000-PR-CN02-0049.01 - Method Testing for HDPE Fire Piping

Document No.:

000-PR-CN02-0049.01

Method Statement Hydrotesting HDPE Firewater Piping

Revision: 1 Date:

2-May-12

Page: 2 of 6

TABLE OF CONTENTS 1. 2. 3. 4. 5. 6.

GENERAL INTRODUCTION ............................................................................................ 3 SCOPE.............................................................................................................................. 3 REFERENCES .................................................................................................................. 3 RESPONSIBILITIES ......................................................................................................... 3 RESOURCES ................................................................................................................... 4 GENERAL REQUIREMENTS ........................................................................................... 4

THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY ("CB&I"). IT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.

Document No.:

000-PR-CN02-0049.01

Method Statement Hydrotesting HDPE Firewater Piping

Revision: 1 Date:

2-May-12

Page: 3 of 6

1.

GENERAL INTRODUCTION This Method Statement addresses the hydrotesting of the underground firewater piping on the project. The pipe material is project pipe class 12PDOH manufactured from high density polyethylene (HDPE). The piping may be hydrotested in smaller systems as it is being installed. Any valves or other bolted in line items installed after the piping has been hydro tested, will be service tested. There shall be a specific check sheet developed to monitor and confirm that these items have been installed per manufacturer’s recommendations with all connections thoroughly cleaned before final bolting. Test pressure is 225 psi. As per NFPA 24 and the Project Process Line List (166000-147-PR08-0001)

2.

SCOPE The scope is to successfully test that the firewater piping has been installed using approved materials, tools and techniques and that it has been successfully hydrotested.

3.

REFERENCES Technical Spec for High Density Polyethylene (HDPE) Piping - 166000-000-SP-PI02-0231 Field Pressure Testing of Piping – 166000-000-SP-PI02-0233 Standard for the Installation of Private Fire Service Mains and Appurtenances – NFPA 24 In case of conflicts between Project Specifications and NFPA 24, NFPA 24 takes precedence.

4.

RESPONSIBILITIES The Construction Manager is responsible to verify the accomplishment of this Method Statement. The Field Engineer and the Supervisors are responsible to verify all Technical aspects related To the Method Statement. The QA/QC leader is responsible to ensure the activities are accomplished to satisfy the Requirements of the Design Drawings and Specifications. . The QA/QC leader is responsible to verify the Control and Storage of all Documents Related to this Method Statement

THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY ("CB&I"). IT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.

Document No.:

000-PR-CN02-0049.01

Method Statement Hydrotesting HDPE Firewater Piping

Revision: 1 Date:

2-May-12

Page: 4 of 6

5.

RESOURCES

5.1 Equipment Manual Pump Cistern Truck Thermometers (Calibrated) Pressure Gauges (Calibrated) 5.2 Devices Valves Vents Blind Flanges with Nipples Hoses Temporary Accessories 5.3 Personnel Supervisor Assistants Workers 6.

GENERAL REQUIREMENTS

All Spool Fabrication Records shall be certified complete and signed off before Starting of Test Provide all necessary Safety precautions to prevent accidental injury and exposure to Hazardous conditions. Test Team shall consist of suitable experienced and trained personnel and supervision. THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY ("CB&I"). IT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.

Document No.:

000-PR-CN02-0049.01

Method Statement Hydrotesting HDPE Firewater Piping

Revision: 1 Date:

2-May-12

Page: 5 of 6

6.

Contd An exclusion zone shall be established around Pipework being pressure tested. Only personnel engaged in the test shall be permitted inside the exclusion zone. The minimum safe clearance distance for Hydrotesting is 2 Meters

7.

Methodology Before Hydrotest place pipe in Trench and Backfill (per NFPA 24 paragraph 10.10.2.2.4 and 10.10.2.2.5). The line shall be backfilled between joints to prevent Movement of pipe and Bolted connections left exposed. When required for safety reasons presented by the hazards of open trenches, The pipe and joints can be backfilled, provided the Unit Manager takes responsibility For locating and correcting leakages. The Hydrotest consists of three Phases, Filling and Expansion Phases and a Test Phase. Filling. The Test section shall be filled slowly. All air should be purged. All appropriate Precautions to be taken to ensure that no air is trapped in the test section.

Expansion Phase. When the system is completely filled and purged of air, it shall be Gradually pressurised in 4 stages, 75psig, 125psig, 175psig and the final pressure of 225psig, at each stage additional water may be added to maintain the pressure. A minimum of 15 minutes is required between stages for piping to stabilise. There is No need to record the amount of water added to the system during the Expansion Phase.

Pressure Test Phase – According to NFPA 24 (Paragraph 10.10.2.2) After the Expansion Phase is complete the system shall be Hydrostatically Tested at 225 psig and the pressure shall be maintained within + or – 5psig for 2 hours. Pressure loss shall be determined by a drop in Gauge pressure or a visual leak. Test Pressure shall be read at a Gauge located at the lowest part of the system (Usually the fill point of the system) another gauge can be located at a connection Point to a Hydrant or if not available the end of the piping system.

THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY ("CB&I"). IT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.

Document No.:

000-PR-CN02-0049.01

Method Statement Hydrotesting HDPE Firewater Piping

Revision: 1 Date:

2-May-12

Page: 6 of 6

Hydrostatic Testing Allowance. Where additional water is added to the system During the Test Phase to maintain the Test Pressure the amount of water added shall Not exceed the limits of Table ‘A ‘

Table ‘A‘

Hydrostatic Test Allowance at 225 psig

Testing Allowance

Nominal Pipe Diameter (in) 2’’ 4’’ 6’’ 8’’ 10’’ 12’’ 14’’ 16’’ 18’’ 20’’ 24’’ 36’’

US Gal / Hour 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 0.18 0.20 0.24 0.36

Litres / Hour 0.076 0.152 0.228 0.304 0.380 0.456 0.532 0.608 0.684 0.760 0.912 1.368

Test Acceptance – Test shall be witnessed and Test Documentation signed Off by CBI Supervisor, QA/QC and Refricar QA/QC. Refricar will receive a NORFI 24 hours prior to Test to inform them of Time and Place of Test. When Documentation is complete QA/QC will send original signed off sheets to the Mechanical Completions Department for entering in WIN PCS. When Documentation is entered into WIN PCS original will be returned to QA/QC for safe keeping.

THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY ("CB&I"). IT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.