THE COMPANY PROFILE

PONTICELLI NIG. LTD. (PNL) was in corporate in the year 1997. Its parent
company-PONTICELLIFRERES-based in France was established in year 1921.

PONTICELLI specialises in producing world class Oil and Gas facilities,

construction and upgrade services. PNL is a majority 60% Nigerian-owned
Company, with the remaining 40% owned by the parent Company
(PONTICELLI FRERES, France).

EXPERIENCE/PROVEN SUCCESS

For well over the 18 years of PNL’s existence, it has been providing a complete
suite of project engineering and construction services in-house. These services
include supervision and project management activities to our projects. PNL was
awarded the OBITE GAS PLANT project in 1997 by the joint venture of
NNPC/TEPNG, an EPIC contract valued at over 150 million USD, which was
successfully completed and commissioned in 1999. The company has since then
executed several other contracts for TOTAL Exploration and Production Nig.
Ltd., Chevron Nig. Ltd., Nigerian Agip Oil Company and so many others. PNL
is currently involved in the 1.25 billion USD OML58 Upgrade Project for
TEPNG, in partnership with SAIPEM Nig. Ltd. PNL is also involved in the
OFON PHASE II EPCI-5 Project for TOTAL.

PONTICELLI Nigeria Limited are specialised in the following disciplines;

Piping and Structural Fabrication Works with special reference to the following
materials:

 Duplex Steel
 Stainless Steel
 Carbon Steel
 CUNI - Cupper Nickel
 GRE(Glass Reinforced Epoxy)
  Shutdown and Revamping Works
 Production Facilities
 General Maintenance Contracting
 Lifting and Rigging Works
 Electrical & Instrumentation Works
 Hydro testing.

ACTIVITIES

The wide range of skills associated with the complementary specialties of our
Parent Company makes PONTICELLI Nig. Ltd. a highly versatile company
with significant added value capable of exploiting its competence in the
following industries:

 OIL & GAS,

 CHEMICAL,
 PETROCHEMICAL,
 PRODUCTION OF THERMAL & NUCLEAR ENERGY,
 PHARMACEUTICAL,
 WASTE TREATMENT,
 IRON & STEEL,
 AUTOMOBILE,
 PULP & PAPER, AND
 FOOD PROCESSING etc.
Our firm and ongoing commitment to improvement has allowed
PONTICELLI Nig. Ltd. to reach and maintain a leadership position in its
area of Operation. This is why, when it comes to rising to the challenge, our
customers turn to us. They know that the quality and skills of our staff can
carry them to the summit of their ambitions.
 NIGERIAN CONTENT
PONTICELLI Nigeria Limited remains unequivocally committed to the
maximization of local capacities and capabilities utilization in the overall
operations of the Company, in Nigeria.

In PONTICELLI Nigeria Limited, our approach is to maximize local content,

without compromising Health, Safety and environment as well as quality and
principal contract terms. This will be achieved by the following measures:

 Timely identification of opportunities for Nigerian Content based on long

and short term demands.

 Development and support of local vendors, contractors and service

providers.

 Management of Nigerian Content realization in a consistent manner

throughout the duration of our project.

 Monitoring of development through the application of key performance

indicators and targets.

The company have also come to rely more on local subcontractors and vendors
most of which have worked with PONTICELLI since the inception of the
Company in Nigeria. PONTICELLI have shared with them knowledge and
know-how in the critical areas of HSE, quality control and project management,
and the company have in turn benefitted from their growth and performance
improvements.
As part of safeguards to guarantee the satisfactory performance of projects the
company permit The Nigerian Content Dept. to supervise and ensure
compliance with all existing and/or contractual provisions and directives on
Local Content especially as stipulated by NNPC.

The Nigeria Content manager is an integral part of the Project Management

Team (PMT) for all projects. He is responsible for providing guidelines and
clarification(s) regarding the implementation of the NCD key tasks on the
Project
The monitoring of the mandatory engagement/involvement of Nigerian
personnel and subcontractors/suppliers and their job performances on the
project with specific focus on HSE&S, Quality, Organization and respect for
schedule shall be one of the key functions.

MAINTENANCE

PONTICELLI Nigeria Limited benefits from the Maintenance capabilities and

expertise of PONTICELLI Freres, our parent company. Valuable human and
material resources have been committed to the realization of PNL maintenance
services.

OML100 & 102 Global Maintenance Contract (offshore) managed by

TOTAL/NNPC was awarded to PNL at the First Quarter of 2004, and was being
managed efficiently by the company’s highly motivated and committed Teams.
The Contract was recently re-awarded with the inclusion of FSO Unity and the
removal of OML102.

The company’s firm and ongoing commitment to improvement has allowed it to

reach and maintain a leadership position in its field.
It also provide the resources for provision of methodologies and a reliable
dedicated work force but, above all, networked co-ordination of all of its
mechanical entities.

PIPING & STRUCTURAL FABRICATION

Prefabrication and erection of Piping and Structural Steel are major activities of
PONTICELLI Nigeria Limited.

The company constantly seek New Procedures, New Techniques, new software
and new equipment which will enable it to cut cost or schedule and/or improve
the reliability of their services for the benefit of its valued clients.

The team of the company, essentially composed of Nigerian staff have the
experience and the skills required for carrying out works of all sizes, in the most
difficult environments and in the most complex situations.

PAINTING & BLASTING

The company’s ultramodern Blasting/Painting Workshop is equipped with
modern facilities, capable of handling blasting and painting jobs of the highest
standards for their clients.

A long list of national and international references are the clients' best guarantee
that their projects will be carried out to their satisfaction in terms of quality, cost
and delivery deadlines. The company’s teams, carries out their activities with
utmost consideration for safety, both for their personnel, Clients’ facilities and
the environment.
LIFTING & RIGGING

PONTICELLI Nigeria Limited has an incomparable know-how in lifting &

rigging activities, trades that helped established the firm.

In order to respond to the needs of a market in constant transformation,

PONTICELLI Nigeria Limited develops concrete solutions with the help of
modern, high-performance methods and equipment.

With their complete fleet of construction equipment, they can handle a wide
variety of operations, including:

 Typical lifting operations,

 Special Operations: skidding, rolling, jacking, winch hoisting,
 Transposing onto multi-wheel trailers with air and water cushions,
 Frame lifting or hoisting with special equipment.

SHUTDOWN & REVAMPING

PONTICELLI has a wide-ranging experience in the execution of the works of

programmed shutdowns, whether including or not, revamping in the industrial
domains of refining, of chemical and energy production.

PONTICELLI is known for effective planning and management of routine

Shutdown and Revamping of production facilities, bearing in mind the value
attached to planned schedule.

LIPRESSURE TESTING (YDRO TESTING)

 RIGGING INDUSTRIAL PIPING MECHANICAL
The efficient and reliable pressure instruments available to the company
enables them to perform the most reliable pressure tests, especially hydro
tests to their fabricated structures and existing plants.

ABSTRACT

The pre-service hydrotest has been with us for over 50 years. The pressure
testing with water was introduced in the 1960’s to combat the consequence of
failure experienced as a result of pipeline testing using air or product. In more
recent years the purpose of the test has moved from being a leak tightness test to
one which benefits the pipeline as a structural system. The benefits are many
but the cost of implementing a pre-service hydrotest can often be high in
relation to the overall cost of the pipe material Given the high cost, and logistics
involved in the test, pipeline owners/constructors are asking “can the pre-
service hydrotest be eliminated?”. Eliminated is a very emotive word and was
chosen carefully as water, as a test medium, presents the owner/constructor with
potential acquisition, storage, disposal, and long term issues which make it an
undesirable product to choose to use in the pipeline before service. This paper
approaches the hydrotest from the structural point of view and asks some
fundamental questions:
• Why was the hydrotest developed?
• What are the advantages and disadvantages? • What are the benefits, perceived
or quantifiable?
• Have hydrotest failures occurred with regularity?
• Have manufacturing, transportation, and construction methods changed to
negate the need for a hydrotest?
• Are there alternative approaches that can be used to replace the hydrotest
without any loss in benefit? The paper concludes that, technically, the pre-
service hydrotest can be replaced but activities need to be put in place to
compensate for all benefits accrued as a result of conducting the test. This
would mean the development of a specification and implementation plan which
would ensure the same level of integrity as that given by the test. A strategy is
proposed and this leads the way to the development of an implementation plan.

INTRODUCTION

Hydrostatic testing is universally known and accepted as a means of

demonstrating the fitness of a pressurized component for service. After a test, a
pipeline or pressure vessel can be expected to safely contain its intended
operating pressure. The confidence level that a pipeline or pressure vessel is fit
for safe service increases as the ratio of test pressure to operating pressure
increases. This highly beneficial aspect of hydrostatic testing applies not only to
a new component to be placed in service for the first time. A similar benefit
accrues to an in-service component if that component is taken out of service
after a period of time and subjected to a hydrostatic test. A “revalidation” test of
the latter type assures either that no significant time-dependent deterioration of
the component has taken place or that any segment that has been significantly
degraded will be revealed and eliminated. There are limitations to the use of
hydrostatic testing to revalidate integrity. Some are economic, some are
technical, and some are both economic and technical in nature. First, taking a
segment of a pipeline out of service means loss of service for the period of the
test. Some operators may have this option; others may not. Certainly an operator
cannot afford to cut off customers without providing alternative supplies. For
single-line systems, this may not be possible. Technical limitations include the
fact that a test is a go/no-go device. A test reveals weaknesses by causing
ruptures or leaks; it does not indicate, for example, other areas where active
corrosion may be taking place. A limitation that has both technical and
economic implications is that a level of test pressure to operating pressure
sufficient to generate high confidence may result in numerous test breaks or
leaks. Repeated test failures may actually reduce confidence in the final margin
of safety demonstrated by the test, and such failures will certainly add
significantly to the cost of the test and the time out of service. With careful
weighing of the benefits and limitations nevertheless, some pipeline operators
will be able to use hydrostatic testing as a means of integrity assessment. The
objective of this presentation is to show how such testing might be used to
assess the integrity of existing gas pipelines. Pressure tests are performed to
ensure the safety, reliability, and leak tightness of pressure systems. A
pressure test is required for a new pressure system before use or an existing
pressure system after repair or alteration.
There are two methods for pressure tests: hydrostatic and pneumatic. A
hydrostatic test is performed by using water as the test medium, whereas a
pneumatic test uses air, nitrogen, or any non-flammable and non- toxic gas. At
PONTICELLI, pressure tests must be hydrostatic unless pneumatic tests can be
justified.

Hydrostatic test is a way in which pressure vessels such as pipelines, plumbing,

gas cylinders and fuel tank can be tested for strength and leaks. The test
involves filling the vessel or pipe system with a fluid, or liquid, usually water,
which may be dyed to aid in visual to lead detection, and pressurization of the
vessel to the specified test pressure. Pressure tightness can be tested by shutting
off the supply valve and observing whether there is a pressure loss. The location
of a leak can be visually identified more easily if the water contains a colorant.
Strength is usually tested by permanent deformation of the container.

Hydrostatic testing is the most commonly method employed for testing pipes
and pressure vessels. Using this testing helps maintain safety standard and
durability of a vessel over time. Newly manufactured pieces are initially
qualified using the hydrostatic test. They are then re-qualified at regular
intervals using the proof pressure test which is also called the ‘modified
hydrostatic test’ pressure for the material.

IMPORTANCE OF HYDRO TEST

Testing of pressure vessels for transport and storage of gases is very important
because such containers can explode if they fail under pressure. The purpose of
hydrostatic testing a pipeline is to either eliminate any defect that might threaten
its ability to sustain its maximum operating pressure or to show that none exists.
A key word here is pressure. Hydrostatic testing consists of raising the pressure
level above the operating pressure to see whether or not any defects with failure
pressures above the operating pressure exist. If defects fail and are eliminated
or if no failure occurs because no such defect exists, a safe margin of pressure
above the operating pressure is demonstrated. Defects adversely affect the
pressure-carrying capacity because they take away stress-carrying material.
Figure 1 illustrates the significant parameters of a longitudinally oriented defect
that extends part of the way through the wall thickness. Longitudinal extent,
depth-to-thickness ratio, and the strength of the material determine the effect of
the defect on hoop stress carrying capacity. Hoop stress is directly related to
pressure by the “Barlow” formula, the design formula, the design formula for
pipelines.

Hydro testing also has its advantages and disadvantages;

Advantages of Hydro testing

If the pipeline is subjected to a high level test, several benefits can be realised:

1. The test removes defects that are smaller than those that would fail at the
operating pressure. Consequently, a safety margin can be defined which
permits the pipeline to be operated safely, even when defect growth
occurs during service.
2. The high stress induced results in local deformation and blunting of
defects that survive the hydro test. This reduces the potential for
subsequent growth during operation.

3. During manufacture, fabrication and installation, the pipe is subjected to

deformation and loads that induce compressive residual stresses. The
hydrotest stresses relieve these residual stresses.

4. Overloading the pipeline at a temperature above the operating temperature

prevent low stress brittle fracture (so called “warm pre-stressing”).
5. Some plastic deformation will be induced during a high-level pressure
test, which can serve to reduce geometric anomalies such as ovality, dents
(introduced during fabrication), roof topping5, and misalignment. If the
pressure is sufficient to cause plastic strain, the pipeline can benefit from
shakedown in the trench and better post-installation stresses.

Disadvantages of Hydrotesting

There are disadvantages with the hydrotest:

1. The pipeline will always have a distribution of yield strength in each pipe
section, and hence the ‘weakest’ pipe will flow plastically first. This can
subject this pipe length to a load, which may be deleterious in future
operational years given that the plastic capacity has been eroded.
Furthermore, the operator will not know which pipe length will be most
affected.

2. Since the stresses concentrate in weak sections (with low yield strength),
stronger sections will not see the full beneficial effects of the hydrotest.

3. Where the pipeline traverses differences in elevation, the hydrotest

concentrates the beneficial effects at the lowest points in the line. Where the
elevation changes are large (e.g. hilly or mountainous areas), it is necessary to
section the pipeline to ensure that each portion of the pipeline is subjected to the
test pressure. This can be time-consuming and costly. Similarly, the same
problems occur in sub-sea pipelines where internal pressurisation is offset by
hydro static pressure.

4. Leaks are very difficult to detect. If pressure loss is detected during testing it
is necessary to check the compressibility and temperature effects, and leakage
from mechanical equipment (e.g. valves, flanges, etc.) to be confident that a
leak is present. If the leak cannot be seen visibly, then further pipeline
sectioning may be necessary.

5. If the pipeline ruptures, a repair can be more costly than if a defect was
detected through another method (e.g. non-destructive inspection) and repaired.

4 A high level test is one, which induces a stress equivalent to a factor of ³ 0.9
times the yield stress.Typically the factors are 0.9, 1.0, or 1.05 x SMYS.

5 “Roof topping” occurs along the seam weld as a direct consequence of poor
control of crimping of the plate edges, which leads to the incorrect curvature for
the pipe diameter being formed. The curvature controls the matching of the
plate ends at the seam weld and if this is insufficient, the two plate ends meet as
a triangular apex, similar to the shape of a pitched roof.

6. Water acquisition can be a problem in offshore, desert, and arctic areas.

Water also has to be treated to prevent corrosion being induced (this is a
particular problem if seawater is being used).

7. Water testing can be a problem in arctic regions due to the potential freezing
of the test water.

8. Even new pipelines will contain debris, detritus, scale, and oil products,
which can pollute the test water. Disposal in an environmentally acceptable way
may require on site treatment or tankering to a disposal site.

9. Water is generally an unwanted product for gas, liquid and oil lines as it can
lead to corrosion during operation. Typically, a pipeline will be de-watered,
cleaned, and dried before entering service. This can be a time-consuming and
costly exercise.

10. In the new, higher grade pipeline materials (X70 and above), the yield to
tensile strength ratio is larger than older, lower grade materials (X65 and
below). The effect is to reduce the circumferential plastic strain capacity for the
same percentage SMYS.
11. The hydro test is not very effective at finding defects that exist in the girth
welds, as the principal stress is hoop orientated. However, the pipeline can be
subjected to axial loads that are not pressure-induced (e.g. ground movement,
spans, etc.) and hence can fail at an internal pressure lower than at the hydrotest
pressure.

PROCEDURE

 Pressure gauges at different levels (lower point and higher point) is

installed.
 Test manifold, pump, etc. are connected.
 It is verified that the test is assembled and isolation of systems by the
installation of spades, blinds, blind flanges are in accordance with test
method.
 Preliminary check at no more than 2 bars is carried out to locate any
major leak.
 Calibrated pressure and temperature recorder is installed.
 The test can only be commenced with the presence of the company’s
authorised supervisor.
 Pressurisation and depressurisation sequence is monitored closely.
Duration of sequence depends on the volume of test fluid required to test
the system. Pressure are built on the piping systems in incremental
sequence (i.e. 25%, 50%, 75%, 100%) with a break in between pressure
build up to allow for settling of the system under pressure.

AFTER TESTING
 After testing, all piping are drained of all test fluid. All piping tested with
water are thoroughly dried. The piping are blown down with dried air and air
circulated through the piping until it has been determined that there are no
trapped pockets of water and that the piping is dry.

PRECAUTION

 It is verified that all pipe connections, including welded connections,

where applicable, are installed in such a way as to allow examination
during testing.
 Barriers around the system being worked on with warning signs is
erected. This is done to keep away unauthorised personnel and to ensure
no interference with the setup.

CONCLUSION

CONCEPT OF HYDROTEST
Pressure tests are performed to ensure the safety, reliability, and leak
tightness of pressure systems. A pressure test is required for a new pressure
system before use or an existing pressure system after repair or alteration.
There are two methods for pressure tests: hydrostatic and pneumatic. A
hydrostatic test is performed by using water as the test medium, whereas a
pneumatic test uses air, nitrogen, or any non-flammable and non- toxic gas. At
PONTICELLI, pressure tests must be hydrostatic unless pneumatic tests can be
justified.

Hydrostatic test is a way in which pressure vessels such as pipelines, plumbing,

gas cylinders and fuel tank can be tested for strength and leaks. The test
involves filling the vessel or pipe system with a fluid, or liquid, usually water,
which may be dyed to aid in visual to lead detection, and pressurization of the
vessel to the specified test pressure. Pressure tightness can be tested by shutting
off the supply valve and observing whether there is a pressure loss. The location
of a leak can be visually identified more easily if the water contains a colorant.
Strength is usually tested by permanent deformation of the container.
Hydrostatic testing is the most commonly method employed for testing pipes
and pressure vessels. Using this testing helps maintain safety standard and
durability of a vessel over time. Newly manufactured pieces are initially
qualified using the hydrostatic test. They are then re-qualified at regular
intervals using the proof pressure test which is also called the ‘modified
hydrostatic test’ pressure for the material.

IMPORTANCE OF HYDRO TEST

Testing of pressure vessels for transport and storage of gases is very important
because such containers can explode if they fail under pressure.

PRECAUTION
 It is verified that all pipe connections, including welded connections,
where applicable, are installed in such a way as to allow examination
during testing.
 Barriers around the system being worked on with warning signs is
erected. This is done to keep away unauthorised personnel and to ensure
no interference with the setup.

PROCEDURE
 Pressure gauges at different levels (lower point and higher point) is
installed.
 Test manifold, pump, etc. are connected.
 It is verified that the test is assembled and isolation of systems by the
installation of spades, blinds, blind flanges are in accordance with test
method.
 Preliminary check at no more than 2 bars is carried out to locate any
major leak.
 Calibrated pressure and temperature recorder is installed.
 The test can only be commenced with the presence of the company’s
authorised supervisor.
 Pressurisation and depressurisation sequence is monitored closely.
Duration of sequence depends on the volume of test fluid required to test
the system. Pressure are built on the piping systems in incremental
sequence (i.e. 25%, 50%, 75%, 100%) with a break in between pressure
build up to allow for settling of the system under pressure.

AFTER TESTING
After testing, all piping are drained of all test fluid. All piping tested with
water are thoroughly dried. The piping are blown down with dried air and air
circulated through the piping until it has been determined that there are no
trapped pockets of water and that the piping is dry.