4 General Technical Specification of Bhilai Steel Plant, SAIL ...

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© 2007 MECON Limited All rights reserved General Technical Specification - After blowing, the line shall be pressurized up to 1.25 times the maximum working pressure using air/ nitrogen. The test pressure shall be held for 30 minutes during which the joints shall be lightly tapped with a wooden hammer of 1.5 kg weight. - Pressure shall be gradually reduced to the operating pressure and all joints checked by soap solution for leakage. If any leakage is detected, line shall be depressurized and defect rectified. - Leakage test for the pipeline system shall be done at operating pressure for a period of 24 hours. During this period, pressure and temperature readings shall be taken at an interval of 1 hour. Duplicate gauge with least count of 0.1 kg/ cm2 for pressure and 0.5 deg. C for temperature shall be used. - The percentage pressure drop (P) shall be calculated as follows : P = 100 (1 – P2/ P1= * T1/ T2 ) Where P1 and P2 are pressure in the pipe at the beginning and end of test and T1 and T2 are absolute temperatures at the beginning and end of the tests. - Leakage of air / nitrogen determined by above formula shall not exceed 0.2% per hour. - After satisfactory completion of leakage test, the pipeline shall be isolated and kept under pressure of 1.0 kg/ cm 2 till the line is commissioned. 008 Commissioning 009 Safety - Before charging the pipeline with oxygen, the line shall be blown with dry, oil free air/ nitrogen at a velocity of minimum 20 m/ s for a period of at least 8 hours. Cleanliness of outlet air shall be checked by holding a piece of white paper for 3 to 5 minute at air outlet. If dust particles are found on the paper, blowing shall be continued till paper test shows negative results. - After completion of blowing, oxygen shall be introduced gradually increasing the oxygen percentage in the pipe. The velocity of oxygen flow shall be limited to 10 m/ s till all air/ nitrogen is exhausted from the pipe. - Oxygen shall be vented through bleeders in open atmosphere at a safe place away from open flames/ fire. Minimum height of bleeder outlet shall be 2.5 m from ground/ platform level or shop roof. - After charging the line completely with oxygen, bleeder valves shall be closed and line may be put into service. - Testing, cleaning and commissioning of oxygen pipelines shall be carried-out only in the presence of and with the permission of senior engineers of the and the Consultant. - The safety department of the shall be informed and their concurrence taken on all matters related to cleaning, testing and commissioning of oxygen pipe lines. - All first aid and fire fighting facilities should be readily available. - During testing of pipelines by air, the area shall be cordoned off and clear working placards shall be displayed. - All safety precautions shall be observed in storage and handling of solvents. Passing and acceptance of pipelines Prior to passing and acceptance of pipelines for operation they shall be inspected with the view to check that all civil, structural, erection and special works are completed. Gases & Liquid Fluids Page 50 of 51 GS-02
© 2007 MECON Limited All rights reserved General Technical Specification Before handing over the pipelines for operation, the Contractor shall provide the following technical documents. 001 Certificates of inspection, degreasing and testing of fittings, pipe joints and parts. 002 Certificate on the inspection of internal cleanliness of pipes. 003 Certificates on pipe, flanges, plugs and welding material. 004 Copies of the welder`s certificates. 005 Results of mechanical testing of samples. 006 Certificate on testing of pipelines for strength and leaks. 007 Principal scheme of pipelines with indications of welded butts and labels. Gases & Liquid Fluids Page 51 of 51 GS-02
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