1.

0 NITROGEN PURGING AND LEAK TEST

1.1 GENERALITIES

Commissioning leak test in process plants can be carried out in two ways
namely:
• Nitrogen leak test
• Helium/Nitrogen leak test.

In the more regular nitrogen leak test, nitrogen gas is injected into the gas
plant/pipeline section using a liquid nitrogen converter unit and suitable high
pressure hoses and pipe fittings. The system is pressurized at a slow rate
until a pressure of one bar (g) is reached.. Pressurization is stopped
temporarily to allow for walk around checks for audible leaks or sharp
pressure drops.
If leaks are found, the system is depressurized and leaks corrected. If not,
the system pressure is then raised in steps of 25%, 50%, 75%, and finally to
the agreed test pressure of the section. The system is then observed for leaks
for an agreed time duration (usually about 8 hours ) by checking for any
pressure drop. Using soap bubble technique, all flanged joints are sprayed
with soapy solution. Leaking joints discovered are marked and later
corrected.

1.2 ADVANTAGES OF NITROGEN LEAK TEST

• The system is tested at pressure close to its working pressure..

• Oxygen content of the system is reduced.
• All leaks are discovered and corrected prior to gas line in.
• The test is cost effective.

1.3 WORK OBJECTIVE

The objective of this leak detection exercise is to discover leaking points in

the pipeline after integrity checks and get them rectified so that escape of
hydrocarbons into the atmosphere is prevented during the normal running of
the plant.

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1.4 WORK METHOD STATEMENT

1. Obtain work permit to carry out nitrogen purging and leak check.
Work permit must have job safety analysis attached.
2. In liaison with Total/Elf and Ponticelli representatives identify and
mark out pipeline sections according to operating pressure, boundaries
isolation points ( e.g. check valves, ball valves, PSVs etc) .
3. Connect up nitrogen hose from vaporizer dryer or Rack to the selected
point(s) of nitrogen injection using suitable hoses and pipe threaded
fittings. Anchor the hose with whip checks to prevent probable hose
whipping during hose failure.
4. Connection to Total/Elf plant system shall be from vaporizer dryer or
Rack of ALN equipment to injection inlet point or from other bypass
points as approved by Ponticelli and Total/Elf.
5. The sequence of leak checks by sections and the test pressure of each
section shall be in conformity with table provided by Ponticelli on
system pressure breakdown.
6. In liaison with Total/Elf and Ponticelli operations representatives,
close the isolation valve(s) so identified as per isolation check list.
7. Carry out a pressure test of the injection hoses and tie in fittings at a
pressure of 4 bar (g) for about 10 to 30 minutes.
8. When the result of the hose test is satisfactory, depressurize the hose
system and open up all the listed and marked injection inlet valves to
the pipeline for the chosen plant section.
9. On receipt of instruction from Total/Elf and Ponticelli, inject
gaseous nitrogen into the chosen pipeline section gradually at a low
flow rate of 200NM3/H. Increase the flow rate at the discretion of the
operator to 500 Nm3/H.Monitor the pressure of the section on the
manometers and observe for any audible leakage or sudden pressure
drop.
10. When the pressure reaches 25% of the rated test pressure, stop
nitrogen injection temporarily. Carry out a walk around checks
11. After a stabilization time of 30 minutes and no leakage found,
increase the nitrogen pressure in steps to 50%, 75%, and finally to the
test pressure. Allow 30 minutes time interval for the pressure to
stabilize throughout the system. Top up the pressure to the test
pressure if there was a noticed slight pressure drop.
12. Monitor and record the test pressure at intervals of 30 minutes. Using
soap solution, spray all flanges and related pipe work and observe for
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bubbles. Bubbles are indicative of leaking points. Mark boldly all leaking
points if any. Or in the use of a certified pressure recorder, the recorder
chart is submitted to client for verification.
13. IF leaking points are observed, depressurize the system and carry out
repair work.. Repeat steps 9 to 11 until no leakage is found and no
unaccounted pressure drop noticed during the agreed time interval (of
about 8 hours ).
14. Prepare a log of leak test pressure against time .
15. When the leak test result of the section or vessel is accepted,
depressurize and proceed with the next plant section.

2.0 NITROGEN PURGING/INERTING.

Nitrogen purging is a generally accepted method of getting rid of

unwanted gases from pipelines and vessels. Three methods can be
distinguished from each other namely ; Displacement method,
Dilution method and Pressurization method
In the oil and gas sector, nitrogen purging is used mainly in the:
(a) Removal of combustible gas and oxygen content of pressure
vessels to an acceptable level before hot work can be carried out
on it in order to prevent explosive mixtures and fire.
(b) After maintenance and reassembly of gas pipelines and vessels, it
is used to remove oxygen to an acceptable level of 3% so that
flammability and explosion do not occur when the flammable gas
is lined in the pipeline or vessel.
(c) After the successful completion of the leak check and purging, the
pipeline is then packed with nitrogen up to 0.5 bar pressure for
preservation before further usage.
(d) It is also used to dry gas pipeline after hydraulic pressure testing
and the attendant dewatering pigging.
In this particular case of integrity checks, we recommend an
amalgam of the methods : which is the combination of the
pressurization and dilution methods for cost effectiveness, safety
and quality.

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 2.2 WORK SCOPE

• Supply of high purity nitrogen gas (99.9% ) in cryogenic

containers and Racks.
• Supply of nitrogen purging equipments.
• Provision of skilled persons to carry out the nitrogen
purging and leak checks safely.
• Mobilization of the equipments safely to Ogbogu flow
station .
• Setting up of the equipments at work site.
• Purging of piping to 3 % oxygen content safe enough for
natural gas line in.
• Checking for leaks at pipeline working pressure
• House keeping.
• Demobilization from work site.
• Preparation of reports.
.
2.3 Base preparation at Air Liquide Nigeria (ALN).

• Preparation of work procedure.

• Preparation of check list of equipments and tools.
• Obtain approval of work procedure and equipment list
from Total/Elf or Ponticelli.
• Test running of equipments to ensure reliability at work
site.
• Confirm and or renew certification status of equipments,
instruments, lifting slings, pad eyes, hoses and valves..
• Ensure pre- mobilization inspection of equipments by
client.
• Pre- work briefing of personnel on work procedure and
safety at work site.
• Preparation of equipments for mobilization.
• Mobilization of equipments to site. Ensure safe off-
loading/loading.

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2.4 On site Preparation

• Participate in site induction by client if any.

• Carry out site safety briefing of personnel and prepare job
safety analysis.
• Obtain work permit from Total/Elf and Ponticelli Ltd
representatives to carry out work. Permit must have job
safety analysis attached.
• Check the condition of equipments, hoses, valves and
instruments and ensure non damage of them due to
transportation.
• Position and connect equipments in line with equipment
layout plan.
• Check equipments for proper functionality.
• Cross check level(s) of nitrogen tank(s) with Ponticelli
representative.
• Discuss permit requirements with work crew.
• Inspect work site facilities with client representatives.
Carry out anomaly hunting of equipment layout and
facility. Report any anomaly to Total/Elf or Ponticelli if
found on facility.
• Identify and mark the sections according to their test
pressure levels, section isolation shut off valves; sample
test point; purge vent valves; nitrogen injection points (in
liaison with Total/Elf and Ponticelli representatives).
• Demarcate or delineate work area with safety tape to
restrict entry of unauthorized personnel within the area.
• Post safety signs such as `NITROGEN PURGING/LEAK
CHECKS IN PROGRESS, KEEP OFF “, etc
• Check good functionality of communication radio with the
crew at the control room or the nominated venting point (If
far away from injection point).
• Obtain authorization to commence work from Total/Elf
operations.

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3.0 NITROGEN PURGING/LEAK CHECK SEQUENCE

The purging/leak check sequence of the pipelines at the flow station shall be
determined by Ponticelli.

4.0 EQUIPMENT LIST

1.0 CRYOGENIC TANK

2 .0 NITROGEN PUMPS
3.0 VAPORIZER (FORCED DRAUGHT)
4.0 TRUCK
5.0 NITROGEN RACKS
6.0 High Pressure Regulators
7.0 PSV
8.0 ACCESSORIES
• High pressure hoses
• Oxygen analyzer
• Fittings
• Pressure gauges
• Tool box

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