P u b l i c Wo r k s A u t h o r i t y

D R A I N A G E A F FA I R S

DOHA WEST SEWAGE TREATMENT WORKS

EXTENSION # 05
CONSULTANT

egis

CONTRACTOR

Suez Environment- Marubeni JV

SUB CONTRACTOR

Gulf East Engineering, Trading & Contg.

M e t h o d S t a t e m e n t f o r t h e P r e s s u r e Te s t i n g
(Hydrostatic & Pneumatic)of Pipe Lines

00
REV.

DATE

09

AJIT CHACKO

ANISHDEV

SHASHI PILLAI

SAISH PILLAI

PAGES

PREPARED

CHECKED

REVIEWD

APPROVED

CLIENT APPRD

DOHA WEST SEWAGE TREATMENT WORKS EXT#5

Doc No: AT-SUEZ-MS-0021/15
METHOD STATEMENT FOR THE PRESURE TESTING
(HYDRO & PNEUMATIC) OF PIPE LINES

TABLE OF CONTENTS
1.

SCOPE

2. PURPOSE
3.

APPLICABLE CODES, STANDARDS AND SPECIFICATIONS

3.1

Standards, Specification and Procedures

3.2

References

4. DEFINITIONS AND ABBREVIATIONS

5.

4.1

Definitions

4.2

Abbreviations

RESPONSIBILITY

6. HYDRO TEST PROCEDURE

6.1

General Requirements/Prerequisites

6.2

Preparation for Test

6.3

Pressure Test

6.4

Retest

6.5

Completion

6.6

Draining and Drying

6.7

Disposal of test water

7. SAFETY PRECAUTIONS

Gulf East Copyright - No reproduction without permission

Rev. 03
Page 2 / 9

Date: 30/11/2015

DOHA WEST SEWAGE TREATMENT WORKS EXT#5

Doc No: AT-SUEZ-MS-0021/15
METHOD STATEMENT FOR THE PRESURE TESTING
(HYDRO & PNEUMATIC) OF PIPE LINES

1.

Rev. 03
Page 3 / 9

Date: 30/11/2015

SCOPE
This procedure describes the general requirements and procedure for Hydrostatic and Pneumatic Leak
Testing to the requirements of QCS 2010 and as otherwise specified of shop and field fabricated pipe spools,
and piping systems after their erection and installation within thebuilding, oust side the building and
network.This procedure covers the requirement of service test with operating pressure for piping system after
assembled and installed.

2.

PURPOSE
The purpose of this procedure is to familiarize all relevant personnel with the requirements for pressure
testing of piping systems by Gulf East and its subcontractors if any.

3.

APPLICABLE CODES, STANDARDS AND SPECIFICATION

3.1Standards, Specification& Procedures
The latest issue of each of the following codes and standards shall be applied. The revisions to be used
shall be those in effect at the time of the purchase order is issued:
QCS2010
: Qatar construction Standards 2010
ASME B 31.3
: Process Piping
Gulf East HSE Plan
Fabrication and Installation Procedure (Method Statement) for GRP, Metal and Plastic Piping
3.2References
Line List
Piping class
HSE Plan
All related ITPs

4.

: DGT-X-LT-000-801
: Gulf East HSE Plan

DEFINITIONS AND ABBREVIATIONS

4.1Definition
Project : Doha West Sewage Treatment Project, Extension: 5
Contractor
: Suez Treatment Solutions Qatar
Consultant
: Egis
Sub-Contractor : Gulf East Engineering, Contracting & Trading
4.2Abbreviations
SUEZ
HSE
ITP
GRP
QC
BLDG
PTW

5.

:
:
:
:
:
:
:

SUEZ Treatment Solutions Qatar

Health &Safety and Environment
Inspection & Test Plan
Glass Reinforced Plastic
Quality Assurance / Quality Control
Building
Permit to Work

RESPONSBILITIES
Piping Engineer shall be responsible for the preparation and performance of the test described in this
procedure.
Q/C Engineer shall review the hydro test package to ensure that all the pre-test requirements have been met
as per this procedure.
Q/C Engineer shall submit an inspection notification with hydro test package to Company for review and
approval of hydro test package and witnessing the hydro test.

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Doc No: AT-SUEZ-MS-0021/15
METHOD STATEMENT FOR THE PRESURE TESTING
(HYDRO & PNEUMATIC) OF PIPE LINES

6.

Rev. 03
Page 4 / 9

Date: 30/11/2015

PRESSURE TEST PROCEDURES

6.1General Requirements/ Prerequisites

After installation of piping, some lines shall be hydrostatically or pneumatically tested as per
applicable code and specification/line list (refer attached line list).

All installation works concerned are inspected and tested as per ITP

Piping system to be pressure tested shall be inspected prior to conduct the test in accordance with
hydro test packages. The inspection results shall be recorded in the field check list for piping system
before pressure test shall be included in the test package.

Temporary blind and concrete blocks (in case of GRP)shall be placed, if the pipe end is free standing.

All temporary blind flanges are to be marked and the location shall be reflected in the P&ID.

The control valves, if the test pressure is the same on both sides of the valve, the block and bypass
valves shall be left open; the control valve shall be blinded or removed.

In line items removed for testing shall be replaced with temporary spools fabricated to the relevant
piping standard or blind. Test blinds shall be installed as indicated in the pressure test diagrams.

All permanent piping supports shall be installed before conducting the pressure test. Temporary
supports shall be provided during pressure testing, flushing of piping, which has not been designed
to carry out the weight of the piping full of fluid. Supports shall not be removed until after the system
has been fully drained.

No testing shall be permitted until seven days after thrust blocks and other holding down works have
been completed.

Pipe joints, valves and fittings shall be checked carefully for loose bolts or connections which might
cause leakage and delay the execution of the test.

Contractor shall submit the notification with test package for perform the test to main
contractor/consultant prior to scheduled test date for attendance of their representatives.

The pressure tests may be performed more than one piping system at the same time provided the
requirements of pressure test are satisfied.

The tie-in joints where will be cut and joined to the existing lines, during the tie-in work period for
process and utility piping system, will be examined or in lieu of pressure testing with approval from
main contractor/consultant in accordance with the relevant standard.

Service leak test will be applied where pressure testing is deemed to be impractical in accordance
with relevant standardfor piping system. Eg: Tie-in with existing service lines.

Pneumatic testing shall be applied for some piping systems which are specifically mentioned in the
line list.

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DOHA WEST SEWAGE TREATMENT WORKS EXT#5

Doc No: AT-SUEZ-MS-0021/15
METHOD STATEMENT FOR THE PRESURE TESTING
(HYDRO & PNEUMATIC) OF PIPE LINES

Rev. 03
Page 5 / 9

Date: 30/11/2015

6.2Preparation for Test

6.2.1

Pressure Test Package

a) Test Diagram: Piping Field Engineer/Supervisor shall be responsible for the preparation
and
issuance of test diagram which shall be made with isometric and PID.
b) Pressure Test Package: Piping Engineer/Supervisor shall prepare the test packages
based on the test diagram.
c) Q/C Engineer shall review and if there are no comments,the test packages shall be
forwarded to Client for their review and approval prior to perform the pressure test.
d) The following documents shall be included in the Pressure test package as a minimum;
-

Pressure Test Report

Exception Items lists from the test

Field Installation Check List for Piping system pressuretest

Field installation Check List for Piping System and P & ID (marked up line
being tested with test limits)

Isometric drawings (mark up the line with filling, vent, drain and pressure
gauge

6.2.2

locations.

Equipment and Instruments

Following equipment and instruments shall be provided prior to start any pressure test.
a) Calibrated pressure gauges.
b) A suitable pump for filling and capable of attaining required test pressure
c) Temporary blinds, attachment to carry out the test.
d) Pressure test manifold, hoses and temporary piping which can sustain the test pressure
e) De-watering Pump
6.3Pressure Test
6.3.1

Test Medium

a) Hydrostatic Test
-

The hydrostatic test medium shall be TSE water(Chlorine content will be checked for
the SS

lines if any) and supply sources to be used for hydro test will be selected and informed to
main contractor/consultant for review and approval prior to use
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Doc No: AT-SUEZ-MS-0021/15
METHOD STATEMENT FOR THE PRESURE TESTING
(HYDRO & PNEUMATIC) OF PIPE LINES

Rev. 03
Page 6 / 9

Date: 30/11/2015

b) Pneumatic Test
-

The test medium shall be clean, dry compressed air or. If there is a possibility of a
flammable substance being in the line, Nitrogen gas shall be used.

6.3.2

Test Pressure Value

Hydrostatic /Pneumatictest pressures: It shall be applied as per the pressure value mentioned
in the line list or to be calculated in accordance with Qatar construction standard 2010.
6.3.3

Hydrostatic Test: Pressurizing and Reading

Part 1: Underground Pipelines

a) The pressure shall be raised by pumping in water until the test pressure is reached and
shall be maintained at the required level by further pumping until it is steady.
b) The test pressure shall be held long enough for a thorough inspection of all welds or joints.
The minimum time at test pressure shall be maintained for duration of 3 hours.
c) Pumping shall then be stopped and the time taken for the observed pressure to fall by 1.0
m

shall be recorded.

d) If after three hours the test pressure has not fallen by 1.0 m, pumping shall be resumed at
that stage, the time being recorded as three hours. The rates of recorded time.
e) The rate of loss shall then be calculated as the recorded quantity by the recorded time.
f)

The test pump and gauge shall be connected to the pipeline at a location other than the
highest point in the pipeline to facilitate release of air from the highest point.

g) The loss shall not exceed 0.02 liters per mm diameter per kilometer per 24 hours for each
0.1 MPa of head applied.
h) When the entire line is completed a final test shall be performed as per QCS 2010 with the
same procedure mentioned above.
Part 2: Other Pressure Pipelines (PVC, GRP, SS, GI etc...)
a) Water

pipelines and other pressure piping carrying surface water, ground water and

treated effluent excluding raw sewage pressure pipeline having socket and spigot joints
shall be given a pressure and or leakage test. DI or PVC-U pipelines shall be tested as per
AWWA C600 and steel pipe shall be as per AWWA C200.
b) PVC-U treated sewage effluent pipe work shall be completely filled with water and visually
inspected for leakage. No section showing signs of leakage shall be accepted.
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Doc No: AT-SUEZ-MS-0021/15
METHOD STATEMENT FOR THE PRESURE TESTING
(HYDRO & PNEUMATIC) OF PIPE LINES

Rev. 03
Page 7 / 9

Date: 30/11/2015

c) High pressure PVC-U, Steel, DI and other pipe material with solvent welded, welded,
threaded and flanged jointed pipes shall be tested as per QCS 2010.

6.3.4

Pneumatic Test: Pressurizing and Reading

a) Air piping shall be tested pneumatically and no air drop shall be found in two hour period
for all field testing pipelines.
b) All air piping shall be tested by using clean air or nitrogen as per QCS 2010.
c) Low pressure pipe lines shall be tested at a maximum pressure of 140 kPa and for high
pressure lines shall be tested at 1400 kPa.
d) The pressure shall be raised by using compressed air until the test pressure is reached and
shallbe maintained at the required level by further pressurizing by air until it is steady.
e) The test pressure shall be held long enough for a thorough inspection of all welds or joints.
The minimum time at test pressure shall be maintained for duration of 2 hours.
f)
6.3.5

Pressure drops due to thermal contraction are acceptable if the pressure returns to the
original test pressure after the stipulated period of time.

Setting Pressure Test Manifold

a) A minimum two calibrated pressure test gauges shall be installed at the system to be hydro
tested. The one shall be installed on the test pump side and the other one shall be on the
piping system being tested.
b) Recording gauges for pressure and temperature shall be used when the test duration
exceeds four hours, or otherwise as required by Client.
c) For pneumatic test, two pressure test gauges shall be installed as appropriate for the pipe
system configuration at the furthest test termination points from the test compressor or
airline.

6.4Retest
6.4.1

If a pipe line fails to meet the test pressure, any leaks or defects must be repaired in
accordance with the specification and the QCS 2010.

6.4.2

Before starting any weld repairs, joint repair or tightening threaded connections, the lines
shall be depressurized in all cases and only fully drained if absolutely necessary. Leaking
metallic threaded connections shall not be seal-welded without approval of the client
representative.

6.4.3

The repaired line shall be retested, to the originally specified test pressure, until it passes
the pressure test.

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Doc No: AT-SUEZ-MS-0021/15
METHOD STATEMENT FOR THE PRESURE TESTING
(HYDRO & PNEUMATIC) OF PIPE LINES

Rev. 03
Page 8 / 9

Date: 30/11/2015

6.5Completion
6.5.1

6.5.2

6.6

6.7

When the pressure tests are completed to the satisfaction of Client, the pressure in the
system shall be reduced gradually, opening the vent slowly and then drain the water
completely from the system. Vent shall be left open while draining the system

After completion of hydrostatic test, all temporary spool pieces, blanks and test blinds shall be
removed. All instruments, expansion joints, strainers, filter elements, and other components
removed or restrained for the test shall be reinstated in accordance with their relevant
specification. Flanged connections, which are adjacent to temporary spool pieces, be
reinstated with new gaskets. New bolts and nuts shall be provided if test bolting is not of
correct grade for the line service. Temporary test valves, valves at low point test drains and
high point test vents shall be replaced with line class plugs which shall be seal-welded in place.
Temporary supports shall be removed.

Draining and Drying

6.6.1

Drains shall be provided at all low points in the system and immediately above check valves in
vertical lines.

6.6.2

For buried lines where draining may not be possible, the hydrotest water shall be driven out
using oil free compressed air through a drain located on an outlet riser.

6.6.3

Before start draining of the test fluid all vent valves shall be opened and high point vent plugs
removed to ensure against damage by vacuum to any apparatus or piping.

Disposal of Test Water

6.7.1

On completion of hydrotesting the water shall be discharged to an evaporation pond approved

by SUEZ and the Consultant.

7.

SAFETY
7.1

Warning signs shall be posted at appropriates locations for the duration of the tests. Temporary warning
barriers shall be erected to prevent personnel accessing to the test area.

7.2

Only authorized personnel shall be permitted to approach the system undergoing pressure test. All
pressure tests shall be manned throughout the duration and not left unattended

7.3

All necessary measures shall be taken to that all personnel are adequately protected during the course
of the pressure test and no work shall be on the pressurized sections of the line for the duration of the
tests. Care must be taken when venting and draining water/process fluids form tested pipe work due to
the likely risk of contaminants, and gas, these will be exhausted to atmosphere as the pipe work fills
and drains, those shall be extended to a safe area via flexible hose. The outlet of either vent or drain
must be carefully selected and agreed with site HSE so as not to contaminate the environment or other
work areas.

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Doc No: AT-SUEZ-MS-0021/15
METHOD STATEMENT FOR THE PRESURE TESTING
(HYDRO & PNEUMATIC) OF PIPE LINES

7.4

Rev. 03
Page 9 / 9

Date: 30/11/2015

Proper locking of pipes shall be set-up to ensure that no pressurized liquid or gas will be released
un-intentionally.

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