LEAK TEST PROCEDURE

All piping shall be pressure tested after the construction and before being place in operation to prove it has
adequate strength for the propose and that it does not leak. Testing shall not commerce until at last joint to allow
sufficient time for the joint to cool.
External Piping (from outlet of service station to valve
1) Close and plug or cap all opening completed lines.
2)
) !ressuri"ed each completed line to a pressure of #$ psi measure with a pressure gauge.
%point A and point &)
') Testing medium ( )itrogen
*) The piping will be checked with soap and water solution.
+) The pressure will be held for a period of 2' hours. ,f there is no visible loss of pressure after 2' hours-
the line will be deemed to be gas tight.
.) ,f a pressure gauge indicated the pressure drop- the testing operations connection and shut(off valve
be first rechecked for leak and tightened as necessar/.
0) ,f a pressure drop is still evident- then all joints and lastl/ the piping it self will be checked with soap
and water solution.
#)
1$)
S!TE SA"ET# PROCEDURE
Purpose
Polic$ Statement % O&'ectives
,nstall pressure gauge %$ ( $$ psig) to each completed line for pressure indication %refer to figure 1)
12 3astech 4ngineering 5dn. &hd. representative%s) shall carr/ out the testing work.
The representative%s) of 677!- 3as 8ala/sia 5dn. &hd. and 9wner will witness the testing work.
This chapter sets out the principles for the organi"ation of safet/ in all aspects of 12 3astech 4ngineering
5dn. &hd. operations in accordance with 12 3astech 4ngineering 5dn. &hd. polic/ on safet/.
The requirements of this chapter will appl/ equall/ to subcontractors working for 12 3astech 4ngineering
5dn. &hd. in its areas of operation as 12 3astech 4ngineering 5dn. &hd. organi"ation.
12 3astech 4ngineering 5dn. &hd. polic/ of safet/- health and environment.
!rovide a safet/ working environment.
` !rotect the general public and personal from injur/ or ill health and prevent properties from loss
or damage resulting from its related activities.
` 5afeguard the conservation of the environment
`
contribute positivel/ to the compan/:s efficienc/ and business success.
Safet$ Targets
to aim for ;
` )o fatalities and < or injuries.
` !revention of lost time and an/ other significant accidents.
!mplementation Aspects
The polic/ is implemented with special attention to following specific aspects ;(
` The requirements of the relevant government legislation are followed
`
` 2orking or job instruction during or before implementation must pa/ due regard to safet/
requirements.
`
Responsi&ilities
` 4ver/ emplo/ee is responsible for its own safet/ and the safet/ of his fellow colleagues.
` ,t is ver/ important that accident = incidents are reported to avoid recurrence.
`
Duties an( Responsi&ilities
)anager*s Responsi&ilit$
4nsure that working practices and attitude are adopted- and that conform to the polic/ laid b/
4nsure that accident are adequatel/ investigated and effective measure taken to prevent recurrence.
4nsure that effective corrective measure are taken to eliminate ha"ardous conditions and practices.
Pro'ect Engineer*s Responsi&ilit$
5et good e>amples in adopting safe behaviour.
4nsure that all workmen obe/ safet/ rules and follow safet/ procedures and practices.
,nvestigate accidents fire and dangerous accuracies and take effective remedial action to
prevent repetition.
12 3astech will conduct its operation in such a manner as to ;(
in addition to reducing individual suffering = loss- 12 3astech firml/ believes that the polic/ will
,n taking steps to ensure a safet/ working environment- 12 3astech = subcontractor emplo/ees are
,n addition- 12 3astech standard- procedures = regulation will be applied.
All works carried out- is effectivel/ monitored b/ 12 3astech staffs.
Construction equipments- site material and other- to be located at destinated area.
12 3astech 4ngineering 5dn. &hd.
8aintain good housekeeping in all areas under their control.
Su&+contractor*s Responsi&ilit$
The sub(contractor:s emplo/ee shall be made full/ aware of the safet/ regulation applicable to
the work site including the work s/stem e.g. smoking regulation- welding- cutting etc.
The sub(contractor shall ensure that its emplo/ees are provided with the appropriate safet/ and
personal protection equipment.
,or-er*s Responsi&ilit$
Carr/ out their duties in a safe manner and with due regard to health and incidents.
?eport all ha"ard condition to their immediate supervisor without dela/.
2ear protective equipment correctl/ as and when required and maintain these in good order.
.eneral Safet$ Re/uirements
Prevention of Acci(ents
Accidents are unwanted or une>pected occurrences generall/
cause b/ persons indulging in unsafe practices or
create unsafe conditions
or used of unsafe equipment
All accident can be prevent if personal conscientiousl/ tr/ to avoid and eliminate unsafe practices
= conditions
E0ER# PEOPLE 1AS T1E RESPO2S!3!L!T# TO ACT POS!T!0EL# TO
PRE0E2T ACC!DE2T "RO) OCCURR!2.4
1ouse Keeping
3ood housekeeping at all work areas is essential to accident:s prevention of injuries and fires.
?emoves all scar- broken or unwanted parts of equipment from works areas.
!laces steel bars- cables properl/ to avoid tripping ha"ards
Clean up spillages immediatel/.
Personal Protective E/uipment
Alwa/s use personal protective equipment when the job and the condition warrant is use
9ccasional visitor can be e>emption from wearing safet/ footwear
@se of other personal safet/ apparel- such as goggles- gloves etc. is mandator/ when the
circumstances distaste this.
Tools % E/uipment5 )ac6iner$
A visual inspection should be made each da/- or before each use- and < or b/ the user to ensure
!rotective footwear must be worn at worksite
that tools = equipment are in safe operation conditions.
Area of ?estricted Access
Aor safet/ and securit/ reasons- the site to which access is restricted.
5moking is strictl/ prohibited at site.
Alco6ol % Drugs
,t is strictl/ for forbidden to consume or be in of alcohol and drugs at site.
Aire Aighting 4quipment
!ortable carbon dio>ide fire e>tinguisher is provided
"irst Ai(
,f an accidents occur and there are people injured- the first priorit/ is to save lives. An/ injured person
should be given prompt first(aid treatment and such medical attention as ma/ be necessar/.
Airst(aid kit is to be displa/ed in the site office.
Engineering Construction
Cutting = 2elding %Aabrication of !iping)
)o unauthori"ed person shall be allowed to use welding equipment.
!ersonal protective equipment must be worn during welding = cutting which shall included goggles-
face shield.
2hen welding is cutting = welding on a line- no one should work in front of near the open end.
Current must be turned off when equipment is not use for a period of time.
,n changing welding electrodes- care must be taken to avoid making contact with other sides of the
circuit.
2elding is done in restricted area. )ever attempt an/ work which is out side the parameters of the
work barrier.
Civil ,or-s (2ot in t6is scope
9nl/ personal who are ph/sicall/ suitable can be emplo/ed for the jobs.
Assembl/ and installation
)o smoking shall be allowed within or in the vicinit/ of works site.
8atches or lighters is prohibited
Buring installation of service stations- do not works or walk under the load of crane in operation.
)o welding is allowed.
Acci(ents % Emergencies
5tatuar/ ?equirements
There are several enactments in the states relating to statutor/ requirements in the reporting of
accidents. The principle of these are ;(
2orkmen:s Compensation Act
A = 8 Act
?eporting !rocedure for accident- fire emergencies
All workers witnessing in accident should inform their supervisor as soon as possible.
,n the case of accident- the site personal concerned must make a report.
CO))!SS!O2!2. PROCEDURE
.E2ERAL
SCOPE
This document describes the general procedure information and instruction necessar/ for the
commissioning of gas pipeline s/stem.
RE.ULAT!O25 CODES % STA2DARDS
All labour- material and equipment shall be governed b/ the latest applicable codes and standard.
A)5, &1.0 C 3as Transmission and Bistribution !iping 5/stem
85 0$ C Code of !ractice for 5torage- Dandling and Transportation of
85 #$ C Code f !ractice for the installation of Auel 3as !iping 5/stem
And Appliances.
3as 5uppl/ ?egulations 1##.
The labor 9rdinance
1iquidfied !etroleum 3ases.
C 5uruhanja/a Tenaga
CO))!SS!O2!2. OR.A2!7AT!O2
CO))!SS!O2!2. E2.!2EER
of the entire operation. C1,4)T shall nominate an individual who will be the C1,4)T commissioning
coordinator with particular responsibilit/ for the commissioning phase.
The commissioning engineer will be responsible for the planning- organi"ation and supervision of
all activities from the stage of pre(commissioning to commissioning- assisted b/ his team of engineer-
The commissioning engineer will be responsible for all interfacing with C1,4)T commissioning
coordinator.
CO))!SS!O2!2. PERSO22EL
Aor commissioning purposes- the following shall be the minimum requirement ;(
ii) Client ?epresentative C 1 no %C1,4)T)
iii) 3eneral 2orkers
9ne group will be situated at the gas injection point with the other group at the end of a
commissioning section.
The commissioning engineer will take full charge of the commissioning activit/ from the central control
initiall/ at the source of the gas i.e. at the e>isting future take(off and when appropriate- be relocated
to locations along the pipeline s/stem or at the downstream interface- as and when deemed necessar/
b/ the chief commissioning engineer.
CO))U2!CAT!O2
Communication between the various groups engaged in commissioning will be via multi(channel
radio s/stem and < or mobile telecommunication s/stem.
As a minimum- communication equipment will be provided to as follow ;(
Commissioning 4ngineer
,ndividual 3roup 1eader
?eference Test 3auges 1ocations
This telecommunication equipment will be manned continuall/ during the entire commissioning
operationE communication traffic will be restricted to messages directl/ related to commissioning.
2OT!"!CAT!O2 O" AUT1OR!T#
The !olice- Aire Authorities and all other relevant parties shall be given advance notice of the dates
of the commissioning operations.
SA"ET# CODE O" PRACT!CE "OR CO))!SS!O2!2.
SCOPE
This section provides a general guide to safe practice during commissioning to take reasonable care
for the health and safet/ of himself and of other person who ma/ be affected b/ his acts or omissions.
,t is therefore the person:s dut/ to;(
Alwa/s adhere to safet/ regulations.
Alwa/s use the procedures and methods of operation laid down in this procedure and the local rules
and regulations.
12 3astech 4ngineering 5dn. &hd. will nominate a Commissioning 4ngineer and will have sole change
supervisors- technicians- vendor representations and laborers etc.
i) 3roup 1eader C 1 no %12 3astech 4ngineering 5dn. &hd.)
C no %12 3astech 4ngineering 5dn. &hd.)
Alwa/s use the correct tools and equipment for the job- and wear the correct protective clothing.
,mmediatel/ report an/ ha"ard to the appropriate authorit/.
)ever operate valves- unless instructed to do so- or as part of his duties.
Commissioning engineer acting in a supervisor/ capacit/ have the added responsibilit/ of making sure
that all person under their control or direction are aware of the safet/ regulations- work procedure
and equipment provided for their protection- and that the/ are properl/ used. 2hen acting in a
supervisor/ capacit/ the/ must therefore;(
Dave a detailed knowledge of safet/ regulations.
,nclude in all routine orders- specific instructions regarding safet/.
?estrain personnel from taking unnecessar/ risks.
4nsure that all personnel under their control or direction are familiar with safet/ requirement of the
job.
5top an/ dangerous work practice immediatel/ and report an/ such actions to the appropriate
authorit/.
?ectif/ or report an/ defect in plant or equipment that ma/ affect safet/ taking an/ necessar/.
5et a personal e>ample in good safet/ practice at all time.
These recommendations are supplementar/ to the Construction 5afet/ ,nstructions and the
directions from the 5afet/ 9fficer.
SA"ET# O""!CER
The 5afet/ 9fficer will be responsible for all aspect of safet/ control and prevention of accidents
during the testing- commissioning and hand(over operations period.
Responsi&ilities
The safet/ office shall take overall responsibilit/ for the enforcement of the 5afet/ ?egulation and
other safe working practices contained in these !rocedures including ;(
Co(ordination of safet/ measure where construction work has- of necessit/- to be carried out
alongside machiner/ and equipment under test or being commissioned.
4nsuring that- before entr/ onto the site- all supervisor/- construction and operating personnel
are full/ conversant with the 5afet/ ?egulations on work procedures in force.
4nsuring that all personnel are equipped with and use of appropriate protective clothing and that
all ha"ard warning signs and devices- notices and barriers are installed and maintained.
Carr/ out routine inspection on fire fighting equipment and first aid facilities- and check these
are in place and are properl/ serviced.
5topping an/ dangerous work practice and immediatel/ reporting them to the commissioning
engineer.
1OUSEKEEP!2.
The 5afet/ 9ffice shall be responsible for ensuring the following ;(
Aloors- walkwa/s and stairwa/s are kept free from obstructions at all times.
9il spillage and similar ha"ard are cleaned up immediatel/.
?efuse bins are provided and marked clearl/ to separate metal scrap- refuse from an/ material
liable to spontaneous combustion- arrangements are made for the regular empt/ing and safe
disposal of the contents.
5uitable notices should be prominentl/ displa/ed to warn personnel of regulations regarding access.
naked lights- smoking or other ha"ards.
,ORK PER)!TS
A 2ork !ermit 5/stem should be introduced at the commencement of commissioning. 9ne specific
have been introduced into a work area- work shall not commence until a work permit has been issued
b/ the commissioning engineer.
The objective of the permit to work s/stem will be to protect personnel working in ha"ardous areas
such that ;(
9nl/ the central authorit/- at a time- can issue permits to allow personnel working in ha"ardous area.
9nl/ personnel involved in the task and covered b/ the permit can enter the area.
All personnel concerned are made aware of the ha"ards involved and measure to be taken.
The area is clearl/ defined.
The right of personnel to enter and work in the area is limited to a stated time.
Adequate suitable protective clothing and equipment are provided and used.
)ED!CAL SER0!CES
Adequate medical and first aid facilities shall be available at an/ location where commissioning work
is in progress to provide prompt treatment of injuries.
The safet/ officer shall also ensure that evacuation transport facilities are available on a standb/
basis in the event of an emergenc/ occurring during pre(commissioning and commissioning.
OPERAT!O2 SA"ET#
All personnel involved with the commissioning operations should be familiar with the safe action to
take under emergenc/ condition.
report the emergenc/ to the commissioning engineer and safet/ officer for assistance if required.
All personnel- other than those assigned to fire fighting duties- shall assemble outside the main
e>it gate for a head count.
All personnel to be accounted for and na/ injured persons removed to safet/. An/ mission personnel
to be located quickl/ b/ a s/stematic search b/ a nominated search team.
,n case of emergenc/- conditions %fire- e>plosion- gas leak- etc) the following action is required.
All fire fighting facilities to be manned.
,nvestigate damage- repair and return the station to operational status.
)ATER!AL RE8U!RE)E2T
The following list of materials- consumable items- tools and equipment represent the basic
requirement of the commissioning activities ;(
Fendor drawing and operating manuals- if required. %A complete set available at the central
commissioning control location and relevant documents).
4quipment test and inspection Certificate to be available for disposal b/ the commissioning
engineer.
5uitable range of hand tools- spanners- socket sets etc. %9n set each for the central commissioning
control location and individual commissioning groups).
1ubrication equipment- grease guns- lubricant etc. %one set each for the central commissioning
control location and individual commissioning groups).
1 unit of o>/gen detector.
Communication 4quipment ( 8ulti channel radio s/stem and < or mobile telecommunication s/stem.
G5noop/G leak detection fluid.
SC1EDULE O" OPERAT!O2
STATUS PR!OR TO CO))!SS!O2!2.
Commissioning can commence onl/ after ;
D/drostatic < pneumatic testing completed.
Aunctional testing of all equipment completed.
Commissioning site cleaned.
PUR.!2. O" T1E P!PEL!2E S#STE) O" A!R
2ith all pre(commissioning activities completed to the satisfaction of the commissioning engineer-
and all liaison with upstream and downstream interface in(place- the commissioning engineer ma/
start purging the pipeline s/stem of dr/ air with the introduction of nitrogen to flood the entire
pipeline s/stem.
9nce the entire pipeline s/stem is purged until free of air- natural gas will then be introduced in
sections. !ressuri"ation of the pipeline sections will be steps to facilitate leak(checking e>ercise. 9nce
the pipeline is full/ pressuri"ed- we will purge the s/stem until 1$$H 141 is achieved.
&ranch pipe work connection associated with the main pipeline s/stem will be purged separatel/
of nitrogen.
A detail commissioning procedure shall be forwarded prior to the proceedings.