HYDROSTATIC TEST
TRAINING
(PIPING)
BGPP PROJECT
20 DECEMBER 2023
PMC SERVICES-BGPP
BASIC PIPING TRAINING
Pre-commissioning Execution
Contents
► Engineering activities
► Execution activities
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PURPOSE:
This document provides for the pre-commissioning requirements for the New Gas Processing
Plant Project located at Surkhandarya Region, Uzbekistan.
Pre-commissioning execution guideline herein is not intended to be fully comprehensive; hence
it shall be used in conjunction with appropriate technical specifications, standard, code and/or
Manufacturers'/Vendors’ instructions.
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PROJECT DESCRIPTION:
The project envisages the construction of a new Gas Processing Plant to process 5 BCMA of raw
natural gas with high content of CO2 and H2S produced at gas field “Mustaqilligning 25 yilligi”
located in the Surkhandarya region of the Republic of Uzbekistan, in order to produce a treated
gas suitable for domestic use or export.
GPP is fed by Raw Natural Gas, connected from gas field to GPP inlet battery limits through
seven (7) dedicated gas pipelines (one from each of the gathering stations) connected to an
inlet manifold and other four (4) gas pipelines (one for each two gathering stations) connected
to a Test Separation Unit.
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GPP consists of two (2) parallel trains, each train designed for 2.5 BCMA and basically
consisting of the following main units:
► Inlet Gas Separation Unit
► Acid Gas Removal Unit (AGRU) (licensed by Shell)
► Dehydration Unit
► Sulphur Recovery Unit (SRU) (licensed by Shell)
In addition to these, there are other main units common to both trains:
► Formation water treatment (Sour Water Stripper)
► Sulphur Solidification Unit
► Sour Water (Chemical Oxidation) Unit (licensed by Shell)
► Utility Facilities & Offsites (U&O)
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The hydrostatic test is a critical procedure in piping to ensure the integrity and reliability
of the system.
Here are the key principles and considerations for a hydrostatic test in piping:
1.OBJECTIVE:
The primary objective of a hydrostatic test is to verify the structural integrity and leaktightness of the piping system.
2.TEST FLUID:
Water is commonly used as the test fluid for hydrostatic testing. In some cases, other
fluids may be used based on the system's specifications and requirements.
3.PRESSURE TEST LEVEL:
The test is typically conducted at a pressure higher than the maximum operating pressure
of the system. Commonly used test pressure is 1.5 times the design pressure for a
specified duration.
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4.TEST DURATION:
The system is pressurized and held at the test pressure for a specified duration. The duration
can vary but is often maintained for a minimum period (e.g., 2 hours) to detect any potential
leaks or weaknesses.
5.ISOLATION OF SECTIONS:
Large piping systems may be divided into sections for testing. Each section is isolated to
conduct a systematic examination of the entire system.
6.VISUAL INSPECTION:
Visual inspections are conducted before, during, and after the test to identify any visible
defects, leaks, or abnormalities.
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7.PRESSURE RECORDING:
Pressure gauges and recorders are used to monitor and record the pressure throughout the
test duration. This helps ensure that the pressure is maintained within the specified range.
8.TEMPERATURE CONTROL:
The temperature of the test fluid should be considered, especially if it can significantly affect
the pressure. Corrections may be applied if there are temperature variations.
9.SAFETY MEASURES:
Adequate safety measures, including personal protective equipment (PPE), must be in place.
Test personnel should be trained on safety protocols.
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10.TEST COMPLETION CRITERIA:
The test is considered successful if the system maintains the required test pressure without a
significant drop and if there are no visible leaks.
11.DRAINING AND DRYING:
After the test, the water is drained from the system, and the pipes are thoroughly dried to
prevent corrosion.
12.DOCUMENTATION:
Comprehensive documentation, including the test procedure, results, and any deviations
observed, is essential for record-keeping and future reference.
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13.REGULATORY COMPLIANCE:
Ensure that the hydrostatic test complies with relevant codes, standards, and regulatory
requirements applicable to the specific industry and region.
 These principles collectively contribute to the effectiveness of the hydrostatic test,
providing assurance of the structural soundness and leak resistance of the piping
system before it is put into service.
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PRE-COMMISSIONING EXECUTION
ENGINEERING ACTIVITIES
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SUB-SYSTEM:
A Sub-system is a further sub-division of a System, which performs a partial operational
function of the System, with little or no interference from the other Sub-systems.
The Sub-system is the basic unit for Pre-commissioning and Commissioning activities
The breakdown of a plant into Systems and Sub-systems for the Pre-commissioning and
Commissioning activities shall be performed as early as possible during the Detailed
Engineering phase and shall always be approved by Owner.
 The Sub-systems shall be defined to be as independent as possible, not too small, but of
manageable size, and adapted to the requirement of the Start-Up sequence.
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TERMINOLOGY:
READY FOR COMMISSIONING (RFC):
A Sub-system reaches the Ready For Commissioning status (RFC) when:
 All Pre-commissioning activities on that Sub-system have been successfully completed and
approved.
 All reservations preventing Commissioning have been cleared.
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From a methodological point of view, the Pre-commissioning execution can be divided
into three separate types of activities:
► CONFORMITY CHECKS.
► STATIC TESTS.
► PIPING TESTS.
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► CONFORMITY CHECKS:
These Checks are carried out on each item in order to verify visually the condition of the
equipment, the quality of the installation and the compliance with Project drawings and Project
specifications.
 Each Item of the plant shall be checked, and the relevant Conformity Check list filed in the
Sub-system dossier in the relevant discipline section.
► STATIC TESTS:
These tests are carried out on Items to ensure their individual Quality/Performance.
 Static Tests shall concern all disciplines:
e.g. calibration of instruments, machinery alignments, setting of safety valves, cables
insulation and continuity tests, etc.
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► PIPING TESTS:
These tests are carried out on pipe work in order to verify their mechanical integrity,
cleanness, alignment, etc.
 Piping Tests are typically, but not limited to air or water flushing, pressure test (e.g. hydro
test), chemical cleaning, reinstatement, gross air leak test (GALT), blowing etc.
 Piping Tests shall be organized by Test Packs.
A Test Pack is a group of spools or lines subject together to one or several Piping activities at
the same time. Each Test Pack shall be linked to a unique Sub-system number.
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PRE-COMMISSIONING TASK REGISTER:
It is the exhaustive list of all the Pre-commissioning tasks.
It is the reference document used to follow up the Pre-commissioning execution status and
progress.
The Pre-commissioning Task Register shall be established during the pre-commissioning
engineering phase and shall be permanently maintained / updated during the execution
phase.
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The achievement of all the Pre-commissioning tasks on a Sub-system is formalized by the
signature of a specific document called Ready For Commissioning Certificate.
This certificate states that the Sub-system is ready for the commencement of the associated
Commissioning activities.
The pre-requisites for the signature of the Ready For Commissioning Certificate shall be:
► The successful completion of all the Pre-commissioning activities.
► The thorough physical inspection on site of the Sub-system with the Commissioning Team.
► The thorough review and approval of the Pre-commissioning dossier with the
Commissioning Team.
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Before starting any kind of Pre-Commissioning activities, the following must be ensured:
► Permit to Work (PTW) in place.
► Area clean and safe (housekeeping).
► Warning signs and labels installed (i.e. Pre-Commissioning in progress, Danger - Pressurized
piping, System Live, etc.).
► Check PSV certifications and its expiration date.
► Lock-out/tag-out (LOTO) procedure in place.
► Execute works as indicate by the check / test forms and verify that materials/tools and
equipment needed to perform the activities are available
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PIPING TEST:
As part of a fault free Start-up, it is imperative that all dirt, loose scales and construction
debris, as well as any other contaminants, are effectively removed from process equipment
and pipework.
Flushing and Cleaning methods may include any of the methods detailed below or a
combination of different methods.
Conventional Flushing e.g. Water Flush and Air Blowing removes loose scale and construction
debris.
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Each Test Pack dossier shall include, but not limited to:
► The Test Pack number.
► The Sub-system number.
► The reference to the applicable safety procedure.
► The reference to the applicable test procedure used.
► The associated tasks.
► The spools identification and /or line numbers.
► The list of critical devices to be removed for the test.
► The NDT clearance status (per line).
► The associated Sub-system (per line).
► The concerned PID (per line) and its revision number.
► The Isometric drawing numbers and optionally the associated spool numbers.
► The test results.
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► The NDT clearance status (per line).
► The associated Sub-system (per line).
► The concerned PID (per line) and its revision number.
► The Isometric drawing numbers and optionally the associated spool numbers.
► The test results.
► The record chart diagram of the test.
 The Test Pack dossiers shall be submitted to Owner for approval.
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PIPING SYSTEM:
► Confirm that all pipe fittings are installed.
► All permanent spectacle blinds and spacers are installed, as indicated on the technical
documentation.
► Spring supports have been set up in accordance with the relevant Contractor spring hanger
data sheets (normally post hydrotest and flushing).
► Valve interlocks are in place and functional, padlocks or CSO / CSC seals are correctly
installed.
► Flanges are coupled with earthing straps, where required.
► Electrical tracing is installed and ready for service.
► Insulating gaskets and flange bolts installed and tested.
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► Relief valves installed correctly, tagged, seals intact, valid certificate of calibration
available.
► Permanent strainers installed with correct mesh size or internals as appropriate and
assembled with new gaskets / seals.
► All gaskets are installed to the correct specification.
► No temporary piping or temporary closures remaining.
► Valve packing has been checked for leakage and adequate packing material is provided in
the stuffing box to permit adjustment.
► All valve hand wheels are installed.
► Orifice plates and other instrumentation correctly fitted.
► All manual valves are greased & checked operable fully open / fully close.
► Drains and vents on hydrocarbon and chemical systems are properly blanked, blinded or
plugged.
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► All temporary supports removed.
► Labelling / tagging and colour coding in place as specified.
► Sampling arrangements functional (analysers and manual).
► Painting of piping is sufficiently complete so that scaffolding shall not hamper safe
operation after RFSU.
► Fire proofing and fireproof enclosures complete.
► No combustible material in pipe racks e.g. wooden planks.
► Insulation is fully installed on steam and hot process systems except on flanges to
allow for hot bolting to be carried out.
► Firefighting test including monitor, hose reels, hydrants, deluge protection, etc.
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In the context of commissioning activities, FLUSHING AND CLEANING are two distinct
processes, each serving a specific purpose in preparing a system for operational use.
FLUSHING:(Pre-commissioning)
Flushing is primarily aimed at removing loose debris, scale, or other particulate matter from
the piping system.
It helps ensure that the system is free from any solid contaminants that could potentially
interfere with its proper functioning.
METHOD: Flushing is often done by circulating a flushing fluid, which is typically water or a
specialized flushing solution, through the piping system.
The flow is designed to carry away loose particles and contaminants.
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CLEANING: (Pre-commissioning)
involves a more comprehensive process aimed at removing substances like oils, greases, rust,
or any other adherent contaminants from the internal surfaces of the piping system.
The goal is to achieve a clean surface for optimal system performance and to prevent
potential issues like corrosion.
Method: Cleaning may involve chemical cleaning agents or specialized cleaning solutions.
These substances are circulated through the piping system to break down and remove
contaminants.
Mechanical cleaning methods, such as pigging (using a device called a pig), may also be
employed for certain types of systems.
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 In summary:
FLUSHING is focused on removing loose particles and debris, while
CLEANING is a more thorough process aimed at eliminating adherent contaminants from
the internal surfaces of the piping system.
 Both processes are essential in ensuring that the piping system is in an optimal condition
for commissioning and subsequent operation.
 Both flushing and cleaning are typically conducted as part of pre-commissioning activities
to ensure that the piping system is clean and ready for commissioning and operation.
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BEFORE HYDROSTATIC TEST:
Pre-commissioning Cleaning or Pre-operational Cleaning: This refers to the cleaning process
carried out before conducting a hydrostatic test. It aims to remove construction debris, scale,
rust, oil, grease, and any other contaminants that might have accumulated during the
construction phase.
AFTER HYDROSTATIC TEST:
Post-Hydrostatic Test Cleaning: After a successful hydrostatic test, there is often a need for
further cleaning to remove any residual water, testing fluids, or other substances used during
the test. This ensures the system is clean and ready for commissioning and operation.
These terms may slightly vary depending on industry standards, project specifications, or
company-specific terminology, but generally, they capture the essence of the cleaning
processes before and after a hydrostatic test in piping.
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WATER FLUSHING:
All Flushing shall be carried out, ideally, immediately following the hydrostatic testing of the
last test pack within a specific system, and prior to handover of the mechanical equipment
and piping at MC.
Normal Plant water or fresh firewater may be used for Flushing purposes, after having verified
that water chemical composition will not trigger any risk to the piping and components
material.
Attention must be paid where special metallurgy is used, such as stainless-steel pipes or
austenitic steel. They must be cleaned using water with chloride content which has to follow
the requirements specified by the piping department. Seawater should not be used due
negative effect on stainless steel and high chloride levels that could contaminate them;
 AWWA STANDARD
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MECHANICAL CLEANING:
This mechanical cleaning method is performed using scrapers or wire brushes and shall be
acceptable in case where the pipe length is short, and the diameter is sufficiently large.
Internal surfaces are checked and brushed to remove external material and / or debris.
Removed material must be handled outside the piping by hand or by vacuum cleaner and
disposed according with environmental procedures.
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AIR BLOWING AND WATER FLUSHING:
AIR BLOWING involves using compressed air to remove any debris, moisture, or foreign
material from the piping system before conducting the hydrostatic test.
It helps ensure that the system is clean and ready for the actual pressure test.
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AIR BLOWING shall be utilized, as a cleaning method for System in gas service for the lines
with a LARGE DIAMETER which cannot be washed with water and to achieve the required
cleaning velocities for larger bore piping.
The principle employed shall be to pressurize the system concerned with plant air and then
rapidly de-pressure it, by use of a sacrificial valve or bursting disc.
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AIR BLOWING is executed with dry air (dew point -40° C) provided by an external compressor,
equipped with a drying unit, to ensure a suitable flow and blowing pressure.
The minimum exit VELOCITY of the air shall be 50 ft/s [16 m/s].
This can be achieved by continuous blowing by means of direct connection of a compressor or
by Air blasting by means of a rupture disk.
Typical Air Compressor (oil free type) used for such operation is expected to be in the flow
range of 2000 Nm3/h with a nominal discharge pressure up to 8 bar(g).
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 Blowing for lines above 4” shall be executed using the (intermittent) quick depressurization
method.
 Accordingly, temporary rupture disks or quick opening valves shall be provided by Subcontractors.
 As general rule, the first blowing of each line shall take place with the circuit pressurized at
max. of 2 bar(g). Pressure shall be increased up to the target pressure recommended at 3 –
3.5 bar(g) max, unless specified otherwise.
In all cases, the pressure must be continuously monitored and shall not exceed the nominal
operating pressure of the line at any time.
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 Blowing for lines below 4” shall be executed continuously (a buffer tank is usually connected
to the external compressor to keep an adequate delivery pressure during the blowing) until
cleaning acceptance is achieved.
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CHEMICAL CLEANING (SPECIFIC TO NON-STEAM SYSTEMS):
The following is common a methodology used for the chemical cleaning of Systems /
equipment.
Prior to star the chemical cleaning the system to clean must be prepared ensuring that all
stainless steel, brass and bronze components are replaced with temporary bypasses such as
CS Pipes or rubber hoses or spool pieces.
Drains shall be sized to permit complete draining of the equipment in two hours or less.
All transfer and circulating pumps for handling chemical cleaning degreasing, neutralizing and
passivating solutions are furnished by the chemical cleaning contractor and usually operate
from an independent power source.
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CHEMICAL CLEANING:
In piping is a process designed to remove unwanted contaminants, such as rust, scale, oils,
greases, and other deposits, from the internal surfaces of the piping system.
This method is employed during pre-commissioning or maintenance activities to ensure that
the piping is free from substances that could compromise its performance or integrity.
Chemical cleaning is often performed as part of PRE-COMMISSIONING activities to ensure
that the piping system starts with clean and corrosion-resistant surfaces.
chemical cleaning is typically performed BEFORE THE HYDROSTATIC TEST during the precommissioning phase of a piping system.
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"STEAM OUT" And "BOIL OUT" are two different procedures often employed in the
commissioning or maintenance of piping systems.
STEAM OUT:
PURPOSE: The steam out process is used to remove any residual water or moisture from the
piping system, ensuring it is dry before commissioning.
PROCEDURE: Steam is introduced into the system, and the heat from the steam helps
evaporate any remaining water, preventing the presence of liquid water during operation.
APPLICATION: Commonly applied in systems where the presence of water could be
detrimental, such as steam lines, to prevent water hammer or damage caused by the rapid
condensation of water.
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BOIL OUT:
PURPOSE: Boil out is a cleaning process to remove oil, grease, rust, or other contaminants
from the internal surfaces of the piping system.
PROCEDURE: The system is filled with a cleaning solution, often a mixture of water and a
chemical cleaner. This solution is then heated to a boil, and the boiling action helps remove
and dissolve contaminants from the piping.
APPLICATION: Typically used in newly installed or repaired systems where internal surfaces
need thorough cleaning before commissioning.
In summary, steam out is primarily about drying the system using steam, while boil out is a
cleaning process involving the use of a heated solution to remove contaminants from the
internal surfaces of the piping.
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BOIL-OUT OF STEAM GENERATORS (BOILER BOIL-OUT):
This procedure is required to remove oily and greasy material contained inside the steam
generator.
This material is usually applied on the tubes of a boiler to protect them against corrosion
during storage or transport.
Other kind of substance such as cleaners and rust inhibitors can also be employed.
All these substances must be removed in order to ensure good operating conditions.
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OIL FLUSHING:
Normally, the lube oil systems, (supplied by vendor), shall arrive at site already cleaned and
flushed, but some pipe connections between lube oil skid and compressor's skid shall be
realized on site by welding.
All these pipes fabricated on site shall be previously cleaned before their final installation
into the system in order to avoid evident contamination of the system concerned with
flushing.
 Flushing may be started when any components/piping of the system that has been
prefabricated is completed, installed and tested.
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DRYING:
The removal of water, present in the Process Units or part of them, is necessary in all cases
where the presence of water represent a potential source of problems for the start-up
operations.
There are several reasons for executing drying activities, depending on the type of
equipment and its service, here below some examples:
► Avoiding freezing
► Removal of moisture from the lining of heaters and vessels
► Damaging of catalysts
► Prevention of hydrates formation in process equipment
► Prevention of corrosion
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Drying shall normally be carried out in two phases:
• Firstly, to remove all free water from low points within the system
• Secondly, to reduce Dew Point.
Dew Point shall be measured at several points and over an extended period as to
demonstrate effectiveness of the procedure.
The Dew Point is the temperature at which air becomes saturated with moisture, leading to the
formation of dew or condensation.
Dry air, on the other hand, has low humidity and contains minimal water vapor.
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The pipes shall be blown dry with Nitrogen or Instrument Air on completion of hydrostatic
testing.
Water services lines to the respective units shall not be included but commissioned and
passivated immediately after washing flushing is completed to avoid corrosion initiated.
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NITROGEN PURGING:
A complete nitrogen purge is carried out as oxygen can oxidise the solvent directly or bind it
non-regenerably to the strong acids formed in the presence of H2S.
The entry of oxygen should therefore be prevented as much as practical.
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LEAK TESTING:
The Leak Test aims to safely confirm pressure tightness of all flanges and fittings, and that
safe containment shall be achievable at normal operating pressure conditions.
The test should not be confused with the weld strength test (hydrostatic or pneumatic),
which is carried out during Construction to confirm the mechanical strength of welds.
The test requires that the permanent gaskets and permanent valves are installed, since it is
testing the security of the final operating configuration.
It can also be used to confirm that critical isolation valves are not passing to other sections
of equipment (internal leakage).
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The low pressure leak test pressure shall be determined by the design pressure or the supply
pressure availability of dry air.
In general the test pressure shall be 5 or 6 barg but in any case must not exceed the Normal
Design Operating Pressure.
The Test Medium shall be determined by the type of service fluid handled within the system
to be tested.
In most cases the test medium shall be dried air, however in some special cases nitrogen may
be used.
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SERVICE TEST:
Service test shall mainly apply to Utilities and LP services with non-corrosive contents.
The leak testing of such systems shall be part of the Service test.
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REINSTATEMENT AND FINAL CHECKS:
Once the piping system has been cleaned, dried, purged and inspected, in accordance to
the specific procedure, the final reinstatement can be performed.
The final reinstatement shall be done in accordance to the P&ID’s, including:
► Rotating Equipment suction/discharge nozzles,
► Safety Valves,
► Car Seals,
► Mechanical Interlocks,
► Spring Hanger Pins removal & setting,
► Orifice Plates (FE’s, RO’s, FO’s),
► Rupture/Burst Disks,
► Sample Quills and Chemical Injectors.
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BOLT TENSIONING:
Bolt tensioning for critical units shall be applied and shall be generally applied to highpressure flanges with large diameters and bolts with bolt diameters that are generally
greater than 4”.
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FINAL WATER WASH (RINSE):
This procedure is important to remove any residual soda ash or chemical cleaning solution,
which can promote foaming in the amine system of Acid Gas Removal Unit.
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