Nawppl-Bims-Nppl-320-Pl-Pro-00002 - 000 - Pre-Test of Test Headers Procedure PDF

Contractor: Engineering: Project: Company:
NAWARA PROJECT
(PIPELINE)
Contract n°:OTP/PP/189 OMV/BIMS EPCC PPL

Contractor doc. n°: Engineering doc. n°: Job n°: P13IT02472 Company doc. n°:
NAWPPL-BIMS-NPPL-320-PL-PRO-00002 Sheet: 1 1 of 28 Class 1 NAWPPL-BIMS-NPPL-320-PL-PRO-00002
:
NAWARA PROJECT (PIPELINE)
PRE-TEST OF TEST HEADERS PROCEDURE
000 14/09/2016 Issue for Use/ Construction LPA ABG MTO

C02 22/08/2016 :/CO:/CONSTRUCTION
Issued for Approval LPA ABG MTO C
C01 20/07/2016 Issue for OMV Review LPA ABG MTO C
Rev. Date REVISION TITLE PREPARED CHECKED APPROVED COMPANY
This document is the property of ETAP & OMV. It shall not be copied, reproduced and circulated without the Authorization of ETAP & OMV
Contractor doc. n°: Engineering doc. n°: Rev.: C01 C02 000 Company doc. n°:
NAWPPL-BIMS-NPPL-320-PL-PRO-00002 Sheet: 2 of 28 Class: 1 NAWPPL-BIMS-NPPL-320-PL-PRO-00002
INDEX
1 INTRODUCTION .......................................................................................................... 3
1.1 Project Overview ................................................................................................... 3
1.2 Scope .................................................................................................................... 4
1.3 Definitions .............................................................................................................. 4
1.4 Abbreviations ......................................................................................................... 4
2 REFERENCE DOCUMENTS ........................................................................................ 5
2.1 Project documents ................................................................................................. 5
2.2 INTERNATIONAL STANDARDS ........................................................................... 5
2.3 NATIONAL CODES / STANDARDS ...................................................................... 5
3 RESPONSIBILITIES ..................................................................................................... 6
3.1 Site Manager ......................................................................................................... 6
3.2 Quality Manager .................................................................................................... 6
3.3 Quality Inspector .................................................................................................... 6
3.4 HSE Manager ........................................................................................................ 6
3.5 Construction Manager ........................................................................................... 7
3.6 Commissioning Manager ....................................................................................... 7
3.7 Test Engineer ........................................................................................................ 7
3.8 HSE Supervisor ..................................................................................................... 7
3.9 Company Site Representative ............................................................................... 7
3.10 Third Party Authority (TPA) .................................................................................... 8
4 ACTIVITIES TO BE COMPLETED BEFORE THE START OF THE SITE WORKS ...... 8
5 QUALITY ASSURANCE / QUALITY CONTROL ........................................................... 8
6 PIPELIE DESIGN DATA & Pipe Data ........................................................................... 8
6.1 Test Medium ........................................................................................................ 10
7 TEST EQUIPMENT .................................................................................................... 10
8 PREPARATION WORKS ............................................................................................ 11
9 TEST ACTIVITIES SEQUENCE ................................................................................. 11
10 ACCEPTANCE CRITERIA .......................................................................................... 14
11 HSE PRECAUTION .................................................................................................... 14
11.1 General................................................................................................................ 14
12 JOB SAFETY ANALYSIS ........................................................................................... 14
12.1 Work Permit / Work organisation ......................................................................... 14
12.2 Risks Identification and Precautions .................................................................... 14
12.3 REPORTING FORMS ......................................................................................... 21
APPENDIX ........................................................................................................................ 27
APPENDIX 01 : TEST HEADERS FOR MAIN LINE VALVES, PIPING AND VESELS ... 27
APPENDIX 02 : TEST HEADERS FOR PIPELINE SECTIONS ...................................... 28
NAWPPL-BIMS-NPPL-320-PL-PRO-00002_000_ PRE-TEST OF TEST HEADERS

PROCEDURE
1 INTRODUCTION
The objective of the Nawara Development Project is to recover the associated and non-
associated gas reserves from the Nawara Concession, separate and pretreat the fluids
from 9 wells, gather them in Central Processing Facility (CPF), convert them into a
commercial condensate and pre-treated gas, export the condensate via a new pipeline into
the existing TRAPSA pipeline, and export the gas via a new pipeline to Gabès. At Gabès,
the gas will be treated in a dedicated Liquefied Petroleum Gas (LPG) extraction facility to
commercial specification required for end user consumption. In Gabès, the gas will be
conditioned in a Gas Treatment PLANT (GTP) into commercial products, and sold to the
end users: STEG and BIMSP.
The “NAWARA Project - Pipelines” main characteristics and facilities are as follows:
- A 24” pipeline which will deliver the raw gas from Nawara CPF to a Gas Treatment Plant
(GTP) located at Gabès (L=371km);
- A 6” pipeline which convey to TRAPSA the separate condensate extracted at CPF
(L=12km);
- The export lines for Sales Products for delivery to customers at Gabès selected custody
transfer points. The 20” sales gas is delivered at STEG (L=1 km) while 6” Propane and 4”
Butane are delivered at BIMSP (L=1,6 km). The condensate that may form at GTP is
exported by road Tanker.
Figure 1.1 Jenein Sud Exploration Area
1.1 Project Overview

This Project is constituted with different types of Works:
Construction of temporary site facilities and temporary access roads to storage and pipe
laydown areas, fabrication facilities, temporary camp for COMPANY,
CONTRACTOR and
SUBCONTRACTORS, construction offices, to be considered as fundamental preparatory
works within the scope of Works of the Project.

PROCEDURE
Carry out welding, coating, bending, Non Destructive Testing (NDT) and other applicable
procedure qualifications as appropriate for an onshore gas pipeline PROJECT.
Install PIPELINE and Fibber Optic Cable and any other associated cables across all road,
track, river, stream, and pipeline and third party crossings along the route.
1.2 Scope
This Procedure describes the methodology and the sequences of the Hydrostatic testing of
the mainline test headers, Vessels and piping and valves testing using in Nawara pipeline.
This procedure details the general, quality, safety & environmental issues as minimum
requirements, applicable to specific task necessary to pre-test the Test-headers required for
Nawara pipeline project.
The main purpose of this document is to provide the guidance to construction personnel for
the safe execution of the works in accordance with Contractor & Company HSE
requirements and Best Practice construction techniques
Certification of Test-headers procedure will covers the following documents:
b) NAWPPL-BIMS-NPPL-320-YL-PRO-00002 Water filling and Hydro testing

Procedure
c) NAWPPL-BIMS-NPPL-320-YL-PRO-00001 Cleaning and Gauging Procedure
d) NAWPPL-BIMS-NPPL-320-PL-PRO-00003 ITP for hydrotest
DEFINITIONS and ABREVIATIONS:
1.3 Definitions
COMPANY OMV (Tunisien) Production GmbH.

CONTRACTOR The party which carries out all or part of the design engineering,
Procurement, construction and commissioning or management of the
project.
CONTRACTOR include sits approved Manufacturers, Vendors,
Suppliers, and
Subcontractors. Requirements of this specification shall been forced at
all levels
Of the CON CONTRACTOR suppliers to the same extent as required of
CONTRACTOR TRACTOR's procurement process. The COMPANY
shall have access to all
PROJECT NAWARA PIPELINE
1.4 Abbreviations
DP Design Pressure
ID Internal Diameter
ITP Inspection Test Plan
JSA Job Safety Analysis
KM Kilometre
MOP Maximum Operating Pressure

PROCEDURE
MPI Magnetic particle Inspection

NDT None Destructive Testing
PTW Permit to Work
PRV Pressure Relieve Valve
QA/QC Quality Assurance/Quality Control
TPA Third Party Authority
2 REFERENCE DOCUMENTS
2.1 Project documents
1. NAWPPL-BIMS-NPPL-000-YL-BOD-00001 Basis of Design;

2. NAWPPL-BIMS-OF01-321-PR-BOD-00001 24" Raw Gas Pipeline Flow Assurance Basis of
Design;
3. NAWPPL-BIMS-NPPL-000-PR-REP-00001 Heat and Material Balances – Raw Gas and
Condensate Pipelines;
4. NAWPPL-BIMS-NPPL-000-PR-REP-00002 Heat and Material Balances – Sales Gas,
Propane and Butane Pipelines;
5. NAWPPL-BIMS-NPPL-000-MC-REP-00002 Pipeline Mechanical Design Report – Wall
Thickness Calculations;
6. NAWPPL-BIMS-NPPL-000-YL-SPE-00002 Dewatering, Drying and Pre-Commissioning
Specification;
7. NAWPPL-BIMS-NPPL-000-HS-REP-00011 Final environmental management and monitoring
plan (construction and operation phases;
8. NAWPPL-BIMS-NPPL-000-HS-REP-00012 Waste Management Plan;
9. NAWPPL-BIMS-OF01-321-YL-DIA-00001 24" Raw Gas Pipeline - Hydrotest Diagram;
10. NAWPPL-BIMS-NPPL-000-MC-SPE-00017 Piping Hydrostatic Pressure Test Specification;
11. NA-OTP-SGTP-PM-MOM-00001 Compte rendu de la réunion avec la Direction de Sécurité
de l’Industrie et de la Technologie.
2.2 INTERNATIONAL STANDARDS
ANSI/ASME B31.4 (2012) Pipeline Transportation Systems for Liquids and Slurries;
ANSI/ASME B31.8 (2012) Gas Transmission and Distribution Piping Systems;
API RP 1110 Pressure Testing of Steel Pipelines for the Transportation of Gas,
Petroleum Gas, Hazardous Liquids, Highly Volatile Liquids or Carbon
Dioxide;
ISO 9001: 2008 Quality Management Systems Requirements.
ISO/IEC 17025: 2010 General requirements for the competence of testing and
calibration laboratories
2.3 NATIONAL CODES / STANDARDS

PROCEDURE
NT109.01 (1984) Safety of Combustible Gas Pipeline Transportation Systems;

NT109.02 (1985) Safety of Liquid Hydrocarbons Transportation Works by Pipe;
NT 109.03 (1985) Safety of liquefied Hydrocarbons under pressure
transportation works by pipeline;
NT 106.02 (1989) Protection de l’environnement - Rejets d'effluents dans le
milieu hydrique.
3 RESPONSIBILITIES
3.1 Site Manager
•Shall ensure that information concerning the work is on site.

•Plan, directs and monitors the activities of the project team.
•Shall ensure required resources – personnel, equipment and materials are present on-site
and are in the right quantity and condition.
•Shall ensure Risk Assessment is done prior to the commencement of work.
3.2 Quality Manager
The QAQC Manager or the Quality Control Coordinator shall be responsible for:
•Monitoring the implementation of this document.
•Quality surveillance and implementation of the quality plan.
•Ensuring that work execution is in compliance with the overall project quality plan.
•Implementation of relevant Inspection and Test Plans (ITP).
•Delegating, where necessary, part of the above responsibilities to the QC
Coordinator/Field QA/QC personnel.
•Assignment of quality personnel in order to follow and inspect the job, as well as assure
that the procedure has been distributed through DCC.
•Quality personnel ensure that Contractor adheres to approved procedure and check non-
conformity or noncompliance to Client Quality standard
•Ensure that all welds are accepted and required materials certificates are available.
3.3 Quality Inspector
•He is responsible for all the necessary inspections and verifications as per required
standards and contractor procedures.
•Collect the site data and preparation of site reports and approval of TPA
3.4 HSE Manager
•Shall ensure that a fit for purpose JSA is produced for the activity.
•Shall ensure that there is proper control of all activities throughout the operation in such a
way that safety of personnel and equipment are not compromised.
•Shall ensure that is appropriate signage’s
•Shall ensure the use of appropriate and certified equipment for various activities and the
operation of such equipment by certified personnel.

PROCEDURE
3.5 Construction Manager

•Manages all activities related in this procedure concerning to construction aspects of the
project.
•He shall be the focal point for all construction matters. He is responsible to ensure that the
quality of the work is maintained
•Contributes towards the quality plan for the project, in particular, the quality performance
requirements of construction.
•Shall ensure adherence to the method statement and other approved standards, relevant
this activity.
•Ensure that the recommendations of Risk Assessment and JSA are fully implemented.
3.6 Commissioning Manager

•Manages all activities related in this procedure concerning to construction aspects of the
project.
•He shall be the focal point for all construction matters. He is responsible to ensure that the
quality of the work is maintained
•Contributes towards the quality plan for the project, in particular, the quality performance
requirements of construction.
•Shall ensure adherence to the approved procedure and other approved standards,
relevant this activity.
•Ensure that the recommendations of Risk Assessment and JSA are fully implemented.
3.7 Test Engineer

Test engineer is in charge of the field operation. His main responsibilities are as follows;
•Confirm that written approval to start has been received from Company and all required
preparations have been completed inclusive of weld acceptance and material certifications.
•Safety and environmental protection equipment is on site and operational
•Check validity of certification.
•To ensure that the headers are correctly supported, all persons under him are fully aware
of their responsibilities and that they have clear directions and that they understand them.
•He shall ensure that the person monitoring pressure knows the correct test pressure.
•He shall ensure that the person operating the pump knows the correct pressure and has
either direct sight of the pressure measuring instrument or is in visual contact with the
person monitoring the pressure and communications are in place between him and
delegated persons for monitoring the access to the test area.
3.8 HSE Supervisor

•He shall ensure all HSE personnel are available on site prior to the commencement of the
operation, liaise with the medical team to ensure adequate provision of medical evacuation
of personnel and facility, proper and adequate waste management on site, effective
implementation of statuary safety requirements on site.
3.9 Company Site Representative

•He shall witness the test, review all the documentation pertinent to the test, and authorize
the initiation of the hydrotest, assist to the induction and tool box talk, review the PTW and
approve,
Authorize the depressurization of the system, review and sign the required inspection sheet
included in the ITP
.

PROCEDURE
3.10 Third Party Authority (TPA)

•He shall sign the respective documents and charts at the end of the test.
•Shall sign the test acceptance report provided the tests have been success
4 ACTIVITIES TO BE COMPLETED BEFORE THE START OF THE SITE WORKS

Before the commencement of the following site activities Contractor must obtain:
•COMPANY’s clearance (PTW) to start the activities.
•Work force near the testing area shall be informed to keep out of restricted area prior to
commencement of hydrotest activities
•Barriers and warning signs to be in place prior to commencement of hydrotest activities.
•Necessary permit shall be in place before the commencement of any activities
•JSA shall be in place and risk assessment must be issued and attached with the PTW
•COMPANY inspection and approval of all equipment involved to perform the job like
pumps, measurement equipment, etc. Calibration certificate shall be issued to COMPANY
prior to inspection.
•Test Packs shall be issued by BIMS for COMPANY approval 14 days prior to the pre-test.
5 QUALITY ASSURANCE / QUALITY CONTROL

Quality Management Systems shall comply with all the requirements of ISO 9001. BIMS
shall ensure, at all times, a QA program which clearly establishes the authorities and
responsibilities of those responsible for the Quality System. Persons performing Quality
functions shall have sufficient and well-defined authority to enforce Quality requirements
that they initiate or identify and to recommend and provide solutions for Quality problems
and thereafter verify the effectiveness of the corrective action.
Company/BIMS reserves the right to inspect materials and workmanship at all stages to
witness any or all tests. The Inspection and Test Plan will also be reviewed for inclusion of
any mandatory Company /BIMS witness or hold points.
The laboratory, which conducts chemical analysis and the various mechanical tests
required by this procedure, shall have ISO/IEC 17025 accreditation and preferably industry-
specific accreditation
6 PIPELIE DESIGN DATA & PIPE DATA

The following pipe data have been considered, according to doc. Pipeline Mechanical Design
Report – Wall Thickness Calculations and doc. Basis of Design.
1. Test pressure of the test headers will be in accordance with NAWPPL-BIMS-NPPL-000-
MC-SPE-00017 Piping Hydrostatic Pressure Test Specification
2. Pressure for test headers will be 1.25 times the maximum pressure apply in the pipeline
section.
For section 02 to section 13 :
Ptest  1.25 x STP  1.25 x 131.8  164.75 bar

For section 01 and section 14 :
Ptest  1.25 x STP  1.25 x 157.7  197.12 bar

.

PROCEDURE
STP : Selected test pressure

Ptest : Pressure test for the test headers

PROCEDURE
Geographical Data
Pipe Data of Pipeline Section Pressure Data
Section Name
Terminals
Approx water
Point
Approx Total
End Point KP
Point at KP
(m)
(m)
Volume sect
Min.WT (mm)
Lowest Point
pressure at
Pumping
sect(m3)
Approx.
Volume
Approx
Minus
(m3)
STP
KP
Length
Length
Start
Sec.1 -3038 2290 3038 17,48 748 748 194 194 157.7 158,5
Sec.2 2290 18222 -3038 11,91 20512 5525 131,8 142,7
Sec.3 18207 50295 18234 11,91 32088 8643 131,8 135,2
113787 30650
Sec.4 50280 79786 50295 11,91 29506 7948 131,8 136,0
Sec.5 79771 111452 79786 11,91 31681 8534 131,8 136,1
Sec.6 111437 143419 111452 11,91 31982 8615 131,8 136,6
Sec.7 143404 175592 143419 11,91 32188 96481 25988 8670 131,8 132,5
Sec.8 175577 207888 175592 11,91 32311 8703 131,8 136,0
Sec.9 207873 239712 207888 11,91 31839 8576 131,8 134,1
Sec.10 239697 271661 239712 11,91 31964 95762 25795 8610 131,8 136,3
Sec.11 271646 303605 271661 11,91 31959 8609 131,8 135,1
Sec.12 306590 332938 303605 11,91 26348 7097 131,8 144,1
Sec.13 332923 357745 332938 11,91 24822 81307 21595 6686 131,8 133,6
Sec.14 337730 367867 357745 17,48 30137 7812 157,7 161,7
STP : 73572
SELECTED STRENGTH TEST PRESSURE
6.1 Test Medium
The test medium to be used in the hydrotest operations will be potable water. Water for
testing and flushing shall be cleaned and free from any suspended of dissolved substances
which could be harmful to the piece of pipe and the test headers material. Water will be
taken from the approved sources
7 TEST EQUIPMENT
CONTRACTOR shall ensure that all equipment and instruments are properly maintained,
are in full working order and are suitable for the intended use. All instruments shall have a
valid calibration certificate issued within 6 months of the day of use. Subcontractor shall
keep copies of calibration certificates on site, ready for the inspection of Company
Representative
For hydro testing activities the following equipment shall be utilized:
 Water truck for filling

 High pressure pump 0-700 bar x 3Ltr/min
 Air driven Compressor 7barx9000 Ltr/min
 Two (2) Pressure Gauges, 0-250 Barg
.

PROCEDURE
 Hoses, Fittings, Valves for high pressure

 Pressure & Temperature Chart recorder (calibrated) with extra pens and recording
charts,0-250 barg, 0-60ºC complete charts
 Dead Weight tester 0-300 Barg
 Two-way radio short distance
 Relieve valve
8 PREPARATION WORKS
•Check that a PTW form is approved and signed by CONTRACTOR/COMPANY

representatives
•Pre-start meeting to be held to go through JSA and ensure all persons are aware of their
allocated duties
•PTW coordinator shall ensure that there are no potential SIMOPs clashes prior to issuing
the permit
•Check that a JSA form has been signed and the personnel instructed about the safety
measurements.
•Check that testing area is barrier off and warning signs are erected.
•All temporary valves, piping, fittings etc. to be used in the test shall have appropriate
certification.
9 TEST ACTIVITIES SEQUENCE
•Open all valves available on the test heads and start water injection by gravity feed from
the water tanker. Air will be vented on all available high points, especial care will be in the
headers with installed pigs.
•Continue water filling until water coming out from all high vent points.
•Once the water will start coming out from the vent valves, close them ensuring the
complete sealing of the test heads.
•Start pressure chart recorder and set in real time.
•Install the pressure pump to the system
•Open injection valve from high pressure pump and instrument valves.
• Ensure PRV is installed and calibrated to 5 barg above specified test pressure.
• Start high pressure pump and pressurize the test head to 50% of test pressure with a
maximum rate of not exceeding 3bar/min.
Note: No leak repair is allowed above 50% of test pressure. If the leak cannot be
isolated and repaired the headers has to be depressurized to atmosphere.
•Once the pressure is reached, stop pressurization. Close the block valves at the outlet of
the pump for 15 minutes stabilization and leak check.
•When stabilization is complete, and no leak has been occurred, open pump outlet valves
and re-start pressurization to 80% of test pressure with a maximum rate of not exceeding
3bar/min.
•Once the pressure is reached, stop pressurization. Close the block valves at the outlet of
the pump for 15 minutes stabilization and leak check.
.

PROCEDURE
•When stabilization is complete, and no leak has been occurred open pump outlet valves
and re-start pressurization to 100% of test pressure with a maximum rate of not exceeding
1bar/min.
•Continue pressurizing the test heads until the pressure will reach the 100% of the
certification pressure.
•Once the pressure is reached, close the block valves at the outlet of the pump. The
pressure test will be held for minimum 4 hours duration. The pressure to be monitored and
checked every 15 minutes.
•After successful completions of 4 hour holding period depressurize the test heads in a
controlled manner to 80% of test pressure for final leak check.
•If no leak has been occurred depressurize the test head until the pressure has reached
atmospheric conditions. Depressurizing should be done on a continuous release not
exceed 3bar/min.
•Prepare the Certification Documentation
Scheme of Hydrostatic test of test heads test pack for 24” Pipeline
The 24”pipeline will be tested in 14 sections and 14 test headers were builder to speed it
the operation of filling and testing
The test headers will be tie-in on 7 systems and linked by hoses in order to have a bypass
of pressure only one hydrotest operation will be required to pre-test the 7 systems (14 test
headers)
Previous to tie-in pigs will be installed in the test headers, pigs are designed to hold high
pressure keeping the conditions after testing
Adequate filling will be performed to prevent air in the test headers
The test headers will be numbering as the sketch bellow

PROCEDURE

PROCEDURE
10 ACCEPTANCE CRITERIA
The test should be accepted if Pressure was maintained the specified test pressures and
no leak has been occurred or no permanent deformation noted after testing during the 4
hour holding period the
11 HSE PRECAUTION
11.1 General
•All personnel involved in the mentioned activities shall be briefed on JSA through tool box
meeting prior to commencing the job
•Permit to work requirements shall be in place.
•Appropriate warning signs will be installed in key points of the work site.
•Physical barricade shall be placed around the Hydrotest area
•Safety Officers shall always be present during the mentioned activities
•Contractor Safety Officer will closely monitor and supervise safety precautions.
•All people not directly involved in the Hydro testing activities must stay away from the work
site.
•Suitable Personal Protective Equipment, of staff deployed on testing activities. Use of PPE
shall be enforced by close supervision of all activities
•Hazards associated with Hydro testing activities measures must be identified
•A JSA shall be carried out for this activity and JSA should be always present at the
worksite area.
12 JOB SAFETY ANALYSIS
12.1 Work Permit / Work organisation

The following shall apply:
PTW shall be raised
BIMS shall ensure permanent Supervision at the workplace; otherwise job will be stopped.
All personnel to undergo HSE induction.
A pre-job meeting with all personnel involved shall be performed prior to the
commencement of the activity.
Good housekeeping to be maintained at all times.
BIMS Medivac procedure shall be followed in the event of emergency. Site management to
be informed of any accident/injury to personnel before referral to any clinic.
Only authorized personnel are allowed to be within activity area.
Injuries /anomalies, incident must be highlighted and reported.
12.2 Risks Identification and Precautions
See JSA worksheets below.

PROCEDURE
S/N BREAK DOWN HAZARD(S) INVOLVED POSSIBLE RISK RECOMMENDED CONTROL MEASURES Residual Risk
OF JOB IN ACCIDENT S L R S L R
TASKS SCENARIOS
Injury to personnel, M M 2 Induction & mandatory trainings for all workforce. M M 1
Personnel unaware of basic and damage to Awareness shall be created through Tool box Talks
safety practices in construction equipment.
area / ROW.
Injury to personnel M M 2 Awareness through Tool box Talks M M 1
Miscommunication –OMV-BIMS and damage to PTW in process -OMV shall be informed by BIMS of the personnel and
unaware of personnel / property and equipment mobilized for the area
equipment mobilized inside equipment MEDEVAC in place and tested
construction areas All I.D. badges shall be visible
Injury to personnel M M 2 Supervision and strict enforcement safety rules. M M 1
Misuse or not wearing PPE and damage to PPE Policy should be enforced.
1 Mobilization of
personnel property and Training shall be provided to personnel mobilized.
equipment
Constraint in access / operational Injury to personnel M M 2 Provision of First Aiders and ambulance dedicated for pipeline activity at M M 1
area hydrotest site work
Emergency response plan
Availability of medical facilities at Camp
Collision with stationary or Fatality, injury to M M 3 BIMS defensive driving training should be in place for all drivers, training M M 2
moving vehicles, falling of load, personnel, damage and permanent assessment on loading / lashing techniques. The use of
vehicle overturning to equipment, seat-belt is mandatory to all personnel, as well as the use of adequate
PPE
Violation of speed limits Fatality, Injury to M M 3 Maintain speed limit within SITE/ROW and regular installation of signs at M M 1
personnel and appropriate places,
damage equipment Use of IVMS, and application of consequence management
2. Transportation Insecure load, overloading of Fall of load to M M 2 Loading and lashing to be controlled by driver and loading foreman. M M 1
of Hydrotest vehicles, improper lashing & fall pedestrian and to All load must be inspected before leaving the site to the ROW.
Equipment / of load equipment
Hose / Material Alcohol & drugs consumption by Fatality, Injury and M M 2 Random checks for alcohol and drugs consumption. 2 levels sanctions for M M 1
the driver. damage to drivers not obeying rules (1) warning, (2) dismissal
equipment
Bad weather conditions Injury to personnel M M 1 Driver to park their vehicle during sever wind, torrential down pour and M M 1
other adverse weather condition.
NAWPPL-BIMS-NPPL-320-PL-PRO-00002_000_ PRE-TEST OF TEST HEADERS PROCEDURE

Improper connections of brakes, Damage to vehicle M M 2 Daily equipment inspection for all drivers and operator should be M M 1
fifth wheel and king pin due brake failure and conducted before the equipment or vehicle is put into use and all
displaced wheel pull off. connections, brake, stoppers, nuts and bolts checked.
Injury to personnel M M 2 Adequate Safety Sign boards shall be placed to guide the personnel to M M 1
In access to other existing roads, use the alternative arrangement.
walkways, facilities and muster Barricading the area which is being used as access / egress in normal
point etc. operation
Access /
Egress /
Slip/Trip/Fall Injury to personnel M M 1 Ensure good housekeeping and the area is free of any spill to avoid slip M M 1
3 movement of
hazards
people
Walkways must be kept clear of all materials, tools, connections (hoses,
electrical wire etc.) to avoid objects slip/trips/falls
Injury to personnel M M 2 Loading and lashing to be controlled by driver and loading foreman. M M 2
Personnel unaware of collision of and damage to All load must be inspected before leaving the site to the ROW. Barricade /
equipment and material causing equipment. Install warning signs wherever necessary
injury
Injury to personnel M M 2 Ensure that all materials are kept in proper order. M M 1
Poor Housekeeping
JHA must be reviewed before commencement of the activity.
Ensure that valid PTW is in place.
Entanglement, trap, Slip/Trip/Fall Injury to personnel M M 2 Walkways must be kept clear of all materials, tools, connections (hoses, M M 1
4 Visual electrical wire etc.) to avoid objects slip/trips/falls.
inspection of Adequate PPE must be worn during the exercise.
work area, Avoid pinch point, working in between bodies cable of entrapping,
equipment and entangling or in between two moving equipment.
materials to Injury to personnel M M 2 Supervision and strict enforcement safety rules. M M 2
work activity. Misuse or not wearing PPE and damage property PPE Policy should be enforced.
and equipment Training shall be provided to personnel mobilized.
Constraint in access / operational Injury to personnel M M 3 Provision of First Aiders and ambulance dedicated for hydrotest M M 1
area Emergency response plan

S/N BREAK DOWN HAZARD(S) INVOLVED POSSIBLE RISK RECOMMENDED CONTROL MEASURES Residual
OF JOB IN ACCIDENT Risk
TASKS SCENARIOS S L R S L R
Entanglement, trap, Slip/Trip/Fall Injury to personnel M L 2 Ensure good housekeeping and the area is free of any spill to avoid slip M 1
hazards, Avoid pinch point, working in between bodies cable of entrapping,
entangling or in between two moving equipment.
Use of wrong tools Injury to personnel M L 2 Only competent personnel must be used for the operation. M 1
Injury to personnel M L 2 Ensure that all materials are kept in proper order. Ensure that valid PTW is in M 1
5 Connection of Poor Housekeeping
place.
test
header/manifold, Pinch points Injury to personnel M L 3 Adequate PPE must be worn during the exercise. M 2
hoses and other Only experience and competent personnel must be engaged to carry-out the
accessories activities. JSA and PTW must be in place.
Injury to personnel M L 2 Supervision and strict enforcement safety rules. M 1
Misuse or not wearing PPE and damage PPE Policy should be enforced.
equipment Training shall be provided to personnel mobilized.
Constraint in access / operational Injury to personnel M L 1 Provision of First Aiders and ambulance dedicated for hydrotest, Emergency M 1
area response plan Availability of medical facilities at Camp
System failure during hydrostatically Injury to personnel, H L 1 Specific JSA /RA to carry out hydro testing activity, PTW, supporting M L 1
6. Filling of water tested and sudden release of water fatality and damage documents / plot plan, P& ID, Proper inspection of equipment prior to work,
and pressurizing under pressure to property Ensure the pressure gauges are certified & calibrated appropriately.
the test header Demarcate area and warning signs; only approved trained / competent
Hydro test / personnel to carry out the task, Whip check arrestors installed on all hoses
Pressure test. connections, First Aiders with Ambulance at site
Failure of valves and gauges Injury to personnel H M 2 Thorough checking of fitting, valves, gauges and connections before M M 1
and damage to commencing pressure testing. Demarcate area and warning signs; only
equipment approved trained / competent personnel to carry out the task
Rupture of test piece Injury to personnel, M M 2 If any leaks observed depressurized the line before unbolting/tightening. M L 1
fatality and damage Ensure testing carried out with Specs and designed pressure limit
to property

S/N BREAK DOWN HAZARD(S) INVOLVED POSSIBLE RISK RECOMMENDED CONTROL MEASURES Residual
OF JOB IN ACCIDENT Risk
TASKS SCENARIOS S L R S L R
Sudden Release of Pressure. Injury to personnel, M M 3 Specific JSA /RA to carry out hydro testing activity, PTW, supporting M L 2
7. Depressurizing fatality and damage documents / plot plan, P& ID.
and uncoupling to property
of hose and The valve shall be open little by little and the pressures will be4 released in
accessories. that same manner.
The jet of water released during depressurization, shall be safely directed to
containment.
Proper inspection of equipment prior to work
Ensure the pressure gauges are certified & calibrated appropriately
Task carried out by appointed supervisor and trained personnel
Demarcate area and warning signs; only approved trained / competent
personnel to carry out the task
Check and maintenance of the lines and hoses
Whip check arrestors installed on all hoses connections
First Aiders with Ambulance at site
Appropriate permit will be obtain if any chemical used for hydro testing (If
Applicable)
Ensure compliance to approved work procedure.
Entanglement, trap, Slip/Trip/Fall Injury to personnel M L 2 Ensure good housekeeping and the area is free of any spill to avoid slip M M 1
hazards
Walkways must be kept clear of all materials, tools, connections (hoses,
electrical wire etc.) to avoid objects slip/trips/falls.
Adequate PPE must be worn during the exercise.
Avoid pinch point, working in between bodies cable of entrapping, entangling
or in between two moving equipment.
Use of wrong tools Injury to personnel M M 2 Only competent personnel must be used for the operation. M M 1
Injury to personnel M M 2 Ensure that all materials are kept in proper order. M L 1
Poor Housekeeping
.

TBT must be conducted before commence of the day’s activities.

All the hoses, material and equipment to be inspected must be properly
arranged in other not to obstruct the free movement of personnel during the
inspection process..
JHA must be reviewed before commencement of the activity.
Ensure that valid PTW is in place.
Pinch points Injury to personnel M M 3 Adequate PPE must be worn during the exercise. M L 1
Only experience and competent personnel must be engaged to carryout the
activities.
JHA and PTW must be in place.
Injury to personnel M M 2 Supervision and strict enforcement safety rules. M L 1
Misuse or not wearing PPE and damage to PPE Policy should be enforced.
property and Training shall be provided to personnel mobilized.
equipment
Constraint in access / operational Injury to personnel M M 2 Provision of First Aiders and ambulance dedicated for pipeline activity at M L 1
area ROW
Emergency response plan
Trip and fall Hazards resulting from Injury to personnel L L 1 Housekeeping to be carried out continuously. All generated wastes to be M L 1
poor housekeeping and damage to managed according to waste management procedure of the project.
DEMOBILIZATIO property. Rehabilitate site after work.
N:
8. Trip and fall Hazards resulting Injury to M L 2 Housekeeping to be carried out continuously. All generated wastes to M L 1
Site rehabilitation from poor housekeeping personnel and be managed according to waste management procedure of the
damage to project. Rehabilitate site after work.
property.
Personnel
Equipment

Contractor doc. n°: Engineering doc. n°: Rev.: C01 C02 C03 Company doc. n°:

12.3 REPORTING FORMS
Pre-Test Check List

Hydrostatic pre-test Report – Acceptance Certificate


Daily Operation Report

Depressurisation Report

Pressurization Report

APPENDIX
APPENDIX 01 : TEST HEADERS FOR MAIN LINE VALVES, PIPING AND VESELS

APPENDIX 02 : TEST HEADERS FOR PIPELINE SECTIONS

Summary of Comments on NAWPPL-BIMS-NPPL-
320-PL-PRO-00002_C02_PRE-TEST OF TEST
HEADERS PROCEDURE
Page Author OMV Comments BIMS Reponses

Page: 12 Author: XBEJAOUAB Subject: Highlight Date: discrepancy with the duration indicated in the corrected
07/09/2016 14:24:12 previous paragraph.
Page: 13 Author: MALEK2 Subject: Sticky Note Date: The PRV was not shown in the sketch. Please to updated in the sketch
03/09/2016 22:09:50 indicate its location and related connections for
fluid evacuation in case of relief.
Author: sami06 Subject: Sticky Note Date: Pressure test sketch comments were not some of The test header have pigs and the
25/08/2016 09:07:23 addressed. filling should be alternated from the filling shall be done from center in order to
extremity to extremity to allow better air move the air to the end of the headers and
evacuation. elise by the 2" valves
Author: sami06 Subject: Sticky Note Date: second Measurement and recording should be
25/08/2016 09:07:48 done at the end/ extremity of this pack. updated in the sketch
Author: sami06 Subject: Sticky Note Date: show relief valve and reliefs valve set pressure
25/08/2016 09:08:44 done
Page: 14 Author: sami06 Subject: Sticky Note Date: shematic not readable, please include better
25/08/2016 09:09:24 done
Page: 15 Author: sami06 Subject: Sticky Note Date: Please show the construction code and add
25/08/2016 09:10:03 better legible attachment done

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Contractor: Engineering: Project: Company:

Contract n°:OTP/PP/189 OMV/BIMS EPCC PPL

NAWARA PROJECT (PIPELINE)

PRE-TEST OF TEST HEADERS PROCEDURE

000 14/09/2016 Issue for Use/ Construction LPA ABG MTO

NAWPPL-BIMS-NPPL-320-PL-PRO-00002_000_ PRE-TEST OF TEST HEADERS

Figure 1.1 Jenein Sud Exploration Area

1.1 Project Overview

NAWPPL-BIMS-NPPL-320-PL-PRO-00002_000_ PRE-TEST OF TEST HEADERS

b) NAWPPL-BIMS-NPPL-320-YL-PRO-00002 Water filling and Hydro testing

DEFINITIONS and ABREVIATIONS:

COMPANY OMV (Tunisien) Production GmbH.

NAWPPL-BIMS-NPPL-320-PL-PRO-00002_000_ PRE-TEST OF TEST HEADERS

MPI Magnetic particle Inspection

2.1 Project documents

1. NAWPPL-BIMS-NPPL-000-YL-BOD-00001 Basis of Design;

2.2 INTERNATIONAL STANDARDS

2.3 NATIONAL CODES / STANDARDS

NAWPPL-BIMS-NPPL-320-PL-PRO-00002_000_ PRE-TEST OF TEST HEADERS

NT109.01 (1984) Safety of Combustible Gas Pipeline Transportation Systems;

3.1 Site Manager

•Shall ensure that information concerning the work is on site.

3.2 Quality Manager

3.3 Quality Inspector

3.4 HSE Manager

NAWPPL-BIMS-NPPL-320-PL-PRO-00002_000_ PRE-TEST OF TEST HEADERS

3.5 Construction Manager

3.6 Commissioning Manager

3.7 Test Engineer

3.8 HSE Supervisor

3.9 Company Site Representative

NAWPPL-BIMS-NPPL-320-PL-PRO-00002_000_ PRE-TEST OF TEST HEADERS

3.10 Third Party Authority (TPA)

4 ACTIVITIES TO BE COMPLETED BEFORE THE START OF THE SITE WORKS

5 QUALITY ASSURANCE / QUALITY CONTROL

6 PIPELIE DESIGN DATA & PIPE DATA

Ptest  1.25 x STP  1.25 x 131.8  164.75 bar

Ptest  1.25 x STP  1.25 x 157.7  197.12 bar

NAWPPL-BIMS-NPPL-320-PL-PRO-00002_000_ PRE-TEST OF TEST HEADERS

STP : Selected test pressure

NAWPPL-BIMS-NPPL-320-PL-PRO-00002_000_ PRE-TEST OF TEST HEADERS

6.1 Test Medium

For hydro testing activities the following equipment shall be utilized:

 Water truck for filling

NAWPPL-BIMS-NPPL-320-PL-PRO-00002_000_ PRE-TEST OF TEST HEADERS

 Hoses, Fittings, Valves for high pressure

•Check that a PTW form is approved and signed by CONTRACTOR/COMPANY

9 TEST ACTIVITIES SEQUENCE

NAWPPL-BIMS-NPPL-320-PL-PRO-00002_000_ PRE-TEST OF TEST HEADERS

NAWPPL-BIMS-NPPL-320-PL-PRO-00002_000_ PRE-TEST OF TEST HEADERS

NAWPPL-BIMS-NPPL-320-PL-PRO-00002_000_ PRE-TEST OF TEST HEADERS

12 JOB SAFETY ANALYSIS

12.1 Work Permit / Work organisation

12.2 Risks Identification and Precautions

See JSA worksheets below.

NAWPPL-BIMS-NPPL-320-PL-PRO-00002_000_ PRE-TEST OF TEST HEADERS

NAWPPL-BIMS-NPPL-320-PL-PRO-00002_000_ PRE-TEST OF TEST HEADERS PROCEDURE

NAWPPL-BIMS-NPPL-320-PL-PRO-00002_000_ PRE-TEST OF TEST HEADERS PROCEDURE

NAWPPL-BIMS-NPPL-320-PL-PRO-00002_000_ PRE-TEST OF TEST HEADERS PROCEDURE

NAWPPL-BIMS-NPPL-320-PL-PRO-00002_000_ PRE-TEST OF TEST HEADERS PROCEDURE

TBT must be conducted before commence of the day’s activities.

NAWPPL-BIMS-NPPL-320-PL-PRO-00002_000_ PRE-TEST OF TEST HEADERS PROCEDURE

NAWPPL-BIMS-NPPL-320-PL-PRO-00002_000_ PRE-TEST OF TEST HEADERS PROCEDURE