Supersedes

GARDNER DENVER
Number:
Number: QSA 22
Document: QUALITY SPECIFICATION
QSA22 Page 1 of 4
Version: 01 Title: HYDROSTATIC LEAK TESTING PROCEDURE Version: 02
Dated: 02-15-99 Date: 06-15-99
-+
I SCOPE

This specification applies to all pressure bearing components requiring a hydrostatic

leak testing, except single acting compressor parts requiring less than 100 psig
testing of the waterside. Hydrostatic leak testing requirements may be specified on
the engineering drawing, bill of material, purchase order, customer order or quality
plan.

II REFERENCED DOCUMENT

ASTM E1003-84, Standard Method for Hydrostatic Leak Testing.

III SPECIFICATION

1.0 Pressure Gages

1.1 Pressure gages used in testing must be rated to withstand the specified test pressure
and must have an accuracy of 1% or less of full scale.

1.2 The pressure gages selected for the test must be in good working condition, within
calibration and capable of reading 1.5 X but not more then 4 X the test pressure. The
gages must be positioned so they are visible to tester throughout the entire test cycle.

2.0 Test Fluid

2.1 Unless otherwise specified the test fluid shall be water. The test water shall be clean
and of a quality as to minimize corrosion. A rust inhibitor must be used in the fluid
when testing ferrous parts.

2.2 The test fluid and the test piece should be at approximately the same temperature.

3.0 Test Pressure

3.1 The test pressure to be used shall be the working test pressure specified on the
engineering drawing, or engineering RC sizing program report, Pressure Relief Valve
Setting for Manifold. If the pressure is not specified, contact the Product Engineer to
obtain the correct test pressure.

4.0 Openings

4.1 Seal all openings using plugs and covers capable of withstanding the test pressure
that can be completely removed after test.
Supersedes
GARDNER DENVER
Number:
Number: QSA 22
Document: QUALITY SPECIFICATION
QSA22 Page 2 of 4
Version: 01 Title: HYDROSTATIC LEAK TESTING PROCEDURE Version: 02
Dated: 02-15-99 Date: 06-15-99
4.2 The test fluid inlet should be located as near as possible to the bottom of the part with
vents for the purging the trapped air positioned at the highest points on the part.
Components rated at pressures below the test pressure must be isolated.

5.0 Pre-test Inspection

5.1 Inspect the outside of the test piece to verify that it is dry and all welds and
connectors are exposed for visual inspection. Verify all connections are tight.

6.0 Pressurizing

6.1 Prior to pressurizing, the test piece temperature should be a minimum of 60 degrees
Fahrenheit.

6.2 Gradually increase the pressure in the system to 50% of the test pressure and make
an initial check for leakage. Thereafter, slowly increase the pressure to the final test
pressure.

7.0 Test Method

7.1 Unless otherwise specified test pieces which have no internal passages that would
mask leakage (manifolds, piping, etc.) may use the visual inspection method in
section 8.0.

7.2 All DNV parts, nuclear parts, and test parts which have internal passages which
cannot be visually examined (cylinders, heads, etc.) must use the pressure drop
method in section 9.0.

8.0 Visual Inspection Method

8.1 Unless otherwise specified on the engineering drawing, the test pressure shall be
continuously maintained for a minimum time of ten (10) minutes and for any additional
time necessary to conduct the examinations for leakage.

8.2 At completion of the test pressure holding time, the tester shall examine the outside
test piece and all attachment welds, joints, connections, and fittings for leakage.

8.3 The test piece shall show no visual evidence of weeping or leaking.

8.4 The tester shall circle all the leaks found with a green permanent marker (do not use
a black permanent marker) and describe the magnitude of the leak in terms of: damp
area, drops per minute or steady stream.
Supersedes
GARDNER DENVER
Number:
Number: QSA 22
Document: QUALITY SPECIFICATION
QSA22 Page 3 of 4
Version: 01 Title: HYDROSTATIC LEAK TESTING PROCEDURE Version: 02
Dated: 02-15-99 Date: 06-15-99
9.0 Pressure Drop Method

9.1 After reaching the test pressure disconnect the pressure pump and allow the
pressure in the test piece to stabilize.

9.2 After stabilization, the tester shall record the exact pressure and start the test. The
duration for the test shall be as specified on the engineering drawing or customer
order. Certified material shall be tested for the specified duration or ten (10) minutes,
whichever is longer.

9.3 The tester shall monitor the test pressure throughout the test. The final test pressure
in the test piece shall not drop more than 2% of the starting test pressure and shall
show no visual evidence of weeping or leaking.

9.4 The tester shall circle all the leaks found with a green permanent marker (do not use
a black permanent marker) and describe the magnitude of the leak in terms of
pressure drop.

10.0 Acceptance

10.1 If the test piece meets the acceptance criteria listed under the applicable test method,
the tester shall impact stamp the part, with the letters HT encapsulated in a circle and
the hydrostatic test number, adjacent to the part number. The hydrostatic test number
may be omitted from Locomotive Single Acting Compressor components and Air
Cooled components.

10.2 The stamp shall be of a design to preclude introducing any stress into the part. The
stamp shall be legible with a minimum character height of 1/8".

11.0 Identification

11.1 The accepted test piece shall be stamped with a unique serial number to enable
traceability to its test record. The identification shall consist of the complete
production order number followed by a space and the piece sequence number,
example: 1000735 1.

12.0 Rejection

12.1 If the test piece does not meet accepted criteria listed under the applicable test
methods, the tester shall not impact stamp the part. He shall be required to issue a
NMR (IRR) on all rejected units.
Supersedes
GARDNER DENVER
Number:
Number: QSA 22
Document: QUALITY SPECIFICATION
QSA22 Page 4 of 4
Version: 01 Title: HYDROSTATIC LEAK TESTING PROCEDURE Version: 02
Dated: 02-15-99 Date: 06-15-99
13.0 Test Records

13.1 The tester shall note on the test log Exhibit A the following information at a minimum:

a. Date tested.
b. Disposition (certified).
c. Hydro number of test piece, if more than one piece is being tested.
d. Disposition (accept or reject).
e. Tester (employee number).
f. Material (part) number
g. Material (part) description.
h. Quantity tested and approved
i. Gage number and range
j. Specified and actual test pressure (psig) suction water
k. Specified and actual test pressure (psig) discharge air
l. Test times (start time and finish time)

13.2 Records will be maintained per QQSOP 16-001.

13.3 Certified hydrostatic test reports, Exhibit B, will be handled by Quality Assurance.

IV APPROVAL

Duane F. Creger
Corporate Quality Assurance
 Gardner Denver QSA 22
Dept. ___________ Hydrostatic Test Log Report Exhibit A

Suction/Water Discharge/Air

Qty accepted

2
Qty rejected
Specified Actual Specified Actual
Certified X

Complete Prod. Tester Test Test Test Test

order # Dash Employ. Gage # Gage Start & Pressure Pressure Gage # Start & Pressure Pressure
1
Date Sequence Number Number Material Number Material Description Range Finish psig psig Gage range Finish psig psig
Time
G- # G- #
Time S S :
R 0- R 0-
- : F : F :
Time
G- # G- #
Time S S :
R 0- R 0-
- : F : F :
Time
G- # G- #
Time S S :
R 0- R 0-
- : F : F :
Time
G- # G- #
Time S S :
R 0- R 0-
- : F : F :
Time
G- # G- #
Time S S :
R 0- R 0-
- : F : F :
Time
G- # G- #
Time S S :
R 0- R 0-
- : F : F :
Time
G- # G- #
Time S S :
R 0- R 0-
- : F : F :
Time
G- # G- #
Time S S :
R 0- R 0-
- : F : F :
Time
G- # G- #
Time S S :
R 0- R 0-
- : F : F :
Time
G- # G- #
Time S S :
R 0- R 0-
- : F : F :
Time
G- # G- #
Time S S :
R 0- R 0-
- : F : F :
Time
G- # G- #
Time S S :
R 0- R 0-
- : F : F :

1 Example, 1000735-1 Use the complete production order number - piece sequence number. Reference QSA22
2 NMR required if rejected.
 GARDNER DENVER QSA 22
CERTIFIED HYDROSTATIC TEST REPORT Exhibit B

Hydrostatic Test Number: __________________

COMPONENT DATA

Unit Serial Number _____________________________________

Material (part) Number _____________________________________

Material (part) Description _____________________________________

Customer _____________________________________

TEST DATA

SUCTION SIDE DISCHARGE SIDE

WATER PASSAGE AIR PASSAGE
PUMP/COMPRESSOR PUMP/COMPRESSOR

Gage ID Number
Gage Range 0- PSIG 0- PSIG
Start End Start End

Test Time
: : : :
Specification PSIG PSIG
Test Pressure
Actual PSIG PSIG
Test Pressure

TEST RESULTS

Tester: _________________ Test Dept.: __________ Date: _________

Accept Reject NMR #: __________

Comment:

Certified by: ________________________ Date: ___________________

Signed: ___________________________________

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