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P.O.BOX 4626
31952 AL-KHOBAR
Kingdom of Saudi Arabia
Document # QP-MFH-L-02-A Revision 0 Date :OCTOBER 14, 2008
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 :
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
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.
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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
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.
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
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
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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
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.
4.10 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.
4.14 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
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.
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).
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
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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
Note:
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
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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
to the test.Sizing of the relief valve used for testing shall be in accordance
with SAES-004.
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.
6.2.1 Start the air compressor and build-up air receiver pressure to 40-
50 psig.
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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
6.2.3 The RTR line must be free from dirt and other foreign matters.
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.
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.
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
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.
8.1.6 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.
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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
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.
8.1.10 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 ).
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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
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
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