1.0 SCOPE
This procedure is applied to the hydrostatic test of Tube Bundle A and B supplied for FLSmidth, in accordance with the requirement of AS 4037 – 1999, and the requirement of the Company Specification, upon completion of fabrication and accepted all NDT requirements.
2.0 REFERENCE
2.1 AS 4037 – 1999, Pressure equipment – Examination and Testing
2.2 AS 1210 – 1997, Pressure Vessel
2.3 Drawing 0812-0018 – Tube Bundle A
2.4 Drawing 0812-0024 – Tube Bundle B
2.4 Inspection and Test Plan
3.0 TEST EQUIPMENT
3.1 Pressure gauge
3.2 Air Vent valve
3.3 Drain valve
3.4 Pump
3.5 Pressure Recorder
4.0 RESPONSIBILITIES
4.1 The production supervisor is responsible to ensuring that hydrostatic testing is conducted in accordance with relevant job instruction.
4.2 The QC inspector shall issue completed “Hydrostatic Test Instruction” sheet as per attachment to Production Supervisor or the personnel authorized by the production supervisor. The hydrostatic Test Instruction will include, as minimum :
4.2.1 Job Number and Identification of the component or assembly to be tested.
4.2.2 Pressure gauge range
4.2.3 Test pressure
4.2.4 Holding time
4.2.5 Test media
4.2.6 Test position
4.3 The QC Inspector is responsible for compilation of the reports and records for timely submission to the owner representative, third party inspector which witness the hydrostatic testing for approval and signature
5.0 PROCEDURE
5.1 Prior to commencement of hydrostatic test the Tube Bundle shall be thoroughly cleaned internally and externally of all construction debris, weld spatter and oil or grease contamination.
5.2 Before applying the pressure, the equipment being tested shall be inspected or examined to see that it is tight, clean, free from debris, scales, grease, etc. and that all low pressure filling lines.
5.3 Hydrostatic test shall be conducted on the Tube Bundle after :
5.3.1 All fabrications have been completed. All welding on or to the tube bundle and any grinding shall completed before hydrostatic test performed.
5.3.2 All non-destructive examination have been performed, except those required after the testing.
5.4 All Tube Bundle shall be subjected to hydrostatic test pressure which at every point is at 1050 Kpa.
5.5 The information regarding the hydrostatic test pressure shall based on “Hydrostatic Test Instruction” as attached.
5.6 The test shall be held at minimum holding time of 30 (thirty) minutes.
5.7 Upon the hydrotest pressure is reached, the pump shall immediately dismantle from the hydro system.
5.8 Any leaks that occur or are found during hydrostatic test, shall be corrected or repaired in according with the rules of code and the bundle shall retested.
5.9 Following the application of hydrostatic test pressure, examination for leakage shall be made of all joint.
5.10 Pressure gauges to be used in hydrostatic testing shall be calibrated and not more than 4 times of the test pressure.
5.11 An indicating pressure gauge visible to the operator to control the pressure applied shall be connected to the pressure parts directly.
5.12 A vent shall be provided and installed at the high point of the tube bundle in position in which it is to be tested to purge possible air pockets while the bundle is being filled.
5.13 Closed N3; N5 of all tube bundle ; V2 until V5; V6; V8; V9 at tube bundle 4, Opened V1 at tube bundle 1 for inlet.
5.14 Fresh Water inlet at Nozzle N1 tube bundle 1, from N2 tube bundle 1 fresh water flowing to N1 tube bundle 2, from N2 tube bundle 2 flowing to N1 tube bundle 3, from N2 tube bundle flowing to N1 tube bundle 4.
5.15 Waiting until fresh water fill full at all tube bundle (waiting until water through out from N4.
5.16 Make tight N4 and than open air vent valve V7 at tube bundle 4, make sure that there is no air trapped at tube budle.
5.17 Air vent valve V7 closed, Pressure gauge valve V6 opened and increasing Pressure as per point 5.4 and holding time as per point 5.6.
5.18 After completion of hydrostatic testing, the water used for hydrostatic test shall be drained, Open Drain Shock Pressure valve V8 until Pressure Dropped to 50% from Test Pressure and than closed it, Open Drain Valve V2-V5 at nozzle N5 all of tube bundle.
5.19 After drained, for drying process shall be blowed with air compressor from N4 of all tube bundle until make sure that all tube bundle dried.
6.0 SAFETY
6.1 Area of Hydrostatic test have to give safety line, no worker passed through at area during Hydrostatic test about 2 meter from safety line except Hydro test operator.
6.2 At Test Pressure holding time could not Inspected, Only at Design Pressure Holding time could be Inspected, Inspection at pressure increased done by internal (Lintech) and Inspection at pressure released done by Owner / third party ( see Hydro test chart ).
7.0 REPORT
7.1 During hydrostatic test, QC inspector or personnel authorized by production supervisor shall be monitoring the pressure condition, and shall be recorded.
7.2 After completion of hydrostatic test, QC inspector shall be responsible for compilation of the test pressure records for timely submission to owner representative or third party which witness the hydrostatic testing for approval and signature.
7.3 The hydrostatic test records shall be compiled on the Manufacturer Data Book.
Selengkapnya..
Persiapan hydrotest untuk hari kamis,17 September 2009 telah dilakukan. salah satunya adalah persiapan pengetesan kadar asam-basa pada air yang dipakai untuk test. untuk kadar air yang terlalu asam maka tidak dieprbolehkan karena diperkirakan bila pembilasan tidak bersih akan menyebabkan proses korosi pada besi yang lebih cepat.untuk testnya sendiri menggunakan kertas lakmus berwarna,karena ilmu kimia sudah lupa maka aku search lagi melalui internet dan dari wikipedia mendapat keterangan warna seperti diatas :) (tapi tetep lumayan gak ngerti juga) maklum bukan dari background kimia ..
