135355-04-Pro-02-005 - Rev 01 - Hydrotest Procedure For Station Piping

THAI BINH – HAM RONG GAS DISTRIBUTION AND GATHERING SYSTEM
PROJECT, BLOCK 102 & 106 - PHASE 1
HYDROTEST PROCEDURE FOR

STATION PIPING
Document Number
135355-04-PRO-02-005
Project No.: 135355
01 09-12-14 Issued for Construction PNT NTT NVD

Issued for
00 27-10-14 NVT NTT NVD
Review/Comment
Rev Date Purpose of Issue Prepared Checked Approved PTSC
By By By
THAI BINH – HAM RONG GAS DISTRIBUTION AND
GATHERING SYSTEM PROJECT, PHASE 1

STATION PIPING
RECORD OF REVISION
Rev Date Page Contents Remark

No.
00 27 Oct 2014 All Issued for Review/Comment
01 09 Dec 2014 6 Add “risk assessment”
8 Add “”test pressure”
Document No.: 135355-04-PRO-02-005 Rev. 01

Page No.: 2 of 10

STATION PIPING
TABLE OF CONTENTS
1.0 INTRODUCTION 4
2.0 PURPOSE 5
3.0 SCOPE 5
4.0 DEFINITION 5
5.0 REFERENCE 5
6.0 PROCEDURE 6
7.0 SPECIAL REQUIREMENT 10
8.0 APPENDICES 10

Page No.: 3 of 10

STATION PIPING
1.0 INTRODUCTION
Petro Vietnam Gas Joint Stock Corporation (PVGas) is responsible for the development of
Thai Binh - Ham Rong Gas Distribution and Gathering System Project to transport gas from Ham
Rong field (Block 106), Thai Binh field (Block 102) and Other fields (Hong Long, Sapa Nam,
Hong Ha- Block 103 & 107) to industrial zones in Thai Binh and neighboring provinces in the
North of Vietnam (see Figure 1 – Location).
Phase 1 of the Project includes facilities on Thai Binh Platform, Gas Distribution
Center (GDC) and gas transport pipeline connecting Thai Binh field to GDC as
followings:
- Platform topside facilities include Pig launcher and Corrosion Inhibitor skid.
- Spool is installed for connections from Ham Rong field, other fields
- Tie-in point for LNG exports FPSO in the future.

- The pipeline from Thai Binh Platform to GDC shall be designed with additional
capacity to service other platforms 106, 103 & 107. It shall include:
Page No.: 4 of 10

STATION PIPING
 Approximately 13.1 km from 102 - TB -1X to LFP at Con Vanh

 Approximately 5.28 km from LFP to LFS.
 Approximately 5.8 km from LFS to onshore GDC.
In Thai Binh GDC, the 3 phase separator and filter/separator will be expected to
install in order to separate water, flit solid object, take condensate and sale gas.
Condensates will be stored and send out by truck loading system. Sale gas will be
supplied to industrial customers via pipeline or by CNG trailers.
According to the approved Field Development Plan (FDP), the First gas schedule is
targeted on 15th June 2014. However, the above schedule will be updated according to
the First gas schedule of PETRONAS Overseas SDN. BHD (PCOSB), expected to
complete on Q1, 2015
2.0 PURPOSE
This procedure serves as a guideline for the preparation and execution of hydro testing and
flushing on Gas Distribution Center of Thai Binh – Ham Rong Gas Distribution and Gathering
System Project, block 102&106-phase 1 at Thai Binh province, Viet Nam.
3.0 SCOPE
This procedure covers the preparation and execution of hydro testing and flushing works, the
equipment used the detail process of works and safety requirements.
4.0 DEFINITION
Project means THAI BINH – HAM RONG GAS DISTRIBUTION
AND GATHERING SYSTEM PROJECT
Company/Client means PVGAS
Contractor means PTSC
ASME means The American Society of Mechanical Engineers
ANSI means American National Standard Institute
NDT means Non Destructive Testing
PWHT means Post Weld Heat Treatment
P&ID means Process and Instrument Diagram
QA/QC means Quality Assurance/ Quality Control
5.0 REFERENCE
ASME B31.3 : Process Piping
135355-03-STD-06-001 : Piping Construction Standards

Page No.: 5 of 10

STATION PIPING
6.0 PROCEDURE
6.1 INTRODUCTION
The hydro testing shall be carried out in accordance with the specifications, codes and
standards in the contract document, a hydro test involves all the flange connection, pipe
spool installed at Gas distribution Center.
The flushing is to be carried out before hydro testing and lines shall be cleared from
dirt, welding slag, welding rods, grease etc.
6.2 GENERAL REQUIREMENTS
Hydro testing/ flushing shall not be carried out without the approval of COMPANY
Prior to hydro testing and flushing of the piping system or components, the line
completion checklist shall be accomplished and loop checking carried out by
CONTRACTOR QC Engineer and COMPANY Representative.
All QC documentation to be completed and signed off confirming all required NDT has
been completed and accepted with no outstanding weld repairs.
No outstanding “A” items should be left on the system punch list.
6.3 SAFETY
Barricade the area and signboards/ warning signs shall be placed around the hydro test
area. All personnel attending the test shall wear complete standard PPE. Only authorized
crew shall be allowed in the hydro test area at the time of testing.
Risk assessment to be referred to 135355-06-HSE-02-001 Hazard Identification And Risk
Assessment Procedure.
Rev. 01
6.4 FLUSHING & HYDRO TESTING EQUIPMENT
a. Temporary Pipes and Header
b. Temporary Blind Flanges
c. Plugs and Caps
d. Needle Valve (high pressure)
e. Temporary Tank
f. Flushing Hoses
g. Air Compressor
h. Hydro test Pump / Portable Pump
i. Tubing and Fittings
j. Pressure Gauges
k. Temperature Gauge
l. Temperature and Pressure Recorder

Page No.: 6 of 10

STATION PIPING
All the above items and equipment shall be inspected by COMPANY Representative
prior to flushing and hydro testing activities.
The following equipment or items shall not be subjected to the hydro testing:
- Pumps
- Safety valves and flame arrestors
- Pressure vessels
- Any equipment without test pressure specified
- Piping normally open to the atmosphere
- Deck drain, vents and exhaust lines
- Orifice plates, filters and control valves
6.5 PREPARATION FOR FLUSHING & HYDRO TEST
6.5.1 FLUSHING
• The following items shall be removed and isolated prior to flushing activity:
- Orifice plates
- Flow nozzles
- Strainers
- Control valve
- Pump, pressure vessel, filters
• All fabricated works including welding, inspection, NDT and PWHT shall be completed
and accepted before flushing.
• Check and provide additional temporary support for piping system.
• Flushing water should be free from dirt and impurities.
• All ball valves shall be in the open position and all instrument accessories shall be
removed, i.e. relief valves, thermo well connections.
6.5.2 HYDRO TESTING
The system to be tested shall be prepared as follows prior to testing:
 Test package shall be issued to the COMPANY for approval
 Completeness of all components and attachments as per P & ID and isometric
drawings
 Pipes, valve sizes, and flange ratings in accordance with piping layout and isometric
drawings.
 Low point drain and high point vent is installed as specified on isometric drawings.
 Piping is properly supported as per isometric drawings and analysis calculation.
 All flange connections are properly torque.
 Gaskets, temporary blind, spectacle blinds, bleed rings, etc…, are correctly installed.
 Instruments connected to the line shall be temporarily isolated.

Page No.: 7 of 10

STATION PIPING
 Equipment/ items which are not to be tested shall be either disconnected from the
piping or isolated by blinds or the other means during testing.
 For piping class 300 and above, and for all sensitive leak tests, the welds to be
inspected shall be left unpainted.
 The flapper wafer type of check valve shall be removed during testing.
 All bleed valves; drain or vents shall be provided with plugs or blinds whichever is
applicable.
 Location of hydro test pump and recorder shall be easily accessible to the personnel
conducting the test.
 In addition to the block & bleed valves between the pump and the line, the isolation
valve and ball valve shall be installed.
 The gaskets and bolting used on all flanged connections during pressure testing shall
be identical to those specified for the operating duty and shall be replaced after
hydrotest.
 Gauges and recorders shall be calibrated within validity period. Recorder can use for
testing if it have temperature pen and pressure pen together.
 The full scale and range of the pressure gauge and pressure recorder shall be 1.5 to 3
times of the test pressure
6.6 TESTING MEDIUM
For carbon steel materials, the testing medium use potable water.
6.7 FLUSHING & HYDRO TEST PROCEDURE
6.7.1 FLUSHING
All lines two (2) inches and larger, other than instrument and utility air lines shall be flushed
with water so as to completely clear them of any loose mill scale, rust, or various extraneous
material. All lines smaller than two (2) inches, and air lines of any size, shall be cleaned out in
like manner using compressed air.
Rev. 01
6.7.2 HYDRO TESTING
 Test pressure: The minimum hydrostatic test pressure shall be taken as 1.5 times
design pressure for onshore pipeline.
 Fill the system with potable water preferably at the low point in the system. All vent
valve connections shall be open and close only when there is a steady, air-free flow of
test water overflow at the vent valve. The sequence of closure shall be from the
lowest to the highest system vent point. The chart recorder will write immediate when
filling full water in piping system.
 During filling operation the system pressure should not exceed 1-2 bar gauge.
 Filling shall continue until the system is full of test water and fully vented. Upon
completion, fill pump shall be disconnected from the system and all vents shall be
closed.

Page No.: 8 of 10

STATION PIPING
 Minimum two pressure gauge use for testing system, one pressure gauges shall be
installed at the lowest and other pressure gauge will install at highest point of the
system. The full scale and range of the pressure gauge and pressure recorder shall be
1.5 to 3 times of the test pressure
 Start the test pump to pressurize the system in sequence as 50% increments of the test
pressure, line inspection shall be carried out at each increment after 5 minutes with
Pipe class ≤ 300 and 10 minutes with pipe class ≥ 600 intervals to stabilize the
pressure and gradually increase the pressure to the required test pressure.
 During testing, ball valves shall be in half open position.
 When the test pressure has been achieved, the test pump shall be stopped and isolated
from the system.
 Open the isolation valve of the recorder to record the test at a holding time as per
Project Specification Requirements (with minimum 1 hour).
 The system shall be examined for leaks throughout the test period. . If there is any
significant rise in pressure due to temperature, the system should be vented to
maintain the pressure close to the required test pressure.
 If leaks occur during the process of pressurizing or pressure holding, the line shall be
depressurized to rectify leaks.
 After successful completion of the leak testing and approved by COMPANY, the
system shall be depressurized, completely drained and purge or blow-down with
compressed air until dry to the satisfaction of COMPANY. The pressure recorder
chart shall be signed off by CONTRACTOR QC Engineer and COMPANY
Representative.
6.7.3 RECTIFICATION OF LEAKS
Depressurize the system.
Open and dismantle the stud bolt and nuts.
Check the condition of the gasket/ stud bolt and nuts or replace a new gasket if necessary.
Check the surface of flanges and make sure the surface is clean from dirt and impurities.
Install back the gasket and tighten the stud bolts and nuts with the correct torque.
Re- test again with the all steps as above.
If in case of leak via threaded connection
6.7.4 ACCEPTANCE CRITERIA
Upon completion of the pressure test, the test shall be terminated only after written
approval has been given by PVGAS. Approval for termination of the pressure test may be
given after all of the following conditions have been satisfied by the PTSC.
The required accuracy of measuring equipment and records has been demonstrated by the
PTSC
• All leaks have been located and repaired
• The specified hold period has been maintained satisfactorily
• When all pressure drops have been satisfactorily accounted for
Upon successful completion of the hydrostatic pressure test, both the PTSC QA/QC and
Page No.: 9 of 10

STATION PIPING
PVGAS representative shall verify and sign the correctness of all recording charts and
observations taken.
6.8 CLEANING
Upon completion of the test, the system shall be cleaned by flushing with the high-
pressure water pump. The flow shall be from high to low points of the system open-end
flange(s).
7.0 SPECIAL REQUIREMENT

Piping which normally opened to the atmosphere shall be subjected to a service test by
flushing the system.
8.0 APPENDICES
Hydro Test package sample

Page No.: 10 of 10
PTSC OFFSHORE SERVICES JOINT STOCK COMPANY
REQUEST FOR FLUSHING & PRESSURE TESTING
THAI BINH – HAM RONG GAS DISTRIBUTION

Project Sheet 1 of 1
AND GATHERING SYSTEM PROJECT, PHASE 1
Client PVGAS Request No. TP-GDC-FW-001
Location TIEN HAI, THAI BINH Date Of Test TBA
System Piping Description Piping at GDC
Loop No. FW Pressure xxx Barg (xxxPsi)
Type Of Test Hydrostatic Test Test Medium Water
Test Pack No. TP-GDC-FW-001 Holding Time 1 Hour
SCOPE OF INSPECTION
Item P&ID Drawing Punch list
System Sheet Rev. Area Remark
No. No. Sheet Rev. Yes No NA
NOTE:
ISSUED BY: RECEIVED BY: ACKNOWLEDGED BY:

HYDROSTATIC TEST PACKAGE
PROJECT : THAI BINH – HAM RONG GAS DISTRIBUTION AND

CLIENT: PVGAS
TEST PACKAGE No. :

TP-GDC-FW-001
CONTENTS
OK N/A
1. Request for Flushing & Hydro-testing  

2. Piping Test Pack Acceptance Certificates (P01-A)  
3. Test Pack line list (P02-A)  
4. Check Sheet (P03-A)  
5. Punch List (P04-A)  
6. Flushing Certificate (P05-A)  
7. Pressure Test Certificate (P06-A)  
8. Re-instatement certificates (P07-A)  
9. P & ID Drawing  
10. Isometric Drawing  
11.Instrument Calibration Certificate  
00 09-Oct-2014 Issued for Review NVT NTT NVD

Prepared by Checked by Approved by Approved by
Rev. No Date Purpose of Issue PTSC PVGAS
PTSC PTSC
Typed initials in the signature box indicate that the document has been signed (original with Document Control)
Construction Checksheet
Piping Test Pack Acceptance Certificate P01-A Sheet 1 of 1

INFORMATION
Test Pack No. :TP-GDC-FW-001 Type of Test :Hydrostatic Test
System :FW Description Piping at GDC
Loop No. : Holding Time :01 Hour
Test medium :Water Pressure :xxx Barg (xxx Psi)
P&ID No :Refer to P02-A Line No :Refer to P02-A
INSPECTION/TEST OK N/A P/L No
A PRE-TEST REQUIREMENTS
The Test Pack shown above has been checked for material and NDT clearance, all
1 relative acceptance documents are prepared in accordance with project requirements.
2 Attach a Mark-up P&ID showing the test boundaries.

3 Attach a Test Pack Line List P02-A complete with all associated Isometrics.
B POST TEST RESULTS
1 Pre-Test Check Sheet P03-A is completed and attached.
2 Piping Punch List P04-A is attached.
3 Flushing Certificate completed and P05-A attached.
4 Pressure Test Certificate completed and P06-A attached.
5 Reinstatement Certificate completed and P07-A attached.
6 Calibration Certificates for Charts & Gauges etc. included.
The Strength Test has been carried out in accordance with Project Specifications and is
7
certified as complete.
All outstanding Piping Punchlist items have been transferred from Piping punchlist to the
Master Punchlist.
8
NOTE : Only punchlist category "B" items can be transferred to the Master Punchlist.
Comments:
Completed By Approved By Verified By Accepted By

Company
Name
Signature
Date
Test Pack LINE LIST P02-A Sheet 1 of 1

INFORMATION
System :Piping Description :Piping at GDC
Loop No. : Holding Time :xxx Hour
Test Medium :Water Pressure :xxx Barg (xxx Psi)
Item Pipeline Sheet Rev Area P&ID No Sheet Rev
Notes:

Company
Name
Signature
Date
Pre-Test Check Sheet P03-A Sheet 1 of 1

INFORMATION
Loop No. :N/A Holding Time :01 Hour
1 Test Limit is confirmed as shown on the attached P&ID and P02-A Test Pack Line List.
Perform a Line Check and compile a Pipeline Punchlist detailing any defects, incomplete
2
work or incorrect installation.
3 Pipeline correct schedule and type.
4 Test preparations completed as per test pack
5 Check all welded attachments are completed and all well joints are NDT cleared.
6 All vents and drains installed. (add temporary vents and drains for testing as required)
7 Test area barricaded
8 Flange Management certificates for all joints.
9 All chain wheels and extended spindles required for specified valves have been installed
10 All Check Valves to be removed or tied back
11 Ball valves to be half open during test and fully open for flush
12 All in- line valves, except ball valves, to be fully open for test and flush.
All temporary equipment stops, spades, bobbin pieces and supports for pressure test are
13
installed and recorded for checking at post test reinstatement
All instruments relief valves, bursting discs and specified control valves have been
14
removed for pressure test
15 All orifice flanges to be blinded off
16 Essential supports to be fitted and springs and bellows to be gagged during test
Check that all sprinkler heads, rosettes and nozzles have been removed and connections
17
plugged
Sign off any completed items on the Piping Punchlis and ensure there are NO category "A"
18
items outstanding.
19 All test instruments, i.e., pressure gauges, chart, Temp. recorder, and PSV are calibrated.
20 Confirm chloride content of water, 200 ppm for CS and 25 ppm for SS.
Comments:

Company
Name
Signature
Date
Project: THAI BINH-HAM RONG GAS DISTRIBUTION AND
Piping Punch List P04-A SHEET 1 OF 1
Test Pack Number : TP-GDC-FW-001 Type of Test: Hydrostatic Test
System: Pipeline Description: GDC-FW
Loop No. N/A
INSPECTION / TEST OK N/A P/L No
1 The Test Pack Line List can be either:
The P04-A produced by the Pipeline Completion System.
or 
A Punch List sheet produced by the Fabricator.
Drawing No.:
ITEM DESCRIPTION EST. MAT. REQ No CAT CLOSE-OUT DATE SIGNED
HRS. VEIFICATION CLOSED
No
CATEGORIES:
'A' Items to be repaired, completed or corrected before flushing / hydrotest.
‘B’ Items that need to be repaired, to be completed and corrected including items for reinstatement
before commissioning/operating.
Comment:
- Punch list for this package was not affected to hydrostatic test activities.
- Punch list for this package was designated to completion/correction by different item.
Completed by Approved by Accepted/Noted by

Company
Name
Signature
Date
Flushing Certificate P05-A Sheet 1 of 1

INFORMATION
System :Piping Description Piping at GDC
Loop No. :N/A

Test Medium :Water
1 Flushing Limit is confirmed as shown on the attached P&ID and P02-A Test Pack Line List.
2 Equipment bypassed and blinded
3 Valve status in accordance with flushing and testing procedure
4 Flushing medium used
5 Date Flushed
6 Ensure all low point drains and high vent points are flushed
7 Flushing result acceptance - All piping cleared of debris

Drying required and completed - if not immediately followed by hydro testing of same
8
piping flushed
Protection / preservation required and completed - if not immediately followed by hydro
9
testing of same piping flushed
Comments:

Company
Name
Signature
Date
Pressure Test Certificate P06-A Sheet 1 of 1

INFORMATION

Pre-Test preparations complete and P03-A attached together with P&ID showing test limits
2
clearly marked
The Piping Punchlist P04-A is attached and all "A" items on line are clear and have been
3
signed off.
4 Pre-Test Flushing Complete and P05-A attached
5 Calibration Certificates for Recorders and Gauges attached
6 Instruments removed.
7 Test Temporaries installed.
8 Permit to Work or HSE authorization in place.
9 Release for Pressure Test.
Pressure Test record the following:-
Test Date:
Test Medium: Water

10
Duration of Test: 01 Hour
Ambient Temperature:
Test Pressure: xxx Psi
11 Pressure test complete and attached chart complete
Comments:

Company
Name
Signature
Date
Re-Instatement Certificate P07-A Sheet 1 of 1

INFORMATION
Flushing and Hydrostatic testing have been satisfactorily completed and recorded, Check
2
drying of lines complete.
Check Gaskets are the correct type, size and pressure rating and have been installed
3
correctly.
Check Bolts are the correct type, size and pressure rating and have been
4
torqued/tensioned to the correct specification.
5 All vents and drains are correctly installed.
All temporary spades, bobbins, vents and drains have been removed, and openings
6
closed in accordance with specification
Support Gags removed where applicable (it may be required to leave some in place for
7
removal offshore)
Ensure all Valves are the correct bore i.e. Reduced bore/Full bore and Long pattern as per
8
project specification.
9 Ensure all Valves are of the correct material.
10 All process blinds and spades have correctly installed as indicated on P&ID.
11 Spectacle blinds are in the correct position as indicated on P&ID.
12 Extended spindles and chain wheels for specified valves have been correctly installed
13 All locking devices and interlocks for specified valves have been correctly installed.
Correct installation of all Piping, Instruments and Mechanical equipment in accordance
14
with the Isometrics and P&ID's.
15 All outstanding Piping Punchlist items have been transferred to the Master Punchlist.
Comments:-

Company
Name
Signature
Date

135355-04-Pro-02-005 - Rev 01 - Hydrotest Procedure For Station Piping

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THAI BINH – HAM RONG GAS DISTRIBUTION AND GATHERING SYSTEM

PROJECT, BLOCK 102 & 106 - PHASE 1

HYDROTEST PROCEDURE FOR

Project No.: 135355

01 09-12-14 Issued for Construction PNT NTT NVD

HYDROTEST PROCEDURE FOR

Rev Date Page Contents Remark

00 27 Oct 2014 All Issued for Review/Comment

01 09 Dec 2014 6 Add “risk assessment”

8 Add “”test pressure”

Document No.: 135355-04-PRO-02-005 Rev. 01

HYDROTEST PROCEDURE FOR

Document No.: 135355-04-PRO-02-005 Rev. 01

HYDROTEST PROCEDURE FOR

- Tie-in point for LNG exports FPSO in the future.

HYDROTEST PROCEDURE FOR

 Approximately 13.1 km from 102 - TB -1X to LFP at Con Vanh

Document No.: 135355-04-PRO-02-005 Rev. 01

HYDROTEST PROCEDURE FOR

Document No.: 135355-04-PRO-02-005 Rev. 01

HYDROTEST PROCEDURE FOR

Document No.: 135355-04-PRO-02-005 Rev. 01

HYDROTEST PROCEDURE FOR

Document No.: 135355-04-PRO-02-005 Rev. 01

HYDROTEST PROCEDURE FOR

HYDROTEST PROCEDURE FOR

7.0 SPECIAL REQUIREMENT

Document No.: 135355-04-PRO-02-005 Rev. 01

REQUEST FOR FLUSHING & PRESSURE TESTING

THAI BINH – HAM RONG GAS DISTRIBUTION

ISSUED BY: RECEIVED BY: ACKNOWLEDGED BY:

PROJECT : THAI BINH – HAM RONG GAS DISTRIBUTION AND

TEST PACKAGE No. :

1. Request for Flushing & Hydro-testing  

00 09-Oct-2014 Issued for Review NVT NTT NVD

Piping Test Pack Acceptance Certificate P01-A Sheet 1 of 1

2 Attach a Mark-up P&ID showing the test boundaries.

Completed By Approved By Verified By Accepted By

Test Pack LINE LIST P02-A Sheet 1 of 1

Item Pipeline Sheet Rev Area P&ID No Sheet Rev

Completed By Approved By Verified By Accepted By

Pre-Test Check Sheet P03-A Sheet 1 of 1

Completed By Approved By Verified By Accepted By

Completed by Approved by Accepted/Noted by

Flushing Certificate P05-A Sheet 1 of 1

System :Piping Description Piping at GDC

Loop No. :N/A

2 Equipment bypassed and blinded

3 Valve status in accordance with flushing and testing procedure

4 Flushing medium used

7 Flushing result acceptance - All piping cleared of debris

Completed By Approved By Verified By Accepted By

Pressure Test Certificate P06-A Sheet 1 of 1

INSPECTION/TEST OK N/A P/L No

Test Medium: Water

Test Pressure: xxx Psi

11 Pressure test complete and attached chart complete

Completed By Approved By Verified By Accepted By

Re-Instatement Certificate P07-A Sheet 1 of 1

Completed By Approved By Verified By Accepted By

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