a)

SAUDI KAYAN PETROCHEMICAL COMPLEX

DOCUMENT TITLE:

GENERAL PRE-COMMISSIONING PROCEDURE FOR AIR LEAK TESTING

DOCUMENT NO:

700-500Z-0026

Client:

Saudi Kayan Petrochemical Company Al-Jubail, Saudi Arabia Camberley, Houston, Manila, Saudi Arabia A2AD.EP NA NA

Location: Fluor Project No: Contract No: CWP No:

0
REV

21 Aug 07
DATE

5
PAGES

For Client Review

DESCRIPTION

JW
ORIG.

DH
CHKD

GL
FLUOR

KAB
CLIENT

APPROVED BY

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SAUDI KAYAN PETROCHEMICAL COMPLEX Contract A2AD DOCUMENT TITLE

No. 700-500S-0018 21 Aug 2007 Rev. 0

TABLE OF CONTENTS 1. 2. 3. 4. 5. 6. 7. INTRODUCTION ........................................................................................................... 3 REFERENCES .............................................................................................................. 3 PURPOSE ..................................................................................................................... 3 SCOPE OF PROCEDURE ............................................................................................. 3 SAFETY & PRECAUTIONS ........................................................................................... 3 METHOD ....................................................................................................................... 4 IMPLEMENTION............................................................................................................ 4 7.1 7.2 8. 9. Planning.................................................................................................................. 4 Execution ................................................................................................................ 4

ACCEPTANCE CRITERA .............................................................................................. 5 POSTWORK .................................................................................................................. 5

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SAUDI KAYAN PETROCHEMICAL COMPLEX Contract A2AD DOCUMENT TITLE

No. 700-500S-0018 21 Aug 2007 Rev. 0

1.

INTRODUCTION This procedure describes the general requirements for conducting air leak testing of process and utility systems installed for the Saudi Kayan Petrochemical Complex locate at Al-Jubail, Saudi Arabia. This preliminary leak test shall be conducted to test the integrity of the systems prior to commissioning, to minimize the potential for loss of down time when the process and utility fluids are introduced for commissioning and start-up. Detailed procedures for implementation of air leak testing of individual piping and equipment shall be prepared for System or Sub-systems based on this general procedure.

2.

REFERENCES Document No. 700-500S-0001 Specification for Defining Pre-Commissioning Systems Document No. 700-500S-0002 Pre-Commissioning Execution Plan Document No. 700-500S-0003 Specification for P&ID Mark Up Process and Utilities

3.

PURPOSE The purpose of an air leak test of a system or sub-system is to carry out a tightness test to ensure the integrity of the pipe-work prior to placing the system into service, in particular, flanged joints that had been broken during the removal of temporary spades or blinds during hydro or pneumatic test carried out by the construction group.

4.

SCOPE OF PROCEDURE The scope of this procedure is applicable to the following system categories: Hydrocarbon process systems (Gas and Liquid service) Chemical Injection systems Fuel gas systems Nitrogen Instrument and Plant Air Flare and Closed Drains Steam

5.

SAFETY & PRECAUTIONS All personnel directly involved in the leak test shall be aware of the hazards presented by systems containing compressed air at high pressure. The area in which the test is being conducted shall be restricted to essential personnel only with warning notices posted and barriers installed. Normal personal protective equipment should be worn at all times. Refer to the Pre-commissioning and CONTRACTOR Safety Instruction and Policy for comprehensive safety instructions and permitting instructions, if required.

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SAUDI KAYAN PETROCHEMICAL COMPLEX Contract A2AD DOCUMENT TITLE

No. 700-500S-0018 21 Aug 2007 Rev. 0

6.

METHOD During pre-commissioning and prior to MECHANICAL COMPLETION, the system shall be leak tested at system operating pressure. The method and specified systems to be tested may vary as pre-commissioning activities progress. Any changes must be approved by the Pre-commissioning group of the CONTRACTOR and the Pre-Commissioning and Start-up Manager of the COMPANY.

7.

IMPLEMENTION 7.1 Planning Marked up Piping and Instrument Diagrams, showing the system test limits shall be prepared in advance of the leak test. The system shall be checked for outstanding punch list items that require correction prior to MECHANICAL COMPLETION and that all intrusive work on the system has been completed. System isolations shall be in place and clearly identified in the field and on the system P&IDs. System flanges, including instrument connections to piping and vessels, shall be wrapped in masking tape to form a temporary seal with a pin hole in the wrapping at each flange. All flanges should be wiped clean of dirt, grease and water to ensure effective covering of the flange gaps. Sufficient quantities of low chloride bubble formation fluid (Swagelok Snoop or equivalent) shall be available to complete each leak test. Temporary hoses, certified for the test pressure to be used, to transfer air from the reservoir or compressor to the system to be tested, shall be prechecked for leaks and damage to couplings. A pressure gauge of suitable range for the test shall be installed at an elevated point on a system, vessel of column. A larger volume is less susceptible to temperature fluctuations caused by local conditions and therefore will provide more consistent readings. In the absence of a vessel the gauge shall be mounted on the longest available run of large diameter pipe. The calibration certificate for the pressure gauge shall be available for examination by the COMPANY representative. The air quality shall be dry, compressed air and oil free. If available, compressed air from the facilities Plant Air system shall be used for leak testing. Should this Plant Air not be available then an alternative supply of air, of suitable quality, is to be provided. 7.2 Execution Obtain a Permit to Work prior to commencing this activity (if necessary). When preparations are complete and safety requirements have been implemented the leak test can be carried out. Connect hoses to suitable points in the system such as purge connections or low point drains. Commence the filling of the system by gradually opening the purge valves. Walk the system down regularly looking and listening for indication of major

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SAUDI KAYAN PETROCHEMICAL COMPLEX Contract A2AD DOCUMENT TITLE

No. 700-500S-0018 21 Aug 2007 Rev. 0

leaks. An audible whine can often be heard if a severe leak has occurred, usually when the system has reached a pressure above 1 barg. If no leaks are detected (allow time for pressure equalization), increase the flow of air gradually until the test pressure has been reached. Note the time at which the test pressure was reached. Check each flange by applying a small quantity of bubble test fluid at the pin holes. Formation of a bubble indicates a leak and additional tightening of the flange nuts will be required. Depending on the test pressure of the system this may be possible during the test. However if the system pressure is 2 barg pressure or higher then no repair should be attempted until the system, or part of the system, has been depressurized to a safe level, generally 1 barg. When the necessary repairs or tightening has been completed then the system (or part of) can be re-pressurized. The test will be considered complete when all flanges and connections have been checked and are found to be free of leaks. Note the time of test completion and not the system pressure at the test pressure gauge. 8. ACCEPTANCE CRITERA Acceptance is based primarily on all flanges displaying no bubble formation or no loss of pressure over ten minutes. 9. POSTWORK All flanges and connections shall be cleared of tape and cleaned to remove any residual adhesive. The leak test Pre-commissioning document shall be completed immediately and countersigned as having been witnessed by the CONTRACTOR and COMPANY representatives. All barriers and tape that was used for personnel protection during the test shall be removed by the CONTRACTOR. Any temporary blind or spade installed for the test, shall be removed by the CONTRACTOR. All piping and equipment shall be reinstated as per the P&ID.

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