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HYDROTESTING OF RTR PIPES
DOCUMENT: SA-JER-DSAAA-TRJR-509140 REV. 020 DATE: 59-Sept-10

HYDROTESTING OF RTR PIPES

REVISION CONTROL PAGE

MAIN DOCUMENT
REV. DATE DESCRIPTION COMMENTS
00 5-Sept-10 Issued for acceptance Formatted: Font: 10 pt
01 6-Sept-10 Issued for acceptance General Formatted
02 9-sept-10 Issued for acceptance General
Formatted: Font: 10 pt
Formatted: Font: 10 pt
Formatted: Font: 10 pt
Formatted: Font: 10 pt

Document Class: 1

PREPARED BY REVISED BY APPROVED BY TRG APPROVED BY SATORP

NAME Karthik R Selvan C.Bedoya Mukesh Yadav
SIGNATURE

DATE
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HYDROTESTING OF RTR PIPES
DOCUMENT: SA-JER-DSAAA-TRJR-509140 REV. 020 DATE: 59-Sept-10

TABLE OF CONTENTS

1. SCOPE

2. PURPOSE

3. REFERENCES

4. DEFINITIONS

5. RESPONSIBILITIES

6. TEST PREPARATION

7. REQUIREMENTS FOR TEST MANIFOLDS

8. HYDROTESTING

9. SAFETY

10. INSPECTION

11. DOCUMENTATION
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HYDROTESTING OF RTR PIPES
DOCUMENT: SA-JER-DSAAA-TRJR-509140 REV. 020 DATE: 59-Sept-10

1. SCOPE

To establish guidelines for Hydrotesting Reinforced Thermosetting Epoxy-Resin pipes for

Jubail Export Refinery Project.

2. PURPOSE

This procedure is made to enumerate the procedure for Hydrotesting Reinforced

Thermosetting Epoxy-Resin pipes for Jubail Export Refinery Project.

3. REFERENCES

3.1 SATORP STANDARDS

 JERES-S-070- Installation of Utility Piping Systems.

 JERES-A-004- General Requirements for Pressure testing.

3.2 CONTRACTOR Project Procedures

 SA-JER-DSAAA-TRJR-501403 Site Qualtiy Plan

 SA-JER-DSAAA-TRJR-501405 Format for Inspection Logbook and reports
 SA-JER-DSAAA-TRJR-501407 Non-Conformance Procedure
 SA-JER-DSAAA-TRJR-501502 Construction Environmental Management Plan
 SA-JER-DSAAA-TRJR-509004 Reception,Protection and Storage

3.3 Industry codes and standards

 ASTM D4024 – Reinforced Thermosetting Resin Flanges.
 ASTM D3839 – Standard practice for underground installation of RTR.
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HYDROTESTING OF RTR PIPES
DOCUMENT: SA-JER-DSAAA-TRJR-509140 REV. 020 DATE: 59-Sept-10

4. DEFINITIONS

COMPANY SATORP (JV between Saudi ARAMCO and TOTAL)

CONTRACTOR Técnicas Reunidas. TRJR (Técnicas Reunidas Jubail Refinery), OOK entity
and TRG (Tecnicas Reunidas Gulf), IK entity.
Subcontractor Authorized enterprise/s to carryout construction activities on behalf of
Contractor

5. PROCEDURES

5.1 RESPONSIBILITIES

5.1.1 Site Manager shall be responsible for the overall implementation of the company
safety & Quality plan and ensure efficient execution of works in accordance with
project specifications.
5.1.2 QA/QC Manager shall oversee all the activities, whether all are executed as per
the quality plan and project specifications.
5.1.3 Construction Manager shall be responsible to give correct instructions to
supervisor for Implementing the project quality and safety plan.
5.1.4 Supervisor shall monitor the execution of all works. Foreman shall lead the work
force and workmanship during the execution of the work.
5.1.5 QC Supervisor shall ensure that all records pertaining to the particular works are
maintained and accepted by TRGC/SATORP.
5.1.6 QC Inspector shall ensure that all works are carried out as per IFC Drawings,
project specifications and standards and he has to co-ordinate with
TRGC/SATORP QC Inspectors for inspection.

6. TEST PREPARATION
a) Soft seated valves and control valves shall not be installed until after the lines have been
thoroughly flushed.
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Formatted: List Paragraph, Indent: Left: 1.25"

b) Pressure gauges and pressure recorders shall be calibrated before the tests.

a) The calibration interval shall not exceed one (1) month. Calibration certificates shall
be made available to Inspection personnel prior to commencement of the pressure test.
Stickers shall be applied indicating the latest calibration date.
b) All gauges shall have a range such that the test pressure is within 30 to 80% of the full
range.
c) A minimum of two pressure gauges are required for the test system. One pressure
gauge shall be on the test manifold and the other(s) on the test system. Their accuracy
shall be within 5% of one another.
d) When large systems are tested, Inspection personnel will determine the need for
additional gauges.
e) Recording gauges shall be used where it is necessary to keep a permanent record, e.g.,
when the test duration exceeds four hours, or otherwise as required by this standard.
cc) A Stress Analysis shall be performed in cases where thrust blocks are intended to be omitted.
Ensure that all pipe supports are provided in each change of direction during testing of
pressurized RTR pipes. A thrust resistance shall be provided prior to hydrostatic testing by
temporary wooden supports. Alternatively, the Contractor may choose to place concrete thrust
blocks before hydrotest at the risk of having to remove and replace any thrust blocks on leaking
components.
d
d) Vents shall be provided at all high points in the tested system as needed.
e) Drains shall be provided at all low points in the system and immediately above check valves in
vertical lines.
f) Relief valve(s) of adequate capacity set to relieve at 5% above the hydrotest pressure shall be
installed. Sizing of these relief valves used for testing shall follow the requirements of API RP
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520, Part 1. The relief valve(s) shall be tested, dated, and tagged within one week prior to the
hydrotest for new construction projects, and within one month for maintenance operations.

7. REQUIREMENTS FOR TEST MANIFOLDS

a) Calibration of test manifolds shall not exceed 6 months.

a)b) An isolation valve shall be provided between the pressure testing manifold and the
system being tested. The isolation valve shall be rated for the manifold test pressure when in the
closed position.

c) Before employing the pressure testing manifold in the actual system pressure test, it shall be
separately pressure tested to at least 1.2 times the system test pressure but not less than the
discharge pressure of the pump used for the pressure testing.

d) Test fluid shall be filled by using the manifold, temporary piping / Hose at lowest point of the
system and vented of the highest point of the system to minimize the entrapped air as far as
possible. All vent valves shall be opened during filling till system is free from air, verified by
water spouting from the vent.
e) The pressure shall be built-up gradually. To ensure the applied pressure inside the test package
never exceeds the desired pressure, a calibrated safety relief valve shall be provided in the
manifold.
f) In the event of leakage, the manifold will be depressurized. Repair will be executed and the test
will be repeated until no leakage is observed.

8. HYDROTESTING
1) Unless prevailing conditions or regulations require full backfilling of the piping prior to the
hydrotest, underground piping shall be partially backfilled with all joints exposed during the
hydrotest. The exposed joints shall be shaded from direct sunlight, and the hydrotest shall be
performed so that the temperature of the thermoplastic piping material or the temperature of the
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test water does not exceed 40°C during the test period. If the test water is not available at or
below 40°C, the resulting hydrostatic test pressure shall be calculated at the available test water
temperature in accordance with the respective ASTM standards.

2) Hydrostatic testing fluids shall be as follows:

a) Potable water (drinking water and raw water) piping systems shall be hydrotested with
fresh potable water.
3) No adhesive-bonded RTR piping shall be pressurized until it has cured in accordance with the
manufacturer's instructions. Formatted: Font color: Text 1

1) 4) No thermoplastic piping shall be pressurized until it has cured for 24 hours at a surface Formatted: Normal, No bullets or numbering

temperature of 10°C or higher, or for 48 hours at a surface temperature below 10°C. Formatted: Font color: Auto

2)5) The test pump shall be placed on firm ground away from the piping. The pump and the Formatted: Numbered + Level: 1 + Numbering Style: 1, 2,
3, … + Start at: 5 + Alignment: Left + Aligned at: 0.25" +
piping system (piping and equipment) shall be protected from over-pressure by relief valve(s) of Indent at: 0.5"

adequate capacity set at 5% above the test pressure or a maximum of 170 kPa (25 psig) above the
test pressure for pressure piping systems. The relief valve(s) shall be tested, dated, and tagged
within one week prior to the test.
5)6) Calibrated and tagged relief valve(s) may be used as the pressure test instrument upon
written approval of the Company Inspector.
3)7) Gravity sewers shall be tested from manhole to manhole, or manhole to sump inlet. Formatted: Numbered + Level: 1 + Numbering Style: 1, 2,
3, … + Start at: 5 + Alignment: Left + Aligned at: 0.25" +
The upstream manhole may be tested at the same time. Indent at: 0.5"

4)8) Lines whose joints have been backfilled shall be tested at the recommended pressures for Formatted: Numbered + Level: 1 + Numbering Style: 1, 2,
3, … + Start at: 5 + Alignment: Left + Aligned at: 0.25" +
24 hours. Lines whose joints have not been backfilled or are above ground shall be tested at the Indent at: 0.5"

following pressures for 4 hours.

a) Dedicated firewater systems shall withstand a minimum working pressure of not less
than 1026 kPa (175 psi).
b) Irrigation piping downstream of the pressure-reducing valve and/or backflow
preventor: 690 kPa (100 psig).
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c) Water distribution piping network and fire hydrants connected thereto: 1035 kPa (150 psig) or
345 kPa (50 psig) above the maximum operating pressure, whichever is greater.

d) Sanitary sewer and storm water force mains: 1035 kPa (150 psig) or 345 kPa (50 psig) above
the pump shut-off head, whichever is greater.
e) Gravity sanitary sewer pipe tested separately: a column of water equivalent to the rim
elevation of the upstream manhole.
f) All water and sewage retaining structures under atmospheric pressure such as tanks / holding
tanks, manholes, sumps, catch basins, interceptors, lift stations, grease-traps etc may be
tested separately, or a part of the piping system test: filled to top of rim with water for 18
hours, then topped off to top of rim. Site testing shall take place prior to backfill and / or
application of protective coatings.
g) Gravity storm water sewers and manholes not a part of an oily water sewer system: none,
unless called for in the project specifications.

9. SAFETY
a) Subcontractor Safety Supervisor shall carry out the safety site inspections to ensure that safety
requirements laid out in the safe work plan are followed during the testing.
b) Subcontractor Safety Manager / Supervisor shall review Safety Action Plan and secure work
Permit if necessary prior to start of any activities Job safety analysis will be strictly followed as
per attachment.
c) Equipment, tools and materials inspection. All equipments for testing shall have to be inspected
by Subcontractor Safety Manager / Supervisor prior to forwarding to TR Safety Department
inspection prior to use at site to ensure their safe worthiness at work. The inspection reports shall
be kept for record.

10. INSPECTION
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a) The QC inspector of Subcontractor, TRGC & SATORP representative shall carry out the
necessary test & inspection in various stages of the work including the excavation and
compaction work. Inspection shall be based on approved ITP, QC plan and project specifications
listed under technical specification of this statement.
b) Request for Inspection

Request for inspection shall be issued for witness and hold points to CONTRACTOR/
SATORP Project inspection 24 hour in advance on week days and 48 hours in advance for
weekends and holidays.
c) During hydrotest, all exposed pipe, joints, fittings, valves, and hydrants shall be carefully
examined for leakage.
d) Leaking pipes, joints, and fittings shall be replaced.
e) The hydrostatic test shall be repeated after the repair of any defects until the system is proved
satisfactory.
f) The piping shall be satisfactory if there is no evidence of leakage or pressure loss after the
specified test period.

11. DOCUMENTATION

Based on the approved ITP Subcontractor shall prepare and forward all necessary
checklists, test reports, laboratory results, etc., for CONTRACTOR/COMPANY review/
approval.

A log shall be maintained for retrieving Inspection documents easily for reference during
the course of the project.

Signed/completed documents shall be kept in safe custody and hand over in approved
format/folders as part of Project Record Books, as required by contract.