Proc. No.

NTPL/HTP/01
NOVASIX TECHNOLOGIES PVT. LTD. Rev. No. 00
Date 25-11-2023
Page 01 of 06

HYDROSTATIC TEST PROCEDURE

TABLE OF CONTENTS
Section No. Title

1.0 Scope

2.0 Reference documents

3.0 Responsibility

4.0 Procedure

5.0 Visual Inspection

6.0 Acceptance Criteria

7.0 Post Hydrostatic Test Activity

8.0 Report

0 25-11-2023 Initial issue for approval Aniket Godase Vijaykumar Padale

Manager ( QA & QC )
Rev. Date Remarks For Novasix For Novasix
No. Prepared By Approved By
 Proc. No. NTPL/HTP/01
NOVASIX TECHNOLOGIES PVT. LTD. Rev. No. 00
Date 25-11-2023
Page 01 of 06

HYDROSTATIC TEST PROCEDURE

1. SCOPE
This procedure is applicable for hydrostatic testing of pressure vessels, Condensers, Reactors
& Piping constructed as per ASME SEC VIII DIV-1, after completion of all heat treatment &
NDE as applicable but prior to painting.

2. REFERANCE DOCUMENTS
Applicable Drawings & QAP / ITP
ASME Section VIII Div. 1, UG-99, UG-102

3. RESPONSIBILITY
Responsibilities related to hydrostatic testing in accordance to below procedure.
3.1 QAC & Welding Manager
 Responsible for preparation & updating Hydrostatic Test Procedure.
 To issue clearance for pressure test after verify for completion & acceptance of all
examinations, heat treatment & NDE as applicable prior to pressure test on QAP.
3.2 QAC & Welding Engineer
 Ensure that all fabrication has been completed, except for operations which could not be
performed prior to the test such as weld end preparation, cosmetic grinding on the base
metal which does not affect the required thickness and also ensure all examinations have
been performed, except those requires after test.
 Monitoring Hydrostatic test.
 Inspection during & after attainment of test pressure.
 Recording of results and preparation of hydrostatic test report.

3.3 Production Manager

 Preparation & Performance of hydrostatic test.

 Cleaning of vessel, before and after hydrostatic test.
 Drying of internal surfaces of vessel after hydrostatic test.
 Ensuring safety requirements are meet.
 Proc. No. NTPL/HTP/01
NOVASIX TECHNOLOGIES PVT. LTD. Rev. No. 00
Date 25-11-2023
Page 01 of 06

HYDROSTATIC TEST PROCEDURE

4. RESPONSIBILITY
4.1 RELEASED FOR PRESSURE TEST
A Hydrostatic test shall be conducted on all vessels after:
a) All fabrication has been completed, except for operations that could not be performed prior to the
test such as weld end preparation, cosmetic grinding on the base metal that does not reduce the
actual thickness below the design thickness.

b) All examinations have been performed, except those required after test as per QAP/Drawing and
all NCR’s are CLOSED OUT.

c) The QAC & Welding manager after verifying above shall release equipment for hydrostatic
pressure test.

4.2 PREPARATION
Prior to hydrostatic test QAC & Welding Engineer shall ensure the following:
a) The vessel inside is thoroughly cleaned.

b) Painting & Coating

1. Unless permitted by the user or his designated agent, pressure-retaining welds of vessel shall
not be painted or otherwise coated either internally or externally prior to the test.

2. When painting or coating prior to the hydrostatic test is permitted, or when internal non
metallic lining are to be applied, the pressure retaining welds shall first be leak tested in
accordance ASME Section V, Article 10. Such a test may be waived with the approval of the
user or his designated agent.

3. Vessel for lethal service [see UW-2(a)]

i) Shall not be painted or coated either internally or externally prior to the hydrostatic
pressure test.
ii) Shall not be internally lined by mechanical or welded attachments prior to the
hydrostatic pressure test unless the requirements of UCL-51 are followed.

4. The requirement given in (1) & (2) above do not apply to glass-lined vessels.
 Proc. No. NTPL/HTP/01
NOVASIX TECHNOLOGIES PVT. LTD. Rev. No. 00
Date 25-11-2023
Page 01 of 06

HYDROSTATIC TEST PROCEDURE

c) External or Internal surfaces, including weld faces, shall be cleaned of any painting, coating, oil,
Grease, or other contaminations that might mask leak.

d) All the surrounding and the equipment are to be kept clean and dry so that if any leak is here, it
can be easily detected.

e) Hose pipes, fittings, isolation valves and other accessories used shall be capable of withstanding
the test pressure.

f) The blind flanges (not parts of the vessel) shall be verified by the design Engineer for correct
thickness.

g) If required, temporary supports may be provided to support vessel during hydrostatic testing.
Such temporary support(s) shall not be welded directly to the body of the vessel being hydro
tested.

h) Openings shall be suitably blinded except for test medium inlet & vent opening.

i) The vessel shall be positioned to enable complete venting of air from high point and draining
from low point.

j) All bolted connections shall be checked for tightness.

k) The shell circumference shall be measured 2-3 locations and marked on the shell and recorded.

4.3 PRESSURE GAUGES

a) Pressure gauges shall be calibrated and within due date of calibration.

b) Minimum 4” dial indicating pressure gauges shall be used in testing for code items. It
shall be graduated over a range of about the intended maximum test pressure, but in no
case shall be the range be less than 1½ nor more than 4 times the test pressure.

c) The spacing between graduations shall be such that the inspector and the operator
controlling the test shall be able to determine when the required test pressure has been
achieved.

d) Pressure gauges shall be connected directly to the vessel or with a pressure line that does
not include intermediate valves.
 Proc. No. NTPL/HTP/01
NOVASIX TECHNOLOGIES PVT. LTD. Rev. No. 00
Date 25-11-2023
Page 01 of 06

HYDROSTATIC TEST PROCEDURE

e) Fix at least two pressure gauges, one at the highest point and other in such a way that
gauge readings visible to the operator controlling pressure. The applied test pressure shall
be measured at the highest point of equipment.

f) Pressure gauges shall be calibrated immediately after completion of test to validate

pressure gauge reading.

4.4 TEST MEDIA

Plant water or clean water which shall be having chloride contents less than 50 ppm shall be
used for carbon steel vessel & 30 ppm shall be used for Stainless Steel vessel as test media.

4.5 TEST TEMPERATURE

The metal temperature during hydrostatic test shall be maintained at least 17°C above the
MDMT, but not to exceed 48°C. The test pressure shall be applied using water at not less
than ambient temperature.

4.6 TEST PRESSURE

Test pressure as specified on the drawing.

4.7 TEST POSITION

The test position shall be as indicating in the drawing (either horizontal or vertical).

4.8 PRESSURIZATION

Equipment shall be pressurized gradually to the required hydrostatic test pressure and hold it
for at least 30 minutes or more as mentioned in the drawing or QAP/ Drawing.

4.9 VENT

Vents shall be provided at all high points of the vessel in the test position such that to purge
possible air pockets while the vessel is filled.
 Proc. No. NTPL/HTP/01
NOVASIX TECHNOLOGIES PVT. LTD. Rev. No. 00
Date 25-11-2023
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HYDROSTATIC TEST PROCEDURE

5. VISUAL INSPECTION

The following inspection shall be carried out by Production & Welding Engineer in presence
of QAC Engineer.

a) Inspection shall be performed at a pressure not less than the test pressure divided by 1.3.
b) Visual inspection shall be made of all joints & connections.
c) The shell circumference shall be measured at same locations during, after test pressure has
reached and after release of pressure for verifying deformation.
d) After release of pressure, the pressure gauge shall be checked to ensure it reads 0.

6. ACCEPTANCE CRITERIA

The vessel shall be accepted provided there is no leakage, no pressure drop and no permanent
deformation during visual inspection of the vessel during hydrostatic test.

7. POST HYDROSTATIC TEST ACTIVITY

The test pressure shall be reduced to zero, vents opened and water drained from vessel. The
vessel shall be dried from the inside by blowing air. The inside of vessel shall be checked for dryness
and cleanliness.

8. REPORT

After completion of hydrostatic test, the results shall be documented in the pressure Test
Report as per Report Format- NTPL/HTR/01 REV-00
 Proc. No. NTPL/HTP/01
NOVASIX TECHNOLOGIES PVT. LTD. Rev. No. 00
Date 25-11-2023
Page 01 of 06

HYDROSTATIC TEST PROCEDURE

HYDRO TEST REPORT

Document Title: Report No: NTPL/HTR/01 REV-00
HYDRO TEST Report Date:
Manufacturer: Novasix Technologies Pvt. Ltd. P.O No.:
Equipment: Job No.:
Drawing No./Rev: QAP No.:
Equipment Tag No: Inspected By:

SR NO DESCRIPTION SPECIFICATION
1 TYPE OF TEST
2 EQUIPMENT
3 MATERAIL OF CONSTRUCTION
4 MEDIA
7 WORKING VOLUME
8 WORKING PRESSURE
9 DESIGN PRESSURE
10 HYDRO TEST PRESSURE
11 TEST DATE
12 TEST START TIME
13 TEST END TIME
14 TEST DURATION
15 PRESSURE GAUGE RANGE & SERIAL NO.
16 CALIBRATION DUE DATE

Remark-

CHECKED BY: WITNESSED BY: REVIEWED BY:

NAME: - NAME: - Mr. NAME: -

SIGN: - SIGN: - SIGN: -

NOVASIX TECHNOLOGIES TPI CLIENT

PVT. LTD.