CE & EH WHP - Pressure Test & Test Pack Procedure: Block 5 - AL SHAHEEN FIELD Development

Block 5 - AL SHAHEEN FIELD Development
Document Title: CE & EH WHP - Pressure Test & Test Pack Procedure
Project: WHP02-SMO1 Document Number: ASYYY-19-302063-0001 Date: 31-Mar-2020 Rev.: 00
Doc Type: PRC System: GENE Phase DE Status: IFR Class: 2
GLF-WHP02-EPCI4
CE & EH WHP - Pressure Test & Test Pack Procedure
Is the document generated from an existing As-Built? YES NO
Originator Document Number Last ASB Rev. :
Remarks:
00 31-Mar-2020 IFR ISSUED FOR REVIEW Kristian Y A P Jemmi A Didi H
Rev. Rev.date Status Description Issued by Reviewed by Approved by
The information contained in this document is the proprietary to North Oil Company. It must not be reproduced, stored, disclosed to any third party or used for any purpose not authorized by North
Oil Company. Printed documents are uncontrolled and considered as "for information only". Reference should always be made to the on-line EDMS for the updated version
Major Projects Template MAJOR-ASY-MPQA-FOR-000004_Rev00 Dated 09/06/2018
Page 1 of 20
REVISION HISTORY
Rev. Rev. Date Status History Issuer Reviewer Approver
00 31-Mar-2020 IFR ISSUED FOR REVIEW Kristian Y A P Jemmi A Didi
Page 2 of 20
CONTENTS
Revision History................................................................................................................................ 2
Contents............................................................................................................................................ 3
1 Introduction................................................................................................................................ 4
2 Objective..................................................................................................................................... 4
3 Scope.......................................................................................................................................... 4
4 Definition and Abbreviation......................................................................................................4
4.1 Definitions............................................................................................................................................ 4
4.2 Abbreviations....................................................................................................................................... 5
4.3 Responsibility....................................................................................................................................... 6
5 General....................................................................................................................................... 6
5.1 Safety Requirements Prior to Pressure Test........................................................................................6
5.2 Pressure Test Requirements................................................................................................................ 7
6 Gauges, Recorder and Thermometer Requirements..............................................................9
7 Documents / Record Preparation.............................................................................................9
7.1 TEST PACK PREPARATION............................................................................................................... 9
7.2 QC DOCUMENT REVIEW................................................................................................................. 10
8 Test Preparation....................................................................................................................... 10
9 Cleaning and Flushing.............................................................................................................11
10 Vessel and Equipment.........................................................................................................11
11 Hydrostatic Test Procedure.................................................................................................11
12 Pneumatic Test Procedure..................................................................................................12
13 After Completion of Test......................................................................................................12
14 Venting /Draining/Drying......................................................................................................13
15 Defects and Repairs.............................................................................................................13
16 Records................................................................................................................................. 13
17 Reference.............................................................................................................................. 14
17.1 Attachment-1...................................................................................................................................... 15
17.2 Attachment-2...................................................................................................................................... 16
17.3 Attachment-3...................................................................................................................................... 18
17.4 Attachment-4...................................................................................................................................... 19
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1 INTRODUCTION
This procedure covers the detail requirements of flushing, draining, hydrostatic & pneumatic
pressure strength test and drying of piping system of Block 5 - AL SHAHEEN FIELD Development
“Gallaf Batch 2”.
The test pressure and system boundary limits shall be covered and will be shown on respective
piping pressure test packages.
2 OBJECTIVE
The objective of this procedure is to provide sufficient guideline on system cleaning &flushing,
strength testing of all pressure component and reinstatement within the test boundary of the system.
This to ensure a consistent project requirement is always achieved as per schedule with highest
quality standard from fabrication and installation of pipework across all project facilities with safe
working environment.
3 SCOPE
This procedure shall apply to Piping for Block 5 - AL SHAHEEN FIELD Development “Gallaf Batch 2”
4 DEFINITION AND ABBREVIATION

4.1 Definitions
Term Definitions
The authorization in writing given by the Employer to the Contractor

on a procedure or to proceed with the performance of a specific part of
the work without releasing in any way the Contractor from any of his
Approval
obligations to confirm with thetechnical specifications, requisitions, etc.
The words “Approve”, “Approved” and “Approval” shall be construed
accordingly.
Employer North Oil Company
CONTRACTOR SMOE Indonesia
Shall Used to indicate that a provision is mandatory
Used to indicate that a provision is not mandatory but is
Should
recommended as good practice.
4.2 Abbreviations
Acronym Description
Page 5 of 20
EPC Engineering, Procurement and Construction

QC Quality Control
QA Quality Assurance
PMT Project Management Team
PTW Permit to Work
NDT Non Destructive Test
CRA Corrosion Resistant Alloy
RFI Request for Inspection
ITP Inspection Test Plan
ITR Inspection & Test Record
HPV High Point Vent
LPD Low Point Drain
PPE Personal Protective Equipment
WPS Welding Procedure Specification
WQR Welding Qualification Report
WQT Welding Qualification Test
4.3 Responsibility
1. Project manager is responsible for implementation of all project piping standard
requirements such as flushing, pressure testing to ensure mechanical strength, cleanliness
and tightness of each piping system and ensure safety of all personnel and equipment.
However, it shall be the responsibility of every individual to ensure that each activity is
performed in a safe and controlled manner. He will ensure as well, that this procedure is fully
adhered and complied with all the safety aspects and objectives throughout the projects.
2. Construction Manager is responsible for ensuring inspections are carried out, documented
and all the relevant parties are informed in advance about inspection schedules. He shall be
responsible to liaise/monitor with the Piping Lead for all day to day activities on flushing and
pressure testing.
3. Piping Lead shall provide pressure test packages for all piping systems. He shall resolve all
arising technical issues with engineering. He shall be responsible for the test equipment
requirements and overall operations of flushing, pressure testing, drying and reinstatement of
all piping systems.
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4. Piping SMOE QC inspector shall be responsible for all piping inspection requirements prior
and after pressure test, procedure, test equipment calibration/certification requirements and
any other certification that may be required. He shall be responsible to prepare, issue an RFI
notification and coordinate with the Employer for witnessing and acceptance of all pressure
testing activities that shall be submitted to the Employer.He shall monitor NDT clearance and
advice of confirmation on the readiness for hydrostatic test to Piping Engineer.
5. Safety Officer/Supervisor shall ensure that all pressure testing activities are carried out
under applicable permit to work system and shall be complying with the HSE plan, safety
work procedure and risk assessment evaluation.
5 GENERAL
5.1 Safety Requirements Prior to Pressure Test
Prior to carry out pressure testing, users shall carefully consider this procedure for the following
safety requirements:
1. All pressure testing activities shall be carried out under applicable permit to work system
(PTW).
2. Pressure test pump shall be provided & calibrated with safety relief valve to avoid over
pressure on the system. Safety relief pressure setting shall be calibrated to 10% above the
test pressure as per ASME B31.3 para 345.5.2. All flexible hose connection shall be provided
with whip connection.
3. All personnel involved with pressure testing activities, including all inspectors and witness
personnel, shall wear the required personnel protection equipment (PPE).
4. Maximum care shall be taken during pneumatic/hydrostatic test to prevent injury to

personnel and damage to nearby equipment. Ensure pressure test area shall be cordoned
off, barricaded, signboards to indicate system test pressure with person name/contact
number and “unauthorized entry” barriers shall be provided. Pressure test area shall not be
left unattended.
5. Ensure all blanking-off devices are of the correct rating and that such items particularly
screwed plugs/connections are not liable to be ejected during testing, eg:, as the result of
thread failure or inadequate thread engagement.
6. Systems must not be subjected to any form of shock loading, such as hammering and
tightening bolts during testing, whilst system under pressure tests.
7. Temporary vents/drain shall be provided if permanent high point vent & low point drain (HPV
& LPD) are not available and shall be kept opened to prevent air locking during water filling.
Vents shall be provided at all high point and drains of low point locations. During test pack
preparation, Piping Engineer shall ensure that adequate vent and drain shall be provided.
Page 7 of 20
System shall be checked on downstream of the check valves for possible trapped pressure
and trapped section drain point.
8. Appendix-Checklist
5.2 Pressure Test Requirements

Prior to carrying out pressure testing, users of this procedure shall carefully consider the following
test requirements:
1. Pressure gauges, temperature and time recorders shall be used for all pressure tests. The
pressure gauges shall be shown in Barg/Psig, recorders shall indicate temperature in degree
Celsius (°C) & pressure in Barg/Psig.
2. Lines shall have all permanent supports installed before pressure test. Requirement for
hydrostatic test for gasservice shall be verified that supports is adequate for liquid filling. The
system as designed and constructed will support the weight of liquid required for
flushing/hydrotesting. Provision of additonal temporary support for testing where if
necessary.
3. Test medium, test pressure and minimum holding time shall be based on latest revision of
project line list.
4. Pneumatic testing over 7 barg shall use Nitrogen as test medium. It is not permitted to use
compressed air and top up with nitrogen.
5. SMOE QA/QC personnel responsible to follow up, review and secure Employer representative
acceptance signature on hard copy report of weld summary which states fit up, visual,
welder identification, WPS no., NDT/material traceability are compiled in the test pack
document before commence pressure test.
6. Pressure shall be maintained for a sufficient time to permit thorough inspection, visual
examination of all surfaces, welds and connections, but not less than 30 min. During increase
of pressure, hold pumping to stabilize pressure and inspect for any leaks. Release air locked
inside test object to avoid fluctuation of pressure. if require, de-air from vent points as
indicated on test isometric. Test recorder shall be started when pressure is stable and test
pump is either disconnected from test manifold or energy source disconnected.
7. Unless otherwise required by Employer, the following systems are excluded from pressure
testing.
8. Any package unit previously tested by manufacturer in accordance with the applicable
codes/specification.
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9. Punch category A (items related to safety/integrity of the system), which affects the integrity
of the system, shall be rectified before flushing and Pressured testing. Original filled in and
updated punch list shall be part of the test package.
10. Pressure and temperature record test chart shall indicate the following;
 Test pack number/Test Date (refer Isometric index for line numbers/spool numbers)
 Responsible test person name/sign
 Test pressure and medium
 SMOE inspector name/sign
 NOC inspector name/sign
 Start time/actual duration of test
 Start/Finish pressure(barg/psig)
 Start/Finish temperature(°C)
 Pressure gauge ID/Serial Number
 Pressure & temperature recorder ID/Serial Number
11. If any inline item, such as valves,instrument and other items that will be exposed to pressure
are included in the pressure test must be capable of withstanding the pressure that includes
the internals and valve housing.Valve acceptable opening position during the test shall be
complied and removed items shall be identify. Any inline items, instrument and valve
included on test shall be identified during pre-line walk before the test. SMOE Piping
Engineer shall ensure that the test isometric indicate the specific valve which shall be in half
open position during pressure test. All other valves shall be tested in the fully open position.
When check valves are included in pressure test theyshall be jacked open or have their
internals removed. Ball and gate valves shall be wide open during flushing and three quarter
open during testing.
12. After system testing is successfully completed, Piping Engineer’s nominated contractor
representative shall carry out the release of pressure and vent shall be opened. Hose
connected to drain/filling points shall empty the system.
13. Test object shall be free from any covers and tarpaulin except for pipe protection during
pressure test. Pipe protection shall be required to open if there is significant pressure drop or
water moisture observed during visual inspection.
Page 9 of 20
14. Following pressure test, SMOE QC shall prepare piping system pressure test report MC-L-002
and shall be offered to sign off after acceptance of pressure test by all authorised persons.
15. For Open drain and other low pressure system service leak test is acceptable by the
Employer as per SUBTS 160 (6.15.2)
6 GAUGES, RECORDER AND THERMOMETER REQUIREMENTS

The pressure gauges shall be shown in Barg/Psig, recorders shall indicate temperature in degree
Celsius (°C) & pressure in Barg/Psig. Gauges/Recorders shall be between 1.5 to 2.5 times of the
test pressure.
All gauges and recorders shall be calibrated prior to the commencement of pressure test schedule
and at a frequency of every six months. Gauges for pressure testing and control of pressure test set
pressure shall have accuracy equal to +2.
A minimum of one pressure gauge shall be installed in the highest point with a vent valve. Second
pressure gauge at lowest point and one recorder shall be installed at lowest or highest point of the
piping system. Test chart shall be approved/signed by all concerned personnel. Test recorders shall
have pressure & temperature indicators. Water filling connection shall be at the lowest point of the
system for test.
Identification number of pressure gauges and recorder shall also be recorded on the test chart. The
chart shall be attached to the pressure test pack after testing is completed successfully.
7 DOCUMENTS / RECORD PREPARATION

7.1 TEST PACK PREPARATION
Piping engineer or Test engineer shall prepare pressure test packages covering piping system
boundary limit on the P&ID and shall be prepared in advance for initial employer review on test
boundary limits and isometric drawing configuration that includes the following below.
Test pack shall be submitted to the Employer for review with all summary reports and material
traceability reports enclosed to the test pack signed off by all concerned parties.
a) P&ID test system boundary mark up in reference with commissioning sub system marked up
(highlighted with red color)
b) Indicates test pressure, test medium, test duration and location.
c) Line list, drawing index & latest isometric and support drawings.
d) Weld report summary which states fit up, visual, welder identification, wps no., NDT/material
traceability report and compiled in the test pack document before commence pressure test.
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e) Mechanical check sheets to be signed off by all concerned personnel after work phase
completion.
Reference (Annex-A Sample Mechanical Completion Check Records numbering below) MC-L-
01, MC-L-02, MC-L-03, MC-L-04
7.2 QC DOCUMENT REVIEW

a) During pre-test line walk piping engineer shall submit pressure test package to SMOE QC
inspector for checking the completion of all NDT requirement .
b) All outstanding items and rectification work should be addressed in the piping punch list. Item
under category A, which may affect the integrity of the system should be rectified before
flushing and hydrotest.
c) Items under category B that would not affect the integrity of the system shall be rectified after
hydrotest. All punchlist items shall be decided jointly by SMOE/Employer Representative and
shall be monitored and cleared during reinstatement.
8 TEST PREPARATION
Items/component within Packaged equipment such as vessels, tanks, pumps, etc not included on
test shall be documented and agreed with Employer .Equipment shall be isolated and all opening
shall be secured.
All inline items such as orifice plates,strainers,filters, flow-measuring elements, level gauges and
pressure gauges shall not be included on the pressure test and shall not be installed until hydrostatic
pressure testing is completed.
All equipment that is likely to cause a restriction or dead end to the flow or could be damaged by
debris during flushing shall not be included in the test
All equipment connections to the piping system to be flushed/tested shall be stress free and blanked
off.
Temporary supports, pads, etc. shall be used as required to take the weight of piping, vessels or
equipment when the line is disconnected.
9 CLEANING AND FLUSHING

a) For pipe sizes 6 inch and above, use of hydro jetting(6000-10000PSI) shall be carried out to
clean pipe internal to ensure cleaniness. For pipe sizes 4 inch and below, high velocity water
flushing shall be performed at a minimum velocity of 10 m/s.
b) Flanged ball valves shall not be installed until flushing is completed. Flanged ball valves may
be installed when flushing is completed and prior to pressure testing, provided the fabrication
contractor has verified acceptable cleaniness of the system.
Page 11 of 20
c) Drying shall take place after complete flushing and draining with compressed air
d) Following flushing and draining , SMOE QC shall prepare piping system flushing/ drying
report which is to be signed by all authorised persons.
e) Either Flushing or testing can be performed first and followed by drying .
10 VESSEL AND EQUIPMENT

Unless otherwise advised, the following components shall be excluded from pressure tests.
 Vessels and equipment
 Vendor furnished piping previously shop tested. All instruments tagged control valves, Relief
valves and check valves.
11 HYDROSTATIC TEST PROCEDURE

As part of the strength test, lines shall be hydro tested after line walk & acceptance of site
installation, NDT clearance following the hydro test, the water on the system should be completely
drained and dried ,
The pressure is applied by means of a suitable test pump gradually to build up pressure to 50% of
test pressure and then hold long enough to equalize piping strains. If no leaks found, thereafter the
test pressure is increased gradually until required test pressure is reached. Leaks shall be checked
between each step. The hydrostatic test shall be held at 100% of the test pressure for a minimum of
30 min or such time as required for a full visual inspection of all joints and connections. If a leak is
found the test shall be stopped and the pressure shall be released. i.e: dropped to zero barg. After
leak has been repaired the test can be resumed according to test procedure.
SMOE Q.C. inspector and Employer representative shall carry out a detailed inspection of weld
joints and connections for any leak. They should also look for any dislocation/movement on
supports. Any joint found leaking during a hydrostatic test should be retested to the specified test
pressure after repairs had been made.
Sensitive equipment (i.e. expansion joints, relief valves, inline instruments, etc.) shall be removed,
blocked off or isolated during testing.
After successfully completion of hydro test, piping flushing certificate, testing/test chart record shall
be filled and signed off by SMOE/COMPANY Representative/ copy would be issued to PIMS.
Refer attachment – 3 Typical Hydrostatic testing set up.
12 PNEUMATIC TEST PROCEDURE

Strength test shall also be done thru Pneumatic testing after line walk & acceptance of site
installation .Test media shall be oil free, dry air or any inert gas and shall be carried out in the
Page 12 of 20
following steps and with proper risk assesment. System boundary shall be reduced to minimum
areas & small volume to minimize hazard to a maximum test pressure of 7 barg. For above 7 barg
test pressure, nitrogen bottles shall be use with pressure regulator to regulate pressure until required
test pressure reached.
Initial pressure of 0.05 MPa(0.5 barg) shall be introduced in the system and a leak test performed. If
found no leak, pressure shall gradually be increased to 25% of the specified test pressure, followed
by 50 %, 75%, 100% and kept every steps for minimum 5 min to equalize strain on the system. Any
leaks observed shall be rectified after releasing the pressure on the system.
If there is no pressure drop on any of the gauges and recorder, the pressure shall be hold for 30min
at full test pressure, if the pressure is holding without any drop, reduce the pressure gradually to
design pressure before examining for the leakages for the Test pressure Range 50 Barg and below
only.
For the Test Pressure above 50 Barg, pressure Gauge and Recorder shall be monitored for the
leaks
Check and examine all the flanges /screwed joints and welds by using bubble forming solution to
detect any leak on the system.
Refer attacment – 1 Snoop liquid leak detector
No rectification/tightening of the bolts shall be carried out under any circumstances when the system
is under pressure.
Refer attacment – 4 Typical pneumatic testing set up.
13 AFTER COMPLETION OF TEST

Tested system shall be depressurised slowly in stages by opening the depressurising valve in the
test rig. All vents and low point drain valves shall be opened, system shall be thoroughly drained
after successful completion of hydrotest. Where required, blowing by air or pressurised air shock
blowing to remove any trapped water shall be performed to remove any residual or trapped water.
Downstream of the check valves shall be check for possible trapped pressure generated during test
and flushing medium to drained off and dry.
End of pipes and nozzle shall be fully protected against the ingress of foreign materials by the use of
end caps, plugs or blind plates sealed with gaskets. These shall not be removed until just prior to
final assembly or box up. Connection to tie-in points shall be verified from the area or package owner
before opening sealed points.
All lines and joints that fail to pass the pressure test shall be re-tested to the same procedure after
repairs.
Page 13 of 20
14 VENTING /DRAINING/DRYING
After acceptance of the test, the pressure shall be released in a manner and at a rate so as not to
endanger personnel or damage equipment and in a slow and controlled manner.
All vents shall be opened before the system is drained and shall remain open during draining to
prevent pulling a vacuum on the system. Valves, orifice plates, expansion joints and short pieces of
piping, which have been removed, shall be reinstalled with correct gaskets in place and orientation if
required.
All lines and piping components shall be completely drained and dried .All draining to be done with
compressed air.
15 DEFECTS AND REPAIRS

Any leak or defect seen on the weld as a result of hydrostatic test is to be fully cut out and reweld,
subject for the specified NDT, flushing and re-hydrostatic test, cleaning and drying.
16 RECORDS
SMOE QC shall prepare piping system flushing & pressure testing reports which is to be witnessed
and signed by authorised persons. The report shall be enclosed on the test pack which includes the
following below:
 Date of Test
 Identification of piping system tested as shown on marked up P& ID’s test boundary limit
including isometrics
 Test pressure and holding time
 Test medium
 Ambient temperature
 Design pressure and temperature
 Result of testing
 Name s and Signatures of SMOE Q.C. inspector and Orsted representative
 Copies of valid calibration certificates
 Pressure/temperature recording chart shall be installed prior to start of test and must be fully
signed off after test.
Page 14 of 20
Once the hydrostatic test is sucessfuly completed.Piping system that require cleaning and dry up
after pressure test shall be completed the re-instatement and Reinstatement of all items removed
from the test shall be carried out.
17 REFERENCE
Codes and Standards
ASME B31.3 - Process piping
EN13480-5 - Metallic Industrial Piping inspection and testing
SUBTS 160 - Piping System design and pollution prevention system
Page 15 of 20
17.1 Attachment-1
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17.2 Attachment-2
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PIPING TEST PACK FLOW CHART
Page 18 of 20
17.3 Attachment-3
Page 19 of 20
17.4 Attachment-4
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Block 5 - AL SHAHEEN FIELD Development

Project: WHP02-SMO1 Document Number: ASYYY-19-302063-0001 Date: 31-Mar-2020 Rev.: 00

Doc Type: PRC System: GENE Phase DE Status: IFR Class: 2