CE & EH WHP - Pressure Test & Test Pack Procedure: Block 5 - AL SHAHEEN FIELD Development

Block 5 - AL SHAHEEN FIELD Development
Document Title: CE & EH WHP - Pressure Test & Test Pack Procedure
Project: WHP02-SMO1 Document Number: ASYYY-19-302063-0001 Date: 31-Mar-2020 Rev.: 00
Doc Type: PRC System: GENE Phase DE Status: IFR Class: 2
GLF-WHP02-EPCI4
CE & EH WHP - Pressure Test & Test Pack Procedure
Is the document generated from an existing As-Built? YES NO
Originator Document Number Last ASB Rev. :
Remarks:
00 26-Apr-2020 IFR ISSUED FOR REVIEW Kristian Y A P Jemmi A Didi H
00 31-Mar-2020 IFR ISSUED FOR REVIEW Kristian Y A P Jemmi A Didi H
Rev. Rev.date Status Description Issued by Reviewed by Approved by
The information contained in this document is the proprietary to North Oil Company. It must not be reproduced, stored, disclosed to any third party or used for any purpose not authorized by North
Oil Company. Printed documents are uncontrolled and considered as "for information only". Reference should always be made to the on-line EDMS for the updated version
Major Projects Template MAJOR-ASY-MPQA-FOR-000004_Rev00 Dated 09/06/2018
Page 1 of 49
REVISION HISTORY
Rev. Rev. Date Status History Issuer Reviewer Approver
00 31-Mar-2020 IFR ISSUED FOR REVIEW Kristian Y A P Jemmi A Didi
00 26-Apr-2020 IFR ISSUED FOR REVIEW Kristian Y A P Jemmi A Didi H
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CONTENTS
Table of Contents
Revision history................................................................................................................................ 2
contents............................................................................................................................................. 3
1 Introduction................................................................................................................................ 6
2 Objective..................................................................................................................................... 6
3 Scope.......................................................................................................................................... 6
4 References.................................................................................................................................. 6
5 Definition and Abbreviation......................................................................................................7
5.1 Definitions............................................................................................................................................ 7
5.2 Abbreviations....................................................................................................................................... 9
6 Role And Responsibilities.......................................................................................................10
7 Safety Requirements Prior to Pressure Test.........................................................................11
8 General Pressure Test Requirements....................................................................................11
9 General Test Preparation........................................................................................................14
9.1 Gauges, Recorder and Thermometer Requirements.........................................................................14
9.2 Testing Equipment............................................................................................................................. 15
9.3 Temporary closure material................................................................................................................ 16
9.4 Documents / Record Preparation....................................................................................................... 17
9.4.1 Document of Test Package..........................................................................................17
9.4.2 Test Package Issuance................................................................................................18
9.4.3 Test Package Work Flow.............................................................................................18
10 Cleaning and Flushing.........................................................................................................19
10.1 Cleaning Methods.............................................................................................................................. 19
10.1.1 Cleaning with Air (Blowing or Air Flushing)..................................................................19
10.1.2 Cleaning with Water (Water Flushing)..........................................................................20
10.1.3 Mechanical Cleaning....................................................................................................20
10.1.4 Chemical Cleaning.......................................................................................................20
10.2 Application Specific to be cleaned...................................................................................................... 20
11 Vessel and Equipment.........................................................................................................21
12 Hydrostatic Test Procedure.................................................................................................21
12.1 Scope and purpose............................................................................................................................ 21
12.2 Preparation for Hydrostatic Test......................................................................................................... 22
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12.2.1 Safety Precaution........................................................................................................22

12.2.2 Safety Exclusion Zone During Pressure Testing..........................................................23
12.2.3 Execution of Hydrostatic Test......................................................................................23
13 Pneumatic Test Procedure..................................................................................................26
13.1 Scope and purpose............................................................................................................................ 26
13.2 Preparation for Pneumatic Testing..................................................................................................... 26
13.2.1 Safety Precaution........................................................................................................27
13.2.2 Safety Exclusion Zone During Pressure Testing..........................................................27
13.2.3 Execution of Pneumatic Test.......................................................................................28
14 Completion of Test............................................................................................................... 30
15 Venting /Draining/Drying......................................................................................................31
16 Defects and Repairs.............................................................................................................31
17 Records................................................................................................................................. 31
17.1 Appendix .1........................................................................................................................................ 33
17.2 Appendix .2........................................................................................................................................ 34
17.3 Appendix .3........................................................................................................................................ 35
17.4 Appendix .4........................................................................................................................................ 36
17.5 Appendix .5........................................................................................................................................ 37
17.6 Appendix .6........................................................................................................................................ 38
17.7 Appendix .7........................................................................................................................................ 39
17.8 Appendix .8........................................................................................................................................ 40
17.9 Appendix .9........................................................................................................................................ 41
17.10 Appendix .10.................................................................................................................................. 42
17.11 Appendix .11.................................................................................................................................. 43
17.12 Appendix .12.................................................................................................................................. 44
17.13 Appendix .13.................................................................................................................................. 45
17.14 Appendix .14.................................................................................................................................. 46
17.15 Attachment .1 Typical Hydrostatic Set up.....................................................................................47
17.16 Attachment 2 Typical Pneumatic Testing Set up............................................................................48
17.17 Attachment .3 Test Pack Work Flow.............................................................................................. 49
17.18 Attachment .4 Snoop Liquid Leak Detector....................................................................................50
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1 INTRODUCTION
This procedure covers the detail requirements of flushing, draining, hydrostatic & pneumatic
pressure strength test and drying of piping system of Block 5 - AL SHAHEEN FIELD Development
“Gallaf Batch 2”.
The test pressure and system boundary limits shall be covered and will be shown on respective
piping pressure test packages.
2 OBJECTIVE
The objective of this procedure is to provide sufficient guideline on system cleaning &flushing,
strength testing of all pressure component and reinstatement within the test boundary of the system.
This to ensure a consistent project requirement is always achieved as per schedule with highest
quality standard from fabrication and installation of pipework across all project facilities with safe
working environment.
3 SCOPE
This procedure shall apply to Piping for Block 5 - AL SHAHEEN FIELD Development “Gallaf Batch 2”
4 REFERENCES
Document No Title
ASME B 31.3 Piping process
ASME B31.8 Gas Transmission and Distribution Piping System
ASME SEC. VIII DIV 2 Pressure Vessel Code
ASME BPVC VIII Div.1 Rules for Construction of Pressure Vessels
ASME PCC-1 Guidelines for Pressure Boundary Bolted Flange Joint Assembly
ASME PCC-2 Repair of Pressure Equipment and Piping
NORSOK-L-005 Compact Flanged Connection
ASME B1.20.1 Pipe Threads, General Purpose
ASME B16.5 Pipe Flanges and Flanges Fitting
Standard Specification for Alloy Steel and Stainless Steel Bolting Materials for
ASTM A193
High Temperature Service
Standard Specification for Alloy/Steel Bolting Materials for Low-Temperature

ASTM A320
Service
EN 837-1 Pressure Gauges - Part 1 Bourdon Tube Pressure Gauges

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API STD 598 Valve Inspection And Testing
API Standard 614 Lubrication, Shaft-sealing and Oil-control Systems and Auxiliaries
SD-NOC-PVV-171 Steel Piping Fabrication
SD-NOC-PVV-173 Pneumatic Testing of Above Ground Piping System
SD-NOC-PVV-175 Cleaning of Piping And Vessel
SD-NOC-PVV-178 Design and Erection of Glass Reinforced Plastic (GRP) Piping System
GM-NOC-PVV-142 Valve Type
SD-NOC-EC-600 Pre-Commissioning and Commissioning Standard
SD-NOC-EC-601 Pre-Commissioning and Commissioning Engineering
SD-NOC-EC-114 Piping Bolt Tightening Procedure
5 DEFINITION AND ABBREVIATION

5.1 Definitions
Term Definitions
The authorization in writing given by the Company to the Contractor

on a procedure or to proceed with the performance of a specific part of
the work without releasing in any way the Contractor from any of his
Approval
obligations to confirm with thetechnical specifications, requisitions, etc.
The words “Approve”, “Approved” and “Approval” shall be construed
accordingly.
COMPANY North Oil Company
CONTRACTOR SMOE Indonesia
Shall Used to indicate that a provision is mandatory
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Used to indicate that a provision is not mandatory but is

Should
recommended as good practice.
(Integrated Commissioning and Progress System) Software, property

of Company. Designates the tool to be used during the Pre
ICAPS
Commissioning and Commissioning activities in order to support and
implement the OPERCOM® methodology
MC Team Integrated Mechanical Completion Team
Holding Time Time when the pressure reaches to demand pressure
A pressure test conducted using water or other approved liquid as the

Hydrostatic Test
test medium
A pressure test conducted using air/dry air or other approved gas as

Pneumatic Test
the test medium or in conjunction with liquid
Test conducted to piping/pipeline/riser by subjecting it to an internal

pressure using liquid or gas to ensure strength of the materials and
Pressure Test
welds at the test pressure. Pressure test can be hydro test, pneumatic
test, and service test.
Also referred to as static commissioning, starts when a system or

Pre commissioning
subsystem achieves Mechanical Completion
A further subdivision of a System, that performs a partial operational

System function to the system, with no or limited interference with the other
subsystems
A major subdivision of an installation, being either process or utility

Subsystem that performs a major operational function of the plant. Systems
include all the component which provide the functionality of the system
A test which is applicable only to piping in Category D Fluid Service

Service Test
where the test pressure is at normal operating pressure of the system.
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5.2 Abbreviations
Acronym Description
EPC Engineering, Procurement and Construction
QC Quality Control
QA Quality Assurance
PMT Project Management Team
PL Punch List
MC Mechanical Completion
PTW Permit to Work
NDT Non Destructive Test
CRA Corrosion Resistant Alloy
RFI Request for Inspection
ITP Inspection Test Plan
ITR Inspection & Test Record
HPV High Point Vent
LPD Low Point Drain
PPE Personal Protective Equipment
WPS Welding Procedure Specification
WQR Welding Qualification Report

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WQT Welding Qualification Test
6 ROLE AND RESPONSIBILITIES

a) Project Management Team and Construction Superintendent Their responsibility is to
ensure safety for all personnel and equipment. However, it shall be noted that every personal
shall participate to ensure each activity is performed in a safe and controlled manner. In
addition, their responsibility is to manage the completion of construction by area or
subsystem.
b) Test Engineer/Piping Engineer The responsibility of test engineer/piping engineer is to
prepare all required documentation e.g. pressure testing procedure, test limit, applicable ITR
etc., all this information are captured inside test package. Detail minimum test package
information refer to Para.8.2. Test engineer/piping engineer also has responsibility at early of
stage of piping pre commissioning activity e.g. to prepare all temporary materials and
equipment such as temporary/closure material, instruments, manifolds, pumps, compressor,
and hose(s), consumable and others.
c) Piping MC Team Piping MC team is integrated team consisting of mechanical completion
coordinator, piping discipline, quality control, and piping pre commissioning team where the
main activity is to carry out inspections/test of work claimed completed by production team.
Prior to pressure test by pre commissioning team, internal inspection/line walk perform by
Piping MC team and QC, this to ensure or to identify any PL, especially PL-A which hydro
test activity/safely energized for commissioning. PL-A shall be closed prior pressure test. In
addition, responsibility of mechanical completion coordinator is to plan and manage MC
activity e.g. monitoring: punch list, progress of open/closed ITR, and in coordination with QC
and commissioning to ensure tracking and closure of mechanical completion by subsystem.
d) PT SMOE Supervisor/Inspector QC Supervisor/inspector responsibility is to perform line
walk/inspection either internal or official. Internal line walk/inspection carry out in order to
ensure the piping works is fabricated and installed as per latest AFC drawing and
specification, including welding and NDT. Official line walk/inspection is carried out with
Company through official RFI notification to Company, record agreed PLs items raised during
line walk/inspection, coordinate with Company for witnessing as required by QC. In addition,
QC also has responsibility to check all equipment (e.g. pressure gauge, pressure recorder
etc.) is having valid certificate prior pressure testing.
e) PT SMOE Piping Testing Supervisor/Foreman Their responsibility is to execute the
activities related to pressure test in a safe and manner. He may coordinate with test
engineer/piping engineer to ensure the correct hydro test tools, equipment, and consumables
(e.g. water, paper chart etc.) are available and are ready for use and having valid certificate
(if applicable). He also responsible to open/close permit to work application.
f) Safety Officer Advisor Their responsibility is to review and monitor the pressure testing
activities from safety’s point of view. Safety advisor may coordinate with test engineer to
review safety precaution prior testing and also ensure that all steps of operation are being
carried-out in safe conditions/out of danger. Ensure area is clearly marked/barricade to avoid
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entries of unauthorized personnel. Their also responsibility to approve hydro test work permit
prior to activities.
g) Company Representative Company representative responsibility is to witnessing and
accepting of the pressure test as required by QC.
7 SAFETY REQUIREMENTS PRIOR TO PRESSURE TEST

Prior to carry out pressure testing, users shall carefully consider this procedure for the following
safety requirements:
a) Prior the pressure testing, HIRA to be established and meeting to be conducted.
b) All pressure testing activities shall be carried out under applicable permit to work system
(PTW).
c) Pressure test pump shall be provided & calibrated with safety relief valve to avoid over
pressure on the system. Safety relief pressure setting shall be calibrated to 10% above the
test pressure as per ASME B31.3 Para 345.5.2. All flexible hose connection shall be provided
with whip connection.
d) All personnel involved with pressure testing activities, including all inspectors and witness
personnel, shall wear the required personnel protection equipment (PPE).
e) Maximum care shall be taken during pneumatic/hydrostatic test to prevent injury to personnel
and damage to nearby equipment. Ensure pressure test area shall be cordoned off,
barricaded, signboards to indicate system test pressure with person name/contact number
and “unauthorized entry” barriers shall be provided. Pressure test area shall not be left
unattended.
f) Ensure all blanking-off devices are of the correct rating and that such items particularly
screwed plugs/connections are not liable to be ejected during testing, eg;, as the result of
thread failure or inadequate thread engagement.
g) Systems must not be subjected to any form of shock loading, such as hammering and
tightening bolts during testing, whilst system under pressure tests.
h) Temporary vents/drain shall be provided if permanent high point vent & low point drain (HPV
& LPD) are not available and shall be kept opened to prevent air locking during water filling.
Vents shall be provided at all high point and drains of low point locations. During test pack
preparation, Piping Engineer shall ensure that adequate vent and drain shall be provided.
System shall be checked on downstream of the check valves for possible trapped pressure
and trapped section drain point.
8 GENERAL PRESSURE TEST REQUIREMENTS

All lines shall be hydrostatically or pneumatically tested. Shop and field tests shall be performed in
accordance with ASME B31.3 and the other requirements of this standard except that pneumatic
testing shall be subject to the Company prior approval and NDT 100% . The pressure testing shall
be in accordance with the Company standards SD-NOC-PVV-171, SD-NOC-PVV-173 and SD-NOC-
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PVV-178. Prior to carrying out pressure testing, users of this procedure shall carefully consider the
following test requirements:
a) Pressure gauges, temperature and time recorders shall be used for all pressure tests. The
pressure gauges shall be shown in Bars(g)/Psi (g), recorders shall indicate temperature in
degree Celsius (°C) & pressure in Bars(g)/Psi (g).
b) Pressure test equipment/recorder shall be calibrated. Certificate to be review and attached in
the test pack, calibration sticker shall be available at each equipment/recorder.
c) Lines shall have all permanent supports installed before pressure test. Requirement for
hydrostatic test for gas service shall be verified that supports is adequate for liquid filling. The
system as designed and constructed will support the weight of liquid required for
flushing/hydro testing. Provision of additional temporary support for testing where if
necessary.
d) The line list shall indicate the type of test and pressure to use on each line. Maximum
operating pressure of each piece of equipment, including instruments, shall be checked
against the test pressure of the piping system in which the piece of equipment is included. If
the test pressure of the piping system is greater than the maximum operating pressure of the
equipment, the equipment shall be blanked-off and tested separately.
e) All joints, including welds, are to be left un-insulated and unpainted for examination during
testing. In case welded joints are painted before testing, then the following requirements shall
apply:
 One-hour minimum piping pressure test duration provided that the rating of the related
piping class does not exceed 300#.
 Two-hours minimum piping pressure test duration for 600# and above related piping
class.
f) Test medium, test pressure and minimum holding time shall be based on company standards
SD-NOC-PVV-171, SD-NOC-PVV-173 and SD-NOC-PVV-178.
g) Any test shall include a preliminary cleaning of the piping after fabrication, to be performed
externally and internally, in order to remove all loose scale, weld spatter, sand and other
foreign material. The cleaning shall be performed according company standards SD-NOC-
PVV-175.
h) Any test shall include a preliminary check at no more than 2 bars (g) to locate any major leak.
Hydrostatic pressure testing shall only be carried-out on perfectly dry surfaces to allow for
proper visual check for leaks.
i) Pneumatic testing over 7 bars (g) shall use Nitrogen as test medium. It is not permitted to use
compressed air and top up with nitrogen.
j) SMOE QA/QC personnel responsible to follow up, review and secure Employer
representative acceptance signature on hard copy report of weld summary which states fit
up, visual, welder identification, WPS no., NDT/material traceability are compiled in the test
pack document before commence pressure test.
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k) Pressure shall be maintained for a sufficient time to permit thorough inspection, visual
examination of all surfaces, welds and connections, but not less than 30 min. During increase
of pressure, hold pumping to stabilize pressure and inspect for any leaks. Release air locked
inside test object to avoid fluctuation of pressure. if require, de-air from vent points as
indicated on test isometric. Test recorder shall be started when pressure is stable and test
pump is either disconnected from test manifold or energy source disconnected.
l) Test water shall be clean and free from minerals and suspended matter. Only water having a
chloride content of 25 ppm or less shall be used in contact with stainless steel. Sea water
shall never be used, accordance with company standard SD-NOC-PVV-171.
m) Test temperature it is recommended that the metal temperature during test be maintained at
least 30°F (17°C) above the minimum design metal temperature to minimize the risk of brittle
fracture, but not exceed 50°C. Para 8.2.4 (a). the permissible minimum test temperature is
specified on the drawing, ASME Sec. VIII Div.2. The temperature of water shall not be less
than the atmospheric temperature and in no case it shall be less than 70°F (20°C). pressure
is not applied until metal temperature and water temperature are equalizer ASME B31.1.
n) Unless otherwise required by company, the following systems are excluded from pressure
testing.
o) Any package unit previously tested by manufacturer in accordance with the applicable
codes/specification.
p) Punch category A (items related to safety/integrity of the system), which affects the integrity
of the system accordance company standard SD-NOC-EC-600 shall be rectified before
flushing and Pressured testing. Original filled in and updated punch list shall be part of the
test package.
q) Pressure and temperature record test chart shall indicate the following;
 Test pack number/Test Date (refer Isometric index for line numbers/spool numbers)
 Responsible test person name/sign
 Test pressure and medium
 SMOE inspector name/sign
 NOC inspector name/sign
 Start time/actual duration of test
 Start/Finish pressure(barg/psig)
 Start/Finish temperature(°C)
 Pressure gauge ID/Serial Number
 Pressure & temperature recorder ID/Serial Number
r) If any inline item, such as valves, instrument and other items that will be exposed to pressure
are included in the pressure test must be capable of withstanding the pressure that includes
the internals and valve housing.Valve acceptable opening position during the test shall be
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complied and removed items shall be identify. Any inline items, instrument and valve included
on test shall be identified during pre-line walk before the test. SMOE Piping Engineer shall
ensure that the test isometric indicate the specific valve which shall be in half open position
during pressure test. All other valves shall be tested in the fully open position. When check
valves are included in pressure test theyshall be jacked open or have their internals removed.
Ball and gate valves shall be wide open during flushing and three quarter open during testing.
s) After system testing is successfully completed, testing team shall carry out the release of
pressure and vent shall be opened. Hose connected to drain/filling points shall empty the
system.
t) Test object shall be free from any covers and tarpaulin except for pipe protection during
pressure test. Pipe protection shall be required to open if there is significant pressure drop or
water moisture observed during visual inspection.
u) Following pressure test, SMOE QC shall prepare piping system pressure test report and shall
be offered to sign off after acceptance of pressure test by all authorised persons.
v) Systematic low pressure passing test shall be executed on critical valves upon reception and
before installation. Valves shall be tested in close position based on an approved procedure,
in both directions at low pressure with Nitrogen at 5 bars (g) and the result of the test shall
comply with Vendor datasheet and Standards. Low pressure closure test shall be carried out
strictly in accordance with company standards SD-NOC-EC-601, GM-NOC-PVV-142 and API
STD 598.
9 GENERAL TEST PREPARATION

Items/component within Packaged equipment such as vessels, tanks, pumps, etc not included on
test shall be documented and agreed with Employer. Equipment shall be isolated and all opening
shall be secured. All inline items such as orifice plates, strainers, filters, flow-measuring elements,
level gauges and pressure gauges shall not be included on the pressure test and shall not be
installed until hydrostatic or pneumatic pressure testing is completed.
All equipment that is likely to cause a restriction or dead end to the flow or could be damaged by
debris during flushing shall not be included in the test. All equipment connections to the piping
system to be flushed/tested shall be stress free and blanked off. Temporary supports, pads, etc.
shall be used as required to take the weight of piping, vessels or equipment when the line is
disconnected.
9.1 Gauges, Recorder and Thermometer Requirements
The pressure gauges shall be shown in Barg/Psig, recorders shall indicate temperature in degree
Celsius (°C) & pressure in Barg/Psig. Gauges/Recorders shall be between 1.5 to 2.5 times of the
test pressure.
All test gauge shall be calibrated at least every 12 months and every 6 months (ASME Sec. VIII
Div.2) para 8.1.4 (c), or earlier if there is a reason to believe that the gauge is not accurate, as per
the calibration system against a dead weight tester or a calibrated master pressure gauge or
calibrated by outside independent laboratory.
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Dial indicating pressure gauge used in testing shall be graduated over a range of about two times
the maximum intended pressure, but in no case shall the range be less than one and one-half no
more than four times the intended test pressure. (ASME Sect VIII Div.2 Para.8.1.4) (b).
A minimum of one pressure gauge shall be installed in the highest point with a vent valve. Second
pressure gauge at lowest point and one recorder shall be installed at lowest or highest point of the
piping system. Test chart shall be approved/signed by all concerned personnel. Test recorders shall
have pressure & temperature indicators. Water filling connection shall be at the lowest point of the
system for test.
Identification number of pressure gauges and recorder shall also be recorded on the test chart. The
chart shall be attached to the pressure test pack after testing is completed successfully.
9.2 Testing Equipment
Following testing equipment shall be used and when applicable calibration certificate shall be
provided:
a) Centrifugal pump for filling water;
b) Tanks for water storage;
c) Water filter;
d) Oil free air compressor;
e) Air driven pump for pressurizing the system;
f) Calibrated analog pressure gauge with valid certificate, reading in Bar or PSI.:
 Accuracy: maximum 2% of full scale;
 Validation shall be for a maximum 12 months. However, re-calibration is required if
the calibrated gauge is damaged;
g) Calibrated analog pressure recorder with valid certificate:
 Applicable/valid range: 30% - 90% of full scale;
 Accuracy: maximum 2% of full scale or ½ chart graduation;
 Validation shall be for a maximum 12 months; however, re-calibration is required if the
calibrated gauge is damaged.
h) Digital pressure gauge may be used during pressure test in lieu of both analog pressure
recorder / pressure gauge. However it shall be met requirement as below:
 Having capability to record data. Recorded data normally store in internal memory
and it can be downloaded once the test is completed and printed. The printed data
has similar function as chat record.
 Digital pressure gauge can be used with wider range (unlike analog where applicable
range is limited as explained in point f and g in Para.9.2) compare to analog pressure
recorder/pressure gauge as long as same providing same degree of accuracy as
obtained with analog pressure recorder/pressure gages.
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i) Test manifold, certified by Local Government - Department of Labor or third party.

j) High pressure flexible hose(s) rated for pressure of the test.
k) PSV (for pneumatic test only).
9.3 Temporary closure material
Temporary closure material is required to isolate the test circuit:
a) Material which has function as positive isolation (e.g. blind flange, spade, cap, pup piece etc.)
is made from carbon steel with suitable rating/thickness of test circuit to be tested. In order to
avoid iron contamination in the case the temporary material is contact with permanent
stainless steel flange, inside part of the material may be coated or painted (primer only).
b) Temporary gasket & IX seal ring:
 When permanent carbon steel flange contact to temporary carbon steel blind flange:
Carbon steel gasket & IX seal ring to be used
 When permanent stainless-steel flange contact to temporary carbon steel blind flange:
stainless steel gasket & IX seal ring to be used
 For details see Figure-2
c) Temporary bolt is made from carbon steel material.
d) Pup pieces (pipe with end cup or end plate) may be used as closure material for open end
pipe:
 In case of the pup piece made with pipe and end plate, the minimum thickness of pipe
is as per piping class and the thickness of the end plate shall be calculated as per
ASME BPVC VIII Div.1.
 In case of the pup piece made with pipe and end cup, the minimum thickness of pipe
and end cup is as per piping class.
 For details see Figure-3
e) Permanent blind flange, spade, bolts may be used during testing, providing that damage is
avoided and to be handled with care.
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9.4 Documents / Record Preparation

9.4.1 Document of Test Package
Piping engineer or Test engineer shall prepare pressure test packages covering piping system
boundary limit on the P&ID and shall be prepared in advance for initial company review on test
boundary limits and isometric drawing configuration that includes the following below.
Test pack shall be submitted to the company for review with all summary reports and material
traceability reports enclosed to the test pack signed off by all concerned parties.
a) P&ID test system boundary mark up in reference with commissioning sub system marked up
(highlighted with red color such as; line system, Injection point, gauge recorder, drain point,
plug and close valve)
b) Indicates test pressure, test medium, test duration and location
c) Line list, drawing index & latest isometric and support drawings
d) Weld report summary which states fit up, visual, welder identification, WPS no., NDT/material
traceability report and compiled in the test pack document before commence pressure test.
e) Mechanical check sheets to be signed off by all concerned personnel after work phase
completion.
The Test Pack numbering system will be as follow:
TP /Location “EHA-CEA”/4 digits of Subsystem No/Fluid/Execution Location, Batam “B”, Qatar
“H”/Sequence No.
Example: TP-EHA-0301-WF-B-0001
A test package folder which consist of more than one subsystem is not allowed, considering the final
dossier of mechanical completion is based on by subsystem.
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9.4.1.1 Test Package Content

A test package will contain below information as below:
Appendix .1 Piping Pressure Test Pack Cover
Appendix .2 Test Pack Travel Sheet
Appendix .3 Test Pack Index Sheet
Appendix .4 Test Pack Check List
Appendix .5 Safe Distance Calculation / For Pneumatic Test
Appendix .6 C-LX-01-Pipework Test Pack Composition
Appendix .7 Test Pack Legend
Appendix .8 C-LX-02A-Pipework Before Test Check List
Appendix .9 T-MX-05 – Cleaning
Appendix .10 Construction Punch List
Appendix .11 Removal Item List
Appendix .12 Temporary Blind Installation / Removal
Appendix .13 T-MX-03 – Pressure Test
Appendix .14 C-LX-02B – Pipework After Test
9.4.2 Test Package Issuance

a) Approved test package by test pack engineer will be issued to PT SMOE document control
(PMT);
b) PT SOME document control (PMT) will handover original test package to QC department;
c) PT SMOE document control (PMT) issue scan copy/softcopy to PT SMOE Planner and PT
SMOE Construction team;
d) PT SMOE document control (PMT) issue scan copy/softcopy to CPY for acknowledge.
9.4.3 Test Package Work Flow

Once the test package is circulated to PT SMOE (PMT) Production team, construction
superintendent will check the readiness of piping/line associated to test package limit. The complete
piping/line will be handed over to piping Mechanical Completion (MC). Production team shall
inform/notify to Piping MC team which line associated to test package is ready to hand over.
Piping MC team together with QC will perform internal line walk prior official line walk. During internal
line walk, piping MC team and QC will check: welding completion, support installation and type,
instrument tapping, valve direction etc. as per latest AFC drawing or as per applicable project
documents. Any items which is not confirm as per latest AFC drawing or other project documents
(e.g. project specification, data sheet, etc.), respective PL shall be issued to relevant department
(e.g. production, engineering, etc.) for immediate rectification. Raised PL may A, B or C category.
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Avoid to raise PL related to hot work since hot work shall be completed & accepted prior to test. Hot
work means any direct welded to the pipe.
Once clearing off all hot work internally, PT SMOE QC inspector will issue RFI to Company for
official line walk/inspection. Punch list may rise during official line walk/inspection and it will be
recorded.
On Company and PT SMOE QC Inspector approval, the test circuit as indicated in test package will
be handed over and tested by piping pre-commissioning team. Pressure test will be witnessed by all
relevant parties.
Once test is accepted, ITR will be signed by all parties. “Original Test Pack” and its original content
including ITR will be archived in test package center.
References Attachment .3 Test Pack Work Flow
10 CLEANING AND FLUSHING

The cleaning method shall be selected in accordance with Cleaning and Flushing Requirements for
Piping Accordance company standard SD-NOC-PVV-175.
10.1 Cleaning Methods
The main cleaning methods are:
10.1.1 Cleaning with Air (Blowing or Air Flushing)
High Velocities and Large Flows: The air velocities through the pipes have to be 30 to 70
m/s. If the continuous blowing method is used for an 18 inch pipe, the required flow rate is
about 17,000 m3/h for a velocity of 30 m/s. This large continuous flow rate of air is seldom
available on site, and temporary site compressors of such range cannot be found easily.
Calculation of the Necessary Flow Rate in the Main Header: The velocity shall be the
lowest figure between 60 m/s and the velocity obtained at 1.5 times the maximum process
flow rate (for gas process lines). Liquid process lines are generally water flushed, if they have
to be air flushed, a velocity of 30 m/s shall be used.
10.1.1.1 Continuous Blowing of Air
Air is continuously blown from a source (Air Compressor of a large capacity) at a high velocity
through the lines (and vessels) to carry away the foreign matters. Due to the high velocity of
the air, light erosion of the walls generally occurs during the air blowing, which is beneficial
with regards to cleaning.
10.1.1.2 Quick Decompression
A network is filled with compressed air up to the setting pressure of a rupture disk. When the
rupture disk blows out, the source of air is stopped and the pressure inside the network
decreases quickly. This operation is in fact generally made with a "quick opening valve" after
having pressurized the network at the desired level of pressure. The quick decompression
causes a high velocity of airflow in the pipes, thus removing foreign matters and performing a
light erosion on the walls, which eliminates rust and scale as seen here above.
Page 18 of 49
10.1.2 Cleaning with Water (Water Flushing)

10.1.2.1 Circulation of Water
The cleaning is made by a circulation of water at high velocity (3-4 m/s) through the pipes. To
obtain such a velocity, a special pump has generally to be used (large flow, small pressure).
10.1.2.2 Water Spray
If there is only dust on the walls of a large vessel, a water spray from a hosepipe might be
sufficient. In some particular cases, air flushing and water flushing can be applied
simultaneously: air (3 barg) is injected in water in order to increase the turbulence. As the
monitoring of such a method is not easy, it should be used with great care and only on
special occasions.
10.1.2.3 High Pressure Water
This process may be used to remove solid particles of foreign matters from inside walls or
inside parts of equipment, in particular where access is a problem.
10.1.3 Mechanical Cleaning
10.1.3.1 Hand Cleaning
When a man can enter into the (vessels, large diameter pipes), it is sometimes more efficient
to clean the walls with a metallic brush and to remove the rust fallen down with a vacuum
cleaner and/or a final blowing.
10.1.3.2 Pipe Cleaning with Pigs
When a pipe has been designed to allow pigs to be sent through, a special pig with metallic
brushes at its periphery is sent to clean the pipe. This special pig takes rust and scale from
the walls but does not remove rust and foreign matters fallen down at the bottom of the pipe;
a "normal" pig has then to be sent to remove the rust and the foreign matters which lay at the
bottom of the pipe.
10.1.3.3 Sand Blasting
For large vessels, sand blasting may be used to remove rust from the inside walls; in such a
case, special instructions shall be given by the Manufacturer.
10.1.4 Chemical Cleaning
10.1.4.1 Chemical Cleaning without further Coating
This type of cleaning is made by chemicals and is mainly used for lubrication lines of rotating
equipment.
10.2 Application Specific to be cleaned
The following principles shall apply:
a) Whenever possible, the cleaning fluid shall flow from top to bottom
b) The diameter of the outlet pipe shall be at least as large as the diameter of the inlet pipe,
and, in any case, as large as possible.
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c) The diameter of the outlet pipe shall be at least two thirds of the diameter of the line to be
cleaned.
d) Main headers shall be cleaned first (i.e. before their connecting lines).
e) Large diameter pipes shall be cleaned before small diameter ones.
f) Dead ends shall be avoided or, if not possible, cleaned separately.
g) Protection of the devices included in the network (control valves, turbine-type flowmeters,
orifice restrictions, etc. shall be carefully studied.
h) Protection of the devices in the vicinity of the network shall be carefully studied, in particular
near the water (or air) outlet, in order not to damage electric motors or instruments with
water or dirty air.
i) Existing block-valves on the lines to be cleaned shall not be used to control an air flow as
they could be damaged by erosion (due to the high velocity of the fluid).
j) A special care shall be taken for vessels designed only for an atmospheric pressure service,
in order not to create, during washing, a high pressure due to a water head.
k) Whenever a vessel full of water has to be emptied, a special note shall be issued to state
that a vent will have to be opened previously in order not to create vacuum in the vessel.
l) Generally, the cleaning fluid shall not flow through a conventional exchanger (use the
bypass, if any, or "break" the line before the exchanger). It shall never flow through a plate
exchanger.
m) The cleaning fluid shall never flow through pumps or compressors: the line shall be
disconnected before the equipment or a "jumper" shall be installed.
n) For large diameter pipes, some temporary supports, hangers, pads, etc., may have to be
added to withstand the weight of valves when a line is disconnected.
o) During flushing, the spring supports, spring hangers, etc., shall be blocked according to the
Manufacturer’s instructions.
p) When a couple of flanges has to be opened to allow the flow to flush out, the distance
between the two flanges shall be at least 1/6 of the pipe diameter.
11 VESSEL AND EQUIPMENT

Unless otherwise advised, the following components shall be excluded from pressure tests.
 Vessels and equipment
 Vendor furnished piping previously shop tested. All instruments tagged control valves,
Relief valves and check valves.
12 HYDROSTATIC TEST PROCEDURE

12.1 Scope and purpose
As part of the strength test, All lines shall be hydrostatically or pneumatically tested, (SD-NOC-PVV-
171 and SD-NOC-PVV-178). Shop and field tests shall be performed in accordance with ASME
B31.3 and the other requirements of this standard except that pneumatic testing shall be subject to
the Company prior approval.
The scope of this document is to cover all required tasks and its quality aspect of pressure test
(hydro test/pneumatic test/service test) for piping/pipeline/riser during construction works in PT
Page 20 of 49
SMOE. Tubing pressure test is not part of this procedure. The purpose of this document is to specify
pressure test procedure and acceptance criteria of piping/pipeline/riser works to guarantee the piping
mechanical completion and quality associated required.
12.2 Preparation for Hydrostatic Test
Reference attachment 1 Typical Hydrostatic Set up
12.2.1 Safety Precaution
a) JRA (Job Risk Assessment) shall be conducted prior to hydrostatic test to identify all
foreseeable critical situations, to evaluate associated risks and to define mitigation measures.
b) Prior starting pressure test activity, the following actions are to be put in place:
 Approved permit by relevant authorities and keep a copy of permit and JSA on the
work site. P&ID must be attached to the Permit to work together with the JSA.
 Fence off/barricade at required safe distance from the test circuit.
 Showing signs around the barricaded area.
 Verify access to all necessary valves, hose(s), and other parts of test circuit is
available, in case not available scaffolding to be provided.
 Verify all equipment (e.g. hose(s), fittings, valves, manifold etc.) to be used as per
suitable rating to test circuit to be tested.
 Whip check shall be used during connecting two or more hose(s).
 System to be properly supported and anchored, in case required, temporary support
may be added.
 Verify that all involved people wearing appropriate PPE.
 Suspend all activities other than pressure test activities inside the barricaded area
when the activities is being executed. Barricaded area as per calculation.
 Unauthorized persons should be out from the area involved in the test.
 Ensure temporary blind flange/bolt type of closure material is tightening with
appropriate value, in order to ensure unexpected release of pressure during testing.
 Adequate & appropriate illumination is in place in case work continues to second shift
or working at night.
 All personnel involved in the activity shall be experienced/competent/trained.
 Carry out a tool box meeting prior starting the activity.
c) During Testing:
 Pressurization of test circuit shall be gradually increased. Following strictly the
indication reported in the pressurization operational steps.
 Inspection by all parties shall be done during holding time and it shall be performed in
safe manner.
d) After Completion of Test:
 Once the test has been completed, depressurization of the test circuit should be done
gradually, and do not stand close to or in front of the depressurization valve.
 All connection containing pressure part e.g. hose(s), safety valves, pressure gauges,
manifold etc., should be dismantled once “ZERO” pressure inside the system.
 Keep the work area clean and tidy.
Page 21 of 49
12.2.2 Safety Exclusion Zone During Pressure Testing

Safety exclusion zone during Hydro-test shall be barricaded at minimum 2 meters from the test
circuit.
12.2.3 Execution of Hydrostatic Test
12.2.3.1 Pre-Requisites of Testing
Prior to commence any pressure test activities, the following pre-requisites shall be accomplished:
a) Pre-test line walk on piping associated to test package against to isometrics/spool
drawings, P&IDs, line list and other relevant documents with latest AFC technical
specifications.
b) Verify all piping hot work which mean any direct weld to pipe shall be completed and
accepted as per quality requirements.
c) PWHT /stress relieving shall be completed and accepted prior pressure test.
d) Verify all pipe support associated to test package is installed as per design (e.g. support
type, support location etc.). In case some support not available, temporary support may
be used. Type of support which weld direct (e.g. saddle, trunnion etc.) to pipe shall be
completed.
e) Spring supports, spring hangers, etc., shall be blocked/removed during testing.
f) Approved documentation: test procedure and test packages. Test packages shall be
assigned to each test circuit.
g) Ensure all equipment/instruments, hose(s) are properly checked and subjected to regular
maintenance and suitable with test pressures.
h) Check the test circuit has properly provided vent in high and drain in low points. In case
vent or drain not available on test circuit (permanent piping), vent and drain may add on
temporary blind flange.
i) All temporary blind flanges or permanent flanges joints must be torqued/tensioned with
appropriate value, accordance with company standard SD-NOC-EC-114.
j) The normal installation of the pressure gauges is first at highest point at the piping to be
tested and second at test manifold.
k) The normal installation of the pressure recorder is at test manifold.
l) The primer coat of the paint system can be applied to piping weldment surfaces prior to
pressure test or as agreed with Company.
m) In case the full coat/top coat of the paint system need to be applied to piping weldment
surfaces prior to pressure test, it shall be agreed with Company by technical query and so
as with its additional requirement as well.
n) Compressors shall be available for drying post to pressure test.
o) Several test packages can be tested together/combined as long as has same
rating/piping class/test pressure regardless of the subsystem.
12.2.3.2 Internal Piping Cleaning
For cleaning and methods of internal piping cleaning accordance with company standard SD-
NOC-PVV-175, Internal cleaning may perform prior or after hydro test.
Page 22 of 49
12.2.3.3 Test Medium

Pressure testing shall not take place with temperatures of environment is 4°C or less, nor
during rain or fog unless the piping test circuit is under proper shelter or inside module.
Hydrostatic testing shall be performed using fresh water with a chloride content less than 25
PPM accordance with company standard SD-NOC-PVV-171. For hydro test at offshore
potable water from AWB may be used.
12.2.3.4 Filling, Pressurization and Depressurization
Filling, pressurization and depressurization should follow guidelines:
a) Piping system shall be filled from low point. Multiple points may use if required.
b) Vent or others highest point connection shall be opened during water filling to remove air
from test circuit. It shall be closed once a continuous water flow is obtained.
c) Reading is made on highest point in order to assure that all elements in piping were
effectively tested. There is no acceptance criteria of pressure different between lowest
and highest point. However, the effect of static head shall be taken into account during
testing order not to exceed yield strength of the test circuit, as practical approach, 10
meter height difference will lead to 1 bar pressure different; Once test pressure is
obtained, isolation valve at test manifold shall be closed. This to ensure no additional
pressure added to piping circuit.
d) Since the pressure at lowest point may having more pressure compare to highest point,
therefore the it shall be checked that the test pressure at lowest point not exceed the yield
strength of the material;
e) Once test pressure is obtained, isolation valve at test manifold shall be closed. This to
ensure no additional pressure added to piping circuit. The actual test pressure may
exceed from theoretical test pressure, however the actual test pressure shall not exceed
to yield strength of the material however refer to section 345.2.1, in case the test pressure
produce the stress in excess of yield strength, the test pressure may reduce;
f) Pressurization and depressurization shall be implemented in controlled manner, by
means gradually increasing/decreasing of the pressure, the steps can be described by
chart as follow:
g) Water temperature shall be maintained at ambient temperature or over during testing
12.2.3.5 Holding Time
a) Duration of test shall be at least 30 minutes. It is starting once the test pressure is
stabilized.
b) Pressurizing interval of the system shall be at 25%, 50%, 75% and 100% respectively.
Stabilizing time of this interval shall be 5 minutes.
c) Additional holding time may require for inspection, only if the inspection couldn’t be
completed within the stipulated time due to complexity of test circuit.
12.2.3.6 Testing Acceptance Criteria
Test pressure and type of test shall (e.g. hydro test, pneumatic or service test), unless
otherwise specified, shall be in accordance with the line list or applicable codes and
standards (e.g. ASME B31.3, B31.8 etc.), unless otherwise specified. As general rules, the
test pressure for hydro test will be 1.5 x design pressure. Piping systems D category (utility
Page 23 of 49
air), as defined in ASME B31.3, shall be service tested where the test pressure is at normal
operating pressure. The piping system working at atmospheric pressure (e.g. drains and
vents) as indicated in line list shall not be subject to pressure test, only visual inspection.
During holding time, PT SMOE-QC and Company shall proceed inspections as follows:
a) Check the test pressure.
b) Check welds and overall piping system. In order to verify possible leakages on piping
connection:
 Visual inspection is utilized if liquid is used as a test fluid.
 Inspection may be repeated in the case such as small leaks or sweating from
welds.
c) The inspection may be repeated in the case such as small leaks or sweating from welds.
The pressure test is declared as accepted when no major leak obverse on tested
piping system moreover on weldment area.
Note:
 Performing hydro test during hot or cold weather will lead to disturbance of
pressure gauges reading/pressure recording, and this condition shall be taken into
account during review chart pressure.
 Pumping or venting operation during inspection for hydrostatic testing shall not be
allowed and are not required to manage pressure variation from ambient
temperature
12.2.3.7 Rectification of Leak
Leak during test may occur on joints (e.g. flange joint, or threaded connection). This
leakage source shall be rectified prior re-test, below are the steps of rectifying the leak.
Flanged joints/threaded connection:
a) Step1
 Isolate the pressure from the pump.
 Depressurize the system being tested gradually.
 Identify from which bolt position or threaded connection the leaking comes
from.
 Loosen the stud bolt or thread connection. Check the flange face or threaded
of the fitting.
 Retighten the stud bolts at using progressive value from recommended value
of tensioning/torqueing (e.g. added 5%, 10% etc. more from recommended
value) but not higher than yield strength of bolt. For the threaded connection,
check the thread condition, if still good, re-apply teflon tape and re-tight.
b) Step2
If leak does not stop after re-tightening, disassemble the flange joint and perform
inspection as follow:
 Inspect the flange face / RTJ groove. Flange face/RTJ groove may repair as
per applicable standard (e.g.as described in ASME PCC-2). Lapping paste
may use during RTJ groove repair activity.
Page 24 of 49
 Inspect the threaded condition, in case damage on threaded part, re-

machining of threaded part may be performed; in case can’t be machined,
replace with new item.
 Inspect alignment of flange.
 Inspect gasket for damage/defect.
 Inspect the bolt and nuts for damage/ defects, bolts with sign of damages shall
be replaced.
c) Step3
After all defective and damage items have been repaired, re-assemble the flange joint
using new gasket and tighten the bolts using the recommended torque / tension value.
Weld Joints:
 Identify and mark the source of leak from weld joint.
 Depressurize the system being tested gradually.
 Clean-up and dry-out the pipe and initiate repair of welding, and normal welding
sequence shall be followed afterward.
12.2.3.8 Dewatering and Drying
After the test is declared completed and accepted, the piping shall be dewatered
immediately. To accelerate the dewatering process oil free compressed air may be used and
care must be taken to all personal who will perform this activity, not to close to the
opening/nozzle/valve area during this process. Once piping network is dewatered then it shall
be dried by compressed oil free air by means circulated the dry oil free air through the all
piping circuit until no water remaining inside the pipe and the pipe declare dry.
12.2.3.9 Reinstatement
Upon completion of pressure testing and drying, reinstatement activities to be performed:
a) Remove temporary item such as blind flange, gasket, stud bolt, plug, valve and pup piece
etc.
b) Restore any equipment/instrument which is excluded from the test.
c) Restore any supports e.g. spring support which is excluded/dismantled from the test.
d) Final flange management to be performed.
e) Perform preservation accordance company standard SD-NOC-PVV-175 (e.g. closing the
pipe or flange by plastic flange cap/tarpaulin)
13 PNEUMATIC TEST PROCEDURE

13.1 Scope and purpose
This procedure covers the pneumatic strength testing of above ground piping systems. It describes
the requirements for the testing procedure and the precautions to be taken. Pneumatic strength
testing is used only for cases where hydrostatic testing is impractical and shall be subject to
Company approval and NDT 100%, Accordance with company standard SD-NOC-PVV-171.
13.2 Preparation for Pneumatic Testing
Reference Attachment .2 Typical Pneumatic Testing Set up
Page 25 of 49
13.2.1 Safety Precaution

a) JRA (Job Risk Assessment) shall be conducted prior to pneumatic pressure test to identify all
foreseeable critical situations, to evaluate associated risks and to define mitigation measures.
The results of the assessment shall be used to prepare the Permit to Work.
b) Prior starting pressure test activity, the following actions are to be put in place:
 Approved permit by relevant authorities and keep a copy of permit and JSA on the
work site. P&ID must be attached to the Permit to work together with the JSA.
 Fence off/barricade at required safe distance from the test circuit.
 Showing signs around the barricaded area.
 Verify access to all necessary valves, hose(s), and other parts of test circuit is
available, in case not available scaffolding to be provided.
 Verify all equipment (e.g. hose(s), fittings, valves, manifold etc.) to be used as per
suitable rating to test circuit to be tested.
 Whip check shall be used during connecting two or more hose(s).
 System to be properly supported and anchored, in case required, temporary support
may be added.
 Verify that all involved people wearing appropriate PPE.
 Suspend all activities other than pressure test activities inside the barricaded area
when the activities is being executed. Barricaded area as per calculation.
 Unauthorized persons should be out from the area involved in the test.
 Ensure temporary blind flange/bolt type of closure material is tightening with
appropriate value, in order to ensure unexpected release of pressure during testing.
 Adequate & appropriate illumination is in place in case work continues to second shift
or working at night.
 All personnel involved in the activity shall be experienced/competent/trained.
 Carry out a tool box meeting prior starting the activity.
c) During Testing:
 Pressurization of test circuit shall be gradually increased. Following strictly the
indication reported in the pressurization operational steps.
 Inspection by all parties shall be done during holding time and it shall be performed in
safe manner.
d) After Completion of Test:
a. Once the test has been completed, depressurization of the test circuit should be done
gradually, and do not stand close to or in front of the depressurization valve.
b. All connection containing pressure part e.g. hose(s), safety valves, pressure gauges,
manifold etc., should be dismantled once “ZERO” pressure inside the system.
c. Keep the work area clean and tidy.
13.2.2 Safety Exclusion Zone During Pressure Testing
Safety exclusion zone during Pneumatic pressure testing shall be barricaded at minimum 100
meters from the test circuit.
Page 26 of 49
13.2.3 Execution of Pneumatic Test

13.2.3.1 Pre-Requisites of Testing
Prior to commence any pressure test activities, the following pre-requisites shall be accomplished:
a) Pre-test line walk on piping associated to test package against to isometrics/spool
drawings, P&IDs, line list and other relevant documents with latest AFC technical
specifications.
b) Verify all piping hot work which mean any direct weld to pipe shall be completed and
accepted as per quality requirements.
c) PWHT /stress relieving shall be completed and accepted prior pressure test.
d) Verify all pipe support associated to test package is installed as per design (e.g. support
type, support location etc.). In case some support not available, temporary support may
be used. Type of support which weld direct (e.g. saddle, trunnion etc.) to pipe shall be
completed.
e) Spring supports, spring hangers, etc., shall be blocked/removed during testing.
f) Approved documentation: test procedure and test packages. Test packages shall be
assigned to each test circuit.
g) Ensure all equipment/instruments, hose(s) are properly checked and subjected to regular
maintenance and suitable with test pressures.
h) Check the test circuit has properly provided vent in high and drain in low points. In case
vent or drain not available on test circuit (permanent piping), vent and drain may add on
temporary blind flange.
i) All temporary blind flanges or permanent flanges joints must be torqued/tensioned with
appropriate value, accordance with company standard SD-NOC-EC-114.
j) The normal installation of the pressure gauges is first at highest point at the piping to be
tested and second at test manifold.
k) The normal installation of the pressure recorder is at test manifold.
l) The primer coat of the paint system can be applied to piping weldment surfaces prior to
pressure test or as agreed with Company.
m) Compressors shall be available for drying post to pressure test.
n) Several test packages can be tested together/combined as long as has same
rating/piping class/test pressure regardless of the subsystem.
13.2.3.2 Internal Piping Cleaning
For cleaning and methods of internal piping cleaning accordance with company standard SD-
NOC-PVV-175, Internal cleaning may perform prior or after Pneumatic test.
13.2.3.3 Test Medium
Pneumatic test shall utilize clean compressed dry air or nitrogen as test medium. Testing with
flammable gases media is particularly dangerous and shall be avoided. Alternatively, clean
nitrogen may be used, provided that it can be supplied to the test assembly at ambient
temperature or above accordance with company standard SD-NOC-PVV-173.
13.2.3.4 Filling, Pressurization and Depressurization
Filling, pressurization and depressurization should follow guidelines:
Page 27 of 49
a) Testing shall not take place in rain or if the ambient temperature is below 5°C Reading is
made on highest point in order to assure that all elements in piping were effectively
tested. However, the effect of static head shall be taken into account during testing in
order not to exceed allowable stress of the test circuit.
b) Piping system shall be filled from low point. Multiple points may use if required.
c) Air or nitrogen shall be slowly admitted to the test assembly until the pressure reaches
the lesser of one-half of the required test pressure or 1.5 bars (g), accordance with
company standard SD-NOC-PVV-173.
d) The pressure shall be slowly increased in increments of approximately 1 bar. The
pressure shall be held for sufficient time at each stage to permit piping strains to equalize.
e) When the required test pressure is attained, the test assembly shall be isolated from the
air or nitrogen source (but not from the relief valve) and the pressure shall be held for 20
minutes to observe any fall in pressure indicative of a major leak.
f) In order to ensure that there will be no leaks on the circuit under test, all joints, flanges
and welds shall be checked by applying the soapy water.
g) If no pressure drops are indicated at the test pressure, the pressure within the test
assembly shall be slowly released, down to the atmospheric pressure.
h) Pressure shall be released by means of a suitable valve arrangement. Pressure release
shall not be achieved by loosening of flange bolts or plugs or via a line ball valve or gate
valve. Care shall be taken to avoid metal temperatures falling below 0°C, particularly near
the vent connection during depressurizing.
13.2.3.5 Holding Time
When the required test pressure is attained, the test assembly shall be isolated from the air
or nitrogen source (but not from the relief valve) and the pressure shall be held for 20
minutes to observe any fall in pressure indicative of a major leak. Consideration shall be
given to the effects of ambient/metal temperature changes during this period. Personnel shall
not stay nearby the test assembly at this stage or during pressurization. Monitoring of
pressure and temperature shall be made from a remote location.
13.2.3.6 Pneumatic Test Acceptance Criteria
Test pressure and type of test shall (e.g. hydro test, pneumatic or service test), unless
otherwise specified, shall be in accordance with the line list or applicable codes and
standards (e.g. ASME B31.3, B31.8 etc.) unless otherwise specified. As general rules, the
test pressure for pneumatic test will be 1.1 x design pressure. Piping systems D category
(utility air), as defined in ASME B31.3, shall be service tested where the test pressure is at
normal operating pressure. The piping system working at atmospheric pressure (e.g. drains
and vents) as indicated in line list shall not be subject to pressure test, only visual inspection.
During holding time, PT SMOE-QC and Company shall proceed inspections as follows:
a) Check the test pressure.
b) Check welds and overall piping system. In order to verify possible leakages on piping
connection:
Page 28 of 49

Visual inspection and soap solution is utilized if air/gas is used as a test fluid
Refer to attachment .4 Snoop liquid leak detector
 Inspection may be repeated in the case such as small leaks or sweating from
welds.
c) The inspection may be repeated in the case such as small leaks or sweating from welds.
The pressure test is declared as accepted when no major leak obverse on tested
piping system moreover on weldment area.
Note:
 Performing pneumatic test during hot or cold weather will lead to disturbance of
pressure gauges reading/pressure recording, and this condition shall be taken into
account during review chart pressure.
 Compressing or venting operation during inspection for Pneumatic testing shall
not be allowed and are not required to manage pressure variation from ambient
temperature.
13.2.3.7 Rectification of Leak
If any defects are found in a welded joint, they shall be repaired (after depressurization) using
an approved weld repair procedure and proved acceptable by radiographic testing prior to
repeating the pneumatic test. Any defects at flanged joints shall be investigated prior to
remedial action. Care shall be taken not to apply excessive torque to bolting in order to
achieve a leak-tight seal. Following repair of any defects, the full pneumatic test procedure of
Section 13.2.2.4 shall be followed when repeating the test.
13.2.3.8 Reinstatement
Upon completion of pressure testing and drying, reinstatement activities to be performed:
a) Remove temporary item such as blind flange, gasket, stud bolt, plug, valve and pup piece
etc.
b) Restore any equipment/instrument which is excluded from the test.
c) Restore any supports e.g. spring support which is excluded/dismantled from the test.
d) Final flange management to be performed.
e) Perform preservation accordance company standard SD-NOC-PVV-175 (e.g. closing the
pipe or flange by plastic flange cap/tarpaulin)
14 COMPLETION OF TEST
Tested system shall be depressurized slowly in stages by opening the depressurizing valve in the
test rig. All vents and low point drain valves shall be open, system shall be thoroughly drained after
successful completion of hydro-test or pneumatic test. Where required, blowing by air or pressurized
air shock blowing to remove any trapped water shall be performed to remove any residual or trapped
water accordance with company standard SD-NOC-PVV-175.
Downstream of the check valves shall be check for possible trapped pressure generated during test
and flushing medium to drained off and dry.
End of pipes and nozzle shall be fully protected against the ingress of foreign materials by the use of
end caps, plugs or blind plates sealed with gaskets. These shall not be removed until just prior to
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final assembly or box up. Connection to tie-in points shall be verified from the area or package owner
before opening sealed points.
All lines and joints that fail to pass the pressure test shall be re-tested to the same procedure after
repairs.
15 VENTING /DRAINING/DRYING
After acceptance of the test, the pressure shall be released in a manner and at a rate so as not to
endanger personnel or damage equipment and in a slow and controlled manner. Accordance with
company standard SD-NOC-PVV-175.
1) All vents shall be opened before the system is drained and shall remain open during draining
to prevent pulling a vacuum on the system.
2) Valves, orifice plates, expansion joints and short pieces of piping, which have been removed,
shall be reinstalled with correct gaskets in place and orientation if required.
3) All lines and piping components shall be completely drained and dried All draining to be done
with compressed air.
16 DEFECTS AND REPAIRS

Any leak or defect seen on the weld as a result of hydrostatic test or pneumatic test is to be fully cut
out and re weld, subject for the specified NDT, flushing and re-hydrostatic test, pneumatic test
cleaning and drying.
17 RECORDS
PT SMOE QC shall prepare piping system flushing & pressure testing reports which is to be
witnessed and signed by authorized persons. The report shall be enclosed on the test pack which
includes the following below:
 Date of Test
 Identification of piping system tested as shown on marked up P&ID’s test boundary limit
including isometrics
 Test pressure and holding time
 Test medium
 Ambient temperature
 Design pressure and temperature
 Result of testing
 Names and Signatures of PT SMOE Q.C. inspector and company representative
 Copies of valid calibration certificates
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 Pressure/temperature recording chart shall be installed prior to start of test and must be fully
signed off after test.
Once the hydrostatic or pneumatic test is successfully completed. Piping system that require
cleaning and dry up after pressure test shall be completed the reinstatement and Reinstatement of
all items removed from the test shall be carried out.
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17.1 Appendix .1
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17.2 Appendix .2
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17.3 Appendix .3
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17.4 Appendix .4
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17.5 Appendix .5
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17.6 Appendix .6
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17.7 Appendix .7
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17.8 Appendix .8
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17.9 Appendix .9
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17.10Appendix .10
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17.11Appendix .11
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17.12Appendix .12
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17.13Appendix .13
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17.14Appendix .14
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17.15 Attachment .1 Typical Hydrostatic Set up
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17.16 Attachment 2 Typical Pneumatic Testing Set up
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17.17 Attachment .3 Test Pack Work Flow
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17.18 Attachment .4 Snoop Liquid Leak Detector
Page 49 of 49

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Block 5 - AL SHAHEEN FIELD Development

Project: WHP02-SMO1 Document Number: ASYYY-19-302063-0001 Date: 31-Mar-2020 Rev.: 00

Doc Type: PRC System: GENE Phase DE Status: IFR Class: 2