SAUDI ARABIAN OIL COMPANY

NEAT KHUFF CONDENSATE FRACTIONATION PROJECT

METHOD STATEMENT
FOR
VALVE TESTING

SUB CONTRACT NO: 308200

DOCUMENT NO: 308200 -MST-ME- 08 Rev 0

Client : Project : Contractor : Date :

SAUDI ARAMCO / NEAT KHUFF CONDENSATE DODSAL& CO. 23-06-02

SNAMPROGETTI FRACTIONATION PROJECT

DOD/NEAT KHUFF/308200-MST-ME-08 Page 1 of 7

23 JUNE 2002
 METHOD STATEMENT
FOR
VALVE CONTROL

REVISION CONTROL

Revision Date of Details of Prepared by Reviewed by Approved by Approved by

Status Issue Revision DODSAL DODSAL DODSAL SP

0 17-06-02 Initial PIB PIB AB

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 METHOD STATEMENT
FOR
VALVE TESTING

INDEX

1.0 PURPOSE

2.0 SCOPE

3.0 REFERENCE DOCUMENTS

4.0 DEFINITIONS

5.0 PROCEDURE

6.0 DOCUMENTATION

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1.0 PURPOSE
The purpose of this Method Statement is to ensure that the body and seat pressure testing of the
Valves are carried out in a safe and efficient manner. This procedure describes the steps, sequence
of events, responsibility, authority and documentation requirements to ensure that the specific task
meet the Customers Specifications.

2.0 SCOPE

This procedure is applicable when valve Pre-installation Testing is a contractual

requirement of a construction project.

3.0 REFERENCES

API Std 598 : Valve Inspection and Testing

API Std 602 : Compact Steel Gate Valves – Flanged, Threaded, Welding and Extended
Body Ends
ASME B31.4 : Liquid Transportation System for Hydrocarbon Liquid
ASME B31.3 : Chemical Plant and Petroleum Refinery Piping
ASME B16.5 : Pipe Flanges and Flange Fittings
ASME B16.34 : Valves Flanges, Threaded, and Welding End

4.0 DEFINITIONS

COMPANY: SAUDI ARABIAN OIL COMPANY (SAUDI ARAMCO)

CONTRACTOR: SNAMPROGETTI

SUB CONTRACTOR: DODSAL & CO

5.0 PROCEDURE

5.1 RESPONSIBILITIES

Project Manager shall ensure compliance by all parties to this procedure, the project quality
assurance manual. QC Inspection Plan and relevant Customer Specification and Drawings.

Construction Manager shall ensure compliance by all craftsmen to the content of this procedure,
Project QA manual and QC ITP.

Pressure Test Supervisor shall ensure compliance by all pipe fitters, welders and other associated
craftsmen to this procedure and the project quality plan. Ensure relevant permits are raised and
received by authorized personnel prior to execution of the work.

Quality Control Supervisor shall review all project specific pressure test procedures prior to submittal
for approval, ensuring that all inspection and test requirements have been identified, the documents
are complete where necessary, and the appropriate and testing personnel are available.

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 Quality Control Inspector shall conduct in accordance with this procedure and the Project Quality
Control Inspection Plan / Procedures. Ensures all pertinent records are placed in the applicable
certification package.

5.2 SAFETY

5.2.1 Safety Officers Responsibility:

The Safety Officer shall be responsible for the entire safety requirement as per Saudi Aramco
Safety. Safety warning signs shall be posted around the Area to warn the personnel of the works in
process.

5.2.2 HSE Plan Requirement

All works shall be carried out as per Snamprogetti & DODSAL Official HSE Plan.

5.3 PRESSURE TEST PREPARATION

5.3.1 Ensure that all materials, relevant drawings and procedures are available to personnel performing
the work. All personnel shall be aware of and understand the requirements of the safety / loss
prevention plans in force.

5.3.2 Ensure test gauges and PSV’s are correctly sized for the test condition, the hydrostatic pressure
test package with calibration documents for gauges. PZV’s are checked and approved.

5.3.3 Ensure that plant, equipment and personnel required to perform the work are suitably qualified and
experienced.

5.3.4 Prepare adequate capacity test pump, pressure hose, fittings, approved test manifold. Ensuring
they are all certified for the pressure range.

5.3.5 Blind flanges of the correct rating and material specification may be utilized for banking of valves for
test purpose. On no account should non-identified blanks or plate materials be used.

To complete the body and seat tests in most cases will require the addition of vent, drain and fluid
inlet connections. These fittings (3/4”) should be of the same materials and rating as the flanges.

Holes required should be made by drilling only. Welding will be completed by qualified welders to
an approved WPS. Non Destructive Testing as per piping specifications (rating) shall be
completed.

Prior to use these test blanks complete with any ancillary pipework will require a safety proof test.
Certificate of all inspection and test will be maintained.

6.3.6 A high point vent and low point drain must be available for all tests.

6.3.7 QC must be notified by raising RFI.

6.3.8 Forward copy of RFI to the Customer’s representative when witness is a specified requirement in
the QC ITP.

5.4 BODY TEST PRESSURE EXECUTION

5.4.1 Ensure the valve is adequately supported. Fill the system with approved test water until it flows out
from the highest point. The valve shall be at the partially open position.

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5.4.2 Close the highest vent point when all trapped air has been released.

5.4.3 Gradually pressurize the system at not more than 90 psig per minute until reaching 225 psig. Allow
the pressure and temperature of the test water to achieve equilibrium.

5.4.4 Examine for the possible leaks and weakness.

5.4.5 The pressure shall be increased in steps with at least 10 minutes hold at each step to permit
inspection for leaks and weaknesses.

5.4.6 Any leakage detected will be brought to the attention of the customer for free issue items and items
and the manufacturer for Dodsal purchases for remedial action recommendation.

5.4.7 Do not attempt to repair leaks and weaknesses when the system is still pressurized.

All test requirements will be conducted in accordance with the requirements for the relevant project
specification and referenced applicable standards.

5.4.8 Increase the pressure not greater than 90 psig until the required test pressure is reached.

5.4.9 When test pressure is reached close isolation valve and disconnect the pressure hose. Observe
gauges (a minimum of two) constantly during test. Access is required to depressurizing valve in
case of thermal expansion. Pressure gauges shall be within 5% of each other. Duration of test
shall be a minimum as required to determined compliance with acceptable criteria / standards.

5.4.10 Obtain the approval of Dodsal QC and Customer if in attendance prior to any depressurization.

5.4.11 Open the depressurization valve gradually in such a way as not to cause vacuum and collapse
during draining. Open the highest vent point before draining.

5.4.12 Ensure that the valve body is thoroughly drained through drain valve.

5.4.13 Multiple Valve Testing

Install valves in series and blind at both ends. Test valves as per item 5.5.1 to 5.5.11.

Any valve leaking shall be removed from the series of valves and resume testing. Repeat the cycle
until the remaining valves in the series passed the required test pressure.

Refer to 5.5.13 for valves seat test pressure.

5.5 SEAT TEST PRESSURE EXECUTION

5.5.1 Ensure that the valve is properly supported prior to the filling and pressurization process. The valve
shall be at the fully closed position.

5.5.2 Install one blanking flange at one end of the valve. The other shall not be blinded. Raise RFI for
test witness.

5.5.3 Fill the system with approved test water until if flows out from the highest vent point. Close the
highest vent when all trapped air has been released.

5.5.4 Gradually pressurize the system at not more than 63 psig per minute until reaching 158 psig. Allow
the pressure and temperature of the test water to achieve equilibrium.

5.5.5 Examine for possible leakage at the seat.

5.5.6 Increase the pressure not greater than 63 psig until the required pressure is reached. The following
provisions must be observed.

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 The pressure shall be increased in steps with at least 10 minutes hold and each step to permit
inspection for leaks and weaknesses.

Any leakage detected will require the pressure to be released and a repair effected where
permissible follow steps up to repair detection and continue all case of seat leakage. Notify the
customer for free issue items and the manufacturer for Dodsal purchases prior to any repair
actions. Instructions to repair must be in writing.

5.5.7 When test pressure is reached close test isolation valve and disconnect the pressure hose.
Observe gauges (a minimum of two) constantly during test. Access to depressurizing valve in case
of thermal expansion is essential. Pressure gauges shall be within 5% of each other when in use.
Duration of test shall be a minimum as required to determine compliance with acceptable criteria /
standards.

5.5.8 Obtain Dodsal QC Inspection approval and acceptance prior to depressurization of the system.

5.5.9 Open the depressurizing valve gradually in such a way as not to cause vacuum and collapse during
draining. Open the highest vent point after initial pressure release before draining.

5.5.10 Ensure that the valve body is thoroughly drained through its drain valve. The test water shall be
discharged to a safe place.

5.5.11 Unbolt the blanking flange and relocate to the opposite end. Close the valve. The other side shall
not be blinded.

5.5.12 Repeat the sequence number 5.5.3 to 5.5.10.

Unbolt the blanking flange clean & dry. Ensure that the flange temporary protectors are re-
fastened. QC inspector returns completed RFI and complete test report.

5.5.13 Multiple Valves Testing

After completion of Body Test of valves, see item 5.4.13, depressurize back to 63 psig.

Close the last valve in the series of valves and depressurize the section between the blind of the
last valve and the seat of the last valve.

Remove the blind and pressurize as per item 5.5.4 to 5.5.9. if valve seat is leaking close the valve
next to the last and repeat the cycle until the remaining valves in the series passed the required test
pressure.

All valves in the series tested successfully shall be assembled in series but to be tested in the
opposite side. Apply pressure as per item 5.5.1 to 5.5.13

6.0 DOCUMENTATION

Request for Inspection

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