Method Statement of Hydrostatic Test

CONTRACT Nº UNIT Nº
STAR-C-01 000
CONTRACTOR DOC No.
2248-000-A-EE-xxx-560 SH/OF
STAR RAFİNERİ, A.Ş. STAR DOCUMENT No.
AEGEAN REFINERY PROJECT (ARP) 000-A-EE-xxx-560 1/28
SUBCONTRACTOR DOCUMENT No.
000-A-EE-xxx-560
REV 0
2248-2560 Field Erected Sphere Tanks
METHOD STATEMENT OF HYDROSTATIC TEST

Tag Nos.: 640TK-002A/B/C/D, 640 TK-001A/B, 630 TK-016, 630 TK-017
(MEGA Reference Doc. No: PR-MG-E-09)
0 24.04.2017 FIRST ISSUE MEGA U.I. S.Ç
PREPARED CHECKED APPROVED

REV. ISSUE DATE REASON FOR ISSUE
BY BY BY
STAR RAFİNERİ, A.Ş. CONTRACT Nº UNIT Nº
AEGEAN REFINERY PROJECT (ARP) STAR-C-01 000
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
METHOD STATEMENT OF STAR DOCUMENT No.
2/28
HYDROSTATIC TEST 000-A-EE-xxx-560
(By MEGA Reference Doc. No: PR-MG-E-09)
000-A-EE-xxx-560
REV 0
INDEX
1. PURPOSE................................................................................................................................................................................................ 3
2. SCOPE .................................................................................................................................................................................................... 3
3. DEFINITIONS........................................................................................................................................................................................... 3
4. REFERENCES ......................................................................................................................................................................................... 4
4.1. OWNER SPECIFICATION & PROCEDURES................................................................................................................................ 4
4.2. RELATED DOCUMENTS .............................................................................................................................................................. 4
5. RESPONSIBILITIES................................................................................................................................................................................. 5
6. EQUIPMENT LIST.................................................................................................................................................................................... 6
6.1. FOR HYDROSTATIC TEST APPLICATION .................................................................................................................................. 6
7. DESCRIPTION OF THE ACTIVITIES ....................................................................................................................................................... 7
7.1. GENERAL REQUIREMENTS ........................................................................................................................................................ 7
7.2. HYDROSTATIC TEST SETUP ...................................................................................................................................................... 8
7.3. PREPARATION OF HYDROSTATIC TEST ................................................................................................................................... 8
8. APPLICATION………………………………………………………………………………………………………. ................................................ 9
8.1. FILLING WATER ......................................................................................................................................................................... 10
8.2. PRESSURE APPLICATION ........................................................................................................................................................ 11
9. INSPECTION……………………………………………………………………………………………………………....................................... .16
10. RECORDS ........................................................................................................................................................................................... 17
11. ATTACHMENT
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
3/28
000-A-EE-xxx-560
REV 0
1. PURPOSE
The purpose of this method statement is to make sure that Hydrostatic pressure testing of Spherical Tanks
is done safely as per client requirement and applicable standarts.
 General Data of Spherical Tanks

IVT VITO TURKEY STAR REFINERY PROJECT - STORAGE TANKS ALIAGA.
Ref. TENDER Enq No. : IVT EPC/ALIAGA/MECHANICAL & PAINTING/001
Hydrostatic Test Mega A.S.
Seq. Height Hydrostatic
Capacity Design
ID From Test
ITEM No: Description Design Code Volume Pressure
mm Ground Pressure
m 3/Tank kg/cm 2
mm kg/cm 2
1 640TK-001 A Unsaturated LPG Storage Tank ASME SEC.VIII DIV.2 951 12.200 2.972 15 21,73
2 640TK-001 B Unsaturated LPG Storage Tank ASME SEC.VIII DIV.2 951 12.200 2.972 15 21,73
3 640TK-002 A Saturated LPG Storage Tank ASME SEC.VIII DIV.2 4.252 20.100 2.955 15 21,75
4 640TK-002 B Saturated LPG Storage Tank ASME SEC.VIII DIV.2 4.252 20.100 2.955 15 21,75
5 640TK-002 C Saturated LPG Storage Tank ASME SEC.VIII DIV.2 4.252 20.100 2.955 15 21,75
6 640TK-002 D Saturated LPG Storage Tank ASME SEC.VIII DIV.2 4.252 20.100 2.955 15 21,75
7 630TK-016 Unsaturated LPG Intermediate Tank ASME SEC.VIII DIV.2 905 12.000 2.972 15 21,83
8 630TK-017 Saturated LPG Intermediate Tank ASME SEC.VIII DIV.2 2.572 17.000 2.962 15 21,59
2. SCOPE
This Method Statement covers the Hydrostatic Testing of Spherical Tanks at the project and to be
followed for all related works at site.
3. DEFINITIONS
Project: AEGEAN REFINERY PROJECT (ARP)
Owner: STAR RAFINERİ A.Ş.
Contractor: TSGI MÜHENDİSLİK İNŞAAT LTD. ŞTİ.
Sub-Contractor: IOT-VITO MÜHENDİSLİK İNŞAAT VE TAAHHÜT A.Ş.
Lower-Tier Sub-contr.: MEGA GENEL END. MÜH. HİZ. VE SAN. UR. TİC. A.Ş.
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
4/28
000-A-EE-xxx-560
REV 0
4. REFERENCES
The following reference documents have been utilized in preparing this method statement and shall be
referred to additional technical information as necessary.
 ASME Sec. VIII, Div.2 - Ed. 2013
 ASME QCM
 PED 97/23 EC
 ASME Sec. IX – Ed. 2013
 630/640-D-EE-V10200TK016/017/001A-B/002A-B-C-D-525601-1001
4.1 CONTRACTOR / OWNER SPECIFICATIONS AND PROCEDURES
 IOT HSSE Initial Setup (IOT/CORP/HSSE/GDN/IHSSES-00)
 Unfired Pressure Vessel General Project Design Specification (STGPS C/D1)
 STGPS – A14
 STGPS C/D1
 GS-IOT-CN-100001-G2560-SPHERE
 PURCHASER’S SPECIFICATIONS & DRAWINGS
 Emergency Response Plan – By Contractor (000-A-EE-0190305)
 Waste Management Plan – By Contractor (000-A-EE-0190007)
 Spill Contingency Plan – By Contractor (000-A-EE-0190008)

CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
5/28
000-A-EE-xxx-560
REV 0
4.2 REFERENCE DOCUMENTS
 Site Quality Control Plan for Sphere Erection – By Sub-Contractor (000-A-EE-0191401,

000-A-EE-0191402, 000-A-EE-0191403, 000-A-EE-0191404, 000-A-EE-0191405, 000-A-
EE-0191406, 000-A-EE-0191407, 000-A-EE-0191408)
 Weld Book including WPS & PQR (000-A-EE-0241401, 000-A-EE-0241402, 000-A-EE-

0241403, 000-A-EE-0241404)
 Welder Performance Qualification Test (000-A-EE-0241022-Rev.0)
 Procedure for Qualification of MT, PT, and VT Personnel (000-A-EE-0191410)
 Magnetic Particle Test (MT) Procedure (000-A-EE-0191413)
 Visual Examination Procedure (000-A-EE-0191415)
 Repair Welding Control Procedure (000-A-EE-0191416)
 Hydro test Procedure (000-A-EE-0191422)
 HSE Plan (000-A-EE-0190001)
 Construction Environmental Control Plan (CEC) (000-A-EE-0190306)
 Traffic Management Plan (000-A-EE-0190004)
 Emergency Response Plan (000-A-EE-0190002)
 Lifting Plan
 Water Management Plan
 Wind Protection Plan
5. RESPONSIBILITIES
- IOT-VITO and MEGA has the responsibility for implementing and ensuring this method statement.
- IOT-VITO and MEGA shall determine the Hydrostatic Test requirements, based on projects
specifications and other reference documents.
- IOT-VITO and MEGA shall be responsible for initiating Hydrostatic Test operations in accordance
with the specifications.
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
6/28
000-A-EE-xxx-560
REV 0
6. EQUIPMENT LIST
6.1 FOR HYDROSTATIC TEST APPLICATION
- PWHT Application System (Test fluid-water, pump, calibrated pressure gauges)
- CS pipes of Main Header, flanges, plugs, gaskets
- Valves and pipes for connection with gauges and the pump, safety valves
- Time recorder, Laser-thermomater, Nivo
- Scaffolding Materials
- Lifting Equipment & Lifting Plan
- Manlifts
- Mobile Cranes (Telescopic)
- Safety Personnel Protection Materials, safety tapes, warning signs etc.
- Welding Machines
- Electrode Dryer Oven
- Consumables
- Grinding/Drilling Machines
- Hand Tools
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
7/28
000-A-EE-xxx-560
REV 0
7. DESCRIPTION OF THE ACTIVITIES
7.1 GENERAL REQUIREMENTS
- Hydrostatic Test that are to be performed by the raw material suppliers shall be specified in the
Procurement Specifications by the Project Manager.
- Hydrostatic Test should be performed after completion of all welding and hot works on the
pressure parts.
- Safety rules and regulations in Hydrostatic Test shall be strictly obeyed during operations.
- Safety distance will be at least 15m away from the sphere heated surface during Hydrostatic Test
operation.
This area will be covered by safety tape.
- In order to prevent any accidental damage by vehicles during Hydrostatic Test, suitable warnings
such as safety tapes through the test fluid pipes will be provided at site.
- Site Supervisor shall prepare the Hydrostatic Test Instructions and Procurement Requisition
Specifications in accordance with the project & code specification. These instructions and
specifications shall be reviewed and signed by the Site Manager for their completeness and usage.
- Hydrostatic Test shall not be performed in rainy/wet weather conditions.

- The Hydrostatic Test will be carried out as specified in ASME SEC.VIII DIV2 Part 8.2 as min-
max. test pressures rates, test fluid and metal temperatures.
- Hydrostatic Test operations shall be done by subcontractor in accordance with “MEGA”

procedures and using calibrated equipments.
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
8/28
000-A-EE-xxx-560
REV 0
7.2 HYDROSTATIC TEST SETUP

CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
9/28
000-A-EE-xxx-560
REV 0
Dia
No Equipments Brand/Model Qty Unıt Remarks
DN
1 4" Gate Valve(Flanged) - 100 5 Pcs.
2 6" Gate Valve(Flanged) - 150 1 Pcs.
3 4" Quick Coupling - 100 2 Pcs.
1/2'' Ball Valve(Npt
4 - 15 2 Pcs. THD Cl.3000
Thd)
5 4" Flex Hose - 100 30 Mt.
40 Bar Cl1, MNPT
6 Manometer - 15 3 Pcs.
CON.
7 Test Pump - - 1 Pcs.
NOTES
1 All valves that subject to hydrostatic test pressure shall be min PN40
2 All gaskets shall be 3mm klingrit type.
- Hydrant line(Main Header) can be seen as colored yellow below. 4’’ sketch 40 CS pipes will be used in
order to bring test fluid to the speheres area.
- Pipe connection will be welded by the qualified welders according to codes & specifications at site.
- Internal visual inspections will be done for pipe joints at site.
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
10/28
000-A-EE-xxx-560
REV 0
- Pipe to tank connections will be done by flanges and suitable gaskets, rest of opennings on the tank will
be closed by blind flanges or plugs except 4’’ level transmittal nozzle(CN1) due to provide air ventiling.
7.3 PREPARATION OF HYDROSTATIC TEST
- Prior to hydrostatic testing, it shall be confirmed that all specified nondestructive examinations of welds
and inspection have been completed with applicable codes and standards. It shall be inspected that clips’
and supports’ internal and external welding is completed as per latest approved drawing prior to
commencement of hydrostatic test. During Hydrotest, accessibility for all the joints will be provided for
inspector.
- Prior to hydrostatic tests; PWHT process shall be already completed for related tanks. (640TK-002
A.B.C.D tanks are subject to PWHT process)
- Interior of the tank shall be cleaned.
- Prior to test, QC Inspector shall check the equipment and device which will be used as follows:
 The capacity of hydrostatic pump and range of pressure gauges,

 The calibration label attached to the pressure test gauges to assure that the pressure test gauges
have been calibrated at least once in every six (6) months and within the calibration due date or if
any time there is reason to believe that they are in error.
 The dial indication pressure gage(s) to be used in testing, they should preferably have the dial(s)
graduated over a range of about double the intended maximum pressure. But the range shall not be
less than 1.5 nor more than 4 (four) times the test pressure.
 The valves and pipe for connection with gauges and the pump.
- Before the tank is filled with test water, the points for settlement measurement shall be marked on a tank
column and the level at measurement points shall be recorded.
- Two pressure gauge shall be installed at the top of the tank and two pressure gauge shall be installed at
the bottom of tank.
- Hydrostatic test continuous recording time and pressure graph shall be provided throughout the testing
cycle.
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
11/28
000-A-EE-xxx-560
REV 0
- Before test water is filled to the tank, all openings (manholes, nozzles, and fittings) shall be closed and
sealed very well by blind flanges and plugs. Only one or two openings at the top of the tank shall be kept
open for air venting until the tank is filled completely with water.
- For the safety, the tank shall be bound with ropes and warning sign during the test.
- Hydrostatic tests shall be carried out using the type of gaskets which be used in service.
- Test fluid-water with a chloride content of greater than 250 ppm shall not be used for hydrostatic test
as specified by STGPS C/D1.
- The metal temperature during a hydrostatic test shall be maintained at least 17°C (30°F) above the
minimum design metal temperature of the vessel, but need not exceed 50°C (120°F), to minimize the
risk of brittle fracture.
8. APPLICATION
8.1 FILLING WATER
- Top level transmittal nozzle will be left open at the high point of the tank, where it will be possible to
purge the air while the tank is being filled.
- Fill sphere ¼ with water；Wait at least 2 hours; Check column base elevation.
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
12/28
000-A-EE-xxx-560
REV 0
- Fill sphere ½ with water；Wait at least 6 hours; Check column base elevation.
- Turn buckles of sway rods shall be tightening by torqueing at least 7406 N.m as per project during that
period.
- Fill sphere¾ with water；Wait at least 2 hours; Check column base elevation.
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
13/28
000-A-EE-xxx-560
REV 0
- Fill sphere full with water；Wait at least 2 hours; Check column base elevation.
- Check of each columns base elevation will be taken from the top of the anchor as seen below at each
stage by the survey.
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
14/28
000-A-EE-xxx-560
REV 0
8.2 PRESSURE APPLICATION
- The test pressure shall not be applied until the vessel and the test fluid are at about the same temperature.
Temperature records will be taken by calibrated laser-thermometer frequently.
- Hydrostatic pressure shall be gradually increased until the test pressure is reached. When the test
pressure is reached, the valve on the pump is to be shut off.
- The hydrostatic test pressure of a completed vessel shall not exceed that values which are resulted below.
--------------------------------------------------------------------------------------------------------------------------------------
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
15/28
000-A-EE-xxx-560
REV 0
--------------------------------------------------------------------------------------------------------------------------------------
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
16/28
000-A-EE-xxx-560
REV 0
- The pressure shall then be reduced to a value not less than the test pressure divided by 1.43 before
examining for leakage.
- Hydrostatic test pressure shall be held for a minimum of one hour per 25mm of shell thickness and in no
case less than one hour.
 640TK-002A/B/C/D -------------------------- 108 min.
 630TK-017 ------------------------------------- 92 min.
 630TK-016 & 640TK-001A/B ------------- 68 min.
- Following the reduction of the test pressure to the level indicated in above, a visual examination for
leakage shall be made by the inspector of all joints and connections and of all regions of high stress such
as knuckle of formed heads, cone to cylinder junctions, regions around openings and thickness transitions.
- Any leaks that are present, except for that leakage that may ocur at temporary test closures for those
openings intended for welded connections, shall be corrected and the vessel shall be retested.
- Repairs will be carried on according to ‘’Assigned WPSs’’. After repair, shall be retested by Magnetic or
Liquid Penetrant Test according to related Codes&Specs.
- After completion of the hydrostatic test, vents and drains shall be opened to remove all water from the
tank. And the emptying rate shall be so adjusted to avoid any vacuum.
- There will be a safety valve on the bottom nozzle of the tank in order to interfere in any case of
overpressure during Hydrostatic Test.
- Hydrostatic test shall be carried out in presence of Owner/PMC , Contractor, AI and NOBO.
- After complete draining of the test water, final readings of the foundation settlements shall be made.
- Each readings of the support cloumns on the planar tilt of foundation by the time of before&during, filling
water and after drilling of the test water shall not be greater than 15mm.
9. INSPECTION
- MEGA & IOT-VITO QC inspector shall be responsible for inspection of all attributes defined in this
section.
- Joints have been properly prepared in accordance with this method statement.
- IOT-VITO & MEGA QC Inspector shall also review the information of the Hydrostatic test graphs,
holding times and settlement readings. If the all information is correct, he shall sign and date the
Hydrostatic Test Report.
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
17/28
000-A-EE-xxx-560
REV 0
- Reinforcing pads of manhole & nozzles shall be pneumatically(bubble leakage test) tested at a minimum
pressure of 0.6 kg/cm² prior to hydrostatic test. (No need to perform bubble leakage test again, if the
manufacturer has already performed it before at shop). After hydrostatic test complition, spin holes of
R.F.Pads will be closed with grease oil.
- Upon completion of the Hydrostatic Test operation, IOT-VITO & MEGA QC Inspector shall verify that
all temporary attachments have been removed.
- In process monitoring of all Hydrostatic Test operations shall be performed by IOT-VITO & MEGA QC
Inspector.
- After hydrostatic testing has been satisfactorily completed, the vessel shall be re-checked by inspectors
for out-of-roundness and for bow.
- After completion of Hydrostatic Test operation, IOT-VITO & MEGA QC Inspector shall submit the all
Hydrostatic Test reports and documents for monitoring and approval.
10. RECORDS
- Hydrostatic test equipments shall be provided with valid calibration and test certificates.
- Base elevation readings shall be recorded for each column of the tank as in before-during-after
hydrostatic test operation.
- The Hydrostatic Test Operator shall indicate the description of elevation read parts, the job no, date of
hydrostatic test, min-max test fluid temperature, water fill rates, holding times, test pressure at the
top&bottom of vessel, pressure holding time and test position.
- QC Personnel shall record the results of hydrostatic test using the Pressure Test Report which shall be
reviewed and approved by the Site Manager. This report shall be presented to Client for his review and
acceptance.
- If the result of the test is acceptable; QC Personnel, Site Manager, NoBo and the Client representative
shall sign and date the Pressure Test Report and QCP.
11. ATTACHMENT
- JSA
- Valve certificates, Pump certificates (will be attached when they are provided)
- Calibration docs. (will be attached when they are provided)
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
18/28
000-A-EE-xxx-560
REV 0
Doc. No : JSA IOT-VITO/MEGA

Hydrostatic Test
Job Safety Analysis Worksheet Rev. No :
Rev. Date: -
Date of Issue: 21.04.2017
JSA for Hydrostatic test of Spherical tanks (including night shift) /

Activity/Aktivite:
Küre Tankların hidrostatik testi (Gece çalışması dahil)
STEPS/Adımlar Who or
Control Measures What will Responsibl

Remark
Hazards/ Risk to be enforced / be e party /
s/
Category/Ris Affected /
N Description of task / Tehlikeler Uygulanacak Açıklam Sorumlu
k Kategorisi Etkilenece
o Yapılacak işin tanımı kontrol Önlemleri a Parti
k kişi ya
da nesne
 Obtain a cold work

permit and other
associated permits
from TSGI facility
operators.
 All workers to be
briefed with a pre-
work briefing using
the method
statement before
hydrostatic testing.
 All workers to use
appropriate PPE at
 Not following HSE
site.
MS procedures
 Barricade the area
 Unauthorized Related Responsible
1 Planning where operation is to
personnel.
be carried out. personnel supervisor
 Defective
 Warning sign of line
tools/equipment
under pressure will
be provide at suitable
location.
 Ensure the
equipment/tool to be
used for hydro-test
(such as hose,
pump, coupling,
pressure gauge,
spade, gasket) are
free from defect,
color coded and
suitable for the
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
19/28
000-A-EE-xxx-560
REV 0
pressure rating of the

system
 Before the lifting, the
pipe line will be
checked for leakage.
 All hydrant points of
the fire water line will
be blinded.
 Safety distance will
be at least 10 mt
away from the
sphere surface
during Hydrostatic
Test operation. This
area will be covered
by safety tape.
 In order to prevent
any accidental
damage by vehicles
during Hydrostatic
Test, suitable
warnings such as
safety tapes through
the test fluid pipes
will be provided at
site.
 Gerekli iş izinleri
alınmış olmalı
 Hidro teste
başlamadan önce
tüm çalışanlar işin
metodu ile ilgili
bilgilendirilmeli
 Yapılan işe uygun
kişisel koruyucu
donanımlar
kullanılmalı
 Hidro testin yapıldığı
Planlama alan barikatla
çevrilmeli
 Uygun yerlere uyarı
 İSG ve MS
işaretleri konulmalı
Prosedürelerini takip
etmeme  Kullanılacak olan İlgili Sorumlu
1 ekipmanların çalışır
 Yetkisiz personel
durumda, renk kodlu Personel süpervizör
 Hasarlı ekipman
ve hasarsız olması
kullanımı
gerekli
 Tüm yangın suyu
muslukları körlenmiş
olmalı
 Hidrostatik Test
işlemi sırasında
emniyet mesafesi
küre yüzeyinden en
az 10 mt uzakta
olacaktır. Bu alan
emniyet şeridi ile
erişime
kapatılacaktır.
 Su besleme hatları
araç kazalarına karşı
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
20/28
000-A-EE-xxx-560
REV 0
uygun emniyet
bantları ve işaretlerle
işaretlenmelidir.
 The water filling

height shall be
closely monitored by
followed by an
Execution Engineer.
 Exceeding maximum  The maximum
Hydrostatic test allowable pressure. pressure must be 22
bar. The test will be
stopped
 Injury to workers.  Ensure the pressure
relieving device is set
at maximum
allowable pressure
 Damage to for weakest portion
equipment/system. of the segment.
 Do not leave the Related Responsible
2 pressurized hose or personnel supervisor
pump unattended
 Un-attended when the filling water
equipment/system. is going on.
 Isolate the
equipment from all
source of energy
when not in use.
 Do not any change
(exceed/decrease)
without permission
from the inspection
engineer.
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
21/28
000-A-EE-xxx-560
REV 0
 Doldurulan su
yüksekliği Saha
Mühendisi tarafından
takip edilmeli ve
yönetilmeli
 Maksimum basınç
değeri 22 bar olmalı
ve 22 barı aştığı
anda sistem
durdurulacak
 Basınç düşürme
 Kabul edilebilir mekanizmasının
maksimum basıncı bölümün en zayıf
aşma parçası için kabul
 Çalışanların edilen max basınça
İlgili Sorumlu
2 Tankların Hidrotesti yaralanması kurulu olduğundan
 Ekipman sisteminin emin olunmalı Personel süpervizör
zarar görmesi  Operasyon devam
 Gözetimsiz ediyorken basınçlı
ekipman/sistem hortum ve pompa
gözetimsiz
bırakılmamalı
 Kullanımda değilken
tüm ekipmanlar
enerjiden alınmalı
 Operasyon sırasında
sorumlu
mühendisten izin
almadan sistemde
değişiklik
yapılmamalı
 Ensure sufficient
illumination in place
prior to commence
the activity.
 Insufficient  TBT and Pre-Task Personnel
illumination meeting will be
involve in
Hydrostatic Test Works  Using dark safety conducted and
glasses workers will be the night Supervisor
3 during night shift  Insufficient H briefed regarding
shift Engineer
activity illumination on night shift hazards
access / egress  Ensure clear safety activity /
 Poor supervision glasses are provided
operation
 Ensure all access /
egress areas are
illuminated
sufficiently
 İşleme başlamadan
önce yeterli
aydınlatmanın
 Yetersiz aydınlatma olduğundan emin
 Karanlık Ortamda olunmalıdır.
Aktivitede
Gece Çalışması koyu iş gözlüğü  TBT ve iş öncesi
kullanımı toplantısı yapılmalı yer alan Süpervizör
3 Sırasında Hidrostatik  Giriş ve çıkışların H ve çalışanlar gece
personel /
Test İşleri yetersiz çalışmalarının Mühendis
aydınlatılması tehlikeleri hakkında operasyon
 Zayıf yönetim bilgilendirilmelidir.
 Açık renk koruyucu
gözlük kullanılmalıdır
 Tüm giriş çıkış yerleri
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
22/28
000-A-EE-xxx-560
REV 0
yeterli şekilde
aydınlatılmalıdır.
 Ensure proper wind

up and
housekeeping at site.
Related Responsible
4 Housekeeping  Slip,Trip,Falls
 The accessories personnel supervisor
(hose and pump) not
being used must be
disconnected and
stored separately
 Rüzgar hızının
uygunluğunun ve
çalışma alanının
düzenli olduğından
emin olunmalı
 Kayma İlgili Sorumlu
4 Tertip Düzen  Kullanılmayan
,takılma,düşme
aksesuarların Personel süpervizör
bağlantısı kesilmeli
ve ayrı ayrı
saklanmalı( hortum
ve pompa)
 Only competent and
experienced workers
shall be engaged in
the operation
 Ensure to lift loads
exceeding 25 Kg with
mechanical tools &
equipment.
 Pinch point, jamming  Workers to maintain
correct body posture
 Ergonomic hazard
while doing manual
 Slips & trips Personnel
handling
Material Handling  Obstruction to  Prefer mechanical involve in Supervisor
5 person and vehicle M handling, wherever it
(Manual/Mechanical) access the activity Engineer
is practicable.
 Mechanical Failure
 Team lifting to be / operation
during operating the
carried out under
Forklift/cranes
direction of
supervisor.
 Ensure all equipment
are certified &
inspected and
operators having
valid licence &
competence
certificate
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
23/28
000-A-EE-xxx-560
REV 0
 Sadece yetkin ve
deneyimli işçiler
çalışmalı
 25 Kg ı aşan yükler
için mekanik araçlar
veya ekipmanlar
 Sıkışma noktası, kullanılmalı
sıkışma  Elle taşımalarda
 Ergonomik tehlike çalışanlar doğru Aktivitede
 Kayma ve tökezleme vücut duruşunu
Malzeme Taşıma yer alan Süpervizör
5  Araç ve çalışanların korumalı.
(Elle/Makine İle) hareketlerinin  Pratik olduğu sürece personel / Mühendis
kısıtlanması her taşıma için
operasyon
 Operasyon sırasında mekanik taşıma
mekanik arızalar tercih edilmeli.
 Takım kaldırma işleri
süpervizör tarafından
yönetilmeli.
 Tüm ekipmanlar
geçerli sertifikalara
sahip olmalı.
 Adequate fire fighting
equipment shall be
deployed at work
location
 Necessary permits to
be obtained prior to
start activity
 TBT to be conducted
prior to start the
activity
 Cylinder to be stored
in trolley in vertical
position with chains
to secure, and cover
on top to protect from
 Fire and explosion direct sunlight
 Faulty machinery  Fire extinguisher to
and tools kept in the vicinity
Personnel
Hot Work  Electrical hazards  Full and empty
 Contact with hot cylinders to be stored involve in Supervisor
6 (welding/cutting/grindin surfaces H separately
the activity Engineer
g)  Struck by flying  Flashback arrestor to
particles / sparks be provided on both / operation
 Back fire due to the ends; one on the
spark during cutting cylinder side and
other on the cutting
torch end
 Welding machine,
cables must be in
good condition and
must be grounded
 All tools must be
current color coded
 Safety guard not to
be removed for
grinding, and must
check the dead man
switch condition
before using the
grinding machine
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
24/28
000-A-EE-xxx-560
REV 0
 RPM of grinding
Wheel must be
greater than the
machine
 Supervisor to brief
workers regarding
hazards and
prevention methods
prior to start
 Proper PPEs shall be
provided to all
workmen and must
be worn at all the
time including
additional PPEs like
face shield etc.
 Must be fire watcher
at hot working area
 Fire blanket must be
use
 All flammable
material should be
removed from
working area
 Welding tent materail
should be
unflammable and
retardent
 İş başı konuşması
yapılmalı
 İşe başlamadan önce
çalışma alanı yanıcı
maddelerden
arındırılmalı
 Yangın söndürme
tüpü ve yangın
battaniyesi çalışma
yerinde
bulundurulmalı.
 Yangın ve patlama  Yangın çadırları
 Hatalı makine ve sertifikalı ve alev
aletler yürümez özellikte
 Elektrik tehlikeleri olmalı Aktivitede
Sıcak Çalışma  Sıcak yüzeylerle  Yetkililer
yer alan Süpervizör
6 (kaynak/kesme/taşlama temas bilgilendirilmeli ve işe
 Savrulan partiküller / bağlamadan önce personel / Mühendis
) kıvılcım gerekli izinler
operasyon
 Kesim esnasında alınmalı.
kıvılcım nedeniyle  Tüpler direk güneş
yangın ışınlarından
korunaklı ve zincirle
bağlanmış
arabalarda
bulundurulmalıdır.
 Yangın söndürme
cihazı aktivite
yerinde bulunmalı
 Dolu ve boş tüpler
ayrı muhafaza
edilmeli
 Alev geri tepiciler
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
25/28
000-A-EE-xxx-560
REV 0
kullanılmalı
 Kaynak makinesinin
kabloları iyi durumda
olmalı
 Tüm araçlarda
geçerli renk kodu
olmalı.
 Süpervizör,
çalışanları tehlikeler
ve korunma
yöntemleri
konusunda
bilgilendirmeli
 Uygun kişisel
koruyucu donanım
tüm çalışanlara temin
edilmeli ve çalışma
alanında sürekli
kullanılması
sağlanmalı
 Sıcak çalışma
yapılan bölgede
yangın gözcüsü
bulunmalı
 Ensure %100 tie off
to a firm anchorage
at all times while
working at height
 All openings on
roof/primary wind
girder/stairway are to
be barricaded or
temporarily closed
using scaffold pipes
or close opening
using any
appropriate method
suitably
 All open edges are to
 Personnel / material be hard barricaded
fall from height and warning signage Personnel
 Improper working to be displayed to
involve in Supervisor
7 Working at height platform alert workers
 Working at height  Temporary working the activity Engineer
without fall platform to be
/ operation
protection checked and verified
for safe to use, not to
store any material on
the temporary
platform to avoid
overloading
 All workers to be
brified on the safe
work practices for
working at height
 Safety harness to be
inspected
periodically, and to
return to supervisor if
found any damages
 Three point contact
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
26/28
000-A-EE-xxx-560
REV 0
to be maintained
while climbing the
loader
 Work at height
training must be
provided for related
personnel
 All hand tools must
be tied while working
at height
 Yüksekte çalışırken
her zaman bir
noktaya emniyet
kemerleriyle bağlantı
olmalıdır.
 Tamamı açık
çatı/merdiven gibi
alanlarda çalışma
sırasında alan geçici
olarak uygun bir
yöntemle
barikatlanmalı.
 Tüm yüksekte
bulunan çalışma
alanları / geçiş
alanları
barikatlanmalı ve
uygun uyarı levhaları
kullanılmalı.
 Geçici çalışma
platformlarının aşırı
 Çalışanın / yüklenmesini
malzemenin önlemek için
yüksekten düşmesi herhangi bir Aktivitede
 Yanlış çalışma malzeme
yer alan Süpervizör
7 Yüksekte Çalışma platformu depolanmamalı.
 Düşmeden koruma  Tüm çalışanlar personel / Mühendis
ekipmanları yüksekte çalışmadan
operasyon
olmaksızın yüksekte önce yüksekte
çalışmak. güvenli çalışmayla
ilgili bilgilendirilmeli /
eğitilmeli.
 Yüksekte Çalışma
Eğitimi alınmadan
yüksekte çalışma
yapılmamalı.
 İskeleler, korkuluklar,
platformlar periyodik
olarak denetlenmeli
ve tehlikeli durumlar
iskele süpervizörüne
bildirilmeli.
 Tırmanma sırasında
üç nokta temas
kuralına uyulmal
 Yüksekte yapılan
çalışmalarda
kullanılan tüm el
aletleri düşme riskine
karşı sabitlenmiş
olmalı
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
27/28
000-A-EE-xxx-560
REV 0
 All personnel should

be trained for
emergency situations
 Muster points should
be ready end
directional sign
 Supervisor /
Engineer will be
informed immediately
 Workforce will be
briefed regarding
emergency situation
during daily toolbox
Related Responsible
8 Emergency situations  Any Injury talks
 TSGI Ambulance: personnel supervisor
0549 352 40 20
 MEGA End. HSE
Dep : 0555 495 41
28
 MEGA End. Site
Engineer : 0534 650
5809
 IOT-VITO HSE Dep :
0535 104 00 53
 • IOT-VITO Site
Engineer : 0535 104
00 43
 Tüm çalışanların acil
durum halinde
yapılacaklar ile ilgili
bilgilendirilmesi ve
toplanma alanlarının
belirlenmesi
 Süpervizör ya da
sorumlu mühendis
hemen
bilgilendirilmeli
 Yapılan günlük iş
başı konuşmalarında
acil durumlara karşı
N/A Süpervizör
 Tüm Yaralanmalar bilgi verilmeli
8 Acil Durumlar N/A
 TSGI Ambulans : Mühendis
0549 352 40 20
 MEGA End. HSE
Birimi : 0555 495 41
28
 MEGA End. Saha
Mühendisi : 0534
650 5809
 IOT-VITO HSE Birimi
: 0535 104 00 53
 IOT-VITO Saha
Mühendisi : 0535
104 00 43
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF
28/28
000-A-EE-xxx-560
REV 0
Assessment By / Değerlendirmeyi Yapan Reviewed by TSGI Construction Team / Reviewed by TSGI HSE Team / İnceleyen
İnceleyen TSGI Insaat ekibi TSGI HSE Ekibi

Method Statement of Hydrostatic Test

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Method Statement of Hydrostatic Test

Загружено:

Авторское право:

Доступные форматы

CONTRACT Nº UNIT Nº

2248-2560 Field Erected Sphere Tanks

METHOD STATEMENT OF HYDROSTATIC TEST

0 24.04.2017 FIRST ISSUE MEGA U.I. S.Ç

PREPARED CHECKED APPROVED

CONTRACTOR DOC No.

4.1. OWNER SPECIFICATION & PROCEDURES................................................................................................................................ 4

4.2. RELATED DOCUMENTS .............................................................................................................................................................. 4

6.1. FOR HYDROSTATIC TEST APPLICATION .................................................................................................................................. 6

7. DESCRIPTION OF THE ACTIVITIES ....................................................................................................................................................... 7

7.1. GENERAL REQUIREMENTS ........................................................................................................................................................ 7

7.2. HYDROSTATIC TEST SETUP ...................................................................................................................................................... 8

7.3. PREPARATION OF HYDROSTATIC TEST ................................................................................................................................... 8

8.1. FILLING WATER ......................................................................................................................................................................... 10

8.2. PRESSURE APPLICATION ........................................................................................................................................................ 11

10. RECORDS ........................................................................................................................................................................................... 17

CONTRACTOR DOC No.

 General Data of Spherical Tanks

followed for all related works at site.

Project: AEGEAN REFINERY PROJECT (ARP)

Owner: STAR RAFINERİ A.Ş.

Contractor: TSGI MÜHENDİSLİK İNŞAAT LTD. ŞTİ.

Sub-Contractor: IOT-VITO MÜHENDİSLİK İNŞAAT VE TAAHHÜT A.Ş.

CONTRACTOR DOC No.

referred to additional technical information as necessary.

 ASME Sec. VIII, Div.2 - Ed. 2013

 ASME Sec. IX – Ed. 2013

4.1 CONTRACTOR / OWNER SPECIFICATIONS AND PROCEDURES

 IOT HSSE Initial Setup (IOT/CORP/HSSE/GDN/IHSSES-00)

 Unfired Pressure Vessel General Project Design Specification (STGPS C/D1)

 PURCHASER’S SPECIFICATIONS & DRAWINGS

 Emergency Response Plan – By Contractor (000-A-EE-0190305)

 Waste Management Plan – By Contractor (000-A-EE-0190007)

 Spill Contingency Plan – By Contractor (000-A-EE-0190008)

CONTRACTOR DOC No.

4.2 REFERENCE DOCUMENTS

 Site Quality Control Plan for Sphere Erection – By Sub-Contractor (000-A-EE-0191401,

 Weld Book including WPS & PQR (000-A-EE-0241401, 000-A-EE-0241402, 000-A-EE-

 Welder Performance Qualification Test (000-A-EE-0241022-Rev.0)

 Procedure for Qualification of MT, PT, and VT Personnel (000-A-EE-0191410)

 Magnetic Particle Test (MT) Procedure (000-A-EE-0191413)

 Visual Examination Procedure (000-A-EE-0191415)

 Repair Welding Control Procedure (000-A-EE-0191416)

 Hydro test Procedure (000-A-EE-0191422)

 HSE Plan (000-A-EE-0190001)

 Construction Environmental Control Plan (CEC) (000-A-EE-0190306)

 Traffic Management Plan (000-A-EE-0190004)

 Emergency Response Plan (000-A-EE-0190002)

 Water Management Plan

 Wind Protection Plan

CONTRACTOR DOC No.

6.1 FOR HYDROSTATIC TEST APPLICATION

- PWHT Application System (Test fluid-water, pump, calibrated pressure gauges)

- CS pipes of Main Header, flanges, plugs, gaskets

- Time recorder, Laser-thermomater, Nivo

- Lifting Equipment & Lifting Plan

- Mobile Cranes (Telescopic)

- Safety Personnel Protection Materials, safety tapes, warning signs etc.

- Electrode Dryer Oven

CONTRACTOR DOC No.

7. DESCRIPTION OF THE ACTIVITIES

7.1 GENERAL REQUIREMENTS

This area will be covered by safety tape.