Hydrostatic Test Procedure For Ug Non-Metallic Piping System

Kuwait National Petroleum Company (K.S.C.) P6011MAA.000.10.51.
052
Clean Fuels Project (CFP) REV F1
KNPC Contract No. CFP/EPC/0054-MAA Page 1 of 16
Contractor JOB CODE : 0-6798-20-0000 S-000-3168-0003V
HYDROSTATIC TEST PROCEDURE

FOR U/G NON-METALLIC PIPING SYSTEM
Operation Center JOB CODE 0-6798-20-0000

Operation Center Doc No. S-000-3168-0003V
F1 20-Jul-16 Issued Final S. Polaki H. Suzuki S. Hanada
A1 3-Jul-16 Issued for Design S. Polaki H. Suzuki S. Hanada
O5 1-Jun-16 Issued for COMPANY Approval S. Polaki H. Suzuki H. Kunifusa
O4 17-Apr-16 Follow up Rev O3 COMPANY Comments S. Polaki H. Suzuki H. Kunifusa
O3 27-Mar-16 Follow up COMPANY Comments S. Polaki H. Suzuki H. Kunifusa

O2 25-Feb-16 Issued for Comment S. Polaki H. Suzuki H. Kunifusa
O1 9-Feb-16 Issued for Comment S. Polaki H. Suzuki H. Kunifusa
Rev. Date Description Orig. Checked Approved
By By
Kuwait National Petroleum Company (K.S.C.)

Clean Fuels Project (CFP)
Kuwait
JGC Corporation / GS Engineering & Construction / SK Engineering & Construction
CONTRACT NO. DOCUMENT NO. REV NO.

CFP/EPC/0054-MAA P6011MAA.000.10.51.052 F1
CONFIDENTIAL OR PROPRIETARY INFORMATION
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Kuwait National Petroleum Company (K.S.C.) P6011MAA.000.10.51.052
Record of Revisions
Rev No Date Description
O1 9-Feb-16 Issued for Comment
O2 25-Feb-16 Issued for Comment
O3 27-Mar-16 Follow up COMPANY Comments(KNPC-JGSK-CFP-MAA-L-16-7863)
O4 17-Apr-16 Follow up Rev O3 COMPANY Comments
O5 1-Jun-16 Issued for COMPANY Approval
A1 3-Jul-16 Issued for Design

Revision up according to revision step rule after COMPANY Approval
F1 20-Jul-16 Issued Final
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TABLE OF CONTENTS
1.0 SCOPE.............................................................................................................................. 4
2.0 CODES AND REFERENCES ............................................................................................ 4
3.0 RESPONSIBILITIES......................................................................................................... 4
4.0 GENERAL …………………………………………………………………………………………..5
5.0 TEST METHODS AND PRESSURES ............................................................................... 6
6.0 PRESSURE TEST BLINDS ............................................................................................... 7
7.0 TEST PROCEDURE .......................................................................................................... 7
8.0 SAFETY ……………………………………………………………………………………………11
Attachments
Attachment-1,Inspection Check List Prior to Pressure Test …………………………………….12
Attachment-2,Minimum Thickness of Steel Blind Flanges (T) ………………………………….13
Attachment-3,Pressure Test Report ……………………………………………………………….14
Attachment-4,Hydrostatic Testing – Pressure Change Calculation …………………………….15
Attachment-5,Pressure & Temperature record during pressure test …………………………...16
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1. SCOPE
This procedure describes the general requirements and procedures for field pressure testing of
underground pressure GRE/GRP piping system, connected equipment and integral components to
assure mechanical strength and tightness.
1.1 Purpose
This procedure explains objectives and requirements of steps to be followed during Field hydro
testing of GRE/GRP piping system for KNPC-Clean Fuels Project.
2. CODES AND REFERENCES

DEP 31.38.01.31 Shop and Field Fabrication of Piping
DEP 74.00.10.10 Shop and Field Pressure Testing of Piping System
DEP 31.40.10.19 Glass-fibre reinforced plastic pipeline and piping systems
S-000-3168-0001V Piping Test Package Preparation and Handling Procedure
S-000-1670-0305V Typical Inspection and Test Plan for Piping Works
S-000-1360-0151V Piping Tie-in Procedure
VV216A-109-A-809 Field Fabrication Procedure (joint / lamination procedure)
74.00.10.10-P6000CFP-000-PV-Section 4-Exhibit H-General Execution Requirements
3. RESPONSIBILITIES
3.1 Project manager shall be responsible for the overall implementation of the company safety &
Quality plan and ensure efficient execution of the works in accordance with the project specifications.
3.2 QA/QC manager shall oversee all the activities, whether all are executed as per the quality plan and
project specifications.
3.3 Construction manager shall be responsible to give correct instructions to supervisor for
implementing project quality and safety plan.
3.4 Supervisor shall monitor the execution of all works.
3.5 Foreman shall lead the work force and workmanship during the execution of the work.
3.6 QC supervisor shall see that all records pertaining to the particular works are maintained and
accepted by PMC.
3.7 QC Inspector shall ensure that all works are carried out as per IFC drawings, project specifications
and standards and he has to co-ordinate with PMC QC inspectors for the inspections.
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The following inspections shall be conducted by QA/QC personnel.

All piping materials
Survey lay out
Elevation of the subgrade and compaction
Bedding
Pipe Alignment and Elevation
Joints Inspection
Testing
Backfilling layers and compaction
4. GENERAL
4.1 Upon completion of installation, U/G GRE/GRP pressure piping systems shall be hydrostatically
pressure tested. The system / loop shall be both strength and leak tested in several sections
separately depending on the readiness of the construction. The entire system (all sections) shall be
Leak/strength tested at one time once the entire system shall be ready.
4.2 PREPARATION
A formal risk assessment should be carried out prior to the system hydro test. All supports, guides,
and anchors shall be in place prior to pressure testing. Temporary supports and restraints shall be
added if required. Pipe systems containing check valves shall have the source of test pressure
located on the downstream side. All adhesive-bonded and laminated joints shall be fully cured prior
to pressure testing. Threaded connections and the bolts of flanged joints shall be made up to the
correct torque prior to pressure testing in accordance with Manufacturers recommendations.
4.3 Test Equipment
4.3.1 Manifold, pressure gauges, Relief valves, test blinds, pressure Hoses, air compressor, hand
pump, torque wrench, hand tools etc...
4.3.2 Testing instruments (Pressure gauge, Pressure/Temperature recorder, Deadweight tester)

calibration and range shall meet DEP 31.40.10.19 Clause 5.2
All inspection, measuring and testing equipment shall be maintained and calibrated, as described
in ISO 9001, with following additional requirements:
a) Test pressure measuring devices shall be either pressure gauges or pressure/temperature

recorder with a full-scale range of no more than two times the test pressure and shall be
accurate to at least ± 0.5% of full-scale range(comply with DEP 31.40.10.19 Clause 5.2);
b) The deadweight tester shall be applied to final entire 4 hours strength test and 24 hours
leak test.
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c) All pressure measuring devices shall be calibrated to certified standard every six months.
4.3.3 A pressure relief valve shall be installed on the discharge of the test pump. This PRV shall be set
at 110% of test pressure. (DEP 74.00.10.10-Gen. Clause 3.1).
4.3.4 The Relief valve shall be tested, dated and tagged prior to the pressure test.
4.3.5 Calibrated torque wrench should be used for flange tightening.
4.3.6 Test Manifold shall be certified
4.4 Test Fluid

Potable water shall be used for GRE/GRV/GRP piping systems.
4.5 Pipe Internal Cleaning
Internal cleaning of pipe shall be done by air blowing prior to hydrostatic test.
4.6 Drain after testing
All piping shall be completely drained after test.
4.7 Inspection check list prior to pressure test

Inspection check list prior to pressure test shall be checked and filled by Subcontractor and
Contractor QC before request for pressure test is issued.
Refer to Attachment-1, Inspection Check List Prior to Pressure Test
4.8 Company Line check and punch listing prior to NFI for testing.
4.9 Request for pressure test

Request for pressure test shall be submitted to Company by Contractor QC section through NFI.
5. TEST METHODS AND PRESSURES
5.1 The following tests shall be carried out:
a) Hydrostatic pressure test
b) Leak tightness test
5.2 Test pressure for hydrostatic test shall be 1.5 times design pressure.
Leak tightness test pressure shall be 1.1 times design pressure.
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6. PRESSURE TEST BLINDS & INSPECTION REQUIREMENTS FOR TEST HEAD
6.1 Test Blind

Test blinds shall be installed as per FPI procedure VV216A-109-A-809.
Refer to Attachment-2, Table for the Thickness of Blind Plate
6.2 Gaskets required for service shall be used during hydrostatic pressure test (DEP 74.00.10.10
Clause 3.3.1)
6.3 Temporary bolts and nuts shall be same length/ diameter as used in service with colour
coding(Silver).
7. TEST PROCEDURE
7.1 Test Preparation
7.1.1 A Hydro test pack for the loop or section to be tested shall be submitted to Company minimum 48
hours prior to test for approval.
7.1.2 It is recommended to limit the testing length to not more than one half kilometres for better quality
of work. However the test sections length can vary depending on site requirements.
7.1.3 All high points shall be provided with vents.
7.1.4 In case the line does not include flanges, it will be necessary to connect temporary flanges or test
end-caps for testing purposes. Any additional flanges for pressure testing shall be removed
afterwards and replaced by pipe.
7.1.5 Steel blind flanges with suitable flange face to be used during hydro testing shall meet the
thickness required as mentioned in attachment 2.
7.1.6 For U/G piping, the section of pipeline to be tested should be partially backfilled up to one x
diameter above pipe crown (minimum 300mm but shall not exceed 1 meter) to ensure proper
support. Temporary supports (e.g. sandbags) or backfilling as required should be provided close to
fittings and at changes of direction during the test. All joints shall be left exposed for inspection
during the test.
7.1.7 Remove any instruments or other items that may be damaged by hydro testing such as valves,
bellows, strainers, flow meters etc. The items to be removed shall be clearly marked in the test pack
and the section closed with blind flanges or a suitable spool piece.
7.1.8 Clean the face of GRE/GRV flanges, blind flanges, gaskets, bolts, nuts and washers.
7.1.9 All gaskets, nuts, washers and bolts used for hydro test shall be replaced after final testing.
7.1.10 Install Kroll and Ziller gasket and blind flanges including bolts, nuts, washers to its appropriate
location. Apply torque using calibrated torque wrench and bolt sequence as per document no.
VV216A-109-A-808.
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7.1.11 Required temporary piping arrangements like blind flanges and dummy spools will be installed in
appropriate locations.
7.1.12 Pressure gauges, Pressure/Temperature recorder, Deadweight tester and pressurizing pump are
connected to the line at the blind flanges/test ends. The pressure gauge shall be installed at the
highest point of the piping system being tested.
7.1.13 Piping section to be hydro tested shall be filled from the lowest point. Vents or other high point
connections shall be opened to expel air from the line.
7.1.14 All valves in the test system shall be full opened position.
7.1.15 Vents should be closed only when clear water with no air bubbles comes through the vent. All air
shall be removed from the piping system by venting before hydrostatic test pressure is applied.
7.1.16 The line shall be filled with water at a steady controlled filling rate. After closing all vents the water
filling will be stopped.
7.1.17 A pressure/temperature recorder and Deadweight tester shall be used during overall final test
governing test for both the Leak and Strength test. The chart will be signed at the start and finish of
the test.
7.2 Pre-Hydrostatic test
7.2.1 Test Package Approval

Subcontractor shall prepare and submit test package for approval to Contractor test team.
7.2.2 Pre-Hydro Test Line Check and punch clearing
Piping systems shall have been completely checked prior to hydro testing by Subcontractor,
Contractor and Company. All Category-(I) Punch Items shall be closed prior to the hydro test.
Subcontractor shall receive the scan copy of approved test package for each piping system from
Contractor test team. The latest drawings (Isometric drawing, PEFS & etc.) shall be attached on
the test package. Subcontractor shall conduct line check and punch clearing with this scan copy.
Subcontractor shall submit to Contractor for Contractor’s line check after cleared Subcontractor
category (l) punch items. Then, Contractor generate punch list and pass to Subcontractor for
clearing. When Subcontractor cleared all category (l) punch items, the test package shall be
treated as test package line completion. Contractor’s internal punch will be closed by Contractor,
not Company.
Once Contractor closes all punch items, Company shall be called for Company’s punch inspection.
Company inspection will be cancelled if more than two category (I) punch items are found at any
time in the inspection and the test pack returned to Contractor for Contractor’s re-inspection.
Company shall verify close out of Company raised punch items.
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7.2.3 All lines shall be checked to ensure the entire system can be completely drained after testing.
7.2.4 Vents, drains and relief valves shall be utilized to prevent damage to the piping system due to
thermal expansion or other hazardous conditions during the test period.
7.2.5 Short pieces of piping which must be removed to permit installation of a blind or blank shall be
tested separately or, where possible, tied together and tested at the same time.
7.2.6 Lines containing check valves shall have the source of pressure located in the piping upstream of
the check valve and checked to insure that the entire length of piping can be completely filled with
water. If this is not possible, remove or jack up the check valve completely and provide necessary
filler piece or blinds.
7.2.7 Systems that include expansion joints shall be investigated to see that any required temporary
restraints, anchors, guides, etc., are installed prior to test.
7.3 Hydrostatic Pressure Test
7.3.1 The specific procedure for application of piping pressure test is given in DEP 31.40.10.19-Gen.
7.3.2 The hydrostatic pressure test consists of the following steps:

1) Filling the pipe section to be tested with water
2) Stabilization of the temperature
3) Strength integrity test (hydrostatic pressure testing)
7.3.3 Time-frame for stabilization is 24 hours. Contractor will perform the temperature stabilization before
hydrostatic pressure test.
7.3.4 Once the temperature has stabilised, a strength test shall be carried out at a pressure equal to 1.5
times the system design pressure and held section by section for a minimum of 4 hours, and no
longer than 6 hours. The pressure will be raised up to the strength test pressure in the following
steps:
1) Raise the pressure to 0.5 X Test pressure with half hour stabilization and monitoring.
2) Raise the pressure to 0.8 X Test pressure with half hour stabilization and monitoring.
3) Raise the pressure to final test pressure. The rate of pressurisation shall not exceed 2 bar per
minute.
7.3.5 Only after acceptable Strength Test has been carried out then a Leak tightness test shall be carried
out at pressure equal to 1.1 times the system design pressure. The test pressure shall be held for a
minimum of 24 hours during which time no water shall be added to or removed from the pipeline.
7.3.6 During both the strength test and leak tightness test, the pressure and temperature shall be recorded
continuously and deadweight tester readings shall be recorded every 30 minutes. The original
pressure and temperature recordings shall be kept in the installation quality records.
7.3.7 As an additional check to determine whether any pressure variation has been caused by a
temperature change or whether a leak is present, the theoretical pressure change resulting from the
measured temperature change shall be calculated using the formulae given in Appendix B of DEP
31.40.10.19-Gen. (Refer to Attachment-4).
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7.3.8 Any leaking or weeping shall constitute a defect , the test shall be terminated and a repair effected.
Joint shall be cut out and Pup piece installed. Then the test procedure shall be repeated.
7.3.9 Over-torquing of flanges to stop leaks shall not be permitted. Leaking flanges shall be remade with
new gaskets and retested. If leakage still occurs, flanges shall be replaced.
7.3.10 The strength test shall be successfully concluded if no leakage is observed by visual check and no
pressure drop is recorded. This is derived from Manufacturer procedure for field hydrostatic testing
of GRE/GRV pipe system(VV216A-109-A-809).For any pressure change due to temperature change,
this shall be calculated using the formulae given in Appendix B of DEP 31.40.10.19-Gen. (Refer to
Attachment-4).
7.3.11 The system shall be drained and dried after successful completion of the test.
7.3.12 Multi-Section Test method

Depending on the length of line to be tested, construction activity in the area, and other
considerations, Contractor may decide to use a Multi-Section Hydro test.
Multi –Section Hydro tests shall be generally be used when the pipe to be tested is long and
Contractor desires to perform partial backfilling to support the construction schedule. Multi-Section
tests shall be composed of 2 or more sections depending on length. Each section shall be receive a
Partial Test which is intended to verify the integrity of the piping and allow the excavation between
the two ends of the pipe section to be backfilled. The Partial Test is NOT the governing test. A final
overall test of all sections joined together shall also be performed and this shall be considered the
final test.
The test method for Multi-Section tests shall be the same as noted above in Sections 7.3.1 through
7.3.12 except as noted below:
Partial tests shall conform to the following:
 NFI shall be issued and Company invited to each Partial Test. Company approval of the Partial
test is not required, but any defects noted by Company shall be corrected prior to backfilling.
 The ends of each Partial Test test section shall not be backfilled until the final overall hydro test
of all sections together is successfully completed.
 The final overall test which incorporates all Partial Test Sections will be the final governing test.
Partial test is performed with

Strength test : 1.5 times x Design pressure / 4hrs without deadweight tester
Leak tightness test : 1.1 times x Design pressure / 24hrs without deadweight tester
With this partial test, integrity of piping system and soundness of field joints can be confirmed. After
completion of partial test, all tested piping components including joints will be backfilled except joints
the end points which shall be left exposed until the final overall test is complete.
(BB) Overall final test

Overall final test is performed with
Strength test : 1.5 times x Design pressure / 4hrs with deadweight tester
Leak tightness test : 1.1 times x Design pressure / 24hrs with deadweight tester
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Final Overall strength test and leaks test to be done with the all sections connected and end
points/joints between sections exposed during the tests.
7.4 Post Hydrostatic Pressure Test
7.4.1 Test Records
Records shall be made of each piping system test, utilizing the forms titled, "Pressure test report
(JGSK-QC-6000-17)", “Pressure and temperature record during pressure test (JGSK-QC-6000-
41)” . These forms, when completed, shall be retained in the field QC document as a permanent
record. Refer to Attachments-3 and 5.
7.4.2 Test Completion

1) After controlled depressurisation, all remaining vent and low point drain valves shall be opened
and the system thoroughly drained.
2) Temporary blinds and other equipment installed for testing shall be removed on completion of
the test.
3) Test pressure gauges shall be removed and any temporary vent and drain facilities installed for
testing shall be removed and the tie-in points plugged in accordance with pressure stipulations
for that section of pipework.
4) Gaskets at flanged joints, which have been broken for testing, shall be renewed.
5) Reinstatement shall be made to the degree required to prepare the line for handover to Pre-
commissioning (i.e. any items that would be removed by pre-commissioning and which are
already removed for hydro testing shall not be reinstated until pre-commissioning is complete)
7.4.3 Pre-commissioning Activity
Test package will be handed over to commissioning team for further pre-commissioning cleaning
activity after reinstatement is completed and punch items are cleared unless commissioning team
request otherwise.
7.4.4 Reinstatement and hand over
After completion of pre-commissioning activity, reinstatement can be completed and test package
will be submitted to the Company for confirmation once Contractor confirms all category (ll) punch
items are cleared and line is reinstated completely. After confirmation by Company, test package
shall be transferred to hand over team to upload into the hand over system.
In case a certain punch item cannot or should not be cleared until after achievement of
PTOP(Provisional Turn Over Package) due to commissioning reasons, these category (ll) punches
would be changed to category (lll) subject to agreement between Company and Contractor.
Category (lll) punch will be transferred into system punch and re-categorized as per system punch
definition.
8. SAFETY
8.1 Testing area must have proper signboards to be placed.
8.2 To the possible extent, movement of men and equipment should be avoided.
8.3 Only authorized testing personnel will be allowed in the test area.
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Attachment-1, Inspection Check List Prior to Pressure Test
“Sample”
The latest format shall be referred to “S-000-1670-0401V”
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Attachment-2, Minimum Thickness of Steel Blind Flanges (T)
Minimum Blind steel Blind Flange Thickness(mm)

Pipe
ID 17102K(F1) 17311K(F2) 175101(F3) 175102(F4) 175104(F5) 175105(F6) 175106(F7) 175109(F8) 175110(F9) 175111(F10) 175113(F11)
(mm)
24 Barg 15.53 Barg 15 Barg 15 Barg 15 Barg 15 Barg 15 Barg 24 Barg 15.53 Barg 24 Barg 24.3 Barg
25 10 10 10 10 10 10 11
40 10 10 10 10 11
50 11 10 10 10 10 10 11 10 11
80 11 10 10 10 10 10 11
100 11 10 10 10 10 10 11 10 11 11
150 17 15 14 14 17 15 17 17
200 22 20 19 19 22 22 22
250 28 24 24 24 28 28 28
300 33 29 28 28 33 33
350 39 33 39 39
400 44 39 38 38 44 44
450 49 42 42 49
500 55 48 47 47 55
600 66 58 56 66 66
700 66
800 88 77 75 77
900 86 84 86
1000 96 94
1100 105 103
1200 115 112
1300 121
1400 131
1500 140
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Attachment-3, Pressure Test Report
“Sample”
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Attachment-4, Hydrostatic Testing – Pressure Change Calculation
Code reference for the formulae is DEP 31.40.10.19-Gen. APPENDIX B

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Attachment-5, Pressure & Temperature record during pressure test
“Sample”
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Kuwait National Petroleum Company (K.S.C.) P6011MAA.000.10.51.

HYDROSTATIC TEST PROCEDURE

Operation Center JOB CODE 0-6798-20-0000

F1 20-Jul-16 Issued Final S. Polaki H. Suzuki S. Hanada

A1 3-Jul-16 Issued for Design S. Polaki H. Suzuki S. Hanada

O5 1-Jun-16 Issued for COMPANY Approval S. Polaki H. Suzuki H. Kunifusa

O4 17-Apr-16 Follow up Rev O3 COMPANY Comments S. Polaki H. Suzuki H. Kunifusa

O3 27-Mar-16 Follow up COMPANY Comments S. Polaki H. Suzuki H. Kunifusa

Kuwait National Petroleum Company (K.S.C.)

CONTRACT NO. DOCUMENT NO. REV NO.

CONFIDENTIAL OR PROPRIETARY INFORMATION

Rev No Date Description

O1 9-Feb-16 Issued for Comment

O2 25-Feb-16 Issued for Comment

O3 27-Mar-16 Follow up COMPANY Comments(KNPC-JGSK-CFP-MAA-L-16-7863)

O4 17-Apr-16 Follow up Rev O3 COMPANY Comments

O5 1-Jun-16 Issued for COMPANY Approval

A1 3-Jul-16 Issued for Design

CONFIDENTIAL OR PROPRIETARY INFORMATION

2.0 CODES AND REFERENCES ............................................................................................ 4

4.0 GENERAL …………………………………………………………………………………………..5

5.0 TEST METHODS AND PRESSURES ............................................................................... 6

6.0 PRESSURE TEST BLINDS ............................................................................................... 7

7.0 TEST PROCEDURE .......................................................................................................... 7

8.0 SAFETY ……………………………………………………………………………………………11

Attachment-1,Inspection Check List Prior to Pressure Test …………………………………….12

Attachment-2,Minimum Thickness of Steel Blind Flanges (T) ………………………………….13

Attachment-3,Pressure Test Report ……………………………………………………………….14

Attachment-4,Hydrostatic Testing – Pressure Change Calculation …………………………….15

Attachment-5,Pressure & Temperature record during pressure test …………………………...16

CONFIDENTIAL OR PROPRIETARY INFORMATION

2. CODES AND REFERENCES

3.4 Supervisor shall monitor the execution of all works.

CONFIDENTIAL OR PROPRIETARY INFORMATION

The following inspections shall be conducted by QA/QC personnel.

4.3 Test Equipment

4.3.2 Testing instruments (Pressure gauge, Pressure/Temperature recorder, Deadweight tester)

a) Test pressure measuring devices shall be either pressure gauges or pressure/temperature

4.3.5 Calibrated torque wrench should be used for flange tightening.

4.3.6 Test Manifold shall be certified

4.4 Test Fluid

4.5 Pipe Internal Cleaning

4.6 Drain after testing

All piping shall be completely drained after test.

4.7 Inspection check list prior to pressure test

4.9 Request for pressure test

5. TEST METHODS AND PRESSURES

5.1 The following tests shall be carried out:

a) Hydrostatic pressure test

b) Leak tightness test

CONFIDENTIAL OR PROPRIETARY INFORMATION

6. PRESSURE TEST BLINDS & INSPECTION REQUIREMENTS FOR TEST HEAD

6.1 Test Blind

7.1 Test Preparation

7.1.3 All high points shall be provided with vents.

CONFIDENTIAL OR PROPRIETARY INFORMATION

7.2 Pre-Hydrostatic test