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SERIAL NO.
REV. NO.
NO. OF PAGES: 44
DATE
NIOEC
000
EG
PI
SP
5005
A0
JULY, 2005
NIOEC SPECIFICATION
FOR
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)
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)
4)
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.
5.
GENERAL REQUIREMENT
5
6
7
7
8
9
9
9
11
12
12
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
14
9.
14
9.1
9.2
9.3
9.4
9.5
9.6
9.7
14
15
15
16
17
17
17
7.
17
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
25
ATTACH. B(1/2)
26
ATTACH. B(2/2)
27
ATTACH. C
28
ATTACH. D
44
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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
JULY, 2005
IPS-C-IN-100
NIOEC-SP-50-05(0)
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.
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NIOEC-SP-50-05(0)
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)
NIOEC-SP-50-05(0)
JULY, 2005
(Eq.1)
S
Where:
PT
P
ST
S
JULY, 2005
NIOEC-SP-50-05(0)
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
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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.
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12
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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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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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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.
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Control Valves
Gauge Glasses
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
Direct Connected
Regulators
Pressure-Balanced
Control valves
Pressure Gauges
Pressure Switches
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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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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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)
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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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.
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NIOEC-SP-50-05(0)
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ATTACHMENT A (1/1)
REPORT NO.:
JOB NO.
SH OF
..
UNIT
ITEM. NO.
Construction Contractor:
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
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
25
Restoration
Restoration
NIOEC-SP-50-05(0)
JULY, 2005
ATTACHMENT B (1/2)
REPORT NO.:
JOB NO.
SH OF
..
UNIT
ITEM. NO.
Construction Contractor:
-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.
Construction Contractor:
TEST PACKAGE
Three Weeks
Before Testing
LINE CLEANING
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
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)
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.
DATE
PREP
10
11
12
13
14
15
16
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:
RECIPIENT
CONTRACTOR
MECHANICAL
CONTRACTOR
PIPING
CONTRACTOR
WELDING
NIOEC
NOTE
ACCEPT
DATE
SIGNATURE
SIGNATURE
RECIPIENT
CONTRACTOR
MECHANICAL
CONTRACTOR
PIPING
CONTRACTOR
WELDING
NIOEC
NOTE
ACCEPT
DATE
SIGNATURE
SIGNATURE
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
DESIGN PRESS.
TEST PRESS.
TEST FLUID.
LINE NO.
ISO. NO.
SHT. NO.
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)
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.
LINE NO.
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.
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.
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.
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
Construction Contractor:
ATTACHMENT C (9/16)
REPORT NO.:
JOB NO.
SH OF
..
UNIT
ITEM. NO.
INSPECTION REPORT
SPOOL NO:
Release Report
LINE NO:
CONS.
CONT.
NO
CHECK ITEMS
1
2
3
4
5
6
7
8
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
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.
Construction Contractor:
LINE
ISOMETRIC
JOINT
NO
SIZE
INCH
WELDER
NO
LOCATION
DATE
WELDED
VISUAL
REPORT
DATE
No.
RT
PT
MT
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
NO.
CHECKED ITEMS
C.C.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
CONTRACTOR
NIOEC
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
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
4- CLEANING RESULT
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 PRESS :
REPORT NO.:
BARG.
ACTUAL PRESS
TEST MEDIUM :
TEST DURATION :
AMB. TEMP:
SH OF
BARG.
LINE NO.
LINE NO.
CONT : CONTRACTOR
CONTRACTOR
NIOEC
PRESSURE TEST
SIGN:
SIGN:
SIGN:
ACCEPTED
DATE :
DATE :
DATE :
POST TEST
SIGN:
SIGN:
SIGN:
DATE :
DATE :
DATE :
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 :
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
Construction Contractor:
ATTACHMENT D(1/1)
REPORT NO.:
JOB NO.
SH OF
..
UNIT
ITEM. NO.
(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