Document Number

EXECUTION PROCEDURE FOR TEST PACK PREPARATION & PRESSURE

GMS-SG-PR-M-008
TEST OF PIPING SYSTEM
Revision: 0 Status: IFA
Document Type: PR System / Subsystem: 00 Discipline: Q Rev. Date: 28-Nov-2010
CONTRACTOR Document: 21119 – PT. SAE Page 1 of xx

ENGINEERING, PROCUREMENT &

CONSTRUCTION (EPC)

GAS METERING STATION

PROJECT

PROCEDURE

EXECUTION PROCEDURE FOR TEST PACK

PREPARATION & PRESSURE TEST OF
PIPING SYSTEM

Issued Checked COMPANY

Rev. Status Date Revision Memo Approved by
by by Approval
28-Nov-
0 IFA Issued For Approval PS AS AGF
2010
 GENERAL PROCEDURE Document Number
FOR GMS-SG-PR-M-004
LOCALIZED ELECTRICAL RESISTANCE POSTWELD HEAT Status:
Revision: 0
TREATMENT OF BUTT WELD IN CARBON STEEL PIPE WORK IFA
Document Type: PR System / Subsystem: 00 Discipline: Q Rev. Date: 2-Nov-2010
CONTRACTOR Document: 21119 – PT. SAE-BPK Page 2 of 10

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 GENERAL PROCEDURE Document Number
FOR GMS-SG-PR-M-004
LOCALIZED ELECTRICAL RESISTANCE POSTWELD HEAT Status:
Revision: 0
TREATMENT OF BUTT WELD IN CARBON STEEL PIPE WORK IFA
Document Type: PR System / Subsystem: 00 Discipline: Q Rev. Date: 2-Nov-2010
CONTRACTOR Document: 21119 – PT. SAE-BPK Page 3 of 10

Table of Contents
Section Title Page
1.0 SCOPE 3
2.0 REFERENCES 3
3.0 TEST PACK PREPARATION & PRESSURE TEST 3
4.0 COMPANY INSPECTION COORDINATION 8
5.0 PIPING LENE CHECK AND PUNCH CLEAR 8
6.0 POST TEST COMPLETION 9
 GENERAL PROCEDURE Document Number
FOR GMS-SG-PR-M-004
LOCALIZED ELECTRICAL RESISTANCE POSTWELD HEAT Status:
Revision: 0
TREATMENT OF BUTT WELD IN CARBON STEEL PIPE WORK IFA
Document Type: PR System / Subsystem: 00 Discipline: Q Rev. Date: 2-Nov-2010
CONTRACTOR Document: 21119 – PT. SAE-BPK Page 4 of 10

1.0 SCOPE
This procedure covers the general requirements for Test Pack Preparation and
Pressure Test for piping systems.

2.0 REFERENCES
Process Piping ANSI/ASME 831.3 (latest addition)
Project Specification which as applicable
Project Line Designation Tables (LDT's)
Specification Piping Fabrication, Erection and Testing
Specification Pipeline Cleaning, Gauging, Filling, Hydro testing, Dewatering,
Swabbing, and Drying

3.0 TEST PACK PREPARATION & PRESSURE TEST

3.1 Test Flow Diagram

The basis of Test Flow Diagram preparation shall be in compliance with
Engineering Procedure for Test Block Diagram Preparation
The Test Flow Diagram shall assign a test block number and show the limits for
each piping system to be tested. Each circuit shall indicate the test pressure and
test medium. The Test Flow Diagram shall indicate appropriate symbols or
notes, identify all test blanks and temporary blind flanges, valve positions
whether closed or open and any inline equipment or instruments to be tested
with the piping system or to be removed for the test.

3.2 Test Package

During the preparation of the Test Package, a P&ID check shall be done against
each isometric drawing in the Test Package. Any discrepancies between the two
shall immediately be brought to the attention of the CIC.
P&ID and installed piping shall be same, and if P&ID are required to correct
against the installed piping, P&ID shall be revised in As Built stage.

The CIC test pack co-ordination group shall maintain a control sheet, which will
be used to track the status & location of each test pack
When handover Original or Copy of Test Package between CIC and
Subcontractor, the presenter shall issue attached TRANSMITTAL FOR TEST
PACKAGE.
The test package shall consist of the following documents:
- Piping Test Block Diagram
 GENERAL PROCEDURE Document Number
FOR GMS-SG-PR-M-004
LOCALIZED ELECTRICAL RESISTANCE POSTWELD HEAT Status:
Revision: 0
TREATMENT OF BUTT WELD IN CARBON STEEL PIPE WORK IFA
Document Type: PR System / Subsystem: 00 Discipline: Q Rev. Date: 2-Nov-2010
CONTRACTOR Document: 21119 – PT. SAE-BPK Page 5 of 10

- Latest P&ID Indicating Test Limits

- Test Block Diagram Control List
- Piping Line Check Record
- Piping Pressure Test Report
- Isometrics Drawing
- QC Isometric Drawing
- Piping Line Check Punch-list (internal CII)
- Exception Item List
- NDE Record Summary
- Welding & Material Traceability
- Pressure Gauge and Recorder Calibration Certificate.

Workflow for the test packages shall be attached "WORK FLOW FOR TEST
PACKAGE".
Prior to client line checking, CIC shall submit the test pack include Applicable
QC documents for COMPANY QC review/approval

3.3 Extend of Testing

The test limits of each test pack will be indicated on the Test Block Diagrams.
The following items shall not be subjected to the pressure test:
- Control Valves, Relief Valves, Rupture Discs, Flame Arrestors
- Restriction Orifices Transmitters, Controllers, Pressure Regulators
Permanent Pressure Gauges, Level Gauges
- Steam Traps
- Strainer Baskets, Filter Elements. Expansion Bellows (see Note-1)
- Any other item designated by the Inspector
All items that are removed from the lines during testing must be disconnected by
qualified personnel & properly stored & protected from damage. Instrument
tubing connected to the root valves (first block valve off the process line) shall
be disconnected & not included in the hydrostatic test.
The location of each check valve within the test shall be reviewed for it's effect
on filling, pressuring, draining. If required. The flappers shall be temporarily
removed or the valve removed & replaced by a temporary spool.

Note-1 :
Generally, expansion joints shall not be included in the test. If it is necessary to
 GENERAL PROCEDURE Document Number
FOR GMS-SG-PR-M-004
LOCALIZED ELECTRICAL RESISTANCE POSTWELD HEAT Status:
Revision: 0
TREATMENT OF BUTT WELD IN CARBON STEEL PIPE WORK IFA
Document Type: PR System / Subsystem: 00 Discipline: Q Rev. Date: 2-Nov-2010
CONTRACTOR Document: 21119 – PT. SAE-BPK Page 6 of 10

do so, the Hydrostatic Test Pressure must be verified against the maximum
allowable pressure of the expansion Joint.

3.4 Test Pressure & Test Medium

The test pressure & test medium shall be identified in each Test Package on the
Pressure Piping Test Report. This pressure shall be in accordance with the
LOT's

The test pressure & test medium shall be in accordance with Specification
Piping Fabrication, Erection and Testing

3.5 Holding Time of Pressure Test

The hydrostatic test pressure shall be maintained for a sufficient time to
determine if there are any leaks & shall not be less than 1 hour.
All joints, connection welds shall be examined after 10 minutes at reached final
pressure. Tests shall be monitored to ensure over pressurizing does not occur
due to temperature increases.
Test pressure during test shall be checked by the calibrated test pressure
gauges, and calibrated chart recorder.

3.6. Test Instrument

The calibrated test instrument should be installed to facilitate easy monitoring of
test.
The test instrument shall be identified with a tracking number. This number shall
be recorded on the leak test report. A log shall be maintained in order to track
the number of tests/gauge and the recalibration status. The pressure instrument
gauge used in testing shall be graduated over a range of about double the
intended maximum test pressure, but in no case shall the range be less than 1.5
nor more than 4 times that pressure. Any instrument showing an uncorrectable
zero reading, shall be re-calibrated and certificate.

3.7 Exposed Joints

All joints, including flanges, butt welds, fillet welds, threaded connections and
bonds are to be left un-insulated & exposed for examination during pressure
testing. Joints previously tested in accordance with ANSI/ASME B31.3.
procedure may be insulated or covered.

3. 8 Test Blind
 GENERAL PROCEDURE Document Number
FOR GMS-SG-PR-M-004
LOCALIZED ELECTRICAL RESISTANCE POSTWELD HEAT Status:
Revision: 0
TREATMENT OF BUTT WELD IN CARBON STEEL PIPE WORK IFA
Document Type: PR System / Subsystem: 00 Discipline: Q Rev. Date: 2-Nov-2010
CONTRACTOR Document: 21119 – PT. SAE-BPK Page 7 of 10

The Test Blind with thickness shall be calculated and identified in each Test
Block Diagram.
In case of required additional test blind, the minimum thickness shall be kept
attached "Minimum Thickness of Test Blind Table

3.9. Temporary Gasket for Pressure Test

Temporary Gasket shall be installed to temporary spool and test blind portion.
Temporary Gasket rating shall meet the requirement of Test pressure.

3.9. NDE Requirements

Pressure Testing shall be conducted after all NDE requirements have been
performed.

3.10. Heat Treatment

Pressure testing shall be conducted after the heat treatment (if required) has
been completed & accepted.

3.11. Isolation by Valves

Generally. a test shall not be performed against a closed valve. If a flanged
valve is to be used to isolate the system or falls at a test boundary, a temporary
test blind shall be installed at one flange. If the isolation involves a non-flanged
valve,
the test pressure shall be checked against the max. Allowable seat pressure of
the valve.

3.12. Rotating Equipment Nozzle

To be confirmed to comply with specification for proper fit up for rotating
equipment prior to pressure test.

3.13. Vents & Drains

All permanent process required vents & drains will be part of the piping design
will be indicated on the isometrics. After pressurizing & during the hydro test
these valves shall be plugged/capped and left in a partially ~pened position.

The addition of any temporary vents & drains required for the hydro-test shall be
indicated in the Test Block Diagrams. The fittings used for these temporary
vents/ drains, which will be left as a permanent attachment to the mainline must
conform to the applicable piping specification. Any seal welding (if required) after
 GENERAL PROCEDURE Document Number
FOR GMS-SG-PR-M-004
LOCALIZED ELECTRICAL RESISTANCE POSTWELD HEAT Status:
Revision: 0
TREATMENT OF BUTT WELD IN CARBON STEEL PIPE WORK IFA
Document Type: PR System / Subsystem: 00 Discipline: Q Rev. Date: 2-Nov-2010
CONTRACTOR Document: 21119 – PT. SAE-BPK Page 8 of 10

testing shall be in accordance with piping specification.

3.14. Repairs or Additions After leak Testing

If repairs or additions are made following the leak test, the effected piping shall
be retested, except for minor repairs or additions when the company may waive
retest requirements where other precautionary measures are taken to assure
sound construction.

3.15. Pressurize & Depressurize for Hydrostatic Testing

Vent in piping to be hydrostatically tested shall be opened to remove any air
when filling water.
When the test gage pressure at not less than 725 psig, the pressure shall be
increased gradually in steps to the specified holding pressure.
After successful completion of the pressure test, testing water shall immediately
be drained to avoid remaining in the system. Also, to prevent a vacuum from
forming in the piping, the vent shall be opened first prior draining water

3.16. Pressurize & Depressurize for Pneumatic Testing

The pressure shall be gradually increased until a gage pressure which is the
lesser of one-half the specified test pressure or 25 psig is attained. at which time
a preliminary check shall be made. 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. The test pressure shall be
maintained at least 10 minutes and checked by pressure instrument.
Then the pressure shall be reduced to the design pressure.
The design pressure shall be maintained at least 1 hour for test confirmation.
Test shall be confirmed by chart recorder and all connecti9ns and welded joints
shall be applied bubble test for inspection of leakage.

3.17. Post Test Requirement

Post test requirement for flushing! Blowing, drying shall be carried out.

4.0 CII / COMPANY INSPECTION COORDINATION

4.1. All inspections requiring COMPANY participation shall be initiated with the
attached form "APPLICATION FOR INSPECTION". This application shall be
initiated by the CIC group requesting the inspection only after the work in the
field is verified as being complete and ready for COMPANY inspection.
 GENERAL PROCEDURE Document Number
FOR GMS-SG-PR-M-004
LOCALIZED ELECTRICAL RESISTANCE POSTWELD HEAT Status:
Revision: 0
TREATMENT OF BUTT WELD IN CARBON STEEL PIPE WORK IFA
Document Type: PR System / Subsystem: 00 Discipline: Q Rev. Date: 2-Nov-2010
CONTRACTOR Document: 21119 – PT. SAE-BPK Page 9 of 10

4.2. The application must clearly identify the subject of the inspection, date, time &
location. It shall also indicate if other parties such as user, subcontractor or other
CII disciplines are required to participate. The initiator of this application if
responsible for proper distribution to all parties involved.

4.3. All efforts shall be made by CIC to submit the application to the COMPANY the
previous day of the required inspection.

4.4. CII QC shall maintain close communication with the COMPANY representatives
on scheduling & witnessing of Hydrostatic Tests. In the event of schedule
conflicts and the COMPANY representative are unable to witness the test at the
predetermined time, CIC shall proceed with the test. Shortly there after & at a
time convenient to the COMPANY, CIC shall meet with the COMPANY for
Company's review & approval of the Test Documents

5.0 PIPING LINE CHECK & PUNCH CLEAR

CII and Subcontractor shall perform the piping line check and prepare punch list
in accordance with the latest construction drawing.
The punch items shall be specified by the following 3 categories.
Punch "A" : To be completed before Pressure Test.
Punch "B": To be completed before Piping Mechanical Completion. (Note. 1)
Punch "C" : To be completed after Piping Mechanical Completion. (Note. 2)
Note. 1 : Piping Mechanical Completion means Piping Construction work shall
be completed in accordance with accepted construction drawings and does not
have the same meaning as "Mechanical Completion" under the Contract.

Note. 2: Punch "C" is assigned for unavailable punch clear for JOB-Pertamina
Talisman reason or commissioning reason. Punch "c" is assigned only after
agreed by JOB-Pertamina Talisman..

CII shall submit test package to JOB-Pertamina Talisman for client line check after
cleared all punch "A”.

JOB-Pertamina Talisman comment shall be mentioned in attached the exception

item list with above category.

The pre-test items (Punch "A") shall be completed & signed off prior to the
 GENERAL PROCEDURE Document Number
FOR GMS-SG-PR-M-004
LOCALIZED ELECTRICAL RESISTANCE POSTWELD HEAT Status:
Revision: 0
TREATMENT OF BUTT WELD IN CARBON STEEL PIPE WORK IFA
Document Type: PR System / Subsystem: 00 Discipline: Q Rev. Date: 2-Nov-2010
CONTRACTOR Document: 21119 – PT. SAE-BPK Page 10 of 10

pressure test. Punch "B" may include items involving installation or completion of
permanent supports. It may involve the removal of test blinds after test & the
reinstallation of proper gaskets, reinstallation of control valves, or other items that
need to be removed for test purposes, removal of temp vents or drains & seal
welding of these temporary connections (if applicable), removal of stops on
springs.

6.0 POST TEST COMPLETION

6.1. The pressure test has been completed & the line or lines have been restored &
verified complete by CIC. CIC shall apply for a post test verification to COMPANY.
This post test inspection shall involve the checking & verifying the completion of
the remaining post test items (Punch "8") that are identified on the exception item
list generated the pre-test line check. If all items are completed, the "post test
acceptance" area at the bottom of the etc