PROCEDURE: 121601-Hydro R0

HYDRO TEST OPERATING PROCEDURE

Requirements:
1. Square Bars-4 nos.
2. Hydro test Needle Valves-8 nos.
3. Pressure Indicators Range-200 kg/cm2(Shell side) & 100
kg/cm2(Tube side) 2 nos. each.
4. Pr. Transducer 100 kg/cm2 1no.
5. Hydro test Pump 2 nos.(working should be tested in advance)
6. Hydro test Hose pipes-4 nos.
7. Water sump for water storage.
8. Submersible pump.
9. PPM Testing kit-2 nos.
10.Blind Flanges as per Drg. 121601-51 R0.
11.Water pumping unit-Pump with 4 hose pipe 15 m length.
12.Torquing unit RSL-4 & RSL-8 in working condition-2 nos.
13.Required size Box Spanners & Fixed spanners.
14.Dummy piping [3 or 4] arrangement to increase Noz O1 elevation
up to 2.6m wrto center line of vessel.
15.Hydro test Fasteners & Gaskets as per Drg. 121601-51 R0.
16.Chemical additives.
Noz. Qty Size

Flange/ Gaske Stud+Nut

Thk
t
Item/Qty Size

1(2) 36x300
#
T1-9 9
2x900#

5109/1
00
5101

5111

612+3/64

2 UN8

Torqu
e
Kg-m
495

5110

5/8UNC

13

D1- 4
4
E1-3 3

2x900#

5105

5104

7/8UNC

41

42x900#
30x300
#
2x900#

5113

5116

5/8UNC

13

5112

5108

5102+3/7
2
5106+7/4
8
5114+5/2
4
124+5/28

324

820

823

821+2/8

1 3/4
8UN
7/88UN

T.Gu
n

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41

PROCEDURE: 121601-Hydro R0

L1-4 4
M
1
M1

2x900#
32x300
#
20

820
106

823
109

821+2/8
107+8/28

242CAP
5105

V12
S6

2x900#

5104

1(2) 8x900#

814

5106+7/4
8
812+3/24

C6

2(2) 6x900#

817

815+6/24

7/88UN
1
7/88UN
-

41
375
-

7/8UNC

41

1
3/88UN
1
1/88UN

275

Shell Side Hydro test Operating Procedure:

Stage :1 SHELL SIDE HYDRO TEST AFTER HELIUM TEST
BEFORE CHANNEL SHELL CLOSING.
Assumptions:
a. The job can be rotated after Hydro.
b. The 0 orientation will be on top during hydro test.
c. Provide 6 connection on hydro test cap of top header and plug (3/4)
on bottom header hydro test cap at 0.
d. Provide connection on man way cap.
e. Hydro test will be done on rollers only.
f. Seam- 431-43 will be covered in local hydro test.
Refer Sketch:1 (excel sheet)
Procedure:
1. Take clearance from Inspection/AI for Hydro test.

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200

PROCEDURE: 121601-Hydro R0

2. Blank all nozzles at specified Torque. Nozzle pipe E1-3 shall be

closed by blind flange with welding. (refer sketch)
3. The top side of shell section shall be kept 50mm up with respect to
bottom end.
4. Check PPM of Inlet water.
5. Use Noz .D1 as pressure raising points and Noz S2 (0 top header)
and D1 for connecting pressure gauges and transducer.
6. Fill water through top header 6 connection till overflow on bottom
header plug.
7. Close top and bottom header connection.
8. Start pressuring the vessel through nozzle D1,up to 50% of Hydro test
pressure. Afterwards raise the pressure in steps of 10% increment after
holding for 5min of Hydro test pressure.
9. After holding the vessel at hydro test pressure for 1Hr [min], reduce
the pressure to design pressure .
10.Inspection should be carried out at design pressure for any leaks.
11.Once inspection is over [if there is no leak] top and bottom header
connection shall be opened first followed by nozzle D1, D2, L2, L4 &
V1.
12.Rotate the job by 180 in such a way that opening of top header will
be at bottom side. Ensure complete draining by rotating vessel 10
both side.

Stage-2 HYDRO TEST OF SEAM-431-433 OF NOZ-E1-3.

Assumptions:

Procedure:

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PROCEDURE: 121601-Hydro R0

Nitrogen fill up on shell side after tube side hydro test:

1 Ensure job item flanges are attached and properly tightened
with proper gasket. (noz-V1-2, L1-3, K, D1-4, header outlets.
2 Close all the openings except Nozzle D1. Attach pressure
indicator to nozzle D1.
3 Fill the N2 up to 0.25kg/cm2 (g) and ensure no leakage.

Tube Side Hydro test Operating Procedure:

Assumptions:
1. The 270 orientation is on top during hydro test.
2. Job cant be rotated after hydro.
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PROCEDURE: 121601-Hydro R0

REFER SKETCH-2 (excel sheet)

Procedure:
1. Take clearance from Inspection/AI for Hydro test.
2. Ensure venting is done as per sketch.
2 Blank all nozzles on dend at specified Torque. Attach dummy pipe
spool with nozzle O1 which will acts as a water inlet point.
3 Ensure Noz-E1-3 seam-431-433 NDT is cleared.
3. Check PPM of Inlet water [should be less than 50PPM] before adding
chemical.
4. Add chemicals in specified proportion in the water bath before
pumping water in vessel.
4. Ensure all weld seams out side surface is free from rust, oil, grease etc.,.
5. Fill up the vessel with water through the nozzle O1. Water filling
continued till the water reaches the top of dummy piping. During filling
air venting shall be provided through the nozzle O for bottom head,
Nozzle T6, and T3 for top head.
1. Air venting opening shall be closed after overflow before
pressurizing.
2. Provide transducer gauge at top side nozzle O and pressure gauge at
bottom side nozzle T3.
8. After fill up of water close the opening on nozzle O and start the
pressurizing the shell through the nozzles T7 and T5.
9. Continue pressurizing of vessel through nozzle T7 and T5 Up to 50%
of Hydro test pressure. Afterwards raise the pressure in steps of 10%
increment after holding 5 min. of Hydro test pressure.
10. After holding the vessel at hydro test pressure for 1Hr [min],
reduce the pressure to design pressure .
11. Inspection should be carried out at design pressure for any leaks.
12. Once inspection is over [if there is no leak] Nozzle O (water inlet)
shall be opened first followed by nozzle T6 and T3. All venting
connection must be open before opening any nozzle for draining.
13.Remove the dummy piping on nozzle O1 and nozzle F to access
bottom and top heads to remove residue water.
Left out water shall be pumped through man way.
14.After complete draining of hydro test water nozzle openings should
be closed except Nozzle O and F [acts as hot air vent]. Allow hot air
through the nozzles O to remove traces of water from tubes inside
diameter.
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PROCEDURE: 121601-Hydro R0

15.Carry out drying as per procedure.

Nitrogen fill up on Tube side:

1. Close all the nozzle openings including Nozzle F and O1.
2. Attach pressure indicator to nozzle F and purge the nitrogen
through the nozzle O1 until the pressure gauge shows the pressure
0.25kg/cm2

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