650-680

Title: API 650 Hydrostatic Test Exemptions

Date: 1-11-2010 (revised 7-3-2012); revised (4-24-13)
Contact: Name: David Clark
Company: Kinder Morgan
Phone: 708-990-0553
E-mail: [email protected]
Purpose: Highlights to the Purchaser and Fabricator, factors to consider before making a decision not to
hydrotest an API 650 tank following fabrication if water is not available.
Source: Started as an e-mail from Bhana Mistry relating to questions about hydrostatic test exemptions in
API 650 and how they are applied or interpreted.

Revision: 4
Impact: This change, highlights to the Purchaser and Fabricator, the issue of not conducting a hydrotest
if water is not available and the conditions to consider prior to making that decision.
Background: Started as an e-mail from Bhana Mistry relating to questions about hydrostatic test exemptions in
API 650 and how they are applied or interpreted.

At the spring 2012 meeting, Doug Miller commissioned Dave Clark, Steve Caruthers, John Lieb
and Rick Ruff to determine requirements and submit a new draft. First section 7.3.5 was broken
down into outline format, and then additional requirements were determined.
Current
wording: Excerpt from Section 7.3

Excerpt from appendix L checklist

Proposal: 7.3.5 Testing of the Shell
 
After the entire tank and roof structure is completed, the shell (except for the shell of tanks designed in
accordance with Appendix F) shall be strength- tested and the foundation initially loaded by one of the
following methods, as specified on the Data Sheet, Line 14:
 
1.        If water is available for testing the shell
 
1.1.      the tank shall be filled with water as follows:
 
a.    fill to the maximum design liquid level, H; or
 
b.    for a tank with a gas liquid - tight roof, fill to 50 mm (2 in.) above the weld connecting the
roof plate or compression bar to the top angle or shell; or
 
c.   fill to a level lower than that specified in Subitem 1 or 2 7.3.5.1.1.a or 7.3.5.1.1.b when
restricted by overflows, an internal floating roof, or other freeboard by agreement between
the Purchaser and the Manufacturer, or
 
d.  fill  to a level of seawater producing a bottom of shell hoop stress in the first shell course
equal to that produced by a full-height fresh water test.
 
1.2.      The tank shall be inspected frequently during the filling operation. , and Any welded joints
above the test-water level shall be examined after the test is complete in accordance with Item
2 7.3.5.2.1 below. This test The tank hydrostatic test shall be conducted before permanent
external piping is connected to the tank and before any welds are painted. Attachments to the
shell defined in 5.8.1.1, located at least 1 m (3 ft) above the water level, and roof appurtenances
may be welded during the filling of the tank. After completion of the hydro-test, only non-
structural small attachments may be welded to the tank in accordance with 7.2.1.11.
 
2.        If sufficient water to fill the tank is not available
 
2.1.      the tank may be tested shall be examined by one of the following:
 
a.    coating painting all of the joints on the inside with applying highly penetrating oil, such as
automobile spring oil, to all of the joints on the inside and carefully examining the outside
of the joints for leakage prior to; or
 
b.    applying vacuum to either side of the joints or applying internal air pressure as specified for
the roof test in 7.3.7 and carefully visually examining the joints for leakage; or
 
c.    Using any combination of the methods stipulated in 7.3.5.2.1.a or 7.3.5.2.1.b.Subitems 1 and
2.
 
2.2.    Additional requirements shall include all of the following:
                   
          a. The design for the tank shell shall be based on 1.1 times the specific gravity of the stored
product or 1.0, whichever is greater. The design basis for the storage tank shall be the
greater of the specific gravity of the product intended for normal operation or 1.0,
including tank shell thickness and foundation design considerations.
 
          b. All tank shell weld intersections shall be radiographed, regardless of thickness.
 
c. Upon completion of these requirements, the first filling of the tank shall be conducted
according to section 7.3.6 as if it were a hydrostatic test, including appropriate
personnel and fire safety precautions, and in accordance with all provisions of 7.3.5.1.1
and 7.3.5.1.2, except that the tank need not be filled above the maximum operating
level.    
 d. All radiography or other NDE and any welding above the hydrostatic test level shall
be completed prior to testing with product.
 
7.3.6 Hydrostatic Testing Requirements
 
7.3.6.1 This The tank hydrostatic test of the tank shall be conducted before permanent external piping is
connected to the tank except for piping that is necessary to fill and empty the tank, which should have
a flexible component to allow for settling. Attachments to the shell defined in 5.8.1.1, located at least 1
m (3 ft) above the water level, and roof appurtenances may be welded during the filling of the tank. After
completion of the hydro-test, only non-structural small attachments may be welded to the tank in
accordance with 7.2.1.11. Any welded joints above the test-water level shall be examined for leakage by
one of the following methods:
 
1. coating all of the joints on the inside with a highly penetrating oil, such as automobile spring oil, and
carefully examining the outside of the joints for leakage;
 
2. applying vacuum to either side of the joints or applying internal air pressure as specified for the roof test
in 7.3.7 and carefully examining the joints for leakage; or
 
3. using any combination of the methods stipulated in Subitems 1 and 2.

----EXCERPT FROM APPENDIX L CHECKLIST----

13. Foundation: Furnished by*_________________________________________ Type* ________________________________

Soil Allow. Bearing Pressure* ________ Per Spec.* _________________________________ Anchors: Size* _____ Qty* _____
Foundation Design Loads: Base Shear Force: Wind* _____ Seismic* _____ Overturning Moment: Wind* ______ Seismic* _____
Ring Forces: Weight of Shell + Roof New* _______ Corroded* _______ Roof Live Load* _______ Internal Pressure* _______
Partial Vacuum* ________ Wind* ________ Seismic* ________ Hydrotest Exemption per 7.3.5.2.2 _______
Bottom Forces: Floor Wt. New* ______ Corroded* ______ Product Wt.* ______ Water Wt.* _____ Internal Pressure* ______
Partial Vacuum* _________ Other Foundation Loads* ____________________ Min. Projection of Fdn. Above Grade: ________
Rationale: In the present language of API 650, 7.3.5 Testing of the Shell (650, Eleventh Edition, June
2007, Addendum 2, November 2009), there are no requirements to evaluate the shell and
foundation design, toughness requirements, and NDE requirements when hydrostatic testing is
not performed. A poll of the members of the Design and Fabrication Subcommittees was taken
regarding this issue. The majority of the respondents were in favor of increasing certain
requirements; however a consensus could not be established. During the Fall 2010 Standards
meeting in Nashville, the SCAST Fabrication Subgroup agreed to the proposed language
addition highlighted in Red Italics. This change highlights the issues deemed important to
responding members of the previous poll taken.