KANTAS

INTERNATIONAL
NIGERIA LIMITED

GENERIC HYDROTESTING
PROCEDURE

Document No.: QMS-QP-20

THIS DOCUMENT CONTAINS

REVISION 0 INFORMATION WHICH IS PROPRIETARY TO KANTAS INTERNATIONAL NIGERIA LIMITED (KANTAS).
THIS INFORMATION
Prepared by: IS TO BE HELD IN CONFIDENCE. DISCLOSURE, REPRODUCTION, OR OTHER USE OF THIS DOCUMENT IS
Ajayi Kunle
PROHIBITED WITHOUT THE PRIOR WRITTEN CONSENT OF KANTAS.     
QA/QC Manager
Reviewed by:
Technical Manager Nwagbara E. C.
Approved by:
Managing Director ONODINGENE Ken
Reviewed by:
CHGC
Date of Issue:

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QMS-QP-22: Hydro-test Procedure
TABLE OF CONTENT

ITEM           PAGE
1.0 Scope 3
2.0 References 3
3.0 Definitions and Abbreviations 3
4.0 Responsibilities 3
4.1 Technical Manager 3
4.2 Project Manager 3
4.3 Foreman 4
4.4 Quality Control Department 4
4.5 Safety and Cashes Manager 4
5.0 Pressure Testing Procedure
5.1 Preparation 4
5.2 Flushing 5
5.3 Hydrostatic Testing 5
5.4 Hydrotesting 5
5.5 Filling 6
5.6 De-Watering and Drying 6
5.7 System Re-instatement 6
5.8 Hydrostatic Test Acceptance Criteria 7
5.9 Test equipment Requirements 7
5.10 Quality Control Inspection 8
5.11 Test Pressure 8
5.12 Test duration 8
5.13 Safety 8

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QMS-QP-22: Hydro-test Procedure
1.0 SCOPE:
This Hydro-testing Procedure outlines the Engineering guidelines and basic Project requirements for
the development of Hydrostatic Pressure Testing Processes that will be implemented during the
execution of construction works for the Piping/ Pipeline Construction Scope.

2.0 REFERENCES:
 Project Drawings
 API-5L
 ASME B31.3
 ASME B31.4
 ASME B31.8
 API-RP-1110
 API-1104

3.0 DEFINITIONS AND ABBREVATIONS:

 ASME – American Society of Mechanical Engineers
 P & ID -Process and Instrument Diagram
 API -America Petroleum Institute
 STP -Specific Test Pressure

4.0 RESPONSIBILITIES:
The Implementation of this Procedure is carried out by the Technical Manager, Project Manager,
Construction Manager, the Quality Control Department/ Representative and the Safety/ CASHES
Manager/ designee.
4.1 TECHNICAL MANAGER:
 Shall review the drawings and draw up plan for the execution of the Project Scope of Work.
 Draw up Plan for the Hydro-test based on Project Schedule.

4.2 PROJECT MANAGER:

 Implement Operating Procedure
 The Project Manager shall designate qualified Personnel to be responsible for all hydrostatic
activities.
 Route drawing revisions through the quality control department for review.
 Establish priority of testing activities and obtain approval from the Technical Manager.
 Establish test boundaries and the location of all blinds, spacers, vents, drains and disposal of
test fluids.
 Ensure that test fluid, duration and the minimum and maximum Test Pressure established by
Client are followed.
 Define Equipment and Instrumentation to be included, or excluded from the test.
 Ensure the most current and approved Drawings are used for the system preparation and
testing.
 Sign off Ready-for-Test, and drained Ready-for-Service on the Pressure Test Report.
 Generate Pressure Test Punch List to correct any discrepancies discovered prior to hydrostatic
test.

4.3 FOREMAN:
 Responsible for assuring that the work activities are performed within the specified
requirements.

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  Ensure that all test preparations including fabrication of test ends, test manifolds, piping, pipe
filling and draining.

4.4 QUALITY CONTROL MANAGER / QC DEPARTMENT:

 Perform Quality control inspection prior to commencement of Pressure testing.
 Issue Drawing Revisions to the construction Manager / Superintendent.
 Maintain required Quality control Documentation.
 Sign off Welding Inspection on the Pressure Test report.
 Ensure the use of hydro test equipment with correct rating.

4.5 SAFETY AND CASHES MANAGER / SAFETY DEPARTMENT:

 Ensure that Job Safety Analysis (JSA) has been prepared, explained and clearly understood by
all Parties involved in the work.
 Ensure that proposed Hydro-testing activities are noted on the General work permit for the
area where the testing will be carried out.
 Ensure barricades and warning signs have been placed around the area of the test.
 Check all equipment to be used in testing for damage or wear and tear, and make sure that
PSV outlet is pointing away from Personnel and equipment.     
 Ensure that PSV’s, chart recorders and gauges are calibrated and certificates are available for
inspection.

5.0 PRESSURE TESTING PROCEDURE:

5.1 PREPARATION:
 The QA/QC Manager or his designee shall inform Client 24 hours prior to the planned
hydrostatic testing activities i.e. before flushing.
 Details of the equipment and instruments to be used and certification to be provided to the
Client for approval.
 The QA/QC Manager or his designee shall compile a test package, which consist of Inspection
and test records and the record of Test blinds installed. Marked up P & ID showing limits of
test, and all isometrics, hydrostatic Test Punch list.
 All piping shall be adequately supported. Temporary Supports shall be used if additional
stability during testing is required.
 System safety relief valves if any shall be isolated prior to testing.
 All hydrostatic test gauges and pressure recorders shall be Calibrated Within six (6) months
prior to their use in accordance with Client approved Procedure.
 In case of many facilities to be tested, one shall be Pressure tested at a time.
 Before filling of the facility, it shall be inspected by the Client Representative and KANTAS
QA/QC Department Representative.
 All valves if installed shall be in the open position during the Hydro-test. Check valves shall
either be removed or blocked in the open position during test.
 The facility shall be hydrostatically tested to the Specific Test Pressure (STP). Each Test plan
shall indicate the Test Pressure, Test medium and any other test pertinent information.

5.2 FLUSHING :
 All facilities to be tested shall be flushed with potable water prior to hydrostatic testing at full
volume to clear any debris and to ensure that there are no restrictions.
 Flushing of system will be performed with one pump. Preferably should be a variable head
pump allowing high flow rate.

5.3 HYDROSTATIC TESTING :

 PACKAGE FOR TEST
 The hydrostatic Test Report.
 Sketch of the system showing the Test Assembly, Locations of blinds Spacers and any vents

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 and/ or drains.

 Pre-Test check list.

 Hydrostatic test Punch list.
 Any RFI’S, change orders or documents, which affect the system.
 Hydrostatic Test and temperature Record.

5.4 HYDROTESTING:
The Quality control department shall ensure that the preparation of the test package is done in
accordance with AFC drawings, relevant Codes and Client Specifications by the Construction
Manager/ Superintendent or his designee. Verification has to be made to guarantee that all NDT’s
has been carried out. Fill system with water, when filling is completed, Pressurizing will begin as
outlined in what follows. Pressure will be brought up to approximately twenty five (25%) of test
pressure and held for a period of time to check for leakage and pressure equalization/
stabilization. If no indication of leakage is detected, the medium will be pressured up to fifty (50%)
of the test pressure and checked for leakage, stabilization is also carried out. The medium can then
be pressured up to the test Pressure. The system will be monitored periodically during the test. If
the pressure falls below the minimum test Pressure during the test, the cause of fluctuation shall
be ascertained and rectified. The hold duration must be maintained only for test pressure that is
stable. If the rate and magnitude of the pressure drop can be accounted for by a corresponding
change in temperature, the test will continue after re-pressurization, taking into consideration the
elapsed test time prior to falling below the minimum test pressure. If leaks are found during test,
the leaks shall be repaired and the system is retested as per Client specification.

If the Pressure begins to rise due to thermal expansion, the Pressure will be adjusted so that over-
pressurization does not occur and this adjustment will be noted on the Recorder Chart.
Test medium shall be clean potable water not less than 60F temperature.
Pressure gauges and recorders shall be used for the test and gauges will be located at highest and
lowest elevations of the test system. The test pump shall be disconnected from the system as soon
as the test pressure is attained.

5.5 FILLING:
The system to be tested shall be filled with potable Water. All air shall be bled from vents and high
Points after filling. All valves, which will not be Isolated, shall undergo the pressure Test in the
full open position.

5.6 DE–WATERING AND DRYING:

After hydrostatic testing, all high point vents and test limit connections shall be carefully opened
to drainage media to avoid vacuum.

5.7 SYSTEM REINSTATEMENT:

Construction Superintendent shall be responsible for clearing all punch list items to obtain final
release of the system and ensure that:
 All temporary connections and blinds installed have been removed.
 All temporary supports, restraint and blocks are removed.
 All high point vents are plugged and sealed.

5.8 HYDROSTATIC TEST ACCEPTANCE CRITERIA:

To satisfy the testing requirements, the pressure in the must be maintained without pressure
variations which cannot be accounted for by changes in temperature. Since precise verifications is
difficult a tolerance of plus or minus 0.2% of the specific test pressure, after temperature
corrections, is accepted.

The test shall be accepted if, all pressure containing components in the test section maintain their
integrity and no leaks are found. Any reduction in pressure outside the limits specified, or
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 variation in temperature which cannot be accounted for shall result in test failure, such as loose
bolts and/fittings, leaking gaskets, test pump failure, air entrapment or weld failure, shall be
located and rectified. The Client Representative and KANTAS QC Personnel shall certify the test
report.

5.9 TEST EQUIPMENT REQUIREMENT:

Test equipment shall be calibrated and shall be individually identified and tracked for usage. All
test instrumentation is subject to re-calibration if there is a reason to question their accuracy.
Listed below is the equipment requirement.
 Hydro-test Manifold
 Pressure Pump
 Flooding Pump
 Two separate Pressure gauges calibrated as per the client specifications.
 Calibrated Dual-pen / ITT barton recorder.

Calibration certificates shall be issued Calibrated Instruments. Calibrated Instrument shall be valid
for a period of 6 months. Pressure indicators used for testing shall preferably have dials graduated
on a range at least 11/2 times the intended maximum test Pressure.

5.10 QUALITY CONTROL INSPECTIONS:

The Quality Control Department and Client inspectors shall witness all hydrostatic test to
ensure that it is conducted in accordance with the applicable code and Client specifications. On
extended tests, QC inspector shall not be required to remain at the test location for the entire test
duration, but rather monitor critical portions of the test as necessary. In-process Inspection shall
be performed by the Quality Control Department through-out the duration of the Preparation
and testing activities for:       
 Correct system preparation.
 The correct type, quantity and calibration of Test instruments.
 Ensure system pressurization in incremental steps to allow stress and strain to equalize.
 Correct Test pressure throughout the duration of the test.
 Inspect system for leakage.
 System draining, cleaning and disposition of Test fluids.

When inspection reveals unacceptable items, these will be entered into the Inspection Log for
tracking if these can be brought back into compliance with the applicable contract documents,
specifications or codes. When corrective action will not bring these items back into compliance,
non-conformance Report shall be generated.

5.11 TEST PRESSURE:

The Test Pressures for Hydrostatic Testing shall be as depicted in The AFC (Isometric drawings)
for the project.

5.12 TEST DURATION:

Test duration shall be the time sufficient to determine leaks as soon as the test pressure is
achieved and stabilizes.

5.13 SAFETY:
Considering the inherent dangers involved with Hydrostatic Pneumatic Testing, Safety shall be
the major concern. The following steps shall be minimum precautions before and when any
system is under Pressure:
 Job safety Analysis.
 Warning sign shall be posted at suitable Location shall be barricaded to prevent access by all
non-essential personnel.
 No attempt to repair leaks shall be made while the system is under Pressure.
 High Pressure Test hoses shall be inspected by Test Personnel before use and shall be
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QMS-QP-22: Hydro-test Procedure
 installed and routed to avoid possible tripping hazards.

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