Hydrotes

Hydrotest a kind of pressure test in which the component being tested is filled
completely with water or another liquid. Pressure, if required, is then applied to
the liquid for the required time and the outside of the component is examined
visually for leaks.

Let us see, how the test from planning through execution is done.

 Preparation of System Test Package

 List of Instruments and status
 Pre-test Inspection
 Pressurizing / Pressure test
 De-pressurizing and Cleaning

Preparation of System Test Package

In order to reduce the number of tests, system test packages are defined for
each test system; they are shown on a pressure test diagram (Figure 1)
based on the piping and instrument diagrams (P&ID) or Isometric drawings
showing the extent of work to be included in each test. The
scope of each
separate test shall be the maximum practicable, considering adequate p
ressure relief protection, compatibility with the supporting steel structures and
availability of test media.

The extent of test systems shall be

such that the static head of the test medium does not create a
pressure greater than the allowable test pressure.

The Figure 1 shows:

 Power Source
 Pressure Pump
 Liquid Test Media Inlet
 Pressure Gauges
 Pressure Relief Valves
 Isolation Valve
 Trapped Air Vent
 Test limits ( highlight line to be tested )
 High Point Vent
 Drain points

The location of temporary supports shall be defined

in field and shown on the piping isometric. The lines and systems that for
process reasons cannot be provided with vents and drains shall be tested at
ground.

Figure 1
A typical Test Package Format includes:

 Pressure test report for Piping/Pipeline/Vessel

 Marked up P&ID (Figure 1)
 Blind check list
 Welding History Report and Welding Joint Marked Isometric Drawing (Weld
Map)
 NDT Report
 PWHT and Hardness test Report
 Pre and Post-Test Punch List (Agency + Client) (Refer Important point SL.
No. 7)
 Copies of reinforcing pad pressure test certificates (If necessary)

List of Instrument & Status

Table 1: STATUS OF INSTRUMENTS DURING PRESSURE TEST (Sample)

*Remove any instrument not listed above or if there is any doubt as to status
prior to pressure testing.

NOTES:

1. Caution: do not force reverse flow.

2. Caution: do not overpressure float or displacer. If in doubt, do not test, block
or drain instead.
3. Install after hydro testing and line flushing.
4. Test gag shall not be used.
5. Blinds not required on PSV outlets discharging into a system being tested at 1
bar g or less.
6. Where test blinds have been installed for pressure testing PSV’s, the Field
Erection Agency shall ensure that blinds are removed upon completion of
tests. PSV’s may be removed prior to pressure testing Where piping lacks
sufficient flexibility to accommodate test blinds.
7. Caution: Check allowable pressure on Gauge Glasses, prior to test.

Pre Test Inspection

Prior to the execution of the pressure test the Mechanical Agency shall
prepare piping for inspection according to the following guidelines:

1. Any test equipment pressurized during the test operations shall be designed for
a working pressure not less than the test pressure. These components shall
have material certificates and the equipment itself shall have data sheets from
the Manufacturer. The test equipment connected to the test section shall have
hydrostatic test certificates and shall have been tested to a pressure at least
1.25 times the test pressure of the test section. The test equipment shall be
internally clean and fit for purpose. (Refer Code)

2. Piping systems shall be completely checked through “Punch List” and the
Punch List Record is approved.(Refer Important point SL. No. 7)

3. All lines shall be checked to ensure the entire system can be drained after the
test.

4. Vents and other high point connections shall be opened to eliminate air from
lines subject to hydrostatic test.
5. In principle all joints not previously tested, including welds, shall be left
unpainted, un-insulated, and exposed for examination during the test.

6. The system shall be provided with suitable relief valves to contain the system
at no more than 10% above the specified test pressure.

7. The test pressure gauge shall be located at the high point of the system. One
additional gauge shall be located at the low point to check that static head
pressure due to vertical legs does not over pressure part of the system.

8. The system shall be properly supported. In particular piping designed for vapour
or gas shall be provided with additional temporary supports, if necessary, to
withstand the weight of the test liquid. Temporary supports shall be identified
with a bright red paint strip and removed after the test.

9. Spring supports shall be locked in position for the test using the pre-set pins or
plates or by blocking the spring.

10. Orifice plates and restriction orifices that interfere with the filling, venting,
or draining of the lines shall be removed; transmitters directly connected to
orifice flanges must be disconnected when replacing the orifice plates to avoid
distorting the connections.

11. The items that shall not be tested in accordance with this specification
shall be isolated or removed and replaced with temporary spools or spacers,
following the requirements in Table 1.

12. Valves shall not be used to isolate a test system.

13. Short pieces of piping which have been removed to permit the preparation
of the system shall be tested separately.

14. In case of any temporary line blanks are needed to isolate the systems
during pressure tests, their thickness shall be as per Code.

15. Any test line blank shall be provided with a lug or handle, extending at
least 100mm and not more than 200mm beyond the flange perimeter, which
shall be painted bright red.

16. Temporary blinds shall be adequately provided with gaskets to prevent

damage to flange facings.

17. Lines containing check valves shall have the source of pressure located
in the piping upstream of the check valve so that the pressure is applied under
the seat. If this is not possible, their internals shall be securely blocked open or
removed.

18. All valves, excluded those herein specified, shall be included in the test;
ball valves shall be in the half open position and all other valves fully open.

19. Should a valve be not included in a system test, its shop test certificate
shall be reviewed and, eventually, a bench hydro-test shall be made.

20. All internal parts or in-line items removed for the duration of the test shall
be labeled with a reference to the component to which they belong or to the
position of the line from which they were removed, to ensure the correct
replacement of components after the test.
Pressurizing / Pressure Test General Procedure:

1. Seal all openings using Plugs or Covers or Blinds that can withstand the test
pressure and can be completely removed after the test.

2. Gauges, one or more test gauges must be connected to the system. If more
than one gauge is used, one may be a recording gauge. At least one gauge
which is used for acceptance of the test shall be calibrated within 30 days prior
to use. One indicating gauge must be easily visible to the operator controlling
the pressure throughout the pressurizing and testing cycle.

3. Before pressurizing is begun, inspect the outside of the test object to verify that
it is dry and all welds and connectors are exposed if a visual inspection is to be
conducted.

4. Gradually increase the pressure in the system to 50 % of test pressure and

make an initial check for leakage. Thereafter slowly increase the pressure to
the final test pressure. The test pressure usually is between 75 % and 150 %
of the operating design pressure.

5. At the completion of test pressure holding time, examine the system for
leakage. Examination for leakage shall be made of all accessible joints and
connections, attachments welds where practical, and weep holes for paddings
and attachments. Also inspect the area around inaccessible leakage sites.

6. The inspector shall circle all accessible leaks found on the equipment using a
non toxic marker. The magnitude of leak shall be described in terms of: damp
or moist area, drops per minute or steady stream.

Types of Pressure test:

 Pressure Drop Method

1. Pressurize the system in accordance with the General procedure.

2. After reaching full pressure check the system to make sure all trapped air has
been removed.
3. Disconnect the pressure pump and allow the pressure in the system to
stabilize for a period of 10 min or 5 % of the test time whichever is longer.
4. After stabilization, record the exact pressure and monitor during the test
period.

 Visual Inspection Method

1. Pressurize the system in accordance with the General procedure.

2. After reaching test pressure, inspect the outside surfaces for leakage.
3. Test pressure should be held for a minimum of 6 min/cm (1.5 min/in.) of wall
thickness. As a minimum the test pressure should be held for 10 min and the
maximum time should be limited to 2h.
4. If the system is not intended to operate under steady pressure, pulse the
pressure in the system one or more times after each complete inspection
cycle by dropping the pressure to 50 % of final test pressure and bringing it
back to test pressure.
5. If the outside of the system is covered by insulation which is not removed,
increase the test time by a factor of 10, to a maximum of 4 h.

Depressurizing and Cleaning Procedure

1. After the satisfactory completion of the tests , air vents need to be opened
during draining to admit air and prevent collapsing of the test system
and shall be depressurized at a rate should not exceed 1 bar (15 psi) per
minute until the pressure has been reduced to 40 % of the test pressure. Then
depressurization should continue at a rate of less than 2 bar (30 psi) per
minute. (Refer Code for directions of depressurization)
2. Check that the rate of drainage from pipelines is compensated by the inflow of
air through the vent, ensuring that no component is subject to vacuum.
3. Replace all the items and the internals removed for the execution of the
pressure test, remove all test blinds, temporary supports etc. Flanged joints
that have been opened shall be provided with new gaskets.
4. If the pressure holding period fails 3 times to meet the acceptance criteria, the
pipeline has to be de-pressurized to 72% of the SMYS, until pressure
stabilization is achieved. The holding period can then be repeated.
5. Painting and insulation shall be completed.
6. Spring hangers shall be unlocked.
7. The system shall be blown out with dry filtered air at about 70°C (Refer Code).
Further drying and cleaning prescriptions for particular systems shall be in
compliance to the relevant Project Specification.
8. The system shall be re-inspected for mechanical completeness and the
system signed-off as completed.

Important points:

1. The Pressure gauge must be able to withstand normal test pressures and be
accurate enough to record small pressure drops, should be calibrated before
each test. The gauge must be accurate to within 1 % of full scale. The gauge
must read at least 1.5 × but not more than 4 × the maximum test pressure to
be used. (refer Hydrotest Code Comparison under the category Hydrotest)
2. The Liquid Test Media is fresh or industrial water (De-mineralized water),
which is as per Client or specification or Code.
3. Hydrostatic test is a pressure test not a NDT method, because it induces
stress on the component being tested, so it should not be repeated frequently
without authorization.
4. The Design Pressure or Maximum Allowable Working Pressure (MAWP) or
Maximum Allowable Operating Pressure (MAOP) is calculated taking
consideration of primary membrane stress, bending stress, Hoop stress,
longitudinal stress etc. (Refer relevant Code)
5. The test pressure shall be measured at the highest point of each section,
making sure that the maximum local pressure does not cause the hoop stress
to exceed 80% – 90% the specified minimum yield stress (SMYS) of the test
material grade.(Refer relevant Code or Hydrotest code comparison)
6. The test must only conducted in Dry Climate with clear sky, do not perform
during rain.
7. During line checking, the incomplete works to be noted in the punch list as per
the categories “A”, “B”, “C”; inspector has to prepare the punch list, each and
every incomplete item to be written in the punch list.

 Punch “A” to be complete before hydro test

 Punch “B” to be complete after HT
 Punch “C” to be complete at the time of Mechanical Completion Check
 Punch “D” (Document) to be complete before turnover.
 Release for Hydro Testing after clearing all “A” punch items.

Code Comparison is made against ASME Boiler and Pressure Vessel

Codes, Pressure piping and API standard practices taking Service, Code
reference, Minimum Hydrostatic test calculation, Maximum permissible test
pressure, Minimum test hold time, pressure gage, test temperature limits into
consideration. Apart from this there are many factors involved in designing the
hydrostatic test. Please click on the link Hydrotest Code Comparison to open
the code comparison chart.