HYDROSTATIC TEST PROCEDURE (117) age | oF DIALOG PLANT SERV! | Date) 2k SDN BHD. 2 | a CLIENT: PETRONAS PENAPISAN MELAKA | CONTRACT TITLE: ENGINEERING DESIGN, PROCUREMENT, FABRICATION AND DELIVERY OF NEW LPG CHLORIDE TREATER VESSEL (TAG NO. V-1338), UNIT 13, PSR-1 CONTRACT NO: PP(M)S8/2008/0084(B) DOCUMENT TITLE: HYDROSTATIC TEST PROCEDURE (HT) DOCUMENT NO: 100820-V1338-HT-001 REV Lt CLIENT COMMENT 7 DEPARTMENT! STATUS CODE: REVIEWED BY: Beaione DATE: 7 Ta 7 REJECTED Comments AS NOTED] MINOR COMMENTS: COMMENT (ASCEPTABLE) ‘STATUS CODE: Q, 5 "PROVED. DO NOT. INFO ONLY RESUBMIT UNLESS MODIFIED. 1 i | (EH Eat 4 4 1 | 23/0109 | FR a | azizmuoa__| RoserT vEoH | WY LOKE 0 | oyoyne | | rzrzmupa | oserr veon |__ wy LoKe rev. 1ssueoare | _oescerprion __| erepaneoay | cuecxen oy | areRoven sy TfL —TSSUED FOR INFORMATION __| TER - ISSUED FOR REVIEW, APPROVAL DeFINATION | T i [APP APPROVAL / FINAL j| Doaumene mae | HYDROSTATIC TEST PROCEDRE (7) DIALOG PLANT SERVICES | Document No —| Douara-ViISeHTOOL | Page Noor SDN BHD Bee. 1 | Date’ 23-Jan-2009 CLIENT: PETRONAS PENAPISAN MELAKA CONTRACT TITLE: ENGINEERING DESIGN, PROCUREMENT, FABRICATION AND DELIVERY OF NEW LPG CHLORIDE TREATER VESSEL (TAG NO. V-1338), UNIT 13, PSR-1 CONTRACT NO: PP(M)SB/2008/0084(B) DOCUMENT TITLE: HYDROSTATIC TEST PROCEDURE (HT) DOCUMENT NO: (000829-V1338-HT-007 REV: [1 CLIENT COMMENT . DEPARTMENT/ 7 STATUS CODE: REVIEWED BY: DEViSION: DATE: 7 z 3 REJECTED COMMENTS AS NOTED. | MINOR COMMENTS COMMENT (ACCEPTABLE) STATUS CODE: [4 5 ‘APPROVED. DO NOT INFO ONLY RESUBMIT UNLESS MODIFIED. L 23/0109 TR aziz muoa _| ROBERT YEOH | _WY LOKE o 03/01/09, TR azzmuoa _| ROBERT YEOH | WY LOKE rev. _|_1ssuE DATE DESCRIPTION PREPARED BY | CHECKED BY | APPROVED BY IFL— ISSUED FOR INFORMATION _| IFR ~ ISSUED FOR REVIEW, APPROVAL DEFINATION : [APP ~ APPROVAL / FINALDIALOG Decumert Tle | HYDROSTATIC TEST PROCEDURE (HT cncegu gees | Ee pam — Pa Ig — CONTENTS 1.0 SCOPE 2.0 APPLICABLE CODE AND STANDARD 3.0 TEST EQUIPMENT 4.0 AIR TEST 5.0 PREPARATION 6.0 PROCEDURE FOR HYDROSTATIC TEST 7.0 RECTIFICATION OF LEAK 8.0 SAFETY 9.0 TEST RECORDS 10.0 CLEANING AND DRYING AFTER HYDROSTATIC TEST 11.0 ATTACHMENT — HYDROSTATIC TEST CERTIFICATEDIALOG Document Title | HYDROSTATIC TEST PROCEDURE (HT) DIALOG PLANT SERVICES | Document No. | DODEDO-VIIIE HT-OOT [Page No. | 3.0f8. ‘SDN BHD (Rev Tt [ate 123-Jan-2008 1 1.0 SCOPE 2.0 3.0 This procedure serves to provide a safe and efficient method of subjecting welded pressure vessel to a hydrostatic test for PETRONAS PENAPISAN (MELAKA) SDN. BHD. (PPMSB) CRU-1 LPG Chloride Treater Vessel V-1338 in accordance with Article T-3 and T-5 of ASME SECTION Vill, DIV. 2 ~ Alternative Rules. Hydrostatic test will only be conducted after a successful NDT acceptance of all welds. It will also be done on a bare vessel without coating. However AT-340 does allow for painting or coating either internally or externally prior to pressure test, except for those in lethal service. However. must be cautioned that paint or coats may mask leaks that would otherwise have been detected during pressure test APPLICABLE CODE AND STANDARD 2.4 ASME Section VIII Div.2 (Article T-3 and T-5} 200¢ Edition, 2006 Addenda, 22 PTS61.10.08.11 TEST EQUIPMENT 3.1 Indicating pressure gauges shall be usec and shall have dials graduated over a range of about double the intended maximum test pressure, but in no case shall the range be neither less than 1.5 times nor more than 4 times that pressure 3.2 All gauges used shall be calibrated against a standard deadweight tester or a calibrated master gauge. The gauges shall be recalibrated at least every 6 months or at any time when there is reason to believe that they are in error. The calibration certificates shall be forwarded to the inspector for review. The calibration record to be attached to the final HT certificate 3.3. The temporary fittings and connections, bolts / nuts hydro test pump, compressed supply line, compatible blinds shall be suitable for the test pressure. The following measuring instruments with valid calibration certificates are required (a) Two Pen Chart Recorder for temperature and pressure, b) Magnetic Skin Thermometer (©) Two Indicating Pressure Gauges (d) SNOPPY Leak test fluid 3.4 Valves shall be used for the following connections (a) Test Pump. (b) Pressure Gauge & Pressure Recorder () OutletDIALOG | oocument Tile | HYDROSTATIC TEST PROCEDURE (HT) Page No. | 4018 Date | 23sJan-2009 DIALOG PLANT SERVICES | Document No. SDN BHD Rew. 35 Bolls and gaskets used for hydrostatic test shall be suitable and safe for testing ‘Those supplied with the pressure vessel for field installation shall not be used for the test. 40 AIRTEST 4.1 Prior to Hydrostatic Test, all nozzle reinforcing pads and other welded attachment provided with tell-tale hole (if any) shall be subjected to Air test at 15 psig (1 barg) for leak. This can be done by pressurizing the pads through the tapped tale-tale hole using air from the compressor or hand pump measured by a calibrated pressure gauge. 4.2 Hold the pressure for THREE minutes and inspect the outside and inside (where accessible) surface at the vicinity of the welded pads using SNOOPY soap suds solution while the pressure is being held. 4.3 Any leak found shall be rectified and followed by NDT to ascertain no leakage before retesting 4.4 ALL telltale hole and vent holes on reinforcing pad and welded attachment shall be left open during the Hydrostatic Test and to be filled or plugged up with GREASE AFTER PAINTING 5.0 PREPARATION 5.1. Allwelding, weld repair, visual inspection, dimensional inspection and NDT shall have been completed with acceptable results attested to by QC Inspector, Authorized Inspector and where required the Purchaser's / owner's Inspector before releasing for the hydrostatic test 52 The pressure vessel shall be flush cleaned of welding slag, welding rod and other debris before bolting up the flanged openings for filing the water. 5.3. The hydrostatic test shall be performed using at least minimum two (2) indicating pressure gauges with one located at the highest point possible as vent for purging possible air pockets during water fing. If the indicating gage is not readily visible to the operator controlling the pressure applied, an additional indicating gage shall be installed at a location visible to the operator who controlled the test pump throughout the whole duration of the test. These indicating pressure gages shall be connected directly to the vessel, It is recommended that a Recording gage be used in addition to the indicating gages 5.4 The pressure vessel shall be hydrostatic tested in the horizontal position.DIALOG | Document Tile | HYDROSTATIC TEST PROCEDURE (HT) ae eee DIALOG PLANT SERVICES {Document No. (000829-V1338-HT-O01 [Page No. | 5 of 8 ‘SDN BHD (Rev. 1 {Date 23-Jan-2009 5 The oulside of the vessel shall be Kept dry during the test so that any leak can be easily identified. Pressure retaining weld should be left unpainted or un-insulated unt the pressure testing has been completed 5.6 The hydrostatic shall be witnessed by the QC Inspector, Authorized Inspector and where required, the Purchaser / Owner's Inspector as indicated in the Inspection Test Plan. 6.0 PROCEDURE FOR HYDROSTATIC TEST 6.1. Ficup blind, instrument valves, pressure gauges and etc. on the vessel as required for test. All flanges & blinds shall be taped using masking tape adhesive. The edges of flanges to be cleaned and free of oll before applying the masking tape, Hole shall be pricked using a nailtip of pen. The leak test will be periodically tested using the ‘snoop fluid, splashed on the pricked holes. 6.2. Hydrostatic test pressure at every point of the vessel shail be not ess than 1.25 times the Design Pressure. Establish the Upper limit of hydrostatic test pressure and ensure that the actual testing pressure is not allowed to exceed this maximum limit. 6.3. Fill in potable water, fitered through 2 10 um fter and allow overflow at the nozzle vent points located at the top of vessel in test position for sufficient time to purge out possible air pocket before blinding off. Potabie water used as test medium shall not have Chioride content exceeding 50 mg/kg 6.4 Following venting, connect the pump to the vessel and commence stage pressuring gradually to alow adequate holding time for interim inspection as indicated in Fig.t below. 5.5 Upon reaching the required test pressure, check carefully for leaks on all connections and joints before disconnecting or shutting off the pump from the vessel. 6.6 Hold the test pressure for the required duration as indicated in Fig.4 6.7 It is recommended for the metal temperature during hydrostatic testing to be maintained at least 30°F (17°C) above the MOMT but in any case shall never be allowed to exceed 120°F (50°C) to minimize the risk of brite fracture. The test pressure shall not be applied until the vessel and the pressurizing medium are at about the same temperature‘Document Tite | HYDROSTATIC TEST PROCEDURE (HT) | DIALOG PLANT Services | Document No. |-00829-Vi338-HT-001 Page No. [ €of8 SDN BHO (Rev. L Date [23-Jan-2008 6.8 The vessel under test shall demonstrate no visible leakage, buckling, deformation or distortion. Following the application of hydrostatic test pressure, visual examination of leakage shall be made of all joints and connections and of all regions of high stress such as head knuckles, regions around openings and thickness transition sections. This visual examination shall be made at a pressure equal to the greater of Design pressure or % of test pressure and shall be witnessed by the Inspector. Any leaks that are present shall be corrected in accordance with the Rules, after which the vessel shall be retested in accordance with these requirements. Figure 1. Hydrostatic Test Stage Pressurizing & inspection Point Holaing : Minimum ONE (1) Hour (excluding settling time of 15 minutes upon pressuring to HT pressure) Depressurze to 3 pressure equal tothe ‘greater af Design Pressure or % 04 Test pressure & HOLD for ‘sufficient ie 10 pe: fall lose visual inspection (on ALL joints 8 Holding Pressure Release Hold at Design Pressure for 3-5 minutes. pressure after Inspect for leak on all joint and seceniance of 1V3 of test pressure & HOLD for 3min. fr gradual rise Time 6.9 Upon satisfactory testing, examination and inspection, release the pressure by opening the drain valve at the bottom gradually and a vent valve at the highest point of the equipment to avoid any surge effect or vacuum on the vesselDIALOG j Document Title | HYDROSTATIC TEST PROCEDURE (HT) DIALOG PLANT services [Document No. | D00829-v1338 7-001 [Page fio. [7 of a Fate SDN BHO Rev. L poate 23 in 60) 7.0 RECTIFICATION OF LEAK 7.1. Ifany leak is detected during testing, the area shall be marked and the following rectification procedure shall be followed: (a) Incase of leaks on flange connection, the nuts shall be re-tightened gradually in ‘a proper sequence so as not to cause over and / or uneven tightening, However if the leaks persist, the vessel will be depressurized/dewatered and the gasket changed before proceeding to re-do the activity once again. (b) Ifany leak is observed in the weld joint, the water shall be drained and the defective area shall be repaired as per approved weld repair procedure. 7.2. Re-testing will only be conducted after the approved production sequence, NDT and PWHT has been successfully verified by 3° party / SSB Inspector. 8.0 SAFETY 8.1 Allhydrostatic testing shall be carried out by trained and competent operators, supervised by the Production and QC Supervisors, within barricaded areas with adequate warning signs displayed and obstruction free passageway for inspection. 82 Only authorized personnel shall be allowed in the area testing and the area shall not left unattended while testing is in progress. Test are limited to 3 persons at a time 83. Care shall be taken that the support and foundation of the pressure vessel can withstand total load to be imposed on them during testing 8.4 Production supervisor shall ensure that bolting up of all flanged connections are properly torque-up using correct type and sizes of bolts, nuts and gaskets, 85 The vessel undergoing hydrostatic test shall not be subjected to any form of shock loading such as hammering ete. it should also not be exposed directly to strong sunlight, to avoid excessive pressure build-up due to heat during hoiding at test pressure. 9.0 TEST RECORD 9.1. After successful completion of hydrostatic test, the QC Inspector will prepare the test certticate and submit together with the pressure record chart to Purchaser/Owner's Inspector if any and Authorized Inspector for review and endorsement 9.2 The test certificate shall contain but not limited to the following information (a) __ Item tested. (b) Test date.DIALOG Document Tle | HYDROSTATIC TEST PROCEDURE (HT) DIALOG PLANT services | DoaanentNo. | BOOSIE H agen] Bars SON BHD (Rev. 1 Date ___| 23-Jan-2008 1) Test pressure (@) Test Temperature (@) Test duration () Test Medium-Potable Water Quality (a) Particulars of pressure gauges / pressure recorder (h) Test Results and Conclusions 10.0 CLEANING AND DRYING AFTER HYDROSTATIC TEST Immediately after hydrostatic testing, completely drain out the water from the interior of the vessel for cleaning, After cleaning and thorough flushing and rinsing out with potable water, air blow to dry the vessel. Do not leave vessel filled with water for an extended period of time, Water quality used here for cleaning, flushing and rinsing shall be reported too 11.0 ATTACHMENT ~ HYDROSTATIC TEST CERTIFICATE.HYDROSTATIC TEST CERTIFICATE EXHIBIT 27 SECTION :20 REVISION: 1 DATE : 08/1007 [CLIENT REPORT NO. [ PROJECT DATE | LOCATION) PROJECT CODE _| DESCRIPTION OF EQUIPMENT (VESSELTANKPIPING) bt PRESSURE GAUGE SERIAL NO RANGE PRESSURE RECORDER SINO. RANGE TEST AESULTS DESIGN PRESSURE VDROSTATIC TEST PRESSURE MEDIUM DATE & TIME START DATE & TIME COMPLETED HOLOING TIME MARKS QC INSPECTOR AUTHORISED INSPECTOR CLIENT TPA ‘DOSH IALOG Nal wortahop, LOT 1830 Kawasan Poxndusiian Nia, Nagar Serbian Dara Khas Tal G05 7000557 Fax 605-7000559