Pressure Test For Piping According To Asme B31.4

PROJECT REPLACEMENT OF 34 INCH
Project: PRESSURE TEST FOR PIPING ACCORDING TO

ASME B31.4 API 1104-API RP 1110
PIPELINE SECTION X 11 KM
Contractor: Alshola Almudia & Solcomei Document Number : TP-210364 GT SRTPPL

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Contractor Job Number : ED 063

S IRT E OIL
Contract Number : 98 208-530-410
COMPANY
Sheet 1/ 13
Project N° TP-210364 GT
PRESSURE TEST FOR PIPING ACCORDING TO

002 13/05/2019 Issued for Review and Approval AB.MOHAMED S.Karoui

001 15/01/2019 Issued for Review and Approval AB.MOHAMED S.Karoui
000 15/12/2018 Issued for Review AB.MOHAMED S.Karoui
Rev. Date REVISION TITLE PREPARED CHECKED APPROVED
Contractor Document Number: SRTPPL-PPL-CV-WP-009 Rev 02


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Project N° TP-210364 GT Sheet 2/ 13
Table of Contents
1. SCOPE: ............................................................................................................................................3
2. DISTRIBUTION ..............................................................................................................................3
3. DEFINITIONS AND REFERENCES .............................................................................................3
3.1. DEFINITIONS .........................................................................................................................3
3.2. ACRONYMS AND ABBREVIATIONS .................................................................................3
3.3. OTHER REFERENCES...........................................................................................................3
4. RESPONSIBILITY ..........................................................................................................................4
5. OPERATING PROCEDURE ...........................................................................................................4
5.1. GENERAL DESCRIPTION ....................................................................................................4
5.2. TEST DEFINITION AND LIMITS .........................................................................................4
5.3. TEST SYSTEM DOSSIER ......................................................................................................5
5.4. TEST FLUID ............................................................................................................................5
5.5. DISPOSAL OF HYDROTEST WATER .................................................................................6
5.5.1. GENERAL REQUIREMENT AND CONSIDERATION ...............................................6
5.5.2. CONTINGENCY PLANS................................................................................................7
5.5.3. PERMITS AND CONSENTS ..........................................................................................7
5.5.4. ENVIRONMENTAL MANAGEMENT PLAN ..............................................................7
5.6. PRE TEST REQUIREMENTS ..............................................................................................10
5.7. PRESSURE GAUGES...........................................................................................................11
5.8. HYDROSTATIC TEST.........................................................................................................11
5.8.1. PRESSURE TEST ..........................................................................................................11
5.8.2. PRESSURUZATION ....................................................................................................11
5.9. FINAL CHECKS BEFORE STARTING PRESSURE HOLDING PERIOD .......................12
5.10. PRESSURE HOLDING .....................................................................................................12
5.11. ACCEPTANCE CRITERIA ..............................................................................................13
5.12. PRESSURE RELEASE ......................................................................................................13
6. FILING ...........................................................................................................................................13
7. FORMS TO BE USED...................................................................................................................13
8. NOTES ...........................................................................................................................................13


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1. SCOPE:
This document specify the requirements for Pressure testing of Piping Systems designed either ASME
B31.8 and API RP 1110 and , including pre-test and post- test activities to be executed on each Test
Package.
2. DISTRIBUTION
This document is distributed, by the Site QC Manager to all involved personnel.
The original issue of this Procedure will be kept by the Quality Assurance Service; the subsequent revisions
shall be distributed in compliance with rev.0 distribution list.
3. DEFINITIONS AND REFERENCES

3.1. DEFINITIONS
Refer to ISO 8402 (Quality management and quality assurance. Vocabulary) for Definitions. Other
definitions are given where deemed necessary.
3.2. ACRONYMS AND ABBREVIATIONS

As to the acronyms and abbreviations used in this document, please refer to the Acronyms and Abbreviations
List of the Company Functions, but more in detail:
• RECAN Site Manager
• REQC Site QC Manager
• IQC Quality Control Inspector
• Company Sirte Oil Company
• CONTRACTOR ALSHULA ALMUDIA & SOLCOMEI
3.3. OTHER REFERENCES
- API 1104 : Assembling and Inspection of Piping Project Specifications

- ASME B 31.8-API RP1110 : Petroleum and natural gas industries-Pipeline
Transportation System Specification for lines Piping Line List Site Document Register (as
applicable)
- Project Scope of work exhibit A
- NOC GES R.04 : OIL AND GAS PIPELINE CONSTRUCTION
- SOC JS-PM-0022 : Pipeline Construction


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4. RESPONSIBILITY
All involved personnel shall comply with this Instruction.
The Site Manager (RECAN) is responsible for distribution, use and application of this Instruction.
Monitoring and consultancy for use, is Site QC Manager (REQC) responsibility.
5. OPERATING PROCEDURE
5.1. GENERAL DESCRIPTION
Once is satisfied that a Test System has been installed, completed and conform to all requirements,
Contractor will punch the system and, after that, formally submit to Company the Test Pack after pressure
test.
The Pressure Test will be then be performed in accordance with the project specifications. The Company will
witness and approve the Test. ALSHOLA ALMUDIA & SOLCOMEI will enter test result on Pressure Test
Report and obtain the required signatures.
ALSHOLA ALMUDIA & SOLCOMEI shall submit the RFI (Request for inspection) to the Company one
day in advance before the test day with specific time and pressure of test, in order to be reviewed and
confirmed.
5.2. TEST DEFINITION AND LIMITS

For the Flow lines, the statement the test shall be performed with all welds unpainted or insulated and
prior to line cover.
The following shall be considered when defining Test System:
 Hydraulic Test shall be performed following the pre-requisitions below and at Clauses 5.4 and 5.5
listed. In addition, for both types, Hydraulic and Pneumatic, the tests shall be performed
with all welds unpainted or un- insulated and prior to line cover.
 Instruments shall be not installed or shall be isolated. Equipment as well shall be blanked off. In all
cases testing of Equipment simultaneous with piping system is subject to approval of Company.
 Ball Valves shall be 45° opened
 Internals of Check valves shall be not removed if locking of flapper in open position is possible from
outside.
 Blanks shall be calculated to stand the test pressure.
 Flow meters, strainers internals shall be capable to stand test pressure or they shall be installed after
test.
 Spring Supports shall be on cold setting.


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5.3. TEST SYSTEM DOSSIER

Shall include:
 Test Pack Cover Sheet, Will collect the signatures of all activities and inspections performed before,
during and after test.
 The Pipe Book
 A Check List, listing all significant Inspections to be done before Test.
 A Pressure Test Report.
 Copy of the P&ID involved, indicating the limits of the test, blinds, filling points and valves
position.
 Mark-up Isometrics AS-BUILT
 A separate Q.C. Folder, including Welding Tracking Program with all relevant documents. The Q.C.
documentation will be not attached to the Test Pack, but the evidence that the lines included are
accepted and relevant documentation completed, shall be the signature (of all parties involved) on
the Cover Sheet form.
5.4. TEST FLUID

Pressure testing, dewatering & drying shall be performed in compliance with the requirements of JS-PM-
0022 and GES R-04.
Low Total Dissolved Solids (TDS) Water, i.e. near Potable Water shall be used for the hydrotest.
COMPANY shall designate the water source/intake location.
Water used for hydrotesting must be chemically treated to avoid corrosion and bio-contamination of the
system.
The following Chemical will be used for the chemical treatment of the hydrotest water of the new pipeline,
in accordance with the rates mentioned in below:
SUPPLIER PRODUCT APPLICATION APPLICATION VOLUME

PERIOD RATE (ppm) REQUIRED
Chimec CH-1365 1 Week to 10 600-800 To be
Days calculated
> 6 Months 1000-1200 To be
calculated
Chemicals should be continuously mixed with water during filling of pipeline.

Precautions are required to avoid contamination of the line and water with substances that may contain
bacteria, such as seawater; surface or stagnant water (ponds), organic matter, mud, dirt, soil, etc.
The above product is considered hazardous materials and require the use of proper safety equipment for
handling, including chemical resistant clothing, footwear and gloves as well as appropriate chemical safety
goggles/face shields.
The hydrotest water shall be disposed of in an environmentally safe manner and in accordance with the
Libyan Law, and shall be approved by COMPANY.


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CONTRACTOR shall evaluate the following options for the hydro testing of the pipeline, bearing in mind
the volume of water, and the subsequent disposal of the hydro test water:
 Hydro test of the entire 11Km pipeline
 Hydro test of the 11Km pipeline in two (2) sections
 Hydro test of the 11Km pipeline in three (3) or more sections
It is proposed that the hydrotesting, dewatering and drying of the pipeline be carried out over the ditch prior
to lowering-in, for evaluation and confirmation by CONTRACTOR.
5.5. DISPOSAL OF HYDROTEST WATER

Dewatering of hydrotest water from a pipeline, either new or used, is the act of discharging hydrotest water
into the environment. This process is expected to have an impact negatively on the environment like; soil
erosion, harm crops, plants, etc., if discharged to land. While discharge to water bodies like river, sea, etc.,
would have more negative impact due to sensitivity of such environment.
To reduce or minimize these impacts a management plan is required to be developed and put in place which
will control how the water is discharged, where to discharge and shall contain measures expected to be
applied in order to reach minimization objectives.
CONTRACTOR must demonstrate ability to mitigate environmental impacts by developing an appropriate

Environmental Management Plan (EMP) for hydrotesting operation as whole work.
The following criteria shall be considered and it must be the base for EMP development.
5.5.1. GENERAL REQUIREMENT AND CONSIDERATION
i. Site certificate must be obtained from COMPANY prior to work commencement.
ii. Hydrostatic test water must be controlled to prevent soil erosion by applying energy dissipation
devices or measures.
iii. Hydrostatic test water must not be release to land where surface run off of the hydrotest water
directly mixes with receiving water (if exist nearby discharge)
iv. Sample of hydrotest water must be provided to COMPANY before discharge. This will help
Environmental Department of the COMPANY to assess/evaluate the impacts.
v. The discharge does not cause any fresh water supplies to be degraded or any damage to crops or
wild plants and trees, etc.
vi. Any hydrotesting activity should aim to minimize any impact on the environment.
vii. The cleanest and most practical water source for hydrotesting water shall be sourced to minimize
treatment requirement prior to disposal via controlled land release.
viii. Disposal to land will require erosion protection, runoff controls and sediment interception to
minimize impact on the receiving environment.


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5.5.2. CONTINGENCY PLANS

Contingency plans must be developed prior to dewatering and need to be applied if one of the following
cases happened:
i. Alternate disposal options if the preferred method is considered to be causing environmental

harm.
ii. A reduction of discharge rates if the discharge is considered to be causing environmental harm.
iii. Addition of further erosion protection, runoff controls and sediment interception measures if
adverse changes are observed at or downstream of the controlled discharge location.
iv. CONTRACTOR must provide contingency procedure for containment of any chemical, fuel
spillage showing how to decontaminate or dispose of.
v. CONTRACTOR must provide contingency procedure if hydrotest water turned coloured

(yellowish-brown) due to discharge of iron oxides and corrosion particles from pipeline.
5.5.3. PERMITS AND CONSENTS

Before starting hydrotest water discharge, permits or consent (if required) must be granted from the
landowner either public or governmental, in order not to cause any delay for the operation.
COMPANY and CONTRACTOR must address this issue to determine whose responsibility.
However, if permit is required CONTRACTOR is responsible to explain and make clear to landowner all
details in the discharge operation.
5.5.4. ENVIRONMENTAL MANAGEMENT PLAN

The following table presents a summary of the potential impacts related to the discharge of hydrostatic test
water, together with mitigation and management measures to avoid or reduce these impacts.
Source of Impact Potential Impact Mitigation and Responsibility Remark

Management
Site Preparation Land Disturbance - Locate discharge Contractor - Justification must
& Wild Life point, which is be presented
Threatening visually and
geographically
suitable.
- Minimize the
following:
Site access
points
Trucks and
traffic


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manoeuvring
operation in site
Public and
foreign entrance to
the site
No plant or tree
clearance must be
done unless
extremely
necessary required
No threat to
wild life and its
inhabitants
Noise level must
be kept low not to
disturb wild life
- All work have to
be carried out in a
way that would
prevent any
anticipated
complaints from
the public
Land - Any chemicals Contractor Decontamination

Contamination must be must be done
transported, stored immediately and
and secured reported to SOC
properly and not to
be in long storage
- Every effort shall
be taken to prevent
spillage of any
kind of chemical,
fuel, etc.


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Hydrotest Water Impact to land - Discharge of Contractor

Discharge and water bodies, hydrotest waters
if existed nearby will be at a
point of discharge sufficient distance
from water bodies
and main public
activities sites and
roads, etc.
- Discharge will be
performed to
discharge
structures to
prevent erosion of
the surrounding
land
- Perform
controlled
discharge of
hydrotest water in
order to control
erosion and use
erosion protection
measures
- Utilize runoff
controls to
maintain stable
landforms and
preventing
unnecessary
flooding
- Use of chemicals - Subject to
in hydrotest water Contractor approval by SOC
will consider before use
biodegradability
and low toxicity
- Reduce the need
for chemicals if Contractor
possible by
minimizing the
time that test water
remains in the
equipment or
pipeline


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- Use break tanks

or energy
dissipaters (e.g.
protective riprap,
sheeting,
tarpaulins) for the
discharge flow - To be agreed
- Obtain necessary with SOC
landowner consent
or permits for the
discharge of
hydrotest water
Site Closure - No leftover

chemical drums
and containers
- No leftover junks,
debris, metals, etc.
- Reinstatement of
disturbed lands at
discharge points
5.6. PRE TEST REQUIREMENTS

All welds and Non Destructive Testing shall be completed.
All connections (flanged) shall be left exposed and welded joints shall be unpainted or un-insulated.
The test system shall be cleaned with the Pigs system. It must be noted however that an effective cleaning
may be only achieved where suitable conditions are maintained during all the fabrication and installation
process.
If required by configuration of the line, additional-temporary vents shall be installed and shall be sealed by
welding after test.
Temporary spools (flanged) shall be provided and installed, to replace during the test the Control
Valves (to be disassembled); otherwise blind flanges shall be used, to split the test loop.


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5.7. PRESSURE GAUGES

At least one gauges and a Continuous Trace Recorder shall be normally installed for each test. If possible,
one should be placed in the highest part and the other in the lowest part of the Test System.
5.8. HYDROSTATIC TEST

5.8.1. PRESSURE TEST
The testing shall comply with Company Spec. And API RP 1110.
The circuit shall be vented during filling and before any pressure is applied. Filling of System to be at
lowest point.
The test pressure shall be gradually reached and shall maintained constant, for the time enough to
enable a visible inspection of the circuit, anyway not less than
24 hours.
Test pressures for lines operating at hoop stresses 30% or more of the SMYS of the pipe material shall be in
accordance with the values given in Table 841.322 (f) ASME B31.8 for hydrostatic testing, i.e. 1.25 M.O.P.
(maximum operating pressure) for location classes 1 (Div 1) and 2, 1.10 M.O.P. for location class 1 (Div 2)
and 1.40 M.O.P. for location classes 3 and 4.
Test pressures for lines operating at hoop stresses less than 30% of the SMYS of the pipe material but at more
than 100 psig (7 Barg), shall be in accordance with the values given in Table 841.322 (f) ASME B31.8 for
location classes 2, 3 and 4.
For the pipe lines not underground, the time of the test not less than 4hours.
Pumping or venting operations during inspection shall be allowed only as consequence of the ambient
temperature variation, in order to restore the test pressure, otherwise the pump shall be isolated from the
circuit.
During inspection, the pressure value shall be controlled and all welds and flanged connections shall be
visually inspected to ascertain possible leakage.
5.8.2. PRESSURUZATION
The pressurization shall be performed at constant rates not exceeding 1 bar/min up to 70% of the
pressure test, and then to 0.5 bar/min from 70% to 80% of the Pressure test.
When approximately 80% of the specified test pressure is reached, this pressure shall be maintained for a
period of time sufficient to stabilize properly.
After the stabilization period – 1 hour as a minimum – is accepted by the Company Representative, the
pressure shall be gradually raised at the rate of 0.12 bar/min. While bringing the pipeline up to pressure,
the and-plot of the pressure volume curve shall be performed until the specified test pressure is reached.
At 35 bar and 95% of the pressure test, the pumping shall be stopped for 15 min, to perform a residual air
content measurement.
The residual air content shall be calculated by the pressure drop method.


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For large water volumes (> 50,000 m3), the air content can be determined by the Pressure/volume plot
method(API RP 1110) and the option of Company a pressure Drop test may be requested for
consistency check.
The air content shall not exceed 0.2% of the calculated capacity of the pressure test Section; pressure
and volume recording shall have the required accuracy and Sensitivity to appreciate this level of air
entrapment.
When the test pressure is reached and before starting the holding period, the Filling valve shall be closed
and the filling line disconnected from the pipeline.
5.9. FINAL CHECKS BEFORE STARTING PRESSURE HOLDING

PERIOD
Prior the commencement of the test holding period, water temperature in the pipeline must be stable.
The required amount of stabilization is to be determined and agreed with Company.
As a guideline, the stabilization period is completed when the pipeline temperature is within 1°C of
the surrounding soil /water temperature.
For long pipeline, extra stabilization time may be necessary, and pressurization shall not start until all the
temperature records are stable.
The residual air content measurement shall not exceed 0.2% of the total volume of the tested section.
During the stabilization and the test periods, care is to be taken that the maximum test pressures are not
exceeded: max 0.5% above the test pressure, if necessary water shall be drained of for this purpose.
The pressure drop and the amount of water are to be measured and recorded.
5.10. PRESSURE HOLDING

During the pressure test, the pressures shall be measured and recorded every half hour using the dead weight
tester.
All valves and other joints where there may be leakages are to be checked carefully. Testing may begin
after leakages have been repaired. Leakage repair shall only be performed after pressure is reduced to a safe
level.
The test is to commence at time to be agreed beforehand with the Company and the recording charts are to be
signed by all parties, with indication of start time.
Observations must be recorded, stating clearly on the corresponding documents, such as pressure and
temperature cards, the pipeline identification.
All drain tests, air venting or water draining events are to be recorded on the pressure cards.
During the test period the following measurements shall be recorded every 30 minutes at both pipeline
ends.
- Pressure from the dead weight testers: maximum and minimum since last measurement,
as well as the average values.
- Ambient temperature and pipeline temperature from the thermo wells.
- Atmospheric pressure


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At the end of the pressure test a second drain test shall be performed: this second Drain test shall reproduce
the first drain test as close as possible (i.e. if 0.5 bar drop was measured for first test then 0.5 bar drop should
be the pressure drop for the second test).
The recording charts are then to be signed off by all parties with clear identification of signatories, start and
finish time on the test.
After all data of the pressure test have to be gathered and submitted to the Company representative, the test
shall be considered acceptable if:
- The acceptance criteria for pressure variation is met
- The residual air content is below 0.2%
- All the measuring devices are performing to the required accuracy.
- All the visual examination of fitting, connections, flanges etc. Are acceptable. Formal
approval of the hydrostatic test can then be given by the Company representative.
5.11. ACCEPTANCE CRITERIA

The pressure test shall be considered acceptable if, at the end (of the 24h holding period for the underground
pipe line, and 4h for the pipe line not underground) the pressure variation does not exceed +/- 0.2% of the
initial test pressure.
If this variation is between 0.2% and 0.4%,it has to be fully explained by temperature variation. In
excess of 0.4% variation, the holding period has to be repeated.
The variation of pressure with temperature can be calculated from Api RP 1110 and Api 1104.
5.12. PRESSURE RELEASE

During depressurization, the pressure decrease rate shall not exceed 3 bar/min. Care shall be taken to ensure
line pressure not being reduced below the static head.
Unless otherwise instructed by Company, all successfully tested pipelines and rises shall remain full of treated
test water and suitably capped off.
6. FILING
Test Pack shall be kept on Engineering Department, QC Folders on QC. Department until composition of final
books.
7. FORMS TO BE USED
To be delivered on site job with a care / approval from company’s site representative
8. NOTES
 After the test the line will be blown up to the Pigs system
 the joints of connection of the systems will be with the flange where is possible

Pressure Test For Piping According To Asme B31.4

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PROJECT REPLACEMENT OF 34 INCH

Project: PRESSURE TEST FOR PIPING ACCORDING TO

Contractor: Alshola Almudia & Solcomei Document Number : TP-210364 GT SRTPPL

Contractor Job Number : ED 063