Naser M.Al-Baddah & Partner General Trading & Contracting Co. W.l.l.

Doc. No. Rev. No.

T#T$%

NBTC M3 QC PNT 28. 1

Cont. No.: 03UT02-053 Approved !: "ite Manager

Page 1 of 8

PROCEDURE FOR PNEUMATIC TESTING FOR PIPING SYSTEM.

Naser M.Al-Baddah & Partner General Trading & Contracting Co. W.l.l.

Doc. No. Rev. No.

T#T$%

NBTC M3 QC PNT 28. 1

Cont. No.: 03UT02-053 Approved !: "ite Manager

Page 2 of 8

PROCEDURE FOR PNEUMATIC TESTING FOR PIPING SYSTEM.

INDEX
1.0 Scope 2.0 Reference 3.0 Responsibility 4.0 Procedure for Testing 4.1 4.2 4.3 !d inistration of Test Preparation for Test Test Mediu

ded4.4 Er Pressure #auges 4.$ Safety Relief %al&e 4.' !cceptance (riteria 4.) Post Test $.* Safety '.* Reports ).* !ttac" ents M+,-.,/.*0,Pressure Test (ertificate M+,-.,/.*2,Test Pac1 Inde2 S"eet M+,-. 3 /.*+ , Mec"anical (o pletion Record M+3 -. 3 /.*4 34T Pressure ("art M+,-., /.*$ ,4ydro Test Pac1 Routing .or M+,-., /.*' ,Piping Iso etric Inde2

Naser M.Al-Baddah & Partner General Trading & Contracting Co. W.l.l.

Doc. No. Rev. No.

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NBTC M3 QC PNT 28. 1

Cont. No.: 03UT02-053 Approved !: "ite Manager

Page 3 of 8

PROCEDURE FOR PNEUMATIC TESTING FOR PIPING SYSTEM.

1.0

Scope. This method statement describes the methods to be followed by NBTC for executing the Pressure testing (Pneumatic) of both underground and aboveground piping systems for the O !" #echanical $ Pro%ect &

2.0 '& !&

Reference. ()* + ,)!! + -' + [class D Sensitive Leak Test - Gas and Bubble Method] .*#/ B $'&$0 Process Piping&

3.0 $&' $&! $&$ 4.0. 4.1

Responsibility. 1. 2 1C manager is responsible to develop the *ervice lea3 test procedure in accordance with the pro%ect specification& Piping /ngineer is responsible to implement the test as per this procedure& 1C4 is responsible to witness the test as per this procedure and to ensure the usage of calibrated gauges& Procedure for Testing: Preparation for Test

)&'&' Pneumatic testing of a piping system shall be carried out only after completion of re5uired inspections and obtaining appropriate approval from the O6N/7& )&'&! Prior to testing8 a through visual inspection shall be made for defects such as improper materials8 poor gas3et installation and loose %oints& .ll bolts shall be made up tight in the system to be tested& The surface of the piping to be tested shall be clean and free of oil8 grease8 paint8 weld slag8 or other contamination& )&'&$ .ll materials within the piping system shall be chec3ed to ensure compliance with approved isometric drawings&

Naser M.Al-Baddah & Partner General Trading & Contracting Co. W.l.l.

Doc. No. Rev. No.

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NBTC M3 QC PNT 28. 1

Cont. No.: 03UT02-053 Approved !: "ite Manager

Page 4 of 8

PROCEDURE FOR PNEUMATIC TESTING FOR PIPING SYSTEM.

)&'&) .ll N9/ re5uirements shall be completed and documents shall be signed off& )&'&: .ll punch list + Category . items (%obs to be carried out before the pneumatic test) shall be completed and clearance shall be obtained from O6N/7& )&'&, No fabricated vents and bleeders will be provided& )&'&; . detailed test pac3age for each piping system shall be submitted to O6N/7 for approval prior to starting pneumatic test& )&'&< . test pac3age shall include0 Pressure Test 7eport& Test diagram& 4dentification of pipe line& Test pressure = holding time& #inimum thic3ness re5uired for each blind& 6eld map with %oints mar3ed& Pipe welding control sheet = related punch list&

)&'&> .ll items in the piping system which is not sub%ected to test pressure shall be isolated 2 removed prior to pneumatic test& )&'&'-.ll valves in the system being tested shall be in full open condition except for ball and plug valves which shall be tested in the half open position to ensure that the valve cavities are pressuri?ed during testing and also to ensure that seals are not exposed to excessive differential pressures& )&'&''.ll permanent piping supports shall be installed before conducting the pressure test& 6herever re5uired8 temporary supports shall be provided and these supports shall not be removed till the system has been fully drained& The temporary supports shall be identified by colour coding (7ed colour)& )&'&'!The piping system shall be blown clean of loose scale and debris prior to commencement of pressure testing& Cleaning and flushing of lines shall be as per O6N/7 approved procedure& )&'&'$Test blinds shall be installed between existing and new piping to prevent introducing testing medium into existing lines8 or pressuri?ing

Naser M.Al-Baddah & Partner General Trading & Contracting Co. W.l.l.

Doc. No. Rev. No.

T#T$%

NBTC M3 QC PNT 28. 1

Cont. No.: 03UT02-053 Approved !: "ite Manager

Page 5 of 8

PROCEDURE FOR PNEUMATIC TESTING FOR PIPING SYSTEM.

the existing system& The test blinds shall be capable of withstanding the test pressure& )&'&')*ystem may be separated into sub@systems for testing& The number of tests shall be held to a minimum& . complete record of each test with accompanying test diagram will be prepared and maintained& )&'&':.ll weld %oints shall be free from paint& )&'&',4nsulation shall not cover %oints or flanged connections on piping to be tested& )&'&';.vailability and wor3ing condition of test pumps8 calibrated gauges8 suitability of the gauges shall be ensured& )&'&'<Temporary gas3ets8 stud bolts and nuts may be used for blinds8 valves8 flanges for testing purpose& .ll the temporary material shall be identified by colour coding with fluorescent orange paint& 4.2 )&!&' 4.3 )&$&' Test Medium The test fluid to be used for pneumatic test will be oil free compressed air& dministration of Test The surface temperature of the piping or component to be tested shall be from ) 9eg C ()- 9eg A) to :! 9eg C ( '!: 9eg A) inclusive8 throughout the test& The pressure in the line shall be raised by compressor and pressuri?ing the system gradually& Alanged %oints may be taped shut using a suitable adhesive coated paper tape such as duct tape or mas3ing tape& 6hen tape is used8 the tape shall be applied very carefully to insure an airtight seal all around both flanges& . small vent hole shall be punched in the tape8 at a location preferably on top& . commercial bubble test fluid (*noop) shall be applied to all %oints under examination8 including each vent hole for taped flanges8 flanged %oints8 valves stems8 pac3ing glands8 and completely coat each threaded or welded %oint&

)&$&! )&$&$ )&$&)

)&$&:

Naser M.Al-Baddah & Partner General Trading & Contracting Co. W.l.l.

Doc. No. Rev. No.

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NBTC M3 QC PNT 28. 1

Cont. No.: 03UT02-053 Approved !: "ite Manager

Page 6 of 8

PROCEDURE FOR PNEUMATIC TESTING FOR PIPING SYSTEM.

)&$&,

The first lea3age chec3 shall be made at -&$ B.7 (: psig) maximum& .ny detectable lea3s shall be eliminated before proceeding& Bold the pressure for a minimum of : minutes at every increment to inspect for any lea3s and wea3ness& 4f lea3s are found8 depressuri?e the system and the lea3ing fittings shall be tightened& The piping shall be sub%ected a test pressure 'bar maximum& 6hen the test pressure is reached ('--C)8 close the isolation valve between the compressor and piping under pressure and disconnect the compressor&

)&$&; )&$&< )&$&>

)&$&'- Bold the pressure for a minimum period of $- minutes 2 as instructed by O6N/78 but a maximum of ) hours& 4f the pressure test is to be maintained for a period of time and the test fluid in the system is sub%ected to thermal expansion8 precaution shall be ta3en to avoid excessive pressure& )&$&'' Observe for any drop in pressure during holding time which indicates lea3age in the system& 9uring the test8 an inspection shall also be made for all the welds and connections for lea3s& 4.4. )&)&' Pressure !auges The pressure gauges shall be of suitable capacity for the test pressure8 having a dial at least '': mm in diameter& The test pressure should be approximately ,- C full scale& The maximum pressure capacity shall not exceed four times the particular test pressure& The gauges being used shall have a valid calibration certificate& There shall be a minimum of two pressure gauges for each test& Safety Relief #al$e. . properly si?ed and calibrated safety valve or relief valve shall be used at the pressure source to protect systems under test& *uch a device shall have a set pressure e5ual to the test pressure plus $&) Bar or ''- C of the test pressure8 whichever is less&

)&)&! )&)&$ 4."

Naser M.Al-Baddah & Partner General Trading & Contracting Co. W.l.l.

Doc. No. Rev. No.

T#T$%

NBTC M3 QC PNT 28. 1

Cont. No.: 03UT02-053 Approved !: "ite Manager

Page 7 of 8

PROCEDURE FOR PNEUMATIC TESTING FOR PIPING SYSTEM.

4.% )&,&'

cceptance &riteria Pressure test of a system shall be considered acceptable if no pressure drop occurs and no lea3age is observed& Post Test Dpon successful completion of the test8 the piping system shall be depressurised& .ll temporary blan3s and blinds shall be removed and all piping components shall be completely reconnected& The pressure in the piping system shall be reduced gradually8 opening the vents slowly and then drain the test fluid completely from the piping system& Ealves8 orifice plates8 expansion %oints that have been removed shall be reinstalled with proper gas3ets and bolts& Ealves that were closed 2 partially closed during pneumatic testing shall be opened fully to ensure drainage of the bonnet cavity& Care shall be exercised in controlling depressurising of piping& .ll temporary materials8 such as gas3ets8 bolts and nuts8 used during pneumatic testing shall be replaced with the new materials& The connecting weld %oint between two construction wor3 pac3ages shall be considered as a golden weld and '-- C radiography shall be performed& Safety Only authorised personnel shall be permitted to approach the system undergoing pressure test& .ll necessary measures shall be ta3en to ensure that all personnel are ade5uately protected during the course of the pressure test and no wor3 shall be permitted on the pressuri?ed sections of the pipeline for the duration of the tests&

4.' )&;&'

)&;&!

)&;&$

)&;&) )&;&: )&;&,

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Naser M.Al-Baddah & Partner General Trading & Contracting Co. W.l.l.

Doc. No. Rev. No.

T#T$%

NBTC M3 QC PNT 28. 1

Cont. No.: 03UT02-053 Approved !: "ite Manager

Page 8 of 8

PROCEDURE FOR PNEUMATIC TESTING FOR PIPING SYSTEM.

:&$

6arning signs shall be posted at appropriate locations for the duration of the tests in /nglish stating F6.7N4N(@P4P/ 4N/ DN9/7 P7/**D7/ T/*TG&

%.0 Reports The test record shall be submitted to O6N/7 for their approval in the format of FP7/**D7/ T/*T C/7T4A4C.T/G& '.0 ttac(ments: M3)*+),.01 M3)*+),.02 M3)0f),.03 M3)*+),.04 M3)*+),.0" M3)*+),.0% ) Pressure Test &ertificate. ) Test Pac- .nde/ S(eet. ) Mec(anical &ompletion Record. ) 1T Pressure &(art. ) 1ydro Test Pac- Routing +orm. ) Piping .sometric .nde/.