De-119955 - Hydro Test

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DE-119955

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Nov. 22, 1997

T.M. AL-SHARIF

Oct. 1997

Oct. 1997

D.R. SANDERS

K.A. PRABHUDESAI

Oct. 1997

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D.L. SANFORD

Oct

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7

PROCEDURE FOR HYDROSTATIC TESTING OF PLATFORM PIPING AND SUBMARINE PIPELINES

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EDSD/2616-0399.doc

Saudi Aramco 2616-ENG (03/99)

8

SAUDI ARABIA

REV.NO. SHT.NO. DRAWING NO. INDEX PLANT NO. DWG.TYPE

SAUDI ARABIAN OIL COMPANY

P:\14 Document Control \RDY\Electronic Files\Construction Procedure\DE-119955.doc

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CONSTRUCTION OF OFFSHORE PLATFORMS AND PIPELINES

PROCEDURE FOR HYDROSTATIC TESTING

OF PLATFORM PIPING AND SUBMARINE PIPELINES

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DE-119955

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ARABIAN GULF EDSD/2616-0399.doc

SAUDI ARABIA



TABLE OF CONTENTS

1.0 SCOPE 3

2.0 APPLICABLE CODES, STANDARDS, SPECIFICATIONS AND REFERENCES 3

3.0 GENERAL REQUIREMENTS 4

4.0 PREPARATION FOR HYDROTEST 6

5.0 TREATMENT OF HYDROTEST FLUIDS 9

6.0 TESTING PROCEDURE 11

7.0 SYSTEM TEST - PLATFORM PIPING 12

8.0 SYSTEM TEST - SUBMARINE PIPELINES 15

9.0 LAY-UP 16

10.0 DISPOSAL OF HYDROTEST FLUIDS 17

11.0 TEST RECORDS 18 (*) Required from CONTRACTOR prior to hydrotesting (where referenced herein).

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DE-119955

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1.0 SCOPE

1.1 This Procedure covers the minimum requirements for hydrostatic pressure testing of platform piping systems and of submarine pipelines.

1.2 The hydrotest for the platform piping shall consist of the strength test, tightness

test and finally the leak test, all to be conducted in stages. The hydrotest for submarine pipelines shall consist of the strength test and tightness test as a minimum and the leak test if required by the Contract Drawings and Scope of Work.

1.3 This Procedure shall be used in conjunction with the Contract Drawing

hydrostatic test diagrams which contain test blind locations, test legends, test pressures, test limits and other pertinent information.

2.0 APPLICABLE CODES, STANDARDS, SPECIFICATIONS AND REFERENCES

2.1 The latest revision of the following Construction Procedures shall apply:

DE-119885 Quality Assurance and Quality Control

DE-119892 Material Procurement, Receiving, Handling and

Storage

2.2 The latest issue of the following SAUDI ARAMCO Engineering Standards shall apply:

SAES-A-007 Hydrostatic Testing Fluids and Lay-up Procedures

SAES-L-850 Design of Submarine Pipelines and Risers

SAES-L-350 Construction of Plant Piping

2.3 The latest edition of the following Industry Codes, Standards and Specifications

shall apply:

ASME/ANSI B16.5 Pipe Flanges and Flanged Fittings

ASME/ANSI B31.3 Chemical Plant and Petroleum Refinery Piping

ASME/ANSI B31.4 Liquid Petroleum Transportation Piping Systems

ASME/ANSI B31.8 Gas Transmission and Distribution Piping Systems

API 6A Specification for Wellhead and Christmas Tree Equipment

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DE-119955

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SAUDI ARABIA



API 6D Specification for Pipeline Valves (Gate, Plug, Ball and Check Valves)

MSS-SP-44 Steel Pipe Line Flanges

NFPA-13 National Fire Protection Association – Standard for the Installation of Sprinkler Systems

2.4 The latest revision of the following SAUDI ARAMCO General Instructions (GIs):

GI 2.102 Pressure Testing Safely

GI 2.102 (Supplement) Checklist for Pressure Testing Safely

3.0 GENERAL REQUIREMENTS

(*) 3.1 CONTRACTOR shall provide the fluids to be used for hydrotests. The fluid

shall be clean, chemically treated sea water for offshore system tests, and clean fresh water for onshore and construction barge tests. Fresh water sources may be from clean condensate. The source and quality of water shall be approved by SAUDI ARAMCO thirty calendar days prior to start of hydrotest. CONTRACTOR shall submit, to SAUDI ARAMCO for review and approval, complete procedures for hydrostatic testing.

3.2 The temperature of the hydrotest fluid shall not be less than 60°F and not

greater than 150°F. Temperature differential between the test fluid temperature and the piping tie-in temperature shall be kept to a minimum.

3.3 The temperature of the hydrotest fluid for submarine pipelines shall have

stabilized prior to start of the hydrotest.

3.4 CONTRACTOR shall make all efforts to minimize the duration of the hydrotest. Re-aeration shall be avoided during the hydrotest and lay-up period when the metal surface is wet.

3.5 The hydrotest shall be scheduled as close to the start-up of the facilities as

possible to minimize the lay-up period.

3.6 CONTRACTOR shall provide materials and equipment required to perform the hydrotest. These shall include, but shall not be limited to pumps, piping connections, isolating valves, calibrated pressure gauges,temperature and pressure recorders, manifolds, chemical tanks, chemical injection pumps, deadweight testers, temporary blind flanges, studs, nuts, gaskets, and other similar equipment. SAUDI ARAMCO will provide only the in-line materials as noted on the Contract Drawings or in the Scope of Work. CONTRACTOR shall install all materials when and as required, and remove them upon successful completion of the hydrotest.

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SAUDI ARABIA



3.7 When filling, the hydrotest fluid shall be injected at the lowest practical point in the system to be tested with all vents open.

3.8 All piping and equipment, including skid mounted packages, shall be

hydrotested after the installation in the final position, although some items may have been previously shop hydrotested.

3.9 The number of flanged joints to be assembled after the hydrotest shall be kept

to a minimum. The gaskets, studs and nuts on all joints disturbed during or after the hydrotest shall be replaced with new gaskets, studs and nuts.

3.10 All permanent flanged joints made up after the strength or tightness tests shall

be inspected using a leak test.

3.11 Critical equipment, may with SAUDI ARAMCO approval, be isolated from the piping system during the hydrotest. Refer to applicable Contract Drawing hydrostatic test diagram for such equipment.

3.12 With the exception of low pressure piping and firewater systems, each

hydrotest shall be conducted at the maximum pressure allowable for the weakest element included in the test.

3.13 The maximum hydrotest pressure for platform piping shall be that which

produces a hoop stress equal to ninety percent of the specified minimum yield strength (SMYS) of the material. The maximum hydrotest pressure shall take into account the liquid head in the piping system as well as the maximum allowable pressure of the weakest element in the system.

3.14 The hydrotest pressure for platform piping shall at no time be below that

specified as the minimum per the applicable code.

3.15 Pipeline test pressures shall be as specified on the Contract Drawings.

3.16 A pneumatic or inert gas test may be used when it is not practical to use a liquid medium for hydrotests. Prior SAUDI ARAMCO approval to use the above test is required in all cases. Pneumatic testing using air or inert gas shall be conducted in accordance with ASME/ ANSI B31.3 Paragraph 345.5, or ASME Section VIII UG-100, as applicable. See Section 7.4 of this Specification for guidelines in the performance of pneumatic tests.

3.17 Any manifold fabricated for hydrotest purposes (either for permanent or

temporary use) shall be tested separately from any other piping before it is used. The manifold shall be tested to a pressure of not less than ten percent above the hydrotest pressure to be applied on the system to be tested.

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DE-119955

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3.18 Any conflict between the requirements of this Procedure and the piping, equipment or vessel test requirement shall be reported to SAUDI ARAMCO's Representative prior to starting or continuing the applicable test.

3.19 CONTRACTOR shall take samples of all chemically treated water and submit

them to SAUDI ARAMCO for testing when requested by SAUDI ARAMCO.

4.0 PREPARATION FOR HYDROTEST

4.1 Platform Piping

4.1.1 Vents shall be provided at all high points in the system to permit evacuation of all entrapped air before starting the hydrotest. Lines shall be purged of air before hydrotest pressure is applied.

4.1.2 A method of drainage shall be provided at all low points in the system.

4.1.3 Prior to the pressure test, the piping system shall be thoroughly

flushed with the hydrotest fluid and cleaned to ensure that it is free of dirt, construction materials, debris, sand, grease and other contaminates. Equipment connections shall be blanked off and not flushed with the piping. Filter elements and orifice plates shall be removed before flushing. Lines shall be flushed in such a way that dirt and debris will not be forced into instruments or trapped in the line.

4.1.4 All check valves shall have their discs and flappers removed prior to

hydrotest. If this is not practical, the hydrotest fluid shall be injected and the hydrotest pressure applied at the upstream side of the check valves and released at the downstream side. All discs and flappers, if removed, shall be replaced after the hydrotest.

4.1.5 Ball valves and gate valves shall generally not be used for isolating

piping sections or equipment during the hydrotest.

4.1.5.1 If it is absolutely necessary to use a closed block valve to block off equipment and/or piping sections for the hydrotest, it may be used provided that the valve seat does not limit the hydrotest pressure. In this case, the piping or equipment on the low pressure side of the block valve must be protected by a relief valve, or drained and vented to atmosphere to prevent overpressure due to possible leakage past the valve seat.

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DE-119955

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4.1.5.2 If the required hydrotest pressure is higher than the maximum allowable valve seat pressure of a segregating valve between two sections with different test pressures, both sections may first be tested at the lower test pressure with the valve open. The valve may then be closed and the hydrotest pressure raised to the higher test pressure on one side of the valve, while maintaining the lower test pressure on the other. The differential pressure shall not exceed the maximum allowable seat pressure. Both sections shall be protected by relief valves.

4.1.5.3 When not used for isolating piping sections or equipment

during the hydrotest, these valves shall be in the three-quarter (3/4) open position to equalize the pressure between the bore and the body cavity. During commissioning, the body cavity must be drained of the hydrotest fluid and thoroughly flushed out with the service product.

4.1.6 Control valves shall be set in the open position, or by-passed and

excluded from the hydrotest.

4.1.7 Gauges and instruments with scale ranges less than 80 percent of the required test pressure shall be removed by CONTRACTOR before hydrotest and the openings closed with steel plugs, flanges or caps with adequate pressure rating. These gauges and instruments shall be reinstalled by CONTRACTOR upon completion of the hydrotest.

4.1.8 Orifice plates shall not be installed until after the lines have been

thoroughly flushed and are free of the hydrotest fluid.

4.1.9 Except as noted in Section 4.1.5 of this Procedure, relief valves shall be removed prior to the hydrotest and the openings closed with blind flanges. These flanges shall be removed and the relief valves reinstalled after completion of the hydrotest.

4.1.10 Positive displacement meters and turbine meters shall not be installed

until after the lines have been thoroughly flushed and shall only be subjected to hydrotest with the concurrence of SAUDI ARAMCO. All rotating equipment shall be blocked in and case drains opened before the hydrotest.

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SAUDI ARABIA



4.1.11 Equipment and piping for new installations shall be hydrotested before applying insulation or tapewrap. For existing facilities, or previously insulated portions, a twenty-four hour recorded test shall be conducted unless otherwise approved by SAUDI ARAMCO.

4.1.12 A bleed valve shall be provided to protect piping and equipment from

overpressure, even though protection is provided by pressure relieving devices. The bleed valve shall be readily accessible during the hydrotest and be piped to the nearest sewer drain.

4.1.13 An isolation valve shall be provided at the point where the temporary

test piping connects to the piping or equipment being hydrotested.

4.1.14 Care shall be taken to avoid overstressing supporting structures, equipment or piping when hydrotest load or static head is applied to any system. Sequencing of systems tests shall be considered to avoid these problems. Where required, temporary supporting of piping shall be provided by CONTRACTOR. Spring hanger stops shall not be removed prior to start-up.

4.1.15 The following lines or systems are excluded from the requirements of

this Specification:

4.1.15.1 Atmospheric sewers and drains, which are tested by filling with water to determine leakage points. (This does not include the closed or pressure drain system).

4.1.15.2 Plumbing system, which are tested in accordance with

plumbing codes.

4.1.15.3 Non-pressurized lines or systems open to the atmosphere.

4.2 Submarine Pipelines

4.2.1 After the pipeline and/or riser(s) have been installed, CONTRACTOR

shall fabricate and install a temporary scraper launcher/receiver in accordance with the Contract Drawings and Scope of Work.

4.2.2 CONTRACTOR shall clean the pipeline of all internal debris by

passing a pipeline cleaning scraper through the line. The flow shall be continued until the effluent becomes clear.

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SAUDI ARABIA



(*) 4.2.3 A scraper with a gauging plate shall be passed through the pipeline to determine the existence of obstructions. The gauging plate shall be made from 1/4 inch thick aluminum. The diameter of the gauging plate shall be 95 percent of the limiting inside diameter of the pipeline (including flanges and fittings) and/or risers as calculated from mill and fabrication tolerances. It is recommended that the gauging plate be centrally located between the scraper cups to minimize the possibility of it getting stuck in the line. CONTRACTOR shall submit for SAUDI ARAMCO approval thirty calendar days prior to commencement of gauging operations CONTRACTOR's proposed gauging plate diameter along with supporting calculations for determining plate size.

4.2.4 If the gauging plate shows the existence of any obstruction or pipeline

damage, the obstruction or damage shall be located and repaired as necessary. A scraper with a gauging plate shall be passed through the pipeline again after the repair has been completed. This sequence shall be repeated until the scraper passes through the pipeline with the gauging plate undamaged. SAUDI ARAMCO shall witness the removal of gauging plates from receivers.

4.2.5 CONTRACTOR shall use bi-directional scrapers complete with

electronic/acoustic locator devices (pingers) for all scraping operations.

5.0 TREATMENT OF HYDROTEST FLUIDS

5.1 The following fluid treatment procedure applies only to carbon steel piping. If

any stainless steel, such as AISI 400 series chromium and AISI 300 series nickel-chromium is present, fresh water with a controlled chloride content and adjusted pH shall be used (ref. Specification SAES-A-007, Section 4.0).

5.2 Oxygen scavenger shall be injected into all hydrotest fluids. When used with

biocide, the oxygen scavenger shall be injected upstream of the biocide. The oxygen scavenger shall be ammonium bisulfite type (SAMS-26-733-265) or equivalent. The scavenger shall be injected into the test fluid at a rate of 200 ppm or 84 US gallons per 10,000 US barrels of water (ref. Specification SAES-A-007, Section 3.1.1.2).

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SAUDI ARABIA



5.3 Bactericide shall be injected into the hydrotest fluid when the fluid will remain in the piping for more than 90 days (including filling time, test period, and wet lay-up period). Bactericide shall be a non-oxidizing type approved by SAUDI ARAMCO such as"TROSKIL-1" (non-SAMS stock), or equivalent. TROSKIL-1 shall be injected into the test fluid at a rate of 200 ppm or 84 US gallons per 10,000 US barrels of water for lines to be laid-up 1 year or less. For lines laid-up for periods of over 1 year but less than 5 years, the dosage rate of biocide shall be 500 ppm or 210 US gallons per 10,000 US barrels of water. For lines laid up for an indefinite period (5 years or more) the dosage rate of biocide shall be 1000 ppm or 420 US gallons per 10,000 US barrels of water. Biocide shall be injected downstream of the oxygen scavenger. The required lay-up period will be specified by SAUDI ARAMCO.

5.4 A suitable dye shall be injected into the hydrotest fluid for use in locating leaks

in submarine pipelines. The type and concentration of the dye shall be such that it is visible to divers during close visual inspection.

5.5 Treatment chemicals shall be injected continuously while the piping system is

being filled to assure thorough mixing. Scrapers shall be used when filling (flooding) pipelines.

5.6 Separate proportioning pumps shall be used for each chemical to avoid

adverse reactions that can occur at very high concentrations. The injection points shall be located directly on the manifold supplying the hydrotest fluid. The chemicals shall be used undiluted.

(*) 5.7 In special cases, side stream mixing or chemical dilutions for mixing tanks may

be utilized as an alternative to proportioning pumps. Alternative methods shall receive prior SAUDI ARAMCO approval.

5.8 Handling, storage and mixing of the chemicals to be used for the treatment of

the hydrotest fluid shall follow the procedures outlined in the Chemical Hazard Bulletins (ref. Specification SAES-A-007), which are available from SAUDI ARAMCO's Industrial Hygiene Services:

Location - Room 131, Building 553, Dhahran Clinic (DHC) Dhahran Telephone 877-8425, Facsimile 877-8841

Mail address - P.O. Box 76, Building 553 Room 131 Dhahran Clinic (DHC) Dhahran

5.9 Eye wash facilities and shower facilities shall be available at the mixing site

before the chemicals are delivered.

5.10 Clean sea water shall be used without any treatment for the hydrotest of the fire water piping system.

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SAUDI ARABIA



6.0 TESTING PROCEDURE

6.1 CONTRACTOR shall ensure that all safety precautions have been taken and non-essential personnel evacuated from the area before any hydrotest is undertaken. Hydrotest shall be supervised by competent CONTRACTOR personnel throughout its duration. Supervising personnel shall be fluent in English.

(*) 6.2 CONTRACTOR shall provide all necessary instrumentation required to execute

the hydrotest in a safe and efficient manner. The pressure gauges and recorders shall be calibrated before use with a deadweight tester as described in Section 6.3 of this Procedure. The calibration interval shall not exceed one month or six tests whichever occurs first, or as may be requested by SAUDI ARAMCO. The calibration certificates shall be available to SAUDI ARAMCO before hydrotest. SAUDI ARAMCO may witness the calibration.

6.3 At least one 24 hour pressure recorder, two pressure indicating gauges and

one deadweight tester shall be used during the hydrotest of a submarine pipeline. The two test gauges shall have scale ranges 33 percent greater than the test pressure and graduations not greater than 10 psi. These gauges shall be verified to be within 5 percent of each other when in use. Stickers shall be applied indicating the latest calibration date. Each instrument shall be connected separately to the test manifold through its own valve. The manifold itself shall be capable of being isolated from the pipe to be tested.

6.4 Hydrotest pressure shall be recorded throughout the 24 hour tightness test and

temperatures shall be recorded for all hydrotests lasting over two hours. All pressure gauges and recorders shall have a scale range such that the test pressure is within 30 percent to 80 percent of the full range. The pressure recording gauge shall be driven by a 24 hour clock. The circular chart shall be at least 12 inches in diameter. If a strip recorder is used, chart speed shall be at least 1-1/2 inches per hour and the chart graduations not less than 50 psi. The recorder chart box shall be locked during the test. Both internal hydrotest water temperature and ambient temperature shall be recorded. If piping undergoing hydrotest is both submerged and in air (for example, a riser), then both seabed and air ambient temperatures shall be recorded.

NOTE: Type of pressure and temperature recorders shall be approved by

SAUDI ARAMCO.

6.5 The deadweight tester shall be capable of monitoring the full testing range at no greater than 80 percent of its capacity and in increments of no greater than 5 psi.

6.6 The hydrostatic test hook-up shall include a relief valve with adequate capacity

to prevent over-pressurization of the system due to temperature rise or operational error. The set pressure of the relief valve shall be five percent or 50 psi above the strength test pressure, whichever is lower.

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6.7 Relief valves shall be calibrated and tagged before each use by using a deadweight tester. SAUDI ARAMCO may at its option witness the calibration.

6.8 Pressure gauges shall not be subjected to pressures in excess of 80 percent of

their full scale range.

6.9 A preliminary pneumatic test of not more than 25 psig may be made at the discretion of SAUDI ARAMCO to locate major leaks prior to a hydrostatic test. If the piping is tested pneumatically, the test shall be conducted in accordance with ASME/ANSI B31.3 Para 345.5 or ASME Section VIII UG-100.

6.10 CONTRACTOR shall have repair personnel and equipment available on site

until all hydrostatic tests are completed so that repairs can be made expeditiously. CONTRACTOR shall correct all defects which become evident at any time prior to final acceptance of the work. Under no circumstances shall repair work be carried out when the system is under pressure.

7.0 SYSTEM TEST - PLATFORM PIPING

7.1 Strength Test

7.1.1 Strength tests shall be performed by CONTRACTOR at the fabrication

yard when each piping system has reached a sufficient degree of completion to justify the test. Any omission of the Strength Test must be approved by SAUDI ARAMCO.

7.1.2 Spool pieces or other parts of the platform piping system that are

shipped incomplete and require offshore fabrication and installation shall be strength and tightness tested offshore, and leak tested after the installation has been completed.

7.1.3 Test pressure shall be applied by a reciprocating pump. The pressure

shall be slowly raised to the specified test pressure as shown on the Contract Drawing hydrostatic test diagram. Once this pressure is reached the isolation valve shall be closed and the pump disconnected before the inspection of the system begins. The test pressure shall be maintained for a period of not less than 10 minutes.

7.1.4 During the strength test the piping under test shall not be subjected to

impact or external stresses, and all personnel shall remain at a distance deemed safe by SAUDI ARAMCO and CONTRACTOR.

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SAUDI ARABIA



7.2 Tightness Test

7.2.1 Following a satisfactory strength test of the piping system, CONTRACTOR shall conduct a tightness test at a hydrostatic pressure equal to two thirds (2/3) of the test pressure applied for the strength test.

7.2.2 The system being tested shall be held at the tightness test pressure

long enough to check all points for leakage. The duration shall not be less than 10 minutes. If there are any reinforcing pads, shop or field fabricated, in the piping under test, the test shall be conducted for a minimum of two hours to check weep holes for leakage.

7.2.3 Should leakage occur during the test, the system shall be

depressurized, repairs made, and re-tested at the same pressure and for the same duration as described in Sections 7.1, 7.2.1 and 7.2.2 of this Procedure.

7.2.4 If a piping system requires a tightness test only (such as for systems

being commodity tested), the test pressure shall be equal to the release pressure of the safety valve having the highest setting.

7.3 Leak Test

7.3.1 A leak test shall be conducted by CONTRACTOR responsible for the

system hook-up or start-up and commissioning.

7.3.2 If new flanged connections or new joints have been made after the leak test, or if the start-up takes place more than 14 days after the leak test, a second leak test shall be conducted to verify the integrity of the system.

7.3.3 The test fluid shall be process medium that is handled by the system

during normal operational conditions.

7.3.4 The piping system shall be in its normal operating condition with all instruments, orifice plates, control valves, check valves with disc and flappers, ball valves, gate valves, gauges and meters installed, equipment connected and blinds removed so that all joints and connections can be checked for leakage.

7.3.5 The test shall be performed at a pressure starting at 100 psig and

increased in increments of 100 psig up to operating conditions.

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7.3.6 The duration of the test shall be the time required for a complete check for leakage of all the connections and joints that have been made after the strength and tightness tests. The minimum duration of this test shall be 10 minutes.

7.4 Pneumatic Test

(*) 7.4.1 Prior SAUDI ARAMCO approval is required to conduct a pneumatic

test using air or inert gas. Pneumatic tests shall be conducted in accordance with ASME/ANSI B31.3 Paragraph 345.5 or ASME Section VIII, UG-100, as applicable.

7.4.2 A preliminary test at not more than twenty-five psig shall be made for

safety reasons. The preliminary check pressure shall not exceed the test pressure.

7.4.3 The test area shall be cleared of personnel while bringing the line up

to test pressure. The pressure shall be increased in gradual steps of five psig or ten percent of the test pressure, whichever is greater. Sufficient time shall be allowed for the piping to equalize strain and to check for leaks until the test pressure is reached. Care must be exercised not to exceed the specified test pressure by more than ten percent.

7.4.4 Pneumatic test systems shall be kept reasonably small in terms of

volume.

7.4.5 A double block and bleed valve arrangement shall be included in the pressurization line to the system being tested. A test pressure gauge shall be installed downstream of the double block and bleed valve. After each pressure step has been reached, close the block valves and open the bleeder to atmosphere. If after a five minute period the step pressure is held, proceed to the next step pressure. If the step pressure is not held, the entire system shall be checked for leakage.

7.4.6 When the system has reached test pressure, the entire system should

be "walked" to determine if there is any audible evidence of leakage. Any leaks found at this time shall be marked for repair after first depressurizing the system.

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7.4.7 The system test pressure shall be reduced to a minimum of five psig and all joints or welds shall be checked for leakage using a bubbling soap solution. Flanged connections shall be taped with one small hole punched on the side or top of the tape for application of the soap solution.

7.4.8 Bolting shall not be tightened while the system being tested is

pressurized above 30 psig.

7.4.9 Pneumatic test pressure shall be maintained for sufficient length of time to permit thorough visual inspection of all joints and weld seams but not less than ten minutes. Pressure shall be released gradually when depressurizing.

7.5 Special Cases

7.5.1 Low pressure equipment and piping in water, instrument air, plant air

and inert gas services operating at 150 psig or less, may be tested with its own product at operating pressures as indicated on the Contract Drawing hydrostatic test diagram. When commodity testing, the requirements of Section 3.14 of this Procedure and the safety precautions of Section 3.15 of this Procedure shall be followed.

7.5.2 Low pressure blow down lines designed for less than 100 psig shall

be pneumatically tested to 110 percent of design pressure. The welds and joints shall then be soap tested at a reduced pressure of five psig in accordance with Section 7.4 of this Procedure.

7.5.3 Fire water piping systems regardless of material shall be hydrotested

at 200 psig or 50 psig higher than operating pressure, whichever is greater and held for a minimum of two hours in accordance with NFPA requirements.

8.0 SYSTEM TEST - SUBMARINE PIPELINES

8.1 Strength Test

8.1.1 After the pipeline (including risers) to be tested has been filled with

treated water, purged of air, and allowed to reach thermal equilibrium, the test pressure shall be applied slowly using a reciprocating pump until it is raised to the strength test pressure as specified on the Contract Drawing hydrostatic test diagram.

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8.1.2 As an exception to Specification SAES-L-021, all pumps shall be disconnected from the system under hydrotest to allow no additional pumping during the test. The test shall be conducted for a minimum of two hours unless otherwise specified in the Scope of Work. During this period the pressure may vary due to temperature change alone. Such pressure variations are predictable and allowable under Specification SAES-L-021. However, if the pressure declines steadily it shall be attributed to a leak in the system. The system shall then be depressurized, repairs made, and re-tested at the same pressure and duration as described in Sections 8.1 and 8.2 of this Procedure.

8.1.3 If there is no unacceptable pressure variation during the two hour

period, the test pressure shall be reduced to 95 percent of the strength test pressure in preparation for the tightness test.

8.2 Tightness Test

8.2.1 The pressure for the tightness test shall be maintained for a minimum

of 24 hours. Only pressure variations caused by temperature changes will be allowed. No additional pumping will be allowed during the tightness test. The entire pipeline shall be checked for leakage. The test pressure shall be verified by CONTRACTOR using the deadweight tester. SAUDI ARAMCO may witness this verification.

8.2.2 Following successful completion of the hydrotest the system shall be

depressurized gradually. Test records shall show both the initial pressurization and the bleed-down portions of the test.

9.0 LAY-UP

9.1 Dewatering, Drying and Lay-Up of Platform Piping

9.1.1 A wet lay-up procedure may be followed only with prior approval of

SAUDI ARAMCO. If wet lay-up is not approved, dry lay-up shall be executed.

(*) 9.1.2 CONTRACTOR shall submit the procedure(s) for dewatering and

drying of all topside platform piping to SAUDI ARAMCO for approval 30 days prior to hydrotesting.

9.1.3 For a piping system undergoing dry lay-up, the system shall be

completely drained and made inert with nitrogen or dried with dry air to an air exit dew point of less than -1°C (30°F). Air flow shall be established through all parts of the system during drying (ref. Specification SAES-A-007 Section 3.2.3).

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9.2 Lay-Up of Submarine Pipelines

9.2.1 Wet lay-up is required for submarine pipelines (including risers and spools) to avoid the possibility of residual water left in the pipe because of incomplete dry-out. Chemicals shall be injected in accordance with Section 5.0 of this Specification unless otherwise instructed by SAUDI ARAMCO.

9.2.2 When wet lay-up (that is, biocide treated seawater) is used on a

pipeline system, CONTRACTOR shall put positive pressure on the system (5 to 20 psig) using nitrogen or hydraulic pressure in accordance with Specification SAES-A-007, Section 5.3.

9.2.3 Dry lay-up is rarely used. When specified, the procedure shall be in

accordance with Specification SAES-A-007, the Contract Drawings and the Scope of Work.

10.0 DISPOSAL OF HYDROTEST FLUIDS

(*) If disposal of hydrotest fluids due to implementation of dry lay-up is required by the

Contract Drawings and Scope of Work, sixty calendar days prior to such disposal CONTRACTOR shall submit a formal written proposal to SAUDI ARAMCO for approval. The proposal shall include, but not be limited to, the following information:

• Location of discharge of the hydrotest fluid

• Quantity of fluid to be discharged

• Temperature of discharge

• Whether sea water, fresh water or treated water

• Length of time water has been in the system

• Description and quantity of chemical products included in the hydrotest fluid

• Whether the piping or pipeline is new construction or old with oil contamination

• Plans for decontamination

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11.0 TEST RECORDS

(*) 11.1 CONTRACTOR shall conduct all calibration tests of CONTRACTOR's test instruments and shall submit written documentation of the results to SAUDI ARAMCO.

11.2 CONTRACTOR shall prepare hydrotest records showing SAUDI ARAMCO's

and CONTRACTOR's names, the names of the individuals responsible for performing the test, the time and date of each test, the P&ID number, the Contract Drawing hydrostatic test diagram number, the test number, the test duration, the test medium, a description of the facility tested, and an explanation of any pressure fluctuations or any deviations or exceptions taken with or without SAUDI ARAMCO concurrence. This shall be summarized in a report prepared and signed by CONTRACTOR and presented to SAUDI ARAMCO for approval.

11.3 CONTRACTOR shall submit a hydrotest package that includes a flushing

report, a hydrotest report per Section 11.2 of this Specification, the Contract Drawing hydrostatic test diagram, Contract Drawing P&ID, and the Punch List Report.

Documents

De-119955 - Hydro Test