01-equipment test procedure.pdf

8/18/2019 01-EQUIPMENT TEST PROCEDURE.pdf

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Cont ract No :

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AZM01040908

Date:

29/11/2008

Rev.: 0

Page 1

of

13

,

.

OWNER:

Equipm.ent , ressureTes,t .

AZMECO

Petrochemical Co,

SUPERVISION:

CECCo.

Procedure No. : MS-AM -08

Procedure

cc:

Mehvarsazan

Content

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Date:

Equipment Pressure Test·

9/11/2008

Rev.: 0

Procedure

Page 2 of 13

Procedure No. :

MS AM

-08

Section 1

General

Content

1

} ~ . D g ~ Q § ~ . . . . . . . . . . . , . . . . . . _ _ __

. .

Cont r .>ct

No:

AZM

01 040908

OWNER:

AZMECO

Petrochemical Co,

SUPERVISION:

CEC

CO.

cc:

Mehvarsazan

PAGE 3

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~ , M E H V A R S A Z A N ENG.

&

CONT

CO

AZERBAIJAN

~ 4 E T i i A N O L

t'LANT I

[,AKU

)

QA QC-

Qaulity Assurance

lI, Quality Conlroi


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Date:

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Rev.: 0

Page 3

of

13

I

Equipme·ntPressure Test

Procedure

Procedure No. : MS-AM -08

Contrac t

No:

AZM01040908

OWNER:

AZMECO

Petrochemical Co.

SUPERVISION:

CEC Co.

CC:

Mehvarsazan

1.

PURPOSE

1 1 The purpose

of

this procedure is to define the methods for carrying out the pressure

tests on equipment after overhaul

Aim of pressure test is to detect possible leakages as well as possible defects of the welded

zone and material as well as flange connection, resulting from the equipment overhaul.

2.

LIMIT OF

APPLICATION

This procedure applies to the METHANOL Plant in AZMECO PETROCHEMICAL Co.,

Equipment working under pressure.

3. REFERENCE

CODES AND STANDARDS

3 1

ASME Section VIII

3-2 ASME B16.5 Latest edition.

4.

ABBREVIATIONS AND TERMS

(Owner

AZMECO Co.s

Me:

Caspian Eng.Co .(CEC)

AMS

Mehvarsazan Technical Co.

DESIGN

PRESSURE:

It is the pressure in bar (g) to

be

used to design all equipment.

OPERATING

PRESSURE:

It is the effective operating pressure in bar (g) of equipment.

TEST PRESSURE:

~

j_..

It

is the pressur.e

(g)

w h i c ~

all. the elements

of

a equipment shall be tested< ,

~ i t H V f

: ; t \ i ~ i ? t 9 \ t ~ t r e ~ d I c a t I O n

of thIS specIficatIOn.

~ i i \ ~ ~ ~ ~ ~ ~ RATING (PN):(Nominal pressure) It is the designation in bar (g) used a

Q ~ s e l ~ t e ~ t e m p e r a ~ u r e dependence adopted for standard

c o m p o ~ e n t s

n ~ e n c a l

1 E . ' ~ I I J ) : b . ' : . f 0 2 Y i : i l f ~ d 3 i ; } J i , . . . p r e t s u r e ratmg for a standard component of the matenal mentIOned m the

s t : a r i . C t a . r c r , - : ~ v ~ t l J l e

maximum allowable working pressure in bar at 20°C.

5. RESPONSIBILITIES

MS-Co. strictly in compliance with the provisions of this procedure shall carry out pressure

tests

of

equipment.


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Contract No :

MC:

Caspian

Engineering

Co.

~ ~ c I I ~ v f l c · 1 I

Date:

29/11/2008

Rev.: 0

. quipment Pressure Test

Procedure

Page 4 of 13

Procedure

No. : MS-AM -08

AZM01040908

OWNER:

AZMECO

Petrochemical Co.

SUPERVISION:

CEC Co.

CC:

Mehvarsazan

MS -Co shall attend any test execution, shall evaluate test results and sign the relevant

certificates.

OWNER OR THIRD PARTY INSPECTOR shall witness the tests according to the Project

Specification", Shall evaluate test results and sign test certificates. Any deviation requires

written permission by OWNER OR THIRD PARTY INSPECTOR.

6

DOCUMENTARY

WORKS

6-1 Test media and pressures on the drawings and certificates

of

equipment shall be followed.

Any deviation

of

test media or pressure shall be with written permission of design

engineer.

6-2 Testing of equipment shall be performed on a test pack basis. Preparation of test packs

shall be based on piping and instrument diagrams (P&ID), test reports and equipment

drawings isometri

6-3 A equipment test pack shall

be

prepared for each (consisting of the following:

6-3-1

Equipment field test report

6-3-2 Punch list(Before and After Test)

6-3-3 Test Permission

6-3-4 Pressure gauge calibration certificates.

6-3-5 All applicable instruction regarding test shall be indicated

. /

Test pressure gauge location

. /

Test vent and drain location

. /

Installation

of

temporary spool pieces (list)

of

required)

. /

Removal

of

designated components (list)

r 1 ~ ; l J E H / A R S A z A l * N C ~ u O O l t l I D shall be issued one copy of each complete test pack

I

A i m ~ ~ ~ ~ r n h ~ ~ M ~

.

s

atic testing shall be carried out. Only when indicated the drawing

Q_ ~ A A r f ~ e l . f i c W r ~ f i n d by written note from CEC, a pneumatic testing may be performed.

u I y

ssur:nce

& QualitY Control


5/12

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AzMe C o

Owner Azerbai jan

Methanol Co

Cont roc t No:

AZM01040908

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Date:

29/11/2008

Rev.: 0

Equipment ressure Test

Procedure

OWNER:

AZMECO

Petrochemical Co

SUPERVISION:

CEC Co

Page 5 o 3

Procedure No. : MS AM 08

cc:

Mehvarsazan

*

Test Packag Flow hart

)

MC/TPI D o c u ~ n t ; r t i o n

Test Group

Line Prepared For

Hydro Test)

1B.·.MEHVARSAZliN ENG 8 ONT

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CO

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'T ' ~ I O W N E R :

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9/11/2008

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SUPERVISION:

rocedure

.

'

CEC Co.

Page 8

of

13

Procedure No. :

MS-AM

-08

CC:

Mehvarsazan

gauge tester. Any gauge showing an uncorrectable zero reading or error of more than

2% of full-scale range shall be discarded. In this case all pressure gauges shall be

calibrated under OWNER

OR

THIRD

PARTY

INSPECTOR OBSERVATION.

The minimum number of pressure gauges for a test system is

2.

Gauges shall be

installed

at

Suitable point, in coordination with

OWNER

OR THIRD

PARTY

INSPECTOR.

7.2.1. Pressure Gauge Calibration

. / Pressure gauges shall be checked by means of a hydraulic pressure gauge against a

standard pressure gauge.

. / The gauge comparator should be firmly fixed to a bench. A test gauge of range

comparable to the gauge under test is fitted to one branch

of

the comparator. The gauge

to be tested is fitted to other branch and the hand

pump on

the comparator operated in

other to check the gauge against the readings of the test gauge. Readings shall be

checked for pressures corresponding to 0, 50, and 100% of

the range

of

the gauge under

test. Actual gauge reading shall be noted for both rising and falling signal.

. /

A calibration record shall be issued.

7.3. Testing fluids

7.3.1. For hydrostat ic testing of equipment is to be performed with clear raw water.

7.3.2 .Any pneumatic testing shall be approved

by

owner.

7.4 Ethylene glycol

• Ethylene glycol water solutions are preferred when testing at freezing

or

near

freezing conditions. Solution freezing point is to set at

5

to c below anticipated

minimum seasonal ambient temperature.

•

Anticipated

corrosion is negligible, comparable to that expected from the fresh

water used. Therefore, in order to minimize the clean-up problem, it is

recommended that no inhibitor be used with the glycol water solution.

• The system should be drained thoroughly after the test. Then after the onset

of

warm

weather, the system may be flushed out with fresh water and/or dried out

~ ~ with-ho ' .

~ : H o / t ~ : S A i : A N ENG

S

ONT O Test ressure

I-

~ i i T ~ ~ ~ ; : ; : : : ; ; : ; : : ; : : : : : r = ~ = =

~ : ' # ~ ; c & g ¥ 6 ~ u

I

st pressure shall be as follow:

(ASME

Section

VIII

Qal.htv \so,u','nce 8

•

. •••

I

.

,

torll

tU

1 I l / h d .

/2 tImes t e eSlgn pressure.

• For a design temperature above the test temperature, the minimum test pressure

shall be as calculated by:


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Date:

,Equipment Pressure Test

AZMECO

29/11/2008

PetrochemicalCo.

Rev.:0

Procedure SUPERVISION:

CECCo.

Page 9

of

13

Procedure No.:MS-AM-08

cc:

Mehvarsazan

1.5

PST

PT=

S

• PT =

Minimum

hydrostaticgaugepressure.

• P = Internaldesigngaugepressure.

• ST

=

Allowablestressattesttemperature.

• S

=

Allowablestressatdesigntemperature

.(See

ASME

B31.3tableK-1)

7.5.2. Thepneumatictestpressureforcomponentsandweldsshallbeas follows:

• Forairpressuretesting,thetestpressureshallnotbe lessthan1.1 timesmaximum

designpressureexceptwitchisreturnondesigndocumentation

ASME

B31.3.

• For systems beingpneumatically tested, apreliminary checkshall be made at a

pressure not exceeding 1.7 bar (g) (25 Psig). The pressure shall be increased

gradually in stepsprovidingsufficienttimeto allowthepipingto equalizestrains

duringtesting.ThepressureincreasingrateshallbedeterminedbyTPIinspector.

• All reinforcingpads and cormections which can not be tested during the hydro

test,shallbepressuretested(airsoap)at0.5-1.0bar(g). All leaksdetectedduring

thetestshallrepairandretested.

• As pneumatic testing presents special risks due to possible release of energy

storedinthecompressedgas,almostcareshallbetakenduringpressurizationand

inspection

of

thesystemstopreventanydangertopersormelorequipmentandthe

chances of a brittlefailure equipmentduring testing. Precautionandprocedure shall

beaslaiddowninparagraph345.5 of theANSIB31.3.

• Asoapsolutionshallbeappliedtoallscrewed,welded,andflangedjoints.

• Flangecormectionshallbesoapsolutiontestedat theoperationpressureafterthe

testpressureperiod.Weldsshallbesoapsolutiontestedat0.5-1.0bar

Test

nressure and

accentancecriteria

Theequipment

or

section thereofundertesting shall be slowly pressurized andthe

testpressure,measuredatthesuitablepointof evaluation,shallbeappliedbycontrol

The duration

of

each pressure test shall be minimum 60 min. unless

~ \ 6 . ? 2 h e r w i s e

specifiedhereinafter

or

intheapplicablestandardasmentionedabove.Any

~ \ F I J ; @:l,lction inthedurationof testshallbeapprovedbyTPIInspector.

Azerbai jan

Methanol

Plant

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Owner Azerbai jan Methano l

Co.

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Engineering Co. I I I , 0 0 I I

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Cont

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aetor:

Contract No:

AZM0104090S

OWNER:


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A z M e C o

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·: en·: r : s - t i = t n = . . . , . ~ . e Cons:.

Extra

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Contractor:

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Contract No :

MC:

Caspian

Engineering Co. I I . I

AZM0104090S

Date:

29111 2008

E quipment Pressure Test

AZMECO

Petrochemical Co.

OWNER:

Rev.: 0

Procedure

SUPERVISION:

CEC Co.

Page 1 o 13


CC:

Mehvarsazan

Pressurizing shall be done by 4 step minimum; each holding on the steps minimum 5

min .Last basic holding time minimum 30 minutes.

For equipment which are tested with compressed air, the pressure drop shall not

exceed 1 percent

of

the test pressure net of instrument and reading accuracy.

7.6.2. Leak Finding

In cases which pressure drop due

to pneumatic test is more than allowable one, then

the system is leaky and water soap solution shall

be

used for leak finding. Leak

finding shall be started with joints and shall be extended to all valves, flanges as well

as seams

of

equipment. Any leaky part shall be re-tested after their repair or

replacement.

7.6.3. While a equipment is under pressure all visible leaks shall be tight where possible.

Welded joints shall be subjected

to

hand hammer test while under test pressure. The

test pressure shall be maintained until the entire section under test has been examined

for leaks. Defects revealed by the test shall

be

repaired, or defective parts replaced

and the system retested. No weld leaks shall be repaired by mechanical caulking.

7.6.4. The pressure shall be released completely prior

to

start of any repair weld. This

applies also for aligning flange connection. After repair weld, the pressure test shall

be repeated.

7.6.5. CEC Co. shall conduct all tests and proper records of all tests shall be kept. Valves

of

line pressure as well as ambient conditions shall be taken at each "reading". The

imexv al

betw een

.the successive readings shall be 2 hours unless otherwise directed

c.

: : : . . . ~ : - - : :

~ ~ c ~ ~ r · Calibrated pressure gauges, temperature indicators etc. shall be

tests.

Q


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Date:

29/11/2008

Rev.:0

Page

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Contract

No :

MC: Caspian Engineering Co.

AZM01040908

I I I I I

OWNER:

Equipment Pressure

Test

AZMECO

Petrochemical Co,

Procedure SUPERVISION:

.,

CECCo.

Procedure No.:MS-AM -08

CC:

Mehvarsazan

7.7.1.

Immediately

After

of

Completion Hydrostatic test, equipment shall

be

dried with blown

out compressed air.

ection

4

Appendix

Form No.

MTC-ME-QA/QC-HT-O1

MTC-ME-QAlQC-HT-02

MTC-ME-QAlQC-HT-03

MTC-ME-QAlQC-HT-04

MTC-ME-QA/QC-HT-05

MTC-ME-QAlQC-HT-06

MTC-ME-QAlQC-HT-08

MTC-ME-QA/QC-HT-09

MTC-ME-QAlQC-HT-13

MTC

-ME-QA/QC-HT-15

Description

No. of

Sheet

FlushingInspectionReport(before)Test

1

GaugeCalibrationReport 1

Releasedformat ForPressureTest

of

Equipment

1

Restament Form

1

Flushing inspectionReport (aftertest) 4

PunchList (aftertest)

1

QCPunchList (before)

Test packagecoversheet I

SnadblastingPrimingInspection forEquipment

1

PressureTestReport

1

I

-

ecessarywillbesubmittedaccordingly

-;

( ) t H e ' r ' f f i r F r l a t ~ \ 1 f t i 1 l

I .

,,' J

~ ' ~ ; ' ~ l : , · ' : T h . ~ ~ : , J L

h.J.,,,,, l

IGAKu i

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· , · I ' . ; ; ~ '

Jr,mc.e

Qualrty Cont rol

L


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Owner

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MC: Caspian Engineer ing

Co.

I >;>.,1.

:: '$0.

I IRo·,..

r i c .

I

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-

Date:

29/11/2008

Rev.: 0

I

Equipment Pressure Test

Procedure

Page 2 of 3


NOTE:

ATTACHMENT

· . · ~ r 6 = 1 ' l ' l = 9. &CC $:.

Co.

CO:1UaGtor:

Contract

No:

AZM01040908

OWNER:

AZMECO

Petrochemical Co.

SUPERVISION:

CEC Co.

cc

Mehvarsazan

The data in the following table are calculated on the basis spade material ASTM 285 GR A with these properties:

Minimum Yield strength: 1687 Kglcm2

Minimum Tensile strength: 3163 Kglcm2

For plates of steels with different mechanical properties, the maximum allowable hydrostatic pressure can

be

calculated with the following ratio:

Px=Yx/Y

Where

Px =Maximum allowable Test Pressure

Yx=Minimum specified Yield strength

of

the different steel

Y =Minimum specified Yield strength of ASTM 285 GR A

Pneumatic test pressure shall not exceed 50

ofthe

values indicated.

{ \ · i r j J . ~ ~ p . S N J . N ENG &

CONT

CO

- v ( .;r,AI

N t,4f.TdN\OL PLANT

I

(iAKU )

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iCi:r l. C .'1:.:.:;urance e Quality Control


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Contrac t No:

AZM01040908

Date:

29/11/2008

Rev.: 0

Equipment Pressure Test

OWNER:

AZMECO

I

Petrochemical Co,

Procedure

SUPERVISION:

CEC Co.

Page 13 of 13


cc:

Mehvarsazan

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AlERBAIJAN ME fHANOl

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Qauilly Assurance e Quality Control

01-equipment test procedure.pdf

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