METHOD STATEMENT FOR

HYDRO-TESTING OF PIPES

CLIENT

MECHANICAL SUB CONTRACTOR

Issued for
0
Approval
Rev Date Description Prepared Checked Approved
 METHOD STATEMENT FOR
HYDRO-TESTING OF PIPES

METHOD STATEMENT FOR CONDENSATE DRAIN PIPING

Sl. NO. DESCRIPTION PAGE NO.

1 PURPOSE 3

2 SCOPE 3

3 REFERENCES 3

4 DEFINATION 3

5 EQUIPMENT AND TOOLS 4

6 KEY PERSONNEL & RESPONSIBILITY 4

7 METHODOLOGY FOR TESTING 5-6

8 HEALTH & SAFETY 6-7

9 HOUSEKEEPING 7
 METHOD STATEMENT FOR
HYDRO-TESTING OF PIPES

1. Purpose

The purpose of method statement describes the procedure for Hydro-Testing of Pipe Work installed at the site as
per approved drawings. All works will be carried out in accordance with site safety rules and regulations as
guided by HSE Management. This method statement shall be read in conjunction with project specification,
relevant codes for installation & testing.

2. Scope and Application of Work:

This method statement defines the construction methodology for the hydro-testing of pipes. The work will be
coordinated with other services during the execution of work in line with the specifications, approved
MAS, approved shop drawings safety and quality requirements.

3. Reference

The following reference documents to the extent specified herein form a part of this method

A Drawi Drawing Description

re ng

 Approved GFC/Shop drawings as listed below for reference.

4. Definitions

ITP Inspection and Test Procedure

PPE Personal Protective Equipment
HSS Health and Safety Standard
DWP Detailed Works Programme
MS Mild Steel
 METHOD STATEMENT FOR
HYDRO-TESTING OF PIPES

5. Equipment & Tools

No major plant and equipment is required for this activity, minor equipment include as listed below are used for
testing.

I. Electric Pump for initial fill of water– Pump should be of suitable head
II. Test Pressure Gauge – 0 – 10kg/cm-2
III. Hand Tools – Spanner, Wrench, etc.
IV. Mobile scaffold / Step ladders.
V. Hand Pump for increasing pressure in the pipe line. (Back-Up)
VI. Temporary Sump if required

6. Key Personnel & Responsibility

The personnel on site will be fully competent to carry out all related works associated with the project to the
relevant standards.

The site personnel will have attended the required contractor’s induction safety and/or competency training and
will abide by the health & safety plans, policy and procedures.

The Project-In-charge is overall responsible person for process implementation. The Engineer Incharge of E&M
will be responsible for all construction activities at the site and will directly supervise through erection
supervisor / skilled workmen the work at site and will also be responsible for controlling the testing activities.

Site representative will be in attendance during all hydro test activity.

7. Methodology for Testing

 METHOD STATEMENT FOR
HYDRO-TESTING OF PIPES

Hydro-Testing
24 hours notice will be provided to M/S client prior to commencement of Hydro-Test.
100% of pipe work shall be pressure tested as per procedure detailed below:

A. Preparation :

1. Identify the piping circuit to be tested, with reference to shop drawings and mark it.
2. Ensure that the circuit to be tested is completed in all respects as follows.
a) The piping is laid to the correct standards and is in the right location.
b) All the required valves, accessories are installed as per the contract / approved drawings and all nut
& bolts are fully tightened.
c) Check physically that all joints are finished properly i.e. welded / screwed.
d) Ensure that all supports and brackets are provided.
e) Ensure that all joints are exposed.
3. The pipe open ends have been closed with blind flange or plate.
4. All equipment such as FWU/PAHU coils, chillers, pumps etc. has been bypassed by providing
spades or temporary blinds at the inlet & outlet connections.
5. Bypass line has been installed between Flow and return headers to ensure circulation of water to
complete circuit.
6. Drain valve at lowest point and air purge valve at highest point has been provided.
7. A quick fill valve is installed at the location where the water is to be filled, which is at one end of the
circuit and at the lowest point. This is to ensure that while filling the water the air from the system is
released through air vent at the highest point to avoid the fluctuations in pressure.
8. Ensure that the components in the circuit are capable of withstanding the testing pressure i.e. Pipes,
fittings, valves etc.
9. Ensure that the test pressure gauge with valid calibration certificate is available.
10. Ensure the required quantity of water for testing is available at site or else organize the required
number of water tankers.
11. Ensure adequate personnel are in attendance to monitor pipe work during testing to allow immediate
action to be taken in case of leakages.

B. Hydro-Testing :

1. Connect the filling pump & electric pump to quick fill line of the circuit to be hydro tested as per
schematic drawing attached.
 METHOD STATEMENT FOR
HYDRO-TESTING OF PIPES

2. Commence filling with water, the circuit to be tested from local water supply – see item 11 above.
3. Continuous venting shall take place during filling to ensure that the system is completely filled with
water. Closing off of vent connections shall be carried out immediately water begins to flow from the
vent connection.
4. Once the above is done, pressurize to 1 bar pressure, visually inspect the entire circuit for any leaks.
If any leaks are detected from welding then drain the circuit and attend to the leaks.
5. Repeat step 1-4 as above. Additional filling & venting may be required to achieve 1kg/cm-2 pressure
6. If no leaks observed, then close the quick fill valve of electric pump & open valve of electric test
pump.
7. Once the above is completed then pressurize the system using test pump to 7kg/cm-2.
8. During pressurizing, continuously monitor the full circuit for any leaks observed.
9. Once the pressure is steady in the circuit at 7 kg/cm-2, close the quick fill valve & remove the test
pump.
10. The pressure is checked after minimum of 2 hours & if constant or is not having any appreciable loss,
the hydro-testing is construed to be successful.
11. Water is flushed out from the drain valve to the nearest drain.
12. Ensure that the inspections are carried out under similar temperature conditions to avoid fluctuations
in pressure due to variations in ambient temperature.
13. All tests are recorded in format as per ITP.

8. Health & Safety

 All activities will be executed in accordance with contractors HSE Plan and HSE guidelines.
 Safety risk assessment shall be performed for every job or task, which has the potential for harm.
 Ensure Personal Protective Equipment (PPE) is available with all the workers.

 All required equipment and tools should be checked before start of work for suitability and
integrity.
 All safety Guidelines shall be adhered as per approved HSE Plan.

 Necessary permit to work to be obtained as per the site requirement.

9. House Keeping

 Effective housekeeping can eliminate some workplace hazards and helps to get job done safely and
properly.
 METHOD STATEMENT FOR
HYDRO-TESTING OF PIPES

 The work area shall be maintained neat and tidy as reasonably practical all the times.