Hydro Test Procedure

Maraba Al-Iraq Al-Khadra’a Co.
Dr. Concrete Building Material Trading & General

Contracting Co.
Hydrostatic Test Procedure
Project: Flowline Installation Services Contract No. PR139390 Doc No MIK-DRC-HYT-P-001 Rev: 01
REV DATE DESCRIPTION PREPARED BY REVIEWED BY APPROVED BY
01R 2018-05-17 ISSUED FOR REVIEW Naveed Ahmed Ali Abdul Nabi Ali Abdul Nabi
02R 2020-20-20 ISSUED FOR REVIEW Naveed Ahmed Ali Abdul Nabi Ali Abdul Nabi
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Contracting Co.
CONTENTS
1. SCOPE ............................................................................................................................................................. 3
2. REFERENCE .................................................................................................................................................3
3. RESPONSIBILITY ........................................................................................................................................3
4. TEST FLUID ..................................................................................................................................................3
5. TEST PREPARATION ..................................................................................................................................4
6. HYDROSTATIC PRESSURE TEST ...........................................................................................................5
7. SAFETY .......................................................................................................................................................... 6
8. SENSITIVE LEAK TEST ............................................................................................................................. 6
9. ALTERNATIVE TESTS ............................................................................................................................... 6
10. INSTRUMENTS .............................................................................................................................................7
11. CLEANING ....................................................................................................................................................7
12. REPORTS AND RECORDS ......................................................................................................................... 7
13. TEST RECORDS ...........................................................................................................................................7
14. ACCEPTANCE ..............................................................................................................................................8
15. RECORDS ......................................................................................................................................................8
Appendix I ....................................................................................................................................................................9
Appendix II. ............................................................................................................................................................... 11
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Contracting Co.
1. SCOPE
These guidelines cover the requirement of Pressure testing of piping systems. This
procedure is prepared to facilitate Pressure testing work in field and to ensure compliance
to code requirements for the Project.
2. REFERENCE
Piping construction works shall be performed in accordance with ASME B31.3 and ASME
section IX.
➢ ASME B31.3 Process Piping

➢ ASME SECTION.IX "Welding and Brazing Qualifications 1) Drawings, Applicable
codes and Standards
➢ ANSI/ASME B31.3 latest edition
➢ ASME Section V latest edition
➢ Line schedule
➢ Field QC Procedure
3. RESPONSIBILITY
The CONTRACTOR shall arrange all the required equipment and accessories like Pumps,
Pressure gauges, valves, hydraulic pumps of suitable capacity, necessary pipes fittings,
flanges, temporary gaskets, bolts & nuts for the Pressure test.
Engineer-In-Charge shall advise or instruct the CONTRACTOR, regarding preparation of

Pressure test loop package prior to commencement of Pressure test work according to Field
QC Procedure.
CONTRACTOR shall prepare and submit all necessary records of test for review and obtain
NDT and punch clearances from Engineer-in-Charge for with Pressure test information to
client, if required.
4. TEST FLUID
The test shall be hydrostatic using water except in following cases.
a) If there is a possibility of damage due to freezing, or if the operating fluid or piping material
would be adversely affected by water, any other suitable liquid may be used. If a flammable
liquid is used, its flash point shall not be less than 500 C and consideration shall be given to
the test environment.
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Contracting Co.
b) Based on process / design requirements, if the hydrostatic testing is not advisable then
pneumatic test may be substituted, using air or any other nonflammable gas.
Water to be used for test shall be fresh and clean. Chloride content of water used shall be
less than 30 ppm. In case of stainless-steel piping hydrotest medium shall be D.M. water.
5. TEST PREPARATION
a) Line check shall be carried out for entire loop as per other applicable sketch/ drawings.
b) All joints, including welds and flanges are to be left uninsulated and exposed for
examination during the test.
c) If a sensitive leak test (Ref. 6.0) is required all joints mentioned above shall also be left
unprimed and unpainted.
d) Piping designed for vapor or gas shall be provided with additional temporary supports, if
necessary, to support the weight of the test liquid.
e) All Expansion joint shall be provided with temporary restraint if required for additional
pressure load under test or shall be isolated from the test.
f) Equipment which is not subjected to pressure test shall be either disconnected from the
piping system or isolated by blinds or either means during the tests.
g) Valves may be used provided the valve is suitable for the proposed test pressure.
h) A flanged joint at which a blank is inserted to blank off other equipment during the test
need not be tested. However, all such joints shall be checked during final system leak test.
i) Blanks used for isolation at a flanged joint of piping system shall be provided as follows:
• Minimum thickness of blanks shall be as shown in attached table.
• A grip colored in red shall be provided at outside of blanks for identifying the
purpose of test use.
• Blind flange shall be of the same rating as piping system.
➢ In case where piping diameter is 1inch or under.
Test Pressure (kg / cm2) Thickness of Blind Plate (mm)
7 or under 1.6
8 ∼14 2.3
15 ∼40 2.5
41 ∼60 3.2
61 ∼115 4.5
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Contracting Co.
116 ∼210 6.0
In case where piping diameter is 26 inch or over, following formula shall be applied to
determine the thickness of blind plate.
Thickness of blind plate tm = t + c
Where t =dg √3.P/16.S.E
dg : Inside diameter of gasket (mm) for raised face flanges, or the gasket pitch diameter for
ring joint and fully retained gasket flanges(inches)
P : Design gauge pressure (psig)
S : stress value for material from Table A-1 B (psig)-ASME B31.3
E: quality factor from table A-1A or A-1 B-ASME B31.3
C : corrosion / erosion, plus mill tolerance allowance(inches)
6. HYDROSTATIC PRESSURE TEST

6.1. Procedure for hydrostatic pressure test shall be as follows:
a) Before pressurising the piping system, the whole loop shall be flushed thoroughly to
ensure removal of soluble (paper) dam, muck etc. to avoid blockage of valves.
b) Fill the water in piping system.
c) Release all air from piping system by opening vents at highest points.
d) Use minimum 2 calibrated pressure gauges; out of which one shall be at highest level
and other near the pump. The range of pressure gauges shall be between 1.5 to 4.0
times the test pressure.
e) Increase water pressure gradually by using pressure pump till the required test
pressure is attained.
f) Check joints at the gauge pressure and confirm that there are no leaks.
Examination shall be carried out after holding the line test pressure for at least 30 minutes or as
specified by drawing / specification.
6.2. Where Piping is supported by spring hangers, constant hangers and similar devices, it shall
be ensured that no load shall be transferred to springs etc. and such devices shall withstand
the load due to hydrotesting of piping system. If required, temporary supports shall be
provided during hydrotesting of piping system.
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Contracting Co.
6.3. Before water in the piping system is drained, vent shall be opened and shall be kept open
until water is fully drained from piping system.
6.4. After completion of the test, pressure shall be released by opening the valve gradually so as
not to endanger personnel or damage the equipment.
6.5. Pressure measurement tools are calibrated, and their statuses of calibration are still valid.
6.6. The hydrostatic test pressure shall be 1.5 times of the design pressure, unless otherwise
specified for deviation. According to ASME B 31.3, the test pressure may vary according to
process requirements or temperature conditions, in such case, the test pressure shall be
followed according to process requirements and line schedule.
6.7. All the temporary tools (such as valve, fitting, hoses, flanges, blind plate, etc) have to be rated
more than the maximum hydrostatic pressure.
7. SAFETY
The safety related issues including but not limited to the following should be addressed in
Job Hazard Analysis (JHA) to be made by CONTRACTOR for performance of Pressure Testing
activities:
7.1. Appointment of CONTRACTOR's Test Controller who is in attendance and responsible

throughout the testing and inspects the welding during testing.
7.2. Appointment of the subcontractor's test controller who will be responsible for ensuring safe
testing in accordance to the specification.
7.3. Display of safety warning signs to alert workers in the vicinity of the pressure testing with
line, identification.
7.4. Pressure test training and maintenance of a competency register as required by
CONTRACTOR Safety Plan.
7.5. Pressure rating for the test manifold and the test equipment and the required
inspection/testing.
8. SENSITIVE LEAK TEST

Piping required to have a sensitive leak test shall be tested by the gas and bubble formation
testing method specified in article 10, section V, of the ASME boiler and pressure vessel code.
If an additional hydrostatic pressure test is required, it shall be done after the sensitive leak
test.
9. ALTERNATIVE TESTS
This test shall be applied in accordance with ASME B31.3 Para 344.9 or ASME B31.4
Para 437.1.4(b), if required, subject to approval from PTT/Consultant.
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Contracting Co.
10. INSTRUMENTS
10.1. All instruments will be protected from damage when hydro testing process and utility piping
systems. Paragraph 2.3 outlines the status of instruments during testing to insure
protection.
10.2. Control valves shall have their bodies shop tested and need not be retested in the field, but
where valve does not restrict test pressure, valve may be included in a system test. Valves
shall be jacked open during test.
11. CLEANING
11.1. Tested piping shall be internally cleaned to remove all remaining dust and foreign matter
by water flushing or blowing with air.
11.2. Flushing shall be done with clean water using hydrostatic test water where possible. Water
used for special flushing or cleaning of austenitic stainless steel shall not contain more than
50 PPM chlorides, i.e.
11.3. Where special treatment is required, such as cleaning of compressor suction and lube oil
piping, a separate procedure shall be prepared by CONTRACTOR'S Operations /
Commissioning Group
12. REPORTS AND RECORDS

12.1. As a minimum, the Subcontractor shall maintain records of all pressure tests, records of all
welding operations, including welder numbers, weld numbers, and post weld heat
treatment charts referenced to weld numbers, records of all hardness tests, records of all
cleaning, pressure gauges calibration sheets, and when certification is required, all
certification records.
12.2. All records shall be submitted and approved by the CONTRACTOR and shall be submitted
to the Owner.
12.3. Piping Field Test Report shall be prepared for each line segment of non-pressure piping.
13. TEST RECORDS

13.1. Records shall be made of each piping system test.
These records, when completed, shall be submitted as part of the test and inspection
certificates which are required for recommissioning.
Records shall include:
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Contracting Co.
1) Date of test
2) Identification of piping system and any vessels or equipment tested with the piping
system.
3) Test medium.
4) Test pressure and maintaining time.
5) Minimum ambient temperature.
13.2. All test records, and authorized CONTRACTOR certifications shall be retained in the Test
Package records for turnover to the Owner. Test data base shall be established to monitor
status and progress.
13.3. Where complete drainage is impossible, the system shall be flushed free of all test water
using boiler condensate or dematerialized water containing less than five (5) PPM chlorides,
alcohol, petroleum distillate or another suitable flushing solution. Hot air drying is not
acceptable in lieu of flushing, but water may be blown out of pockets using air.
14. ACCEPTANCE
14.1. Acceptance criteria for leak test.
No leaks shall be observed in the piping system except that, any leaks from gland packing
of valves at test pressure may be accepted subject to no leaks during system leak test.
Any leaks from gasket at flanged joint where blank is inserted to isolate other equipment or
a test spool is installed as a replacement of piping component may be accepted subject to
no leaks at design pressure during leak test, or during system leak test.
14.2. In case any leak is observed from weld or parent material it shall be repaired by an approved
procedure, all nondestructive tests shall be performed and Re- hydrotest shall be
conducted.
15. RECORDS
15.1. The following records shall be maintained in the Pressure test package.
a. Index sheet.
b. NDT clearance / box-up report.
c. Pressure test report.
d. Time schedule.
e. P&ID/ Loop diagram.
f. Pin hole test for coating / wrapping of U/G piping.
g. Line check report.
h. Final visual inspection punch list.
i. Weld history sheets.
j. Isometric drawings.
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Contracting Co.
15.2. A pressure test report shall be prepared, and duly signed by Engineer-in-Charge on
completion of Pressure test of the system /loop and maintained in the Pressure test loop
package.
Appendix I
Minimum Thickness of Blank for Pressure test
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Contracting Co.
Appendix II
Details of Test Facilities
Schematic DWG for Supplying Source
1. For Pneumatic Test (Not applicable)

2. For Hydrostatic Test
Equipment List for Piping Pressure Test.
1. Pump
- Test Pump (Pressurizing Rump)
- Water Supply Pump
2. Air Compressor (for blowing, if required)

3. Pressure Gauge (Two (2) or more)
4. Rubber Hose W/Steel Wire Reinforced
5. Temporary Piping with accessory
6. Chemical Inhibitor (If required)
7. Radios (Warlike Talkie)
8. Other materials
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Maraba Al-Iraq Al-Khadra’a Co.

Dr. Concrete Building Material Trading & General

Hydrostatic Test Procedure

REV DATE DESCRIPTION PREPARED BY REVIEWED BY APPROVED BY

➢ ASME B31.3 Process Piping

Engineer-In-Charge shall advise or instruct the CONTRACTOR, regarding preparation of

Test Pressure (kg / cm2) Thickness of Blind Plate (mm)

116 ∼210 6.0

Thickness of blind plate tm = t + c

Where t =dg √3.P/16.S.E

P : Design gauge pressure (psig)

S : stress value for material from Table A-1 B (psig)-ASME B31.3

E: quality factor from table A-1A or A-1 B-ASME B31.3

C : corrosion / erosion, plus mill tolerance allowance(inches)

6. HYDROSTATIC PRESSURE TEST

7.1. Appointment of CONTRACTOR's Test Controller who is in attendance and responsible

8. SENSITIVE LEAK TEST

Para 437.1.4(b), if required, subject to approval from PTT/Consultant.

12. REPORTS AND RECORDS

13. TEST RECORDS

Records shall include:

1. For Pneumatic Test (Not applicable)

Equipment List for Piping Pressure Test.

- Test Pump (Pressurizing Rump)

- Water Supply Pump

2. Air Compressor (for blowing, if required)

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