Construction Pre-Commissioning Commissioning

Project Scope of Work Scope Finalization According to Assurance System

Design & Engineering Scope of work completion with all quality
Established Related System, Subsystem Generation parameter
Drawing Subsystem wise check-list All Discipline start-up
System & Subsystem Generation for all Discipline according Procedure
Testing Testing /check-list/ Procedure Line-up with operation
Quality assurance and /document management Hand-over Project to
control Mechanical completion operation
Construction Project completion
completion
 PRE-COMMISSIONING
During construction After construction

System /Subsystem mark-up Generation Inspection and Testing report break-up and submission record

Discipline-wise tag Generation (For piping Test-pack Blowing and Reinstatement

mark-up and test-pack generation )

Leak-test
Inspection testing report and check-list Generation and
issue for construction completion record

System and subsystem wise walk-down/Red-line mark-up

Quality and execution witness report

Mechanical completion certificate and report

Construction completion certificate and report

Start Commissioning and start-up activity

SCOPE:-
This Standard covers the minimum requirements and
acceptance criteria for the inspection and testing of piping
systems. The work shall be carried out in two stages as follows:
Stage 1
Inspection and verification, that all items have been supplied
and installed in accordance with drawings and manufacturers
requirements.
Stage 2
The testing of piping systems, to verify the integrity of the
piping system, prior to putting into service.
Should there be conflict between these standard, local or
statutory requirements, the Superintendent shall be consulted
in writing, for resolution. In general, the most stringent
requirement shall prevail.
 Test-Pack Management
Introduction:-
Test-Pack Management is process to calculate
project piping progress in mathematical number
format and also easy to construction each and every
system with proper record.
Test-pack have specific mark-up made by test-pack
engineer according service, isolation valve and
testing facility through.
Generally test-pack use for Piping & Pipe-line ITR.
Test pack is a bunch of inspection testing
report(ITR) and relevant supporting documents as
below.
 Test-Pack Management
11 ITR-A (Construction) 3 ITR-B(Pre-commissioning)

Line History Sheet WITNESS JOINT CHECK

PIPING TEST EQUIPMENT INSTALLATION CHECK
CALIBRATION CERTIFICATE PIPING COMPLETION CERTIFICATE
TEST PACK LINE LIST
PIPING INSTALLATION
Record Piping Package Index
PIPING PRESSURE TEST CERIFICATE
CHEMICAL CLEANING
Construction Completion System
Flushing Blowing
SUPPORT SUMMARY SHEET
TEST PACK REINSTATEMENT
Bolt Torqueing Report
Test-Pack Management
Calibration certificate of all
equipment's and gauges
use during testing

layout drawing if High-lighted mark-up

applicable P&ID

Flow-sheet Isometric diagram

NDT Report
(RT/UT/DPT/MPT)
1-2-3-4-5-6
1. Project Code/Number
2. TP(Test-pack symbol)
3. Service & System Identity
4. System Number(3 Digit Fixed-XXX)
5. Subsystem Number(2 Digit Fixed-XX)
6. Test-Pack Number(3 Digit Fixed-XXX)
Eg-M205DCL1-TP-CI-011-01-003
 How to Make Test-Pack
Mark-Up:-
STEP-1
Properly Read & Understand P&ID
(Piping and Instrumentation
Diagram).
 P&ID
Piping and Instrumentation Diagrams or simply
P&IDs are the schematics used in the field of
instrumentation and control (Automation)
The P&ID is used to by field techs, engineers, and
operators to better understand the process and
how the instrumentation is inter connected.
 P&ID
Most industries have standardized the symbols
according to the ISA Standard S5.1
Instrumentation Symbol Specification.
Piping & Instrumentation Drawing (original)
Process & Instrumentation Diagram (also
used)
Process Flow Diagram PFD (simplified
version of the P&ID)
STEP-2 DESIGN REVIEW
The Contractor shall carry out a design review in order to
facilitate inspection and testing work and defining the
approach to be taken.
When all HAZOP studies and CSBP Design Reviews have
been completed and the P&IDs are at a stage where
they have been frozen the Contractor shall:

1 . Review and mark up P&IDs to determine extent of each

Test Pack and to define total number of Packs.
2 . Determine which vessels can be pressure tested through
and which cannot (review 70% rule and confirm that
structure/foundations have been designed to accommodate
the weight of water filled lines and vessels).
3 . Consider flanging of vessel nozzles to simplify testing work.
4. Rationalize Piping system test pressures to minimize
the total number of Test Packs required as a result
of maximizing test limits.
5. Prepare a master set of color coded P&IDs to identify
Test-Packs and boundaries.
6. Revise the Line List to reflect rationalized test pressures.
7. Revise the Line List to include a Test Pack Number
against every line.
8. Revise Isometrics to reflect rationalized test pressures
where required.
9. Calculate and tabulate a comprehensive list of carbon
steel, test spade thicknesses required for the maximum
non-shock flange rating for each Piping Specification Class.
10. Identify any lines that require additional temporary
support during hydro testing.
STEP-3 Create Master Test Pack
The Contractor shall create a Master Test Pack to collect and
collate all information required to make up complete test
packs. Each Master Test Pack, for the systems identified by
the Contractor during the Design Review, shall include the
following minimum information:
Test Pack lead sheet identifying Line Number, Isometric
Number, P&ID Number, Test medium, Test pressure and
extent of test.
Marked up a set of P&IDs identifying Test Pack and
delineating test boundaries.
Authorization sheet allowing vessel to be included in test
(where applicable).
Stored energy calculations/exclusion zone distances for
pneumatic tests as per AS3788 Once complete, the Master
Test Pack shall be submitted to the Superintendent for
approval.
STEP-4 Completion of Test Packs by
Contractor
The Contractor shall complete the Master Test
Pack to include a marked up set of isometrics
showing:
Limit of test,
Location, size and rating of blind flanges,
Location, size and thickness of test spades,
Test fill location,
Test vent location(s),
Test pressure gauge locations,
Relief valve set pressure (for pneumatic tests), and
Exclusion zone definition and location of barriers shown on
a plot plan of the area (for pneumatic tests).
STEP-5 Test-pack Review

The Contractor shall submit the Master copy of each

Test Pack to the Superintendent for acceptance.
If Master Test Pack is accepted without comment
the Superintendent shall sign and return this
document to the Contractor who shall prepare
copies as described in the Works, or as directed by
the Superintendent.
If the Superintendent makes comment, the Master
will be returned to the Contractor for correction and
resubmission.
Test Packs shall be color coded.
An example is as follows:
Master Test Pack : Blue Folder
Contractors copy : Red Folder
Spare/Working Field Copies : Yellow Folder
 TEST-PACK
MANAGEMENT
WORK
AND
ITS IMPORTANCE
STAGE 1 - INSPECTION AND CONSTRUCTION VERIFICATION

NON DESTRUCTIVE EXAMINATION - PIPING AND FITTINGS

BRANCH WELDS AND REINFORCING PADS
HARDNESS TESTING

STAGE 2 - TESTING

STAGE 3 - PUNCHLISTING PIPING SYSTEMS

Post Test Punch listing and Reinstatement Pack

Pre-test Punch listing

STAGE 4 - SYSTEM FLUSHING

STAGE 5 - WITNESSING PIPING SYSTEM PRESSURE TESTING

STAGE 6 - SYSTEM DRYING

STAGE 7 - CHEMICAL CLEANING OF PIPING SYSTEMS

STAGE 8 - PNEUMATIC TEST PROCEDURES

STAGE 9 - LEAK TESTING OF PIPING SYSTEMS

Test Records
Test Equipment
Pressure Gauges
Flow Measurement
Simplified Leak test Procedure
STAGE 10 - AIR BLOWING OF PROCESS PIPEWORK

Duration of Air Blow

Location of Target Plates
Location of Target Plates
Air Flow Requirements
Re-instatement