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01 / 11288-11306

01 July 2016
Standard Procedure Procedure No. : QP-06-03
HYDROSTATIC TEST Revision No. : 2

CONTENTS

SECTION TITLE

1.0 PURPOSE

2.0 RESPONSIBILITY

3.0 HYDROTEST PROCEDURE

APPENDIX-1 HYDROSTATIC TEST INSTRUCTION

APPENDIX-2 HYDROSTATIC TEST REPORT

APPENDIX-3 SETTLEMENT REPORT

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Standard Procedure Procedure No. : QP-06-03
HYDROSTATIC TEST Revision No. : 2

1.0 PURPOSE

This procedure applied to the hydrotest of the complete storage tank for
Synthetic Rubber Indonesia - U3 Project in accordance with the
requirements of the API 620 code upon completion of fabrication.

The procedure is applicable for field assembly.

Table of Hydrotest Equipment

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2.0 RESPONSIBILITY

2.1. The production Engineer is responsible for ensuring that hydro test
is conducted in accordance with relevant job instructions which
have been reviewed and accepted by the Client Inspector.

2.2. The QC Inspector shall issue completed “Hydrostatic test


Instruction” Sheets to Production Engineer / Foreman.
The instruction will include, as a minimum :

2.2.1. Job Number and Identification of the components or


assembly to be tested.
2.2.2. Test Media.
Before performing hydro test, water should be tested and
quality of water is indicated on the water quality test report.
2.2.3. Test Position & Holding Time

2.3. The QC Inspector shall be responsible for compilation of reports


and records for timely submission to the Client Inspector for his
review, approval and signature.

3.0 HYDRO TEST PROCEDURE

3.1 General
A Hydrostatic test shall be conducted on storage tank after :

3.1.1. All site erection have been completed, except for operation
which could not be performed prior to the test, such as weld
end preparation, cosmetic grinding on the base material
which does not attach the required thickness

3.1.2. All examination have been performed, except those


required after the test.

3.1.3 All trash, debris, grease, oil, weld scale, weld spatter, and
any other foreign material shall be removed from the
interior of the tank prior conducting hydro test.

3.2 Test Preliminaries


Before water is introduced into the tank, the preliminary operation
described below shall be performed :

3.2.1. The attachment welding around all opening and their


reinforcements in the walls of the tank shall be examined

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Standard Procedure Procedure No. : QP-06-03
HYDROSTATIC TEST Revision No. : 2

by the magnetic-particle method both inside and outside the


tank.

3.2.2. Air at pressure 15 psig shall be introduced between the tank


wall and reinforcing plate, saddle flange, or integral
reinforcing pad on each opening using telltale hole. While
each space is subject to the pressure, a solution film shall be
applied to the all attachment welding around the
reinforcement, both inside and outside the tank.

3.2.3. In cases in which the bottom of the tank rests directly on the
tank grade (preventing access to the underside of the
bottom of the tank), all joints between plate shall be tested
on the inside of the tank by applying a solution film to the
joints and pulling a partial vacuum at least 3 psig by means
of vacuum box with a transparent top. As an alternate to
vacuum box testing, a suitable tracer gas and compatible
detector can be used to test the integrity of welded bottom
joints for their entire length if an appropriate tracer gas
testing procedure has been reviewed and approved by the
Purchaser.

3.2.4. Tanks with anchors shall be grouted (if required by design)


and anchor retainers shall be attached.

3.2.5. After all the welding has been examined and tested and all
defective welding disclosed by such examination and
testing has been repaired and retested, the tank shall be
filled with air to a pressure of 2 psig or one-half the
pressure Pg for which the vapor space at the top of tank is
designed, whichever pressure is smaller. A solution film
shall be applied to all joint in the tank wall above the high
liquid (capacity) design level.

3.3 After the entire tank is completed but before any permanent
external piping is connected to the tank, the test shall be in
accordance with the following method

3.3.1 Tanks that have not been design to be filled with liquid to a
test level higher than their specified capacity level shall be
subjected to combination hydrostatic-pneumatic pressure
test.
3.3.2 The tank shall be filled with water to its high liquid
(capacity) design level with the top vented to the
atmosphere to prevent accumulation of pressure.

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3.4 The quality of water for hydro test of carbon steel material is using
potable water, while for duplex material shall conforms to the
following requirements:
- Water shall be substantially clean and clear.
- Water shall have no objectionable odor ( that is, no hydrogen
sulfide).
- Water pH shall be between 6 and 8.3.
- Water temperature shall below 50 °C ( 120 °F )
- The chloride content of test water shall below 50 ppm

3.5 The Observation of elevation shall be referred to a permanent


benchmark. Six sets of settlement for tank (axis Y) reading are
required :
a. Before start of the hydrostatic test.
b. During the tank has been filled to the maximum test height.
c. After tank has been emptied of test water.

3.6 Rate of Water Filling and Water Temperature.


The rate at which water is introduced into a tank for a hydrostatic
test shall not exceed 3 ft (914 mm) of depth per hour. The
foundation, venting equipment, or other conditions may limit the
water filling to a lower rate. The temperature of the water used in
the test should be not less than 60 0F (15.5 0C) whenever
practicable.

3.7 After the tank is filled with water, the vents at the top of the tank is
closed, air shall be injected slowly into the top of the tank until the
pressure in the vapor space is about one-half the design pressure,
for which this space is designed. The air pressure shall be increased
slowly until the pressure in the vapor space is 1.25 times the design
pressure.

3.8 Test Gauge.

a. An indicating gauge shall be connected directly to the topmost


part of the roof on the test under test. If the indicating gauge is
not readily visible to the operator who is controlling the pressure
applied, an additional indicating gauge shall be provide where it
will be visible to the operator throughout the test.
b. A recording gauge shall also be used on each tank, and record
shall be kept of the pressure during all stages of the test. This
gauge shall be connected either to the piping that leads to the
indicating gauge or directly to the tank at a point near the
indicating gauge connection.

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c. Indicating gauges used during the test shall be calibrated against


a Master Gauge or Dead Weight Tester. Certificate Calibration
of equipment shall be attached on Hydrostatic Test report.

d. If at any time during a test there is reason to believe that a gauge


is in error, its calibration shall be checked.

3.9 Holding Time

As the pressure is being increased, the tank shall be inspected for


signs of distress. The maximum test pressure of 1.25 times the
vapor space design pressure shall be held for at least one hour,
after which the pressure shall be released slowly and the blinds
shall be removed from the nozzle flanges.

3.10 Inspection of Welding Joints

While this pressure is held, a solution film shall be applied to all of


the welding involved above the high liquid (capacity) design level
for which the tank is designed. The solution film examination shall
still be made, above the liquid level, on all welds around openings,
all piping joints, and the compression ring welds to the roof and
shell.

3.11 Visual Inspection


Upon completion of hydrostatic test, the pressure in the tank shall
be released and a thorough visual inspection shall be made of both
the inside and outside of the tank, giving particular attention to all
internal ties, braces, trusses, and their attachments to the walls of
the tank.

3.12 Safety Precaution


An air test introduces some hazard. In view of the large amount of
air that will be present in the tank during this test, no one should be
permitted to go near the tank while pressure is being applied for the
first time during this test. While the pressure in the tank exceeds
the pressure for which the vapor space is designed, the inspections
should be made at a reasonable distance from the tank using field
glasses as required for close-up observation of particular areas.

APPENDIX-1
HYDROSTATIC TEST INSTRUCTION

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APPENDIX-1
HYDROSTATIC TEST REPORT

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APPENDIX - 3
SETTLEMENT REPORT

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