Construction Procedure for Hydrotesting
Transcript of Construction Procedure for Hydrotesting
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CONSTRUCTIONPROCEDURE FOR
HYDROTESTING
SECTION CONTENTS
1.0 PURPOSE 2
2.0 SCOPE 2
3.0 REFERENCES 2
4.0 DEFINITIONS 2
5.0 GENERAL 2
6.0 PROCEDURES 3
7.0 TESTING OPERATIONS 5
8.0 TEST ACCEPTANCE 7
9.0 DEPRESSURIZING 8
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CONSTRUCTIONPROCEDURE FOR
HYDROTESTING
1.0 PURPOSE
The purpose of this procedure is to ensure that Hydrostatic Testing is carried out in a safe manner
and complies with the requirements.
2.0 SCOPE
This procedure covers the activities and preparation required for Hydrostatic Testing for. This
procedure covers the Hydrostatic Testing for the mainline. All mainline valve assemblies shall be
hydrostatically tested independently.
3.0 REFERENCESThe following documents have been complied with in the preparation of this procedure!
"ontract #ocument $nformation.
A%&$'A&() * +1.8 , -as Transmission and #istribution Piping &ystems.
(alaysian -overnment egulation.
/ocal Authority egulations for removal and disposal of water used for testing.
4.0 DEFINITIONS
CLIENT !CONTRACTOR !
ST/!!P ! &uruhan0aya Tenaga'abatan eselamatan dan esihatan
SU"CONTRACTOR ! &ubcontractor'Party assigned by "3%TA"T3
to perform the Hydrostatic Testing activities
5.0 GENERAL
4.1 &T'P shall be notified a minimum of forty eight 5687 hours prior to the start of a
hydrotest operation. &T'P shall be invited to witness all hydrotesting with as much
notice as reasonably practicable. $n the absence of the &T'P epresentative a
competent -as )ngineer shall witness the testing.
4.2 All fields Hydrotesting reports shall be duly signed by the -as )ngineer and "lient and
&T'P such verification shall include signatures names dates and time.
6.0 PROCEDURES
6.1 C#$%&'&(
The cleaning operation is underta9en to remove any debris from the pipeline which may
have remained as a result of construction activities and to remove as far as feasible rust
mill scale which may be present on the pipe wall.
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CONSTRUCTIONPROCEDURE FOR
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The cleaning operation will be conducted between temporary launcher and temporary
launcher' receiver. $t is proposed that one or two pig each consisting of high density foampigs and full circumferential wire brush high density foam pigs be propelled by
compressed air. The pigs will be controlled by regulating bac9 pressure to ensure a
speed of appro:imately ;.4 , 1.; m'sec.
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CONSTRUCTIONPROCEDURE FOR
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water quality
sufficient quantity and flow rate
local authority permission to e:tract water from source
owners way leave
#etermination of water quality will be by visual inspection only. /aboratory
analysis chemical treatment etc is not required. The water for hydrostatic testing
should be visually free from sand silt and suspended solids.
The water source will be of sufficient quantity to enable the filling process to
proceed uninterrupted.
6.4 H+,*%*' T$* P+$-+$
The minimum test pressure at the point of ma:imum elevation for any test section shall
be 1.6 : design pressure i.e. 1.6 : +>; psig ? 4;6 psig 5minimum7
#epending on the site conditions the actual field test pressure may be raised slightly
higher than the minimum required hydrotest pressure as decided by the Test )ngineer.
6.5 P+$%+%*,+ ),+
All valves on the test manifolds that will not be used for the tests shall be blan9ed
off or plugged. =alves under test shall be left in the half open position.
$nstrumentation required for testing shall be set up in the test control cabin and
chec9ed.
Prior to the pressure test notices indicating that the pipeline is under pressure test are to
be stationed at strategic locations along the right of way. 5.3.@7 i.e. at all public
crossings and all points where there is e:posed pipe. &ubcontractor shall cordon of all
test end areas with notices stating that High Pressure Testing is in progressB.
/ine pipe of the same grade diameter and thic9ness as the pipe in the section under test
plus all the necessary equipment for handling transport cutting welding etc. shall be
available as a contingency in the event of a failure during the hydrostatic test.
Prior to any testing operations the stabiliCation of the test water temperature shall be
chec9ed.
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CONSTRUCTIONPROCEDURE FOR
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pressuriCing rate after the stabilisation period. This process will be repeated at the
following points
; , 2; G of test pressure
2; , 4; G of test pressure
4; , 8; G of test pressure
8; , 1;; G of test pressure
&ubcontractor shall plot the pressure versus volume during the pressuriCing stage and
not made of starting and completion times. A temperature recorder and a deadweight
tester shall be operating during this time.
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CONSTRUCTIONPROCEDURE FOR
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8.0 TEST ACCEPTANCE!.1 est "cceptance
Test pressure shall be maintained for a minimum of 26 continuous hours. Acceptance
shall be when the pressure changes while ta9ing into account temperature effects and
any 9nown lea9s does not e:ceed ;.1 bar for each ;.1" loss in temperature.
3n completion of the 26 hour test a Test Acceptance "ertificate approvals shall be
issued by &ubcontractor.
The test pressure was maintained for a minimum twenty four 5267 consecutive
hours at or above the minimum specified test pressure.
Any variation in test pressure during the 26 consecutive hours is e:plainable 5e.g.
temperature fluctuation7.
$f necessary the pressure changes attributed to the temperature effects on the pipeline
system under hydrostatic test shall be calculated and submitted to the "ontractor Test
)ngineer for approval.
!.2 est #ai$ures$f the test fails then the cause shall be investigated and remedied. &ubcontractor shall
then carry out the filling and testing operations again.
$f lea9age is apparent in the system a visual inspection shall be carried out at all above
ground pipewor9 and piping and valves in chambers. &hould a lea9 be detected it shall
be located and repaired and remar9ed in the hydrotest report form. $f the lea9 occurs in
the pipe seam or the pipe body the entire faulty 0oint for the pipe shall be cut out and
replaced with a new 0oint of pipe. $f the lea9 occurs in the circumferential weld the pipe
shall be cut one diameter bac9 either side of the faulty weld and replaced with a new
section shall be mar9ed with its location in the pipeline and shall be delivered to such
place as dictated by the "lient.
$f there is no lea9 found on the above ground pipewor9 the underground pipewor9 shall
be uncovered by bac9!hoe 5"*7 and a visual lea9 chec9 shall be carried out.
9.0 DEPRESSURIZING
$mmediately after the test has been successfully completed and the test acceptance certificates
signed by the relevant parties i.e. &ubcontractor Test )ngineer and "onstruction (anager
-(&* epresentative and &T the pressure shall then be gradually lowered to atmospheric
pressure at an appro:imately rate of F bar per minute.