Professional Documents
Culture Documents
Piping Engineering
Inspection
TESTING TOOL & EQUIPMENT
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345.TESTING
345.1 REQUIRED LEAK TEST
Prior to initial operation, and after completion of the
applicable examination required by para 341,
Each piping system shall be tested to ensure the
tightness.
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1) A hydrostatic test would damage linings or internal
insulation, or contaminet a process which would be
hazardous, corrosive, or inoperative in the presence
of mouisture, or would present the danger of brittle
fracture due to low metal temperature during the
test.
2) A pneumatic test would present an undue hazard of
possible release of energy stored in the system, or
would present the danger of brittle fracture due to
low metal temperature during the test.
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345.2 General requirement for
leak test
Requirements in para 345.2 aplly to more than
one type of leak test.
345.2.1 Limitations on pressure.
a) Stress Exceeding Yield Strength. If the test
pressure would produce a nominal pressure stress
or longitudinal stress in excess of yield strength at
test temperature, the test pressure may be reduced
to the maximum pressure that will not exceed the
yield strength at test temperature.
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b) Test Fluid Expansion. If a pressure test is to be
maintained for a period of time and the test fluid in
the system is subject to thermal expansion,
precautions shall be taken to avoid excessive
pressure.
c) Preliminary Pneumatic Test. A preliminary test
using air at no more than 170 kPa (25psi) gage
pressure may be made prior to hydrostatic testing
to locate major leaks.
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345.2.2 Other Test Requirements
Examination For Leaks. A leak test shall be
maintained for at least 10 min, and all joints and
connections shall be examined for leaks.
Heat Treatment. Leak test shall be conducted
after any heat treatment has been completed.
Low Test Temperature. The possibility of brittle
fracture shall be considered when conducting leak
test at metal temperatures near the ductile-brittle
transition temperature.
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345.2.3 Special Provision for Testing
Piping Subassemblies. Piping subassemblies may be
tested either separately or as assembled piping.
Flanged Joints. A flanged joint which a blank is
inserted to isolate other equipment during a test need
not be tested.
Closure Welds. The final weld connecting piping
systems or components which have been successfully
tested in accordance with para 345 need not be leak
tested provided the weld is examined in-process in
accordance with para 344.7 and passes with 100%
radiographic examination in accordance with para
344.5 or 100% ultrasonic examination in accordance
with para 344.6
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345.2.4 Externally Pressured Piping
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345.2.5 Jacketed Piping
The internal line shall be leak tested on the basic
of the internal or external design pressure,
whichever is critical. This test must be performed
before the jacket is completed if it necessary to
provide visual access to joints of the internal line
as required by para 345.3.1
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345.2.6 Repairs or Additions after
Leak Testing
Repairs or additions are made following the leak test, the
affected piping shall be retested, except that for minor
repairs or additions the owner may waive retest
requirements when precautionary measures are taken to
assure sound construction.
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345.2.7 Test Records
Records shall be made of each piping system during the
testing, including
a) Date of test
b) identification of piping system tested
c) test fluid
d) test pressure
e) certification of results by examiner
These records need not be retained after completion of
the test if a certification by the inspector that the piping
has satisfactorily passed pressure testing as required by
this code is retained.
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345.3 PREPARATION for LEAK TEST
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345.3.3 Piping With Expansion Joints.
a) An expansion joint that depends on eternal main
anchors to restrain pressure end load shall be tested
in place in the piping system.
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c) A piping system contain expansion joints shall be leak
tested without temporary joint or anchor restraint at
the lesser of
1) 150% of design pressure for a bellows-type
expansion joint, or
2) the system test pressure determined in accordance
with para 345
In no case shall a bellows-type expansion joint be
subjected to a test pressure greater that the
manufacturers test pressure.
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d) When a system leak test at a pressure greater than
the minimum test pressure specified in ( c )
Or greater than 150% of the design pressure within
the limitations of para 345.2.1 (a) I required,
bellows-type expansion joints shall be removed
from the piping system or temporary restraints shall
be added to limit main anchor loads if necessary.
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345.3.4 Limits of Tested Piping
Equipment which is not to be tested shall be
either disconnected from the piping or isolated
by blinds or other means during the test .
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TEST PACKAGE
Definition of TEST PACKAGE
A package shall be compiled for each pressure test to be
carried out and shall contain all relevant information
regarding that test. Each test pack shall be allocated a
unique number identifying the pack and test.
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Informasi dalam Test Package
1. Test Package Number
2. Area Location
3. Sub system number
4. Hydro Test Engineer
5. Test Pressure
6. Test Medium
7. Isometric Dwg Number
8. Activity record ( with Date & Signature )
9. Material List Required
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Activity yg di Record dalam TP :
1.TP issue for Approval
2.Approval
3.Punch List A Closed
4.NDT Clear
5.Flushed
6.Testing Preparation
7.Tested
8.Drying
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9. Remove Temporary
10.Reinstatement
11.Torqing
12.Accepted
13.Hand Over to Commisioning
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Example of Test Package
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Line List for TP 31-PG-20-01-001
LINE NUMBER LOCATION
SYSTEM NUMBER
IDENTIFICATION
PIPING CLASS
INSULATION
SEQUENCE
THICKNESS
NPS (INCH)
P&ID NUMBER
SERVICE
NUMBER
TYPE
FROM
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40
Test Limit
Test Limit
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TP : PG-31-20-01-001 (BR) Under Construction
– Piping Installation at Bridge Area
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24” Pipe Fit Up on Going
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24” Pipe on the Ground Fit Up & Welding in Progress
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Description
PUNCHLIST A
Punch list items shall be completed prior to testing.
Piping routing and inline apparatus are installed
completely.
Welding joint on pipe, support that welded to pipe
or fitting.
Bolting joint that is included for test as per
engineering requirement, such as inline valve,
flange to flange connection, and flange to nozzle
connection.
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Description
PUNCHLIST B
Punch list items shall be completed prior to
commissioning including installation of instrument
and electrical items, but exclude insulation and heat
tracing.
All bolting joint shall be torque and tensioned
complete with certification.
All supports are in position as mention on detail
drawing.
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TESTING TOOLS & EQUIPMENTS
1) Pressure and Temperature Recorder
2) Pressure gauge
3) Pressure safety valve
4) Needle valve
5) Test Isolator
6) Pressure manifold
7) Water tank and compressed air vessel
8) Temporary Spool and Support
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9) Filling / injection point
10) Baroscopic
11) Testing pump
12) Flushing blinds
13) Foam Pig
14) Gauging plate
15) Operational Pig
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TESTING TOOLS & EQUIPMENTS
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2) Pressure gauge
Pressure gauge measures the pressure in the
point where pressure gauge is placed and
connected to the system by block and bleed
valve. The measured pressure shall lie on range
20-80% of pressure gauge capacity.
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As a measurement device, pressure gauge must be
calibrated and certified in agreed frequency as per
project specification. (No exact period for
calibration found in ASME standard).
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During testing, the pressure should be equal in
whole point of testing circuit. Therefore, at least
two pressure gauges are required for testing. One
pressure gauge is installed in the test piping such
that it can be easy read by pump operator, and
another is on the system under test. When we test
small circuit line(less than 1 meter of small bore) or
the testing circuit is not accessible to install more
than 1 pressure gauge, and approved by Client
representative, we can use only 1 pressure
recorder. Using 2 pressure gauges in different level
will tells the different pressure in bottom and top
point, when it is different it indicates any leak
occurs that causes pressure drop.
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Example:
Pressure Gauge, Oil Filled, SS, 0 -1000 psi BuTech 1/2" NPT
Pressure Gauge, Oil Filled, SS, 0 -2000 psi BuTech 1/2" NPT
Pressure Gauge, Oil Filled, SS, 0 -3000 psi BuTech 1/2" NPT
Pressure Gauge, Oil Filled, SS, 0 -5000 psi BuTech 1/2" NPT
Pressure Gauge, Oil Filled, SS, 0 -7500 psi BuTech 1/2" NPT
Pressure Gauge, Oil Filled, SS, 0 -10000 psi BuTech 1/2" NPT
Pressure Gauge, Oil Filled, SS, 0 -20000 psi BuTech 1/2" NPT
Notes:
Oil filled is medium inside of pressure gauge to transmit test
pressure to be shown on glass indicator.
SS is stainless steel as material of pressure gauge.
0-1000 psi and so on, is testing pressure range.
Butech is manufacture name.
1/2” NPT is size and type of connection to other device.
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3) Pressure safety valve
Pressure safety valve is to prevent over pressure
during testing to avoid plastic deformation of
piping material
Prior to testing, the valve shall be calibrated and
set up in 10% above test pressure or 90% of
maximum allowable stress retained by piping
material, and we use which is the lesser. The
appropriate certificate shall be attached on test
pack for documentation. Pressure safety valves
are installed near the pump operator and on
system under test.
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Example:
1/2" Pressure Relief Valve 0- 5000 psi (CROSBY,
SERIES 900 OMNI TRIM), NPT inlet
1/2" Pr. Relief Valve 5000-10000 psi with 200 psi
increment CROSBY MAKE
1/2" Pr. Relief Valve 10000-20000 psi with 500 psi
increment CROSBY MAKE
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4) Needle valve
Needle valve is required for:
– Isolation of the tested circuit including test
manifold to testing pump.
– Connection of pressure/temperature recorder
to test circuit.
– Drying and venting prior and after testing.
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Example of needle valve description:
– 1/2" needle valves minimum 15000 psi rated
inlet/outlet port 1/2" NPT thread Male or female
thread as we will adapt to suit on site.
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5) Test Isolator
If the line is subjected to pressure test, than we
need to install test isolator complete with torque
(if required) follows P&IDs and isometric
drawings
Type of isolator available for testing purpose:
- Blind Flange, Blind Spade and Spectacle Blind
- Valve
- Plug and Cap
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Cap, Blind Flange and Needle Valve
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– Blind Flange, Blind Spade and Spectacle Blind
Blind flange, hub and spectacle are installed on flange
joint. When the end of testing circuits is bevel end pipe,
than we need to install temporary cap or weld
flange/hub complete with blind flange/hub. On blind
flange and hub we can put vent and drain point that
required during testing.
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Valve for Test Break in Test Boundary
Ball valve or globe valve can be used as a test break
unless otherwise approved by Client. Type of valve
can be used as test break is ball valve and globe
valve.
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Plug and Cap
For threaded end connection we can isolate piping
line by using threaded plug or threaded cap. Class
of hydro testing plug
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6) Pressure manifold
– Pressure manifold is required to distribute test
medium into several point such as piping line,
pressure gauge, pressure recorder, safety
valve and pump or compressor.
– Type of precision pressure manifold
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7) Water tank and compressed air
vessel
Water tank and compressed air vessel are required to
keep the test medium. These equipments are
connected to water pump or air compressor to
convey the test medium onto test circuit.
8) Temporary Spool and Support
All temporary items are used for testing as mention
and described by testing engineer, or client deems
additional support necessary. After testing, all
temporary appurtenances shall be removed.
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9) Filling / injection point
Filling / injection point of test medium consist of
pump/compressor, hosing line, blind flange
complete with drilled and tapped for hose
connection.
Drilled blind flange is installed to the tested piping
flange. The drilled and tapped is appropriate with
hose size for properly connection.
The hosing is used to transfer testing medium
that injected by pump or compressor from
medium storage.
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Example of hosing:
– ½" flexible rubber hoses, 4 meters long with
swivel ends, ½" BSP Max. Working pressure -
20000 Psi
– Crow foot connections (male & female)
(Otherwise known as quick lock coupling)
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10) Baroscopic
Baroscopic used to inspect inside of piping line.
This equipment consists of mini camera, optic
cable, reader monitor, tools to drive direction of
baroscopic
Using this tool, client can inspect and accept
inside condition of piping line. While not
accepted, flushing can be conducted to clear
debris and rusty inside of pipe.
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11) Testing pump
Testing pump is required during filling and
pressurizing piping line. During holding time, pump
connection shall be isolated from testing circuit.
Practically we isolate it on test manifold.
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Recommended testing pumps are air driven pump
and hand operated pump. The advantages are:
Ability to install at any predetermined
pressure and holds this fixed pressure without
consuming fuel or electrical power.
No heat, flame or spark risk.
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Example:
– Tangy hand operated hydro test pump, output
pressure 1200 Bar G.
– Blagdon B 50, pump stainless steel with 2"
fitted cam locks stainless ends (AIR).
– Hi force hydro testing pump model AHP275
– HL 125M pump unit fitted with VM 7061E2
diesel engine with complete maintenance
schedule, spare list and manual
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12) Flushing blinds
– Flushing blinds are installed on tip of piping
line for flushing purpose. The flushed water
will flow out through the drain point that
attached in flushing blind.
– Flushing blind is designed for flushing only that
works in low pressure, and it is not
recommended to be testing blind during
pressure testing.
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13) Foam pig
Foam pig is used to clean inside of pipe and
remove air trap in a pocket line
The foam pig size suits with inner diameter of
pipe work will be pushed by testing medium
from inlet until outlet point prior to line
pressurization. Foam pig come out through
outlet point together with trapped air and scale
from inside of pipe.
Example:
Foam pigs to suit 1" NB pipe work
Foam pigs to suit 1½ " NB pipe work
Foam pigs to suit 6" NB pipe work
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14) Gauging plate
Gauging plate is used for gauging pigging test
to check the line protrusion of piping line.
Gauging pigging applicable for pipe line service
to check the line protrusion of the line
including 5D or 3D elbows, valves, and other
components
Gauge plate made of aluminum plate with the
diameter is 95% of ID subjected pipe.
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15) Operational Pig
Pig made off rubber to clean piping line from
mud and other unexpected objects.
Operational pig diameter is 1.05 inner
diameter of pipe. During pigging, a guide plate
required with size 0.95 inner diameter of
subjected pipe.
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TESTING PARAMETER
1) Design & Test Pressure
2) Design & Test temperature
3) Test Medium
4) Test Duration
5) Flushing Medium & Pressure
6) Testing Method
7) Piping Line and Material for Testing
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1) Design & Test Pressure
Design pressure is higher than pressure which
occurs in the most severe condition
Design pressure is used to define the minimum
thickness of piping component.
Design pressure is indicated on line list as the
worst severe pressure occurs in piping system.
Design pressure is prepared by process designer
and put it on line list.
Temperature appears while design pressure is
reached called as design temperature.
The test pressure is indicated on project line list
based on the requirements and refers to associate
standard such as ASME B31.3, B31.4 and B31.8.85
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How to define test pressure?
System has any pressure during operation, is
subjected to pressure testing.
– For hydrostatic test, test pressure is not less
than 1.5 x design pressure.
– For pneumatic test, testing pressure is 1.1 of
design pressure.
– For piping line that is operated under 5 Bar G
pressure, can be tested by flushing process only.
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The test pressure may be reduced to the maximum
pressure that will not exceed 90% of yield strength
at test temperature for the weakest point of the
system.
When vessels are to be included in testing circuit,
particular care must be taken to ensure that
pressure applied to the system plus hydrostatic
head does not exceed the test pressure that applied
to vessel during in manufacturer
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2) Design & Test temperature
– Pneumatic test can not be done on
temperature below +5C or above +38C.
– Hydro test shall use glycol mixed when the
circumstance temperature is 5C or below.
– In ACG project, when temperature below +5C,
we only do hydro testing and medium is water
mixed with glycol (composition is for 100%
water, add 25% glycol). The manufacture
mentions the lowest temperature can make
the glycol is freezing
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3) Test Medium
– Fresh water
Fresh water is compressible medium with
stabile property almost in any temperature.
– Potable water
Potable water is used to test potable
water line as subjected by client. Fresh
water can be used in lieu of potable
water which is chloride contents is less
than 30 ppm.
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– Compressed air
Compressed air is used to test line that
water is not permissible in inner of piping
line. Example of lines tested with
compressed air is instrument air line, plant
air line, fuel oil line, utility air line. For safety
purpose, any test pressure more than 24 Bar
G, testing medium to be used is fresh water.
– Nitrogen
Nitrogen is used for pneumatic testing.
– Sea water
Sea water can be used for test sea water
system while the line is GRE or non metallic
material. 90
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Following medium shall not be used as test medium
because they are extremely hazardous:
– Oxygen
– Toxic gasses
– Liquids above flash points or atmospheric boiling
points
– Liquids above 66oC, except necessary for pressurize
hot tap connection on hot lines.
– Hydro carbon shall not be used as medium in oxygen
service.
– Steam, unless for tightness test and service test
– Liquid 49-66oC, unless use as aquifer water in water
injection lines.
– Air use in hydrocarbon lines unless is has been
cleaned to avoid an explosive of hydrocarbon-air 91
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4) Test duration
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5) Flushing Medium & Pressure
For hydro testing:
Flushing medium: Fresh water. For stainless steel
or duplex piping material, chloride ion contents
shall be less than 30 ppm.
For pneumatic testing:
Flushing medium: compressed air that is dry and
oil free contents.
Flushing velocity: in excess of 20 m/sec.
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6) Testing method
Testing method is possible to be change as per
client discretion. For some test pack that consists
of non pressurized pipe line, flushing can be
applied instead of pressure testing. The method
shall be approved by Client.
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7) Piping Line and Material for Testing
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Thank you
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