JEL MAINTANCE PTE.

LTD

HYDROTEST PROCEDURE

EQUATE Petrochemical Co.

AROMATIC, AREA-2 & AREA-3
TURN AROUND - 2017

Doc No. JML-PROC-QC-001

REVIEW AND APPROVAL

JML EQUATE
Name Designation Date Signature Name Designation Date Signature
 JEL MAINTENANCE PTE.LTD

Doc No. JML-PROC-QC-001 HYDROTEST PROCEDURE Rev. 0

REVISION HISTORY
Doc No. JML-PROC-QC-001
Rev. Revision Information Date
0 Issued for Review 15/08/2017

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Doc No. JML-PROC-QC-001 HYDROTEST PROCEDURE Rev. 0

1. OBJECTIVE

This Procedure ensures proper quality control steps are followed during the hydro testing of
piping/Equipment for the EQUATE Petrochemical Co TA 2017 Project.

2. SCOPE

This procedure details the hydro testing method and requirements for EQUATE Petrochemical
Co TAR 2017 Project. This Procedure does not apply for pneumatic.

3. CODE AND STANDARDS

ASME Section V : Non Destructive Testing

ASME Section B31.3 : Process Piping
EQUATE Specification and Scope of works

4. ABBREVIATIONS

JML JML maintenance Pte Ldt

PM Project Manager
QE QA/QC Engineer/Inspector
QA Quality Assurance
QC Quality Control
ITR Inspection Test Request
NDT Non-Destructive Testing
TAR Turnaround

5. RESPONSIBILITIES

QC Inspector is responsible to ensure that the Hydro testing works are carried with respect to
the approved hydro testing procedure. He is also responsible to inspect and accept the test
results.

Final Approval of Hydro test shall be after witness by EQUATE Inspection Engineer.

Safety Officer responsible to ensure the proper barricade and safety measures are taken during
the hydro test.

6. METHOD & SEQUENCE OF ACTIVITIES

6.1 Pre Test Preparation

Prior to start of any pressure test a pressure test package shall be submitted well in advance
for the review and approval of Company.
Clearance from EQUATE Inspection shall be obtained prior to conducting any pressure
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testing.
The Clearance for pressure test shall be based on completion of all NDT and acceptance of
the Test-Package by the Contractor / Company.
Test-Package shall contain the following documents.

a) List of Isometrics/Drawings for test

b) P&ID and isometric drawings marked with test limit.
c) Weld History sheet
d) Punch List.
e) Pressure test diagram.
f) Piping Pressure Test Report.
g) Calibration Certificates of Gauges.

All category punch list items shall be closed out and signed off prior to releasing test package
for pressure test.
All hoses used for pressure test shall be rated and inspected prior to pressure test.
During final service test, these flanged joints shall be inspected for leaks.
Before starting pressure test the piping covered within the test limit shall be flushed using
water or air to clean the line
Test blinds, spades or plugs shall be installed with attachments for connecting pressure
gauges, pressure chart recorders.
Fabricated Blind flanges from MS plates shall not be used as blinds for Hydro testing of pipe
spools.
Water shall be filled using a filling pump or directly from water tankers or from a local water
source approved by EQUATE.
The filling rate should be such that no surge develops in the piping system. Test manifold
used for pressure testing shall be tested and certified by JML QA/QC department and
EQUATE Inspection.
When the line is full, water will start flowing from the high point vents. Piping shall be
thoroughly vented; Water flow through the vent will allow escape of entrapped air in the line.
After venting all high vent points shall be closed and plugged.
All Weld joints shall be left un-painted and uncovered for examination during the pressure
test, except that joints previously tested.

6.2 Test Medium

Hydro test shall be performed by clean fresh water free from foreign materials such as sand,
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dirt, rust etc.

Potable Water will be used for carbon and Low alloy Steel and other materials the chloride
content in the water shall be controlled as specified in the scope of work
DM water is to be used for hydro testing of SS.

6.3 Test Pressure

The test pressure shall be as mentioned in the corresponding drawing.

6.4 Hydrostatic Testing

Test pressure shall not be less than 1.5 times of design pressure.
Pressure shall be applied gradually in a controlled manner to avoid any surging in the line.
Pressure shall be applied in 4 stages. 25% of test pressure shall be applied in first stage with
a stabilization period of 5 minutes.
If the pressure gauge is stable 25% of the test pressure shall be applied in the second stage.
After achieving 50% of test pressure the system shall be allowed to stabilize for another 5
minutes then 75 and 100% respectively.After achieving test pressure the pump should be
stopped and isolated.
Hydro test pressure shall be maintained for a sufficient length of time to check all joints for
any leaks. Minimum test duration shall be 30 minutes and maximum shall be 1 hours.
The loop will be thoroughly checked at all weld joints including all support welds.
If any leakage is found at any welded joint the test shall be cancelled and system shall be de
pressurized safely.
Defected weld joint shall be repaired and required NDT shall be carried out.
Re test shall be carried out after test package clearance from JML QC and EQUATE
Inspection.
After satisfactory completion of pressure test, line shall be depressurized through high point
vent.

6.5 Pressure Gauges

Calibrated and certified Pressure gauges shall be utilized for the test. Pressure test gauges
shall be numbered and calibrated as per the project requirement. The gauge shall be tagged
with the date of calibration and validity.
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The pressure gauges to be selected such that range of pressure gauge shall be 1.5 to 4
times the test pressure with minimum dial face of 150 mm diameter.
Minimum two numbers of pressure gauges shall be fixed. One at the pressure pump location
or at the lowest position and other one at the highest elevation of the test loop.

6.6 Draining & Line Reinstatement

After hydro test is completed the line shall be gradually depressurized and drained.
Before opening the drain valve, Vent points shall be opened for releasing the pressure. All
temporary attachments installed for testing purposes like manifolds, valves, blinds, spacers,
supports shall be removed.
The drained water shall be collected back in a water tanker and shall be disposed in another
location as agreed by the company.
Lines/spools removed for testing purpose shall be re-installed with new gasket after getting
EQUATE approval.

7. DOCUMENTS AND RECORDS

Hydro test Report

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