eni spa
COMPANY TECHNICAL STANDARD
SAFETY REQUIREMENTS FOR LEAK TEST
EXECUTION
28024.COS.AVV.STD
Rev.02 - July 2015
Previous identification code
28024.ICO.AVV.SDS
Rev.02 – July 2015
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ENGINEERING COMPANY STANDARD
Documento riservato di proprietà di Eni spa. Esso non sarà mostrato a terzi né utilizzato per scopi diversi da quelli per i quali è stato inviato.
This document is property of Eni spa. It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
eni spa 28024.ICO.AVV.SDS
Rev 02 – July 2015
Page 3 of 10
Consulted Distribution List
Date Name Surname/Business Unit Company
G. Di Pisa / OCOM Eni/CONSTR
M. Formis / INOF Eni/CONSTR
M. Lombardi / PRECO Eni/CONSTR
S. Mauro / PAWRE Eni/CONSTR
L. Mori / COIMS Eni/CONSTR
I. Hashi Omar / COETA Eni/ITEM
M. Negretti / TEIMA Eni/ITEM
S. Gree Babu / MECC eni/ITEM
P. Cavassi / TEMC eni/ITEM
F. Locati / TEMC eni/ITEM
Informed Distribution List
Date Name Surname/Business Unit Company
F. Bagorda / COQC Eni/CONSTR
S. Mollica / TEIMA Eni/ITEM
T. Cheldi / TEMC Eni/ITEM
A. Marceglia / MECC Eni/ITEM
M. Oddone / SMECO Eni/CONSTR
M. Barbieri / ENTA Eni/ITEM
E. Craighero / TEIN Eni/ITEM
M. Giusto / SEQ/E&P Eni/SEQ/E&P
F. Gasparri / OPSO Eni/PROD
REVISION TRACKING
Rev 00: Actual revision is of 10 pages
Date: June 2015
Rev 01: Actual revision is of 10 pages
Date: July 2015
Rev 02: Actual revision is of 10 pages
Date: July 2015
INFORMATION REQUEST
eni personnel can access company standard repository at:
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External user shall refer to the Project Engineer Manager.
For information about the content of this standard, please refer to responsible and accountable
person as per above RACIE table or to Technical Authority coordinator (COETA).
ENGINEERING COMPANY STANDARD
Documento riservato di proprietà di eni spa. Esso non sarà mostrato a terzi né utilizzato per scopi diversi da quelli per i quali è stato inviato.
This document is property of eni spa. It shall neither be shown to third parties not used for purposes other than those for which it has been sent.
eni spa 28024.ICO.AVV.SDS
Rev 02 – July 2015
Page 4 of 10
TABLE OF CONTENTS
GENERAL .................................................................................................................. 5
1.1 PURPOSE AND SCOPE .................................................................................... 5
1.2 ABBREVIATIONS AND DEFINITIONS ............................................................. 5
1.3 REFERENCE REGULATIONS ............................................................................ 6
1.3.1 Company Standards ...................................................................................... 6
LEAK TEST STEPS SEQUENCE .................................................................................... 6
LEAK TEST HSE REQUIREMENTS ............................................................................... 8
2.1 TRAINING ..................................................................................................... 8
2.2 READY FOR COMMISSIONING ....................................................................... 8
2.3 AREA PREPARATION...................................................................................... 8
2.4 ISOLATION PHILOSOPHY AND PTW .............................................................. 9
2.5 TESTING EQUIPMENT .................................................................................... 9
2.6 PPE ................................................................................................................ 9
2.7 COMMUNICATION .......................................................................................... 9
2.8 EXECUTION ................................................................................................... 9
2.9 DEPRESSURIZATION, REPAIR, TEST EQUIPMENT RIG DOWN ...................... 10
ENGINEERING COMPANY STANDARD
Documento riservato di proprietà di eni spa. Esso non sarà mostrato a terzi né utilizzato per scopi diversi da quelli per i quali è stato inviato.
This document is property of eni spa. It shall neither be shown to third parties not used for purposes other than those for which it has been sent.
eni spa 28024.ICO.AVV.SDS
Rev 02 – July 2015
Page 5 of 10
GENERAL
Leak test (tightness test or cold bolting) is carried out to check that all process equipment
under pressure does not leak (leak free). This test is carried out after Pressure Test (Hydrostatic
or Pneumatic Test) to prove the mechanical reinstatement and integrity of the items which are
being tested.
Leak test (tightness test) is carried out at 110% of the equipment maximum operating
pressure (ASME B31.3 LEAK TESTING) or if a pressure safety valve is installed on piping
system, then at 90% minimum up to 95% maximum of the pressure relieve valve setting.
1.1 PURPOSE AND SCOPE
The main purpose of this document is to detail the steps necessary required to ensure that all
leak test activities are performed in right sequence and safe conditions and to establish HSE
contractual standards for leak Test performed by Contractor either on Contractor site or at
Company construction and operation sites.
The scope of this document covers minimum safety requirement and precautions to be applied
during the Leak Test of Hydrocarbons plant sections.
Safety requirements have been identified during a Safety Review Workshop, based on best
practices and past experiences from previous projects, and through the analysis of past
incidents and near misses.
1.2 ABBREVIATIONS AND DEFINITIONS
Acceptance Criteria The level of health, safety and/or environmental
performance deemed acceptable for a given period or phase
of activities.
Commissioning Team Leader The Contractor/Company responsible of the
Commissioning Activities on site.
Joint Integrity Management The Plant total package of services that provides the best
possible chance of achieving a leak-free start-up. It includes
engineering analysis, unbolting, inspection, machining as
required, gasket installation assembly, controlled bolt up
and full documentation/traceability. Correct assembly of
critical joints requires that the flange is analyzed and the
correct bolt load to seal the joint is established. It requires
the most suitable gasket to be installed for the service,
flange flatness/condition to be inspected and for the
determined bolt load to be applied in a controlled manner.
Hazard The potential to cause harm, illness or injury, damage to
property, plant, products or the environment, production
losses or increased liabilities.
Risk The product of the probability that a specified undesired
event will occur and the severity of the consequences of the
event.
Site Authority The Company/Contractor responsible of the site. He is the
Permit to Work Issuing Authority.
LOTO Lock Out Tag Out
MSDS Material Safety Data Sheet
P&ID Piping & Instrumentation Diagram
PAHH Pressure Alarm High High
PPE Personal Protective Equipment
PSV Pressure Safety Valve
PTW Permit To Work
ENGINEERING COMPANY STANDARD
Documento riservato di proprietà di eni spa. Esso non sarà mostrato a terzi né utilizzato per scopi diversi da quelli per i quali è stato inviato.
This document is property of eni spa. It shall neither be shown to third parties not used for purposes other than those for which it has been sent.
eni spa 28024.ICO.AVV.SDS
Rev 02 – July 2015
Page 6 of 10
1.3 REFERENCE REGULATIONS
1.3.1 Company Standards
27952.ICO.AVV.SDS Facilities Commissioning Specification
27953.VAR.GEN.SDS Mechanical Isolation Philosophy and Procedures
28025.ICO.AVV.SDS Mechanical Lock-Out Tag-Out Procedure
LEAK TEST STEPS SEQUENCE
The LEAK Test steps sequence with the most relevant operative and safety requirements are
summarized in Table 1.
# Step Description Safeguards
1. Lined-up P&IDs of sections to be tested; mark-up of
P&IDs to identify sections to be tested and buffer
sections;
2. Implement LOTO procedure;
3. Collect Mechanical Completion certificates for both
sections to be tested and buffer sections ensuring no
Planning of punch-list related to mechanical, piping and safety
A tightening test critical elements are outstanding; Safety Induction
activities 4. Perform Safety Induction for subsequent Operations
and Training on Mechanical Isolation Procedure;
5. Pre-tightening test walk-down (integrity of system,
installed instrumentation, presence of PSVs/rupture
disks, compliance with P&IDs);
6. Provide proper storage area for Liquid Nitrogen and
Helium full and empty bottles with relevant MSDS.
1. Prepare the area to locate the pressurizing equipment;
2. Perform site specific risk assessment for PTW Site-specific risk
application including clearances, restricted area assessment
identification (safety distance l = P 0.6, where P is the Permit to Work
test pressure in bar) and tagging with relevant safety and Toolbox Talk
Prepare the signs; Suitable PPEs
B
testing section 3. Identify all test points, and line-up valves to be Good radio
closed/open as per marked-up P&IDs implementing communication
LOTO procedure; Preparatory work
4. Apply tape on test points; (See step A)
5. Check calibration certificates of test instrumentation; Valve Checklist
6. Sign the valve checklist.
Equipment
inspection
Permit to Work
1. Check functionality of test cabin and cryogenic and Toolbox Talk
pump/compressor; Shift Handover
2. Check radio communication; procedure
3. Install and set the temporary overpressure protection Suitable PPEs
Rig Up and
C system (PSVs, PAHH tripping cryogenic pump); (focus on
Function Test
4. Verify that hoses and items are fit for purpose (check cryogenic risks for
the rating and the integrity) and correctly constrained naked skin and
(use of restraint devices); hands)
5. Connect all hoses and items. Good radio
communication
Equipment rated
and certified
ENGINEERING COMPANY STANDARD
Documento riservato di proprietà di eni spa. Esso non sarà mostrato a terzi né utilizzato per scopi diversi da quelli per i quali è stato inviato.
This document is property of eni spa. It shall neither be shown to third parties not used for purposes other than those for which it has been sent.
eni spa 28024.ICO.AVV.SDS
Rev 02 – July 2015
Page 7 of 10
# Step Description Safeguards
1. Set exclusion zone (define extension, fence area, check
area is clear of unauthorized people, install warning
signs);
2. Check ambient temperature is higher than a minimum
temperature calculated based on material minimum
Permit to Work
design temperature and expected depressurization
and Toolbox Talk
rate;
Suitable PPEs
3. Perform pressure hold test for hoses to detect any leak
(focus on eye
by noise;
protection)
4. Check pressurization rate is within limits;
Pressure test of
5. Start pressurizing the test section up to a first step
hoses done in
(either 2 barg or 25% of maximum pressure) and
steps
check for audible leaks. If any major leak is detected
Pressurize the Good radio
D proceed to depressurization and repair;
testing section communication
6. Check that safety vents on buffer sections are not
Equipment rated
blowing and the adjacent sections not involved in the
and certified
test are not being pressurized; in case, reconsider
Non-return valve
tightening test battery limit; if not possible abort the
on test manifold
test;
Overpressure
7. Proceed pressurizing by steps (25%-50%-75%-100%
Protection System
test Pressure). After each step hold for 10 min, check
Pressure gauges
for audible leaks or pressure drops;
Exclusion zone
8. After each pressurization step check again that safety
vents on buffer sections are not blowing and the
adjacent sections not involved in the test are not being
pressurized; in case, reconsider tightening test battery
limit; if not possible abort the test.
Permit to Work
and Toolbox Talk
Suitable PPEs
1. Calibrate spectrometer with gas sample from system; (focus on hands)
Tightening 2. Check manometer to ensure proper pressure is uniform LOTO
testing & across the system; Good radio
E
acceptance 3. Check each test point with helium detector probe. Mark communication
criteria test point if a leak above acceptable is found and tag on Equipment rated
drawings. and certified
Non-return valve
on injection point
Exclusion zone
Permit to Work
and Toolbox Talk
1. Check valves position as per marked up P&IDs; Suitable PPEs
2. Open vent valves to a dedicated safe location; (focus on hands)
Depressurize 3. Check pressure and ensure depressurization rate within Good radio
F
system proper limits; communication
4. Proceed until all pressure readings confirm Pressure gauges
atmospheric. Depressurization
Checklist
LOTO
Permit to Work
and Toolbox Talk
LOTO
Suitable PPEs
1. Check manometers to ensure atmospheric pressure in
(focus on eyes and
the system;
hands)
G Repair 2. Verify total depressurization of the system;
Definition and
3. Perform repair activities;
marking of danger
4. Re-test the system (Steps E and F).
areas (in front of
bolted
manholes/blind
flanges)
ENGINEERING COMPANY STANDARD
Documento riservato di proprietà di eni spa. Esso non sarà mostrato a terzi né utilizzato per scopi diversi da quelli per i quali è stato inviato.
This document is property of eni spa. It shall neither be shown to third parties not used for purposes other than those for which it has been sent.
eni spa 28024.ICO.AVV.SDS
Rev 02 – July 2015
Page 8 of 10
# Step Description Safeguards
Permit to Work
and Toolbox Talk
Test equipment 1. Remove test equipment ; Shift Handover
H
Rig Down 2. System de-isolation. procedure
Suitable PPEs
(focus on hands)
Table 1: Procedural steps
LEAK TEST HSE REQUIREMENTS
The HSE minimum requirements for the Leak Test are listed in the following paragraphs.
2.1 TRAINING
SITE AUTHORITY shall provide:
Site specific risk assessment to identify the main safety concerns relevant to the leak
test taking into account the site asset and configuration;
Proper Safety Induction at site to operators according to main findings of the Site
specific risk assessment.
COMMISSIONING TEAM LEADER shall provide:
Job specific risk assessment;
Operators Training on specific tasks regularly updated in the individual HSE passport.
2.2 READY FOR COMMISSIONING
SITE AUTHORITY shall provide:
Mechanical Completion certificate;
Updated documents, drawings and procedures;
Implementation of the Joint Integrity Management.
COMMISSIONING TEAM LEADER shall verify availability of the commissioning certificate,
updated documents, drawings and procedures prior of starting of work.
2.3 AREA PREPARATION
SITE AUTHORITY shall provide:
Proper storage of inert gases in order to minimize risk of asphyxiation (e.g. enclosed
storage areas to be avoided);
COMMISSIONING TEAM LEADER shall provide:
Implementation of a pre-leak test walk down to check the integrity of the system;
Set up of an adequate exclusion zone to avoid presence of unnecessary personnel during
the testing operations;
Implementation of a safe area (inside the exclusion zone) around hoses to minimize the
impact of a potential unfastening of a pressurized hose.
ENGINEERING COMPANY STANDARD
Documento riservato di proprietà di eni spa. Esso non sarà mostrato a terzi né utilizzato per scopi diversi da quelli per i quali è stato inviato.
This document is property of eni spa. It shall neither be shown to third parties not used for purposes other than those for which it has been sent.
eni spa 28024.ICO.AVV.SDS
Rev 02 – July 2015
Page 9 of 10
2.4 ISOLATION PHILOSOPHY AND PTW
SITE AUTHORITY shall apply:
Proper management of the Permit to Work system (including Toolbox Talks);
The Mechanical Isolation procedure (27953.VAR.GEN.SDS) to ensure proper isolation of
the section under testing;
The Lock-Out/Tag-Out procedure (28025.ICO.AVV.SDS).
COMMISSIONING TEAM LEADER shall provide:
Valve checklist to monitor and register valve status during the activities;
Implementation of the Mechanical Isolation procedure (27953.VAR.GEN.SDS);
Implementation of the Lock-Out/Tag-Out procedure (28025.ICO.AVV.SDS).
2.5 TESTING EQUIPMENT
COMMISSIONING TEAM LEADER shall provide:
Proper rating and certification for the equipment involved in the testing operations;
Inert gas pumping equipment provided with temporary overpressure protection systems
(e.g. PSVs on the inert gas manifold);
Non Return Valve on test manifold / injection points;
Availability of pressure gauges to proper monitor pressure inside the testing section and
testing equipment.
2.6 PPE
COMMISSIONING TEAM LEADER shall assure the use of proper PPEs for all the involved
personnel, according to the site-specific risk assessment and job specific risk assessment (see
Table 1 for the part of body that may be affected at different job phases – only indicative –).
2.7 COMMUNICATION
SITE AUTHORITY shall provide:
Proper equipment for radio communication;
Suitable procedure for information exchange protocols.
COMMISSIONING TEAM LEADER shall provide:
Toolbox Talk prior of start of activities to ensure a suitable risk awareness;
Good radio communication to ensure proper information exchange during the testing
operations;
Proper information exchange during shift handover according to SITE AUTHORITY
procedures and protocols.
2.8 EXECUTION
During the execution of the Leak Test, COMMISSIONING TEAM LEADER shall:
Perform section pressurization in gradual steps in order to avoid local overpressure
leading to potential asset damages (see Table 1);
Implement specific procedure for hoses rating, integrity and fastening check before
pressurization activities start;
ENGINEERING COMPANY STANDARD
Documento riservato di proprietà di eni spa. Esso non sarà mostrato a terzi né utilizzato per scopi diversi da quelli per i quali è stato inviato.
This document is property of eni spa. It shall neither be shown to third parties not used for purposes other than those for which it has been sent.
eni spa 28024.ICO.AVV.SDS
Rev 02 – July 2015
Page 10 of 10
Implement a specific procedure for additional pressure check in adjacent section during
pressurization, to avoid undesired pressurization of buffer sections;
Calibrate and check pressure and allowed leak rates as per Table 1 and facilities
commissioning specification 27952.ICO.AVV.SDS.
2.9 DEPRESSURIZATION, REPAIR, TEST EQUIPMENT RIG DOWN
During the Depressurization, Repair and Test Equipment Rig Down phases, JOB RESPONSIBLE
shall:
Open the vent valves to a safe location;
Check depressurization rate until pressure readings confirm atmospheric pressure;
Perform repair activities (if any) from a safe location;
Re-test the system as per this procedure;
Remove test equipment and de-isolate the system as per Lock-out/Tag-out procedure.
ENGINEERING COMPANY STANDARD
Documento riservato di proprietà di eni spa. Esso non sarà mostrato a terzi né utilizzato per scopi diversi da quelli per i quali è stato inviato.
This document is property of eni spa. It shall neither be shown to third parties not used for purposes other than those for which it has been sent.
