FLOODING, CLEANING GAUGING &

HYDROTESTING FOR 32 PIPELINE

DURING PRE-COMMISSIONING
PROCESS

Mohamad Shukri Bin Rahmat

860103-10-5375
SX091166KKJ04

Background Study
PETRONAS Carigali Sdn. Bhd. has undertaken the
development of the NC3 gas field located in
SK316 Block, approximately 200km North of
Bintulu, Sarawak.
The water depth in NC3 field is around 104m107m.
Subsea Pipeline connects NC3 Drilling Platform
to Existing Riser Platform E11R-C. The processed
gas will be evacuated to shore via the existing
trunkline through E11R-C or dedicated newly-tobe-installed trunkline to shore
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Background Study

Field of NC3 and E11-RC Platform

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Background Study
The transportation of gas from fields (offshore) to
the shore is normally by using the sub-sea
pipeline.
Pipeline pre-commissioningis the process of
proving the ability of apipelineandpipingsystems
to contain product without leaking. In this cases,
the said product is gases
The gross volume of the processed gas is
660MMSCFD including 20% CO2.
Installation of the pipelines will be completed
before the offshore facilities are in place
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Background Study
To discuss the requirements to perform
the flooding, cleaning, gauging and
hydrotesting of 32 dia. x 75.5 km
pipeline from E11RC platform to NC3
platform, problem statement and how to
overcome while doing the said services.

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PROBLEM STATEMENT
Pipeline Details
Table below shown summarizes of the 32
Dehydrated Gas & Condensate Pipeline details
covered by the procedure of Flooding, cleaning,
gauging, dewatering and hydrotesting of offshore
oil and gas pipelines during pre-commissioning

PROBLEM STATEMENT

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PROBLEM STATEMENT

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PROBLEM STATEMENT
Flooding, cleaning and gauging (FCG)
operation can be defined as the flooding
operation
will
introduce
chemically
treated filtered seawater into the offshore
pipeline sections
The cleaning operation will remove
construction debris from the internal
pipeline surface
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PROBLEM STATEMENT
Failure to perform one of these Pre-Commissioning
tasks as mentioned will lead to:
1. Gas ingress into the water during flooding may make
hydro testing difficult.
2. Inefficient dewatering of the pipeline may lead to
hydrate formation in gas lines or corrosion problems
during production.
3. The tasks also take time to perform under difficult
conditions.
4. Piping Internal Gauging (PIG) operation that may get
stuck inside a pipeline section
5. Bad gauging performance, bad cleaning/testing/drying
performance
6. Work Schedule delay
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PROBLEM STATEMENT

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PROBLEM STATEMENT

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PROBLEM STATEMENT

Dewatering
Pig

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Flooding, Cleaning,
Gauging Pig
13

PROBLEM STATEMENT

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14

Objectives of Study
To presents an analysis and requirements to
perform of part of pipeline Pre-commissioning
process which is flooding, cleaning, gauging
and hydrotesting of 32 dia. x 75.5 km
pipeline from E11RC platform to NC3 platform
To discuss the problems that could be
encountered
during
flooding,
cleaning,
gauging and hydrotesting during precommissioning process while install and
commissioning of these 32 Pipeline
To discuss the Risk Management in the Pre3/6/16
15
Commissioning
Phase
during
flooding,

Scope of Study
Pipeline Pre-commissioning process of 32
Pipeline
Flooding operation which will introduce
chemically treated filtered seawater into
the offshore pipeline sections.
Cleaning operation which will remove
construction debris from the internal
pipeline surface.
Gauging operation which will confirm that
there are no pipeline deformations or
intrusions/interruption.
Hydro testing operation to treat water used
to drive the cleaning and gauging pigs will
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be discharged to the environment at

Flooding
Pipeline Filling or in other name Flooding
can be explained as method which can be
carried out by propelling PIGs through the
pipeline with water or free flooding with
water.

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Cleaning Gauging
Pipeline Cleaning is carry out by pushing
PIGsor Gel PIGsthrough the pipeline to
remove any debris dirt
Pipeline Gauging is carried out to prove the
dimensional quality of the internal diameter
of the pipeline

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Hydrotesting

Hydrotestingis a process by which the pipeline in question

is the pressure tested to a predefined pressure above the
operating design pressure of the pipeline.

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Hydrotesting

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RESULT AND DISCUSSION

To aid in the planning of such operations, a

number of analyses can be undertaken to
determine the duration to perform each of
these tasks.
The mathematical models can be used to
optimise the equipment required (hoses,
pumps, compressors).
The subsea heads, hot stabs, and pig tracking
system worked flawlessly during FCG
(Flooding, Cleaning, Gauging) operations.
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RESULT AND
DISCUSSION
All FCG pigs performed as expected and no damage
was observed. The water filtration, additive system,
and pumping spread operated consistently at or
above their specified duty levels.
Air content confirmed to be well within the Det
Norske Veritas (DNV) requirement of less than 0.2%
demonstrated the flooding operation's success
A final cleaning run removed less than 2 kg of
construction debris in each section. Iron oxide and
small amounts of sand and some red-coloured dust
were also removed.
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RESULT AND
DISCUSSION

ta of 32 Pipeline

Pressure Test Data of 32 Pipeline during Hydrotesting

Sectio Lengt
n

Volum

e (Cu

(km)

M)

Test

Pressurizati Volum Stabili Pressure

Pressur on Duration
e

(hr)

(barg)

zation

Added period
(Cu M)

(hr)

drop
during
test
period,

1
2

120,08

110

14.5

2,148

%
0.028

9
151.0 241,24

230

29.0

4,128

0.058

75.5

0
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RESULT AND DISCUSSION

As a result:
Analysis of Pipeline Pre-commissioning system and method to
provide output that can be used for pre-commissioning
operation is explained.
The problems that could be encountered without a clear
knowledge of how the operation will proceed can be avoided.
The operation can be monitored by comparing recorded and
predicted values by using mathematical module and from
past experience.
The Risk Management in the Pre-Commissioning Phase of an
oil and gas pipeline project undertaken
Pre-commissioning may therefore be defined as all the checks
that are to be completed prior to commissioning being
permitted to commence.

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CONCLUSION
Successfully performing Pre-commissioning process
which include the cleaning, gauging, filling,
hydrotesting of 32 dia. x 75.5 km pipeline from
E11RC platform to NC3 platform based on Pressure
Test Data
Pressure drop during test period is less than 0.2%
which can be defined as the pipeline is clean from
debris and other material tolerance
These process is managing to meet client schedule
and safety is in zero tolerance and now the said
pipeline is successfully returned to Petronas to
commence a gas flow.
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CONCLUSION
The
design
of
pipeline
is
important
requirement. The designer has to foresee
construction requirements and all project
constrains have to be incorporated in his
design.
Any insufficient design can cause of problems
for construction and pre-commissioning phase
Risk cannot be eliminated as such precommissioning activities contains high risk
that cause of schedule and cost impact
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RECOMMENDATION
Flooding and Pigging subsea pipelines using a
remote flooding module (RFM). This enables
the use of available hydrostatic head to flood
and pig subsea pipelines while meeting the
project requirements in terms of pig speed,
filtration, and chemical treatment.
Recommended to use of ROV driven pumping
units to complete flooding and pressurization
The use of smart gauge tools (SGT) to gauge
pipelines without using aluminium gauge
plates.
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RECOMMENDATIO
N
Using of subsea data loggers to record
pressures and temperatures during subsea
testing, and use of systems to transmit this
data to surface in real-time during the test.
To have a good plan before performing precommissioning process
Review the quality document and
certificates completed with conformance
inspect of materials and equipment are also
conducted probably to prevent risk at work
process
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Thank You

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