Stolthaven Refinery Gas Testing

Overview

This project involved specialist gas testing on a 500-metre pipeline system at Stolthaven Refinery in Dagenham. The pipeline ran both 250 metres above ground and 250 metres below ground, presenting significant technical challenges due to temperature and atmospheric pressure variations between the two sections. The work required expert calculation and adjustment of test parameters to ensure accurate results and full compliance with gas safety standards.

Scope of Works

• Carried out tightness, strength, and purge testing on a 500-metre gas main.
• Used a specialist purge kit, including pressure reading and gas analysis equipment, to perform all testing accurately.
• Conducted 15 separate tests over a two-week period to ensure consistent atmospheric pressure conditions and valid results.
• No installation work was performed on this occasion.

Challenges

• Managing significant atmospheric and temperature variations between above- and below-ground pipe sections.
• Ensuring precise pressure and purge calculations are essential to prevent dangerous conditions.
• Avoiding disruption to the surrounding infrastructure, including an operational car park located above part of the pipeline.

Solutions and Approach

All test results were carefully adjusted to account for fluctuations in temperature and barometric pressure, ensuring accurate readings throughout the process. A fully calibrated purge and gas analysis kit was employed to deliver precise and reliable data. Testing was scheduled during periods of stable atmospheric conditions to maintain consistency, and all work was performed by Gas Safe registered engineers in full compliance with relevant safety regulations.

Results

All sections of the pipeline successfully passed the tightness, strength, and purge tests, confirming the system’s integrity. The testing eliminated the need for costly and disruptive pipeline replacement beneath the car park and ensured continued safe operation of the system. The project was completed with full certification and verification, demonstrating a high level of expertise in complex pressure testing scenarios rarely replicated elsewhere in the UK.