Hydrostatic Pressure Test Kick Off Meeting Hyundai.pptx

Hydrostatic Pressure Test

1. Jafurah Gas Plant Expansion - Utilities, Sulfur & Export Facilities PKG-2 21. Aug. 2025 1 Quality Kick Off Meeting FOR HYDROSTATIC PRESSURE TESTING Contract No. 6600051788 (OOK) & 6600051787 (IK) , BI-10-14815 Prepared Piping QC Supervisor(Hyundai) Abdul Mohsin Reviewed QA Manager (Hyundai) D.H. Lee

2. Contents PURPOSE OF THE MEETING SCOPE OF WORK QC ORGANIZATION CHART APPLICABLE CODES STANDARDS & PROJECT SPECIFICATIONS GERERAL REQUIREMENTS INSPECTION & TESTING 7. LESSONS LEARNED 2

3. KICK OF MEETING FO JUNCTION BOX INSTALLATION 1. PURPOSE OF THE MEETING: To fully understand quality requirements of the Hydrostatic Pressure Testing To ensure approved manpower is in place for all QC activities. To ensure approved plans & procedures are in location. To ensure that required Inspection and Tests, SATIP, SAICs & SATR have been identified for implementation. To discuss lesson learned. To ensure with inspection intervention level (W, H, S etc.) as per approved SATIP. To ensure materials are procured from approved supplier. To ensure the Pressure testing activities are performed & inspected as per approved procedures, plans and approved drawings. To ensure all inspections & tests are performed, recorded & documented. 3 KICK OFF MEETING FOR HYDROSTATIC PRESSURE TESTING

4. 4 2. SCOPE OF WORK : This Kick off meeting includes the Piping Pressure Testing under Jafurah Gas Plant Expansion - Utilities, Sulfur & Export Facilities PKG-2 in Kingdom of Saudi Arabia Estimated total of pressure test: 9000 Dia inch 25 packages KICK OFF MEETING FOR HYDROSTATIC PRESSURE TESTING

5. 5 3 . HYUNDAI PH-2 - QC ORGANIZATION CHART KICK OFF MEETING FOR HYDROSTATIC PRESSURE TESTING

6. 6 4. APPLICABLE CODES & STANDARDS & PROJECT SPECIFICATIONS : Schedule Q Contractor's Quality Requirements, (Contract Edition) SAES-A-004 General Requirements For Pressure Testing SAES-A-005 Safety Instruction Sheet SAES-A-007 Hydrostatic Testing Fluids and Lay-up Procedures SAES-L-150 Pressure Testing of Plant Piping and Pipelines SAES-L-310 Design of Plant Piping SAES-L-350 Construction of Plant Piping SAEP-327 Disposal of Wastewater from Cleaning, Flushing, and Hydrostatic Tests SAEP-1160 Tracking and Reporting of Welding, NDT, and Pressure Testing for Capital Projects . SATIP-A-004-02 Hydrostatic Testing of On-Plot Piping ASME B31.3 Process Piping SAES-L-125 Safety instruction for piping and pipeline GI-0002.102 Pressure testing safety. KICK OFF MEETING FOR HYDROSTATIC PRESSURE TESTING

7. 1-5. Milestone and Action Item 7 5. GENERAL REQUIREMENTS KICK OFF MEETING FOR HYDROSTATIC PRESSURE TESTING PROJECT QUALITY OBJECTIVES INCR’s (Con/Subcontractor) LBE’s : 4:1 Preservation Failure Rate : < 5% RFI Acceptance Rate : >95% PQI Average Score Above : 94%

8. 1-5. Milestone and Action Item 8 Safety Requirements Follow the requirements of G.I. 2.102 Obtain work permit from operating organization. Cordon off the testing area. Only qualified personnel shall be involve. Use only proper test equipment. Avoid striking or working on equipment being tested while under pressure. Piping or equipment must be adequately supported. Safe check list that shall be fill previous HT. Controlled pressure rise. KICK OFF MEETING FOR HYDROSTATIC PRESSURE TESTING GENERAL REQUIREMENTS

9. 1-5. Milestone and Action Item 9 Minimum quality requirements to be followed: Approved Written Test Procedure Test Package Pre- Test Inspection Test Equipment Calibrated Instruments & Gauges Company Standards Construction Procedure Safety Instruction Applicable SATIP, SAIC, SATR, etc. KICK OFF MEETING FOR HYDROSTATIC PRESSURE TESTING GENERAL REQUIREMENTS

10. 1-5. Milestone and Action Item 10 Pressure Test Procedure JUS&ICS2-PI-PD-7010_Work procedure for Special process of Pressure Test of Shop Pipe Spools, approved. The test procedure shall be available on site at all times. Manifold Before employing the pressure testing manifold in the actual system pressure test, it shall be separately pressure tested to at least 1.2 times the system test pressure and not less than the discharge pressure of the pump used for the pressure testing. The requirements of Test Manifold used for pressure testing must be as per SAE-A-004, Appendix-B. KICK OFF MEETING FOR HYDROSTATIC PRESSURE TESTING GENERAL REQUIREMENTS

11. 1-5. Milestone and Action Item 11 Pressure Relief Valve Pressure test relief valve(s) of adequate capacity set to relieve at 5% above the Hydrostatic test pressure. The relief valve(s) Validation period Two week . Relief valves shall be calibrated by Aramco Approved Third Party. Pressure gauges, pressure and temperature recorders All gauges and recorders shall be calibrated prior to use. The calibration interval shall not exceed one (1) month prior to the test date and calibration certificates shall be made available to Inspection personnel prior to commencement of the pressure test. Stickers shall be applied indicating the latest calibration date. All gauges shall have a range such that the test pressure is within 30 to 80% of the full range. A minimum of two pressure gauges are required for the test system. One pressure gage shall be on the test manifold and the other(s) on the test system. Their accuracy shall be within 5% of one another. When large systems are tested, Inspection personnel will determine the need for additional gauges. KICK OFF MEETING FOR HYDROSTATIC PRESSURE TESTING GENERAL REQUIREMENTS

12. 1-5. Milestone and Action Item 12 KICK OFF MEETING FOR HYDROSTATIC PRESSURE TESTING GENERAL REQUIREMENTS Water Quality: Water quality follow SAES-A-007 Para 6 table 2 ， see below Table 2 - Hydrostatic Testing/Wet Lay-up Water Quality Material Category Total Bacteria (per mL) SRB (per mL) O2 Conc. (ppb) pH Range TSS (ppm) Chloride Conc. (ppm) I ≤ 10 4 ≤ 10 3 ≤ 20 6-9 ≤ 50 No Restriction II (A) ≤ 10 4 ≤ 10 3 ≤ 20 6-9 ≤ 50 ≤ 50 II (B) ≤ 10 4 ≤ 10 3 ≤ 20 6-9 ≤ 50 ≤ 500 II (C) ≤ 10 4 ≤ 10 3 No Restriction 6-9 ≤ 50 No Restriction II (D) ≤ 10 4 ≤ 10 3 No Restriction 6-9 ≤ 50 No Restriction II (E) ≤ 10 4 ≤ 10 3 No Restriction 6-9 ≤ 50 No Restriction III No Restriction No Restriction No Restriction 6-10 ≤ 50 No Restriction

13. 1-5. Milestone and Action Item 13 KICK OFF MEETING FOR HYDROSTATIC PRESSURE TESTING GENERAL REQUIREMENTS Vents and Drains: Vents shall be provided at all high points in the tested system as needed. Unless the check valve has a by-pass valve, the disc of the check valve shall be removed, and securely attached to the outside of the check valve prior to the pressure test. Isolation: Blinds, end caps or test headers will be used to isolate test sections. They will be the same class rating as the system or may be fabricated based on appropriate calculations. Preliminary Test Instructions: Complete all non-destructive examinations and necessary inspection with the appropriate individual inspector signing off the required documentation (Field Inspection & Test Plan, etc.), Hydro test package shall be reviewed and approved by SAUDI ARAMCO before commencement of hydro test operations. Internal Cleaning: The assembled piping system shall be cleaned as per JUS&ICS-PI-PD-7038_Procedure for Piping internal cleanliness. An activity which is carried out prior to hydrostatic testing that is required for cleaning the internal surfaces of the piping system to an acceptable level of cleanliness using sufficient quantity of clean air for blowing.

14. 1-5. Milestone and Action Item 14 INSPECTION AND TESTING KICK OFF MEETING FOR HYDROSTATIC PRESSURE TESTING Determining Test Pressure (On-Plot Piping) The hydrostatic strength test pressure for every section of new constructed line shall produce a hoop stress in the pipe of 90% of the specified minimum yield strength (SMYS) at the test temperature. The test pressure shall be calculated based on the pipe nominal wall thickness less the mill tolerance (manufacturer's minus tolerance) The test pressure shall not be less than the minimum test pressure per ASME B31.3 paragraph 345.4.2. (a) not less than 1.5 times the design pressure. (b) when the design temperature is greater than the test temperature, the minimum test pressure, at the point under consideration, shall be calculated using eq. Pt = 1.5 PSt /S Where, P = internal design gage pressure Pt = minimum test gage pressure

15. 1-5. Milestone and Action Item 15 KICK OFF MEETING FOR HYDROSTATIC PRESSURE TESTING INSPECTION AND TESTING S = allowable stress at component design temperature for the prevalent pipe material. St = allowable stress at test temperature for the prevalent pipe material. By flange rating or valves in the line (from ASME B16.5 & ASME B16.34) By operating pressure (for service test)

16. 1-5. Milestone and Action Item 16 KICK OFF MEETING FOR HYDROSTATIC PRESSURE TESTING Flow chart control / Distrubution / Handling Packages

17. 1-5. Milestone and Action Item 17 KICK OFF MEETING FOR HYDROSTATIC PRESSURE TESTING

18. 1-5. Milestone and Action Item 18 KICK OFF MEETING FOR HYDROSTATIC PRESSURE TESTING Piping & Instrumentation Diagram (P&ID

19. 1-5. Milestone and Action Item 19 KICK OFF MEETING FOR HYDROSTATIC PRESSURE TESTING Plant Piping Isometric Drawing

20. 1-5. Milestone and Action Item 20 KICK OFF MEETING FOR HYDROSTATIC PRESSURE TESTING Pressurizing of Plant Piping : The test fluid shall be injected at the lowest point in the system to minimize entrapped air. Gradually increase the pressure in the system to 50% of the required test pressure. The isolation valve between the temporary test manifold/piping and the piping/equipment under pressure test shall be closed and the test pump disconnected. Conduct visual inspection for leaks at 50% of test pressure hold 10 minute. Gradually increase the pressure in the system to 100% of the required test pressure. The test pressure shall be maintained for a sufficient time, but shall not be less than 30 minutes, to determine that there are no leaks. All joints including welded shall be left exposed for visual leak detection during the strength test. External coating and priming of such joints are not allowed Visual Inspection Method: During and after the completion of test pressure, conduct a full visual inspection of the system. All welds, threaded/flanged connections, and including valves must be inspected for leaks. INSPECTION AND TESTING

21. 1-5. Milestone and Action Item 21 INSPECTION AND TESTING KICK OFF MEETING FOR HYDROSTATIC PRESSURE TESTING Depressurizing & Test Water Disposal: Upon completion of a successful hydrostatic test release the pressure through the vent valves and bleed valves. The test liquid shall be slowly drained with vents open to prevent collapse of the system. Lay-up of Piping Systems: Follow approved Piping lay up procedure - Hydrostatic Testing Fluids and Lay-up Procedures as per SAES-A-007.

22. 22 38 1-5. Milestone and Action Item KICK OFF MEETING FOR HYDROSTATIC PRESSURE TESTING INSPECTION AND TESTING List of Check Lists to be used: Applicable SAIC for Each Activity:- SAIC-A-2003: Review of test package preparation SAIC- A- 2010: Pre- test punch listing of on plot piping SAIC- L-2017: Piping / Equipment Internal cleaning inspection SAIC –A- 2008: Verification of Test Medium for Hydrostatic Testing SAIC – A- 2009: Verification of Test preparation and test Equipment for pressure Testing SAIC-A-2011: Inspection of Pressure Test Preparation SAIC –A- 2013: Inspection of Filling & pressurization for Hydro testing of piping systems. SAIC –A- 2015: Visual Inspection of pressure test. SAIC-A- 2017: Depressurization & Disposal of Hydro test water SAIC- A- 2018: Lay-up Inspection for piping and vessels

23. 23 39 1-5. Milestone and Action Item KICK OFF MEETING FOR HYDROSTATIC PRESSURE TESTING Applicable SATR for Each Testing:- SATR-A-2001 – Pressure / Leak Test Report SATR-A-2007 – Pre-Pressure Test Checklist SATR-A-2008 – Piping / Equipment Internal Cleaning Inspection SATR-A-2009 – System lay-up verification report and certificate SATR-A-2011 – Re-instatement Checklist SATR-A-2014 – Water Chemistry Report SATR- L- 2001 – Flange joint Tightening Inspection report

24. 24 40 1-5. Milestone and Action Item KICK OFF MEETING FOR HYDROSTATIC PRESSURE TESTING LESSONS LEARNED 01. SAFETY REQUIREMENTS, Follow the requirements of Saudi Aramco G.I. 2.102 – Pressure Testing Safely Obtain work permit from the issuing authority. Approved Test Procedure / Method Statement / Test package Cordon off the testing area. (Black and Yellow) Installation of Hydrotest board near the Test Manifold. Only qualified personnel and trained personnel shall be involved. Use only proper test equipment Avoid striking or working on equipment being tested while under pressure. Valves or equipment must be adequately supported. Controlled pressure rise. Notification to all affected nearby personnel in advance or before the test. Proper disposal of water as a test medium.

25. 25 41 1-5. Milestone and Action Item KICK OFF MEETING FOR HYDROSTATIC PRESSURE TESTING 02. Welding & NDE Status Verification Prior Water Filling: Complete all welding & non-destructive examinations and necessary inspections with the appropriate individual inspector signing off the required documentation. Ensure that test package complied with all necessary documents. Ensure that the package is submitted to Company review prior to date of test. Check whether you have an approved Test Package. Ensure that all pressure gauges / recorders / Relief valve are calibrated and are with in the validity period as per project requirement. and are having valid calibration sticker. Ensure that you have all calibration certificate attached to Test Package. Ensure that you are using a tested manifold which is above the actual test pressure. Ensure that all safety requirements are followed all through out the testing and so on. Ensure that Piping has completed the flushing requirements prior to testing Ensure that you are using Portable Water for Hydro testing (Water Test Report should be attached to test pack). LESSONS LEARNED

26. 26 26 43 1-5. Milestone and Action Item KICK OFF MEETING FOR HYDROSTATIC PRESSURE TESTING Thank you ！ THE END