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Hydrotest Photo

Hydrotest Chart

Sample Hydrotest Schematic


Berikut ini adalah inti dari procedure/ tata cara (selain daftar isi, referensi dokumen, safety,
daftar peralatan, dan lain2) kerja untuk pekerjaan hydrotest :

1. HYDRO TESTING
1.1 Hydro test preparation
Ready for inspection (RFI) notification shall be informed by construction supervisor to quality
assurance/quality control (QA/QC) department when a piping system is ready for testing.
Verification of all materials, test and mill certificates etc. are compiled and documented by
QA/QC department and traceable for each component, fitting and pipe applied to each spool or
line number. All required non-destructive examination (NDE) results shall be verified to conform
to Company general specifications prior perform hydrotest.

The contractor’s QC inspector and Company representative shall together check visually in detail
for the piping network prior to test. The checking shall include of:
 Compliance with drawing and battery limit of related subsystem
 Welded or flanged joints
 Secure and correct bolting
 Pipe routing and slope
 Location of vent and/or drains
 Pipe support, permanent and/or temporary
 Temporary spading or blinding
 Pipe painting and color coding

The piping supervisor will be responsible for conducting preparation and execution of pressure
test and shall take coordination with QC inspector. Additional material for close the spools such
as blind flange shall be available on test site and tighten properly prior hydro test (check correct
rating).

Pressure gauges and recorder shall be in Bar or Psi unit. Temperature indicator shall be in degree
Celcius. Full gauge range (indicated span) of pressure test gauges are to be selected in such a
way that the test pressure will be in between 50% to 80% of the full range. A minimum of 2 (two)
pressure gauges shall be required for the test. The gauges shall be installed at predetermined
locations with one at the highest elevation point and one at the lowest elevation point wherever
possible.

A certified pressure/temperature recorder (maximum validity of pressure equipment calibration


6 months) with full range in steps shall be used to record the test pressure, temperature and
duration of testing. All relevant details are to be entered in onto the chart. Recorded to be used
shall be of dual pen. All gauges and recorder shall be calibrated prior to utilization for test. Any
indicator showing an unrecoverable zero error or error more than plus or minus 1.0% of full scale
range shall not be used without repair and re-calibration. One temperature indicator recorder
shall be provided.
1.2. Hydrotest Execution
Test manifold shall be assembled onto the piping network for connection to pressure gauges and
recorder. Temperature indicator and pressure source connection. Sufficient valves shall be
provided to allow blocking or releasing pressure.

For hydrostatic test, the pressure is applied by means of a suitable test pump (hydrotest pump
shall be equipped with PSV as safety devices if used during pressure test) and gradually
built up to 35% of the test pressure and held for at least 15 minutes to uniform stress along the
piping network. Pressure then shall be applied until 70% of test pressure and, again, held for 15
minutes. Thereafter, once the required pressure reaches (1.5 design pressure) test pressure,
piping network shall be isolated from the pressure source.

The test pressure shall be maintained 2 hours for holding time as per Company specification
However this holding time can be prolonged to allow sufficient time for inspection. QC Inspector
and Company representative shall carry out a detailed inspection of weld joints and connections
for any leak, attention shall also be paid for dislocation or movement of the supports or distortion.

In case of pressure test is performed in the sunny day, the pressure gauge and temperature
indicator shall be monitored to prevent undue pressure increase due to thermal expansion In
order to avoid excessive pressure the system may be depressurized down to the required test
pressure.

1.3 Limit of Test Pressure


Hydrotest pressure shall be 1.5 times of design pressure and hydrotest pressure shall be indicated
in the drawing, lower limit of the test pressure shall be not less than test pressure specified. Upper
limit is 5% of the test pressure, if during hydrostatic test the test pressure increased
by more than the upper limit, the test pressure shall be released or bleed off to
the specified test pressure.

If during hydrostatic test the test pressure is decreased to a pressure lower than the specified test
pressure and there is no evidence of leakage, the line shall be pressurized back to reach the
specified test pressure and held for 2 (two) hours
1.4 Inspection During Hydrotest
Upon reaching the desired holding time, the test pressure shall be reduced to a
pressure not less than the test pressure by QC Inspector and the Company representative shall
be carry out visual examination at this pressure. Examination for leakage shall
be performed by QCInspector at all welding joints and connections

Leakage is not allowed at time of the required visual inspection, except for leakage that
might occur at temporary test closures for those openings intended for welded connections and
leakage from temporary seals (gaskets). Leakage and damages found during the test shall be
repaired and rectified. And retest shall be performed.

1.5 Pressure Release


After the pressure test, pressure shall be released at a rate so as not to endanger personnel or to
damage equipment by drawing test medium off the line. Pressure released slowly until the
pressure drop to 70% then holding for 15 minutes, release again until pressure drop to 35% then
holding for 15 minutes. Pressure released again until gauge shown0 bar, all vent shall be opened
before the system is drained and shall remain open during draining prevent pulling vacuum on the
system.

1.6 Record
Pressure test chart shall be signed by authorized persons. The following information shall be
added on to the chart:
 Pressure & temperature ranges
 date of test
 identification of piping system tested (line and/or spool number)
 weather condition
 test pressure
 test medium
 result of testing
 names and signatures of executor or supervisor, QCinspector and Company representative
The record and pressure chart will be included in the pre commissioning dossier.

2. POST HYDROTEST DRYING


Upon completion of hydrostatic testing, CONTRACTOR shall dewater the pipeline. Contractor
shall begin the drying operation only after all testing activities are complete and accepted by
Company. Water shall be moved ahead or disposed of after depressurized. Blowing some dry air
inside the pipe spool to ensure that inside pipe is completely drained. Close the spool with proper
closure before continue to other process, which is painting or installation.
Accountability:
Accountable to the Project Manager and Pre-Commissioning Manager for all technical aspects of
Hydro testing and pre-commissioning of Piping & Pipelines and associated systems.
Responsibilities:
Reporting to the Project Manager / Management Team.
Responsible for pipeline cleaning, Gauging, flooding, hydro-testing, Dewatering, Swabbing and
Drying.
Responsible to prepared and finalized pre-commissioning, design package and Construction
Method Statement Package as per project Standard.
Planning, Execution, Control and Supervision of all activities of Hydro testing.
Coordination with Pipe Line spread in charge, QA/QC and HSE team in the organization and
those of client for related activities
Preparation/ review of work procedures for above activities, controlling overall pre-
commissioning/commissioning activities.
Responsible to prepare data sheets of the conducted tests and results
To prepare an excel sheet of tests conducted (failures, passed tests and changes made)
Preparing reports for Client submission, etc.
Manpower, equipment and material planning for cleaning, gauging, Hydro testing, Dewatering,
Swabbing, Drying and leak
Monitoring installation and testing of pipelines, valves, and other piping items. Review hydro
test package, carry out inspection of the lines prior to testing
Review of Calibration records for various instruments and Documentation control.
Preparation of test pack, Planning and execution of preparatory activities.
Checking hydro test equipment and instruments.
Making arrangement for sourcing and transporting of test water and disposal thereof.
Get repaired the line if any leak is attended and Re- Hydro test.
Use of specification and procedure for quality welding.
Taking action while any objection from client and consultant.
Maintaining good contact with consultant and client.
Responsible for HSE of all personnel involved in the operation.
Supervision of pipeline pigging, cleaning, gauging , Pre hydrotest , hydrotesting pre
commissioning and commissioning
Mandatory Knowledge of Hydro testing and pre-commissioning of all types of hydrocarbon
pipelines and associated systems.
Knowledge about P&ID, PFD, Isometric and all relevant Piping equipment data sheet and SIS
sheet, Pipeline Alignment Sheets, Hydro test Diagram and their Calculations.
Prepare the Hydro test Pack, Punch List and Approvals for Piping and pipelines pre-
commissioning on all aspects.
JOB SUMMARY:
Leads work crews in the preparation and carrying out of hydro‐testing, pipe cleaning and blowing
works for gas pipelines, including review of drawing, prefab, pipe erection and other activities
required to complete the assigned scope of works.
PRIMARY DUTIES AND RESPONSIBILITIES:
1. Ensures that workers involved in the hydro‐testing works are properly guided, is completed in
accordance with prescribed information prior to pneumatic and hydrostatic pressure tests being
carried out for all test packages.
2. Prepare technical report, lists of outstanding items on a punch list submits it for construction
to carry out the required test.
3. Monitors the hydro‐testing (hydrostatic and pneumatic) and handle reports on the completion
of tests and to supervise line cleaning after hydro test.
4. Responsible for the examination of systems to ensure completeness, punch lists preparation,
and readiness for hydro tests activities.
5. Interfaces with equipment, piping, instrumentation, electrical inspectors, civil/structural
inspectors, field engineer and other field superintendent before proceeding for hydro tests of
systems.
6. Interfaces with the client’s Quality Assurance representative for his presence at the test.
7. Reviews the documentation relevant to the systems and ensures the systems are constructed
in accordance with the prescribed information – drawings, specifications and vendor information.
8. Coordinates with Project Manager and supervise the preparation of test activity to ensure
all deficiencies are identified and punch lists are prepared
9. When the systems are to be tested, ensures the systems limits are identified, that necessary
test equipment is in place and reviews completion of punch list items to ensure hydro tests may
proceed.
10. Review and approve subcontractor and supplier documentation including quality plans,
inspection and test plans, manufacturing/welding procedures, inspections and test procedures
and manufacturing records.
11. Coordinates and monitors the hydro tests and reports on the completion of hydro tests.
12. Demonstrate a professional work ethic and actively participate as a member of the Discipline
Workface Planning Team.
13. Interfaces with the Discipline Planning Teams to understand the construction schedule.
14. Assesses the impact of inefficiencies on the successful completion of planned activities and
adjust the plan as required.

Purpose

Prepare Hydo / Pneumatic Test Packs as required by the project schedule;


Prepare for and perform Hydro / Pneumatic testing of piping systems;
To maintain awareness of and ensure compliance with all relevant Statutory and Company HSE
Standards.

Coordinates with the Senior Hydro-Test Superintendent and supervise the preparation of the test
activity to ensure all deficiencies are identified and punch lists are prepared;
Identification of hydro and pneumatic test limits;
Prepare marked up P&ID,S indicating test limits;
Prepare marked up isometrics indicating test limits, items to be removed, location of test blinds,
plugs etc.;
Ensure high point vents and low point drains are available in the piping to be tested to avoid dead
legs, air pockets etc.;
Review the test and design pressures by isometric and confirm with the line list;
Identify test equipment required for each test and ensure availability;
Review test material availability, blinds, flanges, plugs, gaskets etc. and raise purchase order to
cover the project piping scope;
Ensure all test equipment calibration is performed and certification available;
Ensure availability of equipment consumables (Charts etc.);
Review and comply with the Project Hydro-test procedure;
Review and comply with the Project Flushing procedure;
Ensure compliance to HSE Procedures;
Compile Test Packs in advance of test date for submission and approval by client;
Interface with Nigerdock QA/QC Department for weld clearance prior to test and with respect to all
flushing, testing and reinstatement activities;
Interface with the Piping Superintendent to identify early opportunity to progress testing;
Perform pre-test line inspection to ensure compliance to the test pack;
Along with the Piping Superintendent ensure all HSE requirements are in place and followed prior
to pressurization;
Attend the test with QA/QC and client;
Ensure complete draining and drying of the piping is performed after test;
Compile and update as required a register of test packs by system and sub system;
Compile and update as required a Test Blind Register, indicating the location of blinds fitted for test
or spectacle blinds turned;
Perform line inspection to ensure reinstatement of all items removed for test and any test blinds
are removed and plugs seal welded if required;
Ensure the completed test sheet is signed by all parties and added to the test pack;
Ensure the Sub System completion check sheets are signed and returned to the Administrator;
Other Duties

Flushing, Drying and Reinstatement

Reports to

Construction Manager

Responsible for New Pipeline Cleaning, Gauging, flooding, Hydro testing, Dewatering, Swabbing and
Drying ( 97 KM )

12”X 12.5KM Pipeline, 8”X 3.0KM, 36”X 82.4KM.

8”X 1.5KM, 2NO Gas Pipeline.


36”X 27 KM, 3NO Gas Pipeline, 36”X 600MTR, 2NO GAS Pipeline.

Station Piping Test pack Preparation, Final Test pack review and submit to the client and

witness of the Hydro Test , Control all test ( Hydro & pneumatic without any accident ).

Identification of test loops, preparation of test packages and coordinating for Hydro test.

Line checking and Punch list preparation and clearing punch list from client side.

Preparing and witnessing the Hydro test / Pneumatic test of pipelines and approval.

Inspection of pipes internal cleaning and Gauging Plate.

Test Pack Co-coordinating and Preparation of final documents for handing over to client.

TECHNICAL SKILLS (GAMA-YEMEN)

Attending contractual meeting and QC meeting with client and consultant.

Test Pack coordinate my Team Members , GRP Document Preparation , Final Test Pack

review and submit to the client and witness of the Hydro Test .

Identification of test loops, preparation of test packs and organizing for Hydro test.

Line checking and Punch list preparation and clearing punch list from client side.

Coordinating and review of PT, PWHT , UT and PMI including RT.

Preparing and witnessing the Hydro test / Pneumatic test of pipelines and approval.

Preparation of final documents for handing over to client.

Co-ordinate between the client ( YLNG ) & contractor ( YEMGAS-Technip, KBR ,Total ).

Inspection of pipes internal cleaning and Gauging Plate.

Control all test ( Hydro & pneumatic without any accident ).

Coordination with Engineering / design, cost control departments.

Ensure quality control of spools and supports for both fabrication & Erection as per
specification.

Inspection activities for fabrication and erection of Pipes, Vessels, Tanks, static and

Rotating equipments, structural platforms.

Inspection of fit up and alignment of rotating machineries.

Ensuring strict compliance to all planned activities.

Well Knowledge with codes, standards such as ASME, ANSI, ASNT, API and HSE practices.

Inspection of Tanks dimensional check like plumbness, chords, peaking, banding.

Inspection of Static and rotating equipments from foundation to commissioning.


Working knowledge in software’s like AutoCAD 2004, etc.

Calibration of Standard Pressure Gauges & Certification .

Purpose of Role

• Prepare Hydo / Pneumatic Test Packs as required by the project schedule

• Prepare for and perform Hydro / Pneumatic testing of piping systems

• To maintain awareness of and ensure compliance with all relevant

• Statutory and Company HSE Standards

Prime Responsibilities and Duties

• Coordinates with the Senior Hydro-Test Superintendent and supervise the preparation of the test
activity to ensure all deficiencies are identified and punch lists are prepared;

• Identification of hydro and pneumatic test limits;

• Prepare marked up P&IDS indicating test limits;

• Prepare marked up isometrics indicating test limits, items to be removed, location of test blinds,
plugs etc.;

• Ensure high point vents and low point drains are available in the piping to be tested to avoid dead
legs, air pockets etc.;

• Review the test and design pressures by isometric and confirm with the line list;

• Identify test equipment required for each test and ensure availability;

• Review test material availability, blinds, flanges, plugs, gaskets etc. and raise purchase order to
cover the project piping scope;

• Ensure all test equipment calibration is performed and certification available;

• Ensure availability of equipment consumables (Charts etc.);

• Review and comply with the Project Hydro-test procedure;

• Review and comply with the Project Flushing procedure;

• Ensure compliance to HSE Procedures;

• Compile Test Packs in advance of test date for submission and approval by client;

• Interface with Nigerdock QA/QC Department for weld clearance prior to test and with respect to all
flushing, testing and reinstatement activities;

• Interface with the Piping Superintendent to identify early opportunity to progress testing;

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