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Qatargas Helium (II) ProjectMain Construction Work

Date : 27-Feb-2012 Procedure for Pneumatic Testing

Doc. No: QHE-MCC-QCP-0xxxx

MG Doc. No: 583-9738

Rev: C1 Pages 1 of 23

COMPANY: Qatargas Company Limited

PROJECT TITLE: Qatargas Helium (II) Project

CONTRACT NO: QHE/CS/FSA/001

LOCATION: Ras Laffan, Qatar

Contractor : CHIYODA ALMANA ENGINEERING LLC (CAEL)

Subcontractor : MEDGULF CONSTRUCTION COMPANY WLL (MG)

C1 Issued for Approval 25-09-2011 Murugan Thomas George J.Nageswara Rao

Rev. No DESCRIPTION DATE PREPARED CHECKED APPROVED

QCP for Pre-fabrication, Installation and Testing of Piping Works



Qatargas Helium II Project

Main Construction Work

QHE-MCC-QCP-0016

Procedure for Pneumatic Testing

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I N D E X

SR.NO. DESCRIPTIONS PAGE NO

1.0 INTRODUCTION 3

2.0 DEFINITIONS 3

3.0 SCOPE OF WORK

4.0 RESPONSIBILITIES

5.0 SAFE WORKING PRACTICES

6.0 EQUIPMENT & INSTRUMENT

7.0 TEST PROCEDURE

8.0 WEATHER CHANGES

9.0 ATTACHMENTS

1.0 INTRODUCTION






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This documents details the safe working practices to be adopted for pneumatic strength testingand ‘soapy bubble’ Leak testing operations on Qatar gas Helium II Project. Test Packdocuments will be developed which contain detailed information and specific testing instructionson a system-by-system basis.

Procedure QGX/20/00/MP/PC/NA/001-pneumatic testing procedure for piping system shall beused in conjunction with this procedure.

1.1 Pneumatic Strength Testing.

Strength Testing is a technique used in Oil and Gas industry to prove the integrity of pressurecontaining components in a system. The objective is to test a system above its design pressureand confirm that it may be safely subjected to its maximum operating pressure under its normaluse.

Pneumatic strength testing uses air to pressurize a system to 110% design pressure (ASMEB31.3) and a hold period will be 15min.The technique is used when it is not practical to carryout hydrostatic testing, eg. Introduction of water into the piping system is detrimental to theprocess (Catalyst or reactor contamination, cryogenic service system etc.)

As the test medium is clear, dry and oil free air, it has the ability to compress and contain alarge amount of stored energy (typically 200 times greater than a hydrostatic test at the same

free volume and pressure condition.)This document provides a written method of working to ensure the pneumatic strength testingand ‘soapy bubble’ leak testing operations are completed in a safe and consistent manner.

2.0 DEFINITIONS

The following definitions apply in this document;

Term Definitions

Acceptance criteria Minimum conditions to be achieved for a test to be deemed successful.

Amen Abbreviation for amendment

ASME American Society of Mechanical Engineers

Bar / bara / barg Bar / absolute / gauge; unit of measurement for pressure

Blind FlangeFull-face metal disc designed to fit to an open-ended flanged pipe topositively seal the system.

0C Degrees Centigrade; Unit of measurement for temperature

CC/UC Controlled copy / Uncontrolled copy

Contractor CAEL

Company QG

Company ApprovalPerson from the company nominated for reviewing and approvingdocumentations.






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Company RepresentativeNominated person from the company for point of contact for all safety,technical, commercial and contractual basis.

Color CodingIdentification system used for highlighting pressurized piping, openvalves, closed valves etc on P & ID’S

FCV Flow Control Valve

HP High Pressure

HSE Health, Safety and Environment

Injection PointManifold consisting of non-return valve and double block and bleedisolation valves.

Job Site ReviewRisk assessment process at the work site to identify any site-specifichazards not covered by the generic risk assessment.

MJ Mega Joule; Unit of measurement for energy

KeySummary of symbols and coding used for mark up on P & ID’s and plotplans

LP Low Pressure

m Meter

m3 Cubic meters, Unit of measurement for volume

m /kg 0.333 Unit of measurement for the constant used in establishing minimumsafe working distance / test exclusion zone distance.

Marked up P & ID’s & Testlimit

Drawing highlighted & test limit marked showing a section of lineproposed for test.

MSDS Material Safety Data Sheet

N/A Not Applicable

NDT Non Destructive Testing

NRV Non Return Valve

Originator Person who created the Document

P & ID’s Piping and Instrumentation Drawings

PCV Pressure Control Valve

Pneumatic Strength TestTechnique which uses air or other gaseous medium to pressurizepiping to 110% design pressure for a fixed period of time to prove theintegrity of pressure containing components in a system.

PPE Personal Protection Equipment

PRV Pressure Relief Valve

Rev Document revision number

Re-Test Repeat test on a piping system which failed to meet the testacceptance criteria during the initial test.

SMYS Specified Minimum Yield Strength.






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Soapy bubble Leak TestingTechniques for checking a pressurized piping system for leaks byapplying approved soapy solution to potential leak sources.

SpadeRound piece of metal with a small tab placed between two flanges toprovide a positive isolation.

TaggingSystem used for identifying valves, isolations and critical componentson a P&ID for cross referencing with the actual piping system.

TP Abbreviation for Test Pack

Test Exclusion Zone Area adjacent to a test system cordoned off to provide a safe distancebetween personnel and pressurized piping,

Test Gas Compressed air used to pressurize a system for pneumatic strengthtesting; typically nitrogen gas or air.

Test Pack

Document created by MG containing all necessary information for safecompletion of a test. E.g. System specific procedure , risk assessment,method statement, marked up P&ID’s and system alignment checklistetc.

Test PressurePressure to which a system nominated for test is to be pressurized(110% design pressure for pneumatic strength test.)

Test System Section of piping designated for testing.

Tool Box Talk To be discuss about job and related safety.

Vent Point Nominated point on a test system for depressurizing and venting air.

3.0 SCOPE OF WORK

MEDGULF CONSTRUCTION CO.W.L.L. to carry out Pneumatic strength testing and soapybubble leak testing operations on the piping systems of Qatar gas Helium II Project. Medgulf willissue a set of marked up P&ID(S), GAD(S) and ISO(S) highlighting the piping selected for testing. This information is to be identified, reviewed and approved, prior to commencing of work by CAEL/COMPANY.

3.1 Exclusions from the Test ProgramThe following items must be removed and or isolated from the test system by spades / blinds

and tested separately in accordance with the applicable specifications, industry design codesand standards to which they have been designated and fabricated.

Piping and Valves

• Unrestrained bellows, expansion joints and other specialty items not rated for the testpressure.

• Piping normally open to atmosphere (eg. Non pressure rated)

• All untested joints/connections are to be recorded on a register.

•Lined piping which has the potential to be damaged during the testing process.

• Control valves such as PCV’s, FCV’s etc.

• Pressure relief devices such as pressure relief valves (PRV’s) and bursting discs.






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• Any other component within the proposed test limits with inadequate pressure rating (lessthan 120% system design pressure)

• All non return valves within test limit.

Equipment

• Rotating machinery such as pumps, turbines and compressors

• Process equipment such as pressure vessels, heat exchangers and tanks.

• Filters

• Permanent hose connections

Instrumentations

• Locally mounted instruments and indicating pressure gauges where the test pressurewould exceed their scale range.

• Restriction devices such as orifice plates, flow nozzles, venturi tubes, variable areameters, PD meters, strainer baskets etc.

• Sample connections

3.2 Test Parameters and Acceptance Criteria

Pneumatic Strength Test

Test Pressure As per Project Specification or110 % System DesignPressure ( ASME B31.3)

Test 15 Minute hold period (minimum) at test pressure

Acceptance Pressure to be maintained at this level for the entire holdperiod

Soapy bubble leak testTest pressure 100% System Design Pressure

Test Apply low chloride soapy solution to all welds and potentialleak sources within test limits at 100% design pressure.

Acceptance No visible leaks

3.3 Applicable Codes and Standards

The following codes and standards apply to the pneumatic strength testing scope of workdescribed in this document.






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Document Reference Document Name ASME B31.3 Process piping

Piping Fabrication, Erection, Inspection and Testing QGX/20/00/MP/TS/NA/001Pneumatic Testing Procedure For Piping System QGX/20/00/MP/PC/NA/001

3.4 Test Systems

Medgulf will prepare the test pack for each test separately. Each test pack shall be reviewedand approved by CAEL and QG, prior to any test. Walk down to be done for each section to betested and punch list will be prepared and cleared, depending on the categories,i.e,A,B etc,prior to test. All concerned party will sign the test pack after successful completion of each test. Testpack shall be kept by Medgulf once the test pack has been signed by all parties.

3.5 Test Package Contents

A test pack shall be created for each system or section to be tested. A unique number shall beallocated for each test package. Each test pack document has the same format and shall

contain the following information and or documentation.

Section Title

Section – 1 Pressure Test Confirmation Record

Section – 2 Piping Pressure Test Release Report

Section – 3 Pre test Punchlist For Piping Work

Section – 4 Piping Pre- test Checklist

Section – 5 Pressure Test Report

Section – 6 P&IDs ( Test Limits Marked)Section – 7 Weld Map(Isometric Drawings)

Section – 8 Line List

Section – 9 Weld History Sheet

Section – 10 NDT Reports

Section – 11 PMI Reports (If applicable)

Section – 12 Pipe Cleaning Record

Section – 13 Flange tightening report

Section – 14 Orifice Flange Inspection Report (If applicable)

Section – 15 Calibration Certificates

Section – 16 Post Test & Reinstatement Checklist






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4.0 RESPONSIBILITY

The organization chart below shows the personnel structure and reporting lines applicable tothis project. Summary of responsibilities to each job title are described below.

Test In charge

The Test in charge is responsible for managing personnel, equipment and consumablesresources to ensure the project is completed safely, consistently and efficiently. CV of Test Incharge to be submitted for approval by the company and contractor.

Duties Include:

• Compilation of job specific procedure, risk assessments and test pack documentation.• Arranging review and approval of the above mentioned documentation.•

Overall supervision, safety andtraining of all crew members at site.• Ensuring all work activities are carried out in accordance with project spec/procedures,safe working practices and permit to work systems.• Logistics management including initial mobilization, final demobilization and timelydelivery of consumables to the work area.• Arranging company/contractor supplied resources for assistance with systempreparation and testing.• Maintaining regular communications with the company/contractor representative, sitesafety manager, permit to work office and other personnel associated with the test program.• Attending the initial kick off meeting and any subsequent planning, progress reportingand safety meetings as dictated by the company/client representative.

• Controlling ‘Management of change’ issues.• Overall supervision of operations on their respective shifts.• Supervision of initial equipment rigs up and function test.• Arranging diesel and electricity supply, scaffolding, lighting and other resources required


Field Piping Engineer

Day Shift Supervisor

Night shift Supervisor

Technicians(Testing Crew)

Technicians(Testing Crew)

Test in Charge





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to support testing activities.• Preparing systems for test in accordance with approved test pack documentation.• Holding Tool Box Talk meetings and completing a risk assessment (job site review)prior to each test or major task.• Supervising the safe completion of pneumatic strength testing and ‘soapy bubble ‘leaktesting operations.• Shift handover with the on coming shift supervisor.

Technicians

Technicians (working under the direct supervision of the shift supervisors) are responsible for:

• Equipment rig-up, function test, and fault reporting.• Preparation of systems for pneumatic testing.• Operation of equipment during testing operations.• Rig down of equipment upon completion of the final test.• Working in accordance with project specs/procedures, safe working practices andpermits to work systems.

Inspectors Inspectors are responsible for:

•

Walk down the line for punch listing after receiving the test package from QA/QC manager • Close out the “A” and “B” Punch once the Field piping engineer completed the punch list.• “A” and “B” punch must be close prior to test commencing.

• Verify and signed the check list as per test package if all preparatory work is completedfor test

• Witness the test and signed the test reports if test is successfully completed.• Coordinate with company/contractor QC personnel.

5.0 SAFE WORKING PRACTICES

This section has the safe working practices to be followed to ensure pneumatic strength/leaktesting operations are completed in a safe and consistent manner.

5.1. Risk Assessment and Job Site Review

Risk assessment contains a three part generic risk assessment covering the risk associatedwith pneumatic strength and leak testing including operations and control methods for mitigatingthe identified risks.

The three risk assessments are:

• Part # 1 Test Equipment Preparation• Part # 2 System Preparation and Testing• Part # 3 Test Equipment Rig Down

Part # 1. Test Equipment Preparation covers the initial stages of the project from positioningand unloading equipment at the nominated lay down area through to rig up and function test in






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preparation for pneumatic strength testing operations. The Project coordinator or shiftsupervisor must review this generic risk assessment upon arrival at site, carry out a siteassessment, and complete the associated ‘job site review’ section. Any additional risks, such aspersonnel and test equipment being protected in the event of an incident must be recorded andhave an associated control measure(s) for mitigation. Conversely, any risks highlighted in thegeneric risk assessment not present at site should also be noted on the job site review form as‘not applicable’. The Project coordinator or shift supervisor must discuss the generic riskassessment and job site review form with the crew and any site personnel affected by the rig upoperations prior to allowing the crew to carry out any tasks.

Part # 2 ‘System Preparation and Testing’ applies to all piping systems proposed for pneumatic strength testing.. The risk assessment covers all aspects of the testing fromchecking valve alignment to system pressurization, testing and depressurization. The job sitereview protocol described above applies and this process must be repeated for each test.

Part # 3. Test equipment rig down covers the final stage of the job where all testing activitiesare complete and equipment is being rigged down and prepared for demobilization. Again the‘job site review protocol described above applies.

5.2. Safety Plan

A project specific safety plan shall be created containing the following information.

• Authorized Test in charge details (Name, site location, cell phone number and email etc.)• MG/CAEL/Company site safety representative (name, site location, cell phone number and email etc.)• First Aid Center and permit to work office contact details.• Local emergency services contact details (Hospitals, fire brigades, police station,environmental agency etc.)• Site plot plan with location of First Aid Center, first aid box, permit to work office andclient office etc.• Mitigation methods to protect personnel and test equipment: provision of temporary blastprotection.• Summary details of the site induction and permit to work systems.• First aid response plan.• Incident, accident and near miss response plan.• Environmental spill response plan.• Emergency response plan in the event of a major incident (e.g. catastrophic test failure).• Entry/exist log to be maintained for all personnel within test zone.

The safety plan will be kept by Test in charge /Supervisor at site location. Copies will also beprovided to the company/contractor representative, permit to work office and medical center.

5.3. Site Safety Induction and Permit to Work

All crew members must attend the Qatar Gas site safety induction orientation upon arrival atsite. The supervisor and any other crewmembers nominated for requesting and managing permitto work must get relevant permit training. All these training provided to the crew members






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involved for the pressure testing shall be recorded. Any questions or concerns about the siteconditions or the planned scope of work should be raised with the instructor.

The Test in charge / shift supervisor must ensure that no work activities are carried out unless avalid permit to work is in place, which accurately describes the task to be undertaken. Theconditions of the permit must be reviewed and discussed with the crew members so that all areaware of their responsibilities. Permits should be revalidated if work activities are expected toextend beyond the originally planned schedule. Copies of permit should be posted at the worksite in accordance with permit to work instructions.

The permit to work system should prevent conflicting work activities from taking place in thesame area at the same time. However, all members of the crew should be vigilant andimmediately report any observed third party work activities with the potential to affect theplanned testing program. All testing crewmember must attend the training and concurring partyapproval

5.4. Tool Box Talks

After completing safety induction and site orientation training the Test in charge shift supervisor will hold Tool Box Talk training with crew members / any third party personnel associated withthe pneumatic strength testing program. Topics discussed will include:

• Review of the pneumatic strength test scope of work and associated hazards.• Identification and discussion of site hazards and potential schedule conflicts.• Site working practices to be implemented for testing.• Emergency response plans in the event of an incident or accident.• Location of nearest muster point• Any other relevant items.• Leak found by any crewmember shall be informed immediately. The sequence for information/reporting shall be follow as:

Subsequent Tool Box Talk meetings will be held prior to undertaking the following tasks. A riskassessment review will be carried out as part of this process.

• Rig up of equipment at lay down• System preparation and testing (toolbox talk meeting for each test system)• Rig down of equipment after completion of final test.

Minutes of each meeting will be recorded on the PPS ‘Tool Box Talk Form’ all attendees mustsign the attendance sheet.


Crew Members Test In charge Piping Engineer SM/CM

QC Representative Company/Contractor

Medgulf Safety





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5.5. Shift Handover

A face-to-face handover will be carried out at the end of each shift between the day shift andnight shift supervisors, with a walk around the work site mandatory.

Points discussed will include• Review of personnel entry/exist log

• Work completed during the shift• Work in Progress

• Work planned for completion during the next shift• Piping systems under pressure• Permit to work status• Barriers and warning signs in place(locations and distances)• Procedural or system changes, if any• Equipment and consumables status.• Any other relevant points.

The above information will be recorded on a ‘Shift Handover Log’. The document and processensures a detailed concise handover. So there are no doubts as to the equipment, system, andoperational status. The incoming and outgoing shift supervisors are both required to sign the logprior to commencement of the new shift.

5.6. Personal Protective Equipment (PPE)

The Test in charge / shift supervisor is responsible for ensuring all crew members wear thefollowing PPE as a minimum requirement.

• Hard hat• Safety glasses• Ear Defenders ( When operating equipment)• Coveralls ( Full arm length)• Gloves• Steel toecap safety boots.

In addition to the above, the project coordinator/shift supervisor must review Material SafetyData Sheets (MSDS) for all materials being handled by the crew and ensure the above PPE isadequate. Any additional PPE requirement dictated by the MSDS conditions or Company/Contractor specific safety rules must be provided to the crew.

5.7. Manual Handling

Manual handling of work activities involving the lifting of heavy and awkward shaped equipmentmust be identified in advance and assessed by the shift supervisor. Forklifts or other lifting aidsshould be arranged for moving heavy equipment.

All crew members are trained in manual handling techniques for moving lighter equipment items. Any lifts must be assessed before being carried out and help from other crew members obtainedif the equipment item is too heavy or difficult for a single person to manage.






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5.8. Working at Height

The Test in charge / shift supervisor is responsible for identifying and assessing any activitiesinvolving working at height and ensuring the appropriate resources are provided tocrewmembers. Any work activities involving working at height must be carried out using certifiedscaffolding and or ladders erected by qualified scaffolding personnel. Full body Harnesses 100%ties may also be required. All equipment used must conform to site standards.

5.9. Testing Schedule

In order to minimize the number of personnel exposed to systems during pressuring, it isrecommended that test systems to be prepared in normal duty time. Testing to be carried outoutside of the normal duty hours of work and there shall be no pressurizing during the normalduty hours.

5.10. Lighting

The Test in charge / shift supervisor will assess the lighting provided and request may be madefor any additional temporary lighting in critical areas if the standard lighting is deemed unsafe for

working. In addition, all personnel working in the exclusion zone during evening testing shall beequipped with flashlights.

5.11. Housekeeping

Good housekeeping will be made at all times

• Hoses not rigged up for test will be placed in stores container.• Valves and fittings will be held in dedicated storage bins.• Tools will be kept in a secure toolbox within the stores container.• Instrumentation and PRV’s will be kept in dedicated transport cases.• Spares will be kept in secure storage bins.• Crew members will check the test system areas on a regular basis to ensure they remainclean and tidy.

5.12. Waste Material

Any waste material created during the course of the test program will be disposed of at theappropriate waste facility.

5.13. Communications

Radios shall be use for communication during testing activities. .Test in charge/ shift supervisor shall have the radios for communication during testing operations. A sufficient quantity of radiosshall be provided to all personnel associated with the testing program, including thosenominated for patrolling the test exclusion zone perimeter are in constant communication duringthe testing phase. Testing will only recommence after the problem has been rectified and






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communication lines re-established.

6.0 EQUIPMENT AND INSTRUMENT

The following equipment items will be used to carry out pneumatic strength testing:

• Approved leak test detection fluid (commercial grade)• Air Compressors with booster and drier facility.• Test Cabin

• Stores Container • Pressure relief valves(calibrated)• Test manifold/Test Heads(pre tested with certificate/test report)• High pressure air hoses(rated, pretested and with certificate)• Hose restraints• Barrier tape and Warning signs• Sign board - Danger! Do not enter –pneumatic test is under progress• Valves and fittings kit• Tool kit• Fire extinguishers• First Aid Kit• Site Vehicles• Radios• Color-coding of equipments for testing.• Calibrated Pressure Gauges• Calibrated Pressure Recorder • Calibrated Temperature Recorder

6.1 Equipment Rig Up

After positioning the equipment in the area where test to be conducted. The following activitieswill be completed by the crew.

• Inspect all equipment items to ensure no damage occurred during transit. Check the

pressure retaining components to ensure tight (e.g. no loosening of piping or hoses duringtransit.)• Arrange diesel supply and fill diesel tanks on the air compression equipment.• Arrange electricity supply and prepare test cabin.• Charge the batteries and check the Radios• Unload auxiliary equipments from the stores container (e.g. hoses, fittings kit, toolboxkit.)

Care to be taken when opening container doors as items may have moved during transit. Arrange forklift/crane for lifting of heavy items Two or more persons required for heavy and awkward shaped manual lifts

• Carry out visual inspection and certification audit of auxiliary equipment items:

Visually inspect hoses for signs of damage. Visually inspect valves and confirm pressure and temperature rating.






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Visually inspect fittings and confirm pressure and temperature rating. Visually inspect instrumentation for signs of damage. Carry out check of the above items against the certification package. Quarantine any items showing signs of damage of inadequate rating for test, and or out of datecertification. Arrange replacements.

• Make up the test injection manifold, consisting of non-return valve and double block andbleed isolation valves• Route the test injection hose from air compressor distance to the nominated injection

point on the test system.• Ensure hoses are carefully routed and avoid access and egress points to preventcreating a trip hazard.• Use restraint system at regular intervals along the length of the hose to preventuncontrolled whipping in the event of failure.• Note the hoses tag numbers and keep the copy of certificate at site all time.

6.2 Select pressure instrumentation for the first test system.

Minimum requirements for test are;

1. Calibrated Pressure Gauge on the Test System

2. Calibrated Pressure Gauges on the Test Manifold3. Calibrated Pressure Safety Relief Valves4. Calibrated Temperature recorder 5. Calibrated Pressure Recorder

6.3 Pressure Gauge for the first test system.

Pressure gauges shall have range of 1.5 to 4 times (as per ASME Sec. VIII, Div.1, Item UG-102) the test pressure and shall be calibrated in accordance with project specification.Calibration of pressure gauges shall be within the previous 30 days of test date (2 pieces of Pressure Gauges are to be installed at least).

6.4 Pressure Relief Valve (PRV) for the first test system.

Testing pressure relief valve shall be located at the first connection on the line (nearestpressurization point) or on test manifold, which is applicable. Pressure relief valve shall be setat 50 PSI (3.4 barg) or 10% above the maximum test pressure, which is the lesser.

Note; The PRV tag number and keep the copy of certificate for audit check by the contractor representative.

1. Functions test of the air compressor accordance with standard practice to ensureworking correctly.

Once all equipment is rigged up in readiness for testing, invite the company/contractor representative to carry out an inspection and certification audit. Remove and replace any itemsfailing inspection.






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7.0 TEST PROCEDURE

7.1. Preparatory Work

Before preparing a piping system for testing the Piping Engineer must confirm that the followinghas been done.

• Two test head of same material and same rating for which test to be performed, are to

be fabricated and required NDE to be performed for both test heads. Both test heads will bewelded together for hydrostatic test prior to use for pneumatic test. The test manifold shall betested to min. 20% above maximum specified test pressure before use.• A qualified QC Engineer has completed a detailed inspection of the piping system andassessed material specifications and testing requirement.

• The piping system is completed, checked and prepare punch list

• Ensure “A” and “B” items in punch list are completed and prior to release for testing.

• All welds have successfully passed 100% NDT tests.

• All welded pipe supports, anchors and associated weld attachments are completed.

• Components excluded from testing (see section 3.1) are removed from the system andblind flanges or temporary spool pieces of appropriate pressure rating are correctly installed.

• Welds, flange connections and other joints are exposed and paint or insulation has notyet been applied to allow ‘soapy bubble’ leak test examination of all potential leak sourceswith in test limit boundaries.

• All specified temporary gaskets to be used only once and temporary high tensile nuts /bolts are fitted to required specification.

• All temporary nut bolt/stud will have color code (Black) for easy traceability.

• All joints are torque / tensioned to the required levels for test.Note: Torque and tension levels for testing above design pressure may be higher thandesign settings for normal operations.

• Proposed test pressure 110% system design pressure is less than 80% of the SpecifiedMinimum Yield Strength (SMYS)

• Manufacturer’s certification has been obtained, reviewed and approved by the companyrepresentative confirming that all valves included within test limits have a pressure rating atleast 120% design pressure. In addition, any valves proposed for test limit isolations arecertified as capable of withstanding a full differential pressure of 120% system designpressure.

7.2. System Preparation






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7.3.System preparation is a critical aspect of pneumatic strength testing operations and must becompleted accurately to ensure no problems for testing. A test pack document has been developed for each test system containing the informationdescribed in section 3.5 earlier.

Temporary supports shall be used during hydrostatic testing of piping which hasnot been designed to carry the weight of the water shall be removed after testing.Types and position shall be decided by MG after approval of Contractor.

Components and instruments such as safety valves, control valves, rupture discs,flame arrestors steam traps, filters (if filter element is not dismantled), orificeplates, strainers, level gauge, pressure gauge etc., or other in line equipment’sshall not be in the line during pressure testing and clearly identified on isometricsby MG.

Critical valves and soft seated ball valves shall not be tested in line if line is notflushed and clearly identified on Isometric by MG.

Restraining bars on expansion joints and spring hanger stops will not be removeduntil after reinstatement and only on the instruction of the Contractor.

Instrument lead lines will be disconnected.

A minimum of two pressure gauges shall be used during pressure testing. Oneshall be located near or at the lowest point; the other shall be located near or atthe highest point of system under test.

Test in charge will be inspect to ensure all items used are correctly installed at thenominated points, have adequate rating and current certification.

All flanges shall be securely taped with masking tape prior to test and provided apin hole in the top section of flanges tape for leak detection.

Barriers will be checked against the marked plot plan to ensure all potentialaccess points to the exclusion zone are cordoned off and warning signs are posted.

Ensure flash lights are in place for crew working in night.

Checks will also be made to ensure lighting is adequate for safe nightshift work,and scaffolding / ladders / harnesses have been provided and inspected for safeaccess to any high points.

Ensure prior to test, sufficient replacement gaskets are in hand.

Ensure PSV condition and look for any sign of tampering.

Any equipment not secured (e.g. loose scaffolding, boards) must be removedfrom the test area prior to proceeding with pressurization as they have the potential






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to become hazardous projectiles in the unlikely event of a catastrophic systemfailure.

When Test in charge / shift supervisor and client representative are satisfy thatequipment rig up and system preparation is correct, a toolbox talk meeting will beheld before giving the instruction to proceed with pressurization and testing

7.4. P&ID Key, Color Coding and Tagging Systems

The color coding and tagging systems shown below apply to the mark-up of test systemP& ID’s. The tagging system also cross references the system alignment.

P & ID color coding;

7.5. Pneumatic Strength Testing

Each test pack document contains a system specific method statement describing thepneumatic strength testing and ‘soap bubble’ leak test procedure to be followed. Key Safetypoints for this phase of the testing program are highlighted below;

All test crew members must be communicated prior to start testing.

All test equipment must be color-coded.

All flanges and joints on the system to be tested are wrapped with a PVC tape to confineany leakage.

Test area to be checked and cleared of all unauthorized personnel and test zoneboundaries to be patrolled thereafter.

Temporary hose to be pressure tested to prove integrity and identified as test equipment.


TEST LIMIT ISOLATION /CLOSEDRED

SAFETY CRITICAL COMPONENTSWITHIN TEST LIMITS.(OPEN)

GREEN

TEST SECTIONS TO BEHIGLIGHTED WITH

YELLOW





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The pneumatic test pressure shall be raised and held at stages corresponding to the testcategory as detailed in Appendix -1. Pressure gauges shall be checked during the test for any corresponding increase/decrease of the pressure in the piping system under test.

Pressurization rate not to exceed 1 bar / minute

System to be monitored for pressure drop and checked for gross leakage.

Check pressure gauge at both ends to ensure no blockage (closed valve)

Carry out a soapy bubble leak test.

If any leaks are detected, the test will be aborted and system fully depressurized to allowrepair. System to be pressurized to 25%, 50%, 75% and 90% increments of final test pressure(110% design pressure) with stabilization periods of 10 min applied at each.

No personnel are to enter the test area beyond the 1.7bar pressure increment stage.

Personnel should only enter the exclusion zone on approval from the projectmanagement once the test has been initiated. Allowable entry shall be when pressure is

reduced from 110% to 100% for snoop test.

System to be pressurized to final test pressure (110%) design pressure) and a holdperiod of 15 minutes (minimum) applied once the pressure is stable.

Following a successful hold test (refer to section 3.2 for acceptance criteria ) the systempressure will be reduced to 100% design pressure and a ‘soapy bubble’ leak test carried outby contractor/company QC inspectors using an approved low chloride leak detectionsolution. After completion of ‘soapy bubble’ leak test the system will be depressurized to

atmosphere pressure via the nominated vent point(s).

Depressurization rate to be controlled to < 2 bar / minute decrease.

7.6. Re-Tests

If a test is abandoned during the incremental pressure stages due to pressure loss / leakageand undergoes repair then the system must be fully vented prior to start of any repair.

If a system undergoes a successful pneumatic strength test but small leaks are detected duringthe ‘soapy bubble’ leak test then the company/client may request to retest the system. In suchcircumstances it is not necessary to carry out the pneumatic strength again (e.g. pressure thesystem to 110% design pressure) as only a soapy bubble retest is required. Therefore, lineshall be pressurized up to 100% of design pressure at increment of 25%, 50%, 75% and 100%with 10 minutes stabilization period without exceeding 1bar/min pressurization rate.






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8.0 WEATHER CHANGES

Changes in weather may cause interference with the testing program and create dangerousworking conditions. Heavy rain or wind would prevent bubble formation during ‘soapy bubble’leak testing.

The Piping Engineer / Test in charge must monitor weather conditions in advance of the testingprogram and assess weather it is practical and safe to proceed. Similarly, weather conditionsmust be monitored during the course of a test to ensure severe conditions will be avoided.

APPENDIX 1

HOLDING ITEMS FOR PNEUMATIC TESTS

HOLDING ITEMS FOR PNEUMATIC TESTS

During pneumatic pressure testing the pressure shall be raised inaccordance with the following criteria depending on the maximum testpressure and volume of system.

1. LOW PRESSURE: PT < 5.00 Bar.g


STEP PRESSURE

1 1.7 Bar.g

2 90% of PT

3 100% of PT

4 PD





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2. HIGH PRESSURE: PT > 5.00 Bar.g

STEP PRESSURE

1 1.7 Bar.g

2 25% of PT

3 50% of PT

4 75% of PT

5 90% of PT

6 100% of PT

7 PD

Whereas PT=Test Pressure PD= design pressure

After completion of pneumatic test:

1) Pressure shall be bled off in a controlled manner, taking full account of hazards, including noise to personnel.

2) Maximum depressurizing rate should be based on the following:

2.1 Over 30 barg to 30 barg : 0.10 bar/sec.

2.2 30 barg to 10 barg : 0.15 bar/sec.

2.3 10 barg to 0 barg “ 0.35 bar/sec.

3) Personnel shall not be present within a safe distance of the discharge point(15m minimum).






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4) Low point drains shall be checked for water collection.

5) When nitrogen is either used as the test medium or introduced afterwards,all necessary safety precautions shall be specified for Contractor andCompany.

Each pneumatic test shall have calculation for stored energy in accordance tothe following formula:

Stored Energy = Free Volume x Pressure

i.e. ft. lb. = ft.³ x lb. /ft²

Example:

Free Volume of line = 60 M³ = 2117.3 ft.³

Test Pressure = 12.5 Bar

Stored Energy = [60 x (3.28) ³] x 12.5 x 14.5 x 144

= 55,260,306 ft. lb

9.0 ATTACHMENTS

Attachment-01 : RFI Format Attachment-02 : Piping Pressure Test Release / Report Attachment-03 : Field Testing of Pipe Work - Flow Chart Attachment-04 : Pressure Test Confirmation Record Attachment-05 : Pressure Test Report Attachment-06 : Pre Test Punch List for Piping Work Attachment-07 : Pipe Cleaning Record Attachment-08 : Post Test & Reinstatement Check List

583-9738 procedure for piping 00

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