PEC LTD.

21 Shipyard Road, Singapore 628144.

Tel: 6268 9788 Fax: 6268 9488

SUPPLIER PEC LTD.

DOCUMENT TITLE HYDROTEST PROCEDURE

PEC LTD

BUKOM SPEL

Contract No:

P.O. No: Req. No:

Equip. Item No: TK-9401. Req. Item No: 1

Construction Work Area: B7            

Supplier Doc No: TK1-WP-TKG - 000 Supplier Rev: 1

Status Code PEC LTD Dept. Date

       

COMMENT STATUS CODE

1 – Rejected
2 – Comments as Noted
3 – Minor Comments, Acceptable  
4 – No Comments  
5 – Information Only            

Rev Date Reason for Issue Prepared Checked Approved

Page 1 of 7
 PEC LTD.
21 Shipyard Road, Singapore 628144.
Tel: 6268 9788 Fax: 6268 9488

SUPPLIER PEC LTD.

DOCUMENT TITLE HYDROTEST PROCEDURE

CONTENTS

1. SCOPE

2. APPLICABLE CODES / STANDARDS

3. TANK DATA

4. DEFINITIONS

5. RESPONSIBILITIES

6. HYDROTESTING PROCEDURE

6.1 PRIOR TO WATER FILLING

WATER FILLLING METHODOLOGY

6.2 VISUAL INSPECTION

6.3 HOLDING TIME

6.4 SHELL SETTLEMENT SURVEY

6.5 ACCEPTANCE CRITERIA

6.6 WATER DRAINING METHODOLOGY

7. BOTTOM PLATE SETTLEMENT SURVEY

8. ATTACHMENTS

1. Attachment-1: Tank Hydro test water filling and settlement report

1. SCOPE
This document describes the Tank Hydrotest Procedure for the Tanks Plant. It also ensures that all the
works are carried out in accordance with API standard 650 and Shell DEP.

2. APPLICABLE CODES / STANDARDS

The following documents should be referred in conjunction with this procedure where applicable.
API 650 Welded Steel Tanks for Oil Storage
ASME IX Welding and Brazing Qualifications

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 PEC LTD.
21 Shipyard Road, Singapore 628144.
Tel: 6268 9788 Fax: 6268 9488

SUPPLIER PEC LTD.

DOCUMENT TITLE HYDROTEST PROCEDURE

DEP Paint and Protective Coatings

3. TANK DATA
Tank Nos : TK-9401
Type of the Roof : Fixed Carbon Steel roof
Tank Diameter (ID) : 35 meters (114.833 ft)
Tank Height : 25 meters (82 ft)
Nominal Capacity : 24,053 m³ (151.3kB)
Design Pressure (int./ext.) : 0.758 kPag (0.11 psig)
Operating Pressure : ATM
Hydrotest Medium : Fresh Water
Hydrotest Holding Time : 24hrs

4. DEFINITIONS
SPEL : SHELL EASTERN PETROLEUM LTD
Contractor(s) : PEC Ltd
NDE : Non-Destructive Examination
VBT : Vacuum Box Test
OPT : Oil Penetrant Test

5. RESPONSIBILITIES

5.1. SUPERVISOR

The supervisor shall be responsible to carry out the hydrotest in a safe manner compliance with
quality requirements and he shall also be responsible;
1. To ensure all necessary documents, permit to work system (PTW) is followed and PTT is
conducted before starting of job.
2. To ensure temporary material used for the hydrotest has the same materials / rating / class
of the item to be hydrotested.
3. For planning, the supply of equipment and safe execution of the required hydrotesting of
tank.
4. To ensure all hydro test team members should understand the job scope clearly and they
carry out their work safely.
5. To ensure test medium used is as per client requirement.
6. For supplying and ensuring the warning signs being displayed and proper barricades are in
place to restrict access during the hydrotest period.

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 PEC LTD.
21 Shipyard Road, Singapore 628144.
Tel: 6268 9788 Fax: 6268 9488

SUPPLIER PEC LTD.

DOCUMENT TITLE HYDROTEST PROCEDURE

5.2. STANDBY MEN

The Standby men must be briefed by supervisor before commencement water filling. He shall be
responsible;
1. To check water filling level, flow rate and record them hourly. This activity must be carried
out during day time.
2. To ensure the maximum water filling rates shall not exceed 200m³/hr, the required rate as
mentioned in the attachment-1: Water filling and draining methodology.
3. To perform visual check hourly around the tank, looking out for any sign of leakage, shell
deformation, including the water filling and drain hose. If noticed any abnormality during
water filling, he should contact the immediate supervisor via radio / grid to shut off the
incoming water supply immediately.

5.3. QC INSPECTOR

QC inspector responsible to carry out site QC inspections, prepare documentations and check list
in accordance with the requirements of the project and get it reviewed/signed by SPEL Prior to
hydro test in order to maintain the integrity of the inspection. He shall also be responsible,
1. To ensure all weld visual inspection, NDE, VBT and OPT tests are completed and reports
are signed off by all relevant parties.
2. To ensure all category “A” punch items are completed and punch list signed off by all
relevant parties.
3. To ensure that test pack is approved by SEPL prior to hydro test.
4. To ensure test equipment is calibrated if applicable and associated calibration certificates
are made available to the SEPL representatives.
5. To ensure the test medium used is as per requirement.
6. To ensure application for inspection (AFI) is submitted to SEPL for hydro test witness

6. HYDROTESTING PROCEDURE
The hydrotesting procedure shall be read in conjunction with attachment-1; Water filling and draining
methodology where applicable.

6.1. PRIOR TO WATER FILLING

1. All hot and cold works on the tank internal/external must be completed.
2. All mechanical work must be inspected, NDE tested and accepted by SEPL
3. All records must be verified by SEPL before box-up for water filling.
4. Clean tank internal and remove all temporary attachments & Debris.
5. Blank off all valves / lines.
6. All bolts and nuts are to be tightened.

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 PEC LTD.
21 Shipyard Road, Singapore 628144.
Tel: 6268 9788 Fax: 6268 9488

SUPPLIER PEC LTD.

DOCUMENT TITLE HYDROTEST PROCEDURE

7. Bottom plate top surface shall be taken as the zero-reference point.

8. Ensure necessary permit applied and approved for the job.
9. Temporary piping and hoses shall be installed where necessary to facilitate the water filling
for hydro test, It shall be removed and reinstated after completion of hydro test.
10. Tank shall be vented by opening of roof manhole and gauge hatch nozzle prior to water
filling.
11. The hydrotest procedure, method of statement and safe work practice need to be discussed
in the toolbox meeting.
12. The tank farm shall be barricaded and displayed the signage to avoid unauthorized entry.
13. Water filling chart must be made available prior to water filling.

6.2. WATER FILLING METHODOLOGY

1. The quality and testing of water is the responsibility of client SEPL if applicable.
2. The client SEPL shall provide adequate points in the plant for test medium to take-over and
sewer system for proper disposal after hydrotesting, discharging the test water to drain.
3. PEC shall never operate process valves. Valves for water take-over shall be installed and
prior specific approval required from SPEL operations representatives for downstream of the
process valves. These can be operated by PEC only under the client SEPL permit to work
system.
4. The water shall be introduced at the lowest point and continuous venting shall take place at
the highest point until the tank is completely filled with water.
5. PEC standby man shall monitor the filling rate and ensure the filling rate does not exceed
200m³/hr,
6. PEC to carryout checks for any leakage thorough weld seam on the shell and shell to
bottom during water filling.
7. Radio / Grid contact will be established and maintained throughout the water filling period.
8. Record the water level and submit reports to SEPL for verification.

6.3. VISUAL INSPECTION

Carry out visual inspection on shell external for sign of any leakage, shell deformation during
water filling as well as after holding period of 24hrs at;
 25% filling level (6.25m approx.)
 50% filling level (12.50m approx.)
 75% filling level (18.75m approx.)
 100% filling level (24.05m approx.)

6.4. HOLDING TIME

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 PEC LTD.
21 Shipyard Road, Singapore 628144.
Tel: 6268 9788 Fax: 6268 9488

SUPPLIER PEC LTD.

DOCUMENT TITLE HYDROTEST PROCEDURE

Water shall be held for 24hrs at following levels prior to shell settlement survey as per project
requirement.
1. At 1/2 level (12.5m approx.) corresponding to maximum filling height of tank
2. At 3/4 level (18.75m approx.) corresponding to maximum filling height of tank
3. At full tank (after the tank has been filled to the maximum test height)

6.5. SHELL SETTLEMENT SURVEY

1. Six (6) sets of shell settlement surveys are required to be carried out in the following stages;
 At empty tank (before start of the hydro test)
 At 1/2 level (12.5m approx.) corresponding to maximum filling height of tank
 At 3/4 level (18.75m approx.) corresponding to maximum filling height of tank
 At full tank (after the tank has been filled to the maximum test height)
 At 1/2 level (during discharge of test water)
 At empty tank (After tank has been emptied of test water)
2. Shell settlement measurements shall be made at 16 locations equally-spaced intervals
around the tank circumference not exceeding 10m (32 ft).
3. Observed settlement readings shall be referred to a permanent benchmark which will not be
affected by tank settlement during hydro test.
4. Any differential settlement greater than 13mm per 10m of circumference or a uniform
settlement over 50mm shall be reported. Filling of the tank shall be stopped until cleared by
SPEL
5. The level instrument shall be set up in positions to minimize the number of times the level
Instrument needs to be moved around the tank.
6. Prepare the settlement report submit to SEPL for verification.

6.6. ACCEPTANCE CRITERIA

If no leaks and shell deformations are observed by a full visual inspection after the minimum
specified holding period of 24hrs, the hydrotest shall be accepted and report signed off by SEPL.
WATER DRAINING METHODOLOGY
1. After hydro test has been accepted by all relevant parties, the tested water shall be drained
by taking precaution measure and maintain the sequence.
2. Dirt and other residue materials are to be cleaned after draining of water and leave the
manhole and mixer nozzle open for natural dry.

7. BOTTOM PLATE SETTLEMENT SURVEY

1. Two (2) sets of bottom plate settlement surveys are required to be carried out in the following stages
as dipicted, Figure-1;
Page 6 of 7
 M

PEC LTD.
21 Shipyard Road, Singapore 628144.
Tel: 6268 9788 Fax: 6268 9488

SUPPLIER PEC LTD.

DOCUMENT TITLE HYDROTEST PROCEDURE

 At empty tank (before start of the hydro test)

 At empty tank (after tank has been emptied of test water)
2. Additional measurements shall be made in the annular plate region at approximately 30 ft (10 m)
intervals around the tank shell.
3. A set of at least 3 measurements shall be made at each location commencing inward from the inside
surface of the tank shell and equally spaced on a radial line.
4. A 100 percent visual examination shall be made of the tank bottom to detect any localized
depressions. The location and extent of depressions shall be indicated on the tank bottom plate
layout drawing.
5. Prepare the settlement report and submit to SEPL for verification.

Figure-1
Tank
D ia m e te r A x is

1 0 ft. (3 m ) T A N K D IA M E T E R
I n t e r v a ls NUM BER O F
D IA M E T E R A X E S
ft. m

£1 5 0 £ 46 4
> 1 5 0 to 2 2 5 > 4 6 to 6 9 6
> 2 2 5 to 3 2 5 > 6 9 to 9 9 8
> 325 > 99 10

8. ATTACHMENTS

 Storage Tank Hydrostatic Test Report

 Tank Foundation Settlement Report

 Construction Punch List

 Tank Hydro test Check List

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