MULTITECH OILFIELDSERVICES LTD

PROJECT TITLE: HYDROTESTING OF QUAD JOINTS INNER PIPES.

DOCUMENT NUMBER: MULTITECH-QA-PR-XXXX

Generic code Organization code Document type Department /discipline Numeric sequence
code code no
MULTITECH PR QA XXXX

PROCEDURE FOR HYDROTESTING.

2 05/12/2016
1 02/12/2016
0. 14/11/2016 Muyideen Balogun Iloghiojie Peter Chindah Gabriel
REV DATE PREPARED BY REVIEW BY APPROVED BY
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REVISION SUMMARY

Rev Section Para/Location Revision Description

1 6.2 (page 7 of 16) Flushing of pipes using water

1 20% interval of pressurization as well as

6.4.1 (page 7 of 16)
pressurization rate to 9.5bar/min.

1 6.3 (page 8 of 16) List of Equipment to deploy

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TABLE OF CONTENT

1. PURPOSE 4

2. SCOPE 4

3. REFERENCES 4

4. DEFINITION AND ABBREVIATION 4

5. REPONSIBILITIES AND AUTHORITIES 4

6. PROCEDURE 5

6.1. PREPARATION
6
6.2. PRE-CLEANING, WATERFILLING, AND TESTING

6.3. LIST OF ALL EQUIPMENT TO BE USED FOR THE HYDROTEST 9

OPERATION

6.4. HYDROSTATICS TEST ACCEPTANCE CRITERIA 9

6.5. CLOSE-OUT ACTIVITIES 12

6.6. SAFETY AND ENVIRONMENTAL PROTECTION 12

7.0. HYDROSTATIC PRE-PRESSURISATION CHECK LIST FORM 14

8.0. PIPELINE HYDROSTATIC TEST PRESSURE AND TEMPERATURE 15

DATE RECORD FORM

9.0. HYDROSTATICS TEST CERTIFICATE FORM 16

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1. PURPOSE
The purpose of this procedure is to prove the integrity of the QUAD JOINT INNER PIPES
through hydrostatic pressure testing and confirm the integrity for its designed use.

2. SCOPE
Hydrostatic testing of the 113 Lengths of Quad Joint Inner Pipes.

3. REFERENCES
- Pipeline Hydro test Specification
- ASME B31.8.
- ASME B31.4.
- API 1110
- EN-12502
- All effective Nigerian Laws, Regulations, Codes & Standards.
- Water Analysis report as required/recommended by the approved project procedure,
applicable code and standards.

4. DEFINITIONS AND ABBREVIATIONS

ASME American Society of Mechanical Engineers
API American Petroleum Institute
Specific Test Pressure (STP)
PTW Permit to Work

5. RESPONSIBILITIES AND AUTHORITIES

Site Superintendent/Testing Engineer - Implements operating procedures on project
sites
Mechanical Fitter - Responsible for assuring proper mechanical fit-up before and during
hydrotesting as well as dis-coupling after dewatering operation.
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Pump Operator- Responsible for pump rig-up, operation, and rig-down.

6. PROCEDURE

6.1 PREPARATION
Before commencement of work at the project site, MULTITECH shall submit the
designated approved Test project teams names and CV's for client approval.
The Site Superintendent shall designate qualified personnel to be responsible for all
hydrostatic testing activities. Prior to commencement of hydro testing activities the
Hydro test, we shall ensure comply and work in accordance with the CLIENT approved
Permit to Work System (PTW). Actual Testing activity shall be executed only after all
NDT results have been confirmed including the pin brazing for CP by the client
designated representative via a written instruction to proceed with Hydro testing and
an approved Hydrotest pack is in place.
All testing equipment to complete the hydro test is to be supplied by MULTITECH. The
Test Engineer shall be responsible for all test preparations including, test manifolds,
piping, pipe filling and draining. The location for filling, testing and draining of the pipes
shall be mutually agreed between the Test Engineer and client.

All water required for filling, flushing, and pressure testing shall be provided by the
Client, who shall also be responsible for the filtration, clarification and Chemical
treatment of the water so as to prevent ingress of foreign matter, sedimentation and
metal corrosion, the water used for filling and testing shall be clean water of potable
quality.

The chemical pre-treatment of water used for pressure testing will depend on the origin
and analysis (particularly salinity) of the water source. Chlorination may be necessary
to stop development of lime, bacteria and other micro-organisms inside the system
under test. The composition and dosing rates of corrosion inhibitors, sterilizing agents,
bactericides and all other chemicals to be used in the pre-treatment of test water shall
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base on the Water analysis report and approved by the Client before use. Agreed
dosing rates shall be controlled and maintained by properly calibrated micro dosing
pumps and the injection shall be carried out well upstream of the fill points so as to
allow thorough mixing before entry to the system under test. This is Client scope.

MULTITECH is responsible for obtaining permits, for using and disposing of water for
cleaning and testing purposes from the Client.

MULTITECH is to provide all necessary permits and approvals for all hydro testing pre-
commissioning /commissioning work.

The appropriate pressure and temperature gauges, recorders, dead weight tester and
valves specified shall be connected to the installed pipes in preparation for the
hydrostatic test. Test measuring equipment shall be calibrated and Certificate shall be
made available at any point in time during testing services.

The connections and the test assembly shall be checked by the Test Engineer for
conformity to this procedure and to ensure that all safety precautions have been taken
into place with warning signs and barriers installed.
All valves, if installed shall be in the open position during the hydro test, Pipe section
shall be prepared as such as to allow all segment of the line be Hydro tested in series
as may be permitted and based on space requirement at end facilities.
The Quad pipe shall be hydrostatically tested to the specific test pressure (STP), the
entire length of the river sections shall be tested as one section prior to pulling into
position. When specified, each test procedure shall contain test plans or sketches,
identifying the pipeline sections to be tested, clearly showing the test limits including
the pipe test legend indicating the test pressure, the test medium and any other
pertinent information. In the event of a conflict between this procedure and the
specification or standards, the more stringent will prevail.

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6.2 Pre-Cleaning by Water filling and Testing.

Before the pipe section is ready for water filling and hydrostatic testing it shall be
flushed using water only. Any other cleaning method shall be the responsibility of the
client provided that it comply with the clients hydrostatic test procedure.
The section ends shall be sealed with temporary header for cleaning purpose.

Notification shall be given to local residents and notices 'KEEP AWAY - PIPES
UNDER TEST' and 'NO PARKING' shall be prominently displayed at points of public
access. Arrangements shall be made to ensure that no unauthorized person may approach
within 50 meters of any exposed pipe, or test end.

Hydrostatic Test Sections and Test Pressures

The pipe sections to be tested are limited by the following factors:
Minimum and maximum test pressures (taking into account that there may be pipe of
different wall thickness in the test string, therefore the thinner walled pipe becomes the limiting
factor);
Elevation difference;
Filling and dewatering plan.
Hydrostatic test section shall be the entire length of the Quad Joint Inner pipe.
The hourly maximum loss of test water volume to be recognizable by the equipment shall
be calculated as V 4 x V total / 3000 but never exceed 4 liters.
Start- and end points of test sections shall ideally be well accessible, next or close to water
sources and/or in low elevations.
The test section distribution is within the scope of works of the Contractor and shall be part of
the hydrostatic test procedure.

Testing of the installed pipes shall be tested and pressurized to a minimum 1.25 of the
Design pressure in accordance with Project Specification.

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After filling, the pipe shall be stabilized. The stabilization period shall be 30 mins. After the
stabilization period, the test shall be started. During the testing of the pipe, the QC will
check for pressure drops. Should a leak occur, the test pressure is reduced to 0. Repairs,
other than welding, are completed and the pipes subsequently re-pressurized and re-
tested.
Test pressures and temperatures shall be recorded on the chart throughout the testing
period. The recorder shall be placed within safe distance of the pipe under testing.
However, request from the client for further relocation (35m away from the test point)
shall attract additional cost of hiring more lengths of hose.
Upon satisfactory completion of the test, the results shall be recorded.

6.3 LIST OF ALL EQUIPMENT TO BE USED FOR THE HYDRO TEST OPERATIONS

S/No Equipment Description Quantity

1 Volume fill Pump 1
2 High Pressure Pump (10,000 Psi rating) 1
3 150bbl Holding Tank 1
4 Pressure Gauge (1 use & 1 back-up) 2
5 Pressure Recorder 1

6.4 HYDROSTATIC TEST ACCEPTANCE CRITERIA

The pre-testing location shall be selected by the Contractor and approved by the Company.
The pipe strings shall be placed on suitable and safe temporary supports at least 600mm
above ground level to facilitate visual inspection. Each pipe string shall contain only pipe of
the same wall thickness. Dome cap test ends shall be fitted at each string; these test ends
shall have been pre-tested and certified to a pressure at least 10% greater than the selected
pre-test pressure. A record of their use along with their unique identification number shall be
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provided to the Clients Representative prior to the any hydrostatic test activities being
undertaken.
The pre-tested pipe sections shall be tested to a test pressure of not less than 5% more than
the test pressure designated for the test section into which it shall be installed.
The duration of the pre-test shall be not less than 4 hours and the test shall be considered
accepted if no signs of a leak are detected upon a visual inspection.

Hydrostatic Test Sections and Test Pressures

The pipe sections to be tested are limited by the following factors:
Minimum and maximum test pressures (taking into account that there may be pipe of
different wall thickness in the test string, therefore the thinner walled pipe becomes the limiting
factor);
Elevation difference;
Filling and dewatering plan.
Hydrostatic test section shall be the entire length of the river crossing as one unit.
The hourly maximum loss of test water volume to be recognizable by the equipment shall
be calculated as V 4 x V total / 3000 but never exceed 4 liters.
Start- and end points of test sections shall ideally be well accessible, next or close to water
sources and/or in low elevations.
The test section distribution is within the scope of works of the Contractor and shall be part of
the hydrostatic test procedure.

The pipe section shall be completely de-watered following successful completion of the
pre-test and approval by Client's Representative and all welds cut out and ends re-bevelled
before transporting to site. The method of testing and criteria expected of the Contractor
by the Client shall be equal to that of the hydrostatic test requirements specified for the
mainline sections themselves.
Following installation of the pre-tested pipe into the crossing / special point section it shall
be tied into the adjacent mainline section and the entire section tested in accordance with
this specification.
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Pre-tested pipes shall be clearly marked to identify them as pre-tested. Marking shall be
made by a coloured paint along the entire length of the pipes. Different sections shall be
marked with different colours. The marking philosophy shall be included in the detailed
testing procedure.
All Pre-test certificates shall be submitted by Contractor for approval by the Clients
Representative.

6.4.1 Pressurization sequence for Hydro-test Operation is summarized in the pressure

diagram below:

TESTING DIAGRAM
4 hours straight Depressurization of statics
100%
head at a rate not exceeding
hour pressure stabilization
9.5 bar/min
80%
1 hours leak check
60%
Statics head
pressure
40%

Time to allow for venting

20%
Pressurization at a rate not exceeding
9.5 bar/min
Time

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6.5 CLOSE-OUT ACTIVITIES

Following acceptance or approval of the Hydro test, the test liquid shall be displaced from
the pipes with compressed air. Free draining of line during de-watering may be allowed.
Following satisfactory testing, temporary test heads, blind flanges, instruments and other
test equipment are removed and returned to MULTITECH yard.
All test records and record charts shall be signed by the CLIENT REPRESENTATIVE, and
included in the documentation package.
On completion of the above, the pipe is released for final installation and tie-in as may be
required.

6.6 SAFETY AND ENVIRONMENTAL PROTECTION

All personnel involved in the Hydro testing operation shall have completed MULTITECH
HSE Induction
Prior to commencing the Hydro testing operation, a detailed Job Hazard Analysis (JHA)
will be carried out. After all known or suspected or potential hazards and risks have
been identified, the workforce shall be informed of the hazards and control measures
that must be in place to eliminate or control the hazards and potential risks surrounding
the Hydro testing Operation.
All personnel shall be equipped with safety PPE, particularly for handling of chemical
additives, which require rubber gloves and safety goggles as a minimum in line with
the MSDS. MULTITECH and CLIENT Safety Representatives shall instruct personnel
in safe working practices and ensure that they are enforced.
All test crew personnel shall be trained and/or experienced in the testing activities
performed.
A communication link system shall be finalized, prior to the start of any hydrostatic
testing activities.
All static machinery, including pumps and compressors, shall be equipped with fire
extinguishers.

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All above ground sections shall be secured and entry restricted to exclude personnel,
other than the test crews during the hydrostatic testing.
Work permits shall be endorsed by security personnel made aware of the nature of the
test and access limitations.
Other than specified above, no work of any kind, either permanent or temporary, shall
be performed on any part of the system while testing is in progress.

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HYDROSTATIC PRE-PRESSURIZATION CHECK LIST

PROJECT: Location:
CLIENT: Job No:
System/Service: Report No:
Testing Sub-contractor: Test Pack No: Date:
ITEM ACTIVITY PROCESS / PROCEDURE REQUIRING ACTIVITY VERIFYING REMARK/
No. INFORMATION COMPLIANCE PARTY SIGNATURE
(Yes /No / NA)
1 General Is the testing Contractor in possession of the latest Testing Ctr
revision of the CLIENT Pre-commissioning Work
Instruction and ITP?
Has the pipeline section been cleaned? T- Ctr / QC Insp.
2 Cleaning Has the cleaning met the acceptance criteria as per T- Ctr / QC Insp.
CLIENT Work Instruction?
Have the gauging Plate dimensions been checked T- Ctr / QC Insp.
3 Gauging and confirmed?
Has any Gauging run been rejected? T- Ctr / QC Insp.
Has the Pipeline cleaning been accepted by T- Ctr / QC Insp.
CLIENT QA/QC Rep?
Have water samples been analyzed? T- Ctr / QC Insp.
Has the water laboratory been certified and T- Ctr / QC Insp.
4 Filling accepted by CLIENT Rep?
Have all valves on branch pipe connections been T- Ctr / QC Insp.
blinded / spaded and left fully opened?
Have all filling data (flow meter readings) been T- Ctr / QC Insp.
recorded?
Have the temperature recorders and thermometers T- Ctr / QC Insp.
been installed as per section 6.7 of this Work
Instruction?
5 Temperature Have all temperature stabilization data been T- Ctr / QC Insp.
Stabilization recorded as per section 6.7?
Has the temperature stabilization been achieved? T- Ctr / QC Insp.
Has the volume of water per stroke of the pressure T- Ctr / QC Insp.
pump been determined?
Has the Serial number of all test equipment and T- Ctr / QC Insp.
instruments been recorded?
Is the Dead Weight Tester having complete set of T- Ctr / QC Insp.
measurement weights / units?
Are all the instruments calibrated with valid T- Ctr / QC Insp.
6 Equipment / certificates?
Instrument Are all the measuring instruments and recorders T- Ctr / QC Insp.
Status having calibration range suitable for the specified
test pressure limit.
Is the calibration range of respective test charts the T- Ctr / QC Insp.
same as that of corresponding recorders?
Is the recorder ink available and suitable as T- Ctr / QC Insp.
required?
Have the recorder clocks been wound T- Ctr / QC Insp.
appropriately and checked to ensure that the
plotter unit is working?
TESTING SUB-CONTRACTOR :
Name: Signature: Date:
CONTRACTOR QA/QC REP:

Name: Signature: Date:

CLIENT REP:

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Name: Signature: Date:

PIPELINE HYDROSTATIC TEST PRESSURE AND

TEMPERATURE DATA RECORD
SYSTEM / SERVICE:
PROJECT:
JOB No: CONTRACT No:

TEST READINGS
TIME PRESSURE DEADWEIGHT PIPELINE AMBIENT REMARK
GAUGE TESTER TEMP. TEMP.
(PSIG) (PSIG) (OC) (OC)

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QUALITY CONTROL
HYDROSTATIC TEST
CERTIFICATE
PROJECT:
CONTRACT No: DATE:
TEST DATA
TEST DESCRIPTION: DESIGN TEMP.
( OC)
EQUIPMENT DESIGN
DESCRIPTION: PRESS.
( PSIG):
DRAWING / LINE No: TEST PRESS.
(PSIG):
TEST PARAMETERS
REQUIRED ACTUAL
TEST DURATION (HOUR)

PRESSURE IN GAUGE -1 (PSI)

PRESSURE IN GAUGE -2 (PSI)

PRESSURE IN RECORDER (PSI)

PRESSURE IN DEAD WEIGHT

(PSI)
PRESSURE ON HOLD
INSPECTED VISUALLY (PSI)
METAL TEMP. RECORDED (OC)

TEST INSTRUMENT DETAILS

RANGE SERIAL No CALIBRATION CERTIFICATE No.
DATE
GAUGE 1
GAUGE 2
PRESSURE RECORDER

TEMPERATURE RECORDER

DEAD WEIGHT TESTER

INFRA RED DIGITAL

THERMOMETER

TEST SUB-CONTRACTORS REP. CONTRACTORS REP CLIENT REP.

Name:
Signature:
Date:
INSPECTION
THE FOLLOWING AREAS WHERE THOROUGHLY CHECKED FOR LEAKS DURING THE VISUAL INSPECTION;
1. ALL WELDED JOINTS (SHELLS, HEADS AND NOZZLE ATTACHMENTS)
2. ALL BOLTED JOINTS (NOZZLES, MAN-WAYS, FLANGES E.T.C)
3. TREADED JOINTS (NPTs)

4. PIPE EXTERNAL SURFACES AS WELL AS PIPE SURFACE DEFORMATIONS.

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