LEAK TEST PROCEDURE FOR REINFORCEMENT PAD FOR TANK WORKS

Contents
1.0 PURPOSE ...............................................................................................................................
2.0 SCOPE ...............................................................................................................................
3. DEFINITIONS AND ABBREVIATIONS ........................................................................................................ 2
4.0 REFERENCES & CODES ........................................................................................................................... 2
5.0 RESPONSIBILITIES ...............................................................................................................................
6.0 GENERAL REQUIREMENTS..................................................................................................................... 3
7.0 PROCEDURE ...............................................................................................................................
8.0 HEALTH, SAFETY AND ENVIRONMENT.................................................................................................. 5
9.0 ACCEPTANCE CRITERIA ......................................................................................................................... 6
10.0 DOCUMENTATION ...............................................................................................................................
11.0 ATTACHMENTS................................................................................................................................

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 LEAK TEST PROCEDURE FOR REINFORCEMENT PAD FOR TANK WORKS

1.0 PURPOSE
The purpose of this procedure is to ensure that pneumatic Leak testing of Nozzle RF Pads for Storage tanks is
conducted to satisfy the requirements of API 650.

2.0 SCOPE
This procedure is applicable to the Pneumatic Leak testing of N ozzl e RF Pads of the above mentioned field erected
tanks as per project specifications and API650.

3. DEFINITIONS AND ABBREVIATIONS

COMPANY : RUMAILA FIELD OPERATING COMPANY (AS SHORT AS ROO)

CONTRACTOR : SAE-A STX ENTECH COMPANY LIMITED
GCMC : GENERAL CONSTRUCTION AND MANAGEMENT CONTRACT
MUST/SHALL : A MANDATORY REQUIREMENT
QA/QC : QUALITY ASSURANCE AND QUALITY CONTROL
ITP : INSPECTION TEST PLAN
NDT : NON DESTRUCTIVE TESTING
NDE : NON DESTRUCTIVE EXAMINATION
4.0 REFERENCES & CODES

REFERENCE TITLE

API STD. 650 WELDED STEEL TANKS FOR OIL STORAGE

ASME SEC V APPENDIX 1 NON DESTRUCTIVE EXAMINATION (LEAK TESTING)

0000BF-C-G0-G000-ME-SPC-0007 ROO – SPECIFICATION FOR ATMOSPHERIC STORAGE TANKS

5.0 RESPONSIBILITIES
5.1 QA/QC ENGINEER / INSPECTOR

• Issue Inspection Request to Inspection authorities.

• Inspection of reinforcing pads prior to testing.
• Maintaining the pressure gauge calibration certificates.
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 LEAK TEST PROCEDURE FOR REINFORCEMENT PAD FOR TANK WORKS

• Monitoring the pneumatic testing.

• Signing the report of leak testing.
• Obtain the acceptance signature as per ITP.
5.2 TANK SUPERVISOR

• Preparing the reinforcing pads for pneumatic testing and including the pressure gauges.
• Examination of reinforcing pads prior to the pressurization to ensure that the preparation is correct.

6.0 GENERAL REQUIREMENTS

• The test medium for leak test shall be compressed air. The surface area to be tested shall be free of oil,
grease, oil, paint or other contaminants that might mask a leak.

• Leak Detector Solution: Liquid detergent, liquid soap with glycerine and linseed oil or any other leak
detection solution available in the market. House hold soap or detergents are not permitted for bubble
testing solution. Solution shall produce a film that does not break away from the area to be tested. And
the bubbles formed shall not break rapidly due to air drying or low surface tension.

• The reinforcing pads shall be tested prior to the hydro test. Fully welded reinforcing pads shall be provided
with tell-tale hole for leak testing. The size of the tell-tale hole for which the hose is connected shall be
¼“NPT threaded connection.

• Prior to test, the QA/QC Engineer shall ensure acceptance of all stage wise inspections, acceptance of all
Non Destructive Examinations as per ITP and verify the inspection records.

• Minimum one indicating pressure gauges shall be connected directly to the pad & shall be readily visible to
the operator controlling the pressure applied, throughout the duration of the test. 1 pressure gauge shall
be located near the medium source.

• Dial indicating pressure gauges used in testing shall be graduated over a range of about double the intended
maximum test pressure, but in no case shall the range be less than neither 1-1/2 nor more than 4 times
that pressure.

• Pressure Gauges shall be calibrated at least every 12 months or at any time there is a reason to believe that
there is an error.

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 LEAK TEST PROCEDURE FOR REINFORCEMENT PAD FOR TANK WORKS

7.0 PROCEDURE
7.1 TEST PRESSURE & TEST DURATION

• The RF pads shall be leak tested at a test pressure as specified on the approved Fabrication drawing or at
minimum 1barg (15psi) if it is not given in the drawing.

• Test duration shall be minimum 15 minutes after application of leak detector solution to allow completion
of inspection.
7.2 TEST TEMPERATURE

• The temperature of the surface of the part to be examined shall not be below 400F (50) nor above
1250F (500C) throughout the examination

7.3 SURFACE PREPARATION

The surface area to be tested shall be free of oil, grease, paint, or other contaminants that might
mask a leak. If liquids are used to clean the components, the component shall be dry before leak
testing.

7.3 LIGHTING & VISUAL AID REQUIREMENTS

• Direct visual examination may be usually be made when access is sufficient to place the eye with in 24 inch
(600mm) of the surface to be examined and at an angle not less than 30 degree to the surface to be
examined.
• Mirrors may be used to improve the angle of vision, and aids such as magnifying lens may be used to assist
examinations. Illumination (natural or supplemental white light) of the examination surface is required for
the specific part, component, vessel, or section thereof being examined.
• The minimum light intensity shall be 100fc (1000lx). The light intensity, natural or supplemental white light
source, shall be measured with a white light meter prior to the examination or a verified light source shall
be used. Verification of light sources is required to be demonstrated only one time, documented and
maintained on file.
• In some cases, remote visual examination may have to be substituted for direct examination. Remote visual
examinations may use visual aids such as mirrors, telescopes, borescopes, fiber optics, cameras, or other
suitable instruments. Such system shall have a resolution capability at least equivalent to that obtainable
by direct visual observation.

7.4 TEST METHOD

• RF pads shall be gradually pressurized through tell-tale hole with compressed air to a test pressure by
testing supervisor. Supervisor shall be familiar performing examination, interpreting and evaluating results.

• Once test pressure is achieved, the leak detector solution shall be applied by plastic squeeze bottle, brush
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 LEAK TEST PROCEDURE FOR REINFORCEMENT PAD FOR TANK WORKS

or hand operated spray applicator on RF pad weld from inside and outside of welds.

• A close visual examination shall be made on all welds of RF Pads during and after application of leak
detection solution.

• Bubble formation during test indicates discontinuities which will be repaired and re-tested.

• After inspection, de pressurization shall be done gradually through pressure regulating valve.

• Grease and Grease Nipples to be provided upon completion of RF pad test and tank hydro-test. The tell-
tale holes shall be left unplugged till tank hydro-test, after completion of all test the hole shall be weather
sealed with hard grease
7.5 REPAIR OF DEFECT, CRACK OR LEAK IN RF PAD WELDS FOUND DURING TEST

• The QC Engineer or Inspector shall identify location of defect detected during the test.

• The Tank Supervisor shall perform the repairs; monitor the execution of repair actions and the subsequent
clearance of same rests with the QC Engineer or QC Inspector.

• The defect area of weld shall be excavated by grinding until the defect is removed completely.

• Where a defect cannot be detected during the grinding process, the NDT technique (MPT – Magnetic
Particle Examination) should be considered, this is not only to locate the defect but also to establish its
complete removal.

• Repair welding shall be completed using an approved WPS for the appropriate welding process.

• All Essential parameters specified on the WPS shall be followed during re-welding.

• Re-welding shall only be conducted by qualified welders.

8.0 HEALTH, SAFETY AND ENVIRONMENT

• Ensure use of rated hose & fittings.

• Ensure to provide whipping arrestor at hose and fitting connections.

• Ensure proper fastening of fittings and hoses before pressurizing.

• Ensure compliance with PTW requirements before testing.

• Barricade the area under test for unauthorized personnel entry.

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 LEAK TEST PROCEDURE FOR REINFORCEMENT PAD FOR TANK WORKS

9.0 ACCEPTANCE CRITERIA

• Any leakage or pressure drop detected during test is unacceptable.

10.0 DOCUMENTATION
• QC Engineer / Inspector shall prepare and sign the Pneumatic Test Report after completion of test.

11.0 ATTACHMENTS
• PNEUMATIC PRESSURE TEST REPORT FORM.

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 LEAK TEST PROCEDURE FOR REINFORCEMENT PAD FOR TANK WORKS

ROO BROWNFIELD OPERATION PROJECT

PNEUMATIC PRESSURE TEST REPORT

Project No: Report No:

Tag Number: Drawing / Rev :

i
Job Description: Test Description:

Test Pressure: Test Date:

Holding Time: Temperature:

(A) Gauge No: Calibration Valid Up to

(B) Gauge No: Calibration Valid Up to

Test Result: Test Medium:

Remarks:

APPROVALS STX Construction STX QA/QC Company

Signature

Name

Date

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