0031R 50 D PR 004 Hydrotest Pre Commissioning Procedure Rev. 0

IN ASSOCIATION
WITH
PT. PERUSAHAAN GAS NEGARA

(Persero) Tbk.
HYDROSTATIC TEST PROCEDURE

Document No. Rev Date
Page 1 of 45
0031R-50-D-PR-0041-A4 B0 27 27 May 2012
CLIENT : PT. PERUSAHAAN GAS NEGARA (PERSERO) Tbk.
PROJECT TITLE : SOUTH SUMATRA – WEST JAVA GAS PIPELINE PROJECT

CONTRACT PACKAGE NO. 3A
BOJONEGARA – CIKANDE DISTRIBUTION PIPELINE
CONTRACT NO. : 012600.PK/HK.02/PPJPGB/2011
General comment :
PTG didn’t follow review result from PMC
Still OBJECTION
0 Issued For Comments 27/05/12 WYN ARF KLM

2726/05/1
B Issued For Comments WYN ARF KLM
2
A Issued For Review 01/05/12 WYN ARF KLM
PRPD CHKD APVD
REV DESCRIPTION DATE PMC PGN PJIT
PTG
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0031R-50-D-PR-0041-A4 B0 27 27 May 2012
REVISION HISTORICAL SHEET
Rev No Date Page Description

A 1 May 2012 All Issued For Review
B 27 26 May 2012 All Issued For Review Issued For Comments

0 27 May 2012 All Issued For Construction
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Page 3 of 45
0031R-50-D-PR-0041-A4 B0 27 27 May 2012
TABLE OF CONTENTS
1. PURPOSE.................................................................................................................................... 4
2. SCOPE......................................................................................................................................... 4
3. DEFINITIONS............................................................................................................................... 5
4. REFERENCES............................................................................................................................. 5
4.1 Standards and Codes......................................................................................................... 5
5. RESPONSIBILITIES.................................................................................................................... 6
6. HYDROTEST METHODOLOGY AND PROCEDURE..................................................................7
6.1 Cleaning, Gauging, and Water Filling Pig...........................................................................7
6.2 Thermal StabilizationWater Filling....................................................................................89
6.3 HydrotestThermal Stabilization........................................................................................... 9
6.4 Hydrotest................................................................................................................... 9106.4
Air Volume Calculation..................................................................................................... 12
6.5 Air Volume Calculation............................................................................................ 12136.5
Dewatering....................................................................................................................... 12
6.6 SwabbingDewatering........................................................................................................ 13
6.7 Swabbing...................................................................................................................... 1313
7. SAFETY..................................................................................................................................... 14
7.1 General............................................................................................................................. 14
7.2 Tool Box Safety Talk......................................................................................................... 14
7.3 Personnel Risk................................................................................................................. 14
7.4 Equipment Risk................................................................................................................ 15
7.5 Pigging Safety.................................................................................................................. 15
7.6 Pressure Testing Safety.................................................................................................... 16
7.7 Environmental Control...................................................................................................... 16
7.8 Actions in the Event of Emergency...................................................................................16
8. ATTACHMENTS......................................................................................................................... 17
8.1 Attachment 1 - Arrangement for Water Filling
8.2 Attachment 2 - Arrangement for Dewatering
8.3 Attachment 3 - Arrangement for Swabbing
8.4 Attachment 4 - Hydrostatic test Package Report
8.5 Attachment 5 - Test Equipment and Calibrated Measuring Instruments
8.6 Attachment 6 - List of Equipment
8.7 Attachment 7 –Lay out of Equipment
8.8 Attachment 8 – Position of plug valves and gate valve during pig running
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0031R-50-D-PR-0041-A4 B0 27 27 May 2012
1. PURPOSE
This procedure is made as a guideline for hydrotest to be performed for South Sumatra – West
Java Gas Pipeline Project, Contract Package No. 3AR Bojonegara - Cikande Distribution
Pipeline, Completion of Remaining CP-3AR Works.
2. SCOPE
For every stage of operation, no operations will commence until written permission from PT.
Promatcon Tepat Guna representatives is received. Permission is granted by signing off the
Operational Commencement Form. Sequence for Pre-commissioning activities consist of the
following step:
Preparatory works
Cleaning
Gauging One Step
Water Filling
Pressurization
Stabilization
Test Hold Period
Test Acceptance
Depressurization
Dewatering Will be described in

separated Procedures
Swabbing
Tie-in 16” & pre-hydrostatic tested 24” Ball Valve and Future Connectionallarrangement
pipeline system shall
Installation be hydrotested at least 2
And Tie-In to Existing Facilities hours
Pre - CommissioningCaliper Pigging Will be described

in separated
Procedures
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0031R-50-D-PR-0041-A4 B0 27 27 May 2012
Drying
Nitrogen Purging & Packing
3. DEFINITIONS
Employer : PT. Perusahaan Gas Negara (Persero) Tbk.

Engineer or PMC : Japan Oil Engineering Co. Ltd., in association with PT. Connusa
Energindo.
Contract : South Sumatra – West Java Gas Pipeline Project Contract
Package No. 3AR Bojonegara – Cikande Distribution Pipeline.
Contractor : PT. Promatcon Tepatguna
Third Party : MIGAS or Indonesian Government approved agencies that carry
out inspection and testing specified by Employer.
Right of Way : The land identified by the Employer within which the Permanent
Works are to be built, the Employer warranting by means of the
issuance a single authorization to the Contractor to commence
the Works that he has secured full rights for such purpose.
Onshore Pipeline Route : The area within ROW, along the Toll road and/or public road
within which the Permanent Works are to be built.
Hydrostatic Test : A pressure test of the pipeline using water as the test medium.
4. REFERENCES
All equipment, materials supplied and work performed shall conform to the latest edition of the
following codes, standards and requirements.
Standards and Codes
ASME B31.8 – 2010 Gas Transmission and Distribution Piping Systems
MIGAS SNI 3474 – 2009 Sistem Penyaluran dan Distribusi Pipa Gas
API Spec. 5L Specification for Line Pipe
Keputusan Dirjen MIGAS No. Pedoman dan Tata Cara Pemeriksaan Keselamatan Kerja Atas
84.K/38/DJM/1998 Instalasi, Peralatan dan Teknik yang Dipergunakan Dalam Usaha
Pertambangan Minyak dan Gas Bumi dan Pengusahaan Sumber
Daya Panas Bumi
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0031R-50-D-PR-0041-A4 B0 27 27 May 2012
KEPMENTAMBEN NO. Keselamatan Kerja Pipa Penyalur Minyak dan Gas Bumi
300.K/38/M.PE/1997
5. RESPONSIBILITIES (WHO, PLEASE SUBMIT ORGANIZATION CHART)

Following are the responsibilities of personnel involved in the scope of this procedure:
Project Manager : Shall be responsible for all activities.

Construction Manager : Shall be responsible for overall control and management for the
activities described in this procedure. Shall be responsible for
coordination with the Engineer and Subcontractor in overall
activities.
He shall coordinate with HSE&S Manager, Project Planning,
QA/QC and Site Superintendent for the properly implementation
of the procedure. He also acts as on-scene Commander in case
of emergency.
HSE&S Manager : Shall be responsible for HSE&S performance and where
necessary initiating corrective action through line management.
QA/QC Manager : Shall report to the Project Manager. Shall be responsible for
quality matters for the activities described in this procedure.
QA/QC Inspector : Shall report to QA/QC Manager.
Shall be responsible for overall control and inspection of QC
activities in line with this written procedure. Shall be responsible
for checking and signing the Pre Pull Back Hydrotest activity
Reports from the Hydrotest Subcontractor.
Safety Inspector : Shall be responsible for overall control and inspection of safety
matters and report to HSE&S Manager.
Plan and maintain the housekeeping at work places.
Construction Superintendent : Shall report to Construction Manager and shall coordinate with
the Supervisor for implementation of this procedure.
Foreman : Shall supervise work at the site. Shall report to the site
Superintendents.
Pre-Comm Manager : Shall be responsible for preparation and implementation of all
site activities related to pre-commissioning, prepare all
necessary inspection reports.
Hydrostatic test Engineer : Shall report to the Construction Manager (Subcontractor) and
shall be responsible for execution and implementation of all site
activities related to this procedure. Prepares necessary
inspection reports as required by this procedure.
HSE Engineer : Shall assist HSE Manager in HSE matters.
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0031R-50-D-PR-0041-A4 B0 27 27 May 2012
6. HYDROTEST METHODOLOGY AND PROCEDURE

Prior to Pre-Commissioning, below activities shall be done:
- All works on the pipeline shall be completed, including crossing, trenching, lowering in,
backfill, etc., before the testing commences.
- Pipe book before Hydrostatic Test shall be prepared and signed by the Engineer, /Employer
and Third Party before carrying out water filling and testing operation.
- All pipeline and components shall be line checked for correctness before testing.
- A qualified and experienced Contractor’s engineer shall be nominated as the Hydrostatic Test
Engineer. (WHO???) He shall be on site throughout all testing operation and shall be
responsible for all testing and associated work. He shall employ sufficient experienced
personnel to enable all aspects of testing to be fully supervised. The Hydrostatic Test
Engineer in conjunction with the Safety and Environment Engineer (WHO??) shall be
responsible for safe planning and operation of the work and minimizing danger to the
environment. Prior to any Hydrostatic Test, the Engineer/Employer shall be notified in
advance in writing and Hydrostatic Test shall commence only after the Employer/Engineer
approval.
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0031R-50-D-PR-0041-A4 B0 27 27 May 2012
Cleaning, Gauging and Water filling Pig

Cleaning, gauging and water filling will be Pcarried out in one step activity.
Temporary hydrostatic test header will be installed at Bojonegara and Cikande Station. Aat
Bojonegara Station, the header contains of 2 (two) bi-directional pigs. Second bi-di pig at the
back and first bi-di pig mounted with gauging plate at the front. The assembly of the pigs
including the position of gauging plate, guide disc, sealing disc and spacer shall refer to
Attachment no. 1. (Please revise it!)
Necessary connection with the filling pump, water tank, pressure gauges, and flushing hoses shall be
made in the launching and receiving ends.
As a minimum one pressure gauge capable of showing a reading of up to 15002000 psig and
temperature shall be installed at both test headers.
The cleaning, gauging and water filling operation shall begin with pumping of water (approximately 20 m3)
in the test section in front of the first pig for cleaning.
Launch the first pig by pumping 20-30 m3 of water behind the first pig (water filling). Air entrapped behind
of the pig inside Launcher shall be vented out through 2” valve by injecting with water.
Piipeline is to be cleaned using a combination of Bi-Di Pig (partial cleaning). Once the line has
been cleaned it will be gauged using an 558,14mm aluminiumaluminum plate installed on a Bi-
Dithe first pig, refer to 96% of Hot Bend inside diameter. (PTG to revise wording due to gauging
together with water filling) ??????
Pipeline size Gauge Plate Gauge Plates

(Inch) Thickness Gauge Diameter (mm)
24 (mm)
6 558,14
Note : Gauging Plate shall be un-slotted
The first pig is a Bi-Di supported gauge plate pig. Extracted gauging pig should be carefully
inspected for line-induced damage and excess debris. Further line cleaning, repair, or gauging
pig runs may be required. Making necessary adjustments will enhance the probability of a
successful survey.
The Water Filling and Gauging Pigs shall be propelled at nominal speed of 1.6 up to 5.5 Km/hr.
The result of Cleaning and Gauginge Pig run shall be analyzed by the Employer/Engineer
together with Test Engineer after completing the hydrostatic test to evaluate the internal status of
the pipeline. After acceptance of the Gauging operation by the Employer/Engineer, Gauging
Plate shall be signed and a photograph of the plate shall be taken and attached to the Gauging
Report.
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0031R-50-D-PR-0041-A4 B0 27 27 May 2012
A deformed, bend or damaged gauging plate shall be evidenced with a Caliper Pig run for further
accurate assessment.
PTG to combine PMC’s comment:
“A deformed, bent or damaged pig shall be evidence of gauging pig run failure and the same
shall not be acceptable”. If dent is found after caliper pig examination, dent pipe shall be
replaced with pre-hydrostatic tested spool, Treatment for this joint is golden joint. Procedure shall
be refer to Tie-in Procedure and also
IifShould Bi-Di Pig become stuck in the line, a we will purpose another procedure. Contingency
Plan shall be conducted as per Employer/Engineer’s assessment together with Contractor.
Contingency Plan will be in details on separate sheets.
PTG shall describe how to fix if Bi-Di pig stuck in the pipeline????????????
Water Filling
The temporary test headers used end cap shall be loaded with two bidirectional pig. Refer to Attachment-
2 "Arrangement for Flushing and Water Filling".
The bi-directional pig will be an assembly of 2 guide discs and 4 sealing discs with total 6 spacers in
between the discs, 1st Pig is Bi-Di Pig combine with Gauging Plate.
PTG to make drawing describing position of gauging plate

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Page 10 of 45
0031R-50-D-PR-0041-A4 B0 27 27 May 2012
Necessary connection with the filling pump, water tank, pressure gauges, and flushing hoses shall be
made in the launching and receiving ends.
As a minimum one pressure gauge capable of showing a reading of up to 1500 psig and temperature
shall be installed at both test headers.
The filling operation shall begin with pumping of water (approximately 20 m3) in the test section in front of
the pig for flushing.
Launch pig by pumping 20-30 m 3 of water behind the first pig. Air entrapped behind of the pig inside
Launcher shall be vented out through 2” valve by injecting with water.
Frequent venting shall be carried out at the launcher header at regular intervals to remove any air, which
may accumulate during filling.
Suitable backpressure (20-25 psi) shall be maintained at the receiver header by throttling the
valve on the header depending on the pipeline elevation.
Plug valves at down streamdownstream side of every Sectional Valves by pass line shall be
closed maintain back pressure (refer to Attachment 8). The columns of water ahead of the pig
shall be flushed out from the receiving end.
During the whole filling operation the valves at the receiving end test headers shall be throttled
suitably to maintain adequate backpressure and for controlled pig movement.
Open the 3/4” gate valve and the 6” downstream plug valve at by pass line to release air trap at
by pass line once the pig has traversed each Sectional Valves then close the 3/4” gate valve after
no air trap is confirmed to maintain the back pressure and also add temporary end cap 3/4”
(NPT) but make sure 3/4” valve gate isn’t block while pressure test..
Once the test section has been completely filled and a minimum pressure of 15 psig has been
achieved at the highest point, all valves in the receiver end shall be closed and the section will be
prepared for pressurization.
Note: Contractor shall commence a Water Sampling before and after Hydrostatic Test.
Please submit water sampling before water filling.
Thermal Stabilization
Once the test section has been completely filled and a minimum pressure 15 psi has been
achieved, thermal stabilization period shall be started. Using Pressure Gauge installed as well as
by Dead Weight Tester PTG to submit certificate !! shall check achieved pressure at the highest
point. Temperature probe shall be installed at 433 locations (KP 0, KP16 and KP32) to measure
the pipe and soil temperature at each pipe end of launching and receiving site, and in the middle
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0031R-50-D-PR-0041-A4 B0 27 27 May 2012
of entire section.
Please added amount of temperature probe, It’s insufficiently and can’t represent
of section will be tested.??
The probe measuring pipe temperature shall be installed by cutting a small portion (a little bigger
than the probe tip) of the coating from the pipe, polishing the exposed portion and fixing the
probe to the pipe with quick setting epoxy ensuring firm contact between the probe and the pipe.
The soil probe shall be poked into the earth junction to the pipe.
Hydrostatic test
6.1 Test Pressure
Before pressurization, pipeline profile shall be built to confirm the test pressure at highest
point, lowest point and testing point. Test pressure of pipeline section section shall be
minimum 1080 Psi. (Tested Pressure = 1.5 x Design Pressure) and at the highest point,
lowest point and test point shall not exceed 90% of the SMYS of the material based upon
the minimum wall thickness in the test section shall be minimum 1080 Psi. (Tested
Pressure = 1.5 x Design Pressure).
The equipment for hydrostatic test of all pressure gauge and temperature gauge shall be
the same (psi, 0F).
Please define each wall thickness in this test section because there are many
wall thickness (bypass piping, tee, future connection)
Pipe 24” 16” 6” Bar tee

Wall thickness 12.7 mm 11.9 mm 7.10 mm 12.7 mm
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0031R-50-D-PR-0041-A4 B0 27 27 May 2012
6.2 Pressurization
A. After complete filling of the section, make the position of the ball valve at by pass line
sectional valve to 10° open.
B. fFilling connection shall be isolated and pressurizing connections shall be established.
C. Higher range pressure gauges and pressure recorder shall be installed in the line
before starting pressurization.
D. Pressure and Temperature Recorder Chart shall be signed by Contractor, Engineer,

Employer and Third Party and started to record on real time basis.
E. Pressurization shall be started with a pressurizing rate of 10 psi per minute up to the
25% of the test pressure (270 psig) and hold for 30 minutes to ensure no leak exist
and pressure has stabilized throughout the entire pipe length.
F. If no leak found continued to raise the Ppressurization up to 50% with the

pressurization rate 10 psi per minute shall be started with a pressurizing rate of 10 psi
per minute up to the 50% of the test pressure (540 psig) and hold for 30 minutes to
ensure no leak exist and pressure has stabilized throughout the entire pipe length.
Conduct first air volume calculation.
G. During this period, monitor the pressure and check the test section for leakage. If a
leak is found, depressurise and dewater the pipeline and repair leaks. Conduct first air
volume calculation.
H. If no leak is found, continue to raise the pressure up to 75% of the required test
pressure (810 psig) with a pressurizing rate of 10 psi per minute and hold 30 minutes
for stabilization. Conduct second air volume calculation.
I. If no leak is found, continue to raise the pressure up to 90% of the required test
pressure (972 psig) with a pressurizing rate of 10 psi per minute.
J. If no leak is found, continue to raise the pressure up to 100% of the required test
pressure (1080 psig) at highest point with a pressurizing rate of 1.5 psi per minute.
K. During pressurizing, pressure and temperature shall be check 50 minutes and the
fitting connections shall be periodically checked for leaks.
L. When the test pressure is reached, the filling valve shall be closed and the
pressurizing line shall be disconnected from the valve on the test header.
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0031R-50-D-PR-0041-A4 B0 27 27 May 2012
Pressurization
After complete filling of the section, filling connection shall be isolated and pressurizing connections shall
be established.
Higher range pressure gauges and pressure recorder shall be installed in the line before starting
pressurization.
Pressure and Temperature Recorder Chart shall be signed by Contractor, Engineer, Employer and Third
Party and started to record on real time basis.
Pressurization shall be started with a pressurizing rate of 10 psi per minute up to the 50% of the test
pressure (540 psig) and hold for 30 minutes to ensure no leak exist and pressure has stabilized
throughout the entire pipe length. Conduct first air volume calculation.
During this period, monitor the pressure and check the test section for leakage. If a leak is found,
depressurise and dewater the pipeline and repair leaks.
If no leak is found, continue to raise the pressure up to 75% of the required test pressure (810 psig) with
a pressurizing rate of 10 psi per minute and hold 30 minutes for stabilization. Conduct second air
volume calculation
If no leak is found, continue to raise the pressure up to 90% of the required test pressure (972 psig) with
a pressurizing rate of 10 psi per minute.
If no leak is found, continue to raise the pressure up to 100% of the required test pressure (1080 psig) at
highest point with a pressurizing rate of 1.5 psi per minute.
During pressurizing the fitting connections shall be periodically checked for leaks.
When the test pressure is reached, the filling valve shall be closed and the pressurizing line shall be
disconnected from the valve on the test header.
6.3 Test Pressure Holding Time (What is duration time for frequently check every pressure
and temperature from Barton, PG, DWTT ?? )
A. After attaining the test pressure, the line shall be left for 60 minutes to stabilize.
B. Final pressure in the line shall be noted from the dead weight tester and held for 24
hours minimum
C. Check and report pressure and temperature from Barton Chart, Pressure Gauge,
Temperature gauge and DWT every 15 minute.
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0031R-50-D-PR-0041-A4 B0 27 27 May 2012
6.4 Test Acceptance

A. 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.
Pressure change due to temperature variation (from the beginning of hold period to
completion of hold period) shall be calculated from the Hydrostatic Test calculation.
After the completion of hold period, pressure variation due to temperature fluctuation
shall be accounted for and corrected. The pressure test is acceptable, if the final
recorded pressure after making necessary correction due to temperature fluctuation is
equal or more than the test pressure minus 0.2% of test pressure. Accepted minimum
pressure after correction is calculated as follows.
P - Test pressure
∆P – Pressure change due to correction of change in temperature fluctuation.
Accepted minimum pressure after correction
P (accept) = (P ± ∆P) - 0.2% of P
Please submit as attachment hydrostatic test calculation due to

temperature variation (include all factor regards it).
If final recorded pressure is less than the acceptable minimum pressure after
correction P ( accept), the hold period shall be extended until the above criteria being
achieved for 24 hours hold period.
After obtaining written acceptance of test from MIGAS, and the Engineer, / Employer
and Third Party, preparation shall be made for de-pressurization of the section.
On successful completion and acceptance of the hydrostatic test the pipeline shall be
slowly depressurized at a moderate and constant rate.
B. If any leakage is observed during pressurization or hold period, line shall be

depressurized for further remedial work.
C. No work shall be carried out to repair leak until less pressure has been reduce to 0
psig.
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0031R-50-D-PR-0041-A4 B0 27 27 May 2012
6.5 Depressurization
A. After acceptance of testing, the section shall be depressurized at a moderate and
constant rate.
B. Rate of depressurization shall be 10 psi per minute up to 75% of test pressure (810
psig) and then at the rate of 15 psi per minute till static head. See Figure 1. Schematic
Hydrostatic Pressure Holding.
C. Depressurization will be done at the launcher end of test header by draining the water
through 1-inch openings through a hose.
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0031R-50-D-PR-0041-A4 B0 27 27 May 2012
Schematic Hydrostatic Test / Graphic Period
30 Minutes
30 Menit
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0031R-50-D-PR-0041-A4 B0 27 27 May 2012
Depressurization
After acceptance of testing, the section shall be depressurized at a moderate and

constant rate.
Rate of depressurization shall be 10 psi per minute up to 75% of test pressure (810 psig)
and then at the rate of 15 psi per minute till static head. See Figure 1. Schematic
Hydrostatic Pressure Holding.
Depressurization will be done at the launcher end of test header by draining the water
through 1-inch openings through a hose.
Schematic Hydrostatic Test / Graphic Period
30 Minutes
30 Menit
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0031R-50-D-PR-0041-A4 B0 27 27 May 2012
Air Volume Calculation
Air volume calculation shall be carried out in order to check the presence of air in the pipeline.
Two separate consecutive pressure lowering of 1 Kg/cm2 by slowly bleeding water from the test
section shall be carried out during all the pressurizing cycling as mentioned above. The 1 st
pressure lowering will be at 50% pressurization and the 2 nd pressure lowering will be at 75%
pressurization.
The water drained the second lowering shall be accurately measured (V 1). This quantity shall be
compared to the theoretical quantity (VP) corresponding to the pressure lowering.
The air volume shall be acceptable if V1 / VP is 1.06. if the V1 / VP ratio exceeds 1.06, the testing
cannot be proceeded until additional pig passage performed to remove the entrapped air in the
section. The observation shall be recorded.
The test shall be repeated as per the above procedure until the above estimated tolerances are
satisfied. The pressurizing can continue, to reach value the test pressure.
∆VpA = 0.8847 x [ Please show the

formula????????R1/ST1 + A ] x Vt/106 x (P1 – P2) x K
With:
VP = Computed water amount required to raise by 'P' the pressure in the section to be
tested (m3)
Vt = Geometrical Volume of the Section (m3)
R1 = Nominal inner radius of pipe (mm)
T1= Nominal pipe thickness (mm)
A = Isothermal compressibility volume for water at the pressurization temperature in the
P range(bar-1) x 10-6
P = Pressure Rise (bar)
K = A dimensionless coefficient that is equal to a value of 1.02 for longitudinally Welded Pipe
= 1.02
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0031R-50-D-PR-0041-A4 B0 27 27 May 2012
Dewatering
6.6 Upon successful completion of the hydrostatic test & depressurization, provide suitable
drains for safe disposal of hydrostatic test water at the launching test header end.
6.7 Dewatering pig shall be propelled from the test header into the line to dewater the section
with the oil free compressor air.
6.8 The water coming out of the receiving test header will be drained (either to the Lake or to
the River as applicable).
6.9 The line shall be considered dewatered when a negligible amount of water is flushed out
by the last pig.
6.10 Water sampling before Dewatering shall be commmence prior to analyzzed.
Swabbing
The swabbing operation is meant to reduce the remaining water in the pipeline to bring the
pipeline into touch dry condition using foam pig. Swabbing operation shall be carried out to
ensure that there is no water left inside the pipeline.
The number of runs for the foam pigs shall be as many as when the final pig run no further water,
debris are pushed in front of the pigs and the pig shall be touch dry. The process will continue till
above acceptance criteria of less than 15% absorbed water weight is met. The swabbing
operation shall be repeated until results obtained are satisfactory to the Employer/Engineer.
Please add item REPORTING!!
After completion of each activity, reports shall be prepared by the Hydrotest Engineer as per
attached format and submitted for Engineer, Employer and Third Party approval.
7. SAFETY
General
Contractor personnel shall be pre-briefed on the operating procedures and the potential hazards
in a pre-mobilization Job Safety Analysis (JSA). The JSA shall be reviewed prior to commencing
any operation activities, refer to Appendix Job Safety Analysis. PTG to submit risk asssement for
this activity to be attached in this procedure.
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0031R-50-D-PR-0041-A4 B0 27 27 May 2012
Prior to commencing the operation contractor personneHydrotest Engineerl shall discuss the
operations with Client Site Representatives to ensure a complete understanding of the operation
will be taken place.
Contractor personnel shall inspect the arrangement of the equipment and equipment itlself with
Engineer, Employer and Third party on site prior to commencing of operations.
Whilst on Launcher / Receiver, contractor personnel shall conduct all activities in accordance with
the site and Owner operating procedures (including the permit to work system).
The contractor field engineer Hydrotest Engineer shall be responsible for ensuring all permit
requirements are fully adhered to. The immediate vicinity around the work area shall be cordoned
off with barrier tape and suitable signs erected.
Tool Box Safety Talk
A Tool Box Safety Talk shall be conducted on-site before each new phase of operations. The talk
shall outline the work to be carried out and shall include but not limited to the following:
> Sequence, co-ordination and details of work to carried out
> Hazards/control measures/emergency response contingency plans
> Safe areas/escape routes/muster points
> Barriers and signs
> The toolbox talk shall be given to each shift (day/night) and the permit re-issued each shift.
Personnel Risk
All personnel shall wear personal protective equipment (PPE) provided for their use. Protective
hard hat, steel toe safety boots, safety glasses and flame retardant coveralls shall be the minimum
safety clothing worn at all times when on-site.
All personnel shall carry ear protection and gloves with them at all times and use them in the
appropriate situations. Waterproof jacket and trousers shall be worn in adverse weather
conditions.
Hearing protection is mandatory where equipment with a sound power level in excess of 85 dB (A)
is in operation.
Portable eye wash station shall be set up in the vicinity of chemical storage and handling. All
personnel handling chemicals will wear appropriate chemical protection suits, gloves and face
shields, to supplement above PPE requirements.
Equipment Risk
Equipment will be located in safe areas, as designated by operations, all diesel driven equipment
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will be fitted with spark arrestors.

All cryogenic storage and vaporization equipment will be located within a bounded area insulated
from the deck by a wood/sand bed and bund tarpaulin. Water will be available to flood the bund
and assist vaporization in the event of a spillage.
All equipment shall be located when in a manner which leaves suitable and safe escape routes.
Equipment shall be positioned so as to leave 0.6 m access in between, such that:
• Prevent trip hazards
• Prevent damage to hoses
• Protect all personnel and site equipment in the event of hose failure (i.e. away from access
routes) etc.
Pigging Safety
Pigging involves the application of pressure to pipelines and equipment; a release of pressure
energy from the system or equipment could pose a risk to personnel. The following safety rules
shall be adhered to at all times:
• The pig traps must never be opened without checking the trap valve positions and ensuring no
pressure is present by checking the pressure gauge and opening trap vents.
• The traps and their piping systems are to be supported and restrained to prevent any
movement during pigging.
• All flexible hoses are to be restrained to prevent movement, with whip lash protection installed
on each joint.
• All hoses and equipment are to be inspected and be in good condition prior to applying
pressure.
• Never attempt any remedial work on any equipment under pressure.
• Always checked that no low pressure or unauthorized fittings/instruments have been used in
the rig up or system.
• All items of equipment containing pressure are to be clearly marked and the areas barrier to
prevent unauthorized access.
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0031R-50-D-PR-0041-A4 B0 27 27 May 2012
Pressure Testing Safety
Hydro-testing involves the application of pressure to pipelines and equipment; a release of

pressure energy from the system or equipment could pose a risk to personnel. The following
safety rules shall be adhered to at all times:
• Piping and connections must never be opened without checking the system valve positions
and ensuring no pressure is present by checking the pressure gauge and opening vents.
• All piping systems are to be supported and restrained to prevent any movement during
testing.
• All flexible hoses are to be restrained to prevent movement, with whip lash protection installed
on each joint.
• All hoses and equipment are to be inspected and be in good condition prior to applying
pressure.
• Never attempt any remedial work on any equipment under pressure
• Always checked that no low pressure or unauthorized fittings/instruments have been used in
the rig up or system.
• All items of equipment containing pressure are to be clearly marked and the areas barrier to
prevent unauthorized access.
Environmental Control
All equipment with the potential for spill causing environmental damage will have drip pans or
tarpaulin sheets incorporated. Drip tray or tarpaulin sheets shall be utilized for retrieval of pigs if
the presence of hydrocarbon liquids may be present.
Actions in the Event of Emergency
In the event of an emergency during operations, all equipment shall be shut down immediately
and put in a safe condition.
If a system is under pressure at the time of an emergency, the injection point must be closed as
soon as pumping has stopped. Non return valves shall be fitted to injection points of systems to
ensure that pressure is contained in the event of hose failure
Work permits (if any) are to be returned to the permit office/control room. Personnel shall proceed
to their allocated emergency muster point in accordance with the platform ongoing response
plan. Please check where is muster point for all area???
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No work can recommence until the permit to work is re-issued. Prior to re-introducing pressure to
the system, all equipment must be checked to ensure no damage or alteration has occurred
during the emergency stand down.
8. ATTACHMENT
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HANDY TALKIE ONLY 4 UNIT. IS IT ENOUGH TO COVER ALL AREA??
ATTACHMENTS
Attachment 1 - Arrangement for Water Filling

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Attachment 2 - Arrangement for Dewatering

Attachment 1 - Arrangement for Water Filling
Attachment 2 - Arrangement for Dewatering
Attachment 3 - Arrangement for Swabbing
Attachment 4 - Hydrostatic test Package Report
Comments:
Form clearance, PMC PGN PJIT : Reviewed by

Form hydrotest : many other company logo, PMC PGN PJIT : witnessed by
Form Berita Acara : This is berita acara partial. Please develop berita acara with
PTG, PMC, PGN, PJIT and MIGAS signature
Attachment 5 – Test Equipment and Calibrated Measuring Instruments (please submit

DWTT)
Attachment 6 - List of Equipment
Attachment 7 – Lay out of Equipment
Attachment 8 – Position of plug valves and gate valve during pig running
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Attachment 3 - Arrangement for Swabbing

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Attachment 4 - Hydrostatic test Package Report

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Attachment 5 - Test Equipment and Calibrated Measuring Instruments

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Attachment 6 - List of Equipment

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Attachment 7 - Lay out of Equipment

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Attachment 8 - Position of plug valves and gate valve during pig

running
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Attachment 9 - Organization Structure

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Attachment 10 - Pig Data

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Attachment 11 - Gauging Plate Position

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Attachment 12 - Formula for Pressure difference due to Temperature

Variation
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Attachment 13 - Job Safety Analysis

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Attachment 14 - Water Sampling

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Attachment 15 - Swabbing Report

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Attachment 16 - Muster Point for All Area

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Attachment 17 – Hydrotest Calculation

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Attachment 18 – Form Report Hydrotest

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0031R-50-D-PR-0041-A4 B0 27 27 May 2012
Attachment 19 – Profile Elevation

Attachement – Organization Structure
Attachment – Pig Data
Attachement – Gauging Plate position

Attachnment – Formula for Air Volume Calculation
Attachment – Formula for Pressure diffirence due to Temperature Varioation

0031R 50 D PR 004 Hydrotest Pre Commissioning Procedure Rev. 0

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IN ASSOCIATION

PT. PERUSAHAAN GAS NEGARA

HYDROSTATIC TEST PROCEDURE

CLIENT : PT. PERUSAHAAN GAS NEGARA (PERSERO) Tbk.

PROJECT TITLE : SOUTH SUMATRA – WEST JAVA GAS PIPELINE PROJECT

CONTRACT NO. : 012600.PK/HK.02/PPJPGB/2011

0 Issued For Comments 27/05/12 WYN ARF KLM

PT. PERUSAHAAN GAS NEGARA

HYDROSTATIC TEST PROCEDURE

REVISION HISTORICAL SHEET

Rev No Date Page Description

B 27 26 May 2012 All Issued For Review Issued For Comments

PT. PERUSAHAAN GAS NEGARA

HYDROSTATIC TEST PROCEDURE

PT. PERUSAHAAN GAS NEGARA

HYDROSTATIC TEST PROCEDURE

Gauging One Step

Test Hold Period

Dewatering Will be described in

Pre - CommissioningCaliper Pigging Will be described

PT. PERUSAHAAN GAS NEGARA

HYDROSTATIC TEST PROCEDURE

Nitrogen Purging & Packing

Employer : PT. Perusahaan Gas Negara (Persero) Tbk.

Standards and Codes

ASME B31.8 – 2010 Gas Transmission and Distribution Piping Systems

API Spec. 5L Specification for Line Pipe

PT. PERUSAHAAN GAS NEGARA

HYDROSTATIC TEST PROCEDURE

5. RESPONSIBILITIES (WHO, PLEASE SUBMIT ORGANIZATION CHART)

Project Manager : Shall be responsible for all activities.

PT. PERUSAHAAN GAS NEGARA

HYDROSTATIC TEST PROCEDURE

6. HYDROTEST METHODOLOGY AND PROCEDURE

PT. PERUSAHAAN GAS NEGARA

HYDROSTATIC TEST PROCEDURE

Cleaning, Gauging and Water filling Pig

Pipeline size Gauge Plate Gauge Plates

PT. PERUSAHAAN GAS NEGARA

HYDROSTATIC TEST PROCEDURE

PTG to combine PMC’s comment:

PTG to make drawing describing position of gauging plate

PT. PERUSAHAAN GAS NEGARA

HYDROSTATIC TEST PROCEDURE

Please submit water sampling before water filling.

PT. PERUSAHAAN GAS NEGARA

HYDROSTATIC TEST PROCEDURE

6.1 Test Pressure

Pipe 24” 16” 6” Bar tee

PT. PERUSAHAAN GAS NEGARA

HYDROSTATIC TEST PROCEDURE

B. fFilling connection shall be isolated and pressurizing connections shall be established.

D. Pressure and Temperature Recorder Chart shall be signed by Contractor, Engineer,

F. If no leak found continued to raise the Ppressurization up to 50% with the

PT. PERUSAHAAN GAS NEGARA

HYDROSTATIC TEST PROCEDURE

PT. PERUSAHAAN GAS NEGARA

HYDROSTATIC TEST PROCEDURE

6.4 Test Acceptance

Please submit as attachment hydrostatic test calculation due to

B. If any leakage is observed during pressurization or hold period, line shall be

PT. PERUSAHAAN GAS NEGARA

HYDROSTATIC TEST PROCEDURE

PT. PERUSAHAAN GAS NEGARA