PROJECT TITLE

HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SNAMPROGETTI

SAUDI ARABIA CO. LTD.

SUBCONTRACT NO. :1210649 JOB H02755 UNIT 00

CUSTOMER:SAUDI ARAMCO OIL COMPANY Doc. no. H99-ZA-E-0004258
PLANT LOCATION:HAWIYAH – SAUDI ARABIA Sh1 of 10 Rev. A

METHOD OF STATEMENT FOR PNEUMATIC TEST FOR REFRIGERANT PIPE

CONTRACT NO. : 6600041164 (IK)
BI/JO NO. : 10-02145
CONSTRUCTION CONTRACTOR: PETROJET
1: Approved 4: Not Applicable
CONTRACTOR review result by: 2: Approved with comments
3: Rejected

Department Date Name Designation Signature

Technical
1 2 3 4
Discipline

Field Engineering
1 2 3 4
Dept.

HSE Dept. 1 2 3 4

QA/QC Dept. 1 2 3 4

1: Approved 4: Not Applicable

2: Approved with comments 5: revise and submit
COMPANY review
result by: 3: Rejected

1 2 3 4 5 Name Signature

A IFR 21-May-19 Issued For Review Mohamed Allam Ateia Hamed Khaled Mosad

Construction Construction
Designation Engineer
E&I Manager
Manager

Rev. Status Date Revision memo Issued by: Checked by: Approved by:
 PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SNAMPROGETTI
SAUDI ARABIA CO. LTD.

SUBCONTRACT NO. :1210649 JOB H02755 UNIT 00

CUSTOMER:SAUDI ARAMCO OIL COMPANY Doc. no. H99-ZA-E-0004258
PLANT LOCATION:HAWIYAH – SAUDI ARABIA Sh2 of 10 Rev. A

TABLE OF CONTENT

TABLE OF CONTENTS.....................................................................................................................
1. GENERAL............................................................................................................................... 1
2. SCOPE.................................................................................................................................... 2
3. DEFINITIONS.......................................................................................................................... 3
4. REFERENCES........................................................................................................................ 4
5. RESPONSIBILIES...................................................................................................................5
6. PROCEDURE......................................................................................................................... 6
7. QUALITY................................................................................................................................. 7
8.MATRIALS, TOOLS & EQUIPMENTS …………………………… 8
9. SAFETY …………………………………………………………………………….…9
10. EMERGENCY RESPON…………………………………………………………………10

11.ATTACHMENT………………………………………………………………………………………11

12 INSPECTION………………………………………………………………………………………...12
 PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SNAMPROGETTI
SAUDI ARABIA CO. LTD.

SUBCONTRACT NO. :1210649 JOB H02755 UNIT 00

CUSTOMER:SAUDI ARAMCO OIL COMPANY Doc. no. H99-ZA-E-0004258
PLANT LOCATION:HAWIYAH – SAUDI ARABIA Sh3 of 10 Rev. A

1. GENERAL

1.1 SITE DESCRIPTION

The Saudi Arabian Oil COMPANY (COMPANY) is the owner of the development of
HAWIYAH GAS PLANT EXPANSION Project (HGP). The proposed projectis located in
the Eastern Province of Saudi Arabia, approximately 65 km southwest of the City of
Hofuf in the Al-Hasa region and approximately 175 km southwest of Dammam Haradh
Gas Increment. SAIPEM has been awarded the construction engineering,
procurement, construction, installation and other activities envisaged to provide
additional gas processing facilities at Hawiyah Gas Plant (HGP) to process 1070
million standard cubic feet per day (MMSCFD). CONSTRUCTION CONTRACTOR was
subcontracted by SAIPEM to perform execution of the Civil, Mechanical, Electrical,
Instrumentation and Telecom works at Procurement, Construction and Pre-
commissioning phases.

PURPOSE
The method statement must ensure that the pneumatic test for refrigerant pipes works
is carried out safely, and in accordance with good engineering practices, as per project
specifications.
This method statement is intended to provide general guidance and establish controls
COMPANY Saudi Arabian
duringOilpreparation
Company and installation.
This statement outlines the methods to be followed for the pneumatic test of copper
pipes works installation activity.
contractor SNAMPROGETTI SAUDI ARABIA CO. LTD.

Contract 2 SCOPE OF WORK

TheagreemententeredbetweenSnamprogetti Saudi Arabia Co. Ltd.andPTJforProject

PETROJET To describe
The Petroleum the& detailed
Projects Technicalscope of work toCo.
Consultations be followed
Acting asfor the pneumatic
subcontractor fortest for copper
(PTJ) pipes worksat Hawiyah Gas Plant (HGP)
construction and pre-commissioning activities, also referred as subcontractor

RFI/AFI 3 For
Request DEFINITIONS/ABBREVATION
Inspection/Application For Inspection

QCIP Quality Control Inspection Plan

Method Statement
AFC Approved For Construction
MSDS Material Safety Data Sheet
PPE Personal Protection Equipment

QA/QC JSTI Job Safety/Task

Quality Assurance Instruction
Quality Control

PCI Power and Control cables installation

LV Low Voltage cables (1000 V and below)

HV High Voltage cables (greater than 1000 V)

ITP Inspection and Test Plan

PTW Permit To Work

JSA Job Safety Analysis

 PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SNAMPROGETTI
SAUDI ARABIA CO. LTD.

SUBCONTRACT NO. :1210649 JOB H02755 UNIT 00

CUSTOMER:SAUDI ARAMCO OIL COMPANY Doc. no. H99-ZA-E-0004258
PLANT LOCATION:HAWIYAH – SAUDI ARABIA Sh4 of 10 Rev. A

4 REFERENCES

Schedule Q Quality requirements

SAES-P-114 Power System and Equipment Protection

SAES-P-100 Basic Power System Design Criteria

SAES-P-104 Wiring Methods and Materials

ANSI C2 National Electrical Safety Code

IEEE -142 Recommended Practice of Grounding of Industrial and Commercial Power

NFPA 70 National Electrical Code

UL 467 Grounding and Bonding Equipment

IEEE 399 IEEE Recommended Practice for Power Systems Analysis

SAES-J-902 Electrical Systems for Instrumentation

SATIP-P-113-03 Diesel Generator Set

ANSI C37.101 Guide for Generator Ground Protection

5. RESPONSIBILITIES:

5.1. The Mechanical work Site Engineer (MSE) shall be responsible for the implementation
of this Method Statements is as follows
A) Ensure availability of required material that compiled with approved submittal.
B) Ensure site Supervisor/ Foreman and Workmen assigned to do this job are
specialist and well trained.
C) Ensure availability of required tools / equipment at site in good operating condition.

D) Ensure the validity of calibration certificates for the gauges use in this activitiy.

5.2.The Mechanical Supervisor/ Foreman shall be responsible for the following:

A) Guide the Workmen to do the job carefully and safely as per safety procedure.
 PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SNAMPROGETTI
SAUDI ARABIA CO. LTD.

SUBCONTRACT NO. :1210649 JOB H02755 UNIT 00

CUSTOMER:SAUDI ARAMCO OIL COMPANY Doc. no. H99-ZA-E-0004258
PLANT LOCATION:HAWIYAH – SAUDI ARABIA Sh5 of 10 Rev. A

B) Check all tools and equipment are working properly and report to Site Engineer for
immediate repair or replacement.
C) Guide the workmen to execute the works as per standards and as per procedures
described in this method statement.

5.3. Mechanical Works Quality Control Inspector (MQCI) shall be responsible for the
Followings:
A) Continuously monitoring site execution work and material to be ensure total
compliance with approved details and Project Specifications.
B) Timely inspection with Engineer Site staff (ESS).

5.4QUALITY CONTROL INSPECTOR

Conduct inspection in accordance with COMPANY specifications. Monitor the

Pneumatic test activities and verify strict compliance to the project requirements,
specifications and manufacturer's recommendations. Prepare daily QC records and
final acceptance documentation where required.

5.6. SAFETY SUPERVISOR

Monitor the work areas of any unsafe conditions. Ensure that all safety
requirements are adequately addressed and the work is being carried out safely in
accordance with HSSE Safety Procedures. Ensure that material safety data sheets
are available at site.

5.7 ENGINEERING DEPARTMENT

Prepare and submit MS for Company review and approval. Provide technical
support to site operations group. Provide the latest revision of AFC drawings,
procedures, material specifications, standards and technical specifications.
Maintain proper documentation and control drawing used on site. Request field
erection material as per schedule. Responsible for the review of project drawings
and data sheets, and resolve technical work execution problems.

6. PROCEDURE
6.1 General Requirements:

A). The HVAC Specification specified in details which piping or equipment shall be
pressure tested and provided the specific applicable standard.
B). New piping system shall be cleaned in accordance with SAES-L-350.
C). Pressure gauges shall be calibrated before the test.
 The calibration interval for Pressure Gauge shall not exceed one (1)
month. Calibration certificates shall be made available to inspection
personnel prior to commencement of the pressure test. Stickers shall be
applied indicating the latest calibration date.
 PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SNAMPROGETTI
SAUDI ARABIA CO. LTD.

SUBCONTRACT NO. :1210649 JOB H02755 UNIT 00

CUSTOMER:SAUDI ARAMCO OIL COMPANY Doc. no. H99-ZA-E-0004258
PLANT LOCATION:HAWIYAH – SAUDI ARABIA Sh6 of 10 Rev. A

 All gauges shall have a range such that the test pressure is within 30 to
80% of the full range.
 A minimum of two pressure gauges are required for the test system. One
pressure gauge shall be on the test manifold and the other(s) on the test
system. Their accuracy shall be within 5% of one another.
 When large systems are tested, inspection personnel will determine the
need for additional gauges.
D). Pressure Gauges and Relief valves shall be calibrated with third party inspection
agency or in house calibration facility in which sub-contractor should submit RFI to
TR/ ARAMCO.
E). Test record shall be recorded on Pressure Test Report Form (Company Pressure
Test Report)
6.2 Requirements for Test Manifold:

A). Calibration of test manifolds shall be as per design pressure. Test manifold shall be
calibrated with third party certification or in house calibration facility in which sub-
contractor should submit RFI to TR/ ARAMCO and its calibration interval shall not
exceed 6 months.
B). An isolation valve shall be provided between the pressure testing manifold and the
system being tested. The isolation valve shall be rated for the manifold test
pressure when in the closed position.
C). The pressure shall be built-up gradually as per the TR/ ARAMCO standard. To
ensure the applied pressure inside the test package never exceeds the desired
pressure, a calibrated safety relief valve shall be provided in the manifold.
D). In the event of leakage, the manifold will be depressurized. Repair will be executed
and the test will be repeated until no leakage is observed.
6.3 Protection from Over Pressure:

All systems (piping and equipment) while being pressure tested shall be protected
from being over-pressured by the following:
A). Relief valve(s) of adequate capacity set to relieve at 5% above the test pressure
shall be installed unless the test pressure is less than 85% SMYS (Specified
Minimum Yield Strength) at which time it can be set at 10% above the test
pressure.
B). All Punch-List “A” Items shall be cleared prior to Pressure Test.
C). Safe access and required temporary supports will be provided for inspection of all
joints and appurtenances prior to walk down and maintained until the satisfactory
completion of the test.
6.4 Pressure Testing of Refrigerant Pipes:

A. Experienced personnel are deployed to supervise and conduct the testing operation in
a safe and efficient manner, taking in to account all aspects of testing such as
coordination, supervision and safety.
 PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SNAMPROGETTI
SAUDI ARABIA CO. LTD.

SUBCONTRACT NO. :1210649 JOB H02755 UNIT 00

CUSTOMER:SAUDI ARAMCO OIL COMPANY Doc. no. H99-ZA-E-0004258
PLANT LOCATION:HAWIYAH – SAUDI ARABIA Sh7 of 10 Rev. A

B. Blow out lines with dry nitrogen prior to testing and charging.
C. Leak test shall be performed by injecting dry nitrogen into the system.

D. The pressure in the piping system shall be gradually increased until a gauge pressure
which is the lesser of one half of the test pressure or 175 kPa (25 psig) is attained, at
which time a preliminary leak test shall be performed to detect and eliminate gross
leaks and/ weakness on the joints under examination (50 psig). If there is no leak, the
pressure shall be gradually increased in steps until the test pressure is reached (250
psig), holding the pressure at each step long enough to equalize piping strains.

E. At 50 Psi, check all joints, seals or connections for leakage.

F. When no leaks are detected, pressurized both high and low sides of system to 250 Psi
(for Refrigerant 134a). The compressor shall be isolated from the system during this
high pressure testing.

G. When the system has been brought up to the test pressure shown on the pressure test
summary, all joints shall be covered with a bubble forming solution in order to detect
any leakage.
H. Pneumatic test pressure shall be maintained for a sufficient length of time to permit
through visual inspection and soaping of all joint but not less than 2 hours.
I. Strength test pressure holding time shall not be less than 2 hours as per HVAC
Specification

SEQUENCE:

 Initial charging shall be 25 psig

 Gradually increase the pressure up to 50 psig. Check all the joints with soap
solution.
 Increase the pressure from 50 psig to the test pressure (250 psig). Each
charging interval shall be 5 mins.
 If any abnormal sound or leakage is observed, follow the emergency response
plan.

J. If leaks are detected, depressurized the system to repair the joints.

K. Make sure that nitrogen gas will be discharged in a well-ventilated area.

L. For any areas without proper ventilation, gas test is mandatory.

M. Attach in every test, the steps to get the test pressure and the depressurization of the
system.

N. Flushing & Pressure testing of refrigerant piping shall be controlled by nitrogen

regulators installed at the nitrogen service valve.
 PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SNAMPROGETTI
SAUDI ARABIA CO. LTD.

SUBCONTRACT NO. :1210649 JOB H02755 UNIT 00

CUSTOMER:SAUDI ARAMCO OIL COMPANY Doc. no. H99-ZA-E-0004258
PLANT LOCATION:HAWIYAH – SAUDI ARABIA Sh8 of 10 Rev. A

O. After pressure test has been done and approved by Contractor/Company, evacuate the
system to remove air, moisture and dirt (if any) in the tube system. (See separate
Method Statement for Evacuation)

6.5 Leak Detection:

A. Leak detection will be by means of soap bubbles which is the simplest, the oldest
and the most recommended method. This can be done by using a commercial
solution such as liquid soap or equivalent.

B. Prior to soaping the joints, the entire line should be “Walked” to determine if there is
any audible evidence of leakage. Any leaks found at the time shall be marked, and
repaired after first depressurizing the line. If any abnormal sound is occurred,
immediately shut off the cylinder valve. Depressurized the system through manifold
to outside the building.

C. Prepare a solution of liquid detergent or liquid soap with water in the proportion of
one (1) pint (0.5 Liter) of detergent or soap and four (4) quarters (3.8 Liters) of
water. Prepare the solution in advance to allow the bubbles and foam to disperse
before using.

D. Apply the soap solution to all fittings and brazing joints in a continuous film relatively
free bubbles and observe closely for any minor soap bubbles generating from the
brazed joints.

E. When leakage is observed, the position of the leak(s) shall be marked. The system
will be depressurized gradually and safely before proceding with the repair.

F. A qualified technician can identify the difference between the bubbles caused by
leak and bubbles naturally present in the soap application.

G. After rectification of leaks, if any, all the above leak detection steps have to be
repeated.

6.6 Repair of Joints:

A) All leaking joints shall be repaired.

B) Brazed joints that leak may be repaired by cleaning the exposed area, re-fluxing and
re-brazing.
C) After joints have been repaired, the joints shall be retested in accordance to steps
mentioned at sections 5.5 & 5.6 of this Method Statement.
 PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SNAMPROGETTI
SAUDI ARABIA CO. LTD.

SUBCONTRACT NO. :1210649 JOB H02755 UNIT 00

CUSTOMER:SAUDI ARAMCO OIL COMPANY Doc. no. H99-ZA-E-0004258
PLANT LOCATION:HAWIYAH – SAUDI ARABIA Sh9 of 10 Rev. A

7. QUALITY CONTROL:

A) QA/QC must ensure that the Brazers are qualified to do the job with valid Brazer’s
identification card.
B) Request for Inspection shall be issued to Contractor/ Company Project Inspector 24
hours in advance on weekdays and 48 hours in advance for weekends and holidays.
C) Inspection shall be done in accordance with the QA / QC Plan.
D) During Inspection, all brazed joints shall be carefully examined for leakage.
E) The brazed joints being tested shall be satisfactory if there is no evidence of leakage
or reasonable drop in pressure after the specified test period.
F) Leaking brazed joints shall be repaired and test shall be repeated until the system is
proven satisfactory.
G) Ensure that the Filler Rod and Flux are as per approved material and in compliance
with the requirements.

8. Materials, Tools and Equipment:

A) Dry Nitrogen
B) Nitrogen Regulator (calibrated)
C) Gage manifold (calibrated)
D) Various Hand Tools
E) Pressure Relief Valve (PRV), with calibration certificate (one week valid for Pressure
Test)
F) Test Manifold (Calibrated)
G) Soap & water solution
H) Warning Sign, Barriers
I) Calibrated Thermometers with calibration sticker & Certificates (If required)

9. SAFETY:

A. All personnel tasked to do this work shall wear Personal Protective Equipment’s (PPE)
at all times on the job site.
B. All equipment’s shall have Aramco stickers or safety tags to ensure that said
equipment’s are approved for a safe working condition.
C. Barriers shall be erected to provide protection against hazards and dangers, hazardous
work areas and hazardous work in all cases where the hazard or danger will exist.
Barricades shall be marked ‘YELLOW’ and ‘BLACK’ to increase the visibility of the
barrier and to highlight the hazards.
 PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SNAMPROGETTI
SAUDI ARABIA CO. LTD.

SUBCONTRACT NO. :1210649 JOB H02755 UNIT 00

CUSTOMER:SAUDI ARAMCO OIL COMPANY Doc. no. H99-ZA-E-0004258
PLANT LOCATION:HAWIYAH – SAUDI ARABIA Sh10 of 10 Rev. A

D. Subcontractor Safety Supervisor shall carry out the safety site imspection to ensure that
safety requirements laid out in the safe work plan are followed during testing.

E. Subcontractor Safety Manager/ Supervisor shall review Safety Action Plan and secure
work permit if necessary.

F. Prior to start of any activities, Job Safety Analysis (JSA) will be strictly followed as per
attachment.

G. Equipment, tools and Materials Inspection. All equipments for testing shall have to be
inspected by Subcontractor Safety manager/ Supervisor prior to forwarding to TR
Safety Department inspection prior to use at site to ensure their safe worthiness at
work. The inspection reports shall be kept for record.

H. Test area shall be marked and warning sign shall be posted to alert approaching
personnel.

I. Enrty to the building shall be controlled by an assigned responsible person.

J. Doors should be in open position to move out all the persons in the room.
K. Force ventilation shall be incorporated inside the building to provent oxygen
replacement.
L. No activity shall be carried out inside the building during pressure testing.

M. Nitrogen cylinders shall be kept outside the building in well ventilated area.

N. Release of pressure shall be done outside the building.

O. When leakage is observed, the system will be depressurized gradually and safely
released and When leakage is observed, the system will be depressurized gradually
and safely released and follow the emergency response plan.

P. Notification must be submitted to TR 24 hrs prior to start the activity.

Q. MAC Safety Supervisor shall carry out safety site inspections to ensure that safety
requirements laid out in the safe work plan are followed during the testing.

10- EMERGENCY RESPONSE PLAN:

A. If any abnormal sound is occurred, immediately shut off the cylinder valve.

B. Depressurized the system through manifold to outside the building.

C. Doors should be in open position to move out all the persons in the room.

D. Forced ventilation shall be incorporated inside the building to prevent oxygen

replacement.

E. Ensure that the system has been depressurized prior to any maintenance work.
 PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SNAMPROGETTI
SAUDI ARABIA CO. LTD.

SUBCONTRACT NO. :1210649 JOB H02755 UNIT 00

CUSTOMER:SAUDI ARAMCO OIL COMPANY Doc. no. H99-ZA-E-0004258
PLANT LOCATION:HAWIYAH – SAUDI ARABIA Sh11 of 10 Rev. A

11- ATTACHMENTS:

1. Approved Brazing Procedure Specification (BPS)

2. Brazing Procedure Pre-qualification Record (BPQR)
3. Other attachment required such as copies of the approved drawings, material
submittals, brochures shall be provided to the concerned personnel at site for proper
implementation of this works.

12-INSPECTION
All stages of work shall be inspected in accordance with the approved project Inspection and
Test Plan (ITP)