KASPL PIPELINE PROJECT

JOB PROCEDURE
FOR
HYDROTESTING OF UNDERGROUND MOV
( API 6D VALVE)

Document No : AMPS- IOCL- KASPL-ML-JP-31, REV NO: 00

TENDER NO : PLCC/KASPL/CL/1771

WORK ORDER NO.: 25612712, Dated: 24.08.2018

CLIENT : M/S INDIAN OIL CORPORATION LIMITED

(Pipelines Division)

AMPS IOCL

Prepared by Checked by Reviewed by Approved by

SIGN

NAME

DATE

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Table of Contents
1 PURPOSE...........................................................................................................................................................3
2 SCOPE................................................................................................................................................................3
3  REFERENCES..................................................................................................................................................3
4 EQUIPMENT & MATERIALS.........................................................................................................................3
5 GENERAL..........................................................................................................................................................3
6 PREPARATION.................................................................................................................................................3
7 WATER FILLING..............................................................................................................................................4
8 TEST PRESSURE & TEST DURATION.........................................................................................................4
9 ACCEPTANCE OF HYDROTEST...................................................................................................................5
10 VALVE INTEGRITY TEST (SEAT HYDRO TEST):...................................................................................5
11 HEALTH, SAFETY & ENVIRONMENT.......................................................................................................5
12 QUALITY CONTROL.....................................................................................................................................5
13 ITP / FORMATS..............................................................................................................................................5

 
 

 
 

 
   

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1 PURPOSE
The purpose of this procedure is to describe the method of conducting a Hydrostatic Test
in a systematic way by following the approved specification for KASPL.

2 SCOPE
The scope of this procedure includes the water filling, hydrostatic testing &
dewatering of fabricated piping system exclusively for MOV Station Piping work.
 
3  REFERENCES
 Tender Document
 IOCL Specification

4 EQUIPMENT & MATERIALS

 Lab Thermometer (0°C to 60°C range, accuracy ± 0.1°C.) / Digital Thermocouple /
Temperature Gun.
 Pre Tested Header.
 A water tank for controlled filling into the manifold.
 Hydrostatic test reciprocating pressure pump. (motorized/engine mounted)
 Calibrated pressure gauges for pressure indication (on test pre tested header)
 Pressure gauges shall have a dial size of not less than 150mm.
 Pressure gauges shall have a range of 0-200 kg/ cm2 & Resolution 2 kg/cm2
 Pressure gauges shall have an accuracy of +/- 2%.
 Block valves for holding the water in the system and for venting.
 Non return valve at the pressurization inlet to hold the pressure while pressurization
in progress using pipe heads to be higher thickness and hydro tested prior to use at
system.

5 GENERAL
5.1 Before Hydro testing of any piping system, it shall be inspected for the following:
a ) Proper piping materials have been used.
b) Piping has been erected as per latest approved drawings.
c) All piping welds have been visually & radio-graphically cleared.
d) All supports have been installed.
e) Proper venting provision is available in the testing section at the highest point to vent
out properly.
5.2 During flushing and during water filling for hydrostatic testing, care shall be taken that
the water /airflow is in the direction of the check valves. During hydrostatic testing, the
pressurization shall be done from the upstream side of the check valves.
5.3 AMPS shall prepare for IOCL's approval a hydrostatic test procedure. The procedure
shall strictly comply with the requirements of this specification and shall be submitted to the
IOCL for approval well in advance.

6 PREPARATION
1. Before the start of testing, the testing scheme shall be prepared by AMPS.
2. The welded pipe section to be pre-tested shall be tested only after NDT clearance. No
joint coating or primer application shall be done prior to hydrostatic test.
3. All welded joints shall be exposed and should be cleaned properly from rust and
foreign material for visual inspection.
4. The test section shall be isolated.
5. Prior to water filling it shall be ensured that all test gauges and hoses are properly
hooked up and that the test section is clean.

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6. All fitting and valve used on the header should be sch. /rating mention sch.600#
respectively.
7. (Pipe book “Part A”) except joint coating shall be submitted before testing
8. Considering the pressure class of valve as 600#, MOAP of mainline as 98.4
Kg/Cm2 and possibility of location of block valves at lowest elevation in mainline
sections during hydrotest, the Pre-hydrotest pressure of the block valves is
proposed to be corresponding to 95% SMYS of the lowest mainline thickness, i.e.
130 kg/cm2(maximum). Duration of test shall be 6 hours.
9.  As assembly of mainline valves will be subjected to temperature variation, there
will be variation in pressure during hydrotest. Pressure variation during hydrotest
shall be acceptable if it can be demonstrated that they are caused by factors other
than a leak. However, minimum pressure during hydrotest shall not be less than
corresponding to 90% SMYS of the lowest mainline thickness, i.e. 124 kg/cm2.

7 WATER FILLING
 Only potable clean water shall be used for the testing. The water from the source shall
be pumped into the receiving tank. From the receiving tank, the water shall be pumped
into the testing module.
 Drain shall be provided for draining out the water from the system.
 During filling of water proper venting shall be done at the highest point to remove any
air lock in the system
 Calibrated pressure gauges shall be installed at both header.
 If a leak is observed the system, will be dewatered and the repairs carried out as per
approved procedure

8 TEST PRESSURE & TEST DURATION

 The minimum test pressure shall not exceed 90% of the SMYS of the pipeline material in
the section under test. i.e. i.e. 124 kg/cm2.The pressure shall be retained in the pipeline for
minimum period of 06 hrs. Duration For hydro test.
 The maximum test pressure shall not exceed 95% of the SMYS of all the pipes i.e. 130
kg/cm2(maximum).
 All test gauges shall be calibrated.
 Once the water has been filled into the test loop and the air vented out, pressure shall
be applied by means of a pressurization pump, suitable for the work.
 After attaining 30% of test pressure, a preliminary inspection shall be carried out of the
holding the test for a while and upon satisfactory inspection, pressurization shall
continue.
 A constant observation of the pressure building shall be maintained by reading of the
gauge at regular interval of 30 minutes in the temperature / pressure recording log
format- AMPS/IOCL/KASPL/ML/IR-31-02.

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 After temperature stabilization, the pressure shall be maintained in the section for at
least 06 hours.
 Header should be pre tested at pressure 90-95% of SMYS, thickness of the same should
be maximum pipeline wall thickness.
9 VALVE INTEGRITY TEST (SEAT HYDRO TEST):
10 After completion of hold period of 6 hours ,pressure is to maintained in section
11

12 ACCEPTANCE OF HYDROTEST
Once there is no evidence of leakage after the holding time, the Hydro test shall be
considered to have been accepted. The system shall be depressurized and the record
signed by AMPS and IOCL.  

13 HEALTH, SAFETY & ENVIRONMENT

All relevant safety precautions relating to the above activity shall be taken to ensure
safe work
Place safe system of works and every discipline are met.
The following safety matters shall be considered.
i) Ensure that only authorized personnel are allowed on site
ii) Provide over pressure cut - off switch on the pump.
iii) Ensure all manifold fittings and pressure gauges are of heavy duty
Type and approved.
ix)Safety sign boards in English and local language shall be posted to warn the people
of the testing operation. The display shall be as follows. .

“PIPE UNDER TEST- KEEP OFF”

14 QUALITY CONTROL
The type of inspection activity and the quality records generated during the activity is
detailed in the Hydrostatic Testing Inspection.

15 ITP / FORMATS

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INSPECTION TEST PLAN : AMPS/IOCL/KASPL/ML/ITP-31

INSPECTION REPORT : AMPS/IOCL/KASPL/ML/IR-31-01
: AMPS/IOCL/KASPL/ML/IR-31-02

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