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REVISION No.
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CONSOLIDATED CONTRACTORS COMPANY

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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

QGll LNG ONSHORE FACILITIES PROJECT

RAS LAFFAN - QATAR

Approved for Construction

Revised to CTJV comments

27/12/05

MR

DM

FG

RD

Approved for Construction

Revised to CTJV comments

14/11/05

MR

DM

FG

RD

Approved for Construction

Revised to CTJV comments

20/10/05

MR

DM

FG

RD

Approved for Construction

Revised to CTJV comments

29/09/05

MR

DM

FG

RD

DATE

PREPARED
BY

SAFETY
REVIEW

QA REVIEW

APPR'D BY
CCIC

REV

COMMENTS

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CTJV

QGX2 PROJECT

CTJV

CONSOLIDATED CONTRACTORS COMPANY

DOCUMENT No.
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INDEX
1.

SCOPE

2.

PURPOSE

3.

REFERENCES

4.

DEFINITIONS

5.

RESPONSIBILITIES

6.

SAFETY

7.

GENERAL

8.

TOOLS AND EQUIPMENT

9.

DOCUMENTS

10.

PREPARATION

11.

TEST PERFORMANCE & WITNESS

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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2.

4.

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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.

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To ensure that all information, material, tools, equipment, manpower and

supervision are available for execution of the work. Also to ensure that work steps
are analyzed and all safety measures are taken so that work can be executed in a
safe and timely manner.

REFERENCES
3.1

Safety Procedure QGX/20/00/SA/PC/NA/100 to 124

3.2

QA-QC Requirements QGX/20/00/CS/PC/NA/020

3.3

Piping Fabrication, Erection and Testing QCP-846-115

3.4

ASME B31.3 Process Piping

3.5

Piping Fabrication, Erection and Testing QGX/20/00/MP/TS/NA/001

DEFINITIONS
For the purpose of this method statement, the following definitions shall apply:

5.

4.1

Company

Qatar Liquefied Gas Company

4.2

Contractor

Chiyoda & Technip Joint Venture (CTJV)

4.3

Sub Contractor

4.3

Permit to Work

Document issued by Qatar Gas / CTJV

4.5

MS

Method Statement

4.6

QCP

Quality Control Procedure

4.7

ITP

Inspection and Test Plan

4.8

NDT

Non-Destructive Testing

4.9

JSA

Job Safety Analysis

Consolidated Contractors Int`l Co / Teyseer JV

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

Contractor & Sub-contractor Engineer/Supervisor/Foreman will ensure the safe and

efficient working environment to plant and equipment to carry out the hydrostatic
testing activity.

5.4

The Contractor and Sub-contractors Quality Control Inspectors will be responsible

for the inspection of pressurized piping system in accordance with the project
specification and procedure.

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

Good housekeeping shall be maintained throughout the period.

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

A safety watch guard will be assigned throughout the test period.

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

JSA and MS shall be attached to work permit.

6.13

All necessary approved PPE shall be provided and worn at all times.
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6.14

Sufficient illumination shall be provided in all areas whilst working at night.

6.15

Subcontractor to obtain PTW prior to start of test.

6.16

All activities shall be suspended in case of emergency and not restarted until the
PTW has been revalidated.

6.17

After successful completion of the pressure testing and gradual de-pressurization,

the draining operation will commence. Draining will be routed to disposal area as
allocated by contractor. During the draining operation, all necessary precautions will
be taken to control the water flow in order to avoid pollution, damage to the existing
facilities and without hazard to vehicles or equipment.

6.18

Sand bedding surround and backfilling of underground systems shall commence as

soon as instructed by the Contractor so to offer a natural anchoring to the pipeline,
protection of bedding/surround the coating from extensive exposure to high
temperatures, or any damaging action inflicted by bad weather conditions and prior
to pressure testing as per conditions in Procedure QGX/20/00/MP/TS/NA/001
Section 13.2. (Applicable for U/G Piping only)

7.

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GENERAL
7.1

Fabrication and Erection

a)
Will be in accordance with all applicable codes and
QGX/20/00/MP/TS/NA/001
b)
All NDT/PWHT requirements shall be completed prior to release for
pressure test.
c)
Reinforcing pads shall be pneumatically tested for any leaks at a
pressure of 60 to 100 psig. A soap solution shall be applied to
inspect all welds. Snoop or equivalent shall be used for stainless
steel.
d)
In case of jacketed pipe the inner shall be hydro tested prior to
fabricating the outer casing.

7.2

Pipe Cleaning Requirements

Pipe cleaning shall be in accordance with QGX/20/00/MP/TS/NA/001
CLAUSE 11.7
a) Pipes of 6 dia and larger shall be internally cleaned by manually flushing
with air blow in order to remove all trash or construction debris left inside
the pipe. All inline instruments shall be removed and protected. All control
valves shall be removed prior to cleaning and testing. Permanent plant
like pumps and vessels shall be isolated from this cleaning process.
b) An inspection sheet is to be signed by subcontractor, contractor and
company with a marked up isometric or line number clearly indicating the
limit of cleaning carried or part thereof inspected and passed clean. This
document will be attached to the test pack.

TOOLS AND EQUIPMENT

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8.2

9.

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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 displacement pumps ( hose from pump to be crimped and fitted

with Chicago Pin and whip cord )
Fill tank and isolation valves
Filling pumps
Test manifolds with PSV set to applicable safety pressure.
Hand tools
Pneumatic sockets
Torque wrenches
Calibrated pressure gauges and recorders
Blinds and plugs QA approved.

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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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.
3

11.

TEST PERFORMANCE AND WITNESS

11.1 Hydrostatic Test:
Fill line with water and vent all air from loop to be tested.
Raise pressure to 1 bar and hold for 10 min checking for leaks at flange
joints.
Raise pressure at a maximum rate of 5 bar/ min.
Continue to raise pressure till desired test pressure is reached and system
has stabilized.
Visual checks of all test gauges shall be made at all hold points.
Hold pressure for 10 min at required test pressure and then inspect all pipe
joints, weld seams, screwed connections, valves, glands etc.
If any leaks are detected pressure needs to be bled off gradually till
atmospheric is reached and leak sealed accordingly. In some cases it might
be required to drain system completely in such event draining procedure
should be followed.
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CONSOLIDATED CONTRACTORS COMPANY

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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

Test Blind Thickness Chart

JSA
Demin Water Analysis Sheet

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CTJV

QGX2 PROJECT