METHOD STATEMENT FOR

HYDROSTATIC/PNEUMATIC /LEAKAGE
TESTING OF PIPING
Equipment description: ABOVE GROUND / UNDER GROUND PIPING

Tag/Item number(s):N/A

30-01-08

SK

MKM

DVR

IFL

Issued for Implementation

25-11-07

SK

MKM

DVR

IFL

Issued for Implementation

12-07-07

FV

MKM

DVR

CCI

Company Comments Incorporated

24-06-07

FV

MKM

DVR

IFL

Issued for Implementation

05-05-07

FV

MKM

CAS

ICC

Issued for Company Comments

OA

24-04-07

FV

MKM

CAS

IIR

Issued for Internal Review

Rev.

Date

By

Chkd

Appr.

Status

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 1 of 26

Pearl GTL Project

QATAR C8 ETP

Revision reason for issue description

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

TABLE OF CONTENTS
1.0

SCOPE ............................................................................................................................................4

2.0

PURPOSE .......................................................................................................................................4

3.0

DEFINITIONS /TERMS....................................................................................................................4

4.0

REFERENCE DOCUEMNTS...........................................................................................................5

5.0

ORGANIZATION .............................................................................................................................6

6.0

RESPONSIBILITES.........................................................................................................................6

6.1

Construction Manager..................................................................................................................... 6

6.2

Engineering Department ................................................................................................................. 7

6.3

Site Engineer .................................................................................................................................. 7

6.4

QC Department............................................................................................................................... 7

6.5

Hydro-Test Engineer....................................................................................................................... 7

6.6

HSSE Engineer............................................................................................................................... 7

7.0

EXECUTION PROCEDURE ............................................................................................................7

7.1

Line Punching and Test Pack Processing Prior Pressure Test ...................................................... 7

7.2

Punch Item Code ............................................................................................................................ 7

7.3

Equipment / Instruments / Tools ..................................................................................................... 8

7.4

Pipe Cleaning Prior to Test ............................................................................................................. 8

7.5

General Requirements.................................................................................................................... 9

7.6

ABOVE GROUND/UNDER GROUND GRE/GRP/GRVE Piping .................................................... 9

7.6.1 Leakage Test and Leak Test Procedures...............................................................................10

7.7

ABOVE GROUND Metallic Piping ................................................................................................ 10

7.7.1 Hydro Static Testing ...............................................................................................................10
7.7.2 Pneumatic Testing ..................................................................................................................11

8.0

INSPECTION AND ACCEPTANCCE OF PRESSURE TEST.......................................................12

9.0

REINSTATEMENT AFTER THE TEST .........................................................................................12

10.0 FLAWLESS START UP INITIATIVE.............................................................................................12

11.0 PRESSURE TEST ACTIVITY FLOW CHART ..............................................................................13
12.0 JOB SAFETY ANALYSIS .............................................................................................................14
ATTACHMENTS ......................................................................................................................................19
Attachment 1: pre-test PUNCH LIST FORM ........................................................................................... 19
Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 2 of 26

Pearl GTL Project

QATAR C8 ETP

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

Attachment 2: Pre Test Check List Form................................................................................................ 20

Attachment 3: Leak Test Report .............................................................................................................. 21
Attachment 4: Pipe Cleaning Report ....................................................................................................... 22
Attachment 5: Post Test Component Reinstatement Report................................................................... 23
Attachment 6: Test Pack Release Record............................................................................................... 24
Attachment 7: Pressure Test Record....................................................................................................... 25
Attachment 8: Bolt Tightening Report...................................................................................................... 26

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 3 of 26

Pearl GTL Project

QATAR C8 ETP

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

1.0

SCOPE
This document is defines the methodology adopted for the Hydrostatic Testing/Pneumatic
Testing of Above Ground and Under Ground piping system in C8(ETP) of PERALGTL Project
Qatar. The scope also covers the Leakage Test for AOC and Drain Lines.

2.0

PURPOSE
The purpose of the Method Statement is to provide the detailed requirements that shall be
followed when hydrostatic/pneumatic/leakage testing of underground/Above Ground Piping
GRE/GRVE/GRP/CS/SS to insure system integrity.
To ensure that all pressure testing activities are carried out in a planned controlled and safe
manner, in order to prevent harm to people and or damage the equipments.
To ensure only competent persons are involved and all other personnel excluded from the test
area.
To provide necessary induction training to the personal involved in pressure testing operation.

3.0

DEFINITIONS /TERMS
PROJECT

Effluent Treatment Plant - Pearl GTL C8

COMPANY

Qatar Shell GTL Ltd.

CONTRACTOR

VSA Consortium

DOC

Doha Operating Centre

ETP

Effluent Treatment Plant

IC

Implementation Contractor

PMC

Project Management Contractor (JGC/KBR)

VSA Consortium

Consortium, Consortium consisting of O2

Pearl (The OTV S.A., SAIPEM S.A .JV)
And Al Jaber Transport and General
Contracting LLC

TP

Test Pack

GA

General Arrangement Drawing

HSSE

Health, Safety, Security and Environment

DM Water

Demineralised Water

ITR

Inspection and Test Records.

KPI

Key Performance Areas

CS

Carbon Steel

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 4 of 26

Pearl GTL Project

QATAR C8 ETP

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

4.0

SS

Stainless Steel

GRE

Glass Reinforced Epoxy

GRP

Glass Reinforced plastic

GRVE

Glass Reinforced Vinyl Ester

NDT

Non Destructive Testing

QC

Quality Control

REFERENCE DOCUEMNTS
F15032-AJE-0-0000-CMT-PLA-0001_O
(T-4.120.342)

Construction Execution Plan

F15032-SSA-0-0000-PMT-PLA-0001_O
(T-4.116.980)

Project Quality Plan

F15032-SSA-0-0000-HSE-PLA-0001
(T-4.116.982)

Project HSSE Plan

F15032-SSA-0-0000-PMT-PLA-0005
(T-4.132.019)

Flawless Start-Up Plan

F15032-AJE-0-0000-CMT-MST-1897

Fabrication and Erection of Piping

(T-4.143.082)
F15032-AJE-0-0000-CMTMST-1902
(T-4.143.087)

Positive Alloy Material Identification

ASME B31.3

Process Piping

DEP 61.10.08.11

Field inspection prior to commissioning of

Equipments

DEP31.40.40. 38

Hydrostatic pressure testing of new pipelines

DEP31.38.01.31

Shop and Field Fabrication of Piping

DEP 31.38.01.11

Piping General Requirements

T-13.377.441
DEP 30.10.60.18

Quality Control Requirements For Welding

Welding of Metals

DEP 31.38.01.29

Pipe supports

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 5 of 26

Pearl GTL Project

QATAR C8 ETP

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

T-13.377.453

5.0

Specification For Flange Joint Integrity and

Tightness

ORGANIZATION

PROJECT MANAGER

HSE MANAGER
CONSTRUCTION
MANAGER

ENG. DEPT

QC MANAGER

SITE ENGINEER

TEST PACK CO-ORDINATOR

HYDROTEST
ENGINEER

TESTING TEAM

6.0

RESPONSIBILITES

6.1

Construction Manager
Under the guidance of Construction Manager the Site Engineer / HSSE Manager and Hydrotest Engineer shall be responsible for the implementation of the procedure within the ETP
Project.
Under the guidance of Construction Manager the Site Engineer / Hydro test Engineer shall be
responsible for the management of all pressure testing on the work site of the Project

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 6 of 26

Pearl GTL Project

QATAR C8 ETP

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

6.2

Engineering Department
Engineering Department shall prepare a comprehensive Test Pack showing the test limits (In
P&ID, isometric and GA Drawing), test media, test pressure, operating pressure, concessions
and deviation approvals and the relevant forms.

6.3

Site Engineer
Site Engineer shall be responsible for the Test Pack punch list clearance for the pressure test.

6.4

QC Department
QC Engineer shall be responsible for verification of punch list item clearance, correctness of
the Test Pack document, the test coverage of the documented test circuit with respect to P&ID
(PEFS), As Built Drawings / Mark up Drawings and GA Drawings, Witnessing the test and
preparation of documentation.

6.5

Hydro-Test Engineer
Hydro-test Engineer shall be responsible to organise the test, after Quality Control clearance of
the Test Pack for the test .Hydro test Engineer or designated Test Pack coordinator is
responsible for the flow of Test Pack. Over all responsibility of conducting the test, in a safe
manner, lies with the Hydro test Engineer.

6.6

HSSE Engineer
HSSE Engineer shall be responsible to ensure that the correct safety precautions detailed in
this method statement are implemented by the pressure testing team.

7.0

EXECUTION PROCEDURE

7.1

Line Punching and Test Pack Processing Prior Pressure Test

According to the project schedule, Engineering Dept shall prepare the Test pack and transmit
to the Test pack coordinator. TP Coordinator shall transmit the TP to construction Manager to
confirm that the piping system in the concerned TP is ready for test. No punch items are
balance.

7.2

Punch Item Code

A Item -Items if not completed, shall not proceed with pressure test on the grounds of safety
to the system or personnel and/or incomplete test parameters.
B Item -items if not completed, can proceed for pressure test, but shall not proceed for
commissioning.
C -Item which are to be completed in a timely manner before commissioning.
Where A items are activities which can affect the performance/integrity of the system during
hydrostatic / pneumatic / leakage testing namely hot work on the pressure containing part,

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 7 of 26

Pearl GTL Project

QATAR C8 ETP

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

proper supports to the pipe etc. The above activities shall be completed before testing. QC
Manager shall have the final authority to decide the punch item code.
If no A item pending in the Test Pack received by the site engineer, he may transmit the TP to
TP Coordinator for further processing after completing his part in the document. TP is then
transmitted to QC Dept. for punching and ITR documentation. The assigned QC Inspector shall
punch the line and verify NDT completion and documentation, attach weld control sheet. If any
A item balance, TP goes back to Construction Manager through TP Coordinator and returns
through the same channel after A item clearance. After clearance from QC Dept, TP is
transmitted to Company inspector for verification. Once the TP is cleared by Company
inspector and returned to TP Coordinator, it is transmitted to the Hydro-test Engineer for
performance of the test.
Once the test pack received at the test centre, testing team shall check that all the sensitive
instruments are isolated; valves in the test circuits isolated/opened (As the case may be) test
limits are bolted properly, expansion bellows removed or secured and pre test checklist
signed off (attachment 2), correct test medium available, test area barricaded and KEEP
AWAY sign boards ready. Issue Inspection request to the concerned QC personnel for test
witnessing according to relevant ITP, well in advance to the test, but at any case not less than
twenty four hour before the commencement of the test.
7.3

Equipment / Instruments / Tools

The following equipments, instruments and tools shall be available for performing the pressure
test. All test equipment must be rated at an equal or greater working pressure than the test
requirements.

7.4

Pressurising Pump (manual/Air Operated)

Air Compressor

Pre tested Testing manifold complete with isolation valve, PSV, hose etc

Two nos. of pressure gauges with current calibration status and serial number.

Filling pumps With Sufficient capacity and suitability

Calibrated torque Wrench

Thermometer

Test Gaskets, Spades, Blanks and other fittings to conduct the test.

Pipe Cleaning Prior to Test

Piping system to be tested shall be cleaned before hydrostatic/pneumatic/leakage testing of
piping.
Pipe cleaning shall be done with compressed air before erecting the pipe spools and also
before pressure testing.

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 8 of 26

Pearl GTL Project

QATAR C8 ETP

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

For piping spools DN20 and above ,pipe cleaning shall be documented with a pipe cleaning
report (Attachment No4) to ensure that the pipe was cleaned and erected. For all other sizes
Pre test Check list item 20 shall be ensured .Q2 KPI
7.5

General Requirements
Range of pressure gauges selected shall in no case be, less than one and half times or more
than four times of the test pressure.
One pressure gauge shall be on the lowest point (On manifold) and the other on the highest
point of the test circuit.
Vents shall be provided at high points of loops to be tested. Consideration shall be given to the
position of the entire test circuit geometric configuration while providing venting arrangement to
ensure entrapped air is vented out fully.
Piping sub-assemblies may be tested either separately or assembled.
All joints, including welded and bonded, are to be left unpainted and exposed for examination
during testing. (Q8 Key Performance area)
Piping shall be provided with necessary supports in order to support the weight of test medium
Special care may be taken in the case of pipes designed for vapour or gas operating medium,
when tested with water. (Q3B KPI)
If a pressure test is to be maintained for period of time in extreme temperature variation and
the test fluid is subject to thermal expansion, precautions shall be taken to avoid excessive
pressure built up due to this climatic factor. Temperature of test medium shall not go below 5
degree centigrade.
Where ever permanent gaskets and bolts are provided, material correctness shall be cross
checked and proper tightness to be reconfirmed by QC Inspector as a Key Performance area
(Q1)

7.6

ABOVE GROUND/UNDER GROUND GRE/GRP/GRVE Piping

In the case of GRE/GRP/GRVE pipelines, special care shall be taken for proper supporting of
the system.
During water filling and pressurising the following procedure should be maintained.

The pressure shall be gradually increased over a 30 minutes period or longer to 1.5
times design pressure or 0.89 times the qualified pressure, which ever the lower.

Pressure shall be monitored to assure that the pressure drop is not due to
temperature variation or settlement.

Pressure shall be maintained for sufficient time for settlement and then for inspection
of joints.(Settlement time for different pipe size shall be according to manufacturers
recommendation)

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 9 of 26

Pearl GTL Project

QATAR C8 ETP

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

7.6.1

A minimum of 1 hour shall be the holding time for hydro static test. Any leaking or
weeping shall constitute a defect and to be rectified.

Over tightening of flanges not permitted, new gaskets shall be provided and if the
leak still persists, flanges must be replaced and the system retested.

After inspection and acceptance of the test by the witnessing inspectors, Depressurising can commence, by opening of the vent, and following the same gradual
mode used for pressurising the system, so as to avoid shock pressure and damage to
piping system.

Leakage Test and Leak Test Procedures

Open vents, Drains and AOC lines may be subjected to gravity leak tests with water. Holding
time for leak test is one hour minimum, but at any case time sufficient to inspect all joints shall
be provided
For AOC Lines up to 800 mm diameter pipe, the leak test shall be done section by section
between the manholes. The open end of the pipe at one test limit is closed with Plumber
Stopper. Suitable size of vent pipe is fitted to the plumber stopper in such a way that the air is
completely vented and a water head up to the ground level is maintained during the test. The
water head is maintained for stimulating the actual head which may occur during the manhole
test.
The other end of the system is blocked with plumber stopper fitted with NRV and manifold to
fill the water.
For the pipes larger than 800 mm diameter, both pipe ends inside the manholes shall be
sealed with grouting and water proofing as per method statement for excavation and backfilling
of trenches (T-4.143.446) and method Statement for grouting
(T-4.143.448).Then water
shall be filled in the open Manhole and Kept for one hour. All the joints to be checked visually
and recorded on the leak test report (attachment No 3)

7.7

ABOVE GROUND Metallic Piping

7.7.1

Hydro Static Testing

If Test Medium for Low carbon and low alloy steel pipes specified is water, potable water with
250mg/kg salts (Chlorides) are permitted. For Austenitic and Ferrite stainless steel,
condensate, DM water may be used. Alternatively, potable water with maximum concentration
250mg/kg of chlorides may be used, if the system is drained and mechanically cleaned
immediately after the test or flushed with DM water after the completion of the test. Same is
applicable for Duplex stainless steel as well.
Filling the test medium may be completed before the intimated test timing, after fulfilling the
safety measures described in the Job Safety Analysis sheet for this activity. Pressurising shall
commence in the presence of the witnessing inspectors or with their consent only.
System shall be pressurised gradually 1 bar/minute up to 35 bars or 50 % test pressure. Hold
for sufficient time for line stabilisation and then raised to 95% test pressure, then rate shall be

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 10 of 26

Pearl GTL Project

QATAR C8 ETP

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

reduced to 0.5bar/minute until test pressure. Any flange joint leak observed shall be rectified
by tightening bolts after dropping pressure to normal.
The pressure shall be maintained for such time that inspectors can check all joints (Welded
and flanged), or for a minimum of 30 minutes with out any reduction in gauge pressure. For big
system with large volume of test medium, the pressure may be reduced to design/working
pressure during inspection of joints, to overcome complications arising from temperature
variations.
After completion of the test to the satisfaction of the witnessing inspectors, system can be
depressurised gradually to atmospheric pressure. Care shall be taken to open vent to avoid
formation of vacuum. Test medium shall be disposed according to RLIC regulations.

7.7.2

Pneumatic Testing
Pneumatic pressure testing is a dangerous operation due to the high energy contained in the
pressured air. For this reason, hydrostatic pressure testing, the safer method, shall be used
wherever practicable.
The following shall be followed in case of pneumatic testing:

Company notified and permissions/agreements for pneumatic test obtained

Local authorities shall be notified/permission obtained.

Minimum ambient temperature allowed for pneumatic test is 70C.

System of test shall be protected with a pressure relief device having a set pressure
of 10% above the pneumatic test pressure of the system.

The system to be tested shall be correctly isolated.

All valves in the system shall be in the open position.

Testing shall not be conducted in wet weather. Screens or wind protection shall be

Provided if the test would otherwise be impaired.

Clear site area off all personnel except the testing team and witnessing inspectors.

Pressure shall be increased gradually to 50% test pressure and checked for leak of joints.
Then pressure is increased to the test pressure in steps of 10% increments allowing sufficient
time for the system to stabilise temperature and strain. The pressure shall then be reduced to
design pressure and joints shall be inspected with liquid soap solutions for leak. The following
precautions shall be followed during depressurising.

Venting shall be to safe location.

De-pressuring shall be done gradually to avoid pressure shocks

In addition to the above, requirements in APPENDIX 1 of DEP61.10.08.11 GEN. shall be

followed for pneumatic testing of piping systems.
Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 11 of 26

Pearl GTL Project

QATAR C8 ETP

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

8.0

INSPECTION AND ACCEPTANCCE OF PRESSURE TEST

Contractor QC Inspector shall record all test results/details of the pressure test on the pressure
test record form (attachment 7) in the test pack. All the witnessing parties shall sign and stamp
on the record with their comments, if any.

9.0

REINSTATEMENT AFTER THE TEST

After completion and acceptance of the test, blanks , blinds and temporary pup pieces shall
be removed, all operating blinds turned to original positions and all lines and piping
components will be completely drained (except those tested pneumatically). Valves, orifice
plates, expansion joints which have been removed shall be reinstalled with proper gaskets and
stud bolts, Acceptance of line reinstatement shall be documented and signed off the Post test
component reinstatement format (attachment 5) by the parties witnessed the test.

10.0

FLAWLESS START UP INITIATIVE

Flange leakage (Q1), lack of cleanliness of the tested pipes and parts (Q2), improper protection
of instruments (Q3D), inadequate testing of the parts in a system (Q8) are potential Key
Performance Areas for Flawless Start up in the pressure test activity. In this method statement,
the above mentioned Q Areas are highlighted and made flawless with the following actions.

Dedicated team selected based on previous experience pressure test and associated
activity.

Testing team shall attend frequent tool box meeting where site Q captains talk on FSI.

Test circuits are punched by Contractor, and Company Inspectors prior to testing.

All instruments are isolated to assure protection of the instruments.

Pipe cleaning and flushing are witness points to confirm cleanliness and pressure test
is a hold point for contractor, and PMC/company inspection.

Expansion bellows shall be removed / restrained before pressure test to prevent the
damage.

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 12 of 26

Pearl GTL Project

QATAR C8 ETP

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

11.0

PRESSURE TEST ACTIVITY FLOW CHART

ENGINEERING DEPT.
To prepare TP with As
Built and Forms

1
CONSTRUCTION
For confirmation of Line
Completion and Punching

7
TP COORDINATOR
For Processing

HYDROTEST
ENGINEER raise
RFI Perform Test

3
QC Dept.

TO CO-ORDINATOR (FOR SAFE KEEPING)

4
5

Line Punch
NDT/PWHT
Coverage ICS/ITR
Input

8
WITNESS TEST
SIGN TEST
RECORD

PMC For Approval

FLUSHING
COMPLETE

10

QC VSA QC PMC
TEST PACK RELEASE
RECORD SIGNED OFF

12
Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 13 of 26

Pearl GTL Project

QATAR C8 ETP

11

REINSTATEMENT
COMPLETED B
ITEM CLEARED

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

12.0

JOB SAFETY ANALYSIS

JOB BEING ANALYZED :

JSA N: F15032-AJE-0-0000-CMTMST-1889

HYDROSTATIC / PNEUMATIC/ LEAKAGE /

TESTING OF PIPING

REV. N: D

WORK LOCATION : RAS LAFFAN

JOB PERFORMERS : VSA

JSA PERFORMED BY : VSA

DEPARTMENT : HSSE

DATE : 30.01.08

JSA APPROVED BY :

DEPARTMENT :

DATE :

CLIENTS APPROVAL :

CLIENT :

DATE :

WHERE REQUIRED)
General job requirements/common PPE

CHANGING CONDITIONS AND

EMERGENCY PROCEDURES

Stop work, switch off equipment,

Supervisor directs personnel to
nearest and safest Muster point
considering wind direction.

A) HSSE Induction,

Supervisor accounts for all workers.

Missing persons are reported to
HSSE Department.

D) Safety Glasses Dark & Clear,

B) Hard Hat,
C) Hearing Protection

When all clear is given, check with

HSSE Department before resuming
the work.

E) Cotton Coveralls,
F) Safety Shoes/Boots,
G) Hand Gloves Both Cotton and Leather
H) Hi-Visibility Vests
I ) Pre Start Tool Box Talk / TSTI Performed
J) Hard Barricade and Signage On the Area

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 14 of 26

Pearl GTL Project

QATAR C8 ETP

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

No.

Job Steps
Pre-task
briefing
(TSTI) and
inspection

Filling of test
medium
(Water / Air /
Nitrogen)

Hazards

Prob.
M

The work force does not

understand the pre task
briefing therefore does
not understand the
potential dangers and
control measures to be
implemented.

Control Measures
Ensure that the pre task briefing is given out in a language
understood by the work force, have it translated. Ask question
regarding the briefing to get feed back from the staff, this ensures
full comprehension.

Prob.

L.C.

Issue any required PPE and replace PPE that has signs of defect.
PPE must include both hearing protection as well as dust inhalation
protection.

Some of the workers

could be lacking PPE or
using defective PPE.
Test medium leak to
surrounding

Take work permit.

Ensure that lock out & tag out is done correctly.
In case of GRE/GRP/GREV pipe lines, ensure proper supporting to
the system.
Keep the vents open during water filling.

Pressuring
the system by
water

Over pressuring and failure

of pipe line.
High pressure leak through
pipe holes.
Failure of support due to
weight.

Be sure that all air is vented out and then only close the vents.
Use pressure pumps of required capacity.
Pressurise the system gradually@ 1 bar/min & above 90%
pressure @ 0.5 bar/min.
Barricade the area and do not allow unauthorised persons to enter
the area under testing.
During pressurising flange bolts tightening not to be done under
pressure.

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 15 of 26

Pearl GTL Project

QATAR C8 ETP

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

No.

Job Steps

Pressuring
the system by
Air / Nitrogen

Hazards

Prob.

Over pressuring and failure

of pipe line.
High pressure leak through
pipe holes.

Control Measures

Prob.

L.C.

Ensure proper supports are provided to the system.

Use tested and certified pressure gauges.
Use correctly rated test equipments and fittings

Ensure that ambient temperature does not exceed 70c.

Provide a pressure relief valve on the system having a set pressure

of 10% above the test pressure.

Ensure proper isolation.

Do not conduct test in wet weather.
Pressurise the system gradually.
Wait for 10 min. each time after increase of 10% pressure.
Barricade the area and do not allow unauthorised persons to enter
the area under testing.
Ensure proper supports are provided to the system.
Use tested and certified pressure gauges.

Depressurising
and release
of test
medium

Sudden release of
pressure and failure of pipe
due to shock pressure
Release l of test medium in
the work area
Removal of gauge/blinds
before release of pressure

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Use correctly rated fittings and test equipments

Depressurise slowly.
Open the vents.
Collect the test medium (water) in a tank.
Dispose off test medium as per RLC regulations (Send it to ETP)
Do not remove pressure gauges / blinds till the pressure is
completely released.
Unit: 0-0000

Sheet: 16 of 26

Pearl GTL Project

QATAR C8 ETP

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

completely.

No.
6

Job Steps
Falling from a
height.
Falling of tools
from height

Hazards
Hazards associated with
Working at height.

Prob.
M

Control Measures
Provide proper access like scaffolds.
Ensure that the scaffold is having a green tag.
Use full body harness.
Tie the tools to your waist using a rope.

Prob.

L.C.

Emergency Response Plan: During the activity all staff must be aware of the ERP for that activity.
In the event of an injury during this task the HSE Officer shall ensure that first aid treatment is available for the activity. The casualty shall be
treated at the scene in the first instance. Should further treatment be required the closest vehicle to the scene of the incident shall be deemed the
ERP vehicle to take the casualty to the RLIC clinic for further treatment.
In the unlikely event that somebody is struck by debris or the trencher itself the casualty shall not be moved at all unless there is an immediate
threat to life by the location they are in or by the nature of the injuries sustained. RLIC ambulance shall immediately be called to the scene; in the
meantime the Primary First Aider shall ensure the stability of the casualty.
In the event of a fire during the activity then the fire extinguishers at the scene should be used to tackle the blaze if possible, all un required staff
should be evacuated from the location to a pre agreed location at the start of the activity.
RLIC fire service should be called immediately to assist. All engines and electrical sources should be switched off and isolated.
During in any ERP all other activities in the area shall immediately be stopped until advised otherwise by the Senior Staff at the scene.
Once the ERP has been activated and the immediate threat is controlled the Project Management must be informed of the incident or accident, this
should include VSA Consortium, JK.
The scene should be sealed, either by staff or barriers if possible to ensure that his area remains the same for photographs and other investigation
Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 17 of 26

Pearl GTL Project

QATAR C8 ETP

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

steps that may be required. Depending on the nature and severity of the incident the Police may be required to attend the scene and to carry out
their own investigation.
For investigation purposes all people who were involved in the activity are to identify themselves to the HSE Officer to assist in the investigation.
All staff involved in the activity must be aware of this ERP prior to the start of work.

Key: PROB. = Probability, L.C = Legal Compliance

L = Low, unlikely to occur, M = Medium, Possibility it may occur, H= High Probability it will occur.
Checked By (Supervisor/HSE Dept)- To Be Signed Off Before Work Commence
Name, Sign & Date:
Name, Sign & Date:

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 18 of 26

Pearl GTL Project

QATAR C8 ETP

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

ATTACHMENTS

Attachment 1: pre-test PUNCH LIST FORM

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 19 of 26

Pearl GTL Project

QATAR C8 ETP

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

Attachment 2: Pre Test Check List Form

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 20 of 26

Pearl GTL Project

QATAR C8 ETP

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

Attachment 3: Leak Test Report

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 21 of 26

Pearl GTL Project

QATAR C8 ETP

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

Attachment 4: Pipe Cleaning Report

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 22 of 26

Pearl GTL Project

QATAR C8 ETP

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

Attachment 5: Post Test Component Reinstatement Report

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 23 of 26

Pearl GTL Project

QATAR C8 ETP

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

Attachment 6: Test Pack Release Record

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 24 of 26

Pearl GTL Project

QATAR C8 ETP

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

Attachment 7: Pressure Test Record

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 25 of 26

Pearl GTL Project

QATAR C8 ETP

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D

Attachment 8: Bolt Tightening Report

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 26 of 26

Pearl GTL Project

QATAR C8 ETP

Orig. Org.:
VSA

PCWBS: NZ
Contractor Doc No: F15032-AJE-0-0000-CMTMST-1889
Project Doc No:

T-4.143.074 Rev D HYDROSTATIC / PNEUMATIC/ LEAKAGE / TESTING OF PIPING

T-4.143.074

Rev.:D