MS FOR HYDROSTATIC PRESSURE TESTING

OF PIPING SYSTEM

DOCUMENT No: 8465-ZQ-M70-F-BEC Rev No. 3

PROJECT
SAIH RAWL DEPLETION COMPRESSION PROJECT
C M E & I INSTALLATION WORKS
CONTRACT REF: C31/0688

DOCUMENT TITLE: METHOD STATEMENT FOR HYDROSTATIC PRESSURE

TESTING OF PIPING SYSTEM

CUSTOMER
COMMENTS : YES NO
PDO REASON FOR COMMENTS
SAIH RAWL DEPLETION COMPRESSION NON-CONFORMITY
PROJECT MODIFIED
THE FACT THAT NO COMMENTS IS RECORDED DOES NOT
PROJECT No SUB - CONTRACT No RELIEVE THE BEC FROM HIS RESPONSIBILITIES WITH
REGARD TO COMPLYING WITH ALL CONTRACTUAL
REQUIREMENTS.
8465 C 31/0688 ANY MODIFICATIONS MADE ARE TO ADAPT LAYOUT OF
ELEMENTS OR EQUIPMENT PROPOSED BY THE BEC TO THE
DOCUMENT NUMBER IDEAL ISTALLATION DESIGN
REV No
8465-ZQ-M70-F-
3
BEC
ABBREVIATION OR ITEM :
.
MS FOR HYDROSTATIC DATE SIGN NAME
PRESSURE TESTING OF
PIPING SYSTEM

REVSION HISTORY

3 10.06.2009 Revised per PDO comments M.M.Hussain H.Mehta P. Nandkumar

2 19.05.2009 Revised per PDO comments M.M.Hussain H.Mehta P. Nandkumar

1 22.02.2009 Revised per PDO comments M.M.Hussain H.Mehta P. Nandkumar
0 03.02.2009 Initial Submission M.M.Hussain H.Mehta P. Nandkumar
Rev Date Revision Description Prepared by Checked by Approved By

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DOCUMENT No: 8465-ZQ-M70-F-BEC Rev No. 3

PROCEDURE FOR
HYDROSTATIC PRESSURE TESTING OF PIPING SYSTEM

INDEX

1.0 PURPOSE

2.0 SCOPE

3.0 REFERENCES

4.0 DEFINITIONS

5.0 ROLES AND RESPONSIBILITIES

6.0 PRESSURE TESTING

7.0 POST TEST

8.0 SAFETY

9.0 Appendixes

Appendix A - Quality and Treatment of Hydro test Water

Appendix B - Test Package Documentation

1.0 PURPOSE

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DOCUMENT No: 8465-ZQ-M70-F-BEC Rev No. 3

This document describes the sequence of events during all processes involved in the Hydrostatic Pressure
Testing of Piping System, detailing the measures adopted for safe and systematic completion of the same and shall
be read in conjunction with the applicable project specification, and relevant codes of Fabrication and
Erection of piping.

2.0 SCOPE

The scope of this procedure covers the minimum requirements for pressure testing of mechanical equipment and
piping during construction and pre-commissioning works at SAIH RAWL DEPLETION COMPRESSION PROJECT
(SRDC).

This procedure shall not cover Main Line Transmission pipe work.

3.0 REFERENCE DOCUMENTS

The following documents shall be used with this procedure.

3.1 Codes, Standards & Technical Specifications

ASME B 31.3 (2006 Edition) : Process Piping

ASME Section V : Nondestructive Examination.
SP 1096 (Dec 2004) : Specification for Welding DSS Piping
SP 1173 (Dec 2004) : Specification for Welding of On Plot Pipe Work
DEP 31.38.01.11 : Piping General requirement
ERD-84-01 : Pre-commissioning of On-Plot Mechanical Equipment and
Piping, Flushing, Hydro testing and Pickling (October 1985)

3.2 Technical Documents

8465-ZQ-M03-F-G : IPT for Hydrostatic Testing of On-Plot Piping

8465-ZQ-M01-F-G : ITP for Fabrication & erection (CS, LTCS & SS)
8465 -ZQ-M02-F-G : ITP for Fabrication & erection (DSS)
8465-ZZ-024-F-G : Safety Regulations for Pressure Testing

4.0 DEFINITIONS

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DOCUMENT No: 8465-ZQ-M70-F-BEC Rev No. 3

For the purposes of this document the following definitions shall hold:

This shall mean Petroleum Development Oman LLC, (PDO) or its

5.0 Company : nominated representative

The term contactor shall refer to Tecnicas Reunidas Group / TR OMAN

Contractor : (TR) / UTE Saih Rawl.

This shall refer to Bahwan Engineering Company LLC or its Project

BEC (Sub Contractor) : Manager

This shall refer to the subject contract i.e. SAIH RAWL DEPLETION
Project : COMPRESSION PROJECT (SRDC)

Vendor : This shall refer to equipment and material suppliers for the Project

Shall : This shall mean mandatory

Should : This shall mean strongly recommended

This word may is to be understood as indicating a possible course of

May : action.

ROLES & RESPONSIBILITIES OF BEC PERSONNEL

5.1. Project

Manager
He shall be responsible for the overall management of the C M E& I work of this contract.

5.2. Site Manager / Construction Manager

He shall be responsible for communicating all element of this Procedure and reference documents
to down the level and arranging all resources to perform Testing and HSE with correct technique.

5.3 QA/QC Manager

QA/QC Manager shall have overall responsibilities for QA/QC activities, he shall be responsible for
testing program development and coordination for hydrostatic testing. He shall be responsible for the
execution of correct testing techniques / control with strict adherence to this Procedure and
reference documents.

5.4 QA/QC Inspector

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DOCUMENT No: 8465-ZQ-M70-F-BEC Rev No. 3

QA/QC Inspectors shall be responsible for carrying out inspection and testing activities. He shall also be
responsible for carrying out line punch clearance and Compilation of test packs and witnessing and
certifying during the result of pressure test.

5.5 Testing Supervisor

Shall be responsible for site construction activities and implementation of Quality and HSE plans during
testing which would include walk down of test circuit.

Prior to any filling activity he will coordinate with TRO & PDO all pressure testing associated with this
procedure.

5.6 SAFETY

Safety officer shall be responsible for coordination with HSE authorities of client. Safety shall monitor all the
works to ensure that they are carried out correct and safe manner and advise supervisors for corrective
measures, if required. He shall ensure that toolbox talks are held which shall cover details of specific tasks to
the personnel and specific job risks involved are explained to the force involved.

6.0. PRESSURE TESTING

6.1 GENERAL REQUIREMENTS

6.1.1 Test Equipment

The equipment supplied shall include, but not be limited to the following:
- Circulation, flushing and pressurizing pumps.
- Temporary pipe fittings / connections, hose connections, spades and blank / blind flanges,
- Temporary pipe work, temporary strainers, valves and spool pieces.
- Temporary supports.
- Test gauges & Pressure/Temperature Recorders, complete with test certificates and double block and
bleed valves for connection to equipment.
- Dead weight tester accurate to 5 kPa with valid calibration certificate.
- Air-compressor for pneumatic testing and equipment drying.
- chemical mixing and injection equipment, if applicable
- Manifold, valves, regulating valves, check valves and high pressure tubing etc.

All supplied equipment and materials shall be approved by the company as required by ERD 84-01 para 3.1.

6.1.2 Testing Media.

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DOCUMENT No: 8465-ZQ-M70-F-BEC Rev No. 3

The test media and pressures shall be as indicated on the approved line list included in the Test Package.
No deviation from test media and/or pressure specified shall be permitted without the approval of the
Company.

The Test media will be water with maximum 200 ppm Chloride contents to be used for the hydrostatic
pressure test. Air (or inert gas) will be used for Instrument air line and Co2 line.

The Company shall approve any test water supplied by the Contractor and additionally specify any additions
of inhibitors or scavengers that may be required. An adequate mixing system shall be provided and utilized
by the Contractor to ensure a uniform solution.

If pneumatic testing is specified the air (or inert gas) used shall be 100% oil free.

Control valves & ESD valves shall not be included during hydro testing.

6.1.3 Preliminary testing of the system may be carried out using air at approximately 150 kPa (g) to check for
missing gaskets etc, to avoid the necessity of draining the system to rectify.

6.1.4 In cases where hydro testing is not considered practicable, a pneumatic test may be substituted with written
approval from the company. Any such testing shall not exceed 700 kPa (7 bars).

6.1.5 Equipment and piping shall be tested in groups or systems. The test pressure to be applied to any groups or
system shall not exceed the maximum test pressure of any component in that group or system and shall
satisfy at least the minimum for every component within the system. Where possible manufacturers
requirements for pressure testing shall be followed.

6.1.6 Lines may be tested with other non-flammable liquids where written approval is given by the Company.

6.1.7 Instrument air distribution lines shall be tested with oil free air.

6.1.8 Equipment / Pipe work

Piping which connects to or is continuous with lines installed by others shall be isolated from these lines by
valves or test blanks. When it is necessary to include portions of such lines in the test, PDO shall be
consulted at test loop preparation stage to determine the conditions of the test.

6.1.9 Valves

Ball valves shall be included in the test system. Lines containing check valves should have the pressure
source upstream of the valve. Relief valves shall not be included in the test circuit.
6.1.10 Instrumentation

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DOCUMENT No: 8465-ZQ-M70-F-BEC Rev No. 3

All gauge glasses and liquid level float chambers together with the lines and piping connecting the
instruments to the main pipelines and / or equipment shall be tested with the same medium and at the same
pressure as the main piping and / or equipment to which they are connected.

Before including gauge glasses and level float chambers the Contractor shall ensure that they are designed
for the test pressure to which they will be subjected. Any not satisfying this requirement shall be removed
from the piping and / or equipment, prior to pressure testing, and the end of the lines plugged, capped or
blinded.

6.1.11 Equipment and Vessels.

Equipment and vessels with Company approved pressure Third Party test certificates do not normally
require further testing. They may be included in a test circuit if approved by PDO.

6.2 TEST PACKAGE PREPARATION

6.2.1 Prior to testing a Pressure Test Package shall be prepared and submitted to PDO for approval. Pressure test
package shall contain the approved isometric drawings and the pressure test details indicating the test
medium, test duration and test pressure.QC release form, Mechanical acceptance certificate and pressure
chart recorder to be the part of test package.

6.2.2 The Test Pack shall contain the following documents / drawings.

In addition to the documents mentioned in Appendix B, the Weld History Sheets duly endorsed by TRO/PDO
for each Test Package will be attached, and NDT reports also to be verified.

The isometric drawing shall indicate:

- Vent and drain points.
- Position of blanks/spades.
- Position of test pressure gauges.
- Temporary spool pieces, if applicable.
- Filling position and pressurization point.
- Valves (mechanical) to be included in the tested.
- Extent of pipe work to be pickled/chemically cleaned (where applicable).

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DOCUMENT No: 8465-ZQ-M70-F-BEC Rev No. 3

6.3 Verification of Test Preparation and Test Equipment

Prior to pressure testing the Contractor shall ensure that the following requirements have been carried out:

6.3.1 Contractor shall ensure that all specified lines are thoroughly flushed with water and free of sand, debris,
obstruction, etc after completion of hydro testing of complete system as per flushing schedule & flushing
procedure and Testing check sheet P-001A4 shall be signed by TR & PDO and included in the Test Package.

After flushing, to ensure that the pipe is internally dry, system to be immediately blown dry with air to a dew point
of -1C.

6.3.2 Contractor shall ensure that flushing by air blowing bursting disc method has been carried out prior to hydro
testing as per approved Air blowing cleaning procedure and Testing check sheet P-002A shall be signed by TR &
PDO and included in the Test Package.

6.3.3 Flow Sheet(s) shall have been submitted to TR & PDO, marked showing each test that is intended to be carried
out. The flow sheet(s) shall show the extent of the test loop clearly marked indicating all blank/ spade positions,
vent positions, pressure gauge positions, and the filling entry point.

6.3.4 All pressure gauges to be used for the test shall have a unique number and shall be calibrated prior to each test
using a standard Dead Weight Gauge Tester. As per Win-pcs Gauges to be calibrated in Bar
The test details of each gauge to be used shall be entered on Test Equipment Calibration check sheet P-001A3.
Any gauge showing an uncorrectable zero reading, or error of more than +/- 2% of full scale range shall be
discarded and a new gauge shall e obtained. New gauges shall also be calibrated prior to use. The gauge
scales shall be calibrated in kPa and shall be not less than 125 mm in diameter.

6.3.5 Checks on the system to be tested shall be made in accordance with check list 8465-ZQ-M03-002 Verification
of Test preparation and Test equipment, and check sheet P-001A2 Piping Installation for Test.

6.4 Hydro testing

All high point vents and other connections which serve as vents shall be open during filling of the equipment / system
and that all air is vented prior to applying test pressure to the system. Venting through high point flanges shall be
acceptable where the system under test does not contain a high point vent.

The filling hose from the pump shall be connected to the lowest point of the system to be tested.

The system shall be filled from the lowest point with all vents open. The vents shall be progressively closed when a
steady air free stream of the water is issuing from the vent.

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DOCUMENT No: 8465-ZQ-M70-F-BEC Rev No. 3

The pump and the high and low section of the equipment or system shall be provided with separate calibrated test
gauges. Double block and bleed valves shall be provided to enable the test gauge to be checked against a standard
gauge at any time during the test.

Pressurize the system to approximately 100 kPa. Ensure that stable conditions have been attained prior to checking
system for leaks.

The pressure shall be increased in stages to allow for equalizing of strain during the test and to allow for leak
checking and inspection of the equipment / system. Stop points and visual checking the equipment or system under
pressure at each stage shall be determined by TR and PDO inspectors before testing commences. At stop points, the
pump shall be stopped and the pressure shall be held for at least 10 minutes for visual check of all welded, threaded
and flanged joints will be done for leak.

When leaks are detected on the equipment / system they shall be rectified only after the test pressure has been
relieved. Tightening of bolts on flanges or joints shall not be undertaken with pressure on the equipment / system.
When leaks have been rectified the test shall be carried out again for the full duration.
Upon reaching the pressure of the equipment / system, it shall be held for sufficient time to permit complete inspection
of all joints for leakage or signs of failure. The pressure shall be held for at least two (2) hours. When the actual
pressures applied exceed the test pressure by more than 2% (due to thermal expansion in a closed system) the
system shall be vented to reduce the pressure to the specified test pressure. The test pressure should be raised as
per below mention table.
In order to flush the line, after the completion of hydro testing the water inside the pipe to be flushed/drained with the
maximum air pressure of 7 bars.

Stage Pressure in KPA Stabilizing Time

1 170 Sufficient time to complete checking
2 25% of Test Pressure 05 minutes.
3 50% of Test Pressure 05 minutes
4 75% of Test Pressure 05 minutes
5 100% of Test Pressure 120 minutes for CPP and 30 minutes for Power Plant

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DOCUMENT No: 8465-ZQ-M70-F-BEC Rev No. 3

6.5 Pneumatic Test

Pneumatic testing shall only be permitted with prior approval of PDO. The pneumatic test pressure shall not exceed
110% of the design pressure however not exceeding 700 kPa. On reaching the specified test pressure the pressure
source shall be disconnected from the system.

The equipment / system shall be pressurized to 150 kPa or 50% of the test pressure, whichever is lower for
preliminary leak test.
After satisfactory preliminary leak test, the pressure is increased gradually in steps no greater than 1/10 of the test
pressure (required pressure rise per step=1/10 X test pressure).

A double block and bleed valve arrangement shall be included in the pressurizing line on the system being tested. A
test recording pressure gauge shall be downstream of the double block. After each pressure step has been reached,
close the block valves and open the bleeder to atmosphere. If after a 10 minutes period the Step Pressure is held,
proceed to the next Step Pressure; if not, examine the entire system for leakage.

Joints shall be tested with soap and water solution and be examined for leaks. Leaks detected on the equipment /
system shall only be rectified once the test pressure has been relieved. Tightening of bolts on flanges or joints shall
not be undertaken with pressure on the equipment / system. When leaks have been rectified the test shall be carried
out again for the full duration.

The test pressure shall be maintained for a minimum of two (2) hours or for as long as it shall takes to inspect all the
equipment / system for leakage or failure.

Pressure shall be reduced gradually exactly the way it has been pressurized (See Para. 6.4).

6.6 Precautions during Testing

The Contractor shall not allow equipment filled with a testing medium to stand for any length of time without venting it
to atmosphere as temperature changes may build up excessive pressure or create a vacuum.

The test pressure shall be carried out as per the piping data sheet, hydro test shall not be conducted when the liquid
temperature and metal temperature difference is over 10 deg C.

Pneumatic pressure tests shall not be carried out when the ambient temperature is below 7 C.

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DOCUMENT No: 8465-ZQ-M70-F-BEC Rev No. 3

7.0 Post Test

7.1 Draining and Drying of the System

On completion of hydrostatic testing the water shall be drained from the system and collected in a container. The
drained water shall be disposed at waste pits of Gas wells of Saih Rawl field.
The equipment / system shall be vented in a controlled manner during drain down so as to prevent a vacuum or
partial vacuum from being drawn.
- After drain down, the equipment or system to be immediately blown dry with air to and ensured that the system
contents no test water.

Check List 8465-ZQ-M03-006 -Draining & drying, Corrosion Protection after Test shall be completed.

7.2 Disposal of Test Water

The Contractor shall be responsible for the disposal of the test water in a manner approved by PDO.
On completion of hydrostatic testing the water shall be drained from the system and collected in a container. The
drained water shall be disposed at waste pits of Gas wells of Saih Rawl field.

7.3 Corrosion Protection

Equipment / system that is to be drained of test media and then left empty one month or more, special
precautions/treatments will be applied to prevent the ingress of air and subsequent corrosion.

Such special treatments shall include one of the following where applicable:
- filling with nitrogen or other inert gas
- filling with sweet dry oil
- installing vapour phase inhibitors
Any such requirement shall be specified by the Contractor for PDO approval prior to the testing programme and
systems selected for special treatment shall be stated in the Remarks / Observations section of the Reinstatement of
Piping after Test check sheet P-001A5.

7.4 Reinstatement of the System

On completion of all flushing and pressure testing the system shall be reinstated as per the construction drawings.
The check sheet P-001A5 Reinstatement of Piping after Test shall be completed. When approved by the Contractor
and accepted by PDO the completed check sheet shall be included with the Test pack.
Any joint that is broken after hydro testing shall have a new permanent service gasket fitted. These joints shall be
taped and subjected to an air pressure test not exceeding 200 kPa to ensure the integrity of the joint. Leak testing
shall be accomplished using soapy water. The gasket schedule shall be completed.

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DOCUMENT No: 8465-ZQ-M70-F-BEC Rev No. 3

The installation of instrument shall be in accordance with DEP 62.37.10.12-Gen as amended by PDO-ES-DE-30-01.

7.5 Pressure Test Certification

On satisfactory completion of pressure testing of a particular system the Contractor shall ensure that Test Check
sheet P-001A4 and P-001A7 are completed and signed and placed in the Test pack.

8.0 Safety Precautions during Testing

Any leaks found at the flanges while pressurization shall be corrected only after the pressure is brought down.

Test pressure will be decreased to zero and the section to be repaired will be dewatered before repairs are done.

While the pipe is under pressure, care shall be taken to avoid any kind of impact load applied on the pipe, associated
fittings or structures.

A minimum distance of 20 m shall be maintained between any piping under pressure and personnel not directly
involved in the test underway.

Warning signs indicating DANGER PRESSURE TESTING will be displayed at the site.

The unsafe work practices and conditions in the work place shall be immediately identified and eliminated through
tool box talks, HSE meetings and instructions.

Hydro Test shall be conducted with all staff and not in the test being evacuated outside the exclusion zone in view of
the potential hazard of Hydro Testing, BEC Responsible staff/ supervision shall be attendance on the work site while
tests are in progress.

All tools and equipments shall be used in accordance with manufacturers recommendations, required tool guards in
place.

All involved in Pressure test activity shall wear adequate PPE.

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DOCUMENT No: 8465-ZQ-M70-F-BEC Rev No. 3

9.0 APPENDIXES

APPENDIX A QUALITY AND TREATMENT OF WATER

A.1.0 CONTRACTOR RESPONSIBILITIES

The Contractor shall carry out, or request the company to carry out on his behalf, all water sampling and analysis that
may be necessary for the Company to approve his water source and quality.

The Contractor shall provide all details of his water treatment proposals necessary to bring the water to the required
quality for both flushing and hydro test use for approval by the Company.

A.2.0 WATER QUALITY

A.2.1 Carbon and Low Alloy Steel

A.2.1.1 Introduction of Air after Hydro test
If air is introduced after the hydro test the water used shall be of the minimum quality below:-

pH : 6.5 to 10.5
Total dissolved solids : less than 1.5 Kg/m3
H2S : Nil
Suspended Solids : Nil
Appearance : Clear with no visible sediment.

If the maximum period of contact of this water is 7 days or less chemical treatment shall not be required. If the period
of contact is in excess of 7 days chemical treatment as specified in A.2.3. shall be provided.

A.2.2.2 Exclusion of Air after Hydro test

If air is excluded from the system by leaving the system full of water and continuously pressurized between 30 and
150 kPa, the quality o the water may be relaxed as below:-

pH : 6.5 to 10.5
Total dissolved solids : less than 30 Kg/m3
H2S : Max. 0.001 Kg/m3
Suspended Solids : Less than 0.0005 Kg/m3
Appearance : Clear with no visible sediment. Black or red water shall be rejected.

Irrespective of the period of contact the above water shall be chemically treated as specified in A.2.3.

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DOCUMENT No: 8465-ZQ-M70-F-BEC Rev No. 3

A.2.2 Stainless, High Alloy and Nickel Steel

If the system or parts of the system contain equipment manufactured from stainless, high alloy nickel steel the
following procedure for the selection of water quality shall be applied.

Start

W ill test or future Can all water be

service temp be removed by draining
above 50C and mopping-up

Can test water be

drained and equipment
flushed through

Use hydrotest water with Use hydrotest water with

Use hydrotest water with max. 200 ppm chloride
max. 1 ppm chloride. Hot
max. 200 ppm chloride Forced air/gas drying not
air/gas drying is
Forced air/gas drying not permitted
permitted.
permitted

Use hydrotest water with

max. 200 pm chloride.
Flush all wetted surfaces
with water of max. 1 ppm
chloride until residual
chloride is less than 5
ppm Forced air/gas
drying not permitted.

All waters used for hydro testing shall be free of sediments, undissolved solids and matter that may
precipitate out during testing or standing and the pH shall be in the range of 6.5 to 10.5.

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DOCUMENT No: 8465-ZQ-M70-F-BEC Rev No. 3

A.2.3 Chemical Treatment

Advice on approved chemicals and treatment rates may be obtained from PDO Corrosion Engineering Section.
The type of treatment to be used will depend on the period of time that the water remains in the system after the
hydrostatic test.
Two different types of treatment are currently approved by the Company.

A.2.3.1. Cocktail Treatment

A single-chemical blend comprising two or more components of oxygen scabvenger, corrosion inhibitor, scale
inhibitor or biocide.

A.2.3.2 Individual Chemical Treatment

Injection of oxygen scavenger, biocide and corrosion inhibitor separately. When using this treatment the oxygen
scavenger shall be added first, and as far upstream in the system as practical to allow complete reaction. The biocide
shall follow and finally the corrosion inhibitor.

A.2.3.3 Contact period

For contact periods up to 3 months the cocktail treatment or individual chemical treatment may be used.
For contact periods of 3 months to 24 months individual chemical treatment shall be employed.

A.2.3.4 Special Treatment

In locations, where no water of suitable quality is available, alternative treatments are possible e.g. for seawater or
sour water (containing H2S). Application for the method of treatment shall be made to PDO Corrosion Engineering
Section ETH/5.

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DOCUMENT No: 8465-ZQ-M70-F-BEC Rev No. 3

Appendix B TEST PACKAGE DOCUMENTATION STRUCTURE

1. Test Package Content sheet

2. Piping isometric index for test
3. Piping Installation for Test
4. Manifold test details
5. Flushing & Testing
6. Reinstatement of Piping after Test
7. Valves
8. Test Completion Records Sheet
9. Piping Cleanliness
10. Insulated Gasket Joints
11. Demolition Record Sheet
12. Calibration Certificate
13. Mechanical Acceptance Certificate
14. Construction Punch List
15. Marked up P & ID
16. Marked up Isometrics
17. Weld History Sheet
18. Support Summary List
19. Water Test Certificate
20. Line List
21. QC Release Form
22. Hydro Test Sketch
23. Equipment list of excluded items

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