On- Plot Hydrotesting

NIMR – G DEVELOPMENT & KARIM WEST WATER

FLOOD PROJECT

METHOD STATEMENT FOR PIPE HANDLING, STORAGE AND STRINGING

CONTRACT NO: C31/1033

NIMR – G DEVELOPMENT & KARIM WEST WATER FLOOD PROJECT


METHOD STATEMENT FOR ON- PLOT PIPING/ EQUIPMENT HYDROTEST

Rev Date Revision

Title

Prepared Checked Approved PDO Approval

Method Statement for Pipe handling and StoragePage 1/14


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CONTENTS

1. Introduction 3

2. Purpose 3

3. References 3

4. Abbreviations 3

5. Personnel 4

6. Equipment List 7

7. Methodology 8

8. QA/QC 14

9. HSE 14

10.Annexure 14



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1.0 INTRODUCTION

Galfar Engineering & Contracting Company awarded for the works required to complete

Nimr – G and Karim West water flood project in contract Number: C-31/ 1033.

2.0 PURPOSE

Purpose of this document to narrate detailed description of activities and Practice for

On- Plot Piping Hydrostatic test for Nimr – G & Karim West Water Flood project to

ensure the work is performed in safe, professional and controlled manner by a

competent personnel.

3.0 REFERENCE

Construction scope of work

MSP -04 Document & Data Control

SP 1006 Health ,Safety & Environmental Specification

SP-2051 Specification for Flushing, Pressure Testing, Pickling and Sensitive

Leak testing of Mechanical Equipments and Piping

4.0 ABBREVIATIONS

PDO: Petroleum development Oman (Company)

HEMP: Hazard and Effects Management process

HSE: Health, safety and Environment

ID: Identification

ITP: Inspection and test plan



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PPE: personal protective Equipment

PTW: permit to work

SP: Specification

QA/ QC: Quality Assurance/ Quality Control

5.0 PERSONNEL

The following personnel with the responsibilities entrusted to them shall be responsible

for carrying the work mentioned in the scope of work.

Project Manger:

Shall be responsible for providing all infrastructures and other resources required for the

completion of the project including safety related PPEs and tackles and competent

manpower.

Reports to the Executive Vice President (O& G and EPC)

Construction Manager:

Shall ensure that work procedures are in place and control measures taken before for

execution of project. Shall responsible for all construction activities, training and

awareness programs for all personnel deployed for the activity and to ensure the work

completed as per the approved Project schedule.

Reports to Project Manger. In his duties, he is assisted by the construction team as

indicated in the organization chart.

Sr. Project Engineer:



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Responsible for formulating and implementing execution plan for the project and to

ensure project progressing on stipulated manner.

Reporting to project Manager

HSE Officer:

In addition to the roles and responsibilities as disseminated generally in the Contract

Specific HSE guidelines, the following activity specific functions shall be carried out;

Disseminate HSE policies specific to the activities involved and facilitate

implementation.

Verify arrangements to handle emergencies; educate the team; observe mock drills for

adequacy of preparedness.

Assist in incident investigations; maintain integrity of investigation process; disseminate

learning and track actions.

Monitor activities, recognize and report non-conformities, recommend and follow-up

corrective and preventive actions.

Analyze and report performance and recommend areas of improvement.

Shall ensure working gas testing equipments available, wherever necessary at site and

is being used

Provide inputs for work specific job Risk assessment and mitigation.

Reports to the construction Manager on day to day matters of the project and

functionally reporting to HSE Manager on HSE related matters.

Sr. QA/ QC Engineer



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Shall be responsible for implementation of QA/ QC specifications, codes, procedures

and guidelines specific to the activity.

Reports to the construction Manager on day to day matters of the project and

functionally reporting to QA/ QC Manager on QA/QC related matters.

QC Inspectors

Liaise with QCI of PDO through the Sr. QA/QC Engineer for conducting day to day

activities for the projects

Hydro test Engineers/ Supervisors

Shall be responsible for interpretations of Project scope of work & drawings and

executes the work as per the Specifications, HSE & QA/ QC guidelines. Ensure the

work is done as per approved method statement and specifications. Also ensure that

Permit to work is obtained through permit Holder.

Apart from the above; Hydro test Engineer is fully responsible for implementation of this

procedure. His responsibilities include but not limited to

Ensure that all activities and documents related to pipeline are completed and

obtain necessary Mechanical Clearance from QA/QC Personnel.

Ensure that Pressure gauges, Pressure recorder’s etc. are as per PDO

Specifications and have valid Calibration Certificates.

Ensure that water used for hydro testing is tested for Quality requirement and

test report available.

Ensure that standard fittings, valves, hoses etc. are used for testing.

Ensure proper communication facilities are available at site.

Liaison with PDO Representative and HSE Dept. on matters regarding Health,

Safety and Environmental Protection.



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Ensure that area is barricaded with warning tape and warning signs are

displayed.

Ensure no unauthorized person enter barricaded area of test section while hydro

test is in progress.

Ensure all personnel involved in the Hydro testing activity are aware of the

communication and emergency procedure.

Ensure that adequate measures are taken to safeguard all personnel and

equipment working in the close vicinity of test section.

Ensure disposal of water is carried out as per PDO requirements.

Ensure necessary Lighting arrangement is there to carry out the work in the

night.

Hydro test Engineer functionally reports to Construction Manager.

6.0 EQUIPMENT LIST

Circulation, Flushing and pressurizing Pumps

Temporary pipe fittings / connections, hose connections, spades and blank /

blind flanges, temporary pipe work, temporary strainers, valves and spool pieces.

Temporary supports.

Test gauges complete with test certificates and double block and bleed valves for

connection to equipment.

Dead weight tester accurate to 5 kPa with valid calibration certificate.

Air-compressor for pneumatic testing and equipment drying.

Chemical mixing and injection equipment.

Medium Density Foam

Crew Transportation vehicle

Pick-up/ Station Wagon



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Consumables

Water treatment chemicals

Pickling chemicals

Temporary gaskets

Corrosion inhibiting chemicals

7.0Methodology

7.1 Permit to work

Permit to work as required shall be obtained by the construction

supervisor/Permit Applicant from the authorities concerned of PDO for the

section to be hydro tested. Necessary permission to carryout work in the night

and also to drive vehicle in the night will be obtained.

7.2Preparation

Prior to pressure testing the Contractor shall ensure that the following are completed.

Flushing operation carried out as per the test pack sheet.

Prior hydrostatic testing system folder shall be submitted and approved by company.

The test pack folder should contain the following:

Data Sheet for Piping for all lines indicating the design pressure and temperature at each line. Refer to DEP 31.38.01.92-Gen - Data Sheet for Piping

An equipment list of items which shall be included in the system test indicating design pressure and temperature ratings.

An equipment list of excluded items with reasons for exclusion.

The pressure test details indicating the test medium, test duration and test pressure.

Piping Installation for Test check sheet.

Test Equipment Calibration check sheet.

Piping Cleanliness check sheet (where applicable).

Piping ISO Index for Test check sheet for each section of pipework included in the system test. The isometric drawing shall indicate:



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Vent and drain points.

Position of blanks/spades.

Position of test pressure gauges.

Temporary spool pieces.

Filling position and pressurization point.

Valves (mechanical) to be included in the tested.

Extent of pipe work to be pickled/chemically cleaned (where applicable).

Prior test shall submit a full set of flow sheets for all systems, marked showing each test that is intended to be carried out.

The flow sheet(s) shall show the extent of the test loop clearly marked indicating all blank/ spade positions, vent positions, pressure gauge positions, and the filling entry point.

All pressure gauges to be used for the test shall have a unique number and shall be calibrated prior to each test using a standard Dead Weight Gauge Tester.

The test details of each gauge to be used shall be entered on Test Equipment Calibration check sheet. Any gauge showing an uncorrectable zero reading, or error of more than 2% of full scale range shall be discarded and a new gauge shall e obtained. New gauges shall also be calibrated prior to use.

The gauge scales shall be calibrated in kPa and shall be not less than 125 mm in diameter.

The WIN PCS / CCMS check sheet shall be completed and approved by the Contractor and accepted by PDO before the testing can take place.

If equipment and vessels are to be included in the system limits, shall ensure that:

Manhole covers are installed with permanent gaskets.

All floats are removed from the equipment and vessels.

Any special precautions have been taken, e.g. exchange floating tube sheet test ring fitted for shell side test, if shell cover is removed. Bellows restraining bars shall be fitted, if required. Differential pressure considerations between shell and tube side of the exchangers shall be observed.

When testing against CLOSED block valves, drains and vents on adjacent equipment or systems are to be left open to prevent pressurization due to leaking valves.

When vessels are to be tested separately from piping, care shall be taken that all pipe connections are blinded or disconnected so that the entire system is not flooded.



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When testing connecting piping and not the vessel, pipe connections shall be blinded and vents and drains of vessels shall be left open.

Equipment and vessels are unpainted and uninsulated.

Blanks installed at interface with all rotating equipment.

7.3Flushing

The piping system and equipment to be flushed prior to test to ensure the line system free from sand, debris, obstructions etc. Flushing will be carried out using pumped water from a separate supply or with water from the fire main system if available, and subject to Company approval. On system / equipment where “once through” flushing is to be carried out, the flush shall continue until clear water is observed at the exit point. Flushing shall be continued for a further period of 5 minutes after the water at the exit point is confirmed clear. On system / equipment where “circulation loop” flushing is to be carried out, the flush shall continue until circulation pump strainers show no further evidence of extraneous materials and the circulating water at the pump suction is clear.

Where possible the flushing water velocity should be approximately 5m/sec. This shall be attained using either flushing pumps or fire main water (if available). Where fire main water is to be used the following may be used as a guide to obtain the required velocities. The guides are based on the assumptions:

Fire main pressure 790 – 930 kPa and one (1) fire hose delivers 300 m3/hr.

For lines up to and including 150 mm diameter, use one (1) fire hose (64 mm. fire hose with 75 mm. hose coupler).

For lines greater than 150 mm. up to and including 250 mm. diameter use two (2) hoses.

For lines greater than 250 mm up to and including 400 mm. diameter use three (3) hoses.

For lines greater than 400 mm. diameter use four (4) hoses.

On completion of flushing, blanks installed for the purpose of flushing which are not required during subsequent pressure testing shall be removed and the joints re-instated with new gaskets. Any joint that has been broken shall have a new gasket fitted. Permanent service gaskets shall be installed after flushing on any joints that will not be broken again during or after hydro testing. All tanks, vessels and drums that were included in the flushing operations, shall be checked to ensure cleanliness and security of internal fittings. Flushing water shall be drained to a suitable open drain or sewer system, or if no open drain or sewer system is provided an area designated by the Company. Flushing documentation shall be carried in specific format identified in CQP.



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7.4Water

filling

The system shall be filled from the lowest point with all vents open. All high point vents and other connections which serve as vents shall be open during filling of the equipment / system. Venting through high point flanges shall be acceptable where the system under test does not contain a high point vent. The vents shall be progressively closed when a steady air free stream of test media is issuing from the vent. The Company shall approve any test water supplied by the Contractor and additionally specify any additions of inhibitors or scavengers that may be required. An adequate mixing system shall be provided and utilised by the Contractor to ensure a uniform solution.

7.5Hydrostatic Testing



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The filling hose from the pressure generator shall be connected to the lowest point of the system to be tested. Pressurize initially up to approximately 100 KPa and check for missing gaskets and leaks. Prior to checking system for leaks external surfaces should be dry. During the test the pressure shall be increased in stages to allow for strain and for leak checking and inspection of the equipment / system. The actual pressure applied shall not exceed the test pressure by more than 2%. Should the actual pressure exceed the test pressure by more than 2% (due to thermal expansion in a closed system) the system shall be vented to reduce the pressure to the specified test pressure. Leaks detected on the equipment / system shall only be rectified once the test pressure has been relieved. Tightening of bolts on flanges or joints shall not be undertaken with pressure on the equipment / system. When leaks have been rectified the test shall be carried out again for the full duration. The test pressure shall be maintained for a minimum of two (2) hours or for as long as it shall take to inspect all the equipment / system for leakage or failure. The pressure generator shall not be connected to the equipment or system under test until immediately prior to the test and shall be disconnected immediately after the test pressure equalizing. Stop points and visual checking the equipment or system under pressure at each stage shall be determined before testing commences.

7.6Draining & Drying

On completion of hydrostatic testing the Contractor shall remove all water from the equipment / system under test. The equipment / system shall be vented in a controlled manner during drain down so as to prevent a vacuum or partial vacuum from being drawn. The equipment / system shall be protected from corrosion once all test media has been drained. Depending on the conditions prevailing at the time of testing i.e. availability of resources and the proposed commissioning schedule a number of options may be available:

After drain down, the equipment or system may be immediately blown dry with air to a dew point of -1C. Special attention shall be given to equipment which is difficult to drain e.g. heat exchangers shall have their individual tubes blown through.

If no reinstatement is required the test media may be displaced with an inert atmosphere e.g. nitrogen or dry crude.

Refilling the equipment / system with the process fluid immediately after draining

7.7Disposal of Test Media

Test water shall be drained to a suitable open drain or sewer system. Chemically treated test media shall be drained via the open / closed drains systems of water handling facilities installed at the location. Where no such facilities exist, an evaporation pond may be utilized taking adequate precautions to keep animals away. Disposal to estuaries or the sea shall be avoided wherever possible.



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7.8Corrosion protection

Equipment / system that is to be drained of test media and then left empty one month or more shall require to provide special precautions/treatments to prevent the ingress of air and subsequent corrosion. Such special treatments shall include one of the following:

filling with nitrogen or other inert gas

filling with sweet dry oil

7.9Reinstatement of the System

On completion of all flushing and pressure testing the system shall be reinstated as per the

construction drawings. Any joint that is broken after hydro testing shall have a new permanent

service gasket fitted. These joints shall be taped and subjected to an air pressure test not

exceeding 400 kPa to ensure the integrity of the joint. Leak testing shall be accomplished using

soapy water. The installation of instrument shall be in accordance with ERD-30-01.

7.10 Documentation /Records

Upon completion of hydrostatic test of each section/line, the hydro testing engineer shall

organize the following documents and hand over to the customer. Original shall be

submitted along with the test pack.

a. Flushing Report MED-QC-830-006 -F/01

b. Hydrostatic Test Report MED-QC-830-006-F/05

c. Hydrostatic test Acceptance Certificate MED-QC-830-006-F/07

d. Drying Acceptance Certificate MED-QC-830-006-F/08

e. Mechanical Acceptance Certificate

f. Original of all record charts.

g. Calibration certificates of all instruments/test equipments

8. 0 QA/QC



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Inspection and Test plan, Storage and handling, stringing quality control procedures are

summarized in project Quality Control plan.

Refer MED – QC – 830- 003.

9. 0 HSE

During all stages of the pipeline construction, the Contractor shall work to the highest

achievable safety and environmental standards. The safety performance of all staff

involved in the work shall be monitored and recorded. Regular safety inspection of the

construction sites shall be carried out, to ensure compliance with the relevant

procedures, as well as maintaining awareness of all staff regarding potential hazards.

The aspects related to the management of safety during the construction phase are

covered in EP 95 0000 and SP-1208/SP-1247 as applicable.

10.0 ANNEXURE

Formats


Documents

On- Plot Hydrotesting