Specification For Hydrotesting of New Pipelines: 0000BF-C-G0-G000-PL-SPC-0001

RUMAILA OPERATING ORGANISATION
SPECIFICATION FOR HYDROTESTING OF NEW PIPELINES
DOCUMENT NUMBER
0000BF-C-G0-G000-PL-SPC-0001
DATE
17 February 2020
Project
Rev Description Originator Review Date
Approval
D. Halliwell S. Keegan T. Johnston

B06 Issued for use 17 Feb 2020
D. Smith S. Wright S. Moyes
Steph Timothy Digitally signed

Derek
Digitally signed by
Digitally signed Stephen Keegan by Timothy G.
by Derek G.
DN: cn=Stephen
G. Johnston
G. en
Keegan,
Smith Date: 2020.02.23
Johnston
o=Engineering
Date: 2020.02.24 Services, 18:24:55 +03'00'
Smith 08:43:11 +03'00'
Keeg
ou=Operations,
email=stephen.kee
gan@roobasra.co
m, c=US
an Date: 2020.02.17
16:37:08 +03'00'
0000BF-C-G0-G000-PL-SPC-0001 Rev B06 – 17 February 2020 Page 1 of 20

This document is the property Rumaila Operating Organisation. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
REVISION DESCRIPTION SHEET
Rev. Para. Reason for Revision

B02 Various Reissued to include ASME B31.3 piping systems and ASME VIII pressure vessels
B03 Various Removed all reference to Piping & Pressure Vessels and reformatted document. Specification
0000RP-C-G0-G000-QA-SPC-0002 now includes pressure testing requirements for Pressure
Vessels, Process and Utility Piping
B04 Section 7 Updated to include lessons learned from CPS-3 report, hydro test failure of threaded test fitting at
Paragraphs high pressure – August 2018. Updated text in italics.
2, 3 & 4
B05 8.1.1 Updated to include visual inspection and photographic evidence of pipe cleanliness as part of
Contractor’s Method Statements and Inspection and Test Plans.
B06 Front page Added NEW in title
All Replaced should with shall throughout
1 Reworded summary to clearly define document application
1st Paragraph
1, Removed reference to old Pipelines

4th Paragraph
1 Deleted, Operators can select
(a)
1 Deleted
(b)
1 Added, and competent CONTRACTOR
(e)
1 Deleted, Users of this specification should be aware that further or differing requirements may be
4th Paragraph necessary for some applications. Nothing in this specification is intended to inhibit the use of
engineering solutions that are not covered by the procedure. This may be particularly applicable
where there is innovative developing technology
1 Deleted, while it is recognized that the conditions of a particular job will necessitate an on-the-job
6th Paragraph approach, the implementation of this procedure will improve the probability that work will be
completed safely and without accidents or injuries
Section 1, Removed reference to testing of in-service Pipelines.
8th Paragraph
1.1 Deleted Operating Pressure Limit
Abbreviations Deleted Service Test
& Definitions
Deleted Revalidation Test
Test medium deleted gas
2.1.1 Deleted reference to in service
nd
Scope 2 Added, This Specification does not apply to existing pipelines. Refer to COMPANY Specifications
Paragraph 0000RP-C-G0-G000-PL-SPC-0001 Specification for Pressure Testing Existing Pipelines to ensure
Integrity
2.1.2 Deleted bullet points b), c), d) and e)

Purpose
3.1 Deleted bullet point b)
General
3.2 Deleted bullet points a) and c)
3.3 (n) Deleted (Both in and out of service)
Deleted bullet points related in service documentation
4 (a) Deleted service and leak test
5.1.1 Deleted reference to ASME B31.4 and hydrotest requirements according to hoop stress
requirements. Replaced with 1.25 time the design pressure for 4 minimum hours.
5.1.2 Section deleted


Service Test
6.1 Replaced source water with Potable water as the preferred test medium
6.2.2 If water is approved by COMPANY from source water.
6.2.3 If water is approved by COMPANY from source water.
6.2.4 Deleted bullet point a) second paragraph
Dewatering Deleted bullet point c)
7 Third paragraph replaced quarterly with annual
Third paragraph replaced certified criteria with hydrotest equipment
Bullet point b) deleted last sentence
Deleted bullet points c) and d)
Bullet point f) deleted measuring device and replaced with chart recorder
Deleted bullet points k) and l)
Mechanical
Cleaning
8.1.2 First paragraph added 6.1
5th & 6th Deleted paragraphs related to pigging
paragraph Deleted Hydraulic flushing’s section
Filling
8.3 Third paragraph deleted last sentence.
Fourth paragraph deleted ambient temperatures
b) Deleted service test
c) Deleted leak test
8.4 Deleted bullet points a) and b)
9 Deleted, when water is used as the test medium
10 Deleted paragraph excluding last sentence
10.1 Deleted, bullet points a), g), n) and t).
10.2 Deleted bullet point b)
11.1 Deleted all ITR’s excluding P04A and P07A
11.2 Deleted
Hold No. Para. Description of Hold

CONTENTS
1 SUMMARY.......................................................................................................................... 5
1.1 Abbreviations and Definitions ............................................................................................. 6
2 INTRODUCTION ................................................................................................................ 8
2.1 Scope and Purpose ............................................................................................................ 8
2.2 Conflicts and Deviations ..................................................................................................... 8
2.3 References Documents ...................................................................................................... 8
2.4 Order of Precedence ........................................................................................................ 10
3 REQUIREMENTS ............................................................................................................. 10
3.1 General ............................................................................................................................. 10
3.2 Design ............................................................................................................................... 10
3.3 Test Pack Documentation ................................................................................................. 11
4 TEST PROCEDURE CHARACTERISTICS ..................................................................... 11
5 HYDROSTATIC TESTING ............................................................................................... 12
5.1 Pipelines ........................................................................................................................... 12
6 PRESSURE TEST MEDIUM. ........................................................................................... 12
6.1 Test Medium ..................................................................................................................... 12
6.2 Corrosion Control .............................................................................................................. 13
7 PRESSURE TEST EQUIPMENT AND MATERIALS ....................................................... 14
8 PRESSURE TEST IMPLEMENTATION ........................................................................... 15
8.1 Line Filling and Cleaning .................................................................................................. 15
8.2 Initial Pressurization .......................................................................................................... 16
8.3 The Test Period ................................................................................................................ 17
8.4 Pressure Test Failures ...................................................................................................... 17
8.5 Acceptance Criteria for Strength Test .............................................................................. 17
9 DEPRESSURIZATION, DISPLACEMENT AND DISPOSAL OF TEST MEDIUM ........... 18
10 TEST RECORDS AND DRAWINGS. ............................................................................... 18
10.1 Test Records ..................................................................................................... 18
10.2 Test Drawings.................................................................................................... 19
11 GOC REQUIREMENTS .................................................................................................... 19
11.1 A - ITR’s ............................................................................................................. 19
11.2 Typical Test Pack .............................................................................................. 20

1 SUMMARY
This specification provides the requirements for pressure testing new steel pipelines for the
transportation of oil, gas and water within Rumaila.
The specification provides guidance so that:
a) A pressure test suitable for the conditions under which the test will be conducted—this includes,
but is not limited to, material characteristics, operating conditions, and various types of anomalies
or other risk factors that may be present;
b) Site-specific procedures are developed and followed during all phases of the pressure testing
process;
c) Pressure tests consider both personnel safety and environmental impacts;
d) Pressure tests are implemented by qualified and competent CONTRACTOR personnel;
e) Pressure tests are conducted in order to meet stated acceptance criteria and pressure test
objectives;
f) Pressure test records are developed, completed, and retained for the useful life of the facility.
Due to the risks involved in the hydrostatic testing of new pipelines, an appropriate risk assessment
must be performed and approved by the COMPANY representative.
This document must be read in conjunction with Energy Isolation Procedure ROO-ALL-HS-PRO-0019.
Personnel involved in hydrostatic test activities must understand the importance of careful planning to
ensure safe and efficient practices and procedures. Employees and CONTRACTORs should be briefed
on-site about specific activities and safety procedures. Only competent personnel with the proper
training, experience and demonstrated skills shall be allowed to perform hydrostatic test activities.
Hydrostatic testing of a pipeline is usually carried out by testing a number of isolated test sections which
aims to establish.
a) The strength of a test section

1.1 Abbreviations and Definitions
AEROBIC
Bacteria that grow in presence of air or un-combined oxygen.
BACTERIA
ANAEROBIC
Bacteria that grow in absence of air or un-combined oxygen
BACTERIA
ANOMALY A deviation from the norm in pipe material, coatings, or welds
A component that is attached to the pipeline, e.g., valve, tee, instrument

APPURTENANCE
connection, supports, anchors, etc.
ASME American Society of Mechanical Engineers
The collection of sessile organisms combined with the deposits formed by

BIOFILM
microbial growth.
Brackish water is water that is saltier than fresh water, but not as salty as sea
water. It may result from mixing of seawater with fresh water, as in estuaries,
BRACKISH or it may occur naturally, as in brackish fossil aquifers. Technically, brackish
WATER water contains between 0,5 and 30 grams of salt per litre—more often
expressed as 0,5 to 30 parts per thousand (ppt or ‰), (Raw water sourced
locally in ROO is considered Brackish).
CERTIFICATION A written testimony of qualification.
CONTRACT Shall mean the formal agreement between COMPANY and SUPPLIER
The party which carries out all or part of the described work and services. The
CONTRACTOR
CONTRACTOR may undertake all or part of the duties of the CONTRACT
COMPANY ROO Rumaila Operating Organisation
Any physical part of the pipeline other than line pipe, including but not limited
COMPONENT
to valves, welds, tees, flanges, fittings, taps, branch connections and outlets.
The deterioration of a material, usually a metal, that results from a reaction

CORROSION
with its environment.
CRACK A very narrow elongated separation caused by mechanical splitting.
DOCUMENT This shall include both text documents and drawings
GOUGE Elongated grooves or cavities caused by mechanical removal of metal.
HYDROSTATIC A pressure test conducted using water or other approved liquid as the test
TEST medium.
MAY One possible course of action
MUST / SHALL A mandatory requirement
A continuous part of a pipeline facility used to transport a gas, petroleum gas,

PIPELINE hazardous liquids, highly volatile liquids or carbon dioxide. Including pipe,
valves, and other appurtenances attached to pipe.
PIPELINE Any physical portion of facilities through which gas, petroleum gas, hazardous
SYSTEM liquids, highly volatile liquids or carbon dioxide are transported. This includes
pipe, valves, and other appurtenances attached to the pipe, compressor units,

pumping units, metering stations, regulator stations, delivery stations, breakout

tanks, holders, and other fabricated assemblies.
PLANKTONIC Bacteria that are found in the water and their movement is controlled by the
BACTERIA movement of water.
ROO Rumaila Operating Organisation
SESSILE
Bacteria that grow on and lie attached to a surface.
BACTERIA
SHOULD A preferred requirement
A pressure test at an internal pressure determined in accordance with Section

STRENGTH TEST
5 of this specification.
STRESS Tensile, shear or compressive force per unit area.
The SUPPLIER is the party, which manufactures or supplies equipment and

SUPPLIER
services to perform the duties of the CONTRACTOR.
Shall mean the party supplying goods, equipment or material specified by the
SUB-SUPPLIER
SUPPLIER
SPECIFIED
MINIMUM YIELD Yield strength value prescribes in the material specification under which pipe
STRENGTH and fittings are purchased from the manufacturer.
(SMYS)
TEST MEDIUM The fluid used to conduct a pressure test.
Shall mean all and any of the works, services and materials required to be
WORK
provided by the CONTRACTOR
NOTE: Throughout this document where the term CONTRACTOR is used, this also means
SUPPLIER

2 INTRODUCTION
2.1 Scope and Purpose
2.1.1 Scope
This procedure shall apply to all Rumaila Operating Organisation locations and facilities including
Qarmat Ali and K44. It shall be followed when planning and execution of hydrostatic testing.
This procedure defines mandatory requirements governing pressure testing of all parts of a new
pipelines including line pipe, appurtenances connected to line pipe, fabricated assemblies, valves,
tees, elbows, reducers, flanges, etc.
This Specification does not apply to process and utility piping, pumping units, compressor units,
breakout tanks, control piping, sample piping, instrument piping/tubing, or any component or piping
system for which other codes specify pressure testing requirements (i.e., piping systems covered
by building codes, etc.).
This Specification does not apply to existing pipelines. Refer to COMPANY Specifications
0000RP-C-G0-G000-PL-SPC-0001 Specification for Pressure Testing Existing Pipelines to ensure
Integrity
2.1.2 Purpose
Hydrostatic test shall be conducted for the following reasons:
a) Verify the strength of a pipeline segment at a 1.25 x the design pressure.
b) Verify that a pipeline segment does not show evidence of leakage.
2.2 Conflicts and Deviations
Any conflicts between this procedure and other applicable ROO Engineering procedure, Materials
Specifications, Standard Drawings, or industry standards, codes, and forms shall be resolved in writing
by the COMPANY Representative.
Direct all requests to deviate from this specification in writing to the COMPANY Representative, who
shall follow internal COMPANY procedure and forward such requests to the Technical Authority (TA).
2.3 References Documents
2.3.1 Regulations, Codes and Standards
The CONTRACTOR shall comply with applicable National or Local codes, regulations, ordinances,
and rules. Unless defined otherwise these shall be those applying to the country where the
equipment is to be installed.
The selection of material and equipment, and the design, construction, maintenance, and repair of
equipment and facilities required by this standard shall comply with the latest edition of the
references listed below, unless otherwise noted. Any conflicts between the requirements of this
Specification and other reference documents shall be referred to COMPANY for resolution.

Document Number Title
ASME (American Society of Mechanical Engineers)

Pipeline Transportation Systems for Liquid Hydrocarbons and Other
ASME B31.4 Liquids
Gas Transmission and Distribution Piping Systems

ASME B31.8
Managing System Integrity of Gas Pipelines
ASME B31.8S
Pipe Flanges and Flanged Fittings
ASME B16.5
ASME B16.9 Factory-Made Wrought Butt welding Fittings
Non metallic Flat Gaskets for Pipe Flanges

ASME B16.21
API (American Petroleum Institute)

Pressure Testing of Steel Pipelines for the Transportation of Gas,
Petroleum Gas, Hazardous Liquids, Highly Volatile Liquids or Carbon
API RP 1110
Dioxide
Managing System Integrity for Hazardous Liquid Pipelines

API Standard 1160
Specification for Pipeline Valves
API 6D
2.3.2 Project Documents
The following documents are available to support this procedure, latest edition shall apply:
.
Document number Title of procedure
ROO-ALL-HS-PRO-0001 Control of Work Manual
ROO-ALL-HS-PRO-0004 Control of Work Policy
ROO-ALL-HS-PRO-0007 Gas Detection
ROO-ALL-HS-PRO-0019 Energy Isolation
ROO-ALL-HS-PRO-0127 Welding and Cutting
0000BF-C-G0-G000-QA-SPC-0002 Rumaila Specification for Carbon Steel Pipeline
Welding and Inspection
0000BF-C-G0-G000-PL-BOD-0001 Pipeline Brown field Basis of design
00100W-C-G0-G000-PE-SPC-0005 Specification for Brownfield Pipeline class Y09E2B
00100W-C-G0-G000-PE-SPC-0006 Specification for Brownfield Pipeline class Y15B2B
0000RP-C-G0-G000-PE-SPC-0007 Specification for Brownfield Pipeline Class Y09E2B
0000RP-C-G0-G000-PE-SPC-0011 Specification for Brownfield Pipeline Class Y03F3B
0000RP-C-G0-G000-PE-SPC-0014 Specification for Brownfield Pipeline Class Y03F6B
0000RP-C-G0-G000-QA-PRO-0003 Materials Traceability & Certification
0000RP-C-G0-G000-QA-PRO-0004 Deviation Request

0000RP-C-G0-G000-QA-PRO-0001 Technical Query

0000RP-C-G0-G000-QA-IDX-0001 Index of Engineering Codes and Standards
0000RP-C-G0-IC-BOD-0001 Brown field Instrument and Control Basis of Design
0000BF-C-G0-G000-PE-PRO-0001 Flange Management Procedure for the Controlled
tightening of pressurised joints
00096R-C-G0-G000-CO-PRO-0001. GOC Completions Procedure
2.4 Order of Precedence
The following hierarchy shall apply to the WORK
1. Statutory Iraqi Laws and Regulations

2. CONTRACT terms and conditions
3. The Material Requisition
4. This PROJECT Specification
5. Other Industry codes and standards
6. Recognised CONTRACTOR Manufactures and Technology specifications
In the event of ambiguity or contradiction between the above, precedence shall be given in the order
listed above. In the event of ambiguity or contradiction within the Specification, CONTRACTOR shall
apply the most onerous requirement. In all cases, CONTRACTOR shall seek approval via an
Engineering or Technical Query before proceeding.
For the avoidance of doubt, hierarchy stipulations in any other document within the specification are
superseded by the above hierarchy.
International codes and standards shall be the latest edition and latest addenda at the time of
CONTRACT award.
3 REQUIREMENTS
3.1 General
a) Every pipeline after construction and prior to initial operation shall successfully pass a hydrostatic
test. The hydrostatic test shall be performed in accordance with section 8 of this specification and
requirements of the applicable design code (ASME B31.4, ASME B31.8, as applicable).
b) If block valves are used for blocking or isolating hydro test sections, the differential pressure across
the valve seat shall not exceed the seat test pressure during strength test and shall not exceed the
rated seat pressure during tightness test.
3.2 Design
a) Supports: For above ground installation, the pipeline shall be analysed to determine whether
temporary supports are required during hydrostatic testing to limit the sustained longitudinal
stresses to acceptable code limits. If temporary supports are found to be needed and more
economical than permanent supports, this should be highlighted in the hydrostatic test procedure.

3.3 Test Pack Documentation
Prior to conducting the pressure test, the following engineering and operations documents shall be
reviewed to make sure that the pressure test is appropriate and feasible:
a) Test Pack including,
b) As built drawings
c) Fabrication Records
d) Weld Map and Weld Summary.
e) Pipeline route.
f) Identification of the test section and its physical boundaries.
g) Test pressure ratings of valves, components, connections, and appurtenances in the test section.
4 TEST PROCEDURE CHAR ACTERISTICS
The following characteristics shall be established and clearly documented in a specific hydrostatic test
procedure and shall be submitted by CONTRACTOR for COMPANY approval:
a) Type of hydrostatic test (Strength Test)
b) Test section boundaries and segmenting of the pipeline including as built drawings.
c) Location of appurtenances within the test section (valves, flange sets, taps, stopples, sleeves,
patches, etc.)
d) Location of isolation points (valves, blind flanges, removal spool, etc.) within the test section
boundaries.
e) Test start time, ambient temperature at start time.
f) Location of measuring devices (Pressure and temperature) within the test section.
g) Water source location.
h) Water additives if any.
i) Water disposal location.
j) Water Injection point within the test section.
k) Condition of right-of-way (UXO clearance).
l) Obstructions impairing access to the pipeline.
m) The amount of exposed pipe within the test section.

a. Large amounts of exposed pipe can result in large temperature related pressure changes,
making a stable test difficult to achieve.
n) Identification of joint connections within the test section:
a. Consider exposing all threaded, bolted or flanged fittings within the test segment prior to the
test for visual inspection during the test.
b. Consider replacing any gaskets within the test section prior to conducting the pressure test.
o) List of nominated personnel who are to supervise the pressure testing operations, and their
qualifications, tasks, responsibilities and authority.
p) Detailed schedule giving proposed dates of the main activity’s tests.
5 HYDROSTATIC TESTING
This section defines specific requirements related to pressure testing of pipelines, such as test medium
and pressure, duration, etc. All testing requirements shall be indicated on the relevant Approved For
Construction pipeline drawings. The COMPANY will allocate one or more water sources for flushing
and testing.
5.1 Pipelines
5.1.1 Strengt h test
All new Pipelines shall be subjected to a hydrostatic strength test equivalent to not less than 1.25
times the design pressure 4 hours minimum.
Acceptance criteria for strength tests is specified in section 8.5 of this specification.
6 PRESSURE TEST MEDIUM.
6.1 Test Medium

"Potable water", shall be the preferred test medium. If water from other sources is used
COMPANY approval is required and, the following should be considered:
a) There are many water sources and the water quality differs from one source to another depending
on the ecoregion, the type of watershed and depth of groundwater source. Some surface water,
particularly those in swampy or low-lying areas, may have high suspended solids concentrations
or other undesirable characteristics (e.g. high bacteria or high salinity/sodicity levels). There is also
a risk of contaminants being present from other industrial discharges.
b) The type of water that is used during hydro testing depends on the water source availability, volume
of water necessary, and criticality of the tested pipeline.
c) Water can be taken from: rivers, water canals, lakes, streams, or comparatively shallow water
sands, where the salinity is low, usually less than 5 000 ppm. Nevertheless, organic content, total
dissolved solids (TDS) and bacteria content varies widely from one source to another.
d) Before start a pipeline flooding operation, the CONTRACTOR shall perform an analysis of the
water intended to be used in hydro testing, to determine the number of active biological colonies.

Based on the obtained results, CONTRACTOR shall present for ROO approval, the recommended
biocide doses.
e) As much as be practical the use of brackish water from unknown sources should be avoided, due
to the uncertainties about its composition and chemical characteristics.
6.2 Corrosion Control
6.2.1 Water Intake
The water inlet should be well off the water source floor to minimize the possibility of picking up
dirt and debris.
Hydro test water shall be filtered to 50 micron (0,002 in) maximum particulate size before filling the
equipment.
6.2.2 Water Anal ysis
If water is approved by COMPANY from source water. Water to be used as a test medium, before
confirming treatment type and chemicals dosage, water should be sampled in the exact location
where the water for hydro testing is taken. The amount of bacteria (at least CARBs and AFPs)
present in the water shall be determined.
Typically, the water composition should meet the below requirements:
a) pH: 6.0 - 9.0
b) Total Dissolved Solids (TDS): < 500 mg/L
c) Total Suspended Solids (TSS): < 1000 mg/L
d) Chlorides (CL): ≤ 5000 ppm
e) Appearance: clear with no visible sediment
6.2.3 Chemical Treatment
If water is approved by COMPANY from source water. Hydro test water chemical treatment
requirements as well as the chemical types depends on factors such as:
a) Water characteristics (pH, solids content, Oxygen content, bacteria presence, salinity, etc.)
b) Pipeline material.
Biocide treatment shall be applied to all waters used for hydrotesting in ROO. All local water
sources contain bacteria which may have a detrimental impact on the pipeline materials and
generate H2S gas causing HSE and handling issues.
Biocide concentration shall be proportional to the number of active biological colonies identified,
but typically doses of 100 to 500 ppm by volume (ml/m3 water) depending on type and strength
should be used. Evidence of the effectiveness of the biocide treatment shall be recorded.
Note: advice on approved chemicals and treatment rates may be obtained from COMPANY.

6.2.4 Dew atering
Water used in hydro test not treated with biocide shall be removed from the pipeline as soon as
feasible. This can be accomplished by one of following methods:
a) Once the pipeline is connected to the wellhead, water will be displacing throughout the
pipeline and processed at the degassing station as part of the normal production fluids.
b) If the pipeline profile is suitable, the pipeline can be drained by gravity through one or both
ends.
In cases b and c; considerations to avoid flooding drain area shall be made, also the chemicals
concentration shall be maintained below regulatory thresholds or be controlled by neutralizing it
prior to being discharged.
Water used in hydro test that have been treated with biocide, can remain in the pipeline as
necessary.
7 PRESSURE TEST EQUIPMENT AND MATERI ALS

All equipment required for a pressure test shall be carefully selected and be in working order.
All valves, fittings, pipe, hoses and instruments that form part of the test equipment shall be fully rated
for the test pressure and using materials that fully conform to the applicable line specification. All test
equipment connections shall be flanged and welded, no threaded connection fittings shall be used
unless accepted in writing by COMPANY. Suitably rated restraints/lashings or other approved
engineering design shall be used to mitigate the risk exposure to pressurised test equipment failure.
Visual inspection of all hydro test equipment including test fittings prior to each test use shall be carried
out by a competent person and documented to confirm compliance. Flange faces, gaskets and hoses
shall be checked for damage. Any damaged fittings shall be replaced before test is commenced.
Annual inspections of hydrotest equipment shall be carried out by CONTRACTOR and results
maintained in a register available for inspection by COMPANY.
Special care should be taken with the pressure gauges, which shall be calibrated within the expected
pressure range of 1.5 – 2 times the test pressure required.
The following information and equipment shall be supplied by CONTACTOR.
a) A schematic equipment layout drawing
b) A high-volume pump and associated piping to fill the line that provides adequate pressure to,
maintains sufficient velocity to move any debris in the pipeline.
c) To prevent the overpressure of test segments, during pressure test. The Installation of a relief valve
should be considered. When the PSV installed at the pressure source, its pressure set shall be
established as the test pressure, plus the lower value of 5% of the test pressure or 2 barg (200
Kpa, 30 Psi).
d) A portable tank or transport into which excess test medium can be discharged and from which
make-up volumes can be drawn.

e) A pressure sensing and display device that has the pressure range and increment divisions
necessary to indicate anticipated test pressures.
f) A continuous-recording pressure chart recorder, accurate within 2% of full scale that allows the
test pressure to be within 60% of the gauge, provides a permanent record of pressure versus time.
The accuracy of this instrument shall be confirmed through the respective calibration certificate
with validity not greater than a year.
g) A test medium temperature sensing and display instrument that is properly calibrated to a range
suitable for anticipated test temperatures. Temperature instrument accuracy shall be within 1°C of
actual temperature. Temperature instrument sensitivity shall be within 0.1°C.
h) A continuous-recording temperature measurement device that provides a permanent record of test

medium temperature versus time. This device should be calibrated immediately before each use
with a certified thermometer.
i) Temporary test manifolds and connections, as needed.
j) If there is a deviation of more than 2% between the gauge and the recorder during the test, the
test shall be stopped, and the equipment recalibrated.
8 PRESSURE TEST IMPLEMENTATION

The hydrotest CONTRACTOR shall write and submit for approval by COMPANY representative, a
specific test procedure including as minimum the requirements detailed in sections 3 and 4 as well as
any other technical aspect considered relevant.
This procedure may be a combination of this spec, international standards guides and the operator’s
standard operating practices.
8.1 Line Filling and Cleaning
8.1.1 Cleaning
Contractor’s Method Statements and Inspection and Test Plans shall ensure the interior of all pipe
lengths are cleaned and carefully examined for the presence of foreign matter before the joints are
lined up for welding. Each joint shall be uniquely numbered with logged photograph evidence of
pipe cleanliness which shall be fully recorded.
At the end of each day’s work or every time jointing and welding operations are interrupted, the
open ends on the welded strings shall be covered with a securely fitted rubber caps, so as to
prevent the entry of dirt, water or any foreign matter into the pipeline. These covers shall not be
removed until the work is to be resumed.
Whenever partially complete pipelines are left with open ends to be tied in after an appreciable
time lag temporary blinded flanges shall be welded to the ends of the pipe.
If suitable, cleaning can be achieved by the use of one of following methods:
8.1.2 Filling
The filling water should comply with sections 6.1, and if approved by COMPANY, 6.2.1, 6.2.2 and
6.2.3, unless a Deviation Request has been raised and accepted by the COMPANY, or when

specific conditions are defined and accept, as part of the specific test procedure presented by the
CONTRACTOR.
Filling should be carried in a way which minimise the amount of air remaining in to test section.
At least one vent point shall be installed on the pipeline at the opposite end of the pipeline to where
the filling is taking place.
Any vent points shall remain open during the filling operation until a continuous flow of water is
observed through them.
The volume of air remaining in the test section after filling shall be such that pressure can be
maintained within +/−1% of the end-point pressure for the test hold period, and isolated for the hold
period of the test.
8.2 Initial Pressurization
a) All personnel should be located at a safe distance of minimum 20m from the test section.
b) All temporary piping and test heads should be adequately secured before the pressurization
process is started.
c) The initial pressurization of the section of pipe to be tested begins once the segment is full of
fluid and the appropriate measures have been taken to bleed any and all air; in other words,
the line segment is “packed.”
d) Initial pressurization of the section shall occur at a controlled rate to avoid surging the pipeline.
The site-specific test procedure should determine the pressurization rate up to the target test
pressure (the pressurization rate is typically 10 psig / min or lower).
e) Pipe connections should be periodically checked for leaks during the pressurization process.
f) Once 80% – 90% of the target test pressure is reached, the rate of pressurization should be
reduced, especially when the pressure is at or near 100% of the target test pressure.
g) Prior to the start of the test, it may be desirable to have a stabilization period, which would allow
both the temperature and pressure to stabilize.
h) Pressure transients may occur during the pressurization process and residual air may go into
solution.
i) Time required for thermal stabilization is dependent on the temperature of the test medium at
the time of filling, heat capacity of the test medium, pipe diameter, depth of buried pipe , and
the ground temperature.
j) Once the desired test pressure is reached, the pressurization equipment should be stopped
and isolated from the section.

Note: Pressure charts, sensors, and displays only show an approximation of the actual
pressure. The charts provide proof of the continuity of the test. The deadweight tester or
electronic equipment provides the actual pressure to be recorded.
8.3 The Test Period

When the test pressure is reached, pressurization should cease and all valves and connections to the
line should be inspected for leakage.
Testing personnel should verify that the specified test pressure is being maintained.
The test period shall begin after the temperature of the test medium, has stabilized.
The test section temperature shall be plotted against time during the temperature stabilisation period
by recording every hour.
a) Strength test: Pressure shall maintain for a minimum of four (4) hours.
8.4 Pressure Test Failures
a) Any leaks or failures of the pipeline should be properly documented in the test report.
b) The mode or manner of failure will be important to guide any subsequent actions taken by
COMPANY.
a. If a rupture or a substantial leak occurs, the test shall be stopped and COMPANY notified
If a substantial failure occurs, the COMPANY shall determine when the test can be re-started.
Pipe or other failed components should be preserved for further examination and failure
analysis if necessary.
b. If a small leak occurs, the pressure should be reduced to an appropriate level while locating
the leak. After successful completion of the required rework, the test should be restarted with
a new hold period for strength test.
8.5 Acceptance Criteria for Strength Test

If, during the hold period, all pressure-containing components in the test section maintain their
integrity at the specified strength test pressure, the strength test performance shall be deemed
satisfactory. The pressure should be maintained within +/- 2% of the test pressure.
If rupture occurs, the damaged pressure-containing component shall be replaced and the strength
test shall be repeated. If leakage occurs during a pressurization or hold period, the quantity of
leaked liquid shall be collected, measured and consider in the determination of the end-point, and
the details of the leak shall be reported.

9 DEPRESSURIZATION, DI SPLACEMENT AND DISPOS AL OF

TEST MEDIUM
Once testing has been completed, depressurization should follow a control plan outlined in as part of
the pressure test procedure.
The preferred disposal method is to displace it to the degassing station associated to pipeline which is
being tested (oil service) or to water injection well (injection water service), otherwise it should be
disposed in accordance with all applicable environmental regulations and in the place determined by
environmental team.
10 TEST RECORDS AND DRAWINGS.

Pressure test records shall be retained for the design life of the pipeline.
10.1 Test Records

Pressure test records shall include the following information:
a) Name of the pressure testing CONTRACTOR.
b) Name, line number or description of the tested pipeline.
c) Diameter(s) of the pipeline in the test segment.
d) Wall thickness (es) of the pipe in the test segment.
e) Grade or SMYS of the pipe material in the test segment.
f) Source of the test medium.
g) Description of any additives injected into the test medium.
h) Description of the pressure test equipment/apparatus.
i) Serial number(s) of pressure test equipment/apparatus.
j) Certifications and calibration data for the pressure test equipment/apparatus.
k) Date and time of the start and end of the pressure test.
l) Date, time of start and end test medium temperature.
m) Duration of the pressure test.
n) Continuous chart showing test pressure versus time.
o) Log of test pressure versus time.
p) Explanation of any pressure discontinuities.
q) Description of any re-pressurizations and/or bleed-offs.

r) Name, signature and title of the person responsible for performing the pressure test.
s) Name, signature and title of COMPANY’s witness.
t) Leak or failure information including location, description, cause (if known), method of repair, and
disposition of failed pipe or components.
10.2 Test Draw ings

a) Sketch or drawing of the pipeline, being tested.
b) As built drawings or AFC red line mark-up drawings
11 GOC REQUIREMENTS
CONTRACTOR shall comply with the requirements of GOC completions procedure 00096R-C-G0-
G000-CO-PRO-0001.
11.1 A - ITR’s
• ROO P04A – Piping Hydrotest Certificate

• ROO P07A – Piping Cleanliness

11.2 Typical Test Pack


Specification For Hydrotesting of New Pipelines: 0000BF-C-G0-G000-PL-SPC-0001

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Specification For Hydrotesting of New Pipelines: 0000BF-C-G0-G000-PL-SPC-0001

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RUMAILA OPERATING ORGANISATION

SPECIFICATION FOR HYDROTESTING OF NEW PIPELINES

SPECIFICATION FOR HYDROTESTING OF NEW PIPELINES

D. Halliwell S. Keegan T. Johnston

Steph Timothy Digitally signed

0000BF-C-G0-G000-PL-SPC-0001 Rev B06 – 17 February 2020 Page 1 of 20

REVISION DESCRIPTION SHEET

Rev. Para. Reason for Revision

1, Removed reference to old Pipelines

2.1.2 Deleted bullet points b), c), d) and e)

0000BF-C-G0-G000-PL-SPC-0001 Rev B06 – 17 February 2020 Page 2 of 20

5.1.3 Section deleted

Hold No. Para. Description of Hold

0000BF-C-G0-G000-PL-SPC-0001 Rev B06 – 17 February 2020 Page 3 of 20

1.1 Abbreviations and Definitions ............................................................................................. 6

2.1 Scope and Purpose ............................................................................................................ 8

2.2 Conflicts and Deviations ..................................................................................................... 8

2.3 References Documents ...................................................................................................... 8

2.4 Order of Precedence ........................................................................................................ 10

3.1 General ............................................................................................................................. 10

3.2 Design ............................................................................................................................... 10

3.3 Test Pack Documentation ................................................................................................. 11

4 TEST PROCEDURE CHARACTERISTICS ..................................................................... 11

5 HYDROSTATIC TESTING ............................................................................................... 12

5.1 Pipelines ........................................................................................................................... 12

6 PRESSURE TEST MEDIUM. ........................................................................................... 12

6.1 Test Medium ..................................................................................................................... 12

6.2 Corrosion Control .............................................................................................................. 13

7 PRESSURE TEST EQUIPMENT AND MATERIALS ....................................................... 14

8 PRESSURE TEST IMPLEMENTATION ........................................................................... 15

8.1 Line Filling and Cleaning .................................................................................................. 15

8.2 Initial Pressurization .......................................................................................................... 16

8.3 The Test Period ................................................................................................................ 17

8.4 Pressure Test Failures ...................................................................................................... 17

8.5 Acceptance Criteria for Strength Test .............................................................................. 17

9 DEPRESSURIZATION, DISPLACEMENT AND DISPOSAL OF TEST MEDIUM ........... 18

10 TEST RECORDS AND DRAWINGS. ............................................................................... 18

10.1 Test Records ..................................................................................................... 18

10.2 Test Drawings.................................................................................................... 19

11 GOC REQUIREMENTS .................................................................................................... 19

11.1 A - ITR’s ............................................................................................................. 19

11.2 Typical Test Pack .............................................................................................. 20

0000BF-C-G0-G000-PL-SPC-0001 Rev B06 – 17 February 2020 Page 4 of 20

The specification provides guidance so that:

c) Pressure tests consider both personnel safety and environmental impacts;

d) Pressure tests are implemented by qualified and competent CONTRACTOR personnel;

a) The strength of a test section

0000BF-C-G0-G000-PL-SPC-0001 Rev B06 – 17 February 2020 Page 5 of 20

1.1 Abbreviations and Definitions

ANOMALY A deviation from the norm in pipe material, coatings, or welds

A component that is attached to the pipeline, e.g., valve, tee, instrument

ASME American Society of Mechanical Engineers

The collection of sessile organisms combined with the deposits formed by

CERTIFICATION A written testimony of qualification.

COMPANY ROO Rumaila Operating Organisation

The deterioration of a material, usually a metal, that results from a reaction

CRACK A very narrow elongated separation caused by mechanical splitting.

DOCUMENT This shall include both text documents and drawings

GOUGE Elongated grooves or cavities caused by mechanical removal of metal.

MAY One possible course of action

MUST / SHALL A mandatory requirement

A continuous part of a pipeline facility used to transport a gas, petroleum gas,

0000BF-C-G0-G000-PL-SPC-0001 Rev B06 – 17 February 2020 Page 6 of 20