PREMONOR S.A.

MOTOR COOLING PIPING REPAIR - MAN Diesel & Turbo Schweiz AG

Títle:

HYDROSTATIC TEST PROCEDURE

Nº Documento.: PREM.PROC-MAN-001
Revisión: 00
Fecha: 24/10/2017

Issued by:

A.Leticia Peña Rivas- Quality Engineer

Reviewed by:

D.Bolaño- Construction Manager

Approved by:

P.Rivera – Production Manager

 HYDROSTATIC TEST PRESSURE
Document:
PREM.PROC-MAN-0001
PREMONOR S.A.
Revision: 00 Date: 24/10/2017
MOTOR COOLING PIPING REPAIR
Sheet: 2 of 7

REVIEW OF CONTENTS

Rev Date Description Issued Reviewed Approved

00 24/10/2017 First Issue L.P.R D.B PR
 HYDROSTATIC TEST PRESSURE
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PREMONOR S.A.
Revision: 00 Date: 24/10/2017
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TABLE OF CONTENTS

1. SCOPE OF APPLICATION…………………………………………………………………………………………….4
a. SCOPE……………………………………………………………………………………………………………4
b. RESPONSABILITIES………………………………………………………………………………………..4
2. REFERENCES……………………………………………………………………………………………………………….5
3. DEFINITIONS………………………………………………………………………………………………………………5
4. PROCEDURE……………………………………………………………………………………………………………….5
a. GENERAL REQUIREMENT………………………………………………………………………………5
b. HYDROSTATIC TEST PRESSURE……………………………………………………………………..6
5. QUALITY ASSURANCE&QUALITY CONTROL………………………………………………………………7
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1. SCOPE OF APPLICATION

1.1 SCOPE

The purpose of this procedure is to define the pressure testing methods , Inspection and Documentation
for the post fabrication testing of piping system.

The following are excluded from the requirements of this procedure:

• Any package unit previously tested in accordance with the code applicable
• Atmospheric sewers and drains
• Line and system open to the atmosphere
• Instrument piping lead lines between the root valve at the process or utility line and the connected
instrument and control piping used to connect air or hydraulically operated control apparatus

1.2 RESPONSABILITIES

The CONSTRUCTION MANAGER:

• Responsible for overall site management , dissemination or execution of quality procedures that
meets Project specification and Project requirements
• Establishment of construction organization , monitor job quality , Schedule and overall Project
management

The CONSTRUCTION RISPONSABLE:

• Shall be responsable for the execution of this procedure , monitoring and control of activities
pertaining to the prefabrication erection and installation of piping and its components , compliance
with HSE procedures
• Shall control of all kind the resources and coordinate the execution of Works and ensure the
productivity
• Shall be supervising closely the activities designated to them and ensure that all instructions are
followed and all necessary Work Permits are duly approved and signed off , prior to commencing
the work and safety procedures of the Project are strictly adhered to.

QA/QC INSPECTOR

• Shall be responsable for inspection on production of pipes , fiftings and spools to ensure the
procedures are being followed in order to ensure that quality standards being achieved as Project
Procedures , requirements and specifications

HSE Dipartment:
• Shall be responsable for the implementation of the HSE Procedures before and during the
execution of the works
• Shall be responsable for check for any unsafe conditions on the working areas and liaise with Field
Supervisor ensuring tht the work is carried out as per approved Project safety and plan procedure
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2. REFERENCES

• ASME B31.3 Process Piping

• ASME VIII Boiler & Pressure Vessel Code
• ASME B 16.5 Pipe Flanges and Flanged Fittings
• ASME B 36.10 Welded and Seamless Wrought Steel Pipe
• ASME B36.19 Stainless Steel Pipe
• ASME B 16.25 Buttwelding Ends
• ASME B16.34 Valves Flanged , Threaded and Welding End
• PREM.PROC-MAN-0002 Procedure for Equipment Calibration and Maintenance
• PREM.PROC-MAN-0003 Procedure for Cleaning &Flushing of Piping
• PEP 97/23
• ASME PCC2
• Piping Line List

3. DEFINITIONS

Pressure Test Pack is a set of partial or complete lines, which can be tested in a single loop together at
the same pressure. These are prepared based on the line pressure rating , material and testing pressure.
More than one TP may be combined as a single loop to carry out test, , depending on the proximately of
lines, reading lines, volume of test medium and safety factors associated with testing provided that both
have typical line class and Test Pressure and its own pressure gauge, to control pressure in each part of
the circuit.

4. PROCEDURE

4.1 GENERAL REQUIREMENT

The pressure test shall be performed after approved NDT,TP and before the internal cleaning of the pipe.

Before applying pressure, all lines or systems shall be inspected to insure that all parts not included in the
test are isolated and properly protected against overpressure.

The calculated and maximum test pressure for each line shall be specified in the Pipe Line List,. Additional
data , as listed bellow, shall be provided by Man Piping Engineers:

• Equipment Test Pressures

• Test Pressure of special piping components such as ball valves and butterfly valves
• Special Testing Instructions and cautionary notes

The use of plate for temporary welded on end closures is not allowable.

Materials used for weld on end closures as caps or blinded flanges must be per project approved piping
material (line class) specifications and must to have a certificate 3.1. Project approved WPS and welding
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Revision: 00 Date: 24/10/2017
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requirements must be adhered to this procedure. Exceptions or deviations of the specifications must be
approved by MAN piping engineer.

4.2 HYDROSTATIC TEST PRESSURE

• Hydrostatic Test shall be performed with water, unless there is the possibility of damage due to
freezing or to adverse effects of water on the piping or the process.
• Hydro Test water shall be clean without any pungent smell
• The test pressure shall be as specified in the Pipe Line List, and in any case less than 1.5 times the
design pressure piping class
• All weld joints shall be left unpainted and insulated and exposed to examination during the test,
except the utilities lines
• All underground portions of pressure pipings shall be tested prior to back filing
• Prior to filling water, the line shall be completely checked to see if it is according to the drawing and
to ensure the line has high point vent and low point drains
• Manual cleaning or Compressed air should be carried out for all lines or spools to remove
Construction debris
• High point vents and low point and drain points are to be provided as required and relevant to line
class. All lines shall be checked to ensure entire system is drained after testing
• Temporary gaskets shall be used at test limits and blinds with proper bolts installed.
• All instruments shall be removed from the circuit to avoid cause damage to it. Testing will not be
conducted against valve seat of inline valves ; pressure test must be done against blind flanges or
caps.
• The test area shall be barricaded-off and warning signs erected.
• Pressure Test , P&ID’s shall be developed for identifying TP . TP shall be by circuits.
• Potable water shall be filled into the line using a pump connected to the line through a test
manifold. The potable water for testing shall be obtained from connection on the availability
sources.
• Clear test area before bringing line up to test pressure, according to the volume of the system that
will be tested this information will be specified on the WMS of the works , the minimum distance
will be 30m. All vents shall be kept open to displace the air that is in the line while filling the line.
• Valves internals are removed, except for butterfly valves included in the pressure test shall be 90%
open . Control and relief valve to be removed
• Hydrostatic Test Pressure shall not be applied, when weather conditions can cause freezing or
heating up of the test water
• The system shall be gradually pressurized until the pressure reaches one half of the test pressure
for preliminary examination for 10 minutes and then gradually pressurized to 75% and then 100%
to the specified test pressure and held for a sufficient time to allow detection of any leaks along the
complete length of piping system under test but in no case less than 15min.
• Test pressure gauge and mechanical recorder ,shall be located at a high point of the system and a
pressure gauge shall, in addition be located at the low point of the system.
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PREM.PROC-MAN-0001
PREMONOR S.A.
Revision: 00 Date: 24/10/2017
MOTOR COOLING PIPING REPAIR
Sheet: 7 of 7

• A pressure relief valve having a set pressure not higher than 110% of test pressure shall be used for
testing. This will be located on the test manifold and the intended use is for emergency
depressurizing only.
• In the event that additions or repairs are made following the test , the affected piping will be
retested at pressures originally specified for the test

5. QUALITY ASSURANCE & QUALITY CONTROL

Records shall be made of each Test Pack utilizing PREMONOR Standard forms , when completed , shall be
retained in the QC files as a permanent record. These records shall include the following information:

• Date of the Test

• Identification of Test Pack and any equipment tested, P&I mark up plus battery limits of the test
system .
• Test Medium
• Test pressure
• Minimum Ambient Temperature
• Test Medium Temperature
• Certification by examiner
• Test Results
• Name of test operator