Hydrostatic Testing
Procedure
DOCUMENT NO.: AZ/HT/JF-788
REV. No.: 0
NO. OF PAGES: 07
CONTRACT NO: TBA
AL ZAMIL JOB NO: JF/JS-788
PROJECT NAME: KHURAIS AL CRUDE INCRIMENT-300 MBCD,
KHURAIS, K.S.A
CLIENT: AL FANAR CONSTRUCTION(AFC)
COMPANY: SAUDI ARABIAN OIL COMPANY
AL-ZAMIL METAL WORKS FACTORY
P.O. BOX 13168, JEDDAH CITY 21493
KINGDOM OF SAUDI ARABIA
TEL. 02-638-0766, FAX 02-638-0768
HYDROSTATIC TESTING PROCEDURE
Name and signature to be provided (No
initial)
0 05/11/2016 Issued for approval M.A.R M.D M.S.I
REV DATE DESCRIPTION PREPD CHKD APPD
REVISIONS
DOCUMENT / DRAWING NO. TOTAL NO. OF SHEETS
(INCLUDING COVER)
AZ/HT/JF-788
7
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HYDROSTATIC TESTING PROCEDURE
INDEX
1. SCOPE
2. PURPOSE
3. RESPONSIBILITY
4. REFERENCE DOCUMENTS
5. TEST PROCEDURE
6. TEST MEDIUM
7. FILLING OF TEST MEDIUM
8. RATE OF WATER FILLING AND WATER TEMPERATURE
9. SAFETY PRECAUTIONS
10. INSPECTION
11.SETTLEMENT TEST
12. HOLDING TIME
13. DRAINING
14.REPAIRS OF WELDS
15.RECORDS
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HYDROSTATIC TESTING PROCEDURE
1. SCOPE:
This document gives requirements for Hydrostatic Testing intended to use for site erected
storage tanks for KHURAIS AL CRUDE INCRIMENT-300 MBCD, KHURAIS, K.S.A
2. PURPOSE:
The purpose of this procedure is to ensure that water fill testing of site erected storage tanks
are conducted in a manner which is based on sound engineering practice and generally
satisfies the requirements of reference documents.
3. RESPONSIBILITY
3.1 The Site Manager/Production Manager or his designee shall be responsible for
preparation & performance of the hydrostatic test.
3.2 Assigned QA/QC Engineer shall be responsible for monitoring the test, inspection after
pressurization and recording the test results.
4. REFERENCES:
• API-650 (2013 )
Add Para for • SAES-A-007 (Hydrostatic testing fluid and Lay-up Testing)
equipment to be • SAES-A-004 (General Requirements for Pressure Testing)
used for
hydrotest • 32- SAMSS-005 Edition 2013 (Manufacture of Atmospheric Tanks)
Add as reference : SAEP-327 ,SAES-W-017,SAES-A-005,GI.002-102
5. TEST PROCEDURE
5.1 This hydrostatic test procedure shall be conducted before permanent external piping
is connected to the tank.
5.2 After completion of the final closure weld seam and immediately prior to hydrostatic test,
the inside of the tank shall be thoroughly cleaned by sweeping or other methods so that
the tank will be free of all trash, dirt, welding rods-tubs, and other construction debris.
5.3 Prior to start of the test, assigned QA/QC Engineer shall verify that all fabrication &
NDE activities are completed and each tank is identified with the correct manufacturing
serial number / work order number. This verification shall be accomplished by reviewing
the ITP (Inspection & Test Plan) to ensure that the applicable fabrication / inspection
checks have been recorded and signed off and that non-conformance if any has its
corrective action / disposition verified and signed off.
5.4 All openings except test medium inlet and vent shall be closed using proper blinds, lugs,
caps or other suitable means.
5.5 A local level indicator will be installed to determine the water level during the hydro test
for Site erected Tanks.
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HYDROSTATIC TESTING PROCEDURE
5.6 Supports used for the item to be hydro-tested shall be proper to ensure a safe &
acceptable test. In order to inspect all welded joints, no support shall be placed on or over
any welded joint, as far as possible.
6. TEST MEDIUM
Provide Water quality details as per SAES-A-007 and
Potable water shall be used. API650
7. FILLING OF TEST MEDIUM FOR SITE ERECTED TANKS
7.1 Tank shall be filled with water by any suitable low pressure filling lines, while venting
through the vent on the upper most nozzle. The capacity of the filling pump shall be
controlled to maintain adequate venting to avoid air pocket entrapments.
7.2 Temperature of filling water shall be below 50 0C
7.3 Water shall be filled up-to maximum design liquid level (as per the Drawing).
7.4 Unless otherwise specified on the approved drawing, holding time shall be at least 24
hours. Add exposure time deatails as per SAES-A-007 / API650
8. RATE OF WATER FILLING AND WATER TEMPERATURE
8.1 The rate at which water is introduced into a tank for water fill test shall not exceed the
following for Site erected Tanks.
Bottom Course Thickness Tank Portion Filling Rate
Less than 22 mm - Top course - 300mm/hour
- Below top course - 450mm/hour
22 mm and thicker - Top third of tank - 230mm/hour
- Middle third of tank - 300mm/hour
-Bottom of third tank - 460mm/hour
8.2 The temperature of the tank during hydro-testing shall not be colder than the design
metal temperature.
9. SAFETY PRECAUTIONS
Prior to testing,the site officer shall ensure that all safety measures /instruction warnings are inplace and strictly implemented as per GI.002-102
9.1 Signs shall be displayed at roped off areas indicating that hydro-test is under progress.
Only authorized persons shall be allowed within the test area during testing.
9.2 All authorized personnel allowed within the test area shall stay clear off the nozzle
during pressurization.
Add this line
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HYDROSTATIC TESTING PROCEDURE
10. INSPECTION
10.1 Inspection for leakage, bulging or other visible defects shall be made on the whole body
of the tank. Close examination shall be carried out on all weld joints and connections.
10.2 The above inspection shall be performed by the assigned QA/QC Engineer.
11. SETTLEMENT TEST (Applicable to Site Erected Tanks)
11.1 Shell elevation measurements shall be made at equally-spaced intervals around the tank
circumference not exceeding 10 m (32 ft). The minimum number of shell measurement
points shall be eight (8).
Observed elevations shall be referred to a permanent benchmark. The level instrument
shall be set up at least1 1/2 times tank diameter away from the tank when tank elevation
readings are taken. Settlement readings are required at six stages of the hydro test as
follows:
1) Before start of the hydrostatic test (empty tank);
2) With tank filled to 1/4 test height (±600 mm [2 ft]);
3) With tank filled to 1/2 test height (±600 mm [2 ft]);
4) With tank filled to 3/4 test height (±600 mm [2 ft]);
5) At least 24 hours after the tank has been filled to the maximum test height.
6) After tank has been emptied of test water.
Internal bottom elevation measurements shall be made before and after hydrostatic
testing. Measurements shall be made at maximum intervals of 3 m (10 ft) measured on
diametrical lines across the tank. The diametrical lines shall be spaced at equal angles,
with a maximum separation measured at the tank circumference of
10 m (32 ft).A minimum of four diametrical lines shall be used.
11.2 Settlement tolerances
If settlement measurements are specified by the client, any differential settlement greater
than 13 mm per 10 m (1/2 in. per 32 ft) of circumference or a uniform settlement over 50
mm (2 in.) shall be reported to the client for evaluation. Filling of the tank shall be
stopped until cleared by the client.
12. HOLDING TIME
For Site Erected Tanks the hydro test water shall be hold for a period of 24 hours this
period may be increased to duration specified on the data sheet if the client requires so.
For Shop Built Tanks minimum 1 hour shall be holding time at the pressure mentioned
on approved Drawing.
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HYDROSTATIC TESTING PROCEDURE
13. DRAINAGE
13.1 After completion of the hydrostatic test, water will be drained through outlet or inlet
nozzles.in accordance with SAEP-327. Add
13.2 After completion of the hydrostatic test, the item shall be dried suitable means
13.3 The direct welding of tank attachments (non-pressure parts) with pressure parts is
permitted only if allowed by the API 650
Provide water disposal point
14. REPAIR & RETEST
14.1 If during inspection leaks, cracks or any other defects are observed, the same shall be
repaired using approved welding procedure(s) and qualified welders.
14.2 Successful repair, tank shall be re-tested as per this procedure.
15. RECORDS
Engineer QA/QC shall record the results of hydrostatic test on the Test Report. This report
shall be signed by Engineer QA/QC and Client’s Representative.
Attach test report form
Attache Tank settlement report form
