eni spa

exploration & production division

COMPANY SPECIFICATION

HYDROCARBON PIPELINES – HYDROSTATIC

TESTING OF PIPELINES

03517.PLI.MEC.SDS
Rev.3 July 2012

ENGINEERING COMPANY STANDARD

This document is property of Eni S.p.A. Exploration & Production Division.

It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 3 of 34

FOREWORD

Rev. 0 27 sheets
December 1988
Issue

Rev. 1 This specification is formed by 21 sheets plus three appendix sheets.

March 1996
This specification has been revised both conceptually and graphically; the general
revision has been carried out in accordance with CEE rules requiring the highlighting of
functional requirements and the deletion of discriminatory elements.

Rev. 2 18 sheets
November 2011
General revision

Rev. 3 34 sheets
July 2012
General revision. In particular Cleaning, Gauging, Line Filling and Pre-testing have been
revised in line with internal normative 23010.SLI.OFF.FUN (Hydrostatic Testing of
Offshore Pipelines) and Test Pressure Requirements have been revised in accordance
with ISO 13623.
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 4 of 34

INDEX

HYDROCARBON PIPELINES – HYDROSTATIC TESTING OF PIPELINES ..................................... 1

1. GENERAL......................................................................................................................... 5
1.1 SCOPE.............................................................................................................................. 5
1.2 NORMATIVE REFERENCES ........................................................................................... 6
1.2.1 EUROPEAN NORMATIVE REFERENCES...................................................................... 6
1.2.2 ISO, IEC AND OTHER ORGANIZATION NORMATIVE REFERENCES......................... 6
1.2.3 NORMATIVE OF OTHER ORGANIZATIONS .................................................................. 6
1.2.4 ITALIAN LEGISLATION.................................................................................................... 6
1.2.5 INTERNAL NORMATIVE.................................................................................................. 6
1.2.6 ORDER OF PRIORITY ..................................................................................................... 7

2. FUNCTIONAL NORMATIVE REQUIREMENTS.............................................................. 7

2.1 DEFINITIONS ................................................................................................................... 7
2.1.1 GENERAL DEFINITIONS ................................................................................................. 7
2.1.2 SPECIFIC DEFINITIONS.................................................................................................. 7
2.1.3 ABBREVIATIONS ............................................................................................................. 9
2.2 OPERATIVE ENVIRONMENT.......................................................................................... 9
2.3 FUNCTIONAL REQUIREMENTS ..................................................................................... 9
2.3.1 TYPE OF FLUIDS............................................................................................................. 9
2.3.2 PIPELINE TEST SECTIONS .......................................................................................... 10
2.3.3 TEST MEDIUM ............................................................................................................... 11
2.3.4 TEST EQUIPMENT AND INSTRUMENTATION ............................................................ 11
2.3.5 PIGGING REQUIREMENTS........................................................................................... 15
2.3.6 CLEANING, GAUGING AND LINE FILLING .................................................................. 15
2.3.7 PRE-TESTING ................................................................................................................ 18
2.3.8 TEST PRESSURES REQUIREMENTS ......................................................................... 20
2.3.9 TESTING PHASE ........................................................................................................... 21
2.3.10 POST-TESTING.............................................................................................................. 24
2.4 ERGONOMICS ............................................................................................................... 24
2.5 PERSONNEL .................................................................................................................. 24
2.6 HEALTH, SAFETY AND ENVIROMENT ........................................................................ 24
2.7 REQUIREMENTS FOR QUALITY MANAGEMENT AND QUALITY ASSURANCE ...... 26
2.8 DOCUMENTATION ........................................................................................................ 26
2.8.1 PRELIMINARY DOCUMENTATION............................................................................... 26
2.8.2 FINAL DOCUMENTATION ............................................................................................. 27

3. SUPPLEMENTARY ELEMENTS ................................................................................... 29

3.1 ENCLOUSURES AND INFORMATIVE ANNEXES ........................................................ 29
3.1.1 ANNEXES ....................................................................................................................... 29
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 5 of 34

1. GENERAL

1.1 SCOPE

This specification gives minimum requirements for the hydrostatic testing

activities, including cleaning, gauging, filling and pressure tests operations to be
carried out for new onshore pipelines before initial start-up; hydrostatic testing is
required to prove cleanliness, gauging, strength and leak tightness.

This specification does not apply totally or in part for onshore pipelines to be
cleaned, gauged, filled, or pressure tested after a routine or emergency
maintenance (repair), as defined elsewhere in the applicable design
documentation.

For all the cases where this specification does not apply totally nor in part,
amendment specification shall be prepared and used in conjunction or in lieu of
this document.

The sequence of the hydrostatic test activities is listed below.

1. Selection of the Test Sections: a) Assemblies

b) Pre-test sections

2. Preparation of the Test Section: a) Cleaning

b) Gauging
c) Line Flooding and Filling

3. Preparation of the Hydrostatic Test: a) Temperature stabilization

b) Pressurization
c) Air content check

4. Pressure Tests: a) Strength test

b) Leak tightness test

5. Post-testing Activities: a) Depressurization

6. Documentation

As hydrostatic testing of pipelines is part of precommissioning phase this Specification must

be read in conjunction with Company Specification No. 03526.PLI.MEC.SDS.

Dewatering, drying and packing shall be performed after the successful completion of the
hydrostatic testing. Minimum requirements and procedures are defined in Company
Specification No. 03526.PLI.MEC.SDS.
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 6 of 34

1.2 NORMATIVE REFERENCES

1.2.1 European normative references

The latest edition of the following rules (Italian version of European normative EN) shall
always apply:

UNI EN 12327 Gas supply systems – Pressure testing, commissioning and

decommissioning procedures – Functional requirements
UNI EN 1594 Gas supply systems – Pipelines for maximum operating
pressure over 16 bar – Functional requirements
UNI EN 14161 Petroleum And Natural Gas Industries - Pipeline
Transportation Systems

1.2.2 ISO, IEC and other organization normative references

The latest edition of the following rules shall always apply:

ISO 13623 Petroleum and natural gas industries – Pipeline

transportation systems

1.2.3 Normative of other organizations

The latest edition of the following rules shall always apply:

ASME B 31.4 Pipeline Transportation System for Liquid Hydrocarbons and

other Fluids
ASME B 31.8 Gas Transmission and Distribution Piping Systems

1.2.4 Italian legislation

The pipeline testing shall comply with all the requirements of the laws and decrees in force
in the country where the pipeline is to be installed.
The Italian law is the following:

Decreto Ministeriale Regola tecnica per la progettazione, costruzione, collaudo,

17 Aprile 2008 esercizio e sorveglianza delle opere e degli impianti di
trasporto di gas
naturale con densità non superiore a 0.8.

1.2.5 Internal normative

03526.PLI.MEC.SDS Hydrocarbons Pipelines – Precommissioning

06806.PLI.MEC.SPC Pigging of Onshore Pipelines
23010.SLI.OFF.FUN Hydrostatic Testing of Offshore Pipelines
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 7 of 34

1.2.6 Order of priority

In case of discrepancies among the various Normative references, the following order of
priority shall be applied:

1. ISO normative (refer to section 1.2.2)

2. Italian and European normative (refer to section 1.2.1);
3. Italian Legislation (refer to section 1.2.4);
4. Normative of other organizations (refer to section 1.2.3).

2. FUNCTIONAL NORMATIVE REQUIREMENTS

2.1 DEFINITIONS

2.1.1 General Definitions

Throughout this specification the following definitions apply.

Company Eni spa - exploration & production division or affiliated

Companies

Contractor The Contractor responsible for the execution of the works

defined in this Specification and in the Contractual
Documents.

Company Representative Any authority or person appointed in writing by the Company.

Contractual Documents Documents issued by Company (reports, specifications, data

sheets, drawings) to define the specific requirements
relevant to the work to be carried out by the Contractor.

Functional Specifications Documents issued by the Company containing the general

minimum requirements to be followed by Contractor during the
execution of the work.

Executor Is the party that performs the works.

Manufacturer/Supplier Is the party which manufactures or supplies equipment and

services to perform the duties specified by the Contractor.

The word shall indicates a mandatory requirement.

The word should indicates a recommendation.

2.1.2 Specific Definitions

Assembly An arrangement of pipes/components such as a crossing, pig

trap or block valve station.

Block valve A valve for interrupting the flow or shutting in a section of a

pipeline. A block valve is normally either fully opened or fully
closed.

Design Pressure The pressure at which design calculations are based.

eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 8 of 34

Golden Weld A weld which is not subject to a hydrostatic pressure test and
as such must pass additional non-destructive inspection.

Hydrostatic pressure test That part of the hydrostatic pressure testing operations during
which the test section is pressurised. The hydrostatic pressure
test includes a strength test and a leak tightness.est.

Line-fill water Water, chemically treated, if required, used as medium to fill

and pressurise the pipeline.

Maximum operating
pressure (MOP) Maximum pressure at which a system can operate
continuously under normal conditions (not exceeding the
design pressure).

Mothballing Activity achieved by filling the line with nitrogen at a pressure

of about 0.5 barg. This is required when commissioning
activities are delayed for more than three months.

Operating pressure (OP) Pressure under normal operating conditions.

Pre-test A pressure test carried out on a part or for all the Assembly
prior to final installation.

Specified minimum
yield strength (SMYS) The minimum yield strength prescribed by the specification
under which pipe is purchased from the manufacturer.

Test engineer The specialist engineer appointed and specifically named by

Contractor to be in full charge of Work.

Test equipment All temporary fittings, piping, test heads, pumps, pigs,
materials, equipment and consumables used for the Work.

Test point The primary point of pressure measurement of a pipeline. This

is normally the point of pressurisation.

Test pressure The pressure at which the pipeline is tested for strength or
leak purposes. Basically, two different pressure values apply
for strength and leak tightness tests, unless otherwise
specified.

Test procedure Contractor procedure covering preparation, pressure testing,

rectifying and post-testing activities.

Test section A section of the pipeline or the entire pipeline which is subject
to a hydrostatic pressure test.

Work The part of the construction contract which includes part or

totally the scope of work relating to the hydrostatic testing of
pipelines, including cleaning, gauging, filling activities and
pressure tests.
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 9 of 34

2.1.3 Abbreviations

DF Design Factor

DP Design Pressure

KP Kilometer Post

MAOP Maximum Allowable Operating Pressure

MOP Maximum Operating Pressure

MSDS Material Safety Data Sheet

SMYS Specified Minimum Yield Strength

TP Test Pressure

2.2 OPERATIVE ENVIRONMENT

In defining the pipeline hydrotest, it shall be paid attention to the environmental conditions
of the installation place, listed in the project specification of the pipeline.

It shall be kept in mind the environmental factors which might have an impact on the correct
performance and testing data detection, such as:

- minimum and maximum temperature;

- elevation in comparison with the sea level.

2.3 FUNCTIONAL REQUIREMENTS

2.3.1 Type of fluids

This specifications covers the following type of fluids categories to be transported
(according to ISO 13623:2009):

Category A Typically non-flammable water-based fluids.

Category B Flammable and/or toxic fluids which are liquids at ambient
temperature and at atmospheric pressure conditions. Typical
examples are oil and petroleum products. Methanol is an example of
flammable and toxic fluid.
Category C Non-flammable fluids which are non-toxic gases at ambient
temperature and atmospheric pressure conditions. Typical examples
are nitrogen, carbon dioxide, argon and air.
Category D Non-toxic, single-phase natural gas.
Category E Flammable and/or toxic fluids which are gases at ambient temperature
and atmospheric pressure conditions and are conveyed as gases
and/or liquids. Typical examples are hydrogen, natural gas (not
otherwise covered in category D), ethane, ethylene, liquefied
petroleum gas (such as propane and butane), natural gas liquids,
ammonia and chlorine.
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 10 of 34

2.3.2 Pipeline test sections

Executor shall define the pre-test and test pipeline sections. Definition of test section shall
take into account:
• codes requirements;
• safety of personnel and the public, and the protection of the
environment and Company/third party facilities;
• construction sequence and responsibility;
• terrain and access;
• minimization of golden welds;
• availability and disposal of test water.

The buried pipeline section shall be delimited by two test heads.

The various sections shall be defined and indicated on the ground profile of the route.

As a general rule the maximum difference in height allowed between the highest point and
the lowest one of the same section is 200 m; as a consequence, in the mountains the
length of the section to be tested is obviously conditioned by this value.

The maximum length of the pipelines to be tested is the following:

- for pipes with ND less than or equal to 650 mm (26"): L = 8-10 km

6 ⋅ 10 6
- for pipes with ND over 650 mm (26"): L= (km)
ND 2 (mm)

The length and the difference in height of the pipelines shall be defined in such a way that
for each pipeline section it is possible to guarantee, at the same time, the minimum and the
maximum requirements in the strength test.

Greater lengths are only allowed if expressly authorized by the Company's Representative.

Contractor shall test separately the following pipelines; it is not necessary a physical
separation as the valves may be used as intercepting devices:

- the overhead pipeline sections laid on piles;

- the suspended bridge sections;
- the section points, when they cannot be tested together with the pipeline;
- the crossing by HDD;
- the crossing by microtunneling 50.0 m or longer.

The following pipeline sections shall be pretested separately; they shall be physically
separated from the pipelines and equipped with an autonomous head:

- crossings of: railways, rivers, motorways, suspended channels;

- Crossing of roads with the following characteristics:

. pipelines with diameter over 406.4 mm (16");

. when the pipe is not provided with casing or with casing length exceeding 30m;
. when the traffic can not be interrupted during testing;
. tunnel section;
. any other section required by the Company's Representative.

The pre-test shall be performed according to the same method described in this
specification at a pressure 500 kPa more than the maximum pressure foreseen for the
strength test, and for at least one hour, without exceeding the yield pressure of the weakest
component of the tested section.
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 11 of 34

The pressure-tested test sections or assemblies shall be tied in by "golden welds" in

accordance with ISO 13623 Clause 11.5 and subjected to both radiographic and ultrasonic
examination in accordance with Company Specifications.

2.3.3 Test medium

Water or oil-free compressed air shall be considered as medium for cleaning and gauging
operations. Water shall be used for pressure test operations.

Water required for pressure test should be selected from a location that will minimise time
for temperature stabilisation. The water for test shall be clear and of good quality to avoid
any ingress of foreign matters, debris, sediment and internal corrosion of the pipeline.

Before starting of tests all the necessary authorizations and licenses shall be obtained , in
particular for water disposal.

Water shall be analysed by qualified and independent testing laboratory. Guidelines for
water analysis are listed under Annex 3. Sea water properly treated could be used.

Company shall approve the quality sources of the proposed test water. Depending on water
source quality, as determined by laboratory analysis, filtration may be required (acceptable
filtration level is 50 µm).

Chemicals, like oxygen scavenger, corrosion inhibitor and biocide may be required to be
added to the filling water, depending on the quality of water, the duration of the pressure
tests and of the commencement time of the drying operations. Basically water inhibition is
not required if the filling, testing and evacuation can be completed within 30 days.

The environmental acceptability of any proposed treatment package shall be demonstrated.

Details for such chemicals, including product data sheets, MSDS, and filtration
requirements shall be provided to Company for approval. Details shall include, but not
limited to, time of effectiveness of the specified injection levels.
Chemicals shall be continuously injected into the test water. Batch chemical treatment shall
not be acceptable.

Line filling should not take place if the ambient temperature is below 2°C unless a suitable
antifreeze has been added to the line-fill water. In this case all required data in the
procedure manual(s) shall be included and submitted to Company for approval.

2.3.4 Test equipment and instrumentation

The number, size and/or performance of each component required for the Work, including
the consumables, spare parts and stand-by units, shall be defined and shall be supplied for
all the test equipment and instrumentation necessary to fulfil the requirements of this
Specification.

A schematic equipment layout of a typical test section is shown in Annex 4.

Any test equipment pressurised during the test operations shall be designed for a working
pressure not less than the test pressure. These components shall have material certificates
and the equipment itself shall have data sheets from the Manufacturer. The test equipment
connected to the test section shall have hydrostatic test certificates and shall have been
tested to a pressure at least 1.25 times the test pressure of the test section unless
otherwise indicated by project). The test equipment shall be internally clean and fit for
purpose.
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 12 of 34

The test heads and temporary pig traps which will be exposed to test pressure shall be
designed, fabricated, installed and tested according to the same code as the pipeline.
However, the allowable “code breaks” between ISO 13623 and other codes may be used,
specifically where prefabricated items are used. The test procedure shall take account of
any proposed code breaks.

Test heads and temporary pig traps shall be numbered and a certificate shall be kept for
each one. This certificate shall show the results of non-destructive tests on each fabrication
weld, the pressure at which it was initially tested, the number of times it has been used and
the test pressure attained on each test. Entries in the record shall be signed by the test
supervisor. Test heads that do not have a complete certificate and record of use from the
new condition shall not be used.

Wall thickness transitions between test heads and the pipeline resulting from unequal wall
thickness or unequal yield strength, or both, shall meet acceptable welding configuration
requirements in accordance with ASME B31.4 and ASME B31.8. The maximum wall
thickness for design pressure of a test head shall not be greater than 1.5 times the nominal
wall thickness of the matching pipe.

All temporary piping shall be adequately supported during all operations. Temporary flexible
hosing shall be of the armoured type and minimum length with safe working pressure at
least equal to the test pressure. Such hoses shall be anchored to prevent “whip” in the
event of failure and shall not be used in any enclosed areas. The hoses shall not be used
above 50 percent of maximum working pressure to ensure creeps do not occur. All hoses
and associated fittings shall be pre-tested, prior to use, for a minimum of one hour.
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 13 of 34

Table 1 - Test Equipment

Filling and pressurising complete with stroke counter or flow meter suitable for the required
pumps duty.
Filters 50 μm, or as specified in the scope of work (if required), compatible
with flow rate of filling pumps. Filters with 50 μm and above should be
suitable for back-flushing.
Break tanks and piping to keep the pumps constantly on load.
Valves to allow exchange or replacement of instruments and equipment during
the hydrostatic pressure test.
Chemical injection for continuous injection of water treatment packages and dye (if
pumps required), including the injection manifold and block valves. The
injection pumps shall have an accuracy within 5 % of the specified
injection rate.
Air-conditioned or complete with the necessary gauges, pressure sensors, recorders,
heated test cabin unit deadweight tester, barometer, etc. for installation at the end of the test
section so that the test supervisor can accurately assess the progress
of the hydrostatic test and record the pressure and water volume
conditions throughout the tests. As an alternative to the deadweight
tester and pressure recorder, the use of a pressure transducer in
combination with a computerised logging system is acceptable.
Filling/Pressurising measuring and recording continuously the flow and temperature of the
flowmeter and line-fill water with the specified accuracy in Table 2.
temperature probe
Pipe wall temperature measuring and recording equipment in accordance with the specified
recorder accuracy in Table 2.
Pressure recorder measuring and recording continuously the pressure at the test head
with the specified accuracy in Table 2.
Ambient air measuring and recording equipment with the specified accuracy in
temperature recorder Table 2.
Soil temperature measuring and recording equipment with the specified accuracy in
probes and recorder Table 2.
Pressure relief valve fitted to the pressurising pump, capable of handling the full capacity of
the pump, and set at 3 % above the specified test pressure to ensure
that the test section is not overpressurised.
Pressure let-down to release the pressure in a controlled manner on completion of the
valve hydrostatic tests.
Tank for calibrating the high-pressure pump and flow meter.
Temporary pig for cleaning, gauging, filling and dewatering operations. The receiver
launchers and should be fitted with a throttling valve.
receivers
Pigs various pigs for cleaning, gauging, filling and dewatering operations.
Pig tracking equipment for locating the pigs in the test section, usually only used when the test
section length is greater than 5 km.
Test head to separate the test section for pressure testing.
Piping, valves, fittings, for supplying and safe disposal of water (inhibited, if required) and air.
etc.
Air compressors if compressed air is to be used to drive pumps or pigs. The air to drive
pigs shall be oil-free and air coolers shall be included if the discharge
temperature is outside the limits specified for the test section.
Equipment and for detecting and repairing pipeline leaks (if any).
materials
Communication for communication between the various locations of the test section.
equipment
Spare parts and stand- to replace any defective test equipment during the hydrostatic pressure
by facilities test.
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 14 of 34

Test instruments shall be in accordance with the requirements of Table 2 below:

Table 2 - Test instruments

Instrument Reading Division Range Accuracy

Dead-Weight Tester 1 kPa 0 to 1.5 times TP ± 0.05 percent

(Note 3) (Note 1)
Pressure Data Logger 1 kPa 0 to 1.5 times TP ± 0.05 percent
(Note 1)
Pressure Gauge 0.1, 0.2 or 0.5 MPa 0 to 1.5 times TP ± 0.6 percent
(Note 2)
Pressure Recorder 0.2 or 0.5 MPa 0 to 1.5 times TP ± 1 percent
(48 hours) (Note 2)
Barometer 1 mbar - ± 0.8 mbar

Ambient Air Temperature Recorder 0.5°C -10° to 80°C ± 1 percent

(48 hours) (Note 2)
Temperature Probes and Recorder 0.1°C 0 to 50°C ± 0.1°C
(Digital) -10 to 60°C ± 0.2°C
(48 hours)
Filling Flowmeter (Turbine) m3/h - ± 1 percent
(Note 2)
Pressurizing Flowmeter strokes/litres - 1 percent volume per
stroke
Notes: 1. Percentage of measured value.
2. Percentage of the full range.
3. For vessel-mounted operations, especially at high pressure, a data-
logger should be used.

Pressure gauges shall be checked for accuracy on site, in the presence of Company, before
the commencement of the hydrostatic pressure test of any test section. This shall be carried
out by comparison with the deadweight tester.

The accuracy of the pressurising flow meter shall be checked by Executor, in the presence of
Company, using a calibrated tank.

Other instruments shall have calibration certificates from a recognised certifying authority or
a Company approved third party. Where instruments are connected with electrical cables to
the test section or are in contact with the test medium, the instrument's calibration shall
include the cabling. The certificates shall not be older than 6 months at the start of pressure
testing.

All permanent in-line instruments and instrument probes shall be removed, blocked and bled
as necessary or otherwise isolated during the operations.

For pipelines with diameter over 323.9 mm (12") the section to be tested shall be provided
with the necessary probes to detect the pipe wall temperature. The probes shall be placed at
the following locations:

- a probe at about 250 m from the pumping head;

- a probe at about every 2 km;
- a probe at about 250 m from the terminal head.

The platinum heat-coupling probes, 100 ohm at 0°C, shall be applied on the external wall, at
the lateral generatrix, after the protective coating has been removed.
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 15 of 34

After the application of the probes the anticorrosion coating will be restored.

2.3.5 Pigging requirements

Pigging operations shall comply with the requirements of Company Specification Pigging of
Onshore Pipelines, 06806.PLI.MEC.SPC.

2.3.6 Cleaning, gauging and line filling

2.3.6.1 General requirements

Prior to pressure testing, the pipeline section shall be cleaned and gauged, to ensure the
removal of construction debris and to check that the sections are free from deformations
and/or obstructions.

Block valves should not be installed before hydro-test, including cleaning operations have
been completed.

The required pressure and volume to drive the pigs shall be calculated as specified.
Pressure / flowrate will be kept under control, to maintain the pigs velocity as much
constant is possible in the range 0.5–1.8 m/s. A proper back-pressure (min. 200 kPa)
should be maintained at pipeline outlet in order to avoid high pig velocity/acceleration.
The elevation difference and back-pressure of the outlet at the receiving end shall be taken
into account.

Temporary pig launchers and receivers shall be approved by Company prior to use and
shall be welded to the test section or flanged if a permanent flange is available.

All piping and valves arrangements for launching and receiving heads shall be arranged
that independent launching and receiving of pigs may be possible. The launching and
receiving heads shall be connected to the pipe ends to allow inspection of the pig upon
arrival.

Mechanical pigs (bi-directional type) shall be selected based on proven performance for
similar diameters / distances and maximum capability. Single pigs or last pig of pig train
shall be fitted with a transponder transmitting a signal, for pig location in section under
cleaning with a length exceeding 5 km.

Use of pigs with wire brushes shall not be admitted in internally coated pipeline.

If compressed air is to be used as the driving medium, the air should be oil-free and the
inlet line of the driving medium should be fitted with a pressure relief valve set at 0.7 MPa.

In sections with a diameter less than DN 250 a higher pigging pressure may be required.
Therefore, water should be used as the driving medium for smaller pipelines.

When the driving medium is water, its source and the filtration method shall be as specified
for line-fill water (refer to Chapter 2.3.3).

If water is to be used to drive pigs, a batch of water corresponding to a minimum of 4 % of

the section volume or 150 linear metres of the line section, whichever is the greater, shall
be introduced ahead of the first cleaning pig to wash foreign materials away. Pigs used in a
pig train shall be separated by the same volume of water as specified in front of the first pig.

If a pig becomes stuck in the pipeline and the driving medium is air, a differential pressure
greater than 0.7 MPa shall not be employed to dislodge the pig.
If the driving medium is water and a differential pressure up to 50 % of MOP is insufficient
to dislodge the pig, the pig shall be located and removed from the pipeline by cutting the
pipe or by other methods to be approved by Company.
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 16 of 34

The pigging operation shall be recorded in a book register including:

• pig type;
• pig number;
• pig launching and receiving time;
• inlet pressure;
• downstream pressure;
• arrival condition of the pig (complete of photographs);
• amount and nature of material received in front of pig (complete of photographs).

2.3.6.2 Cleaning
The Executor shall include in his procedure a method to calculate the estimated amount of
debris to be removed during pipeline cleaning.
The amount of material received at the end of the cleaning section shall be assessed on
volume and weight basis. The quantity of removed debris shall be compared with the
calculated values. A difference of ±10 percent shall be allowed without repeating the
cleaning operation.

After a cleaning run, all pigs received shall be inspected by both Company and Executor
representatives. Received material shall present a decreasing trend in both volume and
particle size and pigs sealing discs shall not present evident damages that could be related
to a lost in the pig cleaning efficiency.

Based on the quality evaluation on the amount of received debris and the pig conditions,
both Company and Executor representatives shall agree on site on the satisfactory
performance of the cleaning operation.

All debris received with the pig shall be disposed off in accordance with Company’s waste
management requirements.

2.3.6.3 Gauging
After cleaning and back-filling the trench, the complete test section shall be gauged by
means of either a gauge plate pig.

The aim of this operation will be to meet the requirement to prove the continuous diameter
of the pipeline, i.e. the absence of any significant dents, ovalities or other defects caused
during the construction phase.

A bi-directional pig with 2 sets of separate guiding and sealing discs shall be fitted with one
or two aluminium gauging plates to be located as follows:

a. If two gauging plates are fitted, one shall be fitted in front of the first set of discs
and the second shall be in front of the last set of discs

b. If only one gauging plate is fitted it shall be at the rear location.

The gauging plates should be made as follows:

• 3 mm thick for pipeline diameters up to DN 100

• 6 mm thick for pipeline diameters from DN 100 to DN 300
• 12 mm thick for pipeline diameters above DN 300.

The gauging plates should have 8 radial incisions at 45 degree intervals.

The radial incisions should extend from the outside diameter of the gauging plate to the
outside circumference of the locating plate of the pig.
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 17 of 34

The gauging plate diameter shall be determined from the formula:

d = ID - 0.01 D - 2b or d = 0.95 x ID, whichever is smaller,

where:

d = gauging plate diameter (mm)

D = nominal outside diameter (mm)
ID = minimum internal diameter (mm)
b = clearance of 5 mm

All gauge devices shall run at a velocity not less than 0.3 m/s and not higher than 2 m/s.

Launch procedures shall be carefully defined in writing and implemented to avoid damage
to the plate (particularly bottom of plate) during the launch process.
Pressure trend at the section inlet shall be recorded to observe if increasing on pressure
may be attributable to gauging plate (pig) being stationary.

Gauging plate measurement, introduction of the gauging pig into the test section, and
removal from the test section shall be carried out in the presence of Company.

A photographic record shall be taken of the condition of each gauging plate after use.
If the test section to be filled with line-fill water is a combination of two or more cleaning
and/or gauging sections, the second filling pig shall be a gauging pig which shall be
inspected by the Company upon removal of the test head.

The gauging plates shall be examined for any signs of damage or irregularities such as
dents and buckles. In case of damage, the gauging pig shall be re-run with new gauging
plates of the same diameter. If the defect cannot be located by the gauging operation,
Executor shall run a geometric inspection (caliper) pig to locate the defect.

Any damage noted by the second gauging pig or by the geometric inspection pig shall be
located and repaired by Executor and agreed with Company.

If from visual inspection, the gauging plate will result not damaged, line gauging shall be
deemed acceptable and line filling shall commence.

2.3.6.4 Filling and flooding

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

The Executorr shall ensure that water for line flooding and filling operations meets the
requirements stated at Chapter 2.3.3.

If block valves are installed, the Executor shall ensure prior to filling that all block valves are
correctly positioned in the fully open position. Provision shall be made to equalise the
pressure between the valve body cavity and the line.

Before filling the test section the Executor shall ensure that that piping and facilities for the
disposal of treated water (if any) are installed and functional.

All necessary measures shall be taken to remove air from the line during filling. This
includes back-pressure control, a steady controlled filling rate and use of a break tank.

Two bi-directional pigs fitted with multiple sealing discs (at least four) shall be used; one at
the air/water interface and one spaced behind to remove air that may pass the air/water
interface pig. The distance between the two pigs should be about 1/10 of the length of the
tested section.
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 18 of 34

Sufficient pressure (min. 0.2 MPa) shall be maintained in front of the air/ water interface pig,
by using backpressure control at the end of the test section.
Depending on the elevation profile of the test section and the pigging pressure, it may be
necessary to increase the pressure at the receiver test head in order to control the pig
speed (to keep approximately between 0.5 m/s and 1.8 m/s).

Where practicable, the test sections shall be filled from the lower end. The test engineer
shall ensure that the pump suction will not draw in air from the suction line.
During the filling operation, venting shall be carried out repeatedly at the section points
where air might accumulate.

In order to assist in controlling the line filling and water treating, and to demonstrate the
successful completion of filling operations, the following measurements and records shall
be recorded:
• dispatching and receiving pressures;
• pig train transit time;
• amount and category of debris removed;
• inlet/outlet water temperatures;
• chemical injection rates (if any).
In the event of chemical injection pump failure, the filling pump shall be stopped.
No filling shall take place if the air temperature is 2°C and falling or in freezing conditions
unless antifreeze precautions are taken.

Final acceptance of satisfactory flooding shall be performed during pressure tests when a
residual air test is performed by pressurisation. In case the air entrapment is found
excessive, an additional pig shall be displaced to ensure the complete and correct filling of
the test section or other measure taken according to agreements with Company.

2.3.7 Pre-testing

2.3.7.1 Pre-testing requirements

A pre-test check shall be performed on each section to be tested before pressurising is
commenced.

The checklist should include checks to confirm that:

a) The test section has been positively isolated from all other pipeline sections.

b) All temporary facilities connected to the test section have been tested for four hours at a
minimum pressure value corresponding to 1.25 times the test pressure value unless
otherwise indicated by project);

c) The test section has been filled completely and air has been vented off.

d) The block valves, if installed, have been returned to the half-open position so that there
is no differential pressure across the seats/seals.

e) All instruments and gauges to be used during pressurising and testing have been
calibrated.

f) All warning notices, marker tapes, protective barriers and other safety equipment have
been positioned and the appropriate authorities have been informed.

g) All necessary personnel at the affected stations have been informed of the
commencement and duration of the hydrostatic pressure test.
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 19 of 34

h) The communication channels have been tested and established and back-up equipment
is available.

i) The personnel engaged in the testing work have been briefed on the emergency plans.

j) The person operating the pressurising equipment has been instructed by the test
supervisor regarding the limiting pressure which shall apply to the test section.

For the above-water/above-ground test section temperature measurements, the

thermocouples should be firmly installed into the line-fill water or firmly attached to bare
pipe and covered with insulating materials. The bare pipe shall be recoated upon
completion and acceptance of hydrostatic pressure testing.

2.3.7.2 Thermal stabilisation

Prior to commencing the hydrostatic test, the water temperature should be within 1°C of
ground temperature. This shall be determined as the difference between average pipe
temperature and average ground temperature over the test section length.
The calculation of the temperature stabilisation period based on the expected line-fill water
temperature and ambient temperature shall be detailed in the test procedure.
Pressure and temperatures, including ambient, shall be recorded every hour during the
stabilisation period. The test section temperature and the ambient temperature
(ground/air/water) shall be plotted against time during the temperature stabilisation period
(at least 24 hours).

2.3.7.3 Pressurization and air content determination

The pressurization should be constant and not exceed 0.1 to 0.15 MPa per minute until a
pressure of 3.5 MPa or 50 % of the test pressure, whichever is lower, has been met.

During this period, volume and pressure readings should be recorded at 0.1 MPa intervals.
The person operating the pressurising equipment shall immediately report to the test
supervisor any variation in the rate of pressure increase resulting from the same volume of
added water.
During pressurisation, all potential leakage points shall be checked.

When the pressure of 3.5 MPa or 50 percent of the test pressure, whichever is lesser, has
been reached, the air content shall be determined. The air content of the filled line shall be
determined during initial pressurization by using the pressure-added volume plot (refer to
Annex 5).

Percentage air content = (Volume of air / Volume of line) times 100.

If the air content exceeds 0.2 percent of the line volume, testing shall be terminated and an
investigation shall be carried out to determine the cause. In case the air entrapment is
found excessive, an additional pig shall be run to ensure the complete and correct filling of
the pipeline or other measure taken according to agreements with Company.

When the air content is within the maximum allowable limit of 0.2 percent of the test section
volume pressurization should continue, at the rate not exceeding 50 kPa per minute, as
follows:

• if flanges are installed, pressurization should continue up to 7 MPa or to the MOP,

whichever is the lesser and be held while checking flanges for leaks. This is the
highest pressure permitted to tighten up any leaking flanges.

• If flanges are not installed or flanges have been checked, pressurization should
continue up to 80 percent of the test pressure and be held at this level for not less
than 2 hours. During this water stabilization period accessible flanges, if installed,
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 20 of 34

should again be checked for small leaks. If any are found, the test section shall be
depressurized at not more than 0.2 MPa per minute down to 7 MPa or to MOP,
whichever is lesser, prior to any bolt tightening.

After stabilization, the pressure should be raised to 95 percent of the test pressure and held
for 30 minutes, then the pressurization should be continued to the specified strength test
pressure at a rate not exceeding 25 kPa per minute.

The pressures and added volumes should be continuously plotted until the specified test
pressure has been achieved. The plot should be constantly checked and, in the event of
any deviation of 10 percent or more from the theoretical line corresponding to 100 percent
water content, the test should be terminated. The pressure should be released and an
investigation shall be carried out to determine the cause of the deviation prior to re-
pressurization.

2.3.8 Test pressures requirements

The hydrostatic test of the section will be completed into two sequential steps:

a. Strength Test, to prove the full strength of the tested section.

b. Leak Tightness Test, to prove that no leaks are present in the tested section.

The strength test pressure shall be a value between the applicable minimum and maximum
test pressure requirements taking in due account the elevation effect for each pipeline
section.

The pipeline test pressure shall be selected in accordance with the most conservative
applicable codes and local legislation.

The minimum strength test pressure at any point of the test section shall be equal to the
test pressure specified in ISO 13623 Clause 6.7.3 (at least 1.25 times MOP).

The minimum pressure in the pipeline during strength testing shall be increased from 1.25
times MOP to 1.40 times MOP for pipelines in location classes 4 and 5, as specified in
ISO 13623 Clause B.6 .

For pipelines conveying category C and D fluids and where a hoop stress design factor (Fh)
of 0.83 has been applied, the strength test pressure may be reduced to a pressure of not
less than 1.20 times the internal design pressure, provided the maximum incidental
pressure cannot exceed 1.05 times the internal design pressure

The maximum allowed test pressure (refer of formula (1) of this Chapter) shall be equal to
the pressure creating a hoop stress of 100 % of SMYS of the line pipe material, based on
nominal wall thickness, or the shop hydro-test pressure, or the flange and valve rating,
whichever the lowest.

The minimum leak tightness test pressure at any point of the test section shall be at least
the test pressure specified in ISO 13623 Clause 6.7.3 or 1.1 times the internal design
pressure, whichever is greater.

During the hydrostatic pressure test the equivalent stress shall not exceed 100 % SMYS of
the line pipe material at any point in the pipeline. The equivalent stress shall be calculated
in accordance with ISO 13623 Clause 6.4.1.2. The calculation shall include major residual
stresses from construction. If the calculated equivalent stress is higher than 100 % of
SMYS, special measures shall be taken to reduce the longitudinal stresses in the test
section.
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 21 of 34

The minimum duration for the hydrostatic pressure test shall be a 4 h strength test followed
by a 24 h leak tightness test for liquid pipelines and a 48 leak tightness test for gas
pipelines.

The maximum allowed test pressure for the strength test shall be calculated according to
the following formula:

t min,h
PT = 20 σy ⋅H (1)
D
where:

t min,h specified minimum wall thickness (m)

PT maximum allowed test pressure (MPa))
D pipeline outside diameter = ID + (2 * t min, h ) (m)
ID pipeline internal diameter (m)
σy specified minimum yield stress (MPa)
H % of Hoop Stress: 1 for onshore pipeline sections

2.3.8.1 Works in Italy

The minimum strength test pressure at any point of the test section shall be equal to the
test pressure specified in D.M. 7/04/2008 as follows:

- 1,30 times MOP for pipelines of first type;

- 1,50 times MOP for pipelines of second and third type.

Note: Pipelines for natural gas transportation are classified as follows:

• pipelines of first type: pipelines with MOP greater than 2.4 MPa;
• pipelines of second type: pipelines with MOP greater than 1.2 MPa and
lower or equal to 2.4 MPa;
• pipelines of third type: pipelines with MOP greater than 0.5 MPa and lower
or equal to 1.2 MPa.

The maximum allowed test pressure shall be equal to the pressure creating a hoop stress
of 100 % of SMYS of the line pipe material, based on nominal wall thickness, or the shop
hydro-test pressure, or the flange and valve rating, whichever the lowest.

The minimum duration for the hydrostatic pressure test shall be a 48 h (combined strength
test and leak tightness test).

2.3.9 Testing phase

2.3.9.1 Strength test

The test engineer shall confirm that the above calculated strength test (test pressure) does
not exceed the pressure to which the pipe has been subjected during the mill test and that it
is not higher than the test pressure of the fittings specified for the pipeline.

The pressure shall be maintained during the strength test at the specified test pressure
(TP) ± 0.1 MPa by bleeding or adding water as required. The volumes of water added or
removed shall be measured and recorded.
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 22 of 34

During the test, the test pressure shall be recorded continuously, and the dead-weight
tester readings and air temperatures shall be recorded at least every thirty minutes. The
pipe and soil temperature shall be recorded at the beginning and end of the four-hour test
period.

The test section temperature and the ambient temperature against time plot created for the
stabilisation period should be maintained.

2.3.9.2 Leak tightness test

Upon successful completion of the strength pressure test, the pressure shall be let down to
the leak tightening pressure by bleeding the required volume from the location where
pressurisation took place. The pressure let down will be carried out at a rate not exceeding
50 kPa per minute and water removed from test section shall be collected and measured.

The leak tightness test should commence immediately after the strength test has been
completed satisfactorily and pressure let down to the specified leak test pressure value. No
water shall be added or removed during the leak tightness test; any filling/bleeding
pipework disconnected and duly blinded off.

If it cannot be ensured that the pressure variations due to temperature fluctuations are in
the limits specified in Chapter 2.3.7, then a combined strength and leak tightness test at the
strength test pressure, without water addition or removal, should be carried out. Under such
occurrence, to allow for pressure variations caused by temperature fluctuations during the
test duration, the test pressure should be set to a level that guarantees that the maximum
test pressure (as defined in Chapter 2.3.8) is not exceeded.

During the test, the pressure shall be recorded continuously, and the dead-weight tester
and air temperature readings shall be recorded every 30 minutes. The pipe and soil
temperature shall be recorded at maximum three-hour intervals.

The temperature recording interval should be reduced to a one-hour duration for the first
and last three-hour periods of the 24-hours (for liquid pipeline systems ) and 48-hours (for
gas pipeline systems to assist with the pressure/temperature variation calculation. The test
section temperature and the ambient temperature against time plot created for the
stabilization period should be maintained.

During the test, the pressure shall be recorded continuously, and the dead-weight tester
and air temperature readings shall be recorded every 30 minutes. The pipe and soil
temperature shall be recorded at maximum three-hour intervals.

The temperature recording interval should be reduced to a one-hour duration for the first
and last three-hour periods of the 24-hours (liquid pipelines) and 48-hours (gas pipelines)
to assist with the pressure/temperature variation calculation. The test section temperature
and the ambient temperature against time plot created for the stabilization period should be
maintained.

The pressure test will be accepted provided that all pressure containing components in the
tested section maintain their integrity and no leaks are found throughout the entire duration
of the pressure test. At no time shall the test pressure fall below the minimum test pressure.
Pressure variations of more than 0.2% of the test pressure shall be acceptable if they can
be demonstrated to be caused by factors other than a leak. Executor has to demonstrate
through calculations that pressure variations are caused by variations in ambient
temperature or pressure and not to any leakages.

For Works in Italy, the 48 hours leak test shall be considered acceptable according to DM
17.04.2008 if the pressure is constant in the tested section during the 48 hours period a
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 23 of 34

part from the variations due to the temperature changes. In case of doubt the test shall be
prolonged of 24 hours.

Pipelines not meeting these requirements shall be repaired and retested in accordance with
the requirements of this specification.

The pressure change due to water temperature shall be calculated with the following
formula or any other formula submitted by test engineer and approved by Company. The
test engineer shall include the calculation method in the test procedure including the
compressibility and thermal expansion values of the test water (including additives, if any)
versus pressures and temperatures. Values shall fully cover pressures and temperatures
values obtained during the pressure test operations.

B
ΔP = ⋅ΔT
⎛ ri ⎞
0.884⎜ ⎟+ A
⎝s⎠

where:

ΔP = pressure change resulting from a temperature change (MPa)

ΔT = algebrical difference between water temperature measured at

the beginning of the test and water temperature measured at
the end of the test (°C)

B = value of the difference between the thermal expansion of water

(at the pressure and temperature measured at the end of the
-1 6
test) and the thermal expansion of the steel (see Annex 2) (°C )*10

A = isothermal compressibility value of water estimated at the

pressure and the temperature values obtained at the end of the
test (see Annex 1) (MPa-1)* 106

ri = rated inner radius of the line pipe (mm)

s = rated line pipe thickness (mm)

For several wall thicknesses, replace

⎛ ri ⎞
K =n
⎡ ri, K l K ⎤
⎜ ⎟
⎝ s⎠
with ∑⎢s ⋅ ⎥
K =1 ⎣ K l t ⎦
where:

lt = total line length (m)

lk = segment line length having a wall thickness sk (m)

sk = wall thickness (mm)

ri,k = internal pipe radius of segment line (length lt) having a wall thickness sk (mm)
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 24 of 34

2.3.10 Post-testing

2.3.10.1 Depressurization
At the end of hydrostatic test, pressure shall be reduced displacing, to the emptying value
measured at the test plate concerned by the emptying operations.
The emptying pressure shall be equal to the maximum water head on the plate, increased
by 200 kPa, but never less than 500 kPa.
This pressure shall be kept constant throughout the depressurization operations.

Valves used for depressurization shall be opened slowly and depressurizing continued at a
rate that does not generate vibrations in associated pipework. Under normal circumstances,
no fitting of any type should be attached to the pressure let-down valve. If fittings or drain
lines are attached, they shall be adequately braced and tied down to prevent movement.

Under normal circumstances the depressurization rate shall not exceed 0.1 MPa per minute
until the pressure has been reduced to 40 percent of the test pressure. Then
depressurization should continue at a rate of less than 0.2 MPa per minute.

Test pressure shall not be used to transfer water from one test section to another. The
above requirements also apply when the test section must be depressurized for the
rectification of damage/defects during the pressure test.

2.3.10.2 Post-testing activities

Dewatering, drying and inerting activities (refer to Company Specification No.
03526.PLI.MEC.SDS Hydrocarbons Pipelines - Precommissioning) should start
immediately after successful completion of the hydro-test in order to minimize the
permanence of water inside the pipeline. Pipeline filling, testing and evacuation should be
completed within 30 days.

The above can be delayed only if water, during filling stage, had been properly inhibited for
a longer permanence (refer to chapter 2.3.3). This is to prevent any corrosion risk.

Executor shall be responsible of the pipeline preservation until the drying and mothballing
are completed.

2.4 ERGONOMICS
There are no specific ergonomic requirements for the subject of this specification.

2.5 PERSONNEL
The Work shall be carried out at site by experienced personnel [test engineer(s)] who shall
have no other duty during the test activities; they shall continuously attend the operations
necessary for completing each task of the Work.

2.6 HEALTH, SAFETY AND ENVIROMENT

Contractor shall take all necessary measures to ensure that his own personnel, those of the
Company and the general public are adequately protected from the consequences of a
possible system failure during the test activities. Executor shall ensure that no other work is
permitted on the pressurized sections during the period of the test and during the
subsequent depressurizing operations.

Executor shall confirm with Company that he has instructed all employees engaged on
testing work, and or any work associated with testing, of the possible consequences of a
pipeline or test fitting failure under pressure test conditions.
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 25 of 34

The pressurizing pump, pressure relief valve and test cabin shall be located away from
public places, roads and living quarters. The test work sites shall be closed off to
unauthorized personnel. The test heads shall be installed in such a way not to injure the
personnel or third parties in case of disjunction. The test station shall be placed outside the
area concerned by a possible bursting of the test head;
The arrangement of the test equipment and the location of the test work sites shall be
approved by Company.

Warning notices reading "NO ADMITTANCE" shall be placed in all the roads leading to the
place where the pipeline is being tested.

Warning notices reading "KEEP AWAY - PIPELINE UNDER TEST" shall be placed at
appropriate locations where the pipeline is not buried, such as test heads and test sections.

Notices shall be in both English and the local/working language.

The sites shall be provided with a radio or other means of voice communication to provide
contact between all locations associated with the test work sites.

The test equipment shall be earthed to be adequately protected against lightning and
accumulation of static electricity.

Flexible pressurizing or monitoring hoses should not be allowed in the test cabin. They
should be anchored at 5 m intervals and protected against external damage. Hoses should
not pass through doorways. Where hoses pass over walkways they should be protected
against any passing personnel or equipment.

Should there be an extension of the duration of testing, notification of this shall be given by
Executor to the persons detailed above.

All chemicals, including corrosion control products and leak detection dyes, should be
handled as if toxic. Before purchase of these, Executor shall request from the Manufacturer
a technical bulletin and written recommendations for storing and disposal of. Executor shall
be responsible for ensuring that the information contained within the documents is
complete. The test engineer shall ensure that any Manufacturer proposed protective
measures are followed, and that the information is available, known and understood by the
personnel carrying out the Work.

Chemicals shall be stored in the original packing and properly marked. Chemicals should
not be stored in large quantities and should be stored well away from heat and flames.
Protective clothing, gloves and goggles shall be worn when handling chemicals.

The seasonal/environmental status of the source of line-fill water and the dilution and
dispersion of the line-fill water after its use shall be taken into account when specifying the
locations, methods, rates and timing. The test engineer shall ensure that the disposal
recommendations of the manufacturers are implemented.

The Executor shall have the written consent of the owner/local Authorities of any source or
property before any water is taken from or discharged into that source or property.

Water, whether contaminated with chemicals or not, shall not be returned to any water
course, lake, sand dunes, or discharged into the sea, without full permission of the
appropriate local Authorities.

If line-fill water contains millscale and/or rust, separation should be made before
discharging. Line-fill water containing biocides shall not be discharged into water courses
and sewer systems.
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 26 of 34

Any arrangement via evaporating ponds or other approved method suggested by local
Authorities shall be implemented by Executor before discharge of hydrotest water.

Executor shall ensure that the owner of any installation and/or any other person within 1 km
of the point of line-fill discharge is not affected by the discharge. Executor shall obtain
agreement from these persons prior to the discharge.

Executor shall at all times ensure that the noise level does not exceed the regulated limits
within inhabited areas.

During the pressure test, all construction activities within 20 m of the pipeline shall be
interrupted.

Before any other work is permitted, including thightening of leaking flanges, on the pipeline
under pressure or associated connections, the pressure shall be reduced to a level not
greater than static head plus 0.1 MPa. It may be possible to isolate the leaking part by use
of a double block and bleed installation.

Executor shall provide a safety manual including instruction for his own personnel to
perform the testing tasks in a safe manner. Manual shall also include instruction for dealing
emergency situation like pipeline or test equipment leaks or bursts, in order to avoid
damage to persons and environment.

2.7 REQUIREMENTS FOR QUALITY MANAGEMENT AND QUALITY ASSURANCE

The possible Requirements for Quality Management and Quality Assurance requirements
are included in the specification attached to the bid.

2.8 DOCUMENTATION

2.8.1 Preliminary documentation

Adequate procedures shall be issued for the execution of all phases of the Work.
The procedures shall cover, but not limited to, the following topics:

a) List of nominated personnel who are to supervise the tests activities with their
qualification tasks, authorities and responsibilities.
b) Detailed programme giving proposed date and duration of all tests activities for
pipeline.
c) Details of the selected test sections, including assemblies and pre-test sections.

d) Identification of potential safety and environmental hazards, including the

necessary measures and emergency plans.

e) Details of the line-fill water, including the source, treatment method,

discharge/disposal, safety precautions and permits.

f) Details of the test equipment, including layouts and size and/or performance.

g) Details of the test instruments, including datasheets and certificates (not older
than 6 months).

h) Details of the test section preparation, including cleaning, gauging and filling (with
relevant pigging details and procedures).

i) Details of the hydrostatic pressure test preparation, including temperature

stabilisation period.
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 27 of 34

j) Details of the pressure tests, including a procedure for monitoring pressure, flow
and temperature at both ends of the section under testing, and a procedure for
determining the volume of the “residual air” in the filled pipeline.

k) Details of the post-testing activities, including depressurising and documentation.

l) Details of rectification activities, including proposal for locating leaks, dewatering

and leak rectification.

m) Safety manual

2.8.2 Final documentation

Within fourteen (14) days of successful completion of the Work, The Executor shall submit
copies (number as specified in contract documents) of the final test report to Company. The
bound report shall, as a minimum, include the following:

a) Procedure manual(s)

b) Calculations for each individual identified pipeline section including, but not limited
to:

b.1) Calculation for definition of pressure and volume of the fluid necessary for pig
running during cleaning, gauging and filling.

b.2) Plot of ground temperature at laying depth of line pipe and fill water
temperature vs. time.

b.3) Calculation of theoretical amount of debris to be removed during pipeline

cleaning.

b.4) Theoretical and hand plot of pressure vs. volume.

b.5) Hydrostatic test certification in a form agreed by Company, including, but not
limited to:
• Pipeline section identification;
• Pipeline section length;
• Controlling location;
• Pipeline data at controlling location (outside diameter; wall thickness;
specification);
• Test pressure value (minimum and maximum);
• Test medium;
• Start/End Date/Time of test;
• Dead-weight tester location (KP; elevation).

c) Procedures as previously submitted for approval, marked-up with any modifications.

d) Summary of all operations and successful tests in a format agreed by Company.

e) Pig data sheets.

f) Records and photographs of all pigs runs.

g) Records and photographs of all gauging plates.

h) Records of failures and subsequent rectification.

eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 28 of 34

i) Instrument certificates of calibration.

j) Chemicals data sheet & MSDS, Manufacturer name, amount injected and method of
disposal.

k) Records of chemical analysis and inspection tests performed prior to and during test
activities.

l) Profiles of the pipeline showing the elevations and test sites and the entire length of
the test sections reporting all instrument and injection connections.

m) Data recorded during the completion of the activities, organised in applicable log
forms. The log forms shall include, but not limited to, the following main data and
information:

m.1) Environmental data

• barometric data;
• ambient temperature data.

m.2) Dead-weight test log, as obtained by operators.

m.3) Pressure and temperature vs. time logs, obtained by applicable field
recorders. The logs will include, but not limited to, the following data:
• pipeline section identification;
• pipeline section length;
• description of detecting chart recorder instruments (make, model, serial
number, accuracy, etc.);
• location of detecting instruments;
• date and time of start and completion of recording;
• references to project documentation (if any).

m.4) Pressure and temperature vs. time logs, obtained by operators during the
site activities. The logs will include, but not limited to, the following data:
• pipeline section identification;
• pipeline section length;
• location of detecting instruments;
• date and time of start and completion of recording;
• pressure and temperature (pipe and ambient) vs. time.

The enclosures shall be complete of the necessary references, by providing a

permanent write-up with the log-chart instrument or by manual labelling.

n) Significant event record (daily log).

o) Problem areas encountered and method of solution.

p) Check lists, signed and approved.

q) Punch list and outstanding works approved by Company.

eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 29 of 34

3. SUPPLEMENTARY ELEMENTS

3.1 ENCLOUSURES AND INFORMATIVE ANNEXES

3.1.1 Annexes
Annex 1 Diagram of water compressibility - (coefficient “A” Value)
Annex 2 Difference between the water thermal coefficient and the steel expansion
coefficient (°C-1) * 10-6 - (coefficient “B” Value)
Annex 3 Water analysis guideline
Annex 4 Schematic of typical test section
Annex 5 Determination of residual air content in the test section during initial
pressurization

Annex 1: Diagram of water compressibility - (coefficient “A” Value)

A ( bar -1 )

48⋅ 10-6

47⋅ 10-6

46⋅ 10-6

45⋅ 10-6

44⋅ 10-6 Pressure

(bar)

1-10
43⋅ 10-6 20-30
40-50
60-70
80-90
100-110
42⋅ 10-6 120-130
140-150
160-170
180-190
41⋅ 10-6 200-210
220-230
240-250
270-280
290-300
40⋅ 10-6

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

TEMPERATURE IN ° C
 eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 30 of 34

Annex 2 : Difference between the water thermal coefficient and the steel expansion
coefficient (°C-1) * 10-6 - (coefficient “B” Value)

bar/°C
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

0,981 -98,62 -79,89 -61,81 -44,34 -27,47 -11,14 4,66 19,98 34,82 49,22 63,20 76,78 89,99 102,83 115,34

10 -95,55 -76,94 -58,99 -41,65 -24,89 -8,67 7,02 22,23 36,97 51,26 65,15 78,64 91,75 104,51 116,93

20 -92,15 -73,48 -55,86 -38,64 -22,01 -5,92 9,65 24,74 19,36 53,55 67,33 80,71 93,72 106,19 118,21

30 -88,74 -70,40 -52,72 -35,63 -19,14 -3,16 12,29 27,26 41,76 55,84 69,51 82,79 95,70 108,26 120,49

40 -85,32 -67,17 -49,58 -32,62 -16,24 -0,41 14,93 29,78 44,18 58,14 71,70 84,87 97,68 110,14 122,28

50 -81,90 -63,84 -46,43 -29,60 -13,36 2,36 17,57 32,31 46,60 60,45 73,90 86,96 99,68 112,04 124,02

60 -78,47 -60,55 -43,27 -26,58 -10,46 5,15 20,23 34,85 49,02 62,76 76,10 89,02 102,67 113,93 125,88

70 -75,03 -57,25 -40,10 -23,54 -7,56 7,97 22,89 37,39 51,44 65,08 78,32 91,17 103,68 115,84 127,69

80 -71,60 -53,96 -36,94 -20,51 -4,65 10,70 25,55 39,94 53,68 67,40 80,53 93,29 105,69 117,76 129,50

90 -68,16 -50,66 -33,77 -17,47 -1,73 13,50 28,23 42,50 56,32 69,73 82,75 95,41 107,70 119,67 131,32

100 -64,72 -47,35 -30,66 -14,43 1,18 16,29 30,90 45,05 58,77 72,07 84,98 97,53 109,73 121,59 133,15

110 -61,78 -44,05 -27,43 -11,38 4,10 19,08 33,58 47,61 61,21 74,41 87,22 99,66 111,75 123,52 134,98

120 -57,84 -40,74 -24,26 -8,34 7,07 21,88 36,26 50,18 63,62 76,74 89,45 101,79 113,79 125,46 136,82

130 -54,40 -37,44 -21,08 -5,29 9,95 24,68 38,94 52,75 66,12 79,09 91,69 103,93 115,83 127,39 138,67

140 -50,96 -34,13 -17,90 -2,25 12,87 27,49 41,63 55,32 68,58 81,45 93,93 106,07 117,87 129,34 140,51

150 -47,53 -30,83 -14,73 0,80 15,79 30,24 44,31 57,89 71,05 83,80 96,18 108,21 119,90 131,28 142,32

160 -44,10 -27,53 -11,56 3,85 18,72 33,10 47,00 60,46 73,51 86,15 98,43 110,36 121,96 133,24 144,22

170 -40,67 -24,23 -8,40 6,89 21,84 35,90 49,69 63,04 75,97 88,51 100,68 112,51 124,01 135,19 146,08

180 -37,74 -20,94 -5,23 9,94 24,56 38,70 52,37 65,62 78,44 90,87 102,94 114,66 126,06 137,15 147,94

190 -33,83 -17,65 -2,06 17,98 27,48 41,51 55,06 68,19 80,91 93,23 105,19 116,82 128,12 139,11 149,81

200 -30,42 -14,37 1,09 16,01 30,40 44,30 57,75 70,77 83,37 95,59 107,45 118,97 130,17 141,02 151,68

210 -27,02 -11,09 4,25 19,04 33,31 47,10 60,43 73,34 85,84 97,95 109,71 121,13 132,24 143,03 153,55

220 -23,63 -7,82 7,40 22,06 36,22 49,90 63,12 75,90 88,30 100,31 111,97 123,29 134,29 144,99 155,42

230 -20,24 -4,56 10,54 25,08 39,13 57,69 65,80 78,48 90,67 102,67 114,23 125,45 136,36 146,96 157,30

240 -16,87 -1,30 13,67 28,10 42,03 55,48 68,48 81,05 93,22 105,03 116,48 127,60 138,42 148,93 159,18

250 -13,50 1,94 16,79 31,11 44,92 58,76 71,15 83,61 95,69 107,39 118,74 129,76 140,48 150,90 161,05

260 -10,14 5,17 19,90 34,12 47,81 61,04 73,81 86,81 98,14 109,74 121,00 131,92 142,54 152,87 162,93

270 -6,80 8,39 23,00 37,11 50,69 63,80 76,48 88,73 100,60 112,10 123,25 134,08 144,61 154,84 164,81

280 -3,48 11,50 26,11 40,09 53,56 66,57 79,14 91,29 103,05 114,44 125,50 136,24 146,67 156,81 166,69

290 -0,17 14,80 29,19 43,07 56,43 69,33 81,78 93,83 105,50 116,79 127,75 138,39 148,73 158,78 168,57

300 3,13 17,98 37,77 46,03 59,29 72,08 84,83 96,38 107,94 119,13 130,00 140,54 150,79 160,75 170,45
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 31 of 34

(Annex 2) : Difference between the water thermal coefficient and the steel expansion
coefficient (oC-1) *10-6 - (coefficient “B” Value)

bar/°C
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

0,981 127,52 139,41 151,00 162,31 173,37 184,18 194,75 205,08 215,22 225,14 234,88 244,41 253,79 263,00 272,03

10 129,02 140,83 152,36 163,58 174,56 185,30 195,79 206,07 216,13 225,99 235,66 245,13 254,44 264,59 272,57

20 130,71 142,42 153,85 165,00 175,90 186,55 196,96 207,16 217,15 226,94 236,53 245,94 255,18 264,27 273,18

30 132,40 144,02 155,35 166,42 177,23 187,80 198,14 208,26 218,18 227,88 237,41 246,75 255,93 264,95 273,80

40 134,10 145,62 156,87 167,85 178,58 189,07 199,33 209,37 219,21 228,84 238,30 247,58 256,69 265,64 274,42

50 135,80 147,24 158,39 169,29 179,93 190,34 200,52 210,49 220,25 229,82 239,20 248,40 257,45 266,33 275,02

60 137,51 148,86 159,92 170,73 181,29 191,62 201,72 211,61 221,30 230,79 240,11 249,24 258,22 267,04 275,70

70 139,22 150,49 161,46 172,18 182,66 192,91 202,93 212,74 222,35 231,78 241,02 250,08 258,99 267,75 276,35

80 140,95 152,11 163,00 173,64 184,03 194,20 204,14 213,88 223,42 232,77 241,94 250,93 259,78 268,47 277,01

90 142,67 153,75 164,56 175,10 185,41 195,50 205,36 215,03 224,48 233,76 242,87 251,79 260,57 269,19 277,66

100 144,42 155,40 166,11 176,58 186,80 196,80 206,59 216,17 225,56 234,76 243,79 252,66 261,36 269,92 278,33

110 146,15 157,04 167,67 178,05 188,20 198,12 207,82 217,33 226,64 235,78 244,73 253,53 262,17 270,77 279,01

120 147,90 158,70 169,24 179,54 189,59 199,44 209,06 218,49 227,73 236,79 245,68 254,40 262,98 271,41 279,69

130 149,65 160,36 170,81 181,02 191,00 200,75 210,31 219,66 228,82 237,81 246,63 255,28 263,69 272,16 280,38

140 151,40 162,03 172,39 182,51 192,41 202,09 211,56 220,84 229,92 238,84 247,59 256,18 264,62 172,92 281,08

150 153,16 163,70 173,98 184,00 193,82 203,42 212,81 222,02 231,03 239,87 248,55 257,07 265,44 273,69 281,78

160 154,93 165,37 175,56 185,51 195,24 204,76 214,08 223,20 232,14 240,91 249,52 257,97 266,78 274,46 282,49

170 156,69 167,05 177,15 187,02 196,66 206,10 215,34 224,39 233,26 241,96 250,49 258,88 267,12 275,23 283,20

180 158,47 168,73 178,75 188,53 198,09 207,45 216,61 225,58 234,38 243,01 251,47 259,79 267,97 276,01 283,92

190 160,24 170,42 180,35 190,05 199,52 208,80 217,89 226,79 235,51 244,06 252,46 260,71 268,82 276,80 284,64

200 162,01 172,10 181,95 191,57 200,97 210,16 219,17 227,99 236,64 245,12 253,45 261,63 269,67 277,59 285,37

210 163,80 173,80 183,55 193,09 202,40 211,53 220,48 229,20 237,77 246,18 254,45 262,56 270,54 278,39 286,11

220 165,58 175,49 185,16 194,62 203,85 212,89 221,74 230,41 238,91 247,26 255,45 263,49 271,40 279,19 286,85

230 167,36 177,19 186,78 196,14 205,30 214,26 223,04 231,63 240,06 248,33 256,46 264,43 272,28 280,00 287,59

240 169,16 178,89 188,39 197,68 206,75 215,63 224,33 232,85 241,21 249,41 257,46 265,37 273,16 280,82 288,75

250 170,94 180,59 190,01 199,21 208,20 217,00 225,63 234,08 242,36 250,49 258,48 266,31 274,04 281,63 289,11

260 172,73 182,30 191,63 200,75 209,66 218,40 226,93 235,31 243,52 251,58 259,49 267,27 274,92 282,46 289,86

270 174,53 184,00 193,25 202,29 211,12 219,77 228,24 236,54 244,68 252,66 260,52 268,23 275,82 283,29 290,64

280 176,32 185,70 194,88 203,83 212,59 221,16 229,55 237,77 245,84 253,76 261,54 269,18 276,71 284,12 291,40

290 178,11 187,47 196,50 205,37 214,05 222,54 230,86 239,01 247,01 254,86 262,57 270,15 277,61 284,95 292,18

300 179,90 189,13 198,13 206,92 215,51 223,93 232,18 240,26 248,18 255,96 263,60 271,11 278,51 285,79 292,95
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 32 of 34

Annex 3: Water analysis guideline

The water sample must be fully representative of the water source to be used for
the line fill. Water sampling shall be by means of clean and sterile bottle and done
possibility in the same position where water for the line fill be kept.

Physical-chemical analyses shall be performed following international applicable

standards. Bacterial analysis hall be by means of the MPN (Most Probable
Number) method.

Suggested analyses are listed in the table below.

TYPE OF ANALYSIS UNIT

Temperature °C
Suspended Solids mg/l
Settleable Matter ml/l
Total Dissolved Solids mg/l
pH
Calcium mg/l
Alkalinity mg/l CaCO3
Temporary Hardness mg/l CaCO3
Chloride mg/l
Sulphate mg/l
COD mg/l
Sulphate Reducing Bacteria cfu/ml
eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 33 of 34

Annex 4: Schematic of typical test section

eni spa 03517.PLI.MEC.SDS
Rev.3 July 2012
exploration & production division
Sh. 34 of 34

Annex 5: Determination of residual air content in the test section during initial
pressurization