STATS GROUP

Process & Pipeline Integrity Solutions

PROJECT:
14” In-line Weld test Tool

CLIENT:
HYDRATIGHT OPERATIONS LTD

DOCUMENT TITLE:
TT0304 & TT0322 In-Line Weld Test Tool

DOCUMENT TYPE: DOCUMENT No.:

Installation and Operating Manual OM-E1197-322

ORIGINAL (If red): COPY No:

ORIGINAL Rev A
STATS CONTRACT / JOB No.: CLIENT PROJECT / JOB No:
Enquiry: E1197
J2583 13853

ISSUE DESCRIPTION PREPARED CHECKED CLIENT APPROVAL

DATE BY BY
S. Peter S. Reid N/ R

13/02/12 Issued For Internal Review

Rev A Issued For Internal Review Rev B Issued For Client Review
Rev C Issued For Construction Rev Z Final Documentation

Copyright © STATS (UK) Ltd 2010

This document is subject to copyright and must not be copied, distributed or reproduced in any format
either in part or as a whole without the express written permission of STATS (UK) LTD.
 In-line Test Tool Installation & Operating Procedure

This Page is intentionally blank.

OM-E1197-322 Page 2 of 19
 In-line Test Tool Installation & Operating Procedure

Introduction: .......................................................................................................................... 4

Safety: .................................................................................................................................. 5

Lifting the Tool: ..................................................................................................................... 7

Selecting the Tool Size: ........................................................................................................ 7

Tool Parts Lists: .................................................................................................................... 8

Size Kit Parts Lists: ............................................................................................................... 9

Size Kit Change-out: ........................................................................................................... 10

Tool and Size Kit Storage: .................................................................................................. 11

Example of Vapour Barrier Installation Procedure: .............................................................. 12

Example of Hydro Test Procedure: ..................................................................................... 14

Trouble shooting: ................................................................................................................ 17

Notes: ................................................................................................................................. 19

OM-E1197-322 Page 3 of 19
 In-line Test Tool Installation & Operating Procedure

Introduction:

STATS AC range of aluminum In-line Weld Test Tools provide a safe, fast and efficient
means of creating a hot work vapour barrier and carrying out localised pressure testing of
pipe work butt welds and joints.

The aluminium in-line test tools have been designed in accordance with STATS (UK) Ltd
engineering standards which are based on international codes. The aluminium in-line test
tools create localised test boundaries for hydrostatic testing and are designed to suit
standard ANSI / ASME B36.10 / API 5L pipe sizes. Alternative sizing kits are available to suit
a range of pipe wall thickness schedules.

The vapour migration barrier is created by deploying the in-line weld test tool into the
existing pipe work, activating the tool and introducing a positive pressure inert medium in the
tool test void. The rear of the tool must be a minimum 500mm from the heat source.

The vapour barrier must not be installed in a pipe or system where there is the potential for
pressurisation of the atmosphere contained by the tool. The containment atmosphere must
always be maintained at ambient pressure.

In-line test tools are supplied solely for the purpose of providing a verified barrier against the
migration of harmful or flammable vapours at ambient pressure and for the purpose of
conducting localised hydro leak and strength tests.

In-line test tools do not provide any form of system isolation and should be used to provide a
verified vapour migration barrier only. All pipe work or systems where the barrier tool is
installed must be open to atmosphere and / or isolated in accordance with the relevant plant
or system statutory isolation procedure.

The hydro test envelope is created by inserting the in-line weld test tool into the pipe work
and locating the tool across the butt weld or joint to be tested.

Localised pressure testing is a means of verifying the integrity of a welded, formed or

flanged joint which has been made on a piping system. Typically these are made during a
repair or modification on a process piping system. The test is typically undertaken using
water as the test medium but can be undertaken using inert gas, if required. The test
undertaken is normally a strength test of the joint at 1.5 times design pressure but the tool
can also be used as a leak testing means typically undertaken at 1.1 times design pressure.

This equipment should only be operated by trained and competent personnel. This
document is specifically written for the installation and operation of STATS AC range of In-
line test tools.

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 In-line Test Tool Installation & Operating Procedure

Safety:
Hazards and risks are unique to each and every task. The operator must be aware of the
hazards and risks associated with the tasks and must carry out a risk assessment for each
individual scope of work prior to carrying out any work. Adopt safe working practices,
exercise common sense and always, read and understand the equipment operating
manuals, work instructions and procedures. As with all open end pipe and pressurised
equipment operations it is essential that all personnel within the work area are made aware
of the risks associated with the operations that are being undertaken. The work area should
be marked off using barrier tape and warning signs erected where they are clearly visible.
Personnel within the work area should be instructed not to stand in front, near or under any
equipment or open ended pipe work in case of dropped objects, failure of lifting or
pressurised equipment.

The location of the ancillary equipment within the work area will have an impact on the
overall safety of the task. Plan the equipment set up, and locate the ancillary equipment
within the low risk work area. Locate and set up the equipment in such a way as to minimise
the trip hazards and obstruction to personnel within the work area.

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 In-line Test Tool Installation & Operating Procedure

The operator should be aware of the hazards relating to the Installation and operation
of the In-Line Weld Test Tool.

Points to consider when carrying out a risk assessment of the task or work scope:

Tool Installation & Removal:

• Lift Injury
• Trapped digit
• Trip Hazard
• Dropped object
• Failure of the lifting equipment

Tool Operation:
• Unexpected pressure increase in the atmosphere contained by the tool
• Failure of the equipment under test
• Failure of the test hoses, the ancillary test or tool activation equipment

Dos & Don’ts

Do:
• Read and understand the equipment operating instructions and work procedures.
• Barrier off the work area and erect warning signs around the work area.
• Walk the job and physically examine the pipe work isolation valves and spades.
• Verify that all branches from the pipe work have been isolated.
• Verify that there is a certificate of isolation pertaining to the pipe work that you are
working on.
• Verify that there is a suitable branch on the line to vent the atmosphere contained by
the tool.
• Carry out a tool box talk with all persons involved with the task or work scope.
• Plan the location of the ancillary equipment within the work area.
• Thoroughly examine all flexible hoses and connections during the assembly of the test
spread.
• Observe manual handling guidelines.
• Observe the test pressure at which the equipment under test can be physically
approached and inspected.
• Observe the maximum working pressure for the tool and the ancillary equipment.
• Ensure that all personnel within the work area remain within the low risk area when the
tool is activated.

Don’t:
• Assume that the pipe work you are working on has been totally isolated.
• Proceed with the work scope without a written copy of the test parameters and test
instructions.
• Allow any person to work directly in front of the pipe work when the tool is installed in
the pipe work.
• Approach and inspect the equipment under test until a reasonable period of time has
elapsed.
• Attempt to manually lift or install equipment greater than 25Kgs in weight.
• Exceed the maximum working pressure of the tooling or the ancillary equipment.

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 In-line Test Tool Installation & Operating Procedure

Lifting the Tool:

Rigging and lifting equipment should be attached to the tool to assist handling and
deployment. The rigging and lifting equipment can be attached to the tool using lifting eye
bolts which can be fitted at the following locations on the assembled tool.

• Carriers: drilled and tapped to accept an M10 x 1.5 lifting eye bolts at eight locations

Selecting the Tool Size:

Sizing kits are available to suit ANSI / ASME B36.10 / API 5L pipe sizes in Sch 40 and Sch
80 wall thickness schedules.

TC0322: Suitable for use in 14" Sch STD, 20, 30 and 40

• Model: TC0322

• Size Kit Part Number: ACK322-70

• Seal OD: 322mm

• M.W.P. 85 Bar G (1233psi)

• Max Hyd Set Pressure: 240 Bar G (3480psi)

• Weight: 70.4 Kgs

• OAL: 500mm

TC 0304: Suitable for use in 14" Sch 80

• Model: TC0304

• Size Kit Part Number: ACK304-70

• Seal OD: 304mm

• M.W.P. 85 Bar G (1233psi)

• Max Hyd Set Pressure: 240 Bar G (3480psi)

• Weight: 62.3 Kgs

• OAL: 500mm

OM-E1197-322 Page 7 of 19
 In-line Test Tool Installation & Operating Procedure

Tool Parts Lists:

Quantity
Item
Component. Part No. required
No.
per tool
1 Tool Body AC 24 0004 0002 1
2 O-ring Kit ACR300 2
3 Piston AC 24 0005 0001 2
ACK322-70
4,5 & 6 Size Kit or 2
ACK304-70
7 Carrier AC 24 0006 0001 2
8 SAE Port Adaptor MB192 4
9 Body End Plug AC 24 0010 0003 2

Fig: 1

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 In-line Test Tool Installation & Operating Procedure

Size Kit Parts Lists:

Size Kit: ACK322-70

Quantity
Item
Component. Part No. required
No.
per Kit
4 Piston Ring AC 25 0007 0003 1
5 Seal AC 25 0009 0003 1
6 Carrier Ring AC 25 0008 0003 1

Size Kit: ACK304-70

Quantity
Item
Component. Part No. required
No.
per Kit
4 Piston Ring AC 24 0007 0009 1
5 Seal AC 24 0009 0009 1
6 Carrier Ring AC 24 0008 0009 1

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 In-line Test Tool Installation & Operating Procedure

Size Kit Change-out:

Tool Disassembly:
1. Clean the tool to remove grease and debris.
2. Ensure your workbench is clean and free from debris.

Rear Size Kit Removal:

1. Remove any fittings from the port adaptors that might clash with the removal of the
size kit components.
2. Hold the tool core, Fig: 2, item1 and unscrew the rear seal carrier, ring and seal.
3. Pull the seal and carrier ring from the seal carrier.

Fig: 2

Front Ring and Seal Removal:

1. Hold the tool core Fig: 2, item1 and unscrew the front seal carrier, ring and seal.
2. Pull the seal and carrier ring from the seal carrier.

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 In-line Test Tool Installation & Operating Procedure

Tool Assembly:

Front Ring and Seal Replacement:

1. Clean and lightly oil or grease the threads on the tool body.
2. Fit the carrier ring seal to the seal carrier.
3. Fit the seal to the seal carrier.
4. Fit the piston ring to the piston.
5. Screw the seal carrier, on to the tool body until it is fully home. (Hand tighten only).
6. Back off the seal carrier by 1/8 of a turn.

Rear Ring and Seal Replacement:

1. Clean and lightly oil or grease the threads on the tool body.
2. Fit the carrier ring seal to the seal carrier.
3. Fit the seal to the seal carrier.
4. Fit the piston ring to the piston.
5. Screw the seal carrier, on to the tool body until it is fully home. (Hand tighten only).
6. Back off the seal carrier by 1/8 of a turn.
7. Refit any fittings that were removed from the port adaptors for tool disassembly.
8. Reconnect the hydraulic control lines to the ports on the tool body, Red line to the
(Hyd) hydraulic set port, Blue line to the (F) test void fill port, Yellow line to the (V)
test void vent port and the Black line to the (DS) downstream monitor port.

************************************************************************************************
In the interests of safety this tool must not be function tested unless the entire tool is located
within a suitable section of pipe work.
**********************************************************************************************************************

Tool Function Test:

1. Insert the entire tool in a suitable test pipe.
2. Operate the hydraulic hand pump to activate the tool. Apply 250 Bar G hydraulic set
pressure.
3. Allow the set pressure to stabilise for 5 minutes and verify that there are no oil leaks
or significant loss of set pressure.
4. Re-establish the hydraulic set pressure and hold for a further 10 minutes. Verify that
there are no oil leaks or significant loss of set pressure.
5. Bleed down the set pressure and allow 5 minutes for the tool seals to fully relax.
6. Remove the tool from the test pipe.
7. Clean the tool and apply corrosion inhibitor.

Tool and Size Kit Storage:

The tool seals are manufactured from an acrylonitrile / butadiene based synthetic rubber.
This material has limited resistance to ultraviolet light and will deteriorate over time if
continuously exposed to light.
To preserve the life of the tool seals, always store the tool sizing kits in a closed container or
black polythene bag.

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 In-line Test Tool Installation & Operating Procedure

Example of Vapour Barrier Installation Procedure:

Objective: To install a verified vapour barrier in the existing pipe work to allow hot work
operations to be undertaken safely.

Equipment Checklist:
• 1 x 14” Hydraulically activated IWTT.
• 1 x Hydraulic Tool Activation Pump.
• 1 x Hi-Force Test Pump.
• 1 x 5 Port Test Manifold MWP 350 Bar G
• 4 x 3 meter ¼” test hose MWP 350 Bar G
• 2 x 5 meter ¼” test hose MWP 350 Bar G
• 1 x 0- 7 Bar G Monitor Gauge
• 1 x Tool box c/w tools, fittings & spares

Installation Procedure:
1. The ID of the pipe into which the tool is to be inserted should cleaned and free from
loose debris, rust and scale.
2. Place barrier tape and warning signs around work area to warn other workers that work
is in progress.
3. The ports required to operate tool are located on the end of the tool body. The ports are
stamped, (H) Hydraulic Port, (DS) Thru Port, (F) Test Void Fill Port and (V) Test Void
Vent Port.
4. Connect a suitably rated hose from the (DS) Thru Port monitor line on the tool and route
it to a safe and accessible monitor area.
5. Submerge the end of the through port hose in a bucket of clean water.
6. Connect a suitably rated hose from a test medium pump fitted with a 7 Bar G indication
gauge to the (F) test void fill port on the tool.
7. Connect a suitably rated hose from the hydraulic hand pump to the (H) hydraulic set port
on the tool.
8. Place the new WN flange over the IWTT tool.
9. Install the IWTT in the pipe work and locate it as far from the heat source as possible.
10. Activate the IWTT seals using the hydraulic hand pump: apply 230 Bar G hydraulic set
pressure.
11. Operate the test medium pump until the medium flows from the vent valve.
12. Verify that all the air is expelled from the IWTT test void.
13. Close the IWTT test void vent valve.
14. To verify the primary and secondary seal integrity, apply 5 Bar G hydrostatic pressure to
the AIT seal annulus.
15. Lock-in 5 Bar G seal annulus pressure and hold for 15 minutes.
16. Reduce the seal annulus pressure to 2 Bar G and lock in.
17. Allow hot work operations to commence.
18. Regularly monitor the IWTT seal annulus pressure to verify the barrier integrity
throughout the duration of the hot work
19. Constant seal annulus pressure confirms the barrier integrity.
20. Continually monitor the containment to detect any vapour migration or pressure build up.

Note: During hot work, the seal annulus pressure may increase slightly due to the localised
temperature increase.

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 In-line Test Tool Installation & Operating Procedure

Barrier Establishment Data Barrier Barrier

Comment
Start Data End Data
Time

Tool Set Pressure (Bar G)

Seal Annulus Pressure (Bar G)

Vapour Migration Detected

(Yes / No)
Sign as stage complete

On completion of hot work:

1. Verify that the atmosphere contained by the tool is at atmospheric pressure.
2. Gently bleed down the seal annulus inert barrier.
3. Verify that the seal annulus pressure is at atmospheric pressure.
4. Verify that the atmosphere contained by the tool is at atmospheric pressure.
5. Gently bleed down the hydraulic set pressure and allow 5 minutes for the tool seals to
fully relax prior to moving the tool in the pipe work.
6. Tidy the work site
7. Write up the daily ops report.

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 In-line Test Tool Installation & Operating Procedure

Example of Hydro Test Procedure:

The objective of the hydro test is to:

A: Verify the strength of a butt weld or joint.
B: Verify the integrity of a butt weld or joint.
C: Remove the residual stresses from the component(s) that may
have been introduced by the welding process.

Strength Test Acceptance Guidelines:

The objective of the strength test is to induce a load on the weld and pipe work to a minimum
1.5 times the design pressure whilst not exceeding 90% of yield of any component and also
to verify that there is no leakage from the weld.
To be considered acceptable, the hydro test must comply with both of these criteria;
therefore, provided that there is no visible leak from the weld and that the test pressure has
been maintained at or above the specified test pressure for the specified hold period and the
strength test is recorded and documented correctly then the pressure test can be deemed
acceptable.

Leak Test Acceptance Guidelines:

The objective of the leak test is to induce a load on the joint, valve or fitting to a minimum 1.1
times the maximum working pressure of the system to which it pertains to verify that there is
no leakage.
To be considered acceptable, the leak test must comply with both of this criteria; therefore,
provided that there is no visible leak from the joint, valve or fitting and that the test pressure
has been maintained at or above the specified test pressure for the specified hold period and
the leak test is recorded and documented correctly then the leak test can be deemed
acceptable.

Test Equipment Checklist:

• 1 x 14” IWTT.
• 1 x Hydraulic Tool Activation Pump.
• 1 x Hi-Force Test Pump.
• 1 x 5 Port Test Manifold MWP 350 Bar G
• 3 x 3 meter ¼” test hose MWP 350 Bar G
• 1 x 5 meter ¼” test hose MWP 350 Bar G
• 1 x Calibrated Chart Recorder
• 1 x Pressure Indication Gauge
• 1 x Tool box c/w tools, fittings & spares

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 In-line Test Tool Installation & Operating Procedure

Tool Installation and Operating Procedure:

1. The ID of the pipe into which the tool is to be inserted should cleaned and free from
loose debris, rust and scale.
2. Place barrier tape and warning signs around work area to warn other workers that
work is in progress.
3. The ports required to operate tool are located on the end of the tool body. The ports
are stamped, (H) Hydraulic Port, (DS) Thru Port, (F) Test Void Fill Port and (V) Test
Void Vent Port.
4. Connect a suitably rated hose from the (DS) Thru Port monitor line on the tool and
route it to a safe and accessible monitor area.
5. Connect a suitably rated hose from the test manifold to the IWTT tool (F) fill port.
6. Connect a suitably rated hose from the test manifold to the chart recorder.
7. Connect a suitably rated hose from the test manifold to the test medium pump.
8. Fit the 10” Standard test gauge to the test manifold.
9. Submerge the end of the through port hose in a bucket of clean water.
10. Locate the IWTT across the butt weld or joint to be tested.
11. Activate the IWTT seals using the hydraulic hand pump: apply 230 Bar G hydraulic
set pressure.
12. Verify that the IWTT test void vent valve is open.
13. Verify that the test manifold vent valve is open.
14. Operate the test medium pump until test medium flows from the test manifold vent
valve.
15. Close the test manifold vent valve.
16. Operate the test medium pump until the test medium flows from the IWTT vent valve.
17. Verify that all the air is expelled from the IWTT test void.
18. Close the IWTT vent valve. To obtain a stable test record it is essential that all
the air is purged from the IWTT test void and ancillary equipment.
19. Operate the test medium pump until the test pressure starts to Increase.
20. Increase the test pressure in three equal stages at 5 minute intervals until the
required test pressure is achieved. Do not exceed 110% of the test pressure whilst
establishing the test.
21. Allow the test pressure to stabilise for 10 minutes.
22. Re-establish the test pressure and chart the test for the full specified hold period.

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 In-line Test Tool Installation & Operating Procedure

Criteria for hydro Test Acceptance: (150% of design pressure)

• Test pressure shall be maintained for a minimum of 15 minutes.
• Ambient temperature shall remain within the design parameters of the equipment
under test.
• Test establishment pressure is limited to a maximum 10% above the stated test
pressure.
• Equipment under test shall be examined for leakage.
• Inspect all test equipment, hoses and connections for leakage.
• Hydro test will be recorded using a calibrated dual scale chart recorder.

Hydro Test Details Test Start Test End Comment

Data Data
Time

Tool Set Pressure (Bar G)

Test Pressure (Bar G)

Vapour Migration Detected

(Yes / No)
Sign as stage complete

On completion of successful hydro test:

1. Verify that the atmosphere contained by the tool is at atmospheric pressure.
2. GENTLY bleed down the test pressure.
3. Verify that the test pressure is bled to atmospheric pressure.
4. Open the release valve on the actuation pump to unset the tool.
5. Allow a 2 minute period for the tool seals to fully relax prior to removing the tool from the
pipe.
6. Break down the pressure test ancillary equipment.
7. Remove the tool from the pipe work.
8. Dry off the tool and apply rust inhibitor.
9. Place the tool in the transit box.
10. Write up the test report and sign off the charts.
11. Tidy the work site.
12. Remove barrier tape and warning signs.

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 In-line Test Tool Installation & Operating Procedure

Trouble shooting:
Establish the possible cause of a failure to obtain a satisfactory test.
Problem Possible Cause Remedy
SECTION: 1
Failure to obtain a leak
tight test void. • Incorrect tool size • Select correct tool
selected to suit the OD to suit the pipe
pipe bore. bore.

• Insufficient hydraulic • Establish the correct

set pressure. hydraulic set
pressure for tool
selected. Refer to the
tool operation
manual.

• Loose debris and mill • Inspect the pipe bore

scale. and remove any
debris and mill scale
from the seal contact
areas of the pipe wall.

• Internal weld bead on • Remove the weld

seamed pipe. bead at the seal
contact area of the
pipe wall.

• Excessively pitted • Clean the pipe bore

internal pipe surface. using rough emery
cloth and apply a
liberal coating of
viscous grease or
mastic to the seal
contact area of the
pipe wall.

• Excessive localised • # Maintain the test

pipe wall erosion. pressure using the
test pump for the
specified hold period.

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 In-line Test Tool Installation & Operating Procedure

SECTION:2
Failure to obtain a stable
test record. • Air trapped in the test • Verify that the IWTT
void or ancillary test void vent port is
equipment. positioned
uppermost. Partially
un-set the tool to
allow any trapped air
to vent past the tool
seals. Verify that all
the air has been
vented from the test
void and from the test
medium circuit.

• Loss of test void • Address and

integrity (SECTION: 1). eliminate the issues
listed in section: 1

• Ambient temperature • Take steps to control

fluctuations the ambient
temperature or
increase the volume
of the test medium
circuit.

• Continual seal creep • Verify that the tool

(seal extrusion or selected is the correct
deformity) usually as OD.
a result of using an
under sized tool.

• Failure or leakage • Inspect the

from ancillary equipment under test
equipment or the and the test medium
equipment under test. circuit to eliminate
this possible cause.

• Mismatched pipe • Adopt an alternative

bores at seal location method to undertake
areas. the hydro test.

#: Should it become evident that the condition of the pipe work is such that it will not allow
the tool seal to perform satisfactorily, and secure a leak tight test void then it must be
established if the hydro test can still be undertaken and accepted by maintaining the test
pressure using the test pump for the specified hold period.

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 In-line Test Tool Installation & Operating Procedure

Notes:

OM-E1197-322 Page 19 of 19