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M.F. AL-HAJRI CONTS.EST.

P.O.BOX 4626
31952 AL-KHOBAR
Kingdom of Saudi Arabia
Document # QP-MFH-L-02-A Revision 0 Date :OCTOBER 14, 2008

Prepared /Compiled by : Reviewed & Approved by :


QA/QC Mechanical QA/QC Manager
Title:
HYDROTEST PROCEDURE Page 1 of 13
Reinforced Thermosetting Epoxy-
Resin (RTR Pipes)

1.0 INTRODUCTION:

This procedure covers all the preparatory works and safety requirements for
internal cleaning, water filling, hydrostatic testing and draining of different
diameters of RTR lines, Fire Hydrant and oily water drainage.

2.0 REFERENCE :

2.1 DRAWING NO.01 - Hydrostatic Test Diagram piping

2.2 ASTM D3350 - Polythelene Plastic pipe and Fittings


2.3 SAES-A-004 - General Requirement for Pressure Testing

2.4 SAES-A-005 - Safety Instruction Sheet

2.5 SAES-A-007 - Hydrotest Testing Fluids and Lay-Up


Procedures
2.6 SAES-L-610 - Non-metallic Piping
2.7 SAES-B-004 - Safety Policy
2.8 SAES-S-060 - Saudi Aramco Plumbing Code
2.9 SAES-L-150 - Pressure Testing of Pipelines and Plant
Piping
3.0 SAES-S-010 - Sanitary Sewer
3.1 SAES-L-460 - Pipeline crossing and Under Road& Railroad
3.2 SAES-A-114 - Excavation and Backfilling
3.3 SAES-S-020 - Industrial Drainage and Sewer
3.4 SAES-S-070 - Installation of Utility Piping
3.5 G.I. 0002.100 - Work Permit System

Page 1 of 13
M.F. AL-HAJRI CONTS.EST.
P.O.BOX 4626
31952 AL-KHOBAR
Kingdom of Saudi Arabia
Document # QP-MFH-L-02-A Revision 0 Date :OCTOBER 14, 2008

Prepared /Compiled by : Reviewed & Approved by :


QA/QC Mechanical QA/QC Manager
Title:
HYDROTEST PROCEDURE Page 2 of 13
Reinforced Thermosetting Epoxy-
Resin (RTR Pipes)

3.6 SAES-B-017 Fire Water System Design


3.7 SAES-L-105 - Piping Material Specification
3.8 G.I. 0002.102 - Pressure Testing Safety

3.9 MFH Sketch No. 00A - Hydrotest Manifold

4.0 MFH QA/QC Plan & ITP

4.1 MFH Safety and Loss Prevention Program

3.0 HYDROSTATIC TEST INFORMATION

3.1 HYDROSTATIC TEST NO. 1:

Strength Test : 150 psig; Duration: 4 hours


Tightness Test : 143 psig; Duration: 10 minutes or
until Inspector has examined
all exposed joints.
Relief Valve Setting : 158 psig for Strength Test
151 psig for Tightness Test

4.0 SAFETY PRECAUTIONS

During pipeline pressure test, great hazards exist to all personnel involved
when all potential risks are not anticipated and resolved prior to the start of the
test. The safety of personnel during testing is of paramount important, hence
no procedure should be allowed which will violate this concept.

Page 2 of 13
M.F. AL-HAJRI CONTS.EST.
P.O.BOX 4626
31952 AL-KHOBAR
Kingdom of Saudi Arabia
Document # QP-MFH-L-02-A Revision 0 Date :OCTOBER 14, 2008

Prepared /Compiled by : Reviewed & Approved by :


QA/QC Mechanical QA/QC Manager
Title:
HYDROTEST PROCEDURE Page 3 of 13
Reinforced Thermosetting Epoxy-
Resin (RTR Pipes)

Precautions, duties and responsibilities of individuals shall be clearly defined


and adhered before and during the test.

The Saudi Aramco Work Permit Procedure will be followed at all times and at all
stages. The person who is responsible for the project, i.e., the construction
superintendent, the QC Supervisor , the safety engineer etc., shall hold a
meeting with all personnel involved to review the specifications, test procedures
and safety requirements. All testing personnel shall be instructed and shall be
made aware of the danger of the energy stored within the pipes and RTR lines
and particular emphases shall be discussed with respect to the danger of air-
water mixture under pressure.

As an absolute minimum requirement the following checklist shall be prepared


and adhered to:

4.1 Submit notification in advance, 2 weeks minimum to Saudi Aramco


Project Engineer of the pressure testing activity. Also submit to APIU the
Hydrotest RTR procedure of the facility for hydrostatic testing.

4.2 The hydrostatic testing will be conducted in strict compliance with the
approved test procedure. A copy of the approved test procedure is to be
kept at the site prior to starting the test.

MFH site superintendent shall see to it that Saudi Aramco Work Permit
and local authorities permits, whenever required, are obtained prior to
conducting any work for the test.

4.3 Warning signs and no parking signs shall be placed at all road crossings
and possible access points to the pipeline informing people that a
hydrotest is occurring, e.g., "DANGER, KEEP OUT, RTR PIPELINE
HYDROTEST IN PROGRESS".

Page 3 of 13
M.F. AL-HAJRI CONTS.EST.
P.O.BOX 4626
31952 AL-KHOBAR
Kingdom of Saudi Arabia
Document # QP-MFH-L-02-A Revision 0 Date :OCTOBER 14, 2008

Prepared /Compiled by : Reviewed & Approved by :


QA/QC Mechanical QA/QC Manager
Title:
HYDROTEST PROCEDURE Page 4 of 13
Reinforced Thermosetting Epoxy-
Resin (RTR Pipes)

4.4 Assign watchmen/flagmen at all crossings to direct continuous flow of


traffic and to prevent people or local inhabitants to approach or stay
closer than 50 meter to any part of the pipeline being tested.

4.5 All system while being hydrostatically tested shall be protected from
over pressure by relief valve(s) of adequate capacity with a relief
pressure setting shown in item 3.1 . The relief valve shall be calibrated,
dated and tagged within one week prior to the test. Sizing of relief valve
used for testing should follow the requirements of API RP-520. Part-1,
Sect. C-4. Calibration certificate shall be made available on site, prior to
commencement of the hydrotest, for Saudi Aramco review.

4.6 A bleed valve shall be provided to protect the piping and equipment
from overpressure, in addition to the pressure relieving device. The
bleed valve shall be readily accessible in case immediate
depressurization is required.

4.7 Pressure gauges shall be calibrated before use. Calibration interval shall
not exceed one (1) month. A minimum of two pressure gauges are
required for the test and verified that they are within 5 percent of each
other when in use. One gauge shall be on the test pump and a minimum
of one on the system being tested. When large systems are being
tested, Inspection shall determine the need for additional gauges.
Sticker shall be attached, to indicate the latest gauge calibration date.
All gauges shall have a range such that the test pressure is within 30 to
80 percent of the full range. Calibration certificates shall be made
available on site prior to commencement of the hydrotest for Saudi
Aramco review.

4.8 The hydrotest manifold employed for pressure testing of piping and
equipment shall be separately tested to at least 20 percent above the
specified system test pressure before use. An isolation valve shall be

Page 4 of 13
M.F. AL-HAJRI CONTS.EST.
P.O.BOX 4626
31952 AL-KHOBAR
Kingdom of Saudi Arabia
Document # QP-MFH-L-02-A Revision 0 Date :OCTOBER 14, 2008

Prepared /Compiled by : Reviewed & Approved by :


QA/QC Mechanical QA/QC Manager
Title:
HYDROTEST PROCEDURE Page 5 of 13
Reinforced Thermosetting Epoxy-
Resin (RTR Pipes)

provided between the manifold and the system being tested. The
isolation valve shall be rated for the test pressure when it is in the
closed position. The hydrotest certificate for the hydrotest manifold shall
be made available on the site prior to commencement of hydrotest, for
Saudi Aramco Inspection review.

4.9 In case of any leaks or weaknesses is detected while the test is in


progress, the whole system shall be depressurized to zero (0) pressure,
before any attempt is made to repair the leak.

4.10 Isolate and disconnect the hydrotest pump from the system upon
reaching the required test pressure.

4.11 A pressure indicator shall be installed at the highest point vent with
correctly rated bleed valve. A responsible person shall be stationed at
this point throughout the duration of the test period to monitor and
ensure that the test pressure does not exceed the required test
pressure.

4.12 The system will be pressurized slowly and is not to exceed 100 psig per
minute. The test manifold must be supported firmly to avoid vibration
during the process of pressurization and depressurization.

4.13 At the completion of the hydrotest, the system will be depressurized to


safe working pressure and the hydrotest water shall be drained to a
temporary drain pond. Security personnel shall be provided until the
drained hydrotest water evaporates to preclude consumption by humans
and livestock.

4.14 Dewater the system and make sure that all vents are fully opened in
order to prevent excessive vacuum build-up in the system.

Page 5 of 13
M.F. AL-HAJRI CONTS.EST.
P.O.BOX 4626
31952 AL-KHOBAR
Kingdom of Saudi Arabia
Document # QP-MFH-L-02-A Revision 0 Date :OCTOBER 14, 2008

Prepared /Compiled by : Reviewed & Approved by :


QA/QC Mechanical QA/QC Manager
Title:
HYDROTEST PROCEDURE Page 6 of 13
Reinforced Thermosetting Epoxy-
Resin (RTR Pipes)

4.15 The temporary flushing and hydrotest water drain pond shall be
constructed in a location and manner approved by Saudi Aramco
representative.

4.16 After completion, the drain pond will be backfilled and contoured to
match existing grade contours.

4.17 See to it that no one is within the discharge end or open end of the RTR
Line , flushed or cleaned by blowing air.

5.0 HYDROTEST AND WET LAY-UP EQUIPMENT, ACCESSORIES AND


MATERIAL LIST

UNIT
ITEM DESCRIPTION
REQUIRED
1 Hydrotest Pump: Reciprocating, 100 BHP, 1800 RPM, 30 GPM, 1 each
8500 psi max.
(Prime Mover: GH, 1982 model, 6 cylinders, 100 HP).

2 Fill Pump: Huding 141 HCL, 4 Suction, 500 GPM 1 each

3 Pressure Indicator:
Bordon Gauge: 0 300 psig 1 each
Bordon Gauge: 0 300 psig 1 each

4 Pressure Relief Valve: dia. threaded set to the required pressure 2 each

5 Hydrotest Manifolds: See sketch # 1 for detail 1 set

6 Hose: High Pressure, 1 dia. 10,000 psi capacity 10 meters

7 Water Tanker: 8,000 gal. Capacity 1 each

Page 6 of 13
M.F. AL-HAJRI CONTS.EST.
P.O.BOX 4626
31952 AL-KHOBAR
Kingdom of Saudi Arabia
Document # QP-MFH-L-02-A Revision 0 Date :OCTOBER 14, 2008

Prepared /Compiled by : Reviewed & Approved by :


QA/QC Mechanical QA/QC Manager
Title:
HYDROTEST PROCEDURE Page 7 of 13
Reinforced Thermosetting Epoxy-
Resin (RTR Pipes)

Note:

1. Unless prevailing conditions or regulation required full backfilling of the


piping prior to hydrotest,underground piping shall be partially backfilled with
all joints exposed during the hydrotest,The exposed joint shall be shaded
from direct to the sunlight,and the hydrotest shall be perform so that the
temperature of thermoplastic piping materials or the temperature of the test
water does not exceed to 40 deg.centigrade during the test period.If the
test water is not available at or below 40 deg. Centigrade,the resulting
hydrotest pressure shall be calculated at the available test water
temperature in accordance with the respective ASTM standards.
2. Hydrostatic Testing fluids :
1.) (Potable Drinking water or Raw Water)piping system shall be
hydrotested with fresh potable water as defined in SAES-S-040.

3. No Thermoplastic piping shall be pressurized until has cured for 24


hours at a surface temperature of 10 deg.centigarade or higher,or for 48
hours at the surface temperature below 10 deg.Centigrade.

4. No adhesive-bounded RTR piping shall be pressurized until it has cured in


accordance with the manufacturers instruction.

5. The test pump shall be placed on the good ground away from the piping.The
pump and the piping system(Piping and Equipment)shall be protected from
over pressured by relief valve of adequate capacity set at 5% above the test
pressure or a minimum of 1034 kpa (150 psig) or 345 kpa (50 psig)
above ground force mains shall be watertight for period of 4 hours as Per
SAES-S-020 Para.(5.3.1.4) above the test pressure for pressure piping
system.The relief valve shall be tested,dated,ang tagged within 1 week prior

Page 7 of 13
M.F. AL-HAJRI CONTS.EST.
P.O.BOX 4626
31952 AL-KHOBAR
Kingdom of Saudi Arabia
Document # QP-MFH-L-02-A Revision 0 Date :OCTOBER 14, 2008

Prepared /Compiled by : Reviewed & Approved by :


QA/QC Mechanical QA/QC Manager
Title:
HYDROTEST PROCEDURE Page 8 of 13
Reinforced Thermosetting Epoxy-
Resin (RTR Pipes)

to the test.Sizing of the relief valve used for testing shall be in accordance
with SAES-004.

6. Instruments to be used, i.e., pressure relief valves, pressure indicators, and


hydrotest manifold shall carry a valid calibration certificate to be submitted
to Saudi Aramco Representative or APIU Inspector prior to the hydrotest.

7. All pressure gauges shall have a range such that the test pressure is within
30 to 80 percent of the full range and shall be mounted at upright position.

6.0 CLEANING
6.1 ABOVEGROUND PIPING

Prior to bolt-up & installation of new RTR spools and tie-in spools shall
be cleaned by air blowing to ensure that the system is clean, free from
foreign matters i.e. mill scale or crust etc.It shall be blown again with air
after its complete assembly and installation prior to water filling and
pressurizing.

6.2 UNDERGROUND PIPING

Underground RTR line shall be cleaned by using propelled by air. The


cleaning operation shall be run and repeated, if necessary until the line
is established cleaned and approved by Inspector.

The procedure involve for cleaning are as follows:

6.2.1 Start the air compressor and build-up air receiver pressure to 40-
50 psig.

6.2.2 Assign watchmen/flagmen at both ends to give signal.

Page 8 of 13
M.F. AL-HAJRI CONTS.EST.
P.O.BOX 4626
31952 AL-KHOBAR
Kingdom of Saudi Arabia
Document # QP-MFH-L-02-A Revision 0 Date :OCTOBER 14, 2008

Prepared /Compiled by : Reviewed & Approved by :


QA/QC Mechanical QA/QC Manager
Title:
HYDROTEST PROCEDURE Page 9 of 13
Reinforced Thermosetting Epoxy-
Resin (RTR Pipes)

6.2.3 The RTR line must be free from dirt and other foreign matters.

7.0 WATER FILLING AND MIXING OF OXYGEN SCAVENGER

Water filling can only be started upon acceptance of the Saudi Aramco Site
Representative, or APIU Inspector that the pipeline is thoroughly cleaned.

The water filling location shall be whenever possible, done at the lowest
location on the RTR line to ensure removal of the maximum amount of air from
the system.

All line valves shall be at open position preferably 2/3 of the way to eliminate
sticking once maximum pressure is achieved. All vent valves on the pipeline
shall also be at open position when filling and then closed tightly one-by-one
after solid water spurts from it and the line is believed to be free of air already.

Established and maintain throughout the system on wet lay-up activity a


minimum residual sulfite level of 20 mg/L in the water as per SAES-A-007,
(item: 5.2.2.2). Record the test result in the hydrostatic test report.

The water filling of the RTR line shall be done at a rate of 20 GPM minimum and
35 GPM maximum. The fill pump to be used is a centrifugal pump.

8.0 HYDROTEST PROCEDURE

8.1 HYDROSTATIC TEST:

8.1.1 After the system is approved clean by Saudi Aramco


Representative or APIU Inspector, install temporary blind flanges
at end points for every hydrostatic test limits shown in the
Hydrostatic test Diagram.

Page 9 of 13
M.F. AL-HAJRI CONTS.EST.
P.O.BOX 4626
31952 AL-KHOBAR
Kingdom of Saudi Arabia
Document # QP-MFH-L-02-A Revision 0 Date :OCTOBER 14, 2008

Prepared /Compiled by : Reviewed & Approved by :


QA/QC Mechanical QA/QC Manager
Title:
HYDROTEST PROCEDURE Page 10 of 13
Reinforced Thermosetting Epoxy-
Resin (RTR Pipes)

8.1.2 Fill the system with hydrotest water at the filling connections as
identified prior for filling.(As marked in hydro test diagram )

8.1.3 Continue filling the line until solid water discharge at opened
vent valves and the line is free of air.

8.1.4 Install calibrated relief valve at designated point or at the Hydro


test Manifold.. Two or more calibrated pressure gauges of
standard rating for test #1 shall be installed at identified
locations and at the test manifold.

8.1.5 Prior to testing, a last pipeline check shall be made to ensure


that all hydrotest materials and test pressure to be introduced
are correct.

8.1.6 After receiving approval to start with the test, close all vent
valves when the system is believed to be free of air. Introduce
pressure gradually and under control in order to allow time for
material to strain and time for personnel to check for leaks, if
there is any.

Do not exceed pressure injection to 50% of the strength test


pressure (refer to item 3.0) until weaknesses have been
repaired and leaks have been stopped.

After preliminary checks for leaks at 50% of the strength test


pressure, the pressure shall be increased in steps no greater
than one-fifth of the strength test pressure with at least ten (10)

Page 10 of 13
M.F. AL-HAJRI CONTS.EST.
P.O.BOX 4626
31952 AL-KHOBAR
Kingdom of Saudi Arabia
Document # QP-MFH-L-02-A Revision 0 Date :OCTOBER 14, 2008

Prepared /Compiled by : Reviewed & Approved by :


QA/QC Mechanical QA/QC Manager
Title:
HYDROTEST PROCEDURE Page 11 of 13
Reinforced Thermosetting Epoxy-
Resin (RTR Pipes)

minutes holds at each step to permit inspection for leaks and


weaknesses in the system.

It leaks and/or weakness are observed during these ten (10)


minutes holds, depressurize the system to zero (0) pressure
before attempting to stop the leaks and repair the weakness in
the system.

8.1.7 When the pressure remains stable, gradually raise the pressure
to the design pressure given in item 3.0(Hydrostatic Test
Information). Isolate the system and disconnect for(4) hours.

8.1.8 Upon acceptance of strength test by the Inspector, the system


will be depressurized to Tightness Test Pressure given in item
3.0 and maintain for at least ten (10) minutes or until Inspector
has examined all exposed joints.

8.1.9 If the tightness test is satisfactory, depressurize the system


under a positive operating pressure not exceeding 1034 kPa
(appro. x 150 psig max.) required for wet lay-up work as per
SAES-S-020 and SAES-S-070 by bleeding down the pressure
at a rate not more than 40 psig per minute.

8.1.10 Immediately after the test, the test water will be disposed off
within (3) days and therefore treatment of hydro test water
through addition of oxygen scavenger and biocide is not
necessary (SAES-A-007 PARA 5.1 ).

Page 11 of 13
M.F. AL-HAJRI CONTS.EST.
P.O.BOX 4626
31952 AL-KHOBAR
Kingdom of Saudi Arabia
Document # QP-MFH-L-02-A Revision 0 Date :OCTOBER 14, 2008

Prepared /Compiled by : Reviewed & Approved by :


QA/QC Mechanical QA/QC Manager
Title:
HYDROTEST PROCEDURE Page 12 of 13
Reinforced Thermosetting Epoxy-
Resin (RTR Pipes)

9.0 QA/QC INSPECTION.

9.1 The Mechanical QC Mechanical piping Inspector shall ensure


that the hydrostatic testing is carried out in accordance within
the approved procedure.
9.2 All testing shall be witnessed by Saudi Aramco
representatives and Contractor QA/QC Inspector.
9.3 QA/QC Inspector shall make sure that the blind flanges,
gaskets shall be of the same rating as the valve and the bolts
shall be of the standard size & confirm to ASTM standards.
9.4 During hydrotest,all exposed pipe,joint,fitting,valves and
hydrant shall be carefully examined for leakage.
9.5 Leaking pipes,joints.and fittings shall be placed in accordance
with section 20.
9.6 The hydrostatic test shall be repeated after the repair of any
defects until the system is proved satisfactory.
9.7 The piping shall be satisfactory if there is no evidence of
leakage or pressure loss after the specified test period.

10.0 REPAIR METHODS :

Permanent Repair for thermoplastic and RTR


piping,if required,shall use one of the following:

a.) Flanges and Flanged spool piece


b.) Spigot end adapter for restrained gasketed joint
RTR piping,a spool with spigot end,and bell-by-
bell couplings.

Page 12 of 13
M.F. AL-HAJRI CONTS.EST.
P.O.BOX 4626
31952 AL-KHOBAR
Kingdom of Saudi Arabia
Document # QP-MFH-L-02-A Revision 0 Date :OCTOBER 14, 2008

Prepared /Compiled by : Reviewed & Approved by :


QA/QC Mechanical QA/QC Manager
Title:
HYDROTEST PROCEDURE Page 13 of 13
Reinforced Thermosetting Epoxy-
Resin (RTR Pipes)

c.) Bell-by-bell coupling for flexible thermoplastic


pipe or adhesive bonded RTR pipe.
d.) Extra - long bell or spigot may be used to insert
replacement spools in underground unrestrained
gasketed joint RTR piping.
e.) Field repair of RTR piping shall be made in
accordance with the pipe manufacturers pre-
qualified repaired procedure.

11.0 QA/QC REPORT/DOCUMENTATION

11.1 A photo copy of approved procedure shall be posted at the


Hydro test area.
11.2 Test result shall be recorded using the Pressure Test
Record Form Copy of the form is hereto attached.
11.3 The following checklists shall be filled up before and after
any Testing-activity.

SATR-A-2014 ------ Water chemistry report


SAIC-A-2140 ------ Internal cleaning report
SAIC-A-2009 ------- Test preparation and verification of
test Equipment.
SAIC-A-2013 ------ Filling and pressurization
SAIC-A-2015 ------ Visual inspection at test pressure
SAIC-A-2017 ------ Depressurization and water disposal
SATR-A-2001 ------ Hydro test report
SA 2642 ------- Engineering Pressure Test Report
SAES-A-004 ------- Gen Requirements for pressure
testing (NDT) request In-Lieu of
Hydrostatic Test.

Page 13 of 13

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