MS of Hydrotest Procedure SSDP Rev C

8/10/2019 MS of Hydrotest Procedure SSDP Rev C

1/39


2/39

METHOD STATEMENT FOR HYDRO TEST & FLUSHING

OF

UNDERGROUND & ABOVEGROUND PIPES


3/39

INDEX OF CONTENTS

1) SCOPE

2) PROJECT DESCRIPTION

3) REFERENCES


4/39

4) GENERAL

5) TEST PACKAGE

) TEST PREPARATION

!) TEST E"UIPMENT AND INSTRUMENTS

#) TEST PRESSURE


5/39

$) DURATION OF TEST

1%) PRESSURE TESTING PROCEDURE

11) RETESTING

12) DEPRESSURISING ' (ATER FLUSHING

13) DE(ATERING


6/39

14) DOCUMENTATION AND REPORTS

15) SAFETY RE"UIREMENTS


7/39

1) SCOPE

WEC Engineers & Constructors Pte Ltd is the Sub Contractor of Foster Wheeler AsiaPacific Pte Ltd., and is contracted for construction of underground piping works andaboe ground piping and other related construction works. !his construction "ethodstate"ent coers the S#ste" $#dro !esting & flushing with of all Pipe lines of different

s#ste"s.!he s#ste" h#drostatic testing operation shall include filling, testing and flushing withdewatering of the pipeline s#ste". %t shall be carried out progressiel# in strict


8/39

accordance with the !est Package to ensure that the pipeline s#ste" can withstand thepressure test and the s#ste" proen to be leak free.

2) PROJECT DESCRIPTION

wner ' E((on)obil Asia Pacific Pte Ltd,

Contractor ' Foster Wheeler Asia Pacific Priate Li"ited.

Sub Contractor ' WEC Engineers & Constructors Pte Ltd.


9/39

*a"e of Pro+ect ' Singapore Sulphur isposition Pro+ect.

!he "ain pro+ect discipline includes'

Construction of all -nder round & aboe ground pipelines and structural works.

thers work as "entioned in the scope of works

3) REFERENCES

AS)E /01.0


10/39

Process Piping 2334

%nspection of E5uip"ent and )aterials

Pressure !esting

$#dro !esting Procedure

)inistr# of )anpower 6))7.

8%S 1292 6$#drostatic and Pneu"atic !esting7.


11/39

P 3091:931 Piping Erection leak testing, Flushing and Cleaning.

!est Pack 6Approed Construction docu"entation coer a test s#ste"

For pressure testing.

P4123 9 )ethod State"ent for )echanical Works

%so"etric drawings

Foster Wheeler Pro+ect Specifications

E((on)obil lobal Practices


12/39

WEC contract scope

4) GENERAL

All lines for testing shall be checked thoroughl# to ensure welding co"pletion,

co"pleteness of test s#ste", *! works co"pletion, te"porar# supports are installed6if re5uired7 and all docu"entation and test packs co"pleted prior to release for h#drotesting. After co"pletion of h#dro testing and acceptance of the Client, the lines shall beflushed to re"oe debris and other foreign "atters inside the pipe, dewatered anddr#ing out the s#ste".


13/39

5) TEST PACKAGE

A co"plete test package shall be sub"itted for approal b# the Contractor prior totesting of an# s#ste". Each test pack shall be assigned with consecutie test nu"bersfor identification and trace abilit#. !est Pack shall be prepared for each test nu"ber

which will contain but not li"ited the following infor"ation'9 !est Pack *u"ber.

!est !er"ination;Li"it.

!est )ediu".


14/39

!est Pressure.

%so"etrics rawings.

P & %


15/39

a7 8eiew all releant plan and iso"etric drawings to ensure that ade5uate ents,drains and spades are proided in order to s#ste" test the line.

b7Each !est Pack 6s#ste"7 will be inspected and recorded before testing and therecord shall be kept in the prescribed for"at. !he purpose of this inspection is toas certain that each test pack is in fact read# for test.

c7 Ensure that all fabrication works, welding, inspection and *! had beenco"pleted and accepted as per the pro+ect specification.


16/39

d7 Ensure that the te"porar# h#dro test e5uip"ents and other fittings are installedand inspected. Plugs shall be used for 8isers and *o==le +oints. !esting willproceed through the ales and the ale will be in open.

e7 Ensure that test blinds installed are of correct thickness and as per iso"etricdrawings.

f7 Ensure that no instru"ent, control ale, orifice plate prior to test.

g7 )ake sure pipe disconnected fro" the e5uip"ent.

h7 Check te"porar# supports 6if re5uired7 hae been properl# installed.


17/39

i7 Check for proper installation of ents and drains.

+7 When a !est Pack has been checked and found read# for test, the testcoordinator shall forward the test record to Contractor ; Client representatie.

!) TEST E"UIPMENT AND INSTRUMENTS

a7 Pressure source'9


18/39

A pu"p haing the necessar# olu"e and head capacit# shall be used as thesource of test pressure. !he s#ste" shall be e5uipped with all the necessar#gauges, check ales and isolation ales. !he test pu"p>s driing source ofpower "a# be h#draulic or electrical. !here shall be proisions for relieingpressure located in the i""ediate reach of the test operator controlling thesource of pressure. Attach"ent for the general arrange"ent of the pressure test

pu"ps connection.

b7 Pressure auges' 9


19/39

Calibrated auges shall be used for pressure testing. !hese gauges shall becalibrated against a standard dead weight tester or a calibrated "aster gaugebefore the first use of the auge. Calibration certificates will be proided beforetesting. %nstru"ents and gauges used for testing shall hae a range of aboutdouble, but not less than 1.? ti"es the test pressure.

c7 Pressure recorder will be installed as per pressure recorder chart detailste"perature and pressure will be identified.

d7 !wo pressure gauges will be installed one is in higher point and the other one islower point.


20/39

e7 For stea" line piping the pressure gauge utili=e shall be calibrated b# singlaswith singlas logo appear on both certificate and pressure gauge.

#) TEST PRESSURE

Each test pack shall be tested to the re5uired test pressure as per Pro+ect Specificationand as per iso"etric drawings.


21/39

$) DURATION OF TEST

!he test pressure shall be hold for 1@ and below is 03 "in, and the dia aboe 1@ willbe 2 hours, 6threaded, socket welded, butt welded and flanged7 hae been inspected forleaks, but in no case less than the code re5uire"ent.

%f during the period of the test 6instructed b# Foster Wheeler or based on the pro+ectspecification7, an# faults are discoered and repaired, and repeat tests will also beconducted as per the pressure testing procedure.


22/39

!est duration for stea" line piping shall be one 617 hour.

1%)PRESSURE TESTIING PROCEDURE

a7 Pressure gauge 61.? ti"es of the test pressure7 shall nor"all# be located at

grade near the test pu"p. Pressure auge dia. inch shall be at least 133"".


23/39

b7 Calibrated !est instru"ents and test e5uip"ents will be used on site. %nstru"entsand test e5uip"ents should be tagged with date last calibrated and alidit# ofcalibration.

c7 *otification will send to Contractor 6FW7 ; Client representatie of the ti"e andlocation of s#ste" h#dro testing before 24 $rs.

d7 Water to be used for s#ste" h#dro testing shall be fresh, clean and free fro"suspended solids and other foreign "atter.

e7 !o fill up the pipe for testing, a suitable high olu"e, low head pu"p will be used,or if the water source hae enough pressure, +ust hook9up the pipe asse"bl#.


24/39

f7 !he water filling operation shall start with ent connection open. Each of theents shall be closed onl# when there is a stead#, air9free strea" of test fluidflowing fro" it.

g7 Filling will continue until the pipe asse"bl# is full of test water, full# ented andwith all ent connection closed. !he fill pu"p 6if used7 will then be disconnectedfro" the s#ste".

h7 -pon satisfactor# co"pletion of filling, the test "ediu" and !est Pu"p andFilters will be connected to the !est $eader.


25/39

a7 !he pipe asse"bl# 6s#ste"7 will be pressuri=ed during which ti"e leak detectioninspection should be carried out continuousl#.

b7 An# leak discoered shall be "arked, the pipe asse"bl# depressuri=edi""ediatel# and an# necessar# repairs shall be done.

c7 Pressuri=ing and testing shall be an attended operationB howeer, "anning leels

should be "ini"u" in areas where s#ste"s are under the test.d7 !he test area will be screened b# te"porar# guards fitted with warning notices

6i.e.' Pressure !est in Progress7.


26/39

e7 nl# authori=ed personnel, i.e. $#dro testing crew,


27/39

57 %f no leaks are found, the pressure will be increased to that specified pressure test6133D7 of the pipe asse"bl#.

r7 When the test pressure has been achieed, the test pu"p will be stopped andisolated fro" the test header.

s7 -pon co"pletion of pressuri=ing, the leak test will co""ence.

%f significant pressure rises occur due to a"bient te"perature ariations,6?D oer the test pressure7 the pipe asse"bl# under test will be ented to"aintain a constant test pressure.


28/39

Additional pu"ping shall be re5uired if the pressure subse5uentl# begins

to drop below the "ini"u" test pressure. 8eduction in pressure shall be carefull# checked whether this is due to

leak or te"perature drop. An# such enting or additions will be carefull# recorded and sub"itted with

the test results for Client 8epresentatie Agree"ent.

t7 All leak tests shall be witnessed and accepted b# the inspector. !he test resultsshall be recorded and a cop# shall be proided to the owner. -pon satisfactor#co"pletion of the leak test and agreed b# Client 8epresentatie, the test will be


29/39

stopped and the pipe asse"bl# depressuri=ed. !he pressure will be graduall#reduced to =ero 637.

u7 ents shall be opened first and then low points drain ales will be opened andthe s#ste" thoroughl# drained.

7 !he test report will be prepared and signed b# releant parties.

(7 After draining the s#ste", all te"porar# blind and blanks, te"porar# supports andte"porar# testing connections will be re"oed.


30/39

#7 A "ini"u" of two pressure gauge shall be installed in the line sub+ect for testing.ne gauge located at the highest point and the other pressure gauge located atthe lowest point.

=7 For high pressure line pressure recorder shall be used for testing.

11) RETESTING

a7 %f testing e5uip"ent failure or other pipe welded +oint 6field weld7 leakage occursduring testing, WEC shall repair and perfor" the retesting.


31/39

b7 %f an# repairs occurred need to rectif# and after repairs had been "ade, the Sub9contractor shall retest the pipe asse"bl# 6s#ste"7 until a successful test isobtained to the satisfaction of the Client 8epresentatie ; Contractor 6FosterWheeler7.

12)DEPRESSURING ' (ATER FLUSHING

a7 After the results of s#ste" h#dro testing of the pipe asse"bl# 6s#ste"7 has beensatisfactoril# accepted, releasing the pressure at the ent points slowl# until itreached the at"ospheric pressure shall depressuri=e the pipe asse"bl#.


32/39

b7 %solation ales shall be opened and drain the water in order to re"oe thete"porar# blinds being used for the testing.

c7 After re"oal of te"porar# blinds 6if need7, the pipe asse"bl# shall be flushedwith water in order to re"oe debris or an# other foreign "atter inside the pipe.

d7 Flushing shall be carried out b# in+ecting water using hose fro" high end of thepipe asse"bl#.

e) Flushing shall be done continuousl# until the result is found satisfactor# and useco"pressed air to dr# out the s#ste" until accepted b# the Contractor 6FW7 ;Client representatie.


33/39

13)DOCUMENTATION AND REPORTS

After co"pletion of S#ste" $#dro !est and Flushing works and acceptance b# Client8epresentatie ; Contractor 6FW7 all original cop# of inspection records shall betransferred to the site office for co"pilation into the final docu"entation and the !est

Packs to be sub"itted to the contractor;Client.

!he following are the docu"ents and check lists attached with the !est Pack'


34/39

Pipe !est Content,

Pipe !est Punch List

Pipe !est 8ecord

Safet# Check list

$olida# !est 8eport. Pipe Co"pletion Checklist.

Welding Su""ar# 8eport.

Pipe Cleanliness 8eport


35/39

As /uilt Sure# 8eport.

All re5uired drawings

14)SAFETY RE"UIREMENTS

a7 !he s#ste" h#dro testing and flushing operations shall be conducted diligentl#,thoroughl#, and in a safe work"anship "anner in accordance with acceptedpiping testing practices.


36/39

b7 Sub9contractor shall correct an# work b# Sub9contractor, or e(isting conditions,which in the opinion of Client are dee"ed to be unacceptable.

c7 !he s#ste" h#dro testing and flushing operations "a# not continue until theunsafe conditions hae been corrected to the satisfaction of the Client ;Contractor.

d7 All areas where S#ste" $#dro testing and flushing are to be carried out, shall be/arricaded with warning signs proided as per the contractor 6FW7 safet#personnel>s instruction.


37/39

e7 For testing at high pressure alwa#s lead to the risk of sudden e(pansion of theco"pressed testing "ediu". !herefore 6if need7 special safet# "easures shall betaken. nl# 5ualified personnel shall be assigned to the perfor"ance of the test.

f7 uring test onl# personnel assigned shall be per"itted to be present in thesurrounding of the pipe asse"bl#.

g7 Sufficient wide safet# =one to be cordoned off prior to start the testing

h7 uring testing, no other work is per"itted within the safet# =one.


38/39

i7 Carr# out Pre task talk before starting the work s#ste" h#dro test and flushingworks.

+7 Attendance of Safet# Superisor during the s#ste" h#dro test and flushing works.

k7 All workers "ust wear re5uired P.P.E. 6Personal Protection E5uip"ent7 and ifneed wear the special protectie e5uip"ents who inole the s#ste" h#dro test

and flushing works.

l7 Stop the work, if there is an# E"ergenc# case in an# ti"e.

"7Cleaning works carried out 6$ouse eeping7 after co"pletion of all testing.


39/39

Documents

MS of Hydrotest Procedure SSDP Rev C