PEW-406.03 Pressure Testing

8/17/2019 PEW-406.03 Pressure Testing

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Saudi AramcoInspection Department

Training & Contractor Workforce Saudization Group

PRESSURE TESTINGPEW-406.03

The training materials contained in this module are the property of the Saudi Arabian Oil Company (Saudi Aramco) andare intended for the exclusive use of Saudi Aramco employees enrolled in advanced inspection training courses Anymaterial contained in this manual !hich is not already in the public domain" may not be copied" reproduced" sold" given or disclosed to third parties or other!ise used" in !hole or in part" for purposes other than for use in Saudi Aramco#s$rofessional %ngineering Development &nit courses !ithout the prior !ritten permission of the Chief %ngineer of Saudi

Aramco


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PEW-406.03 PARTICIPANT REVISION

DATE REVISIN DESCRIPTIN PAGE!S" A##ECTED

'*+*, CO-$.%T% /%0ISIO1S& 2AS3A" S CA0%" - A44AD

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PEW-406.03 PARTICIPANT TABLE OF CONTENTS

$DU%E C$PNENT PAGE

O25%CTI0%S

Terminal Ob6ective

%nabling Ob6ectives

I1T/OD&CTIO1

$urpose

T7$%S O8 $/%SS&/% T%STS

Types of Test -edia

3ydrostatic Tests

$neumatic Tests

Types of $ressure Tests

Strength Test

Tightness Test+

.ea9 Test

Service Test

/evalidation Test

%0A.&AT% $/%SS&/% T%ST $/OC%D&/%

SA%S:A:**,

SA%S:.';*


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Drains and 0ents

Test -anifold

$rotection of System Components

$ressure ation

$aragraph ;'? /emove Air before $ressuri>ing (.i@uid Test)

$aragraph ;', Control $ressure /ise

$aragraph ;'+ /estrict Approach to the System

=itness Strength and Tightness Tests

Strength TestTightness Test,,

Tests of In:service %@uipment

=itness System Depressuri>ation

$aragraph ;' Depressuri>e Safely

$aragraph ;* Dispose of Test -edia Safely

$aragraph ;' 8ollo! Additional Safety $recautions

DOC&-%1T T3% $/%SS&/% T%ST

/eport Strength and Tightness Tests

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%B%/CIS% ' 0%/I87 T%ST $/OC%D&/%

%xercise 'A 0erify Test $rocedure 3ydrotest Diagram and $ID

%xercise '2 0erify Test $rocedure Calculate Test $ressures

%xercise 'C 0erify Correct


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PEW-406.03 PARTICIPANT OBJECTIVES

'ECTIVES

Ter(ina) *+ecti,e

&pon completion of this module" the $articipant !ill be able to inspect pressure testpreparations and !itness a pressure test in accordance !ith applicable standards

Ena*)ing *+ecti,e-

In order to accomplish the Terminal Ob6ective" the $articipant !ill be able to

◊ Identify different types of pressure tests

◊ %valuate a pressure test procedure for compliance !ith applicable Saudi Aramco

and industry standards

◊ 0erify system readiness for pressure testing in accordance !ith SA%S:A:**,"

SA%S:.:';* and SA%S:2:*'E

◊ =itness pressure testing

◊ Document pressure tests

Note: This training material has been developed using the latest available versions of appliable!audi "ramo and industr# standards. $o%ever& these douments are regularl# updated.Therefore& it is the responsibilit# of the 'nspetor to ensure that he is onduting his

inspetions aording to the latest& updated version of these douments.

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PEW-406.03 PARTICIPANT INFORMATION

INTRDUCTIN

$ressure testing is re@uired by most piping codes to verify that a ne!" modified" or repaired piping system is capable of safely !ithstanding its rated pressure and is lea9tight $ressure testing may also be used to establish a pressure rating for a componentor special system for !hich it is not possible to establish a safe rating by calculation

Purpo-e

The purpose of pressure testing is to ensure the safety and reliability of plant and field

e@uipment $ressure testing is one of the methods the inspector uses to determine thate@uipment is safe for operation The piping and much of the e@uipment that Saudi

Aramco uses is designed to contain fluids under pressure $ressure testing chec9s theability of piping and e@uipment to !ithstand operating design pressures

Stresses in components during a pressure test are normally permitted to go as high as*F of the material yield point This approach ensures that the components !ill beexposed to a much higher stress than they !ill experience in service" but under !ell:controlled conditions If no defects are found under these conditions" then the pipingintegrity has been demonstrated

Once !elds have been properly designed for their purpose" and are of the necessary

@uality" one more step is necessary to ensure that the piping system is sound It must bepressure tested Saudi Aramco re@uires pressure testing of piping systems ande@uipment

All defects that are found from !eld inspection must be repaired before the pressuretest If the defects are not repaired" pipe failure may result The ob6ective of the pressuretest is to bring the piping system to a high enough internal pressure under controlledconditions" such that its mechanical integrity has been demonstrated Once the pressuretest has been conducted" the item is considered acceptable for operation


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T.PES # PRESSURE TESTS

T/pe- of Te-t $edia

Different types of tests and test media are used in combination to evaluate safe andreliable operation of plant and field e@uipment

There are t!o types of test media for use !ith pressure tests" namely li@uid or gasTests that use li@uid as a test medium are called hydrostatic tests Tests that use a gasas a test medium are called pneumatic tests

0/dro-tatic Te-t-

3ydrostatic testing is the preferred lea9:testing method and perhaps the most often usedbecause of its inherent safety 3ydrotesting uses !ater as the test medium If a lea9 at a!eld develops during a hydrotest" the internal pressure immediately drops because!ater is an incompressible fluid" and therefore causes no ma6or damage

1evertheless" there can still be a substantial ris9 associated !ith a hydrostatic lea9 testThe danger in a hydrostatic test is mainly due to air trapped in the piping %ven if all air isvented from the piping before pressuri>ing" !or9ers are !ell advised to conduct anyhigh:pressure test !ith safety in mind

Pneu(atic Te-t-

Tests that use a gas as a test medium are called pneumatic tests $neumatic meanspressure exerted by a gas The gas can be air or another gas approved by Saudi

Aramco for use in given testing situations

Saudi Aramco uses the pneumatic pressure test for some testing situations !herehydrostatic tests are not appropriate 8or example" flare lines ,:inch 1$S and larger !ith a design pressure of ;'E 9$a (ga) (E; psig) or lo!er may be pneumatically strengthtested per SA%S:.:';*

There are additional safety considerations for pneumatic pressure tests because the gastest mediums compress under pressure Compressed gas has a much greater potentialfor energy release than the li@uid test mediums used in the hydrostatic pressure testsConse@uently" there is greater ris9 of in6ury to personnel if the vessel or piping failsduring the test


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Inspection for a lea9 is usually done !ith a soapy:!ater mixture that is applied to the 6oints In case of a lea9" bubbles form as air or gas escapes

-ost often compressed air or bottled 1itrogen gas are used for pneumatic test3o!ever" 1itrogen should not be used in a closed area if the possibility exists that theescaping nitrogen could displace the air in the confined space $ersons have been9no!n to become unconscious under such circumstances before reali>ing they !ereshort of oxygen

2ecause of the greater danger of in6ury !ith a gaseous test medium" the pressure thatmay be used for visual examination for lea9s is lo!er for some piping codes than is thecase for a hydrostatic test

Warning: Do not approach any piping or equipment during pneumatic pressurization or while it is at strength test pressure. If the piping or

equipment fails during the strength test, the resulting explosive pressure release could kill ystanders and!or seriously damagesurrounding equipment.

Warning: "ever hammer test any piping or equipment that is undergoing a pneumatic pressure test. #he piping or equipment could e damaged,resulting in an explosive release of pressure. $ystanders could ein%ured or killed, and surrounding equipment damaged.

Warning: &ir is not approved for use as a test medium in any system that wasin hydrocaron service unless the system has een thoroughly

cleaned. #horough cleaning is necessary to avoid an explosivehydrocaron'air mixture.

Warning: In no case will oxygen or any toxic gas e used as a test medium.#hese gases present extreme hazards to personnel and equipment.

$ressure rise must be gradual and 9ept under control to allo! time for material to strainThis also provides personnel !ith time to chec9 for lea9s

Appro,a) fro( t1e Proper Aut1orit/

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Certain types of systems" such as lo!:pressure lines and dry:pipe fire protectionsystems" re@uire pneumatic pressure tests Others can be pneumatically tested as analternative to hydrostatic testing SA%S:A:**, and other pertinent standards provide

specific information

$neumatic testing is not permitted !ithout !ritten approval of the -anager" InspectionDepartment" unless specifically allo!ed by this standard or the referenced Saudi AramcoSA%Ss or SA-SSs This test" !hen conducted" shall be in accordance !ith


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A strength test is applied in the follo!ing cases

◊ 2efore piping system is initially placed in service

◊ After repairs or alterations have been made that affect the strength of pressure

containing parts" except as noted in SA%S:A:**,

◊ At intervals as specified by %@uipment Inspection Schedules

Tig1tne-- Te-t

A Tightness Test is a pressure test" !hich is conducted at ;F of the strength testpressure Tightness test is done immediately after the strength test and its purpose is to

ensure that there is no lea9age in the system 8or pipelines" a ,:hour recordedtightness test shall be applied at this pressure !hen pipeline is buried

%eak Te-t

A .ea9 Test is a pressure test to demonstrate that there are no lea9s in flanges or threaded 6oints at the test pressure .ea9 tests are normally conducted by Operationsduring startup or commissioning of the facilities" using approved plant procedures" andare outside the scope of SA%S:A:**,

Ser,ice Te-t

A Service Test is a strength test performed to prove the integrity of pipelines or plantpiping using the service fluid at the maximum attainable operating pressure

$lant utility piping in air and inert gas services !ith a design pressure (e@ual or less than';* $SI) and lo! pressure steam piping designed for +* $SI" are usually sub6ected tothe service test

Re,a)idation Te-t

A /evalidation Test is a pressure test that is meant to prove the integrity of existingcross: country pipelines or plant piping This test is conducted at the option of" and at theintervals set by" the responsible operating organi>ation 8or revalidation purposes of existing plant piping" the test pressure shall be minimum re@uired by AS-% 2 ?'?

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EVA%UATE PRESSURE TEST PRCEDURE

Test procedures" including hydrostatic test diagrams" shall be prepared by theresponsible engineering group and made available to Inspection prior to conducting thetest The test procedures and diagrams shall include the limits of piping (including testmanifold) and e@uipment included in each hydrostatic test 8urthermore" test pressures"test temperature" test fluid" line flushing re@uirements" and safety precautions shall alsobe included $rior to the hydrotest" the Inspector shall verify the follo!ing

◊ 0erify approved test procedure

◊ 0erify test flo! diagrams

◊ 0erify test pressures

◊ 0erify additional /e@uirements

Verif/

Appro,ed Te-t Procedure

All pressure tests must be controlled by an approved test procedure $ressure testprocedures are governed by these Saudi Aramco documents

◊ SA%S:A:**,

◊ SA%S:.:';*

◊


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◊ Scope

◊ Definitions

◊


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procedures must be approved by the Chief Inspection %ngineer of the ConsultingServices Department


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Verif/ Te-t #)o9 Diagra(

The Inspector determines !hich e@uipment and piping" including piping omponents" !illbe tested This group of process components is usually referred to as the system under test" and can be found by examining the test flo! diagram" also 9no!n as the hydrostatictest diagram The hydrostatic test diagram is used for both hydrostatic and pneumaticpressure tests The hydrostatic test diagram sho!s the limits of the test" including thelocation of isolation blinds (See 8igure ')

The hydrostatic test diagram may also sho! the locations of lo!:point drains and high:point vents" as !ell as the arrangement of the test manifold If these items do not appear on the hydrostatic test diagram" they !ill be provided on separate isometric dra!ings The

Inspector must also verify these separate dra!ings

#igure 58 Te-t f)o9 diagra(

'*


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Verif/ Te-t Pre--ure

The limiting factor for any pressure test is the pressure rating of the !ea9est componentin the system under test The pressure test procedure or the hydrostatic test diagram !illspecify !hich component limits the test pressure The Inspector first verifies that thespecified limiting component has the lo!est pressure rating !ithin the system under test3e then determines that the correct test pressure has been specified

The Inspector !ill usually be re@uired to verify the pressure for the follo!ing systems

◊ $lant piping

◊ $iping components

◊ 0alves

◊ Cross:country pipelines

◊ 3eat exchangers

◊ 2oilers and pressure vessels

Additionally" the Inspector should be familiar !ith the follo!ing factors that affect pressuretests

◊ %levation

◊ Temperature

After calculating the test pressure for the limiting component" the Inspector compares theresult of his calculations to the pressure listed in the hydrostatic testing procedure If thet!o numbers are different" the Inspector notifies his supervisor

2oth internal and external corrosion and erosion reduce the thic9ness of the metal inpiping and vessel parts Therefore" the Inspector compares recent thic9nessmeasurements !ith the thic9ness minimums (tm) for the vessels and piping to determineif all the components are !ithin their respective design safety factors 3e may decide tota9e thic9ness measurements of components that are near their tms or that sho! signs of an increasing rate of thinning The e@uipment history contains this thic9ness information"and the SISs contain the tm for vessels and critical piping

The Inspector contacts his supervisor and the engineering group concerned if he findsany component that cannot !ithstand the specified test pressure" or if his calculationsindicate that the specified test pressure is incorrect If the pressure ratings for all thecomponents meet or exceed the pressure specified for the test" then the system can betested safely

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P)ant Piping

&nless limited by flanges" valves or other components in the line" the hydrostatic

strength test pressure for every section of ne! constructed line shall produce a hoopstress in the pipe of *F of the specified minimum yield strength (S-7S) at the testtemperature per SA%S:.:';* The test pressure shall be calculated based on the pipenominal !all thic9ness less the mill tolerance (manufacturerKs minus tolerance) The testpressure shall not be less than the minimum test pressure per AS-% 2?'? paragraph?,;,

Calculation for the minimum hydrostatic test pressure (per hoop stress) for plant piping isas follo!s

Pt : 7!8;.T"

D

=here"

Pt : minimum test pressure

. : specified minimum yield strength of the pipe material

T : nominal pipe thic9ness x GE;

D : outside diameter of pipe" in inches

The value for 7 can be determined from Table A:' in AS-% 2?'? (See also Addendum)

The values for D and nominal pipe thic9ness can be determined from a commercial pipeschedule derived from AS-% 2?+'* and 2?+' LDimensions and -inimum 1o>>leThic9ness of Seamless and =elded Steel $ipeL

SA%S:.:';* also states that the test pressure shall not be less than the minimum testpressure per AS-% 2?'?" regardless of the above calculation The calculation for theminimum test pressure for AS-% 2?'? is as follo!s

Pd : 7SEt Pt : 586!Pd"

D

=hereH

Pt M minimum test pressure

Pd M maximum allo!able operating pressure

S M maximum allo!able stress for a given temperature

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E M longitudinal 6oint efficiency

t M nominal pipe thic9ness

D M outside diameter of pipe

The value for S can be determined from Table A:' 2?'? (See Addendum)

The value for % can be determined from Table ?*?, or Table A:'2 in 2?'? (See Addendum)

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◊ The hydrostatic shell test for flanged fittings shall be no less than '; times the

'***o8 rating rounded off to the next higher ; psi increment

◊ The test shall be made !ith !ater" !hich may contain a corrosion inhibitor" !ith9erosene" or !ith another suitable fluid" provided its viscosity is no greater thanthat of !ater" at a test temperature not above ';N 8

◊ The test duration shall be a minimum of ' minute for fittings 1$S and smaller"

minutes for fittings 1$S :' : 1$S G" and ? minutes for fittings 1$S '* andlarger

◊ 1o visible lea9age is permitted through the pressure boundary !all

To determine the maximum test pressure for a forged flange" the Inspector refers to AS-% 2'+;" Table 'A" .ist of -aterial Specifications (See 8igure )" and Table "

$ressure Temperature /atings (See 8igure ?) Table 'A is used to determine thematerial of the flange Table is used to determine the operating pressure at a giventemperature

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#igure 78 %i-t of $ateria) Specification- !Ta*)e 5A 2 AS$E 5=86"

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#igure >8 Pre--ure2te(perature Rating !Ta*)e 7 ? AS$E 5=86"

'+


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E


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#igure 48 0/drote-ting of ,a),e-

Table ':A" Table ':2" Table , and Table ; (8igures ; and +) sho! pressure testre@uirements" holding durations" acceptable lea9age rates as per A$I:;G

'G


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#igure 68 Pre--ure te-t reuire(ent- !API26;@"

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#igure =8 Te-t Duration and %eakage Rate- !API26;@"

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Cro--2countr/ Piping

This is the formula for calculating test pressures for cross:country piping (See 8igure E)

The yield strength can be found in A$I Specification ;." Specification for .ine $ipe"Table ?A (See 8igure G) The nominal thic9ness can be determined from a commercialpipe schedule derived from AS-% 2?+'* and 2?+' A partial table is seen on pageE;" LDimensions and -inimum 1o>>le Thic9ness of Seamless and =elded Steel $ipe

#igure 8 Cro--2countr/ Pipe)ine

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#igure @8 Ten-i)e Reuire(ent- for PS% 5 !API 6%"

E


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0eat E


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,


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#igure ;8 0eat E


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$neumatic test" !hen approved" shall be conducted per &


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is then vie!ed for evidence of through:thic9ness discontinuities by the formation of bubbles on the surface Through:thic9ness discontinuities are indicated by the formationof a continuous chain of bubbles in the film solution Through:thic9ness discontinuities

are usually considered unacceptable" and such !elds should be repaired and retested

#igure 538 Vacuu( *o< te-t

Reinforce(ent Pad-

The diagram illustrates testing of a reinforcement pad by the use of 2ubble test 8irst" a

strength test is applied at ; psig ('E? 9$a) through a tapped vent hole and then thepressure is dropped to ?:; psig (':?; 9$a) for a tightness test A bubble solution isapplied to the test area during the tightness test If any lea9age is indicated" release theair pressure" repair" retest by the same procedure (See 8igures '' and ')

E


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#igure 558 u**)e te-t on reinforce(ent pad- of euip(ent

#igure 578 u**)e te-t on a reinforce(ent pad of piping

Varia*)e- t1at Affect Pre--ure

E)e,ation

=here the pipeline traverses hilly terrain" the elevation gradient must be carefullyconsidered in selecting pipeline segments to be tested to ensure the specified allo!ablepercentages of the specified minimum yield strength (S-7S) are !ithin the tolerance@uoted

If !ater is used as a test medium" the test gradient must be based on !ater head in feet=ater pressure may be converted to head by dividing the pressure by *,?? If sea!ater is being used as a test medium" a factor of *,;; should be used This assumes a

specific gravity of '* for sea!ater In any case" the factor of *,?? should be modifiedaccording to the specific gravity of the test medium

(xample

Assume that a line needs to be tested and the elevation of the test site is '** feet Theelevation at the end of the line is ';* feet 8resh !ater !ill be used as a test mediumand it is desired to test the pipe to a minimum of *F and a maximum of ;F of theS-7S of the pipe The pipe is ?*L OD x *?*L !t A$I ;. B+*

G


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&nswer

The difference in elevation is ;* feet" !hich corresponds to a pressure of 'E psig (;*

feet x *,?? M 'E psig) A test pressure e@ual to *F of the S-7S is '",*, psig" sincethe test site is lo!er than the high end of the line" the 'E psig is added to the '",*,psig to obtain a test site pressure of '",+ psig The pressure at the end of the line !illbe '",*, psig" !hich e@uates to *F of the S-7S The pressure at the lo! point !ill be'",+ psig" !hich e@uates to ',F of S-7S

Te(perature

$ressure changes for a change in test !ater temperature and this pressure change canbe estimated by means of the follo!ing calculations and charts

(xample

$ipe data 'GJ OD x *?E;J

=ater Temperature (start) E*oC

At time t ++oC

Test $ressure '"G** psi

)alculate

Dt M 'G *?E; M ,G

=here D M pipe OD" in

T M $ipe !all thic9ness" in

)alculate

Average temperature M (E* ++) M +GoC

&se the chart" enter at +GoC and at the intersection !ith Dt line representing ,G" read 'psig oC

)alculate

E*oC : ++oC M ,oC

, x ' M G, psi

Therefore" a pressure drop G, psi" giving a final pressure of

'"G** P G, M '"E'+ psig


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?*


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?'


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2asis of chart development

d$ M Q2 P aR Q(D x (' P v

) %t CR

!here"

d$ M psig change per oC

2 M Coefficient of expansion of !ater

D M $ipe OD" in

% M -odulus of elasticity of steel

v M $oissons ratio

C M Compressibility factor for !ater

a M Coefficient of expansion of steel

t M $ipe !all thic9ness" in

T M Temperature oC

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VERI#. S.STE$ READINESS

Vi-ua) In-pection

After revie!ing the test procedure and the hydrostatic test diagram" the inspector performs a visual inspection of the test preparations in the field or at the plant under testto ensure that the re@uirements of SA%S:A:**, have been met

The Inspector verifies that the e@uipment on the hydrostatic test diagram matches thee@uipment being tested The pressure ratings on the hydrostatic test diagram shouldmatch the pressure ratings on the e@uipment The test limits should be clearly indicated

on the test diagram along !ith the locations of temporary blinds The Inspector verifiesthat blinds are as indicated on the diagram The Inspector verifies the follo!ing items

◊ Drains and vents

◊ Test manifold

◊ $rotection of system components

◊ $ressure gauges" recorders and relief valves

Drain- and Vent-

SA%S:A:**, specifies that vents and drains must be properly located throughout thesystem under test (See 8igure '?) 0ents must be located at high points in the system sothat all air can be removed as the system fills !ith test medium (!ater) The inspector chec9s that all parts of the system have a vent and that no dead legs exist in the systemDead legs are places !here air can be trapped by rising !ater as the system fills TheInspector must verify that the necessary vents are in place" as specified by thehydrostatic test diagram or the separate isometric dra!ing

$aragraph E, of SA%S:A:**, specifies exceptions to the vent re@uirements

Drains must be located at lo! points throughout the system under test (See 8igure '?)These drains provide locations to remove the !ater from the system after the test iscompleted The inspector chec9s that no dead legs exist !here !ater can be trapped asthe system drains This step is especially important for piping in high temperatureprocesses" because the !ater can vapori>e suddenly into steam during startup Thesudden vapori>ation of !ater in a piping system can cause damage to the plant

??


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The Inspector must verify that the necessary drains are in place" as specified by thehydrostatic test diagram or the separate isometric dra!ing $aragraph ? of SA%S:A:**, specifies exceptions to the drain re@uirements

#igure 5>8 P)ace(ent of ,ent- and drain-

Te-t $anifo)d


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There must be a valve to isolate the test pump from the system under test SA%S:A:**,specifies that the test pump must be isolated from the system under test during the holdperiods and during visual inspection

There must also be a valve to release the pressure If the test is a hydrostatic pressuretest" then the pressure release valve must be connected to piping that carries the testmedium to a safe location for disposal

8igure ', sho!s a typical s9etch for a test manifold that provides !ater filling"pressuri>ing" flo! monitoring" pressure monitoring" and bleed connections A permanentpump out connection in another location provides the drain (de!atering) connection for this particular systemH ho!ever" the drain connection is often provided by temporarypiping

Protection of S/-te( Co(ponent-

There are usually components in the system that must be isolated during the test Achec9list of these components should be provided to the Inspector 3e should verify byvisual inspection that all components designated for isolation have been properlyseparated from the system

In the case of a hydrostatic pressure test" some parts of the system under test mayre@uire structural reinforcement to support thee additional !eight of the test mediumThese parts should be identified on the hydrostatic test diagram The Inspector must

#igure 548 T/pica) -ketc1 for te-t (anifo)d

?;


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visually inspect these locations !ithin the system to verify that the additional support hasbeen properly installed and that it is ade@uate to support the anticipated loads

The Inspector visually inspects the source of the test medium to ensure

◊ That the correct test medium !ill be provided

◊ That the correct chemical treatment !ill be provided if the medium is !ater

◊ That the appropriate personal protective e@uipment !ill be provided if the

temperature of the test medium is above ,NC ('*N8) or belo! :++NC (:';*N8)

The Inspector visually inspects all piping components of the system under test to verify

◊ That all the components are rated for a pressure that meets or exceeds the

pressure specified for the test

◊ That all pipe flanges" bolts" and gas9ets are in serviceable condition

◊ That ne! !eld 6oints are properly completed and left exposed (uncoated and un:

insulated) for the test

The Inspector loo9s for any defective component that might fail even though it is rated ator above the re@uirement for the test pressure 3e also loo9s for components that !ereinstalled incorrectly or for situations !here a component other than the specifiedcomponent has been installed If the given component is rated belo! the test pressure"then that component must be replaced If it is not replaced" that component becomes the

limiting factor for the test and a ne!" lo!er pressure must be specified for the test

Pre--ure Gauge-B Recorder-B and Re)ief Va),e-

Pre--ure Gauge-

SA%S:A:**, specifies that t!o or more pressure gauges must be installed to monitor thepressure during all phases of the test As a minimum" one pressure gauge must belocated at the discharge of the test pump and one pressure gauge must be located!ithin the system under test The inspector verifies that the gauges meet thesere@uirements

◊ The gauges must have a range such that the pressure specified for the test is

bet!een ?*F and G*F of the full range

◊ The gauges must indicate !ithin ;F of each other for any given pressure

◊ The gauges must have calibration stic9ers that indicate calibration !ithin the

past month

?+


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◊ The gauges must have calibration certificates available to document calibration

accuracy

◊ The gauges must have a bloc9 valve and a bleed valve that allo! the pressure gaugeto be replaced !hile the system is pressuri>ed

A calibration stic9er indicates the date a specific pressure gauge !as calibrated 8igure'; sho!s a calibration stic9er

#igure 568 T/pica) ca)i*ration -ticker

8igure '+ sho!s a calibration certificate that certifies the accuracy of a pressure gaugeThe specific pressure gauge certified by this certificate is identified by the serial number"-A4:**G

1otice that the calibration range is from '** psig to +*** psig The verification datasection of the certificate indicates that the pressure gauge !as chec9ed in threeseparate tests 8or each test" the gauge !as pressuri>ed to a series of 9no!n testpressures and the pressure indication !as read and recorded 8or all pressures !ithinthe calibration range" the pressure gauge indicated a true pressure and the error !asrecorded as >ero

?E


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8I


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Te-t Pre--ure Recorder

SA%S:A:**, and SA%S:.:';* also specify the circumstances under !hich a pressure

recorder (8igure 'E) is necessary for pressure tests

◊ =hen it is advisable to 9eep a permanent record of the test

◊ =hen test duration !ill exceed four (,) hours

◊ =hen 6oints are not exposed during the test" such as for buried or insulated

piping This also applies to partially buried or insulated piping for more than?**m or '*F of its total length !hichever is less

$ressure recorders must also be properly calibrated

◊ The recorders must have a calibration stic9er that indicates calibration !ithin thepast month

◊ The recorders must have calibration certificates to document calibration

8igure 'G sho!s a pressure recorder chart from a ,:hour tightness test 1ote that thechart indicates a lea9 The call:outs indicate times of specific events

8igure ' sho!s a pressure recorder chart from a :hour strength test The chartindicates that there !as a failure" necessitating repairs before the system under testcould pass the strength test =hen the recorder !as started at '*?* A- on April +" thesystem !as already pressuri>ed to "***:psi The callouts on the chart indicate times of

specific events

#igure 58 T/pica) pre--ure recorder

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#igure 5@8 Pre--ure recorder for 7421r tig1tne-- te-t

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#igure 5;8 Pre--ure recorder for 721r tig1tne-- te-t

Te-t Pre--ure Re)ief Va),e-

SA%S:A:**, re@uires the system under test to be protected by a pressure relief valve(See 8igure *) The Inspector chec9s that the pressure relief valve is properly locatedat a high point in the system and that the si>e of the pressure relief valve meets the

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re@uirements of A$I /$:;* 3e also chec9s the tag attached for relief valve testverification as follo!s

◊ The pressure relief setting must be ;F above the specified test pressure

◊ The pressure relief valve must have been tested !ithin the past !ee9

◊ The date of the relieving test must be clearly indicated on the tag

#igure 738 Cro--2-ection of a re)ief ,a),e8

8igure ' sho!s a test report for a relief valve The serial number (S1) identifiesthe specific relief valve tested as T3+,+* 1otice that the set pressure is +?**psig The 8inal Test /esults section of the report sho!s that the test medium !as!aterH that the relief pressure !as +?** psigH and the reseat pressure !as ;+E*psig The terminology on the report refers to the relief pressure as the $op $ressureand the reseat pressure as Tight At The report contains the signature of the personperforming the test and the date that the test !as performed

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#igure 758 Te-t report for a re)ief ,a),e

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WITNESS PRESSURE TESTING

Witne-- S/-te( Pre--urization

$aragraph ;" $rinciples of Safe $ressure Testing" of


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Witne-- Strengt1 and Tig1tne-- Te-t-

The Inspector !itnesses the strength test by observing the system under test from adistance as specified in


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Te-t- of In2-er,ice Euip(ent

The strength and tightness tests are performed on ne! e@uipment before the system ishanded over to an operating department 1evertheless" many situations re@uirepressure tests of e@uipment that is already in service 8or example" e@uipment that hasbeen opened and repaired during a TI re@uires pressure tests to verify that there areno lea9s As !ith any other test" the Inspector must verify that the correct test pressure isspecified 3e uses those re@uirements from Section + of SA%S:A:**, that apply for in:service tests

Witne-- S/-te( Depre--urization

$ost:test procedures are specified in paragraphs ;'E through ;' of


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◊ Isolate the test manifold !ith a bloc9 valve and bleed off the pressure !hen this

piping is not needed

◊ Open a vent on any unattended system that has been filled !ith test medium toprevent overpressure (or vacuum) due to temperature changes

◊ 4eep the test relief valve installed until the test medium has been drained from the

system

◊ Drain li@uid from a system slo!ly !ith the vents open to prevent a vacuum

,E


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DCU$ENT T0E PRESSURE TEST

Report Strengt1 and Tig1tne-- Te-t-

The Inspector reports the results of the strength and the tightness test by filling in Saudi Aramco 8orm +,:%ng" the $ressure Test /eport An example of this form appears in Addendum A =hen properly completed" this form records the details of the pressuretest

◊ Data related to the e@uipment or system tested

◊ The conditions for the pressure test

◊ A description of any repairs re@uired to accomplish the pressure test

◊ The InspectorKs remar9s concerning the e@uipment andor the pressure test

The Inspector also reports the pressure test on Saudi Aramco form *?:%ng the%@uipment Inspection /ecord P


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PEW-406.03 PARTICIPANT EXCERCISES

EERCISE 58 VERI#. TEST PRCEDURE

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EERCISE 78 VERI#. S.STE$ READINESS

erif# 5orret Test Pressure elief alves7& Test pressures et. and %itness the pressure test

This eerise is designed to help #ou learn and pratie the revie% and visual inspetiontehniues reuired to verif# that the orret test pressure relief valves7 have beenhosen for a speified pressure test. 8our instrutor %ill provide #ou %ith several

pressure relief valves& pressure gauges. 9oate the !'! and the Test 2lo% +iagram./se Wor "id ;" and the appliable standards to verif# %hih relief valves and pressuregauges ompl# %ith !audi "ramo reuirements.

The instrutor %ill arrange for a field trip to %itness a pressure test and provide #ou ah#drostati test proedure. Witness the test.

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EERCISE >8 DCU$ENT PRESSURE TEST

/se #our field notes from Eerise ;. 5omplete the forms and submit to #our instrutor for evaluation.

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PEW-406.03 PARTICIPANT WORK AIDS

WRF AID 5. PRCEDURES #R EVA%UATING PRESSURE

TEST PRCEDURE

+uring the pre-test inspetion& the 'nspetor hes that all aspets of the pressure test preparation ompl# %ith the reuirements in


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WRF AID 78 PRCEDURES #R VERI#.ING S.STE$

READINESS

The reuirements for the pressure test preparations for the s#stem under test arespeified b#


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◊ Such as !eld 6oints are properly completed and left exposed to vie! during

the pressure test

'* 0erify that the proper test medium has been provided If the test medium is!ater" then verify that all chemical treating re@uirements have been met

'' 0erify that all temporary supports have been installed 0isually inspectthese supports for structural integrity

' 0erify that appropriate measures have been ta9en to control access tothe pressure test location during the test

'? 1otify the


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Work Aid 7A8 Procedure- for Vi-ua))/ In-pecting Te-t

Pre--ureB Re)ief Va),e-B Pre--ure Gauge-BWitne-- Pre--ure Te-ting And Record T1eRe-u)t-8

Note: This %or aid speifies the sub-steps of !tep ? in Wor "id ;.

The reuirements for the loation of a test pressure relief valve %ithin the s#stem under test& is speified b#


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PEW-406.03 PARTICIPANT GLOSSARY

G%SSAR.

dead )eg A section of pipe that has no high:point vent or a section of

pipe that has no lo!:point drainH !hen the pipe is filled !ith

li@uid" air can be trapped in a dead legH !hen a pipe is

drained" li@uid can be trapped in a dead leg

f)uid A term used at Saudi Aramco to mean a combination of vapor and li@uidH for example" a combination of steam and!ater is a fluid

k-i 4ilo pounds per s@uare inchH a unit of pressure ' 9ilopound is e@ual to '"*** pounds

(ediu( The material (li@uid or gas) that exerts pressure on asystem for a pressure testH for example" !ater is a li@uidtest medium

piping" critica) SA%S:A:**; defines critical plant piping as

a) piping !hose failure leads to a ma6or shutdo!n of theplant or a ma6or unit in the plant"

b) piping in high temperature service Q?,*N C (+;*N 8) or higherR"

c) piping under high pressure Q?",;* 9$a (;** psi) or greaterR"

d) piping that carries toxic or corrosive fluids" or e) pipingthat has some other specific operating ha>ard not usuallyexperienced !ith usual plant or process lines Other standards" such as AS-% 2?' and SA%S:.:'**" alsoapply

pipingB non2critica) That piping not covered by the definition of critical piping

piping co(ponent- -echanical elements suitable for 6oining or assembly intopressure:tight fluid:containing piping systemsComponents include pipe" tubing" fittings" flanges" gas9ets"bolting" valves" and devices such as expansion 6oints"flexible 6oints" pressure hoses" traps" strainers" in:lineportions of instruments" and separators

;G


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PEW-406.03 PARTICIPANT GLOSSARY

PSI $ounds per s@uare inchH a unit of pressure

!to" rupture To burstH for example" a balloon ruptures !hen it is filled

!ith too much air

t1ickne-- (ini(u( The minimum thic9ness of metal re@uired to !ithstandoperating pressuresH abbreviated tm" T-" tm or tmin

;


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PEW-406.03 PARTICIPANT ADDENDUMS

ADDENDU$ A PRESSURE REPRT #R$


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ADDENDU$ TA%ES

◊ Table LDimensions and -inimum 1o>>le Thic9ness of Seamless and =elded

Steel $ipeL

◊ AS-% 2?'?" Table A:'

◊ AS-% 2?'?" Table ?*?,

◊ AS-% 2?'?" Table A:' 2

◊ AS-% 2'+;" Table 'A

◊ AS-% 2'+;" Table

◊ A$I ;." Table ,'

◊ AS-% 2?+'- Table


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ADDENDU$ C8 0.DRSTATIC TEST PRCEDURE

#or Ut1(ani/a1 GSP2= Tie2%ine


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Documents

PEW-406.03 Pressure Testing