CLIENT: PROJECT TITLE: ENGINEER:

SARSANG OIL EXPORT PIPELINE

DETAILED ENGINEERING

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Rev. No. Date Reason for Issue Prepared Checked Approved

A 19-Oct-2019 Issued for Review TS

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REVISION CHANGE HISTORY

Related
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TABLE OF CONTENTS

1 GENERAL INFORMATION 5
1.1 Project Description 5
1.2 Purpose of the Document 5
1.3 Pipeline Elevation Profile, Test Pressure and Test Sections 5
1.3.1 Pipeline Elevation Profile 5
1.3.2 Test Pressure 6
1.3.3 Test Sections 7
2 DEFINITIONS AND ABBREVIATIONS 8
2.1 Definitions 8
2.2 Abbreviations 8
3 REFERENCE DOCUMENTS 9
3.1 Project Reference Documents 9
3.2 Codes and Standards 9
4 GENERAL 10
4.1 Safety requirements 10
4.2 Equipment and Instruments 10
4.3 Test Medium and Quantities 11
5 EXECUTION 12
5.1 Preparations & Set-Up 12
5.2 Cleaning and Gauging 12
5.3 Water Filling 13
5.4 Test Preparation & Stabilization 14
5.4.1 Test Preparation 14
5.4.2 Stabilization 15
5.5 Hydrostatic Testing - Pressurization 15
5.6 Hydrostatic Testing – Monitoring 16
5.7 Hydrostatic Testing – Depressurizing 16
5.8 Dewatering and Swabbing 16
6 TEST PACK DOCUMENTATION 17

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2 General INFORMATION

2.1 Project Description

HKN Energy Ltd. (HKN) operates the Sarsang (Swara Tika) field in Northern Kurdistan and are
expanding production of the oil facilities. In order to export the oil, HKN have agreed with the
Kurdistan Ministry of Natural Resources (MNR) to build a pipeline which will connect the Sarsang
facilities to the Receiving Terminal at Shaikan (RETM) from where the MNR has a pipeline
serving multiple users to transport the oil to the KCP (Kurdistan Crude Oil Pipeline).
MNR in agreement with the HKN assigned KAR Group to build and operate the above mentioned
pipeline and terminals.
ILF Consulting Engineers has been contracted to provide Engineering support for this Sarsang Oil
Export Pipeline project (Project).
The Project area is dominated by East-West running mountain ridges of the Zagros Mountains.
The pipeline crosses three mountain ranges segregated by parallel valleys. The elevation is
between 1500m at the beginning of the Swara Tika facilities to 430m at RETM receiving station.
The Project consist of the following facilities:
● Sarsang Pipeline Inlet Terminal (SPIT),
● 12” pipeline from SPIT to Receiving Terminal at RETM,
● Sarsang Pipeline Receiving Terminal (SPRT).

2.2 Purpose of the Document

This document provides a clear set of guidelines for the Contractor to ensure adequate cleaning,
gauging, strength testing, leak testing, swabbing and drying of the pipeline.
This document applies for the entire pipeline, from the isolation joint at SPIT (KP +0.000) up till
the isolation joint at SPRT (KP +20.135)

2.3 Pipeline Elevation Profile, Test Pressure and Test Sections

2.3.1 Pipeline Elevation Profile

The pipeline’s starting point is at an elevation of 1435 meter above sea level; it ends at an
elevation of 431 meter above sea level; the total drop in elevation is 1,004 meters. A rough
pipeline elevation profile is given in the Figure 1.

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Figure 1. Pipeline Elevation Profile

2.3.2 Test Pressure

Technical Note on Hydrostatic Test Scheme for Sarsang Oil Export Pipeline, doc.no. R116-ILF-
AS-00029 Q116, provides the Hydrostatic Test Pressure Calculations following two different
approaches (options). Contractor has indicated to follow Option 2 which considers a varying
internal design pressure corresponding with the pipeline elevation profile. The corresponding
hydrotest pressure profile is shown in Figure 2.

Figure 2. Hydrotest Pressure Profile

Note: The pipeline in its starting section from SPIT will have a reduced design pressure
equivalent to the hydrostatic test pressure, i.e. 62.60 barg. This shall be adequately
documented for future reference and key documents, e.g. Basis of Design and P&IDs.

2.3.3 Test Sections

Contractor has indicated that for the purpose of testing, the pipeline shall be divided into three
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sections as follows, see also Attachment 1:

Test Section-1:
● Test Section Start Point : KP +0.000
● Test Section End Point : KP +6.810
● Test Section Length : 6,810 m
● Ground Elevation @ High Point : 1,435 m
● Ground Elevation @ Low Point : 789 m
● Difference in elevation : 646 m
● Filling Volume is : 492 m3
● Test pressure is 142 barg @ KP +6.810, 79 barg @ KP +0.000

Test Section-2:
● Test Section Start Point : KP +6.810
● Test Section End Point : KP +10.260
● Test Section Length : 3,450 m
● Ground Elevation @ High Point : 789 m
● Ground Elevation @ Low Point : 586 m
● Difference in elevation : 203 m
● Filling Volume is : 249 m3
● Test pressure is 162 barg @ KP +10.260, 142 barg @ KP +6.810

Test Section-3:
● Test Section Start Point : KP +10.260
● Test Section End Point : KP +20.135
● Test Section Length : 9,875 m
● Ground Elevation @ High Point : 586 m
● Ground Elevation @ Low Point : 431 m
● Difference in elevation : 155 m
● Filling Volume is : 713 m3
● Test pressure is 177 barg @ KP +20.135, 162 barg @ KP +10.260

Contractor shall verify the as-build alignment sheets, pipeline profile, elevation difference,
construction plan, back pressure at receiving end, water source, space requirements, ease of
gauging & line filling operations, test medium disposal facilities, etc., in order to confirm the
pre-defined test sections.

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3 DEFINITIONS AND ABBREVIATIONS

3.1 Definitions

Client MNR (Ministry of Natural Resources, Kurdistan Regional Government)

Contractor KAR Group Ltd.
Consultant ILF Consulting Engineers
Subcontractor Company employed by KAR
Third party Any legal entity except the ones listed above

3.2 Abbreviations

ANSI American National Standards Institute

ASME American Society of Mechanical Engineers
MNR Ministry of Natural Resources
SPIT Sarsang Pipeline Inlet Terminal
SPRT Sarsang Pipeline Receiving Terminal

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4 REFERENCE DOCUMENTS

Following documents shall be considered as part of this specification:

● The works shall be done in accordance with the requirements of the referenced documents
and this project procedure.

● It shall be well understood that works shall comply not only to the referenced documents but
also with the ones referenced therein.

4.1 Project Reference Documents

Document Number Details

Q116-ILF-UEO-CCC-DD-EEE-0001 Project Basis of Design

KAR1804-7003-PPL-SP-0012 Specification for Hydrostatic Testing of Pipeline

KAR1804-7003-PPL-CA-0006 Hydrostatic Pressure Test Calculation for Pipeline

KAR1804-7003-PPL-DW-0001 Alignment Sheets 1-2000 KP 00+000 – KP 20+136

Technical Note on Hydrostatic Test Scheme for
R116-ILF-AS-00029 Q116
Sarsang Oil Export Pipeline
ERG-DRG-EMM-197-18 001 General Arrangement Drawing for 12”x16” Pig Launcher

ERG-DRG-EMM-197-18-002 General Arrangement Drawing for 12”x16” Pig Receiver

4.2 Codes and Standards

Reference codes and Standards Details

Pipeline Transportation Systems for Liquids and
ASME B31.4
Slurries
API 5L Specification for Line Pipe
Recommended Practice for the Pressure Testing of
API RP 1110
Liquid Petroleum Pipelines

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5 GENERAL

5.1 Safety requirements

Test sections shall be fit with temporary or permanent pig launcher and receiver traps for
cleaning, gauging and filling activities. For the purpose of hydrostatic testing temporary test
headers shall be installed.
The test headers shall be designed, constructed and tested according the project pipeline design
code, ASME B31.4. As a guideline, the general arrangement drawing for the pig receiver is
provided in the back of this procedure as Attachment 2.
All places and points of public access shall be marked with warning signs: “DANGER PIPELINE
UNDER TEST” and “NO PARKING” in both English and local language. All gates and temporary
entrances providing access to the test section shall be closed.
Areas where the test equipment is located shall be marked and unauthorized access shall not be
permitted
No work shall be permitted on sections under test until depressurization of the test section is
completed.
The pipeline shall be completely backfilled prior to the commencement of hydrotest activities,
otherwise the tie-in locations and locations of temperature probes, which shall be fenced and
guarded during the performance of the hydrotest.
Contractor shall have an emergency response team standby at each end of the test section.
A sandbag wall shall be erected around the test points in order to protect other installations as
required by the owner/operator of those installations.
All local and statutory authorities, residents in the vicinity of the pipeline and all other personnel
shall be notified of the proposed dates of testing and shall be advised of any extension

5.2 Equipment and Instruments

All equipment (Table 1) and instruments Table 2 used for hydrostatic testing shall be calibrated to
meet the requirements of accuracy of +/-0.1% and sensitivity of 0.05%. The calibration shall be
valid throughout the entire period of testing.
All instruments shall operate in the range of 40% to 70% of their maximum indicator level during
operation. The calibrated instruments and their corresponding certificates shall be presented prior
testing.

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Table 1. Equipment

Table 2. Instruments

5.3 Test Medium and Quantities

Section 1 will be filled using potable water from water trucks. Sections 2 & 3 will be filled with
water from the river located at KP +10.260. Water quality reports shall be provided.
The theoretical amount of water required for filling the test three sections is 1454 m3, divided as
follows:
Section 1 : filling volume 492 m3 , additional pre-flush volume 125 m3.
Section 2 : filling volume 249 m3 , additional pre-flush volume 50 m3.
Section 3 : filling volume 713 m3 , additional pre-flush volume 50 m3.

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6 EXECUTION

Contractor shall employ sufficient experienced personnel to enable all aspect of the testing to
be fully supervised.
Contractor shall appoint a qualified and experienced Test Engineer who shall be solely in
charge of all pressure testing activities and associated operations.

6.1 Preparations & Set-Up

Contractor shall manufacture temporary pig traps which shall be used for cleaning the pipeline
and which shall serve as test header too; a sketch is provided in Figure 3. The design
pressure shall be equal to the highest hydrostatic test pressure of the 12” Sarsang
Pipeline, which is 177 barg.
Contractor may utilize the existing project pipe as barrel and install minimum Class #900
rating flange + blind flange.
Nozzle sizes is at the discretion of Contractor but it shall be ensured that sufficient flow into
the pipe can be achieved.
On each side of the test section such a temporary pig trap shall be installed.
Contractor shall ensure pre-flush hose, filling hose and temporary spools, fittings and other
connections are suitably rated for its purpose.

Figure 3. Temporary pig trap and test header

6.2 Cleaning and Gauging

Line Cleaning and Gauging will be conducted by the launching bi-directional pigs and
propelling them to the receiving trap with compressed air. The pig launcher shall be
loaded with one pig at the time, scraper and/or brush pigs shall be used. During the last
cleaning run the pig shall be fitted with gauging plate.
Prior to launching the cleaning pig, the line shall be pressurized to approx. 2 barg to establish
adequate back pressure. The pig speed shall be between 0.3 m/sec and 0.5 m/sec. The speed is

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controlled by throttling the release valve on the pig receiving.

The maximum allowable pressure during the pig runs shall not exceed 7 barg.
Proper communication between launching and receiving traps shall ensure controlled pig
movement on arrival. The operator shall immediately report to the test engineer any apparent
variation which may result in failure or danger such as any abnormal rising of pressure behind the
pig.
Upon pig arrival of the pig, the compressor will be stopped and the pressure will be released to
atmosphere. Prior to unfastening the blind flange, it shall be ensured there is no more pressure in
the pipeline.
Cleaning shall continue until there is no significant volume of debris. Acceptance of cleaning shall
be visually.
Following pipeline cleaning, a gauging run for each test section shall be performed to
demonstrate that the pipe line is free of buckles, wrinkles, dents, etc.
The gauge plate shall be fitted in front of a bi-directional pig with 2 sets of separate guiding and
sealing discs (see Figure 3 – pig 2).
The gauging plate shall be made from Aluminium plate, 6 mm thickness and its diameter shall be
95% or minus one (1”) of the internal diameter of the line pipe.
The pig shall be equipped with a locating device and shall be traceable while travelling through
the pipeline.
After receipt of the gauging pig, the gauging plate shall be examined for any signs of damage or
irregularities such as dents and buckles. In case that damage of the gauge plate is observed the
relevant defect in the pipeline shall be located through analysis of the pressure graph and the
position of the pig, and the damaged pipe section shall be repaired.

6.3 Water Filling

Test section 1 will be filled from water buffer tanks (2x 75m 3) which in turn will be filled by water
trucks (25m3 each). Filling location is at KP +0.000. For the purpose of filling Section 1, the
permanently installed pig trap may be utilized. The pig trap by-pass line (upstream of the barred
tee) shall be blinded off.
Test Sections 2 & 3 shall be filled with water from the river located at KP +10.260. The river water
will be pumped into a buffer tank (100m3) passing through a strainer fitted with mesh 150-micron
filter.
The system outline for Sections 2 & 3 is shown in Figure 4. The pig launcher shall be loaded with
two pigs; the 2nd pig is loaded just in case the air inclusion test (see Section xx of this procedure)
has failed and a second filling pig is required to be launched.

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Figure 4. System Outline

Calibrated flow meter shall be installed downstream of the filling pump in order to calculate the
volume of filling water.
Line filling shall not take place at ambient temperatures below 2˚Celsius.
Air expelled from the test section shall be vented out through vent valves, the valves shall be
manually operated.
At the inclined areas, back pressure shall be maintained by adequate air compressor installed at
the receiving end of the test section to control the quick running of the pig and hence air pocket
generation. At the start of the pre-flushing, the pipeline shall be pressurized till approx. 2 barg.
Upon arrival of the pig at the receiver end, the filling operation is merely completed.

6.4 Test Preparation & Stabilization

6.4.1 Test Preparation

After filling completion of Section 1, the permanent pig trap shall be isolated from the test section
by removing the pig trap isolation valves and temporary replace them with a blind flange with
pressurization and venting nozzles, and instrument connection (see Figure 5).

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Figure 5. Test header at KP +0.000

6.4.2 Stabilization
With the test section full, the thermal stabilization period monitoring will commence.
Temperature probes will be installed along the test section as marked in the layout drawings.
A 2 bar pressure will be placed on the line at the high point during the stabilization process. The
pressure/temperature cycle of this low pressure test will be monitored until obvious deviations due
to line cooling have stabilized, although fluctuations between day and night are expected to
continue due to the portion of pipeline exposed to the local ambient and direct sunlight.

6.5 Hydrostatic Testing - Pressurization

With all isolations completed, and the test section vented of any residual air, the pressure in the
pipeline will be raised at a maximum of 1 bar/minute, and the PV plot analysed for air content
using extrapolation of the projected linear portion of the PV graph from 25-35 bar. A typical
extrapolation form is attached (see Attachment 03 – Air Inclusion Report), utilizing indicative data
to demonstrate the procedure.
The actual values for Pipeline ID, Pipeline length and the actual volume readings will be recorded
on the calculation form, resulting in the Air Inclusion value. The formulas used for the calculations
are included on the calculation form (in the section below “values” and “air inclusion”).
In case the air content is above 0.2% of the test section volume, the pressure will be bled down,
and the pipeline vented and re-pressurized again. These steps will be repeated until the air
content value is below 0.2%.
Providing the air content is less than 0.2% of the test section volume, the pressure will be taken to
50% of the test pressure, where a check of all flanges will take place. The same shall be
performed at 75% of the test pressure.
The pressure will then be raised to 95% of the test pressure and held for 30 minutes to allow for
expansion and thermal stabilization before continuing on at 0.5 bar/min to the final test pressure.
This pressure will be calculated as the minimum on the test section (i.e. highest point), and thus
the line elevation profile in regard to the test instrumentation location will be analyzed to ensure
the correct pressure is achieved at the monitoring station.

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6.6 Hydrostatic Testing – Monitoring

The test pressure shall be held for four hours (Strength test) to identify any significant pressure
losses. The pressure shall be maintained during the strength test at TP ± 1 bar by bleeding or
adding water as required. The volumes of water added or removed shall be measured and
recorded.
If no pressure drop occurs during this interval, pressure shall be lowered to 80% of Leak
Tightness Test value. Then another interval of two hours shall elapse for stabilization, then the
pressure shall be increased to the Leak tightness test value for a period of 24 hours. No water
shall be added or removed during the tightness test; hoses shall be disconnected from the pump.
Should pressure drop occur during the above intervals the aforesaid operations shall be repeated
not more than twice, after which the line shall not be considered fit for testing until Contractor has
established and eliminated the cause of tightness failure.
Pressure and temperature readings shall be taken every one (1) hour as per the attached format.

6.7 Hydrostatic Testing – Depressurizing

After satisfactory completion of the strength and leak tightness tests, the test section shall be
depressurized to hydrostatic head plus 1 bar so that air does not enter into the test section.
Pressure let-down valves shall be opened slowly and depressurizing continued at a rate that does
not generate vibrations in associated pipework. The depressurization rate should not exceed 1
bar/min until the pressure has been reduced to 40 % of the test pressure. Then depressurization
should continue at a rate of less than 2 bar/min.

6.8 Dewatering and Swabbing

Dewatering and swabbing shall be performed by the use of foam pigs that are driven by
compressed air.
Swabbing operations shall continue until the last foam pig exhibits an increase of weight equal to
or less than 10%.

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7 TEST PACK DOCUMENTATION

The Test package shall include the following list of documents, drawings, check forms, etc.:
● Pre-hydro test checklist
● Water quality test report
● Pipeline general arrangement drawing
● Pipeline profile drawing
● Weld map
● Pipe Book
● Calibration certificates of used instruments
● Diagram of Hydrostatic test header, launcher / receiver
● Pipeline cleaning inspection report
● Gauging inspection report
● Filling log
● Pressurization record
● Air Inclusion Report
● Pressure and temperature log
● Pressure test certificate
● Post hydrostatic test check list

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