INTERNAL INSPECTION

USING VT AND VACUUM BOX

METHOD OF STATEMENT
INTERNAL INSPECTION USING VT AND
VACUUM BOX

0 27/12/2022
Rev. Number Date Prepared by Review by Checked by
Basim Hameed Muthana Zaibeg ALI RISHIM
Location No. of Sheets 9
Zubair Filed NDGS│Onshore Plants

Document Title: internal inspection using VT and vacuum box

for storage tanks
 INTERNAL INSPECTION
USING VT AND VACUUM BOX

1. Scope:
• This Method of Statement provides a way for carrying out Tanks and inspection activities in Zubair Oil
Field, to ensure that the work is performed in a safe, professional and controlled manner by competent
trained staff, which will be executed by the technical Team.
• Also to clarify the requirements for vacuum Examination of bottom & roof weld joints for welded Steel
storage tanks during in-service.
• The objective of the vacuum box technique of bubble leak testing is to locate leaks in a pressure
boundary that cannot be directly pressurized. This is accomplished by applying a solution to a local area
of the pressure boundary surface and creating a differential pressure across that local area of the
boundary causing the formation of bubbles as leakage gas passes through the solution.

• Also to clarify the methodology of internal visual test inspection inside the tank which will considered
as a confined space, also using the vacuum box for inspect all the joints of welding.

Inspector in accordance with the requirements of T-150, ASME Code Sec. V. The procedure qualification
record shall be attached to this procedure

2. Purpose:

The purpose of this Method of Statement is to define the activities to be performed by the VT and vacuum box
by the Team relating to storage tank and Integrity Inspection services, and to describe/meet the quality,
execution, and HSE requirements within scheduled period of time.
Also to explain all work steps method which is related to VT, vacuum box and penetrant test if needed in case of
any suspicious test.
As well as to ensure the Vacuum Box Test is carried out in a controlled defined manner in accordance with API
Codes Applicable Edition/Addenda and/or Client’s specifications, whichever is more restrictive

3. Reference:
3.1. Mandatory Documents:
The mandatory documents to be available to start activities are;

- Risk Assessment doc

- Rescue plan doc
- Permit to Work
- Following Client NDT procedures

3.2. Codes and Standards:

API 653 Tank inspection, alteration and reconstruction
ASME Sec V: Non-Destructive Examination-2017
- Tank inspection, repair, alteration, and reconstruction API 653 fifth edition 2014
ERRATA 2020 - Welded steel tanks for oil storage API 650 twelfth edition 2013 addendum2, 2016.
- Guidelines and Methods for Inspection of Existing Atmospheric and Low-pressure Storage Tanks API 575
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third ED, April 2014

3.3. Definition of Terms

HSE : Health, Safety and Environment
NDT : Non-Destructive Testing
QA/QC : Quality Assurance and Quality Control
AGT : Authorized Gas Tester
ASME: American Society for Mechanical Engineers

3.4. Other references:

ASME Code Section V (Non-Destructive Examination), applicable edition/addenda

ANSI/ASME B31.1, applicable edition/addenda, for acceptance criteria
ANSI/ASME B31.3, applicable edition/addenda, for acceptance criteria
National Board Inspection Code, NBIC-23, applicable edition
AWS D1.1- applicable edition
Clients’ specification requirements for acceptance criteria
Specification KOWOVAC VSP

4. RESPONSIBILITIES
Site Engineer / Team leader

 Shall be responsible for organizing the test as per this approved method and approved ITP.
 Conduct toolbox talk with all personnel involved in activity in participate with HSE supervisor.
 Shall ensure all safety precautions/clearance are taken.
 Ensure both VT and vacuum box test were applied safely and following the method.

QC Inspector

 Shall be responsible to witness the test and & coordinating with client inspector for inspection activities.
 Shall also be responsible for maintaining the records/reports duly signed by all concerns.
 Ensure all devices were installed properly to take the exact values readings.

HSE Supervisor

 Check all PTW and safety documents were attached.

 Conduct the TBT with all staff and ensure to take all the signatures.
 Identify all the workplace hazards and match it with risk assessment if need to add others.
 Coordinate with AGT if any gas leak for monitoring.

Rescuer (Rescue Team)

 A certified rescuer will be present on the workplace as rescue team in case of any emergency inside the
confined space.
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 Ensure that all the area clear from hazards and ready to rescue any one of the team.

5. METHOD OF STATEMENT AND TECHNICAL STEPS:

 Performing a visual examination of the bottom and welds prior to performing the vacuum-box test;
 Before starting to use the vacuum box, it will take the electrical source from DGS for nearest source and
the device will be outside the tank.
 Verifying the condition of the vacuum box and its gasket seals;
 Verifying that there is no quick bubble or spitting response to large leaks; and
 Applying the film solution to a dry area, such that the area is thoroughly wetted and a minimum
generation of application bubbles occurs.
 A partial vacuum of 21 kPa (3 lbf/in.², 6 in. Hg) to 35 kPa (5 lbf/in²., 10 in Hg) gauge shall be used for the
test. If specified by the Purchaser, a second partial vacuum test of 56 kPa
 (8 lbf/in.², 16 in. Hg) to 70 kPa (10 lbf/in.², 20 in. Hg) shall be performed for the detection of very small
leaks.
 The vacuum-box test shall have at least 50 mm (2 in.) overlap of previously viewed surface on each
application.
 The metal surface temperature limits shall be between 4 °C (40 °F) and 52 °C (125 °F), unless the film
solution is proven to work at temperatures outside these limits, either by testing or Manufacturer’s
recommendations.
 The vacuum shall be maintained for the greater of either at least 10 seconds or the time required to
view the area under test.
 Approximately 30 inches of the seam under test is brushed with a soap solution or linseed oil.
 The vacuum box is placed over the brushed section of the seam, and a vacuum is applied to the box
 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.

Defect Evaluation
 The presence of a through-thickness leak indicated by continuous formation or growth of a bubble(s) or
foam, produced by air passing through the thickness, is unacceptable
 The presence of a large opening leak, indicated by a quick bursting bubble or spitting response at the
initial setting of the leak test is unacceptable. So then will fix Leaks to be repaired and retested.
 Also if any difficulty will use the PT.

Repair
Any leak in welds shall be repaired in accordance with an approved welding procedure and the
requirements of ASME code Sec IX.
After all repairs have been made; a retest shall be performed in accordance as per the standard

Reporting
 Upon completion of the examination the examiner shall prepare an examination report, for weld
examined, using the Vacuum Box Test report form.
 A record or report of the test including a statement addressing temperature shall be completed and
 INTERNAL INSPECTION
USING VT AND VACUUM BOX

furnished to the customer upon request.

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 or otherwise with the Prior to vacuum testing all joints shall be checked visually.

6. EQUIPMENTS:

 Electrical source from DGS using a cable.

 Hose with 20 M.
 film solution or commercial leak detection solution.
 COUPLANT.
 Box approximately 150mm (6 inches) wide by 750mm (30 inches) long with clear
window in the top, which provides proper visibility to view the area under
inspection.
 The open bottom shall be sealed against the tank surface by suitable gasket
 Light illuminator (natural or artificial): adequate for proper evaluation and interpretation of the test with
1000 lux minimum at the point of examinations and evaluation.
 The gauge of vacuum box will have a range of O psi to -5 psi.
 The gauge of vacuum source shall register a partial vacuum of at least 3 psi (21 Kpa) below atmospheric
pressure or the partial vacuum required by the referencing code section.

7. HEALTH SAFETY ENVIRONMENT

 A task specific PTW to be submitted prior to work start and all activities to be done shall be mentioned /
covered properly.

 Gas concentration shall be detected continuously with a qualified gas tester, and calibrated gas detector.
If any risk of gas leakage or measurements is out of limits, work site will be ceased promptly.

* All HSE requirements shall be satisfied for the work implementation.

* All team members shall aware in all risks around before start work.
* Whilst on the work site, all personnel should follow the procedure for personal protective equipment. As a
minimum all personnel and visitors must wear the follow approved personal protective equipment when
working in operational area:
• Hard hats
• Steel-toed footwear
• Safety goggles
• Coveralls
• Hand gloves
• Gas tester
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Additional personal protective equipment is required when working on a special task, the additional PPE
depends on the task Hazards, additional PPE includes, but not limited to the following items:
• safety harness
* Working crew is responsible to achieve the target within the safety regulations.
* Workplace access and scaffoldings shall be ensured as per safety regulations.
* Confined space work permit shall be adopted before start of work in storage tanks.
* All NDT Operations shall be carried out in compliance of Linscan approved procedures.
* Cold Work Permit shall be required before any NDT operations.
* Housekeeping shall be maintained to keep site cleaned and tidy.
* Personnel found to be repeatedly in breach of PPE rules shall be subject to possible disciplinary action.
* Barricades and warning devices shall be installed in the working area as needed.

 Every precaution and consideration should be taken be to ensure that all potential hazards associated
with the electrical equipment are removed.
 All working group shall be team-working and coordinating to assure the working area “no entry without
authority”. The operator or inspector shall have responsibility to themselves and other persons with
regard to safety and shall ensure that site/yard/others facilities are adequate with regard to , scaffolding
inspected, confined space precaution and requirements all implemented as per HSE plan and risk
assessment and the others like prior to commencement of operations.
 Inspectors check all control area to assure of nobody entry without authority.
 A fire extinguisher should be readily available.
 All electrical connections, such as wires, cables and terminals must be properly insulated and covered,
and should not be touched with bare hands or while in contact with water. This is essential to prevent the
occurrence of an electric shock.
 Thermocouple shall be located on the weld center line and shall either be held in intimate contact with
the surface of the weld mechanically or be attached by capacitance discharge welding. The attachment
points of capacitance welded thermocouple shall be dressed by grinding after removal.
 Heating elements shall be securely fixed in contact with the work piece by stainless steel or mild steel
banding to suit the application.
 The heating element shall be thermally insulated using 50mm thick white ceramic fiber.

Confined Space Entry

Confined Space refers to any place, including any vessel, tank, container, pit, bund, chamber, cellar or any other similar
space which, by virtue of its enclosed nature, creates conditions that give rise to a likelihood of an accident, harm or
injury of such a nature as to require emergency action due to

 the presence or reasonable foreseeable presence of:

-    flammable or explosive atmospheres
-    harmful gas, fume or vapour
-    free flowing solid or an increasing level of liquid
-    excess of oxygen
-    excessively high temperature
 the lack or reasonably foreseeable lack of oxygen
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The key characteristics of a confined space are:

 the space must be substantially enclosed

 there must be a risk of at least one of the hazards listed above occurring within the space
 the risk of serious injury from the hazard must be created by virtue of the enclosed nature of the space
 the potential injury must be serious and be such as to require emergency action to rescue the person
involved.

Hazards of Confined Space

The hazards associated confined spaces include:

 Toxic Atmosphere
A toxic atmosphere may cause various acute effects, including impairment of judgement, unconsciousness and
death. A toxic atmosphere may occur due to the presence or ingress of hazardous substances. These substances
may be present in the Confined Space for various reasons such as:
-    remaining from previous processing or storage
-    arising from the disturbance of sludge and other deposits
-    the presence of a fire or flames within the space
-    seepage from improperly isolated adjoining plant
-    formation during the work processes carried out in the space
-    being released from under scale and in brickwork as a result of the work process
 Oxygen Deficiency
Oxygen can be lacking a confined space for the following reasons:
-    displacement of air by another gas
-    various biological processes or chemical reactions (such as rotting of organic matter, rusting of metals,
burning, etc.)
-    absorption of air onto steel surfaces, especially where these are damp
 Oxygen Enrichment
An excess of oxygen, in the presence of combustible materials, results in an increased risk of fire and explosion.
Some materials, which do not burn in air, may burn vigorously or even spontaneously in an enriched oxygen
atmosphere.
 Flammable or Explosive Atmospheres
A flammable atmosphere presents a risk of fire or explosion. Such an atmosphere can arise from the presence in
the confined space of flammable liquids or gases or of a suspension of combustible dust in air. If a flammable
atmosphere inside a confined space ignites, an explosion may occur, resulting in the expulsion of hot gases and
the disintegration of the structure.
 Flowing Liquid or Free Flowing Solids
Liquids or solids can flow into the confined space causing drowning, suffocation, burns and other injuries.  Solids
in powder form may also be disturbed in a confined space resulting in an asphyxiating atmosphere.
 Excessive Heat
The enclosed nature of a confined space can increase the risk of heat stroke or collapse from heat stress, if
conditions are excessively hot. The risk may be exacerbated by the wearing of personal protective equipment or
by lack of ventilation
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Precautions

The key elements to be considered when drawing up a safe system of work are:

 Competence, training, supervision and suitability

 Permit-to-work procedure
 Gas purging and ventilation
 Dangerous residues
 Testing and monitoring of the atmosphere
 Mechanical, electrical and process isolation
 Respiratory protective equipment
 Other personal protective equipment
 Safe use of work equipment
 Communications
 Access and egress
 Flammable or explosive atmospheres
 Combustible materials
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Rev 0

Vacuum Box Test Page of

Report
Date / /

Project : Item :
Client : Contractor :

Item No: Light intensity :

Examination date : Acceptance criteria:

Material : Drawing No.:

Time : Temperature : C

Reference Procedure: Vacuum pressure :

Welding surface condition: Thickness :

Weld No Welder No Joint Type Judgment Remarks

Name:

Signature: