Method Statement For Hydrostatic Test & Pneumatic Test: Issue Purpose For Construction
Method Statement For Hydrostatic Test & Pneumatic Test: Issue Purpose For Construction
Method Statement For Hydrostatic Test & Pneumatic Test: Issue Purpose For Construction
thuật Hòa Hiệp PHƯỚC GIAI ĐOẠN 1: 1200MW lực Hiệp Phước
Revision Details
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Contractor: Lilama18-ĐCT6 Page 1 / 19
Công ty TNHH kỹ NHÀ MÁY ĐIỆN KHÍ LNG HIỆP Công ty TNHH điện
thuật Hòa Hiệp PHƯỚC GIAI ĐOẠN 1: 1200MW lực Hiệp Phước
CONTENTS
1.0 SCOPE
2.0 DEFINITIONS
3.0 REFERENCE
5.0 PRELIMINARIES
8.0 TESTING
14.0 ATTACHMENT
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1.0 SCOPE
1.1 This document covers the hydrostatic test and pneumatic test for the LNG tanks with the double
steel walls of the full containment type.
1.2 Three LNG tanks listed below are supplied for the LNG receiving terminal and regasification
project of HIEP PHUOC.
2.0 DEFINITIONS
3.0 REFERENCE
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4.1 The hydrostatic test and pneumatic tests of LNG tank will be carried out with the sequence shown
in the following flow chart.
5.0 PRELIMINARIES
5.1 INSPECTION
1) Prior to introduction the test water into the tank, all required non-destructive tests such as
PAUT, surface crack detection and vacuum box testing for all welding of inner tank shell and
bottom plate including attachment welding shall be completed.
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2) Vacuum box test must be applied for the weld joints in the inner shell above the test water
level shown in the following table.
3) Prior to performing the pneumatic test, all required testing of the shell, bottom, and dome
roof of outer tank shall be completed.
4) After the hydrostatic test, required inspection shall be performed in accordance with HL-
LNG-LI18-ITP-001 “Inspection & Test plan”.
5) The hydrostatic test package shall be completed for the Client’s review and approval before
the tank hydrostatic test.
6) All pump columns must be completed installed and as well pressure test, hydrostatic test or
pneumatic test as required on item 10.3.3 of API 625.
1) The appurtenances of inner tank and outer tank will be installed as follows.
● Foot valve, isolator, and filter for pump column (Inner tank)
● Bottom plate (36%NiFe alloy steel) of thermal corner protection (Outer tank)
● Cooldown sensors (Inner tank, outer tank)
● Ring pipe for air purge in annular space (Outer tank)
5.3 CLEANING
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1) Prior to hydrostatic testing, the tank floor and stiffeners shall be swept by broom and no
debris or foreign articles shall be left in the tank.
2) Outside of corner welding between shell and annular of inner tank shall be cleaned.
1) The fresh water will be provided by Client for the hydrostatic test.
2) Quality of test water shall meet the requirements of Q.6.4.2 through Q.6.4.8 in API 620.
1) The following settlement measuring points shall be properly marked using the survey
instrument before filling of test water.
(Note: Sixteen (16) settlement measuring points on the perimeter of concrete slab foundation
and one settlement measuring pint on center concrte column under bottom slab
foundation shall be permanently marked for the future tank operation after discussion
with Hai Linh)
2) The temporary support (C100x50) for the reference benchmark shall be installed as shown in
the following FIG at eight(8) orientation points divided equally on the thermal conrner
protection to monitor the settlement of inner tank.
The eight(8) orientation points shall be at the same orientations as marked on the perimeter of
outer tank.
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3) The reference benchmarks led from the original benchmarks provided from Owner shall be
marked on the proper wall such as steel column, etc. around the tank for the hydrostatic test,
and the temporary surveying stage shall be prepared at the proper places around the tank, if
necessary.
4) The measuring tape shall be installed along the internal ladder to monitor the water level.
● Manometer (min. 2100 mmH₂O height measuring for 1939 mmH₂O (=190 mbarG)
● Emergency vent valve
● Water safety vent (as pressure relief system)
● Access manhole installed in the temporary door shell, if necessary
1) The temporary piping and pumps shall be installed to fill the test water into the tank, and to
transfer the test water to the other tank. The detail piping scheme is shown in
ATTACHMENT-1.
2) The test water will be introduced through the top of nozzle (N2A), and will be discharged
through the temporary piping or hose installed in the pump column (N2A/B).
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5.7 OTHERS
1) The 1st attachments directly welded to the tank body (as the pressure retaining part) such as
shell, bottom, and roof of the inner and outer tanks shall be welded before the hydrostatic test
and pneumatic test.
2) The punch items relative to the hydrostatic test of inner tank and the pneumatic test of outer
tank shall be cleared before start of testing, and the outstanding hot work such as welding,
cutting, etc. shall be minimized in the inner and outer tanks.
3) The water pond box, whose size can be passed through the roof manhole (N21A, 46”) shall be
prepared at the bottom of tank to collect and pump out the standing water remaining on the
tank bottom.
4) Prior to pneumatic test, Pressure Relief Valve (PRV) and Vacuum Relief Valve (VRV) shall
be installed on the roof nozzle.
5) One 2nd opening shell plate of the outer tank shall be permanently installed and welded, and
one 1st opening shell plate of the outer tank shall be permanently installed and welded, except
the area of the temporary door shell to be opened after the pneumatic test., which shall be
minimized.
6) The temporary door shell for temporarily closing of the opening shell area shall have the full
strength for the pneumatic test pressure and vacuum test pressure.
1) Before filling of test water, the initial settlement shall be measured and recorded.
2) The inlet nozzle shall be gradually opened and water-filling rate into the tank shall not exceed
3 feet (914 mm) depth per hour.
3) If the submersible pump will be installed to discharge the test water, the trial operation of
discharge water shall be performed when the water level reaches enough height to operate
(around 1 m).
4) The required test water level (filling height of test water) is as follows.
5) During the water filling and discharging, the roof manhole of outer tank and/or the other
opening shall be kept to open, except the operation test of PRV and VRV.
Just after the operation test, the roof manhole of outer tank and/or the other opening shall be
opened.
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6) During the water filling and discharging, the settlement monitoring shall be performed in
accordance with para. 7.0.
7) After the water is reached to the test water level, the ATR8B (STRAPS UP) and ATR7B
(STRAPS BELOW) of the anchor straps shall be connected, and the permanent weld shall be
made at the connection joint as per the approved WPS.
And then, the required NDE shall be applied to the completed welds.
8) The test water level shall be maintained until completion of the settlement monitoring at the
full filling height. Just after the operation test, the roof manhole of outer tank and/or the other
opening shall be opened.
1) During the water filling and discharging of test water, the settlement of the tank shall be
monitored. Differential settlement, or uniform settlement of substantial magnitude, water
filling must be stop. Any further filling with water will be depend on evaluation of the
measured settlement.
3) The settlement readings shall be taken as follows during water filling and discharging.
4) The settlement readings shall be taken again at the following time for the future tank
operation.
1) Periodic visual checking shall be performed on daily basis, whether extraordinary appearances
are present or not.
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2) Attentive visual checking shall be executed especially during high water levels.
7.3 Reporting
1) The visual checking result and settlement measurement reports shall be submitted to Client
and APAVE for evaluation of the settlement condition of the tank.
8.0 TESTING
1) The hydrostatic test for pump columns shall be completed before start of the water filling
2) The inner tank shall be filled with test water to the test level.
3) After the inner tank is filled to the test level, all welds in the shell including the corner welds
between the shell and bottom shall be visually checked for water leakage.
4) To avoid any risk of the leak, Lilama18 shall ensure that all required inspection shall be
carried out and these records shall be in place. Prior to start water filling, all documents will
be although be reviewed by Client/APAVE.
1) Before the pneumatic test, the operation condition of following devices shall be checked.
● Water safety vent (as safety relief valve) set at the pneumatic test pressure + 20 mmH ₂O
(= 2190 mmH₂O (214.7 mbarg) + 20 mmH₂O)
● Emergency vent valve
● Monometer
3) Just before performing pneumatic test, all openings except the manometer gauges and air inlet
nozzle shall be closed.
4) The block valves of the vacuum relief valves and pressure relief valves shall be closed.
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5) The compressed air shall be introduced into the tank to increase the air pressure to the test
pressure. The capacity and quantity of machinery shall be determined on site considering
availability and time schedule of pneumatic test.
● Pneumatic test pressure of TK-201, 202, and 203 = 214.7 mbarg (=2190 mmH₂O)
7) Safety exclusion zone shall be identified and clearly marked by installing warning signs.
8) During pressurization and tank internal pressure is greater than 75% of tank design pressure
(75% of 190 mbarg = 1454 mmH₂O), only authorized personnel and test crew are allowed to
enter within 30m of the tank.
9) The pneumatic test pressure shall be held for 1 hour before the inspection.
10) At the design pressure, all welding joints that have not been previously inspected, such as
joints between boot pipe and nozzle pipe, shall be inspected by applying leak detection
solution.
● Leak test pressure : 190 mbarg = 1938 mmH₂O (= tank design pressure)
11) The safety vent shall be provided for the pressure relief system during pneumatic test. The
block valves of PRVs shall be closed and all PRVs shall not be in operation.
8.3 OPERATION TEST OF PRESSURE RELIEF VALVE (PRV) AND VACUUM RELIEF
VALVE (VRV)
2) Each pressure relief valve shall be individually tested on the roof, successively after
pneumatic testing.
3) Prior to start of testing, the tank internal pressure shall be kept around 140 mbarg (=1428
mmH2O).
4) The block valve of the 1st pressure relief valve (1st PRV) shall be opened and the tank
internal pressure shall be increased.
5) The operating pressure and blow-down pressure shall be monitored with a manometer.
6) After confirmation of the 1st PRV, pressurizing shall be stopped and the block valve of 1 st
PRV shall be closed.
7) The remaining relief valves shall be individually checked in the same manner as 1 st PRV.
8) After testing for all PRVs, the tank internal pressure shall be reduced to the atmospheric
pressure.
9) And then, All the block valves of the pressure relief valves shall be kept to open.
2) Each vacuum relief valve shall be individually checked on the tank roof.
3) Prior to the operation test of VRV, the tank pressure shall be at the atmospheric pressure.
4) Just before the vacuum testing, all the opening except the manometer gauges, pressure
relief nozzle and air outlet nozzle shall be closed before vacuum test.
5) The block valve of 1st VRV shall be opened, and discharge air from the tank by using the
ejector with flow of compressed air.
6) During air discharging, the vacuum pressure of tank shall be monitored strictly with
manometer.
8) After confirmation of the 1 st VRV, depressurizing shall be stopped and the block valve of
1st VRV shall be closed.
9) The remaining vacuum relief valves shall be individually checked in the same manner as
1st VRV.
10) After testing of VRVs, all block valves of the vacuum relief valves shall be kept to open.
9.1 After Client’s acceptance for the tank hydrostatic test and settlement measurement, the test water
can be discharged.
9.1 The test water will be transferred to the next tank or to the disposal point (THI VAI river)
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9.2 During discharge the water, the tank inner side shall be cleaning.
9.3 Prior to disposal of test water, the sampling of test water shall be tested at the laboratory and shall
meet the Industrial Water Discharge Standard of Attachment-6. And, the test result shall be
submitted to Client for their review and approval (if required).
9.4 When start of disposal of test water, it shall be notified to APAVE to witness the disposal of waste
water.
10.1 During discharging the test water, the inner surface of the shell plate and internal piping
shall be washed by using the inflatable boat on the test water as water level goes down.
10.2 When tank is emptied, the surface of inner bottom plate, pump column and other internals
shall be cleaned by jet washing with fresh water (if required).
10.3 All debris and sludge on the inner tank bottom shall be removed.
10.4 After tank empty and drying, surface of inner tank bottom shall be cleaned by brush,
broom.
10.5 After tank cleaning, all welding seam of inner bottom plate shall be vaccum box test
again to conformed have no leak.
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12.1 HSE concerns, requirements, risk assessment, recommended equipment, access and other detail
instruction shall be reflected on the method statement that will be provided at site prior to starting
the hydrostatic test and the pneumatic test.
13.1 During the tank hydrostatic test, the inspection items in ITP No. 7.0 of Inspection and Test Plan
(Doc. No. HL-LNG-LI18-ITP-001) shall be performed.
14.0 ATTACHMENTS
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Attachment-1: Preparation Scheme for Hydrostatic test and pneumatic test (general)
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Attachment-2: Job Safety Analysis (JSA) (Hydrostatic test & pneumatic test )
JSA Number: JSA Title: Method statement for hydrostatic test & Supervisor: HO NGOC HUYEN
pneumatic test
System: Area: HAI LINH – CAI MEP Industrial zone Date: 30-May-2020
Step Activity/Step Potential Hazard Risk Control Measures Responsible
Person
1 Work Permit Check safety condition for the Prior to start the activity, safe work permit must be obtained. Supervisor
whole work area. Toolbox meeting shall be conducted prior to start the activity. Worker
HSE
2 Tank Cleaning Hands and fingers injuries Use hand protection or gloves Supervisor
Back Pain Remove all unnecessary materials. Proper housekeeping Forman
Tripping hazard Secure confined space entry permit. Provide fan or blower for proper Operator
Heat/ Oxygen deficiency ventilation HSE
Poor illumination Follow standard procedures for the rescue on an injured person inside
Personnel injuries the tank. Summon medical and trained employee in emergency
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