CONSTRUCTION

INSTRUMENT
TUBING PRESSURE & LEAK
TEST
PROCEDURE
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TABLE OF CONTENTS

SECTION DESCRIPTION PAGE

1.0 PURPOSE 2

2.0 SCOPE 2

3.0 REFERENCE 2

4.0 DEFINITION / ABBREVIATION 2

5.0 PROCEDURE 4

6.0 TUBING PRESSURE & LEAK TEST PROCEDURE 5

7.0 SCHEMATIC DIAGRAM 6

7.0 RECORDS AND DOCUMENTATION 6

8.0 APPENDICES 6

1.0 PURPOSE
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This procedure serves as a guideline for the implementation of standard requirements for construction
instrument tubing pressure & leak test. The purpose of pressure & leak test is to confirm the tubing and
fittings joints have been properly tightened and the working pressure of the tubing system flow smoothly.

2.0 SCOPE

This procedure applies to construction instrument tubing pressure & leak test to the following:
- Transport line Instrument air/gas supply line tubing
- Process Impulse and pneumatic signal line tubing
- Fusible plug loop line tubing
- Sample line and N2 line tubing
- Hydraulic line tubing

3.0 REFERENCES

Generally all fabrication, installation and inspection works shall be carried out in accordance with PTS as
main reference, IFC Drawings, manufacturer’s recommendations, applicable codes and standards as
stated below.

No Description

1 Installation of On-Line Instrument (PTS 32.37.10.11)

2 Instrument Signal lines (PTS 32.37.20.10)

4.0 DEFINITIONS / ABBREVIATION

No Description Details

1 AFC Approved For Construction

2 E&I Electrical and Instrumentation

3 FAT Factory Acceptance Test

4 I.S Intrinsically Safe

5 IFC Issued For Construction

6 ITP Inspection Test Plan

7 ITR Inspection Test Report

8 JHA Job Hazard Analysis

9 LCD Liquid Crystal Display

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10 MCT Multi Cable Transit

11 MDR Material Deficiency Report

12 MRIR Material Receipt and Inspection Report

13 PLC Programmable Logic Controller

14 PMT Project Management Team

15 PVC Polyvinyl Chloride

16 QC Quality Control

17 UPS Uninterruptable Power Supply

18 VCI Vapour Corrosion Inhibitor

19 STQ Site Technical Query

20 MT Magnetic Particle Examination

21 FGS Fire And Gas System

5.0 PROCEDURE

5.1 General

5.1.1 This procedure covers the method and document/record control for the pressure & leak test of
instrument tubing installation.

5.2 Requirement and Procedure

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5.2.1 The instrument tubing pressure & leak test team shall consist of the minimum personnel:
i) Supervisor
ii) Instrument Technician

5.2.2 Personnel stated in (i) is the team leader and shall be responsible for the preparation of
procedures if any, scheduling and overall execution of the job. Personnel stated in (ii) shall be
totally involved in the tubing pressure & leak test of the tubing.

5.2.3 Prior to commencement of pressure & leak test activity, the following should be made available by
Supervisor:

• Instrument Hook up drawing

• Inspection report conforming Instrument’s acceptance by QC
• Check sheets
• Leak test equipment

5.2.4 Prior to pressure & leak test activity, all related individually instruments shall be checked to
ensure installation complies with PTS.

5.2.5 All leak test tests shall be witnessed by CONTRACTOR QC and CLIENT representative and the
data will be recorded.

5.3 Test Equipment

5.3.1 A list of typical test equipment is listed below as minimum requirement:

• Air Compressor
• Air Manifold
• Standard Test Gauges
• Standard instrument tube fittings and tools
• Soap solution

6.0 TUBING PRESSURE & LEAK TEST PROCEDURE

6.1.1 Check and verify that all the connection was tightened and installed properly.

6.1.2 Process impulse (IMP), sample line (SPL), hydraulic line (HYD) and transport line Instrument
air/gas supply line shall be pressure tested 1.5 times the maximum operating pressure (refer Note
1 and 2).

6.1.3 Pnuematic signal line (SIG) shall be leak tested at pressure of 2 barg.
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6.1.4 All joints and connection shall be applied with soap solution to facilitate the leak detection of the
line.

6.1.5 The pressure shall be maintained for 60 minutes and pressure drop must not exceeding 0.069 bar
or 1 psi per hour. Minimum scale division of test gauge or manometer used shall be 1 psi.

6.1.6 All joints and connections that were found defective shall be repaired immediately and retested
again.

6.1.7 Reference test gauge must have an accuracy of not less than +/- 5% of the full scale. Complete
with the calibration certificate.

6.1.8 Impulse line shall be isolated to the instrument.

6.1.9 After all the instrument has been checked/tested, all color coded marked will be in place for
identification; Red – Fail, Green – Pass.

6.1.10 All tested lines are to be witness by CONTRACTOR QC and CLIENT representative.

6.1.11 Result will be recorded to the applicable check sheet and signed by CONTRACTOR QC and
CLIENT representative.

Notes :
1) Pressure test for pipe rating 150# below can be with pneumatic test at 1.5 times.
2) For 150# above, the test shall be using water (hydrotest) only because of safety concern using
high pressure pneumatic. Hydrotest performed shall be in accordance with CLIENT approved
hydrotest procedure.
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7.0 SCHEMATIC DIAGRAM

VENT VALVE AT
PRESSURE GAUGE HIGHEST POINT
END PLUG
CLOSE
VALVE

PUMP
TUBING TO
CLOSE BE
VALVE PRESSURE /
LEAK
TESTED

DRAIN VALVE

FIGURE 1 – SCHEMATIC DIAGRAM FOR INSTRUMENT TUBING PRESSURE & LEAK TEST

8.0 RECORDS AND DOCUMENTATION

8.1.1 All result shall be recorded in ITR-I05A.

8.1.2 If hydrotest is required, hydrotest report shall be attached together with the ITR-I05A.

9.0 APPENDICES

9.1 Appendix 1

9.1.1 ITR-I05A – Instrument Tubing Installation & Pressure Testing page 1 of 2.

9.1.2 ITR-I05A – Instrument Tubing Installation & Pressure Testing page 2 of 2.

9.2 Appendix 2

9.2.1 Tubing pressure and leak test Flow chart.

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Prepare procedure,
JHA and any
needed document

Check tubing
Pnuematic line type e.g
signal line (SIG) IMP, HYD, SPL
& supply line

Test
Repair with 2
barg
Check Pressure rate
pressure 150# and above
need to be
Report tested.
and
recorded
Hydrotest
(Refer to CSP -
22)

Pressure
Repair test rate
150# and
below Report
and
recorded

Report
and
recorded

9.3 Appendix 3

9.3.1 Sample calibration certificate page 1.

9.3.2 Sample of Calibration certificate page 2.

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