hydrostatic and settlement tests procedure

8/11/2019 Hydrostatic and Settlement Tests Procedure

http://slidepdf.com/reader/full/hydrostatic-and-settlement-tests-procedure 1/12

HYDROSTATIC AND

SETTLEMENT TESTS

PROCEDURE

Bina

Consulting

Stone

Webster

R n Pin eera T imited

BCE Job no LAJ95 133

SWL Job no 123 65

OLEFIN PLANT

Ilam Petrochemical omplex

ydrostatic and Settlement Tests

Procedure

Nation al Petrochemical Co

DOC.no. I -VD-PCJ-QC-351144

Rev.

no.

2

heet

no. 1 11 1



Hydrostatic And

Settlement

TestsProcedure

CLIENT : ILAM Petrochemical Company

Prj. Doc. NO.: 10-VD-PCJ-QC-351144 ILAM ETHYLENE PLANT-ILAM OLEFIN COMPLEX

02 1.Mar.09 For Approval R.NTech.Dep.

A.S

01 28.Dec.08 For Approval R.NTech.

Dep.A.S

MFS DOC.NO: MFS –PR-HT(IL)-86-06-441 (02) Rev. Date Description Prepare. Chk. App.



Masnouat Felezi Sangin

OLEFIN PLANT

Ilam Petrochemical

Complex National Petrochemical Co.

Doc. No. : 10-VD-PCJ-QC-351144

Hydrostatic And

Settlement Test Procedure

Rev. No. : 02

Sheet no. : 2 / 11

\\Server\Users New\monshi\Monshi\SAYER MON 1 Projects\Olefin Petroshimi Ilam\procedure\ITP-02.doc

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




OLEFIN PLANT

Ilam Petrochemical



Hydrostatic And


Rev. No. : 02

Sheet no. : 3 / 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

API 650 Welded Steel Storage Tanks.

API 653 Tank Inspection, Repair, Alternation and Reconstruction.(Appendix B.)

Client Documents and specification No: 10-00-spc-ME-1003 Rev.c

3.0. Test Stages

This test will divide to following mentioned stages:

Test preliminaries such as visual inspection.

Inspection of Tank Bottom Welds (Vacuum Box Testing)

Inspection of Reinforcement-Plate Welds (Pneumatic Testing)

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.




OLEFIN PLANT

Ilam Petrochemical



Hydrostatic And


Rev. No. : 02

Sheet no. : 4 / 11


4.0. Sequence of Work

Water Filling

Holding Stage

Cleaning and Drying

Settlement

Monitoring

N.D.T Test records

Holding Stage

Water Discharge

Holding Stage

Emptying Stage

Settlement

Monitoring

Leak test

Hydrostatic Test

Holding Stage

Holding Stage at 1/2 Ht




OLEFIN PLANT

Ilam Petrochemical



Hydrostatic And


Rev. No. : 02

Sheet no. : 6 / 11


If any problems meet in visual inspection, following corrective action must be performed

before starting next stage of the test:

Removing all of the defects by using mechanical means or thermal gouging processes.

Repairing arc strikes which have been discovered in or adjacent to weld lines by

grinding and re-welding as required.

The repaired weld shall be visually examined for defects.

6.2. Inspection of Tank Bottom Welds by performing Vacuum Box Test:

After termination of visual inspection and cleaning above-mentioned surfaces, or

performing corrective action, vacuum box testing will be executed by using following

methods:

6.2.1.

Vacuum testing is conveniently performed by using a testing Box with about15 cm

wide and 75 cm long with a glass window in the top and sealing the open bottom

with using a sponge-rubber gasket and suitable connections. Suitable connection

valves and gauges shall be provided on it.

6.2.2. Approximately 75 cm of the seam under test, must brushed with a soap solution or

linseed oil. In freezing weather, a non-freezing solution may be necessary. The

vacuum box will place over the coated section of the seam, and vacuum will apply

to the box. Bubbles will indicate the presence of porosity in the seams or foam,

which was produced by air sucked through the welded seam.

6.2.3. A vacuum can be drawn on the box by any convenient method, such as connection

to a gasoline- or diesel motor intake manifold or to an air ejector or special

vacuum pump.

6.2.4. As an alternate to vacuum box testing, a suitable tracer gas and compatible

detector can be used to test the integrity of welded bottom joints for their entire

length provided that an appropriate tracer gas testing procedure has been reviewed

an approved by the purchaser.




OLEFIN PLANT

Ilam Petrochemical



Hydrostatic And


Rev. No. : 02

Sheet no. : 7 / 11


6.3. Inspection of Reinforcement-Plate Weld

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.




OLEFIN PLANT

Ilam Petrochemical



Hydrostatic And


Rev. No. : 02

Sheet no. : 8 / 11


6.4.1. Hydrostatic Test provision

6.4.1.1. Interior of the tanks shall be free from greases, weld spatter, scale, slag, rust and

any other foreign matter and broom swept.

6.4.1.2. Roof manhole (as vent) shall be open during of filling and emptying operation

(very important).

6.4.1.3.

All appurtenances inside of the tanks such as coils or pipe supports shall have

been installed.

6.4.1.4. Settlement monitoring devices shall be provided prior to filling water.

6.4.1.5. Permanent or temporary tank level gauges shall be provided to monitor the water

level.

6.4.1.6. Cleaning Surfaces (Internal / External) completely and pips and fittings should

be carefully cleaned before assembly and any loose jointing material should be

removed.

6.4.1.7. Installing of valves and fittings.

6.4.1.8. Installing pressure gauges.

6.4.1.9. Temporary water piping and pumps for filling and discharging shall be installed

from the tank to water supply point and disposal point.

6.4.1.10. Hydrostatic test shall be commenced and finished during day lights hours.

6.4.1.11. Hydrostatic test chart(time &levels)shall be provided.

6.4.2. Type of settlement :

Type of settlement will be according to API653 Appendix B, clause B2 and should be

recorded upon related formats.

6.4.3. Settlement Monitoring:

To restrain and monitoring foundation settlement, according to following mentioned

method, filling will be done under controlled condition, which was measured with




OLEFIN PLANT

Ilam Petrochemical



Hydrostatic And


Rev. No. : 02

Sheet no. : 9 / 11


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

6.4.4.1. Filling operation

The test water shall be filled slowly until the water level reaches minimum 300 mm

height. The water-filling rate shall not exceed 900 mm depth per hour, and then inlet

nozzle shall be gradually opened and continuing filling operation. Water will be filled in

to the tanks by approximately filling rate about 900mm /hr, until water level reach

to1/3Ht, at such a head, filling will stop for 6 hours and level at the reference points will

be recorded.

Continuing filling operation with 900mm/hr water flow rate up to water level reached to

2/3Ht of required hydro test level at such a head, filling will stop for 12 hours and levels

will be measured and checked and comparing with registered measure before start of

filling (while tanks were empty) to ensure that uneven settlement have not occur. In thissituation, filling will proceed by the same rate up to water leveled reached to required

height. Each day levels at reference points will register and recorded. (Refer to page 12

for filling diagram).

The filled tanks will be maintained for 24 hours and provided levels remain

consistent, the tank can be off loaded prior to calibration for service.

As filling of tanks, according to the mentioned method, will be done gradually and in

steps, it prevents non-uniform settlement.

During hydro test and after finishing of each one of filling steps or emptying stages,

checking will be made on followings:




OLEFIN PLANT

Ilam Petrochemical



Hydrostatic And


Rev. No. : 02

Sheet no. : 10 / 11


Settlement Monitoring

All shell welding joints lower than liquid level

Corner joints including the fillet weld between shell and bottom, which shall visually

check for water tightness.

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.




OLEFIN PLANT

Ilam Petrochemical



Hydrostatic And


Rev. No. : 02

Sheet no. : 11 / 11


Level Refrence Table

Reference Point Height of Level Indicator Date Time

0º

30º

60º

90º

120º

150º

180º

210º

240º

270º

300º

330º