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.
Revision
Date of Issue
: YT-PF-Z-16-00212
:A
: 28th Feb. 2012
YANBU 2 WATER AND

POWER PROJECT
Contract PO No.: 7200 018 725
Doc No. :YT-PF-Z-16-00212
Rev No. : A
Method Statement for

Underground Piping
Hydro test
Issue Date:28th Feb.2012

Page 2 of 21
REVISION INDEX
Rev
Date
28 Feb. 2012
A
Rev.
th
For Review
Description
Description
For Review
28-Feb-2012
Date
Danish Khan
Prepared By
I. G. YEO
Checked By
S. K. HONG
Approved By
YANBU 2 WATER AND

POWER PROJECT

Underground Piping
Hydro test

Rev No. : A

Page 3 of 21
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
YANBU 2 WATER AND

POWER PROJECT
Rev No. : A

Underground Piping
Hydro test

Page 4 of 21
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: 400m 3
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POWER PROJECT
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Underground Piping
Hydro test

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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 = Poissons 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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POWER PROJECT
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Underground Piping
Hydro test

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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 venders 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
YANBU 2 WATER AND

POWER PROJECT
Rev No. : A

Underground Piping
Hydro test

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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
YANBU 2 WATER AND

POWER PROJECT
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Underground Piping
Hydro test

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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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POWER PROJECT
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Underground Piping
Hydro test

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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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POWER PROJECT
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Hydro test

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Pr.gauge
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
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POWER PROJECT
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Underground Piping
Hydro test

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fixing high point vents, after backfilling has been done than we will proceed with 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
Gate valve
Hydraulic hoses
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.
YANBU 2 WATER AND

POWER PROJECT
Rev No. : A

Underground Piping
Hydro test

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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
YANBU 2 WATER AND

POWER PROJECT
Rev No. : A

Underground Piping
Hydro test

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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.
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POWER PROJECT
Rev No. : A

Underground Piping
Hydro test

Page 14 of 21
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.
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.
YANBU 2 WATER AND

POWER PROJECT
Rev No. : A

Underground Piping
Hydro test
Hydro Test Water Supply Plan

Page 15 of 21
YANBU 2 WATER AND

POWER PROJECT
Rev No. : A

Underground Piping
Hydro test
Water supply line

Page 16 of 21
Water supply line

Temporary pond
Water supply line
11. Reinstatement
YANBU 2 WATER AND

POWER PROJECT
Rev No. : A

Underground Piping
Hydro test

Page 17 of 21
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)
YANBU 2 WATER AND

POWER PROJECT
Rev No. : A

Underground Piping
Hydro test

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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

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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POWER PROJECT
Rev No. : A

Underground Piping
Hydro test

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POWER PROJECT
Rev No. : A

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Hydro test

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Hydro test

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MARAFIQ 2 YANBU 2 POWER &

METHOD STATEMENT FOR

YANBU 2 WATER AND

Method Statement for

Issue Date:28th Feb.2012

YANBU 2 WATER AND

Method Statement for

Doc No. :YT-PF-Z-16-00212

Issue Date:28th Feb.2012

SEGMENT HYDRO TESTING ......8

FIXING TEST PLUGS.........8

PREPARATION PRIOR TO HYDRO TEST..10

CAUSE OF PRESSURE DROP.......13

POST HYDRO TEST ACTIVITIES...14

YANBU 2 WATER AND

Method Statement for

Issue Date:28th Feb.2012

Field Test Procedure

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

YANBU 2 WATER AND

Method Statement for

Issue Date:28th Feb.2012

YANBU 2 WATER AND

Method Statement for

Issue Date:28th Feb.2012

To implement over all safety plan for hydro test

To ensure proper execution of hydro test in accordance with project

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 venders documents for material supply

To organize available resource

To report the Site manager about resource requirements.

YANBU 2 WATER AND

Method Statement for

Issue Date:28th Feb.2012

He shall be responsible for

For managing all necessary inspections, include Witness, Recording,

To ensure all inspection are executed efficiently.

To ensure the Test plan as per project specification requirement.

1.4 HSE Manager

To ensure overall safety of Personal Protective Equipment throughout

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

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.

1.5 Hydro Test Supervisor

To ensure about all equipment and tools are properly arranged,

YANBU 2 WATER AND

Method Statement for

Issue Date:28th Feb.2012

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

To ensure and follow the approved method statement and Safety

To ensure testing area isolation from others and equipments are

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

To achieve test pressure and stability within duration in accordance

To ensure and replace materials flow control device, orifice,

To ensure and clear punch list issued by client and contractors

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

Entire responsible of Preparation of Test package and his crew.