DOCUMENT NO.

PT Caltex Pacific Indonesia

REV.

PP-IN-II-002
DATE :

1
SHEET :

OCT 19, 2001

Hadi Prijono Hadi Prijono Shawn

OF

12

PROCEDURE

PREPARED BY CHECKED BY APPROVED BY

HPR HPR SPD

INSTRUMENT PIPING SYSTEM FIELD PRESSURE TESTING

PT. CALTEX PACIFIC INDONESIA

REV

DATE

PAGES

DESCRIPTION

PREPD

CHKD

APPD

0 1

10/19/01 1/7/02

ALL ALL

ISSUED FOR IMPLEMENTATION CPI SPEC REVIEW TEAM ( HP, TJR, IVS)

HPR Team

HPR Team

SPD Team

TABLE OF CONTENT 1. GENERAL .......................................................................................................................... 2 1.1. 1.2. 1.3. 1.4. 2. Scope........................................................................................................................ 2 References................................................................................................................. 2 Terminology.............................................................................................................. 2 Safety Requirement.................................................................................................... 4

PNEUMATIC TESTING..................................................................................................... 4 2.1. 2.2. 2.3. Testing Pneumatic Transmitted and Signal Instrument Leads ....................................... 5 Category M Instrument Piping ................................................................................... 7 Testing Instrument Air and subheaders ....................................................................... 9

3.

HYDROSTATIC TESTING................................................................................................ 9 3.1. 3.2. 3.3. 3.4. 3.5. 3.6. General..................................................................................................................... 9 Test Fluid................................................................................................................ 10 Test Pressure........................................................................................................... 10 Test Preparation...................................................................................................... 10 Testing Procedure ................................................................................................... 11 Test Completion ...................................................................................................... 11

OPTIONAL ATTACHEMENTS FOR THIS SPECIFICATION: ADDENDUM 1: Project Specific Clarifications & Requirements

PT. CALTEX PACIFIC INDONESIA

Instrument Piping System Field Pressure Testing PP-IN-II-002 Rev. 1

1.

GENERAL 1.1. Scope 1.1.1. This specification prescribes pressure testing of Instrument Piping System leads, from the commodity line block valve to the instrument, to ensure tightness. No deviation shall be made from this specification without written approval from COMPANY. Instrument Piping includes the following: 1.1.2.1 All piping and piping components used to connect instruments to other piping or equipment. 1.1.2.2 All instrument air lines except the main instrument air header. 1.2. References The publications listed below form part of this specification. Each publication shall be the latest revision and addendum in effect. Except as modified by the requirements specified herein or the details of the drawings, Work included in this specification shall conform to the applicable provisions of these publications. 1.2.1. Related Specifications
? ? PP-SC-GG-001 ? ? SP-PI-PP-001 ? ? SP-PI-PP-002

1.1.2.

Pressure Test Procedure General Piping Systems Piping Specification Power Piping Chemical Plant and Petroleum Refinery Piping Liquid Transportation systems for hydrocarbon, LPG, anhydrous ammonia and alcohol. Applicable Standards

1.2.2.

Code and Standards

? ? ANSI B31.1 ? ? ANSI B31.3 ? ? ANSI B31.4 ? ? ISA

1.3.

Terminology In this specification, the following words and terms shall have the meanings hereby assigned to them, unless noted otherwise. 1.3.1. COMPANY Refers to PT. CALTEX PACIFIC INDONESIA, as the ultimate user and owner, the authorized representative of COMPANY or COMPANY third party inspection. 1.3.2. CONTRACTOR

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Instrument Piping System Field Pressure Testing PP-IN-II-002 Rev. 1

Refers to company selected by COMPANY, which may be responsible for the detailed engineering design, material and equipment procurement, and construction as specified in Contract, Scope of Work, or Work Order. 1.3.3. Vendor Refers to the company selected by COMPANY or CONTRACTOR, which is responsible for the purchase agreement or purchase order of the goods/services specified in this specification. Note:
? ? For EPC (Engineering, Procurement and Construction) project purposes:

The terminology shall have the meanings as above.

? ? For Direct Procurement by COMPANY purposes: Vendor shall also be

responsible as CONTRACTOR. 1.3.4. Category D Fluid Service {according to ANSI (American National Standards Institute) B31.3 and ANSI B31.1}: A fluid service in which all the following apply:
? ? The fluid handled is nonflammable and nontoxic. ? ? The design gage pressure does not exceed 150 psi. ? ? The design temperature is between minus 20 degrees F (minus 29 degrees C)

and 366 degrees F (186 degrees C). 1.3.5. Category M Fluid Service (according to ANSI B31.3 and ANSI B31.1): A toxic fluid service in which exposure to very small quantities of the fluid in the environment can produce serious irreversible harm to persons upon breathing or bodily contact, even when prompt restorative measures are taken. Damaging to Human Tissues (according to ANSI B31.3 and ANSI B31.1): 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. (Restorative measures may include flushing with water, administration of antidotes, and administration of medication.) COMPANY Refers to PT. CALTEX PACIFIC INDONESIA, as the ultimate user and owner, the authorized representative of COMPANY or COMPANY third party inspection. 1.3.8. CONTRACTOR Refers to company selected by COMPANY, which is responsible for the detailed engineering design, material and equipment procurement and construction of the whole EPC project. 1.3.9. Vendor Refers to the company selected by COMPANY or CONTRACTOR, which is responsible for the purchase agreement or purchase order of the goods/services specified in this specification

1.3.6.

1.3.7.

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Instrument Piping System Field Pressure Testing PP-IN-II-002 Rev. 1

Note:
? ? For EPC (Engineering, Procurement and Construction) project purposes:

The terminology shall have the meanings as above.

? ? For Direct Procurement by COMPANY purposes:

Vendor shall also be responsible as CONTRACTOR. 1.4. Conflicting Requirements 1.4.1. In case of conflict between this Specification and its associated Specifications and the above Codes and Standards, the Vendor shall bring the matter to the COMPANYs attention for resolution and approval in writing. However, the most stringent requirement shall apply. Should conflicts exist between this specification and other documents, the following order of precedence shall govern: ? ? Scope of Work ? ? Data Sheets. ? ? This Specification ? ? Other COMPANY Specifications ? ? Other Referenced Publications ? ? Approved for Construction Drawings
? ? Vendors Code

1.4.2.

1.5.

Safety Requirement 1.5.1. All field pressure testing activities shall be carried out in strict accordance with job site safety regulations. Compressed gases shall be handled according to safe job procedures. Prior to initial operation, all installed instrument process and utility leads shall be pressure tested to the specified pressure defined in pneumatic test section , of this specification. Pressure testing medium, up to and including 2000 psig (13,790 kPa), shall be nitrogen or other available inert gas. All connections, joints, and fittings shall be checked for leakage with Snoop, Leak-Tec, or equivalent leak detector solution. Over 2000 (13,790 kPa) psig, the testing medium shall be distilled or demineralized water. Checking for leaks shall be by visual observation of the installatio n and of the test pressure gage. Instrument air supply lines and sub header lines shall be commodities tested according to the pneumatic testing section, of this specification. According to the pneumatic testing section, the transmitted and control signal leads shall be tested prior to the final instrument inspection and loop check. Record Retention 1.5.5.1 Upon completion of the project, all testing records shall be sent to the COMPANY.

1.5.2.

1.5.3. 1.5.4. 1.5.5.

2.

PNEUMATIC TESTING

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Instrument Piping System Field Pressure Testing PP-IN-II-002 Rev. 1

2.1.

Testing Pneumatic Transmitted and Signal Instrument Leads 2.1.1. General 2.1.1.1 Prior to final instrument inspection and loop check, a pneumatic test shall be made on all signal leads to ensure non leak conditions. 2.1.1.2 All connections shall be bubble tested using Snoop, Leak-Tec, or equivalent leak detector solution. 2.1.2. Testing Pressure 2.1.2.1 Transmitter leads, controller leads, and tubing downstream of the filter regulator shall be tested at Companys specification about the pressure testing of transmitted and signal leads and downstream pressure of the filter regulator. 2.1.3. Testing Fluid 2.1.3.1 In the event instrument air is not available for testing, instrument quality air from a compressor, bottled dry air, or nitrogen can be used as the test medium. 2.1.4. Testing Preparation 2.1.4.1 Prior to pressure testing, establish identity of each component of a given loop and the component's conformance to design test pressure (refer to pipe line diagram) 2.1.4.2 Flow test diagram shall be provided Those diagram shall separate all pressure piping into individual systems and assure the COMPANY that those systems are tested in accordance with ANSI B31.3. Special external line supports or anchors required for testing shall be indicated on the flow test diagram. 2.1.4.3 Blow air leads clean, to remove any debris inside the tubing or pipe. 2.1.4.4 Identify positively the air circuit from the air supply valve through the instrument to air operated element by setting the instrument to deliver air and observing air output at the disconnected air leads at the air operated element. 2.1.4.5 Pressure Test Gauges ? ? Two dial - indicating pressure gauges, at least, shall be provided at the pump discharge and other suitable locations. ? ? All gauges used shall be checked for accuracy. ? ? Pressure gauge shall be connected at point as near as possible at the highest and lowest point of the piping system to be tested. 2.1.5. Leak Testing Proce dure Using Differential Pressure Indication. 2.1.5.1 Disconnect tubing or pipe comes to instrument air supply pilots, if any, from the section of tubing or pipe to be tested. 2.1.5.2 Connect the test assembly, the tubing to be tested and connected to the dry air supply or other test fluid.

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Instrument Piping System Field Pressure Testing PP-IN-II-002 Rev. 1

2.1.5.3 Adjust the pressure regulator until the red pointer in the pressure gauge reads the pressure test setting. Adjust the precision relay to the pressure test setting. 2.1.5.4 Any drop in pressure will indicate a leak at tubing or pipe. 2.1.5.5 Tubing or pipe will indicate leaks if the black pointer in the pressure gauges line test decrease at the rate of 1 psi (7 kPa) or more per hundred feet (30 m) per 5 second. 2.1.6. Leak Testing Procedure Using Gas and Bubble Formation 2.1.6.1 Objective
? ? The objective of gas and bubble formation leak testing is to detect

gas escaping from a pressurized component by the application of a solution, which will form bubbles as the gas passes through it.
? ? Unless otherwise specified, the test gas will normally be nitrogen;

however, other gases such as air or helium may be used. 2.1.6.2 Bubble Solution The bubble forming solution shall produce a film that does not break away from the area to be tested, and the bubble formed shall not break rapidly due to air drying or low surface tension. The number of bubbles contained in the solution should be minimized to reduce the problem of discriminating between existing bubbles and those caused by leakage. Ordinary household soap or detergents are not permitted as substitutes for bubble testing solutions. 2.1.6.3 The bubble forming solution shall be applied to the surface to be tested by flowing the solution over the examination area. 2.1.6.4 Prepare piping to be tested as indicated in section 3.4, of this specification, Test Preparation. 2.1.6.5 Connect the test assembly, to the instrument leads. Tubing or pipe material and size to be suitable for maximum test pressure range required. Regulator output range must be specified when ordered. 2.1.6.6 Tubing, regulators, fittings, valves, and pipe that necessary to connect the test assembly to the instrument shall be furnished by CONTRACTOR. 2.1.6.7 Instrument leads to be tested that are 1/2 of an inch OD and smaller shall initially be charged to 25% Operating Pressure and a preliminary check made to locate major leaks. Continue in increments of 25% of test pressure until test pressure is achieved and stabilized. 2.1.6.8 Instrument leads to be tested that are larger than 1/2 of an inch OD shall initially be charged to 25% of Operating Pressure and a preliminary check made to locate major leaks. The pressure shall be increased in steps providing sufficient time between steps for equalizing of stress in material. During the testing, the pressure gage should be observed at each step to detect any loss of pressure that would indicate a leak. 2.1.6.9 All joints screwed, welded, flanged, or tubing connection shall then be

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Instrument Piping System Field Pressure Testing PP-IN-II-002 Rev. 1

swabbed with leak detection solution and checked for leaks. 2.1.6.10CONTRACTOR shall notify 24 hours in advance of Pressure tests. 2.1.6.11Test pressure shall be maintained for sufficient length of time to determine if there are any leaks, but no less than 10 minutes. CONTRACTOR shall not be required to maintain test pressure in excess of 1/2 hour after notification of COMPANY. 2.1.6.12CONTRACTOR shall document tests including times, pressures and submit all documentation to COMPNAY. 2.1.7. Test Completion 2.1.7.1 After testing is completed, restore the pneumatic leads to their original configuration. 2.1.7.2 Use the Field Test Record Instrument Pressure Test to record results of all tests. 2.2. Category M Instrument Piping The requirements for testing shall be in accordance with other sections of this specification except as follows: 2.2.1. Hydrostatic Testing The hydrostatic test shall be done before the leak test. Please refer to the section 3 for the hydrostatic testing procedure. 2.2.2. Leak Testing Using Gas and Bubble Formation 2.2.2.1 Scope This procedure describes the method and requirements for the performance of sensitive leak testing using gas and bubble formation testing. Leak test shall be carried out to ensure the tightness of the system 2.2.2.2 Test Preparation To avoid damage to instruments during the pressure testing, the following guide should be observed:
? ? Before testing leads to flow and differential pressure instruments,

close block valves at the commodity line and open the bypass valve at the instrument.
? ? Before testing leads to pressure instruments, close block valve at the

commodity line and at the instrument.

? ? Before testing leads to level instruments (differential type without

bypass valve), close block valves at the vessel and add a temporary bypass line (if bypass valve is not available) between the high pressure and low pressure sides. These are to prevent high differential pressure at the instrument.
? ? All connections, including welds, shall be left uninsulated and

exposed for examination during test.

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Instrument Piping System Field Pressure Testing PP-IN-II-002 Rev. 1

? ? Instrument components installed in the process leads should be

reviewed for maximum pressure rating. If the rating is less than the test pressure, remove the component and install a temporary jumper line.
? ? Analyzer sample lines shall be pressure tested up to the i nstrument.

Disconnect line at analyzer before testing. Pressure reducing regulators and sample vaporizers should be removed and a jumper line installed during test.
? ? All equipment that is removed from lines during testing (particularly

control valves) must be disconnected by qualified mechanics and protected with wooden plugs or plastic caps.
? ? Cleanliness

The Instrument Piping to be tested shall be free of oil, grease, paint, and other contaminants that might mask a leak. If liquids are used to clean the component, the component shall be thoroughly dried before testing.
? ? Pressure Test Gages

When components are to be pressure leak tested, two indicating pressure gages shall be connected to the test assembly. One of the pressures gages and readily visible to the operator controlling the pressure throughout the duration of pressurizing and testing. T he other pressure gages installed at instrument line test. When required, a recording type gage may be substituted for 1 of the 2 dial gages.
? ? Gage Dial Size

Indicating pressure gages used in testing should preferably have dials graduated over a range of about double the intended maximum pressure, but in no case should the range be less than 1-1/2 nor more than 4 times that pressure.
? ? Gage Calibration

All gages used shall be calibrated against a standard dead weight tester, a calibrated master gage, or a mercury column, and recalibration at least once each year. 2.2.2.3 Test Temperature At the time of testing, the minimum metal temperature of the instrument lead shall be no less than the following: Material Carbon Steel Stainless Steel Size 1-1/2 inch or less 1 inch or less Temperature 60 degrees F (16 degrees C) 40 degrees F

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Instrument Piping System Field Pressure Testing PP-IN-II-002 Rev. 1

(4 degrees C) 2.2.2.4 Test Pressure Instrument process and utility leads shall be tested per requirements in Pipe Spec Sheets in Addendum-1 of SP-PI-PP-002 Piping Specification. 2.2.2.5 Testing Procedure Please refer to the 2.1.6 section for the testing procedure of leak testing using gas and bubble formation. 2.2.3. Test Completion 2.2.3.1 Acceptable Test Result The components under test are acceptable when no continuous bubbling is observed. 2.2.3.2 Rejectable Test Result As bubbles are observed, their location is marked. The components will then be depressurized and the leaks repaired. After repairs have been made, the component shall be re-tested in accordance with the requirements of this specification. 2.2.3.3 After testing is completed, remove any temporary bypass lines and reinstall lead in accordance with the project instrument installation drawings. 2.2.3.4 Use the Instrument Pressure Test Record to record results of all tests. 2.3. Testing Instrument Air and subheaders 2.3.1. Instrument air subheader lines and air supply lines to individual instruments whose normal operating pressure is no more than 150 psig (1034 kPa) may be tested at normal operating conditions with commodity carried. Instrument air lines operating over 150 psig (1034 kPa) shall be tested as an instrument process lead. Pleases refer to the 2.2 section for the procedure of testing instrument air and subheader.

2.3.2. 2.3.3.

3.

HYDROSTATIC TESTING 3.1. General 3.1.1. Hydrostatic testing shall be done in accordance with PP-SC-GG-001 Pressure Test Procedure, and SP-PI-PP-002 Piping Specification.

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Instrument Piping System Field Pressure Testing PP-IN-II-002 Rev. 1

3.2.

Test Fluid 3.2.1. Test fluid shall normally be distilled or demineralized water. As an alternate, steam condensate of high purity can be used. Under no circumstances shall fresh water be used that contains 30 ppm or more of chlorides. In areas where the atmospheric temperature is low enough that the testing water will freeze, use a mixture of 50 percent glycol and water. Instrument leads connected to lube or seal oil piping shall be tested with lube or seal oil. In addition, instrument leads can be tested pneumatically but with Company approval.

3.2.2. 3.2.3.

3.3.

Test Pressure 3.3.1. Lines system in external pressure service shall be subjected to an internal line system test pressure of 1-1/2 times the external differential design pressure but no less than a gage pressure of 15 psi (104 kPa). Instrument leads shall be tested at 1-1/2 times the design pressure listed in the Piping Line List.

3.3.2. 3.4.

Test Preparation The following guide should be observed to avoid damage to instruments during the pressure testing 3.4.1. 3.4.2. Instrument pressure rating should be verified to withstand test pressure ratings Before testing leads to flow and differential pressure instruments, close block valves at the commodity line and open the bypass valve and block valves at the instrument. Before testing leads to pressure instruments, close block valve at the commodity line and at the instrument. Before testing leads to level instruments (differential type without bypass valve), close block valves at the vessel and add a temporary bypass line between the high pressure and low pressure sides to prevent high differential pressure at the instruments. All connections, including welds, shall be left uninsulated and exposed for examination during test. Instrument components installed in the process leads should be reviewed for maximum pressure rating. If the rating is less than the test pressure, remove the component and install a temporary jumper line. Analyzer sample lines shall be pressures tested up to the instrument. Disconnect line at analyzer before testing. Pressure reducing regulator and sample vaporizers should be removed and a jump line installed during test When conditions require that a pressure test be maintained for a period of time during which the testing medium in the system would be subject to thermal expansion, provision shall be made for relief of excess pressure.

3.4.3. 3.4.4.

3.4.5. 3.4.6.

3.4.7.

3.4.8.

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Instrument Piping System Field Pressure Testing PP-IN-II-002 Rev. 1

3.5.

Testing Procedure 3.5.1. Hydrostatic Test 3.5.1.1 The pump shall be attended constantly during the test by suitable members of operators. 3.5.1.2 Procedures for hydrostatic pressure test shall be as specified below. ? ? After filling the water and purging the air in the piping system to be tested, the pressure shall be increased gradually in the steps as shown in Table 2, maintaining for at least 3 minutes in each step to allow the equalization of strain during test and to check for leaks. ? ? The test pressure shall be maintained for at least 30 minutes prior to starting inspection. ? ? After the pressure test, the pressure value shall be decreased down to max. operating pressure x 1.1 Then welded joints shall be checked against leakage.

Pressure Test Leak Te st Test Pressure

Min. 30 min.

Remarks : 1. Check period for leak in each step, if it exceeds 3 minutes, mayTime be extended till the completion of check. 2. The piping system to be tested shall not be left under pressure for a long period without COMPANYs agreement. 3.5.2. Leak Test 3.5.2.1 Procedures for leak test shall be as specified below : ? ? The piping system shall be pressurized up to 50 percent of the test pressure and shall be checked for leaks. ? ? The pressure shall be maintained for at least 15 minutes prior to starting the inspection. 3.6. Test Completion 3.6.1. In the event that repairs or additions are made following the pressure test, the affected lead or leads shall be retested at the pressure originally specified for the test.

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3.6.2. 3.6.3.

After testing is completed, remove any temporary bypass lines and reinstall lead in accordance with the project instrument installation drawings. Upon completion of the pressure testing, the only retained records shall be a letter of certification by the COMPANY authorized Inspector. The letter of certification has a meaning that the entire instrument process and utility leads and hydrostatic leads has been pressure tested as required by these procedures. Upon completion of the project, these hydrostatic test records shall be sent to the COMPANY.

3.6.4.

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