GARRAF GAS TREATMENT UNIT

Document No.: GF-GGTU-G-PR-0536

Revision: B
Page: 1 of 10

GF-GGTU-G-PR-0536 HYDRO TEST PROCEDURE PAGE 1 OF 11

GARRAF GAS TREATMENT UNIT

CONTRACT NO.: PCIHBV/2012/DD/405

HYDRO TEST PROCEDURE

GF-GGTU-G-PR-0536

PETRONAS CARIGALI IRAQ HOLDING B.V

PREPARED CHECKED REVIEWED APPROVED

OWNERS COMMENT
BY BY BY BY
REV DATE DESCRIPTION
NAME & NAME & NAME & NAME &
Approved / Reviewed
SIGN SIGN SIGN SIGN
B 21-Jul-16 For Approval RHA LDG NMG YSS Approved with Comment

Resubmit for Approval

Resubmit for Review

Name Signature Title Date

The Signing, countersigning or other endorsements of any drawings and documentation by PCIHBVs Representatives, agents or employees shall neither
be construed as implying the responsibility for the correctness and accuracy of such documents nor relieving the CONTRACTOR of its obligations to
review all information, data, drawings, and specifications provided by PCIHBV.
 GARRAF GAS TREATMENT UNIT
Document No.: GF-GGTU-G-PR-0536
Revision: B
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REVISION HISTORY

Rev. Date Description of Change

A 02-July-2015 For Approval

Contents
 GARRAF GAS TREATMENT UNIT
Document No.: GF-GGTU-G-PR-0536
Revision: B
Page: 3 of 10

1.0 PURPOSE:............................................................................................. 4
2.0 SCOPE:................................................................................................. 4
3.0 REFERENCES........................................................................................4
4.0 PROCEDURE.........................................................................................4
5.0 SAFETY PRECAUTIONS...........................................................................9
6.0 ATTACHMENT......................................................................................11

.0 PURPOSE:

The purpose of these procedures is to ensure that pressure tests are conducted safely
and effectively .The procedure serves as guideline for preparation and execution of
hydro test and flushing process.

.0 SCOPE:
 GARRAF GAS TREATMENT UNIT
Document No.: GF-GGTU-G-PR-0536
Revision: B
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This procedure is applicable for hydro testing of above ground piping and underground piping for
GARRAF GAS TREATMENT UNIT.

.0 REFERENCES:

3.1 ASME B 31.3: Piping process.

3.2 Method statement of hydro test..GF-GGTU-G-MS-1009
3.3 Specifications of fabrication and installation...GF-GGTU-J-SP-1007
3.4 Specification of design basicGF-GGTU-J-SP-1001
3.5 Specification for pipe materials and valve. GF-GGTU-J-SP-1003

.0 PROCEDURE:

.1 General:
Hydro test flushing shall be not be carried out without approval from PCIHIBV.

.1.1 Each hydro test procedure shall consist of the following:

4.1.1.1 Hydrostatic test flow sheet. refer to attachment #1

4.1.1.2 Testing details indicating the test pressure, attached the markup P&ID, G/A DWG
and Isometric drawing for the testing. As specified in the test pack index. Refer to
attachment # 2.
4.1.1.3 Hydro test flow chart shall be extended to Company flow chart shall be done at
least two(2) days advance notice shall be given prior to the schedule test date.
.1.2 Contractor shall be performed the hydro test after the following activities are
completed i.e.
.1.2.1 Visual Inspection clearance.
.1.2.2 All NDT requirements shall be completed prior to release for pressure test.
.1.2.3 Reinforcing pads should be carried out by DPT (dye penetrant test).
.1.2.4 The pipe support shall be completely installed.
.1.2.5 All piping joints and surfaces shall be dry before the commencement of the hydro
test.
.1.2.6 Red line markup shall be done to ensure the additional joint (captured if any).
.1.2.5 Punch list clear which full under gat A.

.2 Test Equipment and tools:

4.2.1 The following equipments shall be available to perform the field testing of piping system:

a) Hydro test Pump.

b) Pressure Gauge.
c) Pressure and temperature Recorder.
d) Tube and Fittings.
e) Air compressor.
f) Pressure Relief Valve.
g) Bolt and nuts .
h) Water Tank.
i) High Pressure Hose and Fitting.
j) Gate Valves
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k) Temporary pipe and header.

l) Temporary blind flange.
m) Plug and cap.
n) Flushing hose.
o) Temporary gasket.
p) Strainer or mesh for flushing purpose.

4.2.2 The pressure recorder shall be calibrated, and checked for accuracy prior to test the
Calibration certificate for the pressure test recorder shall be submitted to the contractor
inspector together with the test report upon completion of the hydro test.

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

4.2.4 Pressure gauges shall have a range of 1.5 to 2.2 times required test pressure and pressure
gauge .

4.2.5 Pressure release setting on the pressure relief valve adjusted 10% higher than the system
testing pressure.

4.2.6 All temporary material e.g. pipe, header, blind flange, gasket, bolt and nuts etc. shall be marked
or uniquely color code from permanent material.

4.2.7 Prior to hydro testing and flushing of the piping system or components, the line completion
checklist shall be accomplished carried out by contractor QA/QC inspector and company
representative.

.3 Hydrostatic Test Procedure:

4.3.1 All piping system shall be tested in accordance with project specifications and the Latest edition
of ASME B31.3.

4.3.2 Prior to commencement of hydro testing, Contractor inspection shall submit the test package of
the system to be tested, to the PCIHBV for review.

4.3.3 The piping system shall be subdivided into sub-systems for testing where necessary. The hydro
test flow sheet shall indicate the test limit points i.e. the location of block, valves, and blind
flanges for isolating the sub-systems.

4.3.4 Blind flanges shall be installed for equipment excluded from the hydro test Blind flanges may be
installed with temporary connection where necessary to by-pass the equipment.
The blind flanges shall be installed to the following equipment i.e. Pumps, turbines, blowers
and compressors etc.

4.3.5 Pressure gauges, pressure transmitters and flow meter, along with the secondary be piping
connection the instruments to the block valve at the equipment or primary piping shall excluded
from the hydrostatic test.

4.3.6 Fresh water shall be used with the high volume low pressure pump to fill the system.
The filling points shall be at lowest point in the system.
To prevent trapping of air or vapors in the system, vents shall be located at the highest point.
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4.3.7 All vent valves and other high point connections which serve as vents shall be opened
During filling and closed only when water starts to overflow.

4.3.8 After filling, the pumping system shall be shut off and disconnected from the system.
- Ensure that all flange properly torque.

4.3.9 System under hydro test shall be adequately supported to withstand the test pressure and
temporary supports shall be installed where necessary.

4.3.10 External surfaces of the piping system shall remain dry during inspection whilst checking for
leak.

4.3.11 The pressure shall be raised gradually pressurize system (25%, 50%, 75 %.....) with stop 15
minute for each step to allow the pressure to stabilize.as chart below.
The Pressurizing of the system shall continue until the required pressure is reached.

4.3.12 From reached to maximum pressure test make sure stabilize pressure about 15 minute after
that start holding pressure one hour.

Pressure
(Barg)
Holding time for inspection

3rd stage 75%

2nd stage
50%

1st stage 25%

Time/

4.3.13 The test pressure shall be maintained for one (1) hour to permit visual inspection to be made of
all surface, weld and connection
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4.3.14 The rate of pressure increase shall not exceed 3.5 bar per minute.

4.3.15 The pump shall be shut off once the required test pressure is achieved with test pressure of test
pack.

4.3.16 Minimum testing period including holding time shall be 30 minutes and pressure shall be
released if it exceeds the test pressure due to temperature variation. This shall be done by
opening the bleed valve to release the excess pressure in order to maintain the test pressure.

4.3.17 Open the block valve leading to the pressure recorder after the system pressure is stabilized.

4.3.18 Prior to any pressure test a document named "Test Package" shall be prepared by contractor
and approved by PCIHBV.

4.3.19 The following documents of "Test Package" shall be compiled:

a) Test Diagram LegendMarked P&ID.

b) Line-List
c) Marked - Up P & ID
d) Isometric Drawings
e) Welding Inspection Summary Report
f) NDE Report (3rd party)
g) Gauge and Recorder Certificate
h) Punch list for ITR-A

*All document as specified in HT package index.

4.4 Flushing procedure:

4.4.1 All pipe work should be cleaned internally before testing. All valves, gasket, flanges, bolting,
fitting and other components shall be of the required specifications. All joints shall be exposed
for physical inspection during the duration of the test.

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

4.4.3 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 where practical to ensure that no be in
the open position and non-return valves defeated, all instrument accessories shall be removed,
likewise relief valves, and thermo well connections.

4.4.4 All block valves to instrument impulse line connections shall be closed prior to flushing .

4.4.5 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
the duration of the test is completed.
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4.4.6 At least one (1) day before flushing commences, contractor inspector shall inform the company
inspector for the line inspection. All details for line inspection shall be mentioned in the pre-
hydrostatic checklist.
4.4.7 Visual inspection shall be conducted by contractor inspector, and to be witnessed by the
company inspector to ensure that the system Installation is completed. The visual inspection
report shall be completed upon satisfactory inspection of the line .

4.4.8 Flushing shall be done in the presence of contractor inspector and company inspector.

4.4.9 Piping system shall be flushed with clean water with a velocity of 3 m/s. This is lowest velocity
for flushing. Test sample shall be taken until the test system is free from dirt and foreign
materials, by using a 100 mesh wire

4.4.10 After flushing, checks shall be carried out to ensure all non-return valves are still defeated.
Swing checks valves are opened and set all ball valve at half open position.

4.5Schematic for Hydro test:

4.6Rectification of leak:

4.6.1 System need to depressing

4.6.2 Any leak in flange connections, bolting shall be carefully and gradually tightened in proper
sequence to prevent uneven tightening.
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4.6.3 If leak occurred in the weld joint the water shall be drained and the leak shall be repaired as per
approved welding procedure (GF-GGTU-X-PR 0528).
After verification work has been carried out the HT/leak/flushing shall follow the above step
describe in (4.3).

4.7Draining and Drying:

4.7.1 After hydrostatic testing of the system is completed satisfactorily, care should be taken during
depressurization so as to avoid any surging effects. Tested system shall be completely drained
and blown dry.

4.7.2 After the system has been depressurized, all vents shall be opened before the system is
drained and shall remain opened during draining to prevent vacuum effect in the system.

4.7.3 The system shall be completely drained. Compressed air shall be used to blow dry the system.

4.7.4 All ring spacer, blind flanges, etc. installed for testing shall be removed and pressure relieving
devices replaced.

4.7.5 Upon completion of test, the system shall be reinstated to its designed conditions.

.0 SAFETY PRECAUTIONS:

5.1 Good housekeeping to maintain throughout.

5.2 Only dedicated trade workers to be involved in this activity.

-Work leader - Hydro tester
-Supervisor -Safety
5.3 During pressure build-up, shall take suitable precaution to prevent building up of excessive
pressure, the pressure pump shall be monitored at all times.

5.4 Pressurization of the system shall be done in an increment of 25% of the required test pressure
per 15 min. to avoid over pressurization of the system and to allow stabilization of the test
medium in the system.

5.5 The test area shall be cordoned off and provided with warning sign boards CAUTION!
Hydrostatic Test in Progress, also warning signs shall indicate the date and duration of test,
and the test pressure.
All personal attending the test shall wear safety goggles only authorized personal shall be
attend in the hydro test area at time of testing.

5.6 The safety officer(s) will conduct a joint walk with subcontractor / contractor testing personal in
order to familiarize the piping system to be tested prior to test commencing.

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

5.8 When venting water from the pressure test particular care shall be taken to ensure that water
dose not vent into any place where personal working, also electrical tools and panels etc.
 GARRAF GAS TREATMENT UNIT
Document No.: GF-GGTU-G-PR-0536
Revision: B
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.0 ATTACHMENT:

6.1 ATTACHMENT#1. (Hydrostatic test flow sheet)

6.2 ATTACHMENT#2..Test pack index