PROVISION OIL OFFLOADING LINE (OOL) INSPECTION
(AGBAMI FPSO)
HYDROTEST PROCEDURE
Document No. March, 2025 Revision No. : 00
ARDUNNY ENGINEERING NIGERIA LIMITED
Project Title
PROVISION OIL OFFLOADING LINE (OOL) INSPECTION
(AGBAMI FPSO)
Document Title
HYDROTEST PROCEDURE
Document Number: AGB-AOL-AEN-FT-PRO-QA-0006-00
Country and Facility Document Component Location
Originator Discipline Document Type Sequential Doc. Number
Code Type Code Code
XXX XXX XXXX XX XXX
K01 3-Mar-25 Issued For Use BEM ATSAAKAA -
Rev Rev. Date Description By Checked By Approved By
PROVISION OIL OFFLOADING LINE (OOL) INSPECTION
(AGBAMI FPSO)
HYDROTEST PROCEDURE
Document No. March, 2025 Revision No. : 00
HYDROTEST PROCEDURE
TABLE OF CONTENT
PROVISION OIL OFFLOADING LINE (OOL) INSPECTION
(AGBAMI FPSO)
HYDROTEST PROCEDURE
Document No. March, 2025 Revision No. : 00
1. INTRODUCTION
1.1 Purpose
1.2 Applicable Code and Reference Data for Hydrostatic Test
1.3 Responsibility
2. CONDITIONS FOR HYDROSTATIC TEST
2.1 Preliminary
2.2 Hydrostatic Test Pressure and Water Volume.
2.3 Treated Water Requirement
3. PRE-TEST PREPARATION
3.1 Safety Valves
3.2 Test Gauges
3.3 Temporary Facility
3.4 Communication
3.5 Advance Material Readiness
4. HYDROSTATIC TEST GENERAL REQUIREMENTS
4.1 Boiler Metal Temperature
4.2 Sectional Testing of the HRSG System
4.3 Double Valve Arrangement
4.4 Communication
5. PROCEDURE
5.1 Inspection before Hydrostatic Test
5.2 Hydrostatic Test
6. INSPECTION AND TEST
7. Post Hydrostatic Test Procedures
8. APPENDICES AND ATTACHMENT
8.1 The Pressure curve of Hydrostatic Test for HRSG (Typical)
8.2 Pressure Test Circuit.
1. INTRODUCTION
After installation of all pressure parts, Section I of the ASME Boiler and Pressure Vessel
Code requires that a boiler shall be subjected to a Hydrostatic Pressure Test. This will be
PROVISION OIL OFFLOADING LINE (OOL) INSPECTION
(AGBAMI FPSO)
HYDROTEST PROCEDURE
Document No. March, 2025 Revision No. : 00
conducted at a test pressure of 1.5 times the maximum allowable working pressure as
stamped on the boiler identification plate.
This procedure is applicable to the hydrostatic test for the pressure parts of HP, IP, LP,
CPH section for 1100MW SUGEN CCGT HRSG.
This description only describes the general procedure for the hydrostatic pressure test of
the
HRSG. The detailed description will be contained in an additional detail engineering
document.
1.1 Purpose
The primary purpose of this procedure is to provide a good quality of performance of
HRSG before chemical cleaning and commissioning operation. And also to find a fault in
site welding parts and to repair it.
1.2 Applicable Code and Reference Data for Hydrostatic Test
a) ASME Boiler and Pressure Vessel Code Sect. I
b) ANSI B31.1 (for external piping)
c) IBR1950
1.3 Responsibility
a) Erector is responsible for confirming and controlling the hydrostatic test job is being
carried out according to the prescribed procedure.
b) The manager in charge of hydrostatic test for HRSG must follow the procedure as
requested, review and manage in accordance with the prescribed procedure.
c) Temporary control office should be placed around the pressurization pump. The
communication system for pressurization and depressurization shall be carried out
by means of walkie-talkie.
2. CONDITIONS FOR HYDROSTATIC TEST
PROVISION OIL OFFLOADING LINE (OOL) INSPECTION
(AGBAMI FPSO)
HYDROTEST PROCEDURE
Document No. March, 2025 Revision No. : 00
2.1 Preliminary
Before starting to fill the boiler make sure all drums and headers are cleared of foreign
material. Close all drains. Open all vents normally used when filling the HRSG (such as
superheater link vents, economizer link vents, drum vents).
2.2 Hydrostatic Test Pressure and Water Volume
Design Hydrostatic Water
Pressure Test Pressure Volume Remarks
System
(barg) (barg) (M3) (Test Circuits Color / P&ID No.)
HP (F.W)
257 385.5 3 Dark Blue (IND696-XG02-HAD10-220011)
HP
145 218 161 Purple (IND696-XG02-HAD10-220011)
(SH,Eva,Eco)
IP (F.W,Eco)
110 165 3 Blue (IND696-XG02-HAD50-220051 / 220052)
IP (SH,Eva)
38 57 43 Mauve (IND696-XG02-HAD50-220051)
RH Mauve (IND696-XG02-HAD50-220052 /
38 57 50
(RH,HP Bypass Outlet) HAD10-220011)
LP (F.W)
50 75 2 Light Blue (IND696-XG02-HAD80-220081)
Orange (IND696-XG02-HAD80-220081 /
LP & LBG 11 16.5 47
LAA20-412001 / LBG10-421111)
Deae. To Cond. Sys 50 75 3 Brown (IND696-XG02-LAA20-412001)
Deaerator 8 12 25 Deep Purple (IND696-XG02-LAA20 / 412001)
CPH 50 75 34 Light Green (IND696-XG02-LCA30-413032)
HP Bypass Cooling
58 87 Nil Gray (IND696-XG02-HAD10-220011)
water
Total 371
2.3 Treated Water Requirement
1) Superheater and Reheater
- Type : Demineralized water
- Temperature : 21 ºC to 49 ºC
- Contents : Ammonia 10ppm solution
Hydrazine 200ppm solution
- pH : 10
PROVISION OIL OFFLOADING LINE (OOL) INSPECTION
(AGBAMI FPSO)
HYDROTEST PROCEDURE
Document No. March, 2025 Revision No. : 00
NOTE : Demineralized or Condensate quality water is defined as containing no more
than 1 ppm (1 ㎤/㎥) of identifiable solids and essentially a zero
concentration (or lowest detective level ) of organic material.
CAUTION : The use of fill water, treated with solid chemicals, should be avoided.
Deposits of solid materials in superheaters can be detrimental from heat
transfer and corrosion standpoints. Superheaters containing stainless steel
tubing are particularly vulnerable to stress corrosion cracking in the
presence of such chemicals as caustic and chlorides.
2) Remainder of HRSG unit:
Fill with treated condensate or treated demineralized water, or, if not available,
with a clean source of filtered water with 10 ppm (10 cm3/m3) of ammonia and
200 ppm (200 cm3/m3) of hydrazine
The water conditions as stated above can be adjusted by pouring chemicals, Ammonia in
the temporary storage tank i.e. condensate storage tank.
The water can be treated with only ammonia. This will however reduce the period of time
that this water can be left in the system.
3. PRETEST PREPARATION
3.1 Safety Valves
All safety valves will be checked for having the Hydro Plug inserted if applicable. The
Compression screw on the Safety Valve must be turned clockwise until the locknut makes
up on the Yoke.
3.2 Test Gauges
- Only recently calibrated test gauges are to be used.
- Dial pressure gauges used in the testing shall preferably have dials graduated over
their entire range of about double the intended maximum test pressure, but in no
case shall the
range be less than 1½ times that pressure.
PROVISION OIL OFFLOADING LINE (OOL) INSPECTION
(AGBAMI FPSO)
HYDROTEST PROCEDURE
Document No. March, 2025 Revision No. : 00
- There should be at least two (2) pressure gauges installed, one of which is at the
highest point of the system, the other gauge is to be installed at the Hydro-Pump.
3.3 Temporary facility
Description Capacity Q’ty Remarks
D.M Pump 1 Water filling for Temp. Tank
Filling Water Pump 20 kg/cm2g 1 Water filling for System
Pressurizing pump 450 kg/cm2g 1 Pressurizing
Temporary Water Tank 10 m3 1 Pressurizing
Air Compressor 10 kg/cm2g 1
Fire Hose 2 ½” ~ 20m 5 Water filling for System
High Pressure Hose ½ “~ ¾” Multitude Pressurizing
Temporary Piping Water filling & Pressurizing
3.4 Communication
All communication between the boiler control station and the Hydro-Pump station will be
with Radios. Back-up radios are to be readily available at each control station.
- Radio : More than 4 walkie-talkie
- Location : Control center (filling water pump or pressurization pump area) Top
(pressure gauge, thermometer and vent area) Inspector
- Inspector and recorder must be placed in a convenient area to communicate for the
pressure gauge, inspection of thermometer and control center.
3.5 Advance Material Readiness
Scaffolds, lights and repair tools are to be ready at time of Hydro-Test.
4. HYDROSTATIC TEST GENERAL REQUIREMENT
PROVISION OIL OFFLOADING LINE (OOL) INSPECTION
(AGBAMI FPSO)
HYDROTEST PROCEDURE
Document No. March, 2025 Revision No. : 00
4.1 Boiler Metal Temperatures
The metal temperature of all components to be Hydro-Tested must be at least 21 ºC (70
ºF) before applying the Hydro Test pressure but shall not exceed 48.8 ºC(120ºF)
4.2 Sectional Testing of the HRSG Systems
When Hydrostatic Testing is to be done on a section of the system which is not directly
linked to a lower than test pressure designed system, but segregated by the test boundary
isolation, all vent valves in the lower pressure designed system must be open to avoid
over pressurization of the same.
4.3 Double Valve Arrangements
- All components tested will be as indicated on the flow chart or P&ID for the specific
test.
- Always open the root valve fully and throttle with the down stream valve when
depressurizing or draining a system.
4.4 Communication
All communication / Co-ordination concerning the Hydro-Test has to be addressed through
designated personnel.
5. PROCEDURE
5.1 Inspection before Hydrostatic Test
5.1.1 Check for any foreign materials of tools, clothes and other things inside the drum,
heater, manifolds etc. and then close the manholes and all holes of the pressure.
5.1.2 The pressure gauge to be used for Hydro-Test should exactly be calibrated. In
addition to this, the filling piping and pressurization shall be checked.
5.1.3 It is very important to check whether the instruments and the temporary construction
piping
PROVISION OIL OFFLOADING LINE (OOL) INSPECTION
(AGBAMI FPSO)
HYDROTEST PROCEDURE
Document No. March, 2025 Revision No. : 00
are free from foreign particulate matters.
5.1.4 The safety valves gagged. (when the worker install safety valve, he must check
whether the test plug is inserted or not, and if inserted, a tag with „ No operating”
must be attached)
5.1.5 Before filling , to close the block valves and open the vent valve of each system,
Authorization of concerned in charge is required to be done in the valve operation
list.
5.1.6 In case of deaerator, Spray valve & tray should be separated to avoid foreign
material. But if spray valve is installed in deaerator, take a note water filling must not
be done through spray valve.
5.2 Hydrostatic test
5.2.1 Water filling
In case of non availability of condensate transfer pump, which are to fill the water,
filling of water shall be done by temporary filling water pump shall be installed in
each system as paragraph 5.2.1.2.
5.2.1.1 In advance, in the close condition of the specified valve, it has to be checked then
the signature on the control list is requested under the open condition of top air
vent valve. If the above condition is pleased it may be filled for water washing.
5.2.1.2 It is a fundamental rule to fill the inside of HRSG through specified valves for each
system(HP, IP, LP, CPH and Deaerator).
5.2.1.3 If water is seen being filling from bottom valve, each air vent valve shall be closed
on sequentially till top air vent valve at that time a full filling should be confirmed
at top air vent valve.
5.2.2 Pressurization
5.2.2.1 HP F.W. Section
a) The pressure should be increased by 3~5 kg/cm^2/min. up to Max. allowable
working pressure(design pressure 257barg).
b) Observe test section for any obvious leaks.
PROVISION OIL OFFLOADING LINE (OOL) INSPECTION
(AGBAMI FPSO)
HYDROTEST PROCEDURE
Document No. March, 2025 Revision No. : 00
c) Then the pressure should be increased by 2~3 kg/cm^2/min till the hydro-test
pressure (385.5 barg) of HP F.W. section and held for min. 30 minutes. The
pressure must be under control at all times and shall never exceed by more
than 6%(23.1 bar) of the desired Hydrostatic Test Pressure.
d) The pressure shall be reduced by 2~3 kg/cm^2/min. (depressurization rate) till
the design pressure by opening drain valve.
e) A close visual inspection of all boiler pressure parts and connecting piping
shall be carried out after the pressure was lowered from hydrostatic test
pressure to design pressure.
f) If the result during checking is under the normal condition, the pressure shall
be reduced by 3~5 kg/cm^2/min. by opening a drain valve.
5.2.2.2 HP section
a) The pressure should be increased by 3~5 kg/cm^2/min. up to Max. allowable
working pressure(design pressure 145 barg).
b) Observe test section for any obvious leaks.
c) Then the pressure should be increased by 2~3 kg/cm^2/min till the hydro-test
pressure (217.5 barg) of HP section and held for min. 30 minutes. The
pressure must be under control at all times and shall never exceed by more
than 6%(13.0 bar) of the desired Hydrostatic Test Pressure.
d) The pressure shall be reduced by 2~3 kg/cm^2/min. (depressurization rate) till
the design pressure by opening drain valve.
e) A close visual inspection of all boiler pressure parts and connecting piping
shall be carried out after the pressure was lowered from hydrostatic test
pressure to design pressure.
f) If the result during checking is under the normal condition, the pressure shall
be reduced by 3~5 kg/cm2^/min. by opening a drain valve.
5.2.2.3 IP F.W Section
a) The pressure should be increased by 3~5 kg/cm^2/min. up to Max. allowable
working pressure(design pressure 110 barg).
b) Observe test section for any obvious leaks.
c) Then the pressure should be increased by 2~3 kg/cm^2/min till the hydro-test
pressure (165 barg) of IP F.W. section and held for min. 30 minutes. The
PROVISION OIL OFFLOADING LINE (OOL) INSPECTION
(AGBAMI FPSO)
HYDROTEST PROCEDURE
Document No. March, 2025 Revision No. : 00
pressure must be under control at all times and shall never exceed by more
than 6%(9.9 bar)
of the desired Hydrostatic Test Pressure.
d) The pressure shall be reduced by 2~3 kg/cm^2/min. (depressurization rate) till
the design pressure by opening drain valve.
e) A close visual inspection of all boiler pressure parts and connecting piping
shall be carried out after the pressure was lowered from hydrostatic test
pressure to design pressure
f) If the result during checking is under the normal condition, the pressure shall
be reduced by 3~5 kg/cm^2/min. by opening a drain valve.
5.2.2.4 IP Section
a) The pressure should be increased by 3~5 kg/cm^2/min. up to Max. allowable
working pressure(design pressure 38 barg).
b) Observe test section for any obvious leaks.
c) Then the pressure should be increased by 2~3 kg/cm^2/min till the hydro-test
pressure (57 barg) of IP section and held for min. 30 minutes. The pressure
must be under control at all times and shall never exceed by more than
6%(3.4 bar) of the desired Hydrostatic Test Pressure.
d) The pressure shall be reduced by 2~3 kg/cm^2/min. (depressurization rate) till
the design pressure by opening drain valve.
e) A close visual inspection of all boiler pressure parts and connecting piping
shall be carried out after the pressure was lowered from hydrostatic test
pressure to design pressure.
f) If the result during checking is under the normal condition, the pressure shall
be reduced by 3~5 kg/cm2^/min. by opening a drain valve.
5.2.2.5 LP F.W. Section
a) The pressure should be increased by 3~5 kg/cm^2/min. up to Max. allowable
working pressure(design pressure 50 barg).
b) Observe test section for any obvious leaks.
c) Then the pressure should be increased by 2~3 kg/cm^2/min till the hydro-test
pressure (75 barg) of LP F.W section and held for min. 30 minutes. The
pressure must be under control at all times and shall never exceed by more
than 6%(4.5 bar) of the desired Hydrostatic Test Pressure.
PROVISION OIL OFFLOADING LINE (OOL) INSPECTION
(AGBAMI FPSO)
HYDROTEST PROCEDURE
Document No. March, 2025 Revision No. : 00
d) The pressure shall be reduced by 2~3 kg/cm^2/min. (depressurization rate) till
the
design pressure by opening drain valve.
e) A close visual inspection of all boiler pressure parts and connecting piping
shall be carried out after the pressure was lowered from hydrostatic test
pressure to design pressure.
f) If the result during checking is found in normal condition, the pressure shall be
reduced by 3~5 kg/cm^2/min. by opening a drain valve.
5.2.2.6 LP section
a) The pressure should be increased by 2~3 kg/cm^2/min. up to Max. allowable
working pressure(design pressure 11 barg).
b) Observe test section for any obvious leaks.
c) Then the pressure should be increased by 2~3 kg/cm^2/min till the hydro-test
pressure (16.5 barg) of LP section and held for min. 30 minutes. The pressure
must be under control at all times and shall never exceed by more than 6%(1
bar) of the desired Hydrostatic Test Pressure.
d) The pressure shall be reduced by 2 ~ 3 kg/cm^2/min (depressurization rate)
till the design pressure by opening drain valve.
e) A close visual inspection of all boiler pressure parts and connecting piping
shall be carried out after the pressure was lowered from hydrostatic test
pressure to design pressure.
f) If the result during checking is found in normal condition, the pressure shall
be reduced by 3~5 kg/cm^2/min. by opening a drain valve.
5.2.2.7 CPH section
a) The pressure should be increased by 3~5 kg/cm^2/min. up to Max. allowable
working pressure (design pressure 50 barg).
b) Observe test section for any obvious leaks.
c) Then the pressure should be increased by 2~3 kg/cm^2/min till the hydro-test
pressure(75 barg) of CPH section and held for min. 30 minutes. The pressure
must be under control at all times and shall never exceed by more than 6%
(4.5 bar) of the desired Hydrostatic Test Pressure.
d) The pressure shall be reduced by 2 ~ 3 kg/cm^2/min (depressurization rate) till
the design pressure by opening drain valve.
PROVISION OIL OFFLOADING LINE (OOL) INSPECTION
(AGBAMI FPSO)
HYDROTEST PROCEDURE
Document No. March, 2025 Revision No. : 00
e) A close visual inspection of all boiler pressure parts and connecting piping
shall be
carried out after the pressure was lowered from hydrostatic test pressure to
design pressure.
f) If the result during checking is found in normal condition, the pressure shall be
reduced by 3~5 kg/cm^2/min. by opening a drain valve.
5.2.2.8 Deaerator section
a) The pressure should be increased by 3~5 kg/cm^2/min. up to Max. allowable
working pressure (design pressure 8 barg).
b) Observe test section for any obvious leaks.
c) Then the pressure should be increased by 2~3 kg/cm^2/min till the hydro-test
pressure(12 barg) of Deaerator section and held for min. 30 minutes. The
pressure must be under control at all times and shall never exceed by more
than 6% (0.7 bar) of the desired Hydrostatic Test Pressure.
d) The pressure shall be reduced by 2 ~ 3 kg/cm^2/min (depressurization rate)
till the design pressure by opening drain valve.
e) A close visual inspection of all boiler pressure parts and connecting piping
shall be carried out after the pressure was lowered from hydrostatic test
pressure to design pressure.
f) If the result during checking is found in normal condition, the pressure shall
be reduced by 3~5 kg/cm^2/min. by opening a drain valve.
5.2.2.9 HP Bypass Cooling Water Section
a) The pressure should be increased by 3~5 kg/cm^2/min. up to Max. allowable
working pressure (design pressure 58 barg).
b) Observe test section for any obvious leaks.
c) Then the pressure should be increased by 2~3 kg/cm^2/min till the hydro-test
pressure(87 barg) of HP Bypass cooling water section and held for min. 30
minutes. The pressure must be under control at all times and shall never
exceed by more than 6% (5.5 bar) of the desired Hydrostatic Test Pressure.
PROVISION OIL OFFLOADING LINE (OOL) INSPECTION
(AGBAMI FPSO)
HYDROTEST PROCEDURE
Document No. March, 2025 Revision No. : 00
d) The pressure shall be reduced by 2 ~ 3 kg/cm^2/min (depressurization rate)
till the design pressure by opening drain valve.
e) A close visual inspection of all boiler pressure parts and connecting piping
shall be carried out after the pressure was lowered from hydrostatic test
pressure to design pressure.
f) If the result during checking is found in normal condition, the pressure shall
be reduced by 3~5 kg/cm^2/min. by opening a drain valve.
6. INSPECTION AND TEST
6.1 All welding points, valves and hangers which were welded on pipe must be
inspected during the hydrostatic test. During the inspection if there is an abnormal
condition the inspection should be stopped and a repair work should be done.
6.2 The test data should be recorded at an interval of 5 minutes but not less than 5
measuring data in each case during hold time and during subsequent inspection,
and the basis of the pressure is the pressure gauge installed at the highest point of
the system, and temperature should be recorded from the temporary temperature
gauge installed near the pressure gauge.
6.3 The inspection must be witnessed as per the inspection points in hydro test
inspection table.
NOTE : Hydrostatic test pressure should not be applied to the boiler of the metal
temperature of the pressure parts is below 70° F ( 21° C ). Since there is
generally some time delay between the hydrostatic test and the initial boiling
out and cleaning for the boiler the unit should remain full of water, air should
not be allowed to enter.
7. Post Hydrostatic Test Procedures
7.1 Hydrostatic test water will be left in the system for preservation. Pressure
approximately 3 to 5 psig (21 to 34 kPa) to be maintained, checked and recorded on a
regular basis.
PROVISION OIL OFFLOADING LINE (OOL) INSPECTION
(AGBAMI FPSO)
HYDROTEST PROCEDURE
Document No. March, 2025 Revision No. : 00
7.2 Remove all hydrostatic test plugs and gags from the safety valves prior to starting up
the unit.
NOTE: Since there is generally some time delay between the hydrostatic test and
the initial boiling out and acid cleaning of the HRSG, it should remain full of
water; air should not be allowed to enter.
8. ATTACHMENT
8.1 The pressure curve of hydrostatic test for HRSG
A. HP F.W Section pressure curve (Typical)
B. HP Section pressure curve (Typical)
C. LP Section Pressure Curve(Typical)
D. LP F.W Section Pressure Curve (Typical
E. CPH Section pressure curve (Typical)
F. IP & RH Section Pressure Curve (Typical)
G. IP F.W Section Pressure Curve (Typical)
H. Deaerator Section Pressure Curve (Typical)
I. HP Bypass Cooling Water Section Pressure Curve (Typical)
8.2 Pressure Test Circuit ------- 1 Set
Red Color Marking(“golden joint”) means pipe will be blanked before hydrostatic test and RT will
be done for weld joint after Hydrostatic test.
