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1.1

Leak Testing Procedure

Objective
The objective of this section is to guarantee the integrity of process equipment and / or pipework that has been reassembled after inspection, maintenance, repairs, modifications or replacement, prior to it being returned to operation. This is required in order to eliminate the loss of containment of process fluids, thereby protecting the safety of all personnel either involved with, or in the vicinity of, the plant and maintaining the integrity of the Installation.

1.2

Definitions for Leak Testing Vacuum Test A test to prove that the equipment does not suffer from ingress of fluid from external sources. Normally required for any equipment that is designed to operate under vacuum conditions. A pressure test, carried out at 95% of the Relief Valve setting, prior to returning an item of plant into service after the pressure containment envelope has been breached, to check integrity of the system and confirm absence of leaks. For hydrocarbon systems, this test is normally performed with the use of nitrogen. A pressure test carried out at a positive pressure, approximately 2 - 10 bar(g), for gross leak identification. A Nitrogen Leak Test carried out with a Nitrogen/Helium mixture, using Helium Sensing instruments to monitor for leakage from potential leak paths (flanges, seals etc.) A pressure test carried out using the service fluid under its maximum operating conditions and a leak search carried out. A specific document or procedure produced to cover a unique situation. The OP is the gauge pressure which prevails inside equipment and piping during any intended operation. The OP is determined by the process engineer The MOP shall be determined by the process engineer in consultation with the process control engineer. The MOP is typically 105 % of the OP in order to provide sufficient flexibility for the control of the intended operations. The MOP shall be not less than 1.0 bar above the OP, except in pressurised LPG storage facilities, where the MOP is equal to the vapour pressure at the derived maximum operating temperature and assessed LPG composition. If this margin is not sufficient for control, starting up, shutting down or other specific operations, a higher MOP shall be specified. The reason for this increased MOP shall be stated in the pertaining documents.

Reinstatement Test

Gross Leak Check Sensitive Leak Test

In-Service Reinstatement Test Method Statement Operating Pressure (OP)

Maximum Operating Pressure (MOP)

Design pressure (DP)

The DP (sometimes referred to as the upper design pressure, UDP) is the gauge pressure at the top of the equipment in its operating position that is taken to determine the minimum thickness of equipment parts at the DT. The DP is initially selected by the process engineer and finally determined in close consultation with the mechanical design engineer. Since the DP is related to the top of the equipment, for other parts or elements of the equipment the designer shall establish the associated design pressures taking into account the maximum pressure drop caused by flow through the equipment, plus the fluid static head.

NOTE: The definitions for pressure were taken from DEP 01.00.01.30-GEN Definitions of Temperature, Pressure and Toxicity Levels - December 2008 (DEP Circular 14/09 has been incorporated) 1.3 Reinstatement Policy This section address the decision making process to determine the testing that is required, prior to reintroducing the process fluid into a system after intrusive inspection, maintenance and / or engineering work. The Standard is to carry out testing using Inert Medium or Sensitive Leak testing using Nitrogen/Helium mix if assessed as necessary. In-service Leak Testing may be utilised only if achieving the Standard is Not Practicable and has been Risk Assessed as acceptable. Minimum In-service Reinstatement pressure is Maximum Operating Pressure as defined in 4.2 above and shall be used for Low Risk scenarios where 5 or less flanges have been disturbed. IMPORTANT NOTE: It is a deviation from this Procedure, if In-service Leak testing is proposed or carried out to Operating Pressure as defined in 4.2 above. 1.3.1 Method Options in Order of Consideration 1. 2. Sensitive Leak Test using N 2 /He to 95% RV pressure. Nitrogen Testing to 95% RV pressure - Acceptance criteria is 15 minutes holding pressure.
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The PDO Standard is Sensitive Leak Testing for Sour Service and Nitrogen for Sweet Service. Option 3 below shall only be considered if Options 1 & 2 are Not Practicable, the affected flanges are 5 or less and a Risk Assessment has been conducted. Refer to Section 4.4 for more detail. 3. Gross Leak Check (10% of MOP or 10bar maximum), followed by In-service Leak Test to MOP.

On facilities where High H2S levels are encountered i.e. Harweel, Sensitive Leak testing shall be enforced.