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ENGINEERING, PROCUREMENT, CONSTRUCTION, AND COMMISSIONING

(EPCC) OF BUKIT TUA DEVELOPMENT PROJECT


KETAPANG PSC, EAST JAVA, INDONESIA
ONSHORE RECEIVING FACILITY (ORF)

HYDROTEST PROCEDURE FOR PIPELINE

PREPARED FOR

PC KETAPANG II LTD.
CLIENT

EPCC
CONTRACTOR

CONSORTIUM

pt. RAGA PERKASA EKAGUNA


ENGINEERS & CONSTRUCTORS

Job No. : QPCA00


Rev.

Date

24-Dec-13

pt. KRAKATAU ENGINEERING

Contract No. : 5600025662


Description
Issued For Review

Doc. No.:
By

Chk.

App.

ADR

ABR / RZL

WHY

11-BTORF-P-PRO-0003
Rev : A
PC Ketapang II Ltd. APPROVAL
Sign

Date

EPCC OF BUKIT TUA DEVELOPMENT PROJECT - ORF


HYDROTEST PROCEDURE FOR PIPELINE

REVISION LOG REGISTER


Revisions had been performed on following pages:
No

Page

Date

11-BTORF-P-PRO-0003 REV.A

Revision

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HYDROTEST PROCEDURE FOR PIPELINE

TABLE OF CONTENTS
REVISION LOG REGISTER
2
table of Contents
3
1.
INTRODUCTION
4
1.1
General4
1.2
Scope 4
1.3
Definition and Abbreviations
4
1.3.1 Definition
4
1.4
Reference, Codes and Standard5
1.4.1 National Laws and Standards 5
1.4.2 Project Specification
5
1.4.3 Petronas Technical Standards 5
1.4.4 International Codes and Standards
6
1.5
Conflict Requirements 6
2.
Hydro testing Procedure6
2.1
General Methodology 6
2.2
Pressurization 7
2.3
Hold Period (The Pipeline Shall be Isolated from This Point Forward)
2.3.1 Acceptance Criteria
8
2.4
Depressurization
8

11-BTORF-P-PRO-0003 REV.A

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1. INTRODUCTION
1.1

General

PC Ketapang II Ltd (PCK2L) plans to develop the Bukit Tua Field, in the Ketapang Block, East Java. Bukit
Tua which is primarily an oil field but with significant associated gas, is located 35 km north of Madura
Island and 110 km northeast of Gresik at a water depth of approximately 57 m.
Figure 1.1: Bukit Tua Field Location

The Preferred Development Option is a not-normally-manned Well Head Platform (WHP) which is tied
back to a spread-moored Floating Production, Storage and Offloading (FPSO), anchored approximately
900 m from the WHP. The Full Well Stream (FWS) from the wells are separated into gas and liquid
streams in the production separator on WHP. The gas and liquid are evacuated to the FPSO via two
separate single phase 16 gas and 8 liquid infield flowlines. Associated gas is compressed and
conditioned on the FPSO and exported via a 12 gas pipeline to WHP and there onwards via a 12 gas
export pipelines to the Onshore Receiving Facilities (ORF) in Gresik. Oil is exported by tandem mooring
from the FPSO whilst produced water is treated for overboard disposal.
The FPSO vessel, moorings, topsides and the flexible pipeline risers at the FPSO will be leased. FPSOWHP interfaces shall include the flexible pipeline risers and radio telemetry link for data, telephone and
remote monitoring and control of the WHP from FPSO.
The export gas shall be received at the ORF where final separation of condensed liquids shall take place
before fiscal gas metering. The metered gas shall be routed to the sales gas delivery point outside plant
battery limits.

1.2

Scope

This procedure cover minimum requirement for site hydrostatic test incoming pipeline onshore, Bukit Tua
Development Project Onshore Receiving Facilities (ORF).

1.3

Definition and Abbreviations


1.3.1

Definition
COMPANY

CONTRACTOR

11-BTORF-P-PRO-0003 REV.A

PC Ketapang II Limited (PCK2L), as the Project


Developer and Operator of the facility/platform.
Consortium of PT Raga Perkasa Ekaguna PT
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HYDROTEST PROCEDURE FOR PIPELINE

VENDOR

1.4

Krakatau Engineering, which carry out all or part of the


detailed design, engineering, procurement, construction,
and commissioning (EPCC) contract of the project.
The Company that manufactures or supplies equipment
and services to perform duties specified by
CONTRACTOR. VENDOR covers
Manufacturers/Supplier/Sub-vendor.

Reference, Codes and Standard

The latest editions, as of the enquiry date, of the following Codes, Standards and Regulations (as far as
they are applicable) are considered part of this specification and are to be used by VENDOR in their
design, manufacturing and testing of the offered equipment or package. Where in house standards have
been developed or are based on recognised National, International or Industry Standards, these may be
offered as an alternative, subject to review and approval by COMPANY.
The Codes, Standards and Regulations include but shall not be limited to the following:
1.4.1

National Laws and Standards


Local Rules, Acts and Regulations of Indonesia
Decree 84.k/38/DJM/1988
Guidelines and Procedures of Working Safety
Inspection on Installation, Equipment and
Engineering used in Natural Gas Mining and
Geothermal Source Exploitation
Regulation
Safety Audit to Installation, Equipment and
06P/0746/M.PE/1991
Technique used in Oil and Gas Mining and
Geothermal Activities
Regulation
Obligation to Own Certificate of Construction
05/P/II/PERTAMB/1977
Worthiness for Oil and Gas Platform in the Off-shore
area
Regulation Number 11 Year
Working Safety on Refinery and Processing Oil and
1979
Gas

1.4.2

Project Specification
11-BTORF-P-DSB-0001
11-BTORF-P-SPC-0020

1.4.3

Piping Design Basis


Piping Material Specification - ORF

Petronas Technical Standards


PTS 61.10.08.11

September 2009

PTS 31.38.01.10
PTS 31.38.01.11
PTS 31.38.01.15

August 2011
October 2011
January 2010

PTS 31.38.01.21

August 2011

PTS 31.38.01.31
PTS 31.40.10.19
PTS 80.45.10.10
PTS 20.081
PTS 20.208

October 2011
January 2010
February 2010
June 1993
November 1995

PTS 39.01.10.12

December 2010

Field inspection prior to commissioning of


mechanical equipment
Piping classes Basis of Design
Piping General Requirements
Piping classes Exploration & Production
(Note 1)
Compilation of a specification for piping
systems
Shop and Field Fabrication of steel piping
GRP Pipelines and Piping systems
Pressure Relief and flare system
Piping General requirements
Painting protective coating and Linings for
Offshore System
Selection of material for life cycle
performance (EP) Upstream Equipment

Note 1: For this project, the onshore receiving facility (ORF) shall be designed referring to this PTS,
rather than the normally used PTS 31.38.01.12 Piping Classes Refining & Chemical.

11-BTORF-P-PRO-0003 REV.A

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HYDROTEST PROCEDURE FOR PIPELINE

1.4.4

International Codes and Standards


American Petroleum Institute
API 5L
Specification for Line Pipe
API 6D
ISO 14313, Petroleum and Natural Gas Industries-Pipeline
Transportation Systems-Pipeline Valves
API 1102
Recommended Practice for Liquid Petroleum Pipelines
API 1104
Standard for Field Welding of Pipelines/ Welding of Pipelines and
related
API 1105
Construction Practices for Oil and Products Pipelines
American Society of Mechanical Engineers
ASME B31.8
Gas Transmission and Distribution Piping Systems

1.5

Conflict Requirements

In the event of any conflict between this Specification and any requirements of statutory and safety
regulations, codes, standards and other documents, the most stringent shall prevail. The order of priority
of documents shall be as follows:

Indonesian Codes and Regulations

Project Specification and Datasheet

Petronas Technical Standard (PTS)

Internationally recognized Codes and Standards


All apparent conflicts shall be reported to the Company in writing for resolution. The Company decision
shall be final. In the case of conflict the more stringent requirement is govern.

2. HYDRO TESTING PROCEDURE


2.1

General Methodology

12 GAS EXPORT pipeline hydro test pressure is: 15MPa (2175.6psig); 1.5x design operating pressure.
The pipeline will be hydro tested after completion and visual acceptance of the gauge plates from the
pigging operation. Battery limit for the hydro testing will remain as per above; top of riser at BTJT-A
platform to end of the onshore tie-in spool (between OIC and ORF EPCC as per drawing: ORF-U-00006
Revision 0).
CONTRACTOR intends to set up the hydro test equipment and pressurize up the pipeline from the ORF
onshore tie-in spool location. Calibrated, pressure gauges and pressure/temperature recorder charts will
be utilized to monitor the pipeline pressure and temperature. The pressure test will be using the same
treated sea water solution as above. The pipeline will be pressurized to the require test pressure and the
volume of air monitored during pressurization. The test system is then isolated and allowed to stabilize.
Once the pressure has stabilized the hold period of 24 hours will commence.
The hydro test is deemed accepted when the following are achieved:

Air entrapped is less than 0.2% of volume


No visible leaks is observed
Pressure is not lower than 98% of test pressure during the 24 hours holding period
No unaccountable pressure changes are observed

The 12 Gas Export pipeline will be deemed mechanically complete and acceptable by COMPANY upon:
Visual inspection of the pipeline gauging plates, and approved when no significant defects are
found on at least one of gauging plates
Hydrostatic Pressure Testing of pipeline has been satisfactorily completed for required 24 hours
period

11-BTORF-P-PRO-0003 REV.A

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HYDROTEST PROCEDURE FOR PIPELINE

The baseline survey by intelligent pig will be performed as per contract and the survey data provided as
part of the pipeline as-built documentation.
The hydrostatic testing spread will be set up onshore at the ORF tie-in flange location.
Hydrostatic testing activities will be performed from onshore to top-of-riser at BTJT-A platform. A small
suction feeder pump will be set up at the quayside near the existing pipe rack structure for supply to the
high pressure positive displacement pump for performing the hydro test. The chemical injection skid will
be transferred from the pigging vessel to onshore and set up accordingly.
Prior to pressurization, the pipeline will be topped up with water while the air being venting out from
venting valve on the riser at BTJT-A. Once top up and venting of the pipeline is completed, the
instrumentation shall be install to the test blind at onshore ORF tie-in flange.
During the pressurization, the following information shall be recorded and logged every 0.1MPa are
increased intervals:
Time
Dead weight tester for the pipeline pressure (bar)
Volume pressurize (bar/liter)

Volume of chemical and Dye injected (m3/liter)

The equipment for hydro test (location Onshore Receiving Facility, landfall point) as below:
1 ea x diesel driven positive displacement HP pump (47GPM/10000psig)
1 ea x air driven positive displacement HP pump
1 set x HP hoses complete with fittings for hydro testing
1 set x HP Xmas tree assembly complete with valves and fittings
2 ea x Deadweight tester units
4 ea x Pressure & Temperature Chart recorder units

2.2

Pressurization

Pressurization will be commence at rate of up to and exceeding 0.1MPa per minute from atmospheric to
3.1MPa (450psig) at which air entrapment calculation will be carried out. A pressure volume graph will be
produced using the figures attained during pressurize to indicate the volume of entrapped air in the
pipeline. Should the air content exceed the maximum allowable of 0.2% of the calculation pipeline
volume, the pipeline shall be depressurized and all air fully vented. Pressurization shall recommence as
before until acceptable air content is attained.
On acceptance of the air content, the pipeline will be further pressurize at rate of up to and not exceeding
0.5MPa per minute to 70% (10.5MPa) the pressurization shall be stopped to allow to stabilize and leak
checked for minimum 3 hours and during the 3 hours stabiles prior the pipeline pressure shall be recorded
interval 15 minutes.
Upon completion 3 hours stabilize at 70% (10.5MPa), pressurized shall be continued to 95% (14.25MPa)
of test pressure, pressurization shall then continue to 100% (15MPa) of the test pressure at a diminishing
rate down to approximately 0.001MPa per minute. Continue pressurizing the line to reach the test
pressure (hydrostatic test pressure+0.2%; 15.03MPa). On reaching the nominated test pressure, the
system will be allowed to stabilize.
Monitoring of the pipeline pressure during the stabilization period will be conducted using a calibrated
dead weight tester (DWT) located onshore. The following information will be monitoring and logged at 15
minutes interval unit stabilization has occurred (i.e. Specified test pressure):
Time
Pipeline pressure
Volume of water added (if any)
Ambient temperature
Subsea temperature (temperature probe is located at onshore test point and offshore platform
location)
11-BTORF-P-PRO-0003 REV.A

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HYDROTEST PROCEDURE FOR PIPELINE

During the stabilization period, re-pressurization may be carried out should the pressure drop below the
required test pressure. The volume of water added will be recorded. Leaks or other defects noted during
the stabilization period shall be rectified. The section requiring rectification shall be depressurizing to a
safe level prior to any repair activity.

2.3

Hold Period (The Pipeline Shall be Isolated from This Point Forward)

Once the pressure in the pipeline has stabilized, a hold period of twenty-four (24) hours shall commence.
During the hold period, the following information shall be recorded and logged at thirty (30) minutes time
intervals:
Time
Pipeline pressure
Ambient temperature
Subsea temperature
2.3.1

Acceptance Criteria

The pipeline hydrostatic test shall be considered complete when the following condition has been met
after the hold period. The pipeline pressure shall not be fall below the required test pressure at any
time during twenty four (24) hours holding period. All variation in test pressure shall be accounted for.
The test period shall be extended if necessary to achieve these criteria.
Note:
1) Should the test hold period be extended, the hold period will be retrospectively selected where
the pressure has maintained within the above criteria for a twenty-four (24) hours period with CSR
approval
2) No visible leaks shall be present on observable section of the pipeline.
Should the system require to re-pressurization during the nominated hold period, owner/contractors
consent will be obtained prior to re-pressurization. The hold period shall start from this point.

2.4

Depressurization

On completion and acceptance of hold period, the pipeline will be depressurized to atmospheric pressure
from the double block and bleed (DBB) on the test blind. The rate of depressurization shall not exceed
0.1MPa per minute.
The pipeline pressure will be monitored and recorded during depressurization until the pipeline is fully
depressurized.
On completion of pipeline depressurization, all logs and acceptance certificates shall be signed off by all
relevant parties.
2.4.1
STEP
1
2
3
4
5
6

Preliminary Checks Preparation


DESCRIPTION
All personal shall be attended the project safety induction
Prior to commencing any work, all items of plant and equipment shall be
checked for transit and lifting damage any incident of damage shall be
reported to the field engineer of Superintendent immediately
All item of plant and equipment requiring certificate shall be checked
against mobilization record
Verified that all certificates are valid and correct
Prior to commencing of the operation work the necessary work permits
shall be obtained. PTW shall be utilized
Lines and communication established and noted regarding persons in
charge, contact name and telephone numbers for the safety and
environmental consideration

11-BTORF-P-PRO-0003 REV.A

CONTRACTOR
PE/Sup
PE/Sup
PE/Sup
PE/Sup
PE/Sup
PE/Sup

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HYDROTEST PROCEDURE FOR PIPELINE

7
2.4.2
STEP
1
2
3
4
5
6
7
2.4.3
STEP
1
2

4
5
6

Provide confirmation that all NDT is complete and acceptable on both


permanent and temporary facilities

PE/Sup

Equipment Set-Up and Layout


DESCRIPTION
Confirm all the permits are in place and valid for the hydro test operation
Proceed toolbox meeting and JSA checked with all relevant parties and
any other site parties working in same area
The set-up of hydro test spread in the designated lay down of working
area
Secure all the connection hoses with whip checks and line up the
system before hydro test operation to be commenced. Area to be
barricade off at onshore and offshore platform location
Secure the working area to post warning signs and erect bunting in
around safe working area
Check engine oil and radiator cooling levels
The hydro test spread will be set up and function test on the working
boat before any operation to be commence

CONTRACTOR
PE/Sup
PE/Sup
PE
PE/Sup
PE/Tech
Tech
PE/Sup

Hydro Test Operation


DESCRIPTION
Confirm that PTW are in place and valid for the hydro testing activity
HOLD POINT
Conduct toolbox talk onboard of barge and perform the JSA check with
relevant parties and any other affected parties working in the same area,
checks or test the communication in between both test ends. Two (2)
personnel shall be on BTJT-A platform during test. MIGAS to be on site
to witness test
Confirm and witness of the test blind had been installed on top riser at
BTJT-A and ORF tie-in flange onshore. All the fitting for venting,
instrument point is position for the pipeline is in place. Provide records of
bolt tensioning for review
Confirm to post warning sign and barrier the safe working area before
commence the hydro test operation at both ends. Danger zones shall be
barricade off
Rig up the 1 high pressure hose from the onshore hydro test spread to
ORF test blind and connect to double block and bleed manifold on the
test blind of the pipeline
Confirm the instrument of hydro test operation is install as per listed and
drawing:
Dead weight tester
Pressure Recorder
Pressure Gauge
Ambient temperature recorder
Sea Bed Temperature probe
Confirm to receiving site that the instrument are installed:
Pressure Recorder
Pressure Gauge
Ambient Temperature
Sea Bed Temperature Probe
Prior to commence of the hydro test operation, prepare the following
logs:
Pressurize Report
Acceptance Air Conclusion Certificate
Stabilization Log

11-BTORF-P-PRO-0003 REV.A

CONTRACTOR
PE
PE

PE

PE
Tech/Rigger
PE

PE

PE

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9
10
11
12
13
14

15

16
17
18
19

20
21
22
23

24
25
26
27
28
29

Hydro Test Report


Request permission from COMPANY to commence the hydro test
operation for the pipeline and confirmation that all parties have reviewed
the approved pre-commissioning procedure
On the permission from COMPANY to commence hydro test operation
for the pipeline. Make announcement to all platform personnel at both
ends
Once confirmation from receiving site of the venting point has already
opened. Open the double block isolate valve at the test blind at onshore
side
Start the pressurizing pump as minimum RPM to top up the pipelines
Continued to pumping water into the pipeline as minimum RPM of the
pressurizing pump
Once water is seen discharging on the receiving end, start to open the
venting point at the test blind, continued venting the water out for 10 to
20 minutes till solid water is confirm coming out on both of pipeline.
Pressure release hose/drain line shall be located at +2m to +4m
elevation
Once the water is coming out is a constant stream, close the venting
point valve for both site of the riser, continued pumping water into the
pipeline till pressure reach 0.05MPa. Volume pumping from 0MPa shall
be noted down
Once pipeline pressure 0.05MPa, stop the pressurizing pump and close
the double block isolate valve on the injection manifold
Plug off the vent point at each riser
Re-confirm to receiving site that the pipeline is plug off and working area
is safe to commence hydro testing operation
Install the chart paper of the pressure recorder and ambient temperature
recorder at launcher site.
Note: Chart shall be signed by COMPANY and Regular Body Inspector
(MIGAS), not the code on the chart
Confirm with receiving site that pressure gauge, temperature probe and
ambient temperature are installed
Once confirm the working area at launcher site is safe to commence the
hydro test, open the double block isolation valve on the test blind at ORF
side
Reset the flow meter, and start the pressurizing pump
Monitor and logging the pressure and flow read of the pump and
increase the flow as required slowly. Prior to commence pressurizing the
pipeline shall follow logs:
Time
Pipeline Pressure
Volume pumping
Ambient Temperature recorder
Sea Bed Temperature probe
Pressurize rate shall be 0.1MPa per minute till reach 20% of the test
pressure
Once reach 20% of test pressure, slowly decrease the pressurizing
pump and turn off the pressurizing pump. Allowed for 30 minutes
stabilization
Once the pressurizing pump has been stop, close the double block
isolate valve on the injection manifold on the test blind at ORF
Engineer or test supervisor shall calculate the air inclusion of the
pipeline, acceptance criteria 0.2% of air content for each pipeline
Check for leak around the launcher and receiving site during this time, if
any leak found for any site of the riser shall be report to the test
supervisor or test engineer
To repair leak, the pipeline shall to depressurize to ambient, then repair

11-BTORF-P-PRO-0003 REV.A

PE
PE
PE
PE
PE/Tech
PE/Tech

PE/Tech

PE/Tech
PE/Tech
PE/Tech
CSR/PE/MIGAS

PE/Tech
PE/Tech
PE/Tech
PE/Tech

PE/Tech
PE/Tech
PE/Tech
PE/Tech
PE/Tech
PE/Tech
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30
31
32
33

34
35
36

37
38
39

40
41
42
43
44

45
46
47

the leak
Once the leak has been repaired. To re-pressurize the pipeline, shall be
follow on step 18 to 28
Once 30 minutes prior of stabilization complete and no leak has found,
continued pressurization up to 70% of test pressure
Open the double block isolate valve on test blind and start the
pressurizing pump
Continued commencing pressurizing to the pipeline and increase the
rate as 1barg per minute till 70% of test pressure, prior to commence
shall be following by the logs
Pressurizing log
Volume pumping log
Once pressure reach 70% of test pressure, decrease the pressurizing
pump and turn off the pressurizing pump
Once the pressurizing stop, close the double block isolate valve on the
injection manifold of the pipeline. Check for leak regularly.
Stabilization prior will take 4 hours approximately: during that prior
logging at ORF will be taken interval 15 minutes following by:
Time
Pressure reading
Ambient temperature
Subsea temperature
Once stabilization has completed continue to commence the
pressurizing for the pipeline
Open the double block isolate valve
Started the pressurizing pump, and increase the volume as per require.
Note: During this state of pressurization from 70% to 100% of test
pressure, pressurization rate of 0.1MPa per minute till 100% test
pressure
Once the pressure reach at 100% test pressure (15MPa), pressurizing
pump will be stop and close the double block isolate valve
Final physical leak check for the launcher and receiver site of the
pipeline
Once confirm no leak is detected for the both site of launcher and
receiver. Carry on stabilization of the pressure for 4 hours
Once stabilization is completed, continues to change the pressure chart
of the pressure recorder and temperature recorder and confirm that the
chart has been signed
Commence 24 hours hydro test period.
During the test hold period, pipeline shall be tested and monitored.
During this period, following logs shall be taken for pipeline:
Pipeline pressure by:
Dead weight tester
Pressure chart recorder
Pressure gauge
Temperature by:
Ambient temperature (recorder)
Subsea temperature
Once the test hold period for pipeline is completed, pressure shall not
drop down more than 0.4MPa per 1C after acceptance criteria
calculation temperature change
Engineer or test supervisor shall be calculated the temperature vs.
pressure for acceptance criteria
Inform all witness parties and if the test is accepted by MIGAS and
COMPANY, the pipeline shall to depressurized as 0.1MPa per min down
to 0MPa (atmospheric)

11-BTORF-P-PRO-0003 REV.A

PE/Tech
PE/Tech
PE/Tech
PE/Tech

PE/Tech
PE/Tech
PE/Tech

PE/Tech
PE/Tech
PE/Tech

PE/Tech
PE/Tech
PE/Tech
PE/Tech
PE/Tech

PE/Tech
PE/Tech
PE/Tech)

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48

Once the test of the pipeline has been completed, the chart shall be
signed follow by the acceptance Certificate and logs:
Pipeline hydro test certificate
Hydro test Report
Chart Paper of Temperature
Chart paper of Pipeline Pressure

11-BTORF-P-PRO-0003 REV.A

PE

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