BR CDZZZZ Pi Spe 5063 c1

TECHNICAL DOCUMENTATION FRONT SHEET
BP EXPLORATION (SHAH DENIZ) LTD

AND
AZERBAIJAN INTERNATIONAL
OPERATING COMPANY
AZERBAIJAN DEVELOPMENTS
Specification for Pressure testing and flushing of Pipework
C1
13/02/12
Approved for Construction
JG
IKB
AD
JS
EAA
D1
07/01/09
Approved for Design
JG
IKB
GC
PR
EA
Rev
Date
Prepared
Checked
Approved
Disc.
Eng.
Disc.
Lead
Contr.
Rep
Reason for Issue
Notes:
Prepared
Reviewed
Approved
Author
Disc
SPA
KBR
BP/AIOC
Category
NOTICE: These materials are the Work

Product of KBR, and no reliance on this work
product is authorised by KBR, and KBR
accepts no liability for any reliance by any
person on the work product contained herein.
BP has expressly authorised KBR to issue this
disclaimer.
This document shall not be reproduced without
permission of AIOC and BP Exploration (Shah
Deniz) Ltd
Code
Location Code
CDZZZZ
Document Type
SPE
System Number
00
Description
Common Document, non-specific
Specification
General
Company
Location
Code
Disc
Doc.
Type
Sequence
No.
Rev.
BR
CDZZZZ
PI
SPE
5063
C1
Page 1 of 25
BR-CDZZZZ-PI-SPE-5063
TECHNICAL DOCUMENTATION FRONT SHEET

Total pages: 1
AzSPU MAJOR PROJECTS

Advised Changes Listing
Changes to be Applied to
Document Title: Specification for Pressure testing and flushing of Pipework
Document Number: BR-CDZZZZ-PI-SPE-0063
1. Section 1.0; Revised for consistency with other specifications

2. Section 2.0; Update reference titles.
3. Section 4.2.5; Include pressure gauges, relief valves and turbine meters.
4. Section 4.3.12; Detail Flushing discharge area.
5. Section 6.2.6; Add ASME B31.8 reference.
6. Section 6.3.2; Add GRE.
7. Section 6.5.3; Replace heavy with pooled when referencing water.
8. Section 6.5.9; Define threaded and plugged drain connection dependant on size.
9. Appendix B; Add Firewater service
10. Appendix B; Add flushing medium for GW and VA services
11. Appendix D; Remove separate references to ACG and Shah Deniz and consolidate.
Note
This sheet is a record of changes agreed by KBR and BP/AIOC made to revision C6 of BRCDZZZZ-PI-SPE-0063 which was renumbered as BR-CDZZZZ-PI-SPE-5063 at Revison D1
C6
C5
Rev
24/09/08
20/08/08
Date
For Construction
For Project Spec Update
Reason for Issue
JG
JG
Prepared
IKB
IKB
Checked
AZP
MC
Approved
Disc. Eng.
Disc. Lead
PE
Kellogg Brown & Root
Prepared
FH
FH
Approved
EA
EA
Approved
TA
BP TA
BP EA
AzSPU MAJOR
PROJECTS
Page 2 of 25
Revision History and Hold Record

Revision History
Date
Rev.
No.
07.01.09
D1
13.02.12
C1
Detailed Description of Change
Front sheet and format brought up to date.

Note added to Advised Changes Listing.
Revision History and Hold Record added
Issued for Construction
AzSPU changed to Azerbaijan Developments
Golden Welds explanation added
Bold format to highlight statement.
Appendix D Test Pressure data revised to line list test pressure
Ref.
Section
6.2.4
6.3.1
App D
Hold Record
Hold Ref.
Description / Reason for Hold
Ref.
Section
Page 3 of 25
Table of Contents
1
SCOPE ..................................................................................................................................................5
1.1
GENERAL..............................................................................................................................................5
CODES AND STANDARDS ..................................................................................................................5
SAFETY .................................................................................................................................................5
REQUIREMENTS ..................................................................................................................................6
4.1
4.2
4.3
4.4
GENERAL..............................................................................................................................................6
IN-LINE EQUIPMENT PHILOSOPHY ..........................................................................................................6
FLUSHING REQUIREMENTS ....................................................................................................................7
PRESSURE TESTING REQUIREMENTS......................................................................................................8
FLUSHING PROCEDURES ..................................................................................................................9
5.1
6
GENERAL..............................................................................................................................................9
PRESSURE TESTING PROCEDURES ............................................................................................. 10
6.1
6.2
6.3
6.4
6.5
6.6
6.7
TEST PRESSURES .............................................................................................................................. 10

HYDROSTATIC TESTING ...................................................................................................................... 10
PNEUMATIC TESTING .......................................................................................................................... 11
LINE SERVICE FLUID TESTING ............................................................................................................. 12
SYSTEM REINSTATEMENT ................................................................................................................... 12
LEAK TEST......................................................................................................................................... 13
SYSTEM OR PART SYSTEM MECHANICAL ACCEPTANCE ......................................................................... 13
APPENDICES ..................................................................................................................................... 13
A.
TYPICAL PIPE TEST RECORD ........................................................................................................ 14
B.
FLUSHING & TESTING MEDIUMS ................................................................................................... 15
C.
TYPICAL FLUSHING TESTING AND PRESERVATION OF PIPING SYSTEMS ............................ 18
D.
PIPING SPECIFICATION HYDROSTATIC TEST PRESSURES ...................................................... 19
E.
CERTIFICATION ................................................................................................................................ 20
Page 4 of 25
1 SCOPE
This specification defines the general principals and procedures that shall be adopted for
testing and flushing prefabricated spools and piping systems designated for installation on
the Azerbaijan Developments use in the Caspian Sea Area.
This specification document (Site Technical Practice, STP) replaces the following
Engineering Technical Practice (ETP) documents for the Azerbaijan Developments
Performance Unit :None.
1.1
General
The scope of this specification excludes the testing of the following: Instrumentation piping downstream of first piping valve.
Risers up to isolation valve flanges.
Package equipment.
Sub-sea pipework.
Testing and flushing procedures may be amended to suit local or special conditions
2 CODES AND STANDARDS

All piping systems shall have been designed and shall be tested in accordance with the
requirements of:
Document Number
Document Title
ASME B31.3-2006
Process Piping
ASME B31.4-2006
Pipeline Transportation System for Liquid Hydrocarbons

and other Liquids
ASME B31.8-2007
Gas Transmission and Distribution Piping Systems
AWWA M55
PE Pipes Design and Installation
NFPA 24
Private fire service mains and their appurtenance
UKOOA
Specification and recommended practice for the use of

GRP Piping offshore
3 SAFETY
During flushing and testing, local safety rules and regulations shall be observed at all
times.
Safety of personnel shall be the highest priority. All safety standards shall be adhered to
at all times.
During pressure testing an exclusion zone shall be marked out with plastic tape and
warning notices displayed announcing that Pressure Testing is being undertaken. Only
personnel that are directly involved in the testing procedure shall be allowed inside the
exclusion zone and only when absolutely necessary. The Site Piping Engineer in
consultation with the Site Safety Officer shall determine the exclusion zone. The Testing
Contractor shall ensure that only competent personnel are involved in the hydrotesting
process. Testing should be co-ordinated with regard to other construction activities.
Page 5 of 25
All personnel directly involved with Pressure Testing will attend a Task Risk Assessment
meeting prior to testing commencing.
Consideration shall be given to additional loadings on piperacks imposed by weight of
hydrotest water. Where necessary, only one line to be tested at any one time on
piperacks.
4 REQUIREMENTS
4.1
General
4.1.1 The Fabricators Piping Engineer shall give the Project sufficient notice of the
intention to test a specific system. The definition of sufficient notice shall be agreed
with the Company at site.
4.1.2 The Fabricator shall submit a copy of the test package and attachments for Project
Review and approval, a minimum of 10 days in advance of testing.
4.1.3 The test package file prior to testing shall as a minimum contain: a)
b)
c)
d)
e)
f)
List of lines in package, their service media, test media and test pressures, and
test duration.
Marked up P&ID showing limits of testing
Test Piping Isometric
Welding, heat treatment and NDE clearance
Line mechanical completion clearance (before testing).
Cleaning and flushing certificate
4.1.4 The following additional documentation shall be added to the test pack after flushing
and testing: a)
b)
c)
d)
Pressure recorder graph trace

Temperature recorder graph trace
Piping test completion /reinstatement certificate.
Calibration certificates for all measuring devices.
4.1.5 The field copy of the test pack shall be retained by the Testing Contractor and
should contain records of any field changes repairs approved material substitutions
and exceptions.
4.1.6 It is the Contractor's responsibility to ensure the correct pressure rating for all
ancillary fittings used (i.e. temporary piping, hoses, and blanks) in order to withstand
the flushing and test pressure.
4.1.7 For systems containing stainless or duplex stainless steel piping or fittings, the
chloride ion content of the flushing and testing water shall be less than 30 p.p.m.
For carbon steel systems the potable water should be free of organic matter.
4.2
In-Line Equipment Philosophy
4.2.1 The overall testing philosophy shall be based as far as practicable on pressure
testing whole systems which have the same design pressure
4.2.2 Pipe spools shall be cleaned post fabrication and shall be kept clean by covering
open ends and flanges.
Page 6 of 25
4.2.3 Mechanical joint quality shall be ensured by protection of flange faces at all times,
correct application of bolt tensioning techniques and elimination of flange
misalignment.
4.2.4 To minimise disruption to the testing procedures it is essential to ensure timely
identification of the number and location of hydrotest vents and drains and the timely
delivery of equipment to avoid post testing re-instatement.
4.2.5 Sensitive instrumentation including but not limited to pressure gauges, pressure
safety valves, thermal relief valves, turbine meters, flowmeters, instrument probes,
plates, rupture discs, spray / deluge nozzles and critical valves as identified on the
P&IDs shall not be included in the flushing and pressure testing of lines but shall be
removed and the pipe ends blinded. Where lines either side of these items are
included in the same test pack, fully rated temporary spools shall be installed to
allow through flushing and testing. Contractor to maintain a record for the removal
and re-instatement of equipment.
4.2.6 All positive displacement meters and their strainers should be removed for flushing
and pressure testing. (Positive displacement meter bodies should be filled with light
oil to prevent corrosion while sitting idle during the flushing/testing period).
4.2.7 Other in-line equipment shall remain in the line, providing that it is capable of
withstanding the line test pressure and shall not suffer damage due to the test media or
pressure.
4.2.8 All in-line hand operated valves shall be in the fully open position during the
pressure test, but not back seated so as to test the valve stem packing. Ball valves
shall be stroked during pressurisation to allow pressure equalisation of the body
cavity, before returning to the fully open position for the duration of the pressure
test. At no time shall the pressure differential between the bore and the cavity
exceed 1.1 x design pressure of the valve.
4.3
Flushing Requirements
4.3.1 All plant items that could be damaged by flushing operations shall not be flushed
through and shall be blanked off, removed from the line, or replaced by a spool. All
strainers shall be removed prior to flushing.
4.3.2 Package units that have been flushed and tested and sealed at the manufacturers
need not be flushed again.
4.3.3 Non return valves (check valves) shall be locked in the open position where
practical or else the valve should be removed. If the valve is to be removed from
the system it shall be replaced with a temporary spool piece. The Contractor shall
maintain a record for the removal and re-instatement of equipment.
4.3.4 All piping and nozzles shall be adequately supported, with all spring or other
variable supports blocked to prevent movement. Temporary supports shall be used
if the supplier deems additional stability necessary.
4.3.5 All deluge, inert gas, CO2, and dry chemical piping shall be flushed out and tested
before installation of the nozzles.
4.3.6 All sprinkler piping shall be flushed out and tested before installation of the sprinkler
heads.
Page 7 of 25
4.3.7 All expansion joints shall be checked for correct installation and proper restraints
fitted.
4.3.8 On piping systems where the flushing medium is water the flow velocities should be
1 to 2 times the normal operating velocity or 3 to 4 m/sec whichever is the greater.
Where flushing velocities cannot be attained the piping shall be high-pressure jet
cleaned.
4.3.9 Flushing below +5C is not acceptable without prior Project approval. If this is
unavoidable then adequate precautions shall be taken to avoid pockets, which could
freeze, and water freezing in the main system.
4.3.10 Flushing water discharges shall be led to suitable adequate drainage systems.
4.3.11 Flushing by means of compressed air, the air shall be dry and oil free with velocities
in excess of 20m/sec.
4.3.12 Flushing air discharge shall be routed to a suitable safe location with regards
personnel protection. The discharge area shall be suitably cordoned off and
identified. The size of the cordoned area shall be discussed and agreed with Site
Piping Engineer in consultation with the Site Safety Officer.
4.3.13 Wherever possible, flushing shall be undertaken during daylight hours and during
dry weather.
4.4
Pressure Testing requirements
4.4.1 It is Company policy to maximize Module completions and onshore hook-ups and
commissioning. Module sub-systems should have been fully tested to module limits
prior to receipt at the module integration yard.
4.4.2 All joints, including welds not previously tested by manufacturers are to be left
accessible, un-insulated and free of dirt, grease and temporary protective coatings.
4.4.3 The Contractor shall prepare piping for inspection and pre-acceptance testing, and
provide all necessary facilities including test equipment.
4.4.4 Pressure gauges used to indicate and record test pressure shall be dead weight tested
for accuracy. Test instrument and gauges should be calibrated prior to use and
thereafter at a frequency of every 5 tests or fortnightly, whichever occurs first, and
witnessed by the Company and Independent Inspection Authority's Inspectors.
4.4.5 A minimum of two gauges shall be used and positioned at the highest and lowest
point in the system. The gauge located at the highest point shall indicate the
required test pressure and a pressure recorder shall record the requisite test
pressure.
4.4.6 Temperature recorders shall be installed for pressure testing.
The ambient
temperature of the pipework shall be recorded continuously and the record chart
shall be included in the test package.
4.4.7 Pressure tests shall not be made against closed block valves. Full pressure rated
blinds shall be used with the valves in the open position.
Page 8 of 25
4.4.8 If testing is carried out through equipment/vessels then all internally housed floats,
vessel internals or other devices, which would be subject to damage shall be
removed.
4.4.9 Pressure testing of systems incorporating check valves shall be carried out in the
preferred direction of flow of the check valve. After pressure testing, care shall be
taken to ensure pipework either side of the check valve is fully depressurised.
Vent/drain connection to be available either side of check valve, to ensure this can
be achieved. The Testing Contractor shall issue a Work Instruction to cover this.
4.4.10 Leak tests may be carried out hydrostatically, pneumatically or by sensitive leak
testing as appropriate to the Construction Methodology and System.
4.4.11 Leak testing to module limits shall be restricted to hydrostatic and pneumatic leak
testing with sensitive leak testing at the Integration yard following hook up of specific
modules and completed systems.
4.4.12 Where possible, all pressure testing involving hydrocarbons and hazardous services
shall be conducted on-shore and that any system be tested once only.
4.4.13 Contractor will provide an isometric drawing showing position and relative elevation
of all blanks, spades, spectacle blinds, valves, vessels, actuators and closures for
testing. The isometric should also show positions of vent and drain points, and
provide system, line, vessel and valve identification. It shall also indicate where
relief valves are due to be removed.
4.4.14 Isometric should also include the position of fill and pressurisation points, test
instruments and any temporary links.
5 FLUSHING PROCEDURES
5.1
General
5.1.1 All piping systems to be pressure tested shall be flushed prior to testing. The
medium used for flushing shall be the same, as that required for the pressure test.
(Except for offshore flushing only where an alternative medium may be used.)
Systems shall be flushed or blown out from the highest points in the system. All
necessary precautions shall be taken to ensure debris is not flushed into associated
equipment or dead ends.
5.1.2 Systems which are open to atmosphere such as vents, open safety valve
discharges, engine exhaust and hose station branches (water and compressed air)
do not require flushing but must be blown down with either air or nitrogen to ensure
that lines are not blocked or restricted.
5.1.3 Flushing medium shall be in accordance with Appendix B.
5.1.4 The location of temporary hose connections into compressed air systems for the
supply of compressed air flushing medium to systems other than compressed air
system shall be determined on site.
5.1.5 Main headers shall be flushed out first and then all the branches, which connect to
any equipment. All necessary precautions shall be taken to ensure that debris is not
flushed into associated equipment or dead ends. The main headers shall be flushed
for not less than 30 minutes and branches for less than 15 minutes.
Page 9 of 25
5.1.6 The contractor shall be responsible for taking all safety precautions during flushing
(e.g. to avoid excessive pressure in the system). Operations shall be carried out in
the presence of and to the Client Representative's satisfaction.
5.1.7
For piping containing check valves, if removed, the valves shall be re-installed into
the line after flushing, fully assembled.
5.1.8 Where lines are broken for flushing, on completion of flushing all broken
connections shall be made up with new gaskets.
5.1.9 Tanks and vessels, into which pipelines have been flushed, shall be drained and
cleaned out following completion of flushing operation.
6 PRESSURE TESTING PROCEDURES

6.1
Test Pressures
6.1.1 The Hydrostatic and Pneumatic test pressures shall be as stated on the line list and
shall be based on the requirements of ASME B31.3, ASME B31.4 and ASME B31.8
as appropriate for piping and piping systems; see APPENDIX D.
6.2
Hydrostatic Testing
6.2.1 Systems, which are, open to atmosphere and not subjected to internal pressure
during operation, shall not be pressure tested, but cleaned and flushed using water
or compressed air.
6.2.2 For testing of systems containing stainless steel/ Duplex piping or fittings, the
chloride ion content of the water shall be less than 30 p.p.m.
6.2.3 Piping Tie-in connection welds do not require hydrotesting, but shall be subjected to
100% NDT. 100% NDT is defined as 100% Radiography/UT + MPI of all accessible
welds, and should be agreed with the Company Site Engineer and recorded in the
test pack.
6.2.4 Golden butt-welds (welds that cannot be pressure tested, but can be subjected to
N.D.E. procedures) shall be agreed by Company.
6.2.5 The system to be tested shall be filled from the lowest point and all vents and other
high point connections, which can serve as vents, shall be open during filling so that
all air is vented prior to applying the test pressure.
6.2.6 The pipe system shall remain pressurised until all joints have been checked for
tightness, but in no case shall duration of the test be less than 30 minutes for ASME
B 31.3 pipework and 24 hours for ASME B31.4 / ASME B31.8 pipework. Suitable
pressure and temperature charts shall be used to record the pressure and
temperature over the test duration.
6.2.7 Precautions must be taken to avoid over pressurising of pipework etc., due to
thermal expansion of the test media, throughout the test period. At no time shall the
pressure be allowed to exceed the prescribed test pressure.
6.2.8 All joints failing to pass the pressure test shall be repaired in accordance with the
Piping Fabrication and Installation Specification and then re-tested.
Page 10 of 25
6.2.9 The test system shall be depressurised by opening the depressurising valve in the
test rig. After depressurisation, all vents and low point drain valves shall be opened
and the system thoroughly drained.
6.2.10 Systems shall be drained (taking care to open the top vents first to avoid any
vacuum condition) and be completely purged of hydrotest water and dried.
6.2.11 When vessels are to be included in the system test, particular care must be taken to
ensure that pressure applied takes due account of the hydrostatic head within the
vessel. Ensure the vessel test pressures (as supplied by the manufacturer) are
equal to or higher than the test pressure described for piping.
6.2.12 Hydrostatic testing below +5C or above +38C is not acceptable without prior Client
approval. If this is unavoidable, suitable precautions shall be taken to ensure that
the test media will not freeze, and that piping system can withstand these
temperatures.
6.2.13 All test media shall be disposed of in a safe and satisfactory manner.
6.3
Pneumatic Testing
6.3.1 Pneumatic testing can be dangerous and must be carried out in strict
accordance with accepted procedures. Pressure relief shall be provided in
accordance with the requirements of ASME B31.3.
6.3.2 Pneumatic testing is prohibited for FRP and GRE.
6.3.3 All pneumatically tested lines shall be tested with clean, dry, oil free air. Pneumatic
test systems shall be kept reasonably small in terms of volume.
6.3.4 The sequence of test pressurising shall be as follows:
a) The system shall be pressurised to 0.35 bar g or 10% of the Maximum pressure
and held for sufficient time to allow the piping to equalise strains (ten minutes
minimum). All joints (threaded, butt welded and flanged) shall be tested for leaks
using a test solution, which has been submitted to and approved by the
Company's Representative. Flanged connections shall be taped and one small
hole punched on topside.
b) The system should then be pressurised gradually to 60% of the indicated test
pressure, and held at that pressure for a sufficient length of time to allow the
piping to equalise strains for a period of not less than ten minutes minimum. The
pressure shall then be reduced to 50% of the indicated test pressure and all
joints re-tested for leaks.
c) Pressurise the system in steps of not more than 10%, until the required test
pressure has been reached. The pressure shall be held at each step during the
pressurising sequence (to allow the piping to equalise strains) for a period of not
less than ten minutes. The required test pressure shall be held for 30 minutes
and then reduced to the maximum working pressure and held for a sufficient
length of time to permit the testing of all joints, but under no circumstances shall
this period be less than thirty (30) minutes.
Page 11 of 25
6.3.5
6.4
Each reinforcing pad (or each segment thereof) and similar attachments shall be
tested at a pressure of at least 1.0 bar g with air, a soap solution shall be used to
detect air leaks. Test and vent holes shall be plugged with Mastic after testing.
Line Service Fluid Testing
6.4.1
Where lines are to be tested with their service fluid, an initial pneumatic test of 1.7
bar g shall be made with a soapy water mixture applied at all joints to locate any
possible leaks. After a satisfactory pneumatic test the lines shall then be filled with
the service fluid and tested at a pressure specified on the line list.
6.4.2
All vents and other connections, which can serve as vents, shall be open during
system filling so that all air is vented prior to applying the test pressure.
6.4.3
Drain lines shall be flushed through and filled with water for a minimum of 30
minutes, no leakage allowed.
6.5
System Reinstatement
6.5.1
Hydrostatic or pneumatic pressure testing shall be followed by reinstatement of

components left out of the pressure test.
6.5.2
When testing is completed, any strainers that had been re-installed after flushing,
shall be removed, cleaned out and reinstalled. Temporary strainers will be kept in
the lines during normal operation. They will be removed and discarded when
deemed no longer necessary by the Operations Engineers.
6.5.3
On completion of draining test systems connect air line from drier package and
dry until dew point reading is minus 10 degree C. Stop drier package and inspect
with a boroscope camera. Where possible all low points shall checked for residual
pools of water. Drying to continue until test system is free of all pooled water, using
a combination of inspection and dewpoint measurement to confirm. If required, on
completion apply vapour-based inhibitor fogged into system on the dry air stream
supplied by the drier package.
6.5.4
If it is impossible to remove the water with air, vapour corrosion inhibitors shall be
used. All temporary connection spools and blanks installed for flushing/testing shall
be removed.
6.5.5
All other items removed for flushing/testing shall be reinstated. Contractor to

maintain a record for the removal and re-instatement of equipment.
6.5.6
All connections broken after test shall be re-made with new gaskets in the
presence of the Company's Inspectors. The bolting shall be torqued to the
requirements of the Piping Fabrication and Installation Specification
6.5.7
Following reinstatement a leak test shall be carried out to prove a sub-system or

system and / or untested joints. The leak test shall be carried out at 95% of the
stage relief valve setting, or the maximum dead head pressure of any pump in the
system not protected by a relief valve.
6.5.8
All temporary restraints, supports and blocks on variable supports shall be

removed and all systems shall be checked out for completeness and compliance
with the Company's Approved Procedures.
Page 12 of 25
6.5.9
6.6
6.6.1
6.7
All hydrotest vents and drains are flanged with the exception of A01G, which shall
be threaded and plugged dependant on size.
Leak Test
A leak test is required following Reinstatement to prove untested joints. Leak
testing is envisaged to the Module limits with system or part-system leak testing
following module integration at the integration yard.
System or Part System mechanical acceptance
6.7.1
Mechanical Completion shall be achieved through the use of Inspection Test

Reports accepted by Contractor and Company inspectors.
6.7.2
Contractor may submit equivalent in-house Inspection Test Reports for Company
Review and Approval prior to use.
7 APPENDICES
Page 13 of 25
Appendix A
TYPICAL PIPE TEST RECORD
A. TYPICAL PIPE TEST RECORD

(alternatively GOC forms SF1, SL1,MP1 and JI1 may be used (see appendix E)
COMPANY:
FACILITY:
SHEET
OF
LOCATION:
SPEC. NO:
DATE & TIME PERFORMED:_____________

oC
AMBIENT TEMPERATURE (Mean 24 hrs):
TEST PRESSURE:
(bar g) TEST MEDIUM TEMPERATURE
oC
TEST MEDIUM: _____________________________________________________

TEST DURATION: ___________________________________________________
TEST CHART NO:____________________________________________________
LINE OR DRAWING NO: REMARKS (LEAKS, LOCATIONS, and CORRECTION
TROUBLE, ETC.
APPROVED TEST PERSONNEL:
DATE: _______
CONTRACTOR PERFORMING TEST: ___________________________________

APPROVED:
_______________________DATE: _______
ACCEPTED: COMPANY
ACCEPTED:
__DATE: ______
INDEPENDENT INSPECTION
DATE: ______
AUTHORITY
Page 14 of 25
Appendix
FLUSHING & TESTING MEDIUMS
B. FLUSHING & TESTING MEDIUMS

The following systems shall be flushed and tested with the fluids recommended
Below: Code
Service
Flushing
Testing
AB
Air, Breathing
Compressed Air
Compressed Air
AC
Air, Bulk Convey
Compressed Air
Compressed Air
AI
Air, Instrument
Compressed Air
Compressed Air
AP
Air, Plant
Compressed Air
Compressed Air
BC
Cement, Bulk / Solid
Compressed Air
Compressed Air
BL
Cement Slurry (LP)
Fresh Water
Fresh Water
BM
Cement Slurry (HP)
Fresh Water
Fresh Water
CA
Methanol
Fresh Water
Fresh Water
CB
Chemical, Acid
Fresh Water
Fresh Water
CC
Chemical, Catalyst
Fresh Water
Fresh Water
CD
Chemical, Caustic
Fresh Water
Fresh Water
CF
AqueousFilm Forming Fluid
Fresh Water
Fresh Water
CG
Glycol (TEG)
Fresh Water
Fresh Water
CH
Wax Inhibitor
Fresh Water
Fresh Water
CI
Corrosion Inhibitor
Fresh Water
Fresh Water
CJ
Antifoam
Fresh Water
Fresh Water
CK
Emulsion Breaker
Fresh Water
Fresh Water
CL
Biocide
Fresh Water
Fresh Water
CM
Scale Inhibitor
Fresh Water
Fresh Water
CN
Glycol (MEG)
Fresh Water
Fresh Water
CS
Sodium Hypochlorite Solution
Fresh Water
Sea Water
CW
Rich Glycol / Water to Regen
Fresh Water
Fresh Water
CX
Chemical, Cement Additive
Fresh Water
Fresh Water
DC
Drain, Open Contaminated
Fresh Water
Fresh Water
DH
Drain, Open Hazardous
Fresh Water
Fresh Water
DM
Drain, Mud
Fresh Water
Fresh Water
DO
Drain, Open Non-Hazardous
Fresh Water
Fresh Water
DS
Drain, Sewer / Sanitary
Fresh Water
Fresh Water
DW
Drain (Open Non-Contaminated) Fresh Water
Fresh Water
Page 15 of 25
Code
Service
Flushing
Testing
DX
Drain, Closed
Fresh Water
Fresh Water
ED
Drill Effluent Overboard
Fresh Water
Fresh Water
FC
Completions Fluid, Brine
Fresh Water
Fresh Water
FJ
Jet Fuel
Compressed Air
Compressed Air
GA
Gas, Firefighting
Compressed Air
Compressed Air
GF
Gas Fuel
Compressed Air
Compressed Air
GI
Gas, Inert
Compressed Air
Compressed Air
GO
Gas, CO2
Compressed Air
Compressed Air
GW
Gas, Waste / Flue
Compressed Air
Service
HG
Heating Medium (Glycol)
Fresh Water
Fresh Water
HO
Heating Oil
Fresh Water
Fresh Water
HW
Heating Medium (Hot Water)
Fresh Water
Fresh Water
MB
Mud, Bulk / Solid
Fresh Water
Fresh Water
MD
Mud, Divert
Fresh Water
Fresh Water
MH
Mud, High Pressure
Fresh Water
Fresh Water
MK
Mud, Choke & Kill
Fresh Water
Fresh Water
ML
Mud, Low Pressure
Fresh Water
Fresh Water
OB
Base Oil
Compressed Air
Compressed Air
OF
Oil, Diesel
Compressed Air
Compressed Air
OH
Oil, Hydraulic
Compressed Air
Compressed Air
OI
Oil, Lubricating
Compressed Air
Compressed Air
OR
Oil, Recovered
Compressed Air
Compressed Air
OS
Oil, Seal
Compressed Air
Compressed Air
PL
Process Hydrocarbons, Liquid
Fresh Water
Fresh Water
PT
Process Two Phase
Fresh Water
Fresh Water
PV
Process Hydrocarbons, Vapour
Fresh Water
Fresh Water
PW
Produced Water
Fresh Water
Fresh Water
SH
Slurry, Cuttings Re-Injection (HP) Fresh Water
Fresh Water
SL
Slurry, Cuttings Re-Injection (LP) Fresh Water
Fresh Water
SP
Steam, Process
Fresh Water
Fresh Water
SU
Steam, Utility Plant
Fresh Water
Fresh Water
VA
Vent Atmospheric
Compressed Air
Service
VG
Emergency Diverter Line
Fresh Water
Service
VH
Vent, Flare (HP)
Fresh Water
Fresh Water
VL
Vent, Flare (LP)
Fresh Water
Fresh Water
VT
Vessel Trim
As per line medium
As per line medium
WB
Water, (Sea) Ballast / Grout
Fresh Water
Fresh Water
WC
Water / Glycol Cooling Medium Fresh Water
Fresh Water
Page 16 of 25
Code
Service
Flushing
Testing
WD
Water, (Fresh) Drill
Fresh Water
Fresh Water
WF
Firewater (Above Ground)
Fresh Water
Fresh Water
WG
Water, Grouting Systems
Fresh Water
Fresh Water
WI
Water (Sea), Injection
Fresh Water
Sea Water
WJ
Water (Sea), Jet
Fresh Water
Fresh Water
WP
Water, Fresh, Potable
Potable Water
Potable Water
WO
Water, Fresh, Hot (Closed Circuit) Fresh Water
Fresh Water
WS
Water, Sea
Fresh Water
Sea Water
WX
Water, HP Wash, Hot
Fresh Water
Fresh Water
Note:
Where line design pressure is less than 1 bar g A service test may be carried out in
lieu of full pressure test. This will be shown on the line list.
Page 17 of 25
Appendix
TYPICAL FLUSHING TESTING AND PRESERVATION OF PIPING
SYSTEMS
C. TYPICAL FLUSHING TESTING AND PRESERVATION OF PIPING SYSTEMS

SYSTEMS
IDENTIFICATION LETTERS
PIPING CLASS SPECIFICATIONS:_________________________________________________________

SYSTEM No_________________
FLUSHING:
PRESSURE TESTING:
PRESERVATION:
REINSTATEMENT:
REMARKS:
Page 18 of 25
Appendix
PIPING SPECIFICATION HYDROSTATIC TEST PRESSURES
D. PIPING SPECIFICATION HYDROSTATIC TEST PRESSURES
Test pressures shown on the line lists are based on the following criteria.
All lines shall be tested at 1.5 x their maximum Process design pressures as specified in the Line
Designation Tables.
Page 19 of 25
Appendix
CERTIFICATION
E. CERTIFICATION
GOC certificates:-
SF1
SL1
MP1
JI1
Page 20 of 25
Project Title:
Maintenance No:
CASPIAN REGION
Work Pack No:
EDITION
SH1 No:
MC1 No:
SYSTEM FLUSHING CERTIFICATE
FORM SF1
SITE:
SHT
OF
TITLE:
Procedure 3.1.3 Complete *
Cleaning & Flushing
YES/NO/NA
FLUSH
MEDIUM
FLUSH
VISUAL
Signature:
P&ID DRAWING & LINE

No(s)
SIGN
DATE
REMARKS:
TICK AS APPROPRIATE
SYSTEM WALKED AND CHECKED AGAINST P&ID(s) AND INTEGRITY CHECK COMPLETE
COMPLETED BY
AGREED BY
COMPANY
SIGNATURE
PRINT NAME
DATE
* Delete as appropriate
GOC
BP Exploration 1989 - 2003 All Rights Reserved
Revisiion C1
1. ***NOTE ! ONE (1) SF1 TO BE RAISED PER HANDOVER CERTIFICATION PACK

(HCP) ***
Page 21 of 25
1.
2.
Project Title:
Maintenance No:
CASPIAN REGION
Work Pack No:
EDITION
SH1 No:
MC1 No:
1.
FORM SL1
SITE:
LEAK TEST CERTIFICATE
SHT
LOCATION
SL1 REF ---
SCOPE OF TEST
SYSTEM
FLUSH MEDIUM
OF
JI1 REF
FLUSH DETAILS COLUMN: MARK F FOR LINE FLUSHED OR V

IF VISUAL ONLY
Pro. 3.1.1 Complete

Joint Integrity
* YES/NO/NA
Pro. 3.1.6 Complete

Piping Completion
* YES/NO/NA
Pro. 3.2.1 Complete

System Flushing
* YES/NO/NA
SIGNATURE:
SIGNATURE:
Pro. 3.2.2 Complete Leak

Test
Pro.3.2.3 Complete Witness
Joint
* YES/NO/NA
* YES/NO/NA
SIGNATURE:
SIGNATURE:
Complete Reinstatement
OPERATING PRESSURE
SIGNATURE:
BAR G
TEST PRESSURE
* YES/NO/NA
OPERATING TEMP
TEST DURATION
P & ID No
LINE No
FLUSH DETAILS
SIGNATURE:
DEG C
FLOW MEDIUM:
HOURS
TEST MEDIUM:
VIBRATION TEST
REQ
EQUIPMENT NUMBER
(FROM)
(TO)
* YES/NO
* YES/NO
* YES/NO
* YES/NO
* YES/NO
* YES/NO
* YES/NO
REMARKS
ALL LINES REQUIRING VIBRATION TESTS MUST BE DETAILED ON THE HANDOVER

PUNCH LIST
PIPING INSTALLATION IN ACCORDANCE WITH RELEVANT CONTRACT SPECIFICATIONS, AND GOC SECTION 3 - PIPE
TESTING.
COMPLETED BY
AGREED BY
COMPANY
SIGNATURE
PRINT NAME
DATE
GOC
Revision C1
Page 22 of 25
Project Title:
Maintenance No:
CASPIAN REGION
Work Pack No:
SH1 No:
EDITION
MC1 No:
PIPING COMPLETION
CERTIFICATE
SITE:
Test Pack No ---
LOCATION
SHT
OF
P & ID No. Refer to Attached Highlighted P&ID(s)
SCOPE OF TEST
See Attached Test Drawing
TEST PACK LIMIT FLUSHED PRIOR TO STRENGTH TEST?

MW1 Complete
Welding & NDE
Pro 3.1.1 Complete
Joint Integrity
Pro 3.1.2 Complete
Pre-Test
Inspection
Pro 3.1.3 Complete
Cleaning &
Flushing
FORM MP1
YES/NO*
SIGNATURE:
YES/NO*
SIGNATURE:
YES/NO*
SIGNATURE:
YES/NO*
SIGNATURE:
OPERATING PRESSURE
STRESS
RELIEVED*
N.D.E. MEDIUM:
*
TEST PRESSURE
FLUSHING MEDIUM:
Pro 3.1.4 Complete

Hydrostatic Testing
Pro 3.1.5 Complete
Pneumatic Testing
Pro 3.1.6 Complete
Piping Completion)
YES/NO*
SIGNATURE:
YES/NO*
SIGNATURE:
YES/NO*
SIGNATURE:
Pro 3.1.7 Complete

Piping Completion
(F&G)
YES/NO*
SIGNATURE:
BAR. OPERATING TEMP

DEG C
YES/NO*
INTERNAL LINING*
M.P.I* / D.P.*
100%* / 10%*
TEST MEDIUM:
ISO No
FLOW MEDIUM:
YES/NO*
EXTERNAL
FINISH*
U.T* /
RAD*
100%* / 10%*
TEST DURATION:
LINE No
PAINT*
WRAP*
NDE ACCEPT.
HOURS
VIBRATION
TEST REQ
YES/NO*
INSULATE*
LINE SPEC:
TEST DATE:
EQUIPMENT NUMBER
(FROM)
(TO)
* YES/NO
* YES/NO
* YES/NO
* YES/NO
* YES/NO
* YES/NO
* YES/NO
* YES/NO
ALL LINES REQUIRING VIBRATION TESTS MUST BE DETAILED ON THE HANDOVER PUNCH LIST
COMPLETED
BY
AGREED BY
COMPANY
SIGNATURE
PRINT NAME
DATE
GOC
Revision C2
Page 23 of 25
Procedure 3.1.1 Complete

Joint Integrity
Project Title:
Maintenance No:
CASPIAN REGION Work Pack No:
EDITION
SH1 No:
MC1 No:
SIGN:

Piping Completion
* YES/NO
SIGN:

Witness Joint
*
YES/NO/N
A
* YES/NO
SIGN:

Cleaning & Flushing

Service Test
JOINT INTEGRITY CERTIFICATE

LOCATION :
Tag
Number
*
YES/NO/N
A
* YES/NO
FORM JI1
SITE:
SIGN:
SIGN:
SHT of
SYSTEM :
Part a
Part b
Part c
Installation Phase
Commissioning Phase
Operational Phase
Location
(P&ID and Description)
Joint
Installed by
Date of
Installation
Leak Tested
by
SL1 Leak Test

Number
Parts A & B
To be completed before the SH1 can be signed and the equipment safely operated
COMPLETED BY
AGREED BY
Service Test
after start up
Service Test
after warm up
Service Test
Period
Service Test
Period
Service Test
Period
Service Test
Period
Tag Removal
Date
Complete Post SH1 acceptance - the equipment can be operated safely without jeopardizing plant,
personnel or the environment
REMARKS;
COMPANY
SIGNATURE
PRINT NAME
DATE
* DELETE AS APPLICABLE
GOC
Revision C2
Page 24 of 25
JOINT INTEGRITY CERTIFICATE
Form JI1 SHT of
Part a
Tag
Number
Location
(P&ID and Description)
* DELETE AS APPLICABLE
Part b
Joint
Installed
by
Date of
Installation
Leak Tested
by
GOC
Part c
SL1 Leak Test

Number
Service Test
after start up
Service Test
after warm up
Service Test
Period
Service Test
Period
Service Test
Period
Service Test
Period
Tag Removal
Date
Revision C2
Page 25 of 25

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TECHNICAL DOCUMENTATION FRONT SHEET

BP EXPLORATION (SHAH DENIZ) LTD

Specification for Pressure testing and flushing of Pipework

Approved for Construction

Approved for Design

Reason for Issue

NOTICE: These materials are the Work

TECHNICAL DOCUMENTATION FRONT SHEET

AzSPU MAJOR PROJECTS

1. Section 1.0; Revised for consistency with other specifications

Kellogg Brown & Root

Revision History and Hold Record

Detailed Description of Change

Front sheet and format brought up to date.

Description / Reason for Hold

CODES AND STANDARDS ..................................................................................................................5

TEST PRESSURES .............................................................................................................................. 10

TYPICAL PIPE TEST RECORD ........................................................................................................ 14

FLUSHING & TESTING MEDIUMS ................................................................................................... 15

TYPICAL FLUSHING TESTING AND PRESERVATION OF PIPING SYSTEMS ............................ 18

PIPING SPECIFICATION HYDROSTATIC TEST PRESSURES ...................................................... 19

2 CODES AND STANDARDS

Pipeline Transportation System for Liquid Hydrocarbons

Gas Transmission and Distribution Piping Systems

PE Pipes Design and Installation

Private fire service mains and their appurtenance

Specification and recommended practice for the use of

Pressure recorder graph trace

In-Line Equipment Philosophy

Pressure Testing requirements

4.4.6 Temperature recorders shall be installed for pressure testing.

6 PRESSURE TESTING PROCEDURES

Line Service Fluid Testing

Hydrostatic or pneumatic pressure testing shall be followed by reinstatement of

All other items removed for flushing/testing shall be reinstated. Contractor to

Following reinstatement a leak test shall be carried out to prove a sub-system or

All temporary restraints, supports and blocks on variable supports shall be

System or Part System mechanical acceptance

Mechanical Completion shall be achieved through the use of Inspection Test

A. TYPICAL PIPE TEST RECORD

DATE & TIME PERFORMED:_____________

(bar g) TEST MEDIUM TEMPERATURE

TEST MEDIUM: _____________________________________________________

APPROVED TEST PERSONNEL:

CONTRACTOR PERFORMING TEST: ___________________________________

B. FLUSHING & TESTING MEDIUMS

Air, Bulk Convey

Cement, Bulk / Solid

Cement Slurry (LP)

Cement Slurry (HP)

AqueousFilm Forming Fluid

Sodium Hypochlorite Solution

Rich Glycol / Water to Regen

Chemical, Cement Additive

Drain, Open Contaminated

Drain, Open Hazardous

Drain, Open Non-Hazardous

Drain, Sewer / Sanitary

Drain (Open Non-Contaminated) Fresh Water

Drill Effluent Overboard

Completions Fluid, Brine

Gas, Waste / Flue

Heating Medium (Glycol)