CONTENT

1.0 GENERAL

2.0 CODES AND STANDARDS

3.0 CLEANING OF PIPELINE BY PIGGING

3.1 GENERAL
3.2 PREPARATORY WORKS AND EQUIPMENT USED
3.3 SAFETY PROCEDURE
3.4 CLEANING OPERATION

4.0 PRESSURE TESTING

4.1 GENERAL
4.2 TESTING OPERATION
4.3 LEAK DETECTION OF PIPELINE
4.4 TEST ACCEPTANCE CERTIFICATE

5.0 FINAL TIE IN AND COMMISSIONING

5.1 SAFETY
5.2 SAFETY EQUIPMENT LIST
5.3 COMMISSIONING
5.4 SAFETY OFFICER SCOPE OF WORK
5.5 HOUSEKEEPING
5.6 OPERATIONAL SAFETY
5.7 MATERIAL REQUIREMENT
5.8 REQUIREMENTS PRIOR TO COMMISSIONING
5.9 DECOMMISSIONING
5.10 FINAL TIE-IN AND COMMISSIONING DETAIL
5.11 AFTER COMMISSIONING
5.12 LEAK TEST PROCEDURE

6.0 LIST OF CONTACT NUMBER

APPENDICES
Appendix 1 - Schematic Drawing

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1.0 GENERAL

This procedure covers all operations for the internal cleaning, testing, and
commissioning of the following gas pipeline system:

a) Approximately 33.0m of 63mm PE service line to MULTI CHOICE

MARKETING (M) SDN BHD (PLANT 2)

This procedure describes methods which will be employed for the following
operations:

1.1 Cleaning of pipeline.

1.2 Pressure testing
1.3 Commissioning

2.0 CODES AND STANDARDS

Specifications governing the cleaning, testing and commissioning of pipelines

shall include but not necessarily be limited to the following:-

i) MS 930: 1986, UDC 696.2: 683.9.001.3 Code of practice for the

Installation of Fuel Gas Piping System and Appliance.
ii) ASME/ ANSI B31.8
iii) OSHA 1994 (Act 514)
iv) Gas Supply Act 1993
v) The Petroleum (Safety Measures) Act 1984.
vi) Factories and Machinery Act 1967 (Act 139)

3.0 CLEANING OF PIPELINE BY PIGGING

3.1 GENERAL

Prior commissioning of pipelines, internal of pipelines shall be cleaned by means

of air blowing and pigging using soft pig to remove dirt, debris and foreign
particles that may jeopardize the integrity of the pipeline system.

Medium used to blow internal of pipelines is air by using compressor. The inlet
pressure shall not be lower than 30 psig and shall be applied continuously for no
less than 5 minutes per run.

The pipeline shall be determined as free of dirt and foreign particles after a
series of blow runs and subject to the satisfaction of GMB. The final run shall be
witnessed and certified by GMB representative.

Upon completion of cleaning operation for the service pipeline, the installation of
tapping saddle shall take place. Tapping saddle location shall be free of water to
prevent foreign material entering the cleaned pipe. The pipeline pneumatic
testing shall commence after completion of cleaning activity and installation of
pipeline appurtenance such as service valves, saddle tee, reducers etc.

3.2 PREPARATORY WORKS AND EQUIPMENT USED

Preparatory Works
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 For Launching end: A launcher is prefabricated and installed by flanged
connections. Launcher shall be equipped with relief
valve and pressure inlet point.

For Receiver end: A receiver and shall be opened pipe and installed
wire netting to trap the pig.

All materials used in the pressure test shall be thoroughly checked to meet the
test pressure requirement.

Equipment to be used Quantity

a. Air Compressor 1 unit

b. Launcher and receiver 1 set
c. Signboards 1 set

3.3 SAFETY PROCEDURES

3.3.1 All site staff and workers shall be briefed of sequences of operations and safety
procedures to be adhered to before commencing of work. AITESBs project
manager or their representative shall be present to supervise the safety aspect
during the cleaning, pressure test and commissioning activities.
3.3.2 Before commencing, signboards shall be placed around launcher and receiver
area to warn public of cleaning operations taking place. Safety barriers will be
located where necessary.
3.3.3 Communication points will be established between launcher and receiver to
ensure prompt action can be taken during cleaning operations.
3.3.4 Receiver end shall be directed away from the public. AITESB shall provide
adequate protective shield such as pig arrester net at the outlet.

3.4 CLEANING OPERATIONS

Upon confirmation of all equipment and personnel are ready, cleaning operations
shall commence with the presence of GMB representative.

Pressure will be built up to and released into the pipeline to push out any dirt or
foreign particles in the pipeline. The discharge at the receiving end shall be
observed to determine the condition of discharge.

Subsequent blow runs shall be conducted until the condition of discharge at

receiving end is only nitrogen or air without any dirt of foreign particles. GMB site
representative shall determine the final run, which very much so depends on the
construction practice.

The job sequence of cleaning activity for PE pipeline as follows:

1. The 63mm PE service line to be cleaned by launching the pig from the 2
riser, until satisfaction of GMB.

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 2. Upon completion of cleaning activity, install 63mm end cap at the open end
of new 63mm service.

3. The pipeline is now ready for pneumatic testing.

4.0 PRESSURE TESTING

4.1 GENERAL

Upon completion of cleaning and installation of service valve and tapping

saddle, the service line is now ready for pneumatic testing.

Safety procedures will be briefed on testing operations and necessary barricades

and signage will be installed at appropriate points.

GMB shall be notified to witness test accordingly. Competent person shall be

present to monitor the equipment set-up prior to the testing and through out the
testing period.

Instruments used i.e. pressure gauges and pressure chart recorder shall be
inspected prior of testing commencement. AITESB shall provide calibration
certificate to GMB, minimum 1 day before the scheduled pressure testing.

4.2 TESTING OPERATIONS

Nitrogen shall be injected into pipeline.

The testing pressure shall be minimum of 1.5 times the Design Pressure, which is
1.5 x 60 Psi = 90 Psi. To accommodate pressure fluctuation as a result from
temperature effect, the minimum test pressure is recommended at 100 Psi. Upon
achieving the testing pressure, the nitrogen source shall be isolated from the
pipeline system.

The test duration shall be as follow, commence from the stabilized testing
pressure, which is 100 Psi minimum. Refilling of testing medium is totally
prohibited during the official test. Test pressure and temperature shall be
monitored and recorded using forms as per Appendix.

Test Duration Test Pressure

Pipe Size Length
( minimum ) ( minimum )

63mm 33.0m 24 hours 100 psi.

4.3 LEAK DETECTION OF PIPELINE

Any reduction of pressure during test period shall indicate leak on pipeline
system, once ascertained that equipment do not contribute to pressure drop.
Leakage shall be located by either physical discharge of sound or identified by
soap solution to pinpoint exact location of leakage.

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 Upon locating the leakage, remedial works shall be done on that portion of the
pipeline and retest shall be conducted.

The repair shall be done by cut out with a spacing of 300mm on both sides of the
leak points.

The pressure test shall be repeated until the pressure test requirement is fully
complied.

4.4 TEST ACCEPTANCE CERTIFICATE

A Test Acceptance Certificate shall be completed and endorsed by GMB and

relevant Competent Person upon the successful completion of the test.

5.0 COMMISSIONING

5.1 SAFETY

The configuration of the existing pipeline will be determined and a safe method
of preparing for tie-in will be developed. Following are the steps to be taken.

1. Commissioning area to be barricaded and marked for no trespassing to

public.
2. Area to be designated as "No Smoking Area" within 5 m of the tie-in point.
3. Ensure all electrical and electronic equipment to kept 5 m away from tie-
in point.
4. Fire extinguisher to be strategically placed at site.
5. Medical first aid kits shall be made available.
6. If a generator is used for electro fusion or welding, it shall be placed no
less than 5 m from the tie-in tapping point.

5.2 SAFETY EQUIPMENT LIST

Fire fighting equipment

Two (2) number of fire extinguisher shall be standby at site.

Signboard 'NO SMOKING', 'COMMISSIONING IN PROGRESS' sign (to be

placed where
applicable).

Personal Protective Equipment (PPE)

The following clothing should be worn by all personal:-

i) Safety Helmet
ii) Safety Boots

5.3 COMMISSIONING

This section provides a general guide to safe practice during commissioning

operations. Recommendations are given rather than a rigid set of rules, as the

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 effect of local unusual circumstances must be considered in determining any
required safety procedures.

It is the responsibility of each person engaged in commissioning to take

reasonable care for the health and safety of him self and of other persons who
may be affected by his acts or omissions.

It is therefore the persons duty to:

1. Always adhere to safety regulations.

2. Always use the procedures and methods of operations laid down in this
procedure and the local rules and regulations.

3. Always use the correct tools and equipment for the job, and wear the correct
protective clothing.

4. Immediately report any hazard to the appropriate authority.

5. Never operate valves, unless instructed to do so, or as part of his duties.

Project Manager acting in a supervisory capacity has the added responsibility of

making sure that all persons under their control or direction are aware of the
safety regulations, work procedures and equipment provided for their protection,
and that they are properly used. When acting in a supervisory capacity they
must therefore:

a. Have a detailed knowledge of safety regulations.

b. Include in all routine orders, specific instructions regarding safety.

c. Restrain personnel from taking unnecessary risks.

d. Ensure that all personnel under their control or direction are familiar with
safety requirements of the job.

e. Stop any dangerous work practice immediately and report any such
actions to the appropriate authority.

f. Rectify or report any defects in plant or equipment that may affect safety,
taking any necessary.

g. Set a personal example in good safety practice at all times.

5.4 SAFETY OFFICERS SCOPE OF WORK

The Safety Officer will be responsible for all aspects of safety control and
prevention of accidents during the testing, commissioning and hand-over
operations period.

In conjunction with the Construction Manager he will prepare any necessary

addenda to the standing Construction Safety Regulations to cover the additional
hazards involved in the testing and operation of machinery and equipment and
the subsequent introduction of gas into the system.

Safety Officers Responsibilities

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 The Safety Officer shall take overall responsibility for the enforcement of the
Safety Regulations and other safe working practices contained in these
Procedures including:-

i) Co-ordination of safety measures where construction work has, of necessity, to

be carried out alongside machinery and equipment under test or being
commissioned.

ii) Ensuring that, before entry onto the site, all supervisory, construction and
operating personnel are fully conversant with the Safety Regulations on work
procedures in force.

iii) Ensuring that all personnel are equipped with and use of appropriate protective
clothing and that all hazard warning signs and devices, notices and barriers are
installed and maintained.

iv) Carry out routine inspection on fire fighting equipment and first aid facilities, and
check these are in place and are properly serviced.

v) Stopping any dangerous work practice and immediately reporting them to the
Construction Manager.

5.5 HOUSEKEEPING

The Supervisor shall be responsible for ensuring the following:-

i) Floors, walkways and stairways are kept free from obstructions at all times.

ii) Oil spillage and similar hazards are cleaned up immediately.

iii) Suitable notices should be prominently displayed to warn personnel of

regulations regarding access, naked lights, smoking or other hazards.

5.6 OPERATIONAL SAFETY

All personnel involved with the commissioning operations should be familiar with
the safe action to take under emergency condition. Report the emergency to the
Project Manager and Safety Officer for assistance if required.

In case of emergency, conditions (fire, explosion, gas leakage, etc) the following
action is required:-

i) All personnel, other than those assigned to fire fighting duties, shall assemble at
the nearest assembly point.

ii) All personnel to be accounted for and any injured persons removed to safety. Any
missing personnel to be located quickly by a systematic search by a nominated
search team.

iii) All fire fighting facilities to be manned.

iv) Investigate damage, repair, and return the station to operational status.

5.7 MATERIAL REQUIREMENT

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 The following list of materials, consumable items, tool and equipment represent
the basic requirements of the commissioning activities:-

a) Suitable Range of hand tools, spanners, socket sets etc. (On set each for the
central commissioning control location and individual commissioning groups).

b) Lubrication equipment, grease guns, lubricant etc. (One set each for the central
commissioning control location and individual commissioning groups).
c) 1 unit of gas detector.

d) Communication Equipment - Mobile telecommunication system.

5.8 REQUIREMENTS PRIOR TO PRE-COMMISSIONING

a) All equipments such as fittings, spanner, non spark tools or any other
equipment shall be on site and confirm in good condition by the site supervisor.
b) Site personnel to be briefed on work activity before commencement of any work.
c) Commissioning can commence only after:
- Pneumatic testing completed.
- Commissioning site cleaned.
- Obtain Approval to Operate (ATO)
- Obtain work permit from GMB O & M Department.

5.9 DECOMMISIONING,

The job sequence for de-commissioning is as follows.

1. Close PE-SV-1
2. Close inlet and outlet valves at service station.
3. Install hose at venting point (P1) at existing service station area.
4. Start purging at P1 to release gas and de-pressurise until atmospheric
pressure. Ensure SV-1 is tightly Closed and NO PASSING.
5. De-commissioning completed.

5.10 FINAL TIE-IN & COMMISSIONING DETAIL

The job sequence of commissioning for PE pipeline as follows:

1. Close existing service valve PE-SV-1

2. Cut new PE 63mm service line
3. Cut existing PE 63mm service line
4. Connect the existing and new service line using coupler to complete the
pipeline system.
5. Carry out electrofusion work. Upon completion of electrofusion work, wait for
cooling time prior to removal of pipe clamp. Final tie-in completed.

6. The completed pipeline shall be packed with 0.5 bar N2 before the
commissioning works.
7. Install hose at venting point (P2), service station area.
8. Open PE-SV-1 to start displacing the N2 inside the new line. The nitrogen
shall be pushed by natural gas and shall be released at purge point P2.
9. Commissioning is completed.

5.11 AFTER COMISSIONING

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 Each connection shall be leak tested and confirm by GMB.

5.12 LEAK TEST PROCEDURE

All flanged and threaded connections for the entire pipeline system will have to
be checked to ensure that they are leak free with each step in pressure increase.

All flanges are to be taped prior to any pressurization and a needle sized hole
made at a location easily observable.

Any leak will be detected by observing the formation of bubbles after the
application of Snoop liquid at the needle size hole. Should there be no bubbles
observed after one minute of observation it can be concluded that the fit up is
leak free.

Any leaks will be classified as the observation of bubble formation after the
application of snoop leak detection fluid at the following locations:

1. Around the tread for screwed connections

2. At the needle sized hole for flanged connections

All leaks will have to be fixed prior to the commencement of any further steps.

6.0 LIST OF CONTACT NUMBER

N NAME DESIGNATION CONTACT

O NO.
1 Mr. Mokhtar Mohd Nor Project Manager, GMB 019 3544892
2 Mr. Faizul Hisyam Abd Ghaffar Project Engineer, GMB 016 7130495
3 En. Muzaffar Project Supervisor, 019 315 2806
GMB
4 Ir. Adli Ibrahim Project Manager, 019 2124421
AITESB
5 Mr. Mohd Zahir Safety Supervisor, 013 3604421
AITESB
6 GMB Toll Free 1-88-800-
9119