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MANGALA DEVELOPMENT PIPELINE PROJECT-

EPC FOR MARINE FACILITIES AT BHOGAT


LEIGHTON PROJECT NO: I0199

“WORK METHOD STATEMENT”

Document Control Procedure Document Control Procedure


PIPELINE FLOODING, CLEANING, GAUGING,
HYDROTESTING AND LEAK TEST

DOCUMENT NUMBER

BSPL-1520-LCL1-CT-MS-0016

A1 06/12/10 Issued for Client Review JSH CMU ARE

A0 19/11/10 Issued for Internal Review JSH CMU ARE

Rev Date Purpose of Issue Pre By Chk By Apr By CEIL


INDEX
1.0 Introduction..................................................................................................................................... 4
Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 2 of 37

1.1 Project Description..................................................................................................................... 4


2.0 Scope.......................................................................................................................................... 4
3.0 Safety.......................................................................................................................................... 5
3.1 HSE References; CEIL / Contractor...........................................................................................5
4.0 Responsibilities.......................................................................................................................... 6
5.0 Abbreviations.............................................................................................................................. 7
6.0 Reference Documents.................................................................................................................8
6.1 Project Specification................................................................................................................... 8
6.2 Project Drawings....................................................................................................................... 8
6.3 Project Procedures and Plans...................................................................................................9
7.0 Equipments & Instrumentation................................................................................................10
7.1 Pigging Operation................................................................................................................... 10
7.2 Testing Operation.................................................................................................................... 10
7.3 General................................................................................................................................... 11
8.0 Methodology of Pigging............................................................................................................. 12
A. The battery limit for 24” Twins pipeline Pigging.......................................................................12
8.1 Pigs Description...................................................................................................................... 12
8.1.1 Cleaning Pig............................................................................................................................ 12
8.1.2 Displacement Pig.................................................................................................................... 12
8.1.3 Gauging Pig............................................................................................................................ 12
8.2 Chemical Injection.................................................................................................................. 12
8.3 Preparatory Work for Pigging..................................................................................................13
8.3.1 Launcher End......................................................................................................................... 13
8.3.2 Receiver End......................................................................................................................... 13
8.4 Cleaning, Gauging and Flooding.............................................................................................13
B. The battery limit for U-loop pigging (Including 24” Twins Pipeline, Tie-In spool & PLEM).......15
8.5 Pig Description........................................................................................................................ 15
8.5.1 Gauging Pig............................................................................................................................ 15
8.6 Chemical Injection.................................................................................................................. 15
8.7 Preparatory Work for Pigging..................................................................................................15
8.7.1 Launcher End......................................................................................................................... 15
8.7.2 Receiver End......................................................................................................................... 15
8.8 Gauging and Flooding............................................................................................................. 15
8.9 Stuck Pig Contingency Plan...................................................................................................17
8.9.1 Pig Stuck................................................................................................................................. 17
8.9.2 Dislodging a Stuck Pig............................................................................................................17
8.9.3 Location of a Stuck Pig............................................................................................................ 17
9.0 Methodology of Hydro testing and Leak test.....................................................................18
9.1 Pre-testing of Test Heads......................................................................................................18
9.2 Pretesting of Hoses............................................................................................................... 19
9.3 Pre - Testing of PLEM................................................................................................................20
9.4 Pre - Testing of Tie-in Spool...................................................................................................21
9.5 Hydro testing of 24” Pipeline......................................................................................................22
9.5.1 Preparatory Work...................................................................................................................22
9.5.2 Temperature Stabilization.......................................................................................................22
9.5.3 Pressurization & Air Volume Check........................................................................................23
9.5.4 Stabilization Period at 80% Test Pressure..............................................................................23
9.5.5 Pressurization to Test Pressure and Stabilization...................................................................24
9.5.6 Pressure Hold Period............................................................................................................. 24
9.5.7 Test Acceptance..................................................................................................................... 25

November 2010 Page 2 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 3 of 37

9.5.8 Depressurization.................................................................................................................... 25
9.6 Hydro testing of 6” Reject Water Flexible Pipeline.................................................................26
9.6.1 Preparatory work for Flooding................................................................................................26
9.6.2 Thermal Stabilization..............................................................................................................26
9.6.3 Pressurization........................................................................................................................ 27
9.6.4 Air Entrapment Test................................................................................................................28
9.6.5 Pressure Stabilization............................................................................................................28
9.6.6 Pressure Hold Period............................................................................................................. 28
9.6.7 Test Acceptance..................................................................................................................... 29
9.6.8 Depressurization.................................................................................................................... 29
9.6.9 Post Test Work....................................................................................................................... 29
9.7 Post Installation Leak testing of pipeline, PLEM, SPM with floating and subsea hoses.........30
10.0 Attachments............................................................................................................................... 31
APPENDIX A: Gauge Plate Diameter calculation..................................................................32
APPENDIX B: Hydro Test calculation....................................................................................34
APPENDIX C: Project Drawings............................................................................................37

November 2010 Page 3 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 4 of 37

1.0 Introduction
1.1 Project Description
Cairn Energy India Pty. Ltd. (Company) intends to install a Single Point Mooring (SPM) system
and 2 no. x 24” diameter x 6.0 km crude oil pipeline as part of its marine infrastructure for its
Bhogat terminal. The marine pipeline will run from the Land Fall Point (LFP) to the Single Point
Mooring (SPM). The SPM will be used for loading crude oil onto Aframax / Seawaymax tankers.
Leighton Contractor (India) Pvt. Ltd. (Contractor) has been awarded the EPC Contract for the
marine facilities project. Leighton’s scope of work will be carried out as outlined below:
 Pre Engineering survey of the offshore/onshore fields for obtaining field data for design of
dredging, SPM, PLEM, Pipeline and other accessories etc.
 Detailed Engineering of SPM & PLEM system, Offshore/Onshore Pipelines, Diffuser &
Reject water pipeline system, and accessories including installation engineering for
SPM/PLEM and pipelines.
 Procurement of SPM / PLEM system, including piles, chains, subsea hoses, floating hoses,
hawser and associated equipment.
 Procurement of diffuser system, reject water pipeline materials, pipe fittings, as required.
 Installation of a 2 no. x 24” dia. X 6.0 km of long concrete coated and thermally insulated and
heat traced submarine pipeline from the LFP to the PLEM. Line pipes to be free issued by
CEIL.
 Installation of a SPM & PLEM System (at approx. 28 m water depth) including piling, anchor
chain tensioning and installation, connecting subsea and floating hoses with SPM & PLEM
system.
 Installation of a 2 no. x 24” dia. X 0.6 km shore based pipeline from the LFP to the Battery
Limit Point (BLP).
 Testing and pre-commissioning of the complete system.
 Marine pipeline hook-up with onshore pipeline at the BLP.
 Installation and pre-commissioning of Diffusers and reject water pipeline.

2.0 Scope
The scope of this Method Statement is to describe the methodology involved in the pigging and
hydro testing activities and to detail out the steps to be taken to meet the Project Specification
requirements for execution of “Flooding, Cleaning, Gauging, Hydro Testing and Leak Testing”.

Following sequence of activities during pre-commissioning are;


1. Flooding, Cleaning and Gauging of the 24” twins pipelines using pig trains consisting of three
pigs. Pigs shall be launched from Offshore (KP6) and received in Onshore (KP -0.12).
2. The pipeline system (excluding spool) shall be hydro tested prior to backfilling.
3. After tie-in (from KP-0.12 to KP-0.6) and backfilling of the pipelines, Cleaning with gauging of
the U-loop (Pipelines, Tie-In Spools and PLEM system) shall commence. Pig shall be
launched and recovered onshore (KP -0.6).
4. Hydro testing of the U-loop (Pipelines, Tie-In Spools and PLEM).
5. Hydro Testing of 6” Reject Water HDPE Flexible Pipeline.
6. The overall system (Pipelines, Tie-In spools, PLEM and SPM system) shall be leak tested.

November 2010 Page 4 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 5 of 37

3.0 Safety
All works shall be undertaken in accordance with this document, contract requirements,
approved Leighton HSE procedures and any specific job safety & environmental analysis
conducted prior to commencement of work.

3.1 HSE References; CEIL / Contractor

o IFC International Finance Corporation – Workers’ accommodation: processes and Standards


(A guidance note by IFC and the EBRD)
o International Finance Corporation – Policy and performance standards on social and
Environmental Sustainability
o International Finance Corporation & World bank Group- Environmental, Health and Safety
(EHS) Guidelines
o Cairn India Limited – Health, Safety and Environment (HSE) Policy
o Cairn India Limited – Security Policy
o Cairn India Limited – Corporate Social Responsibility Policy
o Cairn India Limited – Drug and Alcohol policy
o Cairn India Corporate Worker Accommodation Standard – Doc No, CIL/HSE/09/001712
o Contractor HSSE Requirements Manual (Doc No – CIL /HSE/09/001737)
o Leighton India Limited Drug and Alcohol policy
o Leighton India Limited Health Safety and Environmental policy
o Leighton India Limited Community Relations

November 2010 Page 5 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 6 of 37

4.0 Responsibilities

 The Project Manager will report to top management on all aspects and performance of the
project. He shall coordinate and monitor the progress and performance of the project. He will
be responsible for approval of this procedure and overall scope of work.

 The Construction Manager reports to the Project Manager, he is responsible for all
construction, installation and pre-commissioning activities as required contractually with
Company. He will coordinate with construction team, engineering team and subcontractors
to ensure HSE and Quality system procedures compliance during construction phase of the
project. He is also responsible for coordination with Client, resolution of site issues and
change in construction sequence / program as situation may demand at project site.

 Hydro test Engineer shall liaise with construction manager for execution. He is responsible
for preparation of WMS, identifying the required hydro test equipments, instruments, spares
and accessories and ensuring all available at site for execution of the pre-commissioning
activities at project site. He is also responsible to supervise and monitor the complete pre-
commissioning activities at site. He will also co-ordinate with construction team, QC team,
Barge Superintendent for necessary permission to start the activities as per WMS / ITP and
completion of hydro testing.

 Quality Control Engineer reports to Quality manager, he is responsible for inspection of


pipeline welding, NDT, field joint coating and releasing the pipeline system including SPM for
pre-commissioning as per schedule program. He is also responsible for witnessing
complete pre-commissioning and coordinates with Client representative to witness and
clarify the all testing as per approved WMS / ITPs etc.

 Site Safety Officer shall be responsible for the development, communication and
implementation of an effective, strategic health, safety and environment programmed. He will
make sure that we have, at all times, the capability and recourses to operate safely and with
no harm to health and will make sure that our health, safety and environment policy and
procedures are implemented properly at all levels. He will coordinate and monitor activities
relating to health, safety and environment at all working locations, promote safety awareness
and device safety training and education for project team members and sub-contractors. He
will also liaise with the environmental agency and other local authorities on environmental
and safety aspects of the project.

 Barge Superintendent is responsible to provide barge crew, survey team, diving team and
crane facilities for execution of hydro test activities as per the hydro test engineer’s
requirement time to time at offshore location.

November 2010 Page 6 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 7 of 37

5.0 Abbreviations

COMPANY : Cairn Energy India Pty. Ltd. (CEIL)


CONTRACTOR : Leighton Contractors (India) Pvt. Ltd. (LCL1)
PLEM : Pipeline End Manifold
SPM : Single Point Mooring
LFP : Land Fall Point
BLP : Battery Limit Point
BOM : Bill of Material

November 2010 Page 7 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 8 of 37

6.0 Reference Documents

The latest revision of the following reference documents shall be used in conjunction with this
procedure.

6.1 Project Specification

Table 6.1 Project Specification


Document No. Title
BSPL-1520-LCL1-SS-MAN-2015(Rev C1) Crude Oil (CO) Pipeline Pre-Commissioning Manual

6.2 Project Drawings

Table 6.2 Project Drawings


Document No. Title
BSPL-1520-LCL1-CT-DWG-0199 Rev.C1 24” Pig Launcher
BSPL-1520-LCL1-CT-DWG-0200 Rev.C1 24” Pig Receiver
BSPL-1520-LCL1-CT-DWG-0216 Rev.C1 24” Pig Receiver For Fabrication
BSPL-1520-LCL1-CT-DWG-0204 Rev.A1 Layout for 24” Pipeline Water Filling
BSPL-1520-LCL1-CT-DWG-0205 Rev.A1 Layout for Cleaning, Gauging & Flooding
Layout for gauging of U-loop (Pipeline, Tie-in Spool &
BSPL-1520-LCL1-CT-DWG-0206 Rev.A1
PLEM)
BSPL-1520-LCL1-CT-DWG-0207 Rev.A1 Layout for Pre-Test of 24” Lay down head(Launcher)
BSPL-1520-LCL1-CT-DWG-0208 Rev.A1 Layout for Pre-Test of 24” Pig Receiver
BSPL-1520-LCL1-CT-DWG-0209 Rev.A1 Layout for Pre-Test of 24” Tie-In Spool
BSPL-1520-LCL1-CT-DWG-0210 Rev.A1 Layout for Pre-Test of Hoses
BSPL-1520-LCL1-CT-DWG-0211 Rev.A1 Layout for Pre-Test of PLEM
BSPL-1520-LCL1-CT-DWG-0212 Rev.A1 Layout for Hydro testing of 24” Pipeline – Option 1
BSPL-1520-LCL1-CT-DWG-0213 Rev.A1 Layout for Hydro testing of 24” Pipeline – Option 2
Layout for Hydro testing of U-Loop (Pipeline, Tie-In
BSPL-1520-LCL1-CT-DWG-0214 Rev.A1
Spool & PLEM)
Layout for Leak Test of 24” Twins Pipelines, PLEM,
BSPL-1520-LCL1-CT-DWG-0215 Rev.A1
Tie-in Spools, SPM, Subsea and Floating Hoses
Layout for Hydro testing of 6” Reject water Flexible
BSPL-1520-LCL1-CT-DWG-0217 Rev.A1
Pipeline

November 2010 Page 8 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 9 of 37

6.3 Project Procedures

Table 6.3 Project Procedure


Document No. Title
Method Statement for Pipeline Installation (Bottom
BSPL-1520-LCL1-CM-MS-0006
Pull Method)
Method Statement for Reject water (RW) Pipeline
BSPL-1550-LCL1-CM-MS-0012
Installation
BSPL-1550-LCL1-CM-MS-0013 Method Statement for Diffuser Installation
Method Statement for Pipeline End Manifold (PLEM)
BSPL-1540-LCL1-CM-MS-0004
Installation
Method Statement for Floating Hoses, Stringing,
BSPL-1530-LCL1-CM-MS-0008
Testing and Installation.
BSPL-1520-LCL1-CM-MS-0004 Method Statement for Pipeline Stringing at Shore
BSPL-1520-LCL1-CM-MS-0007 Method Statement for Field Joint Welding and Repair

November 2010 Page 9 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 10 of 37

7.0 Equipments & Instrumentation

The following equipments & instruments as minimum to be available at site for the pigging and
hydro-testing operation.

7.1 Pigging Operation

 Fill Pumps 400m3/hr, 200 meters head – 2 Nos.


 Chemical dozing pumps – 2 Nos.
 8” Flow meters – 2 Nos.
 Strainers 150 microns – 2 Nos.
 Non Return Valves – 2 Nos.
 Pressure Gauge (0 to 40 kg/cm2) – 4 Nos.
 Pump delivery manifolds
 4”, 6”, 8” Valves as required

7.2 Testing Operation

 High pressure Test pumps – 158LPM with adjustable PRV – 1 No.


341LPM with adjustable PRV – 1 No.

 Dead weight Testers – 2 Nos.


Range: 2 to 250 kg/cm²

 Pressure Chart Recorders – 2 Nos.


Range: 0 to 100 kg/cm2

 Temperature Chart Recorders – 2 Nos.


Range: 0 to 100ºC

 Pressure Gauges – 4 Nos.


Range: 0 to 100 kg/cm²

 Digital Temperature Indicator – 4 Nos.


Range: -100 to 199.9ºC

 RTD Sensors (Sub Sea) - 2 Nos.


Range: -10 to 40ºC

 RTD Sensors (Pipe Wall) - 2 Nos.


Range: -10 to 40°C

November 2010 Page 10 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 11 of 37

7.3 General

 Hoses for pigging and hydro-testing


 Manifold and fitting for both pigging and testing
 Material container
 Rigging tools and tackles
 Chemical & Dye
 Pigs

November 2010 Page 11 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 12 of 37

8.0 Methodology of Pigging


The pigging operation comprising of cleaning and gauging of the pipelines will commence only
after all the pipeline crossings and free span corrections and back filling operations have been
completed.

Work permits shall be obtained prior to commencement of the work.

The battery limits for flooding, cleaning, gauging shall be as below:

A. The battery limit for 24” Twins pipeline Pigging will be from Pig Launcher LDH (Offshore
KP 6) to Pig Receiver (Onshore KP -0.12).

Pig Launcher and Pig Receiver as per drawing nos. BSPL-1520-LCL1-CT-DWG-0199 &
BSPL-1520-LCL1-CT-DWG-0200.

Pigging operation shall be done as per drawing nos. BSPL-1520-LCL1-CT-DWG-0204 &


BSPL-1520-LCL1-CT-DWG-0205.

8.1 Pigs Description

8.1.1 Cleaning Pig

The cleaning pig used in the operation will be a bi-directional disc type & equipped with spring-
loaded steel wire brushes or nylon/polyurethane brushes as cleaning elements. The brushes will
be fitted onto the pig body in such a way to provide a 360 deg cleaning coverage. The brush
cleaning pig shall be capable of removing any loose debris in the pipeline including welding slag,
loose mill scale, corrosion product, etc. by magnets fitted on pig body.

8.1.2 Displacement Pig


The displacement pig used will be a bi-directional guide disc, with at least four sealing discs.

8.1.3 Gauging Pig


The gauging pig shall be a bi-directional with polyurethane disc type pig, equipped with a
removable gauging plate in front of the third disc. Gauging plate shall be made of aluminium,
thickness and diameter as per table in Appendix – A. The gauge plate shall have a radial incision
at 45deg interval.

8.2 Chemical Injection

The filtered seawater will be used to push the pig train and shall be mixed with chemical which is
a cocktail of Oxygen Scavenger (Sodium / ammonium bisulfate), Bactericide (Quaternary
ammonium compound Quat 2C or equivalent), and Corrosion inhibitor (Poly phosphate).The
treated sea water as above will be used to push pig train & for hydro test.

Fluorescent dye Remidol – RDH / INDION 175D shall be used with the chemicals for detection
of leaks.
The dosage of chemical Remidol 4000 / INDION 175 shall depends as per water analysis report
and manufacturers recommendation.

November 2010 Page 12 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 13 of 37

The florescent dye shall be added at 15 to 20 ppm.


The chemicals will be mixed with seawater on the suction / delivery side of the pump or into
brake tank. 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 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.

8.3 Preparatory Work for Pigging

8.3.1 Launcher End

Lay down Head with inserted pigs shall be laid on the sea bed.
Filling pump delivery hoses shall be connected to the input connections of the Lay down Head /
Sledge. One pressure gauge of suitable range shall be fitted on delivery manifold of the pump.

It shall be ensured that the valves of Lay down head / Sledge in good working condition and can
be operated without any difficulty.
It shall be ensured that the valves V1, V2, V3, and V4 in the subsea lay down Head are in
closed position. On confirmation by diver that all the above valves are in closed position then
pigging operation should commence.

8.3.2 Receiver End

Pig receiver fitted at LFP with discharge hoses will be rigged up, and control valves will be
opened to avoid any surge during the run and installed pressure gauge to monitor the back
pressure. The water will be discharged to sea through hose pipes in safe manner.

8.4 Cleaning, Gauging and Flooding

Flooding, Cleaning, Gauging are the sequence of operations and the followings pigs train are
launched.

 Cleaning pig
 Batching pig
 Gauging pig

Lay down Head loaded with pig train (1brush pig+1batching pig+1gauging pig) as shown in
drawing no. BSPL-1520-LCL1-SS-DWG-006 Rev. C1 shall be fitted to the pipeline end through
Sledge. Flooding hoses will be connected to 8” manifold at Lay down head prior to launching
First pig.

Open Valve No. 1 and slug of filtered water equivalent to 150m of line volume shall be pumped
into the line ahead of the pig.

Close Valve No 1.
Valve No 2 will be opened and Pig No 1 (Brush pig) will be launched with filtered water.

Following the launch of Pig No 1 a slug of 150 linear meters of filtered water shall be pumped.

November 2010 Page 13 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 14 of 37

Close Valve No 2.
Valve No 3 will be opened and Pig No 2 (Batching Pig) will be launched and propelled with
filtered water.

Following the launch of Pig No 2 a slug of 150 linear meters of filtered water shall be pumped.

Close Valve No 3.

Valve No 4 will be opened and Pig No 3 (Gauge Pig) will be launched and propelled with filtered
water.

Open Valves No.1, 2, 3 and 4.

Hydro test team should maintain constant communication between launcher and receiver end
personnel. On completion of 90% of fill volume behind the first pig, inform to receiver end
operator to continuously note the pig arrival and other condition.

All pigs will be received in receiver as per drawing no. BSPL-1520-LCL1-CT-DWG-0200 Rev.C1.

After all pigs reached in to the Pig receiver and confirmed by Pig receiver end operator, pumps
shall be stopped.

All pigs shall be retrieved in presence of Company Representative and gauge plate shall be
inspected for its condition. Any signs of damage or irregularities such as dents, buckles, flat
spots, construction debris etc. shall be analyzed and the results shall be issued by the
Contractor in report to the Company.

A record of gauge plate acceptance shall be signed by all the agencies (CEIL, Leighton QC).

In the event of any significant damage to the gauging plate, an additional gauging pig to be run,
to reconfirm the presence of any possible obstruction in the pipeline.

The amount of material received at the end of the last Pig run should be assessed on a volume
and weight basis. The material received should show a reducing trend in both volume and
particle size. Pig run should continue until the volume of the received material is less than 5kgs
and if it is anticipated that further pig runs will not result in a significant reduction in the material
received.
During the pigging operation, maintain pig speed of minimum 0.1m/s to 0.5m/s
The following readings shall be Monitored and recorded for every 30 minutes:

 Pressure at launcher from gauge

 Flow meter readings

 Chemical injected in terms of volume

November 2010 Page 14 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 15 of 37

B. The battery limit for Pipeline Pigging will be (U-loop including 24” Twin Pipelines, Tie-In
Spools and PLEM) from 1st Pig Receiver (Onshore KP -0.6) to 2nd Pig Receiver (Onshore
KP -0.6).

Refer Drawing Nos. BSPL-1520-LCL1-CT-DWG-0204, BSPL-1520-LCL1-CT-DWG-0206.

8.5 Pig Description

8.5.1 Cleaning Pig with Gauge plate


The cleaning pig used in the operation will be a bi-directional disc type & equipped with spring-
loaded steel wire brushes or nylon/polyurethane brushes as cleaning elements. The brushes will
be fitted onto the pig body in such a way to provide a 360 deg cleaning coverage. The brush
cleaning pig shall be capable of removing any loose debris in the pipeline including welding slag,
loose mill scale, corrosion product, etc. by magnets fitted on pig body. This Pig equipped with a
removable gauging plate in front of the third disc. Gauging plate shall be made of aluminium,
thickness and diameter as per table in Appendix – A. The gauge plate shall have a radial incision
at 45deg interval.

8.6 Chemical Injection

The filtered seawater with previously added chemical and dye will be circulated to push the pig
so there is no need to add extra Chemical and Dye. The flow rate obtained from the pump will
be continuously monitored by a flow meter, which will be installed on the pump outlet manifold.

8.7 Preparatory Work for Pigging

8.7.1 Launcher End

Among two Pig Receivers, one will be used as a Pig Launcher with inserted Gauge pig and
other as a Pig Receiver.
Filling pump delivery hoses shall be connected to the input connections of the Pig Launcher.
One pressure gauge of suitable range shall be fitted on delivery manifold of the pump.

It shall be ensured that the valves of Pig Launcher in good working condition and can be
operated without any difficulty. It shall be ensured that the valves V1, V2, V3, and V4 of Pig
Launcher are in closed position. After confirmation of all the above valves are in closed position,
pigging operation should commence.

8.7.2 Receiver End

Pig receiver fitted at LFP with discharge hoses to be rigged up, and control valves to be opened
to avoid any surge during the run. The installed pressure gauge to monitor the back pressure.
The water will be circulating through hose pipes in safe manner as per the above arrangement.

8.8 Gauging and Flooding

Equipment layout during the pigging operation is as per drawing nos. BSPL-1520-LCL1-CT-
DWG-0204 & BSPL-1520-LCL1-CT-DWG-0206.

November 2010 Page 15 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 16 of 37

Pig Launcher loaded with one Gauge Pig as shown in drawing no. BSPL-1520-LCL1-CT-DWG-
0206 shall be fitted to the pipeline end.
Flooding hoses will be connected to Pig launcher prior to launching Gauge pig.

Open Valve No. 1 and slug of filtered water equivalent to 150m of line volume shall be pumped
into the line ahead of the pig.

Close Valve No 1.

Valve No 4 will be opened and Gauge Pig will be launched and propelled with filtered water.

Open Valve No.1.

On completion of 90% of fill volume behind the first pig, continuously note the pig arrival and
other condition.

Gauge Pig will be received in receiver. After the pig reached in to the Pig receiver and confirmed
by receiving end operator, the pumps shall be stopped

Gauge pig shall be retrieved in presence of Company Representative and gauge plate shall be
inspected for its condition.

Any signs of damage or irregularities such as dents, buckles, flat spots, construction debris etc.
shall be analyzed and the results shall be issued by the Contractor in report to the Company.

A record of gauge plate acceptance shall be signed by all the agencies (CEIL, Leighton QC).

In the event of any significant damage to the gauging plate, an additional gauging pig to be run,
to reconfirm the presence of any possible obstruction in the pipeline.

During the pigging operation, maintain pig speed of minimum 0.1m/s to 0.5m/s
The following readings shall be Monitored and recorded for every 30 minutes:

 Pressure at launcher from gauge

 Flow meter readings

 Chemical injected in terms of volume

November 2010 Page 16 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 17 of 37

8.9 Stuck Pig Contingency Plan

8.9.1 Pig Stuck

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 totalize 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.

An indication of a pig being stuck will be obtained from the sudden rise in the pressure reading
on the gauge and none or very little out flow at the Pump outlet. The volume of water pumped
into the pipeline will be obtained from the flow meter. This volume will give an approximate
“hang-up” location of the pig. The client representative will be notified on pig being stuck.
Pumping will be stopped and the further course of action will be decided.

Following is the procedure, which proposes to adopt for dislodging and locating the stuck pig.

8.9.2 Dislodging a Stuck Pig

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 10 to 20kg/cm² 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.

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.

Should the above operations prove un-successful, relocate pigging spread to receiver end and
commence pumping from receiver end to launcher end, in an attempt to push the pig in the
reverse direction. The brush pig fitted with the pinger transmitter shall be located with the help of
pig locater, survey spread and diving team.

A visual survey by the divers will be conducted to access any brakeage in concrete coating and
further course of action will be decided after consultation with the client representative.

8.9.3 Location of a Stuck Pig

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 from the flow
meter readings and this location will be scanned for any buckles in the pipeline.

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.

November 2010 Page 17 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 18 of 37

9.0 Methodology of Hydro testing and Leak test


Sr. Test
Section Duration Remark
No. Pressure
1 Test Head (Pig Launcher (LDH) & Pig Receiver) 4 Hours 58.75 bar Pre Installation
2 PLEM Hydro testing 4 Hours 50 bar Pre Installation
3 Subsea & Floating Hoses Hydro testing 4 Hours 19 bar Pre Installation
4 24” Tie-in Spool Hydro testing 4 Hours 58.75 bar Pre Installation
5 24” No.1 Pipeline Hydro testing (KP-0.12 to KP 6 ) 24 Hours 58.75 bar Post Installation
6 24” No.2 Pipeline Hydro testing (KP-0.12 to KP 6) 24 Hours 58.75 bar Post Installation
24-Inch Pipeline Hydro testing after Tie-in with PLEM
7 24 Hours 50 bar Post Installation
(KP -0.6 to KP 6)
8 6-Inch Reject Water Flexible Pipeline Hydro testing 24 Hours 17.5 bar Post Installation
Overall System (Pipeline, Tie-in spool, PLEM and SPM with
9 4 Hours 19 bar Post Installation
Hoses) Leak Test

Note: 1 Bar = 1.02 Kg/cm²

9.1 Pre-testing of Test Heads

Refer Drawing Nos. BSPL-1520-LCL1-CT-DWG-0207 & BSPL-1520-LCL1-CT-DWG-0208 for


Pre-testing of Test heads
 Hydro-testing of Test heads will be carried out at onshore.
 Test heads shall be filled with fresh or untreated sea water.
 Pressure Gauges for testing shall have valid calibration certificates
 Vent shall be left open until the trapped air bubbles are released for the system.
 The vents shall be closed prior to pressurizing the System
 Test heads shall be pressurized at a controlled rate of not greater than 2 kg/cm² per minute
up to 59.93 kg/cm² (1.25 times of test pressure) and the pressure pump shall be shut off and
pressure hose isolated from the system. The pressure thus reached shall be kept for 4 hours
of hold period.
 All welded joints and flange connection shall be checked for any leakage. If any leakage
found in welding, repair shall be carried out after the pressure has been released to zero.
The pressurization and the hold period shall be started fresh. If small leakage found in flange
connection, gasket to be checked and bolt shall be tightened until leakage is stopped without
depressurization. The drop in pressure due to leakage will be re built to the maximum
pressure and the hold period shall be started fresh.
 All readings to be noted for every 30 min and record is maintained during the hold period.
Upon successfully completion of hold period and acceptance of test, the test head shall be
depressurized in a controlled manner at a rate not exceeding 2 kg/cm² per minute and
dewatered.

November 2010 Page 18 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 19 of 37

9.2 Pretesting of Hoses

Both the floating and underbouy hose strings shall be hydro tested for integrity in the field before
attaching them to the buoy piping. Pretesting of floating and underbuoy hose strings shall be
carried out for a period of 4 hours to a specified test pressure.

Refer Drawing No. BSPL-1520-LCL1-CT-DWG-0210 for Hydro testing of Hoses:

 Hydro-testing of Floating Hoses / Subsea Hoses will be started after completion of assembly
on the barge.
 Hoses shall be filled with filtered sea water.

Pressure Gauges for testing shall have valid calibration certificates


Pressure Pump, Pressure Gauge and other accessories required shall be fitted before
commence the hydro testing

Vent shall be left open until the trapped air bubbles are released for the system.
The vents shall be closed prior to pressurizing the System
 Hoses shall be pressurized at a controlled rate of not greater than 2kg/cm² per minute up to
19 kg/cm² and held for 2(two) hours.
 The pressure shall be lowered to 50% of test pressure i.e., 9.5 kg/cm² and held for 2 (two)
hours to allow for hose expansion.
 Pressure shall then be increased to system hydro test pressure of 19 kg/cm² and held
without additional pumping for 4 hours, the recordings and reports during the 4 hours.
 All readings will be noted for every 30 min and record is maintained during the hold period
 Upon successfully completion of hold period and acceptance of test, the floating Hose shall
be depressurised and dewatered in a controlled manner at a rate not exceeding 2 kg/cm² per
minute.

November 2010 Page 19 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 20 of 37

9.3 Pre - Testing of PLEM

Refer Drawing No. BSPL-1520-LCL1-CT-DWG-0211 for Pretesting of PLEM

 Hydro-testing of PLEM will be carried out on the barge.


 PLEM shall be filled with treated sea water.
 Pressure Gauges for testing shall have valid calibration certificates
 Vent shall be left open until the trapped air bubbles are released for the system.
The vents shall be closed prior to pressurizing the System
 PLEM shall be hydro tested prior to any field joint coating work and same shall be
pressurized at a controlled rate of not greater than 2kg/cm² per minute up to 80% of the test
pressure. Upon achieving this pressure, test pump shall be shut off to stop injection of water
in the system, visual inspection of any potential leakage shall be performed and allow
system and pressure to be stabilized for 30 minutes.
 After stabilization at 80% of the test pressure period has been successfully completed, the
full pressurisation 51 kg/cm² (100% of test pressure) shall be resumed at a controlled rate of
1kg/cm² per minute till up to 100% of test pressure, and the pressure pump shall be shut off
and pressure hose isolated from the system. The pressure thus reached shall be kept for 4
hours of hold period.
 All readings will be noted for every 30 min and record is maintained during the hold period
 Upon successfully completion of hold period and acceptance of test, the PLEM shall be
depressurized in a controlled manner at a rate not exceeding 2kg/cm² per minute and
dewatered.

November 2010 Page 20 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 21 of 37

9.4 Pre - Testing of Tie-in Spool

Refer Drawing No. BSPL-1520-LCL1-CT-DWG-0209 for Pretesting of Tie – in Spool


 Hydro-testing of Tie-in spool will be carried out on the barge.
 Tie-in spool shall be filled with untreated sea water.

Pressure Gauges for testing shall have valid calibration certificates

Vent shall be left open until the trapped air bubbles are released for the system.

The vents shall be closed prior to pressurizing the system

 Tie-in spool shall be hydro tested prior to any field joint coating work and same shall be
pressurized at a controlled rate of not greater than 2 kg/cm² per minute up to 80% of the test
pressure. Upon achieving this pressure, test pump shall be shut off to stop injection of water
in the system, visual inspection of any potential leakage shall be performed and allow
system and pressure to be stabilized for 30 minutes.
 After stabilization at 80% of the test pressure period has been successfully completed, the
full pressurisation 59.93 kg/cm² (100% of test pressure) shall be resumed at a controlled rate
of 1kg/cm² per minute till up to 100% of test pressure, and the pressure pump shall be shut
off and pressure hose isolated from the system. The pressure thus reached shall be kept for
4 hours of hold period.
 All readings will be noted for every 30 minutes and record is maintained during the hold
period.
 Upon successfully completion of hold period and acceptance of test, the tie-in spool shall be
depressurized in a controlled manner at a rate not exceeding 2 kg/cm² per minute and
dewatered.

November 2010 Page 21 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 22 of 37

9.5 Hydro testing of 24” Pipeline

Post installation hydro testing of submarine pipeline and onshore pipeline shall be carried out for
a period of 24 hours to a pressure of 59.93 kg/cm². In event of separate testing following will be
the battery limits.

A. The battery limit for pipeline hydro testing will be Pig Receiver (Onshore KP -0.12) to
Pig Launcher LDH (Offshore KP 6).
B. The battery limit for pipeline hydro testing will be (U-loop Including 24” Twins
Pipelines, Tie-In Spools and PLEM) from 1st Pig Receiver (Onshore KP -0.6) to 2nd Pig
Receiver (Onshore KP -0.6).

9.5.1 Preparatory Work

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.

A drain hose shall be connected to the pig barrel at other end and the hose terminated at
approved point for disposal of inhibited water.

Filling pump delivery hoses shall be connected to the input port of the barrel.

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 kg/cm² per minute.

The general sequence of hydrostatic testing operations for the main line shall be as follows:

 Temperature stabilization.
 Pressurizing and air content check.
 Pressure holding.
 Depressurization

Refer Drawing No. BSPL-1520-LCL1-CT-DWG-0212, BSPL-1520-LCL1-CT-DWG-0213, BSPL-


1520-LCL1-CT-DWG-0214 for pressurizing arrangement.

9.5.2 Temperature Stabilization

The line shall be left for minimum 2 hours thermal stabilization, during which time the following
readings shall be noted at 2-hour intervals.

 Sub sea temperature, using temperature probe and indicator.


 Pipe wall temperature using temperature indicator.

The thermal stabilization shall be considered achieved when difference between pipe
temperature reading and sub sea temperature reading is less than 2°c.

November 2010 Page 22 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 23 of 37

9.5.3 Pressurization & Air Volume Check

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

Communication shall be established between those involved in testing operation such as pump
operator, launcher-end technician, receiver-end technician and test controller.
Chemical shall be added with the pressurization water as per required dosage.

The line shall be pressurized gradually at a rate not exceeding 2 kg/cm² per minute up to 50% of
test pressure is reached , hold the line at 50% of test pressure for 1 hour and observe any drop
in pressure.

A P/V Plot shall be made with increments of 5 kg/cm². The air content of the line shall be
measured and shall not be exceed 0.2% of the pipeline fill volume.

For Air Volume Calculation refer Appendix – B.

If the air content is found to exceed 0.2%, then the line shall be vented and re-pressurized. The
valve at one end of the pipeline shall be opened and topped with water from the other end to
vent the air content naturally. Close the valve and restart pressurization. Re-check the air
content in the pipeline. If after successive trials of venting the air content remains at more than
0.2% of the volume of the test section, then additional pigs shall be passed and the entire
pipeline will be filled with treated sea water as mentioned above to remove the air Pockets. The
procedure for establishing the air content shall be repeated till the air content in the test section
does not exceed the allowable limit of 0.2% of the volume of the test section. In case the air
content is within 0.2% of the test section, then pressurizing can continue.

9.5.4 Stabilization Period at 80% Test Pressure

After completion of the air content check, pressurization shall continue at a rate of not greater
than 2 bar/min. The volume of water added shall be noted from the stroke counter during
pressurization as follows:

 For each 5 kg/cm² increment test pressure as recorded by dead weight tester.

On achieving the required test pressure in the line, the pressure pump shall be stopped, the
pressurization valve closed and the pressurization hose disconnected from the pipeline then
stabilization period shall be commenced.
This pressure shall be maintained for at least 4 hours to enable the test section to be stabilized.
During this stabilization period following reading shall be recorded every half an hour.

 Pipeline pressure (continuous recorder)


 Dead weight readings
 Ambient temperature (continuous recorder)
 Sub sea Temperature

November 2010 Page 23 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 24 of 37

In case of considerable pressure drop, which indicate a leak in system, the cause of the leakage
shall be investigated and leak shall be resolved after the pressure has been release to zero. The
pressurization and the hold period shall be started fresh.

The stabilization period shall be minimum period of 4 hours. When the pressure change is less
than 1% of the test pressure over two hour period, the stabilization period is considered
complete.

9.5.5 Pressurization to Test Pressure and Stabilization


After the successfully stabilization at 80% of test pressure the full pressurization 100% test
pressure shall resumed. The pressurization rate shall be maximum 2 bar/min.

On achieving the required test pressure in the line, the pressure pump shall be stopped, the
pressurization valve closed and the pressurization hose disconnected from the pipeline then
stabilization period shall be commenced.

This pressure shall be maintained for at least 4 hours to enable the test section to be stabilized.
During this stabilization period following reading shall be recorded every half hour.

 Pipeline pressure (continuous recorder)


 Dead weight readings
 Ambient temperature (continuous recorder)
 Sub sea Temperature

A pressure drop will occur due to the stabilization process of the pipeline. However, during the
stabilization period the pressure should not fall below the test pressure, so re-pressurization
should not be required this period.

Should the pressure drop be more than 10% of the actual test pressure 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.

Sub-sea terminations on the lines shall be visually inspected by divers in order to detect the
fluorescent color released at the leaking points.

The stabilization period shall be minimum period of 2 hours. When the pressure change is less
than 1% of the test pressure over one hour period, the stabilization period is considered
complete.

9.5.6 Pressure Hold Period

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

New charts duly signed by all parties shall be installed in all recorders. The hold period shall be
for a minimum period of 24hrs.

November 2010 Page 24 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 25 of 37

During the hold period, the followings readings shall be noted.

 Pipeline pressure (continuous recorder)

 Dead weight readings – Every 1 Hour

 Pressure gauge (At Testing End) – Every 1 Hour

 Ambient temperature (continuous recorder)

 Sub sea temperature ( Temperature indicator) - Every 2 Hours

9.5.7 Test Acceptance

The Hydrostatic Test shall be considered positive if test pressure has kept a constant value
throughout the specific hold period, except for change due to temperature difference.
The test will be deemed acceptable if the pressure variation after taking into account any
temperature gains \ losses over the 24 hour are ± 0.2% of test pressure.
For Pressure change due to temperature change calculation refer Appendix – B.
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.
If at any moment during the test period, the pressure is higher than 110% of the test pressure,
the line will be depressurized to 108% of test pressure.

On satisfactory completion of the test period all charts shall be removed, all log forms shall be
completed and signed by all parties and turned over to the Company and Client.

9.5.8 Depressurization

Upon successful completion of the pressure test, connect ½” hose or large size.
Depressurization will commence and gradually increase the rate not exceeding 2kg/cm² per
minutes.

The instruments, hoses and other temporary items shall be removed and the line restored for
further.
The site shall be re-instated to its original condition by removing all the temporary facilities.
The pipeline shall be preserved with chemically treated water at 0.5 kg/cm² pressure.

November 2010 Page 25 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 26 of 37

9.6 Hydro testing of 6” Reject Water Flexible Pipeline

 Flooding and Hydro testing shall be carried out from Onshore to Offshore.
 At a time of Diffuser installation make sure that test section isolated by installing suitably
rated blinds.
 Diving support not required for flooding and Hydro testing unless leak found in test section.
 Refer Drawing No. BSPL-1520-LCL1-CT-DWG-0217 for Hydro testing of 6” Reject Water
Flexible Pipeline.

 Following is the duration of stabilization and Test hold period :

Sr.
Hydro Test Scenario Duration
No.
1 Thermal Stabilization after Flooding 2 Hours
2 Stabilization after 100% pressurization 2 Hours
3 Test Hold period after 100% pressurization 24 Hours

9.6.1 Preparatory work for Flooding

Test limits shall be identified and test section isolated by installing suitably rated blinds, spades,
plugs, caps etc. Permanent instruments on the line shall be removed and their connection points
plugged. 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.

Fill Pump delivery hoses shall be connected to the input port of the test blind.
Start the Fill pump and the pipeline will be filled with chemically treated filtered water.
Suction piping and pump construction shall be such that the entry of air is prevented.

During Filling Operation following readings shall be monitored at regular intervals

 Line Pressure at Onshore end


 Flow Meter reading (Volume of water pumped)
 Volume of Chemical pumped

9.6.2 Thermal Stabilization

Temperature sensor shall be attached on the pipe line with proper covering to avoid direct sun
light for measuring the pipe wall temperature. Another temperature sensor shall be installed at
soil to measure soil temperature.

With the Temperature sensor indicators, soil temperature and pipe wall temperature shall be
recorded at 2 hours intervals.

Pressurization of pipeline will be commenced after The thermal stabilization shall be considered
achieved when difference between pipe temperature reading and soil temperature reading is
less than 2°c.

November 2010 Page 26 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 27 of 37

9.6.3 Pressurization

After acceptance of thermal stabilization, the high pressure hoses shall be connected to the
pipeline. Test Pressure shall be 17.5 barg (i.e. 17.85 Kg/cm²).

Communication shall be established between those involved in testing operation such as pump
operator, launcher-end technician.

Chemical shall be added with the pressurization water as per required dosage.

All the instruments such as Dead Weight Tester, pressure recorder, temperature recorder and
pressure gauges shall be fitted.
Start the pressure pump, vent-off all the air inside the pipeline, close the vent valve at launcher.

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

A pressure shall be gradually increased at the rate 2 kg/cm² per minute. The pressure should be
raised to a value no greater than 110% of the nominal test pressure.

The dead weight tester readings shall be recorded periodically throughout the pressurization as
follows:

 Each 5 kg/cm² increment up-to 80% of test pressure


 Each 2 kg/cm² increment between 80% to 100% of test pressure

During the pressurization period the following shall be monitored and recorded:

 Dead Weight Tester


 Ambient temperature readings from recorder
 Pipe wall temperature readings
 Soil temperature readings

On achieving the required test pressure in the line, the pressure pump shall be stopped, the
pressurization valve closed, the pressurization hose disconnected from the pipeline and the
stabilization period shall commence.

The pressurizing shall be cycled according to the following sequence:

 Pressurised to 50% of test pressure, hold pressure for 1 hour.


 Drop pressure to static head of test section at test head.
 Pressurise to test pressure.

In case, during pressure hold period indicated above, a decrease in pressure is observed, the
above operations shall not be repeated more than twice, after which the test section shall not be
considered capable of test, until the contractor has isolated and eliminated the cause for the lack
of water tightness.

November 2010 Page 27 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 28 of 37

9.6.4 Air Entrapment Test

At 50% of the test pressure, calculate air content in the pipeline will be established and this
should be less than 0.5% 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 shall be made second
time.

In case the air volume content is more than above limits during second pressurization, the line
shall be re-filled.

9.6.5 Pressure Stabilization

The followings readings shall be noted after every 30 minutes interval during the stabilization
period:

 Pipeline pressure (continuous recorder)


 Dead weight tester readings
 Ambient temperature (continuous recorder)
 Soil Temperature

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

A pressure shall be hold for a period of at least 2 hours to allow for stabilization.

Should the pressure drop be more during the first one hour of stabilization period, the possibility
of the defect exists and the line should be inspected for leakage in the test equipment.

If the pressure falls below the test pressure, then the line shall be Re-pressurized up to the test
pressure.

Stabilisation is defined as a pressure change over 1 hour of less than 2% of the test pressure.

9.6.6 Pressure Hold Period

Upon successful completion of the line stabilization and after the company’s approval of the
stabilization, the 24 hours continuous hold period shall commence.

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)
 Soil temperature (every two hours)
 Pipe-wall temperature (every two hours)

November 2010 Page 28 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 29 of 37

9.6.7 Test Acceptance

The pressure shall be greater than or equal to the nominal test pressure for the hold period.
There shall be no unaccountable pressure drop during the test. The maximum pressure drop
during the hold period should not exceed 4% of the nominal test pressure.

No leakage shall be observed from pipe during the test, no permanent deformation or damage
shall be observed in the area of end fittings. In case the above criteria are not met then after
detection of cause of fall in pressure, the test duration shall be extended by another 24 hours.
New chart shall be placed in all recorders to continue recording. If the test section fails to
maintain the specified test pressure after isolation, a search shall be made for the location of
leakage/failure and necessary/rectification measures shall be made by suitable methods
approved by Company. After completion of repair, the hydrostatic test shall be repeated in full,
as per this procedure.

If at any moment during the test period, the pressure is higher than 110% of the test pressure
then the line will be depressurized to 108% of test pressure.

In the event the test is unacceptable after 24 hours, the test period will be extended for a further
24 hours until the results are acceptable to the client.

9.6.8 Depressurization

Upon successful completion of the pressure test, connect hose ½” or large size depending on
the out flow rate and tied with the stable object. Depressurization will commence and gradually
increase the rate not exceeding 2 kg/cm² per minutes.

On satisfactory completion of the test period all charts shall be removed, all log forms shall be
completed and signed by all parties and turned over to the Company and Client.

9.6.9 Post Test Work

On satisfactory completion of the test period and Depressurization all the chart shall be removed
from the Instruments.

On complete depressurization, the instruments, hoses and other temporary items shall be
removed and the line restored.

The site shall be re-instated to its original condition by removing all the temporary facilities.

November 2010 Page 29 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 30 of 37

9.7 Post Installation Testing (Leak Test) of Pipeline, PLEM, SPM with Floating and Subsea
Hoses.

Refer Drawing No. BSPL-1520-LCL1-CT-DWG-0215 for Post Installation Testing of PLEM, SPM
with Floating and Subsea Hoses.

 Post installation testing of PLEM, SPM with floating and Subsea hoses shall be carried out
on completion of the installation of PLEM, SPM and all submarine and floating hoses.

 The SPM system including floating hoses, buoy piping, sub sea hoses and PLEM piping will
be filled with chemically treated filtered sea water with fluorescent dye.
Pressure Gauges for testing shall have valid calibration certificates
Vent shall be left open until the trapped air bubbles are released for the system.
The vents shall be closed prior to pressurizing the System

The system shall be pressurised to a pressure of 19 kg/cm² and held for 2 hours.
 The pressure shall be lowered to 50% of test pressure i.e. 9.5 kg/cm² and held for 2 hours.
The system will then be re-pressurised and depressurized 4 to 5 times (with a hold period of
15 to 20 minutes every time) to test pressure to allow for hose expansion.
 Pressure shall then be increased to system hydro test pressure of 19 kg/cm² and held
without additional pumping for 4 hours, the recordings and reports during the 4 hours.
 All pressurization and test hold periods shall be monitored by Pressure Gauge.
 Upon reaching the test pressure (19 kg/cm²) the pumps will be isolated and the pressure
held for a period of 4 hours.
 During the hold period all pressure readings shall be collected and submitted to client for the
acceptance of the test.
 On acceptance of the hydro test by the client the pipeline shall be depressurized at a rate
not exceeding 2kg/cm² per minute.

November 2010 Page 30 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 31 of 37

10.0 Attachments

November 2010 Page 31 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 32 of 37

APPENDIX A

Gauge Plate Diameter Calculations

November 2010 Page 32 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 33 of 37

GAUGE PLATES DIAMETER CALCULATIONS

The gauge plate diameter shall be equal to 95% of inside diameter of the heaviest wall pipe in
the test section.

d = 0.95 x ID
Where,
d = Gauging plate diameter (mm)

ID = Minimum Internal Diameter (mm)

Gauge Plate details as follows:

Gauge Plate
Maximum
Section Thickness Diameter
Wall thickness
mm mm mm

24” Pipeline 14.3 12 552.33

November 2010 Page 33 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 34 of 37

APPENDIX B

Hydro test Calculations

November 2010 Page 34 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 35 of 37

HYDROTEST CALCULATIONS

GENERAL

Pipeline Volume (PV)

PV =  x (I.D.2) x L / 4

Where:

PV : Pipeline volume in cubic meters (m³)

 : 3.14159

ID : Inside diameter (m)

L : Pipeline length (m)

Air Volume Calculations:

V = (Va – Vt) x 100


FV

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:

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

Where,

v = incremental volume in m3 (Vp)

p = incremental pressure in bar

V = pipeline volume in m3

November 2010 Page 35 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 36 of 37

D = pipeline outside diameter in m

t = nominal wall thickness in m

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

u = Poisson’s ratio = 0.3 bar

B = Bulk modulus of water in bar

Seabed temperature in ºC

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-1

u = Poisson ratio (for steel 0.3bar) = 0.3 BAR

α = coef of linear expansion of steel °C-1

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

B = Bulk modulus of water BAR

D = pipeline outside diameter M.

t = nominal wall thickness M.

November 2010 Page 36 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)


Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
WORK METHOD STATEMENT
Document No. BSPL-1520-LCL1-CT-MS-0016

PIPELINE FLOODING,CLEANING,GAUGING, Rev. A1


HYDROTESTING AND LEAK TEST Page No. Page 37 of 37

APPENDIX C

Project Drawings

November 2010 Page 37 of 37 BSPL-1520-LCL1-CT-MS-0016 (A1)

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