document

STRATEGIC BUSINESS UNIT FOR HYDRO STATIC TEST (H.T.B.U)

1 P a g e ASSISTANT GENERAL MGR ENG. ZAKARIA EL-GHARABAWI

H.T.B.U

PETROLEUM MARINE SERVICES CO.

STRATEGIC BUSINESS UNIT FOR

HYDRO STATIC TEST

UHYDROSTATIC TEST IS OUR BUSINESS



H.T.B.U

UAbstractAs the company technical capabilities have grown significantly since PMS was established in 2001, Hydro test department established at 2007 a proposal of a business unit is made here-by to open a new market in favor of our company. A Strategic Business Unit, SBU, can constitute a smaller part of a company with competitors different from those of the parent company providing extra income to it. SBU can handle theoperations performed as part of the pre-commissioning of the UOffshore PipelineU whichinclude the Following activities:

� Test procedure� Flooding,� Cleaning, � Gauging, � Pressurization� Completion of Testing� Depressurization� Leak test � Dewatering � Test Records � RE-instatement

The technical resources, hydro test equipments, previous projects and engineering expertise that are contained in skillful different major engineers optimize the success of this SBU that can be extended afterwards providing a growing income with the least expenditures.



H.T.B.U

UTable of Contents1. Introduction.............................................................................................................................................................................42. Human Resources .............................................................................................................................................................53. Hydro test Equipment.......................................................................................................................................................6 3.1 Pumps working with Engine driven.........................................................................................................6 3.2 Pumps working with Air driven...................................................................................................................74. Instrument…………………………………………………………………………………………………………...…….......................85.1 Daily Rate for Hydro Test Crew …….……………………………………......................................……...…….......….95.2 Daily Rate for Hydro Test Equipment…….…………………………………………...……..…...............................96.General preparation……………………………………………………………………………………………………...…....…10

6.1 Instruments.............................................................................................................................................................10 6.2 Cleaning, Gauging Acceptance …………………………………….….….…………………...............….10 6.3 Cleaning and Gauging Operations......................................................................................................10 6.3.1 Pig Arrangement ……………………………………………………….………………………….....………..….…10 6.3.2 Sequence ……………………………………………………………….………..….……………………………......….11 6.3.3 Stuck Pig Contingency Procedure……………..……….……………….…………………................….147. Pressure TEST PROCEDURE……………………………………………………………………………………….……….…...15 7.1 Introduction………………………………………….…………………………….….………………………….…..…….15 7.2 Piping System Pressure Test Sequence………………………………………………..…………........….15 7.3 Pressurization ……………………………….………………………………..………………………………….....….….15 7.4 Stabilization............................................................................................................................................................17 7.5 hold period………………………………………………………….……………………………….……………..…....….17 7.6 Acceptance/ Completion..........................................................................................................................17 7.7 Air Volume Content Calculation…………………………….………………...……………………....…..….19 7.8 Depressurization…………………………………………….……………………………………….………….....….…208. URisk assessmentU (HEALTH, SAFETY AND ENVIRONMENT)……………..…………………….. ...…..…...21 8.1 MANAGEMENT OF CHANGE…………………………………………………..….……………………… ...……22 8.2 Preparation for Testing.....................................................................................................................................22 8.3 Checking Of Equipment And Instrumentation...............................................................................22 8.4 BARRIERS AND SIGNS…………………………………………………..……….….……………..………… ….....….229.1 Project Carried Out By Hydro test Department In A.R.E …………....………..........………...........…...23

9.2 Project Carried Out By Hydro test Department In KSA……………....……………...................….........25

10. Expected Project During 2010 / 2011 Inside Egypt................................................................................26

11. Calculation Sheets........................................................................................................................................................27

12. Pipeline Pigging General Arrangement……………………………………..………………………….....…..….29

13. Pipeline Dewatering General Arrangement………………….…………………….……………….....…...….36

14. Filling Equipment General Arrangement…………………………………………………………….. . .…....…38

15. Test Equipment General Arrangement……………………………….…………………………………..............4016. Records & Documentation and Calibration Certificate………………..........................................…42



H.T.B.U

U1. Introduction

PMS company hydrostatic test department capabilities cover two interrelating domains pigging and hydrostatic test. This know-how encourages us to make a strategic planning to create a business unit that has already its product to give and market that need this service.

The engineers can perform all needed calculations for the pigging and which include the Following activities:

� UTest RequirementsPressure testing shall be carried out in accordance with the requirements of specification.Pressure Piping includes all piping designed to convey or contain process or utility fluids Test sections documentation shall contain Uisometrics of piping system diagram (P&ID)

� Test media For hydrostatic testing of piping system, test medium shall be used as per SAES (Saudi Aramco engineering standards)

� UTest DurationTest Pressure shall be held for a minimum period of one (2) hour to enable thorough inspection of the piping system of piping components for leaks. (As per SEAS)

� Preparation For TestingAll joints in a test shall be accessible during test and shall not be painted, insulated or otherwise covered unit satisfactory of testing in accordance with specification.

� UTest EquipmentsPressure required all Pressure gauges and chart recorders shall have been calibrated current calibration certificates.

� Completion of TestingPressure test be considered complete when:All defective welds, materials, flange leaks, valve gland leaks or other such Defects have been corrected and accepted by the owner’s representative. All documentation and test section information is complete and accepted by owner’s Representative.

� UTest Records Records for piping which require that pressure be held for a specified period of time shall Include any corrections of test Pressure due to temperature variations between the start and finish of the test.

� Re-instatementAfter successful completion of Pressure testing, the system shall be returned to a state of commissioning readiness.

� UTest Procedure



H.T.B.U

U2. Human ResourcesThe following is a summary of the number of Engineers, Mechanical and ElectricalTechnical of the Hydro Static Test Department.

2.1 ENGINEERS

NO. NAME JOP DESCRIPTION 1 ZAKRYIA EL-GHARABAWi ASSISTANT GENRAL MGR 2 MOHAMED HELMY EL SAYED Sector head 3 TAMER SABER GNEIDY HYDROTEST ENGINEER 4 MOSTAFA HAMED GASER HYDROTEST ENGINEER 5 MOHAMED EL-HABASHY HYDROTEST ENGINEER 6 MOHAMED KAMEL EL-SAKHAWY HYDROTEST ENGINEER 7 MOHAMED EL-SAID ALY HYDROTEST ENGINEER 8 EL-SAID SHAWKY EL-SAID HYDROTEST ENGINEER 9 MOTAZ AHMED FATHY HYDROTEST ENGINEER 10 MOHAMED ABD-ELGHANY MOHAMED HYDROTEST ENGINEER

2.2 Technical

NO. NAME JOP DESCRIPTION 1 KMAL BSHR MOHAMED SUPERVISOR 2 MOHAMED MAHMOUD SHOUKRY SUPERVISOR 3 AMR RAMDAN MOHAMED MECHANCAL Technical 4 ISLAM MOHAMED EL-NAGAR MECHANCAL Technical 5 AHMED MOHAME HEBALA Electrical Technical 6 HASSAN AHMED ABD EL-RHMAN MECHANCAL Technical 7 FATHY ABD EL-MNEM MECHANCAL Technical 8 MOHAMED ABD EL-RHEIM Electrical Technical 9 AHMED MOHAMED HUSSIEN MECHANCAL Technical 10 MAHMOUD MOHAMED DIAB MECHANCAL Technical 11 MOHAMED MORSY MOHAMED MECHANCAL Technical 12 AHMED MOHAMED ABD EL-KADER MECHANCAL Technical 13 ARFA EL-SAYED ABD ALLA MECHANCAL Technical 14 MOHAMED FAKRY HGAZY MECHANCAL Technical 15 MOHAMED ASSAM ABRHAIM Electrical Technical



H.T.B.U

U3. HYDRO TEST EquipmentU3.1 Pumps working with Engine driven.

SerialEquip. descriptionModelMax. Pbar

Max.Q - l/min

Holland Special Pumps BV Unit D 300 /200-500

1

Centrifugal PumpHSP200-50010 bar600 m³/hr

Cummins engineNT855-G6CPL:1381

Holland Special Pumps BV Unit D 300 /200-500

2

Centrifugal PumpHSP200-50010 bar600 m³/hr

Cummins engineNT855-G6CPL:1381

3Gardner Denver Pressurizing

PumpTX 450SBUP to 700 bar300 l/min

John Deer Diesel Engine6135HF485UWoma Pumps

4Woma - Filling Pump 40 bar400ARP - P7540 bar2 X 858

(102m³/h)

Volvo Penta EngineTAD940VE

5Woma - Filling Pump700ARP - P7560 bar2X1017

(122m³/h)


6Woma-Pressurizing Pump400ARP - P65240 bar457(27m³/h)


7Woma - Diesel driven550ARP - P70300 bar509(30m³/h)Volvo Penta EngineTAD1252VE

UFilling Pumps

8FILLING PUMP 250 LNN-4713 bar1200 M³/hr

Cummins engineKTA19-M3CPL:4150

9FILLING PUMP 250 LNN-4713 bar1200 M³/hr

Cummins engineKTA19-M3UPortable Break FILLING PUMPS

10Break Tank Filling PUMP (1)1D81Z55 M٣/hr

ENGINEHatz

11Break Tank Filling PUMP (2)1D81Z55 M٣/hrENGINEHatz

12Break Tank Filling PUMP (3)NFT-100-315/310DEUTZ DIESEL ENGINEF3L 9123150 M³/hr

13Break Tank Filling PUMP (4)NFT-100-315/310DEUTZ DIESEL ENGINEF3L 9123150 M³/hr



H.T.B.U

U3.2 Pumps working with Air driven.


Max.Q - l/min

Max.air pressuremax. flow

rate

UAir Driven Pumps

1HaskelDSF-1006500.5

2HaskelDSF-603501

3HaskelD14SFD - 1251000 bar10

4HaskelD14SFD - 315700 bar10

5Haskel

two pumps on one Skid

D14SFD-125

700 bar

10 L/MIN8.6 bar

14 cu m/hr D14SFD-12510 L/MIN

6HaskelASF-60350 bar1 L/MIN



H.T.B.U

U4. Instrument:There are many instruments using during hydrostatic test such as Dead Weight Testers, Pressure & temp. Recorder, pressure gauges, high pressure hoses, fitting and valves


UDead Weight Testers

1Dead Weight TesterAMETEKD14SFD - 3150-10000psi

2Dead Weight TesterBudenberg 80HP

UPressure Recorders

1Pressure & temp. RecorderPT-12-T400 bar & 100 Cº




5Pressure & temp. RecorderPT-12-T0 : 30 bar &100 Cº

6Pressure RecorderFox Boro0-250 bar



H.T.B.U

U5. Daily Rate for Hydro Test Crew :-

1- ULABOURS

ITEM DESCRIPTION QTYDaily Rate 12 Hr/Day

DAY($ )/

1 ULABOURS-:

1-2 ) Hours / day12(Operator 1 3002-2 Engineer 1 500

U5.2 Daily Rate for Hydro Test EQUIPMENT:-

ITEM DESCRIPTION QTYDaily Rate 24 Hr/Day

DAY($ )/

2-1 FILLING PUMP 600 M٣/HR 1 1600

2-2 (700 BAR)Pressurizing pump 1 1700

2-3 filter 50 micron 1 150

2-4 Chemical injection pumps 1 2502-5 Pressure relief valve 1 30

2-6 Dead weight tester 1 1002-7 Pressure gauge 1 10

2-8 Pressure & Temperature recorder(24 HOURS) 1 100

2-9 flow meter 1 30



H.T.B.U

6. General preparation� Vents shall be installed at high points.� Testing shall be carried out in the presence of the Owner’s Representative. Records

of all pressure tests shall be maintained. 6.1 Instruments� Pressure gauges� Pressure recorder� Temperature recorder� Dead weight tester and or,� Crystal pressure gauge6.2 Cleaning, Gauging Acceptance

The quantity of construction debris between the scrapers shall show a reducing trend in volume during scraper recovery. Cleaning of the pipeline shall be done to level matching the client request and specifications. Gauging of the pipeline shall be achieved when the gauge plate is recovered without evidence of damage. If the gauge plate is damaged, a technical evaluation and discussion shall be undertaken onsite between Company and Contractor representatives to agree the actions to be taken

6.3 Cleaning and Gauging Operations

6.3.1 Pig Arrangement Pigs will be inserted in the lay down heads according the bellow schematic (lay down head fabrication details)

LAYDOWN / SUBSEA LAUNCHER (Offshore)

. o Pig #1 - Bi-Di Cleaning / Brush pig c/o Pinger.. o Pig #2 - Bi-Di Cleaning / Brush pig c/o Pinger . o Pig #3- Bi-Di Magnetic pig c/o Pinger.. o Pig #4- Bi-Di Magnetic pig c/o Pinger.. o Pig #5 - Bi-Di Gauging pig c/o Pinger.



H.T.B.U

6.3.2 Sequence

Upon completion of all preparation works the Pipeline will be ready for the commencement of cleaning, gauging operations as the following :

1. Issue a Permit to start rig up the equipment on the barge deck. 2. Barriers and signs shall be erected on a safe distance (5 meters). 3. Connect suction hoses between the suction pumps and suitable sea suction level. 4. Connect discharge hoses from pump output to the collecting manifold. 5. Connect the chemical tanks through the suction hoses to the chemical pumps and

connect the delivery hoses (1/2” hoses) to the collecting manifold through ½" needle valves for the chemicals.

6. Connect the filling hoses to the lay down head first valve (2" ball valve) for adding the front water for lubricating and cleaning.

7. Divers shall connect and secure the filling hoses and open the 2" valve on the pig launcher.

8. The onshore team will prepare drain hoses which shall be connected and secured to the pig receiver drain valves to the evaporation pond.

9. After finishing all the previous preparations the onshore team and offshore team will communicate to confirm that the system is ready to begin activities.

10. Before sending the pig train, an initial batch of clean, filtered but chemically untreated seawater corresponding to 200 linear meters (114.239 m3) of the line section shall be pumped in front of the first cleaning pig for lubrication and cleaning the pipe of foreign materials.

11. After confirming that the added volume is in the pipeline by the flow meter reading. 12. Stop the filling pumps in order to connect the hoses for launching the first pig. 13. Divers to connect and secure the filling hoses and open the 6” ball valve (LBV-1) on

the pig launcher located behind the first pig. 14. Start launching the first cleaning/brush pig with Pinger (pig # 1) into the 36” pipeline

and observe the launching pressure. 15. Pumping a batch of clean, filtered and chemically treated seawater corresponding

200 linear meters of the line section (114.239 m3) shall be introduced behind the first cleaning pig.

16. After confirming that the added volume is in the pipeline by the flow meter reading 17. Stop the filling pumps in order to attach the hoses for launching the second cleaning brushes pig. 18. Divers to connect and secure the filling hoses and open the proponent valve

(LBV-2). 19. Start launching the second cleaning / brush pig (pig #2) into the pipeline while

observing the launching pressure. 20. Pumping a batch of clean, filtered and chemically treated seawater corresponding

to200 linear meters of the line section((114.239 m3))shall be introduced behind the cleaning pig to launch the second cleaning brush pig.

21. After confirming that the added volume is in the pipeline by the flow meter reading

22. Stop the filling pumps in order to attach the hoses for launching the third bi-directional magnetic pig with Pinger.



H.T.B.U

23. Divers to connect and secure the filling hoses and open the proponent valve (LBV-3) . 24. Start launching the third bi-directional magnetic pig (pig # 3) into the pipeline. 25. Pumping a batch of clean, filtered & treated seawater corresponding 200 linear meters of the line section((114.239 m3)) shall be introduced behind the pig to launch the third bi-directional magnetic pig. 26. After confirming that the added volume is in the pipeline by the flow meter reading. 27. Stop the filling pumps in order to connect the hoses for launching the third bi-directional magnetic pig. 28. Diver to connect and secure the filling hoses and open the proponent valve (LBV-4). 29. Start launching the fourth bi-directional magnetic pig (pig #4) into the pipeline. 30. Pumping a batch of clean, filtered and chemically treated seawater corresponding

200 linear meters of the line section ((114.239 m3)) shall be introduced behind the pig to launch the fourth bidirectional magnetic pig.

31. After confirming that the added volume is in the pipeline by the flow meter reading. 32. Stop the filling pumps in order to connect the hoses for launching the fifth bi-

directional gauging pig. 33. Divers to connect and secure the filling hoses and open the proponent valve

(LBV-5). 34. The pipeline shall be gauged to ensure that pipeline is free of defects. 35. The gauging pig shall be identical to the cleaning pigs and shall include an

aluminum gauging plate; each gauging plate shall be 6 mm thick. The leading edge shall be chamfered 45o to half the plate thickness. The gauging plate diameter shall be 97% of, or 25 mm less than, the minimum pipeline inside diameter, whichever is the greater.

36. The gauging pig like the all previous pigs shall be equipped with pig locator (Pinger) since the location of stuck pigs is of paramount importance, the use of best available pig location equipment shall be a priority.

37. A gauging plate identification number shall be stamped on the aluminum plate and the number recorded prior to introducing the gauging pig into the pipeline.

38. Run the gauging pig equipped with gauging plate through the pipeline. Company Site Representative will witness the removal of gauging pig from the temporary receiving; any signs of damage shall be analyzed and reported to Company Site Representative.

39. A deformed, bent or severely nicked plate shall not be acceptable. If any, proceed immediately with locating any defects in the pipeline after the company site representative judge of the level of damage to the gauging plate, this may require a second gauge.

40. Gauging plate shall become the property of Company and shall be delivered to Company upon completion of gauging operations.

41. Contractor shall submit to Company for approval a report on gauging pig runs and gauging plate Condition at the completion of gauging pig run.

42. Start launching the gauging pig (pig # 5) into the pipeline. 43. Recommence pumping to launch the Gauging and the whole Pig train.44. Inform the offshore operator on the vessel at the pipeline end that the Pig train (5 bi-directional pigs) has been launched.



H.T.B.U

45. The gauging pig will be sent using a volume equal to 104% of the total pipeline fill (including the patches between the pigs ), the last 100% of this flooding water will be chemically treated water.

46. Continue to flood the pipe section until the 5th pig has been received onshore in the receiver.

47. The pigging operation will be carried out in controlled manner to maintain the pig train speed between minimum 0.3 m/s and not exceeding 2 m/s.

48. Communication between the offshore team and the onshore team shall be continued during the whole operation.

49. When the seawater stopped to expel from the drain hose on receiving head and minor pressure rise shall be indicated on the pressure gauge on the barge so the onshore team announce to the offshore team that one or more of the pigs have been arrived.

50. Pumping shall be continued, in order to preserve a constant a pig speed so the onshore team shall check the arrival by using the Pinger receiver.

51. Log the arrival time of Pigs, Operator to check the actual / expected arrival time.

52. Then shut down the filling and suction pumps.

53. Disconnect filling hose from filling inlet valve, close and plug the inlet valve

54. Log the following records at (30) minute intervals:

54.1. Pipeline pressure during the whole pigging operations 54.2. Flow rate (Flow meter readings) 54.3. Cumulative volume ( pig Position ) 54.4. Filling water temperature 54.5. The Pigs position and velocity will be computed from the flow meter readings.

All the recorded data will be logged in the reports attached in the appendices and shall be signed by the client and delivered after finishing the operations.

55. After confirming the arrival of all pigs, The pigs recovery will be done mechanically and no wash out during the recovery as following steps and attached drawings :

55.1. Open the receiving head gate to recover the Pigs. 55.2. Pulling method (such as Air tugger or other available method on site, Etc.)

to pull the pigs out of the receiver. 55.3. Holder on support. 55.4. A wire or rope will be attached to the pig pad eye and start pulling out

and receiving it on the holder which shall be positioned on a support to be at the same level of the pulling line.

55.5. The recovery of the pigs shall photo recorded and checked by the company site representative to ensure that no broken pieces or missing parts.

55.6. The collected dirt in front of the last pigs recovered shall be checked and analyzed to check the level of the cleanliness, acceptance which shall be as per company specifications.

55.7. Extra care will be taken on removing the Gauging Pig to ensure no damageoccurs to the gauging plate.



H.T.B.U

56. Contractor and Company onshore Site Representatives will witness the removal of gauging pig from the temporary receiving head; any signs of damage shall be analyzed and reported to Company Site Representative.

57. After successful cleaning / gauging operations and being accepted by Company Site Representative, retrieve the filling system and prepare the pipeline for hydrostatic testing operations.

6.3.3 Stuck Pig Contingency Procedure 1-Should any of the pigs become stuck or passing along the pipeline, pigging

operations shall be stopped per client request and locate the blocked pig(s) and/or line damage and report the results to Company Site Representative.

2-Contractor shall carry out any necessary remedial action then the pipeline shall be flooded, cleaned and re-gauged which shall be started from the onshore side.

The following plan will be followed to define the cause of obstruction:3.1 A diving support vessel will be deployed over the pigs’ locations and divers

will confirm the position subsea using diver held Pinger receiver and visually inspect the pipe for any damage.

3.2 If any damage is observed, remedial action will be carried out. 3.3 Mobilizing the necessary equipment to the shore or preparing the offshore

to launch new pigs for cleaning and re-gauging.

3.4 If no damage found, trials to push out the stuck pig(s) will be done by increasing the water flow and monitor the result by increasing the volume behind the pig which will increase the back pressure which shall be enough to be used to move out the stuck pig from its position (Water Hammering Techniques).

3.5 Otherwise, a Foam pig shall be launched from the onshore temporary pig receiver at the pipeline start up point using compressed air.

3.6 Stuck Pig and /or pigs should be pushed back to the lay down pig launching head at KP28.

4-Gauge plate will be inspected in presence of Company Site Representative. 5-If gauge plate is damaged, a new pigging operation will be carried out with a new gauging plate



H.T.B.U

7. RESSURE TEST PROCEDURE

7.1 Introduction

� The hydro testing shall be performed for the piping system loops. The testing head shall be located as injection Point (lowest point at). The vents located at highest points as mentioned before in the description.

� The test pressure (TP) shall be according to the table of line information.

� PMS shall submit pressurization / temperature charts prepared for the test to Company Site Representative for approval before commencing the test.

� Flooding and venting for purpose of testing shall be performed in a manner that minimizes air inclusion in the piping system.

� All fittings, hoses and valves used during testing shall be capable for pressurization exceeding the maximum test pressure and the pressurizing pump shall be capable of testing. Pressure range exceeding test pressure by at least 20%.

7.2 Piping System Pressure Test Sequence

Upon completion of all preparation works, securing the plant site so the piping system will be ready for the commencement of pressure testing operations as the following: Open the valves on testing head.

� Open the venting points to allow water / air expel until the system topping up.� Start-up the filling pumps and begins topping up the system from testing head whilst

venting.� Allow water to expel from the venting points until no further entrapped air is

observed (complete stream of water), and close the vent points and then stop pumping.

� Inform the Company Site Representative that system is topped up and ready for the pressure testing operation and then obtain permission to commence.

� Thereafter open instruments valve and start the system pressurization. 7.3 Pressurization

Pressurization shall be carried out in the presence of the Company Site Representative. The pressure rise will be gradual and under control to allow time for material to strain and for personal to check for leaks.



H.T.B.U

7.3.1 Pressure test using Sea Water as a test medium:

� Pressurize up to 25% at (1) bar/minute, and stop to carry out air inclusion test.� Pressurize up to 50% of test pressure at (1) bar/minute, and stabilize for (10)

minute and check any visual leak

� Pressurize up to 70% of test pressure at (1) bar/minute, and stabilize for (10) minutes check any visual leak.

� Pressurize up to 90% of test pressure at (1) bar/minute, and stabilize for (10) minutes check any visual leak.

� Pressurize up to 100% of test pressure at (0.1) bar/minute, stop and commence stabilization period.

note: while operation is RUNNING, if there is any leak appears:-

� Stop pressurizing pump immediately, Depressurize the system to atmospheric pressure.

� Looking for any leakage from testing connections by visual detection and elimination.

� Inform the Company Site Representative that the leak is over and ready to commence.

7.4 Stabilization :-� When the test pressure is attained, the pressurizing pump will be

stopped. The system is allowed to stabilize for a period of not less than (30) minutes.

7.5 hold period :-

� 1-The test pressure will be held without additional pumping for a minimum period of (24) hours.

� During the test period, the following parameters shall be recorded:-� Time� Pipeline Pressure� Ambient temperature (every ½ hour)� Water pressure and temperature (continuously and every ½ hour)� 2- The pressure and temperature recorders shall be started with the

charts in a real time orientation for continuous record throughout the test, from commencement of pressurization to final accepts of test.



H.T.B.U

7.6 Acceptance/ Completion

� Upon completion of the pipeline hydrostatic testing and being accepted by Company Site

� Representative, in written approval.� 1- At any certain time during the hold period if any pressure drop

below the hydrostatic test� pressure noticed, the reduction in pressure shall be accounted for by

temperature fluctuations� As per allowed pressure drop tolerances. Calculation sheet and graphs

for estimate pressure� Change due to the temperature change attached in the appendices.� 2- The pressure test shall be considered successful when the pressure

has been held for 24 hours� with no signs of leakage and the pressure variation is within ± 0.2% of

the test pressure in� Accordance with DNV-OS-F101 section 9 O 500. (Kindly refer to the

calculation sheet� attached in the appendices)� 3- The pressure variation due to temperature variation formula is as

follow:

��– ��



H.T.B.U



H.T.B.U

7.7 Air Volume Content Calculation

� The air content of the filled line shall be determined by recording the quantity of water(V1) that was

� used to generate a pressure rise of (P1).then measured quantity (V1) should be compared to the

� theoretical one (VP)� The theoretical quantity of water which used to generate the pressure

rise shall be according to the� following formula: (Kindly refer to the calculation sheet attached in the

appendices)

�� Where :-



H.T.B.U

7.8 Depressurization:-

� Start to depressurize the line after the data and information from the test has been approved.

� Depressurization of the pipeline shall be performed as a controlled operation, normally at a rate 1 Bar / Minute until the pressure has been reduced to 40% of the test pressure. Then depressurization should continue at a rate of less than 2 bars per minute to a hydrostatic head , and will be recorded.

After that, after reaching to zero bars, close all valves on testing and venting head, and then disconnect all hoses, equipment and instruments.



H.T.B.U

8. HEALTH, SAFETY AND ENVIRONMENT The safety of personnel is of importance during all operations and related activities. All safety precautions shall be taken to minimize the risk to all Personnel involved. It is the responsibility of the supervisor as well as the individual to ensure that the following points are considered prior to commencement of activities:

� Ensure that all equipment is in good condition and suitably maintained.� Ensure good housekeeping to avoid unnecessary trip hazards.� Check if personnel require any further training prior to commencing activities.� Ensure all personnel have the correct PPE.� Check if manual handling is necessary or can be avoided.� Ensure installation of any screens or barriers for the protection of others if

Necessary.� Ensure availability and accessibility of first aid facilities.� Ensure all equipment is certified in accordance with Company, Contractor and

PMS HSE requirements.� Ensure availability of data sheets on site.� Provide checklist procedure covering all operational activities.� Ensure attendance of all relevant personnel at the toolbox talk prior to the

commencement of work and at the beginning of each shift.� Ensure completion and availability of work permit.� Prior to any system being worked on (pressurized), all non-essential personnel will

be removed from the cordoned area.� Once the system is under pressure, only authorized personnel will be allowed to

enter the cordoned area for flange inspections and such like.

A copy of the risk assessment shall be attached to the permit to work and discussed at the beginning of each shift to ensure personnel are aware of risks and limitations.



H.T.B.U

8.1 MANAGEMENT OF CHANGE :-� Any work arising that requires a change to organization, personnel, systems,

process /method, procedures, products, materials or laws and regulations shall be subject to the process of re-evaluation and approval in strict accordance with the relevant project specifications / HSE requirements. Any change resulting from the above shall be incorporated in the procedures and risk assessed accordingly.

8.2 Preparation For Testing :-

� Prior to arrival at the work site(s) all PMS personnel shall attend the Company HSE induction course.

� Once on site the PMS Representative shall ensure that all personnel comply with requirements of Company regarding reporting, safety and attendance at any briefing and meetings where their presence is required.

� Upon completion of the relevant induction training, the personnel will be post at plant sites to keep the test area clear of all people not concerned with the test and start to rig up the equipments.

� Check the isolation of the equipments not adequate for test pressure (according to the P&ID and the description of equipment rig up for each loop).

� There are an additional bleeding and isolating valves� Test manifold to be with pressure test diagram.

8.3 CHECKING OF EQUIPMENT AND INSTRUMENTATION� The PMS Representative shall be responsible for ensuring that the equipment and

instrumentation that is delivered to the site is in accordance with the equipment and instrument lists.

� PMS Representative shall also check and ensure that all relevant equipment have satisfactory Certification.

� Instrumentation will be calibrated by a certified company.8.4 BARRIERS AND SIGNS

� The PMS Representative shall agree with the Site Safety Officer the positions of a safe boundary for each operation and the positions in which signs are to be placed. Barrier tape / bunting and warning signs shall mark the agreed boundary.

No work other than that controlled by the PMS Representative shall be allowed within the define boundary during operations for which PMS is responsible. Entry of unauthorized personnel shall be prohibited. PMS personnel shall patrol and monitor thecordoned boundary during operations to prevent the entry of unauthorized personnel and the commencement of other work.



H.T.B.U

9. Project Carried Out By Hydro test Department In A.R.E

S/N Project name Equipment Marine unit/barge Duration

1

GUPCO TART BEACH PALL PIPE 20" 40KM

1-FILLING PUMP 40 BAR 2- FILLING PUMP 60 BAR 3- PRESSURIZING PUMP 300 BAR 4- AIR DRIVEN PUMP (HASKEL) 350BARC/W PRESSURE/ TEMPERATURE RECORDER &DEAD WIEGHT TESTER& PRESSURE GUAGE 5- FILLING PUMP CONTAINER

P.M.S 11 + O NSHORE SIT

FROM 1/7/2007 TO 1/9/2007

2

RASHPETCO P1

1-FILLING PUMP 40 BAR 2- FILLING PUMP 60 BAR 3- PRESSURIZING PUMP 300 BAR 4- AIR DRIVEN PUMP (HASKEL) 350BARC/W PRESSURE/ TEMPERATURE RECORDER &DEAD WIEGHT TESTER & PRESSURE GUAGE

PMS MAYO

DURING JANUARY 2008

3

PETROBEL DENNIS PIPES


PORT SAID ON SHORE + PMS Mayo

FROM JUNE TO OCTOBER 2008

4

RASHPETCO P2


PMS MAYO

FROM MAY TO JUNE 2008

5

GUPCO MORGAN 36 P/F

1- AIR DRIVEN PUMP (HASKEL) 300BARC/W PRESSURE/ T EMPERATURE RECORDER &DEAD WIEGHT TESTER & PRESSURE GUAGE

TIM BARGE

DURING JANUARY 2008



H.T.B.U

9.1 Project Carried Out By Hydro test Department In A.R.E


6

NORTH SINA PETROLUEM COMPANY

1-FILLING PUMP 40 BAR 2- FILLING PUMP 60 BAR 3- PRESSURIZING PUMP 300 BAR 4- AIR DRIVEN PUMP (HASKEL) 350BARC/W PRESSURE/ TEMPERATURE RECORDER &DEAD WIEGHT TESTER & PRESSURE GUAGE 5- FILLING PUMP CONTAINER

PMS 11 PMS 17 PMS MAYO

FROM JANUARY TO JUNE 2008

7

GUPCO SAQQARA

1- AIR DRIVEN PUMP (HASKEL) 350 BAR C/W PRESSURE/ TEMPERATURE RECORDER &DEAD WIEGHT TESTER & PRESSURE GUAGE

C – MASTER

FROM JANUARY TO APRIL 2008

8

GENERAL PETROLUEM COMPANY PIPE 11"

1- AIR DRIVEN PUMP (HASKEL) 350 BAR C/W PRESSURE/ TEMPERATURE RECORDER &DEAD WIEGHT TESTER & PRESSURE GUAGE

PMS 17

DURING OCTOBER 2008

9

PETROBEL PIPE 6"& 8"

1- AIR DRIVEN PUMP (HASKEL)

350 BAR C/W PRESSURE/ TEMPERATURE RECORDER &DEAD WIEGHT TESTER & PRESSURE GUAGE

MACOBRE 12

FROM MARCH 2008 TO JANUARY 2009

10

GENERAL PETROLUEM COMPANY AMER 5" P/F

1- TEST PUMP 25 BAR C/W 2-PRESSUR GAUGE & PRESSURE TEMPERATURE RECORDER

PMS 17

DURING JULLY 2008

11

GUPCO SAQQARA

1- AIR DRIVEN PUMP (HASKEL) 350BARC/W 2-PRESSURE/ TEMPERATURE RECORDER &DEAD WIEGHT TESTER & PRESSURE GUAGE 3- FILLING PUMP CONTAINER

AHMED JACK UP BARGE

FROM OCTOBER TO NOVEMBER2008



H.T.B.U

9.2 Project Carried Out By Hydro test Department In KSA


1

ARAMCO


FROM NOVEMBER2008 TILL NOW

2

KHAFJI JOIN

VENTURE KJO


FROM JANUARY 2009 TILL NOW

3 PIP6 24" Subcontractor SAQA SAbESCO & PMS SUPERVISION ONLY

P.M.S 11 FROM DECGMBER 2008 TO JANUARY 2009



H.T.B.U

ARAMCO PROJECT PIPE LINES CURRY OUT BY PMS HYDROSTATIC TEST CREW DURING 2009:

1- ARAMCO ( KSA ) BERRI OIL FIELD

Test Pressure

Duration Length Diameter Pipe Line Location Code

4200 PSI 2009 5.58 KM 24 inch Berri TP-3 to Berri 194 1

4200 PSI 2009 9.57 KM 24 inch Berri 194 to Berri TP1 2

4200 PSI2009 3.6 KM 12 inch Berri 142 to Berri 119 3

4200 PSI 2009 3.47 KM 12 inch Berri DS203 to valve skid 4

2- ARAMCO ( KSA ) SAFANIYA OIL FIELD

Test Pressure


4200 PSI 2009 8.6 KM 24 inch SFNY 900 to SFNY TP-17 1

4200 PSI 2009 11 KM 24 inch SFNY 666 to SFNY TP-17 2



H.T.B.U

ARAMCO PROJECT PIPE LINES CURRY OUT BY PMS HYDROSTATIC TEST CREW DURING FROM

27/3/2010 TO 12/9/2010 :

1-ARAMCO ( KSA ) ZULUF OIL FIELD

Test Pressure


4200 PSI 2010 5.6 KM 16 inch Zulf TP-5 to Zulf 360 1





3800 PSI 2010 5.6 KM 30 inch Zulf TP-4 to Zulf TP-7 6

2- ARAMCO ( KSA ) MARJAN OIL FIELD

Test Pressure


4200 PSI 2010 800 M 16 inch MAHRA 24 to MRJN TP-8 1

4200 PSI 2010 3.1 KM 16 inch MRJN TP-6 to MRJN 105 2



STRA

TEG

IC B

USI

NES

S U

NIT

FO

R H

YDRO

STA

TIC

TEST

(H.T

.B.U

)

28 P

ag

e

ASS

ISTA

NT

GEN

ERA

L M

GR

ENG

. ZA

KARI

A E

L-G

HA

RABA

WI

H.T

.B.U

STRA

TEG

IC B

USI

NES

S U

NIT

FO

R H

YDRO

STA

TIC

TEST

(H.T

.B.U

)

29 P

ag

e

ASS

ISTA

NT

GEN

ERA

L M

GR

ENG

. ZA

KARI

A E

L-G

HA

RABA

WI

H.T

.B.U

STRA

TEG

IC B

USI

NES

S U

NIT

FO

R H

YDRO

STA

TIC

TEST

(H.T

.B.U

)

30 P

ag

e

ASS

ISTA

NT

GEN

ERA

L M

GR

ENG

. ZA

KARI

A E

L-G

HA

RABA

WI

H.T

.B.U

STRA

TEG

IC B

USI

NES

S U

NIT

FO

R H

YDRO

STA

TIC

TEST

(H.T

.B.U

)

31 P

ag

e

ASS

ISTA

NT

GEN

ERA

L M

GR

ENG

. ZA

KARI

A E

L-G

HA

RABA

WI

H.T

.B.U


32P a g eASSISTANT GENERAL MGR ENG. ZAKARIA EL-GHARABAWI

H.T.B.U

Al-KHAFJI PROJECT PIPE LINES CURRY OUT BY PMS HYDROSTATIC TEST CREW

DURING FROM 01/01/2010 TO 23/9/2010 :

� PMS Crew Carry Out Hydrostatic Test Required For All Loops On

Al-KHAFJI Platforms (Y2-B ) & ( Y4 ) & ( Y1-B ) AND ( Y3 )With different Pressure

Test ( Form 27 Bar To 70 Bar )

� PMS Hydro Test Engineering Supervision of Per Commissioning Of The

Pipe lines Detailed Below for Hydrostatic test Carry Out By B.J Co.

STRA

TEG

IC B

USI

NES

S U

NIT

FO

R H

YDRO

STA

TIC

TEST

(H.T

.B.U

)

33 P

ag

e

ASS

ISTA

NT

GEN

ERA

L M

GR

ENG

. ZA

KARI

A E

L-G

HA

RABA

WI

H.T

.B.U

10. E

xpec

ted

Proj

ect D

urin

g 20

10 /

201

1 In

side

Egyp

t

Proj

ects

Exp

ecte

d in

Egy

pt D

urin

g 20

10/2

011

No

Proj

ect N

ame

Expe

cted

day

s Ex

pect

ed S

tart

da

ys

Mar

ine

Uni

t Sp

ecifi

cati

on

Not

es

1 D

enis

e - B

- 201

0 L

eak

Tes

t 16"

15

Fr

om 3

1/10

/201

0 M

ayo

Tes

t Pre

ss.=

157

bar

16" 6

.5 K

m

2 P

etro

bel 1

0"

7 Fr

om 5

/12/

2010

To

22/2

/201

0 P

MS

17

T.P

.=35

BA

R &

2.

56K

m

Cos

t Plu

s

3 P

etro

bel 1

4"

7 Fr

om 5

/12/

2010

To

22/2

/201

0 P

MS

17

T.P

.=35

BA

R &

0.

6Km

C

ost P

lus

4 P

etro

bel 1

8"

7 Fr

om 5

/12/

2010

To

22/2

/201

0 P

MS

17

T.P

.=35

BA

R &

1.

1Km

C

ost P

lus

5 A

BU

QIR

Pet

role

um 1

2"

10

/9/2

010

T

est P

ress

.=16

0 ba

r P

/L 1

2" &

4.7

Km

6 A

BU

QIR

Pet

role

um 1

0"

25

P/L

10"

& 1

7Km

7 A

l Am

al P

etro

leum

C

ompa

ny 2

4"

16

P/L

24"

& 1

6.34

km

8 A

l Am

al P

etro

leum

C

ompa

ny 4

" 10

P

/L 4

" & 1

6.34

km

9 A

l Am

al P

etro

leum

C

ompa

ny 8

" 7

P/L

8" &

1.23

2km

10



H.T.B.U

11.Calculation sheets



H.T.B.U

11.1Calculation sheets Included Items:

� Main Pipe Line Data

� Flow Measurement

� Volume To Pressurize

The incremental volume of water added, divided by the

incremental change in pressure is represented by �P

�V .

� Temperature and Pressure Relationship By �P

�T

� Air volume of Content

� Dewatering Operation



H.T.B.U

12.Pipeline piggingGeneral Arrangement



H.T.B.U



H.T.B.U

13. Pipeline DewateringGeneral Arrangement



H.T.B.U



H.T.B.U

14.Filling EquipmentGeneral Arrangement



H.T.B.U



H.T.B.U

15.Test EquipmentGeneral Arrangement



H.T.B.U



H.T.B.U

16.Records and Documentation



H.T.B.U

document

Business

hydro static test h

hydro test equipments

hydro test crew

hydro test department

pressure test procedure

test procedure flooding

gharabawi h

u uabstractas