MS-24 Hydrotest Pipeline Procedure

Method Statement

PT. DUTA GRAHA INDAH Tbk Project

Karebbe HEP- Package K-8A Road and Oil Pipeline Realignment

Location

Soroako – Sulawesi Selatan

Pages

2 of 14

MS 24

ITEM:

CLEANING AND HYDROSTATIC TEST PROCEDURE

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Date

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1.0 PURPOSE 1.1 1.2

1.3 1.4

This procedure is outline guidance for cleaning, testing and dewatering application for Road and Oil Pipeline Realignment Project at Karebbe. The purposed of this procedure is to provide the method and sequence of work in the execution of the hydrostatic testing and drying for the pipeline; 12” Dia Pipe x 1,293 meters long. This works included herein are: Hydrostatic Testing Dewatering and drying

2.0 REFERENCES 2.1 2.2 2.3 2.4

API 1104-2005, Standard for Welding Pipelines and Related Facilities ASME B 31.8-2003, Gas Transmission and Distribution Piping Systems. ASME B31.4-2002, Liquid Petroleum Transportation Piping Systems. API 1110-1997, Recommended Practice, Pressure Testing of Liquid Petroleum Pipelines.

3.0 TESTING AND INSPECTION FIELD ORGANIZATION 3.1 3.2

The works will be carried out by Testing, Dewatering and Drying crews, which is composed of Field Supervision and Skilled labour as shown in - Attachment 01. Witness Inspection, Acceptance and Certification of successful completion of the test will involve the parties presented in - Attachment 01.

4.0 EQUIPMENTS, DEVICES, TOOLS AND CONSUMABLES Equipments, devices, tools and consumables to be used for Hydrostatic testing works are as listed in - Attachment 02 5.0 PIPELINE TEST DATA AND TENTATIVE SCHEDULE 5.1 5.2 5.3 5.4 5.5

General information, Data and Test Section – Attachment 03 Elevation Data – Attachment 04 Formulas for Determine Hydrosatic Testing Pressure and Holding Time – Attachment 05 Tentative schedule for execution works as shown in – Attachment 06 Cleaning, filling, pressure testing, dewatering & drying diagram – Attachment 07

Method Statement

PT. DUTA GRAHA INDAH Tbk Project

Location Pages

Karebbe HEP- Package K-8A Road and Oil Pipeline Realignment

Soroako – Sulawesi Selatan 3 of 14

5.6

MS 24

ITEM:

CLEANING AND HYDROSTATIC TEST PROCEDURE

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The test schematic diagram and general arrangement for Water Filling, Pressure Testing, and Dewatering Diagram shown in – Attachment 08

6.0 DETAIL PROCEDURE FOR PIPELINE CLEANNING, FILLING, HYDROTESTING, DEWATERING WORKS 6.1

Pre-Test Preparation Works 6.1.1 Fabricated all temporary spool, water filling line, test blind, and others related accessories needed for water filling, testing, dewatering. All drawings for for temporary line will submit to Client for approval. 6.1.2 Check and verify the completeness of NDE for pipeline weld joint to assure that all field joint had been Radiography Tested and accepted before the test. 6.1.3 Check the completeness of field Wrapping inspection or Holiday test completed with Test Report. 6.1.4 Prepare all equipment and device for testing to assure all equipments and devices have up-date certification and calibration. 6.1.5 Prepare all other materials and devices such as test gaskets, vent and drain valves and water hose for filling and draining. 6.1.6 After satisfactory cleaning the pipeline will fill the water for hydrostatic testing. Provide shelter at the test start and end point to ensuring that the test heads & test devices are protected from direct exposure to sun ray. 6.1.7 Install barricades, signboards and warning tags at test start and end points.

6.2

Water Filling 6.2.1 Install and set-up water filling line and equipment as shown in Attachement 08 B. Pressure gauge should be placed on STA 0+000 and STA 1+293. 6.2.2 Fill water from 1+293 (road to Sorowako) and close drain at STA 1+293 (road to Sorowako) 6.2.3 Open vent valve in STA 0+000 (road to Malili) 6.2.4 After water comes out through from vent valve at STA 0+000 (makesure no air trap), vent valves in STA 0+000 shall be closed before shutting off the fill pump. 6.2.5 If that much air is allowed to enter the pipe, re-start the filling pump until water comes out through vent valves.

6.3

Pressurization, Pressure Testing and Holding Time Open all valves in pressure injection line and start the pressure pump. When 6.3.1 water comes out through the bleed valve, re-set water meter to zero (0). Open the injection line to start pressurization.

Method Statement

PT. DUTA GRAHA INDAH Tbk Project

Location Pages

Karebbe HEP- Package K-8A Road and Oil Pipeline Realignment

Soroako – Sulawesi Selatan 4 of 14

6.3.2 6.3.3

6.4

MS 24

ITEM:

CLEANING AND HYDROSTATIC TEST PROCEDURE

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Record the ambient temperature. Raise the pressure up to 25% of test pressure then shut off the pump and close the valve in injection line. Hold for 30 minutes to allow some degree of pressure and temperature stability, and also check for leaks on all above ground connection. Eliminate if any leaks at flange and treaded connections. If no leakage detected, raise the pressure up to 50% of test pressure. Hold for 30 minutes & check again. After the hold period, re-start the pressure pump and continue pumping up 6.3.4 to 90% of pressure test. Hold for 30 minutes to allow the pressure and temperature fully stabilize. 6.3.5 Check for leaks at all above ground connections. 6.3.6 Note and record every 30 minutes reading of ambient temperature, water temperature and line pressure both at STA 0+000 (road to malili) and STA 1+293 (road to sorowako) end of test section. 6.3.7 If needed, water to be added to achieve stability at 90% at test pressure. 6.3.8 After the hold period, when pressure and temperature in the line have stabilized, re-start the pressure pump and gradually increase the pressure up to test pressure (Plus 1%, Minus 0%). Pumping shall stop when the test pressure have been reached. 6.3.9 After a hold period of 6 hours will start pressure have stabilized. Holding time period 4 hours, with the first of 2 hours the pressure is stable, no pressure drop then it will continue for another 4 hours for total 6 hours. If any leaks that cause pressure drop, re-test may require for another 6 hours. If any leak detected on welding joint or pipe material, pressure shall be refused for repair work and test shall be carried out from the first step. (mention part 6.4.1) 6.3.10 Variations in pressure reading shall be justified in accordance with Project Specification. 6.3.11 Pressure drop during test shall be limited to and proportional to any drop in temperature of the test water during holding time period or presence of visible leaks on above ground connection where in any effort in tightening cold not eliminate such leak. Uncountable loss in pressure points to presence of leak in the pipeline and if 6.3.12 this condition is encountered, the leak shall be located and when found test shall be aborted. 6.3.13 Test is successfully completed when pressure holds for 6 (six) hours achieved. Dewatering and Drying. 6.5.2 After the test is completed and accepted by Client/Owner/third Party Inspector, the pressure will be relieved through dedicated vent valve. It is

Method Statement

PT. DUTA GRAHA INDAH Tbk Project

Location Pages

Karebbe HEP- Package K-8A Road and Oil Pipeline Realignment

Soroako – Sulawesi Selatan 5 of 14

6.4.1 6.4.2 6.4.3 6.4.4

MS 24

ITEM:

CLEANING AND HYDROSTATIC TEST PROCEDURE

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not allowed to bleed the pressure off at very fast rate as this might cause the pipeline to callapse. Safe rate suggested is 2~3 psi per second is to be carried out. The test equipment, pressure injection and measuring devices shall be disconnected. Inject the Compressed air and gradually increase the pressure up to 450 psig. Continue run compressore to ensure that the line is dry. Completion of dewatering operation will be determined when no significant water out. When pipeline dewatering is deemed acceptable, dismantled the temporary connection.

7.0 INSPECTION, ACCEPTANCE, DOCUMENTS AND RECORDS 7.1 7.2 7.3

7.4

The testing, dewatering and drying works shall be witnessed, inspected and accepted by PT. DGI, KHEPP, third party representative. Purpose for certification, Third Party Representatives shall witness the pressure testing from start until successful completion and sign the test record. The following documents and records will be prepared by PT. DGI for review and signed by all inspecting and accepting parties. 7.3.1 Calibration certificates of Pressure test gauge. 7.3.2 Using the “As-built” Survey, the maximum, minimum and end elevation of each line test section shall be determined in order to calculate the hydrostatic head pressure. 7.3.3 Acceptance criteria for test shown on Diagram – Pressurization, Holding period and De-pessurization. 7.3.4 Record of water volume added or subtracted to stabilized pressure during hold period and at the end of testing including the calculation to justify variations. 7.3.5 Temperature and pressure readings at start of test, during hold period and at end of test including calculations to justify variations. 7.3.6 Pressure test certificate for the successfully completed test. 7.3.7 Pipeline dewatering inspection and acceptance report. 7.3.8 Sample blank forms of inspection, monitoring and acceptance report are presented in – Attachment 10. Sign off the documents shall be completed and copies submitted to all involved parties. The original documents shall be submitted to pipeline certification Company to use in obtaining Third Party Certificate for use the pipeline.

Method Statement

PT. DUTA GRAHA INDAH Tbk Project

Location Pages

Karebbe HEP- Package K-8A Road and Oil Pipeline Realignment

Soroako – Sulawesi Selatan 6 of 14

MS 24

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ATTACHMENT - 01 TEST ORGANIZATION 1. Pipeline Engineer

:

2. QC Engineer

:

3. Pipeline Sptd. / Spv.

:

4. Hydro test, Dewatering and Drying Engineer : 5. Safety Engineer

:

6. Labour Crews
Foreman : …………Persons
Technician : …………Persons
Comp. / Pump Operator : …………Persons
Recorder : …………Pesrons
Skilled Fitter : …………Persons
Welder : …………Persons
Electrician : …………Persons
Safety Man : …………Persons
Driver : …..…... Persons ----------------------------------------------------------------------------------- + Total : …………Persons

WITNESSING, INSPECTING AND ACCEPTING PARTIES 1. QA/QC PT. DUTA GRAHA INDAH 2. QA/QC KHEP PROJECT 3. THIRD PARTY INSPECTOR

Method Statement

PT. DUTA GRAHA INDAH Tbk Project

Karebbe HEP- Package K-8A Road and Oil Pipeline Realignment

Location

Soroako – Sulawesi Selatan

Pages

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MS 24

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ATTACHMENT – 02 LIST EQUIPMENTS, DEVICES, TOOLS & CONSUMABLES 1.0

EQUIPMENTS AND DEVICES 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9

2.0

Air Compressor Air Compressor (Stand by) Filling Pump Pressure Pump Pressure Gauge Temperature Gauge Valves, Fitting, Connectors Flow Meter HT / Radio Communication

700….CFM 600… CFM 600 Ltr/Min 5000 Psi 5000 Psi 200 0F various size

: : : : : : : : :

1 1 2 1 2 2 1 1 4

Unit Unit Units Units Units Units Lot Unit EA

TOOLS AND CONSUMABLES 2.1 Hand Tools 2.2 Test gasket and Joint Sealant/Teflon Tape 2.3 High Pressure Flex. Hose various size

: 1 Lot : 1 Lot : 1 Lot

Method Statement

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Location Pages

Karebbe HEP- Package K-8A Road and Oil Pipeline Realignment

Soroako – Sulawesi Selatan 8 of 14

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ATTACHMENT – 03 GENERAL DATA AND TEST SECTION

1.0

GENERAL DATA Pipeline Route Joint Coating Material Holiday Test Average Depth (from TOP of pipe)

: FUEL PIPELINE RELOCATION D 12” x 1,293M : 2 Layers wrapping polyken : Spy Pin Hole Detector, Audible Type : 0.95 meters

Pipeline Data 1.1 Dia. X Length 1.2 Material Specification 1.3 Pipe Wall Thickness 1.4 Design Pressure/Temperature 1.5 Test Pressure 1.6 Pipeline Class

: 12”Dia. X 1.293 meters : API 5L X52 : 0.344” : 2000 psig. : 2500 psig. : Class 1

PIG CLEANING & TEST SECTION GENERAL INFORMATION

1. TEST SECTION

LINE DESCRIPTION Pipeline Data

FILLING POINT DISCHARGE KM 20.100 KM 21.400

2. Dewatering and Drying Section LINE DESCRIPTION Pipeline Data

START POINT END POINT KM 20.100 KM 21.400

Method Statement

PT. DUTA GRAHA INDAH Tbk Project

Location

Karebbe HEP- Package K-8A Road and Oil Pipeline Realignment

Soroako – Sulawesi Selatan

Pages

9 of 14

MS 24

ITEM:

CLEANING AND HYDROSTATIC TEST PROCEDURE

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ATTACHMENT – 04 ELEVATION DATA NO. LINE DESCRIPTION

Location

Elevation

1. Fuel Pipeline Relocation Start Point End Point Lowest Point Highest Point

KM 20.100 KM 21.400 STA 1+293 STA 0+000

115.708 85.6 85.653 115.708

NOTE :

WILL FILL AFTER PIPELINE DRAWING RECEIVED

Method Statement

PT. DUTA GRAHA INDAH Tbk Project

Karebbe HEP- Package K-8A Road and Oil Pipeline Realignment

Location

Soroako – Sulawesi Selatan

Pages

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MS 24

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ATTACHMENT - 05 REFER TO ASME 31.4 PARAGRAPH 437.4.1 FORMULAS FOR DETERMINE HYDROSTATIC TESTING PRESSURE AND HOLDING TIMES. Hoop Stress at Highest Test Point (SH = Hoop Stress) > 0.2 x SMYS SH = PD/2T Where ; P D T

= Allowable Operating Pressure (refer to ASME 31.4 paragraph 401.2.2) = Diameter Pipe = Pipe Wall Thickness Calculation Hydrostatic Testing of Internal Pressure

•

Hoop Stress test pressure (highest point of pipeline) Allowable stress at test pressure : SH = Hoop Stress < 0.2 x SMYS SH = PD / 2T Where : P = 2000 psi D = 12“ T = 0,344” SMYS = 52000 psi

(12”)(2000 psi) > 0,2 x 52000 2(0.344”) 34883.72 psi > 10400 psi From above calculation: Accordance with ASME 31.4-2002 paragraph 437.4.1, pipeline shallbe subjected at any point to ahydrostatic test equivalent to not less than 1.25 times allowable design pressure for not less than 4 hours

Method Statement

PT. DUTA GRAHA INDAH Tbk Project

Karebbe HEP- Package K-8A Road and Oil Pipeline Realignment

Location

Soroako – Sulawesi Selatan

Pages

11 of 14

MS 24

ITEM:

CLEANING AND HYDROSTATIC TEST PROCEDURE

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ATTACHMENT – 06 TENTATIVE SCHEDULE FOR PIG CLEANING & HYDROTESTING

WORK ITEM

DURATION

1. 2. 3. 4. 5.

3 1 1 1 1

Preparation Pig Cleaning Water Filling Pressure Testing Dewatering and Swabbing

START

FINISH

Days Day Day Day Day

ATTACHMENT – 07 CLEANING, TESTING & DEWATERING SCHEMATIC DIAGRAM

1.

FILLING WATER SCHEMATIC DIAGRAM

:

FIGURE 1

2.

HYDROTEST SCHEMATIC DIAGRAM

:

FIGURE 2

3.

DEWATERING and DRYING SCHEMATIC DIAGRAM

:

FIGURE 3

Method Statement

PT. DUTA GRAHA INDAH Tbk Project

Karebbe HEP- Package K-8A Road and Oil Pipeline Realignment

Location

Soroako – Sulawesi Selatan

Pages

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MS 24

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ATTACHMENT – 08 PRESSURIZATION, HOLDING PERIOD & DE-PRESSURIZATION GRAPH

100%

Holding time 6 Hours

90%

30 Min

Test Press 2500 psig.

80% 70% 60% 50%

30 Min

40% 30%

30 Min

20% 10% 0%

Pressurization

Holding Time

De-pressurization

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Location Pages

Karebbe HEP- Package K-8A Road and Oil Pipeline Realignment

Soroako – Sulawesi Selatan 13 of 14

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ATTACHMENT – 09 CALIBRATION CERTIFICATE OF MEASURING DEVICES

NOTE : WILL BE ATTACHED TO TEST PACKAGE

Method Statement

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Karebbe HEP- Package K-8A Road and Oil Pipeline Realignment

Location Pages

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ATTACHMENT – 10 DOCUMENTATION AND RECORD FORM

HIDROSTATIC REPORT KAREBBE HEP – PACKAGE K – 8A ROAD AND OIL PIPELINE REALIGNMENT TIME

STA 0+000 PRESSURE, Psi TEMP , C

Prepared, by

) ( CV. MITA PERDANA

STA 1+293 PRESSURE, Psi TEMP , C

Witness, by

(

) PT. DGI

REMARKS

Witness/Approved, by

(

) KHEP-PT INCO