Document No :

WUR D-QAC-PG-WP-

WORK PROCEDURE
( HYDROTEST )

Date:
Nov 24, 2010

PT CHEVRON PACIFIC INDONESIA

Issued by
QA/QC DEPT.

TRIPATRA FLUOR CONSORTIUM

Revision:

Page:

1 OF 7

SUMIGITA-INWHA CONSORTIUM
Project Title
CONSTRUCTION SERVICE WUR D LT PROJECT
Contract No. 8967 XK

HYDRO TEST WORK

(P-CSLTD-028)

Fire System Piping and SID Platform Installation

Minas, Suram GS
WR NO. 297464

2/11/2010

Issued For Review

STATUS

DATE

DESCRIPTION

JAY

BDK

PREPARED

NOV
CHK'D

SIC

CHEK'D

APPV'D

TF

CPI

HYDRO TEST PROCEDURE

DOCUMENT NO. :
WUR D-QAC-PG-WPDATE REVISION:

Jun 24, 2011

Issued By :

QA/QC

PT. CHEVRON PACIFIC

INDONESIA
TRIPATRA FLUOR CONSORTIUM

Page
-2-

TABLE OF CONTENT

1. Table Of Content
1
2. Scope ........
2
3. Code, Standards & References .
2
4. Responsibility ....
3
5. Pressure Tests ......
5
6. QA Record.....
6

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HYDRO TEST PROCEDURE

DOCUMENT NO. :
WUR D-QAC-PG-WPDATE REVISION:

Jun 24, 2011

PT. CHEVRON PACIFIC

INDONESIA
TRIPATRA FLUOR CONSORTIUM

Issued By :

QA/QC

Page
-3-

1. SCOPE
This Procedure describes the general requirements and procedure for
field pressure testing of above ground or underground pressure piping
system which has been fabricated, installed and connected equipment
and integral components For Contruction service WUR D contract no
8967 XK CPI project SLS Operation Unit.
Followings piping system need not be field pressure tested.
a. Any package unit previously tested by the manufacturer in
accordance with applicable codes.
b. Instrument piping lead lines between the root valve at the process
or utility line and the connected instrument, and control piping used
to connect air or hydraulically operated control apparatus.
c. The lines and system which are open to the atmosphere, such as
vents or drains downstream of the last shutoff valve.
2. TYPES OF EQUIPEMNT USED
a. Bottom Chart
b. Pressure Gauge
c. Temperature Gauge
d. Pressure Pump
3. CODES, STANDARDS AND REFERENCES
Unless otherwise specifically indicated in writing, all works shall be
performed in accordance with the requirements of below code and
standards and those of the latest editions at the time of call for tender
of the documents listed hereafter:
a) ANSI/ASME B31.3 : Process Piping Code
b) ANSI/ASME B31.4 : Pipeline Transportation System Code
c) PP-SC-GG-001
d) PP-PI-PP-001

: Piping Pressure Test Procedure

: Cleaning Procedure.

e) Client Specifications.

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DOCUMENT NO. :
WUR D-QAC-PG-WP-

HYDRO TEST PROCEDURE

DATE REVISION:

Jun 24, 2011

Issued By :

QA/QC

PT. CHEVRON PACIFIC

INDONESIA
TRIPATRA FLUOR CONSORTIUM

Page
-4-

4. RESPONSIBILITIES
3.1.

Piping Engineering / Piping General Superintendent

a) Piping engineer / Gen. Superintendent shall be responsible
for preparing the pressure test package included test
boundary in accordance with the line designation table.
b) Piping

engineer

Gen.

Superintendent

shall

also

be

responsible for performing the pressure test in accordance

with applicable code, standard and procedure.
3.2.

QA/QC Engineer:
a) Quality Control Engineer shall be responsible for inspecting
the pressure test and recording it with actual data on the
pressure test record.

5. PRESURE TEST
4.1.

General Requirements
a) After installation of piping (complete/partial), all lines shall be
hydrostatically

or

pneumatically

test

as

required

by

applicable code and specification.

b) All testing shall be conducted by Piping Engineer / Gen.
Superintendent and inspected by QC Engineer with Client
representative when required.
c) The line lists shall indicate the design pressure, operation
pressure and temperature. The type of test and medium will
indicate in the piping Isometric drawing. Both drawings shall
be used for conduct the pressure test of piping systems.
d) The piping system may be tested with equipments when the
test pressure of equipments is the same with piping system.
If the test pressure of piping system is greater than the
maximum operating pressure of equipment, the equipment
shall be isolated and tested separately.
e) Personnel protection shall be provided suitably to eliminate
hazards to personnel.

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HYDRO TEST PROCEDURE

DOCUMENT NO. :
WUR D-QAC-PG-WPDATE REVISION:

Jun 24, 2011

PT. CHEVRON PACIFIC

INDONESIA
TRIPATRA FLUOR CONSORTIUM

Issued By :

QA/QC

f)

Page
-5-

Prior to start pressure testing, all welding works included NDE

As per AFC Drawing and PWHT shall be completed.

4.2.

Hydrostatic Testing
a) Test Medium
Water shall normally be used as the test medium unless
otherwise specified by the owner. Test water shall be clean
and shall be of such quality as to minimize corrosion the
materials in the piping system.
b) Test Pressure
The hydrostatic test pressure at any point in the piping
system shall not be less than 1.5 times of design pressure,
but shall not exceed the maximum allowable test pressure of
any non isolated components or as specified in the drawing.

4.3 Test Pressure

a) Preparation of test

All joint including welds previously not pressure tested

shall be left un-insulated and exposed for examination
during the test.

Piping system designed for vapour or gas shall be

provided with additional temporary supports if necessary
to support the test liquid.

Expansion joint shall be provided with temporary

restraint or they shall be isolated during the system
test.

Equipment that is not to be pressure test shall be

either disconnected from the system or isolated by a
blank.

Install pressure gauge which has been calibrated at

grade near pressure test pump. Readings may be
made at higher points providing the gauge pressure
reading plus the static head (0.1bar/m = 0.433psi/ft)

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HYDRO TEST PROCEDURE

DOCUMENT NO. :
WUR D-QAC-PG-WPDATE REVISION:

Jun 24, 2011

Issued By :

QA/QC

PT. CHEVRON PACIFIC

INDONESIA
TRIPATRA FLUOR CONSORTIUM

Page
-6-

between grade and the point of measurement does

not exceed the maximum test pressure. Pressure test
gauges shall be calibrated every 6 month or as per
client specification. Gauge shall be tagged with the
date last calibrated and this activity shall be recorded.
Two (2) calibrated pressure gauges should be installed
to indicate the test pressure. These should be located
at the high and low points of the system.
b) System Inspection

Piping system shall have been completely checked

using a installation check list (issue punch list)

All lines, vessels and equipment shall be checked to

insure the entire system can be completely drained
after testing.

Vents and drains shall be provided at all high points of

the piping system in the position in which the test is
to be conducted to purge air pocket while the
component or system is filling. Venting during the
filling of the system may be provided by the loosening
of flange bolts or by the use of equipment vent.

Lines containing check valves shall have the source of

pressure located in the piping upstream of the check
valve so that the pressure is applied under the seat. If
this is not possible, remove or jack up the check valve
completely and provide necessary filler piece or
blinds.

Expansion joints shall be provided with temporary

restraint if required for the additional pressure road
under test, or they shall be isolated during the system
test.

c) Hydrostatic Test.

Fill the test water into the piping system and ensure
proper venting.

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HYDRO TEST PROCEDURE

DOCUMENT NO. :
WUR D-QAC-PG-WPDATE REVISION:

Jun 24, 2011

Issued By :

QA/QC

PT. CHEVRON PACIFIC

INDONESIA
TRIPATRA FLUOR CONSORTIUM

Page
-7-

The pressure shall gradually be increased up to the

test pressure 925 Psig (As per AFC Drawing).

Maintain the test pressure for a minimum 4 hour.

The acceptance of the hydrostatic test is test pressure

may not exceed than 10% from the test pressure
and may not less than 10% from the test
pressure.

Conduct the examination (Visual) of piping system for

leakage

If there is no pressure drop or cant found any leakage

from examination, Test pressure may be reduced and
shall be thoroughly drained off the test water using a
compressed air.

Restoring the system (If necessary)

d) Retest
If there are found any leakage during the pressure test shall
be retested to the specified pressure after repaired have
been made. Any lines changed after they have been tested
shall be retested.
e) Bolt shall not be tightened while systems are being tested
which are pressured above 2.1bar (30psig)
6. TEST COMPLETION
a) In the event that repairs or additions are made following the pressure
test, the affected piping shall be retested at the pressures originally
specified for the test. Retesting of minor repairs or additions may be
waived subject to client approval.
b) After completion of testing, all temporary blanks and blinds shall be
removed, all operating blinks returned to proper position and all lines
and piping components shall be completely drained. Valves, orifice
plates, expansion joints and short pieces of piping which have been
removed shall be reinstalled with proper gasket in place. All valves that
were closed during hydrostatic test shall be opened to insure draining

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HYDRO TEST PROCEDURE

DOCUMENT NO. :
WUR D-QAC-PG-WPDATE REVISION:

Jun 24, 2011

PT. CHEVRON PACIFIC

INDONESIA
TRIPATRA FLUOR CONSORTIUM

Issued By :

QA/QC

Page
-8-

the bonnet cavity. Lines which are being drained after testing shall have
all vents open. Piping system downstream of check valves should be
inspected to insure complete drainage.
c) After lines have been drained, temporary supports shall be removed.
d) Flange joints where the test blind has been removed shall not be
retested. Special length bolting and flat non-asbestos gaskets shall be
removed and replaced with line class bolts and gaskets after completion
of hydrostatic test.
e) Instruments which were removed or blocked out for test shall be
reinstalled and blocks placed in the normal operating position after test.
7. QA RECORD
7.1 Pressure Test Package
Test packages shall consist of:
a) Cover
b) Exception lists for leak test
c) Field Installation check list for piping
d) P & ID
e) Arrangement Drawings
f)

ISO Drawings

g) Welding History Sheet

h) NDE Report (If required)
i)

Visual Inspection record

j)

Calibration Records.

k) Hydrostatic Chart records

l)

Others

7.2 Pressure Test Record

Pressure Test records shall be provided of each piping system test,
utilizing the form titled, Hydrostatic / Pneumatic Test Record. These
forms, when completed, shall be retained in the field QC document
as a permanent record. These records shall include:
-

Date of Test.

Ambient Temperature

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HYDRO TEST PROCEDURE

DOCUMENT NO. :
WUR D-QAC-PG-WPDATE REVISION:

Jun 24, 2011

PT. CHEVRON PACIFIC

INDONESIA
TRIPATRA FLUOR CONSORTIUM

Issued By :

QA/QC

Identification of Piping System.

Temperature
-

Test Medium.

Test Pressure.

HYDROSTATIC TEST DIAGRAM

Page
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Test Medium

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