HYDROTEST & HOLIDAY TEST PROSEDURE

PROJECT : NPK CHEMICAL PROJECT 500.000 MTPY

OWNER : PT PUPUK ISKANDAR MUDA
CONTRACTOR : PT PP (PERSERO) TBK
DOC. NO. : NPK-000-Q1-SI-1010-V
ISSUED FOR : APPROVAL
JOB NO. : 0029/SPS/SCM/PP/EPC/718003/IX/2019
LOCATION : KRUENG GEUKUEH, NORTH ACEH, INDONESIA

0 ENG IFA

CHK APR
DATE ISSUE ISSUE
REV PREPARE CHECKED APPROVED
ISSUED STAGE PURPOSE OWNER APPROVED

Vendor : THIS VOLUME EMBODIES PROPRIETARY INFORMATION OF PT. PP

PERSERO THIS VOLUME OF THE MATERIAL DESCRIBED THEREON MAY
NOT BE COPIED OR DISCLOSED IN ANY FORM OR MEDIUM TO THIRD
PARTIES, OR USED FOR OTHER THAN THE PURPOSE FOR WHICH IT HAS
BEEN PROVIDED, IN WHOLE OR IN PART IN ANY MANNER EXCEPT AS
EXPRESSLY PERMITTED BY PT. PP PERSERO.
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TABLE OF CONTENTS

REVISION HISTORICAL SHEET ..................................................... 2

COMMENT AND RESPONSE SHEET ............................................. 3
1. GENERAL ........................................................................................ 4
2. DEFINITION ..................................................................................... 4
3. REFERENCE ................................................................................... 5
4. ABBREVIATIONS............................................................................. 5
5. RESPONSIBILITY ............................................................................ 6
5.1 REF. APPROVAL SECTION OF DOCUMENT............................ 6
5.2 INSPECTION AND TEST PLAN STATUS .................................. 6
ATTACHMENT LIST......................................................................... 7
Attachment – 1 Pressure Testing
Attachment – 2 Wrapping ( Polyken )
Attachment – 3 Holiday Test
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REVISION HISTORICAL SHEET

REV. NO ISSUE PROPOSE DATE SUBMISSION

0 IFA
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COMMENT AND RESPONSE SHEET

NO. OWNER COMMENT NAME & CONTRACTOR RESPONSE NAME &

TITLE TITLE
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1. GENERAL
This is Generic Method Statement For pipe Underground for Piping Work. Ongoing Method will be
detailed with the specific requirements of each work area and work construction package, which will
have specifications, standard / codes, testing, drawing and material requirements which will be
unique / specific for each package for the NPK CHEMICAL PROJECT 500,000 MTPY PT. PUPUK
ISKANDAR MUDA.

2. DEFINITION
OWNER : PT. PUPUK ISKANDAR MUDA or his representative
CONTRACTOR : PT PP (Persero) Tbk.
SUBCON : PT. SABERINDO PASIFIC
I – INSPECT : Mandatory examination of work after completion of activities
as indicated by the symbol “I” on the Inspection & Test Plan
(ITP).
Verify acceptance to the specification, industry code and
manufacture’s requirement. Can be a visual, dimensional inspection
or test.
NOTIFICATION : Inspection Request in writing and require a minimum of 24
hours notice of impending inspection / test.
H - HOLD POINT : As notification point, however work may not proceed beyond
this point without acceptance or formal waiver from Inspection
Authority (Client / Owner).
W – WITNESS : Witness of inspection by Client / Owner and Sub-Contractor
may proceed if Client / Owner not appearance at the pointed
time. Witness point shall be given by Notification.
SW - SPOT WITNESS : Witness of inspection by Client / Owner and to be done at
spot or random (random sample).
R – REVIEW : Review of verifying certificate / Review a document to
ensure compliance with specification/Review of inspection report
or proc.
A – APPROVAL : Approval documentation (Procedure, Work instruction,
Inspection report, etc.) or Control document required to be
approved.
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IR : Issued report or documents required (i.e Inspection Report,

Mill Certificate, Fabrication Completed Certificate, Etc.)
Note :
1) Inspection and test items covered by this list and applicable requisition and specifications are PP's
general requirements. If any conflict arise between this list and individual requisition and
specifications, the requirements in individual requisition and specification shall govern.
2) The legend used throughout this list shall have the meaning denoted and can be changed to suit
with Client or Owner Comments.

3. REFERENCE
ASTM : American Standard for Testing and Materials
AWS : American Welding Society
ASME IX : Welding and Brazing Qualification
ANSI B31.1 : Power Piping
ANSI B31.3 : Process Piping
ASME V : Non–Destructive Examination

4. ABBREVIATIONS

AWS = AMERIKA WELDING SOCIETY ANSI = AMERICAN NATION STANDARD

ISTITUTE
ASTM = AMERICAN STANDARD TESTING NCR = NON CONFRIM RECORD
AND MATERIAL
DIN = DEUTCHES INSTITUT NORMUNG MDR = MANUFACTURE DATA RECORD

WPS = WELDING PROSEDUR STANDARD NDT = NON DESTRUCTIVE TEST

PQR = PROSEDUR QUALIFICATION PWHT = POST WELD HEAT TREATMENT
REPORT
WQTR = WELDER QUALIFICATION TEST Proc PROSEDURE
RECORD
N/A = NOT APLICABLE RT = RADIOGRAPHY TESTING
ASME = AMERICAN STANDARD OF UT = ULTRASONIC TESTING
MECHANICAL ENGINEERING
PT = PENETRANT TESTING
MT = MAGNETIC PARTICAL
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5. RESPONSIBILITY
5.1 Ref. Approval Section of Document
A = Where there is a Subcontractor element, the Subcontractor involved will sign the
approval of the activity.
B = Where there is no Subcontractor element, PP will sign approval of activity and
present to the Client.
5.2 Method Statement For Pipe Underground Status
It is to be understood that the Method of Underground Work and Test Plan forms an integral part
of the control / verification documentation. However, where no other documents are required or
exit
"Method Statement Of Pipe Underground work and testing" only will be understood to be the
control / verification document.
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1.REQUIREMENT
The Method statement Pipe Underground ( Pressure Testing, Wrapping & Holiday Test ) shall be made
in accordance with the approved drawings, Project specification, applicable standard & manufacturer’s
guidelines.

2. Pressure Test
- Hydro-test Pressure
- The test pressure for piping shall never be inferior to 1.5 times the design
pressure.
- The Hydrostatic Test pressure shall be identified in each Test Package on the
Pressure piping Test report. This pressure shall be in accordance with line list.

- Maximum allowable test pressure shall be accordance with the applicable piping
class specifications. The minimum allowable test pressure shall be in
accordance with ASME B31.3 Para.345.4 and follow engineering requirement for
test pressure.

- Piping Pressure test shall be performed with calibrated Pressure Gauge.

- Measures shall be taken not to allow air to remain in the high points of the
piping system during hydrostatic testing.

- The test pressure shall be maintained for a sufficient length of time to permit
visual examination to be made on all surfaces, welds and connections, but not
less than ten minutes. During pressurization period and if detected any leak by
not increasing the pressure, no one is authorized to touch the line under
pressure to tight bolts or fittings unless the pressure on the line get dropped down
to 2 bars. Calibrated / certified gauges of recording (pressure) shall be used for
hydrostatic tests.

- The range of pressure gauge shall not be less than 1.5 times pressure (should
be falling between 1/3 to 2/3 of maximum pressure). All equipment shall have
current certification
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3. Test Record
- Test Record shall be made of each piping system test.
These records after completed shall be submitted as part of
the test and inspection certificates which are required for
mechanical completion. Test pressure record shall be signed
before and after pressure test. All test records shall be
added in the test package records before hand over to the
Company. Test register shall be established to monitor
status and progress.
- Test results of the pressure test shall be prepared as an
attached form of the test record ( Barton Chart )
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4. WRAPPING AND COATING MATERIAL

Wrapping material for underground piping:
- Wrapping tape black inner : POLYKEN 980-20
- Wrapping tape white outer : POLYKEN 955-20
- Primer Coating : POLYKEN PRIMER 1027
See Attacment Data sheet.

4.1. APPLICATION COATING AND WRAPPING PROCEDURE

Surface Preparation
 Wipe of all moisture, oil, and grease from the surfaces
 Eliminate sharp projections, if any
 Completely clean and eliminate surface deposits (scaling, rust, dirt contaminants and foreign
matter, etc) from the surfaces power tools.

Coating of Primer
An adequate amount of primer shall be evenly applied to the surfaces using waste cloth, knives, and
rollers or brushed. In other words, neither a large amount of primer shall be applies npr unquoted
portions allowed to remain. Also, primer shall not be sprayed or dropped expect on the coating
surfaces. Application of primer shall be in accordance with manufacturer’s recommendations.

Tapping of Filler Materials

 Mastic shall be used at irregular parts of piping such as flanges, bolts and nuts, valves and other
fitting etc.
 Mastic shall be tamped in the concave sides and smoothed-out by hand or trowel
 Mastic shall be applied to corners at a gradient of about 45˚ and also applied convex portions so
as to be covered at a gradient of about 450 for smooth wrapping.
 Soft bed of polyurethane shall be put between wrapped piping and supports for protection of the
wrapping piping. Soft bed of sand or aggregate-free clean oil shall be prepared prior to placement
of pipe. Bell holes shall be hand dug around welded joints to expose the joints for hydro testing,
and to allow application of coating. Following final testing and coating inspection, these areas
shall be filled by hand.

Wrapping
Wrapping inner wrap tape shall be conducted when the primer paste has been half-dried. Wrapping
shall be completed where the primer paste has been coated on that day, and the primer-coated
surfaced shall not be left without wrapping to the following day.
 Straight pipes, elbows and tees, etc.
a) The tape shall be applied to ensure uniformity of tension and spiral direction during application
by manual or using wrapping tools.
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Basically apply in double layer, completely overlapping tape on the starting and ending portions
of the piping. The tape wrapping shall be finished on the side of the piping where the end of
the tape faces downward. These ends shall be cut using cutters or knives.

 Flanges, Valves, and other fittings

Cut tape to adequate lengths according to the configuration of the surfaces to be wrapped, and
apply these prices of the tape to the surfaces tightly according to the overlapping allowance
specified in the manufacturer’s specification.
 Welding connections
Apply in double layers, 4 inch. (100mm) wide tape to the weld line tightly as stretching it.
Subsequently, the same wrapping procedure as that for straight pipes, elbows and tees shall be
applied. Overload existing wrap 1 inch. (25 mm)
 After the straight pipe is wrapped as aforesaid, insert the said wrapped pipe into the penetration
hole and fix the pipe in position. Clearance between the pipe and the hole shall be filled with mastic.
 Riser portion
Wrapping shall be applied to the riser portion of the underground pipe (include pipe, elbow,
tees, flanges, valves and other fitting) up to 300 mm from ground level. Tape shall be wrapped
upward from the bottom of the piping.
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®
980 / 955 POLYKEN® 980 / 955
METHOD STATEMENT FOR PIPE UNDRGROUND
WRAPPING & TESTING

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METHOD STATEMENT FOR PIPE UNDRGROUND
WRAPPING & TESTING

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6. Holiday Test

6.1. Scope Of Work

This procedure is used to detect all defect of line pipe field joint coating i.e.
dimples, scratches, punctures, bum holes, holidays or foreign matter trapped under, the
applied field joint coating of welding joint and coating or wrapping line pipe for underground
pipeline before buried

6.2. Holiday Test Personel

Shall be trained or have experience personnel to perform holiday detector test activity for
coating or wrapping line pipe. QC inspector shall be witness and issue daily Holiday
test report.

6.3. EQUIPMENTS

• SPY Holiday Detector C/W External Ring and Brush Electrode

• Solid marker
• Hand Glove
• Clothes

6.4. INSPECTION METHOD

• All coated and wrapping pipe shall be inspected according to attachment-1 in the GJE spec GJE-
DED-PIP-SPC-009 for Specification of Wrapping for Pipe and Field Joint.
• QC inspector shall be make sure all coating or wrapping line pipe has free from defect or pin hold.
• Check Holiday test equipment before using, Ampere range, Voltage range calibration, brush
condition, etc
• The minimum detector voltage should be set at 12,500 volts for that determined by the formula,
whichever is greater.
• V = 7850 (t)½ Where "t" are specified minimum coating thickness in (mm).
• And ensure that cable of the equipment is properly functioning (earth all time during testing).
• Holiday tester shall be calibrated with crest meter (calibration equipment) before used.
• The detector electrodes would be sized and operated such to be in direct contact with the coated
surface at all times and moved back and forth on the surface being tested.
• Continuity should be maintained between the detector ground electrode through the earth or
connected directly to the pipe steel should dry soil condition warrant.
• The travel rate of holiday detector shall be not more than 9 - 18 meter per minute. And neither shall
be detector be left stationary while power is on.
• In either case the pipe steel should be grounded.
• All holidays will be clearly marked, repaired and retest.
• Ensure pipe is marked with suitable marker if Holiday test indicate pinhole (defect/un properly
coated), repair immediately and re-holiday tested.
• After lowering the pipe ensure that the area of hoist band is free from damage and check by
holiday test if required
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6.5. ACCEPTANCE CRITERIA

The acceptance criteria as following for :

• Visual Inspection : Surface of wrapping or coated pipe shall be smooth and
no peeling.
• Holiday inspection : No detection of pinholes on the wrapping or coated pipe
during holiday test inspection.

6.6. INSPECTION AND DOCUMENTATION

Final inspection will be done immediately prior to lowering the pipe into the ditch. QC
Inspector prepares the Holiday Test Report for every joint and will report to GJE for sign and
approval.
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