ENGINEERING, PROCUREMENT, CONSTRUCTION, AND COMMISSIONING

(EPCC) OF BUKIT TUA DEVELOPMENT PROJECT

KETAPANG PSC, EAST JAVA, INDONESIA

ONSHORE RECEIVING FACILITY (ORF)

HYDROTEST PROCEDURE FOR PIPELINE

PREPARED FOR
PC KETAPANG II LTD.

CLIENT

EPCC
CONTRACTOR
CONSORTIUM
pt. RAGA PERKASA EKAGUNA
ENGINEERS & CONSTRUCTORS
pt. KRAKATAU ENGINEERING

Job No. : QPCA00 Contract No. : 5600025662 Doc. No.:

Rev. Date Description By Chk. App. 11-BTORF-P-PRO-0003

A 24-Dec-13 Issued For Review ADR ABR / RZL WHY

Rev : A

PC Ketapang II Ltd. APPROVAL

Sign :

Date :
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REVISION LOG REGISTER

Revisions had been performed on following pages:

No Page Date Revision

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TABLE OF CONTENTS
REVISION LOG REGISTER 2
table of Contents 3
1. INTRODUCTION 4
1.1 General4
1.2 Scope 4
1.3 Definition and Abbreviations 4
1.3.1 Definition 4
1.4 Reference, Codes and Standard5
1.4.1 National Laws and Standards 5
1.4.2 Project Specification 5
1.4.3 Petronas Technical Standards 5
1.4.4 International Codes and Standards 6
1.5 Conflict Requirements 6
2. Hydro testing Procedure6
2.1 General Methodology 6
2.2 Pressurization 7
2.3 Hold Period (The Pipeline Shall be Isolated from This Point Forward) 8
2.3.1 Acceptance Criteria 8
2.4 Depressurization 8

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1. INTRODUCTION
1.1 General
PC Ketapang II Ltd (PCK2L) plans to develop the Bukit Tua Field, in the Ketapang Block, East Java. Bukit
Tua which is primarily an oil field but with significant associated gas, is located 35 km north of Madura
Island and 110 km northeast of Gresik at a water depth of approximately 57 m.

Figure 1.1: Bukit Tua Field Location

The Preferred Development Option is a not-normally-manned Well Head Platform (WHP) which is tied
back to a spread-moored Floating Production, Storage and Offloading (FPSO), anchored approximately
900 m from the WHP. The Full Well Stream (FWS) from the wells are separated into gas and liquid
streams in the production separator on WHP. The gas and liquid are evacuated to the FPSO via two
separate single phase 16 gas and 8 liquid infield flowlines. Associated gas is compressed and
conditioned on the FPSO and exported via a 12 gas pipeline to WHP and there onwards via a 12 gas
export pipelines to the Onshore Receiving Facilities (ORF) in Gresik. Oil is exported by tandem mooring
from the FPSO whilst produced water is treated for overboard disposal.
The FPSO vessel, moorings, topsides and the flexible pipeline risers at the FPSO will be leased. FPSO-
WHP interfaces shall include the flexible pipeline risers and radio telemetry link for data, telephone and
remote monitoring and control of the WHP from FPSO.
The export gas shall be received at the ORF where final separation of condensed liquids shall take place
before fiscal gas metering. The metered gas shall be routed to the sales gas delivery point outside plant
battery limits.

1.2 Scope
This procedure cover minimum requirement for site hydrostatic test incoming pipeline onshore, Bukit Tua
Development Project Onshore Receiving Facilities (ORF).

1.3 Definition and Abbreviations

1.3.1 Definition
COMPANY : PC Ketapang II Limited (PCK2L), as the Project
Developer and Operator of the facility/platform.
CONTRACTOR : Consortium of PT Raga Perkasa Ekaguna PT

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Krakatau Engineering, which carry out all or part of the

detailed design, engineering, procurement, construction,
and commissioning (EPCC) contract of the project.
VENDOR : The Company that manufactures or supplies equipment
and services to perform duties specified by
CONTRACTOR. VENDOR covers
Manufacturers/Supplier/Sub-vendor.

1.4 Reference, Codes and Standard

The latest editions, as of the enquiry date, of the following Codes, Standards and Regulations (as far as
they are applicable) are considered part of this specification and are to be used by VENDOR in their
design, manufacturing and testing of the offered equipment or package. Where in house standards have
been developed or are based on recognised National, International or Industry Standards, these may be
offered as an alternative, subject to review and approval by COMPANY.
The Codes, Standards and Regulations include but shall not be limited to the following:

1.4.1 National Laws and Standards

Local Rules, Acts and Regulations of Indonesia
Decree 84.k/38/DJM/1988 Guidelines and Procedures of Working Safety
Inspection on Installation, Equipment and
Engineering used in Natural Gas Mining and
Geothermal Source Exploitation
Regulation Safety Audit to Installation, Equipment and
06P/0746/M.PE/1991 Technique used in Oil and Gas Mining and
Geothermal Activities
Regulation Obligation to Own Certificate of Construction
05/P/II/PERTAMB/1977 Worthiness for Oil and Gas Platform in the Off-shore
area
Regulation Number 11 Year Working Safety on Refinery and Processing Oil and
1979 Gas

1.4.2 Project Specification

11-BTORF-P-DSB-0001 Piping Design Basis
11-BTORF-P-SPC-0020 Piping Material Specification - ORF

1.4.3 Petronas Technical Standards

PTS 61.10.08.11 September 2009 Field inspection prior to commissioning of
mechanical equipment
PTS 31.38.01.10 August 2011 Piping classes Basis of Design
PTS 31.38.01.11 October 2011 Piping General Requirements
PTS 31.38.01.15 January 2010 Piping classes Exploration & Production
(Note 1)
PTS 31.38.01.21 August 2011 Compilation of a specification for piping
systems
PTS 31.38.01.31 October 2011 Shop and Field Fabrication of steel piping
PTS 31.40.10.19 January 2010 GRP Pipelines and Piping systems
PTS 80.45.10.10 February 2010 Pressure Relief and flare system
PTS 20.081 June 1993 Piping General requirements
PTS 20.208 November 1995 Painting protective coating and Linings for
Offshore System
PTS 39.01.10.12 December 2010 Selection of material for life cycle
performance (EP) Upstream Equipment

Note 1: For this project, the onshore receiving facility (ORF) shall be designed referring to this PTS,
rather than the normally used PTS 31.38.01.12 Piping Classes Refining & Chemical.

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1.4.4 International Codes and Standards

American Petroleum Institute
API 5L Specification for Line Pipe
API 6D ISO 14313, Petroleum and Natural Gas Industries-Pipeline
Transportation Systems-Pipeline Valves
API 1102 Recommended Practice for Liquid Petroleum Pipelines
API 1104 Standard for Field Welding of Pipelines/ Welding of Pipelines and
related
API 1105 Construction Practices for Oil and Products Pipelines

American Society of Mechanical Engineers

ASME B31.8 Gas Transmission and Distribution Piping Systems

1.5 Conflict Requirements

In the event of any conflict between this Specification and any requirements of statutory and safety
regulations, codes, standards and other documents, the most stringent shall prevail. The order of priority
of documents shall be as follows:
Indonesian Codes and Regulations
Project Specification and Datasheet
Petronas Technical Standard (PTS)
Internationally recognized Codes and Standards
All apparent conflicts shall be reported to the Company in writing for resolution. The Company decision
shall be final. In the case of conflict the more stringent requirement is govern.

2. HYDRO TESTING PROCEDURE

2.1 General Methodology

12 GAS EXPORT pipeline hydro test pressure is: 15MPa (2175.6psig); 1.5x design operating pressure.
The pipeline will be hydro tested after completion and visual acceptance of the gauge plates from the
pigging operation. Battery limit for the hydro testing will remain as per above; top of riser at BTJT-A
platform to end of the onshore tie-in spool (between OIC and ORF EPCC as per drawing: ORF-U-00006
Revision 0).

CONTRACTOR intends to set up the hydro test equipment and pressurize up the pipeline from the ORF
onshore tie-in spool location. Calibrated, pressure gauges and pressure/temperature recorder charts will
be utilized to monitor the pipeline pressure and temperature. The pressure test will be using the same
treated sea water solution as above. The pipeline will be pressurized to the require test pressure and the
volume of air monitored during pressurization. The test system is then isolated and allowed to stabilize.
Once the pressure has stabilized the hold period of 24 hours will commence.

The hydro test is deemed accepted when the following are achieved:
Air entrapped is less than 0.2% of volume
No visible leaks is observed
Pressure is not lower than 98% of test pressure during the 24 hours holding period
No unaccountable pressure changes are observed

The 12 Gas Export pipeline will be deemed mechanically complete and acceptable by COMPANY upon:
Visual inspection of the pipeline gauging plates, and approved when no significant defects are
found on at least one of gauging plates
Hydrostatic Pressure Testing of pipeline has been satisfactorily completed for required 24 hours
period

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The baseline survey by intelligent pig will be performed as per contract and the survey data provided as
part of the pipeline as-built documentation.
The hydrostatic testing spread will be set up onshore at the ORF tie-in flange location.

Hydrostatic testing activities will be performed from onshore to top-of-riser at BTJT-A platform. A small
suction feeder pump will be set up at the quayside near the existing pipe rack structure for supply to the
high pressure positive displacement pump for performing the hydro test. The chemical injection skid will
be transferred from the pigging vessel to onshore and set up accordingly.

Prior to pressurization, the pipeline will be topped up with water while the air being venting out from
venting valve on the riser at BTJT-A. Once top up and venting of the pipeline is completed, the
instrumentation shall be install to the test blind at onshore ORF tie-in flange.

During the pressurization, the following information shall be recorded and logged every 0.1MPa are
increased intervals:
Time
Dead weight tester for the pipeline pressure (bar)
Volume pressurize (bar/liter)
Volume of chemical and Dye injected (m3/liter)

The equipment for hydro test (location Onshore Receiving Facility, landfall point) as below:
1 ea x diesel driven positive displacement HP pump (47GPM/10000psig)
1 ea x air driven positive displacement HP pump
1 set x HP hoses complete with fittings for hydro testing
1 set x HP Xmas tree assembly complete with valves and fittings
2 ea x Deadweight tester units
4 ea x Pressure & Temperature Chart recorder units

2.2 Pressurization
Pressurization will be commence at rate of up to and exceeding 0.1MPa per minute from atmospheric to
3.1MPa (450psig) at which air entrapment calculation will be carried out. A pressure volume graph will be
produced using the figures attained during pressurize to indicate the volume of entrapped air in the
pipeline. Should the air content exceed the maximum allowable of 0.2% of the calculation pipeline
volume, the pipeline shall be depressurized and all air fully vented. Pressurization shall recommence as
before until acceptable air content is attained.

On acceptance of the air content, the pipeline will be further pressurize at rate of up to and not exceeding
0.5MPa per minute to 70% (10.5MPa) the pressurization shall be stopped to allow to stabilize and leak
checked for minimum 3 hours and during the 3 hours stabiles prior the pipeline pressure shall be recorded
interval 15 minutes.

Upon completion 3 hours stabilize at 70% (10.5MPa), pressurized shall be continued to 95% (14.25MPa)
of test pressure, pressurization shall then continue to 100% (15MPa) of the test pressure at a diminishing
rate down to approximately 0.001MPa per minute. Continue pressurizing the line to reach the test
pressure (hydrostatic test pressure+0.2%; 15.03MPa). On reaching the nominated test pressure, the
system will be allowed to stabilize.

Monitoring of the pipeline pressure during the stabilization period will be conducted using a calibrated
dead weight tester (DWT) located onshore. The following information will be monitoring and logged at 15
minutes interval unit stabilization has occurred (i.e. Specified test pressure):
Time
Pipeline pressure
Volume of water added (if any)
Ambient temperature
Subsea temperature (temperature probe is located at onshore test point and offshore platform
location)

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During the stabilization period, re-pressurization may be carried out should the pressure drop below the
required test pressure. The volume of water added will be recorded. Leaks or other defects noted during
the stabilization period shall be rectified. The section requiring rectification shall be depressurizing to a
safe level prior to any repair activity.

2.3 Hold Period (The Pipeline Shall be Isolated from This Point Forward)
Once the pressure in the pipeline has stabilized, a hold period of twenty-four (24) hours shall commence.
During the hold period, the following information shall be recorded and logged at thirty (30) minutes time
intervals:
Time
Pipeline pressure
Ambient temperature
Subsea temperature

2.3.1 Acceptance Criteria

The pipeline hydrostatic test shall be considered complete when the following condition has been met
after the hold period. The pipeline pressure shall not be fall below the required test pressure at any
time during twenty four (24) hours holding period. All variation in test pressure shall be accounted for.
The test period shall be extended if necessary to achieve these criteria.

Note:
1) Should the test hold period be extended, the hold period will be retrospectively selected where
the pressure has maintained within the above criteria for a twenty-four (24) hours period with CSR
approval
2) No visible leaks shall be present on observable section of the pipeline.

Should the system require to re-pressurization during the nominated hold period, owner/contractors
consent will be obtained prior to re-pressurization. The hold period shall start from this point.

2.4 Depressurization
On completion and acceptance of hold period, the pipeline will be depressurized to atmospheric pressure
from the double block and bleed (DBB) on the test blind. The rate of depressurization shall not exceed
0.1MPa per minute.

The pipeline pressure will be monitored and recorded during depressurization until the pipeline is fully
depressurized.

On completion of pipeline depressurization, all logs and acceptance certificates shall be signed off by all
relevant parties.

2.4.1 Preliminary Checks Preparation

STEP DESCRIPTION CONTRACTOR

1 All personal shall be attended the project safety induction PE/Sup
2 Prior to commencing any work, all items of plant and equipment shall be PE/Sup
checked for transit and lifting damage any incident of damage shall be
reported to the field engineer of Superintendent immediately
3 All item of plant and equipment requiring certificate shall be checked PE/Sup
against mobilization record
4 Verified that all certificates are valid and correct PE/Sup
5 Prior to commencing of the operation work the necessary work permits PE/Sup
shall be obtained. PTW shall be utilized
6 Lines and communication established and noted regarding persons in PE/Sup
charge, contact name and telephone numbers for the safety and
environmental consideration
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7 Provide confirmation that all NDT is complete and acceptable on both PE/Sup
permanent and temporary facilities

2.4.2 Equipment Set-Up and Layout

STEP DESCRIPTION CONTRACTOR

1 Confirm all the permits are in place and valid for the hydro test operation PE/Sup
2 Proceed toolbox meeting and JSA checked with all relevant parties and PE/Sup
any other site parties working in same area
3 The set-up of hydro test spread in the designated lay down of working PE
area
4 Secure all the connection hoses with whip checks and line up the PE/Sup
system before hydro test operation to be commenced. Area to be
barricade off at onshore and offshore platform location
5 Secure the working area to post warning signs and erect bunting in PE/Tech
around safe working area
6 Check engine oil and radiator cooling levels Tech
7 The hydro test spread will be set up and function test on the working PE/Sup
boat before any operation to be commence

2.4.3 Hydro Test Operation

STEP DESCRIPTION CONTRACTOR

1 Confirm that PTW are in place and valid for the hydro testing activity PE
2 HOLD POINT PE
Conduct toolbox talk onboard of barge and perform the JSA check with
relevant parties and any other affected parties working in the same area,
checks or test the communication in between both test ends. Two (2)
personnel shall be on BTJT-A platform during test. MIGAS to be on site
to witness test
3 Confirm and witness of the test blind had been installed on top riser at PE
BTJT-A and ORF tie-in flange onshore. All the fitting for venting,
instrument point is position for the pipeline is in place. Provide records of
bolt tensioning for review
4 Confirm to post warning sign and barrier the safe working area before PE
commence the hydro test operation at both ends. Danger zones shall be
barricade off
5 Rig up the 1 high pressure hose from the onshore hydro test spread to Tech/Rigger
ORF test blind and connect to double block and bleed manifold on the
test blind of the pipeline
6 Confirm the instrument of hydro test operation is install as per listed and PE
drawing:
Dead weight tester
Pressure Recorder
Pressure Gauge
Ambient temperature recorder
Sea Bed Temperature probe
7 Confirm to receiving site that the instrument are installed: PE
Pressure Recorder
Pressure Gauge
Ambient Temperature
Sea Bed Temperature Probe
8 Prior to commence of the hydro test operation, prepare the following PE
logs:
Pressurize Report
Acceptance Air Conclusion Certificate
Stabilization Log
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Hydro Test Report

9 Request permission from COMPANY to commence the hydro test PE
operation for the pipeline and confirmation that all parties have reviewed
the approved pre-commissioning procedure
10 On the permission from COMPANY to commence hydro test operation PE
for the pipeline. Make announcement to all platform personnel at both
ends
11 Once confirmation from receiving site of the venting point has already PE
opened. Open the double block isolate valve at the test blind at onshore
side
12 Start the pressurizing pump as minimum RPM to top up the pipelines PE
13 Continued to pumping water into the pipeline as minimum RPM of the PE/Tech
pressurizing pump
14 Once water is seen discharging on the receiving end, start to open the PE/Tech
venting point at the test blind, continued venting the water out for 10 to
20 minutes till solid water is confirm coming out on both of pipeline.
Pressure release hose/drain line shall be located at +2m to +4m
elevation
15 Once the water is coming out is a constant stream, close the venting PE/Tech
point valve for both site of the riser, continued pumping water into the
pipeline till pressure reach 0.05MPa. Volume pumping from 0MPa shall
be noted down
16 Once pipeline pressure 0.05MPa, stop the pressurizing pump and close PE/Tech
the double block isolate valve on the injection manifold
17 Plug off the vent point at each riser PE/Tech
18 Re-confirm to receiving site that the pipeline is plug off and working area PE/Tech
is safe to commence hydro testing operation
19 Install the chart paper of the pressure recorder and ambient temperature CSR/PE/MIGAS
recorder at launcher site.
Note: Chart shall be signed by COMPANY and Regular Body Inspector
(MIGAS), not the code on the chart
20 Confirm with receiving site that pressure gauge, temperature probe and PE/Tech
ambient temperature are installed
21 Once confirm the working area at launcher site is safe to commence the PE/Tech
hydro test, open the double block isolation valve on the test blind at ORF
side
22 Reset the flow meter, and start the pressurizing pump PE/Tech
23 Monitor and logging the pressure and flow read of the pump and PE/Tech
increase the flow as required slowly. Prior to commence pressurizing the
pipeline shall follow logs:
Time
Pipeline Pressure
Volume pumping
Ambient Temperature recorder
Sea Bed Temperature probe
24 Pressurize rate shall be 0.1MPa per minute till reach 20% of the test PE/Tech
pressure
25 Once reach 20% of test pressure, slowly decrease the pressurizing PE/Tech
pump and turn off the pressurizing pump. Allowed for 30 minutes
stabilization
26 Once the pressurizing pump has been stop, close the double block PE/Tech
isolate valve on the injection manifold on the test blind at ORF
27 Engineer or test supervisor shall calculate the air inclusion of the PE/Tech
pipeline, acceptance criteria 0.2% of air content for each pipeline
28 Check for leak around the launcher and receiving site during this time, if PE/Tech
any leak found for any site of the riser shall be report to the test
supervisor or test engineer
29 To repair leak, the pipeline shall to depressurize to ambient, then repair PE/Tech
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the leak
30 Once the leak has been repaired. To re-pressurize the pipeline, shall be PE/Tech
follow on step 18 to 28
31 Once 30 minutes prior of stabilization complete and no leak has found, PE/Tech
continued pressurization up to 70% of test pressure
32 Open the double block isolate valve on test blind and start the PE/Tech
pressurizing pump
33 Continued commencing pressurizing to the pipeline and increase the PE/Tech
rate as 1barg per minute till 70% of test pressure, prior to commence
shall be following by the logs
Pressurizing log
Volume pumping log
34 Once pressure reach 70% of test pressure, decrease the pressurizing PE/Tech
pump and turn off the pressurizing pump
35 Once the pressurizing stop, close the double block isolate valve on the PE/Tech
injection manifold of the pipeline. Check for leak regularly.
36 Stabilization prior will take 4 hours approximately: during that prior PE/Tech
logging at ORF will be taken interval 15 minutes following by:
Time
Pressure reading
Ambient temperature
Subsea temperature
37 Once stabilization has completed continue to commence the PE/Tech
pressurizing for the pipeline
38 Open the double block isolate valve PE/Tech
39 Started the pressurizing pump, and increase the volume as per require. PE/Tech
Note: During this state of pressurization from 70% to 100% of test
pressure, pressurization rate of 0.1MPa per minute till 100% test
pressure
40 Once the pressure reach at 100% test pressure (15MPa), pressurizing PE/Tech
pump will be stop and close the double block isolate valve
41 Final physical leak check for the launcher and receiver site of the PE/Tech
pipeline
42 Once confirm no leak is detected for the both site of launcher and PE/Tech
receiver. Carry on stabilization of the pressure for 4 hours
43 Once stabilization is completed, continues to change the pressure chart PE/Tech
of the pressure recorder and temperature recorder and confirm that the
chart has been signed
44 Commence 24 hours hydro test period. PE/Tech
During the test hold period, pipeline shall be tested and monitored.
During this period, following logs shall be taken for pipeline:
Pipeline pressure by:
Dead weight tester
Pressure chart recorder
Pressure gauge
Temperature by:
Ambient temperature (recorder)
Subsea temperature
45 Once the test hold period for pipeline is completed, pressure shall not PE/Tech
drop down more than 0.4MPa per 1C after acceptance criteria
calculation temperature change
46 Engineer or test supervisor shall be calculated the temperature vs. PE/Tech
pressure for acceptance criteria
47 Inform all witness parties and if the test is accepted by MIGAS and PE/Tech)
COMPANY, the pipeline shall to depressurized as 0.1MPa per min down
to 0MPa (atmospheric)

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48 Once the test of the pipeline has been completed, the chart shall be PE
signed follow by the acceptance Certificate and logs:
Pipeline hydro test certificate
Hydro test Report
Chart Paper of Temperature
Chart paper of Pipeline Pressure

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