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BP OIL TOLEDO REFINERY Area Procedure No Certified by kjv18696

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									                              BP OIL -- TOLEDO REFINERY

                             Area:                                               Procedure No.:
        Certified                            Refinery Wide                       MAINT 005

Effective Date:                                                                  Rev. No.: 1
December 2006                               Pressure Testing

Written By:                  Auth. By: D.J. Powell                               Page 1 of 5
D. Criss/K. Dages                        (signature on file)



                                           This procedure is written for the following reasons:
                                               1) To ensure uniform practices for pressure testing of
               SCOPE                               pressure-containing piping and equipment..
                                               2) To prevent damage to piping systems and equipment.
                                               3) To highlight potential hazards associated with pressure
                                                   testing.
                                           This procedure defines general requirements and limitations
                                           for pressure testing. This procedure references and identifies
                                           other plant procedures and specifications which provide more
                                           specific information and requirements associated with
                                           pressure testing.

                                           The primary potential hazards associated with pressure
              HEALTH                       testing are injury resulting from rupture of the tested
                                           component and expulsion of repair plugs during heat
  Special PPE & Special Hazards            exchanger testing.

                                           Adherence to the following procedure will limit the risks
                                           associated with the following:
   SAFETY & Environmental                     1) Rupture / failure of tested components.
                                              2) Environmental and personnel exposure due to breach
                                                  of piping and equipment pressure boundaries.
                                           MIT01.014 – BP Oil Toledo Refinery “QC Manual for
                                                         Fabrication and Installation of Piping Systems”
           REFERENCE                       MIT01.012 – BP Oil Toledo Refinery “Piping QC
           DOCUMENTS                                     Requirements for Contractors”
                                           RP 5-5-3 – Piping Erection and Testing
                                           ASME / ANSI B 31.3 Petroleum Refinery Piping
                                           ASME / ANSI B 31.1 Power piping.
                                           API 570
                                           ASME Section VIII, Boiler and Pressure Vessel Code
    SPECIAL MATERIALS &
        EQUIPMENT                          N/A

                                           Failure to comply with this procedure could affect the resulting
                                           quality or integrity of the installed, repaired or re-assembled
             QUALITY                       component or system.

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                                                                   Procedure No. MAINT 005 Rev. No. 1



1.0    General                1.1     All new piping and equipment shall be pressure tested before
                                        placing in service. Existing process piping and equipment shall be
                                        pressure tested after making modifications or repairs. Proposed
                                        exceptions will require written requests to BP‟s inspection
                                        department including a proposed alternate procedure.

                              1.2     Prior to testing, the system shall be properly isolated. The preferred
                                        isolation method is to install pressure-rated blanks or blind flanges.


                                                                       CAUTION
                                        Failure to properly isolate the entire test system could result in over-
                                        pressurization of, and damage to piping and equipment. This is
                                        particularly important during pneumatic testing.


                              __1.3     Before applying pressure, the test equipment shall be inspected to
                                        see that connections are tight, and that all low pressure filling lines
                                        and other appurtenances not subjected to the test pressure have
                                        been disconnected.

                              __1.4     A reliable and calibrated gauge is required for pressure testing.
                                        Gauge requirements are specified in Attachment „C‟ of BP
                                        Procedure MIT01.014.

                              __1.5     Vents are to be used to ensure proper air purge of high points.
                                        Ensure water comes out of the vent before closing to verify the vent
                                        is not plugged.

                              __1.6    After a hydrostatic test, it is essential that all water be drained from
                                       the piping and equipment. All vents are to be opened prior to
                                       withdrawal of the tesing medium to ensure a vacuum is not drawn.
                                       The testing medium shall be drained at a rate that does not exceed
                                       the in flow of air through the vent. Special precautions are also
                                       required after testing fractionating equipment containing trays.

                              __1.7     Where possible, entire systems shall be tested; however, shop
                                        tests are allowed if more economical. Flanges parted for isolation /
                                        blinding do not require a separate pressure test once re-assembled.
                                        A clean / new gasket shall be installed at every flanged joint parted
                                        during the hydrotest.

                              __1.8    It can be hazardous to use gases and vapors as a testing medium
                                        because of the large amount of energy released when failure
                                        occurs. Such testing (pneumatic testing) will normally not be done
                                        if the required test pressure exceeds 100 psi. Exceptions to the rule
                                        will be made only with the approval of the Safety Department and
                                        the Reliability / Maintenance Department. When pneumatic testing
                                        is done, the test area shall be cordoned off and only those people
                                        necessary for the test should be in the testing area. A preliminary
                                        test not to exceed 25 psig shall be made before proceeding
                                        gradually in steps to the full test pressure. When exchangers are
                                        tested pneumatically, care is required when leaking tubes have
                                        been plugged. Serious injury can result if plugs become loose
                                                                                               Page 2 of 5
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                                                                    Procedure No. MAINT 005 Rev. No. 1


                                         during testing. Testing of exchangers, or any equipment completely
                                         filled with water and pressurized with air is not defined as pneumatic
                                         testing. The rules in this paragraph do not apply to the testing of
                                         safety and relief valves and other valves. However, when valves
                                         tested are subjected to the hazards involved, care should be taken
                                         to firmly attach the valves to the test bench. A check should be
                                         made for any loose parts such as plugs or caps.



                                       NOTE: If nitrogen is to be used for testing, the PSM standard for safe
                                             nitrogen usage shall be adhered to . (http://txc-
                                             safetynet.bpweb.bp.com/Process.Safety.Standards/PSS_18_
                                             Nitrogen/PSS_No_18.0.doc


                              __1.9     Compressors, turbines and instruments not capable of withstanding
                                        the test pressure shall not be field pressure tested and should be
                                        blinded or valved off from the tests.

                              __1.10      Except for tightness or service tests, relief or safety valves shall be
                                         removed or blinded upstream and are not to be gagged. Rupture
                                         disks shall be removed during the test.

                              __1.11     When testing tall piping or equipment, the pressure guage shall be
                                         at the bottom of the item, or the readings may be made at higher
                                         points provided the static head between the bottom point of
                                         measurement is subtracted from the specified pressure.

                              __1.12     Pressure testing of expansion joints requires an Engineering review
                                         to determine requirements for restraint or isolation.

                              __1.13     Control valves shall be removed or blinded from piping during
                                         pressure testing and line flushing to protect the valves from dirt,
                                         scale or other foreign objects.

                              __1.14     Where testing is carried out against closed valves, it must be
                                         assumed that the valves leak, and downstream equipment must be
                                         protected against subsequent overpressurization. This should be
                                         done by installing pressure-rated blanks, opening of suitable vents
                                         or by frequent monitoring of downstream pressures.

                              __1.15     Care should be taken to ensure that all pressure has been relieved
                                         before opening any system that has been the subject of a pressure /
                                         leak test.

                              __1.16     Pipe and equipment may be painted before testing. Pieces that
                                         have been previously shop tested may be insulated if included in a
                                         subsequent system test.




                                                                                                  Page 3 of 5
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                                                                  Procedure No. MAINT 005 Rev. No. 1


2.0    Equipment              __2.1    In general, exchangers and boilers will be „tightness‟ or leak tested
                                        after each inspection interval. This is to verify the system has been
                                        re-assembled correctly, that no tube leaks exist and that all flanged
                                        joints are sealing prior to returning the equipment to service.
                                        Tightness pressure tests will normally be at 1.5 times the operating
                                        pressure, but should never exceed 1.1 times the design pressure or
                                        MAWP.


                                                                       CAUTION
                                        During pressure testing of heat exchanger equipment with plugged
                                        tube repais, placement and protection of personnel must consider
                                        the possibility of tube plug blowout / expulsion.


                              __2.2    Alterations or major repairs to vessels, exchangers and boilers will
                                       normally be tested at 1.5 times the design pressure. For vessels
                                       designed or rerated using the design stress in the 1999 addendum
                                       or later of ASME Section VIII, 1.3 times the design pressure is
                                       appropriate for a pressure test.

                              __2.3    Field pressure testing of new equipment or after a major repair or
                                       alteration to existing equipment shall be reviewed on a case-by-
                                       case basis. A testing procedure shall be developed by the
                                       performing contractor or responsible BP representative for approval
                                       by BP Inspection and Engineering (as appropriate). For alterations,
                                       consideration should given to methods for testing of the altered
                                       component only (not the entire equipment). Consideration should
                                       also be given to the design of support structures during the review
                                       process.

                              __2.4    Pressure tests shall be applied to all new pressure vessel reinforcing
                                       pads through tapped tell-tale holes. The re-pad will be tested with
                                       air at 15 psi.

                              __2.5    For pressure vessels, tanks and other equipment, It is necessary
                                                                                                    o
                                       that the testing medium and the vessel metal be at least 60 prior to
                                       application of pressure. Special precautions, therefore, will be
                                       required out of doors during cold weather.

                              __2.6    Water containing chlorides can cause cracking of austenitic
                                       stainless steel. The chloride content of the testing medium shall be
                                       less than 50ppm.

3.0    Piping                 __3.1    Requirements for pressure testing of piping are detailed in BP Oil
                                       Toledo Refinery Inspection procedures MIT01.014 (QC Manual for
                                       Fabrication and Installation of Piping Systems) and MIT01.012 (QC
                                       Requirements for Contractors), and in BP RP 5-5-3 (Piping Erection
                                       and Testing). Specifically, they are contained in Attachment “B” of
                                       MIT01.014 and Attachment #3 of MIT01.012 respectively and
                                       Section 6 of RP 5-3-3.

                              __3.2    Hydrostatic testing is normally required for fabricated piping.
                                       Specific requirements are in Appendix #1 of MIT01.014 and
                                       MIT01.012 and Section 6.0 of RP 5-3-3.
                                                                                              Page 4 of 5
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                                                                Procedure No. MAINT 005 Rev. No. 1



                              __3.3    The option of pneumatic testing of piping systems is available
                                       under certain circumstances. Requirements are detailed in
                                       Appendix #2 of MIT01.014 and MIT01.012 and Section 6.7 of RP 5-
                                       3-3.

                              __3.4    A service test may also be substituted for a hydrostatic or
                                       pneumatic test in certain services. These are normally limited to
                                       plant air, water, condensate, low and medium pressure steam, plant
                                       nitrogen, instrument air and some catalyst handling lines. These
                                       requirements are also discussed in MIT01.014 and MIT01.012




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