Document No:- 9560/NBEL/SITE/QAC/025, REV.

PROJECT : 500 TPD Sulphuric Acid Plant with 5.0 MW Power Generations

LOCATION: 10th of Ramadan City, Industrial Area A1, Egypt

CLIENT EPC CONTRACTOR

BHARAT PETROLEUM CORPORATION LIMITED NUBERG ENGINEERING LIMITED

DOCUMENT TITLE

JOB PROCEDURE FOR TANKS WATER FILL TEST

DOCUMENT NUMBER

9560/NBEL/SITE/QAC/025, REV.0

Document Category Document Review Status (by Owner/PMC)

(Submission Purpose)
Approval ☐ 1. Approved / Reviewed
☐ Review ☐ 2. Approved / Reviewed with comments as marked
☐ Information ☐ 3. Not Approved / Resubmit
☐ FOR REVIEW AND
Implementation ANAND
00 ☐ R. Retained for Information / Records
ASHWANI RAJEEV SHARMA
APPROVAL SHARMA
TYAGI
Date: ___/____/____ Name: ____________________
Rev Checked By
Date DocumentThis
Status
approval does Prepared
not absolve the ByContractor from meeting their contractual obligations
Approved By a
of delivering
. complete, safe and efficiently operating units/facilities meeting all requirements of the contract
 Document No:- 9560/NBEL/SITE/QAC/025, REV.0

JOB PROCEDURE FOR TANKS WATER FILL TEST

CONTENTS

1. SCOPE

2. PURPOSE

3. RERENCE

4. CHECK LIST

5. PROCEDURE

6. CLEANING

7. TESTING OF ROOF

8. CLEANING

9. RECORDS

10. SAFETY

Page:-2/4
 Document No:- 9560/NBEL/SITE/QAC/025, REV.0

JOB PROCEDURE FOR TANKS WATER FILL 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. REFRENCE
a) API 650
b) Approved Drawing
c) NBEL ITP-9560/SITE/QAC/022/ITP-13

4. CHECK LIST
a) After completion of the erection, welding and NDT the following points shall be checked
before testing.
b) All the mechanical activities completion in respect of the drawing.
c) Specification and code requirements.
d) Radiography completion including repairs.
e) The entire NDT test like chalk-diesel test, LPT, RF Pad, pneumatic test, vacuum box test
completion.
f) Finally mechanical clearance from the NBEL/CLIENT be taken before Hydro test in approved
format

5. TEST MEDIA
Testing media for hydro-test/Water Fill test shall be iron free water, which is clean and free from
dust silt.
Maximum chloride content in water for testing for SS & Carbon steel tank it shall be 50PPM, Water
pH shall be between 6 to 8.3 and Free Chlorine content at least 0.2 PPM or as per specification.

6. 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.
a) 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. offsetting marker shall be
minimum 8 Nos or as per the approved Drg.
b) Code: API 650 (7.3.6) Eleven Edition
c) Settling markers shall be provided at every 300 outside the tank at a height of 500 mm from
the top of annular plate.
d) Setting marker shall be welded and initial level reading shall be taken with respect to the
permanent benchmark using dumpy level / Total station.
e) Shell settlement measurements shall be made after tank erection, prior to hydro testing and
during water filling at 1000 mm intervals up to maximum filling height of tank.
f) The levels taken before water filling called as initial level of the tank and shall be record in an
approved format.
g) The water filling height shall be restricted to the max. Liquid Level or up to the curb angle.
Page:-3/4
 Document No:- 9560/NBEL/SITE/QAC/025, REV.0

JOB PROCEDURE FOR TANKS WATER FILL TEST

h) The water filling shall be carried out in four stages (25%, 50%, 75% & 100% of the max liquid
level of the tank)

i) 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.
j) The repaired shall be carried out as per the procedure and tank test shall be recommenced.
k) After each stage of filling, a load stabilization period shall be observed as minimum 24 hours
max between each stage of filling.
l) During the stabilization period the settlement reading shall be observed and recorded jointly
with Client through dumpy level only.
m) Filling and emptying rate shall be 25 m ᶟ/hr (max) or as per data sheet.
n) 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 TPIL.

7. Testing of Roof
a) The roof of tank designed to be gas tight shall be tested by one of the following methods.
i) Applying internal air pressure not exceeding the weight of the roof plates and
applying to the weld joint a bubble solution or other material suitable for the
detection of leaks.
ii) Vacuum testing the weld joints as per API 650 & approved procedure.
b) The roof of a tank is not designed to be gas-tight, such as a tank with peripheral circulation
vents or a tank free or open vents, shall receive only visual examination of its weld joints,
unless otherwise specified in Data sheet.

8. CLEANING
After draining the water the tank shall be thoroughly cleaned, free from dirt and foreign materials
and shall be dried by air.

9. RECORDS
Records shall be prepared a per approved ITP.

10. SAFETY

All Safety precaution shall be taken during water fill up test.

1) Provide for and require that signs, barricade or other protection barriers are placed in a
manner and at a distance sufficient to demarcate a safe zone to protect personnel.
2) Keep unauthorized personnel out of the test area.
3) Do not work over or near where water fill testing is being conducted.
4) Wear PPE as appropriate for the task being performed.
5) Attend required training before working on the task.
6) Verify that test equipment and material.
7) Adequate lighting shall be available through testing operation.

Page:-4/4