008_field Hydrotest Procedure

PACIFIC

PACIFIC PIPE SYSTEMS Pvt. Ltd

TITLE PACKAGE

Cross Country Pipeline

FIELD HYDROTEST PROCEDURE Doc. No.

PROJECT CLIENT

SKS POWER Chhattisgarh

Rev. No. Date :

CONTRACTOR

DOSHION PVT. LIMITED

Page:

4 x 300 M W Raigarh aigarh

PPSPL/SKS/1100/CG/008 D 18/8/2012

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FIELD HYDROTEST PROCEDURE

FOR UNDERGROUND INSTALLATION OF GRP PIPES

Signatur e & Date Name Designation

LINO M ATHEW ATHEW M anager anager Prepared & Review Review ed By

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HYDROSTATIC TESTING OF PRESSURE PIPELINES PART 1 GENERAL 1.01 DESCRIPTION This section describes the requirements requirements and procedures for pressure and leakage testing of all pressure mains. 1.02 REQUIREMENS PRIOR TO TESTING Ø Ø Ø Ø Ø

Air Vents shall be provided in the selected pipeline stretch with provision of two Pressure gauge points. The pipe trench shall have trench zone backfill placed and compacted with a minimum of 1500mm (60”) of material over the pipe. All concrete thrust block and anchor blocks shall be allowed to cure for minimum 7 days prior to take the st retch for Hydro-test. Backfilling shall not be carried out in the joint portion till the line is hydro tested & cleaned for backfilling. backfilling. Separate log sheets to be maintained for the test gaps or make-up pipe piece with clear chainage identification. identification.

PART 2 MATERIALS MATERIALS 2.01 WATER f or hydrostatic testing of potable pipeline and recycled water Ø Potable water shall be used for mains. Raw water shall be used for testing of raw water mains. 2.02 CONNECTIONS: Ø Testing water shall be supplied through a connection equipped with a backflow prevention device at the point of connection to the potable/ Raw water source used. Ø

The Contractor shall provide any temporary piping needed to deliver potable water to the piping that is to be tested RAW



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PART 3 EXECUTIONS ??? 3.01 GENERAL: Ø The Contractor shall furnish all labor, materials, tools, and equipment for testing. Ø Temporary blocking during the tests will be permitted only at temporary plugs, caps or where otherwise directed by the Consulting Engineer. Ø All valves and appurtenances shall be operated during the test period. The test shall be conducted with valves in the open position. Ø At the onset of testing, all valves, air vacuum assemblies, blow offs, and services shall be monitored for possible leakage and repairs made, if necessary, before the test proceeds. The appurtenances shall be monitored through the duration of the testing.



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FIELD HYDROTEST – G.R.P UNDER GROUND PIPING SYSTEM with COUPLING JOINTS Required Tools & Tackles: • • • • • •

• • •

• • • • • • •

Come along jacks with nylon slings- for pipe joining /coupling fixing. Nylon twines for marking pipe alignment. alignment. Limestone powder. Theodolite –for pipe alignment. Earth compaction Equipments. Filling pumps/ Dewatering pump – for f illing of pipe prior to pressure test./Required if trenches are flooded Pressurizing/Reciprocating Pressurizing/Reciprocating Pumps- for Pressurizing the system under Test. Hoses with connectors and fittings. End caps/Blind Flanges as per Diameter –with adequate f lange connectors for filling, air vents and gauges. Nozzles/AVT for release of air. Pressures gauges/Valves and connectors. Rotary Disc cutter /Grinder- 4’’ & 5’’ discs. Knife cutters and blades. Measuring instruments-pi Tapes, Vernier calipers, Feeler Gauges et c. Electrical Extension board. Mobile crane Lifting Tackles with slings for pipe movement.

Segment Hydro testing: Field hydro test shall be conducted in segment or as complete piping system. The segment to be taken up for testing will be decided on site after consulting SPGCL/Third party Inspector and shall be chosen according to site conditions. A clearance of 4 meters minimum shall be maintained between the segments which will be later installed as Make ‐Up pipe piece with double spigot calibration to facilitate the jointing on existing piping segment.



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FIXING BLIND END CAPS: Blind end cap is FRP coupling with one end closed through lamination, while the other end is with groove for rubber gasket to work as sealing end. Insert this End Cap with the last pipe of stretch to be tested after placing the rubber gasket.. Necessary openings could be provided to the end caps for ventilation/pressure gauge. Pressure gauges can be fixed on these opening (there is a screw type t ype connection). connection). After segment test, these end caps could be removed through pullers & upon rubber gasket replacement, could be re ‐used for other segments. Adequate concrete block b lock supports or required Jack props shall be provided to the end cap to prevent the pipe movement during hydro test.



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CHECK LIST PRIOR TO BLINDING OF PIPE ENDS: FEELER

Check each coupling joint is connected correctly and the clearance between the pipe ends is uniform all around. Filler gauge of 0.5mm thickness is inserted in between the pipe and the coupling till the point it touches the rubber gasket. Uniform length of gauge going inside the gap gives the indication of the joint connected properly. This test ensures the rubber gasket correct positioning inside the double bell coupling groove. The test shall be conducted prior to start backfill. Before doing the hydro ‐test shall be completed be completed. At Bend

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locations thrust block to be casted prior testing. Additional lamination lamination to the field is to be provided on the bend portions which will will get embedded in concreting. For this approved lamination layer sequence will be provided from M/s Pacific. Make sure that the backfilling slope at the joints location is maintained with minimum pipe exposure. Internal visual inspection shall be carried out for accessible pipe diameters for any possible damage during installation/ backfilling. Vertical deflection measurements shall be taken to observe the pipe behavior after the backfill. Signatur e & Date Name Designation


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Checks on laid Pipeline Maximum installed diametrical deflection deflection must not exceed the value mentioned in below Table. Bulges, Flat areas or other abrupt changes of pipe wall curvature are not permitted. Pipes installed outside of these limitations may not perform as intended. Checking deflection is to ensure that the initial deflection requirements have been met and should be done for each pipe immediately after completion of installation (typically within 24 hours after reaching maximum cover). The expected initial pipe deflection after backfilling of gravel level is less than 2% for most installation. A value exceeding the amount indicates that the desired quality of the installation has not been achieved and should be improved upon from the next pipe installation (i.e. increased pipe zone backfill compaction, coarser grained pipe zone backfill material or wider trench, etc.) Deflection measurements in each pipe installed are recommended as a good check on pipe installation quantity. Pipes installed with initial deflection exceeding the value in table must be reinstalled so the initial deflection is less than those values.

DN>=300

Deflection % of Diameter 3.0

Procedure for checking the initial diametrical deflection for installed i nstalled pipes: 1. 2. 3. 4.

Complete backfilling to to grade (pipe (pipe zone, zone, crown & native Backfill) Complete removal of temporary temporary sheeting sheeting (if (if used) Turn of of the dewatering system (if used) used) Measure and and record record the pipe’s vertical vertical diameter. OFF



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Note: For smaller diameter pipes, a deflection testing device (commonly called a pig) may be pulled through the pipes to measure the vertical diameter. 5. Calculate vertical deflection: Ensure that the pipes are backfilled to the minimum cover depth requirement before the hydro test.

% Deflection = Actual I.D. – Installed Vertical I.D. X100 Actual I.D. Actual I.D. may be verified or determined d etermined by measuring the diameter of a pipe not yet installed laying loose (no pipes stacked above) on a reasonable plane surface.

I.D. + Horizontal I.D. Calculate as follows: Actual I.D. = Vertical Single measurement for pipe spools would2 not be sufficient. So measurement shall be done for every 3m.

Deflection measurement procedure: The Pipe laying supervisor / inspector will enter into the pipe at a distance of about 1 to 2 m near the coupling and would check the original vertical and horizontal dimensions inside the pipe. If the Pipe or section is found to be over deflected or out of our recommended standard then the procedure is to remove topsoil to the level at which pipe comes back or regains its original shape & then to re-compact re-compact the side fill & topsoil.

PREPARATION PRIOR TO HYDROTEST: Make sure that the test method statement is available with full understanding of implementation to the testing team. Ensure to fix air vent nozzles at high points in the pipe line. Use Use minimum two pressure gauges in the length being tested. Filling points and venting nozzles to be provided with isolation valves. The readings at the pressure shall be calculated taking into account the static head between the lowest pipe invert level along the complete line and the level of the pressure gauge. Signatur e & Date Name Designation


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All flanges are tightened tightened to the specified specified torque bolt bolt sequence. The method method is as follows 1. 2. 3. 4. 5.

Thoroughly clean the flange flange face and the O ‐ring groove. Ensure the sealing gasket is clean and undamaged. Position sealing gasket in groove. Align flanges to be joined Insert bolts, washers washers and nuts. nuts. All hardware hardware must be clean clean and lubricated lubricated to avoid incorrect tightening. Washers must be used on all GRP flanges. 6. Using a torque wrench, wrench, Tighten all bolts bolts to 35Nm torque, torque, following standard standard flange bolt bolt tightening sequences. 7. Repeat this procedure, procedure, raising the bolt bolt torque to 70 Nm, Nm, or until the flanges flanges touch at their inside edges. Do not exceed this torque. To do so may cause permanent damage damage to GRP flanges. 8. Check bolt torques one hour hour and adjust adjust if necessary necessary to 70 Nm.



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PPSPL/SKS/1100/CG/008

Make sure that the valves are anchored and the above ground piping, if i f any, is supported as specified. IMPORTANT:

IN NO CASE, SINGLE PERSON IS ALLOWED TO GET INSIDE OF PIPING FOR INSPECTION!!

Aluminum ladder shall be used for getting down the trenches for f or inspection of pipeline Upon verification of the inspection, when the findings findings are judged acceptable acceptable & recorded, the manhole cover shall be closed, if provided. Prior to start water filling, temporary piping & blinds shall be installed, checked & verified by the client/ consultant / contractor representatives.

WATER FILLING & PRESSURIZING THE SYSTEM: S YSTEM: It shall be confirmed that all the vent points are fully opened to atmosphere, prior to start of water filling to allow the release of air from the pipeline as the water is being filled in the pipe line Introduce water filling through temporary hoses & pump at lowest point. Pump capacity shall be chosen according to the pipe diameter and segment/system linear length. (Pumps having a 3

capacity of 100 m / hour are generally used for larger diameter pipes). The sign that the pipe line is completely filled with water is when the water starts coming through highest venting point on the line. Keep the venting valve open for some time to ensure that no air entrapment is left in the pipe line. Stop water pumps at this stage & check the flanges, valves and connected accessories for any seepage/ leakage while keeping the vents open.

PRESSURIZING: Start pressurizing the segment/system through pump. Once the water starts coming out through vent opening, close the valve at low elevation. Later, on the high elevation end the vent. Valves shall be closed while allowing water to come out. The pressure increment shall be maintained at 0.5 Bars/10 minutes at this stage. When the pressure reaches to 2 bars, the pump shall be stopped. Keep this stoppage for 15 ‐20 minutes. During this time, following checks shall be made:



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A) Pressure at each test gauge gauge shall be checked checked & recorded on inspection sheets. sheets. B) Watch the pressure at the water feed point for any decrease in pressure. C) Walk through along with the underground lines to observe any traces of wet soil and any unusual at every interval of 30 ‐45 minutes.

1.5 times the pipe pressure class Repeat this procedure procedure till the required pressure is achieved. The inspection inspection sheet shall shall be maintained for the observation & findings.

ANY PRESSURE DROP, VALVE LEAKAGES SHALL BE IMMEDIATELY REPORTED TO THE TEAM LEADER Unless there are no findings which prevent the test from continuing, the segment/system shall be further pressurized. Connect the hose with t he pressure pump and start pressurizing the line. At this stage slightly open the vent. Valve f ixed at higher elevation e levation to ensure that no entrapped air is present. Upon confirmation of water coming out, the vent. Valve shall be closed. The system is now totally close and under pressure. Continue the pressure pump until it reaches 5.0 bar. During this operation, the pump shall be constantly attended for pressure control. Stop the pressure pump once it reaches to 5.0 bars and let it to stabilize. There could be a drop of pressure due to thermal expansion, which could either be make ‐up by restarting the pump or keep it as it is & record on the inspection sheet. Keep this stoppage for about 30 minutes. During this period, repeat the same sequence of inspection as described earlier. The finding and observation shall be recorded on inspection sheet. REPEATED

ANY PRESSURE DROP, VALVE LEAKAGES SHALL BE IMMEDIATELY REPORTED TO THE TEAM LEADER. Unless there are no findings which prevent the test from continuing, the segment/ system shall be further pressurized to the t he required field test pressure *THIS TEST PRESSURE SHALL BE MAINTAINED FOR A PERIOD OF MAXIMUM 24hrs, AFTER PRESSURE STABILIZATION, STABILIZATION, As per IS13916. IS13916. Signatur e & Date Name Designation


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Thorough inspection shall be made as FINAL INSPECTION. INSPECTION. After the test pressures is reached then check for any drop in pressure. Enter the findings in Hydro test report which shall be duly signed by the Client, Inspection agency and Contractor. The test shall be considered as “PASS” if no sign of leakage are observed; the inspection sheet(s) shall be signed by the authorities.

POST HYDR HYDROTEST: OTEST: After completion the test open all vent valves. Drain or f lush out o ut the f illed water from f rom the pipe segment/ system through drain valves. This pressure release shall be made slowly @ 2bar/ 5 minutes. Remove the end cap from the segment as per procedure and close the same with temporary cover to avoid any particles from entering inside the line. PPSPL Installation/Site engineer will advice you in this process. Prepare the pipe end to be ready for next installation. Connect the adjacent segment end with closure pipe piece. Continue the installation for the other segments & conduct the hydro test in the similar manner as described earlier, keep connecting the segments through closure spools. The clearance maintained between the two segments can be later installed as Make‐Up pipe piece with double spigot calibration to facilitate the jointing on existing pipe segment. The test of this Make ‐Up pipe can be done during the time of commissioning. commissioning. As per ease of availability of fittings f or Salvaging Salvaging the water or the water will be brought in by bore holes or other water bodies (lake, river, pond etc).

ANNEXURE -I The opened ends of a line must be sealed temporarily with GRP or steel/cast iron end-caps. GRP testing end-caps can be purchased from the manufacturer with the pipes & the fittings. The end-caps should have an inlet & an out let. The inlet should be placed at the bottom of the end-cap at the low end of the test section, and the outlet at the top of the end-cap at the high end. See fig22 for a typical arrangement of a test section & apparatus. The approximate end thrust force is given below in Table. Signatur e & Date Name Designation


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Bracing test-ends and set-up Due to the thrusts occurring at the testing end-caps, temporary blocks must be used to brace the pipe end-caps in order to prevent line displacement as indicated in figure below.

In the gap between the end of the pipeline & the block, jacks should be placed as shown in figure. This will keep the testing end cap at its original position if the block starts to move. The last pipe length should also be wedged on both sides, at the top & at the bottom, in order to prevent. Note: It may be possible to reduce the size of the concrete blocks by driving into the ground, several meters deep, two or more steel piles back to back. Sheet piles so positioned behind the concrete blocks will provide p rovide additional bracing STEEL OR SHEET?



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Filling the line with water: If it is not possible to fill the line from the lowest point, an additional outlet should be added at the inlet end-cap to release air. The line should be filled slowly & evenly with water from the lowest end point. At high points, an air release valve va lve is normally installed, as specified by the design Engineer (see Appendix II for additional details). Though these valves the entrapped air inside the pipe will get released. After filling the line with water, the test section should be left for an initial period of at least 12 hours under a static pressure of 2-3bars for stabilization. The filling rate of the line with water should be controlled such that t hat the water velocity does not exceed 0.3m/sec.

Volume of water required: Below Table indicates the approx volume of water required in order to fill PACIFIC Pipes per 100 meter of pipeline. DN(mm) 80 100 150 200 250 300 350 400 450 500 600 700 800

Water Volume (m^3)/100m of pipeline 0.5 0.8 1.8 3.1 4.9 7.1 9.6 12.6 15.9 19.6 28.3 38.5 50.3

DN(mm) 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 2000 2200 2400

Water Volume (m^3)/100m of pipeline 63.6 78.5 95.0 113.0 132.7 153.9 176.7 201.0 226.9 254.4 314.1 380.1 452.4

A. Test pressure gages shall be calibrated within 90 days of use and clearly marked on each gage the date of calibration, calibration certificates of gages shall be presented before the start of each test and copy included with hydro test report.



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B. Minimum number of 2 calibrated pressure pressure gages shall be used for each hydro test. This is in case of gage failure or incorrect gage reading during test if only using one gage, pressure gage failure is both a safety risk to personel and over pressurizing of equipments. C. Pressure gages used used shall have a range of of reading where as the the final test pressure will will fall in the middle third of the gage range.

THIS PROCEDURE IS MADE MANDATORY TO THE INSTALLER AND DEVIATION SHALL BE CONSULTED WITH THE PACIFIC/DL FIELD SERVICE REPRESENTATIVE REPRESENTATIVE



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008_field Hydrotest Procedure

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