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Hydrotest Chart
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.
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.
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.
1.6 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.
Purpose
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
Reports to
Construction Manager
Responsible for New Pipeline Cleaning, Gauging, flooding, Hydro testing, Dewatering, Swabbing and
Drying ( 97 KM )
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.
Test Pack Co-coordinating and Preparation of final documents for handing over to client.
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.
Preparing and witnessing the Hydro test / Pneumatic test of pipelines and approval.
Co-ordinate between the client ( YLNG ) & contractor ( YEMGAS-Technip, KBR ,Total ).
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
Well Knowledge with codes, standards such as ASME, ANSI, ASNT, API and HSE practices.
Purpose of Role
• 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;
• 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;
• 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;