MMP NICKEL SMELTER PROJECT

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PROJECT NAME : MMP NICKEL SMELTER

WORK PACKAGE : LUMP SUMP EPC SWRO PACKAGE
COMPANY : PT. MITRA MURNI PERKASA
CONTRACTOR : PT. GAPURA LIQUA SOLUTIONS
PROJECT LOCATION : TELUK WARU, BALIKPAPAN - KALIMANTAN TIMUR
CONTRACT NO. : 040/LGL/MMP-GLS/VI/2023

0 11-07-23 Issued For Construction RMW YKL DMR

PT. GLS PT. GLS PT. GLS
Rev. Date Description
Prepare Checked Approved

Consultant: This document embodies proprietary information of PT. MITRA MURNI PERKASA this document or 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. MITRA MURNI PERKASA.

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REVISION SHEET DESCRIPTION

NO PAGE SUBJECT DESCRIPTION OF CHANGE

1 All IFA First submission for approval.

2 1 RE-IFA Revision Cover and numbering document
3 8 RE-IFA Revision Test Block Number
4 11 RE-IFA Revision Writing

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TABLE OF CONTENTS

REVISION SHEET DESCRIPTION ................................................................................................ 2

TABLE OF CONTENTS ............................................................................................................... 3
1 GENERAL .......................................................................................................................... 4
1.1 PPROJECT SUMMARY ............................................................................................................. 4
1.2 PROJECT LOCATION................................................................................................................ 4
1.3 OBJECTIVE.............................................................................................................................. 4
1.4 SCOPE OF WORK .................................................................................................................... 4
1.5 ABBREVIATIONS & DEFINITIONS............................................................................................. 5
1.6 REFERENCES........................................................................................................................... 5
1.7 GENERAL REQUIREMENT ....................................................................................................... 5
2 HEALTH, SAFETY AND ENVIRONMENTAL CONTROL ......................................................... 6
3 WORK IMPLEMENTATION ................................................................................................ 6
3.1 PRESSURE TEST EQUIPMENT .................................................................................................. 6
3.2 PREPARATION ........................................................................................................................ 7
3.2.1 Documents Preparation ............................................................................................. 7
3.2.2 Technical Preparation ................................................................................................ 8
3.3 TESTING PERFORMANCE ........................................................................................................ 9
3.3.1 Test ........................................................................................................................... 9
3.3.2 Pressurizing Chart During Testing............................................................................ 10
3.3.3 Acceptance Criterion................................................................................................ 11
3.3.4 Draining ................................................................................................................... 11
3.3.5 Repairs .................................................................................................................... 11
3.3.6 Records ................................................................................................................... 11
3.3.7 Post Test ................................................................................................................. 11
4 ATTACHMENT ................................................................................................................. 12
ATTACHMENT - HYDROTEST RECORD FORM......................................................................... 12

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1 GENERAL

1.1 PPROJECT SUMMARY

PT. MITRA MURNI PERKASA (MMP) will build 2 production line Ni Matte Smelter at Balikpapan
Regency, East Kalimantan Province. This Company is committed to comprehensively developing
Indonesia’s rich Nickel Ore resources with a complete industrial chain of nickel ore mining,
smelting and seaborne export.

Figure 1-1 Project Location

1.2 PROJECT LOCATION

The Site Location is at Kariangau Industrial area, West of Balikpapan, about 27 km from
Balikpapan City. Its site can be reached by plane from Jakarta by 2 hour-direct flight to
Balikpapan or transit at Makassar. From Balikpapan, the site can be reached by sea for about
30 minutes or by land for about 2 hours through substandard road condition. The distance from
Balikpapan City to site is about 28 km by road.

1.3 OBJECTIVE
This document contains the Work Implementation Method and Implementation Schedule that
will be implemented by PT. Gapura Liqua Solutions on Supply & Install of SWRO – MMP Nickel
Smelter Project at Balikpapan.

1.4 SCOPE OF WORK

This procedure covers for application of Hydrotest of complete steel piping for Supply & Install
of SWRO – MMP Nickel Smelter Project at Balikpapan.

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1.5 ABBREVIATIONS & DEFINITIONS

OWNER PT. MITRA MURNI PERKASA

CONTRACTOR PT. GAPURA LIQUA SOLUTIONS

SUB CONTRACTOR Subcontractor to PT GAPURA LIQUA SOLUTIONS for Detail

Engineering, Fabrication, Construction Engineering and
Installation

VENDOR Organization, manufacturer, or supplier to whom Purchase

Order is issued for the supply of material, equipment, and
service

Project Supply & Install WTP SWRO - MMP NICKEL SMELTER

PROJECT

1.6 REFERENCES
MMP001-210-WS-SPC-4206 Piping Specification
MMP001-210-WS-LST-4208 Piping Line List
MMP001-210-WS-DWG-4223 Piping Isometric Drawing
ASME B31.3 Process Piping
ASME B16.5 Pipe Flange and Flanged Fittings

1.7 GENERAL REQUIREMENT

Hydrotest piping shall be conduct on all pressure envelopes after:
• All fabrication has been completed.
• All NDE have been performed.
• Vents shall be provided at the piping in the position in which it is to be tested to purge
possible air pockets while the piping is filling.
• Calibrated gauge having minimum range 1.5 to 4 of test pressure to be used. Two pressure
gauge shall be provided for pressure test and one of them shall be located at the end pipe,
in the testing position and one of them shall be for recording.

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• When pressure test done the surface shall be used the thermometer to measure metal
temperature during examination.
• Before the hydrostatic testing, Ensure internal of piping free from, welding slag and other
foreign material.
• All of Piping shall be hydrostatically tested as per drawing and the holding time pressure
shall be maintained for minimum of 60 minutes.
• Pressure recorder (pressure time recording device and temperature record) shall be
provided with calibrated condition.
• Girth welds and other fabrication welds will not be painted or coated prior to hydro testing.
• The QC Inspector is responsible for ensuring that Hydrotest is conducted in accordance with
relevant job instructions which conform to OWNER specification or approved procedure.

2 HEALTH, SAFETY AND ENVIRONMENTAL CONTROL

1. Make sure the SIK (Work Permit) has been signed by all parties.
2. Use PPE (Personal Protective Equipment) appropriate to the job.
3. Perform a Safety Talk before work begins.
4. Check the work area for hazards.
5. Perform Equipment Inspection to ensure equipment is in a safe condition.
6. Pay attention to the drainage channel and its relationship with environmental
damage.
7. Do the cleaning of the remaining work materials.
8. All work refers to Contractor's HSE procedures.

3 WORK IMPLEMENTATION

3.1 PRESSURE TEST EQUIPMENT

Minimum test equipment to be prepared before work start:
a) Pressure gauges
b) Air Compressor

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c) Hand Pump
d) Barton chart/pressure recorder
e) Dead weight tester (DWT)
f) Temperature indicator
g) Pipes, valves, and hose arrangements.
h) Communication tools (if needed)
i) Water tanks
All instrument equipment must have a calibration certificate that is still valid and functioning
properly.

3.2 PREPARATION

3.2.1 Documents Preparation

2.2.1.1 General

The piping hydrotest is carried out in accordance with the piping line list following
the project specifications and or approved procedure.

2.2.1.2 Test Block Diagram

Test block diagram shall be prepared in accordance with the approved P&ID and
must contain information as follow:
• Test Block
• Test Block Number
• Test Fluid
• Test Pressure
• Design Pressure and Design Temperature
• Blind and isolation valve location
• Pressure and blowing point location

2.2.1.3 Test Block Number

The test block numbering is as shown below:

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210 – TB – A1 – 00Y

Serial No.
Fluid Symbol
Unit No. based on P&ID
Test Block

3.2.2 Technical Preparation

2.2.2.1 Test Fluid Criteria

• All piping system shall be hydrotest except for the Instrument air pipe & fittings
shall be tested with air as the medium.
• The sea water is prohibited to be used.
• The test medium shall be fresh and clean water.

2.2.2.2 Test Block Diagram

• The Test Block to be tested should be marked with a colored pen on the Test
Block diagram.
• The CONTRACTOR must adapt the Test Block diagram according to the actual line
to be tested.

2.2.2.3 Pressure Gauge

• At least 2 pressure gauges must be used. One is installed near the low point of
the test block while the other is installed at the high point of the test block.
• The pressure gauge used must be calibrated and attached with a calibration
certificate before testing.

2.2.2.4 Line Piping Final Check

• All pipe connections have been completed.

• All openings in the component shall be plugged, capped or valved.
• All piping has been line checked according to the Test block, P&ID, layout
drawing, and punch list.

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• All drain plugs and grease fittings attached to the valve must be closed prior to
testing.
• Vent shall be provided at all high points of the tested section to purge air pockets
while it is being filled.
• Test block must be confirmed for the items below before testing;
• All supporting structures are installed (if required).
• If there is Spring support, make sure it is locked.
• Safety valves, regulator, flow meter, rupture discs and other inline instruments
shall be removed, blinded or gagged.
• Valves and control valves shall be removed.
• The test block should be isolated from rotary equipment by disconnecting the
nozzle.
• Instrument Equipment should be blocked with a blind flange on the inlet.
• Temporary supports must be installed but cannot be permanent.
• Temporary scaffolding, platforms and ladders etc. shall be provided for leak
inspection purposes.

3.3 TESTING PERFORMANCE

Hydrotest work to be carried out with the criteria below unless there are other rules:

3.3.1 Test

• Filling water in the Test Block use a temporary pipe and there is a vent in each of the
highest parts and a drain in the lower part.
• The pressure to be controlled must not exceed the test pressure with the pressure
gauge located at the low end. The minimum testing pressure limit is at least 1.5 x
Design Pressure and a maximum of 95% of the SMYS (Specified Minimum Yield
Strength) of the weakest material.
• Apply pressure with a pressure pump slowly and continuously up to 50% of the Design
Pressure and hold for 10 minutes. Hold at this point and begin examination for leaks.
Check all valves and pipe connections.

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• If there is no leak, continue to apply pressure to 100% of the testing pressure. Hold at
this point and begin examination for leaks. Maintain the stabilizing pressure. Check
all valves and pipe connections.
• After stabilizing the pressure, the test pressure is held for at least 1 hours.
• Pressure must be maintained for a period of time for the pressure to stabilize (steady
state). The length of the time period depends on several factors, for example; the
amount of stable pressure, the time from filling to pressing, the temperature
difference between the filling water and its surroundings, the type and thickness of
the coating (if any), and the water depth at each end of the test.
• If there is a drop from the temperature and pressure stability, then repeated pressure
is applied to a certain pressure before shutting down and stopping for testing. The
addition of water is measured and recorded appropriately.
• Further to the acceptance of the pressure test, the depressurization of the tested
section will start. The depressurization shall be controlled. Control of depressurization
may be made using the bleed valve. Vents may open during draining.

3.3.2 Pressurizing Chart During Testing

Pressure
D E
100%
TP 60 MINUTES

B C F G
50%
10 MINUTES 10 MINUTES

H
Time
A

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3.3.3 Acceptance Criteria

The test is declared acceptable if there is no indication of leakage, pressure change and
deformation during the test and holding time by visual examination.
If there is a leak, then it must be repaired and shall be tested again.

3.3.4 Draining

Upon completion of hydrotesting, piping shall be drained and thoroughly cleaned both
outside and inside.

3.3.5 Repairs

If leaks found at the weld area during hydrostatic test, the areas of leakage shall be marked
and repairs made using applicable and approved Welding Procedure Specification (WPS). Re-
testing shall be performed after the repair is accepted by Client.

3.3.6 Records

• Hydrostatic Test Record shall be completed, reviewed and approved by Client.

• Test pressure shall be recorded by automatic recording device.

3.3.7 Post Test

The following items should be reinstalled after testing is complete:

• Dismantling of the pump. Vents valves, drain valves to be removed and plugged.
• Final check all items completed.
• Reinstatement report (if any) signed by all parties.
• All parts removed to be reassembled.
• Automatic valve and other instruments to be reinstalled.
• The test blind must be removed.
• All temporary supports to be removed.

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4 ATTACHMENT

• Hydrotest Record Form

ATTACHMENT - HYDROTEST RECORD FORM

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 Date :
QI - L.02
PIPING INSPECTION
Test Package No. :

Project No. :
SUBJECT: PRESSURE TEST RECORD

PROJECT : MMP NICKEL SMELTER PROJECT

WORK PACKAGE : SUPPLY & INSTALL WTP SWRO
LOCATION : TELUK WARU, BALIKPAPAN - KALIMANTAN TIMUR
AREA / UNIT :
TEST PACKAGE NO. :

LINE UNDER TEST :

P & ID. NO :

DESIGN PRESSURE : Bar g

TEST PRESSURE : Bar g
DURATION OF TEST : hours/minutes

Start of Test End of Test

Time (Hours)
Pressure (Bar g)
Temperature (oC)

Yes N/A
RECORDING INST. / PRESSURE GAUGE : CHECK CALIBRATION

TEST RESULT : ACCEPTED / REJECTED

Yes N/A
ATTACHED : PRESSURE AND TEMPERATURE GAUGE
: TEST PORTION SCHEMATIC DRAWING ( P& ID Marked Testing )

Remarks :

Actual Pressure = …………… (Kg/cm2/G)/bar

holding time
Test Pressure = ………………. (Kg/cm2/G)/bar

Design Pressure = ………… (Kg/cm2/G)/bar

Prepared by Checked by Reviewed/Witnessed by

SUBCONTRACTOR CONTRACTOR OWNER
Print Name

Signature

Date