DH3E-PAB-M-JEL-0047 Pressure Test Procedure For Circulating Water Piping

A 3/08/2015 Benoni A. Lucio Rosales R. Subramaniam R.
Subramaniam FIRST ISSUE

REV. DATE PREPARED BY CHECKED BY REVIEWED BY APPROVED BY DESCRIPTION
OWNER
POWER GENERATION CORPORATION 1
THERMAL POWER PROJECT MANAGEMENT BOARD 3
OWNER’S ENGINEER
POWER ENGINEERING CONSULTING JOINT STOCK COMPANY 2
CONTRACTOR
SUMITOMO CORPORATION
Black & Veatch (B&V)
Mitsui Engineering & Shipbuilding Co.,Ltd. (MES)
SUB-CONTRACTOR
Jurong Engineering Limited (JEL)
Babcock & Wilcox (B&W)
Toshiba Corporation (TSB)
DUYEN HAI 3 EXTENSION THERMAL POWER CONTRACT No.：

PROJECT:
PLANT PROJECT DH3EXT-25112014
Document Status: FOR APPROVAL

Document Title:
Pressure Test Procedure for Circulating Water Piping
Project Document No.: Rev.:

DH3E-PAB-M-JEL-0047 A
JURONG ENGINEERING LTD.
PRESSURE TEST PROCEDURE FOR
CIRCULATING WATER PIPING REV : A
DUYEN HAI 3 EXTENSION THERMAL POWER PLANT PROJECT, VIETNAM
Contents
1. INTRODUCTION ........................................................................................................................................... 2
2. DOCUMENTS REFERENCE ............................................................................................................................ 3
2.1 ANSI/ASME Code for Process Piping B31.3, ASME 1 (latest revision). .......................................... 3
2.2 Local Authority and / or local regulations for system of pressure vessels related testing. ................. 3
2.3 Final Design Report. ............................................................................................................................ 3
2.4 DH3Ext.EVN Specification on CWP. .................................................................................................... 3
3. SCOPE OF WORKS ........................................................................................................................................ 4
3.1 Requirement for Specification Piping System ..................................................................................... 4
3.2 General requirements and preparation for test ................................................................................. 4
3.3 System Inspection ............................................................................................................................... 4
4. ERECTION EQUIPMENTS, MATERIALS & TOOLS .......................................................................................... 5
5. WORKING SEQUENCE/PROCEDURE ............................................................................................................ 6
5.1 Hydrostatic test ................................................................................................................................... 6
5.2 Retest .................................................................................................................................................. 7
5.3 Test Completion .................................................................................................................................. 7
5.4 Verification of Test .............................................................................................................................. 7
6. QUALITY CONTROL (INSPECTION TEST PLAN) ............................................................................................. 9
7. DETAIL ERECTION SCHEDULE......................................................................... Error! Bookmark not defined.
8. ORGANIZATION CHART ............................................................................................................................. 10
9. MANPOWER MOBILIZATION ......................................................................... Error! Bookmark not defined.
10. RISK ASSESSMENT/JOB SAFETY ANALYSIS (JSA) .................................................................................... 11
11. TEST PACKAGE DOCUMENT .................................................................................................................. 14
1
INTRODUCTION
The purpose of this procedure is to provide the guidance for conducting field hydrostatic test for the
Circulating Water piping and test the integrity of the site welding prior to the operation / service of system.
PROJECT: DUYEN HAI 3 EXTENSION THERMAL POWER PLANT PROJECT-1X688 MW
OWNER: VIETNAM ELECTRICITY (EVN)
LOCATION: DUYEN HAI DISTRICT, TRA VINH PROVINCE, VIET NAM
EPC CONTRACTOR: SUMITOMO CORPORATION (SC)
2
1. DOCUMENTS REFERENCE
Unless otherwise specifically indicated in writing, all work shall be performed in accordance with requirements
of below code and standard and those of the latest editions at the time of call for tender of the documents listed
hereafter:
1.1 ANSI/ASME Code for Process Piping B31.3 (2014 edition), Local Authority and / or local regulations for
system of pressure vessels related testing.
1.2 Final Design Drawing.
1.3 DH3Ext.EVN Specification on CWP. Refer to (Part 2, Vol. 2 Specific Technical Specifications Section 4: Balance
of Plant from page 61 to 80)
3
2. SCOPE OF WORKS
This procedure describes the general requirements and procedure for field pressure testing of CW piping
system which has been fabricated, installed and connected to equipment integral components and is to assure
mechanical strength and tightness for Project.
Following piping system need not be field tested:
 Instrument piping lead lines between the root valve at the process or utility line and the connected
instrument, and control piping used to connect air or hydraulically operated control apparatus.
 The lines and system which are open to the atmosphere, such as vents or drains downstream of the last
shutoff valve.
2.1 Requirement for Specification Piping System

Hydro test shall be applied to the CW piping. Test pressure and duration shall be as followings:
Test Medium Pressure (Bar) Duration (hours)
Pressure test Water 9.0 1
2.2 General requirements and preparation for test

- After installation of piping, all lines shall be hydrostatically as required by applicable code and
specification.
- All testing shall be conducted by Piping Engineer and Inspected by QC Engineer with Client/Owner’s
representative. The line lists shall indicate the design pressure, operation pressure and temperature. The
type of test and medium will be indicated on the piping isometric drawing. Both drawing (Isometric and
P&ID) shall be used for conducting the pressure test of piping system.
- The piping system may be tested with equipment when the test pressure of equipment is the same with
piping system. If the test pressure of piping system is greater than the maximum operating pressure of
equipment, the equipment shall be isolated and tested separately.
- Personnel protection shall be provided suitable to eliminate hazards to personnel.
- International and national safety requirements must be respected.
- Suitable precaution to eliminate hazards to personnel must be taken care.
- Test required to be performed on piping in final condition after completion of all hot works, all necessary
NDT (Non Destructive Testing).
- Site welding seams shall not be coated before pressure test and leak test.
- All supports shall be fixed, additional temporary supports shall be provided if necessary, re-establish the
whole system acc. required conditions.
- Precaution against pressure expansion (overpressure) shall be taken care by installing relief safety valve
before pressurizing ( for large volume of water or test medium only is applicable).
- Vents shall be provided at the highest position to purge air pockets during filling of the system.
- Max. Stress and Temperature shall not be greater than permitted and specified according design data.
2.3 System Inspection

- Piping system shall have been completely checked using the installation check list (issue punch list).
- All lines, vessels and equipment shall be checked to insure the entire system can be completely drained
after testing.
- Vent shall be provided at all high points of the piping system in the position in which the test is to be
conducted to purge air pocket while the component or system is filling. Venting during the filling of the
system may be provided by the loosening of flange bolts or by the use of equipment vent.
- Line containing check valve shall be the source of pressure located in the piping upstream of the check
4
valve so that the pressure applied under the seat. If this is not possible, remove or jack up the check valve
completely or provided necessary filler piece.
-
3. MATERIALS & TOOLS
No. Description Specification

A. Temporary Equipment
As required based on test
1 Water – Filling Pump
requirements
2 Pressurizing Pump
requirements
3 Pressurizing Lines/Hose and Valves
requirements
4 Water – Storage Tank
requirements
Type: analogue, calibration
5 Pressure Gauges (for inspection) validity: 6 months, connector size:
1/2”NPT
6 Blind Plates/Blind Flanges
requirements
B. Tools
1 Walkie-talkie
2 Hand tools
3 Eye Washer
C. Consumables
1 Permanent pen
2 Warning sign
3 Warning tape
D. Personal Protection Equipment
1 Helmet
2 Gloves
3 Light Jacket
4 Safety glasses
5
4. WORKING SEQUENCE/PROCEDURE
4.1 Hydrostatic test

 Test medium
- Water shall be used as the test medium unless otherwise specified by the owner. Test water shall be
clean and shall be of such quality (Potable Water) as to minimize corrosion to the material in the
piping system.
 Test Pressure
- The hydrostatic test pressure at any point in the piping system shall be 1.5 times of design pressure,
but shall not exceed the maximum allowable of any non-isolated components or as specified in the
drawing.
 Following steps
- Isolate test sequences from rest of system by valves or other equipment.
- Fill and vent the system with water of appropriate quality, temporary lines and/or adapters to filling
points / vent points to be provided accordingly.
- Use water at not less than ambient temperature, but in no case less than 20°C.
- Pump and other temporary equipment are to be provided.
- Water supply.
- Wait for temperature settlement between line Material and test medium.
- Start pressure built-up step wise (gradually-According to pressure chart table as shown below) up to
the specified test pressure and maintain for the minimum time specified in corresponding code/norm
at 60 minutes.
- Conduct the examination (Visual) of piping system for leakage if there is pressure drop or can’t found
any leakage from examination. Inspection will start during pressurizing at pressure test and designed
pressure level as shown in pressure chart table
- Then reduce to the design pressure and conduct examination for leakage on all joints and connections
and shall be thoroughly drained off the test water using compressed air.
- Record and verify the test results.
 Test Procedure
- The pressure shall be raised gradually 2 – 5 Bar per minute to the design pressure and pressure shall
be held for minimum of 5 minutes to observe for pressure drop if any, and verify for any leaking
occurred on vicinity of the test.
- Then the pressure shall be raised gradually to hydro test pressure of the section and particular care
shall be taken not to exceed the maximum pressures allowed.
- After the test pressure has been raised, pressure shall be held for 60 minutes to observe for pressure
drop if any.
- Pressure shall then be reduced gradually to design pressure for inspection. During this time, the
piping system shall be examined for any leak test pressure has been raised, pressure shall be held for
60 minutes to observe for pressure drop if any.
6
Time (hr)
Pressure Chart Table
4.2 Retest
 If any leakage is found during the pressure test, the test shall be repeated to the specified pressure after
required Repair had been made.
 Any lines changed after they have been tested shall be retested or relevant NDT shall be carried out as an
alternate based on commissioning / operation schedule. Refer to Part 2, Vol. 1 General Technical
Specifications Page 69, Section 1: Project Requirements and ASME BPVC-IX-2015
4.3 Test Completion
 In the event that repairs or additions are made following the pressure test, the affected piping shall be
retested at the pressures originally specified for the test. Retesting of minor repairs or additions may be
waived subject to owner approval. All tests should be carried out in accordance with the agreed
procedures as detailed in the Inspection and Test Plan.
 After completing of testing, all temporary blank and blinds shall be removed; all operating blinds returned
to proper position and short pieces of piping which have been removed shall be reinstalled with new
gaskets. All valves that were closed during hydrostatic test shall be opened to insure draining the bonnet
cavity. Lines which are being drained after testing shall have all vents open. Piping system downstream of
check valves should be inspected to insure complete drainage.
 After line have been drained, temporary support shall be removed.
 Flange joints all the test blind has been removed shall be retested.
 Special length bolting and flat non-asbestos gaskets shall be removed and replaced with line class and new
gaskets after completion of hydrostatic test.
 Instruments which were removed or blocked out for test shall be reinstalled and blocks placed in the
normal operating position after test.
4.4 Verification of Test
The execution of the test shall be witnessed and approved by all corresponding parties and the test results
be recorded in the specific Records (Pressure Test Record - Form), which must include all essential
7
information and details such as; (ITP reference, Procedure, Test pressure, Medium, Duration, etc.).
8
5. QUALITY CONTROL (INSPECTION TEST PLAN)

Refer to Document number: DH3E-PAB-M-JEL-0102 (ITP)
All the weld documents in the test boundary shall be compiled including all applicable NDE procedures, ITP
before Hydro static test.
Any repair works to be carried out as per approved procedure and recorded.
9
6. PRESSURE TEST SCHEDULE
10
7. RISK ASSESSMENT/JOB SAFETY ANALYSIS (JSA)

See the Table below:
SI NO WORK ACTIVITY HAZARDS SEVERITY LIKELIHOOD RISK LEVEL RISK CONTROL
Refer HSE procedure

Non-compliance of safety HSE
Major Occasional High Conduct tool talk
procedures
Obtain cold work permit
Barricade the area where hydro test being carried out.

Unauthorized personnel Major Occasional High
1 Preparation Post warning signs.
Ensure the equipment/tools used for pressure testing are free from
Defective tools and equipment Major Occasional High
defect and good enough to do hydro testing.
Pipe line vibration more. Moderation Occasional Medium Check for proper supports
Improper tools Moderation Occasional Medium To make tools inventory prior to work
Pump failure Moderation Occasional Medium Electrician and Mechanic always stand by to solve problems
2 Water filling To check for proper tightness, if necessary gasket should be

Flanges leak Moderation Occasional Medium
changed.
Flow meter failure Moderation Occasional Medium Calibration certificate verification and remedial action will be taken.
Water spillage Moderation Occasional Medium All leaks will be arrested during initial start of pump.
11
Proper electrical connections will be checked. Ensure Trained

Pump Failure Moderation Occasional Medium
operating person will be assigned.
Test limits identification and area cordoned off. Awareness of test

Leaks on weld joints-Boiler Moderation Occasional Medium
hazards to persons involved.
Proper tools for valve operation. Good access to operate the

valves.
Valve Failure Moderation Occasional Medium
During pressurizing time the area will be closed for unauthorized
entry with all warning sign boards.
Heavy leaks-boiler water wall Upon observation of heavy leaks, the boiler will be depressurized.
Major Occasional High
panels The water will collected through flash tank.
3 Pressurizing Exceeding the test pressure Major Occasional High Ensure that relief valve at the pump is set at the same pressure.
Keep away the pressurizing segment of the boiler to be hydro

tested.
Injury to workers Major Occasional High Monitor the pressure gauge at safe distance away to potential
source of high pressure jet
Ensure that the workers are wearing required PPE.
Damage to the
Moderation Occasional Medium Observe and act not to increase the pressure beyond the limit
equipment/system
Unattended pressurizing Do not leave the pressurizing pump un attended when the hydro
Moderation Occasional Medium
pump/pressure regulation test is ongoing.
Sufficient lighting arrangements will be made to avoid trip

Inadequate lighting Moderation Occasional Medium
hazards during inspection.
12
Proper access to operate the valve. System will be depressurized

Valves operation-Trip hazard Moderation Occasional Medium
to 0 bar by opening the vent valves.
4 Depressurizing
The hose will be monitored during draining of water, if observed
Water spillage. Moderation Occasional Medium
leaks. Draining operation will be stopped to attend leaks.
13
8. TEST PACKAGE DOCUMENT
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A 3/08/2015 Benoni A. Lucio Rosales R. Subramaniam R.

Subramaniam FIRST ISSUE

POWER ENGINEERING CONSULTING JOINT STOCK COMPANY 2

DUYEN HAI 3 EXTENSION THERMAL POWER CONTRACT No.：

Document Status: FOR APPROVAL

Project Document No.: Rev.:

PROJECT: DUYEN HAI 3 EXTENSION THERMAL POWER PLANT PROJECT-1X688 MW

OWNER: VIETNAM ELECTRICITY (EVN)

LOCATION: DUYEN HAI DISTRICT, TRA VINH PROVINCE, VIET NAM

EPC CONTRACTOR: SUMITOMO CORPORATION (SC)

2.1 Requirement for Specification Piping System

2.2 General requirements and preparation for test

2.3 System Inspection

No. Description Specification

4.1 Hydrostatic test

5. QUALITY CONTROL (INSPECTION TEST PLAN)

6. PRESSURE TEST SCHEDULE

7. RISK ASSESSMENT/JOB SAFETY ANALYSIS (JSA)

Refer HSE procedure

Barricade the area where hydro test being carried out.

2 Water filling To check for proper tightness, if necessary gasket should be

Proper electrical connections will be checked. Ensure Trained

Test limits identification and area cordoned off. Awareness of test

Proper tools for valve operation. Good access to operate the

Keep away the pressurizing segment of the boiler to be hydro

Sufficient lighting arrangements will be made to avoid trip

Proper access to operate the valve. System will be depressurized

8. TEST PACKAGE DOCUMENT

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