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

Docu Docume men nt No No. Revision Date of Issue

: YT YT-PF-PF-Z Z-16 -16-002 -00212 12 :A : 28th Feb. 2012

YANBU 2 WATER WATER AND POWER PROJECT

Contr ontrac actt PO PO No. No.:: 72 7200 018 018 725 725 Doc No. :YT-PF-Z-16-00212 Rev No. : A

Meth Method od Sta Stateme tement nt for for Underground Underground Piping Hydro test

Issue Date:28 th Feb.2012 Page 2 of 21

REVISION INDEX Rev

Date

A

28th Feb. eb. 2012

A Rev.

For Review Review Description

Description For Re Review view

28-Feb-2 28-Feb-2012 012 Date

Danish Danish Khan Khan Prepared By

I. G. YEO YEO Checked By

S. K. HONG HONG Approved By


Contr ontrac actt PO PO No. No.:: 72 7200 018 018 725 725


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


CONTENTS INTRODUCTION FIELD TEST PROCEDURE 1.

RESPONSIBILITIES…………. ………………………..……..…………………..6 1.1 Site Manager ………………………………………..……..…………………..6 ………………………………………..……..…………………..6 1.2 Discipline Manager ………………………..……..…………..………………..6 ………………………..……..…………..………………..6 1.3 QC Manager ………………………..……..……………………………………7 ………………………..……..……………………………………7 1.4 HSE Manager ………………………..……..…………………………………..7 ………………………..……..…………………………………..7 1.5 Hydro Test Supervisor ………………………..……..………………………...7 ………………………..……..………………………...7

2.

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

3.

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

4.

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

5. WATER FILLING…..………… FILLING…..……………………… ………………………...................................... …………...................................... 12 6.

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

7. CAUSE OF PRESSURE DROP…..……………………..…………….….…… DROP…..……………………..…………….….…….13 .13 8.

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

9.

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

10. POST HYDRO TEST ACTIVITIES……………………………………………...14 11. REINSTATEMENT…………………………………………….…….…….…..….16 12. SAFETY PRECAUTION…..…………………………………..……….…….…..17





Introduction This Procedure defines 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 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 soundness of all joints and connections. In testing, testing, sudden pressure surges or water hammer must be avoided.

The Test 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 Trapped air can be released 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. pressure. Prior to start-up of test activities, the Hydro test supervisor supervisor should perform a pre-test calculation calculation to obtain the value of DV/DP. of DV/DP. The dewatering pump as present in site with capacity of Max Head: 50m Max Flow: 400m 3





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 (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 [(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





A = Area of pipe v = velocity of test media

1. Resp Respon onsi sibi bili litie ties s 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. 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 He shall be responsible for •

All checks for ensuring ensuring system integrity integrity and functionality functionality

•

Verification Verification of all statutory permissions/Permit permissions/Permit to work.

•

To ensure and arrange relevant inspection reports and certificates etc.

•

Verification 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





He shall be responsible for •

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 He shall be responsible for •

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 He shall be responsible for •

To ensure about all equipment and tools are properly arranged, and calibrated to issued crew members m embers


Contr ontrac actt PO PO No. No.:: 72 7200 018 018 725 725 Doc No. :YT-PF-Z-16-00212 Rev No. : A •



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 Test package and his crew.

2. Segm Segmen entt hydro hydro tes testin ting g Certain lengths shall be chosen according to site conditions conditions to test the installed piping system in segments. A clearance clearance of 4 meters minimum shall be maintained 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.





A. Using special end caps: 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 method (After segment segment test, these end caps can be be removed either either by cutting the previously previously applied applied lamination lamination joint.). Testing nozzles provided for fixing the Pressure gauges gauges in test Segment. 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.





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 fabricated by vendor (FPI) As per Test Test requirement. requirement. The available Test blind thickness as per vendor (FPI) NPS 3400mm = 390mm Vendor (FPI) supply. 4. Preparation Preparat ion prior pri or to hydro h ydro test t est 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. repaired. Remove debris, debris, loose materials materials inside the pipe should be 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 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 covers/opening shall be closed. In no case, single person is allowed to get inside of piping for inspection. Prior to start water f illing, temporary piping piping & blinds shall be installed, checked & verified by the client/consultant/contractor client/consultant/contractor representatives. Pressure gauges gauges and pressure recorders shall be calibrated before the tests. interval shall not exceed 6 months. Calibration certificates shall be made a) The Calibration interval available available to Inspection personnel personnel prior to commencement commencement of the pressure test. Stickers shall be applied indicating the latest calibration date. b) All gauges gauges shall have a range such that the test pressure is within 30-80% 30-80% of the full range. gauges are required for the test system. One pressure gauge c) A minimum of 2 pressure gauges 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 systems are tested, Inspection personnel personnel will determine the need for additional gauges. Necessary Tools and Equipments: 1.

2.

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

Relief valve – ½”

•

Gate valve – ½”

•

Hydraulic hoses – ½”

•

Pump.

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

3. Ratch Ratchet et span spanne ners rs for for Bolt Bolting ing.. 4. Dummy Dummy Blin Blind d flang flanges es if req requir uired ed.. 5. Rubbe Rubberr Gask Gasket et if requi required red..





6. Fire Fire extin extingu guis ishe herr. 7. Whiplash Whiplash arrestor arrestor (If High High pressu pressure re is applied applied)) 8. Water ater tank tank or Water Water Drum. Drum. 5. Water filling: 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 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. 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 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 t he operating pressures pressures (as per





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, change, by day as well well by night B. Leakage Leakage of valves, valves, fittings fittings,, hydran hydrants ts etc. etc. C. Dama Damage ge in Gask Gasket ets s D. Dirt Dirt at seal sealin ing g rin ring g E. Wrong Wrong ins instal talla latio tion n of O rings rings (slip (slip ring ring)) F.

Pipes Pipes or fitting fittings s insufficie insufficiently ntly blocke blocked d in the in in displace displacement ment

G. Air lo lock H. Dama Damage ge in in test test equ equip ipme ment nt I.

stab stabil iliz izin ing g tim time e too too shor shortt

J.

Improper jo joint

K. Dama Damage ge in fitt fittin ing gs L. Settl Settlem emen entt of the the pip pipe e syste system. m.

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 completed the water water needs to be drained. drained. The drained 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 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 conform NDE Hardness Hardness test is conducted conducted and the report report will be submitted 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 At the end each total loop Hydro tested, t ested, Flushing will show for Pipe inside cleanliness. In case any Elevation change in pipe additional pressure gauge gauge will be fix as per client instruction.




Hydro Test Water Supply Plan






Water supply line Water supply line Temporary pond

Water supply line

11. Reinstatement





After completion of of testing, flushing and and draining, draining, all system shall be restrained restrained as per drawing and specification and includes the following: A.Replace of all temporary temporary materials materials with original original as specified in Isometric 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. Repositi Repositionin oning g of spectacle spectacle blinds blinds to the correct correct position position as per per P&ID D. Reinstallation Reinstallation of all all items those those were removed from the system system before 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 Sub-contractor QC Recor Rec ords ds 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 The following safety precautions should be observed when hydro testing. 1. Tested Tested area area should should be isolat isolated ed by prope properr barricadi barricading. ng. 2. Un-autho Un-authorized rized person persons s will not be be allowed allowed under under testing testing area. area. 3. Proper Proper sign sign board and and caution caution board board must must be fixed during during testing testing.. 4. Do not not disturb disturb the line line and and equipme equipment nt when when pressuriz pressurized. ed. 5.

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













Hydrotest Method Statement 12th Mar 2012-1

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