Chilled Water Pipe Pressure Testing Method Statement

Below is a precise method statement covering the chilled water piping hydrostatic pressure testing.

Below are general requirements:

Prior to water pressure test WIR will be raised as per project requirements for approval of installation of CHW piping work.

Inspection request for pressure testing will be raised with piping portion highlighted on drawing plan offered for testing inspection.

Chilled water piping shall be tested at the 1.5 times of working pressure for minimum 2 hours and final testing with complete system should be for 4 hours.

In case of pressure drop the leak points should be identified and any faulty fittings shall be replaced with new fittings and repeat the testing procedure, after conforming internally, offer for client/consultant inspections.

Estimate the piping volume and make arrangement for required quantity of clean water.

Trained personnel will conduct the test monitored by a responsible site engineer and safety department personnel.

Arrange for test plug, temporary piping / hose pipe connections for filling and draining the water.

Strict and close supervision is necessary before, during, and after the test so to minimize water damage and/or unnecessary stains to finished items within the confines of testing location.

Always coordinate with safety and construction departments for a safe and methodical conduct of testing works.

All other MEP discipline supervisory staff shall be informed by concerned site engineer before carrying out the tests for precautionary measures to protect other MEP services.

Setting Up the Equipment

Place visible signage i.e. “System Under Pressure”, “Keep Away”, “Danger ”, “Caution”

Warning notices and barricades (if deemed necessary) will be used to identify the system under test.

Protection from Water Damage

Eliminate possible sources of water spillages.

Where potential sources of leakage during the test, such as pipe to fitting joints, is above or nearby a finished item, provide adequate protective shield to minimize damage due to water.

Furnish adequate number of personnel with two-way radio and working flashlights, during the filling up with water to the pipes under test for monitoring the pipe joints, they will provide early warning of any leaking point.

When a leaking point is known, immediately inform the site supervisor depressurize the pipelines under test.

Inform client to examine the damaged coating section of pipe before and after repair.

Repairing of Leaks

During initial filling, employ sufficient man power to monitor the entire length of piping system for possible leakages.

If leakages are observed, arrest the leakages immediately.

In case the leakages are major, isolate the leaking portion with nearest isolating valve and / or stop the water filling.

Rectify the leakages and again fill the water.

Examine clearly the source of noted leak.

If the leak is coming from joints/fittings, drain the pipeline and check the joints/fittings of each pipe.

Also check the fitting for any scratch or internal surface damage.

Replace the fitting if necessary.Chilled Water Pipe Pressure Testing Method Statement

In some cases, leaks come from a pipe end plug, in that case drain the pipeline and unscrew the plug, examine closely its threads, if damaged, replace such plug.

Physically inspect the entire circuit for any leaks. If any leaks are detected then they are to be attended prior to proceeding further.

Leaks and repairs (if any) will be repaired as necessary and pipe work will be retested.

Repeat the leak test procedure after clearing the leaks (if any).

Consultant shall be notified in advance, as per agreed procedures and/or contract requirements, to witness the test by issuing an inspection request.

Site Engineer shall ascertain that the pipeline under test is leak proof while coordinating with QC for the consultant site inspection and/or witnessing the test.

QC engineer shall inform the consultant for the testing being conducted.

The consultant shall, on his discretion, witness the whole testing process up to satisfying the design and specification requirements.

All tests result shall be recorded in the format as per approved QC procedure / documentation.

Provide a safe and adequate disposal of test water after successful water pressure test.

Make sure that test water disposal is carried out without damaging any finished item, and to ascertain that it will not cause any untoward incident.

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