INDEPENDENT SURVEYOR, NDT & TECHNICAL SERVICES

HYDROTEST PROCEDURE

DOC. NO : 007/HT/ISyP/API/IX/2017 REVISION:

PT. INDOTIMAS DATE : September, 2017
00
SYIFA PERKASA PAGE : Page 1 of 13

TABLE OF CONTENTS

Paragraph Description Page

1. Scope 2
2. Purpose 2
3. Reference Code 2
4. Responsibilities 2
5. General 2
6. Vacuum Test 2
7. Hydrostatic Test 3
8. Air Test 5
9. Safety Precautions 6

PT.INDOTIMAS SYIFA PERKASA

Hydrotest Test Procedure for Storage Tank
 INDEPENDENT SURVEYOR, NDT & TECHNICAL SERVICES
DOC. NO : 007/HT/ISyP/API/IX/2017
PT. INDOTIMAS DATE : September, 2017
SYIFA PERKASA PAGE : Page 2 of 13
1. Scope:
This Procedure specifies the requirements of
Hydrostatic Test, Vacuum Test and Air Test for
Aboveground Water Storage Tank.
2. Purpose
This Procedure describes the equipment and
materials to be used and factors to be
considered during the Pressure Test of Storage
Tank, and ensure that this procedure shall be
done in accordance with the Project
Specifications and related Standards and Codes.
3. Reference Code:
a. ASME Code Sec. I the applicable 2015 Edition
and Addenda,
b. ASME Code Sec VIII Div. 1, 2015 the
applicable Edition and Addenda,
c. API 650, 2015 Edition Applicable Code For
Storage Tank
4. Responsibilities
4.1 QA/QC Engineer / Inspector
a. Shall be responsible to witness the test and
judge the suitability of work carried out.
b. Responsible to make calculations, prepare
documents and layout systems of work.
c. Assessing the suitability of the method,
medium and test pressure requested given
the design of the item submitted for testing.
d. Produce written instructions for the
supervisor and technicians relating to the
procedures, equipment and personnel to be
employed in the test.
4.2 Construction Supervisor
a. Shall be responsible for organizing the test
as per this procedure and approved ITP and
shall also be responsible for maintaining the
records duly signed by all concerns.
b. Responsible to ensure that the technicians
working under his supervision
c. Shall communicate with his management,
client and other contractors.
d. Shall ensure method statements, risk 6.1 Equipment and Material
assessments and permit to work
requirements are communicated to the
technicians and other personnel.
PT.INDOTIMAS SYIFA PERKASA
Hydrotest Test Procedure for Storage Tank
HYDROTEST PROCEDURE
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4.3 Tank Technician
a. Responsible to carryout pressure testing and
other activities in support of pressure testing.
b. Ensure that all marking around the thank is done
as per the drawing
c. Ensures the pressure gauges used have current
calibrated stickers.
d. Complete pressure test record and submit copy
to program manager.
5. General
5.1 After the completion of all welding works and non-
destructive examinations of bottom plate welds,
shell plate welds, roof plate welds and reinforced
plate welds of the tank
5.2 The tank shall be pressure tested for the
identifications of leakage. This pressure shall be
carried out as per the approved drawing, approved
ITP and standard API 650.
5.3 This test will divide into following mentioned
stages:
a. Test preliminaries such as Visual Inspection.
b. nspection of Tank Bottom Welds (Vacuum Box
Testing).
c. Testing of the Shell Course and Tank Bottom
Settlement (Hydrostatic- Testing).
d. Inspection of Roof-Plate and Reinforcing Plates
(Air Testing).
5.4 Ensure that all of the mentioned test must perform
after controlling all of the N.D.T. test reports.
5.5 Vacuum test is carried out to find any leakage in the
bottom plate by the use the vacuum box testing
equipment.
5.6 Hydrostatic test is conducted to find any leakage in
the shell plate weld and to check the elevation of
the tank bottom settlement. Potable water shall be
used to fill the tank.
5.7 Air test is conducted to check the gas tight of roof
and reinforced plates of shell openings of the tank.
6. Vacuum Test
The Vacuum box test is conducted to check soundness of
annular welded joints and all lap joints of bottom plates
(long seam and short seam).
a. The vacuum box test is performed by using a box
with visible window of fiber glass (i.e. 6’’ Wide by
30’’ long metallic box with a fiber glass). The
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DOC. NO : 007/HT/ISyP/API/IX/2017
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SYIFA PERKASA PAGE : Page 3 of 13
open bottom is sealed against the tank
surface by a sponge rubber gasket.
b. The test scheme shall have suitable
connections, such as necessary valves and
calibrated vacuum gauge.
c. The gauge shall have a range of 21Kpa (6 in.
Hg) to 35Kpa (10 in. Hg) for normal leaks
and 56Kpa (16 in. Hg) to 70Kpa (20 in. Hg)
shall be performed for the detection of very
small leaks.
d. The test scheme shall be demonstrated with
sample test block by application bubble
solution at site before conduction of the test
on the job.
e. The bubble forming solution shall produce a
film that does not break away from the area
to be tested, and the bubbles formed shall
not break rapidly due to air drying or low
surface tension.
f. A vacuum can be drawn on the box by any
convenient method, such as connection to a
diesel motor intake manifold or special
vacuum pump.
6.2 Surface Preparation
a. The surface to be examined and all adjacent
areas shall be cleaned thoroughly and free
from all dirt, grease, lint, scale, welding flux,
weld spatters, paint, oil and other
extraneous matter that could obstruct
surface openings.
b. Prior to vacuum testing all joints shall be
checked visually.
6.3 Procedure of Vacuum Test
a. The temperature of the surface of the part
to be examined shall not below 40C (400F)
and nor above 520C (1250F).
b. The weld seam on the test shall be applied
with a bubble solution for detecting leaks
prior to placing vacuum box.
c. The foaming shall be minimized by means of
uniform application of bubble solution.
d. A vacuum can be drawn on the box by any
convenient method, such as connection to a
gasoline- or diesel motor intake manifold.
e. The gauge shall register a partial vacuum of
at least 21Kpa for inspection of the joints.
f. The required partial vacuum shall be
maintained for greater or either at least 5
PT.INDOTIMAS SYIFA PERKASA
Hydrotest Test Procedure for Storage Tank
HYDROTEST PROCEDURE
REVISION:
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seconds examination time, stop watch to be
used after reaching the 21Kpa /designation
vacuum.
6.4 Evaluation of Defects
a. Bubbles produced by air sucked through the
welded seam can detect the presence of defect.
b. The tested areas are accepted only when no
continuous bubbles formation is observed.
c. A minimum light intensity of 100Lux is required
for conducting the examination.
d. Upon satisfactory inspection, a report shall be
prepared for the further activities.
6.5 Repair and Retest
a. Defects in welds shall be repaired by chipping,
grinding or melting out the defects from one side
or both sides of the joints as required and re-
welding are done.
b. Only the cutting out of defective joints that is
necessary to correct the defect is required.
c. After repairing, retest of vacuum box test of
welded joint shall be carried out.
6.6 Cleaning
After test the area shall be thoroughly cleaned for
the further activities.
7. Hydrostatic Test
Hydrostatic test is conducted to carry out the leakage in
the shell plates and also to carry out elevation
measurement of the bottom foundation of tank by using
tank foundation settlement method.
7.1 General Consideration
a. The water for hydro test will be provided by
SWCC, the initial filling of the first and second
will come from this pipe system source.
b. After the first tank is tested, the water will be
transferred to the second tank. After the second
tank is tested, the water will be transferred to
the third and fourth tank for Testing.
c. Contractor will furnish the pipe and pumps
required to move the water from tank to tank.
d. After the completion of the hydro testing
operations for the first and fourth tank,
contractor will dispose of the water on site at
the designated point.
7.2 Preparation of Hydrostatic Test
a. After the completion of all welding works and
non-destructive examination of tank and all
welded joints shall be signed off by QC welding
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PT. INDOTIMAS DATE : September, 2017
SYIFA PERKASA PAGE : Page 4 of 13
inspector prior to commencement of the
hydrostatic test.
b. Temporary test gaskets shall be used for all
fittings and manholes.
c. The hydrostatic test of tank shall be
conducted before permanent external
piping is connected to the tank.
d. Cleaning inside the tank and removal of
temporary jigs and tools shall be completed.
e. All shell openings shall be closed by block
valves or by appropriate cover plates.
f. Roof manholes shall be opened while
introducing water into the tank or drawing
off water.
g. Initial tank level readings shall be taken
using 16 equally spaced points marked on
the bottom plate projecting out from the
bottom shell around the tank at its base.
h. The above points will be referenced back to
a permanent benchmark.
i. Install temporary plastic tube to be used as a
water level indicator during hydrostatic test.
7.3 Procedure of Hydrostatic Test
a. Proper arrangement shall be carried out for
the water filling. Pipe connection from the
water resource point and providing valves
wherever required.
b. Potable water shall be used for hydrostatic
testing.
c. To protect urgent uneven settlement, water
filling rate shall be controlled. Therefore the
maximum filling and discharge rate shall be
as per standard API 650 as given in the
below table 1.
00
f. Continue filling the tank until the water level
reaches the quarter point of the tank height. At
this point discontinue filling while the level
readings are taken on the 16 points as described
in above (7.1- Item no.7) and readings are
recorded.
g. If the differential readings do not exceed 1½ mm
per meter of circumference, the filling of water
shall continue.
h. As water is being pumped into the tank. Observe
the circumference of the tank for any signs of
leak or distortion in each shell course. If any
signs appear immediately discontinue filling and
determine the cause. Repair shall be made with
the water level at least 300mm below the point
being repaired.
i. Take additional readings when the tank is half
full, three quarter full and full height. The same
criteria for differential settlement as stated in
above (7.1- Item no.7) shall apply to each of the
level readings.
j. Filling of water into the tank shall be continue
until the level reaches the maximum desired
height as shown on approved IFC drawing.
k. The test water will remain in the tank at the
maximum desired height for a period of 48
hours. Final level readings shall be taken prior to
removing any water from the tank.
l. Water filling schedule and holding period shall
be in accordance with API 650 as given in below
table 2:

7.4 Tank Foundation Settlement

a. For the adequacy of tank foundation
performance, a staged hydrostatic procedure
and an extensive settlement monitoring
d. Filling shall be done in four stages 25%, 50%,
program is performed as per project
75% and 100%. After each stage a load
specification and API 650.
stabilization period shall be observed.
b. Therefore the following tolerable settlement
e. As water rises in the tank, observe the shell
criteria are adopted as a basis for evaluating
fittings for any signs of leakage around the
tank performance during hydrostatic testing
blind flanges.
PT.INDOTIMAS SYIFA PERKASA
Hydrotest Test Procedure for Storage Tank
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DOC. NO : 007/HT/ISyP/API/IX/2017
PT. INDOTIMAS DATE : September, 2017
SYIFA PERKASA PAGE : Page 5 of 13
Filling of water shall continue while
elevation measurements are being made
as long as the change in water elevation for
a set of reading does not exceed 300 mm.
c. Shell elevation measurements shall be
made at equally-spaced intervals around
the tank circumference not exceeding 10 m
(32 ft).
d. Install settlement monitoring markers at
eight equally spaced locations along the
perimeter of the tanks.
e. Observed elevations shall be referred to a
permanent benchmark. The level
instrument shall be set up at least 1½ times
tank diameter away from the tank when
tank elevation readings are taken.
f. There are six sets of settlement readings
are required as follows:
- Before start of the hydrostatic test.
- With tank filled to 1/4 test height (±600
mm).
- With tank filled to 1/2 test height (±600
mm).
- With tank filled to 3/4 test height (±600
mm).
- At least 24 hours after the tank has
been filled to the maximum test height.
This period may be increased in
accordance to the requirement of the
project specification.
- After tank has been emptied of test
water.
g. g. If settlement measurements are
specified by the Purchaser, any differential
settlement greater than 13 mm per 10 m.
of circumference or a uniform settlement
over 50 mm shall be reported to
contractor.
h. Filling of the tank shall be stopped until
cleared by the contractor.
i. Internal bottom elevation measurements
shall be made before and after hydrostatic
testing. Measurements shall be made at
maximum intervals of 3m (10ft) measured
on diametrical lines across the tank.
j. The diametrical lines shall be spaced at
equal angles, with a maximum separation
measured at the tank circumference of
PT.INDOTIMAS SYIFA PERKASA
Hydrotest Test Procedure for Storage Tank
HYDROTEST PROCEDURE
REVISION:
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10m (32ft). A minimum of four diametrical lines
shall be used.
7.5 Removal of Test Water
a. After the completion of Hydrostatic test, the
tank shall be emptied at a maximum water level
variation rate as per specification.
b. Make sure that roof manholes and vents are
open during empty operation of conical roof
tank.
c. When the first tank has been tested, make
connections to the second tank through a gate
valve and extend the piping to the designated
point.
d. When the second tank has been tested, connect
the tested tank to the next tank and water to be
filled through the system of temporary valves
and piping.
e. Prior to starting the pumping operation between
two tanks, make sure that roof manholes and
vents are open on both tanks.
f. Transfer to the next tank using gravity and a
temporary pump as required to empty the
tested tank.
g. After all water has been removed from the
tested tank, open all manholes and remove all
temporary blinds and equipment.
h. After final draining and drying, brushing, broom
or vacuum cleaner shall clean surface of the
tanks bottoms.
i. QC Inspectors sign the test data sheet at the
completion of hydro test.
8. Air Test
Air test is carried out to check the gas tight of the
roof plate and reinforced plate of shell openings of
the tank.
8.1 Equipment and Material
a. Pressure Gauge or Manometer
b. Blank/Blind Flange with Safety Relief Valve.
c. Soapsuds
d. Air Supply System
8.2 Procedure of Air Test
After final welding and clearing the tank, an air test
shall be conducted to ensure water tightness and
the integrity of welding according to the procedure
as follows:
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PT. INDOTIMAS DATE : September, 2017
SYIFA PERKASA PAGE : Page 6 of 13
a. The tank workers shall prepare the test
equipment and materials such as; pressure
gauge or manometer, testing piece, supply
air and soapsuds etc.,
b. Before starting the air pressure test, water
shall be filled to 50mm below the curb
angle.
c. Cleaning and visual inspection of entire
welding of roof plates and all roof
accessories shall be carried out prior to test.
d. A manometer of suitable range shall be
connected to the roof nozzle with ¼’’
diameter PVC tube for measurement of
pressure
e. Inlet connection shall be done with ½’’ hose
from the compressor outlet to one of the
roof nozzle.
f. To regulate the pressure, valves shall be
provided on both ends.
g. Once all nozzles and manhole are closed,
pressure shall be applied slowly inside the
roof by controlling the isolation valves.
h. Once the required
i. Set the testing piece to the desired filling
point of air either on manhole or air vents.
j. Fill and press up the tank with compressed
air until it reaches 2.2 Psi on the pressure
gauge or an equivalent water level in the
manometer and hold at this pressure for at
least for 1 hour.
k. Observe the pressure gauge or water level
in the manometer if it remains in the
desired test pressure.
l. If this pressure remains the same then apply
soapsuds to welding seams or joint and the
areas to be check for leaks.
m. If the pressure decreases, re-check the
possible air passage and blank-off or
retighten.
n. If there are leaks then identify and mark the
exact location of defects.
o. Release the air pressure, rectify the leak and
retest again until successful passed the test
in the presence of Client QC Engineer.
p. The inspection and acceptance report shall
be fully accomplished and signed by the
Clients representative, Tank Supervisor and
QC Engineer.
PT.INDOTIMAS SYIFA PERKASA
Hydrotest Test Procedure for Storage Tank
HYDROTEST PROCEDURE
REVISION:
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q. Release the air pressure once the test is
completed then put back all components/parts
that have been removed.
9. Safety Precautions
a. The safety measures shall be implemented during
testing activities and the contractor shall provide
the necessary safety equipment, communication
equipment, access barriers etc.
b. Contractor shall issue a statement to all persons
connected with testing, warning of the hazards of
failure under pressure.
c. There is a possibility that workers can take
remedial action once minor leakages are noticed
before total failure occurs.
d. Hydrostatic tests are conducted under the
constraints of projects specifications.
e. Air/gas used for Air test is compressible to large
extent and has very high potential energy stored
when compressed.
f. Ensure that no any worker shall present inside the
tank prior to pressure test.
g. Use and storage of any compressed gas under high
pressure can be extremely dangerous if proper gas
handling procedures are not observed.
h. Where the test system is testing using
pressurization above its normal working level, it
follows that the tester should be prepared for the
consequences of failure.
i. This means that there may need to be protective
barriers or screens, but all such precautions will be
specifically dedicated to the risk involved in the
test.
j. The technician must be conscious at all times of the
potential for a rise in temperature to significantly
increase pressure.
k. Safety officer must be present at site during test.
l. Tested & certified Lifting equipment shall be used
for lifting and shifting purpose.
m. Safety Precautions shall be followed during
fabrication and erection as per project
specification.
n. Welding cables and power cables to be laid
properly as per Instrumentation and Electrical rules
and local state govt. rules and regulation.
o. Proper housekeeping and clean condition shall be
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maintained in the fabrication shop and site as
per requirement.
p. Wear proper PPE i.e. tall protection harness,
goggles etc.
q. Clean and clear the area and return the used
equipment and materials to the tool room or
shop.
r. Conduct hazard assessment and safety
meeting.
s. Barricading of Tank, First-Aid kit and
emergency phone number shall be available.
t. The contractor shall provide patrols to all
around the tank to watch any special points of
hazards during pressure test of tank.
u. Safety sign boards both in English and
Indonesia language shall be posted at
appropriate locations during tank testing the
display shall be "TANK UNDER PRESSURE TEST
KEEP AWAY".

PT.INDOTIMAS SYIFA PERKASA

Hydrotest Test Procedure for Storage Tank
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DOC. NO : 007/HT/ISyP/API/IX/2017 REVISION:

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REPORT SAMPLE

PT.INDOTIMAS SYIFA PERKASA

Hydrotest Test Procedure for Storage Tank
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DOC. NO : 007/HT/ISyP/API/IX/2017 REVISION:

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SYIFA PERKASA PAGE : Page 9 of 13
0 % TANK SETTLEMENT REPORT

PT.INDOTIMAS SYIFA PERKASA

Hydrotest Test Procedure for Storage Tank
 INDEPENDENT SURVEYOR, NDT & TECHNICAL SERVICES

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DOC. NO : 007/HT/ISyP/API/IX/2017 REVISION:

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25 % TANK SETTLEMENT REPORT

PT.INDOTIMAS SYIFA PERKASA

Hydrotest Test Procedure for Storage Tank
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50 % TANK SETTLEMENT REPORT

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Hydrotest Test Procedure for Storage Tank
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75 % TANK SETTLEMENT REPORT

PT.INDOTIMAS SYIFA PERKASA

Hydrotest Test Procedure for Storage Tank
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100% TANK SETTLEMENT REPORT

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Hydrotest Test Procedure for Storage Tank