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QUALITY CONTROL
PROCEDURE
Kencana Infrastructurc
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Revision No : 0
Cover Pag e
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DATE
NAME
26.12.08
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RE VIE WED BY
PREPARED BY
DATE
NAME
15.12.08
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AP PROVED BY
DATE
NAME
22 .12.08
CO
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DATE
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26.12 .08
TABLE OF CONTENTS
SECTION
DESCRIPTION
PAGE
1.0
PURPOSE
2.0
SCOPE
3.0
REFERENCES
4.0
DEFINITIONS
5.0
PROCEDURE
5.1
GENERAL
2-3
5.2
TEST EQUIPMENT
5.3
FLUSHING PROCEDURE
3-4
5.4
4-6
5.5
RECTIFICATION OF LEAK
5.6
6-7
6.0
SPECIAL REQUIREMENTS
7.0
RECORDS
FIGURE I
FIGURE II
APPENDICES
APPENDIX I
INSPECTION REQUISITION
APPENDIX II
APPENDIX III
FLUSHING REPORT
APPENDIX lV
1.0
PURPOSE
This procedure outlines the flushing process and hydro testing requirements, to
ensure that the piping system are clean from debris or unwanted items and the
integrity of the system is proven.
2.0
SCOPE
This procedure is applicable for flushing and hydro testing of prefabricated
piping spools and completed piping in a system.
3.0
REFERENCES
4.0
DEFINITIONS
Nil
5.0
PROCEDURE
5.1
General
5.1.1 Each hydro test procedure shall consist of the following :
a)
b)
c)
A copy of the hydro test flow chart (Refer to figure II) shall be
extended to Client. This shall be done at least two (2) days
advance notice shall be given prior to the scheduled test
date.
5.1.2 Hydro testing shall only be performed after the following activities
are completed i.e.
a)
Visual Inspection.
b)
c)
NDT
shall
be
dry
before
the
5.2
Test Equipment
5.2.1 a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
5.3
Flushing Procedure
5.3.1 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.
5.3.2 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.
5.3.3 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 foreign materials which cannot
be removed by flushing are left in the line. All ball valves shall be
in the open position and non-return valves defeated, all instrument
accessories shall be removed, likewise relief valves, and thermo
well connections.
5.3.4 All block valves to instrument impulse line connections shall be
closed prior to flushing.
5.3.5 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. Spools used shall be ANSI
flanged and pipe of correct schedule, the weld will be inspected for
safety purposes.
5.3.6 At least one (1) day before flushing commences, Kencana
Infrastructure Site Supervisor shall inform the QC inspector of the
line inspection. All details for lines inspections are to be highlight
in the inspection Requisition Form (Appendix I).
5.3.7 Visual inspection shall be conducted by Kencana Infrastructure
Site Supervisor, and to be witnessed by the QC inspector to
ensure the system installation is completed. The Visual Inspection
Report shall be completed upon satisfactory inspection of the line.
Refer to Appendix II.
5.3.8 Flushing shall be done in the presence of Site Supervisor and to
be witnessed by QC inspector and Clients Representative.
5.3.9
5.3.10 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.
5.3.11 The Flushing Report (Appendix III) shall be prepared by Kencana
Infrastructure QC inspector upon completion of the flushing.
5.4
5.4.3
5.4.4 Blind flanges shall be installed for equipment excluded from the
hydro test. Blind flanges may be installed with temporary tubing
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.
5.4.5 Pressure gauges, pressure transmitters and flow meter, along with
the secondary piping connection the instruments to the block
valve at the equipment or primary piping shall be excluded from
the hydrostatic test.
5.4.6 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.
5.4.7 For stainless steel, the chloride content of the water shall no
exceed 200 ppm.
5.4.8 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.
5.4.9 After filling, the pumping system shall be shut off and
disconnected from the system.
5.4.10
5.4.11
5.4.12
5.4.13
5.4.14
5.4.15
The pump shall be shut off once the required test pressure is
achieved.
5.4.16
5.4.17
Open the block valve leading to the pressure recorder after the
system pressure is stabilized.
5.4.18
Sign the temperature chart and pressure chart before and after
hydro test by the QC inspector.
5.4.19
5.5
a)
b)
The test duration for flanges rated at 300 lbs and above,
the test duration shall be two (2) hours.
Rectification of leak
Any leak in flange connections, bolting shall be carefully and gradually
tightened in proper sequence to prevent uneven tightening. If leak
occurred in the weld joint the water shall be drained and the leak shall be
repaired as per approved welding procedure.
5.6
5.6.2
5.6.3
6.0
5.6.5
SPECIAL REQUIREMENTS
6.1
7.0
5.6.4
Safety Precautions
6.1.1
6.1.2
6.1.3
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.
6.1.4
6.1.5
6.1.6
RECORDS
7.1
7.2
7.3
Title
Responsibility
Retention Period
Visual Inspection
Report
QC Inspector
Until completion
of Project
QC Inspector
QC Inspector
Flushing
Report
Pressure Test
Report
NOTE :
CHECK VALVE STRAINNERS RELIEF VALVE
HAVE BEENS DISMANTLED AND SMALL/SHORT SPOOLS
SHALL BE BOLTED TOGETHER FOR THE HYDROTEST
THERE SHALL BE INSTALLED UPON COMPLETION
HYDROTESTING
P
FP
TB
PG
PR
TR
DP
V
TC
HYDROSTATIC PUMP
FILLING POINT
TEMPORARY BLIND
PRESSURE GAUGE
PRESSURE RECORDER
TEMPERATURE RECORDER
DRAIN POINT
VENT POINT
SPADE
TUBING CONNECTION
APPENDICES
QCP-10 Rev-0
Appendix I
TO :____________________________
REQ. NO. :
INSPECTION REQUISITION
PROJECT/CONTRACT NO.
:
DETAILS OF INSPECTION REQUIRED :
REQUEST BY :
LOCATION :
DATE :
TIME :
QCP-10 Rev-0
Appendix II
REQ. NO. :
ACCEPTED
REJECTED
REMARK :
NAME
DATE
CHECKED BY:
ACCEPTED BY :
ACCEPTED BY :
SUPERVISOR
QC INSPECTOR
CLIENT'S REPRESENTATIVE
QCP-10 Rev-0
Appendix III
PACKAGE NO. /
REPORT NO.
FLUSHING REPORT
PROJECT
CLIENT
PROJECT NO.
SYSTEM FLUSHED
LINE / SPOOL NUMBERS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
REMARKS :
TESTED BY :
SITE PERSONNEL
NAME
DATE
ACCEPTED BY :
QC INSPECTOR
ACCEPTED BY :
CLIENT'S REPRESENTATIVE
QCP-10 Rev-0
Appendix IV
PROJECT NO
REPORT NO
PROJECT TITLE
WORK LOCATION
CLIENT
ITEM TESTED
DATE OF TEST
Test Requirement
Test Conditions
Test Pressure
Holding Time
Piping Class
Test Medium
Applicable Code
Flushing Requirements
(
) Liquid
Others
Condition
Date
) Air
Gauge Pressure
Ambient Temperature
Time
Finish
Results / Remarks
The above mentioned items / lines were listed and accepted / rejected by :
QC Inspector
Client's Representative