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A Issue for approval MOHAMED WALEED

4/10/2021
ATEF ELBEHERY
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‫المملكة العربية السعودية‬
KINGDOM OF SAUDI ARABIA
‫الكيميائية السعودية‬
SAUDI CHEMICAL COMPANY LIMITED
Project No. ‫رقم المشروع‬ ‫تصنيع وتركيب خزان مياه لمكافحة الحرائق‬
SC001 FABRICATION AND ERECTION OF FIRE WATER TANK

CONSTRUCTION OF MILITARY EXPLOSIVES FACTORY

‫المالك‬
SAUDI CHEMICAL COMPANY LIMITED
OWNER
(SCCL)

GENERAL CONTRACTOR: MOBCO

‫المقاول‬
CONTRACTOR SUB-CONTRACTOR: GMCO

LOCATION: TITLE:

METHOD STATEMENT OF HYDROSTATIC TEST FOR FIRE WATER

TANK
SCALE: DOCUMENT No.: REV:

0 0 5 - M S H T - G - A

Sheet 1of14
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FABRICATION AND ERECTION OF FIRE WATER TANK
CONSTRUCTION OF MILITARY EXPLOSIVES FACTORY

HYDROSTATIC TEST PROCEDURE Spec. No. 202101010

Subject:
FOR STORAGE TANK Saudi Chemical
Revision

First Rev. A Document Number

Index

Issue Date: 005-MSHT-G-

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 SAFETY PRECAUTIONS .............................................................................................................. 15

Owner Contractor Subcontractor

SCCL MOBCO GMCO

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FABRICATION AND ERECTION OF FIRE WATER TANK
CONSTRUCTION OF MILITARY EXPLOSIVES FACTORY

HYDROSTATIC TEST PROCEDURE Spec. No. 202101010

Subject:
FOR STORAGE TANK Saudi Chemical
Revision

First Rev. A Document Number

Index

Issue Date: 005-MSHT-G-

1 SCOPE
This Procedure specifies the requirements of Hydrostatic Test and Vacuum Test for
Aboveground Water Storage Tank in the PROJECT OF CONSTRUCTION OF
MILITARY EXPLOSIVES FACTORY for SAUDI CHEMICAL COMPANY LIMITED
(SCCL).

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
ASME Section VIII, Division 1 Boiler and Pressure Vessel Code

4 DEFINITIONS

Employer Saudi Chemical Company Limited (SCCL)

Contractor MOBCO
Sub-Contractor GMCO
Project CONSTRUCTION OF MILITARY EXPLOSIVES FACTORY

Owner Contractor Subcontractor

SCCL MOBCO GMCO

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FABRICATION AND ERECTION OF FIRE WATER TANK
CONSTRUCTION OF MILITARY EXPLOSIVES FACTORY

HYDROSTATIC TEST PROCEDURE Spec. No. 202101010

Subject:
FOR STORAGE TANK Saudi Chemical
Revision

First Rev. A Document Number

Index

Issue Date: 005-MSHT-G-

5 ABBREVIATIONS
API American Petroleum Institute
ASME American Society of Mechanical Engineers
ANSI American National Standard Institute
ASTM American Society for Testing and Materials
IFC Issue for Construction
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.

Owner Contractor Subcontractor

SCCL MOBCO GMCO

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FABRICATION AND ERECTION OF FIRE WATER TANK
CONSTRUCTION OF MILITARY EXPLOSIVES FACTORY

HYDROSTATIC TEST PROCEDURE Spec. No. 202101010

Subject:
FOR STORAGE TANK Saudi Chemical
Revision

First Rev. A Document Number

Index

Issue Date: 005-MSHT-G-

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 as per specification.

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).

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.

7.7 Potable water shall be used to fill the tank.

Owner Contractor Subcontractor

SCCL MOBCO GMCO

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FABRICATION AND ERECTION OF FIRE WATER TANK
CONSTRUCTION OF MILITARY EXPLOSIVES FACTORY

HYDROSTATIC TEST PROCEDURE Spec. No. 202101010

Subject:
FOR STORAGE TANK Saudi Chemical
Revision

First Rev. A Document Number

Index

Issue Date: 005-MSHT-G-

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
40C (400F) and nor above 520C (1250F).

Owner Contractor Subcontractor

SCCL MOBCO GMCO

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FABRICATION AND ERECTION OF FIRE WATER TANK
CONSTRUCTION OF MILITARY EXPLOSIVES FACTORY

HYDROSTATIC TEST PROCEDURE Spec. No. 202101010

Subject:
FOR STORAGE TANK Saudi Chemical
Revision

First Rev. A Document Number

Index

Issue Date: 005-MSHT-G-

 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.

Owner Contractor Subcontractor

SCCL MOBCO GMCO

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FABRICATION AND ERECTION OF FIRE WATER TANK
CONSTRUCTION OF MILITARY EXPLOSIVES FACTORY

HYDROSTATIC TEST PROCEDURE Spec. No. 202101010

Subject:
FOR STORAGE TANK Saudi Chemical
Revision

First Rev. A Document Number

Index

Issue Date: 005-MSHT-G-

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 MOBCO, for all stages.
 After the completion of the hydro testing operations for the tank, MOBCO
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.

Owner Contractor Subcontractor

SCCL MOBCO GMCO

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FABRICATION AND ERECTION OF FIRE WATER TANK
CONSTRUCTION OF MILITARY EXPLOSIVES FACTORY

HYDROSTATIC TEST PROCEDURE Spec. No. 202101010

Subject:
FOR STORAGE TANK Saudi Chemical
Revision

First Rev. A Document Number

Index

Issue Date: 005-MSHT-G-

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

 Install temporary plastic tube or marking 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
if 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 and readings are recorded.

Owner Contractor Subcontractor

SCCL MOBCO GMCO

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FABRICATION AND ERECTION OF FIRE WATER TANK
CONSTRUCTION OF MILITARY EXPLOSIVES FACTORY

HYDROSTATIC TEST PROCEDURE Spec. No. 202101010

Subject:
FOR STORAGE TANK Saudi Chemical
Revision

First Rev. A Document Number

Index

Issue Date: 005-MSHT-G-

 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
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

Owner Contractor Subcontractor

SCCL MOBCO GMCO

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FABRICATION AND ERECTION OF FIRE WATER TANK
CONSTRUCTION OF MILITARY EXPLOSIVES FACTORY

HYDROSTATIC TEST PROCEDURE Spec. No. 202101010

Subject:
FOR STORAGE TANK Saudi Chemical
Revision

First Rev. A Document Number

Index

Issue Date: 005-MSHT-G-

 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.
 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.

Owner Contractor Subcontractor

SCCL MOBCO GMCO

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FABRICATION AND ERECTION OF FIRE WATER TANK
CONSTRUCTION OF MILITARY EXPLOSIVES FACTORY

HYDROSTATIC TEST PROCEDURE Spec. No. 202101010

Subject:
FOR STORAGE TANK Saudi Chemical
Revision

First Rev. A Document Number

Index

Issue Date: 005-MSHT-G-

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.
 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.

Owner Contractor Subcontractor

SCCL MOBCO GMCO

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FABRICATION AND ERECTION OF FIRE WATER TANK
CONSTRUCTION OF MILITARY EXPLOSIVES FACTORY

HYDROSTATIC TEST PROCEDURE Spec. No. 202101010

Subject:
FOR STORAGE TANK Saudi Chemical
Revision

First Rev. A Document Number

Index

Issue Date: 005-MSHT-G-

10 SAFETY PRECAUTIONS
10.1 The safety measures shall be implemented during testing activities and the
contractor shall provide the necessary safety equipment, communication
equipment, access barriers etc.
10.2 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.
10.3 Hydrostatic tests are conducted under the constraints of projects
specifications.
10.4 Ensure that no any worker shall present inside the tank prior to pressure test.
10.5 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.
10.6 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.
10.7 The technician must be conscious at all times of the potential for a rise in
temperature to significantly increase pressure.
10.8 Safety officer must be present at site during test.
10.9 Tested & certified Lifting equipment shall be used for lifting and shifting
purpose.
10.10 Safety Precautions shall be followed during fabrication and erection as per
project specification.
10.11 Welding cables and power cables to be laid properly as per Instrumentation
and Electrical rules and local state govt. rules and regulation.

Owner Contractor Subcontractor

SCCL MOBCO GMCO

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FABRICATION AND ERECTION OF FIRE WATER TANK
CONSTRUCTION OF MILITARY EXPLOSIVES FACTORY

HYDROSTATIC TEST PROCEDURE Spec. No. 202101010

Subject:
FOR STORAGE TANK Saudi Chemical
Revision

First Rev. A Document Number

Index

Issue Date: 005-MSHT-G-

10.12 Proper housekeeping and clean condition shall be maintained in the fabrication
shop and site as per requirement.
10.13 Wear proper PPE i.e. fall protection harness, goggles etc.
10.14 Clean and clear the area and return the used equipment and materials to the tool
room or shop
10.15 Conduct hazard assessment and safety meeting.
10.16 Barricading of Tank, First-Aid kit and emergency phone number shall be available.
10.17 The contractor shall provide patrols to all around the tank to watch any special
points of hazards during pressure test of tank.
10.18 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”.

Owner Contractor Subcontractor

SCCL MOBCO GMCO