Date 

14‐06‐2012  Page 

DOC. No.  CK/QCP/EW/PTP/001 
      CHEMICAL KINETICS 
1 of 7 

Client:                             DESCON   Revision  0

PRESSURE TESTING PROCEDURE

CONTENTS

PAGE NO.
DESCRIPTION

SECTION 1 SCOPE 02

SECTION 2 SAFETY PRECAUTIONS 02

SECTION 3 CRITERIA 02

SECTION 4 HYDROTESTING 03

SECTION 5 PNEUMATIC TESTING 03

SECTION 6 TEST PREPARATION 03

SECTION 7 PRE-TEST REQUIREMENT 04

SECTION 8 PRE-TEST CHECK POINTS 05

SECTION 9 HYDROTESTING PROCEDURE 05 & 06

SECTION 10 TEST CRITERIA 06

SECTION 11 COMPLETION OF TEST 07

SECTION 12 ATTACHMENTS 07
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PRESSURE TESTING PROCEDURE

1. SCOPE

The purpose of this procedure is to define various steps to perform pressure

testing of vessel carried out according to the following:

• ASME VIII Div. 1 Process vessel

• Specification for pressure testing of pipe work

2. SAFETY PRECAUTIONS

2.1 During hydrostatic testing, to avoid the entry of unauthorized persons, the
testing area shall be barricaded up to 6 meter in surrounding and signed.

2.2 An authorized person shall be nominated to operate the pump. When the
testing pressure is achieved, he shall be responsible to shut off the pump
immediately and isolate the system.
2.3 During pneumatic testing, the testing area shall be barricaded up to 12
meter in surrounding the pressure injection area or minimum safe distance
as required. Necessary warning signs and boards shall be used to keep the
unauthorized persons away from the testing area. Test manifold must be
located a minimum of 20m from the test vessel work.

2.4 Pneumatic testing shall be carried out after normal working hours when
only those personnel involved in the test are present on site.

2.5 All hoses and fittings used for pressuring shall be in good condition and
shall be rated for the maximum test pressure.

3. CRITERIA

3.1 After completion of vessel fabrication and installation and NDT

requirement, vessel components and their integral components shall be
hydrostatically (or pneumatic tested where nominated) to make sure
mechanical soundness and tightness of the vessel system in accordance
with ASME VIII Div. 1 and the project specification.

3.2 In special cases where hydro-testing nor pneumatic testing could not be
Executed (i.e. tie-in joint) the following alternative may be adopted with the
approval from the client:

• All type of Fillet Weld (Socket Weld, attachment etc.) will be examined
by liquid penetration testing.
• An in service pressure test shall be carried out during system
commissioning.
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PRESSURE TESTING PROCEDURE

4. HYDROSTATIC TESTING

4.1 Hydrostatic test shall be carried out on the vessel identified in the List.

4.2 Potable water shall be used for hydrostatic testing obtained from approved
source.

4.3 For stainless steel lines the maximum chloride content shall be not be
greater than 30 ppm.

4.4 Immediately after hydrostatic testing, line shall be dried and air blown
where nominated on the Line List. Oil free compressed air at ambient
temperature shall be used for drying so as to avoid concentration of
chlorides. If condensate having a chloride level of less than 1 ppm is used,
air-drying is not required.

5. PNEUMATIC TESTING

5.1 Air used for pneumatic testing shall be dry, clean, oil free and with a dew
point below 10 °C at the test pressure.
5.2 Pneumatic testing shall be carried out on the lines identified in the Line List
only.

6. TEST PREPARATION

Before conducting the pressure test, a test package will be prepared in order to
execute the testing in a proper and documented manner.

Test Package will contain following formats and information:

6.1 Isometrics
6.2 Limit of the test shown on the appropriate vessel & instrument diagram
(P&ID)
6.3 Location and thickness of test spades, and calculation as necessary, to
confirm thickness
6.4 Testing medium
6.5 Test pressure
6.6 Location of vents and drains
6.7 Requirement for isolation or removal of instruments and other in-line items
as per project specified.
6.8 The test pack shall also make provision for the following information to be
added following the pressure testing:
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PRESSURE TESTING PROCEDURE

• Pressure test Certificate

• Record of weld repairs and procedures, welder employed
• Any corrective actions

6.9 Test Pack Legend Sheet

6.10 Test Pack Checklist

7. PRE-TEST REQUIREMENT

7.1 All weld joints shall be left un-insulated, full painting of welds is acceptable
prior to hydrotest.

7.2 It shall be made sure that all vessel work has been satisfactory completed
and all visual inspection, NDT requirement have been met.

7.3 Installation of all necessary support shall be completed. In addition,

temporary supports will be installed, if required.

7.4 Short pieces of vessel, which must be removed to permit installation of

blind or blank, shall be tested separately.

7.5 Generally valves should not be installed in the system during hydrostatic
testing. If this is unavoidable (e.g. Welded valve) the valve is to be opened
halfway.

7.6 In a system, all valves shall be in the open position and to isolate the
system, spades or blinds of required thickness and material shall be used
downstream of any valves.

7.7 Direction of check valve will be checked. Pressure source shall be on the
upstream side of check valve. If this is not possible, the flapper shall be
removed or check valve shall be completely isolated or removed.
7.8 All threaded connections shall be plugged properly with correct thread
matching pressure rated plugs.

7.9 Proper gaskets and bolts shall be installed at all flanged joints. Temporary
gaskets will be used at all reinstate-flanged joints for testing purpose.

7.10 A suitable assembly will be fabricated for filling purpose.

7.11 Before commencing to fill the system, all air will be purged from the system
by opening the vents and other connections in the line and that the system
can be completely drained after the testing.
7.12 Vent connection shall be provided at highest point
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PRESSURE TESTING PROCEDURE

7.13 Where additional vents and drains are required, the client shall approve the
proposed locations. The additional vents/drains shall be marked up on “as
built” drawings. Generally a vent shall be at the highest point on the system
and a drain on the lowest point on the system.

7.14 Calibrated pressure gauges shall be used. Range of pressure gauge shall
be at least 1.5 times of test pressure but not so large as to compromise the
accuracy of the test. Gauge calibration certificate shall be attached to the
test certificate.

7.15 Two pressure gauges shall be installed in a system, one near filling point
and other at higher point.

7.16 All instruments and in-line items to be removed or isolated during the
pressure testing shall be in accordance with project specification.
8. PRE-TEST CHECK POINTS

8.1 Vessel systems shall have been completely checked (Punched) and
released for testing. All fitments shall be welded to vessel and inspected
prior to testing.
8.2 All lines shall be checked to ensure that the entire system can be
completely drained after testing.
8.3 Vents and other higher point connections shall be opened to eliminate air
from lines, which are to receive a hydrostatic test.
8.4 All air shall be removed from the vessel system by venting before
hydrostatic test pressure is applied. Air purging shall be witness by client
representative.
8.5 All elements as listed in Appendix “A” shall be removed.
8.6 All equipments not to be pressurized shall have been isolated.
9. HYDROTESTING PROCEDURE

9.1 Vessel system shall be filled preferably at low point with the help of
prefabricated assembly. Filling shall be done by centrifugal pump or by any
other suitable filling equipment.

9.2 After filling and removing air and gaseous substances, all vent connection
shall be closed or plugged. Pressurizing of the system shall be started by
means of motor pump or manually operated pump.

9.3 Pressurizing shall be done in two steps

9.3.1 In first step, the system shall be pressurized gradually up to

operating pressure and kept hold at this pressure up to 10 to 15
minutes so that uniform hoop stressed could be developed.
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PRESSURE TESTING PROCEDURE

Preliminary checking shall be conducted for confirming the absence of
abnormality or leaks.
9.3.2 In second step, the system shall be pressurized up to desired testing
pressure. Once the testing pressure is achieved, the pressure
source shall be isolated and system kept hold at this pressure for 30
minutes for confirming the absence of abnormality.
9.4 Thorough inspection shall be made of all flange joints, welded joints,
welded seams and packing glands etc. The system shall be held at test
pressure till the completion of inspection.
9.5 If any leakage or abnormality is found, the system shall be depressurized
and rectified and the lines retested. The system shall be held at the test
pressure for a minimum of one hour or as directed by the client’s
representative, after completion of necessary repair work.
9.6 Sealing materials shall not be used to correct leaks at joints.
9.7 After completion of test the depressurizing shall be done gradually. During
draining of system, all vent points shall be opened to avoid vacuum pulling.
All temporary blind shall be removed and line completely drained.

9.8 Water to be drained shall be collected in the water bowzers, drums or

shifted to other lines waiting of the hyrotesting. If non-of said conditions
are available, water shall be drained to the specified location as approved
by the client.

9.9 After draining the system properly, all temporary supports if any shall be
removed and system reinstated as per requirement.

10. TEST CRITERIA

10.1 Leaks

All welds and flanged joints shall be inspected and found free of leaks.

10.2 Pressure

Any drop of pressure during the test period shall be investigated and the
cause rectified. (Allowance shall be made for any effect of temperature
change). The test shall be repeated after the cause of the pressure drop
has been rectified.

10.3 Time

The test pressure must be maintained for a minimum of 30minutes or as

directed by client’s representative, after the test pressure has stabilized
and the test pump disconnected.
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PRESSURE TESTING PROCEDURE

11. COMPLETION OF TEST

11.1 A pressure test shall be considered complete when the following items are
finalized and accepted by the client’s representative:

• All defective welds, defective materials, flange leaks, valve gland leaks
or other such defects have been corrected and, where required,
retested to the client satisfaction.

• All documentation and ‘test pack’ information is complete.

• After completion of test all temporary blanks and blinds shall be

removed, all operating blinds retuned to proper position and all lines
completely drained and the correct line class gaskets and bolting
installed.

• Valves, orifice plates, expansion joints and short pieces of vessel which
have been removed shall be reinstalled with correct line class gaskets
and bolting.

• Lines being drained after testing shall have all vents open

• Lines down stream of a check valve shall be inspected to insure

complete drainage.

• Piping and equipment shall be completely dried.

• After lines have been drained, temporary piping supports shall be
removed. Spring hangers provided with stops to carry the test load
shall have these stops removed after test is complete and prior to
putting line in operation.

• Lines shall be closed to prevent entry of foreign materials.

• Instruments and equipment, which was removed or blocked out for test,
shall reinstall and blocks opened or removed.

12. ATTACHMENTS

12.1 Test Pack Contents

12.2 Test Pack Checklist
12.3 Report on Field Pressure Testing of vessel work
12.4 Hydrostatic Test Pressure Assembly
12.5 Test Pack Legend Sheet
12.6 Weld Summary Sheet
12.7 Mark up P & I D