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HYDRO TESTING PROCEDURE

Rev. No. Date of issue Reason of revision

4 22 April 2021 Comments incorporated according to ED 2019 for WEIL
3 06 April 2021 AI Comments incorporated; Section 2, 3 and 4
2 20 January 2020 Comments incorporated according to ED 2019
1 05 January 2018 Comments incorporated according to ED 2017
0 16 December 2009 Initial Issue
Prepared By Reviewed and Approved By

Anup M Rajesh K Pillai

QA/QC Engineer QA/QC Manager
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1. Scope

This procedure gives minimum requirements to perform Hydrostatic Test for

Pressure vessels, Boilers & Power piping constructed to ASME Sec. Vlll Div. 1,
ASME Sec. I and ASME B 31.1.

2. Reference Documents

 ASME SEC VIII Div.1 – ED 2019

 ASME SEC I – ED 2019
 ASME B 31.1 – ED 2018
 GA Reference Drawings
 Design Calculation Reference
 ITP Reference
 Data Sheet Reference

3. Equipment and Calibration:

3.1. Hydrostatic test shall be conducted using at least two calibrated pressure
gauges with one directly connected to the vessel without any intervening
valves.
3.2. Digital reading pressure gauges (one with recorder) having a wider range of
pressure may be used, provided the readings give the same or greater
degree of accuracy as obtained with dial pressure gauges. Gauge
calibration reports shall be made available to Client for his review prior to the
tests.
3.3. Gauge calibration certificate to be provided mentioning least count of the
instrument for Company Review and approval prior to tests.

4. Test Procedure
After completion of fabrication, all examinations shall have been performed except
those required after the test. The Hydrostatic test pressure shall be as per the table
mentioned in below. The Workshop Engineer shall perform the hydro test in Client
and QC personnel’s presence. The pressure shall be applied as per the below
pressurization and depressurization sequence.
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4.1. Initial Check prior to Pressurization

4.1.1. Check all the Nozzles and Manway bolts are tightened.
4.1.2. Whenever possible, the Hydro test shall be conducted for the vessel
in normal operating position.
4.1.3. Vessels with same MAWP & hydro test pressure may be looped
together for hydro test purpose. Looping shall be done using
hydraulic hose with capacity more than 3 times the hydro test
pressure. There shall not be any valves in between the looping. If the
vessels are looped, a looping diagram shall be prepared and
submitted to client & AI for review and approval. The looping diagram
shall clearly indicate the looping, location of venting, pressure
application point, pressure gauge location, pressure recorder
location.
4.1.4. Vents shall be provided at all high points of the vessel in the position
while the vessel is filling.
4.1.5. For ASME Sec Vlll Div. 1 items, a small liquid relief valve set to 1.3
times the test pressure is recommended for the pressure test system,
in case a vessel, while under test, is likely to be warmed up materially
with personnel absent. If liquid relief valve is not fixed to the pressure
test system, a minimum of 2 calibrated pressure gauges shall be
fixed to the system to ensure the indicated pressure is same all over
the part, and a personnel shall be present till the completion of the
test to watch the pressure gauge reading. If pressure goes beyond 1
1/3 times the hydro test pressure, it shall be reduced immediately to
the test pressure.
4.1.6. For the items constructed in accordance with the Code Section VIII
Div. 1, the temperature of metal is recommended to be maintained at
least 17º C (30º F) above MDMT for item, but need not exceed 48º C
(120º F). After the successful application of the test pressure, the
pressure shall be reduced to a pressure equal to the test pressure
divided by 1.3 for a close examination of Joints.
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4.1.7. An indicating test pressure gauge shall be directly connected to the

top nozzle of vessel without any intervening valves. Pressure &
Temperature chart recorder shall be connected to the vessel.
4.1.8. Potable water shall be used for the Hydro test, Water sampling
certificate shall be provided for review by client. Water shall be of
chloride content (Less than 50 ppm or mg/L or mg/kg).
4.2. Pressurization Sequence
4.2.1. Slowly pressurize the vessel to 0.5 times the hydro test pressure. At
this stage the pressure is stabilized. Pressure stabilization is
achieved when water and vessel temperatures are equaled with all
entrained air vented out. Stabilization should be minimum of 5 mins.
This will allow sufficient time for entrained air to settle out. For this
reason, venting should continue during this stage.
4.2.2. Slowly pressurize the vessel equal to 0.75 times the hydro test
pressure. At this stage also, the pressure is stabilized for 5 mins.
4.2.3. Now slowly pressurize the air receiver equal to the hydro test
pressure. Hold for 5 minutes for the pressure to stabilize. Then the
pressure is for hold for 1 hour.

4.2.4. The test pressure will be held till completion of inspection (minimum 1
hour) or otherwise as per clients requirement.
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4.3. Depressurization Sequence

4.3.1. After 1 hour, the test pressure is slowly reduced to MAWP (Test
pressure / 1.3), at this pressure the inspection/ verification shall be
performed of all joints and connections.
4.3.2. After the inspection for leakages or pressure drop, the pressure is
slowly released by opening the vent, and gradually reducing the
pressure to zero.
4.3.3. Water is drained & item is cleaned thoroughly after the test.
4.4. Hydro test results will be recorded in the enclosed form (Annexure – 1).

5. Reports and Documentation

5.1. Hydrostatic Test Report shall include the following as minimum,
 Client Name
 Date
 Job No.
 Job Name
 Vessel Tag No.
 Drawing No.
 Test Pressure & Temperature
 Gauge details
 Result
 Name & Signature
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Annexure-1
HYDRO TEST REPORT FORMAT- SAMPLE