Pneumatic Test

PREPARED BY CHECKED BY APPROVED BY CERTIFIED (PTT) REV. DATE NO. D1 18-Feb-08 D2 11-Jun-08

PTT PUBLIC COMPANY LIMITED ONSHORE COMPRESSOR STATION 4 PROJECT

REVISED BY

APPROVED BY

DESCRIPTION ISSUED FOR ITB ISSUED FOR ITB

SPECIFICATION FOR PNEUMATIC TEST SPC-0804.02-96.59 REV.D2 TOTAL 10 PAGES

AREA CODE OF SITE LOCATION GENERAL AREA: 010 PTT PLC. CONTRACT NO.

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PTT PLC. PROJECT NO. 0804.02

PNEUMATIC TEST

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CONTENTS SECTION 1.0

GENERAL

3

2.0

PNEUMATIC TESTING

4

3.0

TEST MEDIUM

5

4.0

TEST PRESSURE

5

5.0

BLINDS FOR PRESSURE TEST

5

6.0

TEST PACK PREPARATION

6

7.0

TESTING PREPARATIONS

7

8.0

PNEUMATIC TEST PROCEDURE

8

10.0

SAFETY

9

PNEUMATIC TEST

1.0

GENERAL

1.1

Purpose

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This Specification prescribes minimum requirements on pneumatic test procedure and acceptance criteria of piping works. 1.2

Scope of Application This specification covers all related activities of work to be performed for project by CONTRACTOR on piping construction works.

1.3

Definition

1.3.1 Category D Fluid Service (per ASME B31.3) – A fluid service in which all the following apply: (1) The fluid hanged is nonflammable, nontoxic, and not damaging to human tissues. (2) The design gauge pressure does not exceed 10.35 bar. (3) The design temperature is between -29°C and 186°. 1.3.2 Category M Fluid Service (per ASME B31.3) – A toxic fluid service in which exposure to very small quantities of the fluid in the environment can produce serious irreversible harm to persons on breathing or bodily contact, even when prompt restorative measures are taken. 1.3.3 Damaging to Human Tissues (per ASME B31.3) – A fluid which, under expected operating conditions, can harm skin, eyes, or exposed mucous membranes so that irreversible damage may be done unless prompt restorative measures are taken. 1.3.4 Calculated Test Pressure – the test pressure determined in accordance with paragraph 4.0 1.3.5 Deleted 1.3.6 Deleted 1.3.7 Design pressure – The pressure of each component in a piping system which is not less than the pressure at the most severe condition of coincident internal or external pressure (minimum or maximum) expected during service. 1.3.8 Test pressure – The pressure does not exceed stress intensity of yield strength of each component in a piping system at test temperature and should not be lower than design pressure. 1.4

References

1.4.1 Related Code and Standards (1) ASME B31.3 Process Piping (2 ASME SECTION IX “Welding and Brazing Qualifications”

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ASME SECTION XIII Div 2, AT-502

1.4.2 Related Specifications and Procedure Following specification shall be as a supplementary to this specification and Procedure. (1) Piping Construction (SPC-0804.02-96.51) (2) Hydrostatic Pressure Test (SPC-0804.02-96.58) (3) Internal Cleaning of Piping (SES-PR.Q2-99-0204.10-3500-013) 1.5

Units SI unit shall be used as the measurement system for the drawings and document to be submitted. However, nominal sizes of piping component shall be in accordance with inch system, which abbreviation in (B)

2.0

PNEUMATIC TESTING

2.1

Circuit Monitoring and Checking For pneumatic testing of circuits, access to the area of the test shall be limited to only the personnel directly involved in the test or personnel involved in the inspection and monitoring. During the pressure test the total circuit shall be inspected and tested for any leaks. If any leaks are found on flanged, threaded, plugged or welded joints the system pressure shall be totally released prior to any rectification work starting. Disciplinary action shall be taken against any individual and/or supervisor authorizing and/or undertaking work on the pressurized system. For flanged joint testing during pneumatic testing of circuits the flange joints shall be hermetically sealed by means of adhesive paper tape and a pinhole made in the tape to permit easy detection of leaks.

2.2

Circuit Monitoring and Checking The following equipment and components shall not be included in the system, and this equipment shall be isolated from the test section.

2.2.1 Rotating equipment such as pumps, compressors and turbines. 2.2.2 Safety valves rupture discs, flame arrestor, and stream traps. 2.2.3 Pressure vessels with sophisticated internals. 2.2.4 Equipment and piping lined with refractoriness. 2.2.5 Storage tanks. 2.2.6 Filters, if filter element(s) is not dismantled. 2.2.7 Heat exchangers of which tube sheets and internals have been designed for

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differential pressure between tube side and shell side. 2.2.8 Instrument such as control valves, pressure gages, level gages, and flow meter. (Excluding thermocouples) 2.3

Exclusions The followings are excluded from the testing requirements of this specification :

2.3.1 Any package unit previously tested by the vendor in accordance with the applicable codes. 2.3.2 Plumbing systems, which are tested in accordance with the applicable plumbing codes. 2.3.3 Lines and systems which are open to the atmosphere such as drain, vents, open discharge of relief valve, and atmospheric sewers. 3.0

TEST MEDIUM The gas used as test medium shall use the nonflammable and nontoxic gas such as N2 or inert gas, if not compressed air.

4.0

TEST PRESSURE The test pressure shall be 110% of design pressure and according to test pressure in line list SES-SH-50-0204.10-3500-01-A2. Equipment for testing (referred to sketch in appendix II) should be have as following; 1) 2) 3) 4) 5) 6) 7)

Air Compressor Flexible hose Calibrated Pressure gauge Oil filter Temporary piping set N2 cylinder, if required Safety valve

Note: Safety valve required for pneumatic testing, rapid opening or pop action of over pressure, should be installed and connected with an adequate system of piping not containing valve which can isolate tested system. 5.0

BLINDS FOR PRESSURE TEST

5.1

Plain test blanks shall be used with 3mm flat asbestos gaskets for blanking flat face, and raised face. Provide full face blanks and gaskets for Class 150 connections. However, where permanent operational blinds are installed, they may be used for pressure testing, provided they are rated the testing pressure as per Appendix I.

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5.2

Plate material, extra length bolts and gaskets, which are made at the Job Site could be used the testing. Maximum allowable testing pressure for test blinds refer to Appendix I.

5.3

Temporary spades and blanks installed for testing purposes shall be designed to withstand the test pressure without distortion. Temporary test spades and blanks shall be readily identifiable by painting a red color on the handle.

5.4

For ring joint flanges, spare ring joints shall be required as they are to be used only once.

6.0

TEST PACK PREPARATION

6.1

General

6.1.1 CONTRACTOR will prepare a marked up of P&ID indicating the test limits. 6.1.2 From the marked up P&ID, Subcontractor will divide the piping into suitable Test Packs. The size of the packs may be revised by Subcontractor provided that the specification for limits in Clause 6.2 below is complied with CONTRACTOR shall be notified of such revisions and will authorize Subcontractor to proceed of said revisions meet the specification. 6.2

Test Pack Limits Subcontractor shall not test through equipment without CONTRACTOR’s written approval.

6.3

Test Pack Format (1) Pressure test report for piping (2) Marked-up P&ID (3) Blind check list (4) Welding History Report and Welding Joint Marked ISO Drawing (5) NDE report (6) PWHT and Hardness test report (7) Post-Test Punch List (CONTRACTOR + Client) (8) Copies of reinforcing pad pressure test certificates. (if necessary)

6.3.1 Test Packs shall include the latest available revision of each isometric covering the scope of the test. (1) Test limits and highlight line to be tested. (2) Size (thickness) and location of all test blinds and including those required at instrument connection e.g. orifice flanges. (3) Indentify location for the connection of the fill and drainage points for the system. (4) Vent points (5) Deleted (6) Location and range of pressure gauges to be used. Note that on large piping systems and/or system with none return valves more than one gauge may be required. (7) Deleted

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If required, temporary supports shall also be indicated in the test pack. Any control valve, check valve, safety valves or other piping accessories requiring removal, turning, or some other action should be highlighted.

6.3.2 Test Packs shall also contain copies of P&ID’s marked-up to show at least the following information: (1) Piping Field Test Pack Number (2) Specific Limits of that Test Pack Only (3) Location of Test blinds, Isolation valve and Temporary piping. 6.4

Test Pack Approvals and Distribution The “Original” pack shall be submitted to PTT/Consultant for review.

6.5

Field Revision Request (FRR) CONTRACTOR’s Engineer shall check the status of the affected test pack and advice subcontractor for test packs where pneumatic test completed. CONTRACTOR will over-stamp the original test pack with “RETEST”. The restamp original will then be returned to subcontractor under memorandum with an instruction to carry out the retesting.

7.0

TESTING PREPARATIONS

7.1

All joints, including welds, shall be accessible and left uninstalled, unpainted and exposed for examination during the test joints previously tested in accordance with this specification may be insulated or covered.

7.2

Before testing

7.2.1 Piping systems shall have been completely checked for correctness. 7.2.2 All lines, vessels and equipment shall be checked to insure the entire system can be completely drained after testing. 7.2.3 Temporary gaskets may be used, which are not the same as permanent gaskets provided. (1) Such use will not lead to damage of the flange faces. (2) Temporary gaskets are removed immediately after completion of tests. 7.3

Short pieces of piping, which must be removed to permit installation of a blind or blank, shall be tested separately.

7.4

Lines containing check valves shall have the source of pressure located in the piping upstream of the check valve so that the pressure is applied under the seat. If this is possible, remove or jack open the check valve closure mechanism or remove check valve completely and provide necessary spool piece or blinds. A

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notation shall be included on the Punch List that check valve flapper has been removed. Subcontractor shall install a new gasket wherever the check valve bonnet has been disturbed. Where flappers have been removed, tagging shall mark valves. 7.5

Test equipment to be used during testing shall have suitable capacity for the range of test pressure required. The range of pressure gauges to be used shall be with a minimum span of 1.5 times pressure and maximum span of 2 times of test pressure.

7.6

All pressure gauges are to be calibrated specially for OCS #4 Project prior to use. If gauges have been used previously on other projects or for other purposes, they shall be recalibrated. Validation of gauges and chart recorders shall be for a maximum of 90 days, however, recalibration shall be required if the calibrated gauge/recorder is damaged or strained.

7.7

If the specified test duration exceeds 8 hours, then a chart recorder shall be used to record test pressure.

7.8

Prior approval must be obtained from the CONTRACTOR and PTT/Consultant to include vessels or inline equipment in the pressure test circuit.

8.0

PNEUMATIC TEST PROCEDURE

8.1

Prior testing start, Supervisor/Tester is to set up the exclusion zone, complete with signs, three languages, prior to pressure being raised on the system. Also marshals shall be positioned at all exclusion barriers to ensure no personnel enter the exclusion zone.

8.2

During pneumatic testing care must be exercised not to exceed the specified design pressure by more than ten (10) percent, also see Para. 2.1 (maximum test pressure to ne marked on the Test pressure gauge, prior to pressurized the system)

8.3

When pneumatic testing at over 2kg/Cm2, a preliminary check at 2kg/Cm2 shall be made to locate major leaks. The pressure shall be increased in gradual steps of 4kg/Cm2 or 10 percent of the test pressure, whichever is greater.

8.4

A double block and vent valve arrangement shall be included in the pressurizing line to the system being tested. A test pressure gauge shall be downstream of the double block. After each pressure step has been reached, close the block valves and open vent valve to atmosphere. If after a 10 minutes period the “Step Pressure” has held, proceed to the next “Step Pressure”. If not, examine the entire system for leakage.

8.5

The pressure shall be held at design pressure for 10 minutes prior to raising the pressure to the test pressure. At test pressure shall be held for 30 minutes during which time to access within the exclusion zone will be allowed.

8.6

After 30 mins the test pressure shall be reduced to design pressure at which

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point access within the exclusion zone will be allowed to the testing team only and the inspection of the joints shall be undertaken. All flange, threaded, welded joints and attachment shall be inspected with a proprietary testing solution. The design pressure shall be maintained until inspections of all joints are completed. 8.7

Any leak identified shall be marked with marker pen and the system shall be depressurized prior to any repair or rectification work being undertaken.

8.8

Depressurization of the system on completion of the inspection shall be by nominated vent valves taking into consideration any none return valves included within system.

8.9

All instrument shall be disconnected from the test system prior to the test commencing.

9.0

REPORTS AND TEST RECORDS

9.1

As a minimum, the Subcontractor shall maintain records of all pressure tests, records of all welding operations, including welder, numbers, and post weld heat treatment charts referenced to weld numbers, records of all hardness tests and records of all certification records.

9.2

All records shall be submitted and approved by the CONTRACTOR and shall be submitted to the Client/Consultant.

9.3

All records shall be submitted and approved by the CONTRACTOR and shall be submitted to the CLIENT/CONSULTANT.

10.0

SAFETY

10.1

General

10.1.1 Appointment of CONTRACTOR’s Test Controller who is in attendance and responsible throughout the testing and inspects the welding during testing. 10.1.2 Appointment of the subcontractor’s test controller who will be responsible for ensuring safe testing in accordance with the specification. 10.1.3 Display of safety warning signs to alert workers in the vicinity of the pressure testing with line identification. 10.1.4 Pressure test training and maintenance of a competency register as required by CONTRACTOR Safety plan. 10.1.5 Pressure rating for the test manifold and the test equipment and the required inspection/testing. 10.1.6 The air in the subsystem shall be released slowly by means of opening the

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valves. The vent valves shall be left open until the pressure in the loop reaches zero. 10.1.7 All of the CONTRACTOR and Piping Subcontractors Test Controllers must be cautious when approaching flange joints & listen for escaping air.