Doc.

No:
QUALITY CONTROL DOCUMENT BNL/QCD-PHT-112
Issue Date:
18/01/16
DOC TITLE PROCEDURE FOR HYDROTEST
Page 1 of 13

QUALITY CONTROL DOCUMENT

PROCEDURE FOR HYDROTEST

OF

BRIDGSITE NIGERIA LTD

DOC NO BNL-QCD-PHT-112

18/01/
001 IDC
16
Issued for Internal review T. A. D. H. C. U.

Revision Status Date Revision memo Issued by Checked by Approved by

This document has been generated by an Electronic Document Management System. When printed it is considered as a for information only copy.
The controlled copy is the screen version and it is the holder's responsibility that he/she holds the latest valid version.

CHANGE (S)/AMENDMENT (S)

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The change(s)/amendment(s) noted below have been made and approved by the Managing
Director/CEO for issue.

Change/Amendment No. Date Page Description of Change/

Amendment

TABLE OF CONTENTS
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Content

1.0 Purpose......................................................................................................................................................................4
2.0 Scope.........................................................................................................................................................................4
3.0 References..........................................................................................................................................................4
4.0 Definitions and Abbreviations...........................................................................................................................4
5.0 Responsibilities and Authorities........................................................................................................................4
6.0 Procedure...........................................................................................................................................................4
6.1 Preparation............................................................................................................................................................5
6.2 Pre-Cleaning by Water Filling and Testing...........................................................................................................6
6.3 Equipment.............................................................................................................................................................8
6.4 Hydrostatic Test Acceptance Criteria....................................................................................................................8
6.5 Close-Out Activities................................................................................................................................10
6.6 Safety and Environmental Protection..............................................................................................11
7.0 Appendix..........................................................................................................................................................12
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1.0 Purpose
The purpose of this procedure is to prove the integrity of PIPES through
hydrostatic pressure testing and confirm the integrity for its designed use

2.0 Scope
Hydrostatic testing of the XXX Lengths of Pipes

3.0 References
Pipeline Hydro Test Specification
ASME B31.8.
ASME B31.4.
API 1110
EN-12502
All efective Nigerian Laws, Regulations, Codes & Standards.
Water Analysis report as required/recommended by the
a p p r o v e d project procedure, applicable code and standards.

4.0 Definitions and Abbreviations

ASME - American Society of Mechanical Engineers
API - American Petroleum Institute
Specific Test Pressure (STP)
PTW - Permit to Work

5.0 Responsibilities and Authorities

Site Superintendent/Testing Engineer - Implements operating
procedures on project sites
Mechanical Fitter - Responsible for assuring proper mechanical fit-up
before and during hydrotesting as well as dis-coupling after dewatering
operation.
Pump Operator- Responsible for pump rig-up, operation, and rig-down.

6.0 Procedure
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6.1 Preparation
Before commencement of work at the project site, Bridgsite shall
submit the designated approved Test project teams names and CV's
for client approval.
The Site Superintendent shall designate qualified personnel to be
responsible for all hydrostatic testing activities. Prior to
commencement of hydro testing activities, we shall ensure
compliance and work in accordance with the CLIENT approved Permit
to Work System (PTW). Actual Testing activity shall be executed only
after all NDT results have been confirmed by the client designated
representative via a written instruction to proceed with Hydro
testing and an approved Hydrotest pack is in place.
All testing equipment to complete the hydro test is to be supplied by
Bridgsite. The Test Engineer shall be responsible for all test
preparations including, test manifolds, piping, pipe filling and
draining. The location for filling, testing and draining of the pipes shall
be mutually agreed between the Test Engineer and client.
All water required for filling, flushing, and pressure testing shall be
provided by the Client, who shall also be responsible for the
filtration, clarification and Chemical treatment of the water so as to
prevent ingress of foreign matter, sedimentation and metal corrosion,
the water used for filling and testing shall be clean water of potable
quality.
The chemical pre-treatment of water used for pressure testing will
depend on the origin and analysis (particularly salinity) of the water
source. Chlorination may be necessary to stop development of lime,
bacteria and other micro-organisms inside the system under test.
The composition and dosing rates of corrosion inhibitors, sterilizing
agents, bactericides and all other chemicals to be used in the pre-
treatment of test water shall be based on the Water analysis report
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and approved by the Client before use. Agreed dosing rates shall
be controlled and maintained by properly calibrated micro dosing
pumps and the injection shall be carried out well upstream of the
fill points so as to allow thorough mixing before entry to the system
under test.
Bridgsite is responsible for obtaining permits, for using and disposing of water for
cleaning and testing purposes from the Client.
Bridgsite is to provide all necessary permits and approvals for all hydro testing pre-
commissioning /commissioning work.
The appropriate pressure and temperature gauges, recorders, dead weight tester
and valves specified shall be connected to the installed pipes in
preparation for the hydrostatic test. Test measuring equipment shall be
calibrated and certificate shall be made available at any point in time during testing
services.
The connections and the test assembly shall be checked by the Test
Engineer for conformity to this procedure and to ensure that all safety
precautions have been taken into place with warning signs and barriers installed
All valves, if installed shall be in the open position during the hydro test, Pipe
section shall be prepared as such as to allow all segment of the line be Hydro
tested in series as may be permitted and based on space requirement at end
facilities.
The pipe shall be hydrostatically tested to the specific test pressure (STP), the
entire length of the river sections shall be tested as one section prior to
pulling into position. When specified, each test procedure shall contain test
plans or sketches, identifying the pipeline sections to be tested, clearly
showing the test limits including the pipe test legend indicating the test
pressure, the test medium and any other pertinent information. In the event
of a conflict between this procedure and the specification or standards, the
more stringent will prevail.
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6.2 Pre-Cleaning by Water Filling and Testing

Before the pipe section is ready for water filling and hydrostatic
testing it shall be flushed using water only. Any other cleaning
method shall be the responsibility of the client provided that it comply
with the clients hydrostatic test procedure.
The section ends shall be sealed with temporary header for cleaning
purpose.
Notification shall be given to local residents and notices
'KEEP AWAY - PIPES UNDER TEST' and 'NO PARKING' shall be
prominently displayed at points of public access. Arrangements
shall be made to ensure that no unauthorized person may approach
within 50 meters of any exposed pipe, or test end.
Hydrostatic Test Sections and Test Pressures
The pipe sections to be tested are limited by the following factors:
Minimum and maximum test pressures (taking into
account that there may be pipe of diferent wall thickness
in the test string, therefore the thinner walled pipe becomes
the limiting factor);
Elevation diference;
Filling and dewatering plan.
Hydrostatic test section shall be the entire length of the
Quad Joint Inner pipe.
The hourly maximum loss of test water volume to be
recognizable by the equipment shall be calculated as V 4 x
V total / 3000 but never exceed 4 liters.
Start- and end points of test sections shall ideally be well
accessible, next or close to water sources and/or in low
elevations.
The test section distribution is within the scope of works of the
Contractor and shall be part of the hydrostatic test procedure.
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Testing of the installed pipes shall be tested and pressurized to a

minimum 1.25 of the Design pressure in accordance with Project
Specification.
After filling, the pipe shall be stabilized. The stabilization period
shall be 30 mins. After the stabilization period, the test shall
be started. During the testing of the pipe, the QC will check
for pressure drops. Should a leak occur, the test pressure is
reduced to 0. Repairs, other than welding, are completed and
the pipes subsequently re-pressurized and re- tested.
Test pressures and temperatures shall be recorded on the
chart throughout the testing period. The recorder shall be
placed within safe distance of the pipe under testing.
Upon satisfactory completion of the test, the results shall be
recorded.

6.3 Equipment
Volume fill Pump
High Pressure Pump
Holding Tank
Pressure Gauge
Pressure Recorder

6.4 Hydrostatic Test Acceptance Criteria

The pre-testing location shall be selected by the Contractor and
approved by the Company. The pipe strings shall be placed on suitable
and safe temporary supports at least 600mm above ground level
to facilitate visual inspection. Each p i p e string shall contain only pipe
of the same wall thickness. Some cap test ends shall be fitted at each
string; these test ends shall have been pre-tested and certified to a
pressure at least 10% greater than the selected pre-test pressure. A
record of their use along with their unique identification number shall
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be provided to the Clients Representative prior to the

any hydrostatic test activities being undertaken.
The pre-tested pipe sections shall be tested to a test pressure
of not less than 5% more than the test pressure designated
for the test section into which it shall be installed.
The duration of the pre-test shall be not less than 4 hours and
the test shall be considered accepted if no signs of a leak are
detected upon a visual inspection.

Hydrostatic Test Sections and Test Pressures

The pipe sections to be tested are limited by the
following factors:
Minimum and maximum test pressures (taking
into account that there may be pipe of
diferent wall thickness in the test string, therefore
the thinner walled pipe becomes the limiting
factor);
Elevation diference;
Filling and dewatering plan.
Hydrostatic test section shall be the entire length
of the river crossing as one unit.
The hourly maximum loss of test water volume to
be recognizable by the equipment shall be
calculated as V 4 x V total / 3000 but never
exceed 4 liters.
Start- and end points of test sections shall ideally
be well accessible, next or close to water sources
and/or in low elevations.
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The test section distribution is within the scope of

works of the Contractor and shall be part of the
hydrostatic test procedure.
The pipe section shall be completely de-watered
following successful completion of the pre-test and
approval by Client's Representative and all welds cut out
and ends re-beveled before transporting to site. The
method of testing and criteria expected of the
Contractor by the Client shall be equal to that of the
hydrostatic test requirements specified for the mainline
sections themselves.

Following installation of the pre-tested pipe into the

crossing / special point section it shall be tied into the
adjacent mainline section and the entire section tested in
accordance with this specification. Pre-tested pipes shall
be clearly marked to identify them as pre-tested.
Marking shall be made by a coloured paint along the
entire length of the pipes. Diferent sections shall be
marked with diferent colours. The marking philosophy
shall be included in the detailed testing procedure.
All Pre-test certificates shall be submitted by
Contractor for approval by the Clients Representative.
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6.5 Close-Out Activities

Following acceptance or approval of the Hydro test, the test liquid shall
be displaced from the pipes with compressed air. Free draining of line
during de-watering may be allowed.
Following satisfactory testing, temporary test heads, blind flanges,
instruments and other test equipment are removed and returned to
Bridgsite yard.
All test records and record charts shall be signed by the CLIENT
REPRESENTATIVE, and included in the documentation package.
On completion of the above, the pipe is released for final installation
and tie-in as may be required.

6.6 Safety and Environmental Protection

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All personnel involved in the Hydro testing operation shall have

completed Bridgsite HSE Induction
Prior to commencing the Hydro testing operation, a detailed Job Hazard
Analysis (JHA) will be carried out. After all known or suspected or
potential hazards and risks have been identified, the workforce shall
be informed of the hazards and control measures that must be in
place to eliminate or control the hazards and potential risks
surrounding the Hydro testing Operation.
All personnel shall be equipped with safety PPE, particularly for
handling of chemical additives, which require rubber gloves and
safety goggles as a minimum in line with the MSDS. Bridgsite and
CLIENT Safety Representatives shall instruct personnel in safe working
practices and ensure that they are enforced.
All test crew personnel shall be trained and/or experienced in the
testing activities performed.
A communication link system shall be finalized, prior to the start of
any hydrostatic testing activities.
All static machinery, including pumps and compressors, shall be
equipped with fire extinguishers.
All above ground sections shall be secured and entry
restricted to exclude personnel, other than the test crews
during the hydrostatic testing.
Work permits shall be endorsed by security personnel made
aware of the nature of the test and access limitations.
Other than specified above, no work of any kind, either
permanent or temporary, shall be performed on any part of the
system while testing is in progress.
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7.0 Appendix
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QUALITY CONTROL
HYDROSTATIC TEST
CERTIFICATE
PROJECT:
CONTRACT No: DATE:
TEST DATA
TEST DESCRIPTION: DESIGN TEMP.
( OC)
EQUIPMENT DESIGN
DESCRIPTION: PRESS.
( PSIG):
DRAWING / LINE No: TEST PRESS.
(PSIG):
TEST PARAMETERS
REQUIRED ACTUAL
TEST DURATION (HOUR)

PRESSURE IN GAUGE -1 (PSI)

PRESSURE IN GAUGE -2 (PSI)

PRESSURE IN RECORDER (PSI)

PRESSURE IN DEAD WEIGHT

(PSI)
PRESSURE ON HOLD
INSPECTED VISUALLY (PSI)
METAL TEMP. RECORDED (OC)

TEST INSTRUMENT DETAILS

RANGE SERIAL No CALIBRATION CERTIFICATE No.
DATE
GAUGE 1
GAUGE 2
PRESSURE RECORDER

TEMPERATURE RECORDER

DEAD WEIGHT TESTER

INFRA RED DIGITAL

THERMOMETER

TEST SUB-CONTRACTORS REP. CONTRACTORS REP CLIENT REP.

Name:
Signature:
Date:
THE FOLLOWING AREAS WHERE THOROUGHLY CHECKED FOR LEAKS DURING THE VISUAL
INSPECTION;
1. ALL WELDED JOINTS (SHELLS, HEADS AND NOZZLE ATTACHMENTS)
2. ALL BOLTED JOINTS (NOZZLES, MAN-WAYS, FLANGES E.T.C)
3. TREADED JOINTS (NPTs)
4. PIPE EXTERNAL SURFACES AS WELL AS PIPE SURFACE DEFORMATIONS.