Doosan Heavy Industries & Construction Co.

, Ltd
555 Guygok-Dong, Changwon Gyeongnam, Korea

Doc. Ref : DOOSAN/NHON TRACH CC!! !RO"#CT
Issue : $e% &', (&&
Rev : Rev.(
SIT# : NHON TRACH !ROR"#CT
CONTRACT :
CONTRACT D#SCRI!TION: H#AT R#CO)#R* ST#A+ ,#N#RATOR
CLI#NT : LILA+A COO!#RATION
C-STO+#R : SI#+#NS !O.#R ,#N#RATION / ,#R+AN*
TITL# : !N#-+ATIC T#ST !ROC#D-R#

I. SCOPE
+et0od State1ent of !neu1atic Test
II. RESPONSIBILITY
Site +ana2er : !aec3, "i, Hyun
Construction +ana2er : Na1, San2 Don2
+ec0anica4 +ana2er : +oon, 5a% Do
Safety +ana2er : H6an2, Seon2 -3
III. LIST OF THE METHOD STATEMENT
NO Method Statement Remark
Issued
Date
Re.
& #rection of stee4 structure for Site Office ('/('/ (&( Rev.(
Lay / do6n Construction ('/('/ (&( Rev.(
7 +o%i4i8ation and asse1%4y of 5o%e4co 9'( / $ 7(/('/(&( Rev.(
: +o%i4i8ation and asse1%4y of 5o%e4co SL;((( (9/(;/(&( Rev.(
' #rection <rocedure of Casin2 (=/(9/(&( Rev.&
; #rection <rocedure of stac3 &7/(9/(&( Rev.&
9 #rection <rocedure of 0ar< (/(9/(&( Rev.(
> #rection <rocedure of Stee4 Structure ;/(9/(&( Rev.(
= #rection <rocedure of Dru1 7&/(9/(&( Rev.(
&( #rection <rocedure of !i<in2 &:/(>/(&( Rev.(
&& #rection <rocedure of !aintin2 :/(>/ (&( Rev.(
& #rection <rocedure of Insu4ation :/(>/ (&( Rev.(
&7 $ie4d 1odification for Lin3 <i<e (9/(=/(&( Rev.(
&: Hydrostatic test <rocedure =/&/(&( Rev.(
&' !neu1atic Test !rocedure &'/(/(&& Rev.(
S!o"e o# $orks% +et0od state1ent of !neu1atic Test !rocedure
Br&e# des!r&"t&on o# deta&'ed $ork% Pressure test #or HRS(.
Se)uen!e o# o"erat&ons
& !re<aration for re4evant docu1ent & <er1it ;
!re<aration e?ui<1ent & too4s 9
7 !ressuri8in2 4ine insta44ation >
: !ressuri8in2 4ine for test =
' Recordin2 <ressure data &(
Man"o$er
#n2ineer -ns3i44ed La%ors '
Safety #n2ineer O<erator
Su<ervisor $irst Aider in 2rou< :
S3i44ed La%ors
Mana*ement stru!ture
- )isitin2 1ana2er: Na1 San2 Don2 / +oon 5a% Do
- Site su<ervisor: 5i1 Soo .oon2
- Safety: H6an2 Seon2 -3
- Out of 0ours contact na1e: Na1 San2 Don2 / +oon 5a% Do
- Out of 0our@s <0one no. (= 77': (:9= / (= (7= &:;
- .0o c0ec3s t0e 6or3A Na1 San2 Don2 / +oon 5a% Do
TABLE OF CONTENTS
1. PURPOSE
2. SCOPE
3. REFERENCE DOCUMENTS
4. DEFINITIONS
5. PROCEDURE
6. DOCUMENTATION
7. ATTACHMENTS
Annexure -: Flow Chart for Pneumatic Teting
Annexure -: !rgani"ation Chart for Pneumatic Teting
Annexure -: Pi#e $ork Punch %it
Annexure -: $el& 'n#ection (ummary (heet
Annexure -: 'n&ex of 'ometric Drawing
Annexure -: Preure Tet Certificate
Annexure -: Pi#e $ork )e-'ntatement Check %it
Annexure -: *echanical Com#letion Check %it

+,- PURPOSE
The #ur#oe of thi Proce&ure i to #ro.i&e controlle& ytem for Pneumatic Teting in
or&er to meet #ro/ect #ecification an& re0uirement of reference co&e an& tan&ar&,
2.0 SCOPE
The #roce&ure co.er minimum re0uirement for Pneumatic Teting of a1o.e groun& an&
un&ergroun& #reure #i#ing for 2hon Thach 3 CCPP Pro/ect
3.0 REFERENCE DOCUMENT
3.1 Co&e 4 (tan&ar&:
5+6 A(*7 8 9+,+
536 A(*7 (7C,:
3.2 (iemen Pro/ect (#ecification :
(#ecification of #i#ing ytem for water team cycle an& auxiliary ytem,
4.0 DEFINITIONS
2one
5.0 PROCEDURE
5.1 Gener!
5,+,+ D!!(A2 hall mark P4'D; a #er #i#ing ytem to 1e tete& an& i&entify the #i#ing
iometric an& the e0ui#ment to 1e inclu&e& for uch tet, Tet #ack hall 1e #re#are&
incor#orating marke& u# P4'D; 4 iometric for tet limit, #unch lit, #reure tet
certificate format, $el& 'n#ection (ummary (heet, Pi#e work )eintatement check lit
format, *echanical com#letion check lit format, etc,
5,+,3 All #i#e u##ort, gui&e an& anchor hown on #i#ing iometric hall 1e fitte& in #oition,
Any a&&itional tem#orary u##ort, if re0uire&, hall 1e intalle& 1efore teting, All wel&e&
attachment uch a #i#e u##ort an& hanger lug etc, hall 1e ma&e 1efore #reure tet,
5,+,9 Control .al.e, thermo well, orifice #late, trainer 1aket, filter element, in-line
intrument an& all other in line com#onent una1le to withtan& the tet #reure or lia1le
to &amage 1y the tet me&ium or 1y the im#act of foreign matter &uring the fluhing or
#urging #roce hall 1e remo.e& an& re#lace& with tem#orary #ool or #acer,
5,+,< Flange& relief .al.e an& afety .al.e hall 1e 1lanke& off 1y 1olting a 1lin& flange to the
mate of the inlet flange, (crewe& relief an& afety .al.e hall 1e remo.e& an& re#lace&
with ca#,
5,+,5 $here a .al.e to er.e a tet 1lock, the tet #reure hall not excee& the .al.e eat tet
#reure, 'f the ytem tet #reure i higher than the .al.e eat tet #reure, the .al.e
hall 1e o#ene& an& 1lanke& or remo.e& to allow 1lanking of the marking flange,
5,+,= All .al.e exce#t thoe co.ere& un&er 5,+,< 4 5,+,5 within the ytem to 1e tete& hall 1e
in the o#en #oition,
5,+,> %ine containing check .al.e hall ha.e ource of #reure u#tream of the .al.e, 'f thi i
not #oi1le, wing check hall 1e 1locke& o#en or ha.e the fla##er remo.e&, an& 1all an&
#iton check hall ha.e the internal #art remo.e&, All #art remo.e& hall 1e eale& in
#latic 1ag an& wire& to the .al.e, 'f none of thee are #ractical, the check .al.e hall 1e
1locke& off or com#letely remo.e&,
5,+,? All han&-o#erate& .al.e within a tet loo# hall 1e tem#orarily tagge& with large re&
@CAAT'!2B tag or imilar i&entification to a.oi& acci&ental o#eration &uring filling or
teting,
5,+,C Primary hut-off .al.e in 'ntrument lea& line from the main line an& e0ui#ment hall 1e
cloe&, Pi#ing or tu1ing &own team of the .al.e hall 1e &iconnecte& in or&er to #re.ent
any #reure 1uil& u# or intro&uction of foreign matter into the intrument ytem,
5,+,+- 'ntrument air u1-hea&er hall 1e iolate& from the main hea&er ytem 1y cloing the
1lock .al.e a&/acent to the main hea&er an& &iconnecting the firt union &own tream of
each .al.e, 'ntrument connection hall 1e cloe& with a #ro#erly gaket 1lin& flange, if
flange connection are ue&,
5,+,++ Tem#orary gaket hall 1e ue& to 1lank off line for #reure tet #ur#oe, unle #ecifie&
otherwie, Thee hall 1e remo.e& an& re#lace& with new #ermanent gaket after tet
ha.e 1een atifactorily com#lete&, Dowe.er, #ermanent gaket hall 1e ue& for flange
/oint, which &o not re0uire& to o#en again after teting,
5,+,+3 8olt tightening hall 1e in accor&ance with D!!(A2 Proce&ure,
5,+,+9 All #ot wel& heat treatment of the wel& /oint hall 1e com#lete& #rior to teting,
5,+,+< All 2D7 re0uirement hall 1e fulfille& 4 confirme& #rior to teting,
5,+,+5 The #i#e work ytem hall 1e fluhe& with water or 1lown with air in or&er to remo.e all
&e1ri #rior to teting,
5.2 C"n#$%$"n &"r 'ne()%$* +%%$* %e+%
5,3,+ Pneumatic tet #reure
(E(T7* Deign #reure Tet #reure )emark
'ntrument air line for (tack +- 1ar +3,- 1ar Deign #r x +,3
23 filling line for Drum ++ 1ar +9,3 1ar Deign #r x +,3
5,3,3 *eauring Tool an& 'ntallation
5+6 The #reure gauge intall at tem#orary #i#e,
536 The #reure gauge for #reure tet nee& to 1e cali1rate& an& the certificate a.aila1le at
ite #rior to uing in the #reure tet, %ocation of tet gauge will 1e hown in the
in&i.i&ual tet-#ack,
5,3,9 Communication
5+6 )a&io: more than 3 walkie-talkie
536 %ocation: Control center 5filling air .al.e an& #reuri"ation e0ui#ment area6
To# 5#reure gauge an& .ent area6 'n#ector
596 'n#ector an& recor&er mut #lace in a con.enient area to communicate for the #reure
gauge 'n#ection of control center,
5.3 Pre++(re %e+% e,($')en%+ n# $n+%r()en%+
The e0ui#ment an& intrument to 1e ue& for teting will 1e checke&, maintaine&, tete&
an& er.ice& for continuing #roce ca#a1ility,
5+6 23 8ottle unit for #reing #reure
536 Air Com#reor,
596 The #reure gauge ue& in #reure teting hall ha.e &ial gra&uate& o.er range of
a1out &ou1le the inten&e& maximum tet #reure, 1ut in no cae hall the range 1e le
than +
+
F
3
nor more than 9 time that #reure, The #reure gauge hall 1e cali1rate&
from authori"e& cali1ration agency 1efore ue an& re-cali1rate& at any time that there i
reaon to 1elie.e that they are in error, 7ach gauge hall ha.e an i&entification num1er,
which hall a##ear on the cali1ration certification recor&,
5.4 Pre-%e+% '$'$n. /!0 #"/n1I& re,($re+2.
5+6 (afe acce an& any re0uire& tem#orary caffol&ing hall 1e #ro.i&e& for in#ection of
all /oint an& a##urtenance #rior to walk-&own an& maintaine& until the atifactory
com#letion of the tet,
536 'ometric &rawing #ertaining to the tet #ackage hall 1e lite& on the 'n&ex of
'ometric Drawing,
596 !n com#letion of #i#ing intallation, the ytem will 1e walke& &own 1y the Pi#ing
7ngineer an& outtan&ing item will 1e &ocumente& on the Pi#e work Punch %it,
5.5 Pne()%$* %e+% "& '$'$n..
5,5,+ Preure tet hall 1e normally #erforme& 1y hy&rotatic metho& unle otherwie tate&,
Preure teting of #i#ing hall in accor&ance with the re0uirement of A(*7 8 9+,+, For
&etail, refer Para 5,> of thi #roce&ure,
5,5,3 Preure tet houl& 1e carrie& out on com#lete ytem whene.er #ractica1le,
5,5,9 Anle otherwie tate& on the &rawing, all #reure #i#ing hall 1e tete& in accor&ance
with the tet #reure with tet me&ium a #er %ine %it of each ytem,
5,5,< All #i#ing hall 1e #neumatic #reure tete& when:
5+6 $ater i harmful to the er.ice an& cannot 1e &rie& com#letely,
536 'ntrument air, utility air, nitrogen ytem an& er.ice air,
596 'n cae of #i#ing connecte& to an e0ui#ment or .eel no""le 1y wel&ing an& where the
70ui#ment i not inclu&e& in teting, the #i#ing hall 1e #reure tete& 1efore
intallation, After wel&ing of the #i#ing to e0ui#ment no""le, the final /oint hall 1e
u1/ecte& to 2D7 5)T, AT, *T, PT a a##lica1le6 intea& of #reure tet,
5<6 %ine which are o#en to atmo#here, uch a .ent, &rain an& o#en afety .al.e
&icharge, Thee line hall 1e .iually examine& to .erify that all /oint are #ro#erly
ma&e u#,
556 (afety .al.e, flame arretor, ru#ture &ic an& filter element hall not 1e u1/ecte& to
#reure tet,
5=6 Preure gauge, thermometer, flow meter an& other intrument hall not 1e
u1/ecte& to #reure tet,
5>6 )u11er 7x#anion /oint an& team tra# hall not 1e u1/ecte& to #reure tet,
5?6 Any other e0ui#ment &eignate& 1y (iemen,
5,5,5 $here an item of e0ui#ment ha 1een 1lanke& off at a flange& /oint &uring #reure tet of
#i#ing, it hall not 1e neceary to #reure tet the /oint after the 1lank i remo.e&, (uch
/oint hall 1e .iually examine& to enure that gaket are #ro#erly intalle&, 1olt
tightene& etc, an& in#ecte& for leak &uring commiioning an& er.ice tet, Flange& /oint
that are 1roken for #reure tet #ur#oe hall ha.e a new #ermanent gaket intalle& after
#reure tet i com#lete& #rior to commiioning,
5,5,= Pi#ing that i re#aire& or mo&ifie& after a #reure tet hall 1e re-tete&, exce#t in cae
an& agreement with (iemen, +--G 2D7 5)T, AT, *T, PT a a##lica1le6 may 1e
u1titute& in lieu of retet,
5,5,> +--G 2D7 5)T, AT, *T, PT a a##lica1le6 may 1e u1titute& after agreement with
(iemen intea& of hy&rotatic tet for wel&e& tie in #ortion with exiting #lant facility,
5,5,? All /oint inclu&ing wel& hall 1e left uninulate& an& ex#oe& for examination &uring
teting exce#t thoe /oint #re.iouly tete& in accor&ance with thi #roce&ure,
5.6 Pre'r%$"n "& '$'$n. +3+%e)+ &"r 're++(re %e+%.
5,=,+ Pi#ing hall 1e thoroughly .ente& of air 1efore intro&uction of the tet water, Digh #oint
.ent to 1e #ro.i&e& a re0uire&, A&e0uate meaure hall 1e taken not to allow any air to
remain in the high #oint of the tete& ytem,
5,=,3 Tem#orary 1lin& flange an& tet 1lin& hall 1e intalle& at location hown on the marke&
u# P4'D inclu&e& in the Preure Tet Pack, Tet 1lin& hall 1e of an a&e0uate thickne
to withtan& the tet #reure,
5,=,9 All internal #art an& in-line item remo.e& for the &uration of #reure teting hall 1e
la1ele& an& the com#onent to which they 1elong or the #oition in the line from which they
were remo.e& hall alo 1e la1ele& to enure correct re#lacement of com#onent following
the teting,
5,=,< All .al.e, exce#t a exclu&e& #ecifically herein, hall 1e inclu&e& in the #reure tet,
1all .al.e hall 1e in the half o#en #oition an& all other .al.e fully o#en,
Dowe.er, where the tet #reure to 1e a##lie& to line i greater than the maximum
allowa1le tet #reure #ecifie& for the .al.e, the .al.e hall 1e 1lin&e& on the tet i&e
or re#lace& with a tem#orary #ool,
5,=,5 7x#anion /oint hall 1e #rotecte& from excei.e #reure of the hy&rotatic tet
generally 1y remo.ing them, *etallic 1ellow ex#anion /oint hall not 1e u1/ecte& to
any #reure in exce of it ho# tet #reure,
5,=,= All line in .a#or er.ice hall ha.e ufficient tem#orary u##ort to withtan& weight of
the tet me&ium,
5,=,> All tem#orary u##ort, #ring u##ort retraint, tem#orary #ool, 1lin& an& #lug etc,
hall 1e #rominently flagge& or #ainte&, to enure their remo.al following teting,
5,=,? The tet #reure gauge hall 1e locate& at the high #oint of the ytem, a @CheckB gauge
hall, in a&&itional, 1e locate& at the low #oint of the ytem if ignificant .ertical leg
coul& caue the tatic hea& #reure to o.er-#reure #art of the ytem,
5,=,C All tet manifol& hall 1e hy&raulically tete& an& clearly marke& for the maximum
#reure rating,
5.7 Pne()%$* Pre++(re %e+%.
5,>,+ Pneumatic tet
5+6 Pneumatic tet hall only 1e #erforme& un&er the &irect u#er.iion of an ex#erience&
engineer, who mut enure that tet #roce&ure an& criteria are followe&, All #eronnel
in.ol.e& with teting mut 1e ma&e aware of, an& traine& in, the #roce&ure to 1e
im#lemente&, an& 1e familiar with the ha"ar& aociate& with thi ty#e of tet, A
#reure relie.e .al.e hall 1e ma&e a.aila1le 5for #i#ing ytem of tet #reure a1o.e
+5 1ar6, ha.ing a et #reure no higher than the tet #reure #lu the leer of +-G of
the tet #reure,
The relief .al.e hall 1e locate& at the firt connection on the tem#orary line nearet
the #reure ource, A 1lee& .al.e to facilitate &e-#reuri"ation hall 1e locate& at
the tet manifol& rea&ily accei1le 1y the o#erator in cae &e-#reuri"ation i
re0uire&, An iolation .al.e rate& for the tet #reure hall 1e #ro.i&e& 1etween the
manifol& an& the ytem 1eing tete&,
536 During the tet, the area, which may 1e affecte& 1y 1lat, hall 1e cor&one& off uing
colore& ta#e, (ign hall 1e #lace& to in&icate the &anger, Flahing light hall 1e ue&
to &eignate area un&er tet &uring non-&aylight hour,
7ntry to the cor&one& area hall 1e retricte& to the authori"e& #eronnel who are
#erforming an& witneing the tet,
596 The ytem un&er tet hall ha.e warning notice tag affixe& to all .al.e &uring the
time that the ytem i #reuri"e&,
5<6 $el& an& flange& /oint hall 1e wa11e& with oa# olution to facilitate &etection of
leak,
556 The ytem un&er tet hall 1e gra&ually #reuri"e& to the leer 5-G of the tet
#reure an& hel& for a ufficient length of time to allow #i#ing to e0uali"e train, All
/oint 5threa&e&, ocket wel&e&, 1utt-wel&e& an& flange&6 hall 1e in#ecte& for leak
with oa#u&,
5=6 Preure hall 1e increae& in te# 5each te# to 1e not more than +-G of the #ecifie&
tet #reure6 until the #ecifie& tet #reure ha 1een reache&, hel& for a ufficient
length of time at each te# to allow #i#ing to e0uali"e train, $hen the tet #reure
ha ta1ili"e& the tet #um# hall 1e &iconnecte&, The tet #reure hall 1e maintaine&
for +- minute, :iual in#ection of all /oint an& com#onent for leak with oa#u&
hall 1e #erforme& at the leer of &eign #reure or >1ar5G6
5>6 The #neumatic tet #reure hall 1e either from +3-G u# to maximum +5-G of the
&eign #reure, or a mutually agree& #reure 1etween Dooan an& (iemen
)e#reentati.e,
5?6 Throughout the teting #erio&, the #reure i to 1e cloely monitore& to enure that
o.er-#reuring &ue to thermal ex#anion &oe not occur,
5C6 The #reure tet of the #i#ing ytem hall 1e recor&e& on the Preure Tet
Certificate,
5+-6 After com#letion of a #neumatic tet the ytem hall 1e &e-#reuri"e& in a
afe manner un&er the &irection of a u#er.iing 7ngineer,
5.4 5en%$n. 6 &!(+7$n..
5,?,+ All line hall 1e thoroughly .ente& imme&iately after teting, Care hall 1e taken to enure
againt &amage 1y .acuum to any a##aratu or #i#ing 1y firt o#ening all .ent .al.e an&
remo.ing high #oint .ent #lug,
5,?,3 (#ecial #recaution houl& 1e taken to enure the &rainage of all #ocket where the teting
flui& may 1e tra##e&,

5.8 P"+% %e+% re$n+%%e)en%.
5,C,+ Following acce#tance of a ucceful tet, the ytem hall 1e imme&iately &e#reuri"e&
an& .ente& in a gra&ual an& afe manner, thoroughly &raine& allowing no #ocket of flui&
to remain, Prior to &raining out tet me&ium, all .al.e in #artially o#en #oition hall 1e
fully o#ene& after &ro##ing #reure to ytem #reure, For #neumatic tet, warn #eo#le
in the .icinity #rior to releae of #reure o#en .ent .al.e lowly kee#ing clear of &icharge
an& enure .ente& air or nitrogen cannot caue &anger,
5,C,3 All item remo.e& for the tet hall 1e re#lace& an& all tet 1lin&, tem#orary u##ort, etc,
hall 1e remo.e&, The re#lacement of #i#ing com#onent internal hall 1e carefully
controlle& to enure that they are reintalle& in the correct #lace, Flange& /oint o#ene& for
thee #ur#oe hall 1e re-ma&e with new gaket,
6.0 DOCUMENTATION.
The tet #ack hall 1e #re#are& an& u1mitte& to (iemen for re.iewFa##ro.al #rior to
teting, The tet #ack hall inclu&e following:
5+6 P 4 ' Diagram 5*arke& u# to how tet limit6
536 'ometric Drawing 5*arke& u# to how tet limit6
596 'n&ex of 'ometric Drawing
5<6 $el& 'n#ection (ummary (heet
556 Pi#e work Punch %it
5=6 Preure Tet Certificate
5>6 Pi#e work )e-intatement Checklit
5?6 *echanical Com#letion Checklit
7.0 ATTACHMENTS.
Annexure -: Flow Chart for Pneumatic Teting
Annexure -: !rgani"ation Chart for Pneumatic Teting
Annexure -: Pi#e $ork Punch %it
Annexure -: $el& 'n#ection (ummary (heet
Annexure -: 'n&ex of 'ometric Drawing
Annexure -: Preure Tet Certificate
Annexure -: Pi#e $ork )e-'ntatement Check %it
Annexure -: *echanical Com#letion Check %it