Construction QA/QC

Piping

Rev. No. Rev. Date Description of Revision Revised by Approval

00 21/April/2016 New KIA

PROPRIETARY & CONFIDENTIAL

This document and the information contained herein is E2C proprietary know-how. This document or any part
therefore should not be reproduced stored in a retrieval system or transmitted by any means, electronic or
otherwise, or divulged without permission of E2C.

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TABLE OF CONTENTS

1. Scope ......................................................................................................................3
2. Applicable Codes & Standards ...............................................................................3
3. Witness Inspection Items ........................................................................................3
4. Test and Inspection Agenda ...................................................................................3
4.1 Check of Materials .............................................................................................4
4.2 Edge Preparation ................................................................................................4
4.3 Welding ............................................................................................................. 4
4.4 Joint Preparation and Alignment ........................................................................5
4.5 Inspection of Welding ........................................................................................6
4.6 Nondestructive Examination ..............................................................................7
4.7 Heat Treatment ...................................................................................................8
4.8 Inspection of Completed Spool Piece.................................................................9
4.9 Inspection of pipings for Field Assembly and Erection. ....................................10
4.10 Pressure Test .......................................................................................................11
4.11 Inspection of Insulation ..................................................................................... 19
4.12 Testing (Bench Test) of Relief Valves .............................................................. 19
5. QC Dossier .............................................................................................................19

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1. Scope
1.1 This specification covers the requirements & procedure for tests & inspections of
fabrication and installation of above ground steel piping at the client construction site.

1.2 This specification shall be applied to the inspection items, method and criteria for
installation/construction work performed by the Construction contractor under control of
Construction Management Contractor (CMC), Contractor.

1.3 Any deviations from and/or addition to this procedure, if required in individual cases, shall
be called to the attention of CMC/Owner and approved in writing by CMC/Owner prior to
commencement of fabrication.

1.4 Other tests and inspections, not defined herein, when required by applicable Codes,
Standards, Specifications or Regulations, or by Construction Contractor standard practice,
shall be referred to CMC/Owner for specific instruction.

1.5 Laws, and regulations, if applicable, shall take precedence of this procedure.

2. Applicable Codes & Standards

2.1 Codes & Standards (Latest Editions, including revisions, addenda and supplements)

ANSI B31.1 Power Piping

ANSI B31.3 Chemical Plant and Petroleum Refinery Piping
ASME Boiler and Pressure Vessel Code,
Section V Nondestructive Examination
Section IX Qualification Standard for Welding and Brazing Procedures, Welders,
Brazers, and Welding and Brazing Operators
API 527 Commercial Seat Tightness of Safety Relief Valves with Metal-to-Metal Seats.
ANSI B16.5 Pipe flanges and Flanged Fittings
ANSI B16.34 Valves - Flanged and Buttwelding
NFPA-13 Standard for the Installation of Sprinkler End System

3. Witness Inspection Items

3.1 All field fabricated piping, installation and construction work shall be subjected to test and
inspection under witness by CMC and/or Owner's inspector at any reasonable time and place
before, during and after fabrication.

3.2 Witness test and inspection items shall be in accordance with agreed Inspection and Test
Plan (ITP).

4. Test and Inspection Agenda

The Construction Contractor shall supervise the fabrication and construction work. Verify that
all requirements stipulated in this procedure are fulfilled throughout the fabrication and
construction work; and during test and inspection; that the qualities of the completed work
meet all the requirements of this procedure and all other contractual documents.

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4.1 Check of Materials

4.1.1 The Construction Contractor shall verify the piping materials that any damage and strain
shall not appear. Piping code stencil or color coding marking shall be clearly legible at the
time of material receiving.

4.1.2 All flanges, fittings, boltings and gaskets shall be checked for defects, damaging rust,
etc., which might impair its strength or toughness.

4.1.3 Piping material, size and schedule shall be verified by the Construction Contractor as
required by the applicable drawings.

4.1.4 Low-alloy steel or high-alloy steel pipes and piping components such as fittings, flanges,
valves, etc. for pressure piping systems shall be verified in accordance with "Alloy
Verification Specification. Alloy Verification of materials and welds after completion shall be
performed by the Construction Contractor or approved subcontractor proposed to and accepted
by CMC/Owner and the results shall be reported to CMC/Owner.

4.2 Edge Preparation

4.2.1 Weld bevels shall be made by machining, grinding or thermal cutting. The following
items shall be checked visually whether the surface is ground smoothly and 1/16 in. (1.6mm)
minimum ground back for torch-cut surfaces for thermal cutting.

4.2.2 When alloy steel pipe is cut other than by mechanical means, weld bevels shall be
examined by LPT/MPT after cutting and grinding to final bevel.

4.2.3 Materials which require preheating for welding shall be checked to be preheated at the
same temperature for thermal cutting or gouging, however, preheat to 200 °C shall be
mandatory for low alloy steel.

4.3 Welding
4.3.1 All welding procedures (WPS), welders, and welding operators shall be qualified in
accordance with latest edition of Sec. IX of the ASME Code.

Complete specification and welder's list including test results shall be submitted to
CMC/Owner for review and approval.

4.3.2 The following items shall be checked and monitored during fabrication:

4.3.2.1 Each welder's performance in accordance with ‘Welder Control Procedure for Field
Construction Work’

4.3.2.2 Welding consumable control at the construction site in accordance with ‘Welding
Material Control Procedure for Field Construction Work’

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4.3.3 Weather Condition

In the following weather conditions, Welding Foreman /QC Engineer shall check whether
appropriate protection or action shall be taken and approved by CMC/Owner. Otherwise
welding shall be prohibited.

4.3.3.1 Wind speed exceeding 10m/sec for SMAW and 3m/sec for GTAW.

4.3.3.2 Any dew-fall on the materials to be welded.

4.3.3.3 Any rain

4.3.3.4 Sand storm

4.4 Joint Preparation and Alignment

The Fit-Up of pipes shall be made by mechanical clamps or tack welding. Bridge pieces shall
be avoided. All Fit-Up shall be made by qualified welder or tacker according to the relevant
and approved WPS.

Weld joints shall not be painted or primer coated prior to pressure testing.

During fabrication of stainless steel and non-ferrous materials, tools (e.g. wire brush, grinding
discs, file, etc.) shall be iron carbide free. Grinding discs shall be of aluminium oxide material.
All tools dedicated for the stainless steel fabrication shall be colour coded and be kept
separately from the carbon steel application tools.

Prior to the start of welding, weld bevels shall be checked that they are suitable for welding
process to be used and within the limit of joint as follows:

4.4.1 Bevels shall be in accordance with the following requirements.

4.4.2 All surfaces to be welded shall be clean and free from paint, oil, dirt, scale and foreign
materials detrimental to welding.

4.4.3 The clear distance between the adjacent girth butt weld shall not be less than four times
the pipe wall thickness, or 25 mm whichever is greater. Distance between welds shall be
measured between the adjacent edges of the cap passes.The length of insert pup sections for
both new and existing fabrication shall not be less than 2 pipe diameters. If space limitations
do not permit for the proper pup piece to be used, the resulting two (2) butt welds shall be
100% radiographed.

4.4.4 Galvanizing on the internal and external surfaces of the joint to be welded shall be
removed by grinding before welding. The area to be removed shall include about 10mm from
the edge of the joint. After welding, all external damaged surfaces shall be repaired with
"ZINC IT". No touch-up need be applied on the internal surfaces if inaccessible from the open
end of the pipe, unless written approval from CMC/Owner is secured.

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4.4.5 Defects such as cracks, inadequate penetration of temporary weld and/or tack welds shall
be eliminated.

4.4.6 Alignment of circumferential joint shall match each other within 2.4mm at any point
around the inside surface.

4.4.7 Pipes with longitudinal weld shall be welded together in such a way that the distance
between the longitudinal welds of the pipe measured on the circumferential welds is at least 5
times of the wall thickness of the thicker pipe.

4.4.8 All piping shall be correct in perpendicularity and except the area where the piping
inclination is designated in the drawing. Maximum bent from the centerline between adjacent
support is to be 25mm.

4.4.9 Socket joints required minimum of two (2) passes.

4.5 Inspection of Welding

4.5.1Checking of Welding Method

The following point shall be checked prior to and/or during course of the welding.

4.5.1.1 Welding procedure is strictly adhered to the applicable WPS

4.5.1.2 Type and dryness of welding consumables

4.5.1.3 Welding qualification and position in accordance with identification label of welder.

4.5.1.4 Preheat, interpass-weld-temperature

4.5.1.5 Welding equipment and machine

4.5.1.6 Kind and flow rate of shielding gas, etc

4.5.2 Visual Inspection during Welding

During welding, the following items shall be inspected visually

4.5.2.1 ack welds which have cracked are removed

4.5.2.2 Defects such as pin holes, blow-holes, cracks, etc.

4.5.2.3 Removal of slag, point of arc-strike and termination of arc.

4.5.3 Visual Inspection of Completed Weld

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4.5.3.1 After completion of welding, and before application of nondestructive examinations,

all welds shall be 100% visually inspected for the following items:

a. Irregular bead, excess or concave reinforcement, root penetration.

b. Surface weld defects such as crack, undercutting, lack of fusion.
c. Leg length of fillet weld.
d. Removal of slag, spatter, etc.
e. Inside of flange joint weld.
f. Appearance of inside bead, if possible.
4.5.3.2 Limitation, maximum tolerance, and acceptance criteria shall be as follows and or as
per applicable codes and standards.

a. Undercutting depth max. 0.8mm

b. Height of reinforcement or internal projection.

INTERNAL PROJECTION AND

WALL THICKNESS WELD REINFORCEMENT
(MM)
6.4 and under Max. 1.6
Over 6.4 thru 12.7 3.2
Over 12.7 thru 25.4 4.0
Over 25.4 4.8

4.6 Nondestructive Examination

4.6.1 General

4.6.1.1 More restrictive requirements, when shown on the applicable line table list, isometric
drawing, or other applicable specifications shall take precedence.

4.6.1.2 For P-number 4 material, examination shall be performed after completion of any heat
treatment.

4.6.1.3 Weld joints to be spot examined shall be selected by CMC/Owner.

4.6.1.4 For major defects requiring repairs, the repair procedure shall be submitted to
CMC/Owner for approval prior to commencing repair work.

4.6.1.5 When Construction Contractor plans to adopt the individual procedure for NDE,
Construction Contractor shall submit detailed examination procedure to CMC/Owner for
approval.

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4.6.2 Radiographic Examination

4.6.2.1 Radiographic examination shall be done in accordance with ‘Inspection Procedure for
Radiographic Examination’ and shall be performed by an Independent Third Party (Agency)
proposed to and accepted by CMC/Owner prior to start of work.

4.6.2.2 When "Spot" or "Random" radiography is specified, radiography shall include welds
representing every pipe thickness and material "P-number", each welding process, each welder
or welding operator, progressively throughout the entire job.

4.6.2.3 Progressive Examination

a. When the required spot and/or random examination reveals a defect requiring repair,
two additional examinations of the same type shall be made of other welds done by the
same welder or welding operator.
b. If the second group of weld examined is acceptable, all weld presented by these
additional examinations shall be accepted. And the defective item shall be repaired and re-
examined as specified in applicable Code.
c. When each of the second group reveals a defect requiring repair, two further additional
weld shall be examined. If all of the third groups of welds examined are acceptable, the
welds requiring repair shall be repaired or replaced to meet the requirement of the Code and
all welds represented by the examined welds shall be acceptable.
d. If any of the third group welds examined reveal defects requiring repair, all
comparable welds may be replaced and re-examined as required, or they shall be fully
examined and repaired as necessary to meet applicable quality requirements of the Code.
4.6.3 Liquid Penetrant Examination

4.6.3.1 Liquid penetrant examination shall be performed in accordance with "Inspection

Procedure for Liquid Penetrant Examination.

4.6.3.2 Liquid penetrant examination or magnetic particle examination shall be applied to the
portions from which the fit-up lug have been removed, for following steel piping.

a. Cr-Mo steel
b. Monel
Any defects found shall be removed by grinding and repaired by welding, if any, and the area
shall be re-examined.

4.6.4 Magnetic Particle and Ultrasonic Examination

4.7 Heat Treatment

4.7.1 Preheat. The following requirements shall be checked prior to and/or during welding.

4.7.1.1 Preheat temperature shall be based on higher grade steels for welding dissimilar ferritic
steels having different preheat requirements.
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4.7.1.2 The preheat temperature shall be checked by using temperature indicating crayons,
thermocouple, surface thermometer, pyrometer or other suitable methods to assure that the
required preheat temperature is obtained prior to and is maintained during the welding
operation.

4.7.1.3 The preheat temperature for each weld joint shall be recorded by Inspector's Daily
Work.

4.7.2 Post Weld Heat Treatment. Post weld heat treatment shall be checked for workmanship,
heat chart and following requirements in accordance with the detailed procedure submitted to
CMC/Owner for approval.

4.7.2.1 All flange facings and threaded connections shall be protected by a suitable paint or
compound to prevent damage from scaling or oxidation during heat treatment.

4.7.2.2 The heat temperature, holding time or heating/cooling rate shall be measured and
recorded by using an automatic recorder. The heat treatment chart shall be submitted to
CMC/Owner Inspector for approval.

Thermocouple sketch shall be proposed to CMC/Owner prior to heat treatment, and shall be
supplied with chart. The chart will be identified so as to be traceable to the related welds.

4.7.2.3 The heating and cooling rate above 315°C shall not be more than 220°C per hour
divided by the wall thickness in inches, but in no case more than 220°C per hour.

4.7.3 Hardness Test. For the girth welded parts of P-4 material, hardness of weld metal, heat
affected zone (HAZ) and base metal shall be measured in Brinell Hardness after PWHT per
10% of welded joints for furnace heating and all joint for local heating.

4.8 Inspection of Completed Spool Piece

Spool pieces (shop-fabricated) that have passed welding examination shall be subject to the
following:

4.8.1 Dimensional inspection shall be conducted with reference to the construction drawings
and specifications for the following items:

4.8.1.1 Partial dimensions as required

4.8.1.2 Angle and direction of bent portions

4.8.1.3 Allowance for field welding.

4.8.2 Visual inspection shall be made on the following items:

4.8.2.1 Grinding smoothly after the removal of bridges, and build-up, if necessary;

4.8.2.2 Conditions and position of such weld attachments as pipe shoes, supports, lugs, etc;
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4.8.2.3 Marking provided for facilitating connection of spool pieces;

4.8.2.4 AV marking;

4.8.2.5 Cleanliness inside the piping.

4.9 Inspection of piping for Field Assembly and Erection.

All cut lengths of pipes shall be identified by the heat nos. to ensure complete traceability to
mill certificates. Stainless steel pipes shall always be stored and transported separately to
avoid contact with carbon steel and galvanized pipe spools.

Reinforcing Pads shall have a ¼” tell-tale threaded holes and be tested at 2.0 bar minimum
with a Client approved soapy solution.

4.9.1 Visual inspection shall be performed on the field assembled or erected piping for the
following items:

4.9.1.1 Piping have been fabricated conforming to the construction spool drawings, and
fabrication/dimension tolerance are within the limit in Figure-2;

4.9.1.2 Tolerance for mating flanges of pumps compressor, etc. are within the following range,
unless otherwise manufacturer's recommendation:

Angularity alignment across the face of flanges:0.8 mm

Clearance between the flanges: ± 0.8 mm.
4.9.1.3 Pipe shoes are fixed type or sliding type as specified. Check quality of the welding for
those shoes. Tack welds in connection with other structures have been removed;

4.9.1.4 Dimensions of pipe support are as specified in the construction drawing;

4.9.1.5 Hammering or air blowing has been conducted for cleaning inside the pipes prior to
field installation;

4.9.2 Inspection shall be performed on all the installed or erected piping in accordance with
the construction drawings for the following items:

4.9.2.1 Smoothness of internal weld penetration at flange welds. Internal welds at the joint of
orifice flange to pipe shall be ground smooth and flush with the inside diameter of the pipe;

4.9.2.2 Tag number of valves and correct installation of fluid flow directions, check of
operability/safe accessibility;

4.9.2.3 Check of piping or fitting material selection, diameter, and rating.

4.9.2.4 Check of installed positions, directions, material selection, diameter and rating for
measuring instruments, traps, strainers, and fittings/connections, etc.
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4.9.2.5 Check of supports, vibration stopper, fixing position, method, numbers etc.

4.9.2.6 Check of gasket material, dimension, missing, etc. Construction Contractor to provide
procedure for gasket control, issuance, and installation. Procedure to be approved by
CMC/Owner. Check sheet for gasket installation.

4.9.2.7 Check of bolt/nut missing, correct torque, and material selection, dimension.

4.10 Pressure Test

Minimum thickness of temporary blanks for pressure testing shall be required to be approved
by Client with reference to the contractor’s stress calculations provided.

Stainless steel pipes shall be tested with clean oil and moisture free air.

4.10.1 General

4.10.1.1 Pressure Test Package should be prepared. All relevant documents or drawings need
to be attached. Lines for testing shall be highlighted with yellow color in Isometric Drawings.
After completion of piping installation work, all piping system shall be subject to pressure test.
Pressure test on the piping system shall be conducted with reference to the pertinent "Test
Flow Sheet" which shall specify detail scope of work, such as test pressure, position of
pressure gauges, and testing fluid, etc.

4.10.1.2 Prior to commencing pressure test, it shall be confirmed that any commitment of the
nondestructive examinations, PWHT, line check, etc. have been completed; and equipment
such as vessels, pumps and instruments are isolated from the piping by use of correct rating
blinds or other suitable means approved by Client.

4.10.1.3

a. Calibration of pressure gauges shall be within the calibration frequency specified in

accordance with "Calibration Procedure of Inspection, Measuring & Test Equipment.
b. Gauges shall be scaled to the range of 1.5 to 3 times the relevant test pressure. A
minimum of two calibrated gauges shall be used in pressure test for each continuous
blocked section of piping under the test.
4.10.1.4 Vessels and heat exchangers, ordinarily shall not be included in the hydrostatic test
unless the isolation of these equipment are impossible or impractical. In such cases, system
hydrostatic test including vessels and heat exchangers may be performed provided that ANSI
Code B31.3, para. 345.4.3 and other related paragraph and also the following conditions are
satisfied.

a. The equipment support has been designed to cater for the additional weight of the test
medium;
b. The equipment is not adversely affected by the test medium, including any linings,
coatings, etc.
c. The quantity of test medium required is not excessive;
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a. Adequate vent and drain facilities exist on the equipment;

b. Water in process media does not provide adverse affect;
c. All components of equipment, including the exchanger tubes, may be completely
drainable in the installed position and dried immediately after the hydrostatic test.
4.10.1.5 Equipment shall not be included in the pneumatic testing of the piping system. In
such tests they shall be isolated.

4.10.2 Exclusions

4.10.2.1 Compressors, pumps, turbines, or other rotating machinery shall be isolated and have
casing vents and drains open during tests.

4.10.2.2 Instrument piping downstream of the first block valve. (In the case of double valves
downstream of second valve).

4.10.2.3 Piping not pressurized in service, such as vents, and relief valves, tail pipes, which are
open to atmosphere, shall not be tested.

4.10.2.4 Plastic and RTRP piping which shall be tested as per manufacturer's
recommendations.

4.10.2.5 Leak testing of components assembled after pressure testing. This procedure shall be
carried out as part of the Commissioning Procedure.

4.10.2.6 Sewers and drain system where fluid is flowing at atmospheric pressure, are not
covered by this specification.

4.10.2.7 Flanged systems of fabricated pipework, eg: Rubber lined, FEP lined tested in the
fabrication shop, need not be retested after installation if no further welding is performed and
following conditions apply.

a. The approved test certificate is available to cover the pressure test.

b. There is no statutory requirement for a site pressure test.
4.10.3 Preparation for Pressure Testing

4.10.3.1 Lines should be tested as far as practicable in complete systems to reduce the number
of tests and manhours. For Pre-Assembled Units, Contractor/Site Mechanical Erection
Contractor shall prepare Systems Pressure Test Sketches showing extent of systems to be
tested.

4.10.3.2 All lines shall be cleared of debris by flushing with water or blowing with steam or
air as appropriate and precautions taken to ensure that debris is not flushed into associated
vessels, equipment, or ‘dead ends’.

4.10.3.3 Heat exchangers shall be isolated, wherever possible, until the initial flushing of the
system is complete.
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4.10.3.4 All pipe supports and anchors, including any temporary supports required due to
weight of test medium should be installed prior to pressure testing. All spring loaded pipe
supports shall be locked position with lock-pin during hydrotesting.

4.10.3.5 The limit of each pressure test shall normally be blind flanges, disc, ellipsoidal heads,
caps, plugs, spectacle blinds or spades whenever practicable. Block valves may be used
provided the seat test pressure of the valve is not exceeded, and the downstream piping is
protected from possible over pressure (due to leakage past the valve) by removal of spools,
open vents or drains, or temporary relief valves.

4.10.3.6 All thru valves shall be in fully opened position during pressure test. Test may not be
conducted against a valve seat, if not suitable for the specified test conditions.

4.10.3.7 All systems (piping and equipment) while being strength tested shall be protected
from over pressure by relief valve(s) or adequate capacity to relieve at 5% above the strength
test pressure. The relief valve(s) shall be tested, dated, and tagged. Calibration certificates
shall be made available prior to commencement of test. Non use of relief valves shall be
approved in writing by Client.

4.10.3.8 A bleed valve shall be provided to protect the piping and equipment from
overpressure, in addition to the pressure relieving devices. The bleed valve shall be readily
accessible in case immediate depressurization is required.

4.10.3.9 Vents shall be provided at all high points in the system. Drains shall be provided at all
low points.

4.10.3.10 Check valve disc shall be provided with a drain hole (if the process conditions
permit) or the disc be temporarily removed.

4.10.3.11 All restrictions which will interfere with filling, venting, draining or flushing shall
not be installed until after completion of the line flushing and pressure testing. These include
for example, orifice plates, flow nozzles venturies, positive displacement and turbine meters
and other in-line equipment.

4.10.3.12 Pressure gauges and pressure recorders shall be calibrated before use. A minimum of
two pressure gauges are required for the test system and verified that they are within 5% of
each other when in use. One gauge shall be on the test pump or test manifold and a minimum
of one on the system being tested. Stickers shall be applied indicating the latest calibration
date. Calibration certificates shall be made available to inspection personnel prior to
commencement of the pressure test.

4.10.3.13 Any manifold employed for pressure testing of piping and equipment shall be
separately pressure tested to at least 20% above the specified system test pressure before use.
An isolation valve shall be provided between the manifold and the system being tested.

4.10.4 Test Medium

4.10.4.1 The test medium shall be as specified in the Line Schedule.

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4.10.4.2 When testing with liquid, test fluid shall normally be potable water unless otherwise
agreed with CMC. Salt or Brackish water shall not be used.

4.10.4.3 Water shall not be used for testing of Instrument Air or Refrigeration pipework. This
pipework shall normally be tested with dry air or nitrogen (Dew point –40°C or lower)

4.10.4.4 When austenitic stainless steel, monel and hastelloy pipework is to be hydrostatically
tested, the test fluid shall not contain more than 50 ppm chlorides.

4.10.4.5 Systems containing water, air or inert gas in service, and with a design pressure of
10.34 bar g or less and design temperature is from –29°C through 186°C may be tested during
or prior to commissioning using the service fluid at the design pressure. "Category D fluid
service - ANSI B31.3, para 345.1 (a)"

4.10.4.6 Water for hydrostatic testing of pipework shall be free from suspended solids and
with a pH between 6.0 and 8.0.

4.10.5 Test Pressure

4.10.5.1 The pressure shall be as specified in the Line Schedule, but in case of the test loop
including different pipe class and different test pressure but same rating, test pressure can be
applied to lower test pressure. Approval is required from Client.

4.10.5.2 Hydrostatic test pressure shall be calculated in accordance with ANSI B31.3
paragraph 345.4.2.

4.10.5.3 Pneumatic test pressure shall be calculated in accordance with ANSI B31.3 paragraph
345.5.4.

4.10.5.4 The specified test pressure shall not exceed the following:

a. Maximum differential pressure on heat exchanger tube sheets. If exceeded exchanger

is to be isolated from the test.
b. The shop test pressure for equipment and vessels, as specified on the appropriate data
sheet.
c. Maximum test pressure for flanged joints as laid down in ANSI B16.5 or flange design
standard used.
d. The maximum allowable body test pressure for valves, and other components as
specified on the manufacturer's valve drawing.
4.10.5.5 Fire protection system pressure test shall be in accordance with NFPA-13,
Section 1-11.2.
4.10.6 Hydrostatic Testing

4.10.6.1 All lines shall be hydrostatically tested with the exceptions noted in paragraph 4.10.2
and systems where hydrostatic testing is impracticable (eg: large overhead vapor lines from

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columns, large vapor line to/from compressor and flare headers). In these cases a pneumatic
test may be substituted when agreed with CMC/Owner. In certain cases the higher inspection
levels may be imposed in place of site pressure testing. Pneumatic testing is permissible only
for the Client approved lines.

4.10.6.2 Steam tracing lines should normally be tested by the application of steam preferably
before the joints are insulated.

4.10.6.3 Piping designed for vacuum operation should be hydrostatically tested and then
subjected to a gas leakage test at 1 bar g using soapy water as a detector.

4.10.6.4 Liquid testing medium shall be introduced at the lowest point in the system to
minimize the risk of trapped air pockets. All high point vents shall be left open and not closed
until liquid is observed at the outlet. All trapped air shall be released before testing commence.

4.10.6.5 Piping systems shall not be pressurized at a rate exceeding 7 bar per minute.

4.10.6.6 The system shall be held at the test pressure for a minimum of 10 minutes or such
time as is required for the Inspector to make an adequate visual examination of the system
under test. Visual examination shall be carried out with due care to prevent injury to
personnel.

4.10.6.7 All defective joints and welds shall be repaired and retested in accordance with the
contract fabrication specifications and subsequently hydrostatically retested, except that with
the prior written permission of CMC/ Client, retest after minor repairs may be waived
providing adequate measures are taken to ensure sound construction.

4.10.6.8 When draining the systems after testing, vent valves shall be opened before opening
drain valves to obviate vacuum arising in the system and possible resultant damage to vessel,
etc. Care shall be taken to ensure that adequate ingress of air can be obtained to balance the
outflow of test liquid.

4.10.6.9 On completion of hydrostatic testing, rectification and retest, all components removed
for the test (if any) shall be replaced. Joints made when connecting these components shall be
leak tested as part of the Commissioning Procedure. Ensure all vents and drains permanently
installed on system are closed. If the line has been tested with the working fluid, and no
defects are revealed, the line may be left without draining unless this is necessary to replace
components removed for the test.

4.10.6.10 For closing welds or cut-ins it is preferable to re-test the line hydrostatically but
where this is impractical, radiographic examination shall be done to provide evidence of sound
welding. Written permission shall be secured from CMC/Owner. Any spools removed from a
system having further welding carried out shall be re-tested hydrostatically prior to re-erection.

4.10.6.11 Where Pre-Assembled Units are connected at site with a single interconnecting
buttweld closure spool on a system, hydrostatic retesting of system is not required provided
that radiographic (or ultrasonic) examination shows evidence of sound welding. Written
permission shall be secured from CMC/Owner. Where multiple interconnecting buttweld
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closure spools connect number of Pre-Assembled Units then a suitable section of the system
containing the closure spools shall be hydrostatically retested. In certain cases, 2 buttwelds
may be used on the interconnecting spools.

4.10.6.12 If the system is required to be dried, solvent flushed, sterilized, pressurized with
inert gas or otherwise specially protected after hydrotest, this shall be stated on the Line
Schedule and Isometric drawings. No heat shall be applied for drying purposes.

4.10.6.13 Flange gaskets conforming to line specs can be left in after hydrotest, but temporary
gaskets shall be replaced.

4.10.6.14 The magnitude of loads on equipment nozzles and support elements induced by test
weight shall be reviewed and, if necessary, the loads shall be lowered below the design values.

4.10.6.15 Minimum permissible temperatures of the piping and equipment materials shall be
carefully checked and the testing media and conditions determined accordingly to eliminate
the possible fracture failure during testing.

4.10.7 Pneumatic Test

4.10.7.1 Adequate precautions shall be taken to protect personnel from the explosive nature of
any failure.

4.10.7.2 The area around the system shall be cleared of all unauthorized personnel prior to the
test and warning notices posted. No personnel shall approach the system during the test until
the pressure has been reduced to design pressure.

4.10.7.3 Flanged joints shall be taped and a small hole made in top of tape to enable small
leaks to be more easily detected.

4.10.7.4 Preliminary air test to 1.7 bar g shall be made to check for major leaks before full
pneumatic test (by observing the pressure gauge for pressure loss).

4.10.7.5 The pressure in the system shall be gradually increased in uniform steps, holding the
pressure steady between steps to allow the system to equalize strain and to check for leaks (by
observing the pressure gauge for pressure loss) until the specified test pressure is reached. The
rate of pressurization shall not exceed 1.7 bar per minute.

4.10.7.6 The system shall be held at the test pressure for a minimum of 10 minutes without
loss of pressure (as evidenced by the pressure gauge on the system).

4.10.7.7 The system shall then be depressurized to the Design Pressure as specified on the
Line Schedule, using the vent valve at the compressor, and the system examined for minor
leaks. Examination of the system under pressure shall be undertaken with due care to prevent
injury to personnel.

4.10.7.8 Joints shall be examined by applying soap solution completely around and observe
leaks, except flanged joints, refer paragraph 4.10.7 (3). Extreme care shall be taken with
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instrument air lines where small leakages can result in overload of air dryers and compressors,
etc.

4.10.7.9 Only proper bubble solution shall be used to aid in the detection of leaks, household
soap or detergents are not allowable substitutes.

4.10.7.10 On completion of pneumatic testing, rectification and retest of all defective joints,
see paragraph 4.10.6,(7), the system shall be depressurized and all components removed for
the test (if any) and replaced. Joints made when connecting these components shall be leak
tested as part of the Commissioning Procedure. Ensure all vents and drains permanently
installed on system are closed.

4.10.7.11 If the line is to be filled with inert gas and/or be held with a slight positive pressure,
this shall be stated on the Line Schedule.

4.10.7.12 Each test system shall be kept as small as practicable.

4.10.7.13 Minimum permissible temperatures of the piping and equipment materials shall be
carefully checked and the testing media and conditions determined according to eliminate the
possible little fracture failure during testing.

4.10.8 Test Procedure for Pneumatic Testing

4.10.8.1 Pneumatic testing involves the hazard due to possible release of energy stored in
compressed gas. Therefore, the following particular care should be taken to minimize the
chance of failure during testing.

a. The pressure is increased gradually in steps providing sufficient time to allow the
piping to equalize strains during test.
b. A preliminary check is made to the joints, including welds, at the pressure of not more
than 1.7 bar g, and then, an additional preliminary check at each step increasing the
pressure mentioned below is carried out.
4.10.8.2 Where the test pressure is 14 bar g and under, the pressure shall be increased
gradually at the following steps:

The pressure of each step shall be maintain at least 10 minutes prior to increasing the pressure,
and during this time pressure loss shall be checked observing the pressure gauge.

a. 1st Step:1.7 bar g.

b. 2nd Step:A 50% of the required pressure.
c. 3rd Step:a 10% each of the required pressure is applied up to the final pressure.
4.10.8.3 Where the test pressure exceeds 14 bar g, the pressure shall be increased gradually at
the following steps:

The pressure of each step shall be maintained at least 10 minutes prior to increasing the
pressure, and during this time pressure loss shall be checked observing the pressure gauge.
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a. 1st Step:1.7 bar g

b. 2nd Step:7 bar g
c. 3rd Step:a 50% of the required pressure
d. 4th Step:A 10% each of the required pressure is applied up to the final pressure.
4.10.8.4 The test pressure shall be maintained for at least 10 minutes. It shall then be reduced
to the design pressure prior to starting inspection, and enough to permit complete inspection of
all flanged joints and weld seams under test. No leakages shall be permitted.

4.10.9 Underground Pressure Systems

4.10.9.1 Underground pressure systems, such as firewater, cooling water and closed process
systems shall have all joints exposed until a pressure test had been completed and accepted in
accordance with the applicable section in this specification.

4.10.9.2 To expedite construction, the underground portions of these lines may be backfilled
prior to testing, however 24 hours recorded test will be required.

4.10.10 Piping System Cleaning or Flushing

4.10.10.1 After pressure test, piping system shall be checked visually as follows: Whether all
lines are thoroughly cleared of loose scale and debris by use of air, water, hammering or
combinations.

4.10.10.2 Special cleaning by chemical or mechanical means, when required for compressor
suction and interstage piping or lube and seal oil piping etc., shall be inspected in accordance
with the individual procedure / specifications.

4.10.10.3 Flushing is not to be carried out through machinery or any other equipment which
may be damaged by flushing. Control valves and soft seated valves should be removed during
the flushing and testing operation, but where this is not possible, the internal fittings are to be
removed. Components such as sight glasses, internal floats, flexible hoses, orifice plates, flow
nozzles, pressure relieving devices, expansion bellows, permanent filters and strainer
elements, etc. are to be removed during flushing and testing.

To avoid straining the piping while these items are removed, temporary spacers or spool
pieces should be fitted.

4.10.11 Pressure Test Dossiers

4.10.11.1 A pressure test dossier shall be completed for each piping system tested and shall
contain the following information:

a. Inspection and test report

b. Copy of the Line Schedule associated with the system tested.

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c. Systems pressure test sketch or relevant sections of P&IDs identifying the system
tested.
4.10.11.2 Inspection and test reports shall be numbered sequentially.

4.11 Inspection of Insulation

Insulation inspection shall be performed in accordance with ‘Inspection Procedure for
Insulation’.

4.12 Testing (Bench Test) of Relief Valves

All relief valves shall be bench tested (popping and tightness test) prior to the final installation
as follows:

a. Relief valves shall be set on the test bench. The test bench shall be available with
compressed medium, as well as calibration gauges for the test.
b. The test pressure shall be the cold set differential pressure, stamped on the name plate,
at approximately atmospheric temperature.
c. The value shall be adjusted, if necessary, until it relieves at least two consecutive times
at the test relieving pressure as indicated by the gauge on the test bench with tolerance of
plus or minus 1%.
5. QC Dossier
5.1 After final inspection, all test records and check sheet for test and inspection shall be
issued in the form of QC Dossier.

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