PIPELINE HYDRO TEST YE-KHA-11-200-000531

PROCEDURE Revision : 0 Status: IFC

Document Type : PRC System/Subsystem: Discipline : QUA Rev Date : 09-Mar-10

Contractor document number: TT11-PRC-037 Page 1 of 14

KHARIR CCU EXTENSION

PROJECT
TANMIA
TY/2009-22/ES

PIPELINE HYDROTEST PROCEDURE

0 IFC 09-Mar-10 Issued for Construction R:

B IFA Add’l Total Comments Incorporated

10-Feb-10 A.V. Fernandez Moh’d Arif J.R arot
Issued for Approval

Total Comments Incorporated

IFA 18-Jan-10 Change in Contractor Document No. A.V. Fernandez Moh’d Arif J.R. Barol
A Issued for Approval

A IFA 07-Dec-09 Issued for Approval A.V. Fernandez J.S. Barbas J.R. Barot

Rev. Status Date Revision memo Issued by Checked by Approved by

This document is the property of Company It must not be stored, reproduced or disclosed to others without written authorisa8on
from the Company.
PIPELINE HYDRO TEST YE-KHA-11-200-000531

PROCEDURE Revision : 0 Status: IFC

Document Type : PRC System/Subsystem: Discipline : QUA Rev Date : 09-Mar-10

Contractor document number: TT11-PRC-037 Page 2 of 14

Table of Contents Page

1.1 Introduction 3

1.2 Purpose and Scope

1.3 Procedure Limitations
1.4 Revision History
1.5 References
1.6 Documentation 4
2.0 Responsibilities 4
3.0 General Requirements 4
4.0 Project Particular Data 6
5.0 Pipeline Preparation 7
6.0 Air Pigging 7
7.0 Water Quality 7
8.0 Internal Cleaning, Gauging and Water Filling Equipment 8
9.0 Water Filling 8
10.1 Inspection Equipment and Set-up Requirements 10
10.2 Equipment
10.3 Inspection Equipment Set-up
10.4 Inspection Documentation
10.5 Inspection Requirements
11.0 Pressurizing 12
12.0 Hydrostatic Testing Method 12
13.0 Hydrostatic Leak Test 12
14.0 De-watering of Pipeline 13
15.0 Reinstatement 13
16.0 Safety 13
17.0 Attachments 14

This document is the property of Company It must not be stored, reproduced or disclosed to others without written authorisation
from the Company.
1.1 Introduction

1.2 Purpose and Scope

The purpose of this procedure is to define the method of hydro testing the low
pressure pipelines in Kharir Block 10.
It is also the purpose of this procedure to document all relevant safety
aspects of the work and ensure that they are conducted in a safe and
compliant manner and in accordance with the project construction and safety
procedures.
The scope of this procedure refers to the 12ӯ Export Oil Pipeline as
stipulated in the CCU Extension Project Scope of Work.
This procedure is developed to cover the requirements for cleaning, pigging,
filling, gauging and hydrostatic testing of Export Oil Pipeline.

1.3 Procedure Limitations

The limitations of this procedure shall not extend beyond the boundaries of
the launcher and receiver for the pipeline under inspection.

1.3 Revision History

07-Dec-09 Rev. A Issued for Approval
18-Jan-10 Rev. A Total Comments Incorporated
Issued for Approval
10-Feb-10 Rev. B Additional Total Comments
Incorporated
09-Mar-10 Rev. 0 Issued for Construction

1.4 References

API RP 1110 Pressure Testing of Liquid

Petroleum Pipelines
ASME B31.4 Liquid Transportation Systems for
Hydrocarbons, Liquid Petroleum
Gas, Anhydrous Ammonia and
Alcohol
9161H-271-JSS-3500-005 Rev.0 Specification for Cleaning and
Hydrostatic Test of Pipeline
GS EP PLR 501 Rev. 06 Hydrotesting of Pipelines
GS EP PLR 502 Rev. 04 Pre-commissioning of Gas
Pipelines
YE-KHA-11-200-000632 Pipeline Installation Procedure
YE-KHA-11-200-000505 Project Specific HSE Manual

1.5 Documentation

Form No. Title / Description

QCP-502A Line List
QCP-502B Punch list
QCP-502C Pre-Hydro test Acceptance
QCP-502D Hydro test Sheet
QCP-502E Reinstatement

2.0 Responsibilities
The Project Manager is responsible for the overall administration of this
procedure, including liaison with all relevant departments.
Pipeline Inspectors are responsible for carrying out the inspection work in
accordance with this procedure.
The Pipeline Superintendent is responsible for ensuring that the pipeline is
hydrostatically tested in accordance with drawings, specifications, and liaising
with the Quality Control to ensure that testing and inspection is carried out to
the requirements of TOTAL specifications.

3.1 General Requirements

 Prior to pipeline hydrostatic testing, all relevant documentation shall
be signed and approved by the client.
 Completed pipelines shall be hydrostatically tested as soon as
practically possible after documentation completion and approval.
 The applied hydrostatic test pressure shall be in accordance with
Project Particular Data Sheet on Item 4.0.
 The pipeline test length shall be dictated by the profile, route and the
limitation of the testing equipment.
 The Company shall be notified prior to the pressurization of the
pipeline.
 All safety and PPE equipment shall be worn.
 All safety barriers shall be erected and warning signs posted along
the pipeline.
 Safety officer shall inspect all areas prior to pressurisation and patrol
the hydrotesting site.
4.0 Project Particular Data
The information given below shall be used as Project Particular Data in the pipeline
hydrostatic test procedure.

S. No. Description Export Oil Pipeline

1 Nominal Size (in.) 12

2 Diameter (mm) 323.9

3 Pipe Anti-corrosion Coat Not Coated

4 Pipeline Originating / Terminating From CCU to Tie-in at CPU

5 Product Transported Oil

6 Material Grade (API 5L) X52, PSL2

7 Design Pressure (barg) 30.2

8 Design Temperature (°C) 124

9 Minimum Design Temperature (°C) 8

10 Installation Temperature (˚C) 8 - 50

11 Test Medium Treated Water

12 Hydrostatic System Pressure Test (barg) 37.75

13 Holding Time of System Pressure Test (hr.) 24

14 Hydrostatic Leak Pressure Test (barg) 33.22 ( Not Required )

15 Holding Time of Leak Pressure Test (hrs.) 8 ( Not Required )

Above Ground – Running on
16 Burial Status
Supports
17 Pipeline Design Code ISO 13623
5.1 Pipeline Preparation

 The low pressure pipeline included in this pressure test procedure

shall be clear of all outstanding NDT requirements and accepted by
the Company, prior to internal cleaning.
 A punch list walk through shall be performed by Tanmia and the
Company Representative prior to water filling of the line.
 All outstanding punch list items shall be categorised as ‘A’ or ‘B’
items, as shown on the attached punch list format.
 All outstanding category ‘A’ items shall be addressed and cleared
prior to water filling.
 All outstanding category ‘B’ items can be cleared after pressure
testing.
 Prior to water filling, the pipeline shall be cleaned with polly pigs.
 Permanent Launcher and Receiver shall be provided by the
Company.
 Launcher and receivers shall be provided with sufficient branches to
accommodate all testing equipment and instrumentation, including
PSV. See test diagram attached.
 Launcher and receiver may also be fitted with a pig trap door for
loading / unloading pig trains.
 A test manifold (if used) shall be fabricated and tested to 1.25 times
the pipeline pressure.
 No sectional testing is required for low pressure pipeline.

6.0 Air Pigging

Not required.

7.0 Water Quality

Prior to filling the pipeline, a water sample analysis shall be provided to

the Company along with the amount of inhibitors, oxygen scavenger
and bactericide to be added to the hydro test water.
8.1 Internal Cleaning, Gauging and Water Filling Equipment

 Pig Launcher and Receiver

 2 Ball Valves
 Pump for Water Filling
 Break Tank
 Turbine Meter
 Brushing Pig
 Gauging Pig
 Batching Pig (4 Polyethylene Cups)

9.1 Cleaning, Gauging and Water Filling

9.2 Quality of Water

 The pipeline shall be filled with water treated, as per GS EP COR 560
requirements and sufficient quantities of chemicals shall be available
on site at all times.
 Only fresh water shall be used.
 All water used in the test shall be filtered through 50 microns mesh
screen, removing all solids in excess of 50 microns and keeping solid
content below 20mg/L. A preliminary cleaning of the line shall be
performed prior to the test, preparing the final cleaning activities to be
performed after the hydrotest, as defined in GS EP PLR 502.
 Prior to filling of the pipeline, samples of proposed test water shall be
analyzed by an accepted third party institute, to determine the
possible contaminant and presence of SRB (Sulphate Reducing
Bacteria).
 The analysis shall permit to determine the amounts of bactericide
required.
9.3 Cleaning
 Three pigs shall be used as a minimum.
 The cleaning pigs shall be equipped with brushes and magnets.
 The debris shall be collected (solid or sludge) and measured.
 Cleanliness acceptance criteria shall be as per Project Particular
specifications.

9.4 Gauging
 Gauging operation shall be performed during the filling operation, by
having the last pig with a calibrated aluminium plate of 6-8mm
thickness, segmented and with an edge of 45° - 3mm width.
 The gauge plate shall be 95% nominal ID of 12” pipe.
 The gauging requirement before the hydrotest is independent
from the calliper requirement to be performed during the
dewatering operations, refer to GS EP PLR 502.
 When receiving the pigs, if damages are found on the gauge plate
and can not be explained with certainty, electronic geometric pig must
be run to identify the cause and location. Type of geometric pig is
subject to Company approval.
 Recordings from the electronic geometric pig concerning size,
location of diameter reductions such as dents, buckles, flat spots,
construction debris, etc. over 2% nominal ID shall be analyzed and
subject to Company approval.

9.5 Water Filling

Procedure for pipeline filling shall ensure that all air is removed
from the pipeline and that no air pocket is left during filling; the
separation pigs shall ensure a positive sealing and a constant
velocity over 1m/s maintained.
The following sequence shall be followed during the filling and
cleaning operations:
 Water filling shall take place at the launcher end of the pipeline.
 Draining of the pipeline and disposal of the water shall be as agreed
with the Company.
 Assemble and install pig launcher, receiver and connect pipe work
and calibrated flow meter.
 Install calibrated gauges.
 Install a pig signaller on the pig launcher and on the pig receiver to
give positive indication of the departure/arrival of the first and last
pigs.
 Pump the equivalent of 250 linear meters (minimum) of treated water
into the pipeline.
 Close ball valve, drain launcher and launch first pig equipped with
long range locating device.
 Pump a further 500 linear meters (minimum) of treated water into the
pipeline.
 Close ball valve, drain launcher and launch batching pig.
 Pump the equivalent of a further 500 linear meters (minimum) of
treated water into the pipeline.
 Launch gauging pig, fitted with gauging plate and short range locating
device (such as magnetic or isotopic).
 Fill the entire pipeline with water. Pressure and water volume
readings to be documented every hour.
 Receive and retrieve polly pigs at receiver end.
 Continue pumping treated water until all air is expelled from the line.
 All pigs shall be removed from the pig receiver in the presence of the
Company inspector and shall be carefully examined for possible
damages, abnormal wear of cups/disks, quantity and nature of debris
collected.
 Start pressurization.

10.1 Inspection Equipment Set-up Requirements for Pressure Test

10.2 Equipment
 1 unit pressure safety valve.
 Setting shall be +0.5% of test pressure
 3 units calibrated pressure gauges (with mid range recording. e.g.
gauges to read maximum test pressure between the 10 and 2
o’clock positions on the gauge)
 1 unit calibrated temperature gauge
 1 unit dead weight tester
 1 unit calibrated 3,000 psig pressure / temperature recorder and
charts.

10.3 Inspection Equipment Set up

 Pressure safety valve to be installed on the launcher end of the

line.
 1 unit calibrated pressure gauge to be installed on the launcher
and receiver end of the pipeline.
 Dead weight tester’s instrument tubing to be installed to the
launcher with sufficient instrument tubing to clear the test area by
10 meters.
 1 unit calibrated pressure gauge to be installed in parallel with the
dead weight tester.

10.4 Inspection Documentation

 Weld History Sheet

 NDT clearance certification
 Pre Hydrostatic test acceptance record.
 Pipe and flow line hydrostatic test punch list
 Pipeline Alignment drawing
 Hydrostatic Test Diagram
 Hydrostatic Test record
 Test gauge and recorder calibration record
 Reinstatement

10.5 Inspection Requirements

The Inspector shall check the following points:

 All relevant pre-hydro test documentation is signed off by the

Company.
 All inspection equipment and instrumentation are installed as per
the hydro test diagram.
During and after pressurisation:
 Record pressure measurements every half hour with the aid of the
dead weight tester.
 Check and record medium temperature every half hour.
 Check hose connections for leakage. Should any leakage occur,
pumping is to be stopped, line isolated and the leak rectified prior
to continuation of pressurizing.

11.1 Pressurizing

 Variable speed positive displacement pump equipped with stroke

counter.
 Two way communications between the launcher and receiver ends
shall be provided.

12.1 Hydrostatic Testing Method

 Pressurization of the pipeline shall be performed at a constant rate of
1 bar per minuet to 70% of the pressure test. Stop pumping and
check for leaks.
 Resume pumping to 70% of the total pressure at 1 bar per minute
after satisfactory inspections.
 After satisfactory inspections, resume pumping at 0.5 bar / minute to
80% of required pressure.
 After attaining 80% of the total pressure, the pipeline shall be left to
stabilize for a minimum of 1 hour.
 After the stabilization period and to prevent water surging, pumping
shall be resumed at 0.12 bars per minute until the final pressure
testing requirement is achieved.
 Disconnect pressurization hoses from pipeline after attaining correct
test pressure.
 The hydrostatic system pressure test shall be held for 24 hours.
 Check pipeline and hose connections for leaks to the following format.
1 person either end walking toward the centre. Two people at the
centre of the pipeline walking in opposite directions to meet the
person coming from the end of the pipeline.
 Constant observation for the length of the pipeline shall be
implemented.
13.0 Hydrostatic Leak Test

Not required.

14.1 De-watering of Pipeline

 Unless otherwise instructed by the Company, all successfully tested
pipelines and risers shall remain full of treated test water and suitably
capped off.
 Water disposal shall be as agreed with the Company.
 The treated water may have to be removed from the pipeline, if so
required in the PPS, as part of the Pre-commissioning activities (see
GS EP PLR 502). Flushing and drying procedure shall be addressed
on separate Pre-commissioning procedure.
 Secure a sufficient length of flexible hose to receiver / launcher drain
nozzle.
 Drain the line of all free running water.
 Load and launch cup pig using compressed air to extract any
remaining water in the line.
 Care should be taken with respect to the speed of the de watering pig,
as not to over load the flexible drain hose.
 On completion of water draining open all vents, drains, etc in order to
dry out the line.

15.1 Reinstatement
 On completion and acceptance of the hydro test, all blind flanges,
temporary pipe work and testing equipment shall be removed from
the line.
 Reinstatement shall be in accordance with the contract drawing.
 On completion of reinstatement, site to cleaned and left in an orderly
manner.
 Reinstatement documentation to be completed by the Contractor and
the Company.
16.1 Safety

Controlled areas of the test will be marked off with barrier tape, warning signs
shall be erected at various locations along the pipeline to restrict and warn
non involved hydro test personnel.
Only personnel who are directly involved with hydrostatic testing activities will
be allowed within the taped off and signed areas.
The Controlled areas are:
1. Launcher and Hydrotest fill point
2. Receiver area
3. Manifold area:
 Throughout the period of filling and pressurising, Tanmia will have
representatives at the test station and along the lenth of the pipeline.
 Monitoring of the launcher and reciever areas and 20 meters either side
of the pipeline shall be maintained.

17.1 Attachments
17.2 Pipeline Hydro test Diagram
17.3 Weld History Form
17.4 NDT Clearance Form
17.5 HT Check List Form
17.6 Punch List Form
17.7 Pre Hydro Acceptance Form
17.8 HT Record Form
17.9 Reinstatement Form
17.10 Drawing of Pigs
17.11 Drawing of Testing Manifold