PROJECT MANAGEMENT

Construction
Project Scope of Work
Design & Engineering
Established Related
Drawing
System & Subsystem
Testing
Quality assurance and
control
Construction
completion

PreCommissioning
Scope Finalization According
to Scope of work
System, Subsystem
Generation
Subsystem wise check-list
Generation for all Discipline
Testing /check-list/ Procedure
/document management
Mechanical completion

Commissioning
Assurance System
completion with all
quality parameter
All Discipline start-up
according Procedure
Line-up with operation
Hand-over Project to
operation
Project completion

SHREE CEMENT

PRE-COMMISSIONING
During
construction
System /Subsystem mark-up
Generation

Discipline-wise tag Generation (For piping

Test-pack mark-up and test-pack
generation )
Inspection testing report and check-list
Generation and issue for construction
completion record

After construction
Inspection and Testing report break-up and
submission record

Blowing and Reinstatement

Leak-test

System and subsystem wise walk-down/Red-line markup

Quality and execution witness
report

Construction completion certificate

and report

Mechanical completion certificate and

report

Start Commissioning and start-up activity

SCOPE:This
Standard
covers
the
minimum
requirements and acceptance criteria for the
inspection and testing of piping systems. The
work shall be carried out in two stages as
follows:

Stage 1
Inspection and verification, that all items have
been supplied and installed in accordance with
drawings and manufacturers requirements.

Stage 2
The testing of
integrity of the
into service.
Should there
standard, local

piping systems, to verify the

piping system, prior to putting
be conflict between these
or statutory requirements, the

Test-Pack Management
Introduction: Test-Pack Management is process to
calculate project piping progress in
mathematical number format and also easy
to construction each and every system with
proper record.
Test-pack have specific mark-up made by
test-pack engineer according service,
isolation valve and testing facility through.
Generally test-pack use for Piping & Pipeline ITR.
Test pack is a bunch of inspection testing
report(ITR) and relevant supporting
documents as below.

Test-Pack Management
11 ITR-A (Construction)
Line History Sheet
PIPING TEST EQUIPMENT
CALIBRATION CERTIFICATE
TEST PACK LINE LIST
PIPING INSTALLATION
Record Piping Package
Index
PIPING PRESSURE TEST
CERIFICATE
CHEMICAL CLEANING
Construction Completion
System Flushing Blowing
SUPPORT SUMMARY SHEET
TEST PACK REINSTATEMENT
Bolt Torqueing Report

3 ITR-B(Precommissioning)
WITNESS JOINT CHECK
INSTALLATION CHECK
PIPING COMPLETION
CERTIFICATE

Test-Pack Management
Calibration
certificate of all
equipment's and
gauges use during
testing

layout drawing
if applicable

High-lighted markup P&ID

Isometric
diagram

Flow-sheet

NDT Report
(RT/UT/DPT/M
PT)

TEST-PACK Identification

1-2-3-4-5-6
1. Project Code/Number
2. TP(Test-pack symbol)
3. Service & System Identity
4. System Number(3 Digit Fixed-XXX)
5. Subsystem Number(2 Digit Fixed-XX)
6. Test-Pack Number(3 Digit Fixed-XXX)
Eg-M205DCL1-TP-CI-011-01-003

How to Make TestPack Mark-Up:STEP-1

Properly Read & Understand

P&ID
(Piping and Instrumentation
Diagram).

P&ID
Piping and Instrumentation Diagrams
or simply P&IDs are the schematics
used in the field of instrumentation
and control (Automation)
The P&ID is used to by field techs,
engineers, and operators to better
understand the process and how the
instrumentation is inter connected.

P&ID
Most industries have standardized the
symbols according to the ISA Standard
S5.1 Instrumentation Symbol
Specification.
Piping & Instrumentation Drawing
(original)
Process & Instrumentation Diagram
(also used)
Process Flow Diagram PFD
(simplified version of the P&ID)

STEP-2 DESIGN REVIEW

The Contractor shall carry out a design
review in order to facilitate inspection
and testing work and defining the
approach to be taken.
When all HAZOP studies and CSBP Design
Reviews have been completed and the
P&IDs are at a stage where they have
been frozen the Contractor shall:
1 . Review and mark up P&IDs to determine
extent of each
Test Pack and to define total number of
Packs.
2 . Determine which vessels can be pressure
tested through

3 . Consider flanging of vessel nozzles to

simplify testing work.
4. Rationalize Piping system test pressures to
minimize
the total number of Test Packs required as
a result
of maximizing test limits.
5. Prepare a master set of color coded P&IDs
to identify
Test-Packs and boundaries.
6. Revise the Line List to reflect rationalized
test pressures.
7. Revise the Line List to include a Test Pack
Number
against every line.
8. Revise Isometrics to reflect rationalized test
pressures

STEP-3 Create Master Test

Pack
The Contractor shall create a Master Test
Pack to collect and collate all information
required to make up complete test packs.
Each Master Test Pack, for the systems
identified by the Contractor during the
Design Review, shall include the following
minimum information:
Test Pack lead sheet identifying Line
Number, Isometric Number, P&ID Number,
Test medium, Test pressure and extent of
test.
Marked up a set of P&IDs identifying Test
Pack and delineating test boundaries.
Authorization sheet allowing vessel to be
included in test (where applicable).

STEP-4 Completion of Test

Packs by
Contractor
The Contractor shall complete the
Master Test Pack to include a
marked up set of isometrics
showing:
Limit of test,
Location, size and rating of blind flanges,
Location, size and thickness of test spades,
Test fill location,
Test vent location(s),
Test pressure gauge locations,
Relief valve set pressure (for pneumatic
tests), and
Exclusion zone definition and location of

STEP-5 Test-pack Review

The Contractor shall submit the
Master copy of each Test Pack to the
Superintendent for acceptance.
If Master Test Pack is accepted
without comment the
Superintendent shall sign and return
this document to the Contractor who
shall prepare copies as described in
the Works, or as directed by the
Superintendent.
If the Superintendent makes
comment, the Master will be returned

TEST PACK IDENTIFICATION COLORS FOR EASY OF

IDENTIFICATION

Test Packs shall be color

coded.
An example is as follows:
Master Test Pack : Blue Folder
Contractors copy : Red Folder
Spare/Working Field Copies :
Yellow Folder

TEST-PACK
MANAGEMENT

WORK
AND
ITS IMPORTANCE

STAGE 1 - INSPECTION AND CONSTRUCTION

VERIFICATION
NON DESTRUCTIVE EXAMINATION - PIPING
AND FITTINGS
BRANCH WELDS AND REINFORCING PADS
HARDNESS TESTING
STAGE 2 TESTING
STAGE 3 - PUNCHLISTING
PIPING SYSTEMS
Post Test Punch listing and
Reinstatement Pack
Pre-test Punch listing
STAGE 4 - SYSTEM
FLUSHING

STAGE 5 - WITNESSING PIPING SYSTEM

PRESSURE TESTING

HYDRO-TESTING

Equipment
Contractor Obligations
Equipment Isolation
Valve Configuration
Joints
Loading Considerations
Field Installed Reinforcing Pads
Venting
Testing Medium
Test Pressure
Test Duration
Rectification
Test-pack submission

STAGE 6 - SYSTEM
DRYING
STAGE 7 - CHEMICAL CLEANING OF
PIPING SYSTEMS
STAGE 8 - PNEUMATIC TEST
PROCEDURES
STAGE 9 - LEAK TESTING OF
PIPING
SYSTEMS
Test
Records
Test Equipment
Pressure Gauges
Flow Measurement
Simplified Leak test Procedure
STAGE 10 - AIR BLOWING OF PROCESS
PIPEWORK
Duration of Air Blow
Location of Target Plates
Location of Target Plates
Air Flow Requirements
Re-instatement

THANK
YOU.
ANY
Question??
??