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Hydrostatic Test Procedure

EQUIPMENT NAME : Pressure

Vessel

COMPANY :

PROJECT NAME :

Inter Refineries Pipeline-II(IRP-II) Project Main IRP-II Package


CONTRACTOR :

VENDOR :

Descon Engineering FZE, Sharjah

0 Rev.

19/11/13 Date COMPANY PROJECT No

Issued for Final Description 5595

Ronak Mehta DRWN P/O No.

Saket Kumar CHKD

Saket Kumar APPD APPD APPD

5595-E2-PO-MD-001 Rev .0

DWG No. or DOC No,

Doc. No. 5595-E2-VP-MD-001-014 / DES/2937/QA&QC/14

INTER REFINERIES PIPELINES-II (IRP-II) PROJECT FOR MAIN IRP-II PACKAGE AGREEMENT No. 10-5595-E-2

HYDROSTATIC TEST PROJECT No. 5595-E2 Doc. No. 5595-E2-VP-MD-001-014


Rev. 0 Page 2 of 9

SERVICE PROJECT DOC. TITLE GS E&C P.O. No. ITEM No. VENDOR DOC. Ref. No.

: : Hydro Static Test Procedure : 5595 E2 PO MD-001 : Ref Page No : 06 : DES/2937/QA&QC/14

CHECKED INITIALS SIGNATURE DATE Rejected Comments as noted No Comments Information Only GS E&Cs acceptance of this documents does in no way relieve the supplier of his contractual obligation

Descon Engineering FZE, Sharjah

19/11/13

Issued for Final

Ronak Mehta

Saket kumar

Saket Kumar

Rev

Date

Description

Prepared

Checked

Approved

Authorised

NOTES: -. Revisions are denoted by a vertical line placed in the right-hand margin against the revised text.

Descon Engineering FZE, Sharjah

INTER REFINERIES PIPELINES-II (IRP-II) PROJECT FOR MAIN IRP-II PACKAGE AGREEMENT No. 10-5595-E-2

HYDROSTATIC TEST PROJECT No. 5595-E2 Doc. No. 5595-E2-VP-MD-001-014


Rev. 0 Page 3 of 9

REVISION INDEX DETAILS

Rev. 0

Location of Change All Pages

Brief Description of Change


Issued For Final

Descon Engineering FZE, Sharjah

INTER REFINERIES PIPELINES-II (IRP-II) PROJECT FOR MAIN IRP-II PACKAGE AGREEMENT No. 10-5595-E-2

HYDROSTATIC TEST PROJECT No. 5595-E2 Doc. No. 5595-E2-VP-MD-001-014


Rev. 0 Page 4 of 9

TABLE OF CONTENTS

1. 2. 3. 4. 5. 6. 7. 8. 9.

OBJECTIVE SCOPE APPLICABLE FOR EQUIPMENTS APPLICABLE CODES PREPARATION FOR TEST TEST GAUGES & RECORDERS APPLICATIONOF TEST PRESSURE, HOLDING TIME AND EXAMINATION ACCEPTANCE CRITERIA DRAINING & DRYING OF EQUIPMENT

5 5 5 6 6 6 7 8 8 8 8 8

10. SAFETY PRECAUTIONS 11. RECORDS 12. ATTACHMENT

Descon Engineering FZE, Sharjah

INTER REFINERIES PIPELINES-II (IRP-II) PROJECT FOR MAIN IRP-II PACKAGE AGREEMENT No. 10-5595-E-2

HYDROSTATIC TEST PROJECT No. 5595-E2 Doc. No. 5595-E2-VP-MD-001-014


Rev. 0 Page 5 of 9

1) OBJECTIVE The objective of this procedure is to define the Hydrostatic Leak testing requirements for a pressure vessels in accordance with applicable code, standards and project requirements. 2) SCOPE This procedure is applicable for the shop pressure testing (Hydrostatic Leak test) of pressure vessels. This procedure does not cover the requirements for carrying out pressure tests at field sites where a specific procedure shall be developed depending on the type of field work involved. 3) APPLICABLE EQUIPMENTS
S.No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Item No. 013-V-101 013-V-102 013-V-103 2975-F 100-V-101 312-V-001 410-V-006 1141-D-001 1141-D-002 1141-D-003 900-V-101 900-V-102 900-V-103 1000-V-001 Service Name ULG SUMP VESSEL GAS OIL SUMP VESSEL INSTRUMENT AIR RECEIVER JET A1 SUMP VESSEL GAS OIL SUMP VESSEL ULG / GAS OIL SUMP VESSEL INSTRUMENT AIR RECEIVER ULG SUMP VESSEL GAS OIL / JET A1 SUMP VESSEL INSTRUMENT AIR RECEIVER ULG SUMP VESSEL GAS OIL SUMP VESSEL INSTRUMENT AIR RECEIVER GAS OIL SUMP VESSEL MDMT - C 5 5 5 5 5 5 5 5 5 5 5 5 5 5 Design Temperature -C 87 87 100 87 87 87 100 87 87 100 87 87 100 87 Test Pressure kg/cm2 9.3 / 4.55 4.64 / 4.55 13.18 / 13.0 4.64 / 4.55 7.11 / 4.55 7.11 / 4.55 13.82 / 13.0 4.64 / 4.55 4.64 / 4.55 13.44 / 13.0 4.64 / 4.55 4.64 / 4.55 13.18 / 13.0 4.64 / 4.55 Min Metal Temperature -C 5 5 5 5 5 5 5 5 5 5 5 5 5 5

Descon Engineering FZE, Sharjah

INTER REFINERIES PIPELINES-II (IRP-II) PROJECT FOR MAIN IRP-II PACKAGE AGREEMENT No. 10-5595-E-2

HYDROSTATIC TEST PROJECT No. 5595-E2 Doc. No. 5595-E2-VP-MD-001-014


Rev. 0 Page 6 of 9

15 16 17 18 19

1000-V-002 1000-V-003 1100-V-051 1100-V-052 410-T-030 / 031

ULG SUMP VESSEL INSTRUMENT AIR RECEIVER LPG OFFLOADING COMPRESSOR SUCTION KOD INSTRUMENT AIR RECEIVER ANTI FREEZE CHEMICAL STORAGE TANK

5 5 5 5 5

87 100 87 100 87

4.64 / 4.55 13.18 / 13.0 23.97 / 15.86 13.73 / 13.0 FULL OF WATER

5 5 5 5 5

4) APPLICABLE CODES ASME Code Sec VIII Div.1 EDD 2010 5595-E2-AMD-MD-002

5) PREPARATION FOR TEST The test pressure shall be 1.3 x MAP (maximum allowable pressure) The test pressure shall be maintained for a period not less than one hour. The PH of water shall be kept between 6 to 8 The minimum metal temperature during initial pressure testing of vessels shall not be lower than 7C. However, the test temperature shall not exceed 49C (120F). The chloride content of water shall not exceed 50 ppm for testing vessels fabricated. The test medium for hydrostatic testing shall be clean water containing a suitable wetting agent to reduce the surface tension. All reinforcing pads shall be tested by using air with a minimum of 1.05 kg/cm2 to a maximum of 1.4kg/cm2 6) TEST GAUGES & RECORDERS The Quality Control Engineer shall ensure that the test gauges meet the following requirements. Location A minimum of two number calibrated pressure gauges with proper assembly valves shall be attached to the item under test such that the gauges are clearly visible to the operator who is pressurizing the system. At least one pressure gauge will be mounted close to the

Descon Engineering FZE, Sharjah

INTER REFINERIES PIPELINES-II (IRP-II) PROJECT FOR MAIN IRP-II PACKAGE AGREEMENT No. 10-5595-E-2

HYDROSTATIC TEST PROJECT No. 5595-E2 Doc. No. 5595-E2-VP-MD-001-014


Rev. 0 Page 7 of 9

highest point on the item. Hydrostatic test shall be recorded by one number of pressure recorder. Range The range of pressure gauges shall be about double the intended test pressure but in no case it shall be less than 1.5 nor more than 4 times of the intended test pressure. Gauge Calibration All test gauges shall be calibrated at least every 6 months (or earlier if there is a reason to believe that the gauge is not accurate) as per the calibration system against a Dead Weight Tester or a Calibrated Master Pressure Gauge. The maximum permissible error shall not exceed 1% of the full scale reading. Test Pressure Upper limit and Stresses during test All vessels shall be hydrostatically tested at a pressure based upon The design pressure for vessel design to ASME VIII DIV 1. The maximum allowable pressure new and cold for vessel design to ASME VIII Div 1. Above mentioned project specifications.

7) APPLICATION OF TEST PRESSURE, HOLDING TIME AND EXAMINATION 1. The pressure shall be gradually increased until the required pressure has been reached. Once the pressure has been achieved and stabilized (for about ten minutes) the pressurizing system must be isolated from the pressure source. 2. The minimum holding time at test pressure is one hour. 3. Close examination need not be carried out at the test pressure. Close examination shall be carried out on all welds and the regions of high stress such as head knuckles, 4. areas around openings and thickness transition areas. 5. Upon completion of the test, the pressure shall be gradually reduced to zero before opening the drains.

Descon Engineering FZE, Sharjah

INTER REFINERIES PIPELINES-II (IRP-II) PROJECT FOR MAIN IRP-II PACKAGE AGREEMENT No. 10-5595-E-2

HYDROSTATIC TEST PROJECT No. 5595-E2 Doc. No. 5595-E2-VP-MD-001-014


Rev. 0 Page 8 of 9

8) ACCEPTANCE CRITERIA The pressure test shall be considered as acceptable when there is no evidence of leakage and there is no visible deformation on any component. 9) DRAINING & DRYING OF EQUIPMENT After the hydrostatic Leak test the vessel shall be immediately and carefully drained and all parts and all parts where water could collect shall be dried. When the pressure will reach at zero than all drain nozzles will be opened and equipment will be left for drying, pressurize dry air may be used for early drying before sand blasting and painting. The nozzles that are to be used for draining purpose should be at minimum elevation. 10) SAFETY PRECAUTIONS The following safety precautions shall be taken during the test: Cordon-off the test area and put warning signs as necessary Only authorized personnel are allowed inside the cordon-off area. The test is continuously monitored during the test by a competent personnel Provide proper access (scaffolding/ladder) to all parts of the vessel for close examination All authorized personnel to wear adequate personal protective equipment during the test. No hammering/grinding/welding work is permitted when the item is under pressure

11) RECORDS The following records shall be maintained for all pressure tests. Pressure test certificate Calibration records of test gauges

12) ATTACHMENT Hydrostatic test report format

Descon Engineering FZE, Sharjah

INTER REFINERIES PIPELINES-II (IRP-II) PROJECT FOR MAIN IRP-II PACKAGE AGREEMENT No. 10-5595-E-2

HYDROSTATIC TEST PROJECT No. 5595-E2 Doc. No. 5595-E2-VP-MD-001-014


Rev. 0 Page 9 of 9

DESCON ENGINEERING FZE.


HYDROSTATIC / PNEUMATIC TEST CERTIFICATE

Doc No: Rev Date: Page: 1 of 1

Work Order No.: Project: Job Description:

Customer:

Drawing No.:

Rev.

Master Gauge: Gauges:

Dead Weight Test Sr. No. Gauge No. (a) Code No.: Gauge No. (b) Code No.:

Model / Certificate No. Pressure & Temp. Recorder Certificate No: N/A

NOTE: Applicable Code: ASME SEC.VIII Div-1 ED.2007 Test Medium: Ambient Temperature: To: Test Duration (Hours): Not Satisfactory

Test Pressure:

Water (Potable)

Test Medium Temperature:

Time:

From:

Test Result:

Satisfactory

REMARKS:

QA/QC Engineer / Inspector

Customer / TPI Inspector

Authorized Inspector

Name: Sign:

Name: Sign:

Name: Sign:

Descon Engineering FZE, Sharjah