The Shell Petroleum Development Company of Nigeria Ltd

Originator Prime Sources Limited (PSL)

Project Gbaran P h a s e 3 B - U Z U with C P F U p g r a d e -

Package 1 Pipelines

Document Title Procedures for Pre-commissioning & Commissioning.

Document Number:

DCAF Control ID

Security Classification Restricted

Owning Discipline LA Pipelines.

Month/Year May/2023

Proprietary Information: This document contains proprietary information and may not be partly or
wholly reproduced without prior written permission from Shell Petroleum Development Company.
Revision Date Description Originator Checker Approver

D01 21/10/2022 Issued for Review Peter.S Iyere

Document title: Procedures for Hydrostatic Testing Document Number: Restricted
and Pre-commissioning Report

ADDITIONAL AGREEMENT/APPROVAL RECORD

Party Ref Ind Name Sign Date

Revision Philosophy
All revisions for review will be issued at R01, with subsequent R02, R03, etc as required.
All revisions approved for issue or design will be issued at A01, with subsequent A02, A03, etc
as required.
Documents approved for Construction will be issued at C01, C02, and C03 respectively.
Documents or drawings revised as “As built” will be issued as Z01, Z02 Z03 etc.
Narrative sections revised from previous approved issues are to be noted in the table below
and/or highlighted in the RH margin (using the appropriate revision status) thus: | A02
Previous revision highlighting to be removed at subsequent issues.
Drawings/diagrams revised from previous approved issues are highlighted by 'clouding' the
affected areas and the use of a triangle containing the revision status.

Revision History

Revision No. Date of issue Reason for change

D01 10/06/2022 Issued for Review

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CONTENTS

1. INTRODUCTION 6

1.1. Background 6

1.2. Project Overview 6

2. scope 8

2.1. PURPOSE OF THIS DOCUMENT 8

3. DEFINITIONS AND ABBREVIATIONS 9

3.1. Definitions And Abbreviations 9

3.1. Definitions 11

3.2. Terms, Explanation/Definitions 12

3.3 ABBREVIATIONS 12

3.4. UNITS 12

4.0. CODES, STANDARDS & BASIC REFERENCE DOCUMENTS 12

4.1. Documents / Number 12

4.2. industry Codes and Standards 13

4.2.1 Number / Documents 13

4.3. Conflicting Requirements 13

4.4. Specific Definition 13

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5.0. Responsibilities and Authorities 14

5.1. Pre-commissioning Project Organization 14

6. Hydrostatic Pressure Testing & Pre-commissioning 15

6.1. SCOPE 16

6.2. Table 6-2; Pipeline Pig Launcher/Receiver Location 16

6.3 LINE-FILL WATER 17

6.4. DISPOSAL OF LINE-FILL WATER 17

7. Procedure For Pressure Testing & Pre-commissioning 17

7.1. Purpose 17

7.2. TEMPORARY TEST END AND PIG TRAPS 18

7.3. CLEANING 18

7.3.1 Figure-1: Pig Arrangement For Gauging/ Filling Operation 19

7.3.2 GAUGING AND FILLING 20

7.3.3 TABLE 7-1: Gauge Plate Diameter Calculation Results 20

7.3.4 Figure 7-2: Pig Train Arrangement For Cleaning Operation 22

.
7.3.5 TABLE 7-2: PIG TO PIG LENGTH 22

8. BASELINE INTEGRITY SURVEY (Caliper Pigging) 23

8.1. INTRODUCTION 23

8.2. FINAL REPORTS 23

8.3. Hydrotest Pre-Test Check 24

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8.4. Test Section Elevation Calculations 25

8. 5 Temperature Stabilization / Pressurization 25

8.6. HYDROSTATIC PRESURE TEST 25

8.6.1. DURATION 25

8.6.2. STRENGTH TEST 26

8.6.3. LEAK TIGHTNESS TEST 26

8.6.4. ACCEPTANCE CRITERIA 26

8.6.5 DEPRESSURIZATION AND DEWATERING 26

8.6.5.1 DEPRESSURIZATION 27

8.6.5.2 DEWATERING 28

9. PRE-DRYING CHECK 28

9.1. DRYING 28

9.2. LAY-UP AND PRESAVATION 29

9.3. DOCUMENTATION 29

10. SAFETY 30

10.1 SAFETY SYSTEMS 31

10.2. CHECK POINT LIST 32

10.2.1 PRE-COMMISSIONING CHECK LIST 33

11. UTILITIES 33

11.1 ELECTRICAL SYSTEMS 33

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11.1.2 CATHODIC PROTECTION AND EARTHING 34

12. PRE-COMMISSIONING AND START-UP OPERATION 34

12.1 GENERAL 34

12.2. PRE-COMMISSIONING 34

12.2.1 SCOPE 34

12.2.2 PURPOSE 35

12.3 METHOLOGY FOR PRE-COMMISSIONING 35

12.3.1 Figure 12.1: Pre-commissioning and C0mmissioning Map 36 3

12.4 PRE-COMMISSIONING ACTIVITIES 36

12.5 COMMISSIONING TEAM 36

12.5.1 Responsibility of Project & Construction Group 36

12.5.2 Responsibility of O & M Group 37

12.5.3 Responsibility of Fire & Safety Rep. 37

12.6 SEQUENCE OF OPERATION 37

12.7 RECOVERY PIG 37

12.8 ACCEPTANCE CRITERIA 37

12.9 CERTIFICATES 37

12.10 READY FOR COMMISSIONING CHECK LIST 37

12.10.1 PRE-COMMISSIONING CHECK LIST 37

12.10.2 READY FOR COMMISSIONING 38

16. APPENDICES

APPENDIX A: PRESSURE TEST FLOW CHART AND SEQUENCE 38

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APPENDIX B: GRAPHICAL REPRESENTATION OF PRESSURE BUILD UP AND 39

TEST TIME

APPENDIX C : HYDROTEST RECORD DOCUMENTS 40

APPENDIX D: DETAILS OF TEMPORARY PIG TRAPS 51

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1. INTRODUCTION
1.1. Background

The Gbaran Integrated Oil and Gas node, situated in the seasonal fresh-water swamp covers an area

approximately 3,000 km2 spread across Bayelsa, Rivers, and Imo States in the eastern part of the Niger
Delta. It is a major oil and gas production hub in SPDC, covering twelve producing fields – Gbaran,
Etelebou, KoloCreek, Adibawa, Adibawa NE, Ahia, Assa, Enwhe, Mini-Nta, Obele, Rumuekpe, and Ubie –
in Oil Mining Leases (OMLs) 16, 17, 21, 22, 27 and 28. The geographic centre of the Gbaran/Ubie node
is located at Gbaran, 100 km NW of Port Harcourt and 40 km NE of Yenagoa.

The Gbaran-Ubie Central Processing Facility (CPF) came on stream in year 2010. It currently has a Gas
production capacity of 1.25 Bscfd and oil production capacity of 120 Mbpd. There are remote field manifold
locations at Zarama, Kolocreek, Gbaran and Koroama for NAG well manifolds. The Gbaran CPF gas
production capacity was debottlenecked to 1.2 Bscfd in 2013 and then 1.25 Bscfd in 2017. Current project
scope includes a CPF capacity upgrade to ca 1.4 Bscfd.

Uzu is a green field, but near Zarama, a producing field and 15 km NE of Gbaran CPF. Uzu field was
discovered in 1971 and located in OML 28. Uzu appraisal well was drilled from Zarama location (tagged
ZARA015 well) thereby providing opportunity to utilize existing facilities and ROWs in the Zarama area.
1.2. Project Overview

SPDC JV with Shell as operator of OMLs 16, 17, 21, 22, 27 and 28 on behalf of the joint venture partners,
embarked on the Gbaran Phase 3B - Uzu with CPF Upgrade project which aims to develop 815 Bscf (UR)
of gas and 11.5 MMbbls (UR) of oil & condensate to meet SPDC’s commitment to sustain NLNG gas
supply obligation and grow oil production.

The project scope includes infill drilling involving 5 NAG wells and 1 oil well, flowlines, test line and a
NAG bulk line from the Uzu field to the Gbaran CPF. The facility upgrade scope at the Gbaran Central
Processing Facility include debottlenecking of the existing 2 dehydration trains to accommodate
additional 200 MMscfd from the EPC for Gbaran Phase 3b - UZU with CPF Upgrade Project.

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All six wells to be drilled as part of this development will be from two existing Zarama 15 and Zarama 08-11
NAG well locations. Three NAG wells will be drilled, and one existing well will be completed at Zarama 15
location. At the Zar 8-11 location, 1 NAG well and 1 Oil well will be drilled.
Extension of Zarama 15 location will be required to accommodate expansion of the existing cellar for three
more wells (with provision for relief well) and a new manifold location, while free slots at Zarama 08-11
location will be used for the 1 NAG and 1 Oil well drilling. Four NAG wells will be hooked up to the new Uzu-1
manifold (adjacent to Zarama 15 well location) via 6” 1500# NAG DSS flow lines and bulk flowed via new 16”
x10 km 1500# CS bulkline to a new Uzu-2 manifold at the Zarama NAG manifold location. The new NAG well
at Zarama 08-11 location will be hooked up to the new Uzu-2 manifold via new 6” 1500# DSS flowline.

The Uzu NAG fluids will be evacuated via the existing 20-inch Zarama bulkline to the Koroama Slug catcher at
Gbaran CPF. A connection will be provided from the new Uzu-2 manifold (at Zarama NAG manifold location)
to the existing Zarama bulkline. The existing Zarama NAG wells will be evacuated to the CPF via a new 16” x
10 km 1500# CS bulkline connected to the Zarama slug catcher via the LP (compression) manifold.

One oil well will also be drilled, completed, and tied in to existing 16” x 17.5 km Zarama Oil bulkline and 6” x
17.5 km Zarama test line via new 6” 1500# CS Oil and test flowlines. The connection of the new oil and test
line to the existing oil and test lines shall be via barred tees.

The CPF upgrade scope shall include debottlenecking of the existing dehydration trains 1 & 2 packages
respectively in order to increase overall plant capacity to ca.1.4 Bscfd. The dry gas outlet from gas processing
train is sent to dedicated metering train before exporting it.
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Fig1 Schematic of the Uzu With CPF Upgrade Project locations and facilities.

2. SCOPE OF WORK

The Hydrostatic Pressure Test, Pre-commissioning, and commissioning activities of the EPC FOR
GBARAN PHASE 3B-UZU WITH CPF UPGRADE-PACKAGR1 Pipeline project are covered by
these procedures.

The scope of the Procedures is to describe all the activities following the completion of construction
works and prior to start-up of the pipeline system normal operation. The system initial conditions are the
following:

1. pipeline and piping erection completed,

2. CP and all Instruments are completely installed.

The first stages of activities, which start after the completion of construction works, are as follows:

 Pipeline flushing, pigging and, cleaning, and Gauging

 Line Filling and Hydrostatic Pressure Test
 Leak Test
 Dewatering and drying.

CONTRACTOR shall supply all material and equipment for Pressure Test, cleaning, gauging, dewatering,
and commissioning of the Gas pipelines.

PSL shall ensure all equipment and instruments are pre-mobbed, properly maintained, are in full working
order and are suitable for intended use.
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This scope of works shall be performed in conjunction with the following assignments:
• Confirm testing and pre-commissioning methods proposed in Detailed Engineering Design (DED) or provide
alternatives for approval by PRINCIPAL.
• Perform all works necessary for the completion of these activities.
• Provide all equipment and material requisition and procurement including delivery to sites, and incidental
matters relating to temporary works.
• Supply all certificates, qualifications, calculations, reports, drawings, and
documentation required by PRINCIPAL COMPANY.
• Carry out all construction activities required for the performance of testing and precommissioning works. These
works shall include but not limited to the following:
cleaning, gauging, flooding, testing, dewatering, and conditioning of the
new pipelines.
• Carry out repairs to damaged pipelines caused by failure to properly carry out work.
• Repairs and re-test in case of leaks/failure of test.
• Disposal of water in a safe manner and to a safe location as agreed by PRINCIPAL COMPANY.
The main bulklines cleaning and testing activities are summarised in Table below:
Table 1-1: Scope Limit for Pipeline Cleaning / Pigging Activities.
Pipeline Description Launching Receiving Location Distance
Location (km)
16" x 8 km Zarama 15 Well to Zarama 15 Well Zarama NAG 7.9
Zarama NAG MFD CS bulkline Location Manifold
16” x 10 km Zarama NAG Zarama NAG Gbaran CPF 10.6
MFD to Gbaran CPF CS Manifold
bulkline
6” x 0.5 km 1500# CS Oil 16” x 17.5 km Zarama Oil Bulkline 0.5
flowline to the Gbaran CPF Zarama Oil bulkline
location C/S bulk line.

6” x 0.5 km 1500# CS oil test insulating joint at existing 6” x 17.5 km 0.5

line the well site Zarama oil test line.

2.1 PURPOSE OF THIS DOCUMENT

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The purpose of this document is to define the Technical instructions steps based on COMPANY specifications
and global standards in implementing the scope of activities above required for the pre-commissioning, testing,
and commissioning of the new constructed pipeline and telecoms/electrical cables installed.

3. DEFINITIONS AND ABBREVIATIONS

3.1. Definitions

The following definitions & abbreviations are used extensively throughout this document.

3.2 Term Explanation/Definition

COMPANY/PRINCIPAL Shell Petroleum Development Company of Nigeria Limited

PROJECT Gbaran Phase 3B – UZU With CPF Upgrade- Package 1

Pipelines

CONTRACTOR/
MANUFACTURERE /
SUPPLIER/VENDOR: The part y that carries out all or p a r t of the de s i gn ,
engineering, procurement, construction, commissioning, or
management of the PROJECT.

SUBCONTRACTOR The party or entity which CONTRACTOR has contracted part of

the WORK, providing service(s) to CONTRACTOR.

Vendor The party which supplies or manufactures equipment required

to perform the duties specified herein and, on the datasheets, and
drawings.

Pipeline A system of pipes and other components used to transport

hydrocarbon between plants. A pipeline extends from pig trap to pig
trap (including the pig traps), or, if no pig trap is fitted, to the first
isolation valve within the plant.

Bulkline A pipeline transporting un-processed hydrocarbon from a remote

gathering point (manifold) to a processing plant.

Flowline A pipeline transporting un-processed hydrocarbon from a well head

to a remote gathering point (manifold) or
May Indicates a possible course of action.

Must/Shall Indicates a mandatory requirement.

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Should Indicates a preferred course of action or strongly
recommended to comply with the requirement of this
procedure.

3.3. Abbreviations

API American Petroleum Institute

Bpd Barrels per day
Bscfd Billion Standard Cubic Foot per Day
CHEM Chemical
CPF Central Processing Facility
CS Carbon Steel
CUM Cumulative
DEP Design and Engineering Practice
ENGR Engineer
EPC Engineering-Procurement-Construction
HSE Health Safety and Environment
ID Internal Diameter
INJ Injection
ISO International Organization for Standardization
MAOP Maximum Allowable Operating
MFD Manifold
MGR Manager
Mscfd Million standard cubic feet per day
NAG Non-Associated Gas
NLNG Nigerian Liquefied Natural Gas
NUPRC Nigerian Upstream Petroleum Regulatory Commission
OD Outer Diameter
PSL Prime Sources Limited
PTR Pressure Test Result
QA/QC Quality Assurance/Quality Control
REV Revision
ROW Right of Way
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SI International System of Units

SMYS Specified Minimum Yield Strength

SPDC Shell Petroleum Development Company of Nigeria Ltd
THK Thickness
TP Test Pressure

3.4. Units

The units shall generally be S.I units, though diameters have been indicated in inches with common industry
practice.

4. CODES STANDARDS AND BASIC REFERENCED DOCUMENTS

4.1. General
Design, fabrication, and installation work shall be governed by the following regulations, codes, and standards:
4’1 Document Number
DEP 31.40.40.38-Gen Hydrostatic Pressure Testing of New Pipelines

DEP 31.40.50.30-Gen Pre-commissioning of Pipelines

ISO 14001 requirements Dewatering & Environment

DEP 31.40.00.10 – Gen. Pipeline Engineering (Amendment/Supplement to ISO

13623:2009)
DEP 31.40.60.11-Gen. Pipeline leak detection

UZU-CW348814-GEN-LA7880-00008: Specification for Hydrostatic Testing and Pre-

Commissioning.
UZU-CW348814-GEN-LA5507-0001 : Pipeline Design Basis.

DEP 61.40.20.30-Gen. Welding of pipelines and related facilities

4.2. Industry Codes and Standards

4.2.1 Number Document

API RP 1110 Recommended Practice for the Pressure Testing of Steel Pipelines for
the Transportation of Gas, Petroleum Gas, Hazardous Liquids, Highly
Volatile Liquids, or Carbon Dioxide
API Spec 5L Specification for Line Pipe
API STD 1104 Welding of Pipelines and Related Facilities
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ASME B31.3 Process Piping
ASME B31.4 Pipeline Transportation Systems for Liquids and Slurries
ASME B31.8 Gas Transmission and Distribution Piping Systems

ISO 9000 / 9001 Quality Systems

ISO 13623 Petroleum and Natural Gas Industries – Gas Transportation System
ISO 45001 Occupational Health and Safety Management Systems

4.3. Conflicting Requirement

For areas of conflict between relevant documentation, the following order of precedence shall
apply:

• Nigerian local laws and regulations

• Requisition for Quotation
• Equipment Datasheets
• Referenced Project Specifications/Documents
• Industry Codes and Standards

4.4 Specific definitions

Assembly An arrangement of pipes/components such as a crossing, pig trap, block

valve station or riser.

Commissioning Activity where the fluid to be transported is initially introduced into the
pipeline.

Test equipment All temporary fittings, piping, test heads, pumps, compressors, pigs,
materials, and consumables used for the pressure testing operations and
pre-commissioning of the pipeline.

Final cleaning cleaning of the pipeline and its components beyond that carried out as
part of the hydrostatic testing activities specified in DEP 31.40.40.38-
Gen.

Fluid Fluid to be conveyed in the pipeline during operation.

Golden weld Weld that is not subjected to a hydrostatic pressure test and is therefore
subjected to additional non-destructive inspection.
.
Hydrostatic pressure test That part of the testing operations where the pipeline is pressurized. The
hydrostatic pressure test includes a strength test and a leak tightness test.

Isolation valve Valve used for interrupting the flow or isolating one section of a pipeline
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from an adjacent section or a facility connected to the pipeline. An
isolation valve is normally either fully opened or fully closed. Also
referred to as a block valve.

Key personnel Personnel appointed and specially named by the CONTRACTOR to be

in full charge of all pre-commissioning operations.

Line-fill water Water, chemically treated if required, used as medium to fill and
pressurize the test section.

Pipeline Section of a system of pipes and other components or the entire system
used for the transport of fluids, between plants. A pipeline extends from
pig trap to pig trap (including the pig traps), or, if no pig trap is fitted, to
the first isolation valve within the plant.
Pre-commissioning Series of activities that can include freshwater swabbing, dewatering,
final cleaning and drying to prepare the pipeline internally for
commissioning.

Pre-commissioning plan CONTRACTOR's plan for the preparation and execution of pre-
commissioning activities including the equipment to be used.

Pre-test A hydrostatic pressure test is carried out on part or all of an Assembly

prior to final installation.

Shore (A) A measure of hardness for rubbers/elastomers. The higher the number
the greater the resistance to indentation.

Sleeping pig Pig present in the pipeline at the commencement of pre-commissioning.

Test point The primary point of pressure measurement of a test section. This is
normally at the point of pressurization.

Test pressure The pressure at which the pipeline is tested for strength.

Test section A section of the pipeline or the entire pipeline which is subject to a
hydrostatic pressure test.

5. RESPONSIBILITIES AND AUTHORITIES

1. Construction Manager Responsible for the practical management and planning of
every stage of a construction project
2. Site Manager Responsible for the coordination of all the site Personnel to
achieve the desired Project objective
3. Site Engineer  Offering technical advice on a construction site for
subcontractors, craftspeople, and operatives
 Managing the site and select parts of construction projects
day-to-day.
 Overseeing construction work and ensuring the quality of
the work is maintained.
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 Ensuring the plans, drawings and quantities are accurate.
 Maintain the latest revision of approved documents are
available on site for construction.
 Capturing of daily progress data for reporting

4. Commissioning Lead.  The Commissioning Engineer shall have direct

site responsibility for a safe and successful
execution of this document.
 He shall be responsible for all test preparation
activities, calculations, and documentation,
including testing and dewatering operations.
 He shall liaise with the Project Manager in any
area of technical support.
5. HSE Supervisor Responsible for carrying-out all the required HSE-related
pre-inspections, administering safety indoctrination,
enforcing safety regulations, and completing the associated
inspection documentation
6. Hydrotest Engineer The test supervisor shall be in full charge of all activities
related to the hydrostatic testing operations.
The test supervisor shall prepare a procedure for all pressure
testing operations, including a statement of the responsibilities
of his subordinates.
Responsible for assuring that the work activities are
performed within the specified requirements.

7. QA/QC Representative Responsible for performing the required inspections and

completing the associated inspection documentation

8. HSE Officer The implementation of all safety measures in accordance

with the HSE plan and that the whole work force is aware
of its proper implementation.
Inspection of all the site activities and training personnel
in accident prevention and its proper reporting to the
construction manager and the project manager.
The site is maintained in a clean and tidy manner.
Ensure only trained persons shall operate the power tools.
Ensure all concerned personals shall use pipe and all other
items as required.
Ensure adequate lighting is provided in the working area at
night-time.
Ensure high risk elevated areas are provided is barricade, tape,
safety nets.
Ensure service area/inspection area openings are provided
with barricade, tape, and safety nets.
Always ensure safe access to sitework.
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5.1 PRE-COMMISSIONING PROJECT ORGANOGRAM

SPDC

PSL PROJECT MANAGER

CONSTRUCTION MANAGER

COMMISSIONING ENGINEER

PRE-COMMISSIONING TEAM

6. HYDROSTATIC PRESSURE TEST AND PRECOMMISSIONING

6.1 General
The pressure testing, pre-commissioning and commissioning activities steps is summarized in table below:
Fabrication and Certification of Hydrotest Headers
Water filling
A Hydrotest of Pipeline
Pressurization, Stabilization & Depress.
Depressurization
Dewatering

6. Pre-commissioning & Commissioning

No Activity Description Work Steps
. Swabbing
Drying
Pre-Commissioning (Pipelines)
Nitrogen Purging
A Punch List Closed
PSUA Completed
Red line Mark-up Drawings Issued
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Punch List Closed
Pre-Commissioning
(Cable Lay) PSUA Completed
Red line Mark-up Drawings Issued
RFC Achieved
B Commissioning (Pipelines) Introduction of Hydrocarbon
Commissioning (Cable Lay) Cable Energization

C Commissioning (General) Reliability Test Run to be measured as per daily completion up to

90 days

6.2 SCOPE
This section covers the pressure testing and pre-commissioning of the EPC for Gbaran phase 3B-Uzu with
CPF upgrade pipelines viz. (the 16 inches X 10km Uzaram NAG MFD to Gbaran CPF and 16 inches x
8km Zarama-15 well location to Zarama NAG MFD bulk lines) and (2nos) 6 inches x 0.5 km flowlines to
existing 6 inches x 17.5 km test line; and together with the associated manifold piping and major creeks
and road crossings pipelines.
The pipeline and associated piping of the 16-inch diameter by 10km and 16-inches x 8km, with estimated
volume shown in Table 1-1: Pig to Pig Length shall be hydrotested by pumping filtered river water from
ZARAMA15 (UZU-1) end through the Permanent pig trap/ or TEMPORARAY PIG TRAP at UZU-1
NAG PIG LAUNCHER (A-100) to the permanent pig trap/ or Temporary PIG at Zarama NAG MF (UZU
-2). All line-fill water analysis and compliance shall be in line with DEP 31.40.40.38. Gen (section 4).
Pre-commissioning activities shall be executed in the sequence defined in the flowchart in APPENDIX A:
PRESSURE TEST FLOW CHART AND SEQUENCE unless otherwise specified in this Procedure.
Before testing commences, all documentation for the pipelines, piping and major river crossings shall be
checked and accepted by the COMPANY representative. A signed off checklist by the COMPANY
representative accepting the under listed documents shall be required. The documentation shall include
but not limited to, the following Quality Control Records, which shall be incorporated in the ‘’As Built’’
documentation:

1. Pipe and material traceability records and certificates (including the new gaskets, bolts, and nuts),
approved WPS and welders certificate.
2. Weld map for the entire line
3. Radiographic reports
4. Field coating reports
5. Profiles for each crossing
6. Pre-commissioning checks
7. Pipeline mechanical completion dossier
8. Test packs
9. Pipeline material certificates/records
10. Pre-commissioning and commissioning procedures
11. As built drawings
12. List of nominated personnel who are in charge to supervise the pressure testing activities, their
responsibilities, and authorities.
13. Documentation confirming the acceptance of welding.
14. Welding inspection reports
15. Isometric drawings
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16. Details of the line-fill water including the source
17. Pre-pressure checklist filled out.
18. Identification of potential safety and environmental hazards, including the necessary measures and
emergency plans
19. General map of testing section and testing equipment layout.
20. Pre-mob certificates of Test equipment, Hoses and Pressurizing pumps – Test blinds, High Pressure
test header and relief valves.

Prior to any hydrostatic test, CONTRACTOR shall be notified in advance and the hydrotest shall
commence only after obtaining signature on system check sheets of - A & B of the system completion
management plan and after mechanical clearance has been obtained.
The Equipment I Instruments to be used for p e r f o r m i n g the work s ha l l include, but not limited to
the following:
 Pigs for filling, cleaning, and gauging: cleaning pigs with steel wire brushes .
 Four cup batching pigs.
 Gauging pig with gauge plate diameter equal to 95% of heavy wall pipe section.
 Positive displacement pump equipped with a stroke counter and capable of exceeding the
maximum test pressure by at least 20 barg.
 Positive displacement meters to measure the volume of water used for filling the line having
valid calibration certificate.
 Portable tank of sufficient size to provide continuous supply of water to the pump during
pressurization.
 Bourdon pressure gauges of suitable pressure range and accuracy with valid calibration
certificate .
 Dead weight tester with an accuracy of 0.01 bar, measuring in increments of 0.05 bar and
with a valid calibration certificate .
 Temperature recorders with valid calibration certificate.
 Thermocouples with valid calibration certificate.
 Laboratory thermometers 0°C to 60°C range and accuracy ± o . 1 ° c .
 Measuring cylinder to check quantity of water during air volume calculation
 Injection facilities to inject additives in the test medium in the required proportion .
 Communication equipment suitable for continuous connection between the two ends .
 Temporary test headers fabricated in conformity with ASME section VIII, division 2 with
particular reference to appendix 1 8 and 1 9 having sufficient length of accommodate the required
number of pigs. The header shall also have provision for pig stopper.
 Piping and valve arrangement for launching and receiving of pigs independently.
6.2 Table 6-2: Pipeline Pig Launcher/Receiver Location
Line Description 16” x 8 km Bulkline 16” x 10 km Pipeline
Pig Launcher Location Zarama 15 Location Zarama NAG Manifold
Pig Receiver Location Zarama NAG Manifold Gbaran CPF
Pipeline Length (m) 7876.10 10596.92
NOTE 1: The actual length of pipeline length shall be based on lengths established in Alignment sheets from
Zarama 15 location to Zarama NAG Manifold, UZU-CW348814- GBRG1-LA2373-00001 and Alignment
sheets from Zarama NAG Manifold to Gbaran CPF, UZU-CW348814-GBRG2-LA2373-00001.
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6.3 LINE-FILL WATER
Having considered operational difficulties inherent to source for water, filtered river water from nearby river shall
be used in the line filling and the launching of pigs for hydrotest. This will be pumped through the permanent/or
temporary pig launcher at ZARAMA-15 and the permanent/or Temporary pig receiver at ZARAMA NAG MF
(UZU-2) and will stand as receiver for the purpose of the pigging, hydrotest and dewatering operations.
Temporary pig traps shall also be provided for the river crossing string filling and testing if full-length straight-
line section testing is not permitted by COMPANY. The river water sample shall pass through a certified analysis
by an approved independent testing laboratory, which certificates shall be sent to COMPANY for approval.
The result of this analysis shall determine whether chemical pre-treatment is to be done or not, i.e., chlorination,
corrosion inhibitors, sterilizing agents bactericides etc.
The line fill-in water analysis and compliance shall be in line with DEP 31.40.40.38 Gen (section 4).

6.4 DISPOSAL OF LINE-FILL WATER

Hydrotest and flushing water, after use, shall first be held in an evaporation pond to ensure any debris
collected from the pipe internals are separated and the water subjected to quality test. All discharge points
shall be registered with DPR.
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7. PROCEDURE FOR PRESSURE TESTING & PRECOMMISSIONING

7.1 PURPOSE:
1. To ensure the safety and structural integrity of the as-layed new constructed pipelines.
2. To identify design errors, installation defects and manufacturing defects and most importantly,
3. To settle the pre-startup and commissioning approval of the pipeline by providing the confidence that the
pipeline is Fit-For-Purpose, meet design intents and can withstand customer use environmental
conditions.
4. To verify that Design-For-Reliability (DFR) issues were fully implemented during the design stages.
5. And to demonstrate that the pipeline design doesn’t compromise the reliability of components selection
during design and that materials do not exceed their full technological limits.

7.2 Temporary Test Ends and Pig Traps

CONTRACTOR shall provide temporary pigging facilities (if P2 CONTRACTOR has not installed the
Permanent PIG LAUNCHER/RECEIVER at the commencement of testing and pigging operation) to be used for
hydrotest and pre-commissioning of the WORK. The requirement for temporary pig traps shall be in
accordance with relevant sections of DEP 31.40.10.13-Gen, Design of Pipeline Pig Trap.
Materials for major components of the pig traps shall comply with material specification as in section 5.3 of
31.40.10.13-Gen Design of Pipeline Pig Trap. All main line items shall be compatible with the main line pipe
with respect to weldability, wall thickness, material grade, transitions, and dimensions.
The dimensions and other construction details of temporary pig traps shall be as indicated in APPENDIX D. The
minimum wall thickness of the temporary equipment shall be not less than 4.8 mm and the ratio between pipeline
and equipment wall thickness should not exceed 1.5.
6.3 CLEANING
Prior to cleaning the pipelines, all main line valves on the launcher and receiver ends shall be removed
to avoid damage to the valve seals. This will be achieved by removing the main line valves alongside
interconnecting pipe spools and replace it with temporary spool if necessary.
A temporary spool will be used to replace the valves during the cleaning and hydrotest of the pipeline.
Immediately after de-watering the temporary spool will be removed, and the main line valves will be
tied-in to the pipeline. Golden welds shall be in accordance with ASME B31.4 (ref. 437.1.4 and
A437.1.4) if necessary.
The permanent launcher and pig receiver installed at Zarama-15 (UZU-1), and Zarama NAG MF Pig
Receiver respectively will be used for all pigging operations. While temporary pig traps shall be
fabricated and used for the major river crossings. The aim of the cleaning operation is to ensure that the
pipeline is free of all loose scale and construction debris to the extent acceptable to the COMPANY
representatives.
Cleaning of the pipeline will be achieved using water as a dynamic driving medium to launch a number
of cleaning (foam/brush) pigs through the pipeline system from Pig Launchers to Pig Receivers. The pig
trap areas must have safety barriers and warning signs.
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The actual number of runs of the pig trains can only be determined by observing the debris collected at
the receiver end of each pig run. Total number of the pig runs shall be determined in conjunction with
COMPANY representative.
Three stages of pigging shall be required after construction work is completed, pre-commissioning, and operation
phases of the pipeline, namely:
i. Construction pigging – Cleaning, flooding, gauging, and hydrostatic testing is carried out
immediately after the pipelines laying operation. Pigging shall be carried out after completion of
pipeline / flowline and test pack documentation is approved.
ii. Pre-commissioning Pigging – Consists of de-watering and drying of the complete system, if
required. The pipeline system shall be purged with nitrogen and then maintained at 0.5 barg
pressure above the ambient pressure until gas is introduced in.
iii. Commissioning Pigging – Consists of hydrocarbon filling and pressurization. Pressurization is
usually carried out under the direct supervision of the operator.
The procedure shall be as follows:

1. Install the Foam pig in the pipeline.

2. Fill up with water behind the first pig and insert the second pig (Brush pig).
3. Continue pumping water until the pig train has been propelled through the pipeline.
4. During the operations, the cleaning pig velocity shall not be less than 0.5m/s and not higher
than 2.5m/s.
5. Repeat the above procedure as deemed necessary by the site conditions.
6. Each pigging operation shall be documented in a pig register.
(Note: the distance between pigs in a train shall be at least 4% of the pipeline length)
Figure 1: Pig Arrangement for Gauging and Filing Operation.

4% of the Total
Length

7.3.2 GAUGING AND FILLING

Once pipeline cleaning is completed successfully the main line valves and interconnecting pipe spools
on the launchers and receivers shall be replaced to their original position. As in the case of line pipe
cleaning, the gauging pig train shall be launched from the pig launchers at ZARAMA-15 (UZU-1) to the
pig receivers at ZARAMA NAG MF (UZU-2). A gauging pig train consisting of a brush pig and a
gauging pig is inserted into the line. With a brush pig in the launcher, water volume corresponding to
approximately 4% of pipeline length will be pumped into the line, and then a gauging pig will be
inserted behind the water slug.
(NOTE: The aluminum gauging plate will have an outside diameter of (335.16mm) for the 16-inch main
Bulk lines as well as the river crossing section based on calculation below).
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Water will be pumped into the pipeline behind the gauging pig train to hydrodynamically propel the
train to the downstream end of the line and at the same time fill the line ready for hydrotesting.
Water volume shall be recorded by a calibrated flow meter. All line-fill water shall be filtered at inlet to
fill pumps before being admitted into the pipeline through foot valve with wire mesh.
During the operations, the pig speed shall be maintained at approximately 0.6m/s and not exceed 1.8m/s.
Pressure in front of the pig shall be carefully monitored and controlled at not less than 2 barg. When the
gauging train has arrived at the permanent/or temporary pig receivers, the gauging pig will be removed,
and the plate checked for damage. After the COMPANY has accepted the gauging plate, the line can be
filled with water and all the air bled from the system.
(NOTE: The maximum air content of 0.2% of the test pressure volume is allowed). All air vents will be
closed, and the line will be allowed to stabilize for 24hrs.
For the Aluminum gauge plates with wall thicknesses of 12mm for the 16-inches sections, the outside
diameters will be calculated as follows:

7.3.3 Table 7-1

GAUGE PLATE DIAMETER (d), (mm) CALCULATIONS RESULTS.
LINE GAUGE
PIPE PIPE PLATE
SIZES THK OD ID DIA (d) SLECT Whichever is smaller
S/N (inches) (MM) (MM) (MM) (MM) based on d=0.95*ID
1 16 17.8 406.4 370.8 356.736 352.26
2 16 20.8 406.4 364.8 350.736 346.56
3 16 20.3 406.4 365.8 351.736 347.51
4 16 23.3 406.4 359.8 345.736 341.81
5 16 26.8 406.4 352.8 338.736 335.16
6 6 11.8 152.4 128.8 117.276 122.36
             
Gauge Plate Diameter is calculated as (d) =ID-0.01OD-2*b or d=0.95*ID, whichever is smaller.
where b is clearance of 5mm, and ID=Nominal Internal Pipe Diameter and OD= Nominal Outside
Pipe Diameter.
ID =OD-(2*THK)
Note: The 6’’x 0.5KM (2nos) is not piggeable.

The second formula is adopted because the diameter is smaller.

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Cleaning, gauging, and filling operations shall be performed in accordance with the requirements of
DEP 31.40.40.38-Gen. Feb. 2011.

4% of the Total
Length

Figure 1-2: Pig Train Arrangement for Cleaning Operation

Table 1-2: Pig to Pig Length

Pig to Pig Length Approx. Water
Description Length (m)
(4 % of Length, m) Volume (m3)
16" Zarama 15 to Zarama
7,876.00 315.04 850.50 (NOTE 1)
NAG MFD CS Bulkline
16” Zarama NAG MFD to
10,596.92 423.88 1113.67 (NOTE 1)
Gbaran CPF CS Bulkline

6” CS Oil Flowline 458.70 18.35 7.86 (NOTE 1)

6” CS Oil Test Line 458.70 18.35 7.86 (NOTE 1)
NOTE:
1. The approximate volume of water required for hydrotest is calculated based on Class 1
wall thickness calculation of UZU-CW348814-GEN-LA1380-00001, Line Pipe Wall
Thickness Calculation Report.
2. The actual length of the pipelines shall be as indicated in Alignment Sheets based on
detailed field survey.

Each pigging operation shall be documented in a pig register (see attached report format
– APPENDIX C)
8. Baseline Integrity Surveys (Calliper Pigging) – Optional Scope
8.1 Introduction
For the new bulk lines, baseline survey pigging shall be carried out with complete verification digs and the
resulting data will be reviewed; and detailed report of the pipeline profile condition shall be prepared and handed
over to COMPANY for approval. All measures shall be taken to ensure that the calliper pigs do not get stuck.
Gauging plate measurement shall be introduced into the test section, and removal from the test section shall be
carried out in the presence of the principal. A photographic record shall be taken of the condition of each gauging
plate after use. Upon removal of the gauging plates, it 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, the CONTRACTOR shall run a geometric inspection pig to locate the
defect.
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Any damage noted by the second gauging pig or by the geometric inspection pig shall be located and repaired by
the CONTRACTOR. The CONTRACTOR shall not proceed with the testing procedure before a re-run gauging
plate has been accepted by the principal.
Geometry PIG is designed to provide information such as dents, ovalities, bend radius and angle, and indications
of significant internal corrosion.
(If approved), electronic caliper pig shall run through the entire length on the as-installed pipeline by mechanical
arms to accurately record the geometric conditions of the pipeline as well as pipeline features by measuring
changes in the pipeline’s internal diameter.
The minimum expected information of the electronic caliper pig survey on the as-installed pipelines shall be as
following:
i. Confirm that installation of the pipeline is as specified before commissioning.
ii. Verify that pipe with the correct wall thickness is installed where specified and measure the lengths of
pipe with different wall thickness.
iii. Detect and identify faults in the pipelines such as dents, buckles, wrinkles, out-of- roundness, and
other obstructions such as partially closed valves.
iv. Measure girth weld penetrations.
v. Measure exact distances between mainline valves.
vi. Obtain a baseline record of pipeline as-built condition for comparison with similar future surveys.

8.2 Final report

The Final Report for Calliper Gauge Pigging generally contains the following:
-General Information
- Technical Data
- Survey Procedures
- Results
- Features List
- Calibration Curves
- Printout of Chart

The Oil flowlines to be tied in to existing 16” x 17.5km Zarama Oil pipeline and 6” Test line shall be
nonpiggable.

8.3 HYDROTEST PRE-TEST CHECK

A pre-test check shall be performed, detailing the status and location of each item to be inspected before
pressurizing is commenced.
The check shall confirm that:
1. Test section has been completely filled and air vented.
2. Valid calibration certificates available for all equipment, instruments and gauges.
3. Limiting pressure at test point determined and communicated to pressurizing equipment operator.
4. Mainline valves have been returned to the full-open position so that there is no differential pressure across
the seats/seals.
5. Valid calibration certificates are available for all instruments and gauges.
6. The test section has been isolated from all other pipeline sections.
7. 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.
8. The test section has been filled completely and air has been vented off.
9. The block valves, if installed, have been returned to the half-open position so that
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10. there is no differential pressure across the seats/seals.
11. All instruments and gauges to be used during pressurising and testing have been calibrated and valid test
certificates have been approved by the principal.
12. All warning notices, marker tapes, protective barriers and other safety equipment have been positioned
and the appropriate authorities have been informed.
13. All relevant personnel at the affected stations have been informed of the commencement and duration of
the hydrostatic pressure test.
14. The communication channels have been tested and established and back-up equipment is available.
15. The personnel engaged in the testing work have been briefed on the emergency plans.
16. The person operating the pressurising equipment has been instructed by the test supervisor regarding the
limiting pressure which shall apply to the test section.
For the above-water/above-ground test section temperature measurements, the thermocouples should be firmly
installed into the line-fill water or firmly attached to bare pipe and covered with insulating materials. The bare
pipe shall be recoated upon completion and acceptance of hydrostatic pressure testing.

8.4 Test Section Elevation Calculations.

Highest Pipeline Elevation = Hh
Lowest Pipeline Elevation = Hl
Difference in Elevation = Hh - Hl
The Pressure Head generated at the lowest point due to the elevation difference shall
correspond to 5 % of SMYS as stated above, or to 50 m (165 ft), whichever is the lower, or as specified in the
scope of work.

8.5 Temperature Stabilization and Pressurization.

Before the hydrostatic test is commenced, the water temperature should be within 1.0°C
(1.8°F) of ground or seabed temperature, determined as the difference between average
pipe temperature and average ground temperature over the test section length.

Initially, the pressurization shall be constant at 1 to 1.5 bars per minute until a pressure of 25
% of TP has been achieved. During this period, volume and pressure readings shall be
recorded at 1 bar intervals. Any variation in the rate of pressure-increase by the same
volume of water added shall be reported immediately and all the potential leakage points
shall be checked during pressurization.

When the pressure of 25 % of TP has been reached, the air content shall be determined.
The content of the filled line shall be determined during initial pressurization by using the
Pressure vs. Added Volume plot % air content = (volume of air / volume of line) x 100.

If the air content exceeds 0.2 % of the line volume, testing shall be terminated, and
investigation shall be carried out to determine the cause. If the air entrapment is found
excessive, an additional pig shall be displaced to ensure the complete filling of the
pipeline.
When the air content is within the maximum allowable limit of 0.2 % of the pipeline volume,
pressurization shall continue up to 50 % of the test pressure and held while checking flanges
for leaks. This is the highest pressure permitted to tighten up any leaking flanges. After the
flanges have been tightened; pressurization shall be continued up to 80% of the test
pressure by increasing the pressure at a rate of 0.1 MPa per minute.
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The pressure shall be held here for 1 hour. During this water stabilization period, accessible flanges (if installed)
shall be checked again for leaks.
After stabilization, the pressure shall be raised to the test pressure at a rate of 0.5 bar per
minute and subsequently held there for pressure testing to commence.

During pressurization, pumps will pressurize the line in steps until the desired test pressure
has been attained. The test engineer shall carry out a plot of Pressure vs. Added-Volume
using measurements of volume-added by flow meter (calibrated with a tank of known
volume) and instrument readings of pressure gauge plus dead weight tester.

Pressure vs. Added-Volume readings shall be taken at 1 bar intervals up to 25 % of test

pressure and then at 10 minutes interval up to the test pressure. Any variation in the rate of
pressure increase by the same volume of added water shall be reported to the test
engineer.
At the test pressure, a new chart shall be started. The temperature and pressure readings
shall be logged hourly as well as for ambient temperature and pipe water temperature.
APPENDIX C shows records required for hydrotest.

A pressure strength and leak tightness test (pressure test) shall then be carried out for
duration of 4 hours and 24 hours respectively.

APPENDIX A shows the chart sequence for hydrotest while APPENDIX B shows the
graphical pressure build-up and hydrotest time.

8.6 Hydrostatic Pressure Test

8.6.1 Duration
The minimum duration for the hydrostatic pressure test shall be a 4-h strength test followed by a 24-h leak
tightness test while the piping spools shall be a 4-hour strength test duration only.

8.6.2 Strength Test

The minimum strength test pressure at any point of the test section shall be equal to the test pressure of 1.25 x
internal design pressure of the pipeline or to the pressure creating a hoop stress of 96 % SMYS of the line pipe
material, whichever is higher, unless otherwise specified by the principal.
The test pressure shall be 297.5barg for the 16-inches pipelines section within class 1 & 2 location. The
pressure shall be maintained during the strength test at the test pressure ± 1 bar by bleeding or adding
water as required. The volumes of water added or removed shall be measured and recorded. During the
test, pressure shall be recorded continuously, and air temperatures shall be recorded at least every 30
minutes. The pipe and soil temperature shall be recorded at the beginning and end of the 4-hour test.
During the hydrostatic pressure test the equivalent stress shall not exceed 100 % SMYS of the line pipe material.
The test engineer shall shall ensure that the TP does not exceed the pressure to which the
pipe has been subjected during the mill test and that it is not higher than the test pressure
of the fittings specified for the pipeline.
The equivalent stress is calculated in accordance with ISO 13623:2000 Clause 6.4.1.2 and shown below:

Equivalent Stress Evaluation

Pipeline State 16” ZARAMA-15 to ZARAMA MFD

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Hydro test Operation Hydro test Operation Hydro test Operation

Shp N/mm2 475.4 380.3 391.4 313.1 388.4 259.0
Hoop Stress
tb.min 18.74 21.89 25.56
Pipe Wall Thk mm

Pipeline State 16” ZARAMA to GBARAN CPF

Hydro test Operation Hydro test Operation Hydro test Operation

Shp N/mm 2
490.8 392.6 401.9 321.5 397.2 264.8
Hoop Stress
tb.min 21.37 24.51 28.18
Pipe Wall Thk mm

Pipeline State 6” OIL FLOWLINE

Hydro test Operation Hydro test Operation Hydro test Operation

Shp N/mm2 385.4 308.3 317.6 254.1 310.7 207.1

Hoop Stress

tb.min 10.83 12.40 14.39

Pipe Wall Thk mm

GENERAL HYDROTESTING NOTE

1. THE PIPELINE LENGTH FOR THE 16" ZARAMA 15 (UZU-1) TO ZARAMA NAG MFD (UZU-1)
PIPELINE IS 8KM/10KM.

2. DURING HYDROTESTING THE COMBINED STRESS IN A TEST SECTION SHALL NOT EXCEED
100%SMYS OF THE LINE PIPE MATERIAL.

3. DURING STRENGTH TEST THE TEST PRESSURE AT ANY POINT OF THE TEST SECTION SHALL
BE 1.25 TIMES THE DESIGN PRESSURE.

4. DURING STRENGTH TEST, THE HOOP STRESS SHALL NOT EXCEED 100% OF SMYS AT ANY
POINT IN THE TEST SECTION.

5. THE PRESSURIZING MEDIUM SHALL BE TREATED WATER FILTERED TO 50 MICRON.

6. DURING PRESSURIZATION, AIR CONTENT SHALL NOT EXCEED 0.2% OF TEST SECTION
VOLUME.

7. THE TEST SECTION WILL BE PRESSURIZED TO THE TEST PRESSURE PLUS ADDITIONAL 3
BARG TO ALLOW FOR STABILIZATION BEFORE THE COMMENCEMENT OF STRENGTH TEST.

8.6.3 Leak Tightness Test

The leak tightness test should commence immediately after the strength test has been completed
satisfactorily. During this phase no water shall be added or removed.
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During the test, the pressure shall be recorded continuously, and air temperatures readings shall be
recorded at least every one hour.

8.6.4 Acceptance Criteria

The pressure test operation shall be accepted after successful completion of the leak tightness test. The
tightness test shall be deemed acceptable if no pressure change occurs otherwise any pressure change shall
be accounted for by a corresponding temperature change.
8.6.5 Depressurization and Dewatering.

8.6.5.1 Depressurising.
After the satisfactory completion of the pressure testing, the test location shall be depressurized to the
hydrostatic head plus 0.1 MPa at the highest point so that air does not enter the test section. Pressure let down
valves shall be opened slowly, and depressurizing continued at a rate that does not generate vibrations in the
associated pipework. Under normal circumstances, no fitting of any type shall 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.
The depressurization rate shall not exceed 1 bar (15 psi) per minute until the pressure has been reduced to 40%
of the test pressure. After the pressure has been reduced to 40% of the test pressure, depressurization shall
continue at a rate of less than 2 bar (30 psi) per minute. The tested pipeline shall be fully depressurized prior to
transfer of test water into the new test section.
Precaution shall be taken to avoid vibration as follows:
1. Release pressure at rate of 1 bar per minute
2. Adequate bracing and tie-down to prevent movement of temporary connection and fitting.

8.6.5.2 Dewatering
Hydrotest and flushing water, after use, shall first be held in an evaporation pond to ensure any debris collected
from the pipe internals are separated and the water subjected to quality test. All discharge points shall be
registered with the DPR.
Dewatering of the entire line will be accomplished using a pig train comprising of bi-directional pigs and foam
pigs propelled by compressed air. Pigging shall be carried out against a back pressure of hydrostatic head plus 1
bar so that air does not enter into the water filled section. No attempt should be made to dewater the test section
by letting water run out under the effect of gravity.

9. PRE-DRYING CHECKS.
Before commencement of vacuum drying, CONTRACTOR-PSL shall verify the following:
 The pipeline has been isolated from other pipelines and pipework.
 Valves are designed for vacuum drying and have been placed into half-open position.
 Valve body bleeder parts are vacuum tight.
 Temporary connections, pig trap valves and pig trap end closure seals are able to withstand the prevailing
vacuum pressure.
9.1 Drying
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After hydrotest activities is completed and accepted, the pipeline shall be pigged with high sealing disc pigs by
dry air or nitrogen in combination with water absorbing foam pigs having a large water absorption capacity
(approximately 80%) of their body mass, high abrasion resistance and a density between 30-50kg/m^3 as
follow:

 High/Medium/low Density Foam Pig shall be used for complete removal of water.
 The travelling speed of the foam pigs shall not exceed 1.2m/s;
 A back pressure of at least 0.5 barg shall be maintained at the pig receiver end;
 Pigs in a pig train shall be separated by at least 300 linear pipeline metres.

Note: Nitrogen used for drying shall have a minimum dewpoint of -50 degree centigrade at atmospheric
pressure.
9 . 2 Lay-Up and Preservation
Once drying has been completed to a specification acceptable to PRINCIPAL, ahead of commissioning, the
pipelines shall be preserved, and if ready three (3) months or more ahead of the remaining work, the pipeline
should be preserved with 0.5 barg of Nitrogen. Pressure gauge should be installed for monitoring the pressure
and to ensure it is maintained at 0.5barg at all times.
Note: The preservation with nitrogen is OPTIONAL Scope of WORK.

9.3 Documentation.
CONTRACTOR shall keep record of all parameters recorded during each of the operation. The
hydrostatic pressure test records shall be reviewed by 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 COMPANY.
Upon completion of the hydrostatic pressure test operation CONTRACTOR shall compile a final
Hydrostatic Pressure Test Reports comprising as a minimum the following:

1. Originals of all recorder charts

2. All pressure readings
3. All temperature readings
4. Volumes of water added or bled off.
5. Instrument test certificates
6. Air content plot and calculation
7. Pig register of cleaning, gauging, and filling
8. Photographic record of the used gauging plates
9. Leak Locating if required.
10. Pig register of dewatering
11. Rectification records if carried out.
12. Test Procedure.

NOTE: An explanation and disposition shall be given for any pressure discontinuities, including test
failure, that appear on the recording charts.
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(A) The report should be submitted to the principal in draft form for each test section within
1 week after completion of the test or as specified in the scope of work. The complete
report shall be submitted within 4 weeks after testing of the last section, for the principal’s approval.

9.4 Rectification of Damages/Defects

Damage and/or defect detected during pre-cleaning, filling, gauging and pressure test operations shall be
located and repaired or replaced by CONTRACTOR. Repair/replacement procedure shall be approved by
COMPANY before implementation by CONTRACTOR.
If a leak is suspected, the CONTRACTOR 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, the CONTRACTOR shall
use a method which enables the locating of leaks at test pressure without endangering the
personnel carrying out the work.
Following the completion of repairs; the activity which has been interrupted for the repair works should be
repeated until the failed activity has been successfully completed. Records shall be kept for all
damages/defects identified and repairs carried out as follows:

a) Exact time/date, Location, Types and causes of the defects and/or failures.
b) Physics of failure and Method of repair used.
c) Equipment, Materials, and personnel used.

10. SAFETY
10.1 Safety Systems
Prior to mobilization, a briefing will be conducted at the base in order to brief all supervisory/field
per sonne l on all aspects (including safety) of the work scope. On reaching worksite, all personnel
will undergo the standard Site Safety Induction.

The PSL Operations Permit-to-Work system will be implemented and strictly adhered to for all
operations. No work will be carried out unless the required permit has been raised, authorized, and
signed on. If the scope of work changes during the duration of the permit, the supervisor will ensure that
any changes to the work are discussed with the permit controller, and the permit modified (if necessary)
and re- issued.
Prior to operations commencing, a Pre-Job Safety Meeting will be held to ensure that all parties
involved in, or affected by the work and personnel are aware of its nature and of the hazards involved.
The meeting will be held on site and recorded on the Pre- Job Safety Meeting Form. Any outstanding
actions following the meeting will be closed out prior to operations commencing.

A Toolbox Safety Talk will be conducted on site before each new job task or section of a job
procedure. All on-shift GPPS personnel will attend, with details of the work, the
hazards and the precautions being discussed. Where shift work is in operation, the Toolbox Safety
Talk will be given to personnel on both shifts. The talk(s) will be logged in the Daily Operations Report.

To ensure the safe continuity of the work, shift handovers (if need be) will be conducted by the
supervisors face-to-face. All shift handover details will be recorded on the Shift Handover Form.
Any changes to the scope of work must be risk assessed. Prior to implementation, the changes must be
reviewed and accepted by both t h e p r i n c i p a l and PSL. In addition to the risk assessment being
reviewed covering changes to the scope of work a specific JSA shall also be conducted with the
principal, P S representatives, the work f a c i l i t y S a f e t y O f f i c e r , a n d t he C M .
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a. WARNING SIGNS
Prior to commencement of the pressure testing activities, relevant inscription safety warning signs
shall be positioned at strategic units of the activity area.

b. COMMUNICATION

Portable handheld VHF radios or Thuraya mobile phones shall be provided for use by the
supervisors at both the pig launcher and the receiver areas for easy relating of information. A
monitoring team of the line as the test runs shall also be provided with a portable handheld VHF
radio or Thuraya mobile phone and boat.

c. EMERGENCY PLAN

For possible envisaged emergencies, contingency plans shall equally be put in place, i.e. there will
be a stand by ambulance and trained first aider to mind a first aid box that shall be provided. The
Commissioning Engineer, Safety Coordinator and Project Manager shall be on cellular phones for
a close and effective readiness.

d. SAFETY AWARENESS/CONSCIOUSNESS

Prior to the job commencement, a general meeting including all the commissioning team for the
pressure test shall be held to discuss the work activities and the safety precautions. Toolbox safety
meeting shall be held on daily basis with full documentation in place.

e. DEDICATED SAFETY OFFICER

Two safety officers at each station shall be deployed to monitor and ensure the safe work
procedure compliance.

10.2 Check Point List

The below check list, duly signed by CONTRACTOR and COMPANY, shall be part of the
Mechanical Completion Certificate.

The issuance by COMPANY of the Mechanical Completion Certificate shall not necessarily signify
that the installations has been mechanically completed in every respect and CONTRACTOR shall
complete all outstanding work as quickly as practicable but, in any case, before applying for the
Provisional Acceptance Certificate.

For each pipeline the activities to be performed are in the below check list.

Each activity (as applicable) shall be clearly stated marking the appropriate column of the relevant
check list according to the following check list legend.
X= PERFORM & INSPECT BY CONTRACTOR QA/QC
S= REVIEW
I= INSPECT/APPROVE
R= CHECK
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W= WITNESS

PRECOMMISSIONING CHECKLIST

Manifold: Area Code:

Applicable Item No. ACTIVITY CONTRACTO COMPAN
R Y
GENERAL PROCEDURES
INSPECTION
Provide inspection to check X
conformity to engineering flow
diagrams, construction drawings,
Vendor documents and specifications
Verify completion of work and R/I
approve. Check all exceptions and
add to CONTRACTOR’s punch list
REMOVAL OF RUST
PREVENTATIVIES
Remove rust preventatives and oils X
used to protect Materials during the
construction period
SAFETY NOTICE
Provide a list of proper settings for X
safety devices and protective systems
and instruments
Prepare and maintain records X
required on safety devices

PRECOMMISIONING CHECKLIST

Manifold: Area Code:

Applicable Item No. ACTIVITY CONTRACTO COMPAN
R Y
ABOVE GROUND PIPING
Line size correct X R
Branches located correctly X R
Vents and drains installed X R
Correct rating and type of valves X R
Correct direction of flow for X R
valves
 Document title: Procedures for Hydrostatic Testing Document Number: Restricted
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Check for proper slope where X R
required

PRECOMMISSIONING CHECKLIST

Manifold: Area Code:

Applicable Item No. ACTIVITY CONTRACTOR COMPANY
UNDER GROUND PIPING
Line size correct X S
Branch locations correct X R
Vents and drains installed X R
Direction of flow correct on X R
valves
Temporary blinds removed X R
Cathodic protection installed X R
Pig launchers/receivers X R
installed

PRECOMMISSIONING CHECKLIST

Manifold: Area Code:

Applicable Item No. ACTIVITY CONTRACTO COMPAN
R Y
ELECTRICAL SYSTEM
Activities and control for X R
distribution board

Activities and control for cable X W

system
Activities and control for lightening X R
system
Activities and control for Cathodic X R
Protection/Earthing system

11.UTILITIES

11.1 Electrical System

11.1.2 Cathodic Protection/Earthing

Checks and tests shall be recorded and submitted to COMPANY as follows:

1. Natural Pipe to Soil Potential

 Document title: Procedures for Hydrostatic Testing Document Number: Restricted
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2. Cable Installation & CP Integration at the Stations.

1. Anode Resistance to soil at CPT along the pipeline ROW.

2. Isolation Joint resistance immediately after the full-bore ball valve at UZU-1 and before the pig
receiver at UZU-2.
3. Hook up sacrificial anode CP to permanent CP system provided by other.
4. Termination of 48 core discrete fibre optic cable from the splicing joint/JB at Zarama oil MF to the
substation RMU & the FAR.
5. Polarized potential survey for New Pipelines.
6. Recorded results of Polarized Potential Survey, Off and On (Uninterrupted)

11 COMMISSIONING OPERATIONS

12.1 GENERAL

The pipelines commissioning shall be done in accordance with the procedure detailed below. During the
commissioning operation the maximum rate of pigging shall be 1.0m/s. Flow and pressure shall be
monitored during the operations to ascertain the rate of pigging achieved.

Record shall be taken at 15min intervals for instantaneous monitoring and the pressure at the pig launcher
and receiver ends.

All flow and pressure records and charts shall be witnessed by CONTRACTOR and COMPANY
representatives and shall be included in the final reports. A pig register shall be kept at all times and pigs
shall be numbered consecutively.

12.2 PRE-COMMISSIONING.
Prior to the start of pre-commissioning activities, PSL and COMPANY shall perform a joint walkdown and
conformity check for each system and sub systems, to verify that all process items/piping/pipelines have been
completely installed and necessary isolations and other safety barriers are in place. The COMPANY
Commissioning & Start-Up team shall also verify that documentation to support Construction Completion is in
place, so that work will not be repeated.
All pre-commissioning checks shall be documented on check sheets known as “B” check sheets in
CONTRACTOR’s Completions Management System (CMS) and retained in Commissioning dossiers by Systems
and Subsystems.

12.2.1 SCOPE
The SCOPE of the commissioning procedures covered the complete pipelines and the intersite composite cables
systems and the detailed commissioning and start-up activities.

12,2,2 PURPOSE.
The purpose of the commissioning procedure is to specify the pre-requisites leading to the introduction of high
voltage electricity and permanent operating fluid and it also incorporate shut-down and safeguarding tests to
verify the operability of the system under dynamic flowing conditions.
It’s also to describe the plant performance testing and documentations that will meet the verification certificate of
readiness format (where applicable).

12.3 Methodology for Pre-commissioning.

12.3.1 Fig.3 Pre-Commissioning / Commissioning Process Map

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12.4 Pre-commissioning activities

Pre-commissioning activities shall include, but not be limited to, the under-listed activities:
A. Mechanical & Pipelines:
• Thorough cleaning and flushing of the internals of the system piping and pipeline to ensure no debris.
• Dewatering, drying out and lay up of vessels and piping systems with the installation and removal of
temporary blinds as necessary.
• Removing, cleaning, and replacing screens and filters, including the replacement and adjustment of
packing and seals, where necessary and required.
• Alignment checks in accordance with the manufacturers’ requirements.
• Installation of final gaskets, tightening and bolt tensioning of flanges.
• Installation of safety equipment and ensuring they are charged and fully functional.

B. Instrumentation & Telecommunication:

• Testing of power cables (continuity, insulation resistance and HiPOT tests)
• Near End cross Talk (NEXT), Impedance, Far End Cross Talk (FEXT), Resistance/loop, Wire map tests for the
structured cabling system
• Optical Time Domain Reflectometer (OTDR) and Power loss tests for the Fibre optic cabling system.

12.5 COMMISSIONING TEAM.

For efficient startup/commissioning, Specialized taskforce can be formed; iincluding specialists from:
 Projects/Construction Group
 Operations & Maintenance Group
 Fire & Safety Group
The role of PSL during commissioning is to provide support to COMPANY commissioning team that will now
form the integrated commissioning experts from various disciplines.
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12.5-1 Responsibility of Projects/Construction Group

The group will ensure:

 Mechanical completion of pipeline system

 Hydro-testing and pigging of entire pipeline.

 Inertization of pipeline

 Ensuring readiness of pipeline system for commissioning

 Handing over of pipeline system (including spares, tools, equipment etc) for operation

 Handing over of relevant documents and certificates to O&M group.

12.5.2 Responsibility of O&M Group

The O&M group will ensure:
 Verification and taking over of all contracts pproject and operation related documents bbefore pre
commissioning activities
 All checks for ensuring system integrity and functionality Verification of all statutory permissions.
 Verification of relevant inspection reports and certificates etc.
 Verification of vender’s documents for materials supply.
 Verification of agreements and MOUs with pproduct suppliers and consumers
 Preparation of check list with target ccompletion dates for all contracts works and material Pos.
 Enlisting of all construction surplus materials, and equipment with all relevant inspection, test certificates
and other documents.
 Ensure preparation of check list for bbalance jobs
 Verification and taking over the project DFR, concept note and project approvals Etc.

12.5.3 Responsibility of Fire & Safety Representative

 Verification of Fire network and Equipment as per relevant OISD Standards.
 Check the adequacy of first aid fire Fighting appliance as OISD Std.117
 Ensuring placement of fire fighting equipment/instruments as per OISD Std.117
 Check the compliance of safety audits, OISD audits and Pre-commissioning audits
 Check the integrity of fire fighting system Before start up and commissioning.

12.6 Sequence of operations:

Once pre-commissioning has been completed and mechanical completion certificate has been issued by
COMPANY, the equipment and/or system is considered Ready for Commissioning.
Before commencement of commissioning, confirm that the Open/Close status of the Valves is in line with
the P&ID's.

The following sequence shall be adhered to during the commissioning operations.

 Document title: Procedures for Hydrostatic Testing Document Number: Restricted
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Step 1: Launching a foam pig using the pipeline product fluid to remove all the air in the
pipeline.

Step 2: Recover the foam pig at the receiver end.

12.7 RECOVERY OF PIGS

The pigs shall be removed from the receiver by CONTRACTOR in the presence of COMPANY
representatives. Recovered pigs shall be carefully examined to ascertain the degree and regularity of the
wear on the foam.

12.8 ACCEPTANCE CRITERIA

Commissioning shall be deemed complete when the Hydrocarbon Liquids to be transported is successfully
received and the pipeline packed to the operating pressure.

12.9 CERTIFICATES

Following completion of the commissioning activity of individual test section, the following test
certificate shall be prepared:

 completed commissioning logs for the pipelines;

 pressure gauge readings for commissioning the pipelines;
 pressure recorder charts with important information clearly noted for commissioning of the
pipelines;
 pig registers for commissioning of the pipelines;
 acceptance certificates
 Instruments calibration certificates.

Forms for the operation data recording shall be filled in, as applicable.

12.10 READY FOR COMMISSIONING CHECKLIST

12.10.1 Pre-commissioning check list

A check list is prepared, which covers the technical, safety as well as statutory
requirement before the pipeline and associated facilities is declared ready
for commissioning.
The attached check list, duly signed by CONTRACTOR and COMPANY, shall be part of commissioning
documentation.
For each pipeline the activities to be performed are in the below check lists.
Each activity shall be clearly stated marking the appropriate column of the relevant check list according to
the following check list legend.
X= PERFORM & INSPECT BY CONTRACTOR QA/QC
S= REVIEW
I= INSPECT/APPROVE
R= CHECK
W = WITNESS

12.10.2 READY FOR COMMISSIONING CHECK LIST

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Applicable Item No. ACTIVITY CONTRACTOR COMPANY

L-1 PIPELINE
Plug or cap vents and drains X R

All temporary piping/fitting removed X R

Check tightness of pipeline supports and X W
anchors
Pipeline road crossing sleeve vent provided and X W
clear
Cathodic protection test points junction boxes X W
are tested
Provide pressure test signed certificate X I

Test pig signaller operates properly X W

Pig receiver/launchers manhole gates open/close X W
properly and gaskets installed
Right of way is clean of construction debris and X R
levelled
Pipelines backfill stabilised adequately X R
Road crossing signs are legible X R
Equipment is properly tagged X S
Construction documents are available such as x-
ray results, pressure test records, M.C. and QC
forms etc. X S
Confirm fences, gates, ladders, and platforms X R
are installed and constructed according to
design
Warning signs and marker posts installed and X R
legible
Electrical and instrument tracing marks X R
installed

READY FOR COMMISSIONING CHECK LIST

Applicable Item No. ACTIVITY CONTRACTO COMPAN

R Y
L-1 PIPELINE (contd.)
Confirm pipeline earth connection X W
properly
Re-instate as per P&ID after X R
dewatering and drying
Perform pipeline drying X I
Grease nipples installed. Valves are X W
greased, rotated and adjust actuators
setting
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Check operation of actuator X W
Isolation valves installed X S
Check valve operation using valve X W
wheels
Check extension stem for free X R
movement
Drain and flush connections X R
provided
Re-instate internals of check valves, X W
and traps

READY FOR COMMISSIONING CHECK LIST

Applicable Item No. ACTIVITY CONTRACTOR COMPAN

Y
M-2 SCRAPER TRAPS
Provide pressure test signed X S
certificate
Blinds removed X S
Check anchor bolts tightness X S
Leak tested X W
Check that plugs or blanks are X R
fitted to drain valve

READY FOR COMMISSIONING CHECK LIST

Applicable Item No. ACTIVITY CONTRACTOR COMPANY

P-1 UNDERGROUND PIPING
Temporary piping and fittings X S
removed
In-line instruments installed X S
Vents and drains installed, and X R
correctly valved (provided with plug)
cap or blind flange as required
Temporary blinds removed X R
Check anchor after hydro test X R
completion for movement and
settlement
Direction of flow correct on valves X R
also check type, rating, etc.
Bolts, stud, gaskets correct rating X S
and size, check bolts tightness
Use operator to check valve X W
movement
Check hydro testing documents X S
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Cathodic protection test connections X S
installed and tested
Ensure system thoroughly cleaned as X R
per contract procedure
Ensure that marker posts and X R
warning signs are provided as
required
Hydrotest vents/drains connections X R
are plugged and seal welded
Perform dewatering/drying according X W
to approved procedure

READY FOR COMMISSIONING CHECK LIST

Applicable Item No. ACTIVITY CONTRACTO COMPANY

R
P-2 ABOVE GROUND PIPING
Demonstrate drainage for line sloping X S
Weepholes in reinforcing pads X S
Vents and drains installed and correctly X R
valved (provide with cap, plug or blind
flange as required)
Temporary blind removed X R
Provide hydrotest signed certificate X S
Piping colour coding completed as per X R
code standard
Check tightness of field supports X S
Check anchors and guides after hydrotest X R
completion for settlement and movement
Pipe shoes installed and welded (as X R
required)
Check hydrotest drain plugs and vent X R
connections are seal welded
Conduct tightness test X W
Correct direction of flow for valves X R
Bolts, studs and gaskets correct rating and X S
size. Also check tightness of bolts
Valves lubricated and packed and operable X S
Check valve operating using chain wheels X R
Check setting of valve operator and ensure X W
smooth valve operation
Valve stem orientation correct X S

READY FOR COMMISSIONING CHECK LIST

Document title: Procedures for Hydrostatic Testing Document Number: Restricted
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Applicable Item No. ACTIVITY CONTRACTOR COMPANY
I-1 INSTRUMENTS
Refer to Instrument pre- X S
commissioning checklist

READY FOR COMMISSIONING CHECK LIST

Applicable Item No. ACTIVITY CONTRACTOR COMPAN

Y
X-4 CATHODIC PROTECTION
Refer to CP pre-commissioning X S
checklist

1. APPENDICES

APPENDIX A: PRESSURE TEST FLOW CHART AND SEQUENCE

APPENDIX B: GRAPHICAL REPRESENTATION OF PRESSURE BUILD UP AND TEST
TIME APPENDIX C: HYDROTEST RECORD DOCUMENTS

APPENDIX D: DETAILS OF TEMPORARY PIG TRAPS

APPENDIX E: CONVENTIONAL PIG TYPES

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APPENDIX E – CONVENTIONAL PIG TYPES

PIG TYPE USE PROPERTI POSSIBLE

ADVANTAGES ES
DISADVANTAGES ATTACHMENTS
Cup • Where extra sealing • Can pass • Not bi- • Geometry
required restrictions up to directional (calliper)
• Gauging 25% of • Measurement
• Cleaning bore • Brushes
• Separation • Pig tracking
• Filling • Gauge Plate
• Dewatering • Blades
• Batching • Bypass Facility
• Magnets
Disc • Gauging • Bi-directional • Brushes
• Cleaning • Pig tracking
• Separation • Gauge Plate
• Filling • Blades
• Dewatering • Bypass Facility
• Batching • Magnets

Foam • Cleaning • Bi - directional • Abrasives

(Polyuretha • Batching • Absorb water so • Urethane
ne foam) • Dewatering can be used to Coating
• Air Drying indicate level of • Wrappings
dryness of the
pipeline
Solid • Dewatering • High sealant
Polymer • Batching
• Chemical cleaning
Sphere • Batching • No flow limits • Requires special
• Dewatering • Bi – directional sphere Tees.
• Automatic • Seals not as
launching. good as other pigs

Gel • Batching • Bi - directional

• Debris removal • Suitable for
Dewatering reductions in
• Drying bore
• Chemical • Operate best
treatments and is the most
efficient system in
conjunction with
mechanical or
foam pigs.
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APPENDIX A: PRESSURE TEST FLOW CHART AND

SEQUENCE
Document title: Procedures for Hydrostatic Testing Document Number: Restricted
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APPENDIX B: GRAPHICAL REPRESENTATION OF PRESSURE BUILD UP AND TEST TIME

Build pressure Depressurization

Hold Pressure for 4 hrs
@ 0.5 bar/min @ 0.5 bar/min

Build pressure @
Compressor Capacity Depressurization
@ 1 bar/min

Hold
Hold Pressure for Depressurization
1 hr leak Pressure
1 hour. @ 2 bar/min
check, for 1 hr Hold for
Hold for 1 hr
Build pressure. then 15 mins
@ 1 bar/min tighten Hold
flange. for 30
mins

80 % TP 80 % TP
50 % TP 50 % TP

25 % TP 25 % TP

0 bar 0 bar
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APPENDIX C: HYDROTEST RECORD DOCUMENTS

PRESSURE TEST REPORT (PTR)

PROJECT
GBARAN PHASE 3B - UZU WITH CPF UPGRADE - PACKAGE 1
NAME
REPORT NO. TEST DATE
TEST SECTION
DRAWING NO/REV NO.
PIPELINE SPECIFICATION
TEMPERATURE MEASUREMENT LOCATION
16" NAG MFD 16” GBARAN CPF
6” CS OIL FLOWLINE 6” CS OIL TEST LINE
CS CS BULKLINE
BULKLINE

STRENGTH TEST PRESSURE REQUIRED TIGHTNESS

TEST
MAXIMUM MINIMUM MAXIMUM MINIMUM
PRESSURE PRESSURE PRESSURE PRESSURE

TEST PRESSURE
RECORDED
STRENGTH TEST TIGHTNESS TEST
INITIAL RECORDED PRESSURE
MAXIMUM RECORDED PPRESSURE
MINIMUM RECORDED PRESSURE
START OF TEST
END OF TEST
DURATION
TEMPERATURE DURING TIGHTNESS TEST
16" NAG MFD 16” GBARAN 6” CS 6” CS OIL
AMBIENT
CS CPF CS OIL TEST
BULKLINE BULKLINE FLOWLI LINE
INITIAL NE

FINAL
PRESSURE RECORDER MAKER & SERIAL
NO
DEADWEIGHT TESTER MAKER & SERIAL
NO
TEMPERATURE GAUGE MAKER & SERIAL
NO
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PRESSURE TEST
REPORT (PTR)
PROJECT
GBARAN PHASE 3B - UZU WITH CPF UPGRADE - PACKAGE 1
NAME
REPORT NO. TEST DATE
YES NO
ATTACHED PRESSURE CHART NO.:
TEMPERATURE CHART
NO. :
TEST RESULT ACCEPT ACCEPT WITH COMMENT REJECT
PREPARED BY SITE/BASE ENGR

INSPECTED BY QA/QC ENGR

APPROVED BY QA/QC MGR

APPROVED BY CLIENT
(SIGN) (DATE)
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BRUSH CLEANING PIG RECORD

PROJECT GBARAN PHASE 3B - UZU WITH CPF UPGRADE - PACKAGE 1
NAME
REPORT NO. TEST DATE
TEST SECTION FROM TO
PIG LAUNCHING POINT
DRAWING NO/REV NO.
PIPELINE OD: WALL THK: LENGTH:
SPECIFICATION
ESTIMATE
PIPELINE
VOLUME
TIME LAUNCHED

TIME RECEIVED
TOTAL TIME
AVERAGE SPEED
NO OF COMPRESSOR
TYPE OF PIG
CONDITION OF PIG BEFORE RUN: AFTER RUN:
MAXIMUM PRESSURE

ACCEPT ACCEPT WITH COMMENT

INSPECTION RESULT REJECT COMMENT:

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BRUSH CLEANING PIG RECORD

PROJECT GBARAN PHASE 3B - UZU WITH CPF UPGRADE - PACKAGE 1
NAME
REPORT NO. TEST DATE
PREPARED BY S I T E /BASE ENGR

INSPECTED BY Q A /QC ENGR

APPROVED BY QA/QC MGR

INSPECTOR
APPROVED BY CLIENT
(SIGN) (DATE)
 Document title: Procedures for Hydrostatic Testing Document Number: Restricted
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PIG REGISTER

PROJECT NAME GBARAN PHASE 3B - UZU WITH CPF UPGRADE - PACKAGE 1

REPORT NO. TEST
DATE
TEST SECTION FROM TO
PIG LAUNCHING POINT
DRAWING NO/REV NO.
PIPELINE SPECIFICATION OD: WALL THK: LENGTH :
ESTIMATED PIPELNE VOL.
PIG TYPE
TIME/ TIME/ AVERAG
PIG NO PIG TYPE & RUN TIME CONDITIO
DATE DATE E VEL
MAKER N
LAUNCHE RECEIVE (m/s)

ACCEPT ACCEPT WITH COMMENT

INSPECTION RESULT
REJECT COMMENT:

PREPARED BY S I T E /BASE ENGR

INSPECTED BY Q A /QC ENGR

INSPECTOR APPROVED BY Q A /QC MGR

APPROVED BY CLIENT

(SIGN) (DATE)
 Document title: Procedures for Hydrostatic Testing Document Number: Restricted
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WATER FILLING
LOG
PROJECT GBARAN PHASE 3B - UZU WITH CPF UPGRADE - PACKAGE 1
NAME
REPORT NO. TEST DATE
TEST SECTION FROM TO
DRAWING NO/REV NO. N/A
PIPELINE SPECIFICATION OD: WALL THK: LENGTH:
ESTIMATE PIPELINE VOLUME
FILL BEGAN (DATE / TIME)
FILL COMPLETE (DATE / TIME)
FILL PUMP DESCRIPTION
START FLOW METER READING
FINAL FLOW METER READING
TOTAL M3 PUMPED BEHIND PIG
FINAL PRESSURE AT FILL POINT
PUMP WATER CUM CHEM INJ CUM VOL
OBSERVE
DISCHARG FLOW VOL D
TIME REMARK
E METER WATER FOLWRA A (d/m3) B (d/m3) C (d/m3)
(Hrs) S
PRESSURE READING PUMPED TE (M3/S)
(Barg) (M3) (M3)

ACCEPT WITH COMMENT REJECT

INSPECTION
RESULT
COMMENT:
Document title: Procedures for Hydrostatic Testing Document Number: Restricted
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WATER FILLING
LOG
PROJECT GBARAN PHASE 3B - UZU WITH CPF UPGRADE - PACKAGE 1
NAME
REPORT NO. TEST DATE

PREPARED BY S I T E /BASE ENGR

INSPECTED BY Q A /QC ENGR

INSPECTOR APPROVED BY Q A /QC MGR

APPROVED BY CLIENT

(SIGN) (DATE)
 Document title: Procedures for Hydrostatic Testing Document Number: Restricted
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AIR CONTENT P/V

LOG
PROJECT GBARAN PHASE 3B - UZU WITH CPF UPGRADE - PACKAGE 1
NAME
REPORT NO. TEST
DATE
TEST SECTION FROM TO
DRAWING NO/REV NO.
PIPELINE SPECIFICATION OD: WALL THK: LENGTH:

PRESSURIZATION BEGAN (DATE / TIME)

TEST PRESSURE AT TEST POINT
DEAWEIGHT SERIAL NO
TEST POINT & ELEVATION
PRESSU CUM
TIM dV AMB TEMP REMARKS
RE VOLUME
E (Barg) (S.C.F) (°C)

ACCEPT ACCEPT WITH COMMENT

INSPECTION
RESULT
REJECT COMMENT :
Document title: Procedures for Hydrostatic Testing Document Number: Restricted
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AIR CONTENT P/V

LOG
PROJECT GBARAN PHASE 3B - UZU WITH CPF UPGRADE - PACKAGE 1
NAME
REPORT NO. TEST
DATE
PREPARED BY S I T E /BASE ENGR

INSPECTED BY Q A /QC ENGR

APPROVED BY QA/QC MGR

INSPECTOR
APPROVED BY CLIENT
(SIGN) (DATE)
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 Document title: Procedures for Hydrostatic Testing Document Number: Restricted
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GAUGE PIG RECORD

PROJECT GBARAN PHASE 3B - UZU WITH CPF UPGRADE - PACKAGE 1

NAME
REPORT NO. TEST
DATE
TEST SECTION FROM TO
PIG LAUNCHING POINT
DRAWING NO/REV NO.
PIPELINE SPECIFICATION OD: WALL THK: LENGTH:
ESTIMATE PIPELINE VOLUME
GAUGE PLATE DIAMETER
GAUGE PLATE DIAMETER AS %
OF PIPELINE I.D
TIME LAUNCHED
TIME RECEIVED
TOTAL TIME
AVERAGE SPEED
NO OF COMPRESSOR
TYPE OF PIG
CONDITION OF PIG BEFORE RUN AFTER RUN
CONDITION OF GAUGE PLATE BEFORE RUN AFTER RUN
MAXIMUM PRESSURE

ACCEPT WITH COMMENT REJECT

INSPECTION RESULT

COMMENT:
 Document title: Procedures for Hydrostatic Testing Document Number: Restricted
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GAUGE PIG RECORD

PROJECT GBARAN PHASE 3B - UZU WITH CPF UPGRADE - PACKAGE 1

NAME
REPORT NO. TEST
DATE

PREPARED BY S I T E /BASE ENGR

INSPECTED BY QA/QC ENGR

INSPECTOR
APPROVED BY QA/QC MGR

APPROVED BY CLIENT

(SIGN) (DATE)
Document title: Procedures for Hydrostatic Testing Document Number: Restricted
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APPENDIX D: DETAILS OF TEMPORARY PIG TRAPS