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									                             District Cooling Plant For King Abdullah Financial
                                                   District
Contract No. 504054-C-2001                         Job No.

                                      Method Statement



 .




                                METHOD STATEMENT
                                             OF
                     HYDROSTATIC TESTING OF PIPELINES
           (COLD & HOT WATER, CHILLED WATER & FIRE WATER PIPING)




                                                  Doc. N.             Rev. No.          Date:        Page No.
                                                                                  2 September 2012    1 of 10
                                 District Cooling Plant For King Abdullah Financial
                                                       District
 Contract No. 504054-C-2001                            Job No.

                                              Method Statement



Rev.     Date:                        Issued Status         Prepared by   Checked by         Approved by



  CONTENT:


  1.      GENERAL INFORMATION

          1.1      Introduction
          1.2      Purpose
          1.3      Scope of Work
          1.4      Location
          1.5      Definitions


  2.      EXECUTION

          2.1      Materials
          2.2      Tools & Equipments
          2.3      Procedure of Work
          2.4      Responsibilities


  3.      QA / QC

          3.1      Reference Standard
          3.2      Responsibilities
          3.3      Test and Measurement
          3.4      Inspection


  4.      SAFETY

          4.1      Guidelines
          4.2      Responsibilities
          4.3      Hazard Analysis




                                                      Doc. N.              Rev. No.          Date:         Page No.
                                                                                       2 September 2012     2 of 10
                                District Cooling Plant For King Abdullah Financial
                                                      District
Contract No. 504054-C-2001                             Job No.

                                          Method Statement




 1.0       GENERAL INFORMATION


     1.1   Introduction

            SNC LAVALIN has awarded to KETTANEH Construction Saudi Arabia Ltd. the
            subcontract for the construction of KING ABDULLAH FINANCIAL DISTRICT,
            RIYADH, K.S.A.


       1.2 Purpose

            To provide a procedure for Hydrostatic Testing of Cold & Hot Water, Chilled Water &
            Fire Water Piping to be performed throughout the project to ensure conformity with
            project specifications and to provide a specific information, requirements and guidelines
            on safe pressure testing.

       1.3 Scope of Work

            This method statement outlined the procedure for Hydrostatic Testing of Cold & Hot
            Water, Chilled Water & Fire Water piping system in the KAFD in accordance with project
            specifications and approved drawings.


       1.4 Location

            Hydrostatic Testing for chilled water & fire water piping system shall be conducted as
            specified in the approved drawings for the KAFD, Riyadh KSA.


       1.5 References ( Code and Standards )

            15410                :       Project Specification – Plumbing Piping
            15500                :       Project Specification – Fire Protection System
            15550                :       Project Specification – HVAC Piping & Piping Specialties



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                                       District Cooling Plant For King Abdullah Financial
                                                             District
Contract No. 504054-C-2001                                  Job No.

                                                Method Statement



 1.0         EXECUTION

       2.1    Materials

              1. Carbon Steel Pipes & Fittings
              2. PVC Pipes & Fittings
              3. CPVC Pipes & Fittings


       2.2    Tools and Equipments

              a.      Test Manifold
              b.      Pressure Gauge
              c.      Pressure Relief Valves
              d.      Test Pump (Manual & Motorized)
              e.      Various Hand Tools
              f.      Water Trucks


       2.3    Procedure of Work

              2.3.1     Test Package

                     Test Package for Hydro test shall be submitted to SNC-LAVALIN for review prior
                      to commencement of any Hydro test.
                     Test Package shall include as build drawing, test diagram showing test limits,
                      calibration certificates ( where required ) and other Inspection Report as per SNC-
                      LAVALIN requirements.

              2.3.2     Test Equipment Verification for Pressure Test

                     The pressure testing manifold shall be tested separately to at least 1.2 times the
                      system pressure before employing for actual hydrostatic testing.
                     Pressure rating or design of test manifold component such as isolation valves pipes
                      and fittings are not less than 20% above the system test pressure.
                     Relief valves of adequate capacity are set to relieve at 5% above the test pressure.
                     The relief valves are tested, dated and calibrated
                     In addition to the pressure relieving device, a blow valve or bleed valve shall be
                      provided to protect the piping and equipment from over pressure



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                                                                                            2 September 2012    4 of 10
                                   District Cooling Plant For King Abdullah Financial
                                                         District
Contract No. 504054-C-2001                                Job No.

                                            Method Statement



                  A minimum of two pressure gauges are required for the system. When large systems
                   are tested, Inspection personnel will determine the need for additional gauges.
                  Pressure gauges are calibrated with one (1) month prior to the test. Stickers shall be
                   applied indicating the latest calibration dare.
                  All gauges shall have a range such that the pressure is within 30% to 80% of the full
                   range.
                  Calibration Certificates of Pressure Gauges and Pressure Relief Valves shall be
                   available at the test area for review.
                  Testing piping, fittings, hoses and isolation valves are designated or have pressure
                   rating that match or exceed the system test pressure.
                  Paddle blinds or spectacle blinds and isolation valves that are to be used to isolate the
                   test section are of the same class rating of the system or may be fabricate based on
                   appropriate calculations.
                  No thermoplastic piping shall pressurize until it has cured for 24 hours.

           2.3.3     Test Preparation for Pressure Test

                  The authorization to carry out hydro test shall be given after review of test package
                   Documentation and visual check of pipeline against the drawing and hydraulic test
                   preparation.
                  The hydrostatic test for Cold & Hot Water, Chilled Water & Fire Water Piping shall
                   be conducted in accordance with project specifications
                  Potable water (Drinking & Raw Water) piping system shall be hydro tested with fresh
                   potable water. Other utility piping system shall be hydro tested potable water, well
                   water or sea water
                  Test limits, pressure, test medium and safety requirements shall be identified.
                  The Test Package shall be available for verification at the test area and has been
                   review by SNC-LAVALIN prior to hydro test.
                  Pre-Test Punch List items are cleared.
                  Components which interfere with filling, venting, draining or flushing shall not be
                   installed until after the line flushing and pressure testing.
                  Temporary supports shall be installed wherever required.
                  All joints shall be left expose for visual inspection during test.
                  Work permit is obtained for all pressure testing and associated work within restricted
                   areas
                  Equipment and appurtenances that are not adequate for test pressure shall be isolated
                  The test areas shall be marked and warning signs shall post to alert approaching
                   personnel.
                  A blow down valve of adequate pressure rating is installed to depressurize the system.

                                                         Doc. N.               Rev. No.         Date:        Page No.
                                                                                          2 September 2012    5 of 10
                                  District Cooling Plant For King Abdullah Financial
                                                        District
Contract No. 504054-C-2001                              Job No.

                                            Method Statement



                  An isolation valve of adequate pressure rating is installed to isolate the test piping
                   manifold from the system under test.
                  The relief valve shall be located in the manifold near the test pump.
                  A pressure gauge shall be located at the test manifold and one pressure gauge on the
                   furthest route of the piping network being tested.
                  Vent shall be provided at all high points in the system being tested.
                  A blow down valve or bleed valve shall be readily accessible in case immediate
                   depressurization is required.
                  Temporary connections shall be provided for de-pressurization and draining of the
                   system to the sewer or disposal area.


           2.3.4     Hydro Test Crew

                  Hydrostatic Testing shall be done by trained personnel in the proper handling and
                   usage of applicable tools and equipment prior to start of handling testing.
                  Personnel conducting the hydrostatic testing shall be fully aware of the general
                   requirement s of safe pressure testing of pipelines

           2.3.5     Pressurization

                  No adhesive bonded Piping shall be pressurized until it has cured in accordance with
                   the manufacturer’s instruction.
                  The test pump & test manifold shall be 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 same shall be direct from a water truck or 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 closed when air has released from the system.
                  After venting, valves used only for the pressure test shall be plugged or seal welded.
                  Vents and drains used only for the pressure test shall be plugged or seal welded.
                  To pressurize the system, motorized or manual test pumps shall be used depending
                   on size of the system being tested.
                  Preliminary check for leak for at 50% of the test pressure shall be done.


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                                        District Cooling Plant For King Abdullah Financial
                                                              District
Contract No. 504054-C-2001                                     Job No.

                                                  Method Statement



                        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
                         manifold & the piping system under pressure test is closed and the test pump is
                         disconnected.
                        No repair of leaking joints until the system has been de-pressurized.

                 2.3.6    Depressurization and Draining of Test Medium

                         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 vents shall be opened before draining to facilitate drainage and to prevent
                          formation of a vacuum.
                         Water used for hydrostatic testing can be used for another test, to be used for water
                          spray of trenches, to be used for water flooding of pipe sand covering or to a safe
                          and approved discharge area.
                         All temporary items installed for testing purposes shall be removed
                         All pipe ends shall be covered after draining the system to prevent entry of foreign
                          materials into the system.


       2.4       Responsibilities

              Site Engineer shall organize, manage and supervise all activities related to Hydrostatic
                Testing of pipelines 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         QA / QC

       3.1 Reference Standards

                 15410                 :       Project Specification – Plumbing Piping
                 15500                 :       Project Specification – Fire Protection System

                                                              Doc. N.              Rev. No.         Date:        Page No.
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                                        District Cooling Plant For King Abdullah Financial
                                                              District
Contract No. 504054-C-2001                                     Job No.

                                                 Method Statement



                    15550              :       Project Specification – HVAC Piping & Piping Specialties
                                               Kettaneh QA / QC Plan

       3.2       Responsibilities

                    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 arrange Inspection & Testing required with SNC-LAVALIN in accordance
                     with the QA/QC Plan. He shall maintain and keep records for all QC Documents.
                    Site Engineer, Supervisor and Foreman shall assist the QA/QC Inspector whatever he
                     required in relation to the quality of works, procedures or documents.
 ]
       3.3 Test and Measurement

                    For Pressure Test, a calibrated Pressure Gauge shall be used for measuring the test
                     pressure.
                    The piping being tested shall considered satisfactory if no reasonable drop on the water
                     level or pressure loss after the specified test and no evidenced of water leakage on the
                     pipes, fittings and to joints.

       3.4       Inspection

                     Request for Inspection shall be issued to SNC-LAVALIN 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 QA / QC Plan.
                     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 loss after the specified test period.
                     Leaking pipes, joints and fittings shall be replaced and test shall be repeated until the
                      system is proven satisfactory.

 4.0         SAFETY

       4.1 Guidelines

                     Work permit shall be obtained for all pressure testing activities.
                     Persons conducting the hydrostatic testing shall wear the Personal Protective
                      Equipment at all times on job site.


                                                              Doc. N.              Rev. No.         Date:        Page No.
                                                                                              2 September 2012    8 of 10
                                     District Cooling Plant For King Abdullah Financial
                                                           District
Contract No. 504054-C-2001                                 Job No.

                                                 Method Statement



                   Test section or test area shall be identified and shall be provided with barricades such
                    as safety tapes or physical barriers
                   Only authorized person shall be allowed to enter or crossed to the test area.
                   Warning sign boards and lights shall also be 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
                    can go in and out the excavated area.
                   All test equipment and test instrument shall be calibrated or certificated.
                   At least one person is to be stationed at the test area to check and monitor the test
                    pressure and possible leakage of pipe and joints

 4.2      Responsibilities

                   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.
                   Operators, riggers and spotters of heavy equipment shall follow and implement proper
                    safe working procedure at all times.

       4.2 Hazard Analysis

    Job Description                    Hazard             Preventive Measures                    Responsibilities
 1.Pressurization              1. Injury to worker     1. Install pressure relief           Engineer, supervisor
                                From overpressure      Valve.                                and foreman
                                Pipe blown-out         2.provide temporary pipe
                                  Or detached             support
                                                       3.proper venting required
                                                       4.temporary connections
                                                       Shall have the same
                                                       Rating or exceed the
                                                       Pipe being tested
                                                       5.install blow down valve or
                                                       Bleed valve
                                                       6.depressurized required
                                                       Before repair of leaks
                                                       7.unauthorized person not
                                                       Allowed in the test area
                                                       8.pressurization to be done
                                                       Slowly and monitor
                                                       Pressure rise


                                                          Doc. N.                     Rev. No.          Date:        Page No.
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                             District Cooling Plant For King Abdullah Financial
                                                   District
Contract No. 504054-C-2001                        Job No.

                                      Method Statement




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