Hydrostatic Test Procedure

EQUIPMENT NAME : Pressure Vessel

COMPANY : PROJECT NAME : Inter Refineries Pipeline-II(IRP-II) Project

Main IRP-II Package CONTRACTOR :

VENDOR : Descon Engineering FZE, Sharjah

0 19/11/13 Issued for Final Ronak Mehta

Saket Kumar

Saket Kumar

Rev. Date Description DRWN CHKD APPD APPD APPD

COMPANY PROJECT No

5595 P/O No. 5595-E2-PO-MD-001

DWG No. or DOC No, Doc. No. 5595-E2-VP-MD-001-014 / DES/2937/QA&QC/14 Rev .0

INTER REFINERIES PIPELINES-II (IRP-II) PROJECT

FOR MAIN IRP-II PACKAGE

AGREEMENT No. 10-5595-E-2

HYDROSTATIC TEST

PROJECT No. 5595-E2 Doc. No. 5595-E2-VP-MD-001-014 Rev. 0 Page 2 of 9

Descon Engineering FZE, Sharjah

SERVICE :

PROJECT DOC. TITLE : Hydro Static Test Procedure

GS E&C P.O. No. : 5595 – E2 – PO – MD-001

ITEM No. : Ref Page No : 06

VENDOR DOC. Ref. No. : DES/2937/QA&QC/14

Descon Engineering FZE, Sharjah

CHECKED DATE INITIALS SIGNATURE

Rejected Comments as noted No Comments Information Only GS E&C’s acceptance of this documents does in no way relieve

the supplier of his contractual obligation

D 19/11/13 Issued for Final Ronak Mehta

Saket kumar

Saket Kumar

Rev Date Description Prepared Checked Approved Authorised

NOTES:

-. Revisions are denoted by a vertical line placed in the right-hand margin against the revised text.

INTER REFINERIES PIPELINES-II (IRP-II) PROJECT

FOR MAIN IRP-II PACKAGE

AGREEMENT No. 10-5595-E-2

HYDROSTATIC TEST

PROJECT No. 5595-E2 Doc. No. 5595-E2-VP-MD-001-014 Rev. 0 Page 3 of 9

Descon Engineering FZE, Sharjah

REVISION INDEX DETAILS

Rev. Location of Change Brief Description of Change 0 All Pages Issued For Final

INTER REFINERIES PIPELINES-II (IRP-II) PROJECT

FOR MAIN IRP-II PACKAGE

AGREEMENT No. 10-5595-E-2

HYDROSTATIC TEST

PROJECT No. 5595-E2 Doc. No. 5595-E2-VP-MD-001-014 Rev. 0 Page 4 of 9

Descon Engineering FZE, Sharjah

1. OBJECTIVE 5

TABLE OF CONTENTS

2. SCOPE 5

3. APPLICABLE FOR EQUIPMENTS 5

4. APPLICABLE CODES 6

5. PREPARATION FOR TEST 6

6. TEST GAUGES & RECORDERS 6

7. APPLICATIONOF TEST PRESSURE, HOLDING TIME AND EXAMINATION 7

8. ACCEPTANCE CRITERIA 8

9. DRAINING & DRYING OF EQUIPMENT 8

10. SAFETY PRECAUTIONS 8

11. RECORDS 8

12. ATTACHMENT 8

INTER REFINERIES PIPELINES-II (IRP-II) PROJECT

FOR MAIN IRP-II PACKAGE

AGREEMENT No. 10-5595-E-2

HYDROSTATIC TEST

PROJECT No. 5595-E2 Doc. No. 5595-E2-VP-MD-001-014 Rev. 0 Page 5 of 9

Descon Engineering FZE, Sharjah

1) OBJECTIVE

The objective of this procedure is to define the Hydrostatic Leak testing requirements for a

pressure vessels in accordance with applicable code, standards and project requirements.

2) SCOPE

This procedure is applicable for the shop pressure testing (Hydrostatic Leak test) of pressure

vessels.

This procedure does not cover the requirements for carrying out pressure tests at field sites

where a specific procedure shall be developed depending on the type of field work involved.

S.No

3) APPLICABLE EQUIPMENTS

Item No. Service Name

MDMT - C Design

Temperature - C

Test Pressure kg/cm2

Min Metal Temperature

- C

1 013-V-101 ULG SUMP VESSEL 5 87 9.3 / 4.55 5

2 013-V-102 GAS OIL SUMP VESSEL 5 87 4.64 / 4.55 5

3 013-V-103 INSTRUMENT AIR RECEIVER 5 100 13.18 / 13.0 5

4 2975-F JET A1 SUMP VESSEL 5 87 4.64 / 4.55 5

5 100-V-101 GAS OIL SUMP VESSEL 5 87 7.11 / 4.55 5

6 312-V-001 ULG / GAS OIL SUMP VESSEL 5 87 7.11 / 4.55 5

7 410-V-006 INSTRUMENT AIR RECEIVER 5 100 13.82 / 13.0 5

8 1141-D-001 ULG SUMP VESSEL 5 87 4.64 / 4.55 5

9 1141-D-002 GAS OIL / JET A1 SUMP VESSEL 5 87 4.64 / 4.55 5

10 1141-D-003 INSTRUMENT AIR RECEIVER 5 100 13.44 / 13.0 5

11 900-V-101 ULG SUMP VESSEL 5 87 4.64 / 4.55 5

12 900-V-102 GAS OIL SUMP VESSEL 5 87 4.64 / 4.55 5

13 900-V-103 INSTRUMENT AIR RECEIVER 5 100 13.18 / 13.0 5

14 1000-V-001 GAS OIL SUMP VESSEL 5 87 4.64 / 4.55 5

INTER REFINERIES PIPELINES-II (IRP-II) PROJECT

FOR MAIN IRP-II PACKAGE

AGREEMENT No. 10-5595-E-2

HYDROSTATIC TEST

PROJECT No. 5595-E2 Doc. No. 5595-E2-VP-MD-001-014 Rev. 0 Page 6 of 9

Descon Engineering FZE, Sharjah

15 1000-V-002 ULG SUMP VESSEL 5 87 4.64 / 4.55 5

16 1000-V-003 INSTRUMENT AIR RECEIVER 5 100 13.18 / 13.0 5

17 1100-V-051 LPG OFFLOADING COMPRESSOR SUCTION KOD 5 87 23.97 / 15.86 5

18 1100-V-052 INSTRUMENT AIR RECEIVER 5 100 13.73 / 13.0 5

19 410-T-030 / 031

ANTI FREEZE CHEMICAL STORAGE TANK 5 87 FULL OF

WATER 5

4

• ASME Code Sec VIII Div.1 EDD 2010

) APPLICABLE CODES

• 5595-E2-AMD-MD-002

• The test pressure shall be 1.3 x MAP (maximum allowable pressure) 5) PREPARATION FOR TEST

• The test pressure shall be maintained for a period not less than one hour.

• The PH of water shall be kept between 6 to 8

• The minimum metal temperature during initial pressure testing of vessels shall not be

lower than 7°C.

• However, the test temperature shall not exceed 49°C (120°F).

• The chloride content of water shall not exceed 50 ppm for testing vessels fabricated.

• The test medium for hydrostatic testing shall be clean water containing a suitable wetting

agent to reduce the surface tension.

• All reinforcing pads shall be tested by using air with a minimum of 1.05 kg/cm2 to a

maximum of 1.4kg/cm2

6) TEST GAUGES & RECORDERS

The Quality Control Engineer shall ensure that the test gauges meet the following

requirements.

A minimum of two number calibrated pressure gauges with proper assembly valves shall

be attached to the item under test such that the gauges are clearly visible to the operator

who is pressurizing the system. At least one pressure gauge will be mounted close to the

Location

INTER REFINERIES PIPELINES-II (IRP-II) PROJECT

FOR MAIN IRP-II PACKAGE

AGREEMENT No. 10-5595-E-2

HYDROSTATIC TEST

PROJECT No. 5595-E2 Doc. No. 5595-E2-VP-MD-001-014 Rev. 0 Page 7 of 9

Descon Engineering FZE, Sharjah

highest point on the item. Hydrostatic test shall be recorded by one number of pressure

recorder.

Range The range of pressure gauges shall be about double the intended test pressure but in no

case it shall be less than 1.5 nor more than 4 times of the intended test pressure.

Gauge Calibration All test gauges shall be calibrated at least every 6 months (or earlier if there is a reason

to believe that the gauge is not accurate) as per the calibration system against a Dead

Weight Tester or a Calibrated Master Pressure Gauge. The maximum permissible error

shall not exceed ± 1% of the full scale reading.

• All vessels shall be hydrostatically tested at a pressure based upon

Test Pressure – Upper limit and Stresses during test

• The design pressure for vessel design to ASME VIII DIV 1.

• The maximum allowable pressure new and cold for vessel design to ASME VIII Div 1.

• Above mentioned project specifications.

1. The pressure shall be gradually increased until the required pressure has been reached.

Once the pressure has been achieved and stabilized (for about ten minutes) the

pressurizing system must be isolated from the pressure source.

7) APPLICATION OF TEST PRESSURE, HOLDING TIME AND EXAMINATION

2. The minimum holding time at test pressure is one hour.

3. Close examination need not be carried out at the test pressure. Close examination shall

be carried out on all welds and the regions of high stress such as head knuckles,

4. areas around openings and thickness transition areas.

5. Upon completion of the test, the pressure shall be gradually reduced to zero before

opening the drains.

INTER REFINERIES PIPELINES-II (IRP-II) PROJECT

FOR MAIN IRP-II PACKAGE

AGREEMENT No. 10-5595-E-2

HYDROSTATIC TEST

PROJECT No. 5595-E2 Doc. No. 5595-E2-VP-MD-001-014 Rev. 0 Page 8 of 9

Descon Engineering FZE, Sharjah

8) ACCEPTANCE CRITERIA

The pressure test shall be considered as acceptable when there is no evidence of leakage and

there is no visible deformation on any component.

9) DRAINING & DRYING OF EQUIPMENT

After the hydrostatic Leak test the vessel shall be immediately and carefully drained and all

parts and all parts where water could collect shall be dried.

When the pressure will reach at zero than all drain nozzles will be opened and equipment will

be left for drying, pressurize dry air may be used for early drying before sand blasting and

painting. The nozzles that are to be used for draining purpose should be at minimum elevation.

• The following safety precautions shall be taken during the test: 10) SAFETY PRECAUTIONS

• Cordon-off the test area and put warning signs as necessary

• Only authorized personnel are allowed inside the cordon-off area.

• The test is continuously monitored during the test by a competent personnel

• Provide proper access (scaffolding/ladder) to all parts of the vessel for close examination

• All authorized personnel to wear adequate personal protective equipment during the test.

• No hammering/grinding/welding work is permitted when the item is under pressure

Pressure test certificate

11) RECORDS

The following records shall be maintained for all pressure tests.

Calibration records of test gauges

Hydrostatic test report format 12) ATTACHMENT

INTER REFINERIES PIPELINES-II (IRP-II) PROJECT

FOR MAIN IRP-II PACKAGE

AGREEMENT No. 10-5595-E-2

HYDROSTATIC TEST

PROJECT No. 5595-E2 Doc. No. 5595-E2-VP-MD-001-014 Rev. 0 Page 9 of 9

Descon Engineering FZE, Sharjah

DESCON ENGINEERING FZE. HYDROSTATIC / PNEUMATIC TEST

CERTIFICATE

Doc No: Rev Date: Page: 1 of 1

Work Order No.: Customer:

Project:

Job Description:

Drawing No.: Rev. `

Master Gauge: Dead Weight Test Sr. No. Model / Certificate No.

Gauges: Gauge No. (a) Code No.: Pressure & Temp. Recorder Certificate No: N/A

Gauge No. (b) Code No.:

NOTE:

Applicable Code: ASME SEC.VIII Div-1 ED.2007

Test Pressure: Test Medium: Water (Potable)

Test Medium Temperature: Ambient Temperature:

Time: From: To: Test Duration (Hours):

Test Result: Satisfactory Not Satisfactory

REMARKS:

QA/QC Engineer / Inspector Customer / TPI Inspector Authorized Inspector

Name: Name: Name:

Sign: Sign: Sign: