LEAK TEST PROCEDURE Doc No: STS/QAC/SOP/03

Rev No: 00
Date Rev: 17 Dec 2008
Page No: 1 of 8

REVISION HISTORY

Rev Originator Description Of Amendments Date

00 Farid New Document 17.12.2008

Designation Name Signature

Originator Mechanical Eng Mohd Farid Abu Bakar

Reviewed

Approved
Controlled document: No part of this document may be printed or reproduced for external purposes
without the written permission of the management appointee of Science-Tech Solutions Sdn Bhd.

SCIENCE-TECH SOLUTIONS SDN BHD

1. SCOPE

This procedure covers the minimum requirement for Leak Test on equipment and Piping as part of
work completion acceptance criteria and in accordance to client specifications

2. REFERENCE

2.1. ASME VII Div I

2.1.1. UG-100, "Pneumatic Test"

2.1.2. UG-99, "Standard Hydrostatic Test"

2.2. ASME B31.3

2.2.1. Chapter VI, "Inspection, Examination and Testing- Clause 345"

2.3. Mechanical Integrity System Manual

2.3.1. PSM-MI-20408- Pressure Testing of Pressure Vessels, Heat Exchanger and Process
Piping.

3. DETERMINE TEST PRESSURE AND METHOD

3.1. Pressure Vessel

Establish maximum test pressure for equipment, taking into account the static head of the
test media as per following;

3.1.1. 1.3 times the design pressure, or

3.1.2. the test pressure stamped on the equipment name plate, or
3.1.3. Set pressure of the pressure relief device having the lowest setting ( to very system
tightness only), or
3.1.4. As specified by client

3.2. Piping System

The minimum hydrotest pressure should not less than 1.5 the design pressure as per ASME
B31.3

3.3. Heat Exchanger

The test pressure for shell test, tube test, final shell test, differential pressure test as applicable
per drawing/datasheet or IRP.

4. PROCEDURES

4.1. The preferred method to be used as per following;

 4.1.1. The preferred method of testing shall be hydrostatic test. If a hydrostatic test is not
possible or practical, test method 4.1.2 or 4.1.3 below may be selected upon written
approval of appropriate involved parties.

4.1.2. Pneumatic test may be performed if a hydrostatic test is not practical. For pneumatic
test, the minimum test pressure for pressurized piping system and equipment shall be
not less than 1.1 times the design or 50% of operating pressure or 150kpa whichever is
less. The pneumatic pressure testing shall only be performed upon approval of client.

4.1.3. Alternative test shall only be performed under following circumstances;

4.1.3.1. Damage of internal lining or insulation due to hydrotesting, introduction of

contamination or present of hazard due to brittle fracture due to temperature
during testing.

4.1.3.2. A pneumatic test would cause present of undue hazard due to possible of release
of energy stored in the system, or would present the danger of brittle fracture.

4.2. Hydrotest procedure as follows;

4.2.1. Determine the test pressure;

I. If design temperature <343C, the test pressure shall be 1.3 times the design
pressure.

II. If design temperature >343C, the test pressure shall be 1.5 times the design
pressure times a correction factor for allowable stress at the different
temperatures;

Pt=1.3P (St/S)

where St = Stress at 37.8C

S = stress at design temperature.

4.2.2. Determine that the pipe rack, supports, and vessel foundation are design to handle
additional weight when filled with water.

4.2.3. Prepare the system by providing blinds, temporary connections and disconnect
equipment and instruments. Remove any orifice plates that will interfere with filling or
draining the system.

4.2.4. When the equipment is prepared and found ready for the test, it should be thoroughly
checked and approved by client representative.

4.2.5. Barricade the equipment area with signage of hydrotest in progress, before introduce
pressure.
 4.2.6. Vent shall be provided at all high points of the equipment on the position in which it is
to be tested to purge possible air pockets while the equipment is being fill up.

4.2.7. A pump shall be connected to the equipment with check valve.

4.2.8. Two pressure gauges with suitable range shall be installed on the lowest and highest
points of the equipment. The gauges shall be visible to person controlling the pressure
applied. All pressure gauges shall be made sure having a valid calibration certificate.

4.2.9. Fill up the equipment with water or N2 for carbon steel equipment until full. Let the
water flow out for a while to ensure there is no air pocket in the equipment. Chloride
content shall be less than 30ppm or demineralized water shall be used for stainless steel
pressure test.

4.2.10. Wipe out all the remaining water at the checking point. This will help for leak detection.

4.2.11. Pressure up the equipment slowly until it reached the design pressure, hold for 5
minutes. Check equipment for any sign of leakage.

4.2.12. Pressure up the equipment slowly until it reached 100% of the test pressure value and
hold for 30 minutes. Check any sign of leakage.

4.2.13. Client and DOSH representative shall conduct visual inspection to verify test result.
Should the is a leakage detected, equipment shall be repair and repeat the test until
accepted.

4.2.14. Upon approved test result, pressure shall be released.

4.2.15. In releasing the pressure, it shall be done slowly until the pressure reach zero and
remove all temporary blind and valves.

4.2.16. Air shall be blow extensively through drain and vent point or flushing using
demineralized should water has been used as medium for stainless steel.

4.2.17. All data shall be recorded in Hydrostatic Test Record, inclusive but not limited to;
I. Equipment Tag No:
II. Equipment Name:
III. Design Pressure:
IV. Test Pressure
V. Test Medium

4.3. Alternative Test Procedure

4.3.1. All welds, including those made by the manufacture, which have not been hydrotested
or pneumatic tested, shall be tested as follows;
 4.3.1.1. Circumferential, longitudinal and spiral groove welds shall undergo 100%
radiography testing.

4.3.1.2. All other welds, including structural attachment welds, shall be examined using
DPT or MPT.

5. ATTACHMENT
5.1. Pressure / Leak test chart
5.2. Equipment Hydro Test Diagram
5.3. Piping Hydrotest Diagram.