PIPELINE CLEANING, GAUGING Doc. No.

: DRAFT
& HYDROSTATIC TESTING Rev. : 0
Engineering, Procurement and Construction PROCEDURE Date :
Page : 1 of 6

LIST OF CONTENTS

SECTION Page

1. INTRODUCTION ................................................................................... 3

2. TEST MEDIUM ...................................................................................... 3

3. CLEANING AND GAUGING ................................................................. 3

4. HYDROTEST SET-UP ......................................................................... 4

5. PRESSURIZATION TO TEST PROCEDURE ...................................... 4

6. PRESSURE TEST ................................................................................ 5

7. DE-PRESSURIZATION ........................................................................ 6

8. FINAL DOCUMENTATION ................................................................... 7

9. SAFETY ................................................................................................. 7
 PIPELINE CLEANING, GAUGING Doc. No. : DRAFT
& HYDROSTATIC TESTING Rev. : 0
Engineering, Procurement and Construction PROCEDURE Date :
Page : 2 of 6

1. INTRODUCTION

This procedure includes cleaning, gauging & hydrostatic testing (hydrotest) of the
pipeline to be installed during the EPC Services of “Pembangunan” Project scope
of work.

Before hydrotest, the sealines and dog-legs will be cleaned and gauged from pig
launcher to pig receiver. As-laid surveys shall also be completed for assurance that
the subsea lines have been laid within the specifications for alignment and length of
free-spans.

All hydrostatic test pressures shall be a minimum of 1.5 times the design pressure.
After pressurization and stabilization of the pipeline test pressure, the hydrostatic
test shall be held for at least 24 hours without interruption.

2. TEST MEDIUM

The pipelines will be filled with chemically treated sea water filtered through 100
mesh screen to remove all solids in excess of 250 microns.

Inhibitor chemicals needed to neutralize the sea water and protect the pipelines from
internal corrosion shall be used as follows :
 Petrolite Fludex WF-3006 or approved equivalent
 Corrosion Inhibitor / Oxygen Scavenger / Bactericide
 Estimated Dosage 1,250 ppm or manufacturer’s recommendations

3. CLEANING AND GAUGING

Prior to cleaning and gauging, the Hydrotest Team shall isolate any connected
systems from the pig launcher and receiver with blind flanges. The test head, all
gauges, filling, injecting, and venting lines to the launcher and receiver shall then be
connected.

The following sequence shall be followed during the filling, cleaning and gauging
operations :

1) Pump approximately 250 linear metres of pipeline volume of sea water into
the pipeline.

2) Launch the brush pig with pinger (if required).

3) Pump another slug of approximately 100 linear metres volume of sea water
into the pipeline.
 PIPELINE CLEANING, GAUGING Doc. No. : DRAFT
& HYDROSTATIC TESTING Rev. : 0
Engineering, Procurement and Construction PROCEDURE Date :
Page : 3 of 6

4) Launch the gauging pig.

5) Fill the entire pipeline with treated water.

6) Receive the gauging pig and brush pig if any.

7) Continue pumping until all air is expelled.

When the pigs are removed from the receiver in the presence of COMPANY, the cup
wear will be inspected for regularity and the gauging plate for wear or damage.

Blocking of pigs at any point along the line will entail suspension of filling operations
and subsequent recovery of pigs, diagnosis of blockage, and restoration of the line
to test condition. The line will then be cleaned and gauged again according to the
procedure above.

4. HYDROTEST SET-UP

Hydrostatic testing of the sealines, dog-legs and risers is a continuation of works

initiated by the cleaning and gauging section of this procedure.

In preparation for hydrotesting, water temperatures shall be monitor prior to testing

commences from appropriate locations. From these temperature records, pressure
variations during testing may be explained and stabilization periods established.

A reduction in recorded pressure equivalent to the hydrostatic head between the

mean sea level and location of the pressure measuring gauge may be applied to the
test pressure where appropriate (i.e. 1.5 psi per foot measured, added to gauge test
pressure at the top of riser).

5. PRESSURIZATION TO TEST PRESSURE

A pressure recording gauge will be installed in parallel with the dead weight tester.
The pressure recording gauge will be checked periodically through the
pressurization and test by the dead weight tester.

During the pressurization, the Bourdon Pressure Gauges will be used for test
operator guidance only.

While bringing the pipeline up to test pressure, a hand-plot of the pressure volume
curve shall be started and continued until test pressure is achieved.
 PIPELINE CLEANING, GAUGING Doc. No. : DRAFT
& HYDROSTATIC TESTING Rev. : 0
Engineering, Procurement and Construction PROCEDURE Date :
Page : 4 of 6

During the pressurization, the test operator(s) will take continuous recordings of:
 Pump delivery rate
 Pressure in line
 Temp. in line
 Ambient air temp
 Temp. of filling water tank
 Subsea (bottom) temp.

At the agreed time of commencement, the following sequence will be followed for
hydrotesting :

1) Begin pressurization at approximately 20 psi / min.

2) At 50% test pressure stop and vent air (record water amount vented if any).

3) Resume pressurization at approx. 10 psi / min to approx. 70% test pressure

and stop.

4) Maintain pressure for sufficient time for stabilization. (Subject to COMPANY

approval).

5) Continue pressurization at approx. 5 psi / min to test pressure.

6) A drain test to test for air may be conducted if required, before raising the
pressure to the final test pressure.

A check for leaks and amplitude if any will be conducted at this point and corrective
action taken if necessary.

When test water temperature and pressure is stabilized, all connecting pipes except
those for pressure measurement, will be disconnected. After repair of possible leaks
the pressure test will begin.

6. PRESSURE TEST

During the 24 hours test period, care shall be taken that the maximum test pressure
is not exceeded. If it is necessary to drain off water for their purpose, the pressure
drop and the amount of water drained are to be measured accurately.
 PIPELINE CLEANING, GAUGING Doc. No. : DRAFT
& HYDROSTATIC TESTING Rev. : 0
Engineering, Procurement and Construction PROCEDURE Date :
Page : 5 of 6

The following measurements will be recorded over the 24 hours test period :
1) Every half an hour, pressure measured by dead weight tester, also maximum
and minimum observed pressure during last half hour and average pressure
value.
2) Every half an hour, the ambient temp., sea water temp. and pipe temp. from
pipeline thermowells.

If during the tests a leak is found in an element which does not belong directly to the
pipeline, the test will be resumed after the leakage has been repaired.

Failures in the pipeline disclosed by loss of pressure will be located by dye injection
and repaired. Air supplied from the lay barge may be use to de-water the pipeline
through the test head; the treated water will be disposed of properly. The pick-up
and lay-down procedures outlined in the Construction procedures will be followed for
handling the pipe. Following repairs, the pipeline will be re-filled, cleaned and
gauged as per sections 1.0 – 3.0 of this procedure and then re-tested until a
continuous test period is satisfactorily attained.

Precise records will be recorded in the event of failure occurring during the test to
include :
1) Exact location of failure
2) Type of failure
3) Cause of failure
4) Method of repair

Any pipe fittings or valves that fail are replaced will be clearly marked with their
pipeline location and failure pressure.
At the end of the pressure test a second drain test may be conducted and recorded
if required.

The second test will be made to reproduce the first test as much as possible. (i.e. if
first test measured 0.5 bar pressure drop, the second should also).

After all test records and data have been submitted to COMPANY and approval has
been given, pressure will be released.

7. DE-PRESSURIZATION

Pressure will be released at the following rates :

 100% - 90% - 15 psi/min.
 90% - 80% - 30 psi/min.
 PIPELINE CLEANING, GAUGING Doc. No. : DRAFT
& HYDROSTATIC TESTING Rev. : 0
Engineering, Procurement and Construction PROCEDURE Date :
Page : 6 of 6

 80% - 0% - 45 psi/min.
Following de-pressurization, the lines will be left full of treated water and all
previously blinded flanges will be re-connected or left as per COMPANY instructions.

The areas will be cleaned up and all waste or scrap disposed of properly.

8. FINAL DOCUMENTATION

On completion of the hydrostatic test the following bound documents will be

submitted :

1) Completed hydrostatic test forms

2) Pipeline profile diagram showing test-head, pig launcher/receiver location and

make-up

3) The Test Procedure

4) Log of operations

5) Theoretical and observed hand plot of pressure-volume and temperature-

volume curve

6) Instrument certifications

7) Additive data sheet, supplier and amounts injected

All applicable documents will be submitted to COMPANY for co-signature before

compiling final deliverables.

9. SAFETY

During the hydrotest, no other work will be done on or within the immediate area of
the pipeline or risers at both ends of the sealine.