Plant Client Code Doc ID Code UAN

HMU Shell MDS HMU RP EQS-G000-DZ-00061 KXER-00661

Hydrotest Procedure
Rev. 01 Pages attached 7

Primary Reformer Burner

Item F-2001-F1A/F1B

TON 1031B001-Z70

01 - Client comments incorporated 14/02/19 -

Rev. Status Description Date Prepared Date Checked Date Approved AC
Category Code:

Barcode
 Hydrotest Procedure

Client Information

Client name Shell MDS (Malaysia) Sendirian Berhad

Project Reference Down Fired Burner Revamp

Unit Primary Reformer HMU

Tag F-2001-F1A/F1B

Purchase Order Number 4500095341

Document Number / Type N/A

Greens Combustion Document Information

Project / Reference Number GAS1627

Document Number / Reference GAS1627 / 140

Engineer N. Turle

Issue number 002

Date 14/02/2019

Document Status For Approval

Master Doc No : GCL PDC 01 Revision : 1 26/07/2012

A31, Arena Business Centres, Holyrood Close, Poole, Dorset, UK, BH17 7FJ
Telephone +44 (0)1202 607563 Email info@greenscombustion.com
 GREENS COMBUSTION LIMITED
A31 Arena Business Centre
Holyrood Close
Poole
Dorset
BH17 7FJ
Tel: +44 (0)1202 607563
Company Registration Number: 5733303

Hydrotest Procedure
1. Purpose

1.1 To establish a procedure which defines the methods and requirements for pressure testing of Greens
Combustion Limited (GCL) products.

2. Scope

2.1 To meet project testing requirements, whilst proving component integrity, in a safe and controlled
manner. Testing to be carried out in accordance with ASME B31.3 wherever possible.

2.2 SAFETY – The following safety precautions shall be observed during pressure testing.

2.2.1 Air under pressure is extremely dangerous. The pressure test inspector shall ensure all operators
understand and take precautions to prevent the entrapment of air in any component, which is subject
to a hydraulic pressure test.

2.2.2 The test pressure stated within the project specific documents must not be exceeded under any
circumstances.

2.2.3 Test area to be cordoned and access to be restricted to authorised personnel only. All equipment to be
used in testing to be suitable for the test pressure and in good condition.

3. Test Requirements

3.1 The test shall only be performed after 48 hours have elapsed from the last welding or PWHT on
pressure parts and equipment supporting parts.

3.2 No welding shall be done on the equipment and on any part in electric contact with the equipment
while the equipment is holding water.

3.3 Pressure gauges shall be calibrated before the beginning of the test with a minimum a validity of 3
months for calibration.

3.4 The scale range shall be from 0 to a maximum of 2.2 times the test pressure.

3.5 The smallest scale division shall not exceed 5 % of the maximum scale indication.

3.6 The test pressure shall be that stated on the detailed drawing of the component being tested with a
minimum of 3.0 Barg.

3.7 Test medium to be de-ionised / de-mineralised water with the addition of a corrosion inhibitor to
inhibit rust and corrosion. The de-ionised water shall have a maximum chloride content of 5 ppm.

1
Master Doc No : GCL PTP 01 Revision : 2 22/03/2016
 GREENS COMBUSTION LIMITED
A31 Arena Business Centre
Holyrood Close
Poole
Dorset
BH17 7FJ
Tel: +44 (0)1202 607563
Company Registration Number: 5733303

Hydrotest Procedure
4. Hydraulic Test Procedure (For inner and outer gas gun assemblies only)

4.1 Blank off all openings except the fill point and incorporate two calibrated pressure gauges. 1 Gauge
shall be positioned at the pump discharge; the other shall be positioned at the highest point of the test
assembly. Gauge calibration to be traceable to national standard.

4.2 It is recommended that a relief valve is incorporated within the system which is set at a pressure
approximately 10% above the required test pressure.

4.3 Fill gas gun assembly with de-ionised / de-mineralised water (test water to verify that chloride content
is below 5 PPM) until all internal air has been allowed to escape. Fill to be from low point in system
where ever possible and vent at highest point. Filling and Testing should not commence if ambient and
/or system surface temperature is below 10°C or above 40°C.

4.4 Close vessel and remove spilled water from the vessel surface.

4.5 Upon reaching the test pressure the system under test is to be isolated and the test pump
disconnected. Test pressure to be noted.

4.6 Test period should be at least 5 minutes. Carry out a new equipment inspection. Note: No item shall be
physically inspected at full pressure. Once the unit has been held at the correct pressure for the
required duration the pressure should be dropped to the design operating pressure for visual
examination.

4.7 Any leaks found are to be marked and reported to the GCL Project Manager and/or customer witness.

4.8 On completion of satisfactory test, release pressure gradually to atmospheric pressure.

4.9 The equipment shall be fully drained, dried and cleaned.

4.10 Vessel to be hard stamped in accordance with project requirements.

4.11 A Test Certificate shall be raised and signed by the Pressure Test Inspector.
The Test Certificate is to be offered to any witnessing Inspectors for their endorsement.
The Certificate should note the following as a minimum:
Date of test
Identification of component assembly being tested
Test Pressure
Test Medium
Test Duration
Certification of results by examiner
Pressure Test Inspector’s name
Test gauge ID No’s and calibration due date
A Pressure Gauge Calibration Certificate shall be provided by the Pressure Test Inspector.
2
Master Doc No : GCL PTP 01 Revision : 2 22/03/2016
 GREENS COMBUSTION LIMITED
A31 Arena Business Centre
Holyrood Close
Poole
Dorset
BH17 7FJ
Tel: +44 (0)1202 607563
Company Registration Number: 5733303

Hydrotest Procedure
5. Corrective Actions

5.1 Any leaks /pressure drop found shall be reported to GCL Project Manager.

5.2 GCL Project Manager to determine corrective action.

5.3 Following corrective action pressure test to be repeated in accordance with this procedure. GCL to
witness as a minimum.

3
Master Doc No : GCL PTP 01 Revision : 2 22/03/2016
 GREENS COMBUSTION LIMITED
A31 Arena Business Centre
Holyrood Close
Poole
Dorset
BH17 7FJ
Tel: +44 (0)1202 607563
Company Registration Number: 5733303

Hydrotest Procedure

Certificate of Test Template - POG Outer Gun

4
Master Doc No : GCL PTP 01 Revision : 2 22/03/2016
 GREENS COMBUSTION LIMITED
A31 Arena Business Centre
Holyrood Close
Poole
Dorset
BH17 7FJ
Tel: +44 (0)1202 607563
Company Registration Number: 5733303

Hydrotest Procedure

Certificate of Test Template - Fuel Gas Inner Gun

5
Master Doc No : GCL PTP 01 Revision : 2 22/03/2016