TKF00MEMST0007Rev.2MethodstatementofFlushingandHydrotestingforStationPiping

2 31-12-2012 REVISED AND RE-ISSUED FOR IMPLEMENTATION M.Kara A. Yildirim M.Kopuz

1 27-08-2012 REVISED AS PER JESA-TKF-DCS-1605 RE-ISSUED FOR IMPLEMENTATION M.Kara A. Yildirim M.Kopuz

0 15-08-2012 REVISED AS PER JESA-TKF-DCS-1548 AND RE-ISSUED FOR IMPLEMENTATION M.Kara A. Yildirim M.Kopuz

A 30-06-2012 ISSUED FOR REVIEW M.Kara A. Yildirim M.Kopuz

Rev. No. Date Description

Prepared Checked Reviewed ORIGINATOR TEKFEN

Groupe OCP S.A. Casablanca, 2, rue Al Abtal, Hay Erraha, Morocco

KHOURIBGA JORF LASFAR PHOSPHATE SLURRY PIPELINE SYSTEM

EPC CONTRACTOR

Document Title

METHOD STATEMENT OF FLUSHING AND HYDROTESTING FOR STATION PIPING

SUBCONTRACTOR

Document No. Rev. No. Total pages

Org. Code Area Code Disc. Code Doc. Type Seq. No.

TKF 00 ME MST 0007 2 41


Groupe OCP S. A. Casablanca Morocco

Document Title:

METHOD STATEMENT OF FLUSHING AND HYDROTESTING

FOR STATION PIPING

Issue date 31-12-2012 Doc. No : TKF-00-ME-MST-0007 Rev.2 Page 2 of 31

TABLE OF CONTENTS

1.0 Purpose

2.0 Scope

3.0 General Requirement of pressure test of pipework

4.0 Definitions

5.0 Reference Documents

6.0 Codes and Standards

7.0 Organization

8.0 Responsibilities

9.0 Determination of Test Fluid

10.0 Determination of Test pressure

10.1 Flushing

10.2 Execution Conditions

11.0 Execution of Hydrostatic Test Pipework

12.0 Acceptance of Pressure Test for Pipework

13.0 Safety in Pressure Testing & Flushing for Pipework

14.0 Pressure Test activity flow chart

15.0 Hazard effect and management plan for flushing and hydrotesting

16.0 Emergency Response Plan

17.0 Attachments



Document Title:


FOR STATION PIPING

Issue date 31-12-2012 Doc. No : TKF-00-ME-MST-0007 Rev.2 Page 3 of 31 1.0 PURPOSE

The purpose of this method statement is to ensure that all activities related to flushing and hydrotesting are carried out in a controlled manner in accordance with Project specifications.

2.0 SCOPE

This method statement covers the detailed requirements for pressure testing and flushing of fabricated spools and piping system at the Pump station under the OCP Khouribga-Jorf Lasfar Phosphate Slurry Pipeline project.

3.0 GENERAL REQUIREMENT OF PRESSURE TEST FOR PIPEWORK

3.1 General 3.1.1 All work shall be performed in compliance with the HSE Plan for OCP slurry pipeline project

TKF-00-HS-PLN-0010 Hazards and Effect Management Plan. 3.1.2 Contractor shall, submit a copy of each test package and attachments for Company review and

approval 7 days in advance of subject test. Test package prior to testing shall contain below listed items as minimum :

Scope of work (site specific ) Details of the piping pressure test sections. Schematic drawing of test sections. Drawing of test equipment arrangement and connections, which include component

material and pressure rating. Drawing of test header. Hydrostatic pressure diagram for test section. Water analysis. List of lines in the package, test media and test pressures Marked up P& IDs showing limits of testing Test Piping Isometrics Welding, heat treatment and NDE clearance Cleaning and Flushing certificate Safety requirement (site specific). List of test team personal with responsible

3.1.3 Piping systems which are open to atmosphere (such as drains, vents, outlets of safety valves,

perforated pipes etc.) and not subjected to internal pressure during operation, shall not be pressure tested, but cleaned and flushed using water or compressed air.

3.1.4 Packaged units such as hydraulic pump sets, compressors, generators and diesel drives etc. shall be isolated and by-passed if necessary.

3.1.5 Pressure gauges used to indicate and record test pressure . The gauges shall be calibrated prior to use and thereafter at a frequency of every 10 tests and witnessed by Company when requested .

3.1.6 The ambient temperature of the pipework shall be recorded continuously and the record shall be included in the test packages.

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Issue date 31-12-2012 Doc. No : TKF-00-ME-MST-0007 Rev.2 Page 4 of 31 3.1.7 If defect is found, it shall be repaired in accordance with the Approved method statement for

Station piping Fabrication and Installation TKF-00-ME-0001 and re-testing shall be carried out in accordance with this method statement.

3.1.8 The overall pressure testing philosophy shall be based as far as possible on the testing of complete systems including valves, vessels, and in-line instruments with the same design and consequently the same test pressure.

3.1.9 A leak test shall be performed following reinstatement to prove a sub-system or system and / or untested joints. The leak test will be carried out at 95 % of the stage relief valve setting or the maximum dead head pressure of any pump in the system not protected by a relief valve

3.1.10 There are two types of performing strength test related to the media that is used to obtain pressure:

Hydrostatic Test Pneumatic Test

4.0 DEFINITIONS

Definitions of the terms and Legend for the abbreviations used in this document and its

Employer, Company, Client : Groupe OCP S.A Engineer, PMT,Consultant : Jacobs Engineering S.A. (Owners Engineer) Contract : The main contract between the Owner and the Contractor. Contractor, Buyer : Tekfen Construction and Installation Co. Inc., acting as

main EPC contractor to owner for execution of the Project.

Works, Facilities : All the system, equipment, material, provided by the Contractor in connection with the design, engineering, construction and/or

installation of the Project

Drawing : Related drawings approved by the Company for Construction.

Approved : The revision of the related Contractors document such as procedure, plan, drawing etc. which was approved by the Company.

Minimum Test Pressure : The lowest allowable test pressure gage reading. (The calculated test pressure plus the additional pressure resulting from the static head of the test fluid).

Maximum Test Pressure : The highest allowable test pressure gage reading. (The pressure test rating of the weakest component in the test system).

Piping : An assembly of piping components being tested at one time using a single test method statement.

Test Temperature : The minimum temperature occurring during the test period of either the metal temperature of the piping being tested (including any vessels or equipment included in the test) or the test fluid



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FOR STATION PIPING


temperature.

System Test : A test that includes multiple sections of piping, having the same or different design pressures, but which are tested together at one time using a single test method statement and pressure.

5.0 REFERENCE DOCUMENTS

Following parts and clauses of the contract documents are referred.

1593-S-M-046 Technical Specification for Station Piping Materials 1593-S-M-051 Technical Specification for Station Piping Works 1593-S-P-011 Technical Specification for hydrostatic testing of cross-country

pipelines. 1593-S-P-017 Technical Specification for Non Destructive Examination of Field Welds 1593-S-P-020 Technical specification for Welding and Qualification Procedures PAC-00-PP-SPE-0005 Technical Specifications for Station Piping and Valves. PAC-00-PP-SPE-0007 Technical Specification for Rubber Lining of Pipes and

Pipe Fitting

PAC-00-PP-SPE-0008 Technical Specification for Polyurethane Lining PAC-00-PP-SPE-0009 Technical Specification for Fabrication of Pipe Spools PAC-00-PP-DAT-0300 Station Piping Class Data Sheet Pack. TKF-00-QA-PLN-0001 Project Quality Plan TKF-00-QA-PLN-0002 Inspection and Test Plan TKF-00-QA-PLN-010 Corrective and Preventive Action Procedure TKF-00-HS-PLN-0001 HSE Execution Plan TKF-00-HS-PLN-0003 Personnel Transportation Management Plan TKF-00-HS-PLN-0009 The Equipment and Materials Transportation

Management Plan

TKF-00-GE-PRO-0002 General Welding Procedure TKF-00-GE-PRO-0003 NDT Works Procedure



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FOR STATION PIPING

Issue date 31-12-2012 Doc. No : TKF-00-ME-MST-0007 Rev.2 Page 6 of 31 6.0 CODES and STANDARTS All work shall be performed in accordance with the requirements of the latest editions

of all applicable codes, rules and regulations.

API 5L Specification for Line Pipe. API 1104 Welding of Pipelines and Related Facilities ASME B 31.11 Slurry Transportation Piping Systems ASTM American Society for Testing Materials ISO International Organization For Standardization



Document Title:


FOR STATION PIPING


7.0 ORGANIZATION

CONSTRUCTION MANAGER ENGINEERING DEPARTMENT

QC DEPARTMENT

SITE ENGINEER

TEST ENGINEER

TESTING TEAM

TEST PACK COORDINATOR



Document Title:


FOR STATION PIPING


8.0 RESPONSIBILITIES 8.1 Construction Manager

Under the guidance of Construction Manager the Site Engineer / HSE Engineer and Hydrotest Engineer shall be responsible for the implementation of the procedure within the OCP slurry pipeline Project. Under the guidance of Construction Manager the Site Engineer / Hydro test Engineer shall be responsible for the management of all pressure testing on the work site of the Project

Engineering Department Engineering Department shall prepare a comprehensive Test Pack showing the test limits (In P&ID, isometric and GA Drawing), test media, test pressure, operating pressure, concessions and deviation approvals and the relevant forms.

8.2 Engineering Department

Engineering Department shall prepare a comprehensive Test Pack showing the test limits (In P&ID, isometric and GA Drawing), test media, test pressure, operating pressure, concessions and deviation approvals and the relevant forms.

8.3 Site Engineer

Site Engineer shall be responsible for the Test Pack punch list clearance for the pressure test.

8.4 QC Department

QC Department shall be responsible for verification of punch list item clearance, correctness of the Test Pack document, the test coverage of the documented test circuit with respect to P&ID , As Built Drawings / Mark up Drawings and GA Drawings, Witnessing the test and preparation of documentation.

8.6 Hydro-Test Engineer

Hydro-test Engineer shall be responsible to organize the test, after Quality Control clearance of the Test Pack for the test .Hydro test Engineer or designated Test Pack coordinator is responsible for the flow of Test Pack. Over all responsibility of conducting the test, in a safe manner, lies with the Hydro test Engineer.

Before Start up hydrotest activities , SPA have to prepare in three Languages (Turkish, Arabic and English) and all hydrotesting team shall be trained by Hydrotest Engineer about the risk related these activities. These Method Statement shall be dispatched by Hydrotest Engineer to all people concerned about the method statement

8.7 HSE Engineer

HSE Engineer shall be responsible to ensure that the correct safety precautions detailed in this method statement are implemented by the pressure testing team.



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FOR STATION PIPING


9.0 Determination of Test Fluid

9.0.1Test fluid shall be in accordance with Company Specification for Hydrostatic Testing Doc. No.: 1593-S-P-011

9.0.1 Following tests may be applied in lieu of the hydrostatic strength test subject to Companys approval.

9.0.2 Pneumatic strength test instead of hydraulic test will be applied for conditions below.

a. For testing linings or internal coating of Station Piping.

b. Where hydrostatic test would contaminate a process which would be hazardous, corrosive, or inoperative in the presence of moisture,

c. Where it is difficult to obtain water having a Cl (chloride ion) content within the specified limits for pipes made of austenitic stainless steel,

d. Where piping system is not designed to carry full water load and it is difficult to support the weight of water with additional temporary support.

9.1 Line Punching and Test Pack Processing Prior Pressure Test

9.1.1 According to the project schedule, Engineering Dept shall prepare the Test pack and transmit to the Test pack coordinator. TP Coordinator shall transmit the TP to construction Manager to confirm that the piping system in the concerned TP is ready for test. No punch items are balance.

Punch Item Code

A Item -Items if not completed, shall not proceed with pressure test on the grounds of safety to the system or personnel and/or incomplete test parameters.

B Item -items if not completed, can proceed for pressure test, but shall not proceed for commissioning.

C -Item which are to be completed in a timely manner before commissioning. Where A items are activities which can affect the performance/integrity of the system during hydrostatic / pneumatic / leakage testing namely hot work on the pressure contain

proper supports to the pipe etc. The above activities shall be completed before testing. QC Manager shall have the final authority to decide the punch item code. If no A item pending in the Test Pack received by the site engineer, he may transmit the TP to TP Coordinator for further processing after completing his part in the document. TP is then transmitted to QC Dept. for punching . The assigned QC Inspector shall punch the line and verify NDT completion and documentation, attach weld control sheet. If any A item balance, TP goes back to Construction Manager through TP Coordinator and returns through the same channel after A item clearance. After clearance from QC Dept, TP is transmitted to Company inspector for verification. Once the TP is cleared by Company



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inspector and returned to TP Coordinator, it is transmitted to the Hydro-test Engineer for performance of the test. Once the test pack received at the test centre, testing team shall check that all the sensitive instruments are isolated; valves in the test circuits isolated/opened (As the case may be) test limits are bolted properly, expansion bellows removed or secured and pre -test checklist signed off , correct test medium available, test area barricaded and KEEP AWAY sign boards ready. Issue Inspection request to the concerned QC personnel for test witnessing according to relevant ITP, well in advance to the test, but at any case not less than twenty four hour before the commencement of the test.

9.2 Equipment / Instruments / Tools

The following equipments, instruments and tools shall be available for performing the pressure test. All test equipment must be rated at an equal or greater working pressure than the test requirements.

9.2.1 Pressurizing Pump .Two type pressure test pump will be used

a-Hand operated test pump :Test pressure 2-200 bar

b-Electric or petrol engine driven test pump : 2-200 bar

9.2.2 Air Compressor(if necessary)

9.2.3 Pre tested Testing manifold complete with isolation valve, PSV, hose etc

9.2.4 Two nos. of pressure gauges with current calibration status and serial number.

9.2.5 Filling pumps -With Sufficient capacity and suitability

9.2.6 Calibrated torque Wrench

9.2.7 Thermometer

9.2.8 Test Gaskets, Spades, Blanks and other fittings to conduct the test.

9.2.9 Pipe Cleaning Prior to Test

Piping system to be tested shall be cleaned before hydrostatic/pneumatic/leakage testing of piping. Pipe cleaning shall be done with compressed air before erecting the pipe spools and also before pressure testing. For piping spools DN20 and above ,pipe cleaning shall be documented with a pipe cleaning report to ensure that the pipe was cleaned and erected. Test water will be stored at the sufficient volume mobile tank for feeding test pump or will be flushed line .Second sufficient volume mobile tank will be used for discharge of tested or flushed line water.

9.2.10 General Requirements

One pressure gauge shall be on the lowest point (On manifold) and the other on the highest point of the test circuit.

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Vents shall be provided at high points of loops to be tested. Consideration shall be given to the position of the entire test circuit geometric configuration while providing venting arrangement to ensure entrapped air is vented out fully.

Piping sub-assemblies may be tested either separately or assembled. All joints, including welded and bonded, are to be left unpainted and exposed for

examination during testing. Piping shall be provided with necessary supports in order to support the weight of

test medium If a pressure test is to be maintained for period of time in extreme temperature variation and the test fluid is subject to thermal expansion, precautions shall be taken to avoid excessive pressure built up due to this climatic factor. Temperature of test medium shall not go below 5 degree centigrade. Where ever permanent gaskets and bolts are provided, material correctness shall be cross checked and proper tightness to be reconfirmed by QC Inspector as a Key Performance area

10.0 Determination of Test Pressure

10.0.1 The hydrostatic and pneumatic test pressures shall be as indicated on the line list (PAC-00-ME-DAT-0002) and shall be based on the requirements of ASME 31.11, ASME B31.1, ASME B31.4 and ASME B31.8 as appropriate for piping and piping systems. Systems, which are, open to atmosphere and not subjected to internal pressure during operation, shall not be pressure tested, but cleaned and flushed using water or compressed air.

10.1 Flushing

10.1.1 General

10.1.1.1 Flushing shall be performed prior to hydro test.

10.1.1.2 Package units that have been flushed and tested and sealed at the manufacturers shall not be flushed again unless specified otherwise.

10.1.1.3 Instrument measurement devices shall not be installed until flushing and hydrostatic testing is completed.

10.1.1.4 Ball valves shall be in fully open position during flushing .

10.1.1.5 Lines which do not require flushing but shall be blown down with either air or nitrogen to ensure that lines are not blocked or restricted.

10.1.1.6 Main headers shall be flushed out first and then all the branches, which connect to any equipment. All necessary precautions shall be taken to ensure that debris is not flushed into associated equipment or dead ends. Flushing will be done by discharging hydrostatic test fluid or air.



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10.1.1.7 Flushing through mechanical equipment (i.e. vessels, pumps, exchangers and skid units) shall not be permitted. However, testing may be undertaken when considered practical.

10.2 Execution conditions

10.2.1.1 For the flushing, Contractor shall provide all necessary pumping units, any vessel, tanks or reservoirs, filters and strainers to the site in required quantities.

10.2.1.2 The medium used for flushing shall be the same as that required for the pressure test.

10.2.1.3 Where the flushing medium is water the flow velocities should be 11/2 to 2 times the normal operating velocity or 3 to 4 m/sec whichever is the greater. Where flushing velocities cannot be attained the piping shall be high-pressure jet cleaned.

10.2.1.4 Where the flushing medium is air or steam, the flow velocity should not be less than 20 m/sec.

10.2.1.5 Circulation of the flushing media shall continue until the piping system has been free from slags, dirts any other foreign materials. Company supervisors shall witness the process and check cleanness of flushing water visually at any time they require.

10.2.1.6 Flushing through mechanical equipment ( i.e vessels, pumps, exchangers, and skid units) shall not be permitted. However flushing into tanks and vessels may be allowed at the discretion of the Company site Engineer providing that the flushing water discharges shall be lead to suitable drainage system.

Flushing air discharge shall be routed to a suitable safe location as regards personnel protection.

11 EXECUTION OF HYDROSTATIC TEST FOR PIPEWORK

11.0 General 11.0.1 All in-line valves shall be in fully open position during the test

11.0.2 At least two pressure gauges shall be provided for strength test in consideration with the following conditions:

a. One gauge shall be installed at piping system near pressure source. b. One gauge shall be installed at piping system as far as possible from pressure source. c. Pressure range of gauge shall be of 1.6 2.0 times of test pressure. d. All pressure gauges used for the test shall be calibrated and certified.



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e. One pressure gauge will be installed at the lowest point of the piping system and the test pressure will be considered as, at this gauge, if these pressure difference in between gauges, due to height.

11.0.3 The following piping components shall be removed, isolated, or replaced with temporary test spool:

a. Expansion bellows having a test pressure less than the systems test pressure, b. Disk of check valve locating at opposite against the flow of pressure source, c. Relief valve and rupture disc, d. In-line instrument designated by the Company.

11.0.4 Blinds used for isolation at a flanged joint of piping system shall be provided as follows:

a. Minimum thicknesses of blinds are provided and selected acc.to ANSI 16.5 standard as resist of test pressure

b. A handle colored in red will be provided at outside of blinds for identifying the purpose of test use.

11.0.5 Blind flange shall be the same rating as piping system.

11.0.6 Any tie-in welds that cannot be hydrotested require additional NDT testing in accordance with Technical Specification for Non Destructive Examination of Field Weld No. 1593-S_P-017 must be identified in advance by contactor and procedures approved in advance by the Owner.

11.0.7 Joints, including welds, shall be left un-insulated and exposed for examination during the test, except that joints previously tested in accordance with this method statement may be insulated or covered. However, by getting Companys approval, it should be possible to make the strength and leak test of the process piping systems after coating and wrapping in some practical cases. The joints which are left un-insulated for testing purpose shall be insulated after test.

11.0.7 Underground portions of piping systems may be tested and covered before testing aboveground portions.

11.0.10 Lines that are supported by counterweight shall be temporarily blocked during testing in order to sustain the weight of the test fluid. Spring hangers that have been provided with stops for carrying the test load normally do not require additional temporary supports; if this is not the case, temporary support must be provided before filling the system.In case of using temporary support will be provided calculation note from Engineering Department.

11.0.8 Before testing, the following procedures shall be carried out: a. Verify that any required heat treatment has been performed. b. Piping systems shall have been completely checked (punched out). c. Lines, vessels, and equipment shall be checked to ensure that the entire system can be

completely drained after testing. d. Vents or other high point connections shall be opened to eliminate air from lines that are

to receive a hydrostatic test. e. Verify that there are not any obstacles in the pipework, if any big obstacles found it should

be checked and removed from the inside of the pipework by lifting up and down or any other applicable methods.

f. Before testing, test team has to verify that mechanical equipment is well isolated and protected.

g. For communication of testing team mobile phones or hand radios will be used at site before (prechecking) and during test.

11.0.9 Field personnel shall review all vessels and internals in order to determine best method

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to prevent air entrapment when filling and to prevent vacuum when draining.

For prevention of system ; vents or other high point connections shall be checked and opened before test and after test during water filling and drain time by test team to eliminate air and vacuum from lines .

11.0.10 Short pieces of piping that must be removed to permit installation of a blind or blank shall be tested separately.

11.0.11 Flanged joints at which a blind is inserted to isolate a system from other equipment during a test shall be leak tested as per para 3.1.11 after reinstatement.

11.0.12 Lines containing check valves shall have the source of pressure located in the piping upstream of the check valve so that the pressure is applied under the seat. If this is not possible, remove or jack up the check valve closure mechanism or remove check valve completely, and provide necessary filler piece or blinds.

11.0.13 When conducting tests at freezing temperatures, the test shall not take more than 1 hours, and special precautions such as warming the line test water or adding anti-freezing solutions to the test water shall be done to avoid freezing damage. Heating machines, insulating the pipework are other examples of suitable precautions.

11.0.14 Systems that include expansion joints shall be investigated to see that any required temporary restraints, anchors, or guides are installed or removed prior to test. When a pressure test is required to be maintained for a period of time during which the testing medium in the system would be subject to thermal expansion, provision shall be made for relief of any pressure greater than the maximum test pressure.

11.0.15 During strenght testing an exclusion zone shall be marked out with plastic barrier tape and warning notice displayed announcing that Pressure Testing is being undertaend. Only personnel that are directly invovled in the testing method statement shall be allowed inside teh exclusion zone and only when absolutely necessary. The Site Piping Engineer in consultation with the Site Safety Officer shall determine the exclusion zone. Only competent personnel shall be involved in the hydrotesitng process.

11.0.16 All personnel directly invovled with Pressure Testing will attend a Task Risk Assessment Meeting prior to testing commencing.

11.1 Hydrostatic Test 11.1.01 Procedure for hydrostatic test shall be as follows:

a. Fill with water in piping system. Approved water will be used. A water analysis must be performed 14 days prior to using water obtained for the pressure test.

b. Release all air from piping system, c. Pressurization must be carried at a steady rate of not more than 2 bars per minute as

follows: c.1.Pressurize to %75 of approved test pressure. c.2. Pressurize to %90 of approved test pressure. Hold the pressure for half an hour. c.2. Pressurize to %100 of approved test pressure.

d. Hold test pressure at least 1 hours minimum, then check joints and confirm no leaks.

e. The following measurements must be recorded:

e.1.Initial test pressure reading from pressure gauge..

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e.3.Continuous test pressure vs. time measurement and recording.

e.4.pipe/soil temperature vs.time at least every 0.5 hours.

e.5. If necessary pipe/soil temperature measurement and recording.

e.6. Recording for pressure/temperature (ambient) .

11.1.02 Water to be used for test shall be fresh and clean. Chloride (Cl-) ion content of water used for austenitic stainless steel and other Ni-Cr alloy shall be less than 30 p.p.m, and all water shall be immediately drained and completely blown out after testing. The system will be dried if specified.

11.1.03 The pipe system shall remain pressurized until all connections have been checked for tightness, but in no case shall the duration of the test be less than 1 Hours . The entire line should be walked to determine whether there is any evidence of leakage. Any leaks found at the time shall be marked and repaired after first depressurizing the line. For repair of leakage; first reason of leakage have to verify, decide necessary work that will done and after depressurizing the line repair works have to start.

11.1.04

11.1.05 After the test has been completed, the pressure must be bled down slowly at a rate of not more than 3 bar per minute to a pressure not less than atmospheric pressure.

11.1.06 All drained lines shall be thoroughly dried after testing by blowing through with warm, dry, oil free air with velocities in excess of 20m/sec.

11.1.07 When ever possible, flushing shall be undertaken during daylight hours and during dry weather.

11.1.08 In order to hydrostatic testing as much piping as possible at one time, a systems test may be employed. This test shall include one or more lines and, if possible, connected pumps and equipment.

11.1.09 The maximum system test pressure shall not exceed the pressure test rating of any piping component, or the shop test pressure of any vessels or equipment included in the test system.

11.1.10 Where a suitable valve is not available, vessels, equipment, or other piping not included in the system pressure test shall be either disconnected from the system or isolated by blinds or other means during the test.

11.1.11 Hydrostatic test pressure shall not be applied until the vessel or equipment and its contents are at approximately the same temperature.

11.1.12 Ball valves shall be half closed during strength test.

11.1.13 Check valves shall have their disk removed or jacked open.

11.1.14 Bonded joints shall not be put in pressure testing before 24 hrs after bonding of the joints completed.

11.2 Pneumatic Test 11.2.01 The test medium shall be oil free air or any inert gas.

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11.2.02 After lining of piping system ,liner shall successfully complete low pressure pneumatic air test. The liner shall be tested minimum pressure of 200 psig for a minimum of ten (10) minutes ,or as required by owner, to determine that no measurable pressure loss has occurred. See PSI doc 1593-S-P-009 Rev 0 section 7.2.

11.2.03 Pneumatic test shall not be executed when the ambient temperature is below 5 o C.

11.2.04 The use of air testing shall be limited to a maximum pressure of 6.8 barg above this pressure nitrogen shall be used.

11.2.05 Procedure for pneumatic strength test shall be as follows:

a. Increase pressure at the lesser of .35 barg or 10 % of the test pressure gradually by using air compressor, gas holder, line air or the combination of those pressure sources. Then check joints and confirm no leaks as a preliminary tightness check.

b. Thereafter, increase pressure gradually to 60 % and wait for a sufficient length of time to allow the piping equalize strains for a period of time not less than ten minutes. The pressure shall then be reduced to 50 % of the indicated test pressure and all joints re-tested for leaks.

c. Pressurize the system in steps of not more than 10 % until the required test pressure has been reached. The pressure shall be held at each step during the pressurizing sequence for a period of time not less than 10 minutes. The required test pressure shall be held 30 minutes and reduced to the maximum working pressure and held for a sufficient length of time to permit the testing of all joints, but under no circumstances shall this period be less than 30 minutes. Joints and welds shall be covered with soap solution in order to detect any leakage. Soap shall be a commercial preparation made specifically for leak detection.

11.2.06 A bubble-forming solution shall be used to detect leaks.

11.2.07 Each reinforcing pads and similar attachments shall be tested at a pressure of at least 1 barg with air, a soap solution shall be used to detect the leaks.

11.2.08 At time of testing, the minimum pipe metal temperature shall be in accordance with Table 4:

TABLE 4 Minimum pipe metal temperatures

Materials and W/T Minimum Temperature Carbon Steel,W/T 40mm & less 15oC Post Heated Ferritic Steel, W/T 25 mm & less

15oC

Austenitic Steel, W/T 25 mm & less 4oC Minimum temperatures for materials not listed above shall be determined by

Company when required by field construction. 11.2.09 Clear the test area before bringing the line up to test pressure. It may be

desirable to conduct pneumatic tests during weekends when fewer personnel are present.

11.2.10 A pressure relief device shall be provided, having a set pressure no higher than the test pressure plus the lesser of 50 kPa or 10 % of the test pressure.

11.2.11 Before soaping the joints, the entire line should be walked to determine whether



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there is any audible evidence of leakage. Any leaks found at the time shall be marked and repaired after first depressurizing the line. For repair of leakage; first reason of leakage have to verify, decide necessary work that will done and after depressurizing the line repair works have to start.

11.3 Line Service Fluid Test (Commodity Test) for Category D Fluid Service 11.3.01 A piping system used only for Category D Fluid Service, not previously

hydrostatic or pneumatic tested in accordance with this method statement, may be tested at the normal operation conditions of the system during operation by examining for leaks at every joint.

11.3.02 A preliminary check shall be made at no more than 172 kPa pressure when the contained fluid is a gas or vapor. The pressure shall be increased gradually in steps providing sufficient time to allow the piping to equalize strains and to check leaks.

11.3.03 Unless dictated otherwise by contractual provision, line service fluid test shall be performed by Companys Designated Inspector prior to mechanical completion.

11.3.04 Lines which require Line Service Fluid testing shall be clearly identified on the piping drawings and line lists.

11.4 System Reinstatement 11.4.01 When the strength tests are completed, all strainers shall be removed, cleaned

out and reinstalled. Temporary strainers shall be kept in the lines during normal operation. They will be removed and discarded when deemed no longer necessary by the Operations Engineer.

11.4.02 If it is impossible to remove the water with air.

11.4.03 All connections broken after shall be made up with new gaskets in the presence of the Companys Inspectors and they shall be leak tested after reinstatement. The bolting shall be torqued to the requirements of the Company Specification .

11.4.04 If leaks are found, their location shall be marked, the pressure shall be gradually released, and the piping shall be drained or vented. Appropriate repair or replacement shall be made. The affected piping shall be retested at the pressures originally specified for the test. Retesting of minor repairs or additions may be waived, provided approval of Company is obtained and the welding is nondestructively examined.

11.4.05 After completion of testing, all temporary blanks and blinds shall be removed, all operating blinds returned to proper position, and all lines and piping components shall be completely drained. Valves, orifice plates, expansion joints, and short pieces of piping that have been removed shall be reinstalled with proper new gaskets in place.

11.4.06 Lines being drained after testing shall have all vents open. Piping systems downstream of check valves should be inspected to ensure complete drainage.

11.4.07 Direct connected transmitters at orifice flanges must be disconnected when replacing orifice plates to avoid distorting the connections.

11.4.08 Care shall be exercised in controlling the rate of drainage from vessels with respect to the inflow of air through the vent to ensure that the vessel is not subjected to vacuum. After vessels have been completely drained, vents, cyclones, and other internal closures that were opened before testing shall be closed.

11.4.09 After lines have been drained, temporary supports shall be removed, and



Document Title:


FOR STATION PIPING


insulation and painting completed. Spring hangers provided with stops to carry the test load shall have these stops removed.

11.4.10 General items for the re-assembly works as listed below: a. Instruments which were removed or blocked out for test shall be reinstalled and blocks

placed in the normal operating position. b. Temporary bolts and gaskets used for pressure testing shall be removed and replaced

with new line class bolts and gaskets. c. Check valves that were jacked open or the internals were removed for pressure testing

shall be returned to their proper operating position. d. Vessel and equipment internal closures which were opened specifically for pressure

testing shall be closed. e. Instruments and process lead lines that were subjected to the hydrostatic pressure test

shall be blown out with dry air or nitrogen. f. All vents and drain connections that are added solely for pressure testing shall be screw

plugged and seal welded . Drains shall have either the valve closed and plugged or, if the valve is removed, the connection plugged and seal welded. Seal welded vent and drain connections shall be inspected by visually and by magnetic particle inspection.

g. Painting and lining shall be completed after NDE inspection of seal welded vents and drains.

h. Strainer screens shall be removed, cleaned, and reinstalled

12.0 ACCEPTANCE OF PRESSURE TEST FOR PIPEWORK

No leaks shall be acceptable for the piping systems.

13.0 SAFETY IN PRESSURE TESTING & FLUSHING FOR PIPEWORK

Site piping engineer in consultation with the site Safety officer shall determine the exclusion zone.

Only one personnel (site supervisor or foreman) shall be involved in the hydrostatic testing. All tests shall be coordinated with regard to other construction activities. If required, a risk analysis may be done for special and difficult conditions by Site piping

engineer and Site safety officer.

13.1 Hydrostatic Pressure Testing Precautions for hydraulic pressure testing include the following:

a. To avoid the risk of freezing, the temperature of the water during the test should not be less than +4 Co.

b. Steps should be taken to ensure that blanking devices and items such as screwed plugs or connections are not liable to be ejected during testing, particularly as the result of thread failure.

c. Pipe work being tested must be totally filled with liquid and properly vented to exclude air pockets.

d. Hydrotesting testing should be carried out by a person trained for the purpose and have experience in such works.



Document Title:


FOR STATION PIPING


e. The pressure should be applied gradually or increased by steps of approximately 10 % until the required test pressure is reached. At this stage the pressure should not be further increased.

f. The pipe work should not be approached for close examination until a reasonable period of time has elapsed. For the safety of personnel, it may be necessary to consider remote viewing procedures rather than close physical examination related to the hydraulic test pressure.

g. The pipe work shall not be subjected to any form of shock loading such as hammer testing while undergoing a pressure test.

h. If a leak is observed, pressure shall be decreased and tightening of the bolts can be executed.

i. Test area shall be barricaded for the entrance of the personnel.

j. Safety warning signs and warning lights in foggy weathers shall be used for the information of the personnel.

13.2 Pneumatic Testing 13.2.1 This method of testing is potentially more dangerous because the energy stored within the pressure system could be released explosively in the event of failure under test. Pneumatic testing should be avoided unless there are technical reasons for it.

13.2.2 Before testing, an assessment of the equipment or pipe work should be made and a detailed inspection should be carried out.

13.2.3 Where practicable, steps should be taken to reduce to a minimum the internal volume of the system to be tested. This has the effect of reducing the consequences of a rupture under test. It may be practicable to isolate sections of the complete system and to test them separately, followed by reassembly and leak testing.

13.2.4 Local chilling during filing and emptying of the pipe work should be reduced by exercising sufficient control to avoid sudden changes in flow rate across inlet and exhaust control valves or nozzles.

13.2.5 Full number of studs or bolts provided for blanking flanges shall always be used. Any studs or bolts with worn or damaged threads shall be replaced.

13.2.6 Test gas shall be controlled by using reducing valves and other valves that regulate the flow of test gas into the pipe work or equipment.

13.2.7 Flexible pipes and their connections shall be regularly examined to reduce the risk of failure. The risk of injuries to personnel nearby may be reduced by the use of safety restraints attached of the connection.

13.2.8 Test area shall be barricaded for the entrance of the personnel.

13.2.9 Safety warning signs and warning lights in foggy weathers shall be used for the information of the personnel.



Document Title:


FOR STATION PIPING


13.2.10 Interchangeable pressure test components such as blank flanges, studs, pressure gauges, pressure relief devices and flexible connections shall be regularly examined by an appointed personnel.

13.2.11 Pressure test components shall be stored and identified to assist correct selection and use for the warning intended.

13.2.12 A range of air pressures may be required from a common source of supply. In order to reduce the risk of an incorrect pressure being connected, it may be advisable to have different sizes or types of connections on hose ends, and to arrange that the equipment or the pipework being tested has compatible connections.

13.2.13 Where flexible tube connections are used, they shall be securely fastened.

13.2.14 Proper pressure relief devices should always be provided and used for pressure testing. As it is vital that safety valves are supplied and maintained in proper working order, a test of the setting is required at the initial and subsequent periodic examination, repair or replacement. Safety valves shall be removed regularly and be stripped, cleaned, examined and before re-use the set pressure checked



Document Title:


FOR STATION PIPING

Issue date 31-12-2012 Doc. No : TKF-00-ME-MST-0007 Rev.2 Page 21 of 31 14.0PRESSURETESTACTIVITYFLOWCHART 1 2

7 3 8 5 6 4

9

10121111

ENGINEERING DEPT. To prepare TP with as

built and forms

CONSTRUCTION for confirmation of line completion and

punching

TP COORDINATOR

for processing

WITNESS TEST,SIGN TEST

,RECORD

FLUSHING COMPLETE

REINSTATEMENT COMPLETE

,B ITEM CLEARED

QC JESA-QC TEKFEN TEST

PACK RELEASE RECORD

JESA for approval

QC DEPARTEMENT Line Punch

NDT/PWHT/ITR/Weld log input

HYDROTEST ENGINEER raise RFI-Perform test



Document Title:


FOR STATION PIPING

Issue date 31-12-2012 Doc. No : TKF-00-ME-MST-0007 Rev.2 Page 22 of 31 15.0 HAZARD EFECT AND MANAGEMENT PLAN FOR FLUSHING AND HYDROTESTING

15.1 INTRODUCTION 15.1.1 Hazard Assessment

Hazard assessments form the basis of controlling hazards. That should be seen as an important tool in ensuring that the activities dont present risks and that the controls implemented are appropriate.

Hazard assessment is something that we do every day so we shall not be scared of it. For example: When pouring water into a bath, we check the water temperature by sampling with our hand. This is the tool to control the hazard of scalding because the water may be too hot. In the same way, we use hazard assessments for activities such as lifting a box. By following the activity in steps, and identifying the potential hazards in a logical way, we can perform the activity in a safely manner.

Hazard assessment for the project activities is a systematic process whereby Workers, Foremans, Supervisors, Engineers and Managers identify, assess and control hazards that may affect anybody involved in the project activities or third party.

Once the hazards are identified, an action plan is prepared and hazards are then controlled by being eliminated or minimized. Workers, Foremans, Supervisors, Engineers and Managers are an essential part of the Hazards Assessment process.

Hazard assessment is and can be a pro-active way of preventing an accident or incident occurring and can be useful in preventing an incident/accident reoccurring.

15.1.2 Scope The Hazards and Effects Management Plan (HEMP) is a live document, which will be updated during the project execution. The scope of this document is as follows:

Assess the significant HSE hazards associated with all the construction activities of the OCP Slurry Pipeline Project.

To propose realistic control measures which can minimise the risks associated with the identified hazards.

To define certain recovery measures to ensure minimum harm to Health of Employees, Equipment and Environment if any of the controls fail.



Document Title:


FOR STATION PIPING


15.2 METHODOLOGY 15.2.1Process

Hazards and Effects Management Process (HEMP) comprises five steps as follows:

Identify and list activities for Specific work Identify hazards, threats and potential hazardous events Assess the risks against accepted screening criteria, taking into account the likelihood

of occurrence and severity of the consequences to people, assets and the environment

Record the significant hazards and effects Implement suitable risk reduction measures (control and mitigate) Plan for recovery in the event of a loss of control

15.2.2 Hazard Identification Hazard identification is carried out based on the judgment of the experts in the fields. This process is based on brainstorming, think of the activities to be performed and then think what could go wrong.

15.2.3 Risk Assessment

After identifying the hazards of the activities of the proposed scope of work of the OCP Slurry Pipeline project, the associated risks are assessed on the following RAM (Risk Assessment Matrix). (Ref-HSEP 2.22- Hazard Identification and Risk Assessment)



Document Title:



Incident Severity Incident Likelihood or Probability Improbable Remote Occasional Probable Frequent

Productivity or Downtime

Environment Property Personnel Severity Level

A B C D E

> 2 weeks Permanent damage

beyond project boundary

Total facility loss Fatality or total

permanent disability

5

1 week to

2 weeks

Permanent damage within project boundary or reportable release

beyond boundary

Damage to an entire facility or loss of multiple systems in a

facility

Permanent partial disability 4

> 1 day to

< 1 week

Reportable release within project boundary

with no permanent damage

Damage to an entire facility or

multiple systems in a facility

requiring repair or replacement

Days away 3

day to

1 day

Release within project boundary below

reporting quantity with clean-up by external

source

Damage to a facility element or system requiring

repair or replacement

OSHA Recordable or

E-1 2

< day

Release within project boundary below

reporting quantity with clean-up by internal

source

Damage to a facility element or system requiring negligible or no

repair

First aid 1

Risk Mitigation Controls High (H)

Operation not permitted; must implement controls to reduce risk to an acceptable

or manageable level.

Medium (M)

Operation permitted with a

time limited waiver endorsed by management.

Low (L)

Operation permitted with implementation of core

HSE program elements.

L

M

H



Document Title:


Issue date 31-12-2012 Doc. No : TKF-00-ME-MST-0007 Rev. 2 Page 25 of 31

Job / Task 4.7 HEMP - 012 - Hydro Testing Piping (Pressure, Flushing)

ACTIVITY SIGNIFICANT HAZARDS

HAZARD EFECTS

What could go wrong? How serious would that

be?

RISK RATIN

G

CONTROL MEASURES How to prevent it?

Elimination (E), Prevention (P), Control (C) or Mitigation (M)

RESIDUAL RISK

RATING (After the

controls are in place)

RECOVERY MEASURES

HYDRO TESTING OF

PIPING

Incompetent/ Untrained

Personnel. Inadequate

Supervision

Fatality, Injury, Asset Damage

H

H

Discuss SPA Toolbox talk. Ensure all persons in the crew are attended HSE induction. Prepare the method statement, SPA approval, and the work

permit system shall be obtained prior to start activities. All persons involved on the job have to discuss and

understand the work permit, method statement and the SPA. Approved hydro test engineer and competent supervision.

L

L

FOLLOW EMERGENCY

RESPONSE PROCEDURE

Call

HSE Manager

0661775749

Dy HSE Manager Stations

0652706957

HSE Supervisor JORF

0662164708

Construction Site Chief Stations

0652706963

Site Engineer JORF Terminal station

Defective Equipments and Tools


Ensure all equipment shall be inspected and certified. Ensure the relief valves and pressure gauges calibrated. Check all the emergency systems and devices are functional

and current certification provided. Follow Method statement. All the hoses must be inspected before the activity starts for

the defects Ensure whip line check safety cables are installed on all the

hose connections / couplings suitable fire extinguishers to be placed on site use only good quality and proper size of spanners and hand

tools use only standard torque wrenches and pressure hoses

High pressure Personal Injury Property Damage

Proper and specific toolbox talk Pressure systems are depressurized, drained, vented and

made safe and that all preparatory work is completed All the equipment used for the activity should be tested and

certified



Document Title:





HAZARD EFECTS


be?

RISK RATIN

G



RESIDUAL RISK

RATING (After the


RECOVERY MEASURES

All the certificates shall be made available at site Ensure Whip check safety cables are installed on all the

hose connections / Couplings Barricade the area and display sufficient warning signs Inform the other close by work activity supervisors No other activity shall be allowed in the vicinity No one except the experienced test group people shall be

allowed with in the 30 meter distance on both the ends Emergency response team shall be informed Medics with standby ambulance All the high pressure flexible hoses must be anchored with

sand bags or satisfying weight / loads to prevent undue movement

0655247378

TIGHTENING THE FLANGE TO ARREST THE LEAK

WHILE PIPE IS UNDER PRESSURE

Bursting the gasket / pipe

Defective spanner

Untrained manpower

Inadequate supervision


H

H

Do not tight any flange when the pipe is under pressure Depressurize the line before tightening the flange Use only good tools and spanners Deploy only trained manpower under close supervision Use proper PPEs specific to the work

L

FOLLOW EMERGENCY

RESPONSE PROCEDURE

Call

HSE Manager

0661775749

Dy HSE Manager Stations

0652706957

Inadequate communication system.

Injury, Asset Damage

Follow Method statement. 2 way radio/GSM, flags and signals.

Stored mechanical energy

Isolation failure. Fatality, Injury Damage to

equipment.

Isolation shall be verified by walking the plant and reviewing the Drawings prior to start-up of pressure testing.

All Isolation shall only be conducted by a qualified and competent Isolating Authority.



Document Title:





HAZARD EFECTS


be?

RISK RATIN

G



RESIDUAL RISK

RATING (After the


RECOVERY MEASURES

All pressure gauges shall be properly calibrated prior to start of pressure testing.

Isolate the work area, authorized personnel only allowed near test area.

HSE Supervisor JORF

0662164708

Construction Site Chief Stations

0652706963

Site Engineer JORF Terminal station

0655247378

2

DRAINING AND DRYING

THE PIPE AND

EQUIPMENT

Water spreading all over the area

Dewatering Partial drainage

of water from the pipe

Personal Injury Environmental

damage Development of

corrosion

Drain the water to a designated area Inspection prior to start the work Dry completely all the system

WASTE MANAGEMENT

Used Test water Scrape material

Damage to environment

Collect all the tools and material and dispose as per waste management procedure.

Vacuum truck. controlled disposal



Document Title:

METHOD STATEMENT OF FLUSHING AND HYDROTESTING FOR STATION

PIPING

Issue date 31-12-2012 Doc. No : TKF-00-ME-MST-0007 Rev. 2 Page 28 of 31 16.0 EMERGENCY RESPONSE PLAN

During the activity all staff must be aware of the ERP for that activity. Medical coverage must be available with a trained Nurse at site. Minor injuries shall be treated at the scene in the first instance. Should further treatment be required the IP shall immediately be transferred to the Ambulance and to be shifted to the Hospital 9Hassan-II-Khouribga and Settat) (Oum Arrabia) at JORF) for further treatment.

In the unlikely event that somebody is struck by debris or the trencher itself the casualty shall not be moved at all unless there is an immediate threat to life by the location they are in or by the nature of the injuries sustained. RLIC ambulance shall immediately be called to the scene; in the meantime the Primary First Aider shall ensure the stability of the casualty.

In the event of a fire during the activity then the fire extinguishers at the scene should be used to tackle the blaze if possible, all un required staff should be evacuated from the location to the nearest Assembly Point. Local Civil fire service should be called immediately to assist if necessary. All engines and electrical sources should be switched off and isolated. During in any ERP all other activities in the area shall immediately be stopped until advised otherwise by the Senior Staff at the scene. Once the ERP has been activated and the immediate threat is controlled the Project Management including HSE must be informed of the incident or accident. The scene should be sealed, either by staff or barriers if possible to ensure that this area remains the same for photographs and other investigation steps that may be required. Depending on the nature and severity of the incident the Police may be required to attend the scene and to carry out their own investigation. For investigation purposes all people who were involved in the activity are to identify themselves to the HSE Supervisor to assist in the investigation process.



Document Title:


PIPING


Project Manager 0652706939

Deputy Project Manager 0661754502

Sr. Const. Manager. P/L & Stations 0661050035

Sr. Const Manager. Feeder P/L 0655247041

Construction Manager Pump Stations 0652706931

Construction Manager(Main P/L)

0661748625

Construction Manager for Const. E &I Works

0661079671

Administration Manager 0652305111

Camps Manager 0661742894

HSE Manager 0661775749

Dy HSE Manager 0652706957

HSE Supervisor 0662164708

Doctor 0652305099

Nurse 0673239318

Nurse 0672336678

DriverPlate #: by -893- wt

0675064890

Nurse 0633762444

Driver Plate #: 19683 - 57- 0665162838

Nurse 0673239318

DRIVER 42415 -72- 0600721188

Nurse 0670860067

Driver Plate #: 58353- 8- 0673682057

Nurse 0653367457DriverPlate #: 25496 - 48 - 0648058753

Nurse 0668151042DriverPlate #: 19682 - 57- 0677844600

Nurse 0633744372

DriverPlate #: 24489 - 34- 0673202568

Nurse 0679689108

DriverPlate #: 62017 - 8- 0666994488

Doctor 0661715561

Nurse 0668151042

Nurse 0676130602

Doctor 0661696119

Nurse 0670228021

Nurse 0655435848LGC - AMBULANCE DRIVERPlate #: 19901 -40- 0671534026

0650388372

0523492003

177

19

SETTAT CAMP- NIGHT

SETTAT CAMP- DAY

Overall project Mustafa TEZER

Overall project Ali Nejdet BAKKAL

Ahmet YILDIRIM

Khouribga Kenan SEKERYAPAN

AMINE MORABIT

FIHER YOUSEF

BOUCHRA HAJLI

WASSIM FATIHA

HICHAM CHAKIB

AMINE MAHHDDAR

AYOUB HANANE

DAOUI STATION

Head Station / TSF

KHOURIBGA CAMP-NIGHT

ROW - PAINTING/ COATING CREW

ABDELWAHED ADLI

LEHSEN LOJINI

AZIZ HAFDI ROW - WELDING CREW

ROW - STRINGING CREWABDELAH EL MEZAH

ISSAM TAYEBHELASSA STATION

YOUNES ARBANI

JAMAL KASAROUI

GSM

Necmettin SENGUN

Ali HAMZALIOGLU

Abid FAYYAZ

Anouar SADIQ

Deniz CAYMAZ

Name

Mustafa KOPUZ

A. Fatih ISILDAR

Mustafa ERCIN

AMRI NOUREDDINE

ABDELAH ABOUTOUM MHAMMED ABOUTOUM

YOUNES ERRAKI

ANAS EL ATTARY

ZAHRA BENSADA

Revised - 08 August-2012

Location

Overall project

Overall project

Overall project

Civil Protection Khouribga

Gendarmerie

TSF

Head Station / TSF

JORF LASFAR

Job Title

LGC WORK LOCATIONS

NAJIB DAKHILI

ROW - BENDING CREW

YOUNES MOUNDA

Reda SAAA

TEKFEN CONSTRUCTION OCP SLURRY PIPELINE PROJECT

Overall project

Overall project

Overall project

In case of emergency call the numbers above. Acil durumlarda yukaridaki numaralari arayabilirsiniz.

En cas D'Urgence appeler les numeros ci dessus.

Police

Head Station / TSF

KHOURIBGA CAMP-DAY

Emergency Contacts & Response Team

EL FAKIR MOHAMMED

ABDELHAMID TALITE

Overall project

HAFIDA EL FETTAHI

TERMINAL STATION



Document Title:


PIPING

Issue date 31-12-2012 Doc. No : TKF-00-ME-MST-0007 Rev. 2 Page 30 of 31 17.0 ATTACHMENT

17.0.1 Test Header

17.0.1 Pump Station Line List (PAC-00-ME-DAT-002) for Test Pressure



Document Title:


PIPING


7 10 Oct 12 NT

6 24 Jul 12 NT

5 17 Jul 12 NT

4 15 Jun 12 HG

3 10 Apr 12 HG

2 20 Mar 12 HG

1 07 Mar 12 HG

0 04 Jan 12 HG

B 07 Dec 11 HG

A 01 Aug 11 -

Reviewed

TEKFEN

Org. Code Area Code Disc. Code

1305 PAC 00 ME 7 10

Issued for Construction Code A (Design Update) AR MK

PUMP STATION LINE LIST

Checked

MK

Total pages

(w.

attachmts)

Issued for Internal Review

Prepared

Rev.

No.

AR MK


Issued for Construction Code A (Design Update) AR

MK

MK

DAT 0002

Description

SUBCONTRACTOR

PAC Proj.

No.

Document No.

Doc. Type Seq. No.

Groupe OCP S.A.Casablanca, 2, rue Al Abtal, Hay Erraha,

Morocco

EPC CONTRACTOR

ORIGINATOR

KHOURIBGA JORF LASFAR

PHOSPHATE SLURRY PIPELINE SYSTEM

Document Title

DateRev.

No.


MK

Issued for Construction Code A (Design Update)

Issued for Construction Code A per JESA-TKF-DCS-0472 (No

Comments)

Issued for Information

AR

AR

AR



No TagSequence

NumberContents Area From To Pipe Class

Size

(NB)

Internal

Diameter

(mm)

Max Flow

Rate

(m/h)

Max Velocity

(m/s)

Operating

Pressure

(kPa)

Pressure

Rating

(kPa)

Test Pressure

(kPa)P&ID

1 03-0101-RL31-400-PS 0101 PS 03 Low grade thickener 1216-TH-001 & -002 underflow pumps03-LR-001 RL31 400 363.3 1350 3.6 1100 5100 5610 PAC-03-PR-PID-0001

2 03-0103-UL30-400-PS 0103 PS 03 03-LR-001 03-0104-PL34-400-PS UL30 400 363.3 1350 3.6 1100 5100 5610 PAC-03-PR-PID-0001

3 03-0104-PL34-400-PS 0104 PS 03 03-0103-UL30-400-PS Head Station receiver PL34 400 377.8 1350 3.3 1100 1965 2162 PAC-03-PR-PID-0001

4 03-0105-EL21-400-PW 0105 PW 03 03-0001-EL21-400-PW 03-0101-RL31-400-PS EL21 400 387.3 1350 3.2 600 1965 2950 PAC-03-PR-PID-0001

5 03-0001-EL21-400-PW 0001 PW 03 Process water supply - EL21 400 387.3 1350 3.2 600 1965 2950 PAC-03-PR-PID-0001

6 03-0201-RL31-300-PS 0201 PS 03 High grade thickener 1216-TH-003 underflow pumps 03-LR-002 RL31 300 280.7 675 3.0 1100 5100 5610 PAC-03-PR-PID-0001

7 03-0202-UL30-300-PS 0202 PS 03 03-LR-002 03-0203-PL35-300-PS UL30 300 280.7 675 3.0 1100 5100 5610 PAC-03-PR-PID-0001

8 03-0203-PL35-300-PS 0203 PS 03 03-0202-UL30-300-PS Head Station receiver PL35 300 301.4 675 2.6 1100 1965 2162 PAC-03-PR-PID-0001


10 03-1103-EL22-150-PS 1103 PS 03 03-0101-RL31-400-PS Drain to station pad EL22 150 154.1 - - 0 N/A N/A PAC-03-PR-PID-0001

11 03-1104-SS20-50-PW 1104 PW 03 03-LR-001 Hose connection SS20 50 49.2 20 2.9 600 1965 2947 PAC-03-PR-PID-0001

12 03-1105-EL22-150-PS 1105 PS 03 03-LR-001 Drain to station pad EL22 150 154.1 - - 0 N/A N/A PAC-03-PR-PID-0001




16 03-1301-SS20-50-PW 1301 PW 03 Process water supply Hose connection SS20 50 49.2 20 2.9 600 1965 2947 PAC-03-PR-PID-0001

17 07-0001-RL31-450-PS 0001 PS 07 Low grade thickener 1116-TH-001 & 002 underflow pumps07-TK-001 RL31 450 413.9 1350 2.8 350 5100 5610 PAC-07-PR-PID-0001

18 07-0003-RL21-450-PS 0003 PS 07 07-TK-001 Feeder line pumps RL21 450 413.9 1350 2.8 350 1965 2160 PAC-07-PR-PID-0001

19 07-1401-RL21-200-PS 1401 PS 07 07-PU-201 Low grade thickener RL21 200 178.7 250 2.8 675 1965 2160 PAC-07-PR-PID-0001

20 07-1003-EL22-500-PS 1003 PS 07 07-TK-001 overflow Drain to station pad EL22 500 488.9 - - 0 N/A N/A PAC-07-PR-PID-0001

21 07-1004-EL22-350-PS 1004 PS 07 07-TK-001 Drain to station pad EL22 350 336.5 - - 0 N/A N/A PAC-07-PR-PID-0001

22 07-1008-SS20-80-PW 1008 PW 07 07-0003-RL21-450-PS Hose connection SS20 80 73.7 40 2.6 600 1965 2947 PAC-07-PR-PID-0001

23 07-1301-EL21-400-PW 1301 PW 07 Process water supply - EL21 400 387.3 - - 600 1965 2950 PAC-07-PR-PID-0001

24 07-1302-SS20-100-PW 1302 PW 07 07-1301-EL21-400-PW Blank flange SS20 100 97.2 - - 600 1965 2947 PAC-07-PR-PID-0001

25 07-1303-SS20-50-PW 1303 PW 07 07-1302-SS20-100-PW Hose connection SS20 50 49.2 20 2.9 600 1965 2947 PAC-07-PR-PID-0001


27 07-1305-SS20-80-PW 1305 PW 07 07-1302-SS20-100-PW Sump SS20 80 73.7 - - 600 1965 2947 PAC-07-PR-PID-0001


29 07-1307-SS20-80-PW 1307 PW 07 07-1301-EL21-400-PW Hose connection SS20 80 73.7 40 2.6 600 1965 2947 PAC-07-PR-PID-0001

30 07-1001-SS20-40-PW 1001 PW 07 07-0003-RL21-450-PS Spillage sump SS20 40 40.9 27 5.7 600 1965 2947 PAC-07-PR-PID-0002

31 07-0101-RL21-450-PS 0101 PS 07 07-0003-RL21-450-PS 07-PU-001 RL21 450 413.9 1350 2.8 350 1965 2160 PAC-07-PR-PID-0002

32 07-0105-RL31-450-PS 0105 PS 07 07-PU-004 07-0004-RL31-450-PS RL31 450 413.9 1369 2.8 3296 5100 5610 PAC-07-PR-PID-0002



35 07-1311-EL21-200-PW 1311 PW 07 07-1301-EL21-400-PW - EL21 200 202.7 - - 600 1965 2950 PAC-07-PR-PID-0002

36 07-1312-EL21-150-PW 1312 PW 07 07-1311-EL21-200-PW 07-0101-RL21-450-PS EL21 150 154.1 - - 600 1965 2950 PAC-07-PR-PID-0002


38 07-1314-SS20-100-PW 1314 PW 07 07-1311-EL21-200-PW - SS20 100 97.2 - - 600 1965 2947 PAC-07-PR-PID-0002


40 07-1316-EL21-150-PW 1316 PW 07 07-1315-EL21-400-PW 07-1315-EL21-400-PW EL21 150 154.1 180 2.7 600 1965 2950 PAC-07-PR-PID-0002



43 07-0004-RL31-450-PS 0004 PS 07 Pump train discharge 07-LR-001 RL31 450 413.9 1369 2.8 3296 5100 5610 PAC-07-PR-PID-0003

44 07-0005-UL30-450-PS 0005 PS 07 07-LR-001 Overland pipeline to Head Station UL30 450 413.9 1369 2.8 3296 5100 5610 PAC-07-PR-PID-0003



47 07-1321-SS20-100-PW 1321 PW 07 07-1314-SS20-100-PW - SS20 100 97.2 - - 600 1965 2947 PAC-07-PR-PID-0003






53 07-1327-SS20-50-PW 1327 PW 07 07-1321-SS20-100-PW Hose connection at 07-LR-001 SS20 50 49.2 20 2.9 600 1965 2947 PAC-07-PR-PID-0003

54 07-1411-RL21-200-PS 1411 PS 07 07-PU-202 07-1412-RL21-200-PS RL21 200 178.7 - - 675 1965 2160 PAC-07-PR-PID-0003

55 07-1412-RL21-200-PS 1412 PS 07 07-1411-RL21-200-PS 07-1413-RL21-200-PS & 07-1414-RL21-200-PS RL21 200 178.7 - - 675 1965 2160 PAC-07-PR-PID-0003




59 07-1501-EL21-200-GW 1501 GW 07 Daoui wash plant 07-TK-101 EL21 200 202.7 - - 100 1965 2950 PAC-07-PR-PID-0004

60 07-1502-SS20-80-GW 1502 GW 07 07-TK-101 Drain to station pad SS20 80 73.7 - - 100 1965 2947 PAC-07-PR-PID-0004

61 07-1503-EL22-200-GW 1503 GW 07 07-TK-101 Drain to station pad EL22 200 202.7 - - 0 N/A N/A PAC-07-PR-PID-0004

62 07-1211-EL21-200-GW 1211 GW 07 07-TK-101 - EL21 200 202.7 - - 100 1965 2950 PAC-07-PR-PID-0004

63 07-1111-EL21-200-GW 1111 GW 07 07-TK-101 - EL21 200 202.7 - - 100 1965 2950 PAC-07-PR-PID-0004


Groupe OCP S.A. Casablanca Morocco

Doc. no: PAC-00-ME-DAT-0002 Issue date: 10 Oct 2012 Rev. 7

Document Title:


Total Pages: 10

Page 2 of 10

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(NB)

Internal

Diameter

(mm)

Max Flow

Rate

(m/h)

Max Velocity

(m/s)

Operating

Pressure

(kPa)

Pressure

Rating

(kPa)

Test Pressure

(kPa)P&ID




Document Title:


Total Pages: 10

64 07-1121-SS20-80-GW 1121 GW 07 07-1111-EL21-200-GW 07-PU-101 SS20 80 73.7 - - 100 1965 2947 PAC-07-PR-PID-0004

65 07-1123-SS30-50-GW 1123 GW 07 07-PU-101 07-1124-RH60-25-GW SS30 50 49.2 - - 3446 5100 7650 PAC-07-PR-PID-0004

66 07-1124-RH60-25-GW 1124 GW 07 07-1123-SS30-50-GW 07-PU-001 RH60 25 unknown - - 3446 7750 9688 PAC-07-PR-PID-0004






















88 07-1413-RL21-200-PS 1413 PS 07 07-1412-RL21-200-PS Settling Pond 1 RL21 200 178.7 250 2.8 675 1965 2160 PAC-07-PR-PID-0006

89 07-1414-RL21-200-PS 1414 PS 07 07-1412-RL21-200-PS Settling Pond 2 RL21 200 178.7 250 2.8 675 1965 2160 PAC-07-PR-PID-0006

90 08-0020-RL31-350-PS 0020 PS 08 Low grade thickener 1316-TH-006 & -001 underflow pumps- RL31 350 312.5 598 2.2 350 5100 5610 PAC-08-PR-PID-0001

- 08-0021-RL31-350-PS 0021 PS 08 08-0020-RL31-350-PS 08-TK-001 RL31 350 312.5 598 2.2 350 5100 5610 PAC-08-PR-PID-0001

91 08-0022-RL31-350-PS 0022 PS 08 08-0020-RL31-350-PS 08-TK-002 RL31 350 312.5 598 2.2 350 5100 5610 PAC-08-PR-PID-0001

92 08-0010-RL31-350-PS 0010 PS 08 High grade thickener 1316-TH-008 underflow pumps 08-0011-RL31-350-PS & 08-0012-RL31-350-PS RL31 350 312.5 849 3.1 350 5100 5610 PAC-08-PR-PID-0001

93 08-0011-RL31-350-PS 0011 PS 08 08-0010-RL31-350-PS 08-TK-001 RL31 350 312.5 849 3.1 350 5100 5610 PAC-08-PR-PID-0001

- 08-0012-RL31-350-PS 0012 PS 08 08-0010-RL31-350-PS 08-TK-002 RL31 350 312.5 849 3.1 350 5100 5610 PAC-08-PR-PID-0001

94 08-0201-RL21-500-PS 0201 PS 08 08-TK-002 08-0030-RL21-500-PS RL21 500 464.9 598 1.0 350 1965 2160 PAC-08-PR-PID-0001

95 08-0101-RL21-500-PS 0101 PS 08 08-TK-001 08-0030-RL21-500-PS RL21 500 464.9 849 1.4 350 1965 2160 PAC-08-PR-PID-0001







102 08-1301-EL21-500-PW 1301 PW 08 Process water supply - EL21 500 488.9 - - 600 1965 2950 PAC-08-PR-PID-0001

103 08-1331-EL21-250-PW 1331 PW 08 Process water supply - EL21 250 254.5 370 2.0 600 1965 2950 PAC-08-PR-PID-0001

104 08-1302-SS20-100-PW 1302 PW 08 08-1331-EL21-250-PW 08-1304-SS20-80-PW SS20 100 97.2 - - 600 1965 2947 PAC-08-PR-PID-0001



107 08-1305-SS20-50-PW 1305 PW 08 08-1331-EL21-250-PW Hose connection SS20 50 49.2 20 2.9 600 1965 2947 PAC-08-PR-PID-0001



110 08-1308-SS20-50-PW 1308 PW 08 08-1306-SS20-100-PW Hose connection to top of tank SS20 50 49.2 20 2.9 600 1965 2947 PAC-08-PR-PID-0001


112 08-1401-RL21-200-PS 1401 PS 08 08-PU-201 Low grade thickener 1316-TH-006 RL21 200 178.7 - - 675 1965 2160 PAC-08-PR-PID-0001

113 08-0030-RL21-500-PS 0030 PS 08 08-0201-RL21-500-PS 08-0031-RL21-500-PS RL21 500 464.9 1446 2.4 350 1965 2160 PAC-08-PR-PID-0003



116 08-0031-RL21-500-PS 0031 PS 08 08-0030-RL21-500-PS 08-0102-RL21-500-PS & 08-0202-RL21-500-PS RL21 500 464.9 1446 2.4 350 1965 2160 PAC-08-PR-PID-0003

117 08-1032-SS20-50-PW 1032 PW 08 08-0031-RL21-500-PS Spillage sump SS20 50 49.2 - - 600 1965 2947 PAC-08-PR-PID-0003






123 08-1312-EL21-150-PW 1312 PW 08 08-1331-EL21-250-PW 08-1311-EL21-400-PW EL21 150 154.1 220 3.3 600 1965 2950 PAC-08-PR-PID-0003

Page 3 of 10

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Size

(NB)

Internal

Diameter

(mm)

Max Flow

Rate

(m/h)

Max Velocity

(m/s)

Operating

Pressure

(kPa)

Pressure

Rating

(kPa)

Test Pressure

(kPa)P&ID




Document Title:


Total Pages: 10











134 08-0032-RL31-500-PS 0032 PS 08 08-0107-RL31-500-PS & 08-0207-RL31-500-PS 08-LR-001 RL31 500 464.9 1470 2.4 4120 5100 5610 PAC-08-PR-PID-0004

135 08-0033-UL30-500-PS 0033 PS 08 08-LR-001 Overland pipeline to Head Station UL30 500 464.9 1470 2.4 4120 5100 5610 PAC-08-PR-PID-0004




139 08-1322-SS20-50-PW 1322 PW 08 08-1317-SS20-100-PW Hose connection SS20 50 49.2 20 2.9 600 1965 2947 PAC-