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WATER PROJECT
Contract PO No.: 7200 018 725 Method Statement for Issue Date:28th Feb.2012
Doc No. :YT-PF-Z-16-00212 Underground Piping Page 2 of 21
Hydro test
Rev No. : A
REVISION INDEX
Contract PO No.: 7200 018 725 Method Statement for Issue Date:28th Feb.2012
Doc No. :YT-PF-Z-16-00212 Underground Piping Page 3 of 21
Hydro test
Rev No. : A
CONTENTS
INTRODUCTION
1. RESPONSIBILITIES. ......6
1.3 QC Manager....7
5. WATER FILLING........................................12
6. PRESSURIZING.....12
8. WATER SUPPLY........13
9. DRAIN .............14
11. REINSTATEMENT......16
Contract PO No.: 7200 018 725 Method Statement for Issue Date:28th Feb.2012
Doc No. :YT-PF-Z-16-00212 Underground Piping Page 4 of 21
Hydro test
Rev No. : A
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
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 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
Contract PO No.: 7200 018 725 Method Statement for Issue Date:28th Feb.2012
Doc No. :YT-PF-Z-16-00212 Underground Piping Page 5 of 21
Hydro test
Rev No. : A
Suction Head: 9m
Where,
V= volume of pipe
D = outside Diameter
t = Wall thickness
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.
Q = AV
Where
Q = Discharge
YANBU 2 WATER AND
POWER PROJECT
Contract PO No.: 7200 018 725 Method Statement for Issue Date:28th Feb.2012
Doc No. :YT-PF-Z-16-00212 Underground Piping Page 6 of 21
Hydro test
Rev No. : A
A = Area of pipe
1. Responsibilities
To deal with Hydro test supervisor for safe and proper execution.
1.3 QC Manager
YANBU 2 WATER AND
POWER PROJECT
Contract PO No.: 7200 018 725 Method Statement for Issue Date:28th Feb.2012
Doc No. :YT-PF-Z-16-00212 Underground Piping Page 7 of 21
Hydro test
Rev No. : A
To execute and monitor the approved Test plan and procedure effectively
Conduct and manage internal safety Tool-box meeting with relevant crew
members.
To ensure that permit to work was obtained prior to start the Hydro
testing work.
Contract PO No.: 7200 018 725 Method Statement for Issue Date:28th Feb.2012
Doc No. :YT-PF-Z-16-00212 Underground Piping Page 8 of 21
Hydro test
Rev No. : A
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.
There is more than one method to close temporarily the pipe ends for hydro test
purposes.
YANBU 2 WATER AND
POWER PROJECT
Contract PO No.: 7200 018 725 Method Statement for Issue Date:28th Feb.2012
Doc No. :YT-PF-Z-16-00212 Underground Piping Page 9 of 21
Hydro test
Rev No. : A
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.
Contract PO No.: 7200 018 725 Method Statement for Issue Date:28th Feb.2012
Doc No. :YT-PF-Z-16-00212 Underground Piping Page 10 of 21
Hydro test
Rev No. : A
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
YANBU 2 WATER AND
POWER PROJECT
Contract PO No.: 7200 018 725 Method Statement for Issue Date:28th Feb.2012
Doc No. :YT-PF-Z-16-00212 Underground Piping Page 11 of 21
Hydro test
Rev No. : A
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 &
to get inside of piping for inspection. Prior to start water filling, temporary piping & blinds
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.
Contract PO No.: 7200 018 725 Method Statement for Issue Date:28th Feb.2012
Doc No. :YT-PF-Z-16-00212 Underground Piping Page 12 of 21
Hydro test
Rev No. : A
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
Contract PO No.: 7200 018 725 Method Statement for Issue Date:28th Feb.2012
Doc No. :YT-PF-Z-16-00212 Underground Piping Page 13 of 21
Hydro test
Rev No. : A
section 02625). In case of there is any leak in pipe and lamination, it will be Repair as
The following causes may affect pressure and can be used a check list.
A. Temperature change, by day as well by night
C. Damage in Gaskets
G. Air lock
J. Improper joint
K. Damage in fittings
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.
YANBU 2 WATER AND
POWER PROJECT
Contract PO No.: 7200 018 725 Method Statement for Issue Date:28th Feb.2012
Doc No. :YT-PF-Z-16-00212 Underground Piping Page 14 of 21
Hydro test
Rev No. : A
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
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
Contract PO No.: 7200 018 725 Method Statement for Issue Date:28th Feb.2012
Doc No. :YT-PF-Z-16-00212 Underground Piping Page 15 of 21
Hydro test
Rev No. : A
Contract PO No.: 7200 018 725 Method Statement for Issue Date:28th Feb.2012
Doc No. :YT-PF-Z-16-00212 Underground Piping Page 16 of 21
Hydro test
Rev No. : A
11. Reinstatement
YANBU 2 WATER AND
POWER PROJECT
Contract PO No.: 7200 018 725 Method Statement for Issue Date:28th Feb.2012
Doc No. :YT-PF-Z-16-00212 Underground Piping Page 17 of 21
Hydro test
Rev No. : A
After completion of testing, flushing and draining, all system shall be restrained as
such as spades and blinds with gaskets and temporary supports were used
B.Original gasket to be installed after removal of all test blinds/spades as per test
D. Reinstallation of all items those were removed from the system before hydro
testing such as control valve, rupture discs, strainer steam traps inline
E.Inspection of the completed system to confirm that, the correct flow direction of
QC Records
Before commencing Hydro Test QC should provide Test package with include
documents as follows
Test package
Contract PO No.: 7200 018 725 Method Statement for Issue Date:28th Feb.2012
Doc No. :YT-PF-Z-16-00212 Underground Piping Page 18 of 21
Hydro test
Rev No. : A
Contract PO No.: 7200 018 725 Method Statement for Issue Date:28th Feb.2012
Doc No. :YT-PF-Z-16-00212 Underground Piping Page 19 of 21
Hydro test
Rev No. : A
YANBU 2 WATER AND
POWER PROJECT
Contract PO No.: 7200 018 725 Method Statement for Issue Date:28th Feb.2012
Doc No. :YT-PF-Z-16-00212 Underground Piping Page 20 of 21
Hydro test
Rev No. : A
YANBU 2 WATER AND
POWER PROJECT
Contract PO No.: 7200 018 725 Method Statement for Issue Date:28th Feb.2012
Doc No. :YT-PF-Z-16-00212 Underground Piping Page 21 of 21
Hydro test
Rev No. : A