ms for pressure testing for fw tie in

MS-P-022 REV.00

METHOD STATEMENT

FOR

PRESSURE TESTING OF FIRE WATER LINE PIPE FOR TIE-IN PIPE

Contract NO: J-194

KARAN UTILITIY AND COGENERATION PROJECT

KHURSANIYAH, KINGDOM OF SAUDI ARABIA

1. PURPOSE / SCOPE:

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Signature

00 13 Oct. 2010Print Name

AJR N.E. Pacleb R. A. Dimatatac P. Ranzenbacher Rev. DATE Prepared By

MMGChecked By

MMGApproved By

MMGApproved By PETROFAC

MS-P-022 REV.00

The scope and purpose of this document is to describe the execution

methodology of Tie in works to be carried out to the existing fire water pipe

line.

2. DEFINITION OF TEST PRESSURE

Hydrostatic Test: A pressure test conducted using water or other approved

liquid as the test medium.

3. REFERENCES:

ASME 31.1 : Power piping

ASME 31.3 : Process piping

SAES-A-004 : General requirement for pressure testing.

SAES-A-007 : Hydrostatic Testing Fluids and Lay-up Procedure.

SAES-A-104 : Waste water treatment, reuse, and disposal.

GI-2.102 : Pressure Testing

SAEP-327 :Disposal of Waste Water from cleaning flushing, and

dewatering pipelines and vessel.

SAES-O-020 : Industrial drainage and sewers.

MMG-QCD-3-021 : Flushing and pressure testing of pipe work.

SAES-L-150 : Pressure testing of plant piping and pipe lines

GI-2.100 Rev. 2009 : Work permits system

SAEP-302 : Instructions for Obtaining a Waiver of a Mandatory

Saudi Aramco Engineering Requirement.

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MS-P-022 REV.00

4. RESPONSIBILITY

4.1 TESTING/PIPING SUPERVISOR

Ensure compliance by all labour and equipment availability and other

associated craftsmen to the requirements of this procedure, Project

Quality Control procedures / test plans, relevant approved test package,

safety procedures. Secure all necessary work permits.

4.2 QUALITY CONTROL INSPECTOR

Conduct activities in accordance with the Project QA Manual and

Quality Control Inspection Plan. Prepare testing records and final

acceptance documentation where required. Maintain close working

relationship with the Client's Representative.

4.3 SAFETY SUPERVISOR

Ensure that work permits are obtained prior to commencement of

testing. Check personally and confirm compliance to safety

requirements, such as wearing personal protective equipment. Check

work areas for any unsafe conditions. Liaison with the Field

Supervisors ensuring that work is carried out in accordance with Project

Safety Plan / JSA.

4.4 ENGINEERING DEPARTMENT

Provide technical support to MMG Site Operation section. Provide

relevant test diagram, material specifications, standards and technical

specifications. Responsible to prepare test packages or to revise test

packages.

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MS-P-022 REV.00

5. REQUIRED TOOLS:

5.1 Tested water pump/compressor

5.2 Tested manifold

5.3 Calibrated pressure gauge

5.4 Calibrated relief valve

5.6 Flexible hoses

5.7 Hand tools,

5.8 Spades and blinds.

5.9 Temperature chart recorder. (for underground piping)

5.10 Drum or Water Container etc.

6. FLUSHING PREPARATION:

6.1 Make sure that all punch list ‘A’ marked by QCI has rectified prior

to testing, and get clearance for flushing.

6.2 All flushing should progress in a down word direction wherever

Possible, to encourage the removal of all debris / solids which may be

present inside the pipes.

7 FLUSHING/ PIPE CLEANING

7.1 Use water or compressed air for flushing.

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7.2 Continue flushing until the specification is satisfied and that all foreign

Materials and debris have been removed from the piping system. Raise

RFI for further clearance.

8 HYDROTEST PREPARATION

8.1Obtain work permit/access prior to start any pressure testing.

8.2The area shall be marked and warning signs shall be posted, to alert

approaching personnel.

8.3Personnel shall be posted to keep area clear of all personnel not connected

with the test.

8.4Test pump / manifold should be in good condition and manifold should be

Separately tested 20% more than the test pressure.

8.5 Pressure test gauge should be in current calibrated condition. A minimum

of two (2) pressure gauges are required for the test system and verified

that they are within 5% of each other when in use. All gauges shall have a

range such that the test pressure is within 30% to 80% of the full range of

the gauges. All piping system under test shall be protected from over-

pressure by installing relief valves which are set10% above the required

test pressure of the system.

8.6 To isolate the system temporary blind flanges and test blinds shall be

installed at locations shown on the marked up P&ID included in the

Pressure Test Pack. Test blinds shall be of an adequate rating to

withstand the test pressure.

8.7 Coordinate to Aramco where to isolate the System of actual Fire Water

line pipe.

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MS-P-022 REV.00

8.8 Make sure that every system vent should installed at highest elevation &

drain at lowest elevation.

8.9 Test fluid should be used as specified in the test package.

8.10 If test loop prepared to conduct on ground, make sure that system has

slope and test fluid injected by lowest elevation. Pressure gauge and

vent should be installed at top elevation.

8.11 Once the QC Inspector satisfied that test preparation is acceptable, test

fluid may be introduced in to the system. Test fluid shall be injected at

the lowest point and vented at the highest point of the system to

minimize the risk of air entrapment.

8.12 Prepare the test loop as per approved test package’s test diagram.

Once all preparation has been completed, test supervisor should raise

RFI for QC involvement.

8.13 An approved MS/Test procedure shall be available at site prior to

commencing any pressure testing activities.

9 TEST FLUID

Test fluid shall normally be water e.g. clean condensate, sweet water, or treated

sea water, test fluid should must conform to SAES-A-007 “General requirement

for pressure testing”.

10 TEST EXECUTION (HYDROTEST)

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10.1 Once the pre test activities have cleared QC inspection, the inspector

shall sign RFI, after realistic time and date with the responsible

supervisor this he will note on RFI, returning a copy to the supervisor

and providing a copy for the client if a witness, or hold is identified in the

checklist as per test package.

10.2 After test fluid has been introduced and the system is full (filled during

vent in open condition), temperature equilibrium should be attained

between test fluid and piping system after filling and before applying

pressure.

10.3 When equalization has taken place all vent and drains are closed,

gradually increase test pressure but not more than 100 psi per minute

until 50% test pressure is achieved. Hold until integrity is verified by

visual examination. If no leaks are detected continue to increase

pressure in one fifth (1/5th) test pressure stages until ultimate pressure is

achieved.

10.4 Test pressure will be maintained in accordance with specified

requirement. If a pressure drop occurs, the cause shall be investigated,

and if necessary the system shall be de-pressurized, repair affected and

the test conducted again. If found any remedial work requiring welding

shall necessitate draining of the test fluid.

10.5 Once the required pressure has stabilized. Check the pressure gauges

and chart recorder (if required). Isolate the system. Maintain for the

specified test duration. If any leakage found depressurize the line and

rectify it. Once repair are completed, pressurize again.

10.6 Pressure should be released only after approval and acceptance.

10.7 Prior to opening any drain valve, ensure pressure has been released

and all vent are fully open, so as to prevent the formation of a vacuum

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within the system. Drain the test fluid in controlled manner ensuring

protection of equipment from fluid ingress and ensure that drained test

fluid channelled into the agreed location.

10.8 Carry out the hydro test on the tie- in joints during start up for a

minimum of four (4) hours, if no leak, and then proceed with the final

backfill.

11 QUALITY CONTROL AND ASSURANCE

All stages of work shall be inspected in accordance with the Approved

Project Quality Control Inspection and Test Plan.

12 DISPOSAL OF TEST MEDIUM

The disposal sites for the test fluid shall be reviewed and approved prior

to the hydrostatic test in accordance with SAEP-327 "Disposal of waste

water from Cleaning, Flushing, and Hydrostatic Tests".

SAFETY PRECAUTIONS

Barricade the working area.

Accomplish/comply with checklist for pressure testing safely (Supplement G.I. 2.102)

All safety precautionary signboards must be visibly posted.

Wear full body harness when working at heights.

Ensure that only authorized personnel are within the affected area.

Copy of approved JSA to be maintained at work site by work supervisor,

requirements discussed in daily TBT.

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Complete WERA prior to commencing work.

.

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ms for pressure testing for fw tie in

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