PO DESCRIPTION: FIELD FABRICATED TANK WORK

PO No.:
SUBJECT :

DOCUMENT NO. :

SUR-SUB-ME-007
WATER FILLING EXECUTION
PROCEDURE FOR FIELD ERECTED TANK
SUR-M-99BB-91-001

For Approval
CLIENT

OWNERS ENGINEER

CONTRACTOR

SUB CONTRACTOR

INCO ENGINEERING CO. LLC

11 February 2012

Issued for Review

Sudhish Krishnan

Debajit

Rev.
No

Date

Description

Prepared
by

Reviewed
by

Approved
by

It may NOT be used, disclosed or reproduced for other purpose pertaining to this document or its contents without specific, written prior permission of
Daewoo E&C Co., Ltd.

1.0

PURPOSE:
To establish an acceptable system of carrying out the water fill up testing for the tank as per
the design and code requirement. This procedure covers the filling, settlement measurement
and testing procedure of fixed roof tanks. The water fill up test shall be done after entire
completion of the tank and before any permanent external piping is connected to the tank, the
shell shall be tested with full of water.

2.0

SCOPE:
Sets out the method to be used by INCO for performing water fill up testing of Fuel Oil tanks
(4 Nos), Treated Water Tank (2 Nos.), Demi water tank (2 Nos.), RO Permeate water Tank(2
Nos.), and Fire Water Tank (2Nos.) as per the attached hydro test sequence plan.

3.0 REFERENCE DOCUMENTS:

1) API 650
2) Client Approved fabrication drawing.
3) Permit for Water Disposal shall be obtained from environmental authority and will be
submitted before testing.
4.0

DEFINITIONS;
None

5.0

RESPONSIBILITIES AND AUTHORITIES:

The Site Engineer shall be responsible for compliance with activities described in this
procedure. Responsibilities of other personal shall be as indicated in the section of this
procedure.
The responsibility of the Site Engineer shall be to ensure that the water fill up testing
activities are being performed in accordance with the project specifications and to prepare
the equipments, tools, data and drawings required to perform the test in a safe and trouble
free manner.
Safety officer shall be responsible for the enforcement of safety
procedures to ensure that the hydro test is performed in a safe manner.
Water fill up Testing

- Site engineer & Fabrication supervisor/Foreman

Inspection of water fills up Testing of Tank

6.0 PROCEDURE;
6.1

Tank Details:
1) Tank

Fuel Oil Tank.

11,207 M3

Tank inside diameter :

28000 mm

Tank height

18200 mm

Nominal capacity

- QA/QC Engineer

practices and

2) Tank
Nominal capacity

:
:

2297 M3

Tank inside diameter:

15000 mm

Tank height

13000 mm

Fire Water Tank.

1724 M3

Tank inside diameter:

14000 mm

3) Tank
Nominal capacity
Tank height
4) Tank
Nominal capacity

11200 mm

RO Permeate Water Tank.

644 M3

Tank inside diameter:

Tank height
5) Tank
Nominal capacity
Tank height

10000 mm
:

8200 mm

: Treated Water Tank.

:

Tank inside diameter:

6.1.1

Demi Water Tank.

2951 M3
17000 mm

: 13000 mm

The hydrostatic test shall be performed in accordance with API 650 para 7.3.6
HYDROSTATIC TEST TABLE

Sl.
No.
1.
2.
3.
4.
5.

6.2
6.2.1

Tank

Applicable
code

Fuel Oil Tank

Fire Water Tank
Demi Water Tank
RO Permeate Water
Tank
Treated Water Tank

API 650
API 650
API 650
API 650
API 650
Table - 1

Max.
Design
Liquid
Level
17.300 mtr
10.390 mtr.
12.100 mtr.
7.200 mtr.

Test Water
Level

Type of test.

18.180 mtr
11.180 mtr.
12.980 mtr.
8.180 mtr.

Water fill up
Water fill up
Water fill up
Water fill up

12.100 mtr.

12.980 mtr.

Water fill up

PREPARATION AND CHECK;

All welding and inspection shall be completed and accepted by the engineer except roof
plate opening for ventilation.
6.2.2 Cleaning inside the tank and the removal of temporary jigs, tools and foreign material will be
checked completely.
6.2.3 Prior to hydrostatic test, the erection work shall be done in accordance with the field erection
procedure and it shall have been inspected and accepted by client.

6.2.4 All shell opening shall be closed with blind flanges, permanent valve covered with temporary
blind plates.
6.2.5 The Zero Load settlement reading must have been taken and submitted client.
6.2.6 Reference point shall be marked around the base of tank for subsequent leveling reference (8
Points)
6.2.7 Before water is filled into the tank, the level at each reference point should be recorded.
6.2.8 While water filling or draining is performed, nozzles and manholes on the tank roof shall be
kept opened to avoid distortion of the tank, due to an excessive breathing load.
6.3

SAFETY:
Work permit to carry out the hydro test shall be made available for carrying out the water fill
up test.
1
2
3
4

6.3

Assure the safety & personnel during the test at all times. Comply of precaution with
statutory & other relevant regulations.
Take all necessary measures to ensure that all personnel and property are adequately
protected during the course of works.
Unauthorized person will not be allowed in the vicinity during water fill up test of the
tank.
Safe distance shall be barricaded and place sign board saying KEEP AWAY, TANK
WATER FILLUP TEST IN PROGRESS

TEST MEDIUM :
6.3.1 The test medium shall be Potable Water.
6.3.2 The required water shall be bring by Tanker and filled as shown in the map for water
filling one after another tank.

6.4

WATER FILL UP TEST:

6.4.1

6.4.2
6.4.3
6.4.4
6.4.5

6.4.6

The shell fittings and lower piping are to be checked for leaks and signs of
distress, if defect discovered after the tank has been filled with the water for
testing shall be made with the water level at least 1 foot below any point being
repaired of, if welding shall not be done on any tank unless all connection line
have been completely blinded.
Pinhole leaks or porosity in a tank bottom joint may be repaired by applying
an additional weld bead over the defective area. Other defects or crack in tank
bottom shall be repaired as required by API 650 section 6.1.7
All defects, cracks or leak in shell joint or the shell to bottom joint shall be
repaired in accordance with API 650 section 6.1.7
During water test, the foundation settlement shall be checked at each stage
and the records shall be submitted to contractor or client for information.
Frequency of settlement measurements shall be taken as follows.
a) Before water filling;
b) During filling.
c) After water draining.
Water filling shall be stopped at the intervals listed below; filling shall be
halted during these periods for settlements taken.

6.4.7

The tank filling sequence shall be as follows:

For Tank ID less than 25000 mm.
1st step : Settlement check for hydrostatic test.
2nd step : Half water filling in tank.
3rd step : Full water filling in tank.
4th step : half draining of water in tank.
5th step : Settlement check after full draining of tank.
For Tank ID more than 25000 mm.
1st step : Settlement check for hydrostatic test.
2nd step : 1/4th filling of water.
3rd step : filling of water
4th step : 3/4th filling of water
5th step : Full water filling in tank.
6th step : 1/4th the draining of water.
7th step : half draining of water in tank.
8th step : 3/4th draining of water.
9th
step : Settlement check after full draining of tank.

6.4.8
6.4.9
6.4.9.1
6.4.9.2
6.4.9.3

The holding period for each steps will be one hour but for step full filling 48
hours. If it is agreed that there is no significant settlement of the tank, each
steps draining shall be carried out for all remaining tanks.
Water discharge.
Roof manholes and fittings are to be opened so as to have as large an area as
the tank outlet.
When the test water filling to be drain or transfer to another tank, before
opening the drain valve all the roof nozzles, vents and manholes should be
kept open to prevent tank from distortion due to excessive breathing load.
After the water filling test, any standing water, or other dirt left in the tank
shall be cleaned out so that the tank interior is ready for use.
After test water has been removed the tank walls and floor plates must be
washed with potable water by high pressure jet hose.

6.4.11 Water filling test instruction.

a) Never close a tank, for any length of time, without adequate venting.
b) Make certain roof manhole and /or other roof fittings having as large an area as the
water inlet are open before filling the tank with water.
c) Before, during and after filling the tank with water, check the elevations around the
bottom and immediately report any differential or excessive settlement to the client.
All elevations should be referenced to a temporary retrievable bench mark.
d) Open roof manhole and or other roof fittings having as large an area as the water
outlet and drain all water from the tank.
7.0 REPAIRS TO WELDS:

Any leak found in welds shall be called to the attention of clients inspector and prior
approval shall be obtained from him for the repairs. All completed repairs shall be subject to
the approval of the clients inspector.
Repairs of defects discovered after the tank has been filled with water for testing, the
water shall be drained at least one foot below any point being repaired or if repairs have to be
made on or near the tank bottom, tank shall be drained completely.

8.0

TEST COMPLETION:
Upon the completion of tank test, the test report shall be signed off; Signature for acceptance
from client representative shall be obtained.
Then the water will be transferred to the next tank in sequence, and the procedures will be
repeated until all tanks have been tested and approved.
Upon final completion of all Tanks to be Hydro-Tested, the water will be tested by a
certified laboratory.
The disposal will be all dependent upon the results, if no hazards are present, the water can be
used for dusting the roads, if contaminant exceeds legal limits, and then the water will be
disposed of accordingly to compliance regulations.

9.0

RECORDS:
1) Hydrotest sequence plan Annexure - 1.
2) Map for hydrotest Annexure - 2 (Page 1 & 2).
3) Transferring of water from tank to tank annexure - 3
4) Water draining and disposal plan annexure 4
5) Settlement report format.