Pneumatic Testing Procedure for Pipelines

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Document No.0005 Revision :0001 Prepared By: Ku Masayu Ku Husin

Purpose
This procedure is a necessary action and safety practices for pressure testing all new LPG line piping at Kapar Energy Venture.

Responsibility
Project Engineer & Project Supervisor, LINKTECH ENGINEERING

Discussion
In order to ensure the integrity of pipeline in a round of stations, LINKTECH ENGINEERING will perform the test witnesses by IPSM. Due to the freezing risks associated with pressure testing with water and the environmental hazard of hydro testing with fuel, LINKTECH uses pneumatic (air) testing. The pressure testing procedures adopted by LINKTECH ENGINEERING follow API and ASME recommended standard and practices. The procedures also outline proper safety practices that must be followed in order to minimize risks.

Requirements
Tools and Equipments All personnel within test area shall be required to wear eye and hearing PPE. Air compressor & Nitrogen gas

Linktech Engineering Rev:0001 No. 7, Jalan DC A,Taman Desa Coalfield 47000 Sungai Buloh, Selangor Phone/fax: 03-6038 6386

Ensuring Safety of Work Site Pneumatic testing can be dangerous and should be performed with caution and careful attention to all safety procedures. To ensure the safety of all workers and residents, the following safety precautions must be completed prior to conducting the pressure testing: Notify station personnel of area to be avoided due to risks during pressure testing. Ensure that no high pressure testing occur in the work centers Mark off the area as a dangerous site

The information should be provided if the test occurs in the town or near high traffic area. Pedestrian must be advised to avoid the area. Results : After following the above procedures, the necessary step to ensure safety will be complete.

Conducting the Pressure Test

To conduct a pressure test of pipelines in or around all stations, complete the following steps: 1. 2. 3. 4. 5. 6. 7. Identify the maximum test pressure to be used, as determined by Project Engineer. Identify the steel pipe to be test. Examine all connections prior to the test to ensure proper tightness Determine the pressure rating for all connected fittings and devices to ensure they are rated for the maximum test pressure. Place 150# blind flange or other suitable cover on all opening that not closed off by valves. Plug all test, drain and vent ports that are not required for the test. If the section of the pipe being tested is isolated from other section by in-line valves, ensure the portion not being tested is open to the atmosphere. Apply the preliminaries test pressure of 25psi. Note: This pressure should be held a minimum of 10 minutes to allow for the location of any major leaks. If leak a detected during this step, or any time during the test, relieve the pressure and consult the Project Engineer for instruction.

8.

Linktech Engineering Rev:0001 No. 7, Jalan DC A,Taman Desa Coalfield 47000 Sungai Buloh, Selangor Phone/fax: 03-6038 6386

9.

10. 11. 12. 13. 14.

Apply the test pressure increments of 25psi, or as directed the Project Engineer, until the maximum test pressure reached. Hold the pressure for 5 minutes at each 25psi increment before adding more pressure. Hold the maximum test pressure for 10 minutes After the required 10 minutes, reduce the pressure to 100psi or predetermined pressure. Hold this pressure for 24 hours. Obtain confirmation of a successful test by Station Representative after the 24 hours period. Remove the pressure, with caution to avoid escaping air stream , and high decibel noise level.

Results : After completing this step , pressure testing is completed. Once test is successfully completed, the line is ready for service.

Reference API recommended practice; ASME for piping; Facilities Engineering , Maintenance and Construction (FEMC)

Linktech Engineering Rev:0001 No. 7, Jalan DC A,Taman Desa Coalfield 47000 Sungai Buloh, Selangor Phone/fax: 03-6038 6386