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Hydrostatic Test Procedure
Date: 15/01/2014
QUALITY CONTROL
PROCEDURE
Industrial projects company (INPEC)
HYDROSTATIC TEST PROCEDURE
Copy No.
Controlled
Uncontrolled
0.0 First issue 01/09/2012
Name Sign/date Name Sign/date Name Sign/date
REV. COMMENTS DATE PREPARED BY APPROVED BY ACCEPTED BY
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Hydrostatic Test Procedure
Date: 15/01/2014
Table of Content
1) Scope
2) Reference Code
3) Testing Schedule
4) Pressure Gauges
5) Test Medium
6) Preparation for Pressure Testing
7) Filling with Test Medium and Venting
8) Test Pressure
9) Holding Time, Test Temperature and Close Examination
10) Test Pressure Release
11) Repair Case
12) HSE Precautions
13) Report
14) Attachments
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Hydrostatic Test Procedure
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1 Scope:
1.1 This procedure is applicable to Boilers, Boiler External Piping
and pressure Vessels constructed to ASME Code Sec. I, B
31.1, Sec. VIII, Div. 1 respectively. It also applies to Code
items Repairs and Alterations in accordance with the
National Board Inspection Code (NBIC).
This procedure gives instructions to the Company's personnel
and describes the method used to perform the Hydrostatic Test
of Code items manufactured or erected by INPEC.
1.2 The local standards, legal regulations and other suitable
precautions regarding health work and fire protection shall be
observed, also if they are not mentioned herein.
2 Reference Code:
- ASME Code Sec. I the applicable Edition and Addenda,
- ASME Code Sec VIII Div. 1 the applicable Edition and Addenda,
- ASME Code Sec B 31.1 the applicable Edition and Addenda,
- National Board Inspection Code "NBIC" for repairs or alterations of
pressure retaining items.
- Company's QC Manual.
2.1 In case of any conflicts between Client specification and Code
requirements, the Code requirements shall govern.
3 Testing Schedule:
3.1 Hydrostatic Test shall be performed after all manufacturing
and inspection activities for the system or portions that will
be subjected to this test.
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Hydrostatic Test Procedure
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3.2 Welds or other type joints shall not be painted, insulated or
coated prior to completion of testing.
3.3 Hydrostatic Test shall be performed in the presence of the
ASME Authorized Inspector and if required the Client
inspector.
3.4 INPEC shall officially inform the ASME Authorized Inspector
and if required the Client inspector by the date and the time
of the test execution at least by 24 hours in advance.
4 Pressure Gauges:
4.1 At least one calibrated pressure gauges shall be directly
connected to the system being tested at the highest point,
and shall be visible to the operator controlling.
4.2 The pressure gauges shall have a range of about double the
test pressure, but shall not be less than 1 ½ nor more than 4
times the test pressure.
4.3 An additional calibrated pressure gauge may be fitted at a
suitable location visible to the operator controlling the
pressure at all time. If this gauge is not fitted at the highest
point, then the test pressure shall be accordingly corrected
for the static head difference.
4.4 Calibration of pressure gauges shall be at intervals not
exceeding one year.
5 Test Medium:
5.1 The test medium used for Hydrostatic Testing shall be
- Potable water for carbon and low alloy steel.
- Demineralized water for high alloy steel, such as austenitic
stainless steels.
6 Preparation for Pressure Testing:
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6.1 The personnel protection and the addition of temporary
supports shall be considered prior to pressure testing, to
avoid distortions.
6.2 No temporary welds shall be applied to the Code item to be
tested.
6.3 All connections shall be blanked off by means of adequate
plugs or blind flanges of the rating specified in the drawing
and bolting of the same size and resistance as those specified
in the drawing.
7 Filling with Test Medium and Venting:
7.1 Test medium shall be supplied to the Code item being tested
through a connection at the lowest point. The filling
connection shall be filled with a suitable valve.
7.2 Nozzles or other openings at the top of item being tested shall
be left open during filling to allow for proper and complete
venting of air.
7.3 When the item being tested is completely filled with the test
medium, all openings shall be closed, not fully secured
tightened while pumping is in progress to ensure complete
venting, and then secularly tightened.
7.4 The pressure is then raised gradually until the specified test
pressure is reached. Then all valves are securely tightened.
8 Test Pressure:
8.1 The test pressure shall be at least the test pressure required
by the applicable code and project specification.
8.2 For items constructed according to ASME Code Sec I,
- Hydrostatic pressure tests shall be applied by raising the
pressure gradually to not less than 1.5 times the maximum
allowable working pressure to be marked on the boiler and as
shown on the data report. No part of the boiler shall be
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Hydrostatic Test Procedure
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subjected to a general membrane stress greater than 90% of its
yield strength (0.2% offset) at test temperature.
8.3 For items constructed according to ASME Code Sec. VIII Div
1,
- Vessels designed for internal pressure shall be subjected to a
hydrostatic test pressure which at every point in the vessel is at
least equal to 1.3 times the maximum allowable working
pressure to be marked on the vessel multiplied by the lowest
stress ratio LSR (for the materials of which the vessel is
constructed) of the stress value S for the test temperature on
the vessel to the stress value S for the design temperature.
8.4 For items constructed according to ASME Code Sec. B31.1,
- The hydrostatic test pressure at any point in a metallic piping
system shall be not less than 1.5 times the design pressure.
-For design temperature above the test temperature, the
minimum test pressure shall be calculated by the following eq.,
except that the value of ST/S shall not exceed 6.5:
PT = (1.5 PST)/S
Where
P = internal design gage pressure
PT = minimum test gage pressure
S = stress value at design temperature
ST = stress value at test temperature
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Hydrostatic Test Procedure
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- The possibility of brittle fracture shall be considered when
conducting leak tests at metal temperatures near the ductile-
brittle transition temperature.
8.5 For items repaired or alternated according to NBIC, the test
pressure shall be the minimum required to verify the leak
tightness integrity of the repair, but not more than 150% of
the MAWP stamped on the pressure-retaining items, as
adjusted for temperature. When original test pressure
included consideration of corrosion allowance, the test
pressure may be further adjusted based on the remaining
corrosion allowance.
- During a pressure test where the test pressure will exceed 90%
of the set pressure of pressure relief device, the device shall be
removed whenever possible. If not possible, a spindle restraint
may be used following the valve manufacturer's instructions
and recommendations.
9 Holding Time, Test Temperature and Close Examination:
9.1 The test pressure shall be maintained for at least 10 minutes,
and then reduced gradually to the close examination
pressure as stated in Table No.1.
9.2 Close visual examination of all joints and connections shall
then be carried out for any signs of leakage and/or
deformation.
9.3 The metal temperature during the close examination shall not
exceed that stated in Table No. 2.
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Maximum metal Minimum test metal Applicable Code
temperature during temperature Section
close examination
ASME Code Sec.I &
120°F (49°C) F (21°C)° 70
ASME B.31.1
F (17°C) above° 30 ASME Code Sec.
120°F (49°C)
MDMT VIII, Div. 1
For Boilers & BEP as for
Sec. I, above.
For pressure vessels
National Board
120°F (49°C) 60°F (16 °C). Unless
Inspection Code
notch toughness
properties permit lower
temperatures
Table (1): Maximum and minimum metal temperatures during
Hydrostatic Test.
Close examination pressure Applicable Code Section
Pressure equal to MAWP ASME Code Sec. I & ASME B.31.1
Test pressure divided by 1.3 ASME Code Sec. VIII, Div. 1
National Board Inspection Code
Pressure equal to MAWP
(NBIC)
Table (2): Pressure during close examination.
10 . Test Pressure Release:
10.1 Before Conducting the test QC shall authenticate the release
for items to be tested, where the QC release for test ensure
that all the per-fabrication and fabrication processes have
been performed according to the drawings and project
specifications.
10.2 As the test is completed, the pressure shall be released by
opening the valve at the highest connection and allowing the
pressure to drop gradually to atmospheric pressure.
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Hydrostatic Test Procedure
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10.3 The item being tested shall then be drained through a
connection at the bottom, while leaving sufficient opening at
top open.
11 Repair Case:
11.1 In case of items failed to pass the test, a repair process shall
be applied to these items according to ASME Code and
project specifications where the repaired items shall be
retested again according to the above mentioned steps.
12 . HSE Precautions:
12.1 HSE Head shall control all the safety related attributes to the
execution of the hydro test, where the equipments
connections shall be checked prior conduction of the test, all
the PPE of those who are involved in the test shall be worn,
and the testing area shall be barricaded.
12.2 HSE Department will conduct a safety toolbox for INPEC
staff whom are involved in the test for awareness about the
safety precautions have to be taken during the test.
13 . Report:
13.1 For hydro test, INPEC shall prepare all the tested items
related documentation (Test package) before released to
test, and the result of test shall be recorded on the attached
Hydrostatic Test Form (Exhibit No.28- Hyd. Test Report).
14 Attachments:
- Hydrostatic Test Form (Exhibit No.28- Hyd. Test Report).
