Procedure for Pre-Hydro

Test

PROJECT NO. GGCL - 114642

PROJECT NAME PALSANA REINFORCEMENT PHASE II PROJECT
CLIENT GUJARAT GAS COMPANY LIMITED (GGCL)
TPIA INTERNATIONAL CERTIFICATION SERVICES PVT. LTD
CONTRACTOR LEODUCT ENGINEERS & CONSULTANT LTD.
JOB PROCEDURE GGCL/LDEC/PRP-2 / JP18
Rev. 00

Procedure
for
Pre- Hydro Test

00 For Approval

Rev. Date Description Prepared By Reviewed By Approved By

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 Procedure for Pre-Hydro
Test

1 Scope
 This scope covers the cleaning, filling, pre hydrostatic testing & dewatering
of pipeline strings fabricated exclusively for road, rail, canal, river, and
underground utilities crossings. For construction of Steel network for
transportation & distribution of Natural gas.
2 Aapplicable Codes & Specification
 Following standards and codes of latest edition have been used in this
specification.
2.1 Governing Standard
 ASME B 31.8 - Gas Transmission and Distribution Piping Systems.
 GGCL Tender Document
GGCL/SPD/2010/BID-CONST/ARC/01 of 04
 PNGRB-2008
 Pressure Testing of Liquid Petroleum pipelines API RP 1110.
2.2 Reference Standard
[1] GGCL OSHA Risk Register
[2] Proposed route alignment sheet
[3] OISD Standard 141 Design and Construction Requirements for
Cross-country Hydrocarbon Pipelines.
3 Procedural Step
3.1 Health, Safety & Environment
 Safety permit is required for lifting, Loading and unloading process.
 GGCL approved unloading /execution plan with methodology is referred.
 The Pre-testing headers shall be hydro tested separately.
 Over pressure cut - off switch on the pump shall be provided.
 All manifold fittings and pressure gauges are of heavy duty type and
approved with necessary Tics shall be ensured.

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 All the persons involved in the activities shall have appropriate Safety
Passport issued by GGCL.
 Site specific Risk Assessment and appropriate mitigation action shall be
ensured before execution of activities on daily basis.
 Line pipe section of a 12 meter or greater in length shall be supported at 1.5
meter from both the ends and at the Center
 PPEs shall be used in this activity as per the PPE’s Matrix approved by
GGCL
 All the materials used for pressurization purpose shall confirm to required
class / rating.
 Emergency contact details to be specified with specific personnel & Contact
number including hospital.
 Adequate safety signs stating “PIPE UNDER TEST KEEP OFF” with local
language translation for the job shall be provided.
3.2 Execution
 Prior to any Hydrostatic Pre Testing activity, GGCL/ICS shall be notified.
 A calculated length of pipe string depending upon the crossing width shall
be selected for pre-testing.
 The sections of pipeline for the crossings shall be pre-tested as a single
string.
 Welded pipe sections shall be pre-tested at a location near the crossing so
as to reduce the further handling of section after testing.
 The pre-tested pipes for using as pup pieces shall be marked in red - paint
along the whole length of the pipe. While using section of the pre-tested
pipe, the pipe number and heat number shall be transferred to every section
of the pipe, which has been cut for use and recorded. Any pipe section
which shall be found without a heat number or pipe number shall not be

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 Procedure for Pre-Hydro
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allowed to be a part of the pipe line and pressure gauge limit shall be 1.5
times the test pressure.
3.2.1 Preparation
 Before the start of testing, the scheme shall be prepared by CONTRACTOR
and submit to GGCL/ICS for approval.
 Pipe Book or Line History sheet for the pre hydro test section or assembly
to be cleared before water filling.
 Pre-testing skid will consist of the following equipment.
 A water tank for controlled filling into the manifold.
 Hydrostatic test reciprocating pressure pump.
 Calibrated pressure gauges for pressure indication at both ends (on test
headers)
 Block valves for holding the water in the system and for venting.
 Non-return valve at the pressurization inlet to hold the pressure while filling
and pressurization is in progress.
 The welded pipe section to be pre-tested shall be tested only after NDT
clearance. No joint coating or primer application shall be done prior to
hydrostatic pretest.
 All welded joints shall be cleaned and exposed for visual inspection.
 The test section shall be isolated.
 Prior to water filling it shall be ensured that all test gauges and hoses are
properly hooked up and that the test section is clean.

3.2.2 Water filling

 Only tested soft and clean water shall be used for the testing. The water
from the source shall be pumped into the receiving tank. From the receiving
tank, the water shall be pumped into the pre-testing module.

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 Drain shall be provided for draining out the water from the system.
3.2.3 Pressurization
 Test Pressure
 The hydrostatic test pressure in any part of the pipeline under test shall not
be less than 75 bars.
 All test gauges shall be calibrated / certified and traceable to the Statutory
Equipment Register and it shall be in BAR unit.
 Once the water has been filled into the test loop and the air vented out,
pressure shall be applied by means of a pressurization pump, suitable for
the work.
 Pressurization shall be done at a uniform rate.
 After attaining 30% of test pressure, a preliminary inspection shall be
carried out of the holding the test for a while and upon satisfactory
inspection, pressurization shall continue.
 The pressure gauge at both ends shall provide the guidance to the pressure
build up in the system.
 A constant observation of the pressure building shall be maintained by
reading of the gauge at regular interval of 15 minutes in the temperature /
pressure recording log format
 Once the test pressure is built up, observations shall be made to stabilize
the pressure to the test pressure and also for temperature stabilization as
format
 After temperature stabilization, the pressure shall be maintained in the
pipeline for at least two hours. The pipes under test shall be subjected to
visual inspection for any leakage or deformation. Temperature and time
shall be recorded.

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 During the test, care shall be taken that the hydrostatic test pressure never
exceeds the maximum specified test pressure. Water shall be bled off, if
required. A calibrated safety relief valve shall be installed on pump.

3.2.4 Acceptance of Hydro Test

 Hydrostatic test shall be considered as positive if no abrupt drop in the
pressure is observed through the test duration, except for a change due to
temperature effects as per the specifications. It should also be observed
that there is no evidence of sweating before, during and after the ‘Hold
Period’ on all the weld joints.
 Once there is no evidence of leakage after the holding time, the Hydro test
shall be considered to have been accepted.
 The system shall be depressurized and the record signed by
CONTRACTOR and GGCL/TPIA.
 The vents will be gently released till the gauge pressure comes to zero.
 The water in the entire test loop will be dispose off for swabbing and drying.
 The type of inspection activity and the quality records generated during the
activity is detailed in the Hydrostatic Pre-testing Inspection & Test Plan
4 Documentation
 Inspection Report
 Inspection Test Plan

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Tentative Layout of Equipment and Instruments for Pre-Hydro Test

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