CONSOLIDATED CONTRACTORS COMPANY DOCUMENT No.

: MS-742-120
REVISION No. : 2
& PAGE : 1
TEYSEER CONTRACTING COMPANY J.V. OF :
9

METHOD STATEMENT

FOR

HYDROTESTING OF BONDSTRAND FRP

U/G & A/G PIPING SYSTEM

RAS LAFFAN ONSHORE EXPANSION PROJECT

MS-742-120
RAS LAFFAN – QATAR

Incorporated company comments

as per CMS&A Transmittal
2 22/11/04 PVK NC RS HH IK --------
No. RGX-T4-CMSF/CCIC-2971
Issued for Construction
Incorporated company comments
as per CMS&A Transmittal
1 03/11/04 PVK NC RS HH IK --------
No. RGX-T4-CMSF/CCIC-2893
Issued for Construction

Reissued with revised JHA and full

F 05/10/04 PVK NC RS HH IK --------
set of documents for approval

Incorporated Client’s comments

E 06/09/04 PVK NC RS HH IK --------
Reissued for Approval

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-742-120
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TEYSEER CONTRACTING COMPANY J.V. OF :
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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
2 12. POST HYDROSTATIC TEST MEASURES
13. CORRECTIVE ACTION
2
14. ATTACHMENT
14.1 TEST BLIND THICKNESS CHART
14.2 PIPE CLEANING INSPECTION
DOCUMENT
14.3 PROCEDURE FOR PRESSURISING GRE
PIPES. (Att. 7.1 GRE PIPE HYDROTESTING
2 PROCEDURE, 7.2 PRESSURE TEST REPORT
FOR GRE PIPE)

14.4 JHA

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 CONSOLIDATED CONTRACTORS COMPANY DOCUMENT No. : MS-742-120
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1. SCOPE
1.1 This method statement mark out the boundary of related activities in various
stages in connection with the Hydrostatic testing of FRP underground and
aboveground 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 : Basic Engineering and Site Data
b) RGX-S-00-1360-002 : Piping Material and Service Classification
c) RGX-SS-00-1360-050 : Fiberglass Reinforced Pipe (FRP)
d) RGX-SS-00-1360-003 : Piping, Fabrication, Erection, Inspection
and Testing.
3.2 Quality Control Procedure :
a) QCP-742-115 : Piping Fabrication, Erection and Testing of
Underground and Above ground piping.
b) ITP-742-142 : Inspection and Test Plan for Fibre Glass
Reinforced Pipe (FRP)
3.3 Standards and Codes :
a) ASME B31.3 : Process Piping (Latest Revision)

4. DEFINITIONS

4.1 Company : Ras Gas

4.2 Contractor : Chiyoda, Snamprogetti & Company Joint
Venture (CMS & A)
4.3 Sub-contractor : Consolidated Contractors Intl Co./
Teyseer Contracting Co. JV (CCC/TCC)
4.4 PTW : Permit to work Document issued by RAS GAS /
CMS&A
4.5 MS : Method Statement
4.6 QCP : Quality Control Procedure
4.7 ITP : Inspection and Test Plan
4.8 JHA : Job Hazard Analysis
4.9 PPE : Personal Protective Equipment
4.10 QCI : Quality Control Inspector
4.11 CTR : Contractor
4.12 SCTR : Sub-contractor
4.13 RFI : Request for Inspection

4.14 FRP : Fiber Glass Re-inforced Pipe

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 CONSOLIDATED CONTRACTORS COMPANY DOCUMENT No. : MS-742-120
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5 RESPONSIBILITIES

5.1 Ref. T3-L-TRCS-808 June 19 th, 2003 CMS&A will retain named competent
person to oversee preparation and execution of testing.
5.2 The Sub-contractor’s personnel shall be involved and responsible for the
activities pertaining to Hydrostatic test for the execution/implementation
according to the applicable safety procedures and project specifications
under the supervision of contractor.
5.3 Engineer(s)/Supervisors/foremen will ensure the safe and efficient working
environment to plant and equipments to carryout the Hydrostatic testing
activities on each stage.
5.4 The QCI(s) with the help of Engineer(s)/Supervisor/Foremen are responsible
for the inspection of pressurized piping system in accordance with the project
specification and procedure.
5.5 The subcontractor test team shall be responsible for the pretest safety
precaution, inspection and ensure that only concerned personnel are within
the 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 Non-essential personnel shall be cleared from the vicinity of the test pipe
system. Pipe must be adequately supported and stable in event of a joint /
flange failure.
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 the safety department and subcontractor’s SCTR
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 CTR.
6.7 The safety officer(s) will conduct a joint walk with subcontractor/contractor
testing personnel in order to ensure adequate safety precautions prior to test
commencing.
6.8 Proper and safe means of access/egress shall be provided and maintained for
the workers /QCI(s) in order to carryout preparation and inspection of the
piping system to be tested.

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6.9 Minimum exclusion zone diameter placing the pressure containing components
at the center point shall be 10 mts (to be agreed with safety (CMS&A) on a
case by case basis) in every direction depending upon the test pressure and
volume.
Communication for emergency purposes (Telephone/Radio) will be
maintained at site.
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. or on to ground where it can wash away
backfill or undermine foundations.
6.12 JHA shall be attached to work permit prior to commencement of pressure test
and be signed by the test team and must apply during execution of testing.
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
prior to commencement of pressure test activities.
6.16 All activities shall be suspended in case of an emergency and respond
accordingly.
6.17 The testing supervisor must remain at the test site throughout the duration of
the test and must personally confirm with one other competent person
depressurization to zero BarG when test is completed.
6.18 Procedure check list for hydro testing inc. depressurization to be used.
Signature of supervisor in charge of testing required for each step. (check
list to be reviewed / authorized by CMS&A/PMT safety before acceptance).
7 GENERAL
7.1 Pipe Cleaning Requirement :
a) It is a requirement to get the pipe cleaned internally by manually or air
blown in order to remove all trash or construction debris left inside the
pipe, therefore no debris will be accumulated inside any manual operated
valve, which might cause damage to valve seats while on pressure
testing.
b) An inspection sheet is to be signed by subcontractor, contractor and
company with a marked up isometric or line number/isometric number
clearly mentioned the limit of cleaning carried out or part thereof
inspected and passed as clean. This document will be attached with the
test pack.

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8 TOOLS AND EQUIPMENTS

8.1 The following Tools and Equipments shall be made available to perform the field
testing of piping system.
· Certified pressure gauges
· Certified Diesel Pressure Displacement Pumps
· Certified High Pressure Compressors
· Fill Tank and Isolation Valves
· Filling Pumps
· Test Manifolds/ and gauges
· Hand tools
· Certified hoses/fittings
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 4.0 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

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
definition the extent of the test will be marked up by contractor. 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 the limits as per the test block diagram and
test package number.
· Pressure Test Confirmation Record.
· Line list with agreed test pressure endorsed by eng.
· Piping Pressure Test Release Report.
· Pretest Punchlist of Piping Work.
· Location Map.
· Blind thickness chart
· Isometric control sheet from Talisman.
· Cleaning Record

9.4.2 The marked isometric drawing will indicate the location of

pressurisation point, depressurisation point, pressure gauge location, vents

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location, removal of control valves, FE, flow gauges, level gauges, strainer
elements which is not required to be part of the test. (these parts will be
clearly marked on test block diagram as well).
9.4.3 Pre-test punchlist 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 Record shall be completed and signed by CTR and
Company.
9.5 Test Medium :
a) Hydrostatic Test :
Clean and fresh water shall be used. All water shall be drained 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 trims, 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.
10PREPARATIONS

10.1 Components and instruments will be removed, refer 9.6.2. Instrument lead
lines will be disconnected.
10.2 Test manifold will be connected at the lowest point.
10.3 Certified pressure gauges will be installed one on the test manifold, the other
shall be located at the highest point. (minimum two gauges will be installed
for each test loop).
10.4 All safety measures will be taken into account as mentioned in item 6.
10.5 Hydrostatic test loops shall have all high points in the piping with a vent and
all low points with a drain regardless of whether or not they are specifically
shown on the drawings.
10.6 All necessary test blinding will be done as per the test loop diagram by
selecting proper thickness of the blind from the blind chart. The blinding will
be done by using temporary suitable full face gaskets must be used to
withstand the test pressure.

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10.7 Ensure all parts of the pipe testing loops are tightened adequately enough to
with stand the test pressure. All bolts are torque tightened as per bolt
tightening sequence. (Ref. RGX-S-00-1360-050 Rev. 1, Table 3)

10.8 Adequate temporary supports should be used where volume and weight of
water may cause line deflection.
· All permanent support to be installed.
· All guides shall be fully installed.
· All anchor points to be fully installed.
10.9 When testing underground piping system the line must be partial back filled
with sand and temporarily blocked at directional changes to prevent
excessive movement during test. Joint areas are to be left open.

10.10 Care must be taken into consideration to prevent aboveground system from
lowering or moving excessively during test or increase of sudden
depressurization.

11 TEST PERFORMANCE AND WITNESS

11.1 1Hydrostatic Test :

· The recommended test pressure is 1.5 times the design pressure.
· Sudden pressure surges or water hammer should be avoided during
pressurization.
· Open all vents during filling to avoid entrapping air prior to applying
pressure in the system.
· Care shall be taken to avoid increase in pressure due to temperature
variation during test.
· Hydrostatic testing shall not be done against closed valves.
· Pressure shall be applied in approximately 5 steps over a 30 minutes
period until the test pressure reached.
· Each pressurization step to be recorded on the pressure test report, copy
of pressure test report to be attached.
· Release pressure and repeat the cycle three times. The pressure shall
then be applied as above and held constant for an 8 hour period.
· The test will not be conducted when the outside of the pipe is wet.
· Open all vent and drain to depressurize gradually the system pressure.

12POST HYDROSTATIC TEST MEASURES

· Pressure shall be released gradually in steps. The vents and drains

shall be kept open until the lines are fully drained.

· All temporary facilities installed to facilitate pressure test shall be

removed.

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· After satisfactory performance of hydrotest all relevant documents are to
be signed of by CTR & Company.

13 CORRECTIVE ACTIONS

13.1 If any leakage or weeping is identified the system shall be depressurized,

repaired and re-tested.

13.2 All joints failing to pass the pressure test shall repaired in accordance with
the specification RGX-S-00-1360-050 (Rev. 1) Table –3, Section 9.2, 9.3,
14.4 and relevant sections shall be retested.

14ATTACHMENT

14.1 Test Blind Thickness Chart

14.2 Pipe Cleaning Inspection Document
14.3 Procedure for Pressurising GRE Pipes
14.4 JHA

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