Lead Leak Test Commissioning Engineer

Offshore Frontier Solutions; Kuala Lumpur; On-site; MYR 244,000 - 326,000; Full time

Job summary

A global engineering company is seeking a Lead Leak Test Commissioning Engineer in Kuala Lumpur, Malaysia. This role involves planning and executing N2-He leak tests and Flange Management for FPSO projects. Candidates should have a diploma or bachelor's in Mechanical Engineering and at least three years of relevant experience. Strong skills in N2-He leak testing, safety compliance, and vendor supervision are crucial. Join us at the forefront of innovative engineering solutions and take your career to new heights.

Benefits

Competitive salary

Career development opportunities

Health and safety benefits

Qualifications

• Minimum 3 years FPSO project experience in managing N2-He leak testing.
• Proven experience on FPSO/FSO projects.
• Strong HSE-focused mindset.

Responsibilities

• Plan and execute N2-He leak testing and Flange Management.
• Lead on-site operations with contractors and vendors.
• Ensure compliance with HSE policies and protocols.

Skills

N2-He leak testing

Flange Management

Hot Oil Flushing

Analytical problem-solving

Effective communication

Vendor/contractor supervision

Education

Diploma/Bachelor’s in Mechanical Engineering

Tools

MS Office

Digital flange registers

Job description

Lead Leak Test Commissioning Engineer

OFS Malaysia is a subsidiary of Offshore Frontier Solutions Pte. Ltd. (OFS), a MODEC Group company in Malaysia. Being part of Modec means being the protagonist of a challenging career and being in touch with the latest deep-water production systems, knowing that your career begins in Malaysia, but your talent can take you anywhere in the world.

If you want to be one of the greatest in the market, this is your opportunity!

We are currently looking for talented individuals to join us as a Lead Leak Test Commissioning Engineer.

Location: KL Eco City, Malaysia.

Position Summary

The Integrity Leak Test Engineer is responsible for planning, executing, and supervising Nitrogen-Helium (N2-He) leak testing, Flange Management, Hot Oil Flushing (HOF), and PSV calibration for FPSO projects across construction, mechanical completion, and commissioning phases. The role ensures technical integrity, safe execution, and timely delivery of joint integrity, leak testing, and flushing programs across modules, vendors, and contractors.

Qualifications & Experience

• Education: Diploma/Bachelor’s in Mechanical Engineering or equivalent.
• Experience: Minimum 3 FPSO project experience in managing N2-He leak testing and Flange Management scope for projects; exposure to Hot Oil Flushing.

Technical Competencies & Skills

• Proven experience in N2-He leak testing and Flange Management on FPSO/FSO projects.
• Knowledge of Pressure Safety Valves (PSV) types, calibration requirements, and set-point control.
• Understanding of commissioning systems/sub-systems, boundaries, work packs, and ITRs.
• Hot Oil Flushing know-how: cleanliness criteria (e.g., ISO 4406), flow/temperature control, filter selection, temporary spool-ups, and acceptance testing.
• Ability to prepare specifications, work packs, and MTOs (bolts, nuts, gaskets, filters, strainers, temporary spools).
• Well versed with joint integrity processes, torque/tensioning methods, flange assembly, and controlled tightening sequences.
• Strong analytical/problem-solving skills; HSE-focused mindset including pressure and high-temperature fluid safety.
• Proficient in MS Office; experience with digital flange registers and completion systems is an advantage.
• Effective communication, coordination, and team leadership skills; vendor/contractor supervision experience.

Key Responsibilities

• Specification & Planning
  • Prepare project N2-He leak test specifications and scope mark-ups aligned with commissioning boundaries.
  • Technical Evaluation, Competency assessment & selection of Sub Contractor providing the Integrity leak test, PSV calibration, HOF, Flange management services.
  • Develop leak testing strategies per system/sub-system and establish acceptance criteria.
  • Define HOF strategy, system boundaries, cleanliness criteria, and execution sequence (including ISO code targets, flow/temperature profiles, filtration strategy).
  • Prepare temporaries and define test/flush mediums, instrumentation, and isolation plans.
  • Plan and manage PSV calibration schedules; define readiness prerequisites for testing and flushing.
• Procedure & Documentation Control
  • Review and approve Contractor procedures for Leak Testing, Flange Management, Hot Oil Flushing, and Responsibility Matrices.
  • Review/approve N2-He leak test packs and HOF work packs, including boundaries, ITRs, P&IDs/PEFS, flushing diagrams, monitoring points, and acceptance records.
  • Establish and maintain a single-source-of-truth Flange Register for all joints across module yards, including pre/post-leak test and pre/post-flushing reinstatement status.
  • Prepare MTOs for replacement materials (bolts, nuts, gaskets), filters, strainers, oil inventory, temporary spools/hoses, heaters, and pumps required for testing, PSV calibration, and HOF.
• Execution & Supervision
  • Lead on-site N2-He leak test, Flange Management, PSV calibration, and HOF activities with contractors, vendors, and yard teams.
  • Ensure availability and certification of documentation, tools, consumables, calibrated instruments, helium detectors, N2-He skids, heaters, filter skids, and pumps.
  • Coordinate parallel activities safely: multi-train flushing, external heaters and filter stands, off-module flushing where feasible.
  • Verify pre-flushing readiness: pre-clean of pipes/reservoirs, correct oil grade and volume, strainers installed, bypass/temporary spool fit-up, contamination baseline sampling.
  • Monitor and control HOF parameters: flow rate/velocity, bulk oil temperature, differential pressure across filters/strainers, particle counts/ISO codes, and flushing duration until acceptance criteria are met.
  • Enforce adherence to site procedures and PTW; conduct toolbox talks and risk assessments specific to pressure and high-temperature fluids.
  • Coordinate with Construction and MC teams to align readiness and punch closure for both leak testing and flushing.
  • Manage walk-downs, punch list resolution, and completion dossiers for offered systems/sub-systems, including HOF and leak test records and reinstatement certificates.
  • Drive Management of Change (MOC) during engineering and execution phases.
• Interface & Stakeholder Management
  • Liaise with commissioning, operations, vendor package teams, and module leads to align leak testing and HOF with start-up priorities.
  • Enable early testing and flushing at fabrication yards where feasible, especially for high-pressure/critical systems to reduce post-integration duration.
  • Coordinate with vendor packages for pre-start-up flushing requirements and cleanliness verification.
• Handover & Start-Up Readiness
  • Minimize untested/witness joints (WJ); categorize WJs by start-up criticality and plan reinstatement verification.
  • Ensure leak-free and cleanliness-compliant status of critical systems for RFSU.
  • Support offshore sweep-tests if required and provide complete turnover packages with leak test and HOF records, calibration certificates, and reinstatement status.

HSEQ Responsibilities

• Lead HSE planning for leak testing, flange assembly, PSV calibration, and HOF, including task risk assessments (TRA/JSA), SIMOPS reviews, and lifting plans for heavy equipment.
• Ensure full compliance with company and client HSE policies, applicable standards (e.g., pressure systems regulations, hazardous area rules), and statutory requirements.
• Implement and enforce PTW, LOTOTO, line break, and pressure test safety protocols; verify isolation plans and pressure/temperature limits before energization.
• Conduct daily toolbox talks and pre-job briefings; ensure crew competency and certifications (bolting, pressure testing, confined space, hot work).
• Establish emergency response plans for pressure excursions, leaks, hot oil exposure, and environmental releases; coordinate drills with HSE.
• Manage chemical and environmental controls: oil handling, spill prevention, waste disposal, filter media management, and correct labeling/MSDS availability.
• Maintain HSEQ documentation: incident/near-miss reports, NCRs, audit/inspection findings, safety observations, and lessons learned; drive close-out actions.
• Perform field audits on joint integrity practices (gasket selection, flange face inspection, bolt lubrication, torque/tensioning sequence) and equipment condition (calibration, certification, pressure ratings).
• Ensure ergonomics and safe material handling during installation/removal of temporaries, hoses, and skids; enforce barricading and exclusion zones.
• Track HSEQ KPIs: PTW compliance, stop-work participation, zero harm targets, and trend analysis of pressure/high-temperature related hazards.