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STANDARD STDE-PRD-005
SIA STANDARD
Titolo
Title HYDROSTATIC TEST PROCEDURE
Rev. Pag. di
FOR WATER/FOAM BASED SYSTEM Sheet of
3 1 11

HYDROSTATIC TEST PROCEDURE

FOR WATER/FOAM BASED SYSTEM

3 08/10/2020 Fourth Issue L.C. R.R. T.Z.

2 05/06/2019 Third Issue L.C. R.R. T.Z.
1 21/11/2018 Second Issue M.M. R.R. T.Z.
0 18/05/2017 First Issue M.M. R.R. T.Z.
Data Descrizione Preparato Controllato Approvato
Rev.
Date Description Prepared Checked Approved
 Commessa Documento Riferimento
Job No. Doc. No. Reference

STANDARD STDE-PRD-005
SIA STANDARD
Titolo
Title HYDROSTATIC TEST PROCEDURE
Rev. Pag. di
FOR WATER/FOAM BASED SYSTEM Sheet of
3 2 11

INDEX

1. INTRODUCTION ................................................................................................................................................... 3

2. SAFETY PRECAUTIONS .................................................................................................................................... 4

3. REFERENCE DOCUMENTS ............................................................................................................................... 4

3. TEST FLUID .......................................................................................................................................................... 4

4. TEST PREPARATION.......................................................................................................................................... 5

4.1. CLEANING .................................................................................................................................................. 5

4.2. PREPARATION AND ISOLATION............................................................................................................ 5

5. TEST PRESSURE GAUGE ................................................................................................................................. 5

6. TESTING PROCEDURE ...................................................................................................................................... 6

6.1. FACTORY ACCEPTANCE TEST ............................................................................................................. 6

6.2. SITE ACCEPTANCE TEST ....................................................................................................................... 8

7. ACCEPTANCE CRITERIA................................................................................................................................... 9

7.1. CONFORMITY............................................................................................................................................ 9

7.2. NON-CONFORMITY ................................................................................................................................ 10

8. APPENDIX: SIA TEST CERTIFICATE TEMPLATE ....................................................................................... 11

 Commessa Documento Riferimento
Job No. Doc. No. Reference

STANDARD STDE-PRD-005
SIA STANDARD
Titolo
Title HYDROSTATIC TEST PROCEDURE
Rev. Pag. di
FOR WATER/FOAM BASED SYSTEM Sheet of
3 3 11

1. INTRODUCTION

Scope of this procedure is to provide a guide on the Hydrostatic Pressure Test procedures carried
out for the following equipment:
- Water/Foam based pre-assembled skid manifold & piping (Valves’ trim excluded)
- Water/Foam based system distribution piping line(s)
Usually the pre-assembled skid manifold & piping are tested during manufacturing or at Factory
Acceptance Test (FAT) at vendor/manufacturer facilities, while the Water/Foam based system
comprising the distribution piping line(s) is tested by Client or Contractor during Site Acceptance
Test after final installation.
This procedure covers the general minimum requirements for pressure testing of the systems.
Pressure test shall be of a hydrostatic leak test type, conducted with water as test fluid.
The purpose of the Hydrostatic Test is to ensure piping integrity and absence of leaks.
Lines which are open to the atmosphere, such as drains, do not require pressure testing. These lines
shall be visually examined to determine that all joints are properly mounted and tighten up.
In the event that repairs are necessary after the pressure test, the affected part shall be re-tested,
except that in the case of minor repairs, the Owner may waive retest requirements when
precautionary measures are taken to assure proper construction.
For any additional information, please refer to:

S.I.A. - Safety Industrial Applications s.r.l.

Via Aldo Moro 6 20005 Pogliano Milanese (MI) – ITALY
Tel.:+39 02-35969811 / Fax:+39 02-93549537
Web: www.sia-italia.com E-mail: info@sia-italia.com
 Commessa Documento Riferimento
Job No. Doc. No. Reference

STANDARD STDE-PRD-005
SIA STANDARD
Titolo
Title HYDROSTATIC TEST PROCEDURE
Rev. Pag. di
FOR WATER/FOAM BASED SYSTEM Sheet of
3 4 11

2. SAFETY PRECAUTIONS

Full care and precaution shall be given by the factory management for the safety of the workmen
to prevents accidents during the execution of the works.
Every test shall be performed by qualified and well-prepared personnel, who are thoroughly familiar
with all equipment and test.
Every test shall be performed when the weather condition is suitable for inspection.

WARNING
The decision to activate the system must be taken by the person in charge of the safety
department. Always operate carefully and taking care of safety precautions.
Before running the test always advise all personnel, delimit the test area and be sure that no
personnel are present inside the room where the discharge will take place.

3. REFERENCE DOCUMENTS

- ASME B31.1 Power Piping

- ASME B31.3 Process Piping
- NFPA 15: 2017 Standard for Water Spray Fixed Systems for Fire Protection
- NFPA 13: 2019 Standard for the Installation of Sprinkler Systems

3. TEST FLUID
The hydrostatic test shall be made using fresh water or industrial water. The water shall have a
suitable corrosion level. Where the use of sea water is unavoidable, agreement between Owner and
Manufacturer/Vendor shall be made, before proceeding with the work. When sea water is used,
quick draining and sufficient cleaning by fresh water shall be performed after completion of the
testing.
Where atmospheric temperature for piping is 0 °C or below, water shall not be used unless it is
heated by steam or other heat source and maintained at temperature of 4°C or above during the
testing.
If there is a possibility of damage due to freezing, or if the operating fluid or material would be
adversely affected by the water, any other suitable nontoxic liquid, such as oil or kerosene, may be
used with agreement between Owner and Manufacturer/Vendor.
 Commessa Documento Riferimento
Job No. Doc. No. Reference

STANDARD STDE-PRD-005
SIA STANDARD
Titolo
Title HYDROSTATIC TEST PROCEDURE
Rev. Pag. di
FOR WATER/FOAM BASED SYSTEM Sheet of
3 5 11

4. TEST PREPARATION

Prior to start with the Hydrostatic Test, assure that all piping system, including all valves, drains, and
accessories, is properly installed and secured.
If present, underground supply shall had been installed, flushed and already separately tested.

4.1. CLEANING

Prior to test, the system shall be cleaned. All joints, including welds, shall be left un-insulated and
exposed for examination during the test, except joints previously tested in accordance with this
specification may be insulated or covered.
The system shall be inspected for completeness and conformity to drawings and specifications.
All required non-destructive testing (NDT), if required, shall had been completed with satisfactory
results prior to test.
Trash and construction debris shall be removed by flushing with water or by blowing with air or
nitrogen in line with the pressure test medium. All lines shall be completely free of weld slag and
other foreign material and shall be reasonably clean. Piping shall be isolated, if necessary, using
blinds caps or plugs suitably.

4.2. PREPARATION AND ISOLATION

All instruments in the system shall be excluded from flushing / testing by isolation or removal. All
other valves in the system shall be kept in open position.
The area shall be continuously monitored by test personnel while testing is being performed, so
that any change in test procedures or conditions will be noted immediately and corrective-action
taken as required.
During water-filling, the air is to be removed from the line by leaving the vent valves open until
water spurts from them. If the system has an irregular shape, one suitable way to properly vent the
system, is to slowly fill with water increasing the pressure up to 2 +/-0.5 bar; this will let the air in
the system flowing out easily through the vent, avoiding an air sack built-up.

5. TEST PRESSURE GAUGE

Two calibrated pressure gauges, at least, shall be provided: one at the pump outlet and one at other
suitable locations (for example, manifold inlet or lowest elevation point in the piping).
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Job No. Doc. No. Reference

STANDARD STDE-PRD-005
SIA STANDARD
Titolo
Title HYDROSTATIC TEST PROCEDURE
Rev. Pag. di
FOR WATER/FOAM BASED SYSTEM Sheet of
3 6 11

All test gauges used shall be checked for accuracy. Calibration certificate shall be available at work
site and all gauges shall be properly identified to enable tractability to the calibration certifications.
The test pressure gauge shall have a range from zero up to 1.5 times the intended maximum test
pressure.
Test pressure gauges shall be chosen so that the test pressure reading value is between 30% and
70% of the full-scale measuring range.

6. TESTING PROCEDURE

Hydrostatic test pressure shall be applied by means of a suitable test pump or other pressure
source, which shall be positively isolated from the system until ready to test.
The pump shall be attended constantly during the test by an authorized operator. Whenever the
pump is left unattended, it shall be positively disconnected from the system, while the pressure
gauge remains connected to the test system.
Ensures that the test area is properly flagged, barricaded, or otherwise controlled to prevent
unauthorized personnel entry. Ensure that personnel not qualified or not directly involved in the
test is removed for their safety.

6.1. FACTORY ACCEPTANCE TEST

Prefabricated manifold and connected piping spools normally exposed to pressure, shall be tested
after manufacturing (welding and NDT performed) at factory facilities.
Other portions of pipe, such as test connections, water alarm gong connections, drain and auxiliary
drains, typically are not subject to high pressures and do not have to be tested.
According to ASME B31.3, the test pressure shall not be less than 1.5 times the minimum design
pressure. Nevertheless, the test pressure shall not exceed the maximum allowable test pressure for
flanges, according to ASME B16.5 or ASME B16.47.
According to ASME B31.1 the test pressure shall not exceed the maximum allowable test pressure
of any non-isolated component, nor shall it exceed the limits of calculated stresses due to occasional
loads.
The pressure shall be continuously maintained for a minimum time of 10 minutes and may then be
reduced to the design pressure and held for such time as may be necessary to conduct the
examinations for leakage. Examinations for leakages shall be made for all joints and connections.
A preliminary test using air at no more than 1.7 bar gage pressure may be made prior to hydrostatic
or pneumatic testing to locate major leaks.
 Commessa Documento Riferimento
Job No. Doc. No. Reference

STANDARD STDE-PRD-005
SIA STANDARD
Titolo
Title HYDROSTATIC TEST PROCEDURE
Rev. Pag. di
FOR WATER/FOAM BASED SYSTEM Sheet of
3 7 11

Procedures for hydrostatic pressure test shall be as specified in below steps:

1. Inspect the system to verify that openings (tie-in flanges) are plugged, and outlet valves (for
example drain) are closed.
2. Be sure that all inline valves are open.
3. Connect the test pump to the inlet connection (tie-in) and close with temporary blind
flange/cap other inlets (if any).
4. Connect the water source to the test pump.
5. Fill the system slowly to avoid entrapment of air.
6. Open a valve (for example manifold drain) to vent any trapped air. Close the valve when water
flows continuously through it.
7. When the system pressure reaches the water source pressure, close the supply isolation valve
and inspect the entire system for leaks. These may result from flanges not bolted properly,
plugs not properly installed, improperly tightened fittings, etc.
a. If leaks are found, open the main drain outlet and allow the system to drain. Repair any
leaks found and repeat this procedure.
b. If no leaks are detected, re-open the supply isolation valve and start increasing pressure
with the pump.
8. Set the pressure up to maximum test pressure (see above). The pressure shall be increased
gradually step-by-step, maintained for some time between each step to allow the
equalization of strain and to check for leaks.
9. Monitor the test gauge to determine that the system pressure is stable. If pressure drops,
check for leaks in the system, for open valves, or for leaks in the test apparatus.
10. Once it is determined that the test pressure is stabilized, disconnect the power to the test
pump and close the supply isolation valve. Record the time of the test pressure at this step.
11. Hold the test pressure for at least 10 min, or more time necessary to examine all joints and
connections.
12. No leaks shall be found after this period. If not, repairs or additions shall be made after the
leak test, and then the affected piping shall be retested.
13. When the test is successful, slowly open the drain valve to drain the system. Be careful that
no damage to nearby equipment occurs and no personnel is harmed.
14. Disconnect the test pump and restore the system to its original configuration.
 Commessa Documento Riferimento
Job No. Doc. No. Reference

STANDARD STDE-PRD-005
SIA STANDARD
Titolo
Title HYDROSTATIC TEST PROCEDURE
Rev. Pag. di
FOR WATER/FOAM BASED SYSTEM Sheet of
3 8 11

6.2. SITE ACCEPTANCE TEST

According to NFPA 13, all piping and attached appurtenances subjected to system working pressure
shall be hydrostatically tested at 14 bar and shall maintain that pressure without loss for 2 hours.
Loss shall be determined by a drop in gauge pressure or visual leakage.
Portions of systems normally subjected to system working pressures in excess of 10 bar, shall be
tested at a pressure of 3.4 bar in excess of system working pressure.
Other portions of pipe, such as test connections, water alarm gong connections, drain and auxiliary
drains, typically are not subject to high pressures and do not have to be tested.
A preliminary test using air at no more than 1.7 bar gage pressure may be made prior to hydrostatic
or pneumatic testing to locate major leaks.
Procedures for hydrostatic pressure test shall be as specified in below steps:
1. Inspect the system to verify that openings (nozzles connections) are plugged and outlet valves
(for example drain) are closed.
2. Verify that the Deluge Valve Skid (inlet) tie-in is properly connected to the main water supply.
3. Check the skid valves for correct positioning/setting:
a. The skid tie-in isolation valve shall be closed.
b. The valves on the line to be tested shall be open.
c. The Deluge Valve, and the downstream isolation valve(s) if any, of the other lines shall
be closed.
d. All other valves positioning/setting shall be set according to normal operating conditions
(see for ex. relevant P&ID).
4. Slowly open the skid tie-in isolation valve, to fill the line with water. Open one manual valve
(for example manifold drain) during this operation, to vent any trapped air. Close the valve
when water flows continuously through it.
5. When the system pressure reaches the water source pressure, close the skid tie-in isolation
valve and inspect the entire system for leaks. These may result from flanges not bolted
properly, plugs not properly installed, cracked or improperly tightened fittings, etc.
e. If leaks are found, open the main drain connection and allow the system to drain. Repair
any leaks found and repeat this procedure.
f. If no leaks are detected, re-open the supply valve and start increasing pressure with the
pump.
 Commessa Documento Riferimento
Job No. Doc. No. Reference

STANDARD STDE-PRD-005
SIA STANDARD
Titolo
Title HYDROSTATIC TEST PROCEDURE
Rev. Pag. di
FOR WATER/FOAM BASED SYSTEM Sheet of
3 9 11

6. Set the pressure up to maximum test pressure (see above). The pressure shall be increased
gradually step-by-step, maintained for at least 2 minutes between each step to allow the
equalization of strain during test and to check for leaks.
If the main supply pump cannot be used to reach the test pressure, an additional pump can
be connected to distribution piping (for example at the drain outlet) to be able to set the
system to the test pressure. Close the skid tie-in isolation valve before turning on the
secondary pump.
7. Monitor the test gauge to determine that the system pressure is stable. If pressure drops,
check for leaks in the system, for open valves, or for leaks in the test apparatus.
8. Once it is determined that the test pressure is stabilized, disconnect the power to the test
pump and close the skid tie-in isolation valve. Record the time of the test pressure at this
step.
9. Hold the test pressure for 2 hours.
10. No leaks shall be found after this period. If not, repairs or additions shall be made after the
leak test, and then the affected piping shall be retested.
11. When the test is successful, slowly drain the system. Be careful that no damage to nearby
equipment occurs and no personnel is harmed.
12. Disconnect the test pump and restore the system to its original configuration.

7. ACCEPTANCE CRITERIA

The system must hold the test pressure for required time without leakages and loss of pressure.
Absence of water leakage is verified by visual examination of the system (welding, fittings, flanges,
etc.) and possible pressure loss is observed by means of the test gauge.
Fittings and flange that present leakages shall be properly tighten and re-checked. Welds or portion
of welds that leak during hydrostatic test shall be repaired, cut-out, re-welded, inspected (if
needed).
The line shall be hydrostatically tested again, until the test is considered concluded with positive
results.

7.1. CONFORMITY

The tested system is accepted if in compliance with the reference documents.

Records shall be made for each system during the testing and these records shall include the
following items.
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Job No. Doc. No. Reference

STANDARD STDE-PRD-005
SIA STANDARD
Titolo
Title HYDROSTATIC TEST PROCEDURE
Rev. Pag. di
FOR WATER/FOAM BASED SYSTEM Sheet of
3 10 11

1. Extent of testing and specification

2. Identification of the object of the test
3. Pressurizing apparatus
4. Design temperature and pressure
5. Test ambient conditions
6. Test pressure and test duration
7. Test fluid
8. Date (and time if needed) of test
9. Approval signature of witness (Owner's and Manufacturer/Vendor's representative)
10. Signature of person in charge of testing
11. Applicable remarks concerning defects

7.2. NON-CONFORMITY

Whenever the tested system is not compliant with the parameters listed in the reference
documents, it is rejected and consequently the Test Report will show the negative result of the test.
if required, non-conformities may be recorded in a dedicated Punch List and managed accordingly.
 Commessa Documento Riferimento
Job No. Doc. No. Reference

STANDARD STDE-PRD-005
SIA STANDARD
Titolo
Title HYDROSTATIC TEST PROCEDURE
Rev. Pag. di
FOR WATER/FOAM BASED SYSTEM Sheet of
3 11 11

8. APPENDIX: SIA TEST CERTIFICATE TEMPLATE