LEAK TEST PROCEDURE FOR UNDERGROUND FIRE WATER PIPING

1.Purpose
2.Scope
3. References
4. Responsibility
5. Work Procedures
6. Special Condition
7. Health and safety
8. Attachment
1) Job Safety Analysis

1. Purpose

This procedure is to provide method and process of work with regard to the leak test for Fire Water Piping to ensure flange joint tightness after installation of carbon steel riser piping (hereinafter called “riser pipe”) and PIV to RTR pipe main header. Conducting of leak test will be also able to reconfirm the soundness of RTR piping after backfilling.

2. Scope of Work

This procedure covers leak test for underground fire water piping at Plants and refinery projects.

3. References

3.1 ASME (American Society of Mechanical Engineering) Standards

ASME B31.3 Chemical Plant and Petroleum Refinery Piping.

3.2 ASTM (American Society of Testing and Materials) Standards

ASTM D4024 Reinforced Thermosetting Resin (RTR) Flanges

3.3 Saudi Aramco Standard

( 1) SAES-A-004 General Requirement for Pressure Testing.
(2) SAES-A-007 Hydrostatic Testing Fluids and Lay-up Procedure.
(3) SAES-B-017 Fire Water System Design.
(4) SAES-L-105 Piping Material Specifications.
(5) SAES-S-070 Installation of Utility Piping System.
(6) SAEP-351 Bolted Flange Joints Assembly.
(7) SATIP-L-350-05 Fire Water Distribution Piping Installation.
(8) SATIP-S-070-03 Thermoplastic and RTR Piping.
(9) 01-SAMSS-034 RTR (Fiberglass) Pressure Pipe and Fittings.

3.4 FPI Manual

(1) V-216A-109-A-513 Preservation Procedure (Storage Procedure) at Construction Site.
(2) V-216A-109-A-515 Field Fabrication Procedure (For Adhesive & RSLJ Connection)
(3) V-216A-109-A-516 Repairing Procedure
(4) V-216A-109-A-518 Bolt Torqueing / Flange Tightening Procedure
(5) V-216A-109-A-519 Field Hydro Static Test Procedure
(6) V-216A-109-A-801 Installation, Operation and Maintenance Manual

3.5 Method Statement

(1) PIP-MS-001 Special Process Procedure for RTR Pipe Work
(2) PIP-MS-010 Procedure for Piping Pressure Test
(3) PIP-MS-021 Method of Statement for RTR Flange Tightening/ Bolt Torqueing

4. Responsibility

4.1 Construction Manager

Construction Manager shall be responsible for the overall implementation and monitoring of all the activities involved. He shall be responsible for safe and productive work culture. He shall be dealing with construction team for implementing work in correct procedure at site.

4.2 QC Manager

QC Manager shall be responsible to ensure that all related works are in accordance with the approved drawings and specification requirements of PMT as well as the implementation of quality control procedure.

4.3 Safety Manager

Safety Manager shall be responsible for coordination with HSE authorities of the Company Safety Officer. He shall also monitor the works to ensure that they are carried out correctly and in safe manner and advice Supervisors for corrective measure, if required.

4.4 Supervisor

Supervisor shall be directly involved in the planning and executions of the activities for related works. He shall ensure the implementation of quality plans and also responsible Obtaining PTW prior to commencement of work. HSE Plan must be implemented and Observed during RTR pipe works.

4.5 QC Inspector

QC Inspector shall be responsible for the necessary inspections and tests to be carried out for all the activities involving earthworks.

4.6 Foreman/Leadman

Foreman shall be responsible for the direct execution of related works according to the plan and shall directly control and give instruction to the working personnel. He is responsible for the usage of Proper tools /equipment, personal protection equipment’s and housekeeping.

4.7 Direct/Skilled Worker

Responsible in implementation of general works on site in different category and Specialization for direct execution of work according to Project specification/Standards.

5. Work Procedures

5.1 General requirement

All pressure test requirement other than specified in this method statement should be referred from approved procedure (PIP-MS-010: Procedure for piping pressure Test)

5.2 Preparation

Riser pipe and PIV should be hydro tested as per requirement before installation.
External coating(APCS-113A) for riser pipe should be completed before installation, however touch up to weld joint can be conducted at site, if necessary.
– Test boundary should be marked on P&ID and it should be available during leak test.

5.3 Installation

Riser pipe and PIV shall be aligned and installed properly.
Flange Tightening and Bolt Torqueing shall be conducted according to project specification and approved method statement (PIP-MS-021: Method of Statement for RTR Flange Tightening/ Bolt Torqueing).

5.4 Leak Test

After installation of riser pipe and PIV into RTR piping at multiple sections (PIV to PIV), temporary test blind shall be installed.
Basically several sections will be leak tested at one time, however test boundary should be adjusted according to site requirement and conditions.
PIV should be in close position if it is at test boundary.
– After complete water filling, system should be pressurized gradually till operating pressure.
Test pressure (Operation pressure) is to be maintained till visual check for all flange joint is completed (Minimum pressure holding time is one hour) If leakage or pressure drop is observed, release the pressure and repair the leakage.

5.5 Test completion

– After leak test completed and confirmed no leak, test result shall be recorded.

6. Special Condition

In case riser pipe or PIV (with valve open) can be installed before RTR pipe hydro test, flange joint tightness should be verified together with RTR hydro test and separate leak test will not be required.
In case riser pipe or PIV cannot be aligned properly, RTR pipe should be adjusted (cut and modification will be conducted) and re-hydro test (with test pressure) shall be conducted to confirm integrity of modified joint. Flange joint integrity and RTR pipe soundness can be verified by test pressure for this case.

7. Health and safety

7.1 Protection and safety shall be in accordance with Saudi Aramco Safety Manual and safety Manual approved by Saudi Aramco
7.2 Ensure that all personnel involved in the work are wearing standard personnel protective equipment (PPE)
7.3 A duly approved work permit shall be obtained before start of any activity at site.
7.4 Provide warning sign and sufficient barricade on working area and only assigned personnel will be allowed in the area
7.5 The work shall be executed in accordance with the approved job safety analysis (JSA). The permit shall be obtained prior to any commencement of the work when required.
7.6 During leak test, JGC/DEC Safety will co-ordinate with testing group for ensuring that all safety measures are implemented
7.7 During pressurization, all personnel should be outside of marked test area. Saudi Aramco General Instruction Gl-2-102 Pressure Testing Safely shall be followed.
7.8 Safety Officer shall monitor the work activities to help and to protect all assigned workers against exposure to safety hazards
7.9 The Site of all work activities shall be kept in a clean and tidy manner.