QP.SPC.L.010 R1_Hydrotesting

STANDARDS PUBLICATION

CORPORATE TECHNICAL SPECIFICATION FOR CLEANING, GAUGING AND FLOODING OF

NEW PIPELINES

DOC. NO.: QP-SPC-L-010

(Formerly ES-L-40.1)

REVISION 1

CORPORATE QUALITY & MANAGEMENT SYSTEMS DEPARTMENT

CORPORATE TECHNICAL SPECIFICATION FOR CLEANING, GAUGING AND FLOODING OF NEW PIPELINES Doc. No.: QP-SPC-L-010

Doc. File No.: QP-SPC-L-010 R1 Page 2 of 28 Custodian Dept.: QA

TABLE OF CONTENT

FFFOREWORD…………………………………………….……………………………….…………..3 1.0 OBJECTIVE ....................................................................................................................4

2.0 SCOPE............................................................................................................................4

3.0 APPLICATION ................................................................................................................4

4.0 TERMINOLOGY..............................................................................................................4 4.1 DEFINITIONS .............................................................................................................................4 4.2 ABBREVIATIONS .......................................................................................................................4 5.0 REFERENCE STANDARDS AND SPECIFICATIONS ..................................................5 5.1 NATIONAL /INTERNATIONAL STANDARDS ............................................................................5 5.2 QP STANDARDS........................................................................................................................5 5.3 ORDER OF PRECEDENCE .......................................................................................................5 6.0 REQUIREMENTS FOR CONTRACTORS......................................................................5

7.0 MATERIALS AND EQUIPMENTS..................................................................................6 7.1 GENERAL...................................................................................................................................6 7.2 MATERIALS................................................................................................................................7 7.3 EQUIPMENTS ............................................................................................................................7 7.4 PIGS ...........................................................................................................................................8 7.5 CONSUMABLES & WATER .......................................................................................................9

8.0 CLEANING GUAGING AND FLOODING REQUIREMENTS ......................................11 8.1 OPERATIONAL SEQUENCE ...................................................................................................11 8.2 USE OF APPROVED PROCEDURES & DETAILS ..................................................................12 8.3 PREPARATORY WORK...........................................................................................................13 8.4 CLEANING, GAUGING AND FLOODING.................................................................................13 9.0 ACCEPTANCE CRITERIA ...........................................................................................17 9.1 GENERAL REQUIREMENTS ...................................................................................................17 9.2 CLEANING ACCEPTANCE CRITERIA ....................................................................................17 9.3 GAUGING.................................................................................................................................17 9.4 FLOODING ...............................................................................................................................17 10.0 HSE AND PERMITS REQUIREMENTS .......................................................................18

11.0 QUALITY ASSURANCE...............................................................................................18

12.0 DOCUMENTATION.......................................................................................................19

13.0 APPENDCES 13.1 APPENDIX I - Table 1 - Minimum Gauge plate diameter……………….……………….20 13.2 APPENDIX II - Table 2 - Preservation measures for water filled pipeline…….…..……21 13.3 APPENDIX III -Table 3 - QP approved preservation…………………………..… ……..22 13.4 APPENDIX IV -Table 4 - Contractor check list………………………….………..……….23 13.5 APPENDIX V - Table 5 - Equipment list……………………………………………………25 13.6 APPENDIX VI- Figure 1- Pipeline Pre-Commissioning Sequence…………………….. 27 REVISION HISTORY LOG………………………………………………….……………….…….28

CORPORATE TECHNICAL SPECIFICATION FOR CLEANING, GAUGING AND FLOODING OF NEW PIPELINES

Doc. No.: QP-SPC-L-010 Rev. 1


FOREWORD This document has been developed by Corporate Quality and Management Systems Department, reviewed by Corporate User Departments before endorsed by concerned QP Management for use as Corporate Technical Specification for Cleaning, Gauging and Flooding of New Pipelines. This specification supersedes the existing QP specification no. ES-L-40.1: Cleaning, Filling, Flushing, Gauging and Hydrostatic Pressure Testing of pipeline. This document is published for QP Departments/ Contractors/ Consultants utilisation. It should be emphasised that this document is to be used for QP operations wherever applicable and appropriate. The document in its present form reflects as far as possible the current QP requirements taking into account the known available industry practices and the applicable latest national and international standards. This document will subject to periodical review after endorsement to re-affirm its adequacy or to conform to any changes in the corporate requirements or to include new developments on its subject as captured by International /industry Standards. It is recognized that there will be case where addenda, data sheets, or other clarifications need to be attached to the standard to suit a specific application or service environment. As such, the content of the document shall not be changed or re-edited by any user (QP or its contractors, suppliers, agents, etc.), but any addenda or clarifications entailing major changes shall be brought to the attention of the Custodian Department. The Custodian of this document is Corporate Quality and Management systems Department therefore, all technical comments, views, recommendations, etc on this document should be forward to: Manager Corporate Quality and Management systems Department (QA) Royal Plaza Building, 4th floor, Tel. 4138333 Fax: 4291066 E-mail : [email protected]




1.0 OBJECTIVE The objective of this document is to identify the corporate requirements for cleaning, gauging and flooding of new pipelines.

2.0 SCOPE 2.1 This specification defines the corporate requirements for cleaning, gauging and flooding

of new onshore and offshore carbon steel pipelines, flow-coated, non-flow-coated pipeline, stainless steel pipeline, CRA cladded pipelines and GRE/GRP pipelines, which have been installed onsite and supported accordingly.

2.2 The hydrostatic pressure testing of new pipelines and Piping Station will be address in a different document (QP-SPC-L-011). The pre-commissioning and commissioning of new pipelines will also be covered in another document (QP-SPC-L-012).

2.3 This Specification covers new Pipelines within the State of Qatar for the interest of Qatar Petroleum (QP). It is applicable for pipeline of diameter not more than 48 inch(1200 mm).

3.0 APPLICATION 3.1 This specification is intended for application by QP, their consultants, contractors, sub-

contractors and parties intend to operate new pipelines under QP interest.

3.2 This specification shall be used in conjunction with proper engineering study to address the cleaning, filling, flushing and gauging requirement suitable for the intended new pipeline operating and maintenance scenario which shall be performed prior to utilizing this specification.

4.0 TERMINOLOGY

4.1 DEFINITIONS

Contractor - EPIC Contractor. Consultant - Design Consultant to the EPIC Contractor. Contract - Agreement between QP and the EPIC Contractor. Pinger device - Pig tracking device using pulse of sound for echo sounder. Flow-coated - Pipeline with internal coating with the objective of reducing surface

roughness.

4.2 ABBREVIATIONS

CRA - Corrosion Resistance Alloy. EPIC - Engineering, Procurement, Installation and Commissioning. GRE - Glass fibber-reinforced epoxy. GRP - Glass fibber-reinforced plastic. PH - The negative logarithm (to the base10) of hydrogen ion activity. F.S.D - Full scale deflection QP - Qatar Petroleum.




5.0 REFERENCE STANDARDS AND SPECIFICATIONS Latest edition of the following standards shall apply, unless otherwise amended by this specification.

5.1 NATIONAL /INTERNATIONAL STANDARDS

ANSI/ASME B31.8 - Gas Transmission and Distribution Piping Systems ANSI/ASME B31.4 - Pipeline Transportation System for Liquid Hydrocarbon and

Other Liquids. API 1104 - Welding of Pipelines and Related Facilities- ASME Section VIII - Section VIII Division 1 Rules for Construction of

Pressure Vessels. DNV -OS-F101 - Submarine Pipeline Systems ISO 9001:2000 - Quality Management Systems-Requirements

5.2 QP STANDARDS QP-STD-Q-004 - Corporate Standard for Quality Requirements for Projects QP-SPC-L-011 - Technical Specification for Hydrostatic Testing of New pipelines QP-SPC-L-012 - Technical Specification for Pre-commissioning and

Commissioning of New pipelines QP-PHL-S-001 - QP Corporate Fire and Safety Philosophy ES-30.1 - Offshore Pipeline Installation. ES-30.2 - Fabrication of Submarine Pipelines.

5.3 ORDER OF PRECEDENCE

In case of any conflict between the requirements of this specification and the referenced standards and specifications, the following precedence shall be applicable:

a) This Specification b) Project Specifications c) QP Standards/Specifications d) Other approved International Standards

6.0 REQUIREMENTS FOR CONTRACTORS 6.1 All pipelines and systems installed by Contractor shall be cleaned, gauged and flood with

water by Contractor and witnessed by QP Representative. Contractor shall notify QP one week in advance of starting the operations.

6.2 Contractor shall be responsible for performing the filling, cleaning batching and gauging specified herein to demonstrate that the pipeline system is clean and free from debris and obstructions. All necessary work to clean and remove any obstruction including remedial works shall be performed at Contractor’s expenses.

6.3 All debris and dust removed from the pipeline shall be safely disposed of by Contractor.

6.4 Contractor shall furnish all the required materials, supervision, labour, equipment including pigs, inspection, monitoring, services and expenses necessary for the successful completion of the work as specified herein in a satisfactory manner to QP.




6.5 The engineer, supervisors and personnel provided by contractor shall have adequate past experience of such operation. Contractor shall satisfy QP as to the competence of all Contractor’s employees engaged in the testing operation.

6.6 Contractor shall take appropriate measures and due care not to damage in any way the flatpacks / umbilicals attached to the pipelines and existing pipelines, electrical or telephone cable, marine structure, hereafter collectively referred to “as existing facilities” while cleaning, gauging and flooding of the lines. The Contractor shall bear the costs for repairs to the pipeline system and existing facilities as a result of damage by the Contractor’s during performance of the operation.

6.7 Contractor shall provide at all times reasonable site access to QP Representatives.

6.8 Contractor shall be responsible for recovery of any pig and regain the integrity of the pipeline without cost to QP

7.0 MATERIALS AND EQUIPMENTS

7.1 GENERAL

7.1.1 Contractor shall furnish all the necessary materials, equipment, pigs, personnel, spares and instrumentation required to perform the Works as described in this specification.

7.1.2 The spare parts shall be located at the Site and shall be provided in sufficient quantities to ensure a continuous and reliable execution of the operations specified herein.

7.1.3 All the Contractor’s materials, equipments and instruments provided shall be in good condition for use and replacements shall be made, where necessary. All the materials provided shall be subject to the prior approval of the QP and shall be produced from an approved manufacturer with appropriate certification. The materials and temporary pig traps/test heads shall be designed and installed by the Contractor to match the requirement specified in the Contractor’s cleaning, gauging, flooding and dewatering procedures, as approved by the QP. The test head shall be designed in accordance with ASME Section VIII Division 1. Adequate valves and piping shall be provided to allow launching and receiving each pig independently. The equipments should include but not limited to Table 5.

7.1.4 All temporary piping shall be adequately supported throughout the activities. Temporary flexible hosing shall be of the armoured type with a minimum length having a safe working pressure at least equal to twice the test pressure. Such hoses shall be anchored to prevent 'whip' in the event of failure and shall not be used in any enclosed areas. The hoses shall not be used above 50% of maximum working pressure to ensure that creep and yield do not occur. All hoses and associated fittings shall be pre tested, on site prior to use. The test duration shall be for a minimum period of one hour.

7.1.5 All temporary pig traps/test heads shall be pre-tested for one hour to maximum test pressure, prior to use.

7.1.6 The connection between the temporary pig traps and pipeline shall be performed such that the wall thickness transition meets the welding specification stipulated in the ANSI/ASME B31.4 (Para 434.8.6) and ANSI/ASME B31.8 (Ref. Appendix I, Fig. 15). Non-destructive test shall be performed on the full circumference of the weld in accordance with API 1104.

7.1.7 All permanent in-line instruments and instrument probes shall be removed, and/or otherwise isolated during the pigging and cleaning operations.




7.1.8 Upon completion of pipeline cleaning, gauging and flooding the Contractor shall be required to remove all temporary facilities and reinstate any permanent facilities.

7.1.9 All test instrumentation and critical equipment shall have 100% redundancy.

7.1.10 No cleaning, gauging or flooding activities shall be undertaken with the permanent pipeline valves in place. Where necessary, spools and blind flanges will be temporarily installed until the activities are completed.

7.2 MATERIALS

All the necessary specification pipe materials such as flanges, blind flanges, bolts and nuts, gaskets, plugs, fittings, pipes, valves, etc., together with all necessary spare parts required for the cleaning, gauging and flooding operations and including, but not limited to, the materials required for isolation of the pipeline system under test shall be provided by the Contractor.

7.3 EQUIPMENTS

The equipment to be supplied by contractor shall include, as a minimum, but not be limited to:

a) Air compressors and drivers of suitable capacity and pressure complete with condensers, separators and dehydration units as required to provide oil free, compressed and dehydrated air.

b) Instruments to monitor and record the air and water flow, pressure, dew point and ambient temperature as specified below;

c) Temperature recorders with an accuracy of ± 0.2%.

d) Piping manifold to suit the air and water flow into and out of the pipeline consisting of:

• Non-return valve in each compressor outlet

• Instrument spool piece with fittings for instruments detailed below;

• Pressure regulating device at the inlet to the pipeline

e) Pressure gauges, transmitter and chart recorders which shall operate in a range of 40 to 70 percent of their maximum indication with an accuracy of ± 0.1%.

f) Flow meter(s) and recorder with an accuracy of ± 0.15% for measuring the water volume required to fill the line.

g) Pigs and temporary pig launching and receiving facilities with all associated valves, signallers, fittings and connections, including temporary facilities.

h) All temporary piping and facilities for the safe disposal of debris containing air and entrained debris to an acceptable noise level.

i) Injection pumps(s) to continuously inject chemicals into the filling water.

j) Associated water supply including all equipment, filter of 50 microns, break(s) etc.

k) Pig signallers shall be fitted to a pig trap/test heads to give positive indication of the launching and receiving of pigs.

l) Water pumps(s) and drivers of suitable capacity and pressure for line flooding. The stuffing boxes shall be water sealed to prevent air from entering the internals of the




pump or shall have a mechanical seal fitted. Should a single pump be furnished, a standby unit must be available.

7.4 PIGS

7.4.1 All pigs shall be bi-directional. Only new pigs of a design/manufacture with proven track record for the proposed duties shall be used. Full details including a construction drawing of the pig shall be furnished to the QP for approval.

7.4.2 Cleaning pigs shall be selected such that it is capable to remove any remaining loose debris in the pipeline including welding slag, loose millscale, and corrosion product without scraping the internal surface of the pipeline. If necessary, contractor shall recommend and perform a test to prove this capability on the same linepipe section witnessed by QP representative. The cleaning pig shall be bi-directional disc type brush pigs (mandrel pig). The brush pig is to have magnetic cleaning part behind the brush section or a magnetic cleaning pig is to follow behind the brush pig to collect ferrous debris or broken bristle of the brush pig. Suitably selected wire brush shall be used for normal carbon steel pipeline. For new GRP /GRE pipelines and carbon steel pipeline with internal coating, the wire brush shall be replaced with polyurethane blades or Prostran brush in order not to damage the internal plastic or coating material. The sealing discs shall have a hardness of 70 Shore A (±10). The thickness of the sealing discs shall be a minimum of 20mm or 10% of the nominal internal diameter of the pipeline whichever is smaller. The sealing discs diameter shall be sized to be approximately 4% to 5% larger than the nominal internal diameter of the pipeline. The distance of between the outer sealing discs shall be not less than 1.5 times nominal internal diameter of the pipe. If further cleaning pig run is required the same requirements shall be applied.

7.4.3 For air cleaning, the plastic brush foam pig proposed for cleaning after the third bi-directional disc type brush pig shall be able to remove the loose debris remains in the pipeline. All foam pigs shall be slightly oversized in relation to the internal diameter of the pipe, unless specified otherwise. The contractor shall obtain recommendation from the supplier that the pig can be used for cleaning the specific pipeline after providing details of the pipeline which shall include the nominal internal diameter of the pipeline and the material of the pipeline internal surface. The foam pig shall have sufficient length such that they do not experience excessive fluid pass whist negotiating tee branches or bends. The length of the foam pig body shall be at least 1.5 times the nominal pipeline diameter. For pipeline with nominal diameter of 10-inch and above, the foam pig shall be equipped with polyethylene or polypropylene rope loop through the nose of the pig in order to enhance it retrieval from the pig trap.

7.4.4 The gauging pigs shall be bi-directional disc type pigs. Two gauging plates shall be fitted on the gauging pig, one behind the first cup and one before the last cup. The gauging plates shall be removable type of 6mm thick machined aluminium with adequately spaced radial incision. The incision shall extend from the outside diameter of the plate to the outside circumference of the flange of the pig. The leading edge of the gauging plate shall be chamfered for 3mm at 45°C.

7.4.5 All gauging plates diameter shall be 97% of the nominal internal diameter of the pipeline system being gauged. The nominal internal diameter shall be calculated from:

Nominal Internal Diameter = Nominal O.D. - (2 x nominal wall thickness).

Note: For pipeline with various wall thicknesses the gauge plate shall be sized based on the minimum calculated nominal internal diameter through out the pipeline system.




Calculation shall be perform to confirm that the selected gauge plate will be able to pass induction bends (with 3% permissible out of roundness) as well as the inside lamination or in bell couplers of GRP/GRE pipelines.

7.4.6 For passage of intelligent pig, the calculated gauge plate diameter shall be greater than or equal to the value stated in Table 1. If the calculation results with lesser value, confirmation with regard to pigability of the pipeline shall be obtained from intelligent pigging contractor and shall be forwarded to QP acceptance/approval.

7.4.7 Calliper pigs may be used for pipeline geometry inspection when gouge plates were found damage. The calliper shall be capable of negotiating symmetrical reductions in ID of up to 10% and asymmetrical reductions up to 15%. It must be capable of operating in chemically treated water and capable of recording changes in internal pipe geometry with a minimum resolution of 2% of pipe internal diameter and detecting all girth welds and/or locating defects to within a distance of 5 metres.

7.4.8 The Calliper pig shall be capable of either completing its survey in a single pass or being re-launched and remotely energised to enable an overlap of data to cover the full length of the line. Duplication of critical parts shall be provided to minimise the risk of breakdown during operations.

7.4.9 Pinger devices shall be provided for installation in the leading and/or trailing pigs of each pig train. The batteries provided for these pingers shall have a minimum life of six months after being put into use. When more than one pinger is located in pigs train each pinger or transponder shall be uniquely identifiable. Further, the tracking equipment for these pinger devices shall be provided.

7.5 CONSUMABLES & WATER

7.5.1 General

The Contractor shall provide and use at the Site sufficient quantities of all the consumables necessary to comply with this specification during the various operations specified herein. These consumables shall include, but not be limited to, bactericide, corrosion inhibitor, oxygen scavenger, dye, etc., diesel oil and lubricating oils for the pumps, etc, and electricity for telecommunications, lighting and control purposes. All the consumables shall be provided in sufficient quantities to ensure a continuous and reliable execution of the operations specified herein.

7.5.2 Water and inhibitors

• All water to be put into the pipeline system must be filtered and treated in accordance with Table 2 of this specification. The filtration shall achieve a purity of 50 microns absolute for the cleaning stage while for the line fill water after the last cleaning train the filtration purity shall be ultra high level of 10 microns absolute. For offshore pipeline the line fill water shall also be impregnated with fluoroscene or rodamine dye to 15 ppm concentration to facilitate leak detection during hydrostatic test.

• The recommended chemical inhibition package(s) shall provide maximum protection to internal surface but minimises effect on the environment when disposed of. The Contractor shall demonstrate to QP the effectiveness of the proposed chemicals by means of laboratory tests. Results of the study shall be submitted to the QP for approval along with specifications and procedure for testing of water quality. Consideration shall be given to the maximum anticipated duration of flooded condition of each pipeline for determining the correct concentrations of chemicals in




the water of the hydrostatic test. Whenever applicable, the chemical inhibition package shall be of the following:

a) The recommended oxygen scavenger used must be able to achieve a quicker scavenging action.

b) The biocide does not suffer any incompatibility with the oxygen scavenger when diluted in seawater.

c) The performance of the proposed corrosion inhibitor will not be impaired as a result of interaction with other added chemical.

d) Shall not damage the soft seals in the valves and other equipments.

e) In case of leak it shall not be harmful to marine life environment.

• All chemicals shall be handled, stored and used in accordance with the manufacturer’s standards. The Contractor shall take due precautions during disposal of the treated seawater to ensure conformance with procedures previously approved by QP. In no case shall disposal overboard be allowed within 1km of production stations.

• Dosing pump shall be used for feeding the inhibitors into the water. The injection lines all have separate flow control valves and meters with an accuracy of +5 percent of the specified rate.

• The oxygen scavenger feeding point shall be located at the most upstream point of the water supply while the biocide and the corrosion inhibitor shall be fed at the at the upstream of a turbulent area, e.g. of a partially throttled valve to ensure that the chemicals will mix with the water evenly.

• Suitable tanks or other measures shall be provided to ensure that the oxygen scavenger used does not come into contact with air before it is injected into the pipelines.

• For water cleaning, the biocide is to be added to the final 2 x pipe volumes. If the flushing water is then to be drained and the pipe to remain empty prior to start up, the corrosion inhibitor is be added to the final pipe volumes of water and allow for the final volume of water to have 1 hour soaking / contact time before draining. When pipeline flooding is performed after air cleaning, the amount of the treated water shall be at least adequate to fill the overall pipeline length plus additional 250m linear length.

• Water analysis shall be performed on samples taken from the following locations:

a) From the site of treated water at commencement of hydrostatic test, i.e. prior to subsequent storage in the line. These are to be used to determine the quality of treated water entering the pipeline internally.

b) From the site of final discharge during appropriate stages of dewatering. These are to be used to determine the quality of treated water after the hydrostatic test and storage period.

• All tests shall preferably be conducted on-site. Any tests proposed to be carried out in a laboratory shall be justified by Contractor and shall be subject to QP’s approval.

• Each water analysis shall determine, record and report the following: a) pH

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b) Total Suspended Solids c) Total Viable Bacteria d) Sulphate Reducing Bacteria e) Total Dissolved Iron f) Concentration of Inhibited Chemicals g) Residual Oxygen

• The total suspended solids shall be not more than 20g/m3.

• The concentration of approved chemical products which are required to prevent internal corrosion of the pipelines can be found in Table 3.

• Residual oxygen content shall not exceed the level appropriate to the oxygen scavenger as proposed by the Contractor and approved by QP.

• For filling and pigging, as a minimum, the following instruments, gauges and meters shall be provided:- a) Flow-meter on the main fill or pigging line downstream of the pump. b) Flow-meters on each chemical injection line. c) Pressure gauge on the pump outlet line. d) Pressure gauge and 24 hour pressure recorder on the pig launcher or pigging

head. • Flow-meters shall show both instantaneous flow rate and cumulative flow. The

maximum flow rate expected shall be within 50% to 90% of the range of the meters. They shall have a certified accuracy of 2% at full scale deflection (F.S.D).

• For filling and pigging, pressure gauges and recorders shall be chosen so that the maximum pressure expected shall be within 50% to 90% of the gauge recorder range. They shall have a certified accuracy of 1% F.S.D.

• All flow-meters, pressure gauges and pressure recorders shall have been calibrated by an independent agency within the previous two months prior to commencement of the filling and pigging operations. Copies of the calibration certificates shall be presented to QP for approval and shall be included in the final filling and pigging report.

8.0 CLEANING, GAUGING AND FLOODING REQUIREMENTS

8.1 OPERATIONAL SEQUENCE

Purpose of cleaning, gauging and flooding is to clean the pipeline system by removal of construction debris and loose mill scale and to check the pipeline system is free from deformation and obstructions.

The general sequence of filling, pigging, gauging and flooding shall be as follows :

a) Installation of launcher and receiver at each end of the pipeline to be tested. b) Cleaning Pig Runs c) Gauging of pipeline d) Flooding of the pipeline section with suitable filtered chemically treated water. e) Upon completion of filling allow a minimum twenty-four hour stabilisation period.

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chloride content, total suspended solids, pH value, dissolved solids, sulphate reducing bacteria, concentration of inhibitor chemicals, dissolved iron




f) Removal of launcher and receiver g) The direction of the pigging for the cleaning, gauging and flooding operation shall

be specified in the project scope of work.

8.2 USE OF APPROVED PROCEDURES & DETAILS

8.2.1 Mobilisation of materials, equipment and spares shall be commenced only after the procedures and other submissions have been approved by QP. The Contractor shall submit in writing a procedure for cleaning, pigging, gauging and flooding of individual pipeline test sections for the QP approval at least four weeks prior to commencing the work.

8.2.2 The procedure shall include but not be limited to:

a) Pigs for cleaning, gauging and flooding

b) Fill pump: Type and number of fill pumps to meet the following:

c) Differential head 20% greater than the maximum required

d) Flow rate; Minimum 400 m3/hr Maximum 1000 m3/hr

e) Proposed location and source of water, additives, chemicals and dosage proposed.

f) Details of all equipment, materials, instrumentation and spares used during cleaning, pigging and flooding including the type and rating of all test equipment.

g) Testing procedures for all main equipment and instruments.

h) Procedure for monitoring pressure and flow at both ends of the pipeline section(s).

i) Procedure for controlling flow, pressure and control of spacing of pigs.

j) Procedure for pig launching / receiving using temporary pig traps and or test heads.

k) Procedure for water sampling and analysis.

l) Procedure for determining level of cleanliness of pipeline.

m) List of nominated personnel supervising the cleaning, pigging and flooding with dates and time of duty, location and duration of activities of all personnel required. Contractor shall name his authorised representative for the duration of activities.

n) Current certification (not more than 6 months old) for all instrumentation.

o) Procedure for gauging the pipeline.

p) Type and sequence of pigs and the pig tracking system.

q) Pig inspection procedures including procedures to be followed in case of gauging pig indicates damage.

r) Procedure for Health, Safety and Environment

s) Contingency/recovery procedure to dislodge a stuck pig.

t) Design details of temporary traps and/or test heads.

u) Details of all chemicals used, rate of dosages and safety precautions required.

v) P& ID's, plot plans and layout details of all items of equipment used in cleaning, pigging and flooding.

w) Procedure for disposal of water for cleaning, inhibited water and other chemicals used for flooding as per the applicable QP environmental guidelines.




x) Procedure for disposal of debris during cleaning and gauging.

8.2.3 The mobilisation work shall be performed in accordance with QP approved procedures. Pipeline cleaning, pigging and flooding shall not commence until written approval of the cleaning, pigging and flooding procedures have been obtained.

8.2.4 The QP approved procedures shall be used by the Contractor for all the filling, cleaning, gauging and hydrostatic testing operations as specified herein. Any changes to these procedures and other submissions by the Contractor shall be subject to the prior approval of QP.

8.3 PREPARATORY WORK

8.3.1 All the necessary equipment shall be set up and checked by the Contractor to ensure conformance with QP approved procedures so that the pipeline system is ready for the cleaning, gauging and flooding operations.

8.3.2 The Contractor shall prepare a check list for each pigging operation to ensure that all valves are in the correct initial positions and all other operational requirements are met.

8.3.3 Contractor shall be fully responsible for checking dimensions of the proposed pigs against pipeline, riser and Contractor’s proposed pig trap dimensions to ensure that the sequence in his proposed programme can be achieved.

8.3.4 All pigs shall be inspected by QP prior to their insertion into the launcher. Each pig shall be uniquely identified and marked for direction of travel. The sizes of the two gauging plates shall be measured by QP and QP’s representative shall sign on these plates after these measurements have been made and before installation onto the pig body. New gauging plates shall be used for each pipeline.

8.3.5 The receiving facilities for the pigs shall be such that extraneous matter cannot be washed back down the pipeline after completion of the pig runs. Pig Signaller shall be installed at the minor barrel of the receiver end to give positive indication upon the arrival of the pig.

8.3.6 The Contractor shall ensure that the required quantities of all chemicals are available at all times and no shortages will interrupt the continuous operation of the work.

8.4 CLEANING, GAUGING AND FLOODING PROCESS

Among the few cleaning methods available in the industry, the methods acceptable for new QP pipelines are the air or gas cleaning and the water cleaning methods which are described in the following sub-section. The appropriate cleaning method shall be selected suitable for the physical condition of the pipeline and intended operational service such that no debris will remain on the pipeline to interfere with the drying and inhibition effectiveness as well as prevent fouling on downstream plant facilities and improve efficiency and quality of the transported product. For special condition, other cleaning method may be recommended subject to QP approval.

8.4.1 Air or Gas Cleaning

• For newly constructed pipeline the air cleaning in conjunction with brush pig may be recommended for relatively short pipeline section in the range around 20km long or less containing less than 5 gram of fine rust or debris per square meter, provided that the remaining (if any) will not enhance pipeline internal corrosion instead. For this option, it is significantly important to ensure that thorough cleaning have been carried during pipeline construction. This includes brushing and removing any loose dirt from




the inside of the pipe prior to welding of the line pipe joint. Therefore, this cleaning method shall not be used unless QP is satisfied with the construction procedure, records and other information.

• If the air cleaning method is selected because the use of water being ruled out for corrosion prevention reason, hydrostatic testing shall not be used for the system pressure test. Instead, the pipeline shall be pressure tested using air or gas as per ASME B31.8 or ASME/ANSI B31.4 as applicable, subject to QP approval.

• The air cleaning of the pipelines is to be performed using bi-directional spring loaded brush pig propelled by oil free, compressed and dehydrated air (see clause 7.4 for pig details). After the third bi-directional disc type brush pig has been received, foam pig with plastic brush may follow subject to approval by QP Representative. The final run shall be executed with pigs provided with air jet holes or nozzles to keep the internal dust in turbulence, ahead of the pig. The swabbing run shall only be executed once the quantity of debris is accepted by QP Representative.

• No extraneous material shall be introduced into the pipeline which could contaminate the internal condition of the pipeline during cleaning operations.

• All pigging operations shall be continuous and not interrupted. The pig velocity shall be in the range 0.5 to 2.0 m/sec. The pressure and flow at the outlet shall be controlled such as to maintain sufficient back pressure to prevent the run away of pigs, and to receive the pigs. When pigs are due to arrive at the recovery end of the pipeline, the discharge flow shall be throttled down such that the pig velocity approaches zero when entering the receivers.

• Immediately upon receipt, each pig shall be again visually inspected, and full details noted on a check list which shall be submitted for QP approval. Debris recovered off the pigs, from the pigs or within the pig trap shall be monitored, measured and recorded. Photographs shall be taken of all pig trains for inclusion in as-built records.

• By the time the last pig of the last train arrives at the downstream end of the pipeline, the first criterion mentioned in Clause 9.2 shall be satisfied. If any of the conditions for acceptance are not met or QP Representative is not satisfied, then the cleaning may be extended with further pigs run depending on QP approval. The air cleaning shall continue until the acceptance criteria are met and QP Representative is satisfied. If for some reason, any of the pigs is found to have not performed in accordance with its designation due to its failure or has been proven to have been detrimental to the pipeline air cleaning programme, the operation shall then be repeated at Contractor's cost.

• Pipelines gauging shall commence after the air clean has been accepted. The gauging runs shall be performed using oil free, compressed and dehydrated air as the propelling medium. Contractor shall perform the following during the gauging:

a) Continuously meter and log the volume and pressure of air.

b) Record the temperature of the air at intervals to be agreed with the QP.

• The gauge plate shall be in good condition upon receiving. If damage is found on the gauge plate, a second gauging pig shall be run. Should a second plate be received damaged, the cause of the damage shall be identified and eliminated as approved by QP. The gauging shall be repeated until the QP Representative is satisfied if accepted.




• If hydrostatic testing is to be performed on the pipeline, flooding shall follows after QP has approved the gauging results. The flooding shall be performed by propelling at least two Bi directional pigs with treated fresh water at 150m apart. Care shall be taken during flooding the pipelines to ensure that air is fully displaced and no further air is introduced in the water column until the pigs has arrived at the receiver. The Bi directional pigs may remain in pipeline traps/test heads during subsequent hydrostatic testing.

• Water sample shall be taken upon receiving the first pig and immediately prior to receiving the last pig and the analysis mentioned in Clause 7.5.2 shall be performed.

• The second cleaning criterion mentioned clause 9.2 shall be satisfied. Otherwise, the cleanliness of the pipeline shall be re-evaluated by testing the discharge water during the de-watering process following completion of hydrostatic test. If the second criterion is still not satisfied the cleaning contractor shall remain responsible to clean the pipeline until the specified cleanliness is achieved.

8.4.2 Water Cleaning

• The water cleaning technique is applicable to all pipelines irrespective their length or internal condition except when the introduction of water into the pipeline is prohibited as part of corrosion prevention measure. This method is suitable for significant amount of debris in long pipeline section or when substantial amount of loose debris (from construction) are present in the line. Especially for long pipeline this method is attractive as it allows for cleaning, gauging and flooding to be carried out concurrently and hence reduce the working period. This method shall be opted when it become evident from the construction record or other information that the pipeline has not been properly cleaned during construction to QP satisfaction.

• Generally the water cleaning of the pipeline shall begin with introducing a slug of clean, filtered and treated water of approximately 150 linear meters for the purpose of wetting, washing and rinsing away any foreign material like sand, stones, electrode, and other material left during installation process. However in the even that removal of debris is considered to risky because excessive debris may cause the pigs become stuck in the line, a high velocity water flush at 3 m/s or above which create enough turbulence to dislodge the loose debris and keep it in suspension shall be carried out first.

• The water used for filling, cleaning, gauging and hydro-testing shall be selected from a location that will minimise the temperature stabilisation period for the hydrostatic test. The water used for filling, cleaning and gauging shall be clean filtered seawater treated in strict accordance with requirements of this specification.

• The water will be followed by a ‘pig train’ consisting of the following:

a) 1st cleaning pig (see clause 7.4 for selection)

b) A batching / displacement pig.

c) A slug of 150 linear metres clean filtered and treated seawater.

d) 2nd cleaning pig (see clause 7.4 for selection).

e) A slug of 100 linear metres clean filtered & treated seawater.

f) A gauging pig installed with pigger and driven by clean, filtered and treated seawater.




• A certified, calibrated, turbine flow-meter shall be used during the filling operations to monitor the filling rate. Prior to launching any of the pig, any water presence in the launcher shall be removed and if necessary, the launcher shall be depressurised. Once ready the staff stationed at the receiver end shall be notified. The pigs shall then be loaded and launched in accordance Contractor’s procedure. Pig tracking shall commence immediately. The pigs shall be propelled at a rate not less than 0.5 m/s and not exceed 1 m/s. Sufficient pressure shall be maintained at the downstream of the pig(s) by suitably adjusting a vent valve installed at the receiver to ensure optimum control during the pig run and ensure that no air is introduced during the filling operation until the pig arrives at the receiver.

• During filling and pigging Contractor shall record hourly the instantaneous and cumulative flow meter readings. During pigging the Contractor shall record hourly the pressure at the pump and the pigging head or pig launcher. The chemical injection rate shall be adjusted to give the correct concentrations with respect to the actual volume of water being pumped into the line.

• All flow and pressure charts and records shall be witnessed by both the Contractor and QP representatives and shall be included in the final pigging and hydro testing report.

• The concentration of chemical additives shall be confirmed by periodic analysis of samples taken from downstream of the chemical injection points. Frequency and timing of samples shall be at the direction QP.

• The analysis of water samples taken during cleaning, gauging and flooding at the receiving end shall be as mentioned in Clause 7.5.2.

• The pigs shall be removed from the pig receiver by the Contractor in the presence of QP. Recovered pigs shall be carefully examined to ascertain the degree and regularity of the wear of the cups and gauging plates (where applicable).

• Photographs shall be taken of all pig trains for inclusion in as-built records.

• If, on completion of a cleaning run, the QP Representative is not satisfied that the pipeline is clean then the Contractor shall continue with additional runs until the QP Representative is satisfied.

• Should a gauging plate be received damaged, a second gauging pig shall be run. Should a second plate be received damaged, the cause of the damage shall be identified and eliminated and gauging repeated until the QP Representative is satisfied if accepted. The gauging plates shall be stamped with pipeline identifier and transmitted to QP for record purposes.

8.4.3 Stuck Pig

• Blocking of any pigs at any point along the line shall entail suspension of pigging operations. In this case QP representative shall be immediately notified and the Contractor shall locate the position of the blocked pig, recover it, in accordance with the approved procedure mentioned in 7.2.2 ,contractor will then be responsible to ascertain the causes for blockage and if necessary carry out all work required to restore the line to the testing condition in accordance with the approved procedure.

• Attempt to dislodge stuck pig shall not be carried out without QP instruction. The pressure applied to recover the pig shall be not more than the pipeline design pressure.




9.0 ACCEPTANCE CRITERIA

9.1 GENERAL REQUIREMENTS

The acceptance criteria shall be use as a guideline for:

a) A measure against which to accept the pipeline system. It shall establish the basis for Contractor's Engineering procedures and eventual execution of the pre-commissioning activities.

b) A measure against which to accept the Work.

9.2 CLEANING ACCEPTANCE CRITERIA

9.2.1 The following acceptance criteria shall be used to define air cleaning completion: a) The air cleaning process can be stopped when there is no longer a significant

discharge of debris at the end of the line where pigs are received. The colour of polyurethane foam swabbing pigs shall be white (or other suitable colour, upon which dirt is easily detectable). Pigs shall be received close to their original colour to permit acceptance of the pipe cleaning.

b) If the air cleaning is followed by hydrostatic testing, the pipeline shall only be considered clean when the solid contents directly ahead of the last pig is less than one percent (1%) by volume of the collected water sample.

9.2.2 The following acceptance criteria shall be used to define water cleaning completion: a) Pipeline shall be considered clean when the solid contents directly ahead of the last

pig is less than one percent (1%) by volume of the collected water sample.

b) The colour of polyurethane foam received shall be close to their original colour to permit acceptance of the pipe cleaning.

9.3 GAUGING ACCEPTANCE CRITERIA

9.3.1 The following acceptance criteria shall be used to define acceptable condition of the metal plate of gauging pig:

9.3.2 Any significant increase in pressure occurring during the gauging operation which may be attributable to the pig being stationary shall be reported at once to QP representative.

9.3.3 No sign of damage or irregularities such as dents, buckles, flat spots, construction debris and etc.

9.4 FLOODING ACCEPTANCE CRITERIA

9.4.1 Acceptability of the flooding operation shall be based on a successful and uninterrupted pig train transit through the line. Comparison between calculated and actual values shall be made for:

a) Dispatch and receipt pressures (average and surge values).

b) Accumulated flows both water and air in and out.

c) Pig train transit time.

9.4.2 Final acceptance of satisfactory flooding coincides with integrity testing where an air entrapment test is performed during pressurisation. If it is shown that unsatisfactory




flooding has occurred or air entrapment proves excessive, then a further high sealant pig shall be displaced through the line to ensure complete line fill volume.

10.0 HSE AND PERMITS REQUIREMENTS

10.1 The Contractor shall provide a safety manual which shall cover as a minimum all personnel, equipment and chemicals required to complete all activities.

10.2 The safety of personnel during the works shall be assured at all times. No procedure shall be allowed which may endanger personnel. All safety precautions shall comply with statutory and other relevant regulations.

10.3 The contractor shall identify the hazards associated with all activities, ensure warning signs and notices at appropriate places, protection soil and water contamination from spill liquids

10.4 The Contractor shall take all necessary measures to ensure that all personnel are adequately protected during the course of the activities and, in particular, to ensure that no other work is permitted on the sections of the line for the duration of the activities.

10.5 The Contractor shall provide estimates of the noise levels expected during pre-commissioning activities for QP approval.

10.6 Warning notices both in Arabic and English shall be placed at appropriate locations for the duration of the Works. The boundaries of the equipment area shall be defined by marker tapes.

10.7 When directed by QP, the Contractor shall in all ways co-operate with other operations related to the pipeline construction or testing and/or facilities at the site.

10.8 The Contractor may have to undertake more review to check the adaptability to local legislations and ensure that all applicable Environment Protection laws are complied. Accordingly, Contractor shall obtain all permits required for the treated water and shall make contact with local government or private agencies for the necessary permits or fees.

10.9 The Contractor shall take all precautions as specified by the suppliers when using and handling all chemicals.

10.10 The Contractor shall take all precautions for the safe disposal of debris and water and shall submit his procedure for QP approval. For QP requirement refer to QP.SPC.L.012

10.11 The Contractor shall ensure that all equipment complies with QP Corporate Fire and Safety Philosophy QP-PHL-S-001.

11.0 QUALITY ASSURANCE

11.1 Contractor shall operate a Quality system meeting the requirements of the relevant part of ISO 9001:2000. Guidance for Purchaser conformance requirements to ISO is given in QP Standard No. QP-STD-Q-004.




11.2 Contractor shall provide documents such as plans, procedures, instructions, etc. for the accomplishment of all works covered in this specification to provide the required quality. Specific adherence to the guidelines set down in ISO 9001:2000 series. Documentation shall be detailed out by the Contractor and shall be subject to review and approval by QP. QP reserves the right to undertake such audit as deemed necessary to assess the effectiveness and implementation of the Contractor’s Quality System.

12.0 DOCUMENTATION

12.1 GENERAL REQUIREMENTS

All correspondence, drawings, instructions, data sheets, design calculations, or any other written information shall be in the English language.

All dimensions, units of measurements, physical constant, etc. should be in SI units, unless otherwise specified.

In addition, all documents (texts, specifications, data sheets, drawings etc.) should be provided with electronic files in the approved software (Ms Word, Excel, Auto Cad and etc.). Design calculations should be submitted in the approved and widely used software agreed by QP.

12.2 SPECIFIC REQUIREMENTS

The Contractor shall develop QP approved digital data base which shall contain full results of cleaning, pigging and flooding activities. In addition to the data base, the Contractor shall produce and compile a set of manuals (number as specified in Contract documents) in an Engineering approved format. The manual shall be submitted within fourteen days of completing the dewatering, drying and inerting operations. The manual shall contain: a) Clean, pigging and flooding manual b) Summary of all cleaning, pigging and flooding activities c) Procedures, as previously submitted for approval d) All calculations e) Record of all pigs used f) Photograph of pigs removed from pipeline during cleaning operation identified

sequentially. g) Report of pipeline gauging pig runs. h) Results of pipeline gauge pig run and any remedial action taken/recommended. i) Instrument certificates and calibration j) Chemical standards, dosage records and methods of disposal k) Details of any stuck pigs and method of removal l) Accumulated flows both water and air in and out m) Daily log of events and a report of all operations carried out n) Problems encountered and method of solution o) Approved document shall be submitted in electronic form as well as hard copy.




13.0 APPENDICES 13.1 APPENDIX I

TABLE 1- MINIMUM GAUGE PLATE DIAMETER Pipeline Nominal Outside Diameter Minimum Gauge Plate Diameter

4-inch ( mm) 88 mm

6-inch ( mm) 38 mm

8-inch ( mm) 181 mm

10-inch ( mm) 231 mm

















48-inch ( mm) 1110 mm




13.2 APPENDIX II

TABLE 2 – PRESERVATION MEASURES FOR WATER FILLED PIPELINE

Treatment for Hydrotest Line fill water Pipeline Material Product Service

Treatment for cleaning water Up to 6 month

Preservation after Hydro-testing

More than 6 Preservation month after Hydro-testing

Portable Water

Oil & Gas

None − Biocide

− Biocide; − Oxygen Scavenger; − Advise to raised PH to

9; and − corrosion inhibitor

Carbon Steel

Water Injection

− Biocide; − Oxygen Scavenger;

and − Advise to raised PH

to 9

− Biocide; − Oxygen Scavenger;

and − Advise to raised PH to

9

− Biocide; − Oxygen Scavenger; − Advise to raised PH to

9; and − corrosion inhibitor

Oil & Gas

− Mandatory use of de-aerated water; and

− advise to raised PH to 9

− Mandatory use of de-aerated water;

− advise to raised pH to 9; and

− Oxygen Scavenger


− Biocide; − advise to raised pH to

9; Oxygen Scavenger, and corrosion inhibitor

Stainless Steel and CRA cladded

Water Injection


− Biocide; and − advise to raised PH

to 9;


− Biocide; − advise to raised PH to

9; − Oxygen Scavenger


− Biocide; − advise to raised pH to

9; − Oxygen Scavenger,

and corrosion inhibitor Seawater

(NOT recommended & subject to QP approval

Oil & Gas

− Biocide − Biocide; − Oxygen Scavenger; − Advise to raised pH to 9; and − Corrosion inhibitor

Carbon Steel

Water Injection

− Biocide Not Suitable

Stainless Steel and CRA cladded

Not Suitable

Note “Analysis on the water sample shall be performed every 6 months to confirm concentration of the preservatives.”

Sreeram Srinivas

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Sreeram Srinivas

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Sreeram Srinivas

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Sreeram Srinivas

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Sreeram Srinivas

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Sreeram Srinivas

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13.3 APPENDIX III

TABLE 3 – QP APPROVED PRESERVATION

CHEMICAL CONCENTRATION

Catalysed Oxygen Scavenger 150 ppm

Biocide 300 ppm

Temporary Corrosion Inhibitor 2000 ppm

‘Cocktail’ Mixtures 500 ppm

Sreeram Srinivas

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Sreeram Srinivas

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Sreeram Srinivas

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13.4 APPENDIX IV

Table 4 Contractor Check List No. Clause Description Remark Status 1 8.2 and 11 Preparatory Documentation

List of nominated personal accompanied with their resumes

Detailed schedule including mobilization date

Approved Procedure for cleaning, gauging and flooding with details of pipeline to be tested.

Approved Procedure for stuck pig recovery

Approved Health, Safety and Environment Procedure

Emergency Plan

Permit to work from local authority

Permit to work from private agencies (if applicable)

Permit of water disposal from local authority

2 8.3 Preparatory Equipment and Material

Equipment

List of pump and performance

List of compressor and performance

List of instrument

Calibration certificates

Temporary fitting and component

(piping, pig trap, flexible hoses and connectors, etc)

List of temporary fitting and component

Specification of each temporary fitting and component

Material

List of pigs with details of type, material, dimension, hardness and compressibility

Sketch of gauge plate with details related to diameter, thickness, design (incision details) and location on the pig

Pig tracking system details

Line fill water

Source of water

Location and method of water withdrawal

Independent testing laboratory

Water analysis report

Propose location and method for water disposal

Additives

Description of chemical treatment, dosage and available stock

Description of dye, dosage and available stock




TABLE 4 CONTRACTOR CHECK LIST (Continued) No. Clause Description Remark Status 3 Preparatory Work

Set up of all Equipments, instruments and fittings

Ensure supports are adequately provided.

Anchor flexible hose.

Identify the number of valves and ensure all are in correct position.

Number the pig and gauge plate with unique identification and mark for direction of travel.

Arrange for QP representative to inspect on the pig and measure the gauge plate and sign prior to installation to the pig body.

Check and ensure that the arrangement of the receiving facility will not allow for extraneous mater to wash back into the pipeline after pigging.

Health Safety and Environmental measures

Provide estimate of noise level.

Notify related parties

Install warning notices both in Arabic and English

Mark boundary of all equipment using marker tapes

Patrols to watch special points of hazard

Prepare pig register for each operation.

4. Cleaning

Identify proposed number of cleaning runs.

Driving medium and pressure.

Data recording of pigging activity

5. Gauging

Driving medium and pressure.


6. Line Flooding

Filling sequences of test section and pressure.





13.5 APPENDIX V

TABLE 5 EQUIPMENT LIST No. Equipment Function and Requirement Capacity and Accuracy

1. Air Compressors For cleaning method using oil free compressed air to drive pigs. Air coolers shall be included if the discharge temperature is outside the limits specified for the test section.

2. Filling and pressure pumps

For cleaning method using water to drive pigs and for line flooding activity. Fitted with stroke counter or flow meters suitable for the work scope.

The pressurizing flow meter should have accuracy of 1% volume per stroke.

3. Chemical injection pumps

For continuous inhibitor injection. Complete with injection manifold and block valves.

The injection rate accuracy shall be not more than 5% of the specified rate.

Temporary pig launchers and receivers

For cleaning, gauging and filling operation. The receiver should be fitter with a throttling valves.

-

4. Filters For line fill water filtration suitable with the filling pump.

10 micron filtration purity.

5. Break tanks and piping

To keep the pump constantly on load. -

6. Tank For calibrating the high pressure pun and flow meter -

7. Filling/pressurising flow meter and temperature probe

For measuring and recording the flow and temperature of the line-fill water as per the specified accuracy.

The filling flow meter should have reading in m3/hour with ± 1% of the full range accuracy and the temperature probe should have 0.1°C reading division for 0 to 50°C range with ± 0.1°C accuracy..

8. Pressure relief valve

Fitted to the pressurizing pump. To match the full capacity of the pump.

9. Pipe wall temperature recorder

Measuring and recording pipe wall temperature. With 0.5°C reading division for 0 to 100°C range and reading accuracy of 1% of the full temperature range.

10. Ambient air temperature recorder

Measuring and recording ambient temperature. Same as above

11. Soil temperature probes and recorder

Measuring and recording soil temperature. Same as above

12. Seawater temperature probes and recorder

Measuring and recording seawater temperature. Same as above

13. Air-conditioned or heated test cabin unit

Complete with the necessary gauges, recorders, deadweight tester, barometer, etc. for installation at the end of the test section so that the test engineer can accurately assess the progress and record the pressure and water volume condition as per the specification.

-




TABLE 5 EQUIPMENT LIST(Continued)

No. Equipment Function and Requirement Capacity and Accuracy

14. Communication equipment

For communication between the various locations of the related section.

-

15. Spare parts and stand-by facilities.

To replace any defective equipment.

16. Diesel Engine (If required)

Shall be used only in places at least 15m away from Zone 1 area. If used in Zone 2 away from Zone 1 by 15, protection shall be provided following shall applies:

Surface temperature limited to 250oC or to the specified temperature class

Provided with exhaust flame trap and spark arrestor.

Non-electric starting system is used.

Provided with inlet air shut down control system to operate on high temperature, over speed and gas detection.

Utilize non-metallic cooling fan blades and antistatic fire resistant type fan belts.

-




Note: 1. Water cleaning in conjunction with brush pig is recommended for pipeline carrying dry product containing H2S, CO2 and other corrosive substance without corrosion inhibitor facility. However in

the absent of water, air cleaning may be performed with precision detail to achieve the optimum level of cleanliness adequately confirmed by analysis of the discharged of test water. 2. For pipeline to be operated with wet product (containing water), pre-commissioned with final product in combination with commissioning can be opted provided that the water selected for

pipeline filling in Step 4 meet the preservation requirement period (See Note 3). 3. As part of the Cleaning, gauging and Flooding procedure, treatment of filling water shall be identified as per Table 2 base on the linepipe material, type of product and the required preservation

period for the water fill pipeline. For pre-commission with drying activity the required treatment for the water fill shall be the same as that for pipeline to be water filled up to 6 months prior to introducing the product. For pre-commissioning with the product (in combination commissioning), the treatment for water fill shall be selected based on the intended period for the new pipeline to be left idle. As minimum requirement the treatment shall be suitable for pipeline protection up to 6 month or more.

13.6 APPENDIX VII DIX VII

FIGURE 1 - PIPELINE PRE-COMMISSIONING SEQUENCEFIGURE 1 - PIPELINE PRE-COMMISSIONING SEQUENCE

CONSTRUCTION RELATED ACTIVITIES PRE-COMMISSIONING ACTIVITIES COMMISSIONING ACTIVITIES

(1) (2) (3) (4) (5) (6) (7) (9)

FLOODING

AND INTEGRITY TESTING (Note 3)

DEWATERING Bulk Dewatering

(Using Dry Air Driven Conventional Pigs) Final Dewatering

(Using Dry Air Driven Foam Pigs)

DRYING TO -20°C DEW

POINT (Note 4)

NITROGEN PURGING AND

PACKING [Including corrosion

inhibitor batching (optional)]

PIPELINE MOTHBALLING

AT 3.0 Bar a

NITOGEN REMOVAL BY INTRODUCING

THE PRODUCT

PIPELINE IP

SURVEY FOR BASELINE DATA

GENERATION

PRE-CLEANING BEFORE

INSTALLATION

POST INSTALL

CLEANING (Using

Water/Air Driven Pigs)

(Note 1)

GAUGING (Using Air

Driven Gauging

Pigs)

FLOODING

AND INTEGRITY TESTING (Note 3)

PIPELINE STANDING

IDLE UNTIL COMMISSIONING

PERIOD

PIPELINE DEWATERING

BY INTRODUCING

THE PRODUCT

PIPELINE IP SURVEY FOR BASELINE DATA

GENERATION

4. Vacuum drying shall be employed for dry sour gas service pipeline and long pipeline which cannot be dried in sections. Other drying method may be proposed on other than these pipelines but subject to QP approval.

Reference Document Reference Document Reference Document QP-STD-L-010 QP-STD-L-011 QP-STD-L-012

OPTION 1

NO

YES

INVOLVEMENT OF FINAL PRODUCT

(Note 2)

OPTION 2

NOT MORE THAN 3 MONTH




REVISION HISTORY LOG

Revision Number: 1 Date: 31/07/2007

Reason for Change/Amendment:

Item Revised:

Changes/Amendments Made: This Standard is an update of the old revision QP specification no. ES-L-40.1: to cover the recent corporate cleaning, gauging and flooding of new pipelines requirements and the latest revisions of reference standards.

Note: The revision history log shall be updated with each revision of the document. It shall contain a

written audit trail of the reason why the changes/amendments have occurred, what the

changes/amendments were, and the date at which the changes/amendments were made.

Documents

QP.SPC.L.010 R1_Hydrotesting