ITP 01 : PRESSURE TEST

INSPECTION AND TEST TECNICAL INSTRUCTION.

M.S.M. ALVA, S.L.

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ITP 01: PRESSURE TEST

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1.- OBJECT

The object of this Technical Instruction is to define the way to perform a Pressure Test to vessels designed for internal pressure; this test will be required for post-fabrication, alteration and repairs prior to the stamp being applied. A Pressure Test is performed to determine the integrity of the container and related components; it will expose leaks at flanged connections and at welded and/or brazed joints. The most desirable pressure test is a Hydrostatic Test where the vessel is filled with a liquid and pressurized in excess of its maximum allowable working pressure. The hydrostatic test must be conducted after the vessel has been completed. It is noted that no welding shall de done on a vessel after the hydrostatic vessel. Another option of pressure test is a Pneumatic Test; the code provides requirements for the vessels that can be prove by a Pneumatic Test.

2. SCOPE

2.1 - All completed pressure vessels must be subjected to a pressure test. 2.2 Manufacturer responsibility: - To provide qualified personnel to perform the test. - To provide the technical and mechanical meanings needed to perform the Pressure Test (this will include test gages, pumps, air compressor, gaskets, temporary accessories, and every other meaning needed for the Pressure Test). To assembly and dismantle all the items, included temporary inletoutlet to fill and drain the vessel, needed to perform the Pressure Test. - To notify in advance to the Authorized Inspector when the Pressure Test is going to take place. - To perform the Pressure Test. - To prepare a final Pressure Test Report.

Prepared by:

Reviewed by:

Approved by:

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2.3 User responsibility: - To supply water and/or other non hazard fluids for the Pressure Test when this in particularly is indicated in the contractual conditions specified in the agreement between user and manufacturer.

3. - REFERENCE CODE

2010 ASME BOILER & PRESSURE VESSEL CODE, 2011 ADENDA. SECTION VIII, DIVISION 1, RULES FOR CONSTUCTION OF PRESSURE VESSELS. SUBSECTION A GENERAL REQUIREMENTS: PART UG GENERAL REQUIREMENTS FOR ALL METHODS OF CONSTRUCTION AND ALL MATERIALS. INSPECTION AND TEST (UG-99, UG-100, UG102).

4. DEFINITIONS

Pressure Vessel: a relatively high-volume pressure component (such as a spherical or cylindrical container) with a cross section larger than the associated piping.

Design Pressure: the pressure used in the design of a vessel component together with the coincident design metal temperature, for the purpose of determining the minimum permissible thickness or physical characteristics of the different zones of a vessel. When applicable, static head shall be added to the design pressure to determine the thickness of any specific zone of the vessel.

Maximum Allowable Working Pressure (MAWP): the maximum gauge pressure permissible at the top of a completed vessel in its operating position at the designated coincident temperature for that pressure. The MAWP of a vessel maybe determined by using the thickness provided for fabrication, not including any allowance for corrosion, to determine the allowable pressure. It is often more convenient to arbitrarily let the MAWP of the vessel be equal to de Design Pressure, and not conduct the calculations to determine the actual MAWP. The definition of the MAWP from Appendix 3, ASME Section VIII Div. 1 Ed. 2010,

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5. HYDROSTATIC TEST.

The most desirable pressure test is a Hydrostatic Test where the vessel is filled with a liquid and pressurized in excess of its maximum allowable working pressure. The hydrostatic test must be conducted after the vessel has been completed, except for operations which could not be performed prior to the test such as weld end preparation, cosmetic grinding on the base material which does not affect the required thickness. And all examinations have been performed, except those required after the test.

5.1 Hydrostatic Test Pressure. The completed vessels designed for internal pressure shall have satisfactorily passed the hydrostatic test pressure, which at every point in the vessel is at least equal to 1.3 times the MAWP multiplied by the Lowest Stress Ratio for the materials of which the vessel is constructed; this is the minimum test pressure that may be used. (Paragraph UG-99 (b))

Ptest = 1.3 MAWP(Sa / S)min. Where: Ptest: minimum required Hydrostatic Test Pressure. (Sa / S)min: Lowest Stress Ratio (LRS).The smallest ratio of the allowable stress at test temperature to the allowable stress at design temperature for all the materials used in the vessel. It is noted that it is the smallest value for the materials used for pressure containment in the vessel.

Paragraph UG-99 (b) provides the minimum test pressure that may be used, and UG-99 (c) provides an optional basis; however, the code does not specify a maximum pressure to which a vessel can be hydrostatically tested. If the vessel experiences visible permanent deformation as a result of the pressure test, the Inspector has the right to reject the vessel. This, in effect, defines the upper limit on hydrostatic test pressure. The test pressure should not be so large as to result in visible permanent deformation anywhere in the vessel.

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5.2 Preparation of a Hydrostatic Test Pressure.

a) None vessel may be painted or coated either internally or externally prior to pressure test, so there will not be leaks masked that would be otherwise have been detected during the pressure test. b) The hydrostatic test must be conducted after the vessel has been completed, except for operations which could not be performed prior to the test such as weld end preparation, cosmetic grinding on the base material which does not affect the required thickness. c) Before applying pressure, the test equipment shall be examined to see that it is tight and that all low-pressure filling lines and other appurtenances that should not be subjected to the test pressure have been disconnected, also all other vessel nozzles and connections must be closed of with test blinds or plugs, the nozzles on the upper part of the vessel, in the position is set to be tested, will be the last ones to be closed, because they will be used to vent the equipment while it is filling. d) Two indicating gauges shall be connected directly to the vessel or with a pressure line that does not include intermediate valves. The indicating gauges will be visible at all times to the AI and to the operator in charge of the test. d.1 The dial range of the gauges used for the final hydrostatic testing shall be as specified in paragraph UG-102(b) (i.e. gauges shall have dials graduated not over a range of four times the test pressure but in no case shall the range be less than 1.1/2 times that pressure) d.2 - The test gauges should have current calibration stickers, with the last date of calibration. d.3 The test gauges shall be calibrated against a calibrated master gauge at any time there is reason to believe they are in error. d.4 Before and after any pressure test the test gauges chosen to be used will be tested against a calibrated master gauge, to find out if there is any error. d.5 Every time that is possible one of the gauges should be on the higher part of the vessel to be tested. d.6 Like other measuring equipment the gauges shall have assigned a serial number.

e) All the examination should have been performed, except those required after the test, this will be indicated in the Inspection Points Plant (PPI). f) There will be designated a testing area where the pressure test will take place, this area should be restricted, and only will be allowed the workers necessary to perform the test. As

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good practice the vessel should be oriented so that bolts, flanges, and other possible missiles point away from people and other equipment.

g) Any no-hazardous liquid may be used for the hydrostatic test medium if the test temperature is below its boiling point. Hydrostatic test on some pressure system materials, such as stainless steel, should only be preformed with liquid that has been specified its chemical composition and temperature. h) It is recommended that the metal temperature of the vessel should be sufficiently warm to preclude the possibility of brittle fracture. The metal temperature should be maintained at 17C above the minimum design metal temperature, but need not exceed 48C, to minimize the risk of brittle fracture, and to avoid the possibility of burns from potential leaks.

5.3 Performance of Test Pressure.

i)

Once the vessel it is full of liquid and it has been vented, then the vents should be closed, before applying pressure the vessel must be checked again to prevent leaks.

j)

Pressurize the vessel, raising the pressure in the vessel gradually until the designated test pressure is achieved. Once the test pressure is reached, it will be hold for ten minutes, and then the pressure shall be reduced to a value not less than the test pressure divided by 1.3, the pressure will be hold enough time to permit the inspection of the vessel, in that time it must be checked every flanged connections and all welded and/or brazed joints, it should be performed a full and thorough inspection for leaks. If there are any leaks at welded joints the test would be considered fail. If the vessel is subjected to visible permanent distortion, the AI shall reserve the right to reject the vessel.

k) The AI will decide when the pressure test of the vessel has to be decrease, and how, the velocity of the decrease. First the vents should be opened, and they will be maintained like that until all the liquid is drained to avoid vacuum in the vessel, then the drains will be opened to let the vessel be completely empty of liquid.

5.4 End of Test Pressure.

l)

All the plugs and blinds connected to the nozzles for the pressure test should be removed, and all appurtenances removed before the pressure test should put in place again.

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m) Once the vessel it is completely drained, if there is any remain of liquid, it should be dried or blown away, to prevent damages caused from freezing. n) A Hydrostatic Test Pressure Record should be made (Exhibit number ITP-01/01), in order to validate the pressure test, this record must have the following information: n.1 - Identification of the vessel. n.2 Location of the vessel. n.3 MAWP of the vessel. n.4 Test Pressure. n.5 Date and time when the Test started. n.6 Date and time when the Test was completed or failed. n.7 Test liquid. n.8 External temperature. n.9 Temperature of test liquid. n.10 Organization conducting the test. n.11 People witnessing the test and their organization. n.12 Identification number of the gauges used.

6. PNEUMATIC TEST. There are pressure vessels where a Hydrostatic Test is not desired because the nature of the service or because of the nature of the design. This may include vessels in a service where the test liquid can contaminate the process or where it is impracticable to design the vessel such that it can be supported with the weight of the test liquid. For such instances, the Manufacturer may conduct a Pneumatic Test. Any decision to conduct a Pneumatic Test requires very careful consideration because the stored energy of a compressible fluid is considerably greater than when a liquid is used. In the unlikely event when a component fails during the Pressure Test, extensive damage may occur to the vessel and its surroundings.

6.1 Pneumatic Test Pressure. The completed vessels designed for internal pressure shall have satisfactorily passed the Pneumatic test pressure, which at every point in the vessel is at least equal to 1.1 times the MAWP multiplied by the Lowest Stress Ratio for the materials of which the vessel is constructed; this is the minimum test pressure that may be used.

Ptest = 1.1 MAWP(Sa / S)min. Where: Ptest: minimum required Pneumatic Test Pressure.

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(Sa / S)min: Lowest Stress Ratio (LRS).The smallest ratio of the allowable stress at test temperature to the allowable stress at design temperature for all the materials used in the vessel. It is noted that it is the smallest value for the materials used for pressure containment in the vessel.

6.2 Preparation of a Pneumatic Test Pressure.

a) None vessel may be painted or coated either internally or externally prior to pressure test, so there will not be leaks masked that would be otherwise have been detected during the pressure test. b) The Pneumatic Test must be conducted after the vessel has been completed, except for operations which could not be performed prior to the test such as weld end preparation, cosmetic grinding on the base material which does not affect the required thickness. c) Before applying pressure, the test equipment shall be examined to see that it is tight and that all low-pressure filling lines and other appurtenances that should not be subjected to the test pressure have been disconnected, also all other vessel nozzles and connections must be closed of with test blinds or plugs. d) Two indicating gauges shall be connected directly to the vessel or with a pressure line that does not include intermediate valves. The indicating gauges will be visible at all times to the AI and to the operator in charge of the test. d.1 The dial range of the gauges used for the final hydrostatic testing shall be as specified in paragraph UG-102(b) (i.e. gauges shall have dials graduated not over a range of four times the test pressure but in no case shall the range be less than 1.1/2 times that pressure) d.2 - The test gauges should have current calibration stickers, with the last date of calibration. d.3 The test gauges shall be calibrated against a calibrated master gauge at any time there is reason to believe they are in error. d.4 Before and after any pressure test the test gauges chosen to be used will be tested against a calibrated master gauge, to find out if there is any error. d.5 Every time that is possible one of the gauges should be on the higher part of the vessel to be tested. d.6 Like other measuring equipment the gauges shall have assigned a serial number. e) All the examination should have been performed, except those required after the test, this will be indicated in the Inspection Points Plant (PPI). Before a Pneumatic Test the full length of the following welds shall be examined, by magnetic particle or liquid penetrant methods when the

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material is ferromagnetic, or by the liquid penetrant method when the material is nonmagnetic; for the purpose of detecting cracks: e.1 All welds around openings. e.2 All attachment welds, including welds attaching non-pressure parts to pressure parts, having a throat thickness greater than in. (6 mm). f) There will be designated a testing area where the pressure test will take place, this area should be restricted, and only will be allowed the workers necessary to perform the test. As good practice the vessel should be oriented so that bolts, flanges, and other possible missiles point away from people and other equipment. g) The metal temperature should be maintained at 17C above the minimum design metal temperature to minimize the risk of brittle fracture.

6.3 Performance of Test Pressure.

h) Pressurize the vessel; the pressure in the vessel shall be gradually increased to not more than one-half of the test pressure. Thereafter, the test pressure shall be increased in steps of approximately one-tenth of the test pressure until the required test pressure has been reached. i) Once the test pressure is reached, it will be hold for ten minutes, and then the pressure shall be reduced to a value not less than the test pressure divided by 1.1, the pressure will be hold enough time to permit the inspection of the vessel, in that time it must be checked every flanged connections and all welded and/or brazed joints, it should be performed a full and thorough inspection for leaks. If there are any leaks at welded joints the test would be considered fail. If the vessel is subjected to visible permanent distortion, the AI shall reserve the right to reject the vessel. j) The AI will decide when the pressure test of the vessel has to be decrease, and how, the velocity of the decrease.

6.4 End of Test Pressure.

k) All the plugs and blinds connected to the nozzles for the pressure test should be removed, and all appurtenances removed before the pressure test should put in place again.

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l)

A Pneumatic Test Pressure Record should be made (Exhibit number ITP-01/02), in order to validate the pressure test, this record must have the following information: l.1 - Identification of the vessel. l.2 Location of the vessel. l.3 MAWP of the vessel. l.4 Test Pressure. l.5 Date and time when the Test started. l.6 Date and time when the Test was completed or failed. l.7 Test liquid. l.8 External temperature. l.9 Organization conducting the test. l.10 People witnessing the test and their organization. l.11 Identification number of the gauges used.

7. FILE DOCUMENTS.

MSM ALVA will be responsible of file all the reports related to the Pressure Tests.

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ANNEX 1:

A Hydrostatic Test Pressure Record should be made (Exhibit number ITP-01/01). A Pneumatic Test Pressure Record should be made (Exhibit number ITP-01/02)

Hydrostatic Test Pressure Record should be made (Exhibit number ITP-01/01). Rev.: 0

HYDROSTATIC TEST PRESSURE REPORT

Test Start Date/Time: Customer: Test End Date/Time:

Vessel Number: Manufacturer: Production N: Place of Test Pressure: Drawing Number: Material Specification and Type/Grade Number: Manufacturer Ref: Production Year:

Design and Test Conditions

Design Pressure: MAWP: External Temperature: Design Temperature: Test Pressure: Fluid Temperature: Design Fluid: Test Fluid:

El equipo con los datos de identificacin y condiciones de diseo arriba referenciados, se ha sometido a una prueba de presin en las condiciones siguientes:

Test Conditions Vessel N Ptest (bar g) Temperature (C)

Length of Time (minutes)

Gauges Result ID N Range

People witnessing the test and their organization. Manufacturer: V B. M.S.M. ALVA S.L. Authorised Inspector: V B. User: V B.

Sign/Date:__________

Sign/Date:__________

Sign/Date:__________

Pneumatic Test Pressure Record should be made (Exhibit number ITP-01/02). Rev.: 0

PNEUMATIC TEST PRESSURE REPORT

Test Start Date/Time: Customer: Test End Date/Time:

Vessel Number: Manufacturer: Production N: Place of Test Pressure: Drawing Number: Material Specification and Type/Grade Number: Manufacturer Ref: Production Year:

Design and Test Conditions

Design Pressure: MAWP: External Temperature: Design Temperature: Test Pressure: Fluid Temperature: Design Fluid: Test Fluid:

El equipo con los datos de identificacin y condiciones de diseo arriba referenciados, se ha sometido a una prueba de presin en las condiciones siguientes:

Test Conditions Vessel N Ptest (bar g) Temperature (C)

Length of Time (minutes)

Gauges Result ID N Range

People witnessing the test and their organization. Manufacturer: V B. M.S.M. ALVA S.L. Authorised Inspector: V B. User: V B.

Sign/Date:__________

Sign/Date:__________

Sign/Date:__________