Hydrostatic Test Procedure

QUALITY CONTROL

PROCEDURE

Industrial projects company (INPEC)

HYDROSTATIC TEST PROCEDURE

HYDROSTATIC TEST PROCEDURE

0.0 First issue 01/09/2012

Name Sign/date Name Sign/date Name Sign/date

REV. COMMENTS DATE PREPARED BY APPROVED BY ACCEPTED BY

Copy No.

Controlled

Uncontrolled

Table of Content

6) Preparation for Pressure Testing 7) Filling with Test Medium and Venting 8) Test Pressure

9) Holding Time, Test Temperature and Close Examination 10) Test Pressure Release

11) Repair Case 12) HSE Precautions 13) Report

1 Scope:

1.1 This procedure is applicable to Boilers, Boiler External Piping

and pressure Vessels constructed to ASME Code Sec. I, B 31.1, Sec. VIII, Div. 1 respectively. It also applies to Code items Repairs and Alterations in accordance with the National Board Inspection Code (NBIC).

This procedure gives instructions to the Company's personnel and describes the method used to perform the Hydrostatic Test of Code items manufactured or erected by INPEC.

1.2 The local standards, legal regulations and other suitable

precautions regarding health work and fire protection shall be observed, also if they are not mentioned herein.

2 Reference Code:

- ASME Code Sec. I the applicable Edition and Addenda,

- ASME Code Sec VIII Div. 1 the applicable Edition and Addenda, - ASME Code Sec B 31.1 the applicable Edition and Addenda,

- National Board Inspection Code "NBIC" for repairs or alterations of pressure retaining items.

- Company's QC Manual.

2.1 In case of any conflicts between Client specification and Code

requirements, the Code requirements shall govern.

3 Testing Schedule:

3.1 Hydrostatic Test shall be performed after all manufacturing

and inspection activities for the system or portions that will be subjected to this test.

3.2 Welds or other type joints shall not be painted, insulated or

coated prior to completion of testing.

3.3 Hydrostatic Test shall be performed in the presence of the

ASME Authorized Inspector and if required the Client inspector.

3.4 INPEC shall officially inform the ASME Authorized Inspector

and if required the Client inspector by the date and the time of the test execution at least by 24 hours in advance.

4 Pressure Gauges:

4.1 At least one calibrated pressure gauges shall be directly

connected to the system being tested at the highest point, and shall be visible to the operator controlling.

4.2 The pressure gauges shall have a range of about double the

test pressure, but shall not be less than 1 ½ nor more than 4 times the test pressure.

4.3 An additional calibrated pressure gauge may be fitted at a

suitable location visible to the operator controlling the pressure at all time. If this gauge is not fitted at the highest point, then the test pressure shall be accordingly corrected for the static head difference.

4.4 Calibration of pressure gauges shall be at intervals not

exceeding one year.

5 Test Medium:

5.1 The test medium used for Hydrostatic Testing shall be

- Potable water for carbon and low alloy steel.

- Demineralized water for high alloy steel, such as austenitic stainless steels.

6.1 The personnel protection and the addition of temporary

supports shall be considered prior to pressure testing, to avoid distortions.

6.2 No temporary welds shall be applied to the Code item to be

tested.

6.3 All connections shall be blanked off by means of adequate

plugs or blind flanges of the rating specified in the drawing and bolting of the same size and resistance as those specified in the drawing.

7 Filling with Test Medium and Venting:

7.1 Test medium shall be supplied to the Code item being tested

through a connection at the lowest point. The filling connection shall be filled with a suitable valve.

7.2 Nozzles or other openings at the top of item being tested shall

be left open during filling to allow for proper and complete venting of air.

7.3 When the item being tested is completely filled with the test

medium, all openings shall be closed, not fully secured tightened while pumping is in progress to ensure complete venting, and then secularly tightened.

7.4 The pressure is then raised gradually until the specified test

pressure is reached. Then all valves are securely tightened.

8 Test Pressure:

8.1 The test pressure shall be at least the test pressure required

by the applicable code and project specification.

8.2 For items constructed according to ASME Code Sec I,

- Hydrostatic pressure tests shall be applied by raising the pressure gradually to not less than 1.5 times the maximum allowable working pressure to be marked on the boiler and as shown on the data report. No part of the boiler shall be

subjected to a general membrane stress greater than 90% of its yield strength (0.2% offset) at test temperature.

8.3 For items constructed according to ASME Code Sec. VIII Div

1,

- Vessels designed for internal pressure shall be subjected to a hydrostatic test pressure which at every point in the vessel is at least equal to 1.3 times the maximum allowable working

pressure to be marked on the vessel multiplied by the lowest stress ratio LSR (for the materials of which the vessel is constructed) of the stress value S for the test temperature on the vessel to the stress value S for the design temperature.

8.4 For items constructed according to ASME Code Sec. B31.1,

- The hydrostatic test pressure at any point in a metallic piping system shall be not less than 1.5 times the design pressure. -For design temperature above the test temperature, the

minimum test pressure shall be calculated by the following eq., except that the value of ST/S shall not exceed 6.5:

PT = (1.5 PST)/S

Where

P = internal design gage pressure PT = minimum test gage pressure

S = stress value at design temperature ST = stress value at test temperature

- The possibility of brittle fracture shall be considered when conducting leak tests at metal temperatures near the ductile-brittle transition temperature.

8.5 For items repaired or alternated according to NBIC, the test

pressure shall be the minimum required to verify the leak tightness integrity of the repair, but not more than 150% of the MAWP stamped on the pressure-retaining items, as adjusted for temperature. When original test pressure included consideration of corrosion allowance, the test pressure may be further adjusted based on the remaining corrosion allowance.

- During a pressure test where the test pressure will exceed 90% of the set pressure of pressure relief device, the device shall be removed whenever possible. If not possible, a spindle restraint may be used following the valve manufacturer's instructions and recommendations.

9 Holding Time, Test Temperature and Close Examination:

9.1 The test pressure shall be maintained for at least 10 minutes,

and then reduced gradually to the close examination pressure as stated in Table No.1.

9.2 Close visual examination of all joints and connections shall

then be carried out for any signs of leakage and/or deformation.

9.3 The metal temperature during the close examination shall not

Applicable Code Section Minimum test metal

temperature Maximum metal

temperature during close examination

ASME Code Sec.I & ASME B.31.1 70

° F (21°C) 120°F (49°C)

ASME Code Sec. VIII, Div. 1 30 ° F (17°C) above MDMT 120°F (49°C) National Board Inspection Code For Boilers & BEP as for

Sec. I, above.

For pressure vessels 60°F (16 °C). Unless notch toughness

properties permit lower temperatures

120°F (49°C)

Table (1): Maximum and minimum metal temperatures during Hydrostatic Test.

Applicable Code Section Close examination pressure

ASME Code Sec. I & ASME B.31.1 Pressure equal to MAWP

ASME Code Sec. VIII, Div. 1 Test pressure divided by 1.3

National Board Inspection Code (NBIC) Pressure equal to MAWP

Table (2): Pressure during close examination.

10 . Test Pressure Release:

10.1 Before Conducting the test QC shall authenticate the release

for items to be tested, where the QC release for test ensure that all the per-fabrication and fabrication processes have been performed according to the drawings and project specifications.

10.2 As the test is completed, the pressure shall be released by

opening the valve at the highest connection and allowing the pressure to drop gradually to atmospheric pressure.

10.3 The item being tested shall then be drained through a

connection at the bottom, while leaving sufficient opening at top open.

11 Repair Case:

11.1 In case of items failed to pass the test, a repair process shall

be applied to these items according to ASME Code and project specifications where the repaired items shall be retested again according to the above mentioned steps.

12 . HSE Precautions:

12.1 HSE Head shall control all the safety related attributes to the

execution of the hydro test, where the equipments

connections shall be checked prior conduction of the test, all the PPE of those who are involved in the test shall be worn, and the testing area shall be barricaded.

12.2 HSE Department will conduct a safety toolbox for INPEC

staff whom are involved in the test for awareness about the safety precautions have to be taken during the test.

13 . Report:

13.1 For hydro test, INPEC shall prepare all the tested items

related documentation (Test package) before released to test, and the result of test shall be recorded on the attached Hydrostatic Test Form (Exhibit No.28- Hyd. Test Report).

14 Attachments: