PROJECT NAME METRADE SPUR LINE PROJECT

OWNER GUJRAT STATE PETRONET LIMITED

CONSULTANT J.P. KENNY (WOOD GROUP ENGINEERING INDIA PVT. LTD)
OWNER’S TPIA VELOSI CERTIFICATION SERVICES INDIA P. LTD.
JOB PROCEDURE JPL/PL/MSPL /P43 Rev.00

HYDROTESTING

OF

PIPELINE

(METRADE SPUR LINE)

J P KENNY/
JPL JPL TPIA
GSPL
PREPARED APPROVED
CHECKED REVIEWED

NAME

SIGNATURE

DATE

. DOCUMENT NO. REV. SHT.

PRCEDURE FOR HYDROTESTING OF PIPELINE
JPL/PL/MSPL /P43 00 1 of 14
 TABLE OF CONTENTS

SN DESCRIPTION PAGE

1.0 PURPOSE 03
2.0 SCOPE 03
3.0 REFERENCES 03
4.0 TERMS & DEFINITIONS 03
5.0 METHODOLOGY 03
6.0 HEALTH, SAFETY & ENVIRONMENT 12
7.0 QUALITY ASSURANCE & QUALITY CONTROL 14
8.0 APPENDICES / FORMATS / SKETCHES 14

. DOCUMENT NO. REV. SHT.

PRCEDURE FOR HYDROTESTING OF PIPELINE
JPL/PL/MSPL /P43 00 2 of 14
1.0 PURPOSE
The purpose of this procedure is to lay guidelines and requirements and to establish a
method or a system to control the hydrostatic testing of Metrade spur line.
2.0 SCOPE

The scope of this procedure is to define the methodology for air cleaning, gauging,
water filling, hydro-testing and dewatering of the 12” (for Metrade Spurline) and 8”
(for Indian Steel) diameter buried Pipeline fabricated & installed for GSPL.

3.0 REFERENCES

Following documents in part or in totality shall form the reference documents.

 Tender Specification No: 110159-00-P-1-020-Rev.C

 OISD 141
 API RP 1110
 ASME B 31.4

4.0 TERMS & DEFINITIONS

For the Purpose of this document, the term “shall” indicates a mandatory requirement
and “should” indicates a recommended practice.

Their full meaning in brackets follows acronyms or abbreviation

5.0 METHODOLOGY
Before starting the hydrostatic testing the following the details of the test section shall
be submitted in the Hydro-test pack.
(a) Pipe Book (Part A + Part B)
(b) Elevation chart
(c) Mechanical Clearance certificate
(d) Calibration certificate of all the used instruments.
(e) Test pressure details
(f) Drawing of temporary test headers.
(g) Water sample testing report
(i) Equipment and Instrument list.

that shall be prepared for each test section and submitted to TPI,GSPL / JP Kenny
prior to commencement of the test. The overall tentative layout of equipments and
instruments for hydro testing is shown in Appendix-06

A calculated / predetermined length of pipeline shall be selected for the hydro-test

based on elevation, availability of water and location of stations. Actual Geographical
profile showing the elevation of the complete test section shall be drawn prior to start
of the test and enclosed in the hydro-test pack along with ‘Testing Plan’ (document
no. JPL/PL/MSPL/TP/P43), however the test section shall not exceed 25 Kms.

. DOCUMENT NO. REV. SHT.

PRCEDURE FOR HYDROTESTING OF PIPELINE
JPL/PL/MSPL /P43 00 3 of 14
 Hydro-testing of mainline shall exclude valves at tap – off stations, terminals, pump
stations, SV stations and scrapper station facilities.

Prior to any hydrostatic test TPIA, GSPL / JP Kenny shall be notified in advance and
the hydro-test shall commence only after obtaining signature on Part – B of the Pipe
Book and Certificate of Mechanical & Civil Completion (Document no.
JPL/PL/MSPL/MCC/P43).

Equipment and Instruments

All the instruments to be used shall be a valid calibration certificates as per

specification requirements.

The Equipment / Instruments to be used for performing the work shall include, but
not limited to the following:
 Pigs for filling, cleaning and gauging: Cleaning pigs with Nylon/Polyurethelene
brushes.
 Four cup batching pigs.
 Gauging pig with gauge plate (10mm thk.) diameter equal to 95% of heavy
wall pipe in the pipe sections.
 Fill Pumps with differential head 20% greater than the maximum required and
a flow rate preferably between 200 m3/h to 1000 m3/h.
 Positive displacement pump equipped with digital stroke counter and capable of
exceeding the maximum test pressure by at least 20 bar.
 Positive displacement flow meters to measure the volume of water used for
filling the line having a valid calibration certificate.
 Portable tanks of sufficient size to provide continuous supply of water to the
pump during pressurization.
 Pressure gauges of suitable pressure range of 1.5 times test pressure, min. 6”
dia. Of ±0.1% of full scale with valid calibration certificate.
 Dead weight tester with an accuracy of 0.01 bar and Measuring in increments
of 0.05 bar with a valid calibration certificate not older than one month at the
time of hydrostatic testing in the pipeline.
 Temperature recorders for fill water with chart and ink pen.
 Pressure recorders with charts and ink pen tested with dead weight tester prior
to use. This shall be installed at the test heads.
 Pressure recording charts in Kg/cm².
 Thermocouples for measuring pipe wall and soil temperature with accuracy of
±0.2oC.
 Two laboratory thermometer 0°C to 60°C range and accuracy ± 0.1°C
 Measuring cylinder to check quantity of water during air volume calculation.
 Injection facilities to inject additives in the test medium in the required
proportion.
 Temporary test headers fabricated in conformity with ASME section VIII,
division 2 with particular reference to Appendix 4 and 5 having sufficient length
to accommodate the required number of pigs. The header shall also have
provision for pig stopper and shall also pretested for 4 hours at a pressure
equal to 110% of maximum test pressure.
. DOCUMENT NO. REV. SHT.
PRCEDURE FOR HYDROTESTING OF PIPELINE
JPL/PL/MSPL /P43 00 4 of 14
  Proper piping and valve arrangement for launching and receiving of pigs
independently.
 Unless otherwise specified, all measuring recording instruments shall meet the
specification requirements of contracts.
 Magnetic pigs with suitable magnets.

Test Medium

Cleaning, filling and hydro-testing shall be performed using soft non- aggressive
water, free from sand and silt withdrawn from a suitable source in the pipeline route.
The water shall be filtered and shall not be contaminated. The water shall be tested in
an approved lab for its non aggressiveness and suitability for using as the test
medium with a PH value between 6 to 8. The test report shall be submitted to TPIA,
GSPL / JP Kenny for review. On the basis of water test report and manufacturers /
laboratory’s recommendations, the required quantity of corrosion inhibitor, oxygen
scavenger, bactericides etc. shall be added to the test medium with prior approval
from GSPL / JP Kenny WG.

Test Pressure

1. Unless otherwise specified in the Contract, Minimum test pressure shall be 1.5
times the design pressure, at the highest point of the test section. However, the
maximum test pressure at the lowest point of the test section or at the section with
the least wall thickness shall be limited to hoop stress resulting in 95% of SMYS.

Test Pressure shall be as follows.

Dia. & Thk. Material Min.Test Pressure Max.Test Pressure Remarks

(Min.) Grade in Kg/cm² in Kg/cm².
12” Dia. API 5L - 75
6.4 mm Thk. Gr.X65

Care shall be taken

The maximum test pressure at lowest point shower not be exceeds the pipe mill test
pressure.

In case of any class location is upgraded due to seismic requirements, the hydrostatic
test pressure shall be governed by actual class/population density.

The duration of hydrostatic test shall be minimum 48(24 hours for strength test & 24
hrs for leak test) hours after stabilization.

Cleaning & Gauging of the Pipeline Test Section:

The cleaning operations shall be performed by propelling air driven pigs provided with
spring loaded brushes and chisels. For this purposes temporary test headers shall be
welded to the pipeline. The number of pig runs shall depend on the cleaning results
. DOCUMENT NO. REV. SHT.
PRCEDURE FOR HYDROTESTING OF PIPELINE
JPL/PL/MSPL /P43 00 5 of 14
 and shall be determined by TPIA, GSPL / JP Kenny. Launching & receiving time of pigs
and quantity and type of debris on completion of each run shall be recorded in the
inspection report. The pig velocity shall be controlled by using the valve at receiving
end to maintain the required backpressure of 0.5 to 2 bars if required and pig velocity
shall be approx. 2 to 3 km per hour.

After acceptance of the cleaning, a Gauging pig fitted with gauge plate made of 10
mm thick commercial aluminum plate shall be propelled between the temporary test
heads. The sample calculation for gauging plate sizing is detailed in document no.
JPL/PL/MSPL/GPS/P43.

A column of clean water shall be pumped in front of the pig for lubrication and to
flush out the remaining dirt inside the test section.

The gauge plate shall be jointly signed by JPL, Velosi & GSPL / JP Kenny
representatives before launching. The results of the gauge pig run shall be analyzed to
evaluate the internal status of the pipeline. A deformed, bent or severally nicked plate
or damaged pig shall be evidence of gauging pig run failure and the same shall not be
acceptable. In such cases JPL shall repair and rectify the line and repeat the gauging
pig run to the satisfaction of TPIA, GSPL / JP Kenny.

After acceptance of gauging operation by TPIA, GSPL / JP Kenny, a photograph of the

gauge plate shall be taken and attached with the gauging report.

The parameters of cleaning & gauging operations shall be recorded every 30 minutes
in the formats enclosed.

Test Section Filling:

On acceptance of Gauging, the air pigging headers shall be cut and the temporary test
heads already pretested shall be welded and 100% radiography shall be done, filling
may be started on acceptance the weld.

The hydro test report of the temporary test headers shall be submitted to TPIA,GSPL /
JP Kenny prior to start of welding the test header to the test section.

The filling end test header shall be pre loaded with three numbers of four cup batching
pigs.

The filling operation shall begin with pumping of uninhibited water equal to1km of line
of the volume of test section in front of the first pig with a flow rate preferably 200 m 3
/ hr. to 1000 m3 / hr.

The first pig shall be launched by pumping about 100m of uninhibited water behind
the pig. The water column before and after this pig shall act as a cushion to control
the movement of the filling pig and hence minimize air entrapment.

The second pig shall be launched by pumping inhibited water behind the pig.
. DOCUMENT NO. REV. SHT.
PRCEDURE FOR HYDROTESTING OF PIPELINE
JPL/PL/MSPL /P43 00 6 of 14
 The filling shall continue till the second pig reaches the other end of the test section
and the pressure at the test end rises to the static head.

Required quantity of approved corrosion inhibitor shall be injected during the filling
operation through any of the nozzles provided on the test header or into the break
tank. The quantity of inhibitor shall be controlled by adjusting the flow rate of the
dosing pump.

During the whole filling operation the valves at the receiving end test headers shall be
throttled suitably to maintain adequate back pressure and thus control the pig
movement.

The first two columns of water shall be drained out from the receiving end.

Water temperature shall also be measured on the pump delivery by means of a

recording thermometer throughout the filling stage.

Ground temperature shall be taken by measuring pipe temperature at the

thermocouple prior to starting of the filling operation.

Environmental temperature shall be recorded from the beginning of pressurization to

the end of test by means of a recording thermometer.

Dosing Rate:

The dosing rate shall be decided based on the estimated time required to start the
dewatering (depends on pre-commissioning activities) after particular hydro-test
section. In case the period between hydro-test of the section and dewatering
(depends upon pre-commissioning) fall within 6 months and more than 6 quantity
shall be added as per manufacturer recommendation.

In case of water transfer from one section to another section, additional dosage of
60ppm of inhibitor shall be added to the already dosed water.

Thermal Stabilization:

Once the test section has been completely filled and a minimum pressure of 1 bar has
been achieved at the highest point, the thermal stabilization period shall be started.
The thermal equilibrium between the pipeline and the environment shall be checked
through the thermocouples installed on the pipeline.

The temperature probes shall be installed to measure the pipe & soil temperature at
every 2.5 KM of the pipeline and spacing may be increased to maximum 5.0 KM the
terrain and nature of subsoil along the alignment of the test section also. One probe
each shall be installed at 500m from both end of test headers. Temperature readings
shall be made at 2 hours-intervals.

. DOCUMENT NO. REV. SHT.

PRCEDURE FOR HYDROTESTING OF PIPELINE
JPL/PL/MSPL /P43 00 7 of 14
 Thermal stabilization shall be considered to have been achieved when difference not
higher than 1 deg C is attained between the average values of the two consecutive
readings of pipe to soil temp. Thermal stabilization completion shall be approved by
TPIA, GSPL/JP Kenny.

Digital thermometer
Soil temp.
Thermocouple
Ground level

Insulation coating
Pipe wall view “A”

300mm VIEW “A”

Thermocouple attached to pipe wall by quick

setting epoxy

After completion and acceptance of hydro-testing, thermocouples shall be removed

and coating repaired as per approved coating repair procedure and shall be witnessed
by TPIA, GSPL/JP Kenny.

Pressurization

Operational Steps:

After acceptance of thermal stabilization.

Fill out and sign pipeline pre-pressurization safety checklist as per Document no.
JPL/PL/MSPL/PRN/P43

As soon as the temperature stabilization is achieved, the pressure shall be raised at a

moderate and constant rate not exceeding 2-bar per minute.

The parameters (Volume required) during pressurization shall be recorded throughout

the cycle in the format enclosed:

- Each 5 bar increments up to 80% of the test pressure as recorded by deadweight

tester.

- Each 2 bar increments between 80% and 90% of the test pressure as recorded by
deadweight tester.

- Each 0.2 bar increment between 90% to full test pressure as recorded by
deadweight tester.
. DOCUMENT NO. REV. SHT.
PRCEDURE FOR HYDROTESTING OF PIPELINE
JPL/PL/MSPL /P43 00 8 of 14
 The pressurization shall be cycled with the sequence shown in the following pressure
sequence.

Pressurize to 50% of test pressure, hold pressure for one hour, perform air volume
test and drop pressure to static head.

Pressurize to 75% of test pressure, hold pressure for one hour, perform air volume
test and drop pressure to static head.

Pressurize to test pressure, hold pressure for one hour, perform air volume and during
the pressurization to each test pressure, two tests shall be carried out for the
calculation of air volume in the pipeline under test.

In case, during the hold period indicated above, a decrease in pressure is observed,
the above operation shall not be repeated more than twice, after which the line shall
not be considered capable of test, until the cause for the lack of water tightness is
eliminated.

On acceptance of the air volume test the pipeline pressure shall be raised to the test
pressure and pressure stabilization period shall commence.

Air Volume Calculation:

In order to check the presence of air in the pipeline two separate consecutive pressure
lowering of 0.5Kg/cm² by slowly bleeding water from the test section shall be carried
out during all the pressurizing cycling as mentioned above. The water drained during
the second lowering shall be accurately measured (V 1). This quantity measured shall
be compared to the theoretical quantity (Vр) corresponding to the pressure lowering.
The air volume shall be acceptable if V i / Vр £ 1.02. The observation shall be
recorded in the air volume calculation format enclosed in (document no.
JPL/PL/MSPL/AVC/P43). If Vi / Vр exceeds 1.02, the hydrostatic test can not go on and
additional pig passages shall be performed to remove the air pockets.The theoretical
amount of water that is necessary for pressurization of the section shall be executed
by following formula

Vp = (0.884 ri/ti) x 10-6 x Vt x ∆P x K

48 hour hold period:

After acceptance of air volume the pressure shall be held for 48 hours (24 hours for
strength test & 24 hours for leak test).After 24 hrs of strength test and on achieving
pressure stabilization, pressure pump connections shall be removed and the test
section completely isolated and all connections at the test heads shall be checked for

. DOCUMENT NO. REV. SHT.

PRCEDURE FOR HYDROTESTING OF PIPELINE
JPL/PL/MSPL /P43 00 9 of 14
 leakages. Pressure temperature recorders shall than be started with the chart in real
time orientation and the 24 hour pressure hold period shall start for leak test.

During the pressure hold period the following data shall be recorded in the format
enclosed in document no. JPL/PL/MSPL/24HH/P43

a) Every one hour pressure measurement from dead weight tester

b) Every two hours pipe and soil temperature from the thermocouples.

All data shall be recorded on appropriate forms.

Throughout the hold period, care shall be taken that the maximum test
pressure should not exceed in lowest elevation of the pipeline section under
test. Should it become necessary to de-pressurise, the volume of test medium
bleed off shall be measured and recorded.

Acceptance Criteria:

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.

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
if difference is less than or equal to 0.3 bar. If the value is more than 0.3 bar, the
testing period shall be extended by 24 hrs.

For calculation of the pressure change due to change in temperature the formula and
data illustrated in document no. JPL/PL/MSPL/HTC/P43 shall be used.

On successful completion and acceptance of the hydro-test, the pipeline shall be

slowly depressurized at a moderate and constant rate.

Leaks:

If during the pressurization period or during the test periods any leaks are observed,
these shall be eliminated.

If any leaks are suspected the section shall be initially visually inspected to check the
eventual leaking point. If this check is negative, then the procedure described below
shall be followed. No work shall be carried out to repair leaks until the pressure has
been reduced to a safe pressure (i.e. static head plus 1 Kg) and the water drained

Leak Detection:

To locate buried leaking pipe, the following procedure by elimination shall be followed:

1. To cut the section in an intermediate position

. DOCUMENT NO. REV. SHT.
PRCEDURE FOR HYDROTESTING OF PIPELINE
JPL/PL/MSPL /P43 00 10 of 14
 2. To insert two test heads
3. To reflood the sections
4. To pressurize the two sections
5. To determine the faulty section

This procedure shall be applied until the determination of the defect. As soon as the
defect has been located and repaired, the test section shall be tested again.

If the test section fails to maintain the specified test pressure after isolation, JPL shall
determine by search the location of leakage or failure. All leaks and failure within the
pipe-wall or weld seams shall be repaired by replacement of entire joint or joints in
which leakage or failure occurs. JPL shall comply with instruction of TPIA, GSPL / JP
Kenny whether to replace a section of the line-pipe that includes the line leak or
whether to repair the circumferential weld. The repair shall however meet the
requirements of Tender Specification No: 110159-00-P-1-020-Rev.C. After completion
of repairs, the hydrostatic test shall be repeated.

JPL shall haul and stockpile all damaged and defective pipes to storage locations
designated by TPIA, GSPL / JP Kenny. All cracks and splits resulting from failure shall
be coated with an application of grease to preserve the characteristics of failure from
corrosion. Joint of failed pipes shall be marked with paint, with a tag indicating failure
details, date and location of failure and pressure at which failure occurred.

Pipeline Bulk Dewatering:

Upon successful completion of the hydro-test, JPL shall dewater the section as per the
instruction of TPIA, GSPL / JP Kenny.

The dewatering shall be carried out by using four cup pigs and foam pigs driven by
compressed air. The dewatering shall be done in such a way as to provide adequate
control of pigs during dewatering. Four cup pigs shall first be passed through the line
to displace the water. Foam pigs shall then be passed in order to complete the line
dewatering. The line shall be considered dewatered when a negligible amount of water
is flushed out by the last foam pig.

Before disposal of the hydro-test water, JPL shall add approved chemicals to
neutralize the effects of inhibitor added during the hydro test. During dewatering 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.

Upon completion of the testing and dewatering operation, any provisional traps for
pigs and all other temporary installation relating to the test shall be removed.
Subsequently the individual sections of the line already tested shall be joined in
accordance with the requirements of relevant specifications issued for the purpose.

The line pressure during dewatering operation shall be recorded every 30 minutes in
the format enclosed.
. DOCUMENT NO. REV. SHT.
PRCEDURE FOR HYDROTESTING OF PIPELINE
JPL/PL/MSPL /P43 00 11 of 14
 Once dewatering is over, all thermocouples installed in the pipeline shall be removed
and damaged corrosion coating shall be repaired using approved procedure and
materials.

6.0 HEALTH, SAFETY & ENVIRONMENT

The approved procedure of Health, Safety & Environment shall be followed during the
execution.

The hazards associated with the hydro-test have been identified and the following
guidelines are suggested for implementation of safety norms.

Provisions shall be made for the installation of no – admittance signs to unauthorized

personnel from the road to the R.O.W at critical locations.

Warning signs in English and Local language stating “Pipeline under test – Keep away”
shall be placed in locations where the pipeline is uncovered, and particularly where
the temporary headers and stations are located. Such areas shall be suitably fenced in
such a way as to prevent access of unauthorized personnel. No unauthorized
personnel shall be closer than 40 m to the pipeline under test.

Only the authorized personnel as defined / identified by the Hydro-test Engineer shall
be allowed within the test area when the test section is under pressure.

No stage of the activity shall progress without the specific clearance of testing
engineer.

The temporary test headers shall be installed in compliance with methods and suitable
locations so that their rupture cannot cause any injury to personnel.

The test cabin shall be placed in such a location as to prevent it from being affected
by a catastrophic failure in the test head.

No work on the pipe or test equipment shall be allowed while under pressure except
for tightening of flanges, the removal of connections after closing valves, and the
blinding of ports after achieving the test pressure for isolation of the test section.
No flexible hoses are permissible inside the test cabin, except for essential connection
to the instruments.
For effective communication, a wireless and walkie-talkie system shall be used.

7.0 QUALITY ASSURANCE & QUALITY CONTROL

. DOCUMENT NO. REV. SHT.

PRCEDURE FOR HYDROTESTING OF PIPELINE
JPL/PL/MSPL /P43 00 12 of 14
 The quality assurance and quality control for the project shall be carried out by strictly
implementing the following:
a. Inspection and Test Plan.
b. Quality Records

The type of inspection activity and quality records generated during the activity is
detailed in Inspection and Test Plan. Quality records shall include current calibration
certificates for all measuring instruments.

The overall tentative layout of equipment & instruments for hydrostatic testing is
shown in JPL/PL/MSPL/SK01/P43.

8.0 APPENDICES / FORMATS / SKETCHES

DOC NAME DOC. NO. REV

 Inspection & Test Plan for Hydrostatic Testing JPL/PL/MSPL/ITP/P4301

 List of Formats / Attachments JPL/PL/MSPL/APX/P43 00

a) Testing Plan JPL/PL/MSPL/TP/P43 01
b) Safety Checklist JPL/PL/MSPL/SCL/P43 00
c) Certificate of Mechanical & Civil Completion JPL/PL/MSPL/MCC/P43 00
d) Air Cleaning JPL/PL/MSPL/ACR/P43 00
e) Gauging JPL/PL/MSPL/IRG/P43 00
f) Water Filling JPL/PL/MSPL/WFR/P43 00
g) Thermal Stabilization JPL/PL/MSPL/ITS/P43 00
h) Pressurization JPL/PL/MSPL/PRN/P43 00
i) Air Volume Calculation JPL/PL/MSPL/AVC/P43 00
j) 24 Hours Pressure Hold JPL/PL/MSPL/24HH/P43 00
k) Hydro-test Calculation JPL/PL/MSPL/HTC/P43 00
l) Hydrostatic Test Evaluation JPL/PL/MSPL/HTE/P43 00
m) Depressurization JPL/PL/MSPL/DWT/P43 00
n) Record of Leaks JPL/PL/MSPL/ROL/P43 00
o) Coating Repair JPL/PL/MSPL/CR/P43 00

 Sketches:

Tentative Layout of Equipment & Instruments:

. DOCUMENT NO. REV. SHT.
PRCEDURE FOR HYDROTESTING OF PIPELINE
JPL/PL/MSPL /P43 00 13 of 14
 a) For Hydrostatic Testing JPL/PL/MSPL/SK01/P43 00
b) For Air Pigging JPL/PL/MSPL/SK02/P43 00

Layout Sketch of Hydro-test Header:

c) PIG Launcher JPL/PL/MSPL/SK03/P43 00

d) PIG Receiver JPL/PL/MSPL/SK04/P43 00

Note:- In case of any conflict between this procedure and the contract specification, the later
shall govern.

. DOCUMENT NO. REV. SHT.

PRCEDURE FOR HYDROTESTING OF PIPELINE
JPL/PL/MSPL /P43 00 14 of 14