EPC for Flowlines, Gathering lines and
Export Pipelines (BOC-1703)
Method Statement for HDD Pipelines Hydrostatic Test
001 Review for approval 25-Jan-22 Mustafa Heydar Younes A.
Prepared Checked
Revision Reason for issue date Approved by
by by
Rev.
MGP1-PL1-MSK-BA-6070-0002
Method Statement for HDD Pipelines
Hydrostatic Test
MGP1-PL1-MSK-BA-6070-0002
INDEX
1. Scope of the work .................................................................................................................... 3
2. Purpose of this method statement.......................................................................................... 3
3. Design data .............................................................................................................................. 3
4. Job description ........................................................................................................................ 3
5. Process..................................................................................................................................... 3
5.1 General ..................................................................................................................................... 3
5.2. Order of performance ..................................................................................................... 4
5.2.1 Cleaning and gauging .................................................................................................. 4
5.2.2 Water filling .................................................................................................................. 4
5.2.3 Thermal stabilizing ...................................................................................................... 5
5.2.4 Dewatering ................................................................................................................... 5
5.3. Line Pressure graphic .................................................................................................... 6
6. Health, Safety and Environment ............................................................................................. 6
6.1. General ............................................................................................................................ 6
7. Attachment ............................................................................................................................... 8
7.1. WPS for PIG launcher, Receiver and test header welding ........................................... 8
Method Statement for HDD Pipelines
Hydrostatic Test
MGP1-PL1-MSK-BA-6070-0002
1. Scope of the work
The scope of this document is to specify activities, as per cleaning, gauging, filling, strength tests,
Leak test, dewatering and swabbing for the pipeline (Table 1). Please refer to the general Hydro Test
Procedure for more references (MGP1-PL1-CPP-BA-6070-0016).
2. Purpose of this method statement
The Purpose of this Work Method Statement is to give a precise guide as to how the work shall be
executed and to ensure that the work is performed with respect to Health, Safety, and Environment
and Quality standards.
3. Design data
Table 1. 28” 600# Export Oil Pipeline from CPF-2 to DS1 test design details (HDD Section)
Test Pressure
DN OD Thickness Grade Length DP (4 hour)
inches mm Mm API 5L m bar bar
28 711 15.88 X65 500 95 118.75
4. Job description
The hydrotest activities of the HDD pipe string shall be performed as a Single section. This Includes
cleaning, gauging, water filling, thermal stabilization, strength test, pressure test, de-watering and
swabbing. Precautions shall be considered to avoid any risk of incidents.
5. Process
5.1 General
Company to be notified and all test packs to be submitted and receive clearance for
testing by all parties. The test pack needed to be reviewed by company 72 hours before
the test.
No work shall start before having the work permit in place. (Hot Work Permit for Hydro-
Test)
First activity, the supervisor shall conduct tool box meeting in presence of all the team
involved in this operation, identifying the scope and hazards. He will also outline the
hazards that may occur and of the appropriate measures to be taken in the event of an
emergency
Communication shall be tested by informing base site manager that preparation work
started.
It is essential to be aware of the pressure in hoses, valves and gauges
Method Statement for HDD Pipelines
Hydrostatic Test
MGP1-PL1-MSK-BA-6070-0002
Never attempt any remedial works on equipment whilst under pressure. In case of any
leakage the pressure shall be dropped to 0 bar prior to repairs undertaking
Always tie down and secure hoses to fixed locations to prevent whipping in the event of
failure
Always check that the fittings and equipment to be used are to the correct pressure
rating.
Prior to initiation of the test, a site walkdown of all equipment shall take place with
company to ensure all components are suitable for testing and ANSI class range.
During the testing minimum 30m of radius shall be considered as a minimum safety
radius for hazards at test headers and pipeline. No one shall enter this area during
testing.
5.2. Order of performance
The main activities, specified in this procedure are listed here below
5.2.1 Cleaning and gauging
For cleaning, initially a cleaning run would be applied. By the acceptance of company in term of
cleanliness thereafter, a gauging PIG shall be ran only once the cleaning run/s are completed. A bi-
directional PIG shall be launched from PIG launcher to Pig receiver. After every pigging run, pipeline
shall be depressurized and PIG shall be recovered from receiver side. This operation shall be
continued until the line becomes clean.
After cleaning a pig with a gauging plate shall be ran on a bi-directional PIG fitted with gauging plate,
from launching trap to receiving trap. The inspection of the gauge plate has to be done and final
acceptance of gauging activity shall be confirmed.
The pressure of the PIG would be set at 3 barge to avoid a large storage of pneumatic energy.
Gauging plate is aluminium made 12mm thickness and radiused in 8 locations to allow deformation
when an obstruction occurs. The plate shall be 642mm diameter. It would be placed in front of the
last urethane cup or disc. In case of any plate damage after the run, the plate would be replaced by a
new one and the run will be repeated.
5.2.2 Water filling
Once cleaning and gauging pig runs are completed and accepted by COMPANY, the low pressure
headers will be removed, and high pressure test headers welded into position.
One headers will be used for filling and the other header will be used to vent air. Quality of water shall
be verified before filling. The water would be supplied from water station in tanks of 36000 lit capacity
and would be of potable quality. Pressurizing capacity of the filling water shall be 10 bar.
Method Statement for HDD Pipelines
Hydrostatic Test
MGP1-PL1-MSK-BA-6070-0002
5.2.3 Thermal stabilizing
Fig.03 Testing diagram
After filling completed, water and steel body of pipeline shall be checked for thermal stabilization.
Duration of thermal stabilization is 4-8 hours and depends on, the time when the pipeline
temperatures stabilize (within 1C) with surrounding by recorded parameters. After reaching thermal
stabilization, pressurization shall start.
Pipeline shall be pressurized to test pressure (118.75 bars) for 4 hours.
From 0 bar to 35 bar the pressurizing rate should be between 1 bars per minutes. During this period
pressure and temperature shall be continuously logged. No filling is allowed when the temperature is
2 C or falling.
At 35 bar of test pressure; the pipeline to be stabilized for 30 minutes, during this period air
entrapment calculation shall be done. Air at more than 0.2% of total pipeline volume is not allowed
and the line will become empty of water.
Pressurization shall be resumed from 35 Bar to 90 Bar at rate not more than 0.5 bar., per minute.
Then the pressurization should be continued to 118.75 bar at a rate not exceeding 0.25 bar per
minute.
The pressure should be maintained at 118.75 bar, for 4 hours. The capacity of the pressurizing pump
would be 600 bar.
To fit the bolts of flanges the toque value of 25 bar would be applied.
After the acceptance of test, pipeline shall be de-pressurized at rate not more than 1 bar to 40%, and
at 2 bar., there-after.
5.2.4 Dewatering
After de-pressurization of the line, the compressor shall be fitted to the receiver end. Afterwards in
order to dewatering of the line the bi-directional PIG used to originally fill the pipeline, will be blown
back towards the filling end by the compressed air. Both high pressure test headers shall have
appropriate fittings to allow the compressor to be fitted and also allow for instrument connections i.e.
gauge and vents being fitted. When the dewatering activity is finished then the header shall be cut off.
The disposal water shall be forwarded through a hose to an excavated pond. Due to PTW the pond
depth shall be restricted to 1.5m, therefore to avoid excessive excavation of area in term of length and
width a temporary 1.5m wall will be made by sand bags in the aboveground periphery of the pond.
Accordingly the total accumulative depth of the pond would be 3m. To provide a capacity of 200cubic
meters, the width of the area will be 4m and the length will be 16m.
Method Statement for HDD Pipelines
Hydrostatic Test
MGP1-PL1-MSK-BA-6070-0002
Launching Side
Receiving side
Pipeline section
Directional pig Flanged opening
Fig. De-watering
5.3. Line Pressure graphic
The strength and leak tightness test method, are showed in the follow chart,
Fig. 05 Line Pressure graphic.
6. Health, Safety and Environment
6.1. General
Contractor / subcontractor shall take all necessary measures to ensure that his own personnel, those
of the COMPANY and the general public are adequately protected from the consequences of a
possible system failure during the test activities.
Only authorized personnel shall be allowed access to areas where potentially hazardous operations
are being carried out. A safety radius of 30m is required around the test area.
Between both ends of pipeline communication shall be provided.
Hydro test supervisor must check Availability of permit to work (Hot Work), working of communication
devices, barricades, and calibration certificates of instruments, pump certificate, hose rating, valve
Method Statement for HDD Pipelines
Hydrostatic Test
MGP1-PL1-MSK-BA-6070-0002
rating and fitting rating. A Risk Assessment, JSA and START card must all be in place before the
start of the Hydro-test Activities. A Tool Box Talk (TBT) must be conducted prior to the work activity in
conjunction with the START Card. The areas must be inspected by MSK HSE before the start of the
activity as it is a hold point.
Risk Assessment and all relevant documentation shall be in place out prior to starting Job Activity,
and all local certifications shall be in place.
In case the testing continues into a night shift then the related night permits and lighting shall be
provided at both ends of pipeline.
The Project Risk Assessment Procedure shall be followed and read as per MSK Document HSE
requirements (STARRT / TBT)
Before start of any testing activity, the following certificates of the listed below accessories shall be
certified by third party and available at testing site.
1. Hose certificate – Third Party
2. Valves certificates – Third Party
3. Fittings certificates – Third Party
4. PT report for nipples – NDT Subcontractor
5. Whip check – Third party certificate to be provided
6. Pumps and Compressors certificates – Third Party
7. Gauges and Recorders certificates – Third Party
8. PIG certificate – Third Party
Note: Whip check was also included in the part of pre- test arrangement
Method Statement for HDD Pipelines
Hydrostatic Test
MGP1-PL1-MSK-BA-6070-0002
7. Attachment
7.1. WPS for PIG launcher, Receiver and test header welding
Method Statement for HDD Pipelines
Hydrostatic Test
MGP1-PL1-MSK-BA-6070-0002
