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SPECIFICATION FOR FIELD PIPING TEST PACKS

DESIGN STANDARD 4S-20.05 0ISSUED FORPROJECT NO. PROPAC SHEET 1 OF 3 Rev

PROJ.APPR. P.Healy

DATE OFISSUE

DEPT.APPR.

K.SereniusGENERIC

APPR. DATE28Aug1998

Y:\PROYECTO\1800\documentos\Estandares\00 - STD.PROPAC\piping\4s\4S-20.05.DOC

1. SCOPE

To specify those activities that are to be implemented to control the compilation, review and approvals of pipingTest Packs from the time that fabrication/installation commences through to final handover of the contract works.

2. TEST PACK CONTENTS

All Test Packs, as a minimum, shall contain the following documentation:

2.1 Pipe Line Nomenclature (Portions showing applicable lines, Identifying Line Classification, Test PressureCodes, etc.).

2.2 Flow Diagram (identifying the extent of the test).2.3 Isometrics (as applicable) or field sketch.2.4 Pipeline Check Out Record (Refer to 4S-20.01).2.5 Weld Map (Marked up Isometrics).2.6 Non-Destructive Examination Reports.

2.7 Contractor Inspection Reports.2.8 Deficiency Report (Pre-Hydro Punch List).2.9 Permit to Pressure/Service Test a Pipe Line.2.10 Test Pressure Gauge, Calibration Certificate.2.11 Deficiency Report (Pre-Handover Punch List)2.12 Material Specification Certification (if required - e.g. coded pipe for boilers).

3. PROCEDURE

3.1 The Piping Contractor shall compile Test Packs in accordance with the agreed index, on an ongoing basisensuring that the packs are available as needed to comply with the installation schedule.

3.2 The Piping Contractor shall generate a Test Pack register that is to be submitted for review at least 14days prior to the first pressure test.

3.3 The Piping Contractor shall submit each Test Pack for approval at least 4 days prior to the applicable

pressure test. At this stage the pack shall contain the following minimum requirements - refer to contentsitems 2.1 to 2.4 inclusive.

3.4 At least two full working days prior to the pressure test, the Piping Contractor shall submit the suitably

completed Test Pack for review and permission to pressure test. At this point in time the minimum

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PROJ.APPR. P.Healy

DATE OFISSUE

DEPT.APPR.

K.SereniusGENERIC

APPR. DATE28Aug1998


contents of the pack shall be 2.1 to 2.10 inclusive. (Items 2.5 and 2.6 should be submitted to NonDestructive Examination (N.D.E.) Inspector for signature of Step 5 on 4S-20.01 sheet 6).

3.5 Upon completion of the review of documentation and surveillance of the works, Project Approval (as noted

below) will:

3.5.1 Add further items, if applicable, to the deficiency report and prioritize all outstanding items.

Priority 1 - To be completed prior to pressure testing.

Priority 2 - May be left until after the test.

3.5.2 When all Priority 1 items have been closed out and it is considered suitable to conduct thepressure/service test, issue a permit to test by signing Step 6 on 4S-20.01 sheet 6.

3.6 The Piping Contractor shall present the Test Pack for signature upon the successful completion opressure/service testing.

3.7 After completion of re-instatement and cleaning of the line, the Piping Contractor shall submit the Tes

Pack for final inspection by Project Approval (as noted below). At this stage, the pack shall contain adocuments, Index items 2.1 to 2.12 signed off as applicable. The Contractor shall have transferred aloutstanding deficiency items to the pre-handover Punch list and shall have added any further deficiencies

that have been identified by the Q.C. department.3.8 Having completed the documentation review and surveillance of the works, Project Approval (as noted

below) will:

3.8.1 Add further items, if applicable, to the Deficiency Report, identify and prioritize all outstandingitems.

Priority 1 - To be completed prior to commissioning.Priority 2 - To be completed within a limited period after commissioning.Priority 3 - To be completed within a specified period prior to contract completion.

3.8.2 When all deficiencies have been closed out, sign off item 10 of the Pipeline Check Out Record(i.e. Priority 1, 2 & 3 items).

Examples of Deficiency Priorities:

Priority 1 - Items that would stop commissioning:

- Welds not complete- Flange bolts loose- Instruments or valves not installed- Critical pipe supports not complete- Valve seat installed wrong side

Priority 2 - Items that must be done shortly after commissioning:

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PROJ.APPR. P.Healy

DATE OFISSUE

DEPT.APPR.

K.SereniusGENERIC

APPR. DATE28Aug1998


- Minor pipe supports- Insulation heat conservation or personnel protection- Re-installation of mag-meters or instruments after line tested & flushed/cleaned

Priority 3 - Items that have no effect on line operation:

- Painting flanges- Anti-sweat insulation

- Painting pipe supports

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