FARABI YANBU PETROCHEMICALS COMPANY, LTD YANBU, KINGDOM OF SAUDI ARABIA

LAB#4 PROJECT
Doc HYDROTEST PROCEDURE
FYPC Doc 22098-0300-2999-PP-0040-0001
Rev.03
Sub-Contractor Doc No.

CONTENTS

1. PURPOSE .......................................................................................................................... 2

2. SCOPE ............................................................................................................................... 2

3. DEFINITION ....................................................................................................................... 2

4. REFERENCES ................................................................................................................... 3

5. RESPONSIBILITY .............................................................................................................. 3

6. GENERAL REQUIREMENTS: ............................................................................................ 4

7. PRESSURE TESTING OF PIPING ..................................................................................... 5

8. PREPARATION OF TEST PACKAGE: ............................................................................... 7

9. HYDRO TESTING PROCEDURE ..................................................................................... 11

10. PNEUMATIC TEST........................................................................................................... 13

11. GRAVITY TEST ................................................................................................................ 15

12. BOLT TORQUE FOR FLANGED JOINTS ........................................................................ 16

13. ATTACHMENTS .................................................................. Error! Bookmark not defined.

 FARABI YANBU PETROCHEMICALS COMPANY, LTD YANBU, KINGDOM OF SAUDI ARABIA
LAB#4 PROJECT
Doc HYDROTEST PROCEDURE
FYPC Doc 22098-0300-2999-PP-0040-0001
Rev.03
Sub-Contractor Doc No.

1. PURPOSE

The purpose of this procedure is to ensure the pressure retaining properties of Shop and
field fabricated piping systems, which are designed and constructed in accordance with
ASME B31.3 or B31.9 and as applicable construction code.

2. SCOPE

This procedure defines mandatory general requirements for the hydrostatic testing of
pressure piping which is construction for Wison/Farabi Lab # 04 Project. This procedure
shall be in compliance with ANSI / ASME B31.3 Process Piping.

3. DEFINITION

 COMPANY: Farabi Yanbu Petrochemicals company

 CONTRACTOR: WISON Engineering Co. Ltd
 PMT: Project Management Team
 QA/QC: Quality Assurance / Quality Control
 NCR: Non-Conformance Report
 PPE: Personal Protective Equipment
 RFI: Request for Inspection
 MSDS: Material Safety Data Sheet
 NDE: Non-destructive examination
 HSE: Health, Safety and Environment
 Hydrostatic Test: A pressure test conducted using water or other approved as the test
medium
 Pneumatic Test: A pressure test conducted air or other approved gas as the
 test medium or in conjunction with liquid
 Pressure Test: A test conducted to piping or equipment by subjecting it to an
 internal using liquid or gas to ensure strength or tightness of system at the test pressure
 Service Test: This is a test conducted using the service fluid as the test fluid.
 Visual Test: Piping such as drains, vents and piping downstream of pressure relieving
devices that discharge directly to the atmosphere are exempt from pressure testing
unless the line has a listed design pressure in excess of 100 kPa or by CLIENT approval.
However, atmospheric lines shall be carried out visual inspection.
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LAB#4 PROJECT
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4. REFERENCES

 Project Specifications
 IFC Drawings
 Pressure Relief Valve, Routine Test and Inspection.
 ASME B31.3 Process Piping
 ASME B31.9 Building Services Piping
 ASME B16.5 Pipe Flanges and Flanged Fittings
 8-12-5 Standard Specification for fabrication of Piping
 8-11-8 Standard Specification of piping
 F2164-Standard Practice for Field Leak Testing of Polyethylene (PE) Pressure Piping
Systems Using Hydrostatic Pressure
 F2620 - Standard Practice for Heat Fusion Joining of Polyethylene Pipe and Fittings

5. RESPONSIBILITY
5.1 Construction Manager
The Construction manager responsible for execution of all site activities to this procedure.
Ensure that all construction activities area carried out as per approved ITP and Method
statement. All construction activities carried out as per latest revision drawings.
5.2 Piping Superintendent/Supervisor/Foreman
Ensure compliance by all discipline foremen regarding the works to be undertaken. Ensure
compliance by all foremen and workers to the Customer Specification, Project QA Manual
and Quality Control Inspection Plan. Provide the site QC Section with relevant inspection
requests with sufficient notice to enable stage inspections to be completed in an expedient
manner.
5.3 QA/QC Manager
The QA/QC manager will be responsible for the Quality control functions/activities of the
project, including Quality control inspection schedules and the collection of Quality records
and supports the Construction manager in dealing with the Company for all the Quality
matters. Coordinates with the Project Quality engineer to analyses of non-conformities.

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5.4 QC Engineer
The QC Engineer will be responsible for the necessary and inspection to be carried out for
all the activities involved in the hydro testing of the above ground piping as per the Inspection
plan.
5.5 QC Inspector
The piping inspector will make sure that the document involves in the test packages is ready
as per the specification. He should raise request for inspection (RFI) at appropriate stages
of the work as detailed in the ITP. The piping inspector should
5.6 Safety Manager/ Supervisor
Safety manager/supervisor will make sure that all the safety requirements are fulfilled prior
to start and during the job. Job safety analysis/safety task assignment will be strictly
implemented.

6. GENERAL REQUIREMENTS:

6.1 Construction shall prepare the test packages as per the package list and submit to client
Inspection department for approval prior to hydro test.

6.2 The requirements of this standard apply to field/shop fabricated piping systems. The test
pressure shall be in accordance with minimum requirements of ASME B31.3 or B31.9 as
applicable. All newly constructed plant piping, and prior to initial operation unless
exempted by this standard, shall be subjected to a hydrostatic leak test in accordance with
the requirements of this standard and the appropriate ASME B31 code.

6.3 All NDE shall be completed and accepted before conducting pressure test

6.4 No piping is allowed to be repaired or modified after hydrotest unless approved by Client

6.5 For the following activities, re-testing is not required. Seal welds of threaded connections,
PENETRATION TEST need to be applied after seal welding

6.6 All system undergoing pressure test is being performed shall be protected from over-
pressurization. The manifold shall have the over-pressure protection by safety relief valve

6.7 All “A”-punch items shall be cleared prior to pressure test.

6.8 When valves are used for blocking or isolating pressure test sections, the differential
pressure across the valve seat shall not exceed the seat test pressure, as specified by the
manufacturer. It is not allowed that the test pressure exceeds the rated seat test pressure.
Or, in the case of line valve whose seal design pressure is less than the line design
pressure shall be removed from the line before testing and a dummy pipe-piece is placed
instead.

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6.9 Work Flow

First lay-up will be conducted by the test package wise as the construction work
after the pressure test and reinstatement.

WATER FILLING

PRESSURE TEST

De-WATERING

AIRBLOWING

RE-INSTATEMENT

7. PRESSURE TESTING OF PIPING

7.1 TEST PRESSURE:

The test pressure used for piping subjected to internal pressure shall be as follows

7.1.1 The test pressure shall be calculated in accordance with the requirement of ASME B31.3
and the isometric description as per line class

7.1.2 Minimum hydrostatic test pressure shall not be less than 1.5 times the design pressure for
metallic piping, except for vacuum service line and non-pressure line. HDPE test pressure
shall follow line class requirements

7.1.3 It should also identify the pressure rating of PRV’s and shall be 5% above the maximum
test pressure

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

7.1.5 Pressure Gauges shall be used calibrated with 30 Days

7.1.6 A minimum of two (2) pressure gauges shall be used, on large system inspection will
determine the need for extra gauge

7.2 MANIFOLD

Before employing the pressure testing manifold in the actual system pressure test, it
shall be separately pressure tested to at least 1.2 times the system test pressure and
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LAB#4 PROJECT
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Sub-Contractor Doc No.

not less than the discharge pressure of the pump used for the pressure testing.
Following are important requirements shall be followed prior to use testing manifold

7.2.1 Calibrated Manifold within one-year validity shall be used

7.2.2 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.

7.2.3 Manifold/piping and the piping/equipment under pressure test shall be closed and the
test pump disconnected. The isolation valve downstream of the manifold shall be opened
after the pump is disconnected.
7.2.4 Hydro test Arrangement and Manifold Diagram

7.2.5 Test Diagrams

Hydrostatic test diagrams and test procedures shall be prepared by the construction and
made available to the Wison/Farabi Inspection prior to conducting the test. The test
diagrams and procedures shall include the limits of piping included in each hydrostatic
test, test pressures, test temperature, test fluid, line flushing requirements, and safety
precautions.

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7.3 Test pressure holding time

7.3.1 Unless otherwise specified, the test pressure shall be maintained for 30 Minutes for
metallic piping, one hour for HDPE Piping. The pressure then shall be returned to the
design pressure for a sufficient time to determine that there are no leaks, test duration
shall be extended for large lines upon client request

7.4 Exposed Joints

7.4.1 All joints including welds shall be left un-coated, un-insulated and exposed for visual leak
detection during the test. Coating and priming of these joints are not allowed unless
approved by Wison/Farabi.

7.4.2 If UG line joints are not exposed, holding time shall be 24 hours and test pressure shall
be monitored using recorder

7.5 Protection from Over Pressure

7.5.1 All piping systems while being hydrostatic tested shall be protected from over pressure
by the following
7.5.2 A relief valve of adequate capacity set to relieve at 5 percent above the test pressure
shall be installed. Sizing of these relief valves used for testing shall follow the
requirements of API RP 520, Part 1.
7.5.3 Manual Valve: In addition to the pressure relieving device, a bleed valve shall be
provided to protect the piping and equipment from overpressure. The bleed valve shall
be readily accessible in case immediate depressurization is required.
7.5.4 Isolation Valve: 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.

8. PREPARATION OF TEST PACKAGE:

8.1 FLOW OF TEST PACKAGE:

8.1.1 Once fabricated and erection of a loop is ready for pressure test, Construction will
prepare a marked up of P&ID indicating the test limits. From the marked-up P&ID,
Construction will divide the piping in to suitable Test Packs. the Pressure Test Packages
shall be prepared with required formats and documents. QA/QC contractor shall review
all the requirements for inspection to meet the specifications.
8.1.2 Line check shall be finally conducted by piping supervisor, piping field engineering and
QC to verify that the relevant pipe work has been completed in full compliance with the
requirements specified in the latest P&ID diagram and isometric drawing before the
schedule of testing
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8.1.3 A test package shall be considered ready for testing only when approval is obtained
from Contractor/PMT

8.2 Preparation of Hydro test

8.2.1 An approved test procedure shall be available at the site prior to commencing any
pressure testing activities

8.2.2 QC shall raise an RFI for the joint inspection and walk through of the lines with PMT prior
to the approval for pressure testing

8.2.3 Prepare the records for all fabrication, erection, inspection, NDE and PWHT (when
required) for each test packages. Check for the completion of the above activities on the
lines to be pressure tested

8.2.4 New piping systems shall be flushed clean of loose scale and debris or scraped prior to
commencement of pressure testing. Care shall be exercised to ensure all pipe spools
are internally clean before installation

8.2.5 Soft seated valves and control valves shall not be installed until after the lines have been
thoroughly flushed.

8.2.6 Components which interfere with filling, venting, draining or flushing shall not be installed
until after line flushing and pressure testing are completed. The Void may be created
due to the removal of these components from the line during testing/flushing activities
shall be suitably filled with temporary spool(s).

8.2.7 The approved/calibrated pressure test manifold shall be connected to the line.

8.2.8 Pressure gauges and pressure recorders shall be calibrated before the tests.

8.2.9 The calibration interval shall not exceed one (1) month. 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.

8.2.10 Relief valve of adequate capacity set to relieve at 5% above the test pressure shall be
installed

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

8.2.12 A minimum of two pressure gauges are required for the test system. One pressure gauge
shall be on the test pump and the other(s) on the test system. Their accuracy shall be
within 5 percent of one another

8.2.13 When large systems are tested, Inspection personnel shall determine the need for
additional gauges
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8.2.14 Recording gauges shall be used where it is necessary to keep a permanent record, for
example, when the test duration exceeds four hours, or otherwise as required by this
standard

8.2.15 Spring hangers or spring supports shall be locked during pressure test

8.2.16 All weld joints of the piping system to be tested shall be ensured free of rust and other
foreign matter

8.2.17 All joints shall be exposed for examination during test

8.2.18 All non-destructive testing and stress relieving shall be completed with acceptable
results before hydro testing.

8.2.19 The area around the system to be tested shall be cleared off from un authorized
personnel and warning notices posted during the piping system is under pressurized for
test.

8.3 Equipment / Components excluded from Pressure Test

8.3.1 The following list defines the equipment/piping components/Instruments excluded from
the pressure test loops

8.3.2 Rotating machinery, such as pumps, turbines and compressors Strainers and filter
elements

8.3.3 Pressure relieving devices, such as rupture discs

8.3.4 Locally mounted indicating pressure gauges, where the test pressure may exceed their
scale range, thermowell, control valves, orifice meter, flow nozzles, sight glasses,
venturis, rotameters, positive displacement meters and other in-line instruments
Equipment that cannot be drained.

8.3.5 Instrument impulse lines between the block valve at the process or utility line and the
connected instrument

8.3.6 Expansion joints shall be prevented from excessive travel or deformation under the test
loads by providing temporary restraints. The thrust forces and design test pressure shall
be checked prior to testing. Or they shall be isolated from test if specified by
Manufacturers.

8.4 Isolation of Test Sections

8.4.1 Paddle blinds or spectacle blinds shall be used to isolate the test sections. When this is
not practical, closed block valves (gate, globe, plug, ball) may be used to isolate
equipment or piping sections. Farabi approval is required when a block valve is used for
isolating test section.

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8.4.2 When a block valve is used for isolating test sections, the differential pressure across
the valve seat shall not exceed the seat test pressure during pressure testing and shall
not exceed the rated seat pressure during the leak test. both sides of this valve shall be
protected by relief valves during the test.

8.4.3 All valves, excluding those used for sectioning or blocking test, shall be in the open
position.

8.5 Temporary Connections and Supports

8.5.1 Temporary connections shall be provided for de-pressurizing and draining of the system
to the sewer or disposal area.

8.5.2 The structural support system design for stacked equipment shall be verified for
hydrostatic loads prior to testing

8.5.3 Temporary Support shall not be placed on or over any welding joints.

8.5.4 Spring hangers or spring supports shall be provided with temporary restraints where
needed or prevent excessive movements or deformation under test loads

8.5.5 Sand bag shall be provided on the HDPE pipes where ever necessary during hydro test

8.5.6 All temporary supports, spring support restraints, temporary spools, blind and plugs,
flange connections with temporary gasket and temporary vent valves, etc., shall be
flagged or used with clear color marking, like red color painting, to ensure their removal
after testing and then re-instatement to be carried out.

8.6 TEST WATER CRITERIA:

8.6.1 Fresh potable water shall be used in the hydrostatic test and suitable filter should be
provided in the filling line to the system in order to remove foreign matter such as sand,
rust and other material and the proper water analysis certificate shall be attached to the
test package.8.2 Water PH Level, do not use any water for hydrostatic test if the pH is
less than 7.

8.6.2 The sulfate reducing bacteria (SRB) counts are greater than 102 per ml unless approved
by Wison/Farabi

8.6.3 The maximum chloride content for hydrostatic test water in contact with stainless steel
shall be limited to 50 mg/L.

8.6.4 The requirement of hydro test water quality during hydro test shall be as per the
requirements from the specification

8.6.5 The quality of water shall be reconfirmed by sample testing at a maximum of three
Months before initial water filling in preparation for the hydrostatic testing

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8.7 Blind Flange Thickness calculation

9. HYDRO TESTING PROCEDURE

9.1 Filling and pressurizing

9.1.1 Filling and pressurizing shall be done on the upstream side of check valves in the
system. The test fluid shall be injected at the lowest point in the system to minimize
entrapped air. All vents shall be open during filling.

9.1.2 Filling should be done as explained by the flow diagram for filling and dewatering for
hydro test. See attached sample sketch of a typical pressure test diagram.

9.1.3 Proceed filling the unit through the normal filling connections. As the unit fills, check
periodically for leaks.

9.1.4 The availability of the standard hoses, fittings and clamps used for filling and draining of
water must be checked and designed according to the specification of the activity to
avoid unnecessary release of water that may affect nearby surroundings and can lead
to different hazards.

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9.1.5 The pressure shall be continuously maintained for a minimum time of 30 minutes holding
time to examine for leakage. Inspect all the weld joints for any possible leakage and
check the pressure gauges for any pressure drop to determine that there are no leaks.

9.1.6 Then continue the pressure build up until it reaches the required pressure in bar.
Maintained time should be as long as required to permit leakage inspection. The piping
system shall show no visual evidence of weeping or leaking. The pressure shall be under
control at all times so that the pressure is never exceeded by more than 5% of the
specified test pressure

9.1.7 Pressurize the system gradually using test pump/hand pump attached to the test
manifold onwards to Pipe.

9.1.8 Pressure reading during the test will be taken from the pressure gauge at the highest
point of location

9.1.9 After the test pressure is reached and before commencement of inspection of the
system, the isolation valve between the temporary test manifold and the piping under
pressure test shall be closed and the test pump disconnected.

9.1.10 Unless otherwise specified, the test pressure shall be maintained for 30 minutes. The
pressure then shall be returned to the design pressure for a sufficient time to determine
that there are no leaks

9.2 Repairs After Leak Testing

If leaks are found, their location shall be marked, the pressure shall be gradually
released, and the piping shall be drained or vented. Appropriate repair or replacement
shall be made. The affected piping shall be re-tested at the pressures originally specified
for the test. Retesting shall not be waived for minor repair/addition. If leak occurs it will
be retested, provided approval of the CONTRACTOR/PMT is obtained. Replace
disturbed bolts and gaskets are necessary. Remove and disposed of all non-salvageable
materials from the work site.

9.3 Depressurization of Test Pressure

9.3.1 Upon completion of the test, it will be necessary to release the pressure at the rate of 2-
3Bar /minute. When valves are in tandem (double valve), test pressure should be
released at a moderate rate with the second valve, while the first valve is wide open.
This is to prevent the valve seat of the pressure side valve from being damaged.

9.3.2 All test vents shall be opened before draining to facilitate draining and to prevent
formation of a vacuum

9.3.3 draining of tested water shall be not allowed to release to ditches /trenches. Hydro test
water disposal shall be as per FYPC safety approved procedure
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9.4 Draining of Test Fluid

9.4.1 Release of pressure and draining shall be done on the downstream side of check valves.
All vents shall be opened before draining to facilitate drainage and to prevent formation
of a vacuum. No test fluid shall remain in low spots. The test system shall be thoroughly
blown out to ensure that all residual fluid is removed from the piping.

9.4.2 Vents and drains used only for the pressure test shall be plugged and seal welded after
completion of test

9.4.3 Removal and Reconnection of Components

9.4.4 All temporary items installed for testing purposes (for example, manifolds, valves, blind,
spacers and supports) shall be removed.

9.4.5 After removal of all visible water, close the system to prevent the entry of sand or rain
water.

9.5 Cleaning

9.5.1 Tested piping shall be internally cleaned to remove all remaining dust and foreign matter
by water flushing or blowing with air

9.5.2 Flushing shall be done with clean water using hydrostatic test water where possible.

10. PNEUMATIC TEST

10.1 Test Pressure

pneumatic test shall be not carried out without prior approval from FYPC

As a rule, the test pressure shall be 1.1 times the design pressure.

10.2 Test Boundaries

Close control shall be maintained to limit the stored energy (PV) and the reaction force
(PA) of gas in any single test system. The stored energy level shall be determined by
multiplying the pneumatic test pressure, in kPa, by the volume, in cube meters, of the
proposed test system. The reaction force shall be determined by multiplying the
pneumatic test pressure, in kPa, by the largest cross-sectional area, in square meters,
in the proposed test system. The maximum energy level recommended is 12500 or
maximum reaction force recommended is 2500

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10.3 Test Media

Use utility air, instrument air or nitrogen for all systems requiring a pneumatic test when
indicated. Air source shall be dry, dust and oil free, if system is small, cylinder bank may
be used instead of compressor

10.4 Holding time

After holding the test pressure for 30 minutes, the test pressure shall be reduced to
design pressure and held for a sufficient time to permit an inspection for leaks of all
piping welds and connections.

10.5 Protection from overpressure

A relief valve of adequate capacity shall be set to relieve at 5 percent above the test
pressure. The relief valve shall be tested, the calibration interval shall not exceed one
week (07) days prior to the test date and calibration certificates shall be made
available to Inspection personnel

10.6 Test Procedure

10.6.1 Low Pressure Test

Pneumatic test shall be carefully supervised. When the test pressure is 150 kPa, or less,
the initial pressure may be raised directly to the test pressure.

10.6.2 High Pressure Test

When the test pressure is above 150 kPa, the system shall be initially pressured to 150
kPa. All welds and connections shall be inspected for leakage by applying a leak
detection solution to all of the joints and check the bubbles by visual. In case of leakage
is observed, the position of the leak joints shall be marked. The system will be
depressurized gradually and leaks repaired as required by referencing code section. The
pressure shall be then increased gradually to 50 percent of the test pressure. This
pressure shall be maintained at least 10 minutes. The pressure shall be further increased
in steps of approximately 10 percent of the test pressure until the required test pressure
has been reached.

10.6.3 Precautions

Degree of Test, Pressurizing lines and equipment for tests may be done during normal
working hours to the extent allowed as follows. All pneumatic pressure tests in excess
of the following conditions shall be performed outside of normal working hours.
No Area Isolation. Pneumatic tests at less than 350 kPa may be performed for all pipe
sizes during normal working hours without isolating the area involved.
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Medium Size Testing. Pneumatic tests up to 700 kPa may be performed during normal
working hours without isolating the area involved, provided no piping in the system under
test is larger than NPS 12 inch.
Isolation Required. System containing piping larger than NPS 12 may be pressured up
to 350~700 kPa, but not over one-half the final test pressure, for preliminary
Examination and leak testing. The final pneumatic tests will be performed outside
normal working shift.

10.7 Pneumatic test for reinforcement pads and sleeve

Test pressure shall be gradually raised up to 25 psi, and thereafter hold for 5 minutes to
verify for the leaks with soap solution, and if there is no leak detected, then the pressure
can gradually bring down to 5-10 psi and observe for 30 minutes for pressure drops
10.8 Vendor Recommendation (if applicable)

Vendor’s recommendation for pneumatic test procedure shall be followed.

11. GRAVITY TEST

Ensure that the Gravity Leak Test of pipes is executed and that quality assurance and
quality control activities are conducted in a systematic manner.

 Put Safety Sign boards

 Prepare all the materials and tools needed
 Identify area or section to be tested.
 Provide one inlet pipe that is above at least 200mm from line header. Make sure that all
other openings are plugged.
 Proceed to Gravity Test
 Slowly filled the system with water until it reaches the opening of the inlet pipe
 Mark the level of the water & necessary tagging
 Check all joints & pipe run for possible leaks, repair if necessary.
 During the test, strutting precautions should be taken to prevent any movement on the
drainage pipe
 Leave the test for at least 24 hrs.
 The successful test must be witnessed by Wison/Farabi and let it be documented
 Release water & temporary seal the pipe opening to avoid ingress or debris

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 Close the permit

12. BOLT TORQUE FOR FLANGED JOINTS

The bolt torqueing shall be performed in accordance with project specifications

(Refer to Bolt Torque Procedure for detail

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 FARABI YANBU PETROCHEMICALS COMPANY, LTD YANBU, KINGDOM OF SAUDI ARABIA
LAB#4 PROJECT
Doc HYDROTEST PROCEDURE
FYPC Doc 22098-0300-2999-PP-0040-0001
Rev.03
Sub-Contractor Doc No.