WATER STORAGE TANK

Project Name : ICAD II Fluorine and Chlor-Alkali Chemical Plant

Contract Ref. : JTLI/FCACP/CCESCC/A/038
Document Title : HYDROSTATIC TESTING PROCEDURE
Document No. : AM/QC/159/216
Revision No. : A1
Sheet No. : Page 1 of 16

HYDROSTATIC TESTING PROCEDURE

FIELD ERECTED TANKS
(AM/QC/159/216 REV.0)

A1 26.07.2022 Issued For Review and Approval SV SV SV

 WATER STORAGE TANK
Project Name : ICAD II Fluorine and Chlor-Alkali Chemical Plant
Contract Ref. : JTLI/FCACP/CCESCC/A/038
Document Title : HYDROSTATIC TESTING PROCEDURE
Document No. : AM/QC/159/216
Revision No. : A1
Sheet No. : Page 2 of 16

Rev. Date Description Prepared Checked Approved

REVISION HISTORY

Rev. Date of Issue Status Change Change Summary Validation

Issue Section
 WATER STORAGE TANK
Project Name : ICAD II Fluorine and Chlor-Alkali Chemical Plant
Contract Ref. : JTLI/FCACP/CCESCC/A/038
Document Title : HYDROSTATIC TESTING PROCEDURE
Document No. : AM/QC/159/216
Revision No. : A1
Sheet No. : Page 3 of 16

Contents
1.0 REVISION HISTORY…………………………………………………………..4
2.0 PURPOSE……………………………………………………………………….5
3.0 SCOPE…………………………………………………………………………..5
4.0 DEFINITIONS&ABBREVIATIONS……………………………………………5
5.0 REFERENCES………………………………………………………………….5
6.0 RESPONSIBILITIES……………………………………………………………5
6.1 GENERAL …………………………………………………………………..5
6.2 HYDRO TEST MONITERING TEAM:……………………………………6
6.3 QC INSPECTOR RESPONSIBILITY:-…………………………………..7
6.4 QA-QC ENGINEER RESPONSIBILITY…………………………………7
7.0 HYDRO TEST PROCEDURE………………………………………………...8
7.1 PREPARATION OF THE TANK FOR HYDRO TESTING…………….8
7.2 PREPARATION OF WATER PUMPING ARRANGEMENT:………….9
7.3 GENERAL PREPARATIONS:……………………………………………9
7.4 QUALITY OF HT WATER:…………………………………………….....10
7.5 WATER FILLING PROCEDURE AND SETTLEMENT DURATION…10
7.6 MEASUREMENT OF SETTLEMENTS DURING HT………………….11
8 ACCEPTANCE CRITERIA:……………………………………………...…...16
9 SAFETY:………………………………………………………………………..16
 WATER STORAGE TANK
Project Name : ICAD II Fluorine and Chlor-Alkali Chemical Plant
Contract Ref. : JTLI/FCACP/CCESCC/A/038
Document Title : HYDROSTATIC TESTING PROCEDURE
Document No. : AM/QC/159/216
Revision No. : A1
Sheet No. : Page 4 of 16

1.0 REVISION HISTORY

Revision Date Section / Pages Revised Reason for Revision

A0 14/07/2022 - First Issue

 WATER STORAGE TANK
Project Name : ICAD II Fluorine and Chlor-Alkali Chemical Plant
Contract Ref. : JTLI/FCACP/CCESCC/A/038
Document Title : HYDROSTATIC TESTING PROCEDURE
Document No. : AM/QC/159/216
Revision No. : A1
Sheet No. : Page 5 of 16

2.0 PURPOSE
2.1 The purpose of this procedure is to outline the requirements of hydrostatic testing in
full compliance to project specifications; as per API-650 standard requirements.

3.0 SCOPE
3.1 This procedure is applicable for hydrostatic of above mentioned Field Erected Tanks
as per project specifications (as mentioned above)and Construction standard(API-
650)

4.0 DEFINITIONS & ABBREVIATIONS:

4.1 HT: Hydrostatic test
4.2 ITP: Inspection & Test Plan
4.3 NDT: Non-destructive Test
4.4 QA/QC: Quality Assurance & Quality Control
4.5 WPS: Welding Procedure Specification
4.6 MR: Material Requisition
4.7 Specs: Specifications

5.0 REFERENCES:
5.1 API Std. 650 12th Edition Welded steel tanks for Oil Storage Tanks (clause 7.3.6)

6.0 RESPONSIBILITIES:
6.1 General
6.1.1 This procedure shall be revised by QA/QC Engineer whenever there is a need of
change to suit the job as per requirements, and he shall be responsible for seeking
approval.
6.1.2 SUB-CONTRACTOR Project Manager shall be responsible for the proper execution of
this procedure and to ensure that the works are undertaken in a safe manner as
described in this Method Statement, to the requisite quality in accordance with
relevant quality procedure and to the agreed timescale.
 WATER STORAGE TANK
Project Name : ICAD II Fluorine and Chlor-Alkali Chemical Plant
Contract Ref. : JTLI/FCACP/CCESCC/A/038
Document Title : HYDROSTATIC TESTING PROCEDURE
Document No. : AM/QC/159/216
Revision No. : A1
Sheet No. : Page 6 of 16

6.1.3 SUB-CONTRACTOR Construction Manager is responsible for overall site

management, ensuring that all execution activities are executed according to
drawing & project specification, quality and safety requirements.
6.1.4 SUB-CONTRACTOR Supervisor / Foreman shall be monitoring the works carried out
and is responsible for ensuring the right personnel will perform the job. He organizes
the manpower under him and ensures all necessary equipment and materials are
ready prior to work.
6.1.5 CONTRACTOR / SUB-CONTRACTOR Safety officer is to advise that all safety
regulations are observed and followed to avoid the occurrence of injuries or any
other form of accident that will cause loss of life, damage to properties.
6.1.6 SUB-CONTRACTOR to make sure all personnel are equipped with standard PPE, hard
hat, eye protection, flame retardant coverall, toxic clip etc.
6.1.7 SUB-CONTRACTOR Construction Lead shall liaise and take instructions regarding
safety and security from CONTRACTOR Supervisors and Safety at all times.
6.1.8 SUB-CONTRACTOR will provide suitably qualified and experienced personnel such as
Discipline Leads to oversee the works. Ensuring that all work is carried out in
accordance with this procedure and they will not deviate in any way from the
original Method Statement without prior approval.
6.1.9 SUB-CONTRACTOR Safety Officer and Supervisors will be present as required to
oversee the Health, Safety and Environment Procedures and ensure that all activities
as required by the job Safety Analysis are implemented and monitored.
6.1.10 All works to shall be carried out under company/contractor supervision.

6.2 Hydro test Monitering team:

6.2.1 A Supervisor shall be nominated for all tank hydrostatic testing. The Test Supervisor
is responsible for planning and supervising the hydrostatic test.
6.2.2 Preparation of tanks for hydrostatic testing, including the fitting of appropriate
gaskets, blind flanges. Ensuring adequate venting during filling & draining operations.
6.2.3 Ensuring that all required inspection has been completed prior to hydrostatic testing.
6.2.4 Ensuring the removal of all trash, debris, grease, oil, weld scale, weld spatter etc.
6.2.5 Ensuring the Filling and emptying rate are as per procedure.
6.2.6 Ensuring Cleaning & drying of the tank bottom after hydro test.
 WATER STORAGE TANK
Project Name : ICAD II Fluorine and Chlor-Alkali Chemical Plant
Contract Ref. : JTLI/FCACP/CCESCC/A/038
Document Title : HYDROSTATIC TESTING PROCEDURE
Document No. : AM/QC/159/216
Revision No. : A1
Sheet No. : Page 7 of 16

6.3 QC Inspector responsibility:-

6.3.1 To confirm required bench marks are transferred to tank shell.

6.3.2 To confirm tank internal bottom plate elevation measurements are recorded prior to
water filling.
6.3.3 Preparation of all related inspection test reports and check list Coordinate with
company or contractor during stage wise tank foundation settlement inspection.
6.3.4 To confirm all stage wise tanks settlements are recorded & verified by company or
contractor.
6.3.5 To confirm all required vents are open in roof during water filling/draining.
6.3.6 Testing Personnel shall perform all testing:-

 All shell nozzles shall be blinded off.

 All roof nozzle shall be kept open for ventilation
 To check height & rate of water filling.
 To check any leakage in each stage.
 Foundation settlement Check in each stage.
 Test documentation.

6.4 QA-QC Engineer RESPONSABILITY:

6.4.1 Punch list shall be prepared to ensure the mechanical completion of the tank
construction including clearance of all NDT requirements to the subject tank for
getting prepared for Hydro test.
6.4.2 Radiography test completion including repairs.
6.4.3 All tests like chalk-diesel test, LPT, RF Pad pneumatic test, vacuum box test
completion.
6.4.4 Finally mechanical clearance from company and contractor shall be taken before
Hydrotest in approved format.
6.4.5 To ensure all the documents related to hydro testing are available and recorded
during hydro test.
 WATER STORAGE TANK
Project Name : ICAD II Fluorine and Chlor-Alkali Chemical Plant
Contract Ref. : JTLI/FCACP/CCESCC/A/038
Document Title : HYDROSTATIC TESTING PROCEDURE
Document No. : AM/QC/159/216
Revision No. : A1
Sheet No. : Page 8 of 16

7.0 HYDRO TEST PROCEDURE

7.1 PREPARATION OF THE TANK FOR HYDRO TESTING

7.1.1 All mechanical work with respect to permanent welded attachments to the tank shall
be completed including respective NDT clearance.
7.1.2 Prior to hydro test, the inside of the tank bottom shall be cleaned by sweeping,
vacuuming, or other methods so that the tank will be broom clean and free of all
trash, dirt, welding rod stubs and other construction debris.
7.1.3 No instrumentation will be hooked up while testing will take place including PRV’s,
all roof nozzle shall be kept open during Hydrotest.
7.1.4 Hydrostatic Test shall be completed before the application of the painting.
7.1.5 Any power cables, wire ropes, scaffolding pipe attached, suspended or tied to the
tank shall be removed.
7.1.6 Area around the subject tank shall clear of any machines and construction materials
etc. and barricaded to avoid unauthorized entry. Necessary caution boards shall be
displayed all around the tank.
7.1.7 All other nozzle, man holes in the shell shall be closed with temporary blind flanges.
7.1.8 Tank box up shall be checked to ascertain that no material and personnel are left
inside the tank before closing-the last Manhole.
7.1.9 All roof nozzles shall be kept open for adequate venting during filling and dewatering
to ensure.
7.1.10 Adequate number of settlement markers shall be provided all around the tank shell
outside, 500mm from the tank bottom to check the tank settlement.
7.1.11 Transparent PVC, flexible tube shall be connected to any one nozzle of the bottom
shell with an isolation valve and this tube shall be laid along the spiral stairway up to
the curb angle to indicate the tank water level during the HT.
7.1.12 Tank height shall be marked on the shell surface all along the stairway in every
500mm intervals to check & monitor the water levels during filling and dewatering.
 WATER STORAGE TANK
Project Name : ICAD II Fluorine and Chlor-Alkali Chemical Plant
Contract Ref. : JTLI/FCACP/CCESCC/A/038
Document Title : HYDROSTATIC TESTING PROCEDURE
Document No. : AM/QC/159/216
Revision No. : A1
Sheet No. : Page 9 of 16

7.1.13 The hydro test shall be conducted before connecting any permanent utility / external
piping to tank.

7.2 PREPARATION OF WATER PUMPING ARRANGEMENT:

7.2.1 Necessary location of pumps and filling Tanks to be located where there is no
hindrance to access the tanks in Testing.
7.2.2 A diagram shall be sketch where hoses are attached to the filling Tank and the Tank
to be tested.
7.2.3 Adequate capacity of pumps, fittings, pipes, hoses, valves, NRVs, etc shall be selected
to ensure the completion of HT in stipulated time.
7.2.4 Adequate measures shall be taken to avoid spillage, overflow and dry run of the
pumps.
7.2.5 If diesel operated pump used, all consumables like diesel, filters, lube oil and seals
etc. shall be kept in stock.

7.3 General preparations:

7.3.1 A clear communication shall be made to all the concerned disciplines prior to the
tank HT well in advance.
7.3.2 Tank foundations shall jointly be inspected along with company or contractor
representative for any abnormalities prior to water filling.
7.3.3 No excavation, piling, or compaction activities shall be permitted to the closed
proximity of the tank which is under HT till the completion of filling.
7.3.4 A permanent bench mark (reference level) shall be confirmed 1.5 times tank
diameter far away from the subject tank foundation and all the subsequent
settlement readings of the tank shall be compared with this “reference level”.
7.3.5 A level reading' instrument with support staff shall be made available all the time to
record the settlement readings.
 WATER STORAGE TANK
Project Name : ICAD II Fluorine and Chlor-Alkali Chemical Plant
Contract Ref. : JTLI/FCACP/CCESCC/A/038
Document Title : HYDROSTATIC TESTING PROCEDURE
Document No. : AM/QC/159/216
Revision No. : A1
Sheet No. : Page 10 of 16

7.3.6 A settlement observation register shall be prepared and kept ready prior to water
filling to record any settlement of tank foundation during filling and holding period.
7.3.7 Two or more tanks shall not be filled simultaneously with one pumping operation.
Tanks will be prepared for HT in such a way that one tank of water can be
transferred to the next tank.
7.3.8 However, when one tank is being filled with water, the tank to tank transfer
between other two tanks shall be continued. Also, during the
equilibrium/settlement/monitoring time of one particular tank filling of other tank
shall be continued with same pumping arrangement by switching tank inlet valves.

7.4 Quality of HT water:

7.4.1 The test media shall be potable water, which is clean and free of silt supplied by
Contractor.
7.4.2 Sample water shall be taken from source of water and testing shall be carried out
for chloride concentration by contractor. After obtain approval from of company the
same shall be submitted to sub-contractor to proceed Hydrotest.

7.5 WATER FILLING PROCEDURE AND SETTLEMENT DURATION

7.5.1 Before the start of water filling Inside and Outside Tank shall be cleaned.
7.5.2 Filling of water height, flow rate & holding period shall be followed as per Table-1,
Table-2, Table-3, and Table-4 for respective tanks.
7.5.3 After completion of each stage filling, the settlement reading shall to taken, and the
same shall be recorded along with company or contractor QA/QC personal.
7.5.4 At the hold points filling and emptying of water shall be stopped and settlement
readings shall be taken at the beginning and end of the hold points.
 WATER STORAGE TANK
Project Name : ICAD II Fluorine and Chlor-Alkali Chemical Plant
Contract Ref. : JTLI/FCACP/CCESCC/A/038
Document Title : HYDROSTATIC TESTING PROCEDURE
Document No. : AM/QC/159/216
Revision No. : A1
Sheet No. : Page 11 of 16

7.5.5 If at any stage of filling a questionable amount of rate settlement does occur, further
filling of the tank shall be stopped and corrective measures shall be decided in
consultation with Company/contractor.
7.5.6 Filling of water in tank shall be performed and monitored by nominated personnel
only 24 Hours/day.
7.5.7 At the end of water filling, for the remaining hours in the day's total of 24 ,the
foundation shall be allowed to equilibrate and consolidate, and shall be monitored
by Hydro testing Supervisor/Engineer.
7.5.8 HT water shall be filled 50mm above the Curb Angle to ensure leak testing of Curb
Angle to Roof Plate circumferential joint.

7.6 MEASUREMENT OF SETTLEMENTS DURING HT

7.6.1 Measurement of the tank bottom and tank shell settlement shall be monitored
continuously throughout the HT.
7.6.2 Shell elevation measurements shall be made at equally-spaced intervals around the
tank circumference not exceeding 10 m.
7.6.3 The elevation for settlement marker shall be 500 mm from bottom of annular plate
to top side of top side of marker.
7.6.4 Observed elevations shall be referred to a permanent benchmark (ref Clause 7.3.6 of
API 650) Seven sets of settlement readings shall be taken as follows:
7.6.5 Settlement reading shall be taken as per below stages:-

 Before start of the hydrostatic test (Empty tank reading shall be taken)
 Each stage of water filled as per table:1,table:2,table:3,table:4.
 100%H water Filled (after completion of filling)
 100% H After completion of holding period (Just before draining is begun)
 After tank has been emptied of test water.
 WATER STORAGE TANK
Project Name : ICAD II Fluorine and Chlor-Alkali Chemical Plant
Contract Ref. : JTLI/FCACP/CCESCC/A/038
Document Title : HYDROSTATIC TESTING PROCEDURE
Document No. : AM/QC/159/216
Revision No. : A1
Sheet No. : Page 12 of 16

7.6.6 For all each sets of reading shell be taken as per above steps and average value shall
be calculated as per below formula.

[Link] in each stage = Sum of all reading/ Total number of reading taken.

7.6.7 Based on above average value the graph may drawn for average settlement in each
stage and submit to Company and contractor review approval

Example:

Each Stage [Link]

0% / Ref: 500
Stage-01 495
Stage-02 490
Stage-03 480
Stage-04 480
100% 479
100% 475
0% 475

7.6.8 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
company/contractor for evaluation.
7.6.9 Uneven settlement of the tank on its foundation shall be reported immediately to
the company /contractor representative.
7.6.10 Filling of the tank shall be stopped until cleared by the company or contractor.
 WATER STORAGE TANK
Project Name : ICAD II Fluorine and Chlor-Alkali Chemical Plant
Contract Ref. : JTLI/FCACP/CCESCC/A/038
Document Title : HYDROSTATIC TESTING PROCEDURE
Document No. : AM/QC/159/216
Revision No. : A1
Sheet No. : Page 13 of 16

7.6.11 If filling stopped due to large settlements, a record of such settlements shall be
plotted on each stage of filling scale to show the rate of settlement, the same shall
be submitted to company or contractor for evaluation.
7.6.12 Once the tank has been de-watered the tank bottom internal elevation
measurements shall be taken as described below:
7.6.13 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.
7.6.14 Initial settlement reading and after Hydrotest completion reading shall be compared
as per below formula for settlement of bottom in each point.
Tank bottom settlement = Initial reading –Final reading

7.7 HYDRO TEST TEMPERATURE REQUIREMENTS

7.7.1 During pressure testing, the material temperature of equipment being tested shall
be at least 6˚C above the minimum design metal temperature (MDMT) of the test
equipment to minimize the risk of brittle fracture during testing. However the test
temperature need not exceed 50˚C.
7.7.2 The above temperature shall be checked by thermometer before water filling of the
tank in each stage by QC personal.

7.8 INSPECTION
7.8.1 After completion of filling in each stage the visual examination of the weld seam
shall be carried out by sub-Contractor or contractor QA/QC, and the same shall be
communicated to company for information.
 WATER STORAGE TANK
Project Name : ICAD II Fluorine and Chlor-Alkali Chemical Plant
Contract Ref. : JTLI/FCACP/CCESCC/A/038
Document Title : HYDROSTATIC TESTING PROCEDURE
Document No. : AM/QC/159/216
Revision No. : A1
Sheet No. : Page 14 of 16

7.8.2 After completion of 100% filling, the total weld seam which is under Hydrotest shall
be visually inspected by company /contractor.

7.8.3 During filling/ final inspection if any defects found ,the same shall be repaired as per
below repair procedure
7.8.4 Repair shall be carried out only with the approval of company and contractor
approval.
7.8.5 Filling shall be continued only after attending the weld repair as mentioned below.
7.9 REPAIR PROCEDURE
7.9.1 Repairs of defects discovered after the tank has been filled with water for testing
shall be made with water level at least 0.3M (1ft) below any point being repaired or
if repairs have to made on or near the tank bottom, with the tank empty. Welding
shall not be done on any tank unless all connecting lines have been completely
blinded.
7.9.2 Cracks or leaks in shell joints, shell to bottom joints & any other joint which under
Hydrotest shall be repaired by chipping the joint and re-welding. All welding repair
shall be carried out by approved WPS & Weld Repair Procedure.
7.9.3 Grind the weld surface deep enough to remove rounded/linear defects.
7.9.4 All defects shall be called to the attention of contractor/Company, and approval shall
be obtained before the defects are repaired.
7.9.5 Check visually and by LPT / MT Test to ensure all the defects are removed the same
shall be ensued by QA/QC of company and contractor.
7.9.6 After the defect has been removed fill up the ground spots by welding as per the
approved WPS.
7.9.7 After completion of repair welding final LPT test to be done for final Inspection the
same shall be ensued by company and contractor QA/QC.
7.9.8 Retest shall be done as per the above procedure to ensure satisfactory welds.
 WATER STORAGE TANK
Project Name : ICAD II Fluorine and Chlor-Alkali Chemical Plant
Contract Ref. : JTLI/FCACP/CCESCC/A/038
Document Title : HYDROSTATIC TESTING PROCEDURE
Document No. : AM/QC/159/216
Revision No. : A1
Sheet No. : Page 15 of 16

7.9.9 After completion of visual inspection by company and contractor, the necessary
clearance shall be obtain before start of draining.
7.9.10 HT water of one tank can be used for HT of another tank as per attached sketch.
7.9.11 While transferring the water from one tank to another, it shall be ensured that the
filling criteria as per procedure.
7.9.12 After completion of draining the final settlement reading shall be taken.

7.10 DISPOSAL OF HT WATER SHALL BE IN CCESCC SCOPE (CLIENT SCOPE)

7.11 TANK TO TANK WATER TRANSFER

7.11.1 HT water of one tank can be used for HT of another tank.
7.11.2 Discharge hose of HT completed tank shall be connected to the inlet nozzle of the
other tank.
7.11.3 While transferring the water from one tank to another, it shall be ensured that the
both filling and discharge criteria detailed above are satisfied.
7.12 POST HT OF TANKS
7.12.1 HT water of one tank can be used for HT of another tank.
7.12.2 After HT is completed, all the temporary blind flanges, gate valves, NRVs, hoses
connected to the shell nozzles shall be removed: All manholes shall be opened.
7.12.3 The Sub-Contractor shall clear all debris, loose mill scale, dirt, silt and other foreign
material from the tank bottom and disposed off.
7.12.4 Inside of the tank bottom shall be cleaned by sweeping or other methods so that the
tank bottom will be broom clean” and free of all trash, dirt.
7.12.5 The settlement measurements on bottom plates in different locations and at the
centre of the sump shall be recorded after complete dewatering and disposal of HT
water.
 WATER STORAGE TANK
Project Name : ICAD II Fluorine and Chlor-Alkali Chemical Plant
Contract Ref. : JTLI/FCACP/CCESCC/A/038
Document Title : HYDROSTATIC TESTING PROCEDURE
Document No. : AM/QC/159/216
Revision No. : A1
Sheet No. : Page 16 of 16

8 ACCEPTANCE CRITERIA:

As per ITP & Company Specification hydro test shall be inspected as below

 No leakage.
 Any differential settlement greater than 13 mm per 10 m (1/2 in. per 32 ft) of
circumference of tank foundation.
 A uniform settlement over 50 mm of foundation.

9 SAFETY:

9.1 Uninterrupted supervision during the tank hydrostatic test shall be maintained from
the start of Test till completion of the Test.
9.2 Prior to filling, roof manhole & nozzles shall be left open. The water drain out nozzle
shall be provided with a valve fitted with a hose pipe of sufficient length to dispose the
water to drain the tank in case of emergency.
9.3 The tank manhole cover on roof shall be completely removed prior to draining off
water.