16854548 a2 · 2021. 3. 5. · • api 6a - 21st edition november 2018 / api monogram effective...

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15/10/2020

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M.Rizzi

A.Antolini

C.Capetti

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Ekofisk and Eldfisk Field Maintenance Contract

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701026-PRC-FAT-303

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A2.34A Document Title: Sign:

PRESSURE TEST PROCEDURE Date:

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BD/EKOX/87 00824

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BD/EKOX

W12 530 PA 2 1 9 0 2 BD/EKOX-SA-M-12877

PROCEDURA - Procedure Page 1 of 13

Document No.

701026-PRC-FAT-303 Rev. 0

© 2019 - PETROLVALVES SPA protects all over the world its industrial and intellectual property rights and pursues their undue use

TITOLO -Title

F.A.T. BASED ON API 6A PSL3G GATE VALVES

CLIENTE-Customer ORDINE Nr. - P.O. No.

CONOCOPHILLIPS SKANDINAVIA AS

4521936825

COMMESSA-Job No. PROGETTO-Project

701026 EKOFISK AND ELDFISK FIELD

STANDARD DI RIFERIMENTO - Reference Standards

• API 6A - 21st Edition November 2018 / API Monogram Effective date: November 2019

• API 6A 21st Edition - ERRATA 1 April 2019

• Integrated QHSE Management System Manual

SPECIFICHE RICHIAMATE - Reference Specifications

• DLGS 81/08

• Spec. No. 5060E INSPECTION CHECKLIST

REV. Rev.

DESCRIZIONE Description

DATA Date

PREPARATO Prepared

VERIFICATO Verified

APPROVATO Approved

0 First issue 04.12.2019 M. Rizzi A. Antolini C. Capetti


Document No.

701026-PRC-FAT-303 Rev. 0


I N D E X

1. SCOPE ................................................................................................................................................................ 3

2. REFERENCE DOCUMENTS .................................................................................................................................. 3

3. SYMBOLS AND ABBREVIATIONS ........................................................................................................................ 3

4. APPLICABILITY ................................................................................................................................................... 3

5. GENERAL REQUIREMENTS ................................................................................................................................. 3

6. SAFETY AND ENVIRONMENTAL REQUIREMENTS ............................................................................................... 4

7. RESPONSIBILITIES .............................................................................................................................................. 4

8. TEST AND INSPECTION TO BE PERFORMED ........................................................................................................ 4

9. PRESSURE TEST PROCEDURE ............................................................................................................................. 5

9.1. HYDROSTATIC SHELL TEST ...................................................................................................................................... 5 9.2. HYDROSTATIC SEATS TEST ...................................................................................................................................... 6 9.3. TORQUE/THRUST FUNCTIONAL TEST ........................................................................................................................ 7 9.4. VALVE PREPARATION BEFORE GAS TESTS ................................................................................................................... 7 9.5. GAS BACKSEAT TEST.............................................................................................................................................. 8 9.6. GAS SHELL TEST ................................................................................................................................................... 8 9.7. GAS SEAT TEST..................................................................................................................................................... 9

10. DRIFT TEST – APPLICABLE TO FULL BORE VALVES .............................................................................................10

11. DOCUMENTATION ............................................................................................................................................10

12. ANNEX ..............................................................................................................................................................11

A. TABLES .................................................................................................................................................................. 11 B. FAT TEST REPORT - SAMPLE ................................................................................................................................ 13


Document No.

701026-PRC-FAT-303 Rev. 0


1. SCOPE This procedure covers the method and responsibilities to perform FAT on manual valves Based on API 6A “PSL3 - PSL 3G” Specification.

2. REFERENCE DOCUMENTS The following documents shall be applied:

• Integrated QHSE Management System Manual

• API 6A - 21st Edition November 2018 / API Monogram Effective date: November 2019

• API 6A 21st Edition - ERRATA 1 April 2019

• DLGS 81 / 08 Italian law for injurious prevention

• Spec. No. 5060E INSPECTION CHECKLIST

3. SYMBOLS AND ABBREVIATIONS For the purpose of this procedure, the following symbols and abbreviations apply: DP Double Piston (Seat) MDP Maximum Differential Pressure QC Quality Control SR Self-Relief (Seat) WPR Working Pressure Rating HBP Hydrostatic Body Pressure Non-Pressurized port Pressurized port

Valve fully open Valve half open Valve fully close The symbols of the valves are indicative and applicable to generic valve.

4. APPLICABILITY This procedure is applicable to manually operated valves.

5. GENERAL REQUIREMENTS The inspection shall be carried out in the presence of the PetrolValves QC personnel and the Customer's inspector (when required). Test pressure-measuring devices shall be accurate to at least ±2% of full-scale range. If pressure gauges are used in lieu of pressure transducers, they shall be selected such that the test pressure is indicated within 20% and 80% of the full-scale value. Calibration intervals shall be a maximum of three months. The inspection shall be carried out on the valve with the operator assembled, and before valve painting. No sealants or grease shall be applied to the valves prior to, or during pressure tests.


Document No.

701026-PRC-FAT-303 Rev. 0


Seat Leak detection methods:

• Water level in the suitable calibrated plastic pipe connected directly to the inspection port for Hydro Seat Test

• Bubble Counter / digital flow meter for Gas Seat Test

6. SAFETY AND ENVIRONMENTAL REQUIREMENTS The execution of the provisions of this procedure is entrusted to appropriately qualified and experienced personnel because it calls for procedures that may be injurious to health if adequate precautions are not taken. It is responsibility of the user of this procedure verify that appropriate safety and health practice and devices have been established by the Health, Safety & Environmental responsible. The check list “PROSSA 20” must be verified before starting with FAT activities. Water used for pressure tests shall not be release out of the re-cycling circuit at pressure testing area.

7. RESPONSIBILITIES The Health, Safety & Environmental Department has the responsibility for the safety of the pressure test rigs and for everything is relevant to the safety execution of all pressure tests in the workshop. The Production Department has the responsibility for the execution of: • all pressure tests; • functional test and/or torque tests; • handling and transportation of valves. The QC Department for Pressure Tests has the responsibility to: • verify for the current calibration and adequacy of the manometers used; • evaluate the result of all pressure tests and/or functional tests carried out; • verify that the requirements of this specification are correctly fulfilled; • issue the certification relevant to the pressure test and/or functional tests carried out.

8. TEST AND INSPECTION TO BE PERFORMED

8.1. Visual and Dimensional inspection of the valve operator assembly in compliance with the approved outline drawings.

8.2. Pressure tests. 8.3. Drift Test (if applicable / agreed)

NOTE: References in parenthesis are to API 6A Specification on which each test is based.

A chart recorder shall be used on all hydrostatic tests


Document No.

701026-PRC-FAT-303 Rev. 0


9. PRESSURE TEST PROCEDURE PV internal check: Just after the assembly of the proper operator onto the valve, perform three complete cycles without pressure in order to verify: • proper functionality of the valve/operator • correct alignment of the valve • correct setting of the limit-switches (if applicable)

Monitored pressure shall not vary from the test pressure at the start of the test by more than 5% or 34.5 barg (3.45 MPa - 500 psi), whichever is less, during the entire hold period. The initial test pressure shall not be greater than 5% above the specified test pressure. During the entire holding period, the monitored pressure shall not drop below the specified pressure. Pressure shall be considered stabilized when the rate of change is no more than 5% of the test pressure per hour or 3.45 MPa / h (500 PSI/hour), whichever is less. (API 6A para F.1.10.2). Holding period shall start after Pressure stabilization.

9.1. Hydrostatic Shell Test (API 6A – Para 11.2.3)

• Test medium: Clean room temperature potable water with chloride content 30 ppm maximum,

added with 512% corrosion inhibitor.

• Valve position: half open.

• Test pressure: A: HBP (see Table 1) C: HBP (see Table 1) B: HBP (see Table 1)

• Temperature: ambient

• Holding period: First Holding Period : 3 minutes Second Holding Period: 15 minutes

• Leakage detection: External

• Acceptance criteria: No visible leakage

Procedure: 1. Install the valve in the suitable test rig 2. Stroke the valve to half-open position. 3. Fill up the valve with test medium and flush it for one minute. 4. Pressurise all internal cavities of the valve up to reach test pressure and then isolate the valve from the

pressure source. 5. Check for any external visible leakage during the first holding period. 6. After the first holding period, release pressure to zero. 7. Re-pressurise all internal cavities of the valve up to reach test pressure and then isolate the valve from

the pressure source. 8. Check for any external visible leakage during the second holding period. 9. After the second holding period, release pressure to zero.


Document No.

701026-PRC-FAT-303 Rev. 0


9.2. Hydrostatic Seats Test (API 6A – Para 11.2.4)

• Test medium: as per Para. 9.1

• Valve position: fully closed.

• Test pressure: Upstream

Downstream (for bi-directional valves only)

A: WPR (see Table 1) atmospheric

C: atmospheric atmospheric

B: atmospheric WPR (see Table 1)

• Temperature: Ambient

• Holding period : First Holding Period : 3 minutes Second Holding Period : 3 minutes Third Holding Period : 3 minutes

• Leakage detection: Opposite side

• Acceptance criteria: Valve shall show no visible leakage during each holding period

Upstream

Downstream

Procedure: 1. Stroke the valve to fully closed position 2. Proceed as follows:

2.1. Pressurize upstream side up to reach test pressure and then isolate the valve from the pressure source.

2.2. During the first holding period measure and record leak rate through opening downstream side.

2.3. Open the valve under full differential pressure. 2.4. Release the pressure to zero. 2.5. Closed the valve and re-pressurize upstream side (second time) up to reach test pressure and

then isolate the valve from the pressure source. 2.6. During the second holding period measure and record leak rate through opening downstream

side. 2.7. Open the valve under full differential pressure. 2.8. Release the pressure to zero. 2.9. Closed the valve and re-pressurize upstream side (third time) up to reach test pressure and then

isolate the valve from the pressure source. 2.10. During the third holding period measure and record leak rate through opening downstream

side. 2.11. Release the pressure to zero.

For bi-directional valves, repeat the above steps pressurizing downstream side instead the upstream side.


Document No.

701026-PRC-FAT-303 Rev. 0


9.3. Torque/Thrust Functional Test

9.3.1. Close to open with one side pressurized

• Test medium: as per Para. 9.1

• Valve position: fully closed.

• Test pressure:

Upstream Downstream (for bi-directional valves only)

A: MDP (see Table 2) atmospheric C: atmospheric atmospheric B: atmospheric MDP (see Table 2)

• Acceptance criteria: The Force shall be not greater than 200 N * Handwheel diameter (break out).

Upstream

Downstream

1. Stroke the valve to fully closed position as follows:

- FOR MANUAL VALVES (Wedge Gate) → through handwheel with max force applicable of 200 N * Handwheel diameter

2. Upstream side– Proceed as follows: 3. Pressurise upstream side with Maximum Differential Pressure (MDP). 4. After stabilisation open the valve under rated pressure and record the torque values through torsional

cell measurements during break out. 5. Release the pressure to zero. For bi-directional valves, repeat the above steps pressurizing downstream side instead the upstream side. After hydrotest all traces of test medium shall be removed from the internal parts and the valve must be fully drained.

9.4. Valve preparation before Gas Tests

The surface areas to be tested shall be free of oil, grease, paint or other contamination that may mask a leak. If liquids are used to clean the component or if a hydrostatic test is performed before gas leak testing, the component shall be dry before testing. External leakage will be detected by means of a Mass spectrometer with an automatic internal system calibration. Before the use, the mass spectrometer reading shall be verified through a calibrated leak sample. All potential leak paths shall be bagged and sealed, and leakage detection piped or routed to the safe detection area.


Document No.

701026-PRC-FAT-303 Rev. 0


9.5. Gas Backseat Test (API 6A – Para 11.3.5)

• Test medium: 99% Nitrogen + 1% Helium.

• Valve position: fully open / fully closed.

• Test pressure: A: WPR (see Table 1) C: WPR (see Table 1) B: WPR (see Table 1)


• Holding period: 15 minutes

• Leakage detection: External around the stem

• Acceptance criteria: : No leakage, using a Mass Spectrometer. (< 1 x 10-5 cm3/s / 0,0006 ml/min / 1 x 10-5 mbar l/s – for a helium concentration equal to 10% - as per ASME V Article 10). A maximum reduction of the gas test pressure of 2,0 MPa (300 psi) is acceptable

Procedure: 1. Install the valve in the suitable test rig 2. Valve shall be in the fully open position and the packing gland loose. 3. Pressurise all internal cavities of the valve up to reach test pressure and then isolate the valve from the

pressure source. 4. Check for any external leakage around the stem during the holding period. 5. After the holding period, release pressure to zero.

9.6. Gas Shell Test (API 6A – Para 11.3.3)

• Test medium: 99% Nitrogen + 1% Helium.

• Valve position: half open.

• Test pressure: A: WPR (see Table 1) C: WPR (see Table 1) B: WPR (see Table 1)


• Holding period: 15 minutes

• Leakage detection: External

• Acceptance criteria: No leakage, using a Mass Spectrometer. (< 0,0045 cm3/s / 0,27 ml/min / 0,0045 mbar l/s – for a Helium concentration equal to 1%). A maximum reduction of the gas test pressure of 2,0 MPa (300 psi) is acceptable

Procedure: 1. Install the valve in the suitable test rig. 2. Stroke the valve to half-open position. 3. Pressurise all internal cavities of the valve up to reach test pressure and then isolate the valve from the

pressure source. 4. Check for any external leakage during the holding period. 5. After the holding period, release pressure to zero


Document No.

701026-PRC-FAT-303 Rev. 0


9.7. Gas Seat Test (API 6A – Para 11.3.4)

• Test medium: Nitrogen Gas

• Valve position: Fully closed.

• Test pressure: First Period

Upstream Downstream

(for bi-directional valves)

A: WPR (see Table 1) atmospheric


B: atmospheric WPR (see Table 1)

Second Period Upstream

Downstream (for bi-directional valves)

A: 2 MPa (300 psi) ± 10% atmospheric


B: atmospheric 2 MPa (300 psi) ± 10%


• Holding period: First Holding Period : 15 minutes Second Holding Period: 15 minutes

• Leakage detection: Opposite side

• Acceptance criteria: The maximum allowable leakage rate shall be no visible bubbles during the holding periods); a maximum reduction of the gas test pressure of 2,0 MPa (300 psi) for the primary test is acceptable, while for the secondary test 0,2 MPa (30 psi) is acceptable.

Upstream

Downstream

Procedure:

1. Stroke the valve to fully closed position 2. Proceed as follows: 3. Pressurise upstream side at pressure of first period, up to reach test pressure and then isolate

the valve from the pressure source 4. During the first holding period measure and record leak rate through opening downstream

side. 5. Release the pressure to zero, and fully open and fully closed the valve. 6. Re-pressurise upstream side at pressure of second period up to reach test pressure and then

isolate the valve from the pressure source 7. During the second holding period measure and record leak rate through opening

downstream side. 8. Release the pressure to zero. 9. For bi-directional valves, repeat the above steps pressurizing downstream side instead the

upstream side.


Document No.

701026-PRC-FAT-303 Rev. 0


10. DRIFT TEST – Applicable to Full Bore Valves (API 6A – Para 11.4) After the valve has been assembled, operated and pressure tested, pass a drift mandrel with specific geometry as described in Table 2, through the valve bore. Acceptance criteria: the drift mandrel shall pass completely through the valve bore.

Mandrel geometry is only for reference.

For handling and/or material availability reasons, the mandrel may have different configuration at discretion of PV (below some examples).

11. DOCUMENTATION The following documents must be supplied:

• Type of valve;

• Pressure and duration of tests;

• Leakage rates;

• Functional test results


Document No.

701026-PRC-FAT-303 Rev. 0


12. ANNEX

A. Tables

Table 1 - Hydrostatic Body Test Pressure - Psi (MPa)

End and Outlet connections

Nominal Size of Flange

Working Pressure Rating (WPR)

13 5/8" (346 mm)

and smaller

16 3/4" (425 mm) and larger

Hydrostatic Body

Test Pressure Hydrostatic Body

Test Pressure

(Psi) (MPa) (Psi) (MPa) (Psi) (MPa)

2000 13,8 4000 27,6 3000 20,7

3000 20,7 6000 41,4 4500 31,0

5000 34,5 7500 51,7 7500 51,7

10000 69,0 15000 103,5 15000 103,5

12500 87,0 18750 130,0 18750 130,0

15000 103,5 22500 155,0 22500 155,0

20000 138,0 30000 207,0


Document No.

701026-PRC-FAT-303 Rev. 0


Table 2 - Drift diameter for individual valves – API 6A Standard Values for Full Bore valves


Document No.

701026-PRC-FAT-303 Rev. 0


B. FAT TEST REPORT - SAMPLE

16854548 a2 · 2021. 3. 5. · • api 6a - 21st edition november 2018 / api monogram effective...

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