qcp-10 hydrotest and flushing procedure

8/17/2019 QCP-10 Hydrotest and Flushing Procedure

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Doc Ref QCP 10

QU LITY CONTROL

Date 1

st

January 2009

Kencana Infrastructurc

PROCEDURE

Revision No : 0

Cover Page

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HYDROTEST ND FLUSHING

PROCEDURE

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Date : 1st January 2009

Revision No : 0

HYDROTEST AND FLUSHING

PROCEDURE

Page 1 of 9

TABLE OF CONTENTS

SECTION DESCRIPTION PAGE

1.0 PURPOSE 2

2.0 SCOPE 2

3.0 REFERENCES 2

4.0 DEFINITIONS 2

5.0 PROCEDURE 2

5.1 GENERAL 2-3

5.2 TEST EQUIPMENT 3

5.3 FLUSHING PROCEDURE 3-4

5.4 HYDROSTATIC TEST PROCEDURE 4-6

5.5 RECTIFICATION OF LEAK 6

5.6 DRAINING AND DRYING 6-7

6.0 SPECIAL REQUIREMENTS 7

7.0 RECORDS 7

FIGURE I HYDROTEST SCHEMATIC DIAGRAM 8

FIGURE II HYDROTEST FLOW CHART 9

APPENDICES

APPENDIX I INSPECTION REQUISITION

APPENDIX II VISUAL INSPECTION REPORT

APPENDIX III FLUSHING REPORT

APPENDIX lV PRESSURE TEST REPORT


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1.0 PURPOSE

This procedure outlines the flushing process and hydro testing requirements, toensure that the piping system are clean from debris or unwanted items and theintegrity of the system is proven.

2.0 SCOPE

This procedure is applicable for flushing and hydro testing of prefabricatedpiping spools and completed piping in a system.

3.0 REFERENCES

ANSI B31.3 – Chemical Plant and Petroleum Refinery Piping

ANSI B31.4 – Liquid Petroleum Transportation Piping System

4.0 DEFINITIONS

Nil

5.0 PROCEDURE

5.1 General

5.1.1 Each hydro test procedure shall consist of the following :

a) Hydrostatic test flow sheet.

b) Testing details indicating the test pressure, testing medium

and other test related details i.e. filling points, vent, drainpoints and test limit points.

c) A copy of the hydro test flow chart (Refer to figure II) shall beextended to Client. This shall be done at least two (2) daysadvance notice shall be given prior to the scheduled testdate.

5.1.2 Hydro testing shall only be performed after the following activitiesare completed i.e.

a) Visual Inspection.

b) Post Weld Heat Treatment (PWHT).


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PROCEDURE

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5.1.3 The pipe support shall be completely installed.

5.1.4 All piping joints and surfaces shall be dry before thecommencement of the hydro test.

5.1.5 All hydro testing activities shall be inspected by KencanaInfrastructure Site Supervisor and shall also be witnessed byKencana Infrastructure QC inspector and Client’s Representative.

5.2 Test Equipment

5.2.1 a) Hydro test Pump f) Pressure Relief Valveb) Pressure Gauges g) Temperature Recorderc) Gate Valves h) Vent Release Valved) Tube and Fittings i) Water Tanke) Pressure recorder j) High Pressure Hose and

Fitting.

5.2.2 The pressure recorder will be calibrated, and checked foraccuracy prior to test. The calibration certificate for the pressuretest recorder shall be submitted to the QC inspector together withthe test report upon completion of the hydro test.

5.2.3 The acceptable accuracy for the pressure recorder shall be ±0.5% over the full range.

5.2.4 The range of the pressure gauge and pressure recorder to beused shall not be greater than four times the test pressure.

5.2.5 Pressure release setting on the pressure relief valve shall beadjusted 10% higher than the system testing pressure.

5.3 Flushing Procedure

5.3.1 All pipe work should be cleaned internally before testing. Allvalves, gasket, flanges, bolting, fitting and other components shallbe of the required specifications. All joints shall be exposed forphysical inspection during the duration of the test.

5.3.2 All high points shall be provided with a valve which shall ensure allair removed from the line, the low points shall be also fitted with avalve to facilities the draining of the line.

5.3.3 Prior to hydro test, all lines shall be flushed with clean water, from

the high to the low point.

Prior to flushing, the pipe internal shall be visually inspected


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be removed by flushing are left in the line. All ball valves shall be

in the open position and non-return valves defeated, all instrumentaccessories shall be removed, likewise relief valves, and thermowell connections.

5.3.4 All block valves to instrument impulse line connections shall beclosed prior to flushing.

5.3.5 Prior to flushing, all instruments exposed to damage by debris, i.e.control valves, orifice fittings, PD meters, capacitance probes, etc.shall be removed and dummy spools to be installed until theduration of the test is completed. Spools used shall be ANSIflanged and pipe of correct schedule, the weld will be inspected forsafety purposes.

5.3.6 At least one (1) day before flushing commences, KencanaInfrastructure Site Supervisor shall inform the QC inspector of theline inspection. All details for lines inspections are to be highlightin the inspection Requisition Form (Appendix I).

5.3.7 Visual inspection shall be conducted by Kencana InfrastructureSite Supervisor, and to be witnessed by the QC inspector toensure the system installation is completed. The Visual InspectionReport shall be completed upon satisfactory inspection of the line.

Refer to Appendix II.

5.3.8 Flushing shall be done in the presence of Site Supervisor and tobe witnessed by QC inspector and Client’s Representative.

5.3.9 Piping system shall be flushed with clean water with a velocity of 3m/s for pipe diameter 2 inches and below, and lower velocity forpipe diameter greater than 2 inches.

5.3.10 After flushing, checks shall be carried out to ensure all non-returnvalves are still defeated. Swing checks valves are opened and set

all ball valve at half open position.

5.3.11 The Flushing Report (Appendix III) shall be prepared by KencanaInfrastructure QC inspector upon completion of the flushing.

5.4 Hydrostatic Test Procedure

5.4.1 All piping system shall be tested in accordance with Client’sspecifications and the latest edition of ANSI B31.3 Refer to figure Ifor the Hydro test Schematic Diagram.

5.4.2 Prior to commencement of hydro testing, Kencana InfrastructureSite Supervisor shall submit an isometric drawing of the system to


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5.4.3 The piping system shall be subdivided into sub-systems for testing

where necessary. The hydro test flow sheet shall indicate the testlimit points i.e. the location of block valves, and blind flanges forisolating the sub-systems.

5.4.4 Blind flanges shall be installed for equipment excluded from thehydro test. Blind flanges may be installed with temporary tubingconnection where necessary to by-pass the equipment.

The blind flanges shall be installed to the following equipment i.e.pumps, turbines, blowers and compressors.

5.4.5 Pressure gauges, pressure transmitters and flow meter, along withthe secondary piping connection the instruments to the blockvalve at the equipment or primary piping shall be excluded fromthe hydrostatic test.

5.4.6 Fresh water shall be used with the high volume low pressurepump to fill the system. The filling points shall be at lowest point inthe system.

To prevent trapping of air or vapors in the system, vents shall belocated at the highest point.

5.4.7 For stainless steel, the chloride content of the water shall noexceed 200 ppm.

5.4.8 All vent valves and other high point connections which serve asvents shall be opened during filling and closed only when waterstarts to overflow.

5.4.9 After filling, the pumping system shall be shut off anddisconnected from the system.

5.4.10 System under hydro test shall be adequately supported to

withstand the test pressure and temporary supports shall beinstalled where necessary.

5.4.11 External surfaces of the piping system shall remain dry duringinspection whilst checking for leak.

5.4.12 The pressure shall be raised gradually, with stops to allow thepressure to stabilize. The pressurizing of the system shallcontinue until the required pressure is reached.

5.4.13 Caution shall be taken during pressurization to avoid surging

effects. Pressurization and depressurization will be donegradually (25% of the test pressure requirement per 15 min) atall times.


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5.4.14 The rate of pressurization shall be reduced when approximately

80 percent of the specified test pressure has been attained.

5.4.15 The pump shall be shut off once the required test pressure isachieved.

5.4.16 Whilst holding the system at test pressure, the system pressureshall be released if it exceeds the test pressure due totemperature variation. This shall be done by opening the bleedvalve to release the excess pressure in order to maintain the testpressure.

5.4.17 Open the block valve leading to the pressure recorder after thesystem pressure is stabilized.

5.4.18 Sign the temperature chart and pressure chart before and afterhydro test by the QC inspector.

a) The hydro test time shall commence when KencanaInfrastructure and Client Representative agreed the systempressure is stable. The duration of the test shall be one(1) hour for flanges rated at below 300 lbs.

b) The test duration for flanges rated at 300 lbs and above,

the test duration shall be two (2) hours.

5.4.19 The pressure test Report (Appendix IV) shall be prepared byKencana Infrastructure QC inspector upon completion of thetest.

5.5 Recti fication of leak

Any leak in flange connections, bolting shall be carefully and graduallytightened in proper sequence to prevent uneven tightening. If leakoccurred in the weld joint the water shall be drained and the leak shall be

repaired as per approved welding procedure.

5.6 Draining and Drying

5.6.1 After hydrostatic testing of the system is completed satisfactorily,care should be taken during depressurization so as to avoid anysurging effects. Tested system shall be completely drained andblown dry.

5.6.2 After the system has been depressurized, all vents shall beopened before the system is drained and shall remain opened

during draining to prevent vacuum effect in the system.

5.6.3 The system shall be completely drained. Compressed air shall


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5.6.4 All spades, blind flanges, etc installed for testing shall be

removed and pressure relieving devices replaced.

5.6.5 Upon completion of test, the system shall be reinstated to itsdesigned conditions.

6.0 SPECIAL REQUIREMENTS

6.1 Safety Precautions

6.1.1 During pressure build-up, shall take suitable precaution toprevent building up of excessive pressure, the pressure pumpshall be monitored at all times.

6.1.2 Pressurization of the system shall be done in an increment of25% of the required test pressure per 15 min. to avoid overpressurization of the system and to allow stabilization of the testmedium in the system.

6.1.3 The test area shall be cordoned off and provided with warningsign boards “CAUTION! Hydrostatic Test in Progress”, alsowarning signs shall indicate the date and duration of test, andthe test pressure.

6.1.4 Kencana Infrastructure shall ensure that the correct pressurerating for all ancillary fittings used (i.e. temporary piping, hoses,blanks, etc) can withstand the flushing and pressure test.

6.1.5 All system testing will be carried out in accordance with theapplicable codes, and client’s specification requirements.

6.1.6 No tightening of bolts/nuts to be carried out during thestabilization of the required pressure in the system.

7.0 RECORDS

Title Responsibility Retention Period

7.1 Visual Inspection QC Inspector Until completionReport of Project

7.2 Flushing QC Inspector At least one year afterReport completion of project

7.3 Pressure Test QC Inspector At least one year afterReport completion of project


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FIGURE I – HYDROTEST SCHEMATIC DIAGRAM

NOTE :

CHECK VALVE STRAINNERS RELIEF VALVE

HAVE BEENS DISMANTLED AND SMALL/SHORT SPOOLSSHALL BE BOLTED TOGETHER FOR THE HYDROTEST

THERE SHALL BE INSTALLED UPON COMPLETION

HYDROTESTING


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P HYDROSTATIC PUMP

FP FILLING POINTTB TEMPORARY BLIND

PG PRESSURE GAUGE

PR PRESSURE RECORDER

TR TEMPERATURE RECORDER

DP DRAIN POINT

V VENT POINT

ò SPADE

TC TUBING CONNECTION

FIGURE II – HYDROTEST FLOW CHART


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APPENDICES


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QCP-10 Rev-0

Appendix I

TO :____________________________

INSPECTION REQUISITION

REQ. NO. :

SYSTEM FOR INSPECTION :

PROJECT/CONTRACT NO. :

ISO DRAWING REFERENCE :

DETAILS OF INSPECTION REQUIRED :

REQUEST BY : LOCATION :

DATE : DATE FOR INSPECTION :

TIME : TIME FOR INSPECTION :


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PROJECT :

SYSTEM TESTED :

DETAILS OF PIPEWORK LINE NO :

TYPE OF TEST TO BE CARRIED OUT AFTER

VISUAL INSPECTION : ………………………………………………………………

………………………………………………………………

REMARK :

NAME

DATE

CLIENT'S REPRESENTATIVE

ACCEPTED BY :

QCP-10 Rev-0

Appendix II

REQ. NO. :

VISUAL INSPECTION REPORT

CHECKED BY:

SUPERVISOR

ACCEPTED BY :

QC INSPECTOR

ACCEPTED REJECTED


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QCP-10 Rev-0

Appendix III

FLUSHING REPORT

PACKAGE NO. /

REPORT NO.

PROJECT

CLIENT

PROJECT NO.

SYSTEM FLUSHED

LINE / SPOOL NUMBERS

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

REMARKS :

TESTED BY :

SITE PERSONNEL

ACCEPTED BY :

QC INSPECTOR

ACCEPTED BY :

CLIENT'S REPRESENTATIVE

NAME

DATE


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PRESSURE TEST REPORT

PROJECT NO : REPORT NO :

PROJECT TITLE : WORK LOCATION :

CLIENT : ITEM TESTED :

TYPE OF PRESSURE TEST : DATE OF TEST :

Test Requirement Test Conditions

Test Pressure : Pressure Gauge S/No. :

Holding Time : Chart Recorder S/No. :

Piping Class : Test Medium :

Applicable Code : Pressure Gauge Range :

Finish

Flushing Requirements Gauge Pressure :

( ) Liquid ( ) Air Ambient Temperature :

Others : Time :

Condition :

Date :

Item / Line No. Tested Results / Remarks

The above mentioned items / lines were listed and accepted / rejected by :

Appendix IVQCP-10 Rev-0

Start

QC Inspector Client's Representative

qcp-10 hydrotest and flushing procedure

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