031-Procedure for Hydro and Pneumatic Testing.pdf

Pearl GTL Project Shell Project No: HP-3000-QAT Project Document Number: T- 4.250.908

Purchase Order Number:

2MH127

Tag/Item Number(s):

N/A

Unit(s):

PCWBS:

ASU

Z

LINDE ENGINEERING ENGINEERING

Contractor Project No: 5887 Project Rev.: Rev.: O

Page 2 of 32

QATAR QATA R SHELL SHELL GTL PROJECT (PEARL (PEARL)) C2 AIR SEPARATION UNITS CONSTRUCTION

C

O

04.12.2007

Issued for Company comments

BR

AU/MC

ZG

ICC

B

24.11.2007

Issued for Review

BR

AU/MC

ZG

IFR

A

18.11.2007

Issued for Internal Review

BR

AU/MC

ZG

IIR

Date

Description

GAMA Rev.

Project Rev

No.

No.

Prepared Checked Approved By By By

Status

ORIGINATOR

Document Title:

PROCEDURE FOR HYDRO AND PNEUMATIC TESTING

LINDEGINEERING AG

Document No.

Contractor

Gama Qatar Qatar Co . W. L. L.

LOC470 GAM

PRO

QAC

GTL

031

C

Org.

Doc. Type

Geogr. Area

Seq.

Code

Disc. Code

Rev. No

Project Document Number: T-4.250.908

No

Vendor Vendor Code

Rev No: O

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PROCEDURE FOR HYDRO AND PNEUMATIC TESTING GAM-PRO-QAC-GTL-031 REV-C

Date

04.12.07

TABLE TAB LE OF CONTENTS CONTENTS 1.

SCOPE _______________________ __________________________________ ______________________ ______________________ ______________________ ______________________ ___________ 6

2.

PURPOSE _____________________ _________________________________ _______________________ ______________________ ______________________ ____________________ _________ 6

3.

HSSE ______________________ _________________________________ ______________________ ______________________ ______________________ ______________________ _____________ __ 6

4.

REFERENCE ______________________ _________________________________ ______________________ _______________________ _______________________ ________________ _____ 6

5.

DEFINITIONS _____________________ ________________________________ ______________________ _______________________ _______________________ ________________ _____ 7

6.

RESPONSIBILITIES _____________________________ ________________________________________ ______________________ _______________________ _______________ ___ 8 6.1.

Site Manager ______________________________ ________________________________________________________________ _______________________________________________8 _____________8

6.2.

Construction Manager __________________________________ ___________________________________________________________________ ___________________________________8 __8

6.3.

QA/QC Manager___________________________ Manager_____________________________________________________________ _______________________________________________8 _____________8

6.4.

Welding Inspectors _______________________________ _________________________________________________________________ _________________________________________8 _______8

6.5.

QC Inspectors _____________________________ _______________________________________________________________ _______________________________________________8 _____________8

6.6.

Field Chief Engineer_______________________________________________ Engineer_______________________________________________________________________9 ________________________9

6.7.

HSE Manager _____________________________ _______________________________________________________________ _______________________________________________9 _____________9

6.8.

Piping Superintendent __________________________________ ___________________________________________________________________ ___________________________________9 __9

6.9.

Testing Supervisor _______________________________ _________________________________________________________________ _________________________________________9 _______9

7.

EXCLUSIONS ______________________ _________________________________ ______________________ _______________________ _______________________ ________________ _____ 9

8.

TEST PACK PREPARATION ______________________ _________________________________ ______________________ _______________________ ______________ __ 10

9.

TEST PACK PROCESSING ______________________ _________________________________ _______________________ _______________________ _______________ ____ 11

10.

QA/QC CLEARANCE ______________________ _________________________________ ______________________ ______________________ ___________________ ________ 12

11.

HYDROSTATIC TESTING TESTING ______________________ _________________________________ ______________________ _______________________ ______________ __ 13

11.1.

Test Medium __________________________________ ____________________________________________________________________ ________________________________________13 ______13

11.2.

Test Pressure___________________________________________________ Pressure__________________________________________________________________________13 _______________________13

11.3.

Preparation for testing ________________________________ _________________________________________________________________ __________________________________14 _14

11.4.

Test Pressure Gauges Gauges and recorders _______________________________ ______________________________________________________15 _______________________15

11.5.

Testing witness ________________________________ __________________________________________________________________ ________________________________________15 ______15

12.

SERVICE TESTING _______________________ __________________________________ ______________________ ______________________ ___________________ ________ 16

13.

PNEUMATIC TESTING__________________ TESTING_____________________________ ______________________ ______________________ _____________________ __________ 16

13.1.

General ________________________________ __________________________________________________________________ ______________________________________________16 ____________16

13.2.

Preparation of test Equipment ______________________________ ___________________________________________________________18 _____________________________18

13.3.

Filling System _________________________________ ___________________________________________________________________ ________________________________________19 ______19

13.4.

Initial Pressurization and Leak Test _______________________________ ______________________________________________________20 _______________________20

13.5.

Incremental Pressure Increase ______________________________ ___________________________________________________________21 _____________________________21

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13.6.

Equalization and Inspection ________________________________ _____________________________________________________________21 _____________________________21

13.7.

Hold Period _____________________________ _______________________________________________________________ ______________________________________________22 ____________22

13.8.

Leak Testing __________________________________ ____________________________________________________________________ ________________________________________22 ______22

13.9.

Test Evaluation ________________________________ __________________________________________________________________ ________________________________________22 ______22

13.10.

Completion _____________________________ _______________________________________________________________ ______________________________________________23 ____________23

14.

SAFETY _____________________ _________________________________ _______________________ ______________________ ______________________ ___________________ ________ 23

15.

POST TEST ACTIVITIES _____________________ ________________________________ _______________________ _______________________ _______________ ____ 25

16.

ENGINEERING MODIFICATIONS__________________________ MODIFICATIONS_____________________________________ _______________________ ______________ __ 26

17.

FINAL INSPECTION AND AND SYSTEM TEST STATUS STATUS ______________________ __________________________________ ______________ __ 26

18.

REPORTS AND RECORDS RECORDS ______________________ _________________________________ ______________________ _______________________ ______________ __ 27

19.

ATTACHMENTS________________________ ATTACHMENTS_____________ ______________________ ______________________ ______________________ _____________________ __________ 27

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1. SCOPE This procedure applies to the Hydostatic and pneumatic testing of complete piping system and their integral components to assure mechanical strength and tightness in conjunction with relevant process engineering flow schemes and Piping drawings for C2 ASU PEARL GTL PROJECT by Gama Qatar.

2. PURPOSE The main purpose of this procedure is to define and describe the minimum requirements and responsibilities associated with the pressure testing of piping and integrated components. In addition, the applicable codes and/or standards shall be fully applied to all the testing activities. The main objective of this document is to ensure that; All activities are carried out in accordance accordance with approved procedures, specifications specifications and drawings; All tests, measurements measurements and inspections inspections required by this procedure procedure and/or applicable project specifications are performed; Special working and and control processes processes used if required have been previously previously approved; approved; Qualified personnel personnel are deployed deployed for carrying out testing activities; activities; •

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3. HSSE All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan Industrial City and International standards, codes, LINDE ENGINEERING AG and QSGTL and/or its PMC requirements and instructions. In addition all employees and GAMA subcontractor employees on site will have through LINDE ENGINEERING AG Site Safety Induction and GAMA Qatar Safety induction for site safety, health, environmental and security prior to work activities. Other training courses will be attended as required by LINDE ENGINEERING AG or QSGTL and/or its PMC as required.

4. REFERENCE ASME B 31.3

Process Piping

ASME B 16.5

Pipe Flanges and Flanged Flanged Fittings

ASME B 16.34

Valves Flanged, Threaded Threaded and Welding Ends

DEP 31.38.01.11

Piping General Requirements and its Amendment T-13.376.815

DEP 31.38.01.12

Piping Classes – Refining and Chemicals

DEP 31.38.01.31

Shop and Field Fabrication of Steel Piping

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DEP 30.10.60.18

Welding of Metals (Amendments/suppleme (Amendments/supplements nts to API RP 582)

DEP 61.38.10.10

Shop and Field Fabrication of Orifice Meter Run

DEP 31.40.40.38

Hydrostatic testing of new Pipe line

DEP 31.38.01.11

Piping General Requirements

T-4.234.542

Project Quality Plan

T-4-234-547

procedure for GRP piping

T-4.250.915

Procedure for calibration

T-4.376.808

GRP Pipe Lines and Piping systems

T-4.096.700

Pneumatic and Hydrostatic Pressure Testing

T-13.377.360

Flaw list for Flawless start up-initiative (FSI)

5. DEFINITIONS Company

: QSGTL/or its PMC

Contractor

: LINDE ENGINEERING AG

Sub Contractor

: GAMA QATAR

Contract

: QSGTL Pearl Plant - C2 ASU Project

QA/QC

: Quality Assurance / Quality Control

TPI

: Third Party Inspection

ITP

: Inspection and Test plan

QA/QC

: QA/QC Manager

QCI

: QC Inspector

NDE

: Non-Destructive Examination

NCR

: Non Conformance Report

PTFE

: Poly-tetra-fluoro-ethylene

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CTQ

: Construction Technical Queries

WI

: Welding Inspector

PWHT

: Post Weld Heat Treatment

Date

04.12.07

6. RESPONSIBILITIES 6.1.

ANA GER SITE M ANAGER

Site manager is responsible for the overall supervision of activities carried out during the project execution.

6.2.

CONSTRUCTION M ANA GER Construction Manager is responsible for all testing activities related to the piping and their integral components at field. He is also responsible for co-ordinating with Contractor’s sites supervisors as and when necessary.

6.3.

ANA GER QA/QC M ANAGER

QA/QC is responsible for all quality matters related to the testing of piping system including the administration of non-conformance management in close co-operation with various related departments. He is also responsible for the clearance of test packages for testing and submission of completed test documents to Contractor for Mechanical completion. His responsibility also includes providing the notification to Contractor 24 hours in advance to witness the pressure testing and to verify the calibration of equipment and instruments to be used during the testing activities.

6.4.

WELDING INSPECTORS Welding Inspectors are responsible for the welding and NDE clearance of piping System on a test pack basis in co-ordination with Contractor’s Welding Inspectors.

6.5.

QC INSPECTORS QCI is responsible to verify that piping and piping system components are properly Installed and pre-test punch list is signed-off by Contractor and Company for Pressure testing. He is also responsible to perform tests and inspection in accordance With drawings, procedures, and other applicable specifications as mentioned in the Approved ITPs.

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FIELD CHIEF ENGINEER Field Chief Engineer is responsible for the preparation of test packs in accordance with marked up Piping and Instrument diagram diagram ( P& ID) prepared by Contractor, Contractor, indicating the limits of each test packs. He is also responsible for obtaining the Contractor’s approval on prepared test packs and submission of approved test packs to the GAMA QA/QC along with approved pre-test punch list. He is also responsible for co-ordinating with Contractors engineering department for resolving technical queries if any related to the testing activities.

6.7.

HSE M ANA GER HSE Manager is responsible for all safety aspects arising during testing activities Including the preparation of permits if required, identification of exclusion zone, Communication facility at test location, First-aid facilities, Foreseeable hazards and Contingency actions, Means of escapes, etc.

6.8.

PIPING SUPERINTENDENT Piping Superintendent is responsible to verify that all piping and components are installed and the system is completed according with marked up Piping and Instrument Diagram (P& ID) and drawings included i ncluded in the respective test packs. He is responsible for the preparation of Punch list and submission of it to GAMA QA/QC for the verification of item completion.

6.9.

TESTING SUPERVISOR Testing supervisor is responsible to carry out the pressure testing in accordance with the approved test packs released for pressure testing. He is also responsible to verify the availability of materials required for pressure testing (test blind, bolts, gaskets, hoses, pumps, liquid soap, etc). His responsibility also includes to co-ordinate with Contractor test supervisor with respect to all test activities obtain his approval / agreement as and when required. No testing shall be carried out unless the NDE clearance has been obtained from the Contractor and Company.

7.

EXCLUSIONS The following parts are excluded from the requirements of this procedure, unless specified otherwise by Contractor:

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Any package equipment previously tested by Manufacturer in accordance with applicable Code and specifications, and certificates available.

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Piping open to the atmosphere, downstream of last block valve.

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Instrument air sub-headers, sub-headers, outside the scope scope of Mechanical Mechanical works and not shown shown on piping isometrics.

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Instrument impulse lines between between the block valve at at the process or utility line and and the connected instrument.

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Equipment.

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Instrument components. (Analyser, flow instruments, flow meters, meters, level level gauges, gauges, level instruments, pressure gauges, pressure instruments, pressure regulators, and pressure switches, relief valves etc shall be blind-off or be removed. Orifice plates shall be installed after pressure testing).

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The bench testing of pressure relief valves.

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Sewers (non pressure)

8. TEST PACK PREPARATION •

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GAMA shall prepare the test packs in accordance with marked up Piping and Instrument diagram (P&ID) prepared by Contractor, indicating the limits of each test packs. Each Test number shall be identified by Contractor in the marked up (P& ID)

A master (P&ID) showing the test limits and test pack number shall be maintained by GAMA. All lines included in the test shall be listed on the Piping field test report. The limits for each isometric shall be specified along with the painting and insulation requirements. Each test pack shall contain the copies of relevant (P& ID) marked-up to show the test pack number and limits of subject test pack. Latest available revision of each each isometric isometric describing describing the contents contents of the test shall shall be be included in the Test pack. As minimum, isometric shall be marked up to show the following: Highlight the test limits and line to be be tested.

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Size (thickness) and location of all tests blinds blinds (including those those required at at instrument connections). Filling point, Vent and drain points. Location and range of pressure pressure gauges to be used. used. Minimum 2 gauges required required at both End. Either one on the test manifold. Any control valves check check valves, safety valves or other piping piping accessories requiring removal, turning, or any other action shall be highlighted. Any special requirements when applicable. If required, location location of temporary supports supports shall also be indicated on on the test pack. A copy of the pipe support support index and detail drawing for special special supports supports such as as springs and cold supports. Flange Joint Tightening Record for any joint that requires hydraulic tensioning. If any completed test requires re-testing, the original test pack number shall be maintained and retest reference “Rx” (R1, R2,) shall be added. After preparation of the test pack but in advance of the test time, the original shall be submitted to Contractor Site Quality Assurance Manager for review and approval.GAMA field chief engineer shall maintain the approved original test pack returned by Contractor and copy shall be issued to Test supervisor for further processing. Relevant CTQs, and/or FIR s relating to site modifications, which are not reflected on the isometrics, shall be included in the test packs.

9. TEST PACK PROCESSING PROCESSING •

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Piping superintendent superintendent in co-ordination with with Test supervisor shall prepare the pre-test punch list for each test pack. Piping superintendent superintendent shall prepare the pre-test punch list to verify that piping and piping system component are installed to the extent necessary for pressure testing. Pre-test punch list shall not contain more than 20 items affecting the pressure test. The original punch list shall then be sent to GAMA field chief engineer through Test Supervisor Field Engineer Engineer shall submit the THREE copies copies of test test pack along with original pre-test Punch list to the Contractor’s Senior Site Engineer at least three (3) days prior to the scheduled test date. A combined consolidated consolidated pre-test punch list shall shall be prepared by the Contractor Contractor Piping Engineer in co-ordination with Company Piping Engineer containing all incomplete piping and welding items. A copy of the updated pre-test punch list shall be handed over to test supervisor for action to clear the incomplete Items or shall be approved for testing if no items are identified.

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When all punch items with an exemption to the post test items, mentioned in the consolidated pre-test punch list are complete GAMA, Contractor and Company shall sign and date the bottom of pre-test punch list in the space provided. GAMA field chief engineer engineer who collect the approved pre-test punch punch list from test supervisor and submitted to GAMA QA/QC along with original test pack for weld and NDE clearance.

10. QA/QC CLEA CLEARANCE RANCE •

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During the preparation preparation and finalisation of of pre-test punch list by Contractor and and Company, GAMA QA/QC shall proceed with the Welding and NDE clearance of the field weld (Field weld summary) included in the test packs in co-ordination with Contractor’s Welding Inspector. A visual check check shall be carried carried out by GAMA W I in the field to ensure that that all welding has been correctly carried out as mentioned in the isometric drawings attached to the test pack. If any addition or deletion of weld joint found the same shall be incorporated in the respective as-built drawing. Upon completion completion of the the field verification verification of test pack after pre-test punch list approval, all all NDE including the PWHT and hardness test as applicable for each joints shall be verified and documented in the weld summary report. GAMA QCI shall verify the material traceability report approved approved by Contractor during the installation of piping and integrated components for each isometric drawing and shall be compiled to the original test pack for Contractor Welding Inspector’s final verification during NDE review. Any type of welding modification and and repair that that is performed performed after test pack has been cleared by the welding and/or NDE inspectors shall be reported on a daily welding report by the foreman/supervisors who assigns the work. GAMA WI shall shall submit the inspection request request to the Contractor inspector for the verification and final approval on the rectification work. The prior release shall be declared null and void and the test pack shall be updated with current drawings and documents. All reinforcement pads for branch branch connections shall be tested in accordance with pneumatic Testing as stated below. After the completion of all inspection inspection and verification of documents, original original test pack shall shall be compiled with all all records. records. The The test pack shall then be signed by GAMA WI and will be offered to Contractor Welding Inspector for Welding and NDE clearance. If any outstanding item found during the inspection of Contractor welding inspector and/or Company the same shall be referred to GAMA for rectification otherwise test pack will signed off by Contractor and Company Welding Inspector to accord the Welding and NDE clearance.

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Contractor shall be notified 24 hours prior to the planned planned test time after the test pack pack is approved for testing.

11. HYDROSTATIC TESTING 11.1. TEST MEDIUM •

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Test medium shall be in accordance with piping isometric isometric drawing and/or and/or piping data data sheet issued by the Contractor. Change of test medium shall not be permitted unless prior approval is obtained from Contractor by CTQ. Hydrostatic Testing Testing shall utilise water supplied by Contractor as the test medium. medium. If there is a possibility of damage or if the operating fluid or piping material would be adversely affected by water, this shall be referred to Contractor by CTQ for disposition. Hydrostatic test pressure pressure shall not be applied until the pipe and its contents are at approximately the same same temperature. Hydro tests shall shall not be conducted conducted when the test liquid 0 and/or metal temperature is below 10 C.Water used for testing stainless steel shall contain less than 10ppm of chlorides with a pH value between 6 and 8. Suitable wetting wetting agent agent approved approved by Contractor shall shall be used to reduce surface tension. In the event that hydrostatic testing testing is required for systems that that operate below 00C, all flanged valves shall be removed prior to testing. Pipeline systems systems shall shall be filled from a low low point as identified in the test pack isometric drawing. drawing. During filling of the system, high points shall be vented to allow air/gas to escape.

11.2. TEST PRESSURE •

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The Hydrostatic test pressure for testing of Piping Systems Systems shall be as indicated in the Piping Data Sheets and/or the Isometric Drawings. If test pressures are not shown on these documents, GAMA shall request the test pressure from Contractor by CTQ. No equipment equipment shall be included included in the test, unless the prior approval approval of Contractor has been obtained. In such cases, the test pressure shall not exceed allowable equipment test pressure.

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11.3. PREPARATION FOR TESTING •

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All joints in the piping system shall shall be accessible accessible for visual inspection inspection during tests and shall not be insulated, backfilled, or otherwise covered except the painting of welds which is permissible. The GAMA shall remove any protective tape or other protection applied to field welds prior to pressure testing. All other tape or similar materials applied applied by the GAMA to other other components shall also be removed. The joints, which are previously pressure tested per ASME B31.3or equivalent, may be insulated or otherwise covered. All vents and other connections, which can serve as vents, shall be opened opened during filling so that all air is vented prior to applying test pressure to the system. All piping systems shall have hydrostatic testing vents at high points or other methods available in the Piping System to vent the system. Temporary spades spades and blinds installed for testing purposes purposes shall shall be in accordance with the as specified in the isometric drawing. Temporary piping, piping, jumpers, vent valves, drain valves, spacers, test spades spades and blinds shall shall be readily identifiable by painting a bright fluorescent colour. All temporary items shall be numbered on the test diagrams and the post test punch list shall be used to verify removal after test completion. Pressure tests tests shall not be conducted through control control valves. valves. All control valves valves and relief valves valves may be removed or blinded off during pressure testing. Piping shall be tested prior to installation installation of in-line items such as rupture discs, displacement and turbine meters, orifice plates, flow nozzles, level gauges, rota meter, strainers and similar. Instruments shall not be connected during piping pressure tests. If it is not practicable to perform testing prior to installation of in line items, it shall be the GAMA responsibility to remove or disconnect these items so that tests can be performed, and to re-install such items after testing. Sealing and plugging of systems after removal of inline items shall be performed by GAMA and shall reinstate system after testing. Check valves shall be removed removed unless otherwise agreed by Contractor. Expansion bellows and/or spring supports shall be restrained restrained or removed removed during testing. Each case shall be referred to Contractor for direction. Care shall be taken to avoid avoid overloading any part of the pipe support support system or support structures. Piping which is counterweight supported shall be temporarily blocked to sustain the weight of the test medium. Spring hangers which have been provided with stops for carrying the test load normally do not require additional temporary supports. If this is not the case, temporary support shall be provided before filling the system. Holding pins and spring stops shall not be removed from spring supports or hangers until testing is completed and permission to remove is obtained from Contractor.

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Piping designed designed for vapour or gas shall be provided with additional temporary supports to support the weight of the test liquid. The requirement of temporary supports shall be specified in the isometric drawing attached to the test pack. Large adjacent adjacent lines shall not be tested simultaneously if the weight weight of the combined tests may overload the structure or supports. Compressed Asbestos Fibre (CAF) gaskets gaskets shall not not be used during testing. Aluminium bolts shall not be used during testing. Where components of the test system system require aluminium bolting materials, these shall be replaced by temporary bolts during all pressure testing. Temporary bolting material material shall be identified with easily seen markings. Equipment shall be isolated from pressure test. Test blinds shall shall be installed installed at the flanges of equipment to provide positive isolation prior to filling the test circuit. All Necessary precautions precautions shall be taken to ensure that nitrogen purges in vessels or equipment is maintained and to prevent ingress of moisture. moisture. Purges shall not not be released without Contractor approval and shall be reinstated upon completion of required r equired work, unless otherwise directed by Contractor. RECORDERS 11.4. TEST PRESSURE G AUGES A ND RECORDERS

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Minimum two pressure gauges gauges having a full-scale range of 1.5 to 4 times of test test pressure and an accuracy and and sensitivity of 2 percent percent of full-scale reading shall shall be used. Test gauges shall have a minimum 100 mm face to a maximum of 150 mm. All pressure gauges and chart recorders shall shall be calibrated within 30/31 days days prior to testing. Current calibration certificates shall be available for the Contractor/Company inspection upon request. The calibration shall be carried out in accordance with procedure and T-4.250.915 (Equipment and instrument calibration).Relief value shall be calibrated within 7 days prior to testing, Gauge numbers shall be entered entered on on Piping Piping Field Field Test Test Reports. Reports. Gauges shall have a sticker sticker attached identifying the gauge number and and calibration date. Each item of test equipment shall be permanently marked by GAMA with a unique serial number.

11.5. TESTING WITNESS •

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24 hours prior notification to the Contractor/Company shall be given for witnessing the test by an entry in the Inspection Log Book indicating that a piping system pressure test is to be performed. Witnessing of Piping Field Tests shall be Contractor/Company “Hold point”. During the test, care must must be exercised exercised not to exceed test pressure specified on the isometric drawing and/or piping Data Sheets. Sheets. When conditions require that that a pressure test be maintained

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for a period of time during which the testing medium in the system would be subject to thermal expansion, provision shall be made made for relief of excess pressure. •

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Sealing materials shall not be used to correct correct leaks at at joints with the exception of threaded connections, where PTFE PTFE tape may be used. used. Valve glands shall shall not be tightened to the extent that the valve cannot be operated. If directed by Contractor valves shall be repacked. Unless otherwise otherwise specified, specified, test pressure shall be held for a minimum minimum period of 30 minutes or minutes or a duration, which will permit thorough inspection of the piping system. The same will be recorded. The pressure test shall be considered considered complete complete and accepted accepted when all defective welds, defective materials, flange leaks, valve gland leaks, or other such defects have been corrected and the piping has been retested, when required, to the satisfaction of Contractor. When required, retesting of lines after repair shall be done at original test pressure. All documentation and “test pack” information shall be complete and has been reviewed and signed by Contractor and the Company as required by this procedure and other project specifications. Test pressure pressure recorders for piping which require require that pressure pressure be held for a specified specified period of time shall include any corrections of test pressure due to temperature variations between the start and finish of the test. Records for piping in which a specified leakage leakage rate is permitted shall include the quantity of water added and the time at which the addition was made. All additional test records and authorised Contractor certifications shall be retained in the test Pack.

After the satisfactory satisfactory witnessing of the pressure pressure test GAMA, Contractor, and Company Company shall sign the “Original” Piping Field Test Report

12. SERVICE TESTING •

Hydro testing of piping may be replaced by service test upon approval approval by Contractor and Company. Such test packs shall be processed as normal for weld, NDE and pre-test punch list clearance. Upon completion of all items / clearance piping field test report shall be signed and original shall be over stamped.

13. PNEUMATIC TESTING 13.1. GENERAL •

This section section describes describes minimum required preparation preparation of the piping system prior to pneumatic pneumatic testing. GAMA shall be responsible for the safe conduct of all aspects of pneumatic testing.

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Prior to the Pneumatic testing, the test pack shall be prepared, compiled, compiled, approved and released for testing as specified in the section 8, 9 and 10 of 10 of this procedure. All gaskets used used in the test system shall shall be in accordance accordance with the relevant Piping Piping Material Class. If any flange joints that have been fully tightened and then opened the gaskets shall be replaced and new gaskets shall be provided. All flanged joints included included in the test shall be securely taped taped with masking tape prior to test with a pinhole on the top section of the flange tape tape for leak identification. All tape shall shall be completely removed after completion of the test. All anchors, guides, supports supports and hangers shall shall be checked for correct installation prior to test. In the event it is necessary to utilise temporary supports, these shall be reviewed by Contractor to ensure that the functionality functionality of the support system system is respected during during testing. Temporary supports if provided shall be identified by painting yellow colour. Blinds and spades at at valves and and test system system extremities shall be checked for correct location location and thickness. Temporary test blinds blinds shall have their handles handles painted a bright bright yellow colour for easy visible identification. Thickness of temporary spades and blinds installed for testing purposes shall be in accordance with the specified in the isometric drawing. All valves valves in the test system shall be in the fully open position. Non-return valves shall be checked to ensure that they allow free pressurising and depressurising of the system by either blocking open, removal (and replacement) of valve internals or removal of the valve from the test system. All components components blocked or removed will will be listed on on a ISO to ISO to be included within each test pack. Aluminium bolts shall not be used during testing. Where components of the test system system require aluminium-bolting materials, these shall be replaced by temporary bolts during all pressure testing. Temporary bolting material material shall be identified with easily seen markings. For test systems containing containing bellows, GAMA GAMA shall obtain Contractor Contractor approval of bellows installation and intended test procedure prior to commencing test. GAMA shall verify flow direction of bellows prior to testing. Extreme care shall be taken during during handling and erection of expansion bellows. Shipping rods shall only be removed with Contractor approval. All instruments and/or tubing shall be disconnected from the piping piping system at the Block Block Valves and capped or blinded, prior to testing with the valves in the open position.

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Pressure Gauge

Vent

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PAD AIR SOURCE

13.2.

PREPARATION OF TEST EQUIPMENT The test equipment shall comprise as a minimum the following:

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Primary Compressor Booster Compressor Skid Comprising: Booster Compressor, Strainer, Pre-Filter, After Filter, Dryers, Check Valve, Flow Control Valve, Main Relief Valve/Vent Pipe, Manifold with 2 x 1" and 1 x 3/4" connections and 1 x 2" connection for temporary fill pipe to test manifold. Pressure Gauge Test Manifold Comprising: Solid welded pipe and fitting test manifold on a Portable Test Bench 2-Pressure Gauges, 1-Pressure Recorder, 1-Block valve, 1-Regulating Valve (Globe), Gauge/Recorder isolation valves, Provision for fitting of relief valves, Vent pipes to suit relief valve, All necessary connecting spool pieces to suit various Relief Valves to be used on test manifold, 2" Relieving vent with valve, All necessary supporting frames, for manifold and vent pipes. Temporary Fill Pipeline from test manifold to test line i nlet, Fill Manifold (where required) for parallel test systems Comprising: Valves in Bypass Configuration (with lock), 2" Relieving Vent in each Fill System (with lock) All necessary temporary connecting connecting spool pieces to suit each fill configuration. Relief Valves The test equipment for small Volume Test Test shall shall comprise as a minimum the following Bottled Nitrogen with standard bottle valve regulator and pressure indicator 2 Pressure Gauges Provision for Relief Valve Relieving Vent and Valve Isolation Valves Portable test Bench and Test Manifold as per large volume test rig Pressure Hose, (Contractor approved) All necessary connecting connecting spools and fittings Lighting •

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All piping material considered “Temporary” for testing of Piping Systems shall be of the same specified material rating as the process system flange rating being tested.

Pressure Gauges shall have a range from zero to between 1.5 and 4 times the Test Pressure (minimum nominal size 100mm). The two gauges shall be similar similar and shall be independently calibrated in accordance with the procedure T-4.250.915 (Equipment and instrument calibration). Calibration tags/stickers shall be affixed to the gauges and relevant certification shall be available for review prior to testing. Both gauges shall shall be visible to the operator controlling the pressure. Gauges shall be re-calibrated on a weekly basis by Subcontractor and witnessed by Contractor. Pressure Recorders shall be able to record full pressure gauge range and to operate continually without maintenance, ink filling, and paper changing or drive manipulation for 24 hours minimum. Pressure Recorders/Gauges and Temperature Gauges shall be located so as to be free from vibration. For testing by compressor, the manifold is to be located for safety reasons immediately adjacent to the Booster Compressor Skid. Relief Valves are to be set at 1.0 barg above the Test pressure designated for the system under test. Calibration shall be within 7 days. The relief valve shall be provided with adequate support for maximum relief pressure and maximum flow. Vent/blow down valves shall be likewise supported and vented above head height. The Regulator (Globe) Valve shall be able to control the flow into Test System within the required pressurisation rates. All piping on pressure gauge MANIFOLD shall be in accordance with Piping Classes Specification DEP 31.38.01.12. All welds shall, where possible, be examined 100 percent by radiography and magnetic particle examination. Pressure Gauge Manifolds shall be hydrostatically tested after assembly to a test pressure of 1.20 times 1.20 times (max pressure barg) and then dried with Instrument Air or Nitrogen prior to use. Prior to commencement of any test the GAMA shall confirm that relief valves are correctly set and operating properly and that pressure gauges, pressure recorders and temperature gauges have been correctly set, calibrated and are operating properly. The records shall be made available to contractor for verification.

13.3. FILLING SYSTEM •

The test fill line shall run from the pressure gauge manifold to the fill manifold and and may be constructed from pipe or from suitable high pressure reinforced hose approved by Contractor.

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Only new hose shall be used. The test fill line shall be pressure tested after installation. Testing may be either either hydrostatic or pneumatic. pneumatic. Test pressure shall shall be 1.1 times of testing pressure of the system to be tested. Where fill manifolds are utilised, they shall be pressure tested after manufacture as specified above. Bypass valves are to be provided provided to isolate parallel systems systems and to allow bleeding bleeding from one parallel system to another. The valving shall allow parallel lines to be tested (separately) without re-configuring re-configuring any test piping/equipment. piping/equipment. Vents are to be provided to prevent uncontrolled filling of a system system not under test. test. For each proposed proposed parallel Test Test System, the GAMA shall submit details of Valve and Vent arrangements for Contractor review. All valves shall have facilities to allow locking in both open and closed positions.

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For systems systems which which are are to be compressor compressor tested, prior prior to connecting filling system system to test system, the filling system is to be blown at the maximum rate of the compressor for a minimum of 30 seconds seconds to clear clear any debris in line. The post dryer/filter is to be inspected before and after each test to check that no drying medium has been transported into the Manifold or filling System. Prior to testing of each test system a leak test of the completed filling system shall be performed with nitrogen or dry air at a pressure of 1.7 Barg.

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Where Contractor Contractor agrees, agrees, bottled bottled Nitrogen of welding grade purity may may be used in place place of of compressor equipment equipment for small volume test systems. systems. All precautions and recommendations of the supplier of the bottled gases shall be adhered to. The testing procedure to be used shall be as described for compressor tests; however, pressure recorders and temperature indicators are not mandatory. Blowing of the filling system shall shall be carried out by nitrogen nitrogen blowing at an agreed pressure prior to leak testing.

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13.4. INITIAL PRESSURIZATION AND L EAK TEST •

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Prior to the initial commencement commencement of pressurisation pressurisation pre-test checklist shall be signed off by by the contractor testing supervisor and Gama testing supervisor. After pre-test pre-test check check list signing signing pressurisation shall be commenced and proceeded according to the following sequence: Pressure in system shall be increased gradually to an initial pressure of 10% and held for a minimum of 10 minutes. After agreement with Contractor Testing Supervisor leak test shall be performed as follows: Apply Contractor Contractor approved chloride free leak detection fluid (“SNOOP” or equivalent) equivalent) and using a chemist wash bottle or other suitable means apply to all circumferential welds (not already tested) valve packing and pinholes in tape at pre-taped flanges. Advise Contractor Testing Supervisor of any observed leaks If tightening is required to stop leaks, partially partially depressurise depressurise the system, isolate the immediate work area from persons not necessary for the tightening operation. No one is permitted to stand in front of the gasket plane projection while tightening If tightening does does not stop stop leaks, depressurise system, replace gasket, properly properly tighten up up flanges and retest.

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13.5. INCREMENTAL PRESSURE INCREASE 

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Prior to continuance of test ALL personnel shall be cleared from exclusion zones and ensure ALL essential personnel at compressor/gauge compressor/gauge station are protected by the provided barriers. A register shall be made available for signing in and off area for checking leaks and when compressor is in use. After agreement with Contractor Testing Supervisor pressure in system shall be increased gradually in steps equal to or less than those shown in Table below until the Test Pressure is attained

Note: The minimum time taken to pressurise the system between increment hold points shall be 5 minutes for systems with the Test Pressure less than 30.0 Barg and 10 minutes for systems with Test Pressure greater than 30.0 Barg. Low Pressure [PT < 5.00 Barg] STEP PRESSURE 1 1.5 Barg 2 90% of PT 3 100% of PT 4 PD

High Pressure [PT > 5.00 Barg] STEP PRESSURE 1 10% of PT 2 25% of PT 3 50% of PT 4 75% of PT 5 90% of PT 6 100% of PT 7 PD PT = Test Pressure PD = Design Pressure Note: Number of steps steps may be reduced for small small volume systems, systems, subject subject to Contractor agreement. 

The pressure and temperatures shall be recorded during the complete testing period for evaluation of line tightness.

13.6. EQUALIZATION AND INSPECTION 

At each pressure increment maintain the specific pressure for a minimum of 10 minutes to allow equalisation of piping strains and air pressure and to allow confirmation that specific pressure is being maintained. maintained. After this equalisation period, check check expansion expansion bellow alignment, anchor behaviour and seals, seats and gasket joints as required and tighten on adjust as necessary. necessary. If any abnormalities exist to the above listed items then depressurisation depressurisation of the system shall take place until conditions are repaired. Contractor Testing Supervisor agreement shall be obtained prior to pressurisation to the next pressure increment.

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13.7. HOLD PERIOD 

When the Test Pressure has been attained it shall be held for ten (10) minutes to allow confirmation that the specific pressure is being maintained.

13.8. L EAK TESTING 

After obtaining Company’s / Contractor approval, accepting Test Pressure maintenance, pressure shall be reduced reduced gradually to the Design pressure. pressure. The time taken to depressurise depressurise to Design pressure shall not be less than 5 minutes for systems with Test Pressure less than 30.00 barg and not not less than 10 minutes for systems greater than 30.00 Barg. On reaching Design Pressure, a leak test shall be performed as follows: a)

Apply Contractor approved chloride free leak detection fluid (“SNOOP” or equivalent) and using a chemist wash bottle or other suitable means apply to all areas of interest. b) Advise Testing Supervisor of any observed leaks c) If tightening is required to stop leaks, partially depressurise the system, isolate the immediate work area from persons not necessary for the tightening operation. The Leak Test Shall be conducted by as per LINDE STD LS 133-02

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Gasket/Sealed joints at flanges, blinds, valve bonnets, etc., found to be leaking during the test shall be tightened by normal approved means at a time nominated by the GAMA Testing Supervisor (after agreement by Contractor Testing Supervisor). Supervisor). If normal approved tightening methods fail to stop any such leaks; the Company/Contractor shall be consulted for decision as to the course of action. Valve packing leaks shall be referred to Contractor Testing Supervisor who may require the test to be aborted and the valve packing replaced. If a leak is found in a welded joint or in the parent pipe the test shall be deemed to have “failed”. The system shall be depressurised and the defect repaired. repaired. The repaired repaired weld shall be subjected subjected to the required visual inspection inspection and non-destructive examinations. The repaired weld shall then be tested at the specified test test pressure. Contractor Testing Testing Supervisor may also consider a test to have failed if excessive flange leaks are detected. The test shall be deemed to be “Acceptable” provided the following conditions are met:

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The Test Pressure is maintained for a minimum of 10 minutes minutes (refer section section 13.7 13.7 of this procedure).

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No leaks are detected during leak test

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GAMA, Contractor, and Company signatures signatures are obtained obtained signifying acceptance of the pressure test.

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13.10. COMPLETION 

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After obtaining Contractor/Company’s signatures signatures accepting the pressure test, the system shall be slowly depressurised. depressurised. The system shall be sealed as far far as practical to prevent ingress of moisture. Install relief valve to protect the system, especially bellows against pressure higher than 110 percent design pressure during the above test.

14. SAFETY 

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The Gama Testing Supervisor and HSEM shall co-ordinate with the Contractor Test Supervisor with respect to all test activities, and obtain his approval/agreement when required. The HSEM or his designee shall at all times ensure that only essential personnel are allowed into the designated Exclusion Zone specified in this procedure. Personnel to be inducted shall be identified prior to each test and their specific responsibility to areas shall be assigned. These areas to be walked prior prior to test commencing commencing to familiarise personnel. Personnel to have helmet identification issued at test induction to ensure only essential personnel are within test areas. Contractor Testing Supervisor Supervisor shall ensure that the the Company’s and all Subcontractors whose operations border the Test Systems barriers are fully aware of safety requirements. The HSEM shall assign one person full time to each road barrier. The person assigned shall be in radio contact with HSEM and Gama Testing Supervisor The HSEM shall ensure that adequate radios are available so that he can immediately be made aware of any dangerous situation at the compressor station or along the test pipe system. The Gama Testing Supervisor Supervisor and HSEM shall shall be in radio contact contact with the Contractor Testing Supervisor at all times during testing. Leak detection shall not be carried out during periods of rain. The exclusion zone shall be positively identified by placing of clear warning sign at all vehicular and pedestrian accesses. accesses. Provision for lighting shall be made to ensure the exclusion zone is positively identified during the hours of darkness, if required. It shall be ensured that non-essential personnel are clear of exclusion zones.

Minimum exclusion zone diameter (for Pneumatic testing only), placing the pressure containing components at the center point, shall be as follows:

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TEST PRESSURE (Barg) EXCLUSION ZONE (m) FROM TO 1.51 5.00 15 Note 2 5.01 10.00 30 Note 2 10.01 14.00 40 Note 2 14.01 18.00 50 18.01 22.00 60 22.01 26.00 70 26.01 30.00 80 30.01 36.00 90 36.01 40.00 100 40.01 46.00 110 46.01 52.00 120 52.01 58.00 130 58.01 64.00 140 64.01 69.00 150 69.01 75.00 160 75.01 80.00 170 80.1 & over NOT RECOMMENDED Note 1: Note 2:

No exclusion zone required for test pressures up to 1.5 barg. For small volume systems, subject to ‘Contractor agreement, the requirement for An exclusion zone may be waived. waived.

The exclusion zone distances specified above may be reduced provided effective shielding is applied and Contractor approves Gama proposal. During pressurisation/depres pressurisation/depressurisation surisation Gama Testing Supervisor shall remain at the compressor station. ALL personnel, with the exception of Contractor Testing Supervisor, Gama Testing Supervisor and compressor operator, shall remain outside the exclusion zone distances given above. above. Exceptions to this are as follows: •

a) b) •

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At the 1.5 barg initial leak detection test At the Design Pressure main leak detection test

Only ESSENTIAL ESSENTIAL personnel personnel as directed by the Gama Supervisor will be allowed to enter the exclusion zone for a), b) above to perform leak tests, inspect the pipe system and/or tighten leaking joints and only after the required hold times have elapsed. The Gama Testing Supervisor shall obtain Contractor Testing Testing Supervisor approval prior to authorising ANY personnel personnel to enter the exclusion zone. zone. A register of all persons entering the exclusion zone shall be maintained at field office outside of test area by a designated person of HSEM. All persons shall shall sign off such register register after having completed their activities in the exclusion zone to ensure that all persons have left the zone prior to proceeding with the next test stage.

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The compressors compressors and pressure gauge gauge manifold shall shall be located located not less than 30 meters from the test system pipeline. They shall be located in a safe place place so that they and the operators and test supervisors are at all times protected either by natural obstacles or temporary barricades e.g. concrete blocks etc. If a leak is detected at any any stage during the test the Gama Testing Supervisor Supervisor shall consult with the Contractor Testing Supervisor regarding the need/requirement to depressurise partially or fully prior to further examination, tightening or repair. Where Fill Manifolds Manifolds are utilised the operation of the valves situated at the Fill Manifold shall shall be controlled by a locking system, in order to protect the Test system from being isolated from the safety relief valve valve and/or from uncontrolled filling. The Testing Supervisor is to be solely responsible for the operation of these valves and the keys of this locking system to prevent uncontrolled operation.

The HSEM HSEM shall arrange Necessary fire extinguishers extinguishers at at Pneumatic Pneumatic Test Compressor Fuel tank locations as a precaution of fire safety. When necessary, lighting shall be provided for inspection during testing a) Area Lighting - flood lights b) Weld Inspection - hand-held torches. Lighting may also be provided at the Compressor Station/Pressure Gauge manifold area if required.

15. POST TEST ACTIVITIES •

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After testing of of the piping piping is witnessed witnessed and and report is signed-off, signed-off, all lines and equipment equipment shall be completely drained of the test fluid. Piping systems vents shall be opened while draining to avoid vacuum. vacuum. Special attention shall be given to points where water may be trapped, such as in valve bodies or low points piping. All temporary test blinds shall be removed unless unless otherwise directed by Contractor and and all operation blinds returned to proper position unless otherwise required for commissioning activities and identified to be left in place on the Post Test Punch List. Valves, expansion joints and short pieces of piping, which have been removed, shall be reinstalled with specified gaskets. Wherever applicable protective tape shall be reapplied to field welded stainless steel joints only. Lines down stream of check valves valves shall shall be inspected inspected to insure complete complete drainage. drainage. Check valve internals removed for testing shall be reinstalled unless required to be left out to facilitate commissioning. Test Blinds shall be removed at pumps and dust blinds shall be reinstalled unless stated otherwise on the Post Test Punch List.

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After lines have been been depressurised depressurised and and drained, temporary pipe pipe supports shall be removed. Spring hangers provided with stops to carry the test load should have these stops removed when so directed by Contractor on the Post Test Punch List. Lines shall be closed to prevent prevent entry of foreign materials. Flanged joints at which which test blinds have been removed do not require retesting. Special length bolting used to accommodate test blind thickness and compressed asbestos fibre gaskets shall be removed and replaced with line class bolts and gaskets. Instruments, which were removed or isolated, for test shall be reinstalled and isolations isolations removed. Lines operating at temperatures below 00C, which have been hydrostatically tested shall be completely dried and purged when required by Contractor Commissioning. After the pipe systems systems reinstatement, reinstatement, Gama shall submit a copy of the signed and and completed completed Punch List for verification. verification. Contractor/Company shall confirm completion completion and initial all completed items and returns the copy of the verified punch list to Gama.

16. ENGINEERING MODIFICATIONS •

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All piping modifications that involve welding to piping that has been been pressure tested shall be documented that part of the system including the modification shall be retested. Engineering modifications are identified as changes in type or location of piping components, material type, pipe sizes and schedules; location of inline instruments and orifice runs; size, type or location of engineered supports, or relocation of standard support by more than 200 mm, expansion loops, safety and relief valves, spectacle/maintenance spectacle/maintenance blinds, etc. Contractor shall approve any change to drawings Issued for Construction. The approval shall be in the form of a Construction / Commissioning Technical Query (CTQ), Nonconformance Report, and field revision to the drawing or a Contractor issued/approved field sketch. A copy of the modification modification approval approval document shall be included in the test pack prepared prepared for the re-test. A copy of the CTQ, NCR, field revised isometric or field sketch and quality control documentation/acceptance shall be attached prior to commencement of test. The test packs shall be reviewed and approved by the Contractor before pressure testing.

17. FINAL INSPECTION INSPECTION AND SYSTEM SYSTEM TEST STATUS STATUS •

When Gama has completed completed all testing of a full piping system, system, Contractor shall inspect the completed piping system and shall notify the Gama of any deficiencies or outstanding work, which must be completed prior to acceptance acceptance of the system. If there are no deficiencies, or if all deficiencies have been corrected, the piping system shall be accepted by Contractor.

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The Gama shall shall maintain a master copy copy of all P&ID, P&ID, which have have been colour colour coded to indicate piping systems, and isometrics, which have been accepted by Contractor.

18. REPORTS AND RECORDS •

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As a minimum, minimum, Gama shall shall maintain records records of all pressure tests, tests, Welding and NDE details of all joints records of all welding operations including welder stamp numbers, weld joint numbers, records of post weld heat treatment and hardness tests, pressure gauge calibration sheets, and all required certification records. Material traceability, NDT and Alloy Verification shall be recorded in accordance with the respective quality assurance procedures approved by Contractor After satisfactory completion of of pressure test, Gama shall transmit the signed signed off original Test Test Pack (GAM-QCR-QAC-GTL-065 and P&ID only), plus one (1) copy to the Contractor Quality Assurance Manager. All other records records included in the original original test packs packs shall be be maintained, stored and finally handed over to Contractor in accordance with Quality Records.

19. ATTACHMENTS GAM-QCR-QAC-GTL-064

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GAM-QCR-QAC-GTL-065

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GAM-QCR-QAC-GTL-066

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GAM-QCR-QAC-GTL-067

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GAM-QCR-QAC-GTL-068

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MINIMUM TEST BLIND THICKNESS CHART

C2 ASU PEARL GTL PROJECT RAS LA FFAN INDUSTRIAL INDUSTRIAL CITY PRE-TEST CHECKLIST FOR PNEUMATIC TESTING

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CHECK L IST

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MAIN LINE 1

RECEI RECEIPT PT OF OF APPRO APPROVA VAL L TO TES TEST T

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BLIND BLIND FLAN FLANGE GE LOCATIO LOCATION/TH N/THICK ICKNESS NESS

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VALVE OP OPEN

4

FLAN FLANGE GES S TIG TIGHT HT

5

BONN BONNET ETS S TIG TIGHT HT

6

PACK PACKIN ING G TIG TIGHT HT

7

BELLOWS BELLOWS TIE RODS RODS IN TEST POSITIO POSITION N

8

FLANG FLANGES ES TAP TAPED ED AND AND PIN PINHO HOLED LED

9

LEAK LEAK TEST TEST FLUI FLUID D AVAI AVAILAB LABLE LE

10 TOOLS TOOLS AVAILA AVAILABLE BLE

FILL MANIFOLD 1

FLAN FLANGE GES S TIG TIGHT HT

2

SYST SYSTEM EM BLOW BLOWN N CLE CLEAN AN

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LEAK LEAK TES TEST T COMP COMPLE LETE TED D

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FILL MANIFO MANIFOLD LD VALVE VALVE CONFIG CONFIGURAT URATION ION

5

VENT VENTS S OPEN OPEN/S /SHU HUT T

6

FILL FILL MANI MANIFO FOLD LD VALV VALVE E LOCK LOCKED ED

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LOCK LOCK KEYS KEYS WITH WITH S/C TESTING TESTING SUPDT. SUPDT.

PRESSURE PRESSURE GAUGE MANIFOLD 1

CONN CONNEC ECTI TION ONS S TIGH TIGHT T

2

PRES PRESSU SURE RE TEST TESTED ED

3

RELIE RELIEF F VALVE VALVE CALIBR CALIBRAT ATED ED

4

GAUGES/ GAUGES/REC RECORD ORDER ER CALIBRA CALIBRATED TED

COMPRESSORS 1

RELIE RELIEF F VALVE VALVE CALIBR CALIBRAT ATED ED

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POST POST DRYER DRYER STRAINE STRAINER/FI R/FILTER LTER CLEAN CLEAN

3

ADEQ ADEQUA UATE TE FUEL FUEL

GENERAL SAFETY 1

RADI RADIOS OS AVAI AVAILA LABL BLE E

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EXCLU EXCLUSIO SION N ZONE ZONE IDENT IDENTIFI IFIED ED

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PERS PERSON ONNE NEL L EXCLU EXCLUDE DED D

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COMPRE COMPRESSO SSOR/PG R/PG MANIFOL MANIFOLD D BARRIC BARRICADED ADED

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SAFET SAFETY/ Y/ FIRS FIRST T AID AID NOTIF NOTIFIED IED

GAM-QCR-QAC-GTL-064

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Company

Project No:

Project Title:

Location

Piping Test No:

PIPING FIELD Priority System No:

TEST REPORT S/C Prepared By:

Test Media:

Name:

Signature

Description Of Test

Date:

LINDE Acceptance By: Name:

Reference Flow Sheets (List All applicable): Signature

Line Number

Line Size

Date: Drawing or Isometric Number

Rev (At Time of Test)

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To

Paint Code

Insul. Code

Equipment Tested Trough:

WELDING INSPECTION RELEASE, READY FOR TEST (All Welding and NDT is complete and per specification and piping is ready for test) GAMA WELDING Inspector: Name

Signature:

Date:

GAM-QCR-QAC-GTL-065

GAMA Inspector: Name

Signature:

LINDE Field Signature:

Date::

QSGTL or its PMC Inspector: Name

supports, valves and components components in place except for items nece Test Witnessed By

LINDE Welding Inspector: Name

Lines/ piping as tabulated above have been tested and found to

Engineer: Name

Signature:

QSGTL or its PMC Signature:

Date::

Inspector: Name

Signature

Piping Test No:

PIPING PIPING FIELD FIELD TEST TEST REPORT REPORT Descrip Descr ipti ti on of Test Test Line Number

GAM-QCR-QAC-GTL-065

Line Size

Drawing or Isometric Number

(Continuation Sheet)

Rev (At Time of Test)

Fr o m

To

Paint Code

Insul. Code

C2 ASU PEARL GTL PROJECT RAS LAFFAN INDUSTRIAL CITY

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PIPING PRE TEST PUNCH LIST

Sub contractor Ref:

Report No:

Item Description:

Inspection Date:

Item Location / Area: Sub System: Ref Dwg/Documents: Used Measuring and test equipment ref. (if applicable):

DESCRIPTION OF WORK ITEM NO

ISO or DWG NUMBER

COMPLETED(Date/Initials) COMPLETED(Date/Ini tials)

TO BE DONE BEFORE PRESSURE TEST

GAMA

LINDE

REMARKS: ALL ITEMS SHOWN ABOVE HAVE BEEN VERIFIED AND TEST PACK IS READY FOR TEST TEST

ORGANIZATIONS B D E T B E C C A

GAMA REP LINDE REP QSGTL or its PMC

GAM-QCR-QAC-GTL-066

DATE

NAME

SIGNATURE

QSGTL or its PMC

C2 ASU PEARL GTL PROJECT RAS LAFFAN INDUSTRIAL CITY

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PIPING POST TEST PUNCH LIST

Sub contractor Ref:

Report No:

Item Description:

Inspection Date:

Item Location / Area: Sub System: Ref Dwg/Documents: Used Measuring and test equipment ref. ( if applicable):

DESCRIPTION OF WORK ITEM NO

ISO or DWG NUMBER

TO BE DONE BEFORE PRESSURE TEST

PRIORITY/ CATEGORY (A,B,C,D,E) (X,Y,Z)

COMPLETED(Date/Initials) GAMA

LINDE

ALL PRIORITY A ITEMS SHOWN ABOVE HAVE BEEN VERIFIED AND ARE COMPLETED .INCOMPLETE PRIORITY B ITEMS WILL BE TRANSFERRED TO THE MECHANICAL COMPLETION PUNCH LIST PRIORITY A : ITEMS SHALL BE C OMPLETED BEFORE MECHANICAL COMPLETION (MC) PRIORITY B : ITEMS MAY BE COMPLETED AFTER MC PRIORITY C : ITEMS WILL BE COMPLETED BEFORE SYSTEM RFSU (READY FOR START UP UNIT) IS ACHIEVED PRIORITY D : ITEMS SHALL BE COMPLETED BEFORE RFSU IS ACHIEVED PRIORITY E : ITEMS SHALL BE C OMPLETED BEFORE ACCEPTENCE IS ACHIEVED CATEGORY X: CONSTRUCTION GROUP IS RESPONSIBLE FOR COMPLETION OF ITEM. CATEGORY Y: ENGINEERING INPUT IS REQUIRED FOR COMPLETION OF ITEM. CATEGORY Z: COMMISSIONING GROUP IS RESPONSIBLE FOR COMPLETION OF ITEM.

ORGANIZATIONS B D E T B E C C A

GAMA REP LINDE REP QSGTL or its PMC GAM-QCR-QAC-GTL-067

DATE

NAME

SIGNATURE

QSGTL or its PMC

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A A R

C2 ASU PEARL GTL PROJECT RAS LAFFAN INDUSTRIAL CITY LIST OF BLINDS PER TEST SYSTEM GA MA QA TA R

POSI POSITI TIO ON

LINE NO BLIND BLINDE E NO LIN

GAM-QCR-QAC-GTL-068

PID PID SHEE SHEET T

INSTA NSTALLE LLED D BY DAT DATE

DISM DISMAN ANTL TLED ED BY DATE DATE

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REINFORCEMENT REINFORCEMENT PAD PA D TEST REPORT PROJECT : C2 ASU PEARL GTL PROJECT-RAS LAFFA N INDUSTRIAL INDUSTRIAL CITY

Description Test No

ISO No

ORGANIZATIONS GAMA REP LINDE REP QSGTL or its PMC

GAM-QCR-QAC-GTL-109

Spool No

DATE

Acceptance Signature Pad Ref

Date of Test

NAME

Gama

Linde

QSGTL (OR) PMC

REMARKS

SIGNATURE

MINIMUM TEST BLIND THICKNESS CHART

TEST PRESSURE bar

10

20

30

40

50

60

70

80

90

100

4 (100)

4.4

6.2

7.6

8.8

9.8

11

12

13

14

14

5 (125)

5.5

7.7

9.4

11

13

14

15

16

17

18

6 (150)

6.5

9.2

12

13

15

16

18

1`9

20

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8 (200)

8.6

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15

18

20

21

23

25

26

28

10 (250)

11

16

19

22

24

27

29

31

32

34

12 (300)

13

19

23

26

29

32

34

37

39

41

14 (350)

15

21

25

29

32

35

38

41

43

46

16 (400)

17

24

29

33

37

40

44

47

49

52

18 (450)

19

26

32

37

41

45

49

52

55

58

20 (500)

21

29

36

41

46

51

55

58

62

65

24 (600)

25

35

43

50

55

61

66

70

74

78

PIPE SIZE inches (DN)

NOTES:

1

All All test test spade spades s to to hav have e bri brigh ghtl tly y col colour oured ed handl handles. es.

2

Test Test spad spades es to be manu manufa fact ctur ured ed usin using g AST ASTM M A 36

3

For pipe pipe size sizes s great greater er than than 24", 24", the minimu minimum m thic thicknes kness s of of blin blind d plat plates es will be determined on a case by case basis.

031-Procedure for Hydro and Pneumatic Testing.pdf

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