Design and installation of natural gas pipelines – Code of Practice: Part 3 Pre-commissioning and commissioning of pipelines

IS 15663 Part 3 — Scope Summary

• Scope: Covers pipeline systems for petroleum, natural gas, and related facilities, referencing international standards like ISO 13623, ASME B31.8, API RP 1102, and API RP 1104 for comprehensive guidance.

• Documentation (Clause 7.2): Requires preparation of documents addressing:

  • Health, Safety, and Environment (HSE)
  • Quality Assurance (QA)
  • Quality Control (QC) plans

• Definitions: As per IS 15663 Part 1.

Key Specifications & References

Important Notes:

• Use the latest editions of referenced standards.
• BIS holds copyright; use of symbols, sizes, and grades is allowed for implementation.
• Documentation must comprehensively cover HSE, QA, and QC aspects.

If you need formulas or tables related to design, welding, or testing, please specify the exact clause or topic.

IS 15663 Part 3 - References Summary

• Key International Standards Referenced:

  • ISO 13623: Pipeline transportation systems for petroleum and natural gas.
  • ASME B31.8: Gas transmission and distribution systems.
  • API RP 1102: Steel pipeline crossings of railroads and highways.
  • API RP 1104: Welding of pipelines and related facilities.

• Documentation Requirements (Clause 7.2):

  • Prepare documents covering Health, Safety & Environment (HSE).
  • Include Quality Assurance (QA) and Quality Control (QC) plans.

• Standard Revision & Copyright:

  • Always check for the latest edition of referenced standards.
  • BIS holds copyright; permission needed for reproduction except for implementation details.

• Contact & Regional Offices:

  • BIS headquarters: Manak Bhavan, New Delhi.
  • Regional offices in Kolkata, Chandigarh, Chennai, Mumbai, and branches nationwide.

Practical Notes:

• Use referenced standards for detailed design, welding, and safety requirements.
• Maintain updated documentation per Clause 7.2 for compliance.
• Refer to IS 15663 Part 1 for definitions.

flowchart LR
    A[IS 15663 Part 3] --> B[International Standards]
    B --> ISO13623[ISO 13623]
    B --> ASME_B31_8[ASME B31.8]
    B --> API_RP_1102[API RP 1102]
    B --> API_RP_1104[API RP 1104]
    A --> C[Documentation Clause 7.2]
    C --> HSE[Health, Safety & Environment]
    C --> QA_QC[Quality Assurance & Control]
    A --> D[BIS Contacts & Offices]

For detailed design formulas or tables, consult the individual referenced standards as IS 15663 Part 3 primarily provides references and documentation guidelines.

IS 15663 Part 3 - Definitions Summary

• This part refers to definitions as per IS 15663 Part 1; no new definitions are provided here.
• For understanding terms related to pipeline systems, refer to IS 15663 Part 1.
• The standard aligns with international codes like ISO 13623, ASME B31.8, API RP 1102, and API RP 1104 for consistent terminology and practices.
• Definitions cover key pipeline terms such as:
  • Pipeline transportation system
  • Welding and inspection terms
  • Quality assurance and control terminology
  • Health, safety, and environment (HSE) concepts

Recommended Action:

• Consult IS 15663 Part 1 for detailed definitions.
• Use referenced international standards for cross-verification of terms.
• Ensure documentation complies with Clause 7.2 for HSE and QA/QC plans.

Diagram: Reference Flow for Definitions

flowchart LR
    A[IS 15663 Part 3] --> B[Definitions]
    B --> C[Refer to IS 15663 Part 1]
    C --> D[International Standards]
    D --> E[ISO 13623]
    D --> F[ASME B31.8]
    D --> G[API RP 1102]
    D --> H[API RP 1104]

Summary: IS 15663 Part 3 defers all definitions to Part 1; consult Part 1 for exact terminology used in pipeline design, construction, and quality assurance.

IS 15663 Part 3 — Pre-commissioning Procedure (Clause 5.2)

Key Steps in Pre-commissioning (Clause 5.1)

• De-watering: Remove residual water from the pipeline to prevent corrosion.
• Flushing & Dry Air Blowing: Clean above-ground piping at all stations (dispatch, receiving, valve, pigging, hook-up).
• Swabbing: Use swabs to remove debris and moisture inside the pipeline.
• Low Pressure Leak Check: Conduct air leak tests on above-ground pipeline sections.
• Documentation: Prepare detailed pre-commissioning procedures covering all activities.

Important Specifications:

• Leak Test Pressure: Typically 1.1 times the design pressure or as specified by the project.
• Flushing Velocity: Maintain a minimum flow velocity (e.g., 1.5 m/s) to ensure debris removal.
• Dry Air Pressure: Use clean, dry air at a pressure slightly above atmospheric to ensure drying.

Typical Pre-commissioning Flowchart:

flowchart TD
    A[Start Pre-commissioning] --> B[De-watering]
    B --> C[Flushing & Dry Air Blowing]
    C --> D[Swabbing]
    D --> E[Low Pressure Leak Check]
    E --> F[Documentation & Approval]
    F --> G[Ready for Commissioning]

Note: Refer Clause 6.2 for commissioning procedures following pre-commissioning.

IS 15663 Part 3 — Pre-commissioning Checks (Clause 5.2.1)

Pre-commissioning ensures mechanical completion and system readiness before commissioning. Key checks include:

• Pipe Cover Check:

  • Conduct every 500 m using instruments like Pipe Current Measurement (PCM) to verify coating integrity and cathodic protection.

• System Checks:

  • Verify all facilities against design drawings and specs; record and rectify discrepancies.

• Field Instruments & Equipment:

  • Physically inspect actuated valves, control valves, shut down valves, transmitters, solenoid valves, alarms, meters, and gauges for functionality and correct application.

• Pipeline Survey:

  • Confirm installation of fittings, supports, cathodic protection, route markers, warning signs, fencing, and crash barriers.

• Communication & Electrical Systems:

  • Test communication reliability; verify uninterrupted power supply and earth resistance of earth pits, lightning arresters, and equipment. Check compliance with area classification.

• Instrument Controls & Interlocks:

  • Ensure controls and interlocks operate as per normal conditions.

• Utilities & Alarm Systems:

  • Check power, UPS, water, air supplies, and alarm functioning.

• Safety Preparedness:

  • Identify emergencies and verify mitigation measures.

Summary Table of Pre-commissioning Checks

Additional Notes:

• Documentation of all pre-commissioning checks is mandatory (Clause 7.1a).
• Follow-up commissioning steps include leak tests,

IS 15663 Part 3: Commissioning Procedure Key Points

1. Commissioning Procedure (Clause 6.2)

• Ensures system readiness by validating integrity and operational performance.
• Includes pressure testing, leak checks, and functional testing.

2. Pre-commissioning Procedure (Clause 5.2)

• Preparation steps before commissioning, such as cleaning, drying, and inspection.
• Key activities:
  • Residual dewatering and swabbing
  • Magnetic cleaning and EGP (Electrochemical Gas Purification)
  • Leak testing with dry compressed air at low pressure

3. Commissioning Documentation (Clause 7.1)

Must include records of:

• Pre-commissioning checks
• Residual dewatering and swabbing
• Low pressure leak check (dry air)
• Magnetic cleaning and EGP documentation
• Inertisation process
• Gas-in and commissioning activities:
  • Pressurization of pipeline
  • High pressure leak check
  • Establishment of flows
  • 72-hour continuous run test

Typical Leak Test Pressure Formula:

[ P_{test} = 1.5 \times P_{design} ]

Where:

• (P_{test}) = Test pressure
• (P_{design}) = Design pressure of the pipeline/system

Summary Table of Key Activities

flowchart TD
    A[Pre-commissioning] --> B[Residual Dewatering & Swabbing]
    B --> C[Magnetic Cleaning & EGP]
    C --> D[Low Pressure Leak

IS 15663 Part 3 — Documentation Key Points

Clause 7.1: Commissioning Documentation Must Include:

• Pre-commissioning checks
• Residual dewatering and swabbing records
• Low pressure leak check (above ground piping with dry compressed air)
• Magnetic cleaning and External Grounding Protection (EGP) documents
• Inertisation procedures
• Gas-in and commissioning activities:
  • Pipeline pressurization
  • High pressure leak check
  • Establishment of flows
  • 72-hour run test

Clause 7.2: Documentation Requirements

• Cover Health, Safety, and Environment (HSE) aspects
• Include Quality Assurance (QA) and Quality Control (QC) plans

Related International Standards for Reference

Summary Table: Documentation Components

This ensures comprehensive traceability and compliance with safety and quality standards during pipeline commissioning.

flowchart TD
    A[Pre-commissioning Checks] --> B[Dewatering & Swabbing]
    B --> C[Low Pressure Leak Check]
    C --> D[Magnetic Cleaning & EGP]
    D --> E[Inertisation]
    E --> F[Gas-in & Commissioning Activities]
    F --> G[High Pressure Leak Check]
    G --> H[Flow Establishment & 72h Run]

This flowchart illustrates the sequential documentation process for commissioning.