CLIENT NAME: INDIAN OIL CORPORATION LTD.

(IOCL)

PROJECT TITLE: PARADIP REFINERY PROJECT (PRDP)

PROJECT LOCATION: PARADIP, ORISSA, INDIA

EMERSON PROCESS MANAGEMENT

VENDOR NAME:

CONTRACT No.: 65A10184

P.O. No.: 120_00060_1/201100741.Rev.0

REQ. ITEM No.: TAG No.:

DOCUMENT TITLE: Hydrostatic Test Procedure

VENDOR DOC. No.: 65A10184-10-1050-01-013 SUP REV.: 0

PARADIP PROJECT DOC No.: PDRP8005-8551-QA-PPU-1152

DOC TYPE CODE &

IOCL REV.:
SEQUENCE No.:

STATUS CODE: BY: DEPT: DATE:

Status codes for Vendor Drawings / Documents shall be as follows:

1 : Rejected (Revise & Resubmit)
2 : Comments as Noted (Revise & Resubmit Work may proceed subject to incorporation of comments.)
3 : Acceptable (Incorporate comments, if any. Resubmit as certified final, Work may proceed)
4 : No Comments (Acceptable Certified Final Issue, Do not Resubmit, Work may Proceed)
5 : Information Only (Accepted for Information Only, Work may Proceed, Do not Resubmit)

0 04/11/2013 Issued for Approval RC SS KS

Rev. Issue
Revision Description Prepared Checked Approved
No. Date
BOOT OPERATOR:

IOT Utkal Energy Services Ltd.

EPC CONTRACTOR :

IOT Infrastructure & Energy Services Ltd.

ENGINEERING ASSOCIATE:

IOT Design & Engineering Ltd. New Delhi

 PT.TRANSALI NDO EKA PERSADA
Emerson Process Management DOC. No. : 460-HTP-ENG-001
FOR Hydrostatic Procedure REV : 1
PARADIP REFINERY PROJECT DATE : 05 January 2012
(PRDP)
For
Page : 2 of 5
Process Piping

1. SCOPE:

1.1 This procedure covers the details of hydrostatic testing and documentation to follow the
requirements of ASME B31.3, 2006 Edition & ASME Section VI I I Div. 1, 2010 edition Para. UG-
99b.
1.2 This procedure describes the method to be followed for performing hydrostatic test for the
pressure Piping fabricated by PT. TRANSALI NDO EKA PERSADA for Emerson Process
Management/ I OT DESI GN & ENGI NEERI NG LI MI TED / I OT I NFRASTRUCTURE & ENERGY
SERVI CES LI MI TED / I ndian Oil Corporation LTD.
REF.: ASME B31.3, 2006 Edition, Process Piping
Client Specification: PDRP8005-8551-PS-PPU-1054 R.01 Specification for Design basis
PDRP8005-8230-SP-000-0004 Rev. 01 Specification for Piping Class

2. APPLI ED I TEM:
This procedure to be applied to following item:
- Main Line Metering and interconnecting Pipe
- Drain Line Piping Metering and interconnecting Pipe

3. PREPARATI ON OF TESTI NG
3.1 The following items shall be done before test:
- Non-destructive examination shall be verified to confirm acceptance as per Code and
specification.
- Dimensional inspection.
- Full visual inspection for all welds.
- Completeness of all fabrication
- Completion of Post Weld Heat Treatment & NDT (where applicable)
- Final acceptance of NDE shall be after PWHT (where PWHT is applicable)
3.2 Painting shall not be performed before test.
3.3 I nside and outside of pressure Piping shall be free from all dirt, debris, weld slag and spatter,
oil, rust, scale, paint and all other foreign matter.
3.4 Vent and drain are to be provided for the system before commence of hydrostatic and leak
test.
3.5 All temporary fitting, blind flange shall be suitable for the test procedure and should not have
defect that may cause failure during hydrostatic test.
3.6 Fresh water/ potable water shall be used as test medium at ambient temperature.
3.7 For Carbon steel Piping, chloride content shall not exceed 100 ppm, whilst for Stainless steel,
chloride content shall not exceed 30 ppm, Water sample test report shall be available during
hydro testing

2
 PT.TRANSALI NDO EKA PERSADA
Emerson Process Management DOC. No. : 460-HTP-ENG-001
FOR Hydrostatic Procedure REV : 1
PARADIP REFINERY PROJECT DATE : 05 January 2012
(PRDP)
For
Page : 3 of 5
Process Piping

3.8 Flanges blinded for hydro testing shall be provided with the temporary gaskets installed.
During the test, please ensure that all valves shall not include on hydrostatic test.
3.9 Before hydro testing, the test package shall be prepared and submitted for approval. The P &
I D shall be marked with test limits, material traceability & certificates, weld traceability, NDT
records and reports to include into the test package.

4. SAFETY
Safety shall be strictly observed all time during hydrostatic test. The area shall be cordoned off with
signed boards or barrier, only authorized person is allowed in the test area, all bolting must be
check before pressurize.
Protection shall be applied as necessary to electric motors, junction boxes and instruments in the
vicinity of flushing. When the Hydro testing the piping onto the Skid, make sure that the piping are
tightening properly with it support. During pressurizing, ensure that the areas are safe for
inspection.
Vents are to keep opened to prevent air locking during commencement of pressurizing. Vendor
shall not include all valves in hydrostatic test. I n case any leak during pressurize, test pressure shall
be reduced as minimum pressure when tightening a leaking flange.

5. GAUGE AND RECORDER

5.1 A minimum of 2 (two) pressure gauges shall be used for pressure tests. The full scale of the
other pressure gauge shall be 1½ to 4 times of test pressure.
5.2 The test pump and the line to be tested shall be provided with the separate indicating test
gauges. I n case of testing between a high and low point of the module, gauges shall be placed
one at the top and one at the bottom to measure the pressured drop.
5.3 Calibration
The pressure gauge shall be calibrated using deadweight tester, and still valid before used.
Any gauges showing incorrect zero error more than + 1% of full-scale range shall not be used
without repair and recalibration. The temperature can be recorded by manual record
5.4 Calibration frequency of pressure gauge shall be 12 months and shall be externally calibrated
5.5 Calibrated chart recorder shall be used and shall be frequency calibrated for 12 month
externally

6. TESTI NG

6.1. Test Pressure for Process Piping

6.1.1. The QC I nspector shall liaison with Client Representative for witnessing the test in advance.
6.1.2. Test water shall be clean and free from mineral and suspended matter. Prior testing, all
internal removable part (if any) shall be removed and reinstall after testing or drying. The

3
 PT.TRANSALI NDO EKA PERSADA
Emerson Process Management DOC. No. : 460-HTP-ENG-001
FOR Hydrostatic Procedure REV : 1
PARADIP REFINERY PROJECT DATE : 05 January 2012
(PRDP)
For
Page : 4 of 5
Process Piping

test manifold shall be add during hydrostatic pipe spool.

6.1.3. The pressure shall be gradually increased up to a value of 25% of test pressure.
Thereafter the pressure shall be increased in stages of 75% up to MAWP/ Design Pressure.
When the gradually pressure is reached, hold the pressure for at least 10 minutes.
Then if there is no anomaly, the pressure shall be increased gradually until it reached the
test pressure.
The minimum test pressure shall be 1.5 times Design Pressure for piping under ASME
B31.3, 2006 Edition.
When the test pressure is reached, hold for 1 (one) hour as minimum and thoroughly check
piping for leaks and distortion.
After the minimum holding time is achieved and test is satisfactory, release the pressure
down to Design Pressure.
6.1.4. QC I nspector should check all the weld and connections for any leaks, sweating, etc.
6.1.5. The minimum test pressure shall be accordance with the test pressure stated in Table1
6.1.6. QC I nspector shall record the pressure (on gauge and Recorder), time and temperature
during the test at least every 15 minutes interval.
6.1.7. After all parties are satisfied, the pressure shall be gradually decreased and the water
thoroughly drained and then dried.

7. DEFECT AND REPAI RS

Any leaks or defect seen as results of hydrostatic test is to be repaired subjected to specified NDT
and re-hydrostatic test.

8. DRAI NI NG/ DRYI NG

8.1 After the hydrostatic test, the pressure shall be release in a manner and at rate so as not to
endanger personnel or damage equipment.
8.2 All vents shall be opened before the system is drained and shall remain opened during
draining to prevent pulling a vacuum on the system.
8.3 Piping line shall be completely drained and dried. After blow dray, piping internal shall be
applied with corrosion inhibitor (Rust Veto 377)

9. DOCUMENTATI ON

The pressure recorder chart, report and manual hydrostatic test record prepared by QC I nspector
shall be signed by all parties after completion of the Hydrostatic test. (See attachment for Report)
The documents stated above and calibration certificate of all equipments used in hydrostatic test
shall become part of the Manufacturer’s Data Report.

10. ATTACHMENT : Sample Test Report

1

4
 PT.TRANSALI NDO EKA PERSADA
Emerson Process Management DOC. No. : 460-HTP-ENG-001
FOR Hydrostatic Procedure REV : 1
PARADIP REFINERY PROJECT DATE : 05 January 2012
(PRDP)
For
Page : 5 of 5
Process Piping

Table 1:

Design MAWP Test Pressure I nspection

Holding
No Description Pressure Pressure Kg/ cm^ 2.g Kg/ cm^ 2.g
Time
Kg/ cm^ 2.g Kg/ cm^ 2.g (PSI G) (PSI G)
(Hour)
(PSI G) (PSI G) ( B~ C) ( D~ E)
LPG metering Skid for
Main Line Metering, 35.33 35.33 52.99 35.33
1 Drain Line and 1
interconnecting Pipe (502.53) (502.53) (753.72) (502.53)
(Class B1GP-N1)
Propylene metering
Skid for Main Line 35 35 52.5 35
2 Metering, Drain Line 1
and interconnecting (497.83) (497.83) (746.75) (497.83)
Pipe (Class B1GP-N1)

Reinforcing pad will be air leak tested with soap suds at 50 Psig.(if Any)

PRESSURE (PSIG)

B C
Test Press.

Design Press
D E
75%

50%

25%

F TIME
A (MIN)
15 Min.
HOLDING TIME Inspection
10 Min. 10 Min. 1 hour

10 Min.

5
 PT. TRANSALINDO EKA PERSADA

CLIENT :
PROJECT :
JOB No :

HYDROTEST PRESSURE AND TEMPERATURE READING

for :

PRESSURE ( PSIG ) PRESSURE ( PSIG ) PRESSURE ( PSIG ) TEMPERATURE ( °C ) AMBIENT

TIME ( MINUTES ) ON PRESSURE ON PRESSURE ON PRESSURE ON TEMPERATURE TEMPERATURE (
RECORDER GAUGE GAUGE INDICATOR °C )
START TEST

HOLDING TIME

MAWP

EQUIPMENT :
PRESSURE RECORDER : PR - RANGE 0 ~ PSIG
PRESSURE GAUGE :PG - RANGE 0 ~ PSIG
PG - RANGE 0 ~ PSIG
0
TG - RANGE 0 ~ C

TEST PRESSURE : PSIG

MAWP : PSIG
POSITION :

RESULT OF TEST : ACCEPTED NO LEAKAGE NOR VISIBLE DISTORTION

DATE :

WI TNESSED BY:

PT. TRANSALI NDO