( MEI )

INTER ‐ DISCIPLINE CHECK (IDC)

Project Title: SOUTH SEMBAKUNG DEVELOPMENT IDC No: MEI‐JOBSMN‐TR‐0226

Originator: KDY Date of Circulation: 19 Oct 21 Date to be return to DCC: 22 Oct 21

Document/Drawing No. Title/Description Current Rev. Status

SMN‐J‐PR‐00‐142 Piping Flushing Hydrotest Procedure 01 Re‐IFI

Note.
‐
CIRCULATION LIST
Date
No Discipline Initial Title/Comment Sign
Target Actual
1. Project Manager AZ

2. Engineering Sect. Head AMW 22‐10‐21 Review

3. Construction Sect. Head DPS 22‐10‐21 Review

4. Project Control Sect. Head PR

5. Project Engineer LS 22‐10‐21 Review

6. Process/Process Safety Engineer EHS/YS

7 Medco Reps IK/SS

8 Operation Medco NCY/ALH/YSF

9 Mechanical Engineer AY/YAN Info

10 Piping Engineer AY/BP 22‐10‐21 Review

11. Pipeline Engineer AY/AS Info

12. Instrument Engineer FAP/DW

13. Electrical Engineer SAF/DW

14. Civil Engineer LS

15. Construction Engineer KRH Info

16. QA/QC Engineer HY/MRY/IMI 22‐10‐21 Review

17. HSSE Engineer OS

18. Commissioning Engineer KDY 22‐10‐21 Owner

18. Project & Cost Control Engineer SP/AN/CAA Info

19. Contract Engineer CBO/RTH

20. Document Control ANH/ASA

The above document(s) have been reviewed and incorporate in the referenced document(s)/drawing(s) as appropriate

Final Review by: Approved by:

Dedy Parsaoran Sianturi Akhmad Zamroni

Construction Section Head Project Manager
File: Project Document Control: Ervin / Ahmad
 JOB PERTAMINA – MEDCO E&P SIMENGGARIS

PROJECT TITLE: SOUTH SEMBAKUNG DEVELOPMENT

DOCUMENT TITLE: Piping Flushing Hydrotest Procedure

DOCUMENT NO.: SMN-J-PR-00-142

CONTRACTOR JOB P-MEPS

REV DATE DESCRIPTION
PREPARED CHECKED APPROVED APPROVED
X 26-Aug 21 Inter Discipline Check EMT EMT DSL
00 26-Aug 21 Issued for Information EMT EMT DSL
01 15 Oct 21 Re- Issued for information
EMT EMT
DSL
UNAUTHORIZED COPYING OF THIS DOCUMENT IS NOT PERMITTED.

WO. No:
JOB P-MEPS
3510006782 01
SIMENGGARIS DISCIPLINE:
Page 1 of 11
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SIMENGGARIS BLOCK
Date : 15 Oct 21

COMMENT SHEET

Incorporated
Rev Section Page Comment (Y/N) Description

00 6 Do we have national laws and N Piping and Hydrotest procedure reference

standards? If available please add as per international standard.
00 6 Please pay attention to the use of Y
uppercase and lowercase letters
00 The Hydrotest and Flushing shall be Y The water quality shall be follow result of
performed with water whose have water quality in Simenggaris field
Chloride content below 50 ppm.
00 11 holding time 2 hrs N All requirement as per
00 11 b. Ensure pipes are either adequately Y
drained. c. Pipes and devices
which are removed during flushing
shall be reinstalled.
00 11 Grafik chart dibuat 3 steep ( steep 1: N Note that since there is no specification
35% hold 15 min,steep ke 2:75% hold related to pre-comm/comm hence, CTR
15min & steep ke 3:100% hold 2 hours will utilize CTR standard scope for pre-
comm preparation as written on this
document unless CPY provide guideline
or specification
00 12 add A reinstatement check against the Y
P&IDs will be conducted to ensure the
reinstatement completion prior to put a
system into service
00 12 How about Disposal of water test ?? Y
add 9.3
00 12 10.2 Acceptance criteria for N Note that since there is no specification
Hydrotest?? related to pre-comm/comm hence, CTR
will utilize CTR standard scope for pre-
comm preparation as written on this
document unless CPY provide guideline
or specification
00 12 lampirkan form report Y
00 12 Sample Check sheet Hydrotest, Y
Flushing and Drying

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TABLE OF CONTENTS

COMMENT SHEET ................................................................................................................. 2

TABLE OF CONTENTS .......................................................................................................... 3

1. INTRODUCTION .................................................................................................................. 4
2. PURPOSE ............................................................................................................................. 5
3. DEFINITION AND ABBREVIATION .................................................................................... 5
4. REFERENCE ........................................................................................................................ 5
5. SCOPE OF WORK ............................................................................................................... 5
6. GENERAL REQUIREMENTS AND PREPARATION ........................................................ 6
6.1 FLUSHING ............................................................................................................................ 6
6.2 HYDROTEST ........................................................................................................................ 7
7. EXECUTION ......................................................................................................................... 8
7.1 CLEANING / FLUSHING EXECUTION ............................................................................... 8
7.2 HYDROTEST EXECUTION ................................................................................................. 9
8. POST TEST ......................................................................................................................... 10
8.1 FLUSHING/CLEANING ...................................................................................................... 10
8.2 HYDROTEST ...................................................................................................................... 11
8.3 DISPOSAL WATER ............................................................................................................ 11
9. ACCEPTANCE CRITERIA ................................................................................................. 11
9.1 CLEANLINESS CRITERIA FLUSHING/CLEANING ........................................................ 11
10. ATTACHMENT .................................................................................................................... 11
ATTACHMENT 1 – Sample Flushing Block Diagram (Using Quick Opening Valve) .............. 11
ATTACHMENT 2 – Sample Hydrotest Block Diagram .............................................................. 11
ATTACHMENT 3 – SAMPLE TEST SHEET .............................................................................. 11

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1.
JOB Pertamina - Medco E&P Simenggaris, hereafter known as COMPANY, is the operator of
South Sembakung Field located at Simenggaris Block, North Kalimantan. The South Sembakung
Field has a South Sembakung Gas Plant was designed to produce 30 MMscfd gas for 20 years.
Currently, there are 4 (four) wells which have been drilled; namely SSB-2 as production well and
three development wells namely SSB-4, SSB 5 and SSB-7, which are currently under temporary
suspension.
Based on the Gas Sales and Purchase Agreement (PJBG) to PT. PLN 8 MMSCFD and PT.
Kayan LNG 22 MMSCFD, the addition of 3 (three) development wells will be required, namely
SSB-8, SSB-9 and SSB-10.
COMPANY has initiated the new Project to accommodate produced gas from the new wells. The
project will consist of installation of : new wellsite facilities and its flowlines, LLP production
manifold and LLP production separator, new condensate handling system (heater, tanks, pumps,
custody meter and export line), new (future) compressor package during wells pressure
depletion and other repair and modifications required.

Figure 1 – South Sembakung Field Location

PT. Meindo Elang Indah has been awarded the Engineering, Procurement, Construction,
Installation & Commissioning of South Sembakung Gas Development.

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2.

This document outlines the flushing and Hydrotest methodology that CONTRACTOR intend to
perform on Simenggaris. Project to ensure the cleanliness of the piping line or network prior and
ensure that all joints, including welds, will be tested in conjunction with required test pressure
stipulated in the piping line list. This serves as a supplementary document to the approved project
specifications, applicable codes and standards in which the later shall take precedence over this
document if there are any conflicting clauses

3.

For the purpose of this procedure, the following definition shall be considered as below :

COMPANY JOB PERTAMINA-MEDCO ENERGY E&P SIMENGGARIS

CONTRACTOR PT. Meindo Elang Indah
Worksite PT. Meindo Elang Indah Construction Site/Fabrication Yard
Site Simenggaris Field
COMPANY Representative The person appointed by COMPANY as its duly authorized
representative CONTACTOR with respect to the Contract
EPSCC Engineering. Procurement, Supply, Construction and
Commissioning
IDC Inter Discipline Check
IFI Issued For Information

4.

ANSI/ASME B31.3 2002 Edition Process Piping Guide

API RP 1110 5th Edition Pressure Testing of Steel Pipelines for the Transportation
of gas, petroleum Gas, Hazardous Liquid, High Volatile
Liquid or Carbon Dioxide
SMN-J-PR-00-120 Method Statement Piping Fabrication

5.
The scope of work covers by this procedure are :

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· The cleaning/flushing of piping line or network, its method that will remove all sort of dirt and
debris inside the line or network to achieve the required cleanliness

· Hydrotest or pressure test of piping and its method that will be implemented to complete all
corresponding test in a safe and professional manner

6.

a. Prior to start the flushing, ensure that the test package has been approved by CPY which
means that the NDT result of the line system has been cleared, line checked has been
performed i.e. the installation is as per the isometric drawing, lay out plan and marked up P
& ID and no major punch lists and the Check List Sheet C-LX-02A/C-LX-02B dully signed by
both parties at the end of the preparation of the flushing test as defined in below points b to
i.

b. A notification letter with at least 24-48 hrs period shall be sent to CPY for witnessing the
actual flushing activity. NO flushing shall be performed without the witness of the CPY
representative

c. Ensure the network is adequately supported and/or additional supports to be added if

necessary in order that the network will be strong enough to withstand the weight thus
avoiding stress once the pressure has introduced in the line

d. The cleaning fluid shall never flow through pumps or any equipment. The line shall be
disconnected before the equipment or a jumper or by-pass line shall be installed

e. The Hydrotest and Flushing shall be performed with water whose have Chloride content
below 50 ppm.

f. Large diameter pipes shall be cleaned before small diameter ones

g. Fragile devices included in the network shall be removed as much as possible and based on
the current facility condition

h. Impulse tubing line for process instruments can be isolated by means of the block valve from
the impulse pipe, or whenever possible shall be disconnected.

i. Ensure that adequate protections are installed in adjacent or nearby equipments

j. In all cases the line to be flushed shall be isolated from other piping network

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k. Ensure that gauges have been calibrated with valid certification

l. Ensure that all flexible hoses and the anti-whip hose connection intended for the flushing are
properly connected as per the flushing block diagram

m. Check List Sheet C-LX-02A/C-LX-02B shall be filled and signed by both parties at the end of
the preparation of the first Pre-Commissioning test which, in this case is flushing execution

a. Prior to start the hydro test, ensure that the test package has been approved by CPY which
means that the cleaning/ flushing has been cleared and accepted.

b. A notification letter with at least 24-48 hrs period shall be sent to CPY for witnessing the
actual hydro test activity

c. Ensure the network is adequately supported and/or additional supports to be added if

necessary in order that the network will be strong enough to withstand the weight thus
avoiding stress once the pressure has introduced in the line

d. Fragile devices included in the network shall be removed as much as possible

e. All dismantled items and blind flanges installed shall be listed and included inside the test
package

f. Hydro test can only proceed internal or final test when the flushing activity already
completed and accepted by CPY

g. Temporary and/or re-use gaskets in a good conditions shall be used for all hydrotest
activities.

h. Ensure that adequate protections are installed in adjacent or nearby equipments

i. In all cases the line to be hydro tested shall be isolated from other piping network

j. Ensure that gauges and pressure recorder have been calibrated with valid certificate

k. Minimum of two (2) pressure gauges shall be used and connected at low and high point

l. The test recorder and pressure gauge/s are to be installed in the manner that obstruction will
not occur during the entire testing process.

m. Piping pressure and test medium shall follow the approved line list except in some cases
that hydrotest are not feasible i.e. vent lines downstream of flame arrestors and air intake

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lines wherein the service is considered as atmospheric. Only visual inspection will be carried
out on these lines instead of pressure test subject to CPY approval

n. Holding time for hydrotest will be perform with the holding time is 1 hour

o. Ball, gate, globe, and butterfly valves should be in full open position or based on actual valve
condition in situ

p. Vessels and mechanical equipment such as process pumps should be blinded or spade
from the network, if applicable

7.

CONTRACTOR will perform the pipe cleaning/flushing with a Quick Decompression Method

USING QUICK OPENING VALVE

a. Before starting the test, ensure that the system is lined up as per the flushing block
diagram included in the test package

b. Ensure that the quick opening valve (manual valve) at the air outlet is in closed position

c. The piping network shall be flushed from high point to low point. Where two or more high
points or alternative flow paths exist, the multiple flushing inlet and discharge points will be
required.

d. Large diameter pipes should be cleaned before the small diameter ones and dead ends
will be cleaned separately

e. Start the compressor and open the inlet valve to allow the air flow into the network

f. Monitor properly the pressure on the gauge and ensure that the pressure will not exceed
the maximum pressure required in the network

g. Before opening the valve on the air outlet ensure that all safety measures has been
adhered to

h. Once the pressure reading on the gauge reached the allowable pressure, open the quick
opening valve at the air outlet as possible to fully open and close immediately if in case of
emergency. Ensure that all equipment, instruments etc. adjacent or close to the discharge
point is properly protected

i. Repeat the closing and opening of the outlet valve for several times as possible until the

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cleanliness criteria are met.

The following step by step procedure will be implemented for the final hydrotest or pressure test
with CPY witness

a. Before starting the test, ensure that the system is lined up as per the hydrotest block
diagram included in the test package and that the back of the recorder chart has been
signed by QC and CPY representative before inserting it into the test recorder. After
inserting the chart, the recorder shall be locked and the key will be kept with CPY pre-
commissioning representative

b. Start the filling with required test medium at the lowest point in the line or network. Ensure
that all venting points are open to avoid entrapped air until the system is fully filled

c. Increase the pressure gradually up to 25% and let it stabilize for 5 mins. If no leak,
increase the pressure up to 50% and let it stabilize for 5 mins. Continue building up the
pressure in the system up to 75% until 100% of the desired test pressure with 5mins
stabilization period and if no leaks found in between.

d. Hold the 100% pressure in the system minimum 1 hour . Ensure that the line or network
has been disconnected from the source once 100% has reached to avoid further pressure
introduced into the system. Perform the visual inspection on the system and check all
flange joints, welding joints and other connections for leaks

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e. During this stabilization period the pressure along with the temperature should be properly
monitor from the test recorder plus manual recording as back up. There should not be any
pressure drop shown in the recorder unless it is attributed by the ambient temperature
change which will have effect on the metal temperature resulting to such pressure
fluctuation

f. If the pressure drops are attributed by leaks, after investigating and identified the location
the line or network should then be immediately fully depressurized and do the necessary
repair and/or rectification. Re-test of the same line or network shall be performed in the
same step by step mentioned herein above

g. Should there are no more leaks found during the stabilization period and CPY approved
the test, the system shall then be depressurized

h. Decrease the pressure from 100% to 75% at let the pressure stabilize for 5 mins and
repeat the same way for 25% until 0% with 5 mins stabilization period per each interval.
The depressurization of the system can be done by opening the vent point gradually in a
way that each percentage and stabilization time intervals mentioned here are attained

i. Remove the chart from the test recorder and obtain all parties signatures i.e. QC, Pre-
Comm.Engineer and CPY representative who follow and witnessed the test.

8.

a. Ensure that the system is properly depressurized and compressor is turned off before
removing all temporary connections used on flushing activity

b. Ensure pipes are either adequately drained

c. Pipes and devices which are removed during flushing shall be reinstalled

d. Ensure to properly seal each of the pipe by covering it with plastic or wrapped with
tape to avoid re-introduction of any dirt into the line prior to the pressure test

e. Fill up the corresponding test sheet (T-MX-05/T-MX-027) inside test

package and obtain CPY representative signature as proof of acceptance

f. Remove all barricades and signs the test area and perform proper housekeeping

g. A reinstatement check against the P&IDs will be conducted to ensure the

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reinstatement completion prior to put a system into service

a. Ensure that all temporary items used in hydrotest are properly disconnected from the
network and all permanent items which has been removed prior to the test are restored
back on its designated locations

b. Remove the chart from the recorder and obtain all parties final signatures i.e. QC, Pre-
Comm.Engineer and CPY representative as a proof of acceptance

c. Fill up the corresponding pressure test sheet (T-MX-03) inside the test package and obtain
CPY representative signature as proof of acceptance

d. Remove all barricades and signs around the test area and perform proper housekeeping

The disposal of all water used in flushing, hydrotest, ect in the section of this piping shall
be disposed out in safe area as per CPY approval.

9.

Colour of the air at the discharge point will roughly indicate whether or not rust and dirt remain
in the piping. This is usually sufficient for the majority of process and utilities piping. At the
beginning of the blow out the air is brownish (rust colour) or greyish (other debris i.e. welding
rods, welding slugs, sand etc.). The colour will become brighter and brighter depending on the
number of blow out performed. Considerably, at this point, uncoloured air at the discharge
point means that pipe internal is already clean with the satisfaction and acceptance from CPY
representative hence will authorize to stop the flushing activity

10.
ATTACHMENT 1 – Sample Flushing Block Diagram (Using Quick Opening Valve)
ATTACHMENT 2 – Sample Hydrotest Block Diagram
ATTACHMENT 3 – SAMPLE TEST SHEET

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 PRECOMMISSIONING TEST SHEET
PIPING & VESSEL
PIPING PRESSURE TEST

Task Num ber : 0

Form : TM X03 - PIPING PRESSURE TEST
Dwg / PID :
Task Location : User Group :
Estimated Time (MH) : Expended Time (MH) :
Punch List Items :
Module :
Subsystem :

T E S T P R E P AR AT ION
Weight control (for gas line supports): NO YES
Water quality Inhibitor: NO YES
Filtration: NO YES
Equipment removed: NO YES Conformity PID's* NO YES
REQUEST TO PRESSURE TEST DATE: WITNESSING: NO YES
PERMISSION TO TEST NAME DATE
D AT A
DESIGN PRESSURE: TEST PRESSURE: TEST MEDIUM

CALIBRATION CERTIFICATE: BLIND LIST

T E S T R E S U LT S
TEST DATE: TEST DURATION: WITNESSING BY:
TEST PRESS-START: TEST PRESS- FINISH: TEST MEDIUM TEMP:

R E M AR KS

* Excepted removed equipments, pipework installation is conform to the specification & PID's ,

CONTRACTOR Certifying COMPANY

Carried Out By Checked By Authority CST CMM

Sign

Name
Date

JSN Project SHEET 1 OF 1