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PROJECT PROCEDURE

PIPING FIELD PRESSURE TESTING


CONTRACTOR IDENTIFICATION CODE
3583-XH-SG-P300002
POLYOLEFINS UNIT
BOROUGE 3 PROJECT RUWAIS, U.A.E.
Sheet 2 of 14 Rev Q

Abu Dhabi Polymers Company Limited (Borouge)

BOROUGE IDENTIFICATION CODE
P3-LU-586-00002

THIS DOCUMENT IS BOROUGES PROPERTY AND CANNOT BE USED BY
OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
3583-XH-SG-P300002 Rev.Q
Hydrotest

TABLE OF CONTENTS

1 SCOPE ...................................................................................................................................... 3
2 APPLICATION .......................................................................................................................... 3
3 GENERAL ................................................................................................................................. 3
4 TEST METHOD ......................................................................................................................... 4
5 TEST MEDIA ............................................................................................................................. 4
6 SYSTEM PRESSURE TEST PACKAGE .................................................................................. 5
7 TEST PREPARATION .............................................................................................................. 6
8 TEST PROCEDURE ................................................................................................................. 7
9 DE-PRESSURIZATION AND CLEANING ................................................................................. 9
10 PRESSURE TEST RECORDS ............................................................................................ 10
11 ACCESSORIES AND TOOLS ............................................................................................. 10
12 TEST COMPLETION ........................................................................................................... 11


APPENDICES

ATTACHMENT 1 - STATUS OF INSTRUMENTS DURING PRESSURE TEST.

ATTACHMENT 2 - SCHEDULE OF MAXIMUM ALLOWABLE HYDROSTATIC TEST PRESSURE
(BAR G) FOR THE LISTED TEST BLIND THICKNESSES.

ATTACHMENT 3 - TABLE FOR JACKETED LINES: TEST PRESSURES, REQUIREMENTS FOR
COUNTER PRESSURIZATION AND PRESSURE EQUALIZING. (HOLD)

















PROJECT PROCEDURE
PIPING FIELD PRESSURE TESTING
CONTRACTOR IDENTIFICATION CODE
3583-XH-SG-P300002
POLYOLEFINS UNIT
BOROUGE 3 PROJECT RUWAIS, U.A.E.
Sheet 3 of 14 Rev Q

Abu Dhabi Polymers Company Limited (Borouge)

BOROUGE IDENTIFICATION CODE
P3-LU-586-00002

THIS DOCUMENT IS BOROUGES PROPERTY AND CANNOT BE USED BY
OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
3583-XH-SG-P300002 Rev.Q
Hydrotest


1 SCOPE
This specification defines the requirements and procedures for Steel Piping field pressure
testing of aboveground and underground pressure piping systems for Borouge 3
Petrochemicals Project.

2 APPLICATION
This specification shall apply to all process and utility piping on the project, with the following
exceptions:

- Firewater distribution system which shall be tested in accordance with NFPA 13, 15 and 24
- Any package unit previously tested by the Manufacturer in accordance with the applicable
codes.
- Atmospheric sewers
- Instrument piping lead lines (between the root valve at the process or utility line and the
connected instrument) and piping for pneumatic or hydraulic control apparatus
- Pressure vessels, heat exchangers, pumps, turbines, compressors and blowers
including vessel internal piping and relevant connections.
- In case of plastic pipes this specification is to be considered as applicable. In particular
the pressure values indicated in the line list are given for the standard water/ambient
temperature (i.e. +20
O
C). If water/ambient temperature on site different from the above
standard value, the pressure values have to be checked with TSJ Head office before testing.
3 GENERAL
The testing of piping systems shall be performed in compliance with ASME B31.3, chapter
VI, except where differently stated in the present specification or on the isometric and piping
assembly drawings.
The Mechanical CONTRACTOR shall perform all the activities here described.
After the approval of Test Package content, Contractor (read TSJ)) shall notify the date of
test to the Owner.
The Owner participation to the pressure test shall be as per indication given on the approved
Site Inspection Plan for Piping Works.
The original documentation shall be under the custody of Subcontractor Contractor QA
QC Offices till the time of the official submission of Site Construction Final Dossier.


PROJECT PROCEDURE
PIPING FIELD PRESSURE TESTING
CONTRACTOR IDENTIFICATION CODE
3583-XH-SG-P300002
POLYOLEFINS UNIT
BOROUGE 3 PROJECT RUWAIS, U.A.E.
Sheet 4 of 14 Rev Q

Abu Dhabi Polymers Company Limited (Borouge)

BOROUGE IDENTIFICATION CODE
P3-LU-586-00002

THIS DOCUMENT IS BOROUGES PROPERTY AND CANNOT BE USED BY
OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
3583-XH-SG-P300002 Rev.Q
Hydrotest

3.1 REFERENCE DOCUMENTS
Piping Design and Layout General Specification 3583-XH-SG-P300006
Line List 3583-XH-LL-P300001 (Hold)
Piping Fabrication and Erection General Specification 3583-XH-SG-P360001
Site inspection & Certification Coordination Procedure 3583-LZ-PC-P300006
Piping Test Pack Management Procedure 3583-XH-SG-P300002
4 TEST METHOD
The pressure test shall be either hydraulic or pneumatic as shown on the Line List and on
the piping isometric. When the hydrostatic test is impracticable, such as when the outside
temperature is below +4C, it can be substituted fo r pneumatic test only under permission in
writing from COMPANY. In case of pneumatic test the test pressure shall not exceed 110 %
of design pressure.
5 TEST MEDIA
5.1 Hydrostatic test:
Except when differently stated in the Line List, the hydrostatic test medium shall be fresh
water, clean and free from suspended solids and other foreign matter. Suitable provision
must be made to prevent freezing, e.g. adding glycol to the test fluid. Else switch to
pneumatic test at 110% design pressure.
For lines that are internally sandblasted or pickled the test water shall be added with 0.5% by
weight with sodium nitrite to inhibit rust. After piping has been tested it shall be drained and
blown dry with air, and a powered corrosion inhibitor (i.e. VPI No. 260) SHALL BE BLOWN in
at the rate of at least 106 grams per cubic meter of internal volume. The system shall be
immediately flanged up and ready for plant start-up. Note: Verify that VPI No. 260 is not
objectionable in the process stream.
The allowable chloride content of the water depends on the pipe material, as detailed in the
following subparagraphs.
For those lines where the Line List requires hydrostatic testing with oil (e.g. teal, donor, oil
and grease circuits etc.), white mineral oil shall be used.
The use of test liquids other than those above specified shall be submitted to TSJs
approval.
5.1.1 Carbon Steel and Low-Temperature Carbon Steel (LTCS)
For piping in Carbon and Low-Alloy Steel the hydrostatic test can be made with
drinking, brakish or salt water as available. If drinking water is not used, the test
water shall be fully drained and the equipment flushed with drinking water
immediately after testing and thoroughly dried with hot air or steam.
5.1.2 Austenitic Stainless Steel
The concentration of the chlorides after evaporation of hydro-test water
remaining in the piping system may create pitting or stress corrosion cracking of
the pipe near the welds. Therefore hydro-test water shall be fully drained and/or
flushed from the system.
Water shall be free from sediments or undissolved solids of any type.


PROJECT PROCEDURE
PIPING FIELD PRESSURE TESTING
CONTRACTOR IDENTIFICATION CODE
3583-XH-SG-P300002
POLYOLEFINS UNIT
BOROUGE 3 PROJECT RUWAIS, U.A.E.
Sheet 5 of 14 Rev Q

Abu Dhabi Polymers Company Limited (Borouge)

BOROUGE IDENTIFICATION CODE
P3-LU-586-00002

THIS DOCUMENT IS BOROUGES PROPERTY AND CANNOT BE USED BY
OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
3583-XH-SG-P300002 Rev.Q
Hydrotest

If the pipe metal temperature exceeds 50C during t he commissioning, operation
or non-operation, the piping is flushed with condensate or demineralised water
immediately after test and water can be fully drained and completely removed
immediately after testing, (e.g. mopping up) hydro test water containing up to 20
mm/kg / 20 Parts Per Million or less (PPM) may be used for the pressure test.
If the pipe metal temperature exceeds 50C during t he commissioning, operation
or non-operation, and proper drainage is not possible (i.e. low points in vendor
piping that was not provided with a drain), the recommended practise is to utilize
water containing less than 1 mg/kg chlorides, i.e. condensate or demineralised
water.
Do not dry the system blowing with hot air or any other gas, unless it has been
tested or properly flushed with condensate or demineralised water.
When hydro test involves the jacket pipe of jacketed line, both the core and jacket materials
have to be taken into consideration, and the most severe requirements above mentioned
shall be complied with.

5.2 Pneumatic Test
Pneumatic tests shall be made using dry and clean air (maximum dew point 20C at
operating pressure) such as utility air or nitrogen. In case of pneumatic test the test pressure
shall be as per the line list and isometrics but in any case it shall not be exceed 110 % of
design pressure.
6 SYSTEM PRESSURE TEST PACKAGE
In order to reduce the number of tests, system test pressure packages are defined for each
test system; they are shown on a pressure test diagram based on the piping and instrument
diagrams showing the extent of pipe-work to be included in each test. The scope of each
separate test shall be the maximum practicable, considering adequate pressure relief
protection, compatibility with the supporting steel structures and availability of test fluid.
The extent of test systems shall be such that the static head of the test medium does not
create a pressure greater than the allowable test pressure. The maximum system test
pressure shall not exceed the pressure test rating of any piping component included in the
system.


PROJECT PROCEDURE
PIPING FIELD PRESSURE TESTING
CONTRACTOR IDENTIFICATION CODE
3583-XH-SG-P300002
POLYOLEFINS UNIT
BOROUGE 3 PROJECT RUWAIS, U.A.E.
Sheet 6 of 14 Rev Q

Abu Dhabi Polymers Company Limited (Borouge)

BOROUGE IDENTIFICATION CODE
P3-LU-586-00002

THIS DOCUMENT IS BOROUGES PROPERTY AND CANNOT BE USED BY
OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
3583-XH-SG-P300002 Rev.Q
Hydrotest


The diagrams shall show:
- Test type and pressure
- Test fluid inlet
- Position of pressure gauges
- Vents and drains
- All in-line components, which are to be replaced with temporary spools
- The internals that must be removed for the execution of the test
- Temporary blind spades or blanks
The location of temporary supports shall be defined in field and shown on the piping
isometric. The lines and systems that for process reasons cannot be provided with vents and
drains shall be tested at ground.
7 TEST PREPARATION
Prior to the execution of the pressure test the Mechanical SUBCONTRACTOR shall prepare
piping for inspection according to the following guidelines:
- Piping systems shall be completely checked through Punch List and the Punch List
Record is approved
- All lines shall be checked to ensure the entire system can be drained after the test
- Vents and other high point connections shall be opened to eliminate air from lines subject
to hydrostatic test
- In principle all joints not previously tested, including welds, shall be left unpainted,
uninsulated, and exposed for examination during the test. Only Fluid service category M
carbon steel piping classes can be tested with primer applied.
- The system shall be provided with suitable relief valves to contain the system at no more
than 10% above the specified test pressure
- The test pressure gauge shall be located at the high point of the system. One additional
gauge shall be located at the low point to check that static head pressure due to vertical legs
does not over pressure part of the system
- The system shall be properly supported. In particular piping designed for vapour or gas
shall be provided with additional temporary supports, if necessary, to withstand the weight of
the test liquid. Temporary supports shall be identified with a bright red paint strip and
removed after the test.
- Spring supports shall be locked in position for the test using the pre-set pins or plates or by
blocking the spring
- Orifice plates and restriction orifices that interfere with the filling, venting, or draining of the
lines shall be removed; transmitters directly connected to orifice flanges must be
disconnected when replacing the orifice plates to avoid distorting the connections
- The items that shall not be tested in accordance with this specification shall be isolated or
removed and replaced with temporary spools or spacers, following the requirements in
Attachment 1.
- Valves shall not be used to isolate a test system
- Short pieces of piping which have been removed to permit the preparation of the system
shall be tested separately


PROJECT PROCEDURE
PIPING FIELD PRESSURE TESTING
CONTRACTOR IDENTIFICATION CODE
3583-XH-SG-P300002
POLYOLEFINS UNIT
BOROUGE 3 PROJECT RUWAIS, U.A.E.
Sheet 7 of 14 Rev Q

Abu Dhabi Polymers Company Limited (Borouge)

BOROUGE IDENTIFICATION CODE
P3-LU-586-00002

THIS DOCUMENT IS BOROUGES PROPERTY AND CANNOT BE USED BY
OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
3583-XH-SG-P300002 Rev.Q
Hydrotest

- In case of any temporary line blanks are needed to isolate the systems during pressure
tests, their thickness shall be as per table in Attachment 2, provided that all the requirements
of Attachment 2 are complied with.
- Any test line blank shall be provided with a lug or handle, extending at least 100mm and
not more than 200mm beyond the flange perimeter, which shall be painted bright red
- Temporary blinds shall be adequately provided with gaskets to prevent damage to flange
facings
- Lines containing check valves shall have the source of pressure located in the piping
upstream of the check valve so that the pressure is applied under the seat. If this is not
possible, their internals shall be securely blocked open or removed
- All valves, excluded those herein specified, shall be included in the test; ball valves shall be
in the half open position and all other valves fully open.
- Should a valve be not included in a system test, its shop test certificate shall be reviewed
and, eventually, a bench hydro-test shall be made.
- All internal parts or in-line items removed for the duration of the test shall be labelled with a
reference to the component to which they belong or to the position of the line from which
they were removed, to ensure the correct replacement of components after the test.

For the preparation of the system, such as for the piping connecting the test medium pump
or compressor to the system or for the isolating spades, or manometers, it is not allowed to
use piping components, valves and instruments supplied for the plant construction.
8 TEST PROCEDURE
Before filling in the system with the test medium, it shall be inspected for satisfactory
preparation to the test, including the placement of pressure gauges and then flushed or
purged.
The area around the system being tested shall be cleared of any unauthorised personnel;
barriers and warning notices shall be posted to isolate the area as long as the system is
under pressure.
Throughout the test execution, the pressure shall be continuously monitored to ensure that
over-pressuring due to thermal expansion does not occur.
The system under test shall never be left unattended; if a test cannot be completed within
the working time, the system shall be depressurised and drained.
System that includes expansion joints shall be investigated to verify that any required
temporary restraints, anchors, guides etc., have been installed prior to test. Preparation for
testing of expansion joints shall be in accordance with ASME B 31.3, Para 345.3.3.


PROJECT PROCEDURE
PIPING FIELD PRESSURE TESTING
CONTRACTOR IDENTIFICATION CODE
3583-XH-SG-P300002
POLYOLEFINS UNIT
BOROUGE 3 PROJECT RUWAIS, U.A.E.
Sheet 8 of 14 Rev Q

Abu Dhabi Polymers Company Limited (Borouge)

BOROUGE IDENTIFICATION CODE
P3-LU-586-00002

THIS DOCUMENT IS BOROUGES PROPERTY AND CANNOT BE USED BY
OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
3583-XH-SG-P300002 Rev.Q
Hydrotest

8.1 Hydrostatic Test:
- The maximum system test pressure shall be as shown on the line list and on the piping
isometrics.
- The test pressure gauge shall include a chart pressure recorder. The normal location for
the pressure test gauge is at grade near the pressure test pump. Readings may be made at
higher points providing the gauge pressure reading plus the static head (0.097 bar per
meter) between low point in the system and the point of measurement does not exceed the
maximum test pressure. Pressure test gauges shall be numbered and calibrated a minimum
of once a month, using a dead weight tester. The gauge shall be tagged with the date last
calibrated. Gauges with outdated calibration tags shall be recalibrated before use.
- Hydrostatic test pressure to be maintained for a sufficient length of time to check all joints
(including welds and band joints) to determine if there are any leaks, but in no situation shall
it be less than 15 minutes
- Check on the manometer the test pressure: it must be constant for all the test duration
- Check all welding; leaking welds shall be repaired and pressure test repeated
- Check all flanged and threaded joints; if a leakage occurs, check the tightening and that
flange faces are perpendicular to the pipe and re-execute the test
- Valves included in a pressure test shall be open 90 percent. Valves shall not be included in
a pressure test fully open or fully closed.
If block valves are used for blocking or isolating hydrotest sections, the differential pressure
across the valve seat shall not exceed the seat test pressure during strength test and shall
not exceed the rated seat pressure during tightness test.
8.2 Pneumatic Test:
- Minimum Metal Temperature
At time of testing, the minimum pipe metal temperature should be as listed below:
NOM. WALL MIN.
THICKNESS TEMP.
Carbon Steel 38 mm and less 15C
Post-Heat Treated Ferritic Alloy Steels 25 mm and less 15C
Austenitic Stainless Steels 25 mm and less 12C
Minimum temperatures for materials not listed above will be determined by COMPANY when
required by CONTRACTOR.

- For test pressures exceeding 3.45 bar (50 psig), CONTRACTOR shall provide calculations
for the stored energy of the system prior to conducting the test.

- Pneumatic tests shall include a preliminary check at 0.70 bar to locate major leaks. The
pressure shall be increased gradually in steps to full test pressure, this pressure shall be
maintained for 30 minutes. After 30 minutes the pressure shall be reduced to the design
pressure. All weld and flange joints shall be examined using a leak detection fluid at 0.70 bar
pressure and at design pressure to determine whether leaks are present.
- Pneumatic test pressure shall not exceed 110% of the system design pressure and care
shall be exercised not to exceed the specified test pressure by more than 10%.
- Prior to soaping the joints, the entire line shall be Walked to determine if there is any
audible evidence of leakage. Any leaks found at this time shall be marked, and repaired after


PROJECT PROCEDURE
PIPING FIELD PRESSURE TESTING
CONTRACTOR IDENTIFICATION CODE
3583-XH-SG-P300002
POLYOLEFINS UNIT
BOROUGE 3 PROJECT RUWAIS, U.A.E.
Sheet 9 of 14 Rev Q

Abu Dhabi Polymers Company Limited (Borouge)

BOROUGE IDENTIFICATION CODE
P3-LU-586-00002

THIS DOCUMENT IS BOROUGES PROPERTY AND CANNOT BE USED BY
OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
3583-XH-SG-P300002 Rev.Q
Hydrotest

depressuring the line. Bolting shall not be tightened while systems being tested are
pressured above 2.06 bar.
- Maintain the test pressure for sufficient time to complete the inspection, and in any case
not less than 10 minutes: pressure should be constant during this time. After the inspection,
depressurise the system gradually.

All the defects detected during the tests shall be recorded and repaired. Pressure test shall
then be re-executed. Re-testing of minor repairs or additions may be waived with prior
approval by TSJ upon completion of the weld examination (100% radiography or liquid
penetrants according to the type of weld as per the Specification for Welding of Steel Piping
3583 XH SW P300110.

8.3 Additional requirement for test of jacketed lines
Jacketed lines have to comply with further requirements, as follows:
- Core pipes have to be tested before jacketing, unless all circumferential joints not yet
tested on core pipe result visible during pressure test. When for assembly reasons the jacket
should cover some circumferential joints on core pipe, the jacket shall be fabricated and
applied in two halves and will be assembled after testing of core pipe.
- Test pressures are listed in Attachment 3 Table. In case there are any conflicts with the test
pressures required in the Project Line List, or in case of some jacketed lines are not included
in Attachment 3, the Piping Class specialist must be asked for due clarifications.
- Special attention shall be paid during the pressure test of the jacket pipes, because
either a counter pressurization inside the core pipe or an equalizing of the pressures
inside core and jacket pipes may be needed, in order to avoid the risk of implosion for
core pipe. For this purpose the Table in Attachment 3, including its Notes, gives all
the requirements.
- In any case the maximum external pressure (shown as Pe in Attachment 3 Table), must
not be exceeded.
- When a counter pressure is required, the core pipe must be always pressurized before
pressurizing the jacket pipe.
- When an equalizing is required, testing procedure must ensure that no differential pressure
loading the core wall may occurs throughout the test, including de-pressurization phases.
At least two manometers are needed: the first one shall be connected to core pipe; the
second one shall be connected to jacket pipe. These manometers shall be located so that
both are visible at the same time by only one man.
- Equalizing should be preferred to counter pressurization all the times either these methods
are in alternative.
- Any unknown terminology is defined in the Notes of Attachment 3 Table.
9 DE-PRESSURIZATION AND CLEANING
- The system shall be gradually de-pressurised and vented, completely drained taking care
that no fluid pocket remains in the system; piping systems downstream of check valves shall
be inspected to ensure complete drainage
- When the system is a jacketed line and counter pressurization is required, the core pipe
must be de-pressurized after the jacket pipe.


PROJECT PROCEDURE
PIPING FIELD PRESSURE TESTING
CONTRACTOR IDENTIFICATION CODE
3583-XH-SG-P300002
POLYOLEFINS UNIT
BOROUGE 3 PROJECT RUWAIS, U.A.E.
Sheet 10 of 14 Rev Q

Abu Dhabi Polymers Company Limited (Borouge)

BOROUGE IDENTIFICATION CODE
P3-LU-586-00002

THIS DOCUMENT IS BOROUGES PROPERTY AND CANNOT BE USED BY
OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
3583-XH-SG-P300002 Rev.Q
Hydrotest

- Check that the rate of drainage from pipelines is compensated by the inflow of air through
the vent, ensuring that no component is subject to vacuum.
- Replace all the items and the internals removed for the execution of the pressure test,
remove all test blinds, temporary supports etc. Flanged joints that have been opened shall
be provided with new gaskets
- Painting and insulation shall be completed
- Spring hangers shall be unlocked
- The system shall be blown out with dry filtered air at about 70C. Further drying and
cleaning prescriptions for particular systems shall be in compliance to the relevant Project
Specification.
- The system shall be re-inspected for mechanical completeness and the system signed-off
as completed
10 PRESSURE TEST RECORDS
For each system a record shall be kept, filling in the forms provided from site Quality Control
(QC) procedures. These forms shall be stored in the QC file. These records need not be
retained if a certification by the Inspector that the piping has satisfactorily passed the
pressure test is retained. These records to include:
- Date of test
- Identification of piping system and any vessels or equipment tested with the piping system
- Test medium
- Test pressure
- Minimum ambient temperature
- Test medium temperature
- Certification by examiner
- Chart recording from test pressure gauge
11 ACCESSORIES AND TOOLS
Erection Contractor shall supply all accessories and tools for the execution of the pressure
test.
11.1 Gauge pressure range
The pressure test shall be between 30% and 70% of pressure gauge full scale.
Test pressure and test gauge range shall be indicated on form.

11.2 Calibration
Pressure gauges shall be calibrated according to manufacturer requirements or according to
site QC manual.
Pressure gauge shall be identified by means of stickers. The Calibration Certificates shall be
traceable. Gauge Serial Number and Test Gauge Calibration Certificate shall be indicated on
Form 250 Piping Test Report.


PROJECT PROCEDURE
PIPING FIELD PRESSURE TESTING
CONTRACTOR IDENTIFICATION CODE
3583-XH-SG-P300002
POLYOLEFINS UNIT
BOROUGE 3 PROJECT RUWAIS, U.A.E.
Sheet 11 of 14 Rev Q

Abu Dhabi Polymers Company Limited (Borouge)

BOROUGE IDENTIFICATION CODE
P3-LU-586-00002

THIS DOCUMENT IS BOROUGES PROPERTY AND CANNOT BE USED BY
OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
3583-XH-SG-P300002 Rev.Q
Hydrotest

12 TEST COMPLETION
- After completion of testing, all temporary blanks and blinds will be removed, all operating
blinds returned to proper position and all lines and piping components (except those tested
pneumatically) will be completely drained. Valves, orifice plates, expansion joints and short
pieces of piping which have been removed shall be reinstalled with proper gaskets in place.
Lines being drained after testing will have all vents open. Piping systems downstream of
check valves should be inspected to insure complete drainage. Flanged vents for High
Pressure (HP) and Medium Pressure (MP) Steam lines may be replaced by welded caps
when OWNER directs. The welds of these caps shall be 100 percent x-rayed.
- Acceptance of line restoration will be documented on the Piping Pressure Test Record.





PROJECT PROCEDURE
PIPING FIELD PRESSURE TESTING
CONTRACTOR IDENTIFICATION CODE
3583-XH-SG-P300002
POLYOLEFINS UNIT
BOROUGE 3 PROJECT RUWAIS, U.A.E.
Sheet 12 of 14 Rev Q

Abu Dhabi Polymers Company Limited (Borouge)

BOROUGE IDENTIFICATION CODE
P3-LU-586-00002

THIS DOCUMENT IS BOROUGES PROPERTY AND CANNOT BE USED BY
OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
3583-XH-SG-P300002 Rev.Q
Hydrotest


ATTACHMENT 1: STATUS OF INSTRUMENTS DURING PRESSURE TEST

Instrument Type* Remove Blind Off Include In Test Refer To Notes
1. Analyzers X

2. Control Valves - Pressure balanced, Regulators X

3. Flow Instruments - D/P Cell & Bellows types X

4. Flow Instruments - Rotameters

X 1
5. Flow Meters - Positive displacement type X

6. Flow Meters - Turbine type X

7. Flow Indicating Switches - Bellows type X

8. Flow Switches - Vane type X

9. Gauge Glasses

X 7
10. Level Instruments - Displacer type

X 2
11. Level Instruments - D/P Cell and Bellows types X

12. Level Switches - Float type

X 2
13. Orifice Plates X

3
14. Pr es sur e Gauges X

15. Pressure Instruments - All types X

16. Pressure Regulators X

17. Pressure Switches X

18. PSVs

X

4,5,6
19. PSVs , TSVs - NPS and NPS 1 screwed
X

*
Remove any instrument not listed above or if there is any doubt as to status prior to pressure testing.
NOTES:
1. Caution: do not force reverse flow.
2. Caution: do not overpressure float or displacer. If in doubt, do not test, block or drain instead.
3. Install after hydro testing and line flushing.
4. Test gag shall not be used.
5. Blinds not required on PSV outlets discharging into a system being tested at 1 bar g or less.
6. Where test blinds have been installed for pressure testing PSVs, the Field Erection CONTRACTOR shall
ensure that blinds are removed upon completion of tests. PSVs may be removed prior to pressure testing
Where piping lacks sufficient flexibility to accommodate test blinds.
7. Caution: Check allowable pressure on Gauge Glasses, prior to test.





PROJECT PROCEDURE
PIPING FIELD PRESSURE TESTING
CONTRACTOR IDENTIFICATION CODE
3583-XH-SG-P300002
POLYOLEFINS UNIT
BOROUGE 3 PROJECT RUWAIS, U.A.E.
Sheet 13 of 14 Rev Q

Abu Dhabi Polymers Company Limited (Borouge)

BOROUGE IDENTIFICATION CODE
P3-LU-586-00002

THIS DOCUMENT IS BOROUGES PROPERTY AND CANNOT BE USED BY
OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
3583-XH-SG-P300002 Rev.Q
Hydrotest

ATTACHMENT 2: SCHEDULE OF MAXIMUM ALLOWABLE HYDROSTATIC TEST PRESSURE (BAR G) FOR THE LISTED
TEST BLIND THICKNESSES
Blank
Thickness Pipe Size (NPS)
[ m m ] 2 3 4 6 8 10 12 14 16 18 20 24 30 36 42 48 54 60
6 119.5 55.2 33.4 15.5 9.0 5.9 4.1 3.4 2.5 2.1 1.7 1.2 0.8 0.5 0.4 0.3 0.2 0.2
8 217.5 100.4 60.7 28.0 16.6 10.7 7.6 6.3 4.7 3.7 3.0 2.1 1.4 0.9 0.7 0.5 0.4 0.3
10 344.0 159.0 96.1 44.4 26.2 16.9 12.0 9.8 7.6 6.0 4.8 3.3 2.2 1.5 1.1 0.8 0.7 0.5
12 499.7 231.0 139.7 64.5 38.0 24.4 17.4 14.3 11.1 8.6 7.1 4.8 3.0 2.2 1.6 1.2 1.0 0.8
14

316.5 191.4 88.5 52.2 33.4 23.7 19.7 15.0 12.0 9.6 6.7 4.2 2.9 2.2 1.7 1.3 1.1
16

415.2 251.1 116.0 68.5 43.9 31.3 26.0 19.8 15.7 12.7 8.7 5.7 3.8 2.8 2.2 1.7 1.4
20

653.0 395.0 182.4 107.7 69.1 49.1 40.8 31.2 24.6 19.9 13.8 8.8 6.2 4.4 3.4 2.6 2.2
25

620.5 286.6 169.1 108.7 77.3 64.0 49.0 38.7 31.4 21.8 13.9 9.6 7.1 5.5 4.2 3.4
30

414.2 244.3 157.0 111.7 92.6 70.8 56.0 45.3 31.5 20.1 13.9 10.3 7.8 6.2 4.9
35

565.1 333.3 214.4 152.4 126.3 96.8 76.5 61.9 43.0 27.5 19.0 13.9 10.8 8.4 6.9
40

436.2 280.5 199.4 165.3 126.5 99.9 80.9 56.3 36.0 24.9 18.3 14.0 11.1 8.9
45

355.5 252.6 209.6 160.4 126.8 102.7 71.3 45.5 31.7 23.2 17.8 14.0 11.4
50

439.3 312.2 259.1 198.3 156.6 126.9 88.2 56.4 39.1 28.7 22.0 17.4 14.0
55

378.2 313.6 240.2 189.8 153.7 106.8 68.3 47.4 34.8 26.7 21.1 17.1
60

450.4 373.6 286.1 226.0 183.1 127.2 81.4 56.5 41.5 31.8 25.0 20.3
65

438.7 336.0 265.5 215.0 149.3 95.5 66.4 48.7 37.3 29.4 23.8
70

389.8 308.0 249.5 173.3 110.8 77.0 56.6 43.2 34.1 27.7
75

447.8 353.7 286.6 199.0 127.4 88.5 64.9 49.7 39.2 31.8



PROJECT PROCEDURE
PIPING FIELD PRESSURE TESTING
CONTRACTOR IDENTIFICATION CODE
3583-XH-SG-P300002
POLYOLEFINS UNIT
BOROUGE 3 PROJECT RUWAIS, U.A.E.
Sheet 14 of 14 Rev Q

Abu Dhabi Polymers Company Limited (Borouge)

BOROUGE IDENTIFICATION CODE
P3-LU-586-00002

THIS DOCUMENT IS BOROUGES PROPERTY AND CANNOT BE USED BY
OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
3583-XH-SG-P300002 Rev.Q
Hydrotest



ATTACHMENT 2 (CONTINUED)
SCHEDULE OF MAXIMUM ALLOWABLE HYDROSTATIC TEST PRESSURE (BAR G)
FOR THE LISTED TEST BLIND THICKNESSES

NOTES:
1. The Tabulated Pressures above are based on the formula stated in ASME B31.3, Paragraph 304.5.3 using:
Flat non-asbestos gaskets conforming to ASME B16.21
Carbon steel plate, ASTM A514 Grade S having a minimum specified yield strength of 690 MN/m
2
(100 ksi).
2. For plate which is identified as having a lower minimum yield strength, the allowable hydrostatic pressure must be reduced
in accordance with the following formula:




where:
P
ma
= Maximum Allowable Test Pressure for material selected.
Y = Minimum Specified Yield Strength, ASTM A514 Grade S.
Yx = Minimum Specified Yield Strength for Material Selected.

3. Pneumatic Test Pressures Shall Not Exceed 50 percent of the Values Indicated.


Yx
Pma=
Y