N2664/W/M/MS/06/A/N/2465

METHOD STATEMENT
Rev.: 01 Date: 10.09.06
HYDROTESTING OF ABOVE GROUND PIPING
Page: 1/8

METHOD STATEMENT

HYDROTESTING OF ABOVE GROUND PIPING

N2664/W/M/MS/06/A/N/2465

PRADISH NABiL KHALID

10.09.06 01 Consultants comments incorporated
QA/QC ENGG. PE CM

PRADISH TONI KHALID

02.06.06 00 First Issue For Approval
QA/QC ENGG. PE CM

Date Revision Description of Revision Prepared by Reviewed by Approved by

This document is the property of the Company who will safeguard its rights according to the civil and penal provisions of the law.
 N2664/W/M/MS/06/A/N/2465
METHOD STATEMENT
Rev.: 01 Date: 10.09.06
HYDROTESTING OF ABOVE GROUND PIPING
Page: 2/8

REVISION RECORDING

Date Revision Description of Revision Prepared by Reviewed by Approved by

PRADISH TONI KHALID

02.06.06 00 First Issue For Approval
QA/QC ENGG. PE CM

PRADISH NABiL KHALID

08.07.06 01 Consultants comments incorporated
QA/QC ENGG. PE CM

This document is the property of the Company who will safeguard its rights according to the civil and penal provisions of the law.
 N2664/W/M/MS/06/A/N/2465
METHOD STATEMENT
Rev.: 01 Date: 10.09.06
HYDROTESTING OF ABOVE GROUND PIPING
Page: 3/8

TABLE OF CONTENTS

TABLE OF CONTENTS...................................................................................................................................

1. PURPOSE.................................................................................................................................................

2. SCOPE......................................................................................................................................................

3. REFERENCES..........................................................................................................................................

4. RESPONSIBILITIES.................................................................................................................................

5. PROCEDURE...........................................................................................................................................

6. SAFETY PRECAUTIONS.........................................................................................................................

7. ATTACHMENTS.......................................................................................................................................

This document is the property of the Company who will safeguard its rights according to the civil and penal provisions of the law.
 N2664/W/M/MS/06/A/N/2465
METHOD STATEMENT
Rev.: 01 Date: 10.09.06
HYDROTESTING OF ABOVE GROUND PIPING
Page: 4/8

1. PURPOSE

This Method Statement describes the method to conduct hydrotest on field fabricated piping
systems, which are designed and constructed in accordance with ANSI/ASME B31.3 and
relevant ADWEA standards. Hydro test shall be performed for all erected piping.

2. SCOPE

The requirements of this procedure apply to ABOVE GROUND PIPING SYSTEMS OF CS

AND HAVE reference to relevant ADWEA Standards.

3. REFERENCES

ADWEA Standards:

Specification for Carbon steel piping materials W-P-SS-002-0

Specification for Steel piping Fabrication, Erection and Testing W-P-SS-012-0

ASME Standards:

ANSI/ASME B31.3
ANSI/ASME B31.8
ASME SEC VIII Div. !

4. RESPONSIBILITIES

4.1 The QC Inspector shall be responsible for preparing Hydrostatic Test Record (which will
be submitted for prior Approval), which specifies the detailed scope of work such as test
pressure, position of pressure gauges and testing fluid. Equipment such as vessels,
pumps and instruments are to be isolated from pipe work during Hydro test.

4.2 The QC/Mechanical Engineer shall be responsible for reviewing the Hydrostatic Test
Package which will be submitted for prior Approval before forwarding to ADWEA for
Punch listing/Review.

4.3 The Site Engineer shall be responsible for making all necessary preparation for the
hydrostatic test including cleaning and performing the test in accordance with this
instruction.

4.4 The QC Inspector shall be responsible for the witnessing the test, inspection after full
pressurization and recording the results.

4.5 Hydrostatic test shall be carried out during working hours and in the presence of
ADWEA/Engineer.

This document is the property of the Company who will safeguard its rights according to the civil and penal provisions of the law.
 N2664/W/M/MS/06/A/N/2465
METHOD STATEMENT
Rev.: 01 Date: 10.09.06
HYDROTESTING OF ABOVE GROUND PIPING
Page: 5/8

5. PROCEDURE

5.1 Preparation

5.1.1 Prior to the start of the test, the Site Engineer & QC Inspector shall verify that all other
activities (except pressure test) are completed and equipment such as vessels, pumps
and instruments are isolated from piping by using blinds or other suitable means. New
piping systems shall be flushed with potable water to remove loose scale and debris prior
to commencement of pressure testing, where applicable.

5.1.2 This verification shall be accomplished by reviewing the applicable steps of the Inspection
Test Plan and that all non-conformances (if any) have been closed out. ITP & QC forms
shall be submitted for prior approval by Engineer.

5.1.3 Test Packages shall be submitted to ADWEA for review before commencing of
Hydrostatic Test. The Hydrostatic test package shall include, but not limited to the
following:
a. Hydrostatic Test Pressure
b. Hydro test Diagram marked in applicable Isometrics
c. P & ID with Test Limits
d. Isometric list and Isometrics (if applicable)
e. Welding Inspection Log
f. Piping Cleaning / Pressure Test Report
g. Calibration Certificate for Pressure Gauge.
h. List of equipments and devices with sketch showing arrangement of test plan.

5.1.4 The QC Inspector shall also check the preparation of equipment and device with sketch
showing arrangement of test plan that will be used prior to test as follows:

5.1.4.1 The capacity & location of hydrostatic pump in such a way that the Pressure Gauge
reading is visible to the Pump Operator.

5.1.4.2 The range of pressure gauges i.e. the test pressure is within 30 % to 80% of the full
range. A minimum of two (2) gauges shall be installed on large systems that are being
tested. Gauges used for testing shall be installed as close as possible to the low point
(drain) and high point (vent) of the piping system.

5.1.4.3 The calibration label/sticker shall be visible on the pressure gauges to ensure that the
gauges have been calibrated and are within the calibration due date. Calibration
certificates shall be made available prior to commencement of the pressure test.

5.1.4.4 The ratings of valves and Instruments used for connection with gauge and pump shall be
verified.

5.1.4.5 A bleed valve shall be provided to protect the piping and equipment from overpressure.
The bleed valve shall be readily accessible in case immediate depressurization is
required.

5.1.4.6 Discs and Flappers shall be removed from Check Valve and the Direction of flow of

This document is the property of the Company who will safeguard its rights according to the civil and penal provisions of the law.
 N2664/W/M/MS/06/A/N/2465
METHOD STATEMENT
Rev.: 01 Date: 10.09.06
HYDROTESTING OF ABOVE GROUND PIPING
Page: 6/8

Check Valve to be verified.

5.1.5 All openings except test medium inlet and vent opening shall be closed using correct
rating plugs, caps or other suitable means. Field fabricated blinds shall not be used
without proper calculations for the thickness proof.

5.1.6 Support for hydrostatic test, if used, shall ensure a safe test. In order to inspect all welded
joints, no supports shall be placed on or over any weld joints of the pipe work under
Hydro test. Welded joints to be tested shall be left unpainted to check for any leak. NDT
reports for the welded joints shall be submitted prior to Hydro test for review.

5.1.7 Following components shall be removed, replaced with temporary spool piece or isolated
from pipe work, according to the Hydro test package.

Orifice plate
Filter element
Temporary strainer
Safety and relief valve (Permanent)
Rupture disc
Expansion joint
In-line instruments (If piping have been flushed prior to testing, on/off valve may remain in
line, but valve shall be kept minimum half (1/2) open during test and flushing.
Pressure gauge (Permanent)
Check valve discs shall be removed and securely attached to the outside of check valve
prior to pressure test.

5.2 Testing Equipments

Pressure gauges with valid calibration certificates

Pressure Chart recorders
Power operated Hydraulic pump
All preparatory materials like test blind flange, spectacle blinds, Temporary spools
etc.
Fittings and hoses will be suitable for the rated test pressure of the system.

5.3 Test Water

5.3.1 The water used for Hydrostatic test shall be of potable grade.

5.3.2 The water described above shall be used as a test medium unless otherwise specified for
testing of stainless steel. The water to be used for the testing of stainless steel pipings
shall have maximum chlorine content of 50 ppm to be verified at the site before injection
into the system.

5.4 Filling the water

5.4.1 All vents and other connections that can serve, as vents shall be opened to vent possible
air pocket while the item is being filled with water. Fill water from the lowest point to vent
air completely from the system.

5.4.2 Before applying pressure, the test operator shall check the test equipment to assure that

This document is the property of the Company who will safeguard its rights according to the civil and penal provisions of the law.
 N2664/W/M/MS/06/A/N/2465
METHOD STATEMENT
Rev.: 01 Date: 10.09.06
HYDROTESTING OF ABOVE GROUND PIPING
Page: 7/8

all low pressure filling lines and other appurtenances that should not be subjected to the
test pressure have been disconnected or isolated by valves or other suitable means.

5.5 Application of Pressure

5.5.1 The Hydro test circuit diagram shall show the limits and method of isolation for the
system prepared prior to testing.

5.5.2 Lines above ground shall be tested for a minimum of 1 hour as per Contract to determine
that there are no leaks.

5.5.3 The system will be filled with the approved test fluid introduced from the lowest point of
the test circuit. All vents shall be opened during filling and closed when entrapped air has
been vented. The tightening log for all bolted connection shall be submitted to Engineer
for attestation.

5.5.4 The approved Hydro test manifold will be connected to the line. The system pressure will
be raised gradually using power operated pump.

5.5.5 At 50 percent of strength test pressure, pressurization shall be stopped to check for leak.

5.5.6 If any leakage is found the location of leak shall be identified, the system shall be
depressurized and dewatered. Bolts shall be tightened equally as per the torque
mentioned for leak observed between flange joints. Test fluid shall be refilled and test will
be continued.

5.5.7 After satisfactory preliminary check for leaks at 50% of test pressure, the pressure shall be
increased gradually in steps of 1 bar per minute to the final test pressure. The pressure
shall be held for a period of 30 minutes to check for any leak.

5.5.8 If no leaks are discovered during these stages, pressurization shall be continued up to the
required test pressure. After reaching the test pressure the test system shall be isolated
from the pump.

5.5.9 The test shall be considered satisfactory if there is no evidence of leakage or pressure
loss after the specified test period as mentioned in the specification.

5.5.10 Upon completion, the system shall be depressurized and the lines shall be completely
drained keeping all the vents in the fully open position. The line shall be dried by blowing
dry with oil free compressed air.

5.5.11 The drained water will be disposed off safely into the sewer drains/safer destinations,
which is acceptable to ADWEA/Engineer.

5.5.12 The test result will be documented on the Piping Cleaning & Pressure Test Report.

5.5.13 Inspect the line/system to ensure that all fittings and appurtenances are returned to their
required positions as detailed in the P& IDs.

This document is the property of the Company who will safeguard its rights according to the civil and penal provisions of the law.
 N2664/W/M/MS/06/A/N/2465
METHOD STATEMENT
Rev.: 01 Date: 10.09.06
HYDROTESTING OF ABOVE GROUND PIPING
Page: 8/8

5.6 Emptying the Item

5.6.1 After completion of the hydrostatic test, vents and drains shall be opened to remove all
the water in the item. Oil free compressed air may be used to force evacuation. No heat
shall be applied for drying.

5.6.2 After pressure test & system drying, the piping system shall be checked visually to ensure
that all open ends are closed.

6. SAFETY PRECAUTIONS

6.1 Signs are to be displayed at barrier off areas indicating that hydrostatic test is under
progress. Only authorized personnel shall stay in the test area during the Hydro test.
Client HSE requirements to be fulfilled.

6.2 During pressurization, all personnel should be outside of marked test area.

6.3 Vent lines, safety relief valve and bleed valve shall be vented / positioned to safe location.

7. APPENDICES

7.1 Piping Cleaning / Pressure Test Report.

7.2 Hydro test Limits marked in applicable Isometrics.

This document is the property of the Company who will safeguard its rights according to the civil and penal provisions of the law.
This document is the property of the Company who will safeguard its rights according to the civil and penal provisions of the law.