Suria Engineering

HYDROSTATIC TEST OF REACTOR PIPING

ACT POLYOLS
NOORIABAD, KARACHI.

DOCUMENT CHANGE RECORD

Page Rev. Date Rev: Description Reviewed by Approved by

M.R G.M

01 As per client comments

Name Designation Signature

Prepared By

Approved By

STANDING OPERATING TITLE: HYDROSTATIC TEST

PROCEDURES

DOC. NO. SE-QC-HT-REACTOR REV DATE:21-Dec-20 Page 1 of 4

 CONTENTS

1.Purpose
2.Scope
3.Preparation
4.Storage of Water
5.Water Quality
6.Procedure
7.Safety
8.Inspection and Rectification
9.Reference documents

STANDING OPERATING TITLE: HYDROSTATIC TEST

PROCEDURES
DOC. NO. SE-QC-HT-REACTOR REV DATE:21-Dec-20 Page 2 of 4
 1. PURPOSE

This Practice provides leak-testing procedures for piping designed and constructed
to ASME B31.3 Process Piping, hereinafter referred to as the Code.

2. SCOPE

This Practice describes the procedures, practices, and precautions to be used in

leak testing metallic piping in accordance with the Code, and describes
requirements that are in addition to those of the Code.

Testing will be witnessed as per test marks issued by Third Party (SGS Pakistan)

3. PREPARATION:

 Test shall be carried out after completion of all welding activities, Radiographic
tests, and DPT (if applicable) but before surface treatment.
 It shall be insured that 100% welding has been completed and all weld seams
shall visually be inspected from inside with proper lighting arranged.
 All cleats, erection attachments, remaining weld tacks near weld seam shall be
removed by proper grinding. In case of excessive grinding during removal of
attachments, that portion shall be built-up by tack welds.
 All loose material and debris shall be removed.
 All openings shall be blanked-off and metallic gaskets shall be used for
sealing purpose.
 One vent shall be provided to remove the air pockets/ bubbles. (Filling shall be
continued till the over flow from the vent.)
 Connect the water piping for supply and drain.
 All nozzles will be boxed up prior to filling of water with metallic gaskets, seals,
and Teflon except vents, inlet and outlet nozzles.
 Two calibrated pressure gauges shall be installed out of which one will be at
the highest point.
 A temperature gauge will also be available to ensure the required water/metal
temperature.

4. STORAGE OF WATER:

Water shall be stored in Storage Tank available at Site or inside the water
bowser.

5. WATER QUALITY:

Sweet water shall be used for leak test. In case of stainless-steel vessel, the
chloride content of the water shall not be exceedingly more than 50 ppm (mg/l). The
water shall also be clear of any solid particles.

STANDING OPERATING TITLE: HYDROSTATIC TEST

PROCEDURES
DOC. NO. SE-QC-HT-REACTOR REV DATE: 21-Dec-20 Page 3 of 4
 6. PROCEDURE:
 Water shall be filled through any nozzle until it starts to overflow from all the
nozzles to remove entrapped air.
 Loose blind flanges shall be tightened and air shall be removed from filling
point.
 Pressure shall be increased gradually and hold after every 10 to 15 minutes
(10%,25%,50%,100%). Test pressure should be 1.3 times of working or
design pressure.
 During Hydrostatic Test metal surface temperature should neither be below
160C nor above 480C.
 Once the pressure is increased to the working/ design pressure and all tubes,
nozzles, bolting and the weld seams should be checked for any leak.
 After satisfactory result the pressure shall be increased to the required mark.
 Once the pressure is reached at 130 Bar to the required mark it should be
maintained for 24 Hours.
 All joints, connections and welds shall be examined for leakage.
 Drop the pressure back to working/ design pressure and maintain it for another
30 minutes and check for any leakages.
 Gradually release the pressure to avoid bulging of the piping caused by
sudden vacuum created upon rapid release of water.
 All the highest points nozzles blind covers shall be loosen before
draining of water from the piping. After that water to be drained from any
suitable nozzle as per physical situation.
 Any left-over water shall be removed by blowing air.

7. SAFETY:

 All tools being used should be appropriate and in proper operating condition.
 Only qualified and skilled personnel appointed by the QA/QC manager shall
be allowed to conduct the test.
 Sign shall be displayed to indicate the pressure test is in progress and the
area shall be barricaded.
 Safety relief valve to be used for releasing excess pressure.
 Irrelevant persons entry to be avoided during hydro testing at site.
 Proper PPE’s should be used in the hydro testing area.

8. INSPECTION AND RECTIFICATION:

Any leak shall be identified and marked on the Piping. The area shall be
documented. The piping shall be completely drained and defective welds /
joints shall be repaired.

All leaks shall be repaired by approved weld repair procedure. Radiographic

testing of all repairs shall be carried out.

The piping shall be retested until it is satisfactorily passed.

Applicable forms and documents shall be filled which will become part of the Manufacturer’s
Data Report to be submitted to the client at the time of delivery.

9. REFERENCE DOCUMENTS

 Fabrication codes: ASME VIII div. 1.

 Client’s/ Designer’s procedural documents.

STANDING OPERATING TITLE: HYDROSTATIC TEST

PROCEDURES
DOC. NO. SE-QC-HT-REACTOR REV DATE:21-Dec-20 Page 4 of 4