CONSOLIDATED CONTRACTORS COMPANY DOCUMENT No.

: MS-742-110
REVISION No. : 1
& PAGE : 1
TEYSEER CONTRACTING COMPANY J.V. OF :
10

METHOD STATEMENT

FOR

HYDROTESTING OF
U/G & A/G PIPING SYSTEM

RAS LAFFAN ONSHORE EXPANSION PROJECT

MS-742-110
RAS LAFFAN – QATAR

Issued for Construction

Incorporating comments as per
1 CMS & A Transmittal # 06/07/03 PVK NC PL HH IK -------
RGX-T-CMSF/CCIC-6353

Issued for Approval

Incorporating CMS & A and CPY
D 15/06/03 PVK NC PL HH IK -------
comments.

Incorporated client’s comments

C 01/01/03 NC ART GL HH IK --------
Reissued for Approval

B Issued for Client’s Review/Approval 12/12/02 NC MIJ ET HH IK --------

A For Internal Review / Approval 11/12/02 NC MIJ ET HH IK --------

PREPARED CHECKED SAFETY QA APPR'D BY

REV COMMENTS DATE CMS & A
BY BY REVIEW REVIEW CCC/T

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CONSOLIDATED CONTRACTORS COMPANY DOCUMENT No. : MS-742-110
REVISION No. : 1
& PAGE : 2
TEYSEER CONTRACTING COMPANY J.V. OF :
10

INDEX
1. SCOPE
2. PURPOSE
3. REFERENCES
4. DEFINITIONS
5. RESPONSIBILITIES
6. SAFETY
7. GENERAL
8. TOOLS AND EQUIPMENTS
9. DOCUMENTS
10. PREPARATION
11. TEST PERFORMANCE & WITNESS
12. ATTACHMENT
12.1 TEST MANIFOLD DIAGRAM
12.2 SAMPLE TEST PACKAGE
12.3 TEST BLIND THICKNESS CHART
12.4 PIPE CLEANING INSPECTION
DOCUMENT
12.5 JHA
12.6 A/G PIPING TESTING ACTIVITY FLOW
CHART
12.7 CERTIFICATE OF TESTING
MANIFOLD

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 CONSOLIDATED CONTRACTORS COMPANY DOCUMENT No. : MS-742-110
REVISION No. : 1
& PAGE : 3
TEYSEER CONTRACTING COMPANY J.V. OF :
10

1. SCOPE
1.1 This method statement mark out the boundary of related activities in various stages
in connection with the Hydrostatic testing of underground and above ground piping
system for Ras Laffan Onshore Expansion Project.

2. PURPOSE
2.1 To make certain all adequate manpower, material, tools equipment and proper
Supervision of all safety measures in all respects are taken so that extremely
smooth
And safe Hydrostatic test can be executed.

3. REFERENCES
3.1 Project Specifications:
a) RGX-S-00-1221-001
b) RGX-S-00-1360-002
c) RGX-S-00-1360-003
GX-S-00-1360-015
e) RGX-S-00-13A0-007
f) RGX-S-00-13A0-008
: Basic Engineering and Site Data
: Piping Material and Service Classification
: Piping Fabrication, Erection, Inspection and
Testing.
: Pneumatic Testing Procedure for Piping
System.
: Technical Specification Protection and
Preservation of Equipment and materials.
: Preservation of Austenitic Stainless Steel

3.2 Quality Control Procedure :

a) QCP-742-115 : Piping Fabrication, Erection and Testing of
Underground and Above ground piping.
b) ITP-742-115 : Inspection and Test Plan Piping, Fabrication,
Erection and Testing of aboveground and
underground piping.
3.3 Standards and Codes :
a) ASME B313 : Process Piping (Latest Revision)

3.4 Method Statement :

1 a) MS .742-138 : Protection of CV,ESDV,SDV,XV & Soft Seated
D
Ball valves during Hydro/Pneumatic Test

4. DEFINITIONS
1 4.1 Company : Ras Gas
D
4.2 Contractor : Chiyoda, Snamprogetti & Company Joint Venture
(CMS & A)
4.3 Sub-contractor : CCC/TCC
4.4 PTW : Permit to work Document issued by RAS GAS /
1
D
CMS&A/RLIC
4.5 MS : Method Statement

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 CONSOLIDATED CONTRACTORS COMPANY DOCUMENT No. : MS-742-110
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TEYSEER CONTRACTING COMPANY J.V. OF :
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4.6 QCP : Quality Control Proc
4.7 ITP : Inspection and Test Plan
4.8 JHA : Job Hazard Analysis
4.9 PPE : Personal Protective Equipment
4.10 NDT : Non Destruction Testing
4.11 QCI : Quality Control Inspector
4.12 PWHT : Post Weld Heat Treatment
4.13 CTR : Contractor
4.14 RFI : Request for Inspection
1
D 4.15 HP : Highest point

5. RESPONSIBILITIES

5.1 The Contractor’s & Sub-contractor’s personnel shall be involved and

responsible for the activities pertaining to Hydrostatic test for the
1
D execution/implementation according to the applicable safety procedures and
project specifications under the supervision of contractor.
5.2 Contractor & Sub-contractor Engineer(s)/Supervisors/foremen will ensure the
1 safe and efficient working environment to plant and equipment to carryout the
E Hydrostatic testing activities on each stage.
5.3 The contractor & Sub-contractor QCI (s) shall be responsible for the inspection
of pressurized piping system in accordance with the project specification and
procedure.
5.4 The Contractor’s & subcontractor test team shall be responsible for the pretest
1
E
safety precaution, inspection and ensure that only concerned personnel are
D within the agreed test area.

6. SAFETY

6.1 Good housekeeping to be maintained throughout.

6.2 The Hydrostatic testing will be undertaken in accordance with the project safety
manual (RGX-SS-00-1610-003).
6.3 Nonessential personnel shall be cleared from the vicinity of the test pipe system.
6.4 Personnel involved for the pressure test shall have an identification mark on the
helmet, so that the test personnel are easily identified in the test area.
6.5 Safety watch guard will be assigned throughout the test period.
6.6 The subcontractor will inform their safety department and subcontractor’s day to
day testing activities by means of written advisory (RFI) at least one day
before the test to be conducted. Other subcontractors shall be informed by
1
D CTR. The RFI will be approved by the CTR-QCI and the same copies will be
distributed to all concerned by CTR-QCI to their EHS department
Construction piping and to Company QC as well.

1
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6.7 Contractor / Sub-contractor safety officer(s) will conduct a joint walk with
subcontractor/contractor testing personnel in order to familiarize the piping
system to be tested prior to test commencing.
6.8 Proper and safe means of access/egress shall be provided and maintained D for
the workers /QCI(s) in order to carryout preparation and inspection of the
piping system to be tested.
6.9 Minimum exclusion diameter placing the pressure containing components at the
1 center point shall be10 meters in every direction. Greater distance may be
D required in specific cases.
6.10 Adequate sign boards will be placed around the barricaded areas where the
test being carried out for the awareness of the nearby working personnel who
are not involved in testing activities to keep away from the testing zone.
6.11 When venting water from the pressure test, particular care shall be taken to
ensure that water does not vent into any place where personnel working, also
to electrical tools and live panels etc.
1 6.12 JHA and Method Statement shall be attached to work permit prior to
E
commencement of pressure test and must apply during execution of testing.
D
6.13 All necessary approved PPE will be provided and worn in accordance with
the project safety manual (RGX-SS-001610-003).
6.14 Sufficient illumination of work area, storage area and access/exit routes shall
be provided while working at night.
6.15 Subcontractor to obtain necessary permit to work from contractor/company
1 prior to commencement of pressure test activities.
D
6.16 All activities shall be suspended in case of an emergency and not restarted
until the PTW has been revalidated.

7 GENERAL

7.1 Fabrication and Erection

a) RGX-S-00-1520-005 and ASME B31.3 shall be applicable for this activity.
b) All NDT/PWHT requirements shall be completed prior to release for
pressure test.
1 c) Reinforcing pads should be pneumatically tested for any leaks at a
E pressure of 60 to 100 psig. A soap solution shall be applied to inspect
D all welds. Snoop or equivalent shall be used for stainless steel.
d) In case of jacketed pipe the inner pipe will be hydro tested before
1
fabricating the outer pipe.

7.2 Pipe Cleaning Requirement :

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a) It is a requirement to get the pipe of 6”  and larger cleaned internally by
manually flushing with nitrogen or 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 will be removed prior to
cleaning and testing. Exceptions to this will require preparation of a
Concession Request. Permanent plant equipment such as Pumps,
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/isometric number
1
clearly indicating the limit of cleaning carried out or part thereof inspected
and passed as clean. This document will be attached with the test pack.

8 TOOLS AND EQUIPMENTS

8.1 The following tools and equipments shall be made available to perform the
field-testing of piping system.
1
 Pressure displacement pumps.
 Fill tank and isolation valves.
 Filling pumps.
 Certified test manifolds.
 Hand tools.
 Pneumatic sockets.
 Torque wrenches.
 Calibrated pressure gauges and Recorders as required.
1
 Torque wrenches – manual – pneumatic

8.2 The test manifolds shall be tested to minimum 20% above maximum specified
test pressure before use. Each test manifolds shall have unique number.
After testing, certificate will be produced / and retained by QC.

8.3 Pressure gauges shall have a range of 1.5 to 4 times required test pressure
and the gauges shall be calibrated within the previous 30 days of test date.
Two gauges minimum shall be installed at highest and lowest point .

9. DOCUMENTS

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9.1 Prior to any pressure test a document named “Test Package” shall be
prepared by subcontractor and approved by contractor and company.

9.2 Using marked-up set of Piping /Instrument Diagram (P&ID) in the system
1 definition the extent of the test system will be marked up by contractor (Test
Block Diagram). The contractor will divide the piping into suitable test packs.

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

9.4 Test pack:

9.4.1 The following documents shall be composed.

· Test Block Diagram (P&ID or GA Drg.)
· Isometric drawing marked with all weld nos and the limits as per the test
block diagram and test package number.
1
· Pressure Test Confirmation Record.
· Piping Pressure Test Release Report.
· Pretest Punch list of Piping Work.
· Location Map.
· Blind thickness chart
· Isometric control sheet from Talisman indicating NDT & PWHT.
· Cleaning Record
· Line list highlighted with applicable lines
· Concession request if applicable.

9.4.2 The marked up isometric drawing will indicate the location of pressurization
point, pressure guage, location, vents location, removal of control valves, FE,
Flow gauge, level gauges, Strainer elements, Critical soft seated Ball valves
1 which are not required to be part of the test. (these part will be clearly marked on
D
the test block diagram As-Built.)

9.4.3 Pre-test punch list shall be prepared by SCTR upon completion of test
package
a) ‘A’ item - To be cleared before test.
b) ‘B’ item - to be cleared as post test requirements

9.4.4 Pipe Cleaning Records shall be completed and signed by CTR for 6” and larger
pipe and company for 24” and larger pipes.

10.1 Test Medium:

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 CONSOLIDATED CONTRACTORS COMPANY DOCUMENT No. : MS-742-110
REVISION No. : 1
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TEYSEER CONTRACTING COMPANY J.V. OF :
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1
a) Hydrostatic Test:
D
Clean and fresh water shall be used, for austenitic stainless steel
C
piping water should not contain more than 50 ppm chloride ions, Sea
water may be used for testing sea water cooling lines only. All water
shall be drained immediately upon completion of pressure test.

b) Visual Inspection:
Visual inspection shall be applied in lieu of pressure test for the
following (down stream of last isolation valves)
· Open to atmosphere
· Open-end drain
· Valves without any spools on vessels trim, etc.

9.6 Temperature Precautions :

Precautions shall be taken to avoid over pressurization due to rise in
temperature as follows:
· For Hydro Testing bleeding valve located on the test header will be
utilized for relieving excess pressure in the line.

9 PREPARATIONS

10.1 Temporary supports shall be installed by SCTR if required after Engineering

review.
1
10.2 Components and instruments will be removed, refer 9.6.2. Instrument lead
lines will be disconnected. Critical valves shall be removed as per MS-742-
138
10.3 Test manifold will be connected at the lowest point in the system.
10.4 Certified pressure gauges will be installed One at the test manifold, the other
shall be located at the highest point in the system. (Minimum two gauges will
be installed for each test loop).
10.5 All safety measures will be as per mentioned in item 6.
1
10.6 H.P Vent will be installed and will be kept open till the pipe test loop is filled
with water and all air is purged from the system.

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 CONSOLIDATED CONTRACTORS COMPANY DOCUMENT No. : MS-742-110
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10.7 All necessary test blinding will be performed as per the test loop diagram.
Selection of proper thickness of the blind will be selected from the blind chart.
Temporary gaskets will be installed in accordance with specification and
gasket material shall be new and shall not be reused.
1 10.8 Ensure all parts of the pipe testing loops are tightened in accordance with the
bolt sequence.

11. TEST PERFORMANCE AND WITNESS

11.1 Hydrostatic Test :

· Fill the line with water and vent out all air from the pipe loop to be
1 tested; (refer item 9.5 a)
D
· Raise pressure to 1.0 BAR. hold for 10 minutes, and check for leaks.
1 · Raise pressure at a maximum rate of 5 bar/min.
E
D · Continue to raise pressure until final test pressure has been reached
and stabilized.
· Visual check of all test gauges shall be made at all hold points.
1  Hold the test pressure 10 minutes or as designated in Project
Specification and then inspect all Pipe Joints such as flanges, screwed
connections, valves, glands, etc .
1 · If any leaks are detected, pressure to be blend off completely, system
E vent open and the leak sealed accordingly.
· Minimum testing period including holding time shall be a min. of 30
1 minutes or time of joint inspection for leakage, whichever is longer or
as per project specification. Unless specified otherwise by
manufacturer as other exception.
· The test will not be conducted when the outside of the pipe is wet.
1 · Open all vents and drains and slowly depressurize the system.
D

12. ATTACHMENT

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 CONSOLIDATED CONTRACTORS COMPANY DOCUMENT No. : MS-742-110
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TEYSEER CONTRACTING COMPANY J.V. OF :
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12.1 Test Manifold Diagram

12.2 Sample Test Package (11 Pages)
12.3 JHA
12.4 A/G Piping Testing Activity Flow Chart
12.5 Certificate of Testing Manifold

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