DOC NO HJRSB/PDB/M/PF/02

HYDRO TESTING PROCEDURE

DATE 05/11/2021
ENGINEERING, PROCUREMENT, CONSTRUCTION,
AND COMMISSIONING (“EPCC”) OF UPGRADING REV 0
ELECTRICAL SYSTEM SKID TANK RELOCATION
AT PDB SANDAKAN AVIATION TERMINAL

CONTRACT NO:
RFP – 000000004843, RFP - 000000006737

PROJECT:

ENGINEERING, PROCUREMENT, CONSTRUCTION, AND

COMMISSIONING (“EPCC”) OF UPGRADING ELECTRICAL
SYSTEM SKID TANK RELOCATION AT PDB SANDAKAN AVIATION
TERMINAL

CLIENT:

PETRONAS DAGANGAN BERHAD

CONTRACTOR:

HUNAI JAYA RESOURCES SDN. BHD.

DOCUMENT TITLE:

HYDRO TESTING

PROCEDURE

REV CODE ISSUE DATE DOC HJRSB PDB

STATUS PREPARED APPROVED REVIEWED APPROVED
AG KU IZZUL RAJIED HENRY

ENGINEER PROJECT
MANAGER
0 05/11/2021 IFR
 DOC NO HJRSB/PDB/M/PF/02
HYDRO TESTING PROCEDURE
DATE 05/11/2021
ENGINEERING, PROCUREMENT, CONSTRUCTION,
AND COMMISSIONING (“EPCC”) OF UPGRADING REV 0
ELECTRICAL SYSTEM SKID TANK RELOCATION
AT PDB SANDAKAN AVIATION TERMINAL

1. HYDRO TESTING PROCEDURE

1.1 General

11/2” diesel pipeline hydro test pressure is: 60psig; 135psig design operating pressure. The pipeline will be hydro
tested after physical inspection and visual acceptance of the pipe.

CONTRACTOR intends to set up the hydro test equipment and pressurize the pipeline in fabrication yard.
Calibrated, pressure gauges and pressure/temperature recorder charts will be utilized to monitor the pipeline
pressure and temperature. The pressure test will be using portable water. The pipeline will be pressurized to the
require test pressure and the volume of air monitored during pressurization. The test system is then isolated and
allowed to stabilize. Once the pressure has stabilized the hold period of 1 hour will commence.

The hydro test is deemed accepted when the following are achieved:
 Air entrapped is less than 0.2% of volume
 No visible leaks is observed
 No unaccountable pressure changes are observed

The 11/2” diesel pipeline will be deemed mechanically complete and acceptable by PD&T upon:
 Visual inspection of the pipeline, and approved when no significant defects and leaks are found
 Hydrostatic Pressure Testing of pipeline has been satisfactorily completed for required 1 hour period

During the pressurization, the following information shall be recorded and logged every 30psig at increased
intervals:
 Time
 Temperature (deg. C)
 Pressure (psig)

The equipment for hydro test as below:

 1 nos. x diesel or electric driven positive displacement HP pump
 1 set x HP hoses complete with isolation valve and fittings for hydro testing
 1 set x Pressure & Temperature Chart recorder
1.2 Pressurization
Pipeline will be fully vented to release air trap prior to pressurization at rate of up to 15psig interval. Line check for
leakage before increase pressure to 30psig.

Once 100% test pressure is achieved, pipeline pressure will be recorded in a log table for full duration.

Monitoring of the pipeline pressure during the stabilization period by pressure chart recorder. The following
information will be monitoring and logged at 15 minutes interval.
 Time
 Pipeline pressure
 Ambient temperature

During the stabilization period, re-pressurization may be carried out should the pressure drop below the required
test pressure. The volume of water added will be recorded. Leaks or other defects noted during the stabilization
period shall be rectified. The section requiring rectification shall be depressurizing to a safe level prior to any repair
activity.

1.3 Hold Period

Once the pressure in the pipeline has stabilized, a hold period of one (1) hour shall commence.During the hold
period, the following information shall be recorded and logged at fifteen (15) minutes time intervals:
 Time
 Pipeline pressure
 Ambient temperature

1.3.1 Acceptance Criteria

The pipeline hydrostatic test shall be considered complete when the following condition has been met after the
hold period. The pipeline pressure shall not fall below the required test pressure at any time during one (1)
hour holding period. All variation in test pressure shall be accounted for. The test period shall be extended if
necessary to achieve these criteria.

Note:
1) Should the test hold period be extended, the hold period will be retrospectively selected where the
pressure has maintained within the above criteria for a one (1) hour period with Client approval
2) No visible leaks shall be present on observable section of the pipeline.

Should the system require to re-pressurization during the nominated hold period, Client’s consent will be
obtained prior to re-pressurization. The hold period shall start from this point.
1.4 Depressurization
On completion and acceptance of hold period, the pipeline will be depressurized to atmospheric pressure. The rate
of depressurization shall not exceed 15psig per minute.

The pipeline pressure will be monitored and recorded during depressurization until the pipeline is fully
depressurized.

On completion of pipeline depressurization, all logs and acceptance certificates shall be signed off by all relevant
parties.

1.4.1 Preliminary Checks Preparation

STEP DESCRIPTION ACCEPTED REJECTED REMARKS

Safety Checklist
1 All personal shall be attended the project safety induction
2 Lines and communication established and noted regarding persons
incharge, contact name and telephone numbers for the safety and
environmental consideration

QAQC Checklist
1 All item of hydrotest testing and equipment requiring certificate shall
be checked

2 Verified that all certificates are valid and correct

3 Lines and communication established and noted regarding persons
incharge, contact name and telephone numbers for the safety and
environmental consideration

4 Provide confirmation that all NDT is complete and acceptable on both

permanent and temporary facilities

1.4.2 Equipment Set-Up and Layout

STEP DESCRIPTION ACCEPTED REJECTED REMARKS

1 Confirm all the tools and equipment are calibrate and have valid
certificate for the hydro test
3 Confirm the set-up of hydro test spread in the designated lay down of
working area
4 Secure all the connection hoses with whip checks and line up the
systembefore hydro test operation to be commenced.
5 Secure the working area to post warning signs and erect bunting in
around safe working area
6 Check engine oil and radiator cooling levels
 DOC NO HJRSB/PDB/M/PF/02
HYDRO TESTING PROCEDURE
DATE 05/11/2021
ENGINEERING, PROCUREMENT, CONSTRUCTION,
AND COMMISSIONING (“EPCC”) OF UPGRADING REV 0
ELECTRICAL SYSTEM SKID TANK RELOCATION
AT PDB SANDAKAN AVIATION TERMINAL

7 Confirm the instrument of hydro test operation is install as per listed and
drawing:
 Pressure Recorder
 Pressure Gauge
 Ambient temperature recorder

8 Confirm to receiving site that the instrument are installed:

 Pressure Recorder
 Pressure Gauge
 Ambient Temperature

9 Confirm working area is safe to commence hydro testing operation

10 Install the chart paper of the pressure recorder and ambient temperature
recorder at launcher site.
Note: Chart shall be signed by COMPANY

11 Confirm with receiving site that pressure gauge, temperature probe and
ambient temperature are installed
12 Once confirm the working area at launcher site is safe to
commence the hydro test, open the double block isolation valve on the test
blind
13 Start the pressurizing pump
14 Monitor and logging the pressure and flow read of the pump and
increase
the flow as required slowly. Prior to commence pressurizing the
pipelineshall follow logs:
 Time
 Pipeline Pressure
 Ambient Temperature recorder
15 Pressurize rate shall be 20 psig interval

16 Once reach 20psig of test pressure, slowly decrease the pressurizing

pumpand turn off the pressurizing pump. Allowed for 5 minutes
stabilization

17 Check for leak around the launcher and receiving site during this time, if
any leak found for any site of the riser shall be report to the test
supervisor test engineer

18 To repair leak, the pipeline shall to depressurize to ambient, then

repairthe leak
19 Once the leak has been repaired. To re-pressurize the pipeline, shall be
follow on step 18 to 25

21 Once 5 minutes prior of stabilization complete and no leak has

found,continued pressurization up to 70% of test pressure
22 Continued commencing pressurizing to the pipeline and increase the rate
till 70% of test pressure, prior to commence shall be following by the logs
 Pressurizing log
 Temperature log

23 Once 5 minutes prior of stabilization complete and no leak has

found,continued pressurization up to 100% of test pressure
 DOC NO HJRSB/PDB/M/PF/02
HYDRO TESTING PROCEDURE
DATE 05/11/2021
ENGINEERING, PROCUREMENT, CONSTRUCTION,
AND COMMISSIONING (“EPCC”) OF UPGRADING REV 0
ELECTRICAL SYSTEM SKID TANK RELOCATION
AT PDB SANDAKAN AVIATION TERMINAL
24 Stabilization prior will take another 5 minutes Pressure chart recorder
log to be taken and follow by manual log:
 Time
 Pressure reading
 Ambient temperature

25 Once stabilization has completed, pressure test shall

commence for 2 hours
26 Once confirm no leak is detected in the test duration, the pipeline
pressure is considered successful and passed.
27 Inform all witness parties and if the test is accepted by COMPANY,
thepipeline shall to depressurized at 20psig per min down to 0psig
28 Once the test of the pipeline has been completed, the chart shall
besigned follow by the acceptance Certificate and logs:
 Pipeline hydro test certificate
 Hydro test Report
 Chart Paper of Temperature
 Chart paper of Pipeline
Pressure