GENERAL PROCEDURE

for
PRESSURE TESTING OF PROCESS PIPING SYSTEM

CONTENTS

SECTION

1.0 SCOPE

2.0 GENERAL

3.0 PREPARATION OF FACILITIES FOR TESTING

4.0 PRESSURE TESTS

4.1 TESTING PROCEDURE

4.2 TEST PRESSURE

4.3 DURATION OF TESTS

4.4 REINSTATEMENT TEST

5.0 POST TESTING ACTIVITIES AND DRYING

6.0 TEST CHECKLISTS AND REPORT

7.0 SAFETY

APPENDIX 1 & 2
1.0 SCOPE

This is an outline of general inspection procedure for pressure testing of process piping system. For
project’s specific piping system, project specific inspection procedure(s) need to be developed
incorporating the client/vendor requirements and recommendations example among many others are;
special requirements on testing medium, preservation, acid etching and pneumatic leak testing for
tightness.

This specification prescribes requirements for the extent of pressure testing to be performed by the
Contractor on process piping systems.

Where Chemical Cleaning and Hot Oil Flushing are required, Vendor’s procedures shall be used.

2.0 GENERAL

2.1 Testing and acceptance criteria shall be in accordance with relevant section of the latest
revision and addenda of ANSI B 31.3

2.2 The Contractor shall submit for Client approval prior to execution of pressure tests at site.
Hydrostatic test instructions for each test to be carried out consisting of hydrostatic test packages
indicating

Test limits and scope. Marked up P&ID drawing & marked up ISO, Indicating;

- Test limits and scope, and test pressure calculations

- Flushing routes and method
- Position and status of all blanks, spades, spectacle blinds, valves, vessels, instruments operators
and closures.
- Vent and drain points with the exception of additional vents and drains required as a result of
inspection prior to test.
- Test pressure, test medium, test duration, platform system, line vessel and valve identification.
- Position of fill and pressurization points.
- Position of test instruments and any temporary links.
- General area locations within which the test is confined.
- General notation and special conditions for specific tests (e.g. whether dye is required, etc.).
- Valves requiring 100% shut off tests and pressure at which these are to be carried out.
- Any special written instructions.
- Pipe work completion check sheet (See Appendix 1) covering items detailed in section 3
- Line Schedule/list, which detailed the design conditions.
- NDT Clearance sign by Contractor and Client.
- Testing gauges calibration reports (Once)
- Water analysis report (Once)
- Pressurizing equipment set-up (Once)
- Pneumatic pressurizing equipment & dehydration set-up (Once)

The hydrostatic test flow sheets as set forth above shall divide the entire piping into systems for testing
purposes and the location of block valves/blinds for separating the various systems should be clearly
defined.

2.3 Each line test has to be witnessed and approved by the Client and test results recorded by the
Contractor.

2.4 Atmospheric drains and vents need not be pressure tested. However closed drains shall be
pressure tested.

2.5 The hydrostatic test medium shall normally be fresh water. If used for testing of austenitic and
martensitic stainless steels, the chloride content of the water shall not exceed 2 ppm. For carbon steel
materials, chloride contents up to 20 ppm will be acceptable. In certain cases, it is permissible to use
non-volatile hydrocarbons such as lubricating oil or diesel with prior Client approval. On special
instances Vendor’s requirement on pretreatment of piping and testing medium need to be consider.

2.6 Treated seawater shall not be used as a testing medium.

2.7 To avoid water contamination, pneumatic tests shall be carried out on the following piping
systems (See appendix 2 for more details)

-Diesel fuel
-Instrument air
-Fuel gas (downstream of main fuel gas scrubber)

2.8 Pneumatic tests for lines other than those given in 2.7 shall not be carried out without the approval
of the Client.

2.9 Filling of the piping system under test shall take place through the lowest point in the system
whilst venting shall be from the highest point in order to prevent trapping of air or vapors in the
system.

2.10 Pressure testing shall not be carried out whilst it is raining or when the surface of piping and
equipment has otherwise been wetted.

3.0 PREPARATION OF FACILITIES FOR TESTING

As soon as practical, the Contractor shall prepare the facilities for testing. The preparatory work shall
include, but not be limited to, the following: (Use Appendix 1 Check-sheet as a guides)

3.1 Pipe works including pipes, fittings shall first be inspected for:

 Sizing
 Pressure rating/class
 Routing
 Support types and pipe spans
 Static earthing/bonds
 System completion to ensure no further welding works.

3.2 All component parts of the system shall be examined and checked to ensure that all valves,
flanges, gaskets, fittings, bolting and other components are compatible to the design specification and
correct to the latest issued approved drawings.

3.3 It shall be ensured that the design of the system is such that it can withstand the weight of the
hydrostatic test medium.

34 Where field tests are required for vessels, all internally housed floats, filter elements or other
devices subject to damage during testing shall be removed prior to testing.

3.5 All high and low points must be capable of being vented/drained. Any system high or low points
not so provided must be brought to the attention of the Client for remedial action.

3.6 All valves shall be opened and non-return valves defeated in accordance with the test drawings
and flushing instructions. The Contractor shall remove instruments not to be tested, remove relief
valves, plug thermowell connections, mechanically lock control valves in the open position, disconnect
controls, check spectacle blinds are in the open position if not at test extremity, set all manual in the
open position and disconnect sections of line for flushing purposes.

3.7 The piping systems shall be cleaned with a medium compatible with the test medium. All lines
shall normally be flushed with water having a sufficiently high velocity to ensure removal of debris,
weld and mill scales and other redundant materials trapped internally. A minimum velocity of 3 m/s
shall be achieved unless otherwise approved by the Client. Flow shall be from high to low points and
flanges shall be opened and spool pieces and control valves dropped as necessary to flush the piping
thoroughly.

Orifice plates and filters already installed, which do not have a specified test pressure shall be removed
and all valves in instrument connections shall be closed before flushing begins.

Flushing shall be done in the presence of the Client authorized representative. Water shall be
thoroughly drained as soon as flushing or testing of a line or piece of equipment is completed. (See
Appendix 1 for flushing details)

3.8 Flushing

3.8.1 the initial flushing shall be carried out prior to pressure testing. For austenitic steelwork flushing
can be performed after pressure testing, upon agreement.

General requirements for flushing for specific systems are listed in Appendix 2.

Procedures for flushing shall be developed prior to start. All pipe work shall be free from dirt, grease
and temporary protective coating upon completion of flushing.

3.8.2 Hydro flushing

Items of equipment which would be sensitive to damage during hydro flushing shall be removed,
blocked off or isolated. A list shall be prepared and be part of the flush & test procedure. Ball valves
shall be flushed in fully open position. All piping systems shall be flushed using high-pressure
jetflushing equipment, such as rotating hose or rotating nozzle. Minimum pressure shall be 600 bars.

Below 4", High Velocity Water Flushing (HVWF) may be used. Water velocity shall be a minimum of
10m/s. On systems where high pressure jet flushing cannot be used due to complicated shapes and/or
long runs HVWF may be used.

The flushing medium shall in general be fresh water. When flushing stainless steel lines, the chloride
ion content shall be less than 200 ppm.

After flushing, the piping systems shall be completely drained and protected against corrosion.

3.8.3 Pressurized air shockblowing (PAS)

This method may be used as an initial cleaning method for instrument air, plant air and as an alternative
method for initial cleaning of small-bore pipe (less than 2 inch). This method may also be used when
there are problems removing trapped liquid in the circuit, or to verify cleanliness of small-bore pipe
where video inspection is impossible or inadequate due to pipe dimension or configuration.

When using PAS method for cleaning or verification the procedure shall be repeated until cleanliness is
acceptable.

The air shocking pressure shall never exceed the working pressure of the system and shall never be
more than 8 bars. Safety precaution shall be taken when this method is used.

3.8.4 Pneumatic flushing

In cases where water is not desirable in the piping system (e.g. instrument/utility air), flushing by
pressurized air or PAS shall be carried out. When pressurized air is used, the minimum velocity shall
be 35m/s. Procedure covering all safety aspects shall be established.
3.8.5 After flushing, checking shall be carried out to ensure all non-return valves are still defeated and
that swing checks are open. All ball valves shall be placed in the half open position for hydrostatic
testing.

3.9 All lines to be tested shall be cleaned free of dirt, construction materials, loose weld splatter,
grease etc.

3.10 If required, pressure and temperature recorders shall be installed. The Contractor shall ensure
that recorders are calibrated to the range required for the test and check their accuracy before and
immediately after conclusion of the tests. The Contractor shall produce calibration certificates for each
recorder. Master test gauges, local ambient air temperature sensor and test media temperature sensor
and graph recorders shall be provided. The recorders shall be capable of registering a change in
pressure of 0.5%. It shall also be ensured that correctly ranged charts are provided and sufficient ink is
available for a 4 hour run. In addition a dead-weight tester should be available for hydrostatic testing if
requested by the Client.

Attachment: See attached Pre-test Check sheet

4.0 PRESSURE TESTS

4.1 TESTING PROCEDURE

4.1.1 General

4.1.1.1
Except as otherwise specified herein, all piping shall normally be tested with water up to a test pressure
as set forth in Section 4.2.

4.1.1.2
Where the test pressure as set forth in Section 4.2 does not exceed the shop test pressure applied to the
equipment connected to the piping, both piping and connected equipment shall be tested
simultaneously to the pressure as set forth in Section 4.2.

4.1.1.3
Where the line test pressure as set forth in Section 4.2 is greater than the shop test pressure applied to
the equipment connected to the piping, such connected equipment (except pumps, turbines, blowers,
and compressors) may be tested with water under a pressure equal to the shop test pressure. The
remaining parts of such piping shall be tested as set forth in Section 4.2.

Where a given length of piping is immediately adjacent to such connected equipment and the Client
considers it advisable to test all parts of such piping to the full pressure as set forth in Section 4.2, the
Contractor shall install a blind in the piping immediately adjacent to such connected equipment and test
all parts of the line to the specified pressure. Blinds may also be installed at all connections to pumps,
turbines, blowers and compressors.
4.1.1.4
Gauge glasses, level float cages, thermowells, and all other pressure parts of instruments (except as
mentioned below) shall be included in the hydrostatic test for the equipment or piping to which they are
connected and shall be tested at the same pressure as that equipment, unless the pressure would cause
damage to the instruments. Pressure gauges, pressure transmitters and flow meters together with the
secondary piping connecting the instruments to the block valve at the equipment or primary piping
shall not be included in the hydrostatic test.

4.1.1.5
Instrument air supply lines and air lines to air-motor-operated valves shall not be tested with water but
shall be tested with compressed air.

4.1.1.6
Relief valves and rupture discs shall not be subjected to the pressure tests. All relief valves shall be
bench tested in accordance with the manufacturer's recommended procedures, shall be witnessed and
approved by the Client.

4.1.1.7
Although pressure vessels are tested in the presence of an Inspection Authority at the vendor’s works in
accordance with the relevant construction and design code, they should be retested to the same test
pressure as that used in the previous yard test. This is to ensure that no damage has occurred to the
vessel during transportation and installation. They should not be tested to the same test pressure as that
of the piping system of which they are a component.

4.1.1.8
If the test medium is to be treated with a corrosion inhibitor, bactericide, oxygen scavenger and/or is to
have a dye substance added to it to help located leaks, then an injection pump will be required. In such
cases, the injection pump and metering device is to be connected to the system test header

4.1.2 System Filling

4.1.2.1
The proposed test medium, the degree of filtration, and test medium treatment shall be checked to
ensure that it is in accordance with the specified requirements.

4.1.2.2
A high-volume, low-pressure pump shall be used to fill the system. The fill point shall preferably be the
lowest point in the system. The filling operation shall start with all vent valves and other high point
connections which serve as vents to be open, and each of these shall be closed only when there is a
steady, air-free stream of test fluid flowing from it.

4.1.2.3
The Contractor shall continue to pump and vent the system until it is completely full. It shall be
ensured that all the air has been completely expelled by systematically opening the vent valves, starting
from the highest point in the system.

This vent valve shall then be closed before proceeding to the next highest valve in the system. During
this filling operation, the system pressure should not exceed 1-2 bars gauge.

4.1.2.4
The pumping equipment used for filling the system shall then be switched off and disconnected.

4.1.2.5
The temperature probes (indicators) shall be monitored and sufficient time for the system temperature
to stabilize shall be given.

4.1.2.6
During this period, all visible external surfaces should be dried and the system shall be examined for
any leakage points.

4.1.3 System Pressurizing

4.1.3.1
The determination of the test pressure and test duration must be as set forth in Section 4.2 and 4.3.The
actual test pressure must however be approved by the Client.

4.1.3.2
The Contractor shall connect the high-pressure pump and filters to the test header.

4.1.3.3
The system shall then be pressurized during which time leak detection should be carried out
continuously. A minimum 0f 2 pressure sensing devices must be connected to the test system. All leaks
as discovered shall be marked, and if required, the pump should be stopped, system depressurized by
venting and remedial action taken

It is essential that the pump must not be allowed to run unattended and manning levels should be at a
minimum in areas where systems are under test pressure or being pressurized. Test area, pumps and
instruments should, where possible, be screened by temporary guards fitted with warning notices (i.e.
"Pressure Test in Progress").

4.1.3.4
When approximately 80 percent of the specified test pressure has been attained, the rate of
pressurization should be reduced.

Caution should be exercised during pressurizing to avoid surge effects. Precaution should be taken to
avoid over-pressurizing the line due to thermal expansion throughout the test period. Coated lines must
be both pressurized and depressurized gradually to avoid possible damage to the applied coating. (Max.
2 psig per min. pressure rise)
4.1.3.5
When the test pressure has been achieved at the highest point in the system, the pump shall be shut-off
and isolated from the test header.
4.1.4 System Testing
4.1.4.1
Before commencement of the test, the Contractor shall verify the pressure-recorder reading using a
dead weight tester.

4.1.4.2
The test may then commence by starting the temperature and pressure recorders, noting the exact time.
The duration of the test shall be as set forth in Section
4.3, but in all cases, should be for at least a minimum time period of 1 hour. At the end of the test, the
pressure recorder reading should be verified by the dead weight tester.

If significant pressure rises begin due to ambient temperature variations, the system under test should
be vented to keep the pressure close to the scheduled test pressure. Volume additions will be required if
the pressure subsequently begins to drop below the minimum test pressure. Any such venting or
additions shall be carefully recorded and submitted with the test results for Client approval. Where
doubt exists regarding volumes vented and/or added, the Client reserves the right to request a retest.
4.1.4.3
On completion of a successful test (i.e., zero pressure drop) the test can be stopped. However, the test
may only be accepted in the presence of the Contractor and Client authorized representative
responsible for supervising the tests.
After the system has been pressure tested, it should be depressurized. Care must again be exercised
during depressurization to avoid any surge effects. After depressurization, all vents and low point drain
valves should be opened and the system thoroughly drained. Extreme precaution should be taken while
draining the test system to prevent vacuum formation in the system. The system should then be
completely purged of the hydrotest media.
4.1.4.4
All joints, which fail to pass the pressure tests, have to be retested after the completion of the repairs.
4.1.5 Leak Testing of Shut-off Valves
Depending on the requirements of the particular project specifications, it may be necessary to carry out
leak tests on designated 100-percent shut-off valves. 100% shut-off valves shall normally include all
vents and drain isolation valves, blowdown valves and main block valves, which perform shutdown
isolation duties.
4.1.5.2
The recorders shall then be started and step-by-step valve shut-off tests shall be carried out on the
approved designated 100-percent shut-off valves.
All valves which are required for 100% shut off service shall be leak tested. The leak test shall be
carried out at 1.1 times design pressure for a minimum duration of 1 hour. If possible, the valves shall
be leak tested in situ.
4.1.5.3
Any valve which fails the test shall be repaired or replaced and subsequently retested before
continuing. Alternatively, the valve can be removed and replaced by a spool or a blind, as necessary,
and system testing can continue. The damaged valve shall then be bench tested prior to re-installation.

4.1.6
Pneumatic Testing

4.1.6.1
Pneumatic testing shall be carried out only on piping systems as set forth in Section 2.7.
4.1.6.2
Pneumatic testing shall not be carried out in ambient temperatures below 16’C.
4.1.6.3
Test pressures shall be as set forth in Section 4.2. Under no circumstances shall any pneumatic testing
be carried out above 1.1 times design pressure.
4.1.6.4

Pressure should be introduced gradually into the system allowing adequate time for temperature
equalization and decay of surge. The sequence of test pressuring installed systems shall be as follows:

 A pressure of 0.5 barg shall be introduced in the system and a leak test performed. The
pressure shall gradually be increased to 50% of the specified test pressure and kept for
minimum 10 minutes to equalize strain.

 The pressure shall then be increased in steps of 10% of the specified test pressure, until the
specified test pressure is reached. At each step, the pressure shall be kept for 10 minutes
minimum to equalize strain.

 The specified test pressure shall be kept for one hour. The pressure shall than be reduced to the
design pressure before examining for leakage.

 The piping systems shall not show any sign of plastic deformation or leakage.

4.1.6.5

For pneumatic testing, the test media shall be oil free, dry air or any inert gas. The use of air for testing
shall be limited to a maximum pressure of 7.0 barg. Above this pressure nitrogen shall be used. The
extent of pneumatic testing shall be approved.

For instrument/utility air systems, where the introduction of water is undesirable, test media shall be air
or inert gas.

4.1.6.6

A pressure relief device shall be provided, having a set pressure not higher than the test pressure plus
lesser of 345kpa (50psi) or 10% of test pressure.

4.2 TEST PRESSURE

4.2.1 Field hydrostatic testing shall be carried out in accordance with the project piping schedules or
where this does not exist, with relevant section of ANSI B31.3, when, unless otherwise stated, the
hydrostatic test pressure shall be 1.5 times the design pressure duly elevated for temperature derating
which may be interpolated for varying temperatures and allowable stress values. (ANSI B31.3-1999
Section 345.4.2)

Pt = Minimum Test Gage Pressure P = Internal Design Gage Pressure

St = Stress Value at Test Temperature S = Stress Value at Design Temperature
(See Table A-1 of ANSI B31.3)

4.2.2 Pneumatic pressure testing should be performed in accordance with ANSI B31.3 requirements.
Test pressure shall be 110% of design pressure.
4.2.3 certain process piping such as for sphere/pig receivers and launchers may have been designed to
ANSI B31.8. In this instance and where it is not covered by the piping schedule, B31.8 pressure testing
guidelines shall be used.
4.3 DURATION OF TESTS
These piping systems shall be subjected to a 1-hour pressure test, on the clock/recorder.
4.4 REINSTATEMENT TEST
Upon completion of all testing, the systems shall be reinstated to their as designed condition and a
reinstatement test carried out at 95% of the system relief valve setting. The duration of this test shall be
1 hour. The reinstatement test media shall be potable water or the operating media of the line
concerned. Hydrocarbons, however, shall not be used for reinstatement testing.
5.0 POST TESTING ACTIVITIES AND DRYING

5.1 General Requirement

The tested systems shall be depressurized by opening the depressurizing valve in the test rig. After
depressurization, all vents and low point drain valves shall be opened and the system shall be
thoroughly drained where the test medium is water. Where required, blowing by dry air or Pressurized
Air Shock Blowing to remove any trapped water to be performed.

Systems with drying requirement as defined in Appendix 2 shall be dried out after Hydrotesting with
dry oil-free air with a dew point of –10’C. Drying can be terminated when the dew point at the outlet is
equal to the dew point at the inlet.

Other methods, such as vacuum drying or air shocking, may also be used if the same dryness can be
documented.

If more than 3 months to commissioning, drying shall be followed by preservation with nitrogen to
keep the pipe system completely dry and to avoid condense. Other alternatives are subject to
agreement.

Reinstallation of the system shall be performed in accordance with the test procedure.
Where permanent or temporary strainers have remained in place for the hydrostatic pressure test, they
shall be removed following the test and thoroughly cleaned before reinstalling.

Ends of pipes and nozzles shall be fully protected against the ingress of foreign material by the use of
caps, plugs or plate blinds sealed with gaskets. These shall not be removed until just prior to final
assembly.

Flange parallelism and alignment to equipment shall be checked prior to reinstatement.

Vent holes in reinforcing pads shall be sealed upon completion of pressure test.

5.2 CHEMICAL CLEANING

Lines to be chemical cleaned shall be identified on the P&ID's and Line Index. For system overview
see table 1, Appendix 2.

A procedure shall describe in detail the steps for chemical cleaning.

Chemical cleaning shall include:

 Degassing.

 Chemical cleaning/de-scaling.

 Neutralization.

 Passivation.

 Water flushing.

 Drying.

The end result shall be a clean smooth surface.

Maximum temperatures used during these operations shall not exceed maximum design temperature
for the systems as listed in the Line Index.

For equipment such as turbines, generators, pumps and compressors, the piping to be cleaned shall
have all sensitive items that can be damaged by the cleaning medium removed or blanked off.

Generally, the following items shall not be chemically cleaned (items shall be identified on chemical
cleaning ISO):

 All instrument tubing downstream the first piping block valve.

 Piping systems with copper alloy materials.

 Flexible hoses.

 Vessels.
  Exchangers.

 Pumps.

 All bolted/screwed valves and instruments.

Removed or blanked off items shall be cleaned separately prior to reinstallation.

The systems to be cleaned shall have high and low point vents and drains installed. "Dead legs" shall
be avoided.

Cleaning shall be carried out after pressure testing unless otherwise specified.

If more than 3 months to start up of commissioning activities, system shall be preserved with nitrogen.
Overpressure shall be 0.5 bars.

5.3 HOT OIL FLUSHING

5.3.1 General

Required cleanliness for systems subject to hot oil flushing shall be in accordance with table 1,
Appendix 2.

A detailed procedure for hot oil flushing shall be developed out prior to start.

Filters used for hot oil flushing shall be:

Filters used for hot oil flushing shall be:

 3µm ABS for hydraulic systems.

 <=10µm ABS for lube and seal oil.

Filling of lubricant oil shall take place through filters with 3µm ABS

Flushing and sampling to verify cleanness shall take place at turbulent flow, upstream any filters.

The Reynolds number shall be min. 4000.

The level of cleanness shall be documented from an automatic particle counter or a membrane checked
in a microscope before a flushing operation is considered finalized.

A flow meter shall be installed to verify flow used during flushing operation.

Maximum water content in oil used for flushing shall be less than 500ppm.

6.0 TEST CHECKLISTS AND REPORT

6.1 For all hydrostatic tests, a hydrotest check list is to be compiled, completed and signed by both the
Client authorized representative and the Contractor's representative to demonstrate compliance with
test procedure.
6.2 Followings are typical content of hydrotest package

- Hydrotest completion report signed by Testing Contractor, Contractor, Client and Verification
Authority
- Pipe work completion check sheet covering items detailed in section 3
- Line list, which detailed the design conditions.
- Marked-up P&ID.
- Marked-up ISO Drawing.
- NDT Clearance sign by Contractor and Client.
- Pressure/Temperature Recorder Charts.
7.0 SAFETY

7.1 The following notes have been included for information of all personnel in carrying out pressure
testing.
7.2 Introduction

7.2.1 Accidents, sometimes fatal, can occur during the pressure testing of piping when the energy
contained in the piping system is released with explosive force.

7.2.2 Pressure testing may be carried out using a liquid, usually water, as the test medium (hydraulic
testing), or by using air (pneumatic testing). At pressure ranges most frequently encountered, the
amount of energy contained in air is more than 200 times the energy contained in water at the same
pressure and volume. For this reason hydraulic pressure testing is by far the safer method and should be
used wherever practicable. Pressure testing using air is potentially dangerous and should only be
carried out in circumstances where use of this method is unavoidable.

7.2.3 Pressure tests can basically be divided into two classes:

- Over-pressure testing. These are tests carried at pressures exceeding the designed safe working
pressure with the object of proving the mechanical strength and integrity of the piping (by
discovering possible points of weakness) and as a final check of design and quality of the
piping system.
- Leak tests. These tests are normally carried out at or below normal working pressure and
intended to detect leaks at such places as bolted joints and welded seams and at defects in the
material itself.

7.3 Hydraulic Testing

7.3.1 This method of testing is much safer than pneumatic testing and should be used wherever
practicable. It is recognize that under certain circumstances, however, hydraulic testing may be
unacceptable for technical reasons. The following are examples:
- The piping system may not be capable of withstanding the weight of liquid required hydraulic
tests.
- Contamination of the interior of the piping by water may not be acceptable.

7.3.2 Precautions of hydraulic pressure testing

7.3.2.1
The piping system being tested must be properly vented to exclude any possibility of air pockets.

7.3.2.2
Steps should be taken to ensure that blanking-off devices and such items as screwed plugs or
connections are not liable to be ejected during testing, e.g. as the result of thread failure.

7.3.2.3
A piping system should not be subjected to any form of shock loading such as hammer testing whilst
undergoing a full over-pressure test.

7.3.2.4
A piping system subjected to maximum test pressure should not normally be approached for close
examination until after a reasonable period of time has elapsed. Special consideration should be given
to safety of personnel in the case of piping subject to high pressures where the contained energy is
high. As a rough guide, pressures in excess of 75 bars may be considered high pressure.

7.3.2.5
To avoid the risk of freezing, the temperature of the water during test should be not less than 7’C. The
risk of failure by brittle fracture under the test conditions should be assessed at the design stage and
suitable precautions taken. This may affect the choice of suitable materials of construction or the
selection of the temperature at which the pressure test should be carried out.

7.3.2.6
Care should be taken not to over-stress the piping during test. In the absence of any appropriate
standard or code, the test pressure should be limited to the pressure equivalent of 90% of the yield
strength (proof strength) of the material of construction at test temperature for the weakest part of the
piping system. Please refer to relevant section of B31.3

7.3.2.7
Where pressurizing medium other than water is used, care should be taken to recognize any additional
hazard associated with the liquid concerned. A leak of a highly flammable liquid for example, could
lead to a serious fire. It is also necessary to consider the purity of the testing medium, particularly
where complete drainage of the piping system after test may not be possible.
7.3.3 Precautions for proof hydraulic testing:

7.3.3.1
Where the design pressure of piping systems, for which the strength cannot be satisfactorily calculated,
has to be determined, a proof hydraulic test will be necessary. The following precautions are in addition
to those recommended for hydraulic pressure testing.

- Proof hydraulic testing should be carried out under the direct supervision of a person competent
to carry out such a test.

- The pressure should be applied gradually and increased by steps of approximately 10% until the
required test pressure is reached, or until significant yielding occurs. At this stage the pressure
should not be further increased.

- The onset of yielding should be determined by the use of strain gauges, or a strain indicating
coating or other equally suitable means.

7.4 Pneumatic Testing

7.4.1
This refers to tests carried out and using air, as the testing medium. As stated earlier this method of
testing is potentially dangerous because of the large quantity of energy contained in the system and
likely to be released in the event of a piping failure this method of testing should be avoided wherever
practicable.

7.4.2 Precautions for over-pressure testing using air

7.4.2.1
Pneumatic testing of piping constructed of materials liable to brittle fracture under the test conditions
should be avoided. Precautions should be taken to prevent local chilling during filling and emptying of
the piping systems. Attention is drawn to the fact that if the air pressure is let down to that of the piping
under test from high-pressure storage, its temperature will fall. The test arrangement shall be such that
the temperature of the air entering the piping is not lower than the agreed test temperature. Attention is
also drawn to the possibility of condensation occurring within the piping systems.

7.4.2.2
Before testing, careful inspection of the piping should be carried out.

7.4.2.3
Care should be taken to ensure that the methods used or sealing openings in the piping under test are
adequate.

7.4.2.4
Where the source of pressure is higher than the test pressure, precaution against over-pressurization of
the piping should be taken by the use of reducing valves, pressure gauges and safety valves of adequate
size,

7.4.2.5
Steps should be taken to ensure that people are not likely to be injured in the event of an explosion.
This can be achieved by ensuring that the site is cleared and personnel are adequately protected.

7.4.2.6
The piping under test should not be subjected to any form of shock loading such as hammer

7.4.2.7
The piping system should not be approached for close inspection until after the test pressure has been
reduced.

7.4.2.8
During low pressure testing, rubber tubing is sometimes used for connecting the air supply to the article
under test the tube is simply pushed into a pipe or spigot on the test component without positive
clamping. This arrangement cannot be accepted as a means of preventing over-pressure.

7.4.2.9
Where flexible tubes are used they should be securely fastened at both ends. Accidents can be caused
by tubes whipping when the pressure causes one end to come free.

7.4.2.10
Where more than one connection is available giving different reduced air pressures from a common
manifold, it is advisable to have different sized screw connections on hose ends, and to arrange that the
piping being tested has screw connections of appropriate size according to its test pressure. This will
prevent incorrect test pressures being applied.

Appendix 1: TYPICAL CHECK SHEET

HYDROTESTING PREPARATION CHECKSHEET

Package NO. HT-

Area:
Line No:

Designed Pressure:
Test Pressure:
Test Duration:
Inspected Date:

Check Item Comment Result Y/N

1.0 Document Check:
Marked up P&ID
Marked up Isometric
NDT Clearance
Line list
Fill/Drain and Gauges Positions

2.0 Field Check

Check the Test System for correct:
 Pipe Sizing
 Pipe/Fitting Pressure rating/class
 Pipe Routing
 Support types and pipe spans
 Static earthing/bonds
 Pipe System completion to ensure no further
welding works.

All component parts of the system shall be examined and

checked to ensure compatible to the design specification
 Valves
 Flanges
 Gaskets
 Fitting
 Bolting
 Others

Can the system support the weight of the hydrostatic test

medium?
Remove instruments not to be tested
Remove relief valves
Plug thermowell connections
Mechanically lock control valves in the open position.
Check spectacle blinds are in the open position.
Set all manual in the open position
The piping systems shall be cleaned with a medium
compatible with the test medium.
 A minimum velocity of 3 m/s shall be achieved.
 Flow shall be from high to low points
Discharge flushing medium shall be screen with 200mesh
to ensure all lines are free of dirt/construction materials
 After flushing, ensure all non-return valves are still
defeated and that swing checks are open. All ball valves
shall be placed in the half open position for hydrostatic
testing. All lines to be tested shall be cleaned free of dirt,
construction materials, loose weld splatter, grease etc.

3.0 Others:

4.0 Additional Post Testing Requirements;

Chemical Cleaning required? Yes / No Hot Oil Flushing required? Yes / No

Preservation required? Yes / No

5.0 Notes or comments

The marked items of the system(s) were checked and found satisfactory. Except as commented and the
system can be hydrotested to the required pressure

----------------------------- -------------------------- -------------------------- ------------------------------

Hydrotesting - - -
Contractor Contractor Client Verifying Authority
Date: Date: Date: Date:
Appendix 2:

Table 1.

Requirements for internal treatment of piping after prefab and

installation before commissioning
SYSTE SYSTEM PIPE FLUS TEST CHEM DRYIN PRES FINAL REMAR
M DESCRIP TION MAT H W/ . G ERVA CLEANIN KS
R. WATE PRESER CLEA TION G/
R V. N. REQUIRE
/AIR FLUID D
YES/NO CLEANLI
N ESS
NO
DRILLING WATE NORM FOREIGN
10 C.S YES NO NO
SYSTEMS R AL MATERIAL
S
NO
DRILLING
WATE NORM FOREIGN
11 PROCESS C.S YES NO NO
R AL MATERIAL
SYSTEMS
S
NO
DRILLING
WATE NORM FOREIGN
12 WELLCONTROL C.S YES NO NO
R AL MATERIAL
SYSTEMS
S
NO
WATE NORM FOREIGN
SSTL NO NO NO
R AL MATERIAL
S
NO
RISER AND
WATE NORM FOREIGN
13 WELL SYSTEM- C.S YES NO NO
R AL MATERIAL
TOPSIDE
S
NO
WATE NORM FOREIGN
SSTL NO NO NO
R AL MATERIAL
S
WELL RELATED NO
PRODUCTION WATE NORM FOREIGN
15 C.S YES NO NO
SYSTEMS R AL MATERIAL
TOPSIDE S
SSTL WATE NO NO NO NORM NO
 FOREIGN
R AL MATERIAL
S
GAS AND
NO
WATER
WATE NORM FOREIGN
16 INJECTION SSTL NO NO NO
R AL MATERIAL
WELL SYSTEM
S
TOPSIDE

NO
SEPARATION
WATE NORM FOREIGN
20 AND C.S YES NO NO
R AL MATERIAL
STABILIZATION
S
NO
WATE NORM FOREIGN
SSTL NO NO NO
R AL MATERIAL
S
NO
CRUDE WATE NORM FOREIGN
21 C.S YES NO NO
HANDLING R AL MATERIAL
S
NO
WATE NORM FOREIGN
SSTL NO NO NO
R AL MATERIAL
S
GAS
RECOMPRESSI
23 ON, COOLING
AND
SCRUBBING
NO
GAS COOLING
WATE NORM FOREIGN
23-10 AND C.S YES NO NO
R AL MATERIAL
SCRUBBING
S
NO
GAS COOLING
WATE NORM FOREIGN
23-10 AND SSTL NO NO NO
R AL MATERIAL
SCRUBBING
S
23-20 GAS C.S WATE NO ACC. YES SEE ISO 4406, (100%
RECOMPRESSI R TO NOTE 4 17/14 visual
ON P&ID insp. on
 suction
side of
compresso
r).
NO
If no chem. WATE NORM FOREIGN
23-20 C.S YES NO YES
cleaning req. R AL MATERIAL
S
(100%
visual
GAS ACC.T insp. on
WATE SEE ISO 4406,
23-20 RECOMPRESSI SSTL NO O YES suction
R NOTE 4 17/14
ON P&ID side of
compresso
r).
NO
If no
WATE NORM FOREIGN
23-20 chem.cleaning SSTL NO NO YES
R AL MATERIAL
req.
S
GAS
24
TREATMENT
NO
GAS COOLING
WATE NORM FOREIGN
24-10 AND C.S YES NO NO
R AL MATERIAL
SCRUBBING
S
NO
GAS COOLING
WATE NORM FOREIGN
24-10 AND SSTL NO NO NO
R AL MATERIAL
SCRUBBING
S
GAS NO
24- DEHYDRATION/ WATE NORM FOREIGN
C.S NO NO NO
20/30 REGENERATIO R AL MATERIAL
N S
GAS NO
24- DEHYDRATION/ WATE NORM FOREIGN
SSTL NO NO NO
20/30 REGENERATIO R AL MATERIAL
N S
GAS
26 REINJECTION
TO RESERVOIR
26- REINJECTION C.S WATE YES NO NO NORM NO
 GAS COOLING
AND FOREIGN
10/30 SCRUBBING / R AL MATERIAL
REINJECTION S
MANIFOLD
REINJECTION
GAS COOLING NO
26- AND WATE NORM FOREIGN
SSTL NO NO NO
10/30 SCRUBBING / R AL MATERIAL
REINJECTION S
MANIFOLD
(100%
visual
REINJECTION ACC.T insp. on
WATE SEE ISO4406,17
26-20 GAS C.S NO O YES suction
R NOTE 4 /14
COMPRESSION P&ID side of
compresso
r)
NO
If no
WATE NORM FOREIGN
26-20 chem.cleaning C.S YES NO NO
R AL MATERIAL
req.
S
(100%
visual
REINJECTION ACC.T insp. on
WATE SEE ISO4406,17
26-20 GAS SSTL NO O YES suction
R NOTE 4 /14
COMPRESSION P&ID side of
compresso
r)
NO
If no chem. WATE NORM FOREIGN
26-20 SSTL NO NO YES
cleaning req. R AL MATERIAL
S
GAS PIPELINE
COMPRESSION,
27
MEETERING
AND TRANSFER
NO
GAS COOLING
WATE NORM FOREIGN
27-10 AND C.S YES NO NO
R AL MATERIAL
SCRUBBING
S
27-10 GAS COOLING SSTL WATE NO NO NO NORM NO
 FOREIGN
AND
R AL MATERIAL
SCRUBBING
S
(100%
visual
GAS PIPELINE ACC. insp. on
27- WATE SEE ISO
COMPRESSION / C.S NO TO YES suction
20/30 R NOTE 4 4406,17/14
GAS METERING P&ID side of
compresso
r)
27- If no chem. WATE NORM FOREIGN
C.S YES NO YES
20/30 cleaning req. R AL MAT.
(100%
visual
GAS PIPELINE ACC.T insp. on
27- WATE SEE ISO
COMPRESSION / SSTL NO O YES suction
20/30 R NOTE 4 4406,17/14
GAS METERING P&ID side of
compresso
r)
NO
27- If no chem. WATE NORM FOREIGN
SSTL NO NO YES
20/30 cleaning req. R AL MATERIAL
S
NO
GAS WATE NORM FOREIGN
28 SSTL NO NO NO
SWEETENING R AL MATERIAL
S
OIL
NO
PIPELINE,EXPO
WATE NORM FOREIGN
30 RT STABILIZED C.S YES NO NO
R AL MATERIAL
OIL-Upstream of
S
Piglauncher
NO
WATE NORM FOREIGN
SSTL NO NO NO
R AL MATERIAL
S
CONDENSATE
NO
EXPORT
WATE NORM FOREIGN
31 PIPELINE- C.S YES NO NO
R AL MATERIAL
Upstream of Pig
S
launcher
 NO
WATE NORM FOREIGN
SSTL NO NO NO
R AL MATERIAL
S
GAS EXPORT NO
PIPELINE- WATE NORM FOREIGN
32 C.S YES NO NO
Upstream of Pig R AL MATERIAL
launcher S
NO
WATE NORM FOREIGN
SSTL NO NO NO
R AL MATERIAL
S
WATER
NO
PIPELINE HIGH
WATE NORM FOREIGN
34 PRESSURE- SSTL NO NO NO
R AL MATERIAL
Upstream of Pig
S
launcher
METHANOL NO
PIPELINE - WATE NORM FOREIGN
35 C.S YES NO NO
Upstream of Pig R AL MATERIAL
launcher S
NO
WATE NORM FOREIGN
SSTL NO NO NO
R AL MATERIAL
S
PIPELINE
NO
WELLSTREAM,
WATE NORM FOREIGN
36 MULTIPHASE - C.S YES NO NO
R AL MATERIAL
Upstream of Pig
S
launcher
NO
WATE NORM FOREIGN
SSTL NO NO NO
R AL MATERIAL
S
COOLING NO
MEDIUM AND WATE NORM FOREIGN
40 C.S YES NO NO
REFRIGERATIO R AL MATERIAL
N SYSTEM S
SSTL WATE NO NO NO NORM NO
R AL FOREIGN
MATERIAL
 S
Acceptable
preserve,
NORM NO
HEATING fluid to
WATE AL FOREIGN
41 MEDIUM C.S YES NO NO avoid
R (See MATERIAL
SYSTEM blockage
remarks) S
of heating
unit.
NO
WATE NORM FOREIGN
SSTL NO NO NO
R AL MATERIAL
S
NO
CHEMICAL
WATE NORM FOREIGN
42 INJECTION SSTL NO NO NO
R AL MATERIAL
SYSTEM
S
FLARE, VENT NO
AND BLOW- AIR/ NORM FOREIGN
43 C.S N/A NO N/A
DOWN N2 AL MATERIAL
SYSTEMS S
NO
AIR/ NORM FOREIGN
SSTL N/A NO N/A
N2 AL MATERIAL
S
NO
OILY WATER WATE NORM FOREIGN
44 SSTL NO NO NO
TREATMENT R AL MATERIAL
S
ACC.T
WATE SEE ISO
45 FUEL GAS C.S NO O YES
R NOTE 4 4406,17/14
P&ID
ACC.T
WATE SEE ISO
SSTL NO O YES
R NOTE 4 4406,17/14
P&ID
SEAWATER NO
SYSTEMS (LOW WATE NORM FOREIGN
50 SSTL NO NO NO
TO MEDIUM R AL MATERIAL
PRESSURE) S
51 SEAWATER SSTL WATE NO NO NO NORM NO
SYSTEMS R AL FOREIGN
(HIGH MATERIAL
 PRESSURE) S
NO
BALLAST WATE NORM FOREIGN
52 C.S YES NO NO
SYSTEMS R AL MATERIAL
S
NO
WATE NORM FOREIGN
SSTL NO NO NO
R AL MATERIAL
S
NO
FRESH WATER WATE NORM FOREIGN
53 SSTL NO NO NO
SYSTEM R AL MATERIAL
S
STEAM, NO
CONDENSATE WATE NORM FOREIGN
55 C.S YES NO NO
AND HOT R AL MATERIAL
WATER SYSTEM S
NO
WATE NORM FOREIGN
SSTL NO NO NO
R AL MATERIAL
S
NO
OPEN DRAIN WATE NORM FOREIGN
56 C.S NO NO NO
SYSTEM R AL MATERIAL
S
NO
CLOSED DRAIN WATE NORM FOREIGN
57 C.S NO NO NO
SYSTEM R AL MATERIAL
S
NO
DRY AND WET WATE NORM FOREIGN
60 C.S YES NO NO
BULK LOADING R AL MATERIAL
S
NO
WATE NORM FOREIGN
SSTL NO NO NO
R AL MATERIAL
S
ACC.T
JET FUEL WATE LIQUID ISO 4406
61 SSTL NO O YES
SYSTEM R FILLED 17/14
P&ID
62 DIESEL OIL C.S WATE YES NO NO NORM NO
 FOREIGN
SYSTEM R AL MATERIAL
S
NO
WATE NORM FOREIGN
SSTL NO NO NO
R AL MATERIAL
S
NO
COMPRESSED AIR/ NORM FOREIGN
63 SSTL N/A NO N/A
AIR SYSTEM N2 AL MATERIAL
S
NO
INERT PURGE AIR/ NORM FOREIGN
64 SSTL N/A NO N/A
SYSTEM N2 AL MATERIAL
S
HOT OIL
HYDRAULIC ACC.T
WATE LIQUID FLUSH
65 POWER SSTL NO O YES
R FILLED ISO 4406
SYSTEM P&ID
15/12

NO
SEWAGE WATE NORM FOREIGN
66 C.S YES NO NO
TREATMENT R AL MATERIAL
S
NO
WATE NORM FOREIGN
SSTL NO NO NO
R AL MATERIAL
S
NO
FIRE AND GAS WATE NORM FOREIGN
70 SSTL NO NO NO
DETECTION R AL MATERIAL
S
NO
FIRE WATER WATE NORM FOREIGN
71 SSTL NO NO NO
SYSTEM R AL MATERIAL
S
MISCELLANEO NO
US FIRE WATE NORM FOREIGN
72 SSTL NO NO NO
FIGHTING R AL MATERIAL
SYSTEMS S
77 HEATING AND SSTL WATE NO NO NO NORM NO
VENTILATION R AL FOREIGN
 MATERIAL
S
HOT OIL
ACC.T
LUBE OIL WATE LIQUID FLUSH
SSTL NO O YES
SYSTEM R FILLED ISO 4406
P&ID
17/14
HOT OIL
ACC.T
SEAL OIL WATE LIQUID FLUSH
SSTL NO O YES
SYSTEM R FILLED ISO 4406
P&ID
16/13
ACC.T
SEAL GAS WATE SEE ISO 4406
SSTL NO O YES
SYSTEM R NOTE 4 15/12
P&ID

Notes:

1. SSTL means 316, 6MO, duplex etc.

2. Cleanliness to be verified by visual inspection.

3. If commissioning starts later than 3 months after internal treatment, drying, re-preservation
with preservation fluid or other acceptable methods shall be considered. See also Note 4.

4. Where commissioning is later than 3 months after chemical cleaning, system shall be
preserved with nitrogen, overpressure 0.5 bars. Other alternatives are subject to agreement.