Procedure for Cleaning,ing,Gauging and Hydro Testing of Pipelines.doc

East west Gas Pipeline Project Construction Procedure for Cleaning Gauging And Hydro testing of Pipelines China Petroleum Pipeline Bureau CPP Document No EWPL00 COS PR 0014Rev A1 Page 1 of 57 Procedure for Cleaning Gauging And Hydro testing of Pipelines A12006 6 17 ISSUED FOR REVIEW Du Zhongyuan Zeng Zhaocheng Li Jianhui REVDATEDESCRIPTIONPREPARED BYREVIEWED BYCHECKED BYAPPROVED BY Contract No Document No East west Gas Pipeline Project Construction Procedure for Cleaning Gauging And Hydro testing of Pipelines China Petroleum Pipeline Bureau CPP Document No EWPL00 COS PR 0014Rev A1 Page 2 of 57 Contents 1 0 Project Description 3 2 0 Reference Documents 4 3 0 Resource planning 4 4 0 Safety and Environment 10 5 0 Construction Flow Chart and schedule 12 6 0 Pipeline Section Cleaning and Gauging 13 7 0 Pipeline Section Hydrostatic Test 24 8 0 Termination 39 9 0 Test Report 40 10 0 Quality Control 41 East west Gas Pipeline Project Construction Procedure for Cleaning Gauging And Hydro testing of Pipelines China Petroleum Pipeline Bureau CPP Document No EWPL00 COS PR 0014Rev A1 Page 3 of 57 1 0 PROJECT DESCRIPTION 1 1 General East West Gas Pipeline EWPL project comprise of 48 dia 1386km long mainline dispatch compressor station intermediate compressor stations mainline valve stations and tap off station EWPL originates at Onshore Gas Processing Terminal OGPT of Reliance Industries Limited located at Gadimoga south of Kakinada in state of Andhra Pradesh Pipeline from OGPT traverses through the state of Andhra Pradesh Karnataka Maharashatra and Gujarat and terminates near Bharuch in the state of Gujarat The Contractor shall ensure that the complete pipeline section undergoing cleaning gauging filling and hydrostatic test after mechanically complete in all respects i e wielding complete and confirmed by Engineer in Charge and the pipeline is laid and backfilled The length of the sections basically will be the distance between two line valve stations or a line valve station and the nearby pig trap station The maximum length of each test section shall not exceed 50 km Cleaning Gauging Filling hydrostatic test will be carried out section by section from Kakinada to Bharuch After of the hydrostatic test contractor shall depressurize of the tested pipeline 1 2 Pipeline Design Parameter Length 1386 Km Steel Grade API 5L Grade X70 Diameter 48 Wall thickness 17 2mm 20 7mm 25 4mm Design pressure 98 bar East west Gas Pipeline Project Construction Procedure for Cleaning Gauging And Hydro testing of Pipelines China Petroleum Pipeline Bureau CPP Document No EWPL00 COS PR 0014Rev A1 Page 4 of 57 2 0 REFERENCE DOCUMENTS 2 1 Specifications Following Company specifications shall form integral part of this specification and shall be complied with when applicable to the Works covered in the Contract EWP100 P30 J00 509 Specification for Flushing Gauging and Hydro testing EWP100 P30 J00 505 Specification for Pipeline Welding EWP100 P30 J00 506 Specification for Construction of Pipeline EWP100 P30 J00 515 Specification for Dewatering and pre commissioning 2 2 codes and standards The latest edition of following Codes and Standards are referenced in this specification and all provisions of these reference codes and standards shall be applicable OISD 141 Design and Construction Requirements for Cross Country Hydrocarbon Pipelines ASME B31 8 Gas Transmission and Distribution piping Systems ASME Sec VII Div 2 Boilers and Pressure Vessels Code 3 0 RESOURCE PLANNING East west Gas Pipeline Project Construction Procedure for Cleaning Gauging And Hydro testing of Pipelines China Petroleum Pipeline Bureau CPP Document No EWPL00 COS PR 0014Rev A1 Page 5 of 57 Hydraulic pressure testing operator Filling Water pump operator Air compressor unit operator Welder and pipe fitter Equipment repairman Electrician Driver Excavator operator Crane operator Labor Document control engineer Quality engineer Planning and dispatching Foreman Engineer of hydraulic pressure test HSE engineer Site manager Site vice manager East west Gas Pipeline Project Construction Procedure for Cleaning Gauging And Hydro testing of Pipelines China Petroleum Pipeline Bureau CPP Document No EWPL00 COS PR 0014Rev A1 Page 6 of 57 3 1 Humans The work will be performed by the experienced personnel testing engineers and operators The Test Engineer or his representative shall be present on site throughout all testing operations and shall have overall responsibility for all aspects of testing and associated works together with the safety of all personnel The personnel planned for the pipeline cleaning gauging hydrate sting construction are listed in the table below Post Qty Responsibility Site manager1Responsible for all works of pre commissioning HSE and Quality engineer3Responsible for HSE and quality management of pre commissioning Planning and dispatching1Responsible for construction planning 2 The pig is damaged on the way 1 After depressurization open the quick closure to check if the pig has been sent out If not place the pig correctly and launch again 2 After depressurization put in new pig and restart cleaning The pig is stuck there is no air displacement at the receiving end or the air displacement is small The pipeline deformation is oversized or there may be some larger matter in the pipeline 1 Raise air pressure maximum not more than 1 6MPa to push out the pig and then launch another pig equipped with a tracer Find out the sticking point and cut off the pipe to take out the stuck pig 2 Move the air compressor to the other end of the section launch a pig with a tracer in the opposite direction Find out the sticking point and cut off the pipe to take out the stuck pig The operation of pipe cutting off assembling and welding again shall be in accordance with the pipe welding procedure Doc 6 6 Operation process of pipeline section gauging inspection 6 6 1 Gauging The operation of gauging inspection is carried out after the completion of cleaning East west Gas Pipeline Project Construction Procedure for Cleaning Gauging And Hydro testing of Pipelines China Petroleum Pipeline Bureau CPP Document No EWPL00 COS PR 0014Rev A1 Page 22 of 57 The pig traveling speed will be kept about 5km hr In order to obtain a proper traveling speed during the operation of pigging for the uphill sections the valve L02 fixed on the receiver shall be in close position until the pressure in front of the pig is higher than 0 5barg for the downhill sections with hot bends back pressure shall be built up to 2barg In addition the pressure behind the pig will be no higher than 2 5bar g that will be obtained by reducing air input to the pipeline This can be achieved by adjusting the relief valve fixed at the outlet of the air compressor Other operating procedure of pigging for gauging inspection is the same as cleaning for details please refer the description above The gauge plates shall be examined immediately by the Engineer in Charge and CONTRACTOR s test engineer when the gauging pigs arrived Photos will be taken for recording the conditions of the gauge disks after gauging operation All records will be witnessed by the Engineer in Charge and be included in the final report The temporary launcher and the receiver will be removed if gauging inspection has been checked and accepted by the Engineer in Charge and then preparations for water filling will be carried out Otherwise the cause of the failure will be analyzed and the solutions will be determined by the Engineer in Charge and the test engineer Remedied for the failure of gauging inspection will be undertaken by CONTRACTOR After the completion of pipeline section gauging pipe caps will be adopted to cover both ends of the pipeline sections 6 6 2 Gauging Records All gauging operations will be recorded in tables with the following data Type s of the gauging pig Type of the driving media Time of launching and receiving East west Gas Pipeline Project Construction Procedure for Cleaning Gauging And Hydro testing of Pipelines China Petroleum Pipeline Bureau CPP Document No EWPL00 COS PR 0014Rev A1 Page 23 of 57 Photographic record of the conditions of the gauge disks after use All records shall be witnessed and confirmed by both CONTRACTOR s test engineer and the Engineer in Charge and shall be included in the final report 6 6 3 Checking and acceptance Gauging inspection is deemed acceptable if no dents bends or large gouges are apparent on examination 6 6 4 Measures for the failure of gauging inspection If dents bends or large gouges are found on the gauging plate the following methods will be used to solve the problems Send another gauging pig to determine whether the pipe section is deformed under the conditions of ignoring other factors such as the deformation of the plate arisen from collision with the quick closure when the gauging pig enters into the receiver Check all the construction records of the pipeline installation If any doubtful thing is found that may cause gauging inspection unacceptable find the constructors who have participated in the operation at the time for clarifications If possible manual excavation will be carried out to find out the solutions and another gauging operation shall be taken If the method above does not work check the air flow rate and pressure records of the gauging pigs carefully the location where problem may exist can be predicted send another gauging pig fitted with a pig tracer check carefully for the location where the faults may exist Manual excavation will be carried out to find out the faults and then continue the gauging operation If the above mentioned methods do not work inspect the pipeline with a caliper pig First fill compressed air with certain pressure 2 0 5 0barg into the pipeline with an air compressor Then use the air compressor to send out the caliper pig through the temporary pig traps Control the traveling speed of the caliper pig by monitoring the control valve at the receiver Manual East west Gas Pipeline Project Construction Procedure for Cleaning Gauging And Hydro testing of Pipelines China Petroleum Pipeline Bureau CPP Document No EWPL00 COS PR 0014Rev A1 Page 24 of 57 excavation will be carried out after the examination and setting the location determine the solutions and continue the gauging inspection 7 0 PIPELINE SECTION HYDROSTATIC TEST 7 1 General Hydrostatic test will commence after section cleaning and gauging as well as confirmed by the Engineer in Charge This procedure is intended for hydrostatic test of the pipeline trunk not for PTS LVS and so on The length of test section basically will be the distance between two line valve stations or a line valve station and the nearby pig trap station 7 2 Test section The length of the test sections basically will be the distance between two line valve stations or a line valve station and the nearby pig trap station not exceed 50km As LVSs have been installed before hydrostatic test test ends are about 95m away from LVSs The main lines will be cut off and test heads will be installed locally Test section data of spread 5 and spread 6 are shown as below TEST SECTION FROM km TO km LENGTH km TEST SECTION FROM km TO km LENGTH km 1651 909683 8331 928861 127892 39231 27 2683 83709 50825 689892 392918 7126 32 3709 508738 35328 8410918 71948 80830 10 4738 353773 44735 0911948 808976 427 59 5773 447802 6529 2012976 4999 15222 75 6802 65838 23935 5913999 1521025 526 35 7838 239861 12722 89 East west Gas Pipeline Project Construction Procedure for Cleaning Gauging And Hydro testing of Pipelines China Petroleum Pipeline Bureau CPP Document No EWPL00 COS PR 0014Rev A1 Page 25 of 57 7 3 Water Treatment If the sources don t accord with the Specification about test medium water treatment equipment shall add to the filling system The full filling system is shown below 7 4 Preparations for hydrostatic test 7 4 1 Site layout The arrangement and the layout of the test head main equipment and the devices involved in hydrostatic test are shown in the Figure 5 Figure 5 7 4 2 Equipment devices and instruments for pressure test All equipment and devices involved in hydrostatic test such as Test heads Temporary pipe fittings and valves Pig signalers if required East west Gas Pipeline Project Construction Procedure for Cleaning Gauging And Hydro testing of Pipelines China Petroleum Pipeline Bureau CPP Document No EWPL00 COS PR 0014Rev A1 Page 26 of 57 shall be hydrostatically tested for at least 4 hours equivalent to 1 25 times of the pipeline strength test pressure before putting into use All the test records shall be submitted to Engineer in Charge prior to water filling activity The welding between the test head and the trunk line and the NDT shall be carried out in accordance with the relevant project document All instruments such as Dead weight testers Pressure gauges Flow meters Pressure and temperature recording instruments and transmitters Thermometers and thermocouples shall have been calibrated Calibration certificates shall be submitted to Engineer in Charge prior to water filling operation Prior to pressurization test engineer shall calibrate all pressure gauges with a dead weight tester Pressure gauges and dead weight tester are connected to the same needle valve which has one inlet and two independent outlets 7 4 3 Pig for filling The pig shown as below is used for water filling and dewatering Three pigs will be preplaced in the initial test head two for water filling and one for dewatering Each pig is equipped with 4 6 scraper seal discs and two guide support discs The discs are made of urethane East west Gas Pipeline Project Construction Procedure for Cleaning Gauging And Hydro testing of Pipelines China Petroleum Pipeline Bureau CPP Document No EWPL00 COS PR 0014Rev A1 Page 27 of 57 Figure 6 7 4 4 Test heads The temporary test heads will be fabricated and welded accordingly to welding procedure The temporary test heads shall be tested according with Company specifications and Engineer in Charge shall witness the test head testing The test pressure will be 1 25 times the maximum test pressure of the test section that the test head shall be connected to The Test head acceptance certificate shall be signed by Pertinent test engineer and Engineer in Charge 7 5 Filling After acceptance of gauging run water filling shall commence For this purpose pre tested test headers loaded with three numbers of batching pig shall be welded to the test section Un inhibited water equal to 10 of the volume of test section shall be introduced ahead of the first pig The first batching pig shall be launched using un inhibited water equivalent to 1 5km length of the test section Then the second pig shall be launched using inhibited water till the second pig is received at the other end The water current shall be maintained about 400m3 hr during filling operation The Contractor shall continuously monitor the volume and pressure and at approximately thirty East west Gas Pipeline Project Construction Procedure for Cleaning Gauging And Hydro testing of Pipelines China Petroleum Pipeline Bureau CPP Document No EWPL00 COS PR 0014Rev A1 Page 28 of 57 minute intervals the temperature of the fill water during the filling operation When it has been confirmed that the filling pigs have arrived in the receiving test head maintain water flow until the exhausting water is clean to the satisfaction of Engineer in Charge After water filling it is better that the pressure in the filled pipeline is up to 20barg In this way time for pressurization will be reduced and less water will be needed The thermal stabilization and pressurization operations can commence subsequently The Figure 5 shows the arrangement and connection of the section during filling If the sections locate in area that lack source the testing water shall be supplied by tested pipeline Water will be pushed by a plate pig is drove by compressed air Figure 7 7 6 Formation of Backpressure When the water filling pig propelled by water rushes down from the top of the hill the air in front of the pig will get into the water easily if the pig runs with an accelerating speed as is shown in Figure 8 East west Gas Pipeline Project Construction Procedure for Cleaning Gauging And Hydro testing of Pipelines China Petroleum Pipeline Bureau CPP Document No EWPL00 COS PR 0014Rev A1 Page 29 of 57 Backpressure can be obtained by controlling the valve fixed on the terminal end of the section to reduce the downhill speed of the pig and to reduce the amount of air entering into the water Since a water column of 10m high can produce a pressure of 1bar backpressure value can be determined according to the elevation difference of the slope of the feeding section An operator will be assigned to adjust the control valve at the terminal end of the feeding section to build up backpressure If backpressure produced by the air in front of the feeding pig is not enough compressed air will be fed into the pipeline through the valve fixed on the terminal end of the section to increase the backpressure 7 7 Filling Records During water filling the following records shall be made every 30 minutes water flow rate at the inlet end pressure at the inlet end temperature at the inlet The water flow rate pressure and temperature records shall be confirmed by Engineer in Charge the Supervisory Engineer and Contractor s test engineer and shall be included in the final water filling record Water GG Air Pipeline P Figure 8 East west Gas Pipeline Project Construction Procedure for Cleaning Gauging And Hydro testing of Pipelines China Petroleum Pipeline Bureau CPP Document No EWPL00 COS PR 0014Rev A1 Page 30 of 57 7 7 Temperature Stabilization Turn off all valves at both ends of the water filled section after the completion of water filling After a check has been made to confirm if the pressure has attained at least 1 bar at the highest section the thermal stabilization can be started Thermal equilibrium between the pipeline an