TITLE:

ES&H Manual

 

DOCUMENT ID:

6151 Appendix T4

Pressure Systems Pressure Testing Program

 

NOTICE:

This document is currently under review.  All requirements outlined within this document apply to current laboratory operations until new content is approved, released, and published.

 

1.0            Purpose

 

This technical appendix outlines the general requirements and provides a format for documentation of pressure test procedures performed on pressure vessels and leak tests performed on piping systems.  This appendix does not serve as a stand-alone reference.  The Design Authority is required to use the applicable codes to determine the appropriate test method.

 

2.0            Scope

 

Pressure testing and leak testing are required by applicable codes for pressure vessels and piping systems fabricated at Jefferson Lab.  For fabrications built by outside vendors, the Design Authority must verify that the testing has been conducted and that the recordkeeping requirements of this appendix are met.

 

Pressure/leak test procedures shall use the following references:

 

3.0            Responsibilities

 

Design Authority shall prepare the pressure test Operational Safety Procedure (OSP) or Temporary Operational Safety Procedure (TOSP), supervise and witness the pressure system test.  The Design Authority shall ensure that all documentation of pressure testing is stored in the appropriate Pressure System Project Folder, Testing Sub-Folder and accessible electronically.

 

Test Technicians shall install the pressure test setup, perform the pressure test under the direct supervision of the Design Authority, perform the post-pressure test examinations and maintain the Pressure/Leak Test Worksheet.

 

Quality Assurance Inspector shall witness the pressure test for pressure piping and certify that the pressure vessel satisfactorily passed the pressure testing.

 

4.0            Process Steps or Expectations

 

4.1       Work Control Documentation - The Design Authority shall determine whether an OSP or TOSP is required for the pressure test; and either use an existing OSP or prepare a new OSP or TOSP as applicable.  In the case of fabrication of more than one identical system, the OSP may address the pressure system of the entire lot.  ES&H Manual Chapter 3310 Appendix T1 Operational Safety Procedure (OSP) and Temporary OSP Procedure and ES&H Manual Chapter 3320 Temporary Work Permits contain general guidance for OSP/TOSP preparations.  A sample pressure test OSP is provided electronically in the Pressure Systems directory.

 

            The Design Authority shall prepare a TOSP when the proposed testing has significant safety impacts.  Examples include, but are not limited to:

·         Pressure systems with stored energy greater than 100 kilojoules (kJ)

·         Pressure systems with P*V greater than 25 atm*cu ft for pressures up to 250 psi

·         Test pressure greater than 250 psi

·         Pressure systems whose working fluids are Category M as given in ASME B31.3

 

            In addition to the guidance provided in ES&H Manual Chapter 3310 Appendix T1 Operational Safety Procedure (OSP) and Temporary OSP Procedure and ES&H Manual Chapter 3320 Temporary Work Permits, the OSP/TOSP shall include:

 

4.1.1        Rationale for selection of test type (e.g. pneumatic vs. hydrostatic vs. initial service leak test)

Note: Initial service leak testing is permissible only for B31 pressure piping, not Section VIII vessels.

 

4.1.2        Reference to applicable codes

 

4.1.3        Special considerations required by the code.  Examples include but are not limited to:

·         Joint preparation considerations

·         Temporary supports

·         Special testing for expansion joints

·         Boundaries; disconnection methods for equipment not to be included in the test

 

4.1.4        Qualifications for the Test Technician shall be specified and may vary according to the ancillary hazards present in the test area (example oxygen deficiency hazards).  At a minimum, the Test Technician shall have completed ES&H Orientation (SAF100), ES&H Pressure Systems Hazard Awareness Training (SAF130A), and have read the pressure test OSP/TOSP and have signed the Pressure Test Worksheet.

 

4.1.5        Protection of incidental personnel in the test area shall include:

·         Calculation of stored energy in terms of kilo-joules

·         Normal occupancy of the test area

 

4.1.5.1     Possible controls shall include:

·         Barricades

·         Shields

·         Scheduling of work for after the normal shift

 

4.1.6        Isolation requirement for the test area

4.1.6.1     Post Danger signs indicating:

·         Pressure test is in progress

·         Only Authorized Personnel allowed to enter

·         Name and contact information of the test supervisor

 

4.1.7        Manifold connecting pressure supply with the test setup requirements shall include:

4.1.7.1     Vent valves (or bypass to liquid reservoir for hydrostatic testing) and locations

4.1.7.2     Regulator

4.1.7.3     Fill valve

4.1.7.4     Relief valve

·         Selected according to the applicable ASME code

·         Sized to provide adequate flow

·         Set to not exceed 120% of the required test pressure

·         Bench test the pressure relief device

 

4.1.8        Pressure gage requirements shall follow the requirements of “Measurement and Test Equipment Control and Calibration Procedure”:

·         Gages shall be calibrated

·         Scale should preferably be double the intended maximum test pressure, but in no case shall the range be less than 1.5 or more than 4-times that pressure.

 

4.1.9        Inspection requirements for the assembled test setup.

 

4.1.10    Procedure shall be written in detail for the test.

 

4.1.11    Schematic of the testing installation shall be included.

 

4.1.12    A pressure test worksheet for the test, which is used with the procedure and serves as the test record (See Figure 1 for an example).

 

4.1.13    Approvals

·         Design Authority’s Group Leader

·         Industrial Safety

·         Test area supervisor

·         Division Safety Officer

 

4.2              Recordkeeping - The Design Authority is responsible for the following pressure testing recordkeeping requirements:

 

4.2.1        Pressure Test OSP/TOSP - The signed-off OSP/TOSP shall be retained in the Engineering – Pressure System Directory – Testing Folder and be readily accessible.

 

4.2.2        Pressure Test Worksheet - The completed Pressure Test Worksheet shall be retained in the Pressure System Testing Folder and be readily accessible.  This verifies that the following data are maintained:

·         Date of test

·         Identification of piping system tested

·         Test fluid and pressure

·         Test examination procedures and results

 

4.2.3        Required Retention Time:

·         Pressure vessels: for the life of the vessel

·         Piping systems:  five years after the record is generated.

 

5.0            References

 

ASME Boiler & Pressure Vessel Code

ASME B31.3 Process Piping

ES&H Manual Chapter 3310 Appendix T1 Operational Safety Procedure (OSP) and Temporary OSP Procedure

 

6.0            Worksheet

 

Figure 1.  Pressure Test Worksheet Example

 

 

Pressure Vessel

Pressure Piping

 

Hydrostatic

Pneumatic

Hydrostatic-Pneumatic

Initial Service Leak Check

Sensitive Leak Check

Alternate Leak Check

Test Date:

 

DocuShare  #:

 

Test Technician:

 

Signature indicates that test technician will comply with the OSP/TOSP

Test Inspector:

 

For pressure vessels only

System to be Tested :

 

Indicate if the vessel is tested in the vertical position.

Test Location:

 

Applicable Code:

 

OSP/TOSP number:

 

Certification by Inspector (for pressure vessels ) or by Test Technician (for pressure piping):

 

Certification that pressure system has satisfactorily passed the pressure test.

Specifications

 

Notes:

Allowable leak rate:

 

 

MAWP

 

 

Working Fluid  Category

 

Normal, Category D, or Category M

Working Fluid

 

 

Working Temperature

 

 

Test Parameters

 

Notes:

 

Test Fluid Category:

 

Normal, Category D, or Category M

 

Test Fluid:

 

 

 

Test Temperature:

 

Refer to the code: test temperature requirements may be required to exceed the minimum design metal temperature

 

Relief valve setting:

 

 

 

Hold time:

 

Code requires a  minimum time

 

Test Pressure:

 

Refer to code

Specify test pressure at the top of the vessel in the test position.

 

Test Pressure as percent of MAWP:

 

Calculate and verify compliance with code

 

Inspection Pressure:

 

Test Pressure ÷ 1.3 per ASME BPV Section VIII.

Design Pressure per B31

 

Post Test Inspection Requirements:

 

Refer to code

 

Safety Controls

 

Notes:

 

Stored Energy*

 

Used as one parameter to determine the degree of risk of a pneumatic test.

 

Relief Valve setting

 

Refer to code

 

Relief Valve test

 

Calibrated within 1 year

 

Relief Valve location

 

Recommend at high points to verify air pockets are purged.

Vents should point away from areas that have to be inspected.

 

Pressure Gage calibration date

 

 

 

Personnel Isolation devices

 

 

 

 

* Stored energy calculation

The method of stored energy calculation must be detailed in the OSP/TOSP.  Stored energies of greater than 100 kJ are considered to be high hazard.  This is equivalent to 0.0476 lb TNT.  An alternative P*V calculation can be performed to determine hazard level.  P*V greater than 25 atm*cu ft are considered high hazard and would require a TOSP.

 

For Gases:

An example of an accepted method of calculating the stored energy for gases is excerpted from CASTI Guidebook to ASME B31.3 – Process Piping, 4th edition:

 

            W + Q = ∆U + ∆KE + ∆PE

 

Where:

W = work energy

KE = kinetic energy

 

Q = heat energy

PE = potential energy

 

U = stored energy

 

 

Assuming adiabatic expansion, no change in elevation, and no movement, the first law reduces to:

 

            W = ∆U

            And,    ∆U = (k/k-1) P1V1[ 1- P2(k/k-1)/P1 ] * 144

 

Where:             W = work, ft-lbs (N-m or joules)

                        ∆U = stored energy, ft- lbs (N-m)

                        P1 = pneumatic test pressure, psia (N/m2)

                        P2 = atmospheric pressure, 15 psia ( N/m2)

                        V1 = volume of gas, ft3 ( m3)

K = specific heat ratio, cp/cv at test pressure.  (for air and nitrogen k = 1.4, for helium k = 1.66)

 

            Results are in joules.

 

            To convert to lbs TNT:            TNT = W/∆Hc

 

Where:             W = work energy calculated for the test

                        Hc = heat of combustion of TNT  = 8.207 cal/gmole = 5.026 * 106ft.lb/lb

 

An example of a P*V calculation for gases is provided below:

 

            Determine if a TOSP is required for a 6 NPS sch 10 x 20' transfer line (will have a vacuum jacket) blanked at each end by flanges and having a design pressure of 150 psi:

 

Maximum internal operating pressure = 150 psi + 14.7 psi = 164.7 psid

Test pressure = 1.1 * 164.7 psid = 181.2 psid = 12.3 atm

Internal diameter = 6.357 in = 0.53 ft

Internal volume = 3.14/4 * (0.53*ft)2 * 20ft = 4.41 cubic ft

P * V = 12.3 atm * 4.41 cubic ft = 54.4 atm*cu ft

 

Since P*V > 25 atm*cu ft, a TOSP is required.

The stored energy for liquids can be found by the equation:

 

            E = > (.07) P2*V/(2*B)

 

Where:             E = stored energy (atm*ft3)\

P = test pressure (psi)

                        V = internal volume (ft3)

                        B = liquid bulk modulus (Bwater= 312,000 psi)

                        and 0.07 atm = 1 psi

 

7.0            Revision Summary

 

Revision 0.1 – 05/17/13 – Added notice to reflect current lab operations.

 

ISSUING AUTHORITY

TECHNICAL POINT-OF-CONTACT

APPROVAL DATE

REVIEW REQUIRED  DATE

REV.

ESH&Q Division

Bert Manzlak

12/07/09

12/07/12

0.1

This document is controlled as an on line file.  It may be printed but the print copy is not a controlled document.  It is the user’s responsibility to ensure that the document is the same revision as the current on line file.  This copy was printed on 5/17/2013.