. | me Petrofac Petrojet od Khalda Petroleum Company Project: Salam Gas Trains (SGT3 & 4) Project Location: Egypt Document Reference: 1820-SA3-00-CON-PRO-035 KHALDA Project No.: | 1820 PETROFAC Project No.: | JI-187 METHOD STATEMENT > PEROHG EAC UNTLETD JOB No M187 nm pee ore ss FOR IPING PNEUMATIC & HYDRO TESTING MASTER COPY APPROVED FOR CONSTRUCTION Rev [ Owner Developer Reviewer “Approver Eng 7 Shaya | Eni Ant 7 Yad, Ate |P8 7 Ae —| 8 7 TL ‘A-Review KHALED ABBU | Mohamedreda | Tarek mahmoud | Khaled EbrahiemP METHOD STATEMENT FOR piping penumatic&hydro testing DOC NO.: 1820-SA3-00-CON-PRO-035 Rev: A 1.0 20 3.0 40 5.0 6.0 SCOPE..... PURPOSE...... TABLE OF CONTENTS REFERENCE DEFINITIONS. RESPONSIBILITIES...... PROCEDURE... 61 62 624 6.22 63 6.34 632 63.3 6.34 63.5 636 637 64 64.1 6.4.2 64.3 6.44 SAFETY IDENTIFICATION OF PIPING TEST PACKAGE DOCUMENTS. TESTING MATERIAL AND EQUIPMENT EQUIPMENT... CERTIFICATES, HYDROTEST. ‘SET UP & PREPARATIONS. TEST PROCEDURE, TEST MEDIUM / TEST PRESSURE & TEMPERATURE .. TESTING OF MANHOLES & UNDER GROUND PIPING. TESTING WITH EQUIPMENT....... TESTING OF JACKETED PIPING one POST TEST RE-INSTATEMENT/PRE-COMMISSIONING.... PNEUMATIC PRESSURE TESTING SET UP & PREPARATIONS TEST PROCEDURE & REQUIREMENTS. TEST MEDIUM / TEST PRESSURE & TEMPERATURE........ POST TEST RE-INSTATEMENT / PRE-COMMISSIONING. wo aaanr dw 13 Page 1 of 21- P METHOD STATEMENT FOR piping penumaticfthydro testing DOC NO.: 1820-SA3-00-CON-PRO-035 Rev: A SCOPE The scope of this method statement is the Testing of piping systems. This will cover both pneumatic and hydro testing. PURPOSE The purpose of this method statement is to define the sequence of the activities and the responsibility in order to complete all piping testing fully compliance with AFC drawings, standards and project specification REFERENCE Health & Safety Plan CrafManpower Training Program ITP for Installation of Piping Systems & Hydro Testing Method Statement for Fabrication & Erection of Piping System Procedure for Testing, Inspection, & Measurement, DEFINITIONS RESPONSIBILITIES Construction Manager Responsible for all construction activities. QAN/QC Manager Responsibie for QV/QC activities. Piping Superintendent Responsible for all site piping activities under this method statement, Piping Supervisor Responsible for all dally piping activities under his supervision. Page 2 of 21/ P METHOD STATEMENT FOR piping penumatic&hydro testing DOC NO.: 1820-SA3-00-CON-PRO-035 Rev: A Piping Foreman. Responsible to carry out jobs as per instructions of the Piping Supervisor. HSE Supervisor Responsible for safety matters and safety monitoring and shall be present during all site activities. QC Coordinator Responsible for all the quality of the work QC Inspector Responsible for the inspection, monitoring and review of quality related records at construction PROCEDURE ‘The Construction Piping Superintendent shal be responsible for the overall activities under this construction method statement and shall arrange the work areas and crews accordingly. The Piping Supervisor shall be responsible for the direct supervision of his work crews and daily activities execution, as instructed and planned by the Piping Superintendent IDENTIFICATION OF PIPING TEST PACKAGE DOCUMENTS: The Test Pack consists of all testing records and pre-test, test, and post-test inspection checklists, punches list, hydrostatic test diagrams, and line ist information within the test limit. The hydrostatic test diagram will show the block limits for testing a system/sub-system with the type and test pressure to be applied. The related P & IDs and isometric drawings shows the test limits and identification number of the test package, being part of System/Subsystem integrity, as defined by the commissioning team. The line list mentions the line number, the P&ID, the test pressure and test medium with other service information. Page 3 of 21iad METHOD STATEMENT FOR piping penumaticRhydro testing DOC NO. 1820-SA3-00-CON-PRO-035 R The Test packages shall be prepared by the construction subcontractors technical department as per the marked up P & IDs whose systems/subsystem limits are marked by the commissioning team. TESTING MATERIAL AND EQUIPMENT Testing materials shall be provided by the construction contractor, and shall consist of testing bolts, gaskets, blinds, blind flanges, spades, plugs, etc. which shall all be dedicated for testing purposes only. They shall be properly colour marked, handled and stored in testing lay-down area to avoid mixing them with permanent piping materials that are dismantled during the test-pack preparations. ‘All permanent erection materials, which are dismantled before hydro testing, shall be properly and securely stored in dedicated site stores for proper tracking and efficient reinstatement after hydro testing. To avoid field material shortages and wastage, no permanent erected material shall be lost for any reason 6.21 EQUIPMENT Before mobilization, equipment shall be inspected to ensure that it meets all safety requirements. Plant operators shall be certified. All equipmentitools inspection and calibration certificates shall be available at the point of use. A daily logbook for inspection must be kent at site. LIST OF EQUIPMENT Hand pump/hydro pump Compressors Pressure hoses Pressure relief valves Chart recorders Dead weight tester Truck water tanker Page 4 of 21@ METHOD STATEMENT FOR piping penumaticBthydro testing DOC NO.: 1820-SA3-00-CON-PRO-035 Rev: A All tools and equipment required for piping system pressure tests, including compressors, pumps, connecting piping with strainers and storage reservoirs, pressure gauges, test fluids and additives, etc. shall be supplied by the construction subcontractor. CERTIFICATES Dead weight tester, chart recorder, pressure gauges should be certify by third party. CERTIFICATE VALIDITY Dead weight tester & chart recorder certificates validity is one year. Pressure gauges certificates validity is Six months. ‘Any how any of these equipment shows faulty reading during testing will be subject to recalibration in the instrument work shop against calibrated dead weight tester. HYDROTEST SET UP & PREPARATIONS All lines in vapour service shall have sufficient temporary supports to accommodate the test medium, which will be marked up in the appropriate isometric/P&ID in the test pack. Spring supports for lines in vapour service shall be locked in position for the test using preset pins or plates, or by blocking up the spring. Care shall be taken to avoid overloading any parts of the supporting structure. Engineering shall determine what temporary supports are required together with draining and filling points. These shall be shown on the isometric/P&ID in test packs. Page 5 of 21P METHOD STATEMENT FOR piping penumaticBhydro testing DOC NO.: 1820-SA3-00-CON-PRO-035 Rev: A Temporary supports will be attached to the piping by “U' bolts connected by bolting to steel sections as designated by engineering. No welding of temporary supports will be allowed to the permanent piping. Chain blocks with soft slings will also be employed where deemed necessary by the Piping Supervisor. ‘Temporary blind flanges and test blinds, used to isolate a test system, shall be installed at locations shown on the marked up P&ID and isometric drawings included in the Pressure Test Pack, They shall be of adequate thickness to withstand the test pressure, i.e. the thicknesses of the test blinds are determined by the piping class or by engineering in accordance with ASME B31.3 Section 304.5. Test blinds shall include a lug/handle, extending beyond flange perimeter (at least 100mm), Valves shall not be used to isolate a test system unless justifies and approved by the Piping Engineer Pressure and thermal relief valves and rupture discs shall not be included in system during pressure tests, Control valves, orifice plates, strainer baskets, filter elements, in-line instruments and all other in-line components and valves, which are unable to withstand the test pressure and liable to damage by the test medium or by the impact of foreign matter during the flushing or purging process, shall be removed to the stores and replaced by temporary spools or spacers, which shall be fabricated on site, marked in red, and stored in testing lay-down area. Check valves shall have the source of the pressure on the upstream side of valve. If this is not possible, then swing type check valves shall be blocked open or their flapper removed in a manner acceptable to the inspector. Ball or piston type check valves shall have their internal parts removed. Should none of these be practical, the check valve shall be blocked off or removed. Hydro tests shall not be made against closed valves unless justified and approved by the Piping Engineer. Except as specifically excluded herein, all inline valves shall be included within the pressure test limits; ball valves shall Page 6 of 21P METHOD STATEMENT FOR piping penumaticBhycro testing DOC NO. 1820-SA3-00-CON-PRO-035 Rev: A be in the half open position and all other valves shall be fully opened, However, Where the test pressure to be applied to lines is greater than the maximum. allowable test pressures specified for the valves, the valve should be blinded on the test side or replaced with a temporary spool Short pipe spools requiring removal to permit installation of a test blind, shall be tested separately, or 100 % RT/MPI shall be done upon QC discretion. Instrument/control valves/flow meter/orifice plates etc. or their internal parts shall be removed for the duration of pressure testing using the permanent labelling for traceability to the component to which they belong or the position in the line from which they were removed, to ensure correct replacement of components following the testing. Generic items shall not be labeled. Instrument connections shall be closed with a properly gasketed blind flange, or with a threaded plug. No restrictions to flow such as orifice plates and restriction orifices shall be present during pressure testing. Tubing from instrument valves is to be disconnected and plugged or capped or tubing isolated by closing the block valves. Instrument connections shall be closed with a properly gasket blind flange, if flange connections are used. Expansion joints shall not be included in pressure tests, and shall be replaced with temporary spools. Spring supports shall be locked in position for the test using preset pins. Their retaining pins shall not be removed until all hydro testing session has been completed and lines being drained Vents shall be provided at all high points and drains at all low points in the ‘systems subject to hydro test. The test pressure gauge shall be located at the highest point of the system (ie. at the vent). In addition, another "Check" gauge shall be located at the lowest point of the system (i.e, at the drain) if significant vertical legs could cause the static head pressure to over-pressure parts of the system. Use two calibrated Page 7 of 21P METHOD STATEMENT FOR piping penumaticf&hydro testing DOC NO.: 1820-SA3-00-CON-PRO-035 Rev: A test pressure gauges for appropriate range for the test pressure. They shall have current calibration certificate of accuracy. The pressure gauges shall be tested/recalibrated when shows faulty reading, this shall be witnessed by Client and Petrofac’s QC inspectors. The test pressure shall fall between (25% to 80%) of the dial of the test Pressure gauge. The selection of pressure gauge shall suitably be done to satisfy this pre requisite. Chart recorders shall be used to record the pressure/temperature of the test. They shall be recalibrated when shows faulty reading, this shall be witnessed by Client and Petrofac’s QC inspectors. The Piping shall be thoroughly vented of air, during introduction of the test water. High point vents are to be provided as required in conformance to the relevant line class, TEST PROCEDURE The test pack shall be mechanically cleared. All inline joint types (i.e. threaded, socket weld, butt weld and flanged joints) and support welds to line pipe are categorised as critical *A’ items in the punch list as outstanding critical work which are to be completed/closed by piping construction and cleared by QC prior to starting the hydro test All relevant NDT, heat treatment and inspections must be cleared via the Test Pack welding summary sheet prior to flushing, as per project specification, Care shall be taken to ensure that all pipe work being tested are adequately prepared and cleaned and is capable of being tested at the pressure indicated. Blinds, caps or plugs shall be installed as necessary to isolate the piping system under test. Al joints in the piping system, (threaded, socket weld, butt weld and flanged) shall be exposed accessible during the test using scaffolding or manlfts as Page 8 of 21— & METHOD STATEMENT FOR piping penumatic&ihydro testing 1820-SA3-00-CON-PRO-035 Rev: A appropriate and shall not be insulated or otherwise covered until the satisfactory completion of testing in accordance with this Method Statement. Before filling with the test medium, the system shall be inspected for construction completeness and satisfactory test preparation, including placement of pressure gauges and suitable. The test package sign off sheet shall then be signed by the authorised inspectors/personnel to allow flushing or purging prior to commencing hydro test Prior to testing, the pipe work shall be flushed thoroughly, as per project specification. Engineering shall identify Flushing circuit. Hydro test team shall carry out all flushing, prior to hydro test. The flushing medium shall be disposed of as per approved environmental procedures. Flushing is not permitted through machinery or any other equipment, which may be damaged by the flushing operation. Precautions shall be taken to ensure that debris or dirt is not flushed into vessels, equipment or dead legs, by providing blinds at the interface of the piping and equipment or vessel. Control valves shall, be removed until the initial flushing of the system has been completed. Flushing medium will be either fresh clean water or compressed air; the water for testing may be supplied from the camp water treatment system, the site nearby wells or transported water by tankers, etc. All water will be provided with test certificates proving the chloride content prior to use. Flushing will continue until the discharged water runs clean or that the air flushing shows no sign of detachable debris, and witnessed by client(QC representatives (operations) After completion of flushing or purging, the area surrounding the test pack shall be cleared of unauthorised personnel and barricaded with warning notices of Page 9 of 21ig METHOD STATEMENT FOR piping penumaticEhydro testing DOC NO. 1820-SA3-00-CON-PRO-O35 Rev: A hazard pressure zone, during the pressurising time of the test pack. This arrangement shall be coordinated with the inspector. A preliminary air test to a maximum of 1.7 bar (25 psi) may be made to locate major leaks before a hydrostatic test. Liquid testing medium shall be introduced at the system low point to avoid air pocket formation; Vents at high points shall be left open until test medium flows from the outlet. All air must be removed before pressure greater than that required to fil the system is applied. Allitems, which are excluded from or removed prior to, the pressure test, shall be reinstated after testing is complete. Temporary spool pieces, blanks or plugs (which must be adequate for the condition) shall be removed and the original items re-installed. Any items excluded from the tests shall be defined on the pressure test diagrams. Discontinuous small test packages of the same test pressure and flange ratings may be connected together at their flanged limits and be tested simultaneously. After testing, they shall be erected/assembled back to their right locations. TEST MEDIUM / TEST PRESSURE & TEMPERATURE The test shall be carried out using clean fresh water as the testing medium, which shall be free from suspended solid and other foreign matter. This water shall be supplied from the water treatment plant and transported by water tankers to the point of filling. Water chloride content shall not exceed 300 ppm for carbon ste! piping and S0ppm for stainless stee! piping and stainless steel trim valves. The test pressure (except as noted in ASME B31.3 section 346.4.3) shall be as shown on the line list and are derived as follows: The test medium water temperature shall not be less than 7°C as per project specification. Page 10 of 21— og METHOD STATEMENT FOR piping penumatictthydra testing DOC NO.: 1820-SA3-00-CON-PRO-035 Rev: A Where the water quality is unsatisfactory for testing, a chemical inhibitor shall be provided by the testing subcontractor, upon the approval of the commissioning team/client. Consider the use of storage tanks to fill the water treated with corrosion inhibitor, biocide and oxygen scavenger as required. Such water can be stored for extended period in the tanks at operational volume, used for hydro testing of piping and recycled. Consider constructing the temporary sumps if the plants/units are far from other facilities, fil the treated water for testing and other purposes, use and recycle the water. ‘The hydro-test pressure shall not be less than 1.5 times the design pressure of the system at any point. ‘The hydrostatic pressure testing shall not commence until the test medium temperature is in equilibrium with the pipe work system: ‘The incremental pressure increase shall be 5 bars/one minutes, and shall be controlled by the pump operator, who also monitors the testing temperatures. The test pressure shall be built up gradually in stages to the specified test pressure to allow all air within the system to escape from vents and high points, and shall be held for a minimum period per ASME B31.3 (10Mintues minimum) to allow the pipe under test to equalise the strain. Once the test pressure is realised, the test pressure shall be held for a minimum period as per ASME B31.3. The test duration shall be as per ASME B31.3 as a minimum, but as long as it takes to inspect and witness the tested pipe work joints (i.e. 1 hours). For underground system the duration will be 24 Hours, Dead weight tester , chart recorders and two pressure gauges will be used. For above ground system the duration will be 1 Hours as minimum, chart recorders and two pressure gauges will be used, Page 11 of 21P METHOD STATEMENT FOR piping penumatic&hydro testing DOC NO.: 1820-SA3-00-CON-PRO-035 Rev: A For small spools the duration will be one Hour as a minimum, only two pressure gauges will be used. During the test, all flanges, welds, and joints shall be visually inspected for any leaks by QC/Client Inspectors. Test pumps shall be isolated from the system before the piping inspection. Safe access at height shall be provided by scaffolding or manslif. Should any leaks be found, the test shall be stopped, the system shall be depressurised and drained, the leak repairedicleared and the test shall be restarted Leaks will be repaired as follows: system will be depressurised before work commences. Weld repairs shall be carried out as per the appropriate weld procedures. Flanged joint leaks: bolts shall be retightened or joint shall be dismantled, have flange surfaces checked, re-assembled and properly gasketed and tightened, At the discretion of the inspector and where permitted by the relevant code, repaired defects may be retested by means other than pressure testing (for ‘example, 100 % radiography and MPI or ultrasonic), Depressurisation shall be from high point vents by opening slowiy to allow the water to stabilise and avoid jetting out that may cause harm to personnel in the vicinity. Water will be discharged through the low point drains, in accordance with the environmental policy. The discharge of water that has been used for hydro testing shall either be reused on other lines/systems or discharged according to project specification on Waste Management Requirements, Where testing with water would have an adverse effect on the piping or the process (e.g. lube or seal oil systems), an alternative non-toxics test medium or method shall be submitted and approved in writing by the client. The use of seawater as a testing medium shall not be permitted. Page 12 of 21PP METHOD STATEMENT FOR piping penumaticéhydro testing 6.3.4 Al piping systems will be blown with air to remove surplus water, with all vents and drain points open. At low temperature sites, special care shall be taken to have the test pack dried by air blown to prevent the freezing of residue water in the test pack and avoid burst damaging the inline valves, Testing shall not be carried out below 7°C ambient temperatures as stated above to avoid the possibility of brittle failure at low temperature (at 5°C ), which shall be considered by the construction manager and special measures be taken upon the client commissioning approval. Should these conditions occur during a test, the test shall be aborted and the system de-pressurised and drained. As an alternative solution, special anti coolant additives i.e. glycol shall be used with the test medium to avoid the brittle/expansion effect of the freezing water. At cold sites i.e. CIS countries, these low temperatures may be caused by wing chil ‘TESTING OF MANHOLES & UNDER GROUND PIPING All underground systems shall be filled to the high points. * The level shall be measured with a measuring rod, monitored by Construction supervision and QC inspection. The system shall be walked down to check for leaks. ‘The holding time is 1 hours and the level shall be monitored for loss. If levels are dropped, inspections shall be carried out at the joints for leaks. If leaks are found, joint repairing shall be done and test pack shall be retested similarly. PNEUMATIC PRESSURE TESTING SET UP & PREPARATIONS All temporary supports, spring support restraints, temporary spools, blinds and plugs, etc. shall be distinctively flagged or paint colour coded i.e. red or bright orange by the hydro test team, to ensure their removal following testing. Page 13 of 21PP METHOD STATEMENT FOR piping penumaticthydro testing DOC NO,; 1820-SA3-00-CON-PRO-035 Rev: A Temporary blind flanges and test blinds, used to isolate a test system, shall be installed at locations shown on the marked up P&ID and isometric drawings included in the pressure test pack. They shall be of adequate thickness to withstand the test pressure, i.e. the thicknesses of the test blinds are determined by the piping class or by engineering in accordance with ASME B31.3 Section 304.5. Test blinds shall include a lug/handle, extending beyond flange perimeter (at least 100mm) * Valves can be used to isolate a test system subject to approval by Piping Engineer Pressure and thermal relief valves and rupture discs shall not be included in system during pressure tests. + Control valves, orifice plates, strainer baskets, filter elements, in-line instruments and all other in-line components and valves, which are unable to withstand the test pressure, liable to damage by the test medium or by the impact of foreign matter during the purging process, shall be removed to the stores and replaced by temporary spools or spacers, which shall be fabricated cn site, marked in red, and stored in testing lay-down area. In general and due to the low pressure nature of the pneumatic tests, some components may be left in the test loop subject to approval by Piping Engineer * Check valves shall have source of the pressure on the upstream side of valve. If this is not possible, then swing type check valves shall be blocked open or their flapper removed in a manner acceptable to the inspector. Ball or piston type check valves shall have their internal parts removed. Should none of these be practical, the check valve shall be blocked off or removed. Pneumatic tests shall not be made against closed valves (expect where the pressures are low to justify using valves as test limits , subject to approvai by piping engineer). Except as specifically excluded herein, all inline valves shall be included within the pressure test limits; ball valves shall be in the half open position and all other valves shall be fully opened. However, where the test pressure to be applied to lines is greater than the maximum allowable test Page 14 of 21GP ereostree rote pounce tng ORE Es HSC ON HOON RA pressures specified for the valves, the valve should be blinded on the test side or replaced with a temporary spool. Short pipe spools requiring removal to permit installation of a test blind, shall be tested separately, or 100 % RT/MPI shall be done upon QC discretion, Instrument/control valves/flow meter/orifice plates ete, or th ternal parts shall be removed for the duration of pressure testing using the permanent labelling for traceability to the component to which they belong or the position in the line from which they were removed, to ensure cosrect replacement of ‘components following the testing. Generic items shall not be labelled. instrument connections shall be closed with a properly gasketed biind flange, or with a threaded plug, or isolated by closing the instrument block/isolation valve depending on the pneumatic test pressure. . No restrictions to flow such as orifice plates and restriction orifices shall be present during pressure testing. Tubing from instrument valves is to be disconnected and plugged or capped or tubing isolated by closing the block valve. Instrument connections shall be closed with a properly gasket blind flange, if flange connections are used * Expansion joints shall not be included in pressure tests, and shall be replaced with temporary spools. * Spring supports shall be locked in position for the test using preset pins. Their retaining pins shall not be removed until all hydro testing session has been completed and lines being drained The test pressure gauge shall be located on the system (i.e. at the vent). In addition, another "Check" gauge may be located at the lowest point of the system (ie. at the drain) if significant vertical legs could cause the static head pressure to over-pressure parts of the system. Two calibrated test pressure gauges for appropriate range for the test pressure may be used. They shall have current calibration certificate of accuracy. The pressure gauges shall be testedirecalibrated when shows faulty reading. this shall be witnessed by Client and Petrofac’s QC inspectors. Page 15 of 21-P METHOD STATEMENT FOR piping penumatic&hydro testing DOC NO.: 1820-SA3-00-CON-PRO-035 Rev: A TEST PROCEDURE & REQUIREMENTS Any line or system requiring pneumatic air tests shall be specifically noted in the line list as per the service. Some overhead vapour lines have been specifically designed to be pneumatically tested, and are indicated in the fine list. Also, Instrument Air, Plant Air, Nitrogen lines and Flare header lines and certain lines where hydraulic testing is not preferred or impractical, may be air tested. All possible safety precautions shall be implemented during pneumatic testing and procedures shall be prepared by sub- contractor and reviewed by Petrofac & Client. * The test pack shall be mechanically cleared. All inline joint types (i.e. threaded, socket weld, butt weld and flanged joints) and support welds to line pipe are categorized as critical “A” items in the punch list as outstanding critical work which are to be completed/closed by piping construction and cleared by QC prior to starting the hydro test * All relevant NDT requirements and inspections must be cleared via the test pack weiding summary sheet prior to flushing, as per project specification. * Care shall be taken to ensure that all pipe work being tested are adequately prepared and cleaned and is capable of being tested at the pressure indicated. Blinds, caps or plugs shall be installed as necessary to isolate the piping system under test. The system shall be inspected for construction completeness and satisfactory test preparation, including placement of pressure gauges and suitable. The test package sign off sheet shall then be signed by the authorised inspectors/personnel to allow flushing or purging prior to commencing hydro test. Prior to testing, the pipe work shall be flushed thoroughly, as per project specification. Page 16 of 24- METHOD STATEMENT FOR piping penumaticBhycro testing DOC NO.: 1820-SA3-00-CON-PRO-035 Rev: A + Flushing medium shall be compressed air. Air flushing is not permitted through machinery or any other equipment, which may be damaged by the purging operation. Precautions shall be taken to ensure that debris or dirt is not flushed into vessels, equipment or dead legs, by providing blinds at the interface of the piping and equipment or vessel Control valves shall, be removed until the initial flushing of the system has been completed, Before air flushing/purging, the area surrounding the test pack shall be cleared of unauthorised personnel and barricaded with warning notices of hazardous pressure zone, during the pressurising time of the test pack. This arrangement shall be coordinated with the inspector. * Flushing will continue until the flushing discharged air shows no sign of detachable debris, and witnessed by Clien’@C representatives. + Allitems, which are excluded from or removed prior to, the pressure test, shall be reinstated after testing is complete. Temporary spool pieces, blanks or plugs (which must be adequate for the condition) shall be removed and the original items re-installed. Any items that are excluded shall be defined on the pressure test diagrams. TEST MEDIUM / TEST PRESSURE & TEMPERATURE. The test shall be carried out using compressed air or nitrogen as the testing medium, which shall be free from foreign particles ‘The test pressure (except as noted in ASME B31.3 section 345.4.3) shall be as. shown on the line list. Pneumatic testing temperature shall not exceed 50 °C. The pneumatic-test pressure shall not be more than 1.1 times the design pressure of the system. Page 17 of 21P METHOD STATEMENT FOR piping penumaticBhydro testing DOC NO, 1820-SA3-00-CON-PRO-035 Rev: A The test pressure shall be built up gradually in stages to the specified test pressure and shall be held for a 10 min. period to allow the pipe under test to equalise the strain. Once the test pressure is realised, the test pressure shall be held for a minimum period as per ASME B31.3. The test duration shall be as per ASME B31.3 as 2 minimum, but as long as it takes to inspect and witness the tested pipe work joints (i.e. 1 hours): For small spools the duration will be one Hour as a minimum, only two pressure gauges will be used. Pressurize to 7 psig (0.5 bar) and hold for a sufficient length of time to allow piping to equalize strains, All joints (threaded, socket welded, butt welded, and flanged) shall be inspected for leaks with soap suds. Pressurize gradually in 10% steps to 60% of the specified test pressure and hold for @ sufficient length of time to allow piping to equalize strains (10 minutes minimum). Reduce pressure to 50% of the specified test pressure and visually inspect all joints for leaks. Pressurize in steps (each step to be no more than 10% of the specified test pressure) until the specified test pressure has been reached, holding for a sufficient length of time at each step to allow piping to equalize strains (10 minutes minimum). The test pressure shall be held for one hours and then reduced to design pressure after which all joints shall be inspected for leaks with soap suds. Throughout the test period, the bubble formation properties of the soapsuds shall be checked. All joints in the piping system, (threaded, socket weld, butt weld and flanged) shall be accessible during the test using scaffolding or man-lifts as appropriate and shall not be insulated or otherwise covered until the satisfactory completion of testing in accordance with this Method Statement. Page 18 of 24P METHOD STATEMENT FOR piping penumaticahydra testing DOC NO.; 1820-SA3-00-CON-PRO-035 Rev: A During the test, all flanges, welds, and joints (i.e. at unions, tees, valves or nipple) shall be visually inspected by QC/Client inspectors for any leaks or bubble formation. Test compressors shall be isolated from the system before the piping inspection. Should any leaks be found, the test shall be stopped, the system shall be depressurised, the leak repairedicleared and the test shall be restarted. All defects revealed by the test shall, after the approval by inspector, be repaired and after re-inspection, be retested as specified herein. Leaks shall be repaired as follows: system will be depressurised before work commences. Weld repairs shall be carried out as per the appropriate weld procedures, Flanged joint leaks: bolts shall be retightened or joint shall be dismantled, have flange surfaces checked, re-assembled and properly gasketed and tightened. At the discretion of the inspector and where permitted by the relevant code, repaired defects may be retested by means other than pressure testing (for example, 100 % radiography and MPI or ultrasonic) Depressurisation shall occur through vents, drains by opening slowly to allow safe purging not causing harm to personnel in the vicinity A system under test pressure shall never be left unattended. Ifa test cannot be completed before tne end of a work period, the system shall be depressurised. The subcontractor shall be responsible for all safety precautions and procedures during testing. As a minimum, a 25m exclusion zone for non- testing personnel shall be applied to the test site. in general any high pressure pneumatic testing (above 7bar) shall be planned, when there are minimum ongoing activities at site or on holidays to minimise any safety risk to the site personnel Page 19 of 21P METHOD STATEMENT FOR piping penumatic&hydro testing DOC NO.: 1820-SA3-00-CON-PRO-035 Rev: A All individual tasks of a non-routine nature referenced in this method statement shall be subject to individual Job Safety Analysis (JSA) and risk assessments by Discipline Supervisor at site, before work commences and on a daily basis. Toolbox talks shall be conducted on a daily basis by Discipline Supervisor at site. All personnel shall undergo applicable HSE training and wear PPE ie. safety helmets, safety boots, safety glasses, gloves and coveralls as the minimum requirements and high visibility vests where necessary. Al lifting equipment shall be tested and certified before use. Refuelling of equipment is strictly forbidden while the equipment is running All moving equipment shall be equipped with reversing audible alarm, and heavy equipment movements shall be guided and ushered by Flags men. For dusty working environments, dust masks shall be Provided. Job safety analysis and risk assessment for nearby excavations, working at height, confined spaces, etc. shall be carried out on a daily basis. Special attention shall be given to cordoning off the work areas and provision of applicable signboards. The work area should be barricaded with warning tape & signboards. Only authorised persons shall be allowed in the barricaded area. During lifting operations, the work area shall be barricaded with warning tape and only authorised personnel are allowed within the area (Riggers and Discipline Supervisors). All lifts that are 50% or below the Crane’s rated lift capacity, does not require lifting plan in accordance with the Project Safety Manual, Page 20 of 24P METHOD STATEMENT FOR piping penumaticéhydro testing DOC NO.: 1820-SA3-00-CON-PRO-035 Rev: A Rigging plans are required for loads between 50-85% the Cranes rated lift capacity. No lifting shat! be allowed by a single crane, where the load exceeds 85% of the crane rated lift capacity All works shall be conducted in accordance with relevant project Permit to Work procedures in energised areas, confined spaces, heights, etc. Page 21 of 21Khalda Petroleum Company SGT 3/4 Project Road 290-new Mandi P.O, Box $60, Maadi, Egypt Tel: + 202 27045321 Fax : +202 27045314 10 Petrofac Field Project Manager Project: Salam Gas Plant Trains 3&4 SGT 3/4 Attn : Mr, Samer Diwedar cc: KPC project Bs areroven J FOR INFORMATION project managers Eng. Ayman Saleh /Mr. Jim Flipping Cl (8) APPROVED AS NOTED (J FOR REVIEW Bic) commenten (] AS PER REQUEST Drawing Document | ay | Description Status Code 1820-SA3-00-CON-PRO-018 | A _| Method statement for piping fabrication APPROVED | A 1820-SA3.00-CON-PRO.O35 | A | Method statementfor piping preumatic® | ppprovep | a | hydro testing 0003 | 1820-SA3.00- CON-PRO-064-+ A | Method statement for piping erection —~ | COMMENTED c 0003 | 1820-SA3.00-CON-PRO.065 | A_| Metfad statement for installation of UIG ‘APPROVED A (0003 _| 1820-SA3-00-CON-PRO-028 | A _| Method statement for coating and wrapping | _ APPROVED a Remarks: Transmitted By: [ Malcolm Vickers fel, ——— — _ _KPC Construction Manager = — oe