QUALITY PROCEDURE FOR

HYDROSTATIC TESTING

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PROJECT DABHOL PANVEL PIPELINE PART-A

CLIENT GAIL (INDIA) LIMITED

CONSULTANT ENGINEERS INDIA LIMITED

CONTRACTOR PUNJLLOYD LTD.

____________________________________________________________

For review Arun AVN Reddy P.K.BALI

00 18/08/06 and Kumar
Approval

Prepared Checked by Approved Reviewed Approved

Rev. Date Description by QA/QC by By by
QA/QC Manager Project
Eng. Manager
(PLL)
(PLL) (PLL) EIL/GAIL EIL/GAIL
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TABLE OF CONTENTS

1.0 PURPOSE........................................................................................................................................3

2.0 SCOPE.............................................................................................................................................3

3.0 REFERENCES.................................................................................................................................3

4.0 TERMS & DEFINITIONS...............................................................................................................4

5.0 RESPONSIBILITIES.......................................................................................................................4

6.0 METHODOLOGY............................................................................................................................6

7.0 HEALTH, SAFETY AND ENVIRONMENT................................................................................16

8.0 QUALITY ASSURANCE / QUALITY CONTROL ..............................................................................17

9.0 APPENDICES / FORMATS..........................................................................................................17

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1.0 PURPOSE

The purpose of this Procedure is to describe the method of conducting a

Hydrostatic Testing in a systematic way following the approved specification
and inspection to be used in the 30” DABHOL PANVEL PIPE LINE PROJECT
PART-A Construction Work, by Punj Lloyds limited.

2.0 SCOPE

The scope of this procedure includes the cleaning, gauging, filling, Hydrostatic
Testing & dewatering of pipeline strings fabricated exclusively for Mainline for
construction of the 30” DABHOL PANVEL PIPE LINE PROJECT PART-A .

3.0 REFERENCES

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

 Contract document no. 0318/T-217/05-06/RKS/01

 Recommended Practice for Pressure Testing of Liquid Petroleum Pipeline API
RP 1110
 Standard specification for Hydro static testing of Onshore pipe lines 6-71-0055.
 Design and Construction Requirements For Cross country Hydro corbon
pipelines OISD B141
 Liquid transportation system for Hydro carbons ,LiquidPetroliumGas,Anhydrus
Ammonia,and alcohols ASME31.4
 Job specification Requirements(pipeline)pipeline laying and associated
works.document no.0318-000-16-71-TR-20 REV.A
 Addendum to pipeline standards and specifications Document no: 318-000-16-
71-SP-81 REV.0
 Engineering design basis-specification no: 0318-000-16-71-DB-01 REV.B
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4.0 TERMS & DEFINITIONS

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

 All terms used in the development of this procedure are defined in

a) Quality Assurance Manual

b) EIL Specification

5.0 RESPONSIBILITY

Project Manager - Shall report to Project Director.

- Shall provide all necessary resources to
implement this procedure.

Resident Construction Manager - Shall report to the Resident Project

Manager.
- Shall be responsible for control, supervision and
direction for implementation execution of
construction plans using calibrated Measuring
and Test equipment.

QA/QC Manager / In-charge - Shall report to Project Manager and Head

QA/QC at H.O.
- Shall be responsible for the compliance of this
procedure.

QA/QC Engineer - Shall report to QA/QC Manager / In-charge.

- Shall ensure proper implementation of this
procedure.
- Shall checks and verifies the Hydrostatic Testing
activities.
- Verifies and countersigns report.

Hydro-test Engineer - Shall report to the Resident Construction

Manager.
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- Preparation of schedule addressing specific

issues and characteristics of each spread.
- Overall control and safety management and for
the implementation of the procedure and
supervises the activity.
- Generation of reports during the
Hydrostatic Testing activity and record data.
- Explains to Hydro-testing foremen and all other
persons involved in Hydrostatic
- Testing the detailed operations to be done
during various phases of activity.

Hydro-testing Foreman - Reports to Hydro-testing Engineer.

- Executes the Hydro-testing in accordance with
this procedure.
- Ensures the quality and safety standards are
achieved at all times.
- Carries out the job as per plan and schedule.
- General supervision of Hydro-testing personnel

HSE Officers - Shall report to Resident Construction Manager /

Project Manager administratively and to HO for
technical matters.
- Implementation of all safety requirements during
Hydrotesting operations.
- Ensuring that the communication system is
working properly and that emergency equipment
is in place.
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6.0 METHODOLOGY

Details of the test section shall be illustrated in the Hydro-test Pack, that shall
be prepared for each test section and submitted to EIL/GAIL, prior to
commencement of the test. The overall tentative layout of equipments and
instruments for hydro testing is shown in appendix – 06.

A calculated / predetermined length of pipeline shall be selected for the hydrotest

based on elevation, availability of water and location of stations. Graph showing
the elevation of the complete test section shall be drawn prior to start of the test
and enclosed in the hydrotest pack along with format-01 however,maximum length
of the test section shall not exceed 50 km.

Hydrotesting of mainline shall exclude valves at tap – off stations, terminals ,pump
stations , SV stations and scrapper station facilities.
Prior to any hydrostatic test, EIL/GAIL shall be notified in advance and the
hydrotest shall commence only after obtaining signature on Part – B of the Pipe
Book and Mechanical clearance (Format-02)

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

specification requirement.

The Equipment / Instruments to be used for performing the work shall include,
but not limited to the following :
- Pigs for filling , cleaning and gauging : Cleaning pigs with steel wire brushes .
- Four cup batching pigs.
- Gauging pig with gauge plate diameter equal to 95% of heavy wall pipe in the
pipe sections (after considering all allowed tolerances).
- Fill Pump with differential head 20% greater than the maximum required and a
flow
rate preferably between 400 m3/h to 1000 m3/h.
- Positive displacement pump equipped with a stroke counter and capable of
exceeding the maximum test pressure by at least 20 bar.
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- Positive displacement meters to measure the volume of water used for filling
the line having a valid calibration certificate.
- Portable tank of sufficient size to provide continuous supply of water to the
pump during pressurisation.
- Pressure gauges of suitable pressure range and accuracy with valid calibration
certificate.
- Dead weight tester with an accuracy of 0.01 bar. Measuring in increments of
0.05 bar. and with a valid calibration certificate not older than one month at the
time of first hydrostatic test in the pipe line.
- Temperature recorders for fill water
- Two 48hours recording pressure gauge with charts and ink gauge tested with
dead weight tester prior to use. These shall be installed at the test heads
- Pressure recording charts
- Thermocouples for measuring the pipe wall temperature
- Two Laboratory thermometer 0°C to 60°C range and accuracy  0.1°.
- Measuring cylinder to check quantity of water during air volume calculation.
- Injection facilities to inject additives in the test medium in the required
proportion.
- Temporary test headers fabricated in conformity with ASME section VIII,
division 2 with particular reference to appendix -07 having sufficient length to
accommodate the required number of pigs. The header shall also have
provision for pig stopper.
- Proper Piping and valve arrangements shall be available to allow launching
and receiving of each pig independently.
- Unless other wise specified ,all measuring recording instruments shall meet the
specification requirements of the contrct.

Test Medium

Cleaning, filling and hydro testing shall be performed using soft non aggressive
water, free from sand and silt withdrawn from a suitable source. In the pipe line
route. The water shall be filtered and shall not be contaminated. The water shall
be tested in an approved lab for its non aggressiveness and suitability for using as
the test medium. The test report shall be submitted to EIL for review. On the basis
of water test report and manufacturers / laboratory’s recommendations, the
required quantity of corrosion inhibitor, oxygen scavenger, bactericides etc. shall
be added to the test medium with prior approval from EIL.
Test Pressure

The pipeline shall be hydrostatically tested to the pressures as specified below.

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Hydro test pressure

CLASS
Pipe size Thk (mm) Kg/cm2(g)
Maximum
762 mm OD 10.3 1.25x92.0 =115.0 1

762 mm OD 11.9 1.25x92.0 =115.0 2

762 mm OD 14.3 1.4x92.0 =128.8 3

Hydrostatic shall be done with corrosion inhibitor and dosage od corrosion

inhibitor shall be suitable for a period of three months.The height point of the
test section shall be subjected to the minimum test pressure as specified above.
To minimum number of test sections,the pipeline of location Class 1 can be
combined with location class 2 and tested at apressure of 115 Kg/cm2.g
Similarly pipeline of location class 2 can be combined with location class 3 and
testd at apressure of 128.8 Kg/cm2.g The maximum hydrostatic test pressure
for any section shall not cause stress exceeding 95% of SMYS of the lowest
wall thickness of that section.

In case of any class location is upgraded due to seismic requirements,

thehydrostatic test pressure shall be governed by actual class/ population
density.
The duration of hydrostatic test shall be minimum 24 hours after stabilization.

Cleaning & Gauging of the Pipeline Test Section

The cleaning operations shall be performed by propelling air driven pigs provided
with spring loaded brushes and chisels, or with pigs fitted with full diameter circular
brush having O.D minimum 5 mm more than the I.D of pipe to remove all mill
scale, rust / sand from the internal of the pipe sections based upon the approval of
EIL/GAIL. Since this pipeline is having internal lining it is proposed to propel the
pig having no brushes and chisels.

The number of pig runs shall depend on the cleaning results.

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After acceptance of the cleaning, a Gauging pig fitted with gauge plate made of
10.00 mm thick commercial grade aluminum plate shall be propelled between
the temporary test heads . A column of clean water shall be pumped in front of
the pig for lubrication and to flush out the remaining dirt(if any) inside the test
section.

The gauge plate shall be jointly signed by PLL & EIL / GAIL representative
before insertion with relevant information written on the plate and the test
results of the gauge pig run shall be analyzed to evaluate the internal status of
the pipeline. A deformed, bent or severely nicked plate or damaged pig shall be
evidence of gauging pig run failure and the same shall not be acceptable. In
such cases PLL shall repair and rectify the line and repeat the gauging pig run
to satisfaction of EIL.

The calculation for gauging plate sizing is detailed in Appendix – 4.

After acceptance of gauging operation by EIL/GAIL, a photograph of the gauge

plate shall be taken and attached with the gauging report along with format –
05.

The parameters of cleaning & gauging operations shall be recorded every 30

minutes in the format enclosed in Format – 4 & 5 respectively.

Test Section Filling

On acceptance of Gauging, the air pigging headers shall be cut and the
temporary test headers already pretested at a pressure resulting in a hoop stress
corresponding to 90 % of SMYS shall be welded to the test section.

The hydrotest report of the temporary test headers shall be submitted to

EIL prior to start of welding the test header to the test section

The filling end test header shall be pre loaded with three numbers of four cup
batching pigs.
The filling operation shall begin with pumping of uninhibited water equal to
10% volume of the test section infront of the first pig.
The first pig shall be launched by pumping of uninhibited water equal to 1.5 km of
pipe length behind the pig. The water column before and after this pig shall act as
a cushion to control the movement of the filling pig and hence minimise air
entrapment.
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The second pig shall be launched by pumping in the actual line filling water
behind the pig.
The filling shall continue till the second pig reaches the other end of the test
section and the pressure at the test end rises to the static head.

Required quantity of corrosion inhibitor shall be injected during the filling

operation through any of the nozzles provided on the test header or into the
break tank. The quantity of inhibitor shall be controlled by adjusting the flow rate
of the dosing pump.
The dosing rate shall be as described below
During the whole filling operation the valves at the receiving end test headers
shall be throttled suitably to maintain adequate backpressure and thus control
the pig movement.

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

The different parameters during filling operation shall be recorded once every
thirty minutes in the prescribed format enclosed in Format - 06.

Dosing Rate

The dosing rate shall be decided based on the estimated time required to start
the dewatering(depends on pre-commissioning activities)after particular hydrotest
section. In case the period between hydrotest of the section and dewatering (depends on
pre commissioning) falls with in 6 months,500mg/L(500ppm) and more than 6 months
750mg/L(750ppm)of inhibitor shall be added.

In case of water transfer from one section to another section ,additional dosage of
60 ppm of inhibitor shall be added to the already dosed water.Due to any reason,if time
period exceeds more than six months for the sections which are added 500mg/Lof
inhibitor,additional dosage of inhibitor shall be added for the estimated extended period
as decided by EIL/GAIL.
Thermal Stabilization

Once the test section has been completely filled and a minimum pressure of 1 bar
has been achieved at the highest point, the thermal stabilisation period shall be
started. Thermal equilibrium between the pipeline and environment shall be
checked through the thermocouples installed on the pipeline. Temperature probes
shall be installed to measure the pipe and soil temperature at every 2.5KM of the
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pipeline and spacing may be increased to maximum5.0KM the terrain and nature
of subsoil along the alignment of the test section also.One probe each shall be
installed at 500mtr.from both end of headers.From both the test
headers.Temperature readings shall be made at 2 hours-intervals.Thermal
stabilization shall be consider to have been achieved when a difference not higher
than 1 deg. C is attained between the average valves of the two readings.
Thermal stabilization completion shall be approved by EIL/GAIL.

Digital thermometer
Soil temp. Thermocouple
Ground level

Insulation
coating
Pipe wall view “A”

VIEW “A”

Thermocouple attached to pipe wall by

quick setting epoxy

Pressurization

Operational Steps

Mobilize high-pressure pump and test equipment at pressurisation area. Install

one pressure gauge in parallel with the dead weight tester.

Fill out and sign pipeline pre-pressurisation safety checklist. Format - 03

As soon as the temperature stabilisation is achieved, the pressure shall be

raised at a moderate and constant rate not exceeding 2-bar per minute.
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The parameters (Volume required) during pressurisation shall be recorded

throughout the cycle in the format enclosed in the Format - 08 as follows :

Each 5 bar increments upto 80% of the test pressure as recorded by

deadweight tester.

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

Each 0.2 bar increment between 90% to full test pressure as recorded by
deadweight tester.

The pressurization shall be cycled with the sequence shown in the following
pressure sequence.

Pressurize to 50% of test pressure, hold pressure for one hour, perform air
volume test and drop pressure to static head.
Pressurize to 75% of test pressure, hold pressure for one hour, perform air
volume test and drop pressure to static head.

Pressurize to test pressure, perform air volume test and raise pressure to the
test pressure once again.

In case, during the hold period indicated above, a decrease in pressure is

observed, the above operation shall not be repeated more than twice, after
which the line shall not be considered capable of test, until the cause for the
lack of water tightness is eliminated.

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

Air Volume Calculation

In order to check the presence of air in the pipeline two separate consecutive
pressure lowerings of 0.5 bar by slowly bleeding water from the test section
shall be carried out during all the pressurising cycling as mentioned above. The
water drained during the second lowering shall be accurately measured (V 1).
This quantity measured shall be compared to the theoretical quantity (Vp)
corresponding to the pressure lowering. The air volume shall be acceptable if V 1
/ Vp  1.06.
The observation shall be recorded in the air volume calculation format enclosed
in Format - 09.
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24 hour hold period

The pressure shall be considered to be stabilized when no fluctuation is

observed in the pipeline pressure as seem from the dead weight tester. On
achieving pressure stabilisation, pressure pump connections shall be removed
and the test section completely isolated and all connections at the test heads
shall be checked for leakages. Pressure recorders shall then be started with the
chart in real time orientation and the 24-hour pressure hold period shall start.

During the pressure hold period the following data shall be recorded / reported :
in the format enclosed in Format – 10.

a) Every one hour pressure measurement from dead weight tester

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

All data shall be recorded on appropriate forms attached to the hydrostatic test
procedure manual. Care shall be taken that the maximum test pressure are not
exceeded, Should it become necessary to de-pressurize, the volume of test
medium bleed-off shall be accurately measured and recorded.
Acceptance Criteria

The hydrostatic test shall be considered as positive if pressure has kept a

constant value throughout the test duration, except for change due to
temperature effects.

The pressure change value as a function of temperature change shall be

algebraically added to the pressure value as read on the meters. The pressure
value thus adjusted shall be compared with the initial value and the test shall be
considered as acceptable if difference is less than or equal to 0.3bar . In case of
doubt the testing period shall be extended by 24 hours.
For calculating the pressure change due to change in temperature the formula
and data illustrated in format – 11 shall be used

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

be slowly de-pressurized at a moderate and constant rate . All the thermo
couples installed in the pipeline shall be removed and damaged corrosion
coating shall be repaired using approved procedure & material and shall be
reported in format – 13.
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Leaks

If during the pressurisation period or during the test periods any defect is
observed, these shall be eliminated.

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

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

followed:

1. To cut the section in an intermediate position

2. To insert two test heads
3. To re-flood the sections
4. To pressurize the two sections
5. To determine the faulty section

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

If the test section fails to maintain the specified test pressure after isolation, PLL
shall determine by search the location of leakage or failure. All leaks and failure
within the pipe wall or weld seams shall be repaired by replacement of entire
joint or joints in which leakage or failure occurs.
PLL shall comply with instruction of EIL/GAIL whether to replace a section of
the linepipe that includes the line leak or whether to repair the circumferential
weld. The repair shall however meet the requirements of EIL spec6-77-006. After
completion of repairs , the hydrostatic test shall be repeated .
PLL shall haul and stockpile all damaged and defective pipes to storage locations
designated by EIL/GAIL .All cracks and splits resulting from failure shall be coated
with an application of grease to preserve the characteristics of failure from
corrosion . Joint of failed pipes shall be marked with paint, with a tag indicating
failure details , date and location of failure and pressure at which failure occurred.

Pipeline Bulk Dewatering

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Dewatering of pipeline after hydrostatic testing shall be taken up only when PLL
is ready for swabbing operations as these are envisaged to be carried out at the
time of precommissioning.Till such time the lcontractor is ready to start pre-
commissioning activities, the pipeline / section of pipeline after hydrostatic
testing shall be left filled with inhibited water.
Upon readiness to start pre-commissioning activities, the section shall be
dewatered by propelling a third pig in the test header. Necessry arrangement
shall be made for safe disposal of hydrotest water by making suitable
drains.Dewatering shall start after getting clearance from EIL/GAIL.and the
water shall be transferred to the next test section. wherever required

The dewatering shall be carried out by using four-cup pigs and foam pigs driven
by compressed air. The dewatering shall be done in such a way as to provide
adequate control of pigs during dewatering. Pigs and equipment required for
dewatering shall be approved by EIL/GAIL in advance. Four cup pigs shall first
be passed through the line to displace the water. The line shall be considered
dewatered when a negligible amount of water is flushed out by the last foam
pig
During dewatering care shall be taken to properly dispose the discharging
water in order to avoid pollution, damages to fields under cultivation and / or
existing structures and interference with the traffic.

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

The line pressure during dewatering operation shall be recorded every 30

minutes in the format - 14

Once dewatering is over, the sectionalizing valve and other valve assemblies
shall be installed at the respective locations in accordance with the relevant
procedures and specifications.
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7.0 HEALTH, SAFETY AND ENVIRONMENT

 The approved procedure of Health, Safety & Environment shall be followed

during the execution.
 The hazards associated with the hydro test have been identified and the
following guidelines are suggested for implementation of safety norms.
 Provisions shall be made for the installation of no – admittance signs to
unauthorized personnel from the road to the R.O.W at critical locations.
 Warning signs in English and Local language stating “ Pipeline under test –
Keep off “ shall be placed in locations where the pipeline is uncovered, and
particularly where the temporary headers and stations are located. Such
areas shall be suitably fenced in such a way as to prevent access of
unauthorised personnel. No unauthorized personnel shall be allowed closer
than 40 m to the pipeline under test.
 Only authorized personnel as defined / identified by the Hydro test Engineer
shall be allowed within the test area when the test section is under
pressure.
 No stage of the activity shall progress without the specific clearance of
testing engineer.
 The temporary test headers shall be installed in compliance with methods
and suitable locations so that their rupture cannot cause any injury to
personnel.
 The test cabin shall be placed in such a location as to prevent it from being
affected by a catastrophic failure in the test head.
 No work on the pipe or test equipment shall be allowed whilst under
pressure except for tightening of flanges, the removal of connections after
closing valves, and the blinding of ports after achieving the test pressure for
isolation of the test section.
 No flexible hoses are permissible inside the test cabin, except for essential
connection to the instruments.
 For effective communication, a wireless and walkie-talkie system shall be
used.
 All PPE is a must in this activity.
 All Measuring & Test Equipments used must be well maintained.
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8.0 QUALITY ASSURANCE / QUALITY CONTROL

Quality Assurance will be maintained by systematic implementation of this

procedure and generating necessary quality records.

9.0 APPENDICES AND FORMATS

Appendix : 01 Inspection and test plan Hydro static testing

(PLL-DPPL-PLC-QCP-22 REV.O)

Appendix : 02 Water Compressibility Factor vs Pressure and

Temperature
(PLL-DPPL-PLC-QCP-22 REV.O)
Appendix : 03 Difference between the water & steel thermal
Expansion factor
((PLL-DPPL-PLC-QCP-22 REV.O)

Appendix : 04 Gauge Plate Sizing

(PLL-DPPL-PLC-QCP-22 REV.O)

Appendix : 05 Scheme for Cleaning & Gauging

(PLL-DPPL-PLC-QCP-22 REV.O)
Appendix : 06 Scheme for water filling / pressurization / dewatering
(PLL-DPPL-PLC-QCP-22 REV.O)

Appendix : 07 Hydro test Header

(PLL-DPPL-PLC-QCP-22 REV.O)
Format : 01 Test Plan for Hydro-test
PLL-DPPL-PLC-QCP-22/FO1 REV.0

Format : 02 Mechanical Completion Certificate

PLL-DPPL-PLC-QCP-22/FO2 REV.0
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Format : 03 Safety Check List

PLL-DPPL-PLC-QCP-22/FO3 REV.0)

Format : 04 Inspection Report for Air Cleaning

PLL-DPPL-PLC-QCP-22/FO4 REV.0

Format : 05 Inspection Report for Gauging

PLL-DPPL-PLC-QCP-22/FO5 REV.0 )

Format : 06 Inspection Report for Water Filling

PLL-DPPL-PLC-QCP-22/FO6 REV.0
Format : 07 Thermal Stabilization Report
PLL-DPPL-PLC-QCP-22/FO7 REV.0
Format : 08 Pressurization Report
PLL-DPPL-PLC-QCP-22/FO8 REV.0)
Format : 09 Air Volume Calculation
PLL-DPPL-PLC-QCP-22/FO9 REV.0
Format : 10 24 Hrs. Hold Period Report
PLL-DPPL-PLC-QCP-22/F10 REV.0
Format : 11 Hydro test Calculation Report
PLL-DPPL-PLC-QCP-22/F11 REV.0
Format : 12 Hydrostatic Test Evaluation
PLL-DPPL-PLC-QCP-22/F12REV.0
Format : 13 Coating Repair
PLL-DPPL-PLC-QCP-22/F13 REV.0
Format : 14 Dewatering Report
PLL-DPPL-PLC-QCP-22/F14 REV.0
Format : 15 List of attachments to Hydrostatic test record
PLL-DPPL-PLC-QCP-22/F15 REV.0