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For Approval

0 For Approval
R DATE DESCRIPTION DSGN CHKD APPD
E
PROJECT TITLE :
V

General Provision & Civil Work support IPM


Drilling Project
OWNER :

CONTRACTOR :

DESIGNED DATE TITLE :


BY

CHECKED DATE LEAK TEST PROCEDURE


BY

APPROVED DATE DOCUMENT NUMBER REV


BY
TLU-HAL-C19-CBN-0020 A
STANDARD OPERATIONAL PROCEDURE

LEAK TEST PROCEDURE


PT. CIPTA BANGUN NUSANTARA
EPC, Consultants & Project Managers SECTION : CIVIL
REV. : A
DOC. NO : TLU-HAL-C19-CBN-0020

A. PURPOSE
This procedure is performed to provide guidance to Leak Test Team during Leak
Testing. This document will give boundary data while performing Leak Test.

B. ASSUMPTION/ APPROACHES
Leak Testing for WDS Pipeline will be performed for :
Pipe Line 10” from Wayari River to Wellpad D
Leakages along the piping system and flange connection during Leak Test shall not
be eliminated.

C. IMPORTANT CONSIDERATION
 Prior to any hydrostatic testing activities, the field QC shall familiarize all in charged
personnel with safety requirements associated with the test.
 All personnel shall be equipped with required PPE for handling soap (chemical), such as:
- Safety Glasses/ googles,
- safety helmet+ beenet
- Chemical hand glove ( made of rubber )
- Safety shoes
- Masker and other protection
 HAL HSE shall give an induction to personnel of safe working practices and ensure that
they are enforced.
 All hydrostatic test crew shall be trained and / or experienced in the testing activities
performed.
 All the test region shall be secured and restricted as practicable to outside personnel, other
Than test crew and the client’s / Owner’s representatives using yellow line barricade.
 Other than specified above, no unrelated work of any kind, either permanent or temporary,
Shall be performed on any part of the system while testing is in progress.
 Supervisor to check every personel’s health before doing leak test, and sozialize JSA
before executing work.
STANDARD OPERATIONAL PROCEDURE

LEAK TEST PROCEDURE


PT. CIPTA BANGUN NUSANTARA
EPC, Consultants & Project Managers SECTION : CIVIL
REV. : A
DOC. NO : TLU-HAL-C19-CBN-0020

D. LEAK TEST PREPARATION AND SCHEME


D.1. Pipeline Data:
PSA-IA0251-7359
Description 2” Air Instrument

Seamless, ASTM A106 Gr.B, Beveled ends,


Material
Sch. 20.
Size 10” SCH. 20
Wall Thickness 6 mm
Length 3000 m
Water Volume 0,856 m3
Highest elevation EL. +1003,255
Low Elevation EL. +998,643
Lowest Elevation EL. +962,380
Leak test operating
50 Psig
pressure ( P1 )
Leak test operating
100 Psig
pressure ( P2 )
Leak test operating
150 Psig
pressure ( P3 )

D.3. Preparation
1. Test Package shall be made and shall consist of an minimum : Isometric
drawing, Welding traceability, punch list and others requirement.
2. The proposed equipment / tools to be used:
 Compressor
 Pressure Gauge and Fitting
 Soap and water
3. Prior to the usage of the gauge, make sure that they have been calibrated and good
condition.
4. Pressure gauge shall be installed at the highest point and lowest point.
Witness shall be place at the highest and lowest point
5. Ensure venting valve already installed at every high pressure point
6. Ensure all guides and line stopper already installed.
7. Prepare the All Equipment that needed for Leak Test.
8. In case there is storm/ lightning happen Leak Test will be stopped.
9. Inspect Leak Test unit (calibration).
STANDARD OPERATIONAL PROCEDURE

LEAK TEST PROCEDURE


PT. CIPTA BANGUN NUSANTARA
EPC, Consultants & Project Managers SECTION : CIVIL
REV. : A
DOC. NO : TLU-HAL-C19-CBN-0020

10. All Test will be requested by operation dept.


11. Socialize JSA before executing.

E. PROCEDURE
Leak Test scenario of the lines :
1. Before Leak test, flush the pipe with pressurize air
2. Applied soap and water to every welding join and flange, using Sponge
3. Check all connections (welding joints, flanges, Compressor, instrument, etc) to
make sure they are ready for Leak Test.
4. Keep the vent valves open to freed/release the air during Pressuring
5. Set Pressure to zero ( by reading in pressure gauge )
6. Start pressing to 50 Psig ( P1 ) and hold for 5 minutes, then do pressure up to 100
Psig ( P2 ) and hld for 5 minutes, after that operator shall pressure up to 150 Psig
( P3 ) and hold for 30 minutes
7. During Holding time, dedicated team will search for any air leak in every welding
join and flanges visually by checking if there is any bubling happen
8. After holding time for 30 minutes,and there is no air leak happen, then release the
air pressure down to 100 Psig ( P2 ) and hold for 5 minutes, then do it again to 50
Psig ( P1 ) and hold for 5 minutes, and after that operator shall release the pressure
down to 0
9. During all pressurization tasks, the incremental reading of pressure shall always be
recorded on the inspection forms.
10. Complete the test if at the end of holding time, no leaks encountered.
Note:
If possible, the blind-flange type may be replaced with blind welded type which is
used to cover at the end of each section of the pipe.

F. TEST ACCEPTANCE CRITERIA

1. To satisfy the testing requirements, pressure in the line must be maintained without
Pressure variations no greater than 10 % or 20 psig whichever is less.
2. The test shall accept if: during the test, all pressure containing components in the line
maintain their integrity and no leaks are found.
3. Any reduction in pressure outside the limits specified, or variation in temperature, which
cannot be accounted for, shall result in a test failure. Possible causes for failure, such as a
STANDARD OPERATIONAL PROCEDURE

LEAK TEST PROCEDURE


PT. CIPTA BANGUN NUSANTARA
EPC, Consultants & Project Managers SECTION : CIVIL
REV. : A
DOC. NO : TLU-HAL-C19-CBN-0020

loose bolts and / or fittings, leaking from gaskets, test pump failure or air entrapment shall
be located and rectified.
4. Upon satisfactory completion of the test, BRE QC Inspector and CGS QC inspector shall
verify and sign the recorded inspection forms as the formal documentation of acceptance.
5. After accepted by company, then the line can be depressurized. Release the pressure
gradually and slowly, not faster than 30 minutes from STP to 0 psig.

Psig

150
30 minutes
100
05 minutes 05 minutes
50
05 minutes 05 minutes

0
Duration
G. SAFETY AND ENVIRONMENTAL PROTECTION
1. Prior to any hydrostatic testing activities, the field QC shall familiarize all in charged
personnel with safety requirements associated with the test.
2. All personnel shall be equipped with safety equipment. BRE HSE shall induction
personnel of safe working practices and ensure that they are enforced.
3. All Leak Test Crew shall be trained and / or experienced in the testing activities
performed.
4. All the test region shall be secured and restricted as practicable to outside personnel,
other Than test crew and the client’s / Owner’s representatives using yellow line
barricade.
5. Work permit shall endorse by Client/Owner and security personnel.
6. Other than specified above, no unrelated work of any kind, either permanent or
temporary, Shall be performed on any part of the system while testing is in progress.
STANDARD OPERATIONAL PROCEDURE

LEAK TEST PROCEDURE


PT. CIPTA BANGUN NUSANTARA
EPC, Consultants & Project Managers SECTION : CIVIL
REV. : A
DOC. NO : TLU-HAL-C19-CBN-0020

H. JOB HAZARD ANALYSIS


No Job sequence Potential hazard Mitigation
 Keep the safe work distance
Flushing pipe by Hit by pipe if the pipe join fail to  Barricade the pressurezed pipe
1
pressurized air hold the pressure surrounding area
 Place required sign board
Use additional required PPE for
Soap water application Chemical material expose to
2 chemical material : Rubber glove,
to welding join skin
safety glass, masker
 Keep the safe work distance
Press the air in the pipe
Hit by pipe if the pipe join fail to  Barricade the pressurezed pipe
3 to maksimum design
hold the pressure surrounding area
pressure
 Place required sign board

I. INSPECTION RECORD FORM

No Time Pressure ( Psig )