FULL WATER & AIR LEAK TEST PROCEDURE

TABLE OF CONTENT

SECTION 1.0 SCOPE...............................................................................................................................

SECTION 2.0 DEFINITION.......................................................................................................................
SECTION 3.0 REFERENCES.....................................................................................................................
SECTION 4.0 GENERAL REQUIREMENTS...............................................................................................
SECTION 5.0 PREPARATION FOR FULL WATER AND AIR TEST................................................................
SECTION 6.0 FULL WATER TEST PROCEDURE.......................................................................................
SECTION 7.0 TEST WATER.....................................................................................................................
SECTION 8.0 WATER FILLING...............................................................................................................
SECTION 9.0 AIR TEST PROCEDURE....................................................................................................
SECTION 10.0 DOCUMENTATION AND RECORDS................................................................................
SECTION 11.0 SAFETY..........................................................................................................................
SECTION 12.0 INSTALLATION OF BLIND FLANGES...............................................................................
 FULL WATER & AIR LEAK TEST PROCEDURE

1.0 SCOPE

This procedure describes the Full Water & Air Leak testing for Hexane Tank 411 and Mother Liquor
Tank 412 at P27 Site Erection

2.0 DEFINITION

Consistent with other documents throughout the contract the following definitions will be used:

2.1 Owner: PRPC Sdn. Bhd.

2.2 Contractor : TecnimontHQC
2.3 Subcontractor : Litany Energy Services Pte Ltd (LES)

3.0 REFERENCES

Following code, specifications, drawings are referred as part of this procedure

 API 650 -Specification for Welded Steel Tanks for Oil Storage (11th Edition Add3 Aug2011)
 PTS 30.10.02.11 -Metallic Materials – Selection Standard ( DECEMBER 2010)
 PTS 34.51.01.33 - Above Ground Vertical Storage Tanks (Amendments/Supplements to API
Standard 650) JANUARY 2012
 PTS 30.10.60.18 - Welding of Metal
 PTS 64.51.01.31 - Standard Vertical Tanks – Field Erection and Testing
 PTS 70.51.10.11 - Field Inspection Maintenance and Repair of Vertical Storage Tanks
 Approved Project Drawings
 EN 14015 – Specification for the design and manufacture of site built, vertical, cylindrical, flat
bottomed, above ground, welded, steel tanks for the storage of liquids at ambient temperature ad
above
 FULL WATER & AIR LEAK TEST PROCEDURE

4.0 GENERAL REQUIREMENTS

4.1. Vacuum-box test shall be carried out for bottom plate joints prior to full water test – Attachment 3

4.2 Liquid penetrant examination examination shall be carried out for Tank shell to Bottom plate joints
prior to full water test.

4.3 Visual inspection shall be carried out for roof plate joints prior to full water test.

4.4 Full water test shall only be done after completion of all hot work including any repairs or modification
to the tanks

4.5 Sequence of Execution of Testing

4.6 The Tank internal surface shall be cleaned using water jet if needed, air blowing and wipe by dry clothes
if needed. The Tank shall be cleaned and should be free from dirt, dust and other foreign materials.

4.7 The Tank shell, roof and bottom plate thickness measurement shall be carried out prior full water test as
per Project Standard drawing S51.280-A as per attachment 4

5.0 PREPARATION FOR FULL WATER AND AIR TEST

5.1 All the non-destructive examination, including final visual inspection ( except for those after full
water test) dimensional checks, air leak test on repads- if any shall be carried out and accepted
by LES QC Inspector and Client prior full water testing Full Water test shall be performed in tanks
positions. Tanks shall be on the foundation.
 FULL WATER & AIR LEAK TEST PROCEDURE

Full water test shall be carried out using all opening are closed using same type of gaskets and bolt and
nuts which will be used as permanent in during operation

After Full water test any flanges that are opened or loosed shall have their gaskets and bolt and nuts
replaced with new ones.

5.2 The Tank bottom profile shall be measured and recorded before starting to fill the water and
after draining the hydro-test water. The point of reference shall be confirmed using Standard
Drawing No S51.280-A as per attachment -6

5.3 After the test completed 250mm of water should be left inside the tank to ensure that the Tank
Bottom is in contact with its foundation profile. The Tank Settlement check have to be carried
out. The measured value shall be verified against the settlement predictions.

5.4 For air testing, the tank shall be filled with water as mentioned in 6.3 below the shell and
anchorage shall be visually inspected for tightness. The air testing pressure shall be 25 mbar (g)
and shall be applied to the enclosed space above the water level for Site Erection Tanks.

5.5 The metal temperature during the full water testing shall be between 15degC to 48degC

5.6 Elevation and settlement measurements shall be means of survey instruments (by using
Theodolite). Baseline for elevation & settlement shall be established prior to the
commencement of filling of water. The measurement shall be taken and recorded as per
attachment -5 to identify permanent benchmarkinside the ISBL for record purpose.

5.7 The Elevation at tank to be checked at minimum of 8 points (0deg, 45deg, 90deg, 135deg,
180deg, 225deg, 270deg, 315deg) around the circumference at a distance of 10meter maximum
deviation from the reference points.
Settlement monitoring shall be as per below

a. Stage -1 : 0.5H
b. Stage -2 : 0.5H ~ 0.67H
c. Stage -3 : 0.67H ~ 0.83H
d. Stage -4 : 0.83H ~ 1.0H

5.8 Elevations 300mm above tank base shall be recorded as guideline / reference prior of the water
filling.
5.9 Elevations measuring points shall be easily identified and differentiated to other construction
marks
5.10 The first reference point shall be located at Plant North Reference point shall be numbered
consecutively, starting with number 1 at Plant North and moving around in clockwise direction
5.11 Marking on the external tank shell indicating the height of water level shall be prepared and
marking shall be visible and accessible during water level monitoring.
5.12 No pipe shall be connected to Tank during Full Water Test except for the pipe used to fill the
Tank with water
 FULL WATER & AIR LEAK TEST PROCEDURE

6.0 FULL WATER TEST PROCEDURE

6.1 Tanks shall be filled to the top of the shell (Preferable at least 50mm above the weld connecting
the roof and the top curb angle.)

6.2 The tanks will be filled with water provided by TCMHQC from Fire Water hydrant as first choice
if available or Water tanker. Temporary Water hoses will be used to connect the water source
and the tank inlet.
6.3 Flexible hoses will be used for the connection between fire water hydrant or Buffer water tank
of the water supply using Water tanker.

6.4 Tanks shall be filled up to maximum liquid level as mentioned in latest GA drawings. A minimum clearance
of 150mm between the lowest point of the fixed roof member or any attachment should be considered.

6.5 Visual Inspection shall be done for all welds and flange connections ( checks for visible leaks)

6.6 During the test the tank must not exhibit any sign of general deformation or any water leaking
from any part of tank.

6.7 If there is rainfall during the holding period, the period may need to extend

6.8 During this period LES QC Inspector, Client and/or Owner representative will monitor and check
for any leakage or other failure on all joints and connections.

6.9 Following the full water test, the Tanks shall be completely drained and dried to avoid any
remains of the liquids.

6.10 Visual inspection shall be carried out by LES QC Inspector together with TCMHQC representative
to ensure that Tank is properly cleaned, dried and free from any debris or dirt.

7.0 TEST WATER

7.1 Test water shall be supplied by TCMHQC. Water Quality shall be in accordance to PTS
61.10.08.11 Field Inspection prior to Commissioning of Mechanical and PTS 70.51.10.11 Field
Inspection, Maintenance and Repair of Vertical Storage Tank. Fresh water (Portable Water/
treated water containing at least 0.2 PPM free Clorine) test shall be performed by TCMHQC.

7.2 After first water test completion, the water will be transferred to another tank. Before water
transfer from one tank to another tank, water test shall be performed and water shall be filtered
through 10m filters by Vendor. Turbidity check to be done prior to re-use of water to ensure
water quality level.

7.3 Full Water Test Report shall be as per Attachement – 1

 FULL WATER & AIR LEAK TEST PROCEDURE

8.0 WATER FILLING

8.1 Filling of water shall be done through a suitable shell/bottom connector with following filling
rate
STAGE – 1

The tank shall be filled to 0.5H at a maximum filling rate of “a” meters per day. The filling period in any
one day shall not be less than 3 hours and shall not be more than 18 hours. At the end of each filling
period, for the remaining hours in the day’s total 24 the foundation shall be allowed to equilibrate,
consolidate and be monitored. At the end of STAGE-1, there shall be further equilibration and monitoring
period of “X” hours before the commencement of STAGE -2

STAGE – 2

The Tank shall be filled from 0.5H to 0.67H at a maximum filling rate of “b” meters per day. The filling
period in any one day shall not be less than 3 hours and shall not be more than 16 hours. At the end of
the each filling period, for the remaining hours in the day’s total of 24 hours the foundation shall be
allowed to equilibrate, consolidate and be monitored. At the end of STAGE-2 there shall be further
equilibration and monitoring period of “Y” hours before commencement of STAGE -3

STAGE -3

The tank shall be filled from 0.67H to 0.83H at a maximum filling rate of “c” meters per day. The filling
period in any one day shall not be less than 3 hours and shall not be more than 16 hours. At the end of
the each filling period, for the remaining hours in the day’s total of 24 hours the foundation shall be
allowed to equilibrate, consolidate and be monitored. At the end of STAGE-3 there shall be further
equilibration and monitoring period of “Z” hours before commencement of STAGE -4

STAGE -4

The tank shall be filled from 0.83H to 1.0H at a maximum filling rate of “d” meters per day. The filling
period in any one day shall not be less than 3 hours and shall not be more than 14 hours. At the end of
the each filling period, for the remaining hours in the day’s total of 24 hours the foundation shall be
allowed to equilibrate, consolidate and be monitored. At the end of STAGE-4, the Tank shall be left full
and shall be monitored for at least 4 more days.

Exposure time shall not be exceed 21 days for portable water.

For the filling rate and monitoring period, please refer to Attachment – 9

8.2 Levels at the reference points will be measured, recorded and to be compared with the
registered record before water filling start ( while tanks were empty) to ensure that uneven
settlement have not occurred )

NOTE:

I. Before the test water is pumped or drained from tank, adequate measures shall be taken to
avoid a vacuum condition inside the tank. For fixed roof tank, all roof vent and manholes shall
be open conditions to prevent increasing internal pressure. Special care should be taken if the
 FULL WATER & AIR LEAK TEST PROCEDURE

test water.
TCMHQC to explain in detail on draining HT Water :
i) Discharge point/ water disposal point
ii) Duration
iii) Pressure check

8.3 In accordance with the filling rate of at least 3 hours per day, the following daily schedule of
measurement shall be applied.
 Prior to filing period
 Just after the filling period
 2 hours after the filling period ( optional, depending upon results)
 5 hours after the filling period

Also during each equilibration period between the various stages and during the period when tank is
fully filled after completion of STAGE -4, and during the draining of the tank, 3 measurement should be
taken daily.

8.4 Settlement check during water filling report as per Attachment – 5

 If settlement Rates is beyond acceptance value and does not diminish tank shall be emptied and a
geotechnical engineer sahll be consulted by TCMHQC.
 FULL WATER & AIR LEAK TEST PROCEDURE

9.0 AIR TEST PROCEDURE

9.1 Fixed roof tank shall be filled with air and pressurized and to be held for 30 minutes minimum.

9.2 During the holding time, the temperature of the tank (temperature of metal surface) shall be
checked and recorded. The temperature recording shall be carried out at the start of the holding
time to the end of holding time.

9.3 All welded joints above the water level shall be visually check for leaks suing soap film or soapy
solution. Visual Inspection of all welds and flange connections ( check for leaks)

9.4 During the period LES QC InspectorTCMHQC will monitor and check for any leakage or other
failure on all joints and connections.

9.5 Tanks vents shall be tested during or after this test.

9.6 Air Leak Test Report shall be as per Attachment – 2

10.0 DOCUMENTATION AND RECORDS

10.1 The test pack shall be prepared which shall contain required documentation for performing and
the record shall be prepared which contain following required documentation for performing
and recording of the test

 Types of test Fluid

 Holding Time
 Air Test Pressure
 Design Pressure and Temperature
 Location of inlet and outlet
 Test Date
 Ambient Temperature
 Pressure Chart / Recorder
 Equipment Calibration Certificates

10.2 After Completion of the Full water + Air Leak Test, the report including Tank Bottom Profile shall
be filled up and should be duly signed by LES QC Inspector and submitted to Client
Representative for review, acceptance and endorsement.

11.0 SAFETY

11.1 Provide a safety working environment by providing require signs, barricades or other protective
barriers are placed in a manner and at a distance sufficient to demarcate a safe zone to protect
personnel and the public from unanticipated pressure release.

11.2 Keep unauthorized personnel our to the test area. Do not work over or near the testing zone.
Wear a proper PPE as required during performance of test.
 FULL WATER & AIR LEAK TEST PROCEDURE

Supervisors/ Foreman making sure that all person under their control or direction are aware of
the safety regulation, work procedure and Proper equipment are provided for their protection
and Properly used.

11.3 Provide for and require that equipment and materials are arranged to give unobstructed
access/egress during testing and in the event of emergency.

11.4 Before discharge of water to the drainage, water shall be treated as per DOE’s requirements

12.0 INSTALLATION OF BLIND FLANGES

A few simple precautionary measures must be observed during installation of flanges to ensure a proper flange
joint.

 Center the gasket on the flange. This is extremely vital where raised faces are involved visually examine
and clean flanges, bolt & nuts. Replace components if necessary.

 Be sure surface finish and flatness are satisfactory. If found otherwise, correct by re-machining.

 Tighten bolts to compress gasket uniformly. This means going from side to side around the joint. See
Below Figure A (Bolt Tightening sequence)

 Use a torque wrench and well lubricated fasteners to ensure correct initial loading

 Re-torque/tighten 12 to 24 hours after coming on stream, wherever possible. The Joint should stand as
long as possible before re-tightening/toruquing.

Figure A – Proper Bolting Pattern

FULL WATER & AIR LEAK TEST PROCEDURE
FULL WATER & AIR LEAK TEST PROCEDURE