Block 5 - AL SHAHEEN FIELD Development

Document Title: Relief Valves Testing Procedure

Document Number: WHP01-PMC1-ASYYY-19-302033-0001 Date: 26-Jun-2019 Rev.: 00

Doc Type: PRC System: GENE Phase DE Status: IFR Class: 1

GLF - WHP01 – EPCIC2

Relief Valves Testing Procedure

Is the document generated from an existing As-Built? YES NO

Originator Document Number Last ASB Rev. :

Remarks:

00 26-Jun-2019 IFR ISSUED FOR REVIEW TD Hung CQ Man TN Tinh

Rev. Rev. date Status Description Issued by Reviewed by Approved by

The information contained in this document is the proprietary to North Oil Company. It must not be reproduced, stored, disclosed to any third party or used for any purpose not authorized by North
Oil Company. Printed documents are uncontrolled and considered as "for information only". Reference should always be made to the on-line EDMS for the updated version

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 Block 5 - AL SHAHEEN FIELD Development
Document Title: Relief Valves Testing Procedure

Document Number: WHP01-PMC1-ASYYY-19-302033-0001 Date: 26-Jun-2019 Rev.: 00

Doc Type: PRC System: GENE Phase DE Status: IFR Class: 1

REVISION HISTORY

Rev. Rev. Date Status History Issuer Reviewer Approver

00 26-Jun-2019 IFR ISSUED FOR REVIEW TD Hung CQ Man TN Tinh

The information contained in this document is the proprietary to North Oil Company. It must not be reproduced, stored, disclosed to any third party or used for any purpose not authorized by North
Oil Company. Printed documents are uncontrolled and considered as "for information only". Reference should always be made to the on-line EDMS for the updated version

Page 2 of 11
 Block 5 - AL SHAHEEN FIELD Development
Document Title: Relief Valves Testing Procedure

Document Number: WHP01-PMC1-ASYYY-19-302033-0001 Date: 26-Jun-2019 Rev.: 00

Doc Type: PRC System: GENE Phase DE Status: IFR Class: 1

TABLE OF CONTENTS
1. PURPOSE ........................................................................................................................................ 4

2. REFERENCE DOCUMENTS ............................................................................................................... 4

3. DEFINITIONS AND ABBREVIATIONS ............................................................................................. 5

3.1. DEFINITIONS ........................................................................................................................................................ 5

3.2. ABBREVIATIONS .................................................................................................................................................... 5

4. PROCEDURE ................................................................................... ERROR! BOOKMARK NOT DEFINED.

4.1. TESTING EQUIPMENT ............................................................................................................................................ 6

4.1.1. CLAMPING UNIT (TEST TABLE) .................................................................................................................. 6
4.1.2. CONTROL PANEL ...................................................................................................................................... 6
4.1.3. CART WITH WATER TANK ......................................................................................................................... 7
4.1.4. ACCESSORIES AND RECOMMENDED PARTS ................................................................................................ 7
4.2. TEST MEDIA.......................................................................................................................................................... 7
4.3. MAX. TEST PRESSURES .......................................................................................................................................... 8
4.4. TESTING SKETCH .................................................................................................................................................. 8

5. CALIBRATION PROCEDURE ............................................................................................................ 8

5.1. TESTING OBJECTIVE.............................................................................................................................................. 8

5.2. TESTING PREPARATION ......................................................................................................................................... 8
5.3. TESTING PROCEDURE ............................................................................................................................................ 9
5.3.1. POPPING AND RESEATING ........................................................................................................................ 9
5.3.2. SEAT LEAKAGE TEST ................................................................................................................................. 9

The information contained in this document is the proprietary to North Oil Company. It must not be reproduced, stored, disclosed to any third party or used for any purpose not authorized by North
Oil Company. Printed documents are uncontrolled and considered as "for information only". Reference should always be made to the on-line EDMS for the updated version

Page 3 of 11
 Block 5 - AL SHAHEEN FIELD Development
Document Title: Relief Valves Testing Procedure

Document Number: WHP01-PMC1-ASYYY-19-302033-0001 Date: 26-Jun-2019 Rev.: 00

Doc Type: PRC System: GENE Phase DE Status: IFR Class: 1

1. PURPOSE

The pressure relief valves Pre-commissioning activities (Conformity Checks Lists and Static Tests Sheets) and
Commissioning activities (Functional Tests Sheets) will be carried out onsite after installation and/or VENDOR(S) /
SUPPLIER(S) certificates expired prior to installation.
Any calibration certificates, which have been provided and validated, by VENDOR(S) / SUPPLIER(S) will not be certified
again on WORKSITE(S).
This document provides the testing procedure for pressure relief valves in cases:
 The calibration certificates were expired
 Any transportation or storage conditions may have corrupted the pressure safety/relief valves
 The pressure safety/relief valves were found faulty during Commissioning phase.

2. REFERENCE DOCUMENTS

Standards Description

API526 Flanged Steel Pressure Relief Valves

API527 Seat Tightness of Pressure Relief Valves
API576 Inspection of Pressure – Relieving Devices
AS1349 Bourdon Test Pressure and Vacuum Gauges
AS3788 Pressure Equipment – In – Service Inspection
ASME BPVC VIII Div I Section A Boiler and Pressure Vessel Code

COMPANY General Specifications Description

SD-NOC-EC-600 Pre-Commissioning and Commissioning Standard

SD-NOC-EC-601 Pre-Commissioning and Commissioning Engineering
SD-NOC-EC-602 Pre-Commissioning Execution
SD-NOC-EC-603 Commissioning Execution

PROJECT Documents Description

WHP01-PMC1-ASYYY-26-302013-0001 Preservation Procedure and Schedule

WHP01-PMC1-ASYYY-21-302002-0001 Worksite Notification for Inspection Procedure
WHP01-PMC1-ASYYY-26-302026-0001 Flange Management Procedure

The latest revision of above documents will prevail.

The information contained in this document is the proprietary to North Oil Company. It must not be reproduced, stored, disclosed to any third party or used for any purpose not authorized by North
Oil Company. Printed documents are uncontrolled and considered as "for information only". Reference should always be made to the on-line EDMS for the updated version

Page 4 of 11
 Block 5 - AL SHAHEEN FIELD Development
Document Title: Relief Valves Testing Procedure

Document Number: WHP01-PMC1-ASYYY-19-302033-0001 Date: 26-Jun-2019 Rev.: 00

Doc Type: PRC System: GENE Phase DE Status: IFR Class: 1

3. DEFINITIONS AND ABBREVIATIONS

3.1. DEFINITIONS

WORD DEFINITION

COMPANY NORTH OIL COMPANY (NOC)

CONTRACTOR PTSC Mechanical and Construction Limited Company
PROJECT The Al Shaheen Phase 2 Field Development Project for offshore Qatar,
named as GALLAF Batch 1 Topside EPCIC2 Project includes 3 bridges and
3 topsides (DC, EG and FC WHPs)
VENDOR(S) Means any CONTRACTOR’s and/or SUBCONTRACTORS’ supplier(s) of
CONTRACTOR ITEM(S). VENDORS’ presence on WORKSITE may be
required to assist CONTRACTOR and/or COMPANY for the installation,
commissioning and start-up of such CONTRACTOR ITEMS and during the
performance of PERFORMANCE TESTS.
SUPPLIER(S) Means supplier(s) of any COMPANY ITEM(S).
WORKSITE(S) Means the SITE and/or all and any construction location(s), as listed in
EXHIBIT F, where any major parts of the PLANT (such as decks, bridges,
equipment skids and major sub-assemblies) shall be fabricated and
assembled, excluding all other offices, premises and workshops of
CONTRACTOR and SUBCONTRACTORS.

3.2. ABBREVIATIONS

WORD DEFINITION

AFC Accepted for Construction

CCK Conformity Check
ICAPS Integrated Commissioning And Progress System
P&ID Piping & Instrumentation Diagram
PSV Pressure Relief Valve
PIP Piping Tests
PVP Piping & Vessels Preparation

The information contained in this document is the proprietary to North Oil Company. It must not be reproduced, stored, disclosed to any third party or used for any purpose not authorized by North
Oil Company. Printed documents are uncontrolled and considered as "for information only". Reference should always be made to the on-line EDMS for the updated version

Page 5 of 11
 Block 5 - AL SHAHEEN FIELD Development
Document Title: Relief Valves Testing Procedure

Document Number: WHP01-PMC1-ASYYY-19-302033-0001 Date: 26-Jun-2019 Rev.: 00

Doc Type: PRC System: GENE Phase DE Status: IFR Class: 1

4. EQUIPMENT AND FACILITIES

4.1. TESTING EQUIPMENT

A test bench will be used for testing and calibration of PSVs. The typycal test bench as figure below:

Fig. 1: Test bench 10 (TB10)

The complete test bench consists of 3 major parts:
 Test table with sliding clamps
 Control panel
 Transport cart with water tank and high pressure pump
All components can be fitted easily and quickly. The complete unit is mobile.

4.1.1. CLAMPING UNIT (TEST TABLE)

Valve clamping facilities: unilateral onto test table with 4 manually-operated sliding clamps
 The test valves are clamped and tested in vertical position
 Thus and due to filling from below a good venting of valves is provided
 Dimensions of clamping unit (test table): 610 mm x 610 mm
 Diameter test table: 280 mm
 Max. clamping force: 10 tons
 4 sliding clamps with spindle

4.1.2. CONTROL PANEL

Analogue gauges for testing with liquid:

 In order to protect valves and piping, water will be mixed with anti-corrosion agent (1 unit included in scope of
supply)
 1 gauge, diameter 100 mm, accuracy class 1.0; Range 0 – 4000 psi
 1 pressure-control valve for the High Pressure water pump
Analogue gauges for testing with air/nitrogen:
 1 gauge, diameter 100 mm, accuracy class 0.5; Range 0 – 4000 psi
 1 pressure control valve
 Input: max. 414 bar Output: 0-210 bar
The information contained in this document is the proprietary to North Oil Company. It must not be reproduced, stored, disclosed to any third party or used for any purpose not authorized by North
Oil Company. Printed documents are uncontrolled and considered as "for information only". Reference should always be made to the on-line EDMS for the updated version

Page 6 of 11
 Block 5 - AL SHAHEEN FIELD Development
Document Title: Relief Valves Testing Procedure

Document Number: WHP01-PMC1-ASYYY-19-302033-0001 Date: 26-Jun-2019 Rev.: 00

Doc Type: PRC System: GENE Phase DE Status: IFR Class: 1

Analogue gauges for external pressure input :

 1 gauge, diameter 63 mm, accuracy class 1.6; Range 0 to 4000 psi
Calibrating/Reference gauge connections: On top of the control panel 2 calibrating gauge connection sockets are
mounted, also permitting the connection of pressure transducers of data acquisition/processing equipment. They also
allow connection of customer’s own gauges of different accuracies.

4.1.3. CART WITH WATER TANK

Cart with block and caster wheels

Tank: 55 litters capacity for water to be mixed with anti-corrosion fluid
High-pressure pump (pneumatic driven)
Main dimensions:
 Total width: 610 mm
 Total depth: 910 mm
 Total height: 1030 mm
Total weight: approx. 190 kg (without test media)
Painting and surface protection :
 Water tank made of stainless steel
 Control panel painted RAL 5019 (blue)
 Clamping unit (test table) nickel plated
 Cart with primer and anti-corrosion paint (anthracite)
 Gauges are made of stainless steel, high quality with multiple safety glass.
Scale reading of gauges in psi.
For every gauge / pressure transmitter a valid certificate is included.

4.1.4. ACCESSORIES AND RECOMMENDED PARTS

 1 x Vulkollan sealing plate (diameter 280 mm)

 1 x Anti-Corrosion fluid FERROTEC
 1 x bubble bulb for seat leakage testing with air/nitrogen
 1 x Operation manual/machine labels in German and English language
 1 x set (7 pieces) special aluminium hard-coated O-ring seal plates to seal up the flanged valves DN10 – DN200
 Safety rubber plugs for seat leakage testing of safety valves with air/nitrogen for DN 15 – 150 (6”)
 Adapter flanges (steel made) for threaded valves: DIN ISO 228-1 G ½”, G ¾”, G 1”, G 1¼”, G 1½”, G 2” (1 set
with inside / female thread)
 Adapter flanges (steel made) for threaded valves: DIN ISO 228-1 G ½”, G ¾”, G 1”, G 1¼”, G 1½”, G 2” (1 set
with outside / male thread)
 Adapter flanges (steel made) for threaded valves: ANSI B1.20.1 NPT ½”, NPT ¾”, NPT 1”, NPT 1¼”, NPT 1½”, NPT
2” (1 set with inside / female thread)
 Adapter flanges (steel made) for threaded valves: ANSI B1.20.1 NPT ½”, NPT ¾”, NPT 1”, NPT 1 ¼”, NPT 1½”,
NPT 2” (1 set with outside / male thread)

4.2. TEST MEDIA

 Water with anti-corrosion agent via integrated water pump

 Air/nitrogen

The information contained in this document is the proprietary to North Oil Company. It must not be reproduced, stored, disclosed to any third party or used for any purpose not authorized by North
Oil Company. Printed documents are uncontrolled and considered as "for information only". Reference should always be made to the on-line EDMS for the updated version

Page 7 of 11
 Block 5 - AL SHAHEEN FIELD Development
Document Title: Relief Valves Testing Procedure

Document Number: WHP01-PMC1-ASYYY-19-302033-0001 Date: 26-Jun-2019 Rev.: 00

Doc Type: PRC System: GENE Phase DE Status: IFR Class: 1

4.3. MAX. TEST PRESSURES

 DN 10 (3/8”) – DN50 (2”) 210 bar (3045 psi)

 DN 65 (2 1/2”) – DN80 (3”) 130 bar (1185 psi)
 DN 100 (4”) 80 bar (1160 psi)
 DN 125 (5”) 50 bar (725 psi)
 DN 150 (6”) 35 bar (507.5 psi)
 DN 200 (8”) 20 bar (290 psi)

4.4. TESTING SKETCH

Typical schematic is as below:

Install an intermediate pressure gauge in one of the low-pressure ports of the regulator.
Install a “digital bubble counter” into the outlet side of the valve.
Ensure the pressure safety / relief valve and intermediate pressure gauge are attached to low-pressure ports facing up.
Note: All equipment for test will have valid calibration certificate(s) and available to Client for review.

5. CALIBRATION PROCEDURE

5.1. TESTING OBJECTIVE

Safety relief valves shall be tested to check:

 Set pressure.
 Reseat pressure.
 Cold different set pressure.
 Seat leakage.

5.2. TESTING PREPARATION

 Before commencing work, ensure all aspects of the Permit to Work system are being adhered to and that Danger
Tags are attached where appropriate.
 Isolation and interlocking of PSVs shall be performed in accordance with the appropriate isolation procedure for that
particular piece of equipment.
 Ensure that the compressed air supply fittings are in good condition.
 Modification of any PSV from the manufacturers’ specification is prohibited without first obtaining approval.
 The PSV lifting lever shall only be operated when required.
 The in-service visual inspections shall be performed by competent personnel designated by the Maintenance
Supervisor or Production Supervisor.
 Before popping the safety valve, the outlet flange shall be removed.

The information contained in this document is the proprietary to North Oil Company. It must not be reproduced, stored, disclosed to any third party or used for any purpose not authorized by North
Oil Company. Printed documents are uncontrolled and considered as "for information only". Reference should always be made to the on-line EDMS for the updated version

Page 8 of 11
 Block 5 - AL SHAHEEN FIELD Development
Document Title: Relief Valves Testing Procedure

Document Number: WHP01-PMC1-ASYYY-19-302033-0001 Date: 26-Jun-2019 Rev.: 00

Doc Type: PRC System: GENE Phase DE Status: IFR Class: 1

 The inlet nozzle should be wiped clean prior to installing in preparation for test.
 The safety valve “cold different test pressure (CDTP)” shall be ascertained and entered on the test record sheet. This
pressure should be found on the valve data plate or on the valve data sheet.

5.3. TESTING PROCEDURE

5.3.1. POPPING AND RESEATING

 The test pressure shall be increased slowly until the safety valve is observed to popping (pre-pop default level +
3% of set pressure) and the pressure (as indicated by the ‘maximum’ pointer on the test gauge) shall be noted on
the test record sheet. If the difference between the measured popping pressure and the cold set pressure is outside
acceptable tolerances, the valve setting shall be adjusted in accordance with the manufacturer's instructions.
 The test pressure shall then be lowered and the reseating pressure noted and checked that it agrees with the
safety valve specification.

Does not lift at a maximum Lift within default limits:

130% cold different set 1st pop PSV has passed OK
pressure: PRV is stuck shut

Fail

2nd pop Lift within default limits

Default

Fig. 2: Pre-pop test default levels

5.3.2. SEAT LEAKAGE TEST

Unless otherwise specified, the seat leakage rate shall be tested in accordance with API 527. This test procedure is
summarized as follows:
 The outlet flange shall be refitted complete with safety plug and the open end of the bleed pipe shall be immersed
in water to a depth of 13 mm below the surface. The leakage rate in bubbles per minute will then be checked in
accordance with API 527

The information contained in this document is the proprietary to North Oil Company. It must not be reproduced, stored, disclosed to any third party or used for any purpose not authorized by North
Oil Company. Printed documents are uncontrolled and considered as "for information only". Reference should always be made to the on-line EDMS for the updated version

Page 9 of 11
 Block 5 - AL SHAHEEN FIELD Development
Document Title: Relief Valves Testing Procedure

Document Number: WHP01-PMC1-ASYYY-19-302033-0001 Date: 26-Jun-2019 Rev.: 00

Doc Type: PRC System: GENE Phase DE Status: IFR Class: 1

For allowable leakage rates see API 527

6 mm bore
bubble pipe

13 mm max head

Fig. 3: PSV seat leakage bubble test

 The leakage rate in bubbles per minute is determined with pressure as the safety relief valve inlet held at 90% of
the set pressure immediately after popping flow as API 527, except for valves set at 50 psi or below, in which case
the pressure will be held at 5 psi below the set pressure immediately after popping. The test pressure will be applied
for a minimum of 1 minute for valves of inlet sizes through 2"; 2 minutes for sizes through 4"; and 5 minutes for
sizes 6" and 8".
 Should the leakage rate exceed the permitted tolerance, the popping and leakage tests shall be repeated to ensure
that foreign particles are not preventing complete closure.
 Dismantling the valve and lapping the disc and seat in accordance with the manufacturer’s instructions shall
correct failure of the leakage test.
 After testing, the valve shall be identified by a suitable color sticker.
 The bonnet cap shall be firmly secured and locked using a metal link and lead seal.
 Record calibration data into check sheet Safety Relief Valve Calibration.
Note:
1. During testing to API 527 using the cap method, it is possible for air leakage to occur around the top bonnet
flange; the outlet flange made off for the test; and the cap. These should be soap tested during the test to prove
that there is no leakage. Alternatively, a flooded seat test should be nominated for valve discharge flanges
greater than 2 inches and, after such test, the body cavity shall be thoroughly dried with instrument air.
2. Air at atmospheric temperature will be used as the pressure medium. If there is a significant difference between
ambient test and actual service condition, the cold set pressure may have to be altered to exceed the operating
relief pressure. This percentage excess pressure should be qualified by reference to the appropriate
manufacturer's technical information.

The information contained in this document is the proprietary to North Oil Company. It must not be reproduced, stored, disclosed to any third party or used for any purpose not authorized by North
Oil Company. Printed documents are uncontrolled and considered as "for information only". Reference should always be made to the on-line EDMS for the updated version

Page 10 of 11
 Block 5 - AL SHAHEEN FIELD Development
Document Title: Relief Valves Testing Procedure

Document Number: WHP01-PMC1-ASYYY-19-302033-0001 Date: 26-Jun-2019 Rev.: 00

Doc Type: PRC System: GENE Phase DE Status: IFR Class: 1

3. If an unbalanced relief valve is subjected to a continuous; constant back pressure, then the test stand set
pressure should be altered to the desired relief pressure minus the back pressure. If the relief valve is fitted with
balancing bellows, then no correction is required.
4. With the valve mounted vertically, apply pressure to the inlet side of the valve and note popping pressure. This is
checked against data sheet to verify correct setting.

The information contained in this document is the proprietary to North Oil Company. It must not be reproduced, stored, disclosed to any third party or used for any purpose not authorized by North
Oil Company. Printed documents are uncontrolled and considered as "for information only". Reference should always be made to the on-line EDMS for the updated version

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