7) hydro test 3
- 1. DOC NO V DATE PAGE NO 03 OF 05 PROJECT TITLE JOB PROCEDURE FOR HYDRO TEST / WATER FILL UP TEST JOB PROCEDURE FOR HYDROTEST/WATER FILLUP TEST 1. SCOPE This test procedure shall be carried out to detect the leak in shell weld joints and to observe the load stabilization of liquid in interval level height. 2. PURPOSE The purpose of this procedure is providing the guideline and sequential steps for the hydro test / water fill up test for the tank. 3. CHECK LIST After completion of the erection, welding and NDT the following points shall be checked before testing. All the mechanical activities completion in respect of the drawing and HPCL Specification and code requirements. Radiography completion including repairs. The entire NDT test like chalk-diesel test, LPT, RF .Pad pneumatic test, vacuum box test completion. Finally mechanical clearance from the Engineer-In-Charge shall be taken before Hydrotest in approved format 4. TEST MEDIA Test media shall be in iron free water, which is clean and free of silt i.e.; Portable water 5. PROCEDURE Proper arrangement shall be carried out for the water filling (pipe connection from the water resource point and providing valves and NRV wherever required. markers shall be provided on the shell, 500 mm from the bottom to check tank settlement. Size shall be 50 X 50 X 6mm angle and 100 mm long. The nos. of setting marker shall be minimum 8 Nos or as per the approved Drg. Code : API 650 (7.3.6) Eleven Edition Prepared by CONTRACTOR . Concurred by Name : Design: Hindustan Petroleum Crop. Ltd. Approved by Name : Design: Hindustan Petroleum Crop. Ltd
- 2. DOC NO VS DATE PAGE NO 04 OF 05 PROJECT TITLE JOB PROCEDURE FOR HYDRO TEST / WATER FILL UP TEST Settling markers shall be provided at every 300 outside the tank at a height of 500 mm from the top of annular plate. Setting marker shall be welded and initial level reading shall be taken with respect to the permanent benchmark using dumpy level / Total station Shell settlement measurements shall be made after tank erection, prior to hydrotesting and during water filling at 1000 mm intervals up to maximum filling height of tank. The levels taken before water filling called as initial level of the tank and shall be record in an approved format. The water filling height shall be restricted to the max. Liquid Level or up to the curb angle. The water filling shall be carried out in four stages (25%, 50%, 75% 100% of the max liquid level of the tank) Any leaks observed in the shell joint during the hydro test shall be noted and repaired with the water level min. of 300mm below the leak spot. The repaired shall be carried out as per the procedure and tank test shall be recommenced. After each stage of filling, a load stabilization period shall be observed as minimum 24 hours max between each stage of filling. During the stabilization period the settlement reading shall be observed and recorded jointly with HPCL Engineer-In-Charge through dumpy level only. Filling rate shall be not exceed 5 meters per day. After completion of the water filling the water load shall be maintained for 24 hours. After 24 hours the final settlement reading shall be recorded jointly with engineer-In-Charge. Tank shall be emptied at a maximum water level variation rate of 5 meters per day. Care shall be taken that top manholes are open during empty operation of conical roof tanks. If salt water is used then corrosion inhibitor should be sprayed (mixed) prior to filling / after hydro test the tank should be thoroughly cleaned with sweat water. Prepared by CONTRACTOR . Concurred by Name : Design: Hindustan Petroleum Crop. Ltd. Approved by Name : Design: Hindustan Petroleum Crop. Ltd
- 3. DOC NO DATE PAGE NO 05 OF 05 PROJECT TITLE JOB PROCEDURE FOR HYDRO TEST / WATER FILL UP TEST 6. CLEANING After draining the water the tank shall be thoroughly cleaned, free from dirt and foreign materials and shall be dried by air. 7. RECORDS Records shall be prepared and submitted to Engineer in-charge for approval. 8. SAFETY All Safety precaution shall be taken during water fill up test. 9. REFRENCE (A) API 650 (B) OISD 129 (C) PO Tech Specification Note : Permanent B M shall be min. 50Mtr away from Tank shell Prepared by CONTRACTOR . Concurred by Name : Design: Hindustan Petroleum Crop. Ltd. Approved by Name : Design: Hindustan Petroleum Crop. Ltd