DOCUMENT TITLE : DOCUMENT NO. : REV.

HYDROSTATIC TEST PROCEDURE KI – 71251 -017 0.

FOR
ONSHORE PIPELINE PROJECT, EFFECTIVE DATE
TANGGUH - PAPUA 21 /11 /2006
ORIGINATOR REVIEWED BY APPROVED BY

Ujang Adi JD. Sutarno Drs, Bsc

QC Engineer Site Manager Project Manager

CONTENTS

1.0 OBJECTIVE 1/3

2.0 SCOPE 1/3
3.0 REFERENCES 1/3
4.0 PREPARATION 1/3
5.0 HYDROTESTING 1/3
6.0 HYDROTEST ACCEPTANCE CRITERIA 2/3
7.0 DEWATERING 3/3
8.0 SAFETY AND ENVIRONMENTAL PROTECTION 3/3
9.0 INSPECTION RECORD FORMS 3/3

REVISION RECORDS
REV. DATE DESCRIPTION ORIGINATOR REVIEWED APPROVED
BY BY
0 01/09/2004 Issued for Approval TR JDS

DISTRIBUTION REMARKS
1 Quality Assurance Manager
2 Project Manager
3 Site Manager
4 File / DDC

Tari /711876946.doc
HYDROTESTING PROCEDURE
Doc. No. : KI – 71251 -017 Revision : 0
PT. KELSRI
Engineering & Construction Management Date : 12/11/23 Page : 1 of 3
ONSHORE PIPELINE PROJECT, TANGGUH - PAPUA

1.0. OBJECTIVE
To prove construction of Pipeline Work, Onshore Pipeline Project, Tangguh - Papua, by hydrostatic
pressure testing.
2.0. SCOPE
Hydrostatic testing for Onshore Pipeline Project, Tangguh - Papua

3.0. REFERENCES
1. ANSI B31.3 - Piping Standard for Petrochemical Plants.

4.0. PREPARATION
.
1. Provide required vents c/w needle valves at highest points along the line, to remove the trapped
air when the line is being filled with water for hydrotest.
2. Connect the required test manifold, filling water pump, pressure pump, pressure gages, and
temperature at the appropriate locations.
3. Install necessary blind flanges at each pipe ends.
4. The proposed equipment / tools to be used :
 Pressure Pump : 0 – 10.000 psig. or as Design requirement
 Pressure Gage / Pressure Recorder : 0 – 3000 psig. or as Design requirement
 Test Manifold.
5. Prior to usage of the gages, make sure that they have been calibrated.
6. Prepare the test water.
7. Upon Client / SAIPEM permission, propose to utilize the water source from PT. TPPI existing
plant.

5.0. HYDROTESTING
1. Check all connections (welding joints, flanges, valves, water inlets, pump, instrument, etc) to
make sure they are ready for hydrotest. Do not fully tighten the highest blind flanges yet, to
allow releasing the air when the line is being filled with water.
2. Open all block valves at the lines.
3. Keep the vent valves open to bleed the air during water filling.
4. Make sure that the line to be tested has been buried.
5. Slowly start filling the line until the line full of water. If required, assist with the filling pump.
6. Observe the vent valves highest blind flanges to ensure that all air has been removed from the
lines. Close the vent valves and tightening the bolt on the highest blind flanges after the air
bleeding is sufficiently reached.
7. When the line has been full with water, disconnect the testing line from the pump discharges
and close with appropriate blind flange.
HYDROTESTING PROCEDURE
Doc. No. : KI – 71251 -017 Revision : 0
PT. KELSRI
Engineering & Construction Management Date : 12/11/23 Page : 2 of 3
ONSHORE PIPELINE PROJECT, TANGGUH - PAPUA

8. Start pressurizing the line until approximately 30% of the Specified Test Pressure ( STP ) and
hold for 10 minutes. Visually, check the entire line, including the valves and flange
connections. At the same time, observe the line by controlling the pressure indication.
9. Plug all vent valves and keep the valves open.
10. If no indication of leaking, slowly increase the pressure until approx. 70% of STP, and hold for
10 minutes. Repeat the leak inspections as per point 8 above.
11. After completed the 10 minutes holding time and satisfactorily checking, continue the
pressurization until the final STP is reached. Perform the final leak inspection for the whole line
sections, including the valves, flanges and fittings.
12. During all pressurization tasks, the incremental reading of pressure shall always be recorded on
the inspection forms.
13. After reaching the STP and no leaks encountered, the test is started for the duration of ½ hours
holding time. In case the hydro testing is done after backfilling then the holding time shall be 2
hours. Visually, check the entire line, including the valves and flange connections. At the same
time, observe the line by controlling the pressure indication.
14. No further pumping is permitted for the duration of the hydro test holding time.
15. Complete the test if until the end of holding time, no leaks encountered.

6.0. HYDROTEST ACCEPTANCE CRITERIA.

1. To satisfy the testing requirements, pressure in the line must be maintained without pressure
variations, which cannot be accounted by changes in temperature.
2. The test shall be accepted if, during the test, all pressure containing components in the line
maintains their integrity and no leaks are found.
3. Any reduction in pressure outside the limits specified, or variation in temperature, which cannot
be accounted for, shall result in a test failure. Possible causes for failure, such as a loose bolts
and / or fittings, leaking from the gaskets, test pump failure or air entrapment shall be located
and rectified.
4. Upon satisfactory completion of the test, KELSRI Engineer and QC, and Client / WAIJO
Inspector shall verify and sign the recorded inspection forms as the formal documentation of
acceptance.
5. After acceptance from Client /WAIJO, then the line can be depressurized. Release the pressure
gradually and slowly, not faster than 30 minutes from STP to 0 psig.
HYDROTESTING PROCEDURE
Doc. No. : KI – 71251 -017 Revision : 0
PT. KELSRI
Engineering & Construction Management Date : 12/11/23 Page : 3 of 3
ONSHORE PIPELINE PROJECT, TANGGUH - PAPUA

7.0. DEWATERING
7.1. If possible, after testing to the prior line then the water will be transferred to next tested line.
7.2. Dewatering will be disposed to the place determined by client /WAIJO.
7.3. The compressing equipment will be connected to the flow line for removing remaining water
until the flow line is completely dry.
7.4. All the temporary blind and other isolation devices shall be removed. Permanent flanges and
instrument shall be reconnected.

8.0. SAFETY AND ENVIRONMENTAL PROTECTION

1. Prior to any hydrostatic testing activities, the Field / QC - Engineer shall familiarize all in
charged personnel with the safety requirements associated with the test.
2. All personnel shall be equipped with safety wears. KELSRI Safetyman shall instruct personnel
of safe working practices and ensure that they are enforced.
3. All test crew personnel shall be trained and / or experienced in the testing activities performed.
4. All the test are sections shall be secured and restricted as practicable to outside personnel,
other than test crews and the Client’s /WAIJO’s representatives, during hydrostatic test.
5. Work permit shall be endorsed by Client / WAIJO and security personnel are made aware of the
nature of the test.
6. Other than specified above, no unrelated work of any kind, either permanent or temporary, shall
be performed on any part of the system while testing is in progress.

9.0 INSPECTION RECORD FORMS.

Appendix 1. The Hydrostatic Test Inspection Report forms as attachment on the Kelsri’s PQP
Document KQ – 710408 – 001 – Appendix 3 ( Category: Piping Work ).