TGS MARITIME TECHNOLOGY

SDN. BHD
Company No. (601764-M)

HEALTH, SAFETY & ENVIRONMENT

MANAGEMENT SYSTEM

(HSEMS)

PROCEDURE

Title : CARGO HOSE PRESSURE TEST

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NO. DESCRIPTION PAGE NO.

1 Purpose 3

2 Application 3

3 Responsibilities 3

4 Procedure & Plan 3-8

5 Reference 9

6 Appendix NIL
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1.0 PURPOSE

The purpose of these procedures is to ensure that pressure tests are conducted safely and
effectively. They cover pressure testing of new and existing dock hoses at a test pressure more than
0 psig.

2.0 APPLICATION

All managed oil tankers and barges

3.0 RESPONSIBILITIES

Engineering Team Lead – Shore / Master and Chief Officer – Vessel

4.0 PROCEDURE & PLAN

4.1 Lifting & Installed Hose Flange

i. Ensure All Manpower wear PPE. PPE MANDATORY during carried out the Cargo
Pressure Test.

ii. Inform Person Incharge before start job.

iii. Applied Permit To Work (If Applicable) and perform Toolbox meeting before start
work.

iv. Barricade the work site before start the job.

v. Perform lifting and rigging to joint the hose as per required.

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vi. Individual hoses must always be lifted by use of a spreader bar and never just by
slinging either from the ends or the center of the hose. The spreader bar should
provide at least a three point lift on hoses up to 35 feet long and must be used in
conjunction with flat, nylon webbing slings, at least 150 mm wide to prevent damage
from chafing.

TYPICALL SPREADER BAR LIFTING ARRANGEMENT

vii. One sling shall be placed at the nipple area at each end of the hose to support the
hose ends and the other(s) at the center of the hose to prevent sagging

viii. It is always most important to use such straps when handling integrally floating hose.
In this case, the straps not only eliminate chafing but also reduce point loading and
hence deformation of the flotation medium.

ix. For hoses longer than 35 feet, the spreader bar should provided at least a four point
lifting.

x. If nylon or equivalent straps are not available, the best substitute is a sling of large
circumference nylon or polypropylene rope. Wire should not be used

xi. A hose should never be lifted by a single sling at the midpoint, or by two slings
positioned one at each end. When moving a hose, it must be lifted properly and set
down with care on adequate supports. A hose should never be dragged across the
ground.
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xii. Further, when the hose is to be laid down on supports placed on the deck, special
attention is to be given to the flange as it touches down on deck; and to the lower
ends of the hose to avoid large bending stresses.

xiii. The supports upon which a hose should be laid out for the conduct of tests and
inspections should allow the hose to elongate freely during hydrostatic testing.

xiv. This may be achieved with sufficient pipes of minimum diameter 50mm with an
objective of keeping the hose above deck and prevent sagging.

xv. Detailed Lifting procedure TGSSB/LII/001 must apply during lifting process.

xvi. After completion lifting process, joint between hose must be tightening as per torque
value.

xvii. Follows Bolt Tightening WI-19 during installation hose flange. Perform Bolt
tightening and witness bay client.

4.2 Test Preparation

Before testing, the following procedures shall be carried out:

i. Piping systems shall have been thoroughly checked for completeness

ii. Piping systems shall be checked to ensure that the entire system can be completely
drained after testing

iii. Vents or other high point connections shall be opened to eliminate air from lines,
and system shall be purged of air before hydrostatic test pressure is applied.

iv. Short pieces of piping that must be removed to permit installation of a blind or blank
shall be tested separately.

v. Flanged joints at which a blank is inserted to isolate other equipment during a test
need not be tested after blank is removed.

vi. Lines containing check valves shall have the source of pressure located in the
piping upstream of the check valve so that the pressure is applied under the seat.
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vii. Systems that include expansion joints, which have been removed for pressure
testing shall be investigated to see that any required temporary restraints, anchors,
or guide are installed or removed prior to test.

viii. Drain and vent valves are to be in closed position and plugged during test

ix. Lifting procedure TGSSB/LII/001 and Bolt Tightening WI-19 must be follows during
lifting hose and tightening flange.

4.3 Filling Instruction.

i. Prior to filling the test section, ensure that valves, flanges, closures or bull plugs at
the high point are set to an appropriate position (open, closed, or partially open) to
bleed all air out during filling, and that all instrument tubing has been disconnected
and plugged

ii. Fill water shall be fresh water obtained only from approved sources or seawater,
whichever is appropriate for testing medium.

iii. Fill the Cargo pipeline section with water at a continuous rate. Should the fill stop at
any time due to uncontrollable circumstances, the fill line shall be purged of air.
Care shall be taken to ensure that no excess air is entrapped in the pipeline

iv. The Cargo pipeline and components shall be completely filled with water. While the
Bunker pipelines shall be completely filled with bunker oil and the Diesel pipelines
with diesel oil.

v. Measure the quantity of fill water pumped into the pipeline. Consider monitoring the
pressure and temperature of the test medium during the filling operation.

vi. Verify that all valves and components are in the proper orientation prior to
pressurization.

vii. After the stabilization period, the test section shall be pressurized to the test
pressure with caution.
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4.4 Pressure Test.

i. Piping systems shall be pressurized slowly and evenly to prevent vibrations.

ii. When the pressure has been raised to the required test pressure of 1.5 x Maximum
Allowed Working Pressure (MAWP). A leak check shall be done to all valves and
fittings. If leaks are found, system must be depressurized prior to repairs. Affected
piping shall be retested. Pressure holding time shall be fifteen (15) minutes
minimum.

iii. In order to hydrostatic test as much piping as possible at one time, a systems test
may be employed.

iv. The minimum test pressure for a system test shall be such that each line in the
system is subjected to its required minimum test pressure.

v. The maximum system test pressure shall not exceed the pressure test rating of any
piping component

vi. The normal location for the pressure test gauge is at grade near the pressure test
pump.

vii. Gauges shall be a minimum 100 mm (4”) diameter face and shall be graduated over
a range of approximately double the intended test pressure but in no case shall the
range be less than 1.5 times nor greater than 4 times that pressure

viii. All tests shall be witnessed and accepted by the Master and/or Chief Officer. The
test results shall be recorded and reviewed by the Technical Superintendent. The
approved Hydro test Certificate shall be issued to the Vessel and copy provided to
Shore Office.

ix. Detailed for pressure test refer TGSSB/LII/HSE/003

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4.5 Depressing & Dewatering.

i. The test section shall be bled down slowly and carefully after successful completion
of the test period and acceptance of the test.

ii. After completion and acceptance of tests, completely dewater the pipeline.

iii. After lines have been drained, temporary supports shall be removed. If applicable,
spring hangers provided with stops to carry the test load shall have these stops
removed.

iv. Instruments which were removed or blocked out for test shall be reinstalled and
blocks placed in the normal operating position.

v. Temporary bolting and gaskets used for pressure testing shall be removed and
replaced with line class bolts and gaskets

vi. Check valves that were jacked open or had the internals removed for pressure
testing shall be returned to their proper operating position

vii. Vent and drain connections that were added solely for pressure testing shall be
closed and seal welded as required. Drains shall have either the valve closed and
plugged or, if the valve is removed, the connection plugged and seal welded as
required.

4.6 Cleaning & Drying

i. Air dry the pipeline with dehumidified air from an air compressor, or as otherwise
indicated in the scope of work. This process shall continue until there is no evidence
of free water exiting from the test section.

ii. After cleaning and drying, pipeline should be tied-in, purged, and loaded as soon as
practical.
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5.0 REFERENCE

i. IACS Guidelines

ii. ASME B31.3-2010 Process Piping

iii. ASME B31.4-2006 Pipeline Transportation System

iv. ASME B16.34 Valves

6.0 APPENDIX

v. Not in List (NIL)