INSTALLATION OF PIPELINE BY HDD FOR NGN

PIPELINE PROJECT

Document Title Job Procedure for POST HYDROTESTING

Client ASSAM GAS COMPANY LIMITED
Document Number MGBEPL-VCS-AGCL-NGN-JP-18 REV.00
Vendor Mansi Ganga Builders & Engineers Pvt. Ltd.
Vendor Scope Installation of Pipeline by HDD method

0 30.04.2021 ISSUED FOR REVIEW & MGBEPL VCS/AGCL VCS/AGCL

APPROVAL
REV DATE PURPOSE OF ISSUE PREPARED REVIEWED APPROVED
BY BY BY

Page 1 of 12
CONTENTS
S.No. Description Page No.

1. Scope 3

2. Reference 3

3. Equipment and Materials 3

4. Manpower List & Team Responsibilities 4

5. Methodology 4

6. Testing Procedure 5

7. Safety 11

8. Format 12

Page 2 of 12
1.0 SCOPE
The purpose of this procedure is to establish the working method for Post Hydro Testing of
INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH GAS PIPELINE PROJECT.

2.1 REFERENCES

 Tender Document
 VCS/AGCL SPECIFICATION
 Approved Procedure
 API RP-1110
 ASME B31.8 & HSE Manual
 OISD 141 & PNGRB Regulations
 Pipe Book, Standard Drawing

3.1 EQUIPMENT & MATERIALS

 Lab Thermometer.
 Pre Tested Header.
 Air Compressor for Cleaning, Gauging & Dewatering
 A water tank for controlled filling into the manifold.
 Water filling pump with discharge rate of minimum 200M/Hr and differential head of 20%
greater than required.
 Hydrostatic test reciprocating pressurization pump (motorized/engine mounted).
 Calibrated pressure gauges for pressure indication of least count of 0.200kg/ema at both
ends on test pre tested header.
 Block valves for holding the water in the system and for venting.
 Non return valve at the pressurization inlet to hold the pressure while filling &
pressurization in progress.
 Temperature & Pressure recorders (manothermograph)
 Digital Thermocouple for measuring the pipe wall temperature with an accuracy of 10.2°C.
 Pigs for filling, cleaning.
 * 2 cup batching Pig for filling and dewatering.
 * Foam pig for swabbing.
 Bi-directional four cup batch pigs with gauge plate dia. equal to 95% of the inner dia of the
pipe wall.
 Dead weight testers with an accuracy of 0.05 bar.
 Two 24 hours recording pressure gauges with charts and ink gauges tested with dead
weight tester prior to use.
 Aluminum Gauge plate of diameter equal to 95% of the pipe internal diameter.
 Pressurization Pump of capacity to pressurize up to 275 Kg/cm2 at a minimum flow rate of
10LPM.
 Temporary launching and receiving traps with necessary fittings & accessories.
 Valves & fittings of suitable size & pressure rating.

Page 3 of 12
4.1 MANPOWER LIST AND TEAM RESPONSIBILITIES:
SR. DESCRIPTION QUANTITY
1 Site Engineer 01 Nos
2 Supervisor 01 Nos
3 Technician 01 Nos
4 Fitter 01 Nos
5 Welder 01 Nos
6 Grinder 01 Nos
7 Rigger 01 Nos
8 Helper/Labour 6 Nos

Hydro testing Engineer

Shall report to the Resident Construction Manager and shall be responsible for

 Preparation of hydro test section schedules of each spread.

 Overall control and safety management and for the implementation of procedure and
supervises
 the activity.
 Generation of reports during the activity.
 Explaining all other persons involved regarding detailed operations to be carried out during
the activity.

QC Engineer
 Reports to site QA/QC in-charge
 Ensures proper implementation of this procedure.
 Checks and verifies the activity.
 Verifies and countersigns report

HSE Officers
.
Shall reports to Resident Construction Manager/Project Manager administratively and to
HO for technical matters and shall be responsible for
 Implementation of all safety requirements during this operation.
 Ensuring that the communication system is working properly and that emergency
equipment is in place.

5.0 METHODOLOGY

Prior to any post hydrostatic testing activity VCS/AGCL shall be notified. A calculated
length of pipe section shall be identified and prepared for post hydro testing. The sections
of pipeline for the crossings shall be post tested as a single string. Welded pipeline
sections shall be post-tested after successfully completion of pull back operation. The
post tested

Page 4 of 12
pipes to be used as pup pieces in future shall be marked by marker/ paint along the whole
length of the pipe. While using pup pieces of the post tested pipe, the pipe number and
heat number shall be transferred to every pipe pieces, which has been cut for future use
and a record shall be maintained. If any pipe piece is found without a heat number or pipe
number, it shall not be allowed to be a part of the pipeline.
6.1 TESTING PROCEDURE

6.2 PREPARATION
 Before the start of testing, the testing scheme shall be prepared by MGBEPL and shall be
submitted to VCS/AGCL with detail drawing for approval.
 The test section shall be isolated.
 Prior to water filling it shall be ensured that all test gauges and hoses are properly hooked
up and that the test section is clean.
 All fitting and valve used on the header should be of sch/rating mentioned as sch. 160/900
respectively.
 The post testing header shall be hydro tested separately.
 Proper cleaning to be carried out before water filling. The layout for air pigging header is
as per the example Fig (1) below.

Fig (1)
 Pressure gauge range should be 1.5 times of test pressure (Test pressure results in hoop
stress corresponding to 95% of SMYS of pipe materials).
 Header should be pre tested at pressure 90-95% of SMYS, thickness of the same should
be maximum thickness being used in the project. The layout for posttest header is as per
the following example Fig (2):

Fig (2)

Page 5 of 12
6.3 CLEANING & WATER FILLING
 Before filling operation, the pipeline needs to be clean by air driven pigs to remove all mill
scale rust/sand from the internal of pipe sections.
 After cleaning the pipeline by using air and accepted by the VCS/AGCL, the whole length
of pipeline shall be filled with water with inhibitor. The water should be free from
contamination, sand or silt.
 During filling of water, proper venting to be done at highest point to remove all the
entrapped air.
 Only potable clean water shall be used for the testing. The water to be used shall be
filtered & shall not be contaminated, and free from sand or silt. MGBEPL shall submit
laboratory test reports of water used for testing as per requirement. The water from the
source shall be pumped into the receiving tank. From the receiving tank, the water shall be
pumped into the testing section.
 Drain shall be provided for draining out the water from the system.
 During filling of water, proper venting shall be done at the highest point to remove any air
lock in the system.
 Calibrated pressure gauges one at pressurization point and one at the highest point shall
be installed during testing.
 Pressure gauge range should be min. 1.5 times of test pressure and max. 4 times of test
pressure.
 If a leak is observed, the system will be dewatered and the repairs shall be carried out as
per approved procedure.
6.4 THERMAL STABLIZATION
6.3.1 After completion of filling to an initial pressure of at least 1 bar (g) on the highest section,
the thermal stabilization can then be started. Thermal equilibrium between the pipeline and
environment shall be checked through the thermocouples installed on the pipeline
.
6.3.2 Before starting the thermal stabilization, inhibited water will be flushed through the pipeline
for minimum two hours.
6.3.3 After a check has been made to confirm if the pressure has attained at least 1 bar (g) on
the highest section, the thermal stabilization can then be started. Thermal equilibrium
between the pipeline and environment shall be checked through the thermocouples
installed on the pipeline.
6.3.4 Temperature readings shall be made at 2 (two) hours intervals. Thermal stabilization shall
be considered to have been achieved when a difference not higher than 1°C is attained
between the average values of the last two readings. Thermal stabilization completion
shall be approved by the VCS/AGCL.

6.5 PRESSURIZATION
6.5.1 TEST PRESSURE:
The duration of post-installation hydrostatic test is minimum 24 hours after stabilization
and the test pressure shall be as per approved procedure.

Page 6 of 12
HDD Pipe details Post-installation hydrotest pressure (Kg/cm2)
12”, 8” & 6” x WT, API 5L X-70 Grade pipe Sec I 28.5 Kg/ cm2 and For Sec II & III 73.5 Kg/
cm2

The pressurization shall be performed in the presence of Client at a moderate and

constant rate not exceeding 2 bar/minute. One pressure recording gauge shall be installed
in parallel with the dead weight tester. Volume required to reach the test pressure shall be
recorded periodically throughout the pressurization as follows:
- Each 5 bar increments up to 80% of test pressure as recorded by the dead weight tester;
- Each 2 bar increment between 80% to 90% of test pressure as recorded by the dead
weight tester;
- Each 0.2 bar increments between 90% of the test pressure to full test pressure as
recorded by the dead weight tester.
The pressurizing shall be cycled according to the following sequence:
a) Pressurize to 50% of test pressure, hold pressure for 1 hour.
b) Drop pressure to static head + one Bar.
c) Pressurize to 75% of test pressure, hold pressure for 1 hour.
d) Drop pressure to static head + one Bar.
e) Pressurize to test pressure.

A) For Major Water Crossings - Submerged Crossings

After laying operations, MGEPL shall run a gauging 'pig' through the pipe. Then the
complete section of major watercourse crossing must be hydrostatically tested at a
pressure shall be equal to 1.4 times of maximum allowable operating pressure (MAOP) for
a gas pipeline. (Not Exceeding 95% of SMYS of pipe material) immediately after the
approved backfilling of the trench strictly as per specifications. After temperature
stabilization, pressure shall be retained in the pipeline for a minimum 24 hours and
recorded by manothermograph.

B) For HDD Crossings

Before post hydrostatic testing, MGBEPL shall prove the diameter of the pipeline by passing
a gauging pig through the pipeline. Then the complete crossing section shall be post
hydrostatically tested after Installation. The test pressure shall be equal to 1.4 times of
maximum allowable operating pressure (MAOD) for gas pipeline. (Not Exceeding 95% of
SMYS of pipe material) After temperature stabilization, pressure shall be retained in the
pipeline for a period of 24 hours and recorded by manothermograph. The hydrostatic
testing shall be carried out in accordance with approved procedures and specification.

During the pressurization to each test pressure, two tests will be carried out for the
calculation of air volume in the pipeline under test.In case, during the hold pressure
periods indicated above, a decrease in pressure is observed, the above operations shall
be repeated more than twice, after which the line shall not be considered capable of test,
until the MGBEPL, has isolated and eliminated the cause for the lack of water tightness.

6.6 AIR VOLUME CALCULATION

In order to check the presence of air in the pipeline, two separate consecutive pressures
lowering of 0.5 bar shall be carried out when the internal pressure rises to test pressure.
For calculation of air in the pipeline the second pressure lowering shall be used, and the

Page 7 of 12
relevant drained water shall be accurately measured, (VI). This amount measured shall be
compared to the theoretical amount (VP) corresponding to the pressure lowering.
If no air is present in the length under test:
VI / VP = 1

In order that the above ratio is acceptable, it shall not differ from 1 by more than 6% (i.e.
1.06). If the air found in the pipeline is within the above established tolerance, then the
pressurizing can continue. If the ratio VI / VP exceeds 1.06, the hydrostatic testing cannot
go on and additional pig passages shall be performed to remove the air pockets. The test
shall be repeated as per the above procedure until above estimated tolerances are
satisfied. The pressurizing can then continue, to reach the value of the test pressure.
6.7 After the section has been pressurized and the air volume test has given acceptable
results the test pressure shall be held for a minimum of 24 hours after stabilization. After
temperature and pressure has stabilized, the injection pump shall be disconnected and all
connection at the test heads shall be checked for leakage. The pressure recorders shall
then be started with the charts in a real time orientation for continuous recording
throughout the test. During the testing period the following measurements shall be
recorded/reported:
-Every one hour pressure measurements from dead weight testers.
-Every two hours the ambient temperature and the pipe temperature at the temperature
sensors.

During the pressurization to each test pressure, two test should be carried out for the circulation of
air volume in the pipeline under test.

In Case , during the hold pressure periods indicated above, a decrease in pressure in closer end, the
above operations shall not be repeated more than twice, after which the line shall not be considered
capable of test, until the MGBEPL has isolated and eliminated the cause for the lack of water
tightness.

 For Hydrostatic test minimum 2 gauges shall be used, one at the pressurization point and
other at the highest point.
 All test gauges shall be calibrated/certified and made traceable.
 Once the water has been filled into the test loop and the air vented out, pressure shall be
applied by means of a pressurization pump, suitable for the work.
 The pressure gauges at both ends shall provide the guidance to the pressure build up in the
system.
 Once the test pressure is built up, observations shall be made to stabilize the pressure to the
test pressure and also for temperature stabilization as format.
 After temperature stabilization, the pressure shall be maintained in the pipeline for the
period as stipulated above.
 The pipe section under test shall be subjected to visual inspection for any leakage or
deformation. Temperature and time shall be recorded
 The entire carrier pipeline sections at the cased submerged & HDD crossings shall be tested
pre & post hydrostatically.
 All personnel deployed on the site shall be fully aware of their responsibilities and scope of
work.

Page 8 of 12
6.8 POST HYDROTEST ACCEPTANCE
The hydrostatic test shall be considered as positive if pressure has kept a constant value
throughout the test duration, except for change due to temperature effects.
MGBEPL shall furnish actual calculation for the effect of temperature change. The
pressure change value
as a function of temperature change shall be algebraically added to the pressure value as
read on the meters. The pressure value thus adjusted shall be compared with the initial
value and the test
shall be considered as acceptable iſ the difference is less than or equal to 0.3 bar. In case
of doubt the testing period shall be extended by 24 hours.

If test section fails to maintain the specified test pressure after Isolation, MGBEPL
shall determine the reasons for leakage or failure and take corrective actions
accordingly for acceptance of the test.
The cost of repairs or replacements, followed by refilling and re-pressurising the line. due
to poor materials, workmanship shall be borne by MGBEPL . The method of locating and
repairing the leak/burst shall have the prior approval of the VCS/AGCL. All work of
reinstalling line pipe, to replace failures, shall be done in accordance with the
specifications contained herein.

Termination:
After the positive results of testing and all the data have been gathered, the test shall be
terminated upon written approval given by the VCS/AGCL. The pipeline shall be slowly
depressurized at a moderate and constant rate as instructed by the VCS/AGCL.
MGBEPL shall de-water the tested line to be "touch dry" or "swab dry" after test
acceptance. MGBEPL shall specify the methods he intends to use to de-water each hydro-
test section as part of MGBEPL’s hydro-test Plan so that this information can be evaluated.
During de-watering, care shall be taken to properly dispose the discharging water in order
to avoid pollution, damages to fields under cultivation and/or existing structures and
interference with the traffic.
In order to prevent internal corrosion of pipe from Microbiological formation due to
presence of water, soil etc. inside the pipe, tests shall be carried out for reviewing the
presence of SRB bacteria in line with API-38. Remedial action if any shall be taken
thereof.
Upon completion of the testing and de-watering operation, any provisional traps for pigs
and all other temporary installation relating to the test shall be removed. Subsequently the
crossing sections shall either tied to the mainline or alternatively sealed preserved as per
instructions of the Engineer-in-Charge
Test report signed by MGBEPL and VCS/AGCL shall be submitted upon completion of
hydrostatic test each section,

6.9 LINE DEPRESSURIZATION

Depressurization rate shall be regulated to ensure a moderate and constant reduction in
pressure. A rate of maximum 3 bar per minute is allowed. Care shall be taken to ensure
line pressure is not reduced below static head. The depressurization hose shall be
positioned such as to minimize scouring of ground.

6.10 DEWATERING
6.10.1 Dewatering of a section shall be done either by pushing the water back to the source or
pushing the water to receiving trap of the test section.

Page 9 of 12
6.10.2 For pushing of the water back to the source, a compressed air package capable of
dewatering the section shall be connected to the receiving trap. For pushing of the water to
the receiving trap a compressed air package capable of dewatering the section shall be
connected to the launching trap.
6.10.3 The dewatering pig shall be propelled by compressed air. The rate of discharge shall be
controlled from the discharge end by controlling the discharge valve. A minimum pressure
equal to the static head plus 1 bar shall be maintained at the discharge end. Velocity of
discharge water shall be approx. 0.5 to 1 Meter/sec. Care shall be taken to prevent
damage of fields under cultivation and / or existing structures.
6.10.4 In case chemicals have been used in the water, the composition of effluent shall not
exceed the limits set in IS: 2490-Part – I, tolerance limit for Industrial Effluent discharged in
to inland surface water. If the limit is over stepped, the water shall be chemically treated
before discharge or inhibited water shall be collected in to an evaporation pit prepared in
the vicinity of discharge outlet from pipeline. After evaporation of water and removal of
residue of chemical, the pit shall be restored to original condition.
6.10.5 After completion of dewatering, temperature probes shall be removed and all coating
damage shall be repaired. The work shall be carried out in compliance with the pipeline
coating repair procedure.
6.10.6 Foam swabbing shall be done after dewatering. The foam pigs shall be propelled by
compressed air. The procedure shall be repeated till the tested line is “touch dry” or “swab
dry”.
6.10.7 After completion of dewatering, any provisional trap for pigs and all other temporary
installation related to the test shall be removed. Subsequently the individual sections of the
line already tested shall be tied-in and the pretested block valves shall be installed at
locations shown in the construction drawings as per directions of VCS/AGCL,
representative as per approved procedure.

6.11 Measurements
6.11.1 Water Amount Measurement

The water volume added to the section to be tested shall be measured during the filling
stage through a positive displacement meter (a turbine meter may also be used). In the
calculation, as per clause AGCL Specification (AGCL-HDD-HT-SPEC), use shall be made
of the geometrical volume of the section in question. The water amount that has been let
into the section shall be measured during the pressurization Stages through positive
displacement meters or turbine meters.

6.11.2 Pressure Measurement

Pressure shall be recorded with a dead weight tester & shall permit readings of at least
0.05 bar. During the test the pressure shall be recorded by means of a recording pressure
gauge featuring the following specifications:
Accuracy: 0.1% of the full scale value.
Recording: continuous on tape or disk of 12 min. dia., graph width 100mm
Feed: 20mm/h.for tape diagrams, 15/h for disk diagrams. Recording range to be such as
to record pressure between 50% and 90% of the diaphragm width. The recording pressure
gauge shall be checked by means of dead weight test at the beginning, during and at the
end of the hydrostatic test.

6.11.3 Water Temperature Measurement:

Page 10 of 12
Water temperature shall be taken at entry 4 hrs through the temperature decrease that
have been installed along the section under test on the pipe wall.
Further, the temperature measurement shall be taken as below:
 During the filling operation
 During the thermal stabilization stage
 During the hydrostatic test.

The temperature sensors shall enable temperature readings with accuracy of +- 0.2
Degree Celcius.

Water temperature shall also be measure on the pump delivery by means of a recording
thermometer throughout filling stage. The recording thermometer shall feature following
characterstics.

Accuracy-- +- 1 % of the scale range

Scale-- -10 to +-40 Degree Celcius

Recording – Continuous on tape or disk of 12’’ mini diameter, diaphragm width 100 mm
Feed- 20 mm/hr for tape diagram, 15degree/ hr for disk diagram.

Ground temperature shall be taken by measuring pipe temperature at the temperature

sensors prior to starting the filling operation.

Environmental temp shall be recorded from the beginning of the pressurization to the end
of the test by means of a recording thermometer featuring the following characterization.

Accuracy- +- 1 % of the scale range.

Scale—0 Deg C to 60 Deg C.
Recording—Continuous on tape or disk of minimum 12’’ dia diaphragm width 100 mm.
Feed- 20 mm/hr for tape diagram, 15 degree/ hr for disk diagram.

7.1 SAFETY
The approved procedure for Health, Safety & Environment shall be followed during the
execution.. MGBEPL shall ensure that we system Implementation shall be in line with
requirements mentioned elsewhere in RFP documents

 Only trained personnel to be deployed for this activity.

 PPE shall be used in this activity.
 HSE Officer/Activity supervisor shall conduct doily toolbox meeting and record to be
maintained properly
 All Measuring & Test Equipment used shall be well maintained & certified by competent
person.
 All testing devices & Tools used shall be well maintained,
 First old box should be available at site.
 Minimum no. of person to be present near workplace.
 Maintain good housekeeping otsite.
 Work area is to be barrleaded in such a way so as to prevent access of unauthorized
personnel.

Page 11 of 12
 No unauthorized personnel shall be closer than 40m to the pipeline or equipment under
test.
 Ensure all manifold fittings and pressure gauges are of heavy-duty type and approved.
 No Tightening to be done under pressure.
 Provide adeguata warning signs for the job stating "PIPELINE UNDER TEST-STAY
AWAY" with local language translation,
 Pre testing of test headers sholl be carried out in such a way so that their rupture cannot
cause any Injuries to the personnel or third parties.

8.0 FORMAT
Post Hydrotest reports : MGBEPL/VCS/AGCL-HDD/IR-
18 Mechanical Clearance for Hydrotest : Annexure- 1
Inspection Report Air Cleaning : Annexure- 2
Volume Calculation of Pipe Line : Annexure- 3
Details of thermocouple Location : Annexure- 4
Inspection Report Water filling : Annexure- 5
Thermal Stabilization Chart : Annexure- 6
IR-Pressurization (50% Air cycle) : Annexure- 7
Air Volume Calculation (50% cycle) : Annexure- 8
IR-Pressurization (75% Air cycle) : Annexure- 9
Air Volume Calculation (75% cycle) : Annexure- 10
Inspection Report Pressurization : Annexure- 11
IR- 24 hours Hold Period record : Annexure- 12
Acceptance of Hydro Test Evaluation : Annexure- 13
Inspection Report Depressurization : Annexure- 14
Inspection Report Swabbing : Annexure- 15
Coating Repair & Backfilling after : Annexure- 16
removal of thermocouple’s installation
For Hydrotesting

Note: In case of any conflict between the requirements of the procedure and that of above
referred standards and specifications, then the requirements of VCS/AGCL shall govern.

Page 12 of 12
CONTRACTOR: MANSI GANGA BUILDERS AND ENGINEERS PVT LTD

CLIENT : M/S ASSAM GAS

COMPANY LIMITED
INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH
GAS PIPELINE PROJECT
Doc. No.
LIST OF ATTACHMENTS TO HYDROSTATIC TEST RECORD MGBEPL/VCS/AGCL-
HDD/IR- 18-17
Line Size Chainage From To Report No

Section No. Joint No. From To Date

O.D. (Inch) Wall Thk. (mm) I.D.(mm) Grade

Length Mtrs.
Min.: Min.:
API -5L
Max.: Max.: GR.X 70 Volume M3

1. TEST PLAN FOR HYDRO TEST ( Format - 01) YES /NO

2. MECHANICAL CLEARANCE CERTIFICATE ( Format - 0 2 ) YES /NO

3. SAFETY CHECK LIST ( Format - 03) YES /NO

4. INSPECTION REPORT FOR AIR CLEANING ( Format -04 ) YES /NO

5. INSPECTION REPORT FOR GAUGING ( Format - 05 ) YES /NO

6. INSPECTION REPORT FOR WATER FILLING ( Format - 06 ) YES /NO

7. THERMAL STABILIZATION REPORT ( Format -07) YES /NO

8. PRESSURIZATION REPORT ( Format -08) YES /NO

9. AIR VOLUME CALCULATION ( Format -09) YES /NO

10. 24 HOURS HOLD PERIOD ( Format -10) YES /NO

11. HYDROTEST CALCULATION REPORT ( Format -11) YES /NO

12. HYDROSTATIC EVALUATION ( Format -12) YES /NO

13. DEPRESSURISATION REPORT (Formay-13) YES /NO

14. COATING REPAIR ( Format - 14 ) YES /NO

15. DEWATERING REPORT ( Format - 15) YES /NO

16. LIST OF INSTRUMENTS USED. ( Format -16 ) YES /NO

17. NDT Reports of Temporary Joints YES /NO

18. Pre-test Reports of Test Header YES /NO

For MGBEPL For

VCS/AGCL
Sign : Sign :

Name : Name :

Date : Date :
CONTRACTOR: MANSI GANGA BUILDERS AND ENGINEERS PVT LTD

CLIENT : M/S ASSAM GAS

COMPANY LIMITED
INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH GAS
PIPELINE PROJECT
Doc. No. MGBEPL/VCS/AGCL-
TEST PLAN FOR HYDRO TEST HDD/IR-
18-1

Line Size Chainage From To Report No

Section No. Joint No. From To Date

Avg. Inner Test Pressure (Bar)

OD Wall Thk Length Avg. Wall Volume Per
Nominal I.D Radius Total Volume M3
(mm) (mm) (Mtrs.) (mm) Mtr. M3 Min Max.
(mm)
Min

Mix.

Total Length Mtrs.

Note
1) Length of test headers to be included.
2) Test pressure shall be as per min, wall thk of the section
(As Per Pipebook Part-B)
3) In case the test section has multiple wall thickness, inner radious( ri )shall
correspond to the wall thickness which has max. total length in the section.
Test Pressure GENERAL DATA

START END HIGH Water Soure :

Chainage (KM) Fill Pump Location Ch

Elevation (M)

Pressure/kg/cm2 Corrossion Inhibitor :

% OF TEST PRESSURE Dosage ( ppm ) :
50% 75% 100%

Pressure Sequence ( Bar )

Discharge Point Ch

Apperx. water required to raise the

pressure from static condition ( M3 )

A sketch showing Elevation Vs KM ( Chainage ) enclosed.

AIR Cleaning and Gauging Direction :

Fill Direction :
Dewatering Direction :
REMARKS :

For MGBEPL For

VCS/AGCL
Sign : Sign :

Name : Name :

Date : Date :
CONTRACTOR: MANSI GANGA BUILDERS AND ENGINEERS PVT LTD

CLIENT : M/S ASSAM GAS COMPANY LIMITED

INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH GAS PIPELINE
PROJECT
Doc. No.
MECHANICAL CLERANCE FOR HYDROTEST MGBEPL/VCS/AGC
L- HDD/IR-18-2

Line Size Chainage From To Report No

Section No. Joint No. From To Date

O.D. (Inch) Wall Thk. (mm) I.D.(mm) Grade

Length Mtrs.
Min.: Min.:
API -5L
GR.X 70
Max.: Max.: Volume M3

Wall Thk (mm) Length (Mtr) Number Of Welds

Length of not back filled section

CONSTRUCTION PERIOD

Start Date

End Date

THIS IS TO CERTIFY THAT ALL WELDS OF THE ABOVE TEST SECTION HAVE BEEN ACCEPTED AND THE
PIPELINE SECTION HAS BEEN LAID AND BACKFILLED ACCORDING TO THE SPECIFICTIONS. ALL
ACTIVITIES UPTO PART-B OF PIPE BOOK IS COMPLETED.

Remarks ( Exceptions if any)

For MGBEPL For

VCS/AGCL
Sign : Sign :

Name: Name :

Date : Date :
CONTRACTOR: MANSI GANGA BUILDERS AND ENGINEERS PVT LTD
CLIENT : M/S ASSAM GAS
COMPANY LIMITED
INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH GAS PIPELINE
PROJECT
Doc.
SAFETY CHECK LIST No.MGBEPL/VCS/AGC
L- HDD/IR-18-3
Sr.no DESCRIPTION MGBEPL VCS/AGCL

1 The test section has been isolated from all other pipeline sections.

2 Is a copy of the hydrotest pack available at the site

3 Is adequate water disposal arrangement made

Check Houskeeping standards are acceptable at the filling end and receiving
4
end.
5 Check the conditions of the tools and tackles to be used.
Check that the lighting arrangements are adequate and the condition of the
6
electrical wiring circuit boards, conduit etc. are acceptable and safe.
Check that test areas at each end of the test section have been cordoned off
7
with stakes and bunting tape.
Check that emergency equipment are adequate and are working condition-
8 standby vehicle, communication system, first aid boxes, medical facilities,
strecher etc.
9 Check the condition of tools to be used.
All temoprary piping test heads and other equipment connected to the test
10 section have been pre tested to a pressure of at least 1.25 times the test pressure.

Ensure ;complete bolting on cleaning /Batching Pigs are properly tightened before
11
insertion in the test Headers.

12 The test section has been completely filled with water and the air vented off.

13 All instruments and gauges which are used have valid calibration certificates.
Safety valve with set pressure to the max test pressure is installed on the piping system.
14

All warning notices, marker tapes, prortective barriers and other safety
15
equipments have been positioned and all the concerned informed.

16 All persons who may be affected by the operations are inforned of the activity.

Communicution channel is tested and ensured that they are working properly. Backup
17
instruments are available.
Informed the person operating the pressruing equipments of the maximum test
18
pressure which shall be applied to the test section.
Joint inspection of the entire facilities by the hydrotest engineer and HSE officer to
19
ensure all the safety measures have been undertaken before the test.
Note : Hydrotest engineer/ HSE officer to add any other safety points to this list as per the site circumstances if
deemed necessary.
For For
MGBEPL VCS/AGCL
Sign : Sign :

Name : Name :

Date : Date :
CONTRACTOR: MANSI GANGA BUILDERS AND ENGINEERS PVT LTD

CLIENT : M/S ASSAM GAS COMPANY LIMITED

INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH GAS PIPELINE
PROJECT
Doc. No.
INSPECTION REPORT FOR AIR CLEANING MGBEPL/VCS/AGC
L- HDD/IR-18-4
Line Size Chainage From To Report No

Section No. Joint No. From To Date

O.D. (Inch) Wall Thk. (mm) I.D.(mm) Grade

Length Mtrs.
Min.: Min.:
API -5L
GR.X 70
Max.: Max.: Volume M3

Compressor Location KM Make Model

Out Put Max. Pressure kg/sqcm Pigging Dirrction From KM To KM

Start End Pressure ( Kg/ Cm2)

Avg. Vel.
Run No Pig Type REMARKS
Km/HR.
DATE TIME DATE TIM Min Max
E

Acceptance of section cleanning : Yes / No

For MGBEPL For VCS/AGCL

Sign : Sign :

Name: Name :

Date : Date :
CONTRACTOR: MANSI GANGA BUILDERS AND ENGINEERS PVT LTD

CLIENT : M/S ASSAM GAS COMPANY LIMITED

INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH
GAS PIPELINE PROJECT
Doc. No. MGBEPL/VCS/AGCL-
INSPECTION REPORT FOR GAUGING HDD/IR-18-5

Line Size Chainage From To Report No

Section No. Joint No. From To Date

O.D. (Inch) Wall Thk. (mm) I.D.(mm) Grade

Length Mtrs.
Min.: Min.:
API -5L
GR.X 70
Max.: Max.: Volume M3

Compressor Location Ch Make Model

Pigging Dirrction From

Out Put Max. Pressure Kg/sqcm To KM
KM

Gauge Plate Start End Pressure (Kg/Cm2)

Avg. Vel. Km/HR.

Dia (mm) Thk. (mm) Material Date Time Date Time MAX MIN

Enclosure : - The Photography of Gauge Plate Before and After Run

Detail of Gauge Plate Damaged ( iF any ) :

Remark

Acceptance of section Gauging : yes/No

For MGBEPL For

VCS/AGCL
Sign: Sign :

Name: Name :

Date : Date :
CONTRACTOR: MANSI GANGA BUILDERS AND ENGINEERS PVT LTD

CLIENT : M/S ASSAM GAS COMPANY

LIMITED
INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH GAS
PIPELINE PROJECT
Doc. No. MGBEPL/VCS/AGCL-
INSPECTION REPORT FOR WATER HDD/IR-18-6
FILLING
Line Size Chainage From To Report No

Section No. Joint No. From To Date

O.D. (Inch) Wall Thk. (mm) I.D.(mm) Grade

Length Mtrs.
Min.: Min.: API -5L
Max.: Max.: GR.X 70 Volume M3

Test Medium Water Source Location Km

Inhibition Y/N Type Dosage PPM

MTC No & Date Batch. No. TPL Rqt No. & Dt.

Fill Pump Location Ch. Make Out Put

Out Put M3 /hr Max. Pressure Bar

Dosing Pump Make Model Out Put

Ltrs./Min. Max. Pressure

Flow Meter Make Model Out Put

Calibration Certifcate No & Date Fillinf Direction From KM. To KM.

Pig Sequence Prefilling Length ( Mtr.) Volume (m3)

Ist Pig Type Between Pig 1 & 2 Length ( Mtr.) Volume (m3)
2nd Pig Type Pigging Dirrction From KM TO KM.
Volume
Fill Cummulative Volume (M3)
Flow Meter This Filled Water
Date & Time pressure Remarks
Reading (m2) Period Including Filled Volume Temperature (◦C)
(Kg/Cm2)
( M3) Pre fill after Sec. Pig

Readings to be recorded hourly

Filled water temperature to be recorded contineuously on Temperature Recorder
Acceptance of section WATER FILLING : Yes/No
For MGBEPL For
VCS/AGCL
Sign : Sign :

Name : Name :
Date : Date :
CONTRACTOR: MANSI GANGA BUILDERS AND ENGINEERS PVT LTD

CLIENT : M/S ASSAM GAS COMPANY LIMITED

INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH GAS PIPELINE
PROJECT
Doc. No.
INSPECTION FOR THERMAL STABILZATION MGBEPL/VCS/AGC
L- HDD/IR-18-7
Line Size Chainage From To Report No

Section No. Joint No. From To Date

Wall Thk. (mm) I D (mm) Grade Length Mtrs. Volume M³

OD (MM) Min.: Min.:

API - 5L X 70
Max.: Max.:

S-1 S-2 S-3 S-4 S-5 S-6 S-7 S-8 S-9 S-10 AVER. P-1 P-2 P-3 P-4 P-5 P-6 P-7 P-8 P-9 P-10AVER.
Time & Date AMBIENT
S.NO. Soil PIPE
(HRS) TEMP ⁰C
(KM) (KM) (KM) (KM) (KM) (KM) (KM) (KM) (KM) (KM) Temp (KM) (KM) (KM) (KM) (KM) (KM) (KM) (KM) (KM) (KM) Temp

READINGS TO BE TAKEN AT EVERY 2 HOURS INTERVALS

THERMAL STABILIZATION BE CONSIDERED TO HAVE BEEN ACHIEVED, WHEN THE DIFFERENCE BETWEEN THE AVG. PIPE TEMP. AND AVG. SOIL TEMP.IS NOT HIGHER THAN I 1˚C. FOR 2 CONSECUTIVE
READINGS.
"C" VALUATION

Difference between the average pipe wall temperature and soil temp in two cosecutives readings found to be less than/ more than 1 C and hence thermal stabilisation found to be achieved / not achieved
"C" VALUATION
Acceptance of section STABILIZATION : Yes/No

For MGBEPL For

VCS/AGCL
Sign : Sign :

Name : Name :

Date : Date :
CONTRACTOR: MANSI GANGA BUILDERS AND ENGINEERS PVT LTD

CLIENT : M/S ASSAM GAS COMPANY

LIMITED
INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT
NUMALIGARH GAS PIPELINE PROJECT

Doc. No.
INSPECTION REPORT FOR PRESSURIZATION MGBEPL/VCS/AGCL-
HDD/IR-18-8
Line Size Chainage From To Report No
Section No. Joint No. From To Date
Cycle: 50%/75%/100% Test Medium Water Source of Water
Theoritical
Section Length Volume Pipe Material API 5L Gr.X 70

Elevation / Pressure at Highest Pt. Pressurising Pt.

Lowest Pt. Receiving Pt.
Stroke Counter/Flow Mtr.
Date & Time Dead WT. Volume Ambient
S. NO. Reading Remarks
Cum. Vol.M3
Kg/Bar 3 Temp.
Date Time Stroke Counter Flow Mtr. M

10

11

12

13

14

15
1. Pressuriation
Make Model Discharge Pressure
Pump
2. Dead Weight Caliberation Certificate
Make Model
Tester No & Date
Caliberation Certificate
3. Flow Meter Make Model
No & Date

Acceptance of The Pressurization: Yes / No

For MGBEPL For
VCS/AGCL
Sign: Sign:

Name: Name:

Date: Date:
CONTRACTOR: MANSI GANGA BUILDERS AND ENGINEERS PVT LTD

CLIENT : M/S ASSAM GAS COMPANY

LIMITED
INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT
NUMALIGARH GAS PIPELINE PROJECT
Doc. No.
INSPECTION REPORT FOR AIR - VOLUME CALCULATION MGBEPL/VCS/AGC
L- HDD/IR-18-9
Line Size Chainage From To Report No

Section No. Joint No. From To Date

Cycle: 50%/75%/100%

Test Section Length Volume

Air Volume Test Carried out at %of Test Pressure

Test Station Location Test Pressure Bar

Dead Weigth Tester Make Calibration certificate No.

Model Date

Avg. Pipe Temp. ( ˚C )

Pressure Lowering
Dead Weight Tester Bar/(Kg/cm2) Volume of Water
Bar/(Kg/cm2)
Initial

Aftrer First Pressure Lowering

After Second Pressure Lowering

To Calculate the theatrical volume of water required to achieve a change in pressure, the volume presure equation is V p =
{(0.884 ri/t)+A)x 10-6 x Vt X ∆ Px K

Where :
Vp = Computed water amount required to raise by P The Pressure in the section to be tested ( m3
)
Vt = Geometrical Volume of the Section ( M3 )
ri = Nominal inner radius of the pipe (mm)
t = Nominal pipe thickness (mm)

A = Isothermal compressibility value for water at the pressurization temperature

in the" P" range ( Bar-1 ) x 10.6 Refer graph.

∆ P = Pressure Rise ( bar )

K= A dimensionless coefficient that is equal to a
Value of 1.02 for longitudinally welded pipe.
Threrfore Vp = M3
= litre
Actual Volume of water drained to drop pressure by 0.5 kg/cm2 = Liter ( vi)
Threrfore Vi / Vp =
Since the ratio is less than 1.06, the filling is acceptable and the test section may be pressurised to the
Note: In case the test section have multiple wall thickness, ri shall be correspond to the wall
thickness which
have max total length in the test section .
Remarks

Acceptance of The AIR VOLUME : Yes / No

For MGBEPL For

VCS/AGCL
Sign : Sign :

Name : Name :

Date : Date :
CONTRACTOR: MANSI GANGA BUILDERS AND ENGINEERS PVT LTD

CLIENT : M/S ASSAM GAS COMPANY LIMITED

INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH GAS PIPELINE
PROJECT
Doc. No.MGBEPL/VCS/AGCL-HDD/IR-
INSPECTION REPORT FOR PRESSURE TEST ( 24 HOURS HOLD ) 18-
10

Dead Wt
Line Size Chainage From To Report No Tester Make Model Certificate No

Section No. Joint No. From To Date Temp. Meter Make Model Certificate No

Pr. Recorder Make Model Certificate No

Pressure Kg/ Pressure Kg/
Location Elevation Location Test pr. Reqd at
cm2 cm2 I.D.(mm) Grade
Station Length :
O.D.
Highest Point (mm) Min.: Min.:
API -5LGR.X 70
Lowest Point Max.: Max.: Volume (M3)

Pr. Point

Removal Point
Time
S-1 S-2 S-3 S-4 S-5 S-6 S-7 S-8 P-1 P-2 P-3 P-4 P-5 P-6 P-7 P-8 AVER.
Aver. Soil AMBT Temp
S.NO. Date DWT Rdgs (bar) PIPE
(HRS (KM) (KM) (KM) (KM) (KM) (KM) (KM) (KM) Temp⁰C (KM) (KM) (KM) (KM) (KM) (KM) (KM) (KM) ⁰C
) Temp⁰C
1

10

11

12

13

15

For MGBEPL For

VCS/AGCL
Sign : Sign :

Name : Name :

Date : Date :
CONTRACTOR: MANSI GANGA BUILDERS AND ENGINEERS PVT LTD

CLIENT : M/S ASSAM GAS

COMPANY LIMITED
INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH GAS
PIPELINE PROJECT

Doc.
HYDROSTATIC TEST CALCULATIONS No.MGBEPL/VCS/AGC
L- HDD/IR-18-11
Line Size Chainage From To Report No

Section No. Joint No. From To Date

Test Section Length Volume Spread

Test Station Location Ch Test Pressure

Dead Weigth Tester Make Calibration ertificate No.

Sl No Model Date

Pressure Recorder Make Calibration ertificate No.

Sl No Model Date

Description Elevation In Mtrs Pressure in Bar or Kg/ Cm2

Highest Point
Lowest Point
Pressurization Point
Removing Point
Dead Weight Tester
Date Time Average Pipe Temp
(Bar)
Start of Test

End of Test

Algebraic Difference

Calculation of Pressure Change ( P ) due to ∆ change in temperature :

∆p= Bx∆T
0.884x ri / t + A

Where :
∆ =P Pressure change resulting from temperature change

Value of the Difference between thermal expansion of water and steel at temperature and pressure
B=
as measured from enclosed table at the end of the test ( ˚C -1) X 106

ri = Nominal inner redius of pipe ( mm)

t = Nominal wall thickness of pipe ( mm)

A= Algebraic compressipility factor of water ( Bar-1 ) X 106

∆T = Algebraic difference between water temperature at

beginning and at end of the test. ( ˚C )

For MGBEPL For

VCS/AGCL
Sign : Sign :
Name : Name :
Date : Date :
CONTRACTOR: MANSI GANGA BUILDERS AND ENGINEERS PVT LTD

CLIENT : M/S ASSAM GAS

COMPANY LIMITED
INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH
GAS PIPELINE PROJECT

Doc.
HYDROSTATIC TEST EVALUATION No.MGBEPL/IOCL/IH
B-HDD/IR-18-12
Line Size Chainage From To Report No
Section No. Joint No. From To Date
Spread :
Wall Thk. (mm) I.D.(mm) Grade
Length :
O.D. (Inch) Min.: Min.: API -
Max.: Max.: 5LGR.X 70 Volume (M3)
Description Elevation in Mtrs Pressure in Bar / Kg/ Sqcm
Highest Point
Lowest Point
Pressurization Point
Release Point
Observations:
Initial Test Pressure Bar Date Time
Final Test Pressure Bar Date Time

(A) Delta " P " during 24 hours Hold Period :

Initial Pipe Wall Temp ˚C Date Time
Final Pipe Wall Temp ˚C Date Time

( B ) Delta " T " during 24 hours Hold Period :

Initial Soil Temp ˚C Date Time
Final Soil Temp ˚C Date Time

(C) Delta T, Soil Temp Deg ˚C

EVALUATION:
(1) Delta "P" During 24 hours hold period (A) Bar
(2) Accountable pressure loss due to temp.(B) Bar
(3) Final test pressure after accounting pressure loss due to change in
Bar
Temp.
(4) Difference between initial and final test Pressure Bar
2
(5) Allowable Difference 0.3 Bar = 0.306 Kg/cm
CONCLUSION:
Test is Acceptable / Not Acceptable ( Strike out whichever is not applicable )
Section is released for depressurisation : Yes / No
Remarks (if any):

For MGBEPL For

VCS/AGCL
Sign: Sign:
Name: Name:
Date: Date:
CONTRACTOR: MANSI GANGA BUILDERS AND ENGINEERS PVT LTD

CLIENT : M/S ASSAM GAS COMPANY LIMITED

INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH GAS
PIPELINE PROJECT

Doc.
INSPECTION REPORT FOR DE-PRESSURIZATION No.MGBEPL/VCS/AGCL
- HDD/IR-18-13
Line Size Chainage From To Report No
Section No. Joint No. From To Date
Spread :
Dead Wt Reading
S. No. Date Time (Hour)
(Bar)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
30

Remark (IF ANY)

For MGBEPL For

VCS/AGCL
Sign: Sign:
Name: Name:
Date: Date:

CONTRACTOR: MANSI GANGA BUILDERS AND ENGINEERS PVT LTD

CLIENT : M/S ASSAM GAS COMPANY

LIMITED
INSTALLATION OF PIPELINE BY HDD FOR KANDLA GORAKHPUR
PIPELINE PROJECT
Doc. No.
INSPECTION REPORT FOR COATING REPAIR MGBEPL/VCS/AGC
L- HDD/IR-18-14

Line Size Chainage From To Report No

Section No. Joint No. From To Date

Spread :

Wall Thk. (mm) I.D.(mm) Grade

Length :
O.D. (Inch) Min.: Min.:
API -
Max.: Max.: 5LGR.X 70 (M3)
Volume

P-1 P-2 P-3 P-4 P-5 P-6 P-7

(KM) (KM) (KM) (KM) (KM) (KM (KM)

)

LOCATION OF THE COATING REPAIR ON

THE THERMOCOUPLE INSTALLATION
POINT
( Refer ANNEXTURE for Location )

COATING HAS BEEN REPAIRED, HOLIDAY CHECKED AND FOUND SATISFACTORY. THE PITS ARE BACKFILLED.
Remaks:

For MGBEPL For

VCS/AGCL
Sign: Sign:

Name: Name:

Date: Date:
CONTRACTOR: MANSI GANGA BUILDERS AND ENGINEERS PVT LTD

CLIENT : M/S ASSAM GAS COMPANY

LIMITED
INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH GAS
PIPELINE PROJECT
Doc. No.
INSPECTION REPORT FOR MGBEPL/VCS/AGC
DEWATERING L- HDD/IR-18-15
Line Size Chainage From To Report No
Section No. Joint No. From To Date
Spread :
Wall Thk. (mm) I.D.(mm) Grade
Length :
O.D. (Inch) Min.: Min.: API -5LGR.X
Max.: Max.: 70 Volume (M3)
Compressor : Location Ch Make : Model :

Out Put : Max. Pressure kg/ Cm2 Discharge Point :

Dewatering Direction From: Ch To: Ch

Start End Avg. Vel. Pressure (Kg/Cm2) Quantity of Water (

Run No Type of PIG
Km/Hr. Ltr / hour.)
DATE TIME DATE TIME Min Max

ACCEPTANCE OF SECTION DEWATERING : YES / NO

For MGBEPL For

VCS/AGCL
Sign : Sign :
Name : Name :
Date : Date :
CONTRACTOR: MANSI GANGA BUILDERS AND ENGINEERS PVT LTD

CLIENT : M/S ASSAM GAS COMPANY

LIMITED
INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT
NUMALIGARH GAS PIPELINE PROJECT

LIST OF INSTRUMENTS USED Doc. No. MGBEPL/VCS/AGCL-HDD/IR-18-

16
Line Size Thk Chainag From To Report No.
e
Spread Joint No. From To Date
Section No.
CALIBRATION
SR. CERTIFICAT
ITEM DESCEPTIONS MAKE & MODLE S. NO. RANGE DATE Remark
NO. E NO
/VALIDITY
DATE

For MGBEPL For

VCS/AGCL
Sign. Sign.
Name Name
Date Date
PROJECT: INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH GAS PIPELINE PROJECT

Client : M/s ASSAM GAS COMPANY LIMITED ANNEXURE- 1

Report No:
Contractor : M/s Mansi Ganga Builders and Engineers Pvt. Ltd Date:
Location :

MECHANICAL CLEARANCE FOR HYDROSTATIC TEST

Joint No. From To

Change From To
Total Mainline Section Length

Pipe Material & Diameter & Thickness Number of Weld Joint =

Grade
Length of Welded, Radiography, and Joint Coating & Backfilling Section is
Mtrs. =

This is to be certify that all weld of the above test Section have been accepted and the pipeline section has been laid and backfilled according to the Specification.

For MGBEPL
FOR VCS/AGCL
PROJECT: INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH GAS PIPELINE PROJECT
Client : ASSAM GAS COMPANY LIMITED ANNEXURE- 2
Report No:
Contractor : M/S MANSI GANGA BUILDERS AND ENGINEERS PVT. LTD Date:
Location :
INSPECTION REPORT- AIR CLEANING

Joint No. From To

Change From To
Pipe Material & Grade Diameter & Thickness Inner diameter (mm) Section length (MTRS.)

Compressor Make: Max Pressure:

Sr. Date PIG Type Launching Receiving Min. Max. Remarks
No. Time Time Pressure Pressure
kg/cm2 kg/cm2

Acceptance of section air cleaning: Yes / No

For MGBEPL FOR VCS/AGCL

PROJECT: HDD INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH GAS PIPELINE PROJECT
Client : ASSAM GAS COMPANY LIMITED ANNEXURE- 3
Report No:
Contractor : M/S MANSI GANGA BUILDERS AND ENGINEERS PVT. LTD Date:
Location :
VOLUME CALCULATION OF THE PIPELINE

Pipe Material & Grade Diameter & Thickness Inner diameter (mm) Section length
(MTRS.)

LENGTH OF HEADERS:-
1. “NB Launching + Receiving Header Length & spool Pieces = Mtrs + Mtrs
Total Headers Length = Mtrs
Here –
r1 = , t1 = m,
With Header section Length (L) = Mtr. Volume of “
Dia x mm” Mainline (Vt) = (/4) x (di)2 X 1
=
= M3
= Ltrs.

For MGBEPL FOR VCS/AGCL

PROJECT: INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH GAS PIPELINE PROJECT
Client : ASSAM GAS COMPANY LIMITED. ANNEXURE- 4
Report No:
Contractor : M/S MANSI GANGA BUILDERS AND ENGINEERS PVT. LTD Date:
Location :
DETAILS OF THERMOCOUPLE’S LOCATION

Sr. No. Location / Chainage (Mtrs) Remarks

For MGBEPL FOR VCS/AGCL

PROJECT: INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH GAS PIPELINE PROJECT
Client : M/s ASSAM GAS ANNEXURE- 5
COMPANY
Report No:
Contractor : M/S MANSI GANGA BUILDERS AND ENGINEERS PVT. Date:
LTD
Location
:
INSPECTION REPORT-WATER FILLING

Joint No. From To

Change From To

Pipe Material & Grade Diameter & Thickness Inner diameter (mm) Section length (MTRS.)

Flow Meter Make: KARNTI Sr. No.: Least Count : 1 KL

DATE START TIME FLOW METER STOP TIME FLOW METER READING WATER Remarks
READING KL KL FILLED KL

First PIG Launching

Second PIG Launching

Acceptance of section water filling: Yes / No

For MGBEPL FOR VCS/AGCL

THERMAL STABILIZATION CHART

Sr. Date Time TP1 TP2 TP3 TP4 TP5 TS1 TS2 TS3 TS4 TS5 AV AV DIFFER REMARK
No ̊C ̊C ̊C ̊C ̊C ̊C ̊C ̊C ̊C ̊C G TP G ENCE
. ̊C TS1
̊C
1

For MGBEPL FOR VCS/AGCL

PROJECT: INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH GAS PIPELINE PROJECT
Client : M/s ASSAM GAS COMPANY LIMITED ANNEXURE- 7
Report No:
Contractor : M/S MANSI GANGA BUILDERS AND ENGINEERS PVT. LTD Date:
Location :
INSPECTION REPORT-PRESSURIZATION (50% AIR CYCLE)

Joint No. From To

Change From To
Pipe Material & Grade Diameter & Thickness Inner diameter (mm) Section length (MTRS.)

Volume M3
Hydro test Location:
PRESSERIZATION : FOR 50% AIR CYCLE

Sr. No. Date Time Dead Weight Tester. Kg/ cm2 Remarks
1
2
3
4
5
6
7
8
9
Acceptance of Pressurization for 50% Air Volume: Yes / No

For MGBEPL FOR VCS/AGCL

PROJECT: INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH GAS PIPELINE PROJECT
Client : M/s ASSAM GAS COMPANY LIMITED ANNEXURE- 8
Report No:
Contractor : M/S MANSI GANGA BUILDERS AND ENGINEERS PVT. LTD Date:
Location :
AIR VOLUME CALCULATION (50% AIR CYCLE)

Joint No. From To

Chainge From To
Pipe Material & Grade Diameter & Thickness Inner diameter (mm) Section length (MTRS.)

Volume M3
Hydro test Location:
Lowering Dead Wt. tester Initial. Dead Wt. Tester Final. ΔP Vi (ltrs) Vp (ltrs Vi / Vp
(kg/cm2) Kg/ cm2
I

II

Theoretical volume of water required to bleed off for pressure lowering of 0.5 Kg. / Cm2 calculated by the following formula: Vp =

(0.884 x ri/ti +A) x Vt x ΔPx K X 10-6

Where, Vp = Theoretical water amount to lower the pressure

ri = Nominal Inner radius of the Pipe = m
ti = Nominal wall thickness = m
A = Isothermal compressibility value for water at the pressurization
temperature in the range of 1000000 x bar-1
Vt = Geometrical volume of the section (m) = liters.
ΔP = Change Pressure in bar
K = A dimensionless co-efficient which is equivalent to 1.02
Therefore. ri/ti = Pressure = kg/cm2.
Temp (Avg.) = C̊
A =
Vp = ltrs.
i- Vi = ltrs.
Vi/Vp =
ii- Vi = ltrs.
Vi/Vp =

Conclusion: Vi/Vp is less than 1.06 . So Air volume Acceptable.

50% AIR VOLUME ACCEPTABLE: YES/NO

For MGBEPL FOR VCS/AGCL

PROJECT: INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH GAS PIPELINE
PROJECT
Client : ASSAM GAS COMPANY LIMITED ANNEXURE- 9
Report No:
Contractor : M/S MANSI GANGA BUILDERS AND ENGINEERS PVT. LTD Date:
Location :
INSPECTION REPORT-PRESSURIZATION (75% AIR CYCLE)

Joint No. From To

Chainge From To
Pipe Material & Grade Diameter & Thickness Inner diameter (mm) Section length (with Headers)(MTRS.)

Volume M3
Hydro test Location:
PRESSERIZATION : 75% (AIR CYCLE)

Sr. No. Date Time Dead Weight Tester. Kg/ cm2 Remarks
1
2
3
4
5
6
7
8
9
10
11
Acceptance of Pressurization for 75% Air Volume: Yes / No

For MGBEPL FOR VCS/AGCL

Client : ASSAM GAS COMPANY LIMITED ANNEXURE- 10
Report No:
Contractor : M/S MANSI GANGA BUILDERS AND ENGINEERS PVT. LTD Date:
Location :
AIR VOLUME CALCULATION (75% OF PRESSURE CYCLE)

Lowering Dead Wt. tester Initial. Dead Wt. Tester Final. ΔP Vi (ltrs) Vp (ltrs Vi / Vp
(kg/cm2) Kg/ cm2
I
II
Theoretical volume of water required to bleed off for pressure lowering of 0.5 Kg. / Cm2 calculated by the following formula: Vp =

(0.884 x ri/ti +A) x Vt x ΔP x K

Where, Vp = Theoretical water amount to lower the pressure

ri =Nominal Inner radius of the Pipe = m
ti =Nominal wall thickness = m
A =Isothermal compressibility value for water at the pressurization
Temperature in the range of 1000000 x bar-1
Vt =Geometrical volume of the section (m) =
ΔP =Change Pressure in bar
K =A dimensionless co-efficient which is equivalent to 1.02
Therefore. ri/ti =
Pressure = kg/cm2 = Bar
Temp(Avg.) = ̊C
A =
Vp = ltrs.
i- Vi = ltrs. ii- Vi = ltrs.
Vi/Vp = Vi/Vp =

Conclusion:

For MGBEPL FOR VCS/AGCL

PROJECT: INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH GAS PIPELINE PROJECT
Client : ASSAM GAS COMPANY LIMITED ANNEXURE- 11
Report No:
Contractor : M/S MANSI GANGA BUILDERS AND ENGINEERS PVT. LTD Date:
Location :
INSPECTION REPORT - PRESSURIZATION

Joint No. From To

Chainge From To
Pipe Material & Grade Diameter & Thickness Inner diameter (mm) Section length (with Headers) (MTRS.)

Volume M3
PRESSERIZATION : 100% (AIR CYCLE)

Sr. No. Date Time Dead Weight Tester. Kg/ cm2 Remarks
1
2
3
4
5
6
7
8
9
10
11

For MGBEPL

FOR VCS/AGCL
PROJECT: INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH GAS PIPELINE PROJECT
Client : ASSAM GAS COMPANY LIMITED ANNEXURE- 12
Report No:
Contractor : M/S MANSI GANGA BUILDERS AND ENGINEERS PVT. LTD Date:
Location :
INSPECTION REPORT – 24 HOURS HOLD PERIOD RECORD

Joint No. From TO

Chainage From TO
Pipe Material & Grade Diameter & Thickness Section lengt (with Headers) (Mtrs)

Volume = M3
S Date Time P1 P2 TP1 TP2 TP3 TP4 TP5 TS1 TS2 TS3 TS4 TS5 AVG REMARK
r. D.Wt Kg/ Kg/ ̊C ̊C ̊C ̊C ̊C AVG ̊C ̊C ̊C ̊C ̊C TS
N Pr. cm2 cm2 TP ̊C
o (kg/c ̊C
. m2)
1
2
3
4
5
6
7
8
9

For MGBEPL FOR VCS/AGCL

Sr. Date Time D.Wt P1 P2 TP1 TP2 TP3 TP4 TP5 TS1 TS2 TS3 TS4 TS5 AVG REMARK
No. Pr. Kg/ Kg/ ̊
C ̊
C ̊
C ̊
C ̊
C AVG ̊
C ̊C ̊C ̊C ̊
C TS
(kg/c cm cm2 TP C̊
2
m2) ̊C
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

For MGBEPL FOR VCS/AGCL

PROJECT: INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH GAS PIPELINE PROJECT
Client : ASSAM GAS COMPANY LIMITED ANNEXURE- 13
Report No:
Contractor : M/S MANSI GANGA BUILDERS AND ENGINEERS PVT. LTD Date:
Location :
ACCEPTANCE OF HYDROSTATIC TEST EVALUATION

Joint No. From TO

Chainage From TO
Pipe Material & Grade Diameter & Thickness Inner diameter Section length
(mtrs) (Mtrs)

Date Time Dead weight tester Avg. pipe temp (

Dead Weight tester (bar) C̊ )
(kg/cm2)
Start of test
End of test
Difference 24 HOUR
CALCULATION OF PRESSURE CHANGE AS A RESULT OF TEMPERATURE CHANGE
ΔPt = B x ΔT
(0.884 x ri / ti + A) Where,
Initial Pressure (P1) = kg / cm2 = bar
Final Pressure (P2)= kg/cm2 = bar

For MGBEPL FOR VCS/AGCL

ΔP = Pressure change due to water temperature change Initial
Temp = T1 = C̊
Final Temp = T2 = C̊
ΔT = Algebraically difference between the thermal expansion of water = C
̊
A =Isothermal compressibility value for water at the temperature =
ri =Nominal Inner radius of the Pipe = m
ti =Nominal wall thickness = m
B =Volume difference between thermal expansion of water and steel =
From thermal expansion chart)
ri / ti =
ΔP = B x ΔT
(0.884 x ri / ti + A)
ΔP =bar
Unaccountable Pressure
= P1 – (P2 ± ΔP ) < 0.3 bar
But Temp. is ( ) then –
= P1 – (P2 - ΔP ) < 0.3 bar
=
= bar < 0.3 bar Hence
Hydro test of section is acceptable Acceptance
of Hydrostatic section : YES

For MGBEPL FOR VCS/AGCL

PROJECT: INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH
GASClient
PIPELINE PROJECT : ASSAM GAS COMPANY LIMITED ANNEXURE- 14
Report No:
Contractor : M/S MANSI GANGA BUILDERS AND ENGINEERS PVT. LTD Date:
Location :

Joint No. From To

Chainge From To
Pipe Material & Grade Diameter & Thickness Inner diameter (mm) Section length (with Headers) (MTRS.)

Location:
Sr. No. Date Time P1 Kg/ cm2 Remarks
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

For MGBEPL FOR VCS/AGCL

PROJECT: INSTALLATION OF PIPELINE BY HDD FOR NAMBOR GOLAGHAT NUMALIGARH GAS PIPELINE PROJECT
Client : ASSAM GAS COMPANY LIMITED ANNEXURE- 15
Report No:
Contractor : M/S MANSI GANGA BUILDERS AND ENGINEERS PVT. LTD Date:
Location :
INSPECTION REPORT - SWABBING

Joint No. From To

Chainge From To
Pipe Material & Grade Diameter & Thickness Inner diameter (mm) Section length (with Headers) (MTRS.)

Compressor : Out Put Pressure: 12.0 Kg / cm2

Location:
Sr. No. Type of Pig Start End Pressure Remarks
(Kg/ cm2)
Date Time Date Time
1
2
3
4
5
6
7

For MGBEPL FOR VCS/AGCL

Client : ASSAM GAS COMPANY LIMITED ANNEXURE- 16

Report No: Date:

Contractor : M/S MANSI GANGA BUILDERS AND ENGINEERS PVT. LTD
Location :
COATING REPAIR & BACKFILLING AFTER REMOVAL OF
THERMOCOUPLE’S INSTALLED FOR HYDROTESTING

Sr. No. Location Chainage Coating Backfilling Holyday Test Remarks

(Mtrs) Repair

For MGBEPL FOR VCS/AGCL