SICCL-PRC-12-0025

HYDROTEST PROCEDURE
Revision : 00 Status : IFI
Document type : PLN Discipline : PJM Rev. Date : 13/02/24
Contractor document number : Page 1 of 14

SALTA INFRASTRUCTURE AND CONSTRUCTION

COMPANY LIMITED

HYDROTEST WORK METHOD AND PROCEDURE

00 IFI 13-02-2023 ISSUED FOR INFORMATION A. O. C. A. K. M.

COMPANY
Revision Status Date Revision memo Issued by Checked by Approved by
Approval

This document has been generated by an Electronic Document Management System. When printed it is considered as a for information only copy.
The “controlled copy” is the screen version and it is the holder's responsibility that he/she holds the latest valid version.

This document is the property of COMPANY. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
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HYDROTEST PROCEDURE
Revision : 00 Status : IFI
Document type : PLN Discipline : PJM Rev. Date : 13/02/24
Contractor document number : Page 2 of 14

TABLE OF CONTENTS

1.0 PURPOSE.................................................................................................................................4
2.0 SCOPE...................................................................................................................................... 4
3.0 REFERENCES.........................................................................................................................4
4.0 ABBREVIATIONS.................................................................................................................. 4
5.0 RESPONSIBILITIES.............................................................................................................. 4
6.0 PERSONNEL SAFETY.......................................................................................................... 5
7.0 HYDROSTATIC TEST...........................................................................................................5
7.1. EQUIPMENT AND INSTRUMENT FOR TEST.................................................................5
7.2. HYDRO TEST PRE-ACTIVITIES...................................................................................... 6
7.3. TYPICAL CONTENT OF HYDRO TESTING PACKAGE...............................................7
7.4. WATER TEST AND FILLING............................................................................................7
7.4.1. Water Test........................................................................................................................ 7
7.4.2. Filling............................................................................................................................... 7
7.5. PRESSURIZATION.............................................................................................................. 8
7.6. INSPECTION AND LEAKAGE REPAIR............................................................................8
7.6.1. Inspection......................................................................................................................... 8
7.6.2. Leakage repair:.................................................................................................................9
7.7. DEPRESSURIZING & DE-WATERING..................................................................................... 10
8.0 EMERGENCY RESPONSE PLAN..................................................................................... 10
8.1. WORK PERMITS / SAFETY SYSTEMS.................................................................................... 10

This document is the property of COMPANY. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
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HYDROTEST PROCEDURE
Revision : 00 Status : IFI
Document type : PLN Discipline : PJM Rev. Date : 13/02/24
Contractor document number : Page 3 of 14

1.0 PURPOSE

This method of statement provides the general requirement for the “Pipeline Hydro Static Test and
dewatering” for facilities modification in OML-17

2.0 SCOPE

This method of statement details the method and requirements of hydro test and Dewatering for
The internal piping in OML-17

3.0 REFERENCES

 API 1110 Pressure Testing for Liquid Petroleum Pipeline

 ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids
 GF-OGF4-P-SP-1007: Specification for Pipeline Construction
 GF-OGF4-Q-PR-0306: Pipeline Hydrostatic Test Procedure

4.0 ABBREVIATIONS

HHOG: HeirsHoldings Energies B.V.

Contractor: EPPM/ATCO

HT: Hydro-Test
QAQC: quality assurance Quality control
HSE: Health, Safety & Environment

This document is the property of COMPANY. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
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HYDROTEST PROCEDURE
Revision : 00 Status : IFI
Document type : PLN Discipline : PJM Rev. Date : 13/02/24
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5.0 RESPONSIBILITIES

 The construction Engineers are responsible for management of engineering documents and
drawings, drafting process regulations for construction and management of
specifications/standards and construction inspection records;
 The QA/QC Engineer is in charge of management of quality manuals, procedures, quality plans,
quality audit, quality verification, site notification/ non-conformance reports etc., and other
documents and data with regard to quality;
 The Pipeline Engineer will lead the test.

This document is the property of COMPANY. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
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HYDROTEST PROCEDURE
Revision : 00 Status : IFI
Document type : PLN Discipline : PJM Rev. Date : 13/02/24
Contractor document number : Page 5 of 14

6.0 PERSONNEL SAFETY

 All personnel engaged in testing operations are to comply with the safety requirements.
 All work other than hydro testing in the immediate vicinity of the pipe to be tested will be
suspended whilst testing is in progress.
 Prior to pressure test, warning signs shall be placed along the right-of-way at all public
crossings and all points where there is exposed pipe or pipe appurtenances.
 Warning signs and/or bunting will be installed so as to impede access to the pipe to be tested.
 The test equipment and instruments will be located at manifold, where it is convenient to
monitor and operate.
 The radio signal shall be reachable along the pipeline.
 Responsible and experienced personnel shall be in charge of all operations to ensure all safety
measures are taken.
 All other parties are to comply with CONTRACTOR lead engineer instructions and no
person is to enter into the vicinity of the test area without written permission.

7.0 HYDROSTATIC TEST

The Trunk line will be divided into two test sections as below:
 HDD section (Above ground)
 Whole pipeline included HDD section (underground)

The Trunk lines and Hydro-test pressure will be as per the Drawing Requirements. Process chart
will be attached after activity with all result for test and table of value of test pressure for strength
and leak test, duration, and volume of water required for the pipeline.

7.1. Equipment and instrument for test

The list of equipment is indicated below:

 1 Digital Pressure Gauge

 1 Pressure gauges 100 bars

This document is the property of COMPANY. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
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HYDROTEST PROCEDURE
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 1 pressure guage 50 bars

 1 barton recorder
 1 hydro test manifold
 2 Thermocouples (For underground section)
 1 Compressor
 1 filling pump
 1 pressure pump
 Air hoses
All test measurement equipment and devices shall be calibrated. CONTRACTOR shall present the
calibration certificates to HHOG upon request for information, and to be mauled part of hydro test
package documentation.

7.2. Hydro Test Pre-activities:

Prior to hydro testing commencement CONTRACTOR personnel in charge shall ensure that;

 All welding, repairs and NDT of tested section shall be completed and accepted.
 Trunk line cleanings is completed by means of pigging
 All in-line instruments shall be isolated.
 All valves in the test section shall be in full open position.
 Dewatering of trench shall be complete to allow visual inspection.
 All temporary blinds shall be installed correctly in accordance with test sketch.
 Test header shall be installed properly in accordance with test sketch.
 Warning boards/signs and warning tape shall be set properly in order to avoid not-permitted
entering.
 All underground pipelines have to be completely back filled.
 Applications for testing have been approved by HHOG site representative(s).
 Temporary provisions for testing have been prepared.
 Hydro test equipment, chart recorder and other accessories to be approved by HHOG.
 Hard copy of procedure shall to be available at site during the Hydro Test together with all
Calibration certificates.
 Test section has been filled completed and air has been vented.

This document is the property of COMPANY. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
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HYDROTEST PROCEDURE
Revision : 00 Status : IFI
Document type : PLN Discipline : PJM Rev. Date : 13/02/24
Contractor document number : Page 7 of 14

7.3. Typical Content of Hydro Testing Package

The hydro test package shall be submitted and reviewed by the HHOG’s Representative. The
package shall include the followings:
 Diagrams for the test section shall contain the following data: line identification, pipeline size,
test pressure, blind flange and test limit, test medium, pressure gauge, vent valve, test manifolds
(if require for short trunk line section) and its location (detail sketch will be included in hydro
test package)

 Calibration reports for test instrument

 Welding Book for test section
 NDT reports for test section
 Request for inspection
 Check list and test report form

7.4. Water Test and filling

7.4.1. Water Test
 The trunk line shall in general be filled from an approved water source. Water quality shall be
checked and its suitability verified.

 Before filling the water into any section, it shall be filtered by 50 micron filters, then it shall be
chemical treated by Inhibitors such as Biocide and Oxygen Scavenger if required after the
approval of the CONTRACTOR.

As guidance the physical and chemical treatment for test water is required to prevent:

 Corrosion of materials during the pressure test, or after resumption of operations, due to the
presence of this water. Oxygen scavengers (Sodium disulfite) shall be used to remove or decrease
the level of oxygen in the water. The water analysis will jutify the use or not of oxygen scavenger,
depending of the level of dissolved oxygen in the water.
 Massive contamination of the tested pipelines by bacteria, which are likely to remain in the pipes
after dewatering. Biocide shall be used to help reducing the bacteria contained in the water,
specially if the test water is used for more than one week.

7.4.2. Filling

The filling will be done with 02 Coated Foam Pigs.

The filling starts with introducing a batch of 6% of HHOG volume before the first pig.

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HYDROTEST PROCEDURE
Revision : 00 Status : IFI
Document type : PLN Discipline : PJM Rev. Date : 13/02/24
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After sending the first pig, pumping shall continue until the same amount of water introduced
before is pumped. Then, the second pig is launched into the pipeline at speed less than 1 m/s.
Pumping shall continue until both Pigs arrive at receiver end and the section is full.

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HYDROTEST PROCEDURE
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7.5. Pressurization

 Hydro Test pressurizing graph from start till finish shall be as below:

 Pressurizing shall be commenced after ensuring that all trapped air is removed in
accordance with ANSI/ASME B31.4 and B31.8.

 For strength test pressure (according to the designed hydro test pressure) and related data extracted
from approved drawing. Pipeline section shall be tested at 1.25 times the design pressure for a
duration of 4 hours.

Strength Test Pressure = 1.25 * Design Pressure

 The pressurization shall be performed slowly and in steps to ensure getting the pressure readings
accurately.

 During the pressurization, pressure and temperature readings shall be recorded and
maintained for 15 minutes at 40%, 70% and 100% of strength test pressure.
 After reaching the strength test pressure, the pump will be stopped and isolated from the pipeline.
The test pressure and temperature shall be stabilized for 4 hours with measurements taken of the
pressure every 30 minutes.
 The 24 hours Leak Tightness Test will be performed immediately after satisfactory completion of
Strength Test and shall not be less than 1.1 times the design pressure as per ASME B31.4.

Leak Test Pressure = 1.1 * Design Pressure

 The leak tightness test pressure will be held for a minimum period of 24 hours.

 For the 24 hours’ period, the pressure and ambient temperature will be taken every hour.

 Regarding the HDD Section, since this section is above ground, Only Strength test will be
performed for it (No Leak Test will be performed for HDD section).

This document is the property of COMPANY. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
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HYDROTEST PROCEDURE
Revision : 00 Status : IFI
Document type : PLN Discipline : PJM Rev. Date : 13/02/24
Contractor document number : Page 10 of 14

7.6. Inspection and leakage repair

7.6.1. Inspection:
During the test, CONTRACTOR should assign full time engineer to check any pipeline
deformation or Leakage.

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HYDROTEST PROCEDURE
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Acceptance criteria:

 For Strength Test:

The Strength test will be completed and accepted if:

𝑷𝒕−𝑷𝒕+𝟑𝟎
.100 <= 0.5%
𝑷𝒕

Where: Pt= Pressure Measurement taken At the time t.

Pt+30 = Pressure Measurement taken At the time t + 30 min

 For Leak Test

The Leak test will be completed and accepted if one of the following scenarios occurs:

 No leakage observed from visual inspection & No Pressure Drop.

 A pressure drop occurs but pressure curve fluctuation is a result of temperature fluctuation
registered by the temperature recorder.

The pressure changes due to a water temperature changes shall be calculated through the
following formula:

𝛾−2∗(1+𝑣)∗𝛼
∆𝑃 = 𝐾. ∆𝑇 = 𝐷
∗(1−𝑣2)+
1 ∗ ∆𝑇
Where: 𝐸𝑡 𝐵

∆P = incremental pressure (Bar)

∆T = incremental temperature (°C)
D = pipeline outside diameter (m)
E = Young’s elastic modulus of steel (for carbon steel, E = 2070000 bar)
t = nominal pipe wall thickness (m)
ϑ = Poisson ratio (for steel, = 0.3 bar)

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HYDROTEST PROCEDURE
Revision : 00 Status : IFI
Document type : PLN Discipline : PJM Rev. Date : 13/02/24
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B = Bulk modulus of water (1/compressibilty)

(Bar) γ= volumetric expansion coefficient of
water °C-1
α = coefficient of linear expansion of steel (for carbon steel, α = 1.17 x 10-5 °C-1)

7.6.2. Leakage repair:

If a leak is suspected, CONTRACTOR will reduce the pressure to less than 80 percent of the test
pressure before carrying out a visual examination. If it is not possible to locate the suspected leak
by visual examination, CONTRACTOR will use a method which enables the locating of leaks at
test pressure without endangering the personnel carrying out this activity. When the leak has been
found, it will be repaired in accordance with the appropriate guidelines.
When the repair has been accepted by HHOG representatives, then the pressure test shall be
performed as described in clause 7.5.

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SCAFFOLDING PROCEDURE
Revision : 00 Status : IFI
Document type : PLN Discipline : PJM Rev. Date : 13/02/23
Contractor document number : Page 13 of 14

7.7. Depressurizing & De-watering

Upon successfully performing the hydrostatic testing with acceptable results the line will be
safely depressurized in a controlled manner at no more than 1.0 barg / minute by allowing
the test water out of the section(s) under test.

Dewatering consists of force draining the test water using the pigs in the test header pushed by
compressed air in reverse direction in downhill direction.

The locations for de-watering of the pipeline tested sections will be chosen to be in suitable
locations where discharge will be into drains or other suitable locations capable of taking the
water volumes required. These locations shall be approved by HHOG prior to test. Care shall
be taken so that water is disposed of without causing excessive erosion or flooding in the soil
around the right of way.
Once the dewatering is complete, free water left in the pipeline shall be removed by the use
of foam swabbing pigs, driven by compressed air.

8.0 Emergency Response Plan

EPPM/ATCO will prepare an emergency plan which shall describe actions to be taken in
case the test section or test equipment bursts. In case of Emergency Alarm, immediately
contact the persons in charge Life camp clinic and ambulance at Camp facility will be
available 24 hours Radio available in the ambulance at site work for emergency
communication, radio be supplied and should be kept close to the test cabin switch on at
every point time.
In case of Emergency personnel shall stop work and engines/energies, and then go to the
mustering point. The Hydro-test engineer will physically show the muster point during
toolbox talk meeting. He must establish an exhaustive list of the personnel gathered at the
muster point.

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SCAFFOLDING PROCEDURE
Revision : 00 Status : IFI
Document type : PLN Discipline : PJM Rev. Date : 13/02/23
Contractor document number : Page 14 of 14

8.1. Work Permits / Safety Systems

Prior to mobilization, a meeting will be held to brief all personnel on all aspects of the work
scope, with specific regard to Safety requirements, Work Permit Systems and the proposed
work schedule. Hereafter, new crew members will get a briefing onsite at the worksite prior
to the commencement of the operation. On reaching the worksite, all shift personnel will
undergo the Site Safety Induction. The Permit to Work System at work site will be
implemented and strictly adhered to at all time.

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SICCL-PRC-12-0025