ENGINEER’S STAMP: CONTRACTOR’S STICKER:

A Issue for approval

‫حيقنت‬ ‫رادصإلا ببس‬ ‫ةطساوب‬ ‫اهعجار‬ ‫خيراتلا‬
REV ISSUED FOR PREPARED CHECKED APPROVED DATE
‫ ةيدوعسال ةيبرعال ةكلممال‬KINGDOM OF
SAUDI ARABIA ‫ةحلامال هايم?ال ةيلحتل‬
‫ةماعلا ةسسؤمال‬
SALINE WATER CONVERSION CORPORATION (SWCC)
Project NO. ‫عورشملا مقر‬ ‫ة?ثلاثال ةلحرمال ةرونملا ة?نيدمال – عبني هايم لقن ماظن‬
20311 YANBU – MADINAH PHASE 3 WATER TRANSMISSION SYSTEM

‫(ةعومجملا‬B1+B2+C) ‫بيبانأ طوطخ ديدمتو خضلا تاطحم ءاشنإ ذيفنت‬

PACKAGE (C+B1+B2) CONSTRUCTION OF STATIONS AND LAYING OF
PIPELINES
‫سد?نهمال‬
ENGINEER
ILF Consulting Engineers

SINOPEC INTERNATIONAL
PETROLEUM SERVICE
‫لواقملا‬
CONTRACTOR CORPORATION
LOCATION: TITLE:

HYDROSTATIC TEST PROCEDURE FOR STORAGE TANK

SCALE: DOCUMENT No.: REV:

3 2 5 - Q D 6 0 - F -

SUBCONTRACTOR:
Sheet 1of16
 KINGDOM OF SAUDI ARABIA Page: 2 of 16
Saline Water Conversion Corporation
YANBU-MADINAH PHASE 3 WATER TRANSMISSION SYSTEM
HYDROSTATIC TEST PROCEDURE Spec. No. QC10-H-049 M09
Subject:
FOR STORAGE TANK ILF CONSULTING ENGINEERS
IndexRevision

First Rev. A Document Number

Issue Date: 325-QD60-F-

TABLE OFCONTENTS
1 SCOPE ............................................................................................................................................. 3
2 PURPOSE ........................................................................................................................................ 3
3 REFERENCES ................................................................................................................................. 3
4 DEFINITIONS ................................................................................................................................... 3
5 ABBREVIATIONS ............................................................................................................................ 4
6 RESPONSIBILITIES ........................................................................................................................ 4
7 GENERAL ........................................................................................................................................ 5
8 VACUUM TEST................................................................................................................................ 6
9 HYDROSTATIC PRESSURE TEST ................................................................................................ 8
10 AIR TEST ....................................................................................................................................... 12
11 SAFETY PRECAUTIONS .............................................................................................................. 15

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 KINGDOM OF SAUDI ARABIA Page: 3 of 16
Saline Water Conversion Corporation
YANBU-MADINAH PHASE 3 WATER TRANSMISSION SYSTEM
HYDROSTATIC TEST PROCEDURE Spec. No. QC10-H-049 M09
Subject:
FOR STORAGE TANK ILF CONSULTING ENGINEERS
IndexRevision

First Rev. A Document Number

Issue Date: 325-QD60-F-

1 SCOPE
This Procedure specifies the requirements of Hydrostatic Test, Vacuum Test and Air
Test for Aboveground Water Storage Tank in the PROJECT OF YANBU-MADINAH
PHASE 3 WATER TRANSMISSION SYSTEM for SALINE WATER CONVERSION
CORPORATION (SWCC).

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 REFERENCES
API Standard 650 Welded Steel Tanks for Oil Storage
QC10-H-049 M09 Steel Tanks - Rev4
ASME Section VIII, Division 1 Boiler and Pressure Vessel Code
EN 10204 Metallic Products – Types of Inspection Documents

4 DEFINITIONS
Employer Saline Water Conversion Corporation (SWCC)
Engineer ILF Consulting Engineers
Contractor Sinopec International Petroleum Service Corporation (SIPSC)
Project YANBU-MADINA PHASE 3 WATER TRANSMISSION SYSTEM

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 KINGDOM OF SAUDI ARABIA Page: 4 of 16
Saline Water Conversion Corporation
YANBU-MADINAH PHASE 3 WATER TRANSMISSION SYSTEM
HYDROSTATIC TEST PROCEDURE Spec. No. QC10-H-049 M09
Subject:
FOR STORAGE TANK ILF CONSULTING ENGINEERS
IndexRevision

First Rev. A Document Number

Issue Date: 325-QD60-F-

5 ABBREVIATIONS
API American Petroleum Institute
ASME American Society of Mechanical Engineers
ANSI American National Standard Institute
ASTM American Society for Testing and Materials
EN European Standards IFC
Issue For Construction QC Manager
Quality Control Manager QC Engineer
Quality Control Engineer

6 RESPONSIBILITIES
6.1 QA/QC Engineer / Inspector
 Shall be responsible to witness the test and judge the suitability of work
carried out.
 Responsible to make calculations, prepare documents and layout
systems of work.
 Assessing the suitability of the method, medium and test pressure
requested given the design of the item submitted for testing.
 Produce written instructions for the supervisor and technicians relating to
the procedures, equipment and personnel to be employed in the test.
6.2 Construction Supervisor
 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.
 Responsible to ensure that the technicians working under his supervision
 Shall communicate with his management, client and other contractors.
 Shall ensure method statements, risk assessments and permit to work
requirements are communicated to the technicians and other personnel.

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 KINGDOM OF SAUDI ARABIA Page:
Saline Water Conversion Corporation
YANBU-MADINAH PHASE 3 WATER TRANSMISSION SYSTEM
HYDROSTATIC TEST PROCEDURE Spec. No. QC10-H-049 M09
Subject:
FOR STORAGE TANK ILF CONSULTING ENGINEERS
IndexRevision

First Rev. A Document Number

Issue Date: 325-QD60-F-

6.3 Tank Technician

 Responsible to carryout pressure testing and other activities in support of
pressure testing.
 Ensure that all marking around the thank is done as per the drawing
 Ensures the pressure gauges used have current calibrated stickers.
 Complete pressure test record and submit copy to program manager.

7 GENERAL
7.1 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
7.2 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.
7.3 This test will divide into following mentioned stages:
 Test preliminaries such as Visual Inspection.
 Inspection of Tank Bottom Welds (Vacuum Box Testing).
 Testing of the Shell Course and Tank Bottom Settlement (Hydrostatic-
Testing).
 Inspection of Roof-Plate and Reinforcing Plates (Air Testing).
7.4 Ensure that all of the mentioned test must perform after controlling all of the
N.D.T. test reports.
7.5 Vacuum test is carried out to find any leakage in the bottom plate by the use
the vacuum box testing equipment.
7.6 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.
7.7 Air test is conducted to check the gas tight of roof and reinforced plates of shell
openings of the tank.

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 KINGDOM OF SAUDI ARABIA Page:
Saline Water Conversion Corporation
YANBU-MADINAH PHASE 3 WATER TRANSMISSION SYSTEM
HYDROSTATIC TEST PROCEDURE Spec. No. QC10-H-049 M09
Subject:
FOR STORAGE TANK ILF CONSULTING ENGINEERS
IndexRevision

First Rev. A Document Number

Issue Date: 325-QD60-F-

8 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).
8.1 Equipment and Material
 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
open bottom is sealed against the tank surface by a sponge rubber
gasket.
 The test scheme shall have suitable connections, such as necessary
valves and calibrated vacuum gauge.
 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.
 The test scheme shall be demonstrated with sample test block by
application bubble solution at site before conduction of the test on the
job.
 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.
 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.
8.2 Surface Preparation
 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.
 Prior to vacuum testing all joints shall be checked visually.
8.3 Procedure of Vacuum Test
 The temperature of the surface of the part to be examined shall not below
0 0 0 0
4 C (40 F) and nor above 52 C (125 F).

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 KINGDOM OF SAUDI ARABIA Page:
Saline Water Conversion Corporation
YANBU-MADINAH PHASE 3 WATER TRANSMISSION SYSTEM
HYDROSTATIC TEST PROCEDURE Spec. No. QC10-H-049 M09
Subject:
FOR STORAGE TANK ILF CONSULTING ENGINEERS
IndexRevision

First Rev. A Document Number

Issue Date: 325-QD60-F-

 The weld seam on the test shall be applied with a bubble solution for
detecting leaks prior to placing vacuum box.
 The foaming shall be minimized by means of uniform application of
bubble solution.
 A vacuum can be drawn on the box by any convenient method, such as
connection to a gasoline- or diesel motor intake manifold.
 The gauge shall register a partial vacuum of at least 21Kpa for inspection
of the joints.
 The required partial vacuum shall be maintained for greater or either at
least 5 seconds examination time, stop watch to be used after reaching
the 21Kpa /designation vacuum.
8.4 Evaluation of Defects
 Bubbles produced by air sucked through the welded seam can detect the
presence of defect.
 The tested areas are accepted only when no continuous bubbles
formation is observed.
 A minimum light intensity of 100Lux is required for conducting the
examination.
 Upon satisfactory inspection, a report shall be prepared for the further
activities.
8.5 Repair and Retest
 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.
 Only the cutting out of defective joints that is necessary to correct the
defect is required.
 After repairing, retest of vacuum box test of welded joint shall be carried
out.
8.6 Cleaning
After test the area shall be thoroughly cleaned for the further activities

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 KINGDOM OF SAUDI ARABIA Page:
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YANBU-MADINAH PHASE 3 WATER TRANSMISSION SYSTEM
HYDROSTATIC TEST PROCEDURE Spec. No. QC10-H-049 M09
Subject:
FOR STORAGE TANK ILF CONSULTING ENGINEERS
IndexRevision

First Rev. A Document Number

Issue Date: 325-QD60-F-

9 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.
9.1 General Consideration
 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.
 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.
 Contractor will furnish the pipe and pumps required to move the water
from tank to tank.
 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.
9.2 Preparation of Hydrostatic Test
 After the completion of all welding works and non-destructive
examination of tank and all welded joints shall be signed off by QC
welding inspector prior to commencement of the hydrostatic test.
 Temporary test gaskets shall be used for all fittings and manholes.
 The hydrostatic test of tank shall be conducted before permanent
external piping is connected to the tank.
 Cleaning inside the tank and removal of temporary jigs and tools shall be
completed.
 All shell openings shall be closed by block valves or by appropriate cover
plates.
 Roof manholes shall be opened while introducing water into the tank or
drawing off water.
 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.

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 KINGDOM OF SAUDI ARABIA Page:
Saline Water Conversion Corporation
YANBU-MADINAH PHASE 3 WATER TRANSMISSION SYSTEM
HYDROSTATIC TEST PROCEDURE Spec. No. QC10-H-049 M09
Subject:
FOR STORAGE TANK ILF CONSULTING ENGINEERS
IndexRevision

First Rev. A Document Number

Issue Date: 325-QD60-F-

 The above points will be referenced back to a permanent benchmark.

 Install temporary plastic tube to be used as a water level indicator during
hydrostatic test.
9.3 Procedure of Hydrostatic Test
 Proper arrangement shall be carried out for the water filling. Pipe
connection from the water resource point and providing valves wherever
required.
 Potable water shall be used for hydrostatic testing.
 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.
Table 1. Water Filling Rate

Water Filling Rate

Bottom Course Maximum
Tank Portion
Thickness Filling Rate
Top Course 300mm/hr
Less than 22mm
Below Top Course 460mm/hr
 Top Third of Tank 230mm/hr
 22mm and Above Middle Third Tank 300mm/hr
 Bottom Third Tank 460mm/hr

 Filling shall be done in four stages 25%, 50%, 75% and 100%. After each
stage a load stabilization period shall be observed.
 As water rises in the tank, observe the shell fittings for any signs of
leakage around the blind flanges.
 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 (9.1- Item no.7) and
readings are recorded.

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 KINGDOM OF SAUDI ARABIA Page:
Saline Water Conversion Corporation
YANBU-MADINAH PHASE 3 WATER TRANSMISSION SYSTEM
HYDROSTATIC TEST PROCEDURE Spec. No. QC10-H-049 M09
Subject:
FOR STORAGE TANK ILF CONSULTING ENGINEERS
IndexRevision

First Rev. A Document Number

Issue Date: 325-QD60-F-

 If the differential readings do not exceed 1½ mm per meter of

circumference, the filling of water shall continue.
 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.
 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
(9.1- Item no.7) shall apply to each of the level readings.
 Filling of water into the tank shall be continue until the level reaches the
maximum desired height as shown on approved IFC drawing.
 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.
 Water filling schedule and holding period shall be in accordance with API
650 as given in below table 2:

Water Level in Tank Holding Period

1st Filling 1/2 Full 1 day

2nd Filling 3/4 Full 1 day

3rd Filling Full Tank 2 days

Table.2 Water Level and Holding Period

9.4 Tank Foundation Settlement

 For the adequacy of tank foundation performance, a staged hydrostatic
procedure and an extensive settlement monitoring program is performed
as per project specification and API 650.
 Therefore the following tolerable settlement criteria are adopted as a
basis for evaluating tank performance during hydrostatic testing

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 KINGDOM OF SAUDI ARABIA Page:
Saline Water Conversion Corporation
YANBU-MADINAH PHASE 3 WATER TRANSMISSION SYSTEM
HYDROSTATIC TEST PROCEDURE Spec. No. QC10-H-049 M09
Subject:
FOR STORAGE TANK ILF CONSULTING ENGINEERS
IndexRevision

First Rev. A Document Number

Issue Date: 325-QD60-F-

 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.
 Shell elevation measurements shall be made at equally-spaced intervals
around the tank circumference not exceeding 10 m (32 ft).
 Install settlement monitoring markers at eight equally spaced locations
along the perimeter of the tanks.
 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.
 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.

 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.
 Filling of the tank shall be stopped until cleared by the contractor.
 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.
 The diametrical lines shall be spaced at equal angles, with a maximum
separation measured at the tank circumference of 10m (32ft). A minimum
of four diametrical lines shall be used.

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 KINGDOM OF SAUDI ARABIA Page:
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YANBU-MADINAH PHASE 3 WATER TRANSMISSION SYSTEM
HYDROSTATIC TEST PROCEDURE Spec. No. QC10-H-049 M09
Subject:
FOR STORAGE TANK ILF CONSULTING ENGINEERS
IndexRevision

First Rev. A Document Number

Issue Date: 325-QD60-F-

9.5 Removal of Test Water

 After the completion of Hydrostatic test, the tank shall be emptied at a
maximum water level variation rate as per specification.
 Make sure that roof manholes and vents are open during empty
operation of conical roof tank.
 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.
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.
 Prior to starting the pumping operation between two tanks, make sure
that roof manholes and vents are open on both tanks.
 Transfer to the next tank using gravity and a temporary pump as required
to empty the tested tank.
 After all water has been removed from the tested tank, open all manholes
and remove all temporary blinds and equipment.
 After final draining and drying, brushing, broom or vacuum cleaner shall
clean surface of the tanks bottoms.
 QC Inspectors sign the test data sheet at the completion of hydro test.

10 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.
10.1 Equipment and Material
 Pressure Gauge or Manometer
 Blank/Blind Flange with Safety Relief Valve
 Soapsuds
 Air Supply System

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 KINGDOM OF SAUDI ARABIA Page:
Saline Water Conversion Corporation
YANBU-MADINAH PHASE 3 WATER TRANSMISSION SYSTEM
HYDROSTATIC TEST PROCEDURE Spec. No. QC10-H-049 M09
Subject:
FOR STORAGE TANK ILF CONSULTING ENGINEERS
IndexRevision

First Rev. A Document Number

Issue Date: 325-QD60-F-

10.2 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:
 The tank workers shall prepare the test equipment and materials such
as; pressure gauge or manometer, testing piece, supply air and
soapsuds etc.,
 Before starting the air pressure test, water shall be filled to 50mm below
the curb angle.
 Cleaning and visual inspection of entire welding of roof plates and all roof
accessories shall be carried out prior to test.
 A manometer of suitable range shall be connected to the roof nozzle with
¼’’ diameter PVC tube for measurement of pressure
 Inlet connection shall be done with ½’’ hose from the compressor outlet to
one of the roof nozzle.
 To regulate the pressure, valves shall be provided on both ends.
 Once all nozzles and manhole are closed, pressure shall be applied
slowly inside the roof by controlling the isolation valves.
 Once the required
 Set the testing piece to the desired filling point of air either on manhole or
air vents.
 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.
 Observe the pressure gauge or water level in the manometer if it remains
in the desired test pressure.
 If this pressure remains the same then apply soapsuds to welding seams
or joint and the areas to be check for leaks.
 If the pressure decreases, re-check the possible air passage and
blank-off or retighten.
 If there are leaks then identify and mark the exact location of defects.
 Release the air pressure, rectify the leak and retest again until successful
passed the test in the presence of Client QC Engineer.
 The inspection and acceptance report shall be fully accomplished and
 signed by the Clients representative, Tank Supervisor and QC Engineer.
 Release the air pressure once the test is completed then put back all
components/parts that have been removed.

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 KINGDOM OF SAUDI ARABIA Page:
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YANBU-MADINAH PHASE 3 WATER TRANSMISSION SYSTEM
HYDROSTATIC TEST PROCEDURE Spec. No. QC10-H-049 M09
Subject:
FOR STORAGE TANK ILF CONSULTING ENGINEERS
IndexRevision

First Rev. A Document Number

Issue Date: 325-QD60-F-

11 SAFETY PRECAUTIONS
11.1 The safety measures shall be implemented during testing activities and the
contractor shall provide the necessary safety equipment, communication
equipment, access barriers etc.
11.2 Contractor shall issue a statement to all persons connected with testing,
warning of the hazards of failure under pressure.
There is a possibility that workers can take remedial action once minor
leakages are noticed before total failure occurs.
11.3 Hydrostatic tests are conducted under the constraints of projects
specifications.
11.4 Air/gas used for Air test is compressible to large extent and has very high
potential energy stored when compressed.
11.5 Ensure that no any worker shall present inside the tank prior to pressure
test.
11.6 Use and storage of any compressed gas under high pressure can be
extremely dangerous if proper gas handling procedures are not observed.
11.7 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.
11.8 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.
11.9 The technician must be conscious at all times of the potential for a rise in
temperature to significantly increase pressure.
11.10 Safety officer must be present at site during test.
11.11 Tested & certified Lifting equipment shall be used for lifting and shifting
purpose.
11.12 Safety Precautions shall be followed during fabrication and erection as per
project specification.
11.13 Welding cables and power cables to be laid properly as per Instrumentation
and Electrical rules and local state govt. rules and regulation.
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 KINGDOM OF SAUDI ARABIA Page:
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YANBU-MADINAH PHASE 3 WATER TRANSMISSION SYSTEM
HYDROSTATIC TEST PROCEDURE Spec. No. QC10-H-049 M09
Subject:
FOR STORAGE TANK ILF CONSULTING ENGINEERS
IndexRevision

First Rev. A Document Number

Issue Date: 325-QD60-F-

11.14 Proper housekeeping and clean condition shall be maintained in the

fabrication shop and site as per requirement.
11.15 Wear proper PPE i.e. fall protection harness, goggles etc.
11.16 Clean and clear the area and return the used equipment and materials to
the tool room or shop
11.17 Conduct hazard assessment and safety meeting.
11.18 Barricading of Tank, First-Aid kit and emergency phone number shall be
available.
11.19 The contractor shall provide patrols to all around the tank to watch any
special points of hazards during pressure test of tank.
11.20 Safety sign boards both in English and Arabic language shall be posted at
appropriate locations during tank testing the display shall be “TANK UNDER
PRESSURE TEST KEEP AWAY”.

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