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METHOD STATEMENT FOR Pneumatic Test
METHOD STATEMENT FOR Pneumatic Test
Technical
1 2 3 4
Discipline
Field Engineering
1 2 3 4
Dept.
HSE Dept. 1 2 3 4
QA/QC Dept. 1 2 3 4
1 2 3 4 5 Name Signature
A IFR 21-May-19 Issued For Review Mohamed Allam Ateia Hamed Khaled Mosad
Construction Construction
Designation Engineer
E&I Manager
Manager
Rev. Status Date Revision memo Issued by: Checked by: Approved by:
PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SNAMPROGETTI
SAUDI ARABIA CO. LTD.
TABLE OF CONTENT
TABLE OF CONTENTS.....................................................................................................................
1. GENERAL............................................................................................................................... 1
2. SCOPE.................................................................................................................................... 2
3. DEFINITIONS.......................................................................................................................... 3
4. REFERENCES........................................................................................................................ 4
5. RESPONSIBILIES...................................................................................................................5
6. PROCEDURE......................................................................................................................... 6
7. QUALITY................................................................................................................................. 7
8.MATRIALS, TOOLS & EQUIPMENTS …………………………… 8
9. SAFETY …………………………………………………………………………….…9
10. EMERGENCY RESPON…………………………………………………………………10
11.ATTACHMENT………………………………………………………………………………………11
12 INSPECTION………………………………………………………………………………………...12
PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SNAMPROGETTI
SAUDI ARABIA CO. LTD.
1. GENERAL
PURPOSE
The method statement must ensure that the pneumatic test for refrigerant pipes works
is carried out safely, and in accordance with good engineering practices, as per project
specifications.
This method statement is intended to provide general guidance and establish controls
COMPANY Saudi Arabian
duringOilpreparation
Company and installation.
This statement outlines the methods to be followed for the pneumatic test of copper
pipes works installation activity.
contractor SNAMPROGETTI SAUDI ARABIA CO. LTD.
PETROJET To describe
The Petroleum the& detailed
Projects Technicalscope of work toCo.
Consultations be followed
Acting asfor the pneumatic
subcontractor fortest for copper
(PTJ) pipes worksat Hawiyah Gas Plant (HGP)
construction and pre-commissioning activities, also referred as subcontractor
RFI/AFI 3 For
Request DEFINITIONS/ABBREVATION
Inspection/Application For Inspection
4 REFERENCES
5. RESPONSIBILITIES:
5.1. The Mechanical work Site Engineer (MSE) shall be responsible for the implementation
of this Method Statements is as follows
A) Ensure availability of required material that compiled with approved submittal.
B) Ensure site Supervisor/ Foreman and Workmen assigned to do this job are
specialist and well trained.
C) Ensure availability of required tools / equipment at site in good operating condition.
D) Ensure the validity of calibration certificates for the gauges use in this activitiy.
B) Check all tools and equipment are working properly and report to Site Engineer for
immediate repair or replacement.
C) Guide the workmen to execute the works as per standards and as per procedures
described in this method statement.
5.3. Mechanical Works Quality Control Inspector (MQCI) shall be responsible for the
Followings:
A) Continuously monitoring site execution work and material to be ensure total
compliance with approved details and Project Specifications.
B) Timely inspection with Engineer Site staff (ESS).
Monitor the work areas of any unsafe conditions. Ensure that all safety
requirements are adequately addressed and the work is being carried out safely in
accordance with HSSE Safety Procedures. Ensure that material safety data sheets
are available at site.
Prepare and submit MS for Company review and approval. Provide technical
support to site operations group. Provide the latest revision of AFC drawings,
procedures, material specifications, standards and technical specifications.
Maintain proper documentation and control drawing used on site. Request field
erection material as per schedule. Responsible for the review of project drawings
and data sheets, and resolve technical work execution problems.
6. PROCEDURE
6.1 General Requirements:
A). The HVAC Specification specified in details which piping or equipment shall be
pressure tested and provided the specific applicable standard.
B). New piping system shall be cleaned in accordance with SAES-L-350.
C). Pressure gauges shall be calibrated before the test.
The calibration interval for Pressure Gauge shall not exceed one (1)
month. Calibration certificates shall be made available to inspection
personnel prior to commencement of the pressure test. Stickers shall be
applied indicating the latest calibration date.
PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SNAMPROGETTI
SAUDI ARABIA CO. LTD.
All gauges shall have a range such that the test pressure is within 30 to
80% of the full range.
A minimum of two pressure gauges are required for the test system. One
pressure gauge shall be on the test manifold and the other(s) on the test
system. Their accuracy shall be within 5% of one another.
When large systems are tested, inspection personnel will determine the
need for additional gauges.
D). Pressure Gauges and Relief valves shall be calibrated with third party inspection
agency or in house calibration facility in which sub-contractor should submit RFI to
TR/ ARAMCO.
E). Test record shall be recorded on Pressure Test Report Form (Company Pressure
Test Report)
6.2 Requirements for Test Manifold:
A). Calibration of test manifolds shall be as per design pressure. Test manifold shall be
calibrated with third party certification or in house calibration facility in which sub-
contractor should submit RFI to TR/ ARAMCO and its calibration interval shall not
exceed 6 months.
B). An isolation valve shall be provided between the pressure testing manifold and the
system being tested. The isolation valve shall be rated for the manifold test
pressure when in the closed position.
C). The pressure shall be built-up gradually as per the TR/ ARAMCO standard. To
ensure the applied pressure inside the test package never exceeds the desired
pressure, a calibrated safety relief valve shall be provided in the manifold.
D). In the event of leakage, the manifold will be depressurized. Repair will be executed
and the test will be repeated until no leakage is observed.
6.3 Protection from Over Pressure:
All systems (piping and equipment) while being pressure tested shall be protected
from being over-pressured by the following:
A). Relief valve(s) of adequate capacity set to relieve at 5% above the test pressure
shall be installed unless the test pressure is less than 85% SMYS (Specified
Minimum Yield Strength) at which time it can be set at 10% above the test
pressure.
B). All Punch-List “A” Items shall be cleared prior to Pressure Test.
C). Safe access and required temporary supports will be provided for inspection of all
joints and appurtenances prior to walk down and maintained until the satisfactory
completion of the test.
6.4 Pressure Testing of Refrigerant Pipes:
A. Experienced personnel are deployed to supervise and conduct the testing operation in
a safe and efficient manner, taking in to account all aspects of testing such as
coordination, supervision and safety.
PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SNAMPROGETTI
SAUDI ARABIA CO. LTD.
B. Blow out lines with dry nitrogen prior to testing and charging.
C. Leak test shall be performed by injecting dry nitrogen into the system.
D. The pressure in the piping system shall be gradually increased until a gauge pressure
which is the lesser of one half of the test pressure or 175 kPa (25 psig) is attained, at
which time a preliminary leak test shall be performed to detect and eliminate gross
leaks and/ weakness on the joints under examination (50 psig). If there is no leak, the
pressure shall be gradually increased in steps until the test pressure is reached (250
psig), holding the pressure at each step long enough to equalize piping strains.
F. When no leaks are detected, pressurized both high and low sides of system to 250 Psi
(for Refrigerant 134a). The compressor shall be isolated from the system during this
high pressure testing.
G. When the system has been brought up to the test pressure shown on the pressure test
summary, all joints shall be covered with a bubble forming solution in order to detect
any leakage.
H. Pneumatic test pressure shall be maintained for a sufficient length of time to permit
through visual inspection and soaping of all joint but not less than 2 hours.
I. Strength test pressure holding time shall not be less than 2 hours as per HVAC
Specification
SEQUENCE:
M. Attach in every test, the steps to get the test pressure and the depressurization of the
system.
O. After pressure test has been done and approved by Contractor/Company, evacuate the
system to remove air, moisture and dirt (if any) in the tube system. (See separate
Method Statement for Evacuation)
A. Leak detection will be by means of soap bubbles which is the simplest, the oldest
and the most recommended method. This can be done by using a commercial
solution such as liquid soap or equivalent.
B. Prior to soaping the joints, the entire line should be “Walked” to determine if there is
any audible evidence of leakage. Any leaks found at the time shall be marked, and
repaired after first depressurizing the line. If any abnormal sound is occurred,
immediately shut off the cylinder valve. Depressurized the system through manifold
to outside the building.
C. Prepare a solution of liquid detergent or liquid soap with water in the proportion of
one (1) pint (0.5 Liter) of detergent or soap and four (4) quarters (3.8 Liters) of
water. Prepare the solution in advance to allow the bubbles and foam to disperse
before using.
D. Apply the soap solution to all fittings and brazing joints in a continuous film relatively
free bubbles and observe closely for any minor soap bubbles generating from the
brazed joints.
E. When leakage is observed, the position of the leak(s) shall be marked. The system
will be depressurized gradually and safely before proceding with the repair.
F. A qualified technician can identify the difference between the bubbles caused by
leak and bubbles naturally present in the soap application.
G. After rectification of leaks, if any, all the above leak detection steps have to be
repeated.
7. QUALITY CONTROL:
A) QA/QC must ensure that the Brazers are qualified to do the job with valid Brazer’s
identification card.
B) Request for Inspection shall be issued to Contractor/ Company Project Inspector 24
hours in advance on weekdays and 48 hours in advance for weekends and holidays.
C) Inspection shall be done in accordance with the QA / QC Plan.
D) During Inspection, all brazed joints shall be carefully examined for leakage.
E) The brazed joints being tested shall be satisfactory if there is no evidence of leakage
or reasonable drop in pressure after the specified test period.
F) Leaking brazed joints shall be repaired and test shall be repeated until the system is
proven satisfactory.
G) Ensure that the Filler Rod and Flux are as per approved material and in compliance
with the requirements.
A) Dry Nitrogen
B) Nitrogen Regulator (calibrated)
C) Gage manifold (calibrated)
D) Various Hand Tools
E) Pressure Relief Valve (PRV), with calibration certificate (one week valid for Pressure
Test)
F) Test Manifold (Calibrated)
G) Soap & water solution
H) Warning Sign, Barriers
I) Calibrated Thermometers with calibration sticker & Certificates (If required)
9. SAFETY:
A. All personnel tasked to do this work shall wear Personal Protective Equipment’s (PPE)
at all times on the job site.
B. All equipment’s shall have Aramco stickers or safety tags to ensure that said
equipment’s are approved for a safe working condition.
C. Barriers shall be erected to provide protection against hazards and dangers, hazardous
work areas and hazardous work in all cases where the hazard or danger will exist.
Barricades shall be marked ‘YELLOW’ and ‘BLACK’ to increase the visibility of the
barrier and to highlight the hazards.
PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SNAMPROGETTI
SAUDI ARABIA CO. LTD.
D. Subcontractor Safety Supervisor shall carry out the safety site imspection to ensure that
safety requirements laid out in the safe work plan are followed during testing.
E. Subcontractor Safety Manager/ Supervisor shall review Safety Action Plan and secure
work permit if necessary.
F. Prior to start of any activities, Job Safety Analysis (JSA) will be strictly followed as per
attachment.
G. Equipment, tools and Materials Inspection. All equipments for testing shall have to be
inspected by Subcontractor Safety manager/ Supervisor prior to forwarding to TR
Safety Department inspection prior to use at site to ensure their safe worthiness at
work. The inspection reports shall be kept for record.
H. Test area shall be marked and warning sign shall be posted to alert approaching
personnel.
J. Doors should be in open position to move out all the persons in the room.
K. Force ventilation shall be incorporated inside the building to provent oxygen
replacement.
L. No activity shall be carried out inside the building during pressure testing.
M. Nitrogen cylinders shall be kept outside the building in well ventilated area.
O. When leakage is observed, the system will be depressurized gradually and safely
released and When leakage is observed, the system will be depressurized gradually
and safely released and follow the emergency response plan.
Q. MAC Safety Supervisor shall carry out safety site inspections to ensure that safety
requirements laid out in the safe work plan are followed during the testing.
A. If any abnormal sound is occurred, immediately shut off the cylinder valve.
C. Doors should be in open position to move out all the persons in the room.
E. Ensure that the system has been depressurized prior to any maintenance work.
PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SNAMPROGETTI
SAUDI ARABIA CO. LTD.
11- ATTACHMENTS:
12-INSPECTION
All stages of work shall be inspected in accordance with the approved project Inspection and
Test Plan (ITP)