Hydro test Doc. No.

: PLP-HTF-P001
and
Flushing procedure Rev. No. : 0

TITLE:

Hydro test
and
Flushing procedure

DISCIPLINE : PIPING

DOCUMENT NO. : PLP-HTF-P001

PROJECT NAME : PIPING FOR GO3 to VDU

JOB NO. : 62XX-01

OWNER : THE BANKCHAK PETROLEUM PUBLIC COMPANY LIMITED

0 24-8-2019 ISSUED FOR Mr.Ramin Mr.Jakkrid Mr.Chatchawan

REVIEW/COMMENT

REV. DATE. DESCRIPTION PREPARED CHECKED REVIEWED APPROVED

BY BY BY BY

REV. PREPARATION PREPARATION CHACK REVIEW APPROVAL

DEPT

Mr.Ramin
0 QA / QC

24-8-2019

PILIN PROJECT CO., LTD. Page 1

 Hydro test Doc. No. : PLP-HTF-P001
and
Flushing procedure Rev. No. : 0

TABLE OF CONTENTS

SECTION DESCRIPTION PAGE

1.0 PURPOSE 3

2.0 SCOPE 3

3.0 REFERENCES 3

4.0 DEFINITIONS 3

5.0 PROCEDURE 3

5.1 GENERAL 3

5.2 TEST EQUIPMENT 4

5.3 FLUSHING PROCEDURE 4

5.4 HYDROSTATIC TEST PROCEDURE 6

5.5 RECTIFICATION OF LEAK 8

5.6 DRAINING AND DRYING 8

6.0 SPECIAL REQUIREMENTS 8

7.0 RECORDS 9

FIGURE I HYDROTEST SCHEMATIC DIAGRAM 10

FIGURE II HYDROTEST FLOW CHART 11

APPENDICES

APPENDIX I INSPECTION REQUISITION

APPENDIX II VISUAL INSPECTION REPORT

APPENDIX III FLUSHING REPORT

APPENDIX lV PRESSURE TEST REPORT

PILIN PROJECT CO., LTD. Page 2

 Hydro test Doc. No. : PLP-HTF-P001
and
Flushing procedure Rev. No. : 0

1.0 PURPOSE
This procedure outlines the flushing process and hydro testing requirements, to ensure that
the piping system are clean from debris or unwanted items and the integrity of the system is
proven.

2.0 SCOPE
This procedure is applicable for flushing and hydro testing of prefabricated piping spools and
completed piping in a system.

3.0 REFERENCES
ANSI B31.3 – Chemical Plant and Petroleum Refinery Piping
ANSI B31.4 – Liquid Petroleum Transportation Piping System

4.0 DEFINITIONS
Nil

5.0 PROCEDURE
5.1 General
5.1.1 Each hydro test procedure shall consist of the following :
a) Hydrostatic test flow sheet.
b) Testing details indicating the test pressure, testing medium and other test related details
i.e. filling points, vent, drain points and test limit points.
c) A copy of the hydro test flow chart (Refer to figure II) shall be extended to Client. This shall
be done at least two (2) days advance notice shall be given prior to the scheduled test date.
5.1.2 Hydro testing shall only be performed after the following activities are completed i.e.
a) Visual Inspection.
b) Post Weld Heat Treatment (PWHT).
c) NDT
5.1.3 The pipe support shall be completely installed.
5.1.4 All piping joints and surfaces shall be dry before the commencement of the hydro test.
5.1.5 All hydro testing activities shall be inspected by PILIN Site Supervisor and shall also be
witnessed by PILIN QC inspector and Client’s Representative.

PILIN PROJECT CO., LTD. Page 3

 Hydro test Doc. No. : PLP-HTF-P001
and
Flushing procedure Rev. No. : 0

5.2 Test Equipment

5.2.1 a) Hydro test Pump f) Pressure Relief Valve

b) Pressure Gauges g) Temperature Recorder

c) Gate Valves h) Vent Release Valve

d) Tube and Fittings i) Water Tank

e) Pressure recorder j) High Pressure Hose and Fitting.

5.2.2 The pressure recorder will be calibrated, and checked for accuracy prior to test. The calibration

certificate for the pressure test recorder shall be submitted to the QC inspector together with

the test report upon completion of the hydro test.

5.2.3 The acceptable accuracy for the pressure recorder shall be ± 0.5% over the full range.

5.2.4 The range of the pressure gauge and pressure recorder to be used shall not be greater than four

times the test pressure.

5.2.5 Pressure release setting on the pressure relief valve shall be adjusted 10% higher than the

system testing pressure.

5.3 Flushing Procedure

5.3.1 All pipe work should be cleaned internally before testing. All valves, gasket, flanges, bolting,

fitting and other components shall be of the required specifications. All joints shall be exposed

for physical inspection during the duration of the test.

5.3.2 All high points shall be provided with a valve which shall ensure all air removed from the line,

the low points shall be also fitted with a valve to facilities the draining of the line.

5.3.3 Prior to hydro test, all lines shall be flushed with clean water, from the high to the low point.

Prior to flushing, the pipe internal shall be visually inspected where practical to ensure that no

foreign materials which cannot be removed by flushing are left in the line. All ball valves shall

PILIN PROJECT CO., LTD. Page 4

 Hydro test Doc. No. : PLP-HTF-P001
and
Flushing procedure Rev. No. : 0

be in the open position and non-return valves defeated, all instrument accessories shall be

removed, likewise relief valves, and thermo well connections.

5.3.4 All block valves to instrument impulse line connections shall be closed prior to flushing.

5.3.5 Prior to flushing, all instruments exposed to damage by debris, i.e. control valves, orifice fittings,

PD meters, capacitance probes, etc. shall be removed and dummy spools to be installed until

the duration of the test is completed. Spools used shall be ANSI flanged and pipe of correct

schedule, the weld will be inspected for safety purposes.

5.3.6 At least one (1) day before flushing commences, PILIN Site Supervisor shall inform the QC

inspector of the line inspection. All details for lines inspections are to be highlight in the

inspection Requisition Form (Appendix I).

5.3.7 Visual inspection shall be conducted by PILIN Site Supervisor, and to be witnessed by the QC

inspector to ensure the system installation is completed. The Visual Inspection Report shall be

completed upon satisfactory inspection of the line. Refer to Appendix II.

5.3.8 Flushing shall be done in the presence of Site Supervisor and to be witnessed by QC inspector

and Client’s Representative.

5.3.9 Piping system shall be flushed with clean water with a velocity of 3 m/s for pipe diameter 2

inches and below, and lower velocity for pipe diameter greater than 2 inches.

5.3.10 After flushing, checks shall be carried out to ensure all non-return valves are still defeated.

Swing checks valves are opened and set all ball valve at half open position.

5.3.11 The Flushing Report (Appendix III) shall be prepared by PILIN QC inspector upon completion

of the flushing.

PILIN PROJECT CO., LTD. Page 5

 Hydro test Doc. No. : PLP-HTF-P001
and
Flushing procedure Rev. No. : 0

5.4 Hydrostatic Test Procedure

5.4.1 All piping system shall be tested in accordance with Client’s specifications and the latest edition

of ANSI B31.3 Refer to figure I for the Hydro test Schematic Diagram.

5.4.2 Prior to commencement of hydro testing, PILIN Site Supervisor shall submit an isometric

drawing of the system to be tested, to the QC inspector for review.

5.4.3 The piping system shall be subdivided into sub-systems for testing where necessary. The hydro

test flow sheet shall indicate the test limit points i.e. the location of block valves, and blind

flanges for isolating the sub-systems.

5.4.4 Blind flanges shall be installed for equipment excluded from the hydro test. Blind flanges may

be installed with temporary tubing connection where necessary to by-pass the equipment.

The blind flanges shall be installed to the following equipment i.e. pumps, turbines, blowers

and compressors.

5.4.5 Pressure gauges, pressure transmitters and flow meter, along with the secondary piping

connection the instruments to the block valve at the equipment or primary piping shall be

excluded from the hydrostatic test.

5.4.6 Fresh water shall be used with the high volume low pressure pump to fill the system. The filling

points shall be at lowest point in the system.To prevent trapping of air or vapors in the system,

vents shall be located at the highest point.

5.4.7 For stainless steel, the chloride content of the water shall no exceed 200 ppm.

5.4.8 All vent valves and other high point connections which serve as vents shall be opened during

filling and closed only when water starts to overflow.

5.4.9 After filling, the pumping system shall be shut off and disconnected from the system.

5.4.10 System under hydro test shall be adequately supported to withstand the test pressure and

temporary supports shall be installed where necessary.

PILIN PROJECT CO., LTD. Page 6

 Hydro test Doc. No. : PLP-HTF-P001
and
Flushing procedure Rev. No. : 0

5.4.11 External surfaces of the piping system shall remain dry during inspection whilst checking for

leak.

5.4.12 The pressure shall be raised gradually, with stops to allow the pressure to stabilize. The

pressurizing of the system shall continue until the required pressure is reached.

5.4.13 Caution shall be taken during pressurization to avoid surging effects. Pressurization and

depressurization will be done gradually (25% of the test pressure requirement per 15 min) at

all times.

5.4.14 The rate of pressurization shall be reduced when approximately 80 percent of the specified

test pressure has been attained.

5.4.15 The pump shall be shut off once the required test pressure is achieved.

5.4.16 Whilst holding the system at test pressure, the system pressure shall be released if it exceeds

the test pressure due to temperature variation. This shall be done by opening the bleed valve

to release the excess pressure in order to maintain the test pressure.

5.4.17 Open the block valve leading to the pressure recorder after the system pressure is stabilized.

5.4.18 Sign the temperature chart and pressure chart before and after hydro test by the QC inspector.

a) The hydro test time shall commence when PILIN and Client Representative agreed the

system pressure is stable. The duration of the test shall be one (1) hour for flanges rated at

below 300 lbs.

b) The test duration for flanges rated at 300 lbs and above, the test duration shall be two (2)

hours.

5.4.19 The pressure test Report (Appendix IV) shall be prepared by PILIN QC inspector upon

completion of the test.

PILIN PROJECT CO., LTD. Page 7

 Hydro test Doc. No. : PLP-HTF-P001
and
Flushing procedure Rev. No. : 0

5.5 Rectification of leak

Any leak in flange connections, bolting shall be carefully and gradually tightened in proper

sequence to prevent uneven tightening. If leak occurred in the weld joint the water shall be drained

and the leak shall be repaired as per approved welding procedure.

5.6 Draining and Drying

5.6.1 After hydrostatic testing of the system is completed satisfactorily, care should be taken during

depressurization so as to avoid any surging effects. Tested system shall be completely drained

and blown dry.

5.6.2 After the system has been depressurized, all vents shall be opened before the system is drained

and shall remain opened during draining to prevent vacuum effect in the system.

5.6.3 The system shall be completely drained. Compressed air shall be used to blow dry the system.

5.6.4 All spades, blind flanges, etc installed for testing shall be removed and pressure relieving

devices replaced.

5.6.5 Upon completion of test, the system shall be reinstated to its designed conditions.

6.0 SPECIAL REQUIREMENTS

6.1 Safety Precautions

6.1.1 During pressure build-up, shall take suitable precaution to prevent building up of excessive

pressure, the pressure pump shall be monitored at all times.

6.1.2 Pressurization of the system shall be done in an increment of 25% of the required test pressure

per 15 min. to avoid over pressurization of the system and to allow stabilization of the test

medium in the system.

PILIN PROJECT CO., LTD. Page 8

 Hydro test Doc. No. : PLP-HTF-P001
and
Flushing procedure Rev. No. : 0

6.1.3 The test area shall be cordoned off and provided with warning sign boards “CAUTION!

Hydrostatic Test in Progress”, also warning signs shall indicate the date and duration of test,

and the test pressure.

6.1.4 PIPIN shall ensure that the correct pressure rating for all ancillary fittings used (i.e. temporary

piping, hoses, blanks, etc) can withstand the flushing and pressure test.

6.1.5 All system testing will be carried out in accordance with the applicable codes, and client’s

specification requirements.

6.1.6 No tightening of bolts/nuts to be carried out during the stabilization of the required pressure in

the system.

7.0 RECORDS

Title Responsibility Retention Period

7.1 Visual Inspection QC Inspector Until completion

Report of Project

7.2 Flushing QC Inspector At least one year after

Report completion
of project

7.3 Pressure Test QC Inspector At least one year after

Report completion
of project

PILIN PROJECT CO., LTD. Page 9

 Hydro test Doc. No. : PLP-HTF-P001
and
Flushing procedure Rev. No. : 0

FIGURE I – HYDROTEST SCHEMATIC DIAGRAM

NOTE : CHECK VALVE STRAINNERS RELIEF VALVE

HAVE BEENS DISMANTLED AND SMALL/SHORT SPOOLS
SHALL BE BOLTED TOGETHER FOR THE HYDROTEST
THERE SHALL BE INSTALLED UPON COMPLETION
HYDROTESTING

PILIN PROJECT CO., LTD. Page 10

 Hydro test Doc. No. : PLP-HTF-P001
and
Flushing procedure Rev. No. : 0

PILIN PROJECT CO., LTD. Page 11

 Hydro test Doc. No. : PLP-HTF-P001
and
Flushing procedure Rev. No. : 0

APPENDICES

PILIN PROJECT CO., LTD. Page 12

 QCP-10 Rev-0
Appendix I
TO :____________________________

REQ. NO. :

INSPECTION REQUISITION

SYSTEM FOR INSPECTION :

PROJECT/CONTRACT NO. :
ISO DRAWING REFERENCE :

DETAILS OF INSPECTION REQUIRED :

REQUEST BY : LOCATION :

DATE : DATE FOR INSPECTION :

TIME : TIME FOR INSPECTION :

 QCP-10 Rev-0
Appendix II

REQ. NO. :

VISUAL INSPECTION REPORT

PROJECT :

SYSTEM TESTED :

DETAILS OF PIPEWORK LINE NO :

TYPE OF TEST TO BE CARRIED OUT AFTER

VISUAL INSPECTION : ………………………………………………………………

………………………………………………………………

ACCEPTED REJECTED

REMARK :

CHECKED BY: ACCEPTED BY : ACCEPTED BY :

SUPERVISOR QC INSPECTOR CLIENT'S REPRESENTATIVE

NAME
DATE
 QCP-10 Rev-0
Appendix III

PACKAGE NO. /
REPORT NO.

FLUSHING REPORT

PROJECT

CLIENT

PROJECT NO.
SYSTEM FLUSHED

LINE / SPOOL NUMBERS

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

REMARKS :

TESTED BY : ACCEPTED BY : ACCEPTED BY :

SITE PERSONNEL QC INSPECTOR CLIENT'S REPRESENTATIVE

NAME

DATE
 QCP-10 Rev-0
Appendix IV
PRESSURE TEST REPORT

PROJECT NO : REPORT NO :

PROJECT TITLE : WORK LOCATION :

CLIENT : ITEM TESTED :

TYPE OF PRESSURE TEST : DATE OF TEST :

Test Requirement Test Conditions

Test Pressure : Pressure Gauge S/No. :

Holding Time : Chart Recorder S/No. :

Piping Class : Test Medium :

Applicable Code : Pressure Gauge Range :

Start Finish

Flushing Requirements Gauge Pressure :

( ) Liquid ( ) Air Ambient Temperature :

Others : Time :

Condition :

Date :

Item / Line No. Tested Results / Remarks

The above mentioned items / lines were listed and accepted / rejected by :

QC Inspector Client's Representative