Hydro Test Procedure
Hydro Test Procedure
TABLE OF CONTENTS
1.0 PURPOSE
2.0 SCOPE
3.0 REFERENCES
4.0 DEFINITION
5.0 RESPONSIBILITY
6.0 TEST PROCEDURES
7.0 SAFETY PRECAUTIONS
8.0 APPENDICES
9.0 ATTACHMENTS
1.0 PURPOSE
It is the Purpose of this procedure to ensure the pressure retaining
properties of field fabricated piping and pipeline systems, which are
designed and constructed in accordance with ASME B31.3, ASME B31.4,
ASME B31.8 and relevant Saudi Aramco Standards listed in Section 3.
2.0 SCOPE
This Procedure defines the Pressure Testing requirement for all newly
constructed pipeline under this project “BERRI DEVELOPMENT ONSHORE
FLOWLINES & TIE INS PROJECT”.
CONTRACT NO: 6600044385 & BI JOB NO: BI-10-09561-001
3.0 REFERENCES
3.1 Saudi Aramco Engineering Standards:
SAES-A-004 - General Requirement for Lieu of Pressure Testing
SAES-A-007 - Hydrostatic Testing Fluids and Lay-up Procedures
SAES-L-310 - Design of Plant Piping
SAES-L-350 - Construction of Metallic Plant Piping`
SAES-L-150 - Pressure Testing of Plant Piping and Pipelines
SAES-L-410 - Design of Pipelines
SAES-L-450 - Construction of On-Land and Near-shore Pipelines
SAEP-327 - Disposal of wastewater from cleaning, flushing and hydrostatic
test
SAEP-1160 - Tracking and Reporting of Welding, NDT, and Pressure
BERRI DEVELOPMENT
ONSHORE FLOWLINES & TIE INS PROJECT
4.0 DEFINITION
Pressure Test: A test conducted to piping or equipment by subjecting it to an
internal pressure using liquid or gas to ensure strength or tightness of the
system at the test pressure.
Pneumatic Test: A pressure test conducted using air or other approved liquid
as the test medium or in conjunction with liquid.
Tightness Test: A pressure test to ensure tightness of the piping system (no
leak in the system) at test pressure.
System Test: An in- situ pressure test applied to a group of piping and
equipment tested as a system.
Pre Start-up Leak Test: A pressure test to ensure tightness of flanged and
threaded joint at normal operating pressure. It is normally conducted before
initial start-up during commissioning.
BERRI DEVELOPMENT
ONSHORE FLOWLINES & TIE INS PROJECT
5.0 RESPONSIBILITY
5.1 The Managers for Engineering, Construction and QA/QC are
responsible for planning, preparing, collaborating, leading in implementing and
execution of this activity (Hydro testing) in a timely and safe manner.
5.6 Safety Supervisor is responsible for ensuring that all safety requirements
as per G.I.2.100/102 are being followed throughout the activity.
d. Testing Components
Hydro test manifold shall be tested for 1.2 times of the system test
pressure prior to conduct the test for the project. The Test Certificate shall be
available and valid during the execution of Hydro testing.
BERRI DEVELOPMENT
ONSHORE FLOWLINES & TIE INS PROJECT
The capacity & Location of hydrostatic pump shall be noted in such a way
that the Pressure Gauge reading is visible to the Pump Operator.
The range of pressure gauges i.e. the test pressure is within 30 % to 80%
of the full range. Minimum of two (2) on large systems Inspection will
determine the need for extra gauge. Gauges used for testing shall be
installed as close as possible to the low point (drain) and high point (vent)
of the piping system
Pressure Gauges, Pressure and Temperature Recorders calibration
interval shall not exceed one month prior the test date as per SAES-A-004
Para. 5.12.6.2.
Pressure gauge accuracy shall be within 5% of one another.
The pressure gauges to be used must have a calibration sticker indicating
the date of calibration and date of expiry. Calibration certificates shall be
available prior to commencement of the pressure test.
Setting of the Relief valve to relieve at 5% above the hydro test pressure.
The Relief valve shall be tested, dated, and tagged within two weeks prior to
the hydro test. In addition to the pressurerelieving device, a bleed valve shall
be provided to protect the piping and equipment from overpressure. The
bleed valve shall be readily accessible in case immediate depressurization is
required in accordance with SAES-A-004, para. 5.7.2.
An isolation valve shall be provided between the pressure testing manifold
and the system being tested. The isolation valve shall be rated for the
manifold test pressure when in the closed position.(SAES-A-004 Para 5.7.3)
Before employing the pressure testing manifold in the actual system, it
shall be separately tested to at least 1.2 times the system test pressure but
not less than the discharge pressure of the pump used for the pressure
testing.(SAES-A-004 Appendix B ).
Pressure and Temperature recording gauges shall be used for all buried
piping systems on plot as per SAES-L-150 for pipelines.
e. All openings except test medium inlet and vent opening shall be closed using
correct rating plugs, caps or other suitable means. Field Fabricated Blinds shall
not be used without proper calculations for the thickness proof.
f. Support for hydrostatic test, if used, shall ensure a safe test. In order to
inspect all welded joints, no supports shall be placed on or over any weld joints
of the pipe work under Hydro test.
Filter element
Temporary strainer
Safety and relief valve (Permanent)
Rupture disc
Expansion joint
In-line instruments (If piping have been flushed prior to testing, on/off valve
may be remained in line, but valve shall be kept open during test and
flushing.)
Pressure gauge (Permanent)
Temperature gauge and thermo well
Steam trap
Mixing nozzle and mixer
Check valve discs shall be removed and securely attached to the outside
of
check valve prior to pressure test.
Soft seated ball and plug valve (unless piping have been prior to testing)
Equipment that cannot be drained.
b. Application of Pressure
The system may be separated into sub-system for testing. The Hydro test
circuit diagram shall show the limit and method of isolation for system or
sub-system shall be prepared prior to testing.
Lines above ground shall be tested for a sufficient time, not less than 30
minutes to determine that there are no leaks. The strength test pressure
shall be maintained for two hours per SAES-L-150 para. 8.1.
A 24 hour recorded tightness test shall be applied when the pipelines is
buried or insulated, or is partially buried or insulated for more than 300 m
(1000 ft) or 10% of its total length whichever is less.
The system/sub-system will be filled with the approved test fluid
introduced from the lowest point of the test circuit. All vents shall be opened
during filling and closed when entrapped air has been vented.
The approved Hydro test manifold will be connected to the line. The
system pressure will be raised slowly using hand pump/power operated
pump.
At 50 percent of strength test pressure, pressurization shall be stopped to
check for leak.
If any leakage is found, the system shall be depressurized and then
dewatered. Bolts will be loosed prior to repair. Test fluid shall be refilled and
test will be continued.
After satisfactory preliminary check for leaks at 50% of test pressure, the
pressure shall be increased in steps not greater than one-fifth of the strength
test pressure with at least 10 minutes hold at each step to permit inspection
for leakage (ref. G.I.2.102. Para.5.16).
BERRI DEVELOPMENT
ONSHORE FLOWLINES & TIE INS PROJECT
Whether all lines are cleared of loose scale and debris by use of air or
BERRI DEVELOPMENT
ONSHORE FLOWLINES & TIE INS PROJECT
water.
All open ends to be closed after drying procedure.
Apply lay-up procedure for lines, which shall be used as per SAES-A-
007.
The drained water shall be disposed off safely into the sewer drains /
safer destinations, which are acceptable to SAUDI ARAMCO. Furnish
and lay temporary evasion pipe to drain the hydrostatic test water.
Remove all water from the system. For facilities other than pipelines, drain
the system completely, sweep and mop as required to ensure that no
visible traces of water remain. For pipelines, dewatering shall be performed
by scraping with a three-or four cup displacement scraper (or better) unless
system limitations make this option impracticable as per SAES-A-007 Para
5.2.5. 2. After removal of all water, close the system to prevent the entry of
sand or rainwater as per SAES-A-007 Para 5.2.5.3. Install a vacuum
breaker unless it is demonstrated that the system will not collapse under
vacuum as per SAES-A-007 Para 5.2.5.2
c. Reinstatement
All temporary items installed for testing purposes (e.g., manifolds, valves,
blinds, spacers, supports) shall be removed after the test. Permanent items
that were removed shall be reinstalled. Items, such as instrument air tubing,
check valve discs which were disconnected before testing shall be
reconnected. Isolation valves closed for the test purposes and that are
required to be in the open position for process reasons shall be opened. If
the valve cavity has a drain, the cavity shall be drained, (SAES-A-004 Para
7.4).
Warning signs will be displayed at barrier off areas indicating that hydrostatic
test is in progress. Only authorized personnel are allowed to enter the hydro
test area.
Water shall be the pressure test medium for pipelines. Air shall not be
permitted as pressure test medium in hydrocarbon service unless the system
has been cleaned to avoid an explosive hydrocarbon-air mixture.
Oxygen, toxic gas, liquids above their flash points or atmospheric boiling
points, liquids above 66ºC (150ºF), except where necessary for pressure
testing hot tap connections on hot lines shall never be used as a pressure test
mediums because they are extremely hazardous.
Steam may be used as a pressure test medium only in tightness test (per
G.I.2.710) and service tests.
Personnel shall wear appropriate personal protective equipment to protect
against exposure to hot liquid when a liquid above 49ºC (120ºF) and below
66ºC (150ºF) is used as a test pressure medium, such as aquifer water in
testing water injection lines.
Hydrocarbon shall never be used as a pressure test medium for a system that
will be in oxygen service.
Chemical treatment and selection of hydrostatic test water per SAES-A007,
shall be followed to avoid corrosion and possible running failures from
hydrostatic test water.
Test equipments such as test manifolds, relief valves, pressure gauges,
pumps to be used shall be verified, tested, calibrated prior to start activity.
Appurtenances not part of the pressure test shall be blinded to exclude
equipment which cannot withstand the test pressure. If isolation valves are
used in lieu of blinds, provisions shall be made to ensure that no over
pressuring can occur in equipment that is not being tested, due to possible
valve leak.
Portions of the system such as supports, vessels, piping and foundations
shall not be overloaded by the weight of the test liquid.
Traffic shall be diverted or stopped when pipeline being tested crosses under
a road, a personnel shall be posted at the crossing to control traffic in the event
of an incident affecting traffic safety.
Saudi Aramco Representative will be informed on the details of the scheduled
hydrostatic testing if non-Saudi Aramco facilities will be exposed in a pressure
test.
RTCC will notify Industrial Security through SAPMT requiring Traffic Control
at the test site, such as tests of pipelines which cross roads. Test will not be
scheduled during peak traffic hours.
BERRI DEVELOPMENT
ONSHORE FLOWLINES & TIE INS PROJECT
8.0 APPENDICES:
8.1 Saudi Aramco Test and Inspection Plan (SATIP)
SATIP-A-004-02 - Pressure Testing-Hydrostatic Test of Plant Piping
SATIP-A-004-03 - Pressure Testing-Hydrostatic Test of Pipelines
SATIP-A-004-05 - Leak testing (Per SAES-A-004)
BERRI DEVELOPMENT
ONSHORE FLOWLINES & TIE INS PROJECT