WORK PROCEDURE FOR MAINLINE HYDROTEST BY NITROGEN

CNG & CITY GAS DISTRIBUTION PIPELINE PROJECT, PUNE.

DOC.NO.:JPL/PL/MECON/MNGL/P26 REV. NO: 1

LOA NO CLIENT -

- 05.51.23 K8.MNGL.001A (i). LOA. 018.

JAIHIND PRO JECTS LIMITED

MAHARASHTRA NATURAL GAS LIMITED

WORK PROCEDURE FOR MAINLINE HYDROTEST BY NITROGEN

Issued for Approval

App By (JPL)

DATE

DESCRIPTION OF REVISION

PREPBY (JPL)

REVIEW BY (MECON)

APP BY (MECON)

WORK PROCEDURE FOR MAINLINE HYDROTEST BY NITROGEN

CNG & CITY GAS DISTRIBUTION PIPELINE PROJECT, PUNE.
DOC.NO.:JPL/PL/MECON/MNGL/P26 REV. NO: 1

TABLE OF CONTENTS 1.0 PURPOSE......................................................................................................2 2.0 3.0 SCOPE .....................................................................................................3 REFERENCES..........................................................................................3

4.0 TERMS & DEFINITIONS .....................................................................................................3 5.0 6.0 8.0 9.0 RESPONSIBILITIES..................................................................................3
Project Manager.........................................................................................................................................4

METHODOLOGY......................................................................................5 HEALTH, SAFETY & ENVIRONMENT....................................................8 QUALITY ASSURANCE & QUALITY CONTROL.....................................9
1. INSPECTION AND TEST PLAN FOR HYDROSTATIC TESTING 2. CERTIFICATE OF CIVIL& MECHANICAL COMPLETION 3. TEST PLAN FOR HYDROTEST 4. INSPECTION REPORT FOR CALIBRATION OF PRESSURE MEASURING / RECORDING INSTRUMENT 5. 24 HOURS HOLD PERIOD REPORT 6. HYDROTEST HEADER

1.0

PURPOSE

WORK PROCEDURE FOR MAINLINE HYDROTEST BY NITROGEN

CNG & CITY GAS DISTRIBUTION PIPELINE PROJECT, PUNE.
DOC.NO.:JPL/PL/MECON/MNGL/P26 REV. NO: 1

The purpose of this procedure is to lay guidelines and requirements and to establish a method or a system to control the hydrostatic testing of CNG & CITY GAS DISTRIBUTION PIPELINE PROJECT, PUNE 2.0 SCOPE

The purpose of this procedure is to define the methodology for air cleaning, Nitrogen filling, hydro testing of the 6 & 4 diameter buried Pipeline fabricated & installed for JPL. 3.0 REFERENCES

Following documents in part or in totality shall form the reference documents. ANSI B 31.8. ASME B 31.4 API RP 1110. ASME SEC.VIII Div-1 OISD 141

4.0 TERMS & DEFINITIONS For the Purpose of this document, the term shall indicates a mandatory requirement and should indicates a recommended practice. Their full meaning in brackets follows acronyms or abbreviation

5.0

RESPONSIBILITIES

WORK PROCEDURE FOR MAINLINE HYDROTEST BY NITROGEN

CNG & CITY GAS DISTRIBUTION PIPELINE PROJECT, PUNE.
DOC.NO.:JPL/PL/MECON/MNGL/P26 REV. NO: 1

Project Manager

Shall report to Project Director Pipeline, Shall be responsible for providing resources for the implementation of this procedure. Shall report to the Project manager, Shall be responsible for control, supervision and direction for implementation and execution of construction plans using calibrated Measuring and Test Equipment Shall report to Head of QC at HO and Project Manager, Shall be responsible for overall control of QC activities and sub- contractors QC activities, implementation of QAM and HSE Plan, supervision and allocation of inspection teams, develop inspection and test plans. Shall be responsible for custody, maintenance calibration and issuance of all measuring and Test Equipment. Shall maintain status log of all measuring and test equipment. Shall be headed by Management Representative. Shall be responsible for purchasing, controlling, calibration of all measuring and test equipment for all sites of JPL Shall report to the Spread In-charge Preparation of Schedule addressing specific issues and characteristics of each spread. Responsible for overall control of Hydro test site and safety management and for the implementation of approved procedure and supervises the activity. Generates reports during the activity and records data.

Resident Construction Manager

ISO Monitoring Department

Hydro test Engineer/Foreman

WORK PROCEDURE FOR MAINLINE HYDROTEST BY NITROGEN

CNG & CITY GAS DISTRIBUTION PIPELINE PROJECT, PUNE.
DOC.NO.:JPL/PL/MECON/MNGL/P26 REV. NO: 1

QC Engineer

Explains to Hydro test foreman and all other persons involved in Hydro test of the detailed operations to be done during various phases of activity. Reports to QA/QC in-charge Ensures proper implementation of this procedure Checks and verifies the activity Verifies and countersigns Hydro test reports Reports to Construction Manager Manages the implementation of all safety requirements during Hydro test operations. To verify and ensure that the communication system is working properly and that emergency equipment is in place

HSE Officer

6.0

METHODOLOGY

Details of the test section shall be illustrated in the Hydrotest pack as thus (a) Test circuit indicating vents, Valves, fittings, temp. Connecting valve of elevations (b) Pipe Book B (c) Estimated amount of Nitrogen required. (d) Elevation chart (e) Mechanical clearance certificate (f) Calibration certificate The documents shall be prepared for each test section and submitted to MNGL prior to commencement of the test. A calculated / predetermined length of pipeline shall be selected for the hydrotest based on elevation, availability of Nitrogen and location of stations. Graph showing the elevation of the complete test section shall be drawn prior to start of the test and enclosed in the hydro test pack along with format. Hydro testing of mainline shall exclude valves at tap off stations, terminals, pump stations, SV stations. Prior to any hydrostatic test, MNGL shall be notified in advance and the hydrotest shall commence only after obtaining signature on Part B of the Pipe Book and Mechanical Clearance.

WORK PROCEDURE FOR MAINLINE HYDROTEST BY NITROGEN

CNG & CITY GAS DISTRIBUTION PIPELINE PROJECT, PUNE.
DOC.NO.:JPL/PL/MECON/MNGL/P26 REV. NO: 1

All the instruments to be used shall be a valid calibration certificates as per specification requirements. The Equipment / Instruments to be used for performing the work shall include, but not limited to the following. Temporary test headers fabricated in conformity with ASME section VIII, division 2 with particular reference to appendix 4 and 5 having sufficient length to accommodate the required number of pigs. The header shall also have provision for pig stopper. Temporary test headers fabricated for filling of Nitrogen. Unless otherwise specified, all measuring recording instruments shall meet the specification requirements of contracts.

6.1 Test Medium Cleaning and hydrotesting shall be performed using of Nitrogen. 6.2 Test Pressure Hydrostatic test shall be done with Nitrogen. The highest point of test section shall be subjected to the minimum test pressure as specified. The maximum hydrostatic test pressure at any location in the pipeline during testing shall not exceed the pressure required to produce hoop stress equal to 95% of SMYS of pipe material based on the minimum wall thickness of the test section. The test pressure shall be 1.25 times of operating pressure plus the static head (clearance difference between the highest point gauge points) In case of any class location is upgraded due to seismic requirements, the hydrostatic test pressure shall be governed by actual class/population density. The duration of hydrostatic test shall be minimum 24 hours after stabilization.

6.3

Testing & 24 hour hold period The record shall contain at least the following information. i. Time and date of test. ii. Pipe specifications of section under test. iii. Testing medium used

WORK PROCEDURE FOR MAINLINE HYDROTEST BY NITROGEN

CNG & CITY GAS DISTRIBUTION PIPELINE PROJECT, PUNE.
DOC.NO.:JPL/PL/MECON/MNGL/P26 REV. NO: 1

iv. v. vi.

Test pressure at lowest elevation. Test duration Pressure and temperature recording.

All data shall be recorded on appropriate forms. Throughout the hold period, care shall be taken that the maximum test pressure should not exceed in lowest elevation of the pipeline section under test. Should it become necessary to de-pressurise, the volume of test medium bleed off shall be measured and recorded. 6.4 Acceptance Criteria The hydrostatic test shall be considered as positive if pressure has kept a constant value throughout the test duration, and during the test period there is no observable drop in pressure that cannot be accounted for any temperature changes. Leaks If during the pressurisation period or during the test periods any leaks are observed, these shall be eliminated.

Leak Detection To locate buried leaking pipe, the following procedure by elimination shall be followed: 1. 2. 3. 4. To cut the section in an intermediate position To insert two test heads To reflood the sections To pressurise the two sections

WORK PROCEDURE FOR MAINLINE HYDROTEST BY NITROGEN

CNG & CITY GAS DISTRIBUTION PIPELINE PROJECT, PUNE.
DOC.NO.:JPL/PL/MECON/MNGL/P26 REV. NO: 1

5.

To determine the faulty section

This procedure shall be applied until the determination of the defect. As soon as the defect has been located and repaired, the test section shall be tested again. If the test section fails to maintain the specified test pressure after isolation, JPL shall determine by search the location of leakage or failure. All leaks and failure within the pipewall or weld seams shall be repaired by replacement of entire joint or joints in which leakage or failure occurs. JPL shall comply with instruction of MNGL whether to replace a section of the linepipe that includes the line leak or whether to repair the circumferential weld. After completion of repairs, the hydrostatic test shall be repeated. 7.0 TEST REPORT: 8.0 HEALTH, SAFETY & ENVIRONMENT

The approved procedure of Health, Safety & Environment shall be followed during the execution. The hazards associated with the hydrotest have been identified and the following guidelines are suggested for implementation of safety norms. Provisions shall be made for the installation of no admittance signs to unauthorised personnel from the road to the R.O.W at critical locations. Warning signs in English and Local language stating Pipeline under test Keep of shall be placed in locations where the pipeline is uncovered, and particularly where the temporary headers and stations are located. Such areas shall be suitably fenced in such a way as to prevent access of unauthorized personnel. No unauthorized personnel shall be closer than 40 m to the pipeline under test. Only the authorized personnel as defined / identified by the Hydrotest Engineer shall be allowed within the test area when the test section is under pressure.

WORK PROCEDURE FOR MAINLINE HYDROTEST BY NITROGEN

CNG & CITY GAS DISTRIBUTION PIPELINE PROJECT, PUNE.
DOC.NO.:JPL/PL/MECON/MNGL/P26 REV. NO: 1

No stage of the activity shall progress without the specific clearance of testing engineer. The temporary test headers shall be installed in compliance with methods and suitable locations so that their rupture cannot cause any injury to personnel. The test cabin shall be placed in such a location as to prevent it from being affected by a catastrophic failure in the test head. No work on the pipe or test equipment shall be allowed whilst under pressure except for tightening of flanges, the removal of connections after closing valves, and the blinding of ports after achieving the test pressure for isolation of the test section. No flexible hoses are permissible inside the test cabin, except for essential connection to the instruments. For effective communication, a wireless and walkie-talkie system shall be used. 9.0 QUALITY ASSURANCE & QUALITY CONTROL

The quality assurance and quality control for the project procurement shall be carried out by strictly implementing the following: a. Inspection and Test Plan. b. Quality Records The type of inspection activity and quality records generated during the activity is detailed in Inspection and Test Plan. Quality records shall include current calibration certificates for all measuring instruments.

TEST REQUIREMENT: The number, size and/or performance of each component required for the work. Schematic layout of proposed section of each size pipe shall be submitted indicating elevation profile before start of the Hydrotest for MECON approval.

The test equipment will include the following.

WORK PROCEDURE FOR MAINLINE HYDROTEST BY NITROGEN

CNG & CITY GAS DISTRIBUTION PIPELINE PROJECT, PUNE.
DOC.NO.:JPL/PL/MECON/MNGL/P26 REV. NO: 1

Temporary Header Test heads Communication equipment Spare parts and stand by facilities

: For Nitrogen filling as required. : To separate the test sections for pressure testing and both ends. : Fir communication between the various location of the test section . : To replace any defective test equipment during the hydrotesting Pressure test.

The instruments will be in accordance with the requirement of the table below:

Instrument

Reading

Range

Accuracy

Pressure gauge Ambient air temp. recorder (digital )

1, 2 or 5 bar 0.5C

0 to 1.5xTP 0 - 80C

+/- 0.06 % (Note 3) +/- 1 % (Note 3)