GAJAH BARU PROJECT

   

   

   
PRESSURE TEST PROCEDURE
FOR
PORTABLE METHANOL INJECTION PACKAGE
 (GBWP-A-4200)
 
   
   
   

A 08-12-09 ISSUED FOR COMMENT (IFC) GOH P K

REV DATE DESCRIPTION ORIGINATOR REVIEWED APPROVED

STATUS CODE : A = Issued for Comment - B = Issued for Approval - C = Approved for Construction - D = As Built
Info = For Information – X = Document Cancelled
© This document is copyright.
No part may be reproduced or used without the written permission of Premier Oil

PREMIER OIL NATUNA SEA B.V. – GAJAH BARU PROJECT

Contract No : CO-07-138

 
 
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VENDOR NAME:
PT WEATHERFORD INDONESIA

  Doc. No. : CO-07-138-200-42-AA-M-402 CLASS REVISION STATUS

      P.O. No. : 464876 1 A A

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TABULATION OF REVISED PAGES

REVISIONS   REVISIONS  
SHEET SHEET
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41                   ATTACHMENT \ APPENDIX
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DESCRIPTION OF CHANGES

Description of Change (as clouded for

Location of Change /
Revision drawing/block lined at right side for
Section / Page Affected
document)

A ALL FIRST ISSUE

     

     

     

     

     

     

     

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CONTENTS

Description Page No

TABULATION OF REVISED PAGES............................................................................................................... 2

DESCRIPTION OF CHANGES........................................................................................................................ 3
CONTENTS...................................................................................................................................................... 4
S A F E T Y N O T I C E ................................................................................................................................... 5
1. INTRODUCTION................................................................................................................................ 6
1.1 Abbreviations.................................................................................................................................. 6
1.2 Reference Documents.................................................................................................................... 6

2. PREPARATION................................................................................................................................. 7
2.1 Safety Precautions.......................................................................................................................... 7
2.2 Reference Drawings........................................................................................................................ 7
2.3 Test Equipment............................................................................................................................... 7
2.4 Test Requirements.......................................................................................................................... 8

4. LEAK CHECKS FOR PNEUMATIC LINES.....................................................................................10

5. COMPLETION.................................................................................................................................. 10
7. RESULTS......................................................................................................................................... 11
8. ACCEPTANCE................................................................................................................................. 12

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SAFETY NOTICE

ELECTRICAL

WARNING
WORKING ON THIS SYSTEM MAY INVOLVE WORKING WITH LIVE POWER. EXERCISE
CAUTION WHEN WORKING ON THE SYSTEM WITH POWER SUPPLIES SWITCHED ON.

CAUTION
THIS SYSTEM CONTAINS ELECTROSTATICALLY SENSITIVE EQUIPMENT THAT MAY BE
DAMAGED IF CORRECT HANDLING PROCEDURES ARE NOT OBSERVED.

MECHANICAL

WARNING
THIS SYSTEM CONTAINS HEAVY ITEMS OF EQUIPMENT. CARE IS REQUIRED WHEN
REMOVING AND REPLACING HEAVY EQUIPMENT. FAILURE TO OBSERVE REASONABLE
SAFETY PRECAUTIONS MAY RESULT IN PERSONAL INJURY.

HYDRAULIC

WARNING
THIS SYSTEM INCLUDES EQUIPMENT WITH CONTAINED HYDRAULIC AND PNEUMATIC
HIGH PRESSURES. IT IS ESSENTIAL FOR PERSONNEL TO FAMILIARISE THEMSELVES
WITH PRESSURISED EQUIPMENT BEFORE WORKING ON THE EQUIPMENT. FAILURE TO
OBSERVE REASONABLE SAFETY PRECAUTIONS MAY RESULT IN PERSONAL INJURY.

CAUTION
EQUIPMENT MAY BE DAMAGED IF CORRECT PRESSURE RATINGS ARE NOT ADHERED
TO.

COSHH

All reasonable precautions have been taken to ensure that the Controls of Substances
Hazardous to Health (COSHH) regulations are met.

The equipment supplied as part of this system has been manufactured with materials that
do not contain properties deemed hazardous to the health of the user.

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1. INTRODUCTION

The purpose of this document is to provide instructions for the hydrostatic testing by PTWI. This
document is in line with PTWI Quality Procedure ~ reference to standard operation work instruction,
SOWI-OP-09 – Hydraulic / Pneumatic Pressure Test.

Please tick check boxes adjacent to corresponding paragraphs to confirm acceptance, or make
comments referring to results in Section 8.

1.1 Abbreviations

PTWI - PT Weatherford Indonesia

PTSI - PT Saipem Indonesia
GA - General Arrangement
HP - High Pressure
LP - Low Pressure
PMIP - Portable Methanol Injection Package
WP - Working Pressure

1.2 Reference Documents

CO-07-138-200-42-SP-M-201 Rev C Specification for Portable Methanol Package

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2. PREPARATION

2.1 Safety Precautions

The following Safety Precautions will be observed during the Hydrostatic Test :

The test area will be cordoned off and the relevant signs/placard displayed.

All personnel involved with the testing will wear protective eye gear and safety
boots. WAP also recommend protective clothing (overalls and gloves) especially if
in contact with test fluid.

Only personnel directly involved with the test should be present/nearby.

Any fluid spilt will be cleared up or made safe from slippage immediately.

A Risk Assessment should be conducted if applicable.

2.2 Reference Drawings

Check that the latest revisions of the following drawings are available.

Piping & Instrument Diagram CO-07-138-200-42-DG-M-402

2.3 Test Equipments

PTWI will provide the following services and equipments to successfully perform the pressure
tests :

2.3.1 Hydraulic Engineer and Technicians.

2.3.2 Test fluid.- Water with < 30 ppm chloride.
2.3.3 Test gauges, range 0 ~ 3,000 PSI.
2.3.4 Shop air supply @ 10 barg.
2.3.5 Plugs and caps as required.

Note the pump used to leak check all lines shall be the package’s methanol injection pump :
Pump Make : Milton Roy
Pump Model : CP500V300CRTC
Pump Type : Plunger
Pump Tag No. : GBWP-P-4220
Max Flowrate : 8.71 LPH
Max. Pressure : 2,020 PSI
Test Pressure : 3,000 PSI
Plunger Speed : 1 ~ 45 stroke / min

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1. Test Requirements

Prior to testing:

2.4.1 Remove all relief valves and cap tubing / fitting.

2.4.2 Equipment which has previously been hydrostatically tested and certified by an
Inspection Authority can be excluded (e.g. pulsation damper). Ensure, as a far as
possible, that all tubing supplying the isolated component is tested.

2.4.3 Install test pressure gauge (Baker, S/n. 044319/1) at TP2.

2.4.4 Connect a compressed air supply to TP3.

2.4.5 Fit calibrated gauges to system under test.

2.4.6 Check calibration certificates of all test equipment used.

REMOVE
PSV-4202
CLOSE
BV1 -6

CLOSE
BV1-5

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3. PUMP PRESSURE TEST & TUBING LEAK CHECKS

Note: Max. Working Pressure = 2,020 PSI-g ; Test Pressure = 3,000 PSI-g.

3.1 Fill methanol tank, GBWP-T-4200, with at least 75% of water.

3.2 Open BV1-3. Keep BV1-4 closed.

3.3 Open BV1-8, and slowly increase pump output pressure by adjusting PCV-4201.
Monitor PI-4202 and test gauge while regulating.

3.4 Slowly increase pressure (ensure all air is bled from the system), continue to
increase to about 500 PSI.

3.5 Pump stroking frequency should be at 40 ~ 45 spm. Remove cover and adjust the
black knob on the pump controller, if necessary.

3.6 Allow system to stabilise for 10 minutes and visually inspect for leaks.

3.7 Increase system pressure incrementally 25%, 50% 75%, 100% to test pressure
3,000 PSI (approx. 1½ times of max. working pressure).

3.8 Allow pressure to stabilise for five minutes, if necessary slowly increase back to
test pressure. Check system pressure drop over a 15-minute period.

Allow 5 % pressure variation during the test.

3.9 After the 15-minute time lapse, close BV1-8, and remove air supply. De-regulate
PCV-4201 till PI-4201 reads zero (0) PSI.

3.10 Open BV1-6 to vent residue pressure back to tank. Ensure that PI-4202 and test
gauge reading have drop to zero (0).

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4. LEAK CHECKS FOR PNEUMATIC LINES

Note: Air Working Pressure = 65 PSI-g ; Test Pressure = 100 PSI-g

4.1 Reduce pump stroking frequency to zero (0), by adjust the black knob on the pump
controller.

4.2 Connect air supply to TP3.

4.3 Open BV1-8, and set regulated air pressure to 50 PSI. Monitor PI-4201when
adjusting PCV-4201.

4.4 Allow system to stabilise for 10 minutes and visually inspect for leaks. If needed,
apply soap solutions on all threaded joints and fittings, to ensure NO air leakage.

4.6 Increase system pressure incrementally 50%, 100% to test pressure 100 PSI
(approx. 1½ times working air pressure).

4.7 Allow pressure to stabilise for five minutes, if necessary slowly increase back to test
pressure. Check system pressure drop over a 15-minute period.

Allow 5 % pressure variation during the test.

4.8 When 15 minutes have lapsed, close BV1-8, and remove air supply. De-regulate
PCV-4201 till PI-4201 reads zero (0) PSI.

4.9 Open BV1-9 to removed trapped air in the pneumatic lines.

5. COMPLETION

6.1 Remove test gauge from TP2.

6.2 Refit the relief valves onto their respective lines.

6.3 This document serves as a Pressure Test Report, when completed.

This completes the test.

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7. RESULTS
PARAGRAPH DESCRIPTION COMMENTS

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8. ACCEPTANCE

This concludes the hydrostatic test for the scope of this contract. This certifies that the tests detailed
in this procedure were satisfactorily completed and witnessed by the undersigned (any outstanding
work is annotated on the Results pages).

TITLE NAME SIGNATURE DATE

PT Weatherford Indonesia

PT Transalindo Eka Persada

PT Saipem Indonesia

Company’s Representative

MIGAS Inspector

3rd Party Inspector

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