CPM-SU-5252-C

Hydrotest Water Quality for Corrosion Prevention

Operating Environment: Onshore, Pipelines, Topsides, Subsea

This document is the confidential property of Chevron U.S.A. Inc. and its affiliates. When made available to
any contractor providing services to Chevron U.S.A. Inc. or its affiliates, the contractor’s use of this
document shall be governed by the confidentiality provisions of the applicable contract or bid package.
Without limiting the foregoing, neither the whole nor any part of this document may be disclosed by the
contractor to any third party, other than an affiliate of the contractor that requires this information for
purposes of the contract with the Chevron entity, without the prior written consent of the Chevron entity that
has disclosed this document to the contractor. When requested by Chevron U.S.A. Inc. or its disclosing
affiliate, the contractor must return all copies of this document to the Chevron entity requesting such return
and delete any electronic copies from the contractor’s systems.

Any and all modifications (changes, amendments, etc.) to this document must follow approved
Chevron Engineering Standards governance processes.

Rev. Date Description Author Technology Leader

— 12/10 Initial release. J. Maldonado S. Mishael (Sponsor)
A 05/13 Minor revision. J. Maldonado B. Akinpelu (Sponsor)
B 08/15 General revision. S. Hernandez S. Mishael
C 10/17 Minor revision. Document number change from S. Hernandez S. Mishael
PPL-SC-5252 to CPM-SC-5252.

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Hydrotest Water Quality for Corrosion Prevention CPM-SU-5252-C

Summary of Changes
Revised technical content may be marked with change bars in the right margin as directed by Author.
The Author denotes the following technical changes to this revision as detailed below:

Author notations regarding this revision

A review of this specification was conducted to identify and close gaps to mitigate damage seen to valving
and process equipment in major capital projects caused by debris left in piping during fabrication and
construction.
Change in technical content includes guidance for the use of free-flooding (Section 4.2.2) and re-use of
hydrotest water (Section 5.0). Additions and clarifications have been made to some of the requirements.

Safety Critical Changes (if applicable) are noted below

n/a

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Hydrotest Water Quality for Corrosion Prevention CPM-SU-5252-C

Contents
1.0 Scope............................................................................................................................................... 4
2.0 References ...................................................................................................................................... 4
2.1 Owner Documents .............................................................................................................. 4
2.2 Industry Codes and Standards ........................................................................................... 4
2.3 Other References ................................................................................................................ 4
3.0 Terminology .................................................................................................................................... 4
3.1 Acronyms ............................................................................................................................ 4
3.2 Definitions ........................................................................................................................... 5
4.0 Selection of Water .......................................................................................................................... 5
4.1 Considerations for Hydrotest Water Selection .................................................................... 6
4.2 Raw Water .......................................................................................................................... 7
4.3 Treated Water ..................................................................................................................... 8
5.0 Water Treatment Requirements .................................................................................................... 9
6.0 Treatment of Hydrotest Water .................................................................................................... 10
6.1 Filtering ............................................................................................................................. 10
6.2 Chemical Treatment .......................................................................................................... 11
7.0 Discharge of Treated Water ........................................................................................................ 12
8.0 Quality Control ............................................................................................................................. 13

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Hydrotest Water Quality for Corrosion Prevention CPM-SU-5252-C

1.0 Scope
1. This specification outlines the selection and treatment of water to prevent corrosion when
water is left stagnant in piping and pipelines.

Note: Carbon steel and corrosion resistant alloys (CRAs) exposed to hydrotest water can
be damaged by corrosion; special measures must be taken when water will be left
stagnant in a pipe.
2. This specification provides requirements for the following factors in the selection of water
used for hydrotesting of piping and pipelines, and associated equipment, (e.g., valves). The
requirements apply to onshore and offshore locations.
a. Type of water.
b. Water containment time.
c. Pipe material.
d. Treatment of water.
e. Discharge of treated water.

2.0 References
2.1 Owner Documents
PIM-SU-3541 Hydrotesting of Piping Systems

2.2 Industry Codes and Standards

None.

2.3 Other References

International Finance Corporation (IFC)
Environmental, Health, and Safety Guidelines for Offshore Oil and Gas Development,
World Bank Group, 2007.
Environmental, Health, and Safety Guidelines for Onshore Oil and Gas Development,
World Bank Group, 2007.

3.0 Terminology
3.1 Acronyms
CRA Corrosion Resistant Alloy
MIC Microbiologically Influenced Corrosion
THPS Tetrakishydroxymethyl Phosphonium Sulfate

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Hydrotest Water Quality for Corrosion Prevention CPM-SU-5252-C

3.2 Definitions
Containment Time Amount of time that hydrotest water is expected to be
contained in place prior to discharge.
Free Flooding Flooding of a pipe that is allowed to occur from a surrounding
body of water.
Fresh Water Water from either a surface or ground source with a total
chloride content less than 550 ppm.
Demineralized Water Water that is completely or almost free of dissolved minerals
as a result of a process such as distillation, deionization, or
membrane filtration (reverse osmosis or nanofiltration).
Oxygen Scavenger Chemical additive used to remove oxygen.
Raw Water Seawater or fresh water that has not been filtered or chemically
treated.
Treated Water Water containing specified additions of oxygen scavenger and
biocide for the anticipated time of exposure. Treatment may or
may not require filtering.

4.0 Selection of Water

1. To ensure the right balance, the following factors shall be considered when selecting the
hydrotest water to be used in piping and pipelines:
a. Type of water.
b. Treatment required to prevent pipe corrosion.

Note: The combination of the type of water used for hydrotesting, the type of pipe,
and the duration of containment determines whether filtering or chemical
treatments are required for corrosion prevention.
c. Environmental impact upon discharge of water.
Note: More information can be found in the following two International Finance
Corporation (IFC) (2007) references:
– Environmental, Health, and Safety Guidelines for Offshore Oil and
Gas Development
– Environmental, Health, and Safety Guidelines for Onshore Oil and
Gas Development
2. Characterization shall include a complete water analysis including bacterial count.
a. Owner shall be contacted for guidance on water analysis.
b. Depending on the results of the analysis, a kill study shall be required to determine
biocidal treatment and proper dosages of treatment.

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Hydrotest Water Quality for Corrosion Prevention CPM-SU-5252-C

3. Special measures shall be taken when water will be left stagnant in piping and pipelines.

Note: Carbon steel and corrosion resistant alloys (CRAs) exposed to hydrotest water can
be damaged by corrosion. Stagnant water is a problem because it allows debris
such as sand, marine life, and bacteria to settle, and under-deposit corrosion or
microbiologically influenced corrosion (MIC) can occur.

4.1 Considerations for Hydrotest Water Selection

1. The following types of water shall be considered, either of which may require filtering:
a. Raw water (untreated fresh water or seawater).
b. Treated water (fresh water, demineralized water, or seawater).
2. The water shall have the following characteristics:
a. Cause no corrosion to the pipe being tested prior to, during, or after testing is complete.
b. Be free from sand, oil, organic debris, and other pollutants.

Note: See Table 1 and Table 2 for definitions of limits.

c. Have a minimal environmental impact when discharged after hydrotesting.

Table 1: Minimum Criteria for Components of Raw Fresh Water

Component Amount
Natural pH 6.5 to 7.5
Sulfides < 0.1 ppm
Total bacteria count < 104/mL
Total organic content < 2 ppm
Maximum particle size 50 microns
Total salt content < 500 ppm
Chloride content < 200 ppm for carbon steels, 100 ppm for stainless steels
Oxygen content > 1 ppm
Free chlorine* < 1 to 2 mg/L (ppm) for carbon steels
* Chlorine is added to potable waters for disinfection; i.e., to control bacteria harmful to humans. It also
controls bacteria and the risk of MIC. Typical chlorine residuals in potable waters are between 0.2 and
0.5 mg/L (ppm). The corrosion rate of carbon steels, however, increases with as little as 0.5 mg/L and
continues to increase as the residual increases. Austenitic stainless steels are not negatively affected
under 2 mg/L. More highly alloyed stainless steels and chromium containing nickel based alloys can
withstand up to 5 mg/L chlorine.

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Hydrotest Water Quality for Corrosion Prevention CPM-SU-5252-C

Table 2: Minimum Criteria for Components of Raw Seawater

Component Amount
Natural pH 7.0 to 8.7
Sulfides < 0.1 ppm
SRB content < 10/mL
Total bacterial count < 104/ml
Total organic content < 2 ppm
Oxygen content > 1 ppm

3. Selection of water shall be based on the following variables:

a. Pipe or pipeline material.
1) Carbon steel shall be tested with either fresh water or seawater.
2) Stainless steels and clad pipe shall be tested with fresh water.
b. Length of containment within the pipeline segment. Chemical additives shall be
tailored for protection according to the maximum exposure period.
c. Availability of water to hydrotest location.
d. Volume of water.
e. Discharge requirements.
4. Hydrotest water temperature shall not be less than 40°F (4°C) at any time while contained
in the piping system unless the following safeguards are taken.
a. If temperature of hydrotest fluid is less than 40°F (4°C), the use of ethylene glycol or
alternative Purchaser-accepted antifreeze shall be added.
b. If ambient temperature falls below 40°F (4°C) during any stage of the hydrotesting
(filling, pressurizing, draining, drying) then antifreeze shall be added.
1) The selected antifreeze shall be compatible with all other chemicals being used to
treat the water.
2) To prevent freezing, ethylene glycol concentration shall be at least 60 percent.
5. Hydrotest water temperature shall not be greater than 140°F (60°C) at any time while
contained in the piping system. If temperature is expected to be higher than 140°F (60°C),
the corrosion and cracking risks to the materials involved shall be evaluated to determine if
this upper limit can be exceeded.

4.2 Raw Water

4.2.1 Raw Fresh Water

1. Raw fresh water (potable water) shall be used when possible because of its low chloride
content, low solids concentration, and minimal environmental risk from discharge.

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Hydrotest Water Quality for Corrosion Prevention CPM-SU-5252-C

Note: Potable water is expensive and not always available. Its quality varies significantly
by location, and it may still require chemical additions dependent on time of pipe
exposure.
2. Other sources of raw fresh water (such as ground, river, or lake water) may be used if more
accessible and approved by Owner.

Note: These sources of raw fresh water often require filtering or other treatment (see
Section 6.0).
3. Both carbon steel and stainless steel materials may be tested with raw fresh water.
4. The criteria for allowable components in raw fresh water shall be per Table 1.
a. If water properties do not meet these requirements, appropriate filtering, oxygen
reduction, and/or biocide treatments shall be applied; otherwise containment time shall
be limited to 7 days.
b. Water not meeting these requirements shall only be used with written acceptance from
the Owner.

4.2.2 Raw Seawater

Note: Raw seawater (including filtered seawater) has a high salt content and, therefore, is
extremely corrosive.
1. Raw seawater shall not be used in the case of martensitic or duplex/austenitic stainless steel
pipes.
2. Carbon steel pipe materials shall be tested to determine if raw seawater will cause
corrosion.
3. Raw seawater shall be drawn from a location at least 20 ft (6.1 m) above the seafloor and
50 ft (15.2 m) from the surface.
4. Raw seawater shall not be preferred for free flooding. If used, then the following shall be
provided:
a. Method for chemically treating raw seawater.
b. Method for filtering seawater during free-flooding of flooding cap or skid.

Note: Free flooding is not recommended because there is nothing to prevent the ingress
of solids such as sand and organic materials (i.e., living organisms).
5. The criteria for allowable components in raw seawater shall be per Table 2.

4.3 Treated Water

4.3.1 Treated Fresh Water

1. If water properties do not meet the requirements in Table 1, appropriate filtering, oxygen
reduction, and biocide treatments shall be applied.

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Hydrotest Water Quality for Corrosion Prevention CPM-SU-5252-C

2. The use of treated fresh water (including demineralized water) shall be preferred.

Note: Treated fresh water does not pose the corrosion problems typically associated with
raw fresh water.
3. Treated fresh water shall be used for carbon steel and stainless steel pipes.

4.3.2 Treated Seawater

1. Treated seawater shall not be used in the case of martensitic stainless steel pipes.
2. Carbon steel pipe material shall be tested to determine corrosion with treated seawater. For
treatment requirements, refer to Section 6.0.
3. Owner shall be consulted for the use of treated seawater for the following pipe materials:
a. Austenitic stainless steels.
b. Duplex stainless steels.
c. Super duplex/6Mo stainless steels.
d. Flexible pipe (austenitic stainless steel internal carcass).

Note: Stainless steels and other CRAs may be more susceptible to corrosive mechanisms
resulting from improper water treatment than carbon steels.

5.0 Water Treatment Requirements

1. Treatment of water shall be determined by the following:
a. Water type.
b. Pipe material.
c. Containment time.
2. If water properties do not meet the minimum requirements in Table 1 or Table 2, either or
both of the following shall occur:
a. Containment time shall be adjusted accordingly.
b. Appropriate filtering, oxygen reduction, and biocide treatments shall be applied (see
Section 6.0).
3. Determining pipe material and containment duration for each water type shall be as shown
in Table 3.
4. Clad pipelines shall be treated per the alloy used for cladding.
5. When considering water treatment or containment duration, efforts to minimize ecological
risk shall be a priority.
6. When water is going to be transported to site, appropriate precautions shall be taken to
ensure that water quality does not degrade during transportation and storage.

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Hydrotest Water Quality for Corrosion Prevention CPM-SU-5252-C

7. Hydrotest water can be re-used but it shall meet the minimum requirements in Table 1 or
Table 2, or be treated upon recycling according to the requirements of Section 6.0.

Note: 304/304L stainless steel piping is particularly prone to through-wall pitting if

stagnant water is present at low points for several months.

Table 3: Water Type, Material, and Containment Time

Flexible Pipe
Super (Austenitic
Martensitic Austenitic Duplex Duplex/6Mo Stainless Steel
Carbon Stainless Stainless Stainless Stainless Internal
Steel Steels Steels Steels Steels Carcass)
(days) (days) (days) (days) (days) (days)

Raw fresh water < 7a < 30b < 30 < 30 < 30 < 30

Treated fresh < 365c < 365c < 365c < 365c < 365c < 365c
water per
Section 6.0

Raw seawater < 7a Do not use Do not use Consult < 14d Tempe < 14b
Owner

Filtered seawater < 30 Do not use Do not use Consult < 30 Tempe < 30b
Owner

Treated seawater < 365 Do not use Consult Consult Consult Consult Owner
per Section 6.0 Owner Owner Owner

Notes:
a. No chemicals are required (minimal corrosion and environmental risk). This number is dependent upon the
expected operating conditions.
b. Oxygen scavenger addition to O2 to 10 ppb or less.
c. Suitable combination of oxygen scavenger and biocide shall be used.
d. If temperature is less than 59°F (15°C). For temperatures greater than 59°F (15°C), see duplex stainless steel
recommendations.
e. Temperature below the critical pitting temperature.

6.0 Treatment of Hydrotest Water

6.1 Filtering
1. Demineralized water, high purity steam condensate, and potable water from North America
and Europe shall not require filtration.
2. Potable waters sourced from locations outside North America and Europe, including sea,
river, lake, and brackish waters, shall be filtered to remove all particles greater than
50 microns.

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Hydrotest Water Quality for Corrosion Prevention CPM-SU-5252-C

6.2 Chemical Treatment

Note: Oxygen scavengers are used to prevent oxygen-related corrosion of carbon steels and
crevice corrosion of CRAs. They are suitable for systems when a limited amount of
oxygen is present and are ineffective in systems when there is a significant amount of
oxygen (e.g., a pigging loop) where there will be a pocket of air that cannot be
removed.
1. Chemical dosage for oxygen scavenger shall be in accordance with Table 4 and shall be
thoroughly mixed in the water.
a. Oxygen scavengers shall be required for stainless steel scenarios.
b. Oxygen scavengers shall be required for carbon steel with containment periods
requiring the use of treated water.
c. The reaction time of the oxygen scavenger shall be considered so that water entering
the pipeline has low oxygen content.
d. The use of oxygen scavenger with biocide shall require planning with the pipeline
installation Supplier.
e. Sufficient mixing time shall be given to allow for full reaction prior to adding biocide
to the hydrotest water.

Note: When a limited time is available for oxygen scavenger action, activated sulfites
are available that have a faster reaction time with free oxygen than standard
sulfite compounds.

Table 4: Oxygen Scavenger Dosage Level Guidelines

Oxygen Scavenger Type Dosage (ppm)
Ammonium Bisulfite 155*
Amine Bisulfite 155*
Sodium Bisulfite 250*
* Typical dosage level. Actual dosage to be determined by chemical procured
and Supplier product recommendations.

2. Biocide dosage shall be per the requirements listed in Table 5 and shall be thoroughly
mixed in the water.

Note: Biocides control bacterial growth and metabolic processes. Biocides degrade with
time of exposure, consequently increasing exposure periods requires increasing
initial biocide dosing concentrations.
3. A compatible combination of oxygen scavenger and biocide shall be selected.
a. Chemical vendors shall be contacted for chemical compatibility of products.
b. Due to the contained nature of hydrotest waters, corrosion inhibitors are generally
required only for containment periods exceeding one year.

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Hydrotest Water Quality for Corrosion Prevention CPM-SU-5252-C

4. Minimum and maximum chemical concentrations shall be specified by Supplier for Owner
or Purchaser review.

Note: Actual injected chemical concentration may vary significantly from the target
concentration depending on the flooding skid setup.

Table 5: Biocide Dosage Level Guidelines—Manufacturer Recommendations for Biocide

According to Containment Time
Short-Term Containment Long-Term Containment
Biocide Type (180 days or less) (180-365 days)
Dosage (ppm) Dosage (ppm)

Glutaraldehyde – 25% 200* 400*

Glutaraldehyde – 50% 100* 200*

Tetrakishydroxymethyl 250* 400*

Phosphonium Sulfate (THPS)

Quaternary Amines 300* 1000*

*Typical dosage level. Actual dosage to be determined by the chemical procured and Supplier
product recommendations.

7.0 Discharge of Treated Water

1. Hydrostatic test water volume shall be minimized when possible.
Note: This is especially important in subsea applications when neutralization of the water
is not always feasible.

2. For discharge, chemical addition shall be minimized or eliminated when possible.

a. If a biocide has been added, chemical neutralization of unspent biocide based on
vendor procedures may be recommended to avoid toxicity on discharge.
b. If chemical additions are used, discharge planning and permits shall be required.
Note: The process and certifications for performing hydrotest water discharges are
specific to each location. Local legislation and internal guidance from Owner
health, environment, and safety should be sought to determine discharge
requirements.
3. If water properties or containment times require chemical additives to the hydrotest water
for corrosion prevention, ecological risk during discharge shall be considered.
4. If chemical additions are required to satisfy containment criteria for a specific location, all
necessary discharge certifications shall be satisfied for the applicable location.
5. If hydrocarbon or chemical contamination of the equipment to be tested is suspected, the
internals of the equipment shall be cleaned prior to the hydrotest.
6. The environmental impact upon discharge of water shall be considered.
Note: Refer to either of the IFC 2007 references.

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Hydrotest Water Quality for Corrosion Prevention CPM-SU-5252-C

8.0 Quality Control

Prior to start of hydrotesting, Supplier shall provide the following for Owner or Purchaser
review:

1. Drawing that includes lift pumps, filters, chemical injection pumps, chemical injection
points, flowmeters, water sampling points, interconnecting piping.
2. Quality assurance/quality control plan, which includes the following,
a. Real-time monitoring of chemical injection flowrate and water flowrate.
1) Real-time chemical concentrations shall be calculated from the flowrates and
linked to automatic alarm and automatic shutdown events.

Note: Acceptance/rejection of chemical concentrations shall be based on

real-time chemical concentrations and not cumulative chemical
concentrations.
2) Monitored data shall be recorded frequently and shall be available upon Owner or
Purchaser request.
3) Each alarm or shutdown event shall be noted in a log, which shall also include
detailed explanations of the reasons for the alarms and any corrective actions.
b. Water sampling points.
1) Water sampling points shall be located just upstream of where the water goes into
the line and downstream of all pumps, filters, and chemical injection points.
2) A water sampling plan shall be implemented during hydrotesting to measure and
record turbidity, pH, temperature, dissolved oxygen, corrosion inhibitor (if
applicable), oxygen scavenger, and biocide concentrations on a frequent basis.
Water sampling testing shall be performed by a qualified chemist.

Note: Turbidity measurements are used to verify that the filter is functioning. The
pH and temperature are for information only and can be used for
troubleshooting. Dissolved oxygen concentration and oxygen scavenger
concentration is measured to verify that an adequate oxygen scavenger
remains to remove all oxygen.
3) Data shall be made available upon Owner or Purchaser request.
3. After completion of hydrotesting, the requirements found in PIM-SU-3541 for post
hydrotest shall be followed.

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