CONTRACT N UNIT N

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AEGEAN REFINERY PROJECT (ARP) SUBCONTRACTOR DOCUMENT No.

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METHOD STATEMENT

FOR

PRESSURE TEST

0 10.10.2016 ISSUED FOR REVIEW S.GENBAY M.GNGR M.ATLLA

PREPARED CHECKED APPROVED
REV ISSUE DATE REASON FOR ISSUE
BY BY BY
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CONTENTS
1. Purpose .......................................................... Error! Bookmark not defined.

2. Scope ............................................................. Error! Bookmark not defined.

3. References ..................................................... Error! Bookmark not defined.

4. Equipment ...................................................... Error! Bookmark not defined.

5. Manpower ...................................................... Error! Bookmark not defined.

6. Materials ........................................................ Error! Bookmark not defined.

7. Responsibility................................................. Error! Bookmark not defined.

8. Method of Conduit Installation ....................... Error! Bookmark not defined.

9. Quality Control ............................................... Error! Bookmark not defined.

10. HSE Regulations ............................................. Error! Bookmark not defined.

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1. Purpose

The purpose of this method statement is to clarify the Pressure Test activities at
the Aegean Refinery Project (ARP) by ILK TAAHHT SAN. VE TC. LTD T;
located inside Star Refinery in Aliaga / IZMIR.

2. Scope

The method statement identifies the basic system and technique used for the
successful completion of the activities.

3. References
IEC Pressure Test Standards
STGPS-J1 General Specifications Instrumentation
STPGS-J1 sections from 1 to 23. General Instrumentation Specification General
Comments on Instrumentation
000-J-EE-0020100 Construction Specification for Instrument Installation

000-A-EE-0190608 Material Control Procedure Storage

Management and Material Preservation Criteria
000-A-EE-0190611 Preservation Procedure for Equipment
and Materials
000-J-EB-0617001 Instrument Location Plan
000-J-ED-0677001 Process Hook Up Details
000-J-ED-0687001 Pneumatic Hook Up Details
000-J-EE-0020033 Connection vessel & piping details
000-A-EE-0190421 Instrument Install & Test QC plan

000-A-EE-0190407 Construction Subcontractor Quality

Requirement Procedure.
000-A-EE-0190410 Site Construction Quality Plan.

000-A-EE-0190406 Control Procedure for Inspection,

Measuring and Testing Equipment.
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000-A-EE-0190683 Red Marking and As-Built Procedure.

000-A-EE-0190679 Punch List Procedure.

IEC-61511 Safety Instrumented System Standard

ISO 9001:2008 Quality Management System
Ppng and Instrumentation Diagram

4. Equipment

All equipment shall be inspected and approved by the TSGI before attempting
work on site and have valid certificates.

Equipment will be visually checked prior to each major work and validity of
inspection status will be verified.
Tube bender
SS Tube cutter
Hand Pump high pressure
Test Gauge
Portable Air Compressor / Nitrogen Bottle
Tube Fittings
Hand Tools

5. Manpower

All personnel will have been inducted and trained before attempting work on
site and have valid certificates.

Site Engineer
Foreman
Team Leader
Team members
HSE personnel
QC Inspector
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Manpower will be identified by Contractor based on timely completion of the

works as per the project schedule.

6. Materials

Before requisition of the material, Supervisor who is responsible for the job to
be performed will check the Bill of Materials related to the drawing supplied by
the Contractor. Any omissions, shortages, damages and/or discrepancies
observed shall immediately be reported to the Contractor.

Materials off-loaded from Contractor warehouse shall be transported to site

and/or Subcontractor warehouses. Due care shall be given, not to damage the
equipment during transportation.

A final visual inspection shall be performed at the site after the materials are
unloaded to verify the material is in good order, shape and ready to be
installed.

7. Responsibility

7.1 Construction Manager

The Site Manager will provide inputs to the Project execution plan to ensure
that proper strategies & philosophy are addressed.

7.2 E&I Manager

The E&I Manager will check the all installation job as per project documents and
standards. Also should be check together of Civil and Piping activities all
possible interference during the Installation.
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7.3 QA/QC Management

QA/QC Engineer shall ensure quality and compliance during all phases of the
construction.

7.4 HSE Manager

Responsible for the safety control works for all construction sites under the
jurisdiction of his department, inform the site various kinds of safety policies,
Plans
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7.5 Site Engineer/Supervisor

The site engineer/supervisor will perform the necessary studies and check
and will supervise procedures. He will ensure that the work is being carried
out effectively and properly in accordance with established Work Method
Statements and Job Safety Analysis.

7.6 Foreman
Shall be in charge of crew, equipment and material to conduct the work. He
shall organize the site and ensure the site is ready for installation of material.
He shall prepare daily reports for the progress and manpower. He shall be
responsible for maintaining good workmanship and direct the craft installing
the electrical systems. He shall be responsible for receiving and making sure
that all the crew work as per HSE requirements. He shall ensure that work
area is safe and tidy. He reports to supervisor.

8. Method of Pressure Test

The sequence of the Pressure Test activities, can be summarized as follows:

8.1 Pre-Commencement Works

Before each activity the following must be taken into account.

8.1.1 Material Transport from Warehouse

Before start the job, suitable and necessary materials should be taken from
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TSGI warehouse and transport to working/laydown area as per 000-A-EE-

0190608 - Material Control Procedure Storage Management and Material
Preservation Criteria and 000-A-EE-0190611 Preservation Procedure for
Equipment and Materials.

8.1.2 Work Permit

Prior to implementing a Pressure Test activities, a request for a permit to

work submitted. After the related permit is issued, the execution of the work
will be done.

8.1.3 Project Documents & Drawings Checking

Site Engineers should check the all related drawings (Typical Details, Layouts,
etc.) and documents (Method of Statements, specification, related report,
etc) should be get approval by TSGI.

8.1.4 Site Pre-Preparation

Prepare materials and tools use for fabrication of Pressure Test

Scaffoldings shall be prepared prior to installation of the Pressure Test on the

pipe rack or in equipment structures as an access of the worker.

Prepare appropriate tools use for installation of Pressure Test

8.2 Progress of Work

Pressure Test activities will be done as per project specifications and

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instrument data sheet.

Pressure Test shall be routed considering the location of equipments steel

structures and the process pipe routing.

Team has to be applied every step of activity as per drawings & documents.

Forman and Site Engineers should confirm the job has been done as per
drawings & documents during and after.

After job has been done at site as physically, QA/QC inspectors should
checked the job as per approved drawings and documents.

If every step of activity has been done as per drawings & documents, QA/QC
inspector should prepare related check sheet and submit to TSGI to get
signature.

Bolts and nuts shall be tightening properly to resist excessive vibration

during operational stage of the plant.

All activities should be done as per drawing and Document in AFC status and
Vendor specifications. Proper red Line shall be done f any change, previously
checked with Engineering Department.

8.2.1 Preparation prior to Pressure Test :

Obtain work permit from HSE office.

Coordinate in advance to PMC in-charge for works start.
Prepare materials. Tools and Leak Tester use for Air piping, Impulse
tubing Pressure Test
Air piping and Impulse tubing material shall be as per project
specifications and approved.

8.2.2 Impulse Tubing Testing :

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Instrument impulse line need to pressure tested by using

Instrument Air or Nitrogen.
Prior to test the instrument shall be isolated or disconnected
properly and the impulse tubing blown through using nitrogen or air
supply to ensure no debris is present.
The nitrogen cylinder or air compressor complete with regulator,
test gauge and drain or vent point.
Process impulse lines shall be isolated from instruments and
pressure hydraulically 1.5 times of the maximum working pressure.
Initially pressurize the line to a low pressure and check with soap
water test at the corresponding fittings if no leakage found
increases the pressure to the full test pressure.
They shall be isolated from the pressure source and for acceptance,
the pressure reading on a gauge or manometer shall not fall at a
rate exceeding 68.9 millibar or one (1) psi per hour.
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8.2.2.1 INSTRUMENT PIPING/TUBING PRESSURE TEST

Instrument lines between the process isolating valves and the instruments to
which they are connected shall be tested. Prior to the test, the following items
shall be inspected visually:

1. Whether Instruments are correctly installed according to the (P& I)

Engineering Flow Diagram.

2. Whether the upstream and downstream connections of instrument line

for differential pressure type instrument is correct.

3. Whether adequate slope is provided to instrument pressure lead line.

4. Whether sufficient supports are provided to instrument pressure lead

line.
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5. Whether correct materials of the correct ratinq are used for instrument
line.

4.2 TESTING DESCRIPTION

4.2.1 Hydrostatic Test

Instruments process line pressure tests shall be performed hydrostatically at

1.5 times the design Pressure.

Test procedure as per figure Figure.1 Hydrostatic Test:

After closing the process isolating valves and opening the equalizing valve, if
installed, fresh water shall be fed into the pressure lead line. Details are as
follows:

Step 1. Close valves 1,2,8.9

Open valves 3 , 4 , 5 , 6 , 7 .10 - Pump enough water and pressurize system

up to test pressure.

Step 2. Close valves 6,7. Open valve 8 Confirm that pressure gage
indication does not decrease during 2 minutes.

Step 3. Close valves 1,2, 3,5.Open valve 4 and 9,10.

NOTEs:

(1) The analyzer pipeline shall be tested by disconnecting the lead line from
instrument. The test procedure shall be the same with process pipeline.

(2) Test may be performed separately or together with the test for process
piping or equipment.

(3) All instrument piping systems shall be cleaned by air blowing or water
flushing before and/or after the test All joints which are defective shall be
repaired immediately and be retested by the original test
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8.2.3 Air piping Testing:

Prior to testing, the Instrument air tubing connected to instrument

shall be disconnected and the supply sub-header shall be blown-
down to ensure no debris or water is present.

When instrument air is available, instrument air sub headers shall

be service tested, with test gauge at the end and isolate, held for
duration as mentioned in the relevant ITP. The pressure shall not
fall.

The instrument headers and sub-headers shall be installed as per

the approved Instrument hook-up and air supply layout.

Instrument air supply lines shall be isolated from the instrument

and pressurized to 1.5 times the maximum working pressure.

it is later isolated from pressure source and for acceptance, the

pressure reading on a gauge or manometer shall not fall at a rate
exceeding 68.9 millibar or one (1) psi per hour.

Should the test prove unsuccessful, all joints shall be tested with a
soapy water solution; the source of the leak shall be identified,
repaired and tested again.

Testing of pneumatic piping / tubing with liquid is not permitted.

8.2.4 Hydraulc Line Testing:

Hydraulc line need to pressure tested by using water.

All hydraulic lines shall be flushed and pressurized hydraulically 1.5

times of the maximum working pressure.

It shall then be isolated from pressure source and for acceptance;

the pressure reading on a gauge or manometer shall not fall at a
rate exceeding 68.9 millibar or one (1) psi per hour.
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Should the test prove unsuccessful, all joints shall be tested with a
soapy water solution; the source of the leak shall be identified,
repaired and tested again.

8.3 After Work Completion

Before the fnally inspections, housekeepng should be complete. After job has
been completed totally and accepted by TSGI, team has to clean their
working area very well.

Used hand tools should be collected safely and transported to storage

container.

9. Quality Control

The subcontractor E&I QC Inspectors shall be responsible for the necessary

inspection and test to be carried out for all the related activities. They have to
check all related work activities and sure that work execution complies with
the project specification, codes, and standard and other relevant project
documents wherever required. They shall also prepare quality control test
records and documents for final inspection and acceptance by the concerned
department of Contractor / Owner.
QC department are also fully responsible for issuing NFI as per QCP. All
quality control test records and documents, red marks, etc.. will be preserved
by Subcontractor QC department.
Red mark will be prepared for Any changing at site for related drawings
(detail, layouts, wiring diagrams, etc) by supervisor and checked by
nspector then will be submitted to Contractor to get approval. Two copies of
red mark drawings will be given to Contractor, one copy will be kept by
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Subcontractor.

10. HSE Regulations

ILK NAAT TAAHHT SAN. Ve TC. LTD. T. should be fully aware of

the Contractor and Owner Emergency procedures and communicate this
information to its employees for use in the event of major incidents which
may occur.

Personnel Protective Equipment (PPE) to be worn at all time on

site. (Helmet, work glass, safety boot, reflector type vest, etc)
The general environment and working conditions in any area should
be evaluated for hazards, and safety precautions should be taken before
starting work. Personal working around the restricted area must be
informed of hazards involved.

A Toolbox Talk to be conducted prior to commence of any work.

Site facilities (toilet block, smoking point, shade area) shall never be
located close to the work point.

The Site Personnel should ensure that all plant and equipment is
maintained in good condition and free from defects.
Colour coding will be apllied periodically for maintenance tools.
Hot work permit will be used also for cutting of galvanized ladder /
tray application during galvanized pipe installation.

Regular housekeeping is mandatory in the workplace and should be

in daily basis.