MS-P-022 REV.

00

METHOD STATEMENT

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

Contract NO: J-194

KARAN UTILITIY AND COGENERATION PROJECT KHURSANIYAH, KINGDOM OF SAUDI ARABIA

Signature 00 Rev. 13 Oct. 2010 DATE Print Name AJR Prepared By MMG N.E. Pacleb Checked By MMG R. A. Dimatatac Approved By MMG P. Ranzenbacher Approved By PETROFAC

Page 1 of 9

MS-P-022 REV.00

1.

PURPOSE / SCOPE: The scope and purpose of this document is to describe the execution methodology of Tie in works to be carried out to the existing fire water pipe line.

2.

DEFINITION OF TEST PRESSURE Hydrostatic Test: A pressure test conducted using water or other approved liquid as the test medium.

3.

REFERENCES: : Power piping : Process piping : General requirement for pressure testing. : Hydrostatic Testing Fluids and Lay-up Procedure. : Waste water treatment, reuse, and disposal. : Pressure Testing :Disposal of Waste Water from cleaning flushing, and dewatering pipelines and vessel.

ASME 31.1 ASME 31.3 SAES-A-004 SAES-A-007 SAES-A-104 GI-2.102 SAEP-327

SAES-O-020 MMG-QCD-3-021 SAES-L-150 GI-2.100 Rev. 2009 SAEP-302

: Industrial drainage and sewers. : Flushing and pressure testing of pipe work. : Pressure testing of plant piping and pipe lines : Work permits system : Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement.
Page 2 of 9

MS-P-022 REV.00

4.

RESPONSIBILITY 4.1 TESTING/PIPING SUPERVISOR Ensure compliance by all labour and equipment availability and other associated craftsmen to the requirements of this procedure, Project Quality Control procedures / test plans, relevant approved test package, safety procedures. Secure all necessary work permits. 4.2 QUALITY CONTROL INSPECTOR Conduct activities in accordance with the Project QA Manual and Quality Control Inspection Plan. Prepare testing records and final acceptance documentation where required. relationship with the Client's Representative. 4.3 SAFETY SUPERVISOR Ensure that work permits are obtained prior to commencement of testing. Check personally and confirm compliance to safety Maintain close working

requirements, such as wearing personal protective equipment. Check work areas for any unsafe conditions. Liaison with the Field

Supervisors ensuring that work is carried out in accordance with Project Safety Plan / JSA.

4.4 ENGINEERING DEPARTMENT Provide technical support to MMG Site Operation section. Provide

relevant test diagram, material specifications, standards and technical

Page 3 of 9

MS-P-022 REV.00

specifications. Responsible to prepare test packages or to revise test packages.

5. REQUIRED TOOLS: 5.1 Tested water pump/compressor 5.2 Tested manifold 5.3 Calibrated pressure gauge 5.4 Calibrated relief valve 5.6 Flexible hoses 5.7 Hand tools, 5.8 Spades and blinds. 5.9 Temperature chart recorder. (for underground piping) 5.10 Drum or Water Container etc. 6. FLUSHING PREPARATION:

6.1

Make sure that all punch list A marked by QCI has rectified prior to testing, and get clearance for flushing.

6.2

All flushing should progress in a down word direction wherever Possible, to encourage the removal of all debris / solids which may be present inside the pipes.

Page 4 of 9

MS-P-022 REV.00

7 FLUSHING/ PIPE CLEANING 7.1 7.2 Use water or compressed air for flushing. Continue flushing until the specification is satisfied and that all foreign Materials and debris have been removed from the piping system. Raise RFI for further clearance.

8 HYDROTEST PREPARATION 8.1 Obtain work permit/access prior to start any pressure testing. 8.2 The area shall be marked and warning signs shall be posted, to alert approaching personnel. 8.3 Personnel shall be posted to keep area clear of all personnel not connected with the test. 8.4 Test pump / manifold should be in good condition and manifold should be Separately tested 20% more than the test pressure. 8.5 Pressure test gauge should be in current calibrated condition. A minimum of two (2) pressure gauges are required for the test system and verified that they are within 5% of each other when in use. All gauges shall have a range such that the test pressure is within 30% to 80% of the full range of the gauges. All piping system under test shall be protected from overpressure by installing relief valves which are set10% above the required test pressure of the system. 8.6 To isolate the system temporary blind flanges and test blinds shall be installed at locations shown on the marked up P&ID included in the Pressure Test Pack. Test blinds shall be of an adequate rating to withstand the test pressure.

Page 5 of 9

MS-P-022 REV.00

8.7 Coordinate to Aramco where to isolate the System of actual Fire Water line pipe. 8.8 Make sure that every system vent should installed at highest elevation & drain at lowest elevation. 8.9 Test fluid should be used as specified in the test package.

8.10 If test loop prepared to conduct on ground, make sure that system has slope and test fluid injected by lowest elevation. Pressure gauge and vent should be installed at top elevation. 8.11 Once the QC Inspector satisfied that test preparation is acceptable, test fluid may be introduced in to the system. Test fluid shall be injected at the lowest point and vented at the highest point of the system to minimize the risk of air entrapment. 8.12 Prepare the test loop as per approved test packages test diagram. Once all preparation has been completed, test supervisor should raise RFI for QC involvement. 8.13 An approved MS/Test procedure shall be available at site prior to commencing any pressure testing activities.

9 TEST FLUID Test fluid shall normally be water e.g. clean condensate, sweet water, or treated sea water, test fluid should must conform to SAES-A-007 General requirement for pressure testing.

Page 6 of 9

MS-P-022 REV.00

10 TEST EXECUTION (HYDROTEST) 10.1 Once the pre test activities have cleared QC inspection, the inspector shall sign RFI, after realistic time and date with the responsible supervisor this he will note on RFI, returning a copy to the supervisor and providing a copy for the client if a witness, or hold is identified in the checklist as per test package. 10.2 After test fluid has been introduced and the system is full (filled during vent in open condition), temperature equilibrium should be attained between test fluid and piping system after filling and before applying pressure. 10.3 When equalization has taken place all vent and drains are closed, gradually increase test pressure but not more than 100 psi per minute until 50% test pressure is achieved. Hold until integrity is verified by visual examination. If no leaks are detected continue to increase pressure in one fifth (1/5th) test pressure stages until ultimate pressure is achieved. 10.4 Test pressure will be maintained in accordance with specified requirement. If a pressure drop occurs, the cause shall be investigated, and if necessary the system shall be de-pressurized, repair affected and the test conducted again. If found any remedial work requiring welding shall necessitate draining of the test fluid. 10.5 Once the required pressure has stabilized. Check the pressure gauges and chart recorder (if required). Isolate the system. Maintain for the specified test duration. If any leakage found depressurize the line and rectify it. Once repair are completed, pressurize again. 10.6 Pressure should be released only after approval and acceptance.

Page 7 of 9

MS-P-022 REV.00

10.7

Prior to opening any drain valve, ensure pressure has been released and all vent are fully open, so as to prevent the formation of a vacuum within the system. Drain the test fluid in controlled manner ensuring protection of equipment from fluid ingress and ensure that drained test fluid channelled into the agreed location.

10.8

Carry out the hydro test on the tie- in joints during start up for a minimum of four (4) hours, if no leak, and then proceed with the final backfill.

11 QUALITY CONTROL AND ASSURANCE

All stages of work shall be inspected in accordance with the Approved Project Quality Control Inspection and Test Plan. 12 DISPOSAL OF TEST MEDIUM The disposal sites for the test fluid shall be reviewed and approved prior to the hydrostatic test in accordance with SAEP-327 "Disposal of waste water from Cleaning, Flushing, and Hydrostatic Tests". SAFETY PRECAUTIONS Barricade the working area. Accomplish/comply with checklist for pressure testing safely (Supplement G.I. 2.102) All safety precautionary signboards must be visibly posted. Wear full body harness when working at heights. Ensure that only authorized personnel are within the affected area.

Page 8 of 9

MS-P-022 REV.00

Copy of approved JSA to be maintained at work site by work supervisor, requirements discussed in daily TBT.

Complete WERA prior to commencing work.

. ---------------------------------------------------END---------------------------------

Page 9 of 9