SENSOR Hydrotesting Sampling Systems Instruction

Hydrotesting Sampling Systems Instruction Revision History Rev Description of Change Author Effective Date Responsible Manager 0 Initial Release P. O’Neil 10/18/2016 Production Manager 1 Added Chloride Content Details P. O’Neil 9/5/2017 Product Manager 1. Scope This Work Instruction details the necessary steps for Hydrotesting a Sample System. 2. Safety Consideration a) Beware of pressures and do not exceed recommended pressures of test equipment. b) Safety glasses must be worn 3. Machines covered by the procedures a) The staging and assembly area and the tools used in this area. b) Hydrotesting station. 4. Work Instruction a) System must be complete before pressure testing. if not refer to Form No. 101-0200-005 – Assembly Work Instruction. b) Before pressuring the system, verify all tubing connections are tight. This must be done to ensure that tubing has been swaged properly per Form No. 101-0200-008 – Tubing Work Instruction. c) Remove all process gauges and plug ports before proceeding with the test. d) Verify Clean Water with less than 50 PPM Chlorides is being used as Test Medium. e) Connect Hydrotesting hose to Sample Inlet of system. f) Install appropriate test cylinder onto system if needed. g) Verify all valves are in proper position. h) Once valves are in proper position, connect a tubing plug of appropriate size to the Sample Out port. i) Slowly pump pressure until required pressure indicated on associated Clipboard (Form No. 101-0220-001 – Cover Page/System Requirement) is reached. Note: the hydro test pressure at any point in the piping system shall not be less than 1.5 times the design pressure but shall not exceed the maximum allowable test pressure of any non-isolated component. In cases where the customer has specific test pressures on the drawings or data sheets, those pressures should take precedence over the standard test pressures. j) Let system sit for 10 minutes to verify if leak is present. A leak will be shown by seeing a drop in pressure. If leaks occur, make any small adjustments needed to stop leak. k) To verify system has no leaks, there must be no drop in pressure for a 10 minute period. l) If a part(s) will not stop leaking, vent off pressure by turning Vent valve on Hydrotester to Vent. Follow Form No. 101-0100-016 – Control of Nonconforming Product. m) When testing is complete, turn Vent valve on Hydrotester to Vent, remove plug from Sample Out port, disconnect and remove flex hose from Sample Inlet port of system. n) The person doing the testing will then fill out testing tag with their initials and test pressure and attach to back of system plate to show that the system has passed Testing Inspection. o) Attach Instrument Air or Nitrogen to the inlet and allow the entire system to be purged of any remaining test medium. Allow system to purge for 5 minutes, then verify there is no remaining liquid coming out of the outlet port (via a small white cloth) with Instrument Air or Nitrogen flowing out. p) Record testing information on Form 101-0220-002 – Test Report, including, but not limited to operator name, recording the test date, operator initials, and pass/fail result. q) Sign off Form No. 101-0220-001 – Order Cover Page showing the line item was tested. Form No: 101-0200-012 Rev. 1 Issued: 9/5/2017 Page 1 of 2 FILE LOCATION: C:\Users\bterry\Documents\101-0200-012 - Hydrotesting Sampling Systems Instruction (SENSOR Sampling) Rev 1.docx UNCONTROLLED IF PRINTED – Check Form No. 100-0020-000 – QMS Document Master Index - for latest revision of this document Hydrotesting Sampling Systems Instruction 5. Reference Documents Form No. 101-0200-005 – Assembly Work Instruction Form No. 101-0100-016 – Control of Nonconforming Product Form No. 101-0200-008 – Tubing Work Instruction Form No. 101-0220-001 – Order Cover Page Form No. 101-0220-002 – Test Report Form No: 101-0200-012 Rev. 1 Issued: 9/5/2017 Page 2 of 2 FILE LOCATION: C:\Users\bterry\Documents\101-0200-012 - Hydrotesting Sampling Systems Instruction (SENSOR Sampling) Rev 1.docx UNCONTROLLED IF PRINTED – Check Form No. 100-0020-000 – QMS Document Master Index - for latest revision of this document