Document No.

GP 43-46
Applicability Group
Date 31 May 2006

Guidance on Practice for

Pipeline Hydro-test and Pre-commissioning

GP 43-46

BP GROUP
ENGINEERING TECHNICAL PRACTICES
31 May 2006 GP 43-46
Guidance on Practice for Pipeline Hydro-test and Pre-commissioning

Foreword

This is the first issue of Engineering Technical Practice (ETP) BP GP 43-46. This Guidance on
Practice (GP) is not derived from any heritage documents.

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Guidance on Practice for Pipeline Hydro-test and Pre-commissioning

Table of Contents

Section Page
Foreword ........................................................................................................................................ 2
1. Scope .................................................................................................................................... 4
2. Normative references............................................................................................................. 4
3. Terms and definitions............................................................................................................. 4
4. National regulations and regulatory authorities ...................................................................... 5
5. Health, safety, security, and environment .............................................................................. 5
6. Planning of pre-commissioning activities................................................................................ 7
7. Hydro-test and pre-commissioning activities .......................................................................... 9
8. Initial cleaning ........................................................................................................................ 9
9. Gauging ............................................................................................................................... 10
10. Hydro-test requirements ...................................................................................................... 11
10.1. General..................................................................................................................... 11
10.2. Test pressure and duration ....................................................................................... 12
10.3. Test execution .......................................................................................................... 13
11. Final cleaning and dewatering ............................................................................................. 17
11.1. General..................................................................................................................... 17
11.2. De-watering .............................................................................................................. 18
12. Drying .................................................................................................................................. 19
12.1. General..................................................................................................................... 19
12.2. Drying using dry air ................................................................................................... 19
12.3. Drying using dry nitrogen .......................................................................................... 20
12.4. Vacuum drying.......................................................................................................... 20
12.5. Glycol or methanol swabbing .................................................................................... 21
13. Inhibition and preservation ................................................................................................... 22
13.1. Inhibition ................................................................................................................... 22
13.2. Nitrogen/ dry air preservation .................................................................................... 22
13.3. Nitrogen/ dry air purge .............................................................................................. 22
Bibliography .................................................................................................................................. 24

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Guidance on Practice for Pipeline Hydro-test and Pre-commissioning

1. Scope

This GP provides guidance on the hydro-test and pre-commissioning of pipeline systems including the
requirements for dewatering, cleaning, drying, and conditioning of pipelines in preparation for
commissioning. The document is intended for use by the Pipeline Technical Authority (TA) and
project team during CVP Define and Execute stages albeit some of the requirements are pertinent to
extension and modification work undertaken during Operate stage. The document can also be
referenced during Appraise and Select phases to ensure that the pre-commissioning scope is
adequately understood before entering Define.

Pre-commissioning scope covers steps necessary, following completion of construction, to prepare the
pipeline to accept process fluid and to prevent internal corrosion or fluid contamination during
commissioning and operation of the pipeline.

This GP is applicable to onshore and offshore pipelines and covers the activities to be completed
before commencing the commissioning activities described in GP 43-47 Guidance on Practice for
Pipeline Commissioning and Handover to Operations. It does not cover pre-commissioning of above
ground installations such as pump and compressor stations or receipt facilities.

2. Normative references

The following normative documents contain requirements that, through reference in this text,
constitute requirements of this technical practice. For dated references, subsequent amendments to, or
revisions of, any of these publications do not apply. However, parties to agreements based on this
technical practice are encouraged to investigate the possibility of applying the most recent editions of
the normative documents indicated below. For undated references, the latest edition of the normative
document referred to shall apply.

BP
GP 43-08 Guidance on Practice for Selection and Use of Pipeline Codes and
Standards.

American Society of Mechanical Engineers (ASME)

ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and Other
Liquids.
ASME B31.8 Gas Transmission and Distribution Piping Systems.

3. Terms and definitions

For the purposes of this GP, the following terms and definitions apply:

GRP/GRE
Glass-fibre Reinforced Plastics/ Glass-fibre Reinforced Epoxy

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Guidance on Practice for Pipeline Hydro-test and Pre-commissioning

ID
Inside diameter

MAOP
Maximum Allowable Operating Pressure

SMYS
Specified minimum yield strength

GA
General arrangement drawing

4. National regulations and regulatory authorities

a. The Pipeline TA shall review national and/or local regulations, and national codes and
standards that are referred to in the regulations, to determine if there are any requirements
for hydro-test and pre-commissioning that are more stringent than those defined in this GP.

b. If compliance with the national codes and standards is required by law, the national codes
and standards shall be reviewed to determine areas where they exceed the requirements of
this GP, and these shall be implemented. If the national code or standard is not as stringent
as this GP, this GP shall be followed.

c. If compliance with the national codes and standards is not required by law, the Pipeline TA
shall initiate discussion with the regulatory bodies with the objective of obtaining
agreement to follow the requirements of this GP.

5. Health, safety, security, and environment

General HSSE requirements for the project should normally be addressed in the project HSSE plan.
Activities and hazards specific to pre-commissioning works shall be addressed in a specific method
statement for the pre-commissioning works.

a. A risk assessment specific to pre-commissioning activities shall be performed which

considers each pre-commissioning activity.

The objective of the risk assessment is to identify all potential health, safety,
security, and environmental hazards, evaluate the risks associated with the hazards,
and define the control measures that will be put in place to mitigate the risks.

b. The risk assessment shall be appended to the method statement, and the measures required
to control the identified risks shall be clearly cross referenced within the method statement
procedures.

c. An emergency response plan and associated contingency procedures specific to pre-

commissioning shall be included within the method statement to deal with foreseeable
incidents, such as injuries to personnel, loss of containment, pollution incidents, fire, and

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Guidance on Practice for Pipeline Hydro-test and Pre-commissioning

damage to the pipeline or third party property. This should be based on the emergency
response plan which applies during the operations phase.

d. Emergency response procedures for pre-commissioning shall recognise that the non-
routine pre-commissioning activities may introduce both gas and liquid into the pipeline
which, in the event of a leak or loss of containment, gas emission may be followed by
liquid or vice versa.

A liquid leak sustained by propellant gas would persist longer than would be
expected in normal liquid only operation.

e. Equipment to be used for pre-commissioning of the pipeline shall be installed at locations

remote from uncontrolled public access, roads, or accommodation if possible. Access to
and activities at these locations shall be appropriately controlled by means of security
fences, security guards, protection of the public, and permits to work.

f. Entry into controlled areas during hydro-test duration shall be limited to key trained
personnel. Procedures shall be developed for entry into the controlled area in the event of
the need to inspect potential leaks. The pipeline shall be de-pressurised or the leak area
shall be completely isolated for the remaining test segment before applying remedial action
to leaking fittings or flanges (See 10.3.6).

g. The pre-commissioning method statement shall define the methods of communication

between sites to ensure that the hazards associated with the work and the safety precautions
to protect personnel are known, understood, and applied by personnel carrying out the
work.

h. The method statement shall identify specific worksite safety training pertinent to pre-
commissioning activities for personnel, including site induction training and job safety
assessments.

i. Personnel at the work sites shall be informed of hazards through material safety data sheets
and those handling chemicals shall be provided with appropriate training and protective
clothing.

Pre-commissioning activities may require use of chemicals and additives for

cleaning which may introduce hazards that may not be encountered during normal
operation.

j. The use of chemicals shall be clearly identified in risk assessments and in method
statements, particularly the use of chemicals in confined or enclosed spaces.

E.g. chemicals such as anti freeze may be used and therefore preparations for safe
handling, containment, and correct disposal would form part of the risk assessment
and method statement.

k. If nitrogen gas or other asphyxiant gases are used during pre-commissioning, precautions
shall be addressed in the pre-commissioning risk assessment.

l. Venting of hydrocarbon, toxic, or explosive gas mixtures shall be minimised as far as

practicable and appropriate shall be facilities identified in the pre-commissioning method
statement.

m. The location of any vents shall consider wind direction, local population, and site workers.

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n. Maximum permissible levels for noise emissions shall be kept as low as is practicable and
shall be below the levels of noise required by the permanent facility design basis, local
regulatory requirements, and ESIA commitments.

Abnormal noise levels may be generated from pre-commissioning activities such as

gas venting or drying/ purging activities.

o. The effects of noise on the local population, particularly those in remote or rural areas,
shall also be considered and the local authorities and affected parties shall be advised of
any high or intermittent noise levels, particularly if working at night in areas of high
population.

The selection of appropriate equipment and provision of noise absorbing barriers

and silencers where appropriate during venting operations can keep noise levels to
a minimum.

p. Acquisition and disposal of hydro-test and cleaning water shall be addressed in the pre-
commissioning method statement to ensure it is disposed of with minimal impact on the
surrounding environment and in full accordance with relevant regulatory requirements and
permits.

Pre-commissioning activities especially pipeline pigging to clean the pipeline can

sometimes generate quantities of debris that could create disposal difficulties.

q. Internal coating of the pipeline should be considered in CVP Select phase to help avoid
potential future debris problems.

6. Planning of pre-commissioning activities

Before commencing the pre-commissioning, the Pipeline TA shall ensure that detailed plans and
method statements for the works are in place. The detailed plans and method statements shall include
as a minimum:

a. Precise definition of the pipelines or flowlines to be pre-commissioned, including marked

up P&IDs and mechanical layout drawings, (GAs, isometrics, route sheets, etc).

b. A detailed activity programme with critical path activities identified.

c. A P&ID summary and general arrangement of any temporary pipework, equipment, and
facilities for each section to be pre-commissioned. A list of required spares should also be
included.

d. A risk assessment to identify of potential health, safety, and environmental hazards with a
description of the contingency procedures and an emergency plan.

Note: this complements the project HSE plan, and may refer to it as necessary. Refer
to clause 5 above for more information.

e. Details, naming and describing with addresses and contact information, of the principal
contractors and any subcontractors and suppliers. This should also describe the scopes of
work of the subcontractors and suppliers, and how these will be co-ordinated by the
principal contractor.

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f. The principal contractor’s organisation chart for the work, brief job descriptions, and
relevant qualifications for the key personnel. A manpower histogram for the works
detailing the number of personnel and trades should also be included.

g. A summary of the quantities of material and consumables to be used for the pre-
commissioning work including the material datasheets (MSDS), methods of storage,
transportation, safe handling, and disposal.

Note that dewatering operations may require several pigging runs to achieve the
required dryness, so an adequate number of pigs with spares is required.

h. Temporary space requirements for compressors, nitrogen generating plant, dewatering and
drying equipment.

i. Temporary utilities in addition to permanent facilities.

j. Test/calibration procedures or certificates for main equipment and instrumentation.

k. A torquing plan for bolted connections.

l. A detailed procedure for each activity including:

1. A step by step description of the activity.

2. Description of the required personnel, equipment, utilities, and consumables.

3. Permitting requirements.

4. Certification, records, and verification of same.

5. Location and layouts with hazardous area classifications for equipment and supplies.

6. Calculations, drawings, and any other engineering work necessary to demonstrate that
the work will be executed in a manner that is safe and does not impact the
environment.

m. A description of the method to preserve the dryness and cleanliness of the line once pre-
commissioning is complete.

n. Any tie-in work to be carried out after pre-commissioning.

o. The plan/method statement for pre-commissioning of valves, instrumentation, branch off

takes, etc.

p. Pre-commissioning method statement for any mechanical equipment.

Major equipment, such as compressors, would normally be the subject of a separate

method statement.

q. Actual details of the test operation stating what the test is to achieve to verify the success
of the operation.

r. Contingency procedure(s) for the removal of stuck pigs, containing spills, etc.

s. A description of the format of the pre-commissioning handover documentation, with

sample copies of the contractor’s standard forms and sheets.

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7. Hydro-test and pre-commissioning activities

a. The key activities to be addressed in order of execution during pipeline hydro-test and pre-
commissioning are as follows:

1. Initial Cleaning: To remove construction debris.

2. Gauging: To confirm ovality is within specification and absence of dents or buckles.

3. Hydro-test: To confirm the mechanical strength and leak tightness of the pipeline.

4. Dewatering/ final cleaning: To remove hydro-test water and any residual particulate
material.

5. Drying/ conditioning: To prepare the pipeline to receive process fluid or apply

preservation before commissioning.

b. Detailed requirements for each of these stages are discussed in the following clauses.

8. Initial cleaning

a. Pipeline cleaning shall be completed during pre-commissioning before hydro-test to

remove any construction waste, loose scale, rocks, sand, etc. unless the section length is
such that visual inspection or other means can be used to confirm it is not required.

b. The pipeline shall be cleaned in sections, with a section length of typically between 10 and
20 km (6 and 12 mi) dependant on suitable tie-in locations. Suitable points such as block
valve stations or crossings should be used for tie-ins.

c. Block valves shall not be installed before the initial cleaning operations have been
completed in order to avoid damage to valve seats and seals.

d. Initial cleaning shall be carried out by running a robust bi-directional cup or disc pig fitted
with a location device.

Initial cleaning may subject the pig to more severe forces and process conditions
than normal operation due to potential presence of debris and therefore a more
robust design may be required compared to that intended for normal operating
conditions. The initial pig can be propelled by water or compressed air at a pig
speed between 0,5 and 1 m/s (1,6 and 3,3 ft/s) followed by further pigging runs using
brush or foam pigs, depending on the extent of cleaning required.

e. The pigging regime shall be designed to address the anticipated level of debris and scale,
the sensitivity of pipeline receipt equipment and the cleanliness levels required during
operation.

Further guidance on pig selection and pigging procedures is contained in GP 43-50.

Bi-directional pigs are normally used during initial cleaning, before the gauging
run, to confirm that the line can be pigged successfully, because bi-directional pigs
can be reversed in the event that they become stuck.

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f. Use of compressed air to drive pigs shall be at pressures below 7 barg (100 psig) with a
maximum pressure differential of 7 barg (100 psig) applied in the event that the pig
becomes stuck.

g. For the aggressive cleaning of un-lined carbon steel pipelines, including the removal of
scale, mandrel pigs with steel brushes should be used. These shall not be used on internally
lined pipelines.

Alternatively hard foam pigs with studs or brush-coated bodies can also be used.

A magnetic cleaning pig may be used after the brush cleaning has been completed
for final removal of metallic debris.

Mandrel pigs with polyurethane plates, and nylon brushes or criss-cross

polyurethane coated foam pigs can be used for cleaning pipes that are internally
lined.

h. For GRP/GRE pipelines specialist advice from the pipe supplier shall be sought before any
pigging activities. However, similar pigs to those used for internally lined pipes may be
used.

i. The amount of debris received at the end of each pig run shall be assessed. The amount of
material received should decrease with each run and pigging should continue until it is
judged that further pigging will not result in a significant reduction in the material in the
pipeline.

j. Acceptable cleanliness of the section shall be defined by the Pipeline TA based upon the
required operating conditions, sensitivity of valves and other pipeline receipt equipment
and the facilities available for subsequent removal of particulate material.

k. For duties in which product quality is critical, debris handling or disposal may be difficult.
In such circumstances and where extensive cleaning runs cannot be accommodated within
pre-commissioning schedule, internally coated line pipe should be specified at the CVP
Define stage to reduce the potential quantities of dust, mill scale or corrosion products
required to be removed by cleaning runs.

9. Gauging

a. Internal gauging shall be completed during pre-commissioning to confirm that there are no
unintended intrusions (dents, gouges, etc.) into the pipeline and confirm that the ovality of
the pipeline is within acceptable limits.

b. An aluminium gauging plate shall be fitted, located in front of the last set of discs on a bi-
directional pig with two sets of separate guiding and sealing discs. The plate should have 8
radial incisions at 45-degree intervals to allow the plate to buckle in the presence of a pipe
bore reduction or ovality. The gauge plate should be between 3 mm (0,12 in) thick for
pipelines up to 6 in diameter and a maximum of 10 mm (0,40 in) thick for 12 in diameter
or greater.

c. The gauging plate shall have a minimum diameter of 95% of the minimum nominal ID or
greater and not less than 25 mm (1 in) clearance for pipeline nominal ID of 20 in or greater
depending on the specified ovality tolerance.

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Guidance on Practice for Pipeline Hydro-test and Pre-commissioning

d. Each gauge plate shall be permanently marked with a unique identifier before insertion in
to the pipeline.

e. The gauging pig shall be fitted with a pig detector and its position in the line monitored.

f. A pig tracking plan , be it for an onshore or offshore line, should be prepared which
explains the means of tracking, the support operations required, the provision for pipeline
access to be made, and details of anticipated pig progress as a measure of pig location.

g. Launch procedures shall be carefully defined in writing and implemented to avoid damage
to the plate (particularly bottom of plate) during the launch process.

h. Removal of the gauging plate from the line shall be made in the presence of the BP
responsible engineer.

i. A photographic record of the gauging plate shall be taken as it is removed from the
pipeline.

j. If the gauging plate shows any damage, the cause shall be conclusively determined, and
necessary repairs to the pipeline shall be completed.

It may be necessary to run an instrumented geometric inspection pig to locate the

defect.

k. Filling of the pipeline for hydro-test shall not commence until an acceptable gauging run
has been completed.

10. Hydro-test requirements

10.1. General

a. Pressure test using water (i.e. hydro-test) shall be carried out as part of the pre-
commissioning process to the minimum requirement defined by the selected design code
supplemented by the additional requirements of this GP.

Further practical guidance on execution of liquid pipeline pressure tests is available

in API RP 1110.

b. Although permitted by some codes, pneumatic testing shall be avoided if possible.

Pneumatic testing shall only be used after completion of a detailed risk assessment subject
to approval by the Engineering Authority (EA) and the regulatory authorities if hydro-test
is not feasible.

c. The completed test for each section shall be documented in a test pack which shall be
approved by the Pipeline Technical Authority to signify acceptance of the test. The test
pack shall, as a minimum, contain the following:

1. Final test procedure and method statement.

2. Any deviations from above procedure encountered during test execution.

3. Calibration and test certificates for relevant equipment and instrumentation.

4. Recorded test measurements, chart recorder graphs, etc.

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5. Supporting calculations demonstrating test success against specified acceptance

criteria.

10.2. Test pressure and duration

a. The hydro-test shall be split into two phases, including a strength test to demonstrate the
pipeline has the required mechanical strength, followed by a leak tightness test to
demonstrate that the pipeline contains no leaks.

Test pressure is dictated by maximum operating pressure and material yield

strength.

The leak tightness test may be waived for pipeline sections that can be fully visually
inspected during strength test.

b. Strength test pressure is typically up to 90% of SMYS and shall not exceed 100% of
SMYS at any point in the pipeline.

c. Test pressure shall not exceed the test pressure applied to the line pipe in the pipe mill.

d. The combined stress calculated in accordance with ASME B31.4 (ref. 419.6.4) for liquid
lines and ASME B31.8 (ref. A842.223) or other applicable code selected in accordance
with GP 43-08 with due consideration of residual installation stresses (e.g. unsupported
spans, laying or bending stresses) shall not exceed 100% SMYS at any point in the test
section.

e. Strength test shall be applied for a minimum of 4 hours.

f. Leak tightness test pressure shall be between 110 and 125% of MAOP for liquid lines.

g. For gas pipelines, a minimum tightness test pressure of 110% of MAOP shall be applied
but this may need to be increased depending on the selected code requirements.

h. The leak tightness test shall be applied for a duration which allows the effects of normal
ambient temperature changes to be assessed.

This is for a minimum of 8 hours if ambient conditions do not vary or for a minimum
period of 24 hours if ambient temperature changes cause variation in test pressure.

i. The test period shall be restarted in the event that leakage is detected and remedial action is
required to restore test integrity or in the event of failure of test instrumentation.

j. The test pressure at any point of the test section shall be as defined in the applicable design
code of the pipeline.

k. The pressure at the point of application shall be such that the calculated test pressure is
generated at the highest point in the system and meets the specified test criteria.

l. Hydrostatic test sections should be as long as practicable but may need to be split if there
are large elevation changes to ensure the high and low points are within the tolerance limits
of the test.

m. The test sections shall be piggable, either by the use of temporary test headers or by the use
of the permanently installed pig launchers and receivers.

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n. The influence of expected ambient temperature changes shall be addressed in the hydro
test plan to ensure that temperature fluctuations to do not introduce the risk of
overstressing the pipeline.

10.3. Test execution

10.3.1. Test preparation

A range of pre-test checks shall be carried out to confirm facilities and resources are in place
and fully prepared to allow commencement of a safe and successful test. This shall include but
not be limited to checks as described below:

a. Regulatory authorities and other witnessing bodies have been informed.

b. Emergency response plans are in place and associated resources are available.

c. Personnel have been trained and briefed on the test and emergency response procedures.

d. Any pipe hangers, spring supports, pipe bridges, and unsupported spans are confirmed to
be designed to take the additional load from test water.

e. Instrumentation has been tested and calibrated and has current valid certification.

f. Line fill and pressurisation pumps have recently been serviced and are fully functional.

g. The pipeline section to be tested has been isolated from all other facilities and pipeline
sections and drain, vent, and bleed lines have been isolated.

h. Temporary piping and other equipment connected to the test section have been pre-tested
to the required pressure in excess of the test pressure.

i. Appropriate warning notices, marker tapes, protective barriers are in position and
unauthorised personal are excluded from restricted areas.

j. Communication systems are in place and confirmed to be fully functional.

k. Approved arrangements are in place for disposal of test water and consents/permits are in
place.

l. Anticipated ambient conditions and diurnal temperature changes will not introduce the risk
of freezing the test water.

10.3.2. Equipment

10.3.2.1. General

a. Any test equipment pressurised during the testing operations shall be designed for a
working pressure not less than the test pressure.

b. These components shall have material certificates and mechanical equipment and
instrumentation shall have data sheets from the manufacturer.

c. Any test equipment or temporary piping connected to the test section shall have been tested
to a pressure at least 1,25 times the test pressure of the test section.

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10.3.2.2. Test ends, pig traps, and headers

a. Any fabricated piping, temporary pig traps, or test ends shall be fabricated in accordance
with the welding procedures approved for the pipeline and materials shall be provided with
mill certification.

b. Fabricated equipment shall have been subjected to a hydrostatic test to at least the specified
test pressure within the previous six months and shall be supplied with test certification.

c. Fabricated equipment shall not be used if not supplied with a valid certificate and record of
use dating from original manufacture.

d. If the test end is welded to the pipeline, the welded test head shall be cut back to remove all
weld metal and the heat affected zone before each re-use.

e. The new butt weld end preparation shall be dimensionally checked and be subject to
appropriate NDT.

10.3.2.3. Other mechanical equipment

a. Filling pumps and pressurising pumps shall be supplied with flow meters suitable for the
required duty.

b. The pressurising pump shall be fitted with a full capacity relief valve set at the local test
pressure.

c. A test cabin with a temperature controlled environment suitable for the necessary
instrumentation, the dead weight tester, etc. should be provided.

d. Pig detection/ tracking equipment shall be confirmed to be functioning correctly with fully
charged batteries.

10.3.2.4. Instrumentation

a. A pressure recorder shall be positioned in the test cabin to continuously record the
pressure.

b. Pressure gauges shall be checked for accuracy on site by comparison with the dead weight
tester.

c. The flow meters shall be checked against a calibrated volume on site.

d. Other instrumentation shall have a calibration certificate not older than six months at the
start of testing. Copies of the calibration certificates shall be included in the hydrostatic test
pack.

The hydrostatic test pack is normally the formal record of the completed test proving
what has been completed and includes the test procedures and method statements.

10.3.3. Pipeline filling

a. Filling of pipelines with water shall require the use of pigs to eliminate air.

Filling is carried out in order to evacuate air and fill the line with test water before
hydro-testing.

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b. Two bi-directional pigs fitted with multiple sealing discs shall be used; one at the air/water
interface and one spaced behind to remove air that may pass the air/water interface pig.

c. Provision shall be made for removal of water on receipt between the two pigs.

d. Sufficient pressure shall be maintained in front of the air/ water interface pig, by using
backpressure control at the end of the test section.

e. Filling should be maintained a constant rate of around 1 m/s (3,3 ft/s).

This is required to control pig speed and prevent water column separation when the
pig is travelling downhill.

It is preferable to fill from the pipeline low point if possible. Pre-test sections and
testing of associated pipe work within stations and depots may be filled without the
use of pigs provided the configuration of piping is such that all air can be displaced
by water.

f. Transfer of test water between sections shall be considered during test planning to
minimise water extraction and disposal requirements provided final contamination levels
do not compromise disposal capability.

This may require intermediate water treatment to prevent build up of particulate

matter and contaminants.

10.3.4. Quality and treatment of hydro-test water

a. The test water shall be tested to establish its initial quality and to ensure that the water is of
the required quality for both flushing and hydro-test use. Depending on the water source,
filtering of the water to remove contaminants, such as debris, shall be undertaken.

Guidance on quality of test water is provided in GP 06-29.

b. The environmental impact of any chemical treatment or addition of anti-freeze shall be

assessed and confirmed to be acceptable. The impact of chemical treatment on the bulk
modulus of test water (e.g. volume change affecting pressure), particularly use of anti-
freeze, should also be established.

Water for hydro-testing may be obtained from a number of sources depending on

where the pipeline is to be constructed. These water sources may be public potable
water supplies, fire mains, underground wells, rivers, lakes, or the water may be
brought in by third parties by road tanker. Availability of test water may dictate the
length and arrangement of test sections.

c. If test water is transferred from one test section to another, the quality of water shall be
checked and additional chemicals shall be added, as required, to bring it back up to
specification.

d. A test water transfer written procedure shall be prepared.

e. The test water on transfer shall also be re-filtered, to reduce the amount of debris
transferred between sections.

f. In some cases addition of a biodegradable tracer dye may be injected to provide visual
evidence of a leak to aid leak location. The environmental impact of such dyes shall be
assessed and confirmed as acceptable before use.

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10.3.5. Air content check

a. The air content of the filled line shall be determined during initial pressurisation and shall
be less than 0,2%.

1. If the air content exceeds this volume the line shall be emptied and re-filled.

2. The air content shall be determined by plotting the pressure against volume added,
from the start of pressurisation until such time the results plot a straight line.

3. The straight line shall then be projected to cross the horizontal volume added axis.
The volume of air content is measured from the start of pressurisation to the
intersection of the projected line.

4. This volume shall not exceed 0,2% of the total volume of the test section.

b. When it is determined that the air content is less than 0,2%, the test pressure shall be raised
in accordance with 10.3.6 to the MAOP of the pipeline and held for at least two hours to
identify any significant pressure losses.

c. Flanges and valve bonnets, if block valves have remained installed, shall be checked for
leaks.

10.3.6. Temperature stabilisation and pressurisation

a. The temperature of the water in the test section shall be confirmed to be stable before
commencement of the test period.

This may take up to several days depending on the source of test water, ground
temperature, and ambient temperature.

b. During the stabilisation period, pressures and temperatures shall be recorded every hour.
This shall include measurement of ambient and ground temperature conditions.

c. The test water temperature should be within 1,0°C (1,8°F) of ground or seabed temperature
before commencement of the test.

d. The range of diurnal temperature change shall be determined during the stabilisation period
and assessed to confirm that this will not result in overstress of the pipeline during the test
period.

e. Once the temperature is stabilised the test pressure shall then be raised gradually to the test
pressure at a rate of 0,5 – 1.0 bar (7 – 15 psi) per minute.

f. The plot of pressure versus added volume shall be continued at 1 bar (15 psi) increments
until test pressure is reached.

g. Pressurisation shall be aborted if a linear plot is not obtained with the anticipated slope
based on the measurement tolerances of the instrumentation and the reason for the
deviations determined before de-pressuring and re-commencing pressurisation.

h. Visual inspection of flanges and permanent fittings, adhering to the formal safety zone
procedures, shall be undertaken when the pressure has reached 50% of test pressure or
50 barg (725 psig) whichever is lesser.

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i. The risks of intervention to eliminate any leaks during pressurisation or test phase shall be
thoroughly assessed and approved by the Pipeline TA before applying tools to tighten
flange bolts or connectors.

j. The impact of bolt or connector failure under pressure during tightening should be assessed
during this risk assessment with particular emphasis on the risk of failure on small
diameter fittings.

k. On confirmation of no leaks at this stage the pressurisation shall continue to 80% of test
pressure or MAOP (whichever is less) where it should be held for 2 hours to allow
stabilisation of the pipeline within the trench or movement on any pipe supports. The
pressurisation can then continue at a maximum rate of 0,5 bar (7 psi) per minute up to the
test pressure.

10.3.7. Pressure test

a. During the strength test, pressure and temperatures shall be recorded at least every half
hour using calibrated and certified test gauges or instrumentation and plotted against time
maintained.

b. The volume of any water added or removed to maintain test pressure during mechanical
strength test shall be recorded.

c. The test pressure for the strength test shall be maintained within ±1 bar (±15 psi) of the
specified test pressure.

d. The leak tightness test shall follow on directly from the strength test.

e. No water shall be added or removed from the pipeline during the leak tightness test.

f. If the temperature conditions are stable and no water is added or removed during the
strength test, and it can be ensured that temperature increases over the test period do not
induce over pressurisation of the pipeline, the leak tightness test may be combined with the
strength test.

g. On completion of the test period the pipeline shall be de-pressured to minimise surge
effects and vibration in pipe work at a rate typically not exceeding 1 bar/min (15 psi/min).

10.3.8. Acceptance criteria

Pressure variations during strength testing shall be deemed acceptable if they can be
demonstrated by calculation to be caused by factors other than a leak.

An acceptable method for calculation is demonstrated in BS EN 14161 (Formerly

BS PD 8010) clause 6.7.4.

11. Final cleaning and dewatering

11.1. General

a. The need for any further cleaning after hydro-test shall be assessed based on the amount of
debris received during evacuation of the test water.

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b. Further cleaning, if necessary, shall be conducted by initially pigging the pipeline with pig
trains consisting of a series of foam or disk pigs followed by a high sealing disc pig, using
clean filtered water or air as the propellant.

In some cases further chemical treatment of the line may be considered necessary
after de-watering to remove sulphate reducing bacteria or reduce other contaminant
levels depending on the final duty of the pipeline. This can be achieved by propelling
slugs of appropriate biocide or other chemicals between two high performance seal
disk pigs.

11.2. De-watering

11.2.1. Documentation

a. After hydrostatic testing the water shall be removed from the pipeline to allow drying and
commissioning.

With some pipelines, such as those designed to carry unprocessed sweet crude oil, it
may be possible to displace the test water during the initial line fill with process
fluid. This depends on the availability of oil/ water interface storage and separation
facilities.

b. De-watering pig runs shall use high sealing pigs with at least two guiding and four sealing
discs propelled by air.

c. The volume of water displaced shall be measured during the de-watering pig runs to assess
the effectiveness of the de-watering operation and determine the need for additional runs.

d. Two de-watering runs should normally be completed as a minimum.

If the pipeline has been tested with seawater, fresh water swabbing may be required
to reduce the salt content in the pipeline.

e. If required to reduce the salt content to specification, fresh water batches of approximately
5% of the pipeline volume shall be driven through the pipeline between two high sealing
disk pigs.

11.2.2. Records

The following records shall be collated during de-watering.

a. The quantities, pressure, and flow rates of the propellants used.

b. Records of materials and water disposed of at the receiving end after each pig run.

c. Records of any significant damage to the pigs.

d. Salt content of the fresh water swabs if applicable.

e. Final dew point of the air or nitrogen if further drying is planned.

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12. Drying

12.1. General

a. The requirement for drying of the pipeline following dewatering shall be assessed in
consultation with a specialist corrosion engineer as part of the pre-commissioning plan
depending on the final duty of the pipeline.

Drying of the pipeline may be required to preserve the pipeline until introduction of
process fluids or for example on gas pipelines to prevent hydrate formation or on
product or aviation fuel pipelines to minimise product contamination.

Drying by passing dried air down the pipeline is the preferred method for drying
pipelines as it is generally the quickest, cheapest, and most readily available
method. Dry nitrogen may also be used in place of dry air but this may present
logistical challenges in transporting to remote sites. The effectiveness of these
techniques becomes limited on branched pipelines or pipelines with deadlegs.

Vacuum drying may be used when there is a lack of dry air or nitrogen available, or
when pigging is not possible. It may also be used to supplement air or nitrogen
drying to achieve low dew points or to dry branches or deadlegs.

Use of glycol or methanol plugs can be used to minimise risk of hydrate formation
during initial line fill but are unlikely to achieve similar low dew point values to air
or nitrogen drying. This technique is valuable in low temperature environments in
which achieving low dew points with air or nitrogen may take significant time.

b. Glycol or methanol drying should only be used if other techniques are not feasible due to
the hazards of handling and disposing of these fluids.

12.2. Drying using dry air

In this technique air is first dried typically to a dew point below minus 80°C (minus
112°F) in a drying unit and then blown into the pipeline pushing a foam pig. The
water, present in the line evaporates into the pre-dried air and in this air is carried
to a point outside the pipeline. Pipes are typically dried to a dew point in the pipe of
minus 20°C (minus 4°F). However, if required, particularly for process equipment,
dew points down to minus 80°C (minus 112°F) can be achieved.

12.2.1. Initial pigging

a. The pipeline shall initially be pigged with foam swabbing pigs using the dry air as a
propellant.

b. The pigging speed shall be between 1,0 – 1,5 m/s (3 – 5 ft/s).

c. Pigging shall continue until the dew point of the drying propellant at the receiving end
remains below the required dew point for at least 2 swabbing pig runs.

12.2.2. Purging and dryness test

Dry air shall be blown through the pipeline at up to 3 m/s (10 ft/s) until the specified dew point
at atmospheric pressure at the pipe outlet end is maintained while at least one full line content is
displaced and held for an additional period of 12 hours.

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12.3. Drying using dry nitrogen

Drying using dry nitrogen shall generally follow the same procedure as specified for dry air.
Nitrogen shall have dew point below –50°C (–58°F) at atmospheric pressure.

12.4. Vacuum drying

12.4.1. General

a. Vacuum drying may be used when there is a lack of dry air or nitrogen available, or when
pigging is not possible.

b. The geometric stability of the pipeline under vacuum shall be assessed before selection of
this technique.

This technique is unlikely to be suitable for non-metallic pipelines.

Vacuum drying typically consists of the following stages.

 Leak tests.
 Evacuation/ Evaporation.
 Dryness test.
c. Before commencement of a vacuum test it shall be ensured that the system to be dried is
isolated from other piping and pipelines by means of blind flanges or welded caps, and that
temporary connections and pig traps have vacuum tight seals.

d. Valves shall be checked to ensure they are designed for vacuum drying, and body parts are
vacuum tight.

e. Valves should be open before drying commences.

12.4.2. Leak testing

a. The pressure in the pipeline shall be drawn down to slightly above the theoretical
evaporation pressure (a typical pressure is 100 mbara).

b. The vacuum unit should be stopped and the pipeline stabilised for around 12 hours whilst
the pipeline is checked for leaks.

c. Leaks should be rectified by flange tightening, tightening of fittings, taping of flanges, and
application of a suitable sealant to threaded leak paths such as valve stems.

d. When the leaks have been resolved as far as possible, the pressure shall be reduced to
between 50 and 75 mbara and the vacuum unit shall be isolated from the pipeline.

e. Pressure/time curves shall be plotted for a one hour duration.

f. The pressure increase over this period shall be used to calculate the total leak rate.

g. Leaks shall continue to be fixed until the leak rate is brought down to an acceptable level
as required by the leak test specification.

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12.4.3. Evacuation/ evaporation

The pressure in the pipeline system shall then be reduced to the point at which any water
contained in the pipeline is able to evaporate at the pipeline ambient temperature.

Free water evaporates in the system as soon as the pressure in the pipeline is
decreased. Water tends to evaporate at the point nearest the connection to the
vacuum pumping equipment and then free water evaporates along the pipeline
length as the process continues. Associated with this drying process, a pressure
gradient is produced as the vapour flows towards the pumps. As the process
continues, the vacuum pump suction pressure decreases and so the flow of vapour
being removed from the pipeline also decreases.

Evaporation of the water continues until all free water is removed from the pipeline.
At this point residual water remains in the system in the form of water vapour at low
pressure.

12.4.4. Dryness test

a. Once the pipeline has been depressurised to a point at or below the saturated vapour
pressure, the system shall be isolated and allowed to stand for a period of 24 hours.

The dryness of the pipeline is ascertained since any remaining water evaporates and
produces a system pressure increase greater than that noted by the air ingress test
noted in 12.4.2 above.

b. Should water be found in the system then the vacuum pumps shall be reconnected and the
pressure reduced to the agreed dew point level.

12.5. Glycol or methanol swabbing

Glycol or methanol slugs can be passed through the pipeline in order to remove
residual traces of hydro-test water before introduction of the process fluid.

a. The inherent health and safety risks involved during the use of these chemicals means that
this method of drying the pipeline shall only be used when supported by appropriate
detailed method statements and fully trained staff.

The general methodology for drying the pipeline involves the use of two slugs of the
chemical separated by nitrogen. The train comprises a magnetic cleaning pig
followed by cup pigs. A slug of nitrogen is inserted before the magnetic cleaning pig
to prevent any mixing of the air in the pipeline with methanol.

The volume of chemical varies but is generally in the order of 0,1% of the pipeline
inventory for each slug.

b. The chemical slugs shall be separated by a nitrogen slug no less than 800 m (2 600 ft) in
length when compressed to the pressure to be used for the commissioning of the pipeline.

c. The chemical shall be received into temporary tankage.

d. Once the first pig is received at the reception facility, the flow of commissioning fluid shall
be stopped and the residual line pressure shall be used to propel the swabbing train into the
pig hatch.

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The chemical slug continues to be received into tankage until the arrival of the
separation pig. At this point, the buffer slug of nitrogen can be vented off via the
temporary tankage until the second slug of chemical arrives. The second slug is
received into the tankage in the same manner as the first, until the commissioning
fluid interface arrives.

e. The responsible BP engineer shall arrange for the chemical to be analysed during the
swabbing process.

Normally, samples of the composition of the chemical are taken at the start, middle,
and end of each slug.

f. The acceptance of the swabbing operation shall be based on the measurement of the total
volume of liquid received into the tankage and the weight percentage of the chemical in the
last samples of the second slug.

g. A minimum of 50% chemical by weight shall be obtained when the volume of liquid
collected is in excess of 90% of the chemical introduced.

Higher weight percentages of chemical are required when lower volumes of fluid
are collected.

h. The final acceptance of the cleaning operation shall be the responsibility of the appropriate
BP engineer.

13. Inhibition and preservation

13.1. Inhibition

In some cases, such as highly sour service, the pipeline may need to be initially
coated with inhibitor by swabbing with slugs of inhibitor liquid contained between
high sealing disc pigs before introduction of process fluids.
The propellant should be either dry air or nitrogen.

13.2. Nitrogen/ dry air preservation

a. When commissioning of a pipeline does not immediately follow pipeline drying, the
corrosion risk shall be assessed by a corrosion engineer and if necessary the pipeline shall
be purged and pressurised with dry nitrogen/ air for preservation.

b. Appropriate warning signs indicating the hazards of pressurised nitrogen or air shall be
installed in above ground locations whilst the pipeline is pressurised.

13.3. Nitrogen/ dry air purge

a. Nitrogen/ dry air shall be introduced into the line at one end behind a cupped pig, and line
pressure controlled at 2 barg (29 psia) using a valve at the discharge end.

b. The purging operation shall be considered complete when the pig has arrived in the
receiving pig trap. A residual pressure of 1,5 – 2 barg (22 – 29 psia) should be maintained
after purging.

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c. Suitable pressure gauges shall be installed at each end of the pipeline. These gauges shall
be left installed until commissioning and monitored to confirm pipeline conditioning
remains effective.

d. After final completion of nitrogen/ dry air filling of the pipeline and pipeline
appurtenances, the pipeline shall be secured by locking closed isolation valves in order to
prevent air ingress and contamination of the pipeline with water vapour.

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Bibliography

BP
[1] GP 06-29 Guidance on Practice for Corrosion Protection During Hydrotesting.

[2] GP 43-50 Guidance on Practice for Pigging, Pig Launchers, and Receivers.

American petroleum Institute (API)

[3] API RP 1110 Pressure Testing of Liquid Petroleum Pipelines.

British Standards Institute (BSI)

[4] BS EN 14161 Petroleum and natural gas industries Pipeline transportation systems.

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