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REVISION No.
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MS-846-038
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QGX-CCS-004-A-0038
METHOD STATEMENT
FOR
HYDROTESTING OF
U/G & A/G PIPING SYSTEM
MS 846 - 038
27/12/05
MR
DM
FG
RD
14/11/05
MR
DM
FG
RD
20/10/05
MR
DM
FG
RD
29/09/05
MR
DM
FG
RD
DATE
PREPARED
BY
SAFETY
REVIEW
QA REVIEW
APPR'D BY
CCIC
REV
COMMENTS
File No:
CTJV
QGX2 PROJECT
CTJV
DOCUMENT No.
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INDEX
1.
SCOPE
2.
PURPOSE
3.
REFERENCES
4.
DEFINITIONS
5.
RESPONSIBILITIES
6.
SAFETY
7.
GENERAL
8.
9.
DOCUMENTS
10.
PREPARATION
11.
12.
ATTACHMENT
12.1 TEST BLIND THICKNESS CHART
12.2 JSA
12.3 It should be noted that sample test pack complete with
flow chart was submitted and B Approved as part of
QA/QC Documentation. Pack therefore as agreed by
these departments shall be used.
1.
SCOPE
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This Method Statement outlines the requirements and related activities for the
Hydrostatic testing of underground and above ground piping systems.
PURPOSE
2.1
3.
DOCUMENT No.
REVISION No.
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REFERENCES
3.1
3.2
3.3
3.4
3.5
DEFINITIONS
For the purpose of this method statement, the following definitions shall apply:
5.
4.1
Company
4.2
Contractor
4.3
Sub Contractor
4.3
Permit to Work
4.5
MS
Method Statement
4.6
QCP
4.7
ITP
4.8
NDT
Non-Destructive Testing
4.9
JSA
RESPONSIBILITIES
5.1
The Sub Contractor is responsible for the hydrostatic testing of above and
underground piping systems according to applicable safety procedures, project
specifications and manufacturers recommended procedure.
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5.2
The authorized permit holder/signatory shall obtain work permits from the
Company/CTJV as appropriate.
5.3
5.4
5.5
All the safety equipment, vehicles, barricades, road and hazard signs for Hydro
testing Works will be provided by the Sub-contractor.
SAFETY
6.1
6.2
The hydrostatic testing will be undertaken in accordance with the project safety
manual. QGX/20/00/SA/PC/NA/100.
6.3
Non essential personnel shall be cleared from the vicinity of the test pipe system.
6.4
Personnel involved in the pressure test shall have an identification mark on the
helmet so that test personnel can be easily identified in the test area.
6.5
6.6
The subcontractor will inform their safety department of the day to day testing
activities by means of written advisory at least one day before test is conducted.
6.7
Contractor / Subcontractor safety personnel will conduct a joint walk with testing
personnel to familiarize themselves with system to be tested and to identify any
potential hazards.
6.8
Proper and safe means of access and egress shall be provided and maintained for
all personnel in order to carry out inspection and testing of piping system.
6.9
Pressure system shall have a safe exclusion zone in all directions for any non
related activities. The parameters of this zone shall vary according to the volume of
test medium and the pressure it will be subjected to. As rule of thumb this would be
1,5 meter for every 10 bar and sufficient distance to avoid being engulfed if total
release of test medium is released.
6.10
Adequate warning sign boards will be placed around barricaded area where the test
is being carried out for the awareness of non related personnel.
6.11
When venting water from system particular care shall be taken to prevent water
from venting into adjacent work places or onto electrical equipment or wiring.
6.12
6.13
All necessary approved PPE shall be provided and worn at all times.
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6.14
6.15
6.16
All activities shall be suspended in case of emergency and not restarted until the
PTW has been revalidated.
6.17
6.18
7.
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GENERAL
7.1
7.2
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8.2
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The following tools and equipment shall be made available to perform the field
testing of piping systems.
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Pressure gauges shall have a range of 1.5 to 4 times the required test pressure with
adequate dial accuracy to allow an exact reading of the test pressure. Gauges shall
be of 6 dial with build in vibration dampers. Gauges shall be calibrated within 30
days preceding the test. Two gauges minimum shall be installed at lowest and
highest point where practical.
DOCUMENTS
9.1
9.2
9.3
9.4
4
9.5
Prior to any pressure test all pertaining documents shall be compiled in Test
Package and submitted for approval by contractor and company. (Sample of Test
Pack Documents submitted under QCP 846-115)
Using a marked up set of P & ID in the system definition the extent of the test
system will be clearly indicated as well as blank and spade points.
Subcontractor shall not test through equipment without prior approval of contractor
and company.
A typical test pack shall include the following documents:
Marked up last revision of P & ID marked up showing test limits and
routing.
Isometric marked up with all weld numbers and limits as per the P &
ID
Weld history traceability.
Pressure Test Confirmation Record
Piping Pressure Test Release Report
Holiday test result for U/G Piping
Pre Hydro Punch List
Location Map
Blind Thickness Chart
Isometric control sheet from Talisman indicating NDT & PWHT
Cleaning Record
Last revision of the Line List with applicable lines highlighted
Concession Request if applicable
The marked up isometric drawing will indicate the location of pressurization point,
pressure gauge locations, vent location, control valves removed, FE, Flow gauge,
level gauges, strainer elements and critical soft seated ball valves which are not
part of the test.
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QGX2 PROJECT
9.6
9.7
10.
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Pre test punch list shall be prepared by Sub contractor as part of Test Pack and
Items Cat A cleared before test. Cat B items to be cleared as post test requirement.
Pipe cleaning Records shall be completed and signed by contractor for dia 6 and
larger and by Company for 24 and larger.
PREPARATIONS
10.1
Demin water shall be used for hydro testing austenitic stainless steel piping and
piping systems containing dissimilar materials where part of the system is stainless
steel. Water should not contain more than 50 ppm chloride ions. This condition
should be verified by lab testing sample from source prior to filling operation. Sea
water will be permissible for testing of sea water cooling lines only. All water should
be drained from test system immediately upon completion of test unless by
arrangement from contractor.
10.2 Visual inspection shall be applied in lieu of pressure test for lines open to
atmosphere, open ended drains and valves without spools as part of vessel trim.
10.3 Precautions should be taken to avoid over pressurization due to the rise in pressure
caused by escalating temperatures.
10.4 Temporary supports shall be installed by sub contractor if required after engineering
review.
10.5 Components deemed to be excluded as listed in item 9.5 shall be removed.
10.6 Test manifold will be connected at lowest point in system.
10.7 Calibrated pressure gauges will be installed at lowest and highest point practical.
10.8 All safety measures as listed in Section 6 will be met.
10.9 High Point vent will be installed and remain open till line is completely full and
purged of all entrapped air.
10.10 All required blinding and spading will be carried out as detailed in test loop pack.
Blind thickness will be determined from blind chart and temporary gaskets will be
installed at all joints that will require slacking after test.
10.11 All parts of test loop will be tightened in accordance with the bolt sequence and
torque requirements.
10.12 Prior to start filling test system will be walked down and checked in its entirety to
ensure total compliance and safe to fill.
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The minimum testing period including holding time shall be 30 min or time it
takes to complete leak detection whichever is the greatest or as per the
Project Specification. In some cases manufacturers recommendations might
dictate longer or shorter holding periods.
The test will not be conducted when the outside of the system is wet or in
rain unless instructed by contractor.
After acceptance of test all vents and drains will be opened and system will
be depressurized slowly.
Draining should be conducted in safe manner and test medium should be
drained to designated area.
Holding time may be increased as required.
Pressure and temp readings to recorded on charts by means of calibrated
recorder.
ATTACHMENTS
File No:
MS-846-038
4
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CTJV
QGX2 PROJECT