INSPECTION REPORT FOR BLOWING/JOINTING PIT

UPGRADATION OF METERING SKID

OWNER : ONGCLSTK CONTRACTOR : DANIEL MEASUREMENT SOLUTIONS PVT LTD.CONTRACTOR : SAVAIR ENERGY LTD

Job Procedure for

HYDROTESTING

Procedure No. SEL/9031/ML/JP/01

SEL Savair Energy LtdMLMain LineJPJob Procedure

RevDateDescriptionPrepared BySELChecked and approved bySELReviewed and approved byDaniel0

For Review and approvalHP

MD

Contents

S.N.Description:Page No.

1.Purpose3

2.Scope3

3.Reference4

4.Methodology4

5.Inspection & Test Plan (Enclosed)6.Inspection report Format (Enclosed)

PURPOSE

The purpose of this procedure is to lay down guidelines and requirements and to establish a method or a system to control the hydrostatic testing of Upgradation of metering system.

SCOPE

The purpose of this procedure is to define the methodology for cleaninghydrotest and dewatering of the 8, 10,12 & 16 dia Skid fabricated and installed for ONGC.

3.0REFERENCESFollowing documents in part or in totality shall form the reference documents.

ASME B 31.8

4.0 METHODOLOGY

Details of the test section shall be illustrated in the Hydrotest pack, which shall be prepared for each test section and submitted to EIL prior to commencement of the test.A calculated / predetermined length of pipeline shall be selected for the hydrotest based on elevation, availability of water and location of stations. Graph showing the elevation of the complete test section shall be drawn prior to start of the test and enclosed in the hydrotest pack. However max. Length of thetest section shall not exceed 50 Km.

Hydrotesting of mainline shall exclude valves at tap-off stations, terminals, pump stations, SV stations and scrapper station facilities.

Prior to any hydrostatic test, EIL shall be notified in advance and the hydrotest shall commence only after obtaining signature on part A & B of the Pipe Book and after mechanical clearance (Appendix 2 & 3).

The Equipment / Instruments to be used for performing the work shall include, but not limited to the following:

Pigs for filling, cleaning and gauging: cleaning pigs with steel wire brushes.Four cup batching pigs.Gauging pig with gauge plate diameter equal to 95% of heavy wall pipe section.Filling pump with differential head 20% greater than the maximum required and a flow rate preferably between 400m/h to 1000 m/h.Positive displacement pump equipped with a stroke counter and capable of exceeding the maximum test pressure by at least 20 bar.Positive displacement meters to measure the volume of water used for filling the line having valid calibration certificate.Portable tank of sufficient size to provide continuous supply of water to the pump during pressurization.Bourdon pressure gauges of suitable pressure range and accuracy with valid calibration certificate.Dead weight tester with an accuracy of 0.01 bar, measuring in increments of 0.05 bar and with a valid calibration certificate.Temperature recorders with valid calibration certificate.Thermocouples with valid calibration certificate.

Laboratory thermometers 0C to 60C range and accuracy 0.1C.Measuring cylinder to check quantity of water during air volume calculation.Injection facilities to inject additives in the test medium in the required proportion.

Communication equipment suitable for continuous connection between the two ends.Temporary test headers fabricated in conformity with ASME section VIII, division 2 with particular reference to appendix 18 and 19 having sufficient length of accommodate the required number of pigs. The header shall also have provision for pig stopper.Piping and valve arrangement for launching and receiving of pigs independently.All measuring / recording instruments shall meet the specification requirements of the contract.

TEST MEDIUM

Cleaning, filling and hydrotesting shall be performed using soft non-aggressive water, free from sand and silt withdrawn from a suitable source in the pipeline route. The water shall be filtered and shall not be contaminated. The water shall be tested in an approved lab for its non-aggressiveness and suitability for using as the test medium. The test report shall be submitted to EIL for review. On the basis of water test report and manufactures / laboratorys recommendations, the required quantity of corrosion inhibitor, oxygen scavenger, bacterisides etc. shall be added to the test medium with prior approval from EIL.

TEST PRESSURE

The pipeline shall be Hydrostatically tested to a minimum pressure of 1.50 times the maximum operating pressure, or 1.4 times of design pressure that pressure which will induce a hoop stress of 90% of the SMYS of the pipeline material in the system / section under test, At lowest point test pressure as calculated in accordance with above, shall be the max. Pressure at the highest point in the section under test. The highest point of the test section shall be subjected to the minimum test pressure as described above, and the maximum test pressure at the lowest point shall not exceed the one resulting in a hoop stress corresponding to 90% of SMYS of pipe material based on the minimum wall thickness in the test section.

If any section comprises of both normal & heavy wall thickness pipe, this section shall be tested at the test pressure of normal wall thickness pipe.

Cleaning & Guaging of the Pipeline Test Section

Prior to starting the cleaning operation, the safety checklist illustrated in APPENDIX 4 shall be filled up.

The cleaning operations shall be performed by propelling air driven pigs provided with spring loaded brushes and Chisels with full diameter circular brush having O.D. minimum 5 mm more than the I.D. of pipe to remove all mill scale, rust / sand from the internal of the pipe sections.

The number of pigs run shall depend on the subsequent cleaning results.

After acceptance of air cleaning , the test section shall be flushed using uninhibited water equivalent to 10% of the total volume of the test section driven by a four cup cleaning pigs to remove mud, dirt, debris and any other extraneous material. The cleaning shall be considered to be acceptable when no relevant extraneous material are found in front of the last four cup pig.

After acceptance of the cleaning, a Guaging pig fitted with a guage plate made of 10mm thick commercial aluminium plate shall be propelled between the temporary test heads. A column of clean water shall be pumped in front of the pig for lubrication and to flush out the remaining dirt inside the test section.

Tracking arrangement shall be provided in the first pig or in case any of the cleaning / gauging pig gets stuck inside the test section a second pig fitted with a tracking arrangements shall be propelled and it shall be tracked upto the point of fault.

The results of the gauge pig run shall be analyzed to evaluate the internal status of the pipeline and the gauge plate shall be jointly signed by CIPL and EIL/GAIL representative. A deformed, bent of severelly nicked plate or damaged pig shall be evidence of gauging pig run failure and the same shall not be acceptable. In such cases CIPL shall repair and rectify the line and repeat the the gauging pig run to the satisfaction of EIL/GAIL.

The sample calculation for gauging late sizing is as per EIL / GAIL.

After acceptance of gauging operation by EIL / GAIL, a photograph of the gauge plate shall be taken and attached with the gauging report.Photographs shall be taken prior to launch and after receipt with all details written on the gauge plate is Test Section No.________________ From Km____________ Joint No._________.Date & Time of launching__________and Gauge plate OD & thk.

The parameters of cleaning & gauging operations shall be recorded every 30 minutes in the formats enclosed in APPENDIX-5 & APPENDIX-6 respectively.

Test Section Filling

On acceptance of Gauging, the air pigging headers shall be cut and the temporary test heads, already pretested at a pressure resulting in a hoop stress corresponding to 90% of SMYS shall be welded to the test section.

The hydrotest report of the temporary test headers shall be submitted to EIL prior to start of welding the test header to the test section.

The filling end test header shall be pre loaded with min. three numbers of four cup batching pigs.

The filling operation shall begin with pumping un-inhibited water equal to 10% of the volume of the test section in front of the first pig.

First Pig : Pumping uninhibited water equal to 11/2 Km pipe length behind the pig shall launch the first pig. The water column before and after this pig shall act as cushion to control the movement of the filling pig and hence minimize air entrapmentSecond pig: Pumping in the actual line filling inhibited water behind the pig shall launch the second pig.

The filling shall continue till the second pig reaches the other end of the test section and the pressure at the test end rises to the static head.

Required quantity of corrosion inhibitor shall be injected during the filling operation through any of the nozzles provided on the test header or into the break tank. The quantity of inhibitor shall be controlled by adjusting the flow rate of the dosing pump..

The dosing rate shall be as described in the following paragraph.

During the whole filling operation the values at the receiving end test headers shall be throttled suitably to maintain adequate back pressure and thus control the pig movement.The first two columns of water shall be drained out from the receiving end.

The different parameters, during filling operation shall be recorded in once every thirty minutes in the prescribed format enclosed in APPENDIX 7.

Dosing Rate

The dosing rate shall be

750 ppm for fresh fill water60 ppm for reuse of already dosed water. ( In case of water transfer from one test section to another) and also manufacturers report shall be followed.

i.e., the fill water for the first test section shall be dosed at a rate of 750ppm and there after during transferring the water from one section to the next an additional 60ppm shall be added to the water which is to be reused, and if it is required to add fresh water ( in case of a longer test section than the previous) then, the volume of fresh water shall be dosed at a rate of 750ppm.

Note: Dosing rate are to be confirmed before start of hydro test the above dosage are tentative only.

Thermal Stabilization

Once the test section has been completely filled and a minimum pressure of 1 bar has been achieved at the highest point, the thermal stabilization period shall be started. Temperature probes shall be installed to measure the pipe and soil temperature at every 2.5 Km. of the pipeline spacing msy be increased to max. 5 kms depending upon the terrain and nature of subsoil along the alignment of the test section. . Also one probe each shall be installed at five hundred meters from both the test heads.

The probe for 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 pipe. The soil probe shall be poked into the earth adjacent to the pipe.

The temperature reading shall be taken at two-hour intervals with a calibrated digital temperature read out unit one decimal place and thermal stabilization shall be considered to have been achieved when a difference not higher than 1C is attained between the average values of the last two readings of pipeline temp. The temperature readings shall be recorded in the format enclosed in APPENDIX-8.

Digital Thermo meterInsulating Coating

Soil Temp. TermocoupleGroundLevel

A

Pipe WallViewVIEW A

Thermocouple Attached to Pipe Wall by Quick Setting EpoxyFIGURE - 1

After completion and acceptance of hydrotesting, thermocouples shall be removed and the corresponding coating shall be repaired as per approved coating repair procedure.

Pressurization

Operational Steps:

Mobilize high-pressure pump and test equipment at pressurization area. Install one pressure gauge in parallel with the dead weight tester.

Fill out and sign pipeline pre-pressurization safety checklist. APPENDIX-9.

As soon as the temperature stabilization is achieved, the pressure shall be raised at a moderate and constant rate not exceeding 2 bar per minute.

The parameters (Volume required) during pressurization shall be recorded throughout the cycle in the format enclosed in the APPENDIX 10 as follows:Each 5 bar increments upto 80% of the test pressure as recorded by dead weight tester.Each 2 bar increments between 80% to 90% of the test pressure as recorded by dead weight tester.Each 0.2 bar increment between 90% to full test pressure as recorded by dead weight tester.

The pressurization shall be cycled with the sequence shown in the following pressure sequence.

Pressurize to 50% of test pressure, hold pressure for one hour,and perform air volume test and drop pressure to static head.

Pressurize to 75% of test pressure, hold pressure for one hour, and perform air volume test and drop pressure to static head.

Pressurize to test pressure, perform air volume test and raise pressure to the test pressure once again.

In case, during the hold period indicated above, a decrease in pressure is observed, the above operation shall not be repeated more than twice, after which the line shall not be considered capable of test, until the cause for the lack of water tightness is eliminated.

Air Volume Calculation

In order to check the pressure of air in the pipeline two separate consecutive pressures lowering of 0.5 bar by slowly bleeding water from the test section shall be carried out during all the pressurizing cycling as mentioned above. The water drained during the second lowering shall be accurately measured (V1). This quantity measured shall be compared to the theoretical quantity (Vp) corresponding to the pressure lowering. The air volume shall be acceptable if Vi /Cp< 1.06. The observation shall be recorded in the air volume calculation format enclosed in APPENDIX 11.

24 Hour Hold Period

The pressure shall be considered to be stabilized when no fluctuation is observed in the pipeline pressure as seen from the dead weight tester. On achieving pressure stablization, pressure pump connections shall be removed and the test section completely isolated and all connections at the test heads shall be checked for leakages. Pressure recorders shall than be started with the chart in real time orientation and the 24 hour pressure hold period shall start.During the pressure hold period the following data shall be recorded in the format enclosed in APPENDIX-12.

Every one-hour pressure measurement from dead weight tester.Every two hours the ambient temperature, pipe and soil temperature from the thermocouples.

Throughout the hold period, care shall be taken that the maximum test pressure is not exceeded. Should it become necessary to de-pressurize, the volume of test medium bleed off shall be measured and recorded.

Acceptance Criteria

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.

The pressure change value as a function of temperature change shall be algebraically added to the pressure value as read on the meters. The pressure value thus adjusted shall be compared with the initial value and the test shall be considered as acceptable if difference is less than or equal to 0.3 bar.

For calculating the pressure change due to change in temperature the formula and data illustrated in APPENDIX-13 shall be used.

On successful completion and acceptance of the hydrotest, the pipeline shall be slowly depressurized at a moderate and constant rate.

Leaks

If during the pressurization period or during the test periods any defects are observed, these shall be eliminated.

If any leaks are observed the section shall be initially visually inspected to check the eventual leaking point. If this check is negative, then the procedure described below shall be followed. No work shall be carried out to repair leaks until the

pressure has been reduced to a safe pressure (i.e. static head plus 1 kg) and the water drained.

Leak Detection

To locate buried leaking pipe, the following procedure by elimination shall be followed:

To cut the section in an intermediate positionTo insert two test headsTo re flood the sectionsTo pressurize the two sectionsTo determine the faulty section

This procedure shall be applied until the determination of the defect. As soon as the defect has been located and repaired, the test section shall be tested again.

If the test section fails to maintain the specified test pressure after isolation ,CIPL shall determine by search the location of leakage or failure. All leaks and failure within the pipe-wall or weld seams shall be repaired by replacement of entire joint or joints in which leakage or failure occurs. CIPL shall comply with instruction EIL/GAIL whether to replace a section of the line-pipe that includes the leak or whether to repair the circumferential weld. The repair shall however meet the requirements of EIL spec. 6-77-06. After completion of repairs, the hydrostatic test shall be repeated.CIPL shall haul and stockpile all damaged and defective pipes to storage location designated by EIL/GAIL. All cracks and splits resulting from failure shall be coated with an application of grease to preserve the characteristics of failure from corrosion. Joint of failed pipes shall be marked with paint, with a tag indicating failure details, date and location of failure and pressure at which failure occurred.

Pipeline Bulk Dewatering

Written permission shall be obtained from EIL / GAIL for obtaining the dewatering clearence. Upon successful completion of the hydrotest, propelling the third pig in the test header shall dewater the section. Making suitable drains shall make necessary arrangements for safe disposal of hydrotest water.Dewatering shall start after getting clearance from EIL / GAIL and the water shall be transferred to the next section wherever required.

The dewatering shall be carried out by using four-cup pigs and foam pigs driven by compressed air. The dewatering shall be done in such a way as to provide adequate control of pigs during dewatering by keeping air pressure 2 bar minimum. Pigs and equipment required for dewatering shall be approved by EIL in advance. Four-cup pigs shall first be passed through the line to displace the water. Foam

pigs shall then be passed in order to complete the line dewatering. The line shall be considered dewatered when a negligible amount of water is flushed out by the last foam pig.

During dewatering care shall be taken to properly dispose the the discharging water in order to avoid pollution, damages to fields under cultivation and or existing structures and interference with the traffic.

Upon completion of the testing and dewatering operation, any provisional traps for pigs and all other temporary installation relating to the test shall be removed. Subsequently the individual sections of the line already tested shall be joined in accordance with the requirements of relevant specifications issued for the purpose.

The line pressure during dewatering operation shall be recorded every 30 minutes in the format enclosed in APPENDIX-15.

Once dewatering is over, the sectionalizing valve and other valve assemblies shall be installed at the respective locations is accordance with the relevant procedures and specifications. All thermocouples installed in the pipeline shall be removed and corrosion coating shall be repaired wherever required using approved procedure and materials.

If it is required to preserve the pipeline for a specified duration, sufficient quantity of approved corrosion inhibitors depending upon the quality of water, duration of preservation and laboratory test reports, shall be injected into the pipeline as per the direction of EIL and the pressure shall be raised to the required level as mutually agreed upon with EIL/GAIL at a later stage.Subsequent to dewatering, the SV installation followed by final tie-in between the tested sections shall be taken up.

7.HEALTH, SAFETY & ENVIRONMENT

The approved procedure of Health, Safety & Environment shall be followed during the execution.

The hazards associated with the hydrotest have been identified and the following guidelines are suggested for implementation of safety norms.

Provisions shall be made for the installation of no admittance signs to unauthorized personnel from the road to the R.O.W. at critical locations.

Warning signs in English and Local Language stating Pipeline Under test keep off shall be placed in locations where the pipeline is uncovered, and particularly where the temporary headers and stations are located. Such areas shall be

suitably fenced in such a way as prevent access of unauthorized personnel. No unauthorized personnel shall be closer than 40m to the pipeline under test.

Only authorized personnel as defined /identified by the Hydrotest Engineer shall be allowed within the test area when the test section is under pressure. No test activities are in progress with out specific clearance of testing Engineer. When test equipments shall be installed in compliance with methods and suitable instructions only, this may not cause any injury to personnel.

All instruments shall be placed in such a location as to prevent it from being affected by a personnel in the test head.

No leak on the pipe or test equipment shall be allowed whislt under pressure except for tightning of flanges, the removal of connections after closing the valves, and the blinding of ports after achieving the test pressure for isolation of the test station.

No flexible hoses are permissible inside the test cabin, except for essential connection to the instruments.

For effective communication, a wireless and a walkie talkie system shall be used.

QUALITY ASSURANCE & QUALITY CONTROL

The quality assurance and quality control for the project procurement shall be carried out by strictly implementing the following:

Inspections and Test Plan.

Quality Records

The type of inspection activity and quality records generated during the activity is detailed in Inspection and Test Plan. Quality records shall include current calibration certificates for all measuring instruments.

The overall tentative layout of equipment & instruments for pigging hydrostatic testing is shown through Appendix - 16

9.0APPENDICES /FORMATSAppendices 1 to 19 enclosed.Note:- Incase of any conflict between this procedure and the contract specification, .the later shall govern.

DOC.NO.REV.NO. 1APPENDIX - 1INSPECTION & TEST PLAN FOR HYDROSTATIC TESTINGSl.NoActivityInsp.ByCIPLVerifi.By.EILDocument to be submitted by CIPLRemarks1Approval of Procedure & Test DiagramWATest Pack

2Pre Hydrotest Check ListWW

3Mechanical Clearance of the Pipe SectionHAPipe Book, Part-A & B

4Submission Calibration CertificatesHRCertificates

5Submission of Water Test Report and Dosing RecommendationHRTest Report

6Install all Temporary Piping equipmentWRMTest diagram

7Ensuring Communication SystemWRM

8Ensuring Safety RequirementsWW

9Cleaning/GaugingWWInspection report

10Installation of Temp. SensorsHW

11FlushingHWInspection report

12Installation of Temporary Headers With PigsHRMHydrotest report of test headers.

13Filling Rate Dosing rateBack pressure ControlWWWRMRMRMInspection report

14Thermal StabilizationHWInspection report

15Air Volume CalculationHWInspection report

16Pressurization RateLog of Temp.and PressureBleed off water MeasurementWWWRMRMWInspection report

17Leak Detection & Test ExtensionWW

18Rectification & Stocking / Marking of Damaged PipeWW

19Acceptance & evaluation of record dataWWInspection report

20Depressurization & Dewatering to the Accept PointWWInspection report

21Repair of PE coating at repairing temp. Sensors fixing pointWW

LEGEND:A ACCEPTANCE/APPROVAL H HOLD W WITNESS INSPECTIONRM RANDOM INSPECTION R REVIEW OF DOCUMENTSCIPLEILGAILSIGN:SIGN:SIGN:NAME:NAME:NAME:DATE:DATE:DATE:

DOC.NO.REV.NO.0APPENDIX 2

INSPECTION REPORT FOR TEST PLAN FOR POST HYDROSTATC TESTINGLine Dia: 20 inch

Section No:From 35.325 (KM) To 35.521(KM)

Joint No:From35/M23(KM) To 35/FT37(KM)

O.DWall ThickNormal I.D(mm)Length(Mtrs)Avg.Wall(MM)VolumePer Mtrs(m)TotalVolume(m)Test pressure(kg/cm2)

Min.Max.508 mm11.1mm 485.8 196.150 11.10.1853 36.339 139.91

Total length

Note: 1. Length of test headers to be included2.Test pressure shall be as per min. wall thick of pipe in the section.3.strike on which ever applicable.Length of Total section -200 mtrs

Test PressureGENERAL DATAWater Source ________Fill pump location Km___Test station location Km.Location of Temp.Major submersed Crossing included:

STARTENDHIGHLOW

ChainageKM35/M23KM35/FT37KM35/M23KM35/M28

Elevation (M) 216.213 215.483 216.213 204.783

Pressure (kg/cm2) 142.0 142.07 142.0 143.12

Imt H2O = 0.0980665 Kg/cm2(g)% OF TEST PRESSURE

5075100

Pressure Sequence (kg/cm2) 71 106.5 142

Approx. Water to increase Pressure By 2 Bar/Min (Lt./Min)Approx. Water to pressure low 0.5 (Ltrs)Approx pressure change as a function Temp. Change (Bar/C)

ELEVATION(Mtrs).(A Sketch showing elevations Vs Km (Chainage ) to be enclosedChainage (Km)From KM35/m23 to KM 35/FT37Fill DirectionDADRI SIDE KM35-M23Dewatering direction BAWANA SIDE KM35/FT37REMARKS:FOR CIPL FOR EIL/GAIL SignSign NameNameDateDate

DOC.NO.REV.NO.1APPENDIX - 3

CERTIFICATE OF MECHANICAL & CONSTRUCTION COMPLETION FOR P/ L

Line Dia:From(Km) (To)(Km)

Section No.:From(Km) (To)(Km)

Joint No.:From(Km) (To)(Km)

O.D(INCH)WALL THK (MM)I.D (MM)GRADE API 5LGR.X - 60Length ___________(Km)

Min:Min:

Volume ___________(M3)

Max:Max:

Wall Thickness(mm)Length (Mtr)Number of Welds:____________________

Length of not backfilled section:

CONSTRUCTION

Start Date:

End Date:

THIS IS CERTIFY THAT ALL WELDS OF THE ABOVE TEST SECTION HAVE BEEN ACCEPTED AND THE PIPELINE SECTION HAS BEEN LAID AND BACKFILLED ACCORDING TO THE SPECIFICATIONS.ALL ACTIVITIES UPTO PART B OF PIPE BOOK IS COMPLETED AND CERTIFIED.

REMARKS:

FOR CIPLFOR EILFOR GAILSignSignSignNameNameNameDateDateDate

DOC.NO.REV.NO.1APPENDIX 4

CHECK LIST FOR CLEANING, GAUGING AND FILLING

S.NoSAFETY CHECK LISTYESNO1Is a copy of the approved hydrotest procedure available in the area.

2Is a copy of the hydrotest pack available in the area.

3Is adequate water disposal arrangement made.

4Check House keeping standards are acceptable at the filling end and receiving end.

5Check the conditions of the tools and tackles to be used

6Check that the lighting arrangements are adequate and the condition of the electrical wiring, circuit boards, conduit etc.are acceptable and safe.

7Check that test areas at each end of the test section have ben cordoned off with stakes and bunting tape.

8Check that emergency equipment are adequate and are working condition standby vehicle, communication system first aid boxes, medical facilities, stretcher etc.

Note: Hydrotest engineer / HSE officer to add any other safety points to this list as per the site circumstances if deemed necessary.

HYDROTEST ENGINEERHSE OFFICEREILSign:Sign:Sign:Name:Name:Name:Date:Date:Date:

DOC.NO:REV.NO : 1APPENDIX - 5

INSPECTION REPORT FOR AIR CLEANING

Line Dia:From(KM) To(KM)

Section No.:From(KM) To(KM)

Joint No:From(KM) To(KM)

O.D (INCH)WALL THK(MM)I.D (MM)GRADE API 5L GR.X 60Length_________(KM)

Min:Min:

Volume__________(M3)

Max:Max:

CompressorLocation____________Make_______Model_________

Cut out_____________Max.Pressure____________

Piping Direction From___________(KM)To__________(KM)

Run NoPig TypeStartEndAvg.ValKm/HrPressure(Kg/Cm2)Quantity of Debris(In Kg).

DateTimeDateTime

Min.Max.

REMARKS

ACCEPTANCE OF SECTION CLEANING :YES / NO

FOR CIPLFOR EILFOR GAILSignSignSignNameNameNameDateDateDate

DOC.NO:REV.NO:1APPENDIX - 6

INSPECTION REPORT FOR GAUGING

Line Dia:From(KM) To(KM)

Section No:From(KM) To(KM)

Joint No.:From(KM) To(KM)

O.D (INCH)WALL THK. (MM)I.D (MM)GRADEAPI-5LGR.X-60Length _______(km)

Min:Min:

Volume_______(M3)

Max:Max:

CompressorLocationMakeModelOut PutMax.Pressure

Pigging Direction From(KM).To(KM)

Gauge PlateStartEndAvg.val.Km/HrPressure (kg/cm2)Dia(inch)Thk (mm)MaterialDateTimeDateTime

MinMax

Enclosure: The Photograph of Gauge plate before and after Run

Details of Gauge Plate Damage (if any):

REMARKS:

ACCEPTANCE OF SECTION CLEANING:YES / NO

FOR CIPLFOR EILFOR GAILSign :Sign :Sign :Name :Name :Name :Date :Date :Date :

DOC.NO:REV.NO.1APPENDIX 7

INSPECTION REPORT FOR WATER FILLING

Line Dia:From(KM) To(KM)Section No:From(KM) To(KM)Joint No.:From(KM) To(KM)

O.D (INCH)WALL THK.(MM)I.D (MM)GRADEAPI-5LGR.X-60Length_______(km)

Min:Min:

Volume________(M3)

Max:Max:

Test Medium WaterSourceLocation(Km)Inhibition : Y / NTypeDosageppmTypeDosageppmTypeDosageppm

Fill pumpLocationMakeOutputLtrs/MinMax.Pressurebar

Flow MeterMakeModelSr.No

Filling DirectionFromkmTokmPig SequencePrefilling Length (Mtrs)Volume(m3)

1st Pig Type

Between pig 1 & Pig 2 Length (mtrs)Volume(m3)

2nd Pig TypeTimeFill pressure( Kg/cm2)Flow meter Reading(m3)Volumethis period(m3)Cumulative Volume (m3)Fill water Temperature (c)Remarks

Including pre fillFill volumeAfter Sec.Pig

Reading to be Recorded HourlyFill water temperature to be recorded continuously on Temperature RecorderREMARKS:

ACCEPTANCE OF SECTION CLEANINGFOR CIPLFOR EILFOR GAILSign :Sign :Sign :Name :Name :Name :Date :Date :Date :DOC.NO:REV.NO:1APPENDIX 8

THERMAL STABILISATION

Spread:FromToReport No.SectionNo.FromToDate : FromTo

O.D_______(INCH)WALL Thk. (mm)I.D (mm)Grade API 5LGR. X - 60Length___________(km)

Min:Min:

Volume___________(m3)

Max:Max:

S-1(km)S-2(km)S-3(km)S-4(km)S-5(km)S-6(km)S-7(km)S-8(km)S-9(km)s-10(k )Aver.Soil.TempP-1(km)P-2(km)P-3(km)P-4(km)P-5(km)P-6(km)P-7(km)P-8(km)P-9(km)P-10(km)Aver.Pipe.TempAmbieetTemp.

To be taken at 4 intervalsStabilization be considered to have been achieved when the different between the avg.pipe Temp. and avg. soil Temp. is not higherThan 1 deg. For 2 cinsecutive readings.

Of Section Thermal stabilization: YES / NO

FOR CIPLFOR EILFOR GAILSign :Sign :Sign :Name : Name :Name :Date :Date :Date : DOC.NO:REV.NO:1APPENDIX - 12PRESSURE TEST (24 HOURS HOLD)Line Dia:From(km)To(km)Dead.Wt.Tester:-Make:_________Report No.SectionNo.From(km)To(km)Model:_________Date : Joint No:From(km)To(km)Calibration certificate No:__________Temperature:- Make:________Model:_________Certificate No:________O.D_______(INCH)WALL Thk. (mm)I.D (mm)Grade API 5LGR. X - 60Length___________(km)

Min:Min:

Volume___________(m3)

Max:Max:

S-1(km)S-2(km)S-3(km)S-4(km)S-5(km)S-6(km)S-7(km)S-8(km)S-9(km)s-10(k )Aver.Soil.TempP-1(km)P-2(km)P-3(km)P-4(km)P-5(km)P-6(km)P-7(km)P-8(km)P-9(km)P-10(km)Aver.Pipe.TempAmbieetTemp.

Dead weight tester readings to be recorded hourly, pipe & soil temperatures reading to be recorded at every two hourPressure and ambient temperature to be recorded continuously on recorders.All details of thermocouples, calibration status, certificate No.etc. are to be recorded and enclosed.REMARKS:Acceptance of Test Pressure (24 Hours Hold): Yes / No.FOR CIPLFOR EILFOR GAILSign :Sign :Sign :Name : Name :Name :Date :Date :Date :DOC.NO:REV.NO.1APPENDIX - 9

PRE PRESSURIZATION SAFETY CHECK LIST

S.NOCHECH POINTYESNO1The test section has been isolated from all other pipeline Sections.

2All temporary piping, test heads and other equipment connected to the test section have been pre tested to a pressure of at least 1.25 times the test pressure.

3The test section has been completely filled with water and air vented off.

4All instruments and gauges which are used have valid calibration certificates.

5All warning notices, marker tapes, protective barriers and other safety equipment have been positioned and all the concerned informed.

6All persons who may be affected by the operations are informed of the activity.

7Communication channel is tested and ensured that they are working properly. Backup instruments are available.

8Inform the person operating the pressuring equipment of the maximum test pressure which shall be applied to the test section.

9Joint inspection of the entire facilities by the Hydrotest - Engineer and HSE officer to ensure all the safety measures have been undertake before the test.

HYDROTEST ENGINEERHSE OFFICER(CIPL)EILSign :Sign :Sign :Name:Name :Name:Date :Date :Date :

DOC.NO:REV.NO: 1APPENDIX - 10

PRESSURIZATION

From:Cycle: 50% / 75% / 100Report No:Date:To:Pipeline Dia: 12Test Medium: WaterSection Length:(km)Material: API 5L x 60Theoretical volume:(m3)Wall Thickness: 6.4 / 7.1 mmSource of Water:Elevation/Pressure at :Highest Pt -Pressurizing Pt-Lowest Pt -Receiving Pt-

Sl.NoTime Hrs.Dead Wt.Kg/BarStrokesCountedVolumeM3Cum. VolM3Temp.CRemarks

1.Pressurization Pump:MakeModelVolume2.Dead Weight Tester:MakeModelVolume3.Flow Meter:MakeModelVolume

Notes:

ACCEPTANCE OF CLEANING:

FOR CIPLFOR EILFOR GAILSign :Sign :Sign :Name :Name :Name : Date :Date :Date : DOC.NO:REV.NO:1APPENDIX - 11

AIR VOLUME CALCULATION (50% / 75% / 100% cycle)

Sheet No:From(kms)To(kms)Date

Line Dia:JointNo.FromTo

Section No.:Test Section Length Volume

Air Volume Test carried out at % of test pressure.

Test Station LocationTest Pressure Bar.Date & TimeAvg. Pipe Temp. ( C )S.NoDescriptionDead .Wt.Tester(kg/cm2)Pressure Lowering(kg/cm2)Volume ofwaterRemarks1Initial After First Lowering

2After First Lowering

3After second Lowering

To calculate the theatrical volume of water required to achieve a change in pressure, the volume pressure equation

Vp= (0.0884 Ri/T + A) x 10-6 x Vt x P x KWhere:Vp= Computed water amount required to raise by P the pressure in the section to be tested (m)Vt= Geometrical volume of the section (m)Ri= Nominal inner radium of the pipe (mm)T= Nominal pipe thickness (mm)A = Isothermal compressibility value for water at the pressurization temperature in the P range (bar-1) x 106. Refer graph.P= Pressure Rise (bar)K= A dimensionless coefficient that is equal to a value of 1.02 for longitudinally welded pipe.Therefore Vp= m= LiterActual volume of water drained to drop pressure by 0.5 Kg.= Liter (Vi)Therefore

V1 / Vp= Since the ratio is less than 1.06 the filling is acceptable and the test section may be pressurized to the final test pressure.Remarks

ACCEPTANCE OF SECTION CLEANING

FOR CIPLFOR EILFOR GAILSign :Sign :Sign :Name : Name :Name :Date :Date :Date :

DOC.NO:REV.NO:1APPENDIX - 13

HYDROSTATIC TEST CALCULATIONS

Sheet No:From (km)To (km)Date

Line Dia :Joint No:From To

Section Station LocationTest Section LengthVolume

Test Station LocationTest Pressure (Bar)

Dead .Wt.Tester Make:Certificate No.Model:Date:

Date & Time (Hrs)Dead Weight (Bar)Average pipe Temp.Start of Test

End of Test

Algebic Difference

Calculation of Pressure Change (P) due to change in temperature:

p= (B/ (0.0884 Ri/T + A) TWhere:B= Difference between thermal Expansion of water and steel at temperature and pressure as measured from enclosed table at the end of the test. Ri= Nominal inner radius of pipeT= Nominal wall thickness of pipe A= Algebraic compressibility factor of water T= Algebric difference between water temperature at the beginning and at end of the test (C)

Ri= R1 L1 + R2 L2 __________ L1 + L2

Ti= T1 L1+ T2 L2 __________ L1 + L2A= Isothermal compressibility value of water as estimated at the pressure and temperature values obtained at the end of test (bar 1 ) x 10-6)

REMARKS:

FOR CIPLFOR EILFOR GAILSign :Sign :Sign :Name :Name :Name :Date :Date :Date :DOC.NO:REV.NO:1APPENDIX 14

HYDROTEST EVALUATION REPORT

Report No:Date:Spread : From To

O.D (INCH)Wall Thk. (mm)I.D (mm)Grade API 5L Gr. X 60

Length_________(km)

Min :Min:

Volume________(m3)

Max :Max:

Section No:_______________ From Km ____________ To Km________________OBSERVATION

Initial Test Pressure _____________BarDate & Time ___________________

Final Test Pressure_____________ BarDate & Time____________________Delta P during 24 Hours Hold Period

Initial Pipe Wall Temp ____________ BarDate & Time____________________

Final Pipe Wall Temp_____________BarDate & Time____________________

Delta T During 24 Hours Hold Period

Initial Soil Temp_________________ BarDate & Time____________________

Final Soil Temp_________________ BarDate & Time____________________

Delta T, Soil Temp._____________ Deg.C

Leakage During 24 Hours Hold Period

EVALUATIONDelta P During 24 Hours Hold Period (A)__________________ barAccountable Pressure Loss Due to Temp.B__________________ barUnaccountable Pressure Loss__________________ barAllowable unaccountable pressure Loss__________________ barConclusionTest Acceptable / Un acceptableSection Released for depressurizationREMARKS:

FOR CIPLFOR EILFOR GAILSign :Sign :Sign :Name :Name :Name :Date :Date :Date :

OC.NO:REV.NO:1APPENDIX - 15

INSPECTION REPORT FOR DEWATERING

Report No:

Date: Spread : FromTo

O.D _________(INCH)Wall thick (mm)I.D (mm)GradeAPI 5LGr. X-60Length___________(km)

Min: Min:

Volume____________(m3)

Max:Max:

Compressor:LocationMake

OutputMax.Pressure

Dewatering Direction From Km. To Km

Discharge PointRun No.Type of P/GStartEndAvg.ValKm/HrPressure(Kg/Cm2)Qty of Water(Ltrs)

DateTimeDateTime

MinMax

REMARKS:

ACCEPTANCE OF SECTION DEWATERING: YES/NO

FOR CIPLFOR EILFOR GAILSign :Sign :Sign :Name:Name:Name:Date :Date :Date :DOC.NO:REV.NO:1APPENDIX 16LIST OF ATTACHMENTS TO HYDROSTATIC TEST RECORD

Spread :From To

Spread :From ToO.D___________(INCH)Wall Thk. (mm)I.D (mm)Length_________(Km)

Min :Min:Volume__________(m3)

Max :Max:

1.Test Plan for Hydrotest (Appendix 2)YES/NO

2.Certificate of mechanical and construction completion (Appendix 3)YES/NO

3.Air Cleaning (Appendix 5)YES/NO

4.a.Gauging (Appendix 6)YES/NOb.Photography of Gauge PlateYES/NO

5.a.Water filling (Appendix 7)YES/NOb.Fill Water Temperature ChartsYES/NO

6.Thermal Stabilization (Appendix 8)YES/NO

7.a.Pressurization (Appendix 9)YES/NOb.Pressure records charts(s)YES/NOc.Temperature Recorders ChartsYES/NO

8.Air Volume Calculations (Appendix 13)YES/NO

9.a.24 hours Hold (Appendix 12)YES/NOb.Pressure recorders ChartsYES/NOc.Ambient Temperature Recorder ChartsYES/NO

10.Hydrostatic Test Calculations (Appendix 13)YES/NO

11.Hydrostatic Test Evaluation (Appendix 14)YES/NO

12.Calibration CertificatesYES/NO

13.Dewatering (Appendix 15)YES/NOFOR CIPLFOR EILFOR GAILSign :Sign :Sign :Name:Name:Name :Date :Date :Date :DOC.NO:REV.NO:1APPENDIX 17

INSPECTION REPORT FOR SWABBING

Report No:

Date:

Spread : From To

O.D________(INCH)Wall thick(mm)I.D (mm)GradeAPI-5LGr. X-60Length ______ (Km)

Min:Min:

Volume________(m3)

Max:Max:

Compressor:Location Make

Output Max.Pressure

Swabbing From Km To KmDistancePoint

Section Released for SwabbingYes/No

Water Treatment CarriedYes/No

Type of PigStartEndWt.of.PigAvg.Val.Km/HrPressure(Kg/cm2)Remarks

DateTimeDateTimeInitialFinal

ACCEPTANCE OF SECTION SWABBING:YES / NO

FOR CIPLFOR EILFOR GAILSign :Sign :Sign :Name:Name :Name :

APPENDIX 18TENTATIVE LAYOUT OF EQUIPMENT AND INSTRUMENTS FOR HYDROSTATIC TEST

Pressure/Impulse line from test HeaderTemp. GaugeRecorder

Stock CounterDead Wt. TesterGaugeFrom Water Source

BREAK TANK

TEST CABIN

AIR .COMP

Flow MeterAIR COMPRESSORFor BackpressurePUMP SKIDFilling &PressurisingPump

Lines for Pig

Gauge

Temporary Test HeaderTemporary Test Header Receiving End

APPENDIX 19HYDROTEST HEADER

N5 N1 4/6N5 N6 N2 11/2N7 N8 N4 11/2

TENATIVE LAYOUT OF EQUIPMENT AND INSTRUMENTSFOR AIR PIGGING

Pneumatic HoseAIRCOMPRESSOR

GaugeGaugeAir pigging header L . EndAir piggingheader R. End

R Receiving L Launching .