Leak Test Safety Procedure

8/11/2019 Leak Test Safety Procedure

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LEAK TEST PROCEDURE

All piping shall be pressure tested after the construction and before being place in operation to prove it has

adequate strength for the propose and that it does not leak. Testing shall not commerce until at last joint to allow

sufficient time for the joint to cool.

External Piping (from outlet of service station to valve

1) Close and plug or cap all opening completed lines.

2)

) !ressuri"ed each completed line to a pressure of #$ psi measure with a pressure gauge.

%point A and point &)

') Testing medium ( itrogen

*) The piping will be checked with soap and water solution.

+) The pressure will be held for a period of 2' hours. ,f there is no visible loss of pressure after 2' hours-

the line will be deemed to be gas tight.

) ,f a pressure gauge indicated the pressure drop- the testing operations connection and shut(off valvebe first rechecked for leak and tightened as necessar/.

0) ,f a pressure drop is still evident- then all joints and lastl/ the piping it self will be checked with soap

and water solution.

#)

1$)

S!TE SA"ET# PROCEDURE

Purpose

Polic$ Statement % O&'ectives

,nstall pressure gauge %$ ( $$ psig) to each completed line for pressure indication %refer to figure 1)

3astech 4ngineering 5dn. &hd. representative%s) shall carr/ out the testing work.

The representative%s) of 677!- 3as 8ala/sia 5dn. &hd. and 9wner will witness the testing work.

This chapter sets out the principles for the organi"ation of safet/ in all aspects of 3astech 4ngineering

5dn. &hd. operations in accordance with 3astech 4ngineering 5dn. &hd. polic/ on safet/.

The requirements of this chapter will appl/ equall/ to subcontractors working for 3astech 4ngineering

5dn. &hd. in its areas of operation as 3astech 4ngineering 5dn. &hd. organi"ation.

3astech 4ngineering 5dn. &hd. polic/ of safet/- health and environment.


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8aintain good housekeeping in all areas under their control.

Su&+contractor*s Responsi&ilit$

The sub(contractor:s emplo/ee shall be made full/ aware of the safet/ regulation applicable to

the work site including the work s/stem e.g. smoking regulation- welding- cutting etc.

The sub(contractor shall ensure that its emplo/ees are provided with the appropriate safet/ and

personal protection equipment.

,or-er*s Responsi&ilit$

Carr/ out their duties in a safe manner and with due regard to health and incidents.

?eport all ha"ard condition to their immediate supervisor without dela/.

ear protective equipment correctl/ as and when required and maintain these in good order.

.eneral Safet$ Re/uirements

Prevention of Accients

Accidents are unwanted or une>pected occurrences generall/

cause b/ persons indulging in unsafe practices or

create unsafe conditions

or used of unsafe equipment

All accident can be prevent if personal conscientiousl/ tr/ to avoid and eliminate unsafe practices

= conditions

E0ER# PEOPLE 1AS T1E RESPO2S!3!L!T# TO ACT POS!T!0EL# TO

PRE0E2T ACC!DE2T "RO) OCCURR!2.4

1ouse Keeping

3ood housekeeping at all work areas is essential to accident:s prevention of injuries and fires.

?emoves all scar- broken or unwanted parts of equipment from works areas.

!laces steel bars- cables properl/ to avoid tripping ha"ards

Clean up spillages immediatel/.

Personal Protective E/uipment

Alwa/s use personal protective equipment when the job and the condition warrant is use

9ccasional visitor can be e>emption from wearing safet/ footwear

@se of other personal safet/ apparel- such as goggles- gloves etc. is mandator/ when the

circumstances distaste this.

Tools % E/uipment5 )ac6iner$

A visual inspection should be made each da/- or before each use- and < or b/ the user to ensure

!rotective footwear must be worn at worksite


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that tools = equipment are in safe operation conditions.

Area of ?estricted Access

or safet/ and securit/ reasons- the site to which access is restricted.

5moking is strictl/ prohibited at site.

Alco6ol % Drugs

,t is strictl/ for forbidden to consume or be in of alcohol and drugs at site.

ire ighting 4quipment

!ortable carbon dio>ide fire e>tinguisher is provided

"irst Ai

,f an accidents occur and there are people injured- the first priorit/ is to save lives. An/ injured person

should be given prompt first(aid treatment and such medical attention as ma/ be necessar/.

irst(aid kit is to be displa/ed in the site office.

Engineering Construction

Cutting = elding %abrication of !iping)

o unauthori"ed person shall be allowed to use welding equipment.

!ersonal protective equipment must be worn during welding = cutting which shall included goggles-

face shield.

hen welding is cutting = welding on a line- no one should work in front of near the open end.

Current must be turned off when equipment is not use for a period of time.

,n changing welding electrodes- care must be taken to avoid making contact with other sides of thecircuit.

elding is done in restricted area. ever attempt an/ work which is out side the parameters of the

work barrier.

Civil ,or-s (2ot in t6is scope

9nl/ personal who are ph/sicall/ suitable can be emplo/ed for the jobs.

Assembl/ and installation

o smoking shall be allowed within or in the vicinit/ of works site.

8atches or lighters is prohibited

Buring installation of service stations- do not works or walk under the load of crane in operation.

o welding is allowed.

Accients % Emergencies

5tatuar/ ?equirements

There are several enactments in the states relating to statutor/ requirements in the reporting of

accidents. The principle of these are ;(


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orkmen:s Compensation Act

= 8 Act

?eporting !rocedure for accident- fire emergencies

All workers witnessing in accident should inform their supervisor as soon as possible.

,n the case of accident- the site personal concerned must make a report.

CO))!SS!O2!2. PROCEDURE

.E2ERAL

SCOPE

This document describes the general procedure information and instruction necessar/ for the

commissioning of gas pipeline s/stem.

RE.ULAT!O25 CODES % STA2DARDS

All labour- material and equipment shall be governed b/ the latest applicable codes and standard.

A5, &1.0 3as Transmission and Bistribution !iping 5/stem

85 0$ Code of !ractice for 5torage- Dandling and Transportation of

85 #$ Code f !ractice for the installation of uel 3as !iping 5/stem

And Appliances.

3as 5uppl/ ?egulations 1##

The labor 9rdinance

iquidfied !etroleum 3ases.

5uruhanja/a Tenaga


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CO))!SS!O2!2. OR.A2!7AT!O2

CO))!SS!O2!2. E2.!2EER

of the entire operation. C,4T shall nominate an individual who will be the C,4T commissioning

coordinator with particular responsibilit/ for the commissioning phase.

The commissioning engineer will be responsible for the planning- organi"ation and supervision of

all activities from the stage of pre(commissioning to commissioning- assisted b/ his team of engineer-

The commissioning engineer will be responsible for all interfacing with C,4T commissioning

coordinator.

CO))!SS!O2!2. PERSO22EL

or commissioning purposes- the following shall be the minimum requirement ;(

ii) Client ?epresentative 1 no %C,4T)

iii) 3eneral orkers

9ne group will be situated at the gas injection point with the other group at the end of a

commissioning section.

The commissioning engineer will take full charge of the commissioning activit/ from the central control

initiall/ at the source of the gas i.e. at the e>isting future take(off and when appropriate- be relocated

to locations along the pipeline s/stem or at the downstream interface- as and when deemed necessar/

b/ the chief commissioning engineer.

CO))U2!CAT!O2

Communication between the various groups engaged in commissioning will be via multi(channel

radio s/stem and < or mobile telecommunication s/stem.

As a minimum- communication equipment will be provided to as follow ;(

Commissioning 4ngineer

,ndividual 3roup eader

?eference Test 3auges ocations

This telecommunication equipment will be manned continuall/ during the entire commissioning

operationE communication traffic will be restricted to messages directl/ related to commissioning.

2OT!"!CAT!O2 O" AUT1OR!T#

The !olice- ire Authorities and all other relevant parties shall be given advance notice of the dates

of the commissioning operations.

SA"ET# CODE O" PRACT!CE "OR CO))!SS!O2!2.

SCOPE

This section provides a general guide to safe practice during commissioning to take reasonable care

for the health and safet/ of himself and of other person who ma/ be affected b/ his acts or omissions.

,t is therefore the person:s dut/ to;(

Alwa/s adhere to safet/ regulations.

Alwa/s use the procedures and methods of operation laid down in this procedure and the local rules

and regulations.

3astech 4ngineering 5dn. &hd. will nominate a Commissioning 4ngineer and will have sole change

supervisors- technicians- vendor representations and laborers etc.

i) 3roup eader 1 no % 3astech 4ngineering 5dn. &hd.)

no % 3astech 4ngineering 5dn. &hd.)


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Alwa/s use the correct tools and equipment for the job- and wear the correct protective clothing.

,mmediatel/ report an/ ha"ard to the appropriate authorit/.

ever operate valves- unless instructed to do so- or as part of his duties.

Commissioning engineer acting in a supervisor/ capacit/ have the added responsibilit/ of making sure

that all person under their control or direction are aware of the safet/ regulations- work procedure

and equipment provided for their protection- and that the/ are properl/ used. hen acting in a

supervisor/ capacit/ the/ must therefore;(

Dave a detailed knowledge of safet/ regulations.

,nclude in all routine orders- specific instructions regarding safet/.

?estrain personnel from taking unnecessar/ risks.

4nsure that all personnel under their control or direction are familiar with safet/ requirement of the

job.

5top an/ dangerous work practice immediatel/ and report an/ such actions to the appropriate

authorit/.

?ectif/ or report an/ defect in plant or equipment that ma/ affect safet/ taking an/ necessar/.

5et a personal e>ample in good safet/ practice at all time.

These recommendations are supplementar/ to the Construction 5afet/ ,nstructions and the

directions from the 5afet/ 9fficer.

SA"ET# O""!CER

The 5afet/ 9fficer will be responsible for all aspect of safet/ control and prevention of accidents

during the testing- commissioning and hand(over operations period.

Responsi&ilities

The safet/ office shall take overall responsibilit/ for the enforcement of the 5afet/ ?egulation and

other safe working practices contained in these !rocedures including ;(

Co(ordination of safet/ measure where construction work has- of necessit/- to be carried out

alongside machiner/ and equipment under test or being commissioned.

4nsuring that- before entr/ onto the site- all supervisor/- construction and operating personnel

are full/ conversant with the 5afet/ ?egulations on work procedures in force.

4nsuring that all personnel are equipped with and use of appropriate protective clothing and that

all ha"ard warning signs and devices- notices and barriers are installed and maintained.

Carr/ out routine inspection on fire fighting equipment and first aid facilities- and check these

are in place and are properl/ serviced.

5topping an/ dangerous work practice and immediatel/ reporting them to the commissioning

engineer.


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1OUSEKEEP!2.

The 5afet/ 9ffice shall be responsible for ensuring the following ;(

loors- walkwa/s and stairwa/s are kept free from obstructions at all times.

9il spillage and similar ha"ard are cleaned up immediatel/.

?efuse bins are provided and marked clearl/ to separate metal scrap- refuse from an/ material

liable to spontaneous combustion- arrangements are made for the regular empt/ing and safe

disposal of the contents.

5uitable notices should be prominentl/ displa/ed to warn personnel of regulations regarding access.

naked lights- smoking or other ha"ards.

,ORK PER)!TS

A ork !ermit 5/stem should be introduced at the commencement of commissioning. 9ne specific

have been introduced into a work area- work shall not commence until a work permit has been issued

b/ the commissioning engineer.

The objective of the permit to work s/stem will be to protect personnel working in ha"ardous areas

such that ;(

9nl/ the central authorit/- at a time- can issue permits to allow personnel working in ha"ardous area.

9nl/ personnel involved in the task and covered b/ the permit can enter the area.

All personnel concerned are made aware of the ha"ards involved and measure to be taken.

The area is clearl/ defined.

The right of personnel to enter and work in the area is limited to a stated time.

Adequate suitable protective clothing and equipment are provided and used.

)ED!CAL SER0!CES

Adequate medical and first aid facilities shall be available at an/ location where commissioning work

is in progress to provide prompt treatment of injuries.

The safet/ officer shall also ensure that evacuation transport facilities are available on a standb/

basis in the event of an emergenc/ occurring during pre(commissioning and commissioning.

OPERAT!O2 SA"ET#

All personnel involved with the commissioning operations should be familiar with the safe action to

take under emergenc/ condition.

report the emergenc/ to the commissioning engineer and safet/ officer for assistance if required.

All personnel- other than those assigned to fire fighting duties- shall assemble outside the main

e>it gate for a head count.

All personnel to be accounted for and na/ injured persons removed to safet/. An/ mission personnel

to be located quickl/ b/ a s/stematic search b/ a nominated search team.

,n case of emergenc/- conditions %fire- e>plosion- gas leak- etc) the following action is required.


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All fire fighting facilities to be manned.

,nvestigate damage- repair and return the station to operational status.

)ATER!AL RE8U!RE)E2T

The following list of materials- consumable items- tools and equipment represent the basic

requirement of the commissioning activities ;(

Fendor drawing and operating manuals- if required. %A complete set available at the central

commissioning control location and relevant documents).

4quipment test and inspection Certificate to be available for disposal b/ the commissioning

engineer.

5uitable range of hand tools- spanners- socket sets etc. %9n set each for the central commissioning

control location and individual commissioning groups).

ubrication equipment- grease guns- lubricant etc. %one set each for the central commissioning

control location and individual commissioning groups).

1 unit of o>/gen detector.

Communication 4quipment ( 8ulti channel radio s/stem and < or mobile telecommunication s/stem.

G5noop/G leak detection fluid.

SC1EDULE O" OPERAT!O2

STATUS PR!OR TO CO))!SS!O2!2.

Commissioning can commence onl/ after ;

D/drostatic < pneumatic testing completed.

unctional testing of all equipment completed.

Commissioning site cleaned.

PUR.!2. O" T1E P!PEL!2E S#STE) O" A!R

ith all pre(commissioning activities completed to the satisfaction of the commissioning engineer-

and all liaison with upstream and downstream interface in(place- the commissioning engineer ma/

start purging the pipeline s/stem of dr/ air with the introduction of nitrogen to flood the entire

pipeline s/stem.

9nce the entire pipeline s/stem is purged until free of air- natural gas will then be introduced in

sections. !ressuri"ation of the pipeline sections will be steps to facilitate leak(checking e>ercise. 9nce

the pipeline is full/ pressuri"ed- we will purge the s/stem until 1$$H 4 is achieved.

&ranch pipe work connection associated with the main pipeline s/stem will be purged separatel/

of nitrogen.

A detail commissioning procedure shall be forwarded prior to the proceedings.

Leak Test Safety Procedure

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