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10 HX ARAMCO ENGINEERING STANDARDS **x HYDROSTATIC TESTING FLUIDS AND LAY-UP PROCEDURES TABLE OF CONTENTS scope CONFLICTS AND..DEVIATIONS. APPLICABLE ARAHCO STANDARDS GENERAL REQUIREMENT pee CARBON STEEL AND ALLOY STEEL EQUIPMENT STAINLESS STEEL EQUIPMENT OTHER CASES HYDROTEST FLUID PREPARATION DISPOSAL SAFETY NUMBER AES~A-007 ISSUE DATE: 08 JUL 87 REPLACES +: ACS-A-007 PAGE NO. : 1 of: 1 10 4 ql rv 2 NUMBER + AES~A-007 xxx “ARAHCO ENGINEERING STANDARDS **x ISSUE DATE: 08 JUL 87 HYDROSTATIC TESTING FLUIDS AND REPLACES +: ACS~A-O07 22 of 1 LAY-UP PROCEDURES PAGE NO. SCOPE “This standard establishes requirements for hydrostatic test fluid composition and subsequent lay-up procedures for storage tanks, pressure vessels, in-plant piping and pipelines in Aramco facilities both onshore and offshore. The purpose of this standard is to minimize corrosion damage related to hydrostatic testing. CONFLICTS AND DEVIATIONS Auyy conflicts between. this Standard and other. Aramco ae Engineering Standards (AESs), related Aramco Materials System Specifications (AMSSs) codes, forms, and Aramco Nandatory Drawings (AMDs) shall be resolved by the Aramco Chief Engineer, Dhahran. Any deviations providing less than the minimum requirements of this standard require written approval from the Aramco Chief Engineer, Dhahran. APPLICABLE ARAMCO STANDARDS Other Aramco standards and specifications concerned with hydrostatic tests are: AES~A-006 Pressure Testing AES-S-060 Aramco Plumbing Code AES-f:2970 7 Installation of Utility Piping Systems AES-Gr116 Field Cleaning and Flushing of Lubes Seal 011 Systems AES~L-051 Construction Requirements of Cross Country Pipelines GENERAL REQUIREMENTS In the case of new construction, the construction agency shall have the responsibility for adhering to this specifications Projects Inspection shall be the monitoring. authority. For existing facilities, Maintenance or Operations shall have the responsibility for adhering to this specification; Operation Inspection shall be the monitoring authority. NUMBER : AES-A-007 xe ARAMCO . ENGINEERING STANDARDS xxx ISSUE DATE: 08 JUL 87 HYDROSTATIC TESTING FLUIDS AND REPLACES .: ACS-A-007 LAY-UP PROCEDURES PAGE NO. : 3 of 11 The test fluid shall normally be water (e.g. clean condensate, reverse osmosis or electrodialysis watery well water, seawater) which has been treated for control of corrosion and bacteria when applicable. Every possible effort shall be made to minimize the duration of the period between introduction of hydrotest water and commissioning of the equipment. Hydrotest shall be scheduled, as. close. to-start.up date.as possible. Where the period between introduction of hydrotest water and commissioning.exceeds,60,days.a.proper lay-up, shall. be carried out as an inteoral part of the hydrotest procedure. In special cases where there is a possibility that the operating fluid or equipment itself could be adversely affected by incomplete removal of water» a hydrocarbon liquid shall be considered for the hydrotest fluid. Such a fluid, e.g. diesel, shall not have a flash point below 54 deg C (130 deg F). Reacration shall be minimized at any time when metal surfaces are wet. A-pneumatic or inert gas test shall be in accordance with AES-A-004. Totally non-metallic or coated facilities will not require any special corrosion inhibition. However, requirements for a partially coated system shall be the same as for an uncoated ‘system. Any hbydrotest or lay-up procedure shall be compatible with the vmost corrosién=susteptible material in the system being tested. 7 Testing of lube and seal oil systems is covered in AES-A-004. NUMBER : AES-A-007 xxx ARAMCO ENGINEERING STANDARDS ¥x* ISSUE DATE: 08 JUL 87 ) HYDROSTATIC TESTING FLUIDS AND REPLACES : ACS-A-007 LAY-UP PROCEDURES PAGE NO. : 4 of IL Bele? 5.2.1 ? sod «il CARBON STEEL AND ALLOYS. EQUIPMEN: Treatment of Hydrotest Wate Control of corrosion caused by oxygen is required where total tater contact time will exceed 14 days and shall be achieved by the addition of an oxygen scavenger to the hydrotest water. Dosage shall be 200 ppm (2 liters/10,000 ers of water) of a 45% solution: of “a sulfite. type. oxygen scavinger.e.9- K-490 ammonium bisulfite (AMS-26-733-365)- Controh.of corrosion. caused.by bacterial action, is.required there total water contact time will exceed 90 days and shall be cehieved by the addition of a biocide to the hydrotest water- whe selection of the appropriate biocide and dosage rate shall ‘ be made by Corrosion Control Division of Consulting Services Department. wirements for Special Equipment Storage Tanks Storage tanks that are not designed for taking slight positive pressure such 2s open-roof tanks, floating-roof tanks or API atmospheric cone roof tanks cannot. be sealed off from air. Chemical treatment is impractical and therefore not required. It is mandatory to remove the test fluid from the systems as completely as possible immediately after completion of the hydrostatic test. rn“storage tanks that are designed for’ taking positive pressure, the test water will be treated with oxygen ccavengers 5-1-1. hen the water will remain in the system Tee tore than 90-days Cinélddtig filling time, test” and Wet” eer atercgen lay-up period), the water will also require” © bactericidal treatment 5.1.2. Pressure Vessels Treatment shall comply with 5.1.1 and 5.1.2. 5.2.4.1 5.3.11 NUMBER : AES-A-007 xo ARANCO- ENGINEERING STANDARDS ¥Kx ISSUE DATE: 08 JUL 87 HYDROSTATIC TESTING FLUIDS AND REPLACES : ACS~A-007 LAY-UP PROCEDURES PAGE NO. 5 of it In Plant Piping Treatment shall comply with 5.1.1 and 5.1.2. Cross Country and Sub Sea Pipelines . Revalidation of Existing Hydrocarbon Pipelines: No chemical treatment is required. However, in the event of rupture during-hydrotest .qf-cross country, pipelines it is important to igolate the damaged section quickly in order to minimize air ingress to the rest of the system. New installations and existing pipelines carrying fluid other than hydrocarbons: The sane provisions apply as described in 5.1.1 and 5.1.2. Hf Lay up Procedures One of the following lay-up procedures shall be followed as a part of the hydrotest, unless the start-up date will be within 60 days from hydrotesting fluid introduction. This practice, however, does not apply to heat exchangers (including fin-fan coolers). Heat exchangers: shall be properly laid up unless start-up is within 14 days of commencing hydrotest. If lay-up procedure is not required, it is still desirable to keep the system filled with hydrotest fluid as long as possible even after the hydrotest is completed. If 4 lay+up procedure is followed, thé time duration between demothballing for commissioning activities and the system start-up shall be less than 60 days. Wet Lay-up ~ Upon verification of the proper residual sulfite level (section 5.3.2.1 belom) and completion of a successful final hydrostatic test, the system shall remain full of the treated water under positive pressure until the system is ready for commissioning and start-up. NUMBER AES-A-007 ) wx ARAMCO ENGINEERING STANDARDS «xx ISSUE DATE: 08 JUL 87 HYDROSTATIC TESTING FLUIDS AND REPLACES + ACS-A-007 LAY-UP PROCEDURES PAGE NO. 6 of IL $232.2 A minimum residual sulfite level of 20 ppm shall be established throughout the system. This includes dead legs. Water sample(s) shall be analyzed at the pertinent location(s). Sulfite and bactericide levels Cand other chemical analyses specified elsewhere) can be conducted by the Laboratory personnel upon request. Test results shall be reported and documented in the hydrotest report. Once verification is established, the system shall remain closed. Further testing is not required unless. the system is. to.be layed up for more than 6 months or air ingress is known to have occured. The positive pressure maintained during the wet lay-up shall be commensurate with the strength of the system. For storage tanks in 5.2.1.2, it will be 200 Pa to 500 Pa (2 cm to 5 cm water gage) for pressure vessels, it will be 34.5 kPa to 138 kPa (5 to 20 psig). The positive pressure can be maintained by nitrogen or a sweet hydrocarbon gas. Nitrogen is preferred. For in-plant piping and cross-country pipelines, a positive hydraulic pressure utilizing the treated water may be employed in lieu of gaseous pressure. Dry lay-up The sytem shall be completely drained and free from all standing water. Total drainage is an essential step in achieving a dry lay-up. If this cannot be verified by visual inspection or other reliable means e.g. utilizing drains at all low points, a dry lay-up shall not be considered. The system shall be dried to a dew point of -1 deg ¢ (30 deg Foor less at all exit points, by blowing dry air.on, nitrogen through the system. The system shall then be shut. in. for a period of not less than 12 hours’ to allow any remaining moisture to come to equilibrium with the dry air. Exit. dew points shall then be measured again and if found to be above -1 deg © the drying procedure shall be repeated. For steel surfaces seriously contaminated with salt particles and heavy rust, a dew point of -35 deg C (-30 deg F) or less shall be reached and maintained. When this required dew point is reached, the system shall be shut-in and a positive pressure maintained per 5.3.2.2 during the lay-up period. AES-A-007 : NUMBER ) xe ARAMCO - ENGINEERING? STANDARDS *¥# ISSUE DATE: 08 JUL 87 HYDROSTATIC TESTING! FLUIDS AND REPLACES ©: ACS~A-007 LAY-UP PROCEDURES PAGE NO. : 7 of 11 5.3.3.3 5.3.5.1 5.3.5.2 5.3.5.3 A reliable way to reach a ~35 deg C (-30 deg F) dew point is to pressurize the system four times to 303 kPa (44 psig) with dry nitrogen, holding it each time for 15 minutes and then blowing it down to 0 psig except for the final purse which shall be held at a minimum of 34.5 kPa (5-psig). Inert Gas Lay-up Upon: completion. ofa successful, final hydrostatic test, the hydrotest fluid shall be displaced with an inert gas (nitrogen preferred) until no water drains out of the system, and-the-system-shall.ba shut~in under. positive pressure per 5.3.2.2 until the system is ready for commissioning and start-up. Draining the bulk of hydrotest water out of the system and attempting to replace the volume with an inert gas by either repeated repressuring or sweeping shall not be considered as inert gas lay-up~ However» in the case of long pipelines, sweeping with inert gas driven scrapers is considered acceptable. Ambient Lay-up The system is closed after ensuring total drainage of hydrotest and rinse water. If necessary, any standing water shall be swept out and mopped up. Where total drainage cannot be verified by visual inspection or other reliable means e.g. utilizing drains at all low points, ambient lay up shall not be considered. A vacuum breaker and a pressure relief vent shall be installed and made functional during the ambient lay-up. Ifram water, or sea ater has been the hydrotesting fluid, EVs helpful for corrosion control to spray rinse the system with fresh water after the hydrotest water is drained. Where (a) no corrosion allowance has been provided, (b) the anticipted pitting cannot be tolerated or (c) particulate rust cannot be tolerated for any reason, ambient lay-up shall not be permitted. AES~A-007 NUMBER ) we ARANCO ENGINEERING STANDARDS xxx ISSUE DATE: 08 JUL 87 HYDROSTATIC TESTING FLUIDS AND REPLACES : ACS~A-O07 LAY-UP PROCEDURES PAGE NO. .: 8 of 11 6.L.det STAINLESS STEEL EQUIPMENT “There are certain special and critical requirements for the control of water chemistry in hydrotesting stainless steel equipment, e.g. AISI 400 chromium seriess AISI 300, nickel-chromium series. Requirements for Testing Fluids The chloride content of the hydrotesting water shall be limited and the pH of the water shall be adjusted. The uater/must be rendered: anaerobic .and.bactericidal. ca Chloride Content of the Hydrotest Water The maximum allowable chloride content for hydrotest water in stainless steel systems shall be 50 ppm at the time of injection into the system with the exception below UB a bee bes 29 In special cases, with the specific approval of the Corrosion Control Division of Consulting Services Department, water of up to 250 ppm chloride ion may be permitted, provided (a) that the hydrotest period is less than four days and (b) that the system can be rinsed with condensate or demineralized water and (c) that the system can be completely drained immediately after hydrotest/rinse. The chloride content of the hydrotest water shall be verified on site before the water is injected inte the system. pH Adjustment of the Mydrotest Fluid See The hydrotest water Shall have a@ pH of 10.5 +7- 0.5 at ‘the time of injection into the system, effected by addition of soda ash (AMS-26-840-916) or caustic (AMS-26-845-411). Anaerobic Treatment The hydrotest water shall be made anaerobic by the addition of 200 ppm (i.e. 10 L of 20% solution per 10,000 L of water) of sodium sulfite (e.g.» AMS-26-850-982). 7 AES-A-007 NUMBER 5 xx ARAMCO ENGINEERING STANDARDS *#% ISSUE DATE: 08 JUL 87 HYDROSTATIC TESTING FLUIDS AND REPLACES : ACS-A-007 LAY-UP PROCEDURES PAGE NO. : 9 of 11 6.1.3.1 6.1.3.2 6a) 6.1.4.1 6.4.4.2 A residual sulfite level of 20 ppm minimum shall be established. The same provisions apply as described in 5.2.2.1. The sodium sulfite solution shall be mixed on site just prior to injection into the system. A chemically inert Stmosphere (e.g. nitrogen, or a sweet hydrocarbon gas) must be maintained over this solution in a closed mixing vessel. Catalysed sodium. sulfite -shall.not.be used. Bactericidal’ Treatment Tf the hydrotest water is to remain in the stainless steel equipment for more than 14 days Cincluding filling time, test and wet or nitrogen lay-up period), the hydrotest water / shall be made bactericidal. Bactericidal treatment procedures are described below one of these shall be folloued: The hydrotest water shall be treated with a suitable bactericide. The selection of the appropriate bactericide and dosage rate shall be made by Corrosion Control Division of Consulting Services Department. The pH of the water shall be raised to 12.5.minimum by caustic addition alone. If the subsequent service temperature is above 80 deg C (180 deg F), the system shall be rinsed with water of equal or better quality of not more than 7.5 pH prior to commissioning. This alternative approach is recommended in situations in which the bactericide-treated hydrotest fluid must be discharged into an area where it may create detrimental effects on the environment. Uay-Up Procedures Proper lay-up is mandatory for stainless steel equipment unless the start-up date will be within 4 days after the hydrotest. Any one of the four lay-up procedures specified in 5.3.2 through 5.3.5 can be applied. HK ARAMCO ENGINEERING STANDARDS xxx ISSUE DATE NUMBER : AES~A-007 08 JUL 87 ACS-A-007 10 of IL HYDROSTATIC TESTING FLUIDS AND REPLACES LAY-UP PROCEDURES PAGE NO OTHER CASES For aay and all special materials or doubtful situations, the Corrosion Control Division of Consulting Services Department must be contacted. For calvanized steel pipe, the procedures of paragr#phs 5.1, 5.1.J, 5.1.2 and 5.3 shall apply. The rervice watery or water of better quality, shal. be used for lydrotesting the following systems: 61)" Pvc, “ep¥c and’ AMBS Pipes — (AES~S~070) (2) reinforced epoxy piping (AES-S-070) (3) plumbing system (AES-S-060) (4). copper/copper alloy systems (including Monels) CAES=5-060) The hydrotesting water shall also be treated with disinfectant for testing utility or potable water systems. Chlorine water or sodium hypochlorite is required to effect a residual chlorine between 0.2 ppm and 0.5 ppm. No lay-up procedure is required for totally non-metallic facilities (e.g. PVC pipe) or copper/copper alloy (including Honels) systems. In existing plumbing systems which contain carbon steel or alloy steel components lay-up procedures in 5.3 shall be followed except the hydrotesting water shall be treated in accordance with 7.3.1 onlys For cement lined or asbestos-cement pipe, the sulfate ion content” of the water ‘Cexcept~sea"water) shall be limited to match Limitations of the particular-grade of Portland cement employed (i.e. less than 150 ppm for Type I, 150 to 500 ppm for Type II, 500 to 1500 ppm for Type V). Soft water should not be used in cement lined or asbestos-cement pipes- AES-A-007 NUMBER : xxx ARAMCO ENGINEERING STANDARDS xxx ISSUE DATE: 06 JUL 87 HYDROSTATIC TESTING FLUIDS AND REPLACES : ACS-A-007 LAY-UP PROCEDURES PAGE NO. 11 of 11 HYDROTEST FLUID PREPARATION In order to ensure effective corrosion control during and atter hydrotest, the oxygen scavenger and bactericide must be injected continuously while the system is being filled. Separate proportioning pumps should be used for each chemical to avoid adverse reactions. In special cases, side stream of chemical utioris “or mixing tanks. may be utilized as an alternative to 6.2. Chemical injéetion rates should be verified’ by displacement gauges. DISPOSA Bactericides used in hydrotest fluids are toxic materials. Corrosion Control Division of Consulting Services Department shall; as part of the biocide treatment selection process, consult with the Environmental Unit, Process and Control System Department and they shall specify an acceptable disposal procedure on a case by case basis. Hydrotest fluid treated with oxygen scavenger alone will not create any disposal problem. Disposal of pH-adjusted hydrotest fluid will normally not be such a problem as bactericide-treated water, However, the Environmental Unit of the P&CSD shall be consulted for disposal." SAFETY. Handling storage. and mixing ofthe chemicals to:be used for: hydrotest water treatment shall follow procedures outlined in the chemical Hazard Bulletins provided by the Industerial Hygiene Unit, Preventative Medicine Services Department. Eye wash (and shower facilities if possible) must be at the mixing site of the Chemicals and operational before chemicals arrive.

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