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HYDROSTATIC TEST PROUCDURE

Plant: West Qurna 1 Company Document No.


Project:
Rehabilitation of Iraq Gas Facilities CS8
Contract No. UI-61956
Job No. WO#19
Document Title:
Document No. QC-ME-CS8-03
HYDROSTATIC TEST PROUCDURE Rev. 01
Date 30.04.2017

HYDROSTATIC TEST PROUCDURE

Status
Status Code Description
Code

Revise and Resubmit – Address highlighted deficiencies, Up-Rev and


 1
Resubmit at same Project Phase.

Accepted with Comments Noted – Incorporate Comments, Up-Rev and


 2
Resubmit at next project phase

 3 Accepted as submitted

 4 Review Not Required - Do not resubmit

 A Approved

Comments:

Reviewing Engineer’s Name (IN BLOCK LETTERS), Sign and Date

BGC Rep.: Sign: Date:

Note: This sheet shall be the 1st cover page of all A3 & A4 documents. This block will
also form part of the A3 drawing template.

Revision Date Description of Revision Prepared By Verified By Approved By

01 30-04-2017 IFR Ibrahim Thamer Samer S. Mohammed H.

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Table of Contents

1.0 PURPOSE..................................................................................................................................................

2.0 SCOPE.....................................................................................................................................................

3.0 REFERENCES............................................................................................................................................
4.0 DEFINITIONS..............................................................................................................................................
5.0 ROLES & RESPONSIBILITIES IN PRESSURE TESTING........................................................................

6.0 SAFETY REQUIREMENT..........................................................................................................................


7.0 ACCESS......................................................................................................................................................
8.0 WORK PERMITS.........................................................................................................................................
9.0 STRENGHT PRESSURE TESTING............................................................................................................
9.1 NOTIFICATION OF TESTING.....................................................................................................................
9.2 TEST MEDIUM............................................................................................................................................
9.3 TEST PACKAGE........................................................................................................................................
9.4 PREPARATORY WORKS.........................................................................................................................
9.5 NDT CLEARANCE....................................................................................................................................
9.6 TEST EQUIPMENT...................................................................................................................................
9.7 MS FOR CALIBRATION OF PRESSURE GAUGES FOR TEST PURPOSES.......................................

9.7.1 Purpose...................................................................................................................................
9.7.2 Scope......................................................................................................................................
9.7.3 Calibration of Pressure Gauge by Dead Weight Tester...........................................................

9.8 AIR BLOWING PRIOR TO PRESSURE TEST.........................................................................................


9.9 PRESSURE TEST...................................................................................................................................

9.9.1 Hydrostatic Testing: .............................................................................................................


9.9.2 Pneumatic Testing: ....................................................................................................................

9.10 WATER FILLING AND VENTING (HYDROTEST).................................................................................


9.11 TEST PRESSURES AND DURATIONS.................................................................................................
9.12 PRESSURIZATION.................................................................................................................................
9.12.1 Strength Test........................................................................................................................................
9.13 PROCEDURE FOR LOCATING AND REPAIRING LEAKS AND OR FAILURES................................
9.14 CONFIRMATION / CONCLUSION OF THE PRESSURE TEST............................................................
9.15 DE-PRESSURIZATION ...........................................................................................................................
9.16 BULK DEWATERING.............................................................................................................................
9.17 FLUSHING AND DRYING AFTER PRESSURE TESTING.....................................................................
9.18 GENERAL REQUIREMENTS AFTER FLUSHING AND DRYING.........................................................
10.0 MAJOR EQUIPMENT & MATERIALS REQUIRED................................................................................
11.0 MANPOWER REQUIRED.......................................................................................................................
12.0 ATTACHMENTS.............................................................................................................................

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1.0 PURPOSE

The purpose of this Procedure is:


To define the necessary measures and requirements that are to be implemented during the piping
Integrity testing to ensure the safety of construction personnel involved in the project.
To describe safety practices related to pressure testing activities throughout the activity development.
To define individual responsibilities of the people involved in pressure testing activities.
To provide the basis for planning various aspects of pressure test work, giving sufficient detail to
formThe scope of work and technical specification.

2.0 SCOPE

Pressure testing of the Piping constructed and installed in Rehabilitation of Um Qasr Terminal (Jetty
3) project.
3.0 REFERENCES

DEP 31.38.01.11 Piping - General Requirements


DEP 61.10.08.11 Field Inspection Prior to Commissioning of Mechanical Equipment
ASME B31.3 Process Piping
ASME B16.5 Pipe Flanges and Flanged Fittings

4.0 DEFINITIONS

UQUmm Qasr Marine Terminal Jetty 3


BGC Basra Gas Company
WPS Welding Procedure Specification
QC Quality Control
P&ID Piping & Instrument Diagram
IFC Issued For Construction
MAOP Maximum Allowable Operating Pressure
Strength Pressure Test A test used to prove the integrity of the pressure containing
Components of a system.

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5.0 ROLES & RESPONSIBILITIES IN PRESSURE TESTING

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6.0 SAFETY REQUIREMENT

In order to avoid the potential injuries, fatalities and or property damage, pressure testing will be closely
Monitored by the Al-Bilal Test Coordinator and Safety Coordinator. To help ensure the completion of
safe
Pressure testing, the Test Coordinator and Safety Coordinator shall ensure complete compliance by all
Involved parties with this test procedure and the implementation of “Pressure Testing Safely Instruction
Sheet” (See Appendix A).
The Test Coordinator and Safety Coordinator are responsible for monitoring the Pressure testing from its
Start through its completion. They are authorized to stop the testing if the conditions at the site change
Such that to continue with the testing would be unsafe. In addition, all person involved in the testing
Activities shall be monitored for compliance with this procedure and overall safe working practices.
The following information shall be included in each test package as a minimum:

1. Test Manifold Arrangement.

2. Location of check valves (if any), if necessary, check valve must be by-passed or reversed prior to
testing.

3. The location of lowest rated component that determines the test pressure.
As a minimum, the following unsafe practices shall be avoided.

.Conducting pressure testing without approved procedure / test package at site.

.Striking or working on equipment, while it is under pressure, to stop leaks.

.Pressure testing with improper or missing test equipment, such as testing without a relief valve.

.Pressure testing with an inadequately sized relief valve.

.Pressure testing without pressure gauges.

.Omitting or changing steps in the pressure test sequence.

.Failing to vent air from the system prior to the test.

.System not adequately supported to withstand the weight of water during testing.

.Pressure gauges or relief valves not calibrated and tagged.

.Pressure increased very rapidly without control

.Temporary test piping not designed for test pressure.

.No bleed valve provided on test piping or test manifold.

.Failure to pressure test the test manifolds.\


As a minimum, the following safety precautions shall be observed.

.A Safety Checklist shall be employed during the Pressure testing. The procedure shall
address
The safety requirements required prior to testing and during testing.

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.ensuring that all the necessary safety requirements are implemented during the Pressure
testing.

.Ensuring that the approved procedure is available on site at all times during Pressure
testing.

.Test manifolds shall be pre-tested to a minimum of 120% of the required test pressure.
Records of this testing shall be made part of the required test pack.

.A calibrated relief valve set at 5% above the test pressure shall be employed during each
test. The relief valves shall be tested, dated and tagged within one week of the actual test.
Records of which shall be included in the required test pack.
.A minimum of two calibrated pressure gages shall be employed during the Pressure testing.
The gages shall have a range such that the test pressure is within 30 to 80% of the full
range.
Their accuracy shall be within 5% of each other and they shall be tested, tagged and dated
Within 30 days of the actual Pressure testing. One pressure gage shall be located on the
System under test and the other near the test pump.
.Only persons with direct involvement in the Pressure testing shall be permitted within 30
meters
Of the test area while under pressure. This includes all vehicles.
.All personnel involved in Pressure testing operations shall use the appropriate personnel
Protective equipment e.g. hard hats, safety glasses.
.Prior to commencing Pressure testing, warning signs indicating "Danger-High Pressure Test
On-going" shall be posted at pressure location where the Pressure testing will be conducted.
.Any leaks identified shall only be corrected when the system under test has
beendepressurized to a pressure lower than 70% of the test pressure.

.Any welding repairs required shall only be completed once the system under test has been
Depressurized to zero and de-watered.

.The test pump shall be located such that the operator will not be exposed to any danger in the
event of test failure and or unexpected sudden release.

7.0 ACCESS

Access to the location where pressure testing operation is being conducted will be restricted
and the
Area will be kept free of people who are not directly responsible for the testing. In addition, the
area will
Be barricaded and signs posted around the test area notifying others that pressure testing is
taking place. Additional personnel will be posted when required to help prevent access by
unauthorized personnel to the test site.

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8.0 WORK PERMITS

Shall the Pressure testing be performed in restricted areas the appropriate work permit will be
obtained from the Operations of the concern area and shall be available at the site before the
pressure testing activities is commenced and while is being conducted.

9.0 STRENGHT PRESSURE TESTING

Strength testing is conducted for new pipework and extensions to ensure that pipework can
withstand, with respect to integrity, the pressures it could experience under working conditions.

9.1 NOTIFICATION OF TESTING

Al-Bilal will notify BGC prior to the execution of the Pressure testing. ALBILAL QC Inspector will
Perform inspections and request to BGC to perform inspections as per the requirements.

9.2 TEST MEDIUM

With regard to the quality of the water, unless otherwise specified in other project
documentation,
Potable water shall be used for test purposes.
Potable water hauled by water tanker from approved supplier will be used as testMedia for all
the Pressure testing.
Nitrogen provided in nitrogen bottles with regulator will be used as test media for the
entirepneumatictest.

9.3 TEST PACKAGE

The test package will contain (Indicate accordingly) when applicable the following minimum
Documentation:

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TEST PACKAGE DOCUMENTATION CHECK LIST

ITEM TABLE of CONTENTS APPLICABLE NOT APPLICABLE REMARKS


No :
1 Pipe work Pre-test check list √

2 Piping Punch List √

3 Test Blind List √

4 Piping Test Pack Approval to Test √

5 Piping Test Pack Specification and Test Report √

6 Flushing Check List √

7 Test Pack Post Test Drying Certificate √

8 Pipe Work Post Test Check List √

9 P&ID Mark-up √

10 Isometric Drawings √

11 Line List √

12 PSV Calibration Certificate (5% above test pressure) √

13 Pressure Gauge(s) Calibration Certificate(s) √

14 Critical Flange Make Up Checklist √

15 Welding and NDT Summary Sheet √

16 Test Manifold Diagram and Report √

17 Pressure testing Safety Instruction Sheet √

18 Water Analysis Report √ √ Hydro or Pneu

19 Pressure testing Method Statement √

Test package will be assembled and reviewed and will be made available to BGC Inspection
department for review and approval a minimum of 24 hour prior to Pressure testing.
The Test Package shall include but not limited to the following:
.Test Procedure.

.Pressure Test Diagram which shall include the limits of piping (including test manifold) and
Equipment included in each Pressure testing, test pressures, test temperature, test fluid, line
flushing requirements, and safety precautions.
.Relief Valve calibration records.
.Company Safety Instruction Sheet and Pressure Test Report Form.
.Copies of P&ID and isometric drawings of the piping system to be tested.

.Piping spools control sheet with NDT extent and results.

.Pre- test check list.

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.Bolting/Gasket control sheet.

9.4 PREPARATORY WORKS

The following preparatory works shall be performed prior to Pressure testing:

.Fabricate and pre-test all the required temporary manifolds.


.Set up the facilities and equipment. The area shall be barricaded and proper signboards
Posted.
.Safely by-pass the spools/piping where common Pressure testing could be done.
.Install the testing flanges and temporary blind/blank to isolate the test system.

.Bolt torqueing shall be completed on all flanged connections.

9.5 NDT CLEARANCE

All permanent welds shall have all NDT requirements completed and cleared prior to Pressure
Testing. All radiographic films and test reports related to the test system shall be offered
toBGC’s
NDT Unit for their random review. NDT Unit’s concurrence shall be demonstrated by signing in
the check list form.
All joints including welded shall be left exposed for visual leak detection during the
strength test

9.6 TEST EQUIPMENT


The appropriate test equipment will be used during the pressure testing. The following equipment will
be used as a minimum.

.Relief Valve: Relief valves will be tested and identified with a calibration sticker. The sticker will
Contain the serial number, the set pressure and the date of calibration within not more than one
Week prior to the actual Pressure testing. The relief valve will be set to relieve at 5% above the
Required test pressure. Calibration will be done using a calibrated deadweight tester. Relief
Valve Test Report will be used to document the results of relief valve calibration.

.Gauges: Two pressure gauges, with block and bleed valves to permit safe replacement if
Necessary, will be installed. The gauges calibration date shall be within 30 days of the test and
Their range shall be such that the maximum test pressure is within 30 to 80 percent of the full
Range. One gauge will be located in test piping such that it can be read by the pump operator
And the other will be located in the system under test. Calibration will be done using a
Calibrated deadweight tester. Pressure Gauge Test Report will be used to document the
Calibration of the gauges used for each test.

.Bleed Valve: A bleed valve will be installed and easily accessible, if immediate depressurization
Becomes necessary.

.Isolation Valve: An isolation valve will be placed between the pressure testing manifold and the
System being tested. The isolation valve will be rated for the manifold test pressure when it is in
Closed position.

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.Test Manifold: Shall have a valid test pressure certificate that it has been separately pressure
Tested to at least 1.2 times the maximum system test pressure. Each test manifold will be
Identified with its own unique number and this number will be recorded on the Pressure Testing
Report after successful completion of the manifold pressure test.

.Vents: High points vents shall be provided to minimize and remove entrap air during water
Filling.

.Drains: low point drains will be used to remove the test water.
.Isolation: Positive isolation will be provided by cutting out at the test limits and weld temporary
Flanges, caps, test manifolds or by the insertion of blinds in case of flanged connections.

9.7 MS FOR CALIBRATION OF PRESSURE GAUGES FOR TEST PURPOSES

9.7.1 Purpose

The purpose of this Method is to define the procedure for the validation and perform the
certification of all the mechanical pressure gauges required for field pressure testing of plant piping
in Rehabilitation of Um Qasr Terminal (Jetty 3) project.

9.7.2 Scope

This document deals with testing of mechanical pressure gauges designed for measuring gauge
Pressure, which utilize a dial and pointer indication. The gauges may utilize a bourdon tube,
Capsule, diaphragm sensitive or other sensitive element.
This document is not a standard for the manufacture of pressure gauges but it is intended to be as
A reference to decide whether the pressure gauge complies with the minimum requirements to
Conduct the pressure test.
1. All the calibration shall be done in a test cabin/laboratory inspected by BGC Representative
Prior to any calibration activity and the calibration shall be done by an experience technician
Nominated by subcontractor and approved by Company representative.
2. Percentage of error shall be minimized to the lowest value as per manufactures
Recommendations.
3. Upon Calibration completion an adhesive calibration sticker shall be pasted on each device
Indicating name of the subcontractor company who did the calibration, Instrument Tag/Serial
Number, Capacity or Set pressure, Calibration date and due date, and the person who did the
Calibration.
4. Rejected Instrument shall be identified by proper tag and information shall be forwarded to the
Concern department for the replacement.
5. Documentation shall be made for each instrument in separate folder with calibration certificates
And all test records.

9.7.3 Calibration of Pressure Gauge by Dead Weight Tester

Pressure Gauge: The most common sensor used for pressure measurement is the Bourdon tube.
ABourdon tube is usually a metal tube bent into a letter “C” shape. One end of the tube is sealed
Shut, while the other end is connected to the input signal from the process. When force is applied,

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The tube straightens out. The resulting tip movement drives an indicator that indicates the amount
of pressure. Because the outside Bourdon tube is subjected to atmospheric pressure, this tube
often indicates gauge pressure.

The calibration steps are as follows:


1. First of all check the calibration date and due date of Dead weight tester, then clean and Check
The oil level in the oil reservoir.

2. Arrange the weights as required for calibration according with the range of Pressure Gauge.

3. Mount the Pressure gauge on the dead weight tester and calculate the range values to 0%, 30,
50, 80 & 100%.

4. Keep open the pressure valve of dead weight tester and check the gauge zero reading, if the
Zero is not set, remove the gauge cover and pull the needle with needle puller.

5. Apply the pressure 10% of full range and release the pressure then check zero.

6. For the span verification apply the full range pressure, if there is any error in the span then set
Its span, increase its length “L” or decrease by sliding the center pin after loosening the
Adjustable lock screw.

7. When adjusting “L” Length makes sure there is no friction between individual rotator parts.

8. Now verify the span and zero by applying the pressure.

9. Start the calibration by steps up to 100% and reverse.

10. Whenever applying required scale pressure, the piston assembly of dead weight tester rises to
The height of 3/8 inches or middle of blue (low pressure)/red (high pressure) indication is equal
To the pressure gauge indication.

11. The calibration shall be witnessed by BGC Representative and the test results should be
Recorded through the Calibration Test Report-Pressure Gauge.

12. The pressure gauge used in the pressure test shall have a pressure range such that the test
Pressure to be measured is between 30% to 80% of the total range of the pressure gauge itself.

13. Validity of Pressure Gauge calibration is one week from date of calibration.

9.8 AIR BLOWING PRIOR TO PRESSURE TEST

Air Blowing will be done by using air compressor connected to one of the system vent while drains
And the rest of the vents will be kept open.
Pipe spools of bigger sizes will be accessed and the nozzle at the end of the hose pointed to the
Spool internal wall. All valves shall be set in full open position prior to perform cleaning by flushing.
Once the piping air blowing is completed then the preparation for pressure testing will continue.

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9.9 PRESSURE TEST

A systems test shall be employed, so as to pressure test as much piping as possible at one time.
This test may include one or more lines but should not be connected to vessels and equipment.
The minimum test pressure for a system test shall be such that each line in the system is subjected
To a minimum test pressure in accordance with the corresponding Test Pack. The maximum system
Test pressure shall not exceed the pressure test rating of any piping component.
Partial or total systems to be tested may be isolated by closed valves provided the valve seat is
Suitable for the test pressure. Where a valve is not suitable, vessels, equipment or other piping not
Included in the system to be pressure tested shall be disconnected from the system or isolated by
Blinds or other means during the test.
The normal location for the pressure test gauge is at grade near the pressure test pump and at the
Highest point possible on the piping system.

9.9.1 Hydrostatic Testing:

Hydrostatic tests are carried out using water, or other liquids, as the pressuring medium. This
Method is safer than pneumatic testing and should always be used where practicable.

9.9.2 Pneumatic Testing:

Pneumatic tests are carried out using air or inert gas as the pressuring medium. Pneumatic testing
Is potentially more dangerous than hydrostatic testing because of the ability of air or inert gas to be
Compressed. Pneumatic testing should be used only when hydraulic testing is not practical. It
Should be restricted to use on sections of pipe-work and vessels where the inventory can be
Minimized.

9.10 WATER FILLING AND VENTING (HYDROTEST)

This section of the procedure shall be monitored and controlled. Prior to water filling, all in-line valve
shall be set to partially open (50%) position.
The hydrostatic test water will be hauled from the nearest approved water supply. It will be
injectedinto the pipe assembling by a means of filling pump.
All high point vents shall be opened to minimize entrap air during filling. In addition, filling shall
takeplace as much as possible at low point.

Filling will be done by gravity therefore when several spools will be joined together the piping
Assembly shall be jointed in the way the air can be purged easily from de system.
Since the water contact time is unlikely to exceed 14 days, the addition of oxygen scavenger is
notrequired.

9.11 TEST PRESSURES AND DURATIONS

Unless limited by flanges, valves or other component in the line, the strength test pressure for
every
Section of new constructed piping shall produce a hoop stress of a minimum the required by the
Code ASME B31.3 paragraph 345.4.2: Test pressure shall be not less than 1 ½ times the design
Pressure at the test temperature. The maximum system test pressure shall not exceed the
pressure
Test rating of the weakest piping component.
The test pressure shall be maintained for a sufficient time, but shall not be less than 30 minutes, to
Determine that there are no leaks.

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Underground process piping shall be tested prior to backfilling. The test pressure shall be
Maintained for a minimum of 2 hours while the joints are inspected for leakage. If for justifiable
Safety reasons the line must be back-filled, then the joints shall remain exposed during testing.
The maximum test pressure of the pipe material (100% SMYS) for the actual outside diameter(s) &
Wall thickness of the piping together with the flange rating, shall be taken into consideration to find
The weakest component of the system, which is the pressure limit when defining the system test
Pressure to 1.5 times the design pressure.

9.12 PRESSURIZATION

With the section full of water, all the test instruments (pressure gages, relief valves, etc.) installed,
And the pressure test pump connected, the pressurization will commence. The pressure rise during
Testing shall be strictly controlled. The pressure shall be gradually increased to allow time for
Material strain and time for inspection personnel to conduct preliminary checks for leaks.
This activity shall be monitored, controlled and documented in the corresponding test pack.

Prior to pressurization ensure the following shall be verified and done:


.All test limits shall be provided with positive isolation (i.e. blinds).
.All in-line valves shall be set to partially open position (50%) except those used as test limit that
Shall be kept to full close/open position as required.
.All permanent vents and drains valves shall be plugged / blinded and set to partially open
Position.

9.12.1 Strength Test


The test pressure shall be increased gradually until 50% of the strength test pressure has been
reached, then conduct visual inspection for leaks.
After completing visual inspection at 50% of test pressure, the pressure shall be gradually
Increased in steps of not more than one-fifth (20%) of the strength test pressure with at least 5
Minute hold at each step to permit further inspection for leaks and weaknesses. Continue until the
required strength test pressure is achieved.

After the strength test pressure is reached and before commencing a visual inspection of the
System, the isolation valve between the pressure pump and the piping under pressure shall be
closed and the test pump disconnected.
If leaks are found at any time during the pressure test the system shall be depressurized to a
Pressure lower than 50% of the test pressure before any work is done to stop the leak due to the
Tightening of bolts. If the system requires major repairs, like welding works, then the system shall
be depressurized to zero and dewatered before any intervention on it.
If drop in pressure indicates that the leak exists, the procedure describe on the succeeding
Section of this procedure shall be applied.

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9.13 PROCEDURE FOR LOCATING AND REPAIRING LEAKS AND OR FAILURES

In case leak is suspected, the entire system shall be checked for all possible sources of leaks by
Inspecting all valves, flanges, instrument lines, exposed piping and test equipment. A visual
Inspection, throughout the entire section under test, shall be done to locate the leak. When such
Leak is found the system shall be depressurized as described in previous paragraph before any
Work is done to stop leaks or repair weaknesses.

9.14 CONFIRMATION / CONCLUSION OF THE PRESSURE TEST

The Pressure testing shall demonstrate to BGC’s satisfaction that there are no leaks in the piping.
At the moment when the pipe has completed the minimum of test time and with the approval of the
BGC Representative the system will be depressurized to zero.

9.15 DE-PRESSURIZATION

Upon completion of the test the system should be depressurized and emptied in such a way as
Not to cause vacuum and collapse. The depressurizing valve and piping shall be arranged for
Safe discharge of the test medium upon completion of the test. Do not depressurize a system by
Loosening bolts in a flange or by unscrewing fittings because this could lead to injury.

9.16 BULK DEWATERING

Upon successful completion of pressure testing and depressurization the system will be dewatered.
The disposal of hydrostatic test water shall be done to the temporary disposal /tank through
Temporary discharge line or hoses.

9.17 FLUSHING AND DRYING AFTER PRESSURE TESTING

The piping assembled in place will either be clean by water flushing or by pneumatic flushing to
ensure the no presence of loose particles or debris.
Water flushing will be done with a hose connected to a water pump allowing the water to circulate
in order to remove accumulated dust/debris in the pipe.
Pneumatic flushing will be done by using air compressor connected to one of the system vent while
drains and the rest of the vents will be kept open.
Pipe spools of bigger sizes will be accessed and the nozzle at the end of the hose pointed to the
Spool internal wall. All valves shall be set in full open position prior to perform cleaning by flushing.
Flushing will continue until clean air or water comes out from the openings. This activity will be
done and documented.
Loose piping spool tested prior to its installation will be inspected for cleanliness before their final
installation.
Upon completion of flushing, continuous blowing with air will be done until there will be no any trace
of water observed on the internal pipe surface.

9.18 GENERAL REQUIREMENTS AFTER FLUSHING AND DRYING

All vents and drains shall be closed and plugged. Temporary assemblies of piping spools will be
Unbolted, and the temporary isolation removed.
Following the piping shall be transported to the final location for its further final installation.
All the opening shall be kept closed to avoid the entrance of dust/debris.

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10.0 MAJOR EQUIPMENT & MATERIALS REQUIRED

Test Cabin 1 ea

Holding Tank 1 ea

Filling Pump 1 ea

Test Pressure Pump 1 ea

High Pressure Hoses & fitting As required

Suction & delivery hoses As required

Pressure gages 2 per test

Relief Valve Set 1 ea

Air Compressor 1 ea

Blind/ Test Flanges As required

Test Valves, ½”, 1”, 2” As required

Power generator 1 ea

Lifting equipment 1 ea

Water Truck 1 ea

11.0 MANPOWER REQUIRED

Quality Control Inspector 1 ea

Hydrostatic Test Coordinator 1 ea

Foreman-Mechanical 1 ea

Foreman-Hydrotest1 ea

Hydrotest Technician 1 ea

Pipe fitter 1 ea

Skilled Helper / Laborer 3 ea

12.0 ATTACHMENTS

Appendix A – Pressure Testing Safely Instruction Sheet.


Appendix B – Typical Hydrostatic Test Diagram
Appendix C-PIPING PRESSURE TEST CONFIRMATION RECORD
Appendix D- PIPING PRESSURE TEST RELEASE

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Appendix A – Pressure Testing Safely Instruction Sheet

1 Company has assigned person(s) responsible for the test.

2 Written, approved procedure is at the job site

3 System is properly supported (even temporarily) to withstand its own and the test media
Weight.

4 There are any Chemical additives? If so their Safety Data Sheets are available at site?

5 Areas to be kept free of people

6 Location of barricades, warning signs and markings for test area.

7 The required work permits are obtained and available at site.

8 Personnel have personal protective equipment as required

9 There is emergency communication at test site.

10 If water is not the test medium, precautions are taken to prevent hazardous conditions?

11 Relief valve has proper set pressure with set date within 7 days of the pressure test.

12 No block valve in relief valve's outlet.

13 Relief valve located in system under test and near test pump or other test medium supply.

14 There are minimum two accurate and reliable pressure gauges of proper range calibrated
Within 7 days of the test.

15 Pressure gauges are in proper locations and have block valves.

16 Pressure gauge near to test pump can be easily read by the pump operator.

17 Blow down valve on test piping.

18 Isolation valve on temporary test piping.

19 There is blow down valve on system under test readily accessible.

20Temporary test piping pressure tested to at least 20 percent above test pressure of the
System under test. (Exception: Final connection between test manifold and system only if
A higher test pressure is impractical.)

21 Appurtenances that are not part of the test are isolated during the test.

22 Test area shall be marked and warning signs are posted to alert approaching personnel,
Where practical.

23 Personnel are posted at the plant site to keep the test area clear of people not connected
With the test, if necessary.

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HYDROSTATIC TEST PROUCDURE

24 High point vents open while system is filled at the low point.

25 Vents are closed after air is removed from the system.

26 Pressure is increased gradually with at least 5-minute holds at each step in a strength test
.
27Weaknesses are repaired and leaks are stopped before exceeding 50 % of the strength test
Pressure when using liquid or 173 kPa (25 psig)/50 percent of the pressure, whichever is.
The smaller, for any tests using air or other gas.\

28 Test Pressure increased in steps no greater than one-fifth of the test pressure after reaching
50% of the TP.

29 Pressure is lowered below 50% operating pressure, before stopping leaks or repairing,
Including tightening of bolts.

30 Personnel carrying out the test should be provided with a safe place to monitor and control
The progress of the test.

31 Review safety clearance distances for all pneumatic tests and all hydrostatic tests above
Class 300 systems.

32 Only personnel involved with the test are allowed near the system at any time during the
Test.

33 The test pump is located such that the pump operator is not exposed to injury in the event
Of a failure.

34 Depressurizing valve and piping are arranged for safe discharge.

35 System will not be depressurized by loosening bolts or unscrewing fittings.

36 System is depressurized at a slow enough rate to prevent damage.

37 System and the test pump are not allowed to be left unattended during the test.

38 Temporary test piping is not allowed to remain pressurized unnecessarily.

39 Test relief valve is not removed until the test liquid has been drained.

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HYDROSTATIC TEST PROUCDURE

Appendix B – Typical Hydrostatic Test Diagram

Typical Hydro test Diagram

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Document No: QC-ME-CS8-03 Rev: 01
HYDROSTATIC TEST PROUCDURE

Doc. No.
PIPING PRESSURE TEST
Rev:
CONFIRMATION RECORD Date

PIPING PRESSURE TEST CONFIRMATION RECORD

PRESSURE TEST CONFIRMATION RECORD

TEST PACK NO : _________________

TEST MEDIUM : _________________

TEST PRESSURE : _________________

TEST DATE : _________________

TEST PACK DESCRIPTION & CHECK STATUS OF EACH REF. FORMS Al Bilal BGC
DOC NO : ACTIVITY PIPING QC PIPING QC
1 PIPING – RELEASE FOR PRESSURE
TEST/ISO/P&ID WITH TEST LIMIT MARKED
2 LINE CLEANED

3 PUNCH LIST FOR PIPING FOR WORK

4 WELD HISTORY SHEET

5 TEST COMPLETED ACCEPTED

REMARKS :

CERTIFIED THAT THE ABOVE DOCUMENTS ARE INCLUDED


Al Bilal BGC

NAME : NAME :

DATE DATE :

SIGN : SIGN :

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Document No: QC-ME-CS8-03 Rev: 01
HYDROSTATIC TEST PROUCDURE

Doc. No.QC-ITR-CS7-11
PIPING PRESSURE TEST RELEASE Rev: 01R
REPORT Date: 05/07/2015

PIPING PRESSURE TEST RELEASE / REPORT

TEST PACK NO : SHEET 1 OF 1


TEST MEDUM : Temperature C Start Date of Test
C End Start Time Finish Time

WATER ANNALYSIS Report No: Duration of Test Mins.

DESIGN TEST PRESSURE : ACTUAL TEST PRESSURE :

1. Sr. No
PRESSURE GAUGE NOS 2. Sr. No PSV NO:
3. Sr. No
SR Iso. Drawing No: Sht. REV. Line No : Run of Line Remarks
NO NO From To

RELEASED FOR TESTING BY :


Al Bilal Piping BGC Piping Al Bilal QC BGC QC
Name : Name : Name : Name :
Sign : Sign : Sign : Sign :
Date : Date : Date : Date :
TEST WITNESSED/ACCEPTED BY :

Al Bilal BGC

Name : Name :
Sign : Sign :
Date : Date :

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Document No: QC-ME-CS8-03 Rev: 01