P Qac Pro 240 39467 C

AIN TSILA DEVELOPMENT
Main EPC Contract

A-CNT-CON-000-00282
SUB-CONTRACTOR COMMENTS RESPONSE SHEET

PO NO : JI-2045/07-002B
Document Title: HYDROSTATIC TEST PROCEDURE FOR PIPING

Rev: C Sub-Contractor Transmittal No. : TR-GCB EPL-PIUL-0286 Date : 16/11/2022
PIUL Review Transmittal No. : TR-PIUL-GCB EPL-0406 Date : 13/02/2023
PIUL Position
Sl. No. Document No. Rev PIUL COMMENT SUB-CONTRACTOR RESPONSE
( Open or Closed )
01 P-QAC-PRO-240-39467-Rev B Please refer ARH letter attached (page 2) and resubmit the Incorporatd (See below ARH comments: 1, 2, 3, 4, and 5).
documents incorporating comments.
02 P-QAC-PRO-240-39467-Rev B 1-Correct the reference of Algerian regulations mentioned Corrected in page 7 chapter 5.3.1. (Decree N°:21-261)
Closed
on your procedure.
03 P-QAC-PRO-240-39467-Rev B 2-The measuring instruments must be chosen in such a way Corrected in page 11 chapter 7.3 and noted in page 12 chapter 7.4
that the values of the pressures measured are between 1/4 Closed
and 3/4 of the measurement range of the device, and
placed at closest to the high point.
04 P-QAC-PRO-240-39467-Rev B 3-Revise piping attachment, with Test Packs subject to the Revised in page 16 chapter 9.2 (Seet attachement pages 1/6 to 6/6) Closed
provisions of current regulations.
05 P-QAC-PRO-240-39467-Rev B 4- Keep weld joints bare around their entire periphery Added in in page 10 chapter 7.1 Closed
during testing
06 P-QAC-PRO-240-39467-Rev B 5- During the hydrostatic test, no part of the ESP should Added in page 11 chapter 7.3
not be subjected to a stress greater than ninety percent Closed
(90%) of its yield strength at the test temperature.
SUB-CONTRACTOR SIGN OFF
Prepared By: Abdelmalek.BOUHELLOUS COMPANY SIGN OFF

Date : 19/02/2023
PIUL SIGN OFF
Signature:
Date : Date :
Ajay Kumar
Approved By: Abdelmalek.BOUHELLOUS Approved by : _________________________________ Approved by : _________________
Date : 19/02/2023
20/02/2023
Signature: Signature: ____________________________________ Signature: ____________________
Ain Tsila Development
Main EPC Contract
A-CNT-CON-000-00282
Subcontract N°: JI-2045/07-002B
Sub-contractor Name: GCB EPL
PIUL Approval Code

Name:
Signature:
By Ajay Kurup at 2:21 pm, Feb 20, 2023
CODE DEFINITION
1 Accepted without comments

2 Accepted with comments
3 Not Accepted. Revise and

Resubmit
4 For Information
5 Void-Cancelled / Superseded
HYDROSTATIC TEST PROCEDURE FOR PIPING

P-QAC-PRO-240-39467
C Re-Issued for review & comment Feb, 17,2023 A BOUHELLOUS A BOUHELLOUS S. LARBI S. LARBI
B Re-Issued for review & comment Nov, 15,2022 R BELMILOUD A BOUHELLOUS S. LARBI S. LARBI
A Issued for review & comment 02 Jul 2022 A BOUHELLOUS A BOUHELLOUS S. LARBI S. LARBI
Rev Purpose Date Prepared Checked Approved Approved

Document No: P-QAC-PRO-240-39467
Revision C
Revision History
Revision Changes
C Re-Issued For Review & Comments

B Re-Issued For Review & Comments
A Issued For Review & Comments
This revision checked and signed off by:
Name Function or Job Title
Rafik Belmiloud Hydrotest Engineer

Abdelmalek Bouhellous QA/QC Manager
Larbi Said Site Manage
Holds
Hold No. Location Description
Page 2 of 16
Revision C
Contents
REVISION HISTORY 2
CONTENTS 3
Abbreviations 4
1 INTRODUCTION 5
2 PURPOSE OF THE DOCUMENT 5
3 SCOPE OF DOCUMENT 5
4 DEFINITIONS 6
5 REFERENCE DOCUMENTS 6
5.1 Project Reference 6
5.2 Project Specifications 7
5.3 Codes 7
5.3.1 Algerian Codes and Standards 7
5.3.2 International Codes and Standards
6 RESPONSIBILITY 8
6.1 SUBCONTRACTOR – GCB - Responsibilities 8
6.1.1 Piping Engineer 8
6.1.2 Piping Superintendent 8
6.1.3 Piping Supervisor 8
6.1.4 QC ENGINEER 8
6.1.5 QC Inspector 9
6.1.6 HSE Supervisor 9
6.2 CONTRACTOR – PETROFAC - RESPONSIBLITIES 9
7 DESCRIPTION OF ACTIVITIES 10
7.1 GENERAL 10
7.2 TEST PACKAGE DOCUMENTS 10
7.3 TEST PRESSURE 11
7.4 PREPARATION 12
7.5 TEST FLUID 13
7.6 HYDROSTATIC TEST OF PIPING 14
7.7 DISPOSITION TO TAKE AFTER THE 15
7.8 TEST SAFETY 15
8 LIST OF VERIFYING DOCUMENTS 16

9 ATTACHEMENTS 16
9.1 ATTACHEMENT 01 : MINIMUM THICKNESS OF TEST SPADES 16

9.2 ATTACHEMENT 02 : TEST PACK NUMBER LIST 16
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Revision C
Abbreviations
SH SONATRACH
PIUL Petrofac International (UAE) LLC
SC Sub-Contractor ( GCB)
ITP Inspection and Test Plan
QCP Quality Control Procedure
ITR Inspection Test Record
CR Construction Representative
QCE Quality Control Engineer
QCI Quality Control Inspector
QA/QC Quality Assurance/ Quality Control
PPE Personal Protective Equipment
HSSE Health, Safety, Security and Environment
MSDS Material Safety Data Sheet
PDS Product Data Sheet
CMP Construction Management Procedure
ARH Algerian Regulation Hydrocarbons
Engineering, Procurement, Construction,
EPCC
Precommissioning & Commissioning
MAOP Maximum Allowable Operation Pressure
MOP Maximum Operation Pressure
TP Test Pressure
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Revision C
1 INTRODUCTION
GCB hereinafter referred as Subcontractor will execute the (Condensate export pipeline for
Ain Tsila Development Project.) Subcontract on behalf of PETROFAC referred hereafter as
Contractor.
Whereas the SONATRACH, hereinafter collectively referred to as “client” or “COMPANY”
have awarded Petrofac a Contract for EPCC of Ain Tsila Development (hereinafter referred
to as the “Contract” or “Main Contract”).
2 PURPOSE OF THE DOCUMENT

The purpose of this procedure is to define requirements for Hydrostatic Test activities in
order to obtain Safe and consistent Quality activities on Piping Works at Mederba Station
of AinTsila Development Project.
This procedure details the requirements for piping hydro-testing, that is the cleaning, Pressure
Testing, Draining & Drying activities applicable to Ain Tsila Piping at Mederba station.
3 SCOPE OF DOCUMENT
This procedure defines responsibilities and monitoring performances of Hydrostatic Test
activities by GCB in AinTsila Development project.
In case of any conflict between this document and the Project Specification, drawings and
applicable Codes, where Algerian regulations, codes and standards exist, their
recommendations shall always take precedence. Such regulations shall therefore be
deemed to supplement and/or amend the provisions of this procedure.
In the event of conflict between the requirements of this procedure and other referenced
documents, the CONTRACTOR shall request written clarification from COMPANY. The
order of precedence will normally be:
• Algerian Legislation
• Algerian Regulatory Authorities Regulations
• International codes and standards
• COMPANY Philosophy documents
• Project Specifications
Any deviations from these documents shall be agreed with COMPANY prior to
implementation. However, adherence to them does not relieve the SUB-CONTRACTOR of
its obligation to apply good industry practices in the delivery of goods and services to the
Development.
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Revision C
4 DEFINITIONS
The terms and definitions as used within this document are listed below.
“COMPANY” or “SH” means Groupement SONATRACH (the operator of the Ain Tsila
Development)
“CONTRACTOR” or “PIUL” Petrofac International UAE Limited, who is in charge for the
execution of EPC project.
“Sub-contractor” or “SC” Sub-Contractor(GCB), The party that contracts to provide services

or materials necessary for the performance of the contract
“shall” or “must” indicates that the specified action is mandatory (i.e. must be done by
the specified action party)
“should” Indicates that the specified action is recommended but not

mandatory
“will” indicates a commitment by others or a statement of fact
5 REFERENCE DOCUMENTS
5.1 Project Reference

Document Number Description
A-QAC-PLN-000-30000 Project Quality Plan
A-QAC-PRO-000-30014 Procedure for Coordination with Algerian Regulatory Authorities.

A-QAC-PLN-000- 39451 GCB Project Quality Plan
A-QAC-PRO-000-30000 Material Control and Traceability Procedure
A-QAC-PRO-000-30001 Monitoring and Measuring Equipment Control Procedure
A-QAC-PRO-000-30002 Vendor Inspection procedure
A-QAC-PRO-000-30003 Receiving Inspection Procedure
A-QAC-PRO-000-30004 Quality Record Control Procedure.

Qualification and Certification for Measuring and Monitoring
A-QAC-PRO-000-30005
personnel
A-QAC-PRO-000-30008 Quality Auditing Procedure
A-QAC-PRO-000-30009 Non-conforming Item Control Procedure
A-QAC-PRO-000-30010 Corrective Action Procedure
A-QAC-PRO-000-30012 Quality Requirements for Sub-Contractors
A-QAC-PRO-000-30013 Inspection & test control Procedure
Note: In case of conflict with documents, Project Specifications is governing document.
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5.2 Project Specifications

A-PIP-SPE-000-00004 Specification for Preservation and Cleaning of Piping Systems.
A-PIP-SPE-000-30010 : Specification for Pipe Fabrication
A-CIV-SPE-000-30012 : Specification for Underground Piping Systems
Fabrication and Instalation
A-QAC-SPE-000-30005 : Specification for Welding of Piping
A-PIP-SPE-000-00003 : Pressure Testing, and Flushing of Piping Systems
A-PIP-SPE-000-00004 : Specification Preservation and Cleaning of Piping
A-PIP-SPE-000-00006 : Specification Bolt Torquing
A-PIP-SPE-000-00007 : Specification for Material Classes.
5.3 Codes
Current editions of the industry standards including all mandatory addenda in effect at the
time of the order shall apply unless otherwise indicated.
5.3.1 Algerian Codes and Standards
Algerian Gas Pipeline Regles de Security pour les Canalisations de Transport De gas Combustibles
Regulations (Safety Regulations for theTransport by Pipeline of Combustible Gas)
Algerian Liquid Regles de Securite pour les Canalisations de Transport D’Hydrocarbures

Hydrocarbon Liquides (Safety Regulations for the Transport by Pipeline of Liquid
Pipeline Regulations Hydrocarbons)
P-CTE-1 Procédure de traitement des dossiers techniques et modalités d'exécution

des contrôles et essais règlementaires.
Note: French and English side-by-side translation
issued as project document A-PMT-PRO-000-00005.
Decree N° : Applicable for Hydrostatic test of Piping System
21-261 Include Equipment Regulementary under Pressure (ESP).
/ /
5.3.2 International Codes and Standards
ASME B31.3-2016 Process Piping
ASME PCC-2 Repair of Pressure Equipment and Piping
ASME B16.34 Valves Flanged, Threaded and Welding Ends.
API 6D Specification for Pipeline and Piping Valves
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Revision C
6 RESPONSIBILITY
6.1 SUBCONTRACTOR – GCB - Responsibilities

• Completing all Class, A punch list items and obtaining contractor acceptance prior to
test.
• Completing all NDE and obtaining Contractor acceptance prior to test (unless
otherwise advised by Contractor QA/QC Manager).
• Providing and installing all test equipment, including pressure gages, temporary
vent and drain valves, pumps and filling lines.
• Isolating or removing all pressure sensitive instrumentation from pressure test and
providing adequate protection to all other instrumentation.
• Having on hands an ARH approved test procedure.
• Providing adequate written advance notice (minimum 24 hours to Contractor, 10 days
to ARH) to the contractor about time and location of pressure test.
• Providing d o c u m e n t a t i o n as required by Algerian Regulatory Authority (ARH)
to contractor to obtain acceptance of systems that fall within their scope of inspection.
Responsibilities of project personnel related to this procedure are described as below.
6.1.1 Piping Engineer

• Defines the test limits of the test pack.
• Submits the test pack for review and approval by Contractor/Client.
• Ensures that “As Built” drawings are included in the test pack.
• Ensures that necessary temporary supports are identified on Isometric
6.1.2 Piping Superintendent

• Assigns piping supervisors to carry out construction activities.
• Ensures that all construction punch items are cleared prior to QC line check.
6.1.3 Piping Supervisor

• Carries out construction line check against “Pre-Test Checklist”
• Ensures all construction A Punch items are clear prior to QC line check.
• Ensures that all construction B Punch items are recorded on the “Piping Punch List”
((ITR-W-0116X)
6.1.4 QC ENGINEER
• Establish ITP for Piping Hydrostatic Test and equipment installation with the assistance
of site project engineers.
• Ensure inspections and test are conducted as required by the ITP.
• Authorize inspection and test records for submission to Contractor.
• Receives test pack from Piping Superintendent once the test pack is construction A
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Revision C
punch clear.
• Records the time and date test pack is received from construction.
• Arranges document review of test pack.
• Arranges joint QC line check with Subcontractor and Contractor QC.
• Follows up any A punch clearance with construction.
6.1.5 QC Inspector
• Carries out QC line check against “Pre-Test Checklist”
• Raises A & B punch items on the “Piping Punch List”
• Verifies that all A punch items are cleared prior to test.
6.1.6 HSE Supervisor

• The HSE supervisor is responsible for the permanent assessment concerning the full
application of this procedure, also facilitating all inspections and audits related to the
procedure, the HSE team should advise and provide a technical support to all workers
implicated on the work.
6.2 CONTRACTOR – PETROFAC - RESPONSIBLITIES

• Inspection, Verification and acceptance of punch list items prior to pressure test.
• Review and acceptance of NDE prior to pressure test.
• Coordination with ARH witness for inspections.
• Attendance of pressure test at the notified time and location.
• Invite COTRACTOR/ARH for attendance the hydrostatic test where required.
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Revision C
7 DESCRIPTION OF ACTIVITIES
7.1 GENERAL
For piping , the key activities for testing to be addressed are as follows in order of
precedence:
• Before hydrostatic test activities on any piping section is carried out,

Subcontractor Shall ensure that:
✓ The installation of the piping is complete and inspected.
✓ Installation of the piping has been completed to the satisfaction of the
Contractor, Company and ARA.
✓ All construction records are complete and accepted by the Contractor
and Company.
✓ Approved hydro test Construction Method Statements plan are in place.
• All weld joints shull be bare around their entire periphery during testing.
• Produce a detailed hydrostatic testing plan for each test section of piping.
• Initial cleaning to remove construction debris.
• Introduction of water/chemically treated water into piping section.

• Hydrostatic testing to confirm the mechanical strength of the piping.
• Dewatering/cleaning to remove hydro-test water and any residual particulate material.
• Drying/conditioning to preserve the piping sections.
7.2 TEST PACKAGE DOCUMENTS

• The Test Pack consists of cover sheet with identification number of the test Hydro
test ITR`S, punch list, line list, welding summary sheet, marked P & IDs shows the
test limits, marked alignment sheets isometrics show, Cleaning, Water Filling Record,
• Piping and piping systems will be subjected to a hydrostatic test at the Pressure
required by the specifications in the process line list: A-PRO-LST-000-300005
• Contractor shall use the marked up P&ID and Process Line List to acquire testing
pressures for each line to be tested.
• Test packs shall include the following as an index:
 TEST PACK DRAWING REGISTER

 P&ID’S
 APPLICABLE TEST PACK ISOMETRIC’S
o Welding MAP included
o Flanged Joint MAP Included
o Welded Supports – if Applicable
Page 10 of 16
Revision C
✓ WELDING NOTEBOOK (WNB)

✓ BOLT TENSIONING/TORQUING REPORT (BEFOR HYDRO TEST)
✓ PIPEWORK INSTALLATION CHECK LIST
✓ PRE-HYDROSTATIC TEST CHECK LIST
✓ RELEASE FOR HYDROSTATIC TEST
✓ PRESSURE TEST REPORT
✓ POST-HYDROSTATIC TEST CHECK LIST
✓ PUNCH LIST
✓ BOLT TENSIONING/TORQUING REPORT (AFTER HYDRO TEST)
✓ PRESSURE TEST SUMMARY REPORT
✓ SITE QUERY REGISTER
✓ MASTER INSTRUMENT CALIBRATION CERTIFICATE
• Cleaning requirements
After completion of installation and verification of the piping system to be tested; the system
shall be first released for cleaning.
All dirt and sand entered into the piping system shall be removed mechanically, air blown or
flushed. See also Specification Preservation and Cleaning of Piping Systems.
For lines 2 inch and smaller by means of flushing, except seal gas lines, fuel gas lines and
those lines which shall be pneumatic tested (see pneumatic testing).
Lines above 2 inch shall be cleaned by flushing only and/or by means of air blowing prior to
flush (note that the water will cause that debris like sand stick to the walls).
Water quality for flushing shall be at least of same quality as water quality used for hydro-
testing and shall be free of debris, dirt, rust particles, etc.
7.3 TEST PRESSURE
Piping and piping systems will be subjected to a hydrostatic test at the pressure required by
the specifications. The hydrostatic test shall be performed in accordance with the process
Line List. A-PRO-LST-000-300005
Algerian Regulatory Authorities (ARH) requirement:

Below requirements related to hydrostatic test:
• The Pressure test must be at least 1.5 the design pressure.

• During the hydrostatic test, no part of the piping shall be subjected to a stress
greater than ninety percent (90%) of its yield strength at the test temperature.
• The hydro test procedure must be submitted to ARH and approved before using it.
• The presence of the ARH or DME engineer is required.
• The equipment to be hydro tested must not be insulated and all the external shell
should be apparent.
• The measuring instruments must be chosen as the values of the pressure measured
are between ¼ et ¾ of the measuring range of device.
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7.4 PREPARATION
The following items are to be addressed prior to performing hydrostatic tests:
• Test blinds shall be suitably rated to withstand the test pressure and shall comply with
ASME B31.3 and Minimum Thickness Table shown in Attachment I.
• Installing of test blinds and spades at nozzles of rotating and static equipment does not
place unacceptable loads to those nozzles.
• Instrument impulse lines may be tested separately from the piping system to which it
connects.
• Sufficient and adequate temporary supports have been installed. Stops have not been
removed from strings.
• Provision of scaffolding for access for inspection of test system if necessary.
• All pressure sensitive instrumentation has been isolated from the test system.
• Control valves and pressure relief valves have been isolated from the test system.
• Hydrostatic test vents and drains are installed to permit venting and draining of the test
system.
• NDE completed and accepted by QC Inspectors.
• Test blind location has been verified against isometrics and P & ID’s for the test
system.
• All class “A” punch list items have been completed and accepted.
• The calibration certificates will be included in the field testing package and shall be
applicable.
• Contractor and all employees should be aware that piping spools shall be subjected to
high pressure, and as such, all safety protocols shall be observed to ensure materials
meet the correct rating and specifications.
• Equipment to be used during testing shall have suitable capacity for the range of test.
• Needle pressure gauges shall be selected so that the measured pressure values are
between ¼ and ¾ of the measuring range of the device..
• All pressure gauges shall have updated calibration certificates.
• At least two (2) pressure gauges per test system shall be installed. One (1) gauge at the
test pump discharge and one (1) at or near the highest point of the test system. For large
systems, more pressure gauges shall be installed at suitable locations
• Hydro test calculation sheets to provide the calculation pressure at the high and low
test line points and manifold location.
• Contractor shall ensure a manifold and all connections, material and equipment used
are rated to the test pressure, and outfitted with the following:
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Revision C
✓ Pressure & temperature gauges of the correct rating and range.

✓ High point vent outfitted with a gate valve (blind flange shall be connected during
hold period).
✓ Filling connection with a DBB gate valve arrangement.
✓ Rated Pump and water storage.
• The pressure & temperature gauges shall be connected where it will be visible to the
operator throughout the hydrostatic test duration.
• Piping and piping systems will be subjected to a hydrostatic test at the pressure stated
in the Process A-PRO-LST-000-300005
• Prior to hydrostatic test of any piping system all heat treatment and NDE required
within the test limits will be completed and accepted.
• Surface treatment of welds is not permitted after all NDT requirements completed.
• The test pressure will not be applied until the piping or piping system and the
pressuring medium are at about the same temperature.
• All hydrostatic tests will be performed according to an individual test pack containing
exact parameters of the test.
7.5 TEST FLUID:
• Hydro test shall be performed by clean fresh water, free from foreign material such as
sand, dirt, rust etc.
• As per Specification of Pressure Testing and Re-instatement of Piping System (Doc.
No: A-PIP-SPE-000-00003),
✓ a) CS & LTCS piping to be tested with potable water with maximum 250 ppm
chloride content and PH value between 6-8.
✓ b) Austenitic Stainless Steel (e.g. 316/316L) Piping to be tested with Demineralized
water (the content of chloride should be less than 50 ppm) as per ASME PCC2 2018
code.
✓ c) Duplex Stainless Steel Piping may be tested with Potable water (maximum 250
ppm chlorides), as it is higher resistance duplex stainless steel is not susceptible to
chloride attack at 250 ppm. The complete system shall be drained immediately after
hydro testing, Hot air blowing is not allowed.
In the context of this specification, the term “potable water” means water having a chloride
content of no more than 250 mg/kg (250 ppm).
In the context of this specification, the term “demineralized water” means water having a
chloride should be less than 50 ppm.
• Pneumatic test shall be performed using Air.
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7.6 HYDROSTATIC TEST OF PIPING
• Water will be introduced into the piping or piping system at the lower point, and the
air bled off through a partially open vent valve or loose flange at the highest point.
• If there is a place in the piping or piping system where a sizable volume of air could
be trapped, a provision will be made for evacuation of the air.
• Take a temperature reading of metal to insure that it is above the minimum required;
this will be done after filling and bleeding the system but before applying pressure.
Also to include the ground temperature or atmospheric temperature as a comparison.
• The system under test shall be pressurized gradually to 50% of the required test
pressure or 1.7 bar g, whichever is less.
• Hold this pressure for 10 minutes and visually examine the piping system.
• When no leaks are detected the pressure shall be gradually increased to a value of
25%, then 50% of the required test pressure. Thereafter the pressure shall be
increased in steps of approximately 10% of the required test pressure until the required
test pressure is reached. At each increment the pressure will be held for 5 minutes’
minimum to allow piping to equalize strains.
• Timing of the test shall start when the test pressure has stabilized. Under
no circumstances shall this period be less than 30 minutes unless specific piping
codes require otherwise.
• The pressure reading shall be taken at the lowest point in a system (the static load
must be taken into consideration). increments, and until final test pressure (100%) is
observed. If pressure drop is observed during holding time, all leak point(s) shall be
located.
• During the pressurizing stage, check seals, seats, and gasket joints for leakage. If
tightening is required to stop leaks.
• The test pressure shall be reduced to design pressure and all joints (threaded,
welded, and flanged) shall be tested for leaks using the test solution. All leaks and
defects shall be marked.
• If the leak is from a weld connection, then system needs to be slowly
depressurized and drained to allow repair works followed by NDE to be done.
• If any leaks are identified, the system shall be depressurized and repairs performed.
• After repairs are completed and subjected to NDE, contractor shall repeat the
hydrostatic testing until the test is successful and signed off.
• Underground atmospheric lines to be "full of liquid" tested shall be filled with water for
at least 24 hours before visible inspection of the complete test system by the
inspection team.
• Water level in the test system shall be checked and marked at the start of the test and
rechecked after twenty-four (24) hours during visible inspection of the system.
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7.7 DISPOSITION TO TAKE AFTER THE TEST
• Once the tests are accepted, the depressurization of the piping system shall continue
with the hold/stabilization periods at 75%, 50%, 25% decrements until you reach the
atmospheric pressure.
• All lines and equipment shall be completely drained of the test fluid. Piping systems
vents shall be opened while draining to avoid vacuum. Special attention shall be given
to points where water may be trapped, such as in valve bodies or low points. Piping
and equipment shall be dried to the satisfaction of Contractor.
• The After draining /Drying water SS/DSS: -2 deg C dew point is a must and it shall be
measured. LTCS/CS: the lines shall be properly dried and blotting paper check.
7.8 SAFETY
• To ensure the safety of personnel conducting hydrostatic tests, we must define the
area with warning tape have the following sentence:
(CAUTION: DO NOT APPROACH DANGER: HYDROSTATIC TEST)
• The safety distances are 10 meter at least for hydrostatic tests. The safety Instructions
must be observed by all staff.
• For each event specific work permits must be established to ensure that all safety
measures have been taken. In case of increase in pressure in the ambient temperature
effect of more than 5% above the test pressure, we must bring it to the required value
by opening a drain valve.
• Patrolling the perimeter of the test area from the time of erection of barriers until such
time that the system is fully depressurized.
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Revision C
8 LIST OF VERIFYING DOCUMENTS:
No. Project ITR Number ITR Number Description

1 JI-2045- ITR-W-0116X ITR-W-0116X Punch List for Piping Work
2 JI-2045- ITR-W-0117X ITR-W-0117X Pipe Cleaning / Draining / Dry Out Record
3 JI-2045- ITR-W-0118A ITR-W-0118A Piping System Release Report for Pressure Test
4 JI-2045- ITR-W-0119A ITR-W-0119A Piping Pressure Test Report
5 JI-2045- ITR-W-0120A ITR-W-0120A Post Pressure Test – Reinstatement Checklist
9 ATTACHEMENTS:
9.1 ATTACHEMENT 01: MINIMUM THICKNESS OF TEST SPADES (MM)
MINIMUM THICKNESS OF TEST SPADES (MM)

PIPE SIZE TEST PRESSURE
INCHES (BARG)
(DN) 10.3 20.6 31.0 41.3 51.7 62.0 72.3 82.7 93 103
4 (100) 6.0 8.0 10.0 12.0 12.0 12.0 13.0 14.0 15.0 16.0
5 (125) 6.0 10.0 12.0 13.0 14.0 16.0 16.0 18.0 18.0 20.0
6 (150) 8.0 12.0 13.0 15.0 18.0 18.0 19.0 20.0 22.0 22.0
8 (200) 10.0 14.0 16.0 20.0 22.0 22.0 24.0 26.0 28.0 30.0
10 (250) 12.0 18.0 20.0 24.0 26.0 28.0 29.0 32.0 34.0 36.0
12 (300) 14.0 20.0 24.0 28.0 32.0 32.0 35.0 38.0 40.0 42.0
14 (350) 15.0 22.0 26.0 30.0 34.0 36.0 38.0 42.0 44.0 46.0
16 (400) 18.0 24.0 30.0 34.0 38.0 42.0 44.0 48.0 50.0 52.0
18 (450) 20.0 28.0 34.0 38.0 44.0 46.0 50.0 52.0 56.0 60.0
20 (500) 22.0 30.0 36.0 42.0 48.0 52.0 55.0 60.0 62.0 66.0
24 (600) 26.0 36.0 44.0 50.0 56.0 62.0 66.0 72.0 75.0 80.0
9.2 ATTACHEMENT 02: PIPING TEST-PACK DATA
Page 16 of 16
TEST PACK NUMBER LIST
TEST PACK NUMBER AREA LINE NUMBER ISO-TITLE TEST TEST MATERIAL PIPING AG NOMINAL JOINT JOINT JOINT JOIN JOINT SCHEDULE FLUID TYPE DESIGN ARH
MEDUM PRESSURE TYPE CLASS UG CLASS No NAME TYPE T THK PRESSURE YES / NO
(Bar) SIZE (mm) (Bar)
(")
12"-PH-240002-D02L-2-NI PH-240002-2541A-01 LTCS_SOUR D02L-2 AG 1 SHOP BW 12 17,48 SCH80 PROCESS FLUID
12"-PH-240002-D02L-2-NI PH-240002-2541A-01 LTCS_SOUR D02L-2 AG 2 SHOP LET 4 8,56 SCH80 PROCESS FLUID
12"-PH-240002-D02L-2-NI PH-240002-2541A-01 LTCS_SOUR D02L-2 AG 3 FIELD BW 4 8,56 SCH80 PROCESS FLUID
12"-PH-240002-D02L-2-NI PH-240002-2541A-01 LTCS_SOUR D02L-2 AG 6 SHOP LET 1,5 7,14 SCH160 PROCESS FLUID
12"-PH-240002-D02L-2-NI PH-240002-2541A-01 LTCS_SOUR D02L-2 AG 7 FIELD BW 1,5 7,14 SCH160 PROCESS FLUID
12"-PH-240002-D02L-2-NI PH-240002-2541A-03 LTCS_SOUR D02L-2 AG S1 SUP FW 12 17,48 SCH80 PROCESS FLUID
12"-PH-240002-D02L-2-NI PH-240002-2541A-04 LTCS_SOUR D02L-2 AG 7 SHOP LET 2 8,74 SCH160 PROCESS FLUID
CONDENSATE PIG
240-01-01-TP0001 12"-PH-240002-D02L-2-NI PH-240002-2541A-05 WATER 97,67 LTCS_SOUR D02L-2 AG 600 5 SHOP BW 12 17,48 SCH80 PROCESS FLUID 65 YES
RECEIVER AREA
Page 1 de 6
(")
12"-PH-240002-D02L-2-NI PH-240002-2541A-09 LTCS_SOUR D02L-2 AG 11 FIELD THD 0,5 NA 600 PROCESS FLUID
CONDENSATE PIG 12"-PH-240002-D02L-2-NI PH-240002-2541A-09 LTCS_SOUR D02L-2 AG 16 SHOP BW 12 17,48 SCH80 PROCESS FLUID
240-01-01-TP0002 WATER 97,67 600 65 YES
RECEIVER AREA 12"-PH-240002-D02L-2-NI PH-240002-2541A-09 LTCS_SOUR D02L-2 AG 2 SHOP LET 2 8,74 SCH160 PROCESS FLUID
Page 2 de 6
(")
CONDENSATE PIG
240-01-01-TP0002B 12"-PH-240003-D02L-2-NI PH-240003-2541A-02 WATER 97,67 LTCS_SOUR D02L-2 AG 600 6 SHOP LET 2 8,74 SCH160 PROCESS FLUID 65 YES
RECEIVER AREA
12"-PH-240003-D02L-2-NI PH-240003-2541A-03 LTCS_SOUR D02L-2 AG NA NA NA 12 NA 600 PROCESS FLUID
12"-PH-240025-D02L-2-NI PH-240025-2540U-01 LTCS_SOUR D02L-2 UG 16 FIELD BW 12 17,48 SCH80 PROCESS FLUID
CONDENSATE PIG
240-01-01-TP0003 12"-PH-240025-D02L-2-NI PH-240025-2540U-01 WATER 97,67 LTCS_SOUR D02L-2 UG 600 2 SHOP BW 12 17,48 SCH80 PROCESS FLUID 65 YES
RECEIVER AREA
12"-PH-240025-D02L-2-NI PH-240025-2540U-01 LTCS_SOUR D02L-2 UG 4 SHOP BW 12 17,48 SCH80 PROCESS FLUID
2"-PH-240022-A02I-2-NI PH-240022-2541A-01 LTCS_SOUR A02I-2 AG 1 SHOP BW 2 5,54 SCH80 PROCESS FLUID
4"-PH-240027-A02I-2-NI PH-240027-2541A-01 LTCS_SOUR A02I-2 AG 1 FIELD BW 2 5,54 SCH80 PROCESS FLUID
4"-PH-240027-A02I-2-NI PH-240027-2541A-01 LTCS_SOUR A02I-2 AG 3 SHOP LET 0,75 3,91 SCH80 PROCESS FLUID
CONDENSATE PIG 4"-PH-240027-A02I-2-NI PH-240027-2541A-01 LTCS_SOUR A02I-2 AG 5 SHOP BW 4 6,02 SCH40 PROCESS FLUID
240-01-02-TP0001 WATER 5,26 150 3,5 NO
RECEIVER AREA 4"-PH-240027-A02I-2-NI PH-240027-2541A-01 LTCS_SOUR A02I-2 AG 6 SHOP BW 4 6,02 SCH40 PROCESS FLUID
4"-PH-240027-A02I-2-NI PH-240027-2541A-01 LTCS_SOUR A02I-2 AG S1 SUP FW 4 6,02 SCH40 PROCESS FLUID
2"-PH-240032-A02I-2-NI PH-240032-2541A-01 LTCS_SOUR A02I-2 AG 3 FIELD BW 0,75 3,91 SCH80 PROCESS FLUID
240-01-02-TP0002 WATER 5,26 150 3,5 NO
Page 3 de 6
(")
4"-PH-240043-A02I-2-NI PH-240043-2540U-01 LTCS_SOUR A02I-2 UG 1 SHOP BW 4 6,02 SCH40 PROCESS FLUID
4"-PH-240043-A02I-2-NI PH-240043-2540U-01 LTCS_SOUR A02I-2 UG 4 FIELD BW 4 6,02 SCH40 PROCESS FLUID
CONDENSATE PIG
240-01-02-TP0003 4"-PH-240044-A02I-2-NI PH-240044-2540U-01 WATER 5,26 LTCS_SOUR A02I-2 UG 150 13 FIELD BW 4 6,02 SCH40 PROCESS FLUID 3,5 NO
RECEIVER AREA
CONDENSATE PIG
240-01-02-TP0011 RECEIVER AREA 2"-PH-240028-D02L-2-NI PH-240028-2541A-01 WATER 133,73 LTCS_SOUR D02L-2 AG 600 NA NA NA 2 NA 600 PROCESS FLUID 89 NO
240-01-03-TP0012 WATER 133,73 600 89 NO
RECEIVER AREA 2"-PH-240019-D02L-2-NI PH-240019-2541A-01 LTCS_SOUR D02L-2 AG 7 FIELD BW 2 8,74 SCH160 PROCESS FLUID
Page 4 de 6
(")
2"-OD-240002-A02I-2-NI OD-240002-2541A-01 LTCS_SOUR A02I-2 AG 1 SHOP BW 2 5,54 SCH80 OILY DRAIN
2"-OD-240002-A02I-2-NI OD-240002-2541A-01 LTCS_SOUR A02I-2 AG 2 FIELD BW 2 5,54 SCH80 OILY DRAIN
CONDENSATE PIG
240-01-03-TP0013 2"-OD-240002-A02I-2-NI OD-240002-2541A-01 WATER 5,26 LTCS_SOUR A02I-2 AG 150 6 SHOP BW 2 5,54 SCH80 OILY DRAIN 3,5 NO
RECEIVER AREA
2"-OD-240002-A02I-2-NI OD-240002-2541A-01 LTCS_SOUR A02I-2 AG S1 SUP FW 4 6,02 SCH40 OILY DRAIN
CONDENSATE PIG
240-01-03-TP0014 12"-PH-240002-D02L-2-NI PH-240002-2541A-11 WATER 97,67 LTCS_SOUR D02L-2 AG 600 4 SHOP BW 4 8,56 SCH80 PROCESS FLUID 65 YES
RECEIVER AREA
240-01-03-TP0015 WATER 97,67 600 65 NO
RECEIVER AREA 3"-PH-240006-D02L-2-NI PH-240006-2541A-01 LTCS_SOUR D02L-2 AG 8 SHOP LET 1 6,35 SCH160 PROCESS FLUID
240-01-03-TP0016 WATER 133,73 600 89 NO
RECEIVER AREA 2"-PH-240023-D02L-2-NI PH-240023-2541A-01 LTCS_SOUR D02L-2 AG 7 SHOP BW 2 8,74 SCH160 PROCESS FLUID
240-01-03-TP0017 WATER 5,26 600 3,5 NO
Page 5 de 6
(")
240-01-03-TP0018 WATER 133,73 600 89 NO
RECEIVER AREA 2"-PH-240021-D02L-2-NI PH-240021-2541A-01 LTCS_SOUR D02L-2 AG 5 SHOP BW 2 8,74 SCH160 PROCESS FLUID
2"-VT-240004-D02L-2-NI PH-240004K2-2541A-01 LTCS_SOUR D02L-2 AG NA NA NA 2 NA 600 VESSEL TRIM
CONDENSATE PIG 2"-VT-240004-D02L-2-NI PH-240004K3-2541A-01 LTCS_SOUR D02L-2 AG NA NA NA 2 NA 600 VESSEL TRIM
240-01-03-TP0019 WATER 97,67 600 65 NO
RECEIVER AREA 2"-VT-240004-D02L-2-NI PH-240004K4-2541A-01 LTCS_SOUR D02L-2 AG NA NA NA 2 NA 600 VESSEL TRIM
2"-VT-240004-D02L-2-NI PH-240004K5-2541A-01 LTCS_SOUR D02L-2 AG NA NA NA 2 NA 600 VESSEL TRIM
12"-PH-240036-B02I-2-NI PH-240036-2551A-01 LTCS_SOUR B02I-2 AG 3 FIELD BW 12 10,31 SCH40 PROCESS FLUID
12"-PH-240036-B02I-2-NI PH-240036-2551A-01 LTCS_SOUR B02I-2 AG 1 SHOP BW 12 10,31 SCH40 PROCESS FLUID
CONDENSATE PIG
240-01-06-TP0001 12"-PH-240036-B02I-2-NI PH-240036-2551A-01 WATER 54,09 LTCS_SOUR B02I-2 AG 600 2 FIELD BW 12 10,31 SCH40 PROCESS FLUID 36 YES
RECEIVER AREA
12"-PH-240041-B02I-2-NI PH-240041-2551A-01 LTCS_SOUR B02I-2 AG 1 SHOP BW 16 12,7 SCH40 PROCESS FLUID
12"-PH-240041-B02I-2-NI PH-240041-2551A-01 LTCS_SOUR B02I-2 AG 2 FIELD BW 24 14,27 SCH30 PROCESS FLUID
Page 6 de 6

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AIN TSILA DEVELOPMENT

Main EPC Contract

SUB-CONTRACTOR COMMENTS RESPONSE SHEET

Document Title: HYDROSTATIC TEST PROCEDURE FOR PIPING

PIUL Review Transmittal No. : TR-PIUL-GCB EPL-0406 Date : 13/02/2023

SUB-CONTRACTOR SIGN OFF

Prepared By: Abdelmalek.BOUHELLOUS COMPANY SIGN OFF

Main EPC Contract

Subcontract N°: JI-2045/07-002B

Sub-contractor Name: GCB EPL

PIUL Approval Code

1 Accepted without comments

3 Not Accepted. Revise and

HYDROSTATIC TEST PROCEDURE FOR PIPING

Rev Purpose Date Prepared Checked Approved Approved

C Re-Issued For Review & Comments

A Issued For Review & Comments

This revision checked and signed off by:

Name Function or Job Title

Rafik Belmiloud Hydrotest Engineer

8 LIST OF VERIFYING DOCUMENTS 16

9.1 ATTACHEMENT 01 : MINIMUM THICKNESS OF TEST SPADES 16

2 PURPOSE OF THE DOCUMENT

“Sub-contractor” or “SC” Sub-Contractor(GCB), The party that contracts to provide services

“should” Indicates that the specified action is recommended but not

“will” indicates a commitment by others or a statement of fact

5.1 Project Reference

A-QAC-PRO-000-30014 Procedure for Coordination with Algerian Regulatory Authorities.

A-QAC-PRO-000-30000 Material Control and Traceability Procedure

A-QAC-PRO-000-30001 Monitoring and Measuring Equipment Control Procedure

A-QAC-PRO-000-30002 Vendor Inspection procedure

A-QAC-PRO-000-30003 Receiving Inspection Procedure

A-QAC-PRO-000-30004 Quality Record Control Procedure.

A-QAC-PRO-000-30009 Non-conforming Item Control Procedure

A-QAC-PRO-000-30010 Corrective Action Procedure

A-QAC-PRO-000-30012 Quality Requirements for Sub-Contractors

A-QAC-PRO-000-30013 Inspection & test control Procedure

Note: In case of conflict with documents, Project Specifications is governing document.

5.2 Project Specifications

5.3.1 Algerian Codes and Standards

Algerian Liquid Regles de Securite pour les Canalisations de Transport D’Hydrocarbures

P-CTE-1 Procédure de traitement des dossiers techniques et modalités d'exécution

Decree N° : Applicable for Hydrostatic test of Piping System

21-261 Include Equipment Regulementary under Pressure (ESP).

5.3.2 International Codes and Standards

ASME B31.3-2016 Process Piping

ASME PCC-2 Repair of Pressure Equipment and Piping

ASME B16.34 Valves Flanged, Threaded and Welding Ends.

API 6D Specification for Pipeline and Piping Valves

6.1 SUBCONTRACTOR – GCB - Responsibilities

6.1.1 Piping Engineer

6.1.2 Piping Superintendent

6.1.3 Piping Supervisor

6.1.6 HSE Supervisor

6.2 CONTRACTOR – PETROFAC - RESPONSIBLITIES

• Before hydrostatic test activities on any piping section is carried out,

• Introduction of water/chemically treated water into piping section.

7.2 TEST PACKAGE DOCUMENTS

• Test packs shall include the following as an index: