Hydrostatic Test Procedure for Underground Storage Tank

Step 2 - Preparation for test

Water
 Potable water is preferred for hydro-testing. This does not preclude using condensate,
reverse osmosis, well, river, or seawater.
 The tank metal temperature during hydrostatic testing shall not be colder than the design
metal temperature.

Tank
 Ensure the tank is clean, debris-free, and all connections and openings are adequately sealed.
Check the tank's foundation and supports to ensure they can handle the total weight of the
tank when filled with water.
 A pressure gauge shall be installed at the nozzle at the lowest height.
 For installing the pressure gauge special blind flange and piping device shall be provided.
 The vent shall be provided at high points of the tank in the position in which it is to be tested
to purge possible air pockets while the tank is being filled.

Notes:
A hydrostatic test of the tank shall be conducted before permanent external piping is
connected to the tank. Attachments to the shell (defined in API-650- 5.8.1.1), located at least 1 m
(3 ft) above the water level, and roof appurtenances may be welded during the filling of the tank.
After the hydro-test is completed, only non-structural small attachments may be welded to the
tank per API-650-7.2.1.11.

Step 2: Filling the Tank

The water filling rate shall be controlled to protect the urgent uneven settlement.
Therefore the maximum filling and discharge rate shall be as per standard API 650, as given in
the below table.

Water Filling Rate

Tank Portion Maximum Filling Rate

Top third of the tank 230 mm /hr
Middle third of the tank 300 mm/hr
Bottom third of the tank 460 mm/hr

 Filling shall be done in four stages 25%, 50%, 75%, and 100%. After each stage, a load
stabilization period shall be observed.
 As the 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 using 16 equally
spaced points marked on the bottom plate projecting out from the bottom shell around the
tank at its base.
 Water filling shall continue if the differential readings do not exceed 1.5 mm per meter of
circumference.
 As water is being pumped into the tank. Observe the tank's circumference 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 300
mm below the repaired point.

Step 3: Monitor for Leakage

Once the tank is filled to the desired level, monitor the tank for any signs of leakage, such
as water seepage or dripping, for a specified duration of time (e.g., 24 hours). Inspect all tank
joints, connections, welds, and seams for leaks. If any leaks are detected, take appropriate
measures to address them before proceeding with the test.

Step 4: Hydrostatic testing:

 The hydrostatic test pressure should be 1.3 times the design pressure but not less than 1.3
times the MAWP.
 For atmospheric pressure, which is 1.013 bar, the hydrostatic test pressure would be 1.3
times the design pressure of 1.52 bar, which is 1.976 bar.

Step 5: Measure the Pressure

After the specified duration of time has elapsed and no leaks are detected, measure the
pressure inside the tank using pressure gauges or transducers. Record the pressure readings
accurately.

Step 6: Hold the Test Pressure

Maintain the test pressure inside the tank for a specified duration of time (e.g., 1-2 hours) to
ensure the integrity of the tank. Monitor the pressure continuously during this period and take
appropriate measures to maintain the test pressure within the specified range.

Step 7: Inspect for Deformation

After the specified duration of time has elapsed, inspect the tank for any signs of deformation,
bulging, or other structural abnormalities. Pay close attention to areas susceptible to stress, such
as welds, seams, and corners. If any deformations are observed, take appropriate measures to
address them before completing the test.

Step 8: Release Pressure

Once the test is completed and the tank has passed all inspection criteria, slowly release
the test pressure from the tank using appropriate procedures and equipment. Be cautious to
release the pressure slowly to avoid any sudden changes that could cause damage to the tank or
pose a safety risk.

Step 9: Drain the Tank

After the pressure is released, drain the water from the tank using appropriate methods,
such as pumps or gravity drainage. Dispose of the water in accordance with applicable
regulations and environmental requirements.

Step 10: Inspect for Residual Water

After the tank is drained, inspect the tank's interior for any residual water. Dry the tank
thoroughly before putting it back into service.