Doc Ref: QCP-10

q~ QUALITY CONTROL
PROCEDURE
Date: 1st January 2009
Revision No : 0
Kencana Infrastructurc
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\CONTROLL~D COpy NO. I

HYDROTEST AND FLUSHING

PROCEDURE

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KENCANA INFRASTRUCTURE SDN BHD

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 Doc Ref : QCP-10
HYDROTEST AND FLUSHING Date : 1st January 2009
PROCEDURE Revision No : 0
Page 1 of 9

TABLE OF CONTENTS

SECTION DESCRIPTION PAGE

1.0 PURPOSE 2
2.0 SCOPE 2
3.0 REFERENCES 2
4.0 DEFINITIONS 2
5.0 PROCEDURE 2
5.1 GENERAL 2-3
5.2 TEST EQUIPMENT 3
5.3 FLUSHING PROCEDURE 3-4
5.4 HYDROSTATIC TEST PROCEDURE 4-6
5.5 RECTIFICATION OF LEAK 6
5.6 DRAINING AND DRYING 6-7
6.0 SPECIAL REQUIREMENTS 7

7.0 RECORDS 7

FIGURE I HYDROTEST SCHEMATIC DIAGRAM 8

FIGURE II HYDROTEST FLOW CHART 9

APPENDICES
APPENDIX I INSPECTION REQUISITION
APPENDIX II VISUAL INSPECTION REPORT
APPENDIX III FLUSHING REPORT
APPENDIX lV PRESSURE TEST REPORT
 Doc Ref : QCP-10
HYDROTEST AND FLUSHING Date : 1st January 2009
PROCEDURE Revision No : 0
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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
 Doc Ref : QCP-10
HYDROTEST AND FLUSHING Date : 1st January 2009
PROCEDURE Revision No : 0
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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 Kencana

Infrastructure Site Supervisor and shall also be witnessed by
Kencana Infrastructure QC inspector and Client’s Representative.

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
 Doc Ref : QCP-10
HYDROTEST AND FLUSHING Date : 1st January 2009
PROCEDURE Revision No : 0
Page 4 of 9

be removed by flushing are left in the line. All ball valves shall 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, Kencana

Infrastructure 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 Kencana Infrastructure

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 Kencana

Infrastructure QC inspector upon completion of the flushing.

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, Kencana Infrastructure

Site Supervisor shall submit an isometric drawing of the system to
be tested, to the QC inspector for review.
 Doc Ref : QCP-10
HYDROTEST AND FLUSHING Date : 1st January 2009
PROCEDURE Revision No : 0
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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.

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.
 Doc Ref : QCP-10
HYDROTEST AND FLUSHING Date : 1st January 2009
PROCEDURE Revision No : 0
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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 Kencana

Infrastructure 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

Kencana Infrastructure QC inspector upon completion of the
test.

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.
 Doc Ref : QCP-10
HYDROTEST AND FLUSHING Date : 1st January 2009
PROCEDURE Revision No : 0
Page 7 of 9

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.

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 Kencana Infrastructure 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
 Doc Ref : QCP-10
HYDROTEST AND FLUSHING Date : 1st January 2009
PROCEDURE Revision No : 0
Page 8 of 9

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
 Doc Ref : QCP-10
HYDROTEST AND FLUSHING Date : 1st January 2009
PROCEDURE Revision No : 0
Page 9 of 9

P HYDROSTATIC PUMP
FP FILLING POINT
TB TEMPORARY BLIND
PG PRESSURE GAUGE
PR PRESSURE RECORDER
TR TEMPERATURE RECORDER
DP DRAIN POINT
V VENT POINT
ò SPADE
TC TUBING CONNECTION

FIGURE II – HYDROTEST FLOW CHART

APPENDICES
 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