Sohar Refinery Improvement Project

Method statement for pressure testing in

Fired Heater (F1701/1702/1703/1704)

Doc Ref : BEC-OFD0137-MS-054 Rev-0

Project No: OFD0137

Contents

1. Purpose
2. Scope
3. Codes & Standards
4. Definition
5. Roles & Responsibility
6. Test Preparation
7. Pressure Testing
8. Flushing and Cleaning
9. Air blowing
10.

N2 Charging

11.

Safety Precautions

12.

Attachments

Sohar Refinery Improvement Project

Method statement for pressure testing in

Fired Heater (F1701/1702/1703/1704)

Doc Ref : BEC-OFD0137-MS-054 Rev-0

Project No: OFD0137

1. Purpose
This method statement defines general requirements for on-site
pressure
testing
for
radiant
coils
for
fired
heater
(F1701/F1702/1703/1704)
2. Scope
This method statement only covers the hydrostatic testing and
Pneumatic testing of radiant coils for fired heaters (F1701/F1702/1703/1704) under the construction of Bahwan
Engineering Company LLC.
This standard does not cover pressure testing of shop fabricated
convection coil and equipment such as vessels, tanks, heat exchangers
and skid mounted piping systems
3. Codes & Standards

ASME Sec 1- Rules for construction of power boilers

API 560-Fired heater for general refinery services
API RP 520: Part I Sizing, Selection, and Installation of
Pressure Relieving Devices in Refineries
ASME B31.3: Process Piping
ASME B31.8: Gas Transmission and Distribution Piping
Systems
ASME SEC VI: Recommended Rules for the care and
Operation of Heating Boilers
ASME SEC VIII D1 & 2: Boilers and pressure Vessel code
V-6156-101-00000-H07-001-Hydrostatic test procedure
for pressure part process heater
Contractor/ Vendor Document and Drawing
V-6156-101-F1701-B15-001

4. Definition
Pressure Test A test conducted to piping or equipment by
subjecting it to an internal pressure using liquid or gas to ensure
strength or tightness of the system at the test pressure.

Hydrostatic Test A Pressure test conducted using water or

other approved liquid as the test medium

Sohar Refinery Improvement Project

Method statement for pressure testing in

Fired Heater (F1701/1702/1703/1704)

Doc Ref : BEC-OFD0137-MS-054 Rev-0

Project No: OFD0137

Pneumatic Test A Pressure test conducted using air or other

approved gas as the test medium or in conjunction with liquid

5. Roles & Responsibility

ConstructionManager

Shall Report to Site Manager

Shall be overall responsible for control and monitoring of all Fired
heater Installation activities.
Shall have overall responsibility to ensure safety at site for the working
group and environment.
Shall be responsible for the execution of work in accordance with
project HSE and Quality requirements

ConstructionEngineer

Shall report to Construction Manager

Shall ensure that pressure testing activities are ongoing as per project
specification requirements and as per the latest drawings.
Shall be responsible for execution of work in compliance to the project
HSE and Quality
requirements

ConstructionSupervisor/Foreman

Shall report to Construction Engineer

Shall ensure that personnel working are HSE inducted and are
complying with Project HSE Requirements.
Shall conduct HSE tool box talk to all concerned personnel prior to start
of work
Control Execution of Piping installation, storage, tracking of the
material received at site.

QCInspector

Shall report to QC Engineer

Shall monitor & Inspect QA/QC activities against approved Project
specification, drawings.
Shall liaise with Client Inspection Personnel during inspection.

Sohar Refinery Improvement Project

Method statement for pressure testing in

Fired Heater (F1701/1702/1703/1704)

Doc Ref : BEC-OFD0137-MS-054 Rev-0

Project No: OFD0137

Prepare and maintain Inspection documents.

Shall ensure that all instruments are duly calibrated and certified

Item to be checked shall be documented on the pressure test report by

the QA/QC inspector and approved by the DPJV QC/Vendor .

Testing Supervisor
Shall report to construction Engineer
Shall be responsible for site construction activities and implementation
of Quality and HSE plans during testing which would include walk down
of test circuit.
Prior to any pressure testing activity he will coordinate with
DPJV/VENDOR for all pressure testing associated with this procedure.

SafetyOfficer

Shall report to HSE Manager

Ensure valid work permit for all activities performed during installation
and permit condition are complied.
Ensure that employees involved in the scaffolding work are
trained/qualified
Ensure that proper PPEs are being used by employees during pressure
testing activity
Conduct tool box talk in order to explain possible hazards, associated
risks& control measures
Identify specific hazards and assist construction Supervision to ensure
safe progress of work activity.
Control unauthorized entry to work area by proper barricading &
displaying warning
sign boards and indicators.

Sohar Refinery Improvement Project

Method statement for pressure testing in

Fired Heater (F1701/1702/1703/1704)

Doc Ref : BEC-OFD0137-MS-054 Rev-0

Project No: OFD0137

6. Test Preparation

An approved test procedure shall be available at the site prior to

commencing any pressure testing activities.

Coil tubes shall be free of loose scale and debris prior to

commencement of pressure testing, Air Blowing shall be done
before pressure testing and this shall be confirmed in the prepressure test

All welding inspection records for field welds, field modification

welds, and pressure boundary attachment welds shall be verified
to exist and be completed by QC Inspector.

The preliminary walk-down shall be performed by Construction

team in conjunction with QC inspector.

The punch items found out during preliminary walk-down shall be

cleared prior to notification of pressure test to the owner.

All open Non-Conformance Reports shall have been identified and

completed expect those that are not pressure test restraints.

All joints shall be exposed and cleared of insulation and painting

for easy inspection.

Before the start of the test, the construction Supervisor shall

verify that the test area has been secured for the safety of
personnel.

Pressure gauges and pressure recorders shall be calibrated and

tag before the tests.

The calibration date shall not exceed six months. Calibration

certificates shall be made available to inspection personnel prior
to commencement of the pressure test.Stickers shall be applied
indicating the latest calibration date.

Sohar Refinery Improvement Project

Method statement for pressure testing in

Fired Heater (F1701/1702/1703/1704)

Doc Ref : BEC-OFD0137-MS-054 Rev-0

Project No: OFD0137

All gauges shall have a range such that the test pressure is within
30 to 80 % of the full range.

A minimum of two pressure gauges are required for the test

system. One pressure gauge shall be on the test pump and the
others on the test system. Their accuracy shall be within 10% of
one another.

Recording gauges shall be used where it is necessary to keep a

permanent record,
e.g., when the test duration exceeds four hours, or otherwise as
required by this standard.

Isolation of Test Sections

Paddle blinds or spectacle blinds shall be used to isolate the test
sections.
Vents and Drain
Vents shall be provided at all high points in the tested system as
needed.
Temporary Connections and Supports
Temporary connections shall be provided for de-pressurizing and
draining of the system to the sewer or disposal area.

Temporary supports shall be installed prior to hydrostatic testing,

and flushing of the tubing if they were determined to be
required. These supports shall not be removed until after the
system has been fully drained. The structural supports system
for stacked equipment shall be verified for hydrostatic loads prior
to testing.

7. Pressure Testing
7.1 Pneumatic Testing
The test procedures shall be conducted in accordance with the
applicable code. In addition, the following requirements shall
apply.

Care shall be taken to minimize the chance of brittle failure

during a pneumatic leak test. Consult the applicable code(s) for
the minimum temperature.

Sohar Refinery Improvement Project

Method statement for pressure testing in

Fired Heater (F1701/1702/1703/1704)

Doc Ref : BEC-OFD0137-MS-054 Rev-0

Project No: OFD0137

The immediate area should be blocked or roped off, a minimum

safe distance of 30 meters shall establish during pneumatic
testing. Exclude all non-essential personnel from the vicinity.

All personnel in the area of the test should be notified that the
test is to be performed.

During the application of the test pressure, all in-line valves if

not used as test isolation valves shall be in an open position.

7.1.1 Pressurization
A pneumatic test shall include a preliminary test at not more
than 1.75 Bar or 50% of
the final test pressure, whichever is lowest. The pressure shall
be increased gradually
in steps until the test pressure is reached, to allow all the piping
to equalize strains during the test.This pressure shall be held for
minimum 10 minutes at the least pressure.
Depressurize up to design pressure and check for leak.
7.1.2 Inspection
After the test pressure is reached and before commencement
of inspection of the system, the isolation valve between the
temporary test manifold/piping and the piping/equipment under
pressure test shall be closed and the test pump disconnected.
Design pressure shall be maintained for a period of time (30
Min) to permit a thorough inspection of all joints for leakage or
signs of failure.
Joints shall be sprayed or applied with approved soap solution
to detect leakage or passing during visual inspection.
Any joint found leakage during a pressure test shall be rejected
and to be depressurize for repair thereafter retest to the
specified pressure after repairs have been made. Any lines
changed after they have been tested shall be retested.
Test records shall be made for each test by entries on pressure
Test report form
7.2 Hydrostatic Testing

Sohar Refinery Improvement Project

Method statement for pressure testing in

Fired Heater (F1701/1702/1703/1704)

Doc Ref : BEC-OFD0137-MS-054 Rev-0

Project No: OFD0137

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

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

Vents shall be closed when the system is full.

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

7.2.1 Pressurization

Before Pressurization a minimum safe distance of 10 meters shall

be establish and all non- essential personnel shall be excluded.

The test pressure shall be applied gradually with a suitable

hydraulic pump increments of 1/3 or less of the test pressure.

Pressure is to be supplied by means of a pump or other suitable

pressure generating device. The pump shall be positively isolated
from the system expect when being used to pressurize the
system. Pump capacity shall be sized appropriately to insure
timely pressurization.

The pressure shall be gradually increased in steps until the test

pressure is reached, holding the pressure is reached, at each step
long enough to equalize piping strains. For specified test pressure
at each step pressure greater than 14 bar, the test pressure shall
be raised 50 percent in steps initially, and 25 percent increments
thereafter, to preclude possible release of injurious energy
through the test medium erupting from a break. The system
tested shall be held for minimum 5 minute at each step.
Applicable codes must be consulted in establishing the test
pressure increments for achieving test pressure and relieving test
pressure.

From 15 to 20 minutes shall be allowed after filling the system for

temperature stabilization

7.2.2 Inspection

Sohar Refinery Improvement Project

Method statement for pressure testing in

Fired Heater (F1701/1702/1703/1704)

Doc Ref : BEC-OFD0137-MS-054 Rev-0

Project No: OFD0137

After the test pressure is reached and before commencement of

inspection of the
system, the isolation valve between the
temporary test manifold/piping and the piping/equipment under
pressure test shall be closed and the test pump disconnected.

Pressurized piping shall not be left unattended. Sun heating of

piping or equipment under test can cause considerable increase
of pressure due to thermal expansion of the testing liquid.
Precautions shall be taken to avoid excessive pressure.

When testing, the pressure shall be maintained for a period of

time 1 hour to perform a thorough inspection of all joints for
leakage. Any joint found leaking during a pressure test shall be
retested to the specified pressure after repairs have been made.
Any lines changed after they have been tested shall be retested.

Thereafter, the test pressure shall be hold for as long as required

to allow examination by the QC inspector and owner of all joints,
connections and regions and high stress such as around openings
and thickness transition sections.

After completion of the test, pressure shall be released by

opening the test valve gradually.

Before test water is drained, vent shall be opened. The vent shall
be kept open until water is fully drained.

7.2.3 Depressurization and post pressure test

After pressure testing has been successfully completed and
approved by the Contractors Inspector, the following operations shall
be made

Draining of Test Fluid

Release of pressure and draining shall be done on the
downstream side. All vents shall be opened before draining
to facilitate drainage and prevent formation of vacuum. No
test fluid shall remain in low spots.

Disposal of test fluid

The test fluid shall be disposed in accordance with HSE
requirement or as directed by the contractor.

Sohar Refinery Improvement Project

Method statement for pressure testing in

Fired Heater (F1701/1702/1703/1704)

Doc Ref : BEC-OFD0137-MS-054 Rev-0

Project No: OFD0137

Drying Method
After completion of hydro test, the pressure shall be released
gradually. All vents and drains shall be kept open till the lines
are fully drained. After draining, lines/system shall be dried
by compressed air.

Removal and reconnection of components

All temporary items installed for testing purposes (e.g.,
manifolds, valves, blinds, spacers, supports) shall be
removed.

8. Flushing and cleaning

Flushing and Cleaning of all lines shall be done after pressure

testing

Flushing of all lines will be done by water or dry compressed air

wherever water flushing is not desirable to clean the tube of all
dirt, debris or loose foreign materials.

It will be subcontractors responsibility to provide pumping

equipment, compressors, water /air hoses with accessories etc.

Wherever required, instruments such as pumps, pressure

gauges, safety valves etc. Spool pieces, temporary gaskets, tools
and tackles and all other arrangements, equipment, materials
and consumables etc... Required as aids for completing the
flushing as per the direction of the subcontractor.

After flushing is completed and approved the line shall be subject

to air blowing.

9. Air blowing

Air blowing shall also be done after pressure testing and after
flushing and cleaning is done

Air blowing shall be done to dry the tube coils and clean the tube
of all dirt, debris or loose foreign materials.

Sohar Refinery Improvement Project

Method statement for pressure testing in

Fired Heater (F1701/1702/1703/1704)

Doc Ref : BEC-OFD0137-MS-054 Rev-0

Project No: OFD0137

The supply of compressed air for air blowing will be the

subcontractors responsibility and it will be done at his cost.

After air blowing is completed, the valves distance pieces, piping

specials etc. shall be re-installed by the subcontractor with
permanent gaskets. However, flanges at equipment nozzles and
other places where isolation is required during testing, only
temporary gaskets will be provided.

10.

N2 Charging

The lines shall be charged with nitrogen or inert gas to 2.0kg/bar

and all points shall be checked for large leakages.

If there are leaks, it shall be marked, pressure released and

repairs shall be done. Brazed joints with leaks shall be opened
and redone.

The lines shall now be charged with Nitrogen gas again to the
pressure specified in the above and the process of locating leaks
and repairs shall be repeated.

The system shall hold the pressure for a minimum period of 24

hours without revealing any leaks. After the leak test had been
completed successfully, nitrogen gas in the system shall be used
to blow out the system.

11.

Safety Precautions

The pressurize Zone shall be barricaded during pressure testing

and a safe distance zone shall established according to the
following:
o Hydro Testing
10 meters minimum safe
distance
o Pneumatic Testing
30 meters minimum safe
distance

Warning sign shall be posted in the restricted pressurize zones

Protection from Overpressure

Sohar Refinery Improvement Project

Method statement for pressure testing in

Fired Heater (F1701/1702/1703/1704)

Doc Ref : BEC-OFD0137-MS-054 Rev-0

Project No: OFD0137

All Systems (piping and equipment) while being pressure tested

shall be protected from being overpressure by the following
Relief valves of adequate capacity shall follow the requirements of
DPJV Site Technical Query No.SRIP-QT-JS-OS-PP-0071 Pressure
Relief Valve Set Pressure for Hydro test of Metallic Piping System,
which states that:
Set pressure of 1.1 test pressure necessitates huge
numbers of PSV in completing hydro test simultaneously. As per
ASME B16.5, pressure temperature rating is based on flange
rating, thus the pressure relieve valve set pressure according to
flange rating rather than test pressure. Please refer to DPJV Site
Technical Query No.SRIP-QT-JS-OS-PP-0071

As per QCP for pressure Testing of piping system (S-000-5520122) Clause 7.1.7 a relieve valve of adequate capacity to relieve
at 10% above the test pressure shall be installed which is based
on ASME B31.3 for Pneumatic Testing.

An isolation valve shall be provided between the pressure testing

manifold and the system being tested. The isolation valve shall be
rated for the manifold test pressure when in the closed position.

Before employing the pressure testing manifold testing in the

actual system pressure test, it shall be separately pressure tested
to at least 1.2 times the system test pressure but not less than
the discharge pressure of the pump used for the pressure testing.

The area around the system to be tested will be cleared of

unauthorized personnel and warning notices posted during the
time that the piping system is pressurized for test.

It should be noted that the safety of personnel and existing

facilities is of paramount importance at all times. This especially
relevant when conducting operations involving high pressure
testing.

Areas around flexible hose and high pressure pump shall be

cordoned off with barriers and warning tape and whiplash
arrester shall be put in all connecting joints

Sohar Refinery Improvement Project

Method statement for pressure testing in

Fired Heater (F1701/1702/1703/1704)

Doc Ref : BEC-OFD0137-MS-054 Rev-0

Project No: OFD0137

At the boundaries notice or sign boards shall be displayed with

caution notes lie System Under Pressure Do Not Enter or
Hydrostatic/Pneumatic Test in progress in multiple languages.

All appropriate PPE shall be worn (safety Helmet, safety Glasses,

Safety Boots, Gloves and full body Harness when at height)

All requirements as defined in Contractor Project Construction

HSE manual and BEC Project HSE plan shall be complied with
carrying out the works

All the personnel involved in hydrostatic testing and rigging

operations shall briefed about all the possible risk involved with
the operation during the tool box talk meetings.

PTW shall be available for flushing & Pressure / leak Test.

Ares should be barricaded as and where required.

The testing section shall be patrolled continuously throughout

the test duration.
Watchmen on the working area shall be provided to advice/ warn
everyone going near on the activity area

All the personnel involved in the hydrostatic/ pneumatic testing

have been trained and competent for their specific task.
12.1 Attachments
Copy of approved JHA (M-013) for flushing and pressure
/leak testing.