Api 653 Report-Hydrolic Test PDF
Api 653 Report-Hydrolic Test PDF
Api 653 Report-Hydrolic Test PDF
OLEFIN PLANT
Ilam Petrochemical Complex A
National Petrochemical Co.
Bina Consulting Stone & Webster
RnPineera T.imited
Hydrostatic and Settlement Tests DOC.no. :I 0-VD-PCJ-QC-351144
BCE Job no: LAJ950133 Rev. no. : 2
Procedure
SWL Job no: 123065 Sheet no. : 1 1 11+1
HYDROSTATIC AND
SETTLEMENT TESTS
PROCEDURE
Hydrostatic And
Settlement
Tests
Procedure
CONTENT
1.0 Scope 3
2.0 Applicable Codes and Standards 3
3.0 Test Stages 3
4.0 Sequence of Work 4
5.0 Water 5
6.0 Method 5
7.0 Assessment and Report 10
8.0 Cleaning 10
Level Reference Table 11
This procedure briefly describes the general methods to be performed for Hydrostatic and
Settlement testing after completing welding operation and performing required N.D.T.
Test for Storage Tanks.
Before hydrostatic test, reports of all inspection and test as per relevant QCP such as joint
history N.D.T map, punch list, test certificate, general drawing etc. approval by the
owners representative shall be provided.
1.0. Scope
The purpose of performing following test is to controlling and measuring any changes to
body and foundation level and also to prove integrity of Storage Tanks body.
This document applies to Nine Storage Tanks of OLEFIN PLANT ILAM
PETROCHEMICAL COMPLEX.
After completing erection and performing required Tests, Visual Inspection, Vacuum
Box Testing, Pneumatic Test, Hydrostatic operation and settlement test will be
performed. Accoding Applicable codes and standards as defined in item 20.
2.0. Applicable codes and standards
¾ API 650 Welded Steel Storage Tanks.
¾ API 653 Tank Inspection, Repair, Alternation and Reconstruction.(Appendix B.)
¾ Client Documents and specification No: 10-00-spc-ME-1003 Rev.c
3.0. Test Stages
This test will divide to following mentioned stages:
¾ Test preliminaries such as visual inspection.
¾ Inspection of Tank Bottom Welds (Vacuum Box Testing)
¾ Inspection of Reinforcement-Plate Welds (Pneumatic Testing)
¾ Testing of the Shell (Hydrostatic Testing)
It must be mentioned all of the mentioned test must perform after controlling all of the
N.D.T. test reports.
Holding Stage
Hydrostatic Test
Water Discharge
Settlement
Monitoring Holding Stage
Emptying Stage
5.0. Water
¾ For accomplishment of hydrostatic test, storage tanks must filled with plant water and
prior to filling the Storage Tank with water.
TEST METHODS IN ACCORDANCE WITH API 650
6.0. Method
Describing inspection and test methods for following fixed & floating roof storage tanks,
which were fabricated and tested in accordance with API 650:
¾ C5+Feed Tank (TK-031) Floating Roof
¾ Pyrolysis Gasoline Tank (TK-903 A/B) Floating Roof
¾ Benzene Stripper Feed Tank (TK-985)
¾ Chemical Waste Neutralisation Tank (TK-984)
¾ Caustic Tank (TK-981)
¾ Spent Caustic Holding Tank (TK-941)
¾ Fuel Oil Storage Tank (TK-904)
¾ Sulphuric Acid Storage Tank (TK-982)
6.1. Test Preliminary
6.1.1. Visual Examination
All of the weld seams of bottom plates must be visually inspected. This inspecting shall
meet the following requirements:
6.1.1.1. The surface of weld lines must free from cavities and construction derbries using
trains of pigs fitted with brushes.
6.1.1.2. There must not be any pronounced lumps or cavities, which have been caused by
starting or finishing a weld bead.
6.1.1.3. Welds must free from under cutting. The height and spacing or ripples must be
uniform. For welds that attach nozzles, manholes and cleanout openings.
6.1.1.4. The profile of fillet welds must be uniform and surface of the weld must slightly
convex and free from over lap at the toes of weld lines.
If any problems meet in visual inspection, following corrective action must be performed
before starting next stage of the test:
¾ Removing all of the defects by using mechanical means or thermal gouging processes.
¾ Repairing arc strikes which have been discovered in or adjacent to weld lines by
grinding and re-welding as required.
¾ The repaired weld shall be visually examined for defects.
After completing fabrication and prior to filling the tanks with water for performance of
hydrostatic test, all of the reinforcements shall be tested by pneumatic method.
Applying up to 100 Kpa Pressure between the tanks shell and openings reinforce pads,
with using contrived telltale holes on pads, and covering all of the attachments and
welding around the reinforce pads by suitable material such as a soap film or linseed oil.
If weld joints contained any defect, bubbles will appeared on the covered material.
Suitable convenient method shall be applied for repairing all of the existent defects.
6.4. Testing of the Shell by using Hydrostatic Test Method
After the entire tank is completed but before any permanent external piping is connected
to the tank, the shell shall be tested by Hydrostatic Testing. This Test must be performed
after completing tank fabrication and finishing all of the welding operation and
Radiographic Test, prior to painting and / or insulation.
Hydrostatic testing methods consist of filling a Tank System with (Water) containing a
max of 25 ppm chloride up to high liquid level or over flow nozzle, until a certain
pressure is reached, and observing. A loss of liquid pressure can be attributed to a leak, a
decrease in liquid temperature, distortion due to the pressure, or trapped vapor.
During test operation, inspector should check for conformity with design drawings and
specification, accessibility of valves, controls and gages and proper installation of water
pumps. All equipment should be checked for correct identification and operating
instructions.
Water supply pipe work should be flushed thoroughly at the maximum practicable rate of
flow, before connection is made to system piping, in order to remove foreign materials
which may have interred during installation or which may have accumulated in the mains
system at lower rates of flow. The minimum rate of flow for flushing should be not less
than the water demand rate of the system.
Filling operation and method will be according to clause 6.4.3 of this procedure.
concerning speculation upon soil settlement and soil bearing capacity which have been
concluded from ground research.
Considering and marking 12 points (0º, 30º, 60º, 90º, 120º, 150º, 180º, 210º, 240º, 270º,
300º, 330º) around storage tank base ring as leveling references and measuring the
elevation with 1mm accuracy with dial gauge. Before filling tanks with water the level at
each mentioned reference point will be registered. Permanent reference level will be
established in unaffected location of tanks (Bench Mark). Gauge contact surfaces should
be provided with glued glass plates or similar for a smooth contact.
6.4.4. Filling
¾ Settlement Monitoring
¾ All shell welding joints lower than liquid level
¾ Corner joints including the fillet weld between shell and bottom, which shall visually
check for water tightness.
¾ Shell roundness
Note: For repair of any leakage ad weld, water level shall be drained 330 mm below the
failure point and after repair, hydrostatic test shall re-started from actual level.
It must be mentioned prior to the roof installation, fixed roof column supports shall be
inspected for plumbness and tank shells shall be inspected for distortion or ovalization.
Roof support columns which are out-of-plumb by more than 15mm in every 3m and/or
more than 60mm for the total length shall be realigned.
7.0. Assessment and Report
Gauge measurements and visual inspection shall be assessed and reported together with
measurement records, including gauge plots relative to water levels.
The measurement records shall be issued to the engineering manager and company and
the engineering manager shall review and interpret measurement records if anomalies are
happened, the engineering manager shall instruct the site immediately to stop the water
filling, and shall discuss with Company.
8.0. Cleaning
The tanks shall be completely drained and thoroughly dried immediately after hydrostatic
Test. If necessary during discharging the test water, put the inflatable boat on the test
water and brushing the wall by using the boat as water level goes down.
After the tanks were emptied, surfaces of the bottom plates shall be cleaned with fresh
water. Water, which will be used for cleaning, shall be same quality as test water. All
sand, sludge and rubbish shall be removed from the tanks bottom.
After final draining and drying, brushing, broom or vacuum cleaner shall clean surface of
the tanks bottoms.
0º
30º
60º
90º
120º
150º
180º
210º
240º
270º
300º
330º