INSPECTION

After completion of erection the system under the scope of work, shall be
thoroughly inspected for compliance to design requirement for layout, plans,
elevations, connect- ions, details, material quality of welding and erection,
supporting, thermal expansion, safety, suitability for operation through valves,
etc. approaches, maintenance, etc. and quality records are maintained. Piping
system shall be flushed until all pipe lines are thoroughly cleared of
loose scale, contaminants and debris. Pipes, fittings etc.,of each system shall be
cleaned inside and out side by suitable means. The cleaning process shall include
removal of all foreign matter such as scale, sand, weld spatter,
erection clamps, cutting chips etc., by wire brushes, cleaning tools etc.

TESTING
General :
Joints shall not be painted, insulated or coated prior to completion of testing.
All pressure test shall be performed by the Erection agency and shall be inspected
and approved by JSPL.
No test shall be performed until the prefabricated spool/system is examined
physically. and cleared by JSPL.
Valve shall be kept in open position during test
Equipment and components not subjected to pressure test shall be disconnected or
the erection agency shall provide spools, blanks or blind flanges as required to
adequately isolate the equipment during test.
If necessary, temporary pipe supports, pipe anchors etc.,
Hydro testing of spool pieces/piping system of above ground piping (particularly
over pipe racks) shall be carried out bearing in mind the load carrying capacity of
the rack, only one line / piping system shall
be hydro tested at a time.

Hydrostatic Testing :
Hydrostatic testing shall be carried out only on those services mentioned in Table
1.Each spool to be hydro tested shall be provided with suitable blinds at the
ends.
The blinded ends shall be fitted with suitable valves for filling water, draining
water and venting air. The water filling and drain valves shall be installed at the
lowest possible level and the vent valve at the highest
possible level.
Before start of water filling vent valve shall be kept open and water shall be
filled into the line gradually ensuring proper air venting.
Air vent valve shall be closed, once all the air is removed from the pipe line.
Suitable hydrostatic pressure pump shall then be connected to the pipe line and
care shall be taken to ensure gradual increase of pressure in the pipe line.
Following pressurizing sequence shall be followed
Pressurize to 50 % of the test pressure, hold pressure for one hour.
# Drop pressure to static head + 1 bar at lowest point.
# Pressurize to 75 % of the test pressure, hold pressure for one hour.
# Drop pressure to static head + 1 bar at the lowest point.
# Pressurize to the test pressure.

In case during the hold pressure periods indicated above a decrease in pressure is
observed, the above operation shall not be repeated more than twice, after which
the line shall not be considered capable of test until the cause
for leak of water has been isolated and eliminated.

The gauge used for testing shall be installed as close as possible to the low point
of the piping system.

The test pressure as per table-1 shall be maintained for a period of not less than
1 hour. Sweating, oozing of drops shall be observed in the pipe being tested. Check
for
pressure drop if any after the holding time is over. The test pressure shall be
maintained until the entire section under test has been examined. Defects revealed
by the
tests shall be repaired, or defective parts replaced and the system retested. For
acceptance, no drop in pressure during the test period is allowed.

After completion of the hydrostatic test, the system shall be completely drained.
Air vents shall be kept open during system draining to avoid producing a vacuum.

For different service requirements min Percentage of Radiography, Hydrostatic test

pressure and Pneumatic test pressure are indicated in the table below.

Protocol for completion of works before doing hydro/pneumatic test

Name of department : location: section of piping reference drawing

Check following documents:

1) Piping schematic Drawing ,P& ID & erection drawing
2) Pipe & pipe fitting materials as per specification
3) Supports as per drawing
4) Weld joints as per technical specification, radiography test results
5) Cleaning of pipe line
6) Flange joints , threaded joints as per technical specification

Signed by JSPL /CoNTRACTOR Signed by JSPL ENGINEER

Signed by safety engineer

Protocol for hydro test / pneumatic test of pipe line

Name of department : location: section of piping reference drawing

1) test pressure as per specification kg/cm2
a) Hydraulic
b) Pneumatic
2) Duration of test as per specification hr/min
3) Leakage if any
4) Rectification of joints/ flange/threaded
5) Retest
Signed by JSPL /CoNTRACTOR Signed by JSPL ENGINEER
Signed by safety engineer

Protocol for commissioning of pipe line : putting liquid/gas

Name of department location: section of piping reference drawing

1) Liquid : remove all water from pipe line by draining. Blow the air & remove all
moisture from pipe line
2) Gas: after carrying out the pneumatic test blow the air and remove suspended
materials
3) If NG, Syn Gas, CO gas Put the nitrogen purge it from the bleeding points ,
check no traces of O2 is present Seal the pipe line,
Slowly admit the NG/BF Gas/Corex gas/coke oven gas required pressure.

Signed by JSPL /CoNTRACTOR Signed by JSPL ENGINEER

Signed by safety engineer

Pneumatic Testing :
Pneumatic testing shall be carried out for those services indicated in Table -1.

a)For Strength
The test shall be performed with compressed air, dry compressed air or nitrogen.
A Pressure relief device shall be installed between the piping system being tested
and the pressure source in order to protect the piping system from excess pressure.
Pressure relief device shall have a set pressure of not more than the test pressure
plus the lesser of 3.5 kg/cm2 or 10 % of the test pressure.
Pressure in the equipment shall be gradually increased to not more than 50 % of the
test pressure and then thereafter by increments of 10 % of test pressure till it
reaches to the final test pressure.
Pneumatic test pressure shall be maintained until the entire section under test has
been examined for leakage.
While holding the test pressure all welded, threaded and flanged Connections shall
be inspected, by soap solution test. Defects revealed by the tests shall be
repaired, or defective parts replaced and the system retested.

For Leakage
Pressure lowered to max. working pressure and leakage test will be conducted over
duration of 24 hour. Pressure and temperature recording shall be done every 60 min.
interval.
Following formulae for acceptance of leakages shall be adopted during testing of
pipeline with fluid.
100 x( 1 -Pf / Tf x Ti / Pi ) < 4 % for interplant piping
< 2 % for inside shop

Pi = Initial pressure Pf = Final pressure

Ti = Initial temperature Tt = Final temperature

RECORDS
Record shall be made for each pipe line / system and shall be approved by JSPL.
This record shall be submitted to JSPL.
All test results of tested seams shall be recorded in the welding log book.
These records shall certify all the quality control requirements of the regulations
and the engineering design. This record shall include the following.

-- Inspection of Workmanship
-- Examination of Welds / Radiography test report
-- Test Pressure, Design pressure and Working pressure
-- Date of test
-- Pressure gauge calibration due date
-- Fluid media and test fluid media
-- holding time
-- Isometric line diagram
-- Comments during observation of testing.
-- Supplementary Test

COMMISSIONING :
Prior to commissioning:
The tested pipeline kept plugged at both ends, shall be blown with dry compressed
air / Nitrogen at a velocity not less than 20m/sec.
During or prior to initial operation the pressure shall be gradually increased in
steps until the operating pressure is reached, holding the pressure at each step
long enough to equalize piping strains.
While holding the operating pressure, all welded, threaded and flanged connections
shall be inspected.
SUPPLEMEANTARY REQUIREMENTS FOR OXYGEN PIPING :

General :
Oxygen service requires essentially complete removal of contaminants such as hydro
carbon greases, oil,thread lubricants, shop dirt, water, scale, weld spatter,
chips, rust, fluxes, paints, crayon marks, packing
material or any other foreign materials. Many of these materials, especially
hydrocarbon greases and oils,can react violently in the presence of oxygen, causing
fires or explosions. Others such as metal chips, can
be propelled by the oxygen stream with sufficient velocity to trigger an explosion
on impact Still other, by plugging small ports or seizing moving parts can cause
dangerous mal-function of equipment.
All these material are considered contaminants and must be removed. It is
especially important to avoi trapping of contaminants in locations difficult or
impossible to clean after assembly. Therefore, cleaning
and assembly procedure must be integrated to avoid this condition. Further more,
once the system is cleaned, it must be kept clean until it is put into service.

Personnel shall be aware of the proper cleaning techniques to be used and be fully
aware of the serious consequences that could result from inadequate cleaning. They
shall be required to wear apparel which is
free of oil and grease and to work with clean hand gloves. (Note: A cleaned surface
should never be touched or handled by the bare hand as its in the natural skin are
contaminants.)

Utilities directly involved in cleaning operations shall be compatible as follows.

a) Gases like Nitrogen, Compressed air Gases only dry, oil free, inert gases shall
be used for cleaning, purging, drying and testing. b)
Water Water used for making up solutions or for flushing, rinsing or testing shall
be potable. c) Steam Any steam used for direct contact heating or cleaning shall be
free from oil and scale.

JSPL shall approve and/or inspect all materials, equipment procedures, etc., which
is necessary to produce the desired standards of cleanliness.

Welding
The TIG welding process shall be used for at least root pass. Subsequent passes
shall be made with welding processes according to WPS. An internal gas purge shall
be maintained during the entire welding
process.

All roots shall be examined by Liquid Penetrant or Magnetic Particle examination

for minimizing of repairs and by it the risk of contamination.

Inspection
Wherever possible, equipment for oxygen services shall be inspected by using
methods that apply to a particular situation. This covers both, pre-cleaning and
post cleaning inspections. If any of the tests reveal
contaminants, the item must be cleaned.

Static Protection System (Earthing)

The piping work shall be provided with static protection system wherever
applicable. Pipes entering and leaving the units or equipments shall be effectively
earthed at the specified locations, in addition to other
locations as specified in the standard specs.

Cleaning procedure on site :

The cleaning shall be done in general conformance with this specification, and as
outlined in the contractors own cleaning specification which has been explicitly
approved. Contractors specification shall contain a clear, accurate, step by step
description of the cleaning procedure, a description of the
cleaning facilities cleaning agents and inspection methods.

Cleaning Process

The cleaning of pipes and other piping parts shall be done for each single part by
the following steps.
Carbon steel:
a ) Degreasing
b ) Pickling for removal of scale, rust and other contaminants,
c ) Neutralization
d ) Passivation
e ) Drying with oil free air or oil free nitrogen
f ) Covering and sealing of both ends to prevent corrosion.

DEGREASING, PICKLING AND PASSIVATION OF OXYGEN PIPELINES :

In view of the possible hazards due to violent reactions of oxygen with hydrocarbon
materials like oil etc., the oxygen pipelines need to be specially degreased,
pickled, passivated and dried with oil free air or dry
nitrogen before being allowed to carry oxygen, after conducting satisfactory
Radiographic and Pneumatic test.

The following procedure may be adopted for the above.

The pipeline system to be commissioned shall be ready with respect to erection
namely supporting, NDT, leak test etc.
2 Hydro testing of pipeline along with valves to be carried out before taking the
pipe line for degreasing and
pickling.
3 All isolation valves and control valves provided in the pipeline are to be
removed and appropriate spool
pieces to be provided to make the continuity in the pipe line.
4 Degreasing and acid pickling of valves shall be carried out separately by dipping
valves in respective
solution bath.
5 The valves shall be flushed with fresh DM water/Potable water to remove
acidtraces & cleaned with
Trichloro Ethylene (T.C.E.). The valve ends shall be covered & secured after
cleaning with plastic sheets to
prevent entry of dust.
6 The system shall be circulated and flushed with oil free cold water.
7 The system shall be circulated and flushed with hot water at a temperature range
of 50-60C.
8 The system shall be degreased with hot water containing 2-2.5%NaOH and 0.1%
detergent (Surfactant) at a
temperature of 60-70C.
9
10 Oil content, alkalinity and pH shall be analyzed. Degreasing process shall be
continued so as to obtain only
traces of oil content in the samples. DM water / potable water flushing shall be
adopted.
11 Hot DM water/ potable water (60-70C) containing 3%inhibited ammoniated citric
acid along with ABF
( Ammonium biflouride NH4HF2 ) shall be circulated and flushed for pickling the
system. During the pickling
process, the pH value shall be 3-4, percentage of acid not less than 1.5 and Fe+3
shall not be more than 2500 ppm.