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METHOD STATEMENT & RISK ASSESSMENT FOR

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PRESSURE TESTING WORKS

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Private & Confidential Document of WME 1 5/14

 Method Statement for Pressure Testing

Purpose
The purpose of this method statement is to make sure that Hydro-static pressure testing of chilled water
piping system is done safely as per client requirements and applicable standards.

Scope of Work
This method statement covers the Hydro-static testing of mild steel pipework at the project and to be
followed for all piping works at site.

Prior to the start of the hydro-static pressure testing all other works on the system shall have been
snagged by construction team and de-snagged and signed off by the quality department.

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Pressure Testing Method of Statement

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 Permit to work for pressure test to be obtained from safety department.

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 All open flanged, valved or screwed ends will be blanked off.

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 The fill point will be installed at the lowest point of the system, and a valved vent at the highest

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point of the system to be tested. The vent will be piped to a drain point.
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 Pressure gauges with valid calibration certificates/stickers will be fitted adjacent to the pressure
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pump.
 Pipework will be filled with water sufficiently in advance of the test to allow it to come to room
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temperature so that any sweating can evaporate. When the systems sufficiently filled the vent
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valve will be opened and allowed to run freely for a period of 5 minutes to ensure all the air is
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out of the system, at that point the valve will be closed.

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 When the system is full and vented the test rig will be linked to the system and the pressure
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increased to the required system test pressure, as required by the specification 1.5 the operating
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pressure. When the test pressure is reached the valve at the fill point will be closed for a period
of 15 minutes to stabilize the system, the gauges will be checked to see if any pressure loss has
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occurred due to the stabilization, if so the test rig will be applied to bring the system test pressure
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back up to the specification requirements. Upon re-pressurization the test rig shall than be
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dismantled from the system.

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 Care will be taken at this point to record the ambient room temperature of the start and finish
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time of the test. The duration of the test will be 24 hours and temperatures should be recorded
frequently.
 A visual inspection of joints will take place during the test period to check for leaks, if any
leakage found the test will be aborted. After the leakage is rectified, the above procedure will be
repeated for a re-test to take place.
 On satisfactory completion of the test, witnessed by the client, the pressure will be released
through the vent pipe. The system then shall be drained. Pressure testing report shall be witnessed
by the client, the pressure will be released through the vent pipe. The system then shall be
drained. Pressure testing report shall be prepared and signed by the client or any other concerned
party.

Private & Confidential Document of WME 2 5/14

Health & Safety Requirements

In ordered to ensure that all hydrostatic testing of chilled water works to takes place in a safe manner the
following shall be considered

 Spot safety meeting will be done by competent engineer to the working group.
 Fitting, thread and connections will be checking up for broken or unthreaded parts.
 To make sure everyone in testing area knows that the pressure test will be done and proper tags to
be displayed.
 Ensure that all pipes are fastened properly.
 Warning signs will display in both English and the local language
 Valves operations to be understood by operator before pressure test starts
 Restrict the access for common people to testing area, use communication system for
announcements etc.
 Only authorized persons are allowed to check the pipes during the pressure in progress

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 After test is complete the pressure should be released slowly and open all valves once the pressure

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is zero, to ensure that there is no pressure trapped anywhere in the system.

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Private & Confidential Document of WME 3 5/14

 RISK ASSESSMENT FORM FOR PRESSURE TESTING

RISK BEFORE RESIDUAL RISK AFTER

SL NO HAZARDS CONTROL MEASURE CONTROL MEASURES NEEDED TO REDUCE RISK IMPLEMENTING
IN PLACE CONTROL MEASURES

1. Pipe Fitter Shall Be Trained And Competent.

2. Plumber Shall Be Trained And Competent.
3. Work Crews Will Use Appropriate PPE. (Hand Gloves, Safety Goggles).
4. STARRT Talks For Crews by supervisor Involve In Pressure Test.

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5. Ensure Appropriate Barricades (Tape) & Sign Boards Placed Around The Area During

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Hydro Test, Gravity Water
1 High Pressure Testing. Low
Test, High Pressure Leak

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6. Proper Communication during Pressure Testing.
7. Training for Proper Use of Hydro Test Manual and Hydro Test Booster Pump.

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8. Tools Will Be Used Only For Their Intended Purposes & Inspect Prior To Start Of Work.
9. First Aid Kit Will Be Available.

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10. Pressure relive valve to be installed.

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1. All operatives will be trained in the correct and safe manual handling techniques.

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Manual Handling
2. Weights will be kept to safe levels as far as reasonably practicable. Heavy loads will be
Potential injuries associated

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2 Medium broken down if possible. Low
with manual handling tasks
3. Operatives know via their training only lift what is within their own capabilities and to ask for
and incorrect lifting

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assistance if required

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Use of tools and equipment 1. All tools are visually inspected before use

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Potential injury associated 2. Operatives are responsible to keep tools in good condition and report any defects. Faulty
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with use of hand tools – tools will be replaced.

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knocks and abrasions 3. Specific equipment/tools are only used by competent users.
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Minimal hot works take place
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1. Hot works is only allowed under a permit to work system (PTW) – Welders will adhere to
Hot Works PTW controlled by Engineer In-charge at site
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4 Potential injuries associated High 2. Full welding face shields provided for welders. Low
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with hot works 3. Only skilled welders will be allowed for welding.
4. Client/Customer fire procedure will be adhered to.
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5. Hot Work guidance available.

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Slips and Trips 1. Operatives will clear up any rubbish as they go.
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5 Potential injuries associated Medium 2. All spillages will be cleared up immediately and spill kits will be kept handy. Low
with slips and trips 3. Equipment and product will be stored safely while working on site.

Private & Confidential Document of WME 4 5/14