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1.0 PURPOSE

1.1 To established guidelines in conducting hydrostatic pressure test of pressure vessel / piping system

1.2 To check the welded and flange connections of the pressure vessel / piping system of any possible
leaks that may be present.

2.0 SCOPE

2.1 This procedure covers all pressure vessel / piping system to be tested hydraulically for pressure
strength and leakage.

2.2 This procedure shall be in accordance with ASME Section VIII Div.1 and 2 / ANSI B31.1 latest
edition and to the requirements of client's specification for the fabrication / construction of pressure
vessel / piping system.

3.0 GENERAL REQUIREMENTS

3.1 Personnel

3.1.1 Personnel performing the test shall be designated and oriented on this test procedure
by EEI Construction Division

3.2 Pressure Gauges

3.2.1 Gauges to be used shall be calibrated and certified by the authorized testing laboratory
or by EEI in house Instrument Calibration with reference to a master pressure gauge
calibrated / certified by an Authorized Calibration Agency for accuracy before use.

3.2.2 Gauges to be used for the pressure test shall have a maximum graduation of 1.5 to 2
times the test pressure to be applied.

3.3 Testing Medium

3.3.1 The fluid to be used shall be fresh clean water.

4.0 RESPONSIBILITY

4.1 Operation group shall be responsible for initiating and performing this procedure for
hydrostatic pressure test and its correct implementation.

4.2 QC Inspector shall be responsible in the conduct of inspection during and after hydrostatic pressure
test and documentation of such inspection.

4.3 Safety officer shall responsible to ensure all necessary safety measures are in plan prior to start
of pressure test.

4.4 QA - shall be responsible for the verification of the implementation of this procedure.

4.5 Client's Representative shall check / witness and approve the completeness of such test, when
required.
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5.0 PROCEDURE

5.1 Preparation

5.1.1 Prior to pressure test, all weldings to the pressure parts are completed and shall be
thoroughly cleaned of rust, grease, paint or other contaminants capable of masking
a leak. Slags shall be removed and all tackwelds and spatters should be grind smooth.
Any welding on the pressure parts after the hydrotest will invalidate the hydrotest done
and re-test will be required.

5.1.2 Vents shall be at highest points of the pressure vessel / piping system to purge air
pockets during water filling.

5.1.3 Pressure vessel shall be blinded or blank-off at proper spots according to the order of
test limits.

5.1.4 Flange joints at which blanks are inserted to blanf-off other segments during the test
should be checked for tightness and possible sign of leaks.

5.1.5 At least two pressure gauges shall be provided where one is at the lowest and the other
one at the highest location of the pressure vessel / piping system in such a manner
that gauges can function correctly.

5.2 Pressure Application and Inspection

5.2.1 Whenever possible, the test pressure shall not be applied until the pressure vessel /
piping system and the test medium are approximately of the same temperature.

5.2.2 The pressure shall be gradually increased up to the specific test pressure and held
continuosly for at least 10 minutes and may reduce to the design pressure or max.
allowable working pressure and held for such time as maybe necessary to conduct the
examination for leakage.Examination for leakage shall be done on all joints & connections

Note: For a system being hydrotested under sunlight, test pressure shall be controlled by
bleeding to avoid excessive pressure rise as the temperature increases to avoid over
stress on material of pressure parts.

5.2.3 The hydrostatic test pressure at any point in a vessel / piping system shall not be less
than the following:

a. Piping System - 1.5 × Design Pressure

b. Vessel - 1.3 × Max. allowable working pressure ( ASME VIII Div. I )
C. Vessel - 1.25 × Design Pressure

or as specified by the client like compliance to Pressure Equipment Directive ( PED )

which specify higher test pressure or in any case not be less than the test pressure
indicated on the drawing.

5.2.4 In determining the actual value of pressure attained during testing, the pressure reading
of gauge located above the pressure vessel / piping system shall be the basis of acceptance.
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5.2.5 Tested pressure vessel / piping system shall be checked of possible leakage or a
pressure drop during the holding time. In the event of repairs or additons are made
following the pressure test the affected pressure vessel / piping system should be re -
tested in accordance with the requirements.

6.0 ACCEPTANCE CRITERIA

6.1 Acceptable result - areas under test are considered acceptable when no visible leaks are found and
no sudden or gradual decrease on the pressure gauge reading is observed throughout
the duration of test.

6.2 Rejectable results - continuous leaking and sudden or gradual decrease in pressure gauge reading
and / or visible deformation due to presure that indicates yielding of pressure parts.

7.0 CORRECTIVE MEASURE DUE TO REJECTABLE RESULT

7.1 Any leak observed shall be marked for repair and shall be subject for re-test. This procedure of
testing and repair cycle shall be performed until there is no more leak to be found.

7.2 Deformation due to pressure test shall be measured and reported for engineering design evaluation
and disposition.

8.0 POST TEST TREATMENT

8.1 Vent shall be opened prior to opening of the water drain valve.

8.2 After test, the vessel / piping system shall be drained. The inserted blind must be removed,
connections properly reinstalled and temporary supports are removed.
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6.7.3 Final interpretation shall be made within 10 to 60 minutes.

6.8 Post Cleaning

6.8.1 Accepted items shall be cleaned after inspection using suitable techniques
such as simple water rinse, machine wash, vapor decreasing, solvent soak
or ultrasonic cleaning.

6.9 Evaluation

6.9.1 All indication shll be evaluated in terms of acceptance standards of the

referencing codes.

6.9.2 Discontinuities at the surface will be indicated by bleed-out of penetrant;

however, localized surface irregularities due to machining marks on other
surface conditions may produce false indications.

6.9.3 Broad areas of flourescent or pigmentation which could mask indications

of discontinuities are unacceptable, and such areas shall be cleaned and
re-examined

6.10 Techniques for Nonstandard Temperature

6.10.1 General - When it is no practicalto conduct a liquid penetrant examination

within the temperature range of 50 deg. F to 125 deg. F ( 10 C to 52 C ),
the examination procedure at the proposed lwer or higher temperature
range requires qualifiation and shall be in accordance with applicable codes,
standards and specification.

7.0 ACCEPTANCE CRITERIA

7.1 Shall be as required in refencing codes section

8.0 REPORTS

8.1 The liquid penetrant examination report shall be prepared, signed and furnished to the
client and shall contain but not limited to the following:

8.1.1 Date of examination

8.1.2 Component / Weld identifucation

8.1.3 Examination Procedure

8.1.4 Type, Manufacturer, Serial No., and batch no. of PT chemicals used

8.1.5 Findings/Results of Examination

8.1.6 Description of indication and Recommendations.