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BOTA BORU HATLARI LE PETROL TAIMA A..

SPECIFICATIONS FOR HYDROSTATIC TEST AND INTERNAL INSPECTION 4-NGTL 0-GN-P-002-5007

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TABLE OF CONTENTS: 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 SCOPE GENERAL TEST SECTIONS TEST PLAN TEST PROBES INSTRUMENTATION TEST CONDITIONS INTERNAL CLEANING TEMPERATURE THERMOMETER / RECORDING DEVICES FILLING WATER TEST DOCUMENTATION DEPRESSURIZING DISCHARGING WATER FINAL AIR DRYING PIPE INTERNAL INSPECTION

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1.0 SCOPE

The present specifications cover the responsibilities of the CONTRACTOR and the requirements regarding carrying out cleaning of the system, applying hydrostatic test, drying, pipe internal inspection and other works before the operation of pipeline. 1.1 DEFINITIONS The following definitions shall be applied:
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SMYS (Specified Minimum Yield Strength) term shall mean the minimum yield strength of the pipe.

2.0 GENERAL

The CONTRACTOR shall supply the entire workmanship, materials and instrumentation necessary for successfully carrying out work in accordance with the requirements of the present specifications. 3.0 TEST SECTIONS 3.1 The CONTRACTOR shall determine each test section, starting and ending points of such, in accordance with the following principles. A- length/volume: test sections shall not be longer than 20 km and unless otherwise approved by BOTAS, test volume shall not be over 12,500 m. B- pressure: test pressure at the highest elevation point shall not be less than 1.25 times the system project pressure for pipe class places 1 and 2, and shall not be less than 1.40 times the system project pressure for pipe class places 2 and 4. The test pressure at the lowest elevation point shall not exceed a pressure equal to the pressure necessary for the pipe to be stressed up to 110% of SMYS. 3.2 Acceptable maximum elevation difference for each section shall be determined in accordance with the conditions of Article 3.1. Hydraulic load calculations shall be compiled for each section and shall be checked with the test profile criterion after filling water completely. 3.3 The CONTRACTOR, when selecting the test sections, shall consider availability of the water sources for filling the test sections and the appropriate water discharge points after completing the test. 4.0 TEST PLAN Minimum four weeks before the start of the test the CONTRACTOR shall submit BOTAS a detailed test plan for the whole work, including, but not limited with, the following: A- kilometer of places selected as the starting and ending points of each test section; B- hydraulic load calculation for each test section, including minimum, maximum and test pressures; C- places of maximum and minimum stress and hoop stresses related with these; D- kilometers of places selected for filling and discharging water; E- kilometer of places selected for discharging any chemical substance used and methods for discharging such chemical wastes;

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F- specifications to be used for the materials and equipment, including traps, filling and

discharging pipe equipment, valves, flow meters, hydraulic hoses, fittings, pressure pumps, water heaters and compressors.
5.0 TEST HEADS

The Contractor shall be responsible for supplying and manufacturing all of the test heads. Original material test reports, project drawings indicating detailed materials, places and sizes of valves shall be submitted to the approval of BOTAS before the start of manufacture. Test heads shall be projected and constructed to endure testing of the pipe having thickest wall in the system. When in service, the test heads shall not be subject to a stress more than 75% of SMYS of the pipe at the test head. All of the welding works and inspection of the welds shall be carried out in accordance with the BOTAS Specifications for WELDING and NON-DESTRUCTIVE TEST, including the test section of the test head circle welds. Completed test heads shall be tested hydrostatically for 4 hours at a pressure equal to 100% of the SMYS of the test head. The test heads shall have unique serial number and the records on using the test place shall be kept throughout the project.
6.0 INSTRUMENTATION

All of the instrumentation shall be submitted with the calibration documents to be submitted as a part of the test package. The calibration of the instruments shall be carried out as found necessary by BOTAS. 6.1 DEAD WEIGHT TEST DEVICE The dead weight test device shall have a range between 0 and 200 bars, an increment of 0.1 bars, and an accuracy of 0.1% throughout the whole range. Dead weight test device shall be calibrated every two months and a calibration document released in the last 12 months shall be submitted. 6.2 PRESSURE RECORDS Pressure records shall have a range allowing 66% reading of the scale at maximum test pressure. Records shall be 24 hour alternating type, shall have a measurement accuracy of 0.15% and shall have a single sensor and single pen ink system. Blue ink shall be used. 6.3 TEMPERATURE RECORDING DEVICES Temperature recording devices shall have a measurement range between -30 and +45 degrees centigrade. Recording devices 24 hour alternating type having measurement accuracy of + 0.5 degrees centigrade, and these recording devices shall have a single sensor and single pen ink filling system. Ground temperature recording devices shall use green color ink and pipe/water temperature recording devices shall use red color ink. 6.4 FLOW METERS Flow meters shall have 0.001 m3 measurement accuracy and shall be able to measure the required flow rates during filling operations. 6.5 THERMOMETERS

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Thermometers for measuring the temperatures of the underground pipe walls shall have a measurement range between 0 and +30 degrees centigrade and a reading accuracy of +0.1 degrees centigrade. Temperatures used for measuring the ambient air temperature shall have a measurement range between -40 and +50 degrees centigrade and a reading accuracy of +0.5 degrees centigrade. Thermometers for measuring the temperature of the walls of the open pipes shall have a measurement range between -10 and +50 degrees centigrade and a reading accuracy of +0.2 degrees centigrade. Temperatures used for measuring the water filling temperatures shall have a measurement range between 0 and +50 degrees centigrade and a reading accuracy of +0.5 degrees centigrade. 6.6 MANOMETERS Manometers shall be supplied at various ranges for different operations such as filling, pressure test, pressure increase and drying. Measurement range shall change between 0% and 150% of the maximum pressure in different operations.
7.0 TEST CONDITIONS

Hydrostatic tests shall only be carried out when the ground temperature and water temperature is at least 2 degrees centigrade. Minimum 24 hours before the test the CONTRACTOR shall submit a written communiqu to t BOTAS and shall receive the approval of BOTAS.
8.0 INTERNAL CLEANING OF PIPES

8.1 INTERNALLY COATED PIPES Before starting to fill a test section, a construction pig shall be passed through the section for removing the wastes with compressed air and to ensure that no significant block is left in that section. 8.2 NON-INTERNALLY COATED PIPE Before starting to fill a test section, a construction pig with wire brush connections shall be passed through the section to remove the dissolved manufacturing scales with compressed air to ensure that no significant block is left in that section. 9.0 TEMPERATURE THERMOMETERS / RECORDING DEVICES 9.1 A temperature catheter and a recoding device shall be placed on the water inlet pipe and the temperature of the filling water shall be recorded. 9.2 Pipe wall and ground temperatures shall be measured with thermometers placed at approximately 2.5 intervals. The sensor of the pipe wall temperature thermometer shall be placed on the pipe coating and shall be covered with isolation layer.

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The sensors of the ground temperature thermometers shall be placed 0.3 m away from the pipe. Once the thermometer sensors are located, the pipe section viewing outside shall be backfilled and ends protruding outside shall be appropriately protected from the elements. Temperature readings shall be recorded minimum at each four hours during filling and test operations.
10.0 FILLING WATER

10.1 The CONTRACTOR shall have the approval of BOTAS for the following before starting to fill: A- all of the controls for operation and pressure settings of all of the valves and fittings are carried out as required; B- all of the valves are at right position for filling; C- all of the radiographies are accepted for test section; D- all of the ground temperature thermometers are installed as required. 10.2 Water to be used in the hydrostatic test shall have appropriate qualities. Water sample analysis results shall be submitted to BOTAS upon request. Water containing silt, suspended materials or harmful corrosive elements shall not be used unless filtered or chemically treated. The water shall be filtered during filling in and the filter shall be placed at a depth not allowing air dragging inside together with water filled in. 10.3 Pig iron shall be in front of the water filled in and shall advance with the positive back pressure depending on the elevation of the section. Filling operation shall be recorded on the pressure recording device adjusted appropriately and flow measurements shall be read hourly. 11.0 CARRYING OUT THE TEST 11.1 PREPARATION Before carrying out the pressure test, warning signs shall be placed to all of the pipeline junctions and places where open pipes and their fittings are found. Instrumentation or valves on the test heads not to be used for applying pressure shall be blind flanged, shall be capped or a top shall be inserted to the valve in fully open position. 11.2 TEST LABORATORY An airtight, fully closed trailer, with lighting and heating, shall be supplied for sheltering the test instruments and test personnel. The trailer shall stay at construction site throughout the tests. Keeping elastic hoses in the trailer shall not be allowed unless placed separately from the test personnel. 11.3 THERMAL BALANCING After completing the test preparations, pressure pumps shall be connected and the pressure in the test section shall be increased up to eighty percent of the maximum test pressure. Pressure increase rate shall not exceed 5 bars per minute. Pressure shall be recorded on a suitable pressure recording device and shall be monitored visually with the dead weight test device.

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After reaching to the stated pressure, a thermal balancing period of 24 hours shall start. Temperature and pressure readings shall be recorded every four hours during this period. The thermal balancing shall be carried out based on the following: the maximum temperature difference between the average value of the last two readings should be 0.5 degrees centigrade; there should be continuous relation between temperature and pressure; there should not be any visible leakage sign in the beginning of the test; it should be accepted by BOTAS or its representative.

11.4 AIR INPUT TEST An air input test shall be carried out by increasing the pressure by one bar and determining the necessary water volume. If the actual required water volume (Vpa), theoretical required volume (Vp), as calculated with the following formula, is equal to or exceeds the rate of 6%, then test section shall be discharged and refilled over and over again, until the air input test can be carried out successfully.

Vp = (0.884 x ri/s + A) x 10 x Vt x K,
Where; Vpq : required theoretical water volume (m) Vpa : actual added water volume (m) Vt : geometrical volume of the section (m) ri : nominal internal radius of the pipe equipment (mm) s : nominal wall thickness of the pipe equipment (mm) A: isothermal compressibility of water as estimated at the measured pressure and 6 temperature (bar x 10 ) K : dimensionless coefficient equal to 1.02 for welded pipe and to 1.0 for seamless pipe. If Vpa < 1.06Vpq, then test shall be deemed to be acceptable. 11.5 PRESSURIZING 11.5.1 In the test section the test pressure shall be increased from 80% to 100% before the BOTAS or its representative. 11.5.2 Where the test pressure exceeds what is required for stressing the pipe up to 90% of its SMYS, the pressure-volume relations shall be monitored and precautions shall be taken to ensure that a deviation more than 0.2 percent of the total section volume at testing pressure increasing at 0.2 bar steps does not take place. Before reaching to the stated test pressure, when the volume exceeds 0.2% of the total section volume, pressurizing shall be stopped and BOTAS shall instruct the CONTRACTOR about the things to be done. 11.5.3 When the stated test pressure is reached, the pumps shall be left connected but shall be isolated from the test section. Two hours of delay period shall start and pressure and temperature readings shall be taken for every 15 minutes. After the two hours of delay period, if necessary, pressure shall be raised to 100% of the test pressure, pumps shall be disconnected and the relevant valves shall be cancelled, caps or tops shall be mounted on the valves.

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11.5.4 24-hour test shall start and the starting pressure, pipe wall, ground, water and ambient temperatures shall be recorded. Pressure, water temperature and ambient temperature shall be monitored and shall be recorded every hour during the test period. Ground and pipe wall temperatures shall be recorded every four hours during the test. 11.5.5 The pressure shall never be allowed to fall under the test pressure. If the pressure falls, then the test pressure shall be raised to the previous value and the test shall be started again. Any measurable pressure change shall be explained with a suitable change in temperature according to the following formula: Pt = (B x Tm) / (0.884 x ri/s + A) Where; Pa : actual pressure change (Bar) Pt : theoretical pressure change due to change in temperature (Bar) Tm : measurable change in water temperature (C) B : difference between the thermal expansion of water and the thermal expansion of steel -6 at measured pressure and temperature (C x 10 ) A : estimated isothermal compressibility of water at measured pressure and temperature -6 (bar x 10 ) ri : nominal internal radius of the pipe equipment (mm) s : nominal wall thickness of the pipe equipment (mm) If Pa - Pt < 0.3 bar, then the test shall be deemed to be acceptable.
12.0 DOCUMENTATION

12.1 Before starting to any test, the CONTRACTOR, unless otherwise specified, shall submit the sample copies of the test documentation forms to be used at every stage of the hydrostatic test. If required, the test documentation forms shall be revised and approved by BOTAS before being used. 12.2 After successfully completion and acceptance of a test, the CONTRACTOR, within three workdays, shall submit a copy of the entire documents, charts, diagrams and other test records to the BOTAS representative and three copies to the BOTAS central office.
13.0 DEPRESSURIZING

Depressurizing of a test section may start after the successful completion of hydrostatic test. Valves used for depressurizing shall have a nominal size of 2 or less. Attention shall be paid when decreasing the operating pressure down to 50%. 14.0 DISCHARGING WATER 14.1 If necessary, it is possible to transfer water from another test section after completing a test section. The overhead piping system between the test heads shall be supplied by the CONTRACTOR and this shall be connected firmly before transferring water. 14.2 Charging water to a flowing or stagnant water body or to a field owned by state or private owner shall only be allowed if the CONTRACTOR obtains necessary approvals. 14.3 All of the drain lines shall be tightened as required in order to prevent movement during water discharge.

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14.4 Discharging to a flowing water body shall be carried in accordance with the approvals given. 14.5 The CONTRACTOR may be asked to treat water in order remove the oils, organic compounds and particles to decrease such pollutants to an acceptable level. Water sample analysis may be requested by BOTAS in order to ensure that the toxic chemical substances are not present in water. 14.6 Discharging water into a water body shall be carried out in a way not to cause erosion on the bank, landslides and excessive silt formation. 14.7 Test head may be used for sending and receiving dried pigs. Pigs shall be driven by compressed air and shall advance with a speed of 8 km/h or less in order to ensure that the water passing near the pig is minimized. Drying works shall continue until BOTAS or its representative is convinced that it is not possible to take any more water using this method. If possible, drying works shall be completed in day hours and BOTAS or its representative shall be present during such works. 14.8 In cases where the final drying is carried out right after discharging water and where test heads are removed with drying works, the open pipe ends shall be closed with plastic band in order to prevent wastes and small animals to enter into the pipeline. If there is a danger of ditch being filled with water, a metal head shall be welded or sufficient pumping equipment shall be supplied for discharging the water in the ditch.
15.0 FINAL AIR DRYING

15.1 For final drying, it is possible to connect test section to each other in order to form drying sections of 150 km in internally coated pipes and of 100 km non-internally coated pipes. 15.2 Air drying shall be carried out by dragging high density foam pigs inside the drying section. Air drying units, where it is possible to obtain water dew point at 40 degrees under one atmosphere pressure with degreased compressors, shall be used. Equipment shall have the power to ensure volumes necessary for the section length and diameter. 15.3 Foam pigs shall be operated until they are received dry and until the water dew point measured in the section reaches to 0 degrees or lower. Dry air rinsing shall continue until a water dew point of minimum -20 degrees is maintained continuously. This requires the free air volume to change location and rinsing with dry air during the period needed for maintaining minimum -20 degrees water dew point during this period. 15.4 When the required dryness is reached, the section, depending on which is applicable, shall either be closed or connected and the system shall be filled with a minimum pressure of one atmosphere and shall be kept in this way until the operation. Depending on the approval of BOTAS, dew point readings may be requested any time until the system is operated. 16.0 PIPE INTERNAL INSPECTION 16.1 EQUIPMENT For NPS 16 or bigger pipelines, pipe internal inspection shall be carried out as follows, using an electronic measurement pig that will ensure determining the round problems and notches and their locations in the pipe. The tool shall be calibrated before any examination in order to ensure measurement accuracy depending on the size of the defect. The accuracy of the instrument shall be +0.1% according to the place of the defect.

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For pipelines smaller than NPS 16, the CONTRACTOR shall operate a mixed pig, equipped with a 6.4 mm soft steel measurement plate having a diameter 12.7 mm less than the inner diameter of the line pipe and with rubber insulators. If the thick wall pipe in the section is significantly thick or significant in terms of amount, it is possible to decrease the sizing plate diameter based on the approval of BOTAS. When the sizing plate is used with the pig, the CONTRACTOR may decrease the lengths of the sections based on the approval of BOTAS. 16.2 OPERATING THE MEASUREMENT PIG Measurement pig shall operate with compressed dry air and based on the recommendations of the SELLER. If the data obtained from measurement works does not have sufficient quality, the works shall be repeated. 16.3 INTERPRETING THE RESULTS Data recorded from the measurement pig shall be interpreted immediately after every operation. Following the completion of the analysis, the original table shall be submitted to BOTAS together with the written report. After operating the pig with sizing plate, the plates shall be free from notches or scratches. If the measurement plate changed its form in any way, then the reason for this shall be determined and this shall be corrected as stated in Articles 16.4 and 16.5 below. 16.4 ACCEPTANCE CRITERIA 16.4.1 All of the full notches or nicks exceeding maximum depth of 6.3 mm in NPS 12 (323.9 millimeter outer diameter) pipe (except the ones on the welds) or smaller ones or ones greater than two percent of the nominal pipe diameter in pipes greater than NPS 12 shall be removed. 16.4.2 Regardless of their sizes, all of the notches found on a weld in lengthwise, in spiral or circular forms shall be removed. 16.4.3 Regardless of their sizes, notches which contain a stress intensifier such as scratch or groove shall be removed. 16.4.4 Pipe sections where the decrease in the pipe diameter due to not being round shall is over five percent shall be removed. 16.4.5 If both not being roundness and notches are found at the same place, BOTAS shall preserve the right to inspect such marks visually, regardless of their sizes. If the combined measurement exceeds five percent of the pipe cross-section, then the pipe shall be removed. However, notches greater than the ones stated in Article 16.4 shall not be allowed. 16.4.6 Pipe tolerances applied to pipe production shall not be added to the ones handled in the present specifications.
16.5 REPAIRS

Where the measurement inspection shows defects exceeding the abovementioned acceptability criteria, pipeline shall be exposed at the place where the diversion from normal is found for carrying out detailed examination and measurements. The sections of the pipeline having unacceptable defects or damages shall be cut out and shall be replaced with

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pre-tested pipes. All of the welding, examination, coating, etc. works shall be carried out in accordance with the approved operations.

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