspector shall reinspect the system for mechanical completeness and sign off the package as complete. The signed test package shall be retained as part of the contract documentation.

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Reliance Industries Limited Jamnagar Export Refinery Project

*THIS PRINT IS NON-CONTROLLED*

17.

Test Records
17.1. Records shall be made for each system tested which shall include:a) Date of test b) Identification of piping test c) Cross reference to test gauge certificate d) Test medium e) Test pressure f) Test duration g) Approval by the Inspector 17.2. Records for piping which require that pressure be held for a specified period of time shall include any corrections of test pressure due to temperature variations between the start and finish of the test. 17.3. Records for piping in which a specified leakage rate is permitted shall include the time at which water was added and the quantity added. 17.4. All test records and authorised Inspectors certifications shall be retained in the job records.

18.

General Requirements
18.1. Special Tools 18.1.1. Pressure gauges for system testing shall have a range suitable for the systems test pressure to the satisfaction of the Inspection Authority. 18.1.2. Pressure gauges shall have tag numbers which shall appear on calibration certificates. The certification documentation shall be a permanent part of the system pressure test package. No certificate shall be more than one year old and verified accurate by a recognised authority to the satisfaction of the inspection authority. 18.1.3. In case of any disagreements between two pressure gauge readings, during the pressure test cycle, the pressure test shall be stopped and both gauges sent for for re-calibration. To complete the test, two fresh gauges shall be used. 18.2. Packing And Preservation 18.2.1. Desiccant removed from chemically cleaned piping prior to pressure testing shall be regenerated or renewed and replaced together with appropriate warning signs. 18.2.2. All openings in pipework, whether vents or drains to atmosphere or openings for onsite hook up of modules etc, shall be adequately sealed to prevent the ingress of foreign matter.

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Reliance Industries Limited *THIS PRINT IS NON-CONTROLLED* Jamnagar Export Refinery Project 18.2.3. Exposed machined surfaces such as weld bevels and flange facings shall be covered with an approved white spirit soluble rust preventative. 18.2.4. Plastic end caps and thread protection plugs shall be secured with Denso or equal tape. 18.2.5. Flange covers of metal (minimum 3/16 (5mm) thick) or wood (minimum (20mm) thick) shall be gasketed, of the same outside diameter as the flange, and held in place with 50% of the required bolts for the joint (minimum 4 bolts). Covers held on with wire or steel straps are not acceptable. 18.2.6. Gate and globe valves shall be closed. Ball and plug valves positioned either full open or full closed, and diaphragm valves opened. 18.2.7. Warning signs noting items to be removed prior to commissioning (temporary blinds to isolate chemically cleaned pipe, desiccant, etc) shall be prominently displayed and adequately protected from weather and handling damage. 18.2.8. All packing and preservation shall be witnessed and approved by the inspector who will advise the contractor of any systems requiring special protective measures such as blanketing with dry air or inert gas, etc, when long term storage is envisaged. 18.3. Testing Contractor Supplied Items All tools and equipment required for piping system pressure tests, including pumps, compressors, connecting pipework with strainers and storage reservoirs, pressure gauges, temporary blinds, plugs, spools, vents and drains, pigging equipment, gaskets required for test purposes, test fluids and additives, etc, shall be supplied by the contractor.

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