Hydro Test Work Procedure

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PLANT-TECH ARABIA LTD.

Al-Jubail / Kingdom of Saudi Arabia

HYDRO TEST PROCEDURE

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Document No: PT/SAHARA-2012

Page 1 of 9Date:04/Jan/2012

Project specific Work Procedure: Hydrostatic Test Procedure

Document number: PT/SAHARA/001

Prepared by: Reviewed by: Approved by:

R.PALANI V.ILAMARAN SAHARA

Date: 04/Jan/12 Index 1. Purpose 2. Scope 3. Reference Documents 4. Responsibilities 5. Procedure 6. Safety Precautions 7. Inspection 8. Emptying

9. Non Conformance Control 10. Records

Attachment 1. Test Record

1. PURPOSE:

The purpose of this procedure is to prove the integrity of the pressure containing parts of process piping in accordance with the customer requirements.

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PLANT-TECH ARABIA LTD.

HYDRO TEST PROCEDURE

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2. SCOPE :

This procedure describes the requirements of Hydrostatic test for Piping of Modification work at SAHARA

3. REFERENCE DOCUMENTS :

Title

ASME SEC. B.31.3 – Rules for Construction of PROCESS PIPING – 2006.

4. RESPONSIBILITIES :

4.1 The project manager or his designee shall be responsible for preparation and performance of the hydrostatic test including cleaning, accordance with the procedure and written instructions. 4.2 The QA/QC Inspector shall be responsible for monitoring the test,

inspection after pressurization and recording the results.

4.3 The Hydrostatic test is a designated hold point of the Authorized inspector and Clients inspector. The test is always conducted in their presence.

5. TEST PROCEDURE:

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HYDRO TEST PROCEDURE

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After completion of the final weld for the particular Piping, the Piping inside to be cleaned thoroughly and flushed.

Prior to start of the test, the inspector shall verify that all other code requirements are completed and accepted.

Instruments shall not normally be included in the pressure test.

All openings except test medium inlet and vent openings shall be closed using proper plugs, caps and blinds.

Supports used for hydrostatic test shall be safe.

Test pressure will be as stated on Approved Design Drawing. This

verification shall be accomplished by reviewing the inspection check list/ client specification to ensure that the applicable fabrication checks are completed and that non-conformance if any has its corrective action / disposition verified and signed off.

The inspector shall also check following prior to the hydro test as follows: 1 The capacity of the hydro test pump and the range of pressure gauges. 2 The calibration label attached to the pressure gauges have valid

calibration.

3 The valves and fittings for connection and gauges and pump.

5.2 TEST GAUGE 5.2.1 LOCATION

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HYDRO TEST PROCEDURE

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Minimum of two pressure gauges shall be used for testing. The dial of the gauges shall be positioned in such a way that they are clearly visible to the operator controlling the pressure throughout the test. One of the gauges shall be located in the highest point.

5.2.2 RANGE

The pressure gauges used for testing have dials graduated over range of double the intended test pressure, but not in case less than the 1 1/2 nor 4 times test pressure.

5.2.3 CALIBRATION

All gauges shall be calibrated against a master dead weight tester when there is reason to believe that they are in error. In no case, re-calibration frequency shall exceed six (6) months.

5.3 TEST MEDIUM

Potable water shall be used as a test medium with water soluble Rust Proof Agent as specified in the drawing shall be adhered to.

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HYDRO TEST PROCEDURE

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During the hydro test, it is recommended that the metal temperature during test be maintained at least 30° F (-1.1° C) above the minimum design metal temperature specified on the manufactures drawing , but need not exceed 120° F to minimize the risk of brittle fracture.

The test pressure shall not be applied until the item and its contents are at about the same temperature. If the test temperature exceeds 120° F, it is recommended that the test shall not be conduct until temperature is reduced to 120° F or less.

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HYDRO TEST PROCEDURE

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5.5 FILLING OF TEST MEDIUM.

Vents shall be provided at high points of the system; consideration shall be given to the test position of the system and geometric configurations while providing venting arrangements so as to ensure that air is not entrapped in the system while filling of water. The item shall be filled with water by any suitable low pressure filling lines, while venting through the vent on the upper most nozzles. The capacity of the filling pump shall be controlled to maintain adequate venting to avoid pocket entrapments.

Before applying pressure, the test operator shall check equipment to assure that all low pressure filling lines and other appurtenance that should not be subjected to the test pressure have been disconnected or isolated by valves or other suitable means.

5.6 APPLICATION OF PRESSURE.

The pressure in the item shall be increased 100 psi per minute steadily until required test pressure specified in the manufacturing drawings has been reached. When the test pressure is reached the valve between the pump & the pipe line inlet shall be shutoff. Test pressure shall be accordance with DWG.

Unless otherwise specified on the manufacturing drawing, holding time shall be maintained for at least thirty (30) minutes.

After the test pressure has been maintained for the holding time, the pressure shall be reduced to two - third of the test pressure.

6. SAFETY PRECAUTIONS

Signs are to be displayed at roped off areas indicating that hydro test is under progress. Only authorized persons shall be allowed in the test area during testing.

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HYDRO TEST PROCEDURE

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All authorized personnel allowed in the test area shall stay clear off the nozzle during pressurization.

7. INSPECTION

At the pressure prescribed in para 5.6, a visual inspection for leakage, bulging or other visible defects shall be made on the whole body of the item., close examination shall be carried out on all weld joints and connections and regions of high stress such as head knuckles, region around openings and thickness transition section.

The above inspection shall be performed by the QA/QC Inspector under the witness of Client Inspector. The Inspector may carry out his own closure examination as considered necessary.

8. EMPTYING THE ITEM.

After completion of the hydrostatic test, vents and drains shall be opened to remove all the water in the item. Shop air may be used to force evacuation. Check the gauge reading gauge pointer must be backed to zero gauge reading.

After all water has been drained, the item shall be ventilated examined visually, internally for cleanliness and final internal inspection carried out. The item shall be inspected on the external surface for out of roundness or other defects.

9. NON CONFORMANCE CONTROL.

If during inspection leaks, cracks or any other defects are observed it shall be identified and handled in accordance with the non-conformance section of the QC manual.

Any leaks detected shall be eliminated after which the item shall be re-hydro tested.

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HYDRO TEST PROCEDURE

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The QA/QC Inspectors shall record the results of hydrostatic test on the Test Report and shall present to Customer Representative for his review.

If the result of the test is acceptable, the QA/QC Inspector and the Customer Representative shall sign and date the inspection check sheet and hydrostatic test report.

Attachment 1. Test Record

PLANT-TEACH ARABIA LTD.

Pressure Test Certificate

Date 12/12/2011

Job No. Plant Name Equipment Name Equipment No.

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PLANT-TECH ARABIA LTD.

HYDRO TEST PROCEDURE

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Test Description Client:

Test Medium Test Pressure Test Duration

Start Time Finish Time Hold Time

Start

Pressure Finish Pressure Pressure Drop %

Start

Temperature Finish Temperature Date of Test

Recorder Used

Calibration

Cert. Verified Test Accepted

System Dried

Method of

Drying Lay-up Type

Remarks:

RECORD OF

ACCEPTANCE PLANTECH QC SAHARA

SIGNATURE NAME