THE PROVISION OF PIPELINE

INSTALLATION SERVICES

SMG1 FLOWLINE PROJECT

HYDROTEST
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DROTEST_001

HYDRO TEST

CONTENTS

1.0 INTRODUCTION

2.0 REFERENCES

3.0 RESPONSIBILITIES

4.0 PROCEDURE

4.1 Preparation

4.2 General Requirements

4.3 Test Liquid

1.0 INTRODUCTION
The purpose of this procedure is to ensure that all pressure testing work carried out on a
construction site is performed in a planned, controlled and safe manner in order to prevent
accidents, and to ensure that the work meets any regulations and provisions in force.
Pressure testing will be performed to establish the strength, tightness and safe working
pressure of a line or pressure vessel.
It is essential that safe practices be observed during pressure testing of pipes and pressure
vessels, due to the potential hazards associated with high-pressure liquids and gases.
Where an existing site has detailed Company specified requirements for pressure testing
activities, these will take precedence over this procedure, although this will still be utilised by
company personnel as a guide to safety requirements.
 THE PROVISION OF PIPELINE
INSTALLATION SERVICES

SMG1 FLOWLINE PROJECT

HYDROTEST
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2.0 REFERENCES
“Work Permit System“
3.0 RESPONSIBILITIES
Competent Person
The Competent Person is a person fully trained, qualified and experienced in the planning
and performance of pressure testing operations and will have detailed knowledge of the hazards
and safety precautions applicable to this type of work.
He is responsible for the pressure testing work on the site. He shall ensure that all work is
performed by persons who are fully competent.

4.0 PROCEDURE

4.1 Preparations
Prior to commencement of pressure testing activities, and in order to eliminate any
hazards, the following factors will be considered and implemented in the planning and
preparing of all work:
 All persons who will work on a pressure test shall be informed of the potential hazards
and the necessary safety precautions.
 No pressure testing shall be performed without prior receipt of an approved hydro test
procedure.
 Work permits shall be obtained prior to commencement of any pressure testing
activities in accordance with Company site and/or Local Authority requirements, as
applicable.
 Where isolation valves are used to contain test pressures, they must be of adequate
rating for the pressure to be encountered. If isolation valves are used instead of blinds,
provisions shall be made to ensure that no over-pressurising can occur in equipment
that is not being tested, due to possible valve leaks.
 THE PROVISION OF PIPELINE
INSTALLATION SERVICES

SMG1 FLOWLINE PROJECT

HYDROTEST
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 Barricades, barrier tape and warning signs shall be installed in areas of pressure
testing, especially in pipeline loops and road crossings.
 Personnel shall be present during testing at all times to check all areas.
4.2 General Requirements
The following general requirements shall be observed during the performance of pressure
testing:
 Any ancillary equipment not under test shall be isolated by valves or blind flanged
and vented or disconnected.
 Only calibrated test gauges shall be used and they shall be mounted in the upright
position. Pump discharge gauges must be visible to the pump operator for the duration
of the test.
 A block valve is required on the line from the test pump to the equipment under test.
 When draining test fluid, the line shall be vented slowly to avoid an excessive
vacuum.
 Lines should be drained and dried mechanically when the test fluid is corrosive or
otherwise hazardous.
 The pressure rise during a pressure test should be gradual and under control to allow
time for the material to strain, and time for personnel to check for leaks.
 A system under test shall be depressurised before any work is done to stop leaks or
repair weakness, including the tightening of bolts. In tightness tests, bolts may be
tightened without depressurising, if specifically approved in the written test
procedure.
 Hammer testing shall not be done while the system is under pressure.
4.3 Test Liquid
 Water is normally the preferred test liquid. Alternatives may be used but they must be
approved by a deviation from a standard and must be detailed within the specific test
procedure.
 Salt water must not be used for testing any material subject to stress corrosion
cracking in the presence of chloride ions.
 Possible changes in pressure due to thermal expansion, contraction or hydrostatic
heads must be taken into account.
 THE PROVISION OF PIPELINE
INSTALLATION SERVICES

SMG1 FLOWLINE PROJECT

HYDROTEST
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DROTEST_001

Written procedures, approved prior to testing, shall be followed for the disposal of test
mediums, which contain chemical additives for control of corrosion or bacteria.