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Hydro Testing Of Piping System

SABIC /GAS # - Doc. No.: VCN0002-62-QA-P-


9145
Project Title NITROGEN GENERATION UNIT (NGU) Rev. No.: A
Client eTEC / SABIC PMT Page: 1 of 7
Location GAS YANBU Date: 19-Aug-2017

Procedure for
Hydro Testing Of Piping System
Hydro Testing Of Piping System

TABLE OF CONTENTS

Contents
1. OBJECTIVE: ................................................................................................................................ 3
2. SCOPE: ....................................................................................................................................... 3
3. REFERENCES ............................................................................................................................ 3
4. ABBRIVIATIONS/DEFINITIONS .................................................................................................. 3
5. RESPONSIBILITIES .................................................................................................................... 3
6. PROCEDURE .............................................................................................................................. 3
6.1 PREPARATION AND EXECUTION OF HYDROTESTING ................................................... 4
6.1.1 Preparation of Hydro Test .............................................................................................. 4
6.1.2 Execution of Hydrostatic Testing .................................................................................... 5
6.2 DRAINING, BLOWING, REMOVAL OF BLANKS ................................................................. 5
6.3 RELEASING OF SPRING SUPPORTS AND EXPANSION JOINTS ..................................... 6
7. TOOLS & EQUIPMENTS ............................................................................................................. 6
8. HSE INSTRUCTIONS .................................................................................................................. 6
9. RELATED DOCUMENTS ............................................................................................................ 7
10. ATTACHMENTS ...................................................................................................................... 7
Hydro Testing Of Piping System

1. OBJECTIVE:

The objective of this method statement is hydro testing of piping system at the project
sites.

2. SCOPE:

This procedure covers hydro testing of piping system under the scope of project specifications
and Quality Management System.

3. REFERENCES

The following documents are considered as reference document:

ASME B 31.3 Process Piping


SES P01-E15-Rev.02 Pressure testing and lay-up Procedures
PO1-E15 Pressure testing and layup procedure
P13-CO2 Field fabrication and include SHEM Erection

4. ABBRIVIATIONS/DEFINITIONS
CL Client
PM Project Manager
SM Site Manager
I/C In-charge
QA&QC Quality Assurance & Quality Control
MS Method Statement
HSE Health Safety & Environment
PPE Personal Equipment Protection

5. RESPONSIBILITIES
It is overall responsibility of SM/PM to organize resources to perform testing activities
as per project specification, schedule & HSE requirements.
The QA&QC Engineer will ensure that testing is performed as per project
specifications.
HSE instructions for testing process will be carried out under responsibility of SM/PM.
I/C testing shall be responsible to carry out the work as per the test packs and the
parameters outlined therein.
I/C discipline/test pack shall be responsible to complete the piping system (test pack)
as per project specifications and schedule.

6. PROCEDURE

After erection, test packages preparation and approval. I/C Discipline/Test pack shall check
for compliance between the work performed and the following listed drawings, and then fill in
the form Report of Check after Erection.

Isometric drawings
Piping arrangement drawings
Drawings of special supports and standard supports
Drawings and specification for steam-tracing
P & I diagrams of the plant

The I/C discipline/test pack shall also check that the materials erected comply with those
identified in the relevant piping project specifications. I/C QA&QC shall check that welds are
Hydro Testing Of Piping System

performed in accordance with the requirements of the welding specification. Having completed
the checks and any heat treatment required, the I/C QA&QC shall fill in the required section of
the attached Report of Check after Erection.

6.1 PREPARATION AND EXECUTION OF HYDROTESTING

6.1.1 Pretest activity

Preparation and approval of test package.

Complete pretest checklist.

All welding and NDE work complete.

Permanent and temporary supports installed.

Punch categories ABC.

Test system is related for testing by SABIC & ETECH QA/QC.

6.1.2 Test Preparation

P&ID with marked limit or boundary for test system.

All temporary blinds as per blind system thickness. Schedule temporary gasket type
and identified.

Identify the vent and drain, install valve on vent and drain.

Test Procedure shall be approved prior to commencement of Hydro Testing.

Testing system shall be blown to verify inside cleaning.

Soft seated valves and control vales shall be removed before Hydro testing

Calibrated Pressure gauges of 30~80% of full scale range shall be provided, and
calibration interval shall be not more than one month.

Minimum of 2 gauges shall be provided for testing. One gauge shall be installed on
testing assembly, and other one on test system. Their mutual accuracy shall be within
5%. Additional gauges shall be provided if determined by inspection personnel.

Rotary devices, strainer, filter elements and pressure relieving devices shall be
excluded from Hydro testing system.

If required, temporary Vent drains and supports shall be provided before Hydro test.
Hydro Testing Of Piping System

6.1.3 Testing

a) Before proceeding with hydro test of any pipe, circuit, or system, the I/C Discipline
shall confirm erection is duly completed and inspection reports are signed by QAQC.

Obtain authorization to proceed with hydro testing; such authorization will be given by
signature of the I/C QA&QC on the form.

The test pack document with the authorization shall be handed over to I/C Testing.

I/C Testing shall prepare, for each testing circuit, two pressure gauges (certified for
accuracy), which are to be installed into two points of the line or circuit to be tested. On
in the highest section of the line, and other in the lowest section of the line, and at the
maximum distance possible from one another.

a) Pressurizing sequence

Filling and Pressurizing shall be done on the upstream side of check valve and water
shall be injected from lowest point of system.

All vents shall be in open state during water filling.

The test pressure shall be increased in steps with stabilization until required test
pressure has reached. There shall be complete control of operator over the pressure.

b) Holding

Once reached to required test pressure, system shall be disconnected from test pump
and complete system shall be inspected by SENDAN/eTEC/PMT inspection team.

After having maintained for a minimum of 30 min the test pressure, the representatives
of the I/C testing and eTEC/PMT shall certify the testing has been completed.

NOTE: Bolting to be left loose for flushing prior to testing. The isolation blanks shall be
color-coded. Prepare the test package before Hydro testing of Piping

c) Inspection.

Check the pipe line and welding joints and test pressure holding time.

d) Leakage / Repair

If found any leakage than mark the point , if the leakage is from flanges than tighten
the bolts and if the leakage is from welding joint than release the pressure and repair
the joint.

6.1.3.1 During test

Barricade the area and if there is any leakage found between flanges than tighten the
bolts.
Hydro Testing Of Piping System

6.1.3.2 Test acceptance

Project Standard and Specification specifies pressure and leak test procedure and
acceptance criteria of piping.

6.2 Post test

After having performed the testing and with the approval by eTEC/PMT, the I/C Testing shall
arrange for the completely depressurizing of the test system.

On completion of draining operations, the I/C Testing/ I/C Discipline (piping) shall perform the
following:

All vents shall be opened before draining.

Pressure shall be released in a manner and controlled rate to avoid any safety hazard
to equipment or testing personnel.

All equipment/assemblies installed for hydro testing shall be removed and system shall
be re-instated as per IFC drawings.

Removal of blanks, except those placed on level controllers, indicators, control valves
and safety valves.

Position the final gaskets at the locations where temporary gaskets were used.

Final tightening of bolting shall be done and torque procedure shall be followed.

6.3 Water disposal

Water will be drained in the water waste trench

6.4 Golden joints

After completion of hydro testing the welded blind will be removed and golden joint will be
fit up and welding, than 100% Radiography test required.

6.5 RELEASING OF SPRING SUPPORTS AND EXPANSION JOINTS

The I/C Discipline shall, on completion of all erection operations, perform the releasing
(unlocking) of spring supports and expansion joints. Since these components are different
according to type and supplier, the instructions to this purpose will be given each time by
concerning team.

7. TOOLS & EQUIPMENTS


a) Pressure gauge ( Calibrated)
b) Test manifold ( Separately tested with TUV)
c) Pressure release valve ( calibrated as per API-PP520-Part-1)
d) Test pump (Calibrated with TUV)
e) Water Tanker
f) Hoses ( With test tag attached)
g) Test Blind ( with appropriate thickness and design)
Hydro Testing Of Piping System

The test circuit for testing pressure testing consists of the following tools and equipment:

A hydrostatic test pumps capable of producing no less than 150 percent of the test
pressures. Equipment must include appropriate check valves and fittings.

A flexible connection for attachment to the test pump. It shall be used with the
necessary fittings to test through the pipe nozzle, test inlet drain, or hose outlet, as
applicable.

DRYING - All tested lines, which have passed through hydrostatic test, shall be
thoroughly dried by approved flushing / air blowing procedure.

8. HSE INSTRUCTIONS

All equipment and piping including skid-mounted packages shall be tested after
installation even though certain items may have been previously shop tested unless
specified in the contract. All flanged joints, which are made after the pressure test,
shall be inspected during the leak test conducted before or during start-up.

Pressure Gauges shall be calibrated before use. Calibrated interval shall not exceed
one month. A minimum of two pressure gauges shall be applied indicated the latest
calibration date. Recording gauges shall be used where it is advisable to keep
permanent record. All gauges shall have a range such that the test pressure is within
30% & 80% of the full range calibration. Certificates shall be made available to
inspection personnel

Prior to commencement of the Pressure Test bleed valve shall be provided to protect
piping and equipment from over pressure even though there is a provision of a
pressure-relieving device.
Hydro Testing Of Piping System

The system under test shall be protected from over pressure by installing relief valves
of adequate capacity set to relieve at 5% above the test pressure.

Relief valve shall be calibrated immediately before each use. Isolation valve shall be
provided at the point where the temporary test piping connects to the equipment or
piping under pressure test.

When filling, the test fluid shall be injected at the lowest point in the system to minimize
the risk of entrapped air. All vents shall be opened. Filling shall take place upstream of
any check valves, unless the disc has been removed and upstream of any positive
displacement of turbine meters where the reverse rotation could cause damage.

Any liquid fuel spills and accidental waste disposal should be avoided and properly
cleaned up.

When draining the test fluid the system shall be vented slowly to avoid excessive
vacuum.

Hydrostatic testing activity shall be performed in accordance with the safe working
practices in the HSE manual of the project.

Close visual inspection for leakage during the test shall be made with care.

Oxygen equipment and piping shall not be tested with hydrocarbons.

Hammer testing shall not be done while the system is under pressure.

Minimize the disturbances to the natural drainage system.

Any manifold fabricated for hydro test purposes shall be tested separately from any
other piping before it is used in conjunction with testing of any system. The manifold
shall be tested to a pressure not less than twenty percent above the test pressure to
be applied on the system to be tested.

No person shall be allowed near the system under the test when the pressure of over
500-PSI is being applied or the pressure is near the yield strength.

Preserve your natural environment.

No smoking is permitted in restricted areas.

9. RELATED DOCUMENTS

N/A

10. ATTACHMENTS