Hydrotest Preparation
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Transcript of Hydrotest Preparation
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HYDROTEST
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TESTS
DESTRUCTIVE TESTS Tensile, Impact, Bend etc
NON-DESTRUCTIVE TESTS
Radiography
Ultrasonic
Dye Penetration
Magnetic Particle
Leak tests like Air test,Ammonia test etc. Hydrostatic test
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WHY HYDROSTATIC TEST
To ensure the integrity of the equipment To ensure the strength of the weld joints &
material
To ensure the strength of the nozzleflange joints
To relieve the stresses
Ensures safe and reliable performance
during the operational life
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HYDRO TEST
Good planning is essential for completionof hydrotest in minimum possible time
Gauges, transducer/ recorder , Sq. Bar,
Hose pipes, PumpLocation, weight distribution, draining
Saddles, slope, venting
Water- quantity,quality & temperature
Torque tightening / tensioning units
Flanges, bolts / studs
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HYDRO TEST
The hydro test saddles shall be located onshell in such a way that all circumferential
seams are free from saddle location. Long
seams if any covered by the saddle; the
corresponding location of saddle material
shall be grooved to facilitate the inspection
of weld joint under test
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Sketch for Hydro test
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Valves
Pressure Gauge
Towards Venting pipe
Arrangement for Outlet Pressure Gauge
Square Bar
Coupling
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From HydrotestPump
Towards Drain
Valves
Pressure Gauge
Square Bar
Coupling
Arrangement for Inlet Pressure Gauge
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HYDRO TEST
Carry out tightening of Nozzle / Manway covers as per the required
torque
Use proper tightening unit to meet therequirement of PSI / Torque and
follow the tightening sequence as per
approved procedure for bolts / studs
Start filling water after confirmation of
all requirements ( like venting, PPM of
water, Clearance of Job for fill up)
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TIGHTENING SEQUENCE(with torque tightening unit)
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TIGHTENING SEQUENCE(with tensioning unit)
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HYDRO TEST
Ensure that the nozzles (top) are
open for air removal
Let the water flow out of the topnozzles so that the air is removed
Close the nozzle & allow the water to
flow from top and confirm absence ofair bubbles
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AIR LOCK REMOVAL
1 VESSEL IN HORIZONTAL, INCLINED AT 5 DEG.
Packing
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AIR LOCK REMOVAL2 WHEN INTERNALS LIKE TSRs PROVIDED INSIDE THE VESSEL
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AIR LOCK REMOVAL
3 NOZZLES ON DISHEND
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HYDRO TEST
Start the pump for pressurizing thewater inside the equipment. (Selectionof pump depends on the pressure and
discharge of water from pump. Set theoutput pressure of pump such that itshould not exceed hydro test pressurefor safer operation)
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HYDRO TEST
Ensure that minimum two pressure
gauges are attached The pressure gauges shall have an upper
range of 2 times the test pressure but in
no case less than 1.5 times or more than4 times the test pressure. The transducer
shall have minimum upper range of 1.25
times the test pressure. Only calibrated
pressure gauge and transducer shall beused. Validity of calibration shall be
verified on the calibration sticker pasted
on the pressure indicators
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HYDRO TEST
Increase the pressure as per therequirement given in drawing or the
approved procedure
During pressurizing from designpressure to test pressure, no one
shall remain on the vessel or very
near to bolted connections on the
vessel
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HYDRO TEST
Hold the test pressure for minimum30 minutes or as specified by the
drawing / specification. The test
pressure shall not get dropped
during the holding time. The vessel
connections shall not be inspected
closely for any leakage at this stage
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HYDRO TEST
Reduce the pressure to Designpressure
Check for any leakage in weld joints
and bolted joints If no leakage is observed,
depressurizing can be started
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HYDRO TESTDepressurizing :
If cycle is specified , follow the same If not specified, reduce pressure
slowly by opening the square bars (at
top) such that pressure drops to zero Neveropen bottom noz./ Sq. bar
While draining the vessel, the top vent
valve shall be kept open beforeopening any nozzle at the bottom. Thisis for eliminating the possible collapseof thin shells due to vacuum created
within the test vessel
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HYDRO TEST
Pressure gauges once used for apressure test shall be recalibrated. Forthis purpose, the pressure gaugesonce used shall be crossed on the
calibration sticker and send to QA