Project title

OWNER

OWNERS REPRESENTATIVE

EPC CONTRACTORS

SUBSUPPLIER

STAMP

Project PC

GMR ENERGY CCPP SIN154

UNID DCC Contents code

443698680 &MDZ050
Variant - Serial
no. 251017 EK
Origin no. - Dept. MTEC FC

- 2012-07-22 Bauer Simon Adler Thomas First Issue

Rev. Date Coord. Checked Details of revison

Weight - Format - Scale - Specs. -

Date Name Title

Coord. 2012-07-22 Bauer Simon

Leak test package
Checked 2012-07-22 Adler Thomas

Approved 2012-07-22 List Wolfgang

Copyright © Siemens 2012

All Rights Reserved

Handling Internal use only

Drawing-No. / Document-No. Rev.

-
SIN154-EK-&MDZ050-251017
SIEMENS Page-No.

1/6
 Leak and PressureTest Procedure Handhabung/Handling
Nur für internen Gebrauch
Arbeitsanweisung Dichtheits- und Druckprüfung For internal use only
UNID: 443698680 Page 3 of 6

1 Responsibility
The Project Manager or Site Supervisor together with Siemens Site Manager:
 Specifies the test conditions, test equipment and test pressure
 Appoints experienced personnel
 Verifies the test set up, valve line up and safety precautions
 Determines if the component needs to be witness tested
 If applicable the Notified Body provides the necessary documents for the CE declaration of
conformity

The Project Manager or Site Supervisor takes care that the following takes place:
 Preparing the test set up and the safety precautions
 Performing the leak test

2 Test Conditions
Use minimum two calibrated test gauge. Place the pressure gauge up on the unit.
The indication range of the pressure gauge is preferably 2 times the test pressure, but not less than
1.5 and not more than 4 times the test pressure. There shall be one pressure recorder per every
pressure section.
Test pressure: 1.1 times the maximum allowable working pressure for Leakage test.

Holding time: As long as it takes to properly soap-bubble test each and every weld seam and
flanges, but not shorter than 30 minutes.
For the pressure test holding time shall be at minimum 4 hours. Prior to this it is
recommended to pressure the system for a minimum of 6 hours.
Medium: N2
Materials needed:
 Nitrogen bottles with valve and pressure regulator
 Soapy water or any other appropriate bubbling aid

3 General Stipulations
The part to be tested should be completely assembled to allow a complete visual inspection (no
insulation may cover it). During the test a pressure gauge with a pressure writer for each pressure
section shall be connected directly to the components at a visible spot.

3.1 Nitrogen consumption

3.1.1 Nomenclature
Vt = Volume of test pipeline on 1.01325 bar in litre
Vp = Volume of test pipeline on test pressure in litre
Vb = Bottle volume on 1.01325 bar in litre
Vbp = Bottle volume on bottle pressure in litre
Pt = Test pressure in bar (g)
n = Number of bottles

The reproduction, transmission or use of this document or its contents is not permitted without express written
MAX STREICHER GmbH & Co. KG aA authority. Offenders will be liable for damages. All rights, including rights created by patent grant or
registration of utility model or design are reserved.
#3140289
SIN154_EK_LEAK_TEST_PROCEDURE_REVA
 Leak and PressureTest Procedure Handhabung/Handling
Nur für internen Gebrauch
Arbeitsanweisung Dichtheits- und Druckprüfung For internal use only
UNID: 443698680 Page 4 of 6

3.1.2 Approximate pipe volume per meter in litre

DN 25 = 0.6 l / m
DN 50 = 2.2 l / m
DN 80 = 4.8 l / m
DN 100 = 8.2 l / m
DN 150 = 19l / m
DN 200 = 32 l / m
DN 250 = 51 l / m

3.1.3 Example calculation for a DN 250 pipeline

Given:
Pipeline volume per m: V1 = 51 l
Length of test pipeline: L = 10 m

Test pressure (e. g. Leakage test)

MOP: 43 bar
Factor: 1.1
Pt: 43 bar x 1,1 = 47,3 bar (g)

Calculation:
Vt = V1 x L = 51 l x 10 m = 510 l

Vp = Vt x Pt = 510 l x 47.3 bar (g) = 24,123l

3.1.4 Calculation of volume of nitrogen bottle

Example calculation of a 50 l, 200 bar bottle

Given:
Vb = 50 l
pb = 200 bar

Calculation:
Vbp = Vb x pb = 50 l x 200 bar = 10,000 l

3.1.5 Calculation of needed nitrogen bottles

Calculation:

It must be considered that the bottles can only be emptied until the test pressure is achieved. This
means:

Vbp = Vb x pb = 50 l x (200 bar – 47.3 bar) = 7.635 l

n = Vp/Vbp = 24,123 l / 7.635 l = 3.15 bottles ≈ 4 bottles

This means there shall be at least four full 50 l bottles of nitrogen.

For comparison:

n = Vp/Vbp = 24,123 l / 10.000 l = 2.4 bottles ≈ 3 bottles!

Following inaccuracy shall be considered:

The reproduction, transmission or use of this document or its contents is not permitted without express written
MAX STREICHER GmbH & Co. KG aA authority. Offenders will be liable for damages. All rights, including rights created by patent grant or
registration of utility model or design are reserved.
#3140289
SIN154_EK_LEAK_TEST_PROCEDURE_REVA
 Leak and PressureTest Procedure Handhabung/Handling
Nur für internen Gebrauch
Arbeitsanweisung Dichtheits- und Druckprüfung For internal use only
UNID: 443698680 Page 5 of 6

 Indefinite amount of nitrogen can leak through leakages in pipeline system (e. g. Leakage test).
 Indefinite amount of nitrogen can leak through the hose which connect the bottles with the test
pipline when nitrogen bottles are changed.

4 Safety Precautions
The following safety precautions have to be followed, where appropriate to the test being performed:
 Carry out the test in a safe area which means no unauthorized people are in the area or crossing
the area, everybody is instructed and the surrounding is free of any obstacles.
 Fence off or demarcate of the test area (see the attached arrangement drawings with the shut-
off zone of 5 meters)
 Joints in the system which would be subjected to failure or flexible tubing shall be restrained
during the test to prevent personnel injury.
 First increase the pressure to a safe level, for example 2barg and search for visible/audible
leakage. If there is no leak continue to full test pressure.
Additional remarks:
 All safety relief valves in the testing system must be removed and replaced by blind flanges.
 Check all valves and make sure they are in the correct position and are turned off

Info:
The leak test should be made with non flammable inert gas > N2!

5 Additional requirements before start

 The test area has to be cleared from all personnel except those who are carrying out the test.
Care shall be taken during pressurizing the lines step by step. De- or Pressurizing the system
has to be made slowly and gradually, otherwise severe damage to the installed sensitive
equipment may be the result!
 Check that the valves of the main inlet valve line to be pressurized are in the right position.
 Check whether pressure upstream of the main inlet valve at the system is available.
 Check all isolation valves in the whole fuel gas supply system to be in correct position. All
isolating valves of measuring devices have to be opened.
 Please observe not to open drain and vent valves.
 The pressure increase in the systems should not exceed 3bar/min.
 Avoid sudden pressure increase.

Danger:
Pressurizing the system has to be made slowly and gradually, otherwise severe
damage to installed sensitive equipment may be the result, especially dangerous
for the flow meters!

The reproduction, transmission or use of this document or its contents is not permitted without express written
MAX STREICHER GmbH & Co. KG aA authority. Offenders will be liable for damages. All rights, including rights created by patent grant or
registration of utility model or design are reserved.
#3140289
SIN154_EK_LEAK_TEST_PROCEDURE_REVA
 Leak and PressureTest Procedure Handhabung/Handling
Nur für internen Gebrauch
Arbeitsanweisung Dichtheits- und Druckprüfung For internal use only
UNID: 443698680 Page 6 of 6

6 Test Procedure
 The test area shall be cleared of all personnel except those who are carrying out the test. Care
shall be taken during pressurizing the lines step by step.
 Connect the Nitrogen bottle to the purge/filling connection and start increasing the pressure.
 No change of pressure is allowed.
 Maintain the pressure and hold for a visual inspection (with a soap-bubble test) of all joints,
flanges and connections. Any leaks or failure to maintain pressure requires a repair and
retesting.
 Leaving the system under pressure a longer period then on night it is advised to turn the
pressure further, not more than working/operating pressure.
 After finalizing the test (no leakage/pressure drop), the pressure should gradually decreased to
atmospheric pressure by slowly opening.

7 Appendix
7.1 P&ID
Shall be signed and stamped by supervisor and Siemens Site Management. All test section shall be
marked clearly. This P&ID is part of the assembly documentation

7.2 Leak test record

A record shall be made during test with all relevant data (pressure, temperature, pressure recordings
etc.). All parties shall sign this record after successful test.

The reproduction, transmission or use of this document or its contents is not permitted without express written
MAX STREICHER GmbH & Co. KG aA authority. Offenders will be liable for damages. All rights, including rights created by patent grant or
registration of utility model or design are reserved.
#3140289
SIN154_EK_LEAK_TEST_PROCEDURE_REVA