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Pipeline Hydrotest Plan

This hydrotest plan outlines procedures for pre-commissioning activities on the Yemen LNG pipeline project, including water filling, hydrostatic testing, and dewatering of the pipeline. It describes the 28 sections of the 323km 38-inch main line and one section of the 25km 30-inch transfer line. The plan provides details on personnel, equipment, calculations, and environmental protection measures to ensure safety and efficiency during the hydrotesting operations.

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0% found this document useful (0 votes)

412 views73 pages

Pipeline Hydrotest Plan

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fernando

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Download as PDF, TXT or read online on Scribd

You are on page 1/ 73

Document number

HYDROTEST PLAN YE-001-20-SOC-PLN-09275

Revision: 02 Status: IFC
Document Type: PLN System / Subsystem: 99 Date: 01/08/07
Contractor document number: Page 1 of 73

YEMEN LNG
Project

Pipeline

Hydro Test Plan

Rev. Status Date Revision memo Issued by Checked by Approved by

02 IFR 01/08/07 Issued for Review, CPY J. de Jong P. Rijsemus O. Balloy

comments incorporated
H. Mesa
01 IFR 07/06/07 Issued for Review, CPY F. Rosen H. Mesa O. Balloy
comments addressed as per
T-PMT-750692

00 IFR 24/03/07 Issued for Review F. Rosen H. Mesa O. Balloy

This document is the property of Yemen LNG Company. It must not be stored, reproduced or disclosed to others without written
Authorisation from the Company.
Document number
Hydrotest Plan YE-001-20-SOC-PLN-09275
Revision: 02 Status: IFR
Document Type: PLN System / Subsystem: 99 Date: 13/07/07
Contractor document number: Page 2 of 73

TABLE OF CONTENTS

1.0 PURPOSE

2.0 INTRODUCTION
2.1 Reference Documents
2.2 Abbreviations
2.3 Definitions
2.4 Personnel
2.5 Night Work
2.6 Authorization
2.7 Notifications
2.8 Operational Limits

3.0 GENERAL INFORMATIONS

3.1 Pipeline Details
3.2 Materials and Equipment

4.0 PREPARATION
4.1 Test Headers
4.2 Pigs
4.3 Water Basin
4.4 Water Sources

5.0 SECTION WATER

5.1 Filling Water
5.2 Chemicals
5.3 Water Disposal

6.0 TEST SECTIONS

6.1 38” Main Line
6.2 30” Transfer Line
6.3 Definition of Test Sections
6.4 Test Section Details

7.0 OPERATONS – FILLING – TESTING - DEWATERING

7.1 Work Zones
7.2 Water Abstraction & Disposal Locations
7.3 Test Section Details and Work Program
7.4 Operational Sequence ZONE 1
7.5 Operational Sequence ZONE 2
7.6 Operational Sequence ZONE 3

8.0 OPERATIONAL PROCEDURE

8.1 Water Filling
8.2 Hydrostatic Testing
8.3 Calculations
8.4 Dewatering / Disposal

This document is the property of Yemen LNG Company. It must not be stored, reproduced or disclosed to others without written
authorisation from the Company.
Document number
Hydrotest Plan YE-001-20-SOC-PLN-09275
Revision: 02 Status: IFR
Document Type: PLN System / Subsystem: 99 Date: 13/07/07
Contractor document number: Page 3 of 73

9.0 MONITORING AND RECORDING

9.1 Water Filling
9.2 Hydrostatic Testing
9.3 Dewatering

10.0 INSPECTION AND TEST PLAN

10.1 Water Filling
10.2 Hydrostatic Testing
10.3 Dewatering

11.0 HEALTH AND SAFETY

12.0 ENVIRONMENTAL
12.1 Fauna and Flora preservation
12.2 Pollution Prevention
12.3 Waste Management
12.4 Existing infrastructures
12.5 Environmental Emergency Response

APPENDICES:
1. Risk Assessment
2. Environmental Impact Assessment
3. Quality Registers (Forms)
4. Personnel
5. Equipment
6. Calculations
7. Table Factor A, Reduction of Water Volume to Pressure
8. Table Factor B Thermal Expansion of Water
9. Section Details and Work Sequence
10. Sketches of Test Header
11. Water Filling and Dewatering Pig
12. Chemical Data Sheets (MSDS)
13. Site Lay Out
14. List of ‘Golden Welds’
15. Sketch Thermometer Locations
16. Geo-membrane Data Sheet
17. Geo-membrane Installation Guideline
18. Method Statement welding Geo-membrane
19. Field Analysing Kit Manual
20. Life time of chemicals
21. Water Well Analysing Report

1.0 PURPOSE

The purpose of this procedure is to describe and define the methods to be used in “Hydrostatic Testing
of Pipeline” operations and define the Water Management Plan for the Yemen LNG Pipeline Project.

It is the intention of this procedure to be followed and precautions to be taken to ensure that the
operation is conducted in a safe and workmanlike manner. Care shall be taken to ensure safety of
personnel, equipment and not to disturb environment during Hydro testing operations. It is not the
intention of this procedure to supersede or override any applicable specification, code or standard.

2.0 INTRODUCTION

This hydro test plan is based on simultaneously work tasks carried out to optimize the re-use of water
and to minimize the water abstractions from ground water sources and the usage of chemicals.
Describes most practical activities for pre-commissioning work
- WATER FILLING
- HYDROSTATIC TESTING and
- BULK DEWATERING.
Information is provided to the best knowledge and at present available information and utmost
importance to Quality, Health & Safety and Environmental requirements.

A. 323 Km 38” Main Line from the Kamil Processing Unit (KPU) to the Bal Haf Plant
For pre-commissioning services, the 323km Main Line is divided into twenty-eight) 28 sections.

B. 25 Km 30” Transfer Line from the Central Processing Unit (CPU) to the KPU.
Pre-commissioning services on the 30” Transfer Line is performed in one (1) section.

The following Installations are excluded from this test plan and will be tested separately.
- Permanent Pig Launcher and Receiver Facilities for the 30” and 38” Lines at:
o Central Processing Unit (CPU)
o Kamil Processing Unit (KPU)
o Bal Haf
- Block Valve Stations (10) positioned along the 38” Main Line Routing.

The Details of the Test Sections are tabulated in section 6.4 “Test Section Details”, end of this
document.

This Hydro test Plan is combining all Hydro test Documents / Specifications to issue the Parameters
for the Base of executing pre-commissioning work to ensure a safe, valid and efficient work is
carried out.
- Water Filling
- Hydrostatic Testing
- Dewatering

Note: For Swabbing Cleaning and Pre- Drying a separate procedure will be issued.

This plan provides the technical basis in a most practical way for pipeline hydrostatic testing, with
specific reference to the following subjects:

- Test Headers
- Test Sections
- Water Sources and Water Storage
- Water Treatment
- Filling and Dewatering of Test Sections
- Hydrostatic Testing of Pipeline Sections
- Treated Water Disposal
- Safety, Environment and Social
- Resources and Scheduling
- Contingency

2.1. Reference Documents:

GS PLR 501 Rev, 02 Hydrostatic Testing of Pipeline

RP 5259S 819 1300 03 Rev. 2 Cleaning, Hydrostatic Testing, Dewatering and Drying of Pipelines
NC 5259S 810 1300 02 Rev. 4 Study Report: Main Line Hydro testing, Pipeline WT and Design
Stress
ASME B31.8 Gas Transmission and Distribution Piping Systems
GS COR 560 Physical and chemical treatment of hydrostatic test water
YE-001-20-MOC-PLN-09070 Project Health & Safety Plan
YE-001-20-MOC-PRN-09061 Training QHSE
YE-001-20-MOC-PRC-09072 MS Procedure Emergency Response
YE-001-20-MOC-PRC-09077 MS Procedure PPE
YE-001-20-MOC-PRC-09264 Hydrotest Section
YE-001-20-SDL-PRN-09517 Management & Transport Plan
YE-001-20-MOC-SPE-03005 Specification for Pipeline Pre-Commissioning
YE-001-20-MOC-DRW-03711 Typical Pipeline drawing – steep slope construction
YE-001-20-SOC-PRC-09240 Working in steep slope Procedure
YE-001-20-SDC-ITP-09447 ITP Trenching
YE-001-20-MOC-ITP- -09429 ITP Hydro test
YE-001-20-MOC-PLN-09201 Environmental and Social Management Plan
YE-001-20-MOC-PLN-09204 Reinstatement Management Plan
YE-001-20-MOC-PLN-09205 Pollution Prevention Management Plan
YE-001-20-MOC-PLN-09202 Waste Management Plan Environmental
YE-001-20-MOC-PRC-09211 Emergency Response
YE-001-20-MOC-PLN-09213 Water preservation Plan
GS-PLR-104 Onshore Pipeline System
GS-PLR-403 Installation of onshore Pipelines

The documentation required to proceed the Pre-commissioning activities, in compliance with project
safety and environmental conditions will be available on site. Documentation will include but is not
limited to:

• The Method Statement

• Water preservation Plan
• Welding Procedures (Golden welds and piping)
• Pipeline Alignment Sheets
• Pipeline As Built Data
• Pipe Mill Certificates
• Record/Report Sheets
• Equipment Certificates
• Material Certificates
• Operating Certificate for Test Headers
• Instrument Certificates
• Lifting Certificates for Machines
• Lifting Certificates for lifting gear and equipment
• Vehicle Certificates
• Personnel Certificates

2.2. Abbreviations
The following abbreviations are used in this Document

CPU Central Processing Unit

KPU Kamil Processing Unit
LNG Liquefied Natural Gas
ID Internal Diameter
OD Outside Diameter
WT Wall Thickness
KP Kilometre Point
PPM Parts Per Million (Dosage Rate e.g. for Chemical Injection)

2.3. Definitions
The following abbreviations are used in this Document

COMPANY Yemen LNG Company

CONTRACTOR AMEC-SPIE-CAPAG / HAWK – Joint Venture

2.4. Personnel
The organization of the personnel who are listed below is given in Appendix 4. No lead personnel with
less than five years of pipeline construction/hydro testing and pigging experience shall be allowed to the
construction area.

Test Engineer (or his designated deputy)

- Reports to Construction Manager
- Will be located at the hydro test site
- Will have the overall responsibility for the implementation and control of all procedures contained
in this document, in liaison with Company’s Representative.
- Is responsible for the safe conduct of the works and liaises with the H&S Engineer on all matters
to do with health and safety
- Liaises with the H&S Engineer for the works to ensure all health and safety pre-cautions are in
place prior to work commencing and that a pre start toolbox meeting is completed with the crew.
- Ensures that only approved and certified lifting equipment and tools are used so that safety &
quality are not compromised
- Ensures that Company is informed prior to the operation commences
- Assures that the quality record is generated and approved
- Shall be in charge of the Hydrostatic-Testing operation, all equipment and personnel
- Assures the efficiency of Inspection Measuring & Test Equipment
- Responsible for application of the Permit to Work and liaison with other work areas where
SIMOPS may be taken place.

Test Supervisor, (or his designated deputy)

- Reports to Test Engineer
- Located at the individual pig receiving location will have the responsibility for the implementation
and control of all procedures contained in this document, in liaison with the Company’s
Representative.

Health and Safety Engineer

- Reports to H&S Manager.
- Provides advices and instructs on all health and safety issues during the Hydrostatic-Testing
Operation.
- Has the authority to stop the activities if any unsafe acts or conditions occur during the activities.
- Ensures that Work Procedure and Risk Assessment is available at site, conducts a pre-start
toolbox meeting with the Test Supervisor and crew. To be sure that the crew understands the
hazards and risk reduction strategies.
- Ensures that all safety precautions are in place prior to start and remain in place for the duration of
the activities.
- Monitors the workplace and report H&S when incidents occur.
- Monitoring construction activity if they are carried out in a safe manner and as per method
statement.
- Reference with Permit to Work system.

Environmental Inspector
- Reports to Environment Manager.
- Monitors the disturbance of biological environment.
- Monitors pollution of the surroundings due to Hydrostatic-Testing operation..
- Assures the appropriate mitigation measures during Hydrostatic-Testing operations.

Test Operators / Mechanics

- Report to Test Engineer / Supervisor
- Only Qualified Experienced Operators will be at site.
- All Operators will be subjected to reassessments periodically.
- Ensure smooth execution of the activities

QA / QC Engineer
- Ensure issues of test packages, certifications, calibrations of instruments and tools.
- Implement and initiate test records etc.
- Carry out the pre test checks according to check list.

CLO
- Inform third parties and local residences/populous of imminent pressurization and hydro-test.

2.5. Night Work

All Hydrostatic-Testing operation will be done during daytime thus night driving will be reduced to the
minimum. During the 24 hours test period there will be well-trained local foremen to do the readings of
the data.

Local personnel who are patrolling the pipeline if necessary or in case of emergency at night will be
equipped with mobile phone and radio communication to be able to contact the Hydro test cabin and
security supervisor on duty at all times.

No person shall be allowed to drive at night on the R.O.W. unaccompanied.

Camp security will monitor the hydro test communication channel on a continual basis during night shift
work.

All necessary safety equipment and personnel shall be made available during night work and
permission by the Company for the night work shall be taken. The following are the additional
equipment for the night works:

- Provision of food and welfare services at site locations.

- Halogen lamps with stand
- Cabin with Air Condition
- Vehicle for emergency
- Radio hand set communication with camp security

2.6. Authorization

No operations will commence without notification given to the Company’s Representative.

2.7. Notifications

The Company shall be notified as follow:

Water-Filling, 7 days notice
Testing and Dewatering, 14 days notice
24 hours prior to work commencement
This document is the property of Yemen LNG Company. It must not be stored, reproduced or disclosed to others without written
authorisation from the Company.
Document number
Hydrotest Plan YE-001-20-SOC-PLN-09275
Revision: 02 Status: IFR
Document Type: PLN System / Subsystem: 99 Date: 13/07/07
Contractor document number: Page 9 of 73

2.8. Operational Limits

The pipeline sections will be water filled, hydrostatic tested and dewatered from the temporary test
headers located at the begin and end point of each test section. (Refer to Section 6.4 for details of
hydro test sections).

Permanent Pigging Stations and Block Valve Stations are not included in Test Sections.

3.0 GENERAL INFORMATION

The information as detailed in Section 6.4 identifies the quantity, length and volumes of the individual
pipeline sections as well as the minimum and maximum test pressure at the low and high points of each
section to be hydro-tested.

The pre-commissioning work is divided in three Zones

Zone 1 KP 322+654 To KP 204+200
Zone 2 KP 136+300 To KP 0, and to the CPU (30” Transfer Line)
Zone 3 KP 136+300 To KP 204+200

The main water filling points will be at the water wells. It is planned that there will be 2 major filling
points for the pipeline sections with several intermediate filling points along the line. The locations are
shown in the tables in section 4.3.1

The medium utilized to complete the water filling and hydro testing operations will be treated water as
per COMPANY Specification GS COR 560. The required volume of water will be made available from
two water wells along the ROW to be stored in water basins constructed at the same locations.

The re-use of water by transferring water from section to section is minimizing the water abstraction
from water wells and the use of chemicals.

The water quality tests for each water source will indicate which type of chemicals shall be used and the
required concentration in accordance to the Company Specification GS COR 560 (Physical and
chemical treatment of hydrostatic test water)

According to test section length minimum three (3) probes (one at the launcher side, one at the receiver
side and one in middle of that Section) or as practical additional probes in areas with different ground
conditions (Refer to sketch Appendix 15)

The hydrostatic packages shall be submitted to the Company Representative for approval a minimum of
14 days prior to hydro testing.

3.1. Pipeline Details

38” Main Line (Constant ID)

From : Kamil Processing Unit (KPU), End of section near the anchor block.
To : BAL HAF LNG Plant, End of section near the anchor block.
Length : 323 km
ID : 930.4mm
WT : 16.2mm, 18.0mm and 23.7mm
Steel Grade : API 5L X70
Internal Coated : Not
BVS : Ten (10), not included in test sections
This document is the property of Yemen LNG Company. It must not be stored, reproduced or disclosed to others without written
authorisation from the Company.
Document number
Hydrotest Plan YE-001-20-SOC-PLN-09275
Revision: 02 Status: IFR
Document Type: PLN System / Subsystem: 99 Date: 13/07/07
Contractor document number: Page 10 of 73

AGI : Not included in test sections

Test Sections : Twenty-eight. (28)

30” Transfer Line (Constant OD)

From : Central Processing Unit (CPU), End of section near the anchor block.
To : Kamil Processing Unit (KPU), End of section near the anchor block.
Length : 25 km
OD : 30” (762mm)
WT : 15.9mm, 22.2mm
Steel Grade : API 5L X70
Internal Coated : Not
BVS : Not
AGI : Not included in test section
Test Sections : One (1)

For Test Sections details as Test Pressures, Area Class Location, Design Pressure Locations please
refer to Para 6.3 - no. 9 + no. 10 and Para. 6.4,

3.2. Materials and Equipment

All Equipment is certified fit for purpose. It has been checked and tested for good working conditions
and pressure rated and tested to 125 % of the maximum pressure used.

All Materials subjected to pressure provided with material certificates

All Instruments used is certified and certification is valid respectively for 6 and 12 Months.

Instrumentations will be re-certified in an approved method against a certified Master Deadweight

Tester.

Accuracy of Instruments

- Dead Weight Tester Accuracy 0.005 bar

- Pressure Gauge (6”) Accuracy Class 0,025
- Pressure Recorder Accuracy Class 1.0
- Pipe Temperature devices Accuracy 0.03 °C
- Flow Meter (Filling) Accuracy 0.3 – 0.4%
- Flow Meter (Pressurizing) Accuracy 0.3 – 0.4%

4.0 PREPARATION

4.1. Test Headers

Test Headers are fabricated with a safety factor of 1.25 times the maximum test pressure.
Test Headers will be welded to cap-off each end of test section, for launching and receiving of water
filling pigs and dewatering pigs as well for water transfer into the next section.
- Standard Test Headers are fabricated using heavy wall (23.7mm) line pipe
- High Pressure Test Headers are fabricated from extra purchased pipe with 32mm wall thickness to
be used for test pressures above the limits of the Standard Test Headers.
- All associated fittings are fully certified, all welding is done by qualified welders.
For Details of test headers refer to Appendix 10.

4.1.1. Fabrication of 38” Test Header

4.1.1.1. Standard Test Headers are fabricated with 23.7mm wt line pipe.
These test headers are limited to use on test sections with maximum test pressure of
187.167 bar at the location of installation.

4.1.1.2. Extra High Pressure Test Header fabricated with extra purchased 32mm wall thickness
pipe.
Only these test headers to be used with test pressures exceeding 187.167 bar.
Pipe Details: ID 930.4mm, WT 32mm, Grade API 5L X70
Note: The 32mm wt test headers can be used for all test sections.

4.1.2. Fabrication of 30” Test Headers

4.1.2.1. Test Headers are fabricated from 22.2mm line pipe.

4.1.3. Test Header Pre-Test

All Test Headers will be hydrostatic pre-tested in above ground position for two (2) hours to a
pressure equivalent to 100% SMYS.
A Test Package is providing the Test Head pressure calculations, all Instrument Certificates,
Material Certificates, and Welding & NDT Package.

Test Header Pre-Test Pressures and Maximum Operating Pressures

Max Pre-Test Pressure Max. Operating Pressure
Size Test Header WT
(100% SMYS) (fact. 1.25)

38” (ID 930.4mm) 32mm 306.590 bar 248.400 bar

38” (ID 930.4mm) 23.7mm 233.650 bar 186.920 bar

30” (OD 762mm) 22.2mm 281.220 bar 224.970 bar

4.1.4. Test Header Design

Principle Test Header Design for 30” and 38” pipeline.

For Details please refer to Appendix 10

Pig Stopper 3 nos of Pigs

4.2. Pigs

Bi-Directional Pigs will be used for water filling and dewatering of the test sections. Bi-Directional Pigs
are developed to travel through the length of pipeline in either direction to function for air-free water
filling of test section as well for dewatering the section in reverse direction if required

The steel pig-body is designed to hold two set of replaceable supporting and sealing discs at the front
and the rear end. The outside diameter of the support discs at the front and the rear end is the same as
the inner pipeline. The sealing discs are slightly oversized to ensure a proper seal to the inner pipe wall.
The support and sealing discs are made from Omnithane® polyurethane. The pigs are designed to pass
through 3D Bends and will be located in the test headers exactly between the launching and receiving
valves.

Bi-Directional Pig

Applications: Water Filling, Dewatering

For detailed drawing please refer to Appendix 11

Bumper Bar with

device to fit a
transmitter
Bi-Directional Running
Direction

Sealing Guiding
4.3. Water Basin Discs Disc

Water basins are constructed in areas with low water abstraction sources and to be filled with water and
hold the quantity of water required for a non-interrupted water filling of test sections.
Also the water basins can be used for de-watering operations.
The deciding factors for the size and holding capacity of the basin are:
o primal the demand of water required to fill the sections
o the expected hourly water intake from the water well and the hourly water abstraction by the water
pumping into the line
o evaporation of water

CTR has applied for the extra land for construction of water basins.
This document is the property of Yemen LNG Company. It must not be stored, reproduced or disclosed to others without written
authorisation from the Company.
Document number
Hydrotest Plan YE-001-20-SOC-PLN-09275
Revision: 02 Status: IFR
Document Type: PLN System / Subsystem: 99 Date: 13/07/07
Contractor document number: Page 13 of 73

Note: The extra land request is including the location for water drilling and hydro-test platform.

The area will be re-instated after use to original levels.

The filling material for the inner ground layer of the basin will be dessert sand from a dedicated area.
The expected high temperature differences during day & night cause expanding and stretching of the
Geo-membrane. Strong winds may cause the welding of geo-membrane to stop. Therefore construction
work for welding the Geo-membrane may require late night work. Night work permits will be obtained and
work carried out in accordance to the requirements of the permit.

Safety barriers or berms are to be installed to prevent unauthorized personnel or animals entering the
water basin.
Only authorized personnel are permitted to enter the water basin area.
Bulwark ladders or/and rescue ropes along the inner berms of the bund wall are in place for personnel to
escape from the water basin.
Electrically submersible pumps or other adequate equipment are used for water abstraction from the
water basin and transfer to the pumping platform.

Below is a brief description for the handling of Geo-membrane Material. For more detailed
information including transport and storage please read the Manufacturers Instructional Manual and
recommendations as well the Method Statement of Welding of Geo-membrane

The total inner surface of the water basin is sealed welded with “Junifol HDPE Geo-membrane”
material laid out on the sub-soil from crest to crest of the surrounding bund walls.
Protective covering geo-textile layers underneath and on top the Geo-membrane is protecting
against damage.
The Welding-Technician is supervising the work and introduce the procedure of work and also is
training personnel as the work is progressing. The safety instructions and work instructions of the
Technician is strictly to be adhered to.
Before welding the Geo-membrane stripes a test weld is carried out to adjust and learn the settingsof
the welding machine at the local conditions.
A periodically control of the quality of the welded seams is assuring the seal ness of the Geo-
membrane sealing.

To ensure a leak free seal of the water basin attention is paid to

- The sand subsoil well the berm of the surrounding bound wall shall be clean, levelled and
compacted and free of sharp objects.
- The angle of the ascending slopes of the inner berm is recommended with a ratio of 1:2.5 or
less, more depending on the bund wall material.
- The anchor trench or other more practical solutions around the crest of the bound wall is
securing the endings of the Geo-membrane sealing.
- The anchoring on slopes, with also supporting the stability on the slope.
- Stability of the sealing system on slopes.
- Change of weather conditions can have essential influence on the quality of joint and may
require re-settings of the welding machine.
- Protecting the Geo-membrane against damage by wind with adequate weighting on the surface.
- Protecting the welding machine against directs influence of wind – it has effect on the quality of
welding joint.
- Temperature changes occur expanding and shrinking of the material. The methodology of work
shall prevent damage to Geo-membrane under high tension.

4.3.1. Location of Water Basins

The 1st water basin is located at KP 317+000. The 2nd water basin is located at KP 126+470.
The hydro-geological survey for under ground water sources has located water sources in this
area. The field data of the survey will be analysed for the most suitable water drilling location.
Consideration will be paid to the suitability of water basin construction and building hydro
testing platform as well as to the social impact at this region

Area KP Dimensions Storage Capacity Remarks

ZONE 1 317+000 80 m x 100 m x 3.50m 25,000m3 Water Well & Filling Location

ZONE 2 126+470 *) 150 m x 150 m x 2.50m 45,000m3 Water Well & Filling Location

*) Final Water Basin dimensions and location in Zone 2 area is depending on the result of the ground water
survey in this area and the actual delivery of the water well after completion of drilling.

4.4. Water Sources

The water filling of the test section requires a large quantity of water at various locations.
The optional sea water supply from the near-by shore at Bal Haf is not feasible as it will interfere with
the ongoing construction and road work activities of the Bal Haf.
Since there are no adequate water sources such as Rivers, Lakes, or Water Mains available, Water
Wells will be drilled at selected areas for water abstraction.
In areas unsure of under ground water resources the desired location is hydro geological surveyed to
assess the prospects of successful water abstraction.
Authorization is obtained for the hydro-geological survey at the desired locations.

4.4.1. Water Wells

The required quantity of water for filling test sections will be abstracted from water wells drilled
along the pipeline routing.
The systematically re-use of filling water is minimizing the ground water abstraction and
numbers of water wells.
Authorizations for water well drilling and water abstraction from the water well will be obtained
from the Water Resources Authority.

4.4.2. Locations of Water Wells

st
The 1 water will be drilled at KP 318+000.
No Ground water survey is required due to high ground water level.
nd
The 2 water well is planned to drill in the region of KP 126+470
Regional Hydro-geological survey is locating the under ground water resources

Expected final Production flow Total Abstracted

Location of water well Over time period
depth (estimated) Quantity
KP 318+000 60 m 140 m3/h 40,000 m3 6 weeks

KP 126+470 *) 200m - 400 m 40 -50 m3/h 45,000 m3 10 weeks

*) Final water well location will be determined on result of the Hydro-geologist survey for ground water sources
and the actual capacity of the water well after completion of drilling.

4.4.3. Capacity of water wells

The productiveness of the water well will be conducted post-drilling operations. Assessments
will be made to establish true flow rates, and if poor-inadequate, consideration will be given to
drill an additional well.

4.4.4. Construction of a water well at KP 317+000

Estimated depth of water well at KP 317+000 is 60 meter
Estimated depth of water well at KP 126+470 is 200 – 400m meter

See below the schematic illustration of water wells representative for the water well at KP 317
(60m depth) and KP 126 (300m depth).
Dimensions and build-up change with the drilling depth of the bore hole

WATER WELL PROFIL FOR 60 METER

Discharge Water Discharge to

Electrical Cable Valve Water Basin or Pumping Station

Drilling/Concrete Plat form

15“ Drilling
14“ Steel Casing
Cementing

13,5“ Drilling
10“ PVC Casing

Gravel
Submersible Pump, Level

PVC Screen
40m – 60m

FINAL DEPTH 60m

WATER WELL PROFIL FOR 300 METER

Discharge
Valve
Electrical Cable
Water Discharge to
Water Basin or Pumping Station

Drilling/Concrete Plat form

15“ Drilling
Cement Grout
12 3/4“ Steel Casing
Gravel
- 12m

12 1/4“ Drilling

8 5/8“ Steel Casing

Gravel

Submersible Pump, Level

- 234m
66m Slotted Screen

- 294m
FINAL DEPTH -

5.0 SECTION WATER

5.1. Filling Water

The filling water is provided from water wells.

The systematically economical method of re-using chemically treated filling water from section to section
is minimizing the water abstraction, use of chemicals and effects to environment during de-watering

5.1.1. Water Quality

Prior to extraction of hydro-test water from the water well or water basin a water quality analysis will
be conducted. Samples will be analyzed at the location water abstraction using an adequate field
water analysing lab.
The filling water shall be clean and filtered through 100 mesh water filter to remove particles in
excess of 250 micron.
The filling water will be passing through sedimentation/de-aeration tanks and filtered through a 100
mesh screen water filtration skid to be clean and free of sediments.

5.1.2. Water Sampling

The filling water will be analyzed by a of the Company approved laboratory (see appendix 21) in
order to define the necessary chemical treatment of the water in accordance to the company
specifications.

Lead time for the sample collection will consider the time to, collected the sample, have the sample
analyzed and results known, and to: calculate the amount of additional chemicals that may be
required, if any.
The PH value will be between 6 - 8
Water samples analysed for a scale tendency prediction tests.
- Calcium
- Barium
- Strontium
- Magnesium
- Sodium
- Iron
- Bicarbonate
- Sulphate
- Chloride
- PH measurement.
- TDS

At the intermediate pumping stations, water samples will be taken for monitoring of residual biocide
levels as well as dissolved oxygen to maintain the level of concentration.

The water in front and between the pigs will not be chemically treated.

The filling water is chemically treated with the appropriate dosage of chemical inhibitor/scavenger on
independent recommendation to prevent corrosion and kill all bacteria in the pipeline.

5.2. Chemicals

The water filled into the pipeline systems shall be chemically treated with Biocide -where applicable- to
act against bacteria and anaerobic bacteria’s and oxygen scavenger (For MSDS refer to Appendix 12) to
limiting the oxygen within the filling water prior to injection into the individual pipeline sections. (Chemical
treatment of filling water will be in accordance to GS COR 560 Specifications)

5.2.1. Chemical Products

Based on the water analysis result (for lab-analyse see appendix 21) and the duration of fill water
remaining in the test section the following CHAMPION Chemical Products (see appendix 20) will be
used to make the water non-corrosive with the lowest possible environmental impact:

Oxygen Scavenger OS2 @ dosing rate: 120ppm

Biocide Bactron 1710 @ dosing rate: 180ppm
Dosing rate will be established based on water analysis of the actual water
sample from the water well.

The use of Biocide B1710 and Oxygen Scavenger OS2 at the stated concentrations i.e. 180 PPM and
120 PPM will provide effective biocide and oxygen scavenging performances to treat water with high
salt content and protect the pipe from corrosion and bio contamination.

Oxygen Scavenger OS2

When dosed at 120ppm in water with high saltwater content at 5 and 20 °C at 120PPM can scavenge
an initial 9 PPM oxygen content down to trace levels 10 part per billion (PPB) in under 2 minutes. The
rate of oxygen depletion is faster with increasing temperature.

Biocide B1710
When dosed at 180ppm will complete a Log 8 bacterial/ml 100% kill in 6 hours. Tests were carried
out at 25°C on bacteria levels at 1.5 to 2 orders of magnitude greater than that of seawater.

In-Field Analysis
Periodically monitoring of the chemical injection rates and the in-field analysis of chemical level of the
filling water will be used to correct the concentration if required.

Chemical injection points

The Oxygen Scavenger will be injected as far upstream of the Biocide as possible. This will minimize
any interaction between the components and provide the best conditions for the oxygen scavenger to
be fully effective.

Chemical Injection Pumps

Electrical Chemical injection Pumps with the correct flow and adjustable flow rates will be used for
injecting the chemicals.

The MSDS are provided in Appendix 12

5.2.2. Water Treatment for Discharge Water

The water in front and between the pigs is not chemically treated. If subsequent test sections are
ready, this water will be inserted ahead of the fill pigs. If subsequent test sections are not
ready/complete, untreated water will be suitable disposed of along ROW.
Especially care is to be taken during the water discharge with chemical concentrations for
environmental friendly disposal.
▪ The Oxygen Scavenger OS2 can be disregarded as contributing to the environmental
evaluation which leaves the Biocide B1710 as the influencing factor.
▪ The product Biocide B1710 is deactivated within a considerable short time period and is fully
biodegradable.

The OCNS (Offshore Chemical Notification Scheme) has carried out Hazard Assessments on
chemical products in which Chemicals are ranked by Hazard Quotients (HQ).
The products Biocide B1710 and Oxygen Scavenger OS2 are ranking in Lowest Hazard with a HQ of
>0 and <1 in a scale of ≥1000.

5.3. Water Disposal

Water Disposal to the Environment

The degrading process of the Biocide contaminated water is the influence factor for a direct water
disposal to the environment in a environmental friendly manner.
In order to minimize environmental impact and surrounding pollution the area of disposal shall be
limited by banks. Selected Areas shall be agreed with Company and all necessary permission
obtained.
Oxidizing agents are commonly used in the treatment of water
The dosing of oxidizing agents (Hydrogen Peroxide) in the discharging water stream is permitting the
direct water discharge to the environmental in a controlled/environmental friendly manner. Pre-
cautions will be made by using geo-textile on the soil to prevent erosion.

The extra dosing of the oxygenation agent is accelerating the process of degrading the Biocide within
1 – 15 minutes much depending on the PH value and water temperature.
To accelerate the re-oxygenation process compressed air will be injected via a 4 inch pipe with 2mm
holes on the bottom of the breaktank. More specific field data’s may significant reduces the contact
time. A high PH value and water temperature at 20°C will reduce the deactivation time close to 1
minute.
The Hydrogen Peroxide is low toxicity and fully consumed in reaction with B1710.
For MSDS of Hydrogen Peroxide refer to Appendix 12
To determine Bactron 1710 residuals in the discharge water field analyzer kit will be used. (See
appendix 19
Sketch for principle equipment set-up for bulk water disposal

Injection of
Hydrogen 40ft Water Tank with
Peroxide overflow / buffers
Diffuser
Water Disposal to
Environmental

Drain pipe
Diffuser

38“/30“ Pipe

6.0 TEST SECTIONS

The Sectioning of the pipeline is based on the present available data’s for the line length, profile, line pipe
wall thickness location classes and design factors. It also depends on proposed water sources and water
storage basins. Final limits of the test sections will be based on the As Built data.

6.1. 38“ Main Line

The 38” Main Gas Line is divided into twenty-eight (28) test sections excluding the Pig Launcher and
Receiver Facilities at the KPU and the Bal Haf Plant and the 10 nos. of Block Valve Stations.

The Launcher and Receiver Facilities at the KPU and at Bal Haf will be tested separately incorporating
the Anchor Blocks in these tests. The exact test limits will be defined at later stage.

The ten (10) Block valve stations will be tested separately under separate testing specification.

For section details please refer to Para. 6.4

6.2. 30” Transfer Line

The 30” Transfer Line will be tested in one (1) section excluding the Pig Launcher and Receiver Facilities
at the CPU and the KPU

The Launcher and Receiver Facilities at the CPU and the KPU will be tested separately with the Anchor
Blocks included these tests. The exact test limits will be defined in later stage.

The maximum test pressure calculations are based on 100% SMYS of the pipe material, of the thinner of
the two different wall thicknesses:
a) 22.2mm

b) 15.9mm
For section details refer to Para 6.4

6.3. Definition of Test Sections

The splitting of the test sections is based on following criteria’s.

1. Test Section Limits

All BVS KP Positions are used at test section limit locations.
Elevation difference between high points and low points for the test pressure head to remain within
the maximum and minimum test pressures limits. Additional allowance is given to pressure
stabilization and temperature related pressure fluctuations. The actual test pressures will be
recalculated based on the As Built figures.

2. Test Sections allow for BVS to be included in test sections if they are available at the time.

3. Maximum Test Pressures

The maximum hydrostatic test pressure is calculated to 100% SMYS value of the pipes.
The Transfer Line has a nominal pipe size with a constant OD of 30” (762mm) with changing the ID of
the pipe accordingly to the different wall thicknesses of 15.9mm and 22.2mm
Wherefore special notice to be given to the abnormal size of the 38 Main Line with the constant ID of
all pipes of 930.4mm and the consequently change in OD-size of the pipes accordingly to the different
wall thicknesses of 16.2mm,18mm and 23.7mm.
Note: In variation to above higher test pressures to 102% SMYS may be reached locally but require
Company approval. For example if the locating of test section limits in safe working locations is
increasing the hydrostatic head pressure to rise above 100% test pressure. In any case the pipe
certificates of the effected pipes will be reviewed with Company Representative for approval.

4. Minimum Test Pressures

See Para 8.

5. Multiple Wall Thicknesses and Design Factors

Each Hydro test Sections allow for multiple wall thickness and design factors where the maximum test
pressure is not exceeded at the different wall thicknesses.

6. Allowances for Pressure Fluctuations.

All Hydro test Sections allow in average for a test pressure margin of approximately 2 bars to give
allowance for test pressure stabilization and pressure fluctuations effected by temperature changes.
Anyhow, we understand that the maximum test pressure can exceed the 100% SMYS. In this case
pressure will be released to 100%. The drained volume will be measured and calculated in the final
acceptance calculation.

7. The Main Pipeline is considering the following pipe wall thickness changes and locations.
a) 38-inch Main Line

From KP To KP Wall Thickness

0 0+670 23.7 mm
0+670 64+488 18.0 mm
64+488 136+300 16.2 mm
136+300 138+325 18.0 mm
138+325 199+053 16.2 mm
199+053 202+800 18.0 mm
202+800 204+200 23.7 mm (extra pipe for plateau descent)
This document is the property of Yemen LNG Company. It must not be stored, reproduced or disclosed to others without written
authorisation from the Company.
Document number
Hydrotest Plan YE-001-20-SOC-PLN-09275
Revision: 02 Status: IFR
Document Type: PLN System / Subsystem: 99 Date: 13/07/07
Contractor document number: Page 21 of 73

204+200 299+775 18.0 mm

222+100 222+500 23.7mm (extra pipe for steep slope area)
299+775 322+687 23.7 mm
Note: KP Locations for the extra requested pipes wt 23.7mm will be recalculated to the As Built Data.

b) 30-inch Transfer Line

From KP To KP Wall Thickness

0 1+000 22.2 mm
1+000 23+968 15.9 mm
23+968 24+952 22.2 mm

8. Test Section splitting is derived from taking class location, design pressure and test locations into
account.
a) 38-inch Main Line

Location Class Wall Th. from KP to KP

Design Pressure Min Test Pressure
(DP x 1.25 )
Class 2 Div 2 23.7 mm 0 0+633 122.800 bar 153.500 bar
Class 1 Div 2 18.0 mm 0+633 64+488 122.800 bar 153.500 bar
Class 1 Div 1 16.2 mm 64+488 136+300 122.800 bar 153.500 bar
Class 1 Div 2 18.0 mm 136+300 138+325 120.150 bar 150.188 bar
Class 1 Div 1 16.2 mm 1)138+000 199+053 117.830 bar 147.288 bar
Class 1 Div 2 18.0 mm 2)200+100 203+500 120.600 bar 150.750 bar
(Class 1 Div 2 23.7 mm 202+800 204+200 = extra heavy wall)
Class 1 Div 1 18.0 mm 203+500 299+775 134.500 bar 168.125 bar
(Class 1 Div 2 23.7 mm 222+100 222+500 = extra heavy wall)
Class 2 23.7 mm 299+775 322+753 134.500 bar 168.125 bar
Note: KP Locations for the extra requested pipes wt 23.7mm will be recalculated to the As Built Data’s.

b) 30-inch Transfer Line

Location Class Wall Th. from KP to KP Design Pressure Min Test Pressure

Class 3 22.2 mm 0 1+000 130 bar 182.0

bar (x1.4)
Class 1 Div 1 15.9 mm 1+000 23+968 130 bar 162.5 bar (x1.25)
Class 3 22.2 mm 23+968 24+952 130- bar 182.0 bar (x1.4)

6.4. Test Section Details (Zone 1 – 2 – 3)

The permanent Facilities at the CPU, KPU and BAL HAF are excluded from below test sections.
The test limits for the main line test sections need to be defined at these locations.

30 inch (25km) Transfer Line, Yemen LNG Gas Pipeline Project

Actual Test Pressure Max/Min

Test Pressure Start/End Point

Max Pipe Yield Strength (%)

Design Pressure Start/End

Design Pressure Max/Min

WT Start/End (mm)
Elev. Start/End (m)

Elev. Max/Min (m)

@ 100% SMYS
WT 22,2 (mm)
Start/End (Kp)

WT 15,9(mm)
Elev. Diff. (m)
Volume (m3)
Length (km)

@ 15,9mm

@ 22,2mm
Section #

(bar)

(bar)
25,000 943,0 973,9 22,2 130 130 198,3 201,4
1 25,000 11,500 32,8 x x 100
0,000 973,0 941,1 22,2 130 130 201,1 198,2

38 inch (323km) Main Line, Yemen LNG Gas Pipeline Project

Design Pressure Max/Min (bar)

Max Pipe Yield Strength (%) @

Actual Test Pressure Max/Min
Test Pressure Start/End Point
Design Pressure Start/End
WT Start/End (mm)
Elev. Start/End (m)

Elev. Max/Min (m)

@ 100% SMYS
WT 16,2 (mm)
Start/End (Kp)

Elev. Diff. (m)

Volume (m3)

WT 18 (mm)
Length (km)
Section #

WT 23,7

16,2mm

23,7mm
18mm
(bar)

(bar)
1 0,080 31,987 21,751 943,7 962,0 65,3 23,7 x x 122,8 122,8 175,2 179,8 100 75
32,067 899,1 896,7 18,0 122,8 122,8 179,6 153,5
32,067 899,1 931,2 18,0 122,8 122,8 175 179,8
2 32,366 22,009 81,2 x 100
64,433 856,6 850,0 18,0 122,8 122,8 179,1 153,5
64,433 856,6 856,6 16,2 122,8 122,8 160,1 162,4
3 22,209 15,102 24,0 x 100
86,642 843,1 832,6 16,2 122,8 122,8 161,4 153,5
86,642 843,1 881,4 16,2 122,8 122,8 162,3 162,4
4 22,417 15,244 39,4 x 100
109,059 881,4 842,0 16,2 122,8 122,8 158,8 153,5
109,059 881,4 962,5 16,2 122,8 122,8 162,4 162,4
5 10,541 7,168 81,1 x 100
119,600 962,5 881,4 16,2 122,8 122,8 154,5 153,5
119,600 962,5 1020,0 16,2 122,8 122,8 162,4 162,4
6 6,870 4,672 81,1 x 100
126,470 1020,0 962,5 16,2 122,8 122,8 156,7 156,7
Water Well, Filling Location, Water Basin, Kp 126
126,470 1020,0 1042,7 16,2 122,8 122,8 162,1 162,4
6a 4,730 3,216 25,6 x 100
131,200 1042,7 1017,1 16,2 122,8 122,8 159,9 159,9
131,200 1042,7 1124,7 16,2 122,8 122,8 162,4 162,4
7 5,100 3,468 82,0 x 100
136,300 1124,7 1042,7 16,2 122,8 122,8 154,4 153,5
Limit Work Zone 2/3 (Plateau Ascent)
136,300 1124,7 1424,7 18,0 120,2 120,2 179,5 179,8
8 2,455 1,669 303,5 x 100
138,755 1418,0 1121,2 18,0 120,2 120,2 150,7 150,2
138,755 1418,0 1490,5 18,0 120,2 120,2 156 162,4
9 27,645 18,8 137,6 x x 100 86,8
166,400 1490,5 1352,9 16,2 117,8 117,8 148,9 147,3
Intermediate Pump Station at Kp 166,400
166,400 1490,5 1621,7 16,2 117,8 117,8 162,4 162,4
10 23,500 15,98 131,2 x 100
189,900 1620,0 1490,5 16,2 117,8 117,8 149,7 147,3
189,900 1620,0 1705,9 16,2 117,8 117,8 162 162,4
11 9,200 6,256 89,7 x 100
199,100 1705,9 1616,2 16,2 117,8 117,8 153,6 147,3
199,100 1705,9 1707,7 16,2 117,8 120,6 117,8 222,6
12 5,100 3,468 759,0 x x x 91,3 100 95,1
204,200 948,7 948,7 23,7 120,6 117,8 222,6 147,3
204,200 948,7 961,1 18,0 134,5 134,5 171,6 179,8
13 3,400 2,312 95,9 x 100
207,600 865,2 865,2 18,0 134,5 134,5 179,8 168,1
Actual Test Pressure
WT Start/End (mm)
Elev. Start/End (m)

Elev. Max/Min (m)

Start/End Point @
Design Pressure

Design Pressure

Strength (%) @

Strength (%) @
Max Pipe Yield

Max Pipe Yield

Start/End (bar)
WT 16,2 (mm)
Start/End (Kp)

Test Pressure
Max/Min (bar)

Max/Min (bar)
Elev. Diff. (m)
Volume (m3)

100% SMYS
WT 18 (mm)
Length (km)
Section #

WT 23,7

16,2mm

23,7mm
18mm

207,600 865,2 865,2 18,0 134,5 134,5 169,9 179,8

14 10,130 6,888 101,0 x 100
217,730 812,0 764,2 18,0 134,5 134,5 175,1 168,1
217,730 812,0 822,5 18,0 134,5 134,5 171,7 186,9
15 4,770 3,244 165,0 x x 100 79,9
222,500 657,5 657,5 23,7 134,5 134,5 186,9 170,7
222,500 657,5 658,6 18,0 134,5 134,5 170,5 179,8
16 9,055 6,157 95,6 x 100
231,555 563,0 563,0 18,0 134,5 134,5 179,8 168,1
231,555 563,0 563,3 18,0 134,5 134,5 170,1 179,8
17 12,045 8,191 98,7 x 100
243,600 464,6 464,6 18,0 134,5 134,5 179,8 168,1
243,600 464,6 464,6 18,0 134,5 134,5 170 179,8
18 13,800 9,384 99,6 x 100
257,400 365,0 365,0 18,0 134,5 134,5 179,8 168,1
257,400 365,0 365,0 18,0 134,5 134,5 170,5 179,8
19 7,815 5,314 95,0 x 100
265,215 270,0 270,0 18,0 134,5 134,5 179,8 168,1
265,215 270,0 292,0 18,0 134,5 134,5 172,2 179,8
20 14,985 10,19 99,5 x 100
280,200 276,6 192,5 18,0 134,5 134,5 171,5 168,1
280,200 276,6 380,0 18,0 134,5 134,5 179,8 179,8
21 9,000 6,12 103,4 x 100
289,200 378,8 276,6 18,0 134,5 134,5 169,8 168,1
289,200 378,8 396,1 18,0 134,5 134,5 171,7 179,8
22 3,500 2,38 99,6 x 100
292,700 296,5 296,5 18,0 134,5 134,5 179,8 168,1
292,700 296,5 296,5 18,0 134,5 134,5 172,1 179,8
23 2,200 1,496 78,7 x 100
294,900 217,8 217,8 18,0 134,5 134,5 179,8 168,1
294,900 217,8 217,8 18,0 134,5 134,5 171,4 179,8
24 3,000 2,04 85,1 x 100
297,900 166,6 132,7 18,0 134,5 134,5 176,5 168,1
297,900 166,6 175,0 18,0 134,5 134,5 171,6 179,8
25 1,848 1,257 92,4 x 100
299,748 85,2 82,6 18,0 134,5 134,5 179,5 168,1
299,748 85,2 91,7 23,7 134,5 134,5 226,6 234
26 17,252 11,73 82,1 x 100
317,000 9,7 9,6 23,7 134,5 134,5 234 168,1
26 317,000 9,7 14,1 23,7 134,5 134,5 233 234
5,654 3,845 14,3 x 100
A 322,654 7,6 -0,2 23,7 134,5 134,5 233,2 168,1

7.0 OPERATIONS

The hydro test operations of the 38” Main Line and the 30” Transfer Line is grouped into three Zones
accordingly to the available water sources and the construction plan.
Water filling and water disposal program is minimizing the water abstraction from underground water
sources, use of chemicals and disposal of chemically treated water.
The sequence is tentative and may differ from the final sequence. Details will be included in the individual
test plan for each section.

7.1. Work Zones

Total
Nos. of Total Volume
From KP Location To KP Location Diam. Length
Sections (m3)
(km)
Plateau
Zone 1 322+754 Bal Haf 204+200 38” 14 118.6 80,650
Descent
Plateau
Zone 2 136+300 0+000 KPU 38” 7 136.3 92,680
Ascent
0+000 (30”) KPU 25+000 CPU 30” 1 25 10,400
Top TOP
Zone 3 136+300 204+200 38” 5 67.8 46,100
Plateau PLATEAU

7.2. Water Abstraction & Disposal Locations

Water Abstraction Water Disposal

Estimated
Location Water Location Chemical Estimated
Volume Application
(KP) Well (KP) treated Volume (m3)
(m3)
322+754 Flush Water No 100
Optional Flush Water /
265+215 Section Volume No/Yes 6,000
Zone 1 317+000 YES 40,000
231+555 Section Volume Yes 38,000

204+200 Flush Water No 1,000

136+300 Flush Water No 1,000
136+300 Section Volume Yes 8,500
126+470)*
Zone 2 YES 45,000 32+067 Section Volume Yes 37,104
30” Line
)** KP 0 Flush Water No 1,000

25 (CPU))** Flush Water YES 11350

)* Water abstraction / Filling location @ KP 126+470 is depending on the hydro-geological survey for under ground
water sources in this area and the delivery of the water well.
)** Investigation for Water source at KPU or CPU is still to be done.

166+400 Section Volume Yes 25,000

Use water well from
Zone 3 17000
Zone 2 @ KP 126+470*)
204+200 Section Volume Yes 9,722

7.3. For Work Task please refer to Appendix 9

7.4. Operational Sequence ZONE 1

Below work sequence is to read in conjunction with Para. 6.4 and Appendix 9 Test Section Details
and Work Program

Work Zone 1, KP 322+654 to KP 204+200 is divided in 14 Test Sections

Test Volume
From KP To KP Length (m) Test Header
Section (m3)
13 204+200 207+600 3,400 2,312 3 Pigs, wt 23.7mm
14 207+600 217+730 10,.130 6.887 3 Pigs, wt 23.7mm
15 217+730 222+500 4,770 3.243 3 Pigs, wt 23.7mm
Intermediate Pump Station (to be selected during operations) See Appendix 13-3
3 Pigs, wt 23.7mm +
16 222+500 231+555 9,055 6,156
32mm
17 231+555 243+600 12.045 8,189 3 Pigs, wt 23.7mm
18 243+600 257+400 13,800 9,382 3 Pigs, wt 23.7mm
Intermediate Pump Station (to be selected during operations) See Appendix 13-3
19 257+400 265+215 7,815 5,313 3 Pigs, wt 23.7mm
20 265+215 280+200 14.985 10,188 3 Pigs, wt 23.7mm
This document is the property of Yemen LNG Company. It must not be stored, reproduced or disclosed to others without written
authorisation from the Company.
Document number
Hydrotest Plan YE-001-20-SOC-PLN-09275
Revision: 02 Status: IFR
Document Type: PLN System / Subsystem: 99 Date: 13/07/07
Contractor document number: Page 25 of 73

21 280+200 289+200 9,000 6,119 3 Pigs, wt 23.7mm

22 289+200 292+700 3,500 2,380 3 Pigs, wt 23.7mm
23 292+700 294+900 2,200 1,496 3 Pigs, wt 23.7mm
24 294+900 297+900 3,000 2,040 3 Pigs, wt 23.7mm
25 297+900 299+748 1,848 1,256 3 Pigs, wt 23.7mm
26 299+748 317+000 17.252 11.729 3 Pigs, wt 32.0mm
Main Water filling station and Water Well KP 317+000 See Appendix 13-1
26a 317+000 322+654 5.754 3.912 3 Pigs, wt 32.0mm

The only water abstraction location for ‘Zone 1’ test sections is KP 317+000. The quantity of water
which is required for water filling of TS 26a to TS 17 is abstracted from water well. A water basin with
3 3
20,000m storage water is used to maintain a continuous water filling rate of 200m per hour. The
necessity for chemically treatment of pipeline fill water will be determinate on result of the water analysis
taken from the water well used for water filling of the pipeline.

Method of reusing water

1st Step Water abstraction for water filling TS 26a to TS 20, Volume @ 40,000m3
nd
2 Step Water abstraction for water filling TS 19 to TS 17, Volume @ 23,500m3
3rd Step Re-use of water from TS 21 to TS 19 by transferring the volume to TS 16,15,14 and 13.

The test sections from TS 26a to TS 20 will be filled with chemically treated water from the water basin
and water well at KP 317+000. These test sections will be filled and tested in two steps. In between the
two steps the basin at KP 317+000 will be re-filled with water.
After completions of the hydrostatic testing on sections TS 26a to TS 20, the section volumes will be left
into pipeline at static pressure + 1 bar ( at highest point ) until condition for dewatering are ready to
start.
The filling of Sections 19-18-17 will be filled through by-passing water from water basin at KP 317
throughout all tested sections.

No chemical treatment is required for the volume of water in front and between the pigs. This water is
transferred from section to section for disposal at the final receiving end.
Water disposal locations are at KP 265+215 for partially section water discharge, KP204+200 for
discharge of the accumulated water in front and between the pigs and KP 231+555 for the main water
discharge.

Major preparation works at KP 317+000

▪ Water well drilling for water abstraction
▪ Water Basin construction for water storage of 20,000 m3 for line filling
▪ Building a Water Filling/Testing Platform
▪ Filling of water basin with 20,000 m3 of water
▪ Set up water Pumping Station and Chemical Injection Station
▪ Storage of Biocide B1710 and Oxygen Scavengers OS2 to maintain the required chemical
concentration of the filling water.

General preparation for water filling and dewatering

▪ Adequate test headers welded at the section limits with the preloaded pig constellation for water
filling and dewatering activities
▪ Connecting of sections for multiple section water filling/dewatering
▪ Preparation of water disposal locations.
This document is the property of Yemen LNG Company. It must not be stored, reproduced or disclosed to others without written
authorisation from the Company.
Document number
Hydrotest Plan YE-001-20-SOC-PLN-09275
Revision: 02 Status: IFR
Document Type: PLN System / Subsystem: 99 Date: 13/07/07
Contractor document number: Page 26 of 73

General preparation for hydro test

▪ Temperature probes set along the test section
▪ Isolation of the tested section
▪ Set-up testing spread at the relevant testing locations
▪ Provide sufficient water storage for (re-) pressurizing of test sections
▪ Set-up for sufficient water supply for pressurizing of the test sections

7.4.1. Hydrostatic Testing of test sections TS 26a to TS 20

Hydrostatic testing will commence with TS 26a and continue section by section to TS 20
Major preparation works
▪ Isolate test section
▪ Set-up testing spread at the relevant testing locations
▪ Provide sufficient water storage for (re-) pressurizing of test sections
▪ Set-up for sufficient water supply for pressurizing of the test sections
o From water filling location, transferred section by section to the pressurization location.
o By sufficient water storage capacity.

Sequence of Hydrostatic testing of test sections. (See Appendix 9)

Appendix 9 shall be re-structured based on the above situation.

7.4.2. Continue water filling on test sections TS 19 , TS18 and TS 17

7.4.3. Hydrostatic Testing of test sections TS 19 to TS 17

On completion of hydrostatic testing on above sections the water filling operations will
commence with transferring the water from already tested sections for filling of the following
sections.

7.4.4. Water filling of TS 16 to TS 13 with transferring water from dewatering of test sections TS 21 TS
20 and TS 19

Major preparation works

▪ Set-up compressor spread at dewatering point
▪ Interconnect an intermediate pumping stations

Sequence of the combination of Dewatering and Water Filling Operation

▪ Launch dewatering pig TS 21 with compressed air, moving the sections water columns
section by section to the intermediate pumping station at KP 231+555
▪ Start the water transfer pumping station at KP 231+555 to transfer water into test sections
TS 16 – TS 15 – TS 14 – TS 13
▪ Once water filling of TS 16-15-14-13 is completed dewatering could proceed with completion
of TS 19 to Disposal pond at 231+555
▪ Same process will be apply to TS 18 and 17
▪ Section tie-in’s 17/18 -18/19
▪ Pre-commissioning activities (i.e. swabbing /cleaning / pre-drying ) shall immediately start.

7.4.5. Hydrostatic Testing of test sections TS 16 to TS 13

▪ Sections pressurization
On completion of Hydrostatic Testing on above sections the dewatering on above sections will
commence.

7.4.6. Dewatering TS-16 to TS 13

Major preparation works

▪ Connecting Compressors on test headers at KP 204+200 dewatering TS 13 to TS 16

▪ Connecting sections TS 13 to TS 16 for section by section water removal
▪ Set-up for water disposal pond and facilities at KP 231+555
▪ Installation of pipe work for dewatering/water transfer from section to section.

Sequence of Dewatering Operation

▪ Dewatering of TS 13 from KP 204+200 to KP 207+600

▪ Dewatering of TS 14 from KP 207+600 to KP 217+730
▪ Dewatering of TS 15 from KP 217+730 to KP 222+500
▪ Dewatering of TS 16 from KP 222+500 to KP 231+555

7.5. Operational Sequence ZONE 2

Below work sequence is to read in conjunction with Para. 7.4 Test Section Details and Work Program

KP 136+300 to KP 0 (CPU) plus the 30” line is divided in 7 Test Sections

Section #

Section Section Length Volume

Test Header
Start (KP) End (KP) (m) (m3)

30in 25 0 25 11,400 3 Pigs, wt 22.2mm

1 (38”) 0+080 32+067 31,987 21,747 3 Pigs, wt 23.7mm
2 32+067 64+433 32,421 22,042 3 Pigs, wt 23.7mm
3 64+433 86+642 22,154 15,062 3 Pigs, wt 23.7mm
4 86+642 109+059 22,417 15,241 3 Pigs, wt 23.7mm
5 109+059 119+600 10,541 7,167 3 Pigs, wt 23.7mm
6 119+600 126+470 6,870 4,670 3 Pigs, wt 23.7mm
Water filling location Water Basin and Water Well @ KP 126+470
6a 126+470 131+200 4,730 3,215 3 Pigs, wt 23.7mm
7 131+200 136+300 5,100 3,467 3 Pigs, wt 23.7mm
Water Filling Location KP 126+470 is pending. Final location will be determinate upon result of the hydro-geologist
survey for ground water sources in this area.

The only water abstraction location for Zone 2 and Zone 3 Sections is KP 126+470. Filling water will be
abstracted from the water well located nearby the filling location. A water basin will be constructed next
to the water well with 25,000m3 water storage capacity is used to maintain a continuous water filling rate
of 200m3 per hour. The necessity for chemically treatment of the filling water will be determined on
result of the water analysis taken from the water well.

Filling method with the re-using water

1st Step Water abstraction from water well KP 126+470 for filling of TS 6a -TS 7 + TS 6 and TS 5.
Volume 18,520m3
nd
2 Step Water filling of TS 4 + TS 3. De-watering of TS 7 and TS 6a to the water filling station at KP
119+600 for re-use (6683m3) of water filling TS 4 and TS3. Water abstraction from water well
KP 126+470 for filling of TS 4 + TS 3, Volume 23657m3
rd
3 Step Water abstraction from water well for the Filling of TS 2 Volume 22,004m3
4th Step Water filling of TS 1, Volume 21,747 m3, Transfer water from dewatering TS 3 and TS 2
(37,104m3) TS 3 will be emptied. 15357m3 chemical treated water remaining in TS 2.
Note: The 30-in Transfer Line will be separately filled and tested in later stage.

Total quantity of water abstraction from water well at KP 126+470 is 64,182 m3

Major preparation works at KP 126+470

▪ Water well drilling for water abstraction.
▪ Water sampling for assessment of chemical treatment
▪ Water Basin construction for water storage of 25,000 m3 for line filling
▪ Building a Water Filling/Testing Platform
▪ Filling of water basin with the required quantity of water
▪ Set up water Pumping Station and Chemical Injection Station
▪ Water analyse will be taken at this stage and final dosage levels to be incorporated as appendix.

General preparation for water filling and dewatering

General preparation for hydro test

Sequence of work

7.5.1. Water filling of test sections TS 7 to TS 4

1. Water Filling of TS 6a + TS 7, from KP 126+470 to KP 136+300,

The water in front and between pigs is discharged at KP 136+300 to nature as agreed by
the CPY.
2. Water Filling of TS 6, TS 5, - From KP 126+470 to KP 109+059

The water in front and between pigs is transferred into TS 4.

7.5.2. Hydrostatic Testing TS 7 to TS 5

1. Set-up Pressurization spread.

2. Sections Pressurization

7.5.3. Water filling of test sections TS 4 and TS 3

1. Water Filling of TS 4 - From 109+059 KP 86+642

The water in front and between pigs is transferred into TS 3.

2. Water filling of test sections TS 3 From KP 86+642 to 64+433

The water in front and between pigs is transferred into TS 2.

7.5.4. Hydrostatic Testing TS 3 and TS 4

1. Set-up Pressurization spread at TS 4/TS 4 at KP 86+642

Pressurizing / Testing TS 3
2. Set-up Pressurization spread at TS 5/TS 4 at KP 109+059
Pressurizing / Testing TS 4

7.5.5. Water filling of test sections TS 2

1. Water Filling of TS 2 - From 64+433 KP 32+066

The chemical treated water from TS 7 and TS 6a is dewatered to the pumping station at
KP 126+470 in order to be re-used for water filling of TS 2. Balance water quantity for
completing the water filling of TS is abstracted from the water well at KP 126+470

7.5.6. Hydrostatic Testing TS 2

1. Set-up Pressurization spread at TS 3 / TS 2

Pressurizing / Testing TS 3

7.5.7. Water filling of test sections TS 1

1. Water Filling of TS 1 - From 32+066, KP 000+080 (KPU).

Dewatering of TS 3 and partially TS 2 to fill TS 1.

7.5.8. Hydrostatic Testing TS 1

1. Set-up Pressurization spread at TS 1 / TS 2 at KP 32+066

Pressurizing / Testing TS 1 (Water transfer from KP 126+470 water filling station)

Dewatering of TS 1 and TS 2

7.5.9. Dewatering of test section TS 1 from KP 0+080 to KP 32+066 (see appendix 9)

Connecting the compressors at the test header of the 38” Transfer Line at KP 0+080 (KPU) and
reverse launch the two bi-directional filling pigs for dewatering of the section. The pigs will travel

with 1000 meter distance between pig no 1 and pig no 2. Section water is discharged at KP
32+066 in an environmental acceptable manner to the nature, at by the CPY agreed location.

7.5.10. Dewatering of test sections TS 2 from KP 64+488 to KP 32+066 (see appendix 9)

Compressors connected the to the test header of TS 2 at KP 64+488 and launching the 3rd
remaining pig with compressed air. The section water will be discharged at KP 32+066 in an
environmental acceptable manner to the nature. The location of discharge is agreed with the
CPY.

7.5.11. Dewatering of test sections TS 4 – TS 5 – TS 6 from KP 86+642 to KP 126+470 for further use
for water filling of the plateau sections TS 8 - TS 12.
Total volume of chemical treated water available for re-use is 27077m3
Compressors connected to the test header of TS 4 at KP 86+642 and reverse launch the two
bi-directional filling pigs for dewatering of the section. The pigs will travel with 1000 meter
distance between pigs no 1 and pig no 2. The discharge water is passing through TS 5 and TS
6 to the water filling location for further use.
Continue with dewatering of TS 5 and TS 6 following the same sequence as on TS 4.

Upon completion of all dewatering test sections ready for Tie-In.

7.6. Operational Sequence ZONE 3

Below work sequence is to read in conjunction with Para. 7.4 Test Section Details and Work Program

KP 136+300 to KP 204+200

Section Section Length Volume

Section Test Header
Start (KP) End (KP) (m) (m3)

8 136+300 138+755 2,455 1,564 2 Pigs, wt 23.7mm

9 138+755 166+400 27,645 18,845 3 Pigs, wt 23.7mm
10 166+400 189+900 23,500 16,032 2 Pigs, wt 23.7mm
11 189+900 199+100 9,200 6,137 2 Pigs, wt 23.7mm
3 Pigs, wt 23.7mm
12 199+100 204+200 5,100 3,517
+ 32mm

The work Zone 3 is divided into 5 test section. From the Plateau Ascent section (TS 8) to the Plateau
Descent section (TS 12).
▪ The test section TS 6a and 7 will be filled and used as water carrier to fill the Plateau sections TS 8
to TS 12.
▪ The quantity of water required performing the water filling and testing of the test sections is provided
by a) re-using 27077m3 of already chemical treated water from dewatering TS 4 – 5 – 6. This water
is sampled for further re-used to maintain the chemical concentration as per Company
requirements.
▪ The balance of quantity of water required to complete the water filling TS 8 – TS 12 is abstracted
from the water well at KP 126+470 with applying chemical treatment accordingly to the
recommended dosage rates
▪ Water analyse will be taken at this stage and final dosage levels to be incorporated as appendix
This document is the property of Yemen LNG Company. It must not be stored, reproduced or disclosed to others without written
authorisation from the Company.
Document number
Hydrotest Plan YE-001-20-SOC-PLN-09275
Revision: 02 Status: IFR
Document Type: PLN System / Subsystem: 99 Date: 13/07/07
Contractor document number: Page 31 of 73

Filling method with the reusing water

1st Step Water filling of test section 6a and TS 7 (6683m3) to use a water transfer line for water filling
the Plateau test sections. These two sections are filled with already chemically treated water from TS 4
– 5 – 6.
2nd Step Water sampling for maintain the required chemical concentration.
3rd Step Filling of TS 8 – 9 – 10 using the remaining quantity of chemically treated water from TS 4 – 5
– 6 and complete the filling with water abstracted from the water well at KP 126+470.
The required volume of 36441m3 is taken from the remaining water from dewatering TS 4 – 5
– 6 (20394m3) and from water abstraction from the water well at KP 126+470 (16047m3)

5th Step Water Filling TS 11 and TS 12 (9722m3). These two sections filled with re-using the already
chemicals treated water from dewatering TS 9.

During water filling of TS 11 and TS 12 the filling water is sampled at the water transfer station at KP
166+446 in order to maintain the recommended chemical concentrations.

General preparation for water filling and dewatering

1. Adequate test headers welded at the section limits with the preloaded pig constellation for water filling and
dewatering activities
2. Installation of Intermediate Pump station at KP 189+900
3. Connecting of sections for multiple section water filling/dewatering
4. Preparation of water disposal locations.

General preparation for hydro test

1. Temperature probes set along the test section
2. Isolation of the to be tested section
3. Set-up testing spread at the relevant testing locations
4. Provide sufficient water storage for (re-) pressurizing of test sections

Major preparation works

1. Rig up intermediate pump station at KP 166+400 for water transfer filling TS 11 and TS 12
2. Create required back pressure in TS 12 prior to start water filling (to ensure a controlled down
hill moving of the filling pig and a positive pressure at the high point at all time).
3. Connecting of test sections for water transfer from section to section.
4. Connecting Compressors to test header TS 9 at KP 138+755 for launching the dewatering pig
with compressed air.

Water Filling TS 8 and TS 9

1. Water Filling of TS 8 - From KP 126+470 to KP 138+755

Start water filling from the filling station at KP 126+470 and transfer water through TS 6a and
TS 7 for filling TS 8
Start intermediate pumping station for pig launching and filling TS 8. The water volume in font
and between the pigs is transferred into TS 9.

2. Water Filling of TS 9 - From KP 138+755 to KP 166+400

Injecting air pressure in pipeline section for air back pressure in front of the pigs as required.
Continue water filling from pumping station at KP 126+470 through test sections TS 6a – 7and
8 for water filling of TS 9.
The water in front and between the pigs will be transferred into TS 10 or discharged at the end
of TS 9 to the nature as agreed with the COPANY.
This document is the property of Yemen LNG Company. It must not be stored, reproduced or disclosed to others without written
authorisation from the Company.
Document number
Hydrotest Plan YE-001-20-SOC-PLN-09275
Revision: 02 Status: IFR
Document Type: PLN System / Subsystem: 99 Date: 13/07/07
Contractor document number: Page 32 of 73

7.6.1. Hydrostatic Testing TS 9 and TS 8

1. Set-up Pressurization spread at TS 8/TS 9

Pressurizing / Testing TS 9 (use water transferred from KP 126+470)
Pressurizing / Testing TS 8 (use water from water storage tanks)

7.6.2. Water Filling TS 10 - From KP 166+400 to KP 189+900

Main preparation work

▪ Prepare pumping station for water transfer from section to section for water filling TS 10
▪ Prepare for water transfer or for water discharge at the end / start of TS 10 / TS 11 as agreed with
the COMPANY.

1. Water Filling of TS 10 - From KP 166+400 to KP 166+189+900

Water filling for TS 10 will be carried out from pumping station at KP 126+470 transferring the
water through test sections TS 6a – 7 – 8 and 9.into TS 10.
The water in front and between the pigs will be transferred into TS 11 or discharged at the end of
TS 10 to the nature as agreed with the COPANY.

7.6.3. Hydrostatic Testing TS 10

2. Set-up pressurisation spread at TS 9/TS 10

Pressurizing / Testing TS 10 (use water transferred from KP 136+300)

7.6.4. Water filling of TS 11 and TS 12 and with re-using the already chemically treated water from
Dewatering of TS 9.

Sequence of work

1. Water Filling of TS 11 - From KP 189+900 to KP 199+100

Start compressors at KP 138+755 and launch dewatering pigs TS 9 and transfer water out TS 9 to
the intermediate filling station at KP 166+400.
Start intermediate pumping station at KP 166+400 and transfer water through TS 10 to KP 189+900
for water filling of TS 11. The water in font and between the pigs of TS 11 is transferred into TS 12.

7.6.5. Water Filling of TS 12 - From KP 199+100 to KP 204+200

Continue transferring water by dewatering of TS 9 to the intermediate pumping station at KP

166+400.
The intermediate pumping station is transferring the water trough TS 10 and TS 11 for water
filling of TS 12.
The water in front and between the pigs will be discharged to environment at KP 204+200 in an
environmental acceptable manner by CPY agreed location.

7.6.6. Hydrostatic Testing TS 11 and TS 12

1. Set-up Pressurization spread at TS 11/TS 12

Pressurizing / Testing TS 12 (use water transferred from intermediate pumping station
at KP 166+400)
This document is the property of Yemen LNG Company. It must not be stored, reproduced or disclosed to others without written
authorisation from the Company.
Document number
Hydrotest Plan YE-001-20-SOC-PLN-09275
Revision: 02 Status: IFR
Document Type: PLN System / Subsystem: 99 Date: 13/07/07
Contractor document number: Page 33 of 73

2. Set-up Pressurization spread at TS 10/TS 11

Pressurizing / Testing TS 11 (use water transferred from intermediate pumping station at
KP 166+400)

7.6.7. Dewatering TS 6a to TS 12

Pipeline sections will be dewatered in different directions and water discharged at different locations.
▪ Dewatering of TS 9 is partially completed during the water supply for water filling TS 11 and TS
12. The volume of TS 9 is 18795m3 of which 9722 m3 water are transferred to fill TS 11 + 12.
The remaining volume of 9073m3 will be discharged at KP 166+400.
▪ Test sections TS 8 to TS 6a are dewatered section by section in reverse direction to discharge
the water at KP 126+470.
▪ Test Section TS 10 is dewatered in reverse direction and water discharged at KP 166+400.
▪ Test Sections TS 11 and TS 12 dewatered section by section in positive direction with the water
discharge at KP 204+200.
▪ Sufficient back pressure will be kept and maintained at the receiving end accordingly to the
pressure of the water column ahead of the pig.

Sequence of work

1. Re-Commence Dewatering TS 9 (KP 137+755 – KP 166+400)

Compressors for dewatering TS 9 at KP 138+755 are still in place. Installation of water discharge
arrangement at the receiving end at KP 166+400 for water disposal to the nature in an
environmental acceptable manner and water discharge to a CPY agreed location.
▪ Re-start compressors at KP 138+755 continue with dewatering TS 9 until dewatering pig has
been received at the pig receiver at KP 166+400.
▪ The section water is discharged at KP 166+400 in an environmental acceptable manner to the
nature. The discharge location is agreed by the CPY.

2. Dewatering of TS 8 – 7 – 6a
These test sections will be dewatered section by section in reverse direction to discharge the water
will at KP 126+400 in an environmental acceptable manner. The disposal location will be agreed by
CPY.

Dewatering will start with test section TS 8. (KP 138+755 – KP 136+300)

▪ Two nos. of filling pigs will be reverse launched at KP 138+755 with compressed air.
▪ The pigs are launched with 500meter distance between pig no. 1 and pig no. 2.
▪ The section water is transferred into TS 7 at KP 136+300.
▪ On arrival of the dewatering pigs at the receiving end at KP 136+300 – dewatering of TS 7 may
start.

Continue with dewatering of TS 7 (KP 136+300 – KP 131+200)

▪ For dewatering of TS 7 the two water filling pigs at KP 136+300 will be reverse launched using
the compressed air from TS 8.
▪ The two dewatering pigs will be separated by 500 meter between pig no. 1 and pig no. 2.
▪ The section water is transferred into TS 6a at KP 131+200.
▪ On arrival of the dewatering pigs at the receiving end at KP 131+200 – dewatering of TS 6a
may start.

Continue with dewatering of TS 6a (KP 131+200 – KP 126+470)

▪ For dewatering of TS 6a the two water filling pigs at KP 131+200 will be reverse launched using
the compressed air from TS 7.
This document is the property of Yemen LNG Company. It must not be stored, reproduced or disclosed to others without written
authorisation from the Company.
Document number
Hydrotest Plan YE-001-20-SOC-PLN-09275
Revision: 02 Status: IFR
Document Type: PLN System / Subsystem: 99 Date: 13/07/07
Contractor document number: Page 34 of 73

▪ The two dewatering pigs will be separated by 500 meter between pig no. 1 and pig no. 2.
▪ The section water is discharged at KP 126+470.
▪ On arrival of the dewatering pigs at the receiving end at KP 131+200 all residual air will be
vented off.

3. Dewatering of TS 10 (KP 166+400 – 189+900)

TS 10 will be dewatered in reverse direction to discharge the water will at KP 166+400 in an
environmental acceptable manner. The disposal location will be agreed by CPY.
▪ Two nos. of filling pigs will be reverse launched at KP 189+900 with compressed air.
▪ The pigs are launched with 500meter distance between pig no. 1 and pig no. 2.
▪ The section water discharged to nature at KP 136+300 in an environmental acceptable manner.

4. Dewatering of TS 11 and TS 12 (KP 189+900 – 204+200)

These test sections will be dewatered section by section in positive direction to discharge the water
will at KP 204+200 in an environmental acceptable manner. The disposal location will be agreed by
the CPY.
▪ Sufficient back pressure will be kept and maintained at the receiving end accordingly to the
pressure of the water column ahead of the pig.

Dewatering will start with test section TS 11. (KP 189+900 – KP 199+100)
▪ The one remaining pig in the test header at KP 189+900 will be launched using compressed air
▪ The section water is transferred into TS 12 at KP 199+100.
▪ On arrival of the dewatering pigs at the receiving end at KP 199+100 – dewatering of TS 12
may start.

Continue with dewatering of test section TS 12. (KP 199+100 – KP 204+200)

▪ The one remaining pig in the test header at KP 189+900 will be launched using the compressed
air from TS 11.
▪ The section water is discharged at KP 204+200 to nature in an environmental acceptable
manner and at a location agreed by the CPY.
▪ Due to the very high hydraulic back pressure at the receiving end at KP 204+200 especial
attentions has to be given to maintain the required back pressure. The back pressure shall be
at least, but never below the equivalent hydraulic pressure of the water column in front of the
pig.

8.0 OPERATIONAL PROCEDURE

8.1. Water Filling

The water filling point will be at water wells. There are two water wells drilled for the 38” with water
storage basins in place to hold the quantity of water required to start the water filling. The locations
are shown in Para.7.2. The 30” Pipeline will be filled and tested separately, the water abstraction
sources will be investigated either at the KPU or at the CPU.
The Water filling spread will be set-up at the water wells and the water transfer locations.
Water injected in front and between pigs will be transferred from section to section and discharged at
the termination point of the last section.
For the method of discharge the water slug in front and between the pigs refer to Appendix 13 (Site
Lay out)

The ten (10) Block Valve Stations positioned along the line are excluded from the water filling and will
be tested separately. In case these Block valve stations are in position they will be incorporated in the
test section.
This document is the property of Yemen LNG Company. It must not be stored, reproduced or disclosed to others without written
authorisation from the Company.
Document number
Hydrotest Plan YE-001-20-SOC-PLN-09275
Revision: 02 Status: IFR
Document Type: PLN System / Subsystem: 99 Date: 13/07/07
Contractor document number: Page 35 of 73

The permanent pigging facilities at the KPU and at Bal Haf are excluded from the water filling to avoid
debris and dirt entering the pig traps during pigging operations as the cleanliness as part of the re-
instatement thereafter cannot be granted. These AGI’s will be tested separately.

8.1.1. Re-use of Water

The testing plan re-uses water from section to section.

Zone 1 water abstractions for 91km – re-use the water for 27km
Zone 2 water abstractions for 94km – re-use the water for 42km
Zone 3 water abstractions for 54km – re-use the water for 14km
Note: In case there is a shortage of water, water will be used form water basin.

The re-use of water from dewatering sections will be transferred through intermediate pumping
stations.

8.1.2. Back Pressure / Pre-packing

Back pressure in front of the filling pigs is necessary to get a proper pig run and no vacuum can
be occur.

8.1.3. Preparation

▪ The test Sections to be filled will be completed in a state of readiness for this operation.

▪ Test header will be pre-loaded with two filling pigs and one de-watering pig (if the de-
watering is in the same direction as the water filling), otherwise dewatering pig is pre-loaded
in the receiver trap to be reversed with the filling pigs, when de-watering commences.

▪ Before loading the pigs and welding the test header to the pipeline, test headers will be
inspected to ensure the good condition, correct positioned pig stopper and for cleanliness.

▪ No filling will take place until acceptance of the radiography tested circumferences weld of
the test header is confirmed.

▪ Set-up the water filling spread in accordance to the site lay out drawing in Appendix 13

▪ Set-up the chemical injection system in accordance to the site lay out drawing Appendix 13.
The chemical injection rate is adjusted by the pump to the requested rate and controlled by a
measuring cylinder.

▪ The Oxygen Scavenger must go in as far upstream of the Biocide as possible to minimise
any interaction between the chemistries.

▪ Set-up the water discharge for disposal in accordance to the site lay-out Appendix 13.

▪ Connect the sections with cross-over pipe work for water filling of multiple sections.

▪ A strip chart pressure recorder and pressure gauge will be connected to the pig launcher at
This document is the property of Yemen LNG Company. It must not be stored, reproduced or disclosed to others without written
authorisation from the Company.
Document number
Hydrotest Plan YE-001-20-SOC-PLN-09275
Revision: 02 Status: IFR
Document Type: PLN System / Subsystem: 99 Date: 13/07/07
Contractor document number: Page 36 of 73

the filling location to allow instant pressure readings and provide a complete pressure record
of the pigging operation. The pressure chart is printed with time, date, section no, instrument
number. A new pressure chart is used to each filling section.

▪ A pressure gauge will be connected at the end point or cross-over locations for pressure
indication in order to maintain the required back pressure.

▪ Filling water will be logged by a temperature probe (PT 100) lowered in the water tank.

▪ The volume will be recorded by a 6 inch flow meter connected with a computer

▪ Complete the final check of the preparations prior to commence the filling operations.

8.2. Hydrostatic testing

Each section will be tested separately from test header to test header. The spread will be set-up at
the cross-over of the last two sections filled and tested in sequent section by section back to the filling
location. The required volume of water for longer sections will be transferred through the sections to
the pressure pumps. For shorter sections the water will be stored in water tanks. The temperature
probes will be installed at least 1 day before start pressurization.

8.2.1. Preparation

Test Location

Obtain ASH clearance from QA/QC department.

Obtain Company clearance.

In conjunction with the Safety Officer in charge isolate hydrostatic test area and position
“warning” and “no entry” signs.

Check the pressure gauge and pressure recorder against the dead weight tester.

Ensure the correct program-settings and functional order of the buried- and exposed pipe
temperature loggers.

Set up equipment in accordance with equipment setup- and flow diagram (refer to Appendix
13).

Connect the high pressure pump to the water injection point one the test header valve L1 (refer
to Appendix 13).

Ensure the presents of pressure venting valves to avoid pressure-lock-in in the pressure
system.

Ensure the correct settings of the pressure safety valves connected to the high pressure pumps
and check functionality.

Ensure Check valves incorporated the system for protection of high pressure pump and the
piping system.

Connect high pressure instrument hoses to valve L5 and to the pressure recording instruments
located in the instrument cabin. (Refer to Appendix 13).

Perform function test of all pressurizing pipe work within the equipment spread. At at least 1.25
times the maximum test pressure.

Perform a leak check on all inlet pipe work to the high pressure pump, especially downstream
of the flow meter.

Set all pipe work and valves as per valve matrix (refer to Appendix 13). Pressure Safety Relief
valve is attached to the outlet of the high pressure pump as protective measure for the pump
and the high pressure pipe work connected to the pipeline test head valve.

The connected pipe work to the test header (pressure hoses etc.) shall be vented at the test
location prior to start of the hydro test. Pressure at the highest point of that section, shall be
depressurized to not less than 1 bar above static head for air content calculation.

Check correct time settings on recorders and that all instrumentation is installed and
functioning.

Check that all instrumentation utilized has valid certification.

Make sure that valves on section end test header are in correct position and all fittings are fitted
correctly.

Pipeline End Location

Obtain authorization from the Contractors Representative for the individual pipeline test section.

In conjunction with the Safety Officer in charge isolate hydrostatic test area and “warning” and
“no entry” signs are positioned in place.

Set all valves as per valve matrix in Appendix 13.

Check that all required instrumentation is installed. Establish communication with the test cabin
and confirm all pre-operational works for pressurizing the pipeline hydro test section are
completed.

Patrols will be sent all along the ROW of the section. To check the temperature probes that they
are in place and in working condition.

8.2.2. Pressure Volume and Pressure temperature related calculations

Pressures will vary with temperature changes.

These pressure changes due to temperature changes can be calculated by using the formula
given in Appendix 6 “Sample Calculations”

For prediction of volume required for pressure change (for one bar) please refer to sample
calculations in Appendix 6

8.2.3. Pressurization

An elevation profile with the relevant test pressure of each section will be available in the test
cabin.
This document is the property of Yemen LNG Company. It must not be stored, reproduced or disclosed to others without written
authorisation from the Company.
Document number
Hydrotest Plan YE-001-20-SOC-PLN-09275
Revision: 02 Status: IFR
Document Type: PLN System / Subsystem: 99 Date: 13/07/07
Contractor document number: Page 38 of 73

Pipeline temperatures are available for pressure / volume calculations.

Pressure Volume Plot for pressurization is prepared with the calculations of volume required to
rise the pressure for one bar based on the present average pipeline system temperatures.
On completion of all pre-operational checks and thermal stabilization the individual hydro test
sections will be pressurized.

Commence pressurization by introducing water from the high pressure pumps at a rate of
max.1 bar/min. A pressure versus volume plot will be plotted. From this p/v plot the air content
of the pipeline will be calculated. During pressurization the engineer shall make comparison
between pressure-volume relationships for 100% water content, deviation between these two
shall exceed more than 0.2% of the total pipeline volume.
Drain out volumetric test could be added as required on Project Specs

During the pressurizing period and before reaching the designated test pressure complete a
leak check on all accessible pipe work and fittings at all locations shall be done.

Continue with a constant pressurization rate not exceeding one bar per minute.
A pressure versus volume plot will be maintained during all phase of pressurization.

80% of Test Pressure

Reaching 80% of the test pressure at the test cabin the rate is reducing to 0.5 bar pressure
increasing rate per minute. Pumps stopped at 80% of test pressures and test section isolated
by closing the pressure outlet valve at the high pressure pump.
During this pressure stabilization period the test pressure is plotted every 10 minutes.
Leak checks are carry out on all accessible points of the test section.

The engineer shall make comparison between pressure-volume relationships for 100% water
content, deviation between these two shall not exceed more than 0.2% of the total pipeline
volume. If air content is >0.2 %, venting will take place on high point if possible, if not possible
refilling should be considered.
The air content will be checked by following Formula.
Percentage air content= (Volume of Air in m³/Volume of Line in m³) x100
Air Content Acceptance Form is filled in prior to recommence pressurization.
After pressure stabilization has taken place and confirmation of no leaks found restart
pressurization to 100% test pressure at the testing location with a rate of max. 0.5 bar/min to
100% of the test pressure.

100% of Test Pressure

Stop High Pressure Pumps at 100% test pressures and close the pressurizing valve L1
Complete leak check will be done on all accessible pipe work, valves and fittings, at the
termination ends of the test section.

Contact the Test Supervisor (or his designated deputy) located at the pipeline end location and
confirm that pressurization is complete and leak checks have successfully been completed at
the test location.

Complete leak check on all accessible pipe work and fittings.

Contact the Test Supervisor (or his designated deputy) located at the end location in order to
reconfirm that successful leak checks have been completed.

Commence a pressure stabilization period (Decay Period) of minimum two (2) hour.

If during this hold period the test pressure drops one (1) bar below the specified minimum test
pressure, the pressurization pump will be re-started and the system will be brought back to the
specified test pressure. Injected water volume will be recorded and logged. The maximum test
pressure shall not exceed 0.5% and if necessary to drain off water. The pressure drop and
volume of water will be measured and logged.

8.2.4. Air Entrapment Test

The volume for pressurizing is calculated against the theoretical volume necessary to rise to the
same pressure. The difference in volume shall not exceed 0.2% of the total volume of the
tested section.
For sample calculations refer to Appendix 6.

8.2.5. 24-hour Hold Period

Following the stabilization period the test pressure shall than be held for not less than 24 hours.

Period leak checks are carried out at all accessible point during all testing period.
If during this hold period the pressure drops below the specified minimum test pressure (1.25 or
1.4 times the design pressure), the pressurization pump will be started, and the system will be
brought back to the specified test pressure. The time, pressure drained/gained volume of water
will be measured and recorded.
The maximum test pressure shall not exceed 0.5% and if necessary water will be drained.
Unexplainable decrease (max1bar) or increase (0.5%) of pressure shall be observed.
Variations in pressure readings caused by temperature fluctuation will be accepted.

8.2.6. Monitoring and Recording

Personnel at the test cabin will record all data of testing operations including all events during
the test – such as re-pressurizations and bleed downs, weather conditions, leaks, failures etc.
The test records shall be available at the test cabin at all time.

The dedicated Test Engineer shall maintain a plot, containing values of the pressure and
ground/pipe wall temperature versus time. This plot will be produced from pressure readings
taken from the dead weight tester, average ground/pipe wall temperatures and ambient
temperatures.

On successful completion of the 24 hour hold period, the dedicated Test Engineer will complete
the Hydrostatic Test Acceptance Report Appendix 3

During the hydro testing pressurizing phases of the test sections the following will be monitored
and recorded.
- Pipeline pressures vs. time Time / bar(g) each increment
- Pipeline pressures vs. time Time / bar(g) each increment
- Water injection volumes Time / Liter each pressure
increment
- Ground/pipe wall temperatures Time / °C each 30min.
- Ambient temperatures Time / °C each 30 min.
- Pressurization water temp. Time / °C each 30 min
- Log of Events Time

During the hydro testing 24-hour test period of the test sections the following will be constantly
monitored and recorded
- Pipeline test pressures vs. time Time / bar(g) each 30min.
- Ground/pipe wall temperatures Time / °C each 30min.
- Ambient temperatures Time / °C each 30 min.
- Log of Events Time / Events

8.2.7. Leaks and Repairs

Should a considerable pressure drop that cannot be attributed to thermal change occur during
testing, Contractor shall seek the cause. No leaks shall be repaired until the test pressure is
reduced to safe pressure and or dewatered prior to repairs. Any leak shall be observed as well
the location, type of leak and volume shall be recorded. The Test Engineer shall inform
Companies Representative.

If repair of leak require change of parts of the tested section parts shall be marked, Companies
Representative will be informed whether that subjected section can be isolated and repaired or
test section is undertaken for dewatering. Any faulty section shall be repaired/replaced and test
section to be re-tested again following above procedure.

8.2.8. Test Acceptance

The test acceptance and evaluation shall be based on the equation in Para. 8.3.4 to 8.3.7. The
test shall be considered satisfactory when pressure variation can be attributed to change in
temperature using the equation in Para 8.3.7 “Evaluation” as acceptance criteria to make
allowances for movements of pipe, for measuring inaccuracies. The volume change calculation
over the time period is based on the actual volume measured for increasing one bar pressure at
the test pressure.
Also consideration shall be given to the characteristics of the test section i.e. the exposed
pipeline length in comparison to the overall length of section. In any case of doubt in
interpretation of the evaluation of the test, test shall continue till such period the test is
evaluated to the satisfaction of the Test Engineer and Company Representative.
For test acceptance calculations please refer to Appendix 6, for the required Factor A
(pressure) and Factor B (temperature) refer to Appendix 7 and 8.

8.2.9. Depressurization

Upon acceptance of the test, the test section will be depressurized as follows:

The location for water discharge during the depressurization is in an agreed location a carried
out in an environmental acceptable manner to avoid erosion. The method of dewatering is also
depending on the local area and will be agreed on a case by case basis. If possible discharge
water can also be discharged in the previous test section, or via special designed breaktank
with airation pipe.
Connect high pressure pipe work to valve L1 on the temporary test head in order to
depressurize the test section. Slowly open valve L1 regulating the water discharge through the
valve to achieve the required depressurization rate.

Depressurization Rate:
- 100% to 90% test pressure 1 bar per minute
- 90% to 50% test pressure 3 bar per minute
- Continue in a controlled manner to shut in at a pressure equivalent to not less than 1bar at
the high point of the section.
This document is the property of Yemen LNG Company. It must not be stored, reproduced or disclosed to others without written
authorisation from the Company.
Document number
Hydrotest Plan YE-001-20-SOC-PLN-09275
Revision: 02 Status: IFR
Document Type: PLN System / Subsystem: 99 Date: 13/07/07
Contractor document number: Page 41 of 73

8.3. Calculations

8.3.1. Calculation of Minimum Pipeline Test Pressure per Test Section

The minimum hydrostatic test pressure of the relevant test section is defined in the specification
as 1.25 X MOP pressure:
Pt min=1.25* MAOP
Pt min is normally the test pressure at the highest elevation of the test section.

8.3.2. Calculation of Maximum Pipeline Test Pressure per Test Section

The maximum test pressure of a test section corresponds according to the specification to
100% SMYS (SMYS = fy = minimum yield strength MPA).
The calculated maximum test pressure shall not be exceeded by the effect of static head.
Therefore the maximum test pressure is calculated for the lowest point of the pipeline test
section.
Note: The pressure calculation have to consider the different in design of the 38in and 30in
pipe diameters
The 30 inch line is provided with a constant pipeline OD, thus different wall thickness will
change the ID of the pipe
The 38 inch line is provided with a Constant Inner Diameter, thus Pressure Calculations have to
consider the varying outside diameter with changing of wall thicknesses.

a) 30” Transfer Line

P max 20 x 482.633 x WT
= OD (762)

a) 38” Main Line

P max 20 x 482.633 x WT
= OD ((930.4 + (2xWT)

WT = nominal pipe wall thickness mtr.

OD = Pipeline outside diameter mtr.
fy = SMYS = minimum yield strength (= 482.633) MPA

Maximum Test Pressure for 30” Transfer Line based on 100% SMYS
Pipeline OD = 762 mm

A) Wall thickness pipe 15.9 mm

20 x 482.633 x 15.9
P max = = 201.29 bar
762

B) Wall thickness pipe 22.2 mm

20 x 482.633 x 22.2
P max = = 281.22 bar
762

100% SMYS Test Pressure 15.9mm wt pipe = 201.29 bar

100% SMYS Test Pressure 22.2mm wt pipe = 281.22 bar

Maximum Test Pressure for 38” Main Line based on 100% SMYS
A) WT pipe 16.2mm, Pipeline OD = ID 930.4 * (2*16.2) = 962.8 mm
B) WT Pipe 18.0mm, Pipeline OD = ID 930.4 * (2*18) = 966.4 mm
C) WT Pipe 23.7mm, Pipeline OD = ID 930.4 * (2*23.7) = 966.4 mm

A) Wall thickness pipe 16.2 mm

20 x 482.633 x 16.2
P max = =162.41 bar
(930.4 + (2*16.2))

B) Wall thickness pipe 18.0 mm

20 x 482.633 x 18
P max = = 179.79 bar
(930.4 + (2*18))

C) Wall thickness pipe 23.7 mm

20 x 482.633 x 23.7
P max = = 233.96 bar
(930.4 + (2*23.7))

100% SMYS Test Pressure 16.2mm wt pipe = 162.41 bar

100% SMYS Test Pressure 18.0mm wt pipe = 179.79 bar
100% SMYS Test Pressure 23.7mm wt pipe = 233.96 bar

8.3.3. Calculation of Pipeline Test Pressure at the Test Cabin Location

Depending on the actual elevation profile test pressure shall be selected, in such a way that it
shall not be less than the minimum test pressure at the highest point of the section and shall not
exceed maximum test pressure at the lowest point. The exact calculations will be based on the
as-built x,y,z data in the specific Test package for each test section.
The corrosion report will be attached as an appendix in the specific test package.

8.3.4. Calculation Theoretical Pressure vs. Volume change

For calculating the volume required for changing in pressure (e.g. for pressurization) the
following formula can be used

For sample calculations please refer to Appendix 6

For determine the ri/s value on sections with different wall thicknesses the following formula can
be used

ri rix lx riv lv
by x + x = Average Section WT
s sx lt sy lt

For sample calculations please refer to Appendix 6

8.3.5. Calculation Theoretical Pressure vs Temperature change

For calculating the volume required for changing in pressure (e.g. for pressurization) the
following formula can be used

B x (t1 - t2)
∆ VA (litres) = = bar per °C
0.89 x ri + A
s

For sample calculations please refer to Appendix 6

Where:
lt = total length meters
lx = segment line length in metres with wall thickness sx millimetres
sx = wall thickness millimetres
sy = wall thickness millimetres
s = wall thickness millimetres
rix = internal pipe radius of pipe length with wall thickness sx millimetres
riy = internal pipe radius of pipe length with wall thickness sx millimetres
ri = internal pipe radius millimetres
Vri = volume of line using ri litres
∆ VA = calculated volume litres
P1 = initial pressure bar
P2 = final pressure bar
∆ t1 = average pipe wall temperature – start
∆ t2 = average pipe wall temperature – end
A = volume – pressure factor as per Appendix 7
B = volume – temperature factor as per Appendix 8
-6
0.89 = constant calculation coefficient for pressure changes in 10 bar
(In cm/kgf = Factor 0.87.)

8.3.6. Calculation the deviation factor

Deviations between the calculated and actual volume to pressurize the section may be
occurred due to slightly air inclusions and tolerances in pipeline dimensions. Calculations shall
take this deviation into account in the ratio

∆ VAb
to be used in Formel 8.3.6
∆ VA

If no deviate exists then use factor 1.0

∆ VAb = calculated volume litres

∆ VA= calculated volume litres

For sample calculations please refer to Appendix 6

8.3.7. Volume change due to pressure and temperature changes during the test will can be calculated
with using the following equation

⎡⎛ ri ⎞ ∆VAB
V = ⎢⎜ 0,89 × + A ⎟ ( p1 − p 2) − B(t1 − t 2)⎤⎥ × Vri
⎣⎝ s ⎠ ∆VA ⎦ 1000
For sample calculations please refer to Appendix 6

P = line pressure change in kgf/cm2

∆ VA = Volume change in liters
∆ VAb = calculated volume litres
∆ VA = calculated volume litres
A = Volume-pressure factor as per Appendix 7
B = Volume-temperature factor as per Appendix 8
∆ Vh = Hourly volume change in litres
∆ p1 = Initial pressure
∆ p2 = Final pressure
∆ t1 = Average pipe wall temperature – start
∆ t2 = Average pipe wall temperature – end
Vri = Section Volume

8.3.8. Evaluation

For evaluation of the test the following equation can be used as acceptance criteria for
unaccountable volume changes during the 24-hour evaluation period

Vri
∆ Vh (litres) = ≤± 4 x = litre per hour
3000

For sample calculations please refer to Appendix 6

8.3.9. Operational Acceptance

Upon completion of all operations detailed in this procedure and in compliance with the
specification requirements and approved procedure the Hydrostatic Testing Acceptance
Certificate Appendix 3 shall be filled in and signed off. No further operations will commence until
completion of above mentioned form.

8.4. Dewatering / Water disposal

The bulk de-watering is carried out for water transfer to re-using the water for water filling operations
and for disposal in agreed locations an acceptable manner to the environmental. The untreated water in
front and between the pigs is disposed at agreed locations in an environmental acceptable manner
(refer to Appendix 13). The chemically treated section volume is discharged with injecting the chemical
Hydrogen Peroxide in the water discharge stream into a water tank to final disposal to an agreed
location. Water samples taken at the discharge is determined the dosing of the Hydrogen Peroxide.

For Multiple dewatering sections are connected with steel pipe work for water transfer. Preparation for
dewatering on multiple sections has to consider the limited compressor capacities by static head
pressure due to pipeline elevation. The installation of extra pumping station may become necessary for
water transfer to overcome the excessive elevations.
Installation of pressure recording devices and pressure gauges allow for instant pressure read outs for
pressure regulation.
The bulk de-watering will be commence by launching a 3rd pig (pre-loaded) dewatering pig by
dewatering in same direction as the water filling or by returning the bi-directional pigs previously used
for water filling of the hydro test Section. Back pressure will be held at the receiving ends to ensure a
controlled pigging operation and to avoid an uncontrolled down hill moving of the pig.

8.4.1. Preparation for Dewatering for re-use of water

The test Section(s) to be bulk de-watered will be completed and in a state of readiness for
these operations.

Multiple dewatering sections to be connected with adequate steel pipe work for water transfer
from section to section with by-passes installed to launching of pigs for the following section.

Installation of intermediate pumping stations for water will be used to transfer the water if
necessary.

A chart pressure recorder and gauge will be incorporated into the system, via valve
connections. This will allow instant pressure read out, and supply a full pressure record of the
dewatering operation. A new pressure chart will be used for each individual pigging run.

Air compressors will be connected to the inlet valve on the launching test head and the
appropriate valve opened in readiness to commence the dewatering operation.

No pig will be run with a back pressure less than the required pressures for relevant Sections
according to elevation plan. Control of the back pressure will be undertaken by valve operation
at the receiving test head location Intersection or pipeline end termination point.

Prior to any discharge of air from the compressor, the compressor will be started and allowed to
warm up for a minimum period of 5 minutes with its discharge valve in closed position.

At the receiving test head, a gauge will be incorporated into the system via valve connection.

Prior to launching of any pig, radio communications will be established and maintained between
the pig launch location/receipt locations.

Incorporated intermediate pumping station for water transfer in excessive elevation are fitted
with Pressure gauges at the water incoming section to ensure a positive pressure in the water
feed line to the pumps at all time.

8.4.2. Pig Launching

All valve positions will be in references to the Drawings which can be found in Appendix 13.

All valves shall be positioned references to the Drawings which can be found in Appendix 13.

On completion of the preparation work as described in Section 8.4.1, following steps will be
This document is the property of Yemen LNG Company. It must not be stored, reproduced or disclosed to others without written
authorisation from the Company.
Document number
Hydrotest Plan YE-001-20-SOC-PLN-09275
Revision: 02 Status: IFR
Document Type: PLN System / Subsystem: 99 Date: 13/07/07
Contractor document number: Page 46 of 73

performed:

All work to be carried out to the Permit to Work system in place.

Ensure that barriers erected (where necessary) and warning signs are placed.

Conduct Tool Box Talk with all involved personnel for this operation.

Connect piping devices and interconnecting piping.

Connect all instrument devices

Ensure the remaining valves on test headers are in closed position.

Launch pig

Inform receiving location of pig launch, time and pressure.

Continue injecting compressed air behind pig no. 1

Continue monitoring airflow and pressure.

Prepare for launching pig no. 2.

nd
Redirecting the air flow behind the 2 pig.

Monitor pig passage out of the pig launcher.

Inform receiving location of 2nd pig launch time and pressure.

Continue monitoring airflow and pressure during the pigging activity, keeping in regular contact
with the receiving location and also with the tracking crew.

Continuous monitoring pressure and keeping in regular contact with the receiving location and
also with the tracking any crew.

8.4.3. Pig Receiving

All valve positions will be in references to the Drawings which can be found in Appendix 13

All work to be carried out to the Permit to Work system in place.

Ensure that barriers erected (where necessary) and warning signs are place.

Conduct Tool Box Talk with all involved personnel for this operation.

All valves at the pig receiver to be in closed position. Confirm to compressor location.

Check static pressure.

Agree with Test Engineer the required back pressure to be maintained.

Await notice from Compressor station that pig(s) has launched.

Monitor pressure indicator.

When back pressure is achieved, operate valves tomaintains the required back pressure.

Inform compressor station of discharge valve opening time.

In the event that pressure in the line increases beyond the required level, carefully regulate and
control the line back pressure.

On instructions of the Test Engineer vary the back pressure to reflect the elevation differential.
.
Prepare to receive pig no. 1 in the receiver..

Continue discharge water until pig no. 2 arrives.

Receive pig no. 2 in the receiver.

Inform compressor station that second pig has been received at (time) and bulk de-watering of
that section is completed.

Make preparation for either discharge of the resident compressed air or transfer of air into
adjacent system.

In case an intermediate pumping station is incorporate in the dewatering sections (due to

excessive elevations) pumps will be stopped on arrival of the dewatering pig at the location.
Dewatering will continue with compressed air only.

8.4.4. Pig Removal

On completion of pig receipt as detailed in clause 8.4.3, pig removal will be completed as
follows.

- Residual pressure contained within any Section behind the pig train after receipt shall be
either transferred to the adjacent Section or vented off to atmospheric pressure prior to pig
removal.
- On reduction of the pressure behind any pig train to atmospheric pressure the temporary pig
launching and receiving heads will be removed.

The pigs will be removed with pumping clean water behind the pig until pig removed from the
pig trap.
The quantity and conditions of pigs removed from the section will be logged.

Record is taken of the test head number, removed from test section number and KP location
and next destination for the test header.

Upon completion of the bulk dewatering operations as detailed above, all temporary pipe work
and material will be removed from all tie-in points.

Ensure that the open ends of the test Sections are capped off right after test header removal.

Tie-in operation will commence by others.

9.0 MONITORING & RECORDING

9.1. Water Filling (Monitoring and Recording)

During the Water-Filling phases of the test Sections the following will be constantly monitored and
recorded.

- Pipeline pressure bar (g) continuous

- Flow rate m3/hr continuous
- Total flow m3 continuous
- Pig speed m/sec continuous
- Pig distance km continuous
- Fill water temperature °C 30 min.
- Chemical injection dosage ppm 30 min.
- Total chemicals injected ltr. 30 min.

9.2. Hydrostatic Testing (Monitoring and Recording)

- During the hydro testing pressurizing phases of the test sections the following will be constantly
monitored and recorded.
- Pipeline pressures vs. time bar(g) each 1 bar increments
- Ground/pipe wall temperatures °C each 60 min.
- Ambient temperatures °C each 30 min.
- Pressurization water temp. °C each 30 min
- (only during the pressurization phase)
- Water injection volumes ltr. each 1.0 bar
- (Only during the pressurization phase)

9.3. Dewatering (Monitoring & Recording)

During the bulk de-watering of the test Sections the following will be constantly monitored and
recorded.

Compressor Station:
- Pipeline pressure (Pressure Chart Recorder) continuously paper strip chart recording
3
- Flow rate (output of compressors) Total Air Injection m /hr
3
- Total flow Accumulated m /hr after pig launch

Pipeline Intersection (Cross-over)

- Pipeline pressure (Gauge) bar (g) continuously check

Pipeline end termination point:

- Pipeline pressure (Gauge) bar (g) continuously check

10.0 INSPECTION AND TEST PLAN (WATER FILLING)

Strictly following the approved procedure and enforcing on site the QA/QC Measures shall guarantee
the quality assurance for this activity. Quality check shall be performed according to Inspection and Test
Plan Document no.: YE-001-20-MOC-ITP- 09429

The type of inspection activity and the quality records generated during the activity is detailed in the
Inspection and Test Plan document no.: YE-001-20-MOC-ITP-09429

10.1. Water Filling (Inspection and Test Plan)

Quality Records

• Pipeline filling Log

• Chemical Injection Log
• Sample of Valve Matrix, if applicable

10.2. Hydrostatic Testing (Inspection and Test Plan)

Quality Records
• Hydrostatic Test Data
• Pressurization Log
• Air Inclusion Acceptance
• Stabilization Test Report
• Strength Test Log of Operation
• Leak test Log of Operation
• Hydrostatic Test Evaluation Sheet
• Hydrostatic Test Acceptance Certificate

10.3. Dewatering (Inspection and Test Plan)

Quality Records
- Pipeline De-watering Log (Compressor Station)
- Pipeline De-watering Log (Discharge Location)
- Valve Matrix, if applicable

11.0 HEALTH & SAFETY

All personnel working on the Cleaning and Gauging operation will comply with the HSE rules, general and
site specific and be fully trained by CONTRACTOR. Personnel will also adhere to the regulations
including all items listed in the Risk Assessment - APPENDIX “1”.

The H&S personnel compliance shall be certified by the carrying of the Project Safety Passport.
The safety representative will monitor the activities and shall advise and assist the site Construction
Manager with regard to implementation of the overall project safety programme. He will assist the Hydro
testing Supervisor with daily tool box meetings where appropriate, in order to reinforce and explain the
importance and philosophy of safety. Tool Box Talks subject matter shall be recorded together with
names of attendees.

The generic risk assessment for this Method Statement is attached as APPENDIX 1 Specific Risk
Assessments shall be performed for each location where different conditions and/or terrain are
encountered.

Minimum requirements are listed in the following:

• Safety footwear with steel toecaps and non skid soles.

• Safety Helmet.
• Reflective waistcoat / jacket.
• Eye Protection
This document is the property of Yemen LNG Company. It must not be stored, reproduced or disclosed to others without written
authorisation from the Company.
Document number
Hydrotest Plan YE-001-20-SOC-PLN-09275
Revision: 02 Status: IFR
Document Type: PLN System / Subsystem: 99 Date: 13/07/07
Contractor document number: Page 50 of 73

• Ear defenders
• Gloves
• Life Jackets
• Life Rings
• Escape Ropes

All work shall be carried out to the Permit to Work system in place.
Ensure safe access and egress into the operating area during day and night only for authorized
personnel.

General control of the work to be adhered to such us:

- Isolations
- Ground Disturbance
- Confined Spaces
- Working at Height
- Lifting
- Vehicle Safety
- Housekeeping

Welfare:

Personnel will be working on 12 hour shifts

Shift hand-over will be 1/2 hour prior to shift-ends

Radio/phone communication are mandatory.

Insulated containers shall be placed at the main operating locations Radio/phone communication are
mandatory.

Vehicles for shift change will be available at all time

Food will be provided to operating locations.

Ambulance and paramedic and all medical facilities shall be on stand-by in the camp for any emergency
call-out. Each crew will have a delegated first aider.

Each test cabin and also vehicles shall have emergency phone list and/or Radio contact.
In the event of a medical emergency, checks will be carried out with local Hospital for the level of
service available.

12.0 ENVIRONMENTAL

12.1. Fauna and Flora preservation

General Fauna and flora preservation measures during construction activities are depicted in the
Reinstatement Management Plan. Particular fauna and flora preservation measures will be identified
during the Pre-Construction Surveys, then will be detailed in the corresponding reports, and communicated
to the relevant construction personnel.

The main mitigation measures relevant to the ROW construction activities regarding fauna and flora
preservation shall be the following:
- Disturbance to the fauna and flora shall be reduced to the minimum extent possible.
- Activities shall be confined to the planned ROW boundaries in order to avoid damaging any
vegetation located outside of the corridor;
- Hunting and fishing shall be, in any case, prohibited;
- Any sensitive species identified during the pre-construction survey shall be either preserved or re-
located, unless otherwise specified.
Contractor personnel shall strictly adhere to the preservation and mitigation measures requested by
Environment Department.

12.2. Pollution Prevention

Pollution prevention measures to be implemented during the Construction phase are detailed in the
Pollution Prevention management Plan. A copy of this Plan shall be kept at site.

The particular measures to be implemented during the ROW construction shall be the following:
- No storage of any sort of hazardous product shall take place on bare ground - all storage of
chemicals, of any other hazardous liquids, as well as al DG sets, pumps and other equipment fuel
driven shall be installed on secondary containments (drip trays);
- Drip trays shall be checked and cleaned regularly by a designated member of personnel using
absorbent materials and where necessary a small electric pump and disposed as per Waste
Management Plan;
- No refueling, maintenance operations or fuel storage will be allowed within 50m of watercourses or
water resources unless specified otherwise in relevant Method Statements / Procedures and
corresponding contingency measures developed;
- In the event that any maintenance is required on the ROW and cannot take place in designated
areas, the following pollution prevention precautions will be taken:
- information and coordination with Environment Department;
- Use of drip trays and/or absorbent pads to minimize spills.
- Plastic sheeting.
- Spill kits readily available.
- All waste produced by the operation to be brought back to the Waste Collecting Point (WCP) as per
Waste Management requirements. This includes, but not limited to, used oil, oily rags, filters, etc
All refuelling operations on the ROW shall respect the following:
- Re-fueling method of equipment (compressors) is direct supply from the fuel truck to the
compressors/generators or from a diesel storage tank (in second compartment) by using manual
operated diesel pump for re-fueling the equipment. In addition, the re-fueling process should adhere
to the following steps:
- Re-fueling by nominated Re-fueling Operators, only who will be specifically trained in the relevant
procedures;
- Use of drip trays and/or absorbent pads where necessary to minimize spills, to be put in place prior to
the commencement of re-fueling operations.
- Spill kits readily available on site

During water course crossing activities the following additional measures shall be implemented:
- Specific oil spill response equipment will be kept on site for intervention. Where required, bunds, grips
and other measures will be implemented adjacent to watercourses to prevent silt/pollutants ingress
from the construction spread.
- All necessary material for silt and pollution control will be installed in the water course crossings,
including, but not limited to, silt fences, filtering material, geo-textile, Terram.
- Wet cement and/or concrete will not be allowed to enter any watercourse, pond or ditch.
This document is the property of Yemen LNG Company. It must not be stored, reproduced or disclosed to others without written
authorisation from the Company.
Document number
Hydrotest Plan YE-001-20-SOC-PLN-09275
Revision: 02 Status: IFR
Document Type: PLN System / Subsystem: 99 Date: 13/07/07
Contractor document number: Page 52 of 73

12.3. Waste Management

All waste produced on the ROW including those generated from the cleaning of the pipe shall be collected
in the debris collection receptacles and disposed-off in accordance with the Waste Management Plan
(Doc.No. YE-001-20-MOC-PLN-09202). In particular, hazardous waste (if any) shall be segregated from
Non Hazardous waste. The pig receiver area and the ROW shall be kept free from any waste generated by
construction activity.

12.4. Existing infrastructures

Immediate repairs shall be carried out to any bridges, private roads, fences, buildings or other property,
damaged in the course of construction operations, where the repairs cannot await the arrival of the clean
up / reinstatement crew.

Drinking water shall be maintained wherever livestock have access to water. Where activities interfere with
existing water or irrigation supplies that cross the ROW, care shall be taken to maintain such services by
utilizing temporary measures, such as flume pipes of appropriate size to maintain the natural flow.

12.5. Environmental Emergency Response

A copy of the Environmental Emergency Response procedure shall be kept at site.

All construction personnel shall be aware of the Environmental Emergency Response procedure to follow
in case of environmental incident and is responsible to its implementation.
Any environmental incident observed on the site (e.g. chemical spill, oil leakage) as a result of Project
activities shall be immediately reported to the Construction Supervisor and the Environment Department.

The seriousness of the incident will then be evaluated by the Construction Supervisor and the Environment
Department, and will determine the following steps and degrees of response to activate, detailed in the
Environmental Emergency Response Procedure.

12.6. Environmental Impact Assessment

See appendix 2.

APPENDIX 1 Risk Assessment

APPENDIX 2 Environmental Impact Assessment

APPENDIX 3 Quality Registers (Forms)

APPENDIX 4 Personnel

APPENDIX 5 Equipment

APPENDIX 6 Calculations

APPENDIX 7 Table Factor A, Reduction of Water Volume to Pressure

APPENDIX 8 Table Factor B, Thermal Expansion of Water

APPENDIX 9 Section Details & Work Sequence

APPENDIX 10 Sketch of Test Header

APPENDIX 11 Sketch of Filling / Dewatering Pig

APPENDIX 12 MSDS Chemicals

APPENDIX 13 Site Lay Out’s

APPENDIX 14 List of Golden Welds

APPENDIX 15 Pipeline Thermometer Installation

APPENDIX 16 Geo-membrane Data Sheet

APPENDIX 17 Geo-membrane Installation Guide

APPENDIX 18 Method of statement Lining Installations

APPENDIX 19 Field Analyzing Kit

APPENDIX 20 Life Time Chemicals

APPENDIX 21 Water Well Analyzing Report

This document is the property of Yemen LNG Company. It must not be stored, reproduced or disclosed to others without written
authorisation from the Company.

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