227340945-Hydrostatic-Test-Procedure-for-Storage-Tank-New-No-Air-Test.docx

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CONTRACTOR OCATION:

TITE:

*ZROSTATIC TEST PROCEURE !OR STORAGE TANK SCAE:

OCUMENT N5:

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SUHCONTRACTOR: Sn779 D5oDp KINGOM O! SAUI ARAHIA Saline Water Conversion Corporation

Page:

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*ZROSTATIC TEST PROCEURE !OR STORAGE TANK

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

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

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RE!ERENCES......................................................................... ............ ........ 3

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E!INITIONS............................................................................................... 3

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AHHREVIATIONS.......................................................................................... 4

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RESPONSIHIITIES.......................................................................................4

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GENERA................................................................................................... 5

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

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*ZROSTATIC PRESSURE TEST......................................................................8

DB AIR TEST.................................................................................................. 12 DD SA!ETZ PRECAUTIONS...............................................................................13

+ngineering Subcontractor

+PC Contractor

Subcontractor

SINOPEC INTERNATIONA PETROEUM SERVICE CORPORATION

KINGOM O! SAUI ARAHIA Saline Water Conversion Corporation

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2 of 16

ZANHUqMAINA* P*ASE  ATER TRANSMISSION SZSTEM *ZROSTATIC TEST PROCEURE Subject: !OR STORAGE TANK . e n I n o i s i v e ,

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SCOPE )5is Proce-ure specifies t5e reuireents of !7-rostatic )est8 9acuu )est an- Air )est for Abovegroun- Water Storage )an in t5e P,';+C) '& .



PURPOSE )5is Proce-ure -escribes t5e euipent an- aterials to be use- an- factors to be consi-ere- -uring t5e Pressure )est of Storage )an8 an- ensure t5at t5is proce-ure s5all be -one in accor-ance ?it5 t5e Project Specifications an- relate- Stan-ar-s anCo-es.



RE!ERENCES API Stan-ar- 630

Wel-e- Steel )ans for 'il Storage

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Steel )ans  ,ev"

AS$+ Section 9III8 /ivision 14oiler an- Pressure 9essel Co-e +N 1020"

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$etallic Pro-ucts @ )7pes of Inspection /ocuents

E!INITIONS +plo7er +ngineer Contractor Project

Saline Water Conversion Corporation =SWCC> I%& Consulting +ngineers Sinopec International Petroleu Service Corporation =SIPSC>

+PC Contractor

Subcontractor


KINGOM O! SAUI ARAHIA

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Saline Water Conversion Corporation

ZANHUqMAINA* P*ASE  ATER TRANSMISSION SZSTEM *ZROSTATIC TEST PROCEURE !OR STORAGE TANK


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AHHREVIATIONS API

Aerican Petroleu Institute

AS$+

Aerican Societ7 of $ec5anical +ngineers

ANSI

Aerican National Stan-ar- Institute

AS)$

Aerican Societ7 for )esting an- $aterials

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+uropean Stan-ar-s

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Spec. No.

Issue &or Construction

QC $anager

Qualit7 Control $anager

QC +ngineer

Qualit7 Control +ngineer

RESPONSIHIITIES QAQC +ngineer  Inspector 

S5all be responsible to ?itness t5e test an- ju-ge t5e suitabilit7 of ?or carrieout.



,esponsible to ae calculations8 prepare -ocuents an- la7out s7stes of ?or.



Assessing t5e suitabilit7 of t5e et5o-8 e-iu an- test pressure reuestegiven t5e -esign of t5e ite subitte- for testing.



Pro-uce ?ritten instructions for t5e supervisor an- tec5nicians relating to t5e proce-ures8 euipent an- personnel to be eplo7e- in t5e test.

6.2

Construction Supervisor 

S5all be responsible for organiBing t5e test as per t5is proce-ure an- approveI)P an- s5all also be responsible for aintaining t5e recor-s -ul7 signe- b7 all concerns.



,esponsible to ensure t5at t5e tec5nicians ?oring un-er 5is supervision



S5all counicate ?it5 5is anageent8 client an- ot5er contractors.



S5all ensure et5o- stateents8 ris assessents an- perit to ?or reuireents are counicate- to t5e tec5nicians an- ot5er personnel.


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6.

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)an )ec5nician 

,esponsible to carr7out pressure testing an- ot5er activities in support of pressure testing.

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+nsure t5at all aring aroun- t5e t5an is -one as per t5e -ra?ing



+nsures t5e pressure gauges use- 5ave current calibrate- sticers.



Coplete pressure test recor- an- subit cop7 to progra anager.

GENERA

.1

After t5e copletion of all ?el-ing ?ors an- non-estructive eainations of botto plate ?el-s8 s5ell plate ?el-s8 roof plate ?el-s an- reinforce- plate ?el-s of t5e tan

.2

)5e tan s5all be pressure teste- for t5e i-entifications of leaage. )5is pressure s5all be carrieout as per t5e approve- -ra?ing8 approve- I)P an- stan-ar- API 630.

.

)5is test ?ill -ivi-e into follo?ing entione- stages: 

)est preliinaries suc5 as 9isual Inspection.



Inspection of )an 4otto Wel-s =9acuu 4o )esting>.



)esting of t5e S5ell Course an- )an 4otto Settleent =!7-rostatic )esting>.



Inspection of ,oofPlate an- ,einforcing Plates =Air )esting>.

."

+nsure t5at all of t5e entione- test ust perfor after controlling all of t5e N./.). test reports.

.3

9acuu test is carrieout to fin- an7 leaage in t5e botto plate b7 t5e use t5e vacuu bo testing euipent.

.6

!7-rostatic test is con-ucte- to fin- an7 leaage in t5e s5ell plate ?el- an- to c5ec t5e elevation of t5e tan botto settleent. Potable ?ater s5all be use- to fill t5e tan.

tt Air test is con-ucte- to c5ec t5e gas tig5t of roof an- reinforce- plates of s5ell openings of t5e tan.


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SINOPEC INTERNATIONA PETROEUM SERVICE CORPORATION KINGOM O! SAUI ARAHIA Page:

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QC10!0"# $0#

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/ocuent Nuber

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VACUUM TEST )5e 9acuu bo test is con-ucte- to c5ec soun-ness of annular ?el-e- joints an- all lap joints of botto plates =long sea an- s5ort sea>.

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)5e vacuu bo test is perfore- b7 using a bo ?it5 visible ?in-o? of fiber glass =i.e. 6DD Wi-e b7 0DD long etallic bo ?it5 a fiber glass>. )5e open botto is seale- against t5e tan surface b7 a sponge rubber gaset.



)5e test sc5ee s5all 5ave suitable connections8 suc5 as necessar7 valves ancalibrate- vacuu gauge. )5e gauge s5all 5ave a range of 21Epa =6 in. !g> to 3Epa =10 in. !g> for noral leas an- 36Epa =16 in. !g> to 0Epa =20 in. !g> s5all be perfore- for t5e -etection of ver7 sall leas. )5e test sc5ee s5all be -eonstrate- ?it5 saple test bloc b7 application bubble solution at site before con-uction of t5e test on t5e job. )5e bubble foring solution s5all pro-uce a fil t5at -oes not brea a?a7 fro t5e area to be teste-8 an- t5e bubbles fore- s5all not brea rapi-l7 -ue to air -r7ing or lo? surface tension. A vacuu can be -ra?n on t5e bo b7 an7 convenient et5o-8 suc5 as connection to a -iesel otor intae anifol- or special vacuu pup.

F.2

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)5e surface to be eaine- an- all a-jacent areas s5all be cleane- t5oroug5l7 an- free fro all -irt8 grease8 lint8 scale8 ?el-ing flu8 ?el- spatters8 paint8 oil anot5er etraneous atter t5at coul- obstruct surface openings.



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Prior to vacuu testing all joints s5all be c5ece- visuall7.

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)5e teperature of t5e surface of t5e part to be eaine- s5all not belo? " 0C ="00&> an- nor above 320C =1230&>.


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SINOPEC INTERNATIONA PETROEUM SERVICE CORPORATION KINGOM O! SAUI ARAHIA Page: Saline Water Conversion Corporation

Subcontractor



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/ocuent Nuber

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)5e ?el- sea on t5e test s5all be applie- ?it5 a bubble solution for -etecting leas prior to placing vacuu bo.



)5e foaing s5all be iniiBe- b7 eans of unifor application of bubble solution.



A vacuu can be -ra?n on t5e bo b7 an7 convenient et5o-8 suc5 as connection to a gasoline or -iesel otor intae anifol-. )5e gauge s5all register a partial vacuu of at least 21Epa for inspection of t5e joints. )5e reuire- partial vacuu s5all be aintaine- for greater or eit5er at least 3 secon-s eaination tie8 stop ?atc5 to be use- after reac5ing t5e 21Epa -esignation vacuu.

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4ubbles pro-uce- b7 air suce- t5roug5 t5e ?el-e- sea can -etect t5e presence of -efect.



)5e teste- areas are accepte- onl7 ?5en no continuous bubbles foration is observe-.

 

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A iniu lig5t intensit7 of 100%u is reuire- for con-ucting t5e eaination. (pon satisfactor7 inspection8 a report s5all be prepare- for t5e furt5er activities.

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/efects in ?el-s s5all be repaire- b7 c5ipping8 grin-ing or elting out t5e -efects fro one si-e or bot5 si-es of t5e joints as reuire- an- re?el-ing are -one.



'nl7 t5e cutting out of -efective joints t5at is necessar7 to correct t5e -efect is reuire-.



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After repairing8 retest of vacuu bo test of ?el-e- joint s5all be carrieout.

Cj7zgkgl After test t5e area s5all be t5oroug5l7 cleane- for t5e furt5er activities


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ZANHUqMAINA* P*ASE  ATER TRANSMISSION SZSTEM

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Spec. No.

QC10!0"# $0#


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/ocuent Nuber

23Q/60&

*ZROSTATIC TEST !7-rostatic test is con-ucte- to carr7 out t5e leaage in t5e s5ell plates an- also to carr7 out elevation easureent of t5e botto foun-ation of tan b7 using tan foun-ation settleent et5o-.

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)5e ?ater for 57-ro test ?ill be provi-e- b7 SWCC8 t5e initial filling of t5e first ansecon- ?ill coe fro t5is pipe s7ste source.



After t5e first tan is teste-8 t5e ?ater ?ill be transferre- to t5e secon- tan. After t5e secon- tan is teste-8 t5e ?ater ?ill be transferre- to t5e t5ir- an- fourt5 tan for )esting.



Contractor ?ill furnis5 t5e pipe an- pups reuire- to ove t5e ?ater fro tan to tan.



After t5e copletion of t5e 57-ro testing operations for t5e first an- fourt5 tan8 contractor ?ill -ispose of t5e ?ater on site at t5e -esignate- point.

v

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After t5e copletion of all ?el-ing ?ors an- non-estructive eaination of tan an- all ?el-e- joints s5all be signe- off b7 QC ?el-ing inspector prior to coenceent of t5e 57-rostatic test.



)eporar7 test gasets s5all be use- for all fittings an- an5oles.



)5e 57-rostatic test of tan s5all be con-ucte- before peranent eternal piping is connecte- to t5e tan.



Cleaning insi-e t5e tan anreoval of teporar7 jigs an- tools s5all be coplete-.

 

All s5ell openings s5all be close- b7 bloc valves or b7 appropriate cover plates. ,oof an5oles s5all be opene- ?5ile intro-ucing ?ater into t5e tan or -ra?ing off ?ater.



Initial tan level rea-ings s5all be taen using 16 euall7 space- points areon t5e botto plate projecting out fro t5e botto s5ell aroun- t5e tan at its base.


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ZANHUqMAINA* P*ASE  ATER TRANSMISSION SZSTEM

Page:



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Spec. No.

A

QC10!0"# $0#

I%& C'NS(%)IN* +N*IN++,S /ocuent Nuber

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)5e above points ?ill be reference- bac to a peranent benc5ar.



Install teporar7 plastic tube to be use- as a ?ater level in-icator -uring 57-rostatic test.

v

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Proper arrangeent s5all be carrieout for t5e ?ater filling. Pipe connection fro t5e ?ater resource point an- provi-ing valves ?5erever reuire-.



Potable ?ater s5all be use- for 57-rostatic testing.



)o protect urgent uneven settleent8 ?ater filling rate s5all be controlle-. )5erefore t5e aiu filling an- -isc5arge rate s5all be as per stan-ar- API 630 as given in t5e belo? table 1. Tz~j7 D z974 !kjjkgl Rz97

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&illing s5all be -one in four stages 23G8 30G8 3G an- 100G. After eac5 stage a loa- stabiliBation perio- s5all be observe-.



As ?ater rises in t5e tan8 observe t5e s5ell fittings for an7 signs of leaage aroun- t5e blin- flanges.



Continue filling t5e tan until t5e ?ater level reac5es t5e uarter point of t5e tan 5eig5t. At t5is point -iscontinue filling ?5ile t5e level rea-ings are taen on t5e 16 points as -escribe- in above =vDq Ite no.> an- rea-ings are recor-e-.


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/ocuent Nuber

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If t5e -ifferential rea-ings -o not ecee- 1H  per eter of circuference8 t5e filling of ?ater s5all continue.



As ?ater is being pupe- into t5e tan. 'bserve t5e circuference of t5e tan for an7 signs of lea or -istortion in eac5 s5ell course. If an7 signs appear ie-iatel7 -iscontinue filling an- -eterine t5e cause. ,epair s5all be a-e ?it5 t5e ?ater level at least 00 belo? t5e point being repaire-.



)ae a--itional rea-ings ?5en t5e tan is 5alf full8 t5ree uarter full an- full 5eig5t. )5e sae criteria for -ifferential settleent as state- in above = vDq Ite no.> s5all appl7 to eac5 of t5e level rea-ings.



&illing of ?ater into t5e tan s5all be continue until t5e level reac5es t5e aiu -esire- 5eig5t as s5o?n on approve- I&C -ra?ing.



)5e test ?ater ?ill reain in t5e tan at t5e aiu -esire- 5eig5t for a perioof "F 5ours. &inal level rea-ings s5all be taen prior to reoving an7 ?ater fro t5e tan.



Water filling sc5e-ule an- 5ol-ing perio- s5all be in accor-ance ?it5 API 630 as given in belo? table 2:

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2 -a7s

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&or t5e a-euac7 of tan foun-ation perforance8 a stage- 57-rostatic proce-ure an- an etensive settleent onitoring progra is perfore- as per project specification an- API 630.



)5erefore t5e follo?ing tolerable settleent criteria are a-opte- as a basis for evaluating tan perforance -uring 57-rostatic testing


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Spec. No.

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/ocuent Nuber

23Q/60&

&illing of ?ater s5all continue ?5ile elevation easureents are being a-e as long as t5e c5ange in ?ater elevation for a set of rea-ing -oes not ecee- 00 .



S5ell elevation easureents s5all be a-e at euall7space- intervals arount5e tan circuference not ecee-ing 10  =2 ft>.



Install settleent onitoring arers at eig5t euall7 space- locations along t5e perieter of t5e tans.



'bserve- elevations s5all be referre- to a peranent benc5ar. )5e level instruent s5all be set up at least 1H ties tan -iaeter a?a7 fro t5e tan ?5en tan elevation rea-ings are taen.



•

)5ere are si sets of settleent rea-ings are reuire- as follo?s: •

4efore start of t5e 57-rostatic test.

•

Wit5 tan fille- to 1" test 5eig5t =600 >.

•

Wit5 tan fille- to 12 test 5eig5t =600 >.

•

Wit5 tan fille- to " test 5eig5t =600 >.

At least 2" 5ours after t5e tan 5as been fille- to t5e aiu test 5eig5t. )5is perio- a7 be increase- in accor-ance to t5e reuireent of t5e project specification. •



After tan 5as been eptie- of test ?ater.

If settleent easureents are specifie- b7 t5e Purc5aser8 an7 -ifferential settleent greater t5an 1  per 10 . of circuference or a unifor settleent over 30  s5all be reporte- to contractor.



&illing of t5e tan s5all be stoppe- until cleare- b7 t5e contractor.



Internal botto elevation easureents s5all be a-e before an- after 57-rostatic testing. $easureents s5all be a-e at aiu intervals of  =10ft> easure- on -iaetrical lines across t5e tan.



)5e -iaetrical lines s5all be space- at eual angles8 ?it5 a aiu separation easure- at t5e tan circuference of 10 =2ft>. A iniu of four -iaetrical lines s5all be use-.


+PC Contractor

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&irst

,ev.

Issue

/ate:

vs

A

Spec. No.

QC10!0"# $0#


23Q/60&

R7y5|zj 5o T7h9 z974 

After t5e copletion of !7-rostatic test8 t5e tan s5all be eptie- at a aiu ?ater level variation rate as per specification.



$ae sure t5at roof an5oles an- vents are open -uring ept7 operation of conical roof tan.



W5en t5e first tan 5as been teste-8 ae connections to t5e secon- tan t5roug5 a gate valve an- eten- t5e piping to t5e -esignate- point. W5en t5e secon- tan 5as been teste-8 connect t5e teste- tan to t5e net tan an- ?ater to be fille- t5roug5 t5e s7ste of teporar7 valves anpiping.



Prior to starting t5e puping operation bet?een t?o tans8 ae sure t5at roof an5oles an- vents are open on bot5 tans.



)ransfer to t5e net tan using gravit7 an- a teporar7 pup as reuire- to ept7 t5e teste- tan.



After all ?ater 5as been reove- fro t5e teste- tan8 open all an5oles anreove all teporar7 blin-s an- euipent.





After final -raining an- -r7ing8 brus5ing8 broo or vacuu cleaner s5all clean surface of t5e tans bottos. QC Inspectors sign t5e test -ata s5eet at t5e copletion of 57-ro test.

DB AIR TEST Air test is carrieout to c5ec t5e gas tig5t of t5e roof plate an- reinforce- plate of s5ell openings of t5e tan.

DBD Ewikxy7g9 zg{ Mz974kzj 

Pressure *auge or $anoeter



4lan4lin- &lange ?it5 Safet7 ,elief 9alve



Soapsu-s



Air Suppl7 S7ste


+PC Contractor

Subcontractor




&irst

,ev.

Issue

/ate:

QC10!0"# $0#

Spec. No.

A


23Q/60&

DB P4587{i47 5o Ak4 T7h9 After final ?el-ing an- clearing t5e tan8 an air test s5all be con-ucte- to ensure ?ater tig5tness an- t5e integrit7 of ?el-ing accor-ing to t5e proce-ure follo?s: 

as

)5e tan ?orers s5all prepare t5e test euipent an- aterials suc5 asJ pressure gauge or anoeter8 testing piece8 suppl7 air an- soapsu-s etc.8



4efore starting t5e air pressure test8 ?ater s5all be fille- to 30 belo? t5e curb angle.



Cleaning an- visual inspection of entire ?el-ing of roof plates an- all roof accessories s5all be carrieout prior to test.



A anoeter of suitable range s5all be connecte- to t5e roof noBBle ?it5 KDD -iaeter P9C tube for easureent of pressure



Inlet connection s5all be -one ?it5 HDD 5ose fro t5e copressor outlet to one of t5e roof noBBle.



)o regulate t5e pressure8 valves s5all be provi-e- on bot5 en-s.



'nce all noBBles an- an5ole are close-8 pressure s5all be applie- slo?l7 insi-e t5e roof b7 controlling t5e isolation valves.



'nce t5e reuire-



Set t5e testing piece to t5e -esire- filling point of air eit5er on an5ole or air vents.



&ill an- press up t5e tan ?it5 copresse- air until it reac5es 2.2 Psi on t5e pressure gauge or an euivalent ?ater level in t5e anoeter an- 5ol- at t5is pressure for at least for 1 5our.



'bserve t5e pressure gauge or ?ater level in t5e anoeter if it reains in t5e -esire- test pressure.



If t5is pressure reains t5e sae t5en appl7 soapsu-s to ?el-ing seas or joint an- t5e areas to be c5ec for leas.



If t5e pressure -ecreases8 rec5ec t5e possible air passage an- blanoff or retig5ten.



If t5ere are leas t5en i-entif7 an- ar t5e eact location of -efects.



,elease t5e air pressure8 rectif7 t5e lea an- retest again until successful passet5e test in t5e presence of Client QC +ngineer.



)5e inspection an- acceptance report s5all be full7 accoplis5e- an- signe- b7 t5e Clients representative8 )an Supervisor an- QC +ngineer.



,elease t5e air pressure once t5e test is coplete- t5en put bac all coponentsparts t5at 5ave been reove-.


+PC Contractor

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&irst

,ev.

Issue

/ate:

A

Spec. No.

QC10!0"# $0#

I%& C'NS(%)IN* +N*IN++,S /ocuent Nuber 23Q/60&

DD SA!ETZ PRECAUTIONS 11.1

)5e safet7 easures s5all be ipleente- -uring testing activities an- t5e contractor s5all provi-e t5e necessar7 safet7 euipent8 counication euipent8 access barriers etc.

11.2 Contractor s5all issue a stateent to all persons connecte- ?it5 testing8 ?arning of t5e 5aBar-s of failure un-er pressure. )5ere is a possibilit7 t5at ?orers can tae ree-ial action once inor leaages are notice- before total failure occurs. 11. !7-rostatic tests are con-ucte- un-er t5e constraints of projects specifications. 11." Airgas use- for Air test is copressible to large etent an- 5as ver7 5ig5 potential energ7 store- ?5en copresse-. 11.3 +nsure t5at no an7 ?orer s5all present insi-e t5e tan prior to pressure test. 11.6 (se an- storage of an7 copresse- gas un-er 5ig5 pressure can be etreel7 -angerous if proper gas 5an-ling proce-ures are not observe-. 11. W5ere t5e test s7ste is testing using pressuriBation above its noral ?oring level8 it follo?s t5at t5e tester s5oul- be prepare- for t5e conseuences of failure. 11.8

)5is eans t5at t5ere a7 nee- to be protective barriers or screens8 but all suc5 precautions ?ill be specificall7 -e-icate- to t5e ris involve- in t5e test.

11.# )5e tec5nician ust be conscious at all ties of t5e potential for a rise in teperature to significantl7 increase pressure. 11.10 Safet7 officer ust be present at site -uring test. 11.11 )este- L certifie- %ifting euipent s5all be use- for lifting an- s5ifting purpose. 11.12 Safet7 Precautions s5all be follo?e- -uring fabrication an- erection as per project specification. 11.1 Wel-ing cables an- po?er cables to be lai- properl7 as per Instruentation an+lectrical rules an- local state govt. rules an- regulation.


+PC Contractor

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SINOPEC INTERNATIONA PETROEUM SERVICE CORPORATION KINGOM O! SAUI ARAHIA

Page:




&irst

,ev.

Issue

/ate:

A

Spec. No.

QC10!0"# $0#

I%& C'NS(%)IN* +N*IN++,S /ocuent Nuber 23Q/60&

11.1" Proper 5ouseeeping an- clean con-ition s5all be aintaine- in t5e fabrication s5op an- site as per reuireent. 11.13 Wear proper PP+ i.e. fall protection 5arness8 goggles etc. 11.16 Clean an- clear t5e area an- return t5e use- euipent an- aterials to t5e tool roo or s5op 11.1 Con-uct 5aBar- assessent an- safet7 eeting. 11.1F 4arrica-ing of )an8 &irstAi- it an- eergenc7 p5one nuber s5all be available. 11.1# )5e contractor s5all provi-e patrols to all aroun- t5e tan to ?atc5 an7 special points of 5aBar-s -uring pressure test of tan. 11.20 Safet7 sign boar-s bot5 in +nglis5 an- Arabic language s5all be poste- at appropriate locations -uring tan testing t5e -ispla7 s5all be M)ANE (N/+, P,+SS(,+ )+S) E++P AWA<.


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227340945-Hydrostatic-Test-Procedure-for-Storage-Tank-New-No-Air-Test.docx

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