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Hazira

Hazira MIQA Manual

Page No. 1 of 10
PSM Critical

MIQA Procedures
Hydrotesting

Hazira Manufacturing Division

Section No. : HZMM 2.303

Rev. : 00

Date : 01.11.2009

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Hazira MIQA Manual

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Document Control Details

Document First Issue date Prepared/ Compiled By Document ownership Document Functional Owner Mechanical Discipline Head Approved by

01.11.2009 Document Revision No. 0 BR Dave

MR CES

HOD-CES

Revision Date Next Review Date 31/10/2011

Procedure Document No. HZMM 2.303

Reviewed By (Functional Heads):

Head - I&C K Ramesh

Approved By:

_______________ PK Jain (HOD-CES)

Note Signatures do not appear in soft or electronic copy

Section No. : HZMM 2.303

Rev. : 00

Date: 01.11.2009

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BRIEF DESCRIPTION OF THE TASK SET UP SAFE HYDROTESTING. WORKING PROCEDURE FOR

Hydro static pressure testing of equipment/pipeline is common and important maintenance activity in a continuous process industry to check integrity (withstandibility of pressure), it is used for. Maintenance crew must be experienced and supervisor handling the job should be well conversant with the details & procedures. Since the failure during hydro testing can lead to hazardous situation as well revenue loss to the organization in the form of direct cost as well as in the form of opportunity cost, enough importance should be given to this maintenance activity. SCOPE This procedure explains general guidelines about hydro testing including safe practices. Hydro testing helps to identify leak proofness and integrity of the pressure vessels, heat exchangers and piping including welding joints, as a quality assurance measure. Periodicity of testing shall be followed as per statutory requirements, equipment criticality and repair code. It is necessary to have standard guideline in order to regulate the hydrotesting operations for achieving desired results, safety and reliability.
OBJECTIVE

The objective of this procedure is to lay down the practices & procedures to be adopted for hydro testing.
APPLICABLE CODES

ASME Sec VIII Div.1: Design & Construction of Pressure Vessel (UG 99) ASME B31.3: Process Piping Test Pressure Guideline: Annexure -1 Statutory Rules

POTENTIAL ENVIRONMENTAL ISSUES

Environment Alert

The water used for hydrotesting activity is not an environmental hazard. However, Plant level procedure for the safe disposal of contaminated water due to drain or spill after hydrotesting needs to be followed. Section No. : HZMM 2.303 Rev. : 00 Date: 01.11.2009

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1. The standard engineering practice as described in this procedure shall be exercised. 2. Flange joints shall be checked after water filling and recified as required prior to pressurizing for hydro testing. 3. The specification of gaskets, bolts, flanges & flexible hoses shall be maintained as per engineering/piping spec. 4. Any deviations in working conditions shall be analysed with respect to suitability of pressure gauges. Only calibrated pressure gauges to be used for hydor testing. 5. Do not leave pressurized equipment unattended, especially in summer.

POTENTIAL HEALTH ISSUES

SAFETY/OCCUPATIONAL

Safety Alert

Hydro testing is skilled job. Extreme safety precaution needs to be exercised during preparation stage, selection of flexible high-pressure hoses, bolts, gaskets, pressure gauges etc. Following safety precautions will help in preventing the accidents: Work Safety Rules: 1. Proper PPEs required to be used wherever needed in plant areas. 2. Hydrotesting work area to be barricaded before starting the job. Entry in barricaded area to be restricted for unauthorized persons. 3. Use of experienced riggers for handling of heavy items. New employees of contractors should undergo safety induction training program conducted by safety department. 4. Works permit and risk assessment instructions to be followed strictly. 5. Use of certified pressure gauges and tools shall be in good working condition and shall be inspected before use. 6. Blinding flanges, gaskets, flexible hose and bolts to be used as per specification rating. 7. Connecting pressure hoses shall be in good working condition without any visible physical damage. 8. Spillage and overflow of water to be avoided or passage to be provided by using hose pipe etc. to prevent possible slippage during movement. Proper care to be taken to avoid over flow/drain water ingress in the insulation of adjascent equipment/piping. 9. All the electrical items shall be inspected and certified by electrical engineer before use. 10. The studs/bolts which are tightened shall be free from burres, dents etc. The nut shall rotate freely on the studs and the threads shall be lubricated. This will prevent any jerks due to jamming of damaged threads. 11. Do not leave pressurized equipment unattended, especially in summer. Section No. : HZMM 2.303 Rev. : 00 Date: 01.11.2009

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Tools and Tackles Required: 1. Set of spanners of required size. 2. Calibrated pressure gauges (2 nos.) of appropriate range with certification of calibration marked on pressure gauge. 3. Connecting pressure hose pipe with marking of safe work pressure. 4. Hydraulic pump (manual or electic operated). 5. All the electrical appliances shall be protected by standard ELCB as per designed electrical loads. 6. Blind flanges and bolts as per specification rating and size. 7. Flexible hoses for water draining. Documents and Drawings: Refer following documents relevant for carrying out the job: 1. Equipment drawing. Piping P&ID and Isometric drawing. 2. Guide line for hydro test pressure for static equipment (Refer Annexure-I) 3. Pressure Test Certificate: CESH / I&C /3909 (Refer Annexure-II). 4. Hydrotest details: SAP-CIMS Report. SPARES & CONSUMABLES 1. Water (DM water to be used for SS material Chloride >30ppm) 2. Gaskets, studs/bolts with nut as per required sizes and specification rating. 3. Anti seize & anti rust spray. Prerequisites 1. The technician allotted for the job shall be well versed with hydro testing procedures, basics of flange jointing, gaskets, fastneres etc. 2. He shall be able to read the drawing & understand the details mentioned. 3. He shall have thorough understanding of risk assessement and hazards associated with the job. PROCEDURE: This procedure covers the minimum requirements for the pressure testing of equipment / piping during routine maintenance activities. 1. The working personnel shall be experienced (aware of "dos & donts while executing the job). Section No. : HZMM 2.303 Rev. : 00 Date: 01.11.2009

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2. Hydro test pressure shall be desided as per design code/statutory requirements. Refer Annexure-I 3. SS MOC equipment/piping to be tested using DM water (Chloride <30ppm). 4. In case of bellow provision on equipment/piping, locking of bellow is essential prior to proceed for hydro testing. 5. Two calibrated pressure gauges shall be used during testing. Location of pressure gauges on the equipment/pipelines to check the hydro test pressure to be ensured. One pressure gauge at top-most position and another one at bottom, near pump. 6. The provision for venting of the air to be checked on the equipment / pipelines. Proper venting is required before water filling/pressurizing for hydro testing. 7. The following rate of pressurisation shall be taken as guideline. Pressure gauge range shall be 1.25 to 2.5 times the test pressuere. Pressure is gradually increased to 50% of the test pressure. (Applicable as per guideline in Annexure 1). Thereafter, the test pressure is increased in steps, 10% of the test pressure, maintaining time interval of 5 minutes at each step, till required test pressure is reached. The test pressure of fluid is maintained in the closed equipment / piping for 30 to 45 minutes to check the presence of any leakage in the equipment / piping. 4. Once the test is over, the pressure is gradually released by opening the vent valve. The vent valve should remain open till depressurizing and draining of water completely. 5. The test result to be recorded & reported in the pressure test vertificate, format no. CESH/I&C/3909, & submitted to the concerned person. The copy of the same to be preserved in the equipment file. Job Preparation

Work permit to be obtained and display at work place. Work permit instruction to be followed. Risk assessment points to be discussing with workers and to be display at work place and follow strictly. Arrangement for blinding of nozzles/piping as per blinding list. Fixing of pressure gauges. Arrangement for water filling. Arrangement for pressurizing the equipment/piping using hydralic pump.

Job Closure Water draining: Section No. : HZMM 2.303 Rev. : 00 Date: 01.11.2009

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Water used for hydro testing required to be drained in proper manner to avoid spillage and water ingress in the insulation of adjascent equipmen/piping. Initially, water to be drained from the top most located vent using flexible hose till depressurizing of the vessel. Draining to be done in slow manner. Bottom/side nozzle to be used for draining after depressurizing of equipment/piping. Top vent to be kept open for air entry. Water to be drained in water trench only.

De-blinding of nozzle/piping flanges:

Flange joints blinded for hydrotesting purpose to be normalized using gaskets and bolts as per specification. Check flange-gasket faces for corrosion damage, mechanical dents and squareness prior to box-up. Proper size bolts to be used. Short/long bolting must be avoided.

House Keeping:

The contractor shall ensure cleanliness of surrounding area, removal of barricading, spare bolts, gaskets, hoses, pump, cables etc after completion of the job. In case of water spilled in surrounding area, cleaning/moping of area is essential.

Cerification: Hydro test to be witnessed by I&C Engineer along with plant operation and maintenance engineer. Hydro test certificate (CESH/I&C/3909 Refer annexure-II) to be signed by abovementioned representative and hard copy to be preserving in respective eqpt file. Responsibility: 1. Carrying out & necessary arrangement: Maintenance 2. Witnessing/Decision/Report: Engineer 3. Preservation of hydro test record: Engineer 4. Hydrotest deviations: Plant Inspection Inspection Plant HOD

a. Due to any reasons, if the plant does not offer the equipment for hydrotest, such responsibility lies with the concerned Plant and concession-deviation should be raised with due approval of Site President/Manufacturing Chief. For equipment under Gujarat Factory Regulations, valid reasons Section No. : HZMM 2.303 Rev. : 00 Date: 01.11.2009

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should be indicated to the GFR competent person, who is certifying the inspection. b. In case of medium is used other than water, Plant HOD shall approve the same. He may consult CTS/CES, if necessary. c. In case pneumatic test needs to be performed due to process constraint, detail risk assessment shall be carried out by Plant in consultation with safety department. Record: 1. Pressure Test Certificate: CESH / I&C /3909 2. Hydrotest details: SAP-CIMS Report

Section No. : HZMM 2.303

Rev. : 00

Date: 01.11.2009

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Hazira MIQA Manual

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Annexure - I
HYDROTEST PRESSURE OF STATIC EQUIPMENT 1. 2. AS NEW: As per data sheet/design code.

OLD / USED / IDLE FOR MORE THAN 2 MONTHS :

A. 1.5 X MAWP (Permitted maximum working pressure by Process requirement.) OR 1.25 X Design Pressure (Water) Whichever is less. B. 1.1 X Design Pressure (Gaseous Medium) 3. HYDROTEST MEDIUM: A. Normally, testing should be done using fresh water at ambient temperature. In case of non-practicability of using the same, due to process reasons, suitable substitute medium should be decided accordingly. TEST WATER for Austenitic Stainless Steel system shall be basically free of CHLORIDES (Max.30 ppm) to avoid stress corrosion cracking.

B.

4.

PRESSURE GAUGE LIMIT: MIN. RANGE: MAX. RANGE: 1.25 2.5 X Test Pressure X Test Pressure

5.

HOLDING TIME :

At least 1/2 an Hour. OR Up to the satisfaction of the inspector A. As per Statutory acts B. As per design/construction code C. After maintenance activity Whichever is applicable

6.

FREQUENCY :

Section No. : HZMM 2.303

Rev. : 00

Date: 01.11.2009

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Annexure - II PRESSURE TEST CERTIFICATE

FORMAT REF. NO.: CESH/I&C/3909 PLANT: DATE: TEST DATA: PARAMETER MOC TEST PRESSURE (Kg./Cm2g) TESTING MEDIA TEMPERATURE HOLDING DURATION (MINUTES) NO. OF TUBES PLUGGED PRESSURE GAUGE USED: Tag No Calibration due on Range Remarks SHELL SIDE TUBE SIDE EQPT TAG NO: TEST

Before:

Current:

Total:

Remarks:

_____________________________________________________ _________________ WITNESSED BY: (CES-I & C) (Plant-Operations) (Plant-Maintenance)

Section No. : HZMM 2.303

Rev. : 00

Date: 01.11.2009