THE DOW CHEMICAL COMPANY ENGINEERING SPECIFICATION

MATERIALS G8S-5034-03
GLOBAL 15-AUG-2003
Page 1 of 4
Hydrostatic Leak Testing

1 Overview

1.1 Scope

This practice describes leak test requirements for equipment

undergoing hydrostatic testing.

2 Personnel Qualification

2.1 Training

Personnel performing leak testing in accordance with this practice

shall receive a minimum of 2 hours on-the-job training in inspecting
for leaks during hydrostatic testing.

2.2 Visual Acuity

Personnel performing leak testing in accordance with this practice

shall annually demonstrate capability of reading J-1 letters on
standard Jaeger Test type charts, or on equivalent type and size
letters, at a distance of not less than 12 inches (0.3 m).

3 Equipment/Materials

3.1 Pressure Gauges

Two (2) Pressure gauges shall be used and shall have a pressure
indicating range of not less than 1.5 times nor more than 4 times the
intended maximum test pressure.

3.2 Water

The hydrostatic test liquid shall be potable water, condensate, or

demineralized water.

The water used for hydrostatic testing shall meet the requirements of
G8S-4001-60; Specification for Water Quality used for Hydrostatic
Testing.i

Note: Deviations to this Article shall be approved by the Materials

Engineer.

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THE DOW CHEMICAL COMPANY ENGINEERING SPECIFICATION
MATERIALS G8S-5034-03
GLOBAL 15-AUG-2003
Page 2 of 4

3.3 Water Additives

When approved by the Materials Engineer, fluorescent tracer dye may be

added to water in accordance with the dye manufacturer's directions,
thus increasing test sensitivity.

3.4 Developers

When approved by the Materials Engineer, the test surface may be coated
with developer to increase contrast between dry and wet areas, thus
increasing test sensitivity.

4 Testing

4.1 Hydrostatic Tests

Hydrostatic tests shall be conducted in accordance with the applicable

Engineering specification.

Follow all safety requirements during tests and examinations while

equipment is under pressure.

When sensitive leak tests are required (e.g., bubble leak tests, helium
mass spectrometer leak tests, etc.), they shall be performed prior to
hydrostatic testing.

4.2 Temperature

The metal temperature shall be equal to or above ambient temperature to

prevent condensation from forming on the outside surface.

Metal temperature during the hydrostatic test shall not be less than
the minimum design metal temperature for the entire duration of the
test.ii

4.3 Surface Condition

All areas to be examined for leakage shall be clean (free from oil,
grease, sediment, and other contaminants that could mask a leak), dry,
uninsulated, and unpainted.

4.4 Accessibility

Access to the area(s) being hydrostatic leak tested shall be sufficient

to place the eye within 24 inches (0.6 m) of the surface under
immediate observation. The angle between the line of sight and the
surface under immediate observation shall not be less than 30° (mirrors
may be used to improve the angle of vision).

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THE DOW CHEMICAL COMPANY ENGINEERING SPECIFICATION
MATERIALS G8S-5034-03
GLOBAL 15-AUG-2003
Page 3 of 4

4.5 Lighting Conditions

The illumination at the specific part, component, vessel, or section

thereof, under immediate test shall be a minimum of 100 footcandles
(1000 lux). Verification of illumination is not required for external
bubble leak tests performed during daylight hours; otherwise, the light
source, technique used, and illumination verification shall be
demonstrated one time and documented.

Note: Illumination can only be verified by measurement with a light

meter.

When fluorescent dye tracers are used, the specific part, component,
vessel, or section thereof, under immediate test shall be illuminated
with black light while the general area is under subdued or darkened
lighting conditions. The black light shall produce a minimum intensity
of 1000 µW/cm2 at a the surface being examined. Prior to checking for
leaks, the black light shall be allowed to warm up for a minimum of 5
minutes and the inspector shall be in the darkened area for a minimum
of 1 minute.

4.6 Check for Leaks

After the required test pressure has been held for the time required by
the applicable Engineering specification, reduce the pressure to 2/3 of
the test pressure and visually examine 100% of all weld joints and
other connections for fluid leaks or seepage.

4.7 Water Contact Time

Water used for hydrostatic tests shall not remain in contact with
equipment longer than 72 hours unless approved by the Materials
Engineer.

5 Acceptance Standards

Equipment is acceptable when no evidence of fluid seepage is observed.

When fluid seepage is observed, the position of the leak(s) shall be marked
for repair. After repairs have been made, the repaired area(s) shall be
retested in accordance with the requirements of the applicable engineering
specification and this practice.

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THE DOW CHEMICAL COMPANY ENGINEERING SPECIFICATION
MATERIALS G8S-5034-03
GLOBAL 15-AUG-2003
Page 4 of 4

6 Reports

A report of test results shall be made and shall include, as a minimum, the
following:

1. Identification of equipment that is leak tested.

2. Test procedure number and revision.
3. Test pressure and temperature and identification of measuring devices.
4. Test fluid and developer and dyes (if used).
5. Test results (leak locations and estimate of leak rates, if any).
6. Names of test personnel.
7. Date of test.

i
12/3/02; By: John Watson; MOC 2002-0764; Supercedes Issue Date: 15-Apr-2003;
Added reference to G8S-4001-60 at end of sentence.
ii
8/15/03: By: John Watson; MOC 2003-1234; Supercedes Issue Date: 03-Dec-
2002; Added a sentence to clarify the minimum temperature for hydrostatic
testing.

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