PIPELINE HYDROTESTING

PROCEDURE
CONTRACT NO.: ..


A 20 May 12 19 For Approval QC Engineer QA/QC Engineer Project Manager
Rev. Date Pages Descriptio
Prepare! "#:
$o%a&a! $asri
Revie'e! "#:
A. Prasa!
Approve! "#:
(esa& Sai!

Pro)ect : (ara Pro)ect
Co&pa# : *+'ait Oi, Co&pa#
Cotractor : HOT Egieerig a! Costr+ctio Co&pa# *SCC
Doc+&et No. : HOT-.CP-
PIPELINE HYDROTESTING
PROCEDURE
Pipe,ie H#!rotestig Proce!+re
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RE/ISION LOG
RE$%&' RE$%DA(E RE$)ED PA*E RE$)'& DE)CRP('&
A 20 May 12 Fir!t i!!"e )"+,itte- for approval
CONTENTS
SL.NO SECTION PAGE
0.1 PURPOSE 2
3.1 SCOPE 2
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4.1 RE5ERENCE 2
2.1 RESPONS"ILITIES 2
6.1 PIPELINE DESIGN DATA 2
7.1 CONSTRUCTION 5LO( CHART 6
8.1 TEST PAC*AGE 7
9.1 E.UIP$ENTS AND INSTRU$ENTS 7
:.1 PIG $ATERIAL 5OR PIPELINES 8
01.1 SA5ETY 8
00.1 (ATER SOURCE 9
03.1 INTERNAL CLEANING 9
04.1 CALIPER PIGGING (ITH GPS $APPING OPERATION 01
02.1 (ATER 5ILLING 01
06.1 TE$PERATURE STA"ILI;ATION 00
07.1 PIPELINE HYDROTEST 03
08.1 DE(ATERING 06
09.1 S(APPING 07
0:.1 DRYING 07
31.1 PURGING 07
30.1 ATTACH$ENT 07
0.1 P+rpose
(2e p"rpo!e of t2i! proce-"re i! to li!t o"t vario"! !tep! involve- in 2y-ro!tatic pre!!"re te!ting3
pigging3 -raining3 !4a++ing an- -rying of pipeline! for t2e Project title- 56arra Project 7 in line!
4it2 t2e project !pecification%
3.1 Scope
)cope of 4or8 cover! t2e 6ater )"pply3 Q"ality an- (reat,ent3 nternal Cleaning3 Pigging3
*a"ging3 Floo-ing t2ereafter pre!!"ri!ing3 -epre!!"ri!ing on !"cce!!f"l co,pletion of te!ting an-
-i!po!al of 4ater of Pipeline a! per Contract (ec2nical )pecification%
4.1 Re<erece
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Pipe Welding, NDT, Coating
and Backfilling
Cleaning and Gauging
Filling & Air Removing
Temperature ta!li"ation
Pre##uri"ation
Pre##ure $old
Depre##uri"ation and %ater tran#fering &De%atering
Pre##ure Relief & Repair
&n'ualified
(eak Tig)tne## C)eck
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A)ME # 11%9 :i;"i- tran!,i!!ion !y!te,! for .y-rocar+on!3 :i;"i-
Petrole", *a!
<'C )pecification! 01/=.=1009 Pipeline Pigging an- .y-ro!tatic te!t
>ncl"-ing a--en-",?
<'C )pecification 01/=.=100/ Pipeline De4atering -rying @ P"rging
>ncl"-ing a--en-",?
AP 1110 .y-ro!tatic (e!ting of Pipeline%
2.1 Resposi=i,ities
EAperience- !peciali!t! cre4 coor-inate- +y a ;"alifie- an- eAperience- per!on 42o !2all +e
re!pon!i+le for all te!ting an- a!!ociate- 4or8! !2all carry o"t te!ting% )"fficient eAperience-
per!onnel !2all +e re;"ire- a! per t2e re;"ire,ent to ena+le all a!pect of te!ting to +e f"lly
!"pervi!e- an- co,plete- a! per t2e progra,%
/%0 Costr+ctio 5,o' C%art
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8.1 Test pac>age
(e!t pac8age !2all incl"-e +"t not li,ite- to t2e follo4ing!:
a? Pipeline pre!!"re te!ting cover !2eet
+? Pre=2y-ro te!t c2ec8li!t%
c? P"nc2 li!t for Pipeline
-? Mar8e- P@D for t2e line to +e te!te-%
e? Pipeline *eneral arrange,ent -ra4ing
f? Pipeline profile -ra4ing
g? 6el- ,ap
2? Pipe #oo8
i? Cali+ration recor-! for t2e "!e- in!tr",ent!%
j? Diagra, of .y-ro te!t .ea-er3 :a"nc2er / Receiver
8? Pipeline cleaning in!pection report
l? *a"ging in!pection report
,? Filling log
n? Pre!!"riBation Recor-
o? Pre!!"re an- (e,perat"re :og
p? Pre!!"re/vol",e calc"lation for entrappe- air percentage%
;? Pre!!"re (e!t Certificate
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r? Pre!!"re (e!t )pecification
!? De pre!!"riBation Recor-%
t? Pipeline !4a++ing report
"? Pipeline -rying report
v? Po!t 2y-ro!tatic te!t c2ec8li!t
D%0 E?+ip&ets a! Istr+&ets
9.0 E?+ip&ets List
(e!ting e;"ip,ent! !2all -epen- "pon t2e te!t to +e carrie- o"t a! per t2e (ec2nical )pecification
of t2e Contract% (2e follo4ing e;"ip,ent! are generally "!e-%
a? Air Co,pre!!or!%
+? Filling p",p%
c? Pre!!"riBing p",p
-? C2e,ical njection P",p%
e? 6ater tan8er! a! re;"ire-
f? $ac"", (an8er!
g? Die!el generator%
e? (e,porary Pig :a"nc2er/Receiver
f? Air Con-itione- or .eate- te!t Ca+in
g? Pig! @ Pig trac8ing e;"ip,ent
2? Communication equipment
9.3 Istr+&ets
a? Dea- 6eig2t (e!ter
+? Flo4 Meter!%
c? Pre!!"re *a"ge
-? (e,perat"re *a"ge
e? Pre!!"re recor-er 4it2 9D 2o"r! rotating c2art
f? (e,perat"re recor-er 4it2 9D 2o"r! rotating c2art
g? (e,perat"re pro+e!
2? Digital (2er,o,eter
i? )afety relief valve
9.4 Ca,i=ratio o< test Istr+&ets
All in!tr",ent! "!e- for .y-ro te!ting !2all +e cali+rate- +efore 2y-ro!tatic te!ting to ,eet t2e
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acc"racy of E/= 0%1F an- !en!itivity of 0%0/F an- !2all 2ave a vali- cali+ration certificate -"ring t2e
perio- of 2y-ro te!ting% All in!tr",entation !2all operate in t2e range of 90F to 00F of t2eir
,aAi,", in-icator level -"ring operation% (2e in!tr",ent! to +e cali+rate- an- cali+ration
certificate for t2e !a,e !2all +e pre!ente- prior to te!t%
:.1 Pig &ateria, <or pipe,ies
9%1 .ig2/ Me-i", Den!ity foa, Pig !2all +e "!e- +efore cleaning pig to en!"re t2at t2e line i! free fro,
o+!tacle!%
9%2 Cleaning pig >4it2 +r"!2 an- neoprene c"p?
9%1 #atc2ing pig! 4it2 9 neoprene c"p! !"ita+le for Filling /-e4atering
9%9 Foa,/ )ponge Pig! for -rying @ !4a++ing t2e Pipeline%
01.1 Sa<et#
10%1 Proper care !2o"l- +e ta8en to !afeg"ar- per!onnel an- property -"ring te!ting%
10%2 &o 4or8 !2all +e per,itte- on !ection! of pipeline or t2e a!!ociate- connection! "n-er te!t%
10%1 Prior to pre!!"ri!ation3 proper ,ea!"re !2o"l- +e ta8en to prevent -a,age to per!onnel an-
property or -i!r"pt any ot2er eAi!ting !ervice!%
10%9 Area 42ere te!t e;"ip,ent i! place- !2all +e clearly -e,ar8e- to prevent "na"t2ori!e- entry%
10%/ 6arning notice rea-ing 5(ARNING: PIPELINE UNDER TEST7 !2all +e place- at appropriate
location! for t2e -"ration of t2e te!t%
10%C All local an- !tat"tory re;"ire,ent! are ta8en care of%
10%0 Re;"ire,ent! !tate- Contract .ealt23 )afety an- Environ,ental >.)E? Plan !2all to +e "!e- -"ring
eAec"tion of t2e 6or8! at !ite%
10%D )afety officer ,"!t +e pre!ent at !ite%
10%9 #arrica-ing of Pipeline3 Fir!t Ai- <it3 E,ergency P2one no3 infor,ing to <'C a"t2oritie! etc
10%10 (2e co,,"nication facilitie! for t2e tea, involve- in t2e te!t 2ave +een c2ec8e- an- +ac8="p
facilitie! are availa+le%
10%11 (2e per!onnel engage- in t2e te!ting 4or8! 2ave +een +riefe- on t2e e,ergence plan!%
10%12 (2e +ot2 !i-e! operator! 2ave +een in!tr"cte- +y t2e te!t engineer regar-ing t2e li,iting pre!!"re
42ic2 !2all apply to t2e te!t !ection%
00.1 (ater So+rce
11%1 (e!t ,e-i", 4ill +e +rac8i!2 4ater -o!e- 4it2 Co,pany approve- non=foa, corro!ion in2i+itor to
,an"fact"rerG! reco,,en-ation!% (2e c2e,ical -o!ing of +rac8i!2 te!t 4ater !2all follo4 t2e
re;"ire,ent of <'C Engineering *ro"p )pecification 01/=C*=1001%Calc"late- ;"antity of approve-
corro!ion in2i+itor !2all +e a--e- to t2e 4ater "!ing -o!ing p",p%
G&CP MP 101G a pro-"ct of &ational C2e,ical! @ Petrole", n-"!trie! Co=<"4ait >refer attac2e-
Pro-"ct #"lletin? 42ic2 act! a! a Corro!ion n2i+itor3 #acterici-e @ oAygen !cavenger% t i! -e!igne-
a! a !ingle pro-"ct for treat,ent of 4ater re!i-ent in pipeline! an- prevent! corro!ion -"e to
oAygen attac83 anaero+ic +acteria an- !alt 4ater% t! -o!age rate reco,,en-e- +y t2e
,an"fact"rer i! /00pp,%
11%2 All te!t re!"lt!3 reco,,en-e- in2i+itor type an- -o!age! !2all +e !ent to t2e Co,panyH!
repre!entative for approval prior to !tart of filling operation
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Re;"ire,ent of 4ater for Pipeline filling !2all +e -eter,ine- +y "!ing t2e for,"la%
$ I J/9 A D2 A :
62ere $ I *eo,etrical $ol",e of t2e te!t )ection >M1?
D I Pipeline nternal Dia,eter >M?
: I Pipe :ine :engt2 >M?
Q"antity of #rac8i!2 4ater re;"ire- for filling eac2 pipeline !ection i! ,entione- in cla"!e no 19%00
11%1 6ater 4ill +e arrange- fro, neare!t *C in!i-e <'C or +y 4ater tan8er!% After 2y-ro=te!t relea!e3
t2e 4ater 4ill +e tran!ferre- fro, one !ection to t2e ot2er +y te,porary connection!%
11%9 (2e corro!ion in2i+itor ,"!t +e applica+le for ,"lti="!e%
03.1 Itera, C,eaig
03.0 Co<ir&atio prior to piggig
12%1%1 A pre=te!t c2ec8 !2all +e perfor,e- +efore pigging i! co,,ence-% (2e c2ec8 li!t !2all incl"-e t2e
follo4ing!:
(2e per,it for pipeline !ection cleaning an- ga"ging 2a! +een accepte- +y t2e Co,pany%
All te,porary pipe!3 pig trap!3 an- ot2er e;"ip,ent an- in!tr",ent! "!e- to te!t t2e !ection 2ave
+een c2ec8e- in ter,! of !afety an- f"nctionality%
All 2y-rote!t 2ea-! !2all +e prete!te- to ,aAi,", te!t pre!!"re
Prior to 2y-ro=te!ting3 all ne4 pipeline! !2all +e offere- for ,ec2anical clearance%
All in!tr",ent! an- ga"ge! to +e "!e- -"ring t2e te!t 2ave +een cali+rate- !ince not ,ore t2an C
,ont2! an- 2ave vali- te!t certificate!%
All 4arning notice!3 ,ar8er tape!3 !ign!3 protective +arrica-e! an- ot2er !afety e;"ip,ent 2ave
peen po!itione-%
03.3 C,eaig Process.
12%2%1 All pipeline! !2all +e internally cleane- to en!"re t2e re,oval of con!tr"ction -e+ri! an- loo!e !cale
12%2%2 Cleaning !2all +e -one in one !ection3 fro, :a"nc2er to Receiver%
12%2%1 (2e 1!t r"n of cleaning proce!! !2all +e -one +y Me-i", Den!ity Cri!! Cro!! Foa, Pig e;"ippe-
4it2 Pig :ocator%
12%2%9 (2e !econ- r"n of t2e cleaning proce!! !2all +e -one +y .ig2 !eal #i -irectional c"p pig 4it2 4ire
+r"!2 e;"ippe- 4it2 pig locator%
12%2%/ A co,pre!!or 4ill +e "!e- to -rive t2e cleaning pig% (2e pig !pee- !2all +e +et4een 0%1 ,t/!ec an-
1%0 ,t/!ec% (2i! !pee- can +e controlle- +y t2rottling relea!e valve at receiving 2ea-er%
12%2%C (4o tec2nician! 4it2 proper co,,"nication 4ill +e availa+le at eac2 en- of t2e pipeline in or-er to
control pig ,ove,ent an- arrival% (2e operator! !2all i,,e-iately report to t2e (e!t Engineer any
apparently variation 42ic2 ,ay re!"lt in fail"re or -anger !"c2 a! any "n,oral ri!ing of t2e
pre!!"re +e2in- t2e pig%
12%2%0 (2e pa!!ing of t2e pig to any partic"lar area !"c2 a! .ot #en-!/#arre- (ee! ,ay +e -etecte- +y
t2e non intr"!ive pig !ignaler t2at can +e po!itione- in t2e re;"ire- place to -etect t2e ti,e at 42ic2
t2e pig 2a! pa!!e- t2at location%
12%2%D Kpon pig arrival an- -etecte- +y t2e non intr"!ive pig !ignaler3 co,pre!!or 4ill +e !toppe- an-
pre!!"re 4ill +e relea!e- to at,o!p2ere prior to re,oval of t2e pig%
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12%2%9 Cleaning of t2e te!t line !2all +e 4itne!!e- +y Co,pany repre!entative an- Contractor QC
n!pector%
12%2%10Mini,", 2 r"n! 4ill +e carrie- o"t in pipeline an- a--itional r"n! !2all +e ,a-e if re;"ire- to en!"re
!ati!factory cleanne!! a! accepte- +y Co,pany repre!entative%
12%2%11After eac2 r"n of pigging3 t2e pig !2all +e in!pection +y Co,pany repre!entative!%
12%2%12(2e cleaning operation !2all +e contin"e- "ntil t2e vol",e of t2e receive- ,aterial! +y t2e la!t pig
i! le!! t2an / litter!%
12%2%11(2e follo4ing -ata !2all +e recor-e- +y pipeline pigging in!pection for, +y t2e te!t Engineer:
&",+er of pig r"n
(ype of t2e pig%
(ype of t2e -riving ,e-ia
(i,e of la"nc2ing an- receiving
$ol",e an- nat"re of ,aterial! an- !"+!tance! arriving in front of t2e pig at t2e
receiving en-%
12%2%19After cleaning operation3 t2e pipeline !2all +e protecte- +y clo!ing t2e opening! at +ot2 en-!%
12%2%1/Cleaning of non pigga+le line !2all +e carrie- o"t +y "!ing co,pre!!e- air +efore !tart 4ater filling%
03.4 Ga+gig Operatio
12%1%1 Follo4ing internal cleaning3 ga"ging r"n !2all +e ,a-e on t2e entire co,plete pipeline to
-e,on!trate t2at t2e pipe line i! free of +"c8le!3 4rin8le!3 -ent! etc%
12%1%2 *a"ging plate !2all +e ,a-e fro, al",in", plate an- !2all +e 9/F of t2e ,ini,", internal +ore of
t2e line pipe%
04.1 Ca,,iper Piggig 'it% GPS &appig operatio
11%1 After co,pletion of internal cleaning@ *a"ging3 Calliper Pigging 4it2 *P) ,apping !2all +e -one +y
Co,pany approve- )"+contractor% .'(ECC to !"+,it for co,pany approval a !eparate proce-"re
fro, t2e )"+contractor for Calliper Pigging 4it2 *P) Mapping%
02.1 (ater 5i,,ig
19%1 6ater Filling 'peration%
Filling of te!t line !2all +e carrie- o"t in t4o !tage!:
)tage 1: #rac8i!2 6ater fro, !o"rce 4ill +e p",pe- into tan8%
)tage 2: 6ater 4ill +e p",pe- fro, t2e tan8! to te!t 2ea-er "!ing filling p",p%
>Plea!e refer for connection -etail! in (e!t !e;"ence -iagra, enclo!e-?
19%2 Filling 4ater 4ill +e filtere- t2ro"g2 a !trainer fitte- 4it2 /0 ,icron filter%
19%1 Cali+rate- flo4 ,eter !2all +e in!talle- -o4n!trea, of t2e filling p",p in or-er to calc"late t2e
vol",e of te!t 4ater fille-% n2i+itor3 4ill +e injecte- into 4ater a! per ,an"fact"rer! reco,,en-e-
-o!age rate a! approve- +y Co,pany%
19%9 (2e filling operation !2all +e perfor,e- t2ro"g2 t2e te!t 2ea-er! on eac2 pipeline% (2e la"nc2er
!2all +e preloa-e- 4it2 2 no!% of +i=-irectional pig! for filling operation%
19%/ :a"nc2er !2all +e fitte- 4it2 1 noBBle! for filling 4ater%
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&oBBle no% 1 4ill +e "!e- for pre filling 4ater e;"ivalent to 2/0, lengt2 of te!t !ection%
&oBBle no% 2 !2all +e "!e- for la"nc2ing fir!t pig an- in2i+ite- 4ater e;"ivalent 2/0, !ection lengt2
!2all +e p",pe- into t2e line%
&oBBle no% 1 !2all +e "!e- for la"nc2ing !econ- pig an- re;"ire- vol",e of 4ater to fill t2e te!t line
4ill +e p",pe- into t2e line%
14.6 (2e filling pig !pee- !2all +e in range 0% 9 L 0%D,/!ec% P",ping 4ill contin"e "ntil pig! are receive-
at t2e pig receiver% Air eApelle- fro, te!t !ection !2all +e vente- o"t t2ro"g2 vent valve!% (2e
valve! !2all +e ,an"ally operate- 42ile filling to ,aintain a +ac8 pre!!"re of 1%0 +ar to avoi-
"ncontrolle- r"n of pig! an- re,oval of all trappe- air at t2e 2ea-er! ri!er!%
19%0 Recor-! -"ring 4ater filling:
D"ring filling operation t2e follo4ing 4ill +e recor-e- on t2e attac2e- for, for every 10 ,in"te!%
Fille- ;"antity%
Pre!!"re at receiver%
6ater te,perat"re%
Q"antity of in2i+itor p",pe-%
19%D Kpon arrival of filling pig at t2e receiver en-3 filling operation 4ill +e con!i-ere- a! co,plete- an-
t2e te!t !ection i! rea-y for !ta+iliBation
06.1 Te&perat+re Sta=i,i@atio
1/%1 After co,pletion of filling operation3 t2er,al !ta+iliBation of te!t !ection 4ill +e carrie- o"t% (2e
te,perat"re of t2e 4ater in!i-e t2e line can +e con!i-ere- t2e !a,e a! t2at of t2e pipeline o"t!i-e
4all%
1/%2 (4o no!% of te,perat"re recor-er! 4it2 9D 2r% gra-"ate- c2art! 4ill +e fiAe- on t2e te!t line%
1/%1 'ne recor-er 4ill +e fiAe- to pipe !"rface near la"nc2er
1/%9 't2er one to !oil at '%/, fro, pipe%
1/%/ (2e!e te,perat"re recor-er! 4ill +e provi-e- 4it2 -ifferent colo"r pen!%
1/%C (2er,oco"ple 4it2 rea- o"t !2all +e in!talle- at a -i!tance of 0%/8, fro, eac2 en- of t2e te!t
!ection%
1/%0 (2er,oco"ple !2o"l- +e fir,ly attac2e- to t2e +are pipe after re,oving corro!ion protection
coating an- covere- 4it2 in!"lating ,aterial!%
1/%D For !oil te,perat"re ,ea!"re,ent!3 t2ey !2o"l- +e +"rie- at pipe centre line -ept2 an- 0%/,
laterally fro, t2e pipe% All t2er,oco"ple along t2e pipeline !2all +e in!talle- +efore t2e !tart of t2e
filling operation%
1/%9 For a+ove gro"n- te!t !ection te,perat"re ,ea!"re,ent!3 t2e t2er,oco"ple !2o"l- +e fir,ly
attac2e- to +are ,etal an- covere- 4it2 in!"lating ,aterial! or in!talle- into line=fill 4ater%
1/%10 (e,perat"re rea-ing for pipe an- !oil3 at vario"! location!3 !2all +e ,ea!"re- every D2r!% for a
perio- of 29 2r!% an- !2all +e recor-e- in t2e 4ater filling recor- for,%
1/%11 D"ring !ta+iliBation perio-3 t2e follo4ing -ata !2all +e recor-e-
Pre!!"re rea-ing of -ea- 4eig2t te!ter
)oil te,perat"re fro, t2er,oco"ple! in!talle- along pipeline%
Pipe te,perat"re fro, t2er,oco"ple in!talle- along pipeline%
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A,+ient te,perat"re
#aro,eter rea-ing
1/%12 )ta+iliBation !2all +e con!i-ere- !ati!factory 42en t2e -ifference +et4een t2e average !oil an-
average pipe !8in te,perat"re i! not ,ore t2an 1MC%
07.1 Pipe,ie H#!rotestig
07.0 Co<ir&atio prior to press+ri@atio
1C%1%1 A pre=te!t c2ec8 !2all +e perfor,e- +efore pre!!"riBing i! co,,ence-% (2e c2ec8 li!t !2all incl"-e
c2ec8! to confir, t2e follo4ing!:
)ta+iliBation 2a! +een accepte- +y all partie!%
All in!tr",ent! an- ga"ge! to +e "!e- -"ring pre!!"riBing an- te!t 2ave +een cali+rate- an- vali-
te!t certificate! 2ave +een c2ec8e-%
All e;"ip,ent an- -evice! are in goo- con-ition an- 4ell f"nctional%
A te!t ca+in e;"ippe- 4it2 a -ea- 4eig2t te!ter an- c2art recor-er i! in!talle- at a !afe -i!tance of
not le!! t2an 20, fro, te!t line%
At la"nc2er an- receiver pre!!"re recor-er! 4it2 9D 2o"r rotating c2art! 4ill +e in!talle- for
contin"o"! recor-ing or pre!!"re -"ring pre!!"riBing%
9 n",+er! of te,perat"re recor-er! are in!talle- at la"nc2er an- receiver for recor-ing !oil an-
pipe te,perat"re -"ring pre!!"riBation%
A 2ig2 pre!!"re p",p e;"ippe- 4it2 +"ilt in cali+rate- relief valve !et at /F a+ove te!t pre!!"re
!2all +e "!e- to pre!!"riBe t2e te!t line:
07.3 Ca,c+,atios o< Air Cotet
(o -eter,ine t2e re!i-"al air vol",e in t2e line t2e +elo4 -iagra, !2all +e -ra4n:
(2e t2eoretical !lope !2all +e calc"late- fro, t2e follo4ing for,"la:
N$/NP I $ O>D/t? A >1/E? A >1= P 2 ? E > 1 /Q?R
62ere:
N$ : ncre,ental of vol",e in >M
1
?
NP : ncre,ental of Pre!!"re in >#ar?
$ : Fille- $ol",e>M
1
?
D : '"t!i-e Dia,eter >M?
t : 6all (2ic8ne!!>M?
E : So"ngT ) Mo-"l"! 'f Ela!ticity>#ar?
>For Car+on !teel EI2%00A10
C
+ar?
P : Poi!!onT ) Ratio >0%1?
Q : #"l8 Mo-"l"! of 6ater I 21%1A10
1
+ar
#efore pre!!"riBation !tart!3 t2e a+ove calc"lation !2all +e -one an- t2e t2eoretical P/$ plot an-
0%2F off!et vol",e line !2all +e -ra4n%
(2e follo4ing -iagra, !2all +e "!e- a! follo4!:
.'(//00
*+ Bar
,* Bar
T
e
#
t

P
r
e
#
#
u
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e

-
!
a
r
.
tatic
$ead
T)eoritical P/0 lope
Actual P/0 Plot
12tra Ploted
0olume 3f Water Added
+45*
6a2imum Allo%a!le
Air Content
+47+ +45+ +4+* + +47*
8 Air Content
Actual Air Content
Pipe,ie H#!rotestig Proce!+re
Doc Ref : QCP/
!!"e : #
Date : 01 May 2011
Page! : 12 of 19

Fig=1
1C%1 Pre!!"riBing !2all procee- at a ,aAi,", rate of 1 #ar / Min"te%
1C%9 D"ring pre!!"riBation3 t2e follo4ing rea-ing! !2all +e ta8en an- recor-e-
Dea- 4eig2t te!ter rea-ing
)tro8e co"nter rea-ing
Pre!!"re ga"ge rea-ing at receiver%
A,+ient (e,perat"re
6ater te,perat"re%
1C%/ (2e line !2all +e pre!!"riBe- to /0F of t2e final te!t pre!!"re% An act"al P/$ plot !2all +e -ra4n in
or-er to -eter,ine t2e air content in t2e te!t !ection% (2e percentage of air content !2all +e
calc"late- fro, t2e P$=*rap2 a! per Fig%01 +y plotting on grap2%
Percentage of Air I >$ol",e of Air /$ol",e of :ine? A 100
1C%C Air content !2o"l- not eAcee- 0%2F of te!t line vol",e co,paring to t2eoretical ;"antity%
1C%0 (2e !lope of t2e linear part of t2e P/$ plot !2all +e co,pare- 4it2 t2e !lope of t2e t2eoretical plot
for 100F 4ater content% (2e !lope !2all not -iffer +y ,ore t2an 10F%
1C%D f air content i! greater t2an 0%2F of t2e line vol",e3 t2e pre!!"riBing can not go on% (2e te!t
!ection !2all +e -epre!!"riBe- an- a--itional pig pa!!age! !2all +e perfor,e- to re,ove t2e air
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Pipe,ie H#!rotestig Proce!+re
Doc Ref : QCP/
!!"e : #
Date : 01 May 2011
Page! : 11 of 19
poc8et!%
1C%9 Kpon t2e acceptance of t2e air content in t2e te!t !ection3 t2e pre!!"riBation !2all contin"e "ntil
D0F of t2e ,aAi,", te!t pre!!"re i! reac2e-%
1C%10 Pre!!"re i! t2en !ta+iliBe- for a perio- of 2 2r!% D"ring t2i! 2ol- perio- t2e line ,"!t +e c2ec8e- for
any po!!i+le lea8!%
1C%11 (2e pre!!"riBation rate a+ove D0F !2all +e at a "nifor, rate no ,ore t2an 0%/ #ar/ Min"te "ntil
,aAi,", te!t pre!!"re i! reac2e-% Pre!!"re !2all +e recor-e- every 0%/ #ar%
1C%12 62en t2e pre!!"re +eco,e! 100F of te!t pre!!"re3 pre!!"riBing p",p 4ill +e !toppe- an- all
connection! fro, te!t p",p 4ill +e i!olate- fro, te!t !ection an- 29 .r% 2ol- perio- 4ill !tart% (2e
!tart of t2e 2y-rote!t !2all coinci-e 4it2 t2e 2ig2e!t te,perat"re of t2e -ay%
07.04 32 Ho+r Ho,! Perio!
#efore co,,ence,ent of 29 2o"r 2ol- perio- c2art! for te,perat"re an- pre!!"re recor-er! 4ill +e
replace- 4it2 ne4 c2art!%
D"ring 29 2r% 2ol- perio- follo4ing rea-ing! 4ill +e recor-e- at every 2alf an 2o"r%
Dea- 4eig2t te!ter rea-ing
Pre!!"re ga"ge rea-ing at :a"nc2er an- Receiver% A,+ient te,perat"re
#aro,eter rea-ing
(2er,oco"ple rea-ing! at all location! >#ot2 !oil an- pipe te,perat"re?
1C%19 (2e te!t !2all +e -ee,e- accepta+le if any pre!!"re c2ange can +e acco"nte- for +y
corre!pon-ing te,perat"re c2ange "!ing t2e follo4ing for,"la:
UP/ U ( : S=2V />DW>1=v
2
?/EtE1/#? #ar/ XC
UP : Pre!!"re c2ange >#ar?
S : $ol",etric eApan!ion coefficient of 4ater
U ( : (e,perat"re c2ange >XC?
D : Pipeline o"t!i-e Dia,eter >M?
E : So"ngG! Mo-"l"! of car+on !teel >EI2%00A10
C
+ar?
t : &o,inal Pipe (2ic8ne!! >,,?
v : Poi!!onG! Ratio >0%1?
# : #"l8 ,o-"l"! of 4ater at te,perat"re an- pre!!"re of t2e 4ater
21%1W10
1
+ar
V : Coefficient of linear eApan!ion of !teel >11%0W10
=7
A
1C%1/ (2e -ifference +et4een t2e t2eoretical pre!!"re an- ,ea!"re- te!t pre!!"re at t2e en- of 2ol-
perio- !2all not +e greater t2an Y0%2 F of te!t pre!!"re%
1C%1C For acceptance criteria3 !tatic pre!!"re c2ange! !2all +e acco"nte- +y te,perat"re c2ange!% (2e
te!t !2all +e accepte- if c2ange in pre!!"re i! 4it2in accepta+le li,it an- no lea8! are fo"n- -"ring
t2e te!t% A pre!!"re c2ange of Y0%2 F of t2e te!t pre!!"re !2all +e accepte-%
1C%10 f greater pre!!"re -rop! occ"r!3 t2e 2ol-ing perio- !2all +e eAten-e- anot2er 29 2o"r! or t2e
ca"!e of lac8 of 4ater tig2tne!! !2all +e e!ta+li!2e-% n eit2er ca"!e t2e Co,pany 4ill +e infor,e-%
1C%1D A pre!!"re v!% ti,e grap2 !2all +e prepare- for 29 .o"r 2ol- perio- to a!certain t2e act"al pre!!"re
.'(//00
Pipe,ie H#!rotestig Proce!+re
Doc Ref : QCP/
!!"e : #
Date : 01 May 2011
Page! : 19 of 19
c2ange!%
1C%19 'n acceptance3 Pre!!"re 4ill +e relea!e- gra-"ally at t2e rate of 1 #ar/Min"te%
1C%20 :ea8! or fail"re! 4ill not +e accepte-% All lea8! or fail"re! !2all +e rectifie-% (2e te!t !ection/:ine
!2all +e te!te- again% #efore atten-ing any repair3 te!t line !2all +e -epre!!"riBe- to !tatic pre!!"re%
After atten-ing repair! t2e line !2all +e rete!te- to en!"re3 t2ere i! no lea8! or fail"re!%
08.1 De'aterig
10%1 .y-ro te!t 4ater !2all +e -i!po!e- neare!t to -rainage of te,porary -i!po!al pit %Prior to !tart t2e
-raining of te!t 4ater per,i!!ion ,"!t +e ta8en fro, <'C )E< tea, a"t2oritie!% f t2ere i! no
!"ita+le location for -raining of te!t 4ater3 t2en vac"", tan8er! 4it2 te,porary facilitie! for
collection !2all +e "!e- for -i!po!al of te!t 4ater% t !2all +e en!"re- t2at pipeline !ection te!te- 2a!
+een -epre!!"ri!e- 1 +ar a+ove !tatic 2ea- con-ition an- left fille- 4it2 in2i+ite- 4ater%
10%2 All t2e te,porary fitting! an- connection! !2all +e c"t off or -i!connecte-3 an- t2e entire pipeline
!2all +e fiAe- 4it2 all t2e re;"ire,ent! a! per t2e final approve- -ra4ing% De4atering of eac2 line
!2all +e perfor,e- +y t2e #i=Directional/C"p Pig p"!2e- +y co,pre!!e- air%
10%1 Mini,", !pee- an- +ac8pre!!"re of t2e pig! !2all +e ,aintaine- in or-er to o+tain a contin"o"!
operation 4it2 no +loc8age of t2e pig!%
10%9 At t2e receiving en- t2e -i!c2arge an- flo4 !2all +e t2rottle- -o4n to avoi- -a,age to t2e receiving
facilitie!%
10%/ (2e velocity of t2e pig -"ring -e4atering r"n !2all not eAcee- 1%/ 8,/2r O0%9 ,/!ec%R
10%CPig !2all +e trac8e- +y pig !ignal! in!talle- at la"nc2er! an- receiver%
10%0 D"ring t2e arrival of t2e pig! at t2e receiving en- of t2e pipeline t2e -i!c2arge flo4 !2all +e t2rottle-
-o4n !"c2 t2at t2e pig !pee- i! al,o!t Bero 42en entering into t2e receiver3 to avoi- -a,age to t2e
receiving facilitie!%
10%D Kpon pig arrival at trap% (2e pig 4ill +e p"lle- o"t in pre!ence of Contractor/Co,pany
repre!entative an- 4ill +e caref"lly eAa,ine-%
10%9 After t2e acceptance of -e4atering +y Co,pany3 pipeline !2all +e relea!e- for !"+!e;"ent
!4apping an- -rying activitie!%
10%10 (2e 4ater 4ill +e -irectly tran!ferre- +y te,porary !pool! to t2e 2
n-
!ection to +e 2y-ro=te!te-%
09.1 S'a==ig
1D%1 )4a++ing operation !2all +e perfor,e- only after !ati!factorily re,oving +"l8 of 4ater fro, t2e
pipeline%
1D%2 Foa,/)ponge pig !2all +e la"nc2e- t2ro"g2 pig la"nc2er an- propelle- 4it2 co,pre!!e- air%
D"ring !4a++ing operation3 t2e valve at receiver !2all +e t2rottle- for 8eeping a +ac8 pre!!"re of
0%/ +ar% (2i! 4ill +e p"lle- o"t at t2e receiving en- in t2e pre!ence of <'C repre!entative%
1D%1 Foa, pig !2all +e 4eig2e- prior to an- after co,pletion of eac2 r"n% 6eig2t! !2all +e recor-e- to
-eter,ine t2e a,o"nt of 4ater collecte- +y foa, pig%
1D%9 Foa,/)ponge pig! r"n! 4ill +e repeate-3 "ntil !ati!factory re!"lt i! o+tain an- accepte- +y <'C
tea,
1D%/ Date an- (i,e! of pig la"nc2ing an- receiving a! 4ell a! con-ition of pig! at receiver !2all +e
recor-e- in t2e attac2e- for,at!%
0:.1 Dr#ig
19%1 (2e air=-rying operation !2all +e co,,ence- 4it2in 29 2o"r! of co,pletion of t2e -e4atering an-
!4a++ing operation%
19%2 (2e inlet air i! to +e -ry an- 2ave a ,aAi,", -e4 point of =/0XC at at,o!p2ere pre!!"re% (2e
-rying !2all +e verifie- +y ,ea!"ring t2e air -e4 point at inlet an- o"tlet% (2e -e4 point !2all +e =
.'(//00
N
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Receiver (aunc)er
Pipe,ie H#!rotestig Proce!+re
Doc Ref : QCP/
!!"e : #
Date : 01 May 2011
Page! : 1/ of 19
20X C%
19%1 D"ring -rying t2e -e4 point !2all +e contin"o"!ly recor-e- at +ot2 en-! of pipeline !ection! to
-etect pea8! in 4ater -e4 point% n partic"lar3 t2e -rying !2all +e con!i-ere- co,plete 42en t2e
re;"ire- -e4 point of= 20X C at at,o!p2eric pre!!"re !2all +e recor-e- contin"o"!ly%
19%9 After co,pletion of -rying operation3 all te,porary piping an- fitting! !2all +e re,ove-% (2e pipe
line !ection !2all +e clo!e- off%
31.1 P+rgig
20%1 P"rging !2all +e a! per approve- proce-"re to +e !"+,itte- +efore co,,i!!ioning%
30.1 Attac%&ets
21%1 Cleaning Report
21%2 Pipeline *a"ging n!pection Report
21%1 Pre!!"re an- (e,perat"re :og Filling :og%
21%9 Pre!!"riBation Recor- Pre!!"re an- (e,perat"re :og
21%/ Pre!!"re (e!t Certificate Pre!!"riBation Recor-
21%C Pre!!"re (e!t )pecification
21%0 Depre!!"riBation Recor-%
21%D Pipeline !4a++ing report%
21%9 Pipeline Drying report
21%10 Pipeline P"nc2 :i!t
21%11 Pre=2y-ro te!t c2ec8li!t
21%12 Po!t 2y-ro!tatic te!t c2ec8li!t
21%11 Pre!!"re/vol",e calc"lation for entrappe- air percentage
21%19 Pipeline *a"ging n!pection Report
21%1/ Corro!ion n2i+itor Pro-"ct #"lletin%
(2e te,porary pig la"nc2er an- receiving trap!
.'(//00
:;
7;
7;
Pipeline 1nd Flange
Bi Direction
,:
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Pig upport
$<drote#t $eader (aunc)er and Reciever
-
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Pipe,ie H#!rotestig Proce!+re
Doc Ref : QCP/
!!"e : #
Date : 01 May 2011
Page! : 1C of 19
.'(//00