Narmada Hydrotest Procedure (Rigid)-Rev 1

PIGGING AND TESTING PROCEDURE RSPPM PIPELINES

MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

TABLE OF CONTENTS

SECTION

1.0

INTRODUCTION

SECTION

2.0

PIPELINE PIGGING &HYDROTESTING DATA

SECTION

3.0

EQUIPMENT & INSTRUMENTATION

SECTION

4.0

PIGGING PROCEDURE

SECTION

5.0

HYDROTEST PROCEDURE

SECTION

6.0

SAFETY GUIDELINES

SECTION

7.0

RECORDS AND FORMAT FORMS


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

APPENDICES APPENDIX A

GAUGING PLATE DIA CALCULATIONS

APPENDIX B

PIPELINE HYDROTEST CALCULATIONS

APPENDIX C

PIGS & ACOUSTIC PINGER SYSTEM DATA

APPENDIX D

CHEMICALS DATA

APPENDIX E

PUMPS DATA

APPENDIX F

SAFETY PROCEDURE

APPENDIX G

RECORDS & ACCEPTANCE FORMS

APPENDIX E

DRAWINGS

APPENDIX F

CALIBRATION CERTIFICATES


SECTION 1.0 INTRODUCTION

MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

SECTION 1.0 INTRODUCTION 1.1

GENERAL This document describes the Contractor’s proposed procedure for pigging and hydrostatic testing of Rigid pipelines for the RSPPM project of ONGC at Mumbai High fields in India The

work

of

pigging

and

hydro-testing

of

pipelines

will

commence after the completion of all associated installation works such as risers, crossings and free span correction. A work boat will be utilized to carry out the scope of work together with a secondary boat (if required) to perform duties such as preparatory work, receive pigs, transfer personnel, etc. Site conditions often cause changes in offshore work plans and as such, the Contractor reserves its representative’s sole right to alter these procedures in order to best suit the site conditions and

safety

of

personnel

and

equipment.

The

company

representatives onboard the vessel will be informed of any major deviations from this procedure and the reason for it, prior to any such deviations being implemented.


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

SECTION 2.0 PIPELINE PIGGING AND HYDROSTATIC DATA


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

SECTION 2.0 2.1

PIPELINE PIGGING & HYDROSTATIC TESTING DATA The scope of work broadly covers the FLOODING, CLEANING, GAUGING and HYDRO-TESTING of the following segments of rigid pipelines pipelines.

ONGC Pipeline Ref.No Segment

O.D (mm)

Thickness(mm) Length Test Pre. Service ( km ) kg/cm2 P/L R/L

01 02 03

RS 11-ICP 323.9 RS2-ICD 323.9 RS3-BHS 323.9

14.3 14.3 14.3

25.4 25.4 25.4

4.8 8.3 3.6

117.125 117.125 117.125

WF WF WF

04 05 06 07

BHS-RS3 RS1-SA NM-RS2 SC1-RS1

168.3 273.1 168.3 168.3

7.1 12.7 7.9 7.1

14.3 25.4 14.3 14.3

3.4 4.2 4.0 3.6

131.25 117.125 131.25 131.25

GL WF GL GL

08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

IB-ZB ZB-ICD ICP-RS11 SI-5-SHG SF-S1-5 EC-S1-5 IH-II EE-SHG II-S1-4 IJ-SHP S1-6-IM RS7-SHP SHP-RS7 RS5-BHN NM-RS5 SB-RS4 RS4-BHS ID-RS8 RS8-ID

168.3 406.4 114.3 323.9 219.1 219.1 168.3 168.3 168.3 273.1 273.1 323.9 168.3 323.9 168.3 168.3 323.9 114.3 273.1

7.9 15.9 7.1 14.3 11.1 11.1 11.0 11.0 7.1 12.7 12.7 14.3 7.1 14.3 7.9 7.1 14.3 7.1 12.7

14.3 22.2 14.3 25.4 20.6 20.6 18.3 18.3 14.3 25.4 25.4 25.4 14.3 25.4 14.3 14.3 25.4 14.3 25.4

8.9 11.8 4.6 11.6 3.7 4.0 5.3 2.3 3.8 3.0 2.9 4.8 4.8 13.0 2.9 2.6 6.5 3.2 4.0

131.25 117.125 131.25 176.25 171.25 171.25 171.25 171.25 131.25 176.25 176.25 117.125 131.25 117.125 131.25 131.25 117.125 131.25 117.125

GL WF GL WF S1 SAND S1 SAND S1 SAND S1 SAND

GL WF WF WF GL WF GL GL WF GL WF


2.2

MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

REFERENCE All the works shall be carried out as per the followings Specifications, Codes and Standards

a.

ANSI B31.4

- Liquid Petroleum Transportation Piping system

b.

ANSI B31.8

- Gas Transmission and Distribution Piping system

c.

API RP 1110

- Pressure Testing of Liquid Petroleum Pipelines

d.

ASME Sec. VIII

- Boiler and Pressure Vessels Code Div 1.

e.

DNV-OS-F101

- Submarines Pipelines System

f.

ONGC Spec. No

- 2022 Rev.0, Hydro-testing for submarine pipelines.


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

SECTION 3.0 EQUIPMENT AND INSTRUMENTATION 3.1

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

3.1.1 PIGGING OPERATION 1 Fill Pumps 2 3 4 5 6 7 8 9 10 11

500m3/hr, 12 Bar Max. Pressure – 1 ea 150m3/hr, 21 Bar Max. Pressure – 2 ea Chemical dozing pumps – 3 ea 6”/8” Flow meters – 3 ea Strainers 150 microns Non Return Valves – 3 ea Day tank – 1 ea Pressure Gauge (0 to 25 kg/ cm2) – 3 ea Connecting hoses 2” and 4” Pump delivery manifolds 2” Valves - 10 ea 4”,6”,8” Valves as required

3.1.2 TESTING OPERATION 1 High pressure Test pumps – 5000 psi with adjustable volume – 2 ea 2 Dead weight Testers (4 to 250 kg/cm2) – 2ea 3. Pressure Chart Recorders (0 to 250 kg/cm2) – 2 ea 4 Temperature Chart Recorders (0 to 50 deg. C) – 6 ea 5 Pressure Gauges (0 to 250 kg/cm2) – 8 ea 6 Digital Temperature Indicator - 4 ea 7 RTD Sensors – 8 ea


MARCH 2005 Rev-1

3.1.3 GENERAL 1 Hoses for pigging and hydro-testing 2 Manifold and fitting for both pigging and testing 3 Test Cabin and material container 4 5 6

Rigging tools and tackles Chemical INDION-175 T Pigs

DOC NO: NO/RSPPM/01


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

SECTION 4.0 PIGGING PROCEDURE

SECTION: 04 PIGGING PROCEDURE 4.1

INTRODUCTION The pigging operation comprising of cleaning and gauging of the p


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

ipelines will commence only after all the pipeline crossings, free span corrections and burial have been completed. Company shall arrange work permits for 24 hours uninterrupted Operations The cleaning, displacement and gauging pigs will run from the permanent launcher to the permanent receiver. 4.2

PIGS DESCRIPTION

4.2.1 Cleaning Pig: The cleaning pig used will be a bi-directional disc type pig equipped with circular steel wire brushes as cleaning elements. The brushes will be fitted onto the pig body in such a way so as to provide a 360 deg cleaning coverage. The brush cleaning pig shall be capable of removing any lose debris in the pipeline including welding slag, loose mill scale, corrosion product, etc. by magnets fitted on pig body. 4.2.2 Displacement Pig: The displacement pig used will be a bi-directional disc type pig

4.2.3 Gauging pig The gauging pig shall be a bi-directional disc type pig, equipped with a removable gauging plate in front of the third cup. Gauging plate shall be 12.7mm thick machined aluminum. The gauging p i


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

g will have a pinger housing which will enclose an acoustic pinger, capable of emitting signal for a period of twenty (20) days. 4.3

CHEMICAL INJECTION The seawater will be used to push the pig train and shall be mixed with chemical INDION – 175 T which is a cock tail of CORROSSION INHIBITOR, OXYGEN SCAVENGER, BIOCIDE and FLOURESCENT DYE. Technical information sheets for the above chemicals are included in Appendix-E The chemicals will be mixed with seawater on the delivery side of the pump. The chemicals will be stored in drums and a constant volume will be mixed with pumped seawater by chemical dozing pump fitted with adjustable flow screw and also stroke counter for flow measurement depending upon the output flow rate obtained from the pump. The flow rate obtained from the pump will be continuously monitored by a flow meter, which will be installed on the pump outlet manifold.

. 4.4

SEQUENCE OF OPERATION

4.4.0 PREPARATORY WORKS


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

4.4.1

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

4.4.2

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

4.4.3

Exposed portion of test section at both platform ends shall be covered from direct sunlight by suitably covering them as required to reduce temperature effects

4.4.4

One pressure Gauge of suitable range shall be fitted on pig launcher

4.5.0

FLOODING, CLEANING, GAUGING AND FILLING

4.5.1

Equipment layout during the pigging operation is as per sketch attached in annexure

4.5.2Flooding, Cleaning, Gauging and Filling are the sequence of operations and the followings pigs train are launched. -

Cleaning pig with brushes, magnets Batching pig Cleaning pig Gauging pig

4.5.3

Initially pump seawater, volume equivalent to 250 meter length of pipe before launching of any pigs

4.5.4

Launch Cleaning Pig with Brushes and Magnet

4.5.5

Pump seawater equivalent to 250 m length of pipe behind cleaning pig

4.5.6

Launch Batching Pig

4.5.7

Pump seawater equivalent to 250 m length of pipe behind Batching Pig


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

4.5.8

Launch Second Cleaning Pig

4.5.9

Pump seawater equivalent to 250 m length of pipe behind second cleaning pig

4.5.10

Launch Gauge Pig Fitted With Aluminium Gauge Plate

4.5.11 start chemical injection using a chemical dozing pump with Stroke adjustment to pump chemical as per required Concentration 4.5.12 During the pigging operation the following readings shall be Monitored and recorded for every 15 minutes. -

Pressure at launcher from gauge Flow meter readings Chemical injected

4.5.13 Constant communication should be maintained between launcher and receiver end. At completion of 90% of fill volume behind the first pig, inform to receiver end operator to continuously note the pig arrival. 4.5.14 once all pigs arrive in the pipeline pump should be stopped to remove the pigs from the receiver 4.5.15 The gauging pig should be removed carefully from the receiver and the Gauging plate checked for any sings of damages. 4.5.16

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

4.5.17 In the event of any significant damage to the gauging plate, an additional gauging pig will be run, to reconfirm the presence of any possible obstruction in the pipeline. 4.6 4.6.0

STUCK PIG CONTINGENCY PLAN Pig Getting Stuck: 4


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

.6.1 While the cleaning, displacement and gauging pigs are being run, continuous monitoring will be done with the help of a flow-meter with a direct readout totalizer installed on the out flow manifold on the pump. Pressure monitoring in the pipeline will be done through a pressure gauge installed on the launcher. 4.6.2

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

4..6.3

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

4.6.4 Dislodging a Stuck Pig: 4..6.5 All the valves on the receiver will be kept in closed position and pumping will be commenced from launcher end. The pressure will be raised to approximately 300 to 400psi and the valves on the receiver opened instantaneously in an attempt to jerk and dislodge the stuck pig. The cycle may be repeated depending upon the situation. 4.6.6 The event the maximum pressure is not adequate to dislodge the pig, the line shall be de-pressurized, and the pumping shall be commence at the maximum discharge flow-rate of the pump until such maximum pressure is achieved. 4.6.7 Should the above operations prove un-successful, relocate pigging spread to receiver platform and commence pumping from receiving platform to launching platform, in an attempt to push the pig in the reverse direction. 4.6.8 If the above operation fails or if the pig by-passes, then the s


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

econd foam pig shall be launched from the receiving end in an attempt to dislodge the pig and push it back to the launching end 4..6.9 In the event of failure, further course of action will be decided after consultation with the company representative. 4..7.0 Location of a Stuck Pig 4.7. 1 In the event of attempts of getting the stuck pig dislodged fail, the operations for locations of stuck pig will commence. Preliminary approximate position will be determined as described in section 4.7.4 this location will be scanned

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

SECTION 5.0 HYDROSTATIC TESTING PROCEDURE T


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

esting will be carried out from permanent pig launcher to permanent receiver 5.1.0 PREPARATORY WORKS: 5.1.1 Top side pipe-work shall be hooked up to the riser top and all in line pipe-work leading to the pig barrel shall be installed by IOEC on the both platforms. 5.1.2 Test limits shall be identified and test section isolated by installing suitably rated blinds, spades, plugs, caps etc. Permanent instruments and sensors (except the pig signalers) on the line shall be removed and their connection points plugged. Permanent valves which are not rated for the test pressure shall be dropped and the branch suitably blinded. Typical test isolation points are identified. Valves retained for testing shall be kept in full open position during testing and blinded on downstream as applicable. 5.1.3 A drain hose shall be connected to the pig receiver at receiver platform and the hose terminated at approved point for disposal of inhibited water. 5.1.4 Exposed portion of test section at both platform ends shall be covered from direct sunlight by suitably covering them as required to reduce temperature effects. 5.1.5 Filling pump delivery hoses shall be connected to the input port of the barrel or test blind 5.1.6 Start the filling pump and the pipeline will be filled with chemically treated filtered water for any make-up and the pipeline will be pressurized to a pressure of 2.0kg/sq.cm.

5.2

THERMAL STABILISATION Temperature reading will be monitored with suitable thermocouples and Seawater temperature at 2 hours intervals. P


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

ressurization of pipeline will be commenced after temperature of pipeline varies by 1deg.c with the temperature of seawater. 5.3

PRESSURISATION

5.3.1 Preparatory works: 5.3.1.1 After acceptance of thermal stabilization, the high pressure hoses shall be connected to the pipeline as per sketch no: 04 5.3.1.2 Fire water pump shall be using for supply of water to the pressure pump and operator will be continuously noted the water level of the holding drum at any case the air will not allow to enter into the pump suction 5.3.1.3 The vent valve of both ends shall be kept open initially. 5.3.1.4 Communication shall be established between those involved in testing operation such as pump operator, launcher-end technician, receiver-end technician and test controller. 5.3.1.5 Chemical shall be added with the pressurization water as per required dosage. 5.3.1.6 All the instruments such as Dead Weight Tester, pressure recorder, temperature recorder and pressure gauges shall be fitted as per drawing given in appendix

5.4

PRESSURE CYCLE

5.4.1 Start the pressure pump, vent-off all the air inside the pipeline, i


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

nform to remote end or lowest elevation-end technician to close the vent valve, then, close the vent valve at launcher. 5.4.2 Volume of water added into the pipeline section will be measured through stroke counter installed on the pump and recorded throughout the pressurization period. 5.4.3 Pressurize up to 50% test pressure at the rate not exceeding 2 bar/ minute 5.4.4 Stop the pressure pump, close the pressurizing valve at monitoring end and hold the pressure for an hour. 5.4.5 During this hold period checking shall be made both the ends if any visible leaks shall be rectified after depressurize the line to zero. 5.4.6 The following readings shall be monitored and recorded every 15 minutes during one hour hold period. 5.5

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

AIR ENTRAPMENT TEST

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

5.5.2

In case the air volume content is more than 0.2% during s


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

econd pressurization, the line shall be re-filled using two nos of displacement pigs. 5.5.3

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

5.5.4 Start the pressure pump and continue until the pressure reached at test pressure. 5.5.5 The pressurization rate shall be as follows: ¾ 5 Bar/ minute increment up-to 80% of test pressure ¾ 2 Bar/ minute increment between 80% to 90% of ¾ 0.2 Bar/ minute increment up-to full test pressure. 5.5.6

During the pressurization

period the following shall be

monitored and recorded

-

Dead Weight Tester

-

Ambient temperature readings from recorder

-

Pipe wall temperature readings

-

Sub sea temperature readings

5.5.7 On achieving the required test pressure in the line + 2% test pressure, the pressure pump shall be stopped, the pressurization valve closed, the pressurization hose disconnected from the pipeline and the stabilization period shall commence.


5.6

MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

PRESSURE STABILISATION

5.6.1 The followings readings shall be noted every at 15 minutes interval during the stabilization period: -

Pipeline pressure (continuous recorder) Dead weight tester readings Ambient temperature (continuous recorder)

5.6.2 A pressure drop will occur due to the stabilization process of the pipeline line. However, during the stabilization period the pressure should not fall below the test pressure. 5.6.3 Should the pressure drop be more during the first half hour of stabilization period, the possibility of the defect exists and the line should be inspected if the leakage is not found in the test equipment. 5.6.4

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

5.7.0 PRESSURE HOLD PERIOD 5.7.1 Upon successful completion of the line stabilization and after the company’s and client’s approval of the stabilization, the hold period shall commence. 5.7.2 New charts duly signed by all parties shall be installed in all recorders. The hold period shall be for a minimum period of 24hrs. During the hold period the followings readings shall be noted -

Pipeline pressure (continuous recorder) Dead weight readings (every one hour) Ambient temperature (continuous recorder) sub sea temperature (every two hours) Pipe-wall temperature (every two hours)


5.8

MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

TEST ACCEPTANCE

¾ The test will be deemed acceptable if the unaccountable pressure variation after taking into account any temperature gains \ losses over the 24 hour are +/-0.2% of test pressure. ¾ Should the test not be acceptable after 24 hour, the test period will be extended for a further 24 hours until the results are acceptable to the client. 5.9

DEPRESSURIZATION

¾ Upon successful completion of the pressure test, connect hose ¾” or large size depending on the out flow rate and tied with the channel or platform. Depressurization will commence and gradually increase the rate not exceeding 2 bars per minutes.

5.10 POST-TESTED WORK 5.10.1 On satisfactory completion of the test period and Depressurization all the chart shall be removed from the Instruments. 5.10.2 On complete depressurization, the instruments, hoses and other temporary items shall be removed and the line restored. 5.10.3

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


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

SECTION : 06 SAFETY PROCEDURE All operations described in this procedure will be in accordance with the relevant NOCPL, IOEC and ONGC system and policies. Safety is the responsibility of every employee irrespective of status. Employee shall ensure that their work place is safe and functions efficiently and safely. Common sense should be applied for safe working practices to be implemented and adhered to at all times. Particular attention is to be given to work site safety and to any safety procedure provided. The following safety shall be adhered to at all times. •

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

•

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

•

In particular, report all unsafe conditions, tools, equipment and working practices immediately to operational management or supervision on such that corrective action can be taken and accidents avoided.

•

No practical jokes, horseplay, drinking of alcohol or substance abuse are allowed.

•

Do not remove, displace, damage or destroy the safety equipment provided for use on jobs.

•

Permit to work procedures shall be strictly adhered to. No work shall commence until the appropriate permit has been obtained from a competent issuing authority.


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

•

Do not run except in extreme emergencies. Watch where you walk and keep alert to the movement of equipment an others persons around you. Use the handrail when on stairways.

•

All employees shall maintain their work area in a neat, orderly, tidy and litter free condition at all times.

•

All employees shall use personal protective equipment (PPE) provided for their use.

•

Only authorized person shall be allowed to operate plant and power tools.

•

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

•

No person shall stay under loads handled by power operated lifting equipment.

•

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

•

Personnel shall not carry out any work on vessels, pipelines or fittings, which are under pressure. Systems shall be isolated and depressurized prior to remedial work being carried out.

•

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

•

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

•

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

•

When the system is completely filled with testing liquid, place warning tags on all valves under test. Warn your co-workers to keep distance and use barricade tape and signs for the test area.

•

W


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

hen the system is ready to be pressurized, remember or always keep one person watching the pressure gauge. Never let the pressure exceed the maximum test pressure. •

Check all flanges/fittings, etc. if a leak is discovered, depressurized the system. Repair the leak and start again.

•

Never try to tighten a fitting or flange under pressure because it Live Bomb looking for an excuse. Do not be its victim.

•

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

•

Remember to hold the test pressure until your engineer instructions to depressurize the system.

•

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

•

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

•

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

•

Now that your test is complete, restore the system.

Barriers and Signs: During the test operation no unauthorized personnel will be allowed near by test head location and the area will be cordoned off with proper sign board like - DANGER- “PIPELINE UNDER TEST” No other activity will be performed near the pipeline during testing.


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

SECTION : 7 RECORDS AND FORMATS During the different work phases to be performed throughout this procedure, forms are to be filled by the NOCPL engineer. 7.1.1 Daily Operations Report : A log kept at each location listing daily events occurring throughout the contract, this shall be for inspection by the IOEC representative at all times. 7.1.2 Record Charts ( Pressure & Temperature ) Record Charts shall be initialed on and signed off by both the NOCPL, IOEC and ONGC 7.1.3 Pig Register This forms records data of time, launching, receiving, recovery and general condition of all pigs run through the pipeline. 7.1.4 Fill Report This form records the volume of water pumped, pig velocity, distance and amount of chemical added to the filling water. 7.1.5 Gauge Plate Acceptance Certificate: This form records the details of the gauging pig run with all relevant dimensional checks, it is to be signed by all the relevant parties. 7.1.6 Pressurization Report This form records data of pressure increase, rate and volume injected


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

7.1.7 Air Inclusion Report This form records % of air inside the pipeline and related calculations 7.1.8 Hydrotest Report This forms records data of time, pressure and temperature throughout the hydrotest period. 7.1.9 Test Acceptance Certificate: This form includes detail of the actual hydrotest system and instrumentation and is signed by all relevant parties.


APPENDIX – A

MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

APPENDIX- A RSPPM PROJECT GAUGE PLATE CALCULATIONS The following formula as per ONGC spec 2022, page 6 of 21 shall be used to calculate gauge plate diameter. d = D- 2t – (0.01D + 0.4t+5I) d= gauge plate diameter D= nominal O.D of pipe t= max pipe wall thickness I= 0.2t or 5 mm max


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

Gauge plate diameters Sr no

Pipeline Segment

O.D (mm)

Thickness(mm) R/L

P/L

Gauge plate Dia mm

01 02 03

RS 11-ICP 323.9 RS2-ICD 323.9 RS3-BHS 323.9

14.3 14.3 14.3

25.4 ( 5D bend) 25.4 ( 5D bend) 25.4 ( 5D bend)

234.301 234.301 234.301

04 05 06 07

BHS-RS3 RS1-SA NM-RS2 SC1-RS1

168.3 273.1 168.3 168.3

7.1 12.7 7.9 7.1

14.3 25.4 ( 5D bend) 14.3 14.3

117.997 184.009 117.997 117.997

08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

IB-ZB ZB-ICD ICP-RS11 SI-5-SHG SF-S1-5 EC-S1-5 IH-II EE-SHG II-S1-4 IJ-SHP S1-6-IM RS7-SHP SHP-RS7 RS5-BHN NM-RS5 SB-RS4 RS4-BHS ID-RS8 RS8-ID

168.3 406.4 114.3 323.9 219.1 219.1 168.3 168.3 168.3 273.1 273.1 323.9 168.3 323.9 168.3 168.3 323.9 114.3 273.1

7.9 15.9 7.1 14.3 11.1 11.1 11.0 11.0 7.1 12.7 12.7 14.3 7.1 14.3 7.9 7.1 14.3 7.1 12.7

14.3 22.2 14.3 25.4 20.6 20.6 18.3 18.3 14.3 25.4 25.4 25.4 14.3 25.4 14.3 14.3 25.4 14.3 25.4

117.997 326.856 64.53 234.301 146.869 146.869 104.397 104.397 117.997 184.009 184.009 234.301 117.997 234.301 117.997 117.997 234.301 64.53 184.009

( 5D bend)

( 5D bend) ( 5D bend) ( 5D bend) ( 5D bend)

( 5D bend) ( 5D bend)


MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

APPENDIX- B HYDROTEST CALCULATIONS: a)

Pipeline Volume (PV) PV

= π x (I.D.2) x L / 4

Where: PV π ID L b)

: : : :

Pipeline volume in cubic meters (m3) 3.14159 Inside diameter (m) Pipeline length (m)

Air Volume Calculations: V

= (Va – Vt / FV) x 100

Where, V : Air content ( % ) Va : Actual volume pumped ( based on stroke counter or bleeding ) Vt : Theoretical volume to pressurize FV : Pipeline total fill volume The followings formula can be used to calculate the theoretical volume of water required to raise the pressure in the pipeline: ∆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 D = pipeline outside diameter in m


t

MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

= nominal wall thickness in m

E = Young’s elastic modulus of steel = 2.07 x 10 u = Poisson’s ratio

6

bar

= 0.3 bar

B = Bulk modulus of water in bar Sea bed temperature in C c)

Temperature Effect: ∆P ∆T

=

γ-2(1+ u) α D/Et (1-u2) +1/B

Where ∆P= Incremental pressure

BAR

∆T= Incremental temperature

°C

γ= Volumetric expansion coef of water

°C-

u= Poissons ratio ( for steel 0.3bar) α= coef of linear expansion of steel

°C-

E = Young’s elastic modulus of steel = 2.07 x 10 B = Bulk modulus of water in bar D = pipeline outside diameter in m t

= nominal wall thickness in m

6

bar


MARCH 2005 Rev-1

SECTION 3.0 EQUIPMENT AND INSTRUMENTATION

DOC NO: NO/RSPPM/01


MARCH 2005 Rev-1

SECTION 5.0 HYDROSTATIC TESTING PROCEDURE

DOC NO: NO/RSPPM/01


MARCH 2005 Rev-1

SECTION : 06 SAFETY PROCEDURE

DOC NO: NO/RSPPM/01


SECTION : 7 RECORDS AND FORMATS

MARCH 2005 Rev-1

DOC NO: NO/RSPPM/01

Narmada Hydrotest Procedure (Rigid)-Rev 1

Recommend Documents