PIPELINE PRESSURE TESTINGKOC.PS.004 - Safety in Pressure Testing of Process Pipingfl/TPage 1 of 15MWSafety in Pressure Testing of Process Piping Document No. KOC.PS.004Approver (Technical)Manager (IS)AuthorTL. Inspection & Corrosion (S&E)Approver (Administrative)Manager (HSE)Document CoordinatorTL. StandardsScopeAll KOC DirectoratesIssuing GroupHSE GroupIssue DateOctober 6, 2009Control TierTier 3Revision/Review DateMarch 10, 2013Next Revision DateMarch 09, 20161.0PURPOSE AND SCOPEThe purpose of this document is to provide the basic safety requirements while testing in-plant steel piping systems to safeguard KOC employees, Contractors employees and the assets.This document provides safety precautions that are to be considered by all concerned parties while undertaking the site pressure testing of KOC steel process piping whether new or existing. The document is to be applied along with a detailed procedure (s) that must be prepared by the testing authority for KOC review and approval. The requirements of the applicable related project/contract document, KOC standards and the ASME B31.3 Code for process piping shall also be adhered to. This document does not apply to non-metallic piping2.0DEFINITIONSThe following definitions are provided for application and/or information throughout this document2.1Hydrostatic TestingA testing that requires a component is completely filled with a liquid, such as water. Pressure is slowly applied to the liquid until the required pressure is reached. This pressure is held for the required time at which point the component is inspected visually to locate leaks or the pressure on the gauge is recorded to determine the components total leakage.2.2Test PlanA document providing details of the various elements associated with testing process, engineering aspects and safety that are required for the appropriate and safe undertaking of the pressure testing. The document shall include also chronological listing of activities and estimated timing for each activity.2.3Pre Start-up Leak Test:A pressure test to ensure tightness of flanged and threaded joints at the test pressure. It is normally conducted before initial start-up, during commissioning or after plant inspection/repair2.4Pneumatic Test:A pressure test conducted using air or other approved gas (inert gas) as the test medium.Control Tier 3 Rev. Date: March 10, 2013 Uncontrolled Copy if PrintedKOC.PS.004 - Safety in Pressure Testing of Process Pipingf?/YPage 2 of 15MW2.5Pressure Test:A test performed to equipment or piping subjecting it to an internal pressure using liquid or gas to ensure strength and/or tightness of the system at the test pressure.2.6Service Test:A pressure test conducted at operating pressure using the service fluid.2.7Strength Test:A pressure test at an internal pressure determined in accordance with the applicable Code to verify the integrity of the piping systems or equipment for service at the design pressure.2.8System Test:An on-site pressure test applied to a group of piping and equipment tested as a system.2.9Piping:Assemblies of piping components used to convey, distribute, mix, separate, discharge, meter, control, or snub fluid flows. Piping also includes pipe-supporting elements, but does not include support structures, such as building frames, bents, foundations.2.10Piping SystemAll portions of the physical facilities through which gas, petroleum gas, hazardous liquids, highly volatile liquids or carbon dioxide moves during transportation. This includes pipe, valves, and other appurtenances attached to the pipe, compressor units, pumping units, metering stations, regulator stations, delivery stations, breakout tanks, holders, and other fabricated assemblies.2.11Piping components:Mechanical elements suitable for joining or assembly into pressure-tight fluid-containing piping systems. Components include pipe, tubing, fittings, flanges, gaskets, bolting, valves, and devices such as expansion joints, flexible joints, pressure hoses, traps, strainers, in-line portions of instruments, and separators.2.12Piping elements:Any material or work required to plan and install a piping system. Elements of piping include design specifications, materials, components, supports, fabrication, examination, inspection, and testing.2.13Piping installation:Designed piping systems to which a selected Code edition and addenda apply.2.14Proof Pressure TestA test made when formal design calculations of the required thickness of all piping parts have not been accurately performed or are in doubt. The purpose of this test is to demonstrate the integrity of the piping. The test is applied gradually until the test pressure is reached or until significant yielding of any part of the piping occurs. This type of test requires detailed prior analysis and inspection work. It is not applied for new installations orControl Tier 3 Rev. Date: March 10, 2013 Uncontrolled Copy if PrintedKOC.PS.004 - Safety in Pressure Testing of Process Pipingf?/YPage 3 of 15MWmodifications to properly designed existing systems. This type of test been applied in KOC yet.2.15Standard Pressure TestThis test is used when the formal design analysis for the required thickness of all piping parts have been performed. The objective of this test is to prove the quality of materials used and the construction of the piping before it is allowed to enter or re-enter the service. This test is carried out at 1.25 to 1.5 times the design pressure2.16Leak Pressure TestA test designed to determine the presence or absence of leaks in a piping system. A leak test can be used alone or in addition to a strength pressure test as required by the pressure testing plan.This test may be carried out at a pressure not exceeding 10% of the design pressure for piping that have not been subjected to a standard pressure test. It may also be performed at a higher pressure not exceeding 110% of the design pressure on piping that have satisfactorily passed the standard pressure test.2.17Functional TestThis is the test that is carried out using a suitable test medium at design pressure or working pressure; if this is lower, to check that the pressure equipment and its components function properly. This may include the actuation of movable parts such as the opening and closing of valves.2.18Test Performing Party (TPP)An organization or contractor approved by KOC for managing and physically undertaking all the pressure testing phases including disposal of the testing media.2.19Work PermitA permit-to-work system is a formal written system used to control certain types of work that are potentially hazardous. A Work Permit is a document which specifies the work to be done and the precautions to be taken. It allows work to start only after safe procedures have been defined and it also provides a clear record that all foreseeable hazards have been considered.3.0 REQUIREMENTS KOC HSEMS Element No.4, Expectation No.8 KOC HSEMS Element No.5, Expectation No.3 4.0RESPONSIBILITIES 4.1Test Performing Party (TPP)(a)Prepare the detailed testing procedures and verify proper test medium as perpiping code, KOC standards, contract agreement and other relevant documents;Control Tier 3 Rev. Date: March 10, 2013 Uncontrolled Copy if PrintedKOC.PS.004 - Safety in Pressure Testing of Process Pipingf?/YPage 4 of 15MW (b)Prepare the test plan, test loops/diagrams and job safety analysis. Submit all to KOC for approval, revise as instructed and submit the final for site work; (c)Employ only competent (qualified and trained) personnel for carrying out the various test phases. Include safety officers among the testing team; (d)Provide all needed equipment and materials necessary for completing the Pressure Test. These should include but not be limited to: blinds, flanges, fittings, spools, valves, pressure relief valves, emergency pressure shut-off valves, filling and drainage connections, hoses, lifting appliances, pumps, compressors, regulators, fabricated assemblies, pressure and temperature gauges and charts, dead weight testers, and any other materials/components necessary for the successful application of the pressure testing. Protection chambers for high pressure tests shall be provided. (e)Verify test equipment and materials are of proper rating for the test pressures and certification paperwork. (f)Ensure that piping is tested in the installed position with all pipe supports fitted. If piping has to be dismantled additional supporting shall be provided to prevent overstressing of the system. Spring supports shall remain in the locked position. (g)Verify that all supply lines and hose connections are secure with retaining device(s).(h) Obtain Work Permits from KOC and/or concerned State Authorities asneeded. Provide appropriate and on-time notifications to all concerned parties. (i) Communicate to all test team members, their assigned task andresponsibilities (j) Ensure availability of sufficient communication tools adequate forcontinuous coordination of testing activities, personal protectiveequipment (PPE) for the task being performed and as required perKOCMS procedures. (k) Provide all necessary barricade, warning signs (in Arabic, English and otherlanguages as directed by KOC); (l) Check for adequate distance and/or protective barrier for conductingthe test from unanticipated pressure release or equipment failure. (m) Secures the testing media, treat the testing media as per the procedure and fillthe piping as per the approved procedure. (n) Carry out the testing as per the approved plan and procedure; (o) During testing, ensure there will be a continuous checking for visibleleaks. (p) During testing, ensure no unauthorized personnel are in the test area. (q) Rectifies any faced problems, retest, drain the line after successful testing, (r) Upon acceptance of the test by KOC, dispose the testing media at KOCapproved location, remove testing appurtenances and reinstate the piping,piping sections and work sites. (s) Submits to KOC upon completion, all related documents such as test reports,test logs and charts, (t) Remove all warning signs, flagging, and barricades. (u) Notify all personnel that the area is all clear.4.2 KOC Controlling Team (KOC CT)(a) Reviews the TPP testing plan, Job safety analysis (Risk analysis report), the test procedures and liaise with Inspection & Corrosion Teams, KOC Asset (s) and Directorate/Asset HSE Team (s) on all related issues;Control Tier 3 Rev. Date: March 10, 2013 Uncontrolled Copy if PrintedKOC.PS.004 - Safety in Pressure Testing of Process Pipingf?/YPage 5 of 15MW (b)Assists the TPP in obtaining the necessary work permits from concerned KOC Teams/Groups; (c)Ensures that the piping has been cleaned, flushed, repaired, NDT examined, mechanically completed, released for pressure testing and ready for various testing stages; (d)Interviews the TPP testing team (s) and ensures that all personnel are competent, qualified, have past experience on testing and received adequate training on this type of work; (e)Physically inspect the piping or the piping section (s) planned to be tested to ensure that all testing arrangements, materials and safety precautions have been appropriately provided as per the test plan and procedure; (f)Ensures that all permanent and temporary testing appurtenances have proper pressure rating (pressure class), wall thickness and materials that will withstand the test pressure and any loads and stresses imposed or expected due to unforeseen reasons and/or surges. (g)Assist the TTP in obtaining all necessary work permits from KOC or other external authorities.(h) Continuously supervise all stages of testing including filling, holding, depressurizing, draining, disposing of testing media, drying and reinstating the piping as well as the work site.(i) KOC CT is responsible for the proper close out of the work permits.4.3Inspection & Corrosion Team (ICT) (a)liaise with the KOC CT in reviewing and approving the test plan and test procedure received from the TPP; (b)Check that all activities related to the piping loop or the section to be tested, have been completed and accepted. This includes welding repairs and NDT examination, coating/lining application, coating repair and examinations, utilization of proper testing fittings, blanks and connections, testing and calibration of pressure/temperature charts, gauges and dead weight testers, chemical dosing pumps adequacy, ensures that proper chemicals are procured and that manufacturing date is valid. (c)Ensure that test fluid filling, stabilization, holding and depressurizing operations are made correctly and that air is vented in the proper way. (d)Witness the entire test operations and the various components to ensure that no leaks exist in any exposed piping, fitting, valves, etc. (e)Liaise with KOC CT and recommend the course of actions in case of failures in the test loop or the testing application. (f)Sign off the testing charts, log sheets and final test reports.4.4Asset /Directorate HSE Team (a)Review test plan and procedure to ensure that HSE requirements are provided and detailed specially for chemicals, hazards and other risks. (b)Assist in identifying hazard and risk associated with the testing operations. (c)Interview TPP HSE officer(s) to ensure that he/she is qualified and fully aware of his/her duties and the testing job details. (d)Ensures that all safety precautions are applied at the testing site including PPE, personnel awareness, proper handling of appliances and tools, adequate barricading at the exposed pressurized areas, presence of safety signs and warning, safe handling of chemicals, etc.Control Tier 3 Rev. Date: March 10, 2013 Uncontrolled Copy if PrintedKOC.PS.004 - Safety in Pressure Testing of Process Pipingf?/YPage 6 of 15MW (e)Monitor the disposal of testing water at approved location insuring that chemicals dont impose any harm to the environment. (f)Sign off relevant HSE reports indicating safe completion of the piping testing operations and water disposal. 5.0PROCEDURE 5.1PRESSURE TEST PLANThe TPP shall prepare the test plan that will include the following topics as a minimum: (a)the purpose of the plan; (b)Categories of flaws and threats; (c)Safety of the testing process; (d)Communications; (e)Operating conditions; (f)Types of pressure test considered (Refer Appendix 3); (g)Maximum test pressures;(h)Historical engineering and operation documents;(i)Piping/pipelines characteristics;(j)Target test pressures and pressure testing durations;(k)Pressure test failures;(l)Pressure test acceptance criteria5.2RISK ASSESSMENT5.2.1Risks associated with pressure testing should be analyzed as per the following fivesteps which must be considered by the TPP. Risk assessment report (RAR) shall besubmitted to KOC for review before obtaining the work permits. AT KOC discretion,RAR may be waived for simple test loops to be undertaken by competent TPP. (a)Hazard identification; (b)Decision on who might be harmed and how; (c)Evaluating the risks and deciding on precautions; (d)Recording the findings and implementing them; (e)Reviewing the assessment and updating as necessary.5.2.2Hazard IdentificationThe main hazard when pressure testing is the unintentional release of stored energy. Pneumatic testing can lead to a blast wave and missiles. Hydraulic testing blast has little energy.The hazards presented by the compressibility, flammability and toxicity of the testing medium should also be considered.5.2.3Stored Energy:Failures of equipment and piping under pressure testing would release stored energy due to the following reasons which must be considered by the TPP: (a)rupture due to brittle fracture; (b)rupture due to ductile fracture; (c)detachment or removal of blanks, bolts, screwed plugs, isolation valves, etc.Control Tier 3 Rev. Date: March 10, 2013 Uncontrolled Copy if PrintedKOC.PS.004 Page 7 of 15 Safety in Pressure Testing of Process Piping (d) detachment of temporary welds on plugs, at pipe ends and nozzles 5.2.4 Pneumatic Testing (a)The energy released during a total failure of pressure equipment/piping containing compressed air at pressures frequently used in pressure testing is more than 200 times the energy released by the same volume of water compressed to the same pressure. (b)Pneumatic testing shall only be carried out when hydraulic/hydrostatic testing is not practicable and with the permission of KOC. the following are cases where pneumatic testing may be allowed:(i)when the internal surfaces of equipment/piping will be contaminated bythe hydraulic test medium;(ii)when the pressure equipment/piping supports and/or foundations arenot capable of supporting the weight of the equipment/piping filled withthe test medium5.3 (c)When performing pneumatic testing, the test recording equipment and personnel should be located a minimum of 150 feet (~ 46.0 meters) from the equipment/piping under the test. Major work around the testing area and movement of personnel not involved in the test should be prohibited. (d)Pneumatic testing using oxygen shall be entirely prohibited. Only air or inert gasses are allowed.TESTING PROCEDURE5.3.1Purpose of pressure test (a)To detect and eliminate time dependent anomalies (b)To verify structural Integrity of a piping segment (c)To establish operating pressure limit (d)Before returning a line to service (e)Before changing the service of a line (f)To verify absence of leaks5.3.2Test Preparations(a)(b)(c) (d) The internal and external welds and joints where leaks are often found shallbe free of oil, grease, flux, slag, or other contaminants that might temporarilyblock or mask leakage. New systems should be tested prior to painting, wherepractical.Hydrostatic testing should not be performed before a leak test using air or atracer gas. The liquid test media may clog small leaks causing later tests to beinaccurate.The minimum temperature of the liquid should be 7CFor Stainless steel, nickel, or chromium alloys piping, the halogen or sulphurcontent of the de-ionized testing water shall be less than 50 ppm for each.Control Tier 3 Rev. Date: March 10, 2013 Uncontrolled Copy if PrintedKOC.PS.004 - Safety in Pressure Testing of Process Pipingf?/YPage 8 of 15MW (e)Testing shall not start until the fluid has stabilized and the metal temperature and the fluid temperature are approximately the same. (f)For carbon steel piping, rust inhibitor shall be used. (g)Pressure source and test gauge should be upstream of check valve. If pressure source is downstream, check valve should have flapper removed or jacked up. (Pressure must be released downstream of check valve after test completion.)(h) Ensure that test blinds installed are the correct thickness. Ensure that all itemssuch as control valves, relief valves, rupture disks, orifice plates, diaphragminstruments, expansion joints, etc., which could be damaged during pressuretest have been removed or isolated, as indicated on the approved pressuretest loop / flow diagram. (i) Ensure that equipment, such as filters, which have internals that may bedamaged during the pressure test; are either blocked from test or thatinternals have been removed. (j) Check all permanent and temporary supports that are marked on the pressuretest flow diagrams, piping arrangement drawings or spool drawings have beenproperly installed. (k) Ensure that equipment, such as compressors, which must not be included inthe field tests have been properly blocked off with the casing drain open. (l) Check open and closed position of all valves. Valves must be in open positionduring the test (Ball valves to be in the half open position). Valve trims shallnot be used as blinds. (m) Check for proper installation of vents and drains.5.3.3 Safety Considerations (a)TPP shall outline safety precautions and provide procedures for personnel who perform the test (hot work permits, confined space entry, personal protective equipment, lock-out/tag-out procedures, etc.). (b)TPP shall conduct hazard assessment and safety meetings with personnel who will perform the test. (c)TPP shall require all personnel conducting a hydrostatic test to comply with all state and KOC HSEMS procedure. (d)TPP shall identify precautions and procedures to minimize risk to the public and the environment, especially when chemically treated test water is to be used and during the removal of the test medium. (e)TPP to consider measures necessary to restrain temporary piping and hoses used during filling of the line with the test medium, during the pressure test and during the removal of the test medium. (f)TPP to consider additional measures to respond to possible test failures. (g)Safety valves of adequate size and marked with the set pressure should be installed in or close to the test supply line to prevent the test pressure being exceeded. It should not be possible to isolate these valves from the testingControl Tier 3 Rev. Date: March 10, 2013 Uncontrolled Copy if PrintedKOC.PS.004 - Safety in Pressure Testing of Process Pipingf?/YPage 9 of 15MWmedium pressure. Safety valves should be maintained in proper working condition and should have been tested for set pressure before using.(h) Flexible pipes and hoses and their connections should examined to reduce the risk of them bursting or coming apart. Safety restraints should be attached so as to prevent flexible pipes flailing about in the event of them coming apart.5.3.4Cautions During Testing (a)The pressure test gauge and charts shall normally be located at grade near the test pump. (b)Pressure test gauges shall be calibrated to ensure accurate readings. Gauges should be tagged with the date they were last calibrated. (c)Care must be exercised not to exceed pressure test specified on the pressure test data and procedure.5.3.5Pressure Test Implementation (a)Perform line cleaning and filling as per the KOC approved test procedure. Conduct test according to the approved written test plan procedure. (b)Maintain continuous surveillance over the operation to ensure that it is carefully controlled. (c)Maintain pressurizing rate as per the approved procedure; (d)Provide stabilization period as per the procedure. (e)Check all visible connections for leaks. (f)Never tighten connections that are under pressure. If a leak develops, you must depressurize to a safe level and then retighten. (g)Ensure unauthorized personnel are kept out of the test area.(h) Walk the piping route to visually check for evidence of leaks during thepressure test. (i) If a rupture or a substantial leak occurs, the test should be stopped todetermine the cause and the necessary steps taken to repair the source ofleak or area of failure. Retesting shall be started after obtaining the permissionof KOC. (j) If a small leak occurs, the pressure shall be reduced to an appropriate levelwhile locating the leak. After repairs, the test shall be restarted with a newhold period for either a strength or leak test. (k) Confirm acceptance of test by authorized KOC representative.5.3.6Examinations for Leaks(a) Test personnel shall ensure the hydrostatic pressure is maintained for sufficient time to determine if there are any leaks. A minimum time of two hours is required. After the hydrostatic pressure time has been satisfied, all joints shall be examined visually for leaks.Control Tier 3 Rev. Date: March 10, 2013 Uncontrolled Copy if PrintedKOC.PS.004 - Safety in Pressure Testing of Process Piping Page 10 of 15 (b)Examination shall be made of all welds, base metals and mechanical joints (Refer Appendix 4). There shall be no visible evidence of leakage. Welds and joints previously tested need not be examined for leaks. (c)Leakage detected in welded joints shall be repaired by draining, repair welding, non-destructively examining in accordance with original requirements, and re-tested to the original test pressure. (d)Mechanical joint leakage at permanent joints shall be repaired, examined in accordance with original requirements, and re-tested to the original test pressure. (e)When applying pneumatic testing, the pressure in the piping system shall be increased gradually in steps providing sufficient time to allow the piping to equalize strains during the test. When the system pressure reaches the lesser of the test pressure or 25 psi a preliminary leak check of the system shall be made. Following the preliminary leak check the pressure shall be increased gradually until the test pressure is reached. The pressure shall then be reduced to the design pressure before examining for leaks. (f)During pneumatic tests, all joints shall be examined with a bubble-producing solution specifically compounded for leak detection.5.4 DOCUMENTSComplete Test Document shall include but not limited to the following records. The records shall be submitted to KOC by the TPP after accepting the test and signing off the Pressure Test Record (Appendix 2). KOC has the right to review/approve part of the following documents before allowing the starting of pressure tests. (a)Description of line test. (b)Marked piping and instrument diagram (P&ID) showing limits of test loop. (c)Safety check sheet and Risk assessment report (RAR) (d)Piping pre test check list (e)Mechanical completion signed report (s) (f)Hydrostatic test report(g)Monitoring during testing data sheet(h)Welding check sheet(i)Heat treatment check sheet (if applicable)(j)NDT including hardness testing check sheets(k)Chemical cleaning check list(l)Flushing, cleaning and drying check list(m)Punch list check sheets/reports(n)Release note from KOC CT and ICT Representatives6.0REFERENCES (a)KOC- G - 11 Test Water for Hydrotesting and Lay-up (b)ASME B31.3, 2006 : Process PipingControl Tier 3 Rev. Date: March 10, 2013 Uncontrolled Copy if PrintedKOC.PS.004 - Safety in Pressure Testing of Process Pipingf?/YPage 11 of 15MW (c)HSE Guidance GS4: Safety in Pressure Testing (d)API PUBL 1157: Hydrostatic Test Water Treatment and Disposal Options for Liquid Piping Systems7.0 ABBREVIATIONS HSE - Health, Safety & Environment HSEMS - HSE Management System I&C - Inspection & Corrosion IS - Industrial Services KOC - Kuwait Oil Company8.0 HSE RECORDS (RETENTION PERIOD)Refer to Section 5.4 above (5 years)Review/Revision LogReview/ Revision DateDocument ApproverDocument AuthorRevision DetailsJune 18, 2009Manager ISTL I&C (S&EK)Draft circulated for comments.Oct. 06, 2009Manager ISTL I&C (S&EK)Approved by HSEMS implementation committee & issued for ImplementationMar. 10, 2013Manager ISTL I&C (S&EK)Document number changed from KOC.IM.004 to KOC.PS.004. Added new sections Section 3.0 Requirements, Section 7.0 Abbreviations and Section 8.0 HSE Records. Document fully formatted as per the HSEMS document control procedure.Control Tier 3 Rev. Date: March 10, 2013 Uncontrolled Copy if PrintedKOC.PS.004 - Safety in Pressure Testing of Process Piping'^C^*Page 12 of 15MWAPPENDIX 1 Warning Sign, TypicalHigh pressure in ProgressThe colours of the sign shall be as follows:Background colour: yellowTriangular band: blackGraphical symbol: blackBorder: yellow or whiteThe safety colour shall cover at least 50 % of the total area of the sign. (Ref: ISO 3864-1, 2002)Control Tier 3 Rev. Date: March 10, 2013 Uncontrolled Copy if PrintedKOC.PS.004 - Safety in Pressure Testing of Process Piping'fiftPage 13 of 15MWAPPENDIX 2 PRESSURE TEST RECORD FORMAT[Edit to suit but capture all data required for ASME B31.3 compliance]Test Package Number:Project No.: Contract No.:Page: 1 of xxxProject Title:Test InformationSystem Description:Description of Test Boundaries: (Attach Sketch Showing Boundaries as Required. P&ID Recommended)Design Temperature: Design Pressure:Test Method: Test Type: Hydrostatic Strength Pneumatic: D LeakTest Fluid:Test RequirementsRequired Test Pressure:Required Test Duration:Gauge Pressure CalculationElevation Difference Between Gauge And High Point: Air Content Calculated/PlottedTest Pressure at Lowest PointTest Pressure at Highest PointTest ResultsTest Date:Start Time:Finish Time: APPLICABLE CODE:Test Fluid Temperature:Ambient Temperature:AM AMPM PMActual Gauge Pressure:Test EquipmentNB: This is a typical Test Record Format. Other format may be agreed upon if found to add more data and information on the piping test.Control Tier 3 Rev. Date: March 10, 2013 Uncontrolled Copy if PrintedKOC.PS.004 - Safety in Pressure Testing of Process Pipingfl/TPage 14 of 15MWAPPENDIX 3 Piping Tests as Per ASME B31.3 for Process PipingProcess Piping Pressure Tests as per ASME B31.3 CodeFluidService/PipingTypeType of TestHydrostaticPneumaticCombined Hydro/Pneumatic.AlternativeSensitiveInitial ServiceCategory D MetallicPrimary leak test methodMay be substituted in lieu of the hydrostatic method when approved by KOC.May be substituted in lieu of the hydrostatic method when approved by KOC.May be substituted for the hydrostatic or pneumatic leak tests (1)Part of the Alternative Leak TestMay be used at KOC's option in lieu of the hydrostatic leak testCategory DNon-MetallicPrimary leak test methodMay be substituted in lieu of the hydrostatic method when approved by KOC.May be substituted in lieu of the hydrostatic method when approved by KOC.Not ApplicableNot ApplicableMay be used at KOC's option in lieu of the hydrostatic leak testNormal Fluid Service MetallicPrimary leak test methodMay be substituted in lieu of the hydrostatic method when approved by KOC.May be substituted in lieu of the hydrostatic method when approved by KOC.May be substituted for the hydrostatic or pneumatic leak tests (1)Part of the Alternative Leak TestNot ApplicableNormal Fluid Service Non-MetallicPrimary leak test methodMay be substituted in lieu of the hydrostatic method when approved by KOC.May be substituted in lieu of the hydrostatic method when approved by KOC.Not ApplicableNot ApplicableNot ApplicableCategory M MetallicPrimary leak test method. Requires additional Sensitive Leak Test.May be substituted in lieu of the hydrostatic method when approved by KOC. Requires additional Sensitive Leak Test.May be substituted in lieu of the hydrostatic method when approved by KOC. Requires additional Sensitive Leak Test.May be substituted for the hydrostatic or pneumatic leak tests (1)Required to be used inconjunction with hydro, pneumatic, combined test methods, or as a part of the Alternative Leak TestNot ApplicableCategory M Non-MetallicPrimary leak test methodMay be substituted in lieu of the hydrostatic method when approved by KOC.May be substituted in lieu of the hydrostatic method when approved by KOC.Not ApplicableNot ApplicableNot ApplicableHighPressureMetallicPrimary leak test method(2)May be substituted in lieu of the hydrostatic method(2)May be substituted in lieu of the hydrostatic method(2)Not ApplicableNot ApplicableNot Applicable(1)May be substituted for the hydrostatic or pneumatic leak tests provided:a)KOC has determined a hydrostatic test would damage linings or internal insulation, or contaminates a process whichwould be hazardous, corrosive, or inoperative in the presence of moisture, or would present the danger of brittle fracture dueto low metal temperature during the test.b)KOC has determined a pneumatic test would present undue hazard of possible releases of energy stored in the system, orwould present the danger of brittle fracture due to low metal temperature during the test. In either case approval of the I&CTeams must be obtained.(2)Additionally the piping in the installed configuration must be tested to 110% of the design pressure.Control Tier 3 Rev. Date: March 10, 2013 Uncontrolled Copy if PrintedKOC.PS.004 - Safety in Pressure Testing of Process Piping'^C^*Page 15 of 15MWAPPENDIX 4Examples of Failures Revealed During Pressure TestingFig. 1: A 6 Class 300, A350 LF2 Sch. 40 flange-to-pipe weld Passed radiographic inspection but leaked on hydrotestFig. 2: New 4 Sch. 40 A234 WPB Tee Leak discovered during hydrotestControl Tier 3 Rev. Date: March 10, 2013 Uncontrolled Copy if Printed