This document outlines the procedure for conducting a hydrotest/water fill-up test of a tank. It details the preparation steps like ensuring all welding and NDT work is complete. The test will be done using portable water and in stages, filling to 25%, 50%, 75% and 100% and observing for 24 hours between each stage. Settlement will be measured throughout and records submitted after draining and cleaning the tank. Safety precautions must be followed during the water filling test.

1. DOC NO
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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

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DATE
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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