Doc.
No : MEP-P-ES-008
HYDROTESTING OF IN-PLANT PIPING
Rev 0 page 1 of 8
Rev Date : 25 July 2005
PT. MEDCO E&P INDONESIA
STANDARD SPECIFICATION
FOR
HYDROTESTING OF IN-PLANT PIPING
MEP-P-ES-008, Standard Specification For Hydrotesting Of In-Plant Piping, rev 0, 25 July 2005
Custodian: Surface Engineering
Doc. No : MEP-P-ES-008
HYDROTESTING OF IN-PLANT PIPING
Rev 0 page 2 of 8
Rev Date : 25 July 2005
TABLE OF CONTENTS
PAGE
1 SCOPE 3
2 APPLICABLE STANDARDS 3
3 PURPOSE OF TEST 3
4 TEST FLUID 3
5 TEST PRESSURE 3
5.1 General 3
5.2 Flange Limited System 3
6 TEST DURATION 4
7 PREPARATION FOR TEST 4
7.1 Approval 4
7.2 Safety 4
7.3 Isolation 5
7.4 Valves 5
7.5 Sensitive Equipment 5
7.6 Insulated Piping 5
7.7 Test Equipment 5
8 TEST PROCEDURE 6
8.1 Filling 6
8.2 Pressurization 6
8.3 Hold Period 6
8.4 Acceptance of Test 6
8.5 Draining 6
8.6 Flushing 6
8.7 Drying 7
8.8 Restoration 7
9 DOCUMENTATION 7
9.1 Hydrostatic Test Report 7
9.2 Chart Records 7
9.3 OWNERship 7
Appendix-A, Piping Pressure Test Record 8
MEP-P-ES-008, Standard Specification For Hydrotesting Of In-Plant Piping, rev 0, 25 July 2005
Custodian: Surface Engineering
Doc. No : MEP-P-ES-008
HYDROTESTING OF IN-PLANT PIPING
Rev 0 page 3 of 8
Rev Date : 25 July 2005
1 SCOPE
This specification defines the minimum requirements for the hydrostatic testing of plant
piping for Medco Engineering Standard (MES).
2 APPLICABLE STANDARDS
ASME B31.3 Chemical Plant and Petroleum Refinery Piping
ASME B16.5 Steel Pipe Flanges and Flanged Fittings
API-6A Specification for Wellhead Equipment
MEP-P-ES-003 Fabricated Piping Standard
MEP-P-ES-009 Precommission Cleaning of Piping Systems
3 PURPOSE OF TEST
The hydrostatic test demonstrates that the pipework has sufficient strength to withstand
operating pressures and proves that the system is free of leaks.
4 TEST FLUID
4.1 All tests shall be carried out using fresh water except when inclusion of water
would prove harmful to the operating fluid (e.g. Instrument Air). In such cases
nitrogen (or air) may be used when approved by COMPANY.
4.2 COMPANY requires that corrosion inhibitors be added to the test water to
minimize corrosion damage to the inside of the pipe. The inhibitor shall be added
in a manner that will achieve uniform mixing of the inhibitor and the water and the
concentration recommended by the manufacturer.
5 TEST PRESSURE
5.1 General
Unless otherwise specified, the hydrostatic test pressure shall be 1.5 times the
100oF design pressure, measured at any point in the system.
5.2 Flange Limited System
For piping systems designed to conform to flange pressure ratings, the minimum
test pressures are defined as follows:
FLANGE RATING TEST PRESSURE (psig)
ANSI 150 428
ANSI 300 1110
ANSI 600 2220
ANSI 900 3330
ANSI 1500 5558
MEP-P-ES-008, Standard Specification For Hydrotesting Of In-Plant Piping, rev 0, 25 July 2005
Custodian: Surface Engineering
Doc. No : MEP-P-ES-008
HYDROTESTING OF IN-PLANT PIPING
Rev 0 page 4 of 8
Rev Date : 25 July 2005
ANSI 2500 9255
6 TEST DURATION
All pipe systems shall be tested for a minimum of one hour. The COMPANY, for certain
applications may specify longer periods.
7 PREPARATION FOR TEST
7.1 Approval
All details relevant to the hydrotest shall be submitted to COMPANY, in the form of
a hydrotest procedure, for approval before commencement of the test. Details to
be submitted shall include:
a) Test Pressure
b) Test Fluid
c) System description (line numbers, etc.)
d) Location of blanks and spades
e) Duration
f) Fill and vent points
g) Equipment
The information shall preferably be submitted in the form of Hydrostatic Test
Report sheets (Appendix A) and marked up flowsheets.
7.2 Safety
Where piping is being tested in situ and not in the fabrication shop or yard,
CONTRACTOR shall ensure that:
a) The pipe supports for gas lines are adequate to support the additional
weight of water in the pipe. Additional temporary supports shall added if
required.
b) Expansion joints are restrained against the pressure forces or alternatively
are removed from the system.
c) Apparatus is supplied and installed by the CONTRACTOR to prevent the
approved test pressure from being exceeded.
d) All COMPANY safety regulations are complied with.
7.3 Isolation
MEP-P-ES-008, Standard Specification For Hydrotesting Of In-Plant Piping, rev 0, 25 July 2005
Custodian: Surface Engineering
Doc. No : MEP-P-ES-008
HYDROTESTING OF IN-PLANT PIPING
Rev 0 page 5 of 8
Rev Date : 25 July 2005
7.3.1 Open ends of the test section shall be sealed by installation of blind flanges
or spades as appropriate. Blind flanges shall conform to ASME B16.5 for
the class of the system under test.
7.3.2 Closed valves shall not be used to isolate a test section unless specifically
authorized by COMPANY.
7.3.3 CONTRACTOR shall supply all components used for sealing open ends
that are not shown on the drawings for permanent inclusion in the works.
7.4 Valves
7.4.1 Gate, ball, plug, globe or control valves in the test section shall be in the
open position unless supplied with an open by-pass.
7.4.2 The fill point and pressure measuring point shall preferably be on the
upstream side of check valves. When this is not possible, check valves
shall have their clappers or plates removed or locked open. Alternatively
the check valves shall be removed from the line.
7.4.3 Relief valves shall be removed or isolated from the test section.
7.5 Sensitive Equipment
Where certain items of equipment are not recommended by the manufacturer to be
subject to test pressures (P.D. meters, turbine meters, etc), the internals shall be
removed or the entire item removed from the line.
7.6 Insulated Piping
Lines to be insulated shall be hydrotested before the insulation is applied.
7.7 Test Equipment
7.7.1 The pumps, gauges, recorders and dead weight testers for carrying out the
test shall be in first class operating condition and approved by COMPANY
prior to testing.
7.7.2 A calibrated test pressure gauge approved by COMPANY shall be installed
in each system under test in position near the low point of the test section,
which is readily visible to the personnel monitoring the test. The gauge
shall be selected so that the test pressure is between 50% and 90% of the
scale range. Isolation valves shall not be permitted between the test gauge
and the test section.
7.7.3 The Pressure shall be recorded throughout the test by means of an
approved and calibrated chart recorder installed adjacent to and in the
MEP-P-ES-008, Standard Specification For Hydrotesting Of In-Plant Piping, rev 0, 25 July 2005
Custodian: Surface Engineering
Doc. No : MEP-P-ES-008
HYDROTESTING OF IN-PLANT PIPING
Rev 0 page 6 of 8
Rev Date : 25 July 2005
same manner as the test gauge.
7.7.4 Piping, tubing, valves and fittings used in connecting the test equipment to
the test section shall be designed and installed in accordance with ASME
B31.3 for the test pressure concerned.
8 TEST PROCEDURE
8.1 Filling
The test section shall be filled in such a manner as to eliminate air from the
system. The section shall be filled from the low point and air vented from all high
points.
8.2 Pressurization
The pressure shall be raised in discrete steps, allowing sufficient time between
each step to inspect and rectify any leaks.
8.3 Hold Period
The test period shall be deemed to have commenced when the system is leak free
and stabilized at the test pressure.
8.4 Acceptance of Test
8.4.1 For all tests, any pressure loss is unacceptable.
8.4.2 No test shall be considered complete until it has been witnessed and
accepted by COMPANY and the Responsible Government Authorities, if
necessary.
8.5 Draining
The test section shall be completely drained of water with particular attention to low
points. The drained water shall be disposed of in a manner satisfactory to
COMPANY.
8.6 Flushing
Test sections shall be flushed with water to remove foreign material in accordance
with the requirements defined in COMPANY Specification MEP-P-ES-009.
8.7 Drying
When it is required for the test section to be dried as defined in COMPANY
Specification MEP-P-ES-009, air shall be blown through until no more moisture
MEP-P-ES-008, Standard Specification For Hydrotesting Of In-Plant Piping, rev 0, 25 July 2005
Custodian: Surface Engineering
Doc. No : MEP-P-ES-008
HYDROTESTING OF IN-PLANT PIPING
Rev 0 page 7 of 8
Rev Date : 25 July 2005
can be detected in the pipe.
8.8 Restoration
After completion of testing, draining and drying, the test section shall be restored in
the configuration shown on the drawings and made in all respects ready for
operation. COMPANY shall require verification that all spades and blinds have
been removed.
9 DOCUMENTATION
9.1 Hydrostatic Test Report
The hydrostatic test report form included as Appendix A shall be used as the
record for all hydrostatic tests. No test shall be considered completed until
COMPANY has signed the test report.
9.2 Chart Records
Pressure and temperature charts shall be identified and secured with the test
report.
9.3 OWNERship
The originals of the test report and the chart records shall become the property of
COMPANY.
MEP-P-ES-008, Standard Specification For Hydrotesting Of In-Plant Piping, rev 0, 25 July 2005
Custodian: Surface Engineering
Doc. No : MEP-P-ES-008
HYDROTESTING OF IN-PLANT PIPING
Rev 0 page 8 of 8
Rev Date : 25 July 2005
APPENDIX - A
PIPING PRESSURE TEST RECORD
P&ID. NO TEST MEDIUM
ACTUAL TEST PRESSURE TEST NO.
P&ID NO. TEST PRESSURE
LINE NO. DRAWING NO. START TIME FINISH TIME REMARKS
PIPING PRESSURE TEST SATISFACTORILY COMPLETED
/DATE /DATE
TEMPORARY BLINDS, PLUGS AND SUPPORTS HAVE BEEN REMOVED. ITEMS WHICH WERE REMOVED FOR
TEST HAVE BEEN REINSTALLED WITH PROPER BOLTS AND GASKETS. LINES HAVE BEEN CHECKED TO
VERIFY THAT SYSTEM IS FREE OF WATER
AFE NUMBER CONTRACTOR/DATE
AFE TITLE MES INSPECTOR/DATE
MES SUPERINTENDENT/DATE
MES COORDINATOR/DATE
MES OPERATIONS/DATE
PT.MEDCO E&P INDONESIA MEP-P-ES-008
APPROVAL STAMP
SHEET 8 OF 8
MEP-P-ES-008, Standard Specification For Hydrotesting Of In-Plant Piping, rev 0, 25 July 2005
Custodian: Surface Engineering
