Hydro test

Hydro test 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 pressure r
elief 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.

 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 point

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.

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)

Pre-Hydro test Requirements

Inspect each system, checking and certifying the following items conform to the
Contract Scope.
 3.2.1 Check and certify that all valves that have been installed in the system are in the
correct positions as indicated by the hydrostatic test diagrams (that is, open or
closed position).

 3.2.2 Check and certify that all flange bolts are at least flush with the nut, but not
more than five threads beyond the nut.

 3.2.3 Check and certify that all piping systems are per the latest P&ID's.

 3.2.4 Check and certify that all flanges and gaskets are in the correct location.

 3.2.5 Check and certify that all valves have been lubricated and stroked.

 3.2.6 Check and certify that bypass lines and PZV lines are adequately and securely
braced.

 3.2.7 Check and certify that all flange jacking bolts have been installed and greased.

 3.2.8 Check and certify that piping is not under stress from installation (remove
bolting and allow pipe to "spring" if required).

 3.2.9 If dummy leg piping supports are used, check and certify that the open end is
capped and a 1/4-inch drain hole is at the low point.

 3.2.10 Check and certify that all reducers are in the correct position and that
eccentric reducers are per the Isometric Drawing.

 3.2.11 Check and certify that all spectacle blinds are in the correct position and
orientation and the now engaged and painted and ring groove greased.

 3.2.12 Check and certify that lines to be sloped are correctly installed.

 3.2.13 Check and certify that all valve tags (P&ID designation) have been securely
attached and all are “readable’ (not covered with paint, scratched, and so forth). Tag
shall be minimum 15 mm x 30 mm, 16 gauge indent stamped (10 mm) stainless steel
attached with 1 mm stainless wire.

 3.2.14 Check and certify that the correct valve numbers (P&ID) have been clearly
stenciled on all valves 6” and above.
 3.2.15 Check and certify that all the piping has been properly color coded and
banded as per the applicable specifications, and that the direction of the flow,
commodity and line identification markings have been clearly indicated on the pipe.

 3.2.16 Check and certify that vent holes in wear pads have been satisfactorily filled
with a heavy type grease or mastic material (not capable of withstanding pressure).

 3.2.17 Check and certify that all vertically and horizontally mounted valve lifting lugs
and/or shipping feet that protruded into the walkways have been satisfactorily
ground flush or cut off (under no circumstances are bolts to be removed).

 3.2.18 Check and certify that a calibrated hydraulic torque tightening device has been
used for all bolt tightening of flanges 6 inches and larger. Check and certify that
COMPANY approved bolt tightening scheme has been followed and flanges are not
under any unnecessary stresses due to bolting.

 3.2.19 Check and certify that all piping has been adequately supported per
Construction Drawings.

 3.2.20 Check and certify that all anchors, guides, wear pads, and so forth, have been
correctly installed.

 3.2.21 Check and certify that all materials installed are per Drawings and Hydrostatic
Test Diagram.

 3.2.22 Check and certify that all valves have been correctly installed, are at their
designated locations are operable and accessible.

 3.2.23 Check and certify that all flanged connections have gaskets installed per the
Iso.

 3.2.24 Check and certify that all threaded connections have been properly sealed
with COMPANY approved thread compound or seal welded per the applicable
Standards and Specifications.

 3.2.25 Check and certify that all bridge welding, and/or bracket welding has been
completed satisfactorily.

 3.2.26 Check and certify that a method of drainage has been provided at all system
low points.

 3.2.27 Check and certify that a method of venting has been provided at all system
high points.

 3.2.28 Check and certify that all vents and drains are of minimum (1 inch) normal size
and have been properly fitted with valves and bar stock plugs.

 3.2.29 Check and certify that all orifice plates, strainers, and flow meters have been
removed from the system prior to flushing.
  3.2.30 Check and certify that all soft-seated valves and control valves that are to
remain in the system during system flushing and testing have been satisfactorily
locked in the open position.

 3.2.31 Check and certify that all temporary blanks, plugs, caps, temporary and
permanent spectacle plates, blinds, temporary spools, and temporary gaskets
required for system flushing and pressure testing have been properly installed.

 3.2.32 Check and certify that all check valve internals have been removed or held
open.

 3.2.33 Check and certify that all manually operated valves have been installed with
their hand wheels or levers.

*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 vapor 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 Hydro test Code
Comparison under the category Hydro test)
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 Hydro test 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.