EPC for Causeway Pipelines Project

PNEUMATIC TEST PROCEDURE

DOCUMENT NO: 6NCP-GEN-GG-PR-001 Rev:0 Page 1 of 7

ABU DHABI OIL COMPANY LTD. (JAPAN) – ADOC

PNEUMATIC PROCEDURE FOR PROCESS PIPE

WORKS

CONTRACT NO: PSPJ-2015-CR-005

0 ISSUED FOR REVIEW (IFR) 31/08/2016 KRR MSS BVK

REV DESCRIPTION DATE PRPD CHKD APPRD

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DOCUMENT NO: 6NCP-GEN-GG-PR-001 Rev:0 Page 2 of 7

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1.0 INTRODUCTION

Abu Dhabi Oil Company (ADOC) is currently operating three offshore oilfields. These fields
are Mubarraz field, Umm Al Anbar field (referred to as AR), and Neewat Al Ghalan (referred
to as GA).

The Hydrocarbons produced from Mubarraz field are processed in Mubarraz Island (MUB),
whereas the Hydrocarbons produced from AR and GA Fields are processed at the AR site
terminal (AR) (West Mubarraz). Crude Oil from Mubarraz Oilfield along with crude oil from
West Mubarraz is stored on Mubarraz Island and is exported via a Single Point Mooring
(SPM) facility. Mubarraz Island and AR site terminals are connected by a Causeway.

ADOC intends to expand its existing facilities to increase its production targets. As part of the
Causeway project, four (4) new gas pipelines shall be laid underground in the Causeway
between Mubarraz Island, GA and the AR Site Terminal. The main objectives of these
pipelines are to transfer the excess sour gas from MUB to AR site, to supply fuel gas to new
GTGs at MUB from AR site and to increase gas injection capacity at the GA Field in future.

ADOC has awarded the EPC Contract for “EPC for Causeway Pipelines Project” to Target
Engineering Construction Co. (LLC). TARGET Engineering Construction Co. (LLC) has
subcontracted the Residual & Detailed Engineering works to Subcontractor, Amec Foster
Wheeler.

1.1 Scope

The EPC for Causeway Pipelines Project includes the Residual Engineering, Detail
Engineering, Procurement (other than free issue materials), Furnishing, Construction,
Inspection, Testing, Clean-up, Pre-commissioning and assistance for Commissioning for the
following:

 18 inch Sour Gas Pipeline from Mubarraz Island to AR Site terminal

 12 inch LP Sweet Gas Pipeline (primary Fuel Gas supply to Mubarraz Island) from AR
site Terminal to Mubarraz Island
 10 inch HP Sweet Gas Pipeline (secondary Fuel gas Supply to Mubarraz Island) from
AR site Terminal to Mubarraz Island
 6 inch HP Sweet Gas Injection Pipeline from AR Site Terminal to GA Field
 Tie-ins at each location and on plot piping
 Any required modification to existing facilities at each location as to enable piping and
pipeline tie-ins
 Any modifications in Utilities and infrastructure as required
 Cathodic Protection.

2.0 PURPOSE OF THE DOCUMENT

The purpose of this Pneumatic procedure is to ensure that the fabricated spools threading
integrity.

3.0 DEFINITIONS AND ABBREVIATIONS

For the purpose of this document, the words and expressions listed below shall have the
meanings assigned to them as follows
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3.1 Definitions

COMPANY - Abu Dhabi Oil Co. Ltd. (Japan) – ADOC.

CONTRACTOR - Target Engineering Construction Co. LLC (TARGET)

CONTRACT NO - The CONTRACT entered between COMPANY and

CONTRACTOR for the EPC for Causeway Pipelines
Project

PROJECT - Means “EPC for Causeway Pipelines Project “.

SITE - Mubarraz Island / GA Terminal / AR Terminal /
Causeway / CONTRACTOR’s worksite at Abu Dhabi
(If Approved by Company).

SUB CONTRACTOR - any person to whom execution of any part of the

Works, including preparation of any design or supply
of any materials, is subcontracted directly or
indirectly by Contractor, and includes its legal
successors or permitted assigns.

CONTRACT NO - PSPJ-2015-CR-005. The CONTRACT number shall

be referred for all drawings, documents,
correspondence, etc.

3.2 Abbreviations

ADNOC - Abu Dhabi National Oil Company.

ADOC - Abu Dhabi Oil Co.Ltd (JAPAN).
AR - Umm Al Anbar.
CMS - Change Management System
COP - Code of Practice
DCA - Design Change Authorization.
GA - Neewat Al Ghalan.
HSE - Health Safety & Environment.
NCR - Non Conformance Report.
QA / QC - Quality Assurance & Quality Control.
UAE - United Arab Emirates.

4.0 REFERENCES

4.1 Order of Precedence

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Unless otherwise noted, the following is the order of precedence:-

i) Laws, Standard and Regulation of the UAE and the Emirates of Abu Dhabi
ii) ADNOC Code of Practices (ADNOC COP)
iii) Project Data Sheets and Specifications.
iv) COMPANY Engineering Specifications, Procedures and Standards
v) International codes and standards

The CONTRACTOR shall notify the COMPANY of any apparent conflict between codes and
standards and any other specifications noted herein. Resolution and/or interpretation of the
precedence shall be obtained from the COMPANY in writing before proceeding further.

In case of conflict between the various codes and standards the most stringent of the
requirements shall govern. The CONTRACTOR shall refer any such conflict and any other
matter which requires further interpretation to the attention of COMPANY and COMPANY’s
interpretation shall be final.

4.2 Project Reference Document

This procedure is generally in accordance with the stipulations of the AGREEMENT

between COMPANY & CONTRACTOR. The following are referred to in particular.

Document Number Document Tittle

6NCP-G010-0001E-0 EPC scope of work

Quality Management systems –

ISO 9000-2005
Fundamentals and vocabulary
Quality Management systems -
ISO 9001-2008
Requirements
Guide lines for Auditing Management
ISO 19011:2011
System

CONTRACTOR PROCEDURES

6NCP-GEN-QP-PN-001 Project Quality Plan

Specification for piping fabrication ,

6NCP-GEN-LG-SP-021
Erection , Welding and Testing

INTERNATIONAL STANDARDS

ASME B31.3 Process piping

5.0 RESPONSIBILITIES
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Project Manager together with his team is responsible for the day-to-day effective
implementation of this procedure and that all the relevant staffs are aware of their
responsibilities.

Construction Manager is responsible for effective implementation of this procedure and

shall coordinate with COMPANY Representative, QA/QC Manager and Discipline
Engineers/Supervisors for the safe execution of prescribed activities. He shall coordinate with
COMPANY representative for necessary improvement.

QA/QC Manager together with the QA/QC Engineer/Inspector shall ensure that the
procedure is established, and all inspection activities as mentioned relevant ITP,
Specification are carried out and recorded.

QA/QC Engineer/Inspector together with his team shall coordinate with COMPANY
representative/TPI to obtain necessary approvals and responsible for preparing all necessary
check list and documents required for carrying out activities, and responsible to prepare
Material receipt Inspection report. (MRIR)

HSE Manager together with his site based Safety Officers shall ensure the necessary work
permit is ready for the specified work and currently available at the location and safety
measures as identified are in place and followed.

Test Engineer: He is responsible for performing the hydro test as per the project specification
and line list, will be reporting Construction Manager at site. Also ensures that the particular
package is released from QA/QC department in all respect. Ensures that all the equipment
is arranged well before start, water filling, draining system all in place.

6.0 RESOURCES (Equipment)

 Air Compressor
 Pressure Gauges (according to pressure requirements)
 Pressure Relief Valve
 Blinds

7.0 PROCEDURE

 Pneumatic test package shall be prepared by respective QC engineer and submit to

COMPANY for approval prior to any pneumatic test. This test package ensures that
Clearance from the QA/QC department for the completion of all the joints and the relevant
P & Ids and Isometric drawings shall be attached along with package.

 If required a test manifold shall be prepared and to be tested and certified for 110% of the
highest pneumatic test pressure. Same can be used for testing the pipe spools.
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 Particular loop has to be flushed with air for cleanliness.

 Ensure that all the drains are to be blinded.

 Ensure that all high point vents shall be kept open.

 After satisfactory removal of air, the vents shall be plugged.

 Before starting pressurization pressure gauges to fix as marked in the loop file. And all
blinds to be placed at test limit position.

 Pressure to be applied in a controlled manner to avoid any surging in the line. Once
80 percent of the test pressure is reached, the rate of pressurization should be
reduced.

 Once the desired test pressure is reached, the Compressor shall be stopped and to be
isolated.

 After isolation of Compressor the loop under testing shall be kept for a sufficient time to
allow the Company / TPI to witness all the threaded joints and flanged joints for any
leak by applying soap solution.

 Upon completion of the above test slowly depressurise the air by keeping the vent open.

7.1 Pressure Gauge / Safety relief valve

 Calibrated pressure gauges to be selected such that range of pressure gauge should
be 1.5 times the test pressure.

 Pressure gauge shall be fixed at the pressure pump location or at the lowest position of
the test loop.

 After pressurization, the pressure shall be constantly monitored to avoid over-

pressurizing due to rise in ambient temperature.

 Alternatively, a pressure relief valve may be installed which shall be calibrated at 5%

more than the test pressure. In case of rise in pressure due to rise in ambient
temperature, water will flow out of the relief valve and protect the system / piping from
over pressurizing.

8.0 DOCUMENTATION

 Piping QC Inspector responsible to prepare the Pneumatic test package and get it
approval from COMPANY, raising inspection request for the pneumatic test and
witnessing the same and provide pneumatic test certificates for each and every
package.