Hydro testing Procedure Hydro testing Procedure Ref: MG/QSP/MQP-01Ref: MG/QSP/MQP-01

Personnel QualificationPersonnel Qualification

Personnel conducting the test and recording the test result Personnel conducting the test and recording the test result shall be suitably qualified in terms of Experience.shall be suitably qualified in terms of Experience.

EquipmentsEquipments1.Test Manifold (block valve/regulating valve, provision for 1.Test Manifold (block valve/regulating valve, provision for fitting fitting relief valverelief valve2.pressure hoses2.pressure hoses3.Pump (Manual or Hydraulic )3.Pump (Manual or Hydraulic )4.Pressure chart Recorder (only for shop test)4.Pressure chart Recorder (only for shop test)5.Relief Valve5.Relief Valve

6.Minimum Two pressure gauges (one at manifold & other 6.Minimum Two pressure gauges (one at manifold & other one at one at highest point in test system)highest point in test system)

7.Pressure gauges calibration should be valid7.Pressure gauges calibration should be valid.

Preparation for Pressure TestPreparation for Pressure Test

1.Verify all Welding and NDT ,PWHT (If applicable) shall be 1.Verify all Welding and NDT ,PWHT (If applicable) shall be completed and accepted by Client.completed and accepted by Client.

2.All applicable joints and connection (welded/Flanged) shall 2.All applicable joints and connection (welded/Flanged) shall be be exposed and exposed and unpainted.unpainted.3.Pre pressure test check list (MSF-44) shall be prepared and 3.Pre pressure test check list (MSF-44) shall be prepared and signed signed off by QA/QC.off by QA/QC.

8.Pressure Gauge Selection for ASME B31.3/ASME SEC.VIII works8.Pressure Gauge Selection for ASME B31.3/ASME SEC.VIII works

Gauge Dial ≥ 100 mm Dia (4”)Gauge Dial ≥ 100 mm Dia (4”) Range - (1.5 – 4) times of Range - (1.5 – 4) times of test pressuretest pressure

9.Relief valve set pressure – 3 bar or 10% of the 9.Relief valve set pressure – 3 bar or 10% of the test test pressurepressure.

9.Water analysis certificate to be attached with test pack.9.Water analysis certificate to be attached with test pack.

4.Items needs to be isolated from the test system4.Items needs to be isolated from the test system(Control valves, compressors, pumps, rupture disc, relief (Control valves, compressors, pumps, rupture disc, relief valves)valves)5.Only standard Blind Flanges with 5.Only standard Blind Flanges with same ratingsame rating, spades & , spades & Gaskets Gaskets shall be usedshall be used

6.Test Medium – Water (potable, brackish/salt water as 6.Test Medium – Water (potable, brackish/salt water as available)available)7.For Carbon and Low alloy steels – Max.chloride content of 7.For Carbon and Low alloy steels – Max.chloride content of 250 ppm for potable water. If salt or brackish water issued 250 ppm for potable water. If salt or brackish water issued for testing, the system shall be completely drained and for testing, the system shall be completely drained and flushed with potable water immediately and thoroughly dried flushed with potable water immediately and thoroughly dried by using hot air or steam.by using hot air or steam.8.For Austenitic Stainless steel –Boiler feed water, 8.For Austenitic Stainless steel –Boiler feed water, demineralised water or condensate with Max.chloride content demineralised water or condensate with Max.chloride content of 2 ppm.of 2 ppm.

Holding Holding

The start of holding period shall commence from the time The start of holding period shall commence from the time that stabilization has been achieved.that stabilization has been achieved.

For Piping, Minimum holding time – 10 minutes.For Piping, Minimum holding time – 10 minutes.

10.Test fluid shall be filled from lower end of the system, 10.Test fluid shall be filled from lower end of the system, progressing towards the vents on completionprogressing towards the vents on completion.

12.Pressurizing stages – 25%,50%,75% & 100 % of test 12.Pressurizing stages – 25%,50%,75% & 100 % of test pressurepressure.13. Pressure shall be maintained at each stage – 5 minutes.13. Pressure shall be maintained at each stage – 5 minutes.

DepressurizingDepressurizing

1.Always depressure at high point of the system.1.Always depressure at high point of the system.2.Shall be done gradually and evenly.2.Shall be done gradually and evenly.3.Open all vents during draining.3.Open all vents during draining.4.The system shall be completely drained and to ensure that 4.The system shall be completely drained and to ensure that no no water inside the system.water inside the system.5.Blow Air after draining of system for complete dryness.5.Blow Air after draining of system for complete dryness.

ReportReportMSF-045 Pressure test reportMSF-045 Pressure test report

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