Client Approval Remarks

Date Descriptions Prepared by Approved by

Reviewed by
Rev

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 TABLE OF CONTENTS

Section Description Page No.

1.0 Purpose 3
2.0 Scope 3
3.0 Reference Documents 3
4.0 Definitions 3
5.0 Responsibilities 4
6.0 Procedure 4
7.0 Reporting 8
8.0 Attachments 8

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1.0 PURPOSE

Purpose of this document is to establish a detailed procedure for hydro testing field /shop fabricated
piping system and equipments which is controlled by Madina.

2.0 SCOPE

This document describes the application of the pressure testing method of Hydrostatic Testing at
Madina work premises and / or designated work sites.

3.0 REFERENCE DOCUMENTS

3.1 ASME Section VIII Div. 1, Ed 2007 Rules for the construction of Pressure Vessels.

3.2 ASME Sec I, Ed 2007 Power Boilers

3.3 ASME / ANSI B31.1, Ed 2007 Power Piping

3.4 ASME/ ANSI B31.3, Ed 2007 Process Piping

3.5 ANSI/NB23, Ed 2007 National Board Inspection Code

3.6 RGX-S-00-1360-003 Ras Gas Specification (Piping Fabrication, Erection

Inspection & Testing)

4.0 DEFINITIONS

4.1 Test Pressure

The test pressure at which, the Hydrostatic test is to be carried out. This is specified in the
drawing.

For ASME Sec VIII Div.1 work,

a) The minimum hydrostatic test Pressure shall not be less than 1.3 times the maximum
allowable working pressure (MAWP) multiplied by the lowest ratio (for the materials of
which the vessel is constructed) of the stress value for the test temperature on the vessel
to the stress value for the design pressure.

b) A calculated test pressure may be used by agreement between MG and Client. But this shall
comply with the requirements of UG-99 (c) of ASME Sec VIII Div.1.

For ASME Sec I work

c) The hydrostatic test pressure shall not be less than 1.5 times the maximum allowable
working pressure as shown on the data report to be stamped on the boiler.

d) When doing pressure test of completed forced-flow steam generator with no fixed steam
and waterline, having pressure parts designed for different pressure level along the path of
the steam-flow the test pressure shall not be less than 1.5 times the MAWP at the super
heater outlet shown in the master stamping but no less than 1.25times the MAWP of any
Part of the boiler, excluding the boiler external piping.

For ASME B31.1/B31.3 work

The hydrostatic test pressure shall be same as that of ASME Sec I as mentioned above (PG-
99)

For (Boiler External Piping)/Process Piping

The hydrostatic test pressure shall be same as that of ASME B31.3 Per 345.4.2

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 4.2 Inspection Test Pressure
The test pressure, at which, a very close visual inspection of joints and connections for
leaks to be carried out.

4.3 Authorized Inspector (AI)

The individual designated as such by an ASME accredited Authorized Inspection Agency,

who holds a valid certificate of competency, a National Board Commission with an
endorsement and is employed by Authorized Inspection Agency that assumes responsibility
for that person’s action.

4.4 Code
The above documents referenced in section 2.0 (from 2.1 to 2.6) of this procedure

5.0 RESPONSIBILITIES

5.1 Project Engineer

The Project Engineer or his designee is responsible for preparation of the test items for
Pressure Testing.

5.2 Supervisor
The designated Supervisor is responsible for ensuring that during the test; only essential
personnel are present in the work area. The work area shall be suitably cordoned or
otherwise isolated such that un-related personnel do not stray into it.

Further he is responsible for obtaining work permit (if required) and informs safety
personnel and other relevant authorities with sufficient notice prior to the commencement
of filling of water and testing operations.

5.3 QC Inspector
The designated Quality Control Inspector is responsible for witnessing the items being
tested. Where necessary, he is responsible for arranging for witness by the Authorized
Inspector (AI) / Third Party Inspector / Client.

The designated Quality Control Inspector is also responsible to verify and ensure that the
NDE and all hot work has been completed and accepted to the satisfaction of the Inspector
before releasing the item for pressure testing

6.0 PROCEDURE

6.1 Personnel Qualification

Personnel conducting the test and recording test results shall be suitably qualified in terms
of experience and training to properly conduct the test and record results.

6.2 Equipment
6.2.1 The test equipment shall be in accordance with the applicable Clients’ specification and
shall be adequate to provide the necessary test pressure at a safe rate of increase.

6.2.2 All components of the test system shall be rated to perform satisfactorily at the test
pressure as a minimum.

6.2.3 Pressure and temperature recording devices may be used to record the temperatures and
pressure on a continuous basis during the test duration.

6.2.4 A temperature measuring device shall be used to record the metal temperature during the
test.

6.2.5 All pressure/temperature indicators and recording devices shall be calibrated in

accordance with calibration procedure # MG/RLG/QAP-03. Any indicator showing an
uncorrectable zero reading or error of more than 2% of full scale range shall be discarded
and replaced with calibrated indicators.

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6.3 Preparation for Pressure test

6.3.1 The test system shall be checked to identify high points. All high points shall be suitably
vented to avoid air pockets forming whilst filling.
6.3.2 The Q.C. Inspector shall verify the hydro test packs, that all welding, non-destructive
examination, PWHT (if applicable) and other related inspections have been completed and
accepted to the satisfaction of the TPI/Client(RG) before taking up the item for test.

6.3.3 Pressure gauge selection for ASME Section VIII Div. 1 / B31.3 work shall be such that the
maximum reading of the gauge is not less than 1.5 times and not greater than 4 times the
test pressure.

6.3.4 Pressure gauge selection for ASME Section I / B31.1 work shall be such that the maximum
reading of the gauge is not less than 1.5 times the test pressure and upper range about
double the intended pressure.

6.3.5 Pressure gauge shall be located at the highest point and lowest point of the test system
and shall be positioned such that it visible to the operator during the test and the pressure
achieved can be read off easily.

6.3.6 Pressure gauge used for testing shall be calibrated with in 30 days.

6.3.7 All lines and appurtenances (control valves, compressors, pumps, relief valve, rapture disc,
vessel, equipment, turbines & indicating devices) which do not form part of the test system
shall be removed or otherwise isolated from the test system before the test.

6.3.8 Blind flanges, spades and gaskets shall be installed as necessary. All fittings shall be
tightened except the vent points.

6.3.9 The test fluid (water) shall be treated if called for by the Client’s specification with
corrosion inhibitors.

6.3.10 For Boilers and Power Piping items, the temperature of the test fluid shall not be less than
ambient temperature, but in no case less than 20 deg C.

6.3.11 For Pressure Vessels, it is recommended, that the metal temperature during test be
maintained at least 17 Deg C above the minimum design metal temperature, but need not
exceed 48 deg C. The test pressure shall not be applied until the vessel and its content are
at about the same temperature.

6.3.12 It is also desirable that the steel temperature should not be too close to the atmospheric
dew point so that the test results may not be hampered by condensation of moisture from
the atmosphere. Wherever possible, steps should be taken to ensure that the items are
provided with an adequate cover such that the metal temperature does not rise
significantly

6.3.13 The test pressure for Hydro-test shall be communicated to the persons conducting the test
by their respective discipline supervisor who references the same from the applicable
Fabrication Drawing

6.3.14 For B31.1/B31.3 work, a safety release valve shall be included in the test system set at 10%
above test pressure should be used to avoid excessive pressure during pressure test. If at
any testing a safety release valve is not available, the pressure gauges, chart shall be
closely monitored and the even of any increase of 6% above the stated test pressure, the
pressure shall be relieved manually.

For B31.1/B31.3 works, a test pack shall be prepared for each test system. This shall
include as a minimum but not limited to:
a. Marked up P & ID showing test limits (where applicable)
b. Marked up isometric drawings showing all welded joints and test limits
c. Weld history sheet
d. Applicable NDT reports

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 e. Pre-pressure test checklist
f. Pressure test report
g. Pressure temperature chart (If Required)
h. Punch list (if any)
i. Calibration certificates for pressure gauges
j. Calibration certificates for Chart Recorder ( if applicable)

6.3.15 System should be clean thoroughly before blinding

6.4 Filling with test fluid

6.4.1 The test fluid is usually filled from the lower end of the item, progressing towards the
vents on completion. The rate of flow should be such that it does not cause excessive
bubbles which may be entrapped in recesses.

6.4.2 The vents shall be closed after filling the vessel completely and ensuring that no air is left
entrapped within the test system.

6.4.3 Water using for hydro testing for austenitic stainless steel free neither from chlorides nor
in excess of 50 PPM.

6.5 Pressurizing

6.5.1 After filling the test system with the test fluid, the test pressure is gradually increased in
increments of 25%, 50%, 75% & 100% or as designated by Project Engineer at the time of
testing, to avoid any over pressurizing the system and to permit stabilization of the test
fluid to equalize pressure in the system. The test pressure shall be as specified in the
drawing.

6.5.2 The pressure shall be maintained at each incremental stage for a minimum of 5 minutes or
5 bar every 2 minutes or as specified by the Project Engineer. The connections are then
checked for leak tightness.

6.5.3 If leaks are observed at the temporary connections, flange joints, the vessel should be de-
pressurized and the leaking points should be attended suitably (by tightening or by
replacing gaskets if necessary).

6.5.4 The test pressure shall be held at this point to verify that it is stabilized. This should not
take more than a few minutes.

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

6.6.2 For ASME B31.1, the test pressure shall be continuously maintained for minimum 10
minutes. The holding time may be increased to 1 hour or as required by Client.

6.6.3 For other Code works, the holding time at test pressure shall be minimum 1 hour or as
specified by Client.

6.6.4 During holding test pressure shall not more than 6%of the test pressure if it is exceeds more
than6% system should be bleed out and bring back test pressure.

6.7 Inspection

6.7.1 After the holding time is elapsed, the test pressure is reduced (by bleeding the test
system) to the Inspection Test Pressure or otherwise kept at the hydro test pressure as
required by client.

6.7.2 For ASME Section VIII Div. 1 and Sec I work, the Inspection Test Pressure shall be the MAWP.

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 6.7.3 For ASME B31.1 works, the Inspection Test Pressure shall be the Design pressure.

6.7.4 At this Inspection Test Pressure, the Q.C. Inspector shall inspect the vessel to detect leaks.
All weld joints and connections shall be checked visually for leaks.

6.7.5 If leaks are detected at flanges, the pressure shall be reduced to zero, the concerned
flanges tightened and the test re-run

6.7.6 If leaks are detected at welds, the test item is considered to be failed in the test and
suitable repairs shall be undertaken in accordance with approved repair procedures.

6.7.7 Repair procedure shall be submitted to Ras gas for approval prior to do repair.

6.7.8 If there is leak observed outside the test system (such as at a pump connection or outlet
valve) and it is conclusively verified that no leaks are present on the test item, the
pressure may be increased as necessary before or during the holding time to verify to
ensure that the pressure during the holding time and / or the inspection time does not
become less than the specified test pressure. The intent of this paragraph is to cover
possibilities and it is not to be used as a commonplace escape mechanism.

6.7.9 If the test is satisfactory, the Q.C. Inspector shall indicate it by endorsing the pressure test
report.

6.7.10 If the hydrostatic test pressure is allowed to exceed, either intentionally or accidentally
above the test pressure to the degree that the system is subjected to visible permanent
distortion, the Inspector shall reserve the right to reject the system.

6.7.11 If the test is found satisfactory, the QC Inspector shall indicate the same by endorsing
pressure test report and the pressure test chart (if applicable) .

6.8 Depressurizing
Depressurizing shall always be done at higher point of the test system. Venting shall be
sufficient and adequate and shall remain fully open to avoid vacuum collapse of any part of
the system. Depressurizing shall be done gradually and evenly. Where a chart recorder is
used, the chart shall remain in use until depressurizing is completed. Portable water piping
shall be chlorinated after hydro test as per the local cods before being put in service.

7.0 REPORTING

This shall be done on the format appended at the end of this document. Other formats as may be
approved or specified in Contractual Specifications may be used as alternatives but as a minimum,
the following items shall appear:-
- Calibration reference of the pressure indicating gauges
- Date of the test
- MAWP (Maximum Allowable Working Pressure)
- MDMT
- Test Pressure
- Test Temperature of fluid
- Test temperature of metal
- Holding Time
- Provision for acceptance endorsement by QC and TPI/AI/Client
- Calibration certificates of pressure gauges and temperature recorders.
- Any special treatment imparted on the test fluid

8.0 ATTACHMENTS

Pre-pressure Test Checklist (Annexure-I)

Pressure Test Report (Annexure-II)

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