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07/09/06

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Cancelled package of PB N 29 & up-dated line list

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09/08/06

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Modified package of PB N 28 & 12 + BOP 15 & 15B

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03/05/06

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Revised following Clients comments AKP/APC/5054

Modified packages of PB N1/5/9/9A & 29

24/02/06

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First issue- Valid for Units 08,07,06 & Common. Replication of

StageI specification (W/O Boiler)

FUS

REV

DATE

PREPARED

CHECKED

APPROVED

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE II, PHASE 2

CONTRACT No. 20321020
CONSULTANT

CONTRACTOR

abcd
Power
Scale :

SUBCONTRACTOR

Format :

Title :

Language : E
Project :

IS

SOB
NA

KKS

NA

Doc Type :

ER

PRESSURE TEST PROCEDURE

Consortium Participant or Subcontractor Document No. :

abcd

Number of
sheets : 182

Power Turbo-Systems

Sheet N: 1

Plants

Alstom document no :

SOB 99 M ------ER 100

Client Document No. :

90 V- R - 35001

Power Turbo-Systems
Plants

SHOAIBA - STAGE II, PHASE 2

3 X 370 MW OIL FIRED POWER STATION
______
PRESSURE TEST PROCEDURE

______
Table of content

Replication of SHOAIBA Stage I - specification referenced:

00-Y-R-30001 Rev E - Pressure Test Procedure (W/O Boiler)
SECTION 1
SECTION 2
SECTION 3
SECTION 4
SECTION 5
SECTION 6
SECTION 7
SECTION 8
SECTION 9
SECTION 10
SECTION 11
SECTION 12
SECTION 13
SECTION 14

90 V R-35001 D

Application
Reference codes & documents
Temperature of test medium
Testing schedule
Preparation for testing
Test methods
Hydrostatic test
Pneumatic test
Initial service test
Boiler external piping
Re-testing after repairs or modification
Instrument
Certification
Attachments list

Edition September 2006

APPLICATION

1.1

This procedure shall be applied on piping system to ensure the leak tightness.

REFERENCE CODES AND DOCUMENTS

2.1

This procedure is in accordance with ;

ASME Code Section I, Section Vl11, Div. I and Section B 31.1. for boiler external
piping.
NFPA 24 section 10.10.2.2 for fire fighting network.

2.2

Contractual requirements.

TEMPERATURE OF TEST MEDIUM

3.1

The temperature of the test medium shall be that of the available source unless
otherwise specified by the owner. When conducting test at low temperatures, the
possibility of brittle fracture shall be considered. For Pressure Vessels the test
temperature should be at least 30 F above Minimum Design Metal Temperature
(MDMT).

TESTING SCHEDULE

4.1

The pressure test shall be performed following the completion of all fabrication
assembly, erection activities required, PWHT and requested NDE (RT, UT etc.) to
provide leak tightness of the piping system or pressure vessels.

4.2

Pressure test could be done per portions or per areas, according site piping
progress and availability of building or equipments for connection, according to
ASME B 31.1 137.1.5).

PREPARATION FOR TESTING

5.1

Exposure of joints.

5.1.1 All joints including welds not previously tested shall be left un-insulated and unpointed for a proper visual examination during the test.
52

Temporary supports

5.2.1 Piping system designed for vapour or gas shall be provided with temporary Support
if necessary to support the weight of the water.
5.3

Expansion joints.

5.3.1 Expansion joints shall be isolated during the system test or if tested shall be
provided by temporary restraint to avoid additional pressure load under test.

90-V-R-35001 D

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5.4

Piping and equipment not subjected to pressure test.

5.4.1 The piping and equipment not subjected to pressure test shall be either
disconnected from the system or isolated by blanks or similar means.
5.5 Precautions against test medium expansion.
5.5.1 A pressure relief device set at 1.06 times the test pressure is recommended during
pressure test to avoid excessive pressure rise due to expansion.

TEST METHODS

6.1

The test methods shall be the following:

- Hydrostatic test;
- Pneumatic test;
- Initial service test.

HYDROSTATIC TEST (Pressure vessels)

7.1

Vents shall be provided at the high point of the piping system to purge air pockets
while the system is filling. Loosening of flanges having a minimum of four bolts may
provide venting during the filling.

7.2

Water shall normally be used as the test medium.

7.3

The test water shall be clean and of such quality so as to minimise the material
corrosion in the piping system.

7.4

Test pressure:

7.4.1 Carbon & stainless steel pipe:

The hydrostatic test pressure at any point in the system shall not be less than n
times (where n = 1.5 according to ASME Code Sect. I and B 31.1, n = 1.3 according
to ASME Code Sect. VlIl Div. I) the design pressure multiplied by the lowest ratio of
the stress value for the test temperature to the stress value at design temperature,
plus the allowable tolerance of the test gauge.
7.4.2 Glass Reinforced Pipe (GRP) & concrete pipe:
The test pressure for GRP and concrete reinforced pipes shall be the shut-off head
of the connected pump, according the contract section 15801-appendix 2 5.
7.4.3 Fire fighting network:
According to NFPA 24 section 10.10.2.2 about hydrostatic test (see Attachment 4)
All piping shall be tested at 14.5 b without loss during 2 hours.
7.5

The test pressure shall be continuously maintained for a minimum time of one hour
(two hours for fire-fighting network) and may than be reduced to the design
pressure and held for such time as may be necessary to conduct the examination
for leakage.

7.6

Examination for leakage shall be made of all joints and connections.

90-V-R-35001 D

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7.7

The system, exclusive of possible localised instances at pump or valves packing

shall show no visual evidence of weeping or leaking.

PNEUMATIC TEST

8.1

When systems are to be used in service where traces of the testing medium cannot
be tolerated or when piping systems are so designed that they cannot be filled with
water, pneumatic test may be done.
Pneumatic testing may not be used without owners permission.
Pressure vessels to be pneumatically tested will be examined per UW-50 by PT or MT
examination.

8.2

The gas used as the test medium shall be non-flammable and non-toxic.

8.3

Special precaution for protection of personnel shall be observed when a gas under
pressure is used as the test medium. When it is not easily practicable, a hydraulic
test will be preferred.

8.4

The pneumatic test pressure shall be not less than n times (where n = 1.2 according
to ASME Code Sect. VlIl Div. I) the design pressure of the system multiplied by the
lowest ratio of the stress value for the test temperature to the stress value at design
temperature.

8.5

The pressure in the system shall gradually be increased to not more than one half
of the test pressure, after which the pressure in the system shall be increased in
steps of approximately one tenth of the test pressure until the required test pressure
has been reached.

8.6

The test pressure shall be continuously maintained for a minimum time of 15

minutes. It shall then be reduced to the lesser of the design pressure or 100 psig
[700 kPa (gage)] and held for such time as may be necessary to conduct the
examination for leakage.

8.7

Examination for leakage detected by soap bubble or equivalent method shall be

done for all joints and connections.

8.8

The piping system exclusive of possible localised instances at pump or valves

packing, shall show no visual evidence of weeping or leaking.

8.9

Compensation plates and saddles of nozzles attached to the outside of a vessel

shall be provided with at least one telltale hole (maximum size 1/4 in. pipe tap) that
may be tapped for a preliminary compressed-air and soapsuds test for tightness of
welds that seal off the inside of the vessel. These telltale holes shall be left open
when the vessel is in service.

INITIAL SERVICE TEST (only for Non Boiler Ext. Piping).

9.1

When hydrostatic test or pneumatic test are not practical or when the leak tightness
is demonstrable due to the nature of the service an initial service test and
examination could be done with the permission of the owner.

90-V-R-35001 D

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9.2

When performing an initial service test the piping system shall be gradually brought
up to normal operating pressure.

9.3

Examination for the leakage shall be made for all joints and connections .
The piping system exclusive of possible localised instances at pump or valves
packing, shall show no visual evidence of weeping or leaking.

9.4

The initial service test cannot be used for BOILER EXTERNAL PIPING.

9.5

For piping systems for which the design pressure exceeds 10 Bars or the design
temperature exceeds 177C, initial service test shall be complemented by the
following minimum non-destructive examinations

Butt welds: 100% radio graphed,

All other welds: Magnetic Particle or Liquid Penetrant test.

10

BOILER EXTERNAL PIPING

10.1

Pressure test of boiler external piping shall be done in accordance with PG 99 of

ASME Code Section I, described in the following paragraph.

10.2 Boiler external piping shall be tested by water at no less than ambient temperature,
but in no case less than 21. Centigrade. The test shall be made in two stages in
the following sequence:
a) Hydrostatic pressure shall be applied by rising the pressure gradually to 1.5
times the maximum allowable working pressure. The pressure shall be under
proper control at all times so that the required test pressure is never exceeding
by more than 6%. Close visual inspection is not required during this stage.
b) The hydrostatic test pressure may than be reduced to the maximum allowable
working pressure and maintained to this pressure while the boiler external
piping are carefully examined. The temperature can not exceed 49 Centigrade
during the close examination.

11

RETESTING AFTER REPAIRS OR MODIFICATION

11.1

Non pressure part may be welded to the pressure part of boiler or boiler external
piping after the pressure test provided the following:
-

the welding is limited to P No 1;

the attachment is done by stud welding or with fillet welds where throat of the
weld is not to exceed the lesser of 0.7 times the thickness of the pressure part
or 6.4 mm and preheat to minimum temperature of 100 centigrade is applied
when the thickness of pressure part exceed 19 mm.

the completed weld is inspected by the Authorised Inspector

90-V-R-35001 D

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11.2

the manufacturer's DATA REPORT FORM shall be signed only after completion
of the welding.

In the event of repair or addition to NON BOILER EXTERNAL PIPING subsequent

to a test the affected piping shall be retested.

11.3 A system need not to be retested after seal welding or non pressure parts welding
to pressure parts, provided the following:
-

for boiler external piping the requirements of PW-54.3 of ASME Code Sect. I
are met;

for non boiler external piping the requirements of Para 137.8.3 of ASME B31.1
are met.

12

INSTRUMENT

12.1

The pressure gauges employed for the pressure test shall be calibrated.

12.2 The pressure gauges employed for the pressure test shall have the following range:

not more than four times the test pressure;

not less than one and half times the test pressure.

13

CERTIFICATION

13.1

At the end of the test, the PRESSURE TEST REPORT attached shall be filled.

14

ATTACHMENTS

Attachment 1 Pressure test report - Form S006 Rev 1

Attachment 2 Line list for test packages Steam / Water Thermal Cycle
Attachment 3 Line list for test packages Auxiliary systems
Attachment 4 NFPA 24 section 10-2
Attachment 5 Test packages for Steam / Water Thermal Cycle
Attachment 6 Test packages for Auxiliary systems

90-V-R-35001 D

page
1
pages 17
pages 26
page
1
pages 46
pages 82

7/7

abcd

Shoaiba Steam Power Plant Stage II Phase 2

Power Turbo-Systems

Job n:
Report n:
Date:

PRESSURE TEST REPORT

System : ____________________________________________________________________
Line : _______________________________________________________________________

______________________________________________________________
______________________________________________________________
Reference drawing : __________________________________________________________

______________________________________________________________

Working pressure : _______________

bar

Test Medium: ____________________

Design Pressure : _________________

bar

Medium Temperature:______________

Test Pressure : ___________________

bar

External Temperature: _____________

Testing Date : ...

Testing Time : from to .

HYDRAULIC TEST
PNEUMATIC TEST
INITIAL SERVICE TEST

SATISFACTORY

NOT SATISFACTORY

NOTE : _____________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
We certify that the above test have been conducted as per

SUBCON.

AP CONSTR.

AP QA/QC

O/E

OTHERS

NAME :
SIGN. :
DATE
Form S006 Rev. 01

90-V-R-35001 D

Attachment 1

1/1