ALGIERS REFINERY REHABILITATION AND ADAPTATION PROJECT PNEUMATIC TEST PROCEDURE OF ABOVEGROUND PIPING JCC-PRD-PIP-0009-0 Serial Numer Res Page Project N°- Unit Doe Type Discipline 9952C 000 PRD PIP 0009 0 10 Pneumatic test Procedure of Aboveground Piping Pages modified under this revision: First Issue 1 B = 0 | 10092017 | FR ISSUE FOR REVIEW ‘| Ais Lin Shengtong Dong Lizni WreTTEN cneoxen eaamen! aPeROvED svsce. aya a once wer ‘DOCUMENT REVISIONS ‘Sectors changed in ee revision ara seni bya vera ine nthe marginWaYNe es |. REFERENCE DOCUMENTS. . RESPOMSIBILITIES. |. PROCEDURE. . PRESSURE GAUGES. 3. ATTACHMENT. ALGIRS REFINERY REHABILITATION AND ADAPTATION PROJECT PNEUMATIC TEST PROCEDURE OF ABOVEGROUND PIPING. JCC-PRD-PIP-0009-0 Discipline Serial Number Rev. PIP. 0009 0 CONTENTS Project N° - Unit 9952C 000 5.1 Area construction manager. 5.2 Piping Const. engineers. 5.3 QC engineers / inspectors. 6.1 General. 6.2 Test Documents. 6.3 Test pressure. 6.4 Cleaning /Flushing. 6.5 Exclusion Zone. 6.6 Pre-Test procedu 6.7 Pressure relief device 6.8 Test fui 6.9 Test procedure... 6.10Works not excluded. 6.11 Test acceptance... 8.1 Annex I- Minimum thickness of testing blinds 8.2 Annex II — Line list ARH Pneumatic testral ¢ ALGIERS REFINERY —~ = REHABILITATION AND ADAPTATION PROJECT dee PNEUMATIC TEST PROCEDURE OF ABOVEGROUND PIPING JCC-PRD-PIP-0009-0 Projst N® = Unit Doe Disepine SerialNumber Rev " 0009 310 41. PURPOSE ‘The purpose of this procedure is to provide the minimum conditions for carrying out pneumatic testing for all pressurized piping system at the Algiers Refinery Rehabilitation & Adaptation project. It also defines safety measures to be undertaken during the execution of pneumatic testing of piping. These measures must comply with the requirements of the specifications, applicable standards and requirements. 2. SCOPE This procedure is applied to all Aboveground pressurized pif of the ALGIERS REFINERY REHABILITATION & ADAPTATION project. 3. DEFINITIONS ing systems for the construction Project: ALGIERS REFINERY REHABILITATION AND ADAPTATION PROJECT. Company: SONATRACH + Contractor: TECHNIP FRANCE + Subcontractor: China Petroleum Jilin Chemical Engineering & Construction Co.Ltd (CICC) ARH: Hydrocarbons-Regulatory-Authority 4, REFERENCE DOCUMENTS ASME B31.3. Process piping PD's and ISO drawing of aboveground lines Line List 9952T-000-J$S-1470-0001 Job specification for supply aboveground systems. '9952T-000-QCP-1320-0001 QCP Metallic Piping Erection(Above & Aboveground) 99521-000-QCP-1399.0001 QCP Piping Welding Activities Management (NDE/PWHT/PAMI) 99521-000-JSM-6300-0001 Shop and Fabrication, Welding and NDE of Piping Systems. 99521-000- JSD-1300-012 Job Specification For Design Piping System Pressure Testing 9952T-000- PP-0868 Safety Requirements for Pressure test during Construction phase + 9952T-000- PP-0870 Test Pack Management Procedure 5. Responsibilities 5.1 Area construction managerALGIERS REFINERY EP REHABILITATION AND ADAPTATION PROJECT Brame PNEUMATIC TEST if PROCEDURE OF ABOVEGROUND PIPING JCC-PRD-PIP-0009-0 Project N°- Unit Doe ype Dissptne Seri Nombor Rev Page 9952C 000 PRD PIP 0009 0 4/10 Responsible for conducting of pneumatic test, and the PTW work permit system in accordance with schedule, procedure, specifications, priorities and construction drawing. He is also responsible for all manpower/personnel to be qualified and assigned correctly & fully aware of HSE compliances. 5.2 Piping Const. engineers + Report to the area construction manager. The safe operations and quality of work. Ensure the procedure and specifications adhered to. Monitor productivity and efficiency while maintaining harmony among worker. ~ Responsible for the preparation of pneumatic test at site. Ensure that pneumatic testis carried out in accordance with the specifications as well as the agreed priorities and procedures and covered by a proper PTW. ‘Maintain proper documentation and control of drawing used during construction 5.3 QC engineers / inspectors Responsible for the quality of welding, for the safe working practices/condition of welders. ~ Ensure that the approved applicable procedures/tables are adhered to. ~The pneumatic test shall be monitored and witnessed by the QC Inspector and any other parties that may be concerned as stipulated by an approved CCP where applicable. Ensure that all QCP records incorporated in the test package is correct 6. PROCEDURE 6.1 General The pneumatic testing will be conducted to verify the soundness of fittings and exposed welding joints after the completion of mechanical work 6.2 Test Documents The test package conforms to the approved template, which will be prepared by Subcontractor and then approved by Contractor, will include the following documents as per follow:da = Ld ALGIERS REFINERY REHABILITATION AND ADAPTATION PROJECT Gea ek PNEUMATIC TEST PROCEDURE OF ABOVEGROUND PIPING. JCC-PRD-PIP-0009-0 Project N° Unit Dos Ty Discipline Serial Number Rew, Page 9952C 000 PRD PIP 0009 0 10. » TEST PACK CONTENTS 1. Test package flow chart. 2. RFl for Pressure Test. 3. Global DW Area (Plot Plan). 4. Test Package Index (Line list)... 5, Legend of the Test package. 6. Test manifold, 7. PID of the concemed lines with battery limits. 8.Red mark-up Isometric with Welding maps.. 8. List and DWG of supports (if any)... 10. Punch List of circuit. 11. Internal cleaning. 12. Welding Book (Weld History Sheet). 13. NDE Inspection Reports... 14. Test Equipment and Gauge list. 15. Gauges calibration certificates. 16. Water analysis Report.. if required), 17. Inhibitor Analysis Certificate (if required), 18. Pressure test Punch list (release for test) 19. Pressure test execution. 20. Test Approved chart (if any) 21. Punch list after pressure test. 22. Modification after pressure test (if required). seDuly filled i Last Rev. CLxO1 (9952T-000-AcP-1320-0001), All Information. -DWG. saci PID Last Rev. Duly filled / Signed by (JCC /TP)/ Stamped ICC list/W6's Punch list -IC01(9952T-000-AcP-1320-0001).. -W10 (As per QCP-1399). .. 9952-000-QCP-1320-0001 forms. ‘As per JSM-0823. Lab report. Lab report, WS1T(9952-000-QCP-1320-0001). “Thax03W13(9952T-000-QCP-1320-0001), _Duly Signed by Inv parts. -CLXO28W/148 (9952T-000-QCP-1320-0001). .W16(9952T-000-QCP-1320-0001).ae dé ALGIERS REFINERY = S&S REHABILITATION AND ADAPTATION PROJECT eco Smee yn PNEUMATIC TEST PROCEDURE OF ABOVEGROUND PIPING JCC-PRD-PIP-0009-0 Project N° Unit Dec Type Discipline Serial Numbec Rev. Page 9952C 000 PRD PIP 0009 0 0 6.3 Test pressure Maximum test pressure is indicated on line ist for pneumatic test, in order to facilitate the management of network pressure test. SUBCONTRACTOR shall select lines or part of lines such as testing at one test pressure can be extended over the largest possible piping system, For ARH lines having pneumatic test requirement, a deviation approval shall be obtained from ARH before proceeding with test. 6.4 Cleaning/Flushing Cleaning of erected piping shall be done before pressure testing operation by dry compressed Air; its performed in order that dirt, scale and other foreign matter are removed 6.5 Exclusion Zone After test preparation is carried out, the area around the system under test shall be cleared of unauthorized personnel. Authorized personnel must avoid to stay in front of pipe ends, covers, The safety requirement described in 5D Safety requirement for onsite pneumatic pressure testing shall be followed. + Warning notices posted during the time that the piping system is pressurized for the test. The arrangements made to exclude unauthorized personnel, and the perimeter of the hazard zone, shall be agreed by CONTRACTOR. Detailed safe distance calculation to be made available for each test duly approved by TP safety, for review / approval, to SH/PMC to decide Exclusion Zone, prior to test as per 9952T-000-PP-0868. 6.6 Pre -Test Procedure Alljoints and flanges shall be accessible and exposed for examination during the test. The systems shall have been completely checked for correctness. Al lines shall be checked to insure the entire system can be tested completely. Temporary gaskets shall be removed after test. Test temperature shall be at least 10°C more than minimum design metal temperature. Safety relief valve shall be provided (set as pressure slightly than test pressure) while testing (Refer doc 6897-00-43-0001 page 31/51) 6.7 Pressure Relief Device + Apressure relief device shall be provided, having a set pressure not higher than the test pressure plus the lesser of 345 kPa (3.45 bar] (50 psi) or 10% of the test pressure. 6.8 Test Fluid ‘The gas used as test fluid, if not air, shall be nonflammable and nontoxic. If test fluid is air, pressure supplied by means of a compressor, the compressor shalll be portable type with receiver, after cooler and oil separator (refer doc 6897-6-44-0013). 6.9 Test Procedure Test pressure shall be gradually increased until a gage pressure which is the lesser of one-half testALGIERS REFINERY = = REHABILITATION AND ADAPTATION PROJECT cr Grane PNEUMATIC TEST PROCEDURE OF ABOVEGROUND PIPING JCC-PRD-PIP-0009-0 Projet N° Unit Doo Type Discipline Seria Number Rev Poge 9952C 000 PRD PIP. 0009. 0 10. pressure or 1.75 Kg/cm2g (1.7 bar) is attained at which time a preliminary inspection of all joints and flanges shall be made with soap solution If any leak is found, the test shall be aborted and the leaks should be repaired before recommencing the test again. Thereafter, the pressure shall be gradually increased in steps until the test pressure is reached , holding the pressure at each step long enough to equalize piping strains, as follow: 0.3 time test pressure. 0.6 time test pressure. 1 time design pressure. Full test pressure. The full test pressure shall be maintained for at least 10 minutes after which the pressure shall be reduced to the design pressure and maintained for at least 10 minutes. ‘The design pressure, all joints and flanges shall be inspection with soap solution for detection of leak. ~ If no leaks are indicated, pressure shall be released by suitable valve, line ball valve or gate valve. * During pneumatic test, the entire line shall be exposed for examination of any leak 6.10 Works not excluded a. Following works are outside the scope of this specification + Any package unit previously tested by manufacturer All packages should be delivered tested. If not tested, test shall be done at site according to a test procedure prepared by the Manufacturer. * lines and systems open to the atmosphere (manhole vent, ..., but all joint shall be visually inspected. Wherever necessary, such lines shall be tested by continuous flow of fluid to eliminate the possibilty of blockade. However, such lines, if provided with block valve shall be pressure tested up to the first block valve. © Internal piping and connections for piping of pressure vessels, heat exchangers, pumps, turbines, . © pressure vessels with the exception of cases where simultaneous testing of vessel and piping is more practical, © instruments components : - all in-line instruments such as control valves (except welded-in type), safety valves, . For control valves, where by-passes are provided, test shall be performed through the bypass and / or necessary spool shall be used in place of the control valve - all instrument control piping downstream of the first piping block valve. ». Following systems for which specific procedure is required + Lines made from plastic materials (RTRP, PEHD, PVC, ..) + lines in oxygen services (cleaning to be checked, see by example ASTM G93) + Hydraulic systems.Pa ALGIERS REFINERY f. = > REHABILITATION AND ADAPTATION PROJECT dex PNEUMATIC TEST Brant PROCEDURE OF ABOVEGROUND PIPING JCC-PRD-PIP-0009-0 ProjectN®- Unit Doe ype Discipline Seri Number Rew. Page 9952C 000 PRD PIP 0009 0 810 6.11 Test acceptance Pressure tests are fulfilled if: No leak. No crack Pressure gauges + Dial indicating pressure gages used in testing shall be graduated over a range of about double the intended maximum test. All gauges shall have suitable range so that the test pressure of the various systems falls in 40% to 80% of gauge scale range.) Digital reading pressure gages having a wider range of pressure may be used provided the readings give the same or greater degree of accuracy as obtained with dial pressure gages, All gages shall be calibrated against a standard deadweight tester or a calibrated master gage. Gages shall be recalibrated at least every 6 months or at any time there is @ reason to believe that they are in error. Any gauge showing an incorrect zero reading or error of more than more or less 2% of full scale range shall be discarded. Calibration certificates shall be available at the work site and all gauges shall be properly identified to enable traceability to calibration certificates. Each gage shall have an identifying mark or number which shall appear on the pressure test package. 8. 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