Flange Leak Test Program

• The objective of this program is to check the

integrity of process equipment and / or piping
during Plant normal operation.
• This is part of Plant Maintenance Program.
• 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.
 Maersk H2S area of responsibility and
technical capabilities
• Maersk H2S consider this procedure as part of Zohr Plant
Maintenance Program.
• Maersk H2S does not have the required experience in
working with P&ID Plans.
• Maersk H2S does not have the required experience in Process
equipment layout, to correctly identify flanges to be tested.
• Maersk H2S has technical equipment to test the flanges for
leaks in live hydrocarbon containing equipment.
• Maersk H2S can support the Flange Leak Test Program within
the limits of time, equipment and personnel available, after
fulfilling the main duties in Zohr Plant.
 Task Process Flow
Maintenance / Production /
Asset Integrity Department ? Flange Inventory

< 400 ppm > 400 ppm

To be tested 400 ppm To be tested
annually every 6 month

Prepare list of flanges to be tested daily.

Maintenance / Production /
Asset Integrity Department ?
Check if lines / equipment operates at OP
operating Pressure.

Maersk H2S Safety Services Leak Test the flanges

Maintenance / Production / Record data and report back

Asset Integrity Department ?
to relevant department
 Flange Leak Method Statement
• Bump test Multi Gas Detector, test external pump.
• Assess the Area before starting the job: access / egress / escape ways /
scaffold condition / MEWP requirement / SIMOPS activities.
• Identify the lines / flanges together with Production / Maintenance /
Asset Integrity representatives.
• Visual inspection of the flange: check for seeps, hissing sounds, smell,
corrosion signs.
• Clean and dry the radial surface of the flange.
• Seal the connection with masking tape.
• Puncture the tape and make a small hole.
• Mark the hole with permanent marker.
• Wait 15 30 min.
• Insert the sampling probe through the hole and take the sample. If no
readings, wait 30 sec. before remove the sampling probe.
• Record the readings and mark the tape ‘’OK’’ or ‘’LEAK’’ and Tadg ID.
• If leak is detected, remove the tape and follow Petrobel Process Leak
Management Operating Instructions ZH-OPS-HSE-OPI-SAF-001.
 Conclusions:
• Due to the size of this task, an increase in the amount of some Maersk
H2S equipment shall be expected.
• 2 x Draeger X-am 5000, 2 x External Draeger Pumps and 2 x Telescopic
Sampling Probe should be added for this task.
• Amount of AA spare batteries to be increased, to cover extensive use of
the pumps.
• A huge amount of masking tape should be available to seal all flanges
( approx. 24.000 – as per P&ID Plan ).
• Personnel allocated by Maersk for the task will depends on the time
frame requested by Petrobel to cover the ongoing Management Plan.
• Close communication will be needed on a daily basis between Maersk
H2S / Asset Integrity / Maintenance / Production Departments,
including onsite presence of above mentioned Departments
representatives, to ensure the accuracy of the Procedure.
• Non accessible flanges to be evaluated and proper safe access solution
to be implemented .