TANK ERECTION PROCEDURE

*note: this is the sample document for the related job only
*author: theprocedure@engineer.com

TABLE OF CONTENTS
1. SCOPE
2. APPLICABLE CODE
3. FOUNDATION
4. CONSTRUCTION PROCEDURE
4.1. BOTTOM PLATE
4.2. SHELL PLATE
4.3. ROOF STRUCTURE
4.4. ROOF PLATE
4.5. OUTER RAFTER ERECTION PROCEDURE
4.6. WIND PROTECTION OF SHELL PLATE AND ROOF STRUCTURE
4.7. TEST
4.8. CALIBRATION
4.9. ATTACHMENT

1. SCOPE
This specification covers construction (erection) procedure for field erection of Two (2) nos
additional crude Storage Tanks.
2. APPLICABLE CODE
a. ASME IX: : Welding & Brazing Qualification
b. B31.3 : Chemical Plant, Petroleum and Refinery piping.
c. ASME V : Non Destructive Testing
d. API650 : Welded Steel Tank for Oil Storage.
e. BS 2654 : Vertical Steel Welded Non-refrigerated Storage Tank with Butt welds for the
Petroleum Industry.
f. Client Technical Standard
PTS-20.156A :Standard Tank Vol. 1 Part 1
PTS-20.156B :Standard Tank Vol. 1 Part 2
PTS-20.156C :Standard Tank Vol. 2 Part 3
g. Contractor Specification
: Field Inspection Procedure Specification
: Water Filling Test
: Quality Plan

3. FOUNDATION
The following item of the foundation shall be confirmed and accepted by warga Hikmat QC
and Client rep (PPMSB) prior to erection of the tanks.
(Refer to PTS-20.156A 09.00.00- Foundation)
i. Level and Direction of the foundation
ii. Camber and flatness of foundation surface
4. CONSTRUCTION PROCEDURE
(Refer to PTS-20.156B 10.00.00 Erection & 10.02.00 Erection Procedure)
4.1 BOTTOM PLATE
(1) Arrangement and welding of the Bottom plate shall conducted as per Bottom Plate
Welding Sequence in Attachment 1 and detail procedure as follow;
i. Marking of centre line.
ii. Bottom plate arrangement as per welding sequence and applicable drawing.
iii. Fitting between shell and bottom plate.
(2) Bottom plate shall be welded by back step or skip welding method.
(3) To prevent welding distortion, restraint jigs or reinforcing beams shall be used.
4.2 SHELL PLATE
(1) Prior to erection of shell plate, following marking shall be performed on the bottom plate
as shown in Fig. 1 & Fig. 2
i. Marking of radius for shell erection. (The marking shall be larger than the diameter shown
in the drawing, considering weld shrinkage of shell plate).
ii. Radius for checking the roundness of shell plate shall be marked.
iii. The marking allotment of 1st course of shell plate shall be carried out.
(2) Level, roundness and verticality shall be inspected after completion of erection of 1st
course of shell plate.
(3) Shell plate from second to fifth course and top angle shall be erected.

(4) Welding of shell plate shall be performed from lower course, and vertical joint shall be
welded prior to the horizontal joint.
4.2.1 DETAIL ERECTION PROCEDURE OF SHELL PLATE.
The sequence of erection and welding are as follow:
1) Erection of 1st course.
2) Check level, verticality and roundness of 1st course.

3) I) Erection of 2nd course. After completion of erection of second course, the vertical joint
of 1st course shall be welded.
ii) Vertical joint of 2nd course shall be aligned.
iii) Local departure, tolerance cut horizontal and vertical shell seams shall be checked.
4) i) Erection of 3rd course. After completion of erection of third course, the vertical joint of
2nd course shall be welded follow by horizontal joint between 1st course and 2nd course.
ii) Local departure, tolerance cut horizontal and vertical shell seams shall be checked.
5) i) Erection of 4th course. After completion of erection of fourth course, the vertical joint of
3rd course shall be welded follow by horizontal joint between 2nd course and 3rd course.
ii) Joint between shell plate and bottom plate shall be welded.
iii) Local departure, tolerance cut horizontal and vertical shell seams shall be checked.
6) i) Erection of 5th course. After completion of erection of fifth course, the vertical joint of
4th and 5th course shall be welded follow by horizontal joint between 3rd and 4th course, and
between 4th course to fifth course.
ii) Local departure, tolerance cut horizontal and vertical shell seams shall be checked.
7) i) Installation of top angle. Dimensional shall be checked prior welding the top angle to the
top (last) course.
ii) Local departure, tolerance cut horizontal and vertical shell seams shall be checked.
4.3 ROOF STRUCTURE
i. Roof structure shall be assemble on the ground in section or completed depending on size
and weight.
ii. Assembled roof structure shall be erected inside the tank after completion of bottom plate
and annular plate.
4.4 ROOF PLATE
Roof plate shall be arranged on the roof structure and welding to be carried out according to
welding sequence considering the distortion or warping of plates.
4.5 OUTER RAFTER ERECTION PROCEDURE
Roof of outer rafter shall be assemble on the ground in section or completed depending on
size and weight. The sequence of assembly are as follow;
1. Assemble the roof plate on the temporary support.
2. Assemble and welding the center ring and center plate complete with stiffener and rib
plate.
3. Fit the ring on the roof plate.
4. Install the rafter and girder on the roof plate.
5. Erect the outer rafter on the temporary support after completion of bottom plate and
annular plate.

4.6 WIND PROTECTION OF SHELL PLATE AND ROOF STRUCTURE

Shell plate and roof structures shall be protected by heavy wind during the erection using guy
wire rope method. A detailed execution procedure and/ or plan including the detailed
dimensions of the device shall be prepared and submitted to CLIENT site for approval, prior
to commencement of shell construction work.
4.7 TEST
After completion of the entire tank, test shall be performed in accordance with WH FIELD
INSPECTION & TEST PROCEDURE SPECIFICATION.
4.8 CALIBRATION
After completion of the required test, the tank shall be calibrated in accordance to WH
FIELD INSPECTION & TEST PROCEDURE SPECIFICATION.
4.9 ATTACHMENT:
1. Fig 1 AND Fig 2.
2. Welding Sequence For Bottom Plate.

FIELD INSPECTION AND TEST PROCEDURE

*note: this is the sample document for the related job only
*author: theprocedure@engineer.com
TABLE OF CONTENTS
1. Scope
2. Applicable Code, Standard And Specification
3. General
4. Material Inspection
4.1 Material Receiving Inspection
5. Material Traceability Control
5.1 Extent of Traceability Control
6. Dimensional Inspection
6.1 Foundation Receiving Inspection
6.2 Location Mark Check
6.3 Fit-up Inspection
6.4 Roundness
6.5 Plumbness
6.6 Local Deviation
7. Nondestructive Examination
7.1 Visual Inspection
7.2 NDE Procedure
7.3 Radiographic Examination (RT)
7.4 Liquid Penetrant Examination (PT)
7.5 Vacuum Box Test (VBT)
7.6 Pneumatic Leak Test (LT)
7.7 Repair and Re-examination
8. Hydrostatic Test
8.1 Pre-test Check
8.2 Water Filling
8.3 Settlement Monitoring
8.4 Hydrostatic Test
8.5 Cleaning
8.6 Hydrostatic Test for Heating Coil
9. Fixed Roof Test
10. Paint Inspection
11. Tank Calibration
12. Final Inspection
13. Witness Inspection
14. Manufacturers Data Report
1. Scope
This document covers the inspection and test requirements of storage tanks at the
construction site specified for the Two (2) nos additional PSR-2 Crude storage tank at
Petronas Penapisan Melaka. (PPM)
2. Applicable Code, Standard And Specification

The following standards, code, and specifications have been used as a source of information
in the preparation of this document.
API Standard
API 650-9th Ed. 1995 : Welded Steel Tanks for Oil Storage
ASME CODE
ASME SEC. VIII DIV.1 : Rules for Construction of Pressure Vessels
ASME SEC.V : Nondestructive Examination
ASME SEC.IX : Welding and Brazing Qualifications
WHS SPECIFICATION
: Construction (Erection) Procedure Specicification
: NDT (Non Destructive Procedure)
: Scheme for Water Filling Test and Settlement Measurement
: Quality Plan
3. General
(1) Unless otherwise specified in this specification, inspection and testing shall be performed
in accordance with WHs Quality Plan and applicable codes, standards and PTS.
(2) Field QC personnel shall carefully follow the construction and testing of tanks, and shall
make sure that it complies in all details with design, construction, inspection and tests
specified by the applicable codes, standards and specification.
4. Material Inspection
4.1 Material Receiving Inspection
Visual inspection of incoming material including the fabricated tank material sent from the
shop, shall be made by the field QC personnel to ensure that there is no injurious defect on
the surface and cut edges. Check on the identification number of raw material shall be made
against material certificates. Check on the erection mark of fabricated tank material shall be
made against the corresponding drawings.
5. Material Traceability Control
5.1 Extent of Traceability Control
The following tank components are required to be traceable against the material certificate.
The As-built Sketch shall be prepared upon completion of the erection.
a. Shell Plate
Coded marking made at shop can be used to identify the material and be recorded in As-built
Sketch. As-build Sketch may be supported by the related material identification records sent
from shop.
6. Dimensional Inspection
6.1 Foundation Receiving Inspection
All the stage of receiving tank foundation, the field QC personnel shall review the foundation
inspection report. Spot check of actual dimension and bench mark shall be made against the
report.
6.2 Location Mark Check
Prior to the primary laying-down or erection of Bottom Plate, Bottom Sketch Plate, Shell
Plate, Roof Structures and Roof Plate, the field QC personnel shall check the location

marking in accordance with the related orientation drawings. Similarly, prior to make the
Nozzle/Manhole opening, the location marking of opening shall be ensured.

6.3 Fit-up Inspection

Weld preparation and dimensional accuracy shall be checked prior to start welding. Butt
welds of Shell joints shall be matched accurately and retained in position during welding
operation.
Misalignment of Shell weld joint shall not exceed the following tolerance.
a. In completed shell vertical joint
Shell Plate 15.8 mm thk : 1.6 mm
b. In completed shell horizonttal joint
Upper Plate 15.8 mm thk : 1.6 mm
For Bottom Annular butt weld, the tolerances of vertical joints shall be applied.
6.4 Roundness
Prior to commencement of shell to Bottom Sketch plate weld, the tank internal radius shall be
measured. The horizontally measured tank radius at 300 mm above the bottom corner weld
shall not exceed the following tolerances.
Tank < 12 m diameter : + 13 mm 6.5 Plumbness The first course shell plate shall be checked
for plumbness, level and roundness before welding in accordance with WHs construction
procedure to ensure that the tank will be completed within the specified dimensional
tolerances. Plumbness of Shell shall be inspected after completion of all Shell welds. The outof plumbness shall not exceed 1/200 of the total tank height. 6.6 Local Deviation Local
deviation shall be inspected, if there is any noticeable distortion after completion of shell
weld. The Local deviation shall not exceed the tolerance of 13 mm. 6.7 All nozzle and
couplings directly connected with piping shall be at the correct elevations from the surface of
bottom plate and radial positions after completion of welding and erection and remain at the
following tolerance. Elevation of nozzle : + 10 mm Radial position of nozzle : + 15 mm
Nozzle projection : + 10 mm Inclination of flange face : + 0.5
7. Nondestructive Examination
7.1 Visual Inspection
Regardless any other nondestructive inspection method applied, all the site welds shall be
subjected to visual inspection, and meet the requirements of API 650 Sec. 6 para 6.5.
7.2 NDE Procedure
General requirements, examiners qualification, equipment and operation procedure of
nondestructive examination shall be in accordance with WH Specification : Nondestructive
Test Procedure.
7.3 Radiographic Examination (RT)
The following RT shall be performed.
a. Shell vertical / horizontal joints and bottom annular radial joints shall be radiographed in
accordance with the requirement of API 650 Sec. 6 para 6.1.
Heating coil butt joints shall be radiographed on spot basis. Minimum 5% butt joints of
heating coil welded by each welder shall be fully radiographed.
b. Radiographs shall be judged in accordance with API 650 Sec. 6 para 6.1.5.

c. When a spot radiograph fail to comply with the acceptance standard, additional
radiographs shall be taken in accordance with the requirement of API 650 Sec. 6 para 6.1.6.
7.4 Liquid Penetrant Examination (PT)
The following PT shall be performed.
a. The attachment welds of nozzle / manhole welded to shell at site shall be examined by PT.
b. The acceptance standard shall be in accordance with API 650 sec. 6 para 6.4.4.
7.5 Vacuum Box Test (VBT)
The following vacuum box test shall be performed.
a. All Bottom welds, i.e. Bottom-to-Bottom, Sketch Bottom Sketch-to-Bottom Sketch,
Bottom Sketch-to-Shell joints, shall be inspected.
b. Any leakage observed by VBT is unacceptable.
7.6 Pneumatic Leak Test (LT)
The following pneumatic leak test shall be performed.
All attachment weld of reinforcement plate on each shell opening welded at site shall be
inspected in accordance with API 650 Sec. 5 para 5.3.5. Any leakage observed by LT is
unacceptable.
7.7 Repair and Re-examination
When an imperfection is judged to be repaired by welding, repair welding shall be make in
accordance with the applicable welding procedure. Repaired are shall be re-examined by the
same method originally used.
8. Hydrostatic Test
8.1 Pre-test Check
a. Before filling water into the tank, it shall be ensured that all inspection on Bottom, Shell
and Roof including attachment welds shall be completed.
b. Any foreign articles shall not be left in the tank.
8.2 Water Filling
a. The water filling rate shall be decided with consideration given to tank size, pump
facilities, water supply available, stability of foundation settlement, and other matter relating
to safety.
b. When foundation settlements are negligible or significantly greater than expected
settlement, water filling rate may be changed.
c. During the entire filling and emptying operation, roof manhole and/or other openings shall
be kept open.
d. During the water filling, the floating roof shall be checked frequently for leaks.
8.3 Settlement Monitoring
a. Settlement reading shall be take at a minimum of 4 points around the base of tank.
b. Settlement reading shall be taken and reported to Contractor at least once a day while the
tank is being filled with water and emptied.

8.4 Hydrostatic Test

a. Water shall be filled to the specified test level as WH Spec.
b. After the tank filled to test water level, all welds in the shell, including shell to bottom
Sketch Plate welds, shall be visually inspected for water tightness.
c. Water shall be maintained at the test level for minimum of 24 hours after which water may
be discharged.
d. Prior to starting the water discharging, ensure that the roof openings are opened.
8.5 Cleaning
a. During and after the tank is emptied, the inside of tank shall be cleaned.
b. All sand, sludge and rubbish on the tank bottom shall be removed.
8.6 Hydrostatic Test for Heating Coil
Heating coil shall be tested hydrostatically at a pressure specified in applicable drawing.
9. Fixed Roof Test
While the tank is maintained at the test water level, welds on the fixed roof shall be
pneumatically leak tested. Non-pressure tank roofs shall be tested to pressure not exceeding
the weight of the roof plates with compressed air and low-pressure tank roofs shall be tested
to a pressure equal to the maximum internal pressure rating. The inaccessible are during
hydrostatic test shall be inspected in advance by vacuum box.
10. Paint Inspection
Paint inspection shall cover the following items.
a. paint material check
b. surface preparation check
c. paint application check
d. dry film thickness (DFT) check
e. visual inspection of completed surface
f. pinhole test for tank internal lining
The magnetic pull-off type gauge or fixed probe magnetic flux type gauge shall be used for
DFT readings. For each coat of paint, the DFT shall be taken at a frequency of one
measurement of every 10 square meters area. Each measurement consists of an average of
three gauge readings next to one another. All spot measurements shall not be less that 100%
of the specified DFT.
After the final coating has been completed, the field QC personnel shall ensure that the
appropriate clean-up is done, and that any abrasions, nicks or scrapes are repaired as required.
11. Tank Calibration
Tank calibration and preparation of gauge table shall be performed by a specialized firm in
accordance with internationally accepted method and with local statutory requirements.
12. Final Inspection
Prior to tank box-up, the inside of tank shall be thoroughly ensured clean. Flange surfaces of
Nozzle/Manhole shall be carefully inspected for defects which may caused and leakage.
It shall be also ensured that all works required by drawings, specifications and the related
inspection and test plan have been thoroughly completed.

13. Witness Inspection

The scope of inspection by Vendor, CONTRACTOR, and OWNER is indicated in Scope of
Inspection. The Inspection and Test Plan shall be progressively followed by the inspector
throughout site construction.
14. Manufactures Data Report (MDR)
The site portion of MDR shall be compiled at site as the construction is progressing. The
completed site MDR shall be submitted to CONTRACTOR, while a original copy will be
sent to WH home office for retaining. As a minimum, the following inspection records shall
be included in the site MDR as per Quality Plan.
a. Inspection Certificate
b. As-built Sketch of Shell Plate
c. Welders Map of Shell and Bottom Plate/WPS & PQR/Welders Qualification Records
d. NDE Record of RT, PT, VBT and LT
e. Dimensional Inspection Record of Tank Foundation, Roundness and Plumbness
f. Hydrostatic Test Record including settlement data
g. Roof Test Record
h. Paint Inspection Record

SHOP FABRICATION PROCEDURE

*note: this is the sample document for the related job only
*author: theprocedure@engineer.com

TABLE OF CONTENTS
1.0 GENERAL
1.1 Scope
1.2 Drawing
1.3 Material
1.4 Welding
1.5 Inspection
1.6 Post Weld Heat Treatment
1.7 Painting
2.0 SHOP FABRICATION
2.1 Shell Plate
2.2 Roof Plate
2.3 Roof Structure
2.4 Top Angle and Stiffener
2.5 Manhole & Nozzle (Unit Fabrication)
2.6 Reinforcing Plate
2.7 Stairway, Ladder & Platform
2.8 Heater piping. (if any)
2.9 Other Accessories
3.0 Dimensional Tolerance
3.1 Shell Plate
3.2 Roof Plate
3.3 Roof Structure
3.4 Top Angle. Stiffener and top Birder
3.5 Nozzle and Manhole
1. GENERAL
1.1 Scope
This specification covers the requirement for shop fabrication of the EPCC of Two (2) nos
additional crude Storage Tanks.
1.2 Drawing
All shop fabrication shall be carried out in accordance with WH fabrication drawings.
1.3 Material
All material shall comply with WH drawing and applicable CLIENT specification.
1.4 Welding
To submit all WPS and WQT for review and approved by 3rd Party Inspector (Dosh
approved NDT)

All welding shall be carried out in accordance with approved Welding Procedure
Specification. (Shop/Site)
1.5 Inspection
Inspection shall be carried out in accordance with Shop Inspection Procedure Specification.
1.6 Post Weld Heat Treatment
Post weld heat treatment shall not be required for this project.
1.7 Painting
Painting at shop shall be carried out in accordance with Painting specification.
2 SHOP FABRICATION
2.1 Shell Plate
Cutting and/or edge preparation shall be done with flame planer or automatic gas cutting
and/or automatic beveling machine.
All damage such as pop-outs, deep burn serrations shall be repaired by grinding.
After edge preparation, shell plates shall be cold rolled to the curvature in accordance with
fabrication drawings.
The weld edges shall free from oil, dust, scale, water and other foreign materials, then shall
be coated with weld able paint.
2.2 Roof Plate
Roof plate shall be marked off in accordance with fabrication drawing and the edge shall be
cut with automatic gas cutting for shop fabrication.
2.3 Roof Structure
Rafter, girder and column shall be prefabricated to be ready for erection.
2.4 Top Angle and Stiffener
Top angle and stiffener shall be rolled to suit the curvature of the tank with bending roll
machine, then both ends shall be cut and edge prepared.
2.5 Manhole & Nozzle (Unit Fabrication)
Neck plate of manhole shall be cut with automatic gas cutting machine according to the
drawing and be cold rolled.
Seam joint shall be welded and then Flange shall be welded to manhole neck.
Nozzle pipe shall be beveled end with pipe cutter or gas cutting machine, and flange shall be
welded to nozzle pipe.
2.6 Reinforcing Plate
Reinforcing plate shall be outer periphery cut, opened and beveled with automatic gas cutting
machine after marking off then pressed or rolled to suit the tank curvature.
2.7 Stairway, Ladder & Platform
Handrails shall be shaped to the specified curvature with bender.
Treads and platform shall be fabricated to be ready for site erection.
2.8 Heater piping. (if any)

Cutting of pipes may be done either by mechanical or thermal (flame, arch or plasma) means.
For carbon steel, thermal cutting and beveling may be used only if the cut is reasonably
smooth and all oxides are removed from the surface.
2.9 Other Accessories
Other accessories shall be fabricated completely in accordance with drawings.

WELDING MATERIAL CONTROL PROCEDURE

*note: this is the sample document for the related job only
*author: theprocedure@engineer.com
TABLE OF CONTENTS
1. SCOPE
2. REFERENCE
3. RESPONSIBILITIES
3.1 SITE MANAGER
3.2 QC MANAGER
3.3 QA ENGINEER
3.4 QC INSPECTOR
4. WELDING MATERIAL CONTROL
1.0

SCOPE
This procedure shall outline the control of welding materials in welding works for the
EPCC of Two (2)
Nos
crude
Storage
Tank
2.0

REFERENCE
1) PTS 64.51.01.31 - STANDARD VERTICAL TANKS ERECTION & TESTING
(Section 6.5
Welding
Consumables)
2)
IS/D-322
FIELD
INSPECTION
&
TESTING
PROCEDURE
3)
IS/D-310
MATERIAL
CONTROL
PROCEDURE
4)
KOBE
/
ESAB
MANUFACTURE
RECOMENDATION
3.0

RESPONSIBILITIES
3.1
Site
Manager
Shall be responsible for the full implementation of this procedure. He shall assign
knowledgeable
Material Controllers / Welding Foreman who will be able to distinguish all types
welding
consumables.
3.2
QC
Manager
Shall be responsible for ensuring that all personnel involved are indoctrinated and
shall assign
personnel to conduct monitoring and audits for compliance to this procedure.
3.3
QA
Engineer
Shall be responsible for Supervision of Inspection activities, monitoring and
documenting
inspection / monitoring activities.
3.4 QC Inspector

Shall inspect welding material control on daily basis and document any deviation from
this procedure.

4.0 WELDING MATERIAL CONTROL

4.1 All welding materials shall be received by the Material Controller / Welding Foreman.
He shall check
welding material condition, damage, material identification and batch / lot / heat /
number. All welding
materials received shall be accompanied by an Inspection Certification form
manufacturer or supplier
. The QA Engineer shall review the manufacturers inspection certificates for compliance
to the
specifications and if acceptable sign and stamp Issued For Construction. The
certificate shall be
submitted to contractor for review
4.2 The Material Controller / Welding Foreman shall check that sufficient quantity is
stored in baking /
holding oven for daily use. The Material Controller / Welding Foreman shall issue as
follows:
1. Issue electrodes by priority,
a. re-baked electrodes
b. first baked electrodes
c. new electrodes
2. Check size and type of welding material to be issued
3. Issued maximum quantity of 5kg for each portable oven
4. For GTAW rods, original containers shall be issued.
For stainless steels the container or welders quiver shall be
clearly
marked by paint or colored tape with the same color identification as
given by the consumable manufacturer.
5. Issue of portable oven marked with Welders no only to respective welders.
6. Issues of consumables are to be recorded on Consumable Issue Report.
4.3 The Material Controller / Welding Foreman shall monitor / check his welders portable
oven (quivers)
are plugged to power source all the time. At the end of the day, he shall gather all
quivers and take to
the welding material control room.
4.4 After receiving all portable ovens the Material Controller / Welding Foreman shall
place all segregated
electrodes and place at top portion of baling oven and shall be issued first on the next
day. Returned
electrodes shall be re baked only once. There after they shall disposed of as scrap.

PRESSURE TEST PROCEDURE FOR PIPING SYSTEM

*note: this is the sample document for the related job only
*author: theprocedure@engineer.com
TABLE

OF

CONTENTS

1.
SCOPE
2.
REFERENCES
3.
GENERAL
REQUIREMENTS
4.
PNEUMATIC
TEST
5.
EQUIPMENT
FOR
HYDROSTATIC
TEST
6.
PREPARATION
OF
THE
TEST
PACKAGE
7.
LIMITATION,
EXCEPTIONS
AND
EXCLUSIONS
8.
FIELD
PREPARATION
9.
PERFORMANCE
OF
PRESSURE
TEST
10.
EVALUATION
OF
TEST
RESULTS
11.
REPORT
/
DOCUMENTATION
12.
REINSTATEMENT
13. ATTACHMENT 1 (TEST MANIFOLD)
1.0
SCOPE
1.1 This procedure covers the minimum requirements and plans for field pressure test of
piping system for
The EPCC of Two (2) nos additional crude Storage Tanks.
2.0
2.1 ANSI / ASME B31.3

REFERENCE
- Chemical Plant and Petroleum Refinery Piping

3.0
GENERAL
REQUIREMENT
3.1 All piping lines shall be hydrostatic tested, but however, lines which where indicated in
the line list may
be
service
test.
3.2 All lines which were indicated as a tie-in joint need to do 100% NDT such as RT, MPI
or DPT and
carry
out
the
service
test.
3.3 The minimum test pressure shall be as specified in each piping Iso drawing or pressure
test flow
diagram
based
on
ANSI
/
ASME
B31-3
requirement.
3.4 Test medium shall be fresh water, which clean and free from silt or un dissolved solids
of any
description.
3.5 Test medium for austenitic stainless steel piping the water shall not contain more than
30 ppm chloride
10N.
3.6 All the equipment and lines, which are to be tested along with the piping, shall be
blanked off or
replaced with temporary spool pieces. Any test along the said item shall be approved
by
Contractor.

3.7 All pressure gauge and pressure recorder used for the test shall be calibrated and
registered in
accordance with Calibration of Test/ Inspection Tools Control Procedure. Each
certificate shall be
valid for a period of three (3) months. Pressure gauge shall be selected so that the test
pressure of the
system falls between 30% and 75% of the gauge scale range. The following in line
items will not be
subjected
to
Field
Pressure
Testing:1)
Elements
of
strainers
and
filters
2) Pressure relieving devices such as rupture disc, pressure valves etc.
3)
Locally
mounted
pressure
gauge.
4) Pressure measuring and regulating items such as flow control valves, turbine meters
etc.
5)
Equipment
like
pumps,
hose
reels
etc.
6) Lines directly open to the atmosphere such as vents drains, safety valves, discharge
etc. (conformation
is
required
from
Contractor)
4.0
PNEUMATIC
TESTS
4.1 Pneumatic test may be applied for certain lines and test pressure shall be 110% of
design pressure as
specified in each piping Iso drawing and / or pressure test flow diagram as per ANSI /
ASME B.31-3
requirement
345.5.4.
4.2 The pressure shall be increased gradually until a gauge pressure which is the lesser of
the test
pressure or 25 psi (170kpa) is attained and held for 10 minutes, at which time a
preliminary leak check
shall be made with soap solution on all joint. The pressure shall be increased in steps of
25%, 50%
and 75% of the test pressure. At each step the pressure shall be held for sufficient time
to allow the
piping to equalize strains. After holding at test pressure for 10 minutes, the pressure
shall be reduced
to the design pressure for leakage examination. Leak testing of joints shall be done
with soapy water.
Safety precautions shall be taken by placing a safety relief valve on the system under
test.
4.3 The set pressure of the relief valve shall be set at a pressure not higher than the test
pressure plus the
lesser
of
50
psi
(340kpa)
or
10%
of
the
test
pressure
5.0
EQUIPMENT
FOR
HYDROSTATIC
TEST
5.1 Equipment for hydrostatic test shall be properly designed and in good working order
and shall be
compatible with the pressure and capacity required during the test.
5.2 The following equipment will be provided in order to conduct the hydrostatic test but
not necessarily be

2)

limited
to
the
following:1)
One
high
volume
pump
One portable tank to provide a source of pressurizing water
3)
One
hand
pump
for
pressurizing
4)
Pressure
gauges
and
temperature
gauges
5)
Pressure
recorder
6)
Safety
relief
valve
(only
for
pneumatic
test)
7)
Test
manifolds
(if
required)

6.0
PREPARATION
OF
TEST
PACKAGE
6.1 Prior to commencement the Field Hydrostatic Test the piping test package shall be
prepared and
submitted
to
the
Client
Inspector
for
review
/
approval.
6.2 The following documents will be included in the test package:1)
Piping
test
package
certificate
2)
Test
block
diagrams
3)
Signed
off
punch
list
4)
Signed
off
Q.C
check
sheet
5)
Q.C
Iso
drawing
6)
Pressure
Gauge
calibration
Records
(calibration
certificates)
6.3 When the documents in test package are proper and approved by the Contractor. Line
check shall be
made in accordance with approved procedure prior to the test.
6.4 All welds to be pressure tested shall be free of paint, thermal insulation coating and
wrapping.
7.0
LIMITATION,
EXCEPTIONS
AND
EXCLUSIONS
7.1 Where the test pressure of piping attached to a vessel is the same as or less then the test
pressure for the vessel, the piping may be tested with the vessel at the test pressure of the
piping.
7.2 Where the test pressure at the piping exceeds the vessel test pressure and it is not
considered
practicable to isolate the piping from vessels, the piping and the vessels may be tested
together at the
test pressure of the vessels, when approved by the owner, and provided the test
pressure is not less
77%
of
the
piping
test
pressure.
(ASME
B
31.3)(337.4.2)
7.3 The equipment or piping which is not subjected to the test shall be blinded off from the
piping to be
tested.
8.0
FIELD
PREPARATION
8.1 When the whole length of system to be tested is completely installed and boundaries
are checked by
Subcontractor
Q.C
8.2 Test manifold shall be provided in order to supply water to the system, install pressure
gauge,
temperature
gauge
and
safety
relief
valve.
8.3 Pressure gauge shall be provided at two points where one is to be located at highest
location in the

system
and
the
other
at
the
manifold.
8.4 All test blanks required for pressure test shall have sufficient thickness to ensure safety
during test or
permanent blinds may be used for the field pressure testing.
8.5 Prior to commencement of the hydrotest, all hot works shall be completed.
9.0
PERFORMANCE
OF
HYDROSTATIC
9.1 All vents and other connections which can serve as pressure test vents, shall be open
during filling so
that air can be vented prior to applying test pressure to the system.
9.2 The system shall be filled with fresh water by use of electrical or hand pressurizing
pump until the
intended
pressure,
slowly
and
gradually.
9.3 While the system is being pressured all weld joints will be visually inspected for any
leakage.
9.4 Once attained, the intended test pressure shall be held for a period of 30 minutes
minimum or such
time
as
required
for
full
visual
inspection
of
the
system.
9.5 Any joints found leaking during the pressure test shall be retested to the specified test
pressure after
repair
have
been
made.
9.6 After hydrostatic testing of the system is completed, all lines and equipment shall be
drained
completely. The system shall be vented while draining to avoid vacuum.
9.7 All pressure test must be witness and report to be endorsed by Client rep.
10

EVALUATION
OF
TEST
10.1 If there is no leakage during the test it will be considered as accepted and
to be
endorsed
by

RESULTS
test report
Client.

11

REPORT
/
DOCUMENTATION
11.1 After pressure test, the pressure test records and the post-test punch items shall be
signed off by
Subcontractor approved by Contractor and endorsed by PPMs rep. All this documents
shall be
compiled
into
the
Test
package.
12

REINSTATEMENT
12.1 After completion of hydrostatic test, all the system shall be reinstated as per the
approved drawings.

REPAIR PROCEDURE FOR TANK

*note: this is the sample document for the related job only
*author: theprocedure@engineer.com
TABLE OF CONTENTS
1. INTRODUCTION
2. PURPOSE
3. SPECIFICATION
4. APPLICABLE CODE / STANDADR
5. METHOD AND INSPECTION
6. SAFETY
7. REFERENCES & OTHER SUPPORTIVES DOCUMENT - LIST OF WPS & PQR LIST OF WQT ( WELDER LIST )
REPAIR PROCEDURE
1. INTRODUCTION
This repair procedure is required for grind off and / or perform weld repair on minor defect
such as Cluster Porosity, Slug, Under Cut, Arc Strike, Spartter and etc. which have been
found during visual inspection and / or found by NDE.
2. PURPOSE
The purpose of this work is as follow: To grind off all the defect, at the defect area base on
the report and / or marking area and carry out visual inspection and follow by NDE,
examination such as MPI / DPT To perform welding at the defect area after grinding ( surface
preparation ) and carry out NDE such as MPI, DPT or RT
3. SPECIFICATION
As per Owner / Client requiment or NDE report.
4. APPLICABLE CODE / STANDARD
The welding and NTD works are to be carried out and in accordance with the following:
i) ASME VIII DIV 1 - UW 42 Surface Weld Metal Build Up - Appendix 6 Method For
Magnetic particle Testing - Appendix 8 Method For Liquid penetrating Testing
ii) ASME IX - Welding And Brazing Qualification iii) ASME V - Nondestructive
Examination
5. METHOD & INSPECTION
5.1) Mark the defect area to grind off accordingly by appointed inspector and base on NDE
(RT, MPI or DPT) report.
5.2) Grind off the defect until meet the sound metal and perform NDE to confirm the has
been removed from the respective shell area for welding surface preparation.
5.3) Perform surface preparation before performing weld build up.
5.4) Ensure that area is free from Oil, Grease, Water or any other foreign material
5.5) Proceed weld build up by qualified welder, WPS No as per requiment refer to Welding
Qualification. 5.6) Perform NDT upon completion of weld build up on the defect / marking
area.
5.7) If the result of NDE is unacceptable remove the defect by grinding and repeat NDE to
ensure it is completely removed.
5.8) If the result of NDE is acceptable, carry out the Visual Inspection and request for RT to
confirm the weldment are free from and indication / defect.

6. SAFETY
6.1) All condition stated on job safety analysis (JSA) must complied with permit to work
(PTW).
6.2) All personal working at job site shall be informed to the safety awareness by attending
the safety induction or safety tools box meeting conducted by safety prior to commencing of
work.
6.3) Full PPE is ensured whilst working at site.
6.4) Refer to safety requirement.
7. REFERENCES & OTHER SUPPORTIVE DOCUMENT
7.1) WPS & PQR To be Advice
7.2) WQT List or Welder list To be Advice

CALIBRATION OF TEST INSPECTION TOOL CONTROL PROCEDURE

*note: this is the sample document for the related job only
*author: theprocedure@engineer.com
TABLE OF CONTENTS
1.SCOPE
2.REFERENCES
3.RESPONSIBILITIES
4.PROCEDURE
4.1 CALIBRATION
4.2 REGISTRATION
4.3 DOCUMENTATION

1.0 SCOPE
To provide procedure guidelines for controlling calibration test and inspection tools to be
used for inspection at the construction of The EPCC of Two (2) nos. of Storage Tanks.

2.0 REFERENCES
Field Inspection Procedure QA/QC Requirements for Subcontractors Control of Measuring
and Test Equipment Specification for Pressure Testing of Piping.

3.0 RESPONSIBILITIES
3.1 Site Manager Shall be responsible for the full implementation and administration of
this procedure
3.2 QC Manager Shall be responsible for ensuring that all personnel involve are
indoctrinated about this procedure.
3.3 QA Engineer Shall Check and monitor the calibration and registration of testing tools
and equipment necessary for the conduct of inspections in accordance with this procedure.
Shall record and file all documents pertaining to the calibration certificate and registration of
Testing / Inspection Tools.
4.0 PROCEDURE
4.1 Calibration
1) Equipment that needs to be calibrated shall be sent to a calibration Agent equipped
with laboratory facilities for conduction calibration of inspection and test equipment except
for equipment that can be calibrated on site.
2) All equipment tests shall be designated with a controlled serial number which shall
be engraved on the equipment. A calibration label shall be attached to the equipment which
shall contain the serial no, registration no. frequency of calibration and date of calibration
3) Calibration frequency of each equipment shall be subject to change according to the
manufacturers instruction, frequency of use and adjustments mode during calibration.
4) The control of deficient measuring and test equipment shall be controlled in

accordance with Client requirement.

4.2 Registration
All equipment for measuring and testing to be used shall be submitted to the Contractor
for registration. The Equipment Calibration Registration Record shall be filled up and
registry of the necessary information made before submission together with the calibration
certificate.
4.3 Documentation
Registration of equipment in accordance with the Contractors procedure shall be
documented using the Equipment Calibration and Registration Record. The record shall be
filed together with calibration certificates and manufacturers instructions in a manner for
easy filling and retrieval.

MATERIAL IDENTIFICATION AND MARKING PROCEDURE

1.1 SCOPE
This specification describes the requirement of material identification and marking
procedure.
2.0 MATERIAL IDENTIFICATION AND MARKING
2.1 The material identification shall be carried out in order to :i) Confirm that the material to be used shall comply with the Mill Certificate.
ii) Identify the individual primary component (i.e. shell plate, roof plate and bottom
plate) so that it can be traced back to the Mill Certificate later after shop fabrication.
This shall be documented in the Inspection Record.
2.2 The following identification mark shall be used :i) Mill marking which consists of heat number, size, plate number, etc. This
marking shall be stenciled or stamped on the material by the Mill.
ii) Code marking which consists of tank number, drawing number, part number
and serial piece number. The code marking shall correspond to the Mill Certificate as
documented in the Inspection Record.

Procedure List

2009 (9)
o December (9)
INSTALL SHOWER
TANK ERECTION PROCEDURE
FIELD INSPECTION AND TEST PROCEDURE
SHOP FABRICATION PROCEDURE
WELDING MATERIAL CONTROL PROCEDURE
PRESSURE TEST PROCEDURE FOR PIPING SYSTEM
REPAIR PROCEDURE FOR TANK
CALIBRATION OF TEST INSPECTION TOOL CONTROL
PROCED...
MATERIAL IDENTIFICATION AND MARKING PROCEDURE

2010 (2)