Sub-Contractor Comments Response Sheet: Ain Tsila Development

AIN TSILA DEVELOPMENT
Main EPC Contract

A-CNT-CON-000-00282
SUB-CONTRACTOR COMMENTS RESPONSE SHEET

Subcontractor : LEAD CONTRACTING & TRADING LIMITED
Subcontract No : JI-2045/07-002A Sub-Contractor Transmittal No. : TR-LEAD-PIUL-0110 Date :25-03-2021
Document Title : QCP FOR CLEANING, GAUGING AND HYDROTESTING (P-QAC-PRO-200-38257)

PIUL Review Transmittal No. : TR-PIUL-LEAD-00226 Date : 12-04-2021
PIUL Position
Sl. No. Document No. Rev PIUL COMMENT SUB-CONTRACTOR RESPONSE
( Open or Closed )
1.1 Item No. 15.2 PRESSURIZATION

add the following :
• The pressurised section shall be left for 24 hours for thermal Noted and Closed
1 Incorporated
stabilization.
P-QAC-PRO-200-38257 Rev.B • Chart of pressurizing cycle
SUB-CONTRACTOR SIGN OFF
Prepared By: Emad Kamel COMPANY SIGN OFF

Date : 30-06-2021 PIUL SIGN OFF
Signature:
Approved By: John Younan Ajay Kumar

Approved by : _________________________________ Approved by : _________________
Date : 30-06-2021 Date : Date :
Signature: Signature: ____________________________________ 09/07/2021 Signature: ____________________
Ain Tsila Development
Main EPC Contract
A-CNT-CON-000-00282
Accepted without comment
Sub-contractor Name: subject to company approval and
any company comment will be
informed on receipt
PIUL Approval Code/Name/Signature

Name:
Signature:
By ajay.kurup at 8:58 am, Jul 09, 2021
CODE DEFINITION
1 Accepted without comments

2 Accepted with comments
3 Not Accepted. Revise and

Resubmit
4 For Information
5 Void-Cancelled / Superseded
QCP FOR CLEANING, GAUGING AND HYDROTESTING
P-QAC-PRO-200-38257
Re-issued for Review

C 30-Jun-2021 E.Kamel O. Abdelaziz J. Younan
and comments
Re-issued for Review
B 25-Mar-2021 E.Kamel O. Abdelaziz J. Younan
and comments
Issued for Review and
A 26-Nov-2020 E.Kamel Viswanath.S Khalil.T Khalil.T
comments
Rev Purpose Date Prepared Checked Approved Approved
Project: AIN TSILA DEVELOPMENT PROJECT
Document: QCP CLEANING, GAUGING AND
HYDROTESTING
Document No.:P-QAC-PRO-200-38257 Rev C
Revision History:
Revision Changes
A Issued for Review and comments
B Re-issued for Review and comments
C Re-issued for Review and comments
This revision checked and signed off by:

Name Function or Job Title
Khalil Tarboush Project Director
Viswanath Sreepada QA/QC Manager
Emad Kamel Site QA/QC Manager
Ossama Abdelaziz Site Manager
John Younan Project Manager
Holds
Hold No. Location Description
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Contents
1.0 PURPOSE ........................................................................................... 5
2.0 SCOPE .............................................................................................. 5
3.0 PROJECT OVERVIEW ............................................................................ 5
4.0 REFERENCES ..................................................................................... 5
5.0 TERMINOLOGY .................................................................................... 6
6.0 CONFLICTS, OMISSIONS, AND ALTERNATIVES ........................................... 7
7.0 COMPANIES WITNESSING .......................................................................... 7
8.0 PRE-CONDITION .................................................................................... 7
9.0 TEST PACKAGE DOCUMENTS ..................................................................... 7
10.0 PERSONNEL AND EQUIPMENT .................................................................... 7
11.0 PERSONNEL ......................................................................................... 7
12.0 TESTING MATERIAL, EQUIPMENT AND INSTRUMENT ......................................... 8
13.0 LIST OF EQUIPMENT ............................................................................... 9
14.0 CLEANING, GAUGING AND LINE FLOODING ................................................... 11

14.1 GENERAL ................................................................................... 11
14.2 CLEANING .................................................................................. 11
14.3 GAUGING ................................................................................... 12
14.4 Source of test water ........................................................................ 14
14.5 Test Medium ................................................................................ 15
14.6 Water Disposal .............................................................................. 16
14.7 FLOODING WATER ....................................................................... 16
14.8 LINE Flooding ............................................................................... 17
15.0 PRE-TEST REQUIREMENTS ....................................................................... 18

15.1 Requirements Prior to Pressurizing ...................................................... 18
15.2 Temperature Stabilization ................................................................. 19
15.3 PRESSURIZATION ........................................................................ 20
15.4 AIR Content Determination ................................................................ 21
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16.0 HYDROSTATIC PRESSURE TEST ................................................................. 23

16.1 GENERAL ................................................................................... 23
16.2 DURATION of HYDROSTATIC Test ..................................................... 24
16.3 STRENGTH TEST.......................................................................... 24
16.4 LEAK TIGHTNESS TEST ................................................................. 24
17.0 ACCEPTANCE CRITERIA .......................................................................... 25
18.0 POST-TEST REQUIREMENTS ..................................................................... 26

18.1 Depressurizing .............................................................................. 26
18.2 Documentation .............................................................................. 26
18.3 RECTIFICATION REQUIREMENTS ..................................................... 28
19.0 PIPELINE DEWATERING &CLEANING ........................................................... 28

19.1 GENERAL ................................................................................... 28
19.2 Dewatering Records........................................................................ 30
19.3 CLEANING .................................................................................. 30
19.4 Discharges .................................................................................. 30
20.0 PIPELINES DRYING ................................................................................ 31

20.1 General ...................................................................................... 31
20.2 Dry Air ........................................................................................ 31
20.3 Preservation after Drying .................................................................. 32
20.4 Conditioning and Preservation Records ................................................. 32
21.0 DOCUMENTATION COMPLETION FILE FOR HYDROTEST .................................... 32
22.0 CERTIFICATIONS FOR ACTIVITIES PERFORMED AFTER HYDROTEST ...................... 33
23.0 A LIST FOR ALL LINES, BVS STATION AND SECTIONS TO BE TESTED BY THIS
PROCEDURE ........................................................................................ 34
24.0 APPENDIX ........................................................................................... 34
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1.0 PURPOSE
The purpose of this procedure is to define the sequence of the activities and the responsibility in
order to complete all pipeline testing fully compliance with AFC drawings, standards and project
specification of the of onshore export pipelines for AinTsila Development Project.
2.0 SCOPE
This procedure covers the minimum technical requirements for cleaning, gauging, flooding,
hydrostatic pressure testing (strength and leak test) dewatering, final cleaning, sweeping and
drying of onshore export pipelines for AinTsila Development Project.
3.0 PROJECT OVERVIEW

LEAD’s scope of Work includes Construction, Testing & pre-commissioning of Export
System Pipelines and associated work as defined below;
• 34” Gas export Pipeline
• 14” LPG export Pipeline
• 12” Condensate export Pipeline(portion)
• 34” & 14” Export System Launcher & Receiving stations and associated Tie-ins with
Pipeline
• 12” Export System Launching station and associated Tie-ins with Pipeline
• Piping work from Pig Launcher / Receiver to CPF and associated Tie-ins
• Block Valve stations (BVS) including Solar Panel installation
• Electrical & Instrumentation work near Pig Launcher / Receiving stations and BVS
• Cathodic Protection of buried Pipelines
• Work associated with remote stations
• Fiber Optic cabling
• Crossings / Special crossings
• Falaise ascents
4.0 REFERENCES
A-PLE-SPE-200-30010 : Specification for Pipeline Construction
A-PLE-SPE-200-30011 : Specification for Pipeline Hydrotesting
A-PLE-DIA-220-30001 : HYDROTEST DIAGRAM FOR 34" GAS EXPORT
PIPELINE FROM CPF TO TIE-IN GAS
A-PLE-DIA-230-30001 : HYDROTEST DIAGRAM FOR 14" LPG EXPORT
PIPELINE FROM CPF TO TIE-IN LPG
A-PLE-DIA-240-30001 :Hydrotest diagram For 12” Condensate Line From
CPF to Tie-in (MEDERBA)
A-QAC-PLN-200-38187 : ITP For Cleaning ,Gauging and Hydrotesting
A-QAC-PLN-000-30000 : Project Quality plan
A-QAC-PRO-000-30012 : Quality Requirements for Subcontractors
A-QAC-PRO-000-30013 : Inspection & test control Procedure
A-DCC-PRO-000-30000 : Document Numbering Procedure (EPCC)
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A-PLE-SPE-200-30009 : Pipeline material specification

API 1104 : Welding of Pipelines and Related Facilities
ASME B31.8 :Gas Transmission and Distribution Piping Systems
ASME IX : ASME Boiler and Pressure Vessel Code - Section IX:

Welding and Brazing Qualifications
ASME V : ASME Section V - Non Destructive Examination
API- PR 110 :RECOMMENDED PRACTICE FOR THE PRESSURE

TESTING OF LIQUID PETROLEUM PIPELINES
ASME B31.4 :PIPELINES TRANSPORTATION SYSTEMS FOR
LIQUID HYDROCARBONS AND OTHER LIQUIDS
ALGERIAN GAS CODE(1991) : "Règles de Sécurité pour les Canalisations de
Transport de Gaz
Combustibles (herein referred to as the Algerian Gas
Pipeline Code).
5.0 TERMINOLOGY
Company : Groupement ISARENE
Contractor : PIUL ( Petrofac International UAE Limited)
Subcontractor : LEAD (LEAD Contracting & Trading Limited )
Project : AinTsila Development Project
ITR : Inspection test record
RFI : Request for Inspection
PPE : Personnel protective equipment
AFC : Approved for construction
PTW : Permit to Work
HSE : Health Safety & Environment
QCP : Quality control procedure.
ITP : Inspection and test plan.
QC : Quality control.
HSSE : Health safety security environment.
API : American Petroleum Institute
ASME : American Society of Mechanical Engineers
B : Bulk modulus of water [bar]
CS : Carbon Steel
ISO : International Organization for Standardization
MAOP : Maximum Allowable Operation Pressure
MOP : Maximum Operation Pressure
TP : Test Pressure
α : coefficient of linear expansion of steel [°C-1]
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γ : Volumetric expansion coefficient of water [°C-1]

Δp : Incremental Pressure [bar]
ν : Poisson ratio
6.0 Conflicts, omissions, and alternatives

Subcontractor shall follow all codes, regulations, international norms and standards but
any conflict between the requirements of this procedure and the provisions of any applicable
industry standards, codes, or regulations or any specifications, standards, or purchasing
documents contractually required for a given application, shall be submitted to Contractor for
resolution prior to start of work. Contractor’s resolution and approval shall be sought by the
Subcontractor in writing. In all cases, the most stringent requirements shall be applied.
7.0 Companies witnessing

All activities inclusive of cleaning, gauging, flooding, hydrostatic testing, de-watering and
drying shall be conducted in the presence of the Contractor and Companies representative.
Company’s representative will determine in conjunction with the Contractor. Contractor, Company
and ARH representative to validate and accept of all results.
8.0 Pre-condition
Before cleaning, gauging and testing activities on any pipeline section is carried out, Subcontractor
Shall ensure that:
• The installation of the pipeline is complete and inspected.
• Installation of the pipeline has been completed to the satisfaction of the Contractor,
Company and ARA.
• All construction records are complete and accepted by the Contractor and Company.
• Approved hydro test Construction Method Statements plan are in place.
9.0 TEST PACKAGE DOCUMENTS

The Test Pack consists of cover sheet with identification number of the test Hydrotest ITR`S,
punch list, line list, welding summary sheet, marked P & IDs shows the test limits, marked
alignment sheets isometrics show, Cleaning & Gauging Record, Water Filling Record, Pipe & Soil
Temperature Record, Hydrostatic Test Record, Dewatering & drying record, List of spades and
blind flanges, valid copy of calibration certificates of pressure / temperature recorders, pressure /
temperature gauges. For releasing test package for hydro test the following documents to be sent
along with test package VT, RT, UT, PT, coating, holiday, lowering, backfilling
10.0 PERSONNEL AND EQUIPMENT

Subcontractor shall supply all personnel, equipment, instruments, tools, chemicals, inhibitors and
all consumables and materials to complete the cleaning, gauging, testing, de-watering and drying.
These items shall include but not be limited to the following.
Sub-Contractor shall be responsible for ensuring that personnel safety apparel (protective clothing,
hard hats, safety shoes,..) is used and worn.
11.0 Personnel
Subcontractor shall employ trained, experienced and competent personnel including cleaning,
gauging and testing manager, hydrostatic testing engineer, supervisors, technicians, trades
persons and laborers.
Hydrostatic testing engineer shall be considered as one of Subcontractor’s “Nominated Personnel”
and shall be approved by the Contractor. An organization chart inclusive of personnel names
shall be provided as part of the hydro test plan. All involved workers in hydro test will be trained in
chemical use. Precautions of additive chemicals as per MSDS will be communicated via daily
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toolbox talks. Subcontractor will ensure provision of secure containment and segregation for all
hazardous chemicals.
12.0 TESTING MATERIAL, EQUIPMENT and instrument

• Subcontractor shall supply all equipment necessary to complete the cleaning, gauging,
testing, dewatering and drying. The equipment used for testing shall be certified and
approved prior to use.
• Subcontractor shall furnish all fittings, manifold piping, valves, high pressure hose,
temperature and pressure recorders, dead weight tester, cleaning pigs, gauging pigs, filling
pigs, dewatering pigs, swabs, all chemicals are to be provided including scavengers,
biocides as required, charts and all other apparatus and equipment as may be required for
the testing. Chemicals dosing rates shall be as per manufacturer’s recommendations.
Fittings, instruments, pipe, valves etc., shall be of proper rating for the test pressure
specified.
• Any test equipment pressurized during the test operations shall be designed for a working
pressure not less than the test pressure. These components shall have material certificates
and the equipment itself shall have data sheets from the subcontractor. The test equipment
connected to the test section shall have hydrostatic test certificates and shall have been
tested to a pressure at least 1.5 times the test pressure of the test section. The test
equipment shall be internally clean and fit for purpose
• The test heads and temporary pig traps shall be designed, constructed and tested according
to the same code as the pipeline. However, various options of design code break between
ASME B31.8 and other codes may be used where prefabricated items have been used. All
temporary piping, test heads and other equipment connected to the test section have been
tested to a pressure of at least 1.25 times the test pressure
• Test heads and temporary pig traps shall be numbered and a certificate shall be kept by
subcontractor showing the results of non-destructive tests on each weld and of the
hydrostatic pressure test. The number of times each test head is used and the test pressure
attained on each test shall be recorded. The test engineer shall sign entries in the record.
Test heads shall not be used if they do not have a complete certificate and record of use
from the beginning.
• Prior to each re-use, the welded test head shall be cut back to remove all weld metal and
the heat affected zone. To achieve this, at least 12 mm of pipe should be removed. The full
circumference of the new weld end shall be tested ultrasonically for laminations over a width
of 25 mm from the beveled end.
• Flexible hose shall be of the armored type and shall only be used if it is manufactured to
standards applicable for permanent hydraulic installations. Such hose shall only be used in
short lengths as required for the pressurizing line to the test head and for instrumentation.
Only one system of hose connectors from one supplier shall be used to ensure that the
various types are not mixed up. Prior to each re-use, all hoses and connectors shall be
visually inspected for damage. CONTRACTOR / COMPANY shall approve the method of
anchoring.
• Pressure gauges shall be checked for accuracy on site, in the presence of the
CONTRACTOR / COMPANY, before the commencement of the hydrostatic pressure test of
any test section. This shall be carried out by comparison with the dead-weight tester.
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• The accuracy of the pressurizing flow meter shall be checked by the subcontractor, in the
presence of the CONTRACTOR / COMPANY, using a tank for calibration.
• Other instruments shall have calibration certificates from a recognized certifying authority or
a CONTRACTOR / COMPANY approved third party. Where instruments are connected with
electrical cables to the test section or are in contact with the test medium, the instrument's
calibration shall include the cabling.
• The certificates shall not be older than 6 months at the start of testing. The original
certificates shall be shown to the CONTRACTOR / COMPANY and copies included in the
hydrostatic pressure test report. If during the testing period the certificates become older
than 12 months or if the CONTRACTOR or COMPANY has doubts about the calibration of
any instrument to be used for the test, the subcontractor shall have the instruments in
question re-calibrated in the presence of the CONTRACTOR / COMPANY, or a
CONTRACTOR / COMPANY approved third party.
• Testing equipment required to undertake the test shall include filling and pressurizing
pumps, compressors, test end manifolds, pipeline pigging equipment, instrumentation
recorders, all essential equipment.
• Test-end manifolds shall incorporate end enclosures, by-pass pipe work and valves to
enable cleaning, gauging and filling pigs to be launched and received in continuous series.
• Testing materials shall consist of testing bolts, gaskets, blinds, blind flanges, spades, plugs,
etc. which shall all be dedicated for testing purposes only. They shall be properly color
marked, handled and stored in testing lay-down area to avoid mixing them with permanent
piping materials that are dismantled during the test-pack preparations.
• All permanent erection materials, which are dismantled before hydro testing, shall be
properly securely stored in dedicated site stores for proper tracking and efficient
reinstatement after hydro testing. To avoid field material shortages and wastage for any
reason, nonpermanent material shall be erected.
• All equipments shall be inspected to ensure that it meets all safety requirements. All
calibration certificates of test gauges, Dead weight tester, Pressure / Temp. Recorder shall
be available at the point of use.
13.0 LIST OF EQUIPMENT

Flooding and pressurizing pumps Complete with stroke counter or flow meter suitable for the required duty.
Filters 50 micron, as specified in the scope of work, compatible with flow rate of
flooding pumps.
Break tanks and piping To keep the pumps constantly on load
Valves To allow exchange or replacement of instruments and equipment during the
hydrostatic pressure test.
Flooding/Pressurizing flow meter, Measuring and recording continuously the flow of the line-fill water with the
temperature probe specified in Accuracy as per specification.
Chemical injection pump For continuous injection of water treatment packages and dye, including the
injection manifold and line valves. The injection pumps shall have accuracy no
worse than 5%of the specified rate
Air-conditioned or Hydrotest cabin Complete with the necessary gauges, recorders, deadweight tester, barometer,
unit etc. for installation at the end of the test section so that the test engineer can
accurately assess the progress of the hydrostatic test and record the pressure and
water volume conditions throughout the tests. As an alternative to the
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deadweight tester and pressure recorder, the use of a pressure transducer in

combination with a computerized logging system is acceptable.
Pipe wall temperature recorder Measuring and recording equipment in accordance with the accuracy specified
in Accuracy of Test Instruments
Pressure recorder Measuring and recording continuously the pressure at the test head with the
specified accuracy.
Ambient air temperature recorder Measuring and recording equipment in accordance with the specified accuracy
as per Accuracy of Test Instruments.
Soil temperature probes and Measuring and recording equipment in accordance with the specified accuracy
recorder as per Accuracy of Test Instruments.
Pressure relief valve Fitted to the pressuring pump with full capacity of the pump and set at 3%
above the specified test pressure to assure that the test section is not
overpressure.
Pressure let down valve To release the pressure in a controlled manner on completion of the hydrostatic
tests
Tank For calibrating the high-pressure pump and flow meter
Temporary pig launchers and For cleaning, gauging, flooding and dewatering operations.
receivers
Pig’s Various pig’s for cleaning, gauging, flooding and dewatering operations
Pig tracking equipment For locating the pig`s in the test section of longer than 5 km when required
Test head To separate the test section for pressure testing
Air compressors If compressed air is to be used to drive pumps or pigs. The air to drive pig’s
shall be oil-free and air coolers shall be included if the discharge temperature is
outside the limits specified for the test section.
Communication equipment For communication between the various locations of the test section
Spare parts and stand-by facilities To replace any defective test equipment during hydrostatic pressure test
Accuracy of Test Instruments

Instrument Reading division Range Accuracy
Deadweight tester (NOTE 1) 0.01 bar 0 to 1.5 x TP ± 0.05 % (NOTE 2)
Pressure data logger 0.01 bar 0 to 1.5 x TP ± 0.05 % (NOTE 2)
Pressure gauge 1, 2 or 5 bar 0 to 1.5 x TP ± 0.6 % (NOTE 3)
Pressure recorder (24 hours) 2 or 5 bar 0 to 1.5 x TP ± 1 % (NOTE 3)
Barometer 1 mbar - ± 0.8 mbar
Ambient air temperature 0.5 °C 0 to 80 °C ± 1% (NOTE 3)

recorder (24 hours) 0 to 50 °C -10 to 60 ± 0.1 °C
°C ± 0.2 °C
Temperature probes and m3/h - ± 1% (NOTE 3)

recorder (digital)
Pressurizing flow meter strokes/liters - 1% volume per stroke
NOTES:
1. For vessel-mounted operations, especially at high pressure, a data-logger should be used.
2. Percentage of measured value.
3. Percentage of the full range.
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14.0 CLEANING, GAUGING AND LINE FLOODING
14.1 GENERAL
• Upon construction completion and acceptance of activities included into a test section (all
welds qualified and accepted, coating and insulation completed and accepted, lowering in
with backfilling) and installation of the temporary pig trap at both end of the section see
attached, the passage of cleaning and gauging pigs required to clean and confirm the
internal geometry integrity of the pipeline shall be commenced.
• Subcontractor shall clean and gauge sections of lines between suitable tie-in points such
as line valve stations, to ensure the removal of construction debris and loose scale and to
check that the section is free of deformations and/or obstructions.
• Subcontractor shall calculate the required pressure and volume to drive the pigs as
specified.
• The elevation difference and back-pressure of the outlet at the receiving end shall be taken
into account. Line valves shall not be installed before the completion of Hydrotest including
dewatering and cleaning operations have been completed.
• Temporary pig launchers and receivers shall be approved by the CONTRACTOR prior to
use and shall be welded to the test section or flanged if a permanent flange is available.
Compressed air oil-free shall be used to driven the pig during cleaning and gauging
activities.
• CONTRACTOR / COMPANY Representative shall witness all the cleaning and gauging
operations. Pipeline sections shall be cleaned and gauged in accordance with the
requirements of the Construction Specifications with suitable gauging logs maintained and
completed for each operation.
• The pig’s shall be propelled by compressed air in order to maintain the pig speed in range of
0.5 - 2.0 m/s and shall be controlled by building up backpressure in front of the pig. The
amount of backpressure shall be according to the elevations of each section.
14.2 CLEANING
• Suitable pigs for cleaning shall be launched, propelled by air to ensure that the involved
section is cleaned up to the acceptance CONTRACTOR/COMPANY representatives. The
pig’s shall be received by a temporary receiver installed at the end of section and shall be
examined each for pig disc wear and determination of the amount of debris immediately
preceding the pig. Such determination shall be by qualitative methods agreed by
CONTRACTOR/COMPANY representatives on site.
• Block valves shall not be installed before the initial cleaning operations have been
completed in order to avoid damage to valve seats and seals.
• For internally coated pipelines, the pigging shall be performed with a polyurethane pig. The
preferred choice is a Pig with disc and cups because these will normally remove the
deposits from the coating following with a foam pig. The operation shall be repeated as
much as required in order to achieve an acceptable and reasonable cleaning.
• When gas pipeline is without internal coating, a cleaning pig with brushes can be used.
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• Prior to commencement of a hydrotest, each pipeline section shall be cleaned firstly by

running a robust bi-directional disc pig fitted with a location device. This is to be followed
by further pipeline cleaning using trains of pigs fitted with brushes and magnets. Each pig
train shall contain a minimum of 2 Brush pigs followed by a magnetic pig.
• A pressure indicator will be installed at launchers and receivers to control back pressure
• The work shall be performed in strict accordance with this procedure and ASME B31.8.
• Received material shall present a decreasing trend in both volume and particle size. Debris
amount and particle size criteria shall be clearly indicated in the cleaning procedure, which
shall be submitted for CONTRACTOR/COMPANY’s approval.
• In addition, all debris received with the pig shall be disposed of in accordance with the
CONTRACTOR/COMPANY’s waste management requirements. Cleaning pigs will be
launched, propelled by air, sufficient in number to ensure that the Pipeline sections are
cleaned to the Specification or as agreed by Contractor representative on site. The Cleaning
pigs will be received by an Air receiver head, at the end of the Section.
• Amount of Received debris 2 liters max for each 20 km on front of the Cleaning pigs shall be
visually determined.
14.3 GAUGING
• When the section cleaning activities are accepted by the CONTRACTOR/COMPANY, the
Gauging pigs shall be launched and received in a similar manner as the cleaning pig.
• the gauging operation shall be applied after complete backfilling of the pipeline
• The gauging plate shall be run on bi-directional pig (4 disc pig) in order to maintain the
gauging plate in the center of the pipeline during the run.
• The pig speed shall be maintained between 0.5 – 1.5 m/s by maintaining back pressure.
Subcontractor shall photograph and furnish all gauge plates and submit them for
contractor/company.
• Approval. COMPANY shall witness marking immediately prior to placing into testing
section.
• Any evidence of dents, excessive out-of-roundness, or other damage to the pipeline shall
be investigated and the line shall be repaired to the satisfaction of Client or Client’s
representative. A separate gauging run shall be carried out for each test section.
• The gauging plate will have a diameter equivalent to 95% of the minimum internal diameter
of the relevant pipeline (based on the thicker wall line pipe sections including pipeline Valves
and fittings) and not less than 25 mm clearance for pipeline nominal ID of 20 in or greater
depending on the specified ovality tolerance
• The gauging plate shall be made of aluminum 6-10 mm in thickness. All gauging plates shall
be hard stamped with a unique serial number prior to inserting into pipeline. A photographic
record of the condition of the gauging plate and pig’s immediately before and after running
through the pipe shall be undertaken in the presence of the CONTRACTOR/COMPANY
representatives. The gauging pig shall be inserted into the launcher in the presence of the
CONTRACTOR/COMPANY representative.
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• Adequate pig type and material selection shall be considered as far as the internal lined
sections of pipeline are concerned
• On receiving the gauging pig, the gauging plate shall be removed from the pig and then
inspected in the presence of the CONTRACTOR/COMPANY representative. The gauging
plate shall be signed, dated and marked with the test pack number by the CONTRACTOR
and the COMPANY representative. The gauging plate shall remain as the property of the
CONTRACTOR/COMPANY.
• The gauging plate is to be free of dents and buckles and is to be of a standard acceptable to
the CONTRACTOR / COMPANY. Should any damage be evident on the gauging plate
Subcontractor shall investigate, locate and remove all defects in the pipeline and a further
gauging plate run shall be carried out until the gauging plate passes through the section
without damage.
• Figure 1: Pig from specification
Gauging Plate Guiding Disc
GAUGING PLATE DIAMETER CALCULATION:

The Minimum Theoretical inside diameter is MTID = D – (B) -2 (t+ A)
D: Outside diameter t: Wall thickness
A: Wall thickness tolerance (see table 11 of API 5L)
B: Diameter tolerance (see table 10 of API 5L)
Gauging plate diameter (Dg) = 95 % x MTID
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Table 1 Size of Gauging Plates

DIA. THICK. MTID GAUGING A B
PLATE
INCHES mm mm SIZE (mm) mm mm
34 26.46 804.1 763.9 1.5 4.0
34 22.30 812.4 771.8 1.5 4.0
34 13.99 829.2 787.7 1.4 4.0
14 11.68 327.1 310.8 1.2 2.7
14 10.61 329.5 313.0 1.1 2.7
14 7.47 336.5 319.6 0.75 2.7
12 6.05 308.1 292.7 0.6 2.4
12 4.59 311.2 295.6 0.5 2.4
• If from visual inspection, the gauging plate is undamaged, line gauging shall be deemed
acceptable.
• On acceptance of the gauging results, the following section shall be started, until cleaning and
gauging activities are completed for all the sections included in the Hydrotest activity.
• The work shall be performed in strict accordance with this procedure and ASME B31.8.
• The gauging plates shall be examined for any signs of damage or irregularities such as dents and
buckles. In case of damage, the gauging pig shall be re-run with new gauging plates of the same
diameter. If the defect cannot be located by the gauging operation, Subcontractor shall prepare
contingency procedures in the event of unacceptable dents or gouges being found on the gauge
plate (e.g. surveying the pipeline with a caliper pig when required).
• If damaged, the cause and any repairs necessary to the testing section shall be agreed between
CONTRACTOR, subcontractor and CLIENT. Subcontractor shall make all necessary repairs prior
to re-run of the new gauging plate.
• After accepted gauge the plates shall be kept safe by Subcontractor to be included in the Test
Report.
• After gauging operation, the pipeline shall be left and ends of pipe shall be covered till
commencement of the water filling
14.4 Source of test water

• The source of test water for the Pipeline shall be obtained from wells, dedicated wells and storage
ponds shall be provided by CONTRACTOR. Water analyses certificate shall be attached with
hydro test package and approved by Contractor before start of filling operation.
• The water shall be filtered through 50-micron filters as required based on the available
water quality immediately prior to entering the pipeline
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• Water consumption for Hydro test activities will be recorded separately on daily basis and
reported weekly or upon request to Contractor.
• Once the hydrostatic pressure test of a pipeline section is completed, the water shall be
transferred to the other sections.
• Chemicals to be approved by the Contractor as most environmentally benign. Treating dosage

and method shall be in accordance with the chemical manufacturer’s recommendation. If the
dosage is dependent on the length of time that the test water is to remain in the line, the dosage
shall be based on the calendar months to the expected.
• Sub-Contractor shall provided all temporary piping, hoses, pumps, fittings, etc to move the water
from the CPF supply point to Sub-Contractor test location.
14.5 Test Medium

• The water shall be treated with oxygen scavenger/biocides/corrosion inhibitors or cocktail from
reputed manufacturers.
• Type of inhibitors and does shall be as recommended by laboratory after complete analysis for
water and proposed inhibitor type.
• The minimum requirements for the physical and chemical treatments to be performed on water to
be used for hydrostatic testing of pipelines shall be as defined as below. As guidance, the
physical and chemical treatment for test water is required to prevent:
➢ Corrosion of materials during the pressure test, or after resumption of operations, due to the
presence of this water.
➢ Massive contamination of the tested pipelines by bacteria, which are likely to remain in the
pipes after dewatering.
• The quality of water for hydrostatic test shall be agreed before the test based on the water
analysis report. The water for hydro testing shall be free from debris and other contamination and
should not be aggressive to minimize the risk of corrosion. The water shall be treated with oxygen
scavenger/biocides/corrosion inhibitors or cocktail having chemicals in required proportion.
• The quality of hydrostatic test water shall meet the following criteria:
pH 6.5 to 10.5
Chloride ions 100 ~200 ppm
Total dissolved solids Less than 1.5 Kg/m³
H2S Nil
Suspended Solids 0.002 Kg/m³
Sulphate-Reducing Bacteria to be maintained <200 cells per mL
Appearance Clear with no visible sediment
• The quality of water shall be reconfirmed by sample testing at a maximum of two (2) weeks before
initial water filling in preparation for the hydrostatic testing.
• In case multiple water sources or tanker trucks are used to supply water, representative
water samples shall be drawn for testing from each source or tanker.
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• If the water used in the hydrostatic test is from more than one source, ensure that mixing
the waters will not cause scaling.
• If the maximum period of contact of this water (or residual water after dewatering) within
the pipeline is known to be 7 days or less, chemical treatment shall generally not be required. If
the period of contact is or could be in excess of 7 days, prior chemical treatment shall be required
unless CONTRACTOR can demonstrate water quality that does not require treatment.
• All personnel involved in hydro test will be trained in chemical use.
• Precautions of additive chemicals as per MSDS will be communicated via daily toolbox talks.
• Subcontractor will ensure provision of secure containment and segregation for all hazardous
chemicals.
14.6 Water Disposal

• Test fluids shall be discharged in full compliance with current local Algerian regulations, the
Environmental Design Strategy (A-HSE-PHL-000-00001) the COMPANY safety specifications
and procedures.
• The fluid disposal shall be performed such that no harm is done to the surrounding environment.
The fluid disposal location shall be approved by COMPANY.
14.7 FLOODING WATER

• Subcontractor shall ensure that the water to be used for the various pressure testing operations is
of a quality that protects the test section from the ingress of foreign matter, sedimentation and
internal metal corrosion. Only clean fresh water taken from a river or a portable water system
shall be used.
• The water used for pressure testing should be selected from a location that shall minimize the
temperature stabilization period. The water shall be filtered through 50 micron filters, except for
water injection lines for which the water shall be filtered through 2 micron filters, before entering
the test section.
• The arrangement of filters at the test work sites should enable back flushing without disconnecting
the pipe work. There is no requirement to inject dyes.
• Treatment packages containing an oxygen scavenger and biocide shall be added to the flooding
water. Environmentally acceptable line-fill treatment packages should be used. Subcontractor
shall obtain samples from all water sources proposed as line-fill water for analysis by a testing
laboratory approved by contractor/COMPANY.
• Oxygen corrosion generated by the dissolved oxygen in the line-fill water is acceptable for carbon
steel pipelines used for oil and gas service.
• Corrosion inhibitor and dye shall be injected by separate injection pumps and an injection
manifold. The injection points at the manifold shall be positioned at least 1 m apart. Concentrated
chemicals shall not be mixed. The injection should be upstream of the flooding pumps to allow
thorough mixing before entry to the test section.
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• Where the flooding water is to be transferred from one test section to another, the quality of water
shall be checked and chemically retreated as necessary before transferring. No debris shall be
transferred from one test section to another. While transferring water from one section to another
section, a break tank shall be used.
• Line flooding should not take place if the ambient temperature is below 2°C unless suitable
antifreeze has been added to the line-fill water.
• Subcontractor shall provide all details of water treatment necessary to bring the water to the
required quality for the various pressures testing operations specified herein. If the above limits
for biological fouling cannot be met and/or oxygen corrosion must be kept to a minimum as
specified in the scope of work, then Subcontractor shall treat the flooding water.
• For contact periods up to 3 months the cocktail treatment or individual chemical treatment may be
used. For contact periods up to 24 months individual chemical treatment shall be employed.
14.8 LINE Flooding
• The test section shall be filled with water. All instruments and gauges to be used during flooding
and water treating shall have been calibrated and with valid test certificates approved by the
CONTRACTOR /COMPANY.
• Before flooding the test section, the test engineer shall ensure that piping and facilities for the
disposal of treated water are installed and functional.
• All necessary measures shall be taken by the Subcontractor to remove air from the line during
flooding and this includes back-pressure control, a steady controlled flooding rate, use of a break
tank and use of at least two bi-directional pig’s with water in front and in-between. The sections
shall, if possible, be filled from the lower end. The CONTRACTOR /COMPANY shall ensure that
the pump suction shall not draw in air with the water and that the pigs are in good working order
and correctly fitted in the test section. Venting shall be carried out repeatedly at points in the test
section where air might accumulate, e.g., at ancillary piping.
• Water shall be pumped from the temporary water storage tank to the pipeline using a diesel
driven centrifugal pumps. A 50-micron mesh filter shall be installed on the suction line of the
pumps.
• The flooding pig speed should be approximately 0.6 m/s and should not exceed 1.8 m/s. The
pressure in front of the pig shall be carefully monitored and controlled at not less than 2 bar.
Depending on the elevation profile of the test section and the pigging pressure, it may be
necessary to increase the pressure at the receiver test head in order to control the pig speed.
• In order to assist in controlling the line flooding and water treating, the following measurements
and records shall be taken:
➢ Inlet flow-rate of flooding water

➢ Inlet pressure of flooding water
➢ Inlet temperature of flooding water
➢ Pressure at the receiver head
➢ Chemical injection rates
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• In the event of chemical injection pump failure the flooding pump shall be stopped.
• Subcontractor shall install and operate a water flow meter and pressure gauge at the fill point to
aid in determining the location of the filling pig, a pressure gauge shall be installed at the receiving
end to facilitate checking of the back pressure.
• Filling shall be continuous over 24 hours without flow breaking and pigging should minimize the
volume of air trapped within the section.
• During filling, the pigging is determined by the available water rate from the water supply source
available for the section under test. A calibrated flow meter shall be used to monitor and record
the filling rate.
• Flooding sequences for each section shall be carried out as below :

➢ Use of filling pigs of the 4 cup type of the proper size and in first class condition, to preclude
the possibility of air and/or water by-passing them.
➢ 50 m3 to 100 m3 of water (Suitable quantity) shall be filled before launching the first PIG for
flushing the pipeline section according to section profile, diameter and length.
➢ Launching the first filling pig.
➢ 100 m3 volume of water as slug water after first filling pig.
➢ Launching second filling pig and start filling.
➢ Water for filling shall be taken from break tank
➢ All fill pumps shall be fitted with 50 microns mechanical suction filter
➢ After completion of water filling operation, filling pump shall be disconnected and test section
shall be left at the filling pressure and test section will be prepared for thermal stabilization
and pressurizing operation.
15.0 PRE-TEST REQUIREMENTS
15.1 Requirements Prior to Pressurizing

• A pre-test check shall be performed, detailing the status and location of each item to be inspected
before Pressurizing is commenced. The check-list should include checks to confirm that:
➢ The test section has been isolated from all other pipeline sections.
➢ All temporary piping, test heads and other equipment connected to the test section have
been tested to a pressure of at least 1.25 times the test pressure.
➢ The test section has been filled completely and air has been vented off.
➢ No line valve on the pipeline is included in the test section.
➢ All instruments and gauges to be used during pressurizing and testing have been calibrated
and valid test certificates have been approved by the CONTRACTROR/ COMPANY.
➢ All warning notices, marker tapes, protective barriers and other safety equipment have been
positioned and the necessary authorities have been informed.
➢ All necessary personnel at the affected stations have been informed of the commencement
and the duration of the hydrostatic pressure test.
➢ The communication channels have been tested and established and back-up equipment is
available.
➢ The personnel engaged in the testing work have been briefed on the emergency plans.
➢ The person operating the pressurizing equipment has been instructed by the test engineer
regarding the limiting pressure, which shall apply to the test section.
• The test section shall be completely buried, up to the test heads, to the specified depth before
testing commences. The trench should also be reinstated to the maximum extent possible prior to
commencement of the test.
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• Pipe and soil temperature shall be measured and recorded at each end of the test section and at
every 5 km throughout the length of the pipeline using thermocouple type instruments with digital
readout. These shall be firmly attached to bare metal and covered with insulating materials for the
pipe temperature measurements and for the soil temperature measurements they shall be buried
at pipe centerline depth and 0.5 m laterally from the pipe. The points of measurement at each end
of the test section shall be such that there is at least 100m of pipeline buried to specified depth
between that point and the test head. For short lines a minimum of three locations shall be used
to measure pipe and soil temperatures.
• For the aboveground test section temperature measurements, the thermocouple should be firmly
installed into the line-fill water or firmly attached to bare metal and covered with insulating
materials. The location of the thermocouples shall be recorded.
• Pipeline sections to be tested shall be as long as practicable and with a difference in elevation not
exceeding 60 m or as otherwise specified in the Drawings. The SUBCONTRACTOR shall
determine the test sections in accordance with this requirement and to take account of the need
to conserve water use.
• Test ends shall incorporate a device to establish that pigs or spheres have arrived at the receiving
end. Radioactive indicators shall not be used.
• During the running of filling pigs, the SUBCONTRACTOR shall operate pressure indicating and
recording apparatus to the satisfaction of COMPANY and shall arrange for tracking the run of the
pig. The pressure downstream of the pig shall be carefully monitored and controlled at a pressure
of not less than 2bar
15.2 Temperature Stabilization

• After completion of line flooding, the line shall be kept for thermal stabilization.
• The thermal stabilization will start after making sure that at the end of the filling at the highest
elevation location, the water pressure is more than 1 bar
• The temperature of the line-fill water should be stable before testing commences. Prior to
commencing the hydrostatic test, the water temperature should be within 1°C of ground
temperature. This shall be determined as the difference between average pipe temperature and
average ground temperature over the test section length.
• Pressure and temperatures, including ambient, shall be recorded every three (3) hour during the
stabilization period. The test section temperature and the ambient temperature (ground/air/water)
shall be plotted against time during the temperature stabilization period.
• Temperature probes/thermocouples shall be installed as required of specific locations. The

locations shall be mentioned in the test pack of the temperature probes.
• The calculation of the minimum stabilization period based on the expected line-fill water
temperature and ambient temperature
• thermal stabilization shall be end when the difference between the pipeline section and
surrounding has been achieved or minimum 24 hours duration
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15.3 PRESSURIZATION
• The test engineer shall carry out a plot of pressure/added volume using measurement of volume
added either by pump strokes or flow meter and instrument reading of pressure gauge plus dead-
weight tester, as per ARH requirements. A tank shall be available to enable checks to be made of
the volume rating of the pressure pump or flow meter.
• Start to pressurize with 2-3 bar/minute until a pressure 50% of the test pressure has been
attained. During this period, volume and pressure readings should be recorded at 1 bar intervals.
• The person operating the pressurizing equipment shall immediately report to the test engineer
any variation in the rate of pressure increase by the same volume of added water. During
pressurization, all potential leakage points shall be checked.
• When the pressure of 50% of the test pressure has been reached, pressure shall remain for 6
hours for water stabilization and the air content shall be determined. After that 6 hours pressure
shall be gradually increased up to 85% of the test pressure with 1 bar/minute.
• Raise the pressure up to 100% of test pressure at 0.2 bar/minute.
• The pressurised section shall be left for 24 hours for thermal stabilization.
PRESSURIZING CYCLE
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• When the air content is within the maximum allowable limit of 0.2% of the test section volume,
pressurization should continue, at the rate given above, as follows:
➢ If flanges are installed, pressurization should continue up to the MAOP and be held while
checking flanges for leaks. This is the highest pressure permitted to tighten up any leaking
flanges.
➢ If flanges are not installed or the flanges have been checked, pressurization should continue
up to 80% of the test pressure and be held at this level for not less than 2 hours.
➢ During this water stabilization period accessible flanges, if installed, should again be
checked for small leaks. If any are found, the test section shall be depressurized at not more
than 2 bar/min to MAOP prior to any bolt tightening.
• The volume and pressure readings should be recorded at 10-minute intervals until the test
pressure has been reached.
• After stabilization, the pressure should be raised to 95% of the test pressure and held for 30
minutes, and then the pressurization should be continued to the specified test pressure at a rate
not exceeding 1 bar/min.
• The pressures and added volumes should be continuously plotted until the specified test pressure
has been achieved. The plot should be constantly checked and, in the event of any deviation of
10% or more from the theoretical line corresponding to 100% water content, the test should be
terminated. The pressure should be released and an investigation shall be carried out to
determine the cause of the deviation prior to re-pressurization.
• During the test, deadweight tester readings shall be recorded every 30 minutes and pipe, soil and
air temperature recorded every 1.5 hours.
15.4 AIR Content Determination

• The air content of the filled line shall be determined during initial pressurization by using the
pressure-added volume plot. The linear section of the curve shall be extrapolated to the volume
axis, which shall correspond to static head pressure.
• The volume of air can be read from the intersection of the line with the volume axis and shall be
used to calculate the air content thus:
• Percentage air content = (Volume of air / Volume of line) times 100
• If the air content exceeds 0.2% of the line volume, testing shall be terminated and an investigation
shall be carried out to determine the cause. The test section should be emptied and refilled at the
discretion of the contractor / COMPANY.
• During pressurization, subcontractor shall adhere to the following procedure to determine the
volume of air trapped within the test section. Subcontractor shall record pressure and cumulative
volume readings of water added at 1 Bar intervals during pressurization up to 35 Bars and
construct a pressure volume plot. To determine the percentage air entrapment, recording of
pressure and volume shall commence at static head pressure. The linear section shall be
extrapolated back to the volume axis.
• The rate of pressurization shall not exceed 1 Bar/min. The P/V plot shall be continued up to test
pressure and should the volume added be greater than predicted, the cause shall be identified.
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• If the measured volume of entrapped air, reduced to atmospheric pressure, is less than 0.2
percent of the test section volume, then the filling of the lines shall be deemed acceptable for
proceeding with the hydrostatic test. If the volume of entrapped air exceeds 0.2 percent then
Subcontractor shall take measures to reduce the quantity of air in the test section, either by
venting or by refilling the line. In any case the line shall be fully depressurized and another air
entrapment test carried out to determine acceptability of the filling operation.
PRESSURE THEORETICAL
P/V PLOT
ELASTIC CURVE
EXTRAPOLATION OF LINEAR
STATIC HEAD SECTION OF P/V CURVE BACK TO
VOLUME AXIS
VOLUMEOF AIR VOLUMEOF WATER ADDED
Fig.1 Determination of air content by extrapolation of linear portion of P/V curve to intercept the
volume axis
The formula used for the theoretical P/V plot is:
V  D 
= V   0.044  + 4.50  10−5
P  t 
Where V is the incremental volume of water added (m3)
V is the volume of test section (m3)
P is the incremental pressure change (bar)
D is the nominal pipe diameter (m)
t is the nominal wall thickness (m
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16.0 HYDROSTATIC PRESSURE TEST
16.1 GENERAL
• The minimum hydrostatic test pressures are equal to or exceed the requirements of the relevant
Algerian Regulations, as summarized in the table. In all cases the minimum pressures, at low
points, are related to the maximum service pressure (PMS) of the line.
• The test pressure (TP) of each section of the pipelines to be hydro tested shall be determined by
the requirements of ASME B31.8 and shall be subjected at any point to a hydrostatic proof test
equivalent to and not less than as specified in HYDROSTATIC TEST PRESSURE
CALCULATION & DIAGRAM.
• At lowest point the pressure test of the test section should not develop a hoop stress higher than
90% of the SMYS of the pipe, based on nominal wall thickness.
• At higher point the pressure test of the test section shall not be lower than the minimum hydro test
pressure (PT) for zones according to below table 2:
Table 2 – Hydrostatic Test Pressures

Zone
1/1a/2/3
Zone 1/1a Zone 2/3
PMS / Zone Zone 2/3 Maximum
Minimum Minimum
MAOP 1/1a Test Test Combined
Pipeline Test Test
(minimum) Pressure Pressure Test
Pressures Pressures
barg barg barg Pressure
barg barg
barg Note
1
Condensate PMS x PMS x
65 78 71.5 78
Export 1.2 1.1
PMS x PMS x
LPG Export 97.25 145.9 121.6 145.9
1.5 1.25
PMS / PMS /
Gas Export 91.5 136.9 107.6 NA
0.67 0.85
• Subcontractor is to test all pipeline material to the same combined maximum test pressure or
Zone-wise test pressure depending on the test section requirement
• Anywhere in the test segment the pressure level does not produce hoop stress near or above the
SMYS. If lines are tested at pressure that develop a hoop stress based on nominal wall thickness
near SMYS of the pipe, special care shall be taken to prevent the pipe from overstraining ( refer
the article TEST PLAN in API RP 1110)
• For test at pressure levels near SMYS consideration should be given to keeping a pressure-
volume (p-v) plot during pressurization to prevent yielding of the pipe. (refer article TEST PLAN in
API RP 1110).
• During pressurization, Subcontractor shall carry out leak checks.
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• At 90% test pressure the rate of pressurization shall be reduced to max.0.5Bar/min. and at 95% to
a rate as slow as practicable.
• During pressurization, actual hydrostatic pressure test and Depressurizing operations all
globe, gate and ball valves shall be fully opened.
16.2 DURATION of HYDROSTATIC Test

• The minimum duration for the hydrostatic pressure test shall be a two-hour strength test
followed by a 22-hour leak tightness test. The assembly testing shall comprise a two-hour
strength test followed by visual examination at the leak tightness test pressure.
16.3 STRENGTH TEST

• The hydrostatic strength test pressure (TP) shall meet the requirements given in project
specification. The pressure shall be maintained during the strength test at TP ± 1 bar by
bleeding or adding water as required. The volumes of water added or removed shall be
measured and recorded.
• During the test, TP shall be recorded continuously, and the dead-weight tester readings
and air temperatures shall be recorded at least every thirty minutes. The pipe and soil
temperature shall be recorded at the beginning and end of the four-hour test period.
• The test section temperature and the ambient temperature against time plot created for the
stabilization period should be maintained.
16.4 LEAK TIGHTNESS TEST

• The leak tightness test shall be commence immediately after the strength test has been
completed and satisfactorily. No water shall be added or removed during the tightness
test. The test is intended to demonstrate that there is no leak in the pipeline.
• If it can be ensured that the pressure variations due to temperature fluctuations are in the
limits, then a combined strength/leak tightness test at the strength test pressure, without
water addition or removal, should be carried out. To allow for pressure variations caused
by temperature fluctuations during the test duration, the test pressure should be set to a
level of 80% of TP.
• During the test, the pressure shall be recorded continuously, and the dead-weight tester
and air temperature readings shall be recorded every 30 minutes. The pipe and soil
temperature shall be recorded every 1.5 hours. The temperature Recording interval should
be reduced to one-hour duration for the first and last three-hour periods of the 24-hours to
assist with the pressure/temperature variation calculation.
• The test section temperature and the ambient temperature against time plot created for the
stabilization period should be maintained. If the pipeline consists of several sections
which have already been strength tested, the pressure for the final leak tightness test shall
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HYDROTESTING
be based on 80% of the lowest TP of the tested sections. The difference in elevation over
the test section shall be taken into account.
• If a leak is suspected the pressure shall be reduced to less than 80% of test pressure before
carrying out a visual examination. No work shall be carried out to repair leaks until the
pressure has been reduced to a safe pressure i.e. static head plus 1bar.
17.0 ACCEPTANCE CRITERIA

• To determine whether any pressure variation is a result of temperature changes or
whether a leak is present, the pressure/temperature changes shall be calculated from the
pressure/temperature equation formula 2 (2a for restrained test section or 2b for
unrestrained test section) or unless otherwise approved by the COMPANY.
Formula 1. Volume/pressure equation
Formula 2. Pressure/temperature equation

2a) For restrained test sections2b) For unrestrained test sections
Where,
o ΔV = incremental volume [m³]
o ΔP = incremental pressure [bar]
o ΔT = incremental temperature [°C]
o V = pipeline fill volume [m³]
o D = pipeline outside diameter [m]
o E = Young’s elastic modulus of steel (for CS, E = 2.07 x 10⁶bar) [bar]
o t = nominal pipe wall thickness [m]
o Poisson ratio (for steel, ν = 0.3)
o B = bulk modulus of water [bar]
o γ = Factor A, volumetric expansion coefficient of water [°C⁻¹]
o 𝛼 = coefficient of linear expansion of steel (for CS, 𝛼 = 1.17 x 10⁻⁵°C⁻¹) [°C⁻¹]
NOTES:
1. B is very sensitive to temperature and antifreeze.
2. For fresh water, B changes significantly at low temperatures because the density of water is greatest at
4°C.
3. Aboveground test sections, if not anchored, or buried, are normally unrestrained.
• The pressure, the test section temperature and the ambient temperature shall be plotted
against time during the period of the leak tightness test. The tightness test shall be
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HYDROTESTING
deemed acceptable if any pressure change can be accounted for by a corresponding

temperature change using formula.
• Allowance should be made for any recording inaccuracy. In the event of any doubt by
CONTRACTOR or COMPANY about the leak tightness of the line, for example, when
temperature and pressure trends are differentiated, the test shall be extended until such
time as the acceptability is demonstrated.
18.0 POST-TEST REQUIREMENTS
18.1 Depressurizing
• After the satisfactory completion of the strength and leak tightness tests, the test section
shall be depressurized to hydrostatic head plus 1 bar so that air does not enter into the test
section.
• Pressure let down valves shall be opened slowly and depressurizing continued at a rate
that does not generate vibrations in associated pipe-work. Under normal circumstances,
no fitting of any type should be attached to the pressure let down valve. If fittings or drain
lines are attached, they shall be adequately braced and tied down to prevent movement.
• Under normal circumstances, the depressurization rate shall not exceed 1 bar per minute
until the pressure has been reduced to 60% of the test pressure. Then depressurization
should continue at a rate of less than 2 bar per minute. Test pressure shall not be used for
transfer of water from one test section to another.
• The above requirements also apply when the test section must be depressurized for the
rectification of damage/defects during the hydrostatic pressure test.
18.2 Documentation
• The pressure test should be considered as satisfactory if during the 24hr hold period no
observable pressure variation occurs which cannot be accounted for by temperature
change.
• Once sectional pressure testing has been accepted, subcontractor shall commence
depressurization of the system and where appropriate shall transfer the test water to the
next test section. The pressure recorder chart shall not be removed until the pressure has
been reduced to static head.
• Upon successful completion of the hydrostatic pressure testing, both Contractor Inspector
and subcontractor’s Test Engineer shall sign all relevant reports as well as the hydro
testing acceptance certificate. Contractor Inspector and subcontractor shall sign all
records, charts, calculations and plots associated with the test.
• The test section will be tied-in sequentially to the previously tested test section. Golden
joint welding shall be in accordance with the approved welding procedure and shall be
subjected to 100 % radiography and NDT as required. Tie-in connections of test sections
shall be made in accordance with the requirements of API 1104 and Specifications.
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• Sub-contractor shall keep records of all parameters specified in this specification during
each operation. The hydrostatic pressure test records should be reviewed by
CONTRACTOR/ COMPANY at the beginning, at the end and at least once during the
test.
• All recorder charts shall be signed by the test engineer when placed on and taken off the
recorder. All recorder charts taken during the hydrostatic pressure test shall also be signed
by CONTRACTOR/ COMPANY
• Upon completion of each successful section test, a "Hydrostatic Test Certificate” shall be
completed and signed by CONTRACTOR/ COMPANY representatives.
• This shall be supported by original hand-written test data of which photocopies shall be
submitted to CONTRACTOR/ COMPANY. A separate certificate shall be completed for
each test, including pre-test and assembly testing.
• For each complete pipeline, the Subcontractor shall compile a "final hydrostatic test
report", with a general introduction including all relevant pipeline data, detailing each
hydrostatic pressure test.
• The contents, as a minimum, shall include the following as specified herein:
➢ Originals of all recorder charts
➢ All pressure and Temperature readings
➢ Volumes of water added or bled off
➢ Instrument Test Certification
➢ Air content plot and calculation
➢ Pressure and temperature plots against time
➢ Pressure/temperature correlation calculation
➢ Details of line-fill treatment packages
➢ Pig register of cleaning, gauging and flooding
➢ Photographic record of the used gauging plates
➢ Leak locating (if carried out)
➢ Pig register of de-watering
➢ Details of line-fill water disposal
➢ Rectification records (if carried out)
➢ Test procedure
• The draft report should be submitted to the CONTRACTOR/ COMPANY for each test
section within two days after completion of the test. The complete report should be
submitted for COMPANY approval within one week
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18.3 RECTIFICATION REQUIREMENTS
• If a leak is suspected during the hydrostatic test, SUBCONTRACTOR shall reduce the
pressure to less than 80% of the test pressure before carrying out a visual examination.
• If it is not possible to locate the suspected leak by visual examination,
SUBCONTRACTOR shall use a method, which enables the locating of leaks at test
pressure without endangering the personnel carrying out the work. When the leak has
been found, SUBCONTRACTOR shall repair the test section in accordance with the
appropriate guidelines.
19.0 Pipeline Dewatering &Cleaning
19.1 GENERAL
• After successful completion and acceptance of pipeline flooding, gauging and
Hydrotesting on a pipeline section or complete pipeline, Subcontractor shall proceed with
removing the test water from that section of the pipeline. Subcontractor shall only
proceed with dewatering operations when authorized by CONTRACTOR/COMPANY.
• SUBCONTRACTOR shall submit specific MS for each pipeline to be dewatered to

achieve the following key objectives:
➢ Reduce pipeline drying times by maximum removal of water.
➢ Provide adequate control of the pigs during dewatering.
➢ Provide adequate method to inhibit the pipeline systems, which shall not be
dried.
➢ Provide adequate method for the re-use of test water where practicable.
• When Subcontractor needs to bulk dewater a test section in order to transfer water or
to make a tie-in the pipeline, should be left in the bulk dewatered state for a period longer
than two weeks, further dewatering of this section shall be required until all free water is
removed.
• After bulk dewatering has been completed, the Subcontractor shall perform pig runs
propelled by oil free air dehydrated to a relative humidity lower than 80% at the pipeline
temperature and operational pressure. Air for propelling pigs shall be made oil free and
dry by means of oil filter units and air-drying or desiccant units downstream compressors.
The capacity and pressure rating of the air compressor, oil filter and air drying system
shall be sufficient.
• Only one pig (or pig train) shall be sent through the line at any one time. The pig runs
shall preferably be executed in a downhill direction and in one continuous operation.
• The pig velocity shall be kept constant and within the range of 0.5 to 1 m/sec. internal
pipeline pressure shall be kept at least 1 bar above the ambient pressure point along the
pipeline by backpressure control at the discharge end.
Page 28 of 63
HYDROTESTING
• SUBCONTRACTOR shall perform dewatering runs until all free water is removed from
the pipeline in front of the pig train.
• Free draining of the pipeline shall not be permitted.
• The pipeline shall be flushed with fresh water to remove residue from Hydrotest
operations.
• Subcontractor shall perform repeat pigging runs at the discretion of the CONTRACTOR
Representative to facilitate dewatering of the pipeline. Maintain dry airflow until all pigs
received, as indicated by air stream at receiver isolation valve vent.
• Cessation of the dewatering operation shall be approved by CONTRACTOR/

COMPANY.
• Subcontractor shall remove all the temporary test facilities, including the temporary
Scraper traps. Subcontractor shall re-instate exposed pipeline sections used for
hydrostatic test operations and install the Permanent valves, gaskets, bolts.
• Permanent pigging facilities (launcher and receiver), plus intermediate block valves and
ancillaries.
• The acceptance criterion for dewatering shall be when the last foam pig extracted at the
receiving terminal is completely in dried condition.
• In the case of re-use of Hydrotest water, the test water shall filter to a similar condition as
it was prior to introduction into the previous pipeline section. All solids, sludge or other
pollutants filtered from the discharged water shall be disposed of to a Contractor
approved disposal area. Filtering should be via a 50 micron.
• Subcontractor shall be responsible for disposing of the test water in a manner that is
acceptable to CONTRACTOR/COMPANY all disposal plans shall be submitted to and
approved by Contractor prior to any disposal activity. This shall be done in a manner that
shall prevent destabilization to surrounding grounds, cause erosion or landslides, cause
pollution or damage to fields under cultivation or interfere with general traffic.
• Hydro test water containing any type of chemical additives will be disposed as per project
requirements. Evaporation pond HDPE liner will be constructed at an approved location
where test water will be released.
• Ponds depth should not exceed 1.5m and must be fenced to prevent unauthorized entry
and to protect from livestock.
• If required tested water will be sampled as per Algerian regulation discharge limits and
report submitted to Contractor.
• SUBCONTRACTOR shall backfill and re-instates any settlement ponds following
evaporation of test water. Location of any settlement ponds shall be outside the pipeline
corridor.
• Bulk dewatering procedure will be used by pushing pigs from the test head at the starting
point to the receiver test head at the section end, immediately after the successful
Page 29 of 63
HYDROTESTING
completion of hydrostatic testing operation in order to transfer the test water to the next
section through by pass piping on the pumping system and repeat the filling sequence.
• Dewatering pigs shall be previously loaded (together with filling pigs) on the test heads
and shall be of a type fitted to perform several runs on both directions (Bi-directional
Pigs) in order to allow a repetitive run if the residual quantity of water will be estimated
important.
19.2 Dewatering Records

During dewatering of the pipeline section, CONTRACTOR shall measure and record the
Following:
➢ For each dewatering run the quantities, pressure and flow-rate records of the
driving medium.
➢ For the second run the dew points of the air (if super dry air is used).
➢ Details of test water used and any other medium received at the receiving end.
19.3 CLEANING
• For each pipeline section, foam swabbing pigs (density between 30 and 50 kg/rn3) shall
be run for drying in combination with power brush hard foam pig runs to the satisfaction
of COMPANY. Foam pig speed shall not exceed 1.2 m/s.
• Final cleaning shall be carried out by cupped brush pigs with bypass plugs open to
create a swirling motion and to blow the loose dust ahead of the pig.
• Pigs shall be propelled with oil-free compressed air dehydrated to a relative humidity
lower than 80% at the pipeline temperature and operational pressure.
• The line is considered clean when the amount of solids displaced from the line by a new
brush pig is not greater than 10 grams per 10 km section of 16” diameter or less pipeline,
or 18 grams per 10km section of 34” diameter pipeline, as quantified and/or in mutual
Agreement with COMPANY.
19.4 Discharges
• SUBCONTRACTOR shall not discharge to the environment any treated water,
chemicals or other fluids used for dewatering or drying of the pipelines.
• SUBCONTRACTOR shall submit procedures for approval by CONTRACTOR /
COMPANY for the collection and transportation of all treated water, associated
chemicals and fluids to approved disposal sites. SUBCONTRACTOR shall demonstrate
in the procedures all contingency plans required for avoidance of any environmental
damage during the works and include all necessary procedures for clean up in the event of
accidental discharge of fluids to the environment.
• SUBCONTRACTOR shall provide complete details of all chemicals, materials,
equipment and vessels relating to potential pollution and toxicity levels, which may be
used for the work.
• SUBCONTRACTOR shall comply with all relevant environmental legislation and
restrictions applicable to performing the works in Algeria.
Page 30 of 63
HYDROTESTING
• SUBCONTRACTOR shall be responsible for obtaining any Government permits /

Approvals for the disposal of chemicals under this procedure. Such permits shall be
appended to the work permit for the start of pipeline dewatering and drying activities.
• SUBCONTRACTOR shall allow sufficient time in his work program for Government
approval of all import and disposal of any chemicals.
20.0 Pipelines Drying
20.1 General
• SUBCONTRACTOR shall proceed with drying the gas pipeline within 24 hours of the
dewatering operation. Super dry air used in pipelines has a dew point of -20°C. At 1.5
bar(a). Once the specified conditions have been reached, SUBCONTRACTOR shall
isolate the pipeline and commence a soak period. The duration of this period shall be at
least four hours to verify compliance with the specified dew point criteria.
• The maximum duration between the completion of a successful Hydrotest and the
completion of the drying operation of any test section shall be 3 months.
• Dew point meters shall have an accuracy of +/- 2°C and shall have a valid calibration
certificate. The dew point meters shall be checked for calibration at 6 monthly intervals
prior to commissioning.
• SUBCONTRACTOR shall provide evidence to substantiate that the pipeline has been
dried to the required dryness level, such as a plot of pressure drop as a function of time
for the entire operation showing steep pressure drop rate during the final draw down
which shall correspond to the calculated rate, or other suitable documentation.
• SUBCONTRACTOR shall place all intermediate block and pipeline valves in the fully
open position ready for introduction of inventory.
20.2 Dry Air

• With this technique moisture present in the pipeline will be evaporated into the pre-dried
air that is passed into the pipeline.
• The pipeline shall initially be pigged with foam swabbing pigs using dry air as the
propellant. The pigging speed shall be between 1.0-1.5 m/s. Pigging shall continue until
the dew point of the drying propellant at the receiving end remains below the required
dew point for at least 2 swabbing pig runs.
• Dry air shall be blown through the pipeline at up to 3 m/s until the specified dew point at
atmospheric pressure at the pipe outlet end is maintained while at least one full line
content is displaced and held for an additional period of 12 hours.
Page 31 of 63
HYDROTESTING
20.3 Preservation after Drying

• Subcontractor shall maintain the tested sections dry, the section ends shall be sealed by a
welded a plate or other suitable type of closure and gauge to be installed end of section
for monitoring 1 bar
• When all tested sections tie-in operation are completed and the line can be inspected as one
single section, the pipeline will be dried to a dew point of -20°C and maintain at 1.5 to 2 bar
above the ambient pressure at any point along the pipeline section, Pressure and temperature of
the medium introduced into the pipeline shall be measured and recorded constantly at the inlet
of the pipeline
20.4 Conditioning and Preservation Records

• The following shall be provided by CONTRACTOR as a minimum:
➢ Product certificates of the medium introduced into the pipeline.
➢ Quantities introduced into and received from the pipeline.
➢ Batch volume and pigging records.
➢ Dew point, temperature, pressure and flow rates of the medium being used to carry out the
preservation.
21.0 DOCUMENTATION Completion File for Hydrotest

• Upon successful completion of the hydrostatic test, the following records shall be
provided for each pipeline:
➢ Completed hydrostatic test forms
➢ Hydrostatic test diagram
➢ Pipeline cleaning acceptance certificate
➢ Pipeline gauging acceptance test
➢ Pipeline flooding, log of operations
➢ Pressure recording calibrations
➢ 24 hours hold periods, log of operations
➢ Hydrostatic test calculations and test evaluation
➢ Records of failures
➢ Pipeline profile showing the evaluations and test sites over the entire length of the test
section noting all instrument and injection connections
➢ Pressure recording charts with appropriate information spelled out
➢ Temperature data
➢ Dead-weight tester log
➢ Theoretical and hand plot pressure-volume & temperature-volume curves
➢ Instrument certificates of accuracy
➢ Additive’s specification, supplier and amounts injected
➢ A chronological record of events which occurred during the test period including comments
on all leaks and failures and their disposition
Page 32 of 63
HYDROTESTING
➢ Logs showing deadweight pressure and ambient temperature readings with date and time
for each reading. Each log sheet shall be signed by ARH, Subcontractor and Contractor's
designated representative
• The following information shall be listed on accompanying forms for each test section:
➢ Location and elevation of test site
➢ Test medium
➢ Date of test, test duration and the minimum test pressure realized
➢ Size, wall thickness, pipe specification, and length of section tested
➢ Serial number of recorders and dates of calibration
➢ Serial number and date of calibration of dead weight tester
➢ Name and signature of person responsible for the test
22.0 Certifications for Activities Performed after Hydrotest

Upon successful completion of the activities to be performed for hydrostatic test (i.e.
dewatering, swabbing, drying, preservation, etc.), a check form reporting the relevant parameters
of the activity shall be filled and signed by subcontractor, CONTRACTOR and COMPANY.
Page 33 of 63
HYDROTESTING
23.0 A list for all lines, BVS station and sections to be tested by this procedure
Approx.
Test
Description From (KM) To (KM) Zone Length Thickness (mm)
Section
(Mtrs)
TS1 Pig Launcher KP 0+000 Ia 320.7 22.3
TS2 KP78+122.74 tie-in Gas Ia 110.22 22.3
TS3 KP00+000 KP19+992 III/Ia 19754.05 13.99/22.3

BVS-
34" Gas 201 KP19+992 KP20+007 Ia 45.00 22.3
Export Pipe
line From TS4 KP20+007 KP39+977 III/Ia 19970.0 13.99/22.3
CPF to Tie-in BVS-
gas 203 KP39+977 KP39+992 Ia 45.00 22.3
TS5 KP39+992 KP58+990.05 III/Ia 18998.5 13.99/22.3

BVS-
202 KP58+990.05 KP59+006 Ia 45.00 22.3
TS6 KP59+006 KP78+122.74 III/Ia/I 19062.07 13.99/22.3/26.46
TS1 Pig Launcher KP 0+000 I 305.26 10.61
TS2 KP80+692,44 tie-in LPG I 106.54 10.61

14" LPG
Export TS3 KP 0+000 KP30+000 I/II 29777.49 7.47/10.61
Pipeline
From CPF to TS4 KP30+000 KP59+009.39 I/II 29009.38 7.47/10.61
Tie-in LPG BVS-
202 KP59+009.39 KP59+024.88 I 14.5 10.61
TS5 KP59+024.88 KP80+692,44 I/II 21586.96 7.47/10.61
TS1 Pig Launcher KP 0+000 I 192.43 6.05

12"
Condensate TS3 KP 0+000 KP30+000 III/I 29890.32 4.59/6.05
Export
TS4 KP30+000 KP59+026.8 III/I 29026.87 4.59/6.05
Pipeline
BVS-
From CPF to
202 KP59+026.8 KP59+042.3 I 15.5 6.05
LEAD Scope
TS5 KP59+042.3 KP89+000 III/I 29957.63 4.59/6.05
24.0 APPENDIX
Page 34 of 63
HYDROTESTING
APPENDIX 1
Page 35 of 63
HYDROTESTING
Page 36 of 63
HYDROTESTING
APPENDIX 2
Page 37 of 63
HYDROTESTING
Page 38 of 63
HYDROTESTING
Page 39 of 63
HYDROTESTING
APPENDIX 4
CLEANING AND GAUGING LAYOUT
Page 40 of 63
HYDROTESTING
APPENDIX 5
Example of Cleaning Heads: Launcher & Receiver for Pipeline
Page 41 of 63
HYDROTESTING
APPENDIX 6
Page 42 of 63
HYDROTESTING
APPENDIX 7
FILLING LAYOUT
Page 43 of 63
HYDROTESTING
APPENDIX 8
PRESSURIZING LAYOUT
Page 44 of 63
HYDROTESTING
APPENDIX 9
Temperature Points along Test Section
Page 45 of 63
HYDROTESTING
APPENDIX 10
DEWATERING LAYOUT
Dewatering Layout
Aie compressor
by pass line
Evaporation Pit
Page 46 of 63
HYDROTESTING
APPENDIX 11
Catalog of Foam Pigs
Page 47 of 63
Pipeline
Engineering
Pipeline Pigs
03914_Pigging Version 1 06/17
1
Pipeline Pigging & Polyurethane Expertise
Design, Development and Supply of Pipeline Pigs
Pipeline Engineering works very closely with clients to design and develop pipeline pigs
which offer high performance solutions for pipelines.
Pipeline pigs available include:

Foam Pigs
Pipeline Spheres
Solid Cast Polyurethane Pigs
Metal Bodied Pigs
Specialty Pigs
We provide precision solutions for customers’ unique requirements,

with a long established reputation for:
Highly engineered, innovative and cost effective pipeline pigging products and services
Turnkey field support for pigging operations and pipeline services
Development and manufacture of pipeline pigs using our range of high grade polyurethanes
2
Pipeline Pigging
and Pipeline Services
Pipeline Engineering, a CIRCOR Energy
company, is a market leading global
provider of products, services and
engineered solutions for the pipeline
pigging and flow assurance industry.
We have particular expertise in the
design and manufacture of pipeline
pigs, which are engineered to
meet the specific requirements
of individual pipelines.
3
Foam Pigs
Pipeline Engineering’s
Foam Pigs are used in
pipelines for liquid removal,
swabbing, drying, product
separation, cleaning and as
part of progressive pipeline
cleaning campaigns.
These foam pigs are ideal
for all pipelines, including
complex piping systems
with tight radii or mitred
bends and pipelines where
significant variations in
internal diameters exist.
Foam Pigs - Types Density Range

Bare Foam Pigs oam pigs are supplied in all industry
F
standard densities.
Single Spiral Foam Pigs
Criss Cross Foam Pigs DENSITY
Criss Cross Abrasive Foam Pigs Low 1-2LBS / CU.FT.
Medium 5-8LBS / CU.FT.
Fully Coated Foam Pigs
High 9-12LBS / CU.FT.
Wire Brush Foam Pigs
Total Wire Brush Foam Pigs
We can adapt our foam pigs for different
operational requirements. Typical
Applications adaptations include:
Proving ouble Dish & Double Nose
D
Swabbing / Wiping Configurations
De-watering Towing and Lifting Loops
Drying Extended Length

Dual Diameter
Sizes Available Product Separation
” to 60” - Foam pigs are

2 Product Removal
supplied for all pipe sizes. Debris Removal
Scraping / Cleaning
4
Solid Cast Polyurethane Pigs
Solid Cast Pigs are
produced from our high
grade all-polyurethane
formulation which gives
them excellent chemical
and abrasion resistance.
Typically, Solid Cast Pigs
are used as sealing pigs
to remove debris and to
keep pipelines clear of
deposit build-up. Solid
Cast Pigs are also used
for batching operations.
They do not require
maintenance and are
designed to be disposable,
making them the preferred
type of pig when metal
bodied pigs are unsuitable.
The flexibility of our Solid
Cast Pigs makes them ideal
for use in complex pipeline
geometries and small
diameter pipelines, typically
found in process plants.
Applications
Product removal
Batching
Hydrostatic testing
Debris removal
Displacement
Commissioning / Decommissioning
Sizes Available
olid cast pigs are supplied for pipeline sizes ranging
S
from 2” to 14” and larger where required
Density
epending upon operational parameters Solid Cast
D
Pigs are supplied as 65A to 75A shore hardness.
5
Metal Bodied Pigs
Pipeline Engineering is
a market leader in the
design and manufacture
of metal bodied pigs, with
our expertise having been
gained over many years
of operating in the Oil and
Gas sector.
In-house expertise means
that we can produce metal
bodied pigs to meet the
specific requirements of
pipelines where they will
be used. This is achieved
by designing these
Metal Bodied Pigs with a
combination of components
including Cups, Discs,
Brushes, Plough Blades,
Gauge Plates, Magnets
and Tracking Equipment.
Our Metal Bodied pigs are Ancillary Equipment

used during all phases of Pig Trolleys
a pipeline life cycle Pig Baskets / Catchers
Precommissioning
Commissioning Metal bodied pigs are designed to
Production be re-usable with replacement cups,
discs and other components available.
Decommissioning Pipeline Engineering also add wear lines
and unique identification numbers to our
discs to indicate when they need replacing,
Metal Bodied Pigs - Types therefore helping to ensure continued
Uni-directional Standard Cup Pigs effective pigging.
Uni-directional Conical Cup Pigs
Bi-directional Disc Pigs Sizes Available
Cleaning Pigs etal Bodied Pigs are available for
M
pipelines ranging from 6” - 60”
Batching / Separation Pigs
Other sizes are available on request
Gauging Pigs
6
Specialty Pigs
Pipeline Engineering
designs and builds specialty
pigs to meet the specific
pigging requirements of
complex and demanding
pipelines. This is achieved
through analysis of the
existing pipeline issues
including assessment of all
pipeline features.
Using this information we
design, prototype, test and
produce bespoke pigs for
specific pipeline pigging
requirements.
Using specialist pigs
developed this way
enables innovative and
highly effective solutions
to be provided, as well as
ensuring safe and efficient
passage of the pig through
a pipeline.
Computer Aided Design Specialty Pigs - Types

State of the art 3D CAD design capability Multi-diameter Pigs
allows us to initially develop specialty
Articulated Pigs
pigs and simulate their functionality.
Isolation Pigs
Cleaning Assessment Pigs - PECAT™
Pig Development and Testing
Specialty pigs are routinely tested in our High Friction Pigs
purpose built test loops. This process Descaling / Dewaxing Pigs
allows analysis of performance against
the predetermined criteria. It also Powder Removal Pigs
allows further design refinement to be Extended Length Pigs
implemented to benefit specialty pig
performance when in fully operational Bespoke Operational Pigs
conditions.
Specialty Pig
Manufacture / Assembly
On completion of successful trials,
specialty pig designs are transferred
to our computer aided manufacturing
system for production and assembly.
7
Pipeline Spheres
range of Pipeline Spheres
are predominantly used
for batching or separation
operations in pipelines and
removal of liquids from
gas pipelines.
Pipeline spheres are
extremely adaptable and
ideal when negotiation
of short radius bends in
pipelines is required.
Applications Ancillary Equipment

Liquid Removal Inflatable Tool Sets
Batching Inflatable Sphere Pumps
Meter Proving Sphere Handling Equipment
Automated Pigging Sphere Transportation System
Sizing Rings
Spheres – Sphere Diameter Tape
Types & Sizes Available Sphere Loading Trolleys
Solid Spheres - 2” to 12”
Inflatable Spheres - 3” and above
8
Pigging Services
To offer the most

appropriate pipeline pigs,
a detailed understanding
of the variables and factors
that affect pigging tool
performance is essential.
provides comprehensive
services related to all
aspects of pipeline
management and integrity.
We provide a range of
services to support pipeline
pigging operations, this
includes management and
implementation of all types
of pipeline pigging, from
simple operational pigging,
right through to complex
bespoke progressive
pigging campaigns.
Our expertise in pipeline
services and pigging services
assures clients that they are
recieving the best suited
solution.
Pipeline Services Pigging Tool Fleet Management:

Pipeline Cleaning Assessment Initial Pig Fleet Assessment
Pipeline Inspection O
ptimization of Customers Pigging Tool Fleet
Pipeline Pigging Reviews Pig Refurbishment Activities
Pipeline Pigging Pigging Equipment Tracking
Pipeline Pig Testing S
upport Customer with Pipeline Pigging
Expertise & Assessments
Specialty Pipeline Pig Design
N
ew Online Pigging Tool Management System
Pipeline Maintenance
Engineering Services
Project Management
9
Focussed on Operational Excellence
Service
A team of service engineers, certified for onshore and offshore operations are
available to support or manage pipeline pigging and flow assurance projects.
These engineering and project support services are available worldwide.
HSE
Pipeline Engineering places safety at the forefront of all our activities. We are
certified to OHSAS 18001 Health & Safety standard. We are also certified to
ISO 14001 Environmental standard.
Quality
All products are designed and manufactured in line with ISO 9001:2008 and
ISO/TS 29001:2007, the Oil & Gas Industry’s Quality Management standard.
Product components are extensively tested during manufacture to ensure
material consistency and performance.
Design
A team of design engineers work very closely with clients to ensure we
develop and provide the most appropriate pipeline pigs for the service that
they are required to perform.
Manufacture
Our full range of pipeline pigs are manufactured at our U.K. manufacturing
centre which includes ‘state of the art’ computer controlled rapid moulding
machines, mixing and dispensing machines and tooling equipment. Foam
Pigs are also manufactured at our U.A.E. Base, as well as component
fabrication and pipeline pig assembly.
10
CIRCOR Energy is a
global manufacturer and
distributor of engineered
valve and pipeline solutions,
with thousands of customers
in countries worldwide.
We provide precision solutions for

customers’ unique requirements,
with a strong reputation built upon:
ighly engineered, innovative and

H
cost effective products and services.
est-in-class applications
B
knowledge on design, systems
layout and regulatory compliance.
igh availability approach to

H
partnering with customers.
urn-key field support for

T
construction, installation, and
commissioning of a range of systems.
anufacturing plants strategically

M
located throughout the world,
supported by a global network of
sales and service, and distributor
partner offices.
Specializing in valves and pipeline

solutions, Circor Energy offers our
customers:
comprehensive portfolio
A
of thousands of products.
C
ustom design, project management
and engineering services.
culture of continuous
A
improvement that demands
excellence in product performance,
reliability and durability.
www.circorenergy.com
11
CIRCOR is a market-leading, global provider of integrated flow control solutions, specializing
in the manufacture of highly engineered valves, instrumentation, pipeline products and
services, and associated products, for critical and severe service applications in the
oil and gas, power generation, process, aerospace, and defense industries.
Excellence In Flow Control

Asia | Europe | Middle East | North America | South America
Pipeline Engineering CIRCOR Energy | CIRCOR Energy (Sales Hub)

(Head Office) Pipeline Engineering
PO Box 263202, Suite 2018
Gatherley Road 945 Bunker Hill Road Floor 20, Tower A
Catterick Bridge Suite 650 JAFZA One
Richmond, North Yorkshire Houston, Texas 77024 USA Jebel Ali Free Zone
DL10 7JQ United Kingdom Sheikh Zayed Road
PEsales@circor.com
Dubai
Tel: +44 (0) 1748 813 000
United Arab Emirates
Fax: +44 (0) 1748 813 501
Pipeline Engineering PEsales@circor.com
PEsales@circor.com
Circor Middle East (FZE)
Licence No: 124005
CIRCOR Pipeline, Inc. PO Box 263202
Unit FZS5 AA01 Aberdeen Service Center
16315 Market Street
Jebel Ali Free Zone Minto Avenue
Channelview, Texas 77530 USA
Dubai, UAE Aberdeen AB12 3LU
PEsales@circor.com
Tel: +971 4 886 6128 Tel: +44 (0) 1224 879 302
Fax: +971 4 886 6129 Fax: +44 (0) 1224 895 683
PEsales@circor.com
PEmiddleeast@circor.com
www.circorenergy.com
©2017 CIRCOR. All rights reserved.
03914_CRE_PiggingBro 08 2017
PIPELINE ENGINEERING BROCHURE
Foam Pigs
Type Type Density
HPB Light
(HydroPig Bare) (1-2lb/cubic foot)
HPCC Light
(HydroPig Criss Cross) (1-2lb/cubic foot)
HPSC Light
(HydroPig Criss Cross Silicon Carbide) (1-2lb/cubic foot)
HPSS Light
(HydroPig Spiral) (1-2lb/cubic foot)
HPWB Light
(HydroPig Wire Brush) (1-2lb/cubic foot)
RB Medium
(Red Series Bare) (5-8lb/cubic foot)
RCC Medium
(Red Series Criss Cross) (5-8lb/cubic foot)
RWB Medium
(Red Series Criss Cross Wire Brush) (5-8lb/cubic foot)
RSC Medium
(Red Series Criss Cross Silicon Carbide) (5-8lb/cubic foot)
RSS Medium
(Red Series Spiral) (5-8lb/cubic foot)
CB Heavy
(Crimson Series Bare) (8-10lb/cubic foot)
CCC Heavy
(Crimson Series Criss Cross) (8-10lb/cubic foot)
CSS Heavy
(Crimson Series Spiral) (8-10lb/cubic foot)
CWB Heavy
(Crimson Series Criss Cross Wire Brush) (8-10lb/cubic foot)
CSC Heavy
(Crimson Criss Cross Silicon Carbide) (8-10lb/cubic foot)
-1-
PIPELINE ENGINEERING BROCHURE
General function and application:

For liquid removal, swabbing, drying, product separation and many cleaning duties. They are
specifically suited to pipelines and piping systems with very tight radius or mitred bends, and where
significant reductions in internal diameter exist.
Foam pig sizes
HPB Oversized between 1” - 2” of the pipe od
HPCC, HPSS, HPSC, HPWB Oversized between 1% - 2% of the pipe id.
RB, RCC, RSS, RSC, RWB Oversized between 2% - 5% of the pipe id.
CB, CCC, CSS, CSC, CWB Oversized between 2% - 5% of the pipe id.
Foam pig dimensions

Light density foams have an overall length of 1.5 times the nominal diameter and a sealing length of
1.25 times the nominal diameter. Medium and heavy density foams have an overall length of 2 times
the nominal diameter and a sealing length of 1.5 times the nominal diameter.
Foam pig options

Foam pigs can be adapted in the following ways:
Gauge plate(s) Extra long
Transmitter cavity Jetting hole
Tow and lifting loops
Double dish (bi-directional) Spring insert
Double nose (bi-directional) Feed pipe for gas injection
Extra short Studs
-2-
2
2

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AIN TSILA DEVELOPMENT

Main EPC Contract

SUB-CONTRACTOR COMMENTS RESPONSE SHEET

Subcontract No : JI-2045/07-002A Sub-Contractor Transmittal No. : TR-LEAD-PIUL-0110 Date :25-03-2021

Document Title : QCP FOR CLEANING, GAUGING AND HYDROTESTING (P-QAC-PRO-200-38257)

1.1 Item No. 15.2 PRESSURIZATION

SUB-CONTRACTOR SIGN OFF

Prepared By: Emad Kamel COMPANY SIGN OFF

Approved By: John Younan Ajay Kumar

Main EPC Contract

PIUL Approval Code/Name/Signature

1 Accepted without comments

3 Not Accepted. Revise and

QCP FOR CLEANING, GAUGING AND HYDROTESTING

Re-issued for Review

Document No.:P-QAC-PRO-200-38257 Rev C

B Re-issued for Review and comments

C Re-issued for Review and comments

This revision checked and signed off by:

Khalil Tarboush Project Director

Viswanath Sreepada QA/QC Manager

Emad Kamel Site QA/QC Manager

Ossama Abdelaziz Site Manager

John Younan Project Manager

Document No.:P-QAC-PRO-200-38257 Rev C

2.0 SCOPE .............................................................................................. 5

3.0 PROJECT OVERVIEW ............................................................................ 5

4.0 REFERENCES ..................................................................................... 5

5.0 TERMINOLOGY .................................................................................... 6

6.0 CONFLICTS, OMISSIONS, AND ALTERNATIVES ........................................... 7

7.0 COMPANIES WITNESSING .......................................................................... 7

8.0 PRE-CONDITION .................................................................................... 7

9.0 TEST PACKAGE DOCUMENTS ..................................................................... 7

10.0 PERSONNEL AND EQUIPMENT .................................................................... 7

11.0 PERSONNEL ......................................................................................... 7

12.0 TESTING MATERIAL, EQUIPMENT AND INSTRUMENT ......................................... 8

13.0 LIST OF EQUIPMENT ............................................................................... 9

14.0 CLEANING, GAUGING AND LINE FLOODING ................................................... 11

15.0 PRE-TEST REQUIREMENTS ....................................................................... 18

Document No.:P-QAC-PRO-200-38257 Rev C

16.0 HYDROSTATIC PRESSURE TEST ................................................................. 23

17.0 ACCEPTANCE CRITERIA .......................................................................... 25

18.0 POST-TEST REQUIREMENTS ..................................................................... 26

19.0 PIPELINE DEWATERING &CLEANING ........................................................... 28

20.0 PIPELINES DRYING ................................................................................ 31

21.0 DOCUMENTATION COMPLETION FILE FOR HYDROTEST .................................... 32

22.0 CERTIFICATIONS FOR ACTIVITIES PERFORMED AFTER HYDROTEST ...................... 33

24.0 APPENDIX ........................................................................................... 34

Document No.:P-QAC-PRO-200-38257 Rev C

3.0 PROJECT OVERVIEW

Document No.:P-QAC-PRO-200-38257 Rev C

A-PLE-SPE-200-30009 : Pipeline material specification

ASME B31.8 :Gas Transmission and Distribution Piping Systems

ASME IX : ASME Boiler and Pressure Vessel Code - Section IX:

API- PR 110 :RECOMMENDED PRACTICE FOR THE PRESSURE

Document No.:P-QAC-PRO-200-38257 Rev C

γ : Volumetric expansion coefficient of water [°C-1]

6.0 Conflicts, omissions, and alternatives

7.0 Companies witnessing