490 PROJECT : ALRAYAN –JANDAR Gas Pipeline Project

Contract No 16/2012
Company:

SGC – Syrian Gas Company

Contractor:

ASAS Contracting Ltd.

0 00/03/2013 Issued for review M.HADIDI

Rev. Date Description Prepared Checked Approved by SGC Approval

by by
Document Title:
HYDROSTATIC TESTING PROCEDURE

Document Type: Inspection and Test Procedure Rev.

Document No.: E 03-01 0

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Company: Contractor:

PROJECT: ALRAYAN –JANDAR Gas Pipeline Project

Contract No 16/2012
Document Title: Hydrostatic Testing Procedure Document No.: E 03-01

CONTENTS

Item Description page

1 Introduction 3
2 Scope 3
3 Sequence of Operations 3
4 References and Codes 3
5 Responsibilities 4
6 Safety Consideration 4
7 Personnel Qualification 7
8 Equipment, Instruments and consumables 7
9 Test Sections 11
10 Cleaning 11
11 Gauging 12
12 Water Filling 13
13 Requirements Prior to Hydrostatic Testing 15
14 Hydrostatic Test Pressure 18
15 Leak Detection During Hydrostatic Test 20
16 Depressurization 20
17 Bulk Dewatering 20
18 Hydrostatic Documentation 21
19 Attachments 22

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Company: Contractor:

PROJECT: ALRAYAN –JANDAR Gas Pipeline Project

Contract No 16/2012
Document Title: Hydrostatic Testing Procedure Document No.: E 03-01

1. INTRODUCTION
This procedure shall specify the minimum requirements and steps to be followed during
Hydrostatic test as stated in the approved codes, standards and specifications.
2. SCOPE
This procedure shall apply to hydrostatic testing following steps: cleaning, gauging, Hydrostatic
testing and Bulk Dewatering of pipeline and piping sections for ARAYAN – JANDER Gas
Pipeline Project without any harm to people or damage to environment.
3. SEQUENCE OF OPERARIONS

3.1. Pipeline
Sequence of operations for each pipeline test section shall be as follows:
 Water cleaning
 Gauging
 Water filling
 Pressurization (entrapped air test)
 Temperature stabilization
 Strength test
 Leak test
 Depressurization
 Bulk dewatering (if required)
 Removal of temporary pipework and facilities
3.2. Station Piping
Sequence of operations for testing the station pipework as a separate unit, shall be as
follows:
 Water cleaning
 Filling
 Pressurization (entrapped air test)
 Combined strength and leak test
 Depressurization
 Dewatering
 Final tie-in work and removal of temporary pipework and facilities
4. REFERENCES AND CODES

 Contract terms and specifications

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Company: Contractor:

PROJECT: ALRAYAN –JANDAR Gas Pipeline Project

Contract No 16/2012
Document Title: Hydrostatic Testing Procedure Document No.: E 03-01

 AFPC Specification PL-CP - Construction Practices for Pipelines

 ASME B 31.8 - Gas Transmission and Distribution Piping Systems

 API RP 1110 - Pressure Testing of Steel Pipelines for the Transportation of Gas

5. RESPONSIBILITIES

Contractor shall be responsible for safety requirements for all employees engaged in
testing work activities and consequences of a pipe or fitting failure under pressure test
conditions and carry out all co-ordinations required with all third parties.
Hydrostatic testing operations shall be carried out by an experienced test engineer who
shall have no other duties during the hydrostatic testing operations
Contractor shall provide Company:
 A list of nominated personnel who are to supervise the pressure test operations with their
qualifications, tasks, responsibilities and authorities.
Detailed schedule giving proposed dates of main activities, test and mobilization and date
of main personnel.
 Details of the selected sections, including assemblies and pre – test sections.
 Details regarding the hydrostatic testing activities including this procedure, program and
schedule for the work.
 Provide with the necessary quality and quantity of the water supply for the hydrostatic
testing.
 Supply all materials, consumables, equipment, spares, labor, supervision and other
services incidental to and necessary for safe and successful performance of the
hydrostatic testing work in a satisfactory manner for the Company.
 Identify potential environmental hazards, including the necessary measures for on land
water disposal
6. SAFETY

While applying this procedure Contractor’s HSE manual approved by Company shall be adhered
to. Emphasis shall be given to the followings issues:

 HSE manager shall be consulted for planning and implementation of safety issues.
 Ensuring that all workers involved in hydro test works are properly instructed regarding
prescribed steps to be taken prior pneumatic and hydrostatic tests being carried out for all
test packages

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Company: Contractor:

PROJECT: ALRAYAN –JANDAR Gas Pipeline Project

Contract No 16/2012
Document Title: Hydrostatic Testing Procedure Document No.: E 03-01

 Warning of the hazards associated with the energy stored within a pipe under test; in
particular the energy stored within a pipe containing water and air shall be given to
employees.
 Safety of employees engaged in testing work, or work associated with testing in particular
due to the energy stored within line pipe containing water and air and possible
consequences of pipe and fittings failure under pressure test conditions.
 Safety of public and environment as a sequence of hydro testing failure.
 Discharge of test water to land at the end of hydro pressure test.
 No works are permitted on the pressurized sections during the period of the test and
during subsequent pressure reducing operations.
 Monitoring special points of hazard during the identified section test, as in particular road
crossings and points of public access.
 Providing warning notices “Warning! Pipeline is under Test” in English and Arabic
Languages, such as:

ATTENTION!
PIPELINE UNDER TEST
KEEP AWAY
‫انتباه‬
‫تجارب ضغط خط الغاز‬
‫ممنوع التوقف‬

 Providing boundaries of the test equipment. The locations shall be defined by marker
tapes or a fence and by lights at night.
 Assuring no person approaching within 30 m of the test end manifold on pipe before
pressurizing the test section and during the test.
 Locating pressurizing pump, pressure release valve and instrument caravan in a safe
area.

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PROJECT: ALRAYAN –JANDAR Gas Pipeline Project

Contract No 16/2012
Document Title: Hydrostatic Testing Procedure Document No.: E 03-01

 Communication shall be available to provide good tracing of the work and good
controlling for every event. Such communication will be mobile phones and the number of
these phones will be provided to the Company before any activity started.
 Only authorized personnel shall be allowed to approach of the work area.
 The hydrostatic test caravan and machine shall be located at accessible area and away
from the public activities.
 Pressure pump, test cabin and other ancillaries shall be placed at a distance of at least 30
m from the test manifold.
 Distribution hoses must be the correct size and suitable for the expected maximum
working pressure and will be perfectly supported.
 The tightness of compression fittings must be checked regularly.
 Use only the correct type and size of hose and fittings and connections, as clamps
especially made for compressed air.
 Approved PPE for eye, ear, skin, body and head shall be available.
 Never apply compressed air to the skin or direct it to a person, even air pressure of 1 bar
can cause serious injury.
 Never operate any part of a compressed air system at a higher pressure than that for
which it has been designed and rated.
 Shut off the isolating valve and release the air pressure before disconnection a hose or
line.
 Dry powder fire extinguishers have to be available at equipment location.
 During Operation: Check all pressures and temperatures are correct.
 During Operation:
 Don’t make adjustment when a machine is running unless appropriate precaution is
taken.
 Don’t use the machine in a fire hazard area.
 Ensure that all pneumatic control equipment and airline accessories are always
operated below their maximum rated pressure and temperature.

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PROJECT: ALRAYAN –JANDAR Gas Pipeline Project

Contract No 16/2012
Document Title: Hydrostatic Testing Procedure Document No.: E 03-01

 Replace hoses which have the signs of cracking or any mechanical damage are
evident.
Launcher and / or Receiver Location nearby populated area will be avoided, if they are, an
additional safety personnel will be required, to prevent any unauthorized person from
approaching the above ground parts of the pipe and also the launcher and receiver.

7. PERSONNEL QUALIFICATION
Only qualified and well experienced personnel shall be selected for carrying out the activities
involved within this procedure.
8. EQUIPMENTS INSTRUMENTS AND CONSUMABLES
Contractor shall provide the required equipment, instrument and consumable needed for
conducting the activities involved with the procedure.
8.1. Calibration Certificates/Certificate
The Contractor shall prepare the following certificate for the calibration of the following, prior
starting hydrostatic test:
 Pressure gauges
 Pressure records
 Dead weight tester
 Thermometers
 Dew point meter

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PROJECT: ALRAYAN –JANDAR Gas Pipeline Project

Contract No 16/2012
Document Title: Hydrostatic Testing Procedure Document No.: E 03-01

8.2. Equipment and instruments

Ser. Item QYT

No.

1 Air Compressors of 24 m3/min 2

2 Filing Pumps of 35 m3/h 1

3 Pressurizing pumps of 200 bar 1

4 Breaking water tank of 35 m3 1

5 Air conditioned test cabinet : 1

With necessary gauges, recorders, deadweight tester,
barometer

6 Filling/ pressurizing flow meter and temperature probe 1

7 Pipe wall temperature recorder 2

8 Pressure recorder 2

9 Ambient temperature recorder 1

10 Soil temperature probe and recorder 2

11 Pressure relieve valve 1

12 Head test launcher and receiver 4

15 Communication equipment As required

17 Generator 1

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Company: Contractor:

PROJECT: ALRAYAN –JANDAR Gas Pipeline Project

Contract No 16/2012
Document Title: Hydrostatic Testing Procedure Document No.: E 03-01

8.3. Specifications of test equipment:

Instrument Reading divisions Range

Dead weight tester 0.05 bar 0-1.5 TP

Pressure data logger 0.05 bar 0-1.5 TP

Pressure gauge 1.2-5 bar 0-1.5 TP

Pressure recorder 24 h. 2-5 bar 0-1.5 TP

Filling flow meter turbine M3 /h -

Pressurizing flow meter Strokes/liter -

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Company: Contractor:

PROJECT: ALRAYAN –JANDAR Gas Pipeline Project

Contract No 16/2012
Document Title: Hydrostatic Testing Procedure Document No.: E 03-01

8.4. Consumables:

Ser
Item Descriptions
. QYT
No.
1 24 in Bi – directional pig equipped with 2 guide/ support discs and 6
4 scraper /seal discs (Complete Set) – for cleaning and filling
 With spare sealing Discs
 with spare guiding Discs
2 24 in. Cleaning pig equipped with 3 scraper / seal discs and 1 6
brush wraps (Complete Set) – And
 With spare caps
 With spare brushes
 With spare spring blades
24 in. Bi – Batching pig equipped with 4 Conical cups (Complete
4 6
Set
24 in. Scarlet Crisscross Hard foam with wire brushes pig-for
5 6
scraping
6 24 in. Scarlet Crisscross Hard foam pig-for heavy scraping 6
7 24 in. Poly foam Scarlet bare –for drying 10
8 24 in. Poly foam ( red Swab ) – for drying 5
9 24 in soft foam pigs 50
11 Aluminum gauging plate ( Locally) 6
Note:
1. Pigs shall be designed for passing 1.5 radius bend and transverse a full
size branch opening

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PROJECT: ALRAYAN –JANDAR Gas Pipeline Project

Contract No 16/2012
Document Title: Hydrostatic Testing Procedure Document No.: E 03-01

2. Pigs will be provided by SAVAY Product Engineering Department, see

Appendix N0.11

9. TEST SECTIONS
Gas pipeline will be divided into 3 separate sections for hydrostatic test. Date of each section
shall be registered in a report form as identified in Appendix (1) – Test Section Data sheet.
Schematic drawing of each test section, showing filling and pressurizing point, test pressure,
elevation, differential elevation, theoretical length of the section and volume, theoretical volume
to pressurizing per Appendixes: 1 – 1; 1 – 2 and 1 – 3
10. CLEANING
Prior to section cleaning, Contactor shall submit:
 Approved Section Release for Hydrostatic test – Appendix No.2
 Approved Section cleaning report form – Appendix No.3
 Approved Pig Launcher and Receiver head test drawing - Appendix No. 4

10.1. Air Blowing:

Contractor shall pass air through the pipeline for period of 3 hours at minimum speed of 3 m/s
in order to blow out all loose welding slag, sand and debris from the pipeline.

Contractor shall install an impingement plate at the receiving end to ensure that pipeline debris
carried by the air is deflected to the ground.

All personnel at the receiving end will wear eye protection goggles.

Compressors shall supply oil free air with suitable rates to ensure a pig travelling speed
controllable between 1.2 and 1.7 m/sec.

Compressors shall be equipped with non-return valve at the outer let, pressure regulating
device and relieve valve set at 15 bars.

10.2. Brush Pig Cleaning:

Cleaning will be accomplished by pushing a Two Caps Wire Brush Pigs run through the
tested section of the pipeline.

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Company: Contractor:

PROJECT: ALRAYAN –JANDAR Gas Pipeline Project

Contract No 16/2012
Document Title: Hydrostatic Testing Procedure Document No.: E 03-01

A minimum of 2 brush pigs runs will be carried out

Each brush pig will be launched individually and propelled with compressed air through the
entire test section until retrieved at the pig receiver.

When the pig arrives to the pig receiver, the section shall be depressurized and the pig shall
be taken out.

Pressure gauge with suitable range (0-10) bar will be place on the pig launcher.

A report shall be kept for all pigging runs according to Appendix No. 3.

If the pig becomes stuck, the pressure shall be increased up to 7 bars; the location will be
identified by sending another pig with locator to determine location of stuck pig. The pipe shall
be exposed and the cause shall be investigated and repaired to the satisfaction of SGC

11. GAUGING

An aluminum gauging plate of diameter at least (d = 564.00 mm) (0.96x 586.2=562.75 mm)
shall be fitted on stiff pig (disc pig or 4 cup pig) to run through each section propelled by
water to confirm the geometric integrity of the section.

The gauging plate diameter shall be at least 562.70 mm which is 96% of the smallest pipe
internal diameter.

Where the following factors have been taken into consideration:

- The clearance ( 6 mm for each side )
- Tolerance for Diameter of pipe body = 0.25% of OD = (610 x 0.25%) = 1.525 mm
- Tolerance for Diameter of pipe End = 1% of OD = 610 x 0.01= 6.1 mm
- Tolerance for Wall thickness.- maximum 10% of wall thickness = 11.9 x 0.2 = 2.38 mm
D=610-1.52=608.475 mm
Diameter of gauging plate, d:
d = 608.475 – 11.9x2 – 6.1 – 2.38 – 12 =
d = 608.475 – 23.8 – 6.1 – 2.38 – 12 = 557.595 mm
d = 564.195 mm
d = 564.20 mm
Do= 610 – 23.8 = 586.2 mm

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Company: Contractor:

PROJECT: ALRAYAN –JANDAR Gas Pipeline Project

Contract No 16/2012
Document Title: Hydrostatic Testing Procedure Document No.: E 03-01

d/D0 = 564.00/586.2=0.9621

d = 564.20 mm

Internal diameter:

610 mm – 2x11.9 mm = 610 – 23.8 = 586.20 mm

Total clearance:

586.20 – 564.20 = 22.0 mm

28.6/2= 11.0 mm

Aluminum plate 10 mm thickness with edge will be machined with 4 mm shoulder and 45
degree bevel shall be used as a gauging plate.

Gauging plate shall be identified with section number, pipeline kilometers and date of test.

Gauging pig velocity should be approximately 0.6 m/s and should not exceed 1.7m/s.

The gauging plate shall be inspected by the Company before it is used and after it is removed
from the manifold. The following activities shall be undertaken in the presence of the
Company’s hydrostatic test representative:

 Measurement and recording of the cup/disc and gauge plate dimensions, immediately
prior to gauge pig installation.

 Installation in and removal of the gauging pig from the pipeline.

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Company: Contractor:

PROJECT: ALRAYAN –JANDAR Gas Pipeline Project

Contract No 16/2012
Document Title: Hydrostatic Testing Procedure Document No.: E 03-01

 Measurement and recording of the gauge plate dimensions immediately after gauge
pig removal.

All recovered pigs shall be carefully examined to establish the degree of wear or damage to
cups or discs.

All Measurements of the cup/disc dimensions shall be taken and the results recorded in a
report form. See appendix No. 5. The results of the pig run shall be analyzed and the
evaluation submitted to Company within 24 hours.

Contractor shall determine the cause and make all necessary repairs of the pipeline if the
gauging plate shows any damage.

Should a gauging pig get stuck in the pipeline, the contractor shall not employ pressure
greater than the cleaning pressure (7 bars) to dislodge it.

If 7 bar is insufficient to dislodge the pig, the pig must be located and removed from the
pipeline by back pressure (applying pressure at the receiver end) or by cutting or other
method to be approved by company.

Contractor shall determine the cause and make all necessary repairs of the pipeline if the
gauging plate shows any damage.

Contractor shall not proceed with the testing procedure before the rerun gauging plate is
accepted by Company.

12. WATER FILLING

12.1. Material and equipment
 High volume pump with a sufficient capacity will be connected to the test manifold with
good tighten and high pressure flexible hoses or 2” high pressure pipe on the outlet.
 Two Filling Pigs with 4 cups type will be used for water filling to preclude the
possibility of air and/or water by passing them
 Water meter, a recording pressure gauge and pressure gauge shall be installed at fill
point to aid in determining the location of the filling pig.
 A pressure gauge shall be installed at the receiving end to facilitate checking the back
pressure.

12.2. Water filling process

During water filling:

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PROJECT: ALRAYAN –JANDAR Gas Pipeline Project

Contract No 16/2012
Document Title: Hydrostatic Testing Procedure Document No.: E 03-01

 All line valves if any shall be fully opened.

 Filling rate shall be providing maximum velocity of pig to be less than 2 m/sec.
 Flow meter shall be installed between the break tank and the filling pump.
 Portable tank with an adequate capacity shall be installed and connected to the suction
of the filling pump.
 Pressure recorder and gauge (l.5 time of reading) shall be placed at test manifold and
gauge shall be placed at pig receiver.
 All necessary measures shall be taken to remove the air from the line during filling
operation. Such measure shall include, but shall not necessarily be limited to:
o Controlling the filling rate by controlling pig velocity of 2 m/s maximum
o Limitation or elimination of fill pump shut down
o Use of break tank between the water supply source and fill pump
o Maintaining a suitable back pressure against the fill pigs, dependent on pipeline
elevations

12.3. Calculation of filling water volume

Volume of filling water in each section is calculated as follows:

2
D
V =π ×L
4

Where:

V: Line volume (m3)

D: Inside diameter (m)

L: Section length (m)

For 1 Km length, the volume of required water for filling will be:
2
(0.593) 3
V =Π × ×1000=272m /km
4

Filling shall be continuing up to all interrupted air is disposed and calculation check is done.

Contractor will transfer the water from the tested section to another section.

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PROJECT: ALRAYAN –JANDAR Gas Pipeline Project

Contract No 16/2012
Document Title: Hydrostatic Testing Procedure Document No.: E 03-01

Water source will be from the wells in the local area. Water quality as specified in PL-CP
specifications.

Water filling data shall be fulfilled in a water filling report, see Appendix No. 6.

13. REQUIREMENT PRIOR TO HYDROSTATIC TESTING

13.1. Requirements prior to pressurizing

A pre-check shall be performed, detailing the status and location of each item to be inspected
before pressurizing is commenced. This shall include as a minimum:
 The test section has been isolated from all other pipeline sections.
 All the temporary piping, test head and other equipment connected to test section have
been tested to a pressure of at least 1.5 times the test pressure.
 The test section has been filled completely and air has been vented off.
 All instruments and gauging to be used during pressurization and testing have been
calibrated and valid test certificate have been approved by Company and available
 All warning notices “The Pipeline Under Test”, markers, protective barriers and other
safety equipment have been positioned and appropriate authorities have been informed
 All relevant personnel at the affected section have been informed of the commencement
and duration of the hydro test
 The personnel engaged in the testing work have been briefed on the emergency plan
 The person operating the pressurizing equipment has been instructed by the test
engineer regarding the limiting pressure which shall apply to the test section
 Pressurizing equipment and other ancillaries have been placed at a distance of at least
30 m from test manifold
 The thermo couple type temperature recorders (soil temperature recorder) 24 hours
before starting the pressure test have been placed at a distance of 100 m from the
buried end of the test section
 All temporary and permanent valves have blinded prior to start the test
 All flexible hoses have been fixes by approved method

13.2. TEMPERATURE STABILIZATION

Prior to commence the hydrostatic test, there shall be a stabilization period in which the
temperature of the water in the line shall increase or decrease to within 5.0 oC of soil
temperature. This shall be determined as the difference between average water pipe
temperature and average ground temperature over the test section length.

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PROJECT: ALRAYAN –JANDAR Gas Pipeline Project

Contract No 16/2012
Document Title: Hydrostatic Testing Procedure Document No.: E 03-01

During the stabilization period the following measurements shall be taken and recorded every
1 hour:
 Line pressure
 Pipe water temperature
 Soil temperature
 Air temperature

Measured data shall be registered in a report form as indicated in appendix No. 7

13.3. PRESSURIZATION UP TO 35 BARS FOR CALCULATION OF AIR INCLUSION

Contractor, after stabilization, shall carry out pressurization using a positive displacement
pump at a rate 1 bar/min.
The pressurization shall be recorded according to form shown in Appendix No. 8
The volume of water used to pressurize the section shall be measurement by add/bleed
method.
When the pressure reaches (35 bars), the pumping shall be stopped and leak check to be
carried out at the ends of the sections.
Leaks, if any, shall be defined, evaluated, repaired to the Company satisfaction, after reducing
the head pressure and re-pressurizing resumed up to (35 bars) as mentioned in the above
sequence.
13.4. AIR CONTENT DETERMINATION
The air content of the filled line shall be determined during initial pressurization by using
pressure/added volume plot as specified in Figure 1. The linear section of the curve shall be
extrapolated to the volume axis, which shall correspond to static head pressure. The volume of
air can be read from the intersection of the line with the volume axis and shall be used to
calculate the air content:

Volume of air
Percentage of air content = ×100
Volume of line

The test engineer shall draw a plot of pressure add/bleed volume (P/V plot) see Figure 1,
taking the volume added as measured either by pump strokes or flow meter and pressure as
measured by dead weight tester or pressure date logger. A tank should be available to enable
the volume rating of the pressurizing pump or flow meter to be checked. The rate of the
pressurization should be constant and should not exceed 1 bar/minute until a pressure of 35
bars has been attained. During this period, volume and pressure reading should be recorded
at 1 bar intervals.

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PROJECT: ALRAYAN –JANDAR Gas Pipeline Project

Contract No 16/2012
Document Title: Hydrostatic Testing Procedure Document No.: E 03-01

If the measured volume of entrapped air, reduced to atmospheric pressure, is less than 0.2%
of the test section volume thin filling of the line will be deemed acceptable for proceeding with
the hydrostatic test.
If the volume of the entrapped air exceeds 0.2% then Contractor shall take measures to
reduce the quantity of air in the test section, either by venting or by refilling the line. In any
case the line shall be fully depressurized and another air entrapment test shall be carried out
to determine acceptability of the filling operation

FIG.1. DETRMINATION OF RESIDUAL AIR VOLUME

The person operating the pressurizing equipment shall immediately report to the test engineer
any variation in the rate of pressure increase resulting from the same volume added water.
During pressurization, all potential leak points shall be checked. When the pressure of 35 bars
has been reached, the air content shall be determined.

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Contract No 16/2012
Document Title: Hydrostatic Testing Procedure Document No.: E 03-01

When the air content is within the maximum allowable limit of 0.2% of the test section, volume
pressurization should continue, at the rate of 1 bar/minute maximum as follows:
If the flanges are installed, pressurization shall continue up to 70 bars and held whilst the
flanges are checked for leaks. this is the highest pressure permitted at which any leaking
flanges may be tightened up.
Pressurization shall continue up 90 bars and shall be held for 2 h., during this period, if any
leak found, the test section shall be depressurized at a rate not more than 2 bars /minute down
to 70 bars prior to any bolt tighting.
The volume and pressure readings should be raised to 95 bars and held for 30 minutes, and
then the pressurization should continue to the 99 bars as slow as possible, at a rate not
exceeding 0.5 bars/ minute
During pressurization, actual hydrostatic test and bleeding operations, all globe, gate and ball
valves shall be fully opened
During this period, the pressure and added volume should be continuously plotted until 99 bars
pressure have been attained. The plot should be constantly checked and, in the event of any
deviation of 10 % or more from the theoretical line corresponding to 100% 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.

14. HYDROSTATIC PRESUURE TEST

14.1. DURATION OF HYDROSTATIC TEST
The duration for hydrostatic pressure test shall be 4 hours followed by a 24 hours leak
tightness test. The strength test is a specific procedure to verify that the pipe line meets the
requirements of mechanical strength and the leak tightness test is a specific procedure to
verify that the pipe line meets the requirements for tightness.
8.2. STRENGTH TEST
Minimum strength test pressure shall be 93.75 bars.
Maximum pressure will be 98.75 Bars.

Company shall confirm that the TP does not exceed the pressure to which the pipe has been
subjected during the mill test and that it is higher than the test pressure of the fittings specified
for the pipeline.

The pressure test shall be maintained during the strength test at TP ± 1bar by bleeding or
adding water as required. The volumes of water added or removed shall be measured and
recorded.

During the strength test the following shall be recorded:

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Contract No 16/2012
Document Title: Hydrostatic Testing Procedure Document No.: E 03-01

 Test pressure (dead weight tester readings)

 Soil temperature
 Pipe temperature

Every 30 minutes from the start to the end of strength test.

 Air temperature
 Barometric pressure

Every 3 hours.

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

If any leak is found during the strength test then the test shall be discontinued and necessary
repairs made. Contractor shall supply, install and tighten gland packing on those valves that
leak during hydrostatic test.

8.3. LEAKTIGHTNESS TEST

8.3.1 General

The leak tightness test should commence immediately after the strength test have completed
satisfactorily. No water shall be added or removed during the tightness test.

The test is intended to demonstrate that there is no leak in the pipeline.

To allow pressure variation caused by temperature fluctuation during the test duration, the leak
tightness test pressure shall be combined strength/ leak tightness test at strength test
pressure, without water addition or removal. Pressure variation due to temperature fluctuation
shall be controlled so that the PT will not exceed 99 bars.

During the test, the pressure shall be recorded continuously, and the dead weight tester and
air temperature shall be recorded every 30 minutes. The pipe and soil temperature shall be
recorded at maximum 3 hours intervals. The temperature recording interval should be reduced
to a1 hour duration for the first and last 3 hours periods of the 24 hours to assist with the
pressure/temperature variation calculation. The test section temperature and ambient
temperature against time plot create for the stabilization period should be maintained.

8.3.2 Assessment of strength and leak test

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PROJECT: ALRAYAN –JANDAR Gas Pipeline Project

Contract No 16/2012
Document Title: Hydrostatic Testing Procedure Document No.: E 03-01

On the basis of pressure and temperature measurements made during 24 hours leak and
measurements recorded during the entrapped air test, and taking into account possible
inaccuracies in measured or assumed parameters, CONTRACTOR shall demonstrate to
COMPANY’s satisfaction that the section under test has not leaked during leak test period.

The pressure, the test section temperature and ambient temperature should be plotted against
time during the period of the leak tightness test.
The tightness test shall be deemed acceptable if any change can be accounted for by
corresponding temperature change using formula above. Allowance should be made for any
recording inaccuracy.
If the event of any doubt about the leak tightness of the line, for example if the temperature
and pressure trends are different, the test shall be extended until such time as the acceptability
can be demonstrated.
Section Hydrostatic Testing Acceptance Report will be filled as shown in Appendix No. 9
15. LEAK DETECTION DURING HYDROSTAIC TEST
If a leak is suspected, the Contractor shall reduce the pressure to less than 79 Bars and carry
out visual examinations and due means for locating the leak without endangering the
personnel carrying out the work.

16. DEPRESSUTIZATION
After the satisfactory completion of 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 depressurization continued at a rate that
does generate vibrations in associated pipe work.
The depressurization should not exceed 1 bar per minute until the pressure has been
reduced to 35 bars. Then depressurization should continue at a rate of less than 2 bars per
minute.

17. BULK DEWATERING

Bulk dewatering shall be carried out with observation of safety measures to prevent soil
erosion and flooding. Land for bull dewatering shall be agreed with Company Representatives.
When water will be used for further hydrostatic test, Dewatering shall be carried out using
displacement pigs and compressed oil free air until the pipeline is emptied of bulk quantity
of water.
The maximum pig speed during bulk dewatering shall not exceed 1.2 m/s

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Company: Contractor:

PROJECT: ALRAYAN –JANDAR Gas Pipeline Project

Contract No 16/2012
Document Title: Hydrostatic Testing Procedure Document No.: E 03-01

Measured data during Bulk De-watering will be recorded in report form shown in appendix No.
10
The water shall be transferred via a breaking tank and fill pump into the next section, if water
within the specifications, using 4 cup type pig as stated in the filling requirements.
Time lapse between bulk dewatering and drying shall be as short as possible to exclude
running the corrosion inhibitor (dosed) slug.

18. HYDROSTATIC DOCUMENTATIONS

Contractor shall keep reports of all parameters specified during each operation. All recorder
charts shall be signed by the Hydrostatic test engineer when placed on and taken off the
recorder. All recorder charts taken during the hydrostatic pressure test shall be also signed by
Company representative.
Upon completion of a successful section hydrostatic test a “Hydrostatic Test Certificate” shall
be completed and signed by Contractor and Company.
The Contractor shall compile a “Final Hydrostatic Test Report” with general introduction
including all relevant section pipeline data, detailing each hydrostatic pressure test. The
content, as a minimum, shall include the following:
 Originals of all “hydrostatic test certificate”
 Original of all recorder charts.
 All pressure reading
 All temperature reading
 Volume of water added or bled off
 Instrument test certificate
 Air content plot and calculation
 Pressure and temperature plots against time
 Pressure/temperature correlation calculation
 Details of line –fill treatment packages
 Pig register of cleaning, gauging and filling
 Leak location, if carried out
 Detail of line – fill water disposal
 Test procedure

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Company: Contractor:

PROJECT: ALRAYAN –JANDAR Gas Pipeline Project

Contract No 16/2012
Document Title: Hydrostatic Testing Procedure Document No.: E 03-01

28. ATTACHMENTS

Appendix 1 Test Section Data

Appendix 2 Test section Release for hydrostatic test.

Appendix 3 Cleaning Report..

Appendix 4 Manifold / pig receiver design drawing

Appendix 5 Gauging Acceptance Report.

Appendix 6 Water Filling Report.

Appendix 7 Soil, pipe and air temperature

Appendix 8 Register Pressurization Report.

Appendix 9 Test Acceptance Report

Appendix 10 Bulk De – Watering Report.

Appendix 11 Hydrostatic Certificate

Appendix 12 Pigs Types catalog

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Company: Contractor:

PROJECT: ALRAYAN –JANDAR Gas Pipeline Project

Contract No 16/2012
Document Title: Hydrostatic Testing Procedure Document No.: E 03-01

Crossing sections:
1. At 00.00 (after insulation joint + sock and over + Anchor block). Boring length =36 m
(insulation joint)
2. At Homs Phosphate main road: 2 km +634.02 m. length 120 m to 2 km 754.02 m
3. At km 12 + 571.37 m (center of crossing).
4. Rail way crossing: from Km 18 + 082.09m of 30 m length to 18 km 112.09m

Test sections
From 00.00 to 8km + 705m (Km 9 +342.26) (point no. 77)
From 00.00 to 7km + 404m (Km 9 +342.26) (point no. 57)
From

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