METHOD STATEMENT

UG PIPING HYDROTEST

Doc. No.: 199/00/00/CI/MS/NA/A50148

Page: 1 of 8

Rev.: B2 Date: 13/10/2011

UG PIPING HYDROTEST

Review Legend:

Code 1 – Rejected ; Code 2 – Approved as Noted Revise & Resubmit ; Code 3 – Approved as Submitted

Document Reference:

199/00/00/CI/MS/NA/A50148 KETTANEH TCJV REVIEW COMPANY REVIEW

B2 ICA 13/10/2011 FML INR

B1 ICA 07/07/2011 JFH INR

Rev. Doc. Isued

for Date Prepared Checked Status Initial Date Status Initial Date

METHOD STATEMENT

UG PIPING HYDROTEST

Doc. No.: 199/00/00/CI/MS/NA/A50148

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Rev.: B2 Date: 13/10/2011

Table of Contents

1 PURPOSE: 3

2 SCOPE 3

3 REFERENCES 3

3.1 PROJECT DRAWINGS 3

3.2 PROJECT SPECIFICATION 3

3.3 CODES AND STANDARDS 3

4 ABBREVIATIONS 4

5 PERMIT TO WORK 4

6 RESPONSIBILITY 4

7 PROCEDURES 5

7.1 general information 5

7.2 test preparation 5

7.3 testing 6

8 TOOLS AND EQUIPMENTS 7

8.1 EXECUTION 7

8.2 SAFETY 7

9 SAFETY INSTRUCTIONS 8

10 ATTACHMENTS 8

METHOD STATEMENT

UG PIPING HYDROTEST

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Rev.: B2 Date: 13/10/2011

1 PURPOSE:

The purpose of this method statement is to describe the method, the sequence and the responsibilities of the hydrotesting of underground Facilities of network system (partial and complete system) at site.

2 SCOPE The scope of this method statement covers the hydrotesting of piping with relative activities.

3 REFERENCES

3.1 PROJECT DRAWINGS • AFC Isometric drawings latest revision • Piping general underground network drawings • P & IDs • Underground composite drawings and civil work installation drawings

3.2 PROJECT SPECIFICATION • 199/00/00/MP/TS/NA/000103 Technical specification for field testing of

piping. • 199/00/00/MP/DR/TD/000104 Standard drawing for piping arrangements • 199/00/00/CS/PC/NA/000833 Project procedure for traceability and

marking of piping components at site. • 199/00/00/QA/TS/NA/630032 Shop and field piping welding • 199/00/00/ME/TS/NA/630011 General welding requirements • 199/00/00/MP/DB/NA/000101 Amendment of piping material classes • 199/00/00/CS/PC/NA/000840 Project procedure – permit to work

3.3 CODES AND STANDARDS • ASME 16.25 Butt welded ends • ASME 16.34 Valve flanged, threaded and welding ends • ASME 16.5 Pipe flanges and flanged fittings • ASME B31.1 Power piping • ASME B31.3 Process piping

METHOD STATEMENT

UG PIPING HYDROTEST

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• ASME B31.8 Gas transmission and distribution piping

system • ASME SECTION II PART B Material of base metal • ASME SECTION II PART C Welding rod, electrodes and filler metals • ASME SECTION V Non destructive examination • ASME SECTION IX Welding and brazing qualification

4 ABBREVIATIONS • QG Qatar Gas • TCJV Technip Chiyoda Joint Venture • KCQ Kettaheh Construction Qatar • ASME American Society for Mechanical Engineers • NDE Non Destructive Examination • PWHT Post Weld Heat Treatment • PPE Personal Protective Equipments • WPS Welding Procedure Specification • PQR Procedure Qualification Record

5 PERMIT TO WORK Before starting the piping activities, a permit to work should be prepared as per TCJV PTW procedure and submitted to TCJV/QG with all required documents for approval.

All vehicles and acquirements to be inspected and to have QG blue sticker while working at QG site.

6 RESPONSIBILITY It is the responsibility of the construction department to perform hydrotesting activities as per the requirements of Contract Documents, AFC Drawings, project specifications and inspection and Quality Plan.

The responsibility of the QC Inspector is to perform all inspections as per the ITP to ensure compliance to the requirements of the AFC Drawings and project specifications and preparing the inspection reports.

The QC supervisor will coordinate the inspection activities and verify the QC report for

METHOD STATEMENT

UG PIPING HYDROTEST

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Rev.: B2 Date: 13/10/2011

completion and sign the documents.

The Test Team shall be responsible for the pre-test safety precaution, inspection and ensure that only concerned personnel are within the agreed test area.

All safety equipment, barricades and hazard signs for hydro test will be provide by KCQ/FLQ.

To ensure safe monitoring, all Construction personnel, Safety inspectors shall be responsible.

KCQ at their discretion performs Pre-pressure Test to confirm no leakage before official test pressure.

The QC manager will verify the documents as required.

The third party laboratories perform the required inspection or test as per the requirements of specifications.

7 PROCEDURES

7.1 GENERAL INFORMATION The hydrotest will be performed on the fabricated spools in workshop or erected spools at site in a way not to hold the trenches backfilling activities.

When jointing hydrotested and backfilled spools, the line will be re-tested, keeping the connection joint exposed to allow visual inspection for any leakage.

The test medium will be as described in the project specification for field testing of piping 199/00/00/MP/TS/NA/000103.

After finishing the test, the water will be drained from the lowest point. The pipes will be air blown to evacuate all the residual water. Dry and oil free compressed air shall be used.

7.2 TEST PREPARATION Before starting the pressure test, a test pack shall be prepared according to the requirement of the ITP for AG/UG piping erection. It has to contain the following forms:

• Test pack cover sheet • Test pack content sheet, where all the required forms will be mentioned. • P&ID and ISO drawings marked with the lines to be hydrotested. • Line list

METHOD STATEMENT

UG PIPING HYDROTEST

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• Daily welding inspection report. • Line cleaning • Piping pre-test checking list • Punch list • Piping pressure test release & acceptance report • Reinstatement

All NDT and PWHT reports shall be checked and approved by TCJV and company.

A pressure pump with suitable pressure head shall be prepared to be able to reach the testing pressure. A certified manifold with calibrated pressure relief valve and valves shall be prepared.

Two calibrated pressure gages, with maximum reading of 1.5 times the required test pressure, one to be connected to the manifold and one on the highest point of the line.

Pressure test blinds with gaskets as per piping specification shall be used.

7.3 TESTING Prior to pressure testing, test pack shall be submitted to COMPANY/TCJV for review and approval.

Before starting the test, the area of the test will be barricaded and signs shall be installed to show that hydrotest is under process and entry for unauthorized people is forbidden.

Hydrotest will not take place if the outside of the pipe is wet.

Water filling will be done threw the manifold, using an appropriate pump, installed in the lowest point. Be sure that the vents are fully open to allow the evacuation of all the air. After all air is removed, the vents will be closed and pressure will be increased.

Pressurizing and holding time shall be done according to project specification.

An inspection will be held to all the flanged connections and the welded joints for any water leakage.

If any leak is detected, the system shall be depressurized, the defect will be repaired and the pipes re-tested.

METHOD STATEMENT

UG PIPING HYDROTEST

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After completion of the test, the pressure will be reduced slowly by opening the drain valves until the pressure gages show a 0 pressure on the line. Then the vents will be open and the temporary flanges to allow a complete drainage of the line.

De-watering of the Testing water will be loaded to vacuum or pumped to a nearest ditch.

All lines shall be checked to ensure the entire system can be completely drained after testing.

The hydrotest will be completed after acceptance and approval of contractor and company.

8 TOOLS AND EQUIPMENTS

8.1 EXECUTION • Cranes • Compressor to supplying dry air • Vacuum truck • Boom trucks • Forklifts • Trailers • Rigging tools • Chain blocks • Generators • Pressure pump • Manifold • Pressure relief valve. • Pressure gauges • Sign boards • Warning tape

8.2 SAFETY • Nomex coverall • Safety helmet • Safety goggles • Safety shoes

METHOD STATEMENT

UG PIPING HYDROTEST

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• Safety harness • Working gloves • H2S toxic clip • Red mask • Dust mask • Fire extinguisher • Fire blankets

9 SAFETY INSTRUCTIONS • All work permits shall be prepared and approved prior to start any activity. • Work permits shall be present at site in work area. • Care shall be taken for rigging activities to ensure a safe handling. • Housekeeping of the work area. • Arrange tool boxes and continuous training for labors. • Be aware of the prepared JSA • Personnel involved for the pressure test shall have an identification mark on the

helmet (to determined). • Safety watch guards shall be assigned throughout the test period. • All hoses and fitting for pressuring shall be certified and rated for the maximum

test pressure • Adequate signs boards will be placed around the barricaded areas where the test

being carried out for the awareness of the nearby working personnel that are not involved in testing activities to keep away from the testing zone.

• All necessary approved PPE's will be provided and worn in accordance with the project safety procedure.

• Sufficient illumination of work area, storage area and access/exit routes shall be provided while working at night.

10 ATTACHMENTS JSA