Pressure Test, Flushing & Air Blowing Procedure For Piping
Pressure Test, Flushing & Air Blowing Procedure For Piping
Revision : 02
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FOR PIPING
STATUT DE DOCUMENT :
Signature
02 23/12/2015 Update
01 19/10/2015 Update
0 07/09/2015 Creation
1 GENERAL 3
1.1 SCOPE 3
1.2 SCOPE OF CLEANING 3
2 REFERENCE DOCUMENTS, CODES AND STANDARD 4
3.1 MANPOWER 5
3.2 EQUIPMENT: 5
4 TEST PROCEDURE 5
4.1 RESPONSIBILITIES 5
4.2 PIPING QC SUPERVISOR: 5
4.3 HYDRO TEST ENGINEER/SUPERVISOR: 6
4.4 CONTENTS OF PIPING TEST PACKAGE: 6
4.5 INSPECTION BEFORE HYDROTEST: 6
4.6 PRESSURE GAUGES AND RECORDER: 6
4.7 HYDROSTATIC TEST: 7
4.7.1 Preparation for Pressure testing 7
4.7.1 Pressure Testing & Acceptance 8
4.8 PNEUMATIC TESTING: 9
5 FLUSHING 11
5.1 EXCLUSIONS 11
5.2 PREPARATION FOR FLUSHING: 11
5.3 DEWATERING 12
6 AIR FLUSHING (BLOWIN OUT) 12
6.1 EXECUTION 12
6.1.1 Continuous blowing 12
6.1.2 Quick depressurization blowing 12
6.1.3 CLEANLINESS CRITERIA 13
6.2 REINSTATEMENT: 13
7 HSE REQUIREMENTS 13
NOTE: 14
8 ATTACHMENT: 15
HHHH PRESSURE TEST, FLUSHING & Code: DO-TEC-125Eng
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1 GENERAL
SCOPE
002
The purpose of this procedure is to describe the method of carrying out Flushing and blowing of piping
systems and to provide a controlled system of field pressure testing to check the integrity and tightness
of piping systems as required by the project specifications and applicable industry standard.
SCOPE OF CLEANING
The purpose of line’s (separators, filters, pig launchers/receivers, etc.) drying is to ensure that no hydration
formation and or internal piping’s corrosion could appear due to remainder of water’s layer coming from
blowing or flushing activities
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Manpower
Piping Engineer / Supervisor
Equipment:
Before mobilization, equipment shall be inspected to ensure that it meets all safety
requirements. All equipment/tools inspection and calibration certificates shall be available
at the point of use.
hydro test pumps
Pressure hoses (with Technical data sheet)
Testing manifold
Calibrated Pressure Gauges.
Calibrated Pressure Recorder
Temperature Recorder
Truck water tanker with isolation valve
Temporary Pipe Spools/Supports
Temporary Blinds/ Gaskets.
Compressors/Manual Torque Wrenches / Hydraulic pumps/ Hydrolic torque Wrenches/
Bolt Tensioning/ Equipment as required
4 TEST PROCEDURE
Responsibilities
The overall responsibility for implementation and executing the method statement lies
with the Construction Manager (Mechanical) & Hydro Test Engineer / Supervisor.
The pressure test should be carried by experienced personnel. High pressure
pneumatic test, shall be supervised by senior experienced supervisor.
Piping QC Supervisor:
Receives the marked up P&ID showing test limits and unique piping test pack numbers.
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Conduct Pre-test piping inspection along with Hydro test Engineer to generate the
Piping Punch Lists and clearance of lines for hydro test.
Prepare punch lists in agreement with contractor/Company as required.
Compilation of welding history sheets and verifies that all NDE that has been completed
Construction department will issue the original test pack to the QA/QC department when
piping related to that test pack is completed and ready for punching and there
are no outstanding weld repairs.
Informs piping engineer of any “A” PUNCH ITEMS to be cleared before hydro test.
Verifies that all “A” punch items are cleared and signed by all parties prior to test.
The test pack consists of the following documents as a minimum and the Test pack shall
be cleared for NDE requirements in all respects;
Piping Test Pack Cover Sheet referring the Test Pack No, Test Pack Index,
P&ID/ Isometrics within the test limits to show, Weld map, Welding Summary,
Register with VT,NDT & PWHT Reports, Pre- Test Punch List, Flange Tightening
summary / Flange
Tightening Records, Pressure Testing Records, Flushing equipment & Pressure
Gauge Calibration Records…
On completion of piping installation, the system will be walked down jointly by the Piping
Supervisor/ QC inspector. The walk down shall be performed with P&ID and isometrics
included in the test pack. The system shall be punched and all outstanding items will be
documented in Pre-Test report (See attached).
Pressure gauges shall have a unique number and shall be calibrated by an independent
laboratory. Details of each gauge shall be noted on test equipment calibration LOG. New
gauges shall also be calibrated.
Analog Pressure gauge range shall be as minimum 1.5 X Pressure Test and as maximum
4 X Pressure Test.
Pressure, Temperature recorders that are used for pressure testing shall be calibrated for
once in 6 months. Also calibration will be done whenever the device is repaired or the
functioning of recorder is suspicious.
Minimum Two pressure gauges shall be used for the pressure testing of the line. One
pressure gauge at high point and second at the low point or at test manifold (Except the
small line).
All pressure test devices and tools shall be calibrated by an Independent laboratory
accredited or complying with ISO 9001.
Hydrostatic Test:
Test Pack documentation shall be submitted for Contractor/Company approval. Well before
time and ensure that 24 Hours prior notice to starting of Hydro test.
Hydrotest authorization endorsed by the Ministry of Industry, shall be available, for lines
subject to Tunisian regulation, before starting the hydrotest.
Temporary blind flanges, temporary spools and test blinds will be installed at locations
shown on the marked up Isometrics and included in the Test Pack.
Temporary piping components (blind flanges, valves, gaskets.) used shall be of the same line
pressure rating.
Perform a preliminary walk down and check the requirement of any needed scaffolding.
Piping shall be thoroughly vented of air during introduction of the test water. High point vents to
be provided as required and to conform to the relevant line class. All lines shall be checked
to ensure that entire system can be completely drained prior to and after testing.
Flow restriction orifice plates will be removed prior to pressure test.
The minimum metal temperature during initial pressure testing of ferritic piping shall not be
lower than the warmer of the following:
Where base metal impact tests have been conducted, the impact test temperature plus
17°C
7°C
Material and test medium temperature shall be approximately equal prior to pressurizing the
system
Control valves, thermometers and thermal elements from thermo wells, orifice plates,
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strainer baskets, filter elements, in-line instruments and all other in-line components unable to
withstand the test pressure or liable to damage by test medium or by the impact of foreign
matter during the flushing or testing process shall be removed and replaced with temporary
spools or spacers.
Pressure and thermal relief valves and rupture disc will not be included in system during
pressure tests.
All welds and mechanical joints shall be examined visually for leaks.
All valves, except as excluded specifically herein, will be included in the pressure tests, ball
valves would be in the half open position.
Expansion joints will not be included in the pressure tests, unless the manufacturer agrees to
include in the test.
Temporary support if required to restrain the pipe during testing shall be provided in
consultation with field engineering. These supports shall be removed after testing.
Check valves upstream will have source of pressure on the upstream side of the valve. If this
is not possible the complete valve may be removed.
Any modification or repair after hydro test shall be notified to Contractor/Company and the
modification line shall be subjected to retesting after completion of necessary NDE
requirements.
In case of pressure test is performed in the sunny day, the pressure gauge and temperature
indicator shall be monitored to prevent undue pressure increase due to thermal expansion In
order to avoid excessive pressure the system may be depressurized down to the required test
pressure.
If during hydrostatic test the test pressure is decreased to a pressure lower than the specified
test pressure and there is no evidence of leakage, the line shall be pressurized back to reach
the specified test pressure and held for one more hour (with Company approval).
Test medium and pressure will be specified in the piping line list.
Potable water will be used for hydrostatic testing, water analysis shall be provided for
Contractor/Company approval.
Water less than 30 ppm chloride will be used for testing of stainless steel piping. Water
analysis report with less than 5 ppm chloride is attached.
For the system 9 coated piping , the below strategy shall be followed.
1. Hydro test holding time 1 hour, if all weld joints are uncoated and joints are exposed
2. Hydro test holding time 2 hour , if the weld joints are coated and exposed.
3. Hydro test holding time 4 hour, if the weld joints are coated and back filled.
In all scenarios two pressure gauges and one pressure & temperature recorder shall be used.
immediately prior to the test and shall be disconnected immediately after the test pressure has
been reached.
The area around the system to be tested will be cleared of unauthorized personnel and
warning notices posted during the time that the piping system is pressurized for test.
Vent connection shall be provided at all high points of the test system. The system shall be
filled from the lowest point with all vents open Piping and equipment shall be thoroughly vented
of air before the vents are closed and the hydrostatic test pressure is applied.
The system will be pressurized to the specified test pressure in steps stage 25%, 50%, 75% &
100% holding time on each stage will be minimum 5 mn. Pressure test shall be acceptable if
all the joints are leak free. Test pressure shall be maintained for a minimum duration of
one hour or until all joints are inspected whichever is longer.
Calibrated pressure and temperature recorder will be used to record the pressure and
temperature readings on a graph. The recorder shall be connected throughout the pressuring
and depressurizing period. After the depressurization, the recorders can be disconnected from
the test system.
One pressure gauge will be installed on the testing manifold and another highest point of
system being tested. Test pressures shall be read at or near the lowest point of the system to
ensure the minimum test pressure of 10 kPa for every meter of water above the gauge level
shall be added at the lowest point of system. If the difference between the lowest and highest
level is not big, only one pressure gauge at the highest point of system will be installed.
If a leak is found, the pressure shall be reduced to zero pressure and the leak rectified.
When a leak is discovered, bolts shall not be tightened with the system under pressure. The test
shall then be repeated. When leak have confirmed the test shall be carried out again for full
duration.
If hydrostatic testing is not considered practicable, a pneumatic test may be substituted with
written approval from the company.
Immediately after completion of hydro testing and acceptance, all the piping system loops shall
be depressurized in steps and the system will be thoroughly drained of water by first opening
high point vents and then the drains.
If the pressure drop is justified only by a drop in temperature (No leakage), the test can be
considered successful with Contractor and Company approval.
For piping subject to Tunisian Standard NT 109.01, the procedure described on the standard
will be followed.
PNEUMATIC TESTING:
Pneumatic test shall be done according to the Method statement n° NAWGTP-ABB- PF02-000-
CO-MST-00104.
The system to be pneumatically tested shall be connected to the air compressor by an accessible
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connection identified. Suitable precautions as mentioned in the Work Method Statement shall be
taken to eliminate hazard to personnel in the event of leakage in the proximity of the lines being
tested.
a. STEP 1: For systems with test pressure greater than 1. bar, initial pressure should be
raised to 25 psig (1.7 bar) or 25% of the test pressure, whichever is lesser, and held for
10 minutes to check joints and connections for leaks. (refer to table 1), If leaks are
discovered, release pressure, repair, and return to Step 1. If no leak detected, move to
step 2
b. STEP 2: The test pressure shall be gradually increased until it is approximately 1/2 of
the required test pressure and hold for 10 minutes duration. (refer to table 1), as following:
Increase from pressure in Step 1 by 350 kPa (50 psi) or to 35% test pressure, whichever
is greater. Hold for a minimum of 3 min to allow strains to equalize. Continue to increase
by 350 kPa (50 psi) increments until the system pressure is at 50% test pressure.
Hold at 50% test pressure for a minimum of 10 min. Observe pressure gage for loss of
system pressure. If pressure loss exceeds 10% of test pressure, the system pressure
should be reduced to 25% test pressure and check for leaks.
If no loss of pressure is detected, subject to approval of the inspector, proceed to Step3
d. STEP 4: Reduce system pressure to the design pressure for piping. Conduct a
complete inspection for leakage of the vessel or piping system, or both, at locations such
as flanges, weld joints, and threaded connections-using a soap solution a. If no leakage is
discovered, release system pressure. If leakage that is not acceptable is discovered,
relieve all system pressure and repair. Go back to the step 2.
Upon satisfactory completion of the test, the pressure shall be gradually reduced to 0 psig (0
bar). After test, test equipment shall be removed and the system sealed sufficiently with valves or
blind flanges to prevent entry of foreign material into the system.
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5 FLUSHING
EXCLUSIONS
The following lines are excluded from flushing:
Drums, vessels, or towers, flame arrestors and rotating equipment.
All instrument impulse lines downstream of isolation valve.
PREPARATION FOR FLUSHING:
Line flushing operation shall be carried out to pressure testing of the line. In case the sequence of
flushing and pressure testing is to be interchanged then the Company permission shall be
obtained. The Contractor shall prepare a flushing schedule which shall be submitted to the
company for approval prior to the commencement of flushing.
Prior to flushing, it shall be ensured that the system to be flushed is inspected & accepted by
COMPANY.
On completion of flushing, any blinds installed for the purpose of flushing and not required
during subsequent pressure testing shall be removed.
Any equipment not to be flushed shall be suitably isolated or disconnected from the system.
The following shall be checked and ensured:
Temporary strainers, if any installed shall be approved by COMPANY and periodically checked
during the flushing operation and shall be cleaned to remove deposits & debris. Strainers should
be used to protect equipment against the introduction of construction debris or dirt.
Temporary supports (if any) provided are adequate to carry the weight of the piping & test
medium and well fixed to support pipe weight and stored energy
All pipe supports, anchors, guides, clamps & similar items are installed as detailed on the
construction drawing.
Pre-set pin in spring hangers (if any) remains in place until flushing and testing is complete.
Temporary gaskets are fitted in place of special gaskets.
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Soft seated valves (e.g. ball valves) installed are in fully open position or removed from the
lines to be flushed
Where check valves are installed in a system, flushing shall be carried out from a point upstream
of the valve. Where this impractical Check valve shall be reversed or removed from the system
with company approval.
Pressure relieving devices have been isolated or removed & blanked.
Control valves are removed from the line and a suitable temporary spool or spacer piece
inserted as required.
Flow elements, Meters and orifice plates are removed from the system and a suitable spool
piece installed.
Instrument impulse lines are to be isolated
DEWATERING
After pressure test completion and pressure releasing, Contractor will proceed to dewater piping
using air compressor to eliminate as much as possible the water content.
EXECUTION
The methodology shall depend on the piping size as follows
Continuous blowing
The piping circuit is lined-up with the source of air, and it is continuously blown starting from the
main header, then cleaning the sub-headers and finally the distribution lines.
This method is recommended for small or medium bore (generally up to 4”).
Reverse sense of blowinmg could be conducted (where and if required)
possible) meanwhile the bursting disk will be fixed at the lowest point to facilitate the operation. In
the blowing out side, Contractor will fix (where and if possible) a plastic cover sheet in order to
facilitate the identification of dust/debris coming during activities. This operation will be done during
performing the last blow.
In parallel loops bursting membrane shall be fixed alternatively on both ends.
In case of line with main brunch connections Contractor will perform the air blowing as follow:
Compressed air connected to highest point
Bursting disk in each the lowest point (if required according the first blows out)
Contiguously air blowing for small brunch connection
As a general rule, a minimum of three blows should be performed. The quality of air at the blow-
out point is visually checked to assess the completion of the cleaning operation. In case Contractor
could alternate the two listed methods to achieve the cleanliness criteria.
CLEANLINESS CRITERIA
Air blowing effectiveness is normally verified by visual inspection of eventual debris coming from
piping. Screens or bursting discs that are installed at the air outlet points are inspected and
replaced until satisfactory cleaning result.
REINSTATEMENT:
When draining is completed, all items removed for the test system will be reinstated. Reinstatement of piping
component and in-line instruments will be carefully carried out to ensure that they are installed in the correct
place.
Flange joints opened for the purpose of testing shall be tightened with new gaskets Locking
arrangement for spring support shall be removed only by the commissioning team.
Check for correct flow direction when installing valves and on all control valves which have
been removed a re-loop check should be carried out to confirm correct functioning of the valve.
All temporary blinds are removed and replaced with spacers, as required. Any permanent blinds
or spectacle blinds are installed as shown on the drawings.
002
Contractor will seal the system after cleanliness has been achieved to ensure the system
remain clean and free of debris (plastic cover sheet in a both end, or permanently re-installed).
7 HSE REQUIREMENTS
It should be noted that the safety of personnel and existing facilities is of paramount importance at
all times. This especially relevant when conducting operations involving high pressure testing.
Areas around flexible hose and high pressure pump shall be cordoned off with barriers and
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warning tape.
Wipe check to be installed on all pressurized flexible hoses and connections
At the boundaries Notice / Sign boards shall be displayed with caution notes like “System
Under Pressure do not enter“/ “Hydrostatic / Pneumatic Test in progress” etc., Signs To be written
in both Language English & Arabic
All the personnel involved in the Hydrostatic testing and rigging operations shall be briefed
about all the possible risks involved with the operation during the tool box talks meetings.
PTW, RA to be available at any time in work location, Reduce number of persons in area. Only
involved personnel can be in work location.
PPE (ear plugs/muffs, face shield, etc) shall be wear by all involved staff during blowing
Establish communication and to be maintained between the crew and permit holder while
activity is carried.
Separate Risk Assessment shall be conducted, approved and must be part of the method
statement. This shall be followed at site.
Required safety distance during pneumatic test shall be calculated and indicated on the RA and
respected.
Hydrotest water will be collected in the tank and will be evacuated by an approved collector
(Amine collect).
NOTE:
Pressure test chart shall be signed by authorized persons. The following information shall be added on to
the chart: Project name, Location, identification of piping system tested (line and/or spool number), Test
Pack number, test pressure, test medium, date of test, Pressure & temperature scale, Serial number of
recorder, Names and signatures of supervisor, QC inspector and Company representative.
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8 ATTACHMENT:
Republique Tunisienne •
Ministere de l'lndustrie
,
LA BO RATO I RE C ENTRA L
D AN ALYSES &
RAPPORT D'ESSAI
1/1
1. DEMANDEUR (S)
CERI
Chlorures (080302)
4. RESULTATS
4-1. Methodes
4.2-Resultats
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Essai (S) effectue (S) par