SOUTHERN AREA PROJECTS INSPECTION DIVISION ae RAPIU Supervisor - Haimoud, Yousif A pour cU-32,West Admin.Bidg. #1020, UDHALIYAH Tel: 577-8603 Fax: 577-6058 QC DOCUMENT REVIEW RESPONSE REIN: 9.8. NASSAR, PROJECT ENGINEER TEL: S76-7051 IDEPE: _oMPPD/GUPD/HAWT¥AH GAS UNIT fapD: PME OFFICE, HAWIYAH CONTRACTORS PARE FAK: S76-746 pense ve REE: UPD-HGU-O01-14 DATE 2-Jan-14 TITLE: aver fas Project HARYH area |CONTRACTOR: — ent suamrrran; HYdrotest Procedu Pipeline and piping systens : approval Dewoeipts Sefonetiots Te siaiee Status piping ‘systems Prscedure QA/P Hydrotect 001 1 | comers contoted copy tobe avatale se locaton dng the Proce status definition: Approved J2 approved, with conments.Resubmit for record SIReviewed and accepted a.Not Approved. Resubmit incorporating ls.Reviewed. Incorporate comments and 6\Review not required. Document retained for Info Gacter has to provide Phe back their old | = reference, Con and Iota > RAPT betaine the supnitted documents jrontralied copy of approved documents for RAPIU referenc laocumenca. Reviewed by : Ahmed Nefnawy Signature Mechanical Inspector Date = Appiovad by : uff, Brian K Signature RAPIU Fiel@ Supervisor Date® Br. CAT Int Co. Ltd ‘saws Arab | HYDRO TESTING PROCEDURE Dos. Nox GAP HYDROTEST-001 REV.NO CONTRACT NUMBER: 6600026552/6600026568/6600027360 KHUFF GAS PROJECT HAWIYAH & HARADH AREA SAUDI ARAMCO HYDRO TESTING PROCED! FOR As Rev.C] 30-12-13 | QK/QC'Department ger Préject Manager ‘SAPID Rev.B| 18-11-13 |@A/QC Department | QC Manager Project Manager SA PID Rev.A| 20-05-11 | QA/QC Department | QC Manager Project Manager SA PID Rev. | Date: Prepared By: Controlied By: ‘Approved By: Approved By: 1/10Doe. Nor GAP ® BreAT elect HYDRO TESTING PROCEDURE Leaaliadied avs Abia REVO = TABLE OF CONTENTS 1. PURPOSE AND SCOPE OF PROCEDURE 3 2. RESPONSIBILITIES 3 3, HYDROTESTING PROCEDURE 4 4, REFERENCES 10 20® Doe Wo OF steteitlctea HYDRO TESTING PROCEDURE ‘ranovest-2ct REV.NO Saudi Arabia 1. PURPOSE AND SCOPE PURPOSE ~This procedure detalls the procedural requirements for hydro testing of Piping systems, spools, assemblies and for pneumatic testing of associated Attachment. SCOPE- This Procedure covers the preparation, hydrostatic and pneumatic testing, ‘And hydrostatic water treatment, system lay- up reinstatement and safety. A specific detailed procedure will be formulated and submitted for client Approval covering the project which is not covered by this document. NOTE: In accordance with G.l0002.102 A specific procedure shall be develop and Submitted 2 days prior to each test with a volume exceeding 5.7 cubic meters. [A sample format for detoils of each testis attached to this general procedure And details all information required by G.! 0002.102 2. RESPONSIBILITIES It will be the responsibility of the piping engineer and the QC Manager to define test limits on the P & IDs. It will be the responsibility of the QC Manager to ensure that all inspections, testing ‘and NDE is completed, and that the relevant test pack(s) contain the correct documentation, It will be the responsibility of the QC Manager and the piping engineer to ensure that the comprehensive punch list is compiled and any hold items are cleared prior to testing. It will be the responsibility of all personnel involved with tasting activities to ensure safe working practices are followed without exception. 3/10Doe Wor GNF ® ae HYDRO TESTING PROCEDURE HYDROTEST auc bia FEV 3.0 HYDROTESTING PROCEDURE 3.1 PREPARATION 3.1 Prior to scheduling any hydrostatic or pneumatic testing the QC Supervisor / Inspector shall review the respective nondestructive test report, Radiography test Report, magnetic particle inspection report, ultrasonic test report, Liquid Penetrate test report, punch list and fill out @ release notification and The applicable section (s} of the pressure test package and will submit a completed Test package to client in order that verification can be carried out and approval to Test is given the QC Manager shall notify the client. In writing at least twenty four (24) Hours in advance of the intended testing of the piping system / part system ‘Where required by means of submitting a request for client inspection, 3.2 Vents shall be provided at all high points and drains at all low points (when Confirm by client) in the system and immediately above check valve in vertical lines. 3.3 Pneumatic testing shall not be permitted without the prior written approval of the fon of instrument and plant air Manager inspection department with the excej system which may be strength tested with their own product at the operating, Pressure. 3.4 The engineer responsible for carrying out the testing shall verify the system / part System has been successfully cleaned internally and will fill out the respective Cleaning / flushing record and will ensure itis signed by the client's representative. 3.2 CLEANING OPERATIONS & TEST FLUIDS 3.2.1 WATER FLUSHING 3.2.1.1 Equipment which is sensitive to damage during the water flushing shall be Removed blocked off or isolated. it shall be prepared and be part of the Flushing procedure. Ball valves shall be flushed in fully open position, 3.2.1.2 All piping system shall be flushed using high pressure (60.8 Mpa, 8.8 Ksi) jet Such as rotating hose on rotating nozzles. 3.2.1.3 — Below 4” use high velocity water flushing (HVWE ]. On system where high Pressure jet flushing cannot be used due to complicated shapes and/or long Runs use HVWE or slag flushing. Water velocity shall be minimum of 3m/s 4/10Soe NOTENF | &® ar. CAT. nt co. Usd HYDRO TESTING PROCEDURE | eoacresrae | | Saudi Arabia | REV.NO 3.2.1.4—The general flushing medium shall be plant/process water or raw water. Fire Water may be used where process water is not available. Sea water is not Acceptable. When flushing stainless lines. The chloride ion content shall be Less than 5Omg/L. After flushing the piping system shall be completely drained Dried to a dew point below-1 degree and protected against corrosion. 3.2.15—For the purpose of conducting scraper operations scraper launcher and receivers adequate for purpose shall be attached to the lines. mechanical seraper can be used under the condition that damage to the pipe interior surface shall not occur. 3.2.1.6 Pneumatic flushing with dry air (dew point-1 degree or less) or stream with a Minimum exit velocity of 15m/s. repeat flushing until cleanliness is verified by Observing the absence of any solid impact or a polished metal target at the Exit, 3.2.1.7-All water used for hydro—testing of carbon steel piping shall meet the Requirements of SAES-A-007 Section 5.1 and 7.3.1 RSB test for water shall be As per SAES-A-O07 Para. 4.2.3. 3.3 HYDROTESTING (Specific Requirements as per SAES-A-004 & SAES-L-150) NOTE: Activities hall be In accordance with SATIP's: SATIP-A-004-01,SATIP-A-004-02 and SATIP ~A-004-05. All relevant SAIC/SATR referenced therein shall be filled out. 3.3.1 All valves and control valve shall not be installed until after the system / part System have been thoroughly cleaned, Gauged and flushed in accordance with SAES-A-004 7.1.3. .2—All restriction which will interfere with filing, venting ,draining or flushing shall Not be installed until completion of the flushing and subsequent pressure Testing, — As required by SAES-A-004 5.1.1. All system while being strength tested shall be Protected from over pressure by relief valve(s) of adequate capacity set to Relieve at 5% above the strength test pressure and shall be tested, dated and ‘Tagged a maximum Of one (1) week prior to the test and recorded on SAIC/SATR As applicable. 5/20f ae War ONE | ® GAT. Co. de voRoTeST-4 | sau as RETRO | 3.3.4. A bleed valve as required by SAES-A-0045.5.2 shall be provided on the test Manifold to protect the piping and equipment from over pressure, in addition to Pressure relief valve and shall be readily accessible in the event that immediate Depressurization is required. stalled 3.3.5- As per SAES-A.004 7.1.5 A minimum of two (2) pressure gauges will be In the test system, one (1} on the test pump and a minimum of one (1) on the System being tested, All pressure gauges shall be calibrated before use, the Interval of which shall not exceed one (1) month and recorded on SAIC/SATR as Applicable and shall have a sticker applied indicating the date calibration is due. All calibration and issue dates of test equipment shall be recorded on 3 Calibration summary sheet with the calibration report being inserted in the test Package. The pressure gauge shall be checked and verified by QC inspector to Ensure that they are within 5% of each other when in use and that are operating Within 30% to 80% of the full range. 3.3.6 Expansion joints and springs or spring supports shall be provided with temporary Restraints, if required, to prevent excessive travel or deformation under the test Load 3.3.7—The test manifold shall be hydrostatically tested to at least 20% above the Specified test pressure prior to being used as required by SAES-A-004- 5.5.4. And the results recorded on a pressure test certificate which will be inserted in The test package. 3.3.8—An isolation valve as per SAES-A-004 5.5.3, rated for the test pressure when in ‘The closed position, shall be provided between the manifold and the system Being tested. 3.3.9 — Temporary connections shall be provided for de-pressurizing and draining of the Systems to the sewer or disposal area. 3.3.10 — Initially the strength test shall applied at 50% of the test pressure and at further Increments no greater than one fifth with at least five (5) minute holds at each Step to permit inspection for leaks. 3.3.11- A test duration for pipelines and piping’s shall be accordance with SAES-L-150. 3.3.12—Immediately after strength test a tightness test shall be conducted at 95% of 6/10® ‘Doe. Nos GAP Br CAT. Into. Let HYDRO TESTING PROCEDURE HYDROTEST.001 ‘Sauel Arabia | RENO] Strength test pressure. The tightness test shall be as long as is required as per SAES-L-150, for the Inspector to examine all exposed joints. A 24 hours recorded Tightness test is required when the pipeline is buried or insulated, or is partially Buried or Insulated for more than 300 meters (1000 feet} or 10% of its total Length whichever is less. 3.3.13 —Filling of the system, and subsequent pressurization, shall be on the upstream Side of any check valves with the test medium being injected at the lowest point Of the system, to minimize entrapped air, and with the vents in the open Position 3.3.14—The isolation valve between the test manifold and the piping or equipment. Under pressure shall not be closed and the test pump disconnected before Commencement of inspection of the system, 3.3.15 ~ During the hydrostatic testing of the system all in the valve, if installed, shall be In the partially open position if not used as a test segregation valve. The risk of Damaging the seat of soft seated valves should be taken in consideration, 3.3.16 ~The release of pressure shall be carried out gradually and draining of the ‘System shall be done on the downstream side of all check valves with the vents In the open position before draining to prevent forming a vacuum. 3.3.17- Where practicable, short section of pipe /pipe spools may be tested prior to Installation in the system and shall be filled with clean water as the test medium The pipe / pipe spools shall be protected with 2 pressure relief valve and a Minimum of two (2) pressure gauges as detailed in section 3.2.3, 3.2.4 and 3.2.5. after draining the pipe/pipe spool the internal shall be thoroughly cleaned By blowing with clean, dry air. 3.4 POST TESTING 3.1.1 — Upon completion of the hydro test the QC Inspactor shall make-out the relevant SAIC/SATR pressure test reinstatement form duly signed by the client, and insert It into the relevant test pack. 3.1.2— Hydro test water disposal will be carried out in accordance with Gl-432-000: for ‘A system containing between 5,000 and 50,000 barrels of contaminated water a Hydro test water disposal plan will be submitted to the client, and the plan Accepted, prior to draining the water from the system. 7/0Doe. Noa ® Beate inet beset HYDRO TESTING PROCEDURE eee Sau Arabia ey 3.1.3 ~ Unless a specific lay-up Is specified, test fluid shall be removed by multiple Scraper runs or draining each line in accordance with scope of work. Separate Dry-out and lay-up procedure will be submitted. 3.5 . SAFETY (GI-0002-102) 3.5.1 Mishaps and fallures during pressure testing may result in injuries, facilities, ‘And property damage. The greatest potential hazard is an uncontrolled Release of the large amount of energy that can be stored in compressed air Gas or other fluid, either in pneumatic test or in a hydrostatic test, where gas may be trapped in such places as unvented high points, horizontal line, and valve bodies. Other hazards are associated with the handling of chemical additives, entering confined spaces, brittle fracture of materials, and disposal of tests mediums. 35.2 Uncontrolled release of stored energy from compressed air or other gas can Take the form of explosions. High velocity streams of fluid can be created or piping and equipment can be moved. The degree of these hazards is determined primarily by the test pressure and the volume of air, gas or other fluid involved. 3.5.3 Avoid the following typical examples of poor practices which may result in Possible mishaps: Striking or working on equipment to stop leaks, while under pressure * Improper or missing test equipment, such as testing without a relief valve having an inadequately sized relief valve, or having no pressure gauge (s). © Omitting or changing stens in the test sequence such as failing to conduct a low pressure tightness test to check for leaks prior to strength pressure tests at higher pressure + Failure to vent air from the system prior to the test. ‘+ Use of gas instead of water as a test medium ‘+ Metal temperature below that at which the Impact requirements cannot be met by the material © System not adequately supported to withstand the weight of water during the test. 8/10 ees aes® Br. CAT. Ine Go, Ltd Saudi Arabia | Doe. Waza HYDRO TESTING PROCEDURE Eee REVNO c Pressure Gauge(s) and relief vaive(s) not calibrated and tested. Pressure gauge located too far from pressurizing equipment for reading. Appurtenances not adequate for the test pressure, or not isolated from the test. Pressure increased too rapidly to be controlled. Relief valve in operated because of a closed block valve. Temporary test piping not designed for the test pressure. No bleed valve provided on test piping. 3.5.4 Principles of Safe Pressure Testing Pressure testing procedures shall be consistent with the ff BEFORE START OF TEST 3.5.5 Assign Responsibility The Test Engineer Shall Responsible for: Preparation of the test procedures Delivery of the approval test procedure to job site, Safety aspects of the pressure test. Coordination and implementation of the pressure test in a safe manner 3.5.6 Proper Test Medium It may be necessary to mix chemical additives to test fluids to comply with client specifications and standards, if so the utmost care shall be teken to avoid contact with chemicals, personal protective equipment shall be used and manufacturers recommendations followed. The following shall never be used as pressure test mediums because they are externally hazardous: a. Oxygen b. Toxic Gas © Liquids above their flash points or atmospheric bolling points Liquids above 66°C (150°F], Except where necessary for pressure testing hot tap connections on hot lines. 910® Bx CAT rico. te Sand dia 7 ‘Doc. No.: QAIP ] iyoROTEST-01 | HYDRO TESTING PROCEDURE [Rare NO 3.5.7 Restrict Approach to the System Do not approach systems, during the stepwise increase in pressure to the strength test pressure. After the strength test pressure has been reached, held for specified interval and the pressure reduced to tightness test pressure the equipment may be approached. Personnel carrying out the test shall be provided with a safe place from which the progress of the test can be observed and controlled. Personnel shall be located such that a system rupture will not result inany injuries. During any portion of a test, only personnel directly involved with the test shall be allowed near the system. The test pump shall be located such that the pump operate will not bbe exposed to danger in the event of a failure Work Permit: Work Permit Procedure shall be in compliance with client requirements. 4.0 REFERNC! a, SATIP-A-004-01, b. SATIP-A-004.02 ©. SATIP-A-004-05 4. SAES — A-004 fe. SAES-A-007 F SAES-L-150 g SAICL-350 h, GI-0002.102 1. G-432-000 J. Scope of works NOTE: All available records shal! consist in the frst Instance of applicable SAIC or SATR, if none available then CA.T forms shall be utilized after client opproval. 10/10