Subsea

Ver. Status Issue date Made by Checked by Approved by

00 Issued for IDC 2009.10.01 BABU, BASKAR

Originator: BEKKEN, TORE

FAT PROCEDURE XMT ASSEMBLY

GAS TEST & HYDROSTATICAL TEST

10000836407-PDC-000

This document contains Aker Subsea legal entity proprietary and confidential information that is legally privileged and is intended only
for the person or entity to which it is addressed and any unauthorised use is strictly prohibited. It is provided for limited purpose and
shall not be reproduced, stored electronically, transferred to other documents, disseminated or disclosed to any third parties without
the prior written consent of the relevant Aker Subsea legal entity. Any attachments are subject to the specific restrictions and
confidentiality regulations stated therein and shall be treated accordingly. The document is to be returned upon request and in all
events upon completion of use for which it was provided.
 Document: 10000836407-PDC-000
FAT PROCEDURE XMT ASSEMBLY Version: 00 - Issued for IDC
GAS TEST & HYDROSTATICAL TEST Issue date: 2009.10.01
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TABLE OF CONTENTS
1. INTRODUCTION ............................................................................................................................. 3
1.1. Purpose ........................................................................................................................................... 3
1.2. Health, Safety and Environment (HSE) ........................................................................................... 4
1.3. Required documentation.................................................................................................................. 5
1.4. Abbreviations ................................................................................................................................... 5

2. PRE-TEST PREPARATION............................................................................................................ 6
2.1. General Acceptance criteria for pressure testing ............................................................................ 6
2.1.1. Pressure test documentation........................................................................................................... 6
2.2. Project Requirement ........................................................................................................................ 6
2.3. Test equipment list........................................................................................................................... 7
2.4. Test fluid .......................................................................................................................................... 7
2.5. Identification..................................................................................... Error! Bookmark not defined.

3. HYDROSTATIC PRESSURE TEST................................................................................................ 8

3.1. Preparations .................................................................................................................................... 8
3.2. XMT valve status during hydrostatic pressure test.......................................................................... 9
3.3. Test execution ............................................................................................................................... 10

4. GAS PRESSURE TEST ................................................................................................................ 11

4.1. Purpose ......................................................................................................................................... 11
4.2. Preparations .................................................................................................................................. 11
4.3. XMT valve status during gas test .................................................................................................. 12
4.4. Test execution ............................................................................................................................... 13
4.4.1. Gas test execution table ................................................................................................................ 14

5. RE-TEST ....................................................................................................................................... 15

6. APPROVAL................................................................................................................................... 16

7. DISCREPANCY LOG.................................................................................................................... 17
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FAT PROCEDURE XMT ASSEMBLY Version: 00 - Issued for IDC
GAS TEST & HYDROSTATICAL TEST Issue date: 2009.10.01
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1. INTRODUCTION
Each XMT has a unique build number. Fill in the serial number for the XMT in question.

XMT serial number:

1.1. Purpose
The purpose of this document is to ensure correct performance factory acceptance test (FAT) of
the XMT assembly.

The purpose of the FAT is to ensure pressure integrity of the fully assembled XMT. We will
perform two tests.

1. Hydrostatic pressure test with all valves in open position

2. Gas static pressure test with all valves in open position

This FAT, when referenced in combination with other FAT’s, is intended to satisfy, as a
minimum, the performance requirements of ISO 13628-4 and ISO 10423.
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FAT PROCEDURE XMT ASSEMBLY Version: 00 - Issued for IDC
GAS TEST & HYDROSTATICAL TEST Issue date: 2009.10.01
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1.2. Health, Safety and Environment (HSE)

Safety must always be addressed when performing tests and high risk work operation in the
project. Safety activities shall as a minimum be performed according to the table below.

Authorities prior
study

to test or work
prior to test or
Toolbox meeting

work operation

work operation
prior to test or
procedure

personnel
Example of Test or work operation

operation
Category

Consider

Consider
notifying
moving
SAFOP
SJA on
Liquid test. High pressure.
1. Production- and Annulus bore X X X
( ≥ 5000 psi / 345 Bar)

Liquid test. Very high pressure.

2. Production- and Annulus bore X X X X
( ≥ 10 000 psi / 690 Bar)

Gas test. High pressure.

3. Production- and Annulus bore X X X X X
( ≥ 500 psi / 35 Bar)

Complex and simultaneous work

operations i.e.
ƒ Work operations unfamiliar to
4. operators X X X
ƒ Complicated lifting
ƒ Simultaneous lifting and working on
equipment

5. Heavy lifting operations > 10 ton X X X

6. Work with high voltage > 1kV X X X

7. High temperature > 50 deg C X X X

Table: HSE requirement matrix

For all safety matters, reference is made to the procedure HSE Requirements for High Risk
Operations (see table below).

Prior to testing both a SAFOP and a Safe Job Analysis (SJA) shall be performed. The SJA
worksheet shall be available to all personnel and located in the test area during the testing.

When a SAFOP is required, the completed Work Sheet shall be included with the test/operating
procedure. Comments and findings from the SAFOP shall be included as applicable.

The following procedures are applicable to safety during testing and high risk work operations:
Document SAP doc. number
Code of practice for pressure testing global procedure 10000517129
Pressure testing checklist 10000517230
Test procedure guideline 10000106196
Safe operations analysis (SAFOP) 10000106061
Safop work sheet 10000106061
Risk assessment and Job safety analysis (SJA) 10000192087
Table: HSE documents references
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FAT PROCEDURE XMT ASSEMBLY Version: 00 - Issued for IDC
GAS TEST & HYDROSTATICAL TEST Issue date: 2009.10.01
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1.3. Required documentation

The latest version of all documents listed below must be present during the FAT. The responsible
mechanic shall fill in the version numbers and sign before assembly is started.

Document name Document no Ver. Date Signature

XMT GA Drawing 10000784739

XMT Assembly Drawing 10000742171

XMT Hydraulic Schematic 10000724094

XMT Plumbing Schematic 10000775358

SCMMB GA Drawing 10000742580

Test/Flush Kit HCM 12” -5”

10000759653
Assembly Drawing

1.4. Abbreviations
To be found in the HSE folder. Or refer to 10000008969 “Subsea Standard Abbreviations Global
Procedure”.
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GAS TEST & HYDROSTATICAL TEST Issue date: 2009.10.01
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2. PRE-TEST PREPARATION
Before conducting the tests, perform a Safety Job Analysis (SJA) of the tests that are to be
carried out. Thoroughly go through the steps of the test to identify any events that have to be
carried out with greater caution.

At the end of all tests, ensure that there is no trapped pressure anywhere.

2.1. General Acceptance criteria for pressure testing

No bubbles allowed during monitoring hold period. A 5% or 35 bar (500 psi) pressure drop in one
hour (60 minutes), whichever is less, is allowed during the hold period.

That means that the following pressure drop is allowed for other holding periods:

• For 3. minutes holding period 0.25% pressure drop is allowed

• For 15. minutes holding period 1.25% pressure drop is allowed
• For 60. minutes holding period 5% or 35 bar pressure drop is allowed

The test pressure shall be within -0% + 5% of nominal pressure.

2.1.1. Pressure test documentation

All pressure tests shall be documented by chart recorder, unless otherwise is stated. The entire
history from zero pressure and up shall be chart-recorded, i.e. pressurizing, stabilization, test and
bleed off. The charts shall be clearly marked with equipment tag no, test no, date and signature
and be implemented into the relevant part of the step by step procedure. The charts shall be
signed by the Test Operator.

Temperature to be documented on all pressure charts recorded.

2.1.1.1. Pressure test documentation related to gas testing

During gas testing, start the chart recorder after pressure has been build up.

2.2. Project Requirement

Note: Gas test shall be performed with the presence of Client Representative.
Test date need to be informed to client rep. before 5 days.
Check with project engineer or QC lead.
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FAT PROCEDURE XMT ASSEMBLY Version: 00 - Issued for IDC
GAS TEST & HYDROSTATICAL TEST Issue date: 2009.10.01
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2.3. Test equipment list

Make sure all test equipment is fit for purpose. Check that all Autoclave tubing, threads, collars
and fittings have no damage. The test hoses are without damage and are rated for the test
pressure to be used.
This is to ensure that safety during testing is taken care of and that leakage on the test equipment
during testing is prevented.
Record the appropriate serial numbers for the equipment defined below prior to testing.

TEST EQUIPMENT LIST

DESCRIPTION PART NUMBER QTY SERIAL NO

General test equipment:

• Hoses
• Fittings
• HPU with Oceanic HW 443
• Gas booster N/A N/A N/A
• Chart recorder
• ROV
• Camera
• Chinese Fingers

BB11-HS0002-39
XMT Test Skid 1
(or similar)

10014224
X-mas Tree Handling Tool 1
(or similar)

HEX4078-A
H4 Blind Cap 1
(or similar)

BB40-HS0009-76
Volume Displacer 1
(or Similar)

Gasket VGX Seal BB18-HS0020-00 1

Test and Flushing Plate

10081055 1
For SCMMB

14 way Outboard RIMS Test/Flushing

10092469 1
Plate

Tie-In Hub Test/Flush Plate 10082758 1

2.4. Test fluid

Body hydrostatic test shall be performed with Tap Water.
Gas test shall be performed with Nitrogen.
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FAT PROCEDURE XMT ASSEMBLY Version: 00 - Issued for IDC
GAS TEST & HYDROSTATICAL TEST Issue date: 2009.10.01
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3. HYDROSTATIC PRESSURE TEST

The hydrostatic pressure test should be done before the gas test.

NOTE: Perform this test on test stump.

3.1. Preparations
Make sure the following steps are done before and during testing:

Steps Initials

Install XMT on test stump using VGX seal. Isolate pressure in XT Connector
1
Lock (ventilate XT Connector Unlock).

2 Make sure the Hybrid Penetrator is in fully retracted position!

3 Install Volume Displayer.

4 Install SCMMB test & flushing plate.

5 Install RIMS Test & Flushing Plate on ROV Panel.

6 Remove Clamp Connector and install Tie-In Hub Test/Flush Plate.

7 Install H4 blind connector with a VGX seal on top of spool.

8 Set valves in accordance with valve status table in Section 3.2

Connect water pressure hose to production line on XT test skid, SCSSV (1)
9
on SCMMB and AVV (7) on RIMS plate.

10 Fill XMT bore, Meth/Service Lines and CI1 & CI2 with tap water.

11 Close all lines on Tie-In Hub Test/Flush Plate.

12 Unlock High Pressure Test Cap and set on tree.

Vent High Pressure Test Cap Unlock function and apply pressure to lock
function.
13
_________________
Record stroke length:
mm

14 Isolate pressure in Lock and maintain pressure during duration of test.

Preparations successfully completed

15
Date and signature:
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FAT PROCEDURE XMT ASSEMBLY Version: 00 - Issued for IDC
GAS TEST & HYDROSTATICAL TEST Issue date: 2009.10.01
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3.2. XMT valve status during hydrostatic pressure test

Configure the valves on the XMT according to table below:

Valve Type Operation Status Initials

PMV Gate 5 1/8” Hydraulic / SCM Open

PWV Gate 5 1/8” Hydraulic / SCM Open

XOV Gate 2 1/16” Hydraulic / SCM Open

ACV Gate 2 1/16” Hydraulic / SCM Open

AWV Gate 2 1/16” Hydraulic / SCM Open

AMV Gate 2 1/16” Hydraulic / SCM Open

MIV 1” Gate Hyd/Manual ROV / Manual Open

CIV 1 1/2" Rot Gate Hyd/Manual ROV / Manual Open

CIV 2 1/2" Rot Gate Hyd/Manual ROV / Manual Open

PCV Choke Hydraulic / SCM 50%

THR 1/2" Rot Gate Manual ROV / Manual Open

BMV 1/2" Rot Gate Manual ROV / Manual Open

PBT 1/2" Rot Gate Manual ROV / Manual Open

DH CIV 1/2" Rot Gate Hyd/Manual ROV / Manual Open

DH CIIV 1/2" Rot Gate Manual ROV / Manual Open

SCSSV 1/2" Rot Gate Manual ROV / Manual Open

AVV 1/2" Rot Gate Manual ROV / Manual Open

VXT 1/2" Rot Gate Manual ROV / Manual Open

Performed as described above:

Date and signature:

 Document: 10000836407-PDC-000
FAT PROCEDURE XMT ASSEMBLY Version: 00 - Issued for IDC
GAS TEST & HYDROSTATICAL TEST Issue date: 2009.10.01
Page: 10 of 17

3.3. Test execution

Acceptance criteria:
• No visible leakage during hydrostatic pressure test.
• 5% pressure drop per hour acceptable during testing or 34.5 bar whichever is less:
o For 3 minutes holding period at 690 bar, 1.7 bar pressure drop allowed.
o For 15 minutes holding period at 690 bar, 8.6 bar pressure drop allowed.

Steps Initials

1 Start chart recorder.

Slowly start to apply hydro pressure in steps through AVV line 7 on RIMS test
2 & flush plate up to test pressure 690 bar (10 000 psi). Production line on test
skid to be isolated. Allow pressure to stabilise.

Test: 3 min hydrostatic pressure test

Test medium: Water
Pressure: 690 bar (10 000 psi)
Chart time: 3 min
3
Chart record: Beginning pressure [bar] ____________________

Ending pressure [bar] ____________________

Date and signature:

4 Bleed down to 0 bar

Slowly start to apply hydro pressure in steps through AVV line 7 on RIMS test
5 & flushing plate up to test pressure 690 bar (10 000 psi). Production line on
test skid to be isolated. Allow pressure to stabilise.

Test: 15 min hydrostatic pressure test

Test medium: Water
Pressure: 690 bar (10 000 psi)
Chart time: 15 min
6
Chart record: Beginning pressure [bar] ____________________

Ending pressure [bar] ____________________

Date and signature

7 Bleed down to 0 bar

8 Completely drain all water from XMT. Use compressed air if necessary.

Hydrostatic pressure test successfully completed

9
Date and signature:
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FAT PROCEDURE XMT ASSEMBLY Version: 00 - Issued for IDC
GAS TEST & HYDROSTATICAL TEST Issue date: 2009.10.01
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4. GAS PRESSURE TEST

4.1. Purpose
This test is to ensure gas pressure integrity of the fully assembled XT.

Note: Test to be performed on test stump fully submerged in water.

4.2. Preparations
Make sure the following steps are done before and during testing:

Steps Initials

Verify that the hydrostatic test is successfully completed. Purge water out of
1
lines before gas test is started.

2 The test setup shall be set up accordance to chapter 3.1, step 1-7

Connect Gas pressure hose to production line on XT test skid, SCSSV (1) on
3
SCMMB and AVV (7) on RIMS plate.

4 Set valves in accordance with valve status table in Section 4.34.3

5 Close all lines on Tie-In Hub Test/Flush Plate.

Preparations successfully completed

6
Date and signature:
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FAT PROCEDURE XMT ASSEMBLY Version: 00 - Issued for IDC
GAS TEST & HYDROSTATICAL TEST Issue date: 2009.10.01
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4.3. XMT valve status during gas test

Configure the valves on the XMT according to table below:

IMPORTANT: All valves that are stated to be in open position shall only be partially open.

Valve Type Operation Status Initials

PMV Gate 5 1/8” Hydraulic / SCM Open

PWV Gate 5 1/8” Hydraulic / SCM Open

XOV Gate 2 1/16” Hydraulic / SCM Open

ACV Gate 2 1/16” Hydraulic / SCM Open

AWV Gate 2 1/16” Hydraulic / SCM Open

AMV Gate 2 1/16” Hydraulic / SCM Open

MIV 1” Gate Hyd/Manual ROV / Manual Open

CIV 1 1/2" Rot Gate Hyd/Manual ROV / Manual Open

CIV 2 1/2" Rot Gate Hyd/Manual ROV / Manual Open

PCV Choke Hydraulic / SCM 50% Open

THR 1/2" Rot Gate Manual ROV / Manual Open

BMV 1/2" Rot Gate Manual ROV / Manual Open

PBT 1/2" Rot Gate Manual ROV / Manual Open

DH CIV 1/2" Rot Gate Hyd/Manual ROV / Manual Open

DH CIIV 1/2" Rot Gate Manual ROV / Manual Open

SCSSV 1/2" Rot Gate Manual ROV / Manual Open

AVV 1/2" Rot Gate Manual ROV / Manual Open

VXT 1/2" Rot Gate Manual ROV / Manual Open

Performed as described above:

Date and signature:

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FAT PROCEDURE XMT ASSEMBLY Version: 00 - Issued for IDC
GAS TEST & HYDROSTATICAL TEST Issue date: 2009.10.01
Page: 13 of 17

4.4. Test execution

The test pressure shall be held for minimum 60 minutes without GAS leakage from any
component, line or joints.
Acceptance criteria:
• No visible Gas leakage during gas test.
• 5% pressure drop per hour acceptable during testing or 34.5 bar whichever is less:
o For 60 minutes holding period at 690 bar, 34.5 bar pressure drop allowed.
o For 60 minutes holding period at 20 bar, 1 bar pressure drop allowed.
Steps Initials

1 Verify that XMT is fully submerged in water (above the H4 test connector)

2 Slowly start to apply gas pressure in steps up to test pressure 690 bar (10 000 psi).

3 Stabilise pressure and start chart recorder.

4 Hold 690 bar pressure for 60 minutes. Fill in table in Section 4.4.1

WARNING: Valves must be cycled one at a time!

5
NOTE: Bubbles might occur during full stroke of valve.

6 Cycle PMV to close position and then back to open position.

7 Cycle PWV to close position and then back to open position.

8 Cycle AWV to close position and then back to open position.

9 Cycle ACV to close position and then back to open position.

10 Cycle AMV to close position and then back to open position.

11 Cycle XOV to close position and then back to open position.

12 Verify that valve stems do not have leakage after being cycled.

13 Verify pressure is at 690 and top up if necessary.

14 Bleed down gas pressure to 0 bar

15 Slowly start to apply gas pressure in steps up to test pressure 20 bar (290 psi).

16 Stabilise pressure and start chart recorder.

17 Hold 20 bar pressure for 60 minutes. Fill in table in Section 4.4.1

18 Repeat steps 6 – 12 and fill in the results in table in Section 4.4.

19 Bleed down gas pressure to 0 bar and sign charts.

Carefully open one of the following lines on RIMS Test & Flushing Plate: VXT (line 2),
20
AVV (line 7) or ACV (line 14).

21 Cycle all valves release trapped gas pressure.

1 hour gas test successfully completed

22
Date and signature:
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FAT PROCEDURE XMT ASSEMBLY Version: 00 - Issued for IDC
GAS TEST & HYDROSTATICAL TEST Issue date: 2009.10.01
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4.4.1. Gas test execution table

Start pressure Ending pressure
Test Date Signature
[bar] [bar]

Gas pressure test after 1 hr.:

Pressure: 690 bar
Holding time: 60 min
Chart record

Gas pressure test 1 hr.:

Pressure: 20 bar
Holding time: 60 min
Chart record
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FAT PROCEDURE XMT ASSEMBLY Version: 00 - Issued for IDC
GAS TEST & HYDROSTATICAL TEST Issue date: 2009.10.01
Page: 15 of 17

5. RE-TEST
If any leak occurs during hydrostatic testing, please contact support engineer, perform
necessary corrective actions and restart procedure (new copy).

If any leak occurs during gas testing, please contact support engineer, perform necessary
corrective actions and use this re-test plan (copy this page if additional re-tests need to be
performed):

NOTE: Perform re-test in accordance with instructions in above chapter.

NOTE: Bleed pressure after pressure re-test is performed. Attach printout.

Test Start pressure [bar] Ending pressure [bar]

Test: 3 min hydrostatic

pressure test
Test medium: Water
Pressure: 690 bar
Chart time: 3 min

Test: 15 min hydrostatic

pressure test
Test medium: Water
Pressure: 690 bar
Chart time: 15 min

Gas pressure test 1 hr.:

Pressure: 690 bar
Holding time: 60 min
Chart record

Gas pressure test 1 hr.:

Pressure: 20 bar
Holding time: 60 min
Chart record

Re-test successfully completed

Date and signature:

Reason for re-test:

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FAT PROCEDURE XMT ASSEMBLY Version: 00 - Issued for IDC
GAS TEST & HYDROSTATICAL TEST Issue date: 2009.10.01
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6. APPROVAL
Acceptance of FAT

Name Technician

Date and Signature

Name Quality Control

Date and Signature

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FAT PROCEDURE XMT ASSEMBLY Version: 00 - Issued for IDC
GAS TEST & HYDROSTATICAL TEST Issue date: 2009.10.01
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7. DISCREPANCY LOG

NO DISCREPANCY OCCURRED DURING FAT ____________ _______

Technician Date

DISCREPANCY/CORRECTIVE ACTION Technician