est group b.v. the netherlands - · pdf filetest plugs eliminate 80% of time spent welding-on...

1 | March 25 2015 IPLOCA New Technologies| © 2015 Curtiss-Wright

EST Group B.V. The Netherlands Hydrostatic Test Plugs ‘Means to an End or Ends to a Means’


GripTight Safety Gag

Pressure testing of open ended piping systems.

Test plugs (reusable) are temporary end closures that simplify pressure testing piping systems, pipe spools, pipe racks or pressure vessels

Test Plugs Eliminate 80% of time spent welding-on and cutting-off end caps

Use of safety gag designed to prevent the plug from exiting the designated testing area by limiting its travel and changing its direction recommended

GripTight® Test Plug & Safety Gag

Safe, Reliable, and Easy to Use

Provides Enhanced Safety During Testing

Open ended pipe testing

3 | March 25 2015 IPLOCA New Technologies| © 2015 Curtiss-Wright Cost & Time Savings per Test

GripTight® High Pressure Test Plug

Test Faster than Welding on End Caps GripTight® High Pressure Test Plug



Save Time and Money on Every Test

Faster – No welding/cutting end caps - reduces testing times up to 80%

Safer – Will not eject under high pressure Ideal for testing open ended pipes, spools,

tubes and pressure vessels Sizes ½” to 42” NPS (DN15 - DN1100) Extreme pressures, up to 14000 PsiG (960

BarG) Self Gripping - uses line pressure to increase

grip power Seal and Gripper assemblies are field

replaceable Eliminates need for pre & post weld heat

treatment

Industry Best Practice

GripTight® High Pressure Test Plug


5 | March 25 2015 IPLOCA New Technologies| © 2015 Curtiss-Wright Quick and easy installation

GripTight Vent Assembly

GripTight® Vent Assembly

The GripTight Vent Assembly can be used to collect test fluid from test systems: Gives the ability to easily control test medium Contaminated fluids can be handled safely Allows operators to collect any special test medium, such as

glycol Increases safety by keeping test medium off scaffolding and

other walking surfaces

The GripTight Vent Assembly provides the ability to vent as much air as possible from a piping system: Testing with air present in a piping system or components

stores energy within the system ASME B31.1 and ASME PCC-2 require placing vents at the

high points of a vessel or piping to purge air during filling Best hydrostatic testing practice dictates that as much air as

possible must be removed from all test components before hydrostatically testing

Evacuate all the Air from the System Prior to Testing



When a flange modification was required, the entire line needed to be isolated and drained

– Multiple flanged connections needed to be disassembled and a blind installed – Lines containing flammable materials or materials incompatible with water had to be cleaned

Low pressure plumbers plugs were used to isolate the hot work area, often with disastrous results

– Safety concerns injuries, fires and explosions After welding, a test blind was installed on the new flange and the entire line was filled with water and hydro-tested

– Time consuming filling and draining process – Water treatment and disposal concerns – Line dehydration expense

Original Method

6

Flange Weld Testing & Isolation Plugs

7 | March 25 2015 IPLOCA New Technologies | Curtiss-Wright

High Lift Flange Weld Test Plug

Animation shows plug functioning as weld fixture, purge dam and hydrotest while isolating upstream vapors from area of hot work.


Facilitates field flange replacements Flange Classes 150 to 2500 LB Class Sizes from 3/4” to 42” (DN 20-DN 1050), Typical pressures to 2250 PsiG (155 BarG) Larger sizes available Higher test pressures available Faster – one tool to isolate, weld & test Safer – Reduces waste disposal problems

– Typically < 2 gallons (8 liters) per test Reduce Cost – Reduces the expense and

downtime delays of conventional testing methods


Flange Weld Test Plug – Key Points:



Flange Weld Testing and Isolation Plugs enable maintenance staff and contractors to quickly and safely self-perform hydrostatic testing of flange replacements and tie-ins.

What are Flange Weld Testing and Isolation Plugs?

Why Testing & Isolation Plugs? The process of adding or replacing a flange in existing piping systems

is time consuming and potentially hazardous – Original flange weld test methods were time and resource intensive – Potentially flammable and/or explosive vapors must be isolated or evacuated

from hot work areas


When a flange modification was required, the entire line needed to be isolated and drained – Multiple flanged connections needed to be disassembled and a blind installed – Lines containing flammable materials or materials incompatible with water had to be

cleaned

Low pressure plumbers plugs were used to isolate the hot work area, often with disastrous results – Safety concerns injuries, fires and explosions

After welding, a test blind was installed on the new flange and the entire line was filled with water and hydro-tested – Time consuming filling and draining process – Water treatment and disposal concerns – Line dehydration expense

Original Method

1



Double Block & Bleed

Animation shows plug functioning as double block and bleed isolation point to prevent upstream vapors or pressure from entering area of hot work. Once cooled, the plug is repositioned to pressure test the new weld joint.


Sizes ¾” through 42” NPS (DN 20 to DN 1050) Pressures: 2250 PsiG (155 BarG BarG)

between seals, <10 PsiG ( 0.7 BarG) upstream Seal sizing eliminates weld protrusion issues Aluminum construction reduces weight Faster – One tool for isolation & testing Safer – Provides positive means to confirm

isolation of explosive vapors from “hot work” Reduces Cost – Significant reduction of labor

time and test water usage – Uses < 2 quarts (2 liters) per test – No longer flange size / class specific

Double Block & Bleed

Isolate explosive vapors, hydro-test and repair pipe connections


GripTight® Isolation Plug

Animation shows plug functioning as double block and bleed isolation point to prevent upstream vapors or pressure from entering area of hot work or dislodging plug. Once cooled, the plug is repositioned to pressure test

the new weld joint – while installed, the plug will withstand upstream pressures to 1440 psig (100 barg).


Combines proven gripper design in an isolation plug package – Test Pressure (between the seals): 2250 PsiG (155 BarG) – Upstream pressure: 1440 PsiG (100 BarG) – Sizes ¾” through 24” NPS (DN20-DN600)

Faster – One tool for isolation & joint testing – eliminates need for upstream blind

Safer – Positively isolates explosive gases from hot work area, even if / when full operating line pressure is applied upstream

Reduces Cost – Significant reduction of labor time and test water usage – Uses < 0.22 Liters / 0.,06 Gallons per test – No longer flange size / class specific

GripTight® Isolation Plug


Reverse Pressure GripTight® Plug

Animation shows plug installed independent of test blind. As test pressure is applied, GripTight self gripping action further engages the grips. The weld joint is subjected to the full longitudinal, radial, and hoop stresses, just as it

will see in service.


Reverse Pressure GripTight® Plug

Provides a solution where the weld joint is subjected to 100% of the hydrotest stress – radial, hoop and longitudinal Test simulates real world service conditions Sizes from ¾” through 24” NPS (DN 20 DN 600) from stock – larger, smaller, and

custom sizes available Typical working pressure: 2250 PsiG (155 BarG) – higher pressures available Safer – Uses proven gripper design – pressure assisted gripping action Reduce Cost – Uses a minimal amount of water per test


Test Water Usage Comparison

System: 6” SCH 40/STD Pipe, 305 Meter / 1000 ft length

Traditional Blind Flange:

Flange Test Plug:

Double Block and Bleed Plug:

5678 Liters / 1500 Gallons

11.3 Liters / 3 Gallons

0.22 Liters / 0.06 Gallons


Comparative Matrix

Method Strength Weakness Traditional Blind Flange

• Known and accepted process • Tests in working configuration

• Time, cost, safety, practicality

Flange Weld Plug • Fast: Only tests new welded end • Safer: Isolates work from upstream

• Does not test axial stress

Double Block and Bleed

• Fast: Small fill volume • Safer: Double seal verifies isolation • Light weight: Easy to use

• Negligible axial stress • Limited upstream

pressure ability

GripTight Isolation Plug

• Fast: Small fill volume • Safer: Double seal verifies isolation • Safer: Holds upstream line pressure • Light weight: Easy to use

• Negligible axial stress

Reverse Pressure GripTight

• Fast: Only tests new welded end • Safer: Isolates work from upstream • Safer: Holds upstream line pressure • Light weight: Easy to use • Tests in working configuration

• Requires special installation hardware


www.cw-estgroup.com

A.G.C.M. (Ron) de Rijk Director EMEA Sales & Operations

EST Group B.V. Hoorn 312A, 2404 HL , Alphen aan den Rijn, The Netherlands Tel: +31 (0) 172 418841 Mobile: +31 (0) 6 53584683 [email protected]

http://www.cw-estgroup.com/

mailto:[email protected]

mailto:[email protected]

est group b.v. the netherlands - · pdf filetest plugs eliminate 80% of time spent welding-on...

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