Doc No : SJ-NGL2-MS-0027

METHOD STATEMENT Rev : 1

LEAK TEST FOR AIR LINE AND Date : 05. June. 2014
IMPULSE TUBING
Page : 01 of 07

METHOD STATEMENT

FOR LEAK TEST OF INSTRUMENT

AIR LINE AND IMPULSE TUBING

1 05. June. 2014 Issued for Approval

M.Q Mallick M.Q Mallick M.A Raiz
0 13. May. 2014 Issued for Approval
M.Q Mallick M.Q Mallick M.A Raiz
REV DATE DESCRIPTION PREPARED REVIEWED APPROVED

SHAYBAH NGL RECOVERY & UTILITIES FACILITIES PROJECT (PKG 2)

 Document No : SJ-NGL2-MS-0027
Doc No : SJ-NGL2-MS-0027
METHOD STATEMENT Rev : 1
LEAK TEST FOR AIR LINE AND Date : 05. June. 2014
IMPULSE TUBING
Page : 02 of 07

TABLE OF CONTENTS

1.0 Purpose 3

2.0 Scope of Work 3

3.0 Reference Document 3

4.0 Responsibilities 4

5.0 Procedure 5

5.1 General Requirement 5

5.2 Air Line Leak Test 6

5.3 Impulse Tubing Leak Test 7

6.0 Inspection and Quality Record 7

7.0. Test Equipment 7

8.0. Attachments 7

8.1 Test Assembly Diagram Fig.1

8.2 Job Safety Analysis

 Doc No : SJ-NGL2-MS-0027
METHOD STATEMENT Rev : 1
LEAK TEST FOR AIR LINE AND Date : 05. June. 2014
IMPULSE TUBING
Page : 03 of 07

1.0 PURPOSE
The purpose of this Method of Statement is to provide a proper guidelines for
Pressure and leak test of Air line and impulse tubing to insure mechanical integrity of
of system at shaybah NGL Recovery and Utilities project, Pkg#2.

2.0 SCOPE OF WORKS

The scope of this Method Statement covers the objective and requirement of
Pressure and Leak Test of Instrument Air Line and Impulse tubing at NGL Recovery &
Utilities Project (PKG#2).

3.0 REFERENCE DOCUMENTS

3.1 SAES-A-004 General Requirements of Pressure Testing

3.2 SAES-J-901 Instrument Air Supply System
3.3 SAES-J-100 Process Flow Metering 1
3.4 SAES-J-200 Pressure
3.5 SAES-J-300 Level
3.6 SAES-L-150 Pressure Testing of Plant Piping and Pipelines
3.7 SATIP-J-003-01 Instrumentation Piping & Tubing
3.8 SATIP-J-901-02 Instrument Air Distribution Piping Installation
3.9 SATR-J-6001 Pressure/Leak Test for Inst. Air Sub Headers and Pneumatic Hook up
3.10. Schedule "Q" Quality requirement
3.11 Manufacturer's Instruction Manual
3.12 Form#J-010 Instrument Air Line Pressure Test (SA Precommissioning Form)
 Doc No : SJ-NGL2-MS-0027
METHOD STATEMENT Rev : 1
LEAK TEST FOR AIR LINE AND Date : 05. June. 2014
IMPULSE TUBING
Page : 04 of 07

4.0 RESPONSIBILITIES
4.1 Construction Manager
4.1.1 Construction Manager shall be responsible for the over-all direction, monitoring and

control of all the activities related to Pressure and Leak Test for Air Line and Impulse tubing.

4.1.2 Construction Manager shall ensure that Field Supervisor effectively implement
within this Method Statement and related applicable project documents.
4.1.3 Constructions Manager shall be responsible for providing enough manpower as
per construction and Testing schedule.

4.2 Instrument Supervisor

4.2.1 Instrument Supervisor has the responsibility for compliance with this Method Statement
and shall ensure to review contract documents and provide all resources necessary
to effectively implement throughout the construction period.
4.2.2 Instrument Supervisor shall review the construction details and specification with
Instrument Engineers and ensure they fully understand the requirements of the job.
4.2.3 Instrument Supervisor shall ensure that all personnel involved in the work are fully
aware of all quality control requirements.
4.2.4 Instrument Supervisor shall be responsible in delivering the relevant documents and
required materials needed in the implementation of works.
4.2.5 Instrument Supervisor shall check / maintain the adequacy of personnel, equipment
and promoting any required actions necessary to achieve the construction target.
4.2.6 Instrument Supervisor shall monitor the quality and progress of the work and ensure
that job target is achieved.
4.2.7 Instrument Supervisor shall identify any problem, which may affect completion or
progress of the job and produce proposals for submission to construction manager
for resolving the problem.

4.3 QC Manager
4.3.1 QC Manager has the overall responsibility for all QC activities of the project.
He shall be interacting with Construction Manager related to all QC activities.
4.3.2 QC Manager shall be responsible for the control and compliance with design
drawings and specifications for Pressure and leak test of Air Line and impulse tubing
before and during the operation.
 4.4 QC Inspectors
4.4.1 QC Inspector shall be responsible for the QC activities, material control and
traceability, non - conformance management and compilation of Pressure and Leak
Test of Air Line and impulse tubing.

Doc No : SJ-NGL2-MS-0027
METHOD STATEMENT Rev : 1
LEAK TEST FOR AIR LINE AND Date : 05. June. 2014
IMPULSE TUBING
Page : 05 of 07

4.4.2 QC Inspectors shall be responsible for Site QC activities, in co-ordination with

Construction team for Pressure and leak Testing works and inspection activities at Site.

4.5 HSE Manager

4.5.1 Ensures that the HSE functions are being performed / implemented by the line
supervisors.

4.6 HSE Officer

4.6.1 HSE Officer shall monitor related works under carried out, and advise supervisors
for corrective measures, if required. He shall ensure holding of pre task HSE
meeting / daily toolbox talks covering details of specific tasks and specific job
risks involved to the work force involved. He shall also ensure appropriate mode
of communication in case of emergency.

5.0 PROCEDURE

5.1 General Requirements

5.1.1 All pre-test activities (installation and calibration) shall have been completed and
documented prior to start of test.

5.1.2 Necessary and required test equipment, instruments, Pressure gauges and accessories shall
be made available to facilitate performance of test.

5.1.3 All instrument sub-headers and branch system piping, instrument transmission lines shall
be blown free of dirt or scales using clean, oil free, dry plant instrument air or dry bottled
nitrogen prior to testing.

5.1.4 Leak occurrence, as indicated by a drop of pressure shall be located by applying a

commercial bubble fluid or soap solution to areas of suspected leakage, no alteration to
leaking fittings, pipe or tubing shall be attempted until nitrogen test gas has been isolated
and process lines de pressurized.

5.1.5 Leaking fittings, pipe or tubing shall be repaired or replaced as required to provide system
integrity.

5.1.6 After repair the piping system involved shall be re tested until integrity is demonstrated.
5.2 Air Line Leak Test
5.2.1 Instrument Airline to be tested as per SAES-L-150 using the Dry Instrument air or Nitrogen.
Instrument air may be tested at its operating pressure as required by SAES-L-150.

Doc No : SJ-NGL2-MS-0027
METHOD STATEMENT Rev : 0
LEAK TEST FOR AIR LINE AND Date : 13. May. 2014
IMPULSE TUBING
Page : 06 of 07

5.2.2 Disconnect all air consuming pilots, if any, from the section of tubing to be tested.
5.2.3 Connect the Airline to Instrument Air supply system. Dry air to be used for testing the
Lines. 1

5.2.4 Open air supply valve slowly and pressurize air line to operating pressure of instrument
air supply system.

5.2.5 When the system has been fully pressurized it shall be held for Thirty (30) minutes and
checked for leakage at each joint using bubble solution or soap solution. 1
5.2.6 No alteration to Air Line should be attempted until air supply has been isolated and air line
De-Pressurized.

5.2.7 Any observed leakage shall be corrected and a re-test of the system shall be carried out
until a satisfactory result is obtained.
5.2.8 For connection to existing Instrument air lines manufacturers installation procedures for
fitting shall be followed and a GAP inspection gauge used to verify proper make up of
tube connectors.

5.2.9 All new tube connection shall be visually inspected after change over for any leakage.

5.3 Impulse Tubing Leak Test.

5.3.1 Instrument impulse lines, whether piping or tubing, between the root isolation valve and
the instrument isolation shall be pneumatically pressure tested using dry bottled nitrogen
at 1.1 times the design pressure of the piping system or process equipment to which it is
connected.
1
5.3.2 Any Instrument that could be subjected to damage to test shall be disconnected from the
system. 1
5.3.3 Instrument impulse tubing shall be tested by closing the process line block valve and
connecting a pressure test manifold to process instrument manifold or flange connection
points. (Refer to Test Assembly Diagram)

5.3.4 A preliminary check at not more than 25% of operating pressure shall be made with the
supplying manifold valve closed to permit examination for leaks by observing pressure
gauge used in the test.
 5.3.5 The test pressure shall then be increased to full test pressure and shall be held for at least
thirty (30) minutes with supplying manifold valve closed to permit examination for leaks by
observing pressure gauge used in the test.

5.3.5 Leaks, which cause the test pressure to decrease more than one graduation on test gauge
during the holding period, shall not be acceptable.

5.3.6 For connection to existing process tubing during cut over manufacturer installation
procedure for the correct make up of tube connectors shall be followed, a GAP inspection
gauge shall be used to verify proper makeup of fitting. All new tube connection shall also
be visually inspected after change over for leakage.

Doc No : SJ-NGL2-MS-0027
METHOD STATEMENT Rev : 1
LEAK TEST FOR AIR LINE AND Date : 05. June. 2014
IMPULSE TUBING
Page : 07 of 07

6 Inspection and Quality Record

6.1 All stages of work shall be monitored and inspected in accordance with the Approved
Method Statement & relevant SATIP’s and Quality Records shall be maintained properly.
1
6.2 The holding time for testing of Air Line and Impulse tubing shall be Thirty (30) minutes.

6.3 Every test conducted shall be recorded on applicable checklist and shall be signed off by
Subcon, Contractor and Company Quality Representative.

6.4 Test reports shall include but not to be limited to

6.4.1. Calibration Certificates for Gauges.

6.4.2. Pressure Test Reports.
6.4.3. All Test Record.

7 Test Equipment & Tools

7.1 Test Manifold for Pressure Leak Test

7.2 Pressure Test Gauge
7.3 Pressure Relief Valve
7.4 N2 Cylinder
7.5 Flexible Tube
7.6 Electrical Tool Box
7.7 Snoop/Soap Solution for Leak Test

8 Attachments
8.1 Test Manifold Diagram Fig.1
8.2 Job Safety Analysis
SN Material Description Quantity Remarks
1 Pressure/Leak Test Manifold 1
2 Pressure Guage 5 Check Pressure Range
3 PRV 5 Check pressure Range
4 High Pressure Tubing 100 Mtr Check Max pressure
5 Tube Fitting 10 Each Check Type n Size
6 Tafelone Tape 50
7 GAP inspection Gauge 2 Verify size from Hook up.
8 Open Spanner 4 Set Check Size
9 Snoop for Leak Detector 20 bottle

10 Nitrogen Cylinder with Calibrated 4 Cylinder

Regulator and Pressure Guage