Beruflich Dokumente
Kultur Dokumente
FOR RESTRICTED
CIRCULATION
No.
INSPECTION
OF
PIPES, VALVES AND FITTINGS
OISD - STANDARD-130
First Edition, November 1988
Reaffirmed, August, 1999
FOR RESTRICTED
CIRCULATION
No.
INSPECTION
OF
PIPES, VALVES AND FITTINGS
Prepared by
COMMITTEE ON
INSPECTION OF STATIC EQUIPMENT
2
NOTES
3
FOREWORD
The Co-ordinator,
Committee on
“Inspection of Static Equipment,
Oil Industry Safety Directorate,
2nd Floor, “Kailash”
26, Kasturba Gandhi Marg,
New Delhi – 110 001
4
COMMITTEE
ON
INSPECTION OF STATIC EQUIPMENT
List of Members
---------------------------------------------------------------------------------------------------------------------------
Name Designation & Position in
Organisation Committee
---------------------------------------------------------------------------------------------------------------------------
1. Sh. R.K. Sabharwal CMNM-IOC (R & P) Leader
---------------------------------------------------------------------------------------------------------------------------
In addition to the above, several other experts from the industry contributed in the
preparation, review and finalisation of this Recommended Practices.
5
INSPECTION OF PIPES, VALVES AND FITTINGS
CONTENTS
1.0 Introduction
2.0 Scope
6
10.2.5 Hammer Testing
10.3 Inspection of High Temperature Piping
10.4 Inspection of Piping in Corrosive Streams
13.0 Documentation
14.0 References
ANNEXURES
7
INSPECTION OF PIPES, VALVES AND FITTINGS
3.2.1 Electric Resistance Welded Pipes ii) To co-relate the deterioration rate with
design life for further run.
Pipes produced in individual lengths
or in continuous lengths from coiled skelp iii) To determine causes of deterioration and
and subsequently cut into individual lengths to advise remedial measures.
having a longitudinal or spiral butt joint
wherein coalescence is produced by the heat iv) To recommend / forecast short-term and
obtained from resistance of the pipe to the long-term repairs and replacements to
flow of electric current in a circuit of which ensure further run length on the basis of
the pipe is a part, and by the application of economics and safety.
pressure.
v) To advise materials requirement for
3.2.2 Electric Fusion Welded Pipes recommended repairs / replacement
needs.
Pipe having a longitudinal butt joint
wherein coalescence is produced in the vi) To inspect during and upon completion
preformed tube by manual or automatic of repairs.
electric-arc welding. The weld may be single
or double and may be with or without the use vii) To maintain up-to-date inspection
of tilter metal. records and history of piping.
8
viii) To keep the concerned operating and requirement of applicable codes.
maintenance personnel fully informed as specifications, drawings, etc. This inspection
to the condition of the various piping. requires regular checks on the work at
various stages as it progresses.
ix) To advise regarding schedules of piping
inspection and also statutory The inspection shall include:
requirement schedules.
i) Study of tender document and all the
5.0 INSPECTION TOOLS technical specifications.
The following tools may be used as ii) Identification and inspection of material.
aids for carrying out piping inspection.
iii) Approval of welding procedures in
i) Ultrasonic thickness meter. accordance with code and tender
requirement.
ii) Ultrasonic flaw detector.
iv) Carrying out of performance qualification
iii) Magnetic particle testing equipment. test.
9
7.0 CHECK LIST FOR temperature
INSPECTION OF PIPING Stress relief
Radiography
PRIOR TO COMMISSIONING Hydrostatic test pressure
Insulation
The checklist format shall include the Internal lining
following information Underground protection
Erection contractor
Pipe sketch No/drg. No. Contractor's inspector
Location Company's inspector
Service Date of inspection
Material
Dimensions Dia Thk.
Max. allowable working
pressure
Max. allowable working
CHECK LIST
CHECK REMARKS
14. Check for proper hook-up with cathodic protection system wherever applicable.
10
ii) Pipelines touching the ground are subject to corrosion due to dampness of the soil.
iii) Crevice corrosion may take place at the pipe supports or sleepers where pipes are resting on
them.
iv) Deterioration takes place at the pipe support locations where relative movement between pipe
and pipe supports takes place.
vi) Underground pipelines are subject corrosion due to presence of stray currents.
vii) Impingement attack may take place on pipelines in the vicinity of leaky pipes and steam
traps.
viii) Insulated lines where weather shielding is damaged are subject to external corrosion.
ix) Austenetic stainless steel lines where chlorides can leach from external thermal insulation due
to water are subject to stress corrosion cracking.
x) Externally concrete-lined pipelines are subject to localised corrosion due to cracks in the
concrete.
xi) Piping entering into or emerging from the underground may experience severe corrosion due
to coating damage.
xii) Piping corrodes at locations of water accumulation and acid vapour condensation such as in
the vicinity of fire hydrants sulphur recovery plants, cooling towers, jetty, etc.
Usually a greater loss of metal wastage is observed near a restriction in the line or a
change in line direction because of the effects of turbulence or velocity. Therefore, is required to
inspect pipe bends, elbows, and tees and also at restrictions such as orifice flanges and throttling
valves, and areas just down steam of the restriction.
Areas most prone to corrosion, erosion, and other forms of deterioration are :
i) Points at which condensation of acid gases and / or water vapour are likely to occur.
ii) Points at which acid carryover from process operations are likely to occur.
iii) Points at which naphthenic or other organic acids may be present in the process stream.
iv) Points at which high sulphur steams of moderate to high temperature exists.
v) Points at which high temperature and low temperature hydrogen attack may occur.
vii) Valve bodies and trims, fittings, ring grooves and rings, flange faces and unexposed threads.
11
xii) Alkali lines subject to caustic embrittlement with resultant cracking at stressed areas such as
weld joints, bends, etc.
xiii) Areas near flanges or welded attachments, which act as cooling fins, thereby causing
localised corrosion because of condensation.
xv) Chrome-Nickel and chrome-molybdenum lines in high temperature service near points of
increased stress such as bends and anchor points.
xvi) Are where steam or electric tracing come in contact with pipes handling materials such as
caustic soda.
xvii) Austenetic stainless steel lines where polythionic acid formation takes place with
resultant cracking.
xviii) Areas immediately downstream of chemical injection points where localised corrosion
might occur in the reaction zone.
xx) Rubber-lined and glass-lined pipes which may get damaged near the flanges or due to cracks
in the lining.
xxi) Stagnate conditions in areas of pipelines carrying crude oils with high sulphur/chloride
content.
Inspection of process piping in units should be done on-stream as far as is possible once
between two scheduled turnarounds. Inspection, which cannot be made during operation, shall be
done during the plant shut down. However, depending on the corrosion rate and type of
deterioration, the frequency of inspection of process piping can be varied suitably.
The following frequencies for inspection of off-site piping shall be followed (see notes):
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9.2.1 Hydrocarbon Service
iv) Gasoline/
Naphtha 2 4
v) ATF/HSD/LDO/
SKO/Gas Oil 3 5
vi) FO/RCO/VBO/
Bitumen 3 5
9.2.2 Utilities
Underground:
Lined pipe 3 5
Unlined pipe 2 4
iv) Air/Steam 3 6
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v)Steam
condensate 2 4
vi) Ammonia 2 4
vii) Caustic 2 4
viii) DEA/MEA 3 5
ix) Sulphur
dioxide 2 4
x) Sulphuric
acid
(conc. 98%) 2 4
xi) Furfural
/Phenol 2 3
xii) Lined pipes
(excluding
water lines) 3 6
xiii) Benzene 2 4
xiv) Toulene 2 4
xv) Sodium
Hexameta-
phosphate 2 4
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*Notes:
1. The above frequencies are bases on data collected from various refineries.
2. External inspection includes both visual inspection and ultrasonic thickness readings taken externally.
i) Visual inspection
ii) Hammer test
iii) Ultrasonic thickness measurement
iv) Dye penetration test
v) Magnetic particle test
vi) Radiographic test
vii) Hydrotest
4. Piping is coastal installations and in corrosive environment shall be visually inspected once a year.
Years of inspection experience have revealed that failures of most of the Offsite pipelines are due to
external corrosion and that internal corrosion failures are minimum.
5. Inspection data as well as thickness data of newly constructed pipelines shall be collected at the
earliest and with in two years of their commissioning to function as base for establishment of corrosion
rates.
Those underground lines having wrapping and coating as well as cathodic protection shall
be inspected whenever current leaks are observed and/or any damage to the coating is
suspected. The damage to the coating can be located by person survey. Parameters of cathodic
protection like pipe-to-soil voltage or pipe-to-water voltage shall be monitored once a month.
All underground lines having only wrapping and coating shall be inspected once in three
years using Person Survey for locating coating damage, if any. Additionally, all these lines shall
be visually inspected at random once in ten years by digging at a few locations. Pipelines
crossing the roads and dykes shall be inspected once in ten years by digging and exposing the
line completely.
Piping in Offsite areas can and shall be inspected onstream and a regular inspection
programme drawn up. Piping in onsite areas should also be inspected on the run, subject to
feasibility as permitted by process parameters (fluid, pressure and temperature). Any
abnormalities notices during inspection shall be investigated and corrective steps initiated at the
earliest. In setting priorities of inspection of different pipelines, it is recommended that the
following categorisation be adopted:
iii) Where there is reason to suspect, based on experience, that there is excessive metal loss.
i) LEAKS
Visual inspection shall be made to locate leaks. Particular attention should be given to
pipe connections, the packing glands of valves and expansion joints.
ii) MISALIGNMENT
The piping shall be inspected for mis-alignment. The following are some observations
which may indicate misalignment:
a) Pipe dislodged from its support so that that weight of the pipe is distributed unevenly on the
hangers or the saddles.
b) Deformation of the wall of the vessel in the vicinity of the pipe attachment.
d) Shifting of base plate or shearing of the foundation bolts of mechanical equipment to which the
piping is attached.
e) Cracks in the connecting flanges or pump casings and turbines to which the piping is attached.
iii) SUPPORTS
a) Condition of protective coating or fire proofing if any. If fire proofing is found defective,
sufficient fire proofing should be removed to determine extent of corrosion.
b) Evidence of corrosion
c) Distortion
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g) Free operation of pipe rollers.
i) Secure attachment and proper adjustment of pipe hangers, if used. Spring hangers loading
shall be checked both cold and hot and the readings obtained shall be checked against the
original cold and hot readings. The movement of spring supports shell be monitored.
iv) VIBRATION
a) If vibrations or swaying is observed, inspection, shall be made for cracks in welds, particularly
at points of restraint such as where piping is attached to equipment and in the vicinity of
anchors. Additional supports should be considered for poorly braced small size piping and
valves and for main vibrating line to which they are attached.
b) In case of severe vibration, detailed investigations shall be carried out to determine the source
of problems.
v) EXTERNAL CORROSION
Inspection of piping for external corrosion shall be carried out with special attention to
areas as outlined in 8.1
Line shall be checked for bulging, bowing and sagging in between the supports.
Pipes shall be inspected for dents, scratched etc. from external sources.
ix) CRACKS
Pipelines shall be inspected for cracks. particular attention should be given to areas near
the weld joints.
x) INSULATION
Externally coverts lined piping shall be visually inspected for cracking and dislodging of
concrete.
Ultrasonic thickness survey of the pipelines shall be carried out to ascertain the remaining
wall thickness. The following procedure shall be followed for the above-ground pipelines.
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i) Minimum three readings shall be taken on all the bends of the piping network at the outer
curvature. One reading shall be at the centre of the bend and two readings on the same line
on either side of this reading.
ii) Minimum one ultrasonic scan each on the straight pipes on upstream and downstream of the
bend adjacent to welds of the bend to pipe. One ultrasonic scan consists of our readings (3,6,9
and 12 o'clock positions). For pipelines in which there is a possibility of ballast water coming,
one ultrasonic scan will consist of six readings (3,5,6,7,9 and 12 o'clock positions) to scan the
bottom portions where corrosion may take place.
iii)One ultrasonic scan on the entire circumference (four readings) upstream and downstream of
the weld joint for process pipelines.
iv) Minimum one ultrasonic scan (four readings) each on reducer/expander and just downstream
on the pipe.
vi) One ultrasonic scan minimum on straight pipe for every three meters length at lower
elevations where possibilities of collection and stagnation of carryover water, or acid
condensation or SO 2 flow exist.
vii) Branch connection, dead ends, etc, shall be checked by ultrasonic thickness survey for
corrosion and erosion.
Note:
One of the methods of measuring internal corrosion rate of unit piping or Offsite piping is
by installing corrosion probes for measuring corrosion rates. Important pipelines like overhead
lines can be inspected using corrosion probes. If installed the readings shall be taken weekly and
deterioration rate established.
Corrosion coupons should be installed in the important and critical pipelines to measure
internal corrosion rate. The coupons are taken out after a specified period and thoroughly
cleaned. The weight loss of coupons over a specified period gives the internal corrosion rate of
the pipes.
Shutdown inspection of pipelines relates to inspection of the lines when not carrying any
product, and valves and other fittings in the network can be taken out. All piping which cannot be
checked on the run shall be inspected during shutdown. These are mostly high temperature
17
piping. During shutdown inspection, hammer-testing and hydrotesting as applicable should be
carried out in addition to visual, ultrasonic and radiographic inspections. Pipelines in some of the
services like water, phenol and steam are prone to pitting corrosion. Neither ultrasonic nor
radiographic testing will reveal the actual internal condition of the pipes in such service. In such
cases samples shall be cut for thorough internal examination, at scheduled comprehensive
inspections. The samples shall be spilt open in two halves and internal surfaces inspected for
pitting, grooving, etc. The internally striplined bends and pipes shall be visually examined for
bulging, weld cracking, weld, defects, etc. Thickness of the strip should be measured to find out
thinning of the strips.
Welds, heat-affected areas adjoining welds, points of restraint cracking, hydrogen attack
and caustic embrittlement shall be inspected for cracks. For spot checks, dye-penetrant or
magnetic particle inspection should be used. Alloy and stainless steel piping need close
inspection. In-situ metallorgraphy at critical spots may be also done. Magnifying glass should be
used for crack detection.
The gasket faces of flange joints which have been opened shall be inspected visually for
corrosion and for defects such as scratches, cuts and grooving which might cause leakage. Ring
gaskets and joints shall be checked for defects like dents, cuts, pitting and grooving.
Where hot spots on internally insulated pipe were noted during operation, the internal
insulation shall be inspected visually for failure. The pipe wall at the hot spot shall be inspected
visually for oxidation and scaling. The scales shall be removed to expose bare metal and the
area checked for cracks. The thickness of the metal shall be measured to ensure that sufficient
thickness is felt for the service. The outside diameter of piping in high temperature service shall
be measured to check for creep deformation.
Hammer testing shall also be carried out to supplement visual and ultrasonic inspection.
While hammer testing, the following precautions shall be taken:
i) Hammer testing of valves, pipes and fittings of cast iron construction, chrome-steel, austenatic
SS lines and stress relieved lines shall not be carried out.
ii) Care shall be taken not to hammer so hard as to damage otherwise sound piping.
iii) Hammer testing shall not be performed on glass-lined, cement-lined or otherwise internally
coated lines.
iv) Hammer testing shall not be done on operating lines and lines under pressure.
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10.3 INSPECTION OF HIGH TEMPERATURE PIPING
Inspection shall be made for hot spots on internally insulated piping. Any bulging or
scaling shall be noted for further inspection when the equipment is shut down. Some sot spots
can be detected by a red glow, particularly if inspection is made in the dark. Portable infrared
pyrometer or temperature indicating crayon shall be used to determine the skin temperatures.
Sometimes thermographic survey of internally insulated hot piping helps in locating the hot spots.
Furnace transfer lines and column bottom lines, which are operating at very high temperatures,
shall be inspected at every shutdown. Insulation shall be removed at specified locations including
all bends and ultrasonic thickness shall be carried out and the corrosion rate established. Spring
hangers and spring supports of high temperature piping shall also be checked during shutdown.
All the weld joints in this line shall be stress relieved after fabrication. Weld joints at
random shall be checked for suspected cracking. If the line is not thermally insulated, external
thickness measurements shall be taken for suspected internal corrosion. When the line is not in
operation, magnetic testing method will help in locating cracks in the welds.
Pipelines carrying DEA/MEA are prone to internal corrosion and stress corrosion cracking.
All newly constructed piping shall be stress relieved irrespective of the strength and temperature
of the chemicals. All weld joints shall be inspected for cracks using wet fluorescent magnetic
particle test. External thickness measurements shall be taken at all bends and other flow-
restrictions for determining the internal corrosion rate. All socket-welded and seal-welded
threaded connections are prone to stress corrosion cracking if not stress-relieved. Hammer
testing of the line shall not carried out as it may induce localised stresses.
Carbon steel resists phenolic corrosion upto 205 oC provided water is not present.
Corrosion in phenol is very erratic. However, when it occurs, it may be very severe. All bends
and areas of high velocity and where turbulent conditions occur shall be ultrasonically inspected.
However, areas which cannot be inspected ultrasonically shall be radiographed to ascertain their
internal condition.
Caustic is non-corrosive at atmospheric temperatures top carbon steel. Caustic will cause
stress corrosion cracking above 94OC and hence all carbon steel lines shall be stress-relieved
before commissioning or after repairs. Lines shall be checked for embrittlement and metal loss.
Chlorine, though not so corrosive in gaseous phase, becomes highly corrosive when even
a small amount of moisture comes in contact with it. Rubber-lined carbon steel pipes are
generally used in chlorine services. Rubber-lined, pipes shall be checked for bulging of lining at
bends, flanges or at weld joints.
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Sulphuric acid is corrosive in dilute phase. Hydrochloric acid in corrosive at all
concentrations while phosphoric acid is corrosive where it mixes with water in carbon steel pipes.
The following locations shall be checked for acid corrosion in carbon steel lines:
b) Section of the line at bends where elbows tend to corrode due to turbulent acid attack.
e) Heat affected zones of weld joints due to residual stress concentrations and thermo-galvanic
effects.
The condition of the wrapping and coating shall be checked by Pearson survey once in
three years for underground piping not cathodically protected. Excavations shall be done at
vulnerable points like regions of low velocity and straight portions downstream of bends. The
excavation, once in ten years is optimum requirement. After excavation, the wrapping and
coating shall be examined both visually and by holiday detector. Internal metal loss and fouling
may be detected by radiographic examination. Ultrasonic thickness measurements shall be
carried out on the surface of the pipe after removing a bend of wrapping and coating. The
pipeline shall be hydrotested once every five years. The stray current interference of
underground pipe should be checked by Cu-CuSO 4 half-cell. All lines shall be inspected at and
just before the point where they enter the earth or concrete slab as serious corrosion frequently
occurs at such locations. The incidence of stray current interference is high in the underground
portion of cathodically protected and non-cathodically protected piping separated by insulated
flanges or couplings. This current causes severe damage in the unprotected line if the wrapping
and coating is damaged. This location should be inspected once a year by exposing the insulating
flanges or couplings.
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10.6.1 Valves
Steel gate valves steel globe valves, flanged cast iron gate valves, threaded and socket
welded valves, soft-seated ball valves-`Fire Safe Type', plug valves, check valves and butterfly
valves for water service are used in Petroleum installations.
All valves shall be inspected and tested to ensure conformation to required specifications
and for leak tightness. All new valves shall be inspected and tested as per requirements of API-
598. The closure torque during testing for hand wheel and gear operated valves shall not be
greater than that obtainable by hand tightening.
All low alloy valve castings (P numbers 3,4 and 5) in hydrogen service with a hydrogen
partial pressure of 100 psig shall be 100% magnetic particle and radiographically examined.
Examination and acceptance criteria shall be as per ASME Section VIII Appendix 7.
Valves made of steel containing phosphorus or sulphur in excess of 0.5% shall not be
used in H2S service.
Hardness of the body, bonnet and gate and weld metal and HAZ of any pressure retaining
part shall not exceed the limits given below:-
Material Brinell
hardness,
P-1 225
P-3, P-4, P-10, P12 225
P-5, P-6, P-7 225
inconel, Precipitation
hardened 310
- Low pressure sect test shall be conducted with the ball and seat dry and free of oil, grease or
any lubricant.
- The high pressure seat test is not required except for threaded and valves.
21
evidence of erosion. Bodies of valves operating in severe cyclic temperature service shall be
checked internally for cracks.
Gate valves, which have been used for throttling, shall be measured for thickness at the
bottom between the seats, as serious deterioration may have occurred because of turbulence.
This is particularly weak point because of the wedging action of the disc when the valve is closed.
The seating surface shall be inspected visually for defects which might cause leakage. The
wedging guides shall be inspected for corrosion and erosion. The stem and threads on the stem
and in the bonnet of valves shall be examined for corrosion which might cause failure., The
connection between stem and disc shall be inspected to assure that the disc will not detach from
the stem during operating.
Swing check valves shall be inspected by removing the cover or cap. The clapper or disc
shall be checked for freedom of rotation and the nut holding it to the arm shall be checked for
security and presence of a locking pin, lock washer, or tack weld. The arm should be free to
swing and the anchor pin shall be inspected for wear. Also the seating surface on both the disc
and valve body shall be checked for deterioration by feeling them with the fingers. After the valve
has been reassembled, it shall be hydrostatically and/or pneumatically tested for tightness. If
tested pneumatically, a soap solution shall be applied to the edges of the seating surface and
observed for any evidence of leakage.
The gasket faces of flanged joints, which have been opened, shall be inspected visually
for corrosion and for defects such as scratches, cuts and gouges which might cause leakage. The
gasket faces shall be checked for true flatness or warping by placing a straight edge across the
diameter of the face of the flange and rotating it about an axis through the center line of the
flange. Grooves and rings of ring joints shall be checked for defects.
Flanges bolts should be inspected for stretching. Where excessive bolt loading is
indicated or where flanges are deformed, nuts may be rotated along the entire length of the stud.
If studs are stretched, thread pitch will be changed and nuts will not turn freely. Inspection involve
checking to determine whether bolts of the proper specification have been used and may involves
chemical analyse or physical tests to determine the yield point and the ultimate strength of the
material. If flanges are bolted too tightly, they may bends until the outer edges of the flanges are
in contact. When this occurs, there may be insufficient pressure on the gasket to assure a tight
joint. Visual inspection of the gasket will reveal this condition. Permanently deformed flanges
must be replaced.
Calculation of retiring limits for unit piping and offsite piping shall be done as per ANSI B
31-3 end ASME Section VII Div. 1. The retiring limit relates thickness, diameter and allowable
stress to the maximum safe working pressure.
In addition, ANSI B 31.3 contains a formula with material factors for determining the
required thickness but permits the use of the simple formula of Barlow without reservation. The
Barlow formula is:
12.7 P x D
t =- --------------
SE
Where -
t= required thickness of the pipewall in mm.
P= Pressure within the pipe in kg/sq.cm
D= Outside diameter of the pipe in cms.
S= Allowable unit stress in kg/sq.cm. at the maximum operating temperature.
E= Longitudinal joint efficiency.
Note:
22
Metallic piping with t = D/4 requires special consideration.
The Barlow formula gives results particularly equivalent to those obtained by the more
elaborate formula, except at high pressures where thick-walled tubing is required or at high
temperatures where creep properties of the pipe metal become important in determining the
ultimate service strength. At low pressures and low temperatures, the thickness required by the
formula may be so small that the pipe would have insufficient structural strength. For this reason,
an absolute minimum thickness shall be determined for each size of pipe below which thickness
of the pipewall would not be permitted to deteriorate regardless of the results obtained by the
above formula.
The portion of the piping, which may reach the retiring limit before the subsequent
scheduled inspection, shall be replaced. While replacing the pipe, the following points shall be
considered.
i) The metallurgy and dimensions of the new pipe shall match with those of the existing pipe.
ii) Repairs shall be carried out by a qualified welder using qualified welding procedures.
iii) For ERW pipes, the weld seam shall be kept staggered and the ERW seam shall appear in the
upper quadrants.
iv) Piping systems, which are covered under other statutory requirements, shall be checked for
conformation with the appropriate codes, regulations and specifications.
vi) Repaired welds shall be subject to same pre and post-weld heat treatments as required in the
case of new pipes.
vii) Painting, insulation, wrapping and coating shall be done as per the code.
All installed piping shall be pressure tested prior to commissioning. Piping systems open
to atmosphere, such as drains vents and outlet piping for relief valves discharging to atmosphere
and underground sewers shall not require any pressure testing. These lines shall be examined to
determine that all joints are properly made up.
The test pressure and procedure for testing of piping shall be as per ANSI B 31.3 or
equivalent. However, the following additional points shall be considered while carrying out
testing.
i) All floats shall be removed before filling the system with water.
23
ii) All air present in the system shall be vented while admitting the test fluid.
iii) Piping designed for vapour and gas shall be provided with additional temporary supports, if
necessary.
iv) Line containing check valves shall have source of test pressure on the upstream side.
v) Valves shall not be subjected to a test pressure in excess of manufacturer's allowable test
rating. When permitted, the installed valves shall be kept open.
vi) Control and relief valves shall be excluded from the test irrespective of their pressure rating.
vii) Instrument take-off piping upto the first block valve shall be tested along with piping to which it
is connected. Testing of remaining line leading upto the instrument can also be done at the
same time provided instruments are blocked off from the source of pressure and vented to
atmosphere.
viii) Open ends of piping where blanks cannot be used e.g. pumps, compressors, etc. shall be
blinded off by using standard blind flanges of same rating as the piping system being tested.
ix) Indicating pressure gauges mounted locally may be tested with the line, provided the test
pressure is not in excess of their scale ratings.
x) Orifice plates in horizontal lines shall not be installed till completion of test.
xi) The test shall be carried out at ambient temperature and it should not be less than 50 oC.
xii) All vent valves during filling up as during draining must be fully open.
Hydraulic testing of ferritic material shall be carried out using suitably inhabited
water, which permits an extended period between the start of testing and drying of
components. Hydraulic testing of austemotic material shall be carried out using de-
ionized water.
i) Portable water free from oil and suspended matter shall be used for ferritic parts and feritic
parts associated with non-ferrous parts.
ii) Water shall be d-ionized having a conductivity not greater than one micro mho per cm at 250 oC
for austenetic parts end ferritic parts associated with austenetic parts.
13.0 DOCUMENTATION
Isometrics of each circuit as per actual site conditions shall be prepared. The records
shall be maintained to give information like:
ii) Location of thickness measurement points, replacement carried out, corrosion rate, etc.
An isometric sketch for guidance has been given in Annexure-2. All small connections
shall be clearly shown on isometrics and piping drawings. The history and thickness records shall
be maintained in history cards and data record cards.
24
On the basis of records of previous and present inspection, a work schedule shall be
prepared for future inspection onstream as well as during the next shutdown.
14.0 REFERENCES
The following standards, codes and publications have either been referred to or used in
the preparation of this document and this standard shall be read in conjunction with the same
25
ANNEXURE -1
3. Pressure test shall not be carried out at 5. In addition to the above, conditions listed
metal temperatures near the ductile-to- out in Appendices F and G of ANSI B
brittle transition temperature of the 31.3 should be kept note of.-
material.