Method Statemant Hydro

CONSOLIDATED CONTRACTORS COMPANYDOCUMENT No.REVISION No.PAGEOF

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MS-846-038418

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

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Approved for ConstructionRevised to CTJV comments 27/12/05 MR DM FG RD

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Approved for ConstructionRevised to CTJV comments

14/11/05 MR DM FG RD

2 Approved for ConstructionRevised to CTJV comments


1 Approved for ConstructionRevised to CTJV comments


REV COMMENTS DATEPREPARED

BYSAFETY REVIEW

QA REVIEW

APPR'D BY CCIC

CTJV

File No: CTJV QGX2 PROJECT


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MS-846-038428

I N D E X

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 CHART12.2 JSA12.3 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.



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MS-846-038438

1. SCOPE

1.1 This Method Statement outlines the requirements and related activities for the Hydrostatic testing of underground and above ground piping systems.

2. PURPOSE

2.1 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.

3. 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

4. DEFINITIONS

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

4.1 Company : Qatar Liquefied Gas Company

4.2

4.3

Contractor

Sub Contractor

: Chiyoda & Technip Joint Venture (CTJV)

Consolidated Contractors Int`l Co / Teyseer JV

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



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MS-846-038448

5. 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 manufacturer’s recommended procedure.

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.

6. 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.



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MS-846-038458

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.

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. GENERAL

7.1 Fabrication and Erection a) Will be in accordance with all applicable codes and

QGX/20/00/MP/TS/NA/001b) 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


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MS-846-038468

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.

8. TOOLS AND EQUIPMENT

8.1 The following tools and equipment shall be made available to perform the field testing of piping systems.

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.

8.2 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.

9. DOCUMENTS

9.1 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)

9.2 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.

9.3 Subcontractor shall not test through equipment without prior approval of contractor and company.

9.4 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


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MS-846-038478

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

9.5 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.

9.6 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.

9.7 Pipe cleaning Records shall be completed and signed by contractor for dia 6” and larger and by Company for 24” and larger.

10. 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.

11. TEST PERFORMANCE AND WITNESS


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MS-846-038488

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.

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 manufacturer’s 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.

12. ATTACHMENTS

Test Blind Thickness Chart JSA Demin Water Analysis Sheet


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