PROJECT
EXECUTION
PLAN
PRESSURE TESTING, HYDRAULIC FLUSHING, FILTRATION
& TESTING OF PUSH PULL UNITS
BARGE- STB 1
CLIENT- BOS-SHELF
Doc. No: HCL-OP-PEP-002
REV 00
PROJECT EXECUTION PLAN FOR
PRESSURE TESTING, FLUSHING,
FILTRATION ON HPU & FINAL
TESTING OF PUSH PULL SYSTEM
Doc No: HCL-OP-PEP-002
Issue Date: 31.01.2022
Revision Date: 07.02.2022
Revision No: 01
Page: 2/61
Amendment history
Date
Revision
№
31.01.2022
07.02.2022
Clause
№
Purpose and description of inserted or deleted
information
Issued by
00
Initial release
N. Ansari
01
Commented causes edited as per customer request
N. Ansari
CONFIDENTIAL
UNCONTROLLED WHEN PRINTED
PROJECT EXECUTION PLAN FOR
PRESSURE TESTING, FLUSHING,
FILTRATION ON HPU & FINAL
TESTING OF PUSH PULL SYSTEM
Doc No: HCL-OP-PEP-002
Issue Date: 31.01.2022
Revision Date: 07.02.2022
Revision No: 01
Page: 3/61
CONTENTS
Amendment history ............................................................................................................................................. 2
1.
INTRODUCTION .................................................................................................................................... 5
2.
COMPANY INFORMATION ................................................................................................................... 5
3.
PERSONAL PROTECTIVE EQUIPMENT (PPE) REQUIRED TO COMPLETE THE JOB .................. 6
4.
OVERVIEW & SCOPE ........................................................................................................................... 6
5.
DETAILED SCOPE ................................................................................................................................ 8
5.1.
Hydraulic Power Unit & Components ................................................................................................. 8
5.2.
Detailed Activities ................................................................................................................................. 9
5.3.
Activities In Brief ................................................................................................................................ 10
6.
OBJECTIVES ....................................................................................................................................... 11
7.
REFERENCE/ STANDARDS ............................................................................................................... 11
8.
DEFINITIONS ....................................................................................................................................... 12
9.
ROLES, RESPONSIBILITIES and COMPETENCE ............................................................................ 12
9.1.
Assessments....................................................................................................................................... 14
9.2.
Interfaces ............................................................................................................................................. 15
9.3.
Training................................................................................................................................................ 15
10.
ENGINEERING CONSIDERATIONS ................................................................................................... 15
11.
GENERAL SAFETY ............................................................................................................................. 15
12.
QHSE .................................................................................................................................................... 17
13.
METHOD STATEMENT ....................................................................................................................... 17
13.1.
General Requirements ....................................................................................................................... 18
13.2.
Equipment for Pressure Testing & Oil Flushing ............................................................................. 20
13.3.
Measuring and Controlling Devices ................................................................................................. 21
13.4.
Preparation & Flushing/Pressure Testing ........................................................................................ 21
13.5.
Performance of Hydraulic Oil Flushing ............................................................................................ 22
13.6.
Performance of Hydrostatic Pressure Test ..................................................................................... 25
13.7.
Hold Period.......................................................................................................................................... 26
13.8.
Acceptance.......................................................................................................................................... 26
13.9.
Documentation & certificates ............................................................................................................ 26
13.10.
Reference Drawings ........................................................................................................................... 26
14.
FLUSHING & PRESSURE TESTING PROCESS FOR THIS SPECIFIC SCOPE .............................. 27
15.
EQUIPMENT UTILITY REQUIREMENTS ........................................................................................... 28
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PROJECT EXECUTION PLAN FOR
PRESSURE TESTING, FLUSHING,
FILTRATION ON HPU & FINAL
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Issue Date: 31.01.2022
Revision Date: 07.02.2022
Revision No: 01
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16.
PNEUMATIC TESTS ............................................................................................................................ 28
17.
ACCEPTANCE ..................................................................................................................................... 28
18.
HYDRAULIC POWER UNIT & COMPONENTS FINAL OPERATIONAL TESTING &
INSPECTIONS ..................................................................................................................................... 29
18.1.
Travel Cylinders Measurement ......................................................................................................... 34
18.2.
Travel Cylinders Test ......................................................................................................................... 34
18.3.
Main Gripper Jacks Measurement .................................................................................................... 34
18.4.
Main Gripper Hydraulic Jack Test .................................................................................................... 34
18.5.
Aux. Gripper Jacks (Swivel Plates) .................................................................................................. 35
18.6.
Aux. Gripper Hydraulic Jack Test ..................................................................................................... 35
19.
DOCUMENTATION & CERTIFICATES ............................................................................................... 35
20.
PUSH PULL SYSTEM REFERENCE DRAWINGS ............................................................................. 36
APPENDIX 1 – FLUSHING GUIDELINES .......................................................................................................... 40
APPENDIX 2 – PRE FLUSHING CHECKLIST ................................................................................................... 44
APPENDIX 3 – POST FLUSHING CHECKLIST ................................................................................................. 45
APPENDIX 4 – FLUSHING REPORT SAMPLE ................................................................................................. 46
APPENDIX 5 – JOB SCHEDULE FOR HOSES RENEWAL, PRESSURE TESTING, HYDRAULIC HOT OIL
FLUSHING, OFFLINE FILTRATION & FINAL OPERATIONAL TESTING OF THE PUSH PULL UNIT
ON STB 1 ............................................................................................................................................. 48
APPENDIX 6 – Daily Progress Report (Draft Only) ......................................................................................... 50
APPENDIX 7 – Task Risk Assessment (Draft Only) ....................................................................................... 51
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FILTRATION ON HPU & FINAL
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Revision Date: 07.02.2022
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1. INTRODUCTION
HYDROSERV GROUP is a well-known and established provider of ‘Fluid Engineering’
applications and solutions for the Oil and Gas industry which was founded in 1998. Our
ongoing efforts driven by the continued and growing support of our valued customers and
suppliers has assured our involvement in a number of Oil & Gas projects where we have been
recognized as a reliable and successful service company.
Our focus is on improving delivery and customer service while providing cost effective, high
quality services and solutions which are the key to achieving our business objectives. Our
investment in equipment, service facilities and the ongoing development of a competent,
skilled and specialized workforce signifies our commitment to providing the best possible
support and service quality to our customers.
2. COMPANY INFORMATION
COMPANY
NAME
BOS-SHELF
START DATE
TBA
SITE
ADDRESS
BARGE STB 1
END DATE
TBA
JOB NO
9749
USED SOP NO
NA
ZENFIRA NURMAHAMMADOVA
Mohd. Numair Ansari
ACE
PROJECT
JUNIOR
CONTRACTS ADMINISTRATOR
CUSTOMER
CONTACT
DETAILS
Tel: +994 12 444-99-00
Sr. Hydraulic Engineer
HYDROSERV
REPRESENTATIVE
CONTACT DETAIL
Mob: +994 552044709
z.nurmahammadova@bosshelf.com
E-mail:
Numair.Ansari@hydroser
v.az
PEP NO
00
PEP PREPARE DATE
31/01/2022
DOCUMENT
AUTHOR
MOHD. NUMAIR ANSARI
PEP UPDATE DATE
NA
CONFIDENTIAL
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PROJECT EXECUTION PLAN FOR
PRESSURE TESTING, FLUSHING,
FILTRATION ON HPU & FINAL
TESTING OF PUSH PULL SYSTEM
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Issue Date: 31.01.2022
Revision Date: 07.02.2022
Revision No: 01
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3. PERSONAL PROTECTIVE EQUIPMENT (PPE) REQUIRED TO COMPLETE THE JOB
Gloves
Face mask
Eye
protection
Welding
mask
Appropriate
footwear
Hearing
protection
Protective
clothing
4. OVERVIEW & SCOPE
The scope of job is to perform Hydraulic Flushing, Pressure Testing, Filtration, MPI of skid
structure & necessary final testing on the push pull system.
The scope of work comprises is to carry out the required hydraulic service work to perform as
per the comprehensive Health check survey report # 60797 on STB-1 Push Pull units and
associated system condition onboard STB-1 (Structure, Mechanical, Hydraulic).
The scope of work comprises is to detail the required pressure testing, hydraulic hot oil
flushing & to perform a comprehensive testing and accurately evaluate the STB-1 Push Pull
units and associated system condition onboard STB-1 (Structure, Mechanical, Hydraulic).
This procedure covers the minimum requirements and plans for flushing & testing of piping
and hoses coupled with Gas/Fluid carrying systems in oil and gas installations prior to
commissioning. Includes HSE’s Guidance, Roles, responsibilities and competencies, effective
communications and Methods used for flushing and gives advice on the preparations
necessary to avoid conditions likely to result in hazardous situations onboard and the
preparation of a detailed shopping list of such is also part of this health check.
This Includes HSE’s Guidance, Roles, responsibilities and competencies, effective
communications and Methods used advice on the preparations necessary to avoid conditions
likely to result in hazardous situations.
HYDRAULIC POWER UNIT & COMPONENTS DETAILS
Two diesel engine driven hydraulic power units are used to supply hydraulic power to the skid
units. The main hydraulic pumps are mounted to the fly wheel side of the engines with flexible
couplings. If one of the power unit fails, the other unit will automatically take over the operation
of all 4 skid units @ 1/2 speed.
Diesel engine = Deutz (BF12L413 F)
Numbers of engines = 2
Output rating = 2 x 254 kW at 1800 rpm
Hydraulic pumps = Poclain (Model- PL4H18-FOR- 44)
Output rating = 2 x 316 l/min at 1800 rpm, 1 Push/Pull Skid- 500 Tons x Total 4 Skids of 2000
Tons
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PROJECT EXECUTION PLAN FOR
PRESSURE TESTING, FLUSHING,
FILTRATION ON HPU & FINAL
TESTING OF PUSH PULL SYSTEM
Doc No: HCL-OP-PEP-002
Issue Date: 31.01.2022
Revision Date: 07.02.2022
Revision No: 01
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There is 4 Push pull unit in total onboard STB-1 (4 x 500t -> 2000t overall), 1 on each side of
the 2 skid beams. They are made of 2 x travelling cylinders, 2 x main gripper anda swivel
plate fitted with auxiliary grippers.
The work is to be performed for Bos-Shelf in Vessel STB 1 (Bos Shelf Yard)
SCOPE OF WORK AND NOTES:
 Supply of all the new hoses for push pull system including skids, HPU & engine hoses
 Supply & installations of the hydraulic oil filters on HPU
 Removal of existing old hoses & installation of all new pressure tested hoses
 Pressure testing & hot oil flushing of pipings from HPU to Skids including the hoses
 Pressure testing upto 350 BAR (W.P. 350 BAR or Test Pressure Specify by Client) &
hot oil flushing of pipings from HPU to Skids including the hoses. Pressure testing to
be recorded on calibrated chart recorder
 Prepare all the loops on PORT/STBD sides & Carry out hot oil flushing of the
pipelines as per loops on PORT & STBD sides & hydraulic lines to be flushed with
mineral oil (Client provided) to NAS 1638 CLASS 6 (SAE AS 4059 Class 6) ISO 4406
CODE 15/12) or better, flushing flow as per the lines sizes (1/2'', 3/4'', 1'', 1 1/4'', 1
1/2''& 2'') & utilizing high flow flushing equipment to achieve turbulent flow (Reynolds
no. ≥ 4000) @40˚-50˚ C
 Carry out oil analysis utilizing calibrated particle counter & purge the lines upon
successful completion of testing/flushing utilizing dry air or nitrogen
 Structures can be MPI for any cracks. Structure Found in Good Condition Visually &
Greased Properly
 Draining of existing oil in main HPU & pilot HPU reservoirs
 Refilling of new oils into the HPU reservoirs
 Carry out offline filtration of the HPU & Pilot HPU reservoirs upto NAS 1638 CLASS 6
(SAE AS 4059 Class 6 or ISO 4406 CODE 15/12) or better
 Carry out oil analysis utilizing calibrated particle counter & purge the lines upon
successful completion of testing/flushing utilizing dry air or nitrogen
 Delooping of the lines & reinstatement with client assistance as original
 Calibration of all the hydraulic pressure & temperature gauges on control panel PORT
& STBD
 Renewal of filters on HPU
 Final testing on Push/Pull System
 No Inventory found for Push/Pull System except Few short Hoses, most
valves/pumps are obsolete models, since system is old.
 Issuance of certificates & inspection/test reports
Note:
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PRESSURE TESTING, FLUSHING,
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 Any jobs other than mentioned above shall be quoted additionally, manpower &
equipment rates considered job to be conducted onshore for 12 hrs. day/night (as
required) shift
 Client to isolate the system & proper LOTO of system
 Client to provide necessary gate passes, crane assistance, all the scaffolding
erection. Work permits etc.
 Standby rates are applicable in case system not ready for carrying job
 COVID 19 test & quarantine rates not included in offer.
 Oil for flushing & new oil for HPU will be provided by Hydroserv
 Required Scaffolding & crane assistance Bos-Shelf will erect
 Waste oil will be disposed as per the govt. law (if required)












Client Scope:
Support for work permit, work permit shall be prepared by Hydroserv in liaise with
Customer & other stakeholder involved and safety induction and gate pass for
Hydroserv personnel and vehicle.
Transportation to barge, loading, offloading, lifting crane & locating the equipment as
near as possible to the work location to be arranged by client
For Hydroserv testing/flushing equipment & process.
Electric Power Supply - 220 volt, single phase, 50 Hz and 380 volt, three phase, 50
Hz.
Diesel for equipments as needed & scaffolding Works
Water – Good quality of fresh water for drinking & hand wash
Adequate ventilation, lighting and water for Hydroserv personnel to be provided nearby
work location.
Eye wash, first aid kit, fire extinguisher etc. on site.
Shop air upto 7-8 Bar.
Sanitary/medical on site.
Client to provide space for equipment not more than 20 to 25 meters away from the
hydraulic unit which to be flushed.
Lunch boxes for the Hydroserv Personnels day/night shift will be provided by client
5. DETAILED SCOPE
5.1. Hydraulic Power Unit & Components
 Supply of all the new hoses for push pull system
 Removal of existing old hoses & installation of all new pressure tested hoses
 Pressure testing up to 350 BAR (W.P. 350 BAR or test pressure mention by client) &
hot oil flushing of piping from HPU to Skids including the hoses. Pressure testing to
be recorded on calibrated chart recorder
 Prepare all the loops on PORT & STBD sides, Carry out flushing of the pipelines as
per loops on PORT & STBD sides & hydraulic lines to be flushed with mineral oil
(Client provided) to NAS 1638 CLASS 6 (SAE AS 4059 Class 6) ISO 4406 CODE
15/12) or better, flushing flow as per the lines sizes (1/2'', 3/4'', 1'', 1 1/4'', 1 1/2''& 2'')
CONFIDENTIAL
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PROJECT EXECUTION PLAN FOR
PRESSURE TESTING, FLUSHING,
FILTRATION ON HPU & FINAL
TESTING OF PUSH PULL SYSTEM
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Issue Date: 31.01.2022
Revision Date: 07.02.2022
Revision No: 01
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& utilizing high flow flushing equipment to achieve turbulent flow (Reynolds no. ≥
4000) @40˚-50˚ C
Structures to be MPI for any cracks. Structure Found in Good Condition Visually &
Greased Properly
Draining of existing oil in main HPU & pilot HPU reservoirs
Refilling of new oils into the HPU reservoirs
Carry out offline filtration of the HPU & Pilot HPU reservoirs upto NAS 1638 CLASS 6
(SAE AS 4059 Class 6 or ISO 4406 CODE 15/12) or better
Calibration of all the hydraulic pressure & temperature gauges on control panel PORT
& STBD
Renewal of filters on HPU
Final testing of the push pull units
5.2. Detailed Activities
Power Pack (HPU):
 Draining of existing oil in main HPU & pilot HPU reservoirs
 Refilling of new oils into the HPU reservoirs (client provided oil)
 Carry out offline filtration of the HPU & Pilot HPU reservoirs upto NAS 1638 CLASS
6 (SAE AS 4059 Class 6) ISO 4406 CODE 15/12) or better
 Renewal of filters on HPU
 HPU room hoses renewal
 Final testing of HPU by operating the skids one by one & all together
Control panel




Removal of all the Temperature & pressure gauges
Calibration of the gauges
Install back all the gauges on control panel
Final testing
Hydraulic system







Hydraulic hoses from power pack to skid beams- Renewal
Hydraulic tubing/piping & clamps on skid beams- Pressure testing of tubes/pipes
up to 350 BAR pressure
Hydraulic hoses from skid beams to push pull units (cylinders)- Renewal
Push pull system HPU- hoses to renew
Respective valves and fittings- Only damaged ones to replace
Prepare all the loops on PORT/STBD sides HPU to skids pipelines/hoses & Carry
out hot oil flushing upto NAS 1638 CLASS 6 (SAE AS 4059 Class 6) ISO 4406
CODE 15/12) or better
Nitrogen purging & delooping of hoses upon successful flushing
Connections as original upon successful completion of flushing
CONFIDENTIAL
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PROJECT EXECUTION PLAN FOR
PRESSURE TESTING, FLUSHING,
FILTRATION ON HPU & FINAL
TESTING OF PUSH PULL SYSTEM
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Doc No: HCL-OP-PEP-002
Issue Date: 31.01.2022
Revision Date: 07.02.2022
Revision No: 01
Page: 10/61
Travelling cylinders- Final testing
Main grippers- Final testing
Aux grippers- Final testing
Structural (Visual Inspection)



Gripper support structure- To be MPI
Main gripper structure and bolts- To be MPI
Swivel plate structure and bolts- To be MPI
Power pack foundation, bolts, etc…- To be checked
Final Operational test of hydraulic system including hydraulic pump including

As per Op manual or standard running test for such
5 min pressure testing of all cylinder (in both direction for travelling cylinder (dual
acting) at max operating pressure confirming no leaks




Main gripper & aux. gripper pressure hold test and suitability of equipment
Hydraulic oil analysis (Particle count & contaminants)
Records of hoses status
Records of hydraulic system
Final Operational test of control panel
Confirm/review all commands, pilot pressure checks, lights, gauges, counter
are operational and calibrated
5.3. Activities In Brief
S.NO
JOB DESCRIPTION
1
Push Pull Unit General Visual Inspection & Planning
2
System Complete Hydraulic Hoses Renewal
3
Pressure Testing of the Pipelines & Hoses
4
Hydraulic Hot Oil Flushing of the System Pipelines & Hoses
5
Draining Existing Oil in HPU Reservoir & Pilot HPU Reservoir, Filling of New
Oil & Offline Filtration of the HPU & Pilot HPU Reservoirs
6
Control panel gauges calibrations & testing of pilot controls
7
MPI of the Skid Structures 04 Nos.
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8
Final Operational Testing of the Push Pull System
9
Record Finding & Final Evaluation Report Submission
6. OBJECTIVES
This guidance is intended to assist engineers tasked with planning and implementing the
inspection, testing, removal/refit & disconnections/connections of the hydraulic system &
components. The objectives include:
– To define individual responsibilities of the people involved in activities.
– To outline typical techniques for controlling risks associated with disconnections.
– To demonstrate duties incumbent on Clients, Contractors and Employers in assuring
competence of all parties.
– To provide the basis for planning various aspects of crane disconnections, giving
sufficient detail to form the scope of work and technical specification.
– To outline the techniques that is utilized to deliver a certified final service.
7. REFERENCE/ STANDARDS
– ISO 10380:2012 Pipe work-Corrugated metal hoses and hose assemblies
– NORSOK L – 004 Rev 3 PIPING FABRICATION, INSTALLATION, FLUSHING AND
TESTING
– ISO 4406:2021 Hydraulic fluid power — Fluids — Method for coding the level of
contamination by solid particles
– NAS 1638.
– ISO 11171:2016 Hydraulic fluid power — Calibration of automatic particle counters for
liquids
– ASME B31.3 Process piping, ASME B31.1 Power piping
– API Specification 6 A / ISO 10423
– ISO 1402:2021 Rubber and plastics hoses and hose assemblies — Hydrostatic
testing
– ISO 7751:2016 Rubber and plastics hoses and hose assemblies — Ratios of proof
and burst pressure to maximum working pressure
– Reference Email- STB-1 Health Checks Quotation
– Reference Initial Survey Report- STB-1 Health Checks- 60797
Item Description/Document No.
Title
1
N/A Blohm & Voss – Load out N/A Blohm & Voss – Load out
manual (1988)
manual (1988)
2
I21-05-200 Hydraulic schematic GA
I21-05-200 Hydraulic schematic GA
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3
080.0021
Gray
Operating manual
Mackenzie 080.0021 Gray Mackenzie Operating
manual
4
AF0053-INT-TN-0010 STB-1 Push AF0053-INT-TN-0010 STB-1 Push
Pull units
Pull units
8. DEFINITIONS
Pressure testing: A test used to prove the integrity of the pressure containing components
of a system. It is conducted above the design pressure. The objective is to prove the
mechanical strength and integrity of the items being tested and to confirm that it may be safely
subjected to its maximum operating pressure under normal use. The test can also have the
benefit of relieving stresses in the completed assembly.
The majority of the components in a system are normally proven by a strength test. The tests
on each component are frequently conducted in different place and different times e.g.
pressure vessels and other manufacturer’s equipment are normally tested at source.
Flushing: As a pre-commissioning activity, flushing can be defined as the act of pumping
fluid, in sufficient quantity velocity, through a given section of pipe or piping, completely filling
that section of pipe or piping, such that flow of fluid through the system will forcibly remove
any loose rust, mill scale or construction debris from the system
Particle counting: Particle Counting is the measurement of all particles that have
accumulated within a system, including those metallic and non-metallic, fibers, dirt, water,
bacteria and any other kind of debris. It is most useful in determining fluid and system
cleanliness in such filtered systems.
Particle counter: A particle counter is an instrument that detects and counts particles. By its
very nature a particle counter is a single particle counter, meaning it detects and counts
particles one at a time. A high energy light source is used to illuminate the particle as it passes
through the detection chamber. The particle passes through the light source (typically a laser
or halogen light) and is detected by the screen and processed by computer to give the results
of the particles present in the fluid, with size and quantity.
Method Statement: An engineer’s description of the scope, techniques and resources that
are required to successfully complete the task, It will take cognizance of the hazards
associated with the work and will be backed up with risk assessments.
9. ROLES, RESPONSIBILITIES and COMPETENCE
There are two levels of competence required to achieve successful pressure testing & hot oil
flushing, final test on push pull unit:
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Individual competencies of employees to be able to apply the technology and procedures to
the situation. An outline of roles, responsibilities and competencies is illustrated in the below
table.
While Hydroserv will conduct all testing & flushing, Push pull system considered to be
operated by STB 1 Barge Crew as per the Hydroserv requirements for proper testing of all the
hydraulic components & records the findings/observations.
POSITION
ROLE
RESPONSIBILITY
ENGINEERING
TEAM
Develop concepts
and plans for the
health check &
testing of the push
pull unit & system
based
on
the
client’s
requirements.
Prepare
calculations,
documents
and Assess codes and standards.
specifications.
Prepare
drawings,
and
This will be based upon the specifications
requirements of the job,
codes and standards for the Identify hazards and assess risks
industry.
CONFIDENTIAL
UNCONTROLLED WHEN PRINTED
COMPETENCE
PROJECT EXECUTION PLAN FOR
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TESTING OF PUSH PULL SYSTEM
Set up data base system.
PROJECT
MANAGER
Doc No: HCL-OP-PEP-002
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Revision No: 01
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Comprehend pressure ratings
and technology
Prepare systems of work for Implement management system
the mobilization of people to provide a framework for
Ensure the work is plant and materials.
working practices.
planned, resourced,
Supervise the successful Communicate with others to
implemented and
implementation of tests.
ensure
the
transfer
of
closed
out
information.
Define
the
interfaces
satisfactory.
required between groups.
Develop risk assessments and
mitigate consequences
Hand
over
completed
systems to the final user.
Prepare method statements,
procedures and safety plans
Interpret
plans, Put into practice work packages
specifications
and prepared by others.
procedures to implement
Utilise
work
management
work packages.
systems and input information
Ensure that work Ensure that Technicians into reports.
packages prepared have the correct equipment Comprehend
PROJECT
communications
and information to carry out
ENGINEER
/ by others are
techniques and the use of Permit
the work and make them
SUPERVISOR
to Work systems.
Successfully
understand their duties on
implemented
Have knowledge of risk control
safety aspects.
techniques
associated
with
Utilize systems and ensure
pressurized systems.
adequate
reporting
to
communicate progress of Set to work and supervise
Technicians
the work.
SR.
HYD.
ENGINEER /
LEAD
TECHNICIAN /
TECHNICIAN /
MECHANIC
Effect instructions delivered by
the management system.
Comprehend the site rules,
Implement site procedures
system
of
work
and
Receive
information
and
procedures.
Implement
work
communicate effectively with
Utilize the tools, plant,
packages
as
other trades working on the same
materials and consumables
planned
and
system.
to successfully carry out
delivered by others.
Ensure
that
test
control
pressure tests.
techniques are implemented.
Control access to areas
Prepare progress and close out
under test.
reports for the management
systems.
9.1. Assessments
Personnel involved in the performance of work functions specified in this procedure shall be
qualified and trained in accordance with the applicable departmental training procedures. Also
it is necessary for engineers to assure work performance to the standards.
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9.2. Interfaces
On site tasks involves interfaces between parties. Competence includes the ability of
engineers and contractors to control these interfaces. This may be done through effective
communications, which will include permit to work systems or daily site meetings. In the same
way, employees require to be instructed in the rules for the site and the manner in which
testing work will be executed. This will allow them to become familiar with their working
environment.
9.3. Training
Training covers both technical job skills and appreciation of the management techniques being
utilized on the site. It is assumed that job skills will be accumulated through formal learning
and amassed experience through working on similar types of job. It is the employer’s
responsibility to ensure that these skills are present before mobilizing an employee. Training
in the management techniques will include induction, permit to work, safety practices and the
use of specific plant. Instruction addresses how the previously planned work will be executed.
It may be delivered through safety meetings or toolbox talks. It will address conditions on work
permits, handbooks or user’s instructions. It will take account of emergency procedures,
hazards from other site users, isolations etc.
10. ENGINEERING CONSIDERATIONS
Engineering is considered to cover the following aspects of the management for push pull unit
system health checks & testing
–
Definitions of the client’s requirements.
–
Preparation of risk assessments
–
Preparation of interface procedures for the site
–
Review of all the referenced drawings
–
Engineering assessment to define its planning.
–
Planning phase assessments to align the schedule with other work on the site.
–
Generic assessments to cover standard activities.
11. GENERAL SAFETY
Pressure Testing & Hydraulic Hot Oil Flushing of the push pull system, require to be skilled
task. The pressure testing & flushing of pipelines, pipe work, vessels and Hoses, irrespective
of whether it is hydrostatically, hydraulic or pneumatically undertaken, necessitates the
application of force or strain to a given area.
The designated work area will be cordoned off with bunting and warning notices displaying
“CAUTION PUSH PULL UNIT UNDER TEST” similar, positioned at likely routes of access.
This area shall be out of bounds to all unauthorized personnel.
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At the time when any testing, flushing or disconnection on push pull unit in progress, would
normally begin there will still be a relatively large number of construction personnel working
on the plant or unit. It is absolutely imperative that consideration of these personals or anyone
else working in the vicinity, is planned
All personnel directly involved in the scope of work shall understand and be fully aware of their
duties. No work in connection with the scope of work will take place without the prior
authorization and issuing of the necessary work permits.
All flexible connections shall be satisfactorily secured & drained off/capped after
disconnection. All aspects to do with spills, fires and personal contact with fluids will be
discussed and appropriate measures and safeguards implemented.
Leak shall be managed accordingly with use of spill kit, the line shall be depressurized to
atmospheric pressure prior to any disconnection action being taken.
Prior to any work being carried out, the site supervisor will ensure that communications are
open between the relevant authorized parties involved in the work scope.
Face mask, Disposable Coverall & hand gloves are must during this pandemic. All the
guidelines for COVID 19 to be followed strictly during mobilization, execution & staying on
board.
All works managed and executed by Hydroserv during pre-testing/flushing and testing/flushing
are to be carried out in accordance with the Clinet’s HSE Plans and procedures, which comply
with the Employer HSSE Management Policy and Guidelines.
The mineral oil handling & spillage is dangerous, adequate measures for safety and protection
of environment shall be established.
Moreover, the following precautions must be taken when performing hydraulic oil
testing/flushing activities:
• Pre-commissioning activities will be executed under the Permit to Work Procedure;
• All the personnel involved shall be informed on and be aware of the risks connected
• Dedicated HSE Plan shall be developed by the Hydroserv for the hydraulic testing/flushing
activities in accordance with Contractor HSE Site Plan;
• Hydroserv shall give all the instructions for handling and storage of the hydraulic oils in the
HSE plan; cleaning agents shall be carried in closed containers, drums or tanks;
• Materials Safety Data Sheets (MSDS) should be consulted to determine the hazards of
handling specific oil and Task Risk Assessment session shall be conducted;
• Personnel involved in the flushing activities shall use the personal protective equipment
(PPE) required by the HSE Site Plan (safety hat, safety shoes, safety glasses and safety belt
as required);
• Containers of oils such as drums must be properly labelled;
• An emergency shower with eye wash shall be available to wash away splashed oil in eye;
• Lock Out/Tag Out/Try-Out (LOTOTO) & Blind Management Procedure requirements shall
be strictly followed;
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• All electrical and utilities supplies shall be checked for compliance to service duty needs,
functionality, operability and all necessary protection shall be ensured; All equipment and tools
shall be of suitable capacity, in good condition, certified valid for use, inspected and color
coded as per project standards/procedures;
• The flushing/testing area shall be barricaded, and warning signs shall be posted. Only
authorized personnel shall enter in the barricaded area;
• When necessary, adequate drip pans shall be placed underneath the equipment to avoid
contamination;
• During the oil testing/flushing, all the control and safety valves and the instruments shall be
removed and replaced by a spool piece (if any);
• Before the beginning of any operation, Contractor shall verify and make sure that the material
of the piping system to be cleaned is in compliance with the methodology agreed by all the
parties; Specialized Sub-Contractor shall verify and formally accept the piping system;
A careful scrutiny of certified flexible hoses used in oil testing/flushing operations shall be
carried out;
Whip checks shall be used with flexible hoses.
12. QHSE
Hydroserv shall effectively comply with applicable Contractor and Company HSE
requirements and standards. Those are detailed and developed within Project HSE Plan.
Where policies deviate from Hydroserv policies, Hydroserv should/ shall follow their own as
part of their own corporate administration.
Direct attention shall be put on the following subject:
- PPE policy
- Drug and Alcohol policy
- Medical fitness
- Training, certification and competence
- Operational controls and safe system of work
- Management of changes
- Hazard identification and Risk assessment
- Lifesaving rules
13. METHOD STATEMENT
The scope of flushing assumes on push pull system & testing of hydraulic components
assumes that the high level plans including preparation and definition of resources have been
prepared during the engineering phase, also that the high level plans including preparation of
loops and definition of resources have been prepared during the engineering phase. This
scope covers:
1. General requirements
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2. Equipment for pressure testing & flushing
3. Measuring and controlling devices.
4. Preparation of flushing package
5. Performance of flushing
6. Performance of hydraostatic pressure testing
7. Hold Period
8. Acceptance
9. Documentation & certificates
10. Reference Drawings
13.1. General Requirements
Conduct a TBT prior to any task, conduct site, Material & Equipment Survey to ensure the
area is free from trips and hazards. Ensure all drawings & documentations required are at
hand (or readily available); i.e. drawings, certification, etc. After the work, always ensure
tidiness of the area, removing debris, and conduct a survey to ensure the work area has been
made good.
Before commencing any inspection, test or disconnections/connections on push pull unit,
make sure the work are area free of all trip hazards, dirt, stand, mud and foreign materials.
To ensure system is free from any pressure & push pull unit is on rest prior to any
disconnection.
The test pressure & cleanliness requirements shall be as specified in each piping ISO drawing
or pressure test flow diagram based on Customer or Code requirement.
Test covers; flanges, fittings, bolting and gaskets shall be in good condition and shall be
satisfactory in all respects to withstand the test pressure.
PTW, RTC & TRA in place for the activities included.
Spill kit & plugs/caps for the hoses are in place prior to any disconnection.
Test medium shall be hydraulic oil or system fluid as per system requirements. Clean and free
from silt or not dissolved solids of any description. Where the test fluid is water and there is a
possibility to damage a system due to the freezing or any other adverse effects of water. In
that case another suitable nontoxic liquid may be used. If the liquid is flammable, its flash point
shall be at least 49⁰C, and consideration shall be given to the test environment.
All the equipment and lines, which are to be tested along with the piping, shall be blanked off
or replaced with temporary spool pieces. Any test along the said item shall be approved by
Contractor.
Pressure Testing & Flushing operations shall be executed as defined in the detailed testing &
flushing plan. Ensure that a detailed testing & flushing plan has been prepared, and that it
contains all the required information and drawings.
In this operation, pressure testing & oil flushing is considered for Push Pull System in the
Barge STB 1.
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Ensure that sufficient pump capacity (volume and pressure) is available for testing & flushing.
Ensure all lines and systems tested, flushed, blown, drained and dried, where necessary.
Table for the size & flow is shown in APPENDIX – 1, Table -1
Ensure that the required temporary piping, hose connections, blind flanges, temporary
gaskets, temporary strainers, dummy spools, etc., for flushing, and blowing are installed.
Ensure that all temporary fittings along with filter 1 & 3 µ are removed after completion and
acceptance of the flushing operation.
Verify that lines do not flush through exchangers, instruments, control valves, or rotating
equipment. Ensure that all the control equipment excluded from flushing are removed /
isolated before commencing flushing.
Check that the piping systems/lines have been re-installed with the correct materials and
equipment, as required by the specifications.
All the equipment and lines, which are not to be flushed along with the piping, shall be blanked
off or replaced with temporary spool pieces. Any flush along the said item shall be approved
by Client.
Hydraulic oil Testing/flushing operations shall be executed & will be defined in the detailed
testing/flushing plan in MOS & Hydroserv procedure. Ensure that a detailed leak testing &
testing/flushing plan has been prepared, and that it contains all the required information and
drawings.
In this operation, hydraulic hot oil testing/flushing is considered for Push/Pull Hydraulic
System on Barge STB 1. All the actions performed during oil testing/flushing shall be in
accordance with Hydroserv Method statements and specifications. The following is a typical
oil testing/flushing sequence:
1. Conduct leak test on L.P. & start circulation with hydraulic oil system testing/flushing
pump;
2. Inspect the system for leakages;
3. Start spare pump, to increase circulation flow, if system allows it;
4. Inspect again system for leakages;
5. Hammer the lines during testing/flushing with a rubber hammer, flanged connections
and any other position where dirt/scale may accumulate;
6. Periodically check pressure gauges in order to monitor filters differential pressure
increase;
7. In case of two or more testing/flushing circuit, periodically switch circulation from one
circuit to the other(s) utilizing the valves;
8. Visual check filters for particulates accumulation and lab analyses to ascertain oil
cleanness and
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Physical parameters are within required range (see Acceptance Criteria); if oil is
polluted with water or other materials;
9. Confirm oil cleanness has achieved the acceptance criteria, differently continue with
oil testing/flushing.
13.2. Equipment for Pressure Testing & Oil Flushing
Equipment for pressure testing & flushing shall be properly designed and in good working
order and shall be compatible with the oil, pressure and capacity required during the flush.
Castrol VG46 oil will be used throughout the pressure testing & flushing of the hydraulic
system pipelines.
The following equipment will be provided in order to conduct the pressure testing & flushing
but not necessarily be limited to the following: EX-rated flushing power pack, 380V, 50Hz. For flushing with Castrol VG46 Oil
 EX Rated, External Temporary Electrical Driven Oil Flushing Skid EPU 8B
(200 bar, 250 LPM, 380V/50 Hz.)
 Diesel Driven Hydraulic Power Unit DHU 29 (200 bar, 900 LPM, 380V/50 Hz.
For heater) with Electrical Heater (12 KW)
 Optional Diesel Driven Hydraulic Power Unit DHU 4B (150 bar, 600 LPM)
 External Temporary Filling System Filtration Trolley (40 liter/min) & Certified
Test Pump/Chart Recorder upto 10000 PSI
 Electrical Heater (12 KW), 380V/50 Hz.
 External Oil Reservoir 01 (with electrical heaters) or electrical heater
separately
 Portable ISO11171 particle counter to determine fluid cleanliness (ISO 4406)
220V/50 Hz.
 Sample Bottles & oil spill kits
 Air drier or N2 racks for lines purging upon testing/flushing completion
 Laboratory Portable for analyzation sample
 Supply of 10μm and 3μm Filtration System Cartridges, based on Equipment
Project specifications. All the filter cartridge used during Oil Testing/flushing
shall be replaced,
 All required hydraulic certified flexible hoses/piping to form a circuit with the
Equipment Oil skid & associated fittings (Looping/Delooping, Looping materials
Flanges, Blind Flanges, Spools, and Gaskets)
 All required temporary ball valves, SAE flanges and associated fittings
 All required temporary pressure & return manifold as per the requirement
 Toolbox with all the tools,
 Electrical toolbox with all the tools.
 All the testing & measuring equipment like pressure gauges, temperature
gauges, and flow meters shall be calibrated prior to use at site.
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Pneumatic operated hydro test pump units for pressure testing
Chart recorders
Pneumatic operated filtration trolley
Digital gauges (if required)
Safety relief valve
Adaptors, looping hoses, fittings & flushing manifolds
Certificates for above
Hydraulic Oil with MSDS Castrol VG 46 (4 Barrels)
13.3. Measuring and Controlling Devices
Test pressure-measuring devices shall be either pressure gauges or pressure transducers
and shall be accurate to at least ±1% of full-scale range.
And Pressure measurements shall be made at not less than 15% or more than 85% of the full
pressure span of the gauge and recorder. Pressure measuring devices shall be periodically
recalibrated with a master pressure measuring devices or a deadweight tester. Calibration
intervals shall be a maximum of twelve (12) months.
When it is required by Client to comply with API Specification 6 A / ISO 10423 codes, the
pressure gauges of 3 month calibration intervals shall be provided during the test. Any PSVs
that used for testing must have a calibration certificate of twelve (12) month period valid by
the time of pressure testing.
Hydraulic test pump shall be provided to pressurize the equipment to the specific test pressure
and water or water with additives or process medium shall be used as the testing fluid.
Measuring devices shall be either Flow meter, Particle counters, pressure gauges shall be
accurate & calibrated.
Measuring devices shall be periodically recalibrated, and calibration intervals shall be a
maximum of one year.
Any PSVs that used for testing must have a calibration certificate of one year period valid by
the time of flushing.
The equipment shall be operated only by competent and trained personal.
13.4. Preparation & Flushing/Pressure Testing
Prior to commencement of job identify all the systems to be flushed along with the client, and
further shall determine on number of looping systems to be made depending upon sizes of
tubes / hoses to achieve effective flushing results.
Drawings and procedures identifying individual system loops shall be submitted to the client
for approval. On approval of the procedures and drawings, preparations will for the flushing
operation will begin.
Perform pre job safety meeting and ensure all operations personnel are wearing specific PPE
for the operation. Daily toolbox will be required to sign the attendance sheet identifying their
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understanding of the content of the discussion and what their role involves during the
operation.
All aspects to do with spills, fires and personal contact with flushing fluids will be discussed
and appropriate measures and safeguards implemented.
Area covered under flushing will be barricaded with the barrier tape and indication will be
displayed “PRESSURE TESTING OR FLUSHING UNDER PROGRESS”.
This Job will be covered under PTW system.
Perform pre job safety meeting and ensure all operations personnel are wearing specific PPE
for the operation. Daily toolbox will be required to sign the attendance sheet identifying their
understanding of the content of the discussion and what their role involves during the
operation.
New charts shall be fitted to pressure chart recorders. Test manifold shall be provided in order
to supply water to the system, install pressure gauge, temperature gauge and safety relief
valves set at 5% higher than the test pressure
When the whole length of system to be tested is completely installed and boundaries are
checked by Q.C. The “TEST UNDER PROGRESS” warning signs shall be positioned at
appropriate places indicating that no unauthorized personnel shall be allowed within the test
area.
Pressure is pre-determined by maximum system test pressure. According to provided P&IDs.
Job will be performed in 6-8 loops for the tubings in 5 phases
Hydrotest pump to be used to full capacity pressure testing. Max. pressure testing on this
system pressure lines 300 Bar (4500 PSI)
Size of the external pump/skid shall generate constant high turbulent flow in piping system,
and therefore flushing speed, must be chosen after evaluating the maximum operating oil flow
in the system. Flow of both system pumps parallel operation must be considered to choose
the proper flushing speed. As per pumps data-sheet the maximum operating oil flow in the
system is 270 LPM @50 Bar.
The recommended temperature range for flushing is 40°-60°C. Refer to the lube oil technical
data sheet for any temperature restrictions.
The oil flushing by External Skid System should always be conducted in two stages as a
minimum. These stages are as follows:
13.5. Performance of Hydraulic Oil Flushing
The flushing shall be carried out after pressure testing. Equipment that are relatively sensitive
to damage shall be removed, or isolated during performing oil flushing. The purpose of oil
flushing is to ensure satisfactory operation of oil system by removing foreign matters which
may have been collected inside pipe lines of the system during outfitting work, in addition to
increase the usable period of system oil and to prevent deterioration of the system
components. Flushing is to clean the system lines from debris or any foreign matters that may
have come /accumulated in during erection and fabrication stage.
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System oil will be circulated by flushing pump or system pump, with the flow velocity to be
turbulent according to Reynolds Number (Re > 4,000). The maximum allowable contamination
after flushing shall be in accordance with NAS 1638 class 6 (ISO 4406 code 15/12). System
cleanliness shall be confirmed by electronic
particle counting, and a standard of not less than NAS 1638 class 6 (ISO 4406 code 15/12)
shall be achieved.
After a predetermined time a further sample is to be taken. If sample is up to the specification
then flush of the loop is complete. If not then flush is to be continued until 2 consecutive
samples taken at the predetermined time intervals to meet the specifications or better. The
procedure is to be repeated until all the loops in the flushing pack have been flushed to the
specifications.
Oil flushing boundary and flow marked up P & ID shall be prepared before flushing by the
Prior to flushing the system, all interconnection hoses will be flushed and initial oil will
be removed (if required).
Once procedure approval has been received, begin preparing the system loops according to
the approved system loop drawings. Interconnecting the system lines along with the flushing
skid and flushing procedure will be followed.
Any open connections will be blanked off and every effort will be made to prevent ingress of
contamination at all times during the flushing program.
It is essential to create a turbulent flow, which is determined by the Reynolds (Re) number.
For effective flushing, the minimum Re should be 4000. In this case as per client requirement,
Reynold Number is considered as 10000.
Obtaining the correct flow is critical to the removal of solid particulate contamination in
hydraulic fluid systems. For calculation of correct flushing flow and pressure drop, we will be
using the below-mentioned standard formula.
Depending on the viscosity of the system fluid, and pipe work sizes, it may (in some situations)
be necessary to raise the temperature of the system fluid. Raising the temperature will reduce
the fluid viscosity and help enable turbulence to be achieved.
Piping loops are calculated separately, to allow a complete flushing circuit. A unit is then
selected for that specific part of the system pipe work
The following formula will be utilized to determine velocities to be achieved during the flushing
operations:
Q = Re x V x D
21220
Q = Flow Rate (litres/min)
V = Fluid Viscosity (cst)
D = Pipe Inside Diameter (mm)
Re = Reynolds Number (4000)
Re = U x D x 1000
V
U = Velocity (metre / sec)
D = Pipe Inside Diameter (mm)
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V = Fluid Viscosity (cst)
P = Q 1.75 x V 0.25 x SG x L
1270 x D 4.75
P = Pressure Drop (PSI)
Q = Flow Rate (GPM)
V = Fluid Viscosity (cst)
SG = Specified Gravity of Fluid
L = Pipe Length (feet)
D = Pipe inside Diameter (inch)
In any flushing operation, the most important filter is that on the return line, just prior to the
reservoir. Industry practice states that generally contamination is most likely to be
accumulated at this point.
NAS Class levels are controlled by internationals standard such as ISO 4406 or NAS 1638.
Beta rated elements are required to meet the contamination removal specifications. 3-micron
absolute filters on all flushing units are required as standard requirements to achieve NAS
class 6 or better cleanliness level.
Portable particle counting machines calibrated as per ISO 11171 are utilized to determine the
NAS Class level during flushing operations. Results are printed out at the time of the sample
analysis.
Sample valves are fitted upstream on the filter return line, which are used to monitor the NAS
Class levels during the flushing operation.
At the start of the flushing operation and with the use of flushing flow paths indicated on system
schematics and flow rates as calculated, flushing will continue for a minimum period of 3 hours
before a sample is taken for analysis.
At any point during the flushing operation, if the sample is not within the required specification
NAS Class level, flushing will continue until the required NAS Class level is achieved. Once
the required NAS Class level, as per NAS 1638 is achieved, flushing will continue for about 12 hours after which the flushing operation will cease.
On completion of the flushing operation, oil from the flushed systems can be purged
completely with filtered dry air or nitrogen as per client’s instruction. Flushed systems will be
re-instated or blanked off as required.
After all preparation work is complete to the satisfaction of the supervisor, toolbox talk held
and risk assessments implemented, the flushing may commence using the following:
1. The individual system documentation i.e. flushing & testing pack shall be available prior to
any flushing/testing and shall include information such as limits, max pressure, medium,
acceptance criteria.
2. The use of marked up P&IDs coupled with isolation registers should be utilized to identify
the locations of blinds, valves, vents and drains.
3. Flushing & testing equipment such as pumps, hydro test pumps, manifold, pressure gauges,
chart recorders should be within calibration/certification (as per company procedures)
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4. Barriers shall be erected and where practical, Public Address announcements made and
access restriction procedures such as permit to work implemented prior to any process
commencing.
5. Under no circumstances should anyone other than an authorized person be allowed within
the safety barriers.
6. Low pressure pneumatic tests to be performed prior to start of flushing process, any leaks
to be rectifies.
7. Specify sampling points to be used for condition monitoring - during flushing and in-service
8. The flushing & pressure testing should be witnessed and accepted by client representative
or a responsible person within the company and signed as accepted
13.6. Performance of Hydrostatic Pressure Test
PRESSURIZATION
All test equipment & looping hoses will be pre-tested to ensure tightness and integrity of all
temporary connections.
The lines to be tested will be filled using a high flow pump possibly flushing units or air driven
diaphragm pump. All vents and other connections which can serve as pressure test vents
shall be open during filling so that air can be vented prior to applying test pressure to the
system.
On completion of the filling, the pressurization pump shall be started and any trapped air
vented. When only test fluid is being emitted the pump shall be stopped then the bleed valve
closed.
Pressurization of the system under test will be carried out in a steady and controlled manner
(subject to pipe-work specifications) in increments of 25% of the final test pressure. While the
system is being pressured all weld joints will be visually inspected for any leakage.
The pressurization will proceed to 75% of the test pressure when the pressure pump shall be
stopped and the isolation valve closed. Safe leak check on test connections will be carried
out. On completion of a successful leak check pressurization will recommence to test
pressure.
On reaching the specified test pressure the pressurization pump shall be stopped and isolated
by valves from the system under test. The system shall be kept under test pressure for the
specified hold period.
After hydrostatic testing of the system is completed, System can be depressurized till design
or maximum allowable pressure level and a thorough leak check shall be repeated on all
system which is under the test.
Then the final depressurization can be continued in stages of 25% and then all lines and
equipment shall be drained completely. The system shall be vented while draining to avoid
vacuum.
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13.7. Hold Period
All pressure tests must be witness and report to be endorsed by Client rep or TPI (if required).
Following a satisfactory stabilization period, the hold period of 30 Minutes may start on
satisfactory completion. The pressure chart will be signed by the site supervisor; the client’s
representative and a third party if applicable.
13.8. Acceptance
The hydrostatic test shall be considered positive if test pressure has kept a constant value
throughout the specified hold period, except for change due to temperature difference and if
there is no leakage during the test. Test report to be endorsed by Client.
The hydrostatic test at high or low pressure shall be acceptable if the pressure change
observer on the pressure-measuring device is less than 5 % of the test pressure or 34.5 bar
(500 PSI) whichever is less, as per API 6A / ISO 10423.
If test section fails to maintain the specified test pressure due to leakage, the location of
leakage to be located and necessary action to be carried out. After completion of repairs, the
hydrostatic test shall be repeated in full, as per the specification.
When the test is completed, the following records shall be signed by all parties attending the
test shall be part of the test documentation.
13.9. Documentation & certificates
On completion of all flushing operations, documentation with valid equipment certification will
be consolidated into a final report for Client approval.
– Hydroserv flushing & testing certificates.
– Original oil analysis report from particle counter.
– Copies of calibration certificates
– Marked P&IDs where applicable
13.10. Reference Drawings
Pressure Testing & Tubings Flushing of PRS System Pipelines as per Drawing#

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•
•
Pressure test & Flush (PRESSURE LINES ) A & B Travel Cylinders CS hydraulic
tubing. Tubing runs are as shown on Drawing No. I 021-03-200 & . I.21-00-100
Pressure test & Flush (RETURN LINE) CS hydraulic tubing. Tubing runs are as
shown on Drawing No. I 021-03-200.& I.21-00-100
Pressure test & Flush (PRESSURE LINE) Main/Aux. Jack CS hydraulic tubing.
Tubing runs are as shown on Drawing No. I.21-00-100
Offline Filtration of the HPU main & pilot reservoirs as per Drawing . I 21-05-200
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•
Cap off tubing following completion of flushing and testing
•
Below stages & loops are considered based on drawings provided by client. These
stages & loopings can be reduced/modified based on practical routings on board &
back pressure while flushing
14. FLUSHING & PRESSURE TESTING PROCESS FOR THIS SPECIFIC SCOPE
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Ensure system pressure is isolated & lines are drained off or drip tray been utilized during
any disconnections for cathing the oil
Removal of tubings/piping end connections from the system push/pull system PORT &
STBD Sid/HPU/Control/Components and carry out loopings
Ensure that the tubings/pipings are dry without any water content and without any other
medium of fluid internally which could mix with the flushing oil and make it difficult to
achieve cleanliness required (All the above scopes considered to be carried out after
completions of chemical cleaning of the pipelines & drying)
Removal of tubings/piping end connections from the all 4 skids (PORT & STBD)
cylinders/jacks lines and carry out loopings
Fill flushing equipment reservoir with Hydroserv provided oil as per required oil grades of
oil
Loop the tubings and ensure that the filter elements (flushing unit) are in place where
intended
Connect the tubings inlet & outlets to flushing equipment
Carry out dry air test (max 4 bar) to ensure no leakage in the loop
If any leakage arrest leak and carry out air test till all leaks are prevented
Conduct pressure testing as per the specifications on each system tubings
After successful completion of pressure testing & approved, proceed for flushing
Connect particle counter to planned ports for sample analysis online (this online method
will allow constant particle counting without sampling).
Follow the flow requirement as per table shown in Appendix 1.
Once cleanliness code is achieved, inform client for witnessing the particle count as well
as the filters installed.
Once approved & oil is on desired cleanliness level & free from any visual particles and
accepted by client, stop flushing
Use dry air/nitrogen to purge the oil from the loop to flushing equipment reservoir
Once no level change is noted in the reservoir, carry out de-looping
Connect back each tubings wherever removed & closed open ends with proper duct
tapes / masking tapes
Follow the above process for other loops.
Simultaneously ensure that the flushed & tested tubings are reinstated back to the
system one by one without allowing any dirt ingress and keep closed the ports which
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remains open awaiting for other spools which are under flushing process and to be
connected later
15. EQUIPMENT UTILITY REQUIREMENTS
–
–
–
–
–
Electricity - 380 volt, single phase, 50 hz
Air - 7 to 8 bar
Diesel - 500 liters per day
Particle counter 220V
Volume of the flushing oil required as provided
INSTRUMENTS / ACCESSORIES TO BE OMITTED WHILE FLUSHING:
16. PNEUMATIC TESTS
Prior to Flushing, low pressure Pneumatic test may be applied for looped lines and test
pressure shall not exceed 4 bar / System pressure, whichever is less.
The pressure shall be increased gradually until a gauge pressure 1bar is attained and held for
5 minutes by isolating feed valve, preliminary leak can be identified if in case of pressure drop.
The pressure shall be then increased in 1 bar steps, up to 4bar if below, as per system
requirements. Once confirmed for zero leaks on the flushing loop the pressure can be
depressurized and proceed with the Flushing.
17. ACCEPTANCE
The Flushing & Pressure Testing shall be considered positive if the specified NAS
classification levels & tested charts as agreed with the customer. Flushing & testing reports to
be endorsed by the customer.
When the pressure testing is completed, the following records shall be signed by all parties
attending the test shall be part of the test documentation.
For Pressure & A & B Hydraulic Tubings – 350 BAR (Working Pressure) & hold for 30
minutes.
For Return/Drain Hydraulic Tubings – 75 BAR (50 x 1.5 Times) & hold for 30 minutes.
For Pneumatic Tubings – 15 BAR (13.8 x 1.1 Times) & hold for 10 minutes. (If Any)
When the flushing is completed, the following records shall be signed by all parties attending
the test shall be part of the test documentation.
For All the System Hydraulic Tubings – ISO 4406: 1999 15/12 minimum NAS 1638 - class 6
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18. HYDRAULIC POWER UNIT & COMPONENTS FINAL OPERATIONAL TESTING &
INSPECTIONS
Two diesel/hydraulic power units are used to supply hydraulic power to the skid units. The
main hydraulic pumps are mounted to the fly wheel side of the engines with flexible
couplings. If one of the power unit fails, the other unit will automatically take over the
operation of all 4 skid units at half speed.
‐ Diesel engine = Deutz
o N° of engine = 2
o Output rating = 2 x 240 kW at 1800 rpm
‐ Hydraulic pumps = Poclain
o Output rating = 2 x 316 l/min at 1800 rpm
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Operational testing as per operating manual procedure
Hydraulic pump visual inspections for any leaks during testing
Hydraulic cylinders (travel, gripper & swivel) visual inspection including piston rods
& OD conditions, during final testing
Visual inspections for oil leaks on complete system
Controls/pilot visual inspections & records of parameters while test
Leak checks
Oil cooler/heat exchanger visual checks
Main pressure relief valve existing setting checks
Pilot pressure check & existing relief setting during final testing
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Pressure testing of the cylinders (travel & gripper) upto system max. relief setting
pressure
Main gripper & aux. gripper pressure hold test (total 72+08 Nos.)
Travel cylinders pressure test (dynamic) with max. system pressure on both retract
& extend sided (total 08 Nos.) with system running
Travel cylinders speed test & stroke measurements
Accumulator nitrogen pre charge test (if available)
STARTING UP THE SYSTEM (OPERATOR ASSISTANCE FROM BARGE CREW)
For starting of the equipment following steps should be followed:
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Fuel supply “Opened” and Fuel level checked
Condensation water drained
Hydraulic oil main tank level checked & Hydraulic oil aux. tank level checked
Hydraulic oil cleanliness analysis is done utilizing Hydroserve inline or offline
particle counters
Engine oil (sump) level checked (both engines)
Operation levers of hydraulic controls all in “neutral” position
Check battery terminals & alternators V-belts
Air intakes free & Exhaust covers free
Main switch “in” (under cover seat)
Throttle completely open
All control lamps on
Start engine (one after the other)
Throttle back to idle speed, all control lights off
Lube oil pressure “normal” and system oil pressure hydraulics “normal”
After starting of both engines, the hydraulic oil separation cylinder shall be filled
up. In the engine room, at the aux. pump, the system shall be switched on until
the max. pressure is reached. Power pack is now ready to operate. All hydraulic
hoses from power pack to Push/Pull units and Push/Pull units should be visually
inspected. Operation can start.
Notes:
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Throttles will be opened to approx. 2000rpm for operation
As a safety precaution, the hydraulic system is arranged so only one of the
Main grippers or Auxiliary grippers can be applied at the time.
When the main grippers are engaged, the aux. grippers will automatically be
released
After working pressure is obtained at the grippers, levers can be set in “neutral”
before using travelling cylinders
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All pressures of parts shall be read/verified from the control cabin during
operation
If one of the engines fails or shut down the skidding operation can continue at
half speed, without specific action by operator
If any leakage occurs at one of the gripper jacks, such jack can be locked with
a blind plug bolt (Availability of those onboard TBC)
The 2 x Portside and 2 x Starboard side units are operated separately.
Operator to activate both simultaneously.
OPERATING THE SYSTEM
Ensure push pull system’s hydraulic oil, engine oil & diesel for system engine is
filled & upto the operating level. All this consumables to be arranged by client if
needed to replenish. Operator assistance required from Client to operate push pull
system.
Pushing:
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Start : Skid Jack retracted
Main gripper Jack -> « Gripped »
Travelling cylinders -> « Push » (swivel plates are pushed forward by the
travelling cylinders)
Aux. grippers -> “Gripped”
Main gripper -> “Loose”
Travelling cylinders -> « Pull » (Main gripper body is pulled forward towards the
swivel plates)
Step 1 to 5 is a complete cycle of 1 m and can be subsequently continued along the
total length of the track. In the case of a Jacket launch and based on the fact that
units are positioned ready to push (Swivel plate in vicinity of Jacket jacking points),
Step 1 and 2 will initiate the launch.
Pulling:
In the pulling mode, the swivel plate shall be connected to the jacket by bolts and pull
bars.
 Start : Skid Jack retracted
 Aux. grippers -> “Gripped”
 Travelling cylinders -> « Push » (Gripper bodies will be pushed back, away
from swivel plates)
 Main gripper Jack -> « Gripped »
 Aux. grippers -> “Loose”
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Travelling cylinders -> « Pull » (Swivel plates are pulled backwards, towards
the main grippers bodies)
Step 1 to 5 is a complete cycle of 1 m and can be subsequently continued along the
total length of the track.
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18.1. Travel Cylinders Measurement
Two main travelling cylinders for each skid unit with a capacity of 2 x 250 tons (Total 08
Nos.) to confirm below Barrel OD piston/rod = 360/180 mm
 Stroke = 1000 mm
 Work pressure push/pull = 245/327 bar
 Average speed = 0,35 m/min
 Pushing = 12 mm/sec
 Pulling = 16 mm/sec
18.2. Travel Cylinders Test
PORT & STBD travel cylinders will be final operational tested with system.
Start up the system & conduct the hydraulic jack testing on extend upto the max. Pressure
setting of system, as per Hydroserv procedure HCL-OP-PRO-002. Also to check the spring
return action of the jacks
18.3. Main Gripper Jacks Measurement
The main gripper bodies (2 per unit) are provided with single acting spring released
hydraulic jacks (Total 72 Nos.)
Hydraulic Gripper Jacks.
 OD gripper jacks = 180 mm
 Work pressure = 350 bar
 Stroke (min/max) = 10/13 mm
18.4. Main Gripper Hydraulic Jack Test
PORT & STBD main gripper jacks will be final operational tested with system.
Start up the system & conduct the hydraulic jack testing on extend upto the max. Pressure
setting of system, as per Hydroserv procedure HCL-OP-PRO-002. Also to check the spring
return action of the jacks
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18.5. Aux. Gripper Jacks (Swivel Plates)
The swivel plate is equipped with auxiliary grippers jacks which allow for independent
travelling of the skid unit along the skid beam (Only), Total (08 Nos.)
 OD aux. gripper jacks = 100 mm
 Work pressure = 350 bar (TBC mismatch info -> 200 or 350 bar?)
 Stroke (min/max) = 15/20 mm
18.6. Aux. Gripper Hydraulic Jack Test
PORT & STBD aux. gripper jacks will be final operational tested with system.
Start up the system & conduct the hydraulic jack testing on extend upto the max. Pressure
setting of system, as per Hydroserv procedure HCL-OP-PRO-002. Also to check the spring
return action of the jacks
Essential note: If there are any unsafe point covering during the hose replacement, stop the
job and report (on paper and in words) immediately to project supervisor and authorized
people.
D i gi t al l y s iDg at e: 2 019 .1 0 .0
11 :59 :26 + 01' 0
D at e: 2 019 .1 0 .02 1 2:39 :3
19. DOCUMENTATION & CERTIFICATES
On completion of all pressure testing, flushing operations & final operational testing,
documentation with valid equipment certification will be consolidated into a final report for
Client approval.
– Hydroserv flushing & testing certificates.
– Original oil analysis report from particle counter.
– Copies of calibration certificates
– Marked P&IDs where applicable
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20. PUSH PULL SYSTEM REFERENCE DRAWINGS
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APPENDIX 1 – FLUSHING GUIDELINES
FLOW CALCULATION FOR PUSH PULL HYDRAULIC SYSTEM HYDRAULIC TUBINGS FLUSHING WITH VG46 OIL
& Re≥4000- METRIC TUBES
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FLOW CALCULATION FOR PUSH PULL HYDRAULIC SYSTEM HYDRAULIC TUBINGS FLUSHING WITH VG46 OIL &
Re≥4000- INCHES PIPES
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Viscosity & Temperature Graph VG 46 Oil-
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APPENDIX 2 – PRE FLUSHING CHECKLIST
PIPEWORK PRE – FLUSH CHECKLIST
Customer Name:
Subcontract Name:
Location / Site:
Ref No:
System Name:
Line Description:
Line No:
P&ID No:
Yes
1 Check correctness of the flushing loop with marked P&IDs
2 Check that the correct fittings and gaskets are installed at mechanical joints
3 Check the ratings of fittings and temporary hoses
4 Check that all pressure connections are installed correctly as per specification
5 Check pressure gauges calibration is correct
6 Check particle counter calibration is correct
7 Valves within test limits to be opened
8 Ensure the sampling point is installed in the return line (before filter)
9 carry out low pressure pneumatic test to ensure no leak in connections
10 Check flushing medium for conformity to line specification
11 check the flushing area is properly barricaded and warning signs are placed.
12 A valid Permit to work is required prior to start the flushing
13 Ensure flow meter is installed in the supply line
14 Spill kits and trays to be in place.
15 Ensure dry air supply line is available nearby to purge the flushing fluid back to tank
REMARKS:
Completed By:
Company:
On Behalf Of:
Name:
Date:
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APPENDIX 3 – POST FLUSHING CHECKLIST
PIPEWORK POST – FLUSH CHECKLIST
Customer Name:
Subcontract Name:
Location / Site:
Ref No:
System Name:
Line Description:
Line No:
P&ID No:
Yes
1 Check that flushing have been satisfactorily completed and recorded
2 Check drainage / purging of lines complete and accepted
3 Check all temporarily connection / components removed while flushing are
installed back
4 Ensure all open ports are properly covered and protected
5 Ensure all barricades and warning signs are removed after completions of task
6 Ensure proper records / reports and documentations are made and signed off
FOR ITEMS MARKED “NO”RAISE PUNCH LISTS
REMARKS:
Completed By:
Company:
On Behalf Of:
Name:
Date:
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APPENDIX 4 – FLUSHING REPORT SAMPLE
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Test Chart
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APPENDIX 5 – JOB SCHEDULE FOR HOSES RENEWAL, PRESSURE TESTING,
HYDRAULIC HOT OIL FLUSHING, OFFLINE FILTRATION
OPERATIONAL TESTING OF THE PUSH PULL UNIT ON STB 1
&
FINAL
JOB PLANNED SCHEDULE FOR PUSH PULL HYDRAULIC SYSTEM PIPELINES
PRESSURE TESTING, FLUSHING, MPI & OFFLINE FILTRATION
S.No
1
2
3
4
5
6
7
8
9
10
11
Description
Saftey induction and pre
flushing inspection
Pre flushing inspection
Hydraulic Hoses Removal
on PORT Side
Hydraulic Hoses Removal
on STBD Side
Hydraulic Hoses Renewal
on PORT Side
Hydraulic Hoses Renewal
on STBD Side
MPI of Structures for all 4
Skids
Looping - 1st Phase PORT
Outward
Pressure Testing & Flushing
of - 1st Phase- PORT
Outward
Sample Analysis & Mesh
witnessing - 1st loop- PORT
Outwatd
Nitrogen Purging,
Delooping &
Reinstatement- 1st loopPORT Outward
Week 1
Week 2
Week 3
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Week 5
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12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
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Looping - 2nd Phase &
Testing- PORT Inward
Flushing - 2nd loop- PORT
Inward
Sample Analysis & Mesh
witnessing - 2nd loop- Loop
Inward
Nitrogen Purging Delooping
& Reinstatement - 2nd
loop- PORT Inward
Looping – 3rd Phase &
Testing- STBD Inward
Flushing - 3rd loop- STBD
Outward
Sample Analysis & Mesh
witnessing - 3rd loop- STBD
Outward
Nitrogen Purging,
Delooping & Reinstatement
- 3rd loop- STBD Inward
Looping – 4th Phase &
Testing
Flushing – 4th loop- STBD
Inward
Sample Analysis & Mesh
witnessing – 4th loop- STBD
Inward
Nitrogen Purging,
Delooping & Reinstatement
– 4th loop- STBD Inward
Nitrogen Purging
Sample Analysis & Mesh
witnessing – 4th loop
Delooping & Reinstatement
– 4th loop
HPU Cleaning & Offline
Filtrations
28
Final Testing on Push Pull
System
29
Demobilisation of
Equipments
D Day shift
N Night Shift
This is estimated plan - subjected to correction based
*
on actual condition of execution on site.
Note: For any Components Removal/Refit, Separate Job Schedule will be Prepared based on this
initial inspection & test carried out on STB 1
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APPENDIX 6 – Daily Progress Report (Draft Only)
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APPENDIX 7 – Task Risk Assessment (Draft Only)
TRA FOR PUSH PULL UNIT (HOSES DISCONNECTIONS/CONNECTIONS & HYDRAULIC COMPONENTS
REMOVAL/REFIT)-
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TESTING OF PUSH PULL SYSTEM
CONFIDENTIAL
UNCONTROLLED WHEN PRINTED
Doc No: HCL-OP-PEP-002
Issue Date: 31.01.2022
Revision Date: 07.02.2022
Revision No: 01
Page: 52/61
PROJECT EXECUTION PLAN FOR
PRESSURE TESTING, FLUSHING,
FILTRATION ON HPU & FINAL
TESTING OF PUSH PULL SYSTEM
CONFIDENTIAL
UNCONTROLLED WHEN PRINTED
Doc No: HCL-OP-PEP-002
Issue Date: 31.01.2022
Revision Date: 07.02.2022
Revision No: 01
Page: 53/61
PROJECT EXECUTION PLAN FOR
PRESSURE TESTING, FLUSHING,
FILTRATION ON HPU & FINAL
TESTING OF PUSH PULL SYSTEM
TRA FOR HIGH PRESSURE TESTING-
CONFIDENTIAL
UNCONTROLLED WHEN PRINTED
Doc No: HCL-OP-PEP-002
Issue Date: 31.01.2022
Revision Date: 07.02.2022
Revision No: 01
Page: 54/61
PROJECT EXECUTION PLAN FOR
PRESSURE TESTING, FLUSHING,
FILTRATION ON HPU & FINAL
TESTING OF PUSH PULL SYSTEM
CONFIDENTIAL
UNCONTROLLED WHEN PRINTED
Doc No: HCL-OP-PEP-002
Issue Date: 31.01.2022
Revision Date: 07.02.2022
Revision No: 01
Page: 55/61
PROJECT EXECUTION PLAN FOR
PRESSURE TESTING, FLUSHING,
FILTRATION ON HPU & FINAL
TESTING OF PUSH PULL SYSTEM
CONFIDENTIAL
UNCONTROLLED WHEN PRINTED
Doc No: HCL-OP-PEP-002
Issue Date: 31.01.2022
Revision Date: 07.02.2022
Revision No: 01
Page: 56/61
PROJECT EXECUTION PLAN FOR
PRESSURE TESTING, FLUSHING,
FILTRATION ON HPU & FINAL
TESTING OF PUSH PULL SYSTEM
CONFIDENTIAL
UNCONTROLLED WHEN PRINTED
Doc No: HCL-OP-PEP-002
Issue Date: 31.01.2022
Revision Date: 07.02.2022
Revision No: 01
Page: 57/61
PROJECT EXECUTION PLAN FOR
PRESSURE TESTING, FLUSHING,
FILTRATION ON HPU & FINAL
TESTING OF PUSH PULL SYSTEM
TRA FOR FLUSHING-
CONFIDENTIAL
UNCONTROLLED WHEN PRINTED
Doc No: HCL-OP-PEP-002
Issue Date: 31.01.2022
Revision Date: 07.02.2022
Revision No: 01
Page: 58/61
PROJECT EXECUTION PLAN FOR
PRESSURE TESTING, FLUSHING,
FILTRATION ON HPU & FINAL
TESTING OF PUSH PULL SYSTEM
CONFIDENTIAL
UNCONTROLLED WHEN PRINTED
Doc No: HCL-OP-PEP-002
Issue Date: 31.01.2022
Revision Date: 07.02.2022
Revision No: 01
Page: 59/61
PROJECT EXECUTION PLAN FOR
PRESSURE TESTING, FLUSHING,
FILTRATION ON HPU & FINAL
TESTING OF PUSH PULL SYSTEM
CONFIDENTIAL
UNCONTROLLED WHEN PRINTED
Doc No: HCL-OP-PEP-002
Issue Date: 31.01.2022
Revision Date: 07.02.2022
Revision No: 01
Page: 60/61
PROJECT EXECUTION PLAN FOR
PRESSURE TESTING, FLUSHING,
FILTRATION ON HPU & FINAL
TESTING OF PUSH PULL SYSTEM
CONFIDENTIAL
UNCONTROLLED WHEN PRINTED
Doc No: HCL-OP-PEP-002
Issue Date: 31.01.2022
Revision Date: 07.02.2022
Revision No: 01
Page: 61/61