QUALITY CONTROL SYSTEM MANUAL

Hydrostatic Test For Shop and Field of Boilers and Its Components. (SECTION I) ProcedureRev.DatePage08006/12/2015 1 of 1

INDEX

CONTENSSHEET

1. Purpose.2

2. Scope2

3. Applicable Documents.2

4. Responsibilities2

5. Definitions..3

6. Procedures

6.1. Hydrostatic Test3

6.2. Test Gages.4

6.3. Hydrostatic Deformation Test.5

6.4. Acceptance Standard..5

7. Records6

7.1. Forms: Annex AP-TEST-01.....7

1. PURPOSEtc "1.- PURPOSE."The purpose of this document is to establish the activities that will be carried out for the performance of the hydrostatic tests in shop or field site that are required in Boilers and its components.

2. SCOPEThis procedure applies to all the hydrostatic tests to be performed by Cromanza, S.A de C.V., at shop and field in Boilers and its components after all fabrication has been completed, under the Section I of ASME Code.

3. APPLICABLE DOCUMENTS- Chapter 4, 9, and 10, of the Quality Control System Manual

- Section I of the ASME Code, for Boiler and Pressure Vessels, 2013 Edition.

4. RESPONSIBILITIES Quality Control Manager shall be responsible for the approval, implementation and updating of this procedure and approval of test certificates. Witness the test by himself or his designee.

Coordinate all activities related to the verification and record of hydrostatics tests, preparation and preservation of calibrated gages and thermometers in accordance with this procedure. Also, review of test certificates their filling and preservation.

Engineering Manager shall be responsible for the establish fabrication drawings, the test pressure rate and special instructions when applicable, to which the equipment or component will be tested, in accordance to applicable Customer and Code requirements.

Construction Manager (Shop and Field) shall be responsible for the preparation and filling with water of vessels to be tested, installation of all test gages and recorders and assistance during test perform. Drained, and cleanness of vessels after successful tests.

5. dEFINITIONSThe following definitions are applicable to this document:

LEAK: Is the evidence that a fluid is passing from on side to another in a closed vessel, independent the amount of fluid.

COMBINATION UNITS: Is a pressure vessel, which consists of two or more independently pressurized chambers that operate at the same or different pressure.

6. PROCEDUREtc "6.- PROCEDURE."6.1. HYDROSTATIC TESTHydrostatic testing of the completed boiler unit shall be conducted in accordance with the following requirements:

After a boiler has been completed [includes all piping and piping components], it shall be subjected to pressure tests using water at not less than ambient temperature, but in no case less than 70 F [20 C ]. Where required test pressure is specified in this paragraph, whether minimum or maximum pressures, they apply to the highest point of the boiler system. When the boiler is completed in the Cromanza, S.A. de C.V., shop without boiler external piping, subsequent hydrostatic testing of the boiler external piping shall be the responsibility of any holder of a valid S, A, or PP stamp. The pressure relief valves need not be included in the hydrostatic test. The tests shall be made in two stages in the following sequence:

(1) Hydrostatic pressure tests shall be applied by raising the pressure gradually to not less than 1 times the maximum allowable working pressure as shown on the Data Report to be stamped on the boiler. No part of the boiler shall be subjected to a general membrane stress greater than 90% of its yield strength [0.2% offset] at test temperature. The primary membrane stress to which boiler components are subjected during hydrostatic test shall be taken into account when designing the components. Close visual inspection for leakage is not required during this stage.

(2) The hydrostatic test pressure may then be reduced to the maximum allowable working pressure, as shown on the Data Report, to be stamped on the boiler and maintained at this pressure while the boiler is carefully examined. The metal temperature shall not exceed 120 F [50 C] during the close examination.

(3) A completed forced-flow steam generator with no fixed steam and waterline, having pressure parts designed for different pressure levels along the path of water-steam flow, shall be subjected to a hydrostatic pressure test by the above procedure [(1) and (2)] based upon:

a. For the first stage test a hydrostatic test pressure of not less than 1 times the maximum allowable working pressure at the superheater outlet as shown in the master stamping but no less than 1 times the maximum allowable working pressure of any part of the boiler external piping, excluding the boiler external piping.

b. For the second stage test [(2) above] the hydrostatic test pressure may be reduced to not less than the maximum allowable working pressure at the superheater outlet.

6.2. TEST GAGES (1)An indicating gage, visible to the operator controlling the pressure applied, shall be connected to the pressure parts. Hydrostatic head on the gage shall be considered such that the required test pressure is achieved at the top of the boiler.

(2) Dial pressure gages used in testing shall preferably have dials graduated over their entire range of about the intended maximum test pressure, but in no case shall the range be less than 1 that pressure. The spacing between graduations shall be such that the inspector and the operator controlling the test shall be able to determine when the required test pressure has been applied. Digital pressure gages having a wider range of pressure readings may be used provided the readings give the same or greater degree of accuracy as obtained with dial pressure gages.

6.3. HYDROSTATIC DEFORMATION TEST

Where no rules are given and it is impossible to calculate with a reasonable degree of accuracy the strength of a boiler structure or any part thereof, a full-sized sample shall be built by Cromanza, S.A de C.V., and tested in accordance with the Standard Practice for Making a Hydrostatic test on a Boiler Pressure Part to determine the Maximum Allowable Pressure, given in A-22 of Section I of the ASME Code or in such other manner as the Committee may prescribe.

6.4. ACCEPTANCE STANDARDThe Boiler and its components shall not show any leak. In case of leaks it must be examined to determine the magnitude of the discontinuity and to repair in accordance with requirements of Section I of the ASME Code (as apply), after which the vessel shall be re-tested in accordance with paragraph 6.1 to 6.3 above. When repairs are made, the part shall again be tested in the regular way, and if it passes the test the Inspector shall accept it. If does not pass the test the Inspector may permit supplementary repairs, or if in his judgment the pressure part is not suitable for service, he may permanently reject it.

7. RECORDS.All the records and other documents originated by the activities described in this procedure shall be maintained by the Quality Control Manager on Job File and shall be properly filled.

7.1. FormStc "7.1.- Formats." \l 2The Hydrostatic Test results shall be recorder in the Traveler Sheet; acceptance of the test is obtained by signature and dated in the document: Annex Exhibit No. 21Annex: Exhibit No. 21

Approved ByQuality Control ManagerAuthorized Inspector

Sign

Date

006/12/2015S.G.P.S.G.P.S.A.R.M.Q.C.M.S.G.P.Initial issue

RevisionsInvolved Areas

Rev.DateByApprovedReviewedAreaResponsibleModification