Issue Date:

AlMansoori Production Services 02nd Feb 2020

Surface Well Testing Document Number:
MPS/SWT/SOP04_03
Standard Operating Procedures
Rev. No. Page No.
Pressure Testing Procedure 03 1 of 10

Pressure Testing Procedure

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 Issue Date:
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Surface Well Testing Document Number:
MPS/SWT/SOP04_03
Standard Operating Procedures
Rev. No. Page No.
Pressure Testing Procedure 03 2 of 10

Document Revision History

Rev. Affected
Date Description of Change By
Number Pages
00 01st Mar 1998 First Issue All MPS
01 29th April 2012 Total Update All MPS
Introduction and Added Safety Guidelines
02 15th October 2017 All MPS
Prior To Pressure Testing
03 02nd Feb 2020 Updated with new skeleton All MPS

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 Issue Date:
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Surface Well Testing Document Number:
MPS/SWT/SOP04_03
Standard Operating Procedures
Rev. No. Page No.
Pressure Testing Procedure 03 3 of 10

Table of Contents
1. Introduction .............................................................................................................................................................................4
2. Safety Guidelines Prior Pressure Testing ...........................................................................................................................5
3. Duration of Pressure Test and Medium ..............................................................................................................................6
4. Pressure Test Guidelines for Individual Equipment ........................................................................................................6
5. Volume in Tank .......................................................................................................................................................................8
6. Verification & Calibration of Flow Meters ..........................................................................................................................9
7. Quality Assurance Manual ...................................................................................................................................................10

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Surface Well Testing Document Number:
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Standard Operating Procedures
Rev. No. Page No.
Pressure Testing Procedure 03 4 of 10

1. Introduction
Pressure testing is a high-risk activity. When applying such stored energy to an equipment assembly,
especially for the first time, as there is potential for an unintended or premature pressure release
while crews are in the danger zone, nearby to equipment.
Release of stored energy under pressure can cause:
 Test assembly rupture, creating flying fragments.
 Component or connector failure, creating missiles or flying objects projected by force.
 Sudden release of the test medium liquid, water, gas, vapor, dust or other substance under
pressure) causing injury, e.g. Burns, eye damage or pressure injection into bodily tissue.
The purpose of these procedures are to ensure that pressure tests are conducted safely and
effectively. They cover pressure testing of new and existing pressure systems or components at a
test pressure more than 0.0 psig.
Pressure tests are performed to ensure the safety, reliability, and leak tightness of pressure systems.
A pressure test is required for a new pressure system before use or an existing pressure system after
repair or assembly.
There are two methods for pressure tests: hydrostatic and pneumatic. A hydrostatic test is
performed by using water as the test medium, whereas a pneumatic test uses air, nitrogen, or any
non-flammable and nontoxic gas. At MPS pressure tests must be done by hydrostatic unless
pneumatic tests can be justified and with nitrogen only. Pressure tests must always be performed
under controlled conditions, following an approved test procedure, and documented in a test record
with chart recorder. A single approved test plan may be used for several similar tests, but a separate
test record is required for each test.
1. Pressure testing should be carried out for all pressure control equipment, with reference to the
diagrams to the maximum cold working pressure CWP specified by company personnel/program,
before any well effluent is allowed to enter the well test package. It is carried out in order to ascertain
the integrity of all flow-line, vessels, …. etc.
Note: these diagrams are for specific equipment layouts and may vary from job to job dependent on
the equipment shipped from base and hook up.
2. It should be noted that, although a pressure test may have been completed satisfactorily, once a valve
or equipment is been operated or the well flowed through equipment then the imminent integrity of
the equipment is not guaranteed due to e.g. Erosion, etc.
3. Records of all pressure tests carried out should be up dated in EMMS, included on the well test report
and in job file, indicating sequence of testing, test pressures and testing medium.
4. All personnel are encouraged to apply "stop work" authority whenever there is a safety concern
during pressure testing operations.

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Surface Well Testing Document Number:
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Standard Operating Procedures
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Pressure Testing Procedure 03 5 of 10

2. Safety Guidelines Prior Pressure Testing

1. Conduct required tool box talk (TBT) before commencement of the task.
2. It is mandatory to put in place warning signs “pressure test in progress”, barricades or other
protective barriers are placed in a manner and at a sufficient safe distance to define a safe zone to
protect personnel and the public from unanticipated pressure release or equipment failure.
3. Keep unauthorized personnel out of the test area.
4. Inform all site personnel of the planned test through a public speaker or other means of
communication.
5. Personnel performing the pressure test should not approach the pressurized line/equipment,
unless depressurized and only in the performance of their duties. Whenever possible, personnel
should use safety barriers for protection from the pressurized line and position the testing
equipment in such a away with pressure wall protections, to minimize potential hazards.
6. Personnel are not allowed to work over or nearby where pressure testing is being conducted.
7. Wear the PPE as appropriate for the task being performed.
8. Never tamper with or tighten any fittings (i.e., connections, bolts, hoses) while component is under
pressure “pressurized”.
9. Never tighten connections that are under pressure. If a leak develops, you must depressurize to 0.0
psig and then re-tighten.
10. Wear hearing protection (in which may include double hearing protection) that is adequate to
reduce the noise below 80 decibels.
11. Connect calibrated pressure recorders and pressure gauges at a safe distance away from attended
equipment by 20-100 ft dependable on equipment pressure rating.
12. Verify that test equipment materials are rated to withstand the anticipated test pressures.
13. Verify that all lines and connections are secured with retaining devices before and during the
pressure test period.
14. Visually inspect and ensure reliability and proper installation of all tested equipment and valve
positions (full open/close).
15. Only calibrated pressure gauges with valid calibration certificate shall be used. The pressure test
range should be within 20% to 80% of used pressure (i.e. 50% is optimum), so the pressure is in the
center part of the gauge, i.e. It shall have the dial graduates over a range of about doubled the
intended maximum pressure.

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Surface Well Testing Document Number:
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Standard Operating Procedures
Rev. No. Page No.
Pressure Testing Procedure 03 6 of 10

3. Duration of Pressure Test and Medium

1. Hold straight line for pressure tests for a minimum of 15 minutes or extend/reduce period as per
client requirements but pressure test not to exceed equipment maximum design pressure or
equipment cold working pressure (CWP), utilizing calibrated and certified pressure test pumping
system with calibrated chart recorders and equivalent pressure gauges.
2. Chart recorder might be reviewed and witnessed by a company representative (client) to ensure a
satisfactory pressure test in which it should contain the following information’s.
A) Sequence of carried out pressure test versus relevant section of chart.
B) Client name
C) Field name
D) Well number
E) Date
F) Supervisor / job performer name
Note: Original site pressure test charts must be kept on site of the tested equipment for the
duration of the equipment rental/job duration period.
3. Commonly used different pressure test mediums are as follows:
A) Fresh water
B) Nitrogen gas (N2)
4. It is forbidden and not allowed to utilize Hydrocarbon medium to pressure test any equipment i.e.
diesel, base oil, well gas (well pressure) due to the possibility of leaks or explosion, as air might
not be properly flushed out of equipment prior to applying pressure.
Note: prior to pressure testing with nitrogen a hydrotest must have taken place.

4. Pressure Test Guidelines for Individual Equipment

Choke Manifold
Four Valve Manifolds:

1. Open fully all valves (count the turns) and adjustable choke.
2. Flush manifold with fresh water, venting through taps downstream of manifold.
3. Fix properly rated elbow & test plug with valve to choke manifold outlet.
4. Pressure test manifold body to required cold working pressure CWP / 1.5 CWP.
5. Close upstream valves and open downstream valves, test to required CWP.
6. Bleed off the pressure, open upstream valves and close downstream valves and test to
required CWP.
7. Bleed off the pressure and open downstream valves
8. Keep all valves in open position and preserve accordingly by applying grease

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Surface Well Testing Document Number:
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Standard Operating Procedures
Rev. No. Page No.
Pressure Testing Procedure 03 7 of 10

Eruption Manifold
1. Open fully all valves (count the turns) and adjustable choke.
2. Flush manifold with fresh water, venting through taps downstream of manifold.
3. Fix properly rated elbow & test plug with valve to choke manifold outlet.
4. Pressure test manifold body to required cold working pressure CWP / 1.5 CWP.
5. Close two back valves and apply pressure test against them.
6. Close two middle valves and apply pressure test against them.
7. Close four main valves and apply pressure test against each them.
8. Bleed off the pressure and open downstream valves
9. Keep all valves in open position and preserve accordingly by applying grease
Test Separator
Prior to pressure test the separator to cold working pressure, ensure that the separator both pressure
relief valves PRV’s are correctly installed and connected to Nitrogen cylinder with 50-100psig applied
pressure to set the pilots but if applying body test ensure to remove both PRV’s and place a blind
flange. Also, the relief line laid down to a safe area preferably to green burner or to flare stack, to
avoid personnel injury whenever pup up to release excess pressure.

1. For separator body test, ensure to fully open all ball valves all ends and to needle valves and
place plugs for all valves and lines.
2. For separator cold working pressure test, ensure that downstream of flow lines; water, oil and
gas outlets are closed in as applicable.
3. Close sight glass drains valves.
4. Close isolating valves on Barton recorder and sensing line to fisher 4150 (wizard) controller.
5. Raise orifice plate carrier.
6. Connect instrument air supply to oil and water controllers and maintain in an open position.
7. Open all isolating valves.
8. Fill separator with water through fluid inlet making sure all air is expelled by venting at high
points.
9. Pressure test body to the required pressure 1.5 x CWP and examine for leakage.
10. Pressure test valves so that following valves are tested:

 Separator manual inlet ball valve

 Separator both manual bypass ball valves
 Separator gas outlet manual ball valve
 Separator oil outlet manual ball valve
 Separator water outlet manual ball valve

Note: Above are the major separator valves to be pressure tested. Depending on the test
requirements, it may deem necessary to pressure test isolation valves e.g. The liquid meter isolation
manifold valves in order to change the meter while flowing through the separator. These additional
tests should be completed as required.

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Surface Well Testing Document Number:
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Standard Operating Procedures
Rev. No. Page No.
Pressure Testing Procedure 03 8 of 10

11. All pressure tests to include shrinkage tester, Daniel senior orifice fitting and oil/water sight
glasses and level switches.
12. Daniels senior should be body tested with slide valve open and also tested with the slide valve
closed and upper chamber vented.
13. During the pressure testing of separator, this provides a good opportunity to monitor correct
functioning of the oil/water liquid level controllers and sight glasses. Liquid meters can also be
flow proved to check the accuracy of the meter factors on the calibration certificate.
14. This should be carried out by pumping water from the centrifugal transfer pump unit to the
gauge/surge tank (surge tank should have back pressure valve BPV Open to remain at atmospheric
pressure) and checking against the meter reading for that volume (bench meter factor). Calculate
and obtain the meter factor for each specific meter as in step (6) verification & calibration of flow
meters:

5. Volume in Tank
Volume through Meter
Note: Utilizing fresh water will be an uncorrected meter factor and if used then shrinkages will have
to be calculated and used in the oil calculation.
Gas Diverters
1. Flush through manifold with fresh water.
2. Close both valves and conduct pressure test to the required cold working pressure CWP.
3. Bleed off pressure and open both valves.
Oil Diverters
1. Flush through manifold with fresh water.
2. Close both valves and conduct pressure test to the required cold working pressure CWP.
3. Bleed off pressure and open both valves.
Surge Tanks
1. Close outlet valves.
2. Close drain points of sight glasses (if applicable).
3. Fill vessel with water, venting at high spots.
4. Close all vent valves and pressure test to required pressure, examining for leakage.
5. Close both inlet valves to both compartments, bleed off downstream and test to required
pressure.
Gauge Tanks
1. close outlet valves.
2. close drain points sight glasses (if applicable).
3. fill vessel with water, venting at high spots.
4. examine for leakage.
5. close inlet valves to both compartments, test to required pressure.

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Surface Well Testing Document Number:
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Standard Operating Procedures
Rev. No. Page No.
Pressure Testing Procedure 03 9 of 10

Free Standing Valves

1. Close suitably rated valve downstream or blank off valve outlet.
2. Open valve.
3. Flush through valve venting where possible.
4. Carry out body test to required pressure.
5. Close valve and test to required pressure.
6. Bleed off pressure and connect to outlet end of valve.
7. Test to required pressure.
8. Bleed off pressure, open valve and drain.
9. Verification of flow meter calibration

6. Verification & Calibration of Flow Meters

Attestation:
Issued within the scope of The Bureau Veritas Marine branch general conditions at the request of
Almansoori Production Services (LLC) P. O. Box 7663, Abu Dhabi, the undersigned N.E. surveyor to
Bureau Veritas, acting within the general terms and conditions of Bureau Veritas which governs such
interventions, did attend the Mussafah base of Almansoori between the 13th and 15th of July, 1995
to inspect and report on the flow meter calibration set up and reports hereunder our findings.
1. Set-Up:
The system comprises of two-gauge tanks of regular cross-sectional area, connected by 3” pipework
through a centrifugal pump to the flow meter to be calibrated. The return pipework forms a loop
such that fluid can be flowed from one tank to the other passing through the flow meter.
Refer to drawing appended as annex ”A”.
2. Principle:
The proposed procedure for verifying calibration accuracy and determining meter factors, is the
volumetric proving method, in which is suitable for calibration of liquid flow meters.
3. Procedures:
Almansoori Liquid Flow Meter Calibration Procedure, Appended as Annex ‘B’ was reviewed and
found satisfactory.
4. Tank Factor:
The skid mounted double/twin tanks, identified as serial number Bam- 75-002, were measured to
confirm volume per inch increase or decrease in level.
Tank factor: 1” corresponds to 0.593667 BBL level is measured by graduated scale sight glass in
inches. Accuracy of measurement checked and found correct as if master meter.
5. Test:
A functional test of the equipment was performed to prove that operators were familiar with the
procedure and following this correctly. All found satisfactory.

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Standard Operating Procedures
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Pressure Testing Procedure 03 10 of 10

6. Report:
A Report Format Was Reviewed And Found Satisfactory Appended As Annex ‘C’.
7. Conclusion:
The equipment and procedure are considered suitable to check calibration of flow meters.
In witness where of this attestation is issued without prejudice for the ends and purposes assigned.
However, if calibration is suspected for any reason it is advisable to utilize master meters with third
party valid calibration certificate for one year.

7. Quality Assurance Manual

Liquid Flow Meter Calibration:
Purpose:
To determine the liquid flow meter calibration factor and ensure that the factor falls within the
acceptable range.
Scope:
This procedure is applicable to the following types of liquid flow meters used by MPS.

A) 1” Turbine Meters with digital displayers

B) 2” Turbine Meters with digital displayers
C) 3” Turbine Meters with digital displayers

This procedure should be carried out on any liquid flow meter in the event of:

• The meter is been opened for maintenance or any of its parts has been replaced.
• the meter is been in operation for 30 days.
Procedure:
1. Rig up meter on calibration tank as per drawing No. Mps/638/95.
2. start the pump and keep it running until the liquid level is established in the tank.
3. Take tank level measurement and meter reading simultaneously.
4. Keep flowing for at least 10 Bbls.
5. Tank both tank level and meter reading simultaneously and then stop the pump.
6. Calculate the meter factor F1 in accordance with MPS liquid flow meter calibration form.
7. Repeat steps 2 to 6 two more times and obtain F2 And F3.
8. Calculate the average of the meter factors F1, F2 And F3. The average ‘F’ is the meter calibration
factor.
Documents:
Liquid flow meter calibration form drawing No. MPS/638/95

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