Hydrotest Method Statement 12th Mar 2012-1

MARAFIQ 2 YANBU 2 POWER & WATER PROJECT

METHOD STATEMENT FOR SEGMENTAL AND

UNDERGROUND PIPING HYDRO TEST FOR GRP

Document No. : YT-PF-Z-16-00212Revision : ADate of Issue : 28th Feb. 2012

YANBU 2 WATER AND POWER PROJECT

Contract PO No.: 7200 018 725 Method Statement for Underground Piping

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Issue Date:28th Feb.2012

Doc No. :YT-PF-Z-16-00212Page 2 of 19

Rev No. : A

A For Review 28-Feb-2012 Danish Khan I. G. YEO S. K. HONG

Rev. Description Date Prepared By Checked By Approved By

REVISION INDEX

Rev Date Description

A 28th Feb. 2012 For Review



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CONTENTS

INTRODUCTION

FIELD TEST PROCEDURE

1. RESPONSIBILITIES…………. ………………………..……..…………………..6

1.1 Site Manager………………………………………..……..…………………..6

1.2 Discipline Manager………………………..……..…………..………………..6

1.3 QC Manager………………………..……..……………………………………7

1.4 HSE Manager………………………..……..…………………………………..7

1.5 Hydro Test Supervisor………………………..……..………………………...7

2. SEGMENT HYDRO TESTING ………………………..……..…………………..8

3. FIXING TEST PLUGS…………………………………….….…………….…......8

4. PREPARATION PRIOR TO HYDRO TEST……………………………….….10

5. WATER FILLING…..…………………………………......................................12

6. PRESSURIZING………………………………………………………...………..12

7. CAUSE OF PRESSURE DROP…..……………………..…………….….…….13

8. WATER SUPPLY……..……………………………..…………………………....13

9. DRAIN .……...………………………………..……………………...…..……..…14

10.POST HYDRO TEST ACTIVITIES……………………………………………...14

11. REINSTATEMENT…………………………………………….…….…….…..….16

12.SAFETY PRECAUTION…..…………………………………..……….…….…..17



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Introduction

This Procedure defines the work method for field test of GRP Piping for YANBU 2 Power

& Water Project at Yanbu in the Kingdom of Saudi Arabia.The purpose of this procedure

is to set out the requirements and methods for field test of GRP Piping. This procedure

shall be in compliance with the contract and technical specification implemented on the

Yanbu 2 Power & Water Project

Field Test Procedure

Before the installed pipe system can be used, the system should be tested prior to use to

assure soundness of all joints and connections. In testing, sudden pressure surges or

water hammer must be avoided.

The Test Pressure shall, unless otherwise specified, be in accordance in

ASMEB31.3 and MARAFIQ SECTION 02625

The test equipment must be suited to the diameter and pressure, and able to reach the

required test pressure. One pressure gauge must also install along with Blind flange. The

pressure gauge must be connected between the valve and the system in order to indicate

the pressure after the valve is closed. Due to the head of water the pressure gauge

should be located at the lowest point. The pressure gauge should have a full scale

reading of about twice the test pressure. The system needs to be protected by an air

release valve. Trapped air can be released using a vent at the highest point in the

system.

Pre-test Calculation

DV/DP is defined as the change in volume for an associated change in pressure of

a known volume under pressure. Prior to start-up of test activities, the Hydro test

supervisor should perform a pre-test calculation to obtain the value of DV/DP.

The dewatering pump as present in site with capacity of

Max Head: 50m

Max Flow: 400m3



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Suction Head: 9m

For buried pipe it can be calculate through equation

DV/DP = V*[(D/E*t) (1-v2) + C]

Where,

V= volume of pipe

D = outside Diameter

E = Modulus of elasticity (3480904.8 PSI)

t = Wall thickness

v = Poisson’s ratio (0.29)

C = compressibility of SEA WATER (44)

DV/DP = 3.14/4 * 3.42 * 5 [(3.4/3480904.8 * 0.032) (1-0.292) + 44]

DV/DP = 2043 gallon/psi

For example: A fully packed line at 0 psi, with a desired pressure of 76 psi and

DV/DP constant of 2043 gallons/psi, the amount of fluid which will be required to

bring the segment to test pressure will be 76psi x 2043 gallons/psi = 154391 gallons

for 5 Meter length. Our pump capacity is 1761gpm, as per this for 154391 gallons

will fill within 1.30 hours.

Pump Discharge calculation

Q = AV

Where

Q = Discharge



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A = Area of pipe

v = velocity of test media

1. Responsibilities

1.1 Site Manager

He shall be responsible for

To implement over all safety plan for hydro test

To ensure proper execution of hydro test in accordance with project

Method statement and specification.

To arrange required hydro test crew.

To ensure Mechanical completion of pipeline system

To ensuring readiness of pipeline system for Hydro testing.

1.2 Discipline Manager


All checks for ensuring system integrity and functionality

Verification of all statutory permissions/Permit to work.

To ensure and arrange relevant inspection reports and certificates etc.

Verification of vender’s documents for material supply

To organize available resource

To report the Site manager about resource requirements.

To deal with Hydro test supervisor for safe and proper execution.

1.3 QC Manager



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For managing all necessary inspections, include Witness, Recording,

Verifying report, Test pack and results.

To ensure all inspection are executed efficiently.

To ensure the Test plan as per project specification requirement.

To execute and monitor the approved Test plan and procedure effectively

1.4 HSE Manager


To ensure overall safety of Personal Protective Equipment throughout

the entire project

To ensure all Erection, Testing and Pre-commissioning are conducted

with safety standards.

Conduct and manage internal safety Tool-box meeting with relevant crew

members.

To encourage the work force for safe and Productive work.

Monitor the work force on Safety policies, Procedures and Regulations.

To ensure and try to maintain Zero accident entire project.

To ensure that permit to work was obtained prior to start the Hydro

testing work.

1.5 Hydro Test Supervisor


To ensure about all equipment and tools are properly arranged,

and calibrated to issued crew members



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To conduct tool-box meeting about PPE and Test Procedure, Safe

work plan

To ensure and follow the approved method statement and Safety

precautions throughout the test

To ensure testing area isolation from others and equipments are

properly installed, working condition and calibration etc.

To ensure about materials damaged (if found should be replaced)

To achieve test pressure and stability within duration in accordance

within the specification

To ensure and replace materials flow control device, orifice,

gauges and instruments post hydro test activities

To ensure and clear punch list issued by client and contractors

To ensure the area is safe and properly barricaded prior to start

Hydrotesting

Entire responsible of Preparation of Test package and his crew.

2. Segment hydro testing

Certain lengths shall be chosen according to site conditions to test the installed piping

system in segments. A clearance of 4 meters minimum shall be maintained between the

segments which could be later installed as Make-Up pipe piece with plain pipe end to

facilitate the jointing on existing piping segment through bevelling lamination joining

method.

3. Fixing test plugs

There is more than one method to close temporarily the pipe ends for hydro test

purposes.



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A. Using special end caps: Special end cap is composed of full glass laminated closed

cone end with one short length pipe. Piece fixed into it, other pipe end is plain end. This

end piece shall be joined with the existing installed pipe end through bevelling lamination

jointing method (After segment test, these end caps can be removed either by cutting the

previously applied lamination joint.). Testing nozzles provided for fixing the Pressure

gauges in test Segment.

B. Using Blind flange end:

Flanged blind end is a spool consists of flange with pipe piece & blind through a blind

flange with bolts & nuts at one end while the other end is plain pipe, shall be joined

through bevelling lamination.



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Checklist prior to pipe ends blind: To check each bevelling lamination joint is laminated

correctly & has cured well. Lamination hardness shall be checked through Barcol

hardness impresser. Internal visual inspection shall be carried out for accessible pipe

diameters for any possible damage during installation or backfilling. Vertical deflection

measurements shall be taken or to observe the pipe behaviour after the backfilling.

The flange joint Lamination thickness as per Vendor (FPI) specification all flanged

joints fabricated by vendor (FPI) As per Test requirement.

The available Test blind thickness as per vendor (FPI)

NPS 3400mm = 390mm Vendor (FPI) supply.

4. Preparation prior to hydro test

Make sure that the test method statement is available with full understanding while

implementation to the testing team. After the pipe has been installed and prior to hydro

test conduct internal and external visual inspection. Any crazes, cracks, imperfection in

joints must be repaired. Remove debris, loose materials inside the pipe should be

removed. Allowance to each branch to move freely, within the limits, during the hydro

test fixing high point vents, after backfilling has been done than we will proceed with

Pr.gauge



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hydro test The values and reading at the Gauges shall be taking into account the static

head between the lowest pipe inverts along the complete line and the level of the

pressure gauge. Wooden ladder shall be available at each manhole/opening during the

inspection. Upon verification of the inspection, when the findings are all judged,

acceptable & recorded, manhole covers/opening shall be closed. In no case, single

person is allowed to get inside of piping for inspection. Prior to start water filling,

temporary piping & blinds shall be installed, checked & verified by the

client/consultant/contractor representatives.

Pressure gauges and pressure recorders shall be calibrated before the tests.

a) The Calibration interval shall not exceed 6 months. Calibration certificates shall be made

available to Inspection personnel prior to commencement of the pressure test. Stickers

shall be applied indicating the latest calibration date.

b) All gauges shall have a range such that the test pressure is within 30-80% of the full

range.

c) A minimum of 2 pressure gauges are required for the test system. One pressure gauge

shall be on the test manifold and the other on the test system. There accuracy shall be

within 5% of the another

d) When large systems are tested, Inspection personnel will determine the need for

additional gauges.

Necessary Tools and Equipments:

1. Hydro test Manifold made with 4” pipe capacity of 40bar

Relief valve – ½”

Gate valve – ½”

Hydraulic hoses – ½”

Pump.

2. Pressure gauge 2Nos within range of 30-80% of full range.

3. Ratchet spanners for Bolting.

4. Dummy Blind flanges if required.

5. Rubber Gasket if required.



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6. Fire extinguisher.

7. Whiplash arrestor (If High pressure is applied)

8. Water tank or Water Drum.

5. Water filling:

It shall be confirmed that all the vent points are fully opened to atmosphere, prior to start

water filling. Fill with water a lowest point in the line using a small diameter branch

connection. Pump capacity shall be chosen according to the pipe diameter and

segment/system linear length. The sign of complete water filling will appear when the

water starts coming through higher point ventilation opened valves. Stop the water at

this stage & check all the flanges, valves and connected accessories for any leakage

while keeping the vents open. We are Planned to fill the water through the manhole by

using 3 to 4 pumps in accordance with 6” discharge hoses and pumping out water will

be do as same in filling. The source of water (Sea water) filling for Hydro test from

temporary pond through pumps and De watering also as shown in fig page no: 15

6. Pressurizing:

After the water filling process is completed seal the entire test section with the required

blind flanges keeping all valves fully opened which are connected to the system. A

device capable of continuously pressurizing the test section shall be connected to pipe

line with required temperature recorders and the pressure recorder. In order to avoid

pressures exceeding the hydrostatic pressure in the lowest part of the pipe system, the

manometer reading shall be corrected to take account of the water head difference

between the lowest point of the system and the connection point of the pressure

gauge. All Gauges shall be calibrated prior to use in system. For both joint test and the

segmental test, the joint shall be tested at 1.5 times the operating pressures (as per



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section 02625). In case of there is any leak in pipe and lamination, it will be Repair as

per Method statement for Under Ground GRP Repair procedure.

7. Cause of pressure drop

The following causes may affect pressure and can be used a check list. A. Temperature change, by day as well by night

B. Leakage of valves, fittings, hydrants etc.

C. Damage in Gaskets

D. Dirt at sealing ring

E. Wrong installation of O rings (slip ring)

F. Pipes or fittings insufficiently blocked in the in displacement

G. Air lock

H. Damage in test equipment

I. stabilizing time too short

J. Improper joint

K. Damage in fittings

L. Settlement of the pipe system.

8. Water Supply

Refer to Hydro test Water Supply plan on page no.15, in which the highlighted portion

shows the water supply line and dewatering pond outlet as temporary pond.

9. Drain

After the hydro test is completed the water needs to be drained. The drained water

should be dispatched to dewatering pond, as shown in the Hydro test Water Supply

Plan on page no. 15.



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10. Post Hydro test activity:

After completing hydro test remaining joints in the line will be laminated. Purposefully

each end of the Pipe segment is not backfill. The Special end caps has been cut and

Removed for tested spool segment and Modified joints should conduct Barcol

Hardness test. The tie-in joint must treat as “Golden Joint”. Before backfill this golden

joints should conform NDE Hardness test is conducted and the report will be submitted

in package during Total loop will be hydro tested. When all joints will completed as per

the isometric drawing including “Golden Joint” will be tested with entire loop as in

Isometric drawing as per same method statement. Blind Flanges should be bolted in

flange connection. At the end each total loop Hydro tested, Flushing will show for Pipe

inside cleanliness. In case any Elevation change in pipe additional pressure gauge will

be fix as per client instruction.

Hydro Test Water Supply Plan



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11. Reinstatement

Water supply line

Water supply line

Water supply line

Temporary pond



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After completion of testing, flushing and draining, all system shall be restrained as

per drawing and specification and includes the following:

A.Replace of all temporary materials with original as specified in Isometric drawing

such as spades and blinds with gaskets and temporary supports were used

during erection and hydro testing etc.

B.Original gasket to be installed after removal of all test blinds/spades as per test

limit point mark on test package

C. Repositioning of spectacle blinds to the correct position as per P&ID

D. Reinstallation of all items those were removed from the system before hydro

testing such as control valve, rupture discs, strainer steam traps inline

instruments and flow devices etc.

E.Inspection of the completed system to confirm that, the correct flow direction of

instruments as per P&ID

F. Clearing of punch list issued by Client, Contractor and Sub-contractor

QC Records

Before commencing Hydro Test QC should provide Test package with include

documents as follows

Test package

Joint visual inspection report number (Inter & External lamination)

NDE report (If Required)

Pipe cleaning Visual inspection report

Request for inspection (RFI) for hydro test

Pressure gauge, Relief Valve, Manifold calibration certificates

Punch list details (If any).

12. Safety Precaution



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The following safety precautions should be observed when hydro testing.

1. Tested area should be isolated by proper barricading.

2. Un-authorized persons will not be allowed under testing area.

3. Proper sign board and caution board must be fixed during testing.

4. Do not disturb the line and equipment when pressurized.

5. Proper Draining system is provided as shown on Page no. 15.



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Hydrotest Method Statement 12th Mar 2012-1

Documents

special end

hydro test

water supply

start water

hydro test

field test

water project

temporary