1.0 PURPOSE.
2.0 SCOPE.
3.0 APPLICABLE DOCUMENTS.
4.0 RESPONSIBILITY.
5.0 MANPOWER.
6.0 TOOLS & EQUIPMENT.
7.0 GENERAL REQUIREMENTS.
8.0 PREPARATION FOR PRESSURE TEST.
9.0 PROCEDURE OF PRESSURE TEST.
10.0 QUALITY CONTROL.
11.0 SAFETY PRECAUTION.
12.0 ATTACHMENTS.
PRESSURE TESTING OF COMBINED FURNACE HEATER MANIFOLD AND REACTOR RISER PIPE
1.0 PURPOSE
This method statement shall provide minimum guidelines to carry out the Pressure Testing of combined Furnace heater manifold and reactor riser pipe for plants and refinery project. In accordance with contract scope of work and project specification.
2.0 SCOPE
2.1. This Method Statement covers the procedure of Pressure Testing of combined Furnace heater manifold and reactor riser pipe for plants and refinery project.
3.0 APPLICABLE DOCUMENTS
3.1. Saudi Aramco Standard
3.1.1. SAEP-302 Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement.
3.1.2. SAEP-327 Disposal of Wastewater from cleaning, flushing and Dewatering Pipelines & Vessels.
3.1.3. SAES-A-004 Pressure Testing.
3.1.4. SAES-L-150 Pressure Testing of Plant Piping and Pipelines.
3.1.5. SAES-A-007 Flydrostatic Testing Fluids and Lay-up Procedures.
3.1.6. SAES-L-350 Construction of Plant Piping.
3.1.7. GI-0002.102 Pressure Testing Safely.
3.1.8. SATIP-A-004-02 Hydrostatic Testing of on-Plot Piping.
3.1.9. SATIP-A-004-03 Hydrostatic Testing of Pipelines.
3.1.10. SAIC-A-2001 Review Procedure – Pressure Testing (all applications).
3.1.11. SAIC-A-2018 Lay-up of Piping Systems & Vessels.
3.2. Special Process Procedure.
3.2.1. PIP-MS-010 Procedure for Piping Pressure Test.
3.2.2. ENG-PR-001 Lay-up Procedure.
4.0 RESPONSIBILITY
4.1. Construction Manager is responsible on implementing HSE and shall study, analyze and schedule all construction activities with his department to include manpower and equipment line up as well as other possible resources required for the successful implementation of the construction work activities. He shall study all aspects of work procedure as per JGC/DEC Technical Scope of Work and Saudi Aramco Standard.
4.2. Piping Superintendent shall study and review all necessary documents for the Testing works to include, technical scope of work, specification, bill of quantities, planned milestone dates and construction procedure in support to his supervisor.
He shall monitor the availability of materials and equipments in accordance with construction schedules. He shall directly report to construction Manager.
4.3. Piping Supervisor shall be directly reporting to the Piping Superintendent and responsible in the implementation and control of all site activities per Technical Scope of Work and latest approved construction drawings. He shall coordinate with other discipline to visualize possible conflicts in the drawing as well as in the schedules to provide other options in preventing unnecessary delays and obstructions.
4.4. The Welding Supervisor and/or Foreman are solely responsible to ensure that all welding works are in conformance with applicable codes, standards, specifications and approved procedures.
4.5. Piping Foreman shall be responsible for the direct testing activities supervision at site and ensure that the work is performed in accordance with JGC/DEC Technical Scope of Work and latest approved for construction drawings. He shall monitor the availability of materials in line with his required schedule at site and reports directly to Piping Supervisor.
4.6. QC Inspector shall be responsible in inspection and monitoring of the testing activity and ensure that the testing activities is performed and properly documented in accordance with Project requirements.
4.7. Safety Supervisor shall be responsible in monitoring safety aspects and ensuring that the testing activity is done in accordance with JGC/DEC Safety Standard Procedure. He shall discuss to the workers the characteristics of related materials and status of work area giving reminders as an additional point to work safely.
5.0 MANPOWER
5.1. The Piping Superintendent shall control the overall activity of Pressure Testing activity. The basic manpower under him shall consist but not limited to the following:
5.1.1. Piping Supervisor
5.1.2. Piping Foreman
5.1.3. Pipefitters
5.1.4. Helpers
5.2. Safety Engineer/Officer
5.3. QC Inspector
6.0 TOOLS AND EQUIPMENT
6.1. Tools and equipment needed should be in good condition and must be checked by Piping Supervisor / Safety Officer prior to use in the construction area. These includes but not limited to:
6.1.1. Tools & Equipment
6.1.1.1 Test Manifold
6.1.1.2 Test Pump
6.1.1.3 Test blinds
6.1.1.4 Pressure Relief Device
6.1.1.5 High Pressure Hoses
6.1.1.6 Wrenches
7.0 GENERAL REQUIREMENTS
7.1. General Instruction GI-0002.102 “Pressure Testing Safely shall be followed during pressure testing.
7.1.1.A copy of GI-0002.102 and approved pressure testing procedure shall be kept at test site.
7.2. All new constructed plant piping shall be subjected to hydrostatic test in accordance with this procedure and reference documents.
7.3. All welded attachments such as pipe supports and hanger lugs etc. shall be made before testing. No welding should be done after hydro/pneumatic testing except for seal welding at test vent/drain.
7.4. For piping systems, that has already passed a successful pressure testing, a second pressure testing is required if it is subjected to new welding activities and post heat treatment (PWHT) is mandated due to these new welds. It is not require if.
7.4.1. Seal welds of threaded connections
7.4.2. Attachment welds of non-pressure containing parts, such as wear pads.
7.5. All joints excluding butt welds shall be left uninsulated and unpainted for examination during testing except those joints previously tested in accordance with this procedure. Butt weld joints can be painted prior to testing with condition that the weld repair shall not exceed 7.5% joint basis or 0.4% on linear basis.
7.6. A pressure relief valve shall be provided to protect the piping from the over pressure. Relief valve of adequate capacity set to relieve at 5% above the test pressure shall be installed. The relief valve shall be tested, dated, and tagged within one week prior to the pressure test.
7.7. A check valve shall be provided between the pressure testing manifold and pressurizing pump due to easier pressurizing.
7.8. Before employing the pressure testing manifold in the actual system pressure test, it shall be separately pressure tested to at least 1.2 times the system test pressure and not less than the discharge pressure of the pump used for the pressure testing.
7.9. Pressure gauges shall be calibrated before the test. The calibration interval shall not exceed one (1) month. The gauges shall be tagged with the date last calibrated and expire date. Each gauge shall have an identifying mark or number which shall appear on the calibration certificate. All pressure gauges shall have a range such that the test pressure is within 30 to 80% of the full range and their accuracy shall be within 5% of one another. A minimum of two (2) pressure gauges shall be provided for the test system. One pressure gauge shall be on the test manifold and the other(s) on the test system.
7.10. Water quality of intended pressure test water shall be determined well ahead of the actual testing date so that alternative water sources may be identified if the original source water fails to meet requirements.
7.11. Test package must be approved prior to execution of hydro-testing.
8.0 PREPARATION FOR PRESSURE TEST
8.1. Identify limits of testing, water injection point, vent, drain and flushing blowing points on test package. Prepare with the amount of water injected to the system; the type of testing material and rating for its blinds; identify pressure gauge location, test pressure and test medium to be used.
8.2. Prior to testing, air blowing / water flushing must be conducted to internally clean the system to test.
8.3. Prepare testing equipment and test manifolds at designated locations. Test manifold shall be at the lowest point of the line.
8.4. Piping shall be thoroughly vented of air during introduction of the test water. High point vents and low point drains to be provided as attached sketch. All lines shall be checked to ensure entire system can be completely drained after testing.
8.5. Temporary blind flanges and test blinds shall be installed at locations shown on the marked up P&ID Schematics included in the Pressure Test Pack. Test blind shall be of an adequate thickness to withstand the test pressure. Test blind should be lifted and installed by using Flange Jack which is the special jig for safety and easy installation.
8.6. Temporary gaskets shall be installed for pressure test. The temporary gaskets shall be equivalent to permanent gaskets.
8.7. For preventing possible deformation of piping due to the weight of test water, temporary supports or other proper means of support shall be provided when necessary. These supports shall not be removed until the system has been fully drained.
8.8. For pressure tests on piping systems with check valve, pressure shall be put from upstream of the check valve or the internal of the check valve can be removed under Company supervision. Check valve shall not be used for isolation.
8.9. Stopper of spring supports shall not be removed before pressure test.
8.10. Equipment (Drums, Fleat Exchangers, Columns, and etc) that is not to be tested shall be either disconnected from the piping or isolated by blinds or other means during pressure test.
8.11. Instrument connections shall be closed with a properly gasketed blind flange, if flange connections are used. Tubing from instrument root valve is to be disconnected.
8.12. Paddle blinds or spectacle blinds shall be used to isolate the test sections. When this is not practical, closed block valves (gate, globe, plug, ball) may be used to isolate piping sections (providing the valves are not passing, otherwise the spectacle plate/blind shall be installed in the closed position). If closed block valve are used in lieu of blinds, provisions shall be made to ensure no overpressure can occur in the system that is not being tested, due to possible leak through the valves.
8.13. The following components shall be removed or isolated by inserting blinds and/or temporary spools.
8.13.1. Control Valve, Thermo Wells, Orifice Plates, Restriction Orifices, Strainer Elements, Filter Elements, Rupture Discs, Flow Nozzles, Displacement and Turbine Meters, Self Contained Pressure Regulators, Rotameters, Pressure Gauges, Level Gauges, Level Instruments, Conical Strainers, Flow Glasses, Sample Probes, Safety Shower & Eye Washers, Non-Slam Check Valves, Dual Plate Check Valves, Pressure Relief Valves, Steam Traps, Auto Drains, Sample Coolers and Chemical Injections.
8.14. After the pressure test is completed, all lines shall be thoroughly cleaned of dirt, loose scale and debris at flange connections such as test limit or subsystem limit and will be reinstate in-line items.
8.15. After draining lay-up system as per Line designation table (H-000-1360- 302_02G) in accordance with SAES-A-007.
9.0 PROCEDURE OF PRESSURE TEST
9.1. The area around the system to be tested shall be cleared of unauthorized personnel and warning notices posted during the time that piping system is pressurized for the test.
9.2. Vent at high points for reactor riser pipe shall be left open, it should have tag which show Do not close . All air must be removed before the pressure is increased above that is required to fill the system.
9.3. In this case upon start-up of filling, the water level rise up to the top of tube as shown on attached sketch.
9.4. Continue the filling, water flow over the tube and filled up to the next header up to the reactor riser pipe until all lines will be fully filled.
9.5. The test pressure shall gradually be increased to the specified test pressure in accordance with GI-0002.102. 5.2.3 Control Pressure Rise Then the system shall be held for a sufficient time to allow detection of any leaks along the complete length of the piping system under test but in no case less than 30 minutes.
9.6. Make sure that no person is allowed to enter on testing area except to the
testing group.
9.7. After the test pressure is reached and before commencement of inspection of the system, the isolation valve between the temporary test manifold/piping and the piping under pressure test shall be closed and the test pump disconnected.
9.8. A minimum of two (2) pressure gauges shall be used during the test.
9.9. After completion of pressure test, following operation shall be done;
9.9.1. Release of pressure and draining shall be done on the downstream side of check valves. All valves shall be opened before draining to facilitate drainage and to prevent formation of vacuum. No test fluid shall remain in low spots.
9.9.2. Drain water at the nearest sewer lines. Test fluid shall be disposed in accordance with SAEP-327 or as directed by owner.
9.9.3. Vents and drains used only for the pressure test shall be plugged, seal welded.
9.9.4. All temporary items installed for testing purpose (e.g., manifolds, valves, blinds, spacers, supports) shall be removed.
9.9.5. Items that were removed from testing shall be reinstalled. Items such as instrument air tubing, check valves discs which were disconnected before testing shall be reconnected. Isolation valves closed for the test purposed and that are required to be in the open position for process reasons shall be opened. If the valve cavity has a drain, the cavity shall be drained.
9.10. After completion of pressure test, permanent gasket and temporary gasket installed where to be reinstated shall be replaced to a new permanent gasket. Ring Joint gasket and Rubber Sheet gasket.
9.11. In case leak was found, depressurized the line to safe limits or zero reading pressure before any repair works or tightening of bolts. Repair the leaks and pressurize the line.
10.0 QUALITY CONTROL
10.1. ARCC QC personnel shall be assigned to ensure the quality control and assurance requirement of the project.
10.2.ARCC QC Inspector shall coordinate with other inspector to conduct inspection as required in SATIP Piping Aboveground Installation Works.
10.3.ARCC QC Inspector shall be responsible to conduct all required inspections/documentations and to ensure that all applicable requirements, codes, and standards are complied with.
10.4. ARCC QC to utilize the applicable SAIC for every activity.
11.0 SAFETY PRECAUTION
Obtain the approval of the work permit from DEC/JGC before starting any work.
11.1. Provide warning sign and sufficient barricade on working area and only assigned personnel will be allowed in the area.
11.2. During pressure build-up and setting time nobody is allowed to go to the top level of radiant tubes due to pressure.
11.3. All electrical tools shall be checked and color-coded as shown below:
11.3.1. January/May/September – Green
11.3.2. February/June/October Red
11.3.3. March/July/November Blue
11.3.4. April/August/December Yellow
11.4. Continuous monitoring and inspection shall be implemented to detect and correct unsafe practices while performing the work activities.
11.5. Safety harness with double lanyards shall be used all the time when working at elevated temporary platforms 1.8 meters high and above.
11.6. Safety Supervisor shall monitor the work activities to help and to protect all assigned workers against exposure to safety hazards. He shall ensure that Personal Protective Equipment (PPE s) are supplied, used and comply with JGC applicable standards.
11.7. All rigging equipment shall be in good condition and possess a valid certification from authorized certifying and inspection department inspection and color coding shall be done in accordance will JGC inspection guideline.
11.8. Toolbox meeting shall be conducted by Piping Supervisor daily so as work activities will be properly coordinated to all concerned and all safety infractions will be acted immediately.
11.9. All necessary personal protective equipment (PPE) shall be provided and to be worn at all times.
11.10. Housekeeping shall be maintained and working area shall be kept in a clean and tidy manner.
11.11. Job Hazard and Risk Assessment (JHRA) of this method statement shall be disseminated and explained to workers prior to start of work.
12.0 ATTACHMENT
12.1. ATTACHMENT 1 Job Hazard and Risk Assessment
12.2. ATTACHMENT 2 Sketch of piping and coil test scheme
