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SITESERVICESDEPARTMENT

FieldHydrotestProcedureforrestrainedsystem

Project Waste Water Monitoring Skid _ Tasnee

Contractor Industrial Instrumentation and Control Systems Ltd

EndUser SABIC/TASNEE

Reference FieldHydrotest(restrained)

Revision 0

Date Nov15,2015

TableofContents
1 FieldHydrotestProcedure.........................................................................................................2
1.1 General....................................................................................................................................................2
1.2 Reference.................................................................................................................................................2
1.3 Inspection................................................................................................................................................2
1.4 Preparation..............................................................................................................................................2
1.5 WaterFilling.............................................................................................................................................3
1.6 Pressurization..........................................................................................................................................3
1.7 Pressuredrop...........................................................................................................................................3
1.8 Depressurization......................................................................................................................................4
1.9 Precautions..............................................................................................................................................4
1.10 Tools&Accessories.................................................................................................................................4

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1 FieldHydrotestProcedure
1.1 General
This Method Statement describes the objectives and requirements of steps to be followed during the Field
HydrotestingofRTRpipessupplybyFPI.Fieldtestpressure=1.5xDesignpressure.

The procedure written in this Method Statement is as complete as possible; it is not possible to describe
allkindsofcircumstancesthatmaybeencounteredinthefield.ForthisreasonourexperiencedSupervisormay
varythedescribedprocedureinordertoachieveanoptimumsolutionusingthelatesthydrotestingtechniques
andprocessingmethods.
1.2 Reference
FiberstrongInstallationGuideforAboveground/UndergroundPipeSystem
ShellDEP31.40.10.19

1.3 Inspection
Itisimportanttoconductavisualinspectionthroughoutthesystempriortothetestingprocesstoidentifyany
external damage that may have occurred during the installation/handling process of the pipe. If any damage
occurreditshallberepairedaspertheWavistrongRepairProcedure.
Ensurethatalljointsareproperlyinstalledasperapprovedisometricdrawings.Thepipesectionshallbepartially
backfilled and compacted leaving the joints exposed to inspect after pressurizing the system. The partial
backfillingwillpreventextrememovementofthesystemwhilepressurizing.

1.4 Preparation
a. AHydrotestPackforthelooporsectiontobetestedmustbesubmittedforapproval.
b. Itisrecommendabletolimitthetestinglengthuptoonehalfkilometerforbetterqualityofwork.
Howeverthetestsectionslengthcanvarydependingonsiterequirementsasagreedandaccepted
bytheenduser.
c. Allhighpointsshallbeprovidedwithvents.
d. Incasethelinedoesnotincludeflanges,itwillbenecessarytoconnecttemporaryflangesfor
testingpurposes.
e. ForU/G,thesectionalpipelinetobetestedshouldbepartiallybackfilleduptoonexdiameter
abovepipecrownincludingpipetofittingjointstoensureapropersupport.Allstraightpipefield
jointsshallbeleftfullyexposedforinspectionduringthetest.Temporarysupportsortotalbackfill
shouldbeprovidedtothefittingsatthechangeofdirectionduringthetest.
f. ForA/G,checkpipesupportsifitisinstalledaccordingtopipingisometricdrawings.Ifnot,rectify
firstthesupportsbeforedoingthehydrotestandwaterfilling.Ifyes,proceedwiththetest.
g. Removetheconnectinginstrumentifanysuchasvalve,bellow,strainer,flowmeterandothers
wheretheblindflangeistobeconnectedtothefiberglassflange.
h. CleanthefaceofGREflanges,blindflanges,gaskets,bolts,nutsandwashers.
i. Allgaskets,nuts,washersandboltsusedforhydrotestshallbereplacedafterfinaltesting.
j. InstallKrollandZillergasketandblindflangesincludingbolts,nuts,washerstoitsappropriate
location.Applytorqueusingcalibratedtorquewrenchandboltsequenceaspermethodstatement
forflangetightening.
k. Requiredtemporarypipingarrangementslikeblindflangesanddummyspoolswillbeinstalledin
appropriatelocation.
l. PressureGaugesandpressurizingpumpareconnectedtothelineattheblindflanges.

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m. Testingshallbehydrostaticusingseawaterorpotablewaterasthetestingmedium.
n. PipingsectiontobeHydrotestedshallbefilledfromthelowestpoint.Ventsorotherhighpoint
connectionsshallbeopenedtoexpelairfromtheline.
o. Allvalvesinthetestsystemshallbefullopenedposition.

p. Ventsshouldbeclosedonlywhenclearwaterwithnoairbubblescomesthroughthevent.Allair
shallberemovedfromthepipingsystembyventingbeforehydrostatictestpressureisapplied.
q. Thelinewillbefilledwithapprovedwater.Afterclosingallventsthewaterfillingwillbestopped.
1.5 WaterFilling
Thesystemshallbeflushedpriortothehydrostatictesting.Theflushingofthesystemshallbecarriedoutfrom
thehighestpointofthepipeline.Potablewaterorproducedwatershallbeusedforthispurpose.Ensurethatthe
flushingcontinuesuntilclearwaterappears.Oncetheflushingiscompletedwatercanbefilledtothesystem
fromthelowestpointofthepipelineinasteadyandcontrolledmanner.Fillalargeamountofwaterintothe
system.Ensurealltheventsanddrainsareopenedwhilefillingwaterinthesystem.Adequatecareshallbetaken
toventthesystemtoavoidanyairentrapmentinsidethepipelinewhichmaycauseapressurebuildupinthe
system.

1.6 Pressurization
Afterthefillingprocessiscompleted,sealtheentiretestsectionwiththerequiredblindflangeskeepingallvalves
fullyopened.Adevisecapableofcontinuouslypressurizingthetestsectionshallbeconnectedtothepipeline
withtherequiredtemperatureandpressurerecorders.Apressuregaugeshallbeconnectedtothehighestpoint
ofthepipeline.Allpressuregauges,recordersshallbecalibratedpriortouseinthesystem.Startpressurizingthe
systemgraduallyandinasteadyandcontrolledmannerto0.25timesofthetestpressure.Whenthepressure
reaches the required level, maintain the pressure for 30 minutes to allow the system to stabilize. Once the
stabilizationtimeiscompleted,continuepressurizingthesystemgraduallyto0.5timesthetestpressure,and
thenmaintainthepressurefor1hour.Again,oncethestabilizationtimeiscompleted,continuepressurizingthe
systemgraduallyto0.75timesthetestpressure,thenmaintainthepressurefor30minutes.Afterthatincrease
the pressure up to the required test pressure and maintain the pressure for maximum 4 hours. The rate of
pressurizationshallnotexceed2barperminute.

Uponcompletionofpressurizingthesystem,dismantlethehoseconnectionfromthepressurepumpandseal
theendswithsuitableplugs.Theentirepipelineshallbecarefullyinspectedforanyleakagefromthejointsorthe
pipebody.Thetestpressureinthesystemshallbecloselymonitoredandbemaintainedtotherequiredtest
pressure.

Followingsuccessfulconclusionofthestrengthtest,aleaktightnesstestshallbecarriedoutatapressureequal
to1.1timesthedesignpressure.Thetestpressureshallbeheldfor24hoursduringwhichtimenowatershallbe
addedtoorremovedfromthepipeline.Duringthetest,thepressureshallberecordedcontinuouslyevery
30minutes.

1.7 Pressuredrop
Pressuredropmayoccurduetothefollowingreasons

a. Temperaturevariationbetweendayandnight
b. Leakageofaccessoriesconnectedtothesystem
c. Leakagefromthegaskets
d. Dirtatsealingarea

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e. Leakingtestequipment
f. Stabilizingtimetooshort
g. Leakingadhesivebondjoint
h. Leakageofpipeasaresultofdamage(cracks)
i. Settlementofthepipelinesystem
Ifanyleakisobservedfromtheflangeconnections,itisnotpermittedtotorquetheflangeunderpressure,the
lineshouldbedepressurizedandthentheflangestobetightened.Iftheflangeorgasketisfoundtobe
damageditshallbereplacedwithanewone.
Ifaleakageisobservedonthepipebodyorthejoint,thetestshallbeterminatedandtheleakingjoint/pipeshall
berepairedaspertherepairprocedure.
Ifnoleakageorweepingisobservedduringtheinspection,thehydrostatictestissuccessfullycompletedandthe
systemisreadyforuse.

1.8 Depressurization
Thedepressurizationofthesystemshallbecarriedoutcarefullytoavoidanynegativepressureinthesystem.All
theventsshallbekeptopentoallowadequateairintothesystemwhiledrainingthepipeline.Watershallbe
drainedslowlyandinacontrolledmanner.

1.9 Precautions
Allprecautionsshallbetakenwhiletestingthesystem

a. Thetestareashallbebarricaded
b. Placewarningsignsatalladjacentareas
c. Onlyexperiencedpersonnelshalloperatetestequipment
d. Onlyauthorizedpersonnelshallbeinvolvedinthetestorinspectionoperation
e. Onlyonepersonshallbeincharge
f. Donotchangeanythinginthepipelinewhenitisunderpressure
g. Thetestingequipmentshallbeinstalledatasufficientdistancefromthepipeline

1.10 Tools&Accessories

a. Pressurepumpwithconnectinghose
b. Blindflanges/Endcapswithnippleopeningforfilling,ventingandgaugefixing
c. Calibratedpressuregauges&airreliefvalves
d. CalibratedTorqueWrenchforflangetightening
e. RingSpannerswithrequiredboltheadsize
f. Pressure/temperaturerecorder(withuptodatecalibrationcertificates)withafullscalereadingof
abouttwicethetestpressure.

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