COMPOSITE WORKS UNITS & OFFSITES AT GAIL VIJAIPUR

TSPL
Procedure No. TSPL/EIL/GAIL-JP-10

JOB PROCEDURE FOR HYDRO TEST

NAME OF WORK : COMPOSITE WORKS UNITS & OFFSITES AT GAIL VIJAIPUR

OWNER : M/s GAIL (INDIA) LTD

CONSULTANT : M/s ENGINEERS INDIA LIMITED.

CONTRACTOR : M/s THERMOSYSTEMS PVT. LTD.

LOA NO : GAIL/VC/17/C-133/5300029424/C&P/MECH/YS

00 Issued for review &

Approval
Rev Date Description Prepared by Checked Reviewed by Approved by
(TSPL) and EIL EIL
Approved
by(TSPL)

Contents

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 COMPOSITE WORKS UNITS & OFFSITES AT GAIL VIJAIPUR

TSPL
Procedure No. TSPL/EIL/GAIL-JP-10

1. SCOPE

2. REFERENCE

3. METHODOLOGY

4. DOCUMENTATION

1.0 SCOPE:

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 COMPOSITE WORKS UNITS & OFFSITES AT GAIL VIJAIPUR

TSPL
Procedure No. TSPL/EIL/GAIL-JP-10

This procedure covers the general requirements for inspection and

testing of above ground & underground piping system in Composite
Works units and offsites at GAIL, Vijaipur.
2.0 CODE REFERENCE:

The following code, Standard, Specification of latest edition shall

apply
a) ASME B 31.3
b) P & ID
c) GAD & Isometric Drawing
d) Line Schedule
e) EIL Standard specification No. : 6-44-0013, Rev. 4

3.0 METHODOLOGY :

A. FLUSHING :

Flushing of all lines shall be done before pressure testing. Flushing

shall be done by fresh potable water or by dry compressed air.
Required pressure for water flushing shall meet the fire hydrant
pressure or utility water pressure. For air flushing, the line/system
shall be pressurized by compressed air at the required pressure
which shall be 3.5 kg/cm2g maximum. The pressure shall then be
released by quick opening of a valve, already in line or installed
temporarily for this purpose. This procedure shall be repeated as
many times as required till the inside of the pipe is fully cleaned.

In line instruments like control valves, orifice plates, rotameters,

safety valves and other instruments like thermowells which may
interfere with flushing shall not be included in flushing circuit.

The screens/meshes shall be removed from all permanent strainers

before flushing. Screens/meshes shall be reinstalled after flushing
but before testing.

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TSPL
Procedure No. TSPL/EIL/GAIL-JP-10

B. PRESSURE TESTING:

EXTENT OF TESTING:

With the exclusion of instrumentation, piping systems fabricated or

assembled in the field shall be tested irrespective of whether or not
they have been pressure tested prior to site welding or fabrication.

To facilitate the testing of piping systems, vessels and other

equipments may be included in the system with the prior approval of
Engineer-In-Charge if the test pressure specified is equal to or less
than that for the vessels and other equipments.
Pumps, compressors and other rotary equipments shall not be
subjected to field test pressure. Lines which are directly open to
atmosphere such as vents, drains, safety valves discharge need not
be tested, but all joints shall be visually inspected. Wherever
necessary, such lines shall be tested by continuous flow of fluid to
eliminate the possibility of blockage.
Instruments in the system to be tested shall be excluded from the
test by isolation or removals, unless approved otherwise by the
Engineer-In-Charge.
Control valves shall not be included in the test system. Where
bypasses are provided test shall be performed through the bypass
and/or necessary spool shall be used in place of the control valve.

C. TEST PREPARATION FOR TESTING:

Testing shall be carried out with permanent gaskets installed unless

specified otherwise or instructed by the Engineer-in-Charge.
Before testing, all piping shall be cleaned by flushing to make it free
from dirt, loose scale, debris and other loose foreign materials.

All piping systems to be hydrostatically tested shall be vented at the

high points and the systems purged of air before the test pressure is
applied.

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TSPL
Procedure No. TSPL/EIL/GAIL-JP-10

Wherever in the line any void exists due to any reasons, like absence
of control valves, safety valves, check valves etc. it shall be filled with
temporary spools.

All joints welded, screwed or flanged shall be left exposed for

examination during the test. Before pressurizing the lines, each weld
joint shall be cleaned by wire brush to free it from rust and any other
foreign matter.

Where a system is to be isolated at a pair of companion flanges, a

blank shall be inserted between the companion flanges. Minimum
thickness of the blank shall be designed in accordance with
applicable design code.

Open ends of piping system where blanks cannot be used, such as

pumps, compressors, turbines or wherever equipment or pipe spools
have been recovered or disconnected prior to hydrostatic testing,
shall be blinded off by using standard blind flanges of same rating as
the piping system being tested.

Pressure gauges used in testing shall be installed as close as possible

to the lowest point in the piping system to be tested, to avoid
overstressing of any of the lower portions of the system.

Gas lines when hydrostatically tested shall be provided with

additional temporary supports during testing as directed by the
Engineer-in-Charge.
Piping which is spring or counter-weight supported shall be
temporarily supported, where the weight of the fluid would overload
the support. Retaining pins for spring supports shall be removed only
after testing is completed and test fluid is completely drained.

D. TESTING MEDIA:

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 COMPOSITE WORKS UNITS & OFFSITES AT GAIL VIJAIPUR

TSPL
Procedure No. TSPL/EIL/GAIL-JP-10

In general all pressure tests shall be hydrostatic using iron free

water, which is clean and free of silt. Maximum chloride content in
water for hydrostatic testing for SS piping shall be 15- 20 ppm.

Air shall be used for testing only if water would cause corrosion of
the system or overloading of supports etc. in special cases as
directed by Engineer-in-Charge.

If operating fluid in the line is much lighter than testing fluid, the
additional weight of testing fluid may render piping supports (as
designed) inadequate. This will call for additional temporary
supports. The typical examples are flare and vapor lines. It is
preferable that hydrostatic testing is avoided in such systems and
instead pneumatic testing may be specified.

E. TEST PRESSURE:

The hydrostatic/ pneumatic test pressure shall be as indicated in the

line list or as per the instruction of Engineer-in-Charge.
The selection of the piping system for one individual test shall be
based on the following:
i) Test pressure required as per line list.
ii) Maximum allowable pressure for the material of construction of
piping.
Depending upon the above requirements and based on construction
progress, maximum length of piping shall be included in each test.

F. TEST PRESSURE GAUGE:

All gauges used for field testing shall have suitable range so that the
test pressure of various systems falls in 35% to 65% of gauge scale
range. Pressure gage dial shall be minimum of 150 mm. Size of
Bourdon shall not be less than 75% of nominal diameter of dial
range. Gauge shall be of a good quality and in good working
condition.
Prior to the start of any test or periodically during the field test
programme, all test gauges shall be calibrated using a standard dead
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TSPL
Procedure No. TSPL/EIL/GAIL-JP-10

weight gauge tester or other suitable approved testing apparatus.

Any gauge showing an incorrect zero reading or error of more than ±
2% of full scale range shall be discarded. Calibration certificate shall
be furnished for the pressure gages.
G. TESTING PROCEDURE:

i) Hydrostatic Test:
All vents and other connections used as vents shall be left open
while filling the line with test fluid for complete removal of air. In all
lines for pressurizing and depressurizing the system, temporary
isolation valves shall be provided if valved vents, drains do not exist
in the system.

Pressure shall be applied only after the system / line is ready and
approved by the Engineer-in charge.
Pressure shall be applied by means of a suitable test pump or other
pressure source which shall be isolated from the system as soon as
test pressure is reached and stabilized in the system.

A pressure gauge shall be provided at the pump discharge for

guidance in bringing the system to the required pressure.
The pump shall be attended constantly during the test by an
authorized person. The pump shall be isolated from the system
whenever the pump is to be left unattended.
Test pressure shall be maintained for a sufficient length of time not
less than 10minutes. Test pressure shall be released only after
physical checking of all the joints and attachments are completed, to
permit thorough inspection of all joints and connections for leakage
or signs of failure. Any joint found leaking during a pressure test shall
be retested to the specified pressure after repair.
After the hydrostatic test has been completed, pressure shall be
released by opening the vents, in a manner and at a rate so as not to
endanger personnel or damage equipments.
All vents shall be opened before the system is to be drained and shall
remain open till all draining is complete, so as to prevent formation

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TSPL
Procedure No. TSPL/EIL/GAIL-JP-10

of vacuum in the system. After draining, lines / systems shall be dried

by air.

After testing is completed the test blinds shall be removed and

equipment / piping isolated during testing shall be connected using
the specified gaskets, bolts and nuts.
H. Completion of Testing

After the hydrostatic test has been completed, pressure shall be

released by opening the vents, in a manner and at a rate so as not to
endanger personnel or damage equipments.
All vents shall be opened before the system is to be drained and shall
remain open till all draining is complete, so as to prevent formation
of vacuum in the system. After draining, lines / systems shall be dried
by air. In services like dry air, ethylene etc., small traces of water can
cause problem. For such lines hot air drying is to be done after
hydro-test. After testing is completed the test blinds shall be
removed and equipment / piping isolated during testing shall be
connected using the specified gaskets, bolts and nuts. These
connections shall be checked for tightness in subsequent pneumatic
tests to be carried out by the contractor for complete loop / circuit
including equipments (except rotary equipments). Pressure test
shall be considered complete only after approved by the Engineer-in-
Charge.

4.0 DOCUMENTATION:

Record should be maintain in approved format

i) TSPL/IL/GAIL-ITP-09 Rev-00
ii) iii) TSPL/IL/GAIL-HT-F-01 Rev-00

Note: In case of any conflict between the requirements of this

procedure and EIL specification, the later shall govern.

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 COMPOSITE WORKS UNITS & OFFSITES AT GAIL VIJAIPUR

TSPL
Procedure No. TSPL/EIL/GAIL-JP-10