IENCSEPRO0007-2 - General Leak Test Procedure PDF

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of
Israel Gas Transmission Project
2006-01-02 Issued for Tender
Rev.
No.
Date
Description
AA
Prepared
ST
FVDS
Checked
Approved
Date
Contractor
Approved
Company
Document Title
General Leak Test Procedure for

PRMS
Contractor
Company
Company Representative
: Shmuel Turgeman
Reference
Purchase Order No.
Contractor Representative : Mr. Friedrich von der Schulenburg

Document Originator
: Shosh Yaacoby
CoversheetForm_601e_proIngl/07.04.dot
Area Code: GEN

Project Identification
Document-No.
Rev.
60.0710.0000-04-xx
IEN-CSE-PRO-0007
EEN Job-No.
YC
PP Contractor Dis.Code
Code
Doc.Type
Ser.
No.
Z:\DMS_PIA_INGL\OGs\Documents\Procedure\IENCSEPRO0007-2.doc
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Table of Contents
1 ....................General
1.1 ................. Testing pressure value
1.2 ................. Test Medium
1.3 ................. Reference Documents
1.4 ................. Preparatory Work
1.5 ................. Sequences and execution
1.6 ................. Test equipment
2 ....................Safety during test
3 ....................Natural gas metering and regulating system

3.1 ................. High pressure part
3.1.1............... Test limits
3.2 ................. Low pressure part
3.2.1............... Test limits
3.2.2............... Test pressure
4 ....................Acceptance of test
5 ....................Revision Record
Project Title:
Document Title:

General Leak Test Procedure for PRMS
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General
The following procedure is concerning all the operations to be executed to perform the
leak test on natural gas lines, pressure reduction and metering stations. The execution of
the leak test will be done only under the supervision of the Supplying Contractor (SC),
but the Installation Contractor (IC) will be held fully responsible for the execution of this
tightness test.
1.1
Testing pressure value

In accordance with EN standard EN12186. The test pressure shall be 1.1x MOP.
1.2
Test Medium
Nitrogen (N2)
1.3
Reference Documents
A specific tightness test procedure shall be prepared by the IC in accordance with the
relevant P&I Diagram.
1.4
Preparatory Work
All equipment and materials (e.g. nitrogen, gauges, test equipment) necessary to perform the leak test have to be provided by the IC.
The responsibility for all preparatory work is with IC
As minimum the following has to be done:
Checking of all connections, flanges and fittings prior to start of any test
Verifying that all bolts and nuts are mounted with required torque.
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Installation of blind discs and plugs wherever necessary.

Manual functional test of all valves.
Listing of all uninstalled items.
Turn ball valves affected by the test to half open position.
Ensure successful completion of strength tests.
Installation of safety measures (e.g. temporary fences, warning signs etc.).
The pressure safety relief valves (PSV) shall be secured using blind flanges upstream of
each one.
All ball valves located at the PRMS shall be in the half-open position to ensure full expansion of the pressure in the whole valves body.
Slam shut valves shall be open during the tightness test. This shall be ensured by pressurizing the impulse lines with the required value.
1.5
Sequences and execution

Inspection of the connections, flanges and fittings prior to start of any test.
Inspection of the positions of valves incl. drain points.
Filling pipes segment by segment with nitrogen (N2). The filling should be done
through pressure test connections, according INGL standard.
For tightness test the module or pipe section shall be pressurized from one valve
to the next valve downstream. Thus the initial tightness of every single valve shall
be checked according to the NEN 3650 and EN 12186.
Gradually pressurizing the testing module at approx. 25 50 75 100 % of the
pressure value, while checking all points with liquid soap brine for leakages.
At reaching 100 % test pressure, maintain the pressure for minimum of 30 minutes by using a certified pressure gauge class 0.1
Decreasing the pressure to 75 % test pressure and maintaining that level for a
minimum of 30 minutes.
Decreasing the pressure to 1 bar
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Checking all points with liquid soap brine for leakages.

Leaving the station pressurized with nitrogen to avoid any contact with air.
1.6
Test equipment
The test equipment shall fulfil the requirements of EN 12327.
Safety during test

For all safety aspects IC has to nominate a responsible person. In addition, a safety supervisor will be nominated by INGL.
A safety zone of 30m shall be maintained during tightness testing in which no work may
be performed while the tests are in progress.
The following measures shall be taken before and during the test:
The test pressure shall be controlled and monitored from outside the safety zone.
During pressurization and testing only personnel involved in the testing shall be
allowed to access the safety zone; access to the zone shall be restricted to a
minimum
The safety zone shall be marked (temporary fences, warning signs etc.)
The necessary instructions shall be given to individuals working in the vicinity of
the safety zone through IC safety superintendent
Natural gas metering and regulating system
3.1
High pressure part
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3.1.1
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Test limits
Upstream valve of the PRMS until the PCVs.
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Test pressure
The test pressure shall be 88 barg.
3.2
Low pressure part
3.2.1
Test limits
Downstream the PCVs until the last downstream ball valve.
3.2.2
Test pressure
Test pressure shall be 1.1 times MOP barg
Acceptance of test
If any leaks are discovered during the test they shall be located, repaired and the test
shall be repeated.
The test duration shall be as long as necessary for proper inspection but minimum 30
minutes at each individual ultimate test pressure.
Acceptance criteria are fulfilled when pressure test sections are tight at:
test pressure after 30 minutes
1 bar (pre-commissioning pressure) at the end of the tightness test
For each individual test section a separate report has to be issued with the following information as a minimum:
Test method
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Test pressure and duration

Test medium
Acceptance criteria
Clear description of the test limits
Leak detection method
Result
Information about locations and repairs of leaks
Pressure test record documents
Parts which were not tested in full extent and/or not in accordance with this procedure
shall be listed. This listing shall be a part of the tightness test report and therefore shall
be attached. The listed parts have to be retested during hot-commissioning with natural
gas and operating pressure.
The tightness test shall be considered as completed when acceptance has been given
by INGL'
s representative together with an independent control authority.
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Revision Record
Rev.
No.
Date
Description
Prepared
Checked
Approved
EEN
2006-12-31 Discipline Internal Check
2006-01-02 Issued for Tender
Project Title:
Document Title:

Revision:
Date:
Date
Approved
Company
AA
ST
FVDS
YAA
ST
FVDS

Document No.:
IEN-CSE-PRO
2006-01-02

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Page 1

Israel Gas Transmission Project

2006-01-02 Issued for Tender

General Leak Test Procedure for

Purchase Order No.

Contractor Representative : Mr. Friedrich von der Schulenburg

Area Code: GEN

2 ....................Safety during test

3 ....................Natural gas metering and regulating system

Israel Gas Transmission Project

Proj. Identification : 60.0710.0000-04-xx

Testing pressure value

Israel Gas Transmission Project

Proj. Identification : 60.0710.0000-04-xx

Installation of blind discs and plugs wherever necessary.

Sequences and execution

Israel Gas Transmission Project

Proj. Identification : 60.0710.0000-04-xx

Checking all points with liquid soap brine for leakages.

Safety during test

Natural gas metering and regulating system

High pressure part

Israel Gas Transmission Project

Proj. Identification : 60.0710.0000-04-xx

Israel Gas Transmission Project

Proj. Identification : 60.0710.0000-04-xx

Low pressure part

Israel Gas Transmission Project

Proj. Identification : 60.0710.0000-04-xx

Test pressure and duration

Israel Gas Transmission Project

Proj. Identification : 60.0710.0000-04-xx

2006-12-31 Discipline Internal Check

2006-01-02 Issued for Tender

Israel Gas Transmission Project

Proj. Identification : 60.0710.0000-04-xx

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