COMPANY DOC NO:

HYDRAULIC TEST- PROCEDURE QMS/SOP/D/01, REV:0

LOGO & ISSUE NO : 3
COMPANY Date:

NAME
CH NO: 05 Page
ISO 9001: 2015 STD / STANDARD OPERATING REV: 0 1 of 3
PROCEDURES

1. SCOPE:

This procedure outlines the method of carrying out Pressure Test hydraulically on completed
Pressure Vessels, Heat Exchangers, Reactors, Components and Sub-assemblies as required by
the Code of Construction. When preparing a specific procedure to meet the Customers
requirements, this procedure may be used as a guide line.

2. REFERENCE DOCUMENTS:

ASME Sec. VIII Div 1 Latest Edition and Addenda

TEMA
Customer Specifications, as applicable
Manufacturing Drawings.

3. EQUIPMENT:

Pressure gauges (Minimum 2 Nos.) shall be of indicative type.

The indication range shall be not less than 1.5 times and not more than 4 times the test
pressure.
All pressure gauges shall be calibrated and shall have a record showing values of standard
against indicated pressure
The pressure gauges shall be mounted vertically and at-least one gauge shall be on top most
position.
Pump for pressurizing, valves, fittings and hose pipes shall be capable for developing and
withstanding the test pressure.

4. TEST MEDIUM:

The test medium shall be clean water.

5. LOCATION:

Pressure test shall be carried out at a section away from the normal fabrication activities. Only
authorized personnel shall have the access during the testing. When high pressure vessel is
under testing, the area shall be cordoned off and necessary warning board shall be placed to
caution this area as danger zone and prohibited area.
PREPARED BY: DATE: APPROVED BY: DATE:

QC DIRECTOR
 COMPANY DOC NO:
HYDRAULIC TEST- PROCEDURE QMS/SOP/D/01, REV:0
LOGO & ISSUE NO : 3
COMPANY Date:

NAME
CH NO: 05 Page
ISO 9001: 2015 STD / STANDARD OPERATING REV: 0 2 of 3
PROCEDURES

6. HYDRAULIC TEST:

The vessel/component/sub-assembly to be tested shall be cleared by inspection department

for testing.

The surface shall be cleaned off water, oil, grease, paint etc.

The vessel shall be placed on proper supports ensuring that weld seams are accessible for visual
examination. There shall be proper vent and drain facilities at the top and bottom. Except the
water filling and venting connections, all other nozzles shall be covered and bolted. Ensure that
studs of channels and bonnets of Heat Exchangers are properly and sufficiently tightened.

Maximum entrapped air shall be removed during water filling. After water filling, connect the
pump and run it for sufficient time and ensure removal of entrapped air.

Raise the pressure gradually up to 50% of the test pressure. Thereafter, increase the pressure
at the rate of 10% of the specified test pressure with a break of few minutes in between. On
reaching the required test pressure, lock the valves, mark the indicator location on the pressure
gauge and record the time.

Hold the test pressure for 30 minutes or the period specified by the customer.
After the holding period is over, reduce the pressure to the test pressure divided by 1.3.
Examine the entire vessel for any possible leakage. The examination shall include the base
metal, weld joints and all bolted /screwed connections.

There shall be no leakage through the parent metal, weld joints and bolted connections.
However, minor leakage through temporary joints on test blanks may be ignored.

7. RESULT:

In case any unacceptable leakage is noticed, inform the shop personnel and take necessary
corrective action. Retightening of the bolts/studs shall not be carried out under pressurized
condition. After correction, repeat the hydraulic test.

PREPARED BY: DATE: APPROVED BY: DATE:

QC DIRECTOR
 COMPANY DOC NO:
HYDRAULIC TEST- PROCEDURE QMS/SOP/D/01, REV:0
LOGO & ISSUE NO : 3
COMPANY Date:

NAME
CH NO: 05 Page
ISO 9001: 2015 STD / STANDARD OPERATING REV: 0 3 of 3
PROCEDURES

If no leakage is observed, drop the pressure gradually through the vales fitted on top of the
vessel. After the pressure is dropped to ZERO, open the top side nozzle blanks. Afterwards
open the bottom connection, drain the water and dry the vessel by suitable means.

8. DOCUMENTATION:

On satisfactory completion of the test, record the result in the Inspection Check List. And refer
“Hydraulic Test / Pneumatic Report”.

9. RESPONSIBILITY:

SHOP FLOOR ENGINEER

QC SUPERVISORS
PRODUCTION SUPERVISORS

===

PREPARED BY: DATE: APPROVED BY: DATE:

QC DIRECTOR