Pressure Piping Alternative Test Methods Procedure .

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the pressure equipment safety authorityPressure Piping Alternative TestMethodsProcedure RequirementsAB-519Edition 2, Revision 2Issued 2020-06-08

Pressure Piping Alternative Test Methods Procedure RequirementsTable of ContentsFORWARD . ii1.0INTRODUCTION . 12.0DEFINITIONS . 13.0BACKGROUND AND REGULATORY REQUIREMENTS . 24.0CHECKLISTS AND SAMPLE FORMS FOR OWNER-USER PROCEDURES. 4APPENDIX 1: SAMPLE ALTERNATIVE TEST METHODS IN LIEU OFHYDROSTATIC LEAK TEST REQUEST FORM . 9APPENDIX 2: SAMPLE IN-PROCESS INSPECTION/EXAMINATION TRAVELSHEET . 10APPENDIX 3: SAMPLE INITIAL SERVICE LEAK TEST TRAVEL SHEET . 115.0REVISION LOG. 12Issued 2020-06-08AB-519 Edition 2, Revision 2i

Pressure Piping Alternative Test Methods Procedure RequirementsFOREWORDAs provided for under Section 30(2) of the Pressure Equipment Safety Regulation(PESR), the Administrator in the pressure equipment discipline has established thatABSA document AB-519 “Pressure Piping Alternative Test Methods: ProcedureRequirements” specifies requirements for quality management systems and forprocedures pertaining to the use of alternative pressure piping test methods by anOwner-User organization.Issued 2020-06-08AB-519 Edition 2, Revision 2ii

Pressure Piping Alternative Test Methods Procedure RequirementsMinimum Requirements for an Owner-User Procedure That Allows1Alternative Test Methods in Lieu of Hydrostatic Leak Testing forPressure Piping Constructed to ASME B31.31.0INTRODUCTIONThis document outlines the minimum requirements that must be included in an OwnerUser integrity management system procedure that would allow the use of alternativetest methods for an ASME B31.3 closure weld, without ABSA acceptance of eachoccurrence. The provision to utilize alternative test methods without ABSA acceptanceof each specific occurrence is only applicable to an Owner-User company (i.e., AQP8XXX series Certificate of Authorization Permit holder) with an in-house Chief Inspectorthat has requested authorization to utilize the alternative test methods within the scopeof their Owner-User program and has implemented a procedure for this activity that hasbeen accepted by ABSA. The AB-519 procedure may also be utilized to documentjustification and approval for alternative test methods (i.e. initial service leak testing perASME B31.3, paragraph 345.7) on category D fluid service piping systems that will notbe leak tested in accordance with B31.3 paragraphs 345.4, 345.5 or 345.6. The PESR& ASME B31.3 Pressure Piping System Leak Testing Decision Chart included as Figure1, on page 3 of this document, provides a guide to the combined PESR andconstruction code requirements for leak testing.An Owner-User company that does not have an in-house Chief Inspector mayimplement a procedure that meets the requirements outlined within this document toprepare the necessary justification to use alternative test methods, but would have toobtain specific ABSA acceptance (i.e., from the applicable ABSA field Inspector) foreach closure weld that would not be hydrostatically leak tested in accordance with thePESR.ABSA policy documents are living documents that are reviewed periodically to ensurethat they are aligned with current industry practices. We would welcome anysuggestions you have to improve this document. Please provide your comments toinspections@absa.ca.2.0DEFINITIONSClosure Weld - The final weld connecting piping systems and components that will notbe leak tested in accordance with ASME B31.3 paragraphs 345.4, 345.5 or 345.6;a) between two piping systems made of new materials that have not been in serviceand have separately been successfully leak tested, or1The “Alternative Test Methods” terminology used throughout this document and the associated sample forms is asreferred to in Section 30 of the Alberta Pressure Equipment Safety Regulation, and must not be confused with the ASMEB31.3 paragraph 345.9 Alternative Leak Test terminology, as these are different subjects.Issued 2020-06-08AB-519 Edition 2, Revision 2Page 1 of 13

Pressure Piping Alternative Test Methods Procedure Requirementsb) between a piping system made of new materials that has not been in service andhas been successfully leak tested and a piping system that either is or has been inservice. In this case the condition of the portion of the piping system that is or hasbeen in service is important to the quality of the closure weld.In-Process Examiner - The “owner’s Inspector” as described in ASME B31.3paragraph 340 or a competent person delegated by the owner’s Inspector, asdescribed in paragraph 340.4(c), to perform the specified inspection activity. Thepersonnel performing in-process examination shall not perform the production work(e.g. the welder, fitter, etc), and shall be acceptable to the owner.3.0BACKGROUND AND REGULATORY REQUIREMENTSSection 30(1) of the PESR requires that “all pressure piping leak tests must beconducted using the hydrostatic method”. The PESR also provides in Section 30(2) that“despite subsection (1), the Administrator may accept, for a specific pressure pipingsystem, alternative test methods that are allowed in a code or standard that is declaredin force”. Therefore an ABSA Inspector may act on behalf of the Administrator in thisregard, if it is within their delegation of powers, to accept, for a specific pressure pipingsystem, alternative test methods under the PESR. Additionally, the Administrator hasauthorized the acceptance of Owner-User procedures for alternative test methods thatmeet the requirements outlined in this document without specific submission for eachclosure weld, in the case of an Owner-User company with an in-house Chief Inspector.Within PESR Section 6, the ASME B31.3 Process Piping code is declared in force.Although ASME B31.3 permits the use of an initial service leak test in lieu of thehydrostatic leak test for Category D fluids, because of the superseding PESRrequirement for hydrostatic testing [i.e., Section 30(1)] of all pressure piping, the ownermust apply the process described in this requirements document to justify initial serviceleak testing in accordance with B31.3 paragraph 345.7. Additionally, in ASME B31.3there are alternative test methods described as well as a provision to exempt certainwelds (closure welds) from the required leak tests. In paragraph 345.2.3(c), a closureweld is described as “the final weld connecting piping systems and components whichhave been successfully tested in accordance with paragraph 345 ”. It goes on to saythat these welds “need not be leak tested provided the weld is examined in-process inaccordance with paragraph 344.7 and passes with 100% radiographic examination inaccordance with paragraph 344.5 or 100% ultrasonic examination in accordance withparagraph 344.6”.Issued 2020-06-08AB-519 Edition 2, Revision 2Page 2 of 13

Pressure Piping Alternative Test Methods Procedure RequirementsFIGURE 1:Issued 2020-06-08AB-519 Edition 2, Revision 2Page 3 of 13

Pressure Piping Alternative Test Methods Procedure Requirements4.0CHECKLISTS AND SAMPLE FORMS FOR OWNER-USERPROCEDURESThe following checklists outline minimum Alberta requirements, which meet or exceedthe ASME B31.3 requirements, for an Owner-User procedure permitting the use ofalternative test methods in lieu of hydrostatic leak testing for a closure weld within apressure piping system constructed in accordance with the Alberta Safety Codes Actand B31.3. Sample forms are also provided as Appendices of this requirementsdocument for guidance in procedure development.The Owner-User company procedure must be submitted to and be accepted by ABSAprior to use. This procedure acceptance will usually be as part of the Owner-Userintegrity management system implementation audit process.An Owner-User company with an in-house Chief Inspector that has implemented aprocedure complying with all of the following requirements would be authorized to usealternative test methods in lieu of a hydrostatic leak test for closure welds under thescope of their Owner-User integrity management system.An Owner-User company that does not have an in-house Chief Inspector mayimplement procedures complying with all of the following requirements and use thisprocedure to justify the use of alternative test methods in lieu of a hydrostatic leak test.In such cases each submission for a specific closure weld that would use alternativetest methods would require acceptance from the applicable ABSA field Inspector. TheAlternative Test Methods in Lieu of Hydrostatic Pressure Test Request form orequivalent document would be submitted to the ABSA field Inspector to initiate therequest for acceptance of alternative test methods for the specific closure weld, unlessthe alternative test methods had already been accepted as part of the pressure pipingdesign submission (i.e., IMS Procedure Requirements for Closure Welds checklist item19).IMS Procedure Requirements for all Closure WeldsRequirement123CoveredThe procedure must identify the scope of the procedure (i.e., closure welds betweenpiping systems made from new materials only, or closure welds between piping systemsmade from new materials and a piping system that is or has been in service, or both).The procedure must indicate that it is to be applied on a per weld basis and that approvalmust be obtained before work can begin. A method of providing documented evidence ofthe considerations and approvals required must be included in the procedure (e.g., asample Alternative Test Methods in Lieu of Hydrostatic Pressure Test Request Form isavailable).The procedure must indicate who is required to approve the use of the procedure and howthat approval will be documented (i.e., an Alternative Test Methods in Lieu of HydrostaticPressure Test Request form, or equivalent). The Chief Inspector or an individual withequivalent authority must approve procedure use, as well as the Designer of the pipingsystem (see # 8 and 9 below).The Alternative Test Methods in Lieu of Hydrostatic Pressure Test Request form, orequivalent document that is developed as part of the AB-519 IMS procedure, must besubmitted along with the IMS procedure for acceptance by ABSA. A sample form todocument approvals is provided as Appendix 1.Issued 2020-06-08AB-519 Edition 2, Revision 2Page 4 of 13

Pressure Piping Alternative Test Methods Procedure RequirementsIMS Procedure Requirements for all Closure WeldsRequirement456789CoveredThe procedure must require that technical justification for not completing the hydrostaticpressure test is given and must require that all other test methods that have beenexplored are listed. Examples of justifications (acceptable & not) would be:(a) Ambient temperature below freezing temperature of water. This is not justificationalone as other test fluids appropriate for low temperature testing applications may beused, at temperatures below the freezing temperature of water.(b) Acceptable technical justification may be that residual water will contaminate theprocess and the potential energy of a pneumatic test exceeds recognized safetyhazards.(c) Another acceptable justification may be that the closure weld being made is a tie-into a piping system that is not designed for the additional stress caused by ahydrostatic test (i.e., because the supports are not designed for the additional weightof the water) and the potential energy of a pneumatic test exceeds recognized safetyhazards.The procedure must indicate who is required to supervise/track the use of the procedureand who is required to perform the in-process examination. (e.g., This is probably twodifferent people. Supervision of the procedure would most likely be the Owner-User ChiefInspector and the person conducting the in-process examinations would be the In-ProcessExaminer.) NOTE: The personnel performing in-process examination shall notperform the production work (e.g. the welder, fitter, etc), and shall be acceptable tothe owner.The procedure must indicate the piping Code of Construction that the procedure applies to(i.e., ASME B31.3, not ASME B31.1).It must identify the limitations of when the procedure can be used; service conditions (i.e.,pressure, temperature, fluid service, etc), thickness, type of weld (i.e., butt-weld, socketweld), applicable piping sizes, and indicate that outside of these limitations ABSAacceptance of the specific alternative test method is required. If the AB-519 procedure willinclude provisions to document justification for service leak testing of category D fluidservice piping systems this must also be identified or if another procedure is utilized forthis purpose the relevant process shall be identified.Applicable piping design stress calculations and other engineering analysis in accordancewith the Code of construction are required irrespective of the test method; however, aspart of the alternative test method procedure it is required that the Designer, as describedin ASME B31.3 paragraph 301.1, verifies and re-affirms that the applicable stresscalculations and other engineering analysis have been completed and that the pipingstresses meet the Code acceptance criteria.The construction Code defines the temperatures, pressures, and forces applicable to thedesign of piping, and states the consideration that shall be given to various effects andtheir consequent loadings.For example: All B31.3 piping design and construction must consider piping stresses andinclude a formal flexibility analysis unless exempted by one of the following criteria (Ref.B31.3 319.4.1):(a) The piping duplicates, or replaces without significant change, a system operatingwith a successful service record.(b) Can readily be judged adequate by comparison with previously analyzed systems.(c) Is of uniform size, has no more than two points of fixations, no intermediaterestraints, and falls within the limitations of the equation given in 319.4.1(c). It shouldbe noted that the equation given in 319.4.1(c) is not applicable to piping systemsused under severe cyclic conditions.The piping system Designer must be required to document their re-affirmation andapproval on the Alternative Test Methods in Lieu of Hydrostatic Pressure Test Requestform.Issued 2020-06-08AB-519 Edition 2, Revision 2Page 5 of 13

Pressure Piping Alternative Test Methods Procedure RequirementsIMS Procedure Requirements for all Closure WeldsRequirement101112131415CoveredThe procedure must state that all piping components (e.g., piping spools) must behydrostatically leak tested prior to final closure weld completion.The exception, which should be explained in the procedure, is for piping systems inCategory D fluid service which may be subjected to an initial service leak test whenjustified; as described within the procedure (e.g., after consideration of the criticality of theservice fluid and the risk of failure the initial service leak testing approval is documentedon the Alternative Test Methods in Lieu of Hydrostatic Pressure Test Request form).100% RT/UT of final butt-weld is required.100% MT/PT of root pass and final weld is required for butt-welds and 100% MT/PT offinal weld for all other types of closure welds. MT/PT of the final weld will be completedafter the weld has been allowed to slow cool to ambient temperature. The requirement forbutt-weld root pass MT/PT is not intended to apply where conducting the examinationwould contravene WPS heating/cooling requirements.All RT exposures shall be completed by a qualified or Certified Exposure Device Operator(CEDO) and interpreted by a CGSB or SNT-TC-1A Level II or Level III examiner. All otherNDE shall be completed and interpreted by a CGSB or SNT-TC-1A Level II or Level IIIexaminer. The criteria for interpretation shall be as required for the applicable fluidservice, provided by ASME B31.3, Table 341.3.2. The timing of the NDE shall beidentified (e.g., delayed NDE is advised if hydrogen contamination is possible).An initial service leak test on start up, as described in ASME B31.3 paragraph 345.7, andcontrol of the initial pressurization is required for the closure weld joint.The procedure must include, as an attachment, a generic ITP (or Travel Sheet) for the InProcess Examination that addresses the items listed in Step 3 of this checklist A sampleform to document in-process inspections/examinations is provided as Appendix 2.16171819The procedure must indicate the minimum qualifications and competency of the welderand the individual performing the In-Process Examination (Welder – B pressure &applicable WPQ performance variables for the scope of work, In-Process Examiner –‘owner’s Inspector’ as defined by B31.3 or a competent person delegated by the owner’sInspector).The welding must be done using a registered WPS that is appropriate for the scope ofwork.The work must be performed by a pre-approved contractor with an ABSA certified qualityprogram to construct B31.3 piping. The contractor’s quality system shall be appropriate forthe scope of work.3If the design requires submission to ABSA Design Survey (i.e., volume 0.5m ) then thepiping design submission must identify any closure welds, and the use of the acceptedOwner-User alternative test methods procedure must be noted in the submission.Regardless of whether the design is required to be submitted for design registration, it isgood practice to identify closure welds at the design stage.Issued 2020-06-08AB-519 Edition 2, Revision 2Page 6 of 13

Pressure Piping Alternative Test Methods Procedure RequirementsIf the Owner-User wishes to include closure welds between a piping system made ofnew materials that has not been in service and has been hydrostatically tested and apiping system that either is or has been in service the AB-519 procedure must includethe following additional considerations:Additional IMS Procedure Requirements for Closure Welds That are Tie-InsRequirement123456CoveredThe procedure must require that the piping that is/has been in service (existing pipe) canbe traced to the material specification and grade (i.e., the same requirement as is appliedto material used in new construction).The procedure shall require an examination to verify the thickness of the existing pipematerial at the area where the closure weld is to be made.Visual examination of the existing pipe, once cut, is required. The In-Process Examinershall ensure that there are no defects or foreign material on or inside the pipe that wouldaffect the quality of the weld.MT/PT of butt-weld preparation is required.Process contamination of existing piping material shall be addressed. For sour service, abake out before welding may be required and hardness testing of the final weld may alsobe required.For other process fluids, process contamination of the pipe material due to the processfluids and operating conditions must be considered by the Designer, to determine if anymitigation actions are needed to assure production of a sound weld.Consideration must be given as to whether a flexibility analysis of the existing pipingsystem must be completed to ensure safety of the completed piping system.A method of documenting In-Process Examination (e.g., In-Process Examination travelsheet) must be developed as part of the procedure and submitted to ABSA along withthe procedure for acceptance. The method of documentation shall contain the followingrequ

ASME B31.3, paragraph 345.7) on category D fluid service piping systems that will not be leak tested in accordance with B31.3 paragraphs 345.4, 345.5 or 345.6. The PESR & ASME B31.3 Pressure Piping System Leak Testing Decision Chart included as Figure 1, on page 3 of

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