4.2 TEST PROCEDURE FOR RISER

CNPC Offshore Engineering Company Limited

TEST PROCEDURE FOR RISER

Document No. XXX-XXX

Rev. Date

Description PREP’D CHK’D REV’D APP’D COMPANY SOUTH P ARS (PHASE 11) GAS FIELD

DEVELOPMENT

JACKET EPCI PROJECT

CONTRACTOR

SATAUS CODE: A=Issued for Review - B=Issued for Comments -0= Issued for Approval CPOE

JPF

1. INTRODUCTION

This procedure gives the details of how to carry out hydrostatic test of 32” and 4.5”

risers, riser of 32” will be installed on side row B, riser of 4.5” will be installed on the jacket leg A onSPD11A/B

2. APPLICABLE SPECIFICATION AND CODS

DNV-OS-F101 Submarine Pipeline Systems

API RP 2A Recommended Practice for Planning, Designing and Constructing

Fixed Offshore Platforms

API Spec 10 Specifications for Materials and Testing for Well Cements, Third Edition, July 1986

ASTM C150 American Society for Testing and Material, “Specification for

Portland Cement”, Volume 04.01 Cement; Lime; Gypsum ASTM C109 American Society for Testing and Materials,” Test Method for

Compressive Strength of Hydraulic Cement Mortars (using

2-inch or 50-mm Cube Specimens)

ASTM American Society of Testing and Materials

3. SCOPE OF TEST

The tests which will be done in Qingdao Yard shall be limited as following:

z Riser shall be filled and pigged first and then shall be gauged before hydrostatic tested. The test pressure for riser of 32” and 4.5” is based on requirement of riser specification, their test time shall be held for a minimum of 24 hours.

z 3. TEST MEDIUM

Test medium is fresh water.

4. TEST EQUIPMENTS AND INSTRUMENTS

5. SAFETY

The CPOE shall provide a safety manual which shall cover as a minimum all personnel, equipment.

5.1 The safety of personnel during the tests shall be assured at all times. No

procedure shall be allowed which may endanger personnel. All safety precautions shall comply with statutory and other relevant regulations.

5.2 The CPOE shall take all necessary measures to ensure that all personnel are

adequately protected during the course of the tests and, in particular, to ensure

that no work is permitted on the pressurized sections of the line for the duration of the tests.

5.3 Warning notices both in Chinese and English reading “WARNING PIPELINE

UNDER TEST” shall be placed at appropriated locations for the duration of the tests. The boundaries of the test equipment area shall be defined by marker tapes.

5.4 All tests shall be performed safety in accordance with approved procedures using

personnel with the requisite knowledge and ability and under competent supervision. Test areas shall be separated from other places, when tests start.

5.5 The safety of all personnel directly or indirectly involved with testing shall be of

paramount importance. All practical steps shall be taken to ensure their safety. 6. BEFORE TESTS

6.1 This test procedure should be approved by the Client.

6.2 Line check to be carried out prior to testing of pipe system.

6.3 All instruments and equipments for measuring pressure, volume and temperature

must be calibrated within period in-according to China national standard requirement and by recognize calibration lab. All calibrated gauge and recorder must display proper calibrated sticker with gauge and recorder shall not be used.

6.4 CPOE to notify Client installation group to participate and witness testing.

6.5 Weld trace ability record with Weld joint number, Welder number and NDT.

6.6 Equipment like sensitive meter to be re-instate after hydrostatic test.

6.7 All connection area (like flange) to be dry and clean when hydrostatic test.

6.8 All piping shall be adequately supported during the pressure test.

6.9 All in-line valves shall be partially closed and all trapped air vented. Once the

valves are vented, they shall then be stroked to the fully open position and locked.

6.10 Valid permit to work must be applied before commencing work.

6.11 All pressure vessels including header must be certified safe for use and the

maximum allowable pressure must be clearly indicated. A competent person must carry out this inspection and certification.

6.12 Before testing CPOE shall submit the following to the client :

z Stage Release Note

z A Test-Isometric Drawing

z A certificate of NDT clearance.

z Data sheets for all equipments and instruments.

z Calibration certificates for all instrument.

7. FILLING AND PIGGING TEST

7.1 The riser shall be fully filled with fresh water and kept for at least half an hour

before pigging starts.

7.2 Devices and facilities for filling and pigging shall be installed carefully.

7.3 The pigging pig shall be run through entire length of riser. Sizing plate on pig shall

be submitted to client for approval.

7.4 First the inside of pipe shall be circulated with fresh water by a centrifugal pump for

five (5) minutes, until it is clean enough and client approved.

7.5 After draining of the riser, a pigging pig will be installed at an end of the riser, and

then pulled through the line by a wire from the other end of the riser. It is ensured

that is clean enough for inside of the riser and the client approved.

7.6 Riser shall be thoroughly cleaned with pigging pig so as to remove all dirt, sand,

mill scale or debris from the riser. Acceptability of effluents cleanliness shall be at discretion of client.

7.7 The fill report shall be prepared as required, which including:

z Data of water

z Amount of water to be filled

z Mean of filling

z Pollution control for environment

8. GAUGING TEST

8.1 Devices and facilities for gauging shall be installed carefully

8.2 The CPOE shall provide the information as the distance between pigs, number

and types of pigs, location of gauging pigs for approval by client.

8.3 The pig for gauging shall be run through entire length of riser.

8.4 After pigging of the line, a gauging pig will be installed at an end of the line, and

then pulled through the line by a wire from the other end of the line. It is ensured that is gauged internal diameter enough for inside required quality of the line and the client approved.

8.5 A gauging plate which has an external circular crown with a thickness of 10mm.

The diameter of the gauging plate shall be 97% of the pipe ID..

This test is carried out by making a gauging plate pass through the line.

8.5.1 First, the gauging plate is recorded by a photographic record, then installed at

the start end of inside of the line, then pulled through the line by a wire from the other end.

8.5.2 At the receiving trap, the gauging plate shall be inspected in the presence of

Client's and Contractor's Representatives and taken a photographic record of the plate again.

8.5.3 If the gauging plate is damaged after testing, a second gauging plate shall be

used. If the second gauging plate is also damaged, a caliper pig with a tow line and a tail line shall be launched to investigate the extension and location of defects. The defects shall be consequently repaired in accordance with the procedures approved by Client.

8.5.4 Preparation of gauging report with the photographic records for the client

approval.

8.5 After gauging, the gauging pig shall be inspected by client, should there be any

damage to the gauging pig, we shall submit a detailed inspection report explaining the cause of damage. Any signs of damage or irregularities such as dents, buckles,

Spots, construction debris & etc. shall be repaired.

8.6 By now, operations of filling and pigging and gauging, for all insides of pipes are

over, and accepted by Client. Next, connect the test manifold and other pipe fittings for pressure test.

TEST

9. HYDROSTATIC

9.1 Stabilization

At the end of the riser, a pressure gauge shall be installed with a recording system having minimum 24-hour autonomy and a hydrostatic balance.

Water injection first, the vent valve shall be kept opened until water over flow from it. Pressurization shall be carried out in the presence of the client. The pressure increase shall be moderate and constant.

Following is the sequence for pressurization:

a) First pressure shall be increased at a rate of 0.1MPa/min until 80% of test pressure. This pressure be maintained for at least 8 hours to check the leakage. During this stabilization period, readings of pressure, temperature, etc., shall be recorded every half-hour.

b) Pressure shall be re-increased at a maximum of 0.1MPa per minute to 95% of test pressure. The last 5% up to the test pressure shall be raised by a linear diminishing rate down to 0.01MPa per minute.

c) When the specified test pressure has been reached, the pressure hose shall be disconnected and the test section shall be plugged and isolated. A hold period shall be maintained for a minimum of 4 hours. During this hold period, all stop valves and other points, where leakage is likely, shall be checked carefully.

d) The pressure shall have a minimum duration period of 24 hours and shall be commenced after the minimum 4-hour hold period has been completed satisfactorily and after the data obtained on the pressure and temperature recording charts has been reviewed and approved by company.

9.2 Pressure test

After pressurization and stabilization, the test pressure shall be held for 24 hours.

The pressure recorder shall continuously monitor the test trend.

During the test period, the following parameters shall be recorded:

- pressure (internal pressure)

- ambient temperature and inlet water temperature

9.3 Acceptance Criteria for the Pressure Test

The people shall maintain records in a file concerning inconveniences during testing, i.e. position, type, cause of said inconvenience and method of repair.

Pressure drops must not occur during the test period, apart from those drops that are evidently attributable to temperature variations or environmental changes, If this occurs, pressure shall be discharged down to safe pressure (below 2 Mpa), the people shall investigate and eliminate the cause, (repaired without pressure) and re-pressurize the line for another 24-hour period.

We shall be provide a complete record of failures occurring during the testing shall be kept, including their exact location, type and cause of failure, method of repair.

9.4 Completion

Each test is completed once the Client or his Representative provides written approval.

Upon test completion, the riser shall be slowly depressurized until the required pressure is reached, as specified by the Client or Representative. Each riser

shall be blown by dry compressed air until all water has been removed to the satisfaction of Client.

9.5 Documentation

At the end of the test, a testing report (package) shall supplied. This report shall contain the test-history and information collected during the various phases and also following:

z Isometric drawings;

z Summary of all filling, pigging, gauging and hydrostatic testing operations;

z Filling and pigging records as described in this specification;

z Photographs of all pigs before and after running through pipe;

z Any deviations from prescribed procedure;

z Charts from pressure recorder with explanations for any pressure variations;

z Calibration certificate for all equipments;

z Records of amount of debris removed from riser;

z Record of unsuccessful hydrostatic tests and detailed description of the repairs.

10. MEASUREMENTS

During the various test phases, measurements shall be carried out according to the following criteria.

10.1 Quantity of water

The quantity of water let into the section to be tested during pressurization shall be measured with appropriate meter.

10.2 Pressure measurement

The pressure shall be measured with pressure indicators accuracy.

10.3 Temperature measurements

The temperature of water shall be measured:

a) During filling operations

b) During stabilization operations

c) During hydrostatic testing.