CONSTRUCTION

PROCEDURE FOR
HYDROTESTING

SECTION

Page 1 of 8

CONTENTS

1.0

PURPOSE

2.0

SCOPE

3.0

REFERENCES

4.0

DEFINITIONS

5.0

GENERAL

6.0

PROCEDURES

7.0

TESTING OPERATIONS

8.0

TEST ACCEPTANCE

9.0

DEPRESSURIZING

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PROCEDURE FOR
HYDROTESTING

1.0

Page 2 of 8

PURPOSE
The purpose of this procedure is to ensure that Hydrostatic Testing is carried out in a safe manner
and complies with the requirements.

2.0

SCOPE
This procedure covers the activities and preparation required for Hydrostatic Testing for. This
procedure covers the Hydrostatic Testing for the mainline. All mainline valve assemblies shall be
hydrostatically tested independently.

3.0

REFERENCES
The following documents have been complied with in the preparation of this procedure:-

4.0

Contract Document Information.

ANSI/ASME B 31.8 Gas Transmission and Distribution Piping Systems.

Malaysian Government Regulation.

Local Authority Regulations for removal and disposal of water used for testing.

DEFINITIONS
CLIENT

CONTRACTOR

ST/JKKP

Suruhanjaya Tenaga/Jabatan Keselamatan dan Kesihatan

SUBCONTRACTOR

Subcontractor/Party assigned by CONTRACTOR

to perform the Hydrostatic Testing activities

5.0

GENERAL
5.1

ST/JKKP shall be notified a minimum of forty eight (48) hours prior to the start of a
hydrotest operation. ST/JKKP shall be invited to witness all hydrotesting, with as much
notice as reasonably practicable. In the absence of the ST/JKKP Representative, a
competent Gas Engineer shall witness the testing.

5.2

All fields Hydrotesting reports shall be duly signed by the Gas Engineer and Client and
ST/JKKP, such verification shall include signatures, names, dates and time.

6.0

PROCEDURES
6.1

Cleaning
The cleaning operation is undertaken to remove any debris from the pipeline which may
have remained as a result of construction activities and to remove as far as feasible rust
mill scale which may be present on the pipe wall.

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PROCEDURE FOR
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The cleaning operation will be conducted between temporary launcher and temporary
launcher/ receiver. It is proposed that one or two pig each consisting of high density foam
pigs and full circumferential wire brush high density foam pigs be propelled by
compressed air. The pigs will be controlled by regulating back pressure to ensure a
speed of approximately 0.5 1.0 m/sec. Upon

receipt of each pig at the temporary

launcher/ receiver facility, the pigs will be recovered for inspection and an assessment of
their effectiveness made prior to launching the next pig. Upon receipt of the last pig, any
residual pressure will be vented to atmosphere.
Acceptance of the pipeline system as clean will be by visual observation of the water
quality expelled during a pressure purge and by inspection of a final pig run.
6.2

Line Filling
The flooding spread will be located adjacent to the suitable water source. One high
density foam pig will be launched from the scrapper trap and propelled to the opposite
temporary facility by the flooding spread. The flooding spread will consist of a water
winning pump extracting fresh water from the break tank. The flooding pumps will then
transfer the water from the break tank through fine mesh filters to the pipeline to propel
the flooding pig through the pipeline section.
Prior to launching the pig, the flooding spread will be started and approximately 10m of
filtered water will be injected in front of the pig. The valves will then be reconfigured to
allow the launch of the pig. The pig will be propelled the length of the pipeline at an
approximate speed of 0.5 1.0 m/sec whilst simultaneously venting at the temporary
launcher/ receiver to expel air from the system.
The pig will be run without interruption and during its run the following parameters will be
recorded.

Time

Pigging Pressure

Launch End

Pigging Pressure

Receipt End

Volume of water injected

Receipt End.

On confirmation that the pigs have arrived at the receiver the water winning and flooding
pumps will be shut down and vents closed. The pigs will then be recovered.
6.3

Water Source
The water source to be utilised for hydrostatic testing shall be identified on site on the
basis of the following:

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PROCEDURE FOR
HYDROTESTING

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water quality

sufficient quantity and flow rate

local authority permission to extract water from source

owners way leave

Determination of water quality will be by visual inspection only. Laboratory

analysis, chemical treatment etc is not required. The water for hydrostatic testing
should be visually free from sand, silt and suspended solids.
The water source will be of sufficient quantity to enable the filling process to
proceed uninterrupted.
6.4

Hydrostatic Test Pressure

The minimum test pressure at the point of maximum elevation for any test section shall
be 1.4 x design pressure, i.e. 1.4 x 360 psig = 504 psig (minimum)
Depending on the site conditions, the actual field test pressure may be raised slightly
higher than the minimum required hydrotest pressure as decided by the Test Engineer.

6.5

Preparatory Work
All valves on the test manifolds that will not be used for the tests shall be blanked
off or plugged. Valves under test shall be left in the half open position.
Instrumentation required for testing shall be set up in the test control cabin and
checked.
Prior to the pressure test, notices indicating that the pipeline is under pressure test are to
be stationed at strategic locations along the right of way. (R.O.W), i.e.

at

all

public

crossings and all points where there is exposed pipe. Subcontractor shall cordon of all
test end areas with notices stating that High Pressure Testing

is in progress.

Line pipe of the same grade, diameter and thickness as the pipe in the section under test
plus all the necessary equipment for handling, transport, cutting, welding, etc. shall be
available as a contingency in the event of a failure during the hydrostatic test.
Prior to any testing operations, the stabilization of the test water temperature shall be
checked.

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CONSTRUCTION
PROCEDURE FOR
HYDROTESTING

Testing shall not commence until the temperature in the pipeline has stabilized.

Pipe

temperature or water temperature readings shall be taken at the filling end and at one
other point along the system to be tested (preferably at a valve chamber location or
receiver end) at half hour intervals. Stabilisation will be

achieved when the difference

between successive readings is 0.5o C.

A check list of the valve positions after filling operations will be filled and signed

by

the

Test Engineer before testing is allowed to commence.

7.0

TESTING OPERATIONS
7.1

Equipment / Instrumentation
Subcontractor shall supply all apparatus and equipment necessary for filling operations,
including:

0 2,000 psi, 0 100 F, 24 hr chart pressure and temperature recorder.

0 1,000 psi dial type pressure gauge.

Test thermometer with a range of 0 50 C. Divisions 0.1 C. with a valid test

certificate.

The colour of ink in the recorders shall be as follows:Pipeline Pressure

Red

Pipewall temperature or water temperature

Blue

High pressure positive displacement pump capable of delivering a pressure of

25,000 kPa and a variable flow rate between 150 and 200 litres/min.
Subcontractor shall include the list of all equipment to be used for this project as
part of the detailed submission.

7.2

Pressurizing Operations
At the end of the stabilisation period, pressurization operations may commence at the
Test Engineers discretion.
The initial stage of the hydrostatic test shall be to raise the pressure bar per minute
maximum required to develop 20% of the hydrotest pressure. Pressurization will then
stop for a minimum of hour for pressure stabilisation. Should there be a drastic drop in
pressure, Subcontractor test personnel and Test Engineer shall check all visible
connections to pipeline for possible leaks. Pressurization shall commence at a suitable

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PROCEDURE FOR
HYDROTESTING

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pressurizing rate after the stabilisation period. This process will be repeated at the
following points;

0 20 %

of test pressure

20 50 %

of test pressure

50 80 %

of test pressure

80 100 % of test pressure

Subcontractor shall plot the pressure versus volume during the pressurizing stage, and
not made of starting and completion times. A temperature recorder and a deadweight
tester shall be operating during this time.
Upon reaching 100 % of test pressure, Test Engineer shall then inspect all the visible
connections to the pipeline plus all threaded or flanged connections in the valve
chambers throughout the entire pipeline. Should any leak be detected at the flanges or
threads, Subcontractor shall supply manpower and equipment necessary to flog the
flanges or tighten the treaded connections.
The Subcontractor shall ensure that all air trapped in the pipeline and that all connections
are removed or vented prior to the start of the hydrostatic test hold period.
7.3

Hydrostatic / Leak Testing

The hydrostatic strength and leak test shall be carried out for a minimum period of 24
continuous hours, during which Subcontractor shall inspect all above ground fittings and
equipment for leaks. All fittings, valves and equipment in valve chambers shall be
inspected for leaks at least twice during the hold period by Subcontractor. Any leaks shall
be remedied as required.
Subcontractor shall monitor pressure, temperature and visually check for leaks at a
minimum of 30 minutes intervals. Should the pressure drop due to temperature effects
approach the minimum test pressure, and with the consent of the Test Engineer and
client, additional test medium shall be pumped into the system to raise the pressure by
300 kPa. This procedure shall be repeated as and when necessary. Subcontractor shall
accurately measure the water added into the line.
Test pressures shall be recorded using the pressure recorder and manual readings taken
hourly using the dead weight tester and pressure gauge. Temperatures along the pipeline
shall be manually recorded every 4 hours at the intermediate locations using temperature
probes and at the recorder at the test end.

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PROCEDURE FOR
HYDROTESTING

8.0

Page 7 of 8

TEST ACCEPTANCE
8.1

Test Acceptance
Test pressure shall be maintained for a minimum of 24 continuous hours. Acceptance
shall be when the pressure changes, while taking into account temperature effects and
any known leaks, does not exceed 0.1 bar for each 0.1C loss in temperature.
On completion of the 24 hour test, a Test Acceptance Certificate approvals shall be
issued by Subcontractor.

The test pressure was maintained for a minimum twenty four (24) consecutive
hours at or above the minimum specified test pressure.

Any variation in test pressure during the 24 consecutive hours is explainable (e.g.
temperature fluctuation).

If necessary, the pressure changes attributed to the temperature effects on the pipeline
system under hydrostatic test shall be calculated and submitted to the Contractor Test
Engineer for approval.
8.2

Test Failures
If the test fails, then the cause shall be investigated and remedied. Subcontractor shall
then carry out the filling and testing operations again.
If leakage is apparent in the system, a visual inspection shall be carried out at all above
ground pipework and piping and valves in chambers. Should a leak be detected, it shall
be located and repaired and remarked in the hydrotest report form. If the leak occurs in
the pipe seam or the pipe body, the entire faulty joint for the pipe shall be cut out and
replaced with a new joint of pipe. If the leak occurs in the circumferential weld, the pipe
shall be cut one diameter back either side of the faulty weld and replaced with a new
section shall be marked with its location in the pipeline and shall be delivered to such
place as dictated by the Client.
If there is no leak found on the above ground pipework, the underground pipework shall
be uncovered by back-hoe (JCB) and a visual leak check shall be carried out.

9.0

DEPRESSURIZING
Immediately after the test has been successfully completed and the test acceptance certificates
signed by the relevant parties i.e., Subcontractor Test Engineer and Construction Manager,
GMSB Representative and ST, the pressure shall then be gradually lowered to atmospheric
pressure at an approximately rate of bar per minute.