Linkso Engineering &

Technical Services

NIPCO Plc.
ds

Enikkom Construction Limited

ENIKKOM CONSTRUCTION LIMITED

No.7 Joseph Ogunjobi Street,Praise Hill Estate, Arepo
Lagos/Ibadan Expressway,Ogun State.Nigeria
Phone/Fax: 084 465792 & 750202
Email: info@enikkom.com

HYDRO-TEST REPORT
REPORT NO: ECL/HT/0005

PIGGING
LINE FILLING
PRESSURE TESTING
LEAK TIGHTNESS TEST
&
DEWATERING OF
4 X 158m

Table of Contents
1.0

ABBREVIATIONS

2.0

PURPOSE

3.0

SCOPE

4.0

SYNOPSIS

5.0

REFERENCE DOCUMENTS

6.0

TEST EQUIPMENT AND FACILITIES

7.0

CALCULATION FOR HYDRO TEST

8.0

SAFETY

10

9.0

SELECTION AND PREPARATION OF TEST SECTION

10

8.1
8.2

SELECTION OF TEST SECTION

PREPARATION OF THE TEST SECTION

10
10

10.0

LINE FILLING

14

11.0

HYDROSTATIC TEST

14

10.1
10.2

STRENGTH TEST
LEAK TIGHTNESS TEST

15
16

12.0

RECTIFICATION OF DEFECTS

16

13.0

ACCEPTANCE AND DEPRESSURIZATION

16

14.0

DOCUMENTATION

17

15.0

ATTACHMENT

18

1.0ABBREVIATIONS
The following abbreviations are used freely in this document;
Abbreviation
GGL
ECL
AG
ASME
DP
EG
MAWP
MAOP
PEP
RPM
SMYS
STP

Description
Green Gas Limited
Enikkom Construction Limited
Associated Gas
American Society of Mechanical Engineers
Design Pressure
Export Gas
Maximum Allowable Working Pressure
Maximum Allowable Operating Pressure
Project Execution Plan
Revolution per Minute
Specific Minimum Yield Stress
Specified Test Pressure

2.0 PURPOSE
The aim of hydrostatic test is to ascertain the integrity - strength and leak tightness of the
4,8 & 12 dia flow line/pipelines after fabrication, laying and installation by exerting a
specified pressure @ 147 Bar generated through water medium on the gas flowline/
pipelines.

3.0 SCOPE
This procedure covers the Flushing, Pigging, and Gauging and Hydrostatic Pressure testing
of gas pipelines, using corrosion inhibited water pumped from the dredged slot. Other
considerations like Dewatering, Drying and Nitrogen purging are for commissioning, while the
introduction of the Product into the line is Commissioning. These shall be covered under
separate work procedure
.
4.0 SYNOPSIS
This work shall be carried out in accordance with the requirement of GGL Standard
Construction Specification.
The test section shall be prepared prior to pressurizing by cleaning, gauging and filling. For
the gas pipeline to be accepted, it must sustain the Specified Test Pressure (STP) for a
defined period otherwise cause of failure shall be detected, rectified and the gas /pipeline retested in accordance with the stated pipeline specifications.
Prior to commencement of the test, sample of water to be used for filling, flushing and
pressure testing of the gas lines/pipeline shall be taken to GGL approved independent
laboratory, tested and report presented to the client representative for approval. GGL may
equally carry out independent testing of the water samples.
All necessary documentations as indicated in the specifications mentioned above, shall be
carried out at every stage of the activity. The detail test schedule which comprises the
proposed test dates, locations and the mobilization plan of the pressure testing crew shall be
prepared and be made available to GGL minimum of 3 days before planned test date.
5.0 REFERENCE DOCUMENTS
The following document will be referred to in determining the procedural requirement for
carrying out this work.

DNV-OS-F101 Aug 2012 Sec.10 J210

ASME B31.4 Para. 437.4 (Pipeline Transportation systems for liquid hydrocarbons and
other liquids)
ASME B31.8 Gas Transmission and distribution Piping System
API RP 1110 (March 1997) (Pressure Testing of Liquid Petroleum Pipelines)
Pipeline Rule of Thumb, Hand Book

6.0 TEST EQUIPMENT AND FACILITIES

The test manifold shall be designed and fabricated in equivalent to at least 1.5 of the
Maximum Allowable Working Pressure of the gas flowline/ pipeline to be tested. Each major
component of the testing assembly shall be carefully inspected by visually and by
radiography where necessary, and technically certified by GGL. All measuring instruments
required - Pressure / Temperature recorders, Pressure gauges and Thermometers shall be

calibrated to the specified accuracy and their certificates made available to GGL for
confirmation, minimum of 3 days prior to commencement of the hydro test. Besides, the
calibration status for each of the instruments shall also be documented in the ECL Hydro test
Instrument Calibration Record a copy of which is attached, after which a tag reflecting the
calibration date, expiry date and serial number of instrument is posted on each of the
instruments.
At any point in time during the test, the actual position of a pig in the test section shall be
tracked by using the Volume, Speed and Flow rate of the driving medium (water) of the pig.
These 3 variables shall be determined from the flow meter installed across the water delivery
line.
The test packages, schedule and necessary punch list shall be made available to GGL for
review and concurrence prior to hydro testing the lines. At completion of every hydro test, all
items removed or repositioned for the purpose of the test shall be reinstated. Efforts shall be
made to ensure that the environment in which the test is being carried out is preserved.
Listed below are the major components of the test assemblies which must be tested and
certified by GGL before commencement of this activity.
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.
o.
p.
q.
r.
s.

Flush Pump (Make KSB) 6 Suction & 5 Discharge outlet (up to 30 Bar Pressure)
Pressure Pump 2 HP Pump (Union Pump) (500 bar)
High Pressure hoses 206.86n /3000 psi
Mannesmann Compressor 15bar Maximum Pressure
Ingersoll-Rand XP 750 cfm Compressor
Flow meter Serial No. 96AWQ24432
12 Hight Density Criss Cross Foam Pig w/t Wire Brushes
12 Medium Density Criss Cross Foam Pig
Silver Gauging plates wt 7-9mm and OD 266mm
Pig Launcher/Receiver 12
ITT BARTON Pressure / Temperature Recorder -3000PSI, 150oF and 24Hr. 9 Days Wind
(S. # 435167, Model # 3452E)
Temperature Charts
Pressure Gauges Wika (0-160 Bar)
Pressure Guage (0-400 Bar)
Pressure testing header
Cork Valves
Flexible and high pressure flushing Hose and couplings
Water Tanks
Pressure relief Valve 0 155 Bar

7.0 Calculation for Hydro test

S.No

Description

12 Dia Pipe OD

323.85mm

12 Dia Pipe ID

304.8mm

Length of First Hydro test Section 8997m

nd

Length of 2

Volume of 1st Section (73 Ltr. Per Meter)

8,997 Meter

Hydro Test Section 2,750m

2,750 Meter

r2 h Or L

649.481m3

r2 h Or L

200.75m3

3.14*(0.152)2 *8997*1000
6

Volume of 2nd Section (73 Ltr. Per Meter

Wall thickness of Pipe

45 Degree Bend OD

323.85

45 Degree Bend ID

279

10

Wall Thickness of Bend

11

90 Degree Bend OD

323.85

12

90 Degree Bend ID

279

13

Wall thickness of Bend

14

Gauge Plate OD is Minimum 95% ID of Bend

265.05

15

Design Pressure

98 Bar

16

Hydro test Pressure 150% of Design Pressure

147 Bar

17

Pressure Elevation Difference due to Ground Elevation

(First Section)

2.3 Bar

18

Pressure Elevation Difference due to Ground Elevation

(2nd Hydro Test Section)

2.5 Bar

19

Minimum Depth of Pipeline

1.5 Meter

20

Maximum Depth of Pipeline Ch 002+750 to CH 11+747

(8,997m) First Section

23 Meter

21

Maximum Depth of Pipeline CH 0+000 to Ch 002+750

(2,750m) 2nd Section

36 Meter

22

Using the rule of thumb for 10m height of water = 1barg

Back Pressure due to Elevation
Ch 002+750 to CH
11+747 (8,997m) 1st Section

2.15 Bar

23

Using the rule of thumb for 10m height of water = 1barg

Back Pressure due to Elevation CH 0+000 to Ch 002+750
(2,750m) 2nd Section

3.5 Bar

24

Friction loss Calculation During Filling (See the Formula on

Next Page)

1.07 Bar

25

Total Back Pressure due to Elevation Ch 002+750 to CH

11+747 (8,997m) 1st Section (Sn13+SN18+SN19)

5.52 Bar

26

Total Back Pressure due to Elevation Ch 002+750 to CH

11+747 (8,997m) 1st Section (Sn14+SN18+SN19)

7.07 Bar

9.525mm

22.53

22.53

Rule of thumb for 10m height of water (Formula)

P=rho*g*h
P= pressure
rho= density = 1000 kg/m^3 at about 20C
g= gravitational constant on earth at sea level = 9.81 m/s^2
h= height
h= 1x10^5/(1000*9.81)= 10.19367 meters
The friction loss calculated using Hazen Williams formula
f = 0.2083 (100 / c)1.852 q1.852 / dh4.8655

(1)

where
f = friction head loss in feet of water per 100 feet of pipe (fth20/100 ft pipe)
c = Hazen-Williams roughness constant = 120
q = volume flow (m3/s) =0.31 @0.5m/s
dh = inside hydraulic diameter (m) =0.91
Actual Frictional Head loss 1087otal /b8.5mmH20 = 1.07bar
Table 6 Expected Total Back Pressure for different types of Pig / Line Filling
Pig
Types

Filling
Water
Foam
Pig
cup pig
Bi-di Pig
coated
foam pig
Brush
Pig
Filling
Water
Foam
Pig
cup pig
Bi-di Pig
coated
foam pig
Brush
Pig

DP
(Bar
g)

0
0.19
0.22
0.39
0.41
0.62

0
0.19
0.22
0.39
0.41
0.62

Static
Head
(bar)

Frictional
Back
Head
Pressure
Loss
(bar)
(bar)
1st Section

2.30

2.15

1.07

2.30
2.30
2.30

2.15
2.15
2.15

1.07
1.07
1.07

2.30

2.15

1.07

2.30

2.15

1.07
2nd Section

2.5

3.5

1.07

2.5
2.5
2.5

3.5
3.5
3.5

1.07
1.07
1.07

2.5

3.5

1.07

2.5

3.5

1.07

Safety Factor
2.5 Bar

2.5
2.5
2.5
2.5
2.5
2.5

2.5
2.5
2.5
2.5
2.5
2.5

Total Back
Pressure
(bar)

8.02
8.21
8.24
8.41
8.43
8.64

9.57
9.76
9.79
9.96
9.98
10.19

For this project the expected backpressure for pigging activities can be estimated to fluctuate
between 6 8 bars and additional 2.5 bar might be a safety factor taking into consideration heavy
wall sections of road crossings, HDD and bends.
Filling and Cleaning Pump Requirements.
The pump required for the operation must be rated to 1.25 times the expected backpressure.
Therefore the expected discharge pressure for the pump is approximately.
1.25 * 10.19 bar 12.74 bar

The discharge pressure rating for the pump recommended for this operation must be able to
discharge at a pressure capacity well above 12.74 bars.

The pig speed in a normal pigging operation should be within 0.5 1m/s if we assume a maximum
pig speed of 1m/s for this operation the equivalent flow rate would be = 8997/1 = 8997 s =2.5h
Flow rate = 649.481/2.5 = 4.32m3 /mins = 4.32*6.289= 27.01 BPM (1m3 = 6.289 Barrel)
Compressed Air Design
The pig speed should be between 2 8km for normal pig runs and 2 -4km/h for gauging plate
runs while using compressed air as a medium to propel the pig,
By assuming an average pig speed of 4km/h the air flow required
= (649.48 / 8,997) * 4,000 = 289 m3/h = V1
The required driving pressure when the pipeline is full of water must
Total Driving pressure required 12.74 bar = P1
Total Back pressure = 10.5 = P2
Using equation = P1*V1 = P2*V2
V2 = ( P1*V1 ) / P2 = ( 12.74 X 289 ) / 10.5
V2 = 350.65 m3/h
@ 1 m3 = 35.315 CFM
Compressed air requirement = 350 x 35.315 = 12,383ft3/h = 207 CFM
To give allowance for error in calculation 1.25 time the required air will be used = 259CFM
Therefore, a 650 CFM @ 15 Bar compressor should be adequate for the project. To achieve an
8km/hr pigging speed a second compressor would be added while a third would be on standby for
in case of breakdown.
The pig delivery time at average speed of 4-8km/hr less dawn 2 4 hours
1. HYDROSTATIC TEST PUMP DESIGN
The pressurizing pump required should be suitable to pressurize the test section at approximately
1 bar per minute. The volume required to inject to give 1bar pressure can be estimated using the
theoretical equation for volume change V per Pressure change P for pipeline with liquid under
pressures at constant temperature, disregarding effects of air absorption or free air in the line. The
Pressure-volume relationship considering elastic strain in the pipe and Compressibility of the water
is calculated thus

V=

D
1
( 1 ) + ) PV
( Et
B
2

DV/DP = V * [(D/ (E * t) (1 v) + C]
Where,
dV

incremental volume in the same units as V

dP

incremental pressure, bar = 1

volume of the segment 1 = 649.481m3

volume of segment 2 = 200.75m3

Volume of the Segment 2 = 200.75m3

Elastic modulus of steel pipe (psi) = 2.07 x 10*6

Wall Thickness of pipe (m)= 0.0095m

v
C

=
=

Outside diameter (m), = 0.314m

passions ratio steel pipe = 0.3

Bulk compressibility factor of liquid, per psi (the reciprocal of the bulk

modulus)= 46.7 x 10*-6 bar

DV/DP = V * [(D/ (E * t) (1 v) + C]
DV/1 = 649.481 [0.314 / (2.07x10*6) x 0.0095) (1-0.09) + 46.7 x 10*-6]
= 649.481 [0.314/(14697)(0.91) +46.7x10*-6]
= 649.481 [0.314/13374.27)
DV = 0.02m3/min
The test pump required for this project should be capable of pumping at approximately 0.3m3 per
minute at the required test pressure.
Theoretically pressurizing the system from zero to test pressure should be directly proportional to
inject volume as calculated above, due to the pipeline profile air entrapment is expected, careful
estimation of the air entrapment would be carried out and filling process would be done with high
sealing pig to reduce air entrapment in the test system.
Pipe Drying
Most of the data uses for this estimate are theoretical but in the final analysis allowance would be
given for practical field situation.
The air dew point inside the pipeline is assumed to be the same as pipe wall temperature at
15degree C therefore, the moisture content of the air estimated on I-X graph = Xm = 12.8 g/m3.
Dry air system temperature at Outlet (-30 degrees Centigrade dew point) Xout = 0.33 g/m3
The system flow rate Vr is design for 1180 m3/h (expected compressed air capacity equivalent to
what air dryer can handle @ required departing pressure of 0.5 1bar pigging pressure)
N.B The capacity can be adjusted on the field depending on field criteria and client interest)
The moisture removal capacity of the dry air system Vm =
Vm
Vm

= Vr (Xm-Xout) /1000
= 1180 (12.8-0.33)/1000 = 14.72 kg/h

The expected remaining water in the pipeline after successful dewatering, assuming a water film

of 0.1 mm.
Remaining water = W= 3.14/4(D12-D22)*L*1000
W = 3.14/4(0.3142- 0.2952)* 8.997*1000 = kg water
=0.00908 x 8997
= 82 kg of water
The total drying time for this project T:
T

W/Vm

82 / 61.85 = 5.57 hours

8.0 SAFETY
a. Care shall be taken to open or close any valve too quickly
b. Closed valves shall be electrically isolated or locked out (depending on the clients
operating system). The vents on the valve bodies should be opened where applicable.
c. Work area associated with the launcher and receiver test header traps shall be cordoned
off as a no-entry area for non-authorized persons.
d. Warning signs marked STAY CLEAR PRESSURE TESTING IN PROGRESS and hazards
tapes shall be installed.
e. An experienced Safety Officer will be available to ensure safety at all times during
pressure testing.
9.0 SELECTION AND PREPARATION OF TEST SECTION
7.1SELECTION OF TEST SECTION
The test section shall be the entire completed line or section of line on which there will be
no further work between the inlet and outlet. The elevation difference in the test section
shall not exceed 5% of the SMYS of the flow lines or 50m. Also, the inlet and outlet of the
test section shall be provided with suitable flanges to enable pigging and temporary
coupling of the test head and the pig launcher/receiver.
7.2PREPARATION OF THE TEST SECTION
NDT reports for all welds and repairs on the line to be hydro tested shall be cross checked
again by ENIKKOM CONSTRUCTION LIMITED QA/QC Engineer and confirmed by the GGL
Representative to ensure that all welds/repairs meet the minimum standard of
acceptability stated in DEP 61.40.20.30-Gen., before commencement of any of hydro test
activity.
Prior to pressure testing, each line shall be cleaned by flushing and Pigging to remove
construction debris and other loosely adhered material on the metal and ensure that the
line is free of deformation and obstructions.
These pre-test activities shall be
continuously carried out until the requirements of GGL are satisfied. The physical content
and color of the discharge water determines the level of cleanliness of the flow line.
Detailed procedure for the execution of each of the activities highlighted above is stated
as follows:

PROCEDURES
1. The launch and receiver trap dimension shall be
assessed and adjudged capable of accommodating the
pigs
2. All necessary equipment is available for the work
3. Ensure that Permit to Work and relevant permits are
obtained for the proposed test
4. Prior to the installation of the testing assemblies at each
end of The gas pipeline/, ensure each component of the
assemblies are thoroughly inspected and all measuring
instruments currently calibrated
5. Check and use competent personnel
6. Set up warning signs, danger signals, and safety
barricade about 20m away from the test locations.
7. Ensure no other work is permitted on the test section
during the period of the pressure testing.
8. Reemphasize as stated in the ENIKKOM CONSTRUCTION
LIMITED
Emergency
Procedure
in
ENIKKOM
CONSTRUCTION LIMITED PEP the actions and responses
of the pressure testing crew members in case of
emergency.
9. Establish and maintain walkie-talkie or mobile link
between the crew members
10. Define the boundaries of the test equipment sites with
safety hazard tapes.

ACTION PARTY

Project Engr
Test Supervisor/QC
Engr

Test Supervisor
Safety Officer
Field Engr/Test
Supervisor
Safety Officer

Field Engr/ Test

Supervisor
Safety officer

8.1.1 FLUSHING/PIGGING
11. Connect the flushing pump and accessories to
the pipeline/flow line in readiness for flushing.
12. Introduce water from the client approved source
corresponding to minimum of 2% of the section
volume, to wash away the foreign materials.
13. Repeat step 11 until the pipeline / flow line is
acceptably clean to the satisfaction of the GGL
Representative, for the first pig (bi directional
type) to be introduced.
14. Connect the pig trap/receiver together with the
throttling valve set -up at the discharge end of
the line prior to introduction of the first bidirectional pig.
15. Ensure the GGL Representative is present
before the commencement of any pigging
operation.
16. Alert the recording technician to get pig register
copy of which is attached and other necessary
documents ready and ensure the by-pass of the
bi directional pig is kept open before inserting
the pig.
17. Make necessary connections and drive the bidirectional pig by with water through the line to
be received into the pig receiver at the
discharge end.
18. As the bi directional pig moves in the line, its
speed shall be controlled within the range of
0.5m/s - 2.5m/s by adjusting the throttling valve
connected to the receiving end, in order to
ensure effective cleaning of the line.
19. Repeat step 16 and 17 using cleaning brush pig
installed in succession so long the volume of
the discharged material is not lesser than 5
liters. Notwithstanding, the pigging shall still be
done to the satisfaction of the GGL
Representative before proceeding to gauging.
20. Clear the immediate surroundings of the
discharge end of the line of debris received with
the pigs and dispose in accordance with
ENIKKOM
CONSTRUCTION
LIMITED
Waste
Management Procedure, A temporary piping
shall be fabricated to transport the waste water
from the test sections into the waste disposal
area.

Pressure Testing Technician

Pressure Testing Technician

Pressure Testing Technician

Pressure Testing Technician

Field Engr./ Test Supervisor

Field Engr./ Test Supervisor

Pressure Testing Technician

Pressure Testing Technician

Pressure Testing Technician

Safety Officer / Helper

8.1.2 GAUGING
21. When the test section has been accepted clean

Field Engr/Test Supervisor

by the Client
Representative, then the bidirectional pig with 2 sets of separate guiding
and sealing discs shall be fitted with one or two
aluminum gauging plate and located as stated
in section of the DEP 31.40.40.38 Gen. Ensure
the gauging plates are inspected by the GGL
Representative before driving them into the test
sections. The gauge pjlate is dimensioned to
the 95% of the smallest possible ID of the
pipeline.
22. After the inspection, the gauging pig shall be
introduced into the test section and driven
through the line to be received into the pig trap
at the discharge end.
23. Repeat step 17 as the gauging pig is being
driven through the test section.
24. At the emergence of the gauging pig from the
test section, the plate shall be inspected by the
Test supervisor and GGL Representative for
bending, notching and other irregularities as
specified in the above mentioned specification.
25. Photographic records of condition of the
aluminum gauging plate shall be kept after
each test
26. In situation where the aluminum gauging plates
do not meet the acceptance criteria in the
specification, the cause of the defect shall be
located, rectified and the gauging pig re-run
until it emerges in an acceptable condition.
27. In case any of the test pigs gets stuck in the
test section and cannot be removed by the
normal pumping pressure high density pigs
shall be used to unblock the line failing which
the line shall be cut to remove the pig. Then,
the defect shall be repaired in accordance with
appropriate construction specification and the
qualified ENIKKOM CONSTRUCTION LIMITED
Weld Repair procedure.

Pressure Testing Technician

Pressure Testing Technician

Client Representative/ Field
Engr / Test Supervisor

Test Supervisor /
Photographer
Field Engr/Test Supervisor /
Pressure Testing Technician

Field Engr/Pressure Testing

Technician

10.0 LINE FILLING

28. Once cleaning of the bore of the test section is accepted by
the GGL Representative, the open end of the test section
shall be blinded off and a valve is connected for back
pressure control and venting to remove air from the line
during filling.
29. Ascertain from the GGL if the line will be left empty or
unused for more than 7 days. In that case, add the correct
concentration of a GGL approved corrosion Inhibitor to the
filling water.
30. Ensure the suction end of the pump is fitted with a strainer
and does not draw air by keeping it well below the head of
water required to fill the line.
31. The line shall be filled using 2 bi-directional pigs with water
in front and in - between to ensure complete removal of air.
The line is filled when the second bi-directional emerges.
32. After the line has been completely filled, hydro testing can
commence.

Test Supervisor/ Pressure

Testing Technician

Field Engr/Pressure
Testing Technician

Field Engr/Pressure
Testing Technician /Helper
Field Engr/ Test Supervisor

Field Engr/ Test Supervisor

11.0 HYDROSTATIC TEST

The line shall be subjected to the Specified Test Pressure stated in section IV-3 (GGL Scope of
Work for new pipelines, bulk lines and lift gas distribution) of GGL Contract Document.
S. #

Line Size

12Pipeline

Material
Specification
X52

Design Pressure
(barg)
98

33. Disconnect the filling pump and connect the high pressure
pump, hoses and the pressure testing manifold ready to
pressurize the line.
34. Double check the pressure-testing manifold to ensure all its
components are still in order using the pre- test checklist
copy of which is shown in appendix C.
35. Check again to ensure all warning signs, safety hazard
tapes and barricades are still in place.
36. Provide a canopy to shelter the pressure-testing header
before
pressurizing the pipe to prevent temperature
variation.
37. Commence pressurization by raising the pressure at
constant rate of 1bar per minute up to 30 bar or 20% of the
Specified Test Pressure (STP) for each test section.
38. During this period the graph of pressure (Y-axis ) against
water input volume shall be plotted at minimal 1 bar
interval
39. During this period, check thoroughly for leakage on all
exposed part of the test section and test manifold fitting
and connections.
40. After satisfactory completion of the 2hours pressure holding
period and leak check, raise the pressure at a constant rate
of 1 bar per minute up to 70% of the STP
41. During this period the volume and pressure readings should
be recorded at 10 minutes intervals until the 70% of the STP

Test Pressureure
Barg
147
Test Supervisor /
Pressure Testing
Tech.
Field Engr/Pressure
Testing Technician
Safety Officer
Field Engr/ Test
Supv/Pressure
Testing Technician
Pressure Testing
Technician
Test Supervisor /
Field Engineer
Field Engr/ Test
Supv/ Pressure
Testing Technician
Pressure Testing
Technician
Pressure Testing
Technician

is reached.
42. During this water pressure stabilization period accessible
flanges shall be checked again for small leaks. If any are
found,
the line shall be depressurized at the rate of 2
bar/min to 70bar
or to MAOP, whichever is lesser, prior
to bolt tightening
43. If no leak is found, the pressure shall be built up at the rate
of 0.5 bar/min to 95% of the STP and held for 30 minutes,
after which pressurization shall be continued to the STP of
the line.
1. STRENGTH TEST
44. After attainment of the STP specified in Section IV3 of the GGL Contract document the pressure shall
be held at this point for 1 hours.
45. During strength test the test pressure shall be
recorded continuously on the dead weight tester
readings and the air temperature recorded at
every 30 minutes.
46. The Pipe and ground temperature shall be recorded
at the beginning and the end of the 1 hour test
period, while the ambient temperature is recorded
continuously.
47. Ensure that the pressure is maintained at the STP
+/- 1 bar by bleeding or adding water as required.
48. If a leak is suspected, actions shall be taken as
stated in section 13.0 of this procedure to rectify it.
Afterwards, the strength test shall be repeated.
49. After satisfactory completion of the strength test,
disconnect the high pressure pump and blank off
all necessary connections. Ensure the STP is still
maintained
while
carrying
out
these
disconnections.

Field Engr/ Test

Supv / Pressure
Testing Technician

Pressure Testing
Technician

Field Engr/ Test

Supv / Pressure
Testing Technician

Field Engr/Pressure
Testing Technician

Pressure Testing
Technician
Field Engr / Test
Supervisor /
Pressure Testing
Technician
Pressure Testing
Technician

2. LEAK TIGHTNESS TEST

At satisfactory completion of the strength test, the
leak tightness test shall commence immediately to
confirm there is no leak in the line. This test shall last
for 24 hours. The leak tightness test pressure for each
of the test sections shall be equal to the strength test
pressure.
Pressure recorder chart shall be signed by GGL
Representatives
just
prior
to
commencing
pressurization.
50. At confirmation of the STP, start off a new chart in
the 24- hour pressure recorder and take first set of
pressure and temperature readings. After that, log
in the pressure and temperature readings at 30
minutes interval.
The temperature recording
interval shall reduce to 1- hour duration for the first
and last 3-hour periods of the 24 hours. The pipe
and soil temperature shall be recorded at
maximum 3 hour interval.
51. Monitor line on test to observe any pressure drop
or build up within the 24 - hour period.

Field Engr/Pressure
Testing Technician

Field Engr/Pressure
Testing Technician

52. The test pressure in the line may drop or build up

due to temperature changes. If pressure build up
due to temperature becomes excessive, seek
clearance and bleed line to acceptable limit.

Field Engr/Pressure
Testing Technician

53. The pressure testing of the line shall end when the
chart is submitted and accepted by the GGL
Representative.
54. Ensure the ambient temperature and the pipeline
water temperature are recorded at the same time
as the pressure readings.

Field Engr/Test
Supervisor
Field Engr/Pressure
Testing Technician

12.0 RECTIFICATION OF DEFECTS

All established leaks shall be located by dividing the entire line into two sections and each of
the sections will be subjected to full pressure in accordance with this procedure. After this
test, the section that shows signs of leakages will again be divided into two halves and tested
independently. This procedure shall be repeated until finally the leaking point is established
on a short section. The defect detected during the test shall be rectified in accordance with
the appropriate GGL approved specification and ENIKKOM CONSTRUCTION LIMITED Weld
Repair Procedure. After the rectification process, the damage / defect detected and the repair
carried out shall be documented and the report made available to GGL.
All defective materials - Pipe and fittings shall be identified and isolated from other good
materials. Being GGL material(s), they shall finally be disposed off in accordance with the
GGL Representative's advice.
13.0 ACCEPTANCE AND DEPRESSURIZATION
The hydrostatic test shall be considered successful and accepted when the STP has been
held for 24 hours with no significant loss of pressure. The hydrates certificate shall be
completed and signed by ENIKKOM CONSTRUCTION LIMITED Representative and submitted to

the

GGL

55. After satisfactory completion of the strength and leak

tightness tests open the pressure let-down valve slowly to
depressurize the pipeline / flow line.
56. The test section shall be depressurized at the rate of 1 bar
per
minute up to the hydrostatic head plus 1 bar to
prevent air
from entering it. Ensure proper control of
the pressure let-down valve to avoid vibration of the
pipeline/flow line.
57. Ensure the test pressure is never used to transfer water into
another pipeline / flow line
58. Ensure all test plots, records and charts are countersigned
by GGL Site Representative. Afterward, the consent of the
GGL Representative shall be sought for Dewatering.
59. Firmly close off all valves. Ensure Gauge locks and pressure
gauges are installed both ends of the tested section to
monitor the pressure, then hand over the line to GGL
representative.
60. Reinstate all materials fittings, piping etc, that were
repositioned for the purpose of the test.
61. Ensure all valves on the facilities linked to the pipelines/
flowlines that were closed or opened during the test, are
returned to their position.
62. Clean up all dirt and debris accumulated from the test.
63. Using the Acceptance and Depressurization Checklist double
check that proper reinstatement had been done. Invite the
GGL Site Representative to confirm it .before demobilizing.

Representative.
Field Engr /
Pressure Testing
Technician
Field Engr /
Pressure Testing
Technician

Field Engr/Test
Supvr
Field Engr/
Pressure Testing
Technician
Field Engr/
Pressure Testing
Technician
Field Engr/ Site
Supv.
Field Engr/ Site
Supv.
Field Engr/ Site
Supv.
Field Engr/ Site
Supv.

14.0 DOCUMENTATION
Records of all parameters mentioned in this procedure shall be kept during each operation.
Hydrostatic pressure test records shall be reviewed by GGL in the beginning, at the end and
at least once during the test.
The ENIKKOM CONSTRUCTION LIMITED Representative shall sign every recorder chart before
and after placing it on the recorder. For recorder charts taken during the hydrostatic
pressure, the GGL Representative shall sign them.
Upon successful completion of the test a Hydrostatic Test Certificate shall be completed
and signed by both the ENIKKOM CONSTRUCTION LIMITED and GGL representatives
(ECL/GGL) and backed up by original hand written test data of which photocopies is given to
the GGL representative.
A comprehensive hydrostatic report with general introduction including all relevant pipeline
data, and detailing shall be compiled for each test section and submitted to GGL. The
contents of this report, as a minimum, shall include all documents highlighted.14.0
Attachment.

15.0 ATTACHMENT

S. #

Description

Reference

1.

Pigging Record

Attachment # 01

2.

Line Filling Log

Attachment # 02

3.

Pressurizing Report

Attachment # 03

4.

Hydro Test Report

Attachment # 04

5.

Hydro Test Certificate

Attachment # 05

6.

Schematic of Test Section

Attachment # 06

7.

Pressure/Temperature Recorder Charts

Attachment # 07

8.

Calibration Record

Attachment # 08

9.

Gauge Plate Photographic Record

Attachment # 09

10.

Check List

Attachment # 10

ATTACHMENT 1.0
REPORT NO: ECL/HT/0005/01
ENIKKOM CONSTRUCTION LIMITED
PIGGING RECORD
PROJECT:LAYING OF NATURAL GAS PIPE LINE NIPCO II TEST
DATE:10/05/2016
PIPE DATA

Pipeline Identification: 4DIA PIPELINE AT NIPCO LAND FROM (CH 0+ 0.00) TO (CH 0+158.46).
Pipe Diameter:4.5 Grade. W.T.:6.4mm Length:158m..
Location: NIPCO LAND
Activity/PhasePHASE II
PIG DATA

S/
N

DATE

10/5/16

PIG
TYPE
M.
Density
foam Pig.

PIG
LAUNCH
TIME

PIG
RECEIV
E TIME

PEAK
PRESSU
RE

14:45HRS

14:56H
R

2.0SSBA
R

ARRIVA
L
CONDIT
ION OF
PIG
Okay

VOLUME
OF
FOREIGN
MATERIAL
DISCHARG
E WITH PIG
Clean Water.

Propelling medium:WATER
REMARKS
OKAY
For ENIKKOM CONSTRUCTION LIMITED
LIMITED.

For LINKSO NIGERIA

Name
Name.
Sign / Date..
Date

Sign /

For REFLECT ENGINEERING SERVICES LTD.

Name
Sign / Date..

ATTACHMENT 2.0
REPORT NO; ECL/HT/0005/02
ENIKKOM CONSTRUCTION LIMITED
LINE FILLING LOG

Project: LAYING OF NATURAL GAS PIPE LINE NIPCO PHASE II

Pipeline Identification: 4DIA PIPELINE AT NIPCO LAND FROM (CH 0+ 0.00) TO (CH 0+158.46).

Pipe OD:4.5.. Pipe W.T6.4mm. Pipe Length158m.

Estimated pipeline volume (m3):1,281.1 litres.
Type of line-fill waterClean Fresh Water..
Type of line-fill water treatment (if applicable)N/A.
Temperature of line-fill wateroC, Average Temp of Surrounding Soil:oC
DATE

TIME
(hours)
10Min

PUMP
DISCHARGE
PRESSURE (bar)
1.0 Bar

CUMULATIVE WATER
VOLUME PUMPED
(m3)
1,281.1 Litres.

Total Volume
Pumped.

1,281.1 Litres

10/05/16

REMARKS

OKAY

For ENIKKOM CONSTRUCTION LIMITED

LIMITED.

For LINKSO NIGERIA

Name
Name.
Sign / Date..
Date

For REFLECT ENGINEERING SERVICES LTD.

Name
Sign / Date..

Sign /

ATTACHMENT 3.0
REPORT NO; ECL/HT/0005/03
ENIKKOM CONSTRUCTION LIMITED
HYDROTESTING
Sheet 1 of 2
Project:LAYING OF NATURAL GAS PIPELINE, NIPCO PHASE II
Pipeline Identification: 4DIA PIPELINE AT NIPCO LAND FROM (CH 0+ 0.00) TO (CH 0+158.).
Pipe OD:4.5.. Pipe W.T6.4mm. Pipe Length95m..
Date of Hydro testing:08/05/16.....................................................
Initial Pipe Temperature at Pressurizing.34.3 oC, Time..15:16h
Initial Testing Pressure0bar, Final Testing Pressure.147.bar.
Pipe Temperature at 80% of Pressure.37.5 oC, Time.h.
Air Content..Nil..% of the line volume,
Test Pressure:147..bar
STRENGHT TEST

10/05/16

TIME
(hours)
15:13 15:14

PIPELINE PRESS.
(bar)
0 - 35

PIPELINE GUAGETEMP.
(o
C)
31.8

10/05/16

15MINS HOLD FOR

OBSERVATION DOWN
TO 15:29HRS.
15:30 15:31

35-104

33.0

15MINS HOLD TO
15:50HRS.
15:50 15:51

104 140.5

33.0

10 MINS HOLD TO
16:05HRS.
16:03 16:04

140.5 - 148

32.1

DATE

10/05/16

10/05/16
60MINS HOLD TO
17:06HR

VISUAL INSPECTION
(Carried out at 80% of the strength test pressure)
Pipe Temperature at 80% of Test Pressure32.1 oC, Time15:51.. h
Result:
OKAY
.....
..
Sheet 2 of 2
LEAK TIGHTNESS TEST

DATE

TIME
(hours
)

P.PRESS.
GUAGE
@RECO
RDER
SIDE
(bar)

P.PRESS.
GUAGE
2
@RECO
RDER
SIDE
(bar)

GUAGE
PIPELIN
E TEMP.
( oC)

SURF
SOIL
INFRARE
D TEMP.
( oC)

AIR
INFRARED
TEMP.
( oC)

REMARK

10/5/16
10/5/16
10/5/16
10/5/16
10/5/16
10/5/16
10/5/16
11/5/16
11/5/16
11/5/16
11/5/16
11/5/16
11/5/16
11/5/16
11/5/16
11/5/16
11/5/16
11/5/16
11/5/16
11/5/16
11/5/16

17:06
18:06
19:06
20:06
21:06
22:06
23:06
00:06
01:06
02:06
03:06
04:06
05:06
06:06
07:06
08:06
09:06
10:06
11:06
12:06
13:06

148

148.5

148
147
147
146

148.2
147
147
146.5

145.2
144
144

145.5

144
144

144.5
144.5
144.5

144

143.5
143
142
141.5
141.6

142
142.3
144

144.5
145

30.4
28.2
27.2
26.0
24.8
23.5
22.0
21.5
21.5
1.5
21.0
21.0
22.0
22.0
22.5
26.8
30.2
33.8
35.2
39.0

145
144.5

144
144
143
142
142
142
143
144.5
145.0

26.6
25.9
25.7
25.0
23.9
23.2
22.1
22.2
22.0
21.7
21.5
21.5
20.8
20.4
23.8
24.0
32.1
34.5
39.0
39.4

25.7
25.6
24.5
24.0
22.7
22.6
20.2
19.8
19.6
19.5
19.5
19.3
19.0
19.1
22.7
30.0
28.2
28.8
29.5
32.2

11/5/16
11/5/16
11/5/16
11/5/16

COMMENT(S)

For ENIKKOM CONSTRUCTION LIMITED

LIMITED

For LINKSO NIGERIA

Name
Name.
Sign / Date..
Date
For REFLECT ENGINEERING SERVICES LTD
Name
Sign / Date..
ATTACHMENT 5.0
REPORT NO; ECL/HT/0003/05

Sign /

ENIKKOM CONSTRUCTION LIMITED

DEWATERING RECORD
Project:LAYING OF NATURAL GAS PIPELINE, NIPCO PAHSE II
Date :27 & 28 05 - 2016.....................................................
PIPE DATA
Pipeline Identification: 12DIA FROM SHAGAMU INTERCHANGE (KP27+972.20) TO CDK
(KP29+38.70).
Pipe OD:12.. Pipe W.T9.53mm. Pipe Length1.066Km..
Location. SHAGUMU INTERCHANGE. Activity/Phase.Phase II.

S/N
1

DATE
27/06/1
6

2&3
27/06/1
6
28/06/1
6

4
5

28/06/1
6
6

28/06/1
6

7&8
28/06/1
6

PIG
LAUNCH
TIME
20:23

PIG
RECEIVE
TIME
20:40

PEAK
PRESSUR
E(Bar)
2.7

ARRIVAL
CONDITION OF
PIG
Okay with
Much Water.

M.D Foam
Pig.

21:25

21:34

1.2

Little Water.

M.D Foam
Pig.

10:36

10:42

0.7

Okay with No
Water.

Coated
Foam Pig.

11:09

11:15

0.5

Okay with No
Water

M.D Foam
Pig.

13:12

13:20

1.0

No Water.

M.D Foam
Pig.

14:58

15:07

0.8

No Water.

PIG TYPE
Coated
Form Pig.

Propelling medium ..AIR..

REMARKS

.
For ENIKKOM CONSTRUCTION LIMITED
LIMITED
Name
Name.

For LINKSO NIGERIA

Sign / Date..
Date

Sign /

For REFLECT ENGINEERING SERVICES LTD

Name
Sign / Date..
ATTACHEMNT 6.0
ENIKKOM CONSTRUCTION LIMITED
HYDROTEST CERTIFICATE
ProjectLAYING OF NATURAL; GAS PIPELINE, NIPCO PHASE II
ClientNIPCO PLC
Contract No:
Location: SHAGAMU INTERCHANGE.

THIS IS TO CERTIFY
That the pipeline or flow line section described in this certificate was pressure tested in
accordance with the terms of the following Specifications:
Specification: 12 X 1.066 Km (CLASS 1 ASME B31.8)
Pipeline identification: 12DIA FROM SHAGAMU INTERCHANGE (KP27+972.20) TO CDK
(KP29+38.70)
Testing Location: SHAGAMU INTERCHANGE.
Pipe OD (mm): 323.85

Pipe W.T. (mm): 9.53

Pipe length (m):1066

Nominal Test Pressure (bars): 147

Final test pressure at testing location (bar): 147
Reference Pressuring Report No: ECL/HT/0003/03
Reference Hydro test Report No: ECL/HT/0003/04
Description and reasons of leaks: NIL
Residual pressure inside pipeline upon test operations (bar): 147.
Final Result:
For ENIKKOM CONSTRUCTION LIMITED

For LINKSO NIGERIA LINITED.

Name
Name.
Sign / Date..
Date..

Sign /

For REFLECT ENGINEERING SERVICES LTD

Name
Sign / Date..
ATTACHMENT 7.0
PRESSURE / TEMPERATURE RECORDER CHART

ATTACHMENT 8.0
HYDROTEST INSTRUMENTS CALIBRATION RECORD
S/N

EQUIPMENT DESCRIPTION

MODEL/
SERIAL NO

CALIBRATION
DATE

EXPIRY
DATE

EQUIPMENT
RECALL DATE FOR
RECALIBRATION

Note: This record sheet shall be completed when all instruments to be used for hydro test of the
pipelines / flow lines have
been duly calibrated.
ATTACHMENT 9.0
ENIKKOM CONSTRUCTION LIMITED
GGL 12 X 50KM GAS PIPELINE PROJECT
GAUGE PLATE PHOTOGRAPHIC RECORD
S/N

PHOTOGRAPH
DESCRIPTION

PHOTOGRAPH
NO

PHOTOGRAPH
DATE

GAUGE PLATE
DIAMETER/
THICKNESS

REMARK

REC