Fitness for Service Evaluation of Hydrotest Exemption

According to API 653

Hydrostatic Testing – Why?

• To prevent risk of brittle fracture in service

• To prevent product leaks

• To check tank settlement

• Shows the tank is suitable for continued service

Brittle Fracture

• Dependent on
• Material toughness
• Temperature
• Stress level
• Crack like defect

Brittle
• Examples
• Fawley storage tank, UK in 1952 Fracture
• Pittsburgh storage tank, USA in 1988
Crack-like defect
Fawley storage tank, UK in 1952

• 42 m diameter

• During hydrostatic test

• Fracture tougness lowered after welding

Pittsburgh storage tank, USA in 1988

• Tank was moved

• Reassembled with no inspection

• 14000 m3 Diesel oil spilled

• 3000 m3 into the river

Major Alteration or Major Repair

• Nozzle in shell larger than NPS 12

• Replace or add shell plate exceeding 12 in.

• Remove or replace annular plate material

• Replacement of more than 12 in. vertical weld

Major Alteration or Major Repair

• Replacement of more than 12 in. of

radial weld in annular plate

• Installation of new bottom

• Replacement of shell to bottom weld

• Jacking a tank shell

Hydrostatic Test Exemption
Engineer Approval and Owner Authorization
12.3.2.2

Appropriate Following Parts Fitness for Service Evaluation

12.3.2.1.a 12.3.2.1.b/12.3.2.7

Shell Repair Hydrotest Exemption

12.3.2.3

Bottom Repair within Critical Zone

12.3.2.4

Shell-to-bottom Weld Repair

12.3.2.5

Minor Shell Jacking

12.3.2.6

Hydrotest Exemption
12.3.2.7 Fitness for Service Evaluation

Mechanical
Finite Element Modelling
Stress Analysis
Engineering Critical Assessment

Fitness for Service

Materials Inspection
Tank Dimensions
WPQR/WPS
Filling Height
Weld Specimens Old-to-new
Design Temperature
Fracture Toughness (Charpy V)
Thickness Measurements
Material Properties Test
NDT Weld Acceptance Limit
NDT Acceptance Limit

• Undercut acc. to ISO 5817

• Quality level D, C or B

• D) h ≤ 0.2t, but max. 1 mm

• C) h ≤ 0.1t, but max. 0.5 mm

• B) h ≤ 0.05t, but max. 0.5 mm

Weld Specimens

• Piece of existing tank material

• Piece of new tank material

• Welded with new WPS/WPQR

Charpy V Specimens

• Charpy V Specimens for estimating Impact energy (and fracture toughness)

• Tensile tests may be needed to verify mechanical properties

Charpy Specimen Locations

• Sets of three Charpy V specimens

• Weld metal
• HAZ,
• +2 mm from HAZ
• +5 mm from HAZ
Obtain Charpy Impact strength
Obtain Kmat Fracture Toughness from Charpy Tests
Finite Element Model

• Finite element model is based on

• Tank dimensions
• Inspection reports
• Filling height

• Stress analysis
• Determine membrane and bending
stresses
Tank Deformation

• Tank bottom lifts from the ground

• Scale x50
Stress Analysis

• Axial Stress

• High stress at weld toe to shell

• Primarily bending stresses

Examples of FE Models
Engineering Critical Assessment

• Stress level from FE analysis

• Fracture toughness from material test

• Partial safety factors

• Determine critical flaw size

Failure Assessment Diagram
Critical Flaw Size
Fitness for Service Evaluation

• Compare critical flaw size with NDT acceptance limits

If critical flaw size is larger than NDT acceptance limit,

hydrostatic test is not required
Further information at forcetechnology.com