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STRATHSPEY REPLACEMENT Wl PIPELINE PROJECT

CONTl~ACT NO. 77000637

10" WATER INJECTION FLOWLINE

FACTORY ACCEPTANCE TEST (FAT) PROCEDURE

ChevronTexaco

NKTDOC.NO. 2536-DOC-500
CLIENT DOC.NO. NIA

I 00 Issued fO< ConstruCtion 06-06-05 ~~ ~

~-
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A Issued for Oient Review 03·05.05 JO'I MBS PER CRT
ProJect a ....
Re\'. p..,.,.., or iss"" Dole On....... Cb<cker ADDIO\"tf ADiliO•tt
""""''"
NKT FLEXIBLES IS CERTIFIED ACCORDING TO:

71u's documem contoiJIS conjidelll;aJ ;,iformntloll All rig/us (illcludlng copyright. conjidetllinl infonnatlmr, trade secrets, ami desigll
rights) ore owned by NKT Flexibles liS
No use or disclosure is to be n~~Ade u ithout the
l\l·l!Ml.028, "'' OJ
Strathspey Replacement WI Pipeline Project

Factory Acceptance Test Procedure Doc.no. 2536-DOC-500 Rev. 00 Page 2 of 10

TABLE OF CONTENTS

1 INTRODUCTION ...................................................................................................................................................... 3
1.1 REVISION HISTORY .............................................................................................................................................. 3
2 DOCUMENTATION ................................................................................................................................................. 4
3 PIPE AND END FITTING PARTICULARS ......................................................................................................... 5
4 SCOPE OF WORK .................................................................................................................................................... 5
4.1 TEST PROGRAMME ............................................................................................................................................... 5
4.2 TEST MEDIUM ....................................................................................................................................................... 5

4.3 INSTRUMENTATION .............................................................................................................................................. 5

4.4 MEASUREMENTS .................................................................................................................................................. 6

4.5 CALIBRATION ....................................................................................................................................................... 6

5 HYDROSTATIC PRESSURE TEST....................................................................................................................... 7

5.1 HYDROSTATIC PRESSURE TEST PROCEDURE ........................................................................................................ 7

5.2 ACCEPTANCE CRITERIA ........................................................................................................................................ 7

6 ELECTRICAL CONTINUITY ................................................................................................................................ 9

6.1 ELECTRICAL CONTINUITY .................................................................................................................................... 9

6.2 ACCEPTANCE CRITERIA ........................................................................................................................................ 9

7 GAS VENTING SYSTEM TEST ........................................................................................................................... 10

7.1 GAS VENTING SYSTEM TEST .............................................................................................................................. 10
7.2 ACCEPTANCE CRITERIA ...................................................................................................................................... 10

8 CHECK OF FLANGE FACES............................................................................................................................... 10

9 DELIVERY ............................................................................................................................................................... 10

This document contains confidential information. All rights (including copyright, confidential information, trade secrets, and design
rights) are owned by NKT Flexibles I/S
No use or disclosure is to be made without the prior written permission of NKT Flexibles I/S. All rights reserved.
TM-ENG-028, rev. 03
Strathspey Replacement WI Pipeline Project

Factory Acceptance Test Procedure Doc.no. 2536-DOC-500 Rev. 00 Page 3 of 10

1 INTRODUCTION
This procedure describes the requirements for Factory Acceptance Test (FAT) for the
Strathspey Project. The purpose of the test is to verify that the flexible structure and the
end-fittings fulfil the requirements specified by the client.

The FAT will consist of the following tests:

• FAT test as per API 17J, section 9

The FAT will be carried out by NKT Flexibles (NKT) staff at NKTs factory in
Kalundborg, Denmark.

FAT can start when the last end-fitting mounting has been completed and signed off
according to the Document End-fitting Mounting Specification and at least 24 hours
after epoxy pouring.

3rd Party or client representative may verify the FAT.

The work will be carried out according to NKT work procedure AI-OPE-901.
Hold and witness points for the FAT are according to the Project Manufacturing Quality
Plan 2536-DOC-011.

All documents produced by NKT for this project are registered in Master Document
Register.

1.1 REVISION HISTORY

This is the second issue of this document. Rev. A of this document has been approved by
Client without comments. The document is therefore issued in rev. 00 ‘Issued for
Construction’ without further changes.

This document contains confidential information. All rights (including copyright, confidential information, trade secrets, and design
rights) are owned by NKT Flexibles I/S
No use or disclosure is to be made without the prior written permission of NKT Flexibles I/S. All rights reserved.
TM-ENG-028, rev. 03
Strathspey Replacement WI Pipeline Project

Factory Acceptance Test Procedure Doc.no. 2536-DOC-500 Rev. 00 Page 4 of 10

2 DOCUMENTATION
The results for each test will be documented in a test report, Project Document No.
2535-DOC-551 to 2536-DOC-552 issued by NKT. A copy of all relevant calibration
certificates will be attached to the report. All data recorded by the Data Acquisition
System (DAS) can be made available to the client in a readable format on request.

NKT, the client representative and 3rd Party shall if present sign each test for acceptance.

This document contains confidential information. All rights (including copyright, confidential information, trade secrets, and design
rights) are owned by NKT Flexibles I/S
No use or disclosure is to be made without the prior written permission of NKT Flexibles I/S. All rights reserved.
TM-ENG-028, rev. 03
Strathspey Replacement WI Pipeline Project

Factory Acceptance Test Procedure Doc.no. 2536-DOC-500 Rev. 00 Page 5 of 10

3 PIPE AND END FITTING PARTICULARS

Table 3.1 Pipes
Description Pipe No Pipe Pipe ID Design Minimum Test Maximum Test
Length (mm) Pressure Pressure Pressure
(m) (bara) (bara) (bara)
10" WIF #1 2536NKT001 10030 251 345 517.5 543.4
10" WIF #2 2536NKT002 10600 251 345 517.5 543.4

Table 3.2 End-fittings

Description Pipe No End-fitting (A) End-fitting (B) Min. ID of End-
fitting (mm)
10" WIF #1 2536NKT001 12” ANSI B16.5 class 12M102 Grayloc 260
2500
10" WIF #2 2536NKT002 12M102 Grayloc 12” ANSI B16.5 class 260
2500

Table 3.3 Acceptance criteria Electrical Continuity

Description Pipe No Pipe Length Acceptance Criteria Nominal value
(m) (ohm) (ohm)
10" WIF #1 2536NKT001 10030 Less than 10 Ω/km pipe 100. 3 Ω
10" WIF #2 2536NKT002 10600 " 106.0 Ω

4 SCOPE OF WORK
4.1 TEST PROGRAMME
The flexible pipe with end-fittings will be tested according to the following programme:
1. Hydrostatic Pressure Test
2. Electrical Continuity Test
3. Gas Venting System Test
4. Check of Flange Faces

4.2 TEST MEDIUM

Tap water will be used as test medium.

4.3 INSTRUMENTATION
All instrumentation is provided by NKT Flexibles. The instrumentation will as a
minimum consist of the following calibrated instruments:
• 1 pressure transducer, incl. Circular Chart Recorder (CCR)

This document contains confidential information. All rights (including copyright, confidential information, trade secrets, and design
rights) are owned by NKT Flexibles I/S
No use or disclosure is to be made without the prior written permission of NKT Flexibles I/S. All rights reserved.
TM-ENG-028, rev. 03
Strathspey Replacement WI Pipeline Project

Factory Acceptance Test Procedure Doc.no. 2536-DOC-500 Rev. 00 Page 6 of 10

• 1 temperature gauge measuring the internal temperature, incl. CCR

• 1 temperature gauge measuring the ambient temperature, incl. CCR
• 2 volt/ohm meters
• 2 manometers for Gas Venting System Test
• 1 dead weight tester

1 manometer for visual observation is used. This manometer is not calibrated.

4.4 MEASUREMENTS
The measurements will be recorded on a CCR and sampled by the Data Acquisition
System (DAS ) during the test. The sampling rate of the DAS will be one sample per 2
minutes.

The following measurements will be sampled during the test, including pressurisation,
stabilisation, hydrostatic pressure test, and depressurisation periods.
• Internal Pressure accuracy ±1.0%
• Internal pipe temperature accuracy ±2.0ºC
• Ambient temperature accuracy ±2.0ºC

4.5 CALIBRATION
Prior to commencing the FAT, all calibration certification shall be controlled and
validation confirmed.

Prior to hydrostatic pressure testing the pressure transducers shall be calibrated against a
certified dead-weight pressure balance.

This document contains confidential information. All rights (including copyright, confidential information, trade secrets, and design
rights) are owned by NKT Flexibles I/S
No use or disclosure is to be made without the prior written permission of NKT Flexibles I/S. All rights reserved.
TM-ENG-028, rev. 03
Strathspey Replacement WI Pipeline Project

Factory Acceptance Test Procedure Doc.no. 2536-DOC-500 Rev. 00 Page 7 of 10

5 HYDROSTATIC PRESSURE TEST

The pressurisation of the pipes must not start before minimum 24 hours after epoxy
pouring.

5.1 HYDROSTATIC PRESSURE TEST PROCEDURE

The hydrostatic pressure test is equal to 1.5 times the design pressure for flowline. The
hydrostatic test pressure shall be maintained for minimum of 24 hours.

The test will start after the pipe has been filled with water.
The pressure is increased gradually to the minimum hydrostatic test pressure and shall
not exceed it with more than 5%. Average pressurisation rate shall not exceed 18
MPa/hour.

The stabilised pressure will – if necessary – be increased to a value between the

minimum test pressure and 105% of the minimum test pressure. If necessary to achieve
stabilisation the pressure may be cycled to the maximum test pressure, see table 3.1. The
pressure shall be held for a period of at least 2 hours before the pressure test starts to
allow for stabilisation of the system. Stabilisation is achieved when the pressure drop is
less than 1% of the pressure setting in a one-hour period.

The hydrostatic pressure test can start when the pressure is stabilised between the
minimum test pressure and the maximum test pressure and the valve between the high-
pressure pump and the flexible pipe is secured in a closed position. Pressure, ambient
temperature, and internal temperature are monitored during testing as specified in
section 4.4.

Note: All end fitting gas ports are opened prior to test for leakage during FAT. Due to
safety reasons the vent ports cannot be monitored during hydrostatic pressure test.

After completion of the hydrostatic pressure test the flexible pipes will be depressurised.
The average decompression rate must not exceed 108 MPa/hour.

5.2 ACCEPTANCE CRITERIA

The acceptance criterion is that the pressure loss during a 24-hour period must not
exceed 4% of the hydrostatic test pressure recorded at the start of the period. The start
point for the test period may be moved forward in time. At no time during the test may
the pressure drop below minimum test pressure

The evaluation of the pressure loss during the test period can be based on either the CCR
or the DAS recordings.

No leakage shall be observed from the pipe and end fittings during the test period and no
permanent deformation or damage shall be observed in the area of the end-fittings.

This document contains confidential information. All rights (including copyright, confidential information, trade secrets, and design
rights) are owned by NKT Flexibles I/S
No use or disclosure is to be made without the prior written permission of NKT Flexibles I/S. All rights reserved.
TM-ENG-028, rev. 03
Strathspey Replacement WI Pipeline Project

Factory Acceptance Test Procedure Doc.no. 2536-DOC-500 Rev. 00 Page 8 of 10

If the pressure loss during the 24-hour period exceeds 4% of the hydrostatic test pressure
all instruments are to be checked for failure and leaks and the pressurised system shall
be visually inspected for leaks, as per work procedure AI-OPE-901.

A new test according to Section 5.1 will be performed after the possible failure(s) has
been identified and corrected.

This document contains confidential information. All rights (including copyright, confidential information, trade secrets, and design
rights) are owned by NKT Flexibles I/S
No use or disclosure is to be made without the prior written permission of NKT Flexibles I/S. All rights reserved.
TM-ENG-028, rev. 03
Strathspey Replacement WI Pipeline Project

Factory Acceptance Test Procedure Doc.no. 2536-DOC-500 Rev. 00 Page 9 of 10

6 ELECTRICAL CONTINUITY
6.1 ELECTRICAL CONTINUITY
The test is performed after the hydrostatic pressure test.
The electrical continuity test is carried out measuring the resistance between the end-
fittings. The test is done on wet empty pipe.

6.2 ACCEPTANCE CRITERIA

The resistance shall be less than 10Ω per kilometre of the pipe. See
Table 3.3.

This document contains confidential information. All rights (including copyright, confidential information, trade secrets, and design
rights) are owned by NKT Flexibles I/S
No use or disclosure is to be made without the prior written permission of NKT Flexibles I/S. All rights reserved.
TM-ENG-028, rev. 03
Strathspey Replacement WI Pipeline Project

Factory Acceptance Test Procedure Doc.no. 2536-DOC-500 Rev. 00 Page 10 of 10

7 GAS VENTING SYSTEM TEST

7.1 GAS VENTING SYSTEM TEST

In order to ensure that the gas venting system functions properly, the following steps
will be carried out:
1. Each relief vent valve will be tested in the NKT laboratory prior to mounting in
the end-fittings. The valves shall relieve at differential pressure equal to 2 bar
+0/-10%. Test certificates for the relief valves are included in the As-built
Documentation.
2. All relief vent valves are mounted in the end-fittings except for one relief vent
valve on each end-fitting. In this free port at both end-fittings a test pipe is
mounted fitted with a valve at the end and two side branches fitted with
respectively the last relief vent valve and a manometer.
3. The pump is connected to the valve of the test pipe at end-fitting A.
4. The annulus is filled with compressed air until the first relief vent valve is
relieved at end-fitting A. Then this relief vent valve is blocked and the filling of
the annulus is continued until the second relief vent value is relieved. The
procedure is repeated until all relief vent valves have been tested at end-fitting A.
5. To check the free flow through the annulus of the entire length of the pipe the
filling of the annulus must be continued until a pressure increase is registered at
the manometer at end-fitting B. Then the valve at the test pipe is opened to check
for free flow through the annulus.
6. Then the steps 3 to 7 is repeated in reversed order with respect to the end-fitting
(A=>B, B=>A)

7.2 ACCEPTANCE CRITERIA

Gas relief shall be confirmed at all valves and/or free flow through the annulus must be
confirmed.

Note: The manufacturers specified relief pressure is 2 bar ± 0.2 bar

8 CHECK OF FLANGE FACES

The sealing area of the flange faces shall be visual inspected and shall be free of
scratches/dents.

9 DELIVERY
All flexible pipes will be delivered empty of water. A foam pig will be used to empty the
pipe.

This document contains confidential information. All rights (including copyright, confidential information, trade secrets, and design
rights) are owned by NKT Flexibles I/S
No use or disclosure is to be made without the prior written permission of NKT Flexibles I/S. All rights reserved.
TM-ENG-028, rev. 03