227340945 Hydrostatic Test Procedure for Storage Tank New No Air Test (1)

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KINGDOM OF SAUDI ARABIA SALINE WATER CONVERSION CORPORATION (SWCC)

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Project NO. 20311

YANBU YANBU – MADINAH PHASE PHASE 3 WATER WATER TRANSMISSION SYSTEM SYSTEM

(B1+B2+C) PACKAGE (C+B1+B2)

CONSTRUCTION OF STATIONS AND LAYING OF PIPELINES

ILF Consulting Engineers

ENGINEER

SINOPEC INTERNATIONAL PETROLEUM SERVICE CORPORATION CONTRACTOR LOCATION:

TITLE:

HYDROSTATIC TEST PROCEDURE FOR STORAGE TANK SCALE:

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Saline Water Conversion Corporation YANBU-MADINAH PHASE 3 WATER TRANSMISSION SYSTEM HYDROSTATIC TEST PROCEDURE FOR STORAGE TANK

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QC10-H-049 M09

ILF CONSULTING ENGINEERS

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Document Number 325-QD60-F-

TABLE OFCONTENTS 1

SCOPE ............................................................................................................................................. 3

2

PURPOSE ........................................................................................................................................ 3

3

REFERENCES ................................................................................................................................. 3

4

DEFINITIONS................................................................................................................................... 3

5

ABBREVIATIONS............................................................................................................................ 4

6

RESPONSIBILITIES ........................................................................................................................ 4

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GENERAL ........................................................................................................................................ 5

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VACUUM TEST ................................................................................................................................ 6

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HYDROSTATIC PRESSURE TEST ................................................................................................ 8

10

AIR TEST ....................................................................................................................................... 12

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SAFETY PRECAUTIONS .............................................................................................................. 15

Engineering Subcontractor

EPC Contractor SINOPEC INTERNATIONAL PETROLEUM SERVICE CORPORATION

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SCOPE This Procedure specifies the requirements of Hydrostatic Test, Vacuum Test and Air Test for Aboveground Water Storage Tank in the PROJECT OF YANBU-MADINAH PHASE 3 WATER TRANSMISSION SYSTEM for SALINE WATER CONVERSION CORPORATION (SWCC).

2

PURPOSE This Procedure describes the equipment and materials to be used and factors to be considered during the Pressure Test of Storage Tank, and ensure that this procedure shall be done in accordance with the Project Specifications and related Standards and Codes.

3

4

REFERENCES API Standard 650

Welded Steel Tanks for Oil Storage

QC10-H-049 M09

Steel Tanks - Rev4

ASME Section VIII, Division 1

Boiler and Pressure Vessel Code

EN 10204

Metallic Products – Types of Inspection Documents

DEFINITIONS Employer

Saline Water Conversion Corporation (SWCC)

Engineer

ILF Consulting Engineers

Contractor

Sinopec International Petroleum Service Corporation (SIPSC)

Project

YANBU-MADINA PHASE 3 WATER TRANSMISSION SYSTEM



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ABBREVIATIONS API

American Petroleum Institute

ASME

American Society of Mechanical Engineers

ANSI

American National Standard Institute

ASTM

American Society for Testing and Materials

EN

European Standards

IFC

Issue For Construction

QC Manager

Quality Control Manager

QC Engineer

Quality Control Engineer

RESPONSIBILITIES 6.1

6.2

QA/QC Engineer / Inspector 

Shall be responsible to witness the test and judge the suitability of work carried out.

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Responsible to make calculations, prepare documents and layout systems of work.

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Assessing the suitability of the method, medium and test pressure requested given the design of the item submitted for testing.

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Produce written instructions for the supervisor and technicians relating to the procedures, equipment and personnel to be employed in the test.

Construction Supervisor 

Shall be responsible for organizing the test as per this procedure and approved ITP and shall also be responsible for maintaining the records duly signed by all concerns.

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Responsible to ensure that the technicians working under his supervision



Shall communicate with his management, client and other contractors.

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Shall ensure method statements, risk assessments and permit to work requirements are communicated to the technicians and other personnel.



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Tank Technician 

Responsible to carryout pressure testing and other activities in support of pressure testing.

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Ensure that all marking around the thank is done as per the drawing

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Ensures the pressure gauges used have current calibrated stickers.



Complete pressure test record and submit copy to program manager.

GENERAL 7.1 After the completion of all welding works and non-destructive examinations of bottom plate welds, shell plate welds, roof plate welds and reinforced plate welds of the tank 7.2

The tank shall be pressure tested for the identifications of leakage. This pressure shall be carried out as per the approved drawing, approved ITP and standard API 650.

7.3

This test will divide into following mentioned stages: 

Test preliminaries such as Visual Inspection.



Inspection of Tank Bottom Welds (Vacuum Box Testing).

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Testing of the Shell Course and Tank Bottom Settlement (HydrostaticTesting).

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Inspection of Roof-Plate and Reinforcing Plates (Air Testing).

7.4

Ensure that all of the mentioned test must perform after controlling all of the N.D.T. test reports.

7.5

Vacuum test is carried out to find any leakage in the bottom plate by the use the vacuum box testing equipment.

7.6

Hydrostatic test is conducted to find any leakage in the shell plate weld and to check the elevation of the tank bottom settlement. Potable water shall be used to fill the tank.

7.7 Air test is conducted to check the gas tight of roof and reinforced plates of shell openings of the tank. Engineering Subcontractor


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VACUUM TEST The Vacuum box test is conducted to check soundness of annular welded joints and all lap joints of bottom plates (long seam and short seam). 8.1

8.2

8.3

Equipment and Material 

The vacuum box test is performed by using a box with visible window of fiber glass (i.e. 6’’ Wide by 30’’ long metallic box with a fiber glass). The open bottom is sealed against the tank surface by a sponge rubber gasket.



The test scheme shall have suitable connections, such as necessary valves and calibrated vacuum gauge.



The gauge shall have a range of 21Kpa (6 in. Hg) to 35Kpa (10 in. Hg) for normal leaks and 56Kpa (16 in. Hg) to 70Kpa (20 in. Hg) shall be performed for the detection of very small leaks.



The test scheme shall be demonstrated with sample test block by application bubble solution at site before conduction of the test on the job.

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The bubble forming solution shall produce a film that does not break away from the area to be tested, and the bubbles formed shall not break rapidly due to air drying or low surface tension.



A vacuum can be drawn on the box by any convenient method, such as connection to a diesel motor intake manifold or special vacuum pump.

Surface Preparation 

The surface to be examined and all adjacent areas shall be cleaned thoroughly and free from all dirt, grease, lint, scale, welding flux, weld spatters, paint, oil and other extraneous matter that could obstruct surface openings.



Prior to vacuum testing all joints shall be checked visually.

Procedure of Vacuum Test 


The temperature of the surface of the part to be examined shall not below 40C (400F) and nor above 52 0C (1250F).


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8.5

8.6

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The weld seam on the test shall be applied with a bubble solution for detecting leaks prior to placing vacuum box.

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The foaming shall be minimized by means of uniform application of bubble solution.

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A vacuum can be drawn on the box by any convenient method, such as connection to a gasoline- or diesel motor intake manifold.

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The gauge shall register a partial vacuum of at least 21Kpa for inspection of the joints.



The required partial vacuum shall be maintained for greater or either at least 5 seconds examination time, stop watch to be used after reaching the 21Kpa /designation vacuum.

Evaluation of Defects 

Bubbles produced by air sucked through the welded seam can detect the presence of defect.



The tested areas are accepted only when no continuous bubbles formation is observed.



A minimum light intensity of 100Lux is required for conducting the examination.



Upon satisfactory inspection, a report shall be prepared for the further activities.

Repair and Retest 

Defects in welds shall be repaired by chipping, grinding or melting out the defects from one side or both sides of the joints as required and re-welding are done.



Only the cutting out of defective joints that is necessary to correct the defect is required.

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After repairing, retest of vacuum box test of welded joint shall be carried out.

Cleaning After test the area shall be thoroughly cleaned for the further activities



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HYDROSTATIC TEST Hydrostatic test is conducted to carry out the leakage in the shell plates and also to carry out elevation measurement of the bottom foundation of tank by using tank foundation settlement method. 9.1

9.2

General Consideration 

The water for hydro test will be provided by SWCC, the initial filling of the first and second will come from this pipe system source.



After the first tank is tested, the water will be transferred to the second tank. After the second tank is tested, the water will be transferred to the third and fourth tank for Testing.



Contractor will furnish the pipe and pumps required to move the water from tank to tank.



After the completion of the hydro testing operations for the first and fourth tank, contractor will dispose of the water on site at the designated point.

Preparation of Hydrostatic Test 

After the completion of all welding works and non-destructive examination of tank and all welded joints shall be signed off by QC welding inspector prior to commencement of the hydrostatic test.

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Temporary test gaskets shall be used for all fittings and manholes.

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The hydrostatic test of tank shall be conducted before permanent external piping is connected to the tank.

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Cleaning inside the tank and removal of temporary jigs and tools shall be completed.

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All shell openings shall be closed by block valves or by appropriate cover plates.



Roof manholes shall be opened while introducing water into the tank or drawing off water.

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Initial tank level readings shall be taken using 16 equally spaced points marked on the bottom plate projecting out from the bottom shell around the tank at its base.



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The above points will be referenced back to a permanent benchmark.

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Install temporary plastic tube to be used as a water level indicator during hydrostatic test.

Procedure of Hydrostatic Test 

Proper arrangement shall be carried out for the water filling. Pipe connection from the water resource point and providing valves wherever required.



Potable water shall be used for hydrostatic testing.



To protect urgent uneven settlement, water filling rate shall be controlled. Therefore the maximum filling and discharge rate shall be as per standard API 650 as given in the below table 1. Table 1. Water Filling Rate

Water Filling Rate Bottom Course Thickness Less than 22mm   22mm 

and Above

Tank Portion

Maximum Filling Rate

Top Course

300mm/hr

Below Top Course

460mm/hr

Top Third of Tank

230mm/hr

Middle Third Tank

300mm/hr

Bottom Third Tank

460mm/hr

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Filling shall be done in four stages 25%, 50%, 75% and 100%. After each stage a load stabilization period shall be observed.

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As water rises in the tank, observe the shell fittings for any signs of leakage around the blind flanges.

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Continue filling the tank until the water level reaches the quarter point of the tank height. At this point discontinue filling while the level readings are taken on the 16 points as described in above ( 9.1- Item no.7) and readings are recorded.



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If the differential readings do not exceed 1½ mm per meter of circumference, the filling of water shall continue.

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As water is being pumped into the tank. Observe the circumference of the tank for any signs of leak or distortion in each shell course. If any signs appear immediately discontinue filling and determine the cause. Repair shall be made with the water level at least 300mm below the point being repaired.



Take additional readings when the tank is half full, three quarter full and full height. The same criteria for differential settlement as stated in above (9.1- Item no.7) shall apply to each of the level readings.

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Filling of water into the tank shall be continue until the level reaches the maximum desired height as shown on approved IFC drawing.

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The test water will remain in the tank at the maximum desired height for a period of 48 hours. Final level readings shall be taken prior to removing any water from the tank.

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Water filling schedule and holding period shall be in accordance with API 650 as given in below table 2: Water Level in Tank

Holding Period

1st Filling 1/2 Full

1 day

2nd Filling 3/4 Full

1 day

3rd Filling Full Tank

2 days

Table.2 Water Level and Holding Period

9.4

Tank Foundation Settlement 

For the adequacy of tank foundation performance, a staged hydrostatic procedure and an extensive settlement monitoring program is performed as per project specification and API 650.



Therefore the following tolerable settlement criteria are adopted as a basis for evaluating tank performance during hydrostatic testing



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Filling of water shall continue while elevation measurements are being made as long as the change in water elevation for a set of reading does not exceed 300 mm.

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Shell elevation measurements shall be made at equally-spaced intervals around the tank circumference not exceeding 10 m (32 ft).

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Install settlement monitoring markers at eight equally spaced locations along the perimeter of the t anks.

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Observed elevations shall be referred to a permanent benchmark. The level instrument shall be set up at least 1½ times tank diameter away from the tank when tank elevation readings are taken.

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There are six sets of settlement readings are required as follows: 

Before start of the hydrostatic test.

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With tank filled to 1/4 test height (±600 mm).

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At least 24 hours after the tank has been filled to the maximum test height. This period may be increased in accordance to the requirement of the project specification. After tank has been emptied of test water.

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If settlement measurements are specified by the Purchaser, any differential settlement greater than 13 mm per 10 m. of circumference or a uniform settlement over 50 mm shall be reported to contractor.

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Filling of the tank shall be stopped until cleared by the contractor.

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Internal bottom elevation measurements shall be made before and after hydrostatic testing. Measurements shall be made at maximum intervals of 3m (10ft) measured on diametrical lines across the tank.

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The diametrical lines shall be spaced at equal angles, with a maximum separation measured at the tank circumference of 10m (32ft). A minimum of four diametrical lines shall be used.



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Removal of Test Water 

After the completion of Hydrostatic test, the tank shall be emptied at a maximum water level variation rate as per specification.



Make sure that roof manholes and vents are open during empty operation of conical roof tank.



When the first tank has been tested, make connections to the second tank through a gate valve and extend the piping to the designated point. When the second tank has been tested, connect the tested tank to the next tank and water to be filled through the system of temporary valves and piping.

10



Prior to starting the pumping operation between two tanks, make sure that roof manholes and vents are open on both tanks.



Transfer to the next tank using gravity and a temporary pump as required to empty the tested tank.



After all water has been removed from the tested tank, open all manholes and remove all temporary blinds and equipment.



After final draining and drying, brushing, broom or vacuum cleaner shall clean surface of the tanks bottoms.



QC Inspectors sign the test data sheet at the completion of hydro test.

AIR TEST Air test is carried out to check the gas tight of the roof plate and reinforced plate of shell openings of the tank. 10.1 Equipment and Material 

Pressure Gauge or Manometer



Blank/Blind Flange with Safety Relief Valve



Soapsuds

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Air Supply System



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ILF CONSULTING ENGINEERS Document Number 325-QD60-F-

10.2 Procedure of Air Test After final welding and clearing the tank, an air test shall be conducted to ensure water tightness and the integrity of welding according to the procedure as follows: 

The tank workers shall prepare the test equipment and materials such as; pressure gauge or manometer, testing piece, supply air and soapsuds etc.,



Before starting the air pressure test, water shall be filled to 50mm below the curb angle.

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Cleaning and visual inspection of entire welding of roof plates and all roof accessories shall be carried out prior to test.

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A manometer of suitable range shall be connected to the roof nozzle with ¼’’ diameter PVC tube for measurement of pressure

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Inlet connection shall be done with ½’’ hose from the compressor outlet to one of the roof nozzle.

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To regulate the pressure, valves shall be provided on both ends.

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Once all nozzles and manhole are closed, pressure shall be applied slowly inside the roof by controlling the isolation valves.

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Once the required

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Set the testing piece to the desired filling point of air either on manhole or air vents.

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Fill and press up the tank with compressed air until it reaches 2.2 Psi on the pressure gauge or an equivalent water level in the manometer and hold at this pressure for at least for 1 hour.

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Observe the pressure gauge or water level in the manometer if it remains in the desired test pressure.

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If this pressure remains the same then apply soapsuds to welding seams or joint and the areas to be check for leaks.

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If the pressure decreases, re-check the possible air passage and blank-off or retighten.

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If there are leaks then identify and mark the exact location of defects.



Release the air pressure, rectify the leak and retest again until successful passed the test in the presence of Client QC Engineer.



The inspection and acceptance report shall be fully accomplished and

signed by the Clients representative, Tank Supervisor and QC Engineer. 


Release the air pressure once the test is completed then put back all components/parts that have been removed.


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SAFETY PRECAUTIONS 11.1

The safety measures shall be implemented during testing activities and the contractor shall provide the necessary safety equipment, communication equipment, access barriers etc.

11.2

Contractor shall issue a statement to all persons connected with testing, warning of the hazards of failure under pressure. There is a possibility that workers can take remedial action once minor leakages are noticed before total failure occurs.

11.3

Hydrostatic tests are conducted under the constraints of projects specifications.

11.4

Air/gas used for Air test is compressible to large extent and has very high potential energy stored when compressed.

11.5

Ensure that no any worker shall present inside the tank prior to pressure test.

11.6

Use and storage of any compressed gas under high pressure can be extremely dangerous if proper gas handling procedures are not observed.

11.7

Where the test system is testing using pressurization above its normal working level, it follows that the tester should be prepared for the consequences of failure.

11.8

This means that there may need to be protective barriers or screens, but all such precautions will be specifically dedicated to the risk involved in the test.

11.9

The technician must be conscious at all times of the potential for a rise in temperature to significantly increase pressure.

11.10

Safety officer must be present at site during test.

11.11

Tested & certified Lifting equipment shall be used for lifting and shifting purpose.

11.12

Safety Precautions shall be followed during fabrication and erection as per project specification.

11.13

Welding cables and power cables to be laid properly as per Instrumentation and Electrical rules and local state govt. rules and regulation.



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11.14

Proper housekeeping and clean condition shall be maintained in the fabrication shop and site as per requirement.

11.15

Wear proper PPE i.e. fall protection harness, goggles etc.

11.16

Clean and clear the area and return the used equipment and materials to the tool room or shop

11.17

Conduct hazard assessment and safety meeting.

11.18

Barricading of Tank, First- Aid kit and emergency phone number shall be available.

11.19

The contractor shall provide patrols to all around the tank to watch any special points of hazards during pressure test of tank.

11.20

Safety sign boards both in English and Arabic language shall be posted at appropriate locations during tank testing the display shall be “TANK UNDER PRESSURE TEST KEEP AWAY”.



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227340945 Hydrostatic Test Procedure for Storage Tank New No Air Test (1)

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