Specification for Pipeline Hydro-Testing

Document No: A-PLE-SPE-200-30011

Revision 1

Revision History
Revision Changes

A Issued for Review & Comments

B Re-issued for Review & Comments

0 Issued for Design

1 Re-issued for Design

This revision checked and signed off by:

Name Function or Job Title

SG Ramkumar Discipline Engineer

P. Sahoo Discipline Lead Engineer

N.Sarbalina Discipline Lead Engineer

M. Siddiquie Project Engineering Manager

G R Narendiran Discipline Engineer

Holds
Hold No. Location Description

Page 2 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

Contents
REVISION HISTORY 2
CONTENTS 3
ABBREVIATIONS 5
1 INTRODUCTION 6
1.1 PROJECT 6
1.2 PURPOSE 6
2 REFERENCE CODES STANDARDS AND SPECIFICATIONS 6
2.1 GENERAL 6
2.2 ORDER OF PRECEDENCE 7
2.3 ALGERIAN CODES AND STANDARDS 7
2.4 INTERNATIONAL CODES AND STANDARDS 7
2.5 PROJECT DOCUMENTS 8
3 DEFINITIONS 9
4 KEY ACTIVITIES OVERVIEW 9
5 HSE 10
6 CLEANING AND GAUGING 10
6.1 CLEANING 10
6.2 GAUGING 12
6.2.1 GAUGE PLATE REQUIREMENTS 12
6.2.2 DAMAGED GAUGE PLATE 12
7 HYDROSTATIC TESTING 13
7.1 GENERAL 13
7.2 HYDROSTATIC TEST LENGTHS 13
7.3 TEST PRESSURES 13
7.4 HYDROSTATIC TEST WATER 14
7.5 WATER QUALITY 15
7.6 CHEMICAL TREATMENT 15
7.6.1 COCKTAIL TREATMENT 16
7.6.2 INDIVIDUAL CHEMICAL TREATMENT 16
7.7 APPLICATION 16
7.8 TETING MATERIAL AND EQUIPMENT 16
7.9 REQUIREMENTS PRIOR TO TESTING 17
7.10 FILLING 18
7.11 STRENGTH AND LEAK TIGHTNESS TEST DURATION 18
7.12 PRE-TEST SECTIONS 19
8 DEWATERING AND CLEANING 19
8.1 DEWATERING 19
8.2 CLEANING 20
9 CALIPER SURVEY 20

Page 3 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

9.1 SURVEY REQUIREMENTS 20

9.2 CALLIPER ACCURACY 21
9.3 OVALITY AND ACCEPTANCE CRITERIA 21
9.3.1 OVALITY 21
9.3.2 DENTS 22
10 DRYING 23
10.1 GENERAL 23
10.2 DRY AIR 23
10.3 DRY NITROGEN 24
10.4 VACUUM DRYING 24
10.4.1 GENERAL REQUIREMENTS 24
11 PRESERVATION 24
12 LEAKS AND FAILURES 26
13 WITNESS POINTS 26

Page 4 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

Abbreviations

API American Petroleum Institute

ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
BPVC Boiler and Pressure Vessel Code (ASME)
BS British Standard
CPF Central processing facility
DCVG Direct current Voltage Gradient
SAW Submerged Arc Welding
SMLS Seamless
EFW Electric Welded Pipe
HFW High Frequency Welding
ISO International Standard Organization
PMS Maximum Service Pressure (or Maximum
Allowable Operating Pressure)
SMYS Specified Minimum Yield Stress

Page 5 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

1 INTRODUCTION

1.1 PROJECT
Groupement ISARÈNE (the “COMPANY”) will develop the Ain Tsila gas field which is
located in the Illizi basin in the eastern part of the Sahara Desert in south-east Algeria,
south of the Grand Erg Oriental. The field was discovered within the Périmètre Isarène
(Blocks 228, 229a) in 2007 and has been appraised to hold approximately 65 billion
cubic metres (2.29 trillion cubic feet) of recoverable hydrocarbon reserves. The field lies
in the Sahara Desert, approximately 1,100km south-east of Algiers, 175km west of In
Amenas, 175km north- west of Illizi and 450km to the south-east of Hassi Messaoud.
Central Processing Facility (CPF) is designed to produce 10.3 MMSCMD sales gas.
A gathering system, comprising wellsites, wellsite systems, flowlines, manifold stations
and trunk pipelines to gather the produced fluids and transport them to the reception
facilities at the CPF. Raw gas will be treated in the CPF. Processing facilities comprising
pipeline reception facilities, slugcatcher(s), feed gas compression, mercury removal,
gas dehydration, gas conditioning (natural gas liquids extraction), export compression,
condensate stripper, LPG fractionation facilities, condensate and LPG export facilities
and associated utilities, storage and buildings (all located at the CPF). Fiscal metering
for sales gas, LPG and condensate, located at the CPF battery limit.
Sales quality gas will be delivered to SONATRACH TRC’s (TRC) sales gas pipeline
system at a tie-in point on a manifold next to the TFT compressor station. Liquefied
petroleum gas (LPG) will be delivered to TRC’s LPG pipeline system at a tie-in point
located at a block valve station west of the TFT compressor station. Stabilised
condensate will be delivered to TRC’s condensate pipeline system at a tie-in point
located at Méderba, approximately 165km north of Ain Tsila.

1.2 PURPOSE
This specification details the requirements for pipeline hydro-testing, that is the
cleaning, gauging, flooding, hydrostatic testing, dewatering, drying and preservation
activities applicable to all Ain Tsila Gathering and Export System pipelines. Hydrotesting
will be done in accordance with applicable Algerian regulations and ASME codes B31.8
and B31.4.
For pre-commissioning of the above ground installations (AGIs), refer to Specification
for Pressure Testing, Flushing & Reinstatement of Piping Systems (A-PIP-SPE-000-
00003).

2 REFERENCE CODES STANDARDS AND SPECIFICATIONS

2.1 GENERAL
The pipeline hydro-testing shall be carried out in accordance with the documents listed
and referenced in this document.

Page 6 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

2.2 ORDER OF PRECEDENCE

The order of precedence for all the technical documentation shall be as follows:

• Algerian Legislation
• Algerian Regulatory Authorities Regulations
• International codes and standards

• COMPANY Philosophy documents

• Project Specifications
In case of conflict between any of the above then the MOST STRINGENT shall apply
unless a dispensation has been approved by the COMPANY.

2.3 ALGERIAN CODES AND STANDARDS

Algerian Gas Pipeline Regles de Security pour les Canalisations de Transport
Regulations Degas Combustibles (Safety Regulations for the Transport
by Pipeline of Combustible Gas)
Algerian Liquid Regles de Securite pour les Canalisations de Transport
Hydrocarbon Pipeline D’Hydrocarbures Liquides (Safety Regulations for the
Regulations Transport by Pipeline of Liquid Hydrocarbons)
Algerian LPG Regles de Securite pour les Canalisations de Transport
Pipeline Regulations D’Hydrocarbures Liquides liquefies sous pression (Safety
Regulations for the Transport by Pipeline of Hydrocarbons
Liquefied Under Pressure)
P-CTE-1 Procédure de traitement des dossiers techniques et
modalités d'exécution des contrôles et essais
règlementaires.
Note: French and English side-by-side translation issued as
project document A-PMT-PRO-000-00005.
Decree No. 88-35, Dédinissant la nature des canalisations et ouvrages
1988, annexes relatifs à la production et au transport
d’hydrocarbures ainsi que les procedures applicables a leur
réalisation

2.4 INTERNATIONAL CODES AND STANDARDS

Construction of Pipelines shall be in accordance with latest revision of following codes
and standard along with codes and standards referred in the documents listed under
section 2.5. The applicable publications for codes and standards shall be the editions
published till 24th Dec. 2018.
ASME B31.4 (Edition-2016) Pipeline Transportation Systems for Liquid and
Slurries
ASME B31.8 (Edition-2016) Gas Transmission and Distribution Piping Systems

Page 7 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

API 1102 (Edition – 2007) Steel Pipelines Crossing Railroads and Highways
API 1104 (Edition – 2017) Welding of Pipeline and Related Facilities
API 5L ( 46th Edition) Specification for Line Pipe
API 6D Specification for Pipeline and Piping Valves
ASME VIII, Division 1 Boiler and Pressure Vessel Code
API RP 1110 Recommended Practice for the Pressure Testing of
Steel Pipelines for the Transportation of Gas,
Petroleum Gas, Hazardous Liquids, Highly Volatile
Liquids or Carbon Dioxide
API 1104 Standard for Welding Pipelines and Related Facilities
BS 8010-2.8 Code of Practice for Pipelines – Part 2: Pipelines on
land: design, construction and installation – Section
2.8 Steel for oil & gas
ISO 14313 Petroleum and natural gas industries -- Pipeline
transportation systems -- Pipeline valves

2.5 PROJECT DOCUMENTS

Document Numbers Documents
B-PLE-BOD-210-30001 Gathering system pipelines basis of design
P-PLE-BOD-200-30001 Export system pipelines basis of design
B-PLE-LST-210-30001 Gathering system pipelines schedule
P-PLE-LST-200-30001 Export system pipelines schedule
A-PLE-SPE-200-30010 Pipeline construction specification
A-PLE-PHL-200-30001 Pipeline Pigging philosophy
B-PLE-CAL-210-30001 Gathering System Pipeline Mechanical Calculations
P-PLE-CAL-200-30001 Export System Pipeline Mechanical Calculations
A-PLE-DAT-200-30001 Data Sheet for SMLS/HFW Line Pipe with External
Coating
A-PLE-DAT-200-30002 Data Sheet for LSAW Line Pipe with External
Coating
A-PLE-DAT-200-30003 Datasheet for pipeline hot induction bends
A-PLE-DAT-200-30004 Datasheet for pipeline anchor flanges
A-PLE-DAT-200-30005 Datasheet for pipeline barred tees
A-PLE-DAT-200-30006 Datasheet for pipeline monolithic insolation joint
A-PLE-LAY-210-30001 Overall gathering and export system layout

Page 8 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

3 DEFINITIONS

“ISARÈNE”COMPANY means Groupement ISARÈNE (the operator of the Ain

Tsila Development)

“CONTRACTOR” means the party, which carries out all or part of the
design, engineering, installation and commissioning,
procurement and construction applicable to this
specification

“shall” or “must” indicates that the specified action is mandatory (i.e.

must be done by the specified action party)

“should” indicates that the specified action is recommended but

not mandatory. However, the action party will be
responsible for the consequences in the event that
he/she elects not to do it

“will” indicates a commitment by others or a statement of fact

“Purchaser” means the entity defined as such in the purchase order

or Contract

“Seller” means the entity defined as such in the purchase order

or contract

“Sub-supplier” means the entity responsible for the supply of

components or services to the Seller

“Manufacturer” means the entity responsible for the manufacture of an

item ultimately supplied by the Seller to the Purchaser

“Goods” means the physical items delivered under the terms of

the purchase order or contract

“Services” means any services provided pursuant to the purchase

order or contract but not incorporated in the Goods

4 KEY ACTIVITIES OVERVIEW

For each pipeline, the key activities for testing and pre-commissioning to be addressed
are as follows in order of precedence:
1. Produce a detailed hydrostatic testing plan for each test section.
2. Initial cleaning to remove construction debris.
3. Gauging to confirm ovality is within specification and the absence of dents or
buckles.
4. Introduction of water/chemically treated water into pipeline section.
5. Hydrostatic testing to confirm the mechanical strength and leak tightness of the
pipeline, pipeline section or crossing.
6. Dewatering/cleaning to remove hydro-test water and any residual particulate
material.

Page 9 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

7. Disposal of water/chemically treated water after test.

8. Drying/conditioning to preserve the pipeline sections awaiting welding to adjacent
sections.
9. Connection of pipeline sections using golden welds (where appropriate)
10. Final cleaning and gauging of completed pipeline
11. Calliper survey from pig trap to pig trap: To provide a baseline record of the whole
pipeline including golden welds.
12. Final drying/conditioning following completion of construction to preserve the
completed pipeline until commencement of commissioning.
CONTRACTOR shall produce a detailed cleaning and testing plan that complies with
the ARH requirements detailed in Procedure for Processing Technical Dossiers and the
Rules for Carrying Out Regulatory Inspections and Testing (A-PMT-PRO-000-00005).
Each activity must be sufficiently documented, inspected and approved in accordance
with the Procedure for Processing Technical Dossiers and the Rules for Carrying Out
Regulatory Inspections and Testing (A-PMT-PRO-000-00005) prior to commencement
of the next activity.

5 HSE
CONTRACTOR shall include for COMPANY review, as part of their detailed cleaning
and testing plan, adequate measures for safety and environmental control.
These shall include the requirements of the referenced Algerian Regulations and ARH
requirements, CONTRACTOR shall comply with Human Factors Engineering Design
Specification (A-HSE-SPE-000-00001), Specification for Personal Protective
Equipment (C-HSE-SPE-000-00014) and Safety Requirements Specification Overview
(C-HSE-SPE-000-00018).
Additionally, CONTRACTOR shall include detailed requirements and procedures for:
• Exclusion zones: Special precautions, including pre-defined personnel protection
exclusion zones, during pressure testing.
• Night Time Working: Whilst night time working is generally not allowed during
construction, CONTRACTOR may submit a proposal to COMPANY
considering night time supervision of the pipelines during the hydro-testing phase.

6 CLEANING AND GAUGING

6.1 CLEANING
Prior to commencement of a hydrotest, each pipeline section shall be cleaned firstly by
running a robust bi-directional disc pig fitted with a location device. This is to be followed
by further pipeline cleaning using trains of pigs fitted with brushes and magnets. The
detail and design of which shall be submitted to COMPANY for review. Each pig train
shall contain a minimum of 2 Brush pigs followed by a magnetic pig.
Consideration shall be given to the length of the cleaning sections and the effect on the
pig’s performance.

Page 10 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

Block valves shall not be installed before the initial cleaning operations have been
completed in order to avoid damage to valve seats and seals.
CONTRACTOR shall submit a Cleaning Method Statement for review by COMPANY,
incorporating environmental requirements of the Environmental Design Strategy (A-
ENV-PHL-000-00001).
In order to reduce the total water requirements, cleaning pig trains may be propelled by
air, incorporating a suitable slug of water. Where a water slug propelled by compressed
air is used, CONTRACTOR shall ensure that his discharge pipework is designed and
installed to resist the high forces which can be generated when a mixture of air and
water is being used. Venting of air should be accomplished through a knock-out pot and
silencer. Noise levels are not to exceed 90 dBA with provisions of ear defenders are to
be made to all personnel within the vicinity. Noise levels shall conform to the Human
Factors Engineering Design Specification (A-HSE-SPE-000-00001).
CONTRACTOR shall inform, for COMPANY about the volumes and source of water
intended to be used both in front of, and between, the cleaning pigs. All cleaning water
must be disposed of in accordance with the requirements in the Environmental Design
Strategy (A-ENV-PHL-000-00001).
Temporary launchers and receivers shall be fitted to either end of the cleaning section.
These shall incorporate a pressure monitoring and recording device to provide a record
of each cleaning run. Temporary launchers and receivers shall be designed and
operated in accordance with the pollution prevention requirements within the
Environmental Design Strategy (A-ENV-PHL-000-00001) and CONTRACTOR’S
Method Statement shall detail how these requirements will be met.
The first pig to pass through each section shall be run independently to prove each
section prior to the running of cleaning trains. This first pig shall be fitted with a tracking
device which will enable location of the pig should it become lodged within the pipeline.
The acceptance criteria for pipeline cleaning shall be to the satisfaction of Company /
Contractor based on each pig train showing a diminishing trend in recovery of debris
and that the last pig of the cleaning train removes negligible debris and magnetic pigs
receiving minimal debris.
Any obstruction found during the cleaning process shall be cleared by Contractor.
All take-offs and dead legs are to be manually cleaned and after main pipeline cleaning,
they are to be visually inspected for cleanliness.
Inspection and acceptance methodology shall be included in the Method Statement and
include the inspection requirements of the Procedure for Processing Technical Dossiers
and the Rules for Carrying Out Regulatory Inspections and Testing (A-PMT-PRO-000-
00005).
The use of compressed air to drive pigs shall be at a pressure below 7 barg with a
maximum pressure differential of 7barg applied in the event that the pig becomes stuck.
Relevant and appropriate HSE measures shall be in place to ensure safety of the
personnel.

Page 11 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

6.2 GAUGING
Prior to hydrostatic testing, all sections of the pipeline shall be checked for ovality,
buckles, dents and similar irregularities with a gauging plate.
Gauging should be carried out once the backfill is complete. An additional “end to end”
gauging run should be undertaken once the block valves are installed.
A pig tracking system shall be provided. Launch procedures shall be carefully defined
in writing and implemented to avoid damage to the plate during the launch procedure.
CONTRACTOR shall notify COMPANY of his intention to perform the gauging pig runs
in adequate time for COMPANY to witness the loading and removal of the gauging pig.
The plate shall be inspected in accordance with the Procedure for Processing Technical
Dossiers and the Rules for Carrying Out Regulatory Inspections and Testing (A-PMT-
PRO-000-00005). A photographic record shall be made of the gauging plate following
its removal from the pipeline segment, clearly showing areas of damage and including
a means of referencing the photo to the line segment in which the plate was run.
All gauge plates shall be indelibly marked to identify the relevant section and run
number. Upon completion of the gauging operations all gauge plates shall be delivered
to COMPANY for acceptance and record purposes.
Filling of a section of pipeline for hydrostatic test shall not commence until COMPANY
has accepted gauging plates for that particular section.

6.2.1 GAUGE PLATE REQUIREMENTS

CONTRACTOR shall propose, for COMPANY approval, the location of the gauge plate
on the pig. It shall be positioned such that the deformation of the pig discs will not deform
the gauge plate.
The gauging plate will have a diameter equivalent to 95% of the minimum internal
diameter of the relevant pipeline (based on the thicker wall line pipe sections including
pipeline Valves and fittings) and not less than 25 mm clearance for pipeline nominal ID
of 20 in or greater depending on the specified ovality tolerance.
The thickness of the aluminium gauging plate shall be 3mm for pipes up to 6” diameter
and a maximum of 10mm for pipes 12” and over. The leading edge shall be chamfered
at 45-degree. The plate shall have a minimum of 8 radial incisions at 45-degree intervals
to allow the plate to buckle in the presence of a pipe bore reduction or ovality.
CONTRACTOR shall submit a detailed Gauging Method Statement for review by
COMPANY.

6.2.2 DAMAGED GAUGE PLATE

In the event that a damaged gauge plate is received, CONTRACTOR shall run a further,
confirmatory, gauging run in that segment. Should the confirmatory gauge plate also be
received in a damaged condition, CONTRACTOR shall run a calliper pig to locate the
defect and shall repair any such defect prior to line fill.

Page 12 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

7 HYDROSTATIC TESTING

7.1 GENERAL
The hydraulic testing operation shall be carried out by a Specialist Test Engineer
approved by COMPANY They shall have sufficient qualified assistants so that one shall
be available on site at all time during each hydrostatic testing operation. The Specialist
Test Engineer shall be mobilised well in advance of the planned start date for testing
and no later than the date of commencement of mainline welding.
The Specialist Test Engineer shall draw up a procedure of all operations for the tests,
clearly stating the responsibilities of his subordinates during all phases of his work.
The procedure shall be submitted to COMPANY for review not less than 28 days prior
to commencement of testing and shall be approved in writing before any testing
commences. The procedure shall include details of the following:
1. Hydrotest Schedule
2. Safety precautions
3. The design including the Hydrostatic test and supply of test ends
4. The location of the test cabin, pumps, and any other equipment
5. Specification and preparation of test water for initial use and for re-use, including
sampling, laboratory testing facilities, chemical treatment, settling tanks and
filtration system.
6. Filling and pressurising, including the sources of water, storage ponds, test
connections and vent points.
7. Hydrostatic test procedure, including details of test sections.
8. Depressurising and emptying, if appropriate, including details of drainage
connections and method of disposal of water.
9. Detailed programme giving proposed dates of tests.
10. List of nominated personnel supervising tests, with dates and times of duty.
Above ground station pipework shall be tested in accordance with Specification for
Pressure Testing, Flushing & Reinstatement of Piping Systems. Any underground
station pipework shall be tested in a similar manner to the main pipeline.
All measurements and calculations, except nominal pipe sizes, shall be in S.I units.

7.2 HYDROSTATIC TEST LENGTHS

In accordance with the requirements of the Algerian Regulations for Gas, Liquids Under
Pressure and Liquid Hydrocarbons, the maximum allowable length of a hydrostatic test
pipeline section is 30km.

7.3 TEST PRESSURES

The minimum hydrostatic test pressures are equal to or exceed the requirements of the
relevant Algerian Regulations, as summarised in the table. In all cases the minimum
pressures, at low points, are related to the maximum service pressure (PMS) of the line.

Page 13 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

Table 1 – Hydrostatic Test Pressures

Zone
1/1a/2/3
Zone 1/1a Zone 2/3
PMS / Zone Zone 2/3 Maximum
Minimum Minimum
MAOP 1/1a Test Test Combined
Pipeline Test Test
(minimum) Pressure Pressure Test
Pressures Pressures
barg barg barg Pressure
barg barg
barg Note
1
PMS / PMS /
Flowlines 89 132.8 104.7 132.8
0.67 0.85
PMS / PMS /
Trunklines 89 132.8 104.7 132.8
0.67 0.85
Condensate PMS x PMS x
65 78 71.5 78
Export 1.2 1.1
PMS x PMS x
LPG Export 97.25 145.9 121.6 145.9
1.5 1.25
PMS / PMS /
Gas Export 91.5 136.9 107.6 NA
0.67 0.85
Note 1: Contractor is to test all pipeline material to the same combined maximum test
pressure or Zone-wise test pressure depending on the test section requirement.

7.4 HYDROSTATIC TEST WATER

CONTRACTOR shall design the hydrotest program to minimise the use of water,
recycling test water by moving it sequentially from one test section to the next.
CONTRACTOR will allocate one or more sources of water for flushing and hydrostatic
testing. Dedicated wells and storage ponds shall be provided by CONTRACTOR for
hydrotest water.
It may be necessary to share water from time to time with COMPANY or other
contractors as directed by COMPANY, on a priority basis.
The water shall be filtered through 50-micron filters as required based on the available
water quality immediately prior to entering the pipeline.
The CONTRACTOR shall provide, all details of water treatment proposals necessary
to bring the water to the required quality for both flushing and hydrotest use.
CONTRACTOR shall procure such inhibitors, biocides and oxygen scavengers as are
necessary to render the water suitable for introduction into the pipelines. All necessary
clearances and approvals required from relevant authorities for the import & usage of
such chemicals shall be the CONTRACTORS responsibility.
When determining requirements for chemical additives, the, CONTRACTOR shall
consider any constraints that this may impose upon final disposal. Water disposal is the
responsibility of CONTRACTOR and shall be done in accordance with all applicable
permits / approvals and environmental regulations

Page 14 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

7.5 WATER QUALITY

The quality of water shall be reconfirmed by sample testing at a maximum of two (2)
weeks before initial water filling in preparation for the hydrostatic testing.
In case multiple water sources or tanker trucks are used to supply water, representative
water samples shall be drawn for testing from each source or tanker.
If the water used in the hydrostatic test is from more than one source, ensure that mixing
the waters will not cause scaling.
The water used for hydrotest shall be of the minimum quality below:
pH 6.5 to 10.5
Chloride ions 100 ~200 ppm
Total dissolved solids Less than 1.5 Kg/m³
H2S Nil
Suspended Solids 0.002 Kg/m³
Sulphate-Reducing Bacteria to be maintained <200 cells per mL
Appearance Clear with no visible sediment
If the maximum period of contact of this water (or residual water after dewatering) within
the pipeline is known to be 7 days or less, chemical treatment shall generally not be
required. If the period of contact is or could be in excess of 7 days, prior chemical
treatment shall be required unless CONTRACTOR can demonstrate water quality that
does not require treatment.

7.6 CHEMICAL TREATMENT

Use of chemical treatments shall be in accordance with the Environmental Design
Strategy (A-HSE-PHL-000-00001). CONTRACTOR shall be responsible for all required
permits for chemicals and subsequent disposal.
Test water shall be treated with oxygen scavengers to remove dissolved oxygen and
biocides to control bacteria growth.
Chemicals which are known to be persistent, bio accumulate, or toxic shall be avoided.
All chemicals are to be reviewed in terms of dose concentration, toxicity,
biodegradability, bioavailability and bioaccumulation potential.
Chemical supplier shall provide the information on biocide degradation (e g how long
the biocide will stay active in the pipe, what is the period of depletion and what are the
by-products).
The use of all chemicals shall be carried out according to the manufacturer’s
instructions, with trained personnel handling the chemical(s) being trained in the
storage, handling and disposal of the products.
Biodegradable chemicals shall be used. If biodegradable chemicals are not effective
APPROVAL shall be required for the use of neutralizable chemicals. Neutralisation
measures shall be obtained from the manufacturer as part of the chemical treatment
justification and associated plans, procedures and method statements.

Page 15 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

A record of all chemicals and the volume of each injected into hydrostatic test waters
shall be kept, chemical residuals shall be analysed prior to the water disposal.
As test water is transferred from one test section to another, the quality of water i.e. the
amount of treatment remaining, shall be checked and additional chemicals added as
required to bring it back up to specification, if required. Re-used test water shall be re-
filtered through 50 micron filters, to reduce the amount of debris. These tests and
activities shall be properly documented and immediately reported to COMPANY.
Two different types of treatment are proposed: cocktail treatment and individual
chemical treatment.

7.6.1 COCKTAIL TREATMENT

A single-chemical blend comprising two or more components of oxygen scavenger,
corrosion inhibitor, scale inhibitor or biocide.

7.6.2 INDIVIDUAL CHEMICAL TREATMENT

Injection of oxygen scavenger, biocide and corrosion inhibitor shall occur separately.
When using this treatment the oxygen scavenger shall be added first and as far
upstream in the system as practical to allow complete reaction prior to adding the other
chemicals. The biocide shall follow and finally the corrosion inhibitor.
For contact periods up to 3 months the cocktail treatment or individual chemical
treatment may be used. For contact periods up to 24 months individual chemical
treatment shall be employed.

7.7 APPLICATION
Oxygen scavenger shall be injected in a location where there is no contact with air and
contact of water with air shall be avoided downstream of the injection point.
The dosage of oxygen scavenger shall be determined on the basis of the amount of
oxygen present in the water. Tests shall be carried out to determine dosage of oxygen
scavenger and time required for the reaction. If only carbon steel is in contact with the
water the concentration of oxygen in the water shall be reduced below 50ppm.
If oxygen scavenger reacts with the biocide, as occurs for most biocides, the oxygen
scavenger shall be injected before the biocide allowing sufficient time to fully react with
oxygen. Sufficient time shall be determined by tests performed by chemicals supplier.
Good practice is to inject the oxygen scavenger upstream of the pump (in this case
reaction rate in enhanced by the turbulent flow) and biocide downstream of the pump.
Additionally, provisions for the disposal of treated water shall be assessed as part of
the justification to ensure disposal feasibility of the treated hydrotest water.

7.8 TETING MATERIAL AND EQUIPMENT

CONTRACTOR shall supply all temporary fittings, materials, equipment, launcher, pigs,
spheres and consumables required for all testing and dewatering operations.
All fittings and components used in the test shall be to specifications and shall be
designed for a working pressure not less than the maximum test pressure. Pipe and
dome end shall be supplied with mill certificates.
Page 16 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

Test headers shall be fabricated and tested in accordance with the procedures
approved for the pipeline. Test ends shall be numbered and a record shall be kept on
each fabrication weld, the number of times each test end is used and the test pressure
attained on each test. Entries in the record shall be signed by the Specialist Test
Engineer. Test ends which do not have a complete record of use from the new condition
shall not be used.
Prior to each re-use the test end shall be cut back to remove all weld metal and the heat
affected zone. To achieve this at least 12 mm of pipe should be removed. Dimensional
and ultrasonic examination of the new weld end preparation shall be carried out.
All temporary connections fitted to enable the hydrostatic test to be performed shall
preferably be of rigid construction and shall be adequate to handle the test pressures
involved. Flexible hose shall be of the armoured type and shall only be used if it is
manufactured to standards applicable to permanent hydraulic installations. Such hose
shall only be used in short lengths as required for the pressurising line to the test end
and for instrumentation, and each end must be anchored to prevent ‘whip’ in the event
of failure. Flexible hose shall not be used inside the test cabin.
The pressurising pump shall be fitted with a full capacity relief valve set at the local test
pressure. A pressure recorder shall record continuously the pressure at the test
manifold.

7.9 REQUIREMENTS PRIOR TO TESTING

The section of pipeline under test shall be completely backfilled before testing
commences. Test heads and aboveground sections shall be sheltered and thermally
insulated in order to minimise the effects of ambient temperature variations.
Pipeline sections to be tested shall be as long as practicable and with a difference in
elevation not exceeding 60m, or as otherwise specified in the Drawings. The
CONTRACTOR shall determine the test sections in accordance with this requirement
and to take account of the need to conserve water use.
Test ends shall incorporate a device to establish that pigs or spheres have arrived at
the receiving end. Radioactive indicators shall not be used.
The CONTRACTOR shall inform COMPANY before any pigging operation is carried
out. A pig register shall be prepared for the purpose of logging pigs into and out of the
pipeline and for noting details of their as received condition. During the running of filling
pigs, the CONTRACTOR shall operate pressure indicating and recording apparatus to
the satisfaction of COMPANY and shall arrange for tracking the run of the pig. The
pressure downstream of the pig shall be carefully monitored and controlled at a
pressure of not less than 2bar.
Prior to the commencement of testing, all instruments and gauges to be used in testing
shall be calibrated and valid test certificates submitted to COMPANY.
Pressure indicating and recording instruments shall be connected to the test section
before filling commences.
Hydrotest shall be performed by trained personnel and the person operating the
pressurising equipment shall be clearly instructed by the Specialist Test Engineer

Page 17 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

regarding the limiting pressure which shall apply to the pipeline section under test.
During the test any variation in the rate of pressure increase with volume shall be
immediately reported to the Specialist Test Engineer who shall decide such action as
necessary.
Pipe and soil temperature shall be measured and recorded at each end of the test
section and at every 5 km throughout the length of the pipeline using thermocouple type
instruments with digital readout. These shall be firmly attached to bare metal and
covered with insulating materials for the pipe temperature measurements and for the
soil temperature measurements they shall be buried at pipe centreline depth and 0.5 m
laterally from the pipe.
The points of measurement at each end of the test section shall be such that there is at
least 100m of pipeline buried to specified depth between that point and the test head.
For short lines a minimum of three locations shall be used to measure pipe and soil
temperatures.
All line valves shall be in the fully open position prior to filling.

7.10 FILLING
All necessary measures shall be taken to remove air from the line during filling. This
includes backpressure control and a steady controlled filling rate. Use of a break tank,
use of at least two pigs with water in front and in-between, and by regular renewal of
pig rubbers. When practicable the sections shall be filled from the lower end.
The second pig shall be fitted with a gauging plate, in order to gauge the complete test
section length (if this is a combination of two or more cleaning and gauging sections).
The plate shall be inspected by COMPANY prior to installation in the line and after
pressure testing.
In order to assist in controlling the line filling, inlet pressure, inlet flow and downstream
pressure shall be measured and recorded.
A stabilisation period of at least 24 hours is required post-fill such that difference
between water temperature and ground temperature is less than 1°C.

7.11 STRENGTH AND LEAK TIGHTNESS TEST DURATION

Test pressure shall be increased gradually in steps as shown below providing sufficient
time between each step to check for leaks or unacceptable deformation and to allow
the pipeline to equalise strains during testing.
Acceptable steps are:
1. Start to pressurize with 2-3 bar/minute upto 50% of test pressure.
2. Calculate the % of air in the pipeline.
3. Rise the pressure up to 85% of the test pressure with 1 bar/minute
4. Rise the pressure up to 100% of test pressure at 0.2 bar/minute.
5. The pressurised section shall be left for 24 hrs for thermal stabilization.
6. Start of pressure test for 24 hrs. with ±1 bar difference.

Page 18 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

7. After completion of the test, start depressurizing the section up to 60% of the test
pressure at 1 bar/minute and then continue to decrease at 2 bar/minute.
All buried pipeline shall be subjected to a 24-hour minimum duration combined strength
and leak test.
If a leak is suspected the pressure shall be reduced to less than 80% of test pressure
before carrying out a visual examination. No work shall be carried out to repair leaks
until the pressure has been reduced to a safe pressure i.e. static head plus 1bar.
During the test, deadweight tester readings shall be recorded every 30 minutes and
pipe, soil and air temperature recorded every 1.5 hours.
The test will be deemed to complete only with approval from COMPANY, otherwise, it
will have to be extended.

7.12 PRE-TEST SECTIONS

The following sections should not be tested separately and could be tested to the same
pressure as the adjacent pipelines:
• Any heavy thickness desert road / track crossing constructed by open cut
method.
• Any heavy thickness National highway crossing constructed by open cut method.
Pre-tested short sections under all road/track crossings and any plant/station approach
(if required due to unavoidable circumstances) shall not exceed 100 meters length.

Pre-tested short sections shall be tied into the parent pipeline and shall receive final
pressure test in line with the requirements of the documents listed above. Short
sections of station approach (if unavoidable) that cannot meet criteria set above and
that have to be tied-in to the parent pipeline by means of ‘golden welds’ those sections
shall receive strength test at a pressure in accordance with Zone testing requirements
listed in Table – 1.

To avoid damage caused by debris to the valve internal block, valves will not be
installed during the hydrotest including cleaning, filling, pressurizing depressurizing and
de-watering activities. The block valves assemblies will be pre-spooled and tested
separately. The pressure tested valve assemblies will be tied in by golden welds as per
ASME B31.4 (437.1.4(5)(b)) and ASME B31.8(841.31 and A847.b).

8 DEWATERING AND CLEANING

8.1 DEWATERING
Following satisfactory completion of the strength and tightness tests the test section
shall be depressurised to a pressure level approved by COMPANY. Under no
circumstances shall full test pressure be retained to transfer water from one section to
another.
When CONTRACTOR needs to bulk dewater a test section in order to transfer water or
to make a tie-in the pipeline, should be left in the bulk dewatered state for a period

Page 19 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

longer than two weeks, further dewatering of this section shall be required until all free
water is removed.
After bulk dewatering has been completed, the CONTRACTOR shall perform pig runs
propelled by oil free air dehydrated to a relative humidity lower than 80% at the pipeline
temperature and operational pressure. Air for propelling pigs shall be made oil free and
dry by means of oil filter units and air-drying or desiccant units downstream
compressors. The capacity and pressure rating of the air compressor, oil filter and air
drying system shall be sufficient.
Only one pig (or pig train) shall be sent through the line at any one time. The pig runs
shall preferably be executed in a downhill direction and in one continuous operation.
The pig velocity shall be kept constant and within the range of 0.5 to 1 m/sec. internal
pipeline pressure shall be kept at least 1 bar above the ambient pressure point along
the pipeline by backpressure control at the discharge end.
CONTRACTOR shall perform dewatering runs until all free water is removed from the
pipeline in front of the pig train.

8.2 CLEANING
For each pipeline section, foam swabbing pigs (density between 30 and 50 kg/rn3) shall
be run for drying in combination with power brush hard foam pig runs to the satisfaction
of COMPANY. Foam pig speed shall not exceed 1.2 m/s.
Final cleaning shall be carried out by cupped brush pigs with bypass plugs open to
create a swirling motion and to blow the loose dust ahead of the pig.
Pigs shall be propelled with oil-free compressed air dehydrated to a relative humidity
lower than 80% at the pipeline temperature and operational pressure.
The line is considered clean when the amount of solids displaced from the line by a new
brush pig is not greater than 10 grams per 10 km section of 16” diameter or less pipeline,
or 18 grams per 10km section of 34” diameter pipeline, as quantified and/or in mutual
agreement with COMPANY.

9 CALIPER SURVEY

9.1 SURVEY REQUIREMENTS

Calliper surveys shall be performed to survey for any deformations on the interior of the
pipe, using an APPROVED calliper survey tool. Calliper survey shall be carried out for
whole pipeline system except Flowlines from Trap to trap. The calliper run on each
pipeline excepting 6” Flowlines shall include all circumferential welds from permanent
trap to trap including golden welds between packages to provide the project baseline
record
A multi-channel calliper pig design shall be proposed for approval.
CONTRACTOR shall submit a detailed calliper Survey Method Statement to Company.

Page 20 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

Prior to any calliper survey CONTRACTOR shall run a train of pigs including a final
gauging plate and Magnetic pigs to prove the internal bore and cleanliness of the
pipeline section.
Within 24 hours of calliper runs CONTRACTOR shall present a report to COMPANY
identifying indications.
Contractor shall repeat the run after any investigation, repair or failed run. In case of
any suspected anomaly in pigging report, necessary dig verification shall be carried out
to investigate the cause and repeat the Calliper run.

9.2 CALLIPER ACCURACY

CONTRACTOR shall report all indications (ovality and dents) greater than 1%.
The velocity of the calliper pig should be controlled by use of back pressure. This back
pressure shall be proposed by CONTRACTOR for APPROVAL but shall be a minimum
of 2 barg.
CONTRACTOR shall submit a detailed listing of defects identified from Calliper Survey.

9.3 OVALITY AND ACCEPTANCE CRITERIA

Any defect identified in the new pipeline by calliper pig runs shall be investigated and
rectified by CONTRACTOR prior to Mechanical Completion.
Any defects found in the new tie-in pipe-work by calliper runs from permanent pig trap
to permanent pig trap shall be rectified by CONTRACTOR prior to Handover &
Completion.
Any defects found by subsequent intelligent pigging of the pipeline shall be rectified by
CONTRACTOR.

9.3.1 OVALITY
Definition: Ovality shall be measured as:
Ovality % = 2 (Maximum Outside Diameter (Dmax) – (Minimum Outside Diameter
(Dmin)) x 100
(Maximum Outside Diameter (Dmax) + (Minimum Outside Diameter (Dmin))
Ovality Acceptance Criteria: Ovalities > 5% shall be removed or repaired.

Page 21 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

Figure 1: Ovality Measurement

9.3.2 DENTS
Definition: Dents shall be measured as:
Dent size % =
(Nominal Outside Diameter (D) – Minimum Outside Diameter (Dmin)) x100
Nominal Outside Diameter (D)

(Note that this includes any ovality present)

Figure 2: Dent Measurement

Table 2: Dent Acceptance Criteria

Dent Criteria Action to be taken
Reportable dent greater than 1% Excavation and site investigation
of nominal outside diameter but
less than 2%

Page 22 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

Dent greater than or equal to Excavation, site investigation and

2.0% of nominal outside diameter mandatory removal from pipeline
Any size dent that affects the pipe
curvature at the pipe seam or at Remove from pipeline
any girth weld
Any size dent that is coincident
Site investigation
with any DCVG indication
Any dent whereby the parameters
of the dent cannot be determined Site investigation
from the calliper run

10 DRYING

10.1 GENERAL
CONTRACTOR shall submit a detailed drying procedure and method statement for
approval by COMPANY at least 3 months in advance of intended drying. This shall
account for the following requirements:
• CONTRACTOR shall dry the pipeline to ensure a stable dew point of less than or
equal to -20C at 1.5 barg exists throughout the pipelines.
• Drying shall be achieved using one or a combination of super dry air, dry nitrogen
or vacuum drying, as outlined below. CONTRACTOR shall carry out a soak test to
prove pipeline dryness to the agreed final dew point after a period of 24hrs.
• The maximum duration between the completion of a successful hydrotest and the
completion of the drying operation of any test section shall be 3 months.
• CONTRACTOR shall define details of all drying plant and instrumentation to be
used in performance of its drying activity and provide full supporting calculations
and details of the duration of this activity and the acceptance criteria. This shall
include details on proposed monitoring and logging of all data from instrumentation
and drying plant.
• Dew point meters shall have an accuracy of +/- 2°C and shall have a valid calibration
certificate. The dew point meters shall be checked for calibration at 6 monthly
intervals prior to commissioning.
As an option, the CONTRACTOR shall submit a detailed Method Statement of gas-in
for Gathering system pipelines with hydrotest water retained under pressure as the fluid
from wells has water.

10.2 DRY AIR

With this technique moisture present in the pipeline will be evaporated into the pre-dried
air that is passed into the pipeline.

Page 23 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

The pipeline shall initially be pigged with foam swabbing pigs using dry air as the
propellant. The pigging speed shall be between 1.0-1.5 m/s. 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.
Dry air shall be blown through the pipeline at up to 3 m/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.

10.3 DRY NITROGEN

Drying using dry nitrogen shall generally follow the same procedure as specified for dry
air. Nitrogen used for the drying operation shall have a minimum dew point below –
50°C at atmospheric pressure.

10.4 VACUUM DRYING

Vacuum drying may be used with approval from COMPANY.

10.4.1 GENERAL REQUIREMENTS

CONTRACTOR shall provide full supporting calculations for the duration of and
acceptance criteria for this activity.
During all phases of the pipeline drying operation, CONTRACTOR shall log and
continuously record all data from the instrumentation at the pump locations. Data shall
be manually logged at intervals not exceeding 30 mins. Temperature data from
instrumentation remote from the pump locations shall be automatically logged at
intervals not exceeding 1 hour and shall be collected twice per day.
The scanning and logging intervals shall be proposed by CONTRACTOR to
COMPANY.
CONTRACTOR shall produce a detailed operational procedure addressing each of the
above phases. Full calculations supporting CONTRACTOR proposals, including
equipment sizing and control, shall be provided.

11 PRESERVATION
Upon completion of drying of a pipeline or pipeline section CONTRACTOR shall use
nitrogen or super dry air to provide a stable dew point less than or equal to -20°C at a
residual pressure of 1.5 – 2.0 barg for pipeline preservation until connection with the
adjacent section or until handover.
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.
Preservation shall be tested by CONTRACTOR on a monthly basis until handover.
CONTRACTOR shall supply and maintain temporary monitoring equipment to allow for
this. CONTRACTOR shall maintain a log of the preservation monitoring which shall be
made available to COMPANY.

Page 24 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

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

Contractor shall maintain complete and comprehensive records of all hydrostatic tests.
Records shall be accurately dated and shall be clearly identified with respect to the
specific test sections to which they apply.
Test records shall include but not limited to:
• Test instrument calibration certificates
• A chronological record of events which occured during the test period including
comments on all leaks and failures and their disposition
• Logs showing deadweight pressure and ambient temperature readings with date
and time for each reading. Each log sheet shall be signed by ARH, Operator and
Contractor's designated representative
• Test section profile showing elevations and instrument and test point locations
• Calculations to support a valid test for applicable buried assemblies
• Test acceptance certificate signed by Operator and ARH
• Temperature and pressure recorder charts
The following shall be listed on the face of each chart:
• The identity of the test section / facility
• The actual time, date and initials of the personnel starting the test
• The actual time, date and initials of the personnel removing the chart
• Explanations of pressure or temperature discontinuities that appear on any chart.
• The following additional information shall be listed on the back of each chart:
• Project name and job number
• Test section number
• Maximum operating pressure
• Location of test section
• Name and signature of personnel responsible for the test.
• Maintaining repair log if any and submit to Company

The following information shall be listed on accompanying forms for each test section:
• Location and elevation of test site
• Test medium
• Date of test, test duration and the minimum test pressure realised

Page 25 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

• Size, wall thickness, pipe specification, and length of section tested

• Serial number of recorders and dates of calibration
• Serial number and date of calibration of dead weight tester
• Name and signature of person responsible for the test

12 LEAKS AND FAILURES

If a facility fails to hold the test pressure after isolation, Contractor shall expeditiously
locate the problem.
The cost of all labour and materials required to replace, or repair defects caused by
inferior workmanship, and/or materials furnished by Contractor which prove to be
defective under testing shall be the responsibility of Contractor.

13 WITNESS POINTS

Table 1 lists out the witness points of ARH and Operator during the entire process of
hydrostatic testing and dewatering of the ancillary facilities.

Table 1: Witness Point of ARH/Operator

ACTIVITIES CONTRACTOR OPERATOR ARH

Test Plan Review And Approval Y Y Y
Test Pressure Review And Approval Y Y Y
Test Water Source And Disposal Site
Y Y Y
Selection
Water Treatment Review And Selection Y Y Y
Test Equipment, Instruments And
Y Y -
Material Selection
-
Hydrostatic Test Diagram Y Y

Test Pipelines and Ancillary Facility Y Y Y

On Field Calibrations Y Y -

Test Ancillary Facility Cleaning -

Y Y
Completion
Temperature Stabilisation Completion Y Y Y

Air Content Measurement Y Y Y

Pressurisation Y Y Y

Strength Test And Leak Test Y Y Y

Ancillary Facility Dewatering Completion Y Y -

Page 26 of 27
 Specification for Pipeline Hydro-Testing
Document No: A-PLE-SPE-200-30011
Revision 1

Ancillary Facility Drying Completion Y Y -

Review And Certification of Ancillary

Y Y Y
Facility Ready For Commissioning

Page 27 of 27