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CLIENT: CONSULTANT:

National Iranian Oil Company


Arvandan Oil and Gas
Company ENERCHIMI ENG. CO.

SOHRAB WELL HEAD NO.1 FLOW LINE TO


Project: SOUTH AZADEGAN NORTH CLUSTER Client Project No.: 14-71-148 Page 1 OF 13
Consultant Project
Doc. No.: AOGC-036-PI-ESS-004 19381 Rev.: B0
No.:
Specification For Construction Hydrostatic Pressure Testing, Cleaning And
Document Title:
Flushing Of Piping System

SPECIFICATION FOR CONSTRUCTION HYDROSTATIC


PRESSURE TESTING,
CLEANING AND FLUSHING OF PIPING SYSTEM
CLIENT: CONSULTANT:
National Iranian Oil Company
Arvandan Oil and Gas
Company ENERCHIMI ENG. CO.

SOHRAB WELL HEAD NO.1 FLOW LINE TO


Project: SOUTH AZADEGAN NORTH CLUSTER Client Project No.: 14-71-148 Page 2 OF 13
Consultant Project
Doc. No.: AOGC-036-PI-ESS-004 19381 Rev.: B0
No.:
Specification For Construction Hydrostatic Pressure Testing, Cleaning And
Document Title:
Flushing Of Piping System

Revision Summary Index


Modified In Rev. Number Modified In Rev. Number Modified In Rev. Number
Page Page Page
B0
1
2
3
4
5
6
7
8
9
10
11
12

Revision B0
Issued for TENDER
Date 92.12.15
M. K
Consultant

Prepared

Checked M. N

Approved M.N
CLIENT: CONSULTANT:
National Iranian Oil Company
Arvandan Oil and Gas
Company ENERCHIMI ENG. CO.

SOHRAB WELL HEAD NO.1 FLOW LINE TO


Project: SOUTH AZADEGAN NORTH CLUSTER Client Project No.: 14-71-148 Page 3 OF 13
Consultant Project
Doc. No.: AOGC-036-PI-ESS-004 19381 Rev.: B0
No.:
Specification For Construction Hydrostatic Pressure Testing, Cleaning And
Document Title:
Flushing Of Piping System

TableofContentsPage
1.0 INTRODUCTION 4
2.0 terTerms and Definitions: 4
3.0 SCOPE 4
4.0 REFERENCED STANDARDS 5
5.0 GENERAL REQUIREMENTS PRIOR TO FLUSHING AND PRESSURE
TESTING 5
6.0 FLUSHING 7
7.0 PREPARATION FOR PRESSURE TESTING 8
8.0 LEAK TEST 8
9.0 PRESSURE TESTING 9
10.0 COMPLETION OF TESTING 10
11.0 TEST RECORDS 11

ATTACHMENT112
CLIENT: CONSULTANT:
National Iranian Oil Company
Arvandan Oil and Gas
Company ENERCHIMI ENG. CO.

SOHRAB WELL HEAD NO.1 FLOW LINE TO


Project: SOUTH AZADEGAN NORTH CLUSTER Client Project No.: 14-71-148 Page 4 OF 13
Consultant Project
Doc. No.: AOGC-036-PI-ESS-004 19381 Rev.: B0
No.:
Specification For Construction Hydrostatic Pressure Testing, Cleaning And
Document Title:
Flushing Of Piping System

1.0 INTRODUCTION

1.1 General Project Description


Arvandan Oil and Gas company intends to construct an 8" N.B. buried flowline
from Sohrab WH1 to South Azadegan North Cluster.

Sohrab Field is located at North of Azadegan Field, and 115 Km North West of
Ahwaz right along the international border with Iraq.

The major sections of the project are:

Wellhead facilities (at WH No.1).


8" N.B, 50 Km (Approx.) buried flow line.
Receiving trap facility at South Azadegan North Cluster.

2.0 TERTERMS AND DEFINITIONS:

Owner/Client: Arvandan Oil & Gas Company (AOGC).

EPC Contractor:Shall Mean The Contractor Responsible For Engineering,


Procurement & Construction Of The Project.

Vendor:The manufacturer /manufacturer's representative selected by the


contractor & approved by the client to supply equipment/tools.

Will: is normally used in connection with the action by the "company" rather
than by a contractor, supplier or vendor.
May: is used where a provision is completely discretionary.
Should: is used where a provision is advisory only.
Shall: is used where a provision is mandatory.

3.0 SCOPE

3.1 This specification applies to the cleaning, pressure and leakage testing of
underground and above ground piping for Wellhead facilities (at WH No.1) &
Receiving trap facility at South Azadegan North Cluster of SOHRAB Oil field".
3.2 Complete package units delivered by other vendors shall not be flushed and
pressure tested, unless specifically decided.
CLIENT: CONSULTANT:
National Iranian Oil Company
Arvandan Oil and Gas
Company ENERCHIMI ENG. CO.

SOHRAB WELL HEAD NO.1 FLOW LINE TO


Project: SOUTH AZADEGAN NORTH CLUSTER Client Project No.: 14-71-148 Page 5 OF 13
Consultant Project
Doc. No.: AOGC-036-PI-ESS-004 19381 Rev.: B0
No.:
Specification For Construction Hydrostatic Pressure Testing, Cleaning And
Document Title:
Flushing Of Piping System

3.3 Flushing and pressure testing and steam blowout of complete package units in
vendors shop in principle shall be in accordance with this specification, unless
manufacturer foreseen damage to the package in which case manufacturer
shall provide alternative method for approval, by Owner.
3.4 Sewers or non pressurized drains and open vents shall not be pressure tested.
All low pressure piping and equipment shall be pressure tested with air and
colored smoke, using soap and water.

4.0 REFERENCED STANDARDS

4.1 Codes and Standards


Specifications shall comply with the latest revision of relevant codes and
standards referred to in this document at the time of contract award.
In the event of conflict between code and standard and/or this specification, the
matter shall be highlighted for Client's attention/approval. The priority of
references stated in these criteria is as follow:
This job specification
Other job specifications mentioned in this document
IPS standards
International Codes and Standards
The most stringent Codes and Standards
4.2 Reference Codes, Standards and Specifications

ASME B31.3 Chemical Plant and Petroleum Refinery Piping Code.

ASME B16.5 Pipe Flanges and Flanged Fittings.

Construction Standard for Plant Piping System


IPS-C-PI-350
Pressure Testing.

5.0 GENERAL REQUIREMENTS PRIOR TO FLUSHING AND PRESSURE TESTING

5.1 Piping is to be inspected for completeness and conformity to piping drawings


and specifications.
5.2 All required Non Destructive Testing (NDT) and air soap tests of reinforcing
rings shall be completed with results satisfactory to Owner(air soap testing of
CLIENT: CONSULTANT:
National Iranian Oil Company
Arvandan Oil and Gas
Company ENERCHIMI ENG. CO.

SOHRAB WELL HEAD NO.1 FLOW LINE TO


Project: SOUTH AZADEGAN NORTH CLUSTER Client Project No.: 14-71-148 Page 6 OF 13
Consultant Project
Doc. No.: AOGC-036-PI-ESS-004 19381 Rev.: B0
No.:
Specification For Construction Hydrostatic Pressure Testing, Cleaning And
Document Title:
Flushing Of Piping System

reinforcing rings shall be executed in the prefabrication shop as far as


possible).
5.3 All lines shall be tested in accordance with ASME B31 .3 and this specification.
5.4 Owner shall release all piping systems for flushing and hydro testing after he
has satisfied himself that the system is complete and ready for testing. Piping
shall be divided into test systems as shown on Pressure Test Flow Diagrams
by using blinds, caps or plugs suitably.
5.5 All joints (welded, screwed and flanged) whether above or underground, shall
be free of painting, coating or insulation to enable a complete visual inspection.
5.6 Documents for testing shall be available as per section 11.0 of this specification
before any test is started.
5.7 a) All instruments in the test system shall be excluded from the flushing/testing
by isolation or removal, unless otherwise approved by Owner in writing.
b) Instruments shall be shut-off, with their bleeders vented to the atmosphere.
c) Instrument piping shall be tested up to the first block valve.

d) All other valves in the system shall be kept in open position.

5.8 Items to be removed or blanked off prior to flushing/testing shall include, but
shall not be limited to:
- Check valve internals which shall be removed or locked open. Lines
containing check valves shall be pressurized from the upstream side of the
valve.
- Relief valves and rupture discs.

- Orifice plates, flow nozzles or other similar restrictions.

- Venturi type flow meters (flanged).

- Internals of equipment (trays, demisters, level instrument floats, float cages,


etc.), if included in the test system.

- Control valves.

- Expansion joints (or provides temporary restrains).

- Any items not designed to withstand the test pressure, e.g. pressure gauges.

- Internals of strainers and filters, steam/air traps, etc.


CLIENT: CONSULTANT:
National Iranian Oil Company
Arvandan Oil and Gas
Company ENERCHIMI ENG. CO.

SOHRAB WELL HEAD NO.1 FLOW LINE TO


Project: SOUTH AZADEGAN NORTH CLUSTER Client Project No.: 14-71-148 Page 7 OF 13
Consultant Project
Doc. No.: AOGC-036-PI-ESS-004 19381 Rev.: B0
No.:
Specification For Construction Hydrostatic Pressure Testing, Cleaning And
Document Title:
Flushing Of Piping System

5.9 All tests executed with day temperature of 5C and lower or when frost is
expected during night and system may stay filled over night shall have antifreeze,
which is an ethylene glycol water solution as per Attachment Il. During flushing, no
anti-freeze is required. Avoid flushing when temperature is below 00C.
5.10 All temporarily installed items (blanks, spools, strainers, etc.), shall be adequately
marked using red paint or tags for easy traceability.
5.11 Pipe supports and anchors should be fitted prior to pressure testing. In certain
cases, temporary or additional supporting of pipe work may be required due to
weight of testing medium. Piping supported by counterweight or spring without
down travel stop, shall be temporarily supported prior to filling with water. A
spring with "down travel stop shall have the stop (wedges or block) inserted
prior to filling with water. Care shall be taken that gas lines have been suitably
supported to carry the liquid load. If necessary, temporary supports shall be
installed.
5.12 When instrument air and nitrogen lines are tested with water, they shall be dried
completely. These systems shall be cleaned by blowing with air against an open
pipe end (blowing against a small opening like a vent is not allowed). Elbows shall
be turned away from equipment to prevent contamination. Equipment shall be
blinded-off.
5.13 Final bolt tensioning and torquing of flange connections shall be completed as
required during reinstatement of the piping systems.
5.14 When conditions require that a pressure test be maintained for a period of time
during which the testing medium in the system would be subject to thermal
expansion, provision should be made for relief of excess pressure.
5.15 Retesting of line after repair by welding shall be done at pressure originally
specified for the test.

6.0 FLUSHING

6.1 Trash and construction debris shall be removed from the piping systems by
flushing with water or by blowing with air or nitrogen in line with the relevant test
medium. All lines shall be completely free of weld slag and other foreign material
and shall be reasonably clean. Any flanged connection may be broken for blow-
down.
6.2 Flushing through equipment is not allowed unless specifically approved by Owner.
CLIENT: CONSULTANT:
National Iranian Oil Company
Arvandan Oil and Gas
Company ENERCHIMI ENG. CO.

SOHRAB WELL HEAD NO.1 FLOW LINE TO


Project: SOUTH AZADEGAN NORTH CLUSTER Client Project No.: 14-71-148 Page 8 OF 13
Consultant Project
Doc. No.: AOGC-036-PI-ESS-004 19381 Rev.: B0
No.:
Specification For Construction Hydrostatic Pressure Testing, Cleaning And
Document Title:
Flushing Of Piping System

6.3 Care shall be taken with flushing of pump suction lines to prevent contamination of
pumps. The elbow close to the pump shall be turned away and the pump inlet
shall be adequately covered to prevent entering water into the pump.
6.4 All flushing operations shall be carried out in the presence of Owner.
6.5 Flushing shall be performed against open pipe ends. Flushing against small
openings like vents, drains, etc., is not accepted.
6.6 Flushing water shall be drained through hoses to locations as indicated by Owner.
6.7 After completion of the flushing operation, welded-in items which are included in
the test system, shall be inspected for internal cleanliness.

7.0 PREPARATION FOR PRESSURE TESTING

7.1 Blind flanges, blanks, caps or plugs shall be installed to isolate piping systems
and equipment as what indicated on the Test Diagrams.
7.2 Where a system is to be isolated between flanged joints, a blank with temporary
gaskets shall be inserted between the companion flanges. These temporary
gaskets shall be supplied by Erection Contractor in his own charges.
7.3 Open ends of piping systems where blanks cannot be used, or whenever
equipment or pipe spools have been removed or disconnected prior to hydrostatic
testing, shall be blinded off, using temporary blind flanges in accordance with the
pipe class of the piping system.
7.4 For flanged control valves with block valves and a by-pass, if the test pressure
upstream and downstream is the same, the block and by-pass valve shall be left
open, with the control valve removed and blinds or spool piece installed. The
spools shall remain in place until the pipe runs have been thoroughly cleaned.
7.5 In case the test pressure upstream and downstream of the control valve is
different, the test on the upstream portion shall be made with the by-pass valve
open and blanked off, upstream block valve open and blanked off and control
valve removed.
7.6 No testing shall be done against closed valves; blind flange or blank shall be used
instead. Instrument block valves shall be exempted from this rule.

8.0 LEAK TEST

8.1 Prior to pre-commissioning, each piping system shall be tested to ensure


tightness. Air or steam at 25 psig may be used as preliminary test to detect
missing gaskets, etc. As this avoids the necessity of draining the line to make
CLIENT: CONSULTANT:
National Iranian Oil Company
Arvandan Oil and Gas
Company ENERCHIMI ENG. CO.

SOHRAB WELL HEAD NO.1 FLOW LINE TO


Project: SOUTH AZADEGAN NORTH CLUSTER Client Project No.: 14-71-148 Page 9 OF 13
Consultant Project
Doc. No.: AOGC-036-PI-ESS-004 19381 Rev.: B0
No.:
Specification For Construction Hydrostatic Pressure Testing, Cleaning And
Document Title:
Flushing Of Piping System

repairs, however, steam shall not be used for this purpose, if the steam
temperature is more than the design temperature of line.

9.0 PRESSURE TESTING

9.1 Pressure Testing of Internally Pressurized Piping System


9.1.1 The hydrostatic test pressure for piping systems should not be less than
1.5 times maximum design pressure, but shall not exceed the maximum
allowable test pressure for flanges, according to ASME B16.5.

9.1.2 The test pressure shall be corrected to take into account the line
temperature as per clause 345.4.2 of ASME B31.3.

9.1.3 Items which cannot withstand the test pressure, like special strainers, shall
be removed from the system during testing, unless the test pressure is
decreased to suit the weaker component which is at the discretion of
Owner.

9.1.4 Before filling the system with the test fluid, all vents shall be opened.

9.2 Test Gauges


9.2.1 A calibrated pressure gauge shall be provided by Erection Contractor at
the test pump discharge for guidance in bringing the system up to
pressure.

9.2.2 The test pressure shall be checked by means of a gauge having a range
from zero up to 1.5 to 2 times the intended maximum test pressure. The
gauge shall be located at or near the lowest point of the test system.
Where practical, the static head of the water column shall be taken into
account in the test pressure.

9.2.3 The minimum number of pressure gauges for a test system is two. For
large systems, more pressure gauges shall be installed at suitable
locations, in coordination with Owner.

9.2.4 All test pressure gauges shall be calibrated at regular intervals, at least
every two weeks. Calibration certificates shall be available at the worksite
and all gauges shall be properly identified to enable traceability to the
calibration certificates.

9.2.5 Calibration of gauges shall be repeated whenever requested by Owner.

9.3 Test Fluid


CLIENT: CONSULTANT:
National Iranian Oil Company
Arvandan Oil and Gas
Company ENERCHIMI ENG. CO.

SOHRAB WELL HEAD NO.1 FLOW LINE TO


Project: SOUTH AZADEGAN NORTH CLUSTER Client Project No.: 14-71-148 Page 10 OF 13
Consultant Project
Doc. No.: AOGC-036-PI-ESS-004 19381 Rev.: B0
No.:
Specification For Construction Hydrostatic Pressure Testing, Cleaning And
Document Title:
Flushing Of Piping System

9.3.1 Hydrostatic testing is to be performed with clean raw water unless


otherwise noted on Pressure Test Flow Diagrams and systems shall be
properly vented (at the high points) while filling.

9.3.2 The Erection Contractor shall carry out the water analysis at each water
supply point considered for test water. The analysis results shall be
submitted to the Owner. The Erection Contractor shall treat the test water,
if necessary, with chemicals such as corrosion inhibitor, oxygen scavenger
and bactericide, as directed by the Owner.

9.3.3 Corrosion inhibitor and oxygen scavenger shall be added to the test water
in the suction of water filling pump at the rates recommended by the
manufacturers. Rates of corrosion inhibitor and oxygen scavenger may be
increased according to the recommendations of manufacturers, if test fluid
is to be remained for longer times in the piping system after completion of
hydrostatic testing.

9.3.4 In cases where water analysis reveals the possibility of marine growth due
to existence of batteries, the addition of suitable type of bactericide as
approved by the Owner is required per recommendations of the
manufacturer.

9.3.5 For carbon and alloy steel piping, if the chloride content is greater than 50
ppm, up to a maximum of 200 ppm, sufficient quantity of Sodium Nitrate
shall be added to provide a test medium with a PH of 10.5. Instead of
Sodium Nitrate, Sodium Carbonate may also be used.

9.3.6 Hydrostatic test pressure shall be applied by means of a suitable test


pump or other pressure source, which shall be positively isolated from the
system until ready to test.

9.3.7 The test pump shall be constantly attended during the test by an
authorized person. Whenever the pump is left unattended, it shall be
positively disconnected from the system, while the pressure gauge
remains connected to the test system.

9.3.8 The test pressure shall be maintained for at least one hour prior to start of
inspection and Iong enough to enable inspection of the complete test
system by Owner.

10.0 COMPLETION OF TESTING

10.1 Draining and Drying

10.1.1 After completion of the pressure test, the pressure shall be released so as
not to endanger personnel or damage equipment.
CLIENT: CONSULTANT:
National Iranian Oil Company
Arvandan Oil and Gas
Company ENERCHIMI ENG. CO.

SOHRAB WELL HEAD NO.1 FLOW LINE TO


Project: SOUTH AZADEGAN NORTH CLUSTER Client Project No.: 14-71-148 Page 11 OF 13
Consultant Project
Doc. No.: AOGC-036-PI-ESS-004 19381 Rev.: B0
No.:
Specification For Construction Hydrostatic Pressure Testing, Cleaning And
Document Title:
Flushing Of Piping System

10.1.2 Before draining the system, all vents shall be opened and remain open
during draining to prevent pulling a vacuum in the system.

10.1.3 Immediately after testing, all lines and systems shall be flushed and
completely drained.

10.1.4 All lines shall be dried by means of air. Special care shall be taken that no
freezing can occur in winter.

10.1.5 Owner will confirm when a line is considered dried by Erection Contractor.

10.2 Reinstatement of Piping Systems

10.2.1 After completion of testing, flushing and draining, all systems shall be
reinstated as per drawings and specifications. This includes but shall not
be limited to:

- Removal of all temporary pipe spools, temporary supports, temporary materials such
as spades, blinds, gaskets, etc.

- Replacement of all damaged gaskets and/or all test gaskets.

- Repositioning of spectacle blinds to the correct position, as per P&ID.

- Reinstallation of all items removed for hydro testing such as valves, rupture discs,
in-line instruments, internals of strainers and filters, spectacles, traps, etc.

- Inspection of the completed system for correct flow direction of instruments, check
and control valves, etc.

-Pneumatic leak test shall be performed to ensure tightness of flanged/screwed


joints at the time of pre commissioning.

10.2.2 After approval by Owner, the system shall be released for activities like
electrical tracing, painting, insulation, etc.

10.2.3 The "stop" of pipe support springs with "Down travel stop placed prior to
flushing, shall be removed at Owner request during precommissioning or
commissioning stage.

11.0 TEST RECORDS

11.1 Test records shall be prepared and maintained for all piping systems tested. Test
records shall include date of test, identification of piping tested and test pressures,
CLIENT: CONSULTANT:
National Iranian Oil Company
Arvandan Oil and Gas
Company ENERCHIMI ENG. CO.

SOHRAB WELL HEAD NO.1 FLOW LINE TO


Project: SOUTH AZADEGAN NORTH CLUSTER Client Project No.: 14-71-148 Page 12 OF 13
Consultant Project
Doc. No.: AOGC-036-PI-ESS-004 19381 Rev.: B0
No.:
Specification For Construction Hydrostatic Pressure Testing, Cleaning And
Document Title:
Flushing Of Piping System

test fluid and approval signatures of the person in charge testing and Owner and
Erection Contractor's representative. The Field piping and equipment pressure
test report (see Attachment I) shall be used for all test records.
11.2 All tests, satisfactory or not, shall be recorded on the test forms and a complete
set will be made part of the permanent job records.
CLIENT: CONSULTANT:
National Iranian Oil Company
Arvandan Oil and Gas
Company ENERCHIMI ENG. CO.

SOHRAB WELL HEAD NO.1 FLOW LINE TO


Project: SOUTH AZADEGAN NORTH CLUSTER Client Project No.: 14-71-148 Page 13 OF 13
Consultant Project
Doc. No.: AOGC-036-PI-ESS-004 19381 Rev.: B0
No.:
Specification For Construction Hydrostatic Pressure Testing, Cleaning And
Document Title:
Flushing Of Piping System

ATTACHMENT I

FIELD PIPING & EQUIPMENT PRESSURE TEST REPORT

JOB NO. _________________ TEST SYSTEM NO. __________________

DATE __________________

LINE OR EQUIP. LINE FROM TO P & ID TEST TEST DURATION REMARKS


NUMBER SPEC. DRAWINGS MEDIUM PRES.

The piping and/or equipment listed above have been inspected and tested.

Person in Charge of Testing

Owners Representative Erection Contractors Representative