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Checklist for the tank before hydrotest

1. Pre-Hydrotest Inspection

Inspect the tank's exterior for signs of corrosion, wear, or damage.

Verify the integrity of all fittings, connections, and attachments.

Ensure the interior of the tank is clean, free from debris, and properly prepared for testing.

Confirm that all safety devices (e.g., pressure relief valves) are installed and functional.

Make sure access points for inspection and maintenance are unobstructed.

2. Documentation Review

Confirm that all design documents and specifications are available and current.

Review the hydrotest procedure to ensure alignment with API 650 standards.

Obtain and verify all necessary permits for conducting the hydrotest.

Ensure all previous inspections and tests have been documented and passed.

Close any Non-Conformance Reports (NCRs) that may impact the hydrotest process.

3. Fabrication Checks

Inspect the fit-up and welding of the annular plate and perform Ultrasonic Testing (UT) or Radiographic Testing (RT) as required.

Verify the fit-up and welding of the bottom plate; perform a Vacuum Box test to ensure integrity.

Assess the fit-up and welding of the shell sections, ensuring quality in execution.

Conduct Radiographic Testing (RT) on the welds of the roof after fit-up and welding.

Inspect the fit-up and welding of the nozzle pads and nozzles for quality and alignment.

Perform a leak test on the nozzle pad to confirm integrity.

Execute Penetrant Testing (PT) or Magnetic Particle Testing (MT) on areas where temporary items were welded to ensure there are no defects.

4. Equipment and Materials Check

Inspect the hydrotest pump for operational readiness and review maintenance history.

Verify that all pressure gauges are calibrated and functioning correctly.

Ensure that the test medium is suitable, clean, and free of contaminants.

Check that hoses, fittings, and connections are rated for the expected pressure.

5. Safety Precautions

Conduct a safety briefing with all personnel involved in the hydrotest.

Ensure that personal protective equipment (PPE) is available and used appropriately.

Set up warning signage around the test area to indicate potential hazards.

Review emergency shutdown procedures and clarify personnel roles in case of emergencies.

6. Test Preparation

Securely connect all hoses and fittings to the tank and pump.

Gradually fill the tank with the test medium, monitoring for any leaks during the process.

Ensure proper venting of the tank and associated piping to eliminate any trapped air.

Establish a plan for monitoring pressure and temperature during the hydrotest.

7. Post-Hydrotest Actions

Carefully depressurize the tank and document the process.

Conduct a thorough inspection of the tank for any leaks or structural issues.

Record hydrotest results, including pressure readings and any irregularities observed.

Dispose of the test medium in compliance with environmental regulations.

Complete any required follow-up actions based on the hydrotest results.

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