0 | 17.02.2014 Rev | Date oo TATA TATA PROJECTS LIMITED Quality Management Standard Procedure for HYDROSTATIC PRESSURE TEST OF PIPING Doc No: TPL/QMD/ MECH/SPROC/001 First Issue GvA Pampas ctiowe aeeroveday _| oye : / ‘SRK GSVM_ G Soc1.0 2.0 3.0 Ba 32 33 34 35 36 37 38 39 3.10 Bat ae TATA STANDARD PROCEDURE FOR HYDROSTATIC PRESSURE TEST OF PIPING Proc No.: TPL /QMD/MECHI/SPROC / 001 Rev No, & Date: 0 & 17.02.2014 SCOPE This Procedure covers various checks / verifications to be carried out prior to take up of hydrostatic test and procedure for carrying out Hydrostatic Pressure Test. STANDARD AND SPECIFICATIONS All works covered by this procedure shall be carried out in accordance with the relevant sections of the following standards and specifications. ASME B31.3 / ASME B 31.1/1BR Approved drawings Approved FOP CHECK/VERIFICATIONS PRIOR TO TAKING UP HYDROSTATIC PRESSURE TEST Vent isin high point and drain in the lowest point. Minimum 2 Nos. of vents shall be provided. All supports are as per drawing, mainly anchoring point if any. Extra supports to be supported provided, as required. NDT clearance as per FOP & approved drawing. All the tapping points are as per PR diagram. Operating level platform construction (If not existing) Piping layout is in accordance with the applicable drawings. Drains, vents and other fittings are provided in accordance with applicable drawings. Orientation, direction and the flow symbol of the valves are in compliance with Piping Isometric drawings / P&ID. Slopes are maintained in the piping as indicated in relevant Drawings. All shipping and erection stopper, welding jigs and temporary attachments are removed. Test gaskets are used at the flange connections, unless otherwise specified in the approved drawings Thickness and size of Blind / Dummy Flanges are as per ASME B 16.5, Tightness and projection of flange bolts are adequate. All bolts are extended completely and uniformly through their nuts at least by two threads. Bolt tightening sequence is in accordance with "Criss-Cross Stud Tightening Pattern’. (4s shown in the Annexure - I) Page 1 of 63.15 3.16 317 4.0 a 42 42a 422 43 43.4 43.2 5.0 5a 5.2 TATA STANDARD PROCEDURE FOR HYDROSTATIC PRESSURE TEST OF PIPING Proc No.: TPL JQMD/MECH/SPROC / 001 Rev No. & Date: 0 & 17.02.2014 Flushing of all pipe lines is done with specified water to remove dust, dirt and other foreign material All the testing equipments like Pressure Gauge, Safety Relief Valve, Thermometer, Manifolds (Headers) and etc., are in working condition. Test Certificates for the same shall be verified. ‘Suitable drainage system is made for draining of water after satisfactory completion of Hydrostatic Pressure test. HYDROSTATIC TEST PROCEDURE Test Medium: Potable Water shall be used as the test medium, unless otherwise specified by drawing, Maximum Chloride content in water for Hydrostatic Testing of Carbon Steel shall be 250 ppm and for Austenitic and Ferritic Stainless steels shall be 50 ppm. Pressure Gauges and its locatios Pressure gauges shall have a range of not less than 1 ¥ times test the pressure and maximum of 4 times of test pressure. The gauges shall be placed at highest (one no) and at lowest nearby pump (one no). Ensure that pressure gauges installed for hydrostatic pressure testing of piping have valid calibration status and this shall be ensured before the start of the testing program. The calibration certificates of the Pressure gauges shall be shown to Customer for review. Frequency of the Calibration shall be maximum 6 months, unless otherwise specified in Customer Specification. Filling of pipeline (system) with water: Fill the piping system with Water. Ensure proper venting of air through vents provided at high points in the system by tapping with Mallet. Before closing of the last vent in the system under test, make sure that the water is over flowing without bubbles indicating absence of trapped air by running the pump, if necessary. Caution; Make sure that the system is free of alr before applying pressure. PRESSURISING: The test pressure shall be as per the Approved drawings / Technical Specification / Line Designation Table. Apply pressure by means of a suitable test pump of sufficient capacity to build the desired test pressure. Connect the pump to the system only when it is ready for the test. Provide pressure ‘gauge at the pump discharge for guidance in bringing the system up to test pressure, fr Gass Ae: de Page 2 of 653 60 61 62 63 64 65 70 7 72 73 74 75 8.0 sbief Rama Krishna G3V Maniiyata Sr Engineer-QMD Quality Assurance @ TATA STANDARD PROCEDURE FOR HYDROSTATIC PRESSURE TEST OF PIPING Proc No.: TPL JQMD/MECH/SPROC / 001 Rev No. & Date: 0 & 17.02.2014 ‘The pressure shall be gradually increased until a gage pressure which is the lesser of one-half the test pressure or 170 kPa (25 psi) is attained, at which time a preliminary visual check of the entire Pipe Line shall be made, including examination of joints. Thereafter, the pressure shall be gradually increased in steps until the test pressure is reached, holding the pressure for minimum 30 minutes to equalize Piping strains. During the holding period, the Pump shall be disconnected with the System. INSPECTION: After the holding period, all the related pipes and joints shall be visually checked thoroughly for leak tightness and Tapping the Joint vicinity by Mallet. The same shall be offered to Customer as per FOP for witness. After completion of the Hydrostatic Test, pressure shall be released gradually by opening the vent valve from highest point. On reaching down the System to zero pressure reading in the gauge, drain valve shall be opened for draining. While draining, the vent valve shall be kept open for allowing the air flow into pipe. After satisfactory completion of Hydrostatic test, the related Piping shall be flushed with water and dried. SAFETY PERSONNEL. All personnel involved in the operations described by this procedure will have received Safety Induction Training and the job specific training required for the particular operation in which they will participate. ‘Toolbox talk shall be conducted prior to proceeding of the Work Emergency response plan shall be followed in case of emergency. HSE Personal must be present during Hydrostatic testing Relative permits to be taken prior to start the work from TPL DOCUMENTATION: Hydrostatic pressure test report (Form No, FQ/012) shall be made and signature of Customer shall be obtained. RED BY REVIEWED BY sewggpy oe ae ly Oe onan i oe a 1D "fo Head- QMO Page 3 of 6TATA STANDARD PROCEDURE FOR HYDROSTATIC PRESSURE TEST OF PIPING Proc No.: TPL /QMD/MECH/SPROC / 001 Rev No. & Date: 0 & 17.02.2014 ‘Annexure=! Bolt Number shall be marked by chalk piece as shown in the following sketches and tightening shall be in the same sequence, 4: Bolt Tightening Sequence Sequential Order: 1-2, 3-4 Rotation Order: 1, 3,2, 4 8 Bolt Tightening Sequence Sequential Order: 1-2, 3-4, 5-6, 7-8 Rotation Order: 1,5, 3, 7,2, 6,4,8 Page 4 of 6TATA STANDARD PROCEDURE FOR HYDROSTATIC PRESSURE TEST OF PIPING Proc No.: TPL /QMD/MECHI/SPROC / 001 Rev No. & Date: 0 & 17.02.2014 12 Bolt Tightening Sequence Sequential Order: 1-2, 3-4, 5-6, 7-8, 9-10, 11-12 Rotation Order: 1, 5,9, 3, 7,12, 2, 6,10, 4, 8,12 \Cete, Sx 16 Bolt Tightening Sequence Sequential Order: 1-2, 3-4, 5-6, 7-8, 9-10, 11-12, 13-14, 15-16 Rotation Order: 1, 9, 5, 13,3, 11, 7, 15, 2,10, 6,14,4, 12, 8, 16 a 2 18" Page 5 of 6TATA STANDARD PROCEDURE FOR HYDROSTATIC PRESSURE TEST OF PIPING Proc No.: TPL /QMD/MECHI/SPROC / 001 Rev No. & Date: 0 & 17.02.2014 20 Bolt Tightening Sequence Sequential Order: 1-2, 3-4, 5-6, 7-8, 9-10, 11-12, 13-14, 15-16, 17-18, 19-20 Rotation Order: 1, 9,5, 13,3, 11,7, 15, 2,10, 6, 14,4, 12,8, 16 = 180) 24 Bolt Tightening Sequence ‘Sequential Order: 1-2, 3-4, 5-6, 7-8, 9-10, 11-12, 13-14, 15-16, 17-18, 19-20, 21-22, 23-24 Rotation Order: 1, 9, 17, 5, 13, 21,3, 14, 19, 7, 15, 23, 2, 10, 18, 6, 14, 22, 20, 8, 16, 24 Page 6 of 6TATA PROJECTS LIMITED TATA HYDROSTATIC PERSSURE TEST REPORT FOR PIPING Report No. Date: Customer: Project: Job Code no. ‘Area /System: P&IDNo. Line no. Test Package no 1SO Drg.no. Code: Test Medium: Rev No. Water Quality, Design Pressure: Test Pressure: Holding Time: Start location of Hydrostatic test (Refer marked up P& ID) End location of Hydrostatic test: (Refer marked up P & ID) Test medium temperature: Hydrostatic test starting time: Hydrostatic test ending time: Hydrostatic Test pressure: 1 2, Gauges serial no. & Range Calibration status: Hydrostatic test result: ‘Stamping details (If applicable). Sign of FQE Sign of AL. LA Date Date Gauges validated after Pressure test Form No. FQi012 Rev No.2 1: Inspection Authority, Al: Authorized Inspector