WORK METHOD STATEMENT FOR METALLIC PIPING

HYDROSTATIC TEST
 TABLE OF CONTENTS

1. PURPOSE .................................................................................................................................. 5

2. SCOPE OF WORK ................................................................................................................... 5

2.1. Application ................................................................................................................ 5

2.2. Exceptions ................................................................................................................ 5

3. REFERENCES / DEFINITIONS ................................................................................................. 5

4. HEALTH, SAFETY AND ENVIRONMENT.................................................................................. 6

4.1. Test Leader ................................................................................................................. 6

4.2. Work Permit ................................................................................................................ 6

4.3. Test Boundary ........................................................................................................... 6

4.4. Safety Precautions ..................................................................................................... 7

5. METHOD OF EXECUTIONE ...................................................................................................... 8

5.1. Test Package ............................................................................................................ 8

5.2. Test apparatus ............................................................................................................ 9

5.3. Preparations ............................................................................................................ 10

5.4. Closing and Isolation ............................................................................................... 11

5.5. Pressurization ........................................................................................................... 11

5.6. Bolt Tightening .......................................................................................................... 12

5.7. Inspection ................................................................................................................ 12

5.8. Reinstatement ......................................................................................................... 13

5.9. Documentation ........................................................................................................ 13

6. PERSONNEL RULES AND RESPONSIBILITIES .................................................................. 13

7. TOOL AND EQUIPMENT ........................................................................................................ 14

8. ATTACHMENTS ...................................................................................................................... 14
1. PURPOSE

The purpose of this procedure is to provide the requirements of Hydrostatic Testing for the piping
work of, “ONSITE CONSTRUCTION WORKS,

SCOPE OF WORK

1.1. Application

This procedure covers the hydrostatic test for underground and aboveground metallic pressure
piping system and those connected equipment and integral components to assure their
mechanical strength and tightness.

1.2. Exceptions

With reference of ASME B31.3, service testing in line with requirements for category D fluid
services will be acceptable for piping systems sizes DN80 and lesser. Only the following services
are deemed to be Category D fluid service.

a. Utility air

b. Utility water

c. Utility nitrogen

d. Steam, design pressure lower than 3.5 barg (50psi)

e. Steam condensate, design pressure lower than 3.5 barg (50 psi)

2. REFERENCES / DEFINITIONS

a. ASME B31.3 Process Piping

b. ASME Sec VIII Div. I Rules for Construction of Pressure Vessel

c. ASME PCC-2 Repair of Pressure Equipment and Piping

3. HEALTH, SAFETY AND ENVIRONMENT

3.1. Test Leader

A test leader will be appointed to control all test activities as the executer.

3.2. Work Permit

To start a pressure test, the Contractor will follow Company’s PTW procedure along with the
approved WMS, Risk Assessment, Test Package and Marked-up Drawings.
 3.3. Test Boundary

a. A marked-up drawing of the hydrostatic testing shall be prepared by each test

package, and it shall be attached to work permit.

b. Install proper barricade along the test boundary which has been shown in the
marked-up drawing.

c. Install sufficient numbers of warning labels, such as below pictures, on the safety
barricade to ensure people’s awareness.

d. Safety Personnel shall secure the test boundary all the time and remove any
unauthorized personnel from or nearby the test boundary.

e. Inside the barricade, only test leader and test crew are allowed to enter to
operate test equipment i.e. air compressor, gas bottles, valves, etc.

3.4. Safety Precautions

a. Prior to execute a hydrostatic test, the Test Leader shall hold a task specific
TBM with test crew and all participants.

b. Follow all the safety requirements described in the PTW, risk assessment and
applicable procedures all the time during the test.

c. Follow the safety procedure for test machine/tools operation.

d. All participants involving in the hydrostatic test shall wear proper PPE.

e. Wear the Safety Harness when conduct a leak check or test activities at 1.5m or
higher elevation except the activities at permanent platform.

f. Provide suitable Ladders and Scaffolds for 1.5m or higher elevation.

g. Provide adequate lighting in case any night works are expected.

h. Depressurizing shall be gradually made to avoid pressure shock.

i. Drain water shall be properly induced to safe area i.e. trench

4. METHOD OF EXECUTIONE

4.1. Test Package

4.1.1 Test package shall consist of the information, as minimum;

J Test Package General Information Sheet

 J Table of Contents
J Test Package Symbol
J Pressure Test Report
J Line List
J Mark-up P&ID
J Mark Up Isometric Drawing
J Inspection Summary
J Blind List
J Manifold Test Report
J Punch List
J Reinstatement Check List
J Water Analysis Report
J Stored Energy and Safety Distance (Only Pneumatic Test)
J Flange Management

4.1.2 Test package for each loop or section of plant piping system must be submitted for review
and approval.

4.1.3 Line Check

a. Line check shall be conducted by each test package.

b. All findings from line check shall be described on ISO drawings and/or listed in
Punch-list sheets.

c. Punch items will be classified into following categories;

A-punch: Outstanding items that must be completed prior to pressure testing

such as major defects on pressure retaining component, pipe supports
and permanent structure of testing piping system.

B-punch: Items that can be completed either before or after testing and must be
cleared by completion of reinstatement.

C-punch: Items to be completed before commissioning and must be cleared by

completion of handover.

d. All listed and classified punch items shall be returned to construction team to
execute the necessary repair and punch clearing work.
e. Another line check shall be conducted to verify the result of punch clear.
4.1.4 Package Release

When all A-punch items as well as all non-conformities, NDE examinations and post weld
heat treatment (PWHT) are completed, the test package will be released to test team for
scheduling and preparing the designated pressure testing.

4.2. Test apparatus

a. Typical test apparatus are as shown in below diagram;

b. Blind list and items to be excluded from testing shall be provided.

c. Test manifold shall be 100% RT for butt joint and 100% PT/MT for fillet joints,
tested and certified by 3rd party lab. Test pressure shall be above the highest test
pressure among all test packages of which the manifold will be used.

d. Pump capacity shall be chosen according to test volume. Pump having 15~20
liter/min capacity is normally used for a large volume but a hand pump will used
for a small volume of test package.

e. Potable water is applicable for the fluid of hydrostatic test for carbon steel and
LTCS piping materials. If it is not available, further discussion with the Company is
required.

f. If a stainless steel piping is subject to hydrostatic test, the potable water shall
be verified with chloride content, not exceeding 50mg/kg (50ppm), and water
analysis certificate shall be provided.

g. All test instruments i.e. pressure gauges, recorders, relief valves be calibrated
to ensure proper accuracy and have a scale range between 1.5 to 3.0 times the
test pressure. Calibration status shall be once per every 6 months.

h. At least one pressure gauge shall be installed at pressurizing manifold and

nearby end point of the piping system.

i. Additional gauge shall be installed at the highest point of the testing piping
system.

j. Pressure gauge and chart recorder shall be calibrated and the validity provided
by the calibration lab (normally 6 months) shall be checked before use.

k. A pressure relief valve (PSV) shall have a set pressure of 10% above the
hydrostatic test pressure will be installed on pressurizing manifold.

l. Vent points shall be provided to all highest points of piping loops in the test
package to avoid air pockets.

m. All Third party inspection agencies for all test instruments shall be the ones
which have been approved by the Company.
4.3. Preparations

a. Test shall not be carried out in wet weather.

b. All welded joints, threaded joints, bolted connections in the system to be tested
shall be visible left unpainted and un-insulated.

c. Prior to prepare the pressure test, the entire lines shall be thoroughly cleaned
and/or flushed to get rid of all dirt that has been accumulated during fabrication
and construction activities.

d. All unnecessary materials including scaffolds, surplus items, trash, etc. shall be
removed from the piping system to be tested.

e. Any appurtenances that should not be subjected to the test pressure shall be
disconnected or isolated. Items that are not included in the test system shall be
duly identified on isometric with note.

f. The piping system must be properly fixed and pipe-ends must be fully
restrained to prevent any damage/harm when any pressure hunting.

g. All valves (except ball valves) in the piping system shall be fully open and then
turn twice to closing direction to endure that grand packing is subject to full line
test pressure

h. Ball valves that have cavity in the seat shall be set in half-open/closed position
to remain the cavity in open to test pressure.

i. Valves shall not normally be used to isolate a test system. However, when
closed non-flanged isolation valve must be used in lieu of blind, the maximum test
pressure against the seat shall be limited by the valve seat test pressure.
Manufacture’s catalogue shall be submitted for Company approval.

j. Check valves shall have source of the pressure on the upstream side of the
valve. The drain shall be downstream from check valve. If this is not possible, then
swing type disc may be removed.

k. All gasket intended to be used in pressure test shall be permanent gasket.

l. Pressure/temperature chart recorder shall be utilized whenever necessary.

m. Drain points shall be provided to all lowest points of the piping loops in the test
package so as to thoroughly drain the water after test.

4.4. Closing and Isolation

a. For Hydrostatic test, below methods are commonly used for pipe-ends closing
and equipment isolation.

i) For pipe ends : welding pipe cap or steel plate

ii) For flange ends : insert steel plate or spectacle flanges

b. If steel plates are used for closing pipe ends or flange ends, minimum thickness
of such blinding plates shall be as shown in ATTACHMENT #1.

c. All temporary welding joints for pipe-ends closing shall be 100% MT or PT

 tested to ensure the welding quality.

d. A list of all temporary caps and blinding plates to be welded for closing pipe
ends shall be prepared to control the status of MT/PT results. This list will be
separately submitted upon Company’s request.

4.5. Pressurization

a. Water filling shall be made at lowest point, and all the vent points shall be fully
opened to avoid air pockets in the piping system.

b. The pressure shall be gradually increased until the pressure is reached to

175kPa (1.75Barg) or 50% of test pressure which is lesser, then hold and conduct
preliminary check for all joints.

c. Thereafter gradually increase until the pressure reached to each step of 50%
and 75% of the test pressure. Holding 5 minutes at each step to stabilize.

d. Test pressure shall be 1.5 times design pressure (D.P). Holding at this test
pressure is usually for 30 minutes.

e. If there is excessive variation due to thermal expansion, 10 minutes of stable

holding within +/-1.0% of test pressure is considered as “PASS” according to
section 3.3.3 of DEP 74.00.10.10 provided that there is neither leakage nor
physical deformation in the piping system.

f. There could be a pressure increase (or drop) due to thermal expansion (or
shrinkage), which could either be make-up or keep recording it as is by chart
recorder. Especially the pressure may be slightly released when there is
excessive increase above the test pressure (1.5 x D.P).

g. A step by step pressurization chart is shown in ATTACHMENT #2.

4.6. Bolt Tightening

a. No bolt tightening is allowed during the pressure test.

b. In the event of a flange leak, the piping system shall first be depressurized first
and flange seal face shall be inspected.

c. If there is evidence of flange face damage, the flange shall be replaced or

repaired. In all cases, the gaskets shall be replaced. And the bolts are inspected
and replaced in case their thread damaged or over tensioned.

4.7. Inspection

a. At the step of test pressure, examination for leakage shall be made of the joints
and connections and all regions of high stress, such as pipe branches, regions
around openings, flange points, etc.

b. Not only leak detection, but also entire piping system shall be visually inspected
to verify whether there is any physical deformation.

c. Any leaks that are present shall be identified, corrected and retested in
accordance with applicable codes and specification.

d. When there is no sign of leakage, physical deformation or pressure drop in

excess of 1% of test pressure, the pressure shall be gradually decreased, and the
test is considered as “PASS”.
 e. Prior to depressurizing, a vent point at highest point shall be opened to prevent
vacuum. Test water shall be thoroughly drained to safe area.

4.8. Reinstatement

a. All lines shall be internally cleaned / flushed or blow down with dry compressed
air, free from oil and grease, immediately after pressure testing.

b. After completion of pressure test, all facilities which are temporarily installed
and welded to piping system shall be properly removed for next step of the work.

c. During and after reinstatement, all B-punch items shall be completely cleared
before next step of the work e.g. pre-commissioning.

d. If there were any removal or relocation in the piping system for test purpose,
those shall be reinstated to its original position.

e. All areas disturbed during the test operation shall be dressed up and restored to
its original state, and all surplus materials and trash shall be collected and
disposed to designated locations.

4.9. Documentation

a. Prior to pressurization and after pressure test, the recorder chart shall be
signed by Company/Contractor’s representatives.

b. All findings found during pressure test shall be recorded and a pressure test
report shall be prepared after the test.

c. After completion of a pressure test, the test package book shall finally checked,
recorded and kept for handover.

5. PERSONNEL RULES AND RESPONSIBILITIES

Project Manager

Project Manager of the Contractor shall be designated as representative project manager of

the leader of the Consortium.

All project communications from Company to the Contractor shall be addressed to the
Project Manager of the Contractor, while those from the Contractor to the Company shall be
addressed to authorized person appointed by the Company and be issued by the name of
the Project Manager of the Contractor.

Permit Holder

Permit Holder shall be the job task supervisor who is responsible to execute the Job as per
the requirements described in the permit.

Executer

A person ensures that all conditions written on the permit have been met, verified ongoing
precautions to maintain safe work conditions and takes the responsibilities of various roles
specified are fully understood, and authorized to allow or stop the works.
 Permit Issuer

Permit Issuer shall be HDKC engineer or higher who has overall responsibilities of the
PTW, and shall check safe conditions to execute the works as well as ensure that all
activities are with approved PTW requirements. If a work will be conflicted with other works,
the Issuer can coordinate related PTW prior to commence the works.

HSE Supervisor
HSE Supervisor shall control overall safety requirements during pressure testing. S/he shall
verify whether all HSE measures listed in PTW and shall ensure that all activities are with
approved PTW requirements.

6. TOOL AND EQUIPMENT

Prior to mobilization, tools and equipment to be used in the execution of the works for the site
shall be inspected to ensure that they meet the safety requirements. All safety test reports and
certificates will be kept and available whenever necessary.

7. ATTACHMENTS

# 1, Min. Thickness of Blind Plates for Pressure Testing

# 2, Pressurization Steps for Hydrostatic Test

# 3, Risk Assessment
ATTACHMENT #1, Min. Thickness of BLIND PLATES for Pressure Testing

Unit : mm
Test Flange Size
Pressure (inch)
kg/cm2 1.1/2 2 3 4 6 8 10 12 14 16 18 20 24
7 1.6 2.3 3.0 3.2 5.0 6.0 7.5 8.5 9.5 10.5 12.0 13.0 15.5
14 2.3 2.6 4.5 5.0 7.0 8.5 10.5 12.0 13.0 15.0 17.0 18.5 21.5
21 3.2 3.2 5.0 6.0 8.5 10.5 12.5 15.0 16.0 18.5 20.5 22.5 26.5
28 3.2 4.0 6.0 7.0 9.5 12.0 14.5 17.0 18.5 21.0 23.5 26.0 30.5
35 4.0 4.5 6.5 7.5 11.0 13.5 16.5 19.0 20.5 23.5 26.5 29.0 34.5
42 4.0 4.5 7.0 8.5 12.0 15.0 18.0 21.0 22.5 26.0 29.0 31.5 37.5
49 4.5 5.0 7.5 9.0 12.5 19.0 19.0 22.5 24.5 28.0 31.5 34.5 40.5
56 5.0 5.5 8.5 9.5 13.5 17.0 20.5 24.0 26.0 29.5 33.5 36.5 43.5
63 5.0 5.5 9.0 10.0 14.5 18.0 21.5 25.5 27.5 31.5 35.5 39.0 46.0
70 6.0 7.0 10.5 12.0 17.5 21.5 26.5 31.0 33.5 38.5 43.0 47.0 56.0
77 6.5 7.0 11.0 13.0 18.5 23.0 27.5 32.5 35.0 40.0 45.5 49.5 58.5
84 6.5 7.5 11.5 13.5 19.0 24.0 29.0 34.0 36.5 42.0 47.0 51.5 61.0
91 7.0 8.0 12.0 14.0 20.0 25.0 30.0 35.0 38.0 43.5 49.0 53.5 63.5
98 7.0 8.0 12.5 14.5 20.0 26.0 31.0 36.5 39.5 45.5 51.0 56.0 66.0
105 7.5 8.5 13.0 15.0 21.5 27.0 32.5 38.0 41.0 47.0 53.0 58.0 68.5
112 7.5 8.5 13.5 15.5 22.0 27.5 33.5 39.0 42.5 48.5 54.5 59.5 70.5
119 8.0 9.0 14.0 16.0 22.5 28.5 34.5 40.0 43.5 50.0 56.0 61.5 73.0
126 8.0 9.0 14.0 16.5 23.5 29.5 35.5 41.5 45.0 51.5 58.0 63.5 75.0
133 8.5 9.5 14.5 17.0 24.0 30.0 36.5 42.5 46.0 53.0 59.5 65.0 77.0
140 8.5 9.5 15.0 17.0 24.5 31.0 37.0 43.5 47.0 54.0 61.0 66.5 79.0
175 9.5 11.0 16.5 19.0 27.5 34.5 41.5 48.5 53.0 60.5 68.0 74.5 88.0
210 10.5 12.0 18.0 21.0 30.0 38.0 45.5 53.5 58.0 66.0 74.5 81.5 96.5

*NOTE: In case where piping diameter is 26 inch or over, following formula which is based on ANSI
B.31.3 standard shall be applied to determine the thickness of blind plate

D x ٦/ 3P
Thickness of blind plate (t) mm = where,
D : outer diameter of 16SE
gasket (mm)
P : test pressure (kg/cm2)
SE : allowable stress (kg/cm2)
ATTACHMENT #2, Pressurization Steps for Hydrostatic Test

STEP PRESSURE HOLDING TIME ACTIVITY

Step 1 1.75 Barg or 50% T.P As required Primary leak check

which is lesser
Step 2 50% T.P 5 min For pressure stabilization
Step 3 75% T,P 5 min For pressure stabilization
Step 4 100% T.P 30 min Test holding time (+/- 1% T.P)
Step 5 Depressurizing None Open vent/drain valves slowly

NOTE
* 1) T.P means the Hydrostatic test pressure.
* 2) D.P means the design pressure of the test package.
* 3) Pressurizing/venting must be gradually made to prevent pressure shock.
* 4) Pressurizing step is designated on the basis of ANSI B 31.3.
ATTACHMENT #3, Risk Assessment

HAZARD IDENTIFICATION AND RISK ASSESMENT FORM

Risk Rating
Area/Activity
Harm caused by With
under Hazard Control Measure
the hazard Without Control
consideration Likelihood Severity
Control

All Scaffolds to be inspected and tagged prior use by a

Slip / Fall from certified scaffold inspector.
Height. Cracks of Use proper ladders to approach the elevation of joints.
1) Working at
bones or heavy C 3 MEDIUM Wear ALL required PPE; Safety helmet, Coveralls, Safety LOW
higher elevations
impact on body Shoe, Goggles, safety harness, Gloves, etc.
parts, fall on object Use Safety Harness and to be secured to rigid support
or object fall on Prevent drop of objects by proper housekeeping.
body.

Adequate task lighting & mobile tower lighting.

All lighting devices and cables shall be inspected by an
certified electrician prior to power connection and usage.
1. General 2) Working at Poor Visibility, Fall All lighting holders shall be fixed overhead.
C 3 MEDIUM LOW
Night Injury Ensure all cables are laid properly and they are not
obstructing the access.
Ensure all joints on the cables are insulated properly and
industrial and Plugs are recommended for such joints.

Barricading, Cautionary signs, Proper laying of cables and

hoses (buried where vehicular movement.)
3) Sharp edges,
T raining in safe work practices and accident prevention,
Cables, Hoses, Accident, injury,
C 3 MEDIUM Proper supervision, Close monitoring of works, regulating the LOW
Hot metal, POL, slip, trip, and fall
traffic movement use of banks man / while reversing. Traffic
Vehicle movement
management plan will be communicated in the tool box
meeting to all staffs. To be done daily.

Proper PPE's.
1) Water pump :
Use proper rating of hoses, gauges and connectors
Electric shock,
Injury to person C 3 MEDIUM Inspection of hose should be maintained and recorded. Water LOW
pressure part
pump should be secured and when not being used they must
failure
be turned off at all times.

Install barricade & warning labels, Safety standby at each

corner of barricade, access control, Night work if longer safety
2. Test Operation 2) Pressurizing Pressure part failure C 3 HIGH LOW
distance required, assign Test Leader and he holds a task
specific TBM to test crew, wear all required PPEs

All Scaffolds to be inspected and tagged prior use by a

Slip / Fall from certified scaffold inspector.
3) Leak check ; Height. Cracks of Use proper ladders to approach the elevation of joints.
inspection at high bones or heavy C 3 MEDIUM LOW
Wear ALL required PPE; Safety helmet, Coveralls, Safety
elevation impact on body Shoe, Goggles, safety harness, Gloves, etc.
parts, fall on object Use Safety Harness and to be secured to rigid support
or object fall on
body.

Proper PPE's. Use of flashback arrestor, proper hose, gauge

and connector must be regularly checked. Inspection of hose
1) Gas cutting : should be maintained and recorded. Gas cylinder should be
Body contact with secured in upright position and to be placed in appropriate
molten slag’s / hot Injury to person & trolley and secured. Fire extinguisher to be available local to
C 3 MEDIUM LOW
surface. Fire cylinders.
Explosion. Poor Combustible to be removed from work area. Good
housekeeping. housekeeping. When the gas cylinders are not being used
they must be turned off at all times. Only approved safety eye
protection for gas cutting to be used at all times.
3. Reinstate Work

2) Grinding,
Use of Low voltage tools (110 V), avoid loose cloths. Grinder
Drilling, Trimming :
with safe guard. Proper electric connection. PPE's. Cable
Breaking of Fire, Shock, Burn
must be in good condition.
grinding wheel. injury, cut injury,
C 3 MEDIUM All the electrical tools, Earthing and cables, will be inspected LOW
Sparking, Flying Foreign body in Eye
by Electrical in charge and recorded. Usage of goggles, Face
debris. Electric and loss of hearing.
shield and ear plug will be ensured. Noise survey will be
shock and High
conducted and record maintained.
sound
 Remove combustibles. Welding machine maintenance
procedure to be followed, Fire extinguisher, Regular
3) Welding : housekeeping, Use of PPE's, Inspection of welding cables
Welding spark, and electric cables, proper Earthing.
Fire, Shock and
Nitrous Fumes, B 3 MEDIUM Periodically maintained and calibrated machines only will be LOW
Injury to person
short circuit, used, Welder qualification test will be conducted and, Daily
Electrical Shock Tool Box Talk by supervisor, proper ventilation, Fire Watch
and Use of Fire blanket will be ensured by super visor in high
risk areas.

- End of document -