HZMM_2.303_Hydrotesting_Rev00

7/28/2019 HZMM_2.303_Hydrotesting_Rev00

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MIQA ProceduresHazira Manufacturing Division

Hydrotesting

Reliance Industries Ltd.Hazira

Hazira MIQA Manual Page No. 1 of 10

Section No. : HZMM 2.303 Rev. : 00 Date : 01.11.2009

PSM Critical


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Document Control Details

Document FirstIssue date

Prepared/Compiled By

Documentownership

DocumentFunctional

Owner

Approved by

01.11.2009

BR Dave

MR CESMechanical

Discipline HeadHOD-CES

DocumentRevision No.

Revision Date Procedure Document No.

0 - HZMM 2.303

Next ReviewDate

31/10/2011

Reviewed By (Functional Heads):

Head - I&C K Ramesh

Approved By: _______________

PK Jain (HOD-CES)

Note Signatures do not appear in soft or electronic copy

Section No. : HZMM 2.303 Rev. : 00 Date: 01.11.2009


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BRIEF DESCRIPTION OF THE TASK

SET UP SAFE WORKING PROCEDURE FORHYDROTESTING.

Hydro static pressure testing of equipment/pipeline is commonand important maintenance activity in a continuous processindustry to check integrity (withstandibility of pressure), it is usedfor. Maintenance crew must be experienced and supervisorhandling the job should be well conversant with the details &

procedures. Since the failure during hydro testing can lead tohazardous situation as well revenue loss to the organization in theform of direct cost as well as in the form of opportunity cost,enough importance should be given to this maintenance activity.

SCOPE

This procedure explains general guidelines about hydro testingincluding safe practices. Hydro testing helps to identify leak

proofness and integrity of the pressure vessels, heat exchangersand piping including welding joints, as a quality assurancemeasure. Periodicity of testing shall be followed as per statutoryrequirements, equipment criticality and repair code. It isnecessary to have standard guideline in order to regulate thehydrotesting operations for achieving desired results, safety andreliability.

OBJECTIVE

The objective of this procedure is to lay down the practices &procedures to be adopted for hydro testing.

APPLICABLE CODES

ASME Sec VIII Div.1: Design & Construction of PressureVessel (UG 99)

ASME B31.3: Process Piping Test Pressure Guideline: Annexure -1

Statutory Rules

POTENTIAL ENVIRONMENTAL ISSUES

The water used for hydrotesting activity is not an environmentalhazard. However, Plant level procedure for the safe disposal ofcontaminated water due to drain or spill after hydrotesting needs

to be followed.


EnvironmentAlert


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1. The standard engineering practice as described in thisprocedure shall be exercised.

2. Flange joints shall be checked after water filling and recifiedas required prior to pressurizing for hydro testing.

3. The specification of gaskets, bolts, flanges & flexible hosesshall be maintained as per engineering/piping spec.

4. Any deviations in working conditions shall be analysed withrespect to suitability of pressure gauges. Only calibrated

pressure gauges to be used for hydor testing.5. Do not leave pressurized equipment unattended, especially in

summer.

POTENTIAL SAFETY/OCCUPATIONALHEALTH ISSUES


Hydro testing is skilled job. Extreme safety precaution needs to be exercised duringpreparation stage, selection of flexible high-pressure hoses, bolts, gaskets, pressuregauges etc. Following safety precautions will help in preventing the accidents:

Work Safety Rules:

1. Proper PPEs required to be used wherever needed in plant areas.2. Hydrotesting work area to be barricaded before starting the job. Entry in barricaded

area to be restricted for unauthorized persons.3. Use of experienced riggers for handling of heavy items. New employees of

contractors should undergo safety induction training program conducted by safetydepartment.

4. Works permit and risk assessment instructions to be followed strictly.5. Use of certified pressure gauges and tools shall be in good working condition and

shall be inspected before use.6. Blinding flanges, gaskets, flexible hose and bolts to be used as per specification

rating.

7. Connecting pressure hoses shall be in good working condition without any visiblephysical damage.

8. Spillage and overflow of water to be avoided or passage to be provided by usinghose pipe etc. to prevent possible slippage during movement. Proper care to betaken to avoid over flow/drain water ingress in the insulation of adjascentequipment/piping.

9. All the electrical items shall be inspected and certified by electrical engineer beforeuse.

10. The studs/bolts which are tightened shall be free from burres, dents etc. The nutshall rotate freely on the studs and the threads shall be lubricated. This will preventany jerks due to jamming of damaged threads.

11. Do not leave pressurized equipment unattended, especially in summer.

Safety Alert


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Tools and Tackles Required:

1. Set of spanners of required size.2. Calibrated pressure gauges (2 nos.) of appropriate range with

certification of calibration marked on pressure gauge.3. Connecting pressure hose pipe with marking of safe work

pressure.4. Hydraulic pump (manual or electic operated).5. All the electrical appliances shall be protected by standard

ELCB as per designed electrical loads.6. Blind flanges and bolts as per specification rating and size.7. Flexible hoses for water draining.

Documents and Drawings:

Refer following documents relevant for carrying out the job:1. Equipment drawing. Piping P&ID and Isometric drawing.2. Guide line for hydro test pressure for static equipment

(Refer Annexure-I)3. Pressure Test Certificate: CESH / I&C /3909 (Refer

Annexure-II).4. Hydrotest details: SAP-CIMS Report.

SPARES & CONSUMABLES

1. Water (DM water to be used for SS material Chloride

>30ppm)2. Gaskets, studs/bolts with nut as per required sizes and

specification rating.3. Anti seize & anti rust spray.

Prerequisites

1. The technician allotted for the job shall be well versedwith hydro testing procedures, basics of flange jointing,gaskets, fastneres etc.

2. He shall be able to read the drawing & understand the

details mentioned.3. He shall have thorough understanding of risk assessement

and hazards associated with the job.

PROCEDURE:

This procedure covers the minimum requirements for the pressuretesting of equipment / piping during routine maintenanceactivities.

1. The working personnel shall be experienced (aware of "dos &

donts while executing the job).



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2. Hydro test pressure shall be desided as per designcode/statutory requirements. Refer Annexure-I

3. SS MOC equipment/piping to be tested using DM water(Chloride


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Water used for hydro testing required to be drained in propermanner to avoid spillage and water ingress in the insulationof adjascent equipmen/piping.

Initially, water to be drained from the top most located ventusing flexible hose till depressurizing of the vessel. Drainingto be done in slow manner.

Bottom/side nozzle to be used for draining after de-pressurizing of equipment/piping. Top vent to be kept openfor air entry.

Water to be drained in water trench only.

De-blinding of nozzle/piping flanges:

Flange joints blinded for hydrotesting purpose to benormalized using gaskets and bolts as per specification.

Check flange-gasket faces for corrosion damage, mechanicaldents and squareness prior to box-up.

Proper size bolts to be used. Short/long bolting must beavoided.

House Keeping:

The contractor shall ensure cleanliness of surrounding area,removal of barricading, spare bolts, gaskets, hoses, pump,cables etc after completion of the job.

In case of water spilled in surrounding area, cleaning/mopingof area is essential.

Cerification:

Hydro test to be witnessed by I&C Engineer along with plantoperation and maintenance engineer. Hydro test certificate(CESH/I&C/3909 Refer annexure-II) to be signed by above-mentioned representative and hard copy to be preserving inrespective eqpt file.

Responsibility:

1. Carrying out & necessary arrangement: PlantMaintenance2. Witnessing/Decision/Report: InspectionEngineer3. Preservation of hydro test record: InspectionEngineer4. Hydrotest deviations: Plant HOD

a. Due to any reasons, if the plant does not offer the equipmentfor hydrotest, such responsibility lies with the concernedPlant and concession-deviation should be raised with due

approval of Site President/Manufacturing Chief. Forequipment under Gujarat Factory Regulations, valid reasons



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should be indicated to the GFR competent person, who iscertifying the inspection.

b. In case of medium is used other than water, Plant HOD shallapprove the same. He may consult CTS/CES, if necessary.

c. In case pneumatic test needs to be performed due to processconstraint, detail risk assessment shall be carried out by Plantin consultation with safety department.

Record:1. Pressure Test Certificate: CESH / I&C /39092. Hydrotest details: SAP-CIMS Report



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Annexure - I

HYDROTEST PRESSURE OF STATIC EQUIPMENT

1. AS NEW: As per data sheet/design code.

2. OLD / USED / IDLE FOR MORE THAN 2 MONTHS:

A. 1.5 X MAWP (Permitted maximum working pressure byProcess requirement.)

OR1.25 X Design Pressure (Water)

Whichever is less.

B. 1.1 X Design Pressure (Gaseous Medium)

3. HYDROTEST MEDIUM:

A. Normally, testing should be done using fresh water atambient temperature. In case of non-practicability of usingthe same, due to process reasons, suitable substitutemedium should be decided accordingly.

B. TEST WATER for Austenitic Stainless Steel system shallbe basically free of CHLORIDES (Max.30 ppm) to avoidstress corrosion cracking.

4. PRESSURE GAUGE LIMIT:

MIN. RANGE: 1.25 X Test PressureMAX. RANGE: 2.5 X Test Pressure

5. HOLDING TIME: At least 1/2 an Hour.OR

Up to the satisfaction of the inspector

6. FREQUENCY: A. As per Statutory actsB. As per design/construction code

C. After maintenance activity

Whichever is applicable



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Annexure - II

PRESSURE TEST CERTIFICATE

FORMAT REF. NO.: CESH/I&C/3909

PLANT: EQPT TAG NO: TESTDATE:

TEST DATA:

PARAMETER SHELL SIDE TUBE SIDEMOC

TEST PRESSURE

(Kg./Cm2g)

TESTING MEDIA

TEMPERATURE

HOLDING DURATION(MINUTES)

NO. OF TUBES PLUGGED Before: Current: Total:

PRESSURE GAUGE USED:

Tag No Calibration due on Range Remarks

Remarks:

______________________________________________________________________

WITNESSED BY:

(CES-I & C) (Plant-Operations)(Plant-Maintenance)


HZMM_2.303_Hydrotesting_Rev00

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