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PR-1073 - Gas Freeing, Purging and Leak Testing of Process Equipment (Excluding Tanks)
PR-1073 - Gas Freeing, Purging and Leak Testing of Process Equipment (Excluding Tanks)
L.L.C.
Document Title: Gas Freeing Purging and
Leak testing Process Equipment and
Pipework
Document ID
Document Type
Security
Discipline
Owner
Issue Date
Revision
PR-1073
Procedure
Unrestricted
April 2010
4.1
This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any part of
this document may be disclosed to others or reproduced, stored in a retrieval system, or transmitted in
any form by any means (electronic, mechanical, reprographic recording or otherwise) without prior written
consent of the owner.
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Document Authorisation
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ii Revision History
The following is a brief summary of the 4 most recent revisions to this document. Details of all
revisions prior to these are held on file by the issuing department.
Revision
No.
Date
Author
Scope / Remarks
Apr-11
4.1
Mar-11
4.0
Apr-10
3.2
Feb-10
3.1
Jan-09
1.0
Sept
01
UOP/1
Sept
98
UOP/1
Maintenance CoP
CP-115
See Appendix 4
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TABLE OF CONTENTS
1
Introduction........................................................................................................................... 7
1.1
Background..................................................................................................................... 7
1.2
Purpose........................................................................................................................... 7
1.3
Scope.............................................................................................................................. 7
1.4
1.5
1.6
Step-out Approval............................................................................................................ 8
1.7
ALARP............................................................................................................................. 8
General.......................................................................................................................... 10
3.2
3.2.1
3.2.2
3.2.3
3.3
3.3.1
3.3.2
Gas Freeing............................................................................................................ 14
3.3.3
3.3.4
3.3.5
3.3.6
Series Purging........................................................................................................ 15
3.3.7
Displacing To Air..................................................................................................... 15
3.4
3.5
Sampling....................................................................................................................... 16
Leak Testing........................................................................................................................ 17
4.1
Objective....................................................................................................................... 17
4.2
4.3
Reinstatement Policy..................................................................................................... 18
4.3.1
4.4
4.5
4.5.1
4.5.2
4.6
4.7
Vacuum Testing............................................................................................................. 23
4.8
Hazards............................................................................................................................... 24
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5.1
5.2
5.3
Leak Testing.................................................................................................................. 24
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Introduction
1.1
Background
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An explosive atmosphere is not present during such times that work is being
undertaken
IMPORTANT: This procedure will be used for gas freeing, purging and leak testing
process system and equipment that has been commissioned and is being operated
as a production unit.
1.2
Purpose
The purpose of this procedure is to detail the steps necessary to ensure that
hydrocarbon process equipment is correctly gas-freed before the pressure containment
is broken; purged of any explosive mixtures before being returned to hydrocarbon
process service; and leak tested to ensure pressure containment is confirmed.
This procedure may be used in conjunction with PR-1077 - Preparation of Static
Equipment for Internal Maintenance and Inspection.
1.3
Scope
This scope of this procedure1 covers gas-freeing, purging and leak testing of
hydrocarbon process equipment and pipework.
Specific plant / equipment level Work Instructions / Method Statements shall be
developed prior to the work being undertaken. These shall form part of the Scope of
Work.
1.4
The procedure shall not detail removal of instrumentation lines where the volume of
hydrocarbon vapour / gas / liquid is small and will therefore not present an explosion hazard.
However safe working practice shall still be observed when undertaking this work.
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PR-1073 - Gas-Freeing, Purging and Leak Testing Process
Equipment and Pipework
1
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1.5
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1.6
Step-out Approval
This procedure is mandatory and shall be complied with at all times. Should
compliance with the procedure be considered inappropriate or the intended activity
cannot be effectively completed or safely performed, then step out authorisation and
approval must be obtained in accordance with PR-1001e Operations Procedure
Temporary Variance, prior to any changes or activities associated with the procedure
being carried out.
1.7
ALARP
ALARP is the acronym for As Low As Reasonably Practicable which simplified means,
reducing the risk to a level at which the cost and effort (time and trouble) of further risk
reduction are grossly disproportionate to the risk reduction achieved. Full Compliance
to PDO Standards and Procedures is a key element in achieving ALARP.
For more details refer to ALARP Definition
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Production Coordinator
Production Supervisor
Production Operators
Specialist leak
Testing Contractor
Page 9
Equipment selection
Gas testing.
Leak testing.
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3.1
General
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Purging This is the process whereby the atmosphere within the process
equipment / pipework is purged of air by an inert gas i.e. nitrogen prior to final
leak testing and reinstatement.
The following procedures shall be referenced in conjunction with this Section and
Section 3.
PR-1076 - Isolation of Process Equipment
PR-1077 - Preparation of Tanks and Vessels for Internal Work Procedure
PR-1086 - Locked Valve Control
PR-1148 - Confined Space Entry
PR-1154 - Gas Testing
PR-1172 - Permit to Work
3.2
Volume of liquid;
Pressure;
Location;
Concurrent activities;
NOTE: When draining and flushing to an Open Pit a Risk Assessment reviewed and
signed by the appropriate authority shall be required.
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The Residual Risks associated with the draining / flushing operations are LOW
(after putting controls in place as part of the Risk Assessment)
A TRIC Discussion is held and a TRIC Card completed before the operation is
commenced
Open pits shall be lined with thick gauge PVC covered with firefighting foam
to reduce evaporation of hydrocarbon to atmosphere.
Hazardous Areas
A hazardous Zone 1 will be established 1m above the pit and 3m around the
pit. The pit itself shall be Zone 0
All electrical equipment that does not meet the specification for operation
within these Zone ratings shall be isolated
Vacuum Tankers
Continuous gas testing will be required if vehicles such as mobile cranes and
vacuum tankers are required to be run in the vicinity of the pit.
Local gas testing shall be required before other vehicles are allowed to enter or
are restarted in the vicinity of the pit.
General
Page 11
When breaking flanges sufficient bolts will be retained to enable the flanges to
be closed in the event of uncontrolled draining.
PR-1073 - Gas-Freeing, Purging and Leak Testing Process
Equipment and Pipework
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Reduce pressure.
Nitrogen for purging purposes shall be supplied in quads or for large operations tankers
or portable high volume tanks. The nitrogen tanks and associated equipment are
normally supplied by a contractor, who will also supply competent personnel to
operate the equipment. However, this does not remove the responsibility of the PDO
Operations staff for the overall supervision and the safe completion of the work under
the PDO PTW System.
Page 12
Where equipment is located such that any spillages of nitrogen liquid may
cause structural damage, charged fire hoses must be available to deal with any
spillage.
All nitrogen hoses shall have current pressure test certification, be visually
checked for condition.
Great care shall be taken with the choice of location to which temporary vent
lines are directed, due to the hazardous nature of the vented gas. Vent lines
should be vented external of closed modules / areas. Temporary vent lines
must also be secured against movement, especially where the gas released
may be under pressure.
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NOTE: Consideration should be given to installing permanent supply and vent lines
for activities that are carried out regularly.
Prior to starting the purging operation, with the exception of the flare system
which may be required to complete the purge activity, the equipment being
purged shall be isolated from all other equipment.
If the nitrogen is being supplied by `quads', the cylinders shall not be removed
from the frame and the lifting slings shall not be altered in any way.
To avoid reverse flow of product into the nitrogen supply, the line up shall be
equipped with check valves.
CAUTION: Where temporary hoses are used for purging and re-pressurisation
these should be secured in position at 3m intervals to prevent whipping.
Where temporary hoses are fitted with crows foot type connections these
must be fitted with R clips and whip checks.
Page 13
Temporary hose connections and tie-in points shall be blanked off when not in
use and for all tie-in points an isolation valve shall be fitted. Where the
connection is envisaged as being required to operate against a pressure
in the vessel, the connection to the vessel shall comprise a hose
connection coupling, a bleed valve, a check valve and a block valve.
All temporary connections and vent points shall be controlled under the PTW
system. Labels should be fitted to identify all nitrogen purge points and
regular checks carried out to identify the valve status. This status should be
recorded on an Isolation Certificate (IC).
During periods when large numbers of temporary connections are in use (i.e.
during shutdown or startup) regular checks shall be carried out, referring to a
checklist, on all nitrogen utility points in service, in order to identify their
status.
PVC or leather gloves must always be worn when handling anything that
contains, or has been in contact with, cryogenic liquids. These gloves should be
loose fitting so that they may be easily removed if liquid is splashed onto or into
them.
Where spraying or splashing may occur, a face visor must be worn to protect
the face and eyes.
Before the arrival of any temporary nitrogen equipment on site, the dangers of
nitrogen in both liquid and gaseous form should be discussed at a safety
meeting. Refer to Appendix 1.
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Gas Freeing
Before starting the purging operation, the nature and the properties of the substances
to be purged must be taken into account.
a.
b.
c.
NOTE: Certain equipment, particularly filter beds, may require to be purged in one
direction only. Generally this will be in a direction toward the support structure, but at all
times the manufacturer's instructions should be followed.
Several methods of nitrogen purge are available which are described briefly below.
Under normal conditions, a combination of these methods is generally used.
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Four times one bar cycles require four volumes of nitrogen and results in
6.25% hydrocarbons, whereas a single purge to nine bars will require nine
volumes of nitrogen and results in 10% hydrocarbons.
Care must be taken that low-pressure instrumentation is not damaged by the purge.
In a typical case, the required purge will be obtained by use of successive purges, the
number required being based upon experience of the operation but governed at all
times by the sampling procedure.
Series Purging
Where vessels or plant can be pressure purged in series, significant economies in time
and nitrogen can be made by passing each cycle purge forward to the next vessel
before releasing to the vent or flare. Can be used in conjunction with 2.3.5.
Displacing To Air
Following purging, it is normal to displace the nitrogen in the vessel or system with air
to ensure that it is safe to work on. Care must be taken, as with the nitrogen, that the
purge method used is appropriate to the conditions and to the system.
WARNING: AT NO TIME SHALL AIR BE PURGED INTO A LIVE FLARE OR VENT
SYSTEM.
3.4
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Sampling
When purging hydrocarbons using nitrogen, it should be noted that the detector used
must be capable of measuring a hydrocarbon gas in an inert atmosphere. The MSA
Tankscope and Neotronics Digiflamm are examples of detectors that can be used.
For both flowing and cyclic purges the checks should be made at not only the
recognised vents but also at any dead legs in the system.
When purging the nitrogen out of the system with air, it is equally important that
representative checks are carried out. If the vessel or system is going to be entered,
conditions for the entry are as defined in PR-1148 Confined Space Entry.
The recommended criteria to give safe conditions when purging a mixture of
hydrocarbon gases with nitrogen are shown in Table 1.
Table 1 - Recommended Criteria Hydrocarbon / Nitrogen Purge
Mode
O2 Level
Hydrocarbon Level
N2 Level
HC to Inert
<_ 4 %
>t 96%
Air to Inert
<_4%
>t 96%
For specific criteria when purging individual hydrocarbon components with nitrogen,
refer to Table2.
Table 2 - Inert Gas End Points for Purging Equipment Out of Service
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Purge Medium
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Combustible
Percent of
Combustible below
which no mixture is
flammable when air is
added in any amount
Hydrogen
95
96
Carbon
Monoxide
Methane
81
85
19
15
86
89
14
11
Ethane
93
95
Propane
94
95
Butane
95
96
Iso-butane
95
96
Pentane
97
98
Hexane
97
98
Gasoline
96
97
Ethylene
94
95
Propylene
96
97
Benzene
96
97
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Leak Testing
4.1
Objective
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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.
4.2
Reinstatement Test
In-Service
Reinstatement Test
A pressure test carried out using the service fluid under its
maximum operating conditions and a leak search carried out.
Method Statement
Maximum
Operating
Pressure (MOP)
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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)
4.3
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 2 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.
2.
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.
On facilities where High H2S levels are encountered i.e. Harweel, Sensitive Leak testing shall
be enforced.
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PR-1073 - Gas-Freeing, Purging and Leak Testing Process
Equipment and Pipework
2
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4.4
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Prior to the reinstatement of items of plant, all connections that have been
disturbed (flanges, clamps etc) shall have been reinstated in accordance
with SP-2020 Flange Connection Bolt Torquing.
Any replaced or modified item of equipment, which forms part of the pressure
envelope, must have previously undergone a successful strength pressure test
prior to installation. Also, any repairs to equipment shall have been carried
out in accordance with the design specification and in its original location.
2.
3.
Where it can be clearly demonstrated that achieving the Standards above are
not reasonably practicable inservice leak testing using the service medium
will be considered. A Risk Assessment requires to be completed and control
put in place to mitigate any risks that could be encountered by stepping out of
the Standard.
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4.
5.
Sour service shall require that all reinstatement leak testing on process
systems containing or exposed to H 2S or Toxics be carried out using a nitrogen
with a helium trace to a pressure equal to 95% of the RV setpoint for the
system or equipment.
6.
7.
Operations shall obtain quotations for the work from an approved contractor,
based on the scope of work. The quotation should also have a method
statement detailing how the work shall be undertaken and all safety
considerations. Operations shall agree Terms and Conditions and authorise the
work.
8.
Sweet service shall require that all reinstatement leak testing on process
systems containing hydrocarbons be carried out using nitrogen to a pressure
equal to 95% of the RV setpoint for the system or equipment.
9.
10.
11.
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12.
13.
4.5
14.
Gross leak test the system / equipment with N2 or a suitable inert medium
before introducing the inservice medium. The gross leak test requires to be
undertaken at a pressure of 10% of MOP up to a maximum of 10bar,
whichever is achieved first.
15.
The reinstatement or inservice leak test can be carried out using the prescribed
test medium, to the required pressure and as detailed in the approved Method
Statement.
16.
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4.6
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4.7
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Vacuum Testing
Some systems are designed for vacuum service and must be tested for this service. It
is most important to determine that any equipment so tested is designed for vacuum
conditions4, and isolated properly before testing. The vacuum should be of the order of
0.1 bar absolute and this should be held for a period of time after the eductor has been
shut off.
If the equipment is in hydrocarbon service, it should be remembered that any
appreciable leak inwards, of air, may create the possibility of an air / hydrocarbon
explosive mixture.
In addition to the vacuum test, items for vacuum service will be tested to a positive
pressure of 1.0 bar (g) with either nitrogen or air.
4.8
2.
3.
4.
The flange shall be sniffed from the single hole and measured for the
presence of hydrocarbons using the appropriate type of gas detector;
Provided that the above is complied with a waiver (step-out) is not required.
Items for vacuum service should be tested with a vacuum. The reason for this is that applying
a pressure test to vacuum equipment does not necessarily detect places where there can be
leakage in the opposite direction, e.g. a gasket fault.
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PR-1073 - Gas-Freeing, Purging and Leak Testing Process
Equipment and Pipework
4
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Hazards
5.1
5.2
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5.3
If pure nitrogen is inhaled, only a few breaths will fully exchange the air in the
lungs to nitrogen and unconsciousness will rapidly ensue.
Cryogenic liquids have rapid cooling properties and consequently, flesh coming
into contact with un-insulated pipework or vessels containing these liquids may
stick fast due to the moisture in the skin.
Cryogenic liquids have low boiling points and quickly produce clouds of vapour
or gas at ambient temperatures, prolonged exposure to which can damage the
lungs.
Leak Testing
Page 24
Fire or explosion arising from the use of flammable fluids for in-service leak
testing.
Damage to the equipment during test, causing a weakness which might result
in a subsequent failure.
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General
Nitrogen is the main component of breathable air and, as such, is often wrongly
considered not to be a personal hazard. It is provided for use either in a gaseous form
in `quads' or from a nitrogen- producing skid, or in a liquid state in cryogenic bulk tanks
where it is stored at a temperature below its boiling point of -196C.
If undiluted nitrogen is breathed, not only is the blood passing through the lungs not
replenished with oxygen, but also much of the residual oxygen in the blood passes out
into the lungs. The effect is therefore much worse than holding one's breath or rebreathing air. In practice it will take only a few breaths to fully exchange the air in the
lungs for nitrogen, and unconsciousness will rapidly ensue. There is no warning
because the normal stimulus to respiration is the build up of carbon dioxide, not lack of
oxygen. Carbon dioxide will not build up while breathing continues if the gas being
breathed is nitrogen.
Fatalities and serious injuries have occurred when performing activities on
equipment that has recently contained nitrogen. This has happened when, in order
to make progress with the work, sheeting, tarpaulins, boarding etc have been used
to screen or protect the work site, and a confined area has been created around the
equipment. Great care must be taken to ensure that a confined space is not created,
whether deliberately or inadvertently, which might allow the uncontrolled build up of
nitrogen and the consequent exclusion of oxygen. Where it is deemed necessary to
operate within a confined space that has recently contained nitrogen, an oxygen meter
shall be used to continuously monitor the atmosphere.
Liquid nitrogen, released into the atmosphere in an uncontrolled manner, will quickly
change form to a gas, thus producing an asphyxiation hazard from the nitrogenenriched atmosphere.
Precautions
Prior to using nitrogen in either a gaseous or cryogenic form, an assessment of the
risks to both personnel and equipment, from leaks or spills, shall be carried out.
Particular attention should be paid to:
All work involving the use of nitrogen shall be controlled by the Permit to Work (PTW)
System. Barriers and warning notices shall be erected around the work area. All
openings, man ways, pipe ends etc must be clearly marked, and oxygen monitoring
and rescue equipment provided. All personnel involved in the operation shall be
instructed in the hazards associated with nitrogen operations and the types and
functions of monitoring equipment being used.
Where habitats or partial enclosures are required, these shall be treated as Confined
Spaces, and the controls and precautions associated with Confined Space entry shall
be applied.
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Drawings showing the relative positions of blanks, drains and vents, indicating
where valves have been removed, defeated or mechanically locked;
The Method Statement shall detail the checks to be carried out which should include,
but not be limited to:
Valve position.
Bolts to
Correct
Torque (tick)
Test Leak
Rate
Re-Test
Leak Rate (if
required)
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Appendix 3 - Abbreviations
The following abbreviations are used in this Procedure.
Page 30
ALARP
He
Helium
IC
Isolation Certificate
N2
Nitrogen
PCV
PTW
Permit to Work
RV
Relief Valve
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Date:
Brief Description of Change Required and Reasons
UOP7
Custodian of Document
Page 32
Date:
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Description of Change
17
Section 3.3 added footnote On facilities where Very High H 2S are encountered i.e.
Harweel, Sensitive Leak testing shall be enforced
18
19
22
Section 3.4 Step 16 para 2 If this is not possible, due to either the size of system
under test or the availability of N 2 at site then an approved 3rd party company will be
contracted.
22
Section 3.4 Step 18 changed wording N2 leak testing activities will be carried out
by a 3rd party contractor controlled by Operations personnel under the PTW
system.
Added NOTE: Sensitive Leak Testing shall be used where High H 2S is present in
the production streams. Details of Sensitive Leak Testing can be referenced from
SP-2051 Specification for Flushing, Pressure Testing, Pickling and Sensitive Leak
Testing of Mechanical Equipment and Piping.
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Description of Change
8/9
8/9
24
10
18/19
19
19
24
Section 4.6 para 3 changed to read The In-service Reinstatement test must be
carried out to the Maximum Operating pressure. The process medium must be
introduced slowly. The pressure shall be increased in stages of not more than 20%
of the maximum pressure obtainable or 10 bars (g), whichever is the greater, up to
80% of the maximum pressure obtainable and thereafter in 10% or 10 bar (g)
stages.
26
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