Provision of Flow lines and

OHTL EPCC Project 031-SC-21-

EBS
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Hydrostatic Test Procedure for

Process Piping and RTP
Contract No.: 031-SC-21

Date Sign
Code I Information only Submission - Accepted
Code R Rejected – Major Comments – Data Provider to revise and re-
submit. Work should NOT proceed in the affected areas until
comments are resolved.
Code C Comments Returned – Data provider
der too revise
rre i and
evise d re-submit
bmitit for
re-sub
bm
bmit for
fo
the further review.
Code A Accepted – Approved – No furtherr ssubmission
ubmission required
Review Code and Status
attuss

2022.07.27

D03 26-07-2022 IFA Yousef Ahmed Haythem

D02 26-05-2022 IFA Yousef Ahmed Haythem

D01 23-05-2022 IFA Yousef Ahmed Haythem

D00 15-05-2022 IFA Yousef Ahmed Haythem

REV Date Issue Status Prepared By Checked By Approved By
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DOCUMENT REVISION HISTORY SHEET

DATE
Rev REVISION DESCRIPTION UPDATE / AMENDMENT DETAILS
ISSUED
Hydrostatic Test Procedure for
D00 15-05-2022 Issue For Approval
Process Piping and RTP
Hydrostatic Test Procedure for
D01 23-05-2022 Issue For Approval
Process Piping and RTP
Hydrostatic Test Procedure for
D02 26-05-2022 Re Issue For Approval
Process Piping and RTP
Hydrostatic Test Procedure for
D03 26-07-2022 Re Issue For Approval
Process Piping and RTP
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CONTENT

1. GENERAL........................................................................................................................................................... 4
2. REFERENCE...................................................................................................................................................... 4

2.1 Code and standards......................................................................................................................... 4

2.2 Construction procedure ................................................................................................................... 5

3. THE INTERFACE OF THE PRESSURE TEST ................................................................................................... 5
4. PREPARATION FOR THE PRESSURE TEST ................................................................................................... 5

4.1 Pressure test plan ............................................................................................................................. 5

4.2 Equipment.......................................................................................................................................... 7

4.3 Pressure test schedule ..................................................................................................................... 7

5 PRESSURE TEST STEPS AND PROPOSAL:.................................................................................................... 7

5. l Preparation and confirmation ........................................................................................................ 7

5.2 Pressure test methods ..................................................................................................................... 8

5.3 Pressure Test Conditions ................................................................................................................... 9

5.4 Pressure Test Requirements ......................................................................................................... 10

5.4.2 Pressure test for RTP pipeline.................................................................................................. 12

6 REPAIRING AND RETEST .............................................................................................................................. 14
7 DE-WATERING AND AIR BLOWING…..……………………………………………………………………………...14
8 WATER CERTIFICATE FOR HYDROTEST ..................................................................................................... 15
9 HSE Control Method ......................................................................................................................................... 15
10 Equipment list ................................................................................................................................................... 16

ၝ RELEASE CHECKLIST FOR PRUSSURE TEST…………………………………………………………………17

ၝ PRE-TEST CHECK LIST…………………………………………………………………………………18
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1. GENERAL

According to the construction plan, The relative flowlines, trunkline,OGMs and wellheads
are located in S1and S2. The plan is to make sure all the pressure tests to be performed
correctly and safely. The quantity of the Wellheads piping, Trunklines , OGMs facilities
and Flowlines will be adjusted according to the requirement..

2. REFERENCE

2.1 Code and standards

x ASME B31.4-2019 Pipeline Transportation System for Liquid Hydro carbons and
Other Liquids.

x ASME B31.3-2018 Process piping of ASME code for pressure piping.

x API11102013 Pressure Testing of Liquid Petroleum Pipelines

x API-SPEC-15S-2016 Spoilable-Reinforced-Plastic-Line-Pip

x API RP 17B -2014 Recommended Practice for Flexible Pipe

x API Specification 17J-2016 Spoilable Reinforced Plastic Line Pipe

x EBS1-FSFA00-SAPR-SPDS-1001-D01 Design Basis

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2.2 Construction procedure

031-SC21 EBS1-FSFA11-SAPR-PRIS-1001-D00 Flowline Construction Procedure.

3. THE INTERFACE OF THE PRESSURE TEST

Wellhead and OGM construction piping pressure test: The interface of the wellhead piping
is between the Christmas tree and the Flowline pipes. The piping in the OGM and other
related piping above the ground shall be included in the piping pressure test.
Flowline pressure test: The interface of the pressure test is between the flange of the check
valve in the well pad and the flange of the OGM, and other RTP pipelines or carbon steel
pipes, which belong to the contract No.: 31-SC-21. The owner will adjust the plan according
to the actual work.
Trunkline pressure test: The trunkline in the contract including the oil trunkline, water
injection trunkline and other transportation trunkline etc. shall be performed the pressure
test.
The water tank will fill the flowline when filling the system, after that, the pressure test will
be started.

4. PREPARATION FOR THE PRESSURE TEST

4.1 Pressure test plan

4.1.1 Water Resource

All the water will be supplied by mobile water tank. The capacity of the tank is about 20m³,
the filling point of every well flowline is at one of the endings of each flowline. The pressure
gauge shall be installed at the tallest point of the system. The sketch as following:
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WATER TANK FLOWLINE / PIPING

PUMP

The quantity of water for each flowline will be calculated by the actual requirement.

4.1.2 The air release point

The air release point shall be set at the highest point of the pressure system; it is the
pressure gauge point, which normally removed when filling water.

4.1.3 Pressure raising point.

The pressure raising point shall be set near the pressure pump.

4.1.4 Pressure gauge

Pressure gauge shall be installed at the release point and pressure raising point

4.1.5 Water draining point

Water draining point shall be set at the lowest place of the system and connected with the
local drainage system.
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4.2 Equipment
Please see the equipment list in clause 8.

4.3 Pressure test schedule

Start water filling: follow the actual required date of each
flowline start pressure raising: follow the actual required date
of each flowline
Pressure time to maintain: flow each of the requirement of flowline, wellhead piping
System, OGM piping and trunkline..
Draining time: follow the actual required date of each flowline

5 PRESSURE TEST STEPS AND PROPOSAL:

5. l Preparation and confirmation

5.1.1 Confirm that the pressure pump and relative equipment’s are in good condition

5.1.2 Confirm that all the relative staff are ready and the communication way are accessible.

5.1.3 Submit hydrostatic test package and release for hydrostatic report, for final review and
approval to TPI / EBS PMT to make sure there are no activities or inspections pending
before apply hydrostatic test the test package must include the following:
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x Marked-Up P&ID and Isometric drawings those showing system identifications, limits, vent
points, drain points, test blinds and pressure gauges locations.
x Line List.

x Inspection reports.

x Welding and NDT Summary sheet (Register) for piping.

x Calibration Certificates.

x Water analysis.

x Signed Release Checklist for Pressure Test.

x Pre-test Checklist.

x Pressure Test Report.

5.2 Pressure test methods

5.2.1 Check the valves and auxiliary system to ensure they are in good condition. Ensure
that all system are connected.

5.2.2 The filling point and air releasing point shall be monitored by designated person. who
is responsible to close the valve when receiving the signal of filling.

5.2.3 Pressure test is carried out after pipeline cleaning iscompleted.

5.2.4 When there is water outside of test system during pressure test, drainage treatment
should be carried out.
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5.2.5 Before pressure test, the construction unit shall prepare a pressure test plan and submit
it to the PMT and TPI for approval and implementation.

5.2.6 TPI shall carry out pressure test jointly and project PMT & MDOC shall be invited to
participate in pressure test.

5.2.7 When pressure test is carried out, forbidden areas are delimited, warning belts are set
up, and unrelated personnel are prohibited from entering operationareas.

5.2.8 During the freezing weather when hydrostatic testing is done, the system being tested
shall be immediately and completely drained. Any non-drainable portions, where freezing may
damage.

5.3 Pressure Test Conditions

5.3.1 For piping of wellhead, OGMs and Water injection system, the test pressure shall in
accordance with ASME B31.3 unless otherwise specified. The following equipment shall be
excluded from the field hydrostatic test with connected piping:

o Instruments and instrument piping.

o Any equipment specifically recommended by manufacturer not to be hydrostatically
tested.

o Any equipment where hydrostatic testing would be detrimental to its operation or

internals.
o Piping or equipment that has been pickled for cleanliness.
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5.3.2 For pipeline and trunkline: The test pressure shall in accordance with ASME B31.4
unless otherwise specified The connection and installation shall be qualified; buried pipes
except joints (length 500 mm-600 mm), have been backfilled to 500 mm above the top of the
pipe according to backfilling and compaction requirements, and compacted to the required
compactness; Pipeline fixed support and thrust block seat shall meet the design strength
requirements.

5.3.3 Make sure all the interfaces on the pressure test section are sealed and leak-free.

The equipment and obstacles that affect the pressure test should be removed or isolated from
hydrostatic loop.

5.3.4 Pressure test and drainage equipment are ready, water supply is sufficient, pressure
test pump and pressure gauge should be checked and verified.

5.3.5 Pressure gauges for pressure testing shall be qualified by statutory measurement
Institutions and shall be within the validity period; their accuracy shall not be less than 1.5 grade
and the diameter of dials shall not be less than 100 mm. The measurement range should be
1.5 times of the maximum test pressure, and at least two pressure gauges should be installed
in each test system.

5.4 Pressure Test Requirements

5.4.1 Pressure test for field piping system

Field piping system including the OGM piping system, wellhead piping and other above ground
piping in the contract. Operational blinds may be used for field-testing. The construction team
shall furnish any other test blinds or blanks required for field-testing during initial construction.
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1) All welds on metallic piping shall be free of any external painting, insulation; wrapping etc.
the field-testing of piping shall be performed before insulation is applied. If insulation is
applied before field-testing, all shop welds (excluding welds which have been shop or mill
hydrostatically tested), field welds and field joints shall be left exposed until field-testing is
complete. Lines containing check valves should have the source of pressure located
upstream of the check valve. If this is not possible, the check valves should be either
removed or blanked off.

2) Ball valves, globe valves and gate valves may remain partially or fully opened as
required by Company, provided the valve is suitable for the test pressure.

3) Piping, which must be removed to permit installation of test blinds or blanks, shall be
tested separately.

4) Where piping being tested extends beyond the process unit limit without flanges, it shall
be tested to the first block valve or set of flanges outside the unit limits. Care shall be
taken that lines tested beyond unit limits are able to withstand test pressure to be used.

5) The assembly testing shall comprise of a strength test followed by visual examination at
the leak tightness test pressure.

6) The leak tightness test shall commence immediately after satisfactory completion of the
strength test. All connection other than those to test monitoring Instrumentation shall be
removed and the ends Blinded/Capped. All removal of pressure pipe sections is
indicated in hydro testing procedure. No water shall be added or removed during the
leak tightness test. The test is intended to demonstrate that there are no leaks in the
system.

7) Upon completion of test, the test-pressuring manifold shall be immediately disconnected

from the system being tested.

8) During the freezing weather when hydrostatic testing is done, the system being tested.
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9) Shall be immediately and completely drained. Any non-drainable portions, where freezing
may damage.

10) Equipment or operation shall be protected from freezing.

Strength test Tightness test

System Items
Test presser Minimum duration Test presser Minimum duration

Piping in All joints &

Piping 1.5 x Design 1.0 x Design
OGM & Well 30 min connection to be
system pressure pressure
pad visual check

5.4.2 Pressure test for RTP pipeline

(1) During the test, the ambient temperature shall not be lower than 5 Ԩ. when the ambient
temperature is lower than 5Ԩ anti freezing measures shall be taken and all the connect
joints should exposed.

(2) Step 1 Pressurizing: the pressure should be gradually increased 30%, 60%, 80% and
100% from required pressure (10 min hold for each stage) to no greater than 110 % of the
nominal test pressure and held until stabilized.
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(3) Step 2 Stabilization ᧶the stabilization period may last for about 2 h after the end of

pressurization. This stabilization period may be extended if significant pressure drops are
still occurring after the first 2 h, Stabilization is defined as a pressure change over 1 h of
less than 1 % of the test pressure. During stabilization, the pressure should be recorded.

(4) Step 3 Hydrostatic Pressure hold ᧶After pressure stabilization, the pressure shall be
increase to the hydrostatic test pressure ,it shall be minimum of 1.3× nominal pressure
Rating for non-metallic reinforced pipe, and shall be applied to the entire manufactured pipe
length. The pressure shall not reach more than 110% of nominal test pressure, the test
pressure shall be maintained for a minimum of 1 hour during which time there shall be no
leakage or other signs of deterioration. The pressure drop should unaccountable but the
maximum pressure drop during the hold period should not exceed 4 % of the nominal test
pressure before release, the pressure all the connection joints should be inspected visually
to ensure there is no leakage.

(5) Step 4 Depressurizing ᧶Depressurization shall be gradually released at 3 steps,

from100%‹80%‹60%‹30%‹0%, each step need hold 5 minutes to control the pressure.
After depressurization, the end-fitting areas shall be visually examined for any sign of
damage or leakage from both the pipe and the end-fittings or couplers. Procedures
should remove as much water as possible from the pipe after completion of the test.

(6) During the pressurization, stabilization, hydrostatic hold period and depressurization
should be recorded (pressure and temperature).
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Stabilization Hydrostatic leak test

System
Minimum Minimum
Pressure Test Pressure
duration duration
> 1.3 x Design pressure 1h with pressure 1.3 x
RTP Pipeline 1 hour
< 1.1 x Test pressure change over less than Design
1% from test pressure pressur

6 REPAIRING AND RETEST

x The company should be informed immediately if any leaks identified within the
test boundaries, repairing work or additional work necessary as a result of
pressure test, those work shall be conducted after depressurizing, during the
water and those piping system, which have been effected by such work,
shall be subject to additional tests.

x In case of leak during pressurizing, pressure shall be fully released prior

re-bolt tightening.

7 DE-WATERING AND AIR BLOWING

x After completion of the test, the pressure shall be gradually de-pressurized to

the atmospheric pressure, the line shall be drained off and emptied.

x All temporary blanks and blinds for hydrotest shall be removed, and all lines
and piping components to be completely drained.

x Once the system is completely drained off water, compressed air shall be
blown to remove any water which may be present inside the system piping.
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8 WATER CERTIFICATE FOR HYDROTEST

Water shall be used for hydrostatic tests. In addition, water test certificate
should be applied and are approved before starting the hydrostatic test.

9 HSE Control Method

9.1 Construction execution and HSE training shall be planned and executed at the
same time: All the staff shall follow the proposal and plan strictly.

9.2 The position of HSE officer shall be designated at the work site, who is
responsible for all the relative permit work.

9.3 The construction team and all the staff shall wear PPE, follow the rules, and order to
work.

9.4 The safety warning mark and guidance shall be set at the site

9.5 The electrical work shall be regulated and controlled to eliminate the risk of electrical
work.

9.6 The leakage point must be repaired after the pressure is released. And the

pressure test can be restarted after repair is accepted.

9.7 Any temporary welding or hot work shall not touch with the RTP flowline to make

sure the pipe cannot be damaged.

9.8 The blind flange shall be marked and removed after pressure test, which shall be

done by designated person. All the relative work such as the bolts, gasket work

shall be managed and stored well.

9.9 The pressure release point or draining point shall be monitored by designated person.
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10 Equipment list

Sr. No Item Quantity UOM Remark

Digital temperature and pressure
1 1 Set
recorder.

2 Crane 1 set

3 Generator 1 piece

4 Pressure test pump (20MPa) 1 piece

5 Pressure test pump (40MPa) 1 piece

6 Water truck 1 piece

7 Water tank 1 piece

8 0-10Mpa pressure gauge 2 piece

9 0-40Mpa pressure gauge 2 piece

10 Tubes 60 meter

11 Temperature meter 1 set

12 Safety tape warning sign 50 meter

13 Whip check 2 piece

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RELEASE CHECKLIST FOR PRUSSURE TEST

NO Check Item Yes No N/A

1 Welding Register had been reviewed, accepted and signed.

All Items on Pipework Pre-Test Check List have been examined and
2
completed.
All category A punch List items have been rectified and signed for
3
completion.

4 All NCRs closed.

5 System has been set-up for testing as per requirements.

Result:
Remarks:

AL MUTAA QA/QC TPI PMT

NAME

SIGNATURE

DATE
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PRE-TEST CHECK LIST

NO CHECK ITEM Yes No N/A

Check all the NDE requirements are as specified, have been met and
1
recorded.
2 Check all the bores of all orifice flanges have been ground smooth.

3 Pipework internal cleaning confirmed.

Check isometric are latest revision and agree with test pack
4
specification sheet.
5 Check isometric against the P&ID.
6 Check that the correct bolts and gaskets are installed.

7 Check all pipe fittings for correct schedule and material type.

8 Check the valve material specification.

9 Check all the pressure connections is as per specification.

Check for correct direction for check valves, global valves, and control
10
valves.
11 Check orifice valve tap orientation.
Check that all pipe supports are completely installed as per drawing
12 and pipe support standards / specification and schedules – additional
support may be required refer to standard drawing.
13 Check pressure gauge calibration correct.

14 Check that all temporary pipe supports have been removed.

15 Check test medium for conformity to requirements.

Result:

Remarks:

AL MUTAA QA/QC TPI PMT

NAME
SIGNATURE
DATE