GENERAL LEAK TEST PROCEDURE

PROJECT EQUIPMENT NAME EQUIPMENT NO. PMT NO. : : N/A : N/A : N/A

APPROVALS
NAME
Prepared by;

SIGNATURE

DATE

Reviewed by:

Approved by;

REVISION RECORDS
REV 00 01 02 DATE ISSUE 27 AUGUST 2009 30 NOVEMBER 2009 7 DECEMBER 2009 REVISION DESCRIPTION For Review & Approval For Review & Approval For Review & Approval

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TABLE OF CONTENTS

ITEM DESCRIPTION 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 PURPOSE SCOPE REFERENCE CODES & STANDARDS PROCEDURE ATTACHMENTS / WORK FLOW TESTING EQUIPMENT STANDARD OPERATING PROCEDURE ATTACHMENT

PAGE 2 2 2 2 4 6 6 7

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1.0

PURPOSE

The purpose of this procedure is to ensure there is no leak at any equipment and to perform pressure testing rarely and in accordance with technical standard and meet the requirement.

2.0

SCOPE

This procedure covers the minimum requirement for Leak Test on equipment Heat Exchanger, Air Fin Cooler and Piping as part of work completion acceptance criteria. 3.0 REFERENCES CODES & STANDARDS 3.1 ASME VIII Div. 1 3.1.1 3.1.2 3.2 UG-100, Pneumatic Test UG-99, Standard Hydrostatic Test

ASME B31.3 3.2.1 Chapter VI, Inspection, Examination, and Testing Clause 345

4.0

PROCEDURE

The minimum hydrostatic test pressure for pressurized piping systems should not less than 1.5 times the design pressure unless otherwise state and for the equipment pressure is no less than 1.3 times of the design pressure. For pneumatic test, the minimum test pressure for pressurized piping system and equipment should not less than 1.1 times the design pressure.

4.1

When the equipment is prepared and found ready for the test, it should be thoroughly checked and approved by the Client.

4.2

Barricade the equipment area with signage of Hydrotest in Progress, before any application of pressure.

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4.3

Vents shall be provided at all high points of the equipment in the position in which it is to be tested to purge possible air pockets while the equipment is being filled.

4.4

A pump shall be connected to the equipment to be tested and shall be controlled by a valve with a sufficient pressure rating.

4.5

Two pressure gauges with range 1.5 to 4 times of Test Pressure shall be installed on the lower and high points of the equipment (location to be verified at site). The indicating gauges shall be visible to the foremen to controlling the pressure applied. All pressure gauges shall posses a valid calibration certificates.

4.6

Fill up the equipment with potable water with Chloride contents shall not exceed 30 PPM for testing Carbon Steel equipment. For Austenitic Stainless Steel/300 Series Material, Chloride contents shall not exceed 50PPM. Immediately flushing will carry out with demin water for Austenitic / 300 Series Material to avoid from corrosion.

4.7

Let the water flow out for a while to ensure there should be no air pocket left in the equipment. Wipe out all the remaining at the checking point. This will help for easier leak detection.

4.8

Pressure-up the equipment slowly until it reached 10% of test pressure value, hold for 5 minutes. Check equipment for any sign of leak during the process.

4.9

Pressure-up the equipment slowly until it reached 70% of test pressure value. Hold for 5 minutes. Check equipment for any sign of leak during the process.

4.10

Pressure-up the equipment slowly until it reached 100% of test pressure value. Hold for 30 minutes. Check equipment for any sign of leak during the process.

4.11

Liaise Client personnel to inspect and witness the Hydrotest activities. If any leak found or fail the test, equipment shall be repair and to do the test again until a successful test is attained satisfactory.

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4.12

If the test was found successfully and the result is satisfied by Client release the pressure upon permitted by him.

4.13

Gradually release the pressure at least 2/3 from test pressure value. Hold for 5 minutes. Call Client personnel to visually check.

4.14

Gradually release the pressure until zero prior to remove all temporary blinds and valves.

4.15

All data shall be recorded in Hydrostatic Test Record inclusive but not limited: a) Equipment Tag No b) Equipment Name c) Design Pressure d) Test Pressure e) Test Medium (Water/Air)

5.0

ATTACHMENTS / WORK FLOW

Pressure Test Pressure 100 % 2/3 Design Pressure 70%

10%

5min

5min

30min

5 min

HoldingTime

Pressure Test Chart

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Vent

Pressure Gauge

Pressure Gauge

Water Inlet

Equipment Hydrotest Diagram

Pressure Gauge Concerning point - Air trap/air bubble suspected at this point

Pressure Gauge Piping Hydrotest Diagram 6.0 TESTING EQUIPMENT

Pressure Gauge

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6.1 6.2 6.3

Pressure Gauge Pressure Pump Recorder

7.0

STANDARD OPERATING PROCEDURE (S.O.P) 7.1 Before commencing any work, supervisor shall ensure PTW has been applied, approved and validated for the activities. 7.2 All workers shall wear a proper PPE as stated or comply with JSA or PTW before commencing any activities. 7.3 Ensure that trained/ competent worker is put on standby together with calibrated pressure gauge, test blind, chart recorder( if required ), water pump at working area. 7.4 QA/QC Supervisors ensure that all calibrated pressure gauge are not expired and have a valid calibration certificate. 7.5 All electrical hand tools, cables, hoses and equipment must be in good condition, safe for use and shall be inspected & approved by Client prior to use. 7.6 All electrical cables and hoses must be secured properly to prevent tripping hazard.

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