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USGC Gulfstream Program 700_GS_509_13The Dow Chemical Company of 42

Hydrostatic Testing New Equipment / Piping Systems in Construction Areas In Proximity to Operating Systems Procedure - OSBL

Scope 1.1 This procedure covers the general safety requirements for the setup and operation of equipment and instrumentation necessary to perform a hydrostatic test on newly constructed, completely isolated piping systems in close proximity to operating systems – no connection to process or utility systems in Construction OSBL Areas.Parts of this procedure follows under the Gulfstream EH&S variance.

1.2 This practice is to be used in conjunction with G4S-6421-02 [Class C, Hydrostatic Testing], G4S-6421-03 [Class G – Hydrostatic Testing], G4S-6423-01 [Class F – Fire Water Systems Testing], G4S- 6428-01 [Class M – Thermoplastic Piping: Hydrostatic Testing], G8S-4001-60 [Specification for Water Quality Used For Hydrostatic Testing], G8S-5034-03 [Hydrostatic Leak Testing] and G4S- 6421-04 [Hydrostatic Testing Equipment Procedure].NOTE: Contractor specific practices must be evaluated for agreement with Dow Hydrostatic Testing practices and where differences are identified, agreement between the contractor and Dow Engineering practices must be established.

This procedure must be attached and completed as part of the contractor’s specific requirements and documentation for the overall hydrostatic testing process.

L&EOs covered by this procedure

This procedure is used for the following LEO tasks:

Opening vent and drains Line breaks on analyzers & instruments (e.g. blowing leads) Removing/replacing of caps, plugs, blind flanges, and pressure gauges, Removing/replacing safety valves. Removing/replacing small bore piping or tubing Changing gaskets, Connecting Hydro Testing equipment to piping systems Slip blind installation/removal

Categories and attributes

Categories

Critical Emergency Operating Other

Attributes

Routine Non-routine

Equipment Status The status of equipment covered under this LEO procedure is:

In Service Cleared Isolated New & Isolated

Continued on next page

L&EO Hydro Test Procedure This is a controlled document. No un-authorized modifications. Health, Safety, and Environmental

DOW CONFIDENTIAL – Do not share without permission


Hydrostatic Testing New Equipment / Piping Systems in Construction Areas In Proximity to Operating Systems Procedure - OSBL, Continued

Additional Hazard Analysis

Based on a review of section 4.2 of the Global L&EO Standard, the additional Hazard Analysis is NOT required for this procedure. No combustible, flammable, toxic, water reactive or unstable materials have being contained or will be introduced into the piping system that is being hydrostatically tested – new construction, new piping systems.

Hazards and precautions

The table below lists job hazards and the precautions that should be taken when using this procedure. For specific chemical hazards and the precautions needed to prevent exposure, refer to the Material Safety Data Sheets (MSDS) for the chemicals involved.

Hazards and precautions

Abrasions Back Strain Burns (>60C/140F)

Chemical Exposure

Cuts Driving Dust Electrical (>50V) Environmental Ergonomics Falls (>=6 ft) Fire Flammable (L3) Fumes Lighting Low Oxygen Noise (>85db) Pinch Points Pressure (>30

psig) Radioactive (L4)

Rotating Equip Slip Hazard Stairs Temperature Thermal Stress Toxic Weather Excessive force Long duration

task Repetition Heavy lifting Bending torso

Twisting torso Environmental Arms extended Arms out of neutral

Hands/ Wrist out of neutral

Vibrations Other

Hazard Precaution

Chemicals Involved: High Pressure Water

Requirements on what PPE and when it must be used (by task and/or chemical) can be found in the PPE section below.






Hazards and precautions (continued)


Hazard Precaution

Personnel not involved in the LEO Clear the area of non-essential personnel. Area where the hydrostatic testing is to be performed must be cleared of non-essential personnel at least 6.7 ft (2 Meters) from the system being tested. The safe distance must be specified by the group performing the hydrostatic testing.Use “RED BARRICADE and TAGS” to prevent non-essential personnel from entering. For Hydrostatic Testing <1000 PSIG, the area

around the testing rig will be barricaded. Non-essential personnel working around flanges of the system under pressure must be informed of the hazard by the Hydro Testing Crew Foreman. Depending on the assessed potential hazard, HSE personnel may elect to barricade the area further around the flanges.

For Hydrostatic Testing at ≥ 1000 PSIG, the sections of the line where the large percentage of the flanges are located (i.e., control valve stations, pipe section drop downs where there is a high potential to personnel exposure to flanges of the line under pressure, etc) will be Red Barricaded in addition to the area around the test rig. Depending on the assessed potential hazard, HSE personnel may elect to barricade the area further around the flanges.

Test Stand Safe Distance must be clearly established for Pneumatic Testing.Reference: G4D-6422-01 for guidance.Follow the respective Pneumatic Testing LEO Procedure.

Flammables If working in proximity to equipment / lines containing combustible or flammable chemicals or within the 35 FT effected area of a flammable area, monitor area with LEL meter for potential flammables present, surrounding work area.







Hazard Precaution

Radioactive Sources If applicable, close and isolate radiation device per IOES standard and local agency requirements. Follow proper procedure for isolating radiation source and confirming it is isolated.

Environmental Considerations If required, use containers, absorbent materials and spill containment, provide instructions for properly disposal of removed insulation, drained material and washing.

NOTE:

Water used to perform hydrostatic testing must be collected and disposed in accordance with environmental guidelines. Consult Dow environmental coordinator for specific questions.

Emergency Response Procedure Locate and test the nearest safety showers Ensure a clear escape path is kept open as well as identify alternate access/egress routes. Use the buddy system or two way radio communication to contact IR personnel or emergency personnel.

Inadvertent Pressure Release De-pressure equipment by slowly opening specifically identified vents and drains. Break flanges away from the body. Do not stand in the line of fire.

Line Of Fire Ensure that no part of the body is positioned in the line of fire while executing the required tasks.Examples: Inspecting flanges for leaks while the line is pressurized, approaching flanges while the line is being pressurized or under pressure, etc.








Hazard Precaution

Energy Sources Equipment / Piping System must not be connected to any process or utility systems. The Hydrostatic Testing Crew Foreman and the Dow Safe Work Permit Writer must verify that the system is not connected to any Dow process or utility systems.Ensure that all the energy sources are effectively controlled or isolated for the duration of the L&EO. Verify that systems that are being Hydrostatically Tested are isolated from systems that could have construction personnel exposed to the high pressure of the test.If the equipment / piping system being tested is connected to other new systems that are under construction (i.e., branch connections, etc) and that are not part of the system being tested, the equipment / piping system must be isolated following a LOTO process as follows in order of preference:

– The contractor specific LOTO process that meets Dow requirements.

– If contractor does not have a LOTO process, the Gulfstream Construction LOTO Process (F0278 Tagout Authorization Form, F0281 Danger – Do Not Operate Tag, F0279 Tagout Index, etc.) must be followed for new piping systems.

– For OSBL existing processes that are being modified or when specifically requested, the Dow Red Tag Master System must be followed.

If necessary, the “700_GS_509_02 List of Temporary Blinds for Pressure Test” must be filled out documenting the specifications and location of all split blinds utilized for isolation of the system.

Continue on next page.








Hazard Precaution

Energy Sources(Continue)

The isolation of energy sources will be verified by the Hydrostatic Testing Crew Foreman and documented on the attached form “700_GS_ 509_03 F75201 Pressure Test Report”.NOTE: If the system is connected to any Dow process or utility system, the system must be under the control of a Dow Operational Group, the Dow IOES (RTM system)and Return To Operation (RTO) processes must be followed and implemented by Dow Trained and Approved Operations Personnel.

Energy Sources – Pneumatic Testing

Warning:Pneumatic Testing should be used as the last alternative. Carefully planned, approved and supervised procedures must be followed. EMTL DE-G4D-6422-01 must be followed. Pressure testing conducted utilizing pneumatic testing must be approved by Dow Engineering and the Dow Construction Manager. Test Stand Safe Distance must be clearly established for Pneumatic Testing.Reference: G4D-6422-01 for guidance.

Follow the 700_GS_509_12 Pneumatic Testing LEO Procedure instead of this procedure.

Improperly calibrated testing equipment or insufficient personnel training

All hydrostatic testing equipment; pressure gages, relief valves, regulators, etc, must be calibrated and certified prior to be used on any hydrostatic testing.Personnel performing hydrostatic testing must be trained on the specific requirements.

If any physical contact or exposure occurs, report and seek medical treatment immediately!






PPE Requirements on what PPE and when it must be used (by task and/or chemical) can be found in the reference table below.The following PPE must be worn:

LEO Task Chemicals/Agents Involved

Required PPE and when it can be relaxed

Opening vent and drains High Pressure Water Hard Hat, Face Shield, Safety Glasses, High Visibility vest/shirt, Leather Gloves, Long Sleeves, Hearing Protection – may require double hearing protection based on noise level, Safety Steel Toe Shoes. Single Hearing Protection required at ≥ 85 db up to 105 db. Double Hearing Protection required at ≥105db. Face Shield and Double hearing protection can be relaxed once the system is de-pressured and the person is outside <105db limits.

L&EO activity (installing slip blinds, correcting leaks on the system being tested, etc.)

High Pressure Water See above!






Tools and equipment

The tools and equipment listed below are needed to do this job. Box End Wrench Bung Wrench Channel Locks Come Along Dial Indicator Fall Protection Flange Separator Hammer Laser Alignment Pry Bar Radios Rope Screw Driver Stands Supplied Air Bottles Torque Wrench O2/LEL meter Barricade Tape &

Tags Other:

Tools and/or Equipment Use (if explanation is needed)

Barricade ribbon/tape and warning signs Used to warn others of potential hazards and to maintain a safe zone away from the hazard.

O2/LEL Meter If required, to ensure safe atmosphere.

Hazard Monitoring The table below lists required monitoring to do this LEO job.

Type of monitoring Limits Where and When

Oxygen % (in the working atmosphere)

>19.5% - <23.0% If performing LEO in areas that could create an Oxygen deficient atmosphere.

LEL % 0% in case the break involves work within a flammable area.

If performing LEO in areas that contains flammable chemicals.






Identification of LEO Locations

The methods used for identification of line break locations are specified below:

This procedure will be used by non-operations personnel (e.g., construction, maintenance, etc).Acceptable options for identification of line break locations include: o The Hydrostatic Testing Crew Foreman (a trained construction representative) will be

responsible to physically indentify in the field the exact location of every break at the time that each break is initiated, then document as such in “700_GS_ 509_03 F75201 Pressure Test Report” and on the LEO Safe Work Permit.NOTE: This option is not recommended for OSBL – obtain approval from Dow Gulfstream EH&S Leader.

o Use the L&EO identification tags/labels. The L&EO identification tags must have the same information as the L&EO Identification tag on the example on Attachment No.1 (i.e., Yellow Tag) at the end of this procedure. Each tag/label is unique and non-perishable. Each L&EO Identification Tag (i.e., Yellow Tag) hung in the field to identify a L&EO must be numbered and listed on the LEO (Break-Bleed-Vent) Tag Location List. A copy of the LEO (Break-Bleed-Vent) Tag Location List can be found on Attachment No.2 at the end of this procedure or in the Gulfstream Safety Manual under the 52_GS_3320 Line and Equipment Opening Standard.

In case of multiple works being done in the same area, the numbering system used shall ensure that each tag being used to identify the location of the L&EO are clearly associated with the specific job.

If the contractor has a unique identification number for every pneumatic/ hydrostatic test to be performed on a specific project, their unique numbering system could be utilized to identify the specific L&EO identification tags.Example: For Hydrostatic Test on a line in PDH

Numbering System for L&EO Identification Tags (i.e., Yellow Tags):Hydrostatic Test Number: HP0535-04-WO-01

HP0535-1 for L&EO ID Tag #1HP0535-2 for L&EO ID Tag #2And continue, Etc.

If the contractor does not have a unique identification number for every hydrostatic test.A specific numbering convention has been developed to meet this objective:Example: For Hydrostatic Test on a line in PDH

Numbering System for L&EO Identification Tags (i.e., Yellow Tags):Project-P&ID Number-Line Number-L&EO ID NumberPDH-P&ID Number-Line Number-1 for L&EO ID Tag #1PDH-P&ID Number-Line Number-2 for L&EO ID Tag #2And continue, Etc.




This number must be unique to this specific hydro



Before you begin Before beginning this procedure :

1. Review this entire procedure and become familiar with the requirements.

2. Verify that conditions (e.g., extreme environmental conditions, physical/chemical conditions, PPEs, risks associated with the activities) have not changed since the L&EO procedure was written. In case of changes, the work must be stopped and:

o The work being reassessed to document new hazards and precautionso If applicable, a new Hazard Analysis must be completedo As appropriate, the procedure updated.

Ensure an emergency procedure which includes provisions for decontamination of personnel, if necessary, is available prior to the LEO.

3. Evaluate there is a plan, if necessary, to collect and dispose of the hydrostatic test fluid used in the system in compliance with environmental regulations.

4. Safe Work Permits for Hydrostatic Testing will be issued per crew, per line tested for every working Shift/Day.

For Hydrostatic Testing work extending beyond one working shift (12 hrs), the work scope associated with the specific hydrostatic test must be evaluated to determine if the extension on time is justifiable, allowing the safe completion of the job scope: Could the testing be completed within the maximum 16 hours duration of a

Safe Work Permit? Does the same Hydrostatic Testing Crew is willing to stay and complete the

testing? Does the Dow Construction Manager or designee approve the extension of the

safe work permit to 16 hours to complete the specific work scope?

If the hydrostatic test will exceed the 12 hours, and the conditions above cannot be met, or exceeding the 16 hours, the on-coming shift and safe work permit issuer must be at work earlier and proceed to obtain a new safe work permit (i.e., complete field inspection, review job status, etc) and prepare to conduct a shift relief in the field with the off-going shift personnel (hot shift relief). Otherwise the specific piping system being hydrostatically tested must be placed in a safe condition (de-pressured, hydrostatic pump shut-off) and the job must be turned over to an on-coming work shift personnel. A new safe work permit will be issued for the new work shift.

NOTE: Under no circumstances should the line be left pressurized unattended.Example: Foreman shall maintain supervision while line is pressurized.System must be de-pressure when leaving area after hours.






Before you begin(continued)

To minimize the time required to issue the safe work permit, it is recommended that the hydrostatic test crew (i.e., contractor) has the Equipment / Piping System being tested prepared and ready to comply with the safe work permit requirements: The Hydrostatic Testing Crew Foreman and the Dow Safe Work Permit Writer must

verify that the Equipment/Piping System is not connected to any Dow process or utility systems.

Ensure that all the energy sources are effectively controlled or isolated for the duration of the L&EO. Verify that systems that are being Hydrostatically Tested are isolated from systems that could have construction personnel exposed to the high pressure of the test.

If the equipment / piping system being tested is connected to other new systems that are under construction (i.e., branch connections, etc) and that are not part of the system being tested, the equipment / piping system must be isolated following a LOTO process in order of preference:– The contractor specific LOTO process that meets Dow requirements.– If contractor does not have a LOTO process, the Gulfstream Construction LOTO

Process (F0278 Tagout Authorization Form, F0281 Danger – Do Not Operate Tag, F0279 Tagout Index, etc.) must be followed for new piping systems.


If necessary, “700_GS_509_02 List of Temporary Blinds for Pressure Test” must be filled out documenting the specifications and location of all split blinds utilized for isolation of the system.

The isolation of energy sources verification will be documented by the Hydrostatic Testing Crew Foreman on the form “700_GS_ 509_03 F75201 Pressure Test Report”.NOTE: If the system is connected to any Dow process or utility system, the system must be under the control of a Dow Operational Group, the Dow IOES (RTM system)and Return To Operation (RTO) processes must be followed and implemented by Dow Trained and Approved Operations Personnel.

The L&EO breaks must be identified as per the requirements of this procedure [i.e., The L&EO identification tags (Yellow Tagged) and listed in the LEO (Break-Bleed-Vent) Tag Location List].o LEO: Vent and drain valves must be identified as per the requirements of this

procedure [i.e., The L&EO identification tags (Yellow Tagged) and listed in the LEO (Break-Bleed-Vent) Tag Location List].

o LEO: The location where the testing equipment is to be connected to the Equipment/Piping System to be tested must be identified as per the requirements of this procedure [i.e., The L&EO identification tags (Yellow Tagged) and listed in the LEO (Break-Bleed-Vent) Tag Location List].





Hydrostatic Testing New Equipment / Piping Systems in Construction Areas In Proximity to Operating Systems Procedure - OSBL, Continued, Continued

Before you begin (continued)

o The testing equipment (i.e., hydrostatic testing pump and relief device, hoses, gauges, etc) must be connected to the Equipment / Piping System being prepared for hydrostatic testing with a double block and bleeds with check valves (prevent back flow into utility systems and allow to de-pressure the system to connect and disconnect the testing equipment).

o LEO: If additional fill hoses are required to expedite the filling of the Equipment / Piping System, the lines used to fill the system (fill hoses), if connected through locations other than the test rig, must be connected with double block and bleeds with check valves (prevent back flow into utility systems and allow to de-pressure system to connect and disconnect test medium) to the fill valve(s) of the system being tested. The location where the fill lines are to be connected to the Equipment/Piping System to be tested must be identified as per the requirements of this procedure [i.e., The L&EO identification tags (Yellow Tagged) and listed in the LEO (Break-Bleed-Vent) Tag Location List].

NOTE: Do not commence filling of the system until the safe work permit has been issued.

Red barricades and barricade tags must be installed, preventing personnel not involved in the LEO, entering test area as per the guidance of this procedure. Depending on the assessed potential hazard, HSE personnel may elect to barricade the area further around the flanges.






Safe Operating Limits

The Safe Operating Limits must be documented on the “700_GS_509_03 F75201 Pressure Test Report” or a similar form with the same information.

Otherwise the specific Hydrostatic Testing safe operating limits must be documented below as applicable. If not applicable, the line must be filled as “N/A”.

Safe Operating Parameter Limit Value Units

Testing Fluid To BE Used Approved by QC Mgr & Dow Construction Mgr or Designee

Ref: G8S-4001-60

Test Media/Metal Minimum Testing Temperature

DEG C ( DEG F)

Test Media/Metal Maximum Testing Temperature

DEG C ( DEG F)

Ambient Temperature Minimum Temperature

4.4 (40) DEG C ( DEG F)

Minimum Testing Pressure PSIG (Bars)

Maximum Testing Pressure PSIG (Bars)

Hydrostatic Testing Rig Relief Valve Setting

PSIG (Bars)

Holding Time (Test Duration)

Minutes

System Component to be Tested Lowest MAWP

PSIG (Bars)

System Component to be Tested Lowest Brittle Fracture Temperature Limit

DEG C (DEG F)

Test Safe Distance(i.e., Barricading & Tagging)

Feet

Pressure Ramping Rate or Stages:________________________________________________________________

De-Pressure Rate or Stages:________________________________________________________________






Consequences of Deviation

This section lists any consequences of deviation from the procedure steps or safe operating limits.

N/A (There are no Consequences of Deviation associated with this procedure.)

Type of Deviation Consequences and How to Avoid

Inadvertent Pressure Release Personal injury (i.e., Eye injury, etc), equipment damage.De-pressure equipment by slowly opening specifically identified vents and drains. Break flanges away from the body. Do not stand in the line of fire.

Personnel not involved in the LEO, entering test area.

Personal injury (i.e., Eye injury, etc).Clear the area of non-essential personnel. Area where the hydro testing is to be performed must be cleared of non-essential personnel at least 6.7 ft (2 Meters) from the system being tested. Use “RED BARRICADE and TAGS” to prevent non-essential personnel from entering. See “Hazards” section on this procedure.Test Stand Safe Distance must be clearly established for Pneumatic Testing. Reference: G4D-6422-01 for guidance.

Follow the respective Pneumatic Testing LEO Procedure.

Performing improper LEO tasks:o line break on the wrong line or

equipment o opening line or equipment with

hazardous materials when not properly isolated, de-pressured and/or cleaned to acceptable levels

o Improper operation of valves on “In Service” line or equipment.

Possible chemical exposure or uncontrolled release of material. How to Avoid - Perform LEO activities in a cautious, controlled manner. Monitor for signs of material present. Return equipment to a safe position/state, if material is detected. Proper ID of LEO location Follow checklist/procedure Conduct thorough hazard analysis,

follow procedures.






Consequences of Deviation(continued)

This section lists any consequences of deviation from the procedure steps or safe operating limits.

Type of Deviation Consequences and How to Avoid

Failure to wear required PPE Removal or relaxing of PPE prematurelyCorrect PPE not identified

Possible personal injury.How to Avoid – Always use all the required PPE; do not remove or relax PPE if not specifically indicated by this procedure.Know hazards.Follow specified PPE hazards and task.

Inadequate Hazard Monitoring Possible chemical exposure, oxygen deficient atmosphere or fire/explosionHow to Avoid - Maintain hazard monitoring within the scope of work being performed, and take the necessary precautions to prevent exposure to the hazards identified.

Checking for leaks in inaccessible areas; i.e. scaffolds, ladders, platforms, etc.

Possible fall, personal injury.Follow elevated work standard, practices and procedures.Provide adequate access to work areas.






IOES Control Method Exclusive Control

Master Red Tag System Individual Red Tag System In Construction Areas; For Construction Outside Battery Limits (OSBL):o Equipment / Piping System must not be connected to any process or utility

systems. The Hydrostatic Testing Crew Foreman and the Dow Safe Work Permit Writer must verify that the line is not connected to any process or utility systems.

o If the equipment / piping system being tested is connected to other new systems that are under construction (i.e., branch connections, etc) and that are not part of the system being tested, the equipment / piping system must be isolated following a LOTO process in order of preference:– The contractor specific LOTO process that meets Dow requirements.– If contractor does not have a LOTO process, the Gulfstream Construction

LOTO Process (F0278 Tagout Authorization Form, F0281 Danger – Do Not Operate Tag, F0279 Tagout Index, etc.) must be followed for new piping systems.


NOTE: If the system is connected to any Dow process or utility system, the system must be under the control of a Dow Operational Group, the Dow IOES (RTM system)and Return To Operation (RTO) processes must be followed and implemented by Dow Trained and Approved Operations Personnel.






Summary of IOE Methods for One-Plus

List below the method(s) for One-Plus. The method of One-Plus should be listed as a note in the RTMS (if used) for each Isolation of Energy.

Lock Secure handle Disconnect air line

Design Remove fuse Disconnect leads Inaccessible Remove valve handle Round handled valve Slip Blind per Spec Other: Contractor Specific Do Not Operate Tags

List below the energy sources to be isolated and describe the hazards associated with them.

Energy Source Energy Description Hazard of Energy Source

Electrical <120 V >120 V

Electrocution, Electric Shock, Burns

Chemical Release Health or Fire Hazard:

Pressure Gas: <30 psig >30 psig

Liquid: <100psig

>100psig

Eye Injury, Personal Injuryhigh pressure water, potential mechanical system failure under pressure.

Mechanical Pinch Points Suspended Load Spring(s) Rotating Equip Other – de-

pressure

fracture, abrasion, caught between

Other






Line/Equipment Preparation and Opening Procedure

Use the procedure below to prepare a new construction piping system (no chemicals have being introduced into the system) to be isolated for Hydrostatic Testing. If not applicable fill as “N/A”.

Note: These steps must be followed in order and initialed as performed.

Step Action Initials & Date

1 3 Ensure that the Hydrostatic Crew Forman has been trained on the following processes and procedures:

G4S-6421-04-DES Hydrostatic Testing Equipment Procedure.pdfG4S-6421-02-DES Class C – Hydrostatic Testing.pdfG4S-6421-03-DES Class G – Hydrostatic Testing.pdfG4S-6423-01-DES Class F – Fire Water Systems Testing.pdfG4S-6428-01 DES Class M – Thermoplastic Piping.pdfG8S-4001-60 Specification for Water Quality Used For Hydrostatic TestingG8S-5034-03-DES Hydrostatic Leak Testing.pdf 700_GS_250 50050 Piping Pressure Testing.docx 700_GS_250.50050_01 Piping Pressure Testing Attachment 01.docx700_GS_250.50050_02 Piping Pressure Testing Attachment 02.docx700_GS_250.50050_03 Piping Pressure Testing Attachment 03.docx700_GS_250.50050_04 Piping Pressure Testing Attachment 04.docx700_GS_509_00 Hydrotest Legend.pdf700_GS_509_01 F75101 Aboveground Pipe Inspection Record.pdf700_GS_509_02 List of Temporary Blinds for Pressure Test.pdf700_GS_509_03 F75201 Pressure Test Report.pdf700_GS_509_04 F75602 Pipe Restoration Report.pdf700_GS_509_05 F75601 Pipe Cleaning And Verification Checklist.pdf700_GS_509_06 F75102 Visual Inspection of Flanges, Gaskets and Bolting.pdf700_GS_509_07 F78001 Coatings Inspection Record.pdf700_GS_509_08 F02407 Punch List _Construction.pdf

4 6 Confirm that the equipment / piping system to be Hydrostatically Tested in a construction OSBL area is completely isolated from any process and utility system. The Hydrostatic Testing Crew Foreman and the Dow Safe Work Permit Writer must verify that the system is not connected to any Dow process or utility systems.






Line/Equipment Preparation and Opening Procedure(continued)




7 9 Verify that form “700_GS_509_01 F75101 Aboveground Pipe Inspection Record.pdf” has been completed.

10 12 If applicable, verify that form “700_GS_509_06 F75102 Visual Inspection of Flanges, Gaskets and Bolting.pdf” has been completed.

13 15 If applicable, verify that form “700_GS_509_07 F78001 Coatings Inspection Record.pdf” has been completed.

16 18 If applicable, verify that form “700_GS_509_05 F75601 Pipe Cleaning And Verification Checklist.pdf” has been completed.










19 21 Inform and clear the area of non-essential personnel. Area where the hydrostatic testing is to be performed must be cleared of non-essential personnel at least 6.7 ft (2 Meters) from the system being tested. The safe distance must be specified by the group performing the hydrostatic testing.Use “RED BARRICADE and TAGS” to prevent non-essential personnel from entering as follows: For Hydrostatic Testing <1000 PSIG, the area around the testing

rig will be barricaded. Non-essential personnel working around flanges of the system under pressure must be informed of the hazard by the Hydro Testing Crew Foreman. Depending on the assessed potential hazard, HSE personnel may elect to further barricade the area.

For Hydrostatic Testing at ≥ 1000 PSIG, the sections of the line where the large percentage of the flanges are located (i.e., control valve stations, pipe section drop downs where there is a high potential to personnel exposure to flanges of the line under pressure, etc) will be Red Barricaded in addition to the area around the test rig. Depending on the assessed potential hazard, HSE personnel may elect to further barricade the area.

Verify that tags have being hung indicating that Hydrostatic Testing will be taking place.Test Stand Safe Distance must be clearly established for Pneumatic Testing.Reference: G4D-6422-01 for guidance.

Follow the respective Pneumatic Testing LEO Procedure instead of this procedure.








Note: These steps must be followed in order and initialed as performed


22 24 Ensure that all the energy sources are effectively controlled or isolated for the duration of the L&EO. Verify that systems that are being Hydrostatically Tested are isolated from systems that could have construction personnel exposed to the high pressure of the test.If the equipment / piping system being tested is connected to other new systems that are under construction (i.e., branch connections, etc) and that are not part of the system being tested, the equipment / piping system must be isolated following a LOTO process in order of preference:– The contractor specific LOTO process that meets Dow

requirements. – If contractor does not have a LOTO process, the Gulfstream

Construction LOTO Process (F0278 Tagout Authorization Form, F0281 Danger – Do Not Operate Tag, F0279 Tagout Index, etc.) must be followed for new piping systems.


If necessary, the “700_GS_509_02 List of Temporary Blinds for Pressure Test” must be filled out documenting the specifications and location of all split blinds utilized for isolation of the system.The isolation of energy sources will be verified by the Hydrostatic Testing Crew Foreman and documented on the form “700_GS_ 509_03 F75201 Pressure Test Report”.

NOTE: If the system is connected to any Dow process or utility system, the system must be under the control of a Dow Operational Group, the Dow IOES (RTM system)and Return To Operation (RTO) processes must be followed and implemented by Dow Trained and Approved Operations Personnel.










25 27 Any flange that has been opened for the insertion of a slip blind for isolation or disconnected and blind flanged or capped for the purpose of the Hydrostatic Testing of the system must use a L&EO identification tag/label (i.e., Yellow Tagged) and listed on the LEO (Break – Bleed – Vent) Location List.NOTE: This is a LEO step.

28 30 Any flange or tubing open to remove instrument or equipment (i.e., flow meter, pressure device, permanent system pressure relief devices, etc) from the system for the purpose of Hydrostatic Testing must use a L&EO identification tag/label (i.e., Yellow Tagged) and listed on the LEO (Break – Bleed – Vent) Location List.NOTE: This is a LEO step.

31 33 Clearly identify the Hydrostatic Testing vent and drain valves for the specific test. These Drain and Vent valves must use a L&EO identification tag/label (i.e., Yellow Tagged) and listed on the LEO (Break – Bleed – Vent) Location List.Document as completed on form “700_GS_509_01 F75101 Aboveground Pipe Inspection Record.pdf”.NOTE: This is a LEO step.

34 36 When using an air pump to test piping or equipment of a small volume, it should be noted that by opening the air valves on the pump in the wrong sequence the piping or equipment could very easily be over pressured and ruptured on one or two strokes of the pump.

37 39 Never leave the pump running unattended.










40 42 Face shields must be worn while personnel are inside the red barricaded area, when test pressure is applied, while checking for leaks and when the system is being de-pressured. High pressure jets of water or projectiles can be thrown from the equipment being tested and can inflict serious injury.

43 45 A properly sized and calibrated safety valve or relief valve shall be used at the pressure source to protect systems under test. Such a device shall have a set pressure equal to the test pressure plus 50 PSIG (3.4 BAR) or 110% of the test pressure, whichever is less.Document completion of this step on form “700_GS_509_03 F75201 Pressure Test Report.pdf”.

46 48 Document or verify that all of Hydrostatic Test Data / “Safe Operating Limits” have been documented on form “700_GS_509_03 F75201 Pressure Test Report.pdf”.An alternative is to document the Hydrostatic Test Data / “Safe Operating Limits” on the Safe Operating Limits section of this procedure for the system being tested.

49 51 Liquid Relief Device is mandatory if equipment is to be left unattended during the test (hold) period. Hydrostatically testing Equipment / Piping System without a Liquid Relief Device requires the Dow Construction Manager approval.

52 54 All contractor fabricated appliances for testing of pipe lines - such as test stands, test blinds, blind flanges, etc - shall be designed and fabricated in accordance with governing Codes and Standards, such as ASME B31.3, ASME B16.5, ASME B16.47, ASME B16.48, etc.










55 57 Test Equipment – Inspect pump to ensure hose and fittings are in good condition.

58 60 Test Equipment – Inspect pump gauges; ensure that it is on Zero. Test pressure should be approximately 60% of the gauge range. Not Applicable to electronic digital pressure gauges. Size gauge to suit.

61 63 Two pressure gauges are required to be mounted on the system being tested with no isolation possible on either gauge from the system under test.NOTE: Identify break points with L&EO identification tags/labels (i.e., Yellow Tagged) and listed on the LEO (Break – Bleed – Vent) Location List.NOTE: This is a LEO step.

64 66 Connect the pressure source and test rig to the piping system being tested utilizing a Double Block and Bleed with backflow prevention.NOTE: When connecting to the Equipment /Piping System to be tested, always use fittings of rating strong enough to withstand the test pressure. Provide a relief valve on the test rig to protect the connecting fitting in case the pump discharge is isolated from the system being tested with the pump in operation.NOTE: Identify break points with L&EO identification tags/labels (i.e., Yellow Tagged) and listed on the LEO (Break – Bleed – Vent) Location List.NOTE: This is a LEO step.

67 69 Verify that the test media / fluid has been approved and documented on form “700_GS_509_03 F75201 Pressure Test Report.pdf”. The Hydrostatic Testing Crew Foreman and the QC inspector must have signed the form under the “Test Conditions” section.










70 72 Connect and fill the system to be tested with water or approved testing fluid.NOTE: The lines used to fill the system (fill hoses), if connected through locations other than the test rig, must be connected with double block and bleeds with check valves (prevent back flow into utility systems and allow de-pressure system to connect and disconnect test medium) to the fill valve(s) of the system being tested.NOTE: Identify break points with L&EO identification tags/labels (i.e., Yellow Tagged) and list on the LEO (Break – Bleed – Vent) Location List.NOTE: This is a LEO step.

73 75 Purge or vent possible air pockets (flow of liquid at high point in system).NOTE: Identify break points with L&EO identification tags/labels (i.e., Yellow Tagged) and list on the LEO (Break – Bleed – Vent) Location List.NOTE: This is a LEO step.

76 78 Disconnect filling lines and other fittings that are not designed to withstand the hydrostatic test.NOTE: Identify break points with L&EO identification tags/labels (i.e., Yellow Tagged) and list on the LEO (Break – Bleed – Vent) Location List.NOTE: This is a LEO step.

79 81 Screw the air regulator supplying the pump all the way out before opening the air valve (shut off valve) on the test pump. Open the air valve (shut off valve) on the test pump.

82 84 Open the isolation valve from test rig into the system being tested.










85 87 Turn regulator screw until ½ the desired test pressure is reached, if possible, were feasible.NOTE: Regulator may be preset to desired pressure by operating against a closed discharge valve and observing the gauge on the pump.

88 90 Examine the gauges to ensure no leakage exists that may create a pressure drop.NOTE: If a leakage is detected, stop pressurizing the system and correct the leakage.NOTE: Ensure personnel correcting any leaks are utilizing the correct PPE.

91 93 Continue pressurizing until the desired level (test pressure) has been obtained. Shutdown the pump by backing the air regulator on the pump all the way out.

94 96 Close the air valve (shut off valve) supplying the air regulator to the test pump.

97 99 Close the water (test medium) supply to the test rig.

100 101102 Close the isolation valve from the pump into the Equipment/Piping system being tested.

103 104105 Open the bleed valve upstream of the isolation valve from the pump into the Equipment/Piping System being tested to de-pressure connection.

106 107108 System must hold pressure for the minimum time specified in the global testing documents for Class C, Class F and Class M tests.

109 110111 Drop pressure to no less than 2/3 of the test pressure and then visually inspect all joints and connections, if feasible.

112 113114 De-pressure piping and equipment being tested.










115 116117 At completion of the test, test fluid shall be fully drained to prevent over-pressurization due to either freezing or thermal expansion.NOTE: Follow the environmental plan for the collection and disposal of the test fluid.

118 119120 Return the system that was Hydrostatically Tested to “Construction Complete Status”. Reconcile isolation tags / LOTO process and listing. Remove split blinds Remove the Hydrostatic Test equipment. Re-install equipment and instrumentation that were removed for

testing Reconcile the L&EO identification tags/labels (i.e., Yellow Tags)

with the LEO (Break – Bleed – Vent) Location List.NOTE: We recognize that the L&EO breaks have not been leak tested after returning the system to “Construction Complete Status”, but the tags must be reconciled at this time. The system will undergo a detailed Return To Operation (RTO) leak testing as part of the commissioning process.

121 122123 Complete form “700_GS_509_04 F75602 Pipe Restoration Report.pdf”.

124 125126 Complete the Hydrostatic Test documentation.






Related Documents List related and supporting documents here, if applicable. 1. G4S- 6421-04 Hydrostatic Testing Equipment Procedure

2. G4S-6421-02 Class C – Hydrostatic Testing

3. G4S-6421-03 Class G – Hydrostatic Testing

4. G4S-6423-01 Class F – Fire Water Systems Testing

5. G4S- 6428-01 Class M – Thermoplastic Piping: Hydrostatic Testing

6. G8S-4001-60 Specification for Water Quality Used For Hydrostatic Testing

7. G8S-5034-03 Hydrostatic Leak Testing

8. 700_GS_250 50050 Piping Pressure Testing.docx

9. 700_GS_250.50050_01 Piping Pressure Testing Attachment 01.docx




13. 700_GS_509_00 Hydrotest Legend.pdf

14. 700_GS_509_01 F75101 Aboveground Pipe Inspection Record.pdf

15. 700_GS_509_02 List of Temporary Blinds for Pressure Test.pdf

16. 700_GS_509_03 F75201 Pressure Test Report.pdf

17. 700_GS_509_04 F75602 Pipe Restoration Report.pdf

18. 700_GS_509_05 F75601 Pipe Cleaning And Verification Checklist.pdf

19. 700_GS_509_06 F75102 Visual Inspection of Flanges, Gaskets and Bolting.pdf

20. 700_GS_509_07 F78001 Coatings Inspection Record.pdf

21. 700_GS_509_08 F02407 Punch List _Construction.pdf

22. G4D-6422-01 Guidelines for the Application of Pneumatic Testing

23. G4S-6422-01 Class D – Pneumatic Testing – Less Than 15 PSIG (1 Bar)

24. G4S-6422-02 Class DH – Pneumatic Testing – Greater Than 15 PSIG (1 Bar)

Signature This procedure checklist was completed by:

____________________________________ ____________________(Name/Names) (Date)





Hydrostatic Testing New Equipment / Piping Systems in Construction Areas In Proximity to Operating Systems Procedure - OSBL, Continued, Continued

Document and Records Management

This procedure will be filed in the Gulfstream SharePoint.

File this completed procedure in seven day SWP document retention box.






Validation This procedure was validated as the best known way to do this job by: Les Toler / Leen Jongman 03/30/2015(Name/Job Title) (Date)

Approver The last revision of this procedure was approved by:

Cody Beasley / Luis Colon 03/30/2015

(Name/Job Title) (Date)

Review History The following information lists at least the last two reviews to this document, and all reviews that were done in the last 12 months.

Date Reviewed By Comments

03/30/15 Luis Colon / Les Toler /Cody Beasley / Leen Jongman

Reviewed with no changes.

Revision History The following information documents at least the last 3 changes to this document, with all the changes listed for the last 6 months.

Date Revised By Changes

03/30/15 Luis Colon / Les Toler /Cody Beasley / Leen Jongman

Place the Hydrostatic Test Procedure (EMTL G4S-6421-04) into LEO Template Format.




Appendix 1 – LEO Connection TagConnection Tag available through E-Mart, Item #12306




Appendix 2 – LEO (Break-Bleed-Vent) Tag Location ListJob Description or Job No.:______________________________________________

Tag # Tagged By

Tagged Date

Location Reconciled Date

LEO IDInitial

Walk-Thru






See Hydrostatic – Pneumatic Test Reports Forms for Original Form