THE PETROLEUM PROJECTS & TECHNICAL ‫شركة المشروعات البترولية و اإلستشارات الفنية‬

CONSULTATIONS CO.
‫اإلدارة العامة للمعدات‬
General Department of Equipment
‫قطاع اإلختبارات‬
…………….. ‫بتـــروجــــــت‬

HYDRO - TEST PROCEDURE

FOR
RAS GARA
10 "NEWOIL PIPE LINE

Client: PETROPEL
REV: 0.0

PTJ PTB
Name Amin Ahmed Reda Ismail
Signature
Date

1 / 18

Website: www.petrojet.com.eg
THE PETROLEUM PROJECTS & TECHNICAL ‫شركة المشروعات البترولية و اإلستشارات الفنية‬
CONSULTATIONS CO.
‫اإلدارة العامة للمعدات‬
General Department of Equipment
‫قطاع اإلختبارات‬
…………….. ‫بتـــروجــــــت‬

TABLE OF CONTENT

1.0 Data Sheet

2.0 Scope

3.0 Specification and Standard

4.0 List of Equipment & Instruments

5.0 Safety Precaution.

6.0 Documentation

7.0 Testing Of Temporary Launcher & Receiver

8.0 Cleaning and Gauging Procedure.

9.0 Flushing & Filling

10.0 Pressurizing

11.0 Dewatering

12.0 Testing Of Valves Room.

13.0 Attachment.

2 / 18

Website: www.petrojet.com.eg
THE PETROLEUM PROJECTS & TECHNICAL ‫شركة المشروعات البترولية و اإلستشارات الفنية‬
CONSULTATIONS CO.
‫اإلدارة العامة للمعدات‬
General Department of Equipment
‫قطاع اإلختبارات‬
…………….. ‫بتـــروجــــــت‬

1.0 DATA SHEET

SECTION : from (k.p0.0) to (k.p18.0 KM)

NOMINAL DIAMETER : 10"

OUT SIDE DIAMETER : 10"

WALL THICKNESS : 12.7 & 15.09 mm

LENGTH : 18.0 KM

MATERIAL GRADE : API 5L X52

VOLUME / KM : 55.6 M3

TOTAL VOLUME : 1000 M3

TEST MEDIUM : WATER

3 / 18

Website: www.petrojet.com.eg
THE PETROLEUM PROJECTS & TECHNICAL ‫شركة المشروعات البترولية و اإلستشارات الفنية‬
CONSULTATIONS CO.
‫اإلدارة العامة للمعدات‬
General Department of Equipment
‫قطاع اإلختبارات‬
…………….. ‫بتـــروجــــــت‬

2.0 SCOPE

This scope covers Ras Gara 10 " new oil pipe line hydrostatic test carried out by

petrojet and consists of:

- Testing of temporary launcher & receiver

- Pipe line cleaning

- Flushing , gauging & filling

- Pressurizing.

- De watering.

- Testing of valve rooms.

5 / 18

Website: www.petrojet.com.eg
THE PETROLEUM PROJECTS & TECHNICAL ‫شركة المشروعات البترولية و اإلستشارات الفنية‬
CONSULTATIONS CO.
‫اإلدارة العامة للمعدات‬
General Department of Equipment
‫قطاع اإلختبارات‬
…………….. ‫بتـــروجــــــت‬

3.0 SPECIFICATION & STANDARD

This procedure for hydrostatic test written to meet the requirement for

the following specification and standards according to :

- Client Specifications

- ANSI / ASME CODE B 31.4 ( Liqued Transmission & Distribution System )

- PETROJET Procedure

6 / 18

Website: www.petrojet.com.eg
THE PETROLEUM PROJECTS & TECHNICAL ‫شركة المشروعات البترولية و اإلستشارات الفنية‬
CONSULTATIONS CO.
‫اإلدارة العامة للمعدات‬
General Department of Equipment
‫قطاع اإلختبارات‬
…………….. ‫بتـــروجــــــت‬

4.0 LIST OF EQUIPMENT & INSTRUMENTS

Petrojet will supply the following equipment& instruments to execute the work:
4.1 EQUIPMENT
- Air Compressor
- Prime Pump
- Filling Pump
- Pressurizing Pump
- Storage Tank
- High Pressure Hoses

4.2 INSTRUMENTS
- No. Of (2) Pressure Gauge
- No. Of (2) Pressure Recorder
- No. Of (2) Temperature Recorder
- Dead Weight Tester.

7 / 18

Website: www.petrojet.com.eg
THE PETROLEUM PROJECTS & TECHNICAL ‫شركة المشروعات البترولية و اإلستشارات الفنية‬
CONSULTATIONS CO.
‫اإلدارة العامة للمعدات‬
General Department of Equipment
‫قطاع اإلختبارات‬
…………….. ‫بتـــروجــــــت‬

5.0 SAFETY PRECAUTION

 All personnel involved in testing operation shall wear full safety including

hard hats, safety boots and gloves to be worn by mechanical operation.

 The test cabin will be located in a save position approximate 20 mt. From

the pipeline to be tested.

 Warning signs ( written in both English & Arabic) will be erected outside

the cordoned off area

 No personnel will be allowed to work within 30 mt of the pipeline testing

operations are in progress.

8 / 18

Website: www.petrojet.com.eg
THE PETROLEUM PROJECTS & TECHNICAL ‫شركة المشروعات البترولية و اإلستشارات الفنية‬
CONSULTATIONS CO.
‫اإلدارة العامة للمعدات‬
General Department of Equipment
‫قطاع اإلختبارات‬
…………….. ‫بتـــروجــــــت‬

6.0 Documentation

All records for temporary launcher & receiver testing, pipe line cleaning, gauging,

pressurizing and any relevant comments will be completed into "test report" submitted

to the client after hydro test completed .

7.0 TESTING OF TEMPORARY TEST HEAD

- After construction of temporary test head it will be filled with fresh water &

tested as one loop for one hour at the same test pressure of the pipe line.

- After the successful test of the temporary test head it will be separated and

loaded with pigs

- The temporary launcher & receiver will be welded at the two ends of the tested

section.

9 / 18

Website: www.petrojet.com.eg
THE PETROLEUM PROJECTS & TECHNICAL ‫شركة المشروعات البترولية و اإلستشارات الفنية‬
CONSULTATIONS CO.
‫اإلدارة العامة للمعدات‬
General Department of Equipment
‫قطاع اإلختبارات‬
…………….. ‫بتـــروجــــــت‬

8.0 CLEANING AND GAUGING PROCEDURE

- The cleaning and gauging of the pipe line shall be started after the
following.
 All welds have been non-destructively tested and accepted.
 All wrapping and insulation has been completed
 Temporary test head shall be installed at both end of section.
- Compressed air at maximum pressure (7bar) shall be used to run Cleaning and
gauging pigs.
- Cleaning pig shall be urethane Bi direction pig
- Gauging pigs shall be urethane Bi direction pig with gauging plate, with diameter =
90 % of minimum internal diameter of pipe line.
- Gauging plate material shall be soft Aluminum.
- The gauging plate shall be remarked before launching the gauging pig,
The remark shall include:
Gauging plate diameter‫ و‬Section No, Date thin Signed by Client Rep. And Petrojet
test engineer
- Client Rep. Shall witness the cleaning and gauging operation.
- The following records shall be reported in pigging operation registry
(App. 1) and shall signed by Client Rep. and Petrojet test engineer.
- The number of pig runs.
- The type of the pig.
- The pressure behind the pig during operation.
- Time of launching and receiving the pig.
- Type of material arriving in front of the pig.
- The cleaning certificate (App. 2) and gauging certificate (App. 3) shall be
signed by Petrojet Rep. and client Rep.

10/18

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 THE PETROLEUM PROJECTS & TECHNICAL ‫شركة المشروعات البترولية و اإلستشارات الفنية‬
CONSULTATIONS CO.
‫اإلدارة العامة للمعدات‬
General Department of Equipment
‫قطاع اإلختبارات‬
…………….. ‫بتـــروجــــــت‬

9.0 Flushing & Filling

 After gauging had been completed to satisfaction of the client , filling will start
 The volume required to fill the pipe line will be calculated prior of filling
commencement
 The filling pump will be connected to the pipe line
 20 cubic meter of water will be inserted to the pipe line as flushing water.
 The filling pig will be launched, and filling will be continued till the pig arrival at pig
receiver then the filling pump will stopped. The line is now completely filled with
water.
 To ensure that the pipe line is free from the air entrapped, venting will be carried out
several times from launcher and receiver.

11/ 18

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 THE PETROLEUM PROJECTS & TECHNICAL ‫شركة المشروعات البترولية و اإلستشارات الفنية‬
CONSULTATIONS CO.
‫اإلدارة العامة للمعدات‬
General Department of Equipment
‫قطاع اإلختبارات‬
…………….. ‫بتـــروجــــــت‬

10.0 PRESSURIZING
 Check that the pipe line has been completely back filled
 Check that all temporary fitting has been removed.
 Check that all instruments has calibration certificate and approved by the client.
 Pressure pump and instruments at both ends of pipe line will be connected at safe
distance.
 All fitting, hoses, and valves used during pressurizing pressure which exceeds the
max test pressure applied on pipe line.
 All charts which used in recorders will be signed by client representative before
pressurizing commencement.
 Pressurizing will be commencement at static head pressure.
 Pressure will raised gradually with suitable rate to prevent sudden stress to pipe line
 Pressurizing will be stopped at 80% of test pressure for one hour & visual check will
be carried out.
 Pressurizing will be commencement again to 100% test pressure.
 Pressure will be hold for 24 hour
 Pressure will be beaded gradually to static pressure or as client requirement
 At the end of the test cycle, all sheets & test certificate will be submitted to client
representative for sign and approval.

12/18

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THE PETROLEUM PROJECTS & TECHNICAL ‫شركة المشروعات البترولية و اإلستشارات الفنية‬
CONSULTATIONS CO.
‫اإلدارة العامة للمعدات‬
General Department of Equipment
‫قطاع اإلختبارات‬
…………….. ‫بتـــروجــــــت‬

11.0 DE WATERING

After successful test, the pipe line will be cleaned from test water applying compressed

air and the pig will be pushed through the pipe line using compressed air.

12.0 TESTING OF VALVE ROOMS

If the valve room is not available for testing with the pipe line it will be pressure tested

separately as a loop for two hour at the same test pressure of the pipe line.

13/ 18

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THE PETROLEUM PROJECTS & TECHNICAL ‫شركة المشروعات البترولية و اإلستشارات الفنية‬
CONSULTATIONS CO.
‫اإلدارة العامة للمعدات‬
General Department of Equipment
‫قطاع اإلختبارات‬
…………….. ‫بتـــروجــــــت‬
13.0ATTACHMENTS
PIGGING OPERATION REGISTER
Wall thickness: ………mm Nominal diameter: ………..Inch
Grade: ………….
Section From: …… To: ……
Pig type
Inspected & Location
loaded
Date
Time
Location

Launched Date
Time
Pressure
Location

Received Date
Time
Pressure
Location

Inspected Date
Time
Condition
Petrojet Test Eng. Client Rep.
Name. Name.

Sign Sign

Date Date

Appendix (1)
14/18

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THE PETROLEUM PROJECTS & TECHNICAL ‫شركة المشروعات البترولية و اإلستشارات الفنية‬
CONSULTATIONS CO.
‫اإلدارة العامة للمعدات‬
General Department of Equipment
‫قطاع اإلختبارات‬
…………….. ‫بتـــروجــــــت‬

GAUGE PLATE ACCEPTANCE CERTIFICATE

Date: / /

Project:
Client:

SECTION ADTA
From: ………… To: ………………
Length: ……….Km.
Outside diameter: ………..mm.
Internal Diameter: ……… mm.
Wall thickness: …………..mm.
Grade: …………..
Gauge Plate Diameter. : ………..mm.
Gauge Plate Material. :……………

Petrojet Test Eng. Client Rep.

Name. Name.

Sign Sign

Date Date

Appendix (3)
15/18

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THE PETROLEUM PROJECTS & TECHNICAL ‫شركة المشروعات البترولية و اإلستشارات الفنية‬
CONSULTATIONS CO.
‫اإلدارة العامة للمعدات‬
General Department of Equipment
‫قطاع اإلختبارات‬
…………….. ‫بتـــروجــــــت‬

CLEANING ACCEPTANCE CERTIFICATE

Date: / /
Project:
Client:
SECTION ADTA
From: ………… To: ………………
Length: ……….Km.
Outside diameter: ………..mm.
Internal Diameter: ……… mm.
Wall thickness: …………..mm.
Grade: …………..
THE ABOVE MENTIONED SECTION HAS BEEN CLEANED
ACCORDING TO.
 CLIENT SPESIFICATION.
 HYDROTEST PROCEDURE.
 SATISFACTION OF CLIENT REP.
Petrojet Test Eng. Client Rep.

Name. Name.

Sign Sign

Date Date

Appendix (2)
16/18

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THE PETROLEUM PROJECTS & TECHNICAL ‫شركة المشروعات البترولية و اإلستشارات الفنية‬
CONSULTATIONS CO.
‫اإلدارة العامة للمعدات‬
General Department of Equipment
‫قطاع اإلختبارات‬
…………….. ‫بتـــروجــــــت‬

ACCEPTANCE TEST CERTIFICATE

Date: / /
Project:
Client:
Test Section Data :
Test section No.: ………
from: ………………. To: ……………
Pipe Material Grade: …………. Length: ………………
Wall Thickness: ……………….mm Nominal Diameter: ……………Inch

Was Tested AS Out Lined Below

Test Medium:
Test Pressure:

TIME DATE PRESSURE TEMP.

FROM
TO

Dead Wight Serial No.: ………………………….

Pressure Recorder Serial No.: …………………….
Temperature Recorder Serial No.: ………………..

This test is completed with successful result and accepted.

Petrojet Test Eng. Client Rep.

Name. Name.

Sign Sign

Date Date
Appendix (4)

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THE PETROLEUM PROJECTS & TECHNICAL ‫شركة المشروعات البترولية و اإلستشارات الفنية‬
CONSULTATIONS CO.
‫اإلدارة العامة للمعدات‬
General Department of Equipment
‫قطاع اإلختبارات‬
…………….. ‫بتـــروجــــــت‬

DEWATERING ACCEPTANCE CERTIFICATE

Date:

Project:
Client:
SECTION ADTA
From: ………… To: ………………
Length: ……….Km.
Outside diameter: ……… mm.
Internal diameter: ……… mm.
Wall thickness: ………….mm.
Grade: …………..
THE ABOVE MENTIONED SECTION HAS BEEN DEWATERED
FROM WATER ACCORDING TO.
 CLIENT SPESIFICATION.
 HYDROTEST PROCEDURE.
 SATISFACTION OF CLIENT REP.
Petrojet Test Eng. Client Rep.

Name. Name.

Sign Sign

Date Date

Appendix (5)
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