QC PROCEDURE FOR PRESSURE TESTING (CPVC) PLUMBING WORKS

Table of Contents

PURPOSE

SCOPE OF WORKS

DEFINITIONS

REFERENCES

RESPONSIBILITIES

TOOLS, EQUIPMENT AND MATERIAL

PROCEDURE FOR TESTING

POST TEST OPERATIONS

INSPECTION AND TESTING

ATTACHMENT

PURPOSE

The purpose of this procedure is to set out the formal method of pressure testing the potable water line (CPVC) in buildings with quality and safety.

SCOPE OF WORK

The procedure applies in all pressure testing on the potable water lines at Haradh & Hawiyah Gas Compression Project.

DEFINITION

COMPANY : SAUDI ARAMCO

PROJECT :

CONTRACTOR :

SUB-CONTRACTOR :

REFERENCES

The latest revision of Saudi Aramco Engineering Standards shall be used as per references and is part of this Method Statement in the execution work.

Saudi Aramco Construction Safety Manual

10040-00-090-PD-0008 Quality Requirements for Subcontractor

10040-00-090-PD-0010 Inspection and Testing Procedure

SAES –A-004 General pressure test requirement

SATIP-A-004-02 Hydro Testing of On-Plot Piping

SAES-S-060 SAUDI ARMCO plumbing code.

SATIP-S-070-03 Thermoplastic and RTR Piping

SAIC-S-4054 RTR & Thermoplastic pipe installer qualification.

SATR-A-2001 Sheet 1 Pressure Test Report

SATR-A-2002 Calibration Test Report-Pressure Gauge

SATIP-S-040-01 Water Distribution Piping System

RESPONSIBILITIES

Project Manager

Ensure that the requirement for this procedure are fully complied by the site operations personnel, and that all quality measures are met and imposed.

Construction Manager

Responsible for supervising the on- site activity of the entire operation and in compliance with the minimum requirements of procedure set forth.

QC Manager

The QC Manager shall ensure that the procedure shall be in compliance with Project Specifications and another related document.

SITE ENGINEER / HYDRO TEST ENGINEER

Responsible for all the coordination works with various departments and main Contractor in the site.

The site engineer or hydro test engineer should initiate the location of test and provide the pipe layout as per plan.

Safety Manager / Safety Officer

he Safety Manager / Safety Officer shall be responsible for implementing the project safety requirements at site.

Foreman

The Foreman is responsible for giving instruction to his crew during the execution of High pressure testing works.

Permit Receiver

The Permit Receiver is responsible for processing work permit for all related activities.

QC Plumbing Inspector

The QC Plumbing Inspector shall monitor the activities during construction, compliance with the approved test procedure as well as in accordance with Project Specifications, IFC drawings and another related document.

Third Party Laboratory and Technician

Responsible for calibration and testing of Pressure Gauges and Safety Relief Valves, Pressure test manifold as per the ITP and project applicable standards.

TOOLS AND EQUIPMENTS

Pressure Gauges. : All pressure gauges shall be calibrated before use. Calibration test report shall be filled up using SATR-A-2002.

Test Manifold: Manifold to be used for pressure testing of piping shall be separately pressure tested. A copy of Manifold Test Certified shall be incorporated in each test package. The test manifolds shall be pressure tested to at least 1.2 times the system test pressure but not less than the discharge pressure of the pump used for the pressure testing. Pressure Test Report shall be filled up using SATR-A-2001.

Test Pump: The test pump shall have adequate capacity and preferable engine and /or pneumatic driven/manual hand pump.

Test Blinds: Test blinds shall be the same class rating of the system to be tested.

Pressure Relief Device: Pressure Relief Device shall be tested, dated and tagged within one (1) week prior to test date. Relief valve of adequate capacity set to relieve at 5% above the test pressure shall be installed unless the test pressure is less than 85 % Specified Minimum Yield Strength (SMYS) at which time it can be set at 10 % above the test pressure.

Test medium hoses to connect or interconnect system or piping shall be identified and tested. Test reports shall be included in the test package. The hoses shall have adequate capacity and rating.

Test Media: Water quality shall be potable.

Sets of wrenches

Hand tools

PROCEDURE FOR TESTING :

SAFETY MATERS

It is essential that safe practices area observed during hydro testing. All persons who work on the test must be aware of the hazards and the necessary precautions to be observed for the duration of test.

The work are shall be cordoned off with a warning the tape and warning signs displayed. Only persons directly involved with the pressure testing shall be permitted inside the area.

Ensure all vents are fully opened and no air has been trapped inside the pipe during filling operation. Relief valves and pressure gauges shall be mounted in the upright position. The pressure gauge at the manifold shall be visible to the pump operator.

Site engineer shall be fully read and well understood the JSA (Attached) and to be disseminated to the crew prior to start the testing activity.

Relevant works permit to be obtained prior to start the activity

WORK PROCEDUR

In addition to relief valves, a bleed valve shall be provided to protect the piping and equipment from being over pressured. This bleed valve shall be readily accessible in case immediate depressurization is required.(Ref: SAES-A-004 Sec.5 Sub-sec 5.5.2)

All valves, excluding those used for sectioning or blocking test sections as per SAES-A-004 shall be in the open position.

Prepare testing equipment and test manifolds at designated locations. Pressure gauges shall be installed at the highest point of the line injection of pressure through a test manifold. Test manifold shall be at the lowest point of the line. Refer to Attachment-B for pressure test arrangement.

Close all the open end of the piping system to be tested.

Install calibrated pressure gauges directly to the piping system to be tested.

Make an initial tightness inspection prior to start pressurization. Filling and pressurizing shall be done on the upstream side of check valves in the system, the

Test fluid shall be injected at the lowest point in the system to minimize entrapped air. When filling at the lowest point is not practical, the Inspection Department shall be consulted.

Vents shall be provided at all high points in the test system as needed. (Ref: SAES-A-004).Air must be removed before the pressure is increased above that required to fill the system.

The minimum number of gauges required for hydro testing is two (2). One pressure gauge shall be on the tests pump and the other(s) on the test system. When large system is tested, inspection personnel will determine the need for additional gauges, Test gauge accuracy shall be within 5% of each other. All gauges shall have a range such that the test pressure is within 30 to 80 % of the full range.

Components, equipment and other sensitive instrument devices that are to be isolated or excluded from the test and shall meet the requirements of SAES-A-004. Check valves that do not have a by-pass valve, shall be removed or have the disc removed and securely attached to the outside of the valve prior to testing.

System pressure test, 1034KPa (150 PSI) will be conducted at potable water lines for a period of no less than 4 hours. ( SAES-S-060).

The pressure rise during a pressure test shall be gradual and under control to allow time for material to strain, and time for personnel to check for leaks, Gradual percentage and time intervals to be précised.

If pressure drops, depressurize the system and repair all leaks.

Do not exceed 50 % of the strength test pressures until weaknesses have been repaired and leaks have been stopped.

The pressure shall be increased in steps no greater than one-fifth of the strength test pressure with at least 10 minutes holds at each step to permit inspection for leak and weaknesses after the preliminary check at 50 % of the strength test pressure.

Do not proceed to a higher pressure after each of the above steps until weaknesses have been repaired and leaks have been stopped.

After reaching the test pressure, the hydro test manifold shall be isolated from the pump.

If no leaks are discovered or pressure drop found what so ever, depressurization shall be done after the SAPID’S inspection.

When leaks are detected, the system will be depressurized before repair work is performed. This includes tightened of bolts. (Ref: G.I.2.102).

Lines whose joints have been backfilled shall be tested at the following pressure for 24 hours. Lines whose joints have not been back filled or are above ground shall be tested at the following pressure for 4 hours. (SAES-S-070, Para 18.8)

Water distribution piping network, as defined in (SAES-S-040) and fire hydrants connected there to: 1,035 k Pa (150 psi) or 345 k Pa above the maximum operating pressure, which is greater.

POST TEST OPERATIONS:

The test shall be considered satisfactory if there is no evidence of leakage or pressure loss after the specified test period.

Upon completion, the system shall be depressurized and the lines shall be completed drained keeping all the vents in the fully open position.

The drained water will be disposed off safely into the sewer drains/safer destinations. Which are acceptable to Saudi Aramco.

The test result will be documented on the piping pressure test report (SATR-A-2001 Sheet 1)

Inspected the line/system to ensure that all fittings and appurtenances are returned to their required as detailed in the PID’s.

INSPECTION AND TESTING

Testing Requirements in Accordance with SAES-A-004 Paragraph 5.5.

The QC Inspectors of Subcontractor, Contractor and the COMPANY representative shall carry out the necessary tests and inspections in various stages of the high pressure testing works. Inspection shall be based on approved ITP, Checklist and Project Specifications or as stated in the latest construction drawing.

SAES-A-004 General Pressure test requirements

SAES-S-070 Installation of Utility Piping Systems

SATIP-S-070-03 Thermoplastic and RTR Piping

SAES-S-060 Saudi Aramco Plumbing Code.

SATIP-A-004-02 Hydrostatic Testing of On-Plot Piping

SATIP-S-040-01 Water Distribution Piping System

SATR-A-2001 Pressure Test Report

SATR-A-2002 Calibration Test Report-Pressure Gauge

Contractor shall perform inspections and tests in accordance with the approved ITP. Where the ITP identifies tests and inspections to be performed by subcontractors/Third Party, Contractor shall review and approve results of such tests and inspections performed.

ATTACHMENTS

a) Typical Test Manifold.

b) Hydro Test diagram.

c) Pre Test Punch list

d) SATIP (SATIP-S-040-01)

e) SATIP (SATIP-S-004-02)

f) SATIP (SATIP-S-070-03)

g) SATR-A-2002 Calibration Test Report- Pressure Gauge

h) Pressure Test Report – SATR-A-2001

I) Job Safety Analysis

HYDRO TEST PACKAGE

TYPICAL HYDRO TEST MANIFOLD

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QC PROCEDURE FOR PRESSURE TESTING (CPVC) PLUMBING WORKS | ARAMCO PROJECT