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Procedure

Contract No:
AZM01040908

OWNER:
AZMECO
Petrochemical Co,

SUPERVISION:

CECCo.
Page 1 of 13

Procedure No. : MS-AM -08

cc:
Mehvarsazan

Content

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Procedure

Contr.>ct No:
AZM 01 040908

OWNER:
AZMECO
Petrochemical Co,

SUPERVISION:

CEC CO.

Page 2 of 13

Procedure No. : MS-AM -08

cc:
Mehvarsazan

Section 1

General

Content
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AZERBAIJAN

~4ETiiANOL

t'LANT I [,AKU )

QA&QCQaulity Assurance lI, Quality Conlroi

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PAGE 4

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EquipmentPressure Test

Procedure

Contract No:
AZM01040908

OWNER:
AZMECO
Petrochemical Co.

SUPERVISION:

CEC Co.

Page 3 of 13

Procedure No. : MS-AM -08

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 i~ b~ (g) t~ whic~ all. the elements of a equipment
shall be tested
".~\ ~'itHVf :;$t\i~$i?t.9\t~tre~dIcatIOn of thIS specIficatIOn.
~i:i\~~~~~~ RATING (PN):(Nominal pressure) It is the designation in bar (g) used f~r a
Q/~sel~te~tempera~ure dependence adopted for standard compo~ents. T~e n~encal
1E."'~IIJ):b.'!!:.f02Yi:ilf~d3i;}Ji,...pretsure ratmg for a standard component of the matenal mentIOned m the
st:ari.Cta.rcr,-:~v~tlJle maximum allowable working pressure in bar at 20C.

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:
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AZMECO

Petrochemical Co.

SUPERVISION:

CEC Co.

Page 4 of 13

Procedure No. : MS-AM -08

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 ofthe 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)

r1~;lJEH'/ARSAzAl*N(C~uOOlt'lID shall be issued one copy of each complete test pack


I

Aim';~~~~rnh~~M~ . 's atic testing shall be carried out. Only when indicated the drawing
Q_ ~AA srf~el.ficWr~fin d by written note from CEC, a pneumatic testing may be performed.
au I y ssur:nce & QualitY Control

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Owner: Azerbaijan Methanol Co.


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Equipment Pressure Test


Procedure

Controct No:
AZM01040908

OWNER:
AZMECO
Petrochemical Co.

SUPERVISION:

CEC Co.
Page 5 of 13

Procedure No. : MS-AM -08

cc:
Mehvarsazan

Test Packag Flow Chart

MC/TPI

Docu~nt;rtion

Test Group
(Line Prepared For
Hydro Test)

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29/11/2008

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Procedure

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Contract No:

AZM01040908

OWNER:
AZMECO
Petrochem i cal Co_

SUPERVISION:

CEC Co.
Page 6 of 13

Procedure No. : MS-AM -08

cc:
Mehvarsazan

Section 2

Flushing

6-4 FLUSHING PROCEDURE

General
Flushing of equipment shall be carried before the execution of pressure test, by
draining a liquid fluid (raw water).
During flushing equipment as pumps, strainers, valves, and etc. shall be removed
from flushing loop Procedure and acceptance criteria
Equipments shall be generally filling from highest point and drained immediately
from lowest point.
The water tank shalf be carefully cleaned out from any foreign matter before and after
flushing activities.
The water used for flushing shall be drained, until the draining water will be found
clear.
Waste inside tubes of heat exchanger should be cleaned and washed by the jet machne.

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Page 8 of 13

Procedure No. : MS-AM -08

CC:
Mehvarsazan

7.2.1.
./
./

./

7.3.

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.
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.
Testing fluids

7.3.1.

For hydrostatic 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 10 D 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
~~-7
with-ho' .
,.~:.Ho/t~:SAi:AN ENG. SCONT CO Test ressure

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~:'!#~;c&g6~uI st pressure shall be as follow: (ASME Section VIII)

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. pressure.
th e deSlgn
For a design temperature above the test temperature, the minimum test pressure
shall be as calculated by:
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,Equipment Pressure Test

Procedure

Contract No:

AZM0104090S

OWNER:
AZMECO
Petrochemical Co.

SUPERVISION:

CEC Co.

Page 9 of 13

Procedure No. : MS-AM -08

cc:
Mehvarsazan

1.5 PST
PT=

PT = Minimum hydrostatic gauge pressure.


P = Internal design gauge pressure.
ST = Allowable stress at test temperature.
S = Allowable stress at design temperature

. (See ASME B31.3 table K-1)

7.5.2. The pneumatic test pressure for components and welds shall be as follows:
For air pressure testing, the test pressure shall not be less than 1.1 times maximum
design pressure except witch is return on design documentation & ASME B31.3.
For systems being pneumatically tested, a preliminary check shall be made at a
pressure not exceeding 1.7 bar (g) (25 Psig). The pressure shall be increased
gradually in steps providing sufficient time to allow the piping to equalize strains
during testing. The pressure increasing rate shall be determined by TPI inspector.
All reinforcing pads and cormections which can not be tested during the hydro
test, shall be pressure tested (air soap) at 0.5-1.0 bar (g). All leaks detected during
the test shall repair and retested.
As pneumatic testing presents special risks due to possible release of energy
stored in the compressed gas, almost care shall be taken during pressurization and
inspection of the systems to prevent any danger to persormel or equipment and the
chances of a brittle failure equipment during testing. Precaution and procedure shall
be as laid down in paragraph 345.5 of the ANSI B31.3.
A soap solution shall be applied to all screwed, welded, and flanged joints.
Flange cormection shall be soap solution tested at the operation pressure after the
test pressure period. Welds shall be soap solution tested at 0.5-1.0 bar

Test nressure and accentance criteria


The equipment or section thereof under testing shall be slowly pressurized and the
'-2.
.~~c-.) test pressure, measured at the suitable point of evaluation, shall be applied by control
-{~?. l\.' \ armer. The duration of each pressure test shall be minimum 60 min. unless
..~ ~\6.?2!herwise specified hereinafter or in the applicable standard as mentioned above. Any
\-j, ~\FIJ; @:l,lction in the duration of test shall be approved by TPI Inspector.
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E-quipment Pressure Test


. Procedure

Contract No:
AZM0104090S

OWNER:
AZMECO
Petrochemical Co.

SUPERVISION:

CEC Co.

Page 10 of 13

Procedure No. : MS-AM -08

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.

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.

7.6.5.

Q<i:,I,iY f,ssurance

7.7

r:., Quality Control

DRYING

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Date:
29/11/2008

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Azerbaijan Methanol Plant

.,

Contract No:
AZM01040908

OWNER:
AZMECO
Petrochemical Co,

SUPERVISION:

CEC Co.
Page 11 of 13

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.

Section 4

Appendix
Form No.

Description
Flushing Inspection Report (before) Test
Gauge Calibration Report
Released format For Pressure Test of Equipment
Restament Form
Flushing inspection Report (after test)
Punch List (after test)
QC Punch List (before)
Test package cover sheet
Snad blasting Priming Inspection for Equipment
Pressure Test Report

MTC-ME-QA/QC-HT-O 1

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

No. of
Sheet
1
1
1
1
4
1

tI .,,'-,;- ()tHe'r'ffirFrlat~\1fti1l ecessary will be submitted accordingly


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MC: Caspian Engineering Co.

Date:
29/11/2008
Rev.: 0

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Owner: Azerbaijan Methanol Co.


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Equipment Pressure Test


Procedure

Contract No:
AZM01040908

OWNER:
AZMECO
Petrochemical Co.

SUPERVISION:

CEC Co.

Page 12 of 13

Procedure No. : MS-AM -08

cc:
Mehvarsazan

ATTACHMENT 1
NOTE:
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.

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ENG. &CONT. CO

-'v'('.;r,AI.. AN t,4f.TdN\OL PLANT I (iAKU )

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Date:
29/11/2008
Rev.: 0

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Contract No:
AZM01040908

OWNER:
AZMECO
I

Petrochemical Co,

SUPERVISION:

CEC Co.
Page 13 of 13

Procedure No. : MS-AM -08

cc:
Mehvarsazan

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