Ks KSF Exe Mmhe 999 Con PRC 0212 0

PROCEDURE NO.
:
PROJECT SPECIFIC PROCEDURE PSP-KSF-212
P-EDMS DOCUMENT NO. :
KS-KSF-EXE-MMHE-999-
UPSTREAM FACILITIES CON-PRC-0212
REVISION : 0
FLUSHING AND HYDROTEST PROCEDURE OF EPC FLARE STRUCTURE
FOR
PETRONAS CARIGALI SDN BHD
KUALA LUMPUR
CONTRACTOR COMPANY
PREPARED BY REVIEWED BY APPROVED BY REVIEWED BY APPROVED BY
REV
DATE
NO. NAME SIGN DATE NAME SIGN DATE NAME SIGN DATE NAME SIGN DATE NAME SIGN DATE
0 11.10.22 MN 11.10 MRI 11.10 PPC 11.10

FLUSHING AND HYDROTEST PROCEDURE OF PROCEDURE NO. :
EPC FLARE STRUCTURE PSP-KSF-202
UPSTREAM FACILITIES CON-PRC-0202
REVISION : 0
REVISION LIST
SECTION REV. DATE DESCRIPTION OF AMENDMENT

All A 07.02.2022 First Draft – Issue for Review
All B 08.04.2022 Re-issue for Review
0 11.10.2022 Final
PROCEDURE NO. :
FLUSHING AND HYDROTEST PROCEDURE OF PSP-KSF-212
EPC FLARE STRUCTURE
KS-KSF-EXE-MMHE-999-CON-
PRC-0212
UPSTREAM FACILITIES REVISION : 0
PAGE : 1 of 38
TABLE OF CONTENTS
SECTION DESCRIPTION PAGE

1.0 PURPOSE ............................................................................................................ 2
1.1 Project Overview ...................................................................................... 2
1.2 Objectives ............................................................................................... 3
2.0 SCOPE ................................................................................................................ 3
3.0 REFERENCES ....................................................................................................... 4
4.0 DEFINITION & ABBREVIATIONS ............................................................................. 4
4.1 Abbreviations ........................................................................................... 4
4.2 Definition and Term .................................................................................. 4
5.0 PROCEDURES ...................................................................................................... 5
5.1 General ................................................................................................... 5
5.2 Roles and Responsibilities .......................................................................... 6
5.3 Equipment and Materials for Hydrotest / Pneumatic Test ............................. 10
5.4 Flushing Procedure ................................................................................. 11
5.5 Hydrotest Medium .................................................................................. 12
5.6 Hydrotest Procedure ............................................................................... 12
5.7 Pneumatic Test Procedure ....................................................................... 18
5.8 Documentation....................................................................................... 18
5.9 Rectification of Leaks .............................................................................. 19
5.10 Blow Dry and Preservation ....................................................................... 19
5.11 Safety Precaution ................................................................................... 20
6.0 SPECIAL REQUIREMENTS .................................................................................... 21
7.0 RECORDS ......................................................................................................... 22
8.0 APPENDICES ..................................................................................................... 22
PROCEDURE NO. :
EPC FLARE STRUCTURE P-EDMS DOCUMENT NO. :
CON-PRC-0212
PAGE : 2 of 38
1.0 PURPOSE
This procedure outlines the flushing process and hydro testing requirements, to ensure that
the piping system verify the integrity of welds, mechanical strength and quality and material
in the system and clean from debris or unwanted items before the hydrotest and also to detect
leaks on bolted and welded joints and defects in material itself for PROVISION OF
ENGINEERING, PROCUREMENT AND CONSTRUCTION (EPC) OF FLARE PLATFORM FOR
KASAWARI GAS DEVELOPMENT PROJECT.
1.1 Project Overview
PETRONAS Carigali Sdn Bhd (PETRONAS Carigali) assumed the operatorship of Block SK316
upon signing the Production Sharing Contract (PSC) on 5 April 2012. The participating interest
in the Block is 90% owned by PETRONAS Carigali and 10% owned by E&P Malaysia Venture
(EPMV).
Kasawari Field is located in Block SK316 with a water depth of 108 m, approximately 200 km
offshore from PETRONAS LNG Complex (PLC) in Bintulu, Sarawak. PETRONAS Carigali is
undertaking Kasawari Development Project to evacuate Block SK316 sales gas from Central
Luconia Province Basin to PETRONAS LNG Complex (PLC) via E11R-A platform.
Kasawari Complex will consist of one (1) Central Processing Platform (CPP) linked via two (2)
bridges to one (1) 9-slot Wellhead Platform (WHP) and one (1) Flare structure respectively.
The sales gas will be processed, custody metered and compressed at CPP before being
exported to a new platform (E11R-AA) that bridge-links to existing Riser Platform (E11R-A) 81
km away via 28” pipeline. From E11R-A, the sales gas will be sent to Slugcatcher-1 via existing
Trunkline 1 and Trunkline 2.
Kasawari Development Project comprises the following facilities:
a) Kasawari Central Processing Platform (CPP);

b) Kasawari Wellhead Platform (WHP) with bridge link to Kasawari CPP;
c) Flare Structure (FS) with bridge link to Kasawari CPP;
d) Export Pipeline (CPP to new riser platform E11R-AA);
e) Telecommunication tie-in at existing NC3 CPP;
f) Existing platform modification and Host Tie-In at E11R-A;
g) New riser platform E11R-AA with new bridge link between E11R-A and E11R-AA.
A total of six (6) wells will be drilled to produce up to 900MMSCFD of gross gas.
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Figure 1 : Kasawari Schematic Diagram
1.2 Objectives
The Objective of establishing this document is to outline the flushing process and hydro testing
requirements accordance with the expectation of the Contract requirement for PROVISION
OF ENGINEERING, PROCUREMENT AND CONSTRUCTION (EPC) OF FLARE PLATFORM FOR
2.0 SCOPE
This procedure applied to all hydrotest and pneumatic testing (internal and official testing) of
piping systems and identifies the methods, tasks, scope and criteria for testing of the installed
piping systems. This shall cover the work preparation, execution, equipment used for flushing,
hydrotest, pneumatic test, work activities and safety requirement for the PROVISION OF
ENGINEERING, PROCUREMENT, AND CONSTRUCTION (EPC) OF FLARE PLATFORM FOR
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3.0 REFERENCES
i. ASME B31.3 (2018) - Process Piping

ii. ASME PCC-2 (2018) - Repair of Pressure Equipment and Piping
iii. CSP-13 (July, 2020) - Bolt Tightening Procedure
iv. PTS 12.30.02 (Dec, 2017) - Piping General Requirement
v. CSP-22 (Sept, 2011) - Flushing/Hydrotest Procedure
vi. PTS 12.30.05 (Jan, 2017) - Shop and Field Fabrication of Piping
vii. CSP-20 (June, 2014) - Testing and Pre-Commissioning Guideline
viii. KS-GEN-EXE-MMHE-999- - Piping Design Basis
PIP-DES-0001
4.0 DEFINITION & ABBREVIATIONS

4.1 Abbreviations
Abbreviation Description
NDE Non-Destructive Testing
QA/QC Quality Assurance / Quality Control
PTW Permit-to-Work
JHA Job Hazard Analysis
P&ID Piping and Instrument Diagram
NPS Nominal Pipe Size
Hydrotest Hydrostatic Pressure Testing
ASME American Society of Mechanical Engineers
API American Petroleum Institute
IFC Issue for Construction
NOI Notice of Inspection
NPS Nominal Pipe Size
4.2 Definition and Term
COMPANY PETRONAS Carigali Sdn. Bhd. (PCSB)

CONTRACTOR Malaysia Marine And Heavy Engineering Sdn. Bhd (MMHE)
SUBCONTRACTOR OceanMight Sdn Bhd (OMSB)
Shall refers to mandatory requirement
Should refers to a recommendation
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5.0 PROCEDURES
5.1 General
5.1.1 No flushing and hydrotest/pneumatic test shall be carried out without the approval
of COMPANY.
5.1.2 Test packs shall be prepared and submitted for CONTRACTOR / COMPANY review and
approval one month prior to pressure testing. To ensure that the test packs has been
submitted to CONTRACTOR / COMPANY for review / approval.
5.1.3 Prior to flushing and hydrotest / pneumatic test of the piping system or components,
the line completion checklist shall be completed. Line checking shall be jointly carried
out by SUBCONTRACTOR and CONTRACTOR / COMPANY respresentatives.
5.1.4 All pipes, fittings and support as well as temporary item shall be checked against
approved drawings to ensure that piping system can withstand the hydrotest /
pneumatic test pressure.
5.1.5 All punch list items found (Category A) during line checking shall be completed and all
NDE shall be cleared before hydrotest / pneumatic test. All hot works shall be
completed prior to hydrotest and pneumatic test. Category A punchlist items shall be
completed before it is safe to proceed for hydrotest. Category A punchlist is related
with integrity such as straightness of pipe, fulfil of NDE requirements and any hot
work attached to piping system.
5.1.6 Flushing shall be carried out to ensure that the piping interior is free from debris, dirt,
welding slag, welding rods, grease and scales before hydrotest / pneumatic test. Only
competent qualified personnel or personnel undergoing training under the direct
supervision of a competent qualified person shall carry out the flushing. The following
piping items and equipment shall be excluded or isolated from flushing and pressure
testing activity:
a) Rotating machinery such as pump and compressor

b) Filter elements of strainers
c) Pressure relieving devices such as rupture discs and pressure relief valves
d) Vessels and exchangers that have already been tested by the suppliers
e) Any equipment that does not have a specified test pressure at least as great as the
piping test pressure
f) All instruments including but not limited to pressure gauges, pressure transmitters,
flow elements, level gauges, level instruments, temperature gauges and
temperature transmitters
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g) Expansion joints
h) Orifice plates / venture tubes
i) Flow nozzles and deluge nozzles
5.1.7 All in-line equipment or devices which might damage or hamper the flushing and
testing activity shall be removed from the system. All sensitive in-line and on-line
instrumentation items shall be replaced with dummy spool or isolated.
5.1.8 High point vents and low point drains shall be determined prior to flushing and
hydrotest / pneumatic test of the piping system and shall be identified in the
respective test packages.
5.1.9 Seawater shall not be used for flushing and hydrotest. The medium to be use shall be
potable water.
5.1.10 Prior to flushing, the work area shall be cordoned off and notices displaying 'Warning
– Flushing / Hydrotest / Pneumatic Test in Progress' positioned around the area clearly
identifying the process and warning personnel to stay clear.
5.1.11 All piping joints and surfaces should be dry before the commencement of the hydro
test. Flushing/ Hydrotest certificate should be included in test pack.
5.2 Roles and Responsibilities
5.2.1 Listed herewith are responsibilities for each party including process flow during
hydrotest / pneumatic test activity.
Phase Party Scope of Work

CMT Engineer - To develop hydrotest / pneumatic test limit to
ensure all lines are captured in the package.
- To prepare hydrotest / pneumatic test pack and
pressurization graph.
- To ensure pipe installed as per drawing.
- To ensure SUBCONTRACTOR perform the
hydrotest / pneumatic test are following HSE
requirements.
- To ensure hydrotest / pneumatic test are
conducted as per procedure.
CMT Supervisor* - To ensure pipe installed as per drawing.
- To ensure SUBCONTRACTOR perform the
hydrotest / pneumatic test are adhering to HSE
requirements.
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- To ensure all temporary item are inspected and

calibrated prior to hydrotest / pneumatic test.
- To ensure all item used for hydrotest / pneumatic
test are within test limit.
QA/QC QC* - To ensure pipe spool fabricated / installed as per
drawing.
- To ensure the test pressure during hydrotest /
pneumatic test is following test package.
- To ensure all item used for hydrotest pneumatic
HSE HSE* - To ensure hydrotest / pneumatic test activity are
within proper barricade.
- To ensure and verify hydrotest / pneumatic test
are perform as per requirements.
- To advise and check “Line of Fire” within
hydrotest / pneumatic test area.
Pressure Test Engineer - To prepare all temporary item are inspected and
SUBCONTRACTOR calibrated.
- To ensure hydrotest / pnuematic test are perform
following HSE requirements.
Foreman* - To ensure all temporary item are inspected and
calibrated prior to hydrotest / pneumatic test
activity.
- To ensure hydrotest / pneumatic test are perform
Hydrotester* / - To ensure all temporary item are inspected and
Pneumatic Tester* calibrated prior to hydrotest / pneumatic test
activity.
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- To set up and perform hydrotest / pneumatic test

activity as per procedure.
Technician* - To ensure all temporary item are inspected and
calibrated prior to hydrotest / pneumatic test
activity.
- To set up and perform hydrotest / pneumatic test
activity as per procedure.
- To check for any leakage found in the system.
QC Tech* - To ensure pipe spool fabricated / installed as per
drawing.
- To ensure the test pressure during hydrotest /
pneumatic test is following test package.
- To ensure all item used for hydrotest pneumatic
HSE* - To ensure hydrotest / pneumatic test activity are
within proper barricade.
- To ensure and verify hydrotest / pneumatic test
are perform as per requirements.
- To advise and check “Line of Fire” within
hydrotest / pneumatic test area.
* Personnel that are allowed to enter the barricaded hydrotest / pneumatic test area.
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5.3 Equipment and Materials for Hydrotest / Pneumatic Test
5.3.1 Testing equipment for hydrotest / pneumatic test are listed but not limited as below:-
a) Temporary rated spools and bolts and nuts

b) Temporary rated blind flanges and gasket
c) Plug and caps
d) Manifold
e) Needle valve for high pressure
f) Direct hose from water source
g) Flushing hoses
h) High pressure hoses
i) Air compressor / air dryer
j) Hand pump / pneumatic pressurize pump
k) Rated tubing and fittings / rated temporary spool used for drain and vent
l) Pressure gauges
m) Temperature and pressure chart recorder
n) Safety relief valve
o) Flushing pump
p) Wire mesh filter (10µm)
5.3.2 Temporary spools, fittings and valve shall be rated as system piping class or higher.
Calculation for maximum pressure for temporary item shall be calculate and approved
by engineering.
5.3.3 Effective threaded engagement joint for temporary spools and fitting shall follow as
per ASME 1.20.1 Table 2. For ½“ joint connection, number of effective threaded are
4.5 threads.
5.3.4 PTFE or Teflon tape shall be used to avoid leaking at threaded by applying with thin
wrap(4-6 layer of tape).
5.3.5 Physical condition of the temporary rated spool, fittings and valve shall be visually
inspected monthly.
5.3.6 All pressure gauge and recorder shall be calibrated. The scale range for pressure
gauge shall be between 1.5 and 2 times the test pressure. The scale range pressure
recorder shall be between 50% to 75% of paper chart.
5.3.7 Safety relieve valve for the hydrotest shall be set at 1.1 maximum hydrotest pressure
of each piping class.
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5.3.8 All the above items shall be inspected by the SUBCONTRACTOR and CONTRACTOR /
COMPANY representative prior to every flushing and testing activities.
5.3.9 Calibration of testing equipment shall be properly documented, and validity of

certificates shall be verified by CONTRACTOR and COMPANY representative prior to
the test. All test equipment shall be calibrated and recalibrated immediately prior to
the pressure testing and maximum duration between re-calibration shall be 6 months.
5.3.10 After hydrotest/pneumatic test has been carried out all temporary items will be
removed and continue with preservation and reinstatement.
5.3.11 All piping fabrication works like welding, inspection & NDE to be completed and
attached to the test report.
5.3.12 Usage of any non-standard (non-rated) item shall be calculated / approved by

Engineering / COMPANY. Non-standard (non-rated) fabricated item shall be as per
approved drawing and 100% inspected by CONTRACTOR / COMPANY. No handmade
tool equipment shall be used. The calculation for blank and blind for pressure test can
be refer at Appendix VII.
5.4 Flushing Procedure
5.4.1 For piping not permitted to be flushed with water due to process / operational
reasons, air or suitable flushing medium can be used upon CONTRACTOR / COMPANY
approval.
5.4.2 The piping system and its support shall be checked to be able to sustain the load
during flushing and temporary support to be added when necessary.
5.4.3 Flushing water shall be from potable water and shall be free from dirt and impurities
as per test water quality to meet requirement as per test water specification in item
5.5 Hydrotest Medium.
5.4.4 Prior to flushing activities, all valves, instrument and inline strainers and orifice shall
be removed and to be to replace with dummy spools if necessary.
5.4.5 Open the lowest drain point and start the pump to flush water from the system down
to the discharge overboard with flow velocity 3 m/s as minimum.
5.4.6 For pneumatic tested piping,
a) Flushing (quick decompression method) to be conducted after pneumatic test

is conducted.
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b) Quick decompression method of air blowing will be used for cleaning. Piping
system to be filled with compressed air up to 6 bar pressure (maximum
compressed air pressure). After pressurization, quickly release the air using
valve installed at one end of piping (for 30” and 36” line, 4” or 6” of butterfly
valve will be used) and rapid depressurization of piping blows debris out. The
existing valves of piping system shall not be used for this purpose. White cloth
to be used to monitor presence of debris. White cloth shall be clear from debris
which indicate the pipe is clean from dirt and impurities.
5.4.7 Flush all lines from high to low suitable points to ensure thoroughly flushing.
5.4.8 During flushing operation, open necessary intermediate drains to ensure cleanliness
at stub points and dead pockets.
5.4.9 Close all intermediate vents and continue flushing/cleaning operation until the
water/air flowing at the lowest drain point is clean by using 10µm mesh filter.
5.4.10 When the flushing water/air discharge is clear and free from any debris or foreign
material to the satisfaction of COMPANY representative, stop the pump/air
compressor and close the valves downstream of the pump/compressed air supply
discharge/and draining point.
5.4.11 Disconnect the pump from the system and retain the system full of water, ready to
continue for hydrotest / full water head test if the water meets the hydrotest / full
water head test medium specifications. If otherwise, the water shall be thoroughly
drained, and the system shall be filled up with the hydrotest / full water head test
medium.
5.5 Hydrotest Medium
5.5.1 The hydrotest medium for piping line is potable water with chlorine content of less
than 50 ppm only. Refer to Appendix I for sample of water test report.
5.6 Hydrotest Procedure
5.6.1 All piping systems are subjected to hydrotest except open systems (atmospheric
pressure) e.g., drains, vents, wastewater or stated otherwise with the consent of
CONTRACTOR / COMPANY approval. Open systems shall perform full water and test.
5.6.2 All flange joint connection shall be tightened as per required torque value by
competent personnel.
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5.6.3 The hydrotest for the system shall be conducted based on ASME 31.3, Section 345.4.2,
where the test pressure is 1.5 times the design pressure and allowable stress ratio,
with holding time of minimum 30 minutes to 1 hour.
5.6.4 Fill in water at the lowest practical point in the system. The filling operation pressure
shall not exceed 1-2 barg.
5.6.5 All vent valves shall be remained open position until there is a steady overflow of
water from the vent valves. (let it run smooth for 1 min)
5.6.6 The sequence of closure vent valves shall be from the lowest to the highest vent point.
5.6.7 During Hydrotest, ball valves shall be half open, globe and gate valves shall be fully
open and check valves shall be defeated by reversing the valves, removing the valve
plates, or replacing the valve with a suitably designed dummy spool or to include
jumper (only if ball valves were including in hydrotest activity).
5.6.8 Setup the hydrotest equipment as per schematic diagram in Figure 1. Process flow as
per below;
Figure 1: Hydrotest Equipment Schematic Diagram
i. Start the test pump and pressurize the system incrementally with respect to the
test pressure.
ii. Carry out line inspection at each increment after 5 minutes interval to stabilize
the pressure and gradually increasing the pressure to the required test pressure.
iii. If there is a significant rise of pressure due to temperature, vent the system
through the drain valve at the manifold to maintain the pressure.
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iv. Figure 3 (I) shows the pressurization steps for system less than 20.7 barg test
pressure. 80% of test pressure shall firstly be achieved. At this stage of 80% of
test pressure, pressure is held for a minimum of 5 minutes for leak inspection.
After that, the system is gradually increased until 100% of test pressure. When
100% of test pressure is achieved, hold it for a minimum of 30 minutes after
stabilization of the system test pressure.
v. Specific pressure test chart for pressurization, holding and de-pressurize as per
Appendix IV.
vi. Once the holding time starts, CONTRACTOR / COMPANY representative shall sign
off the chart to mark the beginning of the pressure holding. Once the holding
time ends, CONTRACTOR /COMPANY representative shall sign off the chart to
mark the end of the pressure holding. The beginning and end time of the holding
time shall be checked to confirm it meet the duration requirements.
vii. On completion of inspection, the pressure shall be reduced gradually to zero (0)
gauge pressure. The depressurizing rate should follow the same rate as
pressurizing. No joint connection shall be open unless it has been checked and
verified that all pressure gauge readings show zero pressure.
viii. Examine the system visually for leaks and any sign of crack throughout the test
and if leaks occur during the process of pressurizing or holding period,
depressurize the line and rectify the leaks.
ix. Stop the test pump and isolate it from the system when the test pressure has
been achieved.
x. After successful completion of the test, depressurize and completely drain the
system and start the purging or blow dry activity.
xi. The pressure and temperature recorder chart shall be signed by both
SUBCONTRACTOR QC inspector and CONTRACTOR / COMPANY representative on
site upon test satisfaction.
xii. After test, remove all temporary materials and reinstate the line as per approved
isometric drawings.
xiii. Flow Chart Hydrotest activity as per below;
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Figure 2: Flow Chart for Hydrotest

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Figure 3: Pressurizing Method and Holding Time (Below 20.7 barg Pressure)
REMARKS:
1) This method is applicable to Test Pressure below 20.7 bar (300 psi)
2) X-axis indicating time is not drawn to scale.
3) Actual pressurizing rate maybe different depending on the pump capacity.
4) The depressurizing rate should follow the same rate as pressurizing (See Appendix IV)
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Figure 4: Pressurizing Method and Holding Time (20.7 Bar and Above)
REMARKS:
1) This method is applicable to Test Pressure of 20.7 bar (300 psi) and above.
2) X-axis indicating the is not drawn-to-scale.
3) Actual pressurizing rate may be different depending on pump capacity.
4) The depressurizing rate may / should follow the same rate of pressurizing.
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5.7 Pneumatic Test Procedure
5.7.1 Based on ASME B31.3 section 345.5.5, the pressure shall be gradually increased until a
gauge pressure that is lesser than one-half of the test pressure of 170kPa (25psi) is
attained, at which a preliminary check shall be made. Subsequently, the pressure then
shall be gradually increased to not more than 50% of the test pressure, at which
another check shall be made, including examination of joints by using snoopy solution.
Thereafter, the pressure shall be gradually increased in steps of 10% until the test
pressure is reached. Details for pressurization, holding and de-pressurize as per
Appendix V.
5.7.2 The test is conducted at a pressure of 1.1 times the design pressure. Refer to ASME
31.3, Section 345.5.5 for the test pressure.
5.7.3 Holding time shall be of minimum 30 minutes to 1 hour.
5.7.4 The pneumatic test applicable for LP Flare (VL), HP Flare – Cold (VH), AGRU Permeate
Gas to Flare (VP) and LP Fuel Gas Distribution (FG) systems of Flare Platform for
Kasawari.
5.7.5 Each test pack shall be identified of the stored energy and safe distance based on ASME
PCC2. Refer to appendix VI for the calculation.
5.8 Documentation
5.8.1 When hydrotest / pneumatic test is completed satisfactory, the following

documentation asd minimum shall be signed by witnessing parties ( SUBCONTRACTOR
and CONTRACTOR / COMPANY representative);
i. Hydrotest / pneumatic test record and checklist (hydrotest / pneumatic test and
flushing acceptance certificate)
ii. Pressure and temperature recorder chart graphs
iii. Water quality certificate
iv. Calibration records for pressure gauge and pressure recorder
v. Weld summary with NDE records
vi. Drawings (isometric, schematic, P&ID and temporary item drawing)
vii. Plot plan (to be identify and agree by all parties during pressure test walkabout)
viii. Pressurization graph as per Appendix V and VI
ix. Stored energy calculation (eardrum rupture and fatality factor)
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5.9 Rectification of Leaks
5.9.1 When there is an indication of leak during pressure test, the following counter measure
shall be taken:
i. Flange Joint Leak

• Depressurize to ambient pressure.
• Retighten the bolts and nuts as per required thightening torque.
• Continue with the pressure test.
If still leaks;
• Depressurize the system to zero (0) gauge pressure.
• Open and dismantle the stud bolts and nuts.
• Check the surface of the flanges and make sure the surface is free from dirt,
impurities or any scratch.
• Bolt-up the joint back with new gasket and tighten the joint as per CSP-13 Bolt
Tightening Procedure.
ii. Weld Joint Leak
• Depressurize the system to zero (0) gauge pressure.
• Open the vent and drain valves and drain of the test medium.
• Identify the leak weld joint.
• Follow CSP-16 Weld Repair and Buttering Procedure and the relevant WPS for
repair weld joint.
• The weld joint must be cleaned and dry before welding.
• Perform NDE and inspection acceptance.
5.9.2 After the rectification works, proceed back with flushing and hydrotest.
5.10 Blow Dry and Preservation
5.10.1 After the system has been completely drained, start performing the blow dry activity
by using integration of compressor and dryer.
5.10.2 For authentic stainless steel and duplex stainless-steel materials piping, system shall
be drain and dried immediately after hydrotest.
5.10.3 The blow dry activity is accepted when the blowing medium/compressed air humidity
is -10 deg (for non-liquid line) and 0 deg or below with no existing water mist for liquid
line.
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5.10.4 Upon completion of blow dry activity, the tested spool/piping system need to be
preserved prior to reinstatement. The open-end pipe/flange face need to be wrap
with plastic/canvas/neoprene rubber or capped to avoid any foreign materials
entered/damages.
5.11 Safety Precaution
5.11.1 Permit to work (PTW) system must be fully adhered in this operation with the
supervisor in-charge of the job will be the responsible person in ensuring that all
activities are carried out safely.
5.11.2 Briefing and awareness of testing procedures/ PTS requirement shall be conducted to
relevant personnel that are involved in the activities.
5.11.3 Only trained and qualified personnel can conduct the flushing and hydrotest and
pneumatic test activities. The supervisor in-charge of the job will conduct a toolbox
talk safety briefing and JSA and HIT card must be read and understood to all the test
team prior to execute any testing activities to remind the hazards involve and
necessary precaution that the testing crew must observe.
5.11.4 Only authorized personnel shall be allowed to stay within the test area during test
activity. Authorized personnel shall not leave the site until the test is successfully
completed. One each of calibrated pressure gauges shall be used at high point and
lower point. Ensure all the in-line ball valves are in half open position if the valves are
included in the test.
5.11.5 During pressure build-up, suitable precaution shall be taken to prevent building up of
excessive pressure and the pressure pump shall be always monitored.
5.11.6 The test area shall be cordoned-off and provided with warning signboards. Warning
signboard shall include test date / test duration / test pressure / tester contact
number and foreman contact number. Barricade shall be provided around area of
testing and only authorized personal are allowed within the vicinity. Barrier shall be
determined and barricaded and verify by SUBCONTRACTOR safety personel prior to
pressure up the test system.
5.11.7 SUBCONTRACTOR to ensure that any supports and/or equipment (temporary or

permanent) do not obstruct the testing. SUBCONTRACTOR shall ensure that the
correct pressure rating for all ancillary fittings is used (i.e. temporary piping, hoses,
blanks, etc.) which can withstand the flushing and pressure test.
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5.11.8 any rectification works shall adhere to item 5.9 Rectification of Leaks. No tightening
of bolts / nuts shall be carried out once the system is pressurize.
5.11.9 Flushing and hydrostatic / pneumatic testing activities are always to be supervised
when pumps are running, and good communications are always to be maintained
with operators. All equipment and tools shall be inspected for safe use before being
mobilized to site. Anti-whip to be installed on connection prior commencement of the
Hydrotest / pneumatic test.
5.11.10 System under test pressure shall be depressurized as per section 5.9 before any work
is done to stop leaks or repair weakness, including the tightening of bolts.
5.11.11 Supervisor to ensure all personnel involved are wearing sufficient PPE.
5.11.12 To avoid line of fire during Hydrotest / pneumatic test activity, sufficient lighting to be
provided for extended hour at night. Nighttime activity must be notified earlier to
CONTRACTOR / COMPANY.
5.11.13 During hydrotest / pneumatic test, a proper communication system such as walkie
talkie is to be provided.
5.11.14 Prior to hydrotest / pneumatic test, the team need to fill a checklist and to ensure all
the item in the checklist has been cleared out before pressurizing the system. Please
refer to the attachment in Appendix II for the hydrotest checklist.
6.0 SPECIAL REQUIREMENTS
Due to the additional hazards associated with the pneumatic testing, the following
additional safety precautions shall be adopted.
i. Pneumatic testing shall not be carried out where the test pressure exceeds 22
bar. For Flare Structure, the pneumatic test pressure is 11 bar.
ii. System temperature shall be monitored carefully during filling to ensure that
localized temperature does not fall below 10 0C.
iii. The manning level shall be strictly enforced; only authorized personnel only can
enter the test area.
iv. The system shall not be inspected for leaks until the system pressure has been
reduced to the design pressure.
v. To include double ear protection especially during joint inspection as per item
5.7.1.
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7.0 RECORDS
For every system tested satisfactory, original copies of hydrostatic / pneumatic test
and flushing records with the required supporting certificates, isometric drawings,
check sheet and other relevant records / reports are to be compiled together as one
pressure test package and progressively submitted by SUBCONTRACTOR for final
documentation.
i. Hydrotest report including chart

ii. Hydrotest package including mark-up drawings
iii. Weld repair and subsequent NDE documentation (if any)
iv. Calibration record verified by parties (SUBCONTRACTOR and CONTRACTOR /
COMPANY)
v. Hydrotest acceptance certificate
8.0 APPENDICES
Appendix I – Sample Water Test Report
Appendix II – Sample Hydrotest Checklist
Appendix III – Sample Inspection Test Record (ITR)
Appendix III – Sample P01 Pipe Work Completion
Appendix IV – Pressurize, holding and de-pressurize for system less than 20.7 bar
Appendix V – Pressurize, holding and de-pressurize for pneumatic test
Appendix VI – Stored Energy & Safe Distance Calculations for Pneumatic Pressure Test
Appendix VII – Blank and Blind Thickness Calculation as per UG-34

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APPENDIX I
Sample Water Test Report
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APPENDIX II
Sample Hydrotest Checklist
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APPENDIX III
Sample Inspection Test Record (ITR)
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APPENDIX III
Sample P01 Pipe Work Completion
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APPENDIX IV
Pressurize, holding and de-pressurize for system less than 20.7 bar
APPENDIX III
PRESSURIZING METHOD
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APPENDIX V
Pressurize, holding and de-pressurize for pneumatic test
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APPENDIX VI
Stored Energy and Safe Distance Calculations for Pneumatic Pressure Test
When air or nitrogen use as test medium, the stored energy of the test system should be calculated
and converted to equivalent kilograms of TNT(Trinitrotoluene) using equation(ASME PCC2) as below:
where :
E = stored energy, J(ft-lb)
Pa = absolute atmospheric pressure, 101kPa(14.7psia)
Pat = absolute test pressure, Pa(psia)
V = total volume under test pressure, m3(ft3)
The maximum stored energy of the test system should not more than 271 000 000 J (200 000 000 ft-
lb).
And minimum distance between all personal and the test system shall follow as per following:
1. R = 30 m for E ≤ 135 500 000 J
2. R = 60 m for 135 500 000 J < E ≤ 271 000 000 J
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APPENDIX VII
Blank and Blind Thickness Calculation as per UG-34
Blind Flange Calculation Based on ASME VIII (UG-34)
𝐶𝑃 𝑊ℎ𝐺
𝑡 = 𝑑√ + 1.9
𝑆𝐸 𝑆𝐸𝑑 3
Where,
d = Diameter, or short span, measured as indicated in Fig. UG-34
P = Internal design pressure (As per KSF Line List)
S = Maximum allowable stress value in tension from applicable table of stress values
E = Joint efficiency, from table UW-12, of any Category A weld as defined in UW-3(a)
W = Total bolt load given for circular heads for Formulas (3) and (4), 2-5(e)
hG = Gasket moment arm, equal to radial distance from centerline of the bolts to the line of the gasket reaction as show in
Table 2-5.2
𝑊𝑚1 = 𝐻 + 𝐻𝑃
𝑊 = 𝑊𝑚1
= 0.785𝐺 2 𝑃 + (2𝑏 𝑥 3.14𝐺𝑚𝑃)
Where,
G = Diameter at location of gasket load reaction. Except as noted in sketch (1) of Fig. 2-4
P = Internal design pressure (As per KSF Line List)
b = Effective gasket or joint-contract-surface seating width [See note 1, 2-5(c)(1)]
m = Gasket factor, obtained from table 2-5.1
C = A factor depending upon the method of attachment of head, shell dimensions and other items as listed
Related Figures
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Thickness Calculation for Blind
AT OPERATING CONDITION
Pipe Size DN 900 DN750 DN200 DN25
C= 0.3 0.3 0.3 0.3
d, mm = 914.4 762 219.1 33.4
P, N/mm2 = 1 1 1 1
S, N/mm2 = 137.895 124.106 135.8267 137.895

E= 1 1 1 1
W= 770735.482 535704.708 62513.5027 2785.83011
ℎ𝐺 , 𝑚𝑚 = 60.92 55.3597872 24.975 19.8
t, mm = 50.26 44.71 14.34 5.02
AT GASKET SEATING CONDITION

C= 0.3 0.3 0.3 0.3
d, mm = 914.4 762 219.1 33.4
P, N/mm2 = 0 0 0 0
S, N/mm2 = 137.895 137.895 137.895 137.895
E= 1 1 1 1
W= 2227285.4 1406108.18 162243.252 29130.8084
ℎ𝐺 , 𝑚𝑚 = 60.92 61.9 24.975 19.8
t, mm = 45.22 39.67 15.96 15.43
The minimum thickness required for bolted blind is the higher thickness between operating
condition and gasket seating condition.
∴ The minimum thickness of blind for test,

t, mm = 50.26 44.71 15.96 15.43
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Blank calculation
3𝑃
𝑡𝑚 = 𝑑𝑔 √ +𝑐
16𝑆𝐸𝑊
Where,
c = Sum of allowances
dg = Inside diameter of gasket for raised or flat face flanges, or the gasket pitch diameter for ring joint and fully retained
gasketed flanges
E = Joint efficiency, from table UW-12, of any Category A weld as defined in UW-3(a)
P = Design Pressure (As per KSF line list)
S = Maximum allowable stress value in tension from applicable table of stress values
W = Same as defined in para. 304.1.1
Parameters Unit DN900 DN750 DN25 DN200

dg mm 927.1 774.7 31.8 233.4
P Mpa 1 1 1 1
S MPa 137.895 124.106 137.895 135.8267
E 1 1 1 1
W 1 1 1 1
c 0 0 0 0
∴ The minimum thickness of blanks for test,

t, mm = 34.19 30.11 8.67 1.17
PROCEDURE NO. :
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Ks KSF Exe Mmhe 999 Con PRC 0212 0

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PROCEDURE NO.

FLUSHING AND HYDROTEST PROCEDURE OF EPC FLARE STRUCTURE

PETRONAS CARIGALI SDN BHD

0 11.10.22 MN 11.10 MRI 11.10 PPC 11.10

SECTION REV. DATE DESCRIPTION OF AMENDMENT

SECTION DESCRIPTION PAGE

1.1 Project Overview

Kasawari Development Project comprises the following facilities:

a) Kasawari Central Processing Platform (CPP);

Figure 1 : Kasawari Schematic Diagram

i. ASME B31.3 (2018) - Process Piping

4.0 DEFINITION & ABBREVIATIONS

4.2 Definition and Term

COMPANY PETRONAS Carigali Sdn. Bhd. (PCSB)

a) Rotating machinery such as pump and compressor

5.2 Roles and Responsibilities

Phase Party Scope of Work

- To ensure all temporary item are inspected and

- To set up and perform hydrotest / pneumatic test

5.3 Equipment and Materials for Hydrotest / Pneumatic Test

a) Temporary rated spools and bolts and nuts

5.3.9 Calibration of testing equipment shall be properly documented, and validity of

5.3.12 Usage of any non-standard (non-rated) item shall be calculated / approved by

5.4 Flushing Procedure

5.4.6 For pneumatic tested piping,

a) Flushing (quick decompression method) to be conducted after pneumatic test

5.5 Hydrotest Medium

5.6 Hydrotest Procedure

Figure 1: Hydrotest Equipment Schematic Diagram

Figure 2: Flow Chart for Hydrotest

5.7 Pneumatic Test Procedure

5.7.3 Holding time shall be of minimum 30 minutes to 1 hour.

5.8.1 When hydrotest / pneumatic test is completed satisfactory, the following

5.9 Rectification of Leaks

i. Flange Joint Leak

5.10 Blow Dry and Preservation

5.11 Safety Precaution

5.11.7 SUBCONTRACTOR to ensure that any supports and/or equipment (temporary or

6.0 SPECIAL REQUIREMENTS

i. Hydrotest report including chart

Appendix I – Sample Water Test Report

Appendix II – Sample Hydrotest Checklist

Appendix III – Sample Inspection Test Record (ITR)

Appendix III – Sample P01 Pipe Work Completion

Appendix V – Pressurize, holding and de-pressurize for pneumatic test

Appendix VII – Blank and Blind Thickness Calculation as per UG-34

Blind Flange Calculation Based on ASME VIII (UG-34)

Thickness Calculation for Blind

S, N/mm2 = 137.895 124.106 135.8267 137.895

AT GASKET SEATING CONDITION

∴ The minimum thickness of blind for test,

Pipe Size DN 900 DN750 DN200 DN25

Parameters Unit DN900 DN750 DN25 DN200

∴ The minimum thickness of blanks for test,

Pipe Size DN 900 DN750 DN200 DN25

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