Dieterich Standard, Inc. st 5601 N. 71 Street Boulder, CO 80301 Tel: (303) 530-9600 Fax: (303) 530-7064
Engineering Procedure E. P. 4017 Issue Date: July 30, 1976 REVISION AJ
HYDROSTATIC TEST PROCEDURE DP FLOW PRODUCTS AND MATERIAL
Mike Hering Staff Engineer
Kathy Garnett Purchasing Manager
Theresa Sanger Technical Sales Administrator
Bill Ringer Quality Assurance Engineer
Don Verhaagen Engineering Design Manager
Page 1 of 10
EP-4017 REVISION AJ Page 2 of 10 REVISION SHEET Date
Added Section II
Added Sections III, IV, V
Teflon tape requirement added to 1.0 Scope
Added pressure containment leakage statement
Revised test pressure tolerance
Rewritten per ECR R0475
Revised 4.2a & 5.9 per ECR G 0183
Revised 4.1 & deleted Figure 1 & ref. to Figure 1 (in 4.1 & 5.1) per ECR #R1164. Added report #, rev. level and page # (4) to test data sheet.
Revised page numbers to be more descriptive (i.e. was page 1, now page 1 of 4) per ECR 2999, Class IV change eff. record change.
Revised per ECR 2167 - added Para. 2.4.
Revised per ECR 4795. Added para. 2.3, Section 6.0 and Appendix A.
Revised per ECR 4828. Changed title page to read "AND MATERIAL"; added info to pages 3, 4 and 5 of 9; removed "1/2" before NPT on 6.2, 6.7 & 6.8; corrected typo on 4.2(a) from mo to no.
Revised Per ECR 5461. Added para. 4.8; revised para 5.2
Per ECR7260, changed para. 4.5. Added "Ref. DS-8357" in para. 4.8.
Per EC001044 Changed para 2.4.
Per EC001501 Added training personnel issues to para 2.4
Changed para 4.3, Test Medium, to allow for contract specific water requirements.
Changed para 2.3 to hydro direct mount.
Format change only, no context change.
Deleted table in section A.4.2
EP-4017 REVISION AJ Page 3 of 10
Section 4.2 – Added comments regarding Digital Pressure gauges and PED. Section 7.3 – Added test acceptance criteria for PED.
Change eq. 4.4a iii A - Hydro test pressure. Replaced Annubar® with “DP flow product” in title, 1.0 Purpose, 2.0 Scope and 5.0 Test procedure. Corrected 7.0.3 for correct PED sampling method. Made Test Data Sheet into DS-15007.
Para. 4.8 Replaced DS-8357 with DS-8360 Test Log Sheet.
Para 4.4.a.iii Updated requirements for PED to match std 1.5x
EP-4017 REVISION AJ Page 4 of 10 1.0
The purpose of the hydrostatic test is (1) to verify the pressure integrity of the completed DP flow product assembly or component, and/or, (2) to confirm material compliance to applicable code specifications.
When required by the customer specification or the applicable code, each completed DP flow product assembly shall be hydrostatically tested at the pressure indicated below.
Mounting hardware will be hydrostatically tested whenever practical; however, since it typically requires field welding to complete the pressure boundary, mounting hardware will not normally be tested by Dieterich Standard.
MassProbars速 or Probars速 and direct mount Annubars速 shall be checked for leaks as a complete assembly after being leak tested per EP4102. Transmitter and manifolds shall not be disassembled before testing to this procedure. Shop air shall be applied through the transmitter vent valves and integral valves on head closed when no manifold between transmitter and head. When a manifold is between head and transmitter the assembly shall be hydrotested to 400 PSIG. When a customer hydro is requested, then it shall be at that requested hydrostatic pressure.
Individual components or material will be hydrostatically tested to verify pressure containment capability as required for application and, when necessary, to confirm compliance to specifications.
Hydrostatic testing shall be performed and witnessed by qualified personnel. Qualified Level II inspection personnel for ASME QA Manual work shall perform inspection and acceptance of test. Personnel in training may perform hydro tests only under direct supervision of qualified level II personnel. Only non-ASME QA manual work may be used for training. Signatures of both the trainee and the qualified person supervising the test are required on the test report.
Non-conformances to the requirement of any portion of this procedure shall be documented per Section 13 of the Dieterich Standard QA Manual for all ASME Section III assemblies.
An American National Standard Code for Pressure Piping - ANSI/ASME B31.1, Chapter VI. B31.3 Chapter VI.
American Society of Mechanical Engineers Boiler and Pressure Vessel Code - Section III, Articles NB-6000, NC-6000 and ND-6000.
EP-4017 REVISION AJ Page 5 of 10 .3 4.0
PED 97/23/EC ANEX 1 SECTION 7.4
GENERAL REQUIREMENTS .1
Test Configuration: The test fixture shall be specifically designed for the particular model and test pressure. As a minimum, the fixture shall provide appropriate and necessary connections for venting and installation of the test gauge.
Test Gauge: A pressure indicator (PI), in accordance with the following, shall be installed in the fixture to monitor pressure: a. The PI range should be two (2) times the test pressure required, but in no case shall the range be less than 1-1/2 or more than four (4) times the test pressure for analog type gages. Digital type pressure indicators can be used without range restriction provided the combined error due to calibration and readability does not exceed 1% of the test pressure. b. The PI shall be calibrated using a traceable dead weight tester. Calibration will be at regular intervals based on history and usage and tagged with the calibration status. For tests under the scope of the PED the pressure gage will be calibrated by an A2LA certified lab. For QA Manual projects, the PI shall be calibrated at least two weeks prior to each test or series of tests ***. A series of tests is a group of tests using the same PI and is conducted within a period not exceeding two weeks.
Test Medium: Unless otherwise specified in the contract documents, deionized water at approximately ambient temperature shall be used as test medium. If required, specific water requirements shall be listed on the QA documents.
Test Pressure Determination a. Assembly Hydro Test i.
Minimum: Each assembly shall be subjected to a hydrostatic test pressure of not less than 1.5 times the design pressure indicated on the submittal drawing or the customer specification. If the assembly is to be in accordance with ASME Section III Subsection NB (Class 1), then the minimum pressure shall be not less than 1.25 times the design pressure.
ii. Maximum: The test pressure shall not exceed the minimum test pressure (per 220.127.116.11) by more than 6% without engineering approval. If the minimum test pressure is 300 psig or less engineering approval is not required. The upper limit shall be
EP-4017 REVISION AJ Page 6 of 10 established by analysis, but in no case shall the test pressure exceed the maximum test pressure of any component in the assembly. If the assembly is to be in accordance with ASME Section III Subsection NB (Class 1), then the maximum test pressure shall meet the requirements of NB-3226. iii. PED The hydrostatic test pressure requirements from part 4.4.a.i exceed the requirements listed in Annex 1, section 7.4 of the P.E.D. All products requiring hydrostatic testing to comply with the P.E.D. will be tested at 1.5 times design pressure per section 4.4.a.i. b. Material hydro test: Refer to Appendix A.
Test Pressure Holding Time: The hydrostatic test pressure shall be continuously maintained for a minimum of 10 minutes or for the minimum time specified by the code when testing for an upgrade of material per NCA 3867.4e. Additional time may be added to conduct examination for leakage. When conformance to ASME Section III is specified, the test pressure shall be maintained for 10 minutes and then reduced to the greater of design pressure or 75% test pressure during the examination for leakage
Examination for Leakage: Examinations for leakage shall be made of all pressure-retaining joints and connections. Leakage of temporary gaskets and seals is permitted as long as it does not exceed the capacity to maintain the required test pressure for the required holding time. When conformance to ASME Section III (NPT stamp required) is specified the test and examination shall be performed in the presence of the Authorized Nuclear Inspector.
Test Data Sheet: Performance of the hydrostatic test shall be documented on the "Test Data Sheet" DS-15007.
Test Log Sheet: Invoice number, PI calibration number and range, test pressure, and the initials of the operator shall be documented on the "Test Log Sheet" (Ref. DS-8360) maintained at the Hydrostatic test bench.
TEST PROCEDURE FOR DP FLOW PRODUCT ASSEMBLY .1
Install DP flow product assembly in test fixture.
Record the date, design pressure, PI serial number and range, and applicable code on the data sheet. Calculate the required test pressure. Record the invoice number, PI calibration number and range, test pressure, the date, and initials of the operator on the test log sheet.
Open water supply valve and fill the test fixture. Evacuate all air from the
EP-4017 REVISION AJ Page 7 of 10 fixture and sample with vacuum pump.
Slowly pressurize the test fixture to the required test pressure
Hold pressure for the required time.
Record the test pressure and hold time on data sheet.
Inspect for leakage and record on data sheet.
After completion of the examination close the water supply and slowly depressurize the test fixture.
After testing, the Annubar assembly shall be dried with filtered shop air.
TEST PROCEDURE FOR SENSOR MATERIAL .1
The following steps describe the welding of temporary fittings to the sensor material for purposes of hydro testing. The welding is carried out per EP-4005 paragraph 4 â€œGeneral Weldingâ€? (non-Code). After hydro testing, the temporary welds, including the entire heat-affected zone, shall be removed from the sensor material.
Seal one end of the sensor sample using proper sized Annubar tips and the appropriate weld filler to provide seal for each individual internal tube and outer shape tube.
Weld an NPT fitting to each of the internal tubes either directly on end or side or using intermediate tube.
Connect hydro fixture to one of the inner tube fittings and test per 5.2 through 5.8 inclusive. Identify as Tube "A" on Test Data Sheet. Determine test pressure using Appendix A.
Connect hydro fixture to the other inner tube fitting and per 5.2 through 5.8 inclusive. Identify as Tube "B" on Test Data Sheet. Determine the pressure per Appendix A.
Remove sample from fixture and dry out with filtered shop air. Cut off fittings and any tubes installed in 6.2 by making a transverse cut 1/2" below the weld.
Remove portion of inner tubes from the cut end to a depth of approximately 1/8" deep by 1/4" long.
Attach an NPT fitting to the end by welding directly to the outer tube only or to a solid tip with hole that is welded to the outer tube only. The requirement is that each of the inner tubes and the outer tube are connected in common to the NPT fitting so all will be pressurized equally during the test.
EP-4017 REVISION AJ Page 8 of 10
Connect the hydro fixture to the NPT fitting and test per 5.2 through 5.8 inclusive. Identify as Tube "C" on Test Data Sheet. Determine the test pressure, using Appendix A.
Remove sample, drain, cut off fitting and tips, and dry out using filtered shop air.
TEST ACCEPTANCE .1
The test will be considered complete when all joints and connections have been found to be leak-tight at the test pressure.
Completion and results of the test will be documented on the attached "Test Data Sheet". Completed data sheets shall be maintained in the project documentation package.
Items requiring PEDa. PED Category I: Statistical acceptance. Hydrostatic testing will be conducted on a sampling basis. Tests will be performed on a minimum 10% of each different model type manufactured under the PED Quality Manual Supplement requirements. Individual units will be accepted without test providing that model type has previously been tested under the sampling plan. Model types are described by the applicable work instructions. b. PED Category II, III & IV: Items will be 100% hydro tested per this procedure.
EP-4017 REVISION AJ Page 9 of 10 Control No. __________________ Serial No. ___________________ Model ______________________ TEST DATA SHEET Hydrostatic Test Procedure E. P. 4017
Time Test Pressure Held minutes
Inspect test specimen for leakage. If any leakage is found, note location in "remarks" below.
Pressure Gauge Serial No.: ______________
Yes _____ No _____
Remarks: _____________________________________________________________________ _____________________________________________________________________ Test conducted by: _____________________________________________________ Date:
Authorized Nuclear Inspector:
NOTE: Residual moisture is clean, deionized water from hydrostatic testing. DS-15007 (3/27/03)
EP-4017 REVISION AJ Page 10 of 10 APPENDIX A A.1
Purpose The purpose of Appendix A is to determine the test pressure requirements when tubing is being hydrostatically tested.
Scope A.2.1 Round tubing will be hydrostatically tested to determine compliance with engineering, customer, or code requirements. A.2.2 Sensor shape tubing will be tested to determine compliance with engineering, customer or code requirements.
References A.3.1 American Standard National Standard Code for Pressure Piping, ANSI/ASME B31.1, Chapter VI. A.3.2 American Society of Mechanical Engineers Boiler and Pressure Vessel Code, Section III, Articles NB-6000, NC-6000, and ND-6000.
Pressure Determination A.4.1 Pressures are determined for round tube directly using ASTM/ASME A450/A-450M/SA/450SA-450/SA-450M, applicable hydrostatic section and table. A.4.2 Pressures are determined for shape tubing by taking the largest cross section dimension as the equivalent diameter using ASTM/ASME A450/A-450M/SA/450/450SA-450/SA-450M, applicable hydrostatic section and table. The pressure indicated will apply to testing of inner and outer when part of the sensor assembly.