Standard Operating Procedure SOP #: 6.009 Rev. 3

Leak Testing-Process Piping

Approval

Revision History

1 Purpose

1.1 To establish a standard procedure for pressure testing of metallic process piping (e.g. pure/clean steam, water-for-injection, clean in place, sterilize in place, RO/DI, etc.).

2 Scope

2.1 This procedure applies to all Therma projects requiring a pressure test for metallic process piping.

3 Responsibilities

3.1 Therma’s general foreman is responsible for performing the tasks listed herein.

3.2 Project Manager is responsible for coordination with Owner, GC & Jurisdictional Authority as required to witness testing start and finish.

4 Reference Standard

4.1 ANSI/ASME B31.3 Process Piping, Current Edition.

5 Safety

5.1 Foreman shall maintain safe working conditions throughout the process of leak testing including provisions for pre-task planning, hazard marking/signage and awareness, LOTO, pre-test inspections and barricades, etc.

5.2 Caution

5.2.1 Pneumatic testing involves the hazard of released energy stored in compressed gas. Care must therefore be taken to minimize the chance of brittle failure during pneumatic leak test.

5.2.2 If a pneumatic leak test would present unacceptable hazards, a substitute for pressure testing should be developed.

6 Procedures

6.1 Pneumatic Leak Test

6.1.1 Do not perform a pneumatic leak test unless permitted. Hydrostatic leak testing is recommended unless conditions below exist:

• When piping systems are designed not to be filled with water.
• When traces of the testing medium cannot be tolerated.
• When piping size is 6" or larger and city water pressure is too low.

6.2 Pressure Relief Device

6.2.1 A pressure relief device shall be provided, set not higher than 110% of the test pressure.

6.3 Test Fluid

6.3.1 Use nitrogen (N2) or carbon dioxide (CO2) gas as the test medium.

6.4 Leak Test Report

6.4.1 Complete Leak Test Report Form #FN 6.004.1 as much as possible prior to Pre-Test and Test (e.g.: test pressure; allowable drop; duration).

6.5 Pre-test Activities

6.5.1 Inspect the piping systems for visual defects and ensure all connections are tight. 6.5.2 Remove any instrumentation or equipment sensitive to higher test pressures. 6.5.3 Notify the owner or representatives to witness and sign the pressure test log if required.

6.6 Pre-Test or Gross Leak Test - Pneumatic

6.6.1 Slowly pressurize system to pre-test pressure and allow to stabilize for minimum of 1 hour. 6.6.2 Inspect for leaks, safely vent system and make repairs as necessary.

6.7 Hydrostatic Pressure Hold Test

6.7.1 Attach appropriate water supply to the piping system. 6.7.2 Fill and pressurize to approximately 20 psig and hold for at least ten minutes. 6.7.3 Gradually increase test pressure as per approved plans.

6.8 Pneumatic Pressure Hold Test

6.8.1 Fill and pressurize the piping to approximately 25 psig or one-half (1/2) times maximum designed operating pressure. 6.8.2 Maintain test for at least ten minutes, inspect for leaks and repeat if necessary.

6.9 Test Monitoring

6.9.1 Maintain hydraulic or pneumatic test pressure for at least ten minutes. 6.9.2 Record start date, time, test pressure, and temperature. 6.9.3 Confirm the system is leak free, restore instrumentation, and remove any warning tags.

7 Review and Approval

7.1 Therma’s General Foremen shall submit the Leak Test Report Form #FN 6.004.1 to Project Manager for review. 7.2 Project Manager shall review the form and submit to QC Manager/Owner for record.