METHOD STATEMENT FOR HYDRO TEST & FLUSHING

OF

UNDERGROUND & ABOVEGROUND PIPES

INDEX OF CONTENTS

1)

SCOPE

2)

PROJECT DESCRIPTION

3)

REFERENCES

4)

GENERAL

5)

TEST PACKAGE

6)

TEST PREPARATION

7)

TEST EQUIPMENT AND INSTRUMENTS

8)

TEST PRESSURE

9)

DURATION OF TEST

10)

PRESSURE TESTING PROCEDURE

11)

RE-TESTING

12)

DEPRESSURISING / WATER FLUSHING

13)

DEWATERING

14)

DOCUMENTATION AND REPORTS

15)

SAFETY REQUIREMENTS

1) SCOPE
WEC Engineers & Constructors Pte Ltd is the Sub Contractor of Foster Wheeler Asia
Pacific Pte Ltd., and is contracted for construction of underground piping works and
above ground piping and other related construction works. This construction method
statement covers the System Hydro Testing & flushing with of all Pipe lines of different
systems.
The system hydrostatic testing operation shall include filling, testing and flushing with
dewatering of the pipeline system. It shall be carried out progressively in strict

accordance with the Test Package to ensure that the pipeline system can withstand the
pressure test and the system proven to be leak free.
2) PROJECT DESCRIPTION
Owner

: ExxonMobil Asia Pacific Pte Ltd,

Contractor

: Foster Wheeler Asia Pacific Private Limited.

Sub Contractor : WEC Engineers & Constructors Pte Ltd.

 Name of Project : Singapore Sulphur Disposition Project.

The main project discipline includes:
Construction of all Under Ground & above ground pipelines and structural works.
Others work as mentioned in the scope of works
3) REFERENCES
ASME B31.3

 Process Piping 2004

Inspection of Equipment and Materials
Pressure Testing
Hydro Testing Procedure
Ministry of Manpower (MOM).
RIS 12-2 (Hydrostatic and Pneumatic Testing).

 GP 03-19-01 Piping Erection leak testing, Flushing and Cleaning.

Test Pack (Approved Construction documentation cover a test system

For pressure testing.

P4120 - Method Statement for Mechanical Works

Isometric drawings

Foster Wheeler Project Specifications

ExxonMobil Global Practices

 WEC contract scope

4) GENERAL
All lines for testing shall be checked thoroughly to ensure welding completion,
completeness of test system, NDT works completion, temporary supports are installed
(if required) and all documentation and test packs completed prior to release for hydro
testing. After completion of hydro testing and acceptance of the Client, the lines shall be
flushed to remove debris and other foreign matters inside the pipe, dewatered and
drying out the system.

5) TEST PACKAGE
A complete test package shall be submitted for approval by the Contractor prior to
testing of any system. Each test pack shall be assigned with consecutive test numbers
for identification and trace ability. Test Pack shall be prepared for each test number
which will contain but not limited the following information: Test Pack Number.
Test Termination/Limit.
Test Medium.

Test Pressure.
Isometrics Drawings.
P & ID
QC Reports.
Safety check list.

6) TEST PREPARATION

a) Review all relevant plan and isometric drawings to ensure that adequate vents,
drains and spades are provided in order to system test the line.

b) Each Test Pack (system) will be inspected and recorded before testing and the
record shall be kept in the prescribed format. The purpose of this inspection is to
as certain that each test pack is in fact ready for test.

c)

Ensure that all fabrication works, welding, inspection and NDT had been
completed and accepted as per the project specification.

d) Ensure that the temporary hydro test equipments and other fittings are installed
and inspected. Plugs shall be used for Risers and Nozzle joints. Testing will
proceed through the valves and the valve will be in open.

e) Ensure that test blinds installed are of correct thickness and as per isometric
drawings.

f) Ensure that no instrument, control valve, orifice plate prior to test.

g) Make sure pipe disconnected from the equipment.
h)

Check temporary supports (if required) have been properly installed.

i) Check for proper installation of vents and drains.

j)

When a Test Pack has been checked and found ready for test, the test
coordinator shall forward the test record to Contractor / Client representative.

7) TEST EQUIPMENT AND INSTRUMENTS

a) Pressure source:-

A pump having the necessary volume and head capacity shall be used as the
source of test pressure. The system shall be equipped with all the necessary
gauges, check valves and isolation valves. The test pumps driving source of
power may be hydraulic or electrical. There shall be provisions for relieving
pressure located in the immediate reach of the test operator controlling the
source of pressure. Attachment for the general arrangement of the pressure test
pumps connection.

b) Pressure Gauges: -

Calibrated Gauges shall be used for pressure testing. These gauges shall be
calibrated against a standard dead weight tester or a calibrated master gauge
before the first use of the Gauge. Calibration certificates will be provided before
testing. Instruments and gauges used for testing shall have a range of about
double, but not less than 1.5 times the test pressure.

c) Pressure recorder will be installed as per pressure recorder chart details

temperature and pressure will be identified.

d) Two pressure gauges will be installed one is in higher point and the other one is
lower point.

e) For steam line piping the pressure gauge utilize shall be calibrated by singlas
with singlas logo appear on both certificate and pressure gauge.
8) TEST PRESSURE
Each test pack shall be tested to the required test pressure as per Project Specification
and as per isometric drawings.

9) DURATION OF TEST
The test pressure shall be hold for 18 and below is 30 min, and the dia above 18 will
be 2 hours, (threaded, socket welded, butt welded and flanged) have been inspected for
leaks, but in no case less than the code requirement.
If during the period of the test (instructed by Foster Wheeler or based on the project
specification), any faults are discovered and repaired, and repeat tests will also be
conducted as per the pressure testing procedure.

Test duration for steam line piping shall be one (1) hour.
10)PRESSURE TESTIING PROCEDURE
a) Pressure gauge (1.5 times of the test pressure) shall normally be located at
grade near the test pump. Pressure Gauge dia. inch shall be at least 100mm.

b) Calibrated Test instruments and test equipments will be used on site. Instruments
and test equipments should be tagged with date last calibrated and validity of
calibration.
c) Notification will send to Contractor (FW) / Client representative of the time and
location of system hydro testing before 24 Hrs.
d) Water to be used for system hydro testing shall be fresh, clean and free from
suspended solids and other foreign matter.
e) To fill up the pipe for testing, a suitable high volume, low head pump will be used,
or if the water source have enough pressure, just hook-up the pipe assembly.

f) The water filling operation shall start with vent connection open. Each of the
vents shall be closed only when there is a steady, air-free stream of test fluid
flowing from it.
g) Filling will continue until the pipe assembly is full of test water, fully vented and
with all vent connection closed. The fill pump (if used) will then be disconnected
from the system.
h) Upon satisfactory completion of filling, the test medium and Test Pump and
Filters will be connected to the Test Header.

a) The pipe assembly (system) will be pressurized during which time leak detection
inspection should be carried out continuously.
b) Any leak discovered shall be marked, the pipe assembly depressurized
immediately and any necessary repairs shall be done.
c) Pressurizing and testing shall be an attended operation; however, manning levels
should be minimum in areas where systems are under the test.
d) The test area will be screened by temporary guards fitted with warning notices
(i.e.: Pressure Test in Progress).

e) Only authorized personnel, i.e. Hydro testing crew, QC Inspectors, Safety

Personnel and Client Representative are allowed on the testing area.
n) The Pressure Gauges shall be started at the commencement of pressurization to
maintain a record of this phase of the test.
o) The pipe assembly pressure will be built up in stages of the specified test pressure
and the pipe and fittings will be visually examined for leaks.
p) Pressure interval shall be maintained of the test pressure at an interval holding
time of at least 10 minutes. Gradual increase of pressure will be done due to
safety reasons.

q) If no leaks are found, the pressure will be increased to that specified pressure test
(100%) of the pipe assembly.
r) When the test pressure has been achieved, the test pump will be stopped and
isolated from the test header.
s) Upon completion of pressurizing, the leak test will commence.
If significant pressure rises occur due to ambient temperature variations,
(5% over the test pressure) the pipe assembly under test will be vented to
maintain a constant test pressure.

 Additional pumping shall be required if the pressure subsequently begins

to drop below the minimum test pressure.
Reduction in pressure shall be carefully checked whether this is due to
leak or temperature drop.
Any such venting or additions will be carefully recorded and submitted with
the test results for Client Representative Agreement.
t) All leak tests shall be witnessed and accepted by the inspector. The test results
shall be recorded and a copy shall be provided to the owner. Upon satisfactory
completion of the leak test and agreed by Client Representative, the test will be

stopped and the pipe assembly depressurized. The pressure will be gradually
reduced to zero (0).
u) Vents shall be opened first and then low points drain valves will be opened and
the system thoroughly drained.
v) The test report will be prepared and signed by relevant parties.
x) After draining the system, all temporary blind and blanks, temporary supports and
temporary testing connections will be removed.

y) A minimum of two pressure gauge shall be installed in the line subject for testing.
One gauge located at the highest point and the other pressure gauge located at
the lowest point.
z) For high pressure line pressure recorder shall be used for testing.
11)

RE-TESTING

a) If testing equipment failure or other pipe welded joint (field weld) leakage occurs
during testing, WEC shall repair and perform the retesting.

b) If any repairs occurred need to rectify and after repairs had been made, the Subcontractor shall retest the pipe assembly (system) until a successful test is
obtained to the satisfaction of the Client Representative / Contractor (Foster
Wheeler).
12)DEPRESSURING / WATER FLUSHING

a) After the results of system hydro testing of the pipe assembly (system) has been
satisfactorily accepted, releasing the pressure at the vent points slowly until it
reached the atmospheric pressure shall depressurize the pipe assembly.

b) Isolation valves shall be opened and drain the water in order to remove the
temporary blinds being used for the testing.

c) After removal of temporary blinds (if need), the pipe assembly shall be flushed
with water in order to remove debris or any other foreign matter inside the pipe.

d) Flushing shall be carried out by injecting water using hose from high end of the
pipe assembly.

e) Flushing shall be done continuously until the result is found satisfactory and use
compressed air to dry out the system until accepted by the Contractor (FW) /
Client representative.

13)DOCUMENTATION AND REPORTS

After completion of System Hydro Test and Flushing works and acceptance by Client
Representative / Contractor (FW) all original copy of inspection records shall be
transferred to the site office for compilation into the final documentation and the Test
Packs to be submitted to the contractor/Client.

The following are the documents and check lists attached with the Test Pack:

Pipe Test Content,

Pipe Test Punch List

Pipe Test Record

Safety Check list

Holiday Test Report.

Pipe Completion Checklist.

Welding Summary Report.

Pipe Cleanliness Report

As Built Survey Report.

All required drawings

14)SAFETY REQUIREMENTS

a) The system hydro testing and flushing operations shall be conducted diligently,
thoroughly, and in a safe workmanship manner in accordance with accepted
piping testing practices.

b) Sub-contractor shall correct any work by Sub-contractor, or existing conditions,

which in the opinion of Client are deemed to be unacceptable.

c) The system hydro testing and flushing operations may not continue until the
unsafe conditions have been corrected to the satisfaction of the Client /
Contractor.

d) All areas where System Hydro testing and flushing are to be carried out, shall be
Barricaded with warning signs provided as per the contractor (FW) safety
personnels instruction.

e) For testing at high pressure always lead to the risk of sudden expansion of the
compressed testing medium. Therefore (if need) special safety measures shall be
taken. Only qualified personnel shall be assigned to the performance of the test.

f) During test only personnel assigned shall be permitted to be present in the

surrounding of the pipe assembly.

g) Sufficient wide safety zone to be cordoned off prior to start the testing
h) During testing, no other work is permitted within the safety zone.

i) Carry out Pre task talk before starting the work system hydro test and flushing
works.

j) Attendance of Safety Supervisor during the system hydro test and flushing works.
k) All workers must wear required P.P.E. (Personal Protection Equipment) and if
need wear the special protective equipments who involve the system hydro test
and flushing works.

l) Stop the work, if there is any Emergency case in any time.

m) Cleaning works carried out (House Keeping) after completion of all testing.