Tests
Destructive Tests Tensile, Impact, Bend,etc Non-destructive Tests Radiography, Ultrasonic, Dye-penetration, Magnetic Particle and leak testing like Hydrotest, Air Test, Helium Test etc..
Hydrotest-------why?
To ensure the integrity of the vessel and system operation under pressure.
Recommended For pressure vessel operating under pressure
Ensures the strength of weld joints & materials Ensures nozzle-flange joint
Test The strength of The pressure vessel at 1.5 times the designed pressure
Ensures safe & reliable performance during the operational life
Requirements Of Materials , Tools & Equipments
TEST MEDIUM
WATER WITH X PPM AS FREELY AVAILABLE (PARTS PER MILLION---CHLORINE IMPURITIES) X ---- 25 PPM OR LESS FOR SS VESSEL X ---- 80 PPM OR LESS FOR CS VESSEL CHLORINE PARTICLES AFFECT THE ANTICORROSIVE PROPERTIES OF VESSEL
REQUIREMENTS OF MATERIALS , TOOLS & EQUIPMENTS-(CONTD.)
WOODEN SADDLES (SOFT WOOD)
TO SUPPORT THE VESSEL & AVOID ANY DEFORMATION OR DENT AT CONTACT SURFACES CONTACT ANGLE---120 DEGREES
Vessel
1200
Wooden saddle
REQUIREMENTS OF MATERIALS , TOOLS & EQUIPMENTS-(CONTD.)
THERMOCOL SHEETS
20--30 MM THICKNESS USED AS A SOFT PACKING BETWEEN VESSEL & SADDLE
REQUIREMENTS OF MATERIALS , TOOLS & EQUIPMENTS-(CONTD.)
COVER FLANGES
NOZZLES WHICH HAVE ORIGINAL BLIND FLANGES TO BE BLANKED BY THOSE FLANGES OTHER NOZZLES TO BE BLANKED AS PER SPECIFIED DRAWING
REQUIREMENTS OF MATERIALS , TOOLS & EQUIPMENTS-(CONTD.)
HIGH TENSILE FASTNERS
TO BE USED AS SPECIFIED IN THE DRAWING
REQUIREMENTS OF MATERIALS , TOOLS & EQUIPMENTS-(CONTD.)
PIPE FITTING
HIGH PRESSURE (5000 TO 10000 PSI) REQUIRED SIZES (BSP,NPT) TO BE USED FOR INLET & OUTLET EQUIPMENT, VALVES, GAUGES CONNECTIONS
PUMP ACCESSORIES
SQUARE BAR
SHUT OFF VALVE COUPLER
FLOW DIRECTION
REQUIREMENTS OF MATERIALS , TOOLS & EQUIPMENTS-(CONTD.)
GASKETS
TO BE USED JOB GASKET UNLESS OTHERWISE SPECIFIED
REQUIREMENTS OF MATERIALS , TOOLS & EQUIPMENTS-(CONTD.)
PRESSURE GAUGES
USE MINIMUM TWO CALIBRATED PRESSURE GAUGES RANGE--- MIN. 1.5 TIMES THE TEST PRESSURE MAX. 4 TIMES THE TEST PRESSURE EXAMPLE: FOR TEST PRESSURE OF 60 KG/CM2 RANGE SHOULD BE 0-100 KG/CM2 (OR) 0-240 KG/CM2
PUMP ACCESSORIES
SQUARE BAR
SHUT OFF VALVE COUPLER
PRESSURE GAUGE
REQUIREMENTS OF MATERIALS , TOOLS & EQUIPMENTS-(CONTD.)
WATERPUMP & HOSE ASSEMBLIES
SUBMERSSIBLE OR ANY OTHER PUMP IS USED FOR FILLING THE VESSEL CONNECTED THROUGH FLEXIBLE HOSE PIPES TO TANK & VESSEL
REQUIREMENTS OF MATERIALS , TOOLS & EQUIPMENTS-(CONTD.)
HYDROTEST PUMP
REQUIRED FOR PRESSURIZING THE VESSEL TO THE TEST PRESSURE COMPRISES OF A HIGH PRESSURE PUMP B NON-RETURN VALVE C RELIEF VALVES D ATTACHMENTS LIKE HOSES, COUPLERS
PUMP ACCESSORIES
PRESSURE GAUGE SUBMISSILE PUMP
OUTLET HOSE
REQUIREMENTS OF MATERIALS , TOOLS & EQUIPMENTS-(CONTD.)
TORQUE WRENCH, GUN & STUD TENSIONER
ALL THE OPENINGS MUST BE CLOSED WITH BLIND FLANGES TIGHTENING TO BE ENSURED AT DESIRED TORQUE BY TORQUING WRENCH, TORQUING GUN OR STUD TENSIONER
TYPES OF HYDROTEST PUMP
HIGH DISCHARGE LOW PRESSURE
PRESSURE RANGE : UP TO 100 KG/SQ.CM(g) QTY. : 02
LOW DISCHARGE HIGH PRESSURE
PRESSURE RANGE : UP TO 400 KG/SQ.CM(g) QTY. : 06
HYDROTEST PUMP DETAILS
(HIGH PRESSURE, LOW DISCHARGE)
INLET HOSE TANK
TROLLEY OUTLET HOSE
SEQUENCE OF OPERATIONS
SADDLE ARRANGEMENT
REQUIRED NO. OF SADDLES AS MENTIONED ON DRG. TO BE PLACED AT THE DISTANCES PUT THERMOCOL SHEETS ON SADDLES BEFORE KEEPING THE VESSEL
SEQUENCE OF OPERATIONS (CONTD.)
ORIENTATION
LONGSEAM, CIRCSEAM REMAIN EXPOSED FOR VISUAL INSPECTION & NOT COVERED UNDER SADDLE INLET NOZZLE FOR WATER IS AT THE TOP & DRAIN OUT AT THE BOTTOM OF VESSEL
SEQUENCE OF OPERATIONS (CONTD.)
AIR LOCK REMOVAL
ADEQUATE ARRANGEMENT TO BE MADE FOR VENTING THE AIR, TRAPPED INSIDE THE VESSEL FOUR DIFFERENT CASES TO BE STUDIED
AIR LOCK REMOVAL
1 VESSEL IN HORIZONTAL, INCLINED AT 5 DEG.
AIR LOCK REMOVAL
2. WHEN INTERNALS LIKE TSRs PROVIDED INSIDE THE VESSEL
VESSEL SADDLE NOZZLE
D/E
AIR LOCK REMOVAL
3 FOR HORIZONTAL NOZZLE INSIDE THE D/E
AIR LOCK REMOVAL
TIGHTENING SEQUENCE
1 8 4 7 2 5 3
PRESSURE VALVE SETTING
VALVE SETTING FOR REQUIRED PRESSURE
GUIDELINES FOR HYDROTEST
Pump shaft should rotate clock wise looking from shaft side Ensure bypass line is open.
Ensure that bypass line should not connect to the pump suction line. (If discharge line is shut off, bypass water is diverted to the pump suction & as a result there is a rapid rise in temperature , which causes damage to piston plunger packing)
Connect pump outlet to vessel inlet through standard hose pipe, with proper valve connections, square bar, couplers, etc.
Ensure the pressure regulator valve,foot valve,should be in unloading position. Ensure the pressure gauge calibration validity
Ensure water tank or suction line should be free from any foreign material
OPERATING PROCEDURES
Start hydrotest pump Ensure 100% removal of entrapped air ( monitor the tank into which the outlet hose pipe is dipped. As soon as bubbles stop showing up, close outlet valve)
Monitor pressure gauge provided at outlet.
OPERATING PROCEDURES
(Contd.)
As soon as pressure reaches 50% of the test pressure , wait for 10 minutes Increase pressure by 10% in stages till the test pressure is achieved Observe pressure drop ( by marking line on pressure gauges)
Hold the hydrotest pressure for specific time as mentioned in drawing Carry out thorough visual inspection of all joints & connections (If any leakage is noticed, mark the point. The vessel is to be depressurized and then necessary repairs are to be carried out. Again the test procedure is to be repeated)
DOs & DONTs
Ensure pressure gauge readability Working, design & test pressure to be displayed near the vessel Ensure all gasket surfaces are free from dent & scratches before blanking
Do not apply paint, oil, grease on weld joints
Do not weld on job blind flange
THANK YOU
