PT.

HANJUNG

PROCESS SPECIFICATION

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HYDROSTATIC AND AIR LEAK TEST PROCEDURE

PROJECT NAME

: HJ PROJECT

ITEM

: COMPRESSED AIR RECEIVER

ITEM NO.

: DE-101

CUSTOMER

: ABC CHEMICAL CO., LTD

Name Rev No. Date Prepared By QE

Name Date Reviewed By QA MGR

Name Date Reviewed&Approved By QA GEN. MGR

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HYDROSTATIC & AIR LEAK TEST PROCEDURE

Table of content

Paragraph

title

1.0 2.0 3.0 4.0 5.0 6.0 7.0

Scope Reference documents Preparation for test Measuring instruments Test water and metal temperature Testing condition Documetation of test results

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HYDROSTATIC & AIR LEAK TEST PROCEDURE

1.0

Scope This procedure specifies the pressure testing method and its acceptance criteria for compressed air receiver which are manufactu red in accordance with ASME SECT. VIII. Div. 1. and purchasers technical specification.

2.0 Reference documents 2.1 ASME code Sect. VIII Div. 1 (1995 Edition with 1997 Addenda) 2.2 Customer specification : HJ-E-001 Rev. 0

3.0 Preparation for test 3.1 Before the pressure test, all internal surface shall be cleaned by sweeping or other methods so the vessel will be welding Slag and Flux, weld rod stubs, loose scale, dirt and debris. 3.2 Visually inspect all thread connection on the unit being tested. Clean and re-tap thread as required inspection with plug and ring gauge by QC inspector. The test equipment shall be examined before pressure is applied to ensure that it is tight and that all low pressure filling lines and other appurtenance that should not be subjected to the test pressure have been disconnected or isolated by valves or other suitable means. Remove all unnecessary equipment from the test floor and maintain the area in a clean condition during the test. Personnel not directly involved in the test procedure shall not enter or pass through the test area.
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3.4

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3.5

Location of pressure gauge Two pressure gauges shall be connected to the vessel, one should be installed at the top of vessel and others at the bottom in accordance with internal work shop instruction. Vents shall be provided at all high point of vessel in the position in which it is to be test to purge possible air pockets while the vessel is filling. Measuring instrument Pressure gauge (100 kg/cm 2 )

3.6

4.0 4.1

4.1.1 The range of test gauge to be used for this test will be 1.5 to 4.0 times the pressure at which the test is to be performed. 4.1.2 Each indication pressure gauge to be used shall be calibrated using a standard gauge and there shall be used with the calibrated pressure gauge within max. six months from pressure test date. 4.1.3 A record of each calibration should be kept in the QC Department with other inspection records. 4.2 4.3 5.0 5.1 5.2 Digital Thermometer Flashlight, magnifiers and inspection mirror (if necessary) Test water and metal temperature Test water should be clean fresh water. The metal temperature during hydrostatic test shall be not less 40F (4C) but not over than 120F (48C).
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HYDROSTATIC & AIR LEAK TEST PROCEDURE

5.3 5.4 6.0 6.1

Test pressure shall not be applied until the equipment and the test fluid are approximately at the same temperature. Test shall be performed in day time. Pressure testing sequence Hydrostatic test

6.1.1 Following the application of test pressure, a visual inspection for leaks shall be performed at a pressure not less than two-thirds of the test pressure. This test pressure shall be maintained for a minimum of 10 minutes for holding. 6.1.2 The service bolting and gasket to be furnished with the vessel may be used for testing. 6.1.3 Acceptance criteria The pressure test is satisfactory if the pressure is borne by enclosure without any leakage and relevant remaining deformation.

6.1.4 Drainage After completion of the hydrostatic test, water should be gradually drained off. And the vessel should be thoroughly dried using dry air.

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6.1.5 Pressure test diagram

Pressure Tp Dp
10 minutes Min. 1 Hr.Min. Dp : MAWP pressure (230 psig,16.17 Kgf/m 2) Tp : Test pressure (345 psig, 24.25 Kgf/m 2)

Hour 6.2 6.2.1

Air soap (soap bubble) leak test Leak test shall be carried out reinforcing pad for manhole at the pressure of Min. 15 psi (1.06 Kg/Cm2) compressed air at least 5 Min. in accordance with ASME SECT.V, Article 10. 6.2.2 Leak test shall be performed before Hydrostatic pressure test. 6.2.3 All welded area shall be checked during test. 6.2.4 After leak test, the tell-tale hole shall be unplugged and filled with heavy grease only. Documentation of test resul ts All test results shall be documented on the Pressure Test Record (Exhibit 1) by QCI inspector.

7.0

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HYDROSTATIC & AIR LEAK TEST PROCEDURE EXHIBIT 1 PT. HANJUNG

PRESSURE TEST RECORD

TYPE OF TEST HYDROSTATIC PNEUMATIC LEAKAGE

RECORD NO PAGE : M/O NO : OF

TRAVELLER/OPER NO.

REV.

PROC. NO.

REV.

INST. NO.

REV.

DWG. NO.

REV.

PRESSURE GAGE IDENTIFICATION NO. CALIBRATION DATE DESIGN PRESSURE REQUIREMENT ACTUAL RESULT SKECTH

TEST PRESSURE

TEST TEMP.

HOLDING TIME

REMARK

CONVERSION FACTOR

1 kgf/Cm2 = 9.80665 x 104 Pa = 14.224752 Psi

RESULT :

ACCEPTABLE

UNACCEPTABLE

SUPERVISED BY WITNESSED BY WITNESSED BY

: : :