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 1/29
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.
HYDROSTATIC TEST 000-A-EE-xxx-560 2/29

(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

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

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

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

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

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

000-A-EE-xxx-560
REV 0
7.2 HYDROSTATIC TEST SETUP

CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF

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

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

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

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

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

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

000-A-EE-xxx-560
REV 0
--------------------------------------------------------------------------------------------------------------------------------------
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF

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

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

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 Control Who or

What will
Measures to be Remarks Responsibl
Hazards/ Risk enforced / be e party /
/
Category/Ris Affected /
N Description of task / Tehlikeler Uygulanacak Açıklam Sorumlu
k Kategorisi Etkilenece
o Yapılacak işin tanımı kontrol a Parti
k kişi ya da
Önlemleri
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.
 Not following HSE
 All workers to use
MS procedures
appropriate PPE
 Unauthorized Related Responsible
1 Planning at site.
personnel.
 Barricade the personnel supervisor
 Defective
area where
tools/equipment
operation is to be
carried out.
 Warning sign of
line under
pressure will be
provide at suitable
location.
 Ensure the
equipment/tool to
be used for hydro-
test (such as
hose, pump,
coupling,
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF

000-A-EE-xxx-560
REV 0
pressure gauge,
spade, gasket)
are free from
defect, color
coded and
suitable for the
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
 İSG ve MS donanımlar
Prosedürelerini kullanılmalı
takip etmeme  Hidro testin İlgili Sorumlu
1 Planlama  Yetkisiz personel yapıldığı alan
Personel süpervizör
 Hasarlı ekipman barikatla
kullanımı çevrilmeli
 Uygun yerlere
uyarı işaretleri
konulmalı
 Kullanılacak olan
ekipmanların
çalışır durumda,
renk kodlu ve
hasarsız olması
gerekli
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF

000-A-EE-xxx-560
REV 0
 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
uygun emniyet
bantları ve
işaretlerle
işaretlenmelidir.
 The water filling
height shall be
closely monitored
by followed by an
Execution
Engineer.
Hydrostatic test
 Exceeding  The maximum
maximum pressure must be
allowable 22 bar. The test
pressure. will be stopped
 Ensure the
pressure relieving
device is set at
 Injury to workers. maximum
allowable
pressure for
weakest portion of
 Damage to the segment.
equipment/system  Do not leave the
. Related Responsible
2 pressurized hose
or pump personnel supervisor
unattended when
the filling water is
 Un-attended going on.
equipment/system
 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

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
mekanizmasının
 Kabul edilebilir
bölümün en zayıf
maksimum
basıncı aşma parçası için kabul
edilen max
 Çalışanların
basınça kurulu
yaralanması İlgili Sorumlu
2 Tankların Hidrotesti olduğundan emin
 Ekipman olunmalı Personel süpervizör
sisteminin zarar
 Operasyon
görmesi
devam ediyorken
 Gözetimsiz
basınçlı hortum
ekipman/sistem
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-
illumination Task meeting will Personnel
 Using dark safety be conducted and involve in
Hydrostatic Test Works glasses workers will be Supervisor
3  Insufficient H briefed regarding the night
during night shift activity Engineer
illumination on night shift hazards shift activity
access / egress  Ensure clear
 Poor supervision safety glasses are / operation
provided
 Ensure all access
/ egress areas are
illuminated
sufficiently
 Yetersiz  İşleme
aydınlatma başlamadan önce
Aktivitede
Gece Çalışması  Karanlık Ortamda yeterli
koyu iş gözlüğü aydınlatmanın yer alan Süpervizör
3 Sırasında Hidrostatik kullanımı H olduğundan emin
personel /
Test İşleri  Giriş ve çıkışların olunmalıdır. Mühendis
yetersiz  TBT ve iş öncesi operasyon
aydınlatılması toplantısı
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF

000-A-EE-xxx-560
REV 0
 Zayıf yönetim yapılmalı ve

çalışanlar gece
çalışmalarının
tehlikeleri
hakkında
bilgilendirilmelidir.
 Açık renk
koruyucu gözlük
kullanılmalıdır
 Tüm giriş çıkış
yerleri 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
 Kayma olunmalı İlgili Sorumlu
4 Tertip Düzen ,takılma,düşme  Kullanılmayan
Personel süpervizör
aksesuarların
bağlantısı
kesilmeli ve ayrı
ayrı saklanmalı(
hortum ve pompa)
 Only competent
and experienced
workers shall be
engaged in the
operation
 Ensure to lift
 Pinch point, loads exceeding
jamming 25 Kg with
 Ergonomic hazard mechanical tools
 Slips & trips & equipment. Personnel
 Workers to
Material Handling  Obstruction to involve in Supervisor
5 person and M maintain correct
(Manual/Mechanical) vehicle access body posture the activity / Engineer
 Mechanical while doing
operation
Failure during manual handling
operating the  Prefer mechanical
Forklift/cranes handling,
wherever it is
practicable.
 Team lifting to be
carried out under
direction of
supervisor.
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF

000-A-EE-xxx-560
REV 0
 Ensure all
equipment are
certified &
inspected and
operators having
valid licence &
competence
certificate
 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
 Kayma ve
vücut duruşunu Aktivitede
tökezleme
korumalı.
Malzeme Taşıma  Araç ve yer alan Süpervizör
5  Pratik olduğu
(Elle/Makine İle) çalışanların
sürece her taşıma personel / Mühendis
hareketlerinin
için mekanik
kısıtlanması operasyon
taşıma tercih
 Operasyon edilmeli.
sırasında mekanik
 Takım kaldırma
arızalar
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
 Fire and explosion
start activity
 Faulty machinery
and tools  TBT to be
conducted prior to
 Electrical hazards Personnel
Hot Work  Contact with hot start the activity
 Cylinder to be involve in Supervisor
6 (welding/cutting/grinding surfaces H stored in trolley in
 Struck by flying vertical position
the activity / Engineer
) particles / sparks
with chains to operation
 Back fire due to secure, and cover
spark during on top to protect
cutting from direct
sunlight
 Fire extinguisher
to kept in the
vicinity
 Full and empty
cylinders to be
stored separately
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF

000-A-EE-xxx-560
REV 0
 Flashback
arrestor to be
provided on both
the ends; one on
the 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
 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
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF

000-A-EE-xxx-560
REV 0
 İş başı konuşması
yapılmalı
 İşe başlamadan
önce çalışma
alanı yanıcı
maddelerden
arındırılmalı
 Yangın söndürme
tüpü ve yangın
battaniyesi
çalışma yerinde
bulundurulmalı.
 Yangın çadırları
sertifikalı ve alev
yürümez özellikte
olmalı
 Yetkililer
bilgilendirilmeli ve
işe bağlamadan
önce gerekli
izinler alınmalı.
 Tüpler direk
güneş
ışınlarından
 Yangın ve korunaklı ve
patlama zincirle bağlanmış
 Hatalı makine ve arabalarda
aletler bulundurulmalıdır.
 Elektrik tehlikeleri  Yangın söndürme Aktivitede
 Sıcak yüzeylerle cihazı aktivite
Sıcak Çalışma yer alan Süpervizör
6 temas yerinde bulunmalı
(kaynak/kesme/taşlama)  Savrulan  Dolu ve boş tüpler personel / Mühendis
partiküller / ayrı muhafaza
operasyon
kıvılcım edilmeli
 Kesim esnasında  Alev geri tepiciler
kıvılcım nedeniyle kullanılmalı
yangın  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
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF

000-A-EE-xxx-560
REV 0
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 be hard
barricaded and
warning signage
to be displayed to
alert workers
 Personnel /
 Temporary
material fall from
working platform Personnel
height
to be checked
 Improper working involve in Supervisor
7 Working at height and verified for
platform
safe to use, not to the activity / Engineer
 Working at height store any material
without fall operation
on the temporary
protection 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 to be
maintained while
climbing the
loader
 Work at height
training must be
provided for
related personnel
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF

000-A-EE-xxx-560
REV 0
 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
 Çalışanın /
levhaları
malzemenin
kullanılmalı.
yüksekten
 Geçici çalışma
düşmesi
platformlarının Aktivitede
 Yanlış çalışma
aşırı yüklenmesini
platformu yer alan Süpervizör
7 Yüksekte Çalışma önlemek için
 Düşmeden herhangi bir personel / Mühendis
koruma malzeme
ekipmanları depolanmamalı.
operasyon
olmaksızın
 Tüm çalışanlar
yüksekte
yüksekte
çalışmak.
çalışmadan önce
yüksekte 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
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF

000-A-EE-xxx-560
REV 0
nokta temas
kuralına uyulmal
 Yüksekte yapılan
çalışmalarda
kullanılan tüm el
aletleri düşme
riskine karşı
sabitlenmiş olmalı
 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
Related Responsible
8 Emergency situations  Any Injury situation during
daily toolbox talks personnel supervisor
 TSGI Ambulance:
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
N/A  Süpervizör ya da Süpervizör
8 Acil Durumlar  Tüm Yaralanmalar N/A
sorumlu
Mühendis
mühendis hemen
bilgilendirilmeli
 Yapılan günlük iş
başı
konuşmalarında
acil durumlara
karşı bilgi
verilmeli
CONTRACTOR DOC No.

2248-000-A-EE-xxx-560 SH/OF

000-A-EE-xxx-560
REV 0
 TSGI Ambulans :
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
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

Uploaded by

Copyright:

Available Formats

Method Statement of Hydrostatic Test

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Method Statement of Hydrostatic Test

Uploaded by

Copyright:

Available Formats

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.

SUBCONTRACTOR DOCUMENT 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.

SUBCONTRACTOR DOCUMENT No.

 General Data of Spherical Tanks

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.

SUBCONTRACTOR DOCUMENT 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.

SUBCONTRACTOR DOCUMENT 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.

SUBCONTRACTOR DOCUMENT 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