Hassan Allam Construction HAC

Quality Management System

Quality Department

Page 1 of 6
Procedure

PROJECT NAME

PROCEDURE FOR
HYDROSTATIC TEST FOR TANKS

MS-XXXXX

Rev. Issue Date Prepared by Prepared by Reviewed by Approved by

Technical Office Project Quality
Site Manager Project Manager
Manager Manager

Document Ref#. HAC-xxxx-xxxx - Rev. 01- Issued Date. 01/01/2018

 Hassan Allam Construction HAC
Quality Management System
Quality Department

Page 2 of 6
Procedure

Document Revision History

Revision Date Summary of Changes / Details of Issue

TABLE OF CONTENT

1.0 SCOPE.............................................................................................................................................3
2.0 REFERENCES...............................................................................................................................3
3.0 RESPONSIBILITIES.....................................................................................................................3
4.0 RESOURCES..................................................................................................................................3
5.0 PROCEDURE.................................................................................................................................3
6.0 HSE REQUIREMENTS................................................................................................................6

7.0 ATTACHMENTS.........................................................................................................6

Document Ref#. HAC-xxxx-xxxx - Rev. 01- Issued Date. 01/01/2018

 Hassan Allam Construction HAC
Quality Management System
Quality Department

Page 3 of 6
Procedure

1.0 Scope

1.1 This test procedure shall be carried out to detect the leak in shell weld joints and to observe the
uniform settlement of tank foundation.

1.2 This procedure is implemented by (DSD-Ferrometalco — The Egyptian German Company for
Metal Construction) site activities.

2.0 References

2.1 API-650 (Latest edition).

2.2 API-020 (Latest edition).

2.3 UI 9252-02 Site Welded Equipment.

2.4 UI 9252-06 Welding and weld examination.

2.5 UD-ME-51-EB-00001

2.6 UD-ME-51-TL-00001

2.7 UD-ME-89-EB-00002

2.8 UD-ME-89-TL-00001

3.0 Responsibilities

4.0 Resources

4.1 Manpower

4.2 Material

4.3 Equipment and Tools

5.0 PROCEDURE

5.1 PREPARATION FOR HYDROTEST

5.1.1 Prior to the hydrostatic testing, it shall be confirmed that all Specified non-destructive
examinations of welds and inspection shall be completed according to project ITP and
applicable codes and standards.

Document Ref#. HAC-xxxx-xxxx - Rev. 01- Issued Date. 01/01/2018

 Hassan Allam Construction HAC
Quality Management System
Quality Department

Page 4 of 6
Procedure

5.1.2 All the mechanical activities to be completed in respect of the drawing, it shall be closely
checked that clips and supports shall be finished by welding on the pressure Part of internal
and external of tank shell as per latest approved Drawing prior to water filling.

5.1.3 The inside of tank shall be cleaned.

5.1.4 The test shall be done before connecting external piping to the tank.

5.1.5 Before the tank is filled with test water:

5.1.5.1 The points for settlement measurement shall be marked on a permanent benchmark, the
level readings at measurement points shall be recorded at equidistance around the Tank
circumference, and the IA, 1/2, 3/4 and maximum of water level shall be marked on the
outer shell of tank.

5.1.5.2 Reference is made to the letter No. C-UDS-HAC-00431 where TK Uhde decided to
change the hydrostatic test sequence for the Desalinated Water Tanks 89T001A and
89T001B as follow:

A)Application of 100% Dye Penetrant testing (leak through test method) of the shell course
welds up to the water level including the zero joint.

B) The hydrostatic test shall commence after internal surfaces painting for settlement check
only.

5.1.6 Close the manhole in its temporary position for NH3 tank.

5.1.7 The test equipment shall be prepared.

5.2 FILLING OF TEST MEDIUM

5.2.1 Water with chloride content < 200 ppm shall be used for filling except for Nitric Acid tank it
shall be < 50 ppm. Chloride content to be measured and mentioned in test report.

5.2.2 The Tank shall be filled with water by any suitable low pressure filling lines, while the vent
in top of the tank shall be opened to the atmosphere to prevent accumulation of pressure. The
capacity of the filling pump shall be controlled to maintain adequate venting to avoid air
pocket entrapments,

5.2.3 For site-fabricated tank, Filling of water shall be done in steps. Initially, one forth (14 the) of
the tank shall be filled & settlement of the tank foundation shall be observed after filling and
after 24 hours (approx.). Then the level of water shall be increased in steps to one half (%),
three quarter (3/4 the) & full (up to design liquid level) respectively & tank settlement shall
be observed after each stage and after 24 hours of each stage. After drainage, tank settlement
shall be observed and reported.
Document Ref#. HAC-xxxx-xxxx - Rev. 01- Issued Date. 01/01/2018
 Hassan Allam Construction HAC
Quality Management System
Quality Department

Page 5 of 6
Procedure

5.2.4 The Water filling rate shall not exceed 0.2 m water level per hour.

5.2.5 In case of settlement, as stated in 5.3, an appropriate corrective action shall be taken after
client approval before further filling.

5.3 INSPECTION

5.3.1 During test, inspection for leakage, bulging or other visible defects shall be made on the
whole body of the tank. Close examination shall be carried out on all welded joints and
connections.

5.3.2 The tank settlement shall be checked before filling and at every holding stage.

5.3.3 At the maximum test height, tank settlement shall be checked after 24 hours of complete
filling.

5.3.4 The settlement of the tank foundation shall not exceed allowable tolerances. The allowable
tolerance shall be specified by UHDE instruction UI 9252-02 and erection procedure UD-M
E-89-E B-00002.

5.3.5 The above inspection shall be performed by qualified inspector & Client's Inspector.

5.3.6 For NH3 tank, when cup is filled with water and before pneumatic test pressure is applied,
weld the anchor strip to the top edge of the embedded anchor strip in the foundation with
backing strip.

5.3.7 in case when combination hydrostatic-pneumatic tests are required, this procedure will be
implemented in conjunction with pneumatic test procedure no. HAC-CM-GOO-DC-00016.

5.4 SAFETY PRECAUTIONS

5.4.1 All Safety precaution shall be taken during water fill up test.

5.4.2 Signs shall be displayed at roped off areas indicating that test is under progress. Only
authorized persons shall be allowed within the test area during testing.

5.5 DRAINING

After completion of the test, drain valve shall be opened to remove water from inside the tank.
Pump shall be used for complete drainage from the sump. The Water shall be disposed off at
appropriate place identified by site personnel.

5.6 REPAIR OF DEFECTS

Repair of defects shall be as per repair procedure no.: (FIAC-CM-G00-00017)

Document Ref#. HAC-xxxx-xxxx - Rev. 01- Issued Date. 01/01/2018

 Hassan Allam Construction HAC
Quality Management System
Quality Department

Page 6 of 6
Procedure

5.7 CLEANING

5.7.1 After draining the water, the tank shall be thoroughly cleaned, free from dirt and foreign
materials.

5.7.2 If salt water is used then after hydrotest, the tank should be thoroughly cleaned with fresh
water.

5.7.3 After all water has been drained, the Tank shall be dried, examined internally for cleanliness I
drying and final inspection shall be carried out.

5.8 RECORDS

5.8.1 Hydrostatic test shall be documented on attached Hydrotest Report form and tank settlement
report.

5.8.2 After hydrotest, Vacuum box test shall be done on all bottom welds according to vacuum box
procedure no. (HAC-CM-GOO-DC-00015)

6.0 HSE Requirements

7.0 Attachments

Document Ref#. HAC-xxxx-xxxx - Rev. 01- Issued Date. 01/01/2018