HYDROTESTING-I

ENSURE FOLLOWING PRIOR TO WATER FILLING

1. COMPLETION OF WELDING ON PRESSURE PARTS
2. COMPLETION OF ALL NDT TO THE ACCEPTABLE STAGE
3. CLEARANCE OF ALL PENDING NCR / DCR, IF ANY.
4. FINAL CLEARANCE OF MATERIAL CLEARED PROVISIONALLY
5. TESTING OF P TC / MTC, IF ANY, TO THE ACCEPTABLE TEST RESULTS
6. ALL DIAMENSIONAL CHECK WITHIN THE ACCEPTABLE LIMIT
7. VESSEL IS KEPT ON HYDRO TEST SADDLES IN THE SPECIFIED
ORIENTATION AS PER THE DRG. ISSUED BY DESIGN DEPT.
8. ALL LONG SEAMS & CIRC. SEAMS ARE MADE VISIBLE FOR INSPECTION.
9. IF JOB IS PRIMER COATED, ALL PRESSURE WELD JOINTS ARE CLEANED
FREE FROM PAINT.
10.GASKETS & GASKET SEATINGS ARE CHECKED FOR ANY DAMAGE
11.INSIDE SURFACE IS CLEANED
12.AIR VENDING ARRANGEMENTS ARE DONE INSIDE WHEREVER REQUIRD
13.JOB HARDWARES & GASKETS SHOWN IN DRAWING ARE ASSEMBLED
EXCEPT HARDWARES SPECIFIED FOR HYDROTEST.
14.ALL FASTENERS ARE TIGHTENED TO REQUIRED TORQUE
15.ALL OPENINGS ARE CLOSSED EXCEPT TOP ONE FOR FILLING WATER.
16.ARRANGEMENT FOR PRESSURISING SHALL BE THROUGH ONE OF THE
NOZZLES FROM BOTTOM
17.SQUARE BAR ARRANGEMENTS ON INLET AND OUT LET CONNECTIONS.
18.ARROW FOR DIRECTION OF WATER FLOW ON FITTINGS TO BE VERIFIED &
CONFIRMED
19.TWO PRESSURE GAUGES OR ONE PRESSURE GAUGE AND ONE
TRANSDUCER TO BE MADE AVAILABLE.
20.GRADUATIONS ON GAUGES - TWICE THE TEST PRESSURE ( 1.5 TO 4
TIMES THE TEST PRESSURE).
21.GAUGES & TRANSDUCERS SHALL BE CALIBRATED WITH CALIBRATION
STICKER
22.PPM REQUIREMENT OF TEST WATER SHALL BE VERIFIED AND
CONFIRMED.

23.HYDROTEST PUMP (HIGH PRESSURE LOW DISCHARGE OR LOW

PRESSURE - HIGH DISCHARGE SHALL BE MADE AVAILABLE
24.HIGH DISCHARGE PUMPS SHALL NOT BE USED FOR VESSELS WITH
VOLUM BELOW 10 CUB.MTR

WATER FILLING, PRESSURISING & INSPECTION

1. WATER SHALL BE FILLED FROM TOP NOZZLE AND CLOSSED WITH TEST
BLANK.
2. TEST BLANK SHALL BE WITH NIPPLE, SQUARE BAR, PRESSURE GAUGE
AND PIPE CONNECTION FOR VENDING.
3. INLET VALVE SHALL REMAIN CLOSSED TILL WATER FILLING
4. AFTER BLANKING THE TOP NOZZLE WITH GAUGE AND VEND PIPE, WATER
SHALL BE PUMPED FROM BOTTOM
5. VEND PIPE SHALL BE KEPT OPEN IN A BUCKET FULL OF WATER TO
OBSERVE AIR BUBLES.
6. VENDING SHALL BE CONTINUED TILL THE AIR BUBLES IN THE BUCKET IS
DISAPEARED.
7. CLOSE THE OUT LET VALVE ON TOP & CONNECT THE GAUGE TO LINE
PRESSURE.
8. ISOLATE THE GAUGE AT THE BOTTOM FROM LINE PRESSURE AND PUMP
THE WATER IN.
9. RAISE THE PRESSURE TILL 50% OF TEST PRESSURE.
10.OPEN THE INLET GAUGE TO PRESSURE LINE AND VERIFY THE PRESSURE
ON BOTH GAUGES.
11.INCRESE THE PRESSURE IN INCREMENTS OF 10% OF TEST PRESSURE
12.STOP PUMPING FOR 5 MINUTES AFTER EACH INCREMENT OF 10% OF RISE
IN PRESSURE.
13.ISOLATE THE INLET PRESSURE GAUGE WHEN PUMP IN OPERATION.
14.CONNECT THE INLET PRESSURE GAUGE TO LINE PRESSURE WHEN PUMP
IS STOPED FOR PRESSURE VERIFICATION
15.WHEN TEST PRESSURE IS REACHED, STOP PUMPING, CONNECT INLET
GAUGE TO PRESSURE LINE AND HOLD FOR 30 MIN (AS SPECIFIED IN
SPEC) AND OBSERVE THE VESSEL FROM DISTANCE.
16.REDUCE THE TEST PRESSURE TO ABOVE DESIGN PRESSURE AND INSPECT
ALL CONNECTIONS FOR LEAKAGE
17.IF ANY LEAKAGE IS OBSERVED THROUGH GASKET CONNECTION, REPEAT
THE TEST AFTER DEPRESSURISE THE VESSEL & TIGHTEN THE STUDS /
NUTS.

18.IF ANY LEAKGE IS OBSERVED FROM WELD OR PARENT METAL, DRAIN THE
WATER, REPAIR THE LEAK AND REPEAT THE TEST
19.TIME, TEMPERATURE & PRESSURE CHART WHEREVER SPECIFIED SHALL
BE OBTAINED

IMPORTANT SAFETY POINTS IN HYDROTEST

DRAIN THE VESSEL ONLY WHEN TOP OUT LET IS KEPT OPEN

USE MINIMUM 2 GAUGES FOR ANY HYDROTEST

NEVER USE HIGH DISCHARGE PUMPS FOR TESTING LOW VOLUM VESSELS.
( VOLUM LESS THAN 10 M3).

NEVER PRESSURISE ANY VESSEL ABOVE TEST PRESSURE

OR
HYDROTESTING-II
Method/Procedure
1. All the stages as mentioned in the QAP shall be complited in
all respects before hydro- testing.
2. The chloride content in water shall not exceed 25 PPM.
3. If the vertical vessel is to be hydro-tested in horizontal
position the liquid head shall be added to the specified test
pressure mentioned in the drawing.
4. Two numbers of pressure gauges shall be used and they
should be calibrated.
5. Pressure gauges range should be in between 1.5 Min To 4.0
Max times that of the test pressure and shall be 6 minimum
in diameter.
6. The location of pressure gauges shall be at the topmost
position of the vessel. Whenever it is not possible , the
liquid head shall be added to the specified test pressure.
7. Both pressure gauges shall be used for indicating the
pressure through the hydro -test.
8. Water shall be the medium for hydro-test. The temperature
of water shall be room temperature (5 to 50 degree C)
9. The equipment to be hydro-tested shall be properly
supported to withstand the static load.
10.
Fill up the water from the topside opening of the vessel
slowly.
11.
The pressure shall be given preferably from the bottom
side.

12.
During the pressurising of equipment trapped air shall
be removed fully from the equipment.
13.
The vessel shall be pressurised gradually , at the rate
not exceeding 10 PSI/Minute
14.
The test pressure shall not exceed more than least
count of pressure gauge being used for hydro-testing.
15.
The test pressure shall be withheld for minimum 30
Minutes to observe the pressure drop.
16.
After observing the pressure drop, the inspection of all
joints and connection shall be carried out with a pressure
not less than two third the test pressure.
17.
Inspection authority shall witness the hydro test and
record it.
18.
After completion of the hydro-test, the top side valve
shall be opened first and then the bottom side valve to drain
the water.
19.
The vessel shall be dried by compressed or by cloth to
remove the traces of water.

Acceptance Criteria

1. There shall be no pressure drop during the hydro- test.

2. There shall be no leak from the weld joints or gasket joints.
3. There shall be no permanent deformation of any part of the
pressure vessel during hydro-test.