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: Page : 1 of 8
QUALITY SYSTEM PROCEDURE Effective date: Revision: 00
Approved by:
TITLE: HYDROSTATIC AND PNEUMATIC TESTING PROCEDURE
Revision History
1. HYDROSTATIC TEST
1.1 SCOPE
This document describes the Hydrostatic and Pneumatic Testing Procedure to be applied
by company for piping follow codes and client specifications. This testing procedure only
applies to shop testing activities.
1.2 PURPOSE
The objective of this work instruction is to give a guideline to the QC Inspector and
Workshop’s Foremen/Supervisor to ensure hydrostatic testing is conducted in a safe and
efficient manner and in accordance to specification/codes for piping which subject to
internal test.
Client’s specifications
Chloride content in water shall be less than 250 ppm for carbon steel components.
Chloride content in water shall be less than 50 ppm for stainless steel components.
1.6 RESPONSIBILITIES
Mark the test limits on the isometric drawing of latest revision and perform the line check.
Confirm with relevant QC personnel whether NDEs has been completed and accepted.
Orient testing group about handling and usage of testing equipment in order to maintain its
measuring accuracy.
He shall work in-line with the Production Supervisor and QC personnel in fulfilling
requirements.
1.6.3 QC Inspector
QC shall inform to the Production Supervisor about the completion and acceptance status
of the required NDE.
c. Test pressure.
d. Test medium.
a. Test pump.
d. Chart recorder.
e. Test blinds.
At least two the calibrated pressure gauges shall use monitoring the test. The first pressure
gauges shall locate at lower point where can easily visible for monitoring and another
pressure gauge shall locate at the ventilation of higher point.
The range of the gauges shall use within 1.5 to 4.0 times of the test pressure.
A calibrated chart recorder may use during hydrostatic testing for recording.
All examinations and stress relieving activities have to complete before testing.
The Workshop Forman shall ensure all bolts and its nut had tightened.
Barricade must be limited at the testing area with display signboard with “KEEP AWAY
HYDROTEST IN PROGRESS”.
The QC inspector shall send the notification to Client before official testing.
The pressure test follows project specification and approval drawings or 1.5 times of the
design pressure.
The QC inspector shall monitor the testing process and verify that there is no leakage or
visual distortion during or upon completion of test.
Upon completion of the test, test medium shall be drained and unbolt flange joint.
All internal pipe spools shall clean and flush with pressurized water, then drying out by
dried air
If leakage found on products or product welds, their location shall be marked and forward
the report to QC Engineer for investigation before re-testing.
If leakage found on flanged joints, threaded joints shall rectify before re-starting test.
1.12 DOCUMENTATIONS
b. Job number
f. Date of test
h. Test medium
i. Test pressure
j. Test temperature
k. Test results
es
su
Pr
re
Test pressure=1.5xP
P=Design Pressure
50% P
2. PNEUMATIC TEST
Doc. no. : Page : 6 of 8
QUALITY SYSTEM PROCEDURE Effective date: Revision: 00
Approved by:
TITLE: HYDROSTATIC AND PNEUMATIC TESTING PROCEDURE
2.1 SCOPE
This document describes the general procedure used for the leak test of piping system
requiring this method of leak detection.
Client’s specifications
The test package shall be submitted and approved by Client before testing.
Test pressure shall be not less than 1.1 times the design pressure or specification
requirements.
2.4 RESPONSIBILITIES
He shall work in line with the Production Supervisor and QC personnel in fulfilling
requirements.
2.4.3 QC Inspector
The test shall be performed by Workshop Forman under the supervision of Production
Supervisor, QC Engineer.
All relevant documents shall be reviewed and approved by Client before testing.
Check all valve or equipment to ensure fully open position and correct direction.
Adequate measures for safety and environment control shall be established before test. All
required codes and recommendation from principal and or client shall be compiled.
As per pneumatic testing represents special risk, outmost care shall be taken during
pressurization and inspection of the system to prevent any danger to personnel or equipment.
This task shall be executed under supervision of an experienced Production supervisor.
Tightening of plugs, caps and flange connection is not allowed at pressure above 30% of test
pressure. Pressure shall be reduced as required before tightening to carry out.
Testing area shall be marked with warning signs, signboards and to be barricade indicating
risk boundaries. Access to test area shall be limited to test personnel only. Unauthorized
works shall be away from the testing area.
The system or test equipment shall be protected by a pressure relief device having a set
pressure of 10% above the pneumatic test pressure of the system.
All test pressure gauges shall be calibrated and calibration certificates are available at work
site.
Range of pressure gauges shall be not less than 1.5 times or excess than 4.0 times the
design pressure.
Minimum of two gauges are required during the test. One gauge should be located at nearest
to the inlet pressure application and another at or near to the highest point of the test system.
Temperature of the system or equipment shall monitor and record during the test.
All flange joints and weld seams shall be directly checked by detector solution. Application of
the solution shall be in a continuous film relatively free from bubbles. Any indication of bubbles
shall be investigated for the location of leakage and retest is required. If it is from the
connector point, pressure shall be reduced to zero and repair. If it’s from the weld seam, they
shall be dried by using compressed air or gas torch before repairing weld joint. Retest shall be
done after weld repairs have cooled down to room temperature.
Test pressure shall be held a minimum of ten minutes or specific in project specification.
A pressure relief device shall be provided, having a set pressure not higher than 10% of the
test pressure.
Doc. no. : Page : 8 of 8
QUALITY SYSTEM PROCEDURE Effective date: Revision: 00
Approved by:
TITLE: HYDROSTATIC AND PNEUMATIC TESTING PROCEDURE
2.9 DOCUMENTATIONS
b. Job number
f. Date of test
h. Test medium
i. Test pressure
j. Temperature
k. Test results
Pressure
Test pressure=1.1xP
P=Design Pressure
50% P