Amman Strategic Reserve Terminal for Petroleum Products

OMJ DOCUMENT ILF COMMENT SHEET

OMJ-IPR-SRT-QA-
No. No. SRT-OMJ-DCS-5789-A
6500
Rev. B Date 02.02.2020
Status ☒ A: Approved (APP)
☐ B: Approved as noted (AAN)
☐ D: For Information (INF)

SIA AAP APH

Digitally signed by Abed

Abed
DN: cn=Abed, o=ANC,
ou=ANC,

0 4/10/2021 Approved ABD

email=Abd.anc37@gmail.co
m, c=JO
Date: 2021.11.02 11:34:47
+02'00'
ABD MA MA
Issue for Review
B 18/01/2020 ABD ABD AMS MA

Rev. Date Issue Purpose / Description Prepared Checked Approved Accepted

Client

JORDAN OIL TERMINALS COMPANY

Owner´s Engineer Document Title

Process Pipes Hydrotest Testing Procedure-3 Additional Spheres

Contractor Contractor´s Doc. No. Official Document Number Rev.

(for internal use) (for official use) Code

OMJ-IPR-SRT-QA-6534 0
 Process Pipes Hydrostatic Testing Procedure

Table of Contents

1.0 Purpose..................................................................................................................................... 2

2.0 Reference Documents. ............................................................................................................ 2

2.1 International Standards: .................................................................................................... 2

2.2 JV Reference Documents: .................................................................................................. 3

3.0 Responsibilities. ....................................................................................................................... 3

4.0 Preparation. ............................................................................................................................. 4

5.0 Cleaning Operation & Test Fluid. ......................................................................................... 4

6.0 Types & Locations of Hydrotests. ......................................................................................... 5

7.0 Test Packs. ............................................................................................................................... 5

8.0 Pre-Test Walkdown. ............................................................................................................... 6

9.0 Hydro-Testing Methodology. ................................................................................................. 7

10.0 Post Testing Activities........................................................................................................... 9

11.0 Safety. ..................................................................................................................................... 9

CLIENT: JORDAN OIL TERMINALS COMPANY

PROJECT: P40341 Amman Strategic Reserve Terminal for Petroleum Products – Three Additional Spheres
TITLE: DATE: 30/10/2021

Process pipes Hydrostatic

Testing Procedure
REVISION: 0

Page: 2 of 11

1.0 Purpose.

The purpose of this procedure is to outline the method of Hydrostatic testing of Process Piping
systems at Amman Strategic Reserve Terminal for Petroleum Products.

2.0 Reference Documents.

In support of the Works, reference shall be made to the following documents:

2.1 International Standards:

American Society of Mechanical Engineers (ASME)

ASME B 31.3 Chemical Plant and Petroleum Refinery Piping

ASME II. ASME BPVC – Material specifications

ASME V Nondestructive Examination

ASME IX Welding and Brazing Qualifications

SFA – 5.2 Specification for Carbon and Low Alloy Steel Rods for Oxy
Fuel Gas Welding
NFPA Applicable code

European Committee for Standardization

EN 10204 Types of Inspection Documents -Metallic Products

CLIENT: JORDAN OIL TERMINALS COMPANY

PROJECT: P40341 Amman Strategic Reserve Terminal for Petroleum Products – Three Additional Spheres
TITLE: DATE: 30/10/2021

Process pipes Hydrostatic

Testing Procedure
REVISION: 0

Page: 3 of 11

International Organization for Standardization (ISO)

ISO 9001 Quality Management Systems -Requirements

ISO 9004 Managing for the Sustained Success of an Organization – A
Quality Management Approach
ISO 19011 Guidelines for Auditing Management Systems

2.2 JV Reference Documents:

OMJ-SPC-SRT-PI-0101 Piping Design Basis

OMJ-SPC-SRT-PI-0201 Piping Class Painting Specification
OMJ-SPC-SRT-PI-0207 Piping support Catalogue
OMJ-SPC-SRT-PI-0210 Piping tank bund crossing joints specific
Isometrics, PIDs, layouts and vendor documents in Annex 6. Of the request for tender package

3.0 Responsibilities.

It will be the responsibility of the Discipline Engineer and the Q.C. Engineer to define test limits
on the P & IDs. All pressure tests should follow system and sub systems and included in test pack.
It will be the responsibility of the Q.C. Engineer to ensure that all inspections, testing and N.D.E.
is completed, and that the relevant test pack(s) contain the correct documentation.
It will be the responsibility of the Q.C. Engineer and the Discipline Engineer to ensure that a
comprehensive punch list is compiled and any hold items are cleared prior to testing.
It will be the responsibility of all personnel involved with testing activities to ensure safe working
practices are followed without exception.
CLIENT: JORDAN OIL TERMINALS COMPANY

PROJECT: P40341 Amman Strategic Reserve Terminal for Petroleum Products – Three Additional Spheres
TITLE: DATE: 30/10/2021

Process pipes Hydrostatic

Testing Procedure
REVISION: 0

Page: 4 of 11

The Discipline Engineer and the Discipline Foreman shall ensure the required work permits are
available and in place on a daily basis. Similarly, they shall ensure that utilized drawings are latest
revision
The Project QA/QC Manager shall verify compliance to this procedure by Audit, and shall perform
reviews on all Quality related contractual documentation
The QC Inspector shall be responsible for witnessing tests and ensure appropriate documentation.

4.0 Preparation.

• Prior to carrying out any hydrostatic testing the QC Inspector shall review the
respective non-destructive test reports, Radiographic test report, Magnetic
Particle Inspection Report, Ultrasonic Test Report, Liquid Penetrant test
Report and fill out a Release Notification and will notify the client, in writing
at least twenty four (24 ) hours in advance of the intended testing of the piping
system / part system where required by means of submitting a request for
Client Inspection.
• Vents shall be provided at all high points and drains at all low points (when
confirmed by client) in the system and immediately above check valves in
vertical lines.
• The Engineer responsible for carrying out the testing shall verify the system /
part system is internally clean prior to start filling the water. Air blowing can
be used whenever deemed necessary for this purpose.

5.0 Cleaning Operation & Test Fluid.

- Piping to be cleaned of sand, dirt and construction debris either by flushing with water or blowing
with clean dry air.
CLIENT: JORDAN OIL TERMINALS COMPANY

PROJECT: P40341 Amman Strategic Reserve Terminal for Petroleum Products – Three Additional Spheres
TITLE: DATE: 30/10/2021

Process pipes Hydrostatic

Testing Procedure
REVISION: 0

Page: 5 of 11

- All water used for hydro-testing shall meet the requirements approved by Client.

6.0 Types & Locations of Hydrotests.

Required pressure test values shall be stipulated from the line list and which is according to the
requirements of NFPA.
All pressure tests will be performed as per approved test pack and as erected at site.
In exceptional case, pressure tests at shop can only be performed subject to OMJ approval.

7.0 Test Packs.

The Pressure test should be divided in pre-selected Test Packs and each test pack shall include but
not be limited to the following:

• Marked up P & IDs, defining the test boundaries, test medium and pressure.
• Line List.
• Marked up Isometric(s), included in the scope of the test pack.
• Blank copies of Forms
• Signed off Isometric Control Sheet.
• Red line mark-up Isometric (as built-If any).
• NDT reports.
• Pressure gauges calibration certificates.
• Water test certificates
• weld summary
• QA/QC release
• list of closed NCRs
CLIENT: JORDAN OIL TERMINALS COMPANY

PROJECT: P40341 Amman Strategic Reserve Terminal for Petroleum Products – Three Additional Spheres
TITLE: DATE: 30/10/2021

Process pipes Hydrostatic

Testing Procedure
REVISION: 0

Page: 6 of 11

• FQ and TQ lists
• Hydro-test Punch List

8.0 Pre-Test Walkdown.

On completion of the piping installation, Piping Supervisor shall conduct the walked down to
confirm completion of construction activities and ensure that no "A" Punch list items are still open
and all preparatory works are performed as required and the system is ready to be pressure tested
so that he can sign- off Pre-Test checklist.
Through hydro test coordinator QC should receive the Test Pack to complete the walk down jointly
with Contractor and Company Inspectors.
Walk down shall be performed against the marked-up P&IDs and Isometrics included in the test
pack.
Pre-Test Checklist form shall be completed /signed off release for testing in addition to the related
ICS’s.
RFI for hydro-testing will be issued at least three (3) days prior to the scheduled hydro-testing
date.
Punch list items shall be classified as follows:

• Category “A”, Items prevent the start of Pressure Test. Items shall be completed
before Pressure Testing.
• Category “B”, Those punch list items, which shall be attended to before
proceeding any further with pre commissioning activities.
• Category “C”, those punch list items, which can be attended to after
commissioning activities have been completed
CLIENT: JORDAN OIL TERMINALS COMPANY

PROJECT: P40341 Amman Strategic Reserve Terminal for Petroleum Products – Three Additional Spheres
TITLE: DATE: 30/10/2021

Process pipes Hydrostatic

Testing Procedure
REVISION: 0

Page: 7 of 11

9.0 Hydro-Testing Methodology.

• Where practical and in accordance with Client instruction valves and control
valves shall not be installed until after the system / part systems have been
thoroughly cleaned and flushed.
• Vessels, safety relieve valves, equipment, flow meters, instruments, self-
restrained expansion joints, orifice plates, strainers internal as well as fire water
distributer system out of test pack such as underground piping shall be excluded
from any pressure test.
• All restrictions which will interfere with filling, venting, draining or flushing
shall not be installed until after completion of the flushing and subsequent
pressure testing.
• A bleed valve shall be provided on the test manifold to protect the piping and
equipment from over pressure
• All pressure gauges shall be calibrated before use, the interval of which shall
not exceed one (1) month and recorded on a Calibration Certificate and shall
have a sticker applied indicating the date calibration is due. All calibration and
issue dates of test equipment shall be recorded on a calibration summary sheet,
with the calibration report being inserted in the test package. The pressure
gauges shall be checked and verified by the QC inspector to ensure that they
are within 5% of each other when in use.
• Expansion joints and springs or spring supports shall be provided with
temporary restraints, if required, to prevent excessive travel or deformation
under the test load.
CLIENT: JORDAN OIL TERMINALS COMPANY

PROJECT: P40341 Amman Strategic Reserve Terminal for Petroleum Products – Three Additional Spheres
TITLE: DATE: 30/10/2021

Process pipes Hydrostatic

Testing Procedure
REVISION: 0

Page: 8 of 11

• An isolation valve rated for the same pressure as the manifold when in the
closed position shall be provided between the manifold and the system being
tested.
• Temporary connections shall be provided for de-pressurizing and draining of
the systems to the sewer or disposal area.
• The test shall be applied in an initial 50% of the test pressure and on further
increments with holds at each step to permit inspection for leaks.
• The test shall be maintained on the piping and equipment for a minimum
duration of 60 minutes or till walk down is completed.
• Filling and pressurization of the system, shall be on the upstream side of any
check valves with, where possible the test medium being injected at the lowest
point of the system, to minimize entrapped air, and with the vents in the open
position. For lines where no vents are fitted filling may utilize a scraper to expel
air during filling.
• The isolation valve between the test manifold and the piping or equipment
under pressure shall be closed and the test pump disconnected before
commencement of inspection of the system.
• During the hydrostatic testing of the system all in line valves, if installed, shall
be in the partially open position if not used as a test segregation valve.
• The release of pressure shall be carried out gradually and draining of the system
shall be done on the downstream side of all check valves with the vents in the
open position before draining to prevent forming a vacuum.
• Where practicable, short section of pipe/ pipe spools may be tested prior to
installation in the system and shall be filled with clean water as the test medium.
Such test should be referred to a test pack and subject to OMJ QC approval.
The pipe / pipe spools shall be protected with a pressure relief valve and a
CLIENT: JORDAN OIL TERMINALS COMPANY

PROJECT: P40341 Amman Strategic Reserve Terminal for Petroleum Products – Three Additional Spheres
TITLE: DATE: 30/10/2021

Process pipes Hydrostatic

Testing Procedure
REVISION: 0

Page: 9 of 11

minimum of one (1) pressure gauge on the test manifold, after draining the pipe
/ pipe spool the internal shall be thoroughly cleaned by blowing with clean, dry
air.
• In case of leakage is detected from flanged or threaded joints, test to be
postponed, pressure to be released in order to fix the leak reason (bolt tightening
or replacement of gaskets) then the test shall be repeated in order to ensure that
no leak is present.
• In case a leak is detected from a welded joint, the pressure shall be released,
line to be drained and joint to be repaired as per approved repair procedure than
the system can be re-tested to ensure no leak is detected.

10.0 Post Testing Activities.

• Upon completion of the Hydro test the QC inspector shall make-out a pressure
test report form duly signed by the client, and insert it into the relevant test pack.
• Hydro test Water Disposal will be carried out in accordance with Client
instructions.
• Upon completion of testing the QC inspector, in conjunction with the Test
engineer, shall fill out a Pressure Test Reinstatement form which shall be
inserted into the test pack.
• Unless a specific lay-up is required test fluid shall be removed by a method
agreed with Client.

11.0 Safety.

The following principles shall be followed in order to perform a pressure test in a safe manner:
CLIENT: JORDAN OIL TERMINALS COMPANY

PROJECT: P40341 Amman Strategic Reserve Terminal for Petroleum Products – Three Additional Spheres
TITLE: DATE: 30/10/2021

Process pipes Hydrostatic

Testing Procedure
REVISION: 0

Page: 10 of 11

Before start of Test

The Test Engineer shall be responsible for:

• Preparation of the test procedures.
• Delivery of the approved test procedures to job sites.
• Safety aspects of the pressure test.
• Coordination and implementation of the pressure test in a safe manner.

Proper Test Medium

The only allowable test medium is water.

Test water medium criteria as per P40341-SP-CON-MEC-07 (Water to be used in hydrostatic tests
will contain less than 3000 ppm Cl. Minimal temperature will be 5ºC

Restrict Approach to the system

• Do not approach systems, during the stepwise increase in pressure to the test
pressure. Only after the test pressure has been reached, held for the specified
interval and the pressure reduced may the equipment be approached.
• Personnel carrying out the test shall be provided with a safe place from which
the progress of the test can be observed and controlled.
• Personnel shall be located such that a system rupture will not result in any
injuries.
CLIENT: JORDAN OIL TERMINALS COMPANY

PROJECT: P40341 Amman Strategic Reserve Terminal for Petroleum Products – Three Additional Spheres
TITLE: DATE: 30/10/2021

Process pipes Hydrostatic

Testing Procedure
REVISION: 0

Page: 11 of 11

• During any portion of a test, only personnel directly involved with the test shall
be allowed near the system.
• The test pump shall be located such that the pump operator will not be exposed
to danger in the event of a failure.
• Avoid the following typical examples of poor practices which may result in
possible mishaps:
• Striking or working on equipment, while it is under pressure, to stop leaks.
• Improper or missing test equipment, such as testing without a relief valve,
having an inadequately sized relief valve, or having too few pressure gauges
(s).
• Omitting or changing steps in the test sequence such as failing to conduct a low-
pressure tightness test to check for leaks prior to strength pressure tests at higher
pressure.
• Failure to vent air from the system prior to the test.
• Use of gas instead of water as a test medium.
• Metal temperature below that at which the impact requirements cannot be met
by the material.
• System not adequately supported to withstand the weight of water during the
test.
• Pressure gauges(s) and relief valve(s) not calibrated and tested.
• Pressure gauge located too far from pressurizing equipment for reading.
• Appurtenances not adequate for the test pressure, or not isolated from the test.
• Pressure increased too rapidly to be controlled.
• Relief valve inoperative because of a closed block valve.
• Temporary test piping not designed for the test pressure.
• No bleed valve provided on test piping.
Project Title:
Amman Strategic Reserve Terminal for Petroleum Products (ASTPP)
DRN Number: SRT-OMJ-DT-4798 Revision Code: B Page: 1 of 1
DRN Title: Process Pipes Hydrotest Testing Procedure-3 Additional Spheres
Contract No: 4/W/2013

Employer: Consultant: EPCC Contractor:

Document No. Rev. Rev. Date Document Title

Process Pipes Hydrotest Testing Procedure-3

OMJ-IPR-SRT-QA-6534 B 14/01/2020
Additional Spheres

CHANGES TO DOCUMENT:

N/A

Reason For Changes: N/A

other documents affected:

Submitted by: Abed Al Rahman Al Omary Date: 14/01/2020

Approved (Yes/No)

Approved by: Date