Hydro-Testing of

Pressure Equipment

Presented By: Sheikh M Naeem

Action Item: 404881
Incident Report #: 2004-IR-931941
Hydro-Testing
Hydro-Testing is applied to certain equipment
to ensure whether the equipment is suitable
for purposed service or not.
Following type of equipment require hydro-
testing.
1. Pipelines
2. Piping Spools
3. Pressure Vessels
4. Storage Tanks
5. Pulsation Dampeners etc.
Pre-requisites

Prior to Hydro-testing ensure that a detailed

“TEST PACK” is made available and approved
by BPP represented.

Test Pack includes:

1. Task Risk Assessment for the testing.
2. Specific Test Procedure.
3. Duly verified as-built drawings.
4. Non-Destructive Testing reports.
Precautions

• Warning signs should be posted on equipment

being tested and at the perimeter of the test
area.
• Remove all the mechanical equipment and
instrument which do not require testing.
• Prior to pressuring, equipment to be tested
must be thoroughly examined e.g. isolation,
drains closed, vents open / shut as required.
Precautions (conti.)

• Calibrated pressure gauge and safety valve of

adequate size, properly set, seated and
marked with set pressure shall be installed in
the test supply line to avoid over pressure.
• Ensure that the test manifold and fittings
used are of appropriate specification.
• Provide adequate period of time before close
examination of under pressure equipment.
Hydro-Testing Components

1. Filling:
 Only water from an approved source shall be
used for testing purpose.
 Water should be chemically treated against
bacteria and corrosion and should be tested
and approved by laboratory.
 Pipelines should be filled using Two Pigs
being propelled by filling pumps and test
water.
Hydro-Testing Components

2. Pressurizing:
 Pressurization should not begin until the
equipment is full.
 Pressure shall be gradually increased in steps
of 500 psig with ½ hour interval, until the
required test pressure is reached.
 Pressure vessels and piping spools should be
normally tested for two hours.
 Buried lines should be normally tested for 24
hours.
Hydro-Testing Components

3. Depressurizing:
 On completion of test, the pressure shall be
reduced gradually and under controlled
conditions.
 When draining equipment / lines, adequate
vents at the highest point must be opened to
avoid the possibility of drawing a vacuum.
 Drain the test fluid from more than one point.
Hydro-Testing Components
4. Drying:
 All system should be thoroughly drained and
blown with air or nitrogen to minimize
residual moisture after completion of testing.
 Residual water after draining may
contaminate the product, or cause problems if
equipment is on high or low temperature
service.
 Where the need to vent inert gas arises,
consideration must be given to personnel
safety.
Hydro-Testing Components
5. Water Disposal:
 The test fluid must be disposed off in an
approved manner in accordance with all
relevant safety precautions.
 Disposal of test fluid should not contaminate
wells used for domestic water supplies.
 Overland disposal of water should not
contaminate existing surface water, cause
erosion or impart hazard.
 All proposed de-watering sites and procedures
should be approved by BPP Representative.