Pressure Testing

Sadara Project Polyethylene Envelope

Transmittal

Page: 1 of 1 Form Version: 23-Apr-2012

Sadara Unit(s) 455 460 470

Sadara Transmittal Sadara-L&T-T-1304

Issue Date 11 July 2013 Date Reply Needed N/A

From Majid Al Majid To Mr. P. Sankaranarayanan

Company L&T ATCO

Subject SADARA Response to L&T-SADARA-T-821-13, Method Statement for Pressure Testing of High Alloys and Reactive Metals

In respect of the above referenced transmittal;

SADARA request L&T to resubmit the Method Statement after incorporating the comments in the attached file and as discussed. Also, It should be submitted as job specific. Piping hydro test.

Subject File Name Date Rev

Method Statement for Pressure Testing of High Alloys and Reactive Metals

SA-RTIP-PEAAA-LTAT-50-5003 Hydrotest procedure of alloy steel -

commented N/A N/A

SADARA Polyethylene LSPB-1 Project

METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS & REACTIVE

METALS Contractor Job No: 10001 / 6600028371

Date Doc. No Rev. No Page

16-May-13

SA-RTIP-PEAAA-LTAT-50-5003 0 Page 1 of 30

PROJECT: SADARA POLY ETHYLENE LSPB 1

CONTRACT NO: 10001 / 6600028371

CLIENT: SADARA

CONTRACTOR: LARSEN & TOUBRO ATCO SAUDI

METHOD STATEMENT FOR

PRESSURE TESTING OF HIGH ALLOYS & REACTIVE METALS

(SA-RTIP-PEAAA-LTAT-50-5003)

0 16-May-13

Issued for Review & Comments BSK DKU CTK/DKC

Rev Date Description

Prepared

Reviewed

Approved

Approved

L&T ATCO

L&T ATCO

L&T ATCO

SADARA





16-May-13


REVISION RECORD SHEET

Rev. No. Date

Reason for the revision Revision details/ Locations

0 16-May-13

Issued for Review &

Comments Initial Issue





16-May-13


CONTENTS

1. SCOPE ..................................................................................................................................... 4

2. REFERENCES ......................................................................................................................... 4

3. DEFINITIONS ........................................................................................................................... 6

4. ENVIRONMENT, HEALTH & SAFETY ..................................................................................... 6

5. RESPONSIBILITY AND AUTHORITY ...................................................................................... 7

6. GENERAL REQUIREMENTS ................................................................................................... 8

7. PRESSURE TEST PROCEDURE ............................................................................................ 9

8. SPECIFIC TESTING REQUIREMENTS ................................................................................. 10

9. HYDROSTATIC TESTING FLUIDS ........................................................................................ 10

10. PREPARATION OF TEST ...................................................................................................... 12

11. CONDUCT PRESSURE TEST ............................................................................................... 14

12. PNEUMATIC PRESSURE TESTING ...................................................................................... 14

13. SENSITIVE LEAK TEST GAS AND BUBBLE METHOD ...................................................... 15

14. POST PRESSURE TEST ....................................................................................................... 15

15. LAY-UP PROCEDURE FOR STAINLESS STEEL .................................................................. 16

16. QUALITY CONTROL .............................................................................................................. 18

17. DOCUMENTATION ................................................................................................................ 18

18. SCHEMATIC TEST PACKAGE DIAGRAM & TEST MANIFOLD ............................................ 19

19. ATTACHMENTS ..................................................................................................................... 21





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1. SCOPE 1.1. This standard defines mandatory general requirements governing pressure testing of high

alloys and reactive metals in the piping works and process containment equipment (hereinafter called Equipment).

1.2. The requirements of this standard apply to field/shop fabricated piping systems and field fabricated Equipment.

1.3. This standard does not cover pressure testing of new, shop fabricated Equipment such as vessels, tanks, heat exchangers and skid mounted piping which are purchased in accordance with the applicable Project specifications.

1.4. This standard applies to pre start-up leak tests normally conducted by Operations during start-up & commissioning.

1.5. This standard establishes requirements to control corrosion and microbiological damage during and after hydro testing.

1.6. Equipment covered by this standard includes, but is not limited to, storage tanks, pressure containing Equipment, Plant Unit piping, and pipelines both onshore and offshore.

1.7. The procedures in this standard are designed to prevent corrosion due to oxygen (air) ingress and to prevent microbial induced corrosion. Hydro test procedures and lay-up procedures shall prevent oxygen ingress except as specifically allowed in this standard.

1.8. Non-toxic liquids other than water may be used for pressure testing if the operating fluid or the Equipment can be adversely affected by water or by freezing conditions. Water/methanol or water/glycol mixtures may be required in locations where freezing is a concern. Contact the Project Quality Group Representative and Manufacturing Representative for the selection and treatment of the appropriate fluid. Such a fluid shall not have a flash point below 54C (129F).

1.9. Should there be any conflict between this procedure and any Equipment specific specification or standard, the more specific requirements will take precedence.

2. REFERENCES

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.

Comment [SS1]: Scope should be job specific Piping hydro test . NO mentioning of pneumatic or equipment _ REQUIRES RESUBMIISION AS DISCUSSED WITH L&T Construction

Comment [SS2]: What about normal CS piping? No equipment is covered in field testing unless it is specified separately. In that case , a standalone MS shall be prepared and submitted for approval.

Comment [SS3]: Delete the sentence

Comment [CU4]: Operation is using their own standards and procedures which we have to follow. 1.4 should be deleted or rephrased

Comment [CU5]: I am not sure if we will allow the usage of this Chemicals during construction on site. Should be deleted





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G4S-0210-01 - General Cleaning of Piping G4S-0210-02 - Cleaning and Flushing with Water G4S-0210-03 - Cleaning or Drying with Nitrogen G4S-0210-05 - Cleaning by Abrasive Blasting G4S-0260-01 - Hydrogen Peroxide Cleaning, Pickling and Passivation G4S-6421-02 - Class C Hydrostatic Testing G4S-6421-03 - Class G Hydrostatic (Gravity) Testing G4S-6421-04 - Hydrostatic Testing Equipment Procedure G4S-6422-01 - Class D Sensitive Leak Test Gas & Bubble Method G4S-6422-02 - Class DH Pneumatic testing greater than 1 Bar (15 PSIG) G4S-6422-03 - Class DR Pneumatic Testing Refrigeration Piping G4S-6423-01 - Class F- Firewater Systems Testing G4S-6425-01 - Class J Helium Leak Testing G4S-6427-01 - Class L (Category D) Test G4S-6428-01 - Class M Polyethylene Piping Hydrostatic Testing RT8S-4001-60 - Specification for Water Quality used for Hydrostatic Testing RT9S-2500-01 - Tanks Specific Requirements G52T-0450-01 - Leak Testing for Chlorine Piping G52T-0450-02 - Pneumatic Testing for Chlorine Piping G52M-0450-01 - Chlorine Lines: Cleaning, Washing, Drying RT-2642 - ENG Pressure Test Report Form, Appendix 5 A554-O-PRG-QA-GEN-PRO-014 - General Requirements for Pressure Testing and

Lay-up. SA-RTIP-PEAAA-LTAT-50-3027 - Construction work detail procedure for AG piping

2.1 Industry Codes and Standards

American Petroleum Institute:

API RP 520 - Part I - Sizing, Selection, and Installation of Pressure Relieving Devices in Refineries

API RP 560 - Fired Heaters API Std 598 - Valve Inspection & Testing

American Society of Mechanical Engineers:

ASME B31.1 - Power Piping

Comment [CU6]: G4S-0210-03 says Cleaning or Drying with air or Nitrogen

Comment [CU7]: Should be deleted as this service will be flushed with water and Air dried

Comment [CU8]: Should be deleted as Class C is the only applicable hydro test method

Comment [CU9]: Should be deleted as pneumatic testing is not an option

Comment [CU10]: Should be deleted as construction scope of work is clearly defined in DOC. A554-D-455-CM-GEN-DOC-005. G52M-0450-01 is a maintenance procedure





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ASME B31.4 - Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids ASME B31.5 - Refrigeration Piping ASME B31.8 - Gas Transmission and Distribution Piping Systems ASME B31.9 - Building Services Piping ASME SEC I - Rules for Construction of Power Boilers ASME SEC V - Article 10 Leak Testing ASME SEC VIII D1 - Boiler and Pressure Vessel Code ASME SEC VIII D2 - Alternative Rules

National Board of Boiler and Pressure Vessel Inspectors:

NB 23 National Board of Inspection Code

Uniform Mechanical Code (UMC)

Uniform Plumbing Code (UPC)

3. DEFINITIONS

Project - SADARA Polyethylene LSPB 1 Company - SADARA Contractor - Larsen & Toubro ATCO QCI - Quality Control Inspector QG - Quality Group HSE - Health, Safety & Environment

4. ENVIRONMENT, HEALTH & SAFETY

This method statement and the attached job safety analysis is in adherence with the Sadara

EHS&S policy and L&T Project EHS Plan. In addition to above, JSA shall describe the job

specific requirement for each activity. Following are the main reference documents for

preparing this method statement.

A-554-K-PRG-QM-GEN-PLN-004 - RTIP-Construction Environment, Health and Safety (EHS) Standards.

A554-D-455-CM-SOW-CON-005-RTIP - Construction Instructions.





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L&T PROJECT EHS PLAN.

Following points shall be taken care before commencement of the work at site.

Work Permit to be obtained from the competent person. Inspection of all the Plant and machineries used for the lifting activities shall be done by

the Third party agency approved from Sadara Project. Work checklist, where applicable, shall be followed by supervisor as per requirement: Works shall be carried out according to Safe Construction Practices, SADARAs Safety

Regulations. List of emergency contact telephone numbers shall be mentioned in the attached

emergency plan. All personnel involved in works shall be aware of Safety requirements of the project and

site shall be kept clean and in tidy conditions. Contractor shall maintain good housekeeping at all the times. HSE inspector shall monitor the site personnel during the erection and installation

activities. Provide drinking water and potable shelters for the employees. Fire extinguishers shall be kept at the site where required. Hydro test area should be cordoned with barricading tape and appropriate sign boards. All hose connections for hydro test to be provided with hose arrestors. START card to be filled for every task. Plant, machineries & equipment shall be operated by the Operators having valid Saudi

licence and third party certificate from the approved agency

Workmen shall be provided with the following PPE to work in Pipe laying, lamination and hydro

testing.

Safety Helmet Safety Footwear Hand Gloves Safety Goggles Reflecting jacket Dusk Mask (As required)

5. RESPONSIBILITY AND AUTHORITY





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5.1 This procedure shall be Prepared and reviewed by CONTRACTORs QA/QC department and approved by COMPANY before use.

5.2 CONTRACTORs Piping Engineers/Supervisors are required to ensure that all Pressure test work is carried out as per project specifications, approved drawing & HSE requirements.

5.3 CONTRACTORs shall provide with labor, testing, tools and equipment for Construction and inspection record preparation and maintenance.

5.4 CONTRACTOR QCI is responsible for conducting the quality control and inspection works during all Hydro-Testing applications.

5.5 All final tests shall be witnessed and accepted by the Company or Company designee.

6. GENERAL REQUIREMENTS 6.1 Pneumatic testing is not permitted without written approval of the QG Representative, unless

specified by the applicable Project standard. Pneumatic testing, when conducted, shall be in accordance with approved procedures that require additional safety requirements.

6.2 Test pressures and test durations shall be based on the applicable Project standards.

6.3 General requirements for the setup and operation of equipment and instrumentation necessary to perform a Hydrostatic /Pneumatic Test see practice G4S-6421-04 (Hydrostatic Testing Equipment Procedure), G4D-6422-01 (Pneumatic test), G4S-6422-01 (Leak Test).

6.4 The effect of the static head of the testing liquid shall be considered when determining the effective test pressure of any elements within a tested system.

6.5 Test Water sources shall meet the requirements of Materials Engineering EMETL Specification G8S-4001-60.

6.6 Protection from over pressure.

6.7 All systems (piping equipment) while being pressure tested shall be protected from being over pressured by the following:

Pressure test relief valve(s) of adequate set to relieve at 5% above the test pressure shall be installed unless the test pressure is less than 85% SMYS at which time it can be set at 10% above the test pressure. Sizing of these relief valves used for testing shall follow the requirements of API RP 520, Part 1. The relief valve(s) shall be tested, dated, and tagged within one week prior to the pressure test.

Comment [CU11]: Pneumatic testing is not permitted at all

Comment [CU12]: Delete pneumatic test

Comment [CU13]: Delete





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The pressure test relief valve shall be accompanied with a calibration certificate that includes the cold differential test pressure (CDTP), test date and the spring range. The CDTP shall be within the spring range.

In addition to the pressure relieving device, a bleed valve shall be provided to protect the piping and Equipment from overpressure. The bleed valve shall be readily accessible in case immediate depressurization is required.

An isolation valve shall be provided between the pressure testing manifold and the system being tested. The isolation valve shall be rated for the manifold test pressure when in the closed position.

Before employing the pressure testing manifold in the actual system pressure test, it shall be separately pressure tested to at least 1.2 times the system test pressure but not less than the discharge pressure of the pump used for the pressure testing.

The test manifold shall be designed and constructed to meet the minimum system requirements. All pipe, fittings, flanges and materials used for pressure testing shall be in accordance with the governing piping material specification for the piping system.

Test manifolds shall be subjected to 100% RT of all butt welds.

7. PRESSURE TEST PROCEDURE 7.1 A pressure test procedure shall be prepared by the responsible Contractor and submitted to

QG for approval prior to conducting the test. The test procedure shall be available at the test site at all times.

7.2 The pressure test procedure shall include all required documentation specified.

7.3 During a pneumatic pressure test a leak test shall be performed in accordance with ASME SEC

V Article 10 and Article 10 Appendix I except the pressure shall be 5 10 psi. A calculation sheet indicating adequacy of the pressure test relief valve shall be included in the procedure.

7.4 The requirement for pre start-up leak tests and service tests during initial start-up shall be as follows:

New systems after strength tests and prior to initial start-up

For systems with maximum operating pressures greater than 6.894 Mpa (1000 psi), a leak test with inert gas, followed by a service test, shall be conducted at the maximum operating pressure of the piping system.





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For systems with maximum operating pressures less than 6.894 MPa (1000 psi), a pre start-up leak test with inert gas or steam (if designed for steam service) shall be conducted at the available inert gas or steam system pressure (not exceeding the maximum operating pressure), or pressure as recommended by the facility Engineering unit responsible for developing the test package, followed by a service test at normal operating pressure of the piping systems. When inert gas or steam is not available, the service test will satisfy the pre start-up leak test requirements.

If the drop in ambient temperature may cause the test medium to freeze during the test, appropriate precautionary measures must be taken to protect the Equipment or piping systems.

8. SPECIFIC TESTING REQUIREMENTS

This section specifies in details which piping or Equipment that shall be pressure tested and provides the specific applicable standard. It also defines any specific exemptions.

8.1 Plant Piping

Pressure testing of Plant Unit piping shall be in tested accordance with ASME B31.3. All weld joints shall be uncoated, and all joints shall be accessible for visual inspection during pressure testing. If this is not possible, refer to 11.1 for alternative test requirements.

8.2 Valves

Metallic Valves shall be tested in accordance with API 598 as a minimum.

8.3 Gasket Material

All gaskets used in the pressure test shall be the gaskets intended for use.

8.4 Internally Coated Equipment or Piping

The hydro test pressure of all internally coated vessels, tanks or piping shall be reviewed against the coating manufacturers limitations. On completing the hydrostatic test, the pressure should be reduced gradually to prevent decompression failure of the internal coating.

9. HYDROSTATIC TESTING FLUIDS

Comment [CU14]: Gaskets according Pipe spec





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9.1 In the case of new construction, the construction agency shall be responsible for adhering to this specification; QG shall be the monitoring authority.

9.2 Water Quality

9.3 Water quality of intended hydrostatic test waters shall be determined in accordance with RT8S-4001-60 well ahead of the actual testing date so that alternative water sources may be identified if the original source water fails to meet requirements.

9.4 Water quality of hydrostatic test waters shall be reconfirmed by testing as close to the time of the hydrostatic test as practicable. In cases where individual tanker trucks are used to supply a test, the water samples shall be drawn from a representative number of actual truck loads being delivered to the test site.

9.5 Water used for any part of the hydro testing or subsequent lay-up shall have a sulfate reducing bacteria (SRB) count of 10 per ml or less as determined by the Rapid Check II Method or alternative test method approved by the QG Representative. Water that has a higher bacteria count may be accepted at the discretion of the QG Representative, after treatment with biocide and retesting.

9.6 If water from more than one source will be used, ensure that mixing the waters will not cause scaling.

9.7 Water used for any part of the hydro testing or subsequent lay-up shall be clean and free from suspended matter. Suspended matter in the water shall be extracted, before use, by a filter capable of removing 99% of all particles 53m (2.1 mil) in diameter and larger, or equivalent to using a 270 mesh wire mesh screen.

9.8 Water that could result in harm to humans must not be used for hydro testing. For example, service water containing hydrogen sulfide levels that if released to atmosphere would result in air concentrations of 10 ppm hydrogen sulfide or greater in the immediate area of the hydro test must not be used.

9.9 Water may be reused for hydro testing, as in a pipeline tested segment by segment. The water must meet the requirements and must have an oxygen level of less than 20 ppb, or additional chemical treatment will be required.

9.10 See Paragraph 14.1 for restrictions on the quality of water used for testing austenitic stainless steels. Seawater or high TDS aquifer water shall not be used for this purpose.

9.11 The Construction Contractor shall keep a permanent written record of the water supplied for testing stainless steels including a record of tests performed on the water.





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9.12 Minimize the time between introducing hydrostatic test water and commissioning the Equipment.

9.13 Schedule the hydrostatic test as close as possible to the start-up date.

9.14 Where there are limitations in this standard on contact time for hydro test water, this shall be from the first introduction of water into the system until commissioning or until implementation of a complete lay-up. Partial or complete refilling of the system shall count as continuous, cumulative time. Time limitations requiring the initiation of a formal lay-up program shall be from the first introduction of hydro test water.

9.15 Design the hydrostatic test and the lay-up procedure to protect the most corrosion susceptible material in the system.

10. PREPARATION OF TEST 10.1 Site Preparation

An approved test procedure shall be available at the Site prior to commencing any pressure testing activities.

New piping systems shall be cleaned in accordance with the applicable standard. Soft seated valves and control valves shall not be installed until after the lines have

been thoroughly flushed. Components in new piping systems which interfere with filling, venting, draining or

flushing shall not be installed until after line flushing and pressure testing are completed. These include orifice plates, flow nozzles, sight glasses, venturies, positive displacement and turbine meters and other in-line Equipment.

10.2 Pressure gauges

All gauges shall be calibrated prior to use. The calibration interval shall not exceed 6 months prior to the test date and calibration

certificates shall be made available to Inspection personnel prior to commencement of the pressure test. Stickers shall be applied indicating the latest calibration date.

All gauges shall have a range such that the test pressure is within 30 to 70% of the full range.

A minimum of two pressure gauges are required for the test system. One pressure gage shall be on the test manifold and the other(s) at the low point on the test system. Their accuracy shall be within 5% of one another.

When large systems are tested, QG will determine the need for additional gauges.

Comment [CU15]: Time between hydro test and start flushing and drying of Line should not exceed 5 days




Comment [CU19]: Must

Comment [CU20]: Delete and replace with DOC A554-D-455-CM-GEN-DOC-005

Comment [CU21]: Test pack is been released for reinstatement

Comment [CU22]: and drying is completed

Comment [CU23]: delete





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Pressure and temperature recording gauges shall be used for all buried piping systems on plot.

Expansion joints and spring hangers or spring supports shall be provided with temporary restraints where needed to prevent excessive travel or deformation under the test loads.

10.3 Equipment Excluded from Pressure Test

The following list defines the Equipment that shall be excluded from the in-situ pressure testing of the tested system.

Rotating machinery, such as pumps, turbines and compressors; Strainers baskets and filter elements; Pressure relieving devices, such as rupture disks and pressure relief valves; Locally mounted indicating pressure gauges, where the test pressure will exceed their

scale range; Equipment that cannot be drained; Instrument Devices.

10.4 Isolation of Test Sections

Blind flanges, paddle blinds or spectacle blinds shall be used to isolate the test sections. All pipe, fittings, flanges and materials used for pressure testing shall be in accordance with the governing Piping Material Specification for the piping system and shall be capable of withstanding the test pressure.

10.5 Vents and Drains

Vents shall be provided at all high points in the tested system as needed. Excluding scrapable, submarine and buried pipelines, drains shall be provided at all low

points in the system and immediately above check valves in vertical lines. Unless the check valve has a by-pass valve, the disc of the check valve shall be

removed, and securely attached to the outside of the check valve prior to the pressure test.

10.6 Temporary Connections and Supports

Temporary connections shall be provided for de-pressurizing and draining of the system to the sewer or disposal area.

Temporary supports shall be installed prior to hydrostatic testing, and flushing of the piping if required. These supports shall not be removed until after the system has been fully drained. The structural support system for stacked Equipment shall be verified for hydrostatic loads prior to testing.

Comment [CU24]: and insulated


Comment [CU26]: high point vents and low point drains shall be provided as needed






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11. CONDUCT PRESSURE TEST 11.1 The test procedures shall be conducted in accordance with the applicable code. In addition, the

following requirements shall apply.

All piping joints shall be open for visual inspection during pressure testing. If this is not practical as agreed by the QG Representative, the test shall be conducted for 24 hours using pressure and temperature recorders calibrated as required for pressure gages.

Filling and pressurizing shall be done on the upstream side of check valves in the system. The test fluid shall be injected at the lowest point in the system to minimize entrapped air. When filling at the lowest point is not practical, QG shall be consulted. All vents shall be open during filling.

No one shall approach the test area for a minimum of 10 minutes after the test pressure is reached and before commencement of inspection of the system, the isolation valve between the temporary test manifold/piping and the piping/Equipment under pressure test shall be closed and the test pump disconnected. The isolation valve downstream of the manifold shall be opened after the pump is disconnected.

During the application of the test pressure, all in-line valves if not used as test isolation valves shall be in a partially open position.

All piping and Equipment shall comply with the lay-up procedures. Test records shall be recorded on Pressure Test Report Form.

12. PNEUMATIC PRESSURE TESTING 12.1 ASME B31.3, Section 345 requires leak testing of piping systems to ensure tightness, prior to

initial operation, expect as permitted for category D fluids.

Pneumatic testing shall be in accordance with G4D-6422-01. The Pneumatic test pressure per ASME B31.3 is 110% of design pressure. Minimum distance should be maintained while testing, for minimum distance

requirements refer G4D-6422-01. The detection fluid shall be a commercial bubble forming test fluid such as SNOOP or

SHERLOCK, or equivalent. Soaps, detergents and/or industrial compounds that are designated specifically to be cleaning agents shall not be used in bubble forming solutions.

For testing of stainless steel, nickel or chromium alloys, the fluid shall have a sulfur and halogen content of less than 10 ppm of each.

Pneumatic test shall be made with air, nitrogen or other gases. As specified in the technical job instructions. Work order or construction order. Comment [CU28]: should be deleted as

pneumatic test is not an option





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13. SENSITIVE LEAK TEST GAS AND BUBBLE METHOD

This test is performed by pressurizing the system with gas, to 1 BAR (15 psig). This

creates a pressure differential across a leak. Leaks are detected by applying a commercial bubble forming solution to all joints. The locations of commercial bubble are indicated by the formation of bubbles.

This test may be performed at pressures greater than 1 BAR (15 psig). However, all conditions of G4S-6422-02 and G4Q-6422-02 shall be met when a higher pressure is used.

Air compressors shall be equipped with discharge filters for removal of water, oil and foreign matter. Maximum discharge temperature of lubricated air compressors shall be 150C (300F)

A complete line or section of line containing several valves and braches may be tested at one.

CAUTION: PNEUMATIC TESTING should be used only as a leak alternative carefully planned and supervised procedures shall be used to guard against the hazards of latent energy of compressed gases.

The Company is responsible to assure that all conditions and safety concerns identified in G4D-6422-01 are addressed.

14. POST PRESSURE TEST

After pressure testing has been successfully completed and approved by the Project inspector, the following operations shall be made.

14.1 Draining of Test Fluid

Release of pressure and draining shall be done on the downstream side of check valves. All vents shall be opened before draining to facilitate drainage and to prevent formation of a vacuum. No test fluid shall remain in low spots.

14.2 Disposal of Test Fluid

The test fluid shall be disposed with as directed by Project EH&S requirements.

14.3 Test Vents and Drains

Vents and drains used only for the pressure test shall be plugged, seal welded and penetrant tested.

Comment [CU29]: Air

Comment [CU30]: Prior to test an yield stress calculation shall be performed and approved my client

Comment [CU31]: Air

Comment [CU32]: Oil free compressor

Comment [CU33]: Sensitive leak

Comment [CU34]: The test fluid shall be disposed in the Sump

Comment [CU35]: High point vents and low point drains

Comment [CU36]: As a part of reinstatement after pre commissioning is completed





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14.4 Removal and Reconnection of Components

All temporary items installed for testing purposes (e.g., manifolds, valves, blinds spacers, supports) shall be removed.

Items that were removed for testing shall be reinstalled. Items, such as instrument air tubing, check valve discs which were disconnected before

testing shall be reconnected. Isolation valves closed for the test purposes and that are required to be in the open position for process reasons shall be opened. If the valve cavity has a drain, the cavity shall be drained.

15. LAY-UP PROCEDURE FOR STAINLESS STEEL 15.1 Type 300-series stainless steels shall be tested only with water that has very low chloride

content in order to avoid pitting and stress corrosion cracking. The maximum allowable chloride concentration is 20 ppm per RT8S-4001-60. Verify the quality of the water following the requirements.

Exceptions: Type 300-series stainless steel valve trim shall not be a sufficient sole criterion for classifying a carbon steel system as "stainless" for the purpose of applying Section 6. For example, this section shall not apply to carbon steel pipelines with valves having stainless trim unless there are also other stainless steel components included.

In special cases, with the prior written approval of QG Representative, water of up to 200 PPM chloride content is permitted, provided:

That the hydrostatic test period is less than four days, That the system is rinsed with steam condensate or demineralized water until the

effluent chloride content reaches below 20 PPM, and That the system is completely drained immediately after hydrostatic test and rinse.

15.2 Type-400-series stainless steels are highly prone to atmospheric corrosion. Type 400- series

stainless steel trimmed valves shall be removed from pipelines before hydro test. If it is impossible to remove such valves from the line, then written hydro test procedures must prepared and approved ahead of time allowing the valves to remain in place. When Equipment containing any Type-400 series stainless steels is left in place, it shall be hydro tested in accordance with the requirements of Paragraph 14.3, 14.4, and 14.5 of this standard. The hydro test procedure shall carefully detail measures prevent corrosion including lay-up of the Equipment. Do not use ambient lay-up for Equipment made of 400-series stainless steels.

15.3 Treat the hydrostatic test water with oxygen scavenger per paragraph 13.1 if the Equipment

contact time with water might exceed 4 days.

Comment [CU37]: All this activities shall be done after pre commissioning activities have been completed and permission to reinstatement is given.





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15.4 Lay-up the system following the requirements. 15.5 At the end of the lay-up, commission and start up the stainless steel Equipment within 14 days.

Tested Line

(Above Ground Piping)

Dewatering Hose

Schematic Diagram for Disposal of Tested Water

Temporary Storage

Tank Pump

Water Tanker or

Truck

Comment [CU38]: Lines have been flushed and dried according to A554-D-455-CM-GEN-DOC-005 there is no need for such an requirement





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16. QUALITY CONTROL

Quality Control shall be strictly exercised in accordance to approved Inspection & Test Plan and Quality Control Procedures.

Ensure that all the Inspection report formats has been completed and reports have been signed/accepted by all parties before depressurizing the system.

All calibration certificates and water test report are attached in the test pack.

QCI to verify that all punch points (Punch Category that affects Pressure Test) shall be closed before Testing.

17. DOCUMENTATION

The following Documents shall be attached with the pressure test packs.

1. Test package general information sheet. 2. Hydro test package content check sheet. 3. Test package flow chart. 4. Hydro test report. 5. Test diagram legend. 6. Schematic test package diagram & test manifold. 7. Test package index. 8. Pneumatic test calculation sheet ( if applicable) 9. Punch list 10. Safety instruction sheet. 11. Test diagram P&ID ( Marked test boundaries) 12. System definition P&ID 13. Marked air blowing P&ID 14. Isometric drawing. 15. Check list before test 16. Weld/NDT summary sheet. 17. Survey report (if applicable) 18. Calibration certificates.

(Pressure gauge, pressure recorder, test relief valve, temperature gauge, test manifold) 19. Blind control sheet. 20. Valve test report (if applicable)

Comment [CU39]: yield stress calculation

Comment [CU40]: delete, pre commissioning takes care about this





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21. Water analysis report (Test medium) 22. Reinforcing-pad leak testing report (if applicable) 23. Orifice flange joint inspection report (if applicable) 24. Flange joint inspection report. 25. Lay-up inspection. 26. Check list after test. 27. Flushing / Cleaning report.

18. SCHEMATIC TEST PACKAGE DIAGRAM & TEST MANIFOLD

Valve 1

Comment [CU41]: delete, pre commissioning takes care about this

Comment [CU42]: PSV should be placed on the downstream site of the Valve marked as 1 to protect against overpressure of the system





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Appendix A: Dew Point of Natural Gas

Comment [CU43]: What is the purpose of this document





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19. ATTACHMENTS

1. Test package general information sheet 2. Hydro test package content check list 3. Test package flow chart 4. Line List 5. Test diagram legend 6. Calibration Certificate 7. Blind control sheet 8. Bolt torqueing report 9. Punch list 10. Job Safety Analysis (JSA)





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Attachment - 1





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Attachment - 2





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Attachment 3

Comment [CU44]: After pressure testing next step should be water flush prior dry out to -30 C





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Attachment 4





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Attachment 5





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Attachment 6





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Attachment 7





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Attachment 8





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Attachment 9

460 470

The Following Drawings Specification Schedule

Data Sheets Calculation Material Requisition

Are Transmitted TBE Vendor Document MOM

Acceptance/Approval Review Information

This is Record Quatation Construction

Original Revision Final

Size No. of Copies

Receipt Not RequiredReceipt Required (Please Acknowlegde the Receipt of the Duplicate and Return)The Above Documents Received By:

Signature: Name:

John HufnagelJulian Archer

Drawings / File Name Description

To Majid Al Majid

Rev. No.

cc Mark Williams

455

L&T-Sadara-T-821/13

16-May-13 Date Reply Needed 18-May-13

Date:

Sureshbabu Surendran

1

*** Nothing Follows ***


Transmittal

Subject

C.T KuriakoseD.K UpadhayB.S Kumar

Sadara Unit (s)

L&T Transmittal

Issue Date

From

cc

Company


P.Sankaranarayanan

Sadara

SA-RTIP-PEAAA-LTAT-50-5003 A4 0

X

X X

X X





16-May-13


PROJECT: SADARA POLY ETHYLENE LSPB 1

CONTRACT NO: 10001 / 6600028371

CLIENT: SADARA

CONTRACTOR: LARSEN & TOUBRO ATCO SAUDI

METHOD STATEMENT FOR

PRESSURE TESTING OF HIGH ALLOYS & REACTIVE METALS

(SA-RTIP-PEAAA-LTAT-50-5003)

0 16-May-13

Issued for Review & Comments BSK DKU CTK/DKC

Rev Date Description

Prepared

Reviewed

Approved

Approved

L&T ATCO

L&T ATCO

L&T ATCO

SADARA





16-May-13


REVISION RECORD SHEET

Rev. No. Date

Reason for the revision Revision details/ Locations

0 16-May-13

Issued for Review &

Comments Initial Issue





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CONTENTS

1. SCOPE ..................................................................................................................................... 4

2. REFERENCES ......................................................................................................................... 4

3. DEFINITIONS ........................................................................................................................... 6

4. ENVIRONMENT, HEALTH & SAFETY ..................................................................................... 6

5. RESPONSIBILITY AND AUTHORITY ...................................................................................... 7

6. GENERAL REQUIREMENTS ................................................................................................... 8

7. PRESSURE TEST PROCEDURE ............................................................................................ 9

8. SPECIFIC TESTING REQUIREMENTS ................................................................................. 10

9. HYDROSTATIC TESTING FLUIDS ........................................................................................ 10

10. PREPARATION OF TEST ...................................................................................................... 12

11. CONDUCT PRESSURE TEST ............................................................................................... 14

12. PNEUMATIC PRESSURE TESTING ...................................................................................... 14

13. SENSITIVE LEAK TEST GAS AND BUBBLE METHOD ...................................................... 15

14. POST PRESSURE TEST ....................................................................................................... 15

15. LAY-UP PROCEDURE FOR STAINLESS STEEL .................................................................. 16

16. QUALITY CONTROL .............................................................................................................. 18

17. DOCUMENTATION ................................................................................................................ 18

18. SCHEMATIC TEST PACKAGE DIAGRAM & TEST MANIFOLD ............................................ 19

19. ATTACHMENTS ..................................................................................................................... 21





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1. SCOPE 1.1. This standard defines mandatory general requirements governing pressure testing of high

alloys and reactive metals in the piping works and process containment equipment (hereinafter called Equipment).

1.2. The requirements of this standard apply to field/shop fabricated piping systems and field fabricated Equipment.

1.3. This standard does not cover pressure testing of new, shop fabricated Equipment such as vessels, tanks, heat exchangers and skid mounted piping which are purchased in accordance with the applicable Project specifications.

1.4. This standard applies to pre start-up leak tests normally conducted by Operations during start-up & commissioning.

1.5. This standard establishes requirements to control corrosion and microbiological damage during and after hydro testing.

1.6. Equipment covered by this standard includes, but is not limited to, storage tanks, pressure containing Equipment, Plant Unit piping, and pipelines both onshore and offshore.

1.7. The procedures in this standard are designed to prevent corrosion due to oxygen (air) ingress and to prevent microbial induced corrosion. Hydro test procedures and lay-up procedures shall prevent oxygen ingress except as specifically allowed in this standard.

1.8. Non-toxic liquids other than water may be used for pressure testing if the operating fluid or the Equipment can be adversely affected by water or by freezing conditions. Water/methanol or water/glycol mixtures may be required in locations where freezing is a concern. Contact the Project Quality Group Representative and Manufacturing Representative for the selection and treatment of the appropriate fluid. Such a fluid shall not have a flash point below 54C (129F).

1.9. Should there be any conflict between this procedure and any Equipment specific specification or standard, the more specific requirements will take precedence.

2. REFERENCES

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.





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G4S-0210-01 - General Cleaning of Piping G4S-0210-02 - Cleaning and Flushing with Water G4S-0210-03 - Cleaning or Drying with Nitrogen G4S-0210-05 - Cleaning by Abrasive Blasting G4S-0260-01 - Hydrogen Peroxide Cleaning, Pickling and Passivation G4S-6421-02 - Class C Hydrostatic Testing G4S-6421-03 - Class G Hydrostatic (Gravity) Testing G4S-6421-04 - Hydrostatic Testing Equipment Procedure G4S-6422-01 - Class D Sensitive Leak Test Gas & Bubble Method G4S-6422-02 - Class DH Pneumatic testing greater than 1 Bar (15 PSIG) G4S-6422-03 - Class DR Pneumatic Testing Refrigeration Piping G4S-6423-01 - Class F- Firewater Systems Testing G4S-6425-01 - Class J Helium Leak Testing G4S-6427-01 - Class L (Category D) Test G4S-6428-01 - Class M Polyethylene Piping Hydrostatic Testing RT8S-4001-60 - Specification for Water Quality used for Hydrostatic Testing RT9S-2500-01 - Tanks Specific Requirements G52T-0450-01 - Leak Testing for Chlorine Piping G52T-0450-02 - Pneumatic Testing for Chlorine Piping G52M-0450-01 - Chlorine Lines: Cleaning, Washing, Drying RT-2642 - ENG Pressure Test Report Form, Appendix 5 A554-O-PRG-QA-GEN-PRO-014 - General Requirements for Pressure Testing and

Lay-up. SA-RTIP-PEAAA-LTAT-50-3027 - Construction work detail procedure for AG piping

2.1 Industry Codes and Standards

American Petroleum Institute:

API RP 520 - Part I - Sizing, Selection, and Installation of Pressure Relieving Devices in Refineries

API RP 560 - Fired Heaters API Std 598 - Valve Inspection & Testing

American Society of Mechanical Engineers:

ASME B31.1 - Power Piping





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ASME B31.4 - Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids ASME B31.5 - Refrigeration Piping ASME B31.8 - Gas Transmission and Distribution Piping Systems ASME B31.9 - Building Services Piping ASME SEC I - Rules for Construction of Power Boilers ASME SEC V - Article 10 Leak Testing ASME SEC VIII D1 - Boiler and Pressure Vessel Code ASME SEC VIII D2 - Alternative Rules

National Board of Boiler and Pressure Vessel Inspectors:

NB 23 National Board of Inspection Code

Uniform Mechanical Code (UMC)

Uniform Plumbing Code (UPC)

3. DEFINITIONS

Project - SADARA Polyethylene LSPB 1 Company - SADARA Contractor - Larsen & Toubro ATCO QCI - Quality Control Inspector QG - Quality Group HSE - Health, Safety & Environment

4. ENVIRONMENT, HEALTH & SAFETY

This method statement and the attached job safety analysis is in adherence with the Sadara

EHS&S policy and L&T Project EHS Plan. In addition to above, JSA shall describe the job

specific requirement for each activity. Following are the main reference documents for

preparing this method statement.

A-554-K-PRG-QM-GEN-PLN-004 - RTIP-Construction Environment, Health and Safety (EHS) Standards.

A554-D-455-CM-SOW-CON-005-RTIP - Construction Instructions.





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L&T PROJECT EHS PLAN.

Following points shall be taken care before commencement of the work at site.

Work Permit to be obtained from the competent person. Inspection of all the Plant and machineries used for the lifting activities shall be done by

the Third party agency approved from Sadara Project. Work checklist, where applicable, shall be followed by supervisor as per requirement: Works shall be carried out according to Safe Construction Practices, SADARAs Safety

Regulations. List of emergency contact telephone numbers shall be mentioned in the attached

emergency plan. All personnel involved in works shall be aware of Safety requirements of the project and

site shall be kept clean and in tidy conditions. Contractor shall maintain good housekeeping at all the times. HSE inspector shall monitor the site personnel during the erection and installation

activities. Provide drinking water and potable shelters for the employees. Fire extinguishers shall be kept at the site where required. Hydro test area should be cordoned with barricading tape and appropriate sign boards. All hose connections for hydro test to be provided with hose arrestors. START card to be filled for every task. Plant, machineries & equipment shall be operated by the Operators having valid Saudi

licence and third party certificate from the approved agency

Workmen shall be provided with the following PPE to work in Pipe laying, lamination and hydro

testing.

Safety Helmet Safety Footwear Hand Gloves Safety Goggles Reflecting jacket Dusk Mask (As required)

5. RESPONSIBILITY AND AUTHORITY





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5.1 This procedure shall be Prepared and reviewed by CONTRACTORs QA/QC department and approved by COMPANY before use.

5.2 CONTRACTORs Piping Engineers/Supervisors are required to ensure that all Pressure test work is carried out as per project specifications, approved drawing & HSE requirements.

5.3 CONTRACTORs shall provide with labor, testing, tools and equipment for Construction and inspection record preparation and maintenance.

5.4 CONTRACTOR QCI is responsible for conducting the quality control and inspection works during all Hydro-Testing applications.

5.5 All final tests shall be witnessed and accepted by the Company or Company designee.

6. GENERAL REQUIREMENTS 6.1 Pneumatic testing is not permitted without written approval of the QG Representative, unless

specified by the applicable Project standard. Pneumatic testing, when conducted, shall be in accordance with approved procedures that require additional safety requirements.

6.2 Test pressures and test durations shall be based on the applicable Project standards.

6.3 General requirements for the setup and operation of equipment and instrumentation necessary to perform a Hydrostatic /Pneumatic Test see practice G4S-6421-04 (Hydrostatic Testing Equipment Procedure), G4D-6422-01 (Pneumatic test), G4S-6422-01 (Leak Test).

6.4 The effect of the static head of the testing liquid shall be considered when determining the effective test pressure of any elements within a tested system.

6.5 Test Water sources shall meet the requirements of Materials Engineering EMETL Specification G8S-4001-60.

6.6 Protection from over pressure.

6.7 All systems (piping equipment) while being pressure tested shall be protected from being over pressured by the following:

Pressure test relief valve(s) of adequate set to relieve at 5% above the test pressure shall be installed unless the test pressure is less than 85% SMYS at which time it can be set at 10% above the test pressure. Sizing of these relief valves used for testing shall follow the requirements of API RP 520, Part 1. The relief valve(s) shall be tested, dated, and tagged within one week prior to the pressure test.





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The pressure test relief valve shall be accompanied with a calibration certificate that includes the cold differential test pressure (CDTP), test date and the spring range. The CDTP shall be within the spring range.

In addition to the pressure relieving device, a bleed valve shall be provided to protect the piping and Equipment from overpressure. The bleed valve shall be readily accessible in case immediate depressurization is required.

An isolation valve shall be provided between the pressure testing manifold and the system being tested. The isolation valve shall be rated for the manifold test pressure when in the closed position.

Before employing the pressure testing manifold in the actual system pressure test, it shall be separately pressure tested to at least 1.2 times the system test pressure but not less than the discharge pressure of the pump used for the pressure testing.

The test manifold shall be designed and constructed to meet the minimum system requirements. All pipe, fittings, flanges and materials used for pressure testing shall be in accordance with the governing piping material specification for the piping system.

Test manifolds shall be subjected to 100% RT of all butt welds.

7. PRESSURE TEST PROCEDURE 7.1 A pressure test procedure shall be prepared by the responsible Contractor and submitted to

QG for approval prior to conducting the test. The test procedure shall be available at the test site at all times.

7.2 The pressure test procedure shall include all required documentation specified.

7.3 During a pneumatic pressure test a leak test shall be performed in accordance with ASME SEC

V Article 10 and Article 10 Appendix I except the pressure shall be 5 10 psi. A calculation sheet indicating adequacy of the pressure test relief valve shall be included in the procedure.

7.4 The requirement for pre start-up leak tests and service tests during initial start-up shall be as follows:

New systems after strength tests and prior to initial start-up

For systems with maximum operating pressures greater than 6.894 Mpa (1000 psi), a leak test with inert gas, followed by a service test, shall be conducted at the maximum operating pressure of the piping system.





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For systems with maximum operating pressures less than 6.894 MPa (1000 psi), a pre start-up leak test with inert gas or steam (if designed for steam service) shall be conducted at the available inert gas or steam system pressure (not exceeding the maximum operating pressure), or pressure as recommended by the facility Engineering unit responsible for developing the test package, followed by a service test at normal operating pressure of the piping systems. When inert gas or steam is not available, the service test will satisfy the pre start-up leak test requirements.

If the drop in ambient temperature may cause the test medium to freeze during the test, appropriate precautionary measures must be taken to protect the Equipment or piping systems.

8. SPECIFIC TESTING REQUIREMENTS

This section specifies in details which piping or Equipment that shall be pressure tested and provides the specific applicable standard. It also defines any specific exemptions.

8.1 Plant Piping

Pressure testing of Plant Unit piping shall be in tested accordance with ASME B31.3. All weld joints shall be uncoated, and all joints shall be accessible for visual inspection during pressure testing. If this is not possible, refer to 11.1 for alternative test requirements.

8.2 Valves

Metallic Valves shall be tested in accordance with API 598 as a minimum.

8.3 Gasket Material

All gaskets used in the pressure test shall be the gaskets intended for use.

8.4 Internally Coated Equipment or Piping

The hydro test pressure of all internally coated vessels, tanks or piping shall be reviewed against the coating manufacturers limitations. On completing the hydrostatic test, the pressure should be reduced gradually to prevent decompression failure of the internal coating.

9. HYDROSTATIC TESTING FLUIDS





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9.1 In the case of new construction, the construction agency shall be responsible for adhering to this specification; QG shall be the monitoring authority.

9.2 Water Quality

9.3 Water quality of intended hydrostatic test waters shall be determined in accordance with RT8S-4001-60 well ahead of the actual testing date so that alternative water sources may be identified if the original source water fails to meet requirements.

9.4 Water quality of hydrostatic test waters shall be reconfirmed by testing as close to the time of the hydrostatic test as practicable. In cases where individual tanker trucks are used to supply a test, the water samples shall be drawn from a representative number of actual truck loads being delivered to the test site.

9.5 Water used for any part of the hydro testing or subsequent lay-up shall have a sulfate reducing bacteria (SRB) count of 10 per ml or less as determined by the Rapid Check II Method or alternative test method approved by the QG Representative. Water that has a higher bacteria count may be accepted at the discretion of the QG Representative, after treatment with biocide and retesting.

9.6 If water from more than one source will be used, ensure that mixing the waters will not cause scaling.

9.7 Water used for any part of the hydro testing or subsequent lay-up shall be clean and free from suspended matter. Suspended matter in the water shall be extracted, before use, by a filter capable of removing 99% of all particles 53m (2.1 mil) in diameter and larger, or equivalent to using a 270 mesh wire mesh screen.

9.8 Water that could result in harm to humans must not be used for hydro testing. For example, service water containing hydrogen sulfide levels that if released to atmosphere would result in air concentrations of 10 ppm hydrogen sulfide or greater in the immediate area of the hydro test must not be used.

9.9 Water may be reused for hydro testing, as in a pipeline tested segment by segment. The water must meet the requirements and must have an oxygen level of less than 20 ppb, or additional chemical treatment will be required.

9.10 See Paragraph 14.1 for restrictions on the quality of water used for testing austenitic stainless steels. Seawater or high TDS aquifer water shall not be used for this purpose.

9.11 The Construction Contractor shall keep a permanent written record of the water supplied for testing stainless steels including a record of tests performed on the water.





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9.12 Minimize the time between introducing hydrostatic test water and commissioning the Equipment.

9.13 Schedule the hydrostatic test as close as possible to the start-up date.

9.14 Where there are limitations in this standard on contact time for hydro test water, this shall be from the first introduction of water into the system until commissioning or until implementation of a complete lay-up. Partial or complete refilling of the system shall count as continuous, cumulative time. Time limitations requiring the initiation of a formal lay-up program shall be from the first introduction of hydro test water.

9.15 Design the hydrostatic test and the lay-up procedure to protect the most corrosion susceptible material in the system.

10. PREPARATION OF TEST 10.1 Site Preparation

An approved test procedure shall be available at the Site prior to commencing any pressure testing activities.

New piping systems shall be cleaned in accordance with the applicable standard. Soft seated valves and control valves shall not be installed until after the lines have

been thoroughly flushed. Components in new piping systems which interfere with filling, venting, draining or

flushing shall not be installed until after line flushing and pressure testing are completed. These include orifice plates, flow nozzles, sight glasses, venturies, positive displacement and turbine meters and other in-line Equipment.

10.2 Pressure gauges

All gauges shall be calibrated prior to use. The calibration interval shall not exceed 6 months prior to the test date and calibration

certificates shall be made available to Inspection personnel prior to commencement of the pressure test. Stickers shall be applied indicating the latest calibration date.

All gauges shall have a range such that the test pressure is within 30 to 70% of the full range.

A minimum of two pressure gauges are required for the test system. One pressure gage shall be on the test manifold and the other(s) at the low point on the test system. Their accuracy shall be within 5% of one another.

When large systems are tested, QG will determine the need for additional gauges.





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Pressure and temperature recording gauges shall be used for all buried piping systems on plot.

Expansion joints and spring hangers or spring supports shall be provided with temporary restraints where needed to prevent excessive travel or deformation under the test loads.

10.3 Equipment Excluded from Pressure Test

The following list defines the Equipment that shall be excluded from the in-situ pressure testing of the tested system.

Rotating machinery, such as pumps, turbines and compressors; Strainers baskets and filter elements; Pressure relieving devices, such as rupture disks and pressure relief valves; Locally mounted indicating pressure gauges, where the test pressure will exceed their

scale range; Equipment that cannot be drained; Instrument Devices.

10.4 Isolation of Test Sections

Blind flanges, paddle blinds or spectacle blinds shall be used to isolate the test sections. All pipe, fittings, flanges and materials used for pressure testing shall be in accordance with the governing Piping Material Specification for the piping system and shall be capable of withstanding the test pressure.

10.5 Vents and Drains

Vents shall be provided at all high points in the tested system as needed. Excluding scrapable, submarine and buried pipelines, drains shall be provided at all low

points in the system and immediately above check valves in vertical lines. Unless the check valve has a by-pass valve, the disc of the check valve shall be

removed, and securely attached to the outside of the check valve prior to the pressure test.

10.6 Temporary Connections and Supports

Temporary connections shall be provided for de-pressurizing and draining of the system to the sewer or disposal area.

Temporary supports shall be installed prior to hydrostatic testing, and flushing of the piping if required. These supports shall not be removed until after the system has been fully drained. The structural support system for stacked Equipment shall be verified for hydrostatic loads prior to testing.





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11. CONDUCT PRESSURE TEST 11.1 The test procedures shall be conducted in accordance with the applicable code. In addition, the

following requirements shall apply.

All piping joints shall be open for visual inspection during pressure testing. If this is not practical as agreed by the QG Representative, the test shall be conducted for 24 hours using pressure and temperature recorders calibrated as required for pressure gages.

Filling and pressurizing shall be done on the upstream side of check valves in the system. The test fluid shall be injected at the lowest point in the system to minimize entrapped air. When filling at the lowest point is not practical, QG shall be consulted. All vents shall be open during filling.

No one shall approach the test area for a minimum of 10 minutes after the test pressure is reached and before commencement of inspection of the system, the isolation valve between the temporary test manifold/piping and the piping/Equipment under pressure test shall be closed and the test pump disconnected. The isolation valve downstream of the manifold shall be opened after the pump is disconnected.

During the application of the test pressure, all in-line valves if not used as test isolation valves shall be in a partially open position.

All piping and Equipment shall comply with the lay-up procedures. Test records shall be recorded on Pressure Test Report Form.

12. PNEUMATIC PRESSURE TESTING 12.1 ASME B31.3, Section 345 requires leak testing of piping systems to ensure tightness, prior to

initial operation, expect as permitted for category D fluids.

Pneumatic testing shall be in accordance with G4D-6422-01. The Pneumatic test pressure per ASME B31.3 is 110% of design pressure. Minimum distance should be maintained while testing, for minimum distance

requirements refer G4D-6422-01. The detection fluid shall be a commercial bubble forming test fluid such as SNOOP or

SHERLOCK, or equivalent. Soaps, detergents and/or industrial compounds that are designated specifically to be cleaning agents shall not be used in bubble forming solutions.

For testing of stainless steel, nickel or chromium alloys, the fluid shall have a sulfur and halogen content of less than 10 ppm of each.

Pneumatic test shall be made with air, nitrogen or other gases. As specified in the technical job instructions. Work order or construction order.





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13. SENSITIVE LEAK TEST GAS AND BUBBLE METHOD

This test is performed by pressurizing the system with gas, to 1 BAR (15 psig). This creates a pressure differential across a leak. Leaks are detected by applying a commercial bubble forming solution to all joints. The locations of commercial bubble are indicated by the formation of bubbles.

This test may be performed at pressures greater than 1 BAR (15 psig). However, all conditions of G4S-6422-02 and G4Q-6422-02 shall be met when a higher pressure is used.

Air compressors shall be equipped with discharge filters for removal of water, oil and foreign matter. Maximum discharge temperature of lubricated air compressors shall be 150C (300F)

A complete line or section of line containing several valves and braches may be tested at one.

CAUTION: PNEUMATIC TESTING should be used only as a leak alternative carefully planned and supervised procedures shall be used to guard against the hazards of latent energy of compressed gases.

The Company is responsible to assure that all conditions and safety concerns identified in G4D-6422-01 are addressed.

14. POST PRESSURE TEST

After pressure testing has been successfully completed and approved by the Project inspector, the following operations shall be made.

14.1 Draining of Test Fluid

Release of pressure and draining shall be done on the downstream side of check valves. All vents shall be opened before draining to facilitate drainage and to prevent formation of a vacuum. No test fluid shall remain in low spots.

14.2 Disposal of Test Fluid

The test fluid shall be disposed with as directed by Project EH&S requirements.

14.3 Test Vents and Drains

Vents and drains used only for the pressure test shall be plugged, seal welded and penetrant tested.





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14.4 Removal and Reconnection of Components

All temporary items installed for testing purposes (e.g., manifolds, valves, blinds spacers, supports) shall be removed.

Items that were removed for testing shall be reinstalled. Items, such as instrument air tubing, check valve discs which were disconnected before

testing shall be reconnected. Isolation valves closed for the test purposes and that are required to be in the open position for process reasons shall be opened. If the valve cavity has a drain, the cavity shall be drained.

15. LAY-UP PROCEDURE FOR STAINLESS STEEL 15.1 Type 300-series stainless steels shall be tested only with water that has very low chloride

content in order to avoid pitting and stress corrosion cracking. The maximum allowable chloride concentration is 20 ppm per RT8S-4001-60. Verify the quality of the water following the requirements.

Exceptions: Type 300-series stainless steel valve trim shall not be a sufficient sole criterion for classifying a carbon steel system as "stainless" for the purpose of applying Section 6. For example, this section shall not apply to carbon steel pipelines with valves having stainless trim unless there are also other stainless steel components included.

In special cases, with the prior written approval of QG Representative, water of up to 200 PPM chloride content is permitted, provided:

That the hydrostatic test period is less than four days, That the system is rinsed with steam condensate or demineralized water until the

effluent chloride content reaches below 20 PPM, and That the system is completely drained immediately after hydrostatic test and rinse.

15.2 Type-400-series stainless steels are highly prone to atmospheric corrosion. Type 400- series

stainless steel trimmed valves shall be removed from pipelines before hydro test. If it is impossible to remove such valves from the line, then written hydro test procedures must prepared and approved ahead of time allowing the valves to remain in place. When Equipment containing any Type-400 series stainless steels is left in place, it shall be hydro tested in accordance with the requirements of Paragraph 14.3, 14.4, and 14.5 of this standard. The hydro test procedure shall carefully detail measures prevent corrosion including lay-up of the Equipment. Do not use ambient lay-up for Equipment made of 400-series stainless steels.

15.3 Treat the hydrostatic test water with oxygen scavenger per paragraph 13.1 if the Equipment

contact time with water might exceed 4 days.





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15.4 Lay-up the system following the requirements. 15.5 At the end of the lay-up, commission and start up the stainless steel Equipment within 14 days.

Tested Line

(Above Ground Piping)

Dewatering Hose

Schematic Diagram for Disposal of Tested Water

Temporary Storage

Tank Pump

Water Tanker or

Truck





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16. QUALITY CONTROL

Quality Control shall be strictly exercised in accordance to approved Inspection & Test Plan and Quality Control Procedures.

Ensure that all the Inspection report formats has been completed and reports have been signed/accepted by all parties before depressurizing the system.

All calibration certificates and water test report are attached in the test pack.

QCI to verify that all punch points (Punch Category that affects Pressure Test) shall be closed before Testing.

17. DOCUMENTATION

The following Documents shall be attached with the pressure test packs.

1. Test package general information sheet. 2. Hydro test package content check sheet. 3. Test package flow chart. 4. Hydro test report. 5. Test diagram legend. 6. Schematic test package diagram & test manifold. 7. Test package index. 8. Pneumatic test calculation sheet ( if applicable) 9. Punch list 10. Safety instruction sheet. 11. Test diagram P&ID ( Marked test boundaries) 12. System definition P&ID 13. Marked air blowing P&ID 14. Isometric drawing. 15. Check list before test 16. Weld/NDT summary sheet. 17. Survey report (if applicable) 18. Calibration certificates.

(Pressure gauge, pressure recorder, test relief valve, temperature gauge, test manifold) 19. Blind control sheet. 20. Valve test report (if applicable)





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21. Water analysis report (Test medium) 22. Reinforcing-pad leak testing report (if applicable) 23. Orifice flange joint inspection report (if applicable) 24. Flange joint inspection report. 25. Lay-up inspection. 26. Check list after test. 27. Flushing / Cleaning report.

18. SCHEMATIC TEST PACKAGE DIAGRAM & TEST MANIFOLD





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Appendix A: Dew Point of Natural Gas