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PROJECT: 8483
KING ABDULAZIZ CENTER FOR WORLD CULTURE

METHOD STATEMENT:
UTILITY HYDROSTATIC TEST

00 Initial 03.02.11 R.S W.K P.R M.S H.A

Rev Comments Date Prepared Reviewed Technical Reviewed Reviewed Approved

QC QC Reviewed QC HSE SPM
SV SME MGR MGR

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CONTENTS:

1.0 PURPOSE

2.0 SCOPE

3.0 ABREVIATIONS

4.0 RESPONSIBILITIES

5.0 REFERENCES

6.0 TOOLS & EQUIPMENTS

7.0 PROCEDURES

8.0 LOSS PREVENTION

9.0 ATTACHMENTS

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1. PURPOSE

The purpose of this document is to describe the Method Statement (M.S) to be

followed for hydrostatic testing of pipes. This M S explains the instructions to be
followed & the documentation to be employed in order to ensure that the
hydrostatic testing is performed in accordance to the Project Specifications &
Saudi Aramco Standards.

2. SCOPE

The scope of this M.S is to define all activities and requirements, necessary for
gravity & pressure testing of pipes. The test will cover the following piping
services, inside & outside of the building including underground (UG) &
aboveground (AG) utilities.
This Method Statement applies to the following services:
 Hot/Cold Potable and Non Potable Water
 Fire Protection Water
 Waste, Sewer Water & Ventilation
 Waste Water & Ventilation for Laboratory
 Storm Water Drainage
 Water Sewage & Retaining Structures
(Manholes/Tanks etc)
 Force Mains
 Condensate Drainage
 Chilled Water (Supply & Return)

3. ABREVIATIONS

M.S Method Statement

ITP Inspection & Test Plan
RFI Request for Inspection
S.O.L Saudi Oger Limited
S.A Saudi Aramco
QC Quality Control
SAPID Saudi Aramco Project Inspection Department
SAPMT Saudi Aramco Project Management Team
SAIC Saudi Aramco Inspection Checklist
SATR Saudi Aramco Test Report
UG Underground
AG Above Ground
PRV Pressure Relief Valve
PVC Polyvinyl Chloride
UPVC Unplasticed Polyvinyl Chloride
HDPE High Density Polyethylene

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4. RESPONSIBILITIES

4.1 QC Inspector – Prepare the Method Statement

4.2 QC Supervisor – Review & Update
4.3 QC Manager, HSE Manager
4.4 Senior Mechanical Engineer – Technical Review
4.5 Site Project Manager – Approve
4.6 Construction Managers / Site Engineers / Site Foremen – Implement

5. REFERENCES

The following is the list of references which are applicable to the scope of this
Method Statement.

5.1 International Codes

ASME B31.3 Process Piping
UPC Uniform Plumbing Code

5.2 Saudi Aramco Standards

SAES – A – 004 General Requirements for Pressure Testing
SAES – A – 007 Hydrostatic Testing Fluids and Lay-up Procedures
SAES – B – 017 Fire Water Systems Design
SAES – D – 008 Repairs, Alterations & Re-rating of Pressurized
Equipment
SAES – S – 010 Sanitary Sewers
SAES – S – 020 Industrial Drainage & Sewer
SAES – S – 030 Storm Water Drainage System
SAES – S – 040 Saudi Aramco Water Systems
SAES – S – 060 Saudi Aramco Plumbing Code
SAES – S – 070 Installation of Utility Piping System
SAES – L – 056 Pressure Testing of Pipelines & Plant Piping
G.I.2.102 Pressure Testing Safely
SATIP–A–004–02 SATIP for Pressure Testing
SAIC – A – 2001 Review of Pressure Test Process
SAIC – A – 2003 Review Test Pack Preparation
SAIC – A – 2007 Review Lay-Up Procedures
SAIC – A – 2008 Verification of Test Medium
SAIC – A – 2009 Verify Test Prep and Equipment
SAIC – A – 2010 Pre-Test Punch Listing On-Plot Piping
SAIC – A – 2013 Inspection of Filling and Pressurization
SAIC – A – 2015 Visual Inspection at Test Pressure
SAIC – A – 2017 Depressurization and Disposal Test Water
SAIC – A – 2018 Lay-Up Inspection for Piping & Vessels
SATR – S – 4002 Water Sewage and Retaining Structures
(Manhole, catch basin, Holding tank etc.)Leak test

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SATR – A – 2008 Internal cleaning & flushing of the Pipes

6. TOOLS / EQUIPMENTS

Conventional tools and/or equipments will be used as necessitated by work

procedures.

7. PROCEDURES

7.1 Introduction: This method statement is applicable to pressure and gravity

test of pipes and manholes inside building and external networks.

7.2 PRESSURE TESTING PROCEDURE:

7.2.1 PREPARATIONS:-

7.2.1.1 Test packages shall be formed of the following documents:

7.2.1.1.1 Flow Chart of Test Package denoting responsible agencies

for tracking and confirmation of various inspection
requirements
7.2.1.1.2 Schematic diagram of the Test Manifold showing all the
components with clear labels and dimensions (Refer to
attachment 'I': Sample of Test Manifold Diagram)
7.2.1.1.3 Calibration Certificates for Pressure Gauges
7.2.1.1.4 Pressure relief valve (PRV) data sheet calibration
certificates
7.2.1.1.5 Hydrostatic test diagram showing the layout, routing and
limits of pipes to be tested
7.2.1.1.6 Isometric drawing of tested pipe network
7.2.1.1.7 Pre–Test punch list checklist: SAIC-A-2010
7.2.1.1.8 Final Punch list: SAIC-L-2022

7.2.2 The Testing package documents shall be submitted to S.A for review 24
hours prior, each time a test is conducted. All Test Packages shall be
given serial numbers and listed in the order to keep track of the status of
tested and untested pressure. (Attachment III).

7.2.3 Before employing the pressure testing manifold in the actual system
pressure test, it shall be separately pressure tested to at least 1.2 times the
system test pressure (Example: If the test pressure for fire protection
pipes is 14 bars and if it is the maximum value among all services, then
the Manifold shall be tested at a pressure of 16.8 bars) but not less than
the discharge pressure of the pump used for the pressure testing. Test
Manifold shall comply with all the requirements prescribed in SAES – A
– 004, Paragraph 5.5.4.

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7.2.4 All pressure gauges used in this test package and in the system for the
purpose of testing shall be calibrated and the frequency of calibration
shall not exceed one month. The test pressure shall lie between 30% and
80% of the pressure gauges reading scale. The quantity of pressure
gauges shall be decided depending on the size of the network to be tested.
Normally a minimum of two pressure gauges shall be placed as close as
possible to the low point (drain) and high point (vent).

7.2.5 The PRV shall be tested, dated and tagged one week prior to test. The
validity of calibration of PRV is only for one week. The PRV shall be
regulated to requirements of test so as to relief at 5% above test pressure.

7.2.6 The calibration labels shall be available and visible on the pressure
gauges and relief valves.

7.2.7 Only portable clean water shall be used as the testing media. The
inspector shall check the quality of water from time to time. The
temperature of water shall not be less than 16oC. Quality of water to be
used for hydro test shall comply with SAES – A – 007, Paragraph 4.2

7.2.8 The piping system shall be flushed with clean water until the tested
portion of pipe network is free from foreign materials/debris.

7.2.9 The tested portion of pipe work shall be properly supported and
inspected prior to the test.

7.2.10 Approval for formal pressure test application shall be issued from SAPID
Inspector prior to commencing the pressure test via RFI.

7.2.11 All openings except test medium inlet and vent opening shall be closed
using correct rating plugs, caps or other suitable means.

7.2.12 All welded joints are to be exposed (no tape / paint etc.) as required, to
conduct the test & associated inspection.

7.2.13 The following components shall be removed, replaced with temporary

piece or isolated from pipe work, according to the hydro test package:

7.2.13.1 Orifice Plate

7.2.13.2 Filter Element
7.2.13.3 Temporary Strainer
7.2.13.4 Safety & Relief Valve (Permanent)
7.2.13.5 Rupture Disk
7.2.13.6 Expansion Joint

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7.2.13.7 In-line instruments (If piping has been flushed prior to

Testing, on/off valve may be remain in line, but valve shall
be kept open during test and flushing activities)
7.2.13.8 Pressure Gauge (Permanent)
7.2.13.9 Temporary Gauges
7.2.13.10 Stream Trap
7.2.13.11 Mixing Nozzle & Mixers
7.2.13.12 Check Valve discs: shall be removed and securely attached
to the outside of check valve prior to pressure test
7.2.13.13 Soft Seated ball and plug valve
7.2.13.14 Equipments that cannot be drained

7.2.14 All Vents and other connections that can serve as vents shall be opened to
purge all possible air pocket while the pipeline is being filled with hydro
test fluid. Fill from lowest point to minimize trapped air.

7.2.15 For buried pipes, Sand bags shall be laid over the pipe to avoid
displacements of the pipe during pressurization.

7.3 APPLICATION OF PRESSURE:-

7.3.1 Test pressure and duration (Holding Time) shall be as specified in the
applicable SAES e.g. SAES – B – 017 for Fire Water Systems and SAES –
S – 070 for Utility Piping. Refer to Attachment II: a Table summarizing
the required test pressure and duration for all piping services requiring
pressure test.

7.3.2 Water shall be filled from the lowest point in the system using the
approved test package only.

7.3.3 The hydro-test pressure shall be increased steadily, in stages. It should

not be raised directly to the test pressure. The incremental stages will be
as agreed with Inspector, based upon test pressures and the size /
complexity of the test. Usually this is 40% and 95% respectively. At each
step, the test will be held for a minimum of 10 minutes (or as long as it
takes to walk and check the line for leaks). This will allow pipe stresses to
be minimized, and any leaks can be observed on time.

7.3.4 Vents & Drains used only for the pressure test shall be plugged.

7.3.5 Inspection for leakage or other visible defects shall be done on all joints
and connections.

7.3.6 If the test result is successful permission for discharging the test media
from the system shall be issued by SAPID Inspector.

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7.3.7 If a leak was detected in a welded joint the system shall be drained in
order to allow repairing, then the test shall be repeated until the test is
successful.

7.4 DISCHARGING TEST FLUID:-

7.4.1 After completion of the hydrostatic test, vents and drains shall be opened
to remove all test fluid from the system.

7.4.2 The test media (water) shall be discharged safely (as per SAEP-327) into
the nearest drain by opening the valve gradually.

7.5 TEST COMPLETION:-

7.5.1 After completion of test, all accessories and equipments, which were on
the pipe network for the purpose of testing, shall be removed and
permanent equipments/fittings shall be reinstalled.

7.5.2 Vents & drain used for the purpose of testing shall be plugged.

7.5.3 The test manifold shall be disconnected from the system.

7.6 GRAVITY TEST PROCEDURE:

7.6.1 PREPARATION:-

Inspect the installed piping system to ensure that all site related work is
completed, and the following checks have been made:

7.6.1.1 Pipe Deflection shall be checked if within allowable values

7.6.1.2 Check slope and pipe elevations
7.6.1.3 Pipes to be tested should be inspected for installation prior to the
test
7.6.1.4 Visual internal inspection of piping for damage and cleanliness
shall be performed
7.6.1.5 High Points will be provided with air vents and Low points with
drains
7.6.1.6 Clean portable water shall be used as test media
7.6.1.7 External pipes shall be tested from manhole to manhole

7.6.2 TEST SEQUENCE:-

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7.6.2.1 End Caps shall be plugged in both ends of pipe, one end shall be
blinded and the other shall have two openings one for the 3m
water head pipe and the other for water filling and drainage.
7.6.2.2 Water shall be filled slowly from the lowest point till it reaches the
3m level inside the test pipe.
7.6.2.3 Test shall be conducted from manhole to manhole in case of
external network.
7.6.2.4 The test duration shall be at least for 4 hours for pipes which have
not been backfilled. For backfilled pipes, the test duration shall be
24 hours
7.6.2.5 The joints shall be visually checked for leakage
7.6.2.6 If any leakage is traced, the leaking joint shall be repaired after
draining the system
7.6.2.7 Vent pipes shall be filled to the top end for 4 hours of testing

7.6.3 DISCHARGING TEST FLUID:-

7.6.3.1 After completion of test, drain the filled water from the pipe
through the drain valve at the lowest point & all vents shall remain
open
7.6.3.2 End Caps installed for the purpose of the test shall be removed
7.6.3.3 For buried pipes, backfill the pipe line 300mm all around the pipe
with clean sand compacted by water flooding

7.6.4 HYDRO TEST FOR MANHOLE CHAMBER

Manhole chambers shall be tested separately by closing the pipe opening

and filling the manhole completely with water till top of the rim. If a leak
was traced on the joint connection with the pipe, the water shall be
drained from the manhole and the joint shall be repaired from the
interior surface of the manhole chamber. After that the test shall be
repeated until no leak is visible.
For exposed manholes, the duration of the test shall be 8 hours. And for
Backfilled manholes Test duration refer to attachment II: Table 2.

7.6.5 INSPECTIONS

Work execution Inspection and Test shall be monitored and witnessed as

per Saudi Aramco Typical Inspection Plan (SATIP) and recorded in the
Saudi Aramco Inspection check list (SAIC) as applicable.
The limited reference SATIPs and SAICs, listed in this M.S, are as a
minimum. A review of full set of SATIPs and SAICs is required.
S.O.L shall issue a written RFI 24 hour in advance of test/inspection to
permit SAPMT to verify the readiness of the test/inspection and to inform
SAPID Inspector in advance. The test packages documents shall be

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submitted to S. Aramco at least 24 Hrs prior to each time the hydro test is
conducted.

8. LOSS PREVENTION

All activities shall be preformed safely in accordance to the S.O.L approved

Safety Manual & Procedure to minimize injuries. The installers shall wear the
relevant Personal Protective Equipments (PPE) as per the safety guidelines.

The following safety precautions shall be taken,

8.1 All safety precautions will be taken & testing area shall be barricaded
with safety signs which are to be fixed on visible places, e.g. "Keep away-
Hydro test is in progress"
8.2 Only Authorized person shall stay in the Test Area during the Hydro Test
8.3 During Pressurization, all personnel shall remain outside the marked Test
Area
8.4 Saudi Aramco GI.2.102 “Pressure Testing Safely” shall be followed
8.5 Vent Line safety relief valve and bleed valve shall be vented/positioned to
a safe location

9. ATTACHMENTS

Attachment ‘I’ Diagram of Hydro Test Manifold indicating all accessories

shall be attached
Attachment ‘II’ Pressure test information sheet (SA 2642-1) and Pressure
Test report (SA 1642)

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