FLOATING ROOF TESTS

GENERAL

Floating roof shall be subjected to all tests as per construction code. Generally following
tests are conducted:

 Basic Floatation test

 Water accumulation on Deck (for Single Deck Pontoon type roof only)
 Puncture test

FLOATATION TEST:

This is a basic test to ascertain buoyancy and stability of roof during its working life.

Method Step

Fill water in the tank to raise the floating roof. As the roof moves up to its full height, observe
the behaviour of the roof, its sideward movements, variation in rim gap, gaps in the sleeve
for Gauge Well, sweat marks on the deck / compartment welds etc. This provides the basic
information on the design adequacy and construction aspects, namely proper welding,
alignment of roof drain line, rolling ladder adequate clearance for smooth operation of
gauge well, availability of minimum required rim space for fixing peripheral seal etc.

Generally this test is not conducted separately. Observations mentioned above could be
recorded during filling of the tank for other tests, which are mandatory as per Code.

Any abnormal tilting or side ward movement of the roof during floatation shall be noted and
remedial measure taken to rectify the roof, after lowering floating roof on its legs. This
should be completed before installing rim seal.

WATER ACCUMULATION TEST:

As per API 650 this test is to be carried out only for single deck pontoon type floating roof.
Accordingly, a single deck pontoon type floating shall be provided with adequate buoyancy
to hold water equivalent to 10” rainfall calculated on the entire roof surface, during its
operating period.

General

Total volume of water equivalent to 10” rainfall calculated on total area of roof and
calculated depth of submergence at the center of the floating roof shall be made available to
the field staff before the test. This will help them to regulate volume of water to be
introduced on the roof, and to monitor submergence at every stage of filling.

Method Step

 Close primary drain by shutting off the valve on drain line. Provide plugs on emergency
drains, siphon drain, as the case may be.
/Contd…2…
 -2-

 Remove all external materials from the roof.

 Fix a graduated steel scale at the center to monitor depth of submergence during the
test.
 Close deck manholes and inspection manholes provided on each pontoon. Ensure that
the inspection manholes are provided with proper gaskets, and are tightly shut.
 Fill water in the tank to raise floating roof. It is advisable to maintain water level at about
4 (four) metres before taking up water accumulation test. This will give necessary
clearance for submergence of the center of floating roof when the design water load
equivalent to 10” rainfall is applied.
 Release water on deck through of a hose from water main.
 After required quantity of water has been introduced on the roof, disconnect the hose.
 Maximum submergence at any point on the outer rim shall not exceed 65% of its height
when full load of water equivalent to 10” rainfall is introduced on deck.
 Water loading shall be discontinued in case abnormal tilting of roof is noticed at any
stage.
 Record the tilt of roof at various points along the periphery of outer rim.
 If recorded maximum tilt is within limits indicated above, test is successful.
 This test shall be timed when rain is not expected. This will help averting emergency
situations due to excess water on deck.

COMPARTMENT PUNCTURE TEST

As per API 650 this test is performed on both single deck pontoon type and double deck
compartment type floating roofs. However, in a single deck pontoon type roof this test
shall be conducted with any two adjacent compartments punctured along with a
puncture in the deck plate. In double deck floating roof tanks, the top deck is well above
the product level. Hence the test is to be conducted with puncture in any two adjacent
compartments only.
Preliminary
While constructing floating roof, weld small bore socket with plugs in two adjacent
compartments. Additionally, in single deck floating roof tanks, weld similar small bore
socket with plug on deck, at a location near the center of deck. The thread on the plug
shall be checked for tightness, since leak from the threaded portion will allow water to
enter compartments / deck while water accumulation test is in progress.
/Contd…3…
 -3-

This test shall not be coupled with water accumulation test.

Method Step

 After completion of water accumulation test, drain water from the deck.
 Close primary drain by shutting off the valve on drain line. Provide plugs on
emergency drains, siphon drain, as the case may be.
 Remove plugs in the two adjacent compartments and plug provided on the deck (only
for single deck floating roof)
 Water enters the two compartments in case of double deck floating roof, and two
compartments and deck portion in case of single deck floating roof.
 In the stabilized condition, in a single deck floating roof, water level measured on inner
rim and outer rim near the punctured compartments shall not exceed 65% of
respective rim heights.
 In a double deck floating roof, water level measured on outer rim near the punctured
compartments shall not exceed 65% of rim height.
 After successful completion of puncture test, drain water from the compartments and
the deck and dry the surface.
 Seal off the plugs by welding, and provide an additional cover over the area, and weld
the same to prevent entry of product during operation of the tank.