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 J ESA-TKF-DCS-1605
RE-ISSUED FOR IMPLEMENTATION
M.Kara A. Yildirim M.Kopuz
0 15-08-2012
REVISED AS PER J ESA-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

KHOURIBGA JORF LASFAR PHOSPHATE SLURRY PIPELINE SYSTEM

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


Groupe OCP S. A.
Casablanca
Morocco
Document Title:

METHOD STATEMENT OF
FOR STATION PIPING


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-J orf 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.
2


Groupe OCP S. A.
Casablanca
Morocco
Document Title:

METHOD STATEMENT OF
FOR STATION PIPING


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 : J acobs 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


Groupe OCP S. A.
Casablanca
Morocco
Document Title:

METHOD STATEMENT OF
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


Groupe OCP S. A.
Casablanca
Morocco
Document Title:

METHOD STATEMENT OF
FOR STATION PIPING


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


Groupe OCP S. A.
Casablanca
Morocco
Document Title:

METHOD STATEMENT OF
FOR STATION PIPING


7.0 ORGANIZATION

CONSTRUCTION
MANAGER
ENGINEERING
DEPARTMENT
QC
DEPARTMENT
SITE
ENGINEER
TEST
ENGINEER
TESTING
TEAM
TEST PACK
COORDINATOR


Groupe OCP S. A.
Casablanca
Morocco
Document Title:

METHOD STATEMENT OF
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.


Groupe OCP S. A.
Casablanca
Morocco
Document Title:

METHOD STATEMENT OF
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


Groupe OCP S. A.
Casablanca
Morocco
Document Title:

METHOD STATEMENT OF
FOR STATION PIPING


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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Groupe OCP S. A.
Casablanca
Morocco
Document Title:

METHOD STATEMENT OF
FOR STATION PIPING


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.


Groupe OCP S. A.
Casablanca
Morocco
Document Title:

METHOD STATEMENT OF
FOR STATION PIPING


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.


Groupe OCP S. A.
Casablanca
Morocco
Document Title:

METHOD STATEMENT OF
FOR STATION PIPING


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 J oints, 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
2


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Casablanca
Morocco
Document Title:

METHOD STATEMENT OF
FOR STATION PIPING


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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Groupe OCP S. A.
Casablanca
Morocco
Document Title:

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FOR STATION PIPING


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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Groupe OCP S. A.
Casablanca
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METHOD STATEMENT OF
FOR STATION PIPING


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. J oints 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 15
o
C
Post Heated Ferritic Steel, W/T 25 mm &
less
15
o
C
Austenitic Steel, W/T 25 mm & less 4
o
C
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


Groupe OCP S. A.
Casablanca
Morocco
Document Title:

METHOD STATEMENT OF
FOR STATION PIPING


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


Groupe OCP S. A.
Casablanca
Morocco
Document Title:

METHOD STATEMENT OF
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 C
o
.
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.


Groupe OCP S. A.
Casablanca
Morocco
Document Title:

METHOD STATEMENT OF
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.


Groupe OCP S. A.
Casablanca
Morocco
Document Title:

METHOD STATEMENT OF
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


Groupe OCP S. A.
Casablanca
Morocco
Document Title:

METHOD STATEMENT OF
FOR STATION PIPING


14.0PRESSURETESTACTIVITYFLOWCHART
2
7

3
8
5 6 4
10
121111

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
REINSTATEME
NT COMPLETE
,B ITEM
CLEARED
QC J ESA-QC
TEKFEN TEST
PACK RELEASE
RECORD
J ESA for
approval
QC DEPARTEMENT
Line Punch
NDT/PWHT/ITR/Weld
log input
HYDROTEST
ENGINEER raise
RFI-Perform test


Groupe OCP S. A.
Casablanca
Morocco
Document Title:

METHOD STATEMENT OF
FOR STATION PIPING


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.


Groupe OCP S. A.
Casablanca
Morocco
Document Title:

METHOD STATEMENT OF
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)

Groupe OCP S. A.
Casablanca
Morocco
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

Groupe OCP S. A.
Casablanca
Morocco
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
SIGNIFICAN
T 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
Fatality,
Injury,
Asset Damage
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

Groupe OCP S. A.
Casablanca
Morocco
Document Title:



ACTIVITY
SIGNIFICAN
T HAZARDS
HAZARD
EFECTS
be?
RISK
RATIN
G
CONTROL MEASURES
How to prevent it?
RESIDUAL
RISK
RATING
(After the
controls are in
place)
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
Fatality,
Injury,
Asset Damage

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.

Groupe OCP S. A.
Casablanca
Morocco
Document Title:



ACTIVITY
SIGNIFICAN
T HAZARDS
HAZARD
EFECTS
be?
RISK
RATIN
G
CONTROL MEASURES
How to prevent it?
RESIDUAL
RISK
RATING
(After the
controls are in
place)
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


Groupe OCP S. A.
Casablanca
Morocco
Document Title:

METHOD STATEMENT OF FLUSHING
AND HYDROTESTING FOR STATION
PIPING


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
J ORF) 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.


Groupe OCP S. A.
Casablanca
Morocco
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
Driver
Plate #: 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 0653367457
Driver
Plate #: 25496 - 48 -
0648058753
Nurse 0668151042
Driver
Plate #: 19682 - 57-
0677844600
Nurse 0633744372
Driver
Plate #: 24489 - 34-
0673202568
Nurse 0679689108
Driver
Plate #: 62017 - 8-
0666994488
Doctor 0661715561
Nurse 0668151042
Nurse 0676130602
Doctor 0661696119
Nurse 0670228021
Nurse 0655435848
LGC - AMBULANCE DRIVER
Plate #: 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 CREW
ABDELAH EL MEZAH
ISSAM TAYEB
HELASSA 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 CONSTRUCTI ON OCP
SLURRY PI PELI NE PROJ ECT
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


Groupe OCP S. A.
Casablanca
Morocco
Document Title:

PIPING


17.0 ATTACHMENT

17.0.1 Test Header

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

Groupe OCP S. A.
Casablanca
Morocco
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
Date
Rev.
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 Tag
Sequence
Number
Contents 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 pumps 03-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 pumps 07-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
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
No Tag
Sequence
Number
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
Groupe OCP S.A.
Casablanca
Morocco
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
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
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
No Tag
Sequence
Number
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
Groupe OCP S.A.
Casablanca
Morocco
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
143 08-1326-SS20-50-PW 1326 PW 08 08-1317-SS20-100-PW Hose connection to 08-LR-001 SS20 50 49.2 20 2.9 600 1965 2947 PAC-08-PR-PID-0004
144 08-1411-RL21-200-PS 1411 PS 08 08-PU-202 08-1412-RL21-200-PS RL21 200 178.7 - - 675 1965 2160 PAC-08-PR-PID-0004
146 08-1501-EL21-200-GW 1501 GW 08 Gland seal water supply 08-TK-101 EL21 200 202.7 - - 100 1965 2950 PAC-08-PR-PID-0005
181 08-1413-RL21-200-PS 1413 PS 08 08-1412-RL21-200-PS Settling pond 1 RL21 200 178.7 - - 675 1965 2160 PAC-08-PR-PID-0007
183 10-0011-UL60-450-PS 0011 PS 10 Daoui feed pipeline 10-LR-001 UL60 450 404.5 1369 3.0 350 10200 11220 PAC-10-PR-PID-0001
184 10-0012-UL60-450-PS 0012 PS 10 10-LR-001 Daoui Choke Station UL60 450 404.5 1369 3.0 350 10200 11220 PAC-10-PR-PID-0001
Page 4 of 10
No Tag
Sequence
Number
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
Groupe OCP S.A.
Casablanca
Morocco
Document Title:
Total Pages: 10
187 10-0021-UL30-400-PS 0021 PS 10 MEA low grade feed pipeline 10-LR-002 UL30 400 363.3 1350 3.6 350 5100 5610 PAC-10-PR-PID-0001
188 10-0022-RL31-400-PS 0022 PS 10 10-LR-002 Distrubution manifold RL31 400 363.3 1350 3.6 350 5100 5610 PAC-10-PR-PID-0001
191 10-0031-UL30-300-PS 0031 PS 10 MEA high grade feed pipeline 10-LR-003 UL30 300 280.7 675 3.0 350 5100 5610 PAC-10-PR-PID-0001
195 10-0041-UL30-500-PS 0041 PS 10 El Halassa feed pipeline 10-LR-004 UL30 500 464.9 1470 2.4 350 5100 5610 PAC-10-PR-PID-0001
207 10-0301-RL21-900-PS 0301 PS 10 Feeder lines 10-SB-001 RL21 900 870.9 4306 2.0 350 1965 2160 PAC-10-PR-PID-0002
208 10-0302-RL21-900-PS 0302 PS 10 Feeder lines 10-SB-011 RL21 900 870.9 4306 2.0 350 1965 2160 PAC-10-PR-PID-0002
209 10-0303-RL21-500-PS 0303 PS 10 Feeder lines 10-0304-RL21-500-PS & 10-0305-RL21-500-PS RL21 500 464.9 - - 350 1965 2160 PAC-10-PR-PID-0002
210 10-1303-EL22-100-PS 1303 PS 10 10-SB-011 10-1302-EL22-900-PS EL22 100 102.3 - - 0 N/A N/A PAC-10-PR-PID-0003
211 10-0341-RL21-500-PS 0341 PS 10 10-SB-011 10-TK-011 RL21 500 464.9 2156 3.5 350 1965 2160 PAC-10-PR-PID-0003
223 10-1302-EL22-900-PS 1302 PS 10 10-SB-011 Drain to station pad EL22 900 894.9 - - 0 N/A N/A PAC-10-PR-PID-0003
224 10-0371-EL21-900-PW 0371 PW 10 Reservoir process water supply 10-0372-RL21-900-PS EL21 900 894.9 - - 600 1965 2950 PAC-10-PR-PID-0003
226 10-0372-RL21-900-PS 0372 PS 10 10-0371-EL21-900-PW Pump train feeder pipelines RL21 900 870.9 4306 2.0 350 1965 2160 PAC-10-PR-PID-0003
242 10-0374-RL21-100-PS 0374 PS 10 10-0372-RL21-900-PS 10-0375-SS20-80-PW RL21 100 78.3 - - 0 1965 2160 PAC-10-PR-PID-0005
243 10-0375-SS20-80-PW 0375 PW 10 10-0374-RL21-100-PS Discharge direct into spillage sump SS20 80 73.7 - - 600 1965 2947 PAC-10-PR-PID-0005
245 10-0502-UL20-900-PS 0502 PS 10 10-PU-001 10-PU-002 UL20 900 870.9 4426 2.1 819 1965 2160 PAC-10-PR-PID-0005
246 10-0507-UL60-900-PS 0507 PS 10 10-PU-006 10-0411-UL60-900-PS UL60 900 839.2 4426 2.2 4915 10200 11220 PAC-10-PR-PID-0005
Page 5 of 10
No Tag
Sequence
Number
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
Groupe OCP S.A.
Casablanca
Morocco
Document Title:
Total Pages: 10
249 10-1506-RL21-200-PS 1506 PS 10 10-1501-EL21-200-PW 10-0501-RL21-900-PS RL21 200 178.7 - - 350 1965 2160 PAC-10-PR-PID-0005
251 10-0602-UL20-900-PS 0602 PS 10 10-PU-011 10-PU-012 UL20 900 870.9 4426 2.1 350 1965 2160 PAC-10-PR-PID-0005
252 10-0607-UL60-900-PS 0607 PS 10 10-PU-016 10-0411-UL60-900-PS UL60 900 839.2 4426 2.2 4915 10200 11220 PAC-10-PR-PID-0005
255 10-1606-RL21-200-PS 1606 PS 10 10-1601-EL21-200-PW 10-0601-RL21-900-PS RL21 200 178.7 - - 350 1965 2160 PAC-10-PR-PID-0005
256 10-0402-UL20-900-PS 0402 PS 10 10-0502-UL20-900-PS 10-0404-PL20-900-PS UL20 900 870.9 4426 2.1 350 1965 2160 PAC-10-PR-PID-0005
257 10-0403-UL20-900-PS 0403 PS 10 10-0602-UL20-900-PS 10-0402-UL20-900-PS UL20 900 870.9 4426 2.1 350 1965 2160 PAC-10-PR-PID-0005
258 10-0404-PL20-900-PS 0404 PS 10 10-0402-UL20-900-PS 10-0406-UL20-900-PS PL20 900 870.9 4426 2.1 350 1965 2160 PAC-10-PR-PID-0005
260 10-0406-UL20-900-PS 0406 PS 10 10-0404-PL20-900-PS 10-0602-UL20-900-PS UL20 900 870.9 4426 2.1 350 1965 2160 PAC-10-PR-PID-0005
261 10-0407-RL21-900-PS 0407 PS 10 10-0406-UL20-900-PS 10-SB-001 or 10-SB-011 RL21 900 870.9 4326 2.0 350 1965 2160 PAC-10-PR-PID-0005
262 10-1401-SS20-80-PW 1401 PW 10 10-0405-UL20-900-PS Hose connection SS20 80 73.7 40 2.6 600 1965 2947 PAC-10-PR-PID-0005
263 10-1402-EL22-150-PS 1402 PS 10 10-0403-UL20-900-PS Drain to station pad EL22 150 154.1 - - 0 N/A N/A PAC-10-PR-PID-0005
264 10-1403-SS20-80-PW 1403 PW 10 10-0402-UL20-900-PS Drain to station pad SS20 80 73.7 - - 600 1965 2947 PAC-10-PR-PID-0005
267 10-1421-SS20-25-PS 1421 PS 10 10-0404-PL20-900-PS 10-1431-RH10-25-PS SS20 25 24.3 - - 350 1965 2947 PAC-10-PR-PID-0005
270 10-1431-RH10-25-PS 1431 PS 10 10-0404-PL20-900-PS Sample collection point RH10 25 unknown - - 0 1000 1250 PAC-10-PR-PID-0005
275 10-0411-UL60-900-PS 0411 PS 10 10-0507-UL60-900-PS & 10-0607-UL60-900-PS 10-LR-001 UL60 900 839.2 4426 2.2 4915 10200 11220 PAC-10-PR-PID-0007
279 10-0412-UL60-900-PS 0412 PS 10 10-LR-001 Overland pipeline to PMS 1 UL60 900 839.2 4426 2.2 4915 10200 11220 PAC-10-PR-PID-0007
280 10-1712-RL21-200-PS 1712 PS 10 10-PU-203 10-1713-RL21-200-PS & 10-1714-RL21-200-PS RL21 200 178.7 250 2.8 675 1965 2160 PAC-10-PR-PID-0007
284 10-1902-EL21-200-GW 1902 GW 10 10-1802-EL21-200-GW - EL21 200 202.7 - - 100 1965 2950 PAC-10-PR-PID-0008
Page 6 of 10
No Tag
Sequence
Number
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
Groupe OCP S.A.
Casablanca
Morocco
Document Title:
Total Pages: 10
333 10-1721-RL21-200-PS 1721 PS 10 10-PU-201 10-SB-001 RL21 200 178.7 250 2.8 675 1965 2160 PAC-10-PR-PID-0010
337 10-0200-UL60-450-PS 0200 PS 10 10-0012-UL60-450-PS 10-0201-RL21-450-PS UL60 450 404.5 1369 3.0 350 10200 11220 PAC-10-PR-PID-0011
338 10-0201-RL21-450-PS 0201 PS 10 10-0200-UL60-450-PS 10-SB-001 RL21 450 413.9 1369 2.8 350 1965 2160 PAC-10-PR-PID-0011
342 10-0221-RL31-450-PS 0221 PS 10 10-0204-UL60-450-PS Distrubution manifold RL31 450 413.9 1369 2.8 350 5100 5610 PAC-10-PR-PID-0011
350 10-1372-EL21-200-PW 1372 PW 10 10-1371-EL21-450-PW 10-PU-301 EL21 200 202.7 660 5.7 600 1965 2950 PAC-10-PR-PID-0012
356 10-1378-SS20-80-PW 1378 PW 10 10-1373-SS20-100-PW Pump area sump SS20 80 73.7 - - 600 1965 2947 PAC-10-PR-PID-0012
357 10-1379-EL21-250-PW 1379 PW 10 10-PU-301 10-1381-RL21-250-PS EL21 250 254.5 660 3.6 600 1965 2950 PAC-10-PR-PID-0012
358 10-1381-RL21-250-PS 1381 PS 10 10-1379-EL21-250-PW Dilution water RL21 250 230.5 660 4.4 350 1965 2160 PAC-10-PR-PID-0012
359 10-1383-EL21-150-PW 1383 PW 10 10-1371-EL21-450-PW 10-1384-SS20-100-PW & 10-1373-SS20-100-PW EL21 150 154.1 - - 600 1965 2950 PAC-10-PR-PID-0012
366 10-1389-EL21-200-PW 1389 PW 10 10-1371-EL21-450-PW Filter unit 10-FI-001 EL21 200 202.7 - - 600 1965 2950 PAC-10-PR-PID-0012
367 10-2001-SS20-50-PW 2001 PW 10 Filter unit 10-FI-001 Spillage channel or sump SS20 50 49.2 - - 600 1965 2947 PAC-10-PR-PID-0012
370 10-1393-EL21-200-GW 1393 GW 10 Filter unit GSW tank 10-TK-101 EL21 200 202.7 - - 100 1965 2950 PAC-10-PR-PID-0012
Page 7 of 10
No Tag
Sequence
Number
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
Groupe OCP S.A.
Casablanca
Morocco
Document Title:
Total Pages: 10
379 11-0001-UL60-900-PS 0001 PS 11 Overland pipeline from Head Station Overland pipeline to Valve Station UL60 900 839.2 4426 2.2 4915 10200 11220 PAC-11-PR-PID-0001
380 12-0001-UL60-900-PS 0001 PS 12 Overland pipeline from PMS 1 Overland pipeline to PMS 2 UL60 900 839.2 4426 2.2 4915 10200 11220 PAC-12-PR-PID-0001
384 13-0001-UL60-900-PS 0001 PS 13 Overland pipeline from Valve Station Overland pipeline to PMS 3 UL60 900 839.2 4426 2.2 4915 10200 11220 PAC-13-PR-PID-0001
385 14-0001-UL90-900-PS 0001 PS 14 Overland pipeline from PMS 2 Overland pipeline to PMS 4 UL90 900 826.5 4426 2.3 4915 12400 13640 PAC-14-PR-PID-0001
386 15-0001-UL60-900-PS 0001 PS 15 Overland pipeline from PMS 3 Overland pipeline to Terminal Station UL60 900 839.2 4426 2.2 4915 10200 11220 PAC-15-PR-PID-0001
387 16-0001-UL60-900-PS 0001 PS 16 Overland pipeline from PMS 4 16-LR-001 UL60 900 839.2 4426 2.2 1170 10200 11220 PAC-16-PR-PID-0001
388 16-0002-UL60-900-PS 0002 PS 16 16-LR-001 16-0003-UL60-900-PS UL60 900 839.2 4426 2.2 1170 10200 11220 PAC-16-PR-PID-0001
400 16-0015-RL21-900-PS 0015 PS 16 16-0013-UL60-900-PS - RL21 900 870.9 4426 2.1 350 1965 2160 PAC-16-PR-PID-0001
402 16-0022-RL21-900-PS 0022 PS 16 16-0021-UL60-900-PS - RL21 900 870.9 4426 2.1 1170 1965 2160 PAC-16-PR-PID-0001
406 16-1021-SS20-50-PW 1021 PW 16 16-0021-UL60-900-PS Vent SS20 50 49.2 - - 600 1965 2947 PAC-16-PR-PID-0001
414 16-0023-RL21-900-PW 0023 PW 16 16-0022-RL21-900-PS Start-up water divergence to pond RL21 900 870.9 4426 2.1 600 1965 2160 PAC-16-PR-PID-0002
415 16-0016-RL21-900-PW 0016 PW 16 16-0015-RL21-900-PS 16-0023-RL21-900-PW RL21 900 870.9 4426 2.1 600 1965 2160 PAC-16-PR-PID-0002
428 16-1712-RL21-200-PS 1712 PS 16 16-PU-201 Dump pond RL21 200 178.7 250 2.8 675 1965 2160 PAC-16-PR-PID-0002
429 16-1521-EL21-250-PW 1521 PW 16 16-1501-EL21-250-PW 16-1525-SS20-80-PW EL21 250 254.5 - - 600 1965 2950 PAC-16-PR-PID-0002
433 16-1525-SS20-80-PW 1525 PW 16 16-1521-EL21-250-PW Sump SS20 80 73.7 - - 600 1965 2947 PAC-16-PR-PID-0002
Page 8 of 10
No Tag
Sequence
Number
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
Groupe OCP S.A.
Casablanca
Morocco
Document Title:
Total Pages: 10
435 16-1723-RL21-200-PS 1723 PS 16 16-1722-RL21-200-PS Dump pond RL21 200 178.7 - - 675 1965 2160 PAC-16-PR-PID-0002
450 16-0017-RL21-900-PS 0017 PS 16 16-0015-RL21-900-PS 16-SB-001 RL21 900 870.9 4426 2.1 350 1965 2160 PAC-16-PR-PID-0003
455 16-0112-RL21-300-PS 0112 PS 16 16-TK-001 16-0401-RL21-500-PS RL21 300 280.7 - - 350 1965 2160 PAC-16-PR-PID-0003
472 16-0401-RL21-500-PS 0401 PS 16 Export tanks discharge pipelines Export RL21 500 464.9 - - 350 1965 2160 PAC-16-PR-PID-0003
495 16-0031-RL21-600-PS 0031 PS 16 Repulp recirculation 16-SB-021 RL21 600 566.9 - - 350 1965 2160 PAC-16-PR-PID-0005
Page 9 of 10
No Tag
Sequence
Number
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
Groupe OCP S.A.
Casablanca
Morocco
Document Title:
Total Pages: 10
498 16-0311-RL21-500-PS 0311 PS 16 16-SB-021 16-TK-021 RL21 500 464.9 - - 350 1965 2160 PAC-16-PR-PID-0005
499 16-0312-RL21-200-PS 0312 PS 16 16-TK-021 Local distribution RL21 200 178.7 - - 350 1965 2160 PAC-16-PR-PID-0005
505 16-0321-RL21-500-PS 0321 PS 16 16-SB-021 16-TK-023 RL21 500 464.9 - - 350 1965 2160 PAC-16-PR-PID-0005
519 16-1331-RL21-100-PS 1331 PS 16 16-TK-021 16-PU-301 RL21 100 78.3 - - 350 1965 2160 PAC-16-PR-PID-0005
520 16-1332-SS20-80-PW 1332 PW 16 16-1331-RL21-100-PS Hose connection SS20 80 73.7 - - 600 1965 2947 PAC-16-PR-PID-0005
522 16-1334-RL21-100-PS 1334 PS 16 16-PU-301 16-TK-021 RL21 100 78.3 - - 350 1965 2160 PAC-16-PR-PID-0005
523 16-1341-RL21-100-PS 1341 PS 16 16-TK-023 16-PU-302 RL21 100 78.3 - - 350 1965 2160 PAC-16-PR-PID-0005
524 16-1342-SS20-80-PW 1342 PW 16 16-1341-RL21-100-PS Hose connection SS20 80 73.7 - - 600 1965 2947 PAC-16-PR-PID-0005
526 16-1344-RL21-100-PS 1344 PS 16 16-PU-302 16-TK-023 RL21 100 78.3 - - 350 1965 2160 PAC-16-PR-PID-0005
527 16-1361-RL21-500-PS 1361 PS 16 16-TK-021 16-TK-023 RL21 500 464.9 - - 350 1965 2160 PAC-16-PR-PID-0005
Temperature for all lines:
Nominal 20 C
Design 38 C
Operating pressure is a nominal value and should not be used for design validation, as there may be considerable variation along each pipeline.
Changes from Rev 6 to Rev 7 highlighted in red text. 7
Page 10 of 10

TKF00MEMST0007Rev 2MethodstatementofFlushingandHydrotestingforStationPiping

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TKF00MEMST0007Rev 2MethodstatementofFlushingandHydrotestingforStationPiping

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

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