TECHNICAL SERVICES GROUP

SPECIFICATION FOR INSPECTION, FLUSHING AND TESTING OF PIPING SYSTEMS

CAIRN-TSG-L-SP-0012

CAIRN ENGINEERING STANDARD

B1 27.08.2013 Issued for Implementation Vijay Bhatli Vijay Bhatli AA

A1 12.06.2013 Issued for Review Vijay Bhatli Vijay Bhatli AA

Revision Date Description Originator Checker Approver

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 TECHNICAL SERVICES GROUP
SPECFICATION FOR INSPECTION, FLUSHING AND TESTING OF PIPING SYSTEMS
CAIRN-TSG-L-SP-0012 B1
Page 2 of 9

REVISION RECORD

Revision Philosophy
All revisions for review will be issued at A1, with subsequent A2, A3, etc as required.
All revisions approved for issue or implementation will be issued at B1, with subsequent B2, B3, etc as
required.
All revisions approved for issue or design and construction will be issued at C1, with subsequent C2, C3,
etc as required.
Narrative sections revised from previous pprove issues are to be noted in the table below and/or
highlighted using the appropriate revision status thus: | A2
Previous revision highlighting to be removed at subsequent issues.
Drawings/diagrams revised from previous approved issues are highlighted by 'clouding' the affected areas
and by the use of a triangle containing the revision status.

Revision History

Revision Date of issue Reason for change

No.

A1 12.06.2013 Issued for review

B1 27.08.2013 Issued for Implemenation

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 TECHNICAL SERVICES GROUP
SPECFICATION FOR INSPECTION, FLUSHING AND TESTING OF PIPING SYSTEMS
CAIRN-TSG-L-SP-0012 B1
Page 3 of 9

CONTENTS

1.0 SCOPE 4

2.0 REFERENCES 4

3.0 INSPECTION 4

4.0 FLUSHING 4

5.0 PRESSURE TESTING 5

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 TECHNICAL SERVICES GROUP
SPECFICATION FOR INSPECTION, FLUSHING AND TESTING OF PIPING SYSTEMS
CAIRN-TSG-L-SP-0012 B1
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1.0 SCOPE
This specification covers the general requirement for inspection, flushing and testing of piping systems.
However, testing of steam lines falling under IBR shall also be governed by Indian Boiler Regulations.
Flushing and testing of all piping systems shall be witnessed by the Engineer-In-Charge.

2.0 REFERENCES
ASME B31.3 Process Piping
IBR: Indian Boiler Regulations

3.0 INSPECTION
During various stages and after completion of fabrication and erection, the piping system shall be inspected
by the Engineer-In-Charge to ensure that:
- Proper piping material has been used.
- Piping has been erected as per drawings and instructions of Engineer-In-Charge.
- All supports have been installed correctly.
- Test preparations mentioned in this specification have been carried out.

4.0 FLUSHING
Flushing of all lines shall be done before pressure testing.
Flushing shall be done by 'fresh potable water' or by 'dry compressed air wherever water flushing is not
desirable to clean the pipe of all dirt, debris or loose foreign material.
Required pressure for water flushing shall meet the fire hydrant pressure or utility water pressure. For air
flushing, the line/system shall be pressurized by compressed air at the required pressure which shall be 50
psi maximum. The pressure shall then be released by quick opening of a valve, already in line or installed
temporarily for this purpose. This procedure shall be repeated as many times as required till the inside of the
pipe is fully cleaned. In line instruments like control valves, orifice plates, rotameters, safety valves and other
Instruments like thermowells which may interfere with flushing shall not be included in Flushing circuit
The screens/meshes shall be removed from all permanent strainers before flushing. Screens/meshes shall be
reinstalled after flushing but before testing.
During flushing temporary strainers shall be retained. These shall he removed, cleaned and reinstalled after
flushing, but, before resting.
In case any equipment such as vessel, exchanger etc. form part of a piping circuit during flushing, this shall
be done with the approval of Engineer-In-Charge. However, equipment’s thus included in the circuit shall be
completely drained and dried with compressed air after flushing is completed.
During flushing discharged water/air shall be drained to the place directed by the Engineer-In-Charge. If
necessary, proper temporary drainage shall be provided by the contractor. Care shall be taken during flushing
so as not to damage/spoil work of other agencies. Precautions shall also be taken to prevent entry of
water/foreign matter into equipment’s, electric motors, instruments, electrical installations etc. in the vicinity of
lines being flushed.
The contractor shall carry out all the activities required before, during and after the flushing operation, arising
because of flushing requirements, such as but not limited to the following:

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SPECFICATION FOR INSPECTION, FLUSHING AND TESTING OF PIPING SYSTEMS
CAIRN-TSG-L-SP-0012 B1
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Dropping of valves, specials, distance pieces, inline instruments and any other piping part before flushing.
The flanges to be disengaged for this purpose shall be envisaged by the contractor and approved by the
Engineer-In-Charge. These flanges shall be provided with temporary gaskets at the time of flushing.
After flushing is completed and approved, the valve distance pieces, piping specials etc. shall be reinstalled
by the contractor with permanent gaskets. However, flanges at equipment nozzles and other places where
isolation is required during testing, only temporary gaskets shall be provided.
Records in triplicate shall be prepared and submitted by the contractor for each piping system for the flushing
done in the proforma provided/approved by the Engineer-in-Charge.

5.0 PRESSURE TESTING

Pressure testing, in general shall be as per clause 345 of AS ME B31.3, unless otherwise specified, herein.
Lines carrying highly hazardous/poisonous fluids must have a sensitive leak test. For IBR lines, 'IBR
Regulations' shall also be followed.

5.1 Extent of Testing

With the exclusion of instrumentation, piping systems fabricated or assembled in the field shall be tested
irrespective of whether or not they have been pressure tested prior to site welding or fabrication.
To facilitate the testing of piping systems, vessels and other equipment’s may be included in the system with
the prior approval of Engineer-In-Charge if the test pressure specified is equal to or less than that for the
vessels and other equipment’s. Pumps, compressors and other rotary equipment’s shall not be subjected to
field test pressure. Lines which are directly open to atmosphere such as vents, drains, safety valves
discharge need not be tested, but all joints shall be visually inspected. Wherever necessary, such lines shall
be tested by continuous flow of fluid to eliminate the possibility of blockage. However, such lines if provided
with block valve shall be pressure tested up to the last block valve.
Seats of all valves shall not be subjected to a pressure in excess of the maximum cold working pressure of
the valve. Test pressure applied to valves shall not be greater than the manufacturer's recommendation nor
less than that required by the applicable code. Where allowable seat pressure is less than test pressure, test
shall be made through an open valve.
Instruments in the system to be tested shall be excluded from the test by isolation or removals, unless
approved otherwise by the Engineer-In-Charge.
Restrictions which interfere with filling, venting, draining such as orifice plates etc. shall not be installed unless
testing is complete.
Control valves shall not be included in the test system. Where bypasses are provided test shall be performed
through the bypass and/or necessary spool shall be used in place of the control valve.
Pressure gauges which are part of the finished system, but cannot withstand test pressure shall not be
installed until the system has been tested. Where piping systems to be tested are directly connected at the
battery limits to piping for which the responsibility rests with other agencies, the piping to be tested shall be
isolated from such piping by physical disconnection such as valve or blinds.

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SPECFICATION FOR INSPECTION, FLUSHING AND TESTING OF PIPING SYSTEMS
CAIRN-TSG-L-SP-0012 B1
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5.2 General Requirements / Test Preparation for Testing

Testing shall be carried out with permanent gaskets installed unless specified otherwise or instructed by the
Engineer-in-Charge.
No pressure test shall be carried out against closed valve.
The QC-in-Charge shall be notified in advance by the Contractor, of the testing sequence and programme, to
enable him to be present for witnessing the test. The Contractor shall be fully responsible for making
arrangements with the local boiler inspector to witness the tests for steam lines falling under IBR . IBR
certificates for these tests shall be obtained in the relevant IBR forms and furnished to the Engineer-in-
Charge.
Before testing, all piping shall be cleaned by flushing to make it free from dirt, loose scale, debris and other
loose foreign materials.
All piping systems to be hydrostatically tested shall be vented at the high points and the systems purged of air
before the test pressure is applied.
Wherever in the line any void exists due to any reasons, like absence of control valves, safety valves, check
valves etc. it shall be filled with temporary spools.
All joints welded, screwed or flanged shall be left exposed for examination during the test. Before pressurizing
the lines, each weld joint shall be cleaned by wire brush to free it from rust and any other foreign matter.
Where a system is to be isolated at a pair of companion flanges, a blank shall be inserted between the
companion flanges. Minimum thickness of the blank shall be designed in accordance with applicable design
code.
Open ends of piping system where blanks cannot be used, such as pumps, compressors, turbines or
wherever equipment or pipe spools have been recovered or disconnected prior to hydrostatic testing, shall be
blinded off by using standard blind flanges of same rating as the piping system being tested.
One test pressure gauge shall be located at a high point of the system and another pressure gauge shall be
located as close as possible to the lowest point in the piping system to be tested to avoid overstressing of
any of the lower portions of the system. Additional pressure gauges shall be installed at locations decided by
the Engineer-in-Charge.
For lines containing check valves any of the following alternatives shall be adopted for pressure testing:
- Whenever possible pressurize up-stream side of valve.
- Replace the valve by a temporary spool and reinstall the valve after testing.
- Provide blind on valve flanges and test the upstream and downstream of the line separately and remove
the blind after testing. At these flanges, temporary gaskets shall be provided during testing and shall be
replaced by permanent gaskets subsequently.
- For check valves in lines 11/2" and below flapper or seat shall be removed during testing (if possible).
After completion of testing the flapper/seat shall be refitted.
Gas lines when hydrostatically tested shall be provided with additional temporary supports during testing as
directed by the Engineer-in-Charge.
Piping which is spring or counter-weight supported shall be temporarily supported, where the weight of the
fluid would overload the support. Retaining pins for spring supports shall be removed only after testing is
completed and test fluid is completely drained.

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SPECFICATION FOR INSPECTION, FLUSHING AND TESTING OF PIPING SYSTEMS
CAIRN-TSG-L-SP-0012 B1
Page 7 of 9

5.3 Testing Media, Test Pressure and Test Pressure Gauges

5.3.1 Testing Media
In general all pressure tests shall be hydrostatic using iron free water, which is clean and free of
silt. Maximum chloride content in water for hydrostatic testing for SS piping shall be 15- 20 ppm and
carbon steel systems shall have chloride content not exceeding 250ppm.
Water to be used for hydrostatic tests shall be sampled and tests to include dissolved oxygen,
ammoniac nitrogen (as NH4-N), nitrates, nitrites and COD. Calculate The amount of additional
chemicals that may be requried, if any.

x pH : 6.5 to 10.5
x Total dissolved Solids : less than 30 Kg/m³
x H2S : Max. 0.001 Kg/m³
x Suspended Solids : 0.005 Kg/m³
x Appearance/Turbidity : Clear with no visible sediment

Air shall be used for testing only if water would cause corrosion of the system or overloading of
supports etc. in special cases as directed by Engineer-in-Charge.

5.3.2 Test Pressure

The hydrostatic/ pneumatic test pressure shall be as indicated in the line list or as per the
instruction of Engineer-in-Charge.
The selection of the piping system for one individual test shall be based on the following:
Test pressure required as per line list.
Maximum allowable pressure for the material of construction of piping.
Depending upon the above requirements and based on construction progress, maximum length of
piping shall be included in each test.

5.3.3 Test Pressure Gauge

All gauges used for field testing shall have suitable range so that the test pressure of various
systems falls in 35% to 65% of gauge scale range. Pressure gage dial shall be minimum of 150
mm. Size of Bourdon shall not be less than 75% of nominal diameter of dial range. Gauge shall be
in good working condition and have valid calibration certificate traceable to national/international
standards
Prior to the start of any test or periodically during the field test programme, all test gauges shall be
calibrated using a standard dead weight gauge tester or other suitable approved testing apparatus.
Any gauge showing an incorrect zero reading or error of more than ± 2% of full scale range shall be
discarded .The Engineer-in-Charge shall check the accuracy of master pressure gauge used for
calibration. Calibration certificate shall be furnished for the pressure pages.

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SPECFICATION FOR INSPECTION, FLUSHING AND TESTING OF PIPING SYSTEMS
CAIRN-TSG-L-SP-0012 B1
Page 8 of 9

5.4 Testing Procedure

5.4.1 Hydrostatic Test
All vents and other connections used as vents shall be left open while filling the line with test fluid
for complete removal of air. In all lines for pressurizing and depressurizing the system, temporary
isolation valves shall be provided if valved vents, drains do not exist in the system.
Pressure shall be applied only after the system / line is ready and approved / released by the QC
personal.
Pressure shall be applied by means of a suitable test pump or other pressure source which shall be
isolated from the system as soon as test pressure is reached and stabilized in the system.
A pressure gauge shall be provided at the pump discharge for guidance in bringing the system to
the required pressure.
The pump shall be attended constantly during the test by an authorized person. The pump shall be
isolated from the system whenever the pump is to be left unattended.
Test pressure shall be maintained for a sufficient length of time to permit thorough inspection of all
joints for leakage or signs of failure. Any joint found leaking during a pressure test shall be retested
to the specified pressure after repair. Test period shall be maintained for a minimum of one hour.
The pump and the piping system to be tested are to be provided with separate pressure indicating
test gauges.
Care shall be taken to avoid increase in the pressure due to temperature variation during the test.

5.4.2 Pneumatic Test

When testing with air, pressure shall be supplied by means of a compressor. The compressor shall
be portable type with a receiver, after cooler and oil separator.
Piping to be tested by air shall have joints covered with a soap and water solution so that the joints
can be examined for leaks.
All other details shall be same as per hydrotesting procedure (specified above).

5.5 Completion of Testing

After the hydrostatic test has been completed, pressure shall be released by opening the vents, in a manner
and at a rate so as not to endanger personnel or damage equipment’s.
All vents shall be opened before the system is to be drained and shall remain open till all draining is complete,
so as to prevent formation of vacuum in the system. After draining, lines / systems shall be dried by air. In
services like dry air, ethylene etc., small traces of water can cause problem. For such lines hot air drying is to
be done after hydro-test.
After testing is completed the test blinds shall be removed and equipment I piping isolated during testing shall
be connected using the specified gaskets, bolts and nuts. These connections shall be checked for tightness in
subsequent pneumatic tests to be carried out by the contractor for complete loop ( circuit including
equipment’s (except rotary equipment’s).
Pressure test shall be considered complete only after approved by the Engineer-in-Charge.

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SPECFICATION FOR INSPECTION, FLUSHING AND TESTING OF PIPING SYSTEMS
CAIRN-TSG-L-SP-0012 B1
Page 9 of 9

Defects, if any, noticed during testing shall be rectified immediately and retesting of the system (line shall be
done by the contractor at his cost.

5.6 Test Records

When testing team has completed all testing of full piping system, Contractor shall inspect the completed
piping system for reinstatement and any deficiencies or outstanding works which must be completed prior to
acceptance of the system. If there are no deficiencies, the piping system shall be submitted for Pre
Commissioning/ Commissioning activities.

A complete and accurate record shall be endorsed and kept by the company and certifying authority as
necessary for each spool and system tested. It shall include:

x Hydrostatic test diagram

x Line list
x Line history sheet
x Calibration Certificates
x Flushing Report.
x The date of test
x Identification number of piping tested
x The test medium used
x Test pressure and duration that test pressure was maintained.
x Testing Reports acceptance by the designated Inspector

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