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L
TEST
T PROCED
DURE
SAN
NTOS (SAMP
PANG ) PTY LTD
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DOCU
UMENT NO.
9501
1-PP-QA-009
9
REV. 0
Page
e 1 of 14
WORT
TEL FIE
ELD DE
EVELO
OPMEN
NT PRO
OJECT
W
WORTE
EL WEL
LLHEA
AD PLA
ATFORM
M
P
PIPING
LEAK
K TEST PROC
CEDURE
E
DOC
CUMENT NO: 950
01-PP-QA
A-009
UN
NAUTHORIZED COPYING OF
O THIS DOC
CUMENT IS NOT
N
PERMITT
TED.
REV
V
DATE
PURP
POSE
OR
RIGINATOR
CHECKED
APPROVED
A
28-JUN-1
11
IDC
SNY
PWT
BHW
7-JUL-11
IFR
SNY
PWT
2-SEP-11
IFA
A
SNY
23-SEP-1
11
AF
FC
SNY
CONTRACTO
OR
COMPA
ANY
BHW
PSB
AGM/N
NEB
PWT
BHW
PSB
AGM/N
NEB
PWT
BHW
PSB
AGM/N
NEB
DAT
TE
PIPING LEAK
L
TEST
T PROCED
DURE
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NTOS (SAMP
PANG ) PTY LTD
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DOCU
UMENT NO.
9501
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9
REV. 0
Page
e 2 of 14
RECOR
RD OF REV
VISIONS
TH
HE REVISIO
ONS LISTED
D BELOW HAVE
H
BEEN INCORPORATED IN
N THIS COPY OF THE
E DOCUME
ENT
REV.
R
No.
S
SECTION
PAGE
E
NO.
DESC
CRIPTION OF
CH
HANGES by
y
PIPING LEAK
L
TEST
T PROCED
DURE
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NTOS (SAMP
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DOCU
UMENT NO.
9501
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Page
e 3 of 14
CONTENT
TS
Page
e
1. Introducttion
2. Objective
e
3. Referenc
ces, Codes
s and Stan
ndards
..
4. Requirem
ments
..
4.1. General
4.2. Safety
4.3. Methodology
..
...
5.
edium
Test Me
6.
Test Eq
quipment
..
10
7.
Test Pro
ocedure
..
10
7.1. Preparatiion
.
.
10
7.2. Procedurre
11
8.
Accepta
ance Crite
eria
..
12
9.
Reporting
12
10.. Attachm
ment 1. Le
eak Test Check
C
Listt
13
Attachm
ment 2. Le
eak Test Report
R
14
Attachm
ment 3. Te
est Block
15
PIPING LEAK
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T PROCED
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DOCU
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Page
e 4 of 14
1.
Intro
oduction
Santo
os operatio
on for Oyong Oil and Gas
G Field is
s located in Sampang PSC, appro
oximately 8
km south
s
of Ma
adura Island
d and lies in approxim
mately 41 m of water d
depth. The Santos willl
opera
ate new devveloped Wo
ortel Gas Field which is
i located at
a approxima
ately 7 km to the westt
of the
e Oyong Oil and Gas Field
F
and lie
es in approx
ximately 42 m of water..
The existing
e
Oyo
ong producction facilitie
es consist of
o a minimum
m facility tripod wellhea
ad platform
m
with five
f
(5) oil wells
w
and tw
wo (2) gas wells
w
tied back
b
to a sm
mall 30000 bbl floating production
n
and storage
s
barrge with flexxible flow lin
ne jumpers. Oil is treate
ed to crude
e sales spec
cification on
n
the barge
b
then transferred to an FSO
O for storag
ge and subssequent liftiing. Wet ga
as from the
e
low pressure
p
se
eparator (associated ga
as) is comp
pressed and
d combined with wet ga
as from the
e
high pressure separator (associated
d and non-associated
d gas) the
en exported
d from the
e
produ
uction barge via a 56 km wet gass pipeline to
t the Onsh
hore Processsing Facilitty (OPF) att
Grati for treatm
ment to sales specificcation and onward sa
ale to the Indonesia Power (IP))
bined cycle power plan
nt.
comb
d
nt plan for Wortel
W
will involve the drilling and
d completion of two we
ells through
h
The developmen
a min
nimum facility wellhead
d platform, which will be
b tied bacck to the existing Oyon
ng wellhead
d
platfo
orm with a 10
1 diamete
er pipeline. Wortel prod
duction will then flow d
directly into the Oyong
g
PIPING LEAK
L
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T PROCED
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DOCU
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9501
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Page
e 5 of 14
gas export
e
pipelline and be
e delivered to
t the Oyon
ng onshore gas plant a
at Grati for processing
g
and onward sa
ale. The de
esign rate of Wortel gas producction is 50
0 MMscfd with
w
arrivall
presssure 900 psia at Oyong Platform
m. At the end
e
of plate
eau producction where the arrivall
presssure is 290
0 psia, the Wortel ga
as will be routed to the
t
Oyong production
n barge forr
comp
pression offfshore with the
t Oyong gas.
g
Wortel will tie in
n to Oyong Gas and th
he combine gas producction will be
e sent to Th
he Onshore
e
Proce
essing Facility (OPF) Grati for further gas conditioning
c
to meet sa
ales gas sp
pecification.
The facility
f
will be
b the buye
ers include IP Grati, Sampang and
d Pasuruan local goverrnment.
Existting facility at
a OPF will be upgrade
ed to increase the capa
acity from th
he existing 80
8 MMscfd
to 90
0 MMSCFD combined Oyong
O
and Wortel Gas
s.
2.
Obje
ectives
The Leak
L
test sh
hall be perfformed as part
p
of pipin
ng commissioning afterr complete installation,,
hydro
ostatic testin
ng, flushing
g and mech
hanical com
mpletion of piping syste
em in order to ensure
e
the in
ntegrity of th
he system and
a safe forr operation to
t receive hydrocarbon
h
n.
3.
4.
Refe
erences, Codes
C
and Standard
ds
A
ASME
B 31.3 Process Piping
D
Drawing
/ P&ID
P
latest revision
r
E
Equipment
Data Sheett
Requ
uirements
s
4.1. General
A Leak test
t
shall be
b conductted on the
e pipe of gas
g
line se
ection after complete
e
installation, hydrosta
atic testing and pipe cleaning.
c
Th
his leak tesst is carried
d out at the
e
e of installation as an indication that
t
the piping system has been installed to
o
last stage
the requiired standa
ard, commissioned without
w
any leaking a
and ready to receive
e
hydrocarb
bon gas.
PIPING LEAK
L
TEST
T PROCED
DURE
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DOCU
UMENT NO.
9501
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Page
e 6 of 14
In order to
t manage the testing
g of overall piping plan
nt safely, th
he overall piping
p
plantt
shall be split
s
in to le
eak test paccks, to refle
ect pipe work service a
and specific
cation such
h
that each test pack can
c be teste
ed independ
dently from each other
4.2. Safety
Pneumatic leak testin
ng involves the hazard
d of released
d energy sto
ored in com
mpressed
en to minimize the chance of brittle failure
gas. Partticular care must thereffore be take
during a pneumatic
p
le
eak test.
Only perssonnel esse
ential for the
e operation of
o test equipment are tto be allowe
ed in the
test area during presssurization and
a depress
surization. Ensure are
ea surrounding system
e cordoned off,
o and des
signated a 'No Go Area
a' by erectin
ng warning
under test is suitable
d barriers.
signs and
4.3. Methodo
ology
Each of test
t
packag
ges is a sta
and-alone procedure
p
w
with
speciffied test pre
essure and
d
follows the same form
mat using th
he same forrms and tesst procedure
e.
p
shall be at ab
bout 10% ab
bove normal operating pressure.
The test pressure
External relief valve
e shall be installed at N2 supplyy manifold tto protect the
t
system
m
nd shall nott exceeding
g
against ovver pressurre. The unit is set at 110% of test pressure an
of 95% design presssure or relie
ef valve settting.
PIPING LEAK
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TEST
T PROCED
DURE
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DOCU
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9501
1-PP-QA-009
9
REV. 0
Page
e 7 of 14
4.4.1. 9501-LTP-0
9
001
T
Test
Press
sure
112
20 psig
R
Relief
Valv
ve Set Pres
ss :
123
30 psig
NO
SY
YSTEM
LINE NUMB
BER
P&ID N
NUMBER
9501-P-002
9501-10-02-PR-DWG-102
9501-P-002
9
9501-10-02-PR-DWG-102 / 103
3
9501-P-002
1
10"RG - 1004 - 9C1R
9
9501-10-02-PR-DWG-103 / 104
4
9501-P-002
9501-10-02-PR-DWG-102
9501-P-002
9501-10-02-PR-DWG-104
9501-P-002
9501-10-02-PR-DWG-103
9501-P-002
9501-10-02-PR-DWG-104
9501-P-002
9501-10-02-PR-DWG-103
9501-P-002
9501-10-02-PR-DWG-103
10
9501-P-002
9501-10-02-PR-DWG-103
11
9501-P-002
9501-10-02-PR-DWG-102
12
9501-P-002
9
9501-10-02-PR-DWG-104 / 103
3
13
9501-P-002
9501-10-02-PR-DWG-102
14
9501-P-002
9
9501-10-02-PR-DWG-102 / 103
3
15
9501-P-002
9501-10-02-PR-DWG-102
16
9501-P-002
9501-10-02-PR-DWG-103
17
9501-P-002
9501-10-02-PR-DWG-103
18
9501-P-002
9501-10-02-PR-DWG-103
19
9501-P-002
9501-10-02-PR-DWG-103
20
9501-P-002
9501-10-02-PR-DWG-103
21
9501-P-002
9501-10-02-PR-DWG-103
22
9501-P-002
9501-10-02-PR-DWG-102
23
9501-P-002
9501-10-02-PR-DWG-103
24
9501-P-002
9501-10-02-PR-DWG-103
25
9501-P-002
9501-10-02-PR-DWG-103
26
9501-P-002
9501-10-02-PR-DWG-103
27
9501-P-002
1
10"RG - 1036 - 9C1R
9501-10-02-PR-DWG-103
28
9501-P-002
9501-10-02-PR-DWG-103
REMAR
RK
PIPING LEAK
L
TEST
T PROCED
DURE
SAN
NTOS (SAMP
PANG ) PTY LTD
L
DOCU
UMENT NO.
9501
1-PP-QA-009
9
REV. 0
Page
e 8 of 14
4.4.2. 9501-LTP-0
9
002
T
Test
Press
sure
112
20 psig
R
Relief
Valv
ve Set Pres
ss :
123
30 psig
NO
SY
YSTEM
LINE NUMB
BER
P&ID N
NUMBER
9501-P-003
1
10"RG - 1005
5 - 9C1S
9501-10-02-PR-DWG-104
9501-P-003
9501-10-02-PR-DWG-104
9501-P-003
9501-10-02-PR-DWG-104
9501-P-003
9501-10-02-PR-DWG-104
9501-P-003
9501-10-02-PR-DWG-104
9501-P-003
9
9501-10-02-PR-DWG-104 / 103
3
9501-P-003
9501-10-02-PR-DWG-104
9501-P-003
9501-10-02-PR-DWG-104
REMAR
RK
4.4.3. 9501-LTP-0
9
003
T
Test
Press
sure
15
50 psig
R
Relief
Valv
ve Set Pres
ss :
16
65 psig
NO
SY
YSTEM
LINE NUMB
BER
P&ID N
NUMBER
9501-P-002
9501-10-02-PR-DWG-103
9501-P-002
9501-10-02-PR-DWG-103
9501-P-004
9
9501-10-02-PR-DWG-103 / 105
5
9501-P-004
9501-10-02-PR-DWG-103
9501-P-004
9501-10-02-PR-DWG-105
9501-P-004/8
9
9501-10-02-PR-DWG-105 / 111
1
9501-P-004
9
9501-10-02-PR-DWG-105 / 108
8
9501-P-004/7
9
9501-10-02-PR-DWG-105 / 110
0
9501-P-004
9
9501-10-02-PR-DWG-105 / 113
3
10
9501-P-004
9
9501-10-02-PR-DWG-105 / 107
7
11
9501-P-004
9
9501-10-02-PR-DWG-105 / 108
8
12
9501-P-004
9501-10-02-PR-DWG-105
13
9501-P-004
9501-10-02-PR-DWG-105
14
9501-P-004
9501-10-02-PR-DWG-105
15
9501-P-008
9501-10-02-PR-DWG-111
16
9501-P-004
9501-10-02-PR-DWG-105
17
9501-P-004
9
9501-10-02-PR-DWG-105 / 114
4
18
9501-P-004
9501-10-02-PR-DWG-105
19
9501-P-004
9501-10-02-PR-DWG-105
20
9501-P-004
9501-10-02-PR-DWG-105
REMAR
RK
PIPING LEAK
L
TEST
T PROCED
DURE
SAN
NTOS (SAMP
PANG ) PTY LTD
L
DOCU
UMENT NO.
9501
1-PP-QA-009
9
REV. 0
Page
e 9 of 14
21
9501-P-004
9501-10-02-PR-DWG-105
22
9501-P-004
9501-10-02-PR-DWG-105
23
9501-P-004
9501-10-02-PR-DWG-105
24
9501-P-004
9501-10-02-PR-DWG-105
25
9501-P-004
2"- DR - 1409
9 - 1C1
9501-10-02-PR-DWG-105
4.4.4. 9501-LTP-0
9
004
T
Test
Press
sure
5.
20
0 psig
R
Relief
Valv
ve Set Pres
ss :
25 psig
NO
SY
YSTEM
LINE NUMB
BER
P&ID N
NUMBER
9501-P-005
9
9501-10-02-PR-DWG-105 / 114
4
9501-P-005
9501-10-02-PR-DWG-114
9501-P-005
9501-10-02-PR-DWG-114
9501-P-005
9501-10-02-PR-DWG-114
9501-P-005
9501-10-02-PR-DWG-114
9501-P-005
9501-10-02-PR-DWG-114
9501-P-005
9501-10-02-PR-DWG-114
9501-P-005
9501-10-02-PR-DWG-114
9501-P-005
9501-10-02-PR-DWG-114
10
9501-P-005
9501-10-02-PR-DWG-114
11
9501-P-005
9501-10-02-PR-DWG-114
12
9501-P-005
9501-10-02-PR-DWG-114
13
9501-P-005
9501-10-02-PR-DWG-114
14
9501-P-005
9501-10-02-PR-DWG-114
15
9501-P-005
9501-10-02-PR-DWG-114
REMAR
RK
Test Medium
Leakk test will use Nitrogen (N2) from N2
N liquid carrier.
Pneu
umatic leak testing can
n be very hazardous operation
o
du
ue to dange
er of explos
sive rupture
e
should any mecchanical failure occurs. It therefore
e shall onlyy be carried out with th
he following
g
condition:
PIPING LEAK
L
TEST
T PROCED
DURE
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DOCU
UMENT NO.
9501
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Page 10 of 14
All perssonnel conccerned with Gaseous leak testing must be ccompetent and
a familiarr
with hazzard associated with an
ny gas used
d
Where the
t source of pressure
e is higher than
t
test prressure, pre
e-caution ag
gainst over-pressurization of the piping system
s
sha
all be taken
n by the usse of reduc
cing valves,,
a
or adeq
quate safety
y valve
pressure gauges, and/
6.
Test Equipment
The following diagram
d
is illustration for test equipments, manifold
m
syystem and piping testt
age.
packa
7.
Test Procedurre
7.1. Preparattion
7.1.1.
R
Review
the
e system to
o be tested
d referring to test pacckage defin
nition.
7.1.2.
R
Raise
Perrmit to perrform leak test at sp
pecific are
ea limited as in testt
p
package.
PIPING LEAK
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T PROCED
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Page 11 of 14
7.1.3.
D
Determine
e scaffoldin
ng and acc
cess requiired to rea
ach all testt points in
n
t system
the
m.
7.1.4.
P
Prepare
alll test poin
nts/flanges in the test package to be ready for testt
u
using
a ma
asking tape. Make a small hole on the m
masking ta
ape (1 mm
m
d
diameter)
f soap bu
for
ubble test. Use the same
s
hole for repetitive test.
7.1.5.
L
Line
up in
nternal va
alve in the
e test pacckage and
d limit / is
solate the
e
p
package
using valve.
7.1.6.
S
Set-up
N2
2 supply, manifold system
s
an
nd connecttion to the
e injection
n
p
point
of tesst package
e as instruc
cted in the test block diagram.
7.1.7.
Install a sa
afety barricade surro
ounding th
he test pacckage to protect
p
the
e
a
area
from unauthorizzed person
nnel entry.
7.1.8.
D a public announcement th
Do
hat a pneumatic leakk test in th
he specificc
a
area
will be
e commen
nced.
7.2.
Procedu
ure
7.2.1.
S
Start
the Nitrogen
N
G
Generator.
Slowly inccrease the
e manifold system to
o
s and tesst the safetty relief valve as requ
set
uired for th
he package
e.
7.2.2.
S
Start
presssurizing the
e test pack
kage to 25%
% of the prressure tes
st.
C
Carry
out audible lea
ak test and do grosss leak testt, rectify an
ny leak ass
n
necessary
.
7.2.3.
C
Continue
p
pressurize
the system
m in 25% increment and carry
y out grosss
l
leak
test at each stag
ge. Rectify
y the leak as
a required
d.
7.2.4.
C
Continue
p
pressurizin
g to final pressure
p
te
est (100%).
C
Carry
out leak test fo
or all targett pipe jointss.
ely remove the masking tape fro
om successsful tested
d joints.
Immediate
the leak re
C
Complete
eport.
7.2.5.
D
Depressur
rize the sysstem throu
ugh design
nated path as instruc
cted in the
e
t
test
package.
PIPING LEAK
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T PROCED
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Page 12 of 14
7.2.6.
D a reme
Do
edial repairr for any le
eak joint/s. Restart leak test fo
or repaired
d
j
joint/s
until the system complettely accepttable.
7.2.7.
R
Remove
th
he test con
nnections and
a reinsta
ate the systtem.
S
Sign
off le
eak test permit,
p
rem
move the safety ba
arrier and announce
e
c
complete
t
test.
8.
Acce
eptance Criteria
The acceptable
a
leak is conssidered acceptable whe
en leaking is
i less than leaking is less
l
than
80 bu
ubbles per minutes.
m
9.
Rep
porting and
d Accepta
ance
Test result of the leak test including th
he pressure
e records, shall
s
be pre
epared as an
a attached
d
ord by Leakk test engineer. The te
est result sh
hall be available to the
e
form of the Leakk Test Reco
orized Inspe
ector for accceptance
autho
Durin
ng test, QC inspector and authorizzed personn
nel shall mo
onitor the ga
as pressure.
The Leak
L
test shall
s
be con
nsidered in
ncomplete until
u
the rep
port has be
een signed by Santoss
autho
orized repre
esentative.
All te
est data and
d certificate
e shall be compiled
c
an
nd the leak test reportt shall be compiled
c
ass
part pre-commis
p
ssioning rep
port
LEAK TE
EST CHECK
K SHEET
Pro
oject Name
W
Wortel
Field Development
D
Project
Cu
ustomer
S
SANTOS
(Sam
mpang) Pty. Ltd.
L
Syystem Numbe
er
Na
ame of System
m
Te
est Pack
Lo
ocation / Area
W
Wortel
Wellhea
ad Platform
No
o.
Resu
ult
Descrip
ption of Check
k
Remark
Scaffoldin
ng / access to all tested flan
nges have bee
en provided
Barricade
e have been provided to limit personnel entry
Line up th
he system follo
owing the testt package
Close and
d plug all drain
n/vent valves.
Close sen
nsing line and equalize any dP sensor.
ps
sig
0
10
ps
sig
1
11
Apply 25%
% of test presssure
ps
sig
2
12
3
13
Apply 50%
% of test presssure
4
14
Check fo
or gross leak & rectify as necessary
5
15
Apply 75%
% of test presssure
6
16
Check fo
or gross leak & rectify as necessary
17
7
8
18
Do Leak test
t
for all join
nts in the syste
em, and rectifyy any leak/s
9
19
Complete
e the leak jointt/s record.
0
20
Depressu
urize the syste
em through venting path acccording test pa
ack dwg.
1
21
ps
sig
ps
sig
ps
sig
otes :
No
Descrription
Comp
pany
Signature
Print Name
N
Date
Performed by
Witnesse
ed / Approved by
LEA
AK TEST PROCED
DURE
me
Project Nam
Test Pack
Customer
Santos
s Sampang Pty, L
Ltd.
Location
mber
System Num
stem
Name of Sys
Test Pressu
ure
Allowable Leak Rate
Leak
ID
Description
Company
Signature
Print Name
Date
P&ID
P
Number
Equipment / Tag No
Perforrmed by
Size / Rating
Description
Witnessed / Approved
A
by
Leak
k Rate
bubble
es/min
Witnessed / Approved by
SAN
NTOS
Remarks:
Test Package.
Test Limit, close valve to limit the package.
Equalize PdI/PdT and isolate from the system.
N2 Injection Point.
Depressurizing Path
9501-LTP-001
1120 PSIG
Remarks:
Test Package.
Test Limit, close valve to limit the package.
Equalize PdI/PdT and isolate from the system.
N2 Injection Point.
Depressurizing Path
9501-LTP-001
1120 PSIG
Remarks:
Test Package.
Test Limit, close valve to limit the package.
Equalize PdI/PdT and isolate from the system.
N2 Injection Point.
Depressurizing Path
9501-LTP-001
1120 PSIG
Remarks:
Test Package.
Test Limit, close valve to limit the package.
Equalize PdI/PdT and isolate from the system.
N2 Injection Point.
Depressurizing Path
9501-LTP-002
1120 PSIG
Remarks:
Test Package.
Test Limit, close valve to limit the package.
Equalize PdI/PdT and isolate from the system.
N2 Injection Point.
Depressurizing Path
9501-LTP-003
150 PSIG
Remarks:
Test Package
Test Limit, close valve to limit the package.
Equalize PdI/PdT and isolate from the system.
N2 Injection Point.
Depressurizing Path.
9051-LTP-003
150 psig
Remarks:
Test Package.
Test Limit, close valve to limit the package.
Equalize PdI/PdT and isolate from the system.
N2 Injection Point.
Depressurizing Path
9501-LTP-003
150 PSIG
Remarks:
Test Package.
Test Limit, close valve to limit the package.
Equalize PdI/PdT and isolate from the system.
N2 Injection Point.
Depressurizing Path
9501-LTP-003
150 PSIG
Remarks:
Test Package.
Test Limit, close valve to limit the package.
Equalize PdI/PdT and isolate from the system.
N2 Injection Point.
Depressurizing Path
9501-LTP-003
150 PSIG
Remarks:
Test Package.
Test Limit, close valve to limit the package.
Equalize PdI/PdT and isolate from the system.
N2 Injection Point.
Depressurizing Path
9501-LTP-003
150 PSIG
Remarks:
Test Package
Test Limit, close valve to limit the package.
Equalize PdI/PdT and isolate from the system.
N2 Injection Point.
Depressurizing Path.
9051-LTP-003
150 psig
Remarks:
Test Package
Test Limit, close valve to limit the package.
Equalize PdI/PdT and isolate from the system.
N2 Injection Point.
Depressurizing Path.
9051-LTP-004
20 psig
Remarks:
Test Package
Test Limit, close valve to limit the package.
Equalize PdI/PdT and isolate from the system.
N2 Injection Point.
Depressurizing Path.
9051-LTP-004
20 psig