Case Study: Successful Hydrostatic & Pneumatic Testing for a Subsea Manifold
In the high-stakes world of offshore oil and gas, ensuring the integrity of subsea equipment is critical to operational safety and efficiency. At OTS Offshore Trading & Services Co., Ltd, our expertise in hydrostatic testing and pneumatic testing ensures that subsea manifolds meet rigorous international standards. This case study explores a recent project where OTS successfully conducted pressure testing for a subsea manifold, overcoming significant challenges to deliver exceptional results for a multinational client in the EU.
Project Overview
Our client, a leading oil and gas operator in the North Sea, required comprehensive hydrostatic testing and pneumatic testing for a newly fabricated subsea manifold. The manifold, designed to control and distribute fluid flow in a deepwater oilfield, needed to withstand extreme pressures and harsh marine environments. The project demanded compliance with ASME B31.3 (Process Piping Code) and ISO 13628-6 (Subsea Production Systems), ensuring leak-tightness and structural integrity under pressures exceeding 12,000 psi.
Challenges Faced
The project presented several challenges:
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Complex Geometry: The manifold’s intricate design, with multiple welds and connections, increased the risk of undetected defects.
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High-Pressure Requirements: Testing at pressures 1.5 times the design pressure (per ASME B31.3) required precise equipment and safety protocols.
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Environmental Constraints: The subsea environment demanded corrosion-resistant materials and water treatment to prevent damage during hydrostatic testing.
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Tight Timeline: The client needed rapid testing to meet project deadlines, necessitating efficient coordination and execution.
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Safety Risks: Pneumatic testing posed risks due to the high stored energy of compressed nitrogen, requiring stringent safety measures.
OTS’s Solutions
OTS leveraged its expertise and state-of-the-art facilities in Ho Chi Minh City, Vietnam, to address these challenges:
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Advanced Testing Equipment: We deployed high-pressure pumps and nitrogen compressors for hydrostatic testing and pneumatic testing, respectively. Our equipment, compliant with ISO 13628-6, ensured precise pressurization up to 18,000 psi. Safety relief valves and remote-operated control panels minimized operator exposure to high-pressure risks.
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Comprehensive NDT Integration: Before pressure testing, we conducted Non-Destructive Testing (NDT) using Ultrasonic Testing (UT), Magnetic Particle Testing (MT), and Penetrant Testing (PT) to identify potential weld imperfections. This ensured the manifold was defect-free, reducing the risk of failure during testing.
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Corrosion Mitigation: For hydrostatic testing, we used treated water with corrosion inhibitors (e.g., ZERUST® HST-10) to protect the manifold’s internal surfaces, ensuring compliance with environmental standards. Post-test dewatering was performed using controlled methods to avoid damage.
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Safety Protocols: For pneumatic testing, we implemented ASME PCC-2 guidelines, including pressure relief devices and restricted access zones to mitigate explosion risks. Testing was conducted at 110% of the design pressure, with gradual pressurization in 10% increments.
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Efficient Workflow: Our team coordinated closely with the client to streamline preparation, testing, and documentation, completing the project within the tight timeline. All test data, including pressure readings and leak inspections, were documented per ASME B31.3 requirements.
Results Achieved
The project was a resounding success, delivering the following outcomes:
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Compliance with International Standards: The manifold passed all hydrostatic testing and pneumatic testing, meeting ASME B31.3 and ISO 13628-6 standards with zero leaks or deformations.
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Enhanced Safety: Rigorous safety protocols ensured zero incidents, protecting personnel and equipment.
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Client Satisfaction: The client praised OTS’s precision and efficiency, enabling on-time deployment of the manifold in the North Sea.
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Environmental Responsibility: Treated water and proper disposal methods ensured compliance with environmental regulations.
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Operational Readiness: The manifold was certified for operation at its maximum allowable working pressure (MAWP), ensuring reliability for its 25-year operational life.
Why OTS Offshore?
With over a decade of experience serving global oil and gas leaders, OTS Offshore combines technical expertise with a commitment to safety and quality. Our facilities in Ho Chi Minh City are equipped to handle complex subsea equipment testing, and our certified technicians adhere to international standards like ASME and ISO. By integrating hydrostatic testing, pneumatic testing, and NDT, we deliver comprehensive solutions that ensure structural integrity and operational success.
Request a quote for your fabrication project today and discover how OTS Offshore can safeguard your subsea equipment. Contact us at [email protected] or visit www.ots-tl.com. Explore our mechanical fabrication services to learn more about our end-to-end capabilities.
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