NIOEC-SP-50-05(0)

DOCUMENT CODE
PLAN/PRJ/SUB

UNIT

PHASE

DISCIPLANE

DOCUMENT TYPE

SERIAL NO.

REV. NO.

NO. OF PAGES: 44
DATE

NIOEC

000

EG

PI

SP

5005

A0

JULY, 2005

NATIONAL IRANIAN OIL REFINING & DISTRIBUTION COMPANY

NATIONAL IRANIAN OIL ENGINEERING

& CONSTRUCTION COMPANY

NIOEC SPECIFICATION
FOR

FIELD PRESSURE TESTING

FIRST EDITION
JULY, 2005

THIS SPECIFICATION IS THE PROPERTY OF NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY. IT IS CONFIDENTIAL AND ALL
RIGHTS RESERVED TO THE OWNER. NEITHER WHOLE NOR ANY PART OF THIS DOCUMENT MAY BE DISCLOSED TO ANY THIRD PARTY,
REPRODUCTED, STORED IN ANY RETRIEVAL SYSTEM OR TRANSMITTED IN ANY FORM OR BY ANY MEANS WITHOUT THE PRIOR WRITTEN
CONSENT OF THE NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY

JULY, 2005

NIOEC-SP-50-05(0)

NIOEC-SP-50-05(0)

JULY, 2005

REVISION INDEX
REV.

PAGE

REV.
PAGE

REV.
PAGE

REV.
PAGE

26

51

76

27

52

77

28

53

78

29

54

79

30

55

80

31

56

81

32

57

82

33

58

83

34

59

84

10

35

60

85

11

36

61

86

12

37

62

87

13

38

63

88

14

39

64

89

15

40

65

90

16

41

66

91

17

42

67

92

18

43

68

93

19

44

69

94

20

45

70

95

21

46

71

96

22

47

72

97

23

48

73

98

24

49

74

99

25

50

75

100

NOTES:
1)

THIS SHEET IS A RECORD OF ALL REVISIONS TO THIS SPECIFICATION.

2)

REMARKS RELATED TO EACH REVISION SHOW A BRIEF DESCRIPTION. THESE REMARKS SHALL BE
INTERPRETED IN CONJUNCTION WITH THE REVISED TEXT MARKED BY REVISION NUMBERS.

3)

WHEN APPROVED EACH REVISION SHALL BE CONSIDERED AS A PART OF THE ORIGINAL

DOCUMENT.

4)

NUMBER OF PAGES EXCLUDES THIS SHEET AND THE COVER SHEET.

5
4
3
2
1
0

JULY, 2005

M.KHEZRI

A.NAVARCHI

M.R.FARZAM

M.A.A.SAJEDI

REV.

DATE

PREPARED

CHECKED

APPROVED

AUTHORIZED

JULY, 2005

NIOEC-SP-50-05(0)

CONTENTS:

PAGE NO.

1. SCOPE

2. REFERENCES

3. UNITS

4.

DEFINITIONS & TRMINOLOGY

5.

GENERAL REQUIREMENT

6. HYDROSTATIC PRESSURE TESTING FOR PLANT PIPING SYSTEM 5

6.1 General
6.2 Testing Area
6.3 Test Equipment
6.4 Test Medium
6.5 Test Pressures
6.6 Nonmetallic Piping-Test Pressure
6.7 Test Duration
6.8 Test Preparation
6.9 Procedure for Hydrostatic Pressure Test
6.10 Measures to be Taken after Hydrostatic Testing
6.11 Leaking Welds

5
6
7
7
8
9
9
9
11
12
12

PNEUMATIC PRESSURE TESTING

12

7.1
7.2
7.3
7.4
7.5
7.6

General
Test Equipment
Test Medium
Pneumatic Test Pressure
Precautions to be Taken in Pneumatic Pressure Testing
Pneumatic Testing Procedure

12
13
13
13
13
14

8. MANUFACTURING CERTIFICATE FOR FABRICATED PIPING

14

9.

PRESSURE TESSTING THROUGH EQUIPMENT

14

9.1
9.2
9.3
9.4
9.5
9.6
9.7

14
15
15
16
17
17
17

7.

Heaters and Furnaces

Unfired Pressure Vessels
Heat Exchangers
Storage Tanks
Safety and Relief Valves
Pumps, Turbines, Blowers and Compressors
Miscellaneous Equipment

10. PRESSURE TESTING OF INSTRUMENTS

17

11. TEST RECORD

18

JULY, 2005

CONTENTS:

NIOEC-SP-50-05(0)
PAGE NO.

12. APPENDIX 1 (Guide for piping pressure test activities and compilation of
Pressure test package documents)
19
12.0 Scope
12.1 Documentation
12.2 Preparation of Test Package
12.3 Test Scheduling
12.4 Line Checking
12.5 Preparation for Line Check and Hydrotest
12.6 Line Cleaning
12.7 Pressure Test
12.8 Post Test Activities & Restoration
12.9 Final Test Package Documents

19
19
19
20
20
22
22
22
24
24

ATTACH. A

Type of Pressure Testing

25

ATTACH. B(1/2)

Piping Test Package (TP) Flow Chart

26

ATTACH. B(2/2)

Detail Work Flow for A/G. Test Package Document

Handling/ Line Checking/ Pressure Test/ Post Test

27

ATTACH. C

Test Package Documents (Sample File)

28

ATTACH. D

Recommended Pressure Gauge Range

44

JULY, 2005

NIOEC-SP-50-05(0)

1. SCOPE
This Specification covers the minimum requirements of field pressure test to be carried
out on plant piping system, equipment (Heaters and furnaces, unfired pressure vessels,
Heat exchangers, storage tanks) and instruments, upon completion of construction work
and before commissioning.
The test is required in order to prove the strength of system, its tightness (absence of
leaks) and the integrity of weldments and materials.
2. REFERENCES
Throughout this Specification the following dated and undated standards/ codes are
referred to. These referenced documents shall, to the extent specified herein, form a part
of this Specification.
For undated references, the latest edition of the referenced document (including any
supplements and amendments) applies. For dated references, the edition cited applies.
The applicability of changes in dated references that occur after the cited date shall
mutually be agreed upon by NIOEC and the Vendor/Contractor.
ASME (AMERICAN SOCIETY OF MECHANICAL ENGINEERING)
ASME B 31.3 2004
ASME B 31.1
ASME B 31.5
ASME B 16.5

Process Piping
Power Piping
Refrigeration Piping
Steel Pipe flanges and flanged fittings

API (AMERICAN PETROLEUM INSTITUTE)

API 650

Welded steel tanks for oil storage

NIOEC-SP (NIOEC SPECIFICATIONS)

NIOEC-SP-00-02
NIOEC-SP-41-03
NIOEC-SP-44-01
NIOEC-SP-45-03
NIOEC-SP-50-07
NIOEC-SP-50-17

NIOEC Specification for site Preparation-Earth

Work and Sewers
NIOEC Specification for Pressure Vessels
NIOEC Specification for Shell & Tube Heat
Exchanger
NIOEC Specification for Fired Heaters
NIOEC Specification for Cleaning and Protection
of Piping"
NIOEC Specification for Protection of Under
Ground Steel Pipe

NIOEC STANDARD DRAWINGS

NIOEC-SD-5044-1/1

Hydro Static Test Blind

IPS (Iranian Petroleum Standards)

IPS-E-GN-100

Engineering Standards for Units

JULY, 2005

IPS-C-IN-100

NIOEC-SP-50-05(0)

Construction and Inspection Standard for General

Instrument and Testing of Instrument and
Instrument System

3. UNITS
International system of units (SI) shall be used in accordance with NIOEC-SP-00-10, unless
otherwise specified.
4. DEFINITIONS AND TERMINOLOGY
4.1 Employer: Means National Iranian Oil Engineering and Construction Company
(NIOEC).
4.2 Contractor: Means EP contractor or EPC contractor.
4.3 Construction contractor: Construction Contractor is the party which carries out all as
part of construction and/or commissioning for the project.
4.4 Inspector: The Inspector is a person/persons or a body appointed in writing by the
Engineer for the inspection and testing.
4.5 Engineer: The Engineer is a person or a body appointed in writing by the Employer.
4.6 Owner Representative: Refiner representative introduced in writing to the Engineer.
5. GENERAL REQUIREMENTS
5.1 In addition to the requirements specified in this NIOEC Specification
, piping systems shall be tested in accordance with the provisions of ASME code as
follows:
a) For process and general utility services ASME B.31.3.
b) For piping within the scope of steam generation ASME B.31.1.
c) For refrigeration piping system ASME B.31.5.
5.2 For field pressure testing of pressure vessel, heat exchangers, heaters, storage tanks
and underground piping systems, in addition to the stated requirements in related
sections of this NIOEC Specification, referenced codes & standards as specified, and
manufacturers recommendation shall be considered.
5.3 Care shall be taken to ensure that the following equipment is not subjected to field
pressure test:
a) Pumps, turbines and compressors.
b) Rupture discs, safety valves, flame arrestors, filter elements.
c) Instruments, including gage glasses and pressure gages.
d) Equipment where the internal lining may be damaged by the test
medium.
e) Equipment such as filters and driers where the content could be damaged
or contaminated.
f) Vessels and exchangers which have hydrostatic test pressure less than the
line test pressure.
4

JULY, 2005

NIOEC-SP-50-05(0)

6. HYDROSTATIC PRESSURE TESTING FOR PALNT PIPING SYSTEM

6.1 General
6.1.1 Before commencing pressure test, the construction contractor shall be provided
with the following latest approved for construction document for review and
compilation of test package documents and execution of the test, who shall
then prepare a detailed test procedure and submit to Contractor / Employer
for approval.
a) Pressure test flow diagram.
b) Test block list.
c) Field pressure testing (this NIOEC Specification).
d) Any other information as necessary.
Note: As a guide, procedure for pressure test activities of plant piping
systems (including preparation of test package documents, TP
flowchart, line checking, line cleaning, hydrotest, post test activities
and restoration, final test package documents) in line with this
NIOEC Specification is given in APPENDIX 1.
6.1.2 For convenience, vessels may be tested simultaneously with connected piping
provided that requirements as stated in 6.1.3 & 6.1.4 below are met. Vessels
shall not be tested with the piping when the following conditions exist:
a) Large vessels which would overload the foundation or support if filled
with water.
b) Large vessels requiring too much water to fill.
c) Vessels with internals which would be damaged by water.
d) Vessels which are extremely difficult to drain or vent.
6.1.3 Where the test pressure of piping attached to a vessel is the same as or less than
the test pressure for the vessel, the piping may be tested with the vessel at the
piping test pressure.
6.1.4 Where the test pressure of the piping exceeds the vessel test pressure, and it is
not considered practicable to isolate the piping from the vessel, the piping and
the vessel may be tested together at the vessel test pressure, provided that
employer, with the consent of owner, approves and the vessel test pressure is
not less than 77% of the piping test pressure calculated by equation 1. (See
6.5.1)
6.1.5 If a portion of a piping system can not be hydrostatically tested because the
presence of water is objectionable, a notation shall be made on the pressure test
flow sheets indicating that hydrostatic testing by water is prohibited.
6.1.6 Underground lines inside plot limits shall be completely tested, inspected,
drained and approved before backfilling of the lines are carried out.(See
NIOEC-SP-50-17 and NIOEC-SP-00-02)
6.1.7 Cast iron piping with spigot and socket joints shall be intermittently covered,
leaving the joints clear and all the bends securely anchored before testing.

JULY, 2005

NIOEC-SP-50-05(0)

6.1.8 Vents shall be provided at all high points in the piping system and drains shall
be provided at all low points.
6.1.9 Fabrication and welding shall be complete prior to system testing.
6.1.10 Welding cleanup, nondestructive examination, stress-relieving, and other heat
treatments shall be completed before pressure testing is performed.
6.1.11 Insulation shall not be applied over welded or mechanical joints and
connections. Screweds or welds shall not be painted before pressure testing.
6.1.12 Testing shall be performed by qualified personnel of construction contractor
who are thoroughly familiar with all equipment and test procedures.
6.1.13 Pressure testing shall be performed in presence of the Employer inspector.
6.1.14 Pressure testing should be performed when the weather condition is suitable
for inspection.
6.1.15 Pressure relief and thermal expansion relief valves shall be excluded from the
general pressure tests. Blinds shall be installed immediately adjacent to their
inlet and outlet (if required) flanges during tests. Relief valve test gags may
be used in place of blinds. Screwed relief valves shall be removed and the
connections temporarily plugged or capped during the tests.
6.1.16 Lines containing check valves shall have the source of pressure located in the
piping upstream of the check valve so that pressure is applied under the seat.
If this is not possible, the check valve flapper shall be removed or jacked up.
6.1.17 Seats of valves shall not be subjected to a pressure in excess of the maximum
cold working pressure of the valve.
6.1.18 Short pieces of piping which must be removed to permit installation of blind
or blank, should be tested separately.
6.1.19 Pipe supports and anchors should be fitted prior to pressure testing. In certain
cases temporary or additional supporting of pipe work may be required due to
weight of the testing medium.
6.1.20 For permanent flanged joints, permanent service gaskets shall be used. For
temporary flanged joints, test gasket shall be used. Record of such temporary
gaskets, shall be maintained.
6.2 Testing Area
6.2.1 If possible, test equipment including pumps, gages, recorders, and other items
shall be located in the same area.
6.2.2 The area shall be continuously monitored by test personnel while testing is
being performed so that any change in test procedures or conditions will be
noted immediately and corrective action taken as required.

JULY, 2005

NIOEC-SP-50-05(0)

6.3 Test Equipment

The inspector approval shall be obtained prior to use of equipment intended for the
execution of the pressure test.
6.3.1 Instruments
The required instruments for each test shall be as follows:
a) Pressure gage, accurate to within 1% of its range. The range shall be 1.5
to maximum 2 times of test pressure.
b) Dead weight tester and temperature indicator, if specified, instruments
shall be suitably protected from all elements. Prior to testing, they shall
be calibrated (preferably on site) and a record of the instrument
calibration and identification shall be kept as part of the inspection
records. The calibration date and identification should be affixed to the
instruments. Calibration shall be done according to IPS-C-IN-100.
6.3.2 Pumps
Construction contractor shall be responsible for the supply of suitable pumps
for the testing. As a minimum a high volume centrifugal pump for filling and a
variable speed positive displacement reciprocating pump with sufficient
discharge head and capacity for the pressurization shall be provided.
The construction contractor shall provide chemical injection pump and means
necessary for measuring of the inhibitor (if required) to be added to test water.
6.4 Test Medium
6.4.1 The test fluid normally shall be fresh water and shall not contain suspended
solids which may plug small lines. If it is found necessary water filter shall be
used equipped with 100 mesh screen to remove 99% of particles which are
140 microns or more in size.
6.4.2 The water shall have a corrosion inhibitor if so specified on the pressure test
flow sheets.
6.4.3 If the water temperature is likely to fall to zero degrees Centigrade or below,
glycol or another antifreeze approved by the Engineer shall be added.
6.4.4 Carbon and low-alloy steel
Piping manufactured from carbon steel or low-alloy steel may be
hydrostatically tested with fresh water. Brackish or sea water may be used
provided that prior approval of the Engineer is obtained.
6.4.5 Stainless steels
The chloride content in the water used for the hydrostatic testing of piping
manufactured from or containing parts manufactured from austenitic stainless
steel (e.g., 18 Cr- 8 Ni or 18 Cr-10 Ni-2 Mo), shall be less than 40PPM.,
laboratory test report shall be provided.
6.4.6 Duplex stainless steels
The preferred method is to use condensate or demineralized water (up to 2
PPM chloride).

NIOEC-SP-50-05(0)

JULY, 2005

6.4.7 9% Nickel alloy steel

The test water shall be of a neutral PH value, clear and free from sulfides which
may otherwise precipitate stress cracking of the equipment.
6.4.8 In systems where residual moisture can not be tolerated, e.g., in SO2, acid,
ammonia and LPG service and where certain catalysts are used, other test
medium shall be selected. If flammable liquid is used consideration shall be
given to the test environment.
6.5 Test Pressures
6.5.1 General process piping-test pressure
The hydrostatic test pressure, at any point in a metallic piping system shall be
as follows:
a) Not less than 1.5 times of the design pressure.
b) For design temperature above the test temperature the minimum test
pressure shall be calculated by the following formula, except that the
value of ST/S shall not exceed 6.5:
1.5 PST
PT =

(Eq.1)
S

Where:
PT
P
ST
S

= Minimum hydrostatic test pressure

= Internal design gage pressure
= Allowable stress at test temperature
= Allowable stress at design temperature
(See table A-1 ASME B31.3)

c) If the test pressure as defined above would produce a stress in excess of

the yield strength at test temperature, the test pressure may be reduced to
the maximum pressure that will not exceed the yield strength at test
temperature. (All code requirements as mentioned in ASME B 31.3 shall
be considered)
d) Where the pipe work being tested contains flanges, the test pressure as
determined in paragraph 6.5.1 (b) for piping should be in accordance with
section 8 of steel pipe flanged fittings, ASME B 16.5.
6.5.2 Refrigeration service-test pressure
Refrigerant piping shall be tested in accordance with the provisions of ASME
B31.5 "Refrigeration Piping" and be successfully dried out accordingly, or
other measures approved by the Engineer shall be applied against freezing.
Note:
However no oxygen or any combustible gas or combustible mixture of
gases shall be used for testing within the system. Water should not, if
possible, be used for testing of refrigerant piping, but if used, it must be
completely removed as described in paragraph 6.10.5.

JULY, 2005

NIOEC-SP-50-05(0)

6.5.3 Vacuum service-test pressure

Lines in vacuum service shall be tested at a minimum internal pressure of 200
kPa (29 psi) unless limited to a lower pressure by design and/or construction.
6.5.4 Utilities service-test pressure
The test pressure for service air and water piping shall be 1 times the design
pressure or 700 kPa (100 psi) for steel piping, whichever is higher. Flanged
cast iron piping shall be tested to 1 times the design Pressure + Maximum
static head of pipe content during operation; but in no case more than the
following test pressures:
Size (Dia.)
DN 25-300 (NPS 1-12)
DN 350-600 (NPS 14-24)
DN 750 (NPS 30 & LARGER)

Class 125 Flange

1700 KP (250 psi)
1400 KP (200 psi)
700 KP (100 psi)

Class 250 Flange

3500 KP (500 psi)
2800 KP (400 psi)
1400 KP (200 psi)

6.5.5 Jacketed lines-test pressure

In jacketed lines the jacket shall be tested in accordance with paragraph 6.5.1
on the basis of jacket design pressure. The internal line shall be tested on basis
of external or internal design pressure whichever is greater, unless limited by
the engineering design conditions. Limitations shall be noted on the pressure
test flow diagram.
6.6 Nonmetallic Piping-Test Pressure
The hydrostatic test pressure at any point in a nonmetallic piping system shall be not
less than 1.5 times the design pressure, but shall not exceed 1.5 times the maximum
rated pressure of the lowest rated component in the system.
6.7 Test Duration
The test pressure shall be maintained for an adequate time (not less than one hour) to
detect small and slow seepage leaks and to permit a thorough inspection.
6.8 Test Preparation
6.8.1 For hydrostatic testing, all pipe supports shall be in position and completed
before testing is undertaken.
6.8.2 All piping intended for other than liquid service shall be adequately supported
by temporary supports if necessary, particularly on lines using spring or
counterweight supports. Large adjacent lines shall not be tested simultaneously
where the weight of the combined test water load may overload the structure
of supports.
6.8.3 If blind flanges are necessary, the flanges shall be indicated on the pressure test
flow diagrams.
6.8.4 All lines should be cleared of debris by flushing with water or blowing with
steam or air. Precautions should be taken to ensure that debris is not flushed
into associated vessels, equipment or "dead ends".
9

JULY, 2005

NIOEC-SP-50-05(0)

6.8.5 The construction contractor of test shall consider temporary gaskets when
making connections that will be broken for testing or reassembly after testing.
6.8.6 Ball valves and gate valves shall be completely open during the test.
6.8.7 The construction contractor shall take care to avoid contaminating valve seats
with foreign particles.
6.8.8 Lines containing check valves shall have the pressure source located on the
upstream side. If impossible, the check valves shall be removed from the line
or blocked open.
6.8.9 Lines which have spring hangers or are counterweight supported shall be
temporarily blocked up during testing in order to sustain the weight of the test
fluid. Sometimes spring hangers are provided with stops for carrying the test
load and need not be blocked up.
6.8.10 All orifice plates shall be removed before the test.
6.8.11 Equipment that is not to be included in the test shall be isolated by blinds or
shall be disconnected from the piping.
6.8.12 Control valves shall remain in the line for testing. Those which are normally
closed shall be opened by clean dry air. The valves shall not be jacked or
forced open.
6.8.13 Pressure control valves with internal passages between the process fluid and
the diaphragm shall be isolated from the test. External connections shall be
disconnected or blocked during the test. The diaphragm pressure shall be bled
off.
6.8.14 Expansion joints of the sliding sleeve or bellows type should be provided with
temporary means to limit lateral movement.
6.8.15 Expansion joints, instruments, filters and similar equipment for which the
maximum permissible cold test pressure is considerably lower than the
maximum hydrostatic test pressure permissible for the other components of
the system shall be removed or blanked off from the line before testing. Such
equipment should be inspected during the commissioning with due regard to
the pressure limitation.
6.8.16 Plugs shall be removed from tell-tale holes in compensating rings and
reinforcement pads around branches (nozzles) and the holes left open during
hydrostatic testing and observed for any leakage.
6.8.17 Prior to commencement of the test a thorough check shall be made to ensure
all fittings, flanges, plugs, etc., are in place. All flanges and flanged fittings
shall be bolted and bolts properly torqued.
6.8.18 Testing of more than one individual section simultaneously may be carried
out by connecting the sections with suitable jumper lines. The materials used
10

JULY, 2005

NIOEC-SP-50-05(0)

in the fabrication of these jumpers shall be of the same quality as the system
under test, as a minimum. Threaded piping shall be minimized on jumper
lines.
6.8.19 Instrument piping at orifice flanges shall be removed or a drain or vent shall
be opened to ensure that the instrument does not become pressurized because
of a leaking valve.
6.8.20 Mounted instrumentation shall be isolated from the system during testing.
6.8.21The supply connection size shall ensure filling of the system within a
reasonable time, and it shall have a flanged valve.
6.8.22 A valve shall be used for depressurizing, for which a globe valve is preferred.
6.9 Procedure for Hydrostatic Pressure Test
6.9.1 Pressure test sections shall be chosen by the construction contractor, based on
the submitted approved pressure test flow diagram, test block list and testing as
much piping as possible at one time without exceeding the allowable test
pressure of the weakest element in the system.
6.9.2 Vents and other connections that can serve as vents shall be open during filling
so that all air is vented prior to the application of test pressure to the system.
6.9.3 Test pressures shall be taken at the lowest point of a line or test system.
6.9.4 During hydrostatic testing, care must be exercised to limit the applied pressure
to the particular portion of the system designated on the field pressure test flow
diagram.
6.9.5 Care must also be taken to avoid overloading any parts of supporting
structures.
6.9.6 Where conditions require a test pressure to be maintained for a period of time,
during which the test medium in the system might be subject to thermal
expansion, provision shall be made for the relief of excess pressure due thereto.
(By either installation of a proper relief valve or discharging excess pressure.)
6.9.7 Test pressure shall not be applied against any closed valve unless the maximum
allowable working pressure (MAWP) of the valve exceeds the test pressure.
6.9.8 If the test pressure is the same upstream and downstream of a control valve, the
block and by-pass valves shall be left open, with the control valve open or
closed (whichever is most convenient).
6.9.9 If the test pressure is different at upstream and downstream of a control valve,
the test on the upstream portion shall be made with the upstream block valve
and control valve open, downstream block valve and by-pass valve open and
blinded off.
6.9.10 All plain test blanks required for field testing shall be provided and/or made in
the field according to NOEC-SD-50-01.
11

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NIOEC-SP-50-05(0)

6.10 Measures to be Taken after Hydrostatic Testing

6.10.1 After hydrostatic testing is completed and approved by the inspector, the
system shall be depressurized.
6.10.2 After depressurizing, lines and equipment shall be completely drained. The
equipment should be cleaned, if necessary (in the opinion of the inspector).
6.10.3 While draining, the system shall be vented to avoid a vacuum.
6.10.4 Special attention shall be given to points where water may be trapped such as
valve bodies or low points.
6.10.5 Systems shall be dried after draining. The drying process may be
accomplished by blowing warm compressed air through the system or by
another method approved by the Engineer.
6.10.6 All temporary blanks and blinds shall be removed. Valves, orifice plates,
expansion joints and short pieces of piping which have been removed shall be
reinstalled with proper and undamaged gaskets in place. Valves which were
closed solely for hydrostatic testing shall be opened. Temporary piping
supports shall be removed so that insulation and painting may be completed.
6.11 Leaking Welds
Welds or portions of welds that leak during hydrostatic test shall be cut out,
rewelded, radio graphed and line shall be hydrostatically tested again at the
construction contractors, expense.
7. PNEUMATIC PRESSURE TESTING
7.1 General
With prior approval by the Engineer pneumatic testing may be substituted for
hydrostatic testing if the following conditions apply. Pneumatic test should be
specified in pressure test flow sheet when it is substituted for hydrostatic testing.
a) When special supports or other special arrangements would be required on large, lowpressure lines.
b) When hydrostatic tests are uneconomical or impractical.
c) When the possibility exists that piping, insulation, refractory material, or attached
equipment might be damaged by water.
d) When even a small amount of water left in a system, such as a refrigerant system,
could be injurious.

12

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NIOEC-SP-50-05(0)

7.1.1 The following lines are usually excluded from hydrostatic testing, and are
usually tested with compressed air and soap suds:
a) Instrument air lines (test with dry air).
b) Air lines to air-operated valves. (Test with dry air only).
c) Very large (usually over DN 600-NPS 24) gas or steam overhead line.
d) Pressure parts of instruments in gas or vapor service.
7.1.2 If investigation determines that testing is required for relief or blow down
header systems or individual pipe stacks more than 15.2 m in height which are
open to atmosphere, they need only be tested for tightness with soap suds at 0.4
bars (5psi) air pressure.
7.1.3 Piping with linings subject to damage by water, shall be tested with other
suitable test medium. (This shall have been specified in test flow diagram &
test block last.)
7.1.4 Lines over DN 200 (NPS 8) from tank tops will be air tested in order to
minimize excessive loads, and/or the need for special designed supports or
foundations.
7.2 Test Equipment
7.2.1 Instrument
See Clause 6.3.1 of this Standard.
7.2.2 Compressors:
a) The construction contractor shall be responsible for the supply of suitable
compressors for the testing.
b) Air compressors with oil lubricated construction shall not be used for purging
and testing instrument air lines.
7.3 Test Medium
7.3.1 Unless otherwise specified, pneumatic testing shall be performed with clean
dry air or nitrogen.
7.3.2 Air for instrument air lines shall be oil-free.
7.3.3 If other gases are used as a test medium, it shall be nonflammable and
nontoxic.
7.4 Pneumatic Test Pressure
The pneumatic test pressure of any piping system shall be equal to 110% of the
design pressure of the system. If the test pressure exceeds 150 psig written approval
of the Engineer shall be obtained.
7.5 Precautions to be Taken in Pneumatic Pressure Testing
7.5.1 Due to the large energy stored in compressed gas and, hence, the potential
hazard of a sudden release of this energy, pneumatic testing shall be carried out
in small sections to minimize the risk involved.
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JULY, 2005

NIOEC-SP-50-05(0)

7.5.2 A pressure relief device shall be provided, having a set pressure not higher than
the test pressure plus the lesser of 345 Kpa (50 Psi) or 10% of the test pressure.
7.5.3 The possibility of brittle fracture shall be considered when conducting tests at
metal temperatures near the ductile-brittle transition temperature.
7.5.4 Flange joints shall be masked with tape. One small hole shall be punched in the
tape to indicate leaks.
7.5.5 Welds of piping subjected to pneumatic strength test above 150 psig shall be
100% radio graphed.
7.5.6 In view of its hazardous nature, pneumatic pressure test shall only be
undertaken with the presence of the Employers inspector.
7.5.7 All non-essential personnel and members of the public, when necessary, shall
be evacuated from the test area.
7.6 Pneumatic Testing Procedure
The following steps shall be taken in performing pneumatic test:
a) Gradually bring piping system pressure up to the lesser of one-half the test
pressure or 100 kPa (gauge), 14.5 psig, and make a preliminary inspection.
Carry out a leak test using a sonic detector or soapy water. Hold pressure for at
least 10 minutes.
b) The test pressure shall be increased gradually in increments of the lesser of onehalf the test pressure or 100 kPa (14.5 psig) maximum to provide time for
stress in the piping to equalize.
c) When the full test pressure has been reached, the pressure shall be held for a
sufficient time and then be reduced to the design pressure before examining for
leaks.
d) The pressure shall be gradually reduced to atmospheric at the end of the test.
8. MANUFACTURING CERTIFICATE FOR FABRICATED PIPING
The Engineer shall make sure that prefabricated piping which are not included in the
pressure test is certified by an inspectorate authority.
9. PRESSURE TESTING THROUGH EQUIPMENT
9.1 Heaters and Furnaces
Extreme care shall be taken in field testing of heater and furnace tubes, which are
normally field fabricated and must be hydrostatically tested. Where possible, piping
and heater tubes shall be tested together.
Heater tubes shall be tested to manufacturers recommended test pressure. Test shall
be coordinated with heater erection subcontractor.
Requirements specified in NIOEC-SP-45-3 shall also be considered.

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JULY, 2005

NIOEC-SP-50-05(0)

9.2 Unfired Pressure Vessels

9.2.1 Vessel constructed in accordance with ASME Code Section VIII will not
require individual pressure tests at site except in the following cases: (See also
NIOEC-SP-41-03.)
a) Vessels whose condition, resulting from transport, storage, handling, or for
any other cause is suspect in the opinion of the Employers inspector.
b) Vessels which have had any site fabrication / modification which in the
opinion of the inspector necessitate a site pressure test.
9.2.2 Pressure testing of vessels will be carried out in the presence of the Employers
inspector.
9.2.3 With the exception of relief valves, all valves and fittings should be installed
on the vessels and included in the test. Relief Valves must be removed or
otherwise isolated.
9.2.4 All plugs should be removed from tell tale holes in reinforcing pads before the
test pressure is applied.
9.2.5 Provision should be made for the venting of air from the test system.
9.2.6 No insulation, paint or other covering may be applied over any welded seam
before completion of the test.
9.2.7 For individual pressure tests of vessels, as may be required by paragraph 9.2.1,
the hydrostatic test pressure will be indicated on vessels nameplate.
9.2.8 In the case of vessels so designed that they cannot support a full head of water,
or where the foundations impose a weight limitation, a combined hydrostatic
and pneumatic test may be necessary. The procedure in such cases shall be in
accordance with requirements of ASME code section VIII Div. 1 or 2 as
applicable and must be submitted for Employers approval.
9.2.9 Base level checks on large volume vessels, columns and spherical tanks if
required, should be taken on each supporting column during filling and
emptying with water.
9.2.10 On satisfactory completion of a pressure test the vessel should be drained
completely, any blinds inserted for test purposes removed and these joints
remade to the satisfaction of the Employers inspector.
9.3 Heat Exchangers
9.3.1Provided manufacturers test certificates are available, only the following
pressure tests should be carried out on heat exchangers except as required by
paragraph 9.3.2.

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JULY, 2005

NIOEC-SP-50-05(0)

a) On floating head shell and tube type exchangers, a leak test on shell and
tube side separately shall be carried out at test pressure of 1 times the
maximum. Operating pressure (corrected for service temperature) of each
side while testing each side, all vents and drains of other side shall be kept
open. And no parts need to be removed. If any sign of leakage or pressure
drop detected, then the test shall be repeated with appropriate parts
removed to investigate the source of leakage and taking remedial action.
Note (1): Care shall be taken to limit the test pressure to proper amount for
exchangers designed on differential pressure basis.
Note (2): Provision of adequate number of spare gaskets shall be foreseen
in advance.
b) On tube-in-tube type, on both sides, separately, in conjunction with
associated pipe work and the test pressure should be on for the associated
pipe work.
c) On air-cooled types, the bundles are to be isolated and tested separately
from associated pipe work. Test pressure shall be 1 times the maximum
operating pressure corrected for maximum operating temperature.
9.3.2 In the case of tubular exchangers whose condition, resulting from transport or
other causes, is suspect in the opinion of the Employers inspector, a pressure
test on the suspect side at the maximum allowable pressure should be carried
out. Tests may be carried out individually or on groups of exchangers having
similar operating conditions. Special precautions are required when exchanger
tube sheets are designed for differential pressure less than shell and/or tube side
design pressure. (See also 9.3.1 (a) note 1)
9.3.3 After completion of test all equipment must be thoroughly drained and if
necessary, dried out to prevent scaling of tubes before commissioning.
9.3.4 After completion of test all bonnets and covers should be replaced, temporary
blanks removed and all joints remade to the satisfaction of the inspector. All
compressed fiber gaskets shall be renewed.
9.3.5 NIOEC-SP-44-01, NIOEC Specification for shell and tube heat exchanger shall
also be considered.
9.4 Storage Tanks
9.4.1 All tanks shall have bottoms, shells and roofs tested in accordance with API
Standard 650. Shells shall be tested by filling tanks with water. Vacuum testing
shall be used for all tank bottoms and roofs.
9.4.2 Floating roofs shall be tested by the following methods:
a) Center deck plates, pontoon bottom plates and rim plates with welded joints
shall be sprayed with light gas oil on the bottom side and inspected
visually on the top side and inside of rim plates.

16

JULY, 2005

NIOEC-SP-50-05(0)

b) Each completed compartment of pontoon roofs shall be individually tested

with air pressure of 75 MM (3 inches of water gauge). A soapy water
mixture shall be applied to all welded joints under pressure.
c) Roof drains together with any flexible couplings incorporated with them
shall be subjected to a hydrostatic test pressure of 3.5 bars (50 psig) with
the tank empty prior to this test the drain piping should be flushed through
to ensure the absence of any internal obstruction.
9.5 Safety and Relief Valves
9.5.1 The blow off (set) and blow down (re-set) pressure of all relief valves should
be set to the specified figures on P&ID & S.V, data sheets and to the
satisfaction of the inspector and the owner representative.
9.5.2 When settings are finally approved the owner representative will fix a seal to
each valve.
9.5.3 On removal from the testing ring after pressure setting, the inlet and outlet
branches of all relief valves should be covered to prevent ingress of dirt, etc.
These covers should not be removed until a relief valve is being installed.
9.5.4 The Employers inspector and the owner representative will check each valve
after it has been re-installed to ensure that its seal is intact.
9.5.5 In case where the valve exhausts to a pressure system, the downstream side
should be tested to a pressure equal to the test pressure rating of the outlet
system.
9.5.6 Inlet lines to relief valves should be cleared before valves are finally installed.
9.6 Pumps, Turbines, Blowers and Compressors
These shall not be subjected to hydrostatic test in the field.
9.7 Miscellaneous Equipment
Expansion joints shall be provided with temporary restraint if required for additional
pressure load under test, or shall be isolated from the test. Isolate from test if
allowable test pressure is not known. Flame arrestors, filters, and other
miscellaneous equipment that does not have test pressure indicated shall be isolated
from the test.
10. PRESSURE TESTING OF INSTRUMENTS
10.1 Certain types of instruments with their connecting process lead lines shall be tested
at the same pressure as the main pipe lines or the equipment to which they are
connected. Such instruments normally include the following types:

17

NIOEC-SP-50-05(0)

JULY, 2005

Displacer Type Level

Instruments

Control Valves

Gauge Glasses

Flow Meter Pots

Rotameters
10.2 Other types of instruments shall not be tested at line pressure, but shall have
process lead lines tested to the first block valve or valves nearest the instrument.
Care shall be taken that this equipment is protected by removal, or by blocking the
instrument lead line and disconnecting or venting the instruments. These types will
normally include the following:
Analyzers

Diaphragm Type Level Instruments

Differential Pressure Type

Flow Instruments

Direct Connected
Regulators

In-line Type Flow Switches

Open-Float Type Level Indicators

And Alarm Switches

Positive Displacement Type

Flow Meters

Pressure-Balanced
Control valves

Pressure Indicators Recorders

and Transmitters

Pressure Gauges

Pressure Switches

Turbine Type Flow Sensors

10.3 Special precautions shall be taken to insure that instruments and instrument lead
lines to be tested are vented and completely filled before testing, and are
thoroughly drained after test.
10.4 Hydrostatic testing of instruments and instrument piping shall be coordinated with
the instrument erection subcontractor.
11. TEST RECORD DOCUMENTS
Test procedures, documents, reports and test results (one original + 1 copy) shall be
submitted to employer on completion of tests and prior to stat up of unit. Test record
documents shall be as follows:
11.1 Piping installation
Test record documents shall include the following completed and signed final
documents/ reports which are prepared gradually as the fabrication/ erection
activities progresses and finally compiled as Test Package Documents. (Original
+ 1 Copy shall be submitted to Employer)
(See Appendix 1)
a) Test package content.
b) Piping test package cover sheet.
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JULY, 2005

NIOEC-SP-50-05(0)

c) Marked up test flow diagram to show test circuit and test block list.
d) As built Iso drawing or/and QC (Quality Control) Iso drawings with bill of
materials.
e) Piping spool shop fabricated inspection report. (if applicable).
f) NDT/PWHT completion report.
g) Line checks report.
h) Punch list (prepared by construction contractor).
i) Punch list (prepared by contractor/ employer as applicable).
j) Pad test report, as required.
k) Orifice flange inspection report as required.
l) Inspection report for line cleaning.
m) Pressure gauge calibration report.
n) Test medium laboratory test report, as required.
o) Pressure test report.
p) Post test inspection and restoration report.
11.2 Equipment
Records shall be made of each equipment during test which includes:
a) Date and time of test.
b) Identification of the equipment being tested.
c) Test medium used, with laboratory test report, as required.
d) Test pressure.
e) Approved by construction contractor/ contractor and employer and owner
inspector (as required). Original + 1 Copy shall be submitted to the Employer.

12. APPENDIX 1 (Guide for Piping Pressure Test Activities and Compilation of Test
Package Document)
12.0 Scope
As a guide, this procedure covers pressure test activities of piping system including
preparation and compilation of test package documents, TP flow chart, line
checking, line cleaning, hydrotest, post test activities and restoration, final test
package documents in line with this NIOEC Specification.
12.1 Documentation
Prior to the test Employer/ Contractor will provide for Construction Contractor the
following latest approved construction documents for review and compilation of
the test package document and execution of the test.
a) Pressure test flow diagrams.
b) The block list for process unit.
c) Field pressure testing specification.
d) Any other information as necessary.
12.2 Preparation of Test Packages
After completion of installation and preparation of scaffolding Construction
Contractor shall proceed with preparation of test package document for each test
section and submit these to Employer/ Contractor 3 weeks prior to the test.
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JULY, 2005

NIOEC-SP-50-05(0)

The test package documents shall include the following information inserted in
relevant columns and signed by Construction Contractor.
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)

Test package contents

Piping test package cover sheet
Marked up test flow diagram to show test circuit and test block list
As built Iso drawing or/and QC Iso drawings with bill of materials
Piping spool shop fabricated inspection report
NDT/PWHT completion report
Line check report
Punch list A (A1 for welding, A2 mechanical) prepared by Construction
Contractor
Punch list B (B1 for welding, B2 for mechanical) prepared by
Employer/ Contractor
Pad test report as required
Orifice flange inspection report as required
Inspection report for line cleaning
Pressure gauge calibration report
Pressure test report
Post test inspection and restoration report

The test package will be reviewed by Employer/ Contractor and then return it to
Construction Contractor.
12.3 Test Scheduling
Construction Contractor will prepare test schedule in coordination with Contractor
on a weekly basis. Test schedule shall include due dates for different stages of test
preparation, i.e., line checking punch listing, rectification of punch items,
preparation and execution of line cleaning test, dry out and restoration. Copies of
test schedule shall be distributed by Construction Contractor to the relevant parties.
12.4 Line Checking by Contractor, Employer and Construction Contractor
NOTE:
Line checking may be executed jointly or separately, as agreed, however
Construction Contractor shall proceed his initial line checking & rectifies
all deficiencies prior to requesting Employer/ Contractor for line checking.
All mechanical / functional line checking as shown below is normally
performed and related punch list would be prepared and issued to
Construction Contractor within one week.
Construction Contractor shall provide suitable access/platforms for
thorough inspection of lines before submission of test package which
remain up to the end of hydrotest completion and restoration. Rectification
of punch items will be followed and finally the related punch list forms and
line check report will be signed by concerned parties.
A: Mechanical line check after erection.
A.1 Conformity of installed line configuration with piping plan, ISO drawings and P&ID:
1.1 Location / Dimension / Elevation of piping.
1.2 Verticality / Levelness / Straightness.
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JULY, 2005

NIOEC-SP-50-05(0)

1.3 Line Slope Per drawing.

1.4 Reducers Type and Location.
1.5 Installation of Orifice Flange.
A.2 Conformity of materials with ISO drawings bill of material:
2.1 Line size.
2.2 Pipe and fittings material.
2.3 Bolt tension (if specified) and correct length.
A.3 Branches:
3.1 Branches located correctly.
3.2 Type of branch is in accordance to NIOEC Specification for piping material
NIOEC-SP-50-04.
3.3 Branch reinforcement pad and weep holes.
3.4 Gussets installed, where required.
A.4 Gasket installation:
4.1 Type, material, thickness.
A.5 Conformity of pipe supports with isometric drawings and removal of temporary
supports:
5.1 Anchors installed.
5.2 Guides installed.
5.3 Proper shoes installed and welded.
5.4 Spring hangers / supports and their block pins, installation and correctness of
item code number.
A.6 NDT check:
6.1 Welding completed and all NDT (RT, PT, MT, and Hardness) requirements
have been completed satisfactorily and records are available.
6.2 Post weld heat treatment (if any) have been done satisfactorily and records
are available.
6.3 Final inspection of the line and weldment for possible damages, weld spatter,
arc strikes, and any other deficiencies.
B: Functional line checking:
1.
2.
3.
4.
5.
6.

Conformity to all requirements in latest P&ID.

Requirement of operational drain / vent.
Operability.
Accessibility / maintenance.
Readable requirements of instruments.
Checking of Supports, stoppers, guides, including cold offset setting from
thermal stress view point.
7. Spring hanger / support installation and settings.
8. Other general piping engineering matters.
Punch item which do not require line modification / cutting / welding and have no
effect on pressure testing, may be rectified at later stage. Construction contractor
shall provide the list of such items and their estimated completion date.

21

JULY, 2005

NIOEC-SP-50-05(0)

12.5 Preparation for Line Cleaning and Hydrotest

1.Line cleaning / water flushing procedure and pressure test procedure (identifying
cleaning method, test equipment, facilities, pressurizing rate, safety precaution,
location of gauges, point(s) of filling and drainage, vents, etc, marked up on test
flow diagram) shall be submitted by Construction Contractor to Contractor and
Employer for review and acceptance.
Note: Some lines such as seal oil/ lube oil, compressors suction line, etc. require
chemical cleaning. Such chemical cleaning shall be done after completion
of normal cleaning, hydrotest and prior to start up as per NIOEC-SP-5007.
2.For pneumatic test, separate procedure with safety precaution consideration as
required in ASME B31.3 and this NIOEC Specification shall be prepared and
submitted for review and acceptance.
3.Preparation for line cleaning and hydrotest will be checked by Contractor and
Employers inspector, and then punch list(s) (if any) will be issued.
Construction Contractor shall notify Contractor and Employer by issuing
application for inspection, both for line cleaning and pressure test date.
12.6 Line Cleaning
1. Precaution should be taken to ensure that debris is not flushing into vessels,
equipment, pumps, etc., while executing line cleaning / flushing.
2. During cleaning / flushing stage, parts such as PSV, control valves, thermo
wells, strainer element, orifice plates, and all instruments shall not be installed
or somehow exempted. When pre-test cleaning / flushing is completed, control
valve, thermo well, strainer element, level instrument, and expansion joints of
sliding sleeves* shall be installed and included in the test as required.
* For expansion joint Employer and Contractor confirmation required.
3. Line cleaning / Water flushing shall be witnessed by Contractor and Employer
and the corresponding report shall be prepared and signed.
12.7 Pressure Test
Requirements of this NIOEC Specification shall be strictly followed. All pressure
testing will be witnessed by Contractor and Employer inspector and upon
satisfactory completion of the test, the pressure test report will be signed by
concerned parties.
Checking prior and during test are not limited to those described below
requirements of field pressure testing specification shall be followed, however,
following check items are highlighted as guidelines only:

22

JULY, 2005

NIOEC-SP-50-05(0)

1.Verify chloride content and PH of test water prior to release of water to

Construction Contractor for testing of austenitic stainless steel lines or
components (maximum chloride content shall not exceed 40 PPM; laboratory test
report is required.)
2.Pressure source and gauge shall be upstream of check valves, if pressure source
is down stream, check valve should have flapper removed or jacked up. Pressure
must be released downstream the check valve after test completion.
3.Where soft seated ball valves are in line and located at the end of test section, the
pressure side of the line at ball valve flange shall be blinded, if such ball valve is
within the line being tested it shall be in the fully open position.
4.If the test pressure is the same upstream and downstream of a control valve, the
block and by-pass valves shall be left open, with the control valve in open or
closed position.
5.If the test pressure is different at upstream and down stream of a control valve,
the test on the upper stream portion shall be made with the upstream block valve
and control valve open. Down stream block valve and by-pass valve open and
blinded off.
6.Seats of valves shall not be subjected to a pressure in excess of the maximum
cold working pressure of the valve.
7.For permanent flanged joints, permanent service gasket shall be used, for other
temporary flanged joints test gasket shall be used. Record of such temporary
gaskets shall be maintained.
8.Test blinds shall be of correct thickness with handle painted red, a record should
be kept showing the location of test blinds to ensure their removal at the test
completion.
9.Verify location of test gauges and suitability of the pressure gauge range and its
division (Range should be 1.5 to a maximum of 2 times of the test pressure and
accuracy of division to be 1%). See attached table
10. The test gauges shall be calibrated and calibration certificate available.
11. Pipe supports and anchors shall be fitted prior to pressure testing.
Additional supporting of pipe work may be required due to weight of testing
medium.
12. When conditions require that a pressure test be maintained for a period of time
during which the testing medium in the system would be subject to thermal
expansion, provision should be made for relief of excess pressure.
13. During hydrotesting, care must be exercised to limit the applied pressure to the
particular portion of the system designated on the field pressure test flow
diagram.

23

JULY, 2005

NIOEC-SP-50-05(0)

14. Short pieces of piping which must be removed to permit installation of blind or
blank should be tested separately.
15. Each test shall be held for 60 minutes without any loss of pressure prior to
requesting inspector to witness the test.
12.8 Post Test Activities and Restoration
After completion of hydrotesting, followings to be executed:
1. All lines shall be completely drained; care shall be exercised in controlling the
rate of water drain in respect to inflow of air through the vents to ensure that
vacuum is not applied.
CAUTION: Prior to commencing drainage, ensure that all vents are open with
plugs and blind flanges removed.
2. Remove all temporary blanks and blinds.
3. Dry out austenitic stainless steel lines and other carbon steel piping where acid
forming process could be involved.
4. Remove temporary supports and temporary testing connection.
5. Remove temporary gaskets for hydraulic test and install proper service gaskets.
6. All piping components shall be reinstalled except the followings:
Orifice plates.
PSV.
Instrument component (such as PG restriction orifice, etc.).
Spring hanger set pin or spring support stop pin shall not be removed.
12.9 Final Test Package Documents
Records shall be made of the completed and signed final test package documents
(listed in item 12.2).
Original of final test package documents plus one copy shall be submitted to
Employer.

24

NIOEC-SP-50-05(0)

JULY, 2005

ATTACHMENT A (1/1)
REPORT NO.:
JOB NO.
SH OF
..
UNIT
ITEM. NO.

NATIONAL IRANINAN OIL ENGINEERING AND CONSTRUCTION COMPANY

PROJECT:
Contractor:

Construction Contractor:

TYPE OF PIPING PRESSURE TESTING

TEST TYPE

HYDROSTATIC

TEST MEDIUMS

Water
* For SS/HA piping
Max. Cl. 40 ppm

APPLIED (As
per Test Block
Dia.)
General

WORK SEQUENCE

CASE-1
(Base Case)
CASE-2
(When app.
by NIOEC)

PNEUMATIC

IN SERVICE

Air
* Oil free air for IA
to air-operated
valves and N2 for
unit 02

Large Dia Piping

- Air line
- Flare
- Gas

Service Fluid

Only Approved
by NIOEC

Line
cleaning
Line
checks/
Punch out

CASE-1
(Base Case)
CASE-2
(When app.
by NIOEC)

Line
checks/
Punch out

Line checks/
Punch out

Press.
Test
Dry out

Press.
Test

Line
cleaning

Air
blowing

Press.
Test
Restoration

Press.
Test

Flushing/
Blowing

Air
blowing

Service
test

Note for line cleaning

For large diameter piping hand wipe/ sweep should be applied as much as possible (inspection to be recorded).

25

Restoration

Restoration

NIOEC-SP-50-05(0)

JULY, 2005

ATTACHMENT B (1/2)
REPORT NO.:
JOB NO.
SH OF
..
UNIT
ITEM. NO.

NATIONAL IRANINAN OIL ENGINEERING AND CONSTRUCTION COMPANY

PROJECT:
Contractor:

Construction Contractor:

PIPING TEST PACKAGE (TP) FLOW CHART

EXECUTION
(PUNCH OUT/
LINE
CLEANING/
PRESS. TEST/
POST TEST)

REVIEW / LINE CHECK / PUNCH LIST

-line check
- Punch list

- Review

EMPLOYER
(NIOEC)

- Review
QC items
- Punch list

QC Gr.

DOCUMENTATIO
N (FINAL
DOCUMENT
CONFIRMATION)

-Witness
- Confirm
- Signature

- Confirm
- Signature
on orig. TP

-Witness
- Confirm
- Signature

- Confirm
- Signature
on orig. TP

-Witness
- Confirm
- Signature

- Confirm
- Signature
on orig. TP

-Execution
- Confirm
- Signature

- Confirm
- Signature
on orig. TP

CONTRACTOR
Piping Gr.

-Review
-Register

-line check
- Punch list

-Review

RECORD

Working copy
TP Copy
Keep by contractor
(&NIOEC)

Working copy
TP Copy
CONST.
CONTRACTOR
TP Original
Keep by CC
- CC will prepare original TP and one copy for working

LEGEND:
Working copy TP flow

REMARKS

Original TP flow
Original TP (*) working copy TP flow

26

TP Original
Keep by CC
& finally submit
to NIOEC

NIOEC-SP-50-05(0)

JULY, 2005

ATTACHMENT B (2/2)
REPORT NO.:
JOB NO.
SH OF
..
UNIT
ITEM. NO.

NATIONAL IRANINAN OIL ENGINEERING AND CONSTRUCTION COMPANY

PROJECT:
Contractor:

Construction Contractor:

DETAIL WORK FLOW FOR A/G TEST PACKAGE DOCUMENT HANDLING/

LINE CLEANING/ PRESS. TEST/ POST TEST
ACTIVITY
TIME/PERIOD

TEST PACKAGE
Three Weeks
Before Testing

LINE CLEANING

LINE CHECK NIOEC/CONTRACTOR/PUNCH OUT

PRESS. TEST

One Week

POST TEST
Immediately after testing

- Line check
- QC document
review
- Punch list

Confirmation
of
Punch out

Witness

Witness

Check

EMPLOYER
(NIOEC)

Copy of
test pack.

Confirmation
of
Punch out

Witness

Witness

Check

Copy of
test pack.

CONTRACTOR

- Line check
- QC document
review
- Punch list

Two Copies
No

Notice
Notice

CONST.
CONTRACTOR

Test
Package
preparation

No

Follow up
Punch Item

Ok

Ok
-Preparation
of line
cleaning
- Application

Line
cleaning
(R)*

-Preparation
of line
cleaning
- Application

Line
cleaning
(R)*

-Drain out
-(Drying)
- Restoration
- Application

Post Test (R)*

- Finalize test
package

* (R) Inspection record required.

TEST PACKAGE :
- Contents Refer to Test Package Contents
REMARKS

NOT TO INSTALL
- PSV
- Control valve
- Thermwell
- Strainer element
- Orifice plate
- All instruments
- Disconnect all inst.
- Lead piping
- Expansion joint (Note 1)

INSTALLATION
- Control valve
- Thermwell
- Strainer element
- Level Instrument
- Expansion joint (Note 1)

Note 1: NIOEC / Contractor conformation is required.

27

REMOVE
- Temporary blind
- Other temp. part
INSTALLATION
- Expansion joint (Note 1)
NOT TO INSTALL
- PSV
- Orifice plate
* Spring Hanger set pin do not remove

NIOEC-SP-50-05(0)

JULY, 2005

ATTACHMENT C (1/16)
NATIONAL IRANINAN OIL ENGINEERING AND
CONSTRUCTION COMPANY
PROJECT:
Contractor:

Construction Contractor:

REPORT NO.:
JOB NO.
..
UNIT
ITEM. NO.

TEST PACKAGE CONTENS

TEST PACKAGE NO.:

DATE

TEST BLOCK NO.:

PREP

TEST PACK CONTROL SHEET

PIPING TEST PACKAGE COVER SHEET

TEST BLOCK LIST

MARKED UP TEST FLOW DIAGRAM TO SHOW TEST CIRCUIT

AS BUILT ISO DRAWING OR/AND/Q/C ISO DRAWING WITH

BILL OF MATERIAL

PIPING SPOOL SHOP FAB. INSPECTION REPORT

NDT/PWHT/WELD HISTORY (LINE HISTORY SHEET)

PUNCH LIST (A1,A2)

PUNCH LIST (B1,B2)

10

A/G PIPING CHECK LIST

11

PAD TEST REPORT (IF ANY)

12

ORIFICE FLANGE INSPECTION REPORT (IF ANY)

13

PRE-PRESSURE TEST LINE CLEANING

14

PRESSURE GAUGE CALIBRATION RECORD.

15

PIPING PRESSURE TEST REPORT

16

POST TEST & RESTORATION INSPECTION REPORT

28

SH OF

NIOEC-SP-50-05(0)

JULY, 2005

ATTACHMENT C (2/16)
NATIONAL IRANINAN OIL ENGINEERING AND
CONSTRUCTION COMPANY
PROJECT:
Contractor:

Construction Contractor:

TEST PACK CONTROL SHEET

1ST ISSUE: RECEIVED FROM CC

PRE TEST WORK

COMPLETED

RECIPIENT
CONTRACTOR
MECHANICAL
CONTRACTOR
PIPING
CONTRACTOR
WELDING
NIOEC
NOTE

ACCEPT

DATE

SIGNATURE

SIGNATURE

ISSUE 2: RECEIVED FROM CC

PRE TEST WORK

COMPLETED

RECIPIENT
CONTRACTOR
MECHANICAL
CONTRACTOR
PIPING
CONTRACTOR
WELDING
NIOEC
NOTE

ACCEPT

DATE

SIGNATURE

SIGNATURE

ISSUE 3: RECEIVED FROM CC

PRE TEST WORK

COMPLETED

RECIPIENT
CONTRACTOR
MECHANICAL
CONTRACTOR
PIPING
CONTRACTOR
WELDING
NIOEC
NOTE

ACCEPT

DATE

SIGNATURE

SIGNATURE

REPORT NO.:
JOB NO.
SH OF
..
UNIT
ITEM. NO.
TEST PACK No.:

DATE

REJECT

DATE

DATE

REJECT

DATE

DATE

REJECT

DATE

REMARK

THIS TEST PACK HAS BEEN COMPLETED AND ALL PUNCH LIST ITEMS SIGNED OFF AND ACCEPTED AND READY
FOR HYDROSTATIC TESTING
CONS. CONTRACTOR

SIGN.

DATE

CONTRACTOR

SIGN.

DATE

29

NIOEC

SIGN.

DATE

NIOEC-SP-50-05(0)

JULY, 2005

ATTACHMENT C (3/16)
NATIONAL IRANINAN OIL ENGINEERING AND
CONSTRUCTION COMPANY

REPORT NO.:
JOB NO.
..
UNIT
ITEM. NO.

PROJECT:
Contractor:

Construction Contractor:

SH OF

PIPING TEST PACKAGE COVER SHEET

TEST PACKAGE
No.
TEST BLOCK No.
AREA/UNIT
P&ID DWG No.
PLAN DWG No.
ITEM

DESIGN PRESS.
TEST PRESS.
TEST FLUID.

LINE NO.

ISO. NO.

SHT. NO.

INSPECTION / CONFIRMATION SUMMARY

C.C.
NAME/SIGN/
DATE

DESCRIPTION
TEST BLOCK LIST
MARKED UP TEST FLOW DIAGRAM TO SHOW TEST CIRCUIT
AS BUILT ISO DRAWING OR/AND/Q/C ISO DRAWING WITH
BILL OF MATERIAL
PIPING SPOOL SHOP FAB. INSPECTION REPORT (RELEASE)
NDT/PWHT/WELD HISTORY REPORT
PUNCH LIST (A1,A2)
PUNCH LIST (B1,B2)
A/G PIPING CHECK LIST
PAD TEST REPORT (IF ANY)
ORIFICE FLANGE INSPECTION REPORT (IF ANY)
PRE PRESSURE TEST LINE CLEANING
PRESSURE GAGE CALIBRATION RECORD
PIPING PRESSURE TEST REPORT
POST TEST INSPECTION AND RESTORATION REPORT

30

CONTRACTOR
NAME/SIGN/
DATE

NIOEC
NAME/SIGN/DATE

NIOEC-SP-50-05(0)

JULY, 2005

ATTACHMENT C (4/16)

1- TEST BLOCK LIST

TEST FLOW SHEET
2- ISO DRAWINGS & BILL OF MATERIAL
(Item 1 & 2 above appropriate for each test package shall be attached)

31

NIOEC-SP-50-05(0)

JULY, 2005

ATTACHMENT C (5/16)
NATIONAL IRANINAN OIL ENGINEERING AND
CONSTRUCTION COMPANY
PROJECT:
Contractor:

REPORT NO.:

JOB NO.
..
Construction Contractor:
UNIT
ITEM. NO.
PIPING PUNCH LIST A1 (WELDING)

SH OF

TEST PACKAGE:
NO.

ISO DWG NO.

LINE NO.

DESCRIPTION OF CORRECTION REQURED

COMPLETED

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

REMARK:

CONSTRUCTION CONTRACTOR

SIGN

DATE

CONTRACTOR

SIGN

DATE

32

NIOEC

SIGN

DATE

NIOEC-SP-50-05(0)

JULY, 2005

ATTACHMENT C (6/16)
NATIONAL IRANINAN OIL ENGINEERING AND
CONSTRUCTION COMPANY

REPORT NO.:

JOB NO.
..
Construction Contractor:
UNIT
ITEM. NO.
PIPING PUNCH LIST A2 (MECH.)

PROJECT:
Contractor:

SH OF

TEST PACKAGE:
NO.

ISO DWG

LINE NO.

DESCRIPTION OF CORRECTION REQURED

COMPLETED

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

REMARK:

CONSTRUCTION CONTRACTOR

SIGN

DATE

CONTRACTOR

SIGN

DATE

33

NIOEC

SIGN

DATE

NIOEC-SP-50-05(0)

JULY, 2005

ATTACHMENT C (7/16)
NATIONAL IRANINAN OIL ENGINEERING AND
CONSTRUCTION COMPANY
PROJECT:
Contractor:

REPORT NO.:

JOB NO.
..
Construction Contractor:
UNIT
ITEM. NO.
PIPING PUNCH LIST B1 (WELDING)

SH OF

TEST PACKAGE:
NO.

ISO DWG

LINE NO.

DESCRIPTION OF CORRECTION REQURED

COMPLETED

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

REMARK:
CONSTRUCTION CONTRACTOR

SIGN

DATE

CONTRACTOR

SIGN

DATE

34

NIOEC

SIGN

DATE

NIOEC-SP-50-05(0)

JULY, 2005

ATTACHMENT C (8/16)
NATIONAL IRANINAN OIL ENGINEERING AND
CONSTRUCTION COMPANY

REPORT NO.:

JOB NO.
..
Construction Contractor:
UNIT
ITEM. NO.
PIPING PUNCH LIST B2 (MECH.)

PROJECT:
Contractor:

SH OF

TEST PACKAGE:
NO.

ISO DWG

LINE NO.

DESCRIPTION OF CORRECTION REQURED

COMPLETED

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

REMARK:

CONTRUCTION CONTRACTOR

SIGN

DATE

CONTRACTOR

SIGN

DATE

35

NIOEC

SIGN

DATE

NIOEC-SP-50-05(0)

JULY, 2005

NATIONAL IRANINAN OIL ENGINEERING AND CONSTRUCTION COMPANY

PROJECT:
Contractor:

Construction Contractor:

ATTACHMENT C (9/16)
REPORT NO.:
JOB NO.
SH OF
..
UNIT
ITEM. NO.

PIPING SPOOLS SHOP FABRICATED

ISO DRG NO:

INSPECTION REPORT

SPOOL NO:

Release Report

LINE NO:
CONS.
CONT.

NO

CHECK ITEMS

1
2
3
4
5
6
7
8

CONFORMITY WITH ISO DRG (CONFIGURATION, DIMENSIONS, SIZE,)

PIPE MATERIAL & THIKNESS. CORRECT
FLANGE MATERIAL & RATING. CORRECT
TYPE & MATERIAL OF FITTINGS, VALVES & OTHER COMPONENTS (if any) CORRECT
WELDING COMPLETED, VISUALLY INSPECTED. EXT. & INT (if possible) & ACCEPTED
NDE (RT,PT,MT) COMPLETED AND RESULTS STATIS FACTORY
PWHT AND HARDNESS TEST COMPLETED SATIS FACTORILY
OLETS FOR INSTRUMENTS CONNECTIONS CORRECTLY INSTALLED (LOCATION &
ORIENTATION)
INSTRUMENT FLANGES TO PIPE WELDED JOINTS ARE INTERNALLY FLUSHED.
(SMOOTHED)
INTERNAL PARTS OF VALVES & OTHER COMPONENTS PRONE TO DAMAGE WERE
REMOVED BEFORE WELDING OR OTHERWISE PROPERLY PROTECTED.
VISUAL INSPECTION OF SPOOL FOR DAMAGE (SPECIALLY FLANGE FACES)
CLEANINESS OF THE SPOOL EXTERNALLY & INTERNALLY ACCEPTED
OTHERS:

9
10
11
12

CONTRACTOR

NIOEC

REMARKS

FABRICATION & INSPECTION COMPLETED PIPE SPOOL RELEASED FROM WORK SHOP
CONS. CONTRACTOR
NAME. SIGN

DATE

CONTRACTOR
NAME. SIGN

DATE

TOTAL SHOP PREFAB. WEIGHT (kg) =

36

NIOEC
NAME. SIGN

DATE

NIOEC-SP-50-05(0)

JULY, 2005

ATTACHMENT C (10/16)
REPORT NO.:
JOB NO.
SH OF
..
UNIT
ITEM. NO.

NATIONAL IRANINAN OIL ENGINEERING AND CONSTRUCTION COMPANY

PROJECT:
Contractor:

Construction Contractor:

LINE
ISOMETRIC
JOINT
NO

SIZE
INCH

TEST PACKAGE No.:

TEST BLOCK No.:
P&ID No.:

LINE HISTORY SHEET

WELD
TYPE

WELDER
NO

Construction Contractor Q/C

NAME:
SIGN & DATE:

LOCATION

DATE
WELDED

VISUAL
REPORT
DATE
No.

RT

PT

MT

Rep1 Rep2 Rep3 ACCEPT

REPORT

REPORT

Contractor
NAME:
SIGN & DATE:

37

P.W.H.T Report
RJ1

RJ2

ACCEPT

HARDNESS
REPORT

NIOEC
NAME:
SIGN & DATE:

P.M.I
REPORT

REMARKS

NIOEC-SP-50-05(0)

JULY, 2005

ATTACHMENT C (11/16)
NATIONAL IRANINAN OIL ENGINEERING AND
CONSTRUCTION COMPANY

REPORT NO.:
JOB NO.
..
UNIT
ITEM. NO.

PROJECT:
Contractor:

Construction Contractor:

SH OF

A/G PIPING CHECK LIST

SKETCH OF TEST PACKAGE ATTACHED WITH ALL LINES LISTED IN PRESSURE TEST REPORT

NO.

CHECKED ITEMS

C.C.

1
2
3
4

CONFORMITY WITH P & ID; PLAN AND ISO DWGS

WELDING COMPLETED
NDE (RT. PT. MT) COMPLETED
PWHT AND HARDNESS TEST COMPLETED
PIPING COMPONENTS:

5
6
7
8
9
10
11
12
13

PIPES MATERIAL, THICKNESS, AND SIZE CORRECT.

CORRECT VALVES WITH PROPER BOLTS INSTALLED
FLANGES TYPE AND RATING CORRECT
GASKETS TYPE AND MATERIAL CORRECT
REDUCERS PROPERLY INSTALLED
VENTS AND DRAINS INSTALLED
OLETS FOR INSTRUMENTS CONNECTION INSTALLED
FINAL SUPPORTS
MISCELANOUS COMPONENTS (BLINDS REINFORCEMENT BTC)
PIPING FIELD INSTALLATION :

14
15

INSTALLATION STRAIGHT AND PLUMB

ELEVATIONS, SLOPES AND CLEARANCES CORRECT
PREPARATION FOR TEST:

16
17
18

LINE(S) PROPERLY SUPPORTED FOR TEST

SPRING HANGERS STOPPED
CHECK VALVE IN PROPER POSITION OR CHECK DISK
REMOVED
CONTROL, SAFETY VALVE, ORIFICE, GAGE GALSS
EXCLUDED

19

CONTRACTOR

NIOEC

(ITEMS NOT INFLUENCING PRESSURE TEST TO BE INSTALLED LATER (IF ANY))

REMARKS:

CONS. CONTRACTOR
LINES
RELEASED
FOR PRESSURE
TEST

SIGN.

DATE

CONTRACTOR

SIGN.

38

DATE

NIOEC

SIGN.

DATE

NIOEC-SP-50-05(0)

JULY, 2005

ATTACHMENT C (12/16)
NATIONAL IRANINAN OIL ENGINEERING AND
CONSTRUCTION COMPANY
PROJECT:
Contractor:

ORIFICE FLANGE
SPECIFICATION
MARKED

PIPELINE
SPECIFICATION

REPORT NO.:

JOB NO.
..
Construction Contractor:
UNIT
ITEM. NO.
FINAL INPECTION ORIFICE FLANGES

TAG NO.
FLANGE

UNIT:
RATING & FACING

PLANT / AREA
MATERIAL

TAPE

SH OF

TAPS

DESCRIPTION
LINE NO.
DRAWING NO.
LAYOUT/P
&ID
FLUID NAME

SERVICE
ORIENTATION OF ORIFICE
FLANGES/TAPS
SPOOL NO.

GAS

LIQUID

STEAM

VERTICAL
HORIZONTAL
SIZE

JOINT NO.

NDT. REPT.

CONST.

NO.

CONTRACTOR

CONTRACTOR.

UPSTREAM A
DOWN STREAM B
(UPSTREAM A / DOWNSTREAM B)

CONST.
CONTRACTOR

GRIND INTERNAL WELDS

STRAIGHT PIPE MINIMUM LENGTHS
PIPE INSIDE DIAMETER (INSTRUMENT ACCESS)
SEAL WELDING OF CONNECTIONS
HEAD PLUGS. JACKSCREWS. BOLTS. NUTS.
GASKETS
NOTES

CC SIGN.

CONTRACTOR SIGN.

NIOEC SIGN.

DATE

DATE

DATE

39

CONTRACTOR.

NIOEC-SP-50-05(0)

JULY, 2005

ATTACHMENT C (13/16)
NATIONAL IRANINAN OIL ENGINEERING AND
CONSTRUCTION COMPANY
PROJECT:
Contractor:

REPORT NO.:

JOB NO.
..
Construction Contractor:
UNIT
ITEM. NO.
PRE PRESSURE TEST LINE CLEANING

SH OF

AREA/UNIT :
TEST PACKAGE :
TEST BLOCK NO. :
CLEANING METHOD :
WATER FLUSHING :
AIR BLOWING :
OTHER :

INSPECTION RESULT

1- CHLORIDE CONTENT OF FLUSHING WATER FOR STAINLESS STEEL LINE

CHECKED AND SUITABLE
2- ITEMS TO BE EXCLUDED (SUCH AS PSV. CONTROL VALVE OPRFICE PLATE EXPANSION
JOINTS, THERMO WELLS, H/EXCHANGER, MACH, ETC.

3- EQUIPMENT (VESSELS, H/EXCHANGER, MACH, ETC.)

4- CLEANING RESULT

5- ITEMS TO BE INSTALLED AFTER CLEANING AND BE INCLUDED IN PRESSURE

TEST CORRECT
REMARKS:

CONT : CONTRACTOR

CONTRACTOR

NIOEC

NAME:

NAME:

NAME:

SIGN :

SIGN :

SIGN :

DATE :

DATE :

DATE :

40

NIOEC-SP-50-05(0)

JULY, 2005

ATTACHMENT C (14/16)
NATIONAL IRANINAN OIL ENGINEERING AND
CONSTRUCTION COMPANY
PROJECT:
Contractor:

GAUGE NO.

SERIAL NO.

REPORT NO.:

JOB NO.
..
Construction Contractor:
UNIT
ITEM. NO.
PRESSURE GAUGE CALIBRATION RECORD
RANGE

CALIBRATED
DATE

41

VALID

CERTIFICATE
NO

SH OF

REMARK

NIOEC-SP-50-05(0)

JULY, 2005

ATTACHMENT C (15/16)
NATIONAL IRANINAN OIL ENGINEERING AND
CONSTRUCTION COMPANY

JOB NO.
..
Construction Contractor:
UNIT
ITEM. NO.
PIPING PRESSURE TEST REPORT

PROJECT:
Contractor:

AREA / UNIT :

TEST PACKAGE :

P&ID DWG NO :

TEST BLOCK NO:

TEST PRESS :

REPORT NO.:

BARG.

ACTUAL PRESS

TEST MEDIUM :

TEST DURATION :

AMB. TEMP:

POST TEST FLUSHING/

SH OF

BARG.

AIR BLOWING METHOD :

REMARKS:

ISO DWG NO.

LINE NO.

ISO DWG NO.

LINE NO.

CONT : CONTRACTOR

CONTRACTOR

NIOEC

PRESSURE TEST

SIGN:

SIGN:

SIGN:

ACCEPTED

DATE :

DATE :

DATE :

POST TEST

SIGN:

SIGN:

SIGN:

DATE :

DATE :

DATE :

DRAINING / AIR BLOWING

DRYING COMPLETED

42

NIOEC-SP-50-05(0)

JULY, 2005

ATTACHMENT C (16/16)
NATIONAL IRANINAN OIL ENGINEERING AND
CONSTRUCTION COMPANY

REPORT NO.:

JOB NO.
..
Contractor:
Construction Contractor:
UNIT
ITEM. NO.
POST TEST & RESTORATION INSPECTION REPORT

PROJECT:

AREA/ UNIT:

TEST PACKAGE :

DATE :

TEST BLOCK NO. :

WORK ITEM

SH OF

REMARKS

INSPECTION RESULT :

CONSTRUCTION CONTRACTOR

CONTRACTOR

NIOEC

NAME :

NAME :

NAME :

SIGN. :

SIGN. :

SIGN. :

DATE :

DATE :

DATE :

43

NIOEC-SP-50-05(0)

JULY, 2005

NATIONAL IRANINAN OIL ENGINEERING AND CONSTRUCTION COMPANY

PROJECT:
Contractor:

Construction Contractor:

ATTACHMENT D(1/1)
REPORT NO.:
JOB NO.
SH OF
..
UNIT
ITEM. NO.

RECOMMENDED PRESSURE GAUGE

FOR A/G PIPING PRESSURE TEST
NO.

TEST PRESSURE RANGE

PRESSURE GAUGE RANGE

(Bar.)

(Bar.)

06

0 10

7 15

0 20

16 20

0 30

21 30

0 50

31 45

0 70

46 65

0 100

66 100

0 - 150

QUANTITY

NOTE:
1- PRESSURE GAUGE SHOULD BE CALIBRATED AT THE INTERVAL OF MAX. SIX (6) WEEKS.
2- AFTER CALIBRATION, ALL GAUGES SHOULD BE ATTACHED WITH THE SEAL SHOWING GAUGE
SERIAL NO. & CALIBRATION DATE.

44