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METHOD STATEMENT
FOR
PRESSURE LEAK TEST

Rev Date Description Iss’d by Chk’d by App By Company App

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CONTENTS

I. SCOPE

II. REFFERENCE

III. RESPONSIBILITY AND AUTHORITY

IV.PRESSURE LEAK TEST

V.ATTACHMENT
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1. SCOPE

This procedure describes the requirements to be conformed in pressure leak testing on

piping for the construction of Petrochemical Plant, Thermal Power Plant or other similar
plant project.

2. REFERENCE

2.1 ANSI B31.3 : Chemical Plant & Petroleum Refinery Piping

2.2 NFPA : National Fire Protection Association

2.3 Project Specification

3. RESPONSIBILITY AND AUTHORITY

3.1 The PIPING SECTION CHIEF shall have responsibility and authority for direction
and control of the pressure leak test including all necessary provisions to perform
the activities.

3.2 The PIPING ENGINEER shall perform the pressure leak test activities and shall
provide all required inspection and control required for execution of pressure leak
test.

3.3 Prior to pressure test, the QC ENGINEER shall perform the inspection with
respect to the completeness of work, markings, calibrations adjustment,
protection from damage, or other characteristics as required verifying the quality
and conformances of the item to specified requirements (under the presence of
Owner).

3.4 Pressure test shall be performed by the PIPING ENGINEER under the presence
of QC ENGINEER and/or Owner.

3.5 Item to be checked shall be documented on the piping pressure test report by the
QC ENGINEER and approved by the QC SECTION CHIEF.

4. PRESSURE LEAK TEST

4.1 General Requirement

4.1.1 After installation of piping, pressure test required by the applicable

code and specification shall be performed as specified in this
procedure.

4.1.2 All testing shall be conducted by the Piping Engineer and shall be
witnessed by the QC Engineer and OWNER.
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4.1.3 Prior to pressure test, the Piping Engineer shall prepare the pressure
test package including Piping Pressure Test Report, Line & ISO
Drawing, marked up P & ID drawings to show the boundaries of the
test and filling.

4.1.4 The following items shall be shown in the "Pressure Test Package".

(1) Limitation of system to be tested.

(2) Location of temporary blind plate, pressure gauges.

(3) Instruments and equipments to be dismounted during test.

(4) Line number and equipment item numbers to be tested.

(5) Test pressure and test medium.

4.1.5 Valves intended for use in test boundary isolation shall be researched
by Piping Engineer that the valve are capable of withstanding the
pressure loads applied, likewise, all equipment within the test segment
shall be determined as being capable of withstanding the test.

4.1.6 Valves, equipments, etc., not capable of withstanding test pressure

shall be rendered capable or shall be excluded from the test.

4.1.7 Additional supports shall be temporarily installed if the system has not
been designed to support the weight of the test media.

4.1.8 Any expansion joints in the system shall be restrained or they shall be
isolated from the system during the test.

4.1.9 When pressure testing a system, the test pressure shall not exceed
maximum test pressure for any component in the system.

4.1.10 All components in the system that should not be subjected to pressure
test, such as pumps, tanks, heat exchangers, and instruments such as
control valve, relief valve, rupture discs, rotameter, pressure gauge,
gauge glasses, and filler elements shall be isolated from the test.

4.1.11 Two indicating pressure gauges shall be used for all process piping.

4.1.12 For the other piping except process piping may be used one indicating
pressure gauge.

4.1.13 The gauges shall have a reading range of 1 1/2 to maximum of 4 times
the test pressure.
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4.1.14 Calibration of pressure test gauges shall be performed within

calibration frequency not exceeding two weeks.

4.1.15 Gauges in use shall be installed in a manner visually accessible to

personnel performing the test.

4.1.16 When performing pneumatic testing, Tape barrier shall be erected and
access to the area shall be restricted. Safety representative of each
area shall be control (restricted access) the restricted area. And also
safety valve is required for all high pressure testing (above 1.73
kg/cm²).

4.1.17 All welding inspection records for field welds, field modification welds,
and pressure boundary attachment welds shall be verified to exist and
be completed by QC Engineer.

4.1.18 The preliminary walk down shall be performed by Piping Engineer in

conjunction with QC Engineer.

4.1.19 The punching items found out during preliminary walk down shall be
cleared prior to the notification of pressure test to OWNER.

4.1.20 All open Non-Conformance Reports shall have been identified and
completed except those that are not pressure test restraints.

4.1.21 All joints shall be exposed and cleared of insulation and wrapping for
easy inspection.

4.1.22 Touch-up or primer one coating may be applied to shop and field
welds or damaged area prior to pressure testing, except where it may
mask a defect.

4.1.23 Before the start of the test, the Piping Engineer shall verify that tags
("DANGER" Tag) are attached on the all valves and components
within the boundaries of the test. He shall also verify that the test area
has been secured for the safety of personnel.

4.1.24 Piping components or system which cannot be tested or inspected

after completion of erection may be tested prior to the erection.

4.1.25 For low temperature service, it's requested to use air or nitrogen
without moisture content at the test pressure.

4.1.26 Except for the location to be inspected, the thermal insulation work
and painting work shall be performed upon completion of the pressure
leak tests and overall air-tightness tests.

4.2 Pneumatic Test

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4.2.1 The system to be pneumatically tested shall be connected to the air

compressor or compressed gas source by an accessible connection
identified by the Piping Engineer.

4.2.2 He shall assure that clean, dry, oil-free, non-flammable, compressed

air is available and sufficient capacity for the pneumatic test.

4.2.3 The test pressure shall be gradually increased until it is approximately

1/2 of the required test pressure.

4.2.4 Thereafter, the pressure shall be increased in increments of

approximately 1/10 of the test pressure until the test pressure has
been reached.

4.2.5 The test pressure shall be maintained for a minimum of 10 minutes.

4.2.6 The pressure shall be held for as long as required to allow

examination by the QC Engineer and OWNER of all joints,
connections and regions of high stress such as around openings and
thickness transition sections.

4.2.7 To detect and pinpoint leaks, soap solution shall be applied until leaks
shall be seen as evolving bubbles or froth.

4.2.8 Soap solution shall be applied only with an apparatus, which will flow
the solution over the surface without leaving bubbles caused by
application.

4.2.9 Sponges or brushes shall not be used for the application of soap
solution.

4.2.10 Upon satisfactory completion of the test, pressure shall be gradually

reduced to 0 psig.

4.2.11 Test equipment shall be removed and the system sealed sufficiently
with valves or blind flanges to prevent entry of foreign material into the
system.

4.3 Hydrostatic Test

4.3.1 Air vent shall be opened to allow the elimination of air from the system
during the water fill.

4.3.2 The system shall be gradually filled, venting air from high points.

4.3.3 Vents shall be closed when the system is full.

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4.3.4 A gradual and slow filling, combined with the removal of air from the
system, is required to eliminate the danger of water hammer.

4.3.5 The test pressure shall be applied gradually with a suitable hydraulic
pump in increments of 1/3 or less of the test pressure.

4.3.6 The test pressure shall not be applied until the system and the
pressurizing medium are at approximately the same temperature.

4.3.7 From 15 to 20 minutes shall be allowed after filling the system for
temperature equalization.

4.3.8 The test pressure shall be maintained for a minimum of 10 minutes.

4.3.9 Thereafter, the test pressure shall be hold for as long as required to
allow examination by the QC Engineer and OWNER of all joints,
connections and regions and high stress such as around openings and
thicknesses transition sections.

4.3.10 Upon satisfactory completion of the test, the system shall be

depressurized gradually and then drained completely (air blowing, if
required).

4.3.11 Action shall be taken to properly vent the system during drainage after
hydrostatic test to prevent a vacuum in the test line.

4.4 NFPA Piping Test

4.4.1 Hydrostatic Test

1. The firewater piping system including water spray system shall

be subjected to a hydrostatic test in accordance with the NFPA
code requirements.

2. However in case that the hydrostatic test cannot be applied,

100% non-destructive examination may be permitted.

3. The test should be conducted at 14 kgf/cm² G (200 psig) for two

hours, or at 3.5 kgf/cm² G (50 psig) in excess of maximum
pressure anticipated, whichever is greater.

4. All exposed leaks at joints, or otherwise evident in the pipeline,

shall be repaired and tested repeatedly.

5. No leakage shall be permitted in systems constructed of welded

and flanged steel pipe.
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6. Water lines and lead-in connections to system risers shall be

flushed thoroughly at a velocity of about 11 km/hr (10 ft/sec) to
assure the removal of any foreign material.

7. Lines shall be flushed preferably before connections are made to

spray systems.

8. If connections have been made, spray piping shall be blocked off

to prevent plugging.

9. Spray systems shall be flushed separately at about the rated

system flow.

10. Large systems may be tested in their entirely or individually

tested by sections on the basis of valves.

11. Each hydrant and monitor shall be opened and closed under
water pressure with pumps running.

12. Monitors shall be checked carefully to see that they are properly
located to provide effective water spray and streams for the
equipment to be protected.

13. Ineffective monitors shall be relocated.

14. Fixed water spray systems for outside protection shall be tested
for rates of flow per nozzle, total rates, nozzle coverage patterns
and water run-down film character.

15. Flow rates per nozzle shall not vary more than ± 15% of the
calculated rate, and the total rate of each system shall not be
less than the required rate.

16. This test shall include the operation of all devices and
instruments that make up the system.

17. The installer shall correct nozzle locations and modify piping as
necessary.

4.5 Repair Work

Should repairing work or additional work necessary as a result of pressure tests

or leak tests, those works shall be conducted after reducing pressure, and those
piping systems which have been affected by such work shall be subject to
additional tests.

4.6 Flushing and Air Blowing

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After the pressure test and leak test, flushing or air blowing shall be conducted
for the tested system to assure the removal of dirt’s, debris and obstructions.
Details shall be subject to the field instructions by the OWNER and Line Table.

5. ATTACHMENT

The status and result of control according to this procedure shall be documented by use
of the following forms.

5.1 Piping Pressure Test Report (PPTR)