Hydrostatic Testing of Pipeline

UPGRADATION OF METERING SKID
OWNER : ONGC
LSTK CONTRACTOR : DANIEL MEASUREMENT SOLUTIONS PVT LTD.
CONTRACTOR : SAVAIR ENERGY LTD

Job Procedure for
HYDROTESTING
Procedure No. SEL/903/ML/JP/0
SEL Savair Energy Ltd
ML Main Line
JP Job Procedure
Rev Date Descripti! Prepare" #$
SEL
C%ec&e" a!"
apprve" '$
SEL
Revie(e" a!"
apprve" '$
Da!ie)
* +r Revie(
a!" apprva)
,P
MD
OWNER : ONGC

!o"#e"#$
S.N. Decri!tion" Page No.
#. Pur!oe $
%. Sco!e $
$. Re&erence '
'. Met(odo)ogy '
*. In!ection + Tet P)an ,Enc)oed-
.. In!ection re!ort /or0at ,Enc)oed-
OWNER : ONGC

#.1 P2RPOSE
T%e p-rpse . t%is prce"-re is t )a$ "(! /-i"e)i!es a!" re0-ire1e!ts a!"
t esta')is% a 1et%" r a s$ste1 t c!tr) t%e %$"rstatic testi!/ .
Up/ra"ati! . 1eteri!/ s$ste1.
%.1 SCOPE
T(e !ur!oe o& t(i !rocedure i to de&ine t(e 0et(odo)ogy &or c)eaning(ydrotet and
de3atering o& t(e 456 #156#%5 + #.5 dia S7id &abricated and inta))ed &or ONG8.

3.0 REFERENCES
/o))o3ing docu0ent in !art or in tota)ity (a)) &or0 t(e re&erence docu0ent.
9SME : $#.4

4.0 METHODOLOGY
Detai)s . t%e test secti! s%a)) 'e i))-strate" i! t%e ,$"rtest pac&2 (%ic% s%a))
'e prepare" .r eac% test secti! a!" s-'1itte" t EIL prir t
c11e!ce1e!t . t%e test.
A ca)c-)ate" 3 pre"eter1i!e" )e!/t% . pipe)i!e s%a)) 'e se)ecte" .r t%e
%$"rtest 'ase" ! e)evati!2 avai)a'i)it$ . (ater a!" )cati! . stati!s.
Grap% s%(i!/ t%e e)evati! . t%e c1p)ete test secti! s%a)) 'e "ra(! prir
t start . t%e test a!" e!c)se" i! t%e %$"rtest pac&. ,(ever 1a4. Le!/t%
. t%etest secti! s%a)) !t e4cee" 5* K1.
Hydroteting o& 0ain)ine (a)) e;c)ude va)ve at ta!<o&& tation6 ter0ina)6 !u0!
tation6 S= tation and cra!!er tation &aci)itie.
Prior to any (ydrotatic tet6 EIL (a)) be noti&ied in advance and t(e (ydrotet (a))
co00ence on)y a&ter obtaining ignature on !art > 9 + : o& t(e Pi!e :oo7 and a&ter
0ec(anica) c)earance ,9!!endi; > % + $-.
T(e E?ui!0ent @ Intru0ent to be ued &or !er&or0ing t(e 3or7 (a)) inc)ude6 but not
)i0ited to t(e &o))o3ing"
OWNER : ONGC

Pig &or &i))ing6 c)eaning and gauging" c)eaning !ig 3it( tee) 3ire
bru(e.
/our cu! batc(ing !ig.
Gauging !ig 3it( gauge !)ate dia0eter e?ua) to A*B o& (eavy 3a))
!i!e ection.
/i))ing !u0! 3it( di&&erentia) (ead %1B greater t(an t(e 0a;i0u0
re?uired and a &)o3 rate !re&erab)y bet3een '110C@( to #111 0C@(.
Poitive di!)ace0ent !u0! e?ui!!ed 3it( a tro7e counter and
ca!ab)e o& e;ceeding t(e 0a;i0u0 tet !reure by at )eat %1 bar.
Poitive di!)ace0ent 0eter to 0eaure t(e vo)u0e o& 3ater ued &or
&i))ing t(e )ine (aving va)id ca)ibration certi&icate.
Portab)e tan7 o& u&&icient iDe to !rovide continuou u!!)y o& 3ater to
t(e !u0! during !reuriDation.
:ourdon !reure gauge o& uitab)e !reure range and accuracy 3it(
va)id ca)ibration certi&icate.
Dead 3eig(t teter 3it( an accuracy o& 1.1# bar6 0eauring in
incre0ent o& 1.1* bar and 3it( a va)id ca)ibration certi&icate.
Te0!erature recorder 3it( va)id ca)ibration certi&icate.
T(er0ocou!)e 3it( va)id ca)ibration certi&icate.
Laboratory t(er0o0eter 1E8 to .1E8 range and accuracy F 1.#E8.
Meauring cy)inder to c(ec7 ?uantity o& 3ater during air vo)u0e
ca)cu)ation.
InGection &aci)itie to inGect additive in t(e tet 0ediu0 in t(e re?uired
!ro!ortion.
8o00unication e?ui!0ent uitab)e &or continuou connection bet3een
t(e t3o end.
Te0!orary tet (eader &abricated in con&or0ity 3it( 9SME ection
=III6 diviion % 3it( !articu)ar re&erence to a!!endi; #4 and #A (aving
u&&icient )engt( o& acco00odate t(e re?uired nu0ber o& !ig. T(e
(eader (a)) a)o (ave !roviion &or !ig to!!er.
Pi!ing and va)ve arrange0ent &or )aunc(ing and receiving o& !ig
inde!endent)y.
9)) 0eauring @ recording intru0ent (a)) 0eet t(e !eci&ication
re?uire0ent o& t(e contract.
TEST MEDI2M
8)eaning6 &i))ing and (ydroteting (a)) be !er&or0ed uing o&t non<aggreive 3ater6
OWNER : ONGC

&ree &ro0 and and i)t 3it(dra3n &ro0 a uitab)e ource in t(e !i!e)ine route. T(e
3ater (a)) be &i)tered and (a)) not be conta0inated. T(e 3ater (a)) be teted in an
a!!roved )ab &or it non<aggreivene and uitabi)ity &or uing a t(e tet 0ediu0.
T(e tet re!ort (a)) be ub0itted to EIL &or revie3. On t(e bai o& 3ater tet re!ort
and 0anu&acture @ )aboratoryH reco00endation6 t(e re?uired ?uantity o& corroion
in(ibitor6 o;ygen cavenger6 bacteriide etc. (a)) be added to t(e tet 0ediu0 3it(
!rior a!!rova) &ro0 EIL.
TEST PRESS2RE
T(e !i!e)ine (a)) be Hydrotatica))y teted to a 0ini0u0 !reure o& #.*1 ti0e t(e
0a;i0u0 o!erating !reure6 or #.' ti0e o& deign !reure t(at !reure 3(ic(
3i)) induce a (oo! tre o& A1B o& t(e SMYS o& t(e !i!e)ine 0ateria) in t(e yte0 @
ection under tet6 9t )o3et !oint tet !reure a ca)cu)ated in accordance 3it(
above6 (a)) be t(e 0a;. Preure at t(e (ig(et !oint in t(e ection under tet. T(e
(ig(et !oint o& t(e tet ection (a)) be ubGected to t(e 0ini0u0 tet !reure a
decribed above6 and t(e 0a;i0u0 tet !reure at t(e )o3et !oint (a)) not e;ceed
t(e one reu)ting in a (oo! tre corre!onding to A1B o& SMYS o& !i!e 0ateria)
baed on t(e 0ini0u0 3a)) t(ic7ne in t(e tet ection.
I& any ection co0!rie o& bot( nor0a) + (eavy 3a)) t(ic7ne !i!e6 t(i ection (a))
be teted at t(e tet !reure o& nor0a) 3a)) t(ic7ne !i!e.
!%e&"'"( ) Gu&('"( of #*e P'+e%'"e Te$# Sec#'o"
Prir t starti!/ t%e c)ea!i!/ perati!2 t%e sa.et$ c%ec&)ist i))-strate" i!
APPENDI6 7 8 s%a)) 'e .i))e" -p.
T(e c)eaning o!eration (a)) be !er&or0ed by !ro!e))ing air driven !ig !rovided
3it( !ring )oaded bru(e and 8(ie) 3it( &u)) dia0eter circu)ar bru( (aving O.D.
0ini0u0 * 00 0ore t(an t(e I.D. o& !i!e to re0ove a)) 0i)) ca)e6 rut @ and &ro0
t(e interna) o& t(e !i!e ection.
T(e nu0ber o& !ig run (a)) de!end on t(e ube?uent c)eaning reu)t.
9&ter acce!tance o& air c)eaning 6 t(e tet ection (a)) be &)u(ed uing unin(ibited
3ater e?uiva)ent to #1B o& t(e tota) vo)u0e o& t(e tet ection driven by a &our cu!
c)eaning !ig to re0ove 0ud6 dirt6 debri and any ot(er e;traneou 0ateria). T(e
c)eaning (a)) be conidered to be acce!tab)e 3(en no re)evant e;traneou 0ateria) are
OWNER : ONGC

&ound in &ront o& t(e )at &our cu! !ig.
9&ter acce!tance o& t(e c)eaning6 a Guaging !ig &itted 3it( a guage !)ate 0ade o&
#100 t(ic7 co00ercia) a)u0iniu0 !)ate (a)) be !ro!e))ed bet3een t(e te0!orary
tet (ead. 9 co)u0n o& c)ean 3ater (a)) be !u0!ed in &ront o& t(e !ig &or )ubrication
and to &)u( out t(e re0aining dirt inide t(e tet ection.
Trac7ing arrange0ent (a)) be !rovided in t(e &irt !ig or in cae any o& t(e c)eaning @
gauging !ig get tuc7 inide t(e tet ection a econd !ig &itted 3it( a trac7ing
arrange0ent (a)) be !ro!e))ed and it (a)) be trac7ed u!to t(e !oint o& &au)t.
T(e reu)t o& t(e gauge !ig run (a)) be ana)yDed to eva)uate t(e interna) tatu o& t(e
!i!e)ine and t(e gauge !)ate (a)) be Goint)y igned by 8IPL and EIL@G9IL
re!reentative. 9 de&or0ed6 bent o& evere))y nic7ed !)ate or da0aged !ig (a)) be
evidence o& gauging !ig run &ai)ure and t(e a0e (a)) not be acce!tab)e. In uc(
cae 8IPL (a)) re!air and recti&y t(e )ine and re!eat t(e t(e gauging !ig run to t(e
ati&action o& EIL@G9IL.
T(e a0!)e ca)cu)ation &or gauging )ate iDing i a !er EIL @ G9IL.
9&ter acce!tance o& gauging o!eration by EIL @ G9IL6 a !(otogra!( o& t(e gauge !)ate
(a)) be ta7en and attac(ed 3it( t(e gauging re!ort.P(otogra!( (a)) be ta7en !rior to
)aunc( and a&ter recei!t 3it( a)) detai) 3ritten on t(e gauge !)ate i Tet Section
No.IIIIIIIIIIIIIIII /ro0 J0IIIIIIIIIIII
Joint No.IIIIIIIII.Date + Ti0e o& )aunc(ingIIIIIIIIIIand Gauge !)ate OD +
t(7.
T(e !ara0eter o& c)eaning + gauging o!eration (a)) be recorded every $1 0inute
in t(e &or0at enc)oed in 9PPENDIK<* + 9PPENDIK<. re!ective)y.
Te$# Sec#'o" F'%%'"(
O! accepta!ce . Ga-/i!/2 t%e air pi//i!/ %ea"ers s%a)) 'e c-t a!" t%e
te1prar$ test %ea"s2 a)rea"$ preteste" at a press-re res-)ti!/ i! a %p
stress crresp!"i!/ t 9*: . SMYS s%a)) 'e (e)"e" t t%e test secti!.
T%e %$"rtest reprt . t%e te1prar$ test %ea"ers s%a)) 'e s-'1itte" t EIL
prir t start . (e)"i!/ t%e test %ea"er t t%e test secti!.
T(e &i))ing end tet (eader (a)) be !re )oaded 3it( 0in. t(ree nu0ber o& &our cu!
batc(ing !ig.
OWNER : ONGC

T(e &i))ing o!eration (a)) begin 3it( !u0!ing un<in(ibited 3ater e?ua) to #1B o& t(e
vo)u0e o& t(e tet ection in &ront o& t(e &irt !ig.
/irt Pig " Pu0!ing unin(ibited 3ater e?ua) to ##@% J0 !i!e )engt( be(ind t(e !ig
(a)) )aunc( t(e &irt !ig. T(e 3ater co)u0n be&ore and a&ter t(i !ig (a)) act a
cu(ion to contro) t(e 0ove0ent o& t(e &i))ing !ig and (ence 0ini0iDe air entra!0ent
Second !ig" Pu0!ing in t(e actua) )ine &i))ing in(ibited 3ater be(ind t(e !ig (a))
)aunc( t(e econd !ig.
T(e &i))ing (a)) continue ti)) t(e econd !ig reac(e t(e ot(er end o& t(e tet ection
and t(e !reure at t(e tet end rie to t(e tatic (ead.
Re?uired ?uantity o& corroion in(ibitor (a)) be inGected during t(e &i))ing o!eration
t(roug( any o& t(e noDD)e !rovided on t(e tet (eader or into t(e brea7 tan7. T(e
?uantity o& in(ibitor (a)) be contro))ed by adGuting t(e &)o3 rate o& t(e doing !u0!..
T(e doing rate (a)) be a decribed in t(e &o))o3ing !aragra!(.
During t(e 3(o)e &i))ing o!eration t(e va)ue at t(e receiving end tet (eader (a)) be
t(rott)ed uitab)y to 0aintain ade?uate bac7 !reure and t(u contro) t(e !ig
0ove0ent.
T(e &irt t3o co)u0n o& 3ater (a)) be drained out &ro0 t(e receiving end.
T(e di&&erent !ara0eter6 during &i))ing o!eration (a)) be recorded in once every
t(irty 0inute in t(e !recribed &or0at enc)oed in 9PPENDIK >L.
Do$'"( R&#e
T%e "si!/ rate s%a)) 'e
L*1 !!0 &or &re( &i)) 3ater
.1 !!0 &or reue o& a)ready doed 3ater. , In cae o& 3ater tran&er
&ro0 one tet ection to anot(er- and a)o 0anu&acturerH re!ort (a))
be &o))o3ed.
i.e.6 t(e &i)) 3ater &or t(e &irt tet ection (a)) be doed at a rate o& L*1!!0 and t(ere
a&ter during tran&erring t(e 3ater &ro0 one ection to t(e ne;t an additiona) .1!!0
(a)) be added to t(e 3ater 3(ic( i to be reued6 and i& it i re?uired to add &re(
3ater , in cae o& a )onger tet ection t(an t(e !reviou- t(en6 t(e vo)u0e o& &re(
3ater (a)) be doed at a rate o& L*1!!0.
OWNER : ONGC

Note" Doing rate are to be con&ir0ed be&ore tart o& (ydro tet t(e above doage are
tentative on)y.
T*er,&% S#&b'%'-&#'o"
O!ce t%e test secti! %as 'ee! c1p)ete)$ .i))e" a!" a 1i!i1-1 press-re . ;
'ar %as 'ee! ac%ieve" at t%e %i/%est pi!t2 t%e t%er1a) sta'i)i<ati! peri"
s%a)) 'e starte". Te1perat-re pr'es s%a)) 'e i!sta))e" t 1eas-re t%e pipe
a!" si) te1perat-re at ever$ =.5 K1. . t%e pipe)i!e spaci!/ 1s$ 'e
i!crease" t 1a4. 5 &1s "epe!"i!/ -p! t%e terrai! a!" !at-re . s-'si)
a)!/ t%e a)i/!1e!t . t%e test secti!. . A)s !e pr'e eac% s%a)) 'e
i!sta))e" at .ive %-!"re" 1eters .r1 't% t%e test %ea"s.
T(e !robe &or 0eauring !i!e te0!erature (a)) be inta))ed by cutting a 0a)) !ortion
,a )itt)e bigger t(an t(e !robe ti!- o& t(e coating &ro0 t(e !i!e6 !o)i(ing t(e e;!oed
!ortion and &i;ing t(e !robe to t(e !i!e 3it( ?uic7 etting e!o;y enuring &ir0 contact
bet3een t(e !robe and !i!e. T(e oi) !robe (a)) be !o7ed into t(e eart( adGacent to
t(e !i!e.
T(e te0!erature reading (a)) be ta7en at t3o<(our interva) 3it( a ca)ibrated digita)
te0!erature read out unit one deci0a) !)ace and t(er0a) tabi)iDation (a)) be
conidered to (ave been ac(ieved 3(en a di&&erence not (ig(er t(an #E8 i attained
bet3een t(e average va)ue o& t(e )at t3o reading o& !i!e)ine te0!. T(e te0!erature
reading (a)) be recorded in t(e &or0at enc)oed in 9PPENDIK<4.
Digita)
T(er0o 0eter
Inu)ating 8oating
Soi) Te0!. Ter0ocou!)e
Ground
Leve)
M95
Pi!e Na))
=ie3
=IEN M95
OWNER : ONGC

T%er1c-p)e Attac%e" t Pipe Wa)) '$ >-ic& Setti!/ Ep4$
FIGURE .
9&ter co0!)etion and acce!tance o& (ydroteting6 t(er0ocou!)e (a)) be re0oved and t(e
corre!onding coating (a)) be re!aired a !er a!!roved coating re!air !rocedure.
PreuriDation
O+er&#'o"&% S#e+$/
M'i)i<e %i/%?press-re p-1p a!" test e0-ip1e!t at press-ri<ati! area. I!sta))
!e press-re /a-/e i! para))e) (it% t%e "ea" (ei/%t tester.
/i)) out and ign !i!e)ine !re<!reuriDation a&ety c(ec7)it. 9PPENDIK<A.
9 oon a t(e te0!erature tabi)iDation i ac(ieved6 t(e !reure (a)) be raied at a
0oderate and contant rate not e;ceeding % > bar !er 0inute.
T(e !ara0eter ,=o)u0e re?uired- during !reuriDation (a)) be recorded t(roug(out
t(e cyc)e in t(e &or0at enc)oed in t(e 9PPENDIK >#1 a &o))o3"
Eac( * bar incre0ent u!to 41B o& t(e tet !reure a recorded by dead
3eig(t teter.
Eac( % bar incre0ent bet3een 41B to A1B o& t(e tet !reure a recorded by
dead 3eig(t teter.
Eac( 1.% bar incre0ent bet3een A1B to &u)) tet !reure a recorded by dead
3eig(t teter.
T(e !reuriDation (a)) be cyc)ed 3it( t(e e?uence (o3n in t(e &o))o3ing !reure
e?uence.
PreuriDe to *1B o& tet !reure6 (o)d !reure &or one (our6and !er&or0 air vo)u0e
tet and dro! !reure to tatic (ead.
PreuriDe to L*B o& tet !reure6 (o)d !reure &or one (our6 and !er&or0 air vo)u0e
tet and dro! !reure to tatic (ead.
PreuriDe to tet !reure6 !er&or0 air vo)u0e tet and raie !reure to t(e tet
OWNER : ONGC

!reure once again.
In cae6 during t(e (o)d !eriod indicated above6 a decreae in !reure i oberved6 t(e
above o!eration (a)) not be re!eated 0ore t(an t3ice6 a&ter 3(ic( t(e )ine (a)) not be
conidered ca!ab)e o& tet6 unti) t(e caue &or t(e )ac7 o& 3ater tig(tne i e)i0inated.
A'r 0o%u,e !&%cu%&#'o"
In order to c(ec7 t(e !reure o& air in t(e !i!e)ine t3o e!arate conecutive !reure
)o3ering o& 1.* bar by )o3)y b)eeding 3ater &ro0 t(e tet ection (a)) be carried out during
a)) t(e !reuriDing cyc)ing a 0entioned above. T(e 3ater drained during t(e econd
)o3ering (a)) be accurate)y 0eaured ,=#-. T(i ?uantity 0eaured (a)) be co0!ared to t(e
t(eoretica) ?uantity ,=!- corre!onding to t(e !reure )o3ering. T(e air vo)u0e (a)) be
acce!tab)e i& =i @8!O #.1.. T(e obervation (a)) be recorded in t(e air vo)u0e ca)cu)ation
&or0at enc)oed in 9PPENDIK > ##.
12 3our 3o%d Per'od
T%e press-re s%a)) 'e c!si"ere" t 'e sta'i)i<e" (%e! ! .)-ct-ati! is
'serve" i! t%e pipe)i!e press-re as see! .r1 t%e "ea" (ei/%t tester. O!
ac%ievi!/ press-re sta')i<ati!2 press-re p-1p c!!ecti!s s%a)) 'e re1ve"
a!" t%e test secti! c1p)ete)$ is)ate" a!" a)) c!!ecti!s at t%e test %ea"s
s%a)) 'e c%ec&e" .r )ea&a/es. Press-re recr"ers s%a)) t%a! 'e starte" (it%
t%e c%art i! rea) ti1e rie!tati! a!" t%e =8 %-r press-re %)" peri" s%a))
start.
During t(e !reure (o)d !eriod t(e &o))o3ing data (a)) be recorded in t(e &or0at
enc)oed in 9PPENDIK<#%.
a- Every one<(our !reure 0eaure0ent &ro0 dead 3eig(t teter.
b- Every t3o (our t(e a0bient te0!erature6 !i!e and oi) te0!erature &ro0
t(e t(er0ocou!)e.
T(roug(out t(e (o)d !eriod6 care (a)) be ta7en t(at t(e 0a;i0u0 tet !reure i not
e;ceeded. S(ou)d it beco0e neceary to de<!reuriDe6 t(e vo)u0e o& tet 0ediu0
b)eed o&& (a)) be 0eaured and recorded.
Acce+#&"ce !r'#er'&
OWNER : ONGC

The hydrostatic test shall be considered as positive if pressure has kept a
constant value throughout the test duration, except for change due to
temperature effects.
T(e !reure c(ange va)ue a a &unction o& te0!erature c(ange (a)) be a)gebraica))y
added to t(e !reure va)ue a read on t(e 0eter. T(e !reure va)ue t(u adGuted
(a)) be co0!ared 3it( t(e initia) va)ue and t(e tet (a)) be conidered a acce!tab)e
i& di&&erence i )e t(an or e?ua) to 1.$ bar.
/or ca)cu)ating t(e !reure c(ange due to c(ange in te0!erature t(e &or0u)a and data
i))utrated in 9PPENDIK<#$ (a)) be ued.
On ucce&u) co0!)etion and acce!tance o& t(e (ydrotet6 t(e !i!e)ine (a)) be )o3)y
de!reuriDed at a 0oderate and contant rate.
Le&4$
I. "-ri!/ t%e press-ri<ati! peri" r "-ri!/ t%e test peri"s a!$ "e.ects are
'serve"2 t%ese s%a)) 'e e)i1i!ate".
I& any )ea7 are oberved t(e ection (a)) be initia))y viua))y in!ected to c(ec7 t(e
eventua) )ea7ing !oint. I& t(i c(ec7 i negative6 t(en t(e !rocedure decribed be)o3
(a)) be &o))o3ed. No 3or7 (a)) be carried out to re!air )ea7 unti) t(e
!reure (a been reduced to a a&e !reure ,i.e. tatic (ead !)u # 7g- and t(e 3ater
drained.
Le&4 De#ec#'o"
T )cate '-rie" )ea&i!/ pipe2 t%e .))(i!/ prce"-re '$ e)i1i!ati! s%a)) 'e
.))(e":
#. To cut t(e ection in an inter0ediate !oition
%. To inert t3o tet (ead
$. To re &)ood t(e ection
'. To !reuriDe t(e t3o ection
*. To deter0ine t(e &au)ty ection
T(i !rocedure (a)) be a!!)ied unti) t(e deter0ination o& t(e de&ect. 9 oon a t(e
de&ect (a been )ocated and re!aired6 t(e tet ection (a)) be teted again.
OWNER : ONGC

I& t(e tet ection &ai) to 0aintain t(e !eci&ied tet !reure a&ter io)ation 68IPL (a))
deter0ine by earc( t(e )ocation o& )ea7age or &ai)ure. 9)) )ea7 and &ai)ure 3it(in t(e
!i!e<3a)) or 3e)d ea0 (a)) be re!aired by re!)ace0ent o& entire Goint or Goint in
3(ic( )ea7age or &ai)ure occur. 8IPL (a)) co0!)y 3it( intruction EIL@G9IL
3(et(er to re!)ace a ection o& t(e )ine<!i!e t(at inc)ude t(e )ea7 or 3(et(er to re!air
t(e circu0&erentia) 3e)d. T(e re!air (a)) (o3ever 0eet t(e re?uire0ent o& EIL !ec.
.<LL<1.. 9&ter co0!)etion o& re!air6 t(e (ydrotatic tet (a)) be re!eated.8IPL (a))
(au) and toc7!i)e a)) da0aged and de&ective !i!e to torage )ocation deignated by
EIL@G9IL. 9)) crac7 and !)it reu)ting &ro0 &ai)ure (a)) be coated 3it( an
a!!)ication o& greae to !reerve t(e c(aracteritic o& &ai)ure &ro0 corroion. Joint o&
&ai)ed !i!e (a)) be 0ar7ed 3it( !aint6 3it( a tag indicating &ai)ure detai)6 date and
)ocation o& &ai)ure and !reure at 3(ic( &ai)ure occurred.
P'+e%'"e 5u%4 De6&#er'"(
Writte! per1issi! s%a)) 'e 'tai!e" .r1 EIL 3 GAIL .r 'tai!i!/ t%e
"e(ateri!/ c)eare!ce. Up! s-ccess.-) c1p)eti! . t%e %$"rtest2 prpe))i!/
t%e t%ir" pi/ i! t%e test %ea"er s%a)) "e(ater t%e secti!. Ma&i!/ s-ita')e
"rai!s s%a)) 1a&e !ecessar$ arra!/e1e!ts .r sa.e "ispsa) . %$"rtest
(ater.De(ateri!/ s%a)) start a.ter /etti!/ c)eara!ce .r1 EIL 3 GAIL a!" t%e
(ater s%a)) 'e tra!s.erre" t t%e !e4t secti! (%erever re0-ire".
T%e "e(ateri!/ s%a)) 'e carrie" -t '$ -si!/ .-r?c-p pi/s a!" .a1 pi/s
"rive! '$ c1presse" air. T%e "e(ateri!/ s%a)) 'e "!e i! s-c% a (a$ as t
prvi"e a"e0-ate c!tr) . pi/s "-ri!/ "e(ateri!/ '$ &eepi!/ air press-re =
'ar 1i!i1-1. Pi/s a!" e0-ip1e!t re0-ire" .r "e(ateri!/ s%a)) 'e apprve"
'$ EIL i! a"va!ce. +-r?c-p pi/s s%a)) .irst 'e passe" t%r-/% t%e )i!e t
"isp)ace t%e (ater. +a1
pi/s s%a)) t%e! 'e passe" i! r"er t c1p)ete t%e )i!e "e(ateri!/. T%e )i!e
s%a)) 'e c!si"ere" "e(atere" (%e! a !e/)i/i')e a1-!t . (ater is .)-s%e"
-t '$ t%e )ast .a1 pi/.
D-ri!/ "e(ateri!/ care s%a)) 'e ta&e! t prper)$ "ispse t%e t%e "isc%ar/i!/
(ater i! r"er t avi" p))-ti!2 "a1a/es t .ie)"s -!"er c-)tivati! a!" r
e4isti!/ str-ct-res a!" i!ter.ere!ce (it% t%e tra..ic.
Up! c1p)eti! . t%e testi!/ a!" "e(ateri!/ perati!2 a!$ prvisi!a)
traps .r pi/s a!" a)) t%er te1prar$ i!sta))ati! re)ati!/ t t%e test s%a)) 'e
re1ve". S-'se0-e!t)$ t%e i!"ivi"-a) secti!s . t%e )i!e a)rea"$ teste" s%a))
OWNER : ONGC

'e @i!e" i! accr"a!ce (it% t%e re0-ire1e!ts . re)eva!t speci.icati!s
iss-e" .r t%e p-rpse.
T%e )i!e press-re "-ri!/ "e(ateri!/ perati! s%a)) 'e recr"e" ever$ A*
1i!-tes i! t%e .r1at e!c)se" i! APPENDI6?;5.
O!ce "e(ateri!/ is ver2 t%e secti!a)i<i!/ va)ve a!" t%er va)ve asse1')ies
s%a)) 'e i!sta))e" at t%e respective )cati!s is accr"a!ce (it% t%e re)eva!t
prce"-res a!" speci.icati!s. A)) t%er1c-p)es i!sta))e" i! t%e pipe)i!e s%a))
'e re1ve" a!" crrsi! cati!/ s%a)) 'e repaire" (%erever re0-ire" -si!/
apprve" prce"-re a!" 1ateria)s.
I. it is re0-ire" t preserve t%e pipe)i!e .r a speci.ie" "-rati!2 s-..icie!t
0-a!tit$ . apprve" crrsi! i!%i'itrs "epe!"i!/ -p! t%e 0-a)it$ . (ater2
"-rati! . preservati! a!" )a'ratr$ test reprts2 s%a)) 'e i!@ecte" i!t t%e
pipe)i!e as per t%e "irecti! . EIL a!" t%e press-re s%a)) 'e raise" t t%e
re0-ire" )eve) as 1-t-a))$ a/ree" -p! (it% EIL3GAIL at a )ater sta/e.
S-'se0-e!t t "e(ateri!/2 t%e SV i!sta))ati! .))(e" '$ .i!a) tie?i! 'et(ee!
t%e teste" secti!s s%a)) 'e ta&e! -p.
7. 3EALT38 SAFET9 ) EN0IRONMENT
T%e apprve" prce"-re . ,ea)t%2 Sa.et$ B E!vir!1e!t s%a)) 'e .))(e"
"-ri!/ t%e e4ec-ti!.
T%e %a<ar"s assciate" (it% t%e %$"rtest %ave 'ee! i"e!ti.ie" a!" t%e
.))(i!/ /-i"e)i!es are s-//este" .r i1p)e1e!tati! . sa.et$ !r1s.
Prvisi!s s%a)) 'e 1a"e .r t%e i!sta))ati! . ! a"1itta!ce si/!s t
-!a-t%ri<e" pers!!e) .r1 t%e ra" t t%e R.O.W. at critica) )cati!s.
War!i!/ si/!s i! E!/)is% a!" Lca) La!/-a/e stati!/ CPipe)i!e U!"er test 7
&eep ..D s%a)) 'e p)ace" i! )cati!s (%ere t%e pipe)i!e is -!cvere"2 a!"
partic-)ar)$ (%ere t%e te1prar$ %ea"ers a!" stati!s are )cate". S-c% areas
s%a)) 'e
s-ita')$ .e!ce" i! s-c% a (a$ as preve!t access . -!a-t%ri<e" pers!!e).
N -!a-t%ri<e" pers!!e) s%a)) 'e c)ser t%a! 8*1 t t%e pipe)i!e -!"er test.
O!)$ a-t%ri<e" pers!!e) as "e.i!e" 3i"e!ti.ie" '$ t%e ,$"rtest E!/i!eer
s%a)) 'e a))(e" (it%i! t%e test area (%e! t%e test secti! is -!"er press-re.
N test activities are i! pr/ress (it% -t speci.ic c)eara!ce . testi!/
OWNER : ONGC

E!/i!eer. W%e! test e0-ip1e!ts s%a)) 'e i!sta))e" i! c1p)ia!ce (it%
1et%"s a!" s-ita')e i!str-cti!s !)$2 t%is 1a$ !t ca-se a!$ i!@-r$ t
pers!!e).
A)) i!str-1e!ts s%a)) 'e p)ace" i! s-c% a )cati! as t preve!t it .r1 'ei!/
a..ecte" '$ a pers!!e) i! t%e test %ea".
N )ea& ! t%e pipe r test e0-ip1e!t s%a)) 'e a))(e" (%is)t -!"er press-re
e4cept .r ti/%t!i!/ . .)a!/es2 t%e re1va) . c!!ecti!s a.ter c)si!/ t%e
va)ves2 a!" t%e ')i!"i!/ . prts a.ter ac%ievi!/ t%e test press-re .r is)ati!
. t%e test stati!.
N .)e4i')e %ses are per1issi')e i!si"e t%e test ca'i!2 e4cept .r esse!tia)
c!!ecti! t t%e i!str-1e!ts.
+r e..ective c11-!icati!2 a (ire)ess a!" a (a)&ie 7 ta)&ie s$ste1 s%a)) 'e
-se".
4. :UALIT9 ASSURAN!E ) :UALIT9 !ONTROL
T%e 0-a)it$ ass-ra!ce a!" 0-a)it$ c!tr) .r t%e pr@ect prc-re1e!t s%a)) 'e
carrie" -t '$ strict)$ i1p)e1e!ti!/ t%e .))(i!/:
a- I!specti!s a!" Test P)a!.
b- >-a)it$ Recr"s
T%e t$pe . i!specti! activit$ a!" 0-a)it$ recr"s /e!erate" "-ri!/ t%e activit$
is "etai)e" i! I!specti! a!" Test P)a!. >-a)it$ recr"s s%a)) i!c)-"e c-rre!t
ca)i'rati! certi.icates .r a)) 1eas-ri!/ i!str-1e!ts.
T%e vera)) te!tative )a$-t . e0-ip1e!t B i!str-1e!ts .r pi//i!/ %$"rstatic
testi!/ is s%(! t%r-/% Appe!"i4 ? ;E
9.0 APPENDI!ES /FORMATS
Appe!"ices ; t ;9 e!c)se".
Nte:? I!case . a!$ c!.)ict 'et(ee! t%is prce"-re a!" t%e c!tract speci.icati!2
.
t%e )ater s%a)) /ver!.
OWNER : ONGC

DO!.NO. RE0.NO. APPENDI; .
INSPE!TION ) TEST PLAN FOR 39DROSTATI! TESTING
S).N
Activit$
I!sp.#
$
CIPL
Veri.i.
#$.
EIL
Dc-1e!t t 'e
s-'1itte" '$ CIPL
Re1ar&s
; Apprva) . Prce"-re B Test Dia/ra1 W A Test Pac&
= Pre ,$"rtest C%ec& List W W
A
Mec%a!ica) C)eara!ce . t%e Pipe
Secti!
, A
Pipe #&2 Part?A
B #
8 S-'1issi! Ca)i'rati! Certi.icates , R Certi.icates
5
S-'1issi! . Water Test Reprt a!"
Dsi!/ Rec11e!"ati!
, R Test Reprt
E I!sta)) a)) Te1prar$ Pipi!/ e0-ip1e!t W RM Test "ia/ra1
F E!s-ri!/ C11-!icati! S$ste1 W RM
G E!s-ri!/ Sa.et$ Re0-ire1e!ts W W
9 C)ea!i!/3Ga-/i!/ W W I!specti! reprt
;* I!sta))ati! . Te1p. Se!srs , W
;; +)-s%i!/ , W I!specti! reprt
;=
I!sta))ati! . Te1prar$ ,ea"ers Wit%
Pi/s
, RM
,$"rtest reprt .
test %ea"ers.
;A
+i))i!/ Rate
Dsi!/ rate
#ac& press-re C!tr)
W
W
W
RM
RM
RM
I!specti! reprt
OWNER : ONGC

;8 T%er1a) Sta'i)i<ati! , W I!specti! reprt
;5 Air V)-1e Ca)c-)ati! , W I!specti! reprt
;E
Press-ri<ati! Rate
L/ . Te1p.a!" Press-re
#)ee" .. (ater Meas-re1e!t
W
W
W
RM
RM
W
I!specti! reprt
;F Lea& Detecti! B Test E4te!si! W W
;G
Recti.icati! B Stc&i!/ 3 Mar&i!/ .
Da1a/e" Pipe
W W
;9 Accepta!ce B eva)-ati! . recr" "ata W W I!specti! reprt
=*
Depress-ri<ati! B De(ateri!/ t t%e
Accept Pi!t
W W I!specti! reprt
=;
Repair . PE cati!/ at repairi!/ te1p.
Se!srs .i4i!/ pi!t
W W
LEGEND:
CAD ACCEPTANCE3APPROVAL C,D ,OLD CWD WITNESS INSPECTION
CRMD RANDOM INSPECTION CRD REVIEW O+ DOCUMENTS
CIPL EIL GAIL
SIGN: SIGN: SIGN:
NAME: NAME: NAME:
DATE: DATE: DATE:
OWNER : ONGC

DOC.NO. REV.NO.0 APPENDIX
2
INSPE!TION REPORT FOR TEST PLAN FOR POST 39DROSTAT! TESTING
Line Dia " %1 inc(
Section No " /ro0 $*.$%* ,JM- To $*.*%# ,JM-
Joint No " /ro0 $*@M%$ ,JM- To $*@/T$L,JM-
O.D Wa)) T%ic&
Nr1a)
I.DH11I
Le!/t%
HMtrsI
Av/.Wa))
HMMI
V)-1e
Per Mtrs
H1I
Tta)
V)-1eH1I
Test
press-re
H&/3c1
=
I
Mi!. Ma4.
5*G 11 ;;.;11 8G5.G ;9E.;5* ;;.; *.;G5A AE.AA9 ;A9.9;
Tta) )e!/t%
Nte: ;. Le!/t% . test %ea"ers t 'e i!c)-"e"
=.Test press-re s%a)) 'e as per 1i!. (a)) t%ic&
. pipe i! t%e secti!.
A.stri&e ! (%ic% ever app)ica')e.
Le!/t% . Tta) secti! ?=** 1trs
Test Press-re GENERAL DATA
Water S-rce JJJJJJJJ
START END ,IG, LOW
C%ai!a/e
KMA53M=A KMA53+TAF KMA53M=A KMA53M=G
E)evati! HMI
=;E.=;A =;5.8GA =;E.=;A =*8.FGA
Press-re H&/3c1
=
I
;8=.* ;8=.*F ;8=.* ;8A.;=
I1t ,
=
O K *.*9G*EE5 K/3c1
=
H/I : O+ TEST PRESSURE
5* F5 ;**
Press-re Se0-e!ce H&/3c1
=
I F; ;*E.5 ;8=
Appr4. Water t i!crease Press-re #$ = #ar3Mi! HLt.3Mi!I
Appr4. Water t press-re )( *.5 HLtrsI
Appr4 press-re c%a!/e as a .-!cti! Te1p. C%a!/e H#ar3CI
ELEVATIONHMtrsI.HA S&etc% s%(i!/ e)evati!s Vs K1 HC%ai!a/e I t 'e e!c)se"
C%ai!a/e HK1I +r1 7 KMA531=A t KM A53+TAF
+i)) Directi! DADRI SIDE 7 KMA5?M=A
De(ateri!/ "irecti! #AWANA SIDE 7 KMA53+TAF
REMARKS:
+OR CIPL +OR EIL3GAIL
Si/! Si/!
Na1e Na1e
Date Date
OWNER : ONGC

DO!.NO. RE0.NO. APPENDI; . 3
!ERTIFI!ATE OF ME!3ANI!AL ) !ONSTRU!TION !OMPLETION FOR P/ L
Line Dia " /ro0 ,J0- ,To-
,J0-
Secti! N. : +r1 HK1I HTI
HK1I
Li!t N. : +r1 HK1I HTI
HK1I
O.DHINC,I WALL T,K
HMMI
I.D HMMI GRADE API 7
5L
GR.6 ? E*
Le!/t% JJJJJJJJJJJHK1I
Mi!: Mi!: V)-1e JJJJJJJJJJJHM
A
I
Ma4: Ma4:
Wa))
T%ic&!essH11I
Le!/t% HMtrI N-1'er . We)"s:JJJJJJJJJJJJJJJJJJJJ
Le!/t% . !t 'ac&.i))e" secti!:
!ONSTRU!TION
Start Date:
E!" Date:
T,IS IS CERTI+Y T,AT ALL WELDS O+ T,E A#OVE TEST SECTION ,AVE #EEN
ACCEPTED AND T,E PIPELINE SECTION ,AS #EEN LAID AND #ACK+ILLED
ACCORDING TO T,E SPECI+ICATIONS.ALL ACTIVITIES UPTO PART 7 # O+
PIPE #OOK IS COMPLETED AND CERTI+IED.
REMARKS:
OWNER : ONGC

+OR CIPL +OR EIL +OR GAIL
Si/! Si/! Si/!
Na1e Na1e Na1e
Date Date Date
DO!.NO. RE0.NO. APPENDI; <
2
!3E!K LIST FOR !LEANING8 GAUGING AND FILLING
S.N SA+ETY C,ECK LIST YES NO
;
Is a cp$ . t%e apprve" %$"rtest prce"-re avai)a')e i! t%e
area.
=
Is a cp$ . t%e %$"rtest pac& avai)a')e i! t%e area.
A
Is a"e0-ate (ater "ispsa) arra!/e1e!t 1a"e.
8
C%ec& ,-se &eepi!/ sta!"ar"s are accepta')e at t%e .i))i!/
e!" a!" receivi!/ e!".
5
C%ec& t%e c!"iti!s . t%e t)s a!" tac&)es t 'e -se"
E
C%ec& t%at t%e )i/%ti!/ arra!/e1e!ts are a"e0-ate a!" t%e
c!"iti! . t%e e)ectrica) (iri!/2 circ-it 'ar"s2 c!"-it etc.are
accepta')e a!" sa.e.
F
C%ec& t%at test areas at eac% e!" . t%e test secti! %ave 'e!
cr"!e" .. (it% sta&es a!" '-!ti!/ tape.
G
C%ec& t%at e1er/e!c$ e0-ip1e!t are a"e0-ate a!" are
(r&i!/ c!"iti! 7 sta!"'$ ve%ic)e2 c11-!icati! s$ste1
.irst ai" '4es2 1e"ica) .aci)ities2 stretc%er etc.
OWNER : ONGC

Nte: ,$"rtest e!/i!eer 3 ,SE ..icer t a"" a!$ t%er sa.et$ pi!ts t t%is )ist as
per t%e site circ-1sta!ces i. "ee1e" !ecessar$.
,YDROTEST ENGINEER ,SE O++ICER EIL
Si/!: Si/!: Si/!:
Na1e: Na1e: Na1e:
Date: Date: Date:
DO!.NO/ RE0.NO / APPENDI; . =
INSPECTION REPORT FOR AIR CLEANING
Li!e Dia : +r1 HKMI T
HKMI
Secti! N. : +r1 HKMI T
HKMI
Li!t N : +r1 HKMI T
HKMI
O.D HINC,I
WALL T,KHMMI I.D HMMI GRADE API
7 5L GR.6 7
E*
Le!/t%JJJJJJJJJHKMI
Mi!: Mi!:
V)-1eJJJJJJJJJJHMAI
Ma4: Ma4:
C1pressr
Lcati!JJJJJJJJJJJJ
Ma&eJJJJJJJ
M"e)JJJJJJJJJ
C-t -tJJJJJJJJJJJJJ
Ma4.Press-reJJJJJJJJJJJJ
Pipi!/ Directi! +r1JJJJJJJJJJJHKMI TJJJJJJJJJJHKMI
OWNER : ONGC

R-! N Pi/ T$pe
Start E!" Av/.Va)
K13,r
Press-re
HK/3C1=I
>-a!tit$
. De'ris
HI! K/I. Date Ti1e Date Ti1e Mi!. Ma4.
REMARKS
ACCEPTANCE O+ SECTION CLEANING : YES 3 NO
FOR !IPL FOR EIL FOR GAIL
Si/! Si/! Si/!
Na1e Na1e Na1e
Date Date Date
DO!.NO/ RE0.NO/ APPENDI; . >
INSPECTION REPORT FOR GAUGING
HKMI
Secti! N : +r1 HKMI T
HKMI
Li!t N. : +r1 HKMI T
HKMI
O.D HINC,I
WALL T,K. HMMI I.D HMMI GRADE
API?5L
GR.6?E*
Le!/t% JJJJJJJH&1I
Mi!: Mi!:
V)-1eJJJJJJJHMAI
Ma4: Ma4:
C1pressr Lcati! Ma&e M"e)
OWNER : ONGC

O-t P-t Ma4.Press-re
Pi//i!/ Directi! +r1 HKMI. T HKMI
Ga-/e P)ate Start E!"
Av/.va).
K13,r
Press-re
H&/3c1=I
DiaHi!c%I
T%&
H11I
Materia) Date Ti1e Date Ti1e Mi! Ma4
E!c)s-re: T%e P%t/rap% . Ga-/e p)ate 'e.re a!" a.ter R-!
Detai)s . Ga-/e P)ate Da1a/e Hi. a!$I:
REMARKS:
ACCEPTANCE O+ SECTION CLEANING: YES 3 NO
Si/! : Si/! : Si/! :
Na1e : Na1e : Na1e :
Date : Date : Date :
DOC.NO: REV.NO.; APPENDI6
7 F
INSPECTION REPORT FOR WATER FILLING
HKMI
Secti! N : +r1 HKMI T
HKMI
Li!t N. : +r1 HKMI T
HKMI
OWNER : ONGC

O.D HINC,I
WALL T,K.HMMI I.D HMMI GRADE
API?5L
GR.6?E*
Le!/t%JJJJJJJH&1I
Mi!: Mi!:
V)-1eJJJJJJJJHMAI
Ma4: Ma4:
Test Me"i-1 Water S-rce Lcati! HK1I
I!%i'iti! : Y 3 N T$pe Dsa/e pp1
T$pe Dsa/e pp1
T$pe Dsa/e pp1
+i)) p-1p Lcati! Ma&e O-tp-t Ltrs3Mi!
Ma4.Press-re 'ar
+)( Meter Ma&e M"e) Sr.N
+i))i!/ Directi! +r1 &1 T &1
Pi/ Se0-e!ce
Pre.i))i!/ Le!/t% HMtrsI V)-1eH1AI
;
st
Pi/ T$pe
#et(ee! pi/ ; B Pi/ = Le!/t% H1trsI V)-1eH1AI
=
!"
Pi/ T$pe
Ti1e
+i)) press-re
H K/3c1=I
+)( 1eter
Rea"i!/
H1AI
V)-1e
t%is peri"H1AI
C-1-)ative V)-1e H1AI +i)) (ater
Te1perat-r
e HcI
Re1ar&s
I!c)-"i!/ pre .i))
+i)) v)-1e
A.ter Sec.Pi/
Rea"i!/ t 'e Recr"e" ,-r)$
+i)) (ater te1perat-re t 'e recr"e" c!ti!--s)$ ! Te1perat-re Recr"er
REMARKS:
ACCEPTANCE O+ SECTION CLEANING
Si/! : Si/! : Si/! :
OWNER : ONGC
DOC.NO: REV.NO:; APPENDI6 7 G
T3ERMAL STA5ILISATION
S!read" /ro0 To Re!ort No.
SectionNo. /ro0 To Date "
/ro0 To
O.DJJJJJJJHINC,I
WALL T%&. H11I I.D H11I
Gra"e API 7 5L
GR. 6 ? E*
Le!/t%JJJJJJJJJJJH&1I
Mi!: Mi!:
V)-1eJJJJJJJJJJJH1AI
Ma4: Ma4:
S?;
H&1I
S?=
H&1I
S?A
H&1I
S?8
H&1I
S?5
H&1I
S?E
H&1I
S?F
H&1I
S?G
H&1I
S?9
H&1I
s?;*
H& I
Aver.
Si).
Te1p
P?;
H&1I
P?=
H&1I
P?A
H&1I
P?8
H&1I
P?5
H&1I
P?E
H&1I
P?F
H&1I
P?G
H&1I
P?9
H&1I
P?;*
H&1I
Aver.
Pipe.
Te1p
A1'ie
et
Te1p.
To be ta7en at ' interva)
Stabi)iDation be conidered to (ave been ac(ieved 3(en t(e di&&erent bet3een t(e avg.!i!e Te0!. and avg. oi) Te0!. i not (ig(er
T(an # deg. /or % cinecutive reading.
O& Section T(er0a) tabi)iDation" YES @ NO
Si/! : Si/! : Si/! :
OWNER : ONGC

DO8.NO" RE=.NO"# 9PPENDIK < #%
PRESS2RE TEST ,%' HO2RS HOLD-
Line Dia" /ro0,70- To,70- Dead.Nt.Teter"< Ma7e"IIIIIIIII Re!ort No.
SectionNo. /ro0,70- To,70- Mode)"IIIIIIIII Date "

Joint No" /ro0,70- To ,70- 8a)ibration certi&icate No"IIIIIIIIII
Te0!erature"< Ma7e"IIIIIIII
Mode)"IIIIIIIII 8erti&icate No"IIIIIIII
O.DJJJJJJJHINC,I
WALL T%&. H11I I.D H11I
Gra"e API 7 5L
GR. 6 ? E*
Mi!: Mi!:
V)-1eJJJJJJJJJJJH1AI
Ma4: Ma4:
S?;
H&1I
S?=
H&1I
S?A
H&1I
S?8
H&1I
S?5
H&1I
S?E
H&1I
S?F
H&1I
S?G
H&1I
S?9
H&1I
s?;*
H& I
Aver.
Si).
Te1p
P?;
H&1I
P?=
H&1I
P?A
H&1I
P?8
H&1I
P?5
H&1I
P?E
H&1I
P?F
H&1I
P?G
H&1I
P?9
H&1I
P?;*
H&1I
Aver.
Pipe.
Te1p
A1'ie
et
Te1p.
Dead 3eig(t teter reading to be recorded (our)y6 !i!e + oi) te0!erature reading to be recorded at every t3o (our
Preure and a0bient te0!erature to be recorded continuou)y on recorder.9)) detai) o& t(er0ocou!)e6 ca)ibration tatu6 certi&icate No.etc.
are to be recorded and enc)oed.
REM9RJS"
9cce!tance o& Tet Preure ,%' Hour Ho)d-" Ye @ No.
OWNER : ONGC
Si/! : Si/! : Si/! :
OWNER : ONGC
DO8.NO" RE=.NO.# 9PPENDIK < A
PRE PRESSURI?ATION SAFET9 !3E!K LIST
S.NO C,EC, POINT YES NO
;
T%e test secti! %as 'ee! is)ate" .r1 a)) t%er pipe)i!e
Secti!s.
=
A)) te1prar$ pipi!/2 test %ea"s a!" t%er e0-ip1e!t
c!!ecte" t t%e test secti! %ave 'ee! pre teste" t a
press-re . at )east ;.=5 ti1es t%e test press-re.
A
T%e test secti! %as 'ee! c1p)ete)$ .i))e" (it% (ater a!"
air ve!te" ...
8
A)) i!str-1e!ts a!" /a-/es (%ic% are -se" %ave va)i"
ca)i'rati! certi.icates.
5
A)) (ar!i!/ !tices2 1ar&er tapes2 prtective 'arriers a!"
t%er sa.et$ e0-ip1e!t %ave 'ee! psiti!e" a!" a)) t%e
c!cer!e" i!.r1e".
E
A)) pers!s (% 1a$ 'e a..ecte" '$ t%e perati!s are
i!.r1e" . t%e activit$.
F
C11-!icati! c%a!!e) is teste" a!" e!s-re" t%at t%e$ are
(r&i!/ prper)$. #ac&-p i!str-1e!ts are avai)a')e.
G
I!.r1 t%e pers! perati!/ t%e press-ri!/ e0-ip1e!t . t%e
1a4i1-1 test press-re (%ic% s%a)) 'e app)ie" t t%e test
secti!.
9
Li!t i!specti! . t%e e!tire .aci)ities '$ t%e ,$"rtest ?
E!/i!eer a!" ,SE ..icer t e!s-re a)) t%e sa.et$ 1eas-res
%ave 'ee! -!"erta&e 'e.re t%e test.
39DROTEST ENGINEER 3SE OFFI!ER@!IPLA EIL
Si/! : Si/! : Si/! :
OWNER : ONGC
Na1e: Na1e : Na1e:
DO!.NO/ RE0.NO/ APPENDI; . 0
PRESSURIZATION
+r1 :
C$c)e
: 5*: 3
F5: 3 ;**
Reprt N :
Date :
T :
Pipe)i!e Dia : ;=D
Test Me"i-1 : Water
Secti! Le!/t% : H&1I Materia) : API 5L 4 E*
T%eretica) v)-1e : H1AI Wa)) T%ic&!ess : E.8 3 F.; 11
S-rce . Water:
E)evati!3Press-re at :
,i/%est Pt ? Press-ri<i!/ Pt ?
L(est Pt ?
Receivi!/ Pt ?
S).N Ti1e ,rs.
Dea" Wt.
K/3#ar
Str&es
C-!te"
V)-1e
MA
C-1. V)
MA
Te1p.C Re1ar&s
OWNER : ONGC
;. Press-ri<ati! P-1p : Ma&e M"e) V)-1e
=. Dea" Wei/%t Tester : Ma&e M"e) V)-1e
A. +)( Meter : Ma&e M"e) V)-1e
Ntes:
ACCEPTANCE O+ CLEANING:
Si/! : Si/! : Si/! :

DO!.NO/ RE0.NO/ APPENDI; .
AIR 0OLUME !AL!ULATION @=0B / 7=B / 00B cCc%eA
S(eet No " /ro0,70- To,70- Date
Line Dia " JointNo. /ro0 To
Section No. " Tet Section Lengt( =o)u0e
Air V)-1e Test carrie" -t at : . test press-re.
Test Stati! Lcati! Test Press-re #ar.
Date B Ti1e Av/. Pipe Te1p. H C I
S.N Descripti!
Dea"
.Wt.Tester
H&/3c1=I
Press-re
L(eri!/
H&/3c1=I
V)-1e .
(ater
Re1ar&s
; I!itia) A.ter +irst L(eri!/
= A.ter +irst L(eri!/
OWNER : ONGC
A A.ter sec!" L(eri!/
T ca)c-)ate t%e t%eatrica) v)-1e . (ater re0-ire" t ac%ieve a c%a!/e i! press-re2 t%e v)-1e press-re e0-ati!
=! P ,1.144' Ri@T Q 9- ; #1
?E
; =t ; R P ; J
N(ere"
=! P 8o0!uted 3ater a0ount re?uired to raie by P t(e !reure in t(e ection to be teted ,0C-
=t P Geo0etrica) vo)u0e o& t(e ection ,0C-
Ri P No0ina) inner radiu0 o& t(e !i!e ,00-
T P No0ina) !i!e t(ic7ne ,00-
9 P Iot(er0a) co0!reibi)ity va)ue &or 3ater at t(e !reuriDation te0!erature in t(e P range ,bar
?;
- ; #1
E
. Re&er gra!(.
RP P Preure Rie ,bar-
J P 9 di0enion)e coe&&icient t(at i e?ua) to a va)ue o& #.1% &or )ongitudina))y 3e)ded !i!e.
T(ere&ore =! P 0C
P Liter
9ctua) vo)u0e o& 3ater drained to dro! !reure by 1.* Jg. P Liter ,=i-
T(ere&ore
=# @ =! P
Since t(e ratio i )e t(an #.1. t(e &i))ing i acce!tab)e and t(e tet ection 0ay be !reuriDed to t(e &ina) tet !reure.
Re0ar7
988EPT9N8E O/ SE8TION 8LE9NING
Si/! : Si/! : Si/! :
DO8.NO" RE=.NO"# 9PPENDIK < #$
HYDROSTATIC TEST CALCULATIONS
S%eet N: +r1 H&1I T H&1I Date
Li!e Dia : Li!t N: +r1 T
Secti! Stati! Lcati! Test Secti! Le!/t% V)-1e
Test Stati! Lcati! Test Press-re H#arI
Dea" .Wt.Tester Ma&e: Certi.icate N.
M"e): Date :
Date B Ti1e H,rsI Dea" Wei/%t H#arI Avera/e pipe Te1p.
Start . Test
E!" . Test
A)/e'ic Di..ere!ce
OWNER : ONGC
Ca)c-)ati! . Press-re C%a!/e HMPI "-e t c%a!/e i! te1perat-re:
Mp K H#3 H*.*GG8 Ri3T N AI MT
W%ere:
# K Di..ere!ce 'et(ee! t%er1a) E4pa!si! . (ater a!" stee) at te1perat-re a!"
press-re as 1eas-re" .r1 e!c)se" ta')e at t%e e!" . t%e test.
Ri K N1i!a) i!!er ra"i-s . pipe
T K N1i!a) (a)) t%ic&!ess . pipe
A K A)/e'raic c1pressi'i)it$ .actr . (ater
MT K A)/e'ric "i..ere!ce 'et(ee! (ater te1perat-re at t%e 'e/i!!i!/ a!" at e!" . t%e test HCI
Ri K R; L; N R= L=
JJJJJJJJJJ
L; N L=
Ti K T; L;N T= L=
JJJJJJJJJJ
L; N L=
A K Ist%er1a) c1pressi'i)it$ va)-e . (ater as esti1ate" at t%e press-re a!" te1perat-re va)-es 'tai!e" at t%e e!" .
test H'ar
7;
I 4 ;*
?E
I
REMARKS:
Si/! : Si/! : Si/! :
DOC.NO: REV.NO:; APPENDI6 7 ;8
39DROTEST E0ALUATION REPORT
Reprt N: Date :
Sprea" : +r1 T
O.D HINC,I Wa)) T%&. H11I I.D H11I Gra"e
API 7 5L Gr.
6 7 E*
Le!/t%JJJJJJJJJH&1I
Mi! : Mi!: V)-1eJJJJJJJJH1AI
Ma4 : Ma4:
Secti! N:JJJJJJJJJJJJJJJ +r1 K1 JJJJJJJJJJJJ T K1JJJJJJJJJJJJJJJJ
O#SERVATION
I!itia) Test Press-re JJJJJJJJJJJJJ#ar Date B Ti1e JJJJJJJJJJJJJJJJJJJ
+i!a) Test Press-reJJJJJJJJJJJJJ #ar Date B Ti1eJJJJJJJJJJJJJJJJJJJJ
OWNER : ONGC
,9- De)ta P "-ri!/ =8 ,-rs ,)" Peri"
I!itia) Pipe Wa)) Te1p JJJJJJJJJJJJ #ar Date B Ti1eJJJJJJJJJJJJJJJJJJJJ
+i!a) Pipe Wa)) Te1pJJJJJJJJJJJJJ#ar Date B Ti1eJJJJJJJJJJJJJJJJJJJJ
,:- De)ta T D-ri!/ =8 ,-rs ,)" Peri"
I!itia) Si) Te1pJJJJJJJJJJJJJJJJJ #ar Date B Ti1eJJJJJJJJJJJJJJJJJJJJ
+i!a) Si) Te1pJJJJJJJJJJJJJJJJJ #ar Date B Ti1eJJJJJJJJJJJJJJJJJJJJ
,8- De)ta T2 Si) Te1p.JJJJJJJJJJJJJ De/.C
,D- Lea&a/e D-ri!/ =8 ,-rs ,)" Peri"
EVALUATION
De)ta P D-ri!/ =8 ,-rs ,)" Peri" HAI JJJJJJJJJJJJJJJJJJ 'ar
Acc-!ta')e Press-re Lss D-e t Te1p.# JJJJJJJJJJJJJJJJJJ 'ar
U!acc-!ta')e Press-re Lss JJJJJJJJJJJJJJJJJJ 'ar
A))(a')e -!acc-!ta')e press-re Lss JJJJJJJJJJJJJJJJJJ 'ar
C!c)-si!
Test Accepta')e 3 U! accepta')e
Secti! Re)ease" .r "epress-ri<ati!
REMARKS:
Si/! : Si/! : Si/! :
OC.NO: REV.NO:; APPENDI6 ? ;5
INSPECTION REPORT FOR DEWATERING
Reprt N:
Date:
Sprea" : +r1 T
O.D JJJJJJ
JJJHINC,I
Wa)) t%ic&
H11I
I.D H11I Gra"e
API 7 5L
Gr. 6?E*
Mi!: Mi!: V)-1eJJJJJJJJJJJJH1AI
Ma4: Ma4:
OWNER : ONGC
C1pressr: Lcati! Ma&e
O-tp-t Ma4.Press-re
De(ateri!/ Directi! +r1 K1. T K1
Disc%ar/e Pi!t
R-! N.
T$pe .
P3G
Start E!"
Av/.Va)
K13,r
Press-reHK/3C1=I >t$ .
Water
HLtrsI
Date Ti1e Date Ti1e Mi! Ma4
REMARKS:
ACCEPTANCE O+ SECTION DEWATERING: YES3NO
Si/! : Si/! : Si/! :
Na1e: Na1e: Na1e:
DOC.NO: REV.NO:; APPENDI6 7 ;E
LIST O+ ATTAC,MENTS TO ,YDROSTATIC TEST RECORD
Sprea" : +r1 T
Sprea" : +r1 T
O.DJJJJJJJJJJJ
HINC,I
Wa)) T%&. H11I I.D H11I Le!/t%JJJJJJJJJHK1I
Mi! : Mi!: V)-1eJJJJJJJJJJH1AI
Ma4 : Ma4:
;. Test P)a! .r ,$"rtest HAppe!"i4 7 =I
YES3NO
OWNER : ONGC
=. Certi.icate . 1ec%a!ica) a!" c!str-cti! c1p)eti!
HAppe!"i4 7 AI YES3NO
A. Air C)ea!i!/ HAppe!"i4 7 5I
YES3NO
8. a.
Ga-/i!/ HAppe!"i4 7 EI
YES3NO
'.
P%t/rap%$ . Ga-/e P)ate
YES3NO
5. a. Water
.i))i!/ HAppe!"i4 7 FI
YES3NO
'. +i))
Water Te1perat-re C%arts
YES3NO
E. T%er1a) Sta'i)i<ati! HAppe!"i4 7 GI
YES3NO
F. a.
Press-ri<ati! HAppe!"i4 7 9I
YES3NO
'.
Press-re recr"s c%artsHsI
YES3NO
c.
Te1perat-re Recr"ers C%arts
YES3NO
OWNER : ONGC
G. Air V)-1e Ca)c-)ati!s HAppe!"i4 7 ;AI
YES3NO
9. a. =8
%-rs ,)" HAppe!"i4 7 ;=I
YES3NO
'.
Press-re recr"ers C%arts
YES3NO
c. A1'ie!t
Te1perat-re Recr"er C%arts
YES3NO
;*. ,$"rstatic Test Ca)c-)ati!s HAppe!"i4 7 ;AI
YES3NO
;;. ,$"rstatic Test Eva)-ati! HAppe!"i4 7;8I
YES3NO
;=. Ca)i'rati! Certi.icates
YES3NO
;A. De(ateri!/ HAppe!"i4 7;5I
YES3NO
Si/! : Si/! : Si/! :
Na1e: Na1e: Na1e :
DO!.NO/ RE0.NO/ APPENDI; < 7
INSPE!TION REPORT FOR SDA55ING
Reprt N:
OWNER : ONGC
Date:
Sprea" : +r1 T
O.DJJJJJJJJ
HINC,I
Wa)) t%ic&H11I I.D H11I Gra"e
API?5L
Gr. 6?E*
Le!/t% JJJJJJ HK1I
Mi!: Mi!:
V)-1eJJJJJJJJH1AI
Ma4: Ma4:
C1pressr:
Lcati!
Ma&e

O-tp-t

Ma4.Press-re
S(a''i!/ +r1 K1
T
K1 Dista!ce Pi!t

Secti! Re)ease" .r S(a''i!/ Yes3N
Water Treat1e!t Carrie"
Yes3N
T$pe .
Pi/
Start E!" Wt...Pi/
Av/.Va).
K13,r
Press-re
HK/3c1=I
Re1ar&s
Date Ti1e Date Ti1e I!itia) +i!a)
OWNER : ONGC
ACCEPTANCE O+ SECTION SWA##ING: YES 3
NO
Si/! : Si/! : Si/! :
Na1e: Na1e : Na1e :

OWNER : ONGC

APPENDI; <E
TENTATI0E LA9OUT OF E:UIPMENT AND INSTRUMENTS FOR 39DROSTATI! TEST
+r1 Water S-rce
+)( Meter
Li!es .r Pi/
Ga-/e
AIR !M"R#$$!R
%or &ackpressure
Temporary Test 'eader Receiving #nd Temporary Test 'eader
&R#A(
TA)(
"*M" $(ID
%illing
+"ressurising
"ump
AIR .!M"
"ressure, Impulse line from test 'eader
Temp. -auge
Recorder
$tock ounter Dead .t. Tester -auge
T#$T A&I)
OWNER : ONGC
OWNER : ONGC
APPENDI; < 9
39DROTEST 3EADER
N5 OD N; 8D3ED N5 OD NE OD N= ;;3=D NF OD NG OD N8 ;;3=D
OWNER : ONGC
OWNER : ONGC
TENATIVE LAYOUT O+ E>UIPMENT AND INSTRUMENTS
+OR AIR PIGGING
P!e-1atic ,se
AIR
OWNER : ONGC
!OMPRESSOR
Ga-/e Ga-/e
R 7 Receivi!/ L 7 La-!c%i!/ .
Air
piggingheader
R. #nd
Air pigging
header L . #nd

Hydrostatic Testing of Pipeline

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Hydrostatic Testing of Pipeline

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