Rbb-00-100232-Ba-6008-00008-0000 Rev01

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Petroleum Development Oman , ,
PDQ Contract Number: C311394
Restricted
Rabab Harweel Integrated

Project - Off Plot (31-1394)
Hydrostatic Testing, De-Watering &
Pre-commissioning Method Statement for
U/G Pipelines 20" RHIP to BVS 18 ( SGL)
RBB-00-100232-BA-6008-00008-0000
PCAP Yes / -No-
Arnab Mukherjee
01 27-02-2017 Issued For Review
Hydrotest Engineer Construction Manger Contract Manager
Rev. Date Reason for Issue Originator Checker Approver
"Electronic Documents once printed are Non-Controlled and may become Outdated"
This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any part of this document may be disclosed to others or
reproduced, stored in a retrieval system, or transmitted in any form by any means (electronic, mechanical. reprographic recording or otherwise) without
prior written consent of the owner.
RBB-00-100232-BA-6008-00008-0000 Hydrostatic Testing, De-Watering & Pre-commissioning Method
Statement for U/G Pipelines 20” RHIP to BVS-18 (SGL)
Rev No. 01
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Page 2 of 20
Rev No. 01
Contents
1 PURPOSE ................................................................................................................................ 4
2 SCOPE ..................................................................................................................................... 4
3 REFERENCES ............................................................................................................................ 4
4 DEFINITIONS ........................................................................................................................... 4
5 RESPONSIBILITY ...................................................................................................................... 5
5.1 Responsibilities of Hydro test engineer........................................................................................ 5
5.2 Responsibilities of Hydro test Foreman ....................................................................................... 5
6 Equipment, Instruments and Accessories ................................................................................ 6
6.1 EQUIPMENT ............................................................................................................................... 6
6.2 TEST INSTRUMENTS .................................................................................................................... 6
6.3 ACCESSORIES .............................................................................................................................. 7
7 Procedure ............................................................................................................................... 7
7.1 GENERAL .................................................................................................................................... 7
7.2 PRE-REQUISITES.......................................................................................................................... 9
7.3 LINE CLEANING AND GAUGING ................................................................................................. 10
7.4 FILLING ..................................................................................................................................... 11
7.5 THERMAL STABILIZATION.......................................................................................................... 12
7.6 AIR CONTENT / PRESSURIZATION .............................................................................................. 12
7.7 FORMULAS FOR CALCULATIONS OF VARIOUS PARAMETERS ...................................................... 13
7.8 STRENGTH TEST ........................................................................................................................ 15
7.9 LEAK TIGHTNESS TEST ............................................................................................................... 16
7.10 DE-PRESSURIZATION ................................................................................................................. 16
7.11 BULK DE-WATERING ................................................................................................................. 17
7.12 DRYING / PRE-COMMISSIONING ............................................................................................... 17
8 Safety ................................................................................................................................... 18
9 Documentation ..................................................................................................................... 20
10 Attachments ......................................................................................................................... 20
Page 3 of 20
Rev No. 01
1 PURPOSE
The purpose of this procedure is to establish detailed methods for carrying out Cleaning,
Gauging, filling and hydrostatic testing of 20” CS Sales Gas (P1) Pipeline on PDO Contract
Number C311394 in accordance with contract specifications.
2 SCOPE
This procedure details the activities and preparations required for hydrostatic test operations in
a sequential order. The operations include selection of testing water, line cleaning & gauging,
filling, hydrostatic testing, bulk de-watering, etc.,
The scope of this procedure is specific to the above contract, the client being PDO. The total
work shall consist of the following:
20” x 35 km (approx.) Sales Gas (P1) Pipeline from RHIP On-Plot to BVS-18.
3 REFERENCES
C311394 Contract Document for RHIP Contract

PDO-SP-1208 Pipeline construction specification
ASME B 31.4 Pipeline Transportation Systems for Liquid Hydrocarbons & Other
Liquids
ASME B 31.8 Gas Transmission and Distribution Piping Systems
PDO-SP-1212 Hydrostatic testing of new pipelines
PDO-SP-1208 Pipeline construction Specification.
4 DEFINITIONS
 4.1 Strength Test: During this test the pressure in the section is maintained at minimum
90% SMYS of 20” pipeline ±1 bar for 4 hours only by adding and bleeding water to
strength test pressure at the highest point and does not exceed the maximum
permissible pressure (95% SMYS) at any point.
 4.2 Leak Tightness Test: During this test the pipeline section is subjected to an 80% of
Strength Test Pressure test equal to 146 bar for 20” pipeline at the highest point for 24
hours. No water shall be added to or removed from the pipeline during the test.
Page 4 of 20
Rev No. 01
5 RESPONSIBILITY
5.1 Responsibilities of Hydro test engineer
Shall be responsible
 Ensure that Hydro testing is done as per PDO Contract Requirement C311394.
 Ensure that Pressure Gauges, Pressure Recorder, etc., shall have valid calibration
certificates.
 Hydro test Engineer shall ensure that pressure gauges shall be checked for accuracy on
site, in the presence of the Company Site representative, before the commencement of
the pressure test of any section of pipeline or station works which shall be carried out by
comparison with dead weight tester.
 Responsible for all the calculations and documentation.
 Responsible for completion of all records and the documentation.
 Ensure pressure relief valve to be fitted to pipeline set at 3% above specified test
pressure.
 Ensure trained supervision available at site all times.
 Check proper fitting of couplings, check before pressurizing.
 Check proper communication facilities are available at site.
 Liaison with the PDO or his representative(s), and with HSE Dept. on matters regarding
health, safety and environmental protection.
 Ensure that all construction activities are stopped with 50 meters radius of test section.
 Ensure that the area is barricaded with caution tape.
 Display warning signs. English / Arabic are in place.
 Restricted Entry. Ensure that no unauthorized persons are within 50 meters of the test
section.
5.2 Responsibilities of Hydro test Foreman
 Assist Hydro test Engineer during the phase of testing. He will be heading the hydro
testing crew for bolting of the cleaning & test header, blind flanges and other skilled
labors, which may be required from time to time. (For line checking).
 Fixing and checking of all the instruments and pumps and PRV.
 Ensure Daily Tool Box Talk conducted and it should be reported to Hydro test Engineer
Page 5 of 20
Rev No. 01
6 EQUIPMENT, INSTRUMENTS AND ACCESSORIES
6.1 EQUIPMENT
6.1.1 Compressor:
Atlas copco XAMS 856 CD – 600 cfm with an operating pressure of 20 bar. Operating
temperature between 23°C - 52°C at sea level with oil injection cooling system.
6.1.2 Lift Pump:
Self-priming pump with Diesel engine with a maximum suction & discharge capacity of 250
m3/hr with discharge pressure of 3 bar – 1 No.
6.1.3 Filling:
REGENT Pump Model ISO 125x100-400 BS1M with diesel engine made in Australia with
discharge capacity of 200 m3/hr with discharge pressure of 10 bar – 1 No.
6.1.4 Pressure Pump:
GOMA Pump with diesel engine made in India with discharge capacity of 25 Liter/min with
discharge pressure of 600 bar – 2 Nos.
6.1.5 Chemical Injection Pump:
Prominent Pump (HP3aH-064048) Electric motor operated made in Germany with discharge
capacity of 32 Liter/hr with discharge pressure of 10 bar – 1 No.
6.2 TEST INSTRUMENTS
6.2.1 Dead Weight Tester:

Type : Dead Weight Tester
Manufacturer : Budenberg
Model No : 580
Serial No : 580/29382
Range : 700 bar
6.2.2 Pressure recorder:
Type : Pressure Chart Recorder
Manufacturer : Barton
Range : 0 to 20 Bar – 2 Nos.
Range : 0 to 200 Bar – 2 Nos.
Range : 0 to 350 Bar – 1 No.
6.2.3 Pressure Gauges:
Type : Pressure Gauge
Manufacturer : Wika
Range : 0 to 25000 kPa – 3 Nos.
6.2.4 Pressure Gauges:
Type : Digital Pressure Gauge
Manufacturer : Wika
Page 6 of 20
Rev No. 01
Range : 0 to 400 bar – 2 Nos.

6.2.5 Temperature recorders:
Type : Temperature chart recorder.
Manufacturer : Barton
Range : 0 to 100°C – 2 Nos.
6.2.6 Digital Thermocouple Thermometer:
Type : Temperature data logger.
Manufacturer : Center
Range : -200 to 1370°C – 4 Nos.
6.3 ACCESSORIES
 Air-conditioned steel armored test cabin fitted with rigid piping of 700 bar pressure with
provisions for all instruments. Flexible hose shall not be used inside the test cabin. The
pressure reading and recording instruments are connected to a header leading outside
the cabin to which the impulse line from the test section can be connected.
 For filling and pressurizing purposes, 35 Cubic meter tanks with open top arrangement
will be used as break tank.
 Flow meter used will install before starting filling.
 All pigs used shall be of VP Engineering.
 Drying units if used will be with operating pressures of 7 bar and capacities of 21 cubic
meter/min.
 All temporary valves, fittings and piping components to be subjected to test pressure
shall be designed for a working pressure not less than the test pressure. However,
flanges / blinds connected to permanent piping shall be of the same rating as the
permanent piping.
 Flexible hoses shall however be used which will have suitable fittings. Controlled
discharge line and at the outlet of pressure pump these flexible hoses shall be of the
armored type and shall be designed for a pressure of 1.25 times higher than the test
pressure. These hoses shall be in as short lengths as practically possible, avoiding joints
in between and will be firmly anchored or sand bags placed over them.
7 PROCEDURE
7.1 GENERAL
7.1.1 Sectional Hydro test For Road Crossing

For All Road Crossings sections shall be pre-hydro tested and included in the main line hydro
test with pipeline.
Page 7 of 20
Rev No. 01
7.1.2 Final Hydro test for 20” CS Pipelines

The Final Hydro test for 20” CS Sales Gas Pipeline shall be 1st from Ch.19+000 km to 35+000
km, 2nd from Ch.0+000 km to 19+000 km.
TEST SECTION NO.2

SECTION : From KP19+000 To KP35+000
NOMINAL DIAMETER : 20”
OUTSIDE DIAMETER : 508 mm
WALL THICKNESS : 11.91 / 14.3 mm
INSIDE DIAMETER : 484.18 / 479.4
LENGTH : 16195.525M / 196.493M
MATERIAL GRADE : ISO 3183 L 450 MS
VOLUME / KM : 184 m³
TOTAL VOLUME : 3016.122 m³
DESIGN PRESSURE : 120 bar
TEST PRESSURE : STRENGTH TEST 183.0 BAR /
LEAK TEST 146.0 BAR
TEST MEDIUM : WATER
ELEVATION AT
LAUNCHER AREA : 359.51 M
LOW POINT : 359.51 M
HEIGHT POINT : 402.24 M
RECEIVER AREA : 401.26 M
STATIC HEAD : 42.73 M
TEST SECTION NO.1

SECTION : From KP00+000 To KP19+000
NOMINAL DIAMETER : 20”
OUTSIDE DIAMETER : 508 mm
WALL THICKNESS : 11.91 / 14.3 mm
INSIDE DIAMETER : 484.18 / 479.4
LENGTH : 18566.105M / 647.25M
MATERIAL GRADE : ISO 3183 L 450 MS
VOLUME / KM : 184 m³
TOTAL VOLUME : 3533.744 m³
DESIGN PRESSURE : 120 bar
Page 8 of 20
Rev No. 01
TEST PRESSURE : STRENGTH TEST 183.0 BAR /

LEAK TEST 146.0 BAR
TEST MEDIUM : WATER
ELEVATION AT
LAUNCHER AREA : 315.38 M
LOW POINT : 313.23 M
HEIGHT POINT : 359.51 M
RECEIVER AREA : 359.51 M
STATIC HEAD : 46.28 M
First the strength test shall be done for 4 hours and then the pipeline shall be leak tested for 24
hours at 80% of Strength Test.
7.2 PRE-REQUISITES
7.2.1 Prior to the commencement of the main line section testing program, armored test cabin, pumps,
and break tanks shall be located at appropriate locations away from main roads and access
areas, considering the surroundings and safety. A 30 meter exclusion zone shall be marked out
with tiger tapes, around all exposed pipe work, and all access to the Right of Way.
7.2.2 The section of pipeline under test shall be completely backfilled before testing commences.
7.2.3 Prior to the commencement of the main line hydro-testing activities, Water collection ponds of
size 35x38x1.8 & 30x25x1.5 at KP19+000. The pond shall be constructed and the watering
hose layed prior to commencement of filling.
7.2.4 The water used for hydrostatic testing operation shall be in accordance with the requirements
as stated in section of SP1212 and shall pass through a 50-micron filter prior to entering the
pipeline.
7.2.5 Pressure indicating and recording instruments shall be connected to the test section before
filling commences.
7.2.6 All necessary personnel at the affected station have been informed of the commencement and
duration of hydro static pressure test.
7.2.7 The personnel engaged in the testing work have been briefed on the emergency plans.
7.2.8 Pipe and soil temperature shall be measured and recorded at each end 500 meters on the
buried section from the ends and then every 5km length of the pipeline using thermocouple type
instruments with digital readout and print out.
Page 9 of 20
Rev No. 01
7.2.9 To assist in controlling the line filling, inlet pressure, inflow & downstream pressure shall be
maintained by keeping sufficient backpressure, measured and recorded.
7.2.10 All line valves shall be in the fully open position prior to filling.
7.2.11 All instruments per detail in section 6.2. Used shall be having valid calibration certificates as per
the requirements of SP-1212. The test gauges used in field shall be mounted upright on the test
section so as to give the best viewing angle. Standard gauges will be used in conjunction with
the dead weight tester in the test cabin.
7.3 LINE CLEANING AND GAUGING
7.3.1 The line shall be cleaned from launcher to receiver using temporary pigging headers, which will
be welded to the main line and required NDT done. Pigging shall be carried out as per schematic
sketch no.01
7.3.2 The pigs shall be BIDI cleaning type propelled by compressed air at a maximum pressure of 7
bar. A series of cleaning pigs with a combination of bi directional pig shall follow until the required
cleanliness of the pipeline section has been established. In order to assist the speed control of
cleaning pig & final cleaning run should have a constant backpressure of 2 bar shall be
maintained by suitable adjustment of receiver valve. The speed of cleaning pig shall be
maintained between 0.5 to 2.5 m/sec.
7.3.3 A pigging log shall be maintained containing all data regarding Pig type, launching / receiving
times, and quantity of debris and details of received condition of pigs.
7.3.4 Received pigs shall be inspected for cleanliness. Cleaning operation shall continue until the
volume of received material less than 5 lts. or dust & debris brought out is of negligible quantity
and acceptable to PDO.
7.3.5 Upon acceptance of cleaning, gauging of pipeline shall be carried out. The size of gauging plate
shall be 95% of the minimum internal diameter of the system. The thickness of the plate shall
be 12mm and made of Aluminum material.
7.3.6 The gauging plate dimensions and the condition of the plate after the run shall be inspected and
certified for acceptance by PDO.
7.3.7 Gauging plate measurement, introduction and receipt shall be done in presence of PDO
personnel. Gauging plate shall be examined for damages. In case of damage, gauging pig shall
be rerun with new gauging plate till the satisfaction of PDO.
Page 10 of 20
Rev No. 01
7.3.8 In case gauge plate is not acceptable cause of the damage shall be determined and necessary
arrangements for the repair made, if the gauge plate shows cuts breaks or tears deeper than 5
mm.
7.4 FILLING
7.4.1 The filling shall be done as per attached schematic sketch No.02. The filling to carried from the
Pre constructed PE lined pond with the capacity of line volume filled with water at KP19+000.
7.4.2 High Pressure Test Header shall be fabricated, NDT and hydro-tested according to project
specification as per attached schematic sketch No.03.
7.4.3 The water used for filling shall be consistent with the recommendations of SP-1212.
7.4.4 The fill water shall be passed through a break tank fitted with a 50-micron filter before entering
the pipeline with 500ppm NALCO EC1397A cocktail treatment as per chemical supplier’s
recommendation. Pumps specified in Sec 6.1.2 fitted with a flow meter shall be used for filling
purpose. During filling, the impulse lines shall be connected to pressure recorder and pressure
gauges installed in the test cabin as specified in Sec 6.2.2, 6.2.3 & 6.2.4. A temperature recorder
shall also be installed in the cabin and its bulb placed in shade outside the cabin.
7.4.5 Filling shall be carried out by using two bi-directional pigs. At first a volume of water equal to
10% of the section volume or 1.5km linear length of line whichever greater shall be pumped into
section ahead of 1st pig and pig shall be launched, after which another volume of water equal to
the above shall be pumped into the section. Following this, 2nd bi-directional pig shall be
launched and the pumping of water shall follow. The volume of the section can be computed
using the formula given in Sec 7.7.1.
7.4.6 Pumping pressure shall be a minimum to drive the pig train. Air shall be vented at the receiver
end through a valve provided for the purpose so as to maintain a backpressure of minimum 2
bar if required as per site condition. As far as possible, filling shall be carried out starting from
the lower end, though this is not a mandatory requirement.
7.4.7 The filling shall be performed at a controlled rate, the filling pig speed should be maintained at
a constant rate.
7.4.8 Upon arrival of the pig train at the receiver end, the initial volumes of pre-fill water shall be
discharged off suitable, and the valves closed. A minimum pressure of static head plus 2 bar
shall be maintained at the high point and the section shall be left to stabilize.
7.4.9 During filling, temperature of water, pressure at upstream end & flow meter reading shall be
recorded continuously.
Page 11 of 20
Rev No. 01
7.4.10 If the water filling pump stops at any point while filling the line the inlet valve on the header shall
be closed immediately.
7.5 THERMAL STABILIZATION
7.5.1 The section shall be left for a period 6 to 48 hours for stabilizing, the average time of stabilization
being 24 hours.
7.5.2 The pipe and soil probes shall be installed at 500 meter from start and end of pipeline and at an
interval of 5 kms. The temperature of the pipeline and soil shall be recorded.
7.5.3 During this time, the line pressure and ambient temp; shall be recorded every one hour
continuously using recorders.
7.6 AIR CONTENT / PRESSURIZATION
7.6.1 The pressurization shall be done as per attached schematic sketch No.03. Pressurization shall
be carried out with a positive displacement pump fitted with a stroke counter to precisely
determine the volume of water pumped for pressurization. Tentative layout of the section during
pressurization is attached within this document in the drawings section.
7.6.2 It shall be ensured that all valves are in partially open position to prevent damage to the seals
and that all blinds / plugs have been properly installed at both ends.
7.6.3 All equipment, valves, PRV’s shall be checked and tested prior to start of pressurization.
7.6.4 A safety check shall be carried out to confirm that all measures have been complied with before
commencement of pressurization. Pressurization pump shall be fitted with a full capacity relief
valve set at the line test pressure.
7.6.5 The rate of pressurization shall not exceed 1 bar/min and shall continue up to 50% of test
pressure or 35 bar whichever is less. During this period, volume and pressure readings shall be
recorded at 1bar intervals. A plot of pressure / volume shall be made and liner section of the
curve extrapolated to the volume axis which shall be corresponding to the static head pressure.
The calculations for air content shall be carried out and verified that air content is not more than
0.2% of the full line volume. This shall be calculated using the formula:
Percentage air content = Volume of air x 100

Volume of line
7.6.6 When the air content is less than 0.2%, the pressurization shall be continued at a rate not
exceeding 1 bar/min. up to 80% of the test pressure and held for 2 hours for pressure
stabilization and any pressure drop to be noted. During the two hour hold period the pressure
should be recorded every 30 minutes from the dead weight tester. Thereafter the pressure shall
Page 12 of 20
Rev No. 01
be raised to 95% of test pressure at the rate of 1 bar/minute and held for 30 minutes. Thereafter
the pressure should be raised at a reduced rate of 0.5 bar/min maximum. During the
pressurization, the volume and pressure readings will be recorded at 1 bar intervals.
Pressurization volume per bar can be calculated using the formula given in Section 7.7.3.
7.6.7 The pressure shall also be continuously recorded throughout the pressurization on a pressure
recorder. The ambient temperature shall also be continuously recorded on the temperature
recorder.
7.6.8 If during pressure stabilization, any leak is detected, apart from flange joints, then whole system
shall be dewatered and leak shall be repaired. After leak repair, the line shall be backfilled,
cleaned, gauged and will be tested again in accordance with the company approved procedure.
7.6.9 All valves, flanged connections and special fittings shall be carefully checked. If any leak is
detected further pressurization shall be stopped immediately. Leaks if any shall be attended to
only after lowering the pressure to working pressure or less at that point. The personnel
inspecting the piping shall take all safety precautions while inspecting the piping under pressure.
7.6.10 All the above activities are carried out by hydro test foreman and his crew under the direct
supervision of the hydro test engineer.
7.7 FORMULAS FOR CALCULATIONS OF VARIOUS PARAMETERS
7.7.1 Formula for calculation of volume for a given section of pipe
7.7.2 Formula for calculation of Air content in the given section of pipe
Page 13 of 20
Rev No. 01
7.7.3 Formula for calculation of theoretical volume of water required for pressurization in the
given section of pipe
If the slope of the liner section of curve differs by more than 10% from theoretical curve then
testing shall stop and investigation carried out to determine the cause.
Page 14 of 20
Rev No. 01
7.7.4 Formula for calculation of pressure change as a result of temperature change for a
given section of pipe
7.8 STRENGTH TEST
7.8.1 The pressurizing layout and set-up shall be retained. There shall be a provision for a controlled
release of water and arrangement for collection and measurement of the drained water.
7.8.2 The pipeline will be subject to a 4 hours strength test at test pressure 183 bar (90% SMYS)
minimum for buried section. During the strength test, the pressure shall be maintained ± 100
kPa to the test pressure for 24 hours by adding and bleeding water. The volume of water added
or bleed shall be measured and recorded.
7.8.3 When due to thermal variations the pressure increases such that the pressure reaches the
maximum test pressure permissible at the test station end, the pressure shall be reduced to 100
kPa below the maximum permissible pressure by bleeding water in a controlled manner. The
water shall be collected, measured and recorded.
7.8.4 In case the pressure drops to the minimum strength test pressure, water shall be added to raise
the pressure to 100 kPa above the minimum strength test pressure. The record of the flow meter
readings shall be maintained to calculate the volume added.
7.8.5 During the test, pressure from the dead weight tester shall be recorded every 30 minutes.
Record of water bled from the section shall be maintained. Pipe and soil temperature shall be
recorded every hour from the thermocouples. The line pressure shall also be recorded by a
pressure recorder. The ambient temperature shall be recorded by a temperature recorder.
Page 15 of 20
Rev No. 01
7.8.6 At the end of strength test, the pressure shall be brought down to Leak Tightness test pressure,
ie 80% of Strength test pressure by bleeding off water at a rate of 1 bar/min.
7.8.7 During this time, the line pressure and ambient temp; shall be recorded continuously using
recorders at the test station. Pressure and temperature recorder shall be switched on at the start
of pressurization & only switched off at the completion of depressurization. All pressure and
temperature recorder charts shall be signed by PDO representative and contractors
representative. The charts shall be signed when placed on and immediately after being taken
off the recorder.
7.9 LEAK TIGHTNESS TEST
7.9.1 The section shall be isolated from the pressure pump. The valve near the outlet of the pressure
pump shall be closed and pressure pump package disconnected. A Plug shall be installed on
the valve and the valve re-opened. All the other set-up shall be the same as for the strength
test.
7.9.2 The pipeline will be subjected to a 24 hour tightness test immediately after the strength test at
the test pressure of 86.00 bar 80% of Strength test pressure for buried section. During this
period no water shall be added to or removed from the pipeline.
7.9.3 The test shall demonstrate, to company’s satisfaction that there are no leaks in the section.
Allowance shall be made for instrument in-accuracies and the pressure changes as result of
average temperature changes shall be calculated from the formula give in section 7.7.4
(assuming a fully restrained line section). During this 24-hour period, pressure and temperature
shall be recorded continuously by recorders and dead weight tester readings recorded every
one hour.
7.9.4 Pipe and soil temperatures shall be recorded every hour from the thermocouples. The line
pressure shall also be recorded by a pressure recorder. The ambient temperature shall be
recorded by a temperature recorder. Pressure and temperature recorder shall be switched on
at the start of pressurization & only switched off at the completion of depressurization.
7.9.5 If the tightness of the section cannot be clearly established at the end of 24 hours hold period,
the tightness test will be extended further till such period where the acceptability of test can be
demonstrated without making any changes to the line pressure Ref.Clause 8.3.2 of DEP
40.40.38 Gen. and SP1212.
7.10 DE-PRESSURIZATION
7.10.1 Following satisfactory completion of the strength and leak tightness tests, the test section will
be depressurized slowly at rate of 1 bar/min until the pressure has been reduced to 40% of test
Page 16 of 20
Rev No. 01
pressure. Then depressurization shall continue at a rate of less than 2 bar / min to the static
head plus 100 kPa at high point or to the pressure instructed by the Company.
7.10.2 Care shall be taken to minimize vibration in piping and prevent whip in flexible hoses, by
depressurizing as slowly as possible. During the depressurization the pressure recorder shall
maintain a record of the pressure.
7.10.3 On completion of de-pressurization all testing equipment shall be removed from the site. The
pipe and soil temperature thermocouples shall be removed. The coating damage where
thermocouples were attached to the pipe shall be repaired.
7.11 BULK DE-WATERING
7.11.1 Upon completion of depressurization, dewatering of the pipeline shall be carried out in pre-
constructed pond to accommodate total volume of water, on confirmation from PDO. De-
watering shall be done as per attached schematic sketch No.04.
7.11.2 The depressurization of the system shall be carried out carefully to avoid any negative pressure
in the system.
7.11.3 All the vents shall be kept open to allow adequate air in to the system while draining the pipeline.
7.11.4 A backpressure of 100 kPa shall be maintained at the discharge end. Water shall be disposed
off in pre-constructed pond at approved location by PDO representative.
7.12 DRYING / PRE-COMMISSIONING
This article set the procedure for the Drying / Pre-commissioning under the following headings
and sequence. The section to be dried shall be fitted with temporary pig launcher and Receiver.
7.12.1 Removal of Free Water:
7.12.1.1 This shall be carried out via the permanent scraper trap and on-plot valve system from the
BVS-18
7.12.1.2 All the hoses shall be fitted with non-return valves and secured at both ends to eliminate whip
lashing should any of the connecting pipe work fail.
7.12.1.3 BIDI pigs will be run at a maximum of 7 bar pressure until all free water is removed. A single
pig will be in the line at any one time. A downstream pressure of 1 Bar shall be maintained to
ensure pig control.
7.12.1.4 The pigs shall be propelled by oil free air of sufficient quantity to ensure continuous operation.
Page 17 of 20
Rev No. 01
7.12.2 Swabbing:
7.12.2.1 Once the free water received is negligible, the desiccant and pre-cooling unit (air drying unit)
shall be placed downstream of the compressor and repetitive high-density foam pigs will be
run at a maximum of 7 bar pressure. No downstream pressure shall be maintained to ensure
maximum carrying capacity of the air.
7.12.2.2 Repetitive foam drying pigs shall be run, with a maximum of four pigs in line at any one time,
until a “touch dry” pig has been received.
7.12.2.3 On receipt of a “touch dry” foam pig, dew point reading will commence immediately following
the pig entering the receiver.
7.12.3 Release of Entrained Water:
7.12.3.1 At this time consecutive poly coated foam type pigs will be run at a maximum of 7 bar pressure.
Dew point meter reading shall be continue until a dew point meter reading of specified dew
point has been achieved. A maximum of 4 pigs will be in line at any time.
7.12.3.2 On achieving specified dew point, two consecutive low-density foam pigs will be run to remove
residual dust.
7.12.3.3 On receiving a final pig a volume of super dry air equal to the line volume will be pumped. Dew
point meter reading should be -20°C. At which time drying is considered completed and can
be certified.
8 SAFETY
8.1.1 The approval copy of the Project HSE Plan and the specific HSE provisions shall be the working
guidelines for the entire operation.
8.1.2 All personnel involved in these hydrostatic testing operations shall be instructed and made
aware of the as per HEMP list and consequences of failure of pipeline or fittings under pressure
test conditions. Toolbox meetings shall take place prior to start of each shift. The procedure of
the work to be carried out during that shift and the safety precautions to be taken shall be
explained to all those members during the tool box meetings.
8.1.3 During the test, all activities shall cease within a 30 meter radius of the test section and the test
area, and unexposed pipe areas along the line if any, and suitable barriers shall be marked out
with tiger tapes. Boundaries of the test cabin, pumps and all above ground interconnection pipe
work shall also be defined with tiger tapes and flood light will be arranged at night.
Page 18 of 20
Rev No. 01
8.1.4 Special care shall be taken to ensure that all the personnel as well as the environment are
adequately protected during the course of test.
8.1.5 While pipeline is under pressure, nobody shall be allowed to work on it. Only the testing
crewmembers and inspection personnel shall have access to visually inspect for leaks. The
leaks, if any found, shall be attended to and only after the line pressure is reduced completely
as required. Flange leaking, if any shall attended only after the line pressure is reduced to 80%
of test pressure or MAOP.
8.1.6 The test cabin, pressurizing pump etc., shall be located in a safe area, minimum 30 m away
from the test end.
8.1.7 During pressurization no person shall enter into the trench or shall come near any pipe works
within 30 meters or safe distance. During the test, all construction within 50 m of the test section
shall cease.
8.1.8 Safety signboards in English, and Arabic shall be posted at appropriate locations including all
entrances to ROW during the testing period to warn everybody of testing operations. The display
shall be as follows or equivalent:
“WARNING – PIPELINE UNDER HYDRO STATIC TEST”
8.1.9 All the diesel generators to be located so as not to cause a carbon monoxide hazard to
personnel working in test cabin.
8.1.10 All fittings, instruments, materials, equipment, etc., used shall be to specifications approved by
the company and shall be of rating higher than the maximum pressure that it will be subjected
to the test.
8.1.11 Test headers shall be fabricated in accordance with welding procedures approved for the
pipeline. Non-destructive test shall be carried out on each fabricated weld. All butt welds shall
be radiographed and MPI shall be carried out on all fillet welds. UT shall be carried out for cut
hole area. All Test headers shall be tested at 1.25 times test pressure prior to install on line.
8.1.12 Relevant work permit shall be obtained prior to start of work, if required.
8.1.13 Any ancillary piping not under test shall be isolated by valves, spades, spectacle blinds, and
blind flanges of suitable quality or shall be completely disconnected from the test section.
8.1.14 All flexible hoses shall be tied to the rigid objects or sandbags placed over them.
8.1.15 Pressure relief valve shall be fitted on pressurizing system.
Page 19 of 20
Rev No. 01
9 DOCUMENTATION
9.1.1 The approval copy of the Project HSE Plan and the specific HSE provisions shall be the working
guidelines for the entire operation.
Sketch 1 - Layout during Air cleaning & Gauging

Sketch 2 - Layout during Water filling
Sketch 3 - Lay out during pressurisation and Pressure Test
Sketch 4 - Layout during Dewatering
Sketch 5 - Air pigging header details
Sketch 6 – Details of Mainline Header
10 ATTACHMENTS
Cleaning Report ATE-RHIP-MF-017

Gauging Report ATE-RHIP-MF-018
Filling Report ATE-RHIP-MF-019
Thermal Stabilization Report ATE-RHIP-MF-020
Pressurization Report ATE-RHIP-MF-021
Hydrostatic Report ATE-RHIP-MF-022
Dewatering Report ATE-RHIP-MF-023
Drying Report ATE-RHIP-MF-024
Page 20 of 20
#%
COMPRESSOR
(I
1/2"
BRUSH PIG
-1..QIL_
GAUGE PIG
AIR PIGGING LAUNCHER AIR PIGGING RECEIVER
AL TURKI ENTERPRISES LLC.

PROJECT
RABAB HARWEEL INTEGRATED PROJECT
TIT\.E •
SCALE
....
LA.YOUT DURING AIR CLEANING AND GAUGING
I JOB NO. DMWINO NO. -·
0
SKETCH NO. - 1
INHIBITOR
.;/
'/,#'
FILTER GRAVITY FEED/DOSING PUMP
1/2"
#
f
BRfAK-TANK
I I
I I ,.
--------------------------------------------L---------� 2
WATER SOURCE
OR PRE.VIOUS
SECTION
K
?
INHIBITOR
�GRAVITY FEED/DOSING PUt.lP
\ 112·
10-·111
SS.
ESH
M
tfil1
\l*J:_j STOPPER TEST SECTION
�
WATER SOURCE
ALTERNATIVE FIWNG ARRANGEMENT LAUNCHING TEST HEADER RECEIVING TEST HEADER
IF FILL PUMP CAN BE INSTALLED
DIRECTI.Y AT WATER SOURCE.
NOTES:-
1. IN CASE REVERSE DEWATERING IS PLANNED ONLY 2 PIGS SHALL BE USED INSTEAD OF 3 PIGS.
NO. OF 2• DIA VALVES MAY ALSO BE CORRESPONDINGLY REDUCED.
AL TURKI ENTERPRISES LLC.
1---·-_··-
2. FILLING SHALL GENERALLY BE DONE BY CENTRIFUGAL DIESEL DRIVEN PUMPS. WATER MAY ALSO BE PUMPED THROUGH PREVIOUS SECTION(S) · ----------------
IN TO SUBSEQUENT SECTION(S). WATER FIWNG MAY ALSO BE DONE BY DEWATERING PREVIOUS SECTION(S) BY COMPRESSED AIR EITHER PRCJfARADRABAB HARWEEL INTEGRATEDPIPELINI
IP-SAIOW.PUR-IWPUR-RANCBI PROJECT
PROJlcr
DIRECTLY IN TO THE SECTION(S) BEING FILLED OR THROUGH A BREAK TANK AND FILL PUMPS DEPENDING ON THE SECTION ELEVATION
TIT\.E •
PROFILES. IN CASE WATER IS TRANSFERRED DIRECTLY, CARE SHALL BE TAKEN TO ENSURE NO INGRESS OF AIR.
3. THE TEST HEADERS SHALL BE PRE HYDRO-TESTED AT A PRESSURE EQUAL TO OR GREATER THAN THE MAX TEST PRESSURE
FOR A MIN PERIOD OF 4- HOURS BEFORE BEING USED.
SCALE
....
I
LAYOUT DURING WATER FIIJJNG
JOB NO. DMWINO NO. -·
SKETCH NO. - 2 0
WATER
SOURCE DWT.
PRESSURE DEPRESSURISATION
PUMP
WITH STROKE
------- COUNTER
-------�
-------
w
(/)
------- 0
:x::
PSV
2· 2"
TEST SECTION
STOPPER
LAUNCHING TEST HEADER RECEIVING TEST HEADER
NOTES:- AL TURKI ENTERPRISES LLC .

PROJECT
1. IN CASE RE.VERSE DEWATERING IS PLANNED ONLY 2 PIGS SHALL BE USED INSTEAD OF 3 PIGS. RABAB HARWEEL INTEGRATED PROJECT
NO. OF 2• DIA VALVES IAAY AL.SO BE CORRESPONDINGLY REDUCED. TIT\.E •
2. DURING THE PRESSURE TEST (24 HOUR HOLD PERIOD) ALL CONNECTIONS EXCEPT THOSE FOR
INSlRUMENTS SHALL BE DISCONNECTED AND THE VALVES BLIND FLANGED, OR PLUGGED TO ISOLATE THE SECTION. SCALE
....
I JOB NO. DMWINO NO. -·
LAYOUT DURING PRESSURISATION &: PRESSURE TEST
SKETCH NO. - 3 0
AIR COMPRESSOR
#�
(
2" 2·
TEST SECTION
STOPPER
lAUNCHING TEST HEADER RECEIVING TEST HEADER
NOTES:- AL TURKI ENTERPRISES LLC .

1. IN CASE REVERSE DEWATERING IS PLANNED ONLY 2 PIGS SHALL BE USED INSTEAD OF 3 PIGS. PROJECT
NO. OF 2" DIA VALVES MAY ALSO BE CORRESPONDINGLY REDUCED. RABAB HARWEEL INTEGRATED PROJECT
TIT\.E •
LAYOUT DURING DEWATERING
-·
2. THE POSITION OF AIR COMPRESSOR AND DRAIN AS SHOWN IN THE ABOVE FIGURE WILL GET INTERCHANGED.
IN CASE OF REVERSE DEWATERING.
SCALE JOB NO. DMWINO NO.
3. THE WATER BEING DISCHARGED MAY BE USED FOR FILLING SUBSEQUENT SECTION (S) .... SKETCH NO. - 4. 0
COMPRESSOR
D 0
i
.
I
BRUSH PIG
GAUGE PIG
J2 \ J?
® (j)
2
AIR PIGGING LAUNCHER
AIR PIGGING RECEIVER
MTO:-
HYDROTEST
1) TEST PRESSURE 8. 75 BAR 2 HOURS HOLD
2) RATE OF PRESSURISATION @2 BAR/MIN.
3) RATE OF DE-PRESSURISATION@ 2 BAR/MIN
1. 24"xSCH.40 150# A 105 FLANGE 2 NO'S
2. 24"xSCH.40 A 106 GRB PIPE 4M
3. 24"x20" SCH.40 A234 GR.B CON.REDUCER 2 NO'S
4. 2"xSCH.160 A 105 FLANGE 2 NO'S r,fl:. AL TURKI ENTERPRISES LLC.
5. 2"xSCH.80 A 105 WELDOLET 2 NO'S
PROJECT:-
6. W'xSCH.40 A 105 THERADOLET 2 NO'S
A
7. 24"-150# A 105 BLIND FLANGE 2 NO'S RABAB HARWEEL INTEGRTED PROJECT
8. 20"x14.27MM L450(x60) PIPE 2M
TITLE:-
LAYOUT DURING AIR CLEARING AND GAUGING

SCALE JOB NO DRAWING NO REV
- - SKETCH N0-1 0
SKETCH -5
SKETCH-6
AL TURKI ENTERPRISES LLC
CLEANING REPORT
Report No : Date :
CLIENT : Petroleum Development Oman L.L.C PAGE NO : 1 of 1
CONTRACT : RABAB HARWEEL INTEGRATED PROJECT PIPE OUT SIDE DIAMETER :
CONTRACT NO : C31-1394 PIPE IN SIDE DIAMETER :
PIPE LINE : WALL THICKNESS OF PIPE :
VOLUME OF SECTION : LENGTH OF PIPE LINE :
LAUNCHING RECEIVING
Sl.No. PIG TYPE PRESSURE (bar) REMARKS
DATE TIME (hrs) DATE TIME (hrs)
Comments (if any) Cleaning has been accepted line for water filling.
HYDROTEST ENGINEER QCI- ATE PDO
SIGNATURE
DATE
NAME& DESIGNATION
ATE-RHIP-MF-017 Rev.01
GAUGING REPORT
Report No : Date :
CLIENT : Petroleum Development Oman L.L.C PAGE NO : 1 of 1
CONTRACT : RABAB HARWEEL INTEGRATED PROJECT PIPE OUT SIDE DIAMETER :
CONTRACT NO : C31-1394 PIPE IN SIDE DIAMETER :
PIPE LINE : WALL THICKNESS OF PIPE :
LAUNCHING RECEIVING
Comments (if any) Gauging has been accepted line for water filling.
SIGNATURE
DATE
NAME& DESIGNATION
FILLING REPORT
CONTRACT/PROJECT : RABAB HARWEEL INTEGRATED PROJECT C31-1394 Date :
CLIENT : Petroleum Development Oman L.L.C Page NO :
Report No : PIPE OUT SIDE DIAMETER :
PIPE LINE : PIPE IN SIDE DIAMETER :
PIG TYPE : WALL THICKNESS OF PIPE :
FILL PRESSURE FLOMETER FLOW RATE

Sl.No. DATE/TIME (hrs) CUM.VOL (M³) REMARKS
(bar) READING (M³) (M³)
CHEMICAL NAME USED : INITIAL PREFILL VOLUME :
TOTAL QUANTITY USED : II PREFILL VOLUME :
Comments (if any) Sucessfuly completed filling operation
SIGNATURE
DATE
NAME& DESIGNATION
THERMAL STABILIZATION REPORT
PIPE AND SOIL TEMPERATURE ( º C )

DATE/TIME
Sl.No. DIFF
(hrs)
P1 P2 P3 P4 P avg S1 S2 S3 S4 S avg ºC
Comments (if any)
SIGNATURE
DATE
NAME& DESIGNATION
PRESSURIZATION REPORT
PRESSURE THEO. VOLUME STROKE COUNDER

Sl.No. ACT VOL/BAR (liters) CUM VOL (liters) REMARKS
(bar) (liters) READING (M³)
Comments (if any) % OF Air Content = (AV - TV x 100) / PV
Where
AV = Actual Pressurization Volume (ltrs)
TV = Theoritical Pressurization Volume (ltrs)
PV = Theoritical Pipe line Volume (ltrs)
SIGNATURE
DATE
NAME& DESIGNATION
HYDROSTATIC TEST REPORT
CONTRACT : RABAB HARWEEL INTEGRATED PROJECT C31-1394 Date :
PIPE TEMPERATURE ( º C ) SOIL TEMPERATURE ( º C )

DWT AMBIENT
DATE/TIME
Sl.No. READING TEMP. DIFF
(hrs)
(bar) (ºC)
P1 P2 P3 P4 P avg S1 S2 S3 S4 S avg ºC
Comments (if any)
SIGNATURE
DATE
NAME& DESIGNATION
DEWATERING REPORT
LAUNCHING RECEIVING
Comments (if any)
SIGNATURE
DATE
NAME& DESIGNATION
DRYING REPORT
VOLUME OF SECTIO : LENGTH OF PIPE LINE :
LAUNCHING RECEIVING
SL.NO PIG TYPE PRESSURE (bar) REMARKS
Comments (if any)
SIGNATURE
DATE
NAME& DESIGNATION

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;:qc. AL TURKI ENTERPRISES LLC :{:.c��;s;:.

PDQ Contract Number: C311394

Rabab Harweel Integrated

PCAP Yes / -No-

Responsible (RTA/x) Distribution List:

Name Function Signature / Date

Consulted/Informed Distribution List:

Hold Nr. Section Description of Hold

Rev. Date Description of Revision

C311394 Contract Document for RHIP Contract

5.1 Responsibilities of Hydro test engineer

5.2 Responsibilities of Hydro test Foreman

6 EQUIPMENT, INSTRUMENTS AND ACCESSORIES

6.2 TEST INSTRUMENTS

6.2.1 Dead Weight Tester:

Range : 0 to 400 bar – 2 Nos.

7.1.1 Sectional Hydro test For Road Crossing

7.1.2 Final Hydro test for 20” CS Pipelines

TEST SECTION NO.2

TEST SECTION NO.1

TEST PRESSURE : STRENGTH TEST 183.0 BAR /

7.3 LINE CLEANING AND GAUGING

7.5 THERMAL STABILIZATION

7.6 AIR CONTENT / PRESSURIZATION

Percentage air content = Volume of air x 100

7.7 FORMULAS FOR CALCULATIONS OF VARIOUS PARAMETERS

7.7.1 Formula for calculation of volume for a given section of pipe

7.8 STRENGTH TEST

7.9 LEAK TIGHTNESS TEST

7.11 BULK DE-WATERING

7.12 DRYING / PRE-COMMISSIONING

7.12.1 Removal of Free Water:

7.12.3 Release of Entrained Water:

“WARNING – PIPELINE UNDER HYDRO STATIC TEST”

8.1.15 Pressure relief valve shall be fitted on pressurizing system.

Sketch 1 - Layout during Air cleaning & Gauging

Cleaning Report ATE-RHIP-MF-017

AIR PIGGING LAUNCHER AIR PIGGING RECEIVER

AL TURKI ENTERPRISES LLC.

NOTES:- AL TURKI ENTERPRISES LLC .

lAUNCHING TEST HEADER RECEIVING TEST HEADER

NOTES:- AL TURKI ENTERPRISES LLC .

LAYOUT DURING AIR CLEARING AND GAUGING

CLIENT : Petroleum Development Oman L.L.C PAGE NO : 1 of 1

CONTRACT : RABAB HARWEEL INTEGRATED PROJECT PIPE OUT SIDE DIAMETER :

CONTRACT NO : C31-1394 PIPE IN SIDE DIAMETER :

PIPE LINE : WALL THICKNESS OF PIPE :

VOLUME OF SECTION : LENGTH OF PIPE LINE :

HYDROTEST ENGINEER QCI- ATE PDO

CLIENT : Petroleum Development Oman L.L.C PAGE NO : 1 of 1

CONTRACT : RABAB HARWEEL INTEGRATED PROJECT PIPE OUT SIDE DIAMETER :

CONTRACT NO : C31-1394 PIPE IN SIDE DIAMETER :

PIPE LINE : WALL THICKNESS OF PIPE :

VOLUME OF SECTION : LENGTH OF PIPE LINE :

HYDROTEST ENGINEER QCI- ATE PDO

CONTRACT/PROJECT : RABAB HARWEEL INTEGRATED PROJECT C31-1394 Date :

CLIENT : Petroleum Development Oman L.L.C Page NO :

Report No : PIPE OUT SIDE DIAMETER :

PIPE LINE : PIPE IN SIDE DIAMETER :