WORK PROCEDURE

PRODUCTION FACILITY
BANGKO CRESTAL 0-W1-57A

DOC NO:

Page 1 of 12

Rev : 1

HYDROTEST PROCEDURE
PRODUCTION FACILITY BANGKO CRESTAL 0-W1-57A
SR NO. 1259049 01 04770 000

SLO N
MARCH 2015

DESCRIPTION

Issued for Review

& Approval

BP3
DATE

RW
PREPARED BY

REVIEWED BY

CPI

APPROVED BY

WORK PROCEDURE

PQP NO:

PRODUCTION FACILITY
BANGKO CRESTAL 0-0-82A

SUMATRA LIGHT OPERATION

Page 2 of 12

Rev : 0

WORK PROCEDURE
PRODUCTION FACILITY
BANGKO CRESTAL 0-W1-57A

DOC NO:

Page 3 of 12

Rev : 1

GENERAL
1.1 Scope
This specification covers the requirements of Hydrostatic Test
1.2 Codes and Standards
This specification supplements or modifies the requirements of :
1.2.1.RW / CPI Related Specifications and Procedures
SP-PI-PP-001
General Piping System
SP-PI-PP-002
Piping Specification
PP-PI-PP-008
Piping Fabrication, Erection, Inspection, and Testing
Spec.
PP-SC-GG-001 Piping Pressure Test Procedure
SWP-IM-II-001 Rev.0 Standard Working Procedure Hydrostatic Test
for Piping
1.2.2.Relevant Code and Standard
ASME B31.4
1.3 Units
The metric unit shall be applied as the measurement system in documents
as the measurement system in documents and drawings.
1.4 Material, Tool and Equipment
a. Press.& Temp. Recorder ITT Barton, Range Press. 0 1000 psig, Range
Temp. 0 1000C,Range Press .0 2000 psig,Range Tem. 0 - 100 0C,dan
Range Press. 0 3000 Psig,Range Temp 0 - 300 0C.
b. Pressure Gauge
c. Temperature Gauge
d. High Pressure hose connection 6000 psig
e. Fill Pump Alcon, Flow Rate 300 L/m, max. press. 150 psig
f. Spiral Hose Discharge 1 , Suction 3
g. Tool & Connection
h. Blind Flange (see Table 2)
i. Skillet (see Table 3)
j. Non asbestos Gasket
k. High
Pressure
Pump
2
units,
flow
rate
30
L/m,
max.
press.3625.96psigdan 5076.34 psig

2. GENERAL REQUIREMENT
2.1

General
2.1.1

After completion of construction of each system, hydrostatic test shall

be carried out to ensure the tightness of the system.

2.1.2

For painted or insulated lines, the pipe joints that will be leak tested
shall not be painted or insulated or covered until the test has been
successfully completed.

2.1.3

Defects detected during hydrostatic testing, if any, shall be repaired in

accordance with Project Specification then re-testing shall be repeated.

2.1.4

If any repair or modification is made to the system after the hydrostatic

test, the affected piping shall be re-tested. However minor repairs or
modifications may be substituted by other examination methods such

WORK PROCEDURE
PRODUCTION FACILITY
BANGKO CRESTAL 0-0-82A

PQP NO:

Page 4 of 12

Rev : 0

as radiographic examination, liquid penetrant examination, etc. ,with

refers to RW / CPI approval
2.1.5

A flanged joint at equipment shall have blank inserted (skillet)during the

test. With specific RW / CPI approval, testing may be performed through
items of equipment when blinding requirements are excessive or where
the integrity of the equipment flanges, openings, etc. are required to be
pressure tested.

2.1.6

Instrumentation equipment shall not be hydrostatic tested during pipe

testing. This includes control valve, check &relief valves, orifices plates,
flow nozzles, displacement and turbine meters, level gauges,
transmitters, controllers, self contained pressure regulators, pressure
gauges, etc.For control valve may replace by pipe spool.

2.1.7

Hydrostatic testing against closed block valves is not permitted.

2.1.8

In every road intersection shall be provided a safety man during

hydrotest

2.2 Determination of Test Fluid

2.2.1
2.3.

Testingwill be use the natural water.

Determination of Test Pressure

2.3.1. Test pressure shall be refer to SWP-IM-II-001 Rev.0 Date 04

September 2006 Table of Test Pressure for Hydrostatic Test for Piping
(see Table 1)
Service
Produced Fluid

Fitting Rating

Test Pressure
(Psig)

#150

360

#300

925

#600

1850

#900

2775

3. EXECUTION OF TEST
3.1

General
3.1.1

Prior to test, piping system, associated equipment and accessories, are

to be checked against P&ID, isometric drawings and other relevant
specifications to ensure that all fittings, connections, slope of line etc.
are in accordance with design requirements.

3.1.2

Pressure and Temperature Recorders, Pressure and Temperature Gauges

shall be certified and validity of the calibration certificate is valid.

3.1.3

Install the permanent pipe guide and pipe anchor before hydro test.

3.1.4

The highest point of line is the expansion loop and vent valve will be
installed on this point

WORK PROCEDURE
PRODUCTION FACILITY
BANGKO CRESTAL 0-W1-57A

DOC NO:

3.1.5

Page 5 of 12

Rev : 1

At least two (2) pressure gauges shall be provided for each test:
a. One (1) pressure gauge shall be installed in the piping system
near of pressure sources.
b. One (1) pressure gauge shall be installed in the piping system at
the highest point.
c. Pressure gauge range shall be between 1.5 3.0 times the test
pressure.

3.1.6. For isolation at a flanged joint willuse the skillet with the minimum
thickness is .. mm.
3.1.7. For the blind flange thickness should refer to ASME B16.5 Ed. 2003
(see Table 2). No handmade blind is allowed.
3.1.8. Care shall be taken to avoid over loading any parts of the supporting
structures.
3.2

Hydrostatic Test
3.2.1

Procedure for hydrostatic test shall be as follows :

a. A preliminary hydrostatic test may be carried out when the pressure
has reached at normal operating pressure. At this point check for
major leaks and correct by tightening bolting and etc.If in thisstage
no leakage on the piping system and joint, Sub Cont will be inform to
RW and CPI to witness the hydro test and when the RW and CPI
arrived at site then the pressure test can be continued to next step.
b. The area shall be cordoned off during testing, and no person is
allowed in the area.
c. Close all of the drain, and open vent valve at height position
d. Fill the system with water until the water come out from the vent at
height point to free the air that trapped in the piping system
e. Initial pressurize for the piping system
pipegradually to 30% of the test pressure
f.

and

road

crossing

Holding for 10-minutes to allow equalization of pressure and the

piping strains.

g. Check all mechanical joint (flanges connection) using the leak test
solution and examination of full piping system under test shall be
carried out with particular attention to joints.
h. For piping system,increase pressure at each steps by 10%from100
% TP (test pressure)
i.

Holding for 10 minutes at each step to allow equalization of pressure

and the piping strains

j.

Increase pressure until the specified test pressure is reached.

k. If pressure increases by more than 5% during a test, the pressure

shall be reduced back to the test pressure.

WORK PROCEDURE
PRODUCTION FACILITY
BANGKO CRESTAL 0-0-82A

PQP NO:

l.

Page 6 of 12

Rev : 0

Test pressure must never allowedto exceed 1.6 times the design
pressure.

m. Minimum 4 (hour) for off plot

n. If pressure increase by more than 5% during a test
3.2.2

Where piping supportbe hanging on, it shall be fixed to avoid pipe

stress.

3.2.3

After completion of the test, the pressure shall be release by opening

the high level vent valve gradually so as not to endanger personnel
or damaged equipment.

3.2.4

The step release of the pressure for piping system shall be not more
than 10 % of the test pressure and especially to road crossing is
20%.

3.2.5

Before water in the piping system is drained, vent shall be opened

and shall be kept opened until water is fully drained from the piping
system.

3.2.6

Where rainfall during testing more than 2 hours and checking of

leaks in the piping system is impossible, the testing shall be
postponed until weatherclear, if the testing will be continue on
tomorrow then thepressure shall be reduced to 150 psig.

3.2.7

The water will be drain to temporary pit and then to canal around
the location.

4. ACCEPTANCE CRITERIA
4.1

Acceptance Criteria
No Leaks shall be observed as acceptance criteria for the piping system
except in the following cases:
a.Any leaks form gland packing such as valves at test pressure shall be
accepted subject to no leaks at normal operating pressure.

5. POST TEST
a. All equipment shall be completely drained after hydrostatic test. Draining
shall only be started after it is has been made sure that the vents are open
otherwise a partial vacuum or partial vacuum occurring.
b. The rate of drainage from equipment shall be controlled in respect to the
inflow of air to the equipment to prevent a vacuum or partial vacuum
occurring.
c. Spades, blinds and other equipment installed for testing are to be removed
on completion of testing.
d. Flushing shall take place before the piping system is reinstated.
e. Ring joints or gaskets must be renewed whenever a flanged joint is broken
after testing.

WORK PROCEDURE
PRODUCTION FACILITY
BANGKO CRESTAL 0-W1-57A

DOC NO:

f.

Page 7 of 12

Rev : 1

Where necessary valves are to be repacked with the appropriate grade of

material

g. All temporary removed piping parts for pressure testing are to be

reinstalled in the line after test to the satisfaction of RW / CPI.
h. Any temporary bolting which has been used is to be replaced to the
satisfaction of RW / CPI.

6. TEST RECORDS
a. Before commencing the hydrostatic test the following records shall be
completed and approved by RW / CPI and Subcont. These compiled record
will form the test pack.
b. Test packs will be compiled in two sections.
Section one will contain the information for the test and will contains the
following:

The isometric and P & ID drawing covering the test, marked up to

show test limits, vents, filling point, drain point, gauge locations etc.

Gauge log sheet showing gauge to be used and calibration status.

Punch List with before hydrotest and Posthydrotest items completed

and verified by RW / CPI and Subcont QC Inspector.

The test certificates which is used to sign off all documentation and
give the go ahead for the test and sign off for final acceptance of the
test.

WORK PROCEDURE
PRODUCTION FACILITY
BANGKO CRESTAL 0-0-82A

PQP NO:

Rev : 0

Page 8 of 12

7. HYDROSTATIC TEST DIAGRAM

D
e
s
TT
i
P
g
n
P MTP
r
e
s
s
u
r
e

90 %

90 %

80 %

80 %
70 %

70 %

60 %

60 %

50 %

50 %

J
Time

TTP
MTP
A
B
C
D
E
F
G
H
I
J
K

= Target Test Pressure

= Minimum Test Pressure
= 10 minutes Step Holding
= 10 minutes Step Holding
= 10 minutes Step Holding
= 10 minutes Step Holding
= 10 minutes Step Holding
= 240 minutes (4 hours) holding time
= 10 minutes release to step holding
= 10 minutes release to step holding
= 10 minutes release to Step holding
= 10 minutes release to step holding
= 10 minutes release to step holding

WORK PROCEDURE

DOC NO:

TABEL

PRODUCTION FACILITY
BANGKO CRESTAL 0-W1-57A
1. TEST PRESSURE FOR HYDROSTATIC TEST

Page 9 of 12

Rev : 1

WORK PROCEDURE

PQP NO:

PRODUCTION FACILITY
BANGKO CRESTAL 0-0-82A

TABEL 2. MINIMUM THICKNESS OF BLANK

Page 10 of 12

Rev : 0

WORK PROCEDURE

DOC NO:

PRODUCTION FACILITY
BANGKO CRESTAL 0-W1-57A

Page 11 of 12

Rev : 1

WORK PROCEDURE

PQP NO:

PRODUCTION FACILITY
BANGKO CRESTAL 0-0-82A

Page 12 of 12

Rev : 0