S - 29 STANDARD CONSTRUCTION SPECIFICATIONS SECTION 29 PRESSURE TESTING

This Specification covers the pressure testing of pipelines flowlines, station and manifold piping and pressure vessels. It details the procedures to be used in pressure testing and delineates the functions and responsibilities of the testing contractor and the construction/installation contractor concerned. This Specification does not give specific values for test pressure, since these are determined by the particular working pressure, design code and maximum pressure rating applicable to the system under test. This Specification- should be read in conjunction with Sections S-1 (General) and S-35 (Safety). Reference should also he made to Sections S-24, S-25, S-26 and S-34 as appropriate.

The Shell Petroleum Development Company of Nigeria Limited (Second Edition - 1982) (Revision 3 - January 1985)

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SECTION 29 PRESSURE TESTING

INDEX Page PART I

GENERAL

29.1.1 29.1.2 29.1.3 29.1.4 29.1.5 29.1.6 29.1.7 29.1.8 29.1.9 29.1.10

Testing Contractor Provision of Test Facilities and Equipment Approval and Calibration of Test Instruments Testing Personnel Programme and Testing Schedule Water Supply, Quality and Treatment Use of Liquids other than Water Safety and Access to Site Test Failures Documentation

4 4 4 5 5 5 6 6 7 8

PART 2 29.2.1 29.2.2 29.2.3 29.2.4 29.2.5 29.2.6 29.2.7

TESTING OF PIPELINES AND FLOWLINES Test Pressure Test Sections Test Equipment and Facilities Pre-Cleaning by Pigging Water Filling and Gauging Test Procedure Temperature Measurement

9 9 9 9 10 10 11 13

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29.2.8 29.2.9 29.2.10 29.2.11

Water Removal Pre-Installation Tests Final Tie-Ins of Test Sections Final Integrity Test

13 14 15 15

PART 3 29.3.1 29.3.2 29.3.3 29.3.4 29.3.5

STATION AND MANIFOLD PIPING General Test Isometrics, Check Lists and Test Sheets Pre-Test Preparations and Checks Pressure Tests Pneumatic Soap-Bubble Leak Test

16 16 16 17 18 18

PART 4 29.4.1 29.4.2 29.4.3

VALVES General Pre-Testing Valves Final Test for 100% Tight Shut-Off Valves

20 20 20 20

PART 5 29.5.1 29.5.2 29.5.3 29.5.4 29.5.5

PRESSURE VESSELS General Check Lists and Test Sheets Test Pressures Conditions for Pressure Testing Vessels Draining of Vessels

21 21 21 22 22 23

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SECTION 29 PRESSURE TESTING PART 1 GENERAL

29.1.1

TESTING CONTRACTOR The Company will specify in the pipeline construction or plant installation contract whether the facilities concerned are to be pressure tested by the construction/installation contractor or by a third party specialist testing contractor. In either case, the contractor who is to actually carry out the tests will be referred to herein as the "Testing Contractor". If a third party specialist testing contractor is specified, the construction contractor will follow the instructions of the testing contractor in preparing the facilities for the testing operations. The construction contractor shall inform the Company in writing, at least four weeks in advance, of the dote the Testing Contractor is required on Site.

29.1.2

PROVISION OF TEST FACILITIES AND EQUIPMENT The construction/installation contractor shall be responsible for making test preparations, including the fabrication and installation of test ends and manifolds and associated valves and piping, all in accordance with the Approved Working Drawings or as so directed by the Company Representative. The Testing Contractor shall provide all testing equipment (such as water filling and pressurising pumps, pipeline pigs, instrumentation and recorders) and all special equipment and materials necessary for the treatment of water supplies, such as strainer units, settling tanks, chemical dosing injection pumps, anti-corrosion inhibitors and any other chemicals. All such equipment shall be of weatherproof construction, unaffected by rain or dust storms, or shall be housed in suitable weatherproof cabinets or shelters, such that its performance will not be affected by outside influences of any kind. Test equipment for use in Hazardous Areas shall be certified accordingly.

29.1.3

APPROVAL AND CALIBRATION OF TEST INSTRUMENTS All instrumentation, such as flowmeters, dead-weight testers pressure gauges, pressure and temperature recorders and thermometers used in testing shall be subject to approval

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by the Company and shall be calibrated by an approved recognised Authority at the Testing Contractor's own expense. Particulars of each calibration shall be given on official certificates of accuracy issued by the Authority. Witnessed calibration checks on any instruments) may be called for by the Company Representative at any time during and after the course of pressure testing. Such checks may be carried out in the Company's instrument workshops or by an independent official Authority (at the Testing Contractor's own expense). No claims by the Testing Contractor (or any other contractor) for additional costs or delays incurred by such calibration checks will be accepted or recognised by the Company. If it is found that there is a significant difference between the original calibration/accuracy and the check calibration/accuracy of any instrument, which in the opinion of the Company affects the validity of the pressure test, then the whole pressure test shall be repeated at the Testing Contractor's own expense.

29.1.4

TESTING PERSONNEL The Testing Contractor shall employ an experienced responsible person who shall be wholly in charge of all testing operations and Who, for the duration of the tests, shall have no other commitments. He shall be on Site during the course of all testing operations, and shall be responsible for ensuring that the approved schedule of operations and test pressures are strictly adhered to and that no testing operations are carried out by personnel of insufficient knowledge or experience.

29.1.5

PROGRAMME AND TESTING SCHEDULE The Testing Contractor shall analyse the installation to be tested, determine the test sections and prepare testing isometrics for each section. Based on the test requirements of each section he shall draw up a programme and schedule of operations for each test or series of tests to be undertaken, - including temporary works and test provisions, flushing, pigging, water filling, air venting, pressurisation, testing, de-pressurisation and emptying - clearly laying down the responsibilities of his staff during all phases of the work. The schedule shall clearly identify the pipeline or plant sections to be tested, giving locations, test pressures and the duration of tests. This programme and testing schedule shall be submitted to the Company for approval/alteration at least six weeks before test preparations are due to-sltart. Any alteration required by the Company shall be incorporated by the Testing Contractor at no additional expense to the Company.

29.1.6

WATER SUPPLY, QUALITY AND TREATMENT

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All water required for filling, flushing, and pressure testing shall be provided by the Testing Contractor, 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. Wherever possible, the water used for filling and testing shall be sweet water of potable quality. In coastal swamp areas, however, brackish salt water may be used when so authorised by the Company in writing. The abstraction of brackish water from tidal creeks shall only be carried out when the salinity is at minimum level, towards the end of an ebb tide. Seawater shall not be used unless specifically agreed in writing by the Company. The Testing Contractor shall obtain samples of all water proposed or intended to be used as test fluids and shall, at his own expense, provide the Company with certified analyses of these samples by an approved independent testing laboratory. The Testing Contractor shall be responsible for obtaining formal consents from Water Authorities and any other Authorities concerned with the abstraction of water from any source and the return or disposal of water after use. Particular attention shall be paid to the safe disposal of water which has been treated with bactericide or other chemicals. The Testing Contractor shall indemnify the Company against any claim resulting from damage or inconvenience caused by the method used for the disposal of water. All water used for testing shall be pre-filtered through No. 40 mesh size basket filters. The filter units shall be of the "Duplex" dual basket type with 33 S.W.G. stainless steel wire gauze basket inserts and quick-release covers. 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 and in the case of river/creek water or seawater it is also required for preventing growth of molluscs, worms and other animal life forms. The composition and dosing rates of corrosion inhibitors, sterilising agents, bactericides and all other chemicals to be used in the pre-treatment of test water shall be set down in the Test Schedule (29.1.5) and approved by the Company before use. Agreed dosing rates shall be controlled and maintained by properly calibrated microdosing 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. 29.1.7 USE OF LIQUIDS OTHER THAN WATER If a liquid other than water is specified by the Company as a test medium, the Company shall supply and transport the required quantities of such liquids to the point of usage. The Testing Contractor shall make all reasonable efforts to prevent undue loss of such liquid and if, after completion of testing, the liquid is to be cleared from the line, it shall be conserved and returned to the Company.

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29.1.8

SAFETY AND ACCESS TO SITE Throughout the duration of the Contract, the Testing Contractor shall conform strictly to the requirements of Standard Construction Specification S-35 (Safety) and shall be responsible for ensuring that all contract personnel are aware of and work according to the requirements of this document and any other supplementary requirements stipulated by the Company. Where pressure testing is to be carried out at an operating plant site, the Testing Contractor must clarify. with the Company Representative the requirements for entry and which areas require Safety Permits to Work as per applicable Hazardous Area classifications. lie must then ensure that the necessary Permits are obtained according to the formal procedures laid down by the Company and that these are kept valid for the duration of testing operations and all preparatory/associated work. Before starting work the Testing Contractor shall ensure that all requirements for entry have been complied with and that all necessary fire-fighting and safety equipment is to hand. The Testing Contractor shall be responsible for official and third party notifications, posting notices, erecting safety barriers, point to point communications and all other safety precautions before and during pressure testing operations, as follows:(a) The Testing Contractor shall notify the Police and the relevant Federal State Authorities and Town/Village Authorities (as well as any third party owning or operating a road, pathway or service adjacent to or crossing the pipeline or system under test) of the date, time and duration of the test. (The term 'Service' shall include all piped services, power cables and telecommunications, etc.). (b) Notification shall be given to local residents and notices 'KEEP AWAY PIPELINE UNDER TEST' and 'NO PARKING' shall be prominently displayed at road crossings and other. points of public access. Arrangements shall be made to ensure that no unauthorised person may approach within 50 metres of any exposed pipe, above ground installation or test end. (c) The Testing Contractor shall mount patrols in suitable vehicles (with approved means of radio communication to the test headquarters) to watch points of potential hazard during the test, and in particular the crossing points of roads, pathways, railways, waterways and other places of public access. Suitable pumps and hoses shall be kept on standby to be used by the patrol crews in the event of a burst pipe causing flooding of roads, pathways or private properties. The safety of all employees and the public during high pressure level testing shall be of paramount importance and no procedures shall be allowed which violate this concept.

29.1.9

TEST FAILURES

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In the event of a test failure, the failed section shall be repaired or replaced by the construction/installation contractor as directed by the Company Representative. A full record of all labour, plant and materials involved in the repair work shall be kept up to date and agreed with the Company Representative on a daily basis. Unless the cause of failure is then or subsequently shown to be due to a manufacturing defect outside the control of the construction/installation contractor, the cost of the repair work and the cost of a repeat pressure test shall be borne by the construction/installation contractor. Failure due to gasket blow-out (or to scored or bruised flange faces) shall, in any event, be to the account of the construction/installation contractor (or Testing Contractor) responsible for making the joint concerned. 29.1.10 DOCUMENTATION All test plots and record charts shall be signed by the Testing Contractor, the construction/installation contractor and the Company Representative and then retained by the Company.

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SECTION 29 PRESSURE TESTING PART 2 TESTING OF PIPELINES AND FLOWLINES

29.2.1

TEST PRESSURE The hydrostatic test pressure which the pipeline/flowline shall be subjected to will be determined by the applicable design code and will be specified by the Company in the respective construction contract. This pressure shall be repeated in the Testing Schedule (Clause 29.1.5) applicable to the sections of line to be tested, and is referred to hereafter as the 'Specified Test Pressure' or STP. The primary point of pressure measurement (which will normally be at the point of pressurisation) shall be termed the 'Test -point '. The actual pressure to be applied at the test-point will depend on the position of the test-point with respect to the maximum and minimum elevations of pipe within the test section. In general, the pressure applied at the test-point shall generate the Specified Test Pressure at the lowest point of the test section, and the maximum variation in pressure along the test section shall not exceed that caused by a change in elevation of 50 metres

29.2.2

TEST SECTIONS The pipe-line/flowline sections to be tested shall be as long as practicable but the actual lengths of test sections and the locations of test points shall be as agreed with the Company, with due regard to the construction contractor's work programme, the location of suitable water supplies and disposal facilities and, any other special factors affecting that section to be tested. The maximum difference in elevation on any test section shall not be greater than 50 metres unless otherwise directed or agreed by the Company.

29.2.3

TEST EQUIPMENT AND FACILITIES A specially pre-fabricated manifold or 'test end' shall be installed at each end of each test section. The test ends shall incorporate a through conduit block valve with a suitably valved bypass manifold, to enable the various types of pipeline pigs intended to be used for

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cleaning, testing and clearing the line to be launched and received in a continuous series. A device shall be incorporated at the receiving end to indicate the arrival of each pig. Test ends and manifolds shall be designed for a working pressure equivalent to the maximum line test pressure they are to be subjected to. The design factor used shall be 0.72 and the test ends shall be subjected to a pressure test of 1.5 times their design pressure. The design of the test ends and manifolds shall be approved by the Company before construction commences, and the pressure tests on the test ends shall be witnessed by the Company Representative. All testing assemblies and test ends shall be manufactured from new fittings and materials and during fabrication all welds shall be subjected to 100% radiographic examination. The films of such radiographic examination shall be held available for inspection by the Company Representative. Before and after connecting on to the section of line to be tested, test ends and other testing assemblies shall be visually inspected to ensure they are free from mechanical damage, distortion or any other defects which may initiate failure. Where test ends or other components are used more than once they shall be similarly inspected at each time of usage. 29.2.4 PRE-CLEANING BY PIGGING Depending on the function and responsibilities of the contractor concerned, either the Testing Contractor or the construction contractor shall prepare all new lines for testing by cleaning as follows:A single trackable swabbing pig shall be driven through sections of the line between suitable tie-in points as soon as practicable after construction. This pig shall be driven by air and received into a slotted pig trap. The maximum pressure used to drive the pig shall be 7 bar (100 psig). After the sections of line comprising a test section have been joined together, a series of air-driven brushing pigs shall be run through the complete test section (to a slotted pig trap) until the cleanliness of the test section has been established to the satisfaction of the Company Representative. 29.2.5 WATER FILLING AND GAUGING When the test section is adjudged to be clean, the line shall be filled with water, using a pump of adequate capacity and at least two swabbing-pigs to ensure the removal of all air. The rate of filling shall be such that the pigs should travel at a minimum speed of 1 metre per second. After the emergence of all the water filling pigs, water shall continue to be flushed through the line until it is acceptably clean at exit from the line.

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An approved design gauging-pig with a tracking device shall then be driven through the test section to prove the bore. The circular gauging plate shall be of steel or aluminium (as specified or directed by the Company) the diameter of which shall be equal to the smallest internal diameter of the line being pigged, less one wall thickness and less 1.6 mm (1/16 inch). The thickness of the gauging plate will be decided by the Company, depending upon the pipe diameter, but in any case the gauging plate shall he machined flat and truly circular and where specified the leading edge shall have-a 45' bevel. During the-running of the gauging pig, the, amount of water used to propel it shall be metered in order to work out its probable location in the event of it becoming stuck in the line. When the gauging pig has passed through the test section, the plate shall be inspected by the Company Representative for bending, notching or other undue deformations. If such damage is found unacceptable, the gauging pig shall be re-run as many times as necessary until it emerges with the gauging plate in an acceptable condition. Any source of persistent damage to the gauging plate and any pig that becomes stuck and cannot be removed by normal pumping pressure shall be located by the construction contractor and the necessary cut-outs and repairs carried out at his own expense. 29.2.6 TEST PROCEDURE Before the pressure is raised in any test section, the Testing Contractor shall satisfy the Company Representative that all safety precautions have been implemented and that he has sufficient staff available for the duration of the test to meet all contingencies. All fittings on the test ends not in use shall be blanked off or plugged. Hydro-static pressures and ambient temperatures shall be continuously recorded throughout the test on approved calibrated chart recorders. The pressure shall be raised at a moderate constant rate up to 30 bar or 30% of the specified test pressure (whichever is the lower), the graph of pressure (on Y,-axis) against water input volume being plotted simultaneously at 1 bar intervals. The rate of pressurisation shall not exceed 20 bar per hour. The primary air content in the test section shall be determined from a straight line drawn through the plotted P-V curve cutting an intercept off the input volume axis at zero pressure. The primary air content shall not exceed 0.5% of the calculated volumetric capacity of the section of pipe under test. If the air content does ' exceed 0.5% of the volumetric capacity, then further pigging to displace the residual air pockets with water shall be carried out. If the primary air content is less than 0.5% of the section volume, the pressure shall be held at 30 bar or 30% of the specified test pressure (whichever is lower)for a minimum period of 2 hours and a thorough check for-leakage carried out on all exposed parts of the test section and all connections and fittings used for the test. On satisfactory completion of this two-hour holding period and leakage check, the high level pressure test shall then proceed strictly in accordance with the following sequence of operations:-

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(a) Raise pressure at a moderate constant rate (not exceeding 20 bar per hour) up to 70% of the specified test pressure. (b) After 70% of the specified test pressure has been attained, continue to pressurise at a rate not exceeding, 15% of the specified test pressure or 10 bar per hour(whichever is the lower rate) until the specified test pressure has been reached. (c) Maintain full specified test pressure for 2 hours (reducing pressure if necessary to counteract the effect of solar heating or rising ambient temperature).

(d) Reduce pressure to 50% of the specified test pressure at a rate not exceeding 20 bar per hour for the first hour and 60 bar per hour thereafter. (e) After this pressure reduction, carry out a thorough visual inspection of all exposed pipework, joints and fittings for any sign of leakage. (f) Repeat steps (a) to (d).

(g) Repeat steps (a) and (b) so as to arrive at the specified test pressure at about the warmest time of the day. Measure ambient temperature and temperature of water in the pipeline. (h) Disconnect pressurising pump and plug or cap-off the connection on the test section. After establishing that conditions have properly stabilised, start off a new chart in the 24-hour pressure recorder and take first set of pressure and temperature readings. Record the test pressure for 24 hours, logging the gauge pressure and temperature readings at hourly intervals. The pressure shall also be carefully measured with a certified dead-weight tester at the beginning and end of the 24 hour test period, and at prescribed intervals during the test period. (i) At the end of this 24 hour test period there should be no loss in pressure which cannot he accounted for by a decrease in temperature conditions or by residual free air pockets going into solution. If a loss in pressure has occurred, the quantity of water which has to be pumped into the test section to regain the specified test pressure shall be measured and the equivalent rate of leakage calculated. (j) On finishing the test (see following) depressurize the section at a rate not exceeding 20 bar per hour for the first hour and 60 bar per hour thereafter. During all pressurization stages, the relationship between line pressure and water-inputvolume shall be monitored and plotted continuously so that any deviation from the expected relationship will he observed. At a uniform rate of pumped water input (Xaxis), a reduction in the slope of the plot will indicate the onset of leakage or yielding of the pipeline or some other component in the pressure system. The pressurising pump

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shall be stopped if any such deviation in the Pressure/Volume plot is observed and the cause investigated, established and rectified before pumping is resumed. During pressure holding stages the ambient temperature and the pipeline water temperatures shall be recorded at the same time and intervals as the dead-weight tester readings. The test plots and record charts shall be counter-signed by official Representatives of the Testing Contractor, the Construction Contractor and the Company. All the test results, records and calculations shall be submitted to the Company for approval. If the Company considers that the results of the 24-hour pressure and leakage test are inconclusive, the Testing Contractor shall extend the test for a further 24 hours or such extra time as the Company Representative may consider necessary in order to obtain a conclusive result. Any significant loss of pressure which cannot he accounted for by temperature variation or air absorption shall be interpreted as a test failure and the defective point(s) of leakage in the system shall be located and repaired/replaced by the construction contractor as expeditiously as possible in accordance with Clause 29.1.9. After completion of the repair work, the pipeline section shall be refilled with water and the 24 hour pressure test repeated in accordance with the foregoing detailed procedure contained herein. Repairs and re-tests shall continue until the specified test pressure can be satisfactorily maintained for 24-hours. 29.2.7 TEMPERATURE MEASUREMENT In the case of buried -main pipelines, ground temperature probes-shall be installed at each end of the test section and at suitable locations along the section at intervals not exceeding 10 km. These shall be inserted in protective standpipe tubes at a depth equal to the average depth of the line under test and shall have a certified accuracy within 0.1o C. Readings shall be taken at 12 hour intervals, commencing 5 days before the test, and also at the start and finish of the final 24 hour test period. On lines which are predominantly buried, the exposed sections are to he shaded over to minimise the effects of solar heating on the water pressure. On lines which are predominantly exposed, the internal water temperature shall be measured using certified thermometers in thermowells screwed into thredolets at predetermined positions in the line. 29.2.8 WATER REMOVAL

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No attempt shall be made to empty the pipeline simply by letting water run out. After depressurising to the theoretical hydrostatic head at the test point, emptying shall be carried out by running air-driven spheres or swabbing pigs against a small back pressure to ensure that the water is removed in a continuous operation - thus preventing segregation of air and water into the high and low parts of the pipeline profile. The air compressors shall have ample volumetric output and pressure capacity to enable the water clearing pigs or spheres to travel at optimum uniform speed and overcome the hydrostatic head in the system. The maximum air pressure to be used in pigging shall be agreed with the Company beforehand and shall not he exceeded. 29.2.9 PRE-INSTALLATION TESTS Pre-installation hydrostatic tests at the specified test pressure shall be carried out on all pipes and welded assemblies used for tie-in connections, rail crossings, river crossings and major road crossings and other Situations as determined by the Company Representative. In the case of auger-bored (thrust-Lored) crossings, the pre-installation hydrostatic tests shall be carried out in the field location prior to installation of the pipe. Provided that the sections subject to a pre-installation test will be also subject to the main hydrostatic test at a later date, the pre-installation test shall follow the same procedure as for test sections (29.2.6) with the following exceptions:-

(a) (b)

Underground temperatures need not be recorded. The final hold period at the specified test pressure shall be of 3 hours duration.

(c) On completion of the final hold period a final visual check for leaks shall be made when the pressure has been reduced to 30 bar or 50% of the specified test pressure, whichever is the lower.

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29.2.10

FINAL TIE-INS OF TEST SECTIONS After section tests have been completed, the final tie-in welds between the test sections shall be carried out and all such welds subjected to 100% radiography in accordance with the specification. Wherever possible, test ends of sections shall not be cut off until the end of the pipe is about to he tied in to the next section, or permanent manifold or station pipework, etc. If it should become necessary to cut off a test end without immediate tie-in, then the pipe end shall be sealed off with an approved welded-on closure.

29.2.11

FINAL INTEGRITY TEST On long pipelines which have been tested in sections the Company may require a final integrity test of the whole completed pipeline. All the relevant preceding clauses shall apply, except that the test shall consist of a single 24 hour period at a pressure (specified by the Company) which shall he such that the pressure in the lowest point of the line or in the thinnest wall section shall not exceed the corresponding specified test pressure for that part of the system. A certified dead weight tester shall be installed at one end of the line, and certified calibrated pressure recorders and pressure gauges installed at both ends of the line under test.

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SECTION 29 PRESSURE TESTING PART 3 STATION AND MANIFOLD PIPING

29.3.1

GENERAL Process and utility piping for oil gathering flowstations; oil/water pumping stations; gas treatment/compression stations; oil/gas/water manifolding at wellheads; mainline manifolds and tie-in connections and any other interconnecting piping runs shall all be subject to pressure tests, leakage tests and such other checks and inspections as may be called for by the Company to verify the integrity and proper condition of the installation prior to start up, in accordance with the appropriate Design Code. The Testing Contractor shall be responsible for carrying out hydraulic strength tests and leakage checks on the installed pipework and associated equipment to the satisfaction of the Company. The general requirements and procedures for hydrostatic testing shall be as specified in the first part of this specification under 29.1. The Testing Contractor shall draw up a detailed programme and testing schedule as called for under Clause 29.1.5 and at least 48 hours notice shall be given to the Company Representative of the actual date and time at which such tests, checks and inspections are to be carried out. The Testing Contractor shall arrange for the supply of water to the plant and pipework to be tested in accordance with Clause 29.1.6 herein. He shall also be responsible for the provision of all testing equipment, motive power, and calibrated instrumentation, and also supply all necessary staff and labour required for carrying out the tests and collating the results. The Testing Contractor shall clearly identify the test sections by isometric drawings of the system and ensure that each has sufficient vents and drains and is positively isolated by suitably rated dividing spades or blind flanges from other piping sections, particularly those of different ANSI rating. No reliance shall be placed on closed valves for isolation during pressure testing and all valves shall be in the open position unless specifically directed otherwise by the Company.

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29.3.2

TEST ISOMETRICS, CHECK LISTS AND TEST SHEETS At least six weeks before starting these tests and checks the Testing Contractor shall submit to the Company formal test isometrics, check lists and test sheets for approval. The isometric drawings shall clearly show the terminal points of each test section; method of isolation at the terminal points; test point and instrumentation; fill, vent and drain points and additional vents, drains and connections required for the test. The check lists and test sheets shall set out the following essential information (corresponding to each test isometric) in tabular form:(a) Name, description and reference number of service line being tested or proved, specifying Piping Class and working pressure. Items (such as non-return valves, control valves and instrumentation) which are to be kept open, removed or set in a specific position for the test. Actual test or checks to be carried out. (Specifying test pressure and duration of test)

(b)

(c)

(d) Results and other data obtained during tests or checks. Date of test and space for remarks. (e) Names and functions of persons conducting and witnessing the tests with space for signatures. Where there is more than one test pressure for any manifold system, the test isometrics and testing sequence shall preferably be arranged such that upon completion of the hydrostatic test on the higher pressure section, the final joints to the next lower pressure section shall be made and the combined sections tested at the specified test pressure for the lower pressure section. The sequence shall be repeated down through the range of test pressures applicable to the compound system.

29.3.3

PRE-TEST PREPARATIONS AND CHECKS All piping and associated equipment shall be checked for mechanical completeness against the test isometrics, check lists and test sheets , and the piping installation drawings . All incomplete or missing items shall be noted for urgent attention/rectification and any discrepancies or points for concern also recorded for further investigation. Before carrying out the pressure tests, ball valves and plug valves shall be set in the half-open Positions. All other valves shall be set in the open position in accordance with the test sheets. Relief valves and bursting discs shall be removed and their connections blanked off.

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Before starting any testing operations the Testing Contractor shall, ensure that no thrusts, forces or movements can occur during the test which may possibly cause, undue stress or strain to any plant components. The construction / installation Contractor shall be responsible for the supply and installation of any temporary anchors, ties or struts required for carrying out the tests. The installation contractor shall also supply and install all temporary blind flanges and blanking spades, and all additional vents and drains required for the tests.

29.3.4

PRESSURE TESTS The piping system to be tested shall be filled from the lowest point and the air vents left open until all air has been displaced. The whole system shall be flushed through at a high flow rate until the flushing water leaving the system is running clean. The system shall then be pressurised to 1 bar and left shut in for several hours until the temperature of the water within the system has completely stabilised. During this period the system shall be checked for leakages and rectified as necessary and all external surfaces carefully dried. The pressure test shall consist of a 24-hour holding period at the specified test pressure, during which time the test pump shall be disconnected and the connection plugged or capped. Failures in the system disclosed by leakage or loss of pressure shall be located and repaired by the construction/ installation contractor. Repairs to leaks which require the flogging-up of studbolts or any other action which may induce shock waves in the system under test are strictly forbidden. The test pressure shall be wholly relieved before any attempt is made to seal any leak by hammering or the use of air-impact wrenches. Elimination of joint leaks by undue tightening of studbolts shall not be permitted. The joint faces shall be examined, a new gasket inserted and the joint remade. The cost of such repairs shall be borne by the construction/installation contractor except when failure results from defective components or materials supplied by the Company. Failures due to gasket blow-out or flange face damage shall, in any event, be to the account of the contractor responsible for making the joint concerned. All materials necessary to replace those provided by the Company that have been proved to he defective shall be furnished by the Company and the construction/installation contractor's actual cost in making such replacements and retesting the piping system shall be determined from the daily records of the plant and labour used. All such records shall be submitted by the Contractor and to the Company Representative for approval at the end of each working day concerned. After any repair, the test shall be repeated as specified until the test pressure can be satisfactory maintained for the test period without leakage.

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29.3.5

PNEUMATIC SOAP-BUBBLE LEAK TEST Upon completion of hydrostatic testing and removal of test water, the piping shall be dried out internally and all items which were removed for the hydrostatic tests shall be finally replaced. The entire system shall then be subjected to a pneumatic soap-bubble test at a maximum pressure of 5 bar. All flanged joints and the bonnets and glands of any items which were not subject to the hydrostatic test, shall be tested with a detergent soap solution and any leaks evidenced by the formation of bubbles shall be rectified.

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SECTION 29 PRESSURE TESTING PART 4 VALVES

29.4.1

GENERAL During tests on pipelines, manifolds, station pipework and vessels, ball valves and plug valves shall be turned to the half-open position so that the body and gland are subject to the test pressure. All other types of valves shall be in the open position, with suitably rated blank flanges or dome ends welded onto 'dead legs'. On no account shall closed valves be utilised for pressure containment in a system under test. The containment shall be effected by suitably rated spades, blind flanges or welded-on dome end caps.

29.4.2

PRE-TESTING VALVES Unless otherwise specified by the Company, isolating shut-off valves shall be tested according to the individual manufacturer's specification for differential pressure capability, prior to installation. Valves supplied by the Contractor and found to be defective shall be repaired or replaced at the Contractor's own expense.

29.4.3

FINAL TEST FOR 100% TIGHT SHUT-OFF VALVES Upon the satisfactory completion of the hydrostatic test of the piping system, the leakfree tightness of any valve specified as 100% tight shut-off' shall be verified. The test pressure shall be reduced to design pressure and a new chart inserted into the pressure recorder. The valve to be tested shall be closed and seated and the piping on its downstream side (with respect to the pressure recording equipment) shall be slowly vented to atmospheric pressure. The upstream pressure shall be measured using a dead weight tester and recorded on the chart for a period of thirty minutes, during which time there shall be no significant loss of pressure indicated by the dead weight tester (allowing for any temperature change in the system). The valve type and identification number and the dead weight tester readings at the start and finish of the test, shall be marked on the recorder chart and signed for by the Testing Contractor and the Company Representative. This test procedure shall be repeated throughout the system under test until all 100% shut-off valves have been tested. Any valve which fails the test shall be made good or replaced and retested.

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SECTION 29 PRESSURE TESTING PART 5 PRESSURE VESSELS

29.5.1

GENERAL Pressure vessels may be required to be hydrostatically tested after installation in Site or after any repair work or modification affecting the known mechanical strength and integrity of the vessel, as established by previous pressure tests. The test to be carried out shall always be in accordance with the particular design Standard or Code used for the design and manufacture of the vessel. The Company shall advise the Testing Contractor of the test pressure and Code the vessel is to be tested to. The general requirements and procedures for hydrostatic testing and the responsibilities of the Testing Contractor shall be as specified in Part 1 this Specification. The Testing Contractor shall draw up a detailed programme and testing schedule as called for under Clause 29.1.5 and at least 48 hours notice shall be given to the Company Representative of the actual date and time the tests and inspections are to be carried out. As a general rule, all pressure tests carried out on pressure vessels shall he witnessed by an official representative of the UNIC insurance organisation.

29.5.2

CHECK LISTS AND TEST SHEETS At least six weeks before starting these tests and checks the Testing Contractor shall submit to the Company formal check lists and test sheets for approval. The following essential information is required to be set out on these sheets in tabular form:a) Name, description and reference number of vessel being tested or proved, specifying design code, design pressure, design temperature, working pressure. b) Actual test or checks to be carried out. (Specifying test pressure and duration of test). Results and other data obtained during tests or checks.

c)

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d) Names and functions of persons conducting and witnessing the tests with space for signatures. e) Date of test and space for remarks.

29.5.3

TEST PRESSURES Test pressures shall be calculated using the formulae and directives given in the vessel design code (e.g. ASME VIII Div I or BE 5500) and shall be to the approval of the Company Representative. Calculations shall take account, where applicable, of the difference in material strengths (allowable stress) at the design operating temperature and the test temperatures. The formulae for test pressure (Pt) as given in BS 5500:1985 are as given below:For Category 1 and Category 2 construction:

Pt

fa t 1.25[ p__ * __ ] ft t-c

For Category 3 construction: fa t 1.25 [p __ * __ ] or pt ft t-c (whichever is higher value)

Pt

1.5p

p fa

Where is the design pressure; is the nominal design strength value for the material at the test temperature.

ft is the nominal time-independent design strength for the material at design temperature. t c is the nominal thickness of the section under consideration; is the corrosion allowance thickness.

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29.5.4

CONDITIONS FOR PRESSURE TESTING VESSELS Hydrostatic testing of vessels shall only be undertaken in the presence of the Company Representative and should be witnessed by the UNIC Representative, whose signature shall be obtained for any test carried out. In some systems, and providing that the vessel test pressure is not exceeded, vessels forming part of the piping system may be pressure tested with the piping. The vessel and associated equipment shall be checked for mechanical completeness against the appropriate installation drawings. All incomplete or missing items shall be noted for urgent attention/rectification and any discrepancies or points for concern also recorded for further investigation. Vessel breather devices and pressure bursting discs and relief valves shall be removed, and their nozzles or mounting pads sealed with blank flanges. Liquid level sensing floats or other instrument assemblies which may be damaged by hydrostatic test pressure shall be removed. Provision shall be made for venting air from the top of the vessel and from any trays, baffles, weirs etc. No closed valves shall be used for isolation purposes, valves required for draining shall be provided with a blind flange and shall be left open during the test period..

29.5.5

DRAINING OF VESSELS Extreme care shall be taken to prevent collapsing during the emptying or draining of thin-walled vessels and tanks. Free entry of air shall be ensured by the removal of all blind flanges at the nozzles and/or flange pads for breather devices and safety relief valves. Breathers and relief valves shall not be refitted until the vessel has been completely drained. The rate of drain-down shall be carefully controlled so as not to cause the build-up of a vacuum condition inside the vessel. Any damage resulting from incorrect draining shall be the sole responsibility of the Testing Contractor and all costs incurred in repairing and reinstating the damaged vessel or tank shall be at the Testing Contractor's own expense.

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