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HYDRO TESTING FOR GRP 300

As per section 40 05 15
CONTENTS

1. General
2. Backfilling
3. Inspection
4. Preparation
5. Equipment
6. Valves & fittings
7. Tools
8. Man power
9. Water Filling
10. Pressurization
11. Depressurization
12. Pressure testing Safety

MM

PIPE LINE

1. General
The procedures are compiled for uniformity and to assure all level of staff
is aware of the procedure to ensure the quality of the jointing process.
The objective is to ensure that the installed piping system will meet the
specified performance requirements.

2. Backfilling as per ( Section - 31 23 16 )


Prior to the testing process, the pipe system shall be back filled as
described below. This back-fill procedure will prevent extreme movement
of the system while pressurizing.
1 Pipes shall be completely back-filled and compacted except for the
pipe joints that must be left exposed for inspection.(Only straight
sections)
2 Elbows assembly plus 20 meter of straight pipe before and 20
meter pipe after the assembly including joints shall be backfilled
completely and compacted.
3 The sand cover from the pipe crown shall be minimum 500mm for
straight pipe sections without elbows. For elbow section the sand
cover shall be minimum 600 mm from the crown of the pipe.
4 Unsupported sections shall not exceed the two times of the
diameter.

3. Inspection As per ( Section -01 43 00 )


It is important to conduct a visual inspection throughout the system prior to
the testing process, to identify any external damage that may have
occurred during the installation/handling process of the pipe. If any
damage occurred it should be repaired. Ensure that all the joints are cured
properly before starting the testing. As required by our quality and
standards.

Preparation for pressure test as per ( section 40 05 15 )


a) A formal risk assessment should be carried out prior to the hydro
test.
All supports, guides and anchors shall be in place prior to pressure
Testing.
b) Temporary supports and restraints shall be added if required unless
stated otherwise
c) All valves shall be through body rested. Piping containing check
valves shall have the source of test pressure located in downstream
side.
d) Ensure completion of backfilling/plugging is completed prior to Hydro
testing upon completion of the pipe line section.
e) All the flange connections are properly tightened to the required
torque as per the procedure. Any permanent valves in the system
shall be kept fully open. Arrange all necessary equipment i.e. filling
pump with feed tank, pressure pump, gauges etc. The End
caps/blind flanges with required connection for air venting shall be
available to close the system once the water filling process is
completed.
f) Conduct pressure test only on exposed joint of pipe line.
g) Provide temporary drain line to carry testing fluid away from the
pipeline being tested. Remove temporary drain line after completing
the pressure test.
h) The test pressure shall be 15 bar for 4 hour on hold.

5 Equipments used
a.
b.
c.
d.

Water tank
Connecting hose pipe
Diesel water pump
Boom truck

6 Valves and fittings as per ASTM / ANSI B16.34


a. Check valve
b. Relief valve
c. Threaded nipple

d. Coupling
7 Tools use
a.
b.
c.
d.

Certified hydro test manifold


Certified pressure gauges
Water hose coupling
Spanners

8. Man power used


a.
b.
c.
d.
e.
f.

Boom truck operator


Hydro test supervisor
Hydro test technician
Labors
Safety officer
Mechanical QC inspector

9. Water Filling , Potable water quality as per ( SAES-A-007 )


The system shall be flushed prior to the hydrostatic testing. The flushing of
the system shall be carried out from the highest point of the pipeline.
Potable water or equivalent shall be used for this purpose. Prior to
commencement of pressure test. Ensure that the flushing continues until
clear water appears. Once the flushing is completed water can be filled to
the system from the lowest point of the pipeline in a steady and controlled
manner. Fill a large amount of water into the system. Ensure all the vents
and drains are opened while filling water in the system. Adequate care
shall be taken to venting the system to avoid any air trap inside the
pipeline, which may give erroneous results. The water filling stage is
completed when the water starts coming through higher vents, stop the
water pumps and check the flanges, valves and connection for any weep
age and leakages.

10. Pressurization , As per specification ( GI0002.102 para 5.16 )


After the filling process is completed, seal the entire test section with the
required end caps/blind flanges keeping all valves fully opened. A devise

capable of continuously pressurizing the test section shall be connected to


the pipeline with the required pressure recorders. A pressure gauge shall
be connected to the highest point of the pipeline. All pressure gauges,
recorders shall be calibrated prior to use in the system. Start pressurizing
the system gradually and in a steady and controlled manner .The rate of
pressurization shall not exceed 1 bar per minute and allow the system to
stabilize. Once the stabilization time is completed, continue pressurizing
the system gradually to the required test pressure (1.5 x working
pressure) and maintain the pressure for 2 hour for the leak test.
Upon completion of pressurizing the system, dismantle the hose
connection from the pressure pump and seal the ends with suitable plugs.
The entire pipeline shall be carefully inspected for any leakage from the
joints of the pipe body. The test pressure in the system shall be closely
monitored and be maintained to the required test pressure. Visual
inspection of joints shall be carried out at least 6-8 hrs.
Pressure drop may occur due to the following reasons:
a. Temperature variation between day and night
b. Leakage of accessories connected to the system
c. Leakage from the gaskets
d. Dirt at sealing area
e. Leaking test equipment
f. Stabilizing time too short
g. Leaking from the joint
h. Leakage of pipe as a result of damage (cracks)
i. Settlement of the pipeline system
If any leak is observed from the flange connections, it is not permitted to
torque the flange under pressure, the line should be depressurized fully
and then the flanges to be tightened. If the flange or gasket is found to be
damaged it shall be replaced with a new one.
If a leakage is observed on the pipe body or the joint, the test shall be
terminated and the leaking joint/pipe shall be repaired.
If no leakage or weeping is observed during the inspection, the hydrostatic
test is successfully completed and the system is ready for use.

11. Depressurization , As per Specification ( GI0002.102 para 5.19 )

The depressurization of the system shall be carried out carefully to avoid


any negative pressure in the system. All the vents shall be kept open to
allow adequate air into the system while draining the pipeline. Water shall
be drained slowly and in a controlled manner. After completion of hydro
test and draining the water from the system, temporary flanges should be
cut out and removed. Ensure proper end plugging to avoid dust
contaminations.
Dewatering of small /medium section shall be done through gravity
draining.
12. Safety and precautions.
All precaution shall be taken while testing the system
a.
b.
c.
d.
e.
f.
g.
h.

The test area shall be barricaded


Place warning signs at all adjacent areas
Experienced personnel shall operate test equipment
Only authorized personnel shall be involved in the test or
inspection operation
Only one person shall be in-charge
Do not change anything in the pipeline when it is under
pressure.
The testing equipment shall be installed at a sufficient distance
from the pipeline
Proper safety precautions shall be followed under supervision of
Safety officer/Jointing Supervisor.
.................. END .......