DETAIL ENGINEERING DESIGN OF

WHP
CONTRACT

PIPING PRESSURE TESTING

DOCUMENT NO.

REV
.

DATE

DESCRIPTION

23-Aug-2013

Internal Discipline Check

03-Sep-2013

Issued for Review

18-Sep-2013

Issued for Approval

PREPD

CHKD

APPD

COMPANY

This document is the property of COMPANY. It must not be stored, reproduced or disclosed to others without written
authorization from COMPANY.

RECORD OF REVISION
The revisions listed below have been incorporated in this copy of the document.

PIPING PRESSURE TESTING

DOC NO. :

REV NO.
C

REV. C

SECTION

PAGE NO.

DESCRIPTION OF CHANGES

All

All

Issued for Approval

Page 2 of 22

TABLE OF CONTENTS
1.

GENERAL............................................................................................................................................. 4

1.1
1.2
1.3
1.4
1.5
1.6

Scope of Specification..................................................................................4
Definition....................................................................................................4
Terminology................................................................................................ 4
Work Not Included.......................................................................................5
Codes and Specification...............................................................................5
Pressure Testing..........................................................................................6

2.

PRODUCT............................................................................................................................................ 7

2.1
2.2
2.3

Temporary Welded End Closures...................................................................7

Temporary Non Welded End Closures............................................................7
Pressure Test Blinds....................................................................................7

3.

EXECUTION......................................................................................................................................... 7

3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11

Preparation.................................................................................................7
Vessel and Equipment..................................................................................8
Instrument.................................................................................................. 9
Test Water Criteria.......................................................................................9
Test Methods and Pressures for ASME B31.3 Piping Systems.......................10
Hydrostatic Testing of Piping Designed for External Pressure......................10
Test Preparation-Field Procedure................................................................12
Hydrostatic Test Procedure........................................................................13
Pneumatic Test Procedure..........................................................................14
Test Records............................................................................................ 14
Test Completion.......................................................................................15

ATTACHMENT 1..................................................................................................................................... 17
MAXIMUM HYDROSTATIC TEST PRESSURE (PSIG) FOR FLANGES AND VALVES...........................17
ATTACHMENT 2..................................................................................................................................... 19
STATUS OF INSTRUMENTS DURING PRESSURE TEST.......................................................................19
ATTACHMENT - 3...................................................................................................................................... 22
SCHEDULE OF MAXIMUM ALLOWABLE HYDROSTATIC TEST PRESSURE (PSIG) OR THE LISTED
TEST BLIND THICKNESS........................................................................................................................ 22

1.

GENERAL

1.1

Scope of Specification
This specification prescribes minimum requirement for the methods, tasks, scope and criteria
Page 3 of 22

during testing installed piping systems. Any deviation from this specification requires written
authorization from EPC Contractor and Company.
1.2

Definition
Company
Purchaser
Contractor

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Vendor

The party that carries out all or part of the design, engineering, procurement,
construction, commissioning or management of a project or operation of a facility.
The Principal may undertake all or part of the duties of the Contractor
The Manufacturer of the equipment or the Manufacturers agent with the unit
responsibility

1.3

Terminology

1.3.1

Category D Fluid Service (ASME B31.3)

1.3.2

Owners designation for a fluid service in which all the following apply:
A. The fluid handled is non-flammable, nontoxic, and not damaging to the human tissues.
B. The design gage pressure does not exceed 150 psi (1035 kPa).
C. The design temperature is between minus 20 degrees F (-29 degrees C) through 366
degrees F (186 degrees C).
Category M Fluid Service (ASME B31.3)

1.3.3

Owners designation for a fluid service in which the potential for personnel exposure is judged to
be significant, and in which a single exposure to a very small quantity of a toxic fluid, caused by
leakage, can produce serious irreversible harm to persons on breathing or bodily contact, even
when prompt restorative measures are taken.
Damaging to Human Tissues (ASME B31.3)

1.3.4

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
medication.)
Calculated Test Pressure

1.3.5

The test pressure determined in accordance with Section 3.5 and 3.7, of this specification.
Minimum Test Pressure:
The lowest allowable test pressure gage reading. (The calculated test pressure plus the
additional pressure resulting from the static head of the test fluid)
Maximum Test Pressure

1.3.6

The highest allowable test pressure gage reading. (The pressure test rating of the weakest
component in the test system.)
Piping

1.3.7

An assembly of piping components being tested at one time using a single test procedure.
Test Temperature

1.3.8

The minimum temperature occurring during the test period of either the metal temperature of the
piping being tested (including any vessels or equipment included in the test) or the test fluid
temperature.
System Test
A test that includes multiple sections of piping, having the same or different design pressures, but
which is tested together at one time using a single test procedure and pressure.

1.4

Work Not Included

Page 4 of 22

The following are excluded from the requirements of this specification:

A. Any package unit previously tested by the Vendor in accordance with the applicable codes.
B. Atmospheric sewers and drains.
C. Plumbing systems, which are tested in accordance with the applicable plumbing code.
D. Lines and systems open to the atmosphere.
E. Instrument piping lead lines between the root valve at the process or utility line and the
connected instrument and control piping used to connect air or hydraulically operated control
apparatus.
F. Liquid petroleum transportation piping systems under the jurisdiction of ASME B31.4.
G. Gas transmission and distribution piping systems under the jurisdiction of ASME B31.8.
1.5

Codes and Specification

The latest editions of all applicable codes, specifications, and references shall define the
minimum requirements applicable to the subject work and no statement contained in this
Specification shall be construed as limiting the work to such minimum requirements.
The limits of piping covered by codes other than ASME B31.3 shall be indicated on the P&IDs
(piping and instrumentation diagrams). This specification may be used with other sections of the
ASME B31 Code and Section 1 of the ASME Code, where applicable.

1.5.1

Wherever conflicts or omissions between codes, specifications, and contract occur, the most
onerous condition shall apply. Contractor is responsible for reviewing the list below and informing
the Company of any omissions. All conflicts shall be formally brought to the attention of the
Company.
Applicable Codes
American Society of Mechanical Engineers (ASME)
ASME B16.1
ASME B16.5
ASME B16.9
ASME B16.10
ASME B 16.11
ASME B16.20

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ASME B16.21
ASME B16.24

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ASME B16.25
ASME B16.34
ASME B16.36
ASME B16.42
ASME B16.47
ASME B16.48
ASME B31.1
ASME B31.3
ASME B31.4

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ASME B31.8
ASME B36.10M
ASME B36.19M

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Cast Iron Pipe Flanges and Flange Fittings

Pipe Flanges and Flanged Fittings
Factory-Made Wrought Steel Butt Welding Fittings
Face to Face and End to End Dimension of Valves
Forged Steel Fittings, Socket Welding and Threaded
Metallic Gasket for Pipe Flanges Ring Joint, Spiral Wound and
Jacketed
Non Metallic Flat Gaskets for Pipe Flanges
Cast Copper Alloy Pipe Flanges and Flanged Fittings: Classes 150, 300,
400, 600, 900, 1500, and 2500
Buttwelding Ends
Valves-Flanged, Threaded, and Welding End
Orifice Flanges
Ductile Iron Pipe Flanges and Flanged Fittings
Large Diameter Steel Flanges NPS 26 Through NPS 60
Steel Line Blanks
Power Piping
Process Piping
Pipeline Transportation Systems for Liquid Hydrocarbons and Other
Liquids
Gas Transmission and Distribution Piping Systems
Welded and Seamless Wrought Steel Pipe
Stainless Steel Pipe

American Petroleum Institute (API)

Page 5 of 22

API 5L
API 6D
API Std. 594
API Std. 598
API Std. 600
API Std. 602

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API Std. 603

API Std. 608
API Std. 609
API RP 14C

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Specification for Line Pipe

Specification for Pipeline Valves (Gate, plug, Ball & Check valve)
Check Valves: Wafer, Wafer lug & double-flanged type
Valve Inspection and Testing
Bolted bonnet Steel Gate Valves for petroleum industry
Compact Steel; Gate Valves Flanges, Threaded, Welding and
Extended Body Ends
Corrosion Resistant Gate Valves, Threaded, welded and flanged
Metal Ball Valves Flanged, Threaded, and Welding Ends
Butterfly Valves: Double flanged, Lug and Wafer -Type
Recommended Practice for Analysis, Design, Installation, and testing of
basic Surface Safety System for Offshore Petroleum Platform

American Society for Testing Materials (ASTM)

ASTM A36
1.5.2

Specification for Structural Steel

Project Specification
WHP-SPT-006

Receiving, Warehousing, Installation, Cleaning, and Hydrostatic

Pressure Testing of Instrumentation

1.6

Pressure Testing

1.6.1

The pressure test shall be performed after the NDE and before the internal cleaning of the pipe.

1.6.2

The calculated and maximum test pressure for each line shall be specified in the Pipe Line List.
Additional data, as listed below, shall be provided by EPC Contractors Piping Engineering:
o

Equipment test pressures

Test pressures of special piping components such as ball valves and butterfly valves

Special testing instructions and cautionary notes.

2.

PRODUCT

2.1

Temporary Welded End Closures

2.1.1

The use of plate for temporary welded on end closures is not allowed.

2.1.2

Materials used for welded on end closures such as caps or blinded flanges must be per project
approved piping material (line class) specifications. Project approved welding procedures and
welding requirements must be adhered to. Exceptions or deviations to the approved specifications
must be approved by the EPC Contractor piping engineer.

2.2

Temporary Non Welded End Closures

When required, non-welded temporary end closures, such as test plugs, must be selected and
used per manufacturers recommendations and requirements.

2.3

Pressure Test Blinds

Page 6 of 22

2.3.1

Plain test blanks with 1/16 of an inch (2mm) flat non-asbestos full face or ring type gaskets shall
be used for blanking flat face, raised face, male and female, and tongue and groove type flanges.
Provide full face blanks and gaskets at 125# CI connections. However, where permanent
operational blinds are installed, they may be used for field pressure testing.

2.3.2

A field procedure must be established and care taken to ensure the installation and removal of
material specified for testing. The following is one method for identifying test material:

2.3.3

Plate material, extra length bolts, and gaskets for testing shall be furnished by the field unless
dictated otherwise by contract requirements. The outer periphery (edge) of each test gasket shall
be dabbed with a spot of fluorescent yellow paint in 4 spots (90 degree equidistant) prior to
installation. End points of studs and heads of bolts shall be dabbed with a spot of fluorescent
yellow paint. Refer to Attachment 03 for maximum test pressures at various thicknesses for test
blanks
Solution
A. Corrosion Inhibitor
A suitable non-toxic rust inhibitor for hydro testing of clean lines, and / or harden inhibitor in
lines with stainless steel components
B. Soap Solution
A suitable soap solution for determining leaks during the pneumatic testing of systems.

3.

EXECUTION

3.1

Preparation

3.1.1

Prior to initial operation, all installed piping shall be pressure tested except where otherwise
qualified in this specification.

3.1.2

The test shall be hydrostatic using water unless there is a possibility of damage due to freezing;
or, if the operating fluid or piping material would be adversely affected by water, any other
suitable liquid may be used. Testing of ferritic piping, however, is limited to the temperature
restrictions in Section 3.8.7. of this specification.
A. If a flammable liquid is used, its flash point shall be no less than 120 degrees F (49
degrees C) and consideration shall be given to the test environment.
B. If testing with glycol water mixtures to prevent freezing, the disposal problem of the test
fluid shall be considered
A. The following systems may be tested pneumatically (with authorization from

B. The weight of the hydro test liquid would overstress supporting structures or pipe wall in a
gas, steam, or vapor lines.

3.1.3

C. Lined pipe could damage by the hydro test liquid

D. The instrument air headers shall be tested with dry air. A commodity test as described in
Section 3.6.2 of this specification, may be used if the system is complete and the instrument
air compressor is operational
E. The process or piping material would be adversely affected by water
Piping identified as Category M Fluid Service shall be subjected to a sensitive leak test in
accordance with Section 3.6.7 of this specification, before pneumatic testing

3.1.4

As required, additional testing procedures shall be prepared for testing in the range of 5000 to
50,000 psi to supplement this specification

3.2

Vessel and Equipment

3.2.1

The following shall be excluded from hydrostatic tests:

A. Vessels or equipment supported by other vessels or equipment or by a support structure or
foundation, not capable of supporting the hydro test load.

Page 7 of 22

3.2.2

3.2.3

3.2.4

B. Vessels or equipment not capable of sustaining the hydro test load, and those with internals
or linings that would be damaged by the test fluid.
C. Vessels, heat exchangers, heater coils and any other package unit that has been tested
separately shall not be included in any system test.
D. Expansion joints, filter elements, flame arrestors, steam traps, and rupture discs should not
be tested. Protection methods such as isolation through blinding, or removal shall be used.
The following shall be excluded from all pressure tests:
A. Pumps, compressors, and turbines.
B. Equipment and Vendor furnished piping specifically recommended by the Manufacturer not to
be tested.
The pressure on any point in vessels or equipment included in the pressure test shall not be
greater than the shop test pressure for that equipment as stated on the vessel drawing, Vendor's
equipment drawing, or datasheets. In the event the piping test pressure is greater than the vessel
or equipment test pressure, the piping shall be disconnected, blinded, and tested separately. If
the piping cannot be disconnected (welded connection), one of the following shall be
implemented:
A. Written approval from the Vendor to test at the required piping test pressure. Refer to Section
3.5.2. of this specification.
B. Reduce piping test pressure as necessary after review and approval of. Refer to Section
3.5.3. of this specification.
Certain types of exchangers are specifically designed for a low allowable differential pressure
between shell and tubes, as stated on the Vendor drawings and datasheets. These should be
checked; and, if necessary, test both shell and tubes simultaneously as one system, with the
same pressure or exclude both sides from the test.

3.2.5

Pressure vessels with two or more pressure chambers are specifically designed for a low
allowable differential pressure between pressure chambers as stated on the Manufacturers'
drawings. These should be checked; and if necessary, test all adjacent pressure chambers
simultaneously as one system, with the same pressure or exclude all pressure chambers from the
test.

3.3

Instrument
Instrument shall be protected from damage when hydro testing process and utility piping systems.
Attachment 02 outlines the status of instruments during testing to ensure protection.

3.4

Test Water Criteria

3.4.1

Care shall be taken to ensure the use of clean water for these tests. A suitable filter should be
provided in the filling line, should foreign matter such as sand, rust, or other particles be in
evidence in the proposed test water. The use of seawater is prohibited.

3.4.2

Water used for hydrostatic testing of austenitic stainless steel piping, vessels, and equipment
including those with austenitic stainless steel claddings, linings, or internals shall conform to the
requirements listed below. These requirements also apply to 12 chrome claddings or linings that
are welded with austenitic stainless steel weld filler.
A. Water containing more than 200 ppm (Parts Per Million) chlorides shall not be used.
B. Water containing more than 50 ppm but fewer than 200 ppm chlorides shall be treated with an
inhibitor of 1.5 percent soda ash and 0.5 percent sodium nitrate. The chloride content of the
soda ash and sodium nitrate shall not exceed 500 ppm. These percentages are by weight.
Systems containing water with up to 200 ppm chlorides should be flushed with condensate or
demineralized water immediately after testing.
C. Water containing fewer than 50 ppm chloride does not require inhibitor treatment.

Page 8 of 22

3.4.3

D. Steam Condensate and Demineralized water that meet the requirements of 3.4.2.C is
preferred water
E. Other water sources need to be tested for MIC (Microbiologically Influenced Corrosion
Causing Bacteria) by an accredited Biological Testing Laboratory. If MIC is detected, contact
EPC Contractor for proper steps to eliminate the bacteria prior to use. The bacteria analysis
from the lab is required for proper diagnosis
F. Piping, vessels, and equipment must be drained thoroughly after testing. Where complete
drainage is impossible, when other than demineralized water or steam condensate has been
used, the system shall be flushed free of all test water using boiler condensate or
demineralized water containing 200 ppm hydrogen peroxide with less than 1 ppm chlorides,
alcohol, petroleum distillate, or another suitable flushing solution. Hot air drying is not
acceptable in lieu of flushing, but water may be blown out of pockets using instrument air or
other dust filtered air.
G. It should be noted that risk of pitting corrosion is considerably diminished if the time between
pressure testing and start-up is as short as possible. When other than steam condensate or
demineralized water has been used and the time is anticipated to be longer than five (5) days,
flushing with condensate or demineralized water containing 200 ppm hydrogen peroxide is
recommended
H. The above rules also apply to medium and high nickel alloys and ferritic chromium stainless
steel where pitting corrosion is a risk
Piping that has been internally cleaned by sandblasting shall be tested after installation using a
water solution containing a suitable rust inhibitor. After piping has been tested, it shall be drained
and blown dry with air or nitrogen. A suitable corrosion inhibitor not objectionable to process
stream shall be used.

3.4.4

Piping that is to be chemically cleaned after installation shall be tested and all repairs made prior
to cleaning.

3.5

Test Methods and Pressures for ASME B31.3 Piping Systems

3.5.1

Hydrostatic Testing of Piping Designed for Internal Pressure

The hydrostatic test pressure at any point due to Internal Pressure in the system shall be as
follows:
A. For a design temperature above the test temperature, the minimum test pressure shall be as
calculated by the following equation

Pt

1.5PSt
S

where

St
S

6.5 (maximum)
(Equation 1)

Pt = Minimum hydrostatic gage pressure (psi)

P = Internal design gage pressure (psi)
St = Allowable stress at test temperature (psi)
S = Allowable stress at design temperature (psi) (Refer to Table 1, Appendix A, ASME
B31.3)
B. Where the test pressure as defined above would produce a stress in excess of the yield
strength at test temperature, the test pressure shall be reduced as follows

Page 9 of 22

Pm
Pm
Y
T
D

=
=
=
=

2YT
D

(Equation 2)

Maximum Test Pressure (psig)

Minimum Specified Yield Strength (psi)
Specified Pipe Wall Thickness Minus Mill Tolerance (in)
Outside Diameter (in)

3.5.2

If the design conditions of piping attached to a vessel are the same as those of the vessel, the
piping and vessel may be tested together at the test pressure of the vessel. However, if the
piping may be subject to higher design conditions; if it requires a higher test than the connected
equipment; or if the piping is designed for lesser operating conditions than the connected
equipment and could be overstressed by a system test, it shall be isolated and tested separately.

3.5.3

Where the test pressure of the piping exceeds the vessel test pressure and it is not considered
practical to isolate the piping from the vessel, the piping and the vessel may be tested together at
the vessel test pressure, provided approves and the vessel test pressure is not less than 77
percent of the piping test pressure calculated in accordance with Equation 1.

3.6

Hydrostatic Testing of Piping Designed for External Pressure

3.6.1

Lines in external pressure service shall be subjected to an internal test pressure of 1 times the
external differential design pressure but no less than a gage pressure of 15 psi.

3.6.2

Pneumatic Testing

3.6.3

If the piping is tested pneumatically, the test pressure shall be 110 percent of the design
pressure. The test procedure shall be in accordance with section 3.9. of this specification.
Hydrostatic-Pneumatic Testing

A combination hydrostatic-pneumatic test is permissible. The pneumatic test pressure shall be in

accordance with Section 3.6.2. of this specification. The pressure in the liquid filled portion of the
piping shall not exceed that given in Section 3.5.1. of this specification.
3.6.4

Sensitive Leak Test

Piping required to have a sensitive leak test shall be tested by the Gas and Bubble Formation Testing Method
specified in Article 10, Section V, of the ASME Code. Sensitive leak test shall be performed after
hydrostatic test.
3.6.5

Tightness Test
Except for piping systems identified as Category M Fluid Service, piping systems designed for
internal gage pressures at or above 0 but less than 15 psig shall be tested for tightness in
accordance with one of the following methods:

3.6.6

A. Hydrostatic
Fill with water to highest point in system and check all joints for leakage
B. Pneumatic
Pressurize system to 5 psi with air or other non-flammable gas and check all joints for
leakage using a bubble forming solution.
The fluid handled shall be nontoxic and not damaging to human tissue and have a design
temperature within the range of minus 20 degrees F to 366 degrees F (- 29 C to 186 C ),
inclusive.
Initial Service Leak Test for Category D Fluid Service Only (ASME B31.3)
A. A piping system used only for Category D Fluid Service, not previously hydrostatic or
pneumatic tested in accordance with this specification, may be tested at the normal operation
Page 10 of 22

3.6.7

3.6.8

conditions of the system during or prior to initial operation by examining for leaks at every
joint. Commodity testing shall require 's authorization.
B. A preliminary check shall be made at no more than 25 psig pressure when the contained fluid
is a gas or vapor. The pressure shall be increased gradually in steps providing sufficient time
to allow the piping to equalize strains and to check leaks.
Alternative Tests Approval is required) in services other than Category D Fluid Service
A. In circumstances when neither hydrostatic nor pneumatic tests are considered practical, an
alternative test in accordance with Section 3.6.7. B of this specification may be employed if
both of the following conditions apply:
A hydrostatic test would do the following:
(1) Damage linings.
(2) Contaminate a process which would be hazardous, corrosive, or inoperative in the
presence of moisture.
(3) Present a danger of brittle fracture from low metal temperature during test.
B. A pneumatic test would introduce considerable hazard due to possible release of stored
energy in the system or would present a danger of brittle fracture from low metal temperature
during test.
Under the conditions stated in Section 3.6.7. A of this specification, the following Alternate Leak
Test shall be applied:
A. Welds, including those welds used in the manufacture of welding pipe and fittings that have
not been subjected to hydrostatic or pneumatic leak tests in accordance with this specification
shall be non-destructively examined as follows:
(1) Butt welds shall be 100 percent radiographed or 100 percent ultrasonically examined.
(2) All welds, including structural attachment welds, not covered in (1) above, shall be liquid
penetrant examined. If the material is magnetic, magnetic particle examination may be
used in lieu of liquid penetrant examination.
(3) When heat treatment is required, the above examinations shall be performed after heat
treatment.
B. The system or joints to be tested shall be subjected to a sensitive leak test in accordance
with Section 3.6.4 of this specification. Joints that have not been hydrostatic or
pneumatic tested in accordance with this specification shall be examined for leakage.
C. A flexibility analysis of the piping system shall have been made in accordance with the
requirements of ASME B31.3.

3.7

Test Preparation-Field Procedure

3.7.1

Joints, including welds, shall be left non-insulated and exposed for examination during the test,
except that joints previously tested in accordance with this specification may be insulated or
covered. If a sensitive leak test is required (according to Section 3.6.4. of this specification), all
joints mentioned above also shall be left unprimed and unpainted.

3.7.2

Piping designed for vapor or gas shall be provided with additional temporary supports, if
necessary to support the weight of the test liquid. If required, temporary supports shall be
specified in the pressure test documents.

3.7.3

Lines that are counterweight supported shall be temporarily blocked during testing in order to
sustain the weight of the test fluid. Spring hangers that have been provided with stops for
carrying the test load normally do not require additional temporary supports; if this is not the case,
temporary support must be provided before filling the system.

3.7.4

Before testing, the following procedures shall be carried out:

A. Verify that any required heat treatment has been performed.
B. Piping systems shall have been completely checked (punched out).
C. Lines, vessels, and equipment shall be checked to ensure that the entire system can be
completely drained after testing.
Page 11 of 22

3.7.5

D. Vents or other high point connections shall be opened to eliminate air from lines that are to
receive a hydrostatic test.
E. System shall be purged of air before hydrostatic test pressure is applied.
Field personnel shall review all vessels and internals in order to determine best method to prevent
air entrapment when filling and to prevent vacuum when draining.

3.7.6

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

3.7.7

Flanged joints at which a blank is inserted to isolate other equipment during a test need not be
tested after blank is removed.

3.7.8

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 not possible, remove or
jack up the check valve closure mechanism or remove check valve completely, and provide
necessary filler piece or blinds.

3.7.9

When conducting tests at freezing temperatures, the test shall not take more than 4 hours, and
special precautions such as warming the line test water shall be observed to avoid freezing
damage. Follow precautions to minimize the risk of brittle fracture as noted in Section 3.8.7. of
this specification.

3.7.10

Systems that include expansion joints shall be investigated to refer to that any required temporary
restraints, anchors, or guides are installed or removed prior to test.

3.7.11

When a pressure test is required to 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
any pressure greater than the maximum test pressure.

3.7.12

Piping or sections of piping, to be tested may be isolated by closed valves provided the valve
closure is suitable for the test pressure.

3.7.13

Pressure test P&IDs shall be developed for identifying test packages. Test packages shall be by
circuits.

3.8

Hydrostatic Test Procedure

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3.8.1

In order to hydrostatic test as much piping as possible at one time, a systems test may be
employed. This test shall include one or more lines and, if possible, connected to vessels and
equipment.

3.8.2

The minimum test pressure for a system test shall be such that each line in the system is
subjected to a test pressure in accordance with Section 3.5 and 3.7, of this specification.

3.8.3

The maximum system test pressure shall not exceed the pressure test rating of any piping
component, or the shop test pressure of any vessels or equipment included in the test system.
Maximum test pressures for flanges and valves conforming to ASME B16.5 and ASME B16.34
are given in Attachment 01.

3.8.4

Systems or sections of systems to be tested may be isolated by closed valves, provided the valve
body and seat are suitable for the test pressure.

3.8.5

Where a suitable valve is not available, vessels, equipment, or other piping not included in the
system pressure test shall be either disconnected from the system or isolated by blinds or other
means during the test.

3.8.6

The normal location for the pressure test gauge or recorder is at grade near the pressure test
pump. Readings may be made at higher points providing the gage pressure reading and the
static head (0.433 psi/ft) between grade and the point of measurement do not exceed the
maximum test pressure. Test gauges or recorders shall be tagged with the date last calibrated,
and this activity shall be recorded. Test gauges or recorders shall be recalibrated prior to or during
use if the previous calibration date exceeds 3 months.

3.8.7

Hydrostatic test pressure shall not be applied until the vessel or equipment and its contents are at
approximately the same temperature. To minimize the risk of brittle fracture, pressure tests
through vessels and equipment shall not be conducted when the test liquid or metal temperature
is below 60 degrees F (15.6 degrees C). Pressure tests in ferritic piping systems that do not
include vessels or equipment may be conducted below 60 degrees F (15.6 degrees C) but shall
not be conducted when the test liquid or metal temperature is below 40 degrees F (4.5 degrees
C).

3.8.8

Hydrostatic test pressure shall be maintained for a sufficient length of time to visually determine
whether there are any leaks, but no less than 30 minutes. The pressure test shall be considered
satisfactory if no inapplicable pressure loss has occurred during the test. On successful
completion of pressure test, hydrotest chart shall be duly signed.

3.9

Pneumatic Test Procedure

3.9.1

Minimum Metal Temperature

At time of testing, the minimum pipe metal temperature shall be as listed below:
Minimum Temperature
Nominal Wall thickness
60 degrees F (15.6 C)
Carbon steel 1-1/2 inches and less
60 degrees F (15.6 C)
Post heat treated ferritic 1 inch and less
40 degrees F (4.5 C)
Austenitic steels 1 inch and less
Minimum temperatures for materials not listed above shall be determined by Piping
Engineering when required by field construction.

Page 13 of 22

3.9.2

Close control shall be maintained to limit the stored energy and / or the reaction force of gas in
any test system. The maximum stored energy level and maximum reaction force level should be
calculated and should not exceed 9400KJ for stored energy and 215KN for reaction force.

3.9.3

Clear the test area before bringing the line up to test pressure. It may be desirable to conduct
pneumatic tests during weekends when fewer personnel are present.

3.9.4

A pressure relief device shall be provided, having a set pressure no higher than the test pressure
plus the lesser of 50 psi or 10 percent of the test pressure.

3.9.5

When the pneumatic test pressure exceeds 15 psig, a preliminary check at 15 psig shall be made
to locate major leaks. The pressure shall be increased in gradual steps of 5 psig or 10 percent of
the test pressure, whichever is greater.

3.9.6

A double block and bleed valve arrangement shall be included in the pressurizing line to the
system being tested. A test pressure gage shall be downstream of the double block. After each
pressure step has been reached, close the block valve and open the bleeder to atmosphere. If
after a 5-minute period the step pressure is held, proceed to the next step pressure; if not,
examine the entire system for leakage.

3.9.7

When the system has been brought up to the test pressure shown on the piping pressure test
system record, the pressure shall then be reduced to the design pressure before being examined
for leakage. Joints and welds shall be covered with soap solution in order to detect any leakage.
Soap shall be a commercial preparation made specifically for leak detection.

3.9.8

Before soaping the joints, the entire line should be walked to determine whether there is any
audible evidence of leakage. Any leaks found at the time shall be marked and repaired after first
depressurizing the line.

3.9.9

Bolting shall not be tightened while systems being tested are pressured above 30 psig.

3.9.10

Pneumatic test pressure shall be maintained for a sufficient length of time to permit thorough
visual inspection of all joint and weld seams but no less than 10 minutes. The contractor is not
required to maintain test pressure in excess of 2 hours after notification of EPC Contractor's
authorized inspector. Pressure shall be reduced gradually when depressurizing.

3.10

Test Records

3.10.1

Records shall be made of each piping system test utilizing EPC Contractors standard forms,
when completed, shall be retained in the QC file as a permanent record. These records shall
include the following information:
o

Date of test

Identification of piping system and any vessels or equipment tested with the piping system

Test medium

Test pressure

Minimum ambient temperature

Test medium temperature

Certification by examiner

Test results

Name of test operator

Minimum metal temperature (if applicable)

Chart recorder

3.10.2

Upon completion of the project, these records shall be transferred to as specified in the Job
Closeout Procedure.

Page 14 of 22

3.11

Test Completion

3.11.1

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. Re-testing of
minor repairs or additions may be waived, provided approval of is obtained and the welding is
non-destructively examined according to Section 3.6.8. A.2. this specification.

3.11.2

After completion of testing, all temporary blanks and blinds shall be removed, all operating blinds
returned to proper position, and all lines and piping components shall be completely drained.
Valves, orifice plates, expansion joints, and short pieces of piping that have been removed shall
be reinstalled with proper new gaskets in place. Valves that were closed during hydrotest shall be
opened to ensure drainage of the bonnet cavity. Lines being drained after testing shall have all
vents open. Piping systems downstream of check valves should be inspected to ensure complete
drainage.

3.11.3

Direct connected transmitters at orifice flanges must be disconnected when replacing orifice
plates to avoid distorting the connections.

3.11.4

Care shall be exercised in controlling the rate of drainage from vessels with respect to the inflow
of air through the vent to ensure that the vessel is not subjected to vacuum. After vessels have
been completely drained, vents, cyclones, and other internal closures that were opened before
testing shall be closed.

3.11.5

After lines have been drained, temporary supports shall be removed, and insulation and painting
completed. Spring hangers provided with stops to carry the test load shall have these stops
removed.

3.11.6

The following are procedure after test completion:

1. Instruments which were removed or blocked out for test shall be reinstalled and blocks placed
in the normal operating position.
2. Bolting and gaskets used for pressure testing shall be removed and replaced with bolts and
gaskets specified in the Line Class.
3. Gaskets used for pressure testing shall be removed and replaced with line class gaskets.
4. Check valves that were jacked open or the internals were removed for pressure testing shall
be returned to their proper operating position.
5. Vessel and equipment internal closures which were opened specifically for pressure testing
shall be closed.
6. Instruments and process lead lines that were subjected to the hydrostatic pressure test shall
be blown out with dry air or nitrogen.
7. Vent and drain connections that were added solely for pressure testing shall be closed and
seal welded as required. Drains shall have either the valve closed and plugged or, if the valve
is removed, the connection plugged and seal welded as required.
8. Painting and insulation shall be completed after inspection of seal welded vents and drains.
9. Strainer screens shall be removed, cleaned, and reinstalled.

End of Specification

Page 15 of 22

ATTACHMENT 1
MAXIMUM HYDROSTATIC TEST PRESSURE (PSIG) FOR FLANGES AND VALVES

Page 16 of 22

Maximum Hydrostatic Test Pressure (psig) For Flanges And Valves

Material
Carbon
Moly

CR Moly

Stainless Steel

Normal (1.1)

C 1/2 (1.5)

1/2-1/2 1
1-1/4-1/2(1.9)
2-1/4-1(1.10)
5-1/2(1.13),
9-1(1.14)

304(2.1)
316(2.2)
321(2.4)
347.348(2.5)

304L,
316L(2.3)

309(2.6)
310(2.7)

Shell
450
1125
1500
2225
3350

Shell
400
1050
1400
2100
3150

Shell
450
1125
1500
2250
3375

Shell
425
1100
1450
2175
3250

Shell
350
900
1200
1800
2700

Shell
400
1025
1350
2025
3025

Carbon Steel
Flange
Rating
(Class)

150
300
400
600
900

Seat
285
740
990
1480
2220

Seat
265
695
925
1390
2085

Seat
290
750
1000
1500
2250

Seat
275
720
960
1440
2160

Seat
230
600
800
1200
1800

Seat
260
670
895
1345
2015

Page 17 of 22

1500
2500

5575
9275

3705
6170

5225
8700

3470
5785

5625
9375

3750
6250

5400
9000

3600
6000

4500
7500

3000
5000

5050
8400

3360
5600

Notes:
1. The above chart is based on ASME B16.5, and provides the maximum allowable hydrotest
pressures of 1/2-inch through 24-inch flanges (shell test) and flanged and standard class weld
end valves (shell test, with valve open and seat test, with valve closed). Seat test is based on
ASME B16.34, Paragraph 2.5.3.
2. Flanged valves manufactured according to API-600 and API-602 may be tested in accordance
with the above chart. Carbon steel, Normal (1.1), 800# scrd. or S.W. valves manufactured
according to API-602 and API-606 may be tested to 3000 psig (shell test) or 1975 psig (seat
test).
3. For valves not conforming to the above standards or ASME B16.5, the Manufacturers'
recommended test pressure limits for both shell and seat shall be used.
4. Maximum test pressures for flanges and valves over 24 inches and piping components not
covered by this chart shall be provided by EPC Contractor Piping Engineering as applicable.
5. The maximum test pressure for pneumatic testing shall not exceed 75 percent of the stated
values.

ATTACHMENT 2
STATUS OF INSTRUMENTS DURING PRESSURE TEST

Page 18 of 22

Status of Instruments during Pressure Test

1.0

2.0

GENERAL
1.1

This attachment defines additional requirements for pressure testing of

instrumentation.

1.2

Pressure testing of instrument process piping after the piping root valve and control
pneumatic piping are not covered by this specification.

SPECIFIC REQUIREMENT
2.1

The status of instruments during pressure testing shall conform to Table 1 on Sheet 2 of
this attachment. Instruments not covered in Table 1 shall not be subjected to pressure
testing without Owner's authorization.

2.2

When flanged instruments are removed from the test, the flange facings shall be
protected over the entire gasket seating surface with hook or plastic covers, securely
attached to the instrument, to exclude dirt and other foreign matter from the interior of the
instrument and to protect the flange facings.

2.3

When threaded instruments are removed from the test, the threaded ends shall be closed
with metal (of the same basic metallurgy as the instrument material) or plastic protectors,
to exclude dirt and other foreign matter from the interior of the instrument.

2.4

Orifice tap shutoff valves shall be closed and drain valves shall be opened during testing.

2.5

If spacer plates are required to be installed during testing, to replace removed orifice
plates, they shall be installed using test gaskets and test bolting.

2.6

Float type level instruments shall be drained during hydrostatic pressure testing.

2.7

The maximum allowable test pressure for displacer type level instruments shall be verified
prior to inclusion in the test. If they shall not stand the test pressure, they shall be
blocked from the test and drained.

2.8

Pressure instruments shall have their root valve closed and the drain valve shall be open
during testing.

Page 19 of 22

2.9

Analyzer tubing shall be disconnected during testing.

2.10

Control butterfly valves shall be removed during testing.

2.11

Do not reverse flow in Rotameters during testing.

2.12

Test gage may be used if one is furnished.

2.13

Blinds are not required on PSV outlets discharging into a system being tested at 15 psig
or less.

2.14

Instruments shall be protected from damage due to freezing. In preparation for cold weather
and during cold weather, all instruments must be drained and process lead lines blown out
with air or nitrogen

Table 1. Status Of Instruments During Pressure Testing

1. Analyzers
2. Control valves (excluding pressure
regulators, pressure balanced, and
butterfly)
3. Control valves (butterfly)
4. Flow instruments (D/P cell and bellows)
5. Flow instruments (metal tube rotameters)
6. Flow meters (positive displacement)
7. Flow meters (turbine)
8. Flow indicating switches (bellows)
9. Flow switches (vane)
10. Sight and gage glasses
11. Level instruments (displacer)
12. Level instruments (D/P cell and bellows)
13. Level switches (float)
14. Orifice plates
15. Pressure gages
16. Pressure instruments
17. PSVs
18. PSVs TSVs 3/4 and 1 screwed
19. Pressure regulators
20. Pressure switches

Block
And
Vent
X

Remove
For Test

Blank
Off

Include
In Test

Refer
To
2.9

X
X

2.10

X
X
X

2.11

X
X
X
X
X

2.7

2.6
2.5

X
X
X
X

2.8
2.13

X
X
X

Note: See ---- for reference.

Page 20 of 22

ATTACHMENT - 3
SCHEDULE OF MAXIMUM ALLOWABLE HYDROSTATIC TEST PRESSURE (PSIG) OR THE
LISTED TEST BLIND THICKNESS

Page 21 of 22

Schedule of Maximum Allowable Hydrostatic Test Pressure (psig) For the Listed Test Blind
Thickness
Nominal Pipe Size
Plate
2"
Thickness
1/4"
2,013
3/8"
4,528
1/2"
8,050
5/8"
12,579
3/4"
7/8"
1"
1-1/8"
1-1/4"
1-3/8"
1-1/2"
1-5/8"
1-3/4"
1-7/8"
2"

3"

4"

6"

8"

10"

12"

14"

16"

18"

20"

24"

30"

36"

931
2,094
3,722
5,816
8,376

563
1,267
2,252
3,519
5,067
6,896
9,007

260
585
1,041
1,626
2,341
3,187
4,162
5,268
6,503
7,869
9,365

153
345
614
959
1,381
1,879
2,455
3,107
3,836
4,641
5,523
6,482
7,518
8,630
9,819

99
222
395
617
888
1,208
1,578
1,998
2,466
2,984
3,551
4,168
4,834
5,549
6,313

70
158
281
438
631
859
1,122
1,420
1,753
2,121
2,525
2,963
3,436
3,945
4,488

58
131
233
364
523
713
931
1,178
1,454
1,759
2,094
2,457
2,850
3,272
3,722

45
100
178
278
401
546
713
902
1,113
1,347
1,603
1,881
2,182
2,505
2,850

35
79
141
220
317
431
563
713
880
1,064
1,267
1,487
1,724
1,979
2,252

29
64
114
178
257
349
456
577
713
862
1,026
1,204
1,397
1,603
1,824

20
45
79
124
178
242
317
401
495
599
713
836
970
1,113
1,267

13
29
51
79
114
155
203
257
317
383
456
535
621
713
811

9
20
35
55
79
108
141
178
220
266
317
372
431
495
563

Notes:
1. Test blind plates listed in the Plate Thickness Schedule Attachment 3 (above) are intended for
use between bolted flanges only. Use of the listed blind plates as welded end closures is not
permitted. Also, see Paragraph 2.1 Temporary Welded on End Closures.
2. The tabulated pressures above are based on the formula stated in ASME B31.1 or ASME
B31.3 using the following:
A. Flat non-asbestos gaskets conforming to ASME B16.21.
B. Structural grade carbon steel plate, ASTM A36 having a minimum specified yield strength
of 36,000 psi.
3. For plate that is identified as having a lower minimum yield strength, the allowable hydrostatic
pressure must be reduced in accordance with the following formula:
Pma

Yx
Y

where:
Pma
=
Y
=
Yx
=

X Maximum Allowable Hydrostatic Test Pressure (from table above),

Maximum allowable test pressure
Minimum specified yield strength (= 36,000 psi for ASTM A36 material)
Minimum specified yield strength for material selected

4. Pneumatic test pressures shall not exceed 50 percent of the values indicated.

Page 22 of 22