Method Statement for Hydro testing of ETS room

primary side and Pre-insulated piping

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DESIGN & BUILD WORKS FOR LUSAIL PLAZA
TOWERS
Project BP12A / Plot 1 – Contract: 9204
Document Discipline (Mechanical)
Method Statement for Hydro-testing of ETS room
primary side and Pre-Insulated pipes

Document Reference No. Rev Rev. Date Purpose of Issue

9204-BP12A-MMJV-MST-ME-NS-000-00032 000 10-03-2022 Issued for Approval

Prepared by Checked by Reviewed by Approved by

Hasan K. Koen De Rooy /

Print Name Ziad Manasfi N. R. Amaral
Bayrac Johny Ibrahim
Technical / Project Technical Project Director OR
Job Title Method
Manager
HSE Manager QA/QC Manager
Dy. Project Director
Engineer

Signature

Date

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Revision History:

Revision Revision Date Description of / Reason for Change

000 10-03-2022 Issued for Approval

Controlled copy issue log:

NB: This is only applicable to copies issued outside the EDMS (Aconex)

This document has been issued in a controlled manner to the following recipients:

(In the event of a revision, the parties listed are to be issued with the updated version)

Copy No. Company Name Representative

TABLE OF CONTENTS

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1. Description of works
2. Introduction
3. Definitions
4. References
5. Logistics
6. Responsibilities / supervision
7. Procedures / method to be employed
8. Training
9. Working hours
10. House keeping
11. Manpower requirement
12. Material requirement
13. Plant & equipment requirement
14. Q .c approvals and other documentation
15. Supporting documentation
16. Distribution
17. Other information
18. Site safety engineers comments / approval
19. Environment and quality issues
20. Attachments
1. RISK ASSESSMENT
2. INSPECTION & TEST PLAN

1. Description of Works
This Method Statement defines the sequence and describes the Hydro testing of ETS
Room primary side and Pre- Insulated pipes for Lusail Plaza Towers project to the
satisfaction and approval of Consultants/ Marafaq Authority.

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The purpose of this method statement is to describe in detail about the method of
testing in a safe manner and in accordance with the authority requirements meeting
quality assurance / control standards. And works are offered for inspections to meet
specified conformance which will be verified and documented for- Lusail Plaza Towers
project to the approval of the client/consultant/by meeting “Marafeq” regulations.

2. Introduction
This method statement ensures that all works are carried out in a safe manner in accordance
with the contract/authority specifications and approved shop drawings. Works are inspected,
and conformance is verified and documented, furthermore all works shall be carried out as per
the approval project health and Safety Plan.

3. Definitions
 LREDC Developer / Client
 LB-QPM Project Management
 DAR Supervising Consultant
 MMJV Main Contractor
 CM Construction Manager
 QC Quality Control
 HSE Health Safety & Environment
 PPE Personal Protective Equipment

4. Reference
This method statement is subject to the requirements as stated in the following
regulatory & statutory documents, applicable standards / specifications / building
codes:

 Lusail development regulations Document No.: 9204-BP12A-MMJV-MST- ST-NS-000-

00032-Rev.000.
 Project Specification Volume 03,Section 22 - 22.2.26
 Relevant Sections of QCS2014, ASHRAE/BS/BSRIA
Regulations Project approved Schematic/Shop layouts

5. Logistics
MEP Sub-Contractor will deploy a dedicated team for the required logistics and
piping/flushing materials movement in -out…..

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6. Responsibilities / Method to be Employed

MEP Project Manager

Project Engineer

Site Engineer / supervisor

QAQC Engineer

HSE / Safety officer

6.1. MEP Project Manager:

The MEP project manager shall be responsible for overall project planning,
procurement, technical submissions and drawing submissions,
The MEP project manager shall coordinate activities within the site team and with the
management for the timely completion of activity in accordance with contract requirements

6.2. DISCIPLINE /Project Engineer:

The Project engineer for each discipline shall be responsible for the execution of complete
system in accordance with project requirements. He will be responsible for the day to day
activities on site, for materials, drawings, testing & commissioning and allocation of
departmental resources to work areas on site. Project engineer will report to MEP project
Manager.
The project engineer shall coordinate all related mep system activities with all other trades for
progress monitoring.

6.3. Site Engineer:

The site engineer is responsible to carry out the work as per approved shop drawings and
method statements. He is also responsible to ensure adequate tool kits required for the works
are in place prior to the starting of work. The site engineer reports to Construction Manager.

The site Engineer is responsible to ensure work has been done as per the specification and
drawings; inspections are carried out based on ITP and quality control procedure and
coordinate with QA/QC department for PMC OR M/s AEB inspections.
The site engineer is responsible to ensure that all safety precautions are ensured in place, and
that all personal on site are using the required personal protective equipment like helmet,
gloves, shoes, and reflective jackets. The site engineer in coordination with safety officers will
ensure all relevant permissions are taken prior to commencement of works.

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6.4. Supervisor/FOreman:

The supervisor / foreman is directly responsible for the day to day installation works on site,
The supervisor / foreman will complete all the work in coordination with technicians / skilled
or any other staff / work force assigned. The supervisor / foreman will report to site engineer.

6.5. QA/QC Department:

QA /QC department will be responsible for overseeing the quality requirements and
quality control measures for the project in coordination with project engineer and
construction manager.

6.6. HSE Officer:

The HSE officer will be responsible for the safety, health and environmental aspects on site
as per the project safety and environmental requirements / safety standards in
coordination with project engineer and construction manager.

7. Procedures / Method to be employed

7.1. Hydro static (leak) Testing:
Completed portions or sections of Chilled water service pipes are tested in accordance with
following test procedure. All pipework shall be tested hydraulically after assembly on site
and before any insulation is applied or pipework made inaccessible by building cladding, to a
maximum pressure stipulated by requirements of Lusail ‐Marafaq authority [pressure to the
level stated below Test pressure, 23 bar (2300 kPa)] & Pressure holding time shall be 6 hours,
before the inspection of joints.

 Pressure and temperature shall be recorded every hour in an approved hydro test record sheet.
Ref Attachment 1
 Identify the portion of piping circuit to be tested, with reference to shop drawings.
 Check physically whether all joints are completed/finished properly.
 The dead ends and outlets to be plugged/ temporarily looped for test purposes
 Connect a temporary testing line with a calibrated pressure gauge. Ensure that the
components in the circuit are capable of withstanding the testing pressure i.e. pipes, fittings,
valves, Flexible Connectors etc. if any.
 Once the above is checked and found okay, then proceed with the filling of water from the
lowest point of the circuit. This is to ensure that the air from the system is released to avoid
any fluctuations in pressure. The air is to be vented at the highest point by means of air vents
or alternatively partially open valves, where air vents do not exist during partial system being
tested.
 Establish the pressure to be applied by verifying the design/actual system pressure.
 Inspect the entire pipe length physically for any leaks. If any leaks are detected then, the
system water to be drained and the leaks to be attended to prior to proceeding further.
 After rectification of the leaks repeat the testing procedures.
 The start time of the pressure test is to be recorded and the pressure is to be held for a pre
agreed period of time as directed by Inspection engineer depending the project
safety/clearance requirements to a max notice of 24 Hours.
Initial test records shall be offered for consultant verifications, hold test pressure for entire test duration.

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 Ensure that the final inspections/verifications to confirm no leaks are carried out under
similar temperature conditions to avoid fluctuations in pressure due to variations in
ambient temperature.
All tests are recorded as per enclosed pressure test records/check lists. Ref Attachment 1

8. Training
All Required training for stipulated activities are provided to all operative staff for ensuring a
quality workmanship

10. WORKING HOURS

Site operational time shall be followed as per project progress requirements, all relevant local
authority schedules of holidays are to be observed.

11. HOUSE KEEPING

Working Areas will be kept clean by disposing the waste materials at the designated areas.
At the end of days’ work, installation supervisor will ensure that the debris are disposed off. On
regular basis.

12. MANPOWER REQUIREMENT

Subject to main contractors programmer and scope/area available for MEP activities, but not
limiting to below:
Supervisors, Foremen
Charge hands, Arc Welders, pipe fitters
Assistant fitters, Insulators, asst. Insulators, aluminum Cladding
workers Helpers
13. MATERIAL REQUIREMENT
Ensure material being used is of approved manufacturer from project vendor list and of
quality as specified.
Black steel pipes/Pre-insulated pipes etc. &fittings, accessories required –gaskets/ thread seal
compounds etc.

14. PLANT & EQUIPMENT REQUIREMENT

General Tools/equipment involved in chilled water piping but not limited to following,
o Electric Arc Welding machine, Drilling Machines Electrodes – E 6010, Electrodes – E 7018
o Oxy‐Acetylene Cylinder with back flash arrester‐Gas cutter (Oxy‐acetylene)
o Welding Machine, Electric Oven for rods, Cut/Grinding Machine
Hand Tools, (hammer, wrench, pliers, spanners, screwdrivers etc.

o Chain Block, Threading /grooving machine

o Spirit level, water level, Chalk line/chalk powder
o Pressure testing pump, Certified Calibrated pressure gauges

15. QC APPROVAL AND OTHER DOCUMENTRY REQUIREMENTS:

Follow approved Method Statement, ITP, QCP, HSE Plan, and Material/Drg. Approval &
Checklist.

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16. SUPPORTING DOCUMENTATION:
This MS to be read in conjunction with the referenced documents,
Relevant Contract Specification along with approved shop detailed layouts/ drawings.

Project Quality Plan, Project HSE Plan.

17. DISTRIBUTION
Copies of this MS will be circulated to the following for Information &
action Sr. Construction Manager
Site
Engineer
QA/QC
Engineer
HSE
Engineer

18. OTHER INFORMATION‐N/A

Ensure that all the activities have been carried out to suit the site conditions and
involved With Site –in – charge /discipline supervisors

19. MAIN CONTRACTORS SAFETY ENGINEERS APPROVAL FORMAT FOR ACTIVITY

Any Arc welding/Gas torch cutting related OR hot work activity shall be followed as per hot
work permit approvals ref. attached format, which needs 24 Hr. notifications for approvals
APPROVAL STATUS SIGNATURE
Approved
Approved subject to compliance with
the following notes
Not Approved – with reason

20. Environment and Quality Issues

20.1. Precautionary Measure
All precautionary measures shall be briefed to all workers prior to commence activity

20.2 Inspection, Test and Sampling

Request for Inspection and Testing will be submitted prior and after execution of
works.

20.3. Quality Assurance Requirements Table

Ensure that work is executed as per approved shop drawing; method statement and records
are generated referring to approved ITP (Appendix C).
Best management practices shall also be considered which may be stated by product
manufacturer or suppliers.
Authority requirement will take precedence over all requirements in case authority approval
is to be secured. For non-authority approval activities, approved latest project specification
will take precedence.

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It is to be ensure that regular tool box trainings related work quality are conducted and
records are maintained.

21. List of Appendices

Appendix A: Risk Assessment
Appendix B: Inspection and Test Plan (ITP)
1

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1. Appendix A: Risk Assessment

Risk Assessment and Job Hazard

Analysis where applicable

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Risk assessment Risk assessment
(before controls) (after controls)

Likeliho

Likeliho
Activities (check Controls to be implemented

Severi

Severi
Who affected Hazards

factor

factor
all that apply) Risk (mitigation measures) Risk

Risk

Risk
ty

ty
od

od
level level

1. To prevent joint or pipe section failure, fix

brackets close enough together to prevent
excessive movement.
2. Don't exceed pipe operating pressure
3. Ensure that no entry of unauthorized
persons to the area under test.
4. Use calibrated gauges only
5. Ensure pipe not damaged
6. Ensure adequate support where change in
direction or reducer occurs.
7. Fire protection and first-aid equipment will be
available before testing begins.
1. Explosion 8. Ensure the require PPEs are use.
1. Pressure Testing Workers 2. Injury from ejected materials & fittings 2 3 6 6 9. Vulnerable items such as meters and pressure 1 3 3 3
3. Leakage of hazardous substances. switches will be removed.
10. Valid permit to work system will be
obtained prior to operation.
11. The manager or supervisor will carry out an
inspection of the system before starting to test, to
ensure that isolations, blanks and other specified
safety devices are in place before any testing
begins.
12. All operatives will be briefed on the
hazards, precautions and emergency
procedures, before testing starts.
13. Ensure proper equipment's, trained personnel
are engage in the task and safe work procedure are
followed.

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Risk assessment Risk assessment
(before controls) (after controls)
Activities Controls to be implemented

Risk factor

Risk factor
Likelihood

Likelihood
Who affected Hazards

Severity

Severity
(check all that apply) Risk (mitigation measures) Risk
level level

14. Ensure STARRT and/or RAMS are

discussed with the work group prior to
work commencing.
15. Trained, Competent and Authorised
Supervision present at all times to ensure
employees are adhering to safe working
procedure.
16. Work area to be isolated/barricaded
1. Explosion
(potential major risk for ejected material &
1. Pressure Testing Workers 2. Injury from ejected materials & fittings 2 3 6 6 1 3 3 3
fittings & Water) with static guards in place.
3. Leakage of hazardous substances.
17. Good communication to all involves
operatives.
18. Lock out tag out procedure.
19. Isolation of electrical services whilst
conducting water pressure testing.
20. Only authorized, trained/experienced
and competent persons will carry out
pressure testing.

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Risk assessment Risk assessment
(before controls) (after controls)
Activities Controls to be implemented

Risk factor

Risk factor
Likelihood

Likelihood
Who affected Hazards

Severity

Severity
(check all that apply) Risk (mitigation measures) Risk
level level

Severity
1 2 3 4 5
1 - No potential for injury, illness, or incident. 1 - Very Unlikely
2 4 6 8 10
2 - Potential for minor injury, illness, or incident. 2 - Unlikely
3 6 9 12 15
4 8 12 16 20 3 - Potential for a recordable injury, illness, or incident. 3 - Likely
5 10 15 20 25 4 - Potential for major incident, or major injury or illness causing short term disability. 4 - Very Likely
Low 5 - Potential for major incident, or major injury or illness causing a fatality or long term disability. 5 - Certain
Medium
High

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Inspection and Test Plan (ITP)

with applicable Checklists

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Appendix B: Inspection and Test Plan
Project Main contractor

Lusail Plaza Towers (BP12) - Plot 1 (BP 12A); Contract#: 9204

I T P – Method statement for ETS room primary side and Pre-insulated pipes
PROJECT LUSAIL PLAZA TOWER (BP12A) CONTRACT #: 9204 REVISION - 000
Document No. 9204-BP12A-MMJV-MST-ST-NS-000-00032- Rev.000
ACTIVITY ACTIVITY REF./VERIFY DOCUMENTS ACCEPTANCE INSPECTION & ACCEPTANCE
FREQUENCY
NO. DESCRIPTION CRITERIA
QA/QC IDC AEB Marafeq

1 Testing: Inspection Request

1.1 Ensure the pipe joints leak proof Marafeq approved method H H W
statement for hydro test During tests test data forms
1.2 Hydrostatic Testing of CHW pipe to As per approved shop drawing Inspection H H W
ensure tightness [Link]
Method Statement
1.3 Ensure calibration of PR gauges Third party calibration cert. Installation test preparations calibrations H H R
Hourly record of pressure( min 6hr) Marafeq specifications
Legends: H- Hold point (Notification required, presence mandatory) W- Witness point (Notification required, presence not required) S- Surveillance
R- review of document I- inspection/ test

Prepared By: Reviewed and Endorsed for Consultant Approval Approved By:

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Mark Anthony G. Esguerra Helen C. Aguinillo Hasan Kemal Bayrac

Architect (Methods) Sr. QAQC Engineer QA/QC Manager Consultant

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Project Logo
Project Name : LUSAIL PLAZA TOWER (BP12A) CONTRACT #: 9204
Document No. : 9204-BP12A-MMJV-MST-ST-NS-000-00032- Rev.000

ETS ROOM PRIMARY SIDE

PRESSURE TEST REPORT IR Ref. No.: Level/Area/Location : form no‐
Date of Inspection : Drawing Ref. No.: 9204-BP12A-MMJV-MST-ST-NS-000-00032- Rev.000
Specs. Ref. No. :

The lines/system listed above and designated by the test limits as shown on the attached drawings have been
Pressure tested in accordance with the relevant specification and the conditions here under.
TEST CONDITIONS
(max 50 deg c)
TEST MEDIUM CLEAN WATER Ambient temp

System work pressure: 16 Bar

Test time recorded : 9.00am 10.00am 11.00am 12.00am 1.00 pm 2.00 pm
Recorded pressure : P 1-23 bar
P 2-

Start pressure : Finish pressure

Min. Hold time : 2Hr Actual Hold time

Pressure Relief Valve No: P.R.V. Set Pressure:

Start Time : Finish Time

Test Gauge
Test Gauge ref / No. Date Last Calibrated Calibration due
Range
High
w

B
comments:‐

We the under signed have witnessed the pressure test as recorded above on the Pressure Piping Test Pack

Performed by MMJV Approved by- dar Witnessed by MARAFEQ PASS FAIL

Signature

Name

Date

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