GENERAL SPECIFICATION FOR CHEMICAL CLEANING, PRESSURE ...

EMPLOYER: LOTOS PETROBALTIC S.A. JOB 113A20

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AREA: SOUTH-EAST BALTIC SEA Doc. N.

PLANT: B8 OIL FIELD 113A20-PP-SP-10054

GENERAL SPECIFICATION FOR CHEMICAL CLEANING, PRESSURE TESTING AND

FLUSHING

Contractor Doc. N. : 113A20-PP-SP-10054

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This document undergoes an issuance cycle within EDMS "I-DOC". Its distribution is electronically controlled. Printing not reporting the name of the destine, shall be considered as “NOT CONTROLLED” copy

“PETROBALTIC” RIG CONVERSION PROJECT

GENERAL SPECIFICATION FOR CHEMICAL CLEANING, PRESSURE TESTING AND FLUSHING

CONTR. DOC N. : 113A20-PP-SP-10054

05 IFC Issue for Construction M. Colombo

P.S.L. A. Mariani

P.E.M. A. Mariani

P.E.M. 23/09/16


P.S.L. A. Mariani

P.E.M. A. Mariani

P.E.M. 08/07/16


P.S.L. C. Ciapani D.P.E.M.

A. Mariani P.E.M.

18/05/15


P.S.L. C. Ciapani D.P.E.M.

A. Mariani P.E.M.

05/05/15


P.S.L. R. Marchegiani

D.P.E.M. A. Mariani

P.E.M. 13/03/14

00 IFA Issue for Approval M. Colombo

P.S.L. R. Marchegiani

D.P.E.M. A. Mariani

P.E.M. 20/12/13

Rev. Status Description Prepared Checked Approved Date


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REVISION DESCRIPTION SHEET

Rev. Para. Revision Description

01 3.1 Inclusion of ASME B31.8

02 All Issue for Construction

02 9.2 Added chemical cleaning table

03 All Issue for Construction

03 3.2 - 4.1 Added project specification and clarification in Employer scope chapter

04 9.2 Revised chemical cleaning paragraph

05 9.2 Revised piping cleaning paragraph

Hold No.

Para. Description of Hold


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INDEX

1. INTRODUCTION ....................................................................................................... 5

1.1 Scope ...................................................................................................................... 5

1.2 Definition ................................................................................................................ 5

1.3 Abbreviations ......................................................................................................... 5

2. PURPOSE ................................................................................................................. 5

3. REFERENCE DOCUMENTS .................................................................................... 6

3.1 International Codes &Standards .......................................................................... 6

3.2 Project Specification and Philosophies ............................................................... 7

3.3 EU Directives .......................................................................................................... 7

4. SCOPE OF SUPPLY ................................................................................................. 8

4.1 EMPLOYER’s Scope .............................................................................................. 8

4.2 Shipyard Contractor’s Scope................................................................................ 8

5. EXCLUSION ........................................................................................................... 10

6. SAFETY PRECAUTIONS ....................................................................................... 11

7. GENERAL REQUIREMENT .................................................................................... 11

8. PRESSURE TEST LIMITATIONS ........................................................................... 12

8.1 Test Pressure ....................................................................................................... 12

8.2 In-Line Equipment ................................................................................................ 12

9. PREPARATION FOR PIPING CLEANING, FLUSHING AND TESTING ................. 13

9.1 General ................................................................................................................. 13

9.2 Piping Cleaning .................................................................................................... 15

9.3 Flushing Procedures ........................................................................................... 16

9.4 Flushing Requirements ....................................................................................... 16

9.5 Pressure Testing Requirements ......................................................................... 17

9.6 Hydrostatic Testing ............................................................................................. 17


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9.7 Pneumatic Testing ............................................................................................... 18

10. PRESSURE TESTING PROCEDURE .................................................................... 19

10.1 Hydrostatic Testing ............................................................................................. 19

10.2 Pneumatic Testing ............................................................................................... 20

10.3 Service Fluid Testing ........................................................................................... 21

10.4 Correction of Leakage ......................................................................................... 22

11. POST FLUSHING AND TESTING PROCEDURES ................................................ 22

12. PRESSURE TEST RECORDS ............................................................................... 23


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1. INTRODUCTION The B8 oilfield is located in Southern Baltic Sea, at a distance of about 33.9 nautical miles north-north east of the Rozewie lighthouse and about 39.1 nautical miles north of the Jastarnia lighthouse. The nearest ports are located about 65 Nm south south-east of the B8 oilfield.

1.1 Scope

This specification covers the basis for pressure testing and flushing to be applied on the “Petrobaltic” rig conversion project.

1.2 Definition

EMPLOYER: LOTOS PETROBALTIC S.A.

CONTRACTOR: ROSETTI MARINO S.p.A.

Shipyard Contractor is the shipyard selected for the implementation of assembly phase

Supplier/Manufacturer Is the party that is in charge the supply of material, equipment, skid or package

Shall Indicates a mandatory action

Should Indicates a preferred course of action.

May Indicates one acceptable course of action.

1.3 Abbreviations

API American Petroleum Institute ASME American Society of Mechanical Engineers BS British Standard BS-EN British Standard – European Standard DN Diameter Nominal EN Euro Norm NPS Nominal Pipe Size P&ID Piping and Instrumentation Diagram PPM Parts Per Million

2. PURPOSE This specification, together with other documents referenced within it, defines the procedures and minimum technical requirements for the pressure testing and flushing of piping systems (hereafter referred to as a “test system”) for the “Petrobaltic” jack-up rig.


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3. REFERENCE DOCUMENTS Pressure testing and flushing of piping systems shall be carried out in accordance with this specification supplemented by the latest editions of the project documents and national codes and standards listed below. It is the Shipyard Contractor’s responsibility to ensure compliance and that of their sub-supplier with all the applicable project documents, codes, standards and regulations. The edition of the reference documents shall be the edition current at the effective date of purchase order. The Shipyard Contractor shall advise the EMPLOYER of any changes to any reference documents following the date of purchase order placement and shall comply with the EMPLOYER’s instructions to conform to any such changes if necessary. In cases where no specific requirements are given or referenced in this specification for a specific item of the package the Shipyard Contractor shall adhere to internationally accepted modern design and engineering practices in the petroleum and chemical industries with regard to codes, material selection, safety, ease of maintenance and operation etc. Codes and standards applied shall be compatible to the service of the equipment. The Shipyard Contractor shall advise the EMPLOYER of any conflict between any referenced documents and the EMPLOYER will determine which shall govern. Resolution of any conflict shall be obtained from the EMPLOYER in writing before proceeding. In all cases the more stringent requirement shall apply. The order of precedence shall be as follows: 1) EU Regulations 2) Project Documents 3) International Codes and Standards All deviations from the requirements of the project documents listed in the purchase order and all referenced codes and standards shall be stated in the bid. In the absence of such a statement full compliance will be assumed.

3.1 International Codes &Standards

API RP 14E Recommended Practice for design andInstallation of Offshore Platform Piping Systems

ASME B31.3 Process Piping

ASME B31.8 Gas Transmission and Distribution Piping Systems

ASME Boiler & Pressure Vessel Code VIII Division 1 Rules for Construction of Pressure Vessel.

PED 97/23/EC Pressure Equipment Directive


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3.2 Project Specification and Philosophies

113A20-PP-SP-10001 Piping Design Specification

113A20-PP-SP-10016 General Specification for Piping Fabrication and Installation

113A20-PP-LIS-10025 Module 1 – Line List



113A20-PP-LIS-10028 Deck – Line List

113A20-PP-LIS-10146 Turbo generator – Line List

113A20-PP-LIS-10162 Inside hull - Line List

113A20-PP-LIS-10163 Oil Manifold Skid B8-13-XY-001 - Line List

113A20-PP-SP-10052 Typical Piping Assembly

113A20-PP-SP-10124 General Specification for Welding and NDE of Piping

3.3 EU Directives

94/9/EC Equipment intended for use in Potentially Explosive Atmospheres

99/92/EC Minimum requirements for improving the safety and health protection of workers potentially at risk from explosive atmospheres

97/23/EC EU Pressure Equipment Directive

Health and Safety at Work etc, Act 1974


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4. SCOPE OF SUPPLY

4.1 EMPLOYER’s Scope

The Contractor on behalf of EMPLOYER will provide the following documents to the Shipyard Contractor to facilitate planning and to define the limits of pressure testing. These documents define the type of test, test media and test pressure requirements: i) Piping and Instrumentation Diagrams, (hereafter referred to as P&IDs). ii) Line lists. iii) Specifications. iv) Piping Isometric Drawings for pipe 2” and above (hereafter referred to as isometrics).

4.2 Shipyard Contractor’s Scope

The Shipyard Contractor shall submit a copy of Shipyard Contractor’s Test Procedure to the EMPLOYER for approval. EMPLOYER approved Mechanical completion check sheets shall be included in the test pack as verification that the “system” is ready for testing. The Shipyard Contractor shall notify the EMPLOYER of any proposed deviation from this specification and/or line list requirements prior to the commencement of any pressure testing. Deviations from the defined test requirements shall not be permitted without the written approval of the EMPLOYER. It is the Shipyard Contractor’s responsibility to ensure that only appropriately qualified and competent personnel are used for pressure testing activities. The Shipyard Contractor shall prepare a Test Pack Dossier for each test system. Hydrotest packs shall be subject to EMPLOYER review and approval. The Test Pack Dossier shall include, but not be limited to, the documentation and clearances that are required for each test system as identified in Section 12. Vent and drain connections required for the pressure test will be identified on the engineering isometrics by EMPLOYER and be supplied to the Shipyard Contractor in full compliance with the relevant piping specifications. Any additional vent and drain connections that the Shipyard Contractor deems necessary for the pressure test shall be provided and fabricated by the Shipyard Contractor in strict accordance with 113A20-PP-SP-10001 Piping Design Specification, 113A20-PP-SP-10052 Typical Piping Assembly and 113A20-PP-SP-10016 General Specification for Piping Fabrication and Installation. Such vent and drain connections shall be subject to EMPLOYER’s review and approval. Material for the vent and drain connections shall be in accordance with the same Piping Design Specification as the pipe they are attached.


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Welding and non-destructive testing requirements associated with the hydrotest vent and drains shall be in accordance with the 113A20-PP-SP-10016 General Specification for Piping Fabrication and Installation. Blind flanges will be supplied by the Shipyard Contractor where they are indicated on the isometrics. Additional blind flanges to be used for testing purposes only are the responsibility of the Shipyard Contractor. It is the Shipyard Contractor’s responsibility to supply all necessary facilities and materials to carry out the flushing and pressure testing activities. This shall include, but not be limited to, the supply of all pumps, test valves, equipment, tools, materials, hydrotest blanks and blinds, (including temporary pipe supports for hydrotest) and scaffolding to provide adequate and safe access and labor etc to complete the work. The Shipyard Contractor’s attention is drawn to the fact that Petrobaltic rig conversion project includes API 6A 10,000 psi systems. Shipyard Contractor to ensure that test equipment is of adequate rating and the end connections are compatible with the piping systems being tested. Test equipment should be planned in advance of the tests to ensure availability in readiness for testing. All materials provided by the Shipyard Contractor for completion of testing shall be painted yellow for identification and ease of removal after test completion. It is the Shipyard Contractor’s responsibility to inform the EMPLOYER representative and Verification Body at least 24hrs before a system is due to be witness tested. After successful completion of a test, the Shipyard Contractor shall completely drain the test system and remove all temporary items and materials used for testing before reinstating items in accordance with the Shipyard Contractor’s Reinstatement Certificate.


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5. EXCLUSION This specification excludes pressure testing of the following -

i) Pressure Vessels, Exchangers, Pumps, Filters and Package Units etc, which have been tested by the manufacturer in accordance with the Codes and Standards to which they have been constructed.

ii) All instrument control piping and tubing downstream of the first piping block valve shall be tested

ii) The following shall be removed from the system test and replaced with spool pieces or segregated from the test:

Control Valves, Pressure and Thermal Relief Valves, Pressure Indicators, Orifice Plates, Bursting Discs, intrusive Instrumentation etc.

iii) All heating, ventilation and domestic water services within the living quarters.

iv) Riser pipe work below topside tie-in weld and sub-sea pipe work. vi) Pipe work systems open ended to atmosphere shall be purged with dry compressed air unless specifically identified otherwise on isometrics (e.g. Flare lines that cannot be blinded by removal of the tip). vii) Open drains shall be subject to a service leak test by blinding the outlets and completely filling the system / sub system and checking for leaks and falling level at the high point. Tests shall be redone where any leaks are found or where a drop in level at the high point is seen.


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6. SAFETY PRECAUTIONS Pressure testing, particularly pneumatic testing is considered to be a hazardous operation and special precautions shall be implemented. Prior to pneumatic or hydrostatic testing, the Shipyard Contractor shall submit a Safety, Health and Environment Plan to the EMPLOYER for approval. The Plan shall consider and assess the risks and precautions to be implemented during pressure testing. All personnel involved in pressure testing must be made fully aware of the requirements of this Safety Plan. Pressure testing shall be carried out in strict accordance with the European Pressure Equipment Directive 97/23/EC as listed in Section.3.4. Where there is a conflict between this specification and any local regulations, the most stringent shall apply. The Health and safety at Work Act – Section 2 specifically requires the Shipyard Contractor to ensure so far as is reasonably practicable “the health, safety and welfare of all his employees”. This duty includes the provision of safe plant and safe systems of working.

7. GENERAL REQUIREMENT Pressure tests shall as far as is practical are to be carried out for complete systems. Interconnecting lines that have similar flange rating and materials, and use the same test medium, may be included in the same test system. The breaking of flanged joints to insert blanks for testing should be kept to a minimum. All pressure testing shall be carried out in the presence of the EMPLOYER’s Inspector. No piping in the test system shall be subjected to any form of shock loading such as hammer testing or thermal shock when undergoing pressure testing. Test systems or lines that are to be chemically cleaned shall be pressure tested before chemical cleaning operations are carried out.


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8. PRESSURE TEST LIMITATIONS

8.1 Test Pressure

Hydrostatic test pressures shall be in accordance with the following –

i. ASME B31.3 CHPT VI sect.345.4 for pressure ratings up to and including ANSI 1500. ii. ASME B31.3 CHPT IX sect. K345 for the high pressure Water Injection system iii. ASME B31.8 CHPT VIII sect. A847

Pneumatic testing should only be carried out when hydrostatic testing is impractical. The maximum test pressure for pneumatic testing, when authorized, shall be 1.1 times the design pressure stated in the relevant Line List. In addition to the specified system test, the fire main sectioning valves shall be hydrostatically leak tested with a differential pressure across the valve equal to the maximum design pressure. Shipyard Contractor shall ensure that any position indicators function correctly. The sprinkler system distribution piping shall be hydrostatically tested to 1.5 times the design pressure of the system.

8.2 In-Line Equipment

Piping systems may be tested without isolating in-line equipment provided that: a) The equipment test pressure is equal to or greater than that of the piping system. b) The supporting steelwork would not be overstressed if due to their combined weights, the piping and equipment were tested together. c) Equipment shall not suffer damage due to the test medium. d) Equipment shall not include vessels, pumps, exchangers and the like. e) Special attention shall be made to draining, drying and preserving the equipment after the test.


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9. PREPARATION FOR PIPING CLEANING, FLUSHING AND TESTING

9.1 General

Piping being internally cleaned, flushed and then hydrostatically tested shall be, as far as practicable, tested in complete systems and include as many valves or other piping components as possible subject to the exceptions in this specification or unless their inclusion would be detrimental to internal components. The Shipyard Contractor shall prepare piping for inspection and pre-acceptance testing. All lines shall be checked to ensure that they are clear of refuse or material that may have accumulated during fabrication, installation and erection. All plant items including valves (e.g. check valves), vessels, pumps, heat exchanger etc. that could be damaged by flushing / testing operations shall be blanked off or removed from the system. Package units such as hydraulic pump sets, compressors, generators, diesel drives etc. shall be isolated and by-passed as necessary. All sensitive equipment, e.g. Instrumentation, safety valves, thermal relief valves, control valves, turbine meters, instrument probes, orifice plates, rupture discs, spray / deluge nozzles, etc. shall be removed prior to flushing and pressure testing. Where lines either side of these items are to be tested as part of the same test, temporary spool pieces shall be installed. A spool schedule shall be provided for temporary spool pieces and spools identified as per section 4.2. Insulation shall not be applied until all hydrostatic testing has satisfactorily completed. Painting of pipe spools may be completed prior to hydrotesting All piping shall be adequately supported, preferably with permanent supports. Spring supports shall be blocked to prevent movement. Temporary supports shall be used if additional stability is deemed necessary by the Shipyard Contractor. Spring supports shall have hydrostatic test stops inserted before commencing any flushing and testing operations. The Shipyard Contractor shall supply sufficient quantities of equipment and spares in order to carry out the pressure testing program. Pressure gauges used to indicate and record pressures shall be dead weight tested for accuracy. The testing of gauges for accuracy shall be carried out before each test by the EMPLOYER or Notified Body. A minimum of two gauges shall be used and positioned at the highest and lowest point in the system. The gauge located at the highest point shall indicate the required test pressure. Pressure and temperature time recorders shall be used for all hydrotests. Safety and thermal relief valves shall be removed and suitable spool pieces or blanks installed. All in-line valves shall be in the fully open position.

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Swing and piston check valves shall be removed. Dual plate wafer check valves shall be removed. All in-line through conduit gate valves and ball valves may be left in place during flushing and testing and shall be fully open. When flushing and testing through conduit gate valves and ball valves, special care is required to ensure that no debris / water is trapped in the lower section of the valve body. Valves shall be drained using the connection on the valve body after testing is completed. These valves shall be fogged with preservative using the connections on the valve body where specified by the EMPLOYER. Though not preferred and is subject to EMPLOYER approval; if testing takes place through actuated On Off shutdown valves they must be fully open, with assurance they will remain so throughout the test. IMMEDIATELY after testing they must be properly drained and blown dry with compressed air. These valves shall be fogged with preservative using the body vent and drain when required by the EMPLOYER. These requirements can only be avoided if such valves are removed from the line before testing. Special care shall be taken of valves with soft seats, they shall be removed if their inclusion would be detrimental to internal components. Pressure testing shall not be carried out against closed block valves. Blinds or Spectacle Blinds (fully rated) shall be used with valves open. All sprinkler, deluge, CO2 and water fog systems shall be flushed and tested before installation of the sprinkler heads. When hydrostatic/pneumatic testing, only the necessary test personnel shall be allowed within an agreed safe radius of the piping system to be tested. The area under test shall be fenced off for the duration of the tests and a notice displayed ‘Test In Progress’. All hydrotest vents and drains shall be in position prior to flushing and testing. Any additional vents and drains deemed necessary by the Shipyard Contractor for efficient venting and draining of the test systems shall be in accordance with section 4.2 above. Shipyard Contractor shall ensure that all ancillary fittings used are rated for the required flushing and testing pressure. Hoses shall only be used if they have an approved Shipyard Contractor test certificate for the required pressure. Upon completion of the test, all ancillary fittings are to be removed and the system returned to a state of compliance with the P&ID.


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9.2 Piping Cleaning

Internal piping cleaning shall be foreseen after piping erection/fabrication in according to the following table and class.

Class 1: Removal of all loose material, mill scale, rust, welding slag, grease, protective coatings and any adhering foreign material, which could be detached during plant operation. (Chemical cleaning or abrasive blasting)

Class 2: Removal of all loose material and adherent material, which could become detached

during plant operation (Flushing) Here below the table with indication of which lines is required internal piping cleanliness of class 1 or 2

PIPING CLEANING TABLE

LINES FLUID CODE Class 1

(Abrasive blasting or chemical cleaning)

Class 2 (Flushing)

FLUSHING FLUID

(Note 3)

Process lines (except compressors system lines)

CG-CH-CO-DC-DR-FG-LG-MG-HG-RG-TO-TW

NO YES WATER

Process lines (Only compressors system lines) (Note 2)

LG-MG-HG YES (Note 1) YES WATER

Utility lines

CA-GO-IA-UN

NO

YES COMP. AIR

BD-CW-DW-FF-FW-HW-NW-PW-SS-ST-SW-UW-WW

YES WATER

Note 1- The internal piping cleaning Class 1 of compressor system lines shall be foreseen as follow:

C.S. pipe: Abrasive blasting to Sa 2½ (ISO 8501-1:2007) as done by compressor supplier with subsequent flushing or chemical cleaning. S.S. pipe: Pickling and passivation (113A20-PP-SP-10124 chpt 10)

2- For the details of involved lines (number and qty) see line list documents 3- The flushing shall be made with a good water in particular for Stainless Steel materials where the

Chloride ions Cl content shall be less than 30 ppm.

A 100% visual inspection of the effectiveness of the cleaning operation shall be completed.

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9.3 Flushing Procedures

Systems to be flushed or blown down from the highest point on the system; additional flushing points may be required and these shall be indicated in the individual system procedures. All necessary precautions shall be taken to ensure debris is not flushed into connected equipment, valves or dead ends. Small flushing water discharges shall be led to a suitable drain. Discharge from pipes NPS 3 and above shall be led outside modules. All flushing air shall be led outside modules, with particular regard to personnel safety. Oils must not be discharged directly overboard, onshore or offshore. Flushing shall be avoided in sub-zero temperatures. If this is unavoidable, adequate precautions shall be taken to avoid pockets of water freezing in the test system, which shall be drained immediately on completion of flushing.

9.4 Flushing Requirements

All lines that require pressure testing shall be flushed prior to testing and where deemed necessary by the EMPLOYER, after testing. If there is any indication that debris or contaminants could be present, the piping system should be flushed again following the procedures within this specification. The medium used for flushing shall be as shown in the Project Line List. Packaged units that have been flushed and tested by the manufacturer do not require flushing again unless requested by EMPLOYER. For piping systems where the flushing medium is water, the velocities shall be a minimum of 3m/s. For offshore flushing where this minimum velocity is impractical, retro jetting may be substituted with EMPLOYER approval. Piping systems where flushing medium is compressed air shall be oil free and dry; the flow velocity shall be not less than 20 m/s. The location of temporary hose connections for the supply of compressed air flushing shall be determined on site. All fire protection system piping having more than two nozzles or heads shall be flushed. The main headers shall be flushed out first then all the branches which connect to any equipment. All necessary precautions shall be taken to ensure debris is not flushed into dead ends. The main headers shall be flushed for a minimum of 30 minutes and branches for a minimum of 15 minutes. On completion of flushing all broken connections shall be made up with new gaskets. When flushing stainless steel piping, the chloride ion content of the water shall be less than 30ppm. The Shipyard Contractor shall be responsible for taking all safety precautions during flushing, avoiding excessive pressure in the system.


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Fire mains shall be flushed prior to the connection of fire hydrants, monitors, deluge or sprinkler systems. All deluge and sprinkler systems shall be flushed separately to clear all foreign material and obstructions prior to testing. The piping system shall be considered clean when there are no visible deposits on target plates. The completion and acceptance of flushing shall be noted shall be noted on the pressure test certificate.

9.5 Pressure Testing Requirements

Safety of personnel is paramount and in this respect testing procedures should be examined and tests conducted paying full attention to the mandatory requirements. During testing, Safety Standards shall be observed at all times. Good engineering practice shall be observed at all times and dangerous or malpractices shall not be allowed. Before pressure testing commences, a ‘Released for Test Certificate’ shall be issued confirming that the test system is mechanically complete, all welding, heat treatment, integrity management of bolted joints and non-destructive testing has been completed and the system or line is ready for test. Pressure testing shall not commence until a Flushing and Cleaning certificate has been received confirming that the test system has been flushed and cleaned in accordance with the requirements of this specification. Prior to any test commencing, notices marked ‘Test in Progress’ shall be displayed around the perimeter of the test area or on the system being tested and all non-involved personnel shall be warned to keep clear of the area. Pipework subject to test should not normally be approached for examination until a reasonable time period has elapsed. Test packs including any HSE requirements shall be prepared and approved prior to commencement of testing.

9.6 Hydrostatic Testing

Hydrostatic testing shall be carried out with clean fresh water. For testing of systems containing stainless piping or fittings, the chloride ion content of the water shall be less than 30 ppm.


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9.7 Pneumatic Testing

The pneumatic testing of systems shall be avoided wherever practicable. Pneumatic testing shall not be carried out above 1.75 barg without prior authorization in writing from EMPLOYER. When a pneumatic test is authorized, oil free air or an inert gas shall be used. A pressure relief valve shall be provided with a set pressure not higher than the test pressure, plus the lesser of 3.4 barg or 10% of the test pressure.


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10. PRESSURE TESTING PROCEDURE

10.1 Hydrostatic Testing

The system to be hydrostatically tested shall be filled from the lowest point on the system. All vents shall be open prior to filling to eliminate air entrainment. Check valves which have had flappers removed for flushing, shall not be re-assembled until the test is complete. The system subject to hydrostatic test shall be tested via a test manifold which shall have facilities for the following: 1 - Pressure Recorder Connection 1 - Temperature recorder Connection 1 - Test Pressure Gauge Connection 1 - Pump Pressurisation Connection 1 - System Pressurisation Connection 1 - Safety Relief Valve Connection 1 - Vent Connection 2 - Spares Test pressures shall be applied by means of a suitable test pump or other pressure source which shall be isolated from the system until the test is ready to commence. The pump or source of pressure shall have an independent pressure gauge fitted. The pump and recorders shall be attended constantly during the test by an authorized person. The pump shall be isolated from the system whenever the pump is left unattended or when the test pressure has been attained Test pressures shall be checked by means of a certified test gauge and pressure recorder. The pressure gauge shall have a range in the order of 1½ times the intended maximum test pressure. All gauges shall be calibrated against a standard dead weight tester and shall be subject to Certifying Authority inspection and certification. A standard dead weight tester may be requested to check high pressure systems under test at the discretion of the EMPLOYER. Pressure gauges shall be located on each main header and any sub-headers to ensure the whole system is being tested. The hydraulic pressure shall be applied gradually and increased in steps of approximately 10% until test pressure is achieved. Test pressure shall be maintained for at least 60 minutes or as specified in the test pack before any system is put on official test and must be thoroughly checked for leaks during this period.


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Duration of the test shall be a minimum of one hour. Longer test periods consistent with test pressure and extent of the particular system may be necessary. Shipyard Contractor shall submit test period durations for approval by EMPLOYER. Testing should be avoided in sub-zero temperatures. If this is unavoidable, suitable precautions shall be taken to ensure the test medium will resist freezing. Under no circumstances shall non-impact tested carbon steel be tested at temperatures below 5ºC. All tests shall be signed at the start and completion by an authorized Shipyard Contractor Inspector, the EMPLOYER and/or third party Inspection Representative and/or Certifying Authority Surveyor. Should a test fail to be completed, or if it does not meet the specification, the records shall be kept and submitted with final test certificates. After the hydrostatic test has been completed, the pressure shall be released so as not to endanger personnel or damage equipment. All vents shall be opened before the system is drained and shall remain open during draining to prevent pulling a vacuum on the system.

10.2 Pneumatic Testing

Pneumatic testing shall only be permitted in cases where a hydrostatic pressure test is detrimental to the piping system or is not practical. The services to be pneumatically tested shall be shown in the Project Line List. All pneumatically tested lines shall be tested with clean, dry oil free air. Pneumatic testing involves the hazard of released energy stored in compressed gas. It is therefore imperative that test systems subject to pneumatic testing are kept small in terms of volume. Particular care must be exercised to minimize the consequences of brittle failure during a pneumatic leak test, particularly when de-pressurizing a system after test. It is therefore important that the Shipyard Contractor adheres strictly with the minimum pneumatic test temperature requirements of not lower than 5ºC. Only necessary test personnel shall be permitted within a defined 25 meters or agreed safe radius of the equipment or piping system being tested. The sequence of pressurizing shall be as follows:

a) The system shall be pressurized to 1.75 barg and held for sufficient time to allow the piping to equalize strains (10 minutes minimum). All joints (threaded, butt welded and flanged) shall be tested for leaks using a soapy water solution. Flanged connections shall be taped and one small hole punched on the top side.


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b) The system should then be pressurized gradually to 60% of the required test pressure and held at this pressure for a sufficient length of time to allow for all piping strains to equalize. The minimum period shall not be less than ten minutes. The pressure shall then be reduced to 50% of the required test pressure and all joints re-tested for leaks.

c) Pressurize the system in steps of not more than 10% until the required test pressure

has been reached. The pressure shall be held at each step during the pressurizing sequence (to all the piping to equalize strains) for a period of not less than ten minutes. The required test pressure shall be held for 30 minutes and then reduced to the maximum working pressure and held for sufficient length of time to permit testing of all joints, but under no circumstances shall this be less than 30 minutes.

d) Inspection of all pipework being tested shall be performed at each stage.

Each reinforcing pad (or segment thereof) and similar attachments shall be tested at a pressure of at least 1.0 barg with air, a soap solution shall be used to detect air leaks. Test and vent holes shall be left open upon completion of the test. Test personnel must be in attendance during the test period and should monitor the test gauges constantly. All tests shall be signed at the start and completion by an authorized Shipyard Contractor Inspector, the EMPLOYER and/or third party Inspection Representative and/or Notified Body.

10.3 Service Fluid Testing

Subject to EMPLOYER approval, test systems in Category D fluid service (defined in ASME B31.3 para.300.2 and Appendix M-Fig. M300) may be subject to an initial service leak test in accordance with the requirements of ASME B31.3 para.345.7, in lieu of a hydrostatic test. Where piping is to be tested with its service fluid, an initial pneumatic test of 1.75 barg shall be made with a soapy water mixture applied to all joints to locate any possible leaks. After a satisfactory pneumatic test the lines shall be filled with the service fluid at the pressure specified in the Project Line List. All vents and other connections which can serve as vents, shall be open during system filling so that all air is vented prior to applying the test pressure. The service leak test shall be maintained for at least ten minutes for all joints and connections to be examined. Open drain lines shall be flushed through and filled with water and subject to a static head test for a minimum of 30 minutes, no leakages allowed. Non-hazardous atmospheric vents shall be cleaned through using compressed air only.


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10.4 Correction of Leakage

If a piping system under test fails to hold the required test pressure, the system shall be inspected to determine the location(s) of the leakage. The system shall be depressurized and any welded joints failing the pressure test shall be repaired and examined in accordance with 113A20-PP-SP-10124 General Specification for Welding and NDE of Piping. Any leakage detected at a bolted joint shall be refurbished in accordance with 113A20-PP-SP-10016 General Specification for Piping Fabrication and Installation The piping system shall be retested to the original hydrostatic/pneumatic test pressure.

11. POST FLUSHING AND TESTING PROCEDURES When flushing and pressure testing is complete, all strainers shall be removed cleaned out and reinstalled. Temporary strainers will be retained in the lines during normal operation. They will be removed and discarded when deemed no longer necessary by the EMPLOYER. All temporary connection spools and blanks installed for flushing /pressure testing shall be removed. On completion of pressure testing all vents shall be opened first and then the system shall be completely drained and then dried. All temporary blinds and test equipment shall be removed and all items which were removed prior to the test shall be re-installed in accordance with the isometrics. Special care shall be taken to ensure that austenitic/duplex stainless steel lines are completely moisture free in all pockets and crevices. All systems that have been tested with water shall be blown dry with compressed air, to remove all residue of water. To prevent corrosion a water soluble vapor phase corrosion inhibitor such as Corroless CI250 or equal shall be added after all testing. Manufacturer’s recommendations concerning use shall be followed. The corrosion inhibitor need not be used in non-critical lines such as atmospheric vents and drain systems etc. All connections broken after pressure testing has been completed shall be made good upon re-assembly, and need not be re-tested. Temporary restraints on pipe supports shall be removed.


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12. PRESSURE TEST RECORDS The Shipyard Contractor shall provide a Test Pack Dossier containing the records for each test system and pipe spool tested The records shall be signed and approved by the EMPLOYER representative and the Verification Body. The records shall contain the following documents and information: i) Identification number for the test system. ii) The date of the test. iii) Test system P&ID’s. iv) Test system Isometrics. v) List of lines that comprise the test system. vi) The “Released for Test Certificate”, confirming that the test system is mechanically complete, all welding, heat treatment and non-destructive testing has been completed and the system or line is ready for testing. vii) The “Flushing and Cleaning Certificate” confirming that the test system has been flushed and cleaned in accordance with the Project Specification for Flushing and Cleaning of Pipework. viii) Details of weld repairs, non-destructive testing and re-tests. ix) Test medium used. x) Chemical analysis of the test water. xi) Calibration certificates for pressure gauges and chart recorders. xii) A record of the ambient temperature for the duration of the test. xiii) Pressure recorder graph trace (signed by a EMPLOYER representative and the Notified Body). xiv) A “Pressure Test Certificate” signed and dated by the Shipyard Contractor’s Inspector, confirming test pressure, test temperature, test duration and any corrections to the test pressure carried out to compensate for variations caused by temperature changes during the test. xv) A “Pressure Test Reinstatement Certificate”. xvi) Risk Assessments carried out prior to the test. All test records shall be included in the Shipyard Contractor’s data books and submitted to the EMPLOYER.

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