HYDRO TEST PROCEDURE

PROJECT : AIR DIVE SYSTEM

CLIENT : FLASHTEKK ENGINEERING PTE LTD. SINGAPORE

OCSI PROJECT NO : 1003 – 01 / 02

INSPECTION : DNV GL INDIA

REFERENCE NO : OCSI/1003/01-02 HTP – 01. REV.0

DATE : 06/04/2018

AIR DIVE CHAMBER VIEW

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TABLE OF CONTENTS
PageNo

1.0 INTRODUCTION ---------------------------------------------------------------------------------- 3

2.0 HYDROTEST PHILOSOPHY ------------------------------------------------------------------- 3

3.0 SAFETY AND HEALTH--------------------------------------------------------------------------- 3

4.0 EQUIPMENTS REQUIRED ---------------------------------------------------------------------- 4

5.0 SYSTEM PREPARATION------------------------------------------------------------------------- 5

6.0 HYDRO TEST ---------------------------------------------------------------------------------------- 6

7.0 POST HYDROTEST INSPECTION-------------------------------------------------------------- 8

8.0 NDT ----------------------------------------------------------------------------------------------------- 8

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1.0 INTRODUCTION

1.1 Testing Requirements

This document outlines the procedures and guidelines that needs to be undertaken to
ensure proper execution of the Hydrostatic test.

i) ASME SEC VIII. DIV.1 2015 ED.,

ii) PVHO-1 2016 ED

1.2 Reference Drawing

Drawing No. Description

OCSI-GA-1003-01-001 RA - GA For Air Dive chamber

OCSI-GA-1003-02-001 RA - GA For Air Dive chamber

2.0 HYDROTEST PHILOSOPHY

The Hydro testing of the Chamber will be carried out in 2 Stages

Stage 1 : Entry lock chamber

Stage 2 : Main Lock Chamber and Medical lock

Hydrotest medium : Fresh water

Design Pressure : 5.0 barg

Hydrotest Pressure : 7.5 barg

3.0 SAFETY AND HEALTH

Proper planning and coordination is required to conduct the hydrostatic testing safely and
efficiently. A proper risk analysis will be conducted and discussed among the people involved.
Proper PPE and barricade around the area will be maintained and ensure that only competent
person are involved in the Hydrostatic test and proper toolbox meeting has been conducted
prior to start of any activity.

4.0 EQUIPMENT REQUIRED

The following are the guidelines for the list of materials and equipment needed to prepare the
Hydrostatic test:

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i) PVHO approved viewports

ii) Solvent Cleaner

iii) Translucent silicone grease

iv) Soapy water dispensers

v) O-rings, seals and gaskets as per the drawings

vi) High pressure water pump

vii) Calibrated pressure recorder chart to record the test pressure of 7.5 bar with
valid certificates

viii) Calibrated pressure gauges, 0-725 psi / 50 bar with valid certificates

ix) Sets of fittings, hoses, gauges and other required connectors

x) Filling hoses to fill water

xi) Vent pipes suitable to hydrotest pressures

xii) Stop watch

xiii) Sets of tools to rectify any leaks

xiv) Hand tools (if required)

xv) Surface Plate

xvi) Theodolite

xvii) Seal tape

xviii) Blanking plugs

xix) Compression spring

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5.0 SYSTEM PREPARATION

5.1 CHAMBER FOUNDATIONS

The Air Dive Chamber to be located on the surface plate rested on the floor. Ensure that the
surface plate and the chamber are in zero level which will be measured using theodolite.

5.2 CLEANING THE SEALING FACES

Thoroughly clean all the following faces with suitable solvent such as contact cleaner.
View port housings, view port retainers, mating manway flanges both flush and grooved,
manway doors flush, medical lock inner and outer doors

5.3 BLANKING PLUGS

All full coupling penetrators in the shell and heads that are not utilized for test, must be
blanked off from the outside with brass blanking plugs of correct size and thread form. All
plugs are to be fitted using thread seal tape.

5.4 VIEW PORTS

Actual viewports will be used for this test. Proper care is required during installation of the
viewports as they are easily scratched or damaged.

5.5 CHAMBER VENTING

There is a ¾” NPT Vent connection fitted in the top of the chamber.

5.6 FITTING HOSE CONNECTIONS/PRESSURE GAUGE TO MEDICAL LOCK

There are two ½” NPT female couplings on the external medical lock. Fit a shut off valve and
tee in the top coupling to attach a pressure gauge and fit valve to vent off expelled air during
filling. Fit a valve and hose connector to the other coupling for connecting the filler and
pumping hose.

5.7 MEDICAL LOCK – INNER DOOR

The medical lock inner door is held closed with 5/8” UNC Wing Nut.

For the Hydro test a compression spring is to be inserted under the wing nut , so that the
inner door hinge can slightly open when pressure is applied to the inner side of the medical
lock.

5.8 PRESSURE GAUGE REQUIREMENTS (ASME Sec 8 Div 1 UG-102)

Two pressure guage readings are required for the testing of each of the chambers, one at
“High Point” and another one at “Low Point”

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5.9 “HIGH POINT ” - PRESSURE GAUGE FITTINGS

The “high” gauges are to be fitted to the highest penetrators. Fit a nipple and connect a shut
off valve and tee. The gauges are to be connected to one tee port and the other port is
to vent any trapped air.

5.10 “LOW POINT ” - PRESSURE GAUGE FITTINGS

The “Low” gauges are to be fitted at the pressure pump inlet to the chamber.

5.11 CONNECTION TO THE PRESSURE PUMP

Select a ½” NPT penetrator that is easy to access to connect the pressure pump hose.

Fit a nipple and shut off valve with a tee. One tee port is for the “low” Pressure Gauge
and the other to connect the pressure pump hose.

5.12 CONNECTION TO THE CHART RECORDER

Select a ½” NPT penetrator that is easy to access to connect the Chart Recorder hose.

Fit a nipple and shut off valve with a tee. Fit a nipple to the valve suitable to connect
the chart recorder.

6.0 HYDRO TEST

6.1 HYDROSTATIC TEST PROCEDURE

Step 1 Before closing the doors to commence filling and testing the chamber must be inspected
to ensure that all penetrators are plugged or have a fitting connected correctly &
securely plugged. Make sure that the penetrators being utilized for testing have not been
plugged inside. Close all shut off valves including vents and filling/drain valves.

Step 2 Ensure that fittings with shut off valves are in place to connect the pressure pump hose
and the chart recorder hose. Ensure that “High” and “Low” pressure gauges are in place.

Step 3 Pump low pressure compressed air @ 1.0 Bar into the chamber to achieve sufficient
pressure to check all the doors,viewports,penetrators etc. for leaks. Test with soapy
water to identify obvious leaks.

Step 4 Open vents closed in Step 1 before commencing filling with test water.

Step 5 Commence filling with fresh water and continue until all air has been expelled and water
is exiting from the vents. Turn off filler supply valves and close the chamber filler valves.
Close vent shut off valves and open pressure gauge shut off valves. Water shall be
clean, oil free and of such purity as to minimise the corrosion of the material as per
ASME-1 4.8.1.1.

Step 6 Connect the pressure pump to a fresh water supply. Connect the pressure pump hose to
the chamber. Place personnel near to the chamber to observe the doors. If any
leakage found,the pump must be stopped immediately.

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Step 7 Commence pumping and check all around the chamber for leaks if any.
If no leaks detected continue to 2.0 Bar and hold for 10 Minutes.
Test pressure and temperature will be monitored through Pressure / temperature
chart recorder

Step 8 If no sign of leaks recommence pumping to 5 bar which is Design pressure and
hold for 10 minutes.

Step 9 If no leaks Pump to 7.5 bar and hold while carrying out a thorough check for leaks or
any sign of “seepage” through penetrator welds.

Step 10 Once the Chamber is showing 7.5 bar on the pressure gauges and no evident pressure
losses exist, hold the pressure for a minimum of 60 minutes and ensure that this is
recorded on the Pressure Chart Recorder.

Step 11 After DNV GL, FTE has signed off the test, depressurize by opening the
vent valves to safe direction and slowly drain the water.

6.2 HYDROSTATIC TEST SEQUENCE

Stage 1 – Testing Entry lock chamber

 Close the door D1

 Open MLD1 & MLD1A doors.
 Close the door D2 & Open the door D3
 Place a flood light inside the main lock chamber to focus and illuminate on D2.

(a) Fill up entry lock Chamber with water and hydro test as per procedure set out in section 6.1.
(b) Main lock door D2 can be viewed thru flood light illumination via. medical lock
(c) Observe all seam welds,view ports,doors and penetrators for leaks and any decay in the test
pressure.
(d) Record down the reading through the chart recorder.
(e) Release the pressure and drain entry lock chamber completely.

Stage 2 – Testing Main lock chamber & Medical lock hub

 Open the doors D1 & D2 and remove the flood light from main lock chamber.
 Close the door D3.
 Close the medical lock door MLD1A
 Open the medical lock door MLD1

(a) Fill up the water in the main lock chamber and pressurize as per the procedure set out in
section 6.1.
(b) Observe the door D3 from entry lock chamber and medical lock inner door MLD1A from
medical lock outer door MLD1.
(c) Close the medical lock outer door MLD1 properly if no leak from inner door MLD1A.
(d) Then fill the water and pressurize the medical lock housing through the ½” NPT holes and
record down pressure through the pressure gauge connected with medical lock housing.
(e) During this stage the medical lock inner door MLD1A will open automatically and entire main
lock chamber and medical lock housing maintained to the test pressure equally.
(f) Observe all seam welds, view ports, doors, penetrators and medical lock for leaks and any
decay in the test pressure in main lock chamber.
(g) Record down the reading through the chart recorder.

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(h) Release the pressure upon completion of testing.

7.0 POST HYDROSTATIC TEST INSPECTION

Following completion of the tests carry out any further checks requested to the satisfaction of the
attending DNV GL Surveyor.

8.0 NDT

Post hydrotest NDT is to be carried out according to the code requirements.

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