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Wintershall Aktiengesellschaft
Nakhla Phase II - Pipeline Nakhla Jakhira Invitation to Tender Exhibit E3Project Number: L30601 Hydrostatic Testing
Exhibit E3
HYDROSTATIC TESTING
Division E&P / Engineering Department page 11 of 1414
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Wintershall Aktiengesellschaft
Nakhla Phase II - Pipeline Nakhla Jakhira Invitation to Tender Exhibit E3Project Number: L30601 Hydrostatic Testing
CONTENTS
SECTION PAGE
1.0 SCOPE 3
2.0 PREPARATION FOR TESTING 3
3.0 MATERIALS AND EQUIPMENT 5
4.0 FLUSHING 5
5.0 PIPING AND EQUIPMENT EXCLUDED FROM TESTING 6
6.0 TEST FLUID 7
7.0 HYDROSTATIC PRESSURE TEST 9
8.0 PNEUMATIC PRESSURE TEST 10
9.0 SYSTEM SERVICE TEST 11
10.0 TEST RECORDS 12
11.0 RETESTING 13
12.0 COMPLETION OF PRESSURE TEST 14
Division E&P / Engineering Department page 22 of 1414
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Wintershall Aktiengesellschaft
Nakhla Phase II - Pipeline Nakhla Jakhira Invitation to Tender Exhibit E3Project Number: L30601 Hydrostatic Testing
It shall clearly be emphasized, that in case of any deviations or conflicts between the requirements stated in the Technical Specification including appertaining Appendices and this Exhibit E3 the requirements of the Technical Specification (including Appendices) have higher priority and have to be fulfilled by Contractor.
1.0 SCOPE
This specification defines the requirements for flushing, hydrostatic testing, and service
testing of plant piping including equipment skid piping.
As used in this specification, the following definitions shall apply:
Contractor Party responsible for testing pipeline and plant piping systems
Vendor Party responsible for testing skid mounted piping and equipment ; in this
case Contractor and Vendor are the same (identical)
The Contractor or Vendor shall furnish all supervision, labour, equipment, and materials
necessary for the performance of the hydrotesting. The Contractor or Vendor shall obtain
the Company's prior written approval of any deviations from the requirements of this
specification or related contract documents.
The use of this specification does not relieve the Contractor or Vendor of his responsibility
to properly pressure test the plant piping.
2.0 PREPARATION FOR TESTING
2.1 Contractor or Vendor shall be responsible for properly preparing facilities forpressure testing.
Contractor or Vendor shall review all relevant drawings and piping to ensure that adequate
temporary supports, vents, drains, and spades (as necessary to allow testing) are provided
to test the facility in accordance with this specification. Contractor or Vendor shall report to
the Company the findings from this review. Contractor or Vendor shall provide all high
points in the piping with a vent and all low points with a drain, regardless of whether or not
they are specifically shown on the drawings.
Division E&P / Engineering Department page 33 of 1414
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Wintershall Aktiengesellschaft
Nakhla Phase II - Pipeline Nakhla Jakhira Invitation to Tender Exhibit E3Project Number: L30601 Hydrostatic Testing
Contractor or Vendor shall prepare, for the purpose of the pressure tests, a procedure and
schedule for testing all process and utility piping and pipelines within the limits of his
responsibilities. The procedure and schedule shall be presented to the Company at least
twenty (20) days prior to the scheduled start of pressure tests.
Such procedures should include, but are not limited to, details of the following:
a. Mark-ups of piping and instrument diagrams (P&ID's) showing the
limits of piping and equipment to be included in each test.
b. Test medium to be used.
c. Location of all isolation blinds, high-point verts, low-point drains, and
temporary piping supports.
d. Procedures for flushing lines including fill points and equipment to
be removed for flushing.
e. Procedures for filling lines including addition of oxygen scavenger
and bactericide in proper quantities.
f. Procedures for pressurisation of the system, including the location of the injection
points and specified test pressures.
g. The form which shall be used to record hydrostatic test data.
h. Summary/list of test instruments to be applied
2.2 The testing operations shall be conducted diligently, thoroughly, and in a safe, workmanlike manner in accordance with accepted piping testing practices. Any work by Contractor or Vendor, or existing conditions which in the opinion of Company are deemed to be unacceptable shall be corrected by Contractor or Vendor. The testing operations may not continue until the unsafe conditions have been corrected to the satisfaction of Company. Contractor or Vendor shall not receive additional compensation for time lost due to unacceptable conditions.
Division E&P / Engineering Department page 44 of 1414
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Wintershall Aktiengesellschaft
Nakhla Phase II - Pipeline Nakhla Jakhira Invitation to Tender Exhibit E3Project Number: L30601 Hydrostatic Testing
If testing is subcontracted, Contractor or Vendor shall furnish an individual who will be
responsible for supervising testing operations. Company will witness and approve all tests
unless waived by the Company in writing.
3.0 MATERIALS AND EQUIPMENT
Contractor or Vendor shall furnish all materials and equipment necessary to pressure test
all piping. This includes, but is not limited to pumps, compressors, valves, filters, plugs,
blinds, caps, strainers, flanges, bolts, gaskets, all piping incidental to the filling, flushing,
transferring, and disposing of the test medium, bactericides, oxygen scavengers, dyes (if
required), and the test medium. Contractor or Vendor shall provide a suitable pressure
relieving device between the pressurising pump discharge nozzle and the fill point,
calibrated to prevent excess pressure in any of the piping and equipment being tested.
4.0 FLUSHING
Prior to commencing any flushing, Contractor or Vendor shall verify with Company that all
required non-destructive testing (NDT) such as radiography, ultra-sonic, etc., has been
completed. Contractor or Vendor shall also verify that all required post-weld heat-treating
has been completed. Furthermore, prior to flushing the insulating couplings shall be
replaced by spool pieces (see Technical Specification, chapter 4.3.4.7) with subsequent
reinstallation of the insulating couplings prior to hydrotesting/water filling. Upon verification
of the above requirements, the Company shall authorise in writing the Contractor or Vendor
to proceed with flushing.
All completed piping systems shall be flushed prior to testing. All lines two (2) inches and
larger, other than instrument and utility air shall be flushed with water so as to completely
clear them of any loose mill scale, rust, or various extraneous material. Suitable pipeline
scrapers shall be applied and have to be procured by Contractor. All lines smaller than two
(2) inches, and air lines of any size, shall be cleaned out in like manner using compressed
air. The flushing medium shall be at as high a velocity as practical (minimum of 5 ft/sec) in
order to flush out any loose material in the line. Flow shall be from high to low points.
Flanges shall be opened and spool pieces shall be removed as necessary to flush the
piping thoroughly.
Division E&P / Engineering Department page 55 of 1414
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Wintershall Aktiengesellschaft
Nakhla Phase II - Pipeline Nakhla Jakhira Invitation to Tender Exhibit E3Project Number: L30601 Hydrostatic Testing
Flushing shall be performed until a clear stream of flushing medium exits the piping, with a
minimum flush volume being equal to five times the volume of the piping being flushed. All
flushing shall be done in the presence of the Company.
Orifice plates, thermowells, flow straightening vanes, positive displacement (PD) and
turbine meters, corrosion probes, displacement type level instruments, and other
vulnerable equipment, if already installed, shall be removed prior to flushing.
All instrument leads shall be disconnected prior to flushing and shall remain disconnected
during pressure tests. All control valves shall be removed. Spring type supports shall have
stops installed to prevent overloading of the support.
5.0 PIPING AND EQUIPMENT EXCLUDED FROM TESTING
The following piping and equipment shall be excluded or isolated from hydrostatic testing:
a. Rotating machinery, pumps, compressors, etc.
b. Strainers and filters.
c. Pressure-relieving devices such as pressure relief valves and rupture discs.
d. All vessels.
e. All valves, etc. as part of carbon steel piping that are fabricated from duplex.
f. All instruments.
g. Pressure gauges.
h. Expansion joints.
i. Orifice plates.
j. Flow nozzles.
k. Control valves.
l. Corrosion probes/coupons
m. Any other piping or equipment designated by Company.
Division E&P / Engineering Department page 66 of 1414
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Wintershall Aktiengesellschaft
Nakhla Phase II - Pipeline Nakhla Jakhira Invitation to Tender Exhibit E3Project Number: L30601 Hydrostatic Testing
6.0 TEST FLUID
6.1 Except as otherwise specified, all piping shall be tested with water. The test water shall be clean and free from suspended matter. The test water may be analysed by the Company to determine its suitability for use in the testing operations. Suspended matter in the fill water shall be removed before injection into the piping by a filter, capable of removing 99 percent of all particles 92 microns in diameter and larger, or equivalent to using a 100 x 100 wire-mesh screen. If foreign material is pumped into the piping because of faulty equipment or careless workmanship, Contractor shall again flush the line with clean water. For austenitic steels only water with a chloride content of max. 30 ppm shall be used for hydrostatic testing.
When air is specified as the testing medium, the air shall have a dew point of at least -
20°F.
6.2 Conditions requiring the use of oxygen scavenger, bacteria control and corrosion inhibitor depend on how long the test media will remain in the system . If dosing is demanded by
Company, Contractor has to purchase all inhibitors including the dosing equipment
(pumps, storage tank, connecting piping,…)
Oxygen removal and bacteria control shall be performed at the following treatment rates:
Oxygen Scavenger - 100 ppm
Tretolite Kontol K-490, Visco 3656 or equal
6.3 Water used to test piping or vessels fabricated from or containing parts of austenitic stainless steel, ferritic stainless or high nickel alloy shall be free from undissolved
solids and have a max. chloride content of 30 ppm.
6.4 Instrument air lines and utility air lines shall be tested with compressed air.
Division E&P / Engineering Department page 77 of 1414
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Wintershall Aktiengesellschaft
Nakhla Phase II - Pipeline Nakhla Jakhira Invitation to Tender Exhibit E3Project Number: L30601 Hydrostatic Testing
7.0 HYDROSTATIC PRESSURE TEST
7.1 Hydrostatic pressure testing on the total piping system shall be in accordance with
ANSI/ASME B31.3, (latest edition) as a higher demand than ANSI B31.8. Piping test
pressures are a minimum of 1.5 times design pressures. Prior to commencing any
pressure test, Contractor or Vendor shall verify with Company that all required non-
destructive testing (NDT) such as radiography, ultrasonic, etc., has been completed.
Contractor or Vendor shall also verify that all required post-weld heat treating has been
completed and the spool pieces have been replaced by the insulating couplings. Upon
verification of the above requirements, the Company shall authorise the Contractor or
Vendor to proceed with pressure testing.
7.2 Contractor or Vendor shall hydrostatically test piping, vessels and equipment for which he
has fabrication or assembly responsibility. Hydrostatic testing may be performed for
completed systems so for individual components of the system, as approved by the
Company. However, if individual components are hydrostatically tested, the Contractor or
Vendor shall flush the completed assembly prior to the system service test. Should
Contractor or Vendor desire to hydrostatically test through Company furnished equipment,
he may do so with written approval of Company. When hydrostatically testing through
Company furnished equipment, Contractor or Vendor shall exercise due caution to protect
any instrumentation associated with the Company furnished equipment.
Vents shall be open during water filling so that air is vented prior to applying pressure to
the system.
7.3 Testing shall not be done against closed valves. If it is impractical to test through a valve, that valve shall be isolated by blinds or disconnected from the piping
system. The pressure for each section tested shall be contained by suitably placed
spectacle blinds, spades, skillets, blank insert clokes, blind flanges or other means of
positive closure. Contractor or Vendor shall supply calculations to Company verifying the
thickness of blinds to be used for isolation during hydrostatic tests. Test pressure
connections shall be on the upstream side of check valves. Thermowells shall be included
in hydrostatic tests, if fabricated from carbon steel (duplex thermowells are excluded).
Division E&P / Engineering Department page 88 of 1414
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Wintershall Aktiengesellschaft
Nakhla Phase II - Pipeline Nakhla Jakhira Invitation to Tender Exhibit E3Project Number: L30601 Hydrostatic Testing
Pressure tests will be recorded on a pressure recorder (Foxboro 24-hour chart type or
equal) with a range suitable for recording the test pressure. The pipeline pressure during
the test shall be measured by means of a verified dead weight tester. All calibrated gauges
or dead weight testers shall have current calibration record and/or calibration certificate. All
hydrostatic tests shall be a minimum of four (4) hours duration. Readings shall be taken
from the test gauge at fifteen minute intervals during the test and recorded on form
provided by Contractor or Vendor.
During the pressure test, the test medium may be subject to thermal expansion. Contractor
or Vendor shall take proper precautions to avoid excessive pressures; (i.e. pressure bleed
back to test pressure shall be witnessed by Company and noted on test record ;
corresponding amount of bleeded water to be determined).
7.4 For unburied pipe sections all joints, including welds, are to be left uninsulated and
exposed during the test. Only tests with ending pressures equal to or above starting
pressure will be accepted. Contractor or Vendor should schedule tests for that portion of
the day when thermal contraction will not result in ending pressures lower than starting
pressure.
Pressure tests on each major section of piping shall be carried out with all pressure relief
valves removed and their respective nozzles or connections blinded off or plugged. The
pressure relief valves will themselves be tested to their respective set point pressures, by
Contractor or Vendor, in a separate test. Tests of pressure relief valves are to be witnessed
and approved by the Company respectively Companies representative (TUV, GL). Upon
completion of piping or vessel hydrostatic test, pressure relief valves shall be reinstalled in
each system.
7.5 Reinforcing pads shall the air tested to 350 kPa gauge (50 psig) prior to postweld heat
treatment and/or hydrostatic test. All outside welds and inside welds, where possible, shall
be inspected during the test. Test holes shall be open during hydrostatic test and plugged
with a ¼” NPT plug after the hydrostatic test.
Division E&P / Engineering Department page 99 of 1414
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Wintershall Aktiengesellschaft
Nakhla Phase II - Pipeline Nakhla Jakhira Invitation to Tender Exhibit E3Project Number: L30601 Hydrostatic Testing
8.0 PNEUMATIC PRESSURE TEST
8.1 Pneumatic pressure testing of piping system shall be in accordance with ANSI/ASME
B31.3 (latest edition). Piping test pressure is a minimum of 1.10 times design pressure.
Piping test pressures are given on the Piping Material Specification sheets in General
Specification E2, "Piping."
8 .2 Contractor or Vendor shall pneumatically test piping and equipment for which he has
fabrication or assembly responsibility. Pneumatic testing may be performed for completed
systems or for individual components of the system, as approved by the Company.
However, if individual components are pneumatically tested, Contractor or Vendor shall
flush the completed assembly prior to the system service test. Should Contractor or Vendor
desire to pneumatically test through Company furnished equipment, he may do so with
written approval of Company. When pneumatically testing through Company furnished
equipment, Contractor or Vendor shall exercise due caution to protect any instrumentation
associated with the Company furnished equipment.
8.3 Testing shall not be done against closed valves. If it is impractical to test through a valve,
that valve shall be isolated by blinds or disconnected from the piping system. The pressure
for each section tested shall be contained by suitably placed spectacle blinds, spades,
skillets, blank insert chokes, blind flanges or other means of positive closure. Contractor or
Vendor shall supply calculations to Company verifying the thickness of blinds to be used
for isolation during pneumatic tests. Test pressure connections shall be on the upstream
side of check valves. Thermowells shall be included in pneumatic tests.
The testing duration, testing equipment and recording instruments, test gauge reading
interval, documentation and records shall be subject to the written approval of the
Company.
During pressure test, the test medium may be subject to thermal expansion. Contractor or
Vendor shall take proper precautions no avoid excessive pressures; (i.e. pressure bleed
back to test pressure shall be witnessed by Company and noted on test record).
Division E&P / Engineering Department page 1010 of 1414
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Wintershall Aktiengesellschaft
Nakhla Phase II - Pipeline Nakhla Jakhira Invitation to Tender Exhibit E3Project Number: L30601 Hydrostatic Testing
8.4 For unburied pipes all joints, including welds, are to be left uninsulated and exposed during
the test. Contractor or Vendor should schedule tests for that portion of the day when
thermal contraction will not result in ending pressures lower than starting pressure.
Pressure tests on each major section of piping shall be carried out with all pressure relief
valves removed and their respective nozzles or connections blinded off or plugged . The
pressure relief valves will themselves be tested to their respective set point pressures, by
the Contractor or Vendor, in a separate test. Tests of pressure relief valves are to be
witnessed and approved by the Company respectively Companies representative (TUV,
GL) . Upon completion of piping pneumatic test, pressure relief valves shall be reinstalled
in each system.
9.0 SYSTEM SERVICE TEST
9.1 The System Service Test is a test to prove the integrity of completed, fully assembled
piping systems including all vessels and any Company furnished item in the system. The
test shall be designed to demonstrate that systems, upon completion of assembly, are
capable of operation at pressures specified.
After completion of all recorded hydrostatic pressure tests of completed systems, or final
assembly of individually, hydrostatically tested components, each piping system shall be
given a service test at the system design pressure. Contractor shall service test all
completed plant piping systems, including equipment which may have been previously
service tested as a unit by individual Vendors. All valves, control valves, filters, strainers,
turbine meters, PD meters, flow nozzles, level gauges, level switches, level controls,
rupture disks, pressure relief valves, and pressure gauges shall be installed for the test. All
other instruments and any rotating equipment such as pumps and compressors are
excluded from the tests.
During the service test, the isolation valves for relief valves shall be closed and relief valves
removed. After the service test of that portion of the system containing the isolation valves
and prior to depressuring the test water, the relief valve shall be installed. The test
pressure shall be lowered to ninety percent (90 %) of the relief valve set point pressure and
the block valve opened. The purpose of this procedure is to check the connection between
the block valve and relief valve.
All temporary positive closures such as plugs, blinds, spectacles, spades, and skillets
which may have been used during hydrostatic testing, shall be removed and all piping
Division E&P / Engineering Department page 1111 of 1414
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Wintershall Aktiengesellschaft
Nakhla Phase II - Pipeline Nakhla Jakhira Invitation to Tender Exhibit E3Project Number: L30601 Hydrostatic Testing
joints shall be made up as they would be during normal operation of functional systems.
Any used gaskets from prior tests shall be replaced.
9.2 In general the test medium and filling and venting procedures shall be the same as for
hydrostatic tests. Pressure shall be brought to system design pressure and held for thirty
(30) minutes. All connections which were not made prior to hydrostatic tests shall be
checked for leaks and tightened as necessary. Following the initial thirty (30) minute
portion of service test, each valve in the system shall be tested by being closed and used
to hold the test pressure for a period of time necessary to determine whether each valve is
in turn positively shutting off and holding pressure. Packing shall be replaced in equipment,
such as valves, when leaks cannot be stopped by normal tightening of packing glands.
When Contractor is testing systems on completed plants, only one complete system at a
time shall be tested to prevent overstressing of plant structural members. During testing,
Contractor shall take suitable precautions to prevent building up excessive pressures in
adjacent equipment not included in the test, such as opening vent valves in the adjacent
systems, etc.
10.0 TEST RECORDS
Contractor shall furnish all testing equipment and recording instruments with all necessary
supplies and shall maintain accurate and permanent records. The testing and recording
equipment shall be subject to the written approval of the Company.
All reports, records, data and charts clearly marked with the following information shall be
furnished to the Company:
a. Company name and authorised representative.
b. Testing Contractor's name and authorised representative.
c. Line identification of piping and/or equipment tested.
d. Date, start time and stop time of test.
e. Test pressure and duration.
f. Test medium used.
g. Ambient air temperature.
h. The recorder element range.
i. Explanation of any pressure discontinuities that may appear on the chart.
j. Listing of items excluded from the test.
k. Service test record.
Division E&P / Engineering Department page 1212 of 1414
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Wintershall Aktiengesellschaft
Nakhla Phase II - Pipeline Nakhla Jakhira Invitation to Tender Exhibit E3Project Number: L30601 Hydrostatic Testing
l. Marked-up P&ID's depicting valves which passed and failed service test.
m. Signature of Company's and testing Contractor's authorised representative.
11.0 RETESTING
Should piping failure occur during testing, Contractor or Vendor shall locate the failure.
Contractor or Vendor shall at his expense repair all defects resulting from inferior
workmanship or defective materials furnished by the Contractor or Vendor. After repairs
have been made, the Contractor or Vendor shall retest until a successful test is obtained to
the satisfaction of the Company.
Division E&P / Engineering Department page 1313 of 1414
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Wintershall Aktiengesellschaft
Nakhla Phase II - Pipeline Nakhla Jakhira Invitation to Tender Exhibit E3Project Number: L30601 Hydrostatic Testing
12.0 COMPLETION OF PRESSURE TESTS
Upon completion of hydrostatic tests and service tests, the Contractor or Vendor shall:
a. Dispose of all test medium to a location designated by the Company, exercising
proper caution to avoid accidental creation of a vacuum during draining of water
from equipment.
b. Restore any equipment excluded from tests to a fully operational condition.
c. Remove all temporary facilities installed by the Contractor or Vendor including
temporary supports and bracing.
d. Remove any temporary plugs or blinds.
e. Replace any used gaskets or damaged nuts and bolts.
f. Air purge all piping and equipment, unless specifically deleted by Company in
writing, to remove low-point pockets of water. Air purging shall be performed in
the presence of the Company and last a minimum of thirty (30) minutes.
Afterwards drying of the pipeline by means of a methanol batch is Afterwards drying of the pipeline by means of a methanol batch is
requiredrequired”. ”.
g. Remove all stops placed in spring type supports.
h. Remove/dismantle all material and equipment which temporarily has been
installed for hydrotesting, e.g. but not limited o filling lines, drain lines, filling and
drain pumps, mobile tanks,…
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