Hydro Test Procedure

BHARAT HEAVY ELECTRICALS Doc No: BHEL/KKNPP-3&4/TSS/WP/081
LTD.
Kudankulam Nuclear Power Project Rev. No:00 Page 1 of 15
– 3&4
Work Procedure for Hydraulic Testing Date: 23.11.2022
Controlled Copy Distribution List
ISSUED TO
Controlled
Sl.No.
Copy No.
Department Responsible Person Type of Control
NPCIL
CONTROL
01 01 ENC/TSS PACKAGE
COPY
NPCIL MECH
MECHANICAL- CONTROL
02 02
GROUP HEAD COPY
CONTROL
03 03 NPCIL QA HEAD - QA
COPY
CONTROL
04 04 NPCIL FE HEAD - FE
COPY
BHEL
CONTROL
05 05 BHEL SITE INCHARGE
COPY
MECHANICAL - CONTROL
06 06 BHEL -ERECTION
HEAD COPY
BHEL DOCUMENT
07 07 MASTER COPY
DOCUMENTATION CONTROLLER
Prepared by Reviewed by Reviewed by Approved by Issued by

M.CHANDRAMOU R.THANASEKAR
Name R.ELANGO SHASHI KANT S N NAIK
LI AN
SITE-IN- Document
Designation Engineer Section Head Head –Quality
CHARGE Controller
Signature
Date 23.11.2022 23.11.2022 23.11.2022 23.11.2022 23.11.2022
I46/KK34/0/0/QA/QFS/WD033
न्‍यूक्लियरपॉवरकॉर्पोरेशनऑफइंडियालिमिटेड
NUCLEAR POWER CORPORATION OF INDIA LIMITED
(भारतसरकारकाउद्यम A Govt. of India Enterprise)
कु डनकु लमन्‍यूक्लियरपॉवरप्रोजेक्‍ट KUDANKULAM NUCLEAR POWER PROJECT- 3&4
दस्‍तावेजस्‍वीकृ तिसूचना DOCUMENT ACCEPTANCE NOTE
Document No I46 KK34 0 0 QA QFS WD-033
दस्‍तावेजशीर्षक
Work Procedure for Hydraulic Testing
Document Title
संविदाकार Contractor M/s BHARAT HEAVY ELECTRICALS LIMITED
कार्यआदेशसं.
400442 dated 05.08.2019
Work Order No.
Erection work of Turbine, Generator, Condenser,
Secondary cycle & Sea Water System Equipment’s and
कार्यकानाम
piping including Painting, Insulation, Anti Corrosive
Name of Work
Coating and structural steel works in turbine building and
sea water structure of KKNPP 3&4
उपर्युक्‍तदस्तावेजकीसमीक्षाकीगईहैऔरलागूडब्लूडी, कोडऔरविनिर्देशोंकीआवश्यकताओंकीपुष्टिपाईगईहै।
Above document has been reviewed and found conforming to the requirements of applicable
WDs, codes and specifications.
नामएवंपदनाम
हस्‍ताक्षरएवंदिनांक
गतिविधिActivity अनुभाग Section Name &
Signature & Date
Designation
समीक्षित Mechanical
Reviewed by
QA
सहमत
Concurred by
FE
स्‍वीकृ त
Mechanical
Accepted by
LTD.
– 3&4
Revision Status
Date of 1st
Rev.No. Description
Issue/Rev.
00 23.11.2022 Work Procedure for Hydraulic Testing

LI AN
SITE-IN- Document
CHARGE Controller
Signature
Date 23.11.2022 23.11.2022 23.11.2022 23.11.2022 23.11.2022
LTD.
– 3&4
CONTENTS
Sl. No. Description Page No.

1 Scope 5
2 Purpose 5
3 Applicability 5
4 Responsibility 5
5 Reference Documents 5
6 Pre-Requisites 5
7 Equipment’s, Tools & Tackles 6
8 Hydro test 6
9 Job Hazard Analysis 9
10 Enclosures 9
1.0 SCOPE:
LI AN
SITE-IN- Document
CHARGE Controller
Signature
Date 23.11.2022 23.11.2022 23.11.2022 23.11.2022 23.11.2022
LTD.
– 3&4
This Procedure describes the various requirements and step-by-step methods to be

adopted for clearance and Hydro testing of buried PAB89 CS piping system for KKNPP
Unit#3 & 4 for TSS package.
2.0 PURPOSE:
The purpose of this procedure is to provide guidelines to carry out all the activities
pertaining to Hydro testing as per drawings or specification or test schemes.
3.0 APPLICABILITY:
This procedure is applicable for PAB89 buried CS piping system coming under the TSS
package.
4.0 RESPONSIBILITY:
The responsibility of implementation of this procedure lies with Site in-Charge (TSS
Package)/BHEL-PSSR/KKNPP-3 & 4.
5.0 REFERENCE DOCUMENTS:

The following documents are used in the procedure:
a) Technical specification Section-V of Tender document No.

NPCIL/KK/-3&4/CONST/MECH/PT/2018/56.
b) PNAEG-7-008-89: Regulations for design and safe operation of equipment and pipe
lines of Nuclear facilities
c) PNAEG-7-009-89: Welding & Weld surfacing of equipment and applications.
d) PNAEG-7-010-89: Welded Joints and surfacing inspection regulations for the atomic
Power plant Equipment and Pipelines.
e) Approved drawings and testing schemes.
f) Working drawings of relevant system under hydro test.
6.0 PRE-REQUISITES:
1. Completion of all the required weld joints shall be ensured with all necessary
documentation.
2. As built drawings shall be available, checked and reviewed by NPCIL (Mech).

LI AN
SITE-IN- Document
CHARGE Controller
Signature
Date 23.11.2022 23.11.2022 23.11.2022 23.11.2022 23.11.2022
LTD.
– 3&4
3. Circuit clearance shall be obtained from NPCIL for testing.
4. All the joints shall be approachable by providing temporary platform / Scaffolding

and adequate illumination shall be ensured.
5. All the joints shall be left un-insulated and exposed for examination during inspection
and testing. Any exemption in this case, prior approval will be obtained from NPCIL.
6. Availability of equipment, tools and tackles as mentioned below shall be made

available.
7. All hot works shall be completed prior to hydro test.
7.0 EQUIPMENT, TOOLS AND TACKLES:

a) Water filling pump
b) Pressurizing pump
c) Calibrated pressure gauges
d) Mirrors
e) Wire brushes (SS for SS piping)
f) Non return valve (NRV)
g) Safety relief valve
h) Blind Flanges
i) End caps, Gaskets, bolt & nut
j) Hand Lamps
8.0 HYDRO TEST:
8.1 Test Preparations

1. Test loops shall be formed based on the system requirement, feasibility, isolation
points and test pressure requirements. Test loop may consist one or many isometric
drawings.

LI AN
SITE-IN- Document
CHARGE Controller
Signature
Date 23.11.2022 23.11.2022 23.11.2022 23.11.2022 23.11.2022
LTD.
– 3&4
2. Loop (decided) shall be formed well in advance and NPCIL approval shall be taken
for the same.
3. BHEL and NPCIL shall jointly inspect for the mechanical clearance for the test loops
for the following aspects
a) Conformity to P&ID, As-built drawings.
b) Type & location of supports
c) Pressure gauge location & accessibility for inspection
d) Venting arrangement & relief valve arrangement.
e) Line history sheet shall be prepared with fit-up, welding & NDT report details for each &
every joint and shall be verified by BHEL (QA) & NPCIL (QA).
f) All NDT to be cleared and records shall be maintained and tabulated in line history sheet
(LHS) as per the format given at the end of the procedure.
g) Mechanical clearance report shall be prepared as per NPCIL format. Checklist shall be
prepared, filled, and attached to the format.
8.2 System Filling & Testing

1. Refer Sketch -1 for schematic diagram of arrangement for hydro test.
2. System shall be filled with water for hydro test only after necessary approvals from
NPCIL vide clearances according to the formats as per the approved circuit release
report.
3. Test medium:
a) Unless specified, hydro testing shall be performed with ordinary clean water.
b) Filling and venting:
1) System Isolation shall be carried out by closing the end with Plate (blank).
2) For hydro testing, filling shall be gradually done from lower most points in such
a way that no air remains entrapped in any branch line of piping loop.
3) For this purpose, venting shall be done at high points, vents shall be kept open
during filling & till the testing fluid come out without any bubbles.

LI AN
SITE-IN- Document
CHARGE Controller
Signature
Date 23.11.2022 23.11.2022 23.11.2022 23.11.2022 23.11.2022
LTD.
– 3&4
4) Gravity fill will be used for filling & once the system is filled properly, filling
line shall be isolated.
c) Method of pressurization:
i. The pressure in the system shall be gradually increased to half of the test
pressure, then after in steps of approximately one tenth pressure, until required
test pressure has been achieved.
ii. During hydro test of pipe lines, the pressurizing pump shall be isolated.
iii. Rate of pressurizing shall be in such a way that the system pressure shall rise
gradually & not be any abrupt rise in pressure.
d) Extent of examination:
i. Following the application of hydro test pressure for specified period, examination
for leakage shall be made for all joints at leak test pressure as specified in the
work procedure or relevant documents.
ii. All site assembled joints including the weld attachments to the system
boundaries, weld seams, longitudinal weld elbows, list of joints shall be available
prior to testing.
e) Test pressure & hold time

i. The system shall be pressurized as per the drawing / test scheme. Pressure test
gauge shall be used in the system.
ii. Analog type indicating gauge used in testing shall be graduated not less than 1.5
times and not more than 4 times of required hydro test pressure.
iii. Details of set pressure of safety relief valves shall be as indicated in test scheme.
iv. All pressure gauges shall be calibrated and the certificate of calibration shall be
available at site.
v. The measurement error between two pressure gauges shall not exceed +/-
0.5% against the rated pressure value (Pressure difference due to static head to be
considered while comparing the pressure gauge readings).
vi. One pressure gauge shall be installed at the highest point and one shall be
installed near the pump. Minimum of two pressure gauges to be provided in the
loop / equipment.

LI AN
SITE-IN- Document
CHARGE Controller
Signature
Date 23.11.2022 23.11.2022 23.11.2022 23.11.2022 23.11.2022
LTD.
– 3&4
vii. The pipelines and the equipment should be kept under test pressure during hydro
test as per approved test scheme.
viii. After hydro-test, pressure is reduced to leak search pressure indicated in test
scheme and the equipment and pipelines are inspected at the points within the
period required for the inspection.
f) Test temperature
i. For testing, temperature shall be as per the drawings / relevant specification.
ii. Test temperature shall be ambient temperature unless otherwise specified
g) Acceptance.
i. All construction weld joints shall be inspected on full circumference during leak
search to find any sweating on it.
ii. If there is no leakage, pressure drop or metal damage and no visible residual
deformation has been detected after testing, pipeline is considered to have passed
the hydro test to satisfaction.
iii. Leakage beyond acceptable limit shall be repaired and area of repair shall be
retested using original procedure.
h) Depressurization and draining of the system

i. After the leak search is completed, the systems shall be de-pressurized by
gradually opening all vents and drained by opening drain valve. During draining
vent valve shall be kept open.
ii. Rate of depressurization shall be in such a way that, drop in system pressure shall
be gradual and abrupt pressure drop shall be avoided.
iii. After testing, all the temporary arrangements made for test (blanks, drains, vents
etc.) shall be removed and the system shall be normalized and shall confirm to
design requirement.
9.0 JOB HAZARD ANALYSIS:

1. No working on pressurized system shall be permitted
2. The instrument, equipment that is not designed for test pressure shall be disconnected or
isolated.
3. Pressurized systems shall not be left unattended.
4. It shall be ensured that all inline valves are in open condition except the terminal point.
5. The piping system under testing shall be barricaded.

LI AN
SITE-IN- Document
CHARGE Controller
Signature
Date 23.11.2022 23.11.2022 23.11.2022 23.11.2022 23.11.2022
LTD.
– 3&4
6. No hot work is permitted either during or after completing hydro testing.
10.0 ENCLOSURES:
a) Schematic diagram for Hydro test
b) Hydro Test Scheme
c) Mechanical Clearance Report
d) Circuit Release Report (CRR)
e) Integrity / Leak test report

LI AN
SITE-IN- Document
CHARGE Controller
Signature
Date 23.11.2022 23.11.2022 23.11.2022 23.11.2022 23.11.2022
LTD.
– 3&4

LI AN
SITE-IN- Document
CHARGE Controller
Signature
Date 23.11.2022 23.11.2022 23.11.2022 23.11.2022 23.11.2022
LTD.
– 3&4

LI AN
SITE-IN- Document
CHARGE Controller
Signature
Date 23.11.2022 23.11.2022 23.11.2022 23.11.2022 23.11.2022
LTD.
– 3&4

LI AN
SITE-IN- Document
CHARGE Controller
Signature
Date 23.11.2022 23.11.2022 23.11.2022 23.11.2022 23.11.2022
LTD.
– 3&4

LI AN
SITE-IN- Document
CHARGE Controller
Signature
Date 23.11.2022 23.11.2022 23.11.2022 23.11.2022 23.11.2022
LTD.
– 3&4

LI AN
SITE-IN- Document
CHARGE Controller
Signature
Date 23.11.2022 23.11.2022 23.11.2022 23.11.2022 23.11.2022

Hydro Test Procedure

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Hydro Test Procedure

Uploaded by

Copyright:

Available Formats

BHARAT HEAVY ELECTRICALS Doc No: BHEL/KKNPP-3&4/TSS/WP/081

Controlled Copy Distribution List

Prepared by Reviewed by Reviewed by Approved by Issued by

दस्‍तावेजस्‍वीकृ तिसूचना DOCUMENT ACCEPTANCE NOTE

Document No I46 KK34 0 0 QA QFS WD-033

संविदाकार Contractor M/s BHARAT HEAVY ELECTRICALS LIMITED

00 23.11.2022 Work Procedure for Hydraulic Testing

Prepared by Reviewed by Reviewed by Approved by Issued by

Sl. No. Description Page No.

This Procedure describes the various requirements and step-by-step methods to be

5.0 REFERENCE DOCUMENTS:

a) Technical specification Section-V of Tender document No.

c) PNAEG-7-009-89: Welding & Weld surfacing of equipment and applications.

e) Approved drawings and testing schemes.

f) Working drawings of relevant system under hydro test.

2. As built drawings shall be available, checked and reviewed by NPCIL (Mech).

Prepared by Reviewed by Reviewed by Approved by Issued by

3. Circuit clearance shall be obtained from NPCIL for testing.

4. All the joints shall be approachable by providing temporary platform / Scaffolding

6. Availability of equipment, tools and tackles as mentioned below shall be made

7. All hot works shall be completed prior to hydro test.

7.0 EQUIPMENT, TOOLS AND TACKLES:

c) Calibrated pressure gauges

e) Wire brushes (SS for SS piping)

f) Non return valve (NRV)

g) Safety relief valve

i) End caps, Gaskets, bolt & nut

8.0 HYDRO TEST:

8.1 Test Preparations

Prepared by Reviewed by Reviewed by Approved by Issued by

a) Conformity to P&ID, As-built drawings.

b) Type & location of supports

c) Pressure gauge location & accessibility for inspection

d) Venting arrangement & relief valve arrangement.

8.2 System Filling & Testing

b) Filling and venting:

Prepared by Reviewed by Reviewed by Approved by Issued by

e) Test pressure & hold time

Prepared by Reviewed by Reviewed by Approved by Issued by

ii. Test temperature shall be ambient temperature unless otherwise specified

h) Depressurization and draining of the system

9.0 JOB HAZARD ANALYSIS:

3. Pressurized systems shall not be left unattended.

5. The piping system under testing shall be barricaded.

6. No hot work is permitted either during or after completing hydro testing.

b) Hydro Test Scheme

c) Mechanical Clearance Report

d) Circuit Release Report (CRR)

e) Integrity / Leak test report

Prepared by Reviewed by Reviewed by Approved by Issued by

Prepared by Reviewed by Reviewed by Approved by Issued by

Prepared by Reviewed by Reviewed by Approved by Issued by

Prepared by Reviewed by Reviewed by Approved by Issued by

Prepared by Reviewed by Reviewed by Approved by Issued by

Prepared by Reviewed by Reviewed by Approved by Issued by

You might also like