154

COMPANY: PETRO RABIGH-

of 12RABIGH DEVELOPMENT PROJECT, PC-3

METHOD STATEMENT

METHOD STATEMENT

OF

HYDROSTATIC TESTING OF PIPELINES

(UNDER GROUND & ABOVE GROUND GARVITY & PRESSURE LINES)

REVIEW FOR TECNIMONT :

REVIEWED BY APPROVED BY REV.NO.DISCIPLINE HSE QA/QC

KETTANEH ISSUE STATUS

Rev. Date Description Prepared Checked Approved

0 21 Jun 07 Hydrostatic Testing of Pipelines

Russel Z.A. Molla CB

KCS/ MS/HDPE-BUTENE-1/CIV-023 Rev. 00 Date: 21 Jun 07 Page N. 1 of 12



METHOD STATEMENT

CONTENT:

1. GENERAL INFORMATION

1.1 Introduction1.2 Purpose1.3 Scope of Work1.4 Location1.5 Definitions

2. EXECUTION

2.1 Materials2.2 Tools & Equipments2.3 Procedure of Work2.4 Responsibilities

3. QA / QC

3.1 Reference Standard3.2 Responsibilities3.3 Test and Measurement3.4 Inspection

4. SAFETY

4.1 Guidelines4.2 Responsibilities4.3 Hazard Analysis




METHOD STATEMENT

1.0 GENERAL INFORMATION

1.1 Introduction

TECNIMONT Arabia Ltd. (TAL) has awarded to KETTANEH Construction Saudi Arabia Ltd. the subcontract for the construction of PC3 Plant of Rabigh Development Project, Rabigh K.S.A.

1.2 Purpose

To provide a procedure for hydrostatic testing of pipelines to be performed throughout the project to ensure conformity with project specifications and to provide a specific information, requirements and guidelines on safe pressure testing.

1.3 Scope of Work

This method statement outlined the procedure of HYDROSTATIC TESTING for underground and above ground utility piping in the Rabigh Development Project – PC3 in accordance with project specifications and approved drawings.

1.4 Location

HYDROSTATIC Testing shall be conducted in the HDPE & Butene Area of PC3 Plant – Rabigh Development Project, Rabigh K.S.A. for underground & above ground utility piping as specified in the approved drawings.

1.5 Definitions

SAES : Saudi Aramco Engineering StandardPIP : Process Industry PracticesG.I. : General InstructionsPVC : Poly Vinyl ChlorideuPVC : Unplasticized Poly Vinyl ChlorideCPVC : Chlorinated Poly Vinyl ChlorideHDPE : High Density PolyethyleneRTR : Reinforced Thermosetting ResinQA / QC : Quality Assurance / Quality Control




METHOD STATEMENT

2.0 EXECUTION

2.1 Materials

1. PVC / uPVC / CPVC / HDPE Pipes 2. RTR Pipes3. Carbon Steel Pipes4. Reinforced Concrete Pipes

2.2 Tools and Equipments

a. Test Manifoldb. Pressure Gaugec. Pressure Relief Valved. Test Pump ( Manual & Motorized )e. Various Hand Toolsf. Water Trucks

2.3 Procedure of Work

2.3.1 Test Package

Test Package shall be submitted to Tecnimont for approval denoting all responsible discipline for confirmation of the various inspection requirements.

Test Package shall be in accordance with Tecnimont’s ‘Management of Pressure Testing Activities’ with the following documents to be signed-off upon verification and inspection before and after the hydrotest whenever required.

a. Test Package Submittal / Checklist for Releaseb. Layout of Area Interested by Pressure Testc. Marked Line Listd. Marked-up PIDe. Isometric Drawingsf. Pressure Test Diagramsg. Inspection Record for Orifice Flange Runh. Piping Installation & Pressure Test Recordi. Calibration Certificates of Pressure Gaugesj. Calibration Certificates of Pressure Relief Valvek. Test Blinds Installation / Removal Certificatesl. Instrument Reinstatement Certificatem. Construction Punch Listn. Red Line As-built Isometric Drawings with Weld Map




METHOD STATEMENT

o. Weld Summary Recordp. Inspection Reports / Inspection Records as per Inspection Test

Plan. The Management & Flow of Hydrostatic Test Package up to the

Reinstatement completion and the required coordination between Construction’s Test Package shall be in accordance with Tecnimont’s ‘Management of Pressure Testing Activities’.

Post test activities (if required) shall be noted in the Construction Punch List and shall be cleared during Reinstatement.

2.3.2 Test Equipment Verification

The pressure testing manifold shall be tested separately to at least 1.2 times the system pressure before employing for actual hydrostatic testing.

Pressure rating or design of test manifold components such as isolation valves, pipes and fittings are not less than 20% above the system test pressure.

Relief valve of adequate capacity are set to relieve at 5% above the test pressure.

The relief valve are tested, dated and tagged within one week prior to pressure testing.

In addition to the pressure relieving device, a blow down valve or bleed valve shall be provided to protect the piping and equipment from over pressure.

A minimum of two pressure gauges are required for the system. When large systems are tested, Inspection personnel will determine the need for additional gauges.

Pressure gauges are calibrated within one (1) month prior to the test. Stickers shall be applied indicating the latest calibration date.

All gauges shall have a range such that the test pressure is within 30% to 80% of the full range.

Calibration Certificates of Pressure Gauges and Pressure Relief Valves shall be available at the test area for review.

Test piping, fittings, hoses and isolation valves are designed or have pressure rating that matched or exceed the system test pressure.

Paddle blinds or spectacle blinds and isolation valves that are to be used to isolate the test sections are of the same class rating of the system or may be fabricated based on appropriate calculations.

2.3.3 Test Preparation




METHOD STATEMENT

The authorization to carry out the hydro test shall be given after approval of Test Package Documentation and visual check of pipeline against the drawings and hydraulic test preparation.

The hydrostatic test for utility piping shall be conducted in accordance with SAES-S060, SAES-S-070 and SAES-A-004.

Potable water piping system shall be hydro tested with fresh potable water as described in SAES-S-070 clause 18.2a.

Other utility piping systems shall be hydro tested with potable, well water or sea water as described in SAES-S-070 clause 18.2b.

Water distribution network shall be tested at 150 psig as described in SAES-S-070 clause 18.8 and SAES-S-060 clause 103.5.3.3 for hot & cold water within the buildings.

Lines whose joints have not been backfilled for underground piping or are above ground piping shall be tested to a period of 4 hours while 24 hours shall be maintained for lines whose joints have been backfiled or concealed.

Test Limits, pressure, test medium and safety requirements shall be identified.

The approved Test Package shall be available for verification and review at the test area.

Pre-Test Punch List items are cleared. Test Package Flow chart signed-off accordingly. Flushing is completed or internal cleanliness of the system is verified in

accordance with SAES-A-004. Components which interfere with filling, venting, draining or flushing

shall not be installed until after the line flushing and pressure testing. Temporary supports shall be installed wherever required. All joints shall be left exposed for visual inspection during test. Underground piping shall be partially backfilled with all joints exposed

to serve as a pipe support and prevent floatation. Work Permit is obtained for all pressure testing and associated work

within restricted areas as covered in G.I.2.100, Work Permit System. Equipment and appurtenances that are not adequate for test pressure

shall be isolated. The test areas shall be marked and warning signs shall be posted to alert

approaching personnel. A blow down valve of adequate pressure rating is installed to

depressurize the system. An isolation valve of adequate pressure rating is installed to isolate the

test piping manifold from the system under test. The relief valve shall be located in the test manifold near the test pump. A pressure gauge shall be located at the test manifold and one pressure

gauge on the furthest route of the piping network being tested.




METHOD STATEMENT

Vents shall be provided at all high points in the system being tested. A blow down valve or bleed valve shall be readily accessible in case

immediate depressurization is required. Temporary connections shall be provided for de-pressurization and

draining of the system to the sewer or disposal area. General Instruction G.I.0002.102 ‘Pressure Testing Safely’ shall be

followed during pressure testing.

2.3.4 Hydro test Crew

Hydrostatic Testing shall be done by trained personnel in the proper handling and usage of applicable tools and equipments prior to start of hydrostatic Testing.

Personnel conducting the hydrostatic testing shall be fully aware of the general requirements of safe pressure testing of pipelines in accordance with General Instructions G.I.0002.102.

2.3.5 Pressurization

No Thermoplastic Piping shall be pressurized until it has cured for 24 hours at a surface temperature of 10°C or higher.

No adhesive bonded RTR Piping shall be pressurized until it has cured in accordance with the manufacturer’s instructions.

The test pump & test manifold shall be placed on a firm ground away from the piping being tested.

The test manifold shall be supported firmly to avoid vibration during pressurization.

All in line valves are in open position. Filling and pressurization is injected at the test manifold upstream of

check valves and at the lowest point of the system being tested to minimize entrapped air.

Water filling into the system shall be direct from a water truck or form a ground level water tank with pump.

Remove air during filling of water by opening the vents installed at high points and shall be closed when air has been released from the system.

After venting, valves used for venting are placed at partial open position and plugged.

Vents and drains used only for the pressure test shall be plugged or seal welded.

To pressurize the system, motorized or manual test pumps shall be used depending on the size of the system being tested.

The system shall be pressurized slowly. Preliminary check for leaks at 50% of the test pressure shall be done.




METHOD STATEMENT

The pressure is increased in steps no greater than one-fifth of the test pressure after the preliminary check at 50% test pressure. Each step in pressurization is held at minimum of 10 minutes.

After the test pressure is reached (before inspection), the isolation valve between the test manifold & the piping system under pressure test is closed and the test pump disconnected.

No repair of leaking joints until the system has been de-pressurized.

2.3.6 Depressurization and Draining of Test Medium

After pressure testing has been successfully completed and approved, the piping system being tested shall be depressurized and drained.

Release of pressure and draining shall be done on the downstream side of check valves.

All vents shall be opened before draining to facilitate drainage and to prevent formation of a vacuum.

Water used for hydrostatic testing can be used for another test, to be used for water spray of trenches, to be used for water flooding of pipe sand covering or to a safe and approved discharge area.

All temporary items installed for testing purposes shall be removed. All pipe ends shall be covered after draining the system to prevent entry

of foreign materials into the system.

2.3.7 Gravity Test

Testing of sewer system shall be in accordance with SAES-S-020 clause 5.3 and SAES-S-060 clause 712.2.

Gravity sanitary sewer and Industrial drainage system shall be tested with potable water, well water or sea water as described in SAES-S-070 clause 18.2b.

Gravity test shall be maintained for a period of 4 hours for lines whose joints have not been backfilled or are above ground piping while 24 hours shall be maintained for lines whose joints have been backfilled.

Gravity test shall be done from manhole to manhole or a column of water equivalent to the rim elevation of the upstream manhole if pipe is to be tested separately.

If manholes are not part of the test or a section of pipe is to be tested, the pipe ends shall be covered with plumber’s test plugs.

An extension pipe is provided on the test plugs at selected location for water filling and drain points and at least one pipe riser for the water head required that shall be accessible for visual inspection.

Plumber’s test plugs that are not used for other purposes shall be kept open while filling of water to release air inside the system and shall be closed when the system has been properly vented.




METHOD STATEMENT

Drain piping within the buildings shall be tested before being covered and before connecting to a fixture to at least 3 meter water head.

Water filling into the pipe being tested shall be from a water truck or a ground level water tank with electric or engine-driven pump. A water hose shall be placed direct to the manhole, to the pipe being tested or to a pipe connection provided at the plumber’s test plug.

All joints shall be exposed and cleaned for visual inspection. Partial sand covering and backfilling on the body of the pipe being

tested shall be done to prevent floatation during test. Drain valve shall be provided at the lowest portion of the pipe being

tested for safe draining after inspection. Water used for testing can be re-used for another gravity test, for water

flooding of pipe sand covering, for water spray of trenches or discharge to a designated area.

Repair methods for leaking pipes, joints and fittings shall be in accordance with SAES-S-070.

No repair of leaking joints until the system has been drained.

2.4 Responsibilities

Site Engineer shall organize, manage and supervise all activities related to the installation of PVC piping with regards to safety, quality and productivity of the over-all performance of the work.

Site Supervisor and Foreman shall arrange all the necessary manpower, tools and equipments and implement the approved working procedure for a proper execution of the work with regards to safety, quality and productivity.

3.0 QA / QC

3.1 Reference Standards

SAES-S-010 - Sanitary Sewers SAES-S-020 - Industrial Drainage and Sewers SAES-S-040 - Saudi Aramco Water Systems SAES-S-060 - Saudi Aramco Plumbing Code SAES-S070 - Installation of Utility Piping system SAES-A-004 - General Requirements for Pressure Testing G.I. 0002.102 - Pressure Testing Safely Tecnimont ‘Management of Pressure Testing Activities’ Tecnimont ‘Inspection and Test Plan for Non-Metallic Piping’ Kettaneh QA / QC Plan



COMPANY: PETRO RABIGH10 -


METHOD STATEMENT

QA / QC Inspector shall make sure that all activities related to the hydrostatic testing of pipelines are carried out in accordance with the project specifications and procedures. He shall arrange Inspection & Testing required with TECNIMONT and PETRO Rabigh in accordance with the ITP. He shall maintain and keep records for all QC Documents.

Site Engineer, Supervisor and Foreman shall assist the QA/QC Inspector whatever he required in relation to the quality of works, procedures or documents.

3.3 Test and Measurement

For Pressure Test, a calibrated Pressure Gauge shall be used for measuring the test pressure.

For Gravity Test, simply marked the water level at the manhole or pipe being tested at the start of the test.

The piping being tested shall be considered satisfactory if no reasonable drop on the water level or pressure loss after the specified test period and if no evidence of water leakage on the body of the pipes, fittings and to the joints.

3.4 Inspection

Request for Inspection shall be issued to TECNIMONT / PETRO Rabigh Project Inspection 24 hours in advance on weekdays and 48 hours in advance for weekends and holidays.

Inspection shall be done in accordance with the Inspection Test Plan (ITP), and Forms.

During Inspection, all exposed pipes, joints and fittings shall be carefully examined for leakage.

The piping being tested shall be satisfactory if there is no evidence of leakage and no reasonable drop in the water head or pressure loss after the specified test period.

Leaking pipes, joints and fittings shall be replaced and test shall be repeated until the system is proven satisfactory.

4.0 SAFETY

4.1 Guidelines

Work Permit shall be obtained for all pressure testing activities.




METHOD STATEMENT

Person(s) conducting the hydrostatic testing shall wear the Personal Protective Equipments at all times on the job site.

Test section or test area shall be identified and shall be provided with barricades such as safety tapes or physical barriers.

Only authorized person shall be allowed to enter or crossed to the test area.

Warning sign boards and lights shall also be provided (where necessary) to alert approaching personnel not involved in the hydrostatic testing.

Proper access such as ladders and ramps shall be provided at designated areas where workers can go in and out the excavated area.

All test equipments and test instruments shall be calibrated or certified. At least one person is to be stationed at the test area to check and monitor

the test pressure and possible leakage of pipes and joints.


Safety Inspector / Officer in conjunction with the site supervisor or foreman shall physically check and conform that all safety requirements had been provided and implemented.

Personnel conducting the hydrostatic testing shall follow the approved safe working procedure for pressure testing of pipelines.

4.3 Hazard Analysis

Job Description Hazard Preventive Measures Responsibilities1. Pressurization 1. Injury to worker 1. install pressure relief Engineer, supervisor

from overpressure, Valve. and foreman




METHOD STATEMENT

pipe blown-out 2. provide temporary pipe

or detached. supports.

3. proper venting required.

4. temporary connections

shall have the same

rating or exceed the

the pipe being tested.

5. install blowdown valve or

bleed valve.

6. depressurization required

before repair of leaks.

7. unauthorized person not

allowed in the test area.

8. pressurization to be done

slowly and monitor

Pressure rise.
