Pressure test and commission a new polyethylene main

You are the Crew Leader for the Riverlea Stage 3 construction crew.

Simulated workplaceIntermediate missionCAQA Gasline Networks

What is going on

Your crew has laid 640 metres of 125 millimetre polyethylene main through Stage 3 of the Riverlea Estate in North Geelong under work order WO-26-3301. Forty-one butt fusion joints are logged. The main ties into the existing medium pressure network at two points and the developer wants gas available to the first homes by the end of the month. The pressure test is booked for tomorrow and Priya Venkatesan will not close the work order until the test record and the as laid drawing are attached. Commissioning requires a permit, control centre notification and a gas recovery unit. A sediment control failure on this site last week is still fresh in everyone's mind.

Priya Venkatesan, Construction Manager
Subject: Riverlea Stage 3 pressure test and commissioning

Cody's crew has finished laying the 125 millimetre main at Riverlea Stage 3 and the pressure test is booked for tomorrow. Please prepare the permit application for the purge and commissioning, make sure the control centre is notified, and get the job safety analysis done with the crew before anyone opens a valve. The test record and the as laid drawing must be on the work order before I will close it. Let me know if the gas recovery unit is not available.

Your brief

Prepare the crew and the paperwork for the pressure test and commissioning: complete the job safety analysis, apply for the permit, record the test, purge and commission under the procedure, and close out the work order with the records the Construction Manager requires.

Work through it

You do not need to do it all. Doing a few of these will show you what the work is like. Your ticks and notes stay on this device.

Read the Procedure: Construction and Laying of Polyethylene Mains and list the hold points from testing to backfill that apply to this job.
Prepare a Job Safety Analysis using the template for the test and commissioning day, covering pressure, purge gas, traffic and the sediment controls.
Complete a Permit to Work Application for the purge and commission, stating the isolation points, the pressure tier and the control centre notification.
Update WO-26-3301 in the Field Work Orders with the test parameters, duration, gauge identifier and result.
Describe the purge sequence with the gas recovery unit and the detector readings that confirm the main is full of gas.
Record the permit as Restored and then Closed in the Permit to Work Register with the commissioning times.
Update the Network Asset Register with the two new tie-in valves and note the as laid drawing reference on the work order before requesting close out.

My notes: what did I enjoy, and what surprised me?

What someone in this role would produce

Completed job safety analysis
Permit to work application and closed permit record
Work order with test record and as laid reference
Asset register entries for the new valves

Printing this is a record of what you explored. It is not a certificate or a qualification.