METHOD STATEMENT FOR TESTING AND INSPECTION OF BURIED PIPELINES

1.0 1.1

GENERAL INFORMATION Introduction

CTCE-KALIKA JV has to hydrostatic testing of pipeline under the contract KUKL/BDS/01/01

1.2

Purpose
To provide a procedure for hydrostatic testing of pipelines to be performed for the project to ensure conformity with project specifications

1.3

Scope of Work
This method statement outlined the procedure of Hydrostatic testing for underground piping in Bulk distribution System of KVWSSP in accordance with project specifications and approved drawing.

1.4

Location
HYDROSTATIC Testing shall be conducted in the DIP as specified in the approved drawings.

2.0 2.1 2.2

Execution Materials
DI Pipes High pressure pump and engine drive with capacity in excess of test conditions. Calibrated vessel for measuring water pumped into the main. pressure gauge with range to conduct test. Piping connections, hose, and appurtenances. Air Valve Various Hand Tools

Tools and Equipments

2.3 2.3.1

Procedure of Work Test Preparation

The hydrostatic test shall he conducted in accordance with BS 8010 Code of practice for pipelines Part 1: Steel pipelines on land. Test Limits, pressure, test medium and safety requirements shall he identified.

Install thrust restraints before testing, including temporary plugs or caps. For standard concrete thrust blocks, test 28 days after thrust restraint installation or before if required strength of concrete is achieved. (Drawing of the Thrust block submitted herewith for approval) Underground piping shall he partially backfilled with all joints exposed to serve as a pipe support and prevent floatation. Equipment and appurtenances that are not adequate for test pressure shall he isolated. The test areas shall he marked and warning signs shall he posted to alert approaching personnel. The relief valve shall he located in the test manifold near the test pump, A pressure gauge shall he located at the test manifold and one pressure gauge on the furthest route of the piping network being tested. Vents shall he provided at all high points in the system being tested. A plow down valve or bleed valve shall be readily accessible in case immediate depressurization is required. Temporary connections shall he provided for de-pressurization and draining of the system. Complete the Installation of test connections. (Drawing of the Test Connection submitted herewith for approval) Hydrostatic Testing shall be done by trained personnel in the proper handling and usage of applicable tools and equipments prior to start of hydrostatic Testing. The test pump and test manifold shall he placed on a firm ground away from the piping being tested. The test manifold shall be supported firmly to avoid vibration during pressurization. All in line valves are in open position. Filling and pressurization is injected at the test manifold upstream of check valves and at the lowest point of the system being tested to minimize entrapped air. Water filling into the system shall he direct from a ground level water tank with pump, Remove air during filling of water by opening the vents installed at high points and shall be cloud when air has been released from the system. After venting, valves used for venting are placed at partial open position and plugged. Vents and drains used only for the pressure test shall be plugged or seal welded. To pressurize the system. motorized or pumps shall be used depending on the size of the system being tested. The system shall be pressurized slowly.

2.3.2

Hydro test Crew

2.3.3

Pressurization

Preliminary check for leaks at low pressure shall be done. The pressure is increased in steps no greater than one-fifth of the test pressure after the preliminary check at 50% test pressure. Each step in pressurization is held at minimum of 10 minutes. After the test pressure is reached (before inspection), the isolation valve between the test manifold & the piping system under pressure lest is dosed and the test pump disconnected. No repair of leaking joints until the system has been de-pressurized. Pressurizing and calculating the water leakage shall be as per the specification. After pressure testing has been successfully completed and approved, the piping system being tested shall be depressurized and drained. Release of pressure and draining shall be done on the downstream side of check valves. All veins shall be opened before draining to facilitate drainage and to prevent formation of a vacuum. All temporary items installed for testing purposes shall be removed. All pipe ends shall he covered after draining the system to prevent entry of foreign materials into the system.

2.3.4

Depressurization and Draining

2.4

Responsibilities
Site Engineer shall organize, manage and supervise all activities related to the installation of DI piping with regards to safety, quality and productivity of the over-all performance of the work. Site Supervisor and Foreman shall arrange all the necessary manpower, tools and equipments and implement the approved working procedure for a proper execution of the work with regards to safety, quality and productivity.

3.0 3.1

QA / QC Reference Standards
BS 8010 Code of practice for pipelines Part 1: Steel pipelines on land Notify Engineer at least 48 hours prior to testing and when testing equipment is set up and ready. Perform testing in the presence of the Engineer. Provide access to equipment to enable the Engineer to monitor and record test results. QA / QC inspector shall make sure that all activities related to the hydrostatic testing of pipelines are carried out in accordance with the project specifications and procedures. He shall maintain and keep records for all QC Documents.

3.2

Responsibilities

Site Engineer, Supervisor and Foreman shall assist the QA/QC inspector whatever he required in relation to the quality of works procedures or documents. For Pressure Test, a calibrated Pressure Gauge shall he used for measuring the test pressure. The piping being tested shall be considered satisfactory if no reasonable drop on the water level or pressure loss after the specified test period and if no evidence of water leakage greater than allowable leakage on the body of the pipes. fittings and to the joints. Request for inspection shall he issued to the Project inspection 24 hours in advance on weekdays and 48 hours in advance for weekends and holidays. Inspection shall be done in accordance with the Inspection Test Plan and Forms. During inspection all exposed pipes, joints and fittings shall be carefully examined for leakage. The piping being tested shall be satisfactory if there is no evidence of leakage and no reasonable drop in the water head or pressure lose after the specified test period. Leaking pipes, joints and fittings shall he replaced and test shall he repeated until the system is proven satisfactory.

3.3

Test and Measurement

3.4

Inspection

4.0 4.1

Safety Guidelines
Person(s) conducting the hydrostatic testing shall wear the Personal Protective Equipments at all times on the job site. Test section or test area shall be identified and shall he provided with barricades such as safety tapes or physical harriers. Only authorized person shall he allowed to enter or crossed to the test area. Wanting sign boards and lights shall also he provided (where necessary) to alert approaching personnel not involved in the hydrostatic testing. Proper access such as ladders and ramps shall be provided at designated areas where workers can go in and out the excavated area. All test equipments and test instruments shall be calibrated or certified. At least one person is to be stationed at the test area to check and monitor the test pressure and possible leakage of pipes and joints Safety Inspector / Officer in conjunction with the site supervisor or foreman shall physically check and conform that all safety requirements had been provided and implemented

4.2

Responsibilities

Personnel conducting the hydrostatic testing shall follow the approved safe working procedure for pressure testing of pipelines,

4.3

Hazard Analysis
Job Description I. Pressurization Hazard Preventive Measures Responsibilities

I. Injury to worker from overpressure, pipe blown-out or detached.

I. 2. 3. 4.

install pressure release Valve. provide temporary pipe supports. proper venting required. temporary connections shall have the same rating or exceed the pipe being tested. 5. install blowdown valve or bleed valve. 6. depressurization required before repair of leaks. 7. unauthorized person not allowed in the test area. 8. pressurization to be done slowly and monitor Pressure rise.

Engineer, supervisor and foreman

5.0 5.1

DATE FOR TESTING Option -1 : Testing at present location

The testing can be perfomed after the installation of thrust restrained block. The block which is proposed to be made of concrete cannot be casted at site as monsoon has already started and the water table has been risen.

5.2

Option -2 : Testing at the newly proposed laying of pipe at other location

The testing can be perfomed after laying of pipe, installation of thrust restrained block and testing accessories. The pipe cannot be laid during monsoon.

5.3

Probable date of testing

The Testing cannot be done during monsoon. The Date will be fixed with consultation with the Project. However, test will be performed before the laying of pipes at the location other than that at location where the testing is proposed.