Project:

Dabur Honey at
Baddi


DESIGN & TENDER DOCUMENT FOR
Document No. NPI/101138/
Project No.: 101138

Prepared By: VD Checked By:

File Name:

2.6_Hydro.docx

Approved By:






















HYDRO TESTING


DESIGN & TENDER DOCUMENT FOR
Mechanical & Piping SYSTEM
Document No. NPI/101138/PIP /S1/TD/01

Chapter No.:


Version No.:
MODE OF MEASUREMENT
Date:
Checked By: RK / ARZ NNE Pharmaplan
Approved By:

DIL
CHAPTER 2.6

HYDRO TESTING










Chapter No.: 2.6
Version No.:


00
2011.01.06

Page 1 of 6

Project:

Dabur Honey at
Baddi


DESIGN & TENDER DOCUMENT FOR
Document No. NPI/101138/
Project No.: 101138

Prepared By: VD Checked By:

File Name:

2.6_Hydro.docx

Approved By:





Contractor shall perform Hydro testing of all Fabricated and Erected Piping / Storage
tanks & vessels.

The pipe lines under each system shall be subjected to hydrostatic testing as per the
pressure indicated below.

S.
No
Description Design pressure
1. Hot water line 4.5 kg/sq.
2.
Compressed air
line
10 kg/sq.
3. LP steam 5 kg/sq.
4. Process 5 kg/sq.
5.
Storage tanks
vessels
2 kg/sq.
6. F.O. 3 kg/sq.
7. HP Steam 12 kg/sq.


If the test pressure as defined above would produce a stress in excess of the yield stress
at test temperature, the test pressure may be reduced accordingly.

However, in all the cases the minimum hydrostatic test pressure shall be 7
for pipes & 2-kg/sq. cm (g) for storage vessels & tanks.

Upon completion of the installation of all pipe work & storage vessels, the pipes &
shall be thoroughly cleaned, all openings shall be closed with appropriate valves or
blanks furnished and installed by the contractor.
The duration of tests shall be 24 hours. Readings of line / equipment pressure and
atmospheric temperatures shall
thereafter at every 4 hours interval. Two calibrated pressure gauges of suitable range
shall be used. Readings shall be recorded by the contractor in the presence of the
representative of client and shall


DESIGN & TENDER DOCUMENT FOR
Mechanical & Piping SYSTEM
Document No. NPI/101138/PIP /S1/TD/01

Chapter No.:


Version No.:
MODE OF MEASUREMENT
Date:
Checked By: RK / ARZ NNE Pharmaplan
Approved By:

DIL
HYDRO TESTING
Contractor shall perform Hydro testing of all Fabricated and Erected Piping / Storage
lines under each system shall be subjected to hydrostatic testing as per the
pressure indicated below.
Design pressure
Working
temperature
Working Pressure
5 kg/sq. cm
As per design
parameters
3-4 kg/sq. cm
kg/sq. cm
As per design
parameters
68 kg/sq.cm
kg/sq. cm
As per design
parameters
3.0-3.5 kg/sq.cm
5 kg/sq. cm
As per design
parameters
2-3 kg/sq. cm
2 kg/sq. cm
As per design
parameters
Atmospheric
3 kg/sq. cm
As per design
parameters
2-3 kg/sq. cm
12 kg/sq. cm
As per design
parameters
10.54 kg/sq. cm
If the test pressure as defined above would produce a stress in excess of the yield stress
at test temperature, the test pressure may be reduced accordingly.
However, in all the cases the minimum hydrostatic test pressure shall be 7
kg/sq. cm (g) for storage vessels & tanks.
Upon completion of the installation of all pipe work & storage vessels, the pipes &
shall be thoroughly cleaned, all openings shall be closed with appropriate valves or
blanks furnished and installed by the contractor.
The duration of tests shall be 24 hours. Readings of line / equipment pressure and
atmospheric temperatures shall be taken on pressurizing the line / equipment and
thereafter at every 4 hours interval. Two calibrated pressure gauges of suitable range
shall be used. Readings shall be recorded by the contractor in the presence of the
representative of client and shall be signed by both.
Chapter No.: 2.6
Version No.:


00
2011.01.06

Page 2 of 6
Contractor shall perform Hydro testing of all Fabricated and Erected Piping / Storage
lines under each system shall be subjected to hydrostatic testing as per the
Working Pressure
Hydro test
Pressure
7 kg/ sq. cm
15 kg/sq. cm
cm
7.5 kg/sq. cm

6 kg/sq. cm

3 kg/sq. cm
5 kg/sq. cm

18 kg/sq. cm

If the test pressure as defined above would produce a stress in excess of the yield stress
However, in all the cases the minimum hydrostatic test pressure shall be 7-kg/sq. cm (g)
Upon completion of the installation of all pipe work & storage vessels, the pipes & tanks
shall be thoroughly cleaned, all openings shall be closed with appropriate valves or
The duration of tests shall be 24 hours. Readings of line / equipment pressure and
be taken on pressurizing the line / equipment and
thereafter at every 4 hours interval. Two calibrated pressure gauges of suitable range
shall be used. Readings shall be recorded by the contractor in the presence of the

Project:

Dabur Honey at
Baddi


DESIGN & TENDER DOCUMENT FOR
Document No. NPI/101138/
Project No.: 101138

Prepared By: VD Checked By:

File Name:

2.6_Hydro.docx

Approved By:



The test shall be considered successful, if after 24 hours, the pressure drop does not
exceed 2% of the test pressure. If the pressure drop exceeds this value, the joints shall
be subject to soap bubble test and leaks shall be detected
Gas and Vacuum lines). The line shall be de
rectified and the test shall be repeated, till the time the successful results are achieved.

During the pressure test, hammer test shall al
discretion of the representative of client.

Wherever applicable, leak test would be performed using compressed air. The
contractor shall make his own arrangements (like air compressor, testing instruments,
etc.) for conducting the leak test with compressed air.
For weldments, any section showing leakage in more than 2.5% of the total length of the
weld seam shall be rejected. Defects less than the above limits may be allowed to be
repaired by chipping and re
removed totally, cleaned, ground & re
After testing, the pipelines / equipment shall be drained and flushed several times to
ensure complete cleanliness inside the pipe.

After satisfactory completion of
For hydrostatic testing and water flushing, contractor shall furnish necessary equipments
and instruments, pipe work etc. Client will have to provide water available at one point.
Recording of hydrotest shall be carried out in the approved format enclosed herewith.

DESIGN & TENDER DOCUMENT FOR
Mechanical & Piping SYSTEM
Document No. NPI/101138/PIP /S1/TD/01

Chapter No.:


Version No.:
MODE OF MEASUREMENT
Date:
Checked By: RK / ARZ NNE Pharmaplan
Approved By:

DIL
The test shall be considered successful, if after 24 hours, the pressure drop does not
exceed 2% of the test pressure. If the pressure drop exceeds this value, the joints shall
be subject to soap bubble test and leaks shall be detected (in case of Compressed Air,
Gas and Vacuum lines). The line shall be de-pressurized and emptied, the leaks shall be
rectified and the test shall be repeated, till the time the successful results are achieved.
During the pressure test, hammer test shall also be done near the line joints at the
discretion of the representative of client.
Wherever applicable, leak test would be performed using compressed air. The
contractor shall make his own arrangements (like air compressor, testing instruments,
conducting the leak test with compressed air.
For weldments, any section showing leakage in more than 2.5% of the total length of the
weld seam shall be rejected. Defects less than the above limits may be allowed to be
repaired by chipping and re-welding and then retesting. Rejected welds shall be
removed totally, cleaned, ground & re-welded.
After testing, the pipelines / equipment shall be drained and flushed several times to
ensure complete cleanliness inside the pipe.
After satisfactory completion of the hydrostatic test, blank ends shall be removed.
For hydrostatic testing and water flushing, contractor shall furnish necessary equipments
and instruments, pipe work etc. Client will have to provide water available at one point.
hall be carried out in the approved format enclosed herewith.








Chapter No.: 2.6
Version No.:


00
2011.01.06

Page 3 of 6
The test shall be considered successful, if after 24 hours, the pressure drop does not
exceed 2% of the test pressure. If the pressure drop exceeds this value, the joints shall
(in case of Compressed Air,
pressurized and emptied, the leaks shall be
rectified and the test shall be repeated, till the time the successful results are achieved.
so be done near the line joints at the
Wherever applicable, leak test would be performed using compressed air. The
contractor shall make his own arrangements (like air compressor, testing instruments,
For weldments, any section showing leakage in more than 2.5% of the total length of the
weld seam shall be rejected. Defects less than the above limits may be allowed to be
and then retesting. Rejected welds shall be
After testing, the pipelines / equipment shall be drained and flushed several times to
the hydrostatic test, blank ends shall be removed.
For hydrostatic testing and water flushing, contractor shall furnish necessary equipments
and instruments, pipe work etc. Client will have to provide water available at one point.
hall be carried out in the approved format enclosed herewith.

Project:

Dabur Honey at
Baddi


DESIGN & TENDER DOCUMENT FOR
Document No. NPI/101138/
Project No.: 101138

Prepared By: VD Checked By:

File Name:

2.6_Hydro.docx

Approved By:



PROCEDURE FOR HYDRO TESTING
1. Pre Requisite

Bucket water pump (Manually Operated)
Ensure that all Pipe / Equipment (Storage vessels & tanks) Joint Flanges are
provided with Proper Gaskets

2. Procedure:
2.1 Visually inspect the pipes, tanks and vessels.
2.2 Flush all pipes (from inside) of debris, dust, welding flux etc. by filling the water in the
Pipe length / earth to be subjected to Hydrostatic Pressur
2.3 Provide Dead ends at both ends of the Pipe length being subjected to Hydrostatic
Pressure testing. Ensure one of the dead ends has the provision for connecting the
Bucket water pump with an isolating valve.
2.4 Fill the Pipe length with water.
with a Calibrated Dial Pressure Gauge.
2.5 Manually operate the Water pump until the Specified Water pressure is indicated on the
Dial Pressure Gauge.
2.6 Shut off the isolating valve and disconnect the Bucket
2.7 Visually inspect the Pipe for any water leakages especially through Welding joints,
Flanges, fittings, valves etc.
2.8 Hold the Water Pressure in Pipeline/equipment for 24 Hours.
2.9 Record the Observations after every 4 Hours.

3. Observations:
Record the observations in the Table given below.
Hydraulic Test details
Date Maximum Operating
Pressure (Unit)







DESIGN & TENDER DOCUMENT FOR
Mechanical & Piping SYSTEM
Document No. NPI/101138/PIP /S1/TD/01

Chapter No.:


Version No.:
MODE OF MEASUREMENT
Date:
Checked By: RK / ARZ NNE Pharmaplan
Approved By:

DIL
PROCEDURE FOR HYDRO TESTING
Bucket water pump (Manually Operated)
Ensure that all Pipe / Equipment (Storage vessels & tanks) Joint Flanges are
provided with Proper Gaskets and Nut-bolts with plain and spring washers.
Visually inspect the pipes, tanks and vessels.
Flush all pipes (from inside) of debris, dust, welding flux etc. by filling the water in the
Pipe length / earth to be subjected to Hydrostatic Pressure and draining.
Provide Dead ends at both ends of the Pipe length being subjected to Hydrostatic
Pressure testing. Ensure one of the dead ends has the provision for connecting the
Bucket water pump with an isolating valve.
Fill the Pipe length with water. Connect Bucket water pump at one of the Dead ends
with a Calibrated Dial Pressure Gauge.
Manually operate the Water pump until the Specified Water pressure is indicated on the
Shut off the isolating valve and disconnect the Bucket Water pump from the Pipeline.
Visually inspect the Pipe for any water leakages especially through Welding joints,
Flanges, fittings, valves etc.
Hold the Water Pressure in Pipeline/equipment for 24 Hours.
Record the Observations after every 4 Hours.
Record the observations in the Table given below.
Maximum Operating
Pressure (Unit)
Hydraulic Test
Pressure (Unit)
Pressure Hold Time
(Min.)

Chapter No.: 2.6
Version No.:


00
2011.01.06

Page 4 of 6
Ensure that all Pipe / Equipment (Storage vessels & tanks) Joint Flanges are
bolts with plain and spring washers.
Flush all pipes (from inside) of debris, dust, welding flux etc. by filling the water in the
e and draining.
Provide Dead ends at both ends of the Pipe length being subjected to Hydrostatic
Pressure testing. Ensure one of the dead ends has the provision for connecting the
Connect Bucket water pump at one of the Dead ends
Manually operate the Water pump until the Specified Water pressure is indicated on the
Water pump from the Pipeline.
Visually inspect the Pipe for any water leakages especially through Welding joints,
Pressure Hold Time
(Min.)


Project:

Dabur Honey at
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DESIGN & TENDER DOCUMENT FOR
Document No. NPI/101138/
Project No.: 101138

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File Name:

2.6_Hydro.docx

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Pipe details Test Time
Location /
Identification
No.
Drawing
No.
Start










Observations
Water Pressure in Pressure
Gauge drops at a very fast
rate.
Water Pressure drop in
Pressure gauge is at a slow
pace but is continuous.
Water Pressure drop is to
the tune of only 0.1 to 0.2
kg/sq. cm.

DESIGN & TENDER DOCUMENT FOR
Mechanical & Piping SYSTEM
Document No. NPI/101138/PIP /S1/TD/01

Chapter No.:


Version No.:
MODE OF MEASUREMENT
Date:
Checked By: RK / ARZ NNE Pharmaplan
Approved By:

DIL
Hydraulic Test Observations
Test Time
(Hrs.)
Line Pressure (Unit) Pressure Drop (Unit)
Start End Start End Acceptable








Trouble Shooting
Suggested Corrective Action
1. Check all flanges, fittings and valves for water leakage.
Rectify each leakage point one by one.
2. Check tightness of nut bolts of all flanges, valves and
fittings etc.
1. Check nut bolts of all flanges, valves and fittings etc.
Tighten the nut bolts found loose.

2. This may be due to the ambient temperature
Pressure shall be checked after 24 Hours at the same
time. Pressure reading in Pressure gauge shall be
same at same time on consecutive days if there is no
drastic change in ambient conditions.
Chapter No.: 2.6
Version No.:


00
2011.01.06

Page 5 of 6
Pressure Drop (Unit)
Acceptable Actual









Check all flanges, fittings and valves for water leakage.

Check tightness of nut bolts of all flanges, valves and
Check nut bolts of all flanges, valves and fittings etc.
This may be due to the ambient temperature variation.
Pressure shall be checked after 24 Hours at the same
time. Pressure reading in Pressure gauge shall be
same at same time on consecutive days if there is no

Project:

Dabur Honey at
Baddi


DESIGN & TENDER DOCUMENT FOR
Document No. NPI/101138/
Project No.: 101138

Prepared By: VD Checked By:

File Name:

2.6_Hydro.docx

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4. Conclusion:





5. Approval:

Name/
Designation/Organisation
Signature
Date

Pipe shall be identified in terms of Fluid flow and whether Supply pipe or Return
pipe e.g. Cooling Water Supply pipe.
Identify the pipe length (which is subjected
and a copy of relevant portion of drawing shall be enclosed.

6. Precautions:
1. At a stretch not more than 50 RM (Running meter) of Pipe shall be subjected to Hydraulic
Pressure testing.
2. The Hydraulic pressure testing

DESIGN & TENDER DOCUMENT FOR
Mechanical & Piping SYSTEM
Document No. NPI/101138/PIP /S1/TD/01

Chapter No.:


Version No.:
MODE OF MEASUREMENT
Date:
Checked By: RK / ARZ NNE Pharmaplan
Approved By:

DIL
Conducted by Checked by Approved by





Pipe shall be identified in terms of Fluid flow and whether Supply pipe or Return
pipe e.g. Cooling Water Supply pipe.
Identify the pipe length (which is subjected to Hydraulic pressure) on the drawing
and a copy of relevant portion of drawing shall be enclosed.
At a stretch not more than 50 RM (Running meter) of Pipe shall be subjected to Hydraulic
The Hydraulic pressure testing shall be carried out for at least 24 Hours continuously.
Chapter No.: 2.6
Version No.:


00
2011.01.06

Page 6 of 6
Approved by
Pipe shall be identified in terms of Fluid flow and whether Supply pipe or Return
to Hydraulic pressure) on the drawing
At a stretch not more than 50 RM (Running meter) of Pipe shall be subjected to Hydraulic
shall be carried out for at least 24 Hours continuously.