PIGGING AND TESTING MARCH 2005

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TABLE OF CONTENTS

SECTION 1.0 INTRODUCTION

SECTION 2.0 PIPELINE PIGGING &HYDROTESTING DATA

SECTION 3.0 EQUIPMENT & INSTRUMENTATION

SECTION 4.0 PIGGING PROCEDURE

SECTION 5.0 HYDROTEST PROCEDURE

SECTION 6.0 SAFETY GUIDELINES

SECTION 7.0 RECORDS AND FORMAT FORMS

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APPENDICES

APPENDIX A GAUGING PLATE DIA CALCULATIONS

APPENDIX B PIPELINE HYDROTEST CALCULATIONS

APPENDIX C PIGS & ACOUSTIC PINGER SYSTEM DATA

APPENDIX D CHEMICALS DATA

APPENDIX E PUMPS DATA

APPENDIX F SAFETY PROCEDURE

APPENDIX G RECORDS & ACCEPTANCE FORMS

APPENDIX E DRAWINGS

APPENDIX F CALIBRATION CERTIFICATES

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SECTION 1.0

INTRODUCTION
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SECTION 1.0

INTRODUCTION

1.1 GENERAL

This document describes the Contractor’s proposed procedure for

pigging and hydrostatic testing of Rigid pipelines for the RSPPM
project of ONGC at Mumbai High fields in India

The work of pigging and hydro-testing of pipelines will

commence after the completion of all associated installation
works such as risers, crossings and free span correction. A work
boat will be utilized to carry out the scope of work together with
a secondary boat (if required) to perform duties such as
preparatory work, receive pigs, transfer personnel, etc.

Site conditions often cause changes in offshore work plans and

as such, the Contractor reserves its representative’s sole right to
alter these procedures in order to best suit the site conditions
and safety of personnel and equipment. The company
representatives onboard the vessel will be informed of any major
deviations from this procedure and the reason for it, prior to any
such deviations being implemented.
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SECTION 2.0

PIPELINE PIGGING AND HYDROSTATIC DATA

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SECTION 2.0

2.1 PIPELINE PIGGING & HYDROSTATIC TESTING DATA

The scope of work broadly covers the FLOODING, CLEANING,

GAUGING and HYDRO-TESTING of the following segments of
rigid pipelines pipelines.
ONGC Pipeline O.D Thickness(mm) Length Test Pre. Service
Ref.No Segment (mm) P/L R/L ( km ) kg/cm2
01 RS 11-ICP 323.9 14.3 25.4 4.8 117.125 WF
02 RS2-ICD 323.9 14.3 25.4 8.3 117.125 WF
03 RS3-BHS 323.9 14.3 25.4 3.6 117.125 WF
04 BHS-RS3 168.3 7.1 14.3 3.4 131.25 GL
05 RS1-SA 273.1 12.7 25.4 4.2 117.125 WF
06 NM-RS2 168.3 7.9 14.3 4.0 131.25 GL
07 SC1-RS1 168.3 7.1 14.3 3.6 131.25 GL
08 IB-ZB 168.3 7.9 14.3 8.9 131.25 GL
09 ZB-ICD 406.4 15.9 22.2 11.8 117.125 WF
10 ICP-RS11 114.3 7.1 14.3 4.6 131.25 GL
11 SI-5-SHG 323.9 14.3 25.4 11.6 176.25 WF
12 SF-S1-5 219.1 11.1 20.6 3.7 171.25 S1 SAND
13 EC-S1-5 219.1 11.1 20.6 4.0 171.25 S1 SAND
14 IH-II 168.3 11.0 18.3 5.3 171.25 S1 SAND
15 EE-SHG 168.3 11.0 18.3 2.3 171.25 S1 SAND
16 II-S1-4 168.3 7.1 14.3 3.8 131.25 GL
17 IJ-SHP 273.1 12.7 25.4 3.0 176.25 WF
18 S1-6-IM 273.1 12.7 25.4 2.9 176.25 WF
19 RS7-SHP 323.9 14.3 25.4 4.8 117.125 WF
20 SHP-RS7 168.3 7.1 14.3 4.8 131.25 GL
21 RS5-BHN 323.9 14.3 25.4 13.0 117.125 WF
22 NM-RS5 168.3 7.9 14.3 2.9 131.25 GL
23 SB-RS4 168.3 7.1 14.3 2.6 131.25 GL
24 RS4-BHS 323.9 14.3 25.4 6.5 117.125 WF
25 ID-RS8 114.3 7.1 14.3 3.2 131.25 GL
26 RS8-ID 273.1 12.7 25.4 4.0 117.125 WF
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2.2 REFERENCE

All the works shall be carried out as per the followings

Specifications, Codes and Standards

a. ANSI B31.4 - Liquid Petroleum Transportation Piping system

b. ANSI B31.8 - Gas Transmission and Distribution Piping

system

c. API RP 1110 - Pressure Testing of Liquid Petroleum Pipelines

d. ASME Sec. VIII - Boiler and Pressure Vessels Code Div 1.

e. DNV-OS-F101 - Submarines Pipelines System

f. ONGC Spec. No - 2022 Rev.0, Hydro-testing for submarine

pipelines.
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SECTION 3.0

EQUIPMENT AND INSTRUMENTATION

3.1 EQUIPMENT AND INSTRUMENTATION

The following equipments & instruments as minimum will be

available at site for the pigging and hydro-testing operation.

3.1.1 PIGGING OPERATION

1 Fill Pumps 500m3/hr, 12 Bar Max. Pressure – 1 ea

150m3/hr, 21 Bar Max. Pressure – 2 ea
2 Chemical dozing pumps – 3 ea
3 6”/8” Flow meters – 3 ea
4 Strainers 150 microns
5 Non Return Valves – 3 ea
6 Day tank – 1 ea
7 Pressure Gauge (0 to 25 kg/ cm2) – 3 ea
8 Connecting hoses 2” and 4”
9 Pump delivery manifolds
10 2” Valves - 10 ea
11 4”,6”,8” Valves as required

3.1.2 TESTING OPERATION

1 High pressure Test pumps – 5000 psi with adjustable volume – 2 ea

2 Dead weight Testers (4 to 250 kg/cm2) – 2ea
3. Pressure Chart Recorders (0 to 250 kg/cm2) – 2 ea
4 Temperature Chart Recorders (0 to 50 deg. C) – 6 ea
5 Pressure Gauges (0 to 250 kg/cm2) – 8 ea
6 Digital Temperature Indicator - 4 ea
7 RTD Sensors – 8 ea
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3.1.3 GENERAL

1 Hoses for pigging and hydro-testing

2 Manifold and fitting for both pigging and testing
3 Test Cabin and material container
4 Rigging tools and tackles
5 Chemical INDION-175 T
6 Pigs
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SECTION 4.0

PIGGING PROCEDURE

SECTION: 04

PIGGING PROCEDURE

4.1 INTRODUCTION

The pigging operation comprising of cleaning and gauging of the

p
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ipelines will commence only after all the pipeline crossings, free
span corrections and burial have been completed.

Company shall arrange work permits for 24 hours uninterrupted

Operations

The cleaning, displacement and gauging pigs will run from the
permanent launcher to the permanent receiver.

4.2 PIGS DESCRIPTION

4.2.1 Cleaning Pig:

The cleaning pig used will be a bi-directional disc type pig

equipped with circular steel wire brushes as cleaning elements.
The brushes will be fitted onto the pig body in such a way so as
to provide a 360 deg cleaning coverage. The brush cleaning pig
shall be capable of removing any lose debris in the pipeline
including welding slag, loose mill scale, corrosion product, etc.
by magnets fitted on pig body.

4.2.2 Displacement Pig:

The displacement pig used will be a bi-directional disc type pig

4.2.3 Gauging pig

The gauging pig shall be a bi-directional disc type pig, equipped

with a removable gauging plate in front of the third cup. Gauging
plate shall be 12.7mm thick machined aluminum. The gauging
p
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g will have a pinger housing which will enclose an acoustic

pinger, capable of emitting signal for a period of twenty (20)
days.

4.3 CHEMICAL INJECTION

The seawater will be used to push the pig train and shall be
mixed with chemical INDION – 175 T which is a cock tail of
CORROSSION INHIBITOR, OXYGEN SCAVENGER, BIOCIDE and
FLOURESCENT DYE.

Technical information sheets for the above chemicals are

included in Appendix-E

The chemicals will be mixed with seawater on the delivery side

of the pump. The chemicals will be stored in drums and a
constant volume will be mixed with pumped seawater by
chemical dozing pump fitted with adjustable flow screw and also
stroke counter for flow measurement depending upon the
output flow rate obtained from the pump.

The flow rate obtained from the pump will be continuously

monitored by a flow meter, which will be installed on the pump
outlet manifold.

4.4 SEQUENCE OF OPERATION

4.4.0 PREPARATORY WORKS

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4.4.1 Filling pump delivery hoses shall be connected to the input

port of the pig launcher.

4.4.2 A drain hose shall be connected to the pig receiver at receiver

platform and the hose terminated at approved point for
disposal of inhibited water.

4.4.3 Exposed portion of test section at both platform ends shall be

covered from direct sunlight by suitably covering them as
required to reduce temperature effects

4.4.4 One pressure Gauge of suitable range shall be fitted on

pig launcher

4.5.0 FLOODING, CLEANING, GAUGING AND FILLING

4.5.1 Equipment layout during the pigging operation is as per sketch

attached in annexure

4.5.2Flooding, Cleaning, Gauging and Filling are the sequence of

operations and the followings pigs train are launched.
- Cleaning pig with brushes, magnets
- Batching pig
- Cleaning pig
- Gauging pig

4.5.3 Initially pump seawater, volume equivalent to 250 meter

length of pipe before launching of any pigs

4.5.4 Launch Cleaning Pig with Brushes and Magnet

4.5.5 Pump seawater equivalent to 250 m length of pipe behind

cleaning pig

4.5.6 Launch Batching Pig

4.5.7 Pump seawater equivalent to 250 m length of pipe behind

Batching Pig
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4.5.8 Launch Second Cleaning Pig

4.5.9 Pump seawater equivalent to 250 m length of pipe behind

second cleaning pig

4.5.10 Launch Gauge Pig Fitted With Aluminium Gauge Plate

4.5.11 start chemical injection using a chemical dozing pump with

Stroke adjustment to pump chemical as per required
Concentration
4.5.12 During the pigging operation the following readings shall be
Monitored and recorded for every 15 minutes.

- Pressure at launcher from gauge

- Flow meter readings
- Chemical injected

4.5.13 Constant communication should be maintained between

launcher and receiver end. At completion of 90% of fill volume
behind the first pig, inform to receiver end operator to
continuously note the pig arrival.

4.5.14 once all pigs arrive in the pipeline pump should be stopped to
remove the pigs from the receiver

4.5.15 The gauging pig should be removed carefully from the

receiver and the Gauging plate checked for any sings of
damages.

4.5.16 Any further work will be carried out only after the acceptance
of the cleaning and gauging pig runs by the company
representative.

4.5.17 In the event of any significant damage to the gauging plate,

an additional gauging pig will be run, to reconfirm the
presence of any possible obstruction in the pipeline.

4.6 STUCK PIG CONTINGENCY PLAN

4.6.0 Pig Getting Stuck:

4
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.6.1 While the cleaning, displacement and gauging pigs are being
run, continuous monitoring will be done with the help of a flow-meter
with a direct readout totalizer installed on the out flow manifold on the
pump. Pressure monitoring in the pipeline will be done through a
pressure gauge installed on the launcher.

4.6.2 An indication of a pig getting stuck will be obtained from the

sudden rise in the pressure reading on the gauge and none or
very little out flow at the receiver. The volume of water
pumped into the pipeline will be obtained from the flow-meter
tantalizer. This volume will give an approximate “hang-up”
location of the pig. The company representative will be
notified on pig getting stuck. Pumping will be stopped and the
further course of action will be decided upon by the
Contractor’s representative and the company representative
will be advised of that.

4..6.3 Following is the procedure, which the contractor proposes to

adopt for dislodging and locating the stuck pig.

4.6.4 Dislodging a Stuck Pig:

4..6.5 All the valves on the receiver will be kept in closed

position and pumping will be commenced from launcher end. The
pressure will be raised to approximately 300 to 400psi and the
valves on the receiver opened instantaneously in an attempt to
jerk and dislodge the stuck pig. The cycle may be repeated
depending upon the situation.

4.6.6 The event the maximum pressure is not adequate to dislodge

the pig, the line shall be de-pressurized, and the pumping shall
be commence at the maximum discharge flow-rate of the pump
until such maximum pressure is achieved.

4.6.7 Should the above operations prove un-successful, relocate

pigging spread to receiver platform and commence pumping
from receiving platform to launching platform, in an attempt to
push the pig in the reverse direction.

4.6.8 If the above operation fails or if the pig by-passes, then the
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econd foam pig shall be launched from the receiving end in an

attempt to dislodge the pig and push it back to the launching
end

4..6.9 In the event of failure, further course of action will be decided

after consultation with the company representative.

4..7.0 Location of a Stuck Pig

4.7. 1 In the event of attempts of getting the stuck pig dislodged fail,
the operations for locations of stuck pig will commence.
Preliminary approximate position will be determined as described
in section 4.7.4 this location will be scanned

4.7. 2 Further with the help of an acoustic locator system which will be
lowered in to the water from a small boat. A marker buoy will be
dropped at the location where the signal received is maximum.
The cause of the stuck pig will be determined and further course
of action will be decided after consultation with contractor’s
base. The client representative onboard will be informed prior to
carrying out any remedial measures. Divers will inspect over the
pipeline for any possible damage at the buoyed section and
pinpoint the location with the aid of a hand held acoustic
receiver. Details of acoustic pinger location system are attached
in Appendix-D.

SECTION 5.0

HYDROSTATIC TESTING PROCEDURE

T
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esting will be carried out from permanent pig launcher to permanent

receiver

5.1.0 PREPARATORY WORKS:

5.1.1 Top side pipe-work shall be hooked up to the riser top and all in
line pipe-work leading to the pig barrel shall be installed by IOEC
on the both platforms.

5.1.2 Test limits shall be identified and test section isolated by

installing suitably rated blinds, spades, plugs, caps etc.
Permanent instruments and sensors (except the pig signalers)
on the line shall be removed and their connection points
plugged. Permanent valves which are not rated for the test
pressure shall be dropped and the branch suitably blinded.
Typical test isolation points are identified. Valves retained for
testing shall be kept in full open position during testing and
blinded on downstream as applicable.

5.1.3 A drain hose shall be connected to the pig receiver at receiver

platform and the hose terminated at approved point for disposal
of inhibited water.

5.1.4 Exposed portion of test section at both platform ends shall be

covered from direct sunlight by suitably covering them as
required to reduce temperature effects.

5.1.5 Filling pump delivery hoses shall be connected to the input port
of the barrel or test blind

5.1.6 Start the filling pump and the pipeline will be filled with
chemically treated filtered water for any make-up and the
pipeline will be pressurized to a pressure of 2.0kg/sq.cm.

5.2 THERMAL STABILISATION

Temperature reading will be monitored with suitable

thermocouples and Seawater temperature at 2 hours intervals.
P
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ressurization of pipeline will be commenced after temperature of

pipeline varies by 1deg.c with the temperature of seawater.

5.3 PRESSURISATION

5.3.1 Preparatory works:

5.3.1.1 After acceptance of thermal stabilization, the high pressure

hoses shall be connected to the pipeline as per sketch no: 04

5.3.1.2 Fire water pump shall be using for supply of water to the
pressure pump and operator will be continuously noted the
water level of the holding drum at any case the air will not
allow to enter into the pump suction

5.3.1.3 The vent valve of both ends shall be kept open initially.

5.3.1.4 Communication shall be established between those involved

in testing operation such as pump operator, launcher-end
technician, receiver-end technician and test controller.

5.3.1.5 Chemical shall be added with the pressurization water as per

required dosage.

5.3.1.6 All the instruments such as Dead Weight Tester, pressure

recorder, temperature recorder and pressure gauges shall be
fitted as per drawing given in appendix

5.4 PRESSURE CYCLE

5.4.1 Start the pressure pump, vent-off all the air inside the pipeline,
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nform to remote end or lowest elevation-end technician to close

the vent valve, then, close the vent valve at launcher.

5.4.2 Volume of water added into the pipeline section will be measured
through stroke counter installed on the pump and recorded
throughout the pressurization period.

5.4.3 Pressurize up to 50% test pressure at the rate not exceeding 2

bar/ minute

5.4.4 Stop the pressure pump, close the pressurizing valve at

monitoring end and hold the pressure for an hour.

5.4.5 During this hold period checking shall be made both the ends if
any visible leaks shall be rectified after depressurize the line to
zero.

5.4.6 The following readings shall be monitored and recorded every 15

minutes during one hour hold period.

- pressure at DWT
- ambient temperature
- pipe-wall temperature
- sub sea temperature

5.5 AIR ENTRAPMENT TEST

5.5.1 At 50% of the test pressure, before hold period a plot of added
Volume vs. Pressure and theoretical volume will be made and air
content in the pipeline will be established and will be less than
0.2% of volume of test section. In case the air content is more
than the limits, line shall be re-pressurized for air volume test
and calculations made second time.

5.5.2 In case the air volume content is more than 0.2% during
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econd pressurization, the line shall be re-filled using two nos

of displacement pigs.

5.5.3 After air entrapment test has given acceptable results, open
the pressurization valve at launcher.

5.5.4 Start the pressure pump and continue until the pressure
reached at test pressure.

5.5.5 The pressurization rate shall be as follows:

¾ 5 Bar/ minute increment up-to 80% of test pressure

¾ 2 Bar/ minute increment between 80% to 90% of
¾ 0.2 Bar/ minute increment up-to full test pressure.

5.5.6 During the pressurization period the following shall be

monitored and recorded

- Dead Weight Tester

- Ambient temperature readings from recorder
- Pipe wall temperature readings
- Sub sea temperature readings

5.5.7 On achieving the required test pressure in the line + 2% test

pressure, the pressure pump shall be stopped, the pressurization
valve closed, the pressurization hose disconnected from the
pipeline and the stabilization period shall commence.
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5.6 PRESSURE STABILISATION

5.6.1 The followings readings shall be noted every at 15 minutes

interval during the stabilization period:

- Pipeline pressure (continuous recorder)

- Dead weight tester readings
- Ambient temperature (continuous recorder)

5.6.2 A pressure drop will occur due to the stabilization process of the
pipeline line. However, during the stabilization period the
pressure should not fall below the test pressure.

5.6.3 Should the pressure drop be more during the first half hour of
stabilization period, the possibility of the defect exists and the
line should be inspected if the leakage is not found in the test
equipment.

5.6.4 If the pressure fall below the test pressure, then the line shall be
Re-pressurized up to the test pressure

5.7.0 PRESSURE HOLD PERIOD

5.7.1 Upon successful completion of the line stabilization and after the
company’s and client’s approval of the stabilization, the hold
period shall commence.

5.7.2 New charts duly signed by all parties shall be installed in all
recorders. The hold period shall be for a minimum period of
24hrs. During the hold period the followings readings shall be
noted

- Pipeline pressure (continuous recorder)

- Dead weight readings (every one hour)
- Ambient temperature (continuous recorder)
- sub sea temperature (every two hours)
- Pipe-wall temperature (every two hours)
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5.8 TEST ACCEPTANCE

¾ The test will be deemed acceptable if the unaccountable pressure

variation after taking into account any temperature gains \ losses
over the 24 hour are +/-0.2% of test pressure.

¾ Should the test not be acceptable after 24 hour, the test period will
be extended for a further 24 hours until the results are acceptable
to the client.

5.9 DEPRESSURIZATION

¾ Upon successful completion of the pressure test, connect hose ¾”

or large size depending on the out flow rate and tied with the
channel or platform. Depressurization will commence and gradually
increase the rate not exceeding 2 bars per minutes.

5.10 POST-TESTED WORK

5.10.1 On satisfactory completion of the test period and

Depressurization all the chart shall be removed from the
Instruments.

5.10.2 On complete depressurization, the instruments, hoses and

other temporary items shall be removed and the line restored.

5.10.3 The site shall be re-instated to its original condition by

removing all the temporary facilities.
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SECTION : 06

SAFETY PROCEDURE

All operations described in this procedure will be in accordance

with the relevant NOCPL, IOEC and ONGC system and policies.

Safety is the responsibility of every employee irrespective of

status. Employee shall ensure that their work place is safe and
functions efficiently and safely. Common sense should be applied
for safe working practices to be implemented and adhered to at
all times. Particular attention is to be given to work site safety
and to any safety procedure provided. The following safety shall
be adhered to at all times.

• Pre-plan your work with your co-workers and work together. You
must always work as a hydro-testing team. Never assume what
the other persons are doing. Make sure you know the complete
test system you are testing. Work out your test system and
know exactly what the test consists of.

• Help prevent accidents and injury before they occur. Stay alert
at all times. Report situations, which may cause or lead to
accident or injury.

• In particular, report all unsafe conditions, tools, equipment and

working practices immediately to operational management or
supervision on such that corrective action can be taken and
accidents avoided.

• No practical jokes, horseplay, drinking of alcohol or substance

abuse are allowed.

• Do not remove, displace, damage or destroy the safety

equipment provided for use on jobs.

• Permit to work procedures shall be strictly adhered to. No work

shall commence until the appropriate permit has been obtained
from a competent issuing authority.
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• Do not run except in extreme emergencies. Watch where you

walk and keep alert to the movement of equipment an others
persons around you. Use the handrail when on stairways.

• All employees shall maintain their work area in a neat, orderly,

tidy and litter free condition at all times.

• All employees shall use personal protective equipment (PPE)

provided for their use.

• Only authorized person shall be allowed to operate plant and

power tools.

• All employees shall inspect their work areas at the end of the
each shift and ensure that all air, water, diesel and electrical
supplies are shut off unless otherwise instructed.

• No person shall stay under loads handled by power operated

lifting equipment.

• All personal shall be aware of what to do in emergency.

• Personnel shall not carry out any work on vessels, pipelines or

fittings, which are under pressure. Systems shall be isolated and
depressurized prior to remedial work being carried out.

• Locate all points. Remove the plug form the temporary vent
valve and open all valves before filling with testing liquid.

• If the vent valves are closed while filling, air pressure will built
up inside the line and could cause serious injury when removing
a plug. Never remove a plug a valve is open.

• After all of the air is vented, close the vent valve and plug.

• When the system is completely filled with testing liquid, place

warning tags on all valves under test. Warn your co-workers to
keep distance and use barricade tape and signs for the test area.

• W
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hen the system is ready to be pressurized, remember or always

keep one person watching the pressure gauge. Never let the
pressure exceed the maximum test pressure.

• Check all flanges/fittings, etc. if a leak is discovered,

depressurized the system. Repair the leak and start again.

• Never try to tighten a fitting or flange under pressure because it

Live Bomb looking for an excuse. Do not be its victim.

• Continue to bring your test up in segments. Keep checking for

leaks.

• Remember to hold the test pressure until your engineer

instructions to depressurize the system.

• Once you have proved the test system, depressurize the system
to the nearest drain. Never drain the system over or near
electrical equipment. Use a hose and secure it.

• Now that the pressure gauges are at 0psi, and are sure no
pressure exists, remove all plugs and open vent valves slowly.

• Do not close vent valves until all liquids are drained. This will
eliminate Vacuums which would collapse vessels or tanks.

• Now that your test is complete, restore the system.

Barriers and Signs:

During the test operation no unauthorized personnel will be

allowed near by test head location and the area will be cordoned
off with proper sign board like - DANGER- “PIPELINE UNDER
TEST”

No other activity will be performed near the pipeline during testing.

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SECTION : 7

RECORDS AND FORMATS

During the different work phases to be performed throughout

this procedure, forms are to be filled by the NOCPL engineer.

7.1.1 Daily Operations Report :

A log kept at each location listing daily events occurring

throughout the contract, this shall be for inspection by the IOEC
representative at all times.

7.1.2 Record Charts ( Pressure & Temperature )

Record Charts shall be initialed on and signed off by both the

NOCPL, IOEC and ONGC

7.1.3 Pig Register

This forms records data of time, launching, receiving, recovery

and general condition of all pigs run through the pipeline.

7.1.4 Fill Report

This form records the volume of water pumped, pig velocity,

distance and amount of chemical added to the filling water.

7.1.5 Gauge Plate Acceptance Certificate:

This form records the details of the gauging pig run with all
relevant dimensional checks, it is to be signed by all the relevant
parties.

7.1.6 Pressurization Report

This form records data of pressure increase, rate and volume

injected
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7.1.7 Air Inclusion Report

This form records % of air inside the pipeline and related

calculations

7.1.8 Hydrotest Report

This forms records data of time, pressure and temperature

throughout the hydrotest period.

7.1.9 Test Acceptance Certificate:

This form includes detail of the actual hydrotest system and

instrumentation and is signed by all relevant parties.
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APPENDIX – A
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APPENDIX- A

RSPPM PROJECT GAUGE PLATE CALCULATIONS

The following formula as per ONGC spec 2022, page 6 of 21 shall

be used to calculate gauge plate diameter.

d = D- 2t – (0.01D + 0.4t+5I)

d= gauge plate diameter

D= nominal O.D of pipe
t= max pipe wall thickness
I= 0.2t or 5 mm max
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Gauge plate diameters

Sr no Pipeline O.D Thickness(mm) Gauge plate
Segment (mm) P/L R/L Dia mm

01 RS 11-ICP 323.9 14.3 25.4 ( 5D bend) 234.301

02 RS2-ICD 323.9 14.3 25.4 ( 5D bend) 234.301
03 RS3-BHS 323.9 14.3 25.4 ( 5D bend) 234.301
04 BHS-RS3 168.3 7.1 14.3 117.997
05 RS1-SA 273.1 12.7 25.4 ( 5D bend) 184.009
06 NM-RS2 168.3 7.9 14.3 117.997
07 SC1-RS1 168.3 7.1 14.3 117.997
08 IB-ZB 168.3 7.9 14.3 117.997
09 ZB-ICD 406.4 15.9 22.2 326.856
10 ICP-RS11 114.3 7.1 14.3 64.53
11 SI-5-SHG 323.9 14.3 25.4 ( 5D bend) 234.301
12 SF-S1-5 219.1 11.1 20.6 146.869
13 EC-S1-5 219.1 11.1 20.6 146.869
14 IH-II 168.3 11.0 18.3 104.397
15 EE-SHG 168.3 11.0 18.3 104.397
16 II-S1-4 168.3 7.1 14.3 117.997
17 IJ-SHP 273.1 12.7 25.4 ( 5D bend) 184.009
18 S1-6-IM 273.1 12.7 25.4 ( 5D bend) 184.009
19 RS7-SHP 323.9 14.3 25.4 ( 5D bend) 234.301
20 SHP-RS7 168.3 7.1 14.3 117.997
21 RS5-BHN 323.9 14.3 25.4 ( 5D bend) 234.301
22 NM-RS5 168.3 7.9 14.3 117.997
23 SB-RS4 168.3 7.1 14.3 117.997
24 RS4-BHS 323.9 14.3 25.4 ( 5D bend) 234.301
25 ID-RS8 114.3 7.1 14.3 64.53
26 RS8-ID 273.1 12.7 25.4 ( 5D bend) 184.009
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APPENDIX- B

HYDROTEST CALCULATIONS:

a) Pipeline Volume (PV)

PV = π x (I.D.2) x L / 4

Where:

PV : Pipeline volume in cubic meters (m3)

π : 3.14159
ID : Inside diameter (m)
L : Pipeline length (m)

b) Air Volume Calculations:

V = (Va – Vt / FV) x 100

Where,
V : Air content ( % )
Va : Actual volume pumped ( based on stroke counter or
bleeding )
Vt : Theoretical volume to pressurize
FV : Pipeline total fill volume

The followings formula can be used to calculate the theoretical

volume of water required to raise the pressure in the pipeline:

2
∆v / ∆p = V x [ D / E t x (1- u )+1/B]

Where,

∆v = incremental volume in m3 (Vp)

∆p = incremental pressure in bar

V = pipeline volume in m3

D = pipeline outside diameter in m

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t = nominal wall thickness in m

6
E = Young’s elastic modulus of steel = 2.07 x 10 bar

u = Poisson’s ratio = 0.3 bar

B = Bulk modulus of water in bar

Sea bed temperature in C

c) Temperature Effect:

∆P = γ-2(1+ u) α
∆T D/Et (1-u2) +1/B

Where
∆P= Incremental pressure BAR

∆T= Incremental temperature °C

γ= Volumetric expansion coef of water °C-

u= Poissons ratio ( for steel 0.3bar)

α= coef of linear expansion of steel °C-

6
E = Young’s elastic modulus of steel = 2.07 x 10 bar

B = Bulk modulus of water in bar

D = pipeline outside diameter in m

t = nominal wall thickness in m

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SECTION 3.0

EQUIPMENT AND INSTRUMENTATION

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SECTION 5.0

HYDROSTATIC TESTING PROCEDURE

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SECTION : 06

SAFETY PROCEDURE
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SECTION : 7

RECORDS AND FORMATS