1、 A guide to the pressure testing of in-service pressurised equipment PUBLICATION 168 Edition 2 Released by IHS. NOT FOR RESALE THE ENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATION A guide to the pressure testing of in-service pressurised equipment PUBLICATION 168 Edition 2 Copyright 2010 The En
2、gineering Equipment and Materials Users Association. A company limited by guarantee. Registered in England. Company number 477838. ISBN 978 0 85931 181 6 Imprint reference 07-2010 Registered and Trading Address 10-12 Lovat Lane London EC3R 8DN Telephone: +44 (0)20 7621 0011 Fax: +44 (0)20 7621 0022
3、E-mail: saleseemua.org Website: www.eemua.org EEMUA Publication 168 - A guide to the pressure testing of in-service pressurised equipment EEMUA ii ENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATION The Engineering Equipment and Materials Users Association, more commonly known as EEMUA, is a Europ
4、ean non-profit membership Association helping companies that own or operate industrial facilities - the users of engineering equipment and materials. EEMUA aims to improve the safety, environmental and operating performance of industrial facilities in the most cost-effective way, thereby demonstrati
5、ng and pursuing leadership in asset management. EEMUA Members pursue these aims through collaboration for mutual benefit, sharing engineering experiences and expertise and by promoting their distinct interests as the users of engineering products. Specifically, the aims of EEMUA Member companies are
6、 achieved by: providing the organisation within which networking, information sharing and collaboration on non-competitive technical matters can take place; influencing the way written regulations are interpreted and applied in practice; presenting and promoting Members views, and encouraging the ap
7、plication of good, sound engineering practices; developing user guides, specifications, training and competency schemes; facilitating Members participation in national and international standards making; influencing relevant national and European legislation and regulations. Formed in 1949 as the En
8、gineering Equipment Users Association, and re-named in 1983 (as a result of taking over the materials association, OCMA), EEMUA has for more than sixty years given companies that own and operate process plants, power stations and other significant industrial facilities, a collaborative voice in addr
9、essing technical and engineering related issues that impact on good integrity management and asset management practices. The Association is open to companies of all sizes that meet its engineering user criteria. Further details of current Members of EEMUA is available on the Associations website, ww
10、w.eemua.org. EEMUA activities often lead to the production of publications. These are prepared for Members use and are often offered for sale as well. A list of EEMUA publications for sale is given at the end of this Publication. The full list is also on the Associations website, including details o
11、f on-line shopping facilities. To enquire about corporate Membership, write to enquirieseemua.org or call +44 (0)20 7621 0011. EEMUA Publication 168 - A guide to the pressure testing of in-service pressurised equipment EEMUA iii ABOUT THIS PUBLICATION Legal Aspects All rights, title and interest in
12、this Publication belong to EEMUA. All rights are reserved. No part of this Publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means: electronic, mechanical, photocopying, recording or other, without the express prior written agreement of the EEMUA Execu
13、tive Director. Infringement of copyright is illegal and also reduces the Associations income thereby jeopardising its ability to fund the production of future publications. It has been assumed in the preparation of this Publication that: the user ensures selection of those parts of its contents appr
14、opriate to the intended application; and that such selection and application is correctly carried out by appropriately qualified and competent persons for whose guidance this Publication has been prepared. EEMUA and the individual members of the Work Group that prepared this EEMUA publication do not
15、, and indeed cannot, make any representation or give any warranty or guarantee in connection with material contained herein. EEMUA and the individual members of the Work Group that prepared this EEMUA publication expressly disclaim any liability or responsibility for damage or loss resulting from th
16、e use or reliance on this Publication. Any recommendations contained herein are based on the most authoritative information available at the time of writing and on current good engineering practice, but it is essential for the user to take account of pertinent subsequent developments and/or legislat
17、ion. Any person who encounters an inaccuracy or ambiguity when making use of this Publication is asked to notify EEMUA without delay so that the matter may be investigated and appropriate action taken. Consultation and Feedback EEMUA encourages constructive comments on this Publication from both Mem
18、bers of the Association and others. Comments should be sent on the standard feedback form, a copy of which is provided towards the end of this Publication. An electronic version of the feedback form is available from EEMUA - e-mail your request for a copy to enquirieseemua.org, telephone your reques
19、t to +44 (0)20 7621 0011, or download the form from the EEMUA website at www.eemua.org. Submit comments by e-mail (preferred) or post. Comments are considered by the relevant EEMUA Technical Committees and may be incorporated in future editions of this Publication. New editions are publicised on the
20、 EEMUA website. EEMUA Publication 168 - A guide to the pressure testing of in-service pressurised equipment EEMUA iv EEMUA Publication 168 - A guide to the pressure testing of in-service pressurised equipment EEMUA v Contents Scope vii Purpose of this Publication viii Definitions ix 1. Introduction
21、1 2. Purpose of Pressure Testing 3 3. Requirements for a Pressure Test . 5 3.1 General . 5 3.2 Waiving a Pressure Test . 5 3.3 Duration of Pressure Test . 6 3.4 Witnessing Pressure Tests 6 4. Test Fluid 7 4.1 Hydraulic (Hydrostatic) Pressure Tests 7 4.2 Fluids other than Water . 7 5. Test Pressure 9
22、 5.1 Standard Pressure Test 9 5.2 Leak Testing 9 6. Test Temperature 11 7. Practical and Safety Aspects . 13 7.1 Hydraulic Pressure Testing . 13 7.1.1 Preparation . 13 7.1.2 Filling . 14 7.1.3 Testing . 14 7.1.4 Release of Test Pressure . 15 7.2 Pneumatic Pressure Testing . 15 8. Special Precautions
23、 . 17 8.1 Unfired Pressure Vessels 17 8.2 Steam Boilers . 17 8.3 Fired Heaters . 17 8.4 Storage Tanks 17 8.5 Heat Exchangers . 17 8.6 Piping Systems . 17 8.7 Pump Casings, Valves and Other Items . 18 8.8 Gas Cylinders . 18 8.9 Transmission Pipelines . 18 9. References 19 10. Bibliography 21 Appendix
24、 I Comparison of Inspection Techniques . 22 Appendix II Extract from HSE GS4 1998. Definition of Terms 23 Appendix III Test Fluids: Comments and User Experiences 24 AIII.1 General Comments 24 AIII.2 Specific User Experiences . 24 AIII.2.1 Oil Refinery 24 AIII.2.2 Chemical Plant . 25 Figure Figure 1
25、Considerations before returning used pressure equipment to service . 4 Table Table 1 Comparison of Inspection Techniques (IMechE, 2003) . 22 EEMUA Publication 168 - A guide to the pressure testing of in-service pressurised equipment EEMUA vi EEMUA Publication 168 - A guide to the pressure testing of
26、 in-service pressurised equipment EEMUA vii Scope EEMUA Publication 168 provides guidance on if, when and how pressure testing can be carried out on used pressure equipment and systems, based on a risk assessment and a safe system of work, before returning it to service. It gives a formal and clearl
27、y identifiable process which can be followed to manage and minimize the risks associated with in-service pressure testing. Some alternatives to pressure testing are also considered, and when it may be appropriate to employ them. The Guide gives practical advice on the testing and inspection which ma
28、y be carried out once the service life of pressure equipment has begun, but excluding the initial installation and commissioning. It is applicable to all types of non-transportable industrial pressure equipment and systems, including pressure vessels and pipework. This Publication is aimed primarily
29、 at employees, managers and supervisors of pressure testing teams of both plant operators and owners. Engineers in other disciplines or with other responsibilities may also find the information useful. Exclusions from Scope The following topics are either excluded from the scope of this Publication
30、or not dealt with in any great detail: Initial installation and commissioning of unused equipment is excluded. The pressure testing of atmospheric storage tanks is considered a special case, and therefore not included in the scope. The subject is dealt with in EEMUA Publication 159(1). Equipment tha
31、t is subjected to heat for long periods, and/or that has been designed originally to operate in the creep region is not normally pressure tested. For such equipment, alternative non-destructive testing (NDT) and inspection techniques are available. This Publication introduces the subject of testing
32、and inspecting pressure equipment designed to operate in the creep region before it is returned to service. However, it does not at least in the current Edition go into any great detail. Proof testing is excluded. This is a special kind of pressure test used to establish the maximum allowable workin
33、g pressure of a system where this has not been calculated. Test waivers. Occasionally, it might be justifiable for equipment which would normally be pressure tested before returning to service to have the pressure test waived. The pressure test waiver is considered a special case, and excluded from
34、the scope. For guidance on the pressure test waiver, readers are referred to EEMUA Publication 223(2). Subsea equipment: special circumstances may apply to subsea installations. EEMUA Publication 168 - A guide to the pressure testing of in-service pressurised equipment EEMUA viii Purpose of this Pub
35、lication Pressure equipment and systems, including pipework, are ubiquitous throughout industry. Europes pressure equipment market alone has an annual turnover of many tens of billions of Euros. Once new pressure equipment is placed on the market, it will often remain in service for decades. During
36、its long service life, the equipment may be subjected to many repairs, modifications and re-rating requiring significant inspection and testing. Pressure equipment in service presents hazards from stored energy, escape of harmful fluids, or both, and may result in significant loss of plant and harm
37、to people as, regrettably, some high profile accidents have shown. If such disasters are to be avoided in the future, then every opportunity should be taken to learn from others. This Publication aims to contribute to the learning by capturing the combined knowledge and expertise of pressure equipme
38、nt users across a range of industrial segments. Revision from the First Edition The First Edition of this Publication was produced in 1991. Since then there has been a significant rise in the understanding of the technology surrounding pressure testing. The variety and reliability of non-destructive
39、 testing techniques has increased and the application of fracture mechanics has provided a more quantitative approach. This new Second Edition reflects these developments. The Standards for pressure vessels at least, those where proof stress is of primary concern have also changed since the First Ed
40、ition was published. BSIs PD 5500(3) (formerly BS 5500) is a Standard for unfired pressure vessels. It is still used for the design of some new vessels and was used for many older vessels. EN 13445(4-7), the European standard for unfired pressure vessels, is now in place. In-service equipment might
41、therefore be found which was designed to any of these standards. In this Second Edition both the BSI and the EN standards are referenced, as well as the US (ASME) design code(8). Consequently, for this new Second Edition, the original Chapters 1, 5, 6 and 7 have been substantially re-written. Indeed
42、, Chapter 1 has been changed so much it is essentially a new chapter. By contrast, Chapters 2, 3, 4, and 8 have been updated, but remain largely unchanged from the First Edition. Appendices I and II are entirely new, as are Figure 1 and Table 1. Acknowledgement The work of B. J. Darlaston in helping
43、 the EEMUA Committee/authors to draft the Second Edition of this Publication is acknowledged. EEMUA Publication 168 - A guide to the pressure testing of in-service pressurised equipment EEMUA ix Definitions Creep designed Equipment designed to operate at elevated pressure equipment temperatures wher
44、e creep and rupture are a design consideration. Proof stress designed Equipment designed to operate at temperatures pressure equipment where proof stress is a design consideration. EEMUA Publication 168 - A guide to the pressure testing of in-service pressurised equipment EEMUA x EEMUA Publication 1
45、68 - A guide to the pressure testing of in-service pressurised equipment EEMUA 1 1. Introduction In some countries it is a statutory obligation to carry out a pressure test on certain equipment at prescribed intervals. The requirements vary across the European Union (EU) Member States as well as els
46、ewhere. In the United Kingdom, for example, there is no statutory requirement to conduct pressure tests at prescribed intervals. As a result of the different requirements and historical traditions from country to country, the practices applied by EEMUA Member companies vary considerably. It should a
47、lso be recognised that pressure testing of pressure equipment operating for long periods at elevated temperatures and/or designed to operate in the creep region, is not usually appropriate, and alternative strategies may be employed. This Publication does not seek to impose policy, but rather to set
48、 out the various factors and aspects to consider when determining if, when and how a pressure test should be carried out. A process flow diagram to assist with decision making about testing and inspection before returning pressure equipment and systems to service is suggested in Figure 1 on page 4.
49、When undertaking a pressure test on used equipment, there are a number of issues that must be addressed in order to ensure the safety of personnel and the continuing integrity of the equipment. A pressure test involves using an incompressible fluid (usually water, when it can variably be called a hydraulic test, hydrostatic test or hydrotest) or a compressible fluid (air, steam, etc., when it is called a pneumatic test), under high pressure. In either case there is the potential for the sudden releas
