Document Number

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RAPID P0030 CPP QAC PRC 0001 0024

PETRONAS RAPID PROJECT, PENGERANG

P30A - EPCC OF RAPID ADDITIONAL OLEFINS STORAGE FACILITIES

Typical
comment for all

HYDROSTATIC & PROCEDURE FOR

HYDRO PNEUMATIC TESTING OF TANKS

To specify which tank? Hydrostatic-Pneumatic; maybe for Ethylene Storage Tank?

OWNER Approval: PRPC Refinery and Cracker Sdn. Bhd.

Name:
Date (DD-MMM-YY):

Signature:

Document Class: Z

Pages modified under this revision: -

A 29-SEP-2017 IFR – Issued For Review Cheping Narvin Wan Rui

DATE WRITTEN BY CHECKED BY APPROVED BY

REV. STATUS – REVISION MEMO
DD-MMM-YY (name & signature) (name & signature) (name & signature)

Sections changed in last revision are identified by a vertical line in the right margin.

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RAPID P0030 CPP QAC PRC 0001 0024

PROCEDURE FOR

HYDRO PNEUMATIC TESTING OF TANKS

HOLD’s

HOLD No. REF. § DESCRIPTION ACTIONS

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RAPID P0030 CPP QAC PRC 0001 0024

PROCEDURE FOR

HYDRO PNEUMATIC TESTING OF TANKS

Table of Contents

1. PURPOSE .................................................................................................................................... 4

2. REFERENCE DOCUMENTS . ....................................................................................................... 4

3. ACRONYM AND DEFINITIONS ................................................................................................... 4

4. GENERAL .................................................................................................................................... 5

5. SCOPE ......................................................................................................................................... 5

6. RESPONSIBILITIES / PERSONNEL ............................................................................................ 5

7. SOURCE OF WATER .................................................................................................................. 6

8. HYDROSTATIC TEST . ................................................................................................................. 6

9. LEAK TEST . ................................................................................................................................. 8

10. CLEANING . .................................................................................................................................. 9

11. ATTACHMENTS .......................................................................................................................... 9

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RAPID P0030 CPP QAC PRC 0001 0024

PROCEDURE FOR

HYDRO PNEUMATIC TESTING OF TANKS

1. PURPOSE

PETRONAS intends to build a grass root integrated Refinery and Petrochemicals Complex by

developing the RAPID PROJECT (Refinery and Petrochemical Integrated Development) to

meet both domestic and Asia's energy and chemicals demand.This Quality Control

Methodology describes the minimum requirements & procedure for performing Hydro

Pneumatic testing on Tanks by the CONTRACTOR in line with the contractual requirement to

be implemented during the execution of the PETRONAS RAPID Project.

Design and Construction Code & Standard : ASME Section VIII Div.2, Edition 2015-U2 Stamp

+RAPID-FEI-TPX-MEC-DES-0001-0101 AND RAPID-FEI-TPX-MEC-SPN-0001-010.

To list also references for Ethylene Storage Tanks, Heat Exchangers, Rectangular tanks, etc.
2. REFERENCE DOCUMENTS

RAPID-FE1-TPX-MEC-DES-0001-0101 Project Specification-Design Of Pressure Vessels

RAPID-FE1-TPX-MEC-STD-0001-0101 Project Specification-Pressure vessel construction

standard

PTS 31.22.20.31 Pressure Vessels (Based on ASME Section VIII)

State year and
PTS 31.22.10.35 Manufacturing Report for Pressure Vessels
revision
PTS 30.10.60.18 Welding of Metals To include:
- RAPID-FE1-TPX-CMM-SPN-0001-0903
PTS 60.3302 Wastewater Management
- PTS 61.10.08.11.

PTS 60.3309 Air Emissions Management

ASME Section VIII Division 1 Ed. 2015 Rules For Construction of Pressure Vessels

ASME Section VIII Division 2 Ed. 2015 Rules For Construction of Pressure Vessels

ASME Section II Ed. 2015 Boiler and Pressure Vessel Code –Materials
ASME Section V Ed. 2015 Non-Destructive Examination

ASME Section IX Ed. 2015 Welding and Brazing Qualification

3. ACRONYM AND DEFINITIONS

OWNER: PRPC Refinery and Cracker Sdn. Bhd.

CONTRACTOR: China Petroleum Pipeline Bureau (CPP) & China Petroleum Pipeline

Malaysia (CPPM)

PROJECT: EPCC of PETRONAS RAPID PROJECT PACKAGE 30 - ADDITIONAL

OLEFINS STORAGE FACILITIES

ITP Inspection and test plan

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RAPID P0030 CPP QAC PRC 0001 0024

PROCEDURE FOR

HYDRO PNEUMATIC TESTING OF TANKS

RAPID Refinery and Petrochemical Integrated Development

QC Quality control

NDT Non Destructive Testing

TPIA Third Party Inspection Agency

PTS Petronas Technical Standards

Typical comment: Delete all "PMC"

Contractor shall
4. GENERAL

confirmed and witness by

owner
After completion of a specific tank, it shall be confirmed by OWNER/PMC that the tank is

mechanically completed in all respects. OWNER/ PMC shall check physically as well as

documentation wise. Water filling shall start after OWNER/ PMC clearance has obtained.

5. SCOPE

This procedure describes the requirements for performing Field Hydro Pneumatic tesing of

Carbon Steel Storage Tanks for RAPID Project.

Which tank?

6. RESPONSIBILITIES / PERSONNEL

Test Supervisor or test subcontractor shall be in charge and responsible for performing, control,

Please use
coordination and supervision of hydro testing activities.
consistent terms;
if want to use
Test Supervisor, QA/QC Inspector and QA/QC Engineer are responsible to ensure the test are carried out in

then please use

CPP to clarify the
Test Supervisor accordance with the requirements, Project Specifications and this procedure.
highlighted
throughout this
statement
document. Testing Personnel must be skilled to perform the said tasks, May be a qualified third party

contractor, company personnel or a combination of both may be retained to conduct the

hydro pneumatic test of the tank. Testing Personnel shall perform all testing functions set forth

by the
To correct the format...
which

Construction Supervisor that may include, but are not limited to:

a) Isolation of piping ( if any )

add:
b) Filling the tank;
verify all fabrication work is
c) Surveying;

complete and accepted before

d) Leak checks;
filling
e) Foundation checks;
and settlement monitoring

f) Draining of water out from the tank;

Add Test water management and disposal
g) Compliance with environmental / RAPID regulations

h) Test documentation

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RAPID P0030 CPP QAC PRC 0001 0024

PROCEDURE FOR

HYDRO PNEUMATIC TESTING OF TANKS

Water shall be sourced by CPP. Please

TEST refer CONTRACT on the scope of
7. SOURCE OF WATER
supply.

Fresh( potable ) water shall be used for tank hydro testing if possible, At locations potable

water is not available in sufficient quantity or where cost of using potable is prohibited, river

water, dock water or sea water may be used, in such a case a water chemistry test shall be

performed to determine the PH factor, chloride content and presence of other corrosive

elements. Hydro test water shall be supplied by client / owner at site.

Whenever non potable water is used for testing, the length of time that the water is kept in the

tank shall be kept as short as possible.

The content of chloride ion in the test water of medium carbon steel vessel is not more than

250PPM. Test water requirement shall be based on RAPID-FE1-TPX-CMM-SPN-0001-0903 and PTS 61.10.08.11.

This procedure only for Propylene

8. HYDROSTATIC TEST
Storage Vessels 5220-V-104A/B/C/D?
How about other PVs, HEXs, Tanks?
8.1 Requirements for foundation settlement

(a) Visual observation shall be made for inspecting foundation Settlement at the following

steps during liquid filling or discharging process:

■ After being identified as acceptable upon NDT, spherical tank is filled with water for

foundation settlement observation, which is recorded accordingly.

■ Before spherical tank is filled with water, the settlement observation point shall be defined

on each support or pier and clearly marked.Measurement is made by level gauge and

tower rule, with level gauge forming a triangle with the reference point and the support

foundation, and its records are made in the order of supports.

■ before liquid filling;

■ when the liquid level is raised up to 1/3 the inside diameter of spherical vessel(7500mm

from the inside bottom);

■ when the liquid level is raised up to 2/3 the inside diameter of spherical vessel (15000mm

from the inside bottom);

■ 24h later after filling up with liquid;

(b) Settlement shall be measured at each support column foundation. All support column

foundations shall be uniformly settled. The difference in settlement for each support column

foundation after liquid completely drained off shall be not greater than 0.5Db/1000 (Db

foundation circle diameter, mm), that is 11mm. The difference in sinking between two

adjacent support column foundations shall be not greater than 2mm. Otherwise, some

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RAPID P0030 CPP QAC PRC 0001 0024

PROCEDURE FOR

HYDRO PNEUMATIC TESTING OF TANKS

Please check and refer to hydrostatic requirement in PTS 31.22.20.31, RAPID-FE1-TPX-MEC-SPN-0001-0101, RAPID-FE1-TPX-CMM-SPN-0001-0903
and PTS 61.10.08.11.

necessary measures shall be applied.

8.2 Hydrostatic test shall adopt uncontaminated water with water temperature not lower than 5℃ .

Water test pressure shall be 2.86MPa. Make reference to the drawing. As per PROJECT SPECIFICATION and PTS,
for PVs and HEX, the test pressure shall be as per PTS 31.22.20.31 and
RAPID-FE1-TPX-MEC-SPN-0001-0101 para 6.9.1.3.
8.3 Test requirements

■ Prior to static hydraulic pressure test, all data of mechanical property test of the product

template shall be acceptable. All welding works are finished and are qualified upon NDT.

Such gas pressure test shall be performed with participation of Owner and PMC and local

authority Third party authority Inspector. The test work shall be supervised under

supervision of the safety department of the company.

chart recorder
■ Requirement on pressure: Two calibrated pressure gauges with the same scale shall be

provided separately on the top and bottom of spherical tank, and their scale is better to

be 2 times the test pressure, but not less than 1.5 times or more than 3 times. Both

& chart recorder

pressure gauges shall be calibrated, with the precision level not lower than 0.4; and the

diameter of panel is 150mm. Reading of the pressure gauge on the top of tank is taken

as the test pressure.

■ The outer surface of testing spherical vessel shall be kept dry through the whole testing

process.

■ When the metal temperature of vessel shell is close to liquid temperature, the pressure

can be gradually raised up.

■ During testing, the pressure shall be raised gradually up to 50% of the test pressure,

and be HOLD for a period of 10min. Then, all the welded joints and the connection

locations of the vessel shall be inspected for leakage. If no leakage occurs, the pressure

raising can be continued.

■ When the pressure is raised up to design pressure, HOLD pressure for a period of l0min,

the leakage inspection shall be performed once more. If there no leakage occurs, the

pressure raising can be continued.

60 min
■ When the pressure is raised up to the test pressure, a period of 30min shall be HOLD.

Then release the pressure to design pressure, and make a leakage inspection again. If

there no leakage occurs definitely, the spherical vessel is identified as acceptable.

■ After hydrostatic test, We shall do Wastewater Management,the testing liquid shall be

completely drained off. The inside of spherical vessel shall be dried by compressed air.

The testing liquid shall not be drained off directly at the site.

For PV and HEX, the test duration shall be as per PTS 31.22.20.31 para 6.9.1.3.
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RAPID P0030 CPP QAC PRC 0001 0024

PROCEDURE FOR

HYDRO PNEUMATIC TESTING OF TANKS

To explicitly mention requirement of pressure and temperature recorder.

■ During test, it is forbidden to hammer at the tank and it is needed to pay attention to

ambient temperature change and to monitor the reading changes on pressure gauge so

as to avoid overpressure.
It has been discussed during Constructability Review that Leak Test for spherical vessel is not applicable.
For P30 project, leak test is required for cryogenic tank (combined test with hydrostatic test), reinforcing
pad on nozzles, tank bottoms and annulars (vacuum leak test), valves, etc. CPP to advise.
9. LEAK TEST

9.1 Leak test shall be conducted on the spherical vessel after passing hydrostatic test only. The

test pressure is 2MPa.

9.2 Prior to gas-tight test, safety device, valve and pressure gauge etc. on the tank shall have

been installed completely.

9.3 Two calibrated pressure gauges with the same scale are installed separately on the top and

bottom of the tank. Their scale is 1.5-3 times the test pressure, and the diameter of panel is

150mm.

9.4 The testing gas used for leak test shall be the dry and clean air.

9.5 The test temperature of gas in leak test shall be not less than 15°C.

9.6 The pressure gages and safety valve used for leak test shall be calibrated and and shall be

made sure that it is in the term of validity before use.

9.7 Requirements for test

■ During testing, the pressure shall be raised gradually up to 50% of the test pressure and

be HOLD for a period of 5min. All the welded joints and the connection locations of the

spherical vessel shall be inspected for leakage. If no leakage occurs, the pressure

raising will be continued.

■ When the pressure is raised up to the test pressure and HOLD for a period of 10min, the

leakage inspection shall be made once more. If no leakage occurs definitely, the

spherical vessel is identified as acceptable.

■ Release the pressure gradually

■ During test, it is needed to pay attention to ambient temperature change and to monitor

the reading changes on pressure gauge so as to avoid overpressure.

■ Finally to release the pressure in a slow way after a joint inspection by the Owner,

supervisor, and construction contractor.

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RAPID P0030 CPP QAC PRC 0001 0024

PROCEDURE FOR

HYDRO PNEUMATIC TESTING OF TANKS

10. CLEANING

After dewatering of the tank, after hydro test, cleaning of inner wall & bottom shall be carried out

and thoroughly flushed with clean fresh water & debris if any shall be clean removed. Standing

water silt or other dirt left in the tanks after hydro test shall be thoroughly cleaned appropriately.

11. ATTACHMENTS

I. FIELD INSPECTION & TEST PLAN FOR HYDRO TESTING OF TANKS

II. WATER FILLING AND SETTLEMENT RECORD FOR FIELD ERECTED

SPHERES

III. TANK LEAK TEST RECORD

To show common pressure-time graph for the hydrostatic test. Show % of water pressure also acceptable.

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 1. Please separate ITP from procedure

2. Only relevent QC activity to be included
3. All Inspection forms to be attached (with register Which project?
number)

PETRONAS RAPID PROJECT - Refinery Tank Farm

PETRONAS

FIELD INSPECTION & TEST PLAN Civil □ Instrumentation □ H = Hold Point / Approval
FOR HYDRO TESTING OF TANKS Structural □ Pipeline □ W = Witness Point
DISCIPLINE Mechanical □ Process □ R = Review Document
Piping □ Others □ S = Surveillance Inspection
Electrical □

RESPONSIBILITY
INSP. ACCEPTANCE CRITERIA
STAGE /
QC ACTIVITY QUALITY RECORDS OWNER/ REMARKS
NO. (PROCEDURE/DWG/ STD/ FREQ. CONTRACTOR TPIA
SPECS.) PMC

1 Procedure Review HT procedure Before HT HT Procedure H R

2 Preparation of Punch List Punch List Before HT Punch list H R

3 Review of Punch List _ Before HT Punch list H R

_
4 Liquidation of check list, If applicable Before HT Punch list H W

Markup P&IDs and Tank

5 Marking of HT test limits on P&IDs and ISO drawings. Before HT _ P R

drawings

Markup P&IDs and Tank

_
6 Correctness of Testing arrangements Before HT H H
drawings

7 Scrutiny of test packs for Mechanical & NDT Clearance Tank History sheets Before HT LHS W W

8 Review of Calibration certificates of pressure Gauges Calibration certificates Before HT Calibration certificates H H

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 PETRONAS RAPID PROJECT - Refinery Tank Farm

FIELD INSPECTION & TEST PLAN Civil □ Instrumentation □ H = Hold Point / Approval
FOR HYDRO TESTING OF TANKS Structural □ Pipeline □ W = Witness Point
DISCIPLINE Mechanical □ Process □ R = Review Document
Piping □ Others □ S = Surveillance Inspection
Electrical □

RESPONSIBILITY
INSP. ACCEPTANCE CRITERIA
STAGE /
QC ACTIVITY QUALITY RECORDS OWNER/ REMARKS
NO. (PROCEDURE/DWG/ STD/ FREQ. CONTRACTOR TPIA
PMC
SPECS.)

9 Field Calibration, if any Calibration certificates Before HT Calibration certificates H H

10 Water Filling Water filling Report During HT Water filling Report H W

11 Settlement API650 Latest edition During HT Tank settlement report H W

12 Witness of Hydro testing Hydro test Report After HT Hydro test Report H H

Visual inspection of all weld joints for leak during

Visual inspection

13 Visual inspection Reports FINAL H H

Pneumatic Hydrotesting Reports

Pop up of PSV at pre set

14 Pneumatic test FINAL Calibration certificates H H

Pressure

_
15 Draining of Water _ FINAL H W

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 PETRONAS RAPID PROJECT - Refinery Tank Farm

FIELD INSPECTION & TEST PLAN Civil □ Instrumentation □ H = Hold Point / Approval
FOR HYDRO TESTING OF TANKS Structural □ Pipeline □ W = Witness Point
DISCIPLINE Mechanical □ Process □ R = Review Document
Piping □ Others □ S = Surveillance Inspection
Electrical □

RESPONSIBILITY
INSP. ACCEPTANCE CRITERIA
STAGE /
QC ACTIVITY QUALITY RECORDS OWNER/ REMARKS
NO. (PROCEDURE/DWG/ STD/ FREQ. CONTRACTOR TPIA
PMC
SPECS.)

_
16 Removal of temporary blinds/supports _ FINAL H W

Boxing up including reinstallation of flappers of check

17 Boxing UP Reports FINAL Boxing UP Reports H W

valves

18 Review of Records of fasteners & gaskets IMIR/MTC FINAL IMIR/MTC H R

Troque tightening/ tensioning of flange joints, wherever

Torque tightening
Torque tightening

19 FINAL H W
applicable report report

20 Review of Inspection & Test Documents Final Documents FINAL Final Documents H R

What is IMIR / MTC?

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Petroliam Nasional Berhad (Petronas)

Refinery and Petrochemical Integrated Development Project
(RAPID)

How about other PVs, HEXs, and Tanks?

WATER FILLING AND SETTLEMENT RECORD FOR FIELD ERECTED SPHERES

3
Type of Tank: Diameter: m. Height: m. Volume: m

Water Filling
Time Holding
Time

No. Increment Height Rate Remarks

From To
3
1 m m .hrs

3
2 m m .hrs

3
3 M m .hrs

3
4 Full m m .hrs

Tank Settlement Record

Section to be checked (degrees

No. Stage
0-45 45-90 90 - 135 135-180 180 -225 225 -270 270 -315 215-360 Remarks

1 Before Fill HP

4 Full HP

5 Empty HP

Notes:

If

required by approved ITP

CONTRACTOR QA/QC Inspector PMC QA/QC Inspector ()Petronas () VENDOR

Name: Name: Name:

Signature: Signature: Signature:

Date: Date: Date:

Electronic Filename: RAPID-P0030-CPP-QAC-PRC -0001-0024_A.docx

Petroliam Nasional Berhad (Petronas)

Refinery and Petrochemical Integrated Development Project
(RAPID)

Please check comment on sphere leak test.

Refer to MOM of Constructability Review.

SPHERE LEAK TEST RECORD Report No.

Tag Description: Tag No.:

3
Type of Tank: Diameter: m. Height:: m Volume: m

Leak Test for: ( ) V a c u u m Box (HP) ( ) O i l (HP) ( ) A i r (HP)

Test Area / Test Area /

No. Test Date Result No. Test date Result
Portion Portion

Notes:

If required by approved ITP

CONTRACTOR QA/QC Inspector PMC QA/QC Inspector
()Petronas ( ) VENDOR

Name: Name: Name:

Signature: Signature: Signature:

Date: Date: Date:

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