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Pre-commissioning
and Commissioning
of Pipeline
Saurabh Sharma
500042965
TABLE OF CONTENTS
1. INTRODUCTION
2. PRE-COMMISSIONING
2.1 Filling
2.2 Pipeline Cleaning
2.3 Pipeline Gauging
2.4 Hydro-testing
2.5 Points to Note
3. COMMISSIONING
3.1 Dewatering
3.2 Drying
3.2.1 Air Drying
3.2.2 Vacuum Drying
3.2.3 Liquid Swabbing
4. PRODUCT INTRODUCTION
1. INTRODUCTION
Soon after the installation of a pipeline system and prior to introduction of hydrocarbon product, the
system has to go through a pre-commissioning and commissioning phases. Pre-commissioning
involves cleaning and confirmation of the pipeline systems mechanical strength and integrity.
Pipeline system then undergoes a commissioning phase that involves flushing and drying the pipeline
and finally introducing the product.
Specialist contractors perform work for both phases.
2. PRE-COMMISSIONING
Pipeline pre-commissioning relates to activities that start with pipeline cleaning and testing. These
activities are normally carried out soon after pipeline installation and continue until the pipeline
integrity has been established. The main aim of this phase is to ensure that the pipeline is not damaged
during installation and that it has the required mechanical strength. The pre-commissioning activities
include the following:
When the pipeline is laid, the start-up and lay-down heads usually contain a number of pigs. The type
and number of pigs are determined by the requirements of pre-commissioning activities.
In some situations, a pipeline is installed in one construction season and tie-ins are performed later.
It is advisable to carry out the pre-commissioning activities on that pipeline section soon after
installation.
2.1 Filling
After the pipeline is installed on the seabed, it is generally filled with clean water (filtered water) that
is mixed with corrosion inhibitors and a fluorescent dye as per project specifications. The type and
amount of inhibitors depend on pipe material, local environment and duration for which the seawater
will stay in the pipeline. The specialist pipeline hydro-testing contractors determine these chemicals
and the quantities. The fluorescent dye is introduced to facilitate detection of a leak.
2.4 Hydro-testing
After the completion of cleaning and gauging operations, the pipeline is subjected to a hydrostatic
test to confirm the strength and integrity of the completed pipeline. Hydro-test consists in testing the
pipeline by subjecting it to an internal pressure much higher than the design pressure for certain
duration.
During hydro-test, the pipeline is pressurised to a level that would generate a pipe wall hoop stress of
at least 90 % of the specified minimum yield strength of the pipe material based on the un-corroded
wall thickness. If the wall thickness is based on an allowable hoop stress of 72 % of the specified
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minimum yield strength, the corresponding hydro-test pressure will be 1.25 times the design pressure.
Hydro-test pressure must satisfy the applicable design code requirements. The foregoing test pressure
is based on BS PD 8010 and ASME B31.3/31.8. The test pressure requirements may be different in
other codes so one must determine it for the applicable design code. Since a riser is designed for a
hoop stress of 60% of SMYS, the corresponding test pressure for the riser only will be 150% of design
pressure.
The internal pressure in the pipeline is raised in several stages to the pre-calculated level. This is to
allow all the entrenched air to be pushed out completely. The internal pressure is continuously
monitored and allowed to be stabilised at each stage. After the internal pressure has stabilised at the
hydro-test pressure, the pressure is maintained for at least 24 hours. Variations in the ambient
temperature can affect the internal pressure. Therefore, the pressure and temperature are
continuously monitored at close intervals of time as per the specifications. If a drop in pressure is
observed that is in excess of that expected due to the temperature variations, the cause of such
pressure drop is thoroughly investigated. The pressure drop could occur due to malfunctioning of test
equipment or from a leak in the pipeline. If the drop is caused due to a leak in the pipeline, the leak is
detected by searching for the fluorescent dye and the pipeline is de-pressurised, repaired and rehydro-tested.
All chemicals used during pre-commissioning must be environmentally friendly and should not
harm the sea life.
A chemical that can harm the pipeline system must not be used.
In certain circumstances, pipeline may have to be left full of water until tie-in is completed;
this period may as long as 12 or more months. Ensure that the water has sufficient quantity
of appropriate inhibitors.
Installation contractors do not accept responsibility for a pipeline if there are long delays
between installation and tie-ins. Client must take on responsibility for the installed pipeline
only after the contractor has proven pipeline integrity by hydro-testing the pipeline.
Tie-in completions after long time gaps will make it necessary to hydro-test the completed
pipeline system.
If each component of a pipeline system is individually hydro-tested and the tie-ins are
performed by golden welds, full hydro-test of the completed system may not be necessary
if tie-ins are completed soon after the hydro-test of the components. A system test may be
required at 110% design pressure.
A contractor may offer to perform a single hydro-test of the completed pipeline system in
order to reduce costs and schedule. This may be evaluated with full consideration given to
liabilities.
A pipeline system may contain components of different strength. For example, the subsea
pipeline is designed for an allowable hoop stress factor of 0.72 while the riser design factor
may be 0.6. The test pressure must be based on a pressure that produces a hoop stress of 90
% of specified minimum yield strength in the weaker section, i.e., the pipeline. If the riser is
tested on its own, the test pressure could be 1.5 times the design pressure while for the
combined riser and for subsea pipeline, it will be 1.25 times the design pressure.
If the actual wall thickness is greater than the design wall thickness, it is justifiable to test the
pipeline at a higher pressure.
3. COMMISSIONING
Before the hydrocarbons can be introduced into a pipeline system, the water remaining in the pipeline
system must be removed and the pipeline dried internally to a certain level as determined by the
pipeline operational criteria. The pipeline commissioning comprises the following three stages:
Dewatering
Drying
Introduction of product
The commissioning activities are again performed by specialist contractors who should be fully
involved in planning the whole operation.
It is pointed out that gas pipeline commissioning is generally more hazardous compared to an oil
pipeline.
3.1 Dewatering
Dewatering is normally carried out by propelling a train of pipeline pigs through the pipeline using air
or some inert gas. The type and size of pumps and other equipment to push the pigs with air depends
on the pipe size and pipeline length. The number of pigs in a train or how many times the pig trains
are run depends on the drying requirements in general. A film thickness of 0.05 mm to 0.2 mm is often
left on the inside surface of the pipeline without the internal coating. Thinner film thickness is
expected in an internally coated pipe. Disposal of water will be subject to approval of local and federal
regulations. Inhibited seawater is generally discharged into the sea but environmental considerations
may require it to be discharged at least 2 km away from the shore. Therefore, it is a common practice
to push the dewatering pigs from onshore if the pipeline is between an offshore facility and an onshore
facility.
Seabed undulations can cause water to collect in the low spots of the pipeline leading to difficulties in
achieving the required dryness in the pipeline. In such cases, foam pigs may be used. The selection of
pigs to be used for dewatering is important in reducing the amount of water left in the pipeline.
3.2 Drying
The degree of dryness of the internal surface prior to the introduction of the product depends on the
product to be piped. For gas pipelines, the dryness levels are generally higher. For example, the usual
requirement for gas pipeline transporting dry gas, is that water content should not exceed 4
lb/MMSCF at the design pressure and for a dew point of 2o C, and also at the atmospheric pressure
and a dew point of 47o C.
For oil pipelines, further drying of pipeline after the removal of all free water may not be required.
However, further drying of gas pipelines is necessary unless the pipeline is to carry multi-phase wet
mainly gas product.
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Air drying
Vacuum drying
Liquid Swabbing
A variation of the third method involves dewatering and drying by liquid swabbing in a single pass.
The selection of a suitable method depends on several factors:
System design
Location
Level of dryness required
Facilities available
Environmental concerns
Timing
Logistics
Cost effectiveness
For gas pipeline, after the pipeline is dried to the required level, it is filled with nitrogen that is an inert
gas. It is advisable to dry the pipeline shortly before the product is to be introduced to minimise the
possibility of condensation.
Commissioning contractor determines the size of pumps and other equipment. Preliminary studies
must be done at the design stage to determine possible methods for drying in consultation with
specialist contractors.
DISADVANTAGES:
DISADVANTAGES:
Lengthy procedure
Very time consuming particularly for long large diameter pipelines
Large area required for equipment
High noise levels due to pumps and compressors
Nitrogen purging may be required if the product is not introduced in the pipeline within a
short period of drying
Initial air drying may be required to reduce the amount of water to be evaporated by vacuum
drying
DISADVANTAGES:
4. PRODUCT INTRODUCTION
After the pipeline has been dewatered and dried to the requisite level, preparations are made for the
introduction of hydrocarbons usually from the producing offshore facility.
The hydrocarbons to be introduced could be highly inflammable or hydrates may form during the
filling operations. A hydrocarbon such as the gas can cause explosion if it comes into contact with air,
so it is advisable to introduce a batch of inert gas such as nitrogen in front of the product. This is a
definite requirement for gas or gas/condensate pipelines.
The product is introduced in stages. The product injection rates are controlled to minimise transients
and that pressure and temperature do not exceed allowable limits for the pipeline material or the dew
point conditions. The injection rates are determined during hydraulic analysis for start-up.