Doc. n.

RIG5829-PRO-TEC-005-E
saipem
DISCIPLINE PROCEDURE
Rev. 01 Date 17 Mar 14
ON SITE PRESSURE TESTING
Page 2 of 8

Revision Summary

Approved Issued Revision Section/ Page

Description of Revision Approved By
Date Date No. Revised
17 Mar 14 17 Mar 14 01 n/a Issued for approval and implementation V. Bille
 Doc. n. RIG5829-PRO-TEC-005-E
saipem
DISCIPLINE PROCEDURE
Rev. 01 Date 17 Mar 14
ON SITE PRESSURE TESTING
Page 3 of 8

INDEX

1 SCOPE AND PURPOSE 4

2 REFERENCE DOCUMENTS 4
3 DEFINITIONS 4
4 RESPONSIBILITIES 5
4.1 TOOL PUSHER / TOUR PUSHER 5
4.2 CHIEF MECHANIC 5
4.3 THIRD PARTY COMPANY 5
5 ACTIVITIES DESCRIPTION 5
5.1 APPLICABILITY 5
5.2 PREPARATION AND PLANNING 6
5.3 PRESSURE TEST PROCEDURE 6
5.3.1 General Hydrostatic Test Procedure 7
5.3.2 Rotary / Vibrator Hose Field Testing 7
5.3.3 Tests Frequency and Test Pressure 7
6 ATTACHMENTS 8
 Doc. n. RIG5829-PRO-TEC-005-E
saipem
DISCIPLINE PROCEDURE
Rev. 01 Date 17 Mar 14
ON SITE PRESSURE TESTING
Page 4 of 8

1 SCOPE AND PURPOSE

The scope of this procedure is to detail the frequency, parameters, sequence of operation and
responsibilities relating to pressure tests done on site. Pressure tests are performed to ensure the safety,
reliability and leak tightness of pressure equipment and systems.

The purpose is to establish the equipment condition and to ensure that pressure tests are conducted safely
and effectively.

When the pressure test is performed by a Third Party Company, then the Company is responsible for the
operation; and the present document shall be used as a guideline. In case of Third Party Company
Equipment is required to be installed, HSE procedure “Third Party Equipment Installation” (Doc. n. OD-HSE-
036) shall be consulted.

Whenever the Third Company is not required to perform the test or is not available, and exists an agreement
between Saipem and Client, pressure test can be conducted as per present procedure and the report shall
be signed by Rig Chief Mechanic and Client Representative. In this case the attached form shall be
completed.

2 REFERENCE DOCUMENTS

The following documents have been used as reference during preparing of this document:

OD-PRO-HSE-008 Work Permit System

OD-PRO-HSE-028 Pressure Equipment (Operation & Testing)

OD-PRO-HSE-033 Job Safety Analysis

OD-PRO-HSE-036 Third Party Equipment Installation

API RP 7L Procedures for Inspection, Maintenance, Repair and Remanufacture of

Drilling Equipment

ASME, Section VIII Boiler and Pressure Vessel Code – Rules for Construction of Pressure
Vessels

IADC Drilling Manual Latest Edition

3 DEFINITIONS

Bleed-Off (Bleed-Down) Operation to release pressure slowly from a well or from pressurized
equipment.

IADC International Association of Drilling Contractors

MAWP Maximum Allowable Working Pressure

OEM Original Equipment Manufacturer

SV Safety Valve
 Doc. n. RIG5829-PRO-TEC-005-E
saipem
DISCIPLINE PROCEDURE
Rev. 01 Date 17 Mar 14
ON SITE PRESSURE TESTING
Page 5 of 8

Third Party A person or Subcontractor which has a contract with Saipem to provide
some portion of the work or services on a Saipem project.

TP Test Pressure

WP Working Pressure

4 RESPONSIBILITIES

4.1 TOOL PUSHER / TOUR PUSHER

Tool Pusher / Tour Pusher will be responsible for the implementation of this procedure and for the
management of all pressure test activities and works carried out on rig site.

The Tool Pusher / Tour Pusher have to organize the activity and teamwork during the execution of all tests.
He must ensure that all involved personnel in pressure test operations have detailed knowledge of the test
procedure and are fully competent to perform assigned job.

When a Third Party Company is performing the pressure test, Tool Pusher / Tour Pusher shall verify that the
Third Party Company personnel are qualified and respect the Saipem policies and procedures. He shall
check also that the equipment and tools used are working properly and the instruments are calibrated.

4.2 CHIEF MECHANIC

Chief Mechanic is responsible to perform the pressure test operation and to ensure that the pressure test
equipment is correctly and safely installed.

He shall ensure that pressure test equipment is functioning properly and periodical maintenance is
performed as per schedule.

Chief Mechanic is responsible also for calibration of measuring instruments used and he must ensure that all
the measuring instruments have a valid calibration report.

When a Third Party Company is performing the pressure test, Chief Mechanic shall check if the Third Party
equipment is properly installed and does not present any obvious external or internal damage that may affect
correct and safe operation.

4.3 THIRD PARTY COMPANY

The Third Party Company is responsible to perform correct and safe pressure test operation. Third Party
Company shall make sure that all the equipments and tools used are working properly and the instruments
are calibrated prior each test to start. Third Party Company personnel shall be qualified for the job to be
performed and shall respect the Saipem policies and procedures.

After finishing the test, Third Party Company is responsible for cleaning their work location.

5 ACTIVITIES DESCRIPTION

5.1 APPLICABILITY

The present procedure is applicable for all pressure tests performed on rig site for pressure vessels,
pressure piping or other pressure systems.

The list of these equipments and systems, but not limited, may contain:

 Pressure Vessels and Systems:

 Doc. n. RIG5829-PRO-TEC-005-E
saipem
DISCIPLINE PROCEDURE
Rev. 01 Date 17 Mar 14
ON SITE PRESSURE TESTING
Page 6 of 8

 Poor Boy Degasser

 Rig Air Receivers
 Engine Air Receivers
 Other Air Tanks

 Pressure Piping and Systems:

 High Pressure Mud Lines
 Rotary and Vibrator Hoses
 Cementing Hoses
 Chicksan Loops

Note:

The present procedure is not managing pressure tests performed for Well Control Equipment and
Well Control Systems. For this purpose there are implemented special procedures to manage the test
operations for each type/ size of well control system.

5.2 PREPARATION AND PLANNING

Prior to commencement of pressure testing activities and in order to eliminate any hazards, the following
factors will be considered and implemented in the planning and preparing of operations:

 Work permits shall be obtained prior to commencement of any pressure testing activities;
 All persons who will work on a pressure test and / or near pressurized line shall be informed of the
potential hazards and the necessary safety precautions;
 All non-essential personnel shall be evacuated from the vicinity of equipment to be tested;
 Personnel assigned to conduct testing operations shall wear appropriate personnel protective
equipment, such as gloves, eye shields or goggles, and be positioned out of harm’s way in case there is
an uncontrolled release of pressure.
 Prior to start the pressure test operation, the tested equipment or system shall be completely bleed-off;
 Prior to testing, investigations shall be carried out to verify whether or not temporary restraints are
required to restrict the movement of piping and joints during testing and, when necessary, adequate
restraints shall be provided;
 The internal surface of the equipments tested must be dry, clean and free from dust, slag and other
foreign materials. Equipment and/ or systems should be cleaned internally to remove any remaining dirt
and foreign bodies through the flushing water from washing or blowing air.
 Pressure relief or limiting devices on the tested equipment shall be verified as operational, at the
appropriate pressure before the test begins;
 All hose connections shall have a sling secured across them (whip-checks) to restrain the hose in the
event of connection failure;
 Where isolation valves are used to contain test pressures, they must be of adequate rating for the
pressure to be encountered. If isolation valves are used instead of blinds, provisions shall be made to
ensure that no over-pressurizing can occur in equipment that is not being tested, due to possible valve
leaks;
 Barricades, barrier tape and warning signs shall be installed in areas of pressure testing;
 Announce testing is to take place over the public address system;
 Never attempt to tighten, slacken or hammer any item under pressure;
 The potential energy level of compressed fluids shall be minimized by purging air / gases from the
system; also the volume to be tested should be kept to minimum as practicable.

5.3 PRESSURE TEST PROCEDURE

The method used for pressure testing is the hydrostatic. A hydrostatic test is performed by using water as the
test medium.
 Doc. n. RIG5829-PRO-TEC-005-E
saipem
DISCIPLINE PROCEDURE
Rev. 01 Date 17 Mar 14
ON SITE PRESSURE TESTING
Page 7 of 8

5.3.1 General Hydrostatic Test Procedure

The following steps shall be performed during Hydrostatic Test Operation:

 Ensure the pressure gauges used are functioning properly and have valid calibration.
 Remove pressure relief valves or non-reclosing relief devices from the equipment or system to test,
where the test pressure will exceed the set pressure of the valve.
 Ensure that the skillet blanks or test plugs or clamps are appropriate for use and are free of obvious
defects.
 Fill and vent equipment or system to test as necessary to remove as much air as practical.
 Ensure that the water used for the test is at not less than ambient temperature, but in no case less than
70°F (approx. 21°C).
 Pressurize the system, raising the pressure in the system gradually until the designated test pressure is
achieved. The original hydrostatic pressure test pressure must not be exceeded.
 Maintain this test pressure for 10 minutes before inspection. Then, if test is above MAWP, reduce to
MAWP while making a full through inspection for leaks.
 If there is evidence of structural distortion, either reject the equipment/ system or repair as per OEM
recommendations.
 If there is a leakage in the equipment/ system, bleed off, repair the leaks as per OEM recommendations
and restart the hydrostatic test.
 When the test is complete, vent the test pressure to atmosphere and return relief devices to normal
configuration.

5.3.2 Rotary / Vibrator Hose Field Testing

Field pressure testing of rotary and vibrator hoses, when required for establishing periodic safety levels of
continued operation, should be conducted in accordance with the following guidelines:

 Visual inspection should include examination of any external damage to the body, structure, and
couplings. Safety clamps should be checked for proper attachment to the hose, and safety clamp
fasteners should be checked for damage, deterioration, and tightness. Safety wire rope slings should be
checked for damage or deterioration and that they are properly attached to structure capable of
supporting the breaking strength of the safety wire rope sling.
 Hoses should be arranged as straight as possible, and twisting shall be avoided.
 Prior to conducting pressure testing, the rotary hose should be suspended in normal unstressed position
from standpipe to swivel. Vibrator Hoses shall be placed on the ground as straight as possible.
 Rate of pressure rise should not be less than 1,000 PSI (6.9 MPa) or greater than 10,000 PSI (68.9
MPa) per minute.
 All air in the hose shall be bled off prior to applying test pressure. When possible, water should be used
as the test medium.
 The duration for holding the maximum test pressure in the hose should not exceed 10 minutes.
 Field test pressure shall not exceed 1.25 times the maximum working pressure of the hose regardless of
the test pressure that is specified by the hose manufacturer. Test pressures may also be limited to the
maximum working pressure of the valves installed in the mud system that are used to isolate the hose for
pressure testing based on the maximum pressure that can be exerted on the valve gates or seats as
specified by the valve manufacturer.
 A means shall be provided to release the pressure contained in the hose under controlled conditions
after pressure testing is completed.
 Hoses that are found to be leaking during the course of pressure testing should be removed from service
and either repaired or destroyed and disposed of immediately after testing.

5.3.3 Tests Frequency and Test Pressure

Pressure tests shall be performed periodically and also after each repair or modification.
 Doc. n. RIG5829-PRO-TEC-005-E
saipem
DISCIPLINE PROCEDURE
Rev. 01 Date 17 Mar 14
ON SITE PRESSURE TESTING
Page 8 of 8

Test frequency and test pressure recommended for the equipments mentioned in Section 5.1, but not limited,
is detailed in below table:

TEST PRESSURE
TEST
EQUIPMENT/ SYSTEM w/ SV
FREQUENCY Min. TP Max. TP
installed
Pressure Vessels and Systems:
Poor Boy Degasser
Rig Air Receivers 0.9 x SV
5 Years WP 1.25 x MAWP
Engine Air Receivers setting
Other Air Tanks
Pressure Piping and Systems:
High Pressure Mud Lines
Rotary and Vibrator Hoses
1 Year WP 1.25 x MAWP n/a
Cementing Hoses
Chicksan Loops

Min. TP – Minimum Test Pressure

Max. TP – Maximum Test Pressure
SV – Safety Valve

6 ATTACHMENTS

 “On Site Pressure Test Form” (Form n. ZZ RIG5829-PRO-TEC-005-E-A)