0568-Bom20-92p1-0001-001-1-Code-1 Hydro Procedure

This document, including drawings, procedures, specifications, and its contents, is the exclusive property of
MODEC, Inc. and affiliates ("MODEC Group") and is furnished on a confidential basis with the express
agreement that it shall neither be used, sold, transferred, copied, traced, photographed, nor reproduced in
any manner whatsoever, in whole or in part, nor any item herein be sold, manufactured, or assembled
without the written agreement of MODEC, Group. The recipient of this document agrees not to disclose to
any other party information contained herein, nor use such information, except for the specific purpose
intended at the time of release of this document.
Client
Client Client Validity
Doc. No. 600301DTPT74006 Rev. 00 Status EX-CO
No.
UNCONTROLLED WHEN PRINTED

0 ISSUED FOR CONSTRUCTION 6 Sep. 2019 LJM FX SLT QY
B ISSUED FOR REVIEW 13 Jun. 2019 SD FX SLT QY
Rev Status Date Originator Checker Approver Project

Document Title:
FLUSHING, HYDROSTATIC AND PNEUMATIC TEST PROCEDURE

MODEC Contract Title Contract No. Page
Project No.
FPSO Chartering, Operation and Maintenance 5000013874
for Mexico Area 1 Development Project
0568 MODEC Document No. 1 OF 12
0568-BOM20-92P1-0001-001
BOMESC Document NO.
TBJN0144-S-PI-PRD-0002
Eni Mexico Area 1 Development Project
Lead Reviewer: Senthil Rajendra Acceptance Code: 1 - APPROVED Review Date: 02-Nov-2019 06:44:27
Eni Mexico Area 1 FPSO Project Flushing, Hydrostatic and Pneumatic Test Procedure
0568-BOM20-92P1-0001-001, Rev. 0
RECORD OF AMENDMENT
REVISION SECTION PARAGRAPH DESCRIPTION OF CHANGE
B ISSUED FOR REVIEW
0 ISSUED FOR CONSTRUCTION

(To be filled by Client as needed)
Verified by Unit Signature Date
Interdisciplinary
Company

Review
Checked by Unit Signature Date

Company
Checked
Checked by Unit Signature Date
Approved by Unit Signature Date

Company
Approved
Endorsed by Unit Signature Date
0568-BOM20-92P1-0001-001 2 OF 12
0568-BOM20-92P1-0001-001, Rev. 0
TABLE OF CONTENTS
1. SCOPE.............................................................................................................................. 4
2. APPLICABLE CODES AND STANDARDS ..................................................................... 4
3. FLUSHING ........................................................................................................................ 4
4. PRESSURE TESTING ...................................................................................................... 5
5. POST TEST PROCEDURES ............................................................................................ 9
6. TESTING MATERIALS AND EQUIPMENTS ................................................................. 10
7. TEST RECORD .............................................................................................................. 10
8. SAFETY .......................................................................................................................... 10

APPENDIX A .............................................................................................................................. 12
0568-BOM20-92P1-0001-001 3 OF 12
0568-BOM20-92P1-0001-001, Rev. 0
1. SCOPE
This procedure requires the minimum requirements for flushing, pneumatic, hydrostatic and
leaking test to piping systems for MV34 Eni Mexico Area 1 Development Project M4S, M5 and
M6P. This procedure include flushing & borescope requirements to be incorporated according
to MODEC Fabrication of Piping Specification 0568-MI20-00S1-0070-001.
2. APPLICABLE CODES AND STANDARDS

Number/Identification Description

ASME B31.3 Process Piping
Pipeline Transportation Systems for Liquid Hydrocarbons and Other
ASME B31.4
Liquids
ASME B31.8 Gas Transmission and Distribution Piping Systems
Recommended Practice for Design and Installation of Offshore
API RP 14E
Production Platform Piping System
0568-MI20-00S1-0070-001 Fabrication of Piping Specification
3. FLUSHING
3.1 GENERAL
3.1.1 Carbon steel pipes
In most cases, the water used shall be good quality inhibited fresh water. However, in
extraordinary circumstances, when the quantities involved are very large, it is allowed to carry
out the first flushing operations on a given network with raw water not containing more than
50ppm of chlorides and then final rinsing of the same network has to be carried out with
inhibited fresh water.
3.1.2 CRA Pipes / Tubing
As a rule, water containing chloride (more than 50 ppm) should not be used. However, in
some cases it may be used following agreement with the Company. In such case the final
rinsing must be carried out with inhibited water. NaNO3 will be added to the water three times
the chloride ion content.
In specific cases, where system flushing requirements are dictated by specialist suppliers or
criticality of system operation, water mixed with special chemicals / additives shall be used for
system flushing.
For liquid process lines, the flushing velocity shall be lower of 3 m/s and the velocity obtained
with 1.3 times the maximum process flow. For gas process lines, use 3 m/s flushing velocity
(ensure that water-filled lines are adequately supported / no excessive load on support,
hangers, pads, spring supports, or equipment nozzle itself). The flushing velocity shall be
demonstrated, and Photo’s evidence of cleaning shall be included in the inspection records.
Alternately retro jetting equipment and centralizers at various operating pressure with spinning
0568-BOM20-92P1-0001-001 4 OF 12
0568-BOM20-92P1-0001-001, Rev. 0
nozzle shall be used for pipes ≥ 6” NPS to scour the lines to remove foreign particles and
flush dirt/debris from the system. The supply water pressure should be sufficient to dislodge
particles from the pipe internal walls and the water flow adequate to carry debris from the
system to a safe, contained exit point.
3.2 PREPARATION FOR FLUSHING

Before the flushing of piping systems, following items shall be done:
1) It shall be conformed that all gaskets between the flanges maintain a good condition and
retighten of bolts.
2) Line check shall be performed on the installed piping to confirm the correct and suitable
condition with drawing.

3) All instrument elements (restriction orifices, mesh of the Y-strainers, differential pressure
indicators, regulate valves, relief valves etc.) have been removed.
4) All in-line valves shall be open if any.
5) All Block valves, PCV, FCV, Flowmeters, check valves, relief valves have been removed.
6) All valves and blinds are in their proper situation if any.
4. PRESSURE TESTING
4.1 GENERAL
Inspect related drawing and document shall include the following information as minimum:
1) Test method and medium
2) Test equipment and instruments
3) Calibration certificate
4) Marked P&ID showing all the installed blinds, vent and drain valves, and isolation of each
segment to be tested.
All welding, heat treatment and nondestructive testing shall be completed prior to pressure
testing.
Unless noted otherwise, all in-line valves are in normal open, to avoid the corrosion and
damage.
The pressure test includes hydrostatic pressure and pneumatic test. The value of hydrostatic
pressure test shall be no less than 1.5 times of the design pressure. Test pressure shown in
MODEC’S fabrication line list shall be followed. The pressure test is the one that is performed
to confirm the piping systems have the sufficient strength safety against static pressure test.
The pipeline checking in the pressure test is particularly performed to check the condition of
piping work including leakage.
Nondestructive inspection and hydro testing of carbon steel lined piping shall be performed
prior to lining or external coating is applied.
If the valve is to be tested in the closed position, manufacturer's written approval of the
maximum test pressure that may be applied to the valve in the closed position shall be
obtained if the test pressure will exceed published seat pressure rating of the valve.
0568-BOM20-92P1-0001-001 5 OF 12
0568-BOM20-92P1-0001-001, Rev. 0
All test systems shall be reviewed to ensure that vents, drains, blind flanges, etc., are installed
as necessary whether shown on drawings or not.
Temporary supports shall be provided where required due to additional weights of testing
medium.
Closed valves shall not be used to separate test systems, instead blind to be used for
isolation.
Positive provisions shall be made to protect pressure-sensitive equipment and instruments
such as gauges, level controllers, pressure controllers, relief valves, etc.
Any instruments, which are suspected to have been hydrotested, shall be inspected and
recalibrated.
Open ends of a system shall be fitted with flanges, blinds, or plugs prior to pressure test.

Pumps, turbines, compressors, and exchangers shall be excluded from piping pressure tests.
Proper single pipe shall take place of the equipment and fittings where deposition comes into
being easily.
Test media fill point must be upstream of the check valve if check valve is in test.
The hydrostatic test shall employ two pressure gauges, one pressure recorder (chart type or
digital), and one temperature recorder (chart type or digital). Calibration certificates valid for
six months shall be provided, as per MODEC spec 0568-MI20-00S1-0070-001 Fabrication of
Piping Specification.
The pressure test gauges shall be located near the pressure test pump. The pressure tapping
point of pressure record shall be highest point of the test pack. It shall be tagged with the date
last calibrated, and this activity shall be recorded.
All high point vents are open and necessary valves are installed.
All piping joints (including welded, threaded, flanged) shall be left un-insulation and exposed
for examination during the test, except that joints previously tested in accordance with this
specification may be insulated or covered. No painting and insulation before testing.
If welding blind to pipes end made in site, the thickness of general insert blind, see Appendix
A.
All supports on pipe must be checked thoroughly before hydrotest.
Tests shall be witnessed and verified by the Company Inspector.
4.2 SAFETY CONSIDERATIONS

Safety during a hydrostatic test is dependent upon:
1) Displacement of all air from the tank with an incompressible liquid.
2) Personnel, not directly involved with the testing process, are not inside the defined
exclusion zone either above or below while the test is being carried out.
3) No other work being permitted on the equipment during the period of the test.
4) Barrier tapes shall be provided around test areas appropriately with waning notices
displayed 10m distance is needed to place boundary.
0568-BOM20-92P1-0001-001 6 OF 12
0568-BOM20-92P1-0001-001, Rev. 0
4.3 WEATHER CONDITIONS

Tests must be undertaken in good light; testing during daylight hours is preferable.
Tests shall not be carried out during periods of rain or adjacent equipment washdown
activities.
4.4 TEST FLUID

The test medium shall be fresh water mixed with a Company approved corrosion inhibitor.
The Company shall approve the test medium prior to use.
For piping, water used to flush austenitic stainless steel shall have less than 50ppm chlorides
content.
If the ambient temperature is less than 5℃, antifreeze measures should be adopted.

4.5 HYDROSTATIC TESTING
4.5.1 HYDROSTATIC TESTING FOR PIPING

Review all procedures or applicable instructions for special precautions.
Fill the system slowly to avoid water hammer and to adequately bleed all air from the system.
Close each high point vent after steady stream of water which indicates air has been removed.
The pressure shall be increased gradually. The system pressure shall be raised to 60% of the
test pressure in 20% increments, and the pressure shall be held for a minimum of five (5)
minutes at each interval to allow the system to stabilize and a visual inspection for pressure
drop or any leaks to be conducted from outside the exclusion zone. If a leak is suspected, the
system pressure shall be reduced by 10% prior to any person entering the exclusion zone.
Any leaks and other problems found shall be marked and recorded and repair work shall be
done after de-pressured to zero.
After system is charged approaching the test pressure, carefully examine the piping system
for leaks or other evidence of problems.
If the system hasn’t leakage at the test pressure, pressure shall be maintained for no less
than 60 min.
Open vents and drain at each system after test. Exercise care to avoid drain rate to prevent
vacuum. And finally, the system shall be completely blown down with dry air.
Record each test including date, time, system being tested, test fluid, test pressure, and test
temperature. Obtain signature of Client’s authorized inspector.
4.6 PNEUMATIC TESTING

If hydrostatic testing is not considered practical by the Company, a pneumatic test in
accordance with ASME B31.3, may be using compressed air or another nonflammable gas.
A preliminary air test at not more than 170 kPag pressure shall be made.
The pneumatic test pressure shall be 1.1 times the design pressure of the system. The
pressure shall be gradually increased in steps until the pressure is reached, holding the
0568-BOM20-92P1-0001-001 7 OF 12
0568-BOM20-92P1-0001-001, Rev. 0
pressure at each step long enough to equalize piping strain, the pressure shall then be
reduced to the design pressure before examining for leakage.
All joints, welds, and connections shall be swabbed with a soap solution to facilitate the
detection of leaks. Test pressure shall be maintained for at least 30 min.
Replace packing seals in items such as valves when leaks cannot be stopped by normal
tightening of packing glands.
Record each test including date, time, system being tested, test fluid, test pressure, and
atmospheric temperature, Obtain signature of Company's Authorized Inspector.
Release pressure slowly and take preservative measures as agreed with the Company.
Replace material such as gaskets, bolting, damaged during testing.
4.7 LEAK TEST

4.7.1 LEAK TEST FOR PIPING
Fill the system slowly to avoid water hammer and to adequately bleed all air from the system.
Close each high point vent after steady stream of water indicates air has been removed.
Repair the pipe if leakage occurs.
After the tested system is fully filled with water and without leakage, the system shall be kept
water filled at least one (1) hours without leakage.
Record each test including date, time, system being tested, test fluid and test temperature.
Obtain signature of Company's authorized inspector.
Replace material such as gaskets, bolting, etc. damaged during testing
4.8 ACCEPTANCE CRITERIA

Pressure tests shall be deemed complete and acceptable providing:
The test was carried out in accordance with these specifications and the Supplier's approved
test procedure.
The system was free of leaks, seeps and other abnormalities by visual inspection while under
pressure.
The test shall be witnessed by the Company Inspector and verified by the pressure recorder
and temperature recorder charts. The charts shall include the date and time of the test, as
well as the Company Inspector's and the Supplier's representative's signatures.
The test pressure has been maintained for the minimum period required with no additional
test fluid added to the piping.
All defects and leaks, if detected, have been corrected and re-tested to the satisfaction of
MODEC.
All documentation is complete with test supervisor and test inspector signatures, and
accepted by MODEC.
All temporary test blinds have been removed; new gaskets installed.
0568-BOM20-92P1-0001-001 8 OF 12
0568-BOM20-92P1-0001-001, Rev. 0
4.9 BORESCOPE CHECK

Borescope check at following lines after flushing and hydro-testing is required for the following
systems:
Riser lines (Oil, Water Injection, Gas Lift, Gas Injection)
Header to Free Water KO Drum inlet
Cooling medium line
Heating medium line
Compressor suction discharge lines
WI pump suction lines (after strainer)
The borescope check shall be carried out at locations where the chance of debris collection is there,
i.e. at the lowest part of the system.

5. POST TEST PROCEDURES
After testing, the system shall be returned to operational condition and verified by the
Company Inspector in accordance with the following:
1) Temporary blanks and blinds shall be removed, operating blinds shall be returned to proper
position, and all lines and piping components shall be completely drained.
2) All vents of lines being drained shall be open.
3) Piping systems downstream of check valves shall be inspected to ensure complete
drainage.
4) The system shall be purged with compressed air.
5) Drain and vent valves shall be operated several times during purging to remove the
maximum amount of water.
6) Valves, orifice plates, expansion joints, and short pieces of piping that have been removed
shall be reinstalled with correct gaskets in place.
7) Blinds shall be rotated and flanges tightened to the satisfaction of the Company Inspector.
The Inspector may require, at his discretion, a leak test for the flange.
8) Check valve flappers removed for the test shall be reinstalled to the satisfaction of the
Company Inspector.
9) The Inspector may require, at his discretion, a leak test for the reassembled piping.
10) Flanges and/or weld caps welded at the end of a pipe to facilitate hydro testing shall be
removed after the test is completed and the pipe end shall be beveled in accordance with
ASME B31.3.
Direct connected transmitters at orifice flanges shall be disconnected when replacing orifice
plate to avoid distorting the connections.
12) After lines have been drained, temporary supports shall be removed and insulation and
painting completed.
13) Spring hangers provided with stops to carry the test load shall have these stops removed
after installation.
14) Special length bolting and gaskets shall be removed and replaced with line class bolts
0568-BOM20-92P1-0001-001 9 OF 12
0568-BOM20-92P1-0001-001, Rev. 0
and gaskets.
15) Instruments, which were removed or blocked out for tests shall be reinstalled and blocks
placed in the normal operating position.
16) Vessels and piping shall be treated with an industrial corrosion inhibitor solution to
minimize internal corrosion.
17) Lubricating, seals, and control oil systems shall receive a hot oil flush in lieu of water.
After final assembly at the site, the filter casings, cooler MODEC’s, and other system
components shall be opened and wiped clean. Heated flushing oil (150ºF to 180ºF) shall then
be circulated until it runs clean, but for not less than eight hours. The equipment
manufacturer’s representative shall determine the method of checking the cleanliness of the
system. Bearings shall be by-passed during flushing.

6. TESTING MATERIALS AND EQUIPMENTS
1) The hydrostatic test shall employ two pressure gauges, one pressure recorder (chart type
or digital), and one temperature recorder (chart type or digital). Calibration certificates valid for
six months shall be provided.
2) Material such as gaskets, bolting, etc., damaged during tests shall be replaced.
3) All threads of bolts and nuts shall be cleaned by suitable means so as to be free from any
foreign materials and suitable approved lubricant shall be used prior to tightening bolts.
4) Packing seals shall be replaced in equipment such as valves if damage during the tests
prevents the packing glands from stopping leaks at normal tightening.
5) All test materials and equipment shall be suitable for the hydrostatic test pressures and
temperatures. Special consideration shall be given to the possibility of brittle fracture.
7. TEST RECORD
The records shall include the following information:
1) Verification that the system has been returned to operational condition
2) Pressure and temperature recorder charts
3) A pressure test system chart for each piping system or spool
The chart shall indicate:
- Test medium
- Test pressure
- Test duration
8. SAFETY
1) Barrier tapes shall be provided around test areas appropriately with waning notices
displayed 10m distance is needed to place boundary.
2) Caution testing in progress Eye protection PPE should be worn by all personnel involved in
testing.
3) Only authorized personnel (test worker, test engineer and inspector, etc.) should be
0568-BOM20-92P1-0001-001 10 OF 12
0568-BOM20-92P1-0001-001, Rev. 0
allowed in vicinity of testing, i.e. inside barriers. All personal stay out of barrier tapes in the
case of a hydrotest failure.
4) Take-all necessary precaution in cleaning, hydrostatic test work to protect personals and
environment, conditions considered unsafe shall be corrected before work is started or
continued.
0568-BOM20-92P1-0001-001 11 OF 12
0568-BOM20-92P1-0001-001, Rev. 0
APPENDIX A
Schedule of Maximum Allowable Hydrostatic Test Pressure (kPa) for the Listed Test Blind Thicknesses (mm).
Nominal Pipe Size

Plate
Thickness. 2” 3” 4” 6” 8” 10” 12” 14” 16” 18” 20” 24”
6.35 14668 6754 4086 1885 1112 716 509 422 323 255 207 144
9.53 33038 15213 9203 4246 2505 1613 1146 951 728 575 466 324
12.7 58672 58672 16343 7540 4449 2864 2036 1689 1293 1021 827 575
15.88 91733 42239 25552 11789 6956 4478 3183 2640 2021 1597 1294 898

19 60468 36579 16877 9957 6410 4557 3779 2893 2286 1852 1286
22.23 50073 23103 13631 8774 6238 5173 3961 3130 2535 1760
25.4 65373 30161 17795 11455 8143 6754 5171 4086 3309 2298
28.58 38186 22530 14503 10310 8551 6547 5173 4190 2910
31.75 47127 27850 17899 12724 10553 8080 6384 5170 3591
34.93 57040 33654 21664 15400 12773 9779 7727 6259 4346
38.1 67863 40039 25774 18322 15197 11635 9193 7446 5171
41 47002 30256 21509 17839 13658 10792 8741 6070
44.45 54498 35082 24939 20684 15836 12513 10135 7038
47.63 62574 40281 28635 23750 18183 14367 11637 8081
50.8 71181 45821 32573 27016 20684 16343 13238 9193
NOTES:
1) The tabulated pressures above are based on the formula stated in ASME B31.3, Para. 104.5.3 (b)
using the following:
a. Flat non-asbestos gaskets conforming to ASME B16.21.
b. Structural grade, carbon steel plate, ASTM A36 having a minimum specified yield strength of 36,000
psi.
2) For plate that is identified as having a lower minimum yield strength, the allowable hydrostatic
pressure must be reduced by the factor listed below. The factor shall then be applied to the
pressures listed in Attachment 03 pressure table:
P ma = Y x / Y
Where:
P ma = Maximum allowable test pressure

Y = Minimum specified yield strength, ASTM A36
Y x = Minimum specified yield strength for material selected
3) Pneumatic test pressures shall not exceed 50 percent of the values indicated.
0568-BOM20-92P1-0001-001 12 OF 12

0568-Bom20-92p1-0001-001-1-Code-1 Hydro Procedure

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

0568-Bom20-92p1-0001-001-1-Code-1 Hydro Procedure

Uploaded by

Copyright:

Available Formats

This document, including drawings, procedures, specifications, and its contents, is the exclusive property of

UNCONTROLLED WHEN PRINTED

Rev Status Date Originator Checker Approver Project

FLUSHING, HYDROSTATIC AND PNEUMATIC TEST PROCEDURE

Eni Mexico Area 1 Development Project

UNCONTROLLED WHEN PRINTED

Verified by Unit Signature Date

Verified by Unit Signature Date

Checked by Unit Signature Date

Checked by Unit Signature Date

Approved by Unit Signature Date

Endorsed by Unit Signature Date

UNCONTROLLED WHEN PRINTED

2. APPLICABLE CODES AND STANDARDS

UNCONTROLLED WHEN PRINTED

3.2 PREPARATION FOR FLUSHING

UNCONTROLLED WHEN PRINTED

UNCONTROLLED WHEN PRINTED

4.2 SAFETY CONSIDERATIONS

4.3 WEATHER CONDITIONS

4.4 TEST FLUID

UNCONTROLLED WHEN PRINTED

4.5.1 HYDROSTATIC TESTING FOR PIPING

4.6 PNEUMATIC TESTING

4.7 LEAK TEST

UNCONTROLLED WHEN PRINTED

4.8 ACCEPTANCE CRITERIA

4.9 BORESCOPE CHECK

UNCONTROLLED WHEN PRINTED

UNCONTROLLED WHEN PRINTED

UNCONTROLLED WHEN PRINTED

Nominal Pipe Size

UNCONTROLLED WHEN PRINTED

P ma = Maximum allowable test pressure

You might also like