SAUDIARAMCO
NAME:
I DATE:
APPROVAL
EWRB1-QUAL-HTP-O10-PL
Hydrotest Procedures-Rev-8
1
PURPOSE
4
2
SCOPE
4
3
REFERENCE
4
4
DEFINITIONS
5
5
RESPONSIBILITIES
5
6
ORDER OF PERFORMANCE
6
7
INSTRUMENT CALIBRA TION
6
7.1
Calibration General Requirements
6
7.2
Pressure Reference Instrument
7
7.3
Calibration Procedure ( Pressure Gauges & Pressure Recorders
7
7.4
Calibration Procedure (Relief Valves)
8
7.5
Calibration Documentation
8
8
DESCRIPTION OF TEST SECTIONS
8
9
SAFETY PRECAUTIONS
9
TEST PREPARATION
10
10
10.1
Cleaning and Gauging
10
10.2
I
Installation
of Test Headers
10
10.3
I
Line
Preparation and Filling
Short Sections to be gravity filled
Long Sections to be filled with Scrapers
10
10
10
Equipment and Instruments for Hydrostatic Test
Pump Station Equipment and Instruments
Hydrotest Equipment and Instruments
Dewatering Equipment
Drying Equipment
12
12
12
12
Pressure Test General Requirements
13
10.3.1
10.3.2
10.4
10.4.1
10.4.2
10.4.3
10.4.4
10.5
1",
.,UVI
, .JRO TEST PROCEDURES FOR PIPELINE SECTIONS
12
13
11.1
General
13
11.2
Temperature Stabilization
13
11.3
Strength and Tightness Test of Pipeline
14
12
HYDROSTATIC TEST OF ABOVE GROUND PIPING
12.1
General
16
16
EWRB 1-QUAL-HTP-O1 O-PL Hydrotest Procedures-Rev-B
12.3
Strength and Tightness Test
13
TEST ACCEPTANCE
14
CALCULATIONS
15
GENERAL
16
17
18
REQUIREMENTS
AFTER PRESSURE
16
PROCEDURE FOR LOCA TING AND REPAIRING
DURING HYDROSTA TIC TESTING
17
TEST
20
LEAKS OR FAILURE
20
21
DEWA TERING OF PIPELINE SECTIONS
17.1
General
21
17.2
Safety Requirements
17.3
Evaporation Ponds and Disposal Piping
21
21
17.4
Dewatering Procedure
22
17.5
Pipeline Drying After Dewatering
22
18
CALIPER SURVEY
19
INTELLIGENT
20
FINAL PIPELINE DRYING
23
SCRAPING
23
TOOL
24
APPENDIX A -Hydrotest
Schedules
25
APPENDIX
B -Chemical
MSD Sheets
26
APPENDIX
C -Hydrotest
Drawings
APPENDIX D -Safety
APPENDIX E -General
APPENDIX
F -Hydrotest
APPENDIX
G -Water
Instruction
Instruction
& Equipment
Layout
Sheets
28
(GI)
29
Waivers
Disposal
27
Approval
30
31
Form
EWRB1-OUAL-HTP.i)10-PL
Hydrotest Procedures-Rev-B
1
PURPOSE
The purpose of this procedure is to define the actions required and responsibilities
associated with the cleaning and gauging, filling, pressure testing, dewatering,
drying, caliper scraping and intelligent scraping of the newly installed pipeline and
piping sections of the 36-inch Rabigh pipeline.
2
SCOPE
The scope of this procedure includes the pipeline, short sections of pipe without
valves, the scraper launcher station & scraper receiver station and does not include
the intermediate mainline valve assemblies. Refer EWRB1-QUAL-VTP-O17 for the
mainline valve assembly testing.
3
REFERENCE
Hydrotest drawings
VA-369070,
Hydrotest drawings
VA-369071 , Sheet 001 to 004
Hydrotest drawings
VA-369072 , Sheet 001
Hydrotest drawings
VA-369073,
Scope
of Work
Approved
for Rabigh
Hydrostatic
pipeline
Sheet 001 to 002
Sheet 001
pressure
testing
Test Waivers
SIS (Safety Instruction Sheets)
EWRB1-QUAL-PQP-001
Project Quality Plan
EWRB1-QUAL-PQMP-210
Pressure Testing
SAES-A-004
Pressure Testing
SAES-A-007
Hydrostatic Fluids and Lay-Up Procedures
SAES-L-056
Pressure testing of plant piping & pipelines
G.I.2.102
Pressure Testing Safely
G.I. 2.1 02-Att-1
Checklist for Pressure Testing Safely
G.I.432.000
Pipeline Hydrotest Water Disposal
GI 2.100
Work Permit system
GI 2.711
Fire and safety Watch
SAEP-302
Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco
Engineering Requirements
SAEP-31 0
Pipeline Repair and Maintenance
EWRB1-QUAL-HTP-O10-PL
H~rotest
Procedures-Rev-B
.
4
DEFINITIONS
Hydratest Package:
The hydrotest package is a document specific to each
hydrostatic test section. The package includes the
following.
Index Sheet
Hydrotest Drawings
Hydrotest Schedule
Safety Instruction Sheets (SIS Sheets)
Pipelog Book / Weld Map
NDT Summary
Approved Waivers (If applicable)
Each hydrostatic test package shall be reviewed
approved by SAPMT & P.1.0. prior to conducting
and
any
hydrostatic testing.
SIS Sheets
5
Saudi Aramco Safety Instruction Sheets define the pipe
and fitting data used in the construction of the pipeline
together with initial hydrostatic test pressure and test
date. The SIS sheet should be updated with the latest
hydrotest data.
RESPONSIBILITIES
Construction Mgr
Construction Manager shall ensure that all personnel
involved in pipeline hydrotest activities are aware of the
requirements of this procedure and he shall ensure that
they are implemented.
Hydrotest Supervisor
Hydrotest supervisor must follow the requirements of
this procedure and the relevant Saudi Aramco
standards to ensure that all hydrotest activities are
completed as per the requirements of the hydrotest
drawings and QC Plan, to the Satisfaction of Saudi
Aramco.
QA/QC Manager
Project QA/QC Manager
or QC Supervisor
shall
monitor all hydrotest activities to ensure that they are
performed it accordance with this procedure, hydrotest
drawings, QC Plan and Aramco Standards.
EWRB1-QUAL-HTP-o10-PL
Hydratest Procedures-Rev-B
6
QC Inspector
Witness all hydrotest activities as per the requirements
of this procedure, hydrotest drawings, QC Plan and
Aramco Standards
Technical Clerk
He shall file all hydrotest records and maintain status of
sections completed and outstanding.
ORDER OF PERFORMANCE
1.
Perform cleaning and gauging of new pipeline sections
requirements of the procedure EWRB-1-QUAL-CAG-O15.
as per the
2.
Install temporary test headers at the termination points detailed in the relevant
hydrotest diagrams.
3.
Fill the piping with testing fluid.
5.
Perform the pressure test.
6.
On completion of pressure test, dewater the piping using scrapers (if used for
filling) or by draining (for short sections).
7
Remove the test headers and either tie-in to adjoining section or install
temporary headers for drying.
8.
Dry pipeline sections to -1 C prior to installation of valve assemblies and tie in
to scraper facilities (unless the scraper facilities are used for launching drying
scrapers).
7
INSTRUMENT CALIBRATION
Calibrate pressure gauges, pressure recorders and pressure relief valves using a
laboratory calibrated dead weight-tester ( D.W. T. ).
7.1
Calibration General Requirements
The Contractors
site personnel shall carry out all on-site calibrations.
All instruments that will be used for testing shall be calibrated on site using a
laboratory calibrated D.W.T. Calibration shall be witnessed and signed by
Saudi Aramco Inspection Representative or Saipem QC Inspector.
Calibration for gauges and relief valves shall be recorded on a certificate as
well as a sticker/tag to be attached to the instrument.
All relief valves shall be set at 105% of strength test pressure. This set
pressure shall be valid for both strength test and tightness test.
All documentation shall be on site for inspection review.
EWRB1-OUAL-HTP-O10-PL
Hydratest Procedures-Rev-B
.
Relief valves are to be set no more than one week prior to the test for
which they shall be used.
Pressure gauge calibrations to be checked no more than one month prior
to the test for which they shall be used.
Calibration validity of pressure recorder and temperature recorder shall be
a maximum of 6 months.
7.2
Pressure Reference Instrument
Bench mounted dead weight tester and weights shall be calibrated and
certified by a Saudi Aramco approved laboratory, verified by current
calibration certificate and attached sticker. The calibration validity shall not
exceed 6 months.
7.3
Calibration Procedure ( Pressure Gauges & Pressure Recorders)
The dead weight tester (D.W.T.) shall be checked for the correct level
position. A bubble level is normally used for this purpose.
The equipment to be calibrated shall be installed in or connected to the
instrument port of the D.W.T. and tightened into position with the dial or
recorder facing the D.W.T. operator. The pressure shall be increased by
rotating the hand pump spindle clockwise until 25% of gauge/recorder range
has been reached. Meanwhile set the weights on the D.W.T. piston for the
required value of pressure. When the piston floats on its column of oil, the
precise pressure has been reached. A comparison
between the piston
weights and gauge/recorder readings indicates the accuracy of the instrument
being calibrated. Incremental stages of 25% of instrument scale can then be
checked until 100% of scale has been reached. This procedure must then be
carried out in reverse order by reducing the instrument readings in 25%
divisions.
The +/~ accuracy of an instrument can vary slightly between
pressure increases and pressure decreases.
The pressure differences between dead weight and the instrument being
calibrated shall be shown on the calibration sheet as;
Correction +/- ( X ) rising
Correction +/- ( Y ) falling
If the pressure gauge reading is showing a difference of greater than +/- 10psi
from the dead weight tester reading for readings up to 1000 psi or 1 % of scale
range for readings above 1000 psi, the gauge shall be repaired or rejected.
If a pressure recorder varies outside the required accuracy it may be adjusted
as follows prior to re-calibration. A pressure corresponding to the upper range
of the pressure recorder shall be applied to the recorder and the
EWRB1-OUAl-HTP-O10-PL
Hydratest Procedures-Rev-B
measurement checked against the D.W.T. If necessary, the recorder shall
then be adjusted using the linkage adjustment until the reading is correct.
Pressure is then reduced to zero and the zero setting checked. Calibration is
then carried out in a similar manner as for the pressure gauge.
A sticker/tag shall be dated and signed by the Saudi Aramco Representative
or Saipem QC Inspector as witness to the correctness of the calibration. This
sticker/tag is then to be attached to the instrument.
7.4
Calibration Procedure (Relief Valves)
The relief valve shall be mounted on the D.W.T. with the initial setting higher
than required. Weights, corresponding to the required pressure relief valve
(P.R.V.) setting, shall be placed on D.W.T. piston. Pressure shall be
increased on the dead weight tester until piston floats. The screw on the
P.R.V. shall then be slowly unscrewed until the discharge port opens and the
D.W.T. piston suddenly drops as the D.W.T. hydraulic oil is released through
the P.R.V. Lock the adjustment screw on the P.R.V. and close the cap (if
fitted). Install a calibration tag on the valve showing opening pressure, re-set
date and initials of Saudi Aramco Representative or Saipem QC Inspector
7.5
Calibration Documentation
All calibration documentation shall be signed by the calibrating technician and
the Saudi Aramco Representative or Saipem QC Inspector. Photocopies of
calibration
certificates
shall
be
presented
to the
Saudi
Aramco
Representative.
Original calibration certificates shall be retained by Saipem
QA/QC Department for inclusion in completed test packages.
8
DESCRIPTION OF TEST SECTIONS
For the purpose of pressure testing, the pipeline sections will be divided into test
sections by installing temporary test headers.
The new pipeline sections will be filled and tested with seawater from Rabigh. Filling
will take place using a pump station between the Marine Terminal and Royal Wharf
at Rabigh and water pumped to the end of the pipeline adjoining the AY-1 56"
pipeline. Crossovers between temporary test headers will be used to transfer the
water.
Pipeline sections and piping will be tested to the pressure indicated in the tables
shown in Appendix A.
Please refer to the Hydrostatic Test Diagrams and Appendix A for the elevation and
corresponding pressure of the pipeline ends, high point and low point for each test
EWRB1-QUAL-HTP-o10-PL
Hydrotest Procedures-Rev-B
section. Test equipment will be located at either end of test section dependent on
construction requirements and field constraints.
Strength test pressure range is based on pressures corresponding to a maximum
stress of 100% SMYS at the section low point and a minimum of 90% SMYS at the
section high point.
9
SAFETY PRECAUTIONS
It should be noted that the safety of personnel and existing operating plant is of
paramount importance at all times. This is especially relevant when conducting
operations involving high pressure testing. Therefore, Saudi Aramco Safety Manual
(Pressure Testing) instructions requirements of SAES-A-OO4shall be rigidly followed
and backed up by the use of common sense.
As a general guideline, no one, with the exception of experienced testing personnel,
shall be allowed within 3D-meters of any pipe, exposed or otherwise, while under
test. The same conditions apply to vehicles.
Any work area with operating pumps, compressors, etc. shall be cordoned off with
'Tiger tape' or rope to restrict movement of non-testing personnel.
Barriers shall indicate 'Pipe On Test' limits. Warning signs shall be placed in
prominent positions, such as exposed pipe sections, test ends indicating "Danger
High Pressure Testing" in English and Arabic.
Aside from the normally available telephone lines in Saudi Armco facilities along the
pipeline route and base radio stations in camp, vehicles with radios will be provided
to the testing crew and safety personnel to maintain proper communication during the
various phases of the pressure test operation.
All personnel who are not engaged in the pressure testing operations shall be kept
away from the locations until testing operations have been completed.
If required, a night watchman and lighting will be provided for any 24-hour hydrotest.
Any permanent flange, fitting or component found to be leaking shall be identified
and remedial action taken only after the test section has been depressurized to the
head pressure of the liquid.
Welding repairs shall be performed only when the section has been de-pressurized
to zero and partially or fully dewatered as required for the repair.
While the pipe is under pressure, care shall be taken to avoid any kind of impact load
applied on the pipe, associated fittings or structures.
EWRB1-QUAL-HTP-o10-PL
H~rotest
Procedures-Rev-B
10
TEST PREPARATION
Cleaning and Gauging
New pipeline sections, a double joint long and smaller (25 meter and smaller),
will be flushed with compressed air or water to remove all sand, dirt or
construction debris, prior to commencement of pressure testing. If the pipeline
section is more than one double joint (25 Meter), then the pipeline section will
be cleaned and gauged using brush scrapers and gauging plates prior to
hydrotesting. The diameter of the gauging plate shall be 93% of the nominal
10 of the pipe with highest wall thickness.
See separate procedure for Cleaning and Gauging,
Installation of Test Headers
Test headers shall be pressure tested at a minimum of 120% of the pipeline
test pressure prior to installation.
These shall be welded to the sections to be tested and will generally include
scrapers in one or both ends dependant on filling and dewatering directions.
Line Preparation and Filling
All instruments and equipment that are not included in the test, shall be
isolated or removed from the test system, and temporary plugs shall be
installed.
10.3.1 Short Sections to be gravity filled
For short sections and sections where scrapers will not be used for
filling, test water will be introduced into the piping or pipeline section
through one of the nozzles on the test header or other convenient
filling point. Piping and short sections of pipeline will be filled directly
from water tankers.
Such water will not be chemically treated unless it is expected to be
inside the pipe for more than 2 weeks.
Water should, where possible, be filled from the low point with vents
open at high points until water exits from the vents which are then
progressively closed as water exits.
10.3.2 Long Sections to be filled with Scrapers
Long pipeline sections will be filled using scrapers. For sections to be
filled with scrapers, a minimum of two bi-directional scrapers shall be
back loaded into the filling header. Additional scrapers may be
installed as required for dewatering purposes.
EWRB1-QUAL-HTP-O10-PL
Hydratest Procedures-Rev-B
A flushing slug of approximately 100 meters shall be injected ahead of
the first filling scraper. This slug shall provide lubrication for the first
scraper and facilitate the removal of residual debris from the pipeline
by suspension in the flushing water.
For the longer sections, the first filling scraper shall be launched with a
slug of minimum 200 meters. This may be reduced down to 50
meters for short sections of a few kilometers.
The second and last filling scraper shall be launched and propelled
the full length of the section by the chemically treated filling water.
The addition of an oxygen scavenger to the hydrostatic test water is
required where the pipeline contact time with water is likely to exceed
14 days. Prior to the commencement of filling operations, either
samples or a detailed chemical analysis of the filling water shall be
sent to the company supplying the oxygen scavenger to determine the
proper ratio of chemicals to filling water in order to comply with the
current Saudi Aramco standards.
The mainline sections from Rabigh to the AY-1 56" pipeline will be
filled with chemically treated sea water. The only chemical treatment
will consist of oxygen scavenger at the recommended dosing.
Sufficient oxygen scavenger will be used to maintain a minimum
sulfite residual concentration of 20 mg/L after allowing for 10 mg/L per
ppm of dissolved oxygen. Typical dosing levels will be around 100
pmm by volume of 30 to 32% Sulphite solution. The proposed oxygen
scavenger is Champion CORTRON ARE-1866 ammonium bisulphite
as detailed in the attached MSDS or equivalent (as available).
Chemicals shall be injected at the discharge location of the filling
pumps and the required dosing adjusted by regulating the chemical
dosing pump to the filling pump/s flow-meter reading.
Water used for initial flushing will not be chemically treated.
On receipt of the flushing slug, the water shall either be directed into
the next section to act as an additional flushing slug or disposed of as
needed.
When the first filling scraper arrives, the slug behind it shall either be
re-directed into the next section or disposed of as needed.
When the second filling scraper arrives, the filling water behind it shall
be re-directed into the next section as additional flushing water or for
launch of the filling scrapers in that section.
EWRB1-QUAL-HTP-O10-PL
Hydrotest Procedures-Rev-B
10.4
Equipment
and Instruments
for Hydrostatic
Test
The following listed equipment is for main line sections and will be scaled
down accordingly for smaller sections.
10.4.1
Pump Station
Equipment
and Instruments
Holding Tank, 16 M3 Capacity
-3
No (For filling, storage,
as
required)
Suction Pumps
-3
No 300 m3/Hr to feed break
tanks.
10.4.2
Filling Pumps
-3
No 250 M3/Hr at 45 Barg.
Filters
-2
No
Suction and delivery hose
-As
required
Flowmeters
-3
No. (Filling)
Chemical Injection Pump
-2
No. suitably rated
Hydrotest
Equipment
and Instruments
Test Cabin
-1
No. (For 24 Hr Test)
High Pressure Pumps
-4
No. 250 bar from
400 It/min.
High Pressure Hoses & Fittings
As required
Pressure Gauges
2 per section
Pressure Recorder, 24 Hours
1 per section
Temperature Recorder, 24 Hours
1 per section
Dead Weight Tester
1 No
Relief Valve Set
1
(1.05
x
Strength
175 to
test
pressure)
Pipewall Temperature Sensors
As Required
Ground Temperature Sensors
As Required
Temperature Sensor Readout unit
As Required
10.4.3 Dewatering Equipment
High Pressure compressor
5 Nos. 27m3/min @ 27 barg.
Low Pressure compressor
4 Nos. 21 m3/min @ 10 barg
10.4.4 Drying Equipment
Dessicant Drying Units
2 Nos. 100 m3/min @ 10
barg.
EWRB1-OUAL-HTP-O10-PL
Hydrotest Procedures-Rev-B
Pressure Test General Requirements
Prior to commencing any pressure test, each section shall be visually
inspected by hydrotest personnel to ensure that all test limits are in closed
position and all valves that are connected to the test instruments are in open
position.
Areas around test pump and flexible hose shall be cordoned off with barriers
and/or warning tape. Warning signs shall be prominently displayed and
access denied to all non-essential personnel.
The test pump shall be located such that the pump operator shall not be
exposed to danger in the event of failure. The pump shall be manned
continuously during pressurization. Pressure gauges shall be installed so as
to be visible to the operator while operating the pump.
Upon completion of the strength and tightness test, the system shall be
depressurized at a rate not exceeding 7 bar (100 psig) per minute. The final
pressure following depressurization shall remain above the static hydraulic
head to avoid vacuum or air pockets.
The depressurizing valve and piping shall be arranged for safe discharge of
the test water (G.I. 2.102) by connecting a high pressure hose to a valve on
test header (such as the 1" valve) and discharging into empty filling water
break tanks or disposal pond.
11
HYDRO TEST PROCEDURES
11.1
FOR PIPELINE SECTIONS
General
Exercise safety precautions as described in Section 9.
A steady increase in pressure shall be maintained throughout the time
required for reaching the strength test pressure.
Testing will normally start from the test section most remote from the water
source and working back towards the water source. This is subject to field
and schedule constraints.
Temperature Stabilization
For short lengths of pipe up to approximately 100 meters, no temperature
measurements are required and temperature stabilization is not an issue. For
long buried test sections, thermocouples (or other more sensitive devices) will
be installed as described below and used to determine stabilization.
For the pipeline hydrotests between Rabigh and AY-1 56", sufficient number
of thermocouples shall be installed to obtain accurate pipe metal temperature
measurements. Generally these will be installed at a minimum of three
EWRB1-QUAL-HTP-O10-PL
Hydrotest Procedures-Rev-B
.
locations in each test section with a minimum of two required to work during
the complete Pressure Test Period.
The thermocouples shall be installed as follows:
Pipe wall measuring thermocouples shall be attached to the pipewall with
adhesive tape at the three 'o'clock or nine 'o'clock position.
At the same depth, and approximately 1-meter distance from the pipe, a
ground temperature probe shall be installed.
These probes shall be back-filled to the normal depth of cover.
Water/pipe temperature shall be allowed to stabilize for a minimum period of
24 hours prior to the start of any strength test. On completion of the
mandatory 24-hour stabilization period, pipe wall and ground temperature
readings shall be taken on a four (4) hour basis.
When the average temperature readings of the pipe wall are within 1°C for
two consecutive readings, the pipeline section is considered thermally
stabilized and pressurization can begin.
11.3
Strength
and Tightness
Test of Pipeline
Unless limited by flanges or valves in the line, hydrostatic strength test
pressure for every section of newly constructed pipeline segments shall be
calculated to produce a minimum hoop stress of 90% of the SMYS of the pipe
material based on the minimum nominal wall thickness. The test pressure at
the lowest point of the pipeline, considering the hydrostatic head, shall not
result in a hoop stress greater than the SMYS.
As test points may be at intermediate
vary between these limits.
elevations,
end point test pressures will
The test pressures to be used for each pipeline section are specified in tables
in Appendix A. The hydrotest table indicates the following:
The Limits of test sections
The station, elevation and pressure at the test point limits
The station, elevation and pressure at the low point
The station, elevation and pressure at the high point
The strength test pressure & duration
The tightness test pressure & duration
EWRB1-QUAL-HTP~10-PL
Hydrotest Procedures-Rev-B
.
Relief valve set pressure for strength and tightness test.
The hydrotest schedule (See Appendix-A) shall be attached to each individual
test pack displaying the Test Pressure to be maintained at each end of the
section and the calculated test pressure at the highest and lowest elevations.
The high-pressure pump station will be placed at a safe distance (typically 15
meters) from one of the test headers.
Water, for pressurization, will be taken either from the adjoining section or
from water tankers.
Each 24-hour tightness test shall be monitored using a dead weight tester
with the readings taken at 30-minute intervals, a 24-hour pressure chart, logs
of buried pipe and ground temperatures and a 24-hour ambient temperature
chart.
For shorter duration tests a calibrated pressure gauge is sufficient with
readings taken at 15-minute intervals during the test and recorded on the test
forms.
Prior to start of strength and tightness test, the Saudi Aramco representative
shall note start time, date and pipeline section identification number on the
chart. The end of test shall be similarly witnessed.
Pressurizing shall be carried out at a steady rate not exceeding 2 bar (30
psig) per minute. Upon reaching 50% of the strength test pressure, the pump
shall be stopped and the piping checked for leaks. The system shall then be
pressurized in steps, no greater than 20% increments of the test pressure.
After each pressurizing step, a hold period of 10 minutes duration shall be
observed to permit inspection for leaks and weaknesses (G.I. 2.102).
Between 90% and 100% of the Strength Test Pressure, care shall be taken to
minimize the rate of pressurization.
Upon reaching strength test pressure, the pump shall be stopped, isolated,
and the test pressure held for a period of 2 hours. Care shall be taken in
approaching the section under test and shall only be done by those involved
in the pressure testing. Only the temporary equipment such as test headers,
valves and manifolds may be approached during the strength test.
Immediately after the completion of the strength test, a tightness test shall be
conducted at 95% of the strength test pressure.
The pressure shall be bled
down until at or above 95% of the strength test pressure.
The isolation valve between the temporary test piping and the facility or piping
under pressure shall be closed and test pump disconnected after the test
pressure is reached.
EWRB1-QUAL-HTP.Q10-PL
Hydrotest Procedures-Rev-B
The operator shall monitor pressure and collect all discharges, which may
occur from pressure relief or pressure control valves. All discharged test
water shall be collected and measured and used in final calculations.
Test records shall be made of each test by entry on the pressure test report.
The Hydrotest Supervisor, with assistance from Q.C engineer and Safety
Engineer, shall ensure that all activities carried out conform to Saudi Aramco
safety requirements, Saipem safety and safe working practices and all
guidelines and directives contained in G.I. 2.102.
A 24-hour recorded tightness test shall be applied when the pipeline is buried
or insulated, or is partially buried or insulated for more than 300 meters or
10% of its total length whichever is less.
After completion
depressurized.
12
of the tightness test,
the pipeline
section
will
be
HYDROSTATIC TEST OF ABOVE GROUND PIPING
This section describes the hydrotesting of above ground piping such as the scraper
station piping.
12.1 General
Exercise safety precautions as described in Section 9.
Commence filling until air free water comes out at vents. Vents shall be then
plugged.
A steady increase in pressure shall be maintained throughout the time
required for reaching the hydrotest strength test pressure.
12.3
Strength and Tightness Test
The high-pressure pump station will be placed at one of the test manifolds.
Water, for pressurization, will be taken from the water tankers.
Upon reaching 50% of the strength test pressure, the pump shall be stopped
and the piping shall be checked for leaks.
Upon reaching strength test pressure, the pump shall be stopped.
The isolation valve between the temporary test piping and the facility or piping
under pressure shall be closed and test pump disconnected after the test
pressure is reached.
EWRB1-QUAL-HTP-O10-PL
Hydrotest Procedures-Rev-B
The operator shall monitor pressure and collect all discharges, which may
occur from pressure relief or pressure control valves. All discharged test
water shall be collected and measured and used in final calculations.
Test records shall be made of each test by entry on the pressure test report.
The Hydrotest Supervisor. with assistance from QC engineer and Safety
Engineer, shall ensure that all activities carried out conform to SAUDI
ARAMCO safety requirements. Saipem safety and safe working practices and
all guidelines and directives contained in G.I. 2.102.
Hold the above pressure for 2 hours.
Immediately after the completion of the strength test, a tightness test shall be
conducted at 95% of the strength test pressure. The tightness test pressure
shall be maintained as long as required (Minimum 10 minutes) for the
inspector to examine all exposed joints.
A 24-hour recorded tightness test shall be applied when the piping is buried
or insulated, or is partially buried or insulated for more than 300 m (1000 ft) or
10% of its total length whichever is less.
After completion of the tightness test, the piping section will be depressurized.
The strength and tightness test will be carried out at pressures stipulated in
the hydrotest diagram.
The hydrostatic test shall be repeated after the repair of any defects until the
system is proved satisfactory.
The piping shall be satisfactory if there is no evidence of leakage or pressure
loss after the specified test period.
After the pressure test is accepted by Saudi Aramco
Representative, pressure shall be released at the vents provided.
Inspection
All vents shall be opened before draining, to prevent formation of vacuum.
Test records shall be made of each test by entry on pressure test report. The
Hydrotest Foreman and QC Engineer will ensure that all activities carried out
conform to the Safety requirements.
13
TEST ACCEPTANCE
The tightness test shall be demonstrated to Saudi Aramco satisfaction that there are
no leaks in the pipeline or assembly (with the exception of any temporary fittings or
materials used for the test). In case that there is a leak in the buried pipeline, the
procedure described in the Chapter 16 of this document will be applied.
EWRB1-QUAL-HTP-O10-PL
Hydratest Procedures-Rev-B
The temperature effects will be evaluated only for buried pipe sections requiring a 24hour test. These effects shall be calculated using the formula in Section 14,
Calculations, and submitted to SAPMT/Projects Inspection for verification and
approval. The test section shall be depressurized awaiting approval unless the
approval is available at the time of test.
14
CALCULATIONS
The pressure changes due to water temperature changes shall be calculated using
the following formula:
ilPr
=
220 rcw -3Q) /1T
((Olt) + 95)
where:
=
L\Pr
=
L\T
Cw
=
=
=
T
=
0
t
I~
15.6
16.0
17.0
18.0
19.0
20.0
21.0
21.1
22.0
23.0
24.0
25.0
26.0
26.7
27.0
28.0
29.0
30.0
31.0
pressure variation (Kpa)
algebraic difference between water temperature as measured at the
beginning and end of test (oc)
nominal outside diameter of the pipe (Inch or mm)
nominal pipe wall thickness of the pipe (Inch or mm as for 0)
water thermal expansion coefficient in function of the water temperature
Refer table below.
Average of Water Temperatures measured at the beginning and end of
test (oc)
Cw/oc
153.0
158.0
169.4
180.7
192.1
203.4
214.7
216.0
224.6
234.4
244.1
253.8
263.5
270.0
273.2
283.0
292.7
302.4
312.1
ri:fl39.0
40.0
41.0
42.0
43.0
44.0
45.0
46.0
47.0
48.0
49.0
50.0
51.0
52.0
53.0
54.0
55.0
56.0
57.0
Cw/oc
368.7
375.8
383.0
390.1
397.2
404.4
411.5
418.6
425.7
432.9
440.0
447.1
454.2
461.4
468.5
475.6
482.8
489.9
497.0
EWRB1-QUAL-HTP-Q10-PL
Hydrotest Procedures-Rev-B
32.0
32.2
33.0
34.0
35.0
36.0
37.0
37.8
38.0
'8
321.8
324.0
329.0
335.5
342.0
348.5
355.0
360.0
361.6
59.0
60.0
61.0
62.0
63.0
64.0
65.0
65.6
504.1
511.3
518.4
525.5
532.7
539.8
546.9
554.0
558.0
Due to the weight of water, the pressure at the low point will be higher than the high
point. The weight of the water shall be taken in to consideration when reading the
pressure at different elevations (including the Dead Wt Tester height relative to the
end test header). In case of elevation differences, use the chart below to calculate
the pressure.
Elevation difference
(In meters)
e
58.0
Pressure Difference Sea
Water
(psi)
Pressure Difference
Fresh Water
(psi)
1
1.46
1.45
2
2.93
2.90
3
4.39
4.35
4
5.85
5.80
5
7.32
7.25
6
8.78
8.70
7
10.25
10.15
8
11.71
11.60
9
13.17
13.05
10
14.64
14.50
11
16.10
15.95
12
17.56
17.40
13
19.03
18.85
EWRB 1.QUAL-HTP-o1 O-PL Hydrotest Procedures-Rev-B
15
14
20.49
20.30
15
21.95
21.75
16
23.42
23.20
17
24.88
24.65
18
26.34
26.10
19
27.81
27.55
20
29.27
29.00
GENERAL REQUIREMENTS AFTER PRESSURE TEST
De-pressurize the tested line as required.
Where scrapers were used for filling, they will also be used for dewatering,
Where scrapers are not used, dewatering shall be done by gravity or by the use of
compressed air and a temporary hose connected to low point drains may be used to
assist dewatering and disposal of test water.
On dewatering completion, all temporary attachments will be removed and test
vent/drain points plugged and seal welded unless required for drying.
Remove all blind flanges and any other accessories that were installed for testing
purposes, from the system.
All open ends of pressure tested piping shall be protected by end caps or other
suitable means, to prevent contamination.
16
PROCEDURE FOR LOCATING AND REPAIRING LEAKS OR FAILURE
DURING HYDROSTATIC TESTING
If the pressure test indicates that a leak exists, Saipem shall check all possible
sources of leaks by inspecting all valves, flanges, instrument lines, exposed piping
and test equipment. A visual inspection, throughout the entire section under test,
shall be made to check for any damp patches on the backfill, which may indicate a
water leak. Any such areas found shall be exposed and further investigated.
For newly installed pipeline sections, if no obvious fault is located, SAPMT shall be
informed and SAPMT shall approve further action as stated hereafter. Cut the
section, determined to be at fault, in half. This procedure shall be repeated until the
fault is isolated or reduced to 500 M. or less. This shall necessitate de-watering,
cutting, welding two test ends, refill and re-pressurize each time.
EWRB1-QUAL-HTP-O10-PL
Hydratest Procedures-Rev-B
At this point, the entire faulty section shall be exposed to locate and repair the leak.
After repairs are made, refill and restore the pressure to the point at which the
pipeline failed or a leak was detected.
For existing pipeline sections, SAPMT shall be informed of any leaks and SAPMT
shall approve further action.
Comprehensive records shall be kept in regard to all work performed in locating and
repairing all leaks & failures.
17
DEWATERING OF PIPELINE SECTIONS
17.1 General
Upon acceptance of the strength and tightness tests of the respective pipeline
sections, the dewatering operations can be carried out in accordance with this
section.
All dewatering operations shall be performed in accordance with the
requirements of "Construction Specifications" and with GI 432.000 "Pipeline
Hydrotest Water Disposal".
Prior to start any dewatering activities, an inspection shall be made in order to
verify that the test sections are ready for dewatering.
Install air compressors with sufficient output capacity and connect them to the
air inlet either at the scraper trap or at the test header.
Ensure that the evaporation pond is ready and discharge piping is connected.
Ensure that the required work permits are obtained and posted at the work
site.
Ensure that all safety precautions are in place as per Section 17.2 of this
document.
17.2
Safety Requirements
Warning signs shall be installed around scraper trap and test header to keep
people away. The area around the scraper trap and test header shall be
barricaded with warning tapes.
Ensure that all air and water hoses are properly connected, tightened and
anchored to prevent whipping prior to starting the compressors.
17.3
Evaporation Ponds and Disposal Piping
Temporary marl lined evaporation pond(s) will be constructed to contain the
disposal water.
Location(s) will be selected based on suitable ground
EWRB1-QUAL-HTP-o10-PL
Hydrotest Procedures-Rev-B
conditions, elevation relative to adjoining sections, test section terminations
and compressor capacity.
Possible location is at Km 62.288. A single pond will be required to hold
approximately 63,000 cubic metres of water. This is the water from KP 0.15
to KP 100.2.
For the water from KP 100.2 to 143.18, totally 27,000 cubic metres, it is
proposed to push the water back to the intake point at the Rabigh Refinery.
This water has only been treated with oxygen scavenger and the pipe is new.
The fill water piping will be converted into discharge piping.
The temporary evaporation pond(s) shall be fenced until all water evaporates
to prevent animals from drinking the water.
17.4
Dewatering Procedure
Dewatering of the pipeline sections from Rabigh to AY-1 56" tie in will be in
the direction of the disposal pond(s)/locations. The most remote sections will
be dewatered through the next section in the direction of the disposal pond
via the bypass piping.
During dewatering, backpressure will be maintained as required to retain the
hydraulic and compressed air heads.
During dewatering, the sections may be sweet water flushed where feasible,
with the sweet water retained between two dewatering scrapers. If this is not
possible. then sweet water flushing will be carried out following dewatering
and prior to drying.
Water for sweet water flushing shall have 500 ppm or less dissolved solids.
The quantity of water to be used for sweet water flushing shall be a minimum
of 2 cubic metres per km of section to be flushed. Where this is performed
during dewatering then the total quantity will be used to launch the first
scraper and compressed air used to launch the second scraper. Where this
is performed after dewatering, 50% will be injected in front of the first scraper,
50% between the first and second scraper and then the second scraper
launched with compressed air.
17.5 Pipeline Drying After Dewatering
After completion of pipeline dewatering, the hydrotest headers will be cut-off.
Smaller sections may be tied in so that the maximum drying length is around
80 km. Temporary launchers and receivers will be installed at the ends of the
sections to enable launching and receiving of scrapers for swabbing the
pipeline and drying.
Absorbing foam scrapers will be propelled by dry compressed air through the
section to remove the remaining water in the section. The purpose of this
EWRB1-QUAL-HTP-O1O-PL
Hydratest Procedures-Rev-B
swabbing operation is to remove residual water from the pipeline and to
spread the water on the surface of the pipe to aid evaporation. The drying
operation will be complete when an atmospheric pressure dewpoint of -1
Celsius or lower is achieved at the discharge end and the atmospheric
pressure dewpoint following a 24 hour soak test is still-1 Celsius or lower.
After completion of drying operations, the pipeline section ends will be tied in
to adjoining sections or the ends capped and sealed with a 2" access
connection at the end for relief of any residual pressure prior to removal.
The above operations shall be performed on sections of the pipeline prior to
tie in of block valves and scraper launcher and receiver stations. The
purpose of the pipeline drying is for mothballing purposes (using dry air) until
the block valves and scraper stations are tied in.
e
18
CALIPER SURVEY
After all pipeline sections are tested, tied-in and all scraper traps installed, the
pipeline will be caliper surveyed to ensure that no pipe defects are present.
Prior to the caliper survey, two magnetic scrapers shall be run through the section to
remove any residual metallic debris prior to the caliper scraper run.
The caliper survey may be carried out in one 'section from permanent
permanent receiver using compressed
dry air or in two sections
temporary launchers and receivers at a central location.
launcher to
by utilising
Initially compressed dry air will be injected into the pipeline section to provide
backpressure as required by the Caliper Supplier (typically 3 to 5 barg). The caliper
scraper will be calibrated, initiated and then installed in the pipeline. It will be run
using dry compressed air while maintaining the required backpressure until the
caliper scraper has been received at the opposite end of the section.
8
A caliper survey procedure will be submitted for approval to cover the calibration and
interpretation of data for the specific caliper scraper proposed.
19
INTELLIGENT SCRAPING TOOL
Following the Caliper Survey, an intelligent Scraping Tool will be run through the
pipeline prior to commissioning (unless approval is granted to run after
commissioning). The backpressure. propelling medium and any temporary surface
contact fluids (if any) will be dependent on the Intelligent Scraping Tool Selection by
Saipem and as approved by Saudi Aramco Instrument Scraping Unit.
A separate procedure will be submitted for approval to cover the calibration and
interpretation of data for the specific intelligent Scraping Tool used.
EWRB1-QUAL-HTP-O10-PL
Hydratest Procedures-Rev-B
20
FINAL PIPELINE DRYING
After successful completion of the caliper scraping and intelligent scraping (unless
approval is granted to run after commissioning) operations, the whole pipeline from
permanent scraper trap to permanent scraper trap will be dried to -1 degree C, using
dry air.
This will be carried out from permanent scraper launcher to permanent scraper
receiver and may be carried out without any scrapers due to the prior running of the
caliper scraper with dry air. The dry air equipment will be most likely be set up at
Rabigh.
e
Drying will be considered accepted when the discharge dewpoint at the end remote
from the drying equipment is consistently at or below an atmospheric dewpoint of-1
degree C.
'8
EWRB1.QUAL-HTP-C10-PL
Hydrotest Procedures-Rev-B
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APPENDIX
B -Chemical
MSD Sheets
Oxvaen Scavenaer
Attached are the Material Safety Data Sheets for Champion CORTRON ARE1866 oxygen scavenger, an ammonium bisulphite solution.
EWRB1-QUAL-HTP-O10-PL
Hydrotest Procedures-Rev-B
MSDS:ARE-1866
APRroved by: JS
Issued date:12j27j98
Revision
C:AHj4j20jOO
~~ Champion
Arabia,Co.Ltd.
COOYTYftedTo
SECTION
Improvement
I-PRODUCT
CODE CORTRON ARE-1866
CHAMPIONARABI Shutdown and isolations shall be performed by Rabigh Refinery Operations where existing
piping sections where tie-ins are to be done are presently in service. Saipem will be responsible for the
necessary and timely coordination with Rabigh Refinery Operations for the purpose of understanding and
defining the shutdown plan for the concerned facilities. Saipem will furthermore check to ensure that positive
isolations have been properly performed and valves that are required to be closed are locked & tagged in
accordance with G16.012ALTD.
P.O. BOX3254
AL-KHOBAR31952
Emergency
PhoneNo:
812-2100
SAUDIARABIA
ProductName:
CORTRON ARE -1866
ChemicalFamily:
AMMONIUM BISULFITE
CASNo.:
Proprietary
SECTION
II
-HAZA~US
Formula: Proprietary
Issueddate: 2-20-99
Prepared
by:JS(dist64)
INGREDIENTS
HazardsComponents
CASNo.
SULFITE
10192-30-0
WTO/o
OSHA(PEL)
30 -32%
ND
# Denotesa chemicalsubjectto the reporting requirementof SARA Title III section313 of page 1986and 40 CFR part372.
SARA Title III HazardCategories:1
SECTION III
-PHYSICAL
DATA
Boiling Point Op
Vapor Pressure(mm Hg)
Vapor Density (Air=l)
ND
ND
ND
pH
4.0 -6.0
Solubility In Water: Soluble
AppearanceAnd Odor: Yellow liquid with ammoniaodor
Flash Point, Op& Method:
Flammable Limits:
LEL%
UEL%
>200 (PMCC)
Basedon : NA
NA
NA
Fire Hazards:
This product may burn, but does not rea~ily ignite.
ExtinguishingMedia:
Specific Gravity @ 60 of
1.200:t0.03
EvaporationRate
(butyl acetate=1)
Viscosity, cst @ 100 of
ND
1-15
l
2
MSDS:ARE-1866
Diy cherirical,CO2, water sprayor regularfoam. Move containerfrom fire areaif you can do it without risk. Apply cooling water to
sidesof containersthat are exposedto flames until well after fire is out. Stayaway from endsof containers.
Abbreviations:
Conditionsto avoid:
Open flames,sparks
Incompatibility ( materialsto avoid)
Strongalkalies oxidizers
HazardousDecompositionI by products:
Oxidesof nitrogen & sulfur
HazardousPolymerization:
Will not occur
HazardRating Scale:
HEALTH:
(4=severe,
SECTION
VI
-REAcrIVITY
2
3= serious,
FIRE:
0
2= moderate,
REACTIVITY: 0
= slight,
0= minimal)
DATA
PRIMARY ROUTESOF ENTRY:
x
Inhalation:
Absorption:
x
Ingestion:
x
Injection:
NA
HEALm HAZARDS:
May be hazardousif inhaled,ingestedor absorbedthroughthe skin. Corrosiveto tissue. Direct contact with eyesand skin may cause
severedamageandbums. Vapors or mists maycauseirritation of mucousmembranes.
EMERGENCY & FIRST AID PROCEDURES:
In caseof Eye contact immediately flush with running water for at least 15 minutes. For SKIN contact, wash with soapand water,
removing clothing if contaminated.In casesof where this product has been INHALED, victim should be removedto fresh air and
given artificial respiration. If breathingis difficult, oxygen may be given by qualified personnel.In caseof taken internally, DO NOT
induce vomiting. Give large amount of water or milk to drink. Obtain medical attention. ALWAYS LAUNDER CLOTHING
BEFORE REWEARING.
IF CONDITIONS PERSIST.SEEK MEDICAL ATfENTION.
Carcinogenicity?NO
NTP/NO
IARC-Monograph?
ND OSHARegulated?
NO
STEPS TO BE TAKEN IN CASE MATERIAL IS RELEASED OF SPILLED:
Do not touch or walk through spilled material, stop leak if you can do it without risk. Take up with sand or othernon-combustible
absorbentmaterialandplace in a containerfor later disposal.
WASTE DISPOSAL MEmOD:
Contactan BPA or StateApproved DisposalFacility.
MSDS:ARE-1866
Approved by: JS
issued date:12/27/98
Revision
C:AH/4/20/00
RespiratoryProtection:
Ventilation:
Local Exhaust
GeneralExhaust:
Special:
Protective Gloves:
Eye Protection:
Other ProtectiveEquipment:
Work / Hygienic Practices:
SECTION IX -SHIPPING
Use NIOSH APPROVED RESPIRATORif PEL is exceeded.
Recommended
Recommended
Enteringtanks or cleaning up spills; Use SCBA
Neopreneor latex rubber
Chemicalsafetygoggles
Eyewashstations,ample water supply,s~owers.
Clean up spills promptly, washcontaminatedclothings.
DATA
Hazard Classification: 8
Label Required:
Corrosive
Proper Shipping Name:
DOT ER Guide No.: 60
UN/NANo.: UN-2693
Bisulfites, AqueousSolutions,N.O.S., 8 UN 2693 , PGl11
(AMMONIUM BISULFITE)
DOT RQ in pounds 8,333
DOT RQ in gallons 770
FlashPoint, of >200
pH: 4.0-6.0
Pkg.Group:m
IMDGpg.No.: 8126
Prepared by: IS (basedon CfI MSDS)2/20/99
The infonnation containedhereinis basedon dataconsideredaccurate.
Howeverno warrantyexpressedor implied, is given regardingthe accuracyof this dataor the resultsto be obtained from the
usethereof.
APPENDIX C -Hydrotest
Drawings
& Equipment
Layout
VA-369070 Sheet 001
VA-369070 Sheet 002
VA-369071 Sheet 001
VA-369071 Sheet 002
VA-369071 Sheet 003
VA-369071 Sheet 004
VA-369072 Sheet 001
VA-369073 Sheet 001
Equipment Layout
EWRB1.QUAL.HTP-O10-PL
Hydratest Procedures-Rev-B