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TABLE OF CONTENTS

ITEM

DESCRIPTION

PAGE

1.0

INTRODUCTION

2.0

SCOPE

3.0

PRECEDENCE OF CODES, STANDARDS AND


SPECIFICATION

4.0

DEFINITIONS

5.0

CODES & STANDARDS /REFERENCES

6.0

SAFETY PLAN

7.0

TEST PRESSURE & DURATION

8.0

TEST EQUIPMENT & SET UP

9.0

PRESSURE TEST PROCEDURE

10

10.0

PRESSURE TESTING LOG

11

APPENDIX 1 : HYDROTESTING LOG

12

6.0

SAFETY PLAN
Before any machinery/ mechanized equipment or tools put into use on the activity,
a qualified person to make sure that the equipment to be in safe operating
condition shall inspect it. Continued periodic inspection shall be made at such
intervals as necessary to assure its safe operating condition and proper
maintenance.
Any machinery or equipment found to be in unsafe operating condition shall be
tagged at the operators position Out Of Service. Do Not Use and its prohibited
until unsafe conditions have been corrected.
Only qualified and authorized personnel shall operate machinery and mechanized
equipment.
Stationary equipment and machinery shall be placed on a firm foundation and
properly secured before being operated.
During all phases of SAT activity, the safety of public including workers shall be of
prime importance. The following is a list of measures to be taken during the test.
a)

Prior to test, all butt joints shall have been radiographed, passed and
accepted by a recognized JKKP third party. Likewise, all dye penetration
test for socket weld joints are completed and accepted.

b)

Only the authorized personnel shall be allowed into the testing area during
the HT activity.

c)

The test area shall be clearly marked and condoned off to prevent any
unauthorized personnel from approaching.

d)

Authorized personnel will be allowed to remain on site for the entire


duration of the test until the pressure is reduced below the testing pressure.

e)

Authorized personnel shall be equipped with Personal Protective Gear


(PPE) at all phases of testing period.

7.0

TEST PRESSURES AND DURATION


The pipe spools for the service station shall be pressure tested. The skids consist
of welded spools of design class ANSI 300# and ANSI 600# as listed below.
1. Pipe spools having Flange 600# Rating ( Inlet Section )
2. Pipe spools having Flange 300# Rating. ( Outlet Section )
The welded spools shall be hooked up together in an organized arrangement for
simultaneous testing. The spools shall be marked for easy identification.
The system shall be tested to the minimum requirements of PTS 11.34.01
(Nov. 2014). The minimum test pressures for this system shall be 1.5 x
M.A.O.P (Table 3 Pressure Requirements). CONTRACTOR would ensure that
any possible pressure changes due to temperature effects would not cause the
test pressure to drop under the 1.5 x M.A.O.P. criteria. The hydrostatic
pressure would be slightly raised to cater for the pressure drops.
The CONTRACTOR's would ensure that the pressure does not, under any
circumstances go below the minimum hydrostatic testing requirements in
accordance to PTS 11.34.01 (Nov. 2014).

7.1

Hydrotest Pressure Calculation (Flange 600# pipe spools)


MAOP (Inlet Section)

68.95 barg

Minimum Test Pressure (1.5 x MAOP)

103.43 barg

Maximum Test Pressure (100% SMYS)

2413.25 barg

SMYS for Pipe ASTM A 106-B : 35,000 Psi (2413.25 barg)

The pipe shall be hydrostatically tested for at least 4 hours.

7.2

Hydrotest Pressure Calculation (Flange 300# pipe spools)

MAOP (Outlet Section)

24.83 barg

Minimum Hydrostatic Pressure (1.5 x MAOP)

37.25 barg

Maximum Test Pressure (100% SMYS)

2413.25 barg

SMYS for Pipe ASTM A 106-B : 35,000 Psi (2413.25 barg)

The pipe shall be hydrostatically tested for at least 4 hours.

8.0

TEST EQUIPMENT & SET UP


8.1

Test apparatus and equipment

The following test apparatus and equipment is necessary for the entire
operations:
(a) Dead-weight testers: range 100 15000 kPa at 5 kPa intervals, measuring
accuracy of 0.5% of the piping test pressure;
(b) Pressure recorders: range 0 - 15,000 kPa, 24 hour rotation, mechanical
drive, 8 day wind, 0.1% accuracy, single sensor with single pen inking system;
(c)
Temperature recorders: range 10C to 50C, 24 hour rotation,
mechanical drive, 8 day wind, +/- 3.0C accuracy, dual sensors with dual pen
inking system;
(d) Thermometers: range 10C to 50C with accuracy of +/- 0.5C for
measurement of pipe wall temperature, ambient air temperature, filling water
temperature.
(e) Pressure gauges: accuracy better than 1% shall be mounted on the test
manifold and used to manually log the test pressure at half hourly intervals of the
4 hour test.
(f)
High-pressure positive displacement pump capable of delivering a pressure
of above 15,000 kPa and a variable flowrate between 150 and 200 litres/min.
(g)

Dryer unit

The color of ink used in recorder shall be as follows:

Pressure blue

Pipe wall temperature or water temperature red

The test instruments shall have calibration certificates traceable to an acceptable


national standard.
The original copy of the recorder chart along with the hydrotest report shall be
submitted to DOSH for approval.

8.2

Water Source

CONTRACTOR shall acquire water for proof tests in a manner satisfactory


to the authorities having jurisdiction, the landowners affected by this
operation, and COMPANY. The source of water shall be sufficient to
permit continuous filling without interruption. CONTRACTOR is responsible
for obtaining this water and disposing of it after completion of the
test. CONTRACTOR shall supply all fill pipe, pumps for filling and testing the
piping assembly and any other equipment required. COMPANY reserves the
right to require CONTRACTOR to take samples from the source prior to testing.

All valves and appurtenances must be checked prior to filling the piping to
ensure that they are in proper working order and in the proper position for
filling. All fittings shall be checked for tightness prior to filling.
The water pumped into the pipe must be of suitable quality. Water containing
silt, suspended material or harmful corrosive components will not be used
unless it can be satisfactorily treated by use of filter of chemical additives.
The water intake will be screened and located at a depth that will not permit
air to be drawn in with the water while filling.
8.3

Temperature Recorder
A temperature recorder shall be installed by CONTRACTOR on each
section of the pipe. One sensing element shall be placed against
pipe wall, suitably insulated. The temperature recorders
shall
checked
during
filling
and
testing
to
ensure
they
functioning properly.

test
the
be
are

Prior to the testing, the following activities shall have been completed:

9.0

a)

The HT procedure has been approved by client.

b)

The test section of this procedure shall be readily available.

c)

The calibrated pressure gauges and recorders are properly hooked up and
connected securely to the section to be tested.

PRESSURE TEST PROCEDURE


This procedure shall apply for HT testing
a)

Install temporary blinds at each open end of the test sections. The
temporary blinds shall be ANSI 300# and ANSI 600# where is applicable.

b)

Slowly pressurize the test sections up to no more than 80% of the test
pressure. Hold the test pressure for 15 min. during the hold time, visually
inspect all the joints for leakage. At the same time, observe the hold
pressure to see if there any pressure drop. If there any leakage, it shall be
eliminated before proceed to the next step.

c)

After 15 min, slowly pressurize the test sections to the test pressure.

d)

The test pressure shall be held for at least 4 hours, record the pressure
and temperature reading in the pressure testing log at 15 min intervals.

e)

After completion of testing, slowly depressurize the testing sections to the


atmospheric pressure.

10.0

PRESSURE TESTING LOG


Upon completion of the testing, the pressure-testing log shall be completed and
signed by the Gas Competent Person or DOSH and Client accordingly.

APPENDIX 1 : HYDROTESTING LOG