Hydrostatic Testing of Pipeline
Short Description
Hydrotest procedure to be followed...
Description
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
Job Procedure for HYDROTESTING
Procedure No. SEL/9031/ML/JP/01
SEL ML JP
Rev
Savair Energy Ltd Main Line Job Procedure
Date
Description
Prepared By SEL
0
For Review and approval
HP
Checked and approved by
Reviewed and approved by
SEL
Daniel
MD
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
Contents
S.N.
Description:
Page No.
1.
Purpose
3
2.
Scope
3
3.
Reference
4
4.
Methodology
4
5.
Inspection & Test Plan (Enclosed)
6.
Inspection report Format (Enclosed)
UPGRADATION OF METERING SKID
1.0
OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
PURPOSE The purpose of this procedure is to lay down guidelines and requirements and to establish a method or a system to control the hydrostatic testing of Upgradation of metering system.
2.0
SCOPE The purpose of this procedure is to define the methodology for cleaninghydrotest and dewatering of the 8”, 10”,12” & 16” dia Skid fabricated and installed for ONGC. 3.0 REFERENCES Following documents in part or in totality shall form the reference documents. ASME B 31.8
4.0
METHODOLOGY Details of the test section shall be illustrated in the Hydrotest pack, which shall be prepared for each test section and submitted to EIL prior to commencement of the test. A calculated / predetermined length of pipeline shall be selected for the hydrotest based on elevation, availability of water and location of stations. Graph showing the elevation of the complete test section shall be drawn prior to start of the test and enclosed in the hydrotest pack. However max. Length of thetest section shall not exceed 50 Km. Hydrotesting of mainline shall exclude valves at tap-off stations, terminals, pump stations, SV stations and scrapper station facilities. Prior to any hydrostatic test, EIL shall be notified in advance and the hydrotest shall commence only after obtaining signature on part – A & B of the Pipe Book and after mechanical clearance (Appendix – 2 & 3).
The Equipment / Instruments to be used for performing the work shall include, but not limited to the following:
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
Pigs for filling, cleaning and gauging: cleaning pigs with steel wire brushes. Four cup batching pigs. Gauging pig with gauge plate diameter equal to 95% of heavy wall pipe section. Filling pump with differential head 20% greater than the maximum required and a flow rate preferably between 400m³/h to 1000 m³/h. Positive displacement pump equipped with a stroke counter and capable of exceeding the maximum test pressure by at least 20 bar. Positive displacement meters to measure the volume of water used for filling the line having valid calibration certificate. Portable tank of sufficient size to provide continuous supply of water to the pump during pressurization. Bourdon pressure gauges of suitable pressure range and accuracy with valid calibration certificate. Dead weight tester with an accuracy of 0.01 bar, measuring in increments of 0.05 bar and with a valid calibration certificate. Temperature recorders with valid calibration certificate. Thermocouples with valid calibration certificate. Laboratory thermometers 0°C to 60°C range and accuracy ± 0.1°C. Measuring cylinder to check quantity of water during air volume calculation. Injection facilities to inject additives in the test medium in the required proportion. Communication equipment suitable for continuous connection between the two ends. Temporary test headers fabricated in conformity with ASME section VIII, division 2 with particular reference to appendix 18 and 19 having sufficient length of accommodate the required number of pigs. The header shall also have provision for pig stopper. Piping and valve arrangement for launching and receiving of pigs independently. All measuring / recording instruments shall meet the specification requirements of the contract. TEST MEDIUM Cleaning, filling and hydrotesting shall be performed using soft non-aggressive water,
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
free from sand and silt withdrawn from a suitable source in the pipeline route. The water shall be filtered and shall not be contaminated. The water shall be tested in an approved lab for its non-aggressiveness and suitability for using as the test medium. The test report shall be submitted to EIL for review. On the basis of water test report and manufactures / laboratory’s recommendations, the required quantity of corrosion inhibitor, oxygen scavenger, bacterisides etc. shall be added to the test medium with prior approval from EIL.
TEST PRESSURE The pipeline shall be Hydrostatically tested to a minimum pressure of 1.50 times the maximum operating pressure, or 1.4 times of design pressure that pressure which will induce a hoop stress of 90% of the SMYS of the pipeline material in the system / section under test, At lowest point test pressure as calculated in accordance with above, shall be the max. Pressure at the highest point in the section under test. The highest point of the test section shall be subjected to the minimum test pressure as described above, and the maximum test pressure at the lowest point shall not exceed the one resulting in a hoop stress corresponding to 90% of SMYS of pipe material based on the minimum wall thickness in the test section. If any section comprises of both normal & heavy wall thickness pipe, this section shall be tested at the test pressure of normal wall thickness pipe. Cleaning & Guaging of the Pipeline Test Section Prior to starting the cleaning operation, the safety checklist illustrated in APPENDIX – 4 shall be filled up. The cleaning operations shall be performed by propelling air driven pigs provided with spring loaded brushes and Chisels with full diameter circular brush having O.D. minimum 5 mm more than the I.D. of pipe to remove all mill scale, rust / sand from the internal of the pipe sections. The number of pigs run shall depend on the subsequent cleaning results. After acceptance of air cleaning , the test section shall be flushed using uninhibited water equivalent to 10% of the total volume of the test section driven by a four cup cleaning pigs to remove mud, dirt, debris and any other extraneous material. The cleaning shall be considered to be acceptable when no relevant extraneous material are
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
found in front of the last four cup pig. After acceptance of the cleaning, a Guaging pig fitted with a guage plate made of 10mm thick commercial aluminium plate shall be propelled between the temporary test heads. A column of clean water shall be pumped in front of the pig for lubrication and to flush out the remaining dirt inside the test section. Tracking arrangement shall be provided in the first pig or in case any of the cleaning / gauging pig gets stuck inside the test section a second pig fitted with a tracking arrangements shall be propelled and it shall be tracked upto the point of fault. The results of the gauge pig run shall be analyzed to evaluate the internal status of the pipeline and the gauge plate shall be jointly signed by CIPL and EIL/GAIL representative. A deformed, bent of severelly nicked plate or damaged pig shall be evidence of gauging pig run failure and the same shall not be acceptable. In such cases CIPL shall repair and rectify the line and repeat the the gauging pig run to the satisfaction of EIL/GAIL. The sample calculation for gauging late sizing is as per EIL / GAIL. After acceptance of gauging operation by EIL / GAIL, a photograph of the gauge plate shall be taken and attached with the gauging report.Photographs shall be taken prior to launch and after receipt with all details written on the gauge plate is Test Section No.________________ From Km____________ Joint No._________.Date & Time of launching__________and Gauge plate OD & thk. The parameters of cleaning & gauging operations shall be recorded every 30 minutes in the formats enclosed in APPENDIX-5 & APPENDIX-6 respectively. Test Section Filling On acceptance of Gauging, the air pigging headers shall be cut and the temporary test heads, already pretested at a pressure resulting in a hoop stress corresponding to 90% of SMYS shall be welded to the test section. The hydrotest report of the temporary test headers shall be submitted to EIL prior to start of welding the test header to the test section. The filling end test header shall be pre loaded with min. three numbers of four cup batching pigs.
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
The filling operation shall begin with pumping un-inhibited water equal to 10% of the volume of the test section in front of the first pig. First Pig : Pumping uninhibited water equal to 1 1/2 Km pipe length behind the pig shall launch the first pig. The water column before and after this pig shall act as cushion to control the movement of the filling pig and hence minimize air entrapment Second pig: Pumping in the actual line filling inhibited water behind the pig shall launch the second pig. The filling shall continue till the second pig reaches the other end of the test section and the pressure at the test end rises to the static head. Required quantity of corrosion inhibitor shall be injected during the filling operation through any of the nozzles provided on the test header or into the break tank. The quantity of inhibitor shall be controlled by adjusting the flow rate of the dosing pump.. The dosing rate shall be as described in the following paragraph. During the whole filling operation the values at the receiving end test headers shall be throttled suitably to maintain adequate back pressure and thus control the pig movement. The first two columns of water shall be drained out from the receiving end. The different parameters, during filling operation shall be recorded in once every thirty minutes in the prescribed format enclosed in APPENDIX –7. Dosing Rate The dosing rate shall be 750 ppm for fresh fill water 60 ppm for reuse of already dosed water. ( In case of water transfer from one test section to another) and also manufacturer’s report shall be followed. i.e., the fill water for the first test section shall be dosed at a rate of 750ppm and there after during transferring the water from one section to the next an additional 60ppm shall be added to the water which is to be reused, and if it is required to add fresh water ( in case of a longer test section than the previous) then, the volume of fresh water shall be dosed at a rate of 750ppm.
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
Note: Dosing rate are to be confirmed before start of hydro test the above dosage are tentative only. Thermal Stabilization Once the test section has been completely filled and a minimum pressure of 1 bar has been achieved at the highest point, the thermal stabilization period shall be started. Temperature probes shall be installed to measure the pipe and soil temperature at every 2.5 Km. of the pipeline spacing msy be increased to max. 5 kms depending upon the terrain and nature of subsoil along the alignment of the test section. . Also one probe each shall be installed at five hundred meters from both the test heads. The probe for measuring pipe temperature shall be installed by cutting a small portion (a little bigger than the probe tip) of the coating from the pipe, polishing the exposed portion and fixing the probe to the pipe with quick setting epoxy ensuring firm contact between the probe and pipe. The soil probe shall be poked into the earth adjacent to the pipe. The temperature reading shall be taken at two-hour intervals with a calibrated digital temperature read out unit one decimal place and thermal stabilization shall be considered to have been achieved when a difference not higher than 1°C is attained between the average values of the last two readings of pipeline temp. The temperature readings shall be recorded in the format enclosed in APPENDIX-8. Digital Thermo meter Insulating Coating Soil Temp. Termocouple Ground Level “A” Pipe Wall View VIEW “A”
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
Thermocouple Attached to Pipe Wall by Quick Setting Epoxy FIGURE - 1 After completion and acceptance of hydrotesting, thermocouples shall be removed and the corresponding coating shall be repaired as per approved coating repair procedure. Pressurization Operational Steps: Mobilize high-pressure pump and test equipment at pressurization area. Install one pressure gauge in parallel with the dead weight tester. Fill out and sign pipeline pre-pressurization safety checklist. APPENDIX-9. As soon as the temperature stabilization is achieved, the pressure shall be raised at a moderate and constant rate not exceeding 2 – bar per minute. The parameters (Volume required) during pressurization shall be recorded throughout the cycle in the format enclosed in the APPENDIX –10 as follows: Each 5 bar increments upto 80% of the test pressure as recorded by dead weight tester. Each 2 bar increments between 80% to 90% of the test pressure as recorded by dead weight tester. Each 0.2 bar increment between 90% to full test pressure as recorded by dead weight tester. The pressurization shall be cycled with the sequence shown in the following pressure sequence. Pressurize to 50% of test pressure, hold pressure for one hour,and perform air volume test and drop pressure to static head. Pressurize to 75% of test pressure, hold pressure for one hour, and perform air volume test and drop pressure to static head. Pressurize to test pressure, perform air volume test and raise pressure to the test
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
pressure once again. In case, during the hold period indicated above, a decrease in pressure is observed, the above operation shall not be repeated more than twice, after which the line shall not be considered capable of test, until the cause for the lack of water tightness is eliminated. Air Volume Calculation In order to check the pressure of air in the pipeline two separate consecutive pressures lowering of 0.5 bar by slowly bleeding water from the test section shall be carried out during all the pressurizing cycling as mentioned above. The water drained during the second lowering shall be accurately measured (V1). This quantity measured shall be compared to the theoretical quantity (Vp) corresponding to the pressure lowering. The air volume shall be acceptable if Vi /Cp< 1.06. The observation shall be recorded in the air volume calculation format enclosed in APPENDIX – 11. 24 Hour Hold Period The pressure shall be considered to be stabilized when no fluctuation is observed in the pipeline pressure as seen from the dead weight tester. On achieving pressure stablization, pressure pump connections shall be removed and the test section completely isolated and all connections at the test heads shall be checked for leakages. Pressure recorders shall than be started with the chart in real time orientation and the 24 hour pressure hold period shall start. During the pressure hold period the following data shall be recorded in the format enclosed in APPENDIX-12. a) Every one-hour pressure measurement from dead weight tester. b) Every two hours the ambient temperature, pipe and soil temperature from the thermocouples. Throughout the hold period, care shall be taken that the maximum test pressure is not exceeded. Should it become necessary to de-pressurize, the volume of test medium bleed off shall be measured and recorded. Acceptance Criteria
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
The hydrostatic test shall be considered as positive if pressure has kept a constant value throughout the test duration, except for change due to temperature effects. The pressure change value as a function of temperature change shall be algebraically added to the pressure value as read on the meters. The pressure value thus adjusted shall be compared with the initial value and the test shall be considered as acceptable if difference is less than or equal to 0.3 bar. For calculating the pressure change due to change in temperature the formula and data illustrated in APPENDIX-13 shall be used. On successful completion and acceptance of the hydrotest, the pipeline shall be slowly depressurized at a moderate and constant rate. Leaks If during the pressurization period or during the test periods any defects are observed, these shall be eliminated. If any leaks are observed the section shall be initially visually inspected to check the eventual leaking point. If this check is negative, then the procedure described below shall be followed. No work shall be carried out to repair leaks until the pressure has been reduced to a safe pressure (i.e. static head plus 1 kg) and the water drained. Leak Detection To locate buried leaking pipe, the following procedure by elimination shall be followed: 1. 2. 3. 4. 5.
To cut the section in an intermediate position To insert two test heads To re flood the sections To pressurize the two sections To determine the faulty section
This procedure shall be applied until the determination of the defect. As soon as the defect has been located and repaired, the test section shall be tested again.
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
If the test section fails to maintain the specified test pressure after isolation ,CIPL shall determine by search the location of leakage or failure. All leaks and failure within the pipe-wall or weld seams shall be repaired by replacement of entire joint or joints in which leakage or failure occurs. CIPL shall comply with instruction EIL/GAIL whether to replace a section of the line-pipe that includes the leak or whether to repair the circumferential weld. The repair shall however meet the requirements of EIL spec. 6-77-06. After completion of repairs, the hydrostatic test shall be repeated.CIPL shall haul and stockpile all damaged and defective pipes to storage location designated by EIL/GAIL. All cracks and splits resulting from failure shall be coated with an application of grease to preserve the characteristics of failure from corrosion. Joint of failed pipes shall be marked with paint, with a tag indicating failure details, date and location of failure and pressure at which failure occurred. Pipeline Bulk Dewatering Written permission shall be obtained from EIL / GAIL for obtaining the dewatering clearence. Upon successful completion of the hydrotest, propelling the third pig in the test header shall dewater the section. Making suitable drains shall make necessary arrangements for safe disposal of hydrotest water.Dewatering shall start after getting clearance from EIL / GAIL and the water shall be transferred to the next section wherever required. The dewatering shall be carried out by using four-cup pigs and foam pigs driven by compressed air. The dewatering shall be done in such a way as to provide adequate control of pigs during dewatering by keeping air pressure 2 bar minimum. Pigs and equipment required for dewatering shall be approved by EIL in advance. Four-cup pigs shall first be passed through the line to displace the water. Foam pigs shall then be passed in order to complete the line dewatering. The line shall be considered dewatered when a negligible amount of water is flushed out by the last foam pig. During dewatering care shall be taken to properly dispose the the discharging water in order to avoid pollution, damages to fields under cultivation and or existing structures and interference with the traffic. Upon completion of the testing and dewatering operation, any provisional traps for pigs and all other temporary installation relating to the test shall be removed. Subsequently the individual sections of the line already tested shall
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
be joined in accordance with the requirements of relevant specifications issued for the purpose. The line pressure during dewatering operation shall be recorded every 30 minutes in the format enclosed in APPENDIX-15. Once dewatering is over, the sectionalizing valve and other valve assemblies shall be installed at the respective locations is accordance with the relevant procedures and specifications. All thermocouples installed in the pipeline shall be removed and corrosion coating shall be repaired wherever required using approved procedure and materials. If it is required to preserve the pipeline for a specified duration, sufficient quantity of approved corrosion inhibitors depending upon the quality of water, duration of preservation and laboratory test reports, shall be injected into the pipeline as per the direction of EIL and the pressure shall be raised to the required level as mutually agreed upon with EIL/GAIL at a later stage. Subsequent to dewatering, the SV installation followed by final tie-in between the tested sections shall be taken up. 7. HEALTH, SAFETY & ENVIRONMENT The approved procedure of Health, Safety & Environment shall be followed during the execution. The hazards associated with the hydrotest have been identified and the following guidelines are suggested for implementation of safety norms. Provisions shall be made for the installation of no admittance signs to unauthorized personnel from the road to the R.O.W. at critical locations. Warning signs in English and Local Language stating “Pipeline Under test – keep off” shall be placed in locations where the pipeline is uncovered, and particularly where the temporary headers and stations are located. Such areas shall be suitably fenced in such a way as prevent access of unauthorized personnel. No unauthorized personnel shall be closer than 40m to the pipeline under test. Only authorized personnel as defined /identified by the Hydrotest Engineer shall be allowed within the test area when the test section is under pressure. No test activities are in progress with out specific clearance of testing
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
Engineer. When test equipments shall be installed in compliance with methods and suitable instructions only, this may not cause any injury to personnel. All instruments shall be placed in such a location as to prevent it from being affected by a personnel in the test head. No leak on the pipe or test equipment shall be allowed whislt under pressure except for tightning of flanges, the removal of connections after closing the valves, and the blinding of ports after achieving the test pressure for isolation of the test station. No flexible hoses are permissible inside the test cabin, except for essential connection to the instruments. For effective communication, a wireless and a walkie – talkie system shall be used. 8.
QUALITY ASSURANCE & QUALITY CONTROL The quality assurance and quality control for the project procurement shall be carried out by strictly implementing the following: a) Inspections and Test Plan. b) Quality Records
The type of inspection activity and quality records generated during the activity is detailed in Inspection and Test Plan. Quality records shall include current calibration certificates for all measuring instruments. The overall tentative layout of equipment & instruments for pigging hydrostatic testing is shown through Appendix - 16 9.0 APPENDICES /FORMATS Appendices 1 to 19 enclosed. Note:- Incase of any conflict between this procedure and the contract specification, . the later shall govern.
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
DOC.NO.
REV.NO. 1 APPENDIX - 1 INSPECTION & TEST PLAN FOR HYDROSTATIC TESTING Insp.B Verifi. Sl.N Document to be Activity y By. Remarks o submitted by CIPL CIPL EIL 1 Approval of Procedure & Test Diagram W A Test Pack 2 Pre Hydrotest Check List W W Mechanical Clearance of the Pipe Pipe Book, Part-A 3 H A Section &B 4 Submission Calibration Certificates H R Certificates Submission of Water Test Report and 5 H R Test Report Dosing Recommendation 6 Install all Temporary Piping equipment W RM Test diagram 7 Ensuring Communication System W RM 8 Ensuring Safety Requirements W W 9 Cleaning/Gauging W W Inspection report 10 Installation of Temp. Sensors H W 11 Flushing H W Inspection report Installation of Temporary Headers With Hydrotest report of 12 H RM Pigs test headers. Filling Rate W RM 13 Dosing rate W RM Inspection report Back pressure Control W RM
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
14 Thermal Stabilization 15 Air Volume Calculation Pressurization Rate 16 Log of Temp.and Pressure Bleed off water Measurement 17 Leak Detection & Test Extension Rectification & Stocking / Marking of 18 Damaged Pipe 19 Acceptance & evaluation of record data Depressurization & Dewatering to the 20 Accept Point Repair of PE coating at repairing temp. 21 Sensors fixing point LEGEND: “A” ACCEPTANCE/APPROVAL “RM” RANDOM INSPECTION CIPL SIGN: SIGN: NAME: NAME: DATE: DATE:
H H W W W W
W W RM RM W W
Inspection report Inspection report
W
W
W
W
Inspection report
W
W
Inspection report
W
W
Inspection report
“H” HOLD “W” WITNESS INSPECTION “R” REVIEW OF DOCUMENTS EIL GAIL SIGN: NAME: DATE:
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
DOC.NO. 2
REV.NO.0
APPENDIX –
INSPECTION REPORT FOR TEST PLAN FOR POST HYDROSTATC TESTING
Line Dia
:
20 inch
Section No Joint No
O.D 508 mm
:
From 35.325
:
From
Normal Wall Thick I.D(mm) 11.1mm
485.8
Length (Mtrs) 196.150
Total length Length of Total section -200 mtrs Test Pressure START END
(KM) To 35.521 (KM)
35/M23 (KM) To 35/FT37(KM) Test Total pressure Volume(m) (kg/cm2) Min. Max. 11.1 0.1853 36.339 139.91 Note: 1. Length of test headers to be included 2.Test pressure shall be as per min. wall thick of pipe in the section. 3.strike on which ever applicable. GENERAL DATA HIGH LOW Water Source ________ Avg.Wall (MM)
Volume Per Mtrs (m)
KM35/M23 KM35/FT37 KM35/M23 KM35/M28 Chainage 216.213 215.483 216.213 204.783 Elevation (M) 142.0 142.07 142.0 143.12 Pressure (kg/cm ) 2 Imt H2O = 0.0980665 Kg/cm (g) % OF TEST PRESSURE 50 75 100 2
Pressure Sequence (kg/cm2) 71 106.5 142 Approx. Water to increase Pressure By 2 Bar/Min (Lt./Min) Approx. Water to pressure low 0.5 (Ltrs) Approx pressure change as a function Temp. Change (Bar/C) ELEVATION(Mtrs).(A Sketch showing elevations Vs Km (Chainage ) to be enclosed Chainage (Km) Fill Direction Dewatering direction REMARKS: FOR CIPL Sign Name Date
From – KM35/m23 to KM 35/FT37 DADRI SIDE – KM35-M23 BAWANA SIDE – KM35/FT37 FOR EIL/GAIL Sign Name Date
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
DOC.NO.
REV.NO.1
APPENDIX - 3
CERTIFICATE OF MECHANICAL & CONSTRUCTION COMPLETION FOR P/ L Line Dia (Km)
:
From
(Km) (To)
Section No. (Km)
:
From
(Km) (To)
Joint No. (Km)
:
From
(Km) (To)
O.D(INCH)
Wall Thickness(mm)
WALL THK (MM) Min: Max: Length (Mtr)
I.D (MM)
GRADE API – Length ___________(Km) 5L GR.X - 60 Volume ___________(M3)
Min: Max: Number of Welds:____________________ Length of not backfilled section: CONSTRUCTION Start Date: End Date:
THIS IS CERTIFY THAT ALL WELDS OF THE ABOVE TEST SECTION HAVE BEEN ACCEPTED AND THE PIPELINE SECTION HAS BEEN LAID AND BACKFILLED ACCORDING TO THE SPECIFICATIONS.ALL ACTIVITIES UPTO PART – B OF PIPE BOOK IS COMPLETED AND CERTIFIED.
REMARKS:
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
FOR CIPL Sign Name Date
DOC.NO. 4
FOR EIL Sign Name Date
FOR GAIL Sign Name Date
REV.NO.1
APPENDIX –
CHECK LIST FOR CLEANING, GAUGING AND FILLING S.No 1 2 3 4 5 6 7 8
SAFETY CHECK LIST Is a copy of the approved hydrotest procedure available in the area. Is a copy of the hydrotest pack available in the area. Is adequate water disposal arrangement made. Check House keeping standards are acceptable at the filling end and receiving end. Check the conditions of the tools and tackles to be used Check that the lighting arrangements are adequate and the condition of the electrical wiring, circuit boards, conduit etc.are acceptable and safe. Check that test areas at each end of the test section have ben cordoned off with stakes and bunting tape. Check that emergency equipment are adequate and are working condition – standby vehicle, communication system first aid boxes, medical facilities, stretcher etc.
YES
NO
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
Note: Hydrotest engineer / HSE officer to add any other safety points to this list as per the site circumstances if deemed necessary. HYDROTEST ENGINEER HSE OFFICER Sign: Sign: Name: Name: Date: Date:
DOC.NO:
EIL Sign: Name: Date:
REV.NO : 1
APPENDIX - 5
INSPECTION REPORT FOR AIR CLEANING Line Dia (KM)
:
From
(KM) To
Section No. (KM)
:
From
(KM) To
Joint No (KM)
:
From
(KM) To
O.D (INCH)
WALL THK(MM) I.D (MM) Min: Min: Max: Max:
GRADE API Length_________(KM) – 5L GR.X – Volume__________(M3) 60
Compressor Location____________ Make_______ Model_________
Cut out_____________ Max.Pressure____________ Piping Direction From___________(KM)
To__________(KM)
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
Start
Run No Pig Type
Date
End
Time
Date
Time
Pressure (Kg/Cm2) Min. Max.
Avg.Val Km/Hr
Quantity of Debris (In Kg).
REMARKS ACCEPTANCE OF SECTION CLEANING : FOR CIPL Sign Name Date
YES / NO
FOR EIL Sign Name Date
FOR GAIL Sign Name Date
DOC.NO:
REV.NO:1
APPENDIX - 6
INSPECTION REPORT FOR GAUGING Line Dia (KM)
:
From
(KM) To
Section No (KM)
:
From
(KM) To
Joint No. (KM)
:
From
(KM) To
WALL THK. (MM) O.D (INCH)
Compressor
Min: Max:
I.D (MM)
GRADE API-5L GR.X-60
Min: Max: Location
Make
Length _______(km) Volume_______(M3) Model
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
Out Put Pigging Direction From Gauge Plate Dia(inch)
Thk (mm)
Material
Max.Pressure (KM).
To
Start Date
(KM) End
Time
Date
Avg.val. Km/Hr
Time
Pressure (kg/cm2) Min
Max
Enclosure: The Photograph of Gauge plate before and after Run Details of Gauge Plate Damage (if any): REMARKS: ACCEPTANCE OF SECTION CLEANING: FOR CIPL Sign : Name : Date :
YES / NO
FOR EIL Sign : Name : Date :
DOC.NO: –7
FOR GAIL Sign : Name : Date : REV.NO.1
APPENDIX
INSPECTION REPORT FOR WATER FILLING Line Dia (KM) Section No (KM) Joint No. (KM)
:
From
(KM) To
:
From
(KM) To
:
From
(KM) To
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
WALL THK.(MM)
I.D (MM)
Min: Max:
Min: Max:
O.D (INCH)
Test Medium Water Inhibition : Y / N
GRADE API-5L GR.X-60
Source Type Type Type
Fill pump
Location Max.Pressure
Flow Meter
Make
Volume________(M3)
Location Dosage Dosage Dosage Make bar
Output
Model
Filling Direction From Pig Sequence Prefilling Length (Mtrs)
Length_______(km)
km
(Km) ppm ppm ppm Ltrs/Min
Sr.No To
km
Volume(m3)
1st Pig Type Between pig 1 & Pig 2 Length (mtrs)
Volume(m3)
2nd Pig Type
Time
Fill pressure ( Kg/cm2)
Cumulative Volume (m3) Flow meter Fill water Volume Reading Fill volume Temperatur Remarks this period(m3) Including pre fill (m3) e (c) After Sec.Pig
Reading to be Recorded Hourly Fill water temperature to be recorded continuously on Temperature Recorder
REMARKS: ACCEPTANCE OF SECTION CLEANING FOR CIPL FOR EIL Sign : Sign : Name : Name : Date : Date :
FOR GAIL Sign : Name : Date :
UPGRADATION OF METERING SKID OWNER
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LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
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DOC.NO:
REV.NO:1
APPENDIX – 8
THERMAL STABILISATION Spread: SectionNo. From
From From To
To
WALL Thk. (mm) O.D_______(INCH) Min: Max: S-1 (km)
S-2 (km)
S-3 (km)
S-4 (km)
S-5 (km)
S-6 (km)
Report No. Date :
To
S-7 (km)
I.D (mm)
S-8 (km)
S-9 (km)
s-10 (k )
Aver. Soil. Temp
Length___________(km)
Grade API – 5L GR. X - 60
Min: Max: P-1 (km)
P-2 (km)
P-3 (km)
P-4 (km)
P-5 (km)
Volume___________(m3) P-6 (km)
P-7 (km)
P-8 (km)
P-9 (km)
P-10 (km)
To be taken at 4 intervals Stabilization be considered to have been achieved when the different between the avg.pipe Temp. and avg. soil Temp. is not higher Than 1 deg. For 2 cinsecutive readings. Of Section Thermal stabilization: YES / NO FOR CIPL Sign
:
FOR EIL Sign :
FOR GAIL Sign :
Aver. Pipe. Temp
Ambie et Temp.
UPGRADATION OF METERING SKID OWNER
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LSTK CONTRACTOR
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CONTRACTOR
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Name : Date :
Name : Date :
DOC.NO: PRESSURE TEST (24 HOURS HOLD) Line Dia: SectionNo.
REV.NO:1
From (km) From (km)
To(km) To(km)
From (km)
To (km)
Joint No:
WALL Thk. (mm) O.D_______(INCH) Min: Max: S-1 (km)
S-2 (km)
S-3 (km)
S-4 (km)
S-5 (km)
S-6 (km)
S-7 (km)
Name : Date :
S-8 (km)
Min: Max: S-9 (km)
APPENDIX - 12 Dead.Wt.Tester:- Make:_________ Model:_________
Report No. Date :
Calibration certificate No:__________ Temperature:Make:________ Model:_________ I.D (mm) Grade API – 5L GR. X - 60 s-10 (k )
Aver. Soil. Temp
P-1 (km)
P-2 (km)
P-3 (km)
P-4 (km)
P-5 (km)
P-6 (km)
Certificate No:________ Length___________(km) Volume___________(m3) P-7 (km)
P-8 (km)
P-9 (km)
P-10 (km)
Aver. Pipe. Temp
Ambie et Temp.
Dead weight tester readings to be recorded hourly, pipe & soil temperatures reading to be recorded at every two hour Pressure and ambient temperature to be recorded continuously on recorders.All details of thermocouples, calibration status, certificate No.etc. are to be recorded and enclosed. REMARKS: Acceptance of Test Pressure (24 Hours Hold): Yes / No.
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
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FOR CIPL Sign : Name : Date :
FOR EIL Sign : Name : Date :
FOR GAIL Sign : Name : Date :
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
DOC.NO:
REV.NO.1
APPENDIX - 9
PRE PRESSURIZATION SAFETY CHECK LIST S.NO 1 2 3 4 5 6 7 8 9
CHECH POINT The test section has been isolated from all other pipeline Sections. All temporary piping, test heads and other equipment connected to the test section have been pre tested to a pressure of at least 1.25 times the test pressure. The test section has been completely filled with water and air vented off. All instruments and gauges which are used have valid calibration certificates. All warning notices, marker tapes, protective barriers and other safety equipment have been positioned and all the concerned informed. All persons who may be affected by the operations are informed of the activity. Communication channel is tested and ensured that they are working properly. Backup instruments are available. Inform the person operating the pressuring equipment of the maximum test pressure which shall be applied to the test section. Joint inspection of the entire facilities by the Hydrotest Engineer and HSE officer to ensure all the safety measures have been undertake before the test.
HYDROTEST ENGINEER HSE OFFICER(CIPL) Sign : Sign :
YES
EIL Sign :
NO
UPGRADATION OF METERING SKID OWNER
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LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
Name: Date :
Name : Date :
Name: Date :
DOC.NO:
REV.NO: 1
APPENDIX - 10
PRESSURIZATION From
: Cycle : 50% /
75% / 100
Report No
:
Date
:
To
: Pipeline Dia
Section Length Theoretical volume
Test Medium (km) (m3)
: :
Elevation/Pressure at : Highest Pt Lowest Pt -
: 12”
: Water Material : API 5L x 60 Wall Thickness : 6.4 / 7.1 mm Source of Water: Pressurizing Pt Receiving Pt
Sl.No
Time Hrs.
Dead Wt. Kg/Bar
Strokes Counted
Volume M3
Cum. Vol M3
Temp.C
-
Remarks
UPGRADATION OF METERING SKID OWNER
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LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
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1. Pressurization Pump : 2. Dead Weight Tester : 3. Flow Meter :
Make Make Make
Model Model Model
Volume Volume Volume
Notes:
ACCEPTANCE OF CLEANING: FOR CIPL Sign : Name : Date :
FOR EIL
FOR GAIL
Sign : Name : Date :
Sign : Name : Date :
DOC.NO:
REV.NO:1
APPENDIX - 11
AIR VOLUME CALCULATION (50% / 75% / 100% cycle)
Sheet No
:
From(kms)
To(kms)
Line Dia
:
JointNo.
Section No.
:
Test Section Length
Air Volume Test carried out at Test Station Location Date & Time
Date
From
To Volume
% of test pressure.
Test Pressure Avg. Pipe Temp. ( C ) Dead S.No Description .Wt.Tester (kg/cm2) 1 Initial After First Lowering 2 After First Lowering
Bar. Pressure Lowering (kg/cm2)
Volume of water
Remarks
UPGRADATION OF METERING SKID OWNER
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LSTK CONTRACTOR
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CONTRACTOR
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3
After second Lowering
To calculate the theatrical volume of water required to achieve a change in pressure, the volume pressure equation Vp = (0.0884 Ri/T + A) x 10-6 x Vt x ∆ P x K Where: Vp = Computed water amount required to raise by P the pressure in the section to be tested (m³) Vt = Geometrical volume of the section (m³) Ri = Nominal inner radium of the pipe (mm) T = Nominal pipe thickness (mm) A = Isothermal compressibility value for water at the pressurization temperature in the P range (bar -1) x 106. Refer graph. ∆P = Pressure Rise (bar) K = A dimensionless coefficient that is equal to a value of 1.02 for longitudinally welded pipe. Therefore Vp = m³ = Liter Actual volume of water drained to drop pressure by 0.5 Kg. = Liter (Vi) Therefore V1 / V p = Since the ratio is less than 1.06 the filling is acceptable and the test section may be pressurized to the final test pressure.
Remarks ACCEPTANCE OF SECTION CLEANING FOR CIPL Sign Name Date
FOR EIL
: : :
Sign Name Date
FOR GAIL
: : :
Sign : Name : Date :
DOC.NO:
REV.NO:1
APPENDIX - 13
HYDROSTATIC TEST CALCULATIONS Sheet No:
From (km)
To (km)
Line Dia :
Joint No:
From
Section Station Location
Test Section Length
Test Station Location
Test Pressure
Dead .Wt.Tester Start of Test End of Test Algebic Difference
Make: Model: Date & Time (Hrs)
Date To Volume
(Bar) Certificate No. Date : Dead Weight (Bar)
Average pipe Temp.
UPGRADATION OF METERING SKID OWNER
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LSTK CONTRACTOR
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CONTRACTOR
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Calculation of Pressure Change (∆P) due to change in temperature: ∆p = (B/ (0.0884 Ri/T + A) ∆T Where: B = Difference between thermal Expansion of water and steel at temperature and pressure as measured from enclosed table at the end of the test. Ri = Nominal inner radius of pipe T = Nominal wall thickness of pipe A = Algebraic compressibility factor of water ∆T = Algebric difference between water temperature at the beginning and at end of the test (C) Ri = R1 L1 + R2 L2 __________ L1 + L2 Ti = T1 L1+ T2 L2 __________ L 1 + L2 A = Isothermal compressibility value of water as estimated at the pressure and test (bar –1 ) x 10-6)
temperature values obtained at the end of
REMARKS:
FOR CIPL Sign : Name : Date : DOC.NO:
FOR EIL Sign : Name : Date : REV.NO:1
FOR GAIL Sign : Name : Date : APPENDIX – 14
HYDROTEST EVALUATION REPORT Report No: Spread : O.D (INCH)
Date : To
From Wall Thk. (mm) I.D (mm) Min : Min: Max : Max:
Grade API – 5L Gr. X – 60
Length_________(km) Volume________(m3)
Section No:_______________ From Km ____________ To Km________________ OBSERVATION Initial Test Pressure _____________Bar
Date & Time ___________________
Final Test Pressure_____________ Bar
Date & Time____________________
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CONTRACTOR
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(A) Delta P during 24 Hours Hold Period Initial Pipe Wall Temp ____________ Bar
Date & Time____________________
Final Pipe Wall Temp_____________Bar
Date & Time____________________
(B) Delta T During 24 Hours Hold Period Initial Soil Temp_________________ Bar
Date & Time____________________
Final Soil Temp_________________ Bar
Date & Time____________________
(C) Delta T, Soil Temp._____________ Deg.C (D) Leakage During 24 Hours Hold Period EVALUATION Delta P During 24 Hours Hold Period (A) Accountable Pressure Loss Due to Temp.B Unaccountable Pressure Loss Allowable unaccountable pressure Loss Conclusion Test Acceptable / Un acceptable Section Released for depressurization REMARKS:
FOR CIPL Sign : Name : Date :
__________________ bar __________________ bar __________________ bar __________________ bar
FOR EIL Sign : Name : Date :
OC.NO:
FOR GAIL Sign : Name : Date : REV.NO:1
APPENDIX - 15
INSPECTION REPORT FOR DEWATERING Report No: Date: Spread :
From
Wall thick (mm) O.D ______ ___(INCH) Min: Max:
To I.D (mm) Min: Max:
Grade API – 5L Gr. X-60
Length___________(km) Volume____________(m3)
UPGRADATION OF METERING SKID OWNER
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LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
Compressor:
Location
Make
Output
Max.Pressure
Dewatering Direction From
Km. To
Km
Discharge Point Type of Run No. P/G
Start Date
Time
End Date
Time
Avg.Val Km/Hr
Pressure(Kg/Cm2) Min
Max
Qty of Water (Ltrs)
REMARKS:
ACCEPTANCE OF SECTION DEWATERING: YES/NO FOR CIPL
FOR EIL
FOR GAIL
Sign : Sign : Sign : Name: Name: Name: Date : Date : Date : DOC.NO: REV.NO:1 LIST OF ATTACHMENTS TO HYDROSTATIC TEST RECORD Spread : Spread : O.D___________ (INCH) 1.
From
APPENDIX – 16
To
From Wall Thk. (mm) Min : Max :
To I.D (mm) Length_________(Km) Min: Volume__________(m3) Max: Test Plan for Hydrotest (Appendix – 2)
YES/NO
UPGRADATION OF METERING SKID OWNER
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LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
2. (Appendix – 3)
Certificate of mechanical and construction completion YES/NO
3.
Air Cleaning (Appendix – 5) YES/NO
4.
a. Gauging (Appendix – 6) YES/NO b. Photography of Gauge Plate YES/NO
5. filling (Appendix – 7)
a.
Water
b.
Fill
YES/NO Water Temperature Charts YES/NO 6.
Thermal Stabilization (Appendix – 8) YES/NO
7.
a. Pressurization (Appendix – 9) YES/NO b. Pressure records charts(s) YES/NO c. Temperature Recorders Charts YES/NO
UPGRADATION OF METERING SKID OWNER
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LSTK CONTRACTOR
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CONTRACTOR
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8.
Air Volume Calculations (Appendix – 13) YES/NO
9. hours Hold (Appendix – 12)
a.
24
YES/NO b. Pressure recorders Charts c.
YES/NO Ambient
Temperature Recorder Charts YES/NO 10.
Hydrostatic Test Calculations (Appendix – 13) YES/NO
11.
Hydrostatic Test Evaluation (Appendix –14) YES/NO
12.
Calibration Certificates YES/NO
13.
Dewatering (Appendix –15) YES/NO FOR EIL
FOR CIPL Sign : Name: Date : DOC.NO:
Sign : Name: Date :
FOR GAIL Sign : Name : Date : REV.NO:1
APPENDIX – 17
INSPECTION REPORT FOR SWABBING Report No:
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
Date: Spread :
From
To
Wall thick(mm) O.D________ Min: (INCH) Max:
I.D (mm) Min: Max:
Grade API-5L Gr. X-60
Length ______ (Km) Volume________(m3)
Compressor: Location Make
Output Max.Pressure Swabbing From To Km
Km Distance
Point
Section Released for Swabbing
Yes/No
Water Treatment Carried Yes/No Type of Pig
Start Date
Time
End Date
Time
Wt.of.Pig Initial
Final
Avg.Val. Km/Hr
Pressure (Kg/cm2)
Remarks
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
ACCEPTANCE OF SECTION SWABBING: NO FOR CIPL Sign : Name:
YES /
FOR EIL Sign : Name :
FOR GAIL Sign : Name :
UPGRADATION OF METERING SKID OWNER
: ONGC
LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
APPENDIX –18 TENTATIVE LAYOUT OF EQUIPMENT AND INSTRUMENTS FOR HYDROSTATIC TEST Pressure/ Temp. Recorder
BREAK TANK
Flow Meter
AIR COMPRESSOR For Backpressure
Lines for Pig
From Impulse line from test Water HeaderSource Gauge
Stock Counter
Dead Wt. Tester Gauge TEST CABIN
AIR .COMP PUMP SKID Filling &Pressurising Pump
Gauge
Temporary Test Header Receiving End
Temporary Test Header
UPGRADATION OF METERING SKID OWNER
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LSTK CONTRACTOR
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CONTRACTOR
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UPGRADATION OF METERING SKID OWNER
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LSTK CONTRACTOR
: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
: SAVAIR ENERGY LTD
APPENDIX – 19 HYDROTEST HEADER
N5 ½” N1 4”/6”
N5 ½” N6 ½” N2 11/2”
N7 ½” N8 ½” N4 11/2”
UPGRADATION OF METERING SKID OWNER
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LSTK CONTRACTOR
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CONTRACTOR
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UPGRADATION OF METERING SKID OWNER
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LSTK CONTRACTOR
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CONTRACTOR
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TENATIVE LAYOUT OF EQUIPMENT AND INSTRUMENTS FOR AIR PIGGING
Pneumatic Hose
AIR
UPGRADATION OF METERING SKID OWNER
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: DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR
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COMPRESSOR
Gauge
Air piggingheader R. End
R – Receiving L – Launching .
Gauge
Air pigging header L . End
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