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Sadara Project Polyethylene Envelope
Transmittal
Page: 1 of 1 Form Version: 23-Apr-2012
Sadara Unit(s) 455 460 470
Sadara Transmittal Sadara-L&T-T-1304
Issue Date 11 July 2013 Date Reply Needed N/A
From Majid Al Majid To Mr. P. Sankaranarayanan
Company L&T ATCO
Subject SADARA Response to L&T-SADARA-T-821-13, Method
Statement for Pressure Testing of High Alloys and Reactive
Metals
In respect of the above referenced transmittal;
SADARA request L&T to resubmit the Method Statement after
incorporating the comments in the attached file and as discussed.
Also, It should be submitted as job specific. Piping hydro
test.
Subject File Name Date Rev
Method Statement for Pressure Testing of High Alloys and
Reactive Metals
SA-RTIP-PEAAA-LTAT-50-5003 Hydrotest procedure of alloy steel
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commented N/A N/A
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
SA-RTIP-PEAAA-LTAT-50-5003 0 Page 1 of 30
PROJECT: SADARA POLY ETHYLENE LSPB 1
CONTRACT NO: 10001 / 6600028371
CLIENT: SADARA
CONTRACTOR: LARSEN & TOUBRO ATCO SAUDI
METHOD STATEMENT FOR
PRESSURE TESTING OF HIGH ALLOYS & REACTIVE METALS
(SA-RTIP-PEAAA-LTAT-50-5003)
0 16-May-13
Issued for Review & Comments BSK DKU CTK/DKC
Rev Date Description
Prepared
Reviewed
Approved
Approved
L&T ATCO
L&T ATCO
L&T ATCO
SADARA
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
SA-RTIP-PEAAA-LTAT-50-5003 0 Page 2 of 30
REVISION RECORD SHEET
Rev. No. Date
Reason for the revision Revision details/ Locations
0 16-May-13
Issued for Review &
Comments Initial Issue
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
SA-RTIP-PEAAA-LTAT-50-5003 0 Page 3 of 30
CONTENTS
1. SCOPE
.....................................................................................................................................
4
2. REFERENCES
.........................................................................................................................
4
3. DEFINITIONS
...........................................................................................................................
6
4. ENVIRONMENT, HEALTH & SAFETY
.....................................................................................
6
5. RESPONSIBILITY AND AUTHORITY
......................................................................................
7
6. GENERAL REQUIREMENTS
...................................................................................................
8
7. PRESSURE TEST PROCEDURE
............................................................................................
9
8. SPECIFIC TESTING REQUIREMENTS
.................................................................................
10
9. HYDROSTATIC TESTING FLUIDS
........................................................................................
10
10. PREPARATION OF TEST
......................................................................................................
12
11. CONDUCT PRESSURE TEST
...............................................................................................
14
12. PNEUMATIC PRESSURE TESTING
......................................................................................
14
13. SENSITIVE LEAK TEST GAS AND BUBBLE METHOD
...................................................... 15
14. POST PRESSURE TEST
.......................................................................................................
15
15. LAY-UP PROCEDURE FOR STAINLESS STEEL
..................................................................
16
16. QUALITY CONTROL
..............................................................................................................
18
17. DOCUMENTATION
................................................................................................................
18
18. SCHEMATIC TEST PACKAGE DIAGRAM & TEST MANIFOLD
............................................ 19
19. ATTACHMENTS
.....................................................................................................................
21
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
SA-RTIP-PEAAA-LTAT-50-5003 0 Page 4 of 30
1. SCOPE 1.1. This standard defines mandatory general
requirements governing pressure testing of high
alloys and reactive metals in the piping works and process
containment equipment (hereinafter called Equipment).
1.2. The requirements of this standard apply to field/shop
fabricated piping systems and field fabricated Equipment.
1.3. This standard does not cover pressure testing of new, shop
fabricated Equipment such as vessels, tanks, heat exchangers and
skid mounted piping which are purchased in accordance with the
applicable Project specifications.
1.4. This standard applies to pre start-up leak tests normally
conducted by Operations during start-up & commissioning.
1.5. This standard establishes requirements to control corrosion
and microbiological damage during and after hydro testing.
1.6. Equipment covered by this standard includes, but is not
limited to, storage tanks, pressure containing Equipment, Plant
Unit piping, and pipelines both onshore and offshore.
1.7. The procedures in this standard are designed to prevent
corrosion due to oxygen (air) ingress and to prevent microbial
induced corrosion. Hydro test procedures and lay-up procedures
shall prevent oxygen ingress except as specifically allowed in this
standard.
1.8. Non-toxic liquids other than water may be used for pressure
testing if the operating fluid or the Equipment can be adversely
affected by water or by freezing conditions. Water/methanol or
water/glycol mixtures may be required in locations where freezing
is a concern. Contact the Project Quality Group Representative and
Manufacturing Representative for the selection and treatment of the
appropriate fluid. Such a fluid shall not have a flash point below
54C (129F).
1.9. Should there be any conflict between this procedure and any
Equipment specific specification or standard, the more specific
requirements will take precedence.
2. REFERENCES
The selection of material and Equipment, and the design,
construction, maintenance, and repair of Equipment and Facilities
required by this standard shall comply with the latest edition of
the references listed below, unless otherwise noted.
Comment [SS1]: Scope should be job specific Piping hydro test .
NO mentioning of pneumatic or equipment _ REQUIRES RESUBMIISION AS
DISCUSSED WITH L&T Construction
Comment [SS2]: What about normal CS piping? No equipment is
covered in field testing unless it is specified separately. In that
case , a standalone MS shall be prepared and submitted for
approval.
Comment [SS3]: Delete the sentence
Comment [CU4]: Operation is using their own standards and
procedures which we have to follow. 1.4 should be deleted or
rephrased
Comment [CU5]: I am not sure if we will allow the usage of this
Chemicals during construction on site. Should be deleted
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
SA-RTIP-PEAAA-LTAT-50-5003 0 Page 5 of 30
G4S-0210-01 - General Cleaning of Piping G4S-0210-02 - Cleaning
and Flushing with Water G4S-0210-03 - Cleaning or Drying with
Nitrogen G4S-0210-05 - Cleaning by Abrasive Blasting G4S-0260-01 -
Hydrogen Peroxide Cleaning, Pickling and Passivation G4S-6421-02 -
Class C Hydrostatic Testing G4S-6421-03 - Class G Hydrostatic
(Gravity) Testing G4S-6421-04 - Hydrostatic Testing Equipment
Procedure G4S-6422-01 - Class D Sensitive Leak Test Gas &
Bubble Method G4S-6422-02 - Class DH Pneumatic testing greater than
1 Bar (15 PSIG) G4S-6422-03 - Class DR Pneumatic Testing
Refrigeration Piping G4S-6423-01 - Class F- Firewater Systems
Testing G4S-6425-01 - Class J Helium Leak Testing G4S-6427-01 -
Class L (Category D) Test G4S-6428-01 - Class M Polyethylene Piping
Hydrostatic Testing RT8S-4001-60 - Specification for Water Quality
used for Hydrostatic Testing RT9S-2500-01 - Tanks Specific
Requirements G52T-0450-01 - Leak Testing for Chlorine Piping
G52T-0450-02 - Pneumatic Testing for Chlorine Piping G52M-0450-01 -
Chlorine Lines: Cleaning, Washing, Drying RT-2642 - ENG Pressure
Test Report Form, Appendix 5 A554-O-PRG-QA-GEN-PRO-014 - General
Requirements for Pressure Testing and
Lay-up. SA-RTIP-PEAAA-LTAT-50-3027 - Construction work detail
procedure for AG piping
2.1 Industry Codes and Standards
American Petroleum Institute:
API RP 520 - Part I - Sizing, Selection, and Installation of
Pressure Relieving Devices in Refineries
API RP 560 - Fired Heaters API Std 598 - Valve Inspection &
Testing
American Society of Mechanical Engineers:
ASME B31.1 - Power Piping
Comment [CU6]: G4S-0210-03 says Cleaning or Drying with air or
Nitrogen
Comment [CU7]: Should be deleted as this service will be flushed
with water and Air dried
Comment [CU8]: Should be deleted as Class C is the only
applicable hydro test method
Comment [CU9]: Should be deleted as pneumatic testing is not an
option
Comment [CU10]: Should be deleted as construction scope of work
is clearly defined in DOC. A554-D-455-CM-GEN-DOC-005. G52M-0450-01
is a maintenance procedure
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
SA-RTIP-PEAAA-LTAT-50-5003 0 Page 6 of 30
ASME B31.4 - Pipeline Transportation Systems for Liquid
Hydrocarbons and Other Liquids ASME B31.5 - Refrigeration Piping
ASME B31.8 - Gas Transmission and Distribution Piping Systems ASME
B31.9 - Building Services Piping ASME SEC I - Rules for
Construction of Power Boilers ASME SEC V - Article 10 Leak Testing
ASME SEC VIII D1 - Boiler and Pressure Vessel Code ASME SEC VIII D2
- Alternative Rules
National Board of Boiler and Pressure Vessel Inspectors:
NB 23 National Board of Inspection Code
Uniform Mechanical Code (UMC)
Uniform Plumbing Code (UPC)
3. DEFINITIONS
Project - SADARA Polyethylene LSPB 1 Company - SADARA Contractor
- Larsen & Toubro ATCO QCI - Quality Control Inspector QG -
Quality Group HSE - Health, Safety & Environment
4. ENVIRONMENT, HEALTH & SAFETY
This method statement and the attached job safety analysis is in
adherence with the Sadara
EHS&S policy and L&T Project EHS Plan. In addition to
above, JSA shall describe the job
specific requirement for each activity. Following are the main
reference documents for
preparing this method statement.
A-554-K-PRG-QM-GEN-PLN-004 - RTIP-Construction Environment,
Health and Safety (EHS) Standards.
A554-D-455-CM-SOW-CON-005-RTIP - Construction Instructions.
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
SA-RTIP-PEAAA-LTAT-50-5003 0 Page 7 of 30
L&T PROJECT EHS PLAN.
Following points shall be taken care before commencement of the
work at site.
Work Permit to be obtained from the competent person. Inspection
of all the Plant and machineries used for the lifting activities
shall be done by
the Third party agency approved from Sadara Project. Work
checklist, where applicable, shall be followed by supervisor as per
requirement: Works shall be carried out according to Safe
Construction Practices, SADARAs Safety
Regulations. List of emergency contact telephone numbers shall
be mentioned in the attached
emergency plan. All personnel involved in works shall be aware
of Safety requirements of the project and
site shall be kept clean and in tidy conditions. Contractor
shall maintain good housekeeping at all the times. HSE inspector
shall monitor the site personnel during the erection and
installation
activities. Provide drinking water and potable shelters for the
employees. Fire extinguishers shall be kept at the site where
required. Hydro test area should be cordoned with barricading tape
and appropriate sign boards. All hose connections for hydro test to
be provided with hose arrestors. START card to be filled for every
task. Plant, machineries & equipment shall be operated by the
Operators having valid Saudi
licence and third party certificate from the approved agency
Workmen shall be provided with the following PPE to work in Pipe
laying, lamination and hydro
testing.
Safety Helmet Safety Footwear Hand Gloves Safety Goggles
Reflecting jacket Dusk Mask (As required)
5. RESPONSIBILITY AND AUTHORITY
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
SA-RTIP-PEAAA-LTAT-50-5003 0 Page 8 of 30
5.1 This procedure shall be Prepared and reviewed by CONTRACTORs
QA/QC department and approved by COMPANY before use.
5.2 CONTRACTORs Piping Engineers/Supervisors are required to
ensure that all Pressure test work is carried out as per project
specifications, approved drawing & HSE requirements.
5.3 CONTRACTORs shall provide with labor, testing, tools and
equipment for Construction and inspection record preparation and
maintenance.
5.4 CONTRACTOR QCI is responsible for conducting the quality
control and inspection works during all Hydro-Testing
applications.
5.5 All final tests shall be witnessed and accepted by the
Company or Company designee.
6. GENERAL REQUIREMENTS 6.1 Pneumatic testing is not permitted
without written approval of the QG Representative, unless
specified by the applicable Project standard. Pneumatic testing,
when conducted, shall be in accordance with approved procedures
that require additional safety requirements.
6.2 Test pressures and test durations shall be based on the
applicable Project standards.
6.3 General requirements for the setup and operation of
equipment and instrumentation necessary to perform a Hydrostatic
/Pneumatic Test see practice G4S-6421-04 (Hydrostatic Testing
Equipment Procedure), G4D-6422-01 (Pneumatic test), G4S-6422-01
(Leak Test).
6.4 The effect of the static head of the testing liquid shall be
considered when determining the effective test pressure of any
elements within a tested system.
6.5 Test Water sources shall meet the requirements of Materials
Engineering EMETL Specification G8S-4001-60.
6.6 Protection from over pressure.
6.7 All systems (piping equipment) while being pressure tested
shall be protected from being over pressured by the following:
Pressure test relief valve(s) of adequate set to relieve at 5%
above the test pressure shall be installed unless the test pressure
is less than 85% SMYS at which time it can be set at 10% above the
test pressure. Sizing of these relief valves used for testing shall
follow the requirements of API RP 520, Part 1. The relief valve(s)
shall be tested, dated, and tagged within one week prior to the
pressure test.
Comment [CU11]: Pneumatic testing is not permitted at all
Comment [CU12]: Delete pneumatic test
Comment [CU13]: Delete
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
SA-RTIP-PEAAA-LTAT-50-5003 0 Page 9 of 30
The pressure test relief valve shall be accompanied with a
calibration certificate that includes the cold differential test
pressure (CDTP), test date and the spring range. The CDTP shall be
within the spring range.
In addition to the pressure relieving device, a bleed valve
shall be provided to protect the piping and Equipment from
overpressure. The bleed valve shall be readily accessible in case
immediate depressurization is required.
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.
Before employing the pressure testing manifold in the actual
system pressure test, it shall be separately pressure tested to at
least 1.2 times the system test pressure but not less than the
discharge pressure of the pump used for the pressure testing.
The test manifold shall be designed and constructed to meet the
minimum system requirements. All pipe, fittings, flanges and
materials used for pressure testing shall be in accordance with the
governing piping material specification for the piping system.
Test manifolds shall be subjected to 100% RT of all butt
welds.
7. PRESSURE TEST PROCEDURE 7.1 A pressure test procedure shall
be prepared by the responsible Contractor and submitted to
QG for approval prior to conducting the test. The test procedure
shall be available at the test site at all times.
7.2 The pressure test procedure shall include all required
documentation specified.
7.3 During a pneumatic pressure test a leak test shall be
performed in accordance with ASME SEC
V Article 10 and Article 10 Appendix I except the pressure shall
be 5 10 psi. A calculation sheet indicating adequacy of the
pressure test relief valve shall be included in the procedure.
7.4 The requirement for pre start-up leak tests and service
tests during initial start-up shall be as follows:
New systems after strength tests and prior to initial
start-up
For systems with maximum operating pressures greater than 6.894
Mpa (1000 psi), a leak test with inert gas, followed by a service
test, shall be conducted at the maximum operating pressure of the
piping system.
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
SA-RTIP-PEAAA-LTAT-50-5003 0 Page 10 of 30
For systems with maximum operating pressures less than 6.894 MPa
(1000 psi), a pre start-up leak test with inert gas or steam (if
designed for steam service) shall be conducted at the available
inert gas or steam system pressure (not exceeding the maximum
operating pressure), or pressure as recommended by the facility
Engineering unit responsible for developing the test package,
followed by a service test at normal operating pressure of the
piping systems. When inert gas or steam is not available, the
service test will satisfy the pre start-up leak test
requirements.
If the drop in ambient temperature may cause the test medium to
freeze during the test, appropriate precautionary measures must be
taken to protect the Equipment or piping systems.
8. SPECIFIC TESTING REQUIREMENTS
This section specifies in details which piping or Equipment that
shall be pressure tested and provides the specific applicable
standard. It also defines any specific exemptions.
8.1 Plant Piping
Pressure testing of Plant Unit piping shall be in tested
accordance with ASME B31.3. All weld joints shall be uncoated, and
all joints shall be accessible for visual inspection during
pressure testing. If this is not possible, refer to 11.1 for
alternative test requirements.
8.2 Valves
Metallic Valves shall be tested in accordance with API 598 as a
minimum.
8.3 Gasket Material
All gaskets used in the pressure test shall be the gaskets
intended for use.
8.4 Internally Coated Equipment or Piping
The hydro test pressure of all internally coated vessels, tanks
or piping shall be reviewed against the coating manufacturers
limitations. On completing the hydrostatic test, the pressure
should be reduced gradually to prevent decompression failure of the
internal coating.
9. HYDROSTATIC TESTING FLUIDS
Comment [CU14]: Gaskets according Pipe spec
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
SA-RTIP-PEAAA-LTAT-50-5003 0 Page 11 of 30
9.1 In the case of new construction, the construction agency
shall be responsible for adhering to this specification; QG shall
be the monitoring authority.
9.2 Water Quality
9.3 Water quality of intended hydrostatic test waters shall be
determined in accordance with RT8S-4001-60 well ahead of the actual
testing date so that alternative water sources may be identified if
the original source water fails to meet requirements.
9.4 Water quality of hydrostatic test waters shall be
reconfirmed by testing as close to the time of the hydrostatic test
as practicable. In cases where individual tanker trucks are used to
supply a test, the water samples shall be drawn from a
representative number of actual truck loads being delivered to the
test site.
9.5 Water used for any part of the hydro testing or subsequent
lay-up shall have a sulfate reducing bacteria (SRB) count of 10 per
ml or less as determined by the Rapid Check II Method or
alternative test method approved by the QG Representative. Water
that has a higher bacteria count may be accepted at the discretion
of the QG Representative, after treatment with biocide and
retesting.
9.6 If water from more than one source will be used, ensure that
mixing the waters will not cause scaling.
9.7 Water used for any part of the hydro testing or subsequent
lay-up shall be clean and free from suspended matter. Suspended
matter in the water shall be extracted, before use, by a filter
capable of removing 99% of all particles 53m (2.1 mil) in diameter
and larger, or equivalent to using a 270 mesh wire mesh screen.
9.8 Water that could result in harm to humans must not be used
for hydro testing. For example, service water containing hydrogen
sulfide levels that if released to atmosphere would result in air
concentrations of 10 ppm hydrogen sulfide or greater in the
immediate area of the hydro test must not be used.
9.9 Water may be reused for hydro testing, as in a pipeline
tested segment by segment. The water must meet the requirements and
must have an oxygen level of less than 20 ppb, or additional
chemical treatment will be required.
9.10 See Paragraph 14.1 for restrictions on the quality of water
used for testing austenitic stainless steels. Seawater or high TDS
aquifer water shall not be used for this purpose.
9.11 The Construction Contractor shall keep a permanent written
record of the water supplied for testing stainless steels including
a record of tests performed on the water.
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
SA-RTIP-PEAAA-LTAT-50-5003 0 Page 12 of 30
9.12 Minimize the time between introducing hydrostatic test
water and commissioning the Equipment.
9.13 Schedule the hydrostatic test as close as possible to the
start-up date.
9.14 Where there are limitations in this standard on contact
time for hydro test water, this shall be from the first
introduction of water into the system until commissioning or until
implementation of a complete lay-up. Partial or complete refilling
of the system shall count as continuous, cumulative time. Time
limitations requiring the initiation of a formal lay-up program
shall be from the first introduction of hydro test water.
9.15 Design the hydrostatic test and the lay-up procedure to
protect the most corrosion susceptible material in the system.
10. PREPARATION OF TEST 10.1 Site Preparation
An approved test procedure shall be available at the Site prior
to commencing any pressure testing activities.
New piping systems shall be cleaned in accordance with the
applicable standard. Soft seated valves and control valves shall
not be installed until after the lines have
been thoroughly flushed. Components in new piping systems which
interfere with filling, venting, draining or
flushing shall not be installed until after line flushing and
pressure testing are completed. These include orifice plates, flow
nozzles, sight glasses, venturies, positive displacement and
turbine meters and other in-line Equipment.
10.2 Pressure gauges
All gauges shall be calibrated prior to use. The calibration
interval shall not exceed 6 months prior to the test date and
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.
All gauges shall have a range such that the test pressure is
within 30 to 70% of the full range.
A minimum of two pressure gauges are required for the test
system. One pressure gage shall be on the test manifold and the
other(s) at the low point on the test system. Their accuracy shall
be within 5% of one another.
When large systems are tested, QG will determine the need for
additional gauges.
Comment [CU15]: Time between hydro test and start flushing and
drying of Line should not exceed 5 days
Comment [CU16]: Delete
Comment [CU17]: Delete
Comment [CU18]: Delete
Comment [CU19]: Must
Comment [CU20]: Delete and replace with DOC
A554-D-455-CM-GEN-DOC-005
Comment [CU21]: Test pack is been released for reinstatement
Comment [CU22]: and drying is completed
Comment [CU23]: delete
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
SA-RTIP-PEAAA-LTAT-50-5003 0 Page 13 of 30
Pressure and temperature recording gauges shall be used for all
buried piping systems on plot.
Expansion joints and spring hangers or spring supports shall be
provided with temporary restraints where needed to prevent
excessive travel or deformation under the test loads.
10.3 Equipment Excluded from Pressure Test
The following list defines the Equipment that shall be excluded
from the in-situ pressure testing of the tested system.
Rotating machinery, such as pumps, turbines and compressors;
Strainers baskets and filter elements; Pressure relieving devices,
such as rupture disks and pressure relief valves; Locally mounted
indicating pressure gauges, where the test pressure will exceed
their
scale range; Equipment that cannot be drained; Instrument
Devices.
10.4 Isolation of Test Sections
Blind flanges, paddle blinds or spectacle blinds shall be used
to isolate the test sections. All pipe, fittings, flanges and
materials used for pressure testing shall be in accordance with the
governing Piping Material Specification for the piping system and
shall be capable of withstanding the test pressure.
10.5 Vents and Drains
Vents shall be provided at all high points in the tested system
as needed. Excluding scrapable, submarine and buried pipelines,
drains shall be provided at all low
points in the system and immediately above check valves in
vertical lines. Unless the check valve has a by-pass valve, the
disc of the check valve shall be
removed, and securely attached to the outside of the check valve
prior to the pressure test.
10.6 Temporary Connections and Supports
Temporary connections shall be provided for de-pressurizing and
draining of the system to the sewer or disposal area.
Temporary supports shall be installed prior to hydrostatic
testing, and flushing of the piping if required. These supports
shall not be removed until after the system has been fully drained.
The structural support system for stacked Equipment shall be
verified for hydrostatic loads prior to testing.
Comment [CU24]: and insulated
Comment [CU25]: delete
Comment [CU26]: high point vents and low point drains shall be
provided as needed
Comment [CU27]: delete
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
SA-RTIP-PEAAA-LTAT-50-5003 0 Page 14 of 30
11. CONDUCT PRESSURE TEST 11.1 The test procedures shall be
conducted in accordance with the applicable code. In addition,
the
following requirements shall apply.
All piping joints shall be open for visual inspection during
pressure testing. If this is not practical as agreed by the QG
Representative, the test shall be conducted for 24 hours using
pressure and temperature recorders calibrated as required for
pressure gages.
Filling and pressurizing shall be done on the upstream side of
check valves in the system. The test fluid shall be injected at the
lowest point in the system to minimize entrapped air. When filling
at the lowest point is not practical, QG shall be consulted. All
vents shall be open during filling.
No one shall approach the test area for a minimum of 10 minutes
after the test pressure is reached and before commencement of
inspection of the system, the isolation valve between the temporary
test manifold/piping and the piping/Equipment under pressure test
shall be closed and the test pump disconnected. The isolation valve
downstream of the manifold shall be opened after the pump is
disconnected.
During the application of the test pressure, all in-line valves
if not used as test isolation valves shall be in a partially open
position.
All piping and Equipment shall comply with the lay-up
procedures. Test records shall be recorded on Pressure Test Report
Form.
12. PNEUMATIC PRESSURE TESTING 12.1 ASME B31.3, Section 345
requires leak testing of piping systems to ensure tightness, prior
to
initial operation, expect as permitted for category D
fluids.
Pneumatic testing shall be in accordance with G4D-6422-01. The
Pneumatic test pressure per ASME B31.3 is 110% of design pressure.
Minimum distance should be maintained while testing, for minimum
distance
requirements refer G4D-6422-01. The detection fluid shall be a
commercial bubble forming test fluid such as SNOOP or
SHERLOCK, or equivalent. Soaps, detergents and/or industrial
compounds that are designated specifically to be cleaning agents
shall not be used in bubble forming solutions.
For testing of stainless steel, nickel or chromium alloys, the
fluid shall have a sulfur and halogen content of less than 10 ppm
of each.
Pneumatic test shall be made with air, nitrogen or other gases.
As specified in the technical job instructions. Work order or
construction order. Comment [CU28]: should be deleted as
pneumatic test is not an option
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
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Date Doc. No Rev. No Page
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13. SENSITIVE LEAK TEST GAS AND BUBBLE METHOD
This test is performed by pressurizing the system with gas, to 1
BAR (15 psig). This
creates a pressure differential across a leak. Leaks are
detected by applying a commercial bubble forming solution to all
joints. The locations of commercial bubble are indicated by the
formation of bubbles.
This test may be performed at pressures greater than 1 BAR (15
psig). However, all conditions of G4S-6422-02 and G4Q-6422-02 shall
be met when a higher pressure is used.
Air compressors shall be equipped with discharge filters for
removal of water, oil and foreign matter. Maximum discharge
temperature of lubricated air compressors shall be 150C (300F)
A complete line or section of line containing several valves and
braches may be tested at one.
CAUTION: PNEUMATIC TESTING should be used only as a leak
alternative carefully planned and supervised procedures shall be
used to guard against the hazards of latent energy of compressed
gases.
The Company is responsible to assure that all conditions and
safety concerns identified in G4D-6422-01 are addressed.
14. POST PRESSURE TEST
After pressure testing has been successfully completed and
approved by the Project inspector, the following operations shall
be made.
14.1 Draining of Test Fluid
Release of pressure and draining shall be done on the downstream
side of check valves. All vents shall be opened before draining to
facilitate drainage and to prevent formation of a vacuum. No test
fluid shall remain in low spots.
14.2 Disposal of Test Fluid
The test fluid shall be disposed with as directed by Project
EH&S requirements.
14.3 Test Vents and Drains
Vents and drains used only for the pressure test shall be
plugged, seal welded and penetrant tested.
Comment [CU29]: Air
Comment [CU30]: Prior to test an yield stress calculation shall
be performed and approved my client
Comment [CU31]: Air
Comment [CU32]: Oil free compressor
Comment [CU33]: Sensitive leak
Comment [CU34]: The test fluid shall be disposed in the Sump
Comment [CU35]: High point vents and low point drains
Comment [CU36]: As a part of reinstatement after pre
commissioning is completed
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
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Date Doc. No Rev. No Page
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14.4 Removal and Reconnection of Components
All temporary items installed for testing purposes (e.g.,
manifolds, valves, blinds spacers, supports) shall be removed.
Items that were removed for testing shall be reinstalled. Items,
such as instrument air tubing, check valve discs which were
disconnected before
testing shall be reconnected. Isolation valves closed for the
test purposes and that are required to be in the open position for
process reasons shall be opened. If the valve cavity has a drain,
the cavity shall be drained.
15. LAY-UP PROCEDURE FOR STAINLESS STEEL 15.1 Type 300-series
stainless steels shall be tested only with water that has very low
chloride
content in order to avoid pitting and stress corrosion cracking.
The maximum allowable chloride concentration is 20 ppm per
RT8S-4001-60. Verify the quality of the water following the
requirements.
Exceptions: Type 300-series stainless steel valve trim shall not
be a sufficient sole criterion for classifying a carbon steel
system as "stainless" for the purpose of applying Section 6. For
example, this section shall not apply to carbon steel pipelines
with valves having stainless trim unless there are also other
stainless steel components included.
In special cases, with the prior written approval of QG
Representative, water of up to 200 PPM chloride content is
permitted, provided:
That the hydrostatic test period is less than four days, That
the system is rinsed with steam condensate or demineralized water
until the
effluent chloride content reaches below 20 PPM, and That the
system is completely drained immediately after hydrostatic test and
rinse.
15.2 Type-400-series stainless steels are highly prone to
atmospheric corrosion. Type 400- series
stainless steel trimmed valves shall be removed from pipelines
before hydro test. If it is impossible to remove such valves from
the line, then written hydro test procedures must prepared and
approved ahead of time allowing the valves to remain in place. When
Equipment containing any Type-400 series stainless steels is left
in place, it shall be hydro tested in accordance with the
requirements of Paragraph 14.3, 14.4, and 14.5 of this standard.
The hydro test procedure shall carefully detail measures prevent
corrosion including lay-up of the Equipment. Do not use ambient
lay-up for Equipment made of 400-series stainless steels.
15.3 Treat the hydrostatic test water with oxygen scavenger per
paragraph 13.1 if the Equipment
contact time with water might exceed 4 days.
Comment [CU37]: All this activities shall be done after pre
commissioning activities have been completed and permission to
reinstatement is given.
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
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15.4 Lay-up the system following the requirements. 15.5 At the
end of the lay-up, commission and start up the stainless steel
Equipment within 14 days.
Tested Line
(Above Ground Piping)
Dewatering Hose
Schematic Diagram for Disposal of Tested Water
Temporary Storage
Tank Pump
Water Tanker or
Truck
Comment [CU38]: Lines have been flushed and dried according to
A554-D-455-CM-GEN-DOC-005 there is no need for such an
requirement
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
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Date Doc. No Rev. No Page
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16. QUALITY CONTROL
Quality Control shall be strictly exercised in accordance to
approved Inspection & Test Plan and Quality Control
Procedures.
Ensure that all the Inspection report formats has been completed
and reports have been signed/accepted by all parties before
depressurizing the system.
All calibration certificates and water test report are attached
in the test pack.
QCI to verify that all punch points (Punch Category that affects
Pressure Test) shall be closed before Testing.
17. DOCUMENTATION
The following Documents shall be attached with the pressure test
packs.
1. Test package general information sheet. 2. Hydro test package
content check sheet. 3. Test package flow chart. 4. Hydro test
report. 5. Test diagram legend. 6. Schematic test package diagram
& test manifold. 7. Test package index. 8. Pneumatic test
calculation sheet ( if applicable) 9. Punch list 10. Safety
instruction sheet. 11. Test diagram P&ID ( Marked test
boundaries) 12. System definition P&ID 13. Marked air blowing
P&ID 14. Isometric drawing. 15. Check list before test 16.
Weld/NDT summary sheet. 17. Survey report (if applicable) 18.
Calibration certificates.
(Pressure gauge, pressure recorder, test relief valve,
temperature gauge, test manifold) 19. Blind control sheet. 20.
Valve test report (if applicable)
Comment [CU39]: yield stress calculation
Comment [CU40]: delete, pre commissioning takes care about
this
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
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21. Water analysis report (Test medium) 22. Reinforcing-pad leak
testing report (if applicable) 23. Orifice flange joint inspection
report (if applicable) 24. Flange joint inspection report. 25.
Lay-up inspection. 26. Check list after test. 27. Flushing /
Cleaning report.
18. SCHEMATIC TEST PACKAGE DIAGRAM & TEST MANIFOLD
Valve 1
Comment [CU41]: delete, pre commissioning takes care about
this
Comment [CU42]: PSV should be placed on the downstream site of
the Valve marked as 1 to protect against overpressure of the
system
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
SA-RTIP-PEAAA-LTAT-50-5003 0 Page 20 of 30
Appendix A: Dew Point of Natural Gas
Comment [CU43]: What is the purpose of this document
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
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SA-RTIP-PEAAA-LTAT-50-5003 0 Page 21 of 30
19. ATTACHMENTS
1. Test package general information sheet 2. Hydro test package
content check list 3. Test package flow chart 4. Line List 5. Test
diagram legend 6. Calibration Certificate 7. Blind control sheet 8.
Bolt torqueing report 9. Punch list 10. Job Safety Analysis
(JSA)
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
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Attachment - 1
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
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Attachment - 2
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METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
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Attachment 3
Comment [CU44]: After pressure testing next step should be water
flush prior dry out to -30 C
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
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Attachment 4
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METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
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Attachment 5
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
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Attachment 6
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METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
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Attachment 7
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
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Attachment 8
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
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Attachment 9
-
460 470
The Following Drawings Specification Schedule
Data Sheets Calculation Material Requisition
Are Transmitted TBE Vendor Document MOM
Acceptance/Approval Review Information
This is Record Quatation Construction
Original Revision Final
Size No. of Copies
Receipt Not RequiredReceipt Required (Please Acknowlegde the
Receipt of the Duplicate and Return)The Above Documents Received
By:
Signature: Name:
John HufnagelJulian Archer
Drawings / File Name Description
To Majid Al Majid
Rev. No.
cc Mark Williams
455
L&T-Sadara-T-821/13
16-May-13 Date Reply Needed 18-May-13
Date:
Sureshbabu Surendran
1
*** Nothing Follows ***
Method Statement for Pressure Testing of High Alloys and
Reactive Metals
Transmittal
Subject
C.T KuriakoseD.K UpadhayB.S Kumar
Sadara Unit (s)
L&T Transmittal
Issue Date
From
cc
Company
Method Statement for Pressure Testing of High Alloys and
Reactive Metals
P.Sankaranarayanan
Sadara
SA-RTIP-PEAAA-LTAT-50-5003 A4 0
X
X X
X X
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
SA-RTIP-PEAAA-LTAT-50-5003 0 Page 1 of 30
PROJECT: SADARA POLY ETHYLENE LSPB 1
CONTRACT NO: 10001 / 6600028371
CLIENT: SADARA
CONTRACTOR: LARSEN & TOUBRO ATCO SAUDI
METHOD STATEMENT FOR
PRESSURE TESTING OF HIGH ALLOYS & REACTIVE METALS
(SA-RTIP-PEAAA-LTAT-50-5003)
0 16-May-13
Issued for Review & Comments BSK DKU CTK/DKC
Rev Date Description
Prepared
Reviewed
Approved
Approved
L&T ATCO
L&T ATCO
L&T ATCO
SADARA
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
SA-RTIP-PEAAA-LTAT-50-5003 0 Page 2 of 30
REVISION RECORD SHEET
Rev. No. Date
Reason for the revision Revision details/ Locations
0 16-May-13
Issued for Review &
Comments Initial Issue
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
SA-RTIP-PEAAA-LTAT-50-5003 0 Page 3 of 30
CONTENTS
1. SCOPE
.....................................................................................................................................
4
2. REFERENCES
.........................................................................................................................
4
3. DEFINITIONS
...........................................................................................................................
6
4. ENVIRONMENT, HEALTH & SAFETY
.....................................................................................
6
5. RESPONSIBILITY AND AUTHORITY
......................................................................................
7
6. GENERAL REQUIREMENTS
...................................................................................................
8
7. PRESSURE TEST PROCEDURE
............................................................................................
9
8. SPECIFIC TESTING REQUIREMENTS
.................................................................................
10
9. HYDROSTATIC TESTING FLUIDS
........................................................................................
10
10. PREPARATION OF TEST
......................................................................................................
12
11. CONDUCT PRESSURE TEST
...............................................................................................
14
12. PNEUMATIC PRESSURE TESTING
......................................................................................
14
13. SENSITIVE LEAK TEST GAS AND BUBBLE METHOD
...................................................... 15
14. POST PRESSURE TEST
.......................................................................................................
15
15. LAY-UP PROCEDURE FOR STAINLESS STEEL
..................................................................
16
16. QUALITY CONTROL
..............................................................................................................
18
17. DOCUMENTATION
................................................................................................................
18
18. SCHEMATIC TEST PACKAGE DIAGRAM & TEST MANIFOLD
............................................ 19
19. ATTACHMENTS
.....................................................................................................................
21
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
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SA-RTIP-PEAAA-LTAT-50-5003 0 Page 4 of 30
1. SCOPE 1.1. This standard defines mandatory general
requirements governing pressure testing of high
alloys and reactive metals in the piping works and process
containment equipment (hereinafter called Equipment).
1.2. The requirements of this standard apply to field/shop
fabricated piping systems and field fabricated Equipment.
1.3. This standard does not cover pressure testing of new, shop
fabricated Equipment such as vessels, tanks, heat exchangers and
skid mounted piping which are purchased in accordance with the
applicable Project specifications.
1.4. This standard applies to pre start-up leak tests normally
conducted by Operations during start-up & commissioning.
1.5. This standard establishes requirements to control corrosion
and microbiological damage during and after hydro testing.
1.6. Equipment covered by this standard includes, but is not
limited to, storage tanks, pressure containing Equipment, Plant
Unit piping, and pipelines both onshore and offshore.
1.7. The procedures in this standard are designed to prevent
corrosion due to oxygen (air) ingress and to prevent microbial
induced corrosion. Hydro test procedures and lay-up procedures
shall prevent oxygen ingress except as specifically allowed in this
standard.
1.8. Non-toxic liquids other than water may be used for pressure
testing if the operating fluid or the Equipment can be adversely
affected by water or by freezing conditions. Water/methanol or
water/glycol mixtures may be required in locations where freezing
is a concern. Contact the Project Quality Group Representative and
Manufacturing Representative for the selection and treatment of the
appropriate fluid. Such a fluid shall not have a flash point below
54C (129F).
1.9. Should there be any conflict between this procedure and any
Equipment specific specification or standard, the more specific
requirements will take precedence.
2. REFERENCES
The selection of material and Equipment, and the design,
construction, maintenance, and repair of Equipment and Facilities
required by this standard shall comply with the latest edition of
the references listed below, unless otherwise noted.
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
SA-RTIP-PEAAA-LTAT-50-5003 0 Page 5 of 30
G4S-0210-01 - General Cleaning of Piping G4S-0210-02 - Cleaning
and Flushing with Water G4S-0210-03 - Cleaning or Drying with
Nitrogen G4S-0210-05 - Cleaning by Abrasive Blasting G4S-0260-01 -
Hydrogen Peroxide Cleaning, Pickling and Passivation G4S-6421-02 -
Class C Hydrostatic Testing G4S-6421-03 - Class G Hydrostatic
(Gravity) Testing G4S-6421-04 - Hydrostatic Testing Equipment
Procedure G4S-6422-01 - Class D Sensitive Leak Test Gas &
Bubble Method G4S-6422-02 - Class DH Pneumatic testing greater than
1 Bar (15 PSIG) G4S-6422-03 - Class DR Pneumatic Testing
Refrigeration Piping G4S-6423-01 - Class F- Firewater Systems
Testing G4S-6425-01 - Class J Helium Leak Testing G4S-6427-01 -
Class L (Category D) Test G4S-6428-01 - Class M Polyethylene Piping
Hydrostatic Testing RT8S-4001-60 - Specification for Water Quality
used for Hydrostatic Testing RT9S-2500-01 - Tanks Specific
Requirements G52T-0450-01 - Leak Testing for Chlorine Piping
G52T-0450-02 - Pneumatic Testing for Chlorine Piping G52M-0450-01 -
Chlorine Lines: Cleaning, Washing, Drying RT-2642 - ENG Pressure
Test Report Form, Appendix 5 A554-O-PRG-QA-GEN-PRO-014 - General
Requirements for Pressure Testing and
Lay-up. SA-RTIP-PEAAA-LTAT-50-3027 - Construction work detail
procedure for AG piping
2.1 Industry Codes and Standards
American Petroleum Institute:
API RP 520 - Part I - Sizing, Selection, and Installation of
Pressure Relieving Devices in Refineries
API RP 560 - Fired Heaters API Std 598 - Valve Inspection &
Testing
American Society of Mechanical Engineers:
ASME B31.1 - Power Piping
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
SA-RTIP-PEAAA-LTAT-50-5003 0 Page 6 of 30
ASME B31.4 - Pipeline Transportation Systems for Liquid
Hydrocarbons and Other Liquids ASME B31.5 - Refrigeration Piping
ASME B31.8 - Gas Transmission and Distribution Piping Systems ASME
B31.9 - Building Services Piping ASME SEC I - Rules for
Construction of Power Boilers ASME SEC V - Article 10 Leak Testing
ASME SEC VIII D1 - Boiler and Pressure Vessel Code ASME SEC VIII D2
- Alternative Rules
National Board of Boiler and Pressure Vessel Inspectors:
NB 23 National Board of Inspection Code
Uniform Mechanical Code (UMC)
Uniform Plumbing Code (UPC)
3. DEFINITIONS
Project - SADARA Polyethylene LSPB 1 Company - SADARA Contractor
- Larsen & Toubro ATCO QCI - Quality Control Inspector QG -
Quality Group HSE - Health, Safety & Environment
4. ENVIRONMENT, HEALTH & SAFETY
This method statement and the attached job safety analysis is in
adherence with the Sadara
EHS&S policy and L&T Project EHS Plan. In addition to
above, JSA shall describe the job
specific requirement for each activity. Following are the main
reference documents for
preparing this method statement.
A-554-K-PRG-QM-GEN-PLN-004 - RTIP-Construction Environment,
Health and Safety (EHS) Standards.
A554-D-455-CM-SOW-CON-005-RTIP - Construction Instructions.
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
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Date Doc. No Rev. No Page
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L&T PROJECT EHS PLAN.
Following points shall be taken care before commencement of the
work at site.
Work Permit to be obtained from the competent person. Inspection
of all the Plant and machineries used for the lifting activities
shall be done by
the Third party agency approved from Sadara Project. Work
checklist, where applicable, shall be followed by supervisor as per
requirement: Works shall be carried out according to Safe
Construction Practices, SADARAs Safety
Regulations. List of emergency contact telephone numbers shall
be mentioned in the attached
emergency plan. All personnel involved in works shall be aware
of Safety requirements of the project and
site shall be kept clean and in tidy conditions. Contractor
shall maintain good housekeeping at all the times. HSE inspector
shall monitor the site personnel during the erection and
installation
activities. Provide drinking water and potable shelters for the
employees. Fire extinguishers shall be kept at the site where
required. Hydro test area should be cordoned with barricading tape
and appropriate sign boards. All hose connections for hydro test to
be provided with hose arrestors. START card to be filled for every
task. Plant, machineries & equipment shall be operated by the
Operators having valid Saudi
licence and third party certificate from the approved agency
Workmen shall be provided with the following PPE to work in Pipe
laying, lamination and hydro
testing.
Safety Helmet Safety Footwear Hand Gloves Safety Goggles
Reflecting jacket Dusk Mask (As required)
5. RESPONSIBILITY AND AUTHORITY
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
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Date Doc. No Rev. No Page
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5.1 This procedure shall be Prepared and reviewed by CONTRACTORs
QA/QC department and approved by COMPANY before use.
5.2 CONTRACTORs Piping Engineers/Supervisors are required to
ensure that all Pressure test work is carried out as per project
specifications, approved drawing & HSE requirements.
5.3 CONTRACTORs shall provide with labor, testing, tools and
equipment for Construction and inspection record preparation and
maintenance.
5.4 CONTRACTOR QCI is responsible for conducting the quality
control and inspection works during all Hydro-Testing
applications.
5.5 All final tests shall be witnessed and accepted by the
Company or Company designee.
6. GENERAL REQUIREMENTS 6.1 Pneumatic testing is not permitted
without written approval of the QG Representative, unless
specified by the applicable Project standard. Pneumatic testing,
when conducted, shall be in accordance with approved procedures
that require additional safety requirements.
6.2 Test pressures and test durations shall be based on the
applicable Project standards.
6.3 General requirements for the setup and operation of
equipment and instrumentation necessary to perform a Hydrostatic
/Pneumatic Test see practice G4S-6421-04 (Hydrostatic Testing
Equipment Procedure), G4D-6422-01 (Pneumatic test), G4S-6422-01
(Leak Test).
6.4 The effect of the static head of the testing liquid shall be
considered when determining the effective test pressure of any
elements within a tested system.
6.5 Test Water sources shall meet the requirements of Materials
Engineering EMETL Specification G8S-4001-60.
6.6 Protection from over pressure.
6.7 All systems (piping equipment) while being pressure tested
shall be protected from being over pressured by the following:
Pressure test relief valve(s) of adequate set to relieve at 5%
above the test pressure shall be installed unless the test pressure
is less than 85% SMYS at which time it can be set at 10% above the
test pressure. Sizing of these relief valves used for testing shall
follow the requirements of API RP 520, Part 1. The relief valve(s)
shall be tested, dated, and tagged within one week prior to the
pressure test.
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
REACTIVE
METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
16-May-13
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The pressure test relief valve shall be accompanied with a
calibration certificate that includes the cold differential test
pressure (CDTP), test date and the spring range. The CDTP shall be
within the spring range.
In addition to the pressure relieving device, a bleed valve
shall be provided to protect the piping and Equipment from
overpressure. The bleed valve shall be readily accessible in case
immediate depressurization is required.
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.
Before employing the pressure testing manifold in the actual
system pressure test, it shall be separately pressure tested to at
least 1.2 times the system test pressure but not less than the
discharge pressure of the pump used for the pressure testing.
The test manifold shall be designed and constructed to meet the
minimum system requirements. All pipe, fittings, flanges and
materials used for pressure testing shall be in accordance with the
governing piping material specification for the piping system.
Test manifolds shall be subjected to 100% RT of all butt
welds.
7. PRESSURE TEST PROCEDURE 7.1 A pressure test procedure shall
be prepared by the responsible Contractor and submitted to
QG for approval prior to conducting the test. The test procedure
shall be available at the test site at all times.
7.2 The pressure test procedure shall include all required
documentation specified.
7.3 During a pneumatic pressure test a leak test shall be
performed in accordance with ASME SEC
V Article 10 and Article 10 Appendix I except the pressure shall
be 5 10 psi. A calculation sheet indicating adequacy of the
pressure test relief valve shall be included in the procedure.
7.4 The requirement for pre start-up leak tests and service
tests during initial start-up shall be as follows:
New systems after strength tests and prior to initial
start-up
For systems with maximum operating pressures greater than 6.894
Mpa (1000 psi), a leak test with inert gas, followed by a service
test, shall be conducted at the maximum operating pressure of the
piping system.
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
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For systems with maximum operating pressures less than 6.894 MPa
(1000 psi), a pre start-up leak test with inert gas or steam (if
designed for steam service) shall be conducted at the available
inert gas or steam system pressure (not exceeding the maximum
operating pressure), or pressure as recommended by the facility
Engineering unit responsible for developing the test package,
followed by a service test at normal operating pressure of the
piping systems. When inert gas or steam is not available, the
service test will satisfy the pre start-up leak test
requirements.
If the drop in ambient temperature may cause the test medium to
freeze during the test, appropriate precautionary measures must be
taken to protect the Equipment or piping systems.
8. SPECIFIC TESTING REQUIREMENTS
This section specifies in details which piping or Equipment that
shall be pressure tested and provides the specific applicable
standard. It also defines any specific exemptions.
8.1 Plant Piping
Pressure testing of Plant Unit piping shall be in tested
accordance with ASME B31.3. All weld joints shall be uncoated, and
all joints shall be accessible for visual inspection during
pressure testing. If this is not possible, refer to 11.1 for
alternative test requirements.
8.2 Valves
Metallic Valves shall be tested in accordance with API 598 as a
minimum.
8.3 Gasket Material
All gaskets used in the pressure test shall be the gaskets
intended for use.
8.4 Internally Coated Equipment or Piping
The hydro test pressure of all internally coated vessels, tanks
or piping shall be reviewed against the coating manufacturers
limitations. On completing the hydrostatic test, the pressure
should be reduced gradually to prevent decompression failure of the
internal coating.
9. HYDROSTATIC TESTING FLUIDS
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METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
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9.1 In the case of new construction, the construction agency
shall be responsible for adhering to this specification; QG shall
be the monitoring authority.
9.2 Water Quality
9.3 Water quality of intended hydrostatic test waters shall be
determined in accordance with RT8S-4001-60 well ahead of the actual
testing date so that alternative water sources may be identified if
the original source water fails to meet requirements.
9.4 Water quality of hydrostatic test waters shall be
reconfirmed by testing as close to the time of the hydrostatic test
as practicable. In cases where individual tanker trucks are used to
supply a test, the water samples shall be drawn from a
representative number of actual truck loads being delivered to the
test site.
9.5 Water used for any part of the hydro testing or subsequent
lay-up shall have a sulfate reducing bacteria (SRB) count of 10 per
ml or less as determined by the Rapid Check II Method or
alternative test method approved by the QG Representative. Water
that has a higher bacteria count may be accepted at the discretion
of the QG Representative, after treatment with biocide and
retesting.
9.6 If water from more than one source will be used, ensure that
mixing the waters will not cause scaling.
9.7 Water used for any part of the hydro testing or subsequent
lay-up shall be clean and free from suspended matter. Suspended
matter in the water shall be extracted, before use, by a filter
capable of removing 99% of all particles 53m (2.1 mil) in diameter
and larger, or equivalent to using a 270 mesh wire mesh screen.
9.8 Water that could result in harm to humans must not be used
for hydro testing. For example, service water containing hydrogen
sulfide levels that if released to atmosphere would result in air
concentrations of 10 ppm hydrogen sulfide or greater in the
immediate area of the hydro test must not be used.
9.9 Water may be reused for hydro testing, as in a pipeline
tested segment by segment. The water must meet the requirements and
must have an oxygen level of less than 20 ppb, or additional
chemical treatment will be required.
9.10 See Paragraph 14.1 for restrictions on the quality of water
used for testing austenitic stainless steels. Seawater or high TDS
aquifer water shall not be used for this purpose.
9.11 The Construction Contractor shall keep a permanent written
record of the water supplied for testing stainless steels including
a record of tests performed on the water.
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
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Date Doc. No Rev. No Page
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9.12 Minimize the time between introducing hydrostatic test
water and commissioning the Equipment.
9.13 Schedule the hydrostatic test as close as possible to the
start-up date.
9.14 Where there are limitations in this standard on contact
time for hydro test water, this shall be from the first
introduction of water into the system until commissioning or until
implementation of a complete lay-up. Partial or complete refilling
of the system shall count as continuous, cumulative time. Time
limitations requiring the initiation of a formal lay-up program
shall be from the first introduction of hydro test water.
9.15 Design the hydrostatic test and the lay-up procedure to
protect the most corrosion susceptible material in the system.
10. PREPARATION OF TEST 10.1 Site Preparation
An approved test procedure shall be available at the Site prior
to commencing any pressure testing activities.
New piping systems shall be cleaned in accordance with the
applicable standard. Soft seated valves and control valves shall
not be installed until after the lines have
been thoroughly flushed. Components in new piping systems which
interfere with filling, venting, draining or
flushing shall not be installed until after line flushing and
pressure testing are completed. These include orifice plates, flow
nozzles, sight glasses, venturies, positive displacement and
turbine meters and other in-line Equipment.
10.2 Pressure gauges
All gauges shall be calibrated prior to use. The calibration
interval shall not exceed 6 months prior to the test date and
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.
All gauges shall have a range such that the test pressure is
within 30 to 70% of the full range.
A minimum of two pressure gauges are required for the test
system. One pressure gage shall be on the test manifold and the
other(s) at the low point on the test system. Their accuracy shall
be within 5% of one another.
When large systems are tested, QG will determine the need for
additional gauges.
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
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Pressure and temperature recording gauges shall be used for all
buried piping systems on plot.
Expansion joints and spring hangers or spring supports shall be
provided with temporary restraints where needed to prevent
excessive travel or deformation under the test loads.
10.3 Equipment Excluded from Pressure Test
The following list defines the Equipment that shall be excluded
from the in-situ pressure testing of the tested system.
Rotating machinery, such as pumps, turbines and compressors;
Strainers baskets and filter elements; Pressure relieving devices,
such as rupture disks and pressure relief valves; Locally mounted
indicating pressure gauges, where the test pressure will exceed
their
scale range; Equipment that cannot be drained; Instrument
Devices.
10.4 Isolation of Test Sections
Blind flanges, paddle blinds or spectacle blinds shall be used
to isolate the test sections. All pipe, fittings, flanges and
materials used for pressure testing shall be in accordance with the
governing Piping Material Specification for the piping system and
shall be capable of withstanding the test pressure.
10.5 Vents and Drains
Vents shall be provided at all high points in the tested system
as needed. Excluding scrapable, submarine and buried pipelines,
drains shall be provided at all low
points in the system and immediately above check valves in
vertical lines. Unless the check valve has a by-pass valve, the
disc of the check valve shall be
removed, and securely attached to the outside of the check valve
prior to the pressure test.
10.6 Temporary Connections and Supports
Temporary connections shall be provided for de-pressurizing and
draining of the system to the sewer or disposal area.
Temporary supports shall be installed prior to hydrostatic
testing, and flushing of the piping if required. These supports
shall not be removed until after the system has been fully drained.
The structural support system for stacked Equipment shall be
verified for hydrostatic loads prior to testing.
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METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
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11. CONDUCT PRESSURE TEST 11.1 The test procedures shall be
conducted in accordance with the applicable code. In addition,
the
following requirements shall apply.
All piping joints shall be open for visual inspection during
pressure testing. If this is not practical as agreed by the QG
Representative, the test shall be conducted for 24 hours using
pressure and temperature recorders calibrated as required for
pressure gages.
Filling and pressurizing shall be done on the upstream side of
check valves in the system. The test fluid shall be injected at the
lowest point in the system to minimize entrapped air. When filling
at the lowest point is not practical, QG shall be consulted. All
vents shall be open during filling.
No one shall approach the test area for a minimum of 10 minutes
after the test pressure is reached and before commencement of
inspection of the system, the isolation valve between the temporary
test manifold/piping and the piping/Equipment under pressure test
shall be closed and the test pump disconnected. The isolation valve
downstream of the manifold shall be opened after the pump is
disconnected.
During the application of the test pressure, all in-line valves
if not used as test isolation valves shall be in a partially open
position.
All piping and Equipment shall comply with the lay-up
procedures. Test records shall be recorded on Pressure Test Report
Form.
12. PNEUMATIC PRESSURE TESTING 12.1 ASME B31.3, Section 345
requires leak testing of piping systems to ensure tightness, prior
to
initial operation, expect as permitted for category D
fluids.
Pneumatic testing shall be in accordance with G4D-6422-01. The
Pneumatic test pressure per ASME B31.3 is 110% of design pressure.
Minimum distance should be maintained while testing, for minimum
distance
requirements refer G4D-6422-01. The detection fluid shall be a
commercial bubble forming test fluid such as SNOOP or
SHERLOCK, or equivalent. Soaps, detergents and/or industrial
compounds that are designated specifically to be cleaning agents
shall not be used in bubble forming solutions.
For testing of stainless steel, nickel or chromium alloys, the
fluid shall have a sulfur and halogen content of less than 10 ppm
of each.
Pneumatic test shall be made with air, nitrogen or other gases.
As specified in the technical job instructions. Work order or
construction order.
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SADARA Polyethylene LSPB-1 Project
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13. SENSITIVE LEAK TEST GAS AND BUBBLE METHOD
This test is performed by pressurizing the system with gas, to 1
BAR (15 psig). This creates a pressure differential across a leak.
Leaks are detected by applying a commercial bubble forming solution
to all joints. The locations of commercial bubble are indicated by
the formation of bubbles.
This test may be performed at pressures greater than 1 BAR (15
psig). However, all conditions of G4S-6422-02 and G4Q-6422-02 shall
be met when a higher pressure is used.
Air compressors shall be equipped with discharge filters for
removal of water, oil and foreign matter. Maximum discharge
temperature of lubricated air compressors shall be 150C (300F)
A complete line or section of line containing several valves and
braches may be tested at one.
CAUTION: PNEUMATIC TESTING should be used only as a leak
alternative carefully planned and supervised procedures shall be
used to guard against the hazards of latent energy of compressed
gases.
The Company is responsible to assure that all conditions and
safety concerns identified in G4D-6422-01 are addressed.
14. POST PRESSURE TEST
After pressure testing has been successfully completed and
approved by the Project inspector, the following operations shall
be made.
14.1 Draining of Test Fluid
Release of pressure and draining shall be done on the downstream
side of check valves. All vents shall be opened before draining to
facilitate drainage and to prevent formation of a vacuum. No test
fluid shall remain in low spots.
14.2 Disposal of Test Fluid
The test fluid shall be disposed with as directed by Project
EH&S requirements.
14.3 Test Vents and Drains
Vents and drains used only for the pressure test shall be
plugged, seal welded and penetrant tested.
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METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
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14.4 Removal and Reconnection of Components
All temporary items installed for testing purposes (e.g.,
manifolds, valves, blinds spacers, supports) shall be removed.
Items that were removed for testing shall be reinstalled. Items,
such as instrument air tubing, check valve discs which were
disconnected before
testing shall be reconnected. Isolation valves closed for the
test purposes and that are required to be in the open position for
process reasons shall be opened. If the valve cavity has a drain,
the cavity shall be drained.
15. LAY-UP PROCEDURE FOR STAINLESS STEEL 15.1 Type 300-series
stainless steels shall be tested only with water that has very low
chloride
content in order to avoid pitting and stress corrosion cracking.
The maximum allowable chloride concentration is 20 ppm per
RT8S-4001-60. Verify the quality of the water following the
requirements.
Exceptions: Type 300-series stainless steel valve trim shall not
be a sufficient sole criterion for classifying a carbon steel
system as "stainless" for the purpose of applying Section 6. For
example, this section shall not apply to carbon steel pipelines
with valves having stainless trim unless there are also other
stainless steel components included.
In special cases, with the prior written approval of QG
Representative, water of up to 200 PPM chloride content is
permitted, provided:
That the hydrostatic test period is less than four days, That
the system is rinsed with steam condensate or demineralized water
until the
effluent chloride content reaches below 20 PPM, and That the
system is completely drained immediately after hydrostatic test and
rinse.
15.2 Type-400-series stainless steels are highly prone to
atmospheric corrosion. Type 400- series
stainless steel trimmed valves shall be removed from pipelines
before hydro test. If it is impossible to remove such valves from
the line, then written hydro test procedures must prepared and
approved ahead of time allowing the valves to remain in place. When
Equipment containing any Type-400 series stainless steels is left
in place, it shall be hydro tested in accordance with the
requirements of Paragraph 14.3, 14.4, and 14.5 of this standard.
The hydro test procedure shall carefully detail measures prevent
corrosion including lay-up of the Equipment. Do not use ambient
lay-up for Equipment made of 400-series stainless steels.
15.3 Treat the hydrostatic test water with oxygen scavenger per
paragraph 13.1 if the Equipment
contact time with water might exceed 4 days.
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Date Doc. No Rev. No Page
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15.4 Lay-up the system following the requirements. 15.5 At the
end of the lay-up, commission and start up the stainless steel
Equipment within 14 days.
Tested Line
(Above Ground Piping)
Dewatering Hose
Schematic Diagram for Disposal of Tested Water
Temporary Storage
Tank Pump
Water Tanker or
Truck
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SADARA Polyethylene LSPB-1 Project
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16. QUALITY CONTROL
Quality Control shall be strictly exercised in accordance to
approved Inspection & Test Plan and Quality Control
Procedures.
Ensure that all the Inspection report formats has been completed
and reports have been signed/accepted by all parties before
depressurizing the system.
All calibration certificates and water test report are attached
in the test pack.
QCI to verify that all punch points (Punch Category that affects
Pressure Test) shall be closed before Testing.
17. DOCUMENTATION
The following Documents shall be attached with the pressure test
packs.
1. Test package general information sheet. 2. Hydro test package
content check sheet. 3. Test package flow chart. 4. Hydro test
report. 5. Test diagram legend. 6. Schematic test package diagram
& test manifold. 7. Test package index. 8. Pneumatic test
calculation sheet ( if applicable) 9. Punch list 10. Safety
instruction sheet. 11. Test diagram P&ID ( Marked test
boundaries) 12. System definition P&ID 13. Marked air blowing
P&ID 14. Isometric drawing. 15. Check list before test 16.
Weld/NDT summary sheet. 17. Survey report (if applicable) 18.
Calibration certificates.
(Pressure gauge, pressure recorder, test relief valve,
temperature gauge, test manifold) 19. Blind control sheet. 20.
Valve test report (if applicable)
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SADARA Polyethylene LSPB-1 Project
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Date Doc. No Rev. No Page
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21. Water analysis report (Test medium) 22. Reinforcing-pad leak
testing report (if applicable) 23. Orifice flange joint inspection
report (if applicable) 24. Flange joint inspection report. 25.
Lay-up inspection. 26. Check list after test. 27. Flushing /
Cleaning report.
18. SCHEMATIC TEST PACKAGE DIAGRAM & TEST MANIFOLD
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SADARA Polyethylene LSPB-1 Project
METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
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Appendix A: Dew Point of Natural Gas
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METHOD STATEMENT FOR PRESSURE TESTING OF HIGH ALLOYS &
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19. ATTACHMENTS
1. Test package general information sheet 2. Hydro test package
content check list 3. Test package flow chart 4. Line List 5. Test
diagram legend 6. Calibration Certificate 7. Blind control sheet 8.
Bolt torqueing report 9. Punch list 10. Job Safety Analysis
(JSA)
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SADARA Polyethylene LSPB-1 Project
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Attachment - 1
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Date Doc. No Rev. No Page
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Attachment - 2
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SADARA Polyethylene LSPB-1 Project
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METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
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Attachment 3
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Date Doc. No Rev. No Page
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Attachment 4
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METALS Contractor Job No: 10001 / 6600028371
Date Doc. No Rev. No Page
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Attachment 5
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Date Doc. No Rev. No Page
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Attachment 6
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Attachment 7
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Attachment 8
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Attachment 9
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