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IefsyPetp ms suosieghopoy, ‘mtg fami masRss en OO ESC METHOD STATEMENT FOR Doc. No, : 7T04-CS-GS-MS-PI-0002 Rev. Date FIELD PRESSURE TESTING | page 27 Dec. 2016 sLof 19 METHOD STATEMENT FOR FIELD PRESSURE TESTING PROJECT NO. PROJECT NAME COMPANY SITE : 7T04 ERC Refinery Project Egyptian Refining Company(TAKRIR) S.A.E. Mostorod, Egypt 27 Dex. 2016 For Approval KStung 26 Sep. 2016 For Approval M.Nezar LOBaik SD.Lee 04 Aug. 2015 For Approval G.B.Cto SDJung KK,Se0 18 March 2015 For Approval G.B.Cho SDJung K.K,Se0 08 Feb. 2015 For Approval GB.Cho KK Sed SM.Kang, 08 Feb, 2015 For Approval GBCho SDJung RY,Sung DATE DESCRIPTION PREPD CHKD ‘APPR (Hoc) REVD CONTRACTOR COMPANYMETHOD STATEMENT ‘TTOA-CS-G Rss GSESC FOR 21s. ae FIELD PRESSURE TESTING :2of 19 TABLE OF CONTENTS . Reference standards — }. Reference documents —- j. Definitions/Abbreviations . Test Water Criteria . Blinds 10. Test gauges —~ 11. Relief valves - 14. Application of pressure (Hydro/Service/ Pneumatic Test) — 15.Hydrostatic testing ao 16.Service testing - 17.Pneumatic test ~ 18.Leak Test for Drainage and vent water test - 49.Reports and records ~ 20.Non-conformances --——-—— 21.Post-test activities - 22. Attachments --—METHOD STATEMENT Doe. No, : 7T04-CS-GS-MS-PI-0002 saa csiic ron en FIELD PRESSURE TESTING | page 3 of 19 1. SCOPE This Method Statement defines the methods, rules, standards and quality applicable to the execution of Field pressure testing of aboveground and underground piping systems, connected equipment, and integral components of ERC Refinery Project at Mostorod, Egypt. The execution of the pressure tests is compulsory at the end of the piping erection works The tests shall ensure and validate with respect to applicable Codes. 2. PURPOSE The main purpose of this procedure is to define and describe the minimum requirements and responsibilities associated with the pressure testing of piping and integrated components. In addition, the applicable Codes and/or Standards shall be fully applied to all the testing activities. The main purpose of this document is to ensure that: - All activities are carried out in accordance with approved procedures, specifications and drawings; All tests, measurements and inspections required by this procedure and/or applicable project specifications are performed; ‘Special working and control processes to be used if required have been previously approved; Qualified personnel are deployed for carrying out testing activities. 3. REFERENCE STANDARDS Standards & Codes: - ASME Section V: Non-destructive Examination - ASMEB31.3 : Process Piping - ASMEB31.1 : Power PipingMETHOD STATEMENT FOR 27 Dec. 2016 FIELD PRESSURE TESTING 4 of 19 4, REFERENCE DOCUMENTS Project Specifications and Procedures: 7T04-MP-00-TS-002 7TQ4-MP-00-TS-004 7T04-MP-00-TS-012 7T04-CS -00-TS-003 7104-CS-00-TS-016 7T04-CS -00-PC-008 7T04-CS -00-TS-017 7T04-CS-00-PC-011 7T04-CS-00-PC-009 Piping Design General Piping Material Specification and classes Piping Support pipe Welding and Welding Inspection Field Pressure Testing of Piping Carbon Stee! Piping Coating and Wrapping of field joints in Underground Piping Construction Procedure for Alloy Steel Piping Construction Procedure for Piping Construction WorkMETHOD STATEMENT Doe. No. : 7T04-CS-GS-MS-PI-0002 Wyse 51:0 GSEsC FOR Date $27 Dex. 2016 FIELD PRESSURE TESTING | page 5 of (19 5. DEFINITIONS/ABBREVIATIONS, Company (Client) EGYPTIAN REFINING COMPANY (TAKRIR) S.A.E Contractor GS E &C (GS Engineering & Construction CO.,) Al Authorized Inspector TP Test Package TPC Test Package Coordinator P8iD's Piping and instrument diagram PS Pressure system Psv Pressure safety valve ITP Inspection & test plan NDE Non-destructive Examination Visual test PT Penetrate test Magnetic test Radiographic test Ultrasonic test Post weld heat treatment Request for inspection Site Quality Inspector Site Discipline Supervisor Job Safety Analysis Personal Protection Equipment Pre/Commissioning Engineer Welding Inspector Welding Engineer Construction Manager Health Safety and Environment Site HSE Manager Site Discipline Engineer Test Pressure Design Pressure 6. RESPONSIBILITIES 6.1 Contractor - Contractor is responsible for all testing activities related to the piping and their integral components at field and to verify that piping and piping system components are properly installed and ready for test. Contractor is responsible for coordinating with quality personnel for all inspection activities and JSA, Pre-Safety Meetings with crew, and any HSE Permit requirements, specific to pressure testMETHOD STATEMENT Doe. No, : 7T04-CS-GS-MS-PI-0002 Rsa6siic FOR ee FIELD PRESSURE TESTING | page :6 of _ 19 - Contractor shall ensure the respect of all the safety measures established in order to ensure the testing procedures, and methods to inspect, connections, fittings, gauges and flanges for integrity of tightness will at all times use the appropriate PPE, follows the written procedures and reviews with testing group, respecting and following all pre-established safety procedures and safety signs in place to ensure a safe work zone has been established and is maintained during the pipe testing process. 6.2 Site Quality Manager (SQM)-GS - SQM or designee is responsible for all quality matters related to the testing of piping system including the administration of non-conformance management. ‘SQM is also responsible for the clearance of test packages for testing to provide notification to the Contractor in advance to witness the pressure test / Service test. 6.3 Site HSE Manager (SHSM) -GS - SHSM or designee shall be in charge of the overall safety on site during pressure testing activities, ensuring that all safety procedures and precautions are in place and applied and respected by all persons. 6.4 Site Discipline Engineering (SDE) -GS ‘SDE js responsible for the released Test Packages in accordance with marked up P&lDs and Isometrics. SDE shall coordinate technical queries (if any) related to the piping testing activities with Engineering department. 6.5 Test Package Coordinator (TPC) ~GS - TPC is in charge to monitor all phases of test packages, for preparation, checking and follow up; He also carry out expediting action to involved tasks in order to respect the schedule. 6.6 Welding Inspector (WI) -GS - Wis responsible for all welding and NDE clearance related to each piping system/ TP.METHOD STATEMENT Doe. No, : 7TDA-CS-GS-MS-PI-0002 Rev. 35 FOR Date :27 Dec. 2016 FIELD PRESSURE TESTING | page :7 of 19 6.7 Quality Inspector (SQl) -GS - SQlis responsible for all quality and test related to each piping system / TP. 6.8 Site Discipline Supervisor (SDS) -GS - SDS is responsible to verify that all piping and components are installed and the system is completed according to drawings included in the respective TP. 7. EXCLUSIONS The following parts are excluded from the requirements of this procedure, unless specified otherwise by the Contractor: = Any package equipment previously tested by Manufacturer in accordance with Applicable Code and specifications, and certificates available. Instrument air sub-headers, outside the scope of Mechanical works and not shown on piping isometries. Instrument impulse lines between the block valve at the process or utility line and the connected instrument Equipment. Instrument components such as analyzer, flow instruments (*), level gauges, level Instruments, pressure gauges, pressure instruments, pressure regulators, pressure switches, relief valves etc shall be blind-off or be removed. Orifice plates shall be installed after pressure testing Pressure Safety Valve. Control Valves Shall not be included in Hydro Field Test. All in-line piping items excluded and removed during hydrotest shall be listed on the category B of Attachment #8, Punch List (*) FLOW METER installation can proceed upon dedicated request to the ContractorMETHOD STATEMENT Doe. No, : 7T04-CS-GS-MS-PI-0002 Qasesuc row oe ane FIELD PRESSURE TESTING _| page 8 of 19 8. TEST WATER CRITERIA Hydrostatic testing shall be carried out using water except if there is a possibility of damage due to freezing or if the operating fluid or piping material would be adversely affected by water, any other liquid may be used with Contractor and Company approval 8.1 Analysis The test water shall be analyzed and certified by approved laboratory and results shall be reviewed by Contractor and submitted to the Company for approval. Water Quality shall be in accordance with Clause 6 of project specification 7T04-CS-00-TS-016, 9. BLINDS There are 3 types of blind: - "Pan blinds": carbon steel discs with a "pan handle’, installed between two existing flanges. “If site fabricated pan blind will be used, it shall be marked as “Blind” on its handle’. Pan blind shall have a “T" handle solid with no hole on the handle. Spacer blind shall have aT" handle with a 13mm diameter drilled hole on the “T” handle section, size shall be in accordance with approved Engineering Drawings. Carbon steel blind flanges with a rating corresponding to the test package class. Carbon or stainless steel caps (dished end), welded to the pipe ends, preferably on a horizontal spool. For this type of assembly, the subcontractor must provide an extra-length of 50 mm (minimum) of pipe, at the position of each cap to avoid the weld Heat affected area or corrosion. Carbon steel biinds are perfectly clean (no loose scale or rust dust) and degreased. Parts assembled with flanges are equipped with new gaskets. The dimensions (thickness, diameter) of the blinds are as per ASME Code standard and piping class material specification.METHOD STATEMENT ‘TT04-CS-GS-MS-PI-0002 ‘outeyin 7 = FOR 7 aes 6s EsC FIELD PRESSURE TESTING oa 10. 11. ). TEST GAUGES: 10.1 Location Minimum two calibrated pressure gauges without intervening valves shall be connected for each continuous blocked section of piping. Gauges used for testing shall be installed as close as possible to the low point (Drain) and high point (vent) of the piping system. 10.2 Range Pressure gauges having dials graduated of a range twice the required pressure shall preferably be used in testing; however, gauges having a dial graduation of a Range between 2 - 3 times the required test pressures Size of the manometer diameter should be at least 152.4 mm (6") Each gauge shall have an identifying mark or number which shall appear on the Pressure test report. 10.3 Calibration All pressure gauges shall be calibrated every 30 days and at any time if there is a doubt about their reliability Calibrated gauge shall be tagged with the date last calibrated and this activity shall be recorded in calibration certificate. Test gauges could be calibrated at site or test lab using a calibrated dead weights tester RELIEF VALVES Relief valve(s) of adequate capacity set to relieve at 7 percent above the test pressure shall be installed on the test manifold. The relief valve(s) shall be validated prior starting pressure test. All manifolds used for test purpose shall be tested according to the present procedure. The manifold pressure test certificate shall be included in the TP. All temporary spools used shall be fabricated in according to the same piping class of The TP and / or approved by SDE.METHOD STATEMENT Doe. No, : 7T04-CS-GS-MS-PI-0002 teat ee ipl 6§ ESC FOR Dac! 27 Dee. 2016 FIELD PRESSURE TESTING | page :10 of 19 12. 13. SAFETY Suitable precautions in the event of piping system rupture shall be taken to eliminate Hazards to personnel in the proximity of lines being tested. Only authorized personnel shall stay in the test area during the test. Signs shall be displayed to barrier off areas indicating that pressure test is under progress. Safety in charge will coordinate with testing crew to ensure that all safety measures are implemented during pressurization Paying special attention to barricaded area with sufficient warning signs where the test to take place and FLAGMEN from test or construction groups will continuously patrol the barricaded area to ensure that no worker will violate the testing Areas. Minimum distance shall be calculated and maintained between piping under pressure and Personnel not directly involved with the test. The test pump shall be located such that the pump operator will not be exposed to danger in the event of failure. Pressure gauges shall be installed so as to be visible to the operator when operating the pump. PREPARATION All facilities such as and limited to (ladders, scaffoldings, lightning, pumps, manifold, pressure gauge etc.) shall be available until all the involved parties have properly completed their inspection activities. Prior to the start of the test, all activities such as vessels, pumps and instruments isolation from piping by using blinds or other suitable means shall be verified. This verification shall be accomplished by reviewing the applicable steps of the ITP and that all non-conformances have been completed. TP shall be submitted to the Company for Approval before commencing of pressure Test. Pressure testing shall be performed following the completion of PWHT, NDE, punch list and all other fabrication, assembly and erection activities required to provide the system or portions thereof subjected to the pressure test with pressure retaining capability.METHOD STATEMENT Doc. No. : 7T04-CS-GS-MS-PI-0002 Rev. 5 FOR Date 27 Des. 2016 FIELD PRESSURE TESTING | page: 11 of 19 The test package shall include, but not limited to, the following: Involved P&ID's, which shall show all test limits, List of isometric (revision shall be indicated) Line Index. Isometrics (last revision) marked up with test limits and all applicable information {as example valve locked openediclosed, valve removed) Welding History sheet (Computerized history sheet). Punch list Calibration Certificate for Inst. Piping pressure test reports, which shall include date, location, type of test (hydrostatic, pneumatic, visual or service), and information (test medium, design pressure, test pressure, ambient temperature, piping temperature), test duration, Pre-Test Check List. - Water analysis report showing chloride content of test fluid (If required). Upon completion of erection, pending items shall be listed and indicated in TP punch list as follows + Items "A" shall be completed before starting pressure test; + Items "B" could be completed to after pressure hydro-test. 14. APPLICATION OF PRESSURE (Hydro/Service/Pneumatic Test) The System and Sub-System may be separated into TP for testing The hydro test circuit diagram shall show the limit and method of isolation by TP and shall be prepared prior to testing. The circuits will be filled with the approved test fluid introduced from the lowest point All vents shall be opened during filling and closed when entrapped air has been vented. Package shall be pressurized and stabilize following Par. 15 to 17 of this Procedure.METHOD STATEMENT Doc. No. : 7T04-CS-GS-MS-PI-0002 FOR Rev. 5 Date: 27 Dee. 2016 FIELD PRESSURE TESTING _ | Page 12 of 19 14.1 Water Emptying Disposal plan shall be considered especially for chemically conditioned hydro test fluid After completion of the hydrostatic test and fully depressurized the tested system, vents and drains shall be opened to remove all the water immediately , air may be used to force evacuation, No heat shall be applied for drying. After pressure test, piping system shall be checked visually as follows: Whether all lines are cleared of loose scale and debris by use of air or water. All open ends to be closed after drying procedure. After completion of hydro test, Contractor shall verify the complete removal of test fluid in the System. Dewatering should be done from lowest drain point of the system. - Low Point Drain will be done seal welded and coating and wrapping. 14.2 Drying After Hydro test completion, Pipeline shall be dried by air. 15.HYDROSTATIC TESTING Water shall normally be used as test medium during hydrostatic tests, unless otherwise specified by the Contractor. When there is the possibility of damages due to freezing or to adverse effects in the piping or in the process another suitable nontoxic fluid may be used. During water filling, high points shall be vented to allow air/gas to escape. Pipe systems shall be filled from a low point as identified in the test pack isometric drawings. Before applying pressure, the test operator shall check the test equipment to assure that all low pressure filling lines and other appurtenances that should not be subjected to the test pressure have been disconnected or isolated by valves or other suitable means. Unless otherwise specified by the contract, the pressure shalll be raised at a controlled rate (not exceeding 5 bar/min) until the Test Pressure is achieved.METHOD STATEMENT Doe. No. : 7T04-C8-GS-MS-PI-0002 saa G410 FOR AS _ done FIELD PRESSURE TESTING | page: 13 of _ 19 The Test duration will start after the stabilization period for the residual air to go into solution. Test pressure shall be monitored during the full period of the test. The hydrostatic test pressure at any point in the piping system shall not be less than 1.5. Times the design pressure (unless otherwise specified by the contractual documents), but shall not exceed the maximum allowable test pressure of any non-isolated components, such as vessels, pumps, or valves. As per section No, 7.1 and 7.2 of Project Specification no. 7T04-CS-00-TS-016 regarding calculation of test pressure for intemally pressured piping 1- Not less than 1.5 times the design pressure. 2- For design temperature above the test temperature. The minimum test pressure shall be calculated By the following equation, except that the value of ST/S shall not exceed 6.5; Pr= 4.5 PSt s Where: PT = minimum hydrostatic gage pressure (kg/om2) P = internal design gage pressure (kg/cm2) ST= stress value at test temperature (kg/cm2) S = stress value at design temperature (kg/cm2) (See Tables A-I, AS ME 831.3). Examinations for leakage shall be made of all joints, connections and valves The piping system, exclusive of possible localized instances at pump or valve packing shall show no visual evidence of weeping or leaking. The Inspector shall circle all accessible leaks found on piping using a non-deleterious marker. The magnitude of leak shall be described in terms of: Damp or moist area, drops per minute or steady stream, TP will be evaluated by GS considering their criticality and pressure test resulting from this consideration may be conducted after working hours (or all area will be evacuated other than testing crew, quality inspectors and safety supervisors or watchers)METHOD STATEMENT Doc. No. : 7T04-CS-GS-MS-PI-0002 asi csic ror eae FIELD PRESSURE TESTING | Page: 14 of_ 19 Pressure Recorder will be used only during hydrotest for the following: - Underground piping final hydrotest. - Tie-In piping. - Piping interconnecting to Pipe Rack (piping installed on Pipe Rack). 15.1 Test Pressure < 30 Bar For pressure test < 30 bars the system should be pressurized up to Test Pressure (Pt). After 5 minutes stabilization at the maximum pressure, The Test Pressure shall be continuously maintained for Minimum 10 minutes or for the duration to inspect the complete system. After the Holding Time the pressure shall be depressurized at the design pressure (Pd), than the entire system shall be inspected 15.2 Test Pressure > 30 Bars 4 Step: Approved hydro-test manifold will be connected to the line. The system pressure will be raised slowly using hand or power operated pump up to %50 of test pressure and hold for 10 minutes of stabilizing time. 2 Step: System should pressurize up to %70 of test pressure and hold for 10 minutes of stabilizing time. 3 Step: System should pressurize up to %90 of test pressure and hold for 10 minutes of stabilizing time. 4 Step: System should pressurize up to test pressure and the test system shall be isolated from the pump. The Test Pressure shall be continuously maintained for Minimum 10 minutes. 5 Step: After completion of 4 Step the pressure shall be maintained continuously until entire system shall be inspected. During first four steps only pressure behavior should be monitored from the pressure gauge of filling manifold located on the ground The test shall be considered satisfactory if there is no evidence of leakage or pressure loss after the specified test period. During step 1, 2 safe distance concept will be extended to 3 m radius, for critical points to all testing area, in case of there are no pressure drop. Inspection will be done as described at step 5 by barricading only critical areas. See attachment 8METHOD STATEMENT ‘TT04-CS-GS-MS-PI-0002 Rs GSESC FOR Sros.2016 FIELD PRESSURE TESTING 115 of 19 16,SERVICE TEST 16.1 Underground pressure piping shall be tested as per project spec: 7T04-CS-00-TS-016 16.2 Hydro testing of piping may be replaced by service test upon approval by the Company. The test fluid is the service fluid, the pressure shall be gradually increased in steps until operating pressure is reached, holding the pressure at each step long enough to equalize piping strains. For Underground piping of sewer lines, gravity test, (if required) shall be considered and the test limits start /end point connections will be from manhole to manhole after backfiling or will be determined at site depending on the site condition. 17.PNEUMATIC TEST Pneumatic testing shall not be used unless the Contractor specifies pneumatic testing or permits its use as an alternative. It is recommended that pneumatic testing will be used only when one of the following conditions exists: - When piping systems are so designed that they cannot be filled with water; - When piping systems are to be used in services where traces of the testing medium cannot be tolerated. The gas used as the test medium shall be non-flammable and nontoxic. Since compressed gas may be hazardous when used as a testing medium, it is recommended to observe special precautions for protection of personnel. The test equipment shall be examined before pressure is applied to ensure that it is tightly connected. All items not subjected to the test pressure shall be disconnected or isolated by blinds, ‘Temporary valves or other suitable means. Test pressure shall be monitored during the full period of the test. The pneumatic test pressure shall be calculated according to the Code. Thereafter, the pressure shall be gradually increased in steps until the test pressure is reached, holding the pressure at each step long enough to equalize piping strains. The test pressure shall not exceed the maximum allowable test pressure of any non-isolated component such as vessels, pumps, or valves, in the system.METHOD STATEMENT Doe. No, : 7T04-CS-GS-MS-PI-0002 sca Gsisc FOR Sx howans FIELD PRESSURE TESTING | Page 16 of 19 The pressure shall be continuously maintained for a minimum time of 10 min. It shall then be reduced to the lesser of design pressure and held for such time as may be necessary to conduct the examination for leakage. Leakage detection shall be performed by soap/bubble or equivalent method and shall be made on all joints, connections and valves. The piping system, exclusive of possible localized instances at pump or valve packing, shall show no evidence of leaking. Step 1: The package is first pressurized to 2 bars (or 25% of the pressure test if lower than 2 bar). Pressurization is stopped for 10 minutes for stabilization. The package is then inspected by spray soap test (welds, flanges and screwed connection are controlled) to detect eventual leaks. Step 2: The package is then pressurized to 50 % of pressure test (not in the case of pressure test if lower than 2 bar).Stabilization time 10 minutes. If the pressure loss exceeds 10%, the test shall be reduced to 25% and checked for leaks. Step 3: The package is then pressurized in steps of 10% with each step holding time of 5 minutes to reach 100% of pressure test. Holding time at pressure test is 10 minutes. If the pressure loss exceeds 10%, the test shall be reduced to 25% and checked for leaks. Step 4: The package is then depressurized to Design pressure and inspection shall be performed by brush soap. Depressurization is stopped and maintained, in order to achieve the soap test activity. Step 5: The package is finally depressurized to atmosphere gradually keeping in mind the noise level and the risk of collapse. All leaks detected are marked and recorded on the Test Packages. Once leaks have been repaired, the complete test shall be fedone from the initial point according to the above procedure. The successful completion of the tests shall be confirmed by all parties by signing the acceptance certificate enclosed to the test package The bolts shall not be tightened while systems being tested are pressured above 2 Kg/om2. Reinforcing pad of weld branch connection shall be pneumatic leak tested with air at 1.78 kg/cm2 (175 Kpa) through tapped vent hole (Weep hole), and examined for leaks using a soap solution at reduced pressure 0.2 to 0.3 kg/cm2 (20 to 30 Kpa). The tapped vent hole shall be packed with heavy grease after completion of test; hot taps (if any) must be tested before the coupon is cut.METHOD STATEMENT Doc. No. : 7T04-CS-GS-MS-PI-0002 seach FOR a FIELD PRESSURE TESTING | page 17 of _ 19 48.LEAK TEST FOR DRAINAGE AND VENT WATER TEST Drainage and vent water test. Prior Testing, few steps/procedures shall be considered as follow: 1. Visual inspection for welding joints. 2. Surface Blast/ Power Brush cleaning 3. Surface Preparation Inspection 4. Applying the adhesive and thickness testing. 5. Applying wrapping for the field joints. 6. Lowering the pipe in to place as per the given level with considering enough clearance between the pipe and the bedding not less than 100mm. 7. Holiday Testing of complete line. ‘Awater test shall be applied to the drainage system either in its entirety or in sections. If applied to the entire system, all openings in the piping shall be tightly closed, except the highest opening, and the system shall be filled with water to the point of overfiow. If the system is tested in sections, each opening shall be tightly plugged except the highest openings of the section under test, and each section shall be filled with water, but no section shall be tested with less than a 10-foot (3048 mm) head of water. This pressure shall be held for at least 30 minutes. The system shall then be tight at all points. 19.REPORTS AND RECORDS It is responsibility of Contractor to prepare all records required by this procedure and by contractual requirements unless otherwise specified. Subcontractor shall obtain Contractor's approval prior to commencement of any testing and provide Contractor with a proposed list of all blinds installed and their locations. 20.NON-CONFORMANCES All Non-Conformances shall be clarified prior the starting of test pressure, anyway if Non- Conformance will be found during the execution of pressure tests, those shall be notified and the repair procedure to be clarified and approved by the Contractor. The system shall be retested.METHOD STATEMENT Doe. No. : 7104-CS-GS-MS-PI-0002 ssaestic FOR Ba ean FIELD PRESSURE TESTING __| page 18 of 19 24.POST TEST ACTIVITIES 21.1 Removal After test completion the following temporary items installed for test shall be removed + Valves; + Blinds; Spacers; + Supports; + Mock-up or spool pieces. + Draining & drying the lines to be completed after testing completion. 21.2 Reinstatement for system leak test After tests completion the system shall be reinstate as follow: - Items that were removed for testing; Items, such as instrument air tubing, check valve discs which were disconnected before testing shall be re connected; Valves shall be unlocked; PSV/TRY shall be installed, verified and certified (as applicable) Spring supports shall be unlocked. Orifice plates shall be installed. Seal welds on test vents/drains shall be performed; (Not include the valve drains for seal welding unless otherwise indicated on the specifications) Final gasket shall be installed. Bolt torque activities and certification; Reinstatement completion shall be validated by the Contractor representative Punch List items of Category B shall be performed and cleared.METHOD STATEME Doc, No, : 7104-C8-GS-MS-PI-0002 5 Wp sss GSEs FOR ta Ea FIELD PRESSURE TESTING | Page 19 of: 19 22. Attachments: FIN (Field Inspection Notification ) Inter-discipline Release Note for Pipe Lying Into Trench Daily Welding Visual Inspection Report (Computerized from GTP-JC) Release for Wrapping Pre Test Check List Punch List Flushing / Draining / Drying Test Report. Field Pressure Test Report Wrapping Inspection Report (Including Surface Preparation and Holiday Test) 10-Punch Category for the Test Package of Piping[Attachment No. 1 Ssengneering Construction Re aS FIELD TEST/INSPECTION NOTIFICATION FIN lcoupany eaten FIN. NO. JpnojecrNaME, ‘ERCREFINERY PROVE sire lconrmactor “asa su-cowrractor _ORASCOM |rim.o sPEcTioN / TEST REQUEST DATE +: Inspection TestDate Time | Reference (Attachement) Jnesurs/ MOINS with hls name and igrzare ‘COMPANY /TPI‘Attachment No. 2 ‘pian Rating Company (CTAKRIR) SAE Re sos Inter-discipline Release Note Pipe Laying Into Trench Sabeonaactor rea One Date(DD-MM Vout) hhemarks: Above Mentioned item have been completed and accepted and released for piping work. \oxaTone Inued by GS R&C ‘Checked ByGSE&C | Received By GS E&C ISTER Constrection (Chil/ 1) Qc (City Construction (Piplse 1) Name ‘Signature Date€ ON JuaWYDeNY|[Attachment No. 4 Repo No, 7TOCS-OSITRWRPLOTIO “The folowing maybe oaased fr Paltngoating which ready afer fabrication intl Pssroton: Drawing No, Speck No, Mall See quenay tem ype “Phepine Engineer Nama: Dota “The toms! beng released or patncoting shel decrbed suitably -ndcating Tag No,, Dring No, tomatic io. Secon Na. Equparint Na, Pat Spectcation, wc, av apptcabe i requed welche may be atixched inating (ave ibe pared [VERIFICATION Checked fr complaton of provous atten incutng NDT, Ratased fr Paling / Cong,eq eumeubig ‘OueN [Tar raewdn03 so12eTHD sopancoqas 3821 OpAH 40} aS8710U ssyewiey| Gunserouphy 40} poysaes punoy pus 3611 8119 0} GulpI0D9" pyoedsut pue peyooy Burdid ity “Paveop ueed eney v favoboieD soun| yound We Mou] Fb ‘ajreyeul used ancy srees odd ye yeun eUD] CL Penoural ueeq eazy suoddns edid Azeoduey ye yeu xeUD| Z appa 9 Buna ie pom Kero em er a ppm sane wa PH HH paidecoe pue pauode: ‘pawewerduy vee @ABY LON / suoKpedsuensin Bupjom pounbas ye einsua] OL uogeoypeds sed se Aqsauico pajjejsul eve suojoeuUoo eunsseud Je JE SYD) & ‘suojeaypeds 20d 68 suoqauuco pemares uo werees euD| ‘s6umy pe6uo; o Bunes a eUD) L UoqoaNp Moy “Ou Be} 10) SaAFBA YDO4D) 9 2d 9 enpeue aico 20; Budd OUD] _F Y __ UO] RO]eYpUl ee POTEISUI eve seeEO ¥ syOR HALO OM ICUS! __s2dofs 9 dune ‘jono} voneyEysuy Syewonl aurebe vopeyersul Gurded ¥20UD| “SUOIsIAaL y80 axe OBE~Ed 183 Ut Papnjour JUSLUNOOP PUe SU!EIP [FE 84D| le eos] wen] = = “ON 82, Bupse1 one sOIpAH 20) WeWeTEIS POON) eunpesoia GuNSeL 1831 YOJ 3SV37SY GNV LSI MOSH LSal-sud | voprusuy usages |S “ON Juawyseny|[- ara ans 7 Tat keedwoy comme So 4 | [Tr TI L 4 f =[S|- 2-2-1), tautundwos [ova | sowenuocwne if vonduoeed wou young fon ‘a uo poubig pus pareerg “| “nn ve wes t Geoouphy Tiotanea yeorouphy faobere9) ed paveoio eq weD : "yeen00 5 rome Ry see 28 euoyeq powsoy? 04}: V. 7 racy SIT HONNd 9 ‘ON JUSWYSeY|[Attachment No. 7 ‘Gece Piping System ERG Sa) Flushing/Draining/Drying [TeatPckage No. | Report No. SN. Line No/ttem Description ‘Size a en Remarks > + L | Subcontractor Contractor Compeny/TPt ‘Name Signaturettachment No. 8 Sstrrg cent serene cee FIELD TESTINSPECTION REPORT Efe. SSS PIPING PRESURE TEST lprosect no. 17704 REFORTNO. : JPROSECTNAME ——_: ERCREFINARY PROJECT sire :MOSTOROD, EGYPT fpowsacron 2 GS RAC SUB-CONTRACTOR REFERENCE SPECS, _: 7T0-C5.00-T8-016 Spnem Descriptions Potable Water Sub-Syetem Nes frest PACK No: [Dato et Frese Medium: Potable Water free tarts Time Ends Water Anaya Report" applinble": Attached aration fee DETAILS OF TEST [restPreee Fest Pressure: [Actua ex Presure at Start Actual Temprature at St [Actua eat Pressure at Eads [cat Tempratare at [presare Gavge JFempraare Geers ev {Sera aumber: wa 2 Sera member Sr.No. 190 Drawing No LINE Ne, Remarks Bee PP errr] Subcontractor Contractor ‘Compamay/ TPE‘ava OLSVAINOS-aAS 3 LdXOTAOYOISON # LIS OM1OWd AWANLETY OWA? DAWN L9aTOwd 1000-XXLL-XXX-SO-VOLL # ON THOETE OL: “ANWEWOO ‘NIddVaM / DNLLVOD 1LdOd3e NOILDAdSNI/LSAL C1414 6 “ON JUSLUYSeNY|Attachment No. 10 - Punch Category for The Test Package of Piping Punch Category for the Test Package of Ne Description Category ‘CONSTRUCTION GENERAL [Access provision for the piping eniies fo be inspected according to specification or ITP freauirern _ No high point vent and/or low point or pocket drain as per ISO DWG. did > i> direct connection to the equipment shall be confirmed by Mechanical or QC. lOrifice meter upstream/downstream length inadequate. Strainer position not as per drawing. IFiow meter installed wrong direction [Earthing lug welding tothe piping incomplete Missing Electrical Tracing lMissing of direct welded type tracing to service pipe (SECT). 71 [Pipe penetration through walls/grating not large enough. (if walls/grating to be cut) 12 [Pipe penetration through walls/arating not large enough. (if pipe to be cut) 13 [Poor paint quality except touch up paint - 74 |RO tobe installed with correct direction, [Strainer mesh to be installed lOrifice plate to be installed after ushing lMissing Flange Insulation, Missing personnel protection insulation ‘linterference between platform & another (piping, [Cleaning of rust for pipng Remove masking tape from welds or flange surfaces. [Spacing between pipe and structure/grating etc. insufficient for insulation, bolting and etc Piping 1. Wrong type of Reducer Installed 2. |Wrong Material Installed (Flange, nipolet, nipolet flange, etc.) 3. |Level Gauge, Sight Glass, ete not installed for line check 4 [Blind flange not inatalled or wrong type of blind flanged installed 5 |Line plumbing (vertically or horizontally) tolerance over specification requirement. 6 |Line connect to wrong nozzle or wrong equipment 7 8 9 >| o|>|> ulation, etc.) >|>|a|>|0|0| 0/0) m0) a0) >|\0|>|o [Flange not properly aligned (mie-alignment) and gap not within tolerance. lWrong Pipe Spec Material |Remove spool tage from pipe 10 [Permanently install spo! & support before hydrotest (at pump nozzle, compressor nozzle, etc) 11 [No weep hole on vent pipe 18 >|>|a/>|>|>|>|>]a/>|>Attachment No. 10 - Punch Category for The Test Package of Piping Punch Category for the Test Package of No. Description Category Uitlties Station hose connectors to be installed [Steam Lances not installed Flange face damaged or rusted [Eccentric reducer inetalled In wrong position Drain & vent blinds not installed instal Drain Plugs Distance between welds is less than specification requirement. (Welds proximity) Bolts / Nuts 1 [Nonobservance of Bolts/Nuts installation specification and procedure. (Tightening Pattern, etc) 2_|install wrong type of Bolts & Nuts (Not as per drawing) in the permenant positions 3 |Loosen Bolts at relief valve connection. 4 [Botts not tightened at flange connections for the permant flange connection. 5 [Bolts rusted 6 | 7 | 8 [Apply approvded lubricant on bolts thread under nuts Install correct bolts at test limits after test Incorrect Bolts length & material w| a] a|m|>| a) >|> GASKET [Permanent gasket not installed at permanent flange connection during test. 2. |Wrong specification gasket installed [Permanent gasket not installed at hydro test flange connection (test break point) Support Fremporary supports not removed (if welded) Pipe support (dummy pipe, shoe, etc.) to pipe weld incomplete INo weep hole for Shoe/Reinforcing pad according to drawing or specification, [Sealing of vent hole on the pad after test by mastic seal or equivalent according to Spec. Pipe stopper not installed (welded to pressure part) |Gusset plate not installed _ |Pipe support installed not as per dwg |Support anchor & Jack bot to be installed |Lug/Stanchion (dummy pipe) no weep hole INo grouting on support footing [Support welding incomplete at non pressure parts [Temporary tack welding to be removed at botiom of shoe |Support guide not yet installed — 13 |Piping shoe not properly installed (add shim plate) 14 |Pipe stopper on shoe not installed 28 > >|>|>|>|0|a/a|>|>/>|>| a) >|>|>Attachment No. 10 - Punch Category for The Test Package of Piping Punch Category for the Test Package of Piping No. Description 15 [Spring Supportitanger to be set to cold position and stopper removed B Valves. [Control Valve not installed after test (if temporary spool installed) |Giobe Valve or Non Return Valve installed in wrong direction |Cavity vented bail or Gate Vaive installed wrong direction (if flange type) jrong Controlied Valve Installed [Relief Vaive not installed after test /alve damaged [Valve hand wheel orientation not as per drawing (for welded valves) Remove wooden block inside check vaive falve handle location ts not matched with drawing (i lange type), and accessibility for loperation according to spec. |Check Valve rotate to original position and install permanent gasket after pressure test Valve hand wheel not installed or net installed probably [Control Valve to be reinstated after test 18 [Valve locking device to be installed B Blinds 1, [Spectacle Blind, Blind or Spacer not installed or installed as opposite position against P&ID Jshowing due to test limit 2, [Spectacle Blind, Blind or Spacer installed in wrong position if ine has to be cut 3. |Remove temporary Blinds after test 4_ [install permenant Blind at Battery limit after test. INSTRUMENT © [e|~jofalalels|= s o|a|>| o 1 [Orifice tapping point wrong location, > [Flow meter, sight glass, et. (ir-iine instruments) to be installed for dimension and alignment lcheck 3 |Reinstate In-Line instruments after flushing 4. |Orifice flange jacking bott not installed according to specification requirement. DRAWING >\a| >|> 1 [Line installed not as per drawing. Piping not slope as per drawing. 3_[ISO drawing not conforming to P&ID or vice versa. A > > a3