272488010 Leak Test Procedure

West Qurna Field 2nd
Phase Project
(Early Oil Phase)
DOC. TITLE
DOC. NO.
Method Statement for Gross Air Leak Test

of Well Pad # 5 (WU105)
Page
Rev.
1 of 26
00
8015-0151-SECL-00-000-CM-MS-00045
Job No.
SO2476

00
17.SEP.2013
APPROVED FOR USE
M. V. BALILO
H. S. AN
S. K. SONG
K. T. KIM
5.AUG.2013
ISSUED FOR APPROVAL
M. V. BALILO
H. S. AN
S. K. SONG
K. T. KIM
11.JUL.2013
ISSUED FOR REVIEW
M. V. BALILO
H. S. AN
S. K. SONG
K. T. KIM
REV.
DATE
STATUS
PREPARED BY
CHECKED BY
APPROVED BY
AUTHORIZED BY
This document, including any patented or patentable features, embodies confidential information of Samsung Engineering Co., Ltd. and its use is
conditioned upon the users agreement not to reproduce the document in whole or in part, nor the material described thereon, nor to use the
document for any purpose other than specifically permitted in writing by Samsung Engineering Co., Ltd.
Samsung Engineering Co., Ltd

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(Early Oil Phase)
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REVISION LIST
REV.
NO.
DATE
MADE BY
PAGE NO.
DESCRIPTION
11.JULY
2013
M.V.BALILO
ALL
Issued for Review
5.AUG
2013
M.V.BALILO
Marked in
specification
1. Added Blinds List/Removed Item List in Appendix

2. Added Temporary Pressure Gauge List in Appendix
3. Added Protection of devices in Section 6.2.
4. Added sub-system information for each package in Section 7.2
table and Appendix
5. Added hold-up time (10 min) for final test pressure in Section 7.2
6. Added information/details on marked-up P&ID
7. Added & disconnect temporary hose, repeat test and
reinstate package as per P&ID in Section 7.3
8. Added testing boundary and equipment/associated pipings for
each package
Issued for Approval
00
17.SEP
2013
M.V.BALILO
Approved for Use
Note: 1. Revision part of document is easily identified by drawing a vertical line on the right margin and
applied revision number. Also revision part of document will be written in bold.
2. Revision number shall be identified as following:
Class Revision Number
Revision code
A
B,C, -W
Issue status
IDC
IFA, IFR, IFI, IFE, IFD
00, 01...
AFC, AFP, AFU
Z
X1,
CAN
AB
Revision description
Issued for Discipline Check
Issued for Approval
Issued for Review
Issued for Information
Issued for Enquiry
Issued for Design
Approved for Construction
Approved for Procurement
Approved for Use
Cancelled
As-Built

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(Early Oil Phase)
DOC. TITLE

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DOC. NO.
INDEX
Page
1.
OBJECTIVE
2.
SCOPE
3.
REFERENCE DOCUMENTS
4.
ROLES & RESPONSIBILITIES
5.
REQUIRED EQUIPMENT & TOOLS
SAFETY PRECAUTIONS
7.
DETAILED METHOD
8.
ACCEPTANCE CRITERIA
23
9.
CHECK SHEET
24
10.
LEGEND OF SYMBOLS
25
APPENDIX I. SYSTEM BASED GROSS AIR LEAK TEST PACKAGE LIST

APPENDIX II. LEAK TEST PACKAGE MARKED UP P&ID'S
L1-105-001 ~ L1-105-006 (6 Packages)
L2-105-001 ~ L2-105-009 (9 Packages)
APPENDIX III. BLINDS LIST
APPENDIX IV. TEMPORARY PRESSURE GAUGE LIST

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1. OBJECTIVE
The purpose of this procedure is to define all the activities which are performed to
ensure the tightness of plant piping and equipment.
While the pressure tests are carried out on spools during construction in order to
verify the integrity of welds and material, the gross air leak tests are carried out on
entire systems, after flushing and cleaning operations and completion of the
installation to prove the integrity of the permanent parts such as:
-
Gaskets and other flange joints, valves packing, miscellaneous connections such
as vents, drains, safety valves, instruments, connections between systems being
tested.
Joints which temporary piping had been connected with.
Gross air leak tests must also establish that any equipment associated with the
system, which may have been previously dismantled for any reason, has been
correctly reinstalled.
2. SCOPE
2.1.
This method statement shall be applied only to the West Qurna Field 2nd phase
project
2.2.
This method statement covers the gross air leak test using dry air for the system
below :
System:
WU105-01 / WU105-02 (Well Pad # 5)
3. REFERENCE DOCUMENTS
3.1.
Pre-commissioning and Mechanical Completion Execution Plan (8015-0151-SECL00-000-CO-PE-00001)

Tightness Test Procedure (8015-0151-SECL-00-000-CO-PP-00009)
API STD 521 (Guide for Pressure-Relieving & Depressurizing Systems)
ASME B31.3 (Process Piping)
ASME BPVC Section V (Leak Testing)
Operation & Maintenance Manual
Basic Engineering Design data
Process Description
Blinds List/Removed Item List
Temporary Pressure Gauge List

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3.2.

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Related P&ID (Piping & Instrument Diagram)

Refer to attached gross air leak test marked-up P&ID.
4. ROLES & RESPONSIBILITIES

4.1
Pre-commissioning Manager is responsible for establishing methods and procedures,

coordinating with Owner and providing necessary technical support to the site to
execute the said activities on time.
4.2
Supervisors shall be directly responsible for the monitoring the activities on field and
utilizing the resources, effectively maintaining good productivity. He shall obtain
relevant work permits and approved JHA (Job Hazard Assessment) as necessary
and coordinate with Companys acceptability of gross air leak test.
4.3
Engineer / Supervisor shall be responsible for monitoring of the work progress, and
secure relevant and certified documents as part of the requirements before the said
activities begin.
4.4
Safety In-charge / Supervisor shall be responsible for site surveillance, reporting

HSE inactions, recommending corrective actions and ensuring site compliance with
the Contractors Health Safety and Environmental program.
4.5
Skilled Laborers shall be employed for the execution of works. They must
understand the extent of works to be executed, aware of the hazards involved, and
receive relevant instructions from Pre-commissioning Supervisor who is responsible
for the activity.
4.6
Tool box meetings to be conducted at the outset of each activity.
5. REQUIRED EQUIPMENT & TOOLS

5.1.
Required equipment
Instrument Air Package (12-105-00-PK-006)
Temporary connection hose, temporary ladder or scaffolding
5.2.
Tools
Personnel safety working clothes and safety tools (PPE) suitable for activity
Walkie talkie
Portable wrench & hand tools
Soap solution (for bubble test) and sponge

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DOC. NO.
6. SAFETY PRECAUTIONS
6.1.
The safety measures such as warning sign, barrier and watchmen shall be provided
in the test area.
6.2.
Protection of devices in the vicinity of network shall be carefully studied, in particular

near the pressurization and depressurization areas in order not to damage any
mechanical, electrical and instrumentation items.
6.3.
The danger of sudden leaks through the gaskets is anticipated during the
pressurizing. Flange and unions should not be soaped until the system has reached
to a constant pressure level.
6.4.
Non testing block shall be vented properly so that this block can never be
pressurized due to the unexpected leakage of block valve.
6.5.
Non-essential personnel are barred from the area during the test. Contractor will
provide watchmen at key points to ensure security.
6.6.
Leak tests must not be performed unless the entire system is free from hydrocarbons.
7. DETAILED METHOD
Refer to attached marked-up P&IDs for detailed pipes & valve mechanical
arrangement. All drain, vent and the designated valves on the package battery limit
are closed and the instrument line valve is to be opened as shown in the gross air
leak test path.
7.1.
Preparation
All temporary equipment shall be dismantled, and the permanent equipment shall be
reinstated.
It must be ensured that marked-up P&IDs are available, pipes and fittings are
identified, and mechanical arrangement of valve and equipment are properly
identified.
Location of isolation valves and blinds shall be checked according to the approved
marked-up P&IDs.
The locations of test medium introduction during pressure build up and medium
discharge during depressurization should be defined and isolated.

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The location of the pressure gauges/indicators needed during test should be

identified and ensured that they are functional.
Test blocks shall be established and isolated based on the relevant diagrams.
7.2.
Pressure
The pressure reading shall not exceed specified test pressure. Refer to below table
for the correct test pressure of each air leak test package. Be reminded that
overpressure of the system may cause damage to the equipment such as valves,
pitting, exchangers, vessels, turbines, pumps, etc.
Package No.
Test
Pressure
Pressure
Monitoring
L1-105-001
7 barg
PG 100 & PT 003
L1-105-002
7 barg
PG 100 & PT 003
L1-105-003
7 barg
PG 100 & PT 003
L1-105-004
7 barg
PG 100 & PT 003
L1-105-005
7 barg
PG 100 & PT 003
L1-105-006
3.1 barg
PG 011 & PT 005
L2-105-001
7 barg
PG 100 & PT 003
L2-105-002
7 barg
PG 100 & PT 003
L2-105-003
7 barg
PG 100 & PT 003
L2-105-004
7 barg
PG 100 & PT 003
L2-105-005
7 barg
PG 100 & PT 003
L2-105-006
7 barg
PG 100 & PT 003
L2-105-007
7 barg
PG 100 & PT 003
L2-105-008
7 barg
PG 100 & PT 003
L2-105-009
7 barg
PG 100 & PT 003
Remarks
(Sub-system)
WU105-01-04
(Manifold System)
WU105-01-04
(Manifold System)
WU105-01-04
(Manifold System)
WU105-01-04
(Manifold System)
WU105-01-04
(Manifold System)
WU105-01-04
(Manifold System)
WU105-02-02
(Manifold System)
WU105-02-02
(Manifold System)
WU105-02-02
(Manifold System)
WU105-02-02
(Manifold System)
WU105-02-02
(Manifold System)
WU105-02-02
(Manifold System)
WU105-02-02
(Manifold System)
WU105-02-02
(Manifold System)
WU105-02-02
(Manifold System)

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7.3.

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Pressure Build-up Sequence

Pressurization at approximately 25%, 50%, and 75% of the required test pressure
shall be set with a 10-minute hold each time followed by system check.
For example:
If required test pressure = 7 barg
- From starting pressure, raise to 2 barg, hold for 10 minutes
- Raise to 3.5 barg, hold for 10 minutes
- Raise to 5 barg, hold for 10 minutes
If required test pressure = 3.1 barg
- From starting pressure, raise to 1.5 barg, hold for 10 minutes
- Raise to 2.5 barg, hold for 10 minutes
- Slightly raise to 3.1 barg, hold for 10 minutes
7.4.
Sequence (Air Leak Test)
Note: Valves marked x in marked-up P&IDs shall be closed. Unmarked valves or valves
marked o shall be open.

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DOC. NO.
CASE 1: Phase 1 only

L1-105-001: Manifold System (WU105-01-04)
Equipment:
N/A (Piping Only)
Testing limit:
A-002 & C-004 Typical 1 Typical 2 Typical 3 MOV 002
1. Use flexible temporary connection hose to connect instrument air outlet to valve
(L-009) of the Asphaltene Inhibitor injection line.
2. Open the air supply root valve on the instrument air line.
3. Slowly build up pressure up to 7 barg according to the pressure build up
sequence.
4. Stop air injection by closing valve (L-009).
5. Disconnect temporary hose.
6. Apply soap solution around all flange joints and valves around the system.
7. Check for bubbles formation.
8. If bubbles form, tighten the bolts of the flange joint or connection where bubbles
were found.
9. Keep the system pressure at 7 barg.
10. Repeat test. Recheck for any air leaks by applying soap solution on the same
location.
11. If no bubbles are detected, the system has successfully passed the air leak test.
12. Close the air supply root valve on the instrument air line.
13. Discharge air by slowly opening valve (L-029) in the Typical 3.
14. After depressurization, close valves (L-009 & L-029).
15. Remove flexible hose.
16. Reinstate package as per P&ID.

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Equipment:
N/A (Piping Only)
Testing limit:
A-002 & C-004 L-021 of Typical 1
sequence.
were found.
location.
13. Discharge air by opening valve in the Corrosion Inhibitor injection line (L-007).

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Equipment:
N/A (Piping Only)
Testing limit:
A-002 & C-004 L-021 of Typical 1
sequence.
were found.
location.

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Equipment:
N/A (Piping Only)
Testing limit:
A-002 & C-004 L-021 of Typical 1
sequence.
were found.
location.

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Equipment:
N/A (Piping Only)
Testing limit:
A-002 & C-004 L-021 of Typical 1
sequence.
were found.
location.

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Equipment:
CLOSED DRAIN DRUM (105-00-V-001) and Associated Piping
Testing limit:
L-079 105-00-V-001 All closed drain valves
(L-076) on the inlet line of the Closed Drain Drum
3. Slowly build up pressure up to 3.1 barg according to the pressure build up
sequence.
were found.
9. Keep the system pressure at 3.1 barg.
location.
13. Discharge air by opening valve (L-080)

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CASE 2: Phase 1 combined with Phase 2

Equipment:
N/A (Piping Only)
Testing limit:
A-002 & C-004 L-021 of Typical 1
sequence.
were found.
location.

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Equipment:
N/A (Piping Only)
Testing limit:
A-002 & C-004 L-021 of Typical 1
sequence.
were found.
location.

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Equipment:
N/A (Piping Only)
Testing limit:
A-002 & C-004 L-021 of Typical 1
sequence.
were found.
location.

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Equipment:
N/A (Piping Only)
Testing limit:
A-002 & C-004 Typical 1 Typical 2 L005
sequence.
were found.
location.
13. Discharge air by slowly opening valve (L-008) of the Typical 2 outlet.

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Equipment:
N/A (Piping Only)
Testing limit:
A-002 & C-004 L-021 of Typical 1
sequence.
were found.
location.

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Equipment:
N/A (Piping Only)
Testing limit:
A-002 & C-004 L-021 of Typical 1
sequence.
were found.
location.

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Equipment:
N/A (Piping Only)
Testing limit:
A-002 & C-004 L-021 of Typical 1
sequence.
were found.
location.

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Equipment:
N/A (Piping Only)
Testing limit:
A-002 & C-004 L-021 of Typical 1
sequence.
were found.
location.

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(Early Oil Phase)
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Equipment:
N/A (Piping Only)
Testing limit:
A-002 & C-004 L-021 of Typical 1
sequence.
were found.
location.
8. ACCEPTANCE CRITERIA
The test is considered successful and acceptable when there is no significant
pressure loss or bubbles detected.

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9. CHECK SHEET
Gross Air Leak Test Check Sheet

Type of Cleaning: N/A
System / Sub-system:
Date:
Medium:
Pressure: Refer to Remarks column below
Package No.
Description
Time
Start
Finish
Remarks
(Test Pressure)
Comments:
Name
Signature
Date
Contractor
Company

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10. LEGEND OF SYMBOLS

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(Early Oil Phase)
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APPENDIX I. SYSTEM BASED GROSS AIR LEAK TEST PACKAGE LIST

System: WU105-01 (Well Pad # 5)
Sub-system
Packages
WU105-01-01 (Chemical Injection Package)

WU105-01-02 (Instrument Air System)
WU105-01-03 (Well Head Control Panel)
None
None
None
L1-105-001
L1-105-002
L1-105-003
L1-105-004
L1-105-005
L1-105-006
WU105-01-04 (Manifold System)
System: WU105-02 (Well Pad # 5)

WU105-02-01 (Well Head Control Panel)
None
L2-105-001
L2-105-002
L2-105-003
L2-105-004
L2-105-005
L2-105-006
L2-105-007
L2-105-008
L2-105-009
WU105-02-02 (Manifold System)
APPENDIX II. LEAK TEST PACKAGE MARKED UP P&ID'S

Refer to attached marked-up P&IDs
APPENDIX III. BLINDS LIST
Size (in)
Rating
N/A
Qty
P&ID
APPENDIX IV. TEMPORARY PRESSURE GAUGE LIST

Flange
Connection
Range
Qty
P&ID
N/A

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