HYDROSTATIC TEST Doc No: STS/QAC/SOP/03

Rev No: 00
PROCEDURE Date Rev: 17 Dec 2008
Page No: 1 of 11

REVISION HISTORY

Rev Originator Description Of Amendments Date

00 Farid New Document 17.12.2008

Designation Name Signature

Originator Mechanical Eng Mohd Farid Abu Bakar

Reviewed

Approved
Controlled document: No part of this document may be printed or reproduced for external purposes
without the written permission of the management appointee of Science-Tech Solutions Sdn Bhd.

SCIENCE-TECH SOLUTIONS SDN BHD

 1.0 PURPOSEDURE
This procedure provides guideline for execution of hydrostatic piping and heat
exchanger
final inspection as per IRP and ITP.

2.0 SCOPE
The hydrostatic and pneumatic testing works cover the repair works (hot work) on
pressure vessel, heat exchanger, piping and newly fabricated piping,
ifapplicable. All
hydro testing works are required to be supervised and witnessed by Client. In the event
of repair to be carried out on DOSH registered equipment, DOSH officer is required to
witness the testing under FMA Act 1967.

3.0 REFERENCE CODES & STANDARDS

PSM-MI-20408 - Hydrostatic and pneumatic testing of Pressure Vessel,

Heat Exchangers and Process Piping, Oct 2015
Para 5.1 “Determine Test Pressure and Method”
Para 5.1.4 (C) “ Determine the Test Method”
ASME B31.3 - Process Piping, 2014
ASME PCC-2 - Repair of Pressure Equipment and Piping ,2015
Part 5 – Examination and Testing
Article 5.1 “Pressure and Tightness testing of piping
and Equipment”
Para 6.2.1 “ Pneumatic Test Procedure”
Para 6.3.1“ Pneumatic Tightness Test procedures”
PTS 12.02.01 - Field Inspection Prior to Commissioning of
Mechanical Equipment
Para 3.2 “ Hydrostatic Testing”
Para 3.3 “ Pneumatic Testing”
ASME VIII DIV. 1 - Design Rules for Construction of Pressure Vessels, July
2015
UG 102 – Test Gages
API 510 - Pressure Vessel Inspection Code: In-Service
Inspection, Rating, Repair, and Alteration, May 2014
Para 5.8.3 “Test Pressure Determination”
Para 5.8.5 “Hydrostatic Pressure Tests”
Para 5.8.6 “Pneumatic Pressure Tests”
API 570 - Piping Inspection Code: In-Service Inspection Rating,
Repair, and Alteration of Piping System, Feb 2016
Factory & Machinery - Jabatan Kesihatan & Keselamatan Pekerja (JKKP)
Act (1967)
 Standard A - Environmental Quality (Sewage and Industrial
Effluents) Regulations 1979
APHA - Standard Methods for Examination of Water and
Wastewater (American Public Health Association)
Third Schedule, Parameters Limits of Effluent of
Standard A

4.0 PROCEDURE

6.1 Hydrostatic Test

6.1.1 All hydrostatic and pneumatic testing for specific work shall be
accompanied by the latest revision of relevant P&ID's/ Isometric/
General Arrangement drawing.
6.1.2 A minimum of (2) calibrated and valid pressure gauge shall be used
during testing. Pressure gauge range shall be 1.5 to 4 times from
testing range. One (1) pressure gauge shall be located at the high point
and one (1) pressure gauge for injection at the low point. In addition to
pressure gauge, chart recorder to be used if required by Client and/or
DOSH.
6.1.3 Readings at the high point shall govern the test result. Pressure gauge
and chart recorder shall be calibrated for every 1 year ‘OR’ earlier
whenever the accuracy is questionable.
Note: Valid calibration certificate shall be provided
6.1.4 Pipe spool prior for installation for testing shall be free from dust and
debris and ensure all spring hangers are locked and all supports are
installed and instrument devices excluded during testing.
6.1.5 Establish the maximum test pressure for the equipment taking into
account the static head of the test media as per following:

a. After box-up, pressure of pneumatic test for HEX and AFC

as specified in IRP.
b. The test pressure stamped on the equipment name plate,
Piping Isometric, or
c. 1.3 times the design pressure, or
d. Set pressure of the pressure relief device having the
lowest setting. (for equipment with unknown test
pressure).
 6.1.6 Water is to be used as a testing medium unless specified otherwise.
For testing austenitic stainless steel, demin/cold condensate water
shall be used, or a fluid with a maximum chloride content of 30 ppm.

Note: domestic water generally contains 3.9 ppm of chloride

content. (Source: Syarikat Air Melaka Berhad)

6.1.7 Slowly raise the pressure to 2.0 kg/cm 2 and holding time with minimum
of 5 minute. Visually inspect system for leaks.
6.1.8 Increase from pressure of 2.0 kg/cm 2 to 50% operating pressure. Hold
for a minimum of 5 minute to allow strains to equalize.
6.1.9 Continue to increase until the system pressure is at operating pressure.
Hold for a minimum of 5 minute.
6.1.10 Gradually increase pressure to test pressure for a minimum of holding
is 30 minute. Observe pressure gage for loss of system pressure.
6.1.11 Reduce pressure to 2/3 test pressure and check for leaks. Hold for a
minimum of 5 minute.
6.1.12 Perform visual inspection at every single joint.
6.1.13 If no leaks is detected, release pressure gradually at constant rate.
6.1.14 Alternative test shall be performed if both of the following apply:
a. Hydrostatic testing would damage internal lining or insulation,
contaminate a process, or present a hazard of brittle fracture
because of the temperature during the test.
b. A pneumatic test would present an undue hazard of
possible of release of energy stored in the system, or would
present the danger of brittle fracture because of the
temperature during the test.

6.2 Pneumatic Test

6.2.1 Pneumatic test may be performed if a hydro static test is not practical.
The line size should be limited to maximum of 3” diameter, or special
procedures followed to cope with the potential release of energy stored
in compressed gas. This is the least desirable of the test methods.
6.2.2 Air is to be used as a testing medium unless specified otherwise.
6.2.3 The test pressure shall be 110% of the operating pressure.
6.2.4 Slowly raise the pressure to 1.8 kg/cm 2 (25psi) or one-half the test
 pressure (25%) whichever is lower. Hold for 10 min and visually inspect
system for leaks.
6.2.5 Increase from pressure in item specified in paragraph 6.2.4 by
3.57kg/cm2 (50psi) or to 35% test pressure, whichever is greater. Hold
for a minimum of 3 min to allow strains to equalize.
6.2.6 Continue to increase by 3.57kg/cm2 (50psi) increments until the system
pressure is at 50% test pressure. Hold at 50% test pressure for a
minimum of 10 min. Observe pressure gauge for loss of system
pressure.
6.2.7 Gradually increase system pressure in increments of 10% of test
pressure. At each increment observe pressure gauge for 5 min.
6.2.8 Once full test pressure is reached, observe pressure gauge for a
minimum of 10 min.
6.2.9 Reduce pressure to 4/5 test pressure and check for leaks. Hold for a
minimum of 5 minute.
6.2.10 Perform visual inspection at every single joint.
6.2.11 If no leaks is detected, release pressure gradually at constant rate.
6.2.12 Examine all joints for leakage. The “soap bubble” test is an effective
way to locate leakage when testing.
6.3 Alternative Test Pressure / In lieu of Hydro-static and Pneumatic
Testing

6.3.1 All welds, including those made in the manufacture of the pipe and
fitting, which have not been hydro statically and pneumatically tested,
shall be tested as follows:
6.3.1.1 Circumferential, longitudinal and spiral groove welds shall
undergo 100 % radiography testing and if RT is not possible then
UT shear wave shall be applied.

6.3.1.2 All other welds, including structural attachment weld shall be

examined using the liquid penetration or magnetic particle test.

6.4 Test Preparation

6.4.1 Install the hydro test pump, filling pump, and all the accessories for
pressure test.

6.4.2 Install a vent line with a vent valve at the highest point of the piping
system.

6.4.3 Install the gauges for testing as close as possible to the lowest point
 and highest point either for piping, pressure vessel or heat exchanger.
Test gauge range shall be (1.5 to 4.0 time) higher than test pressure
and shall exhibit valid calibration certificate.

6.4.4 Allow water to flow from vent line for a few minutes until all the air
trapped has escaped before closing the vent valve.

6.4.5 When the system has no indication for a leak or a problem, proceed to
start hydro test pump to reach the required test pressure and follow
the step as per table below, please refer attachment 4.0 for pressure
test certificate.

STEP PRESSURE (Kg/cm2) HOLDING TIME Witnesses by

1 2.0 > 5 min Client's rep
2 0.5OP > 5 min Client's rep
3 OP > 5 min Client's rep
4 TP > 30 min 3rdParty/Client's Inspection
5 2/3TP > 5 min 3rdParty/Client's Inspection

6.4.6 Examine and check each joint for leaks during holding time for each
step. Commence inspection of the system in the presence of the
Client's Inspector.

6.4.7 Probable weak points that could be found leaking during testing:
a. Flange Connections
b. Welded Joint
c. Valve Glands

6.4.8 When the required test pressure has been attained satisfactorily in the
presence of the CLIENT'S Inspector, hold the pressure for at least 30
minutes as per above table. During holding time, disconnected the
hose/piping to pump. Marking on the pressure gauge and as long as it
takes to check the full test circuit and then check the pressure drop.
6.4.9 With the approval of the Client Inspector, the test pressure shall be
released gradually to 2/3 Test Pressure and check the full circuit for any
leak and pressure drop then drops to zero gradually. After testing the
circuit will be flushed in line with pre commissioning requirements.
6.4.10 The test water used for testing the piping system/vessel shall be
removed as soon as possible and be dried immediately by blowing
after draining. All vent points will be in open position during draining to
prevent any vacuum forming. The system will be air blown with
 compressed air and all drain points will be checked until no moisture is
presence. Client witness is recommended.
6.4.11 All testing temporary spading shall be color coded with red paint to
identify them as temporary fixtures. After testing the temporary gasket
and stud bolts will be replaced with the original items and torque to the
required tensioned.
6.4.12 Flanges or valves that are permanent fixtures the original gasket and
stud bolts shall be installed during testing.
6.4.13 Prior to testing, Supervisor shall ensure that all work has been
completed and verified. All pre-test QC activities and NDT have been
carried out and shall submit all required documents to consultant in
pack form including but not limited to:

a. All related documents.

b. Punch list items.

c. Test pack and test limit.

d. All bolts are torque

6.5 Differential Pressure Test (when is required on HEX only)

6.5.1 For items working with differential pressure, shell and tube side shall
be pressurized at the same time, but in any case the maximum
difference pressure shall be not over than the allowable differential
pressure as per drawing. In that case, hydrostatic at full pressure on
both sides shall be executed with following steps:

a. The side with the lower test pressure shall be indicated with
sticker “side L” on the pressure gauge while the side with the
higher test pressure shall be indicated with sticker “side H” on the
pressure gauge. Two manometers shall be fitted on both sides.

b. Two sides shall be pressurized at the same time, using only one
pump. To connect the pump simultaneously at the two chambers,
a three-way cock shall be used.

c. During pumping the connection between the “side L” and the “side
H” shall be maintained. When the test pressure of “side L” is
reached the correspondent valve shall be closed.

d. The “side H” shall be pressurized until the test pressure is reached

and the correspondent valve shall be closed. The manometer shall
 be strictly monitored during the whole duration of testing.

e. The Hydrostatic Test sequence shall followed items specified in

paragraph 6.1.6 through 6.1.13.

f. To release the pressure, the valve of “side H” shall be gradually

open until the pressure is at the same value of “side L”. At that
point the two chambers shall be put in connection, and the
pressure release simultaneously on both sides.

g. Open both side valves “side H” and “side L” gradually.

5.0 RECORDS

7.1 Work Control Sheet

7.2 Inspection Request Form

7.3 Inspection Record Form – Pressure Test Certificate

8.0 ATTACHMENTS

Appendix 1.0 : Hydrostatic and Pneumatic Test Diagram.

Appendix 2.0 : Graph of Hydrostatic Testing.

Appendix 3.0 : Graph of Pneumatic Testing.

Appendix 1.0

HYDROSTATIC AND PNEUMATIC TEST DIAGRAM

Vent Point

Pressure Gauge

Test Equipment

Pressure Gauge

Injection Point

Hydrotest
Pump

Draining
Point
Appendix 2.0

GRAPH OF HYDROSTATIC TESTING

Appendix 3.0

GRAPH OF PNEUMATIC TESTING