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HYDROSTATIC PRESSURE TEST (ENGINEERING BEST PRACTICES)

Article · May 2023

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 Page : 1 of 60

Rev: 01
KLM Technology
Group
Guidelines, Consulting and Training
Engineering Best Practices May 2023

www.klmtechgroup.com

KLM Technology Group

#033, Jalan Bayu 8/1, HYDROSTATIC PRESSURE TEST
Taman Nusa Bayu,
79200 Iskandar Puteri,
Johor, Malaysia. (ENGINEERING BEST PRACTICES)

TABLE OF CONTENTS
SCOPE ......................................................................................................................... 4

INTRODUCTION .......................................................................................................... 5

SAFETY IN HYDROSTATIC PRESSURE TEST.......................................................... 6

DEFINITIONS ............................................................................................................. 10

REFFERENCES ......................................................................................................... 14

THEORY ..................................................................................................................... 15

HYDROSTATIC PRESSURE TEST DEFINITION .................................................. 15

EQUIPMENT ........................................................................................................... 19

TEST MEDIA........................................................................................................... 20

TEST DURATION .................................................................................................. 23

TEST PRESSURE ................................................................................................. 24

PREPARATION FOR PRESSURE TEST. .............................................................. 25

PRE-TEST LOGISTICS ........................................................................................ 36

PRESSURE GAUGES ............................................................................................ 37

PROCEDURES OF TESTING................................................................................. 38
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Rev: 01
KLM Technology
Group
Guidelines, Consulting and Training
Engineering Best Practices May 2023

www.klmtechgroup.com

KLM Technology Group

#033, Jalan Bayu 8/1, HYDROSTATIC PRESSURE TEST
Taman Nusa Bayu,
79200 Iskandar Puteri,
Johor, Malaysia. (ENGINEERING BEST PRACTICES)

DE-PRESSURIZATION AND DE-WATERING ....................................................... 47

ACCEPTANCE CRITERIA ..................................................................................... 49

RECORDING AND DOCUMENTATION ................................................................. 50

ACCESSORIES AND TOOLS ................................................................................ 53

TEST COMPLETION .............................................................................................. 53

HYDROSTATIC TEST IN PRESSURE VESSEL .................................................... 54

PNEUMATIC TEST ................................................................................................. 56

LIST OF FIGURE

Figure 1. Hydrostatic pressure testing of pipe. ...................................................... 16

Figure 2. Hydrostatic test phases............................................................................ 40
Figure 3.Record of pressure. ................................................................................. 50

LIST OF TABLE

Table 1. Test requirements for main line piping ................................................. 24

Table 2. Test Pressure .............................................................................................. 25
Table 3. Recommended Maximum & Minimum Temperature During Hydro
static Test. ................................................................................................................. 27
Table 4. Status of instruments during pressure test ............................................ 31
Table 5. schedule of maximum allowable hydrostatic test pressure (bar g) test
blind thickness .......................................................................................................... 33
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Rev: 01
KLM Technology
Group
Guidelines, Consulting and Training
Engineering Best Practices May 2023

www.klmtechgroup.com

KLM Technology Group

#033, Jalan Bayu 8/1, HYDROSTATIC PRESSURE TEST
Taman Nusa Bayu,
79200 Iskandar Puteri,
Johor, Malaysia. (ENGINEERING BEST PRACTICES)

Table 6. Hydrostatic test water volume requirements for standard pipe size. .... 41
Table 7. Comparison of hydrostatic test and pneumatic test. .............................. 58
 Page : 4 of 60

Rev: 01
KLM Technology
Group
Guidelines, Consulting and Training
Engineering Best Practices May 2023

www.klmtechgroup.com

KLM Technology Group

#033, Jalan Bayu 8/1, HYDROSTATIC PRESSURE TEST
Taman Nusa Bayu,
79200 Iskandar Puteri,
Johor, Malaysia. (ENGINEERING BEST PRACTICES)

SCOPE

This Best Practice specifies the major requirements of hydrostatic testing of pressure
piping and vessels, while providing guidelines on some issues that may arise.

Hydrostatic pressure testing is universally known and accepted as a means of

demonstrating the fitness of a pressurized component for pipe service. After a test, a
pipe can be expected to safely contain its intended operating pressure. The
confidence level that a pipe or pressure vessel is fit for safe service increases as the
ratio of test pressure to operating pressure increases. Hydrostatic test reveals
weaknesses of pipe by causing ruptures or leaks.

When compared to other equipment in a hydrocarbon processing plant, the piping

network is designed to the most stringent standards. Mechanical Engineering codes
require a 400% safety factor in the design of these systems. The piping system is
normally considered the safest part of the plant. However, even with this level of
safety, reviews of catastrophic accidents show that piping system failures represent
the largest percentage of equipment failures.

Since these systems are responsible for many catastrophic accidents, operations,
design, and maintenance personnel should understand the potential safety
concerns. Failure of an operating piping can result in health and safety concerns,
damage to property and has the potential for significant environmental impact.
Consequently, it is important to ensure that a pipe is free of leaks and can maintain
its integrity at an approved operating pressure in order to limit the risk to the public
and the environment.

In some countries, approval from regulatory agencies must be acquired prior to

testing. Regulatory approvals have been put in place to minimize the risk of
unacceptable environmental impact or adverse impacts on other users as a result of
testing activities. This test has a lot of considerations that must be considered
(before or after the test) to obtain the maximum result. The purpose of this best
practice is to show how to do the hydrostatic pressure testing in accordance with the
steps, procedures and rules.
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Rev: 01
KLM Technology
Group
Guidelines, Consulting and Training
Engineering Best Practices May 2023

www.klmtechgroup.com

KLM Technology Group

#033, Jalan Bayu 8/1, HYDROSTATIC PRESSURE TEST
Taman Nusa Bayu,
79200 Iskandar Puteri,
Johor, Malaysia. (ENGINEERING BEST PRACTICES)

INTRODUCTION

Pressure testing of a new pipe is required prior to commissioning to prove its

integrity at operating pressure. Hydrostatic testing is the most common pressure
testing method. Testing of an in-service pipeline may be done as part of a
preventative program to verify pipe integrity. In-service pipelines may also be tested
if operating pressure is to be increased, modifications to the pipe are made or a
change in line service planned.

Hydrostatic testing of pressure piping is a mandatory activity before finalization of

any new or modified piping system. It is the final check of mechanical integrity of the
whole system under pressurized conditions in the form of strength and leak testing of
piping with components, pressure vessels, gas cylinders, boilers and others pressure
equipment and systems.

It should be followed religiously as after this activity the piping system has to be
commissioned. Typically, water is used as test media in hydrostatic test process.
The name comes from when engineers used compressed air as their hydraulic fluid
instead of water; the term “hydro” meaning water in Greek) and “statikos,” which
means solid (as in static).

Hydrostatic testing is a common tool used by engineers to ensure that equipment

has been rebuilt or repaired properly. It’s most commonly employed for DOT-
required containers with the aim to work out any potential leaks and verify it is fully
safe for use. A hydrostatic test will bring up any potential leaks in equipment and
also show if there are any structural problems with the exterior or interior of the tank
that might lead to leaks later on.

Hydrostatic testing involves filling the vessels, pipeline or system (which need to be
tested) with water, then pressurized with a hydraulic pump until the test pressure
reaches (normally 1.5 times design pressure of a system regardless of the service
conditions of a piping system), hold the pressure for a specified time by shutting off
the supply valve and checking for any leakage or pressure drop. The process works
because water will breach any gap between two pieces of imperfectly sealed pipe if
there’s enough pressure applied to force its way through. If the pressure drops
beyond the standard tolerable limit, the test is declared failed.
 Page : 6 of 60

Rev: 01
KLM Technology
Group
Guidelines, Consulting and Training
Engineering Best Practices May 2023

www.klmtechgroup.com

KLM Technology Group

#033, Jalan Bayu 8/1, HYDROSTATIC PRESSURE TEST
Taman Nusa Bayu,
79200 Iskandar Puteri,
Johor, Malaysia. (ENGINEERING BEST PRACTICES)

Although water is most commonly used, other fluids such as oil or hydraulic fluid are
sometimes used based on the materials under test and corrosion considerations. It is
important to understand that water or oil are considered to be incompressible under
the most reasonable pressures used in pressure testing. This is beneficial in that the
test requires less energy to exert the required pressure than if a compressible
medium is used. Less energy in means less energy out in the case of a failure.

Working with a company that offers hydrostatic testing services can be more
beneficial than purchasing and operating the equipment because of cost, time, and
resources. Additional benefits include a faster turnaround time, increased safety for
staff and customers resulting in improved product quality assurance; decreased
repair costs; minimizing risk exposure and liability claims. A team of highly trained
hydro-testers can help chemical, industrial or other companies to stay compliant with
hydrostat specifications.

SAFETY IN HYDROSTATIC PRESSURE TEST

Hydrostatic testing is a risky process as it involves pressurizing the system with high
pressure which can fail and cause serious personal injury or property damage.
Although testing is performed under the supervision of a competent person, the
following is the risk associated with hydrostatic testing:

1. In the event of a leak or burst, a person can be injured by exposure to high

pressure liquid. High pressure fluid can tear the skin and damage internal
organs.
2. The pressure hose connection of hydraulic pump to test piping/ vessels can be
detached and may hit a person nearby.
3. To control the above hazards, appropriate safety precautions must be ensured
while performing hydrostatic test
4. The hydrostatic test must only be performed under the supervision of a
competent person.
5. Follow the permit to work system and establish well communication
6. Barricade the area to restrict the man movement and display caution boards to
alert people.
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Rev: 01
KLM Technology
Group
Guidelines, Consulting and Training
Engineering Best Practices May 2023

www.klmtechgroup.com

KLM Technology Group

#033, Jalan Bayu 8/1, HYDROSTATIC PRESSURE TEST
Taman Nusa Bayu,
79200 Iskandar Puteri,
Johor, Malaysia. (ENGINEERING BEST PRACTICES)

7. Provide whip latch arrester to secure the hoses

8. Equipment and accessories used for pressure build-up and inspections must be
certified and calibrated.

Hydrostatic pressure testing is a hazardous activity and poses a risk of serious injury
to persons or property damage. Proper job planning with a permit to work system
and a skilled and competent workforce can minimize the risk of failure and help
prevent accidents. This safety Do’s and Don’ts of hydrostatic testing can be
displayed on the job site to remind the workers about safety precautions. A toolbox
talk must be conducted before starting the daily work to enhance the competency of
involved workforce and also to communicate the safety measures on changing
operational conditions.

Do’s
1. Follow the permit to work system and communicate the associated hazards to
engaged manpower.
2. Perform hydrostatic test under the supervision of a competent person only.
3. Clearly mark the scope of hydrotest on P&ID and ensure positive isolation of
equipment and piping that are not included in the hydrostatic test loop.
4. Inspect all test equipment and tools, even if they are brand new.
5. Check the design pressure of equipment such as vessel, piping, etc. before
the test.
6. Ensure calibration of pressure measuring instruments and tools.
7. All fittings must be rated above the maximum hydrostatic pressure.
8. Ensure the setting and calibration of safety relief valve.
9. Install at least two pressure gauges at an appropriate place so that it is easily
readable.
10. Isolate, barricade the test area with safety signages in local and English
language.
11. If possible, perform the test from a remote area.
 Page : 8 of 60

Rev: 01
KLM Technology
Group
Guidelines, Consulting and Training
Engineering Best Practices May 2023

www.klmtechgroup.com

KLM Technology Group

#033, Jalan Bayu 8/1, HYDROSTATIC PRESSURE TEST
Taman Nusa Bayu,
79200 Iskandar Puteri,
Johor, Malaysia. (ENGINEERING BEST PRACTICES)

12. Make sure that all pipeline and vessel supports are firm, in good condition and
have been inspected prior to start hydrotest.
13. Start the de-pressurization by gradually opening the vent valve.
14. Open the lowest drain point to remove water from the vessel, pipeline, etc.
15. Always wear appropriate personal protective equipment (PPEs).

Don’ts
1. Don’t monitor the pressurization step directly in front of the pressure gauges.
2. Don’t forget to remove the air pockets through the vent line.
3. Don’t attempt to tighten the bolts if the flange leaks during hydrotesting and
system is pressurized.
4. Don’t open the drain valve if the vent valve is closed.
5. Don’t use a pressure gauge with under rated capacity.
6. Don’t allow unauthorized person to enter the test area.
7. Don’t forget to obtain work permit and wear appropriate PPEs.
8. Don’t leave any electrical equipment without adequate protection
9. Don’t leave the remaining/ residual pressure trapped inside the pipeline or
vessel after testing.
10. Don’t forget to provide proper access and egress for work at height.
11. Don’t drain the hydrotest water on the floor, make sure there is adequate
drainage.
12. Don’t miss to isolate monitoring devices/ site glass.
13. Don’t allow other activities in the vicinity of the hydrotesting work area.

Piping under hydrostatic test contains considerable stored energy. If the piping
ruptures in a ductile manner, it releases this energy rapidly. The resulting jet of water
can cause serious injury to personnel in the immediate area. If the piping fails in a
brittle manner, which may occur at cooler temperatures, pieces of steel may become
projectiles.
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Rev: 01
KLM Technology
Group
Guidelines, Consulting and Training
Engineering Best Practices May 2023

www.klmtechgroup.com

KLM Technology Group

#033, Jalan Bayu 8/1, HYDROSTATIC PRESSURE TEST
Taman Nusa Bayu,
79200 Iskandar Puteri,
Johor, Malaysia. (ENGINEERING BEST PRACTICES)

Therefore, the following safety precautions shall be adhered to during hydrostatic

testing.

1. Only personnel directly involved in the test shall be allowed in the test area, all
other personnel shall remain outside the test area;
2. All equipment which must be attended by personnel during the test shall be
located behind a protective structure such as an earthen berm or be located a
minimum of 15 m away from the test section during the strength test;
3. Visual inspection of the test section shall not be conducted while the test
pressure exceeds 115% of MOP
 Page : 10 of 60

Rev: 01
KLM Technology
Group
Guidelines, Consulting and Training
Engineering Best Practices May 2023

www.klmtechgroup.com

KLM Technology Group

#033, Jalan Bayu 8/1, HYDROSTATIC PRESSURE TEST
Taman Nusa Bayu,
79200 Iskandar Puteri,
Johor, Malaysia. (ENGINEERING BEST PRACTICES)

DEFINITIONS

American Society of Mechanical Engineers (ASME)—organization that provides

laws of regulation for boilers and pressure vessels

Average stress and minimum stress - stresses determined from published or

manufacturer’s data on the subject material.

Construction - The complete manufacturing process, including design, fabrication,

inspection, examination, hydrotest, and certification. Applies to new construction
only.

Corrosion - The wasting away of metals as a result of chemical action usually cause
by the presence of O2, CO2, or an acid. Corrosion allowance - Any additional
thickness specified for corrosion during the vessel service life.

Hydrostatic testing - the application of internal pressure above the normal or

maximum operating pressure to a segment of piping or pressure containing
component. This pressure is applied under no flow conditions (in the case of a
pipeline) for a fixed period of time, utilizing a liquid test medium

Main line piping - includes those items through which oil industry fluids are
conveyed, which includes pipe, components, and any appurtenances attached
thereto, up to and including the isolating valves used at pump stations and other
facilities.

NPS - means Nominal Pipe Size, and the NPS system of nominal size designation is
contained in standards prepared by the American Society of Mechanical Engineers.

MOP - Maximum Operating Pressure expressed in kPa. The MOP shall be the lesser
of the design pressure and 80% of the strength test pressure.

Station piping - includes all pipe, components and any appurtenances at Pump
Stations, Tank Farms and Terminals downstream from the first station isolating valve
or sectionalizing valve within the station.
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Rev: 01
KLM Technology
Group
Guidelines, Consulting and Training
Engineering Best Practices May 2023

www.klmtechgroup.com

KLM Technology Group

#033, Jalan Bayu 8/1, HYDROSTATIC PRESSURE TEST
Taman Nusa Bayu,
79200 Iskandar Puteri,
Johor, Malaysia. (ENGINEERING BEST PRACTICES)

Fabricated - include prefabricated components such as: piping spools; scraper

traps; and main line block valves with end extensions and associated by-pass piping.
The term excludes such manufactured components as: valves; strainers; and pump
casings.

Flange - A circular metal plate threaded or otherwise fastened to an end of a pipe for
connection with a companion flange on an adjoining pipe. Also that part of a boiler
head (dished or flat) which is fabricated to a shape suitable for riveted or welded
attachment to a drum or shell

Lining - An internal coating that consists of an applied liquid material which dries
and adheres to the substrate, or a sheet material that is bonded to the substrate. It is
designed for immersion service or vapor-space service. A lining can be reinforced or
unreinforced

P&ID (Piping and Instrument Diagram) - A diagram which shows the

interconnection of process equipment and the instrumentation used to control the
process.

Pressure Vessel - Any vessel designed to hold contents under pressure; these
include storage tanks, valves, and various types of pipe

Maximum Allowable Pressure (MAP) - It refers to the maximum permissible

pressure based on the weakest part in the new (uncorroded) and cold condition and
all other loadings are not taken into consideration.

Maximum Allowable Working Pressure (MAWP) - the maximum permissible

pressure at the top of the vessel in its normal operating position at a specific
temperature, usually the design temperature. It is the least of the values calculated
for the MAWP of any of the essential parts of the vessel, and adjusted for any
difference in static head that may exist between the part considered and the top of
the vessel.

Maximum design temperature - The highest temperature considered in the design,

equal to or greater than the highest expected operating temperature during the
servke life of the tank.
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Rev: 01
KLM Technology
Group
Guidelines, Consulting and Training
Engineering Best Practices May 2023

www.klmtechgroup.com

KLM Technology Group

#033, Jalan Bayu 8/1, HYDROSTATIC PRESSURE TEST
Taman Nusa Bayu,
79200 Iskandar Puteri,
Johor, Malaysia. (ENGINEERING BEST PRACTICES)

Operating Pressure - The pressure at the top of the vessel at which it normally
operates. It shall be lower than the MAWP, design pressure, or the set pressure of
any pressure relieving device.

Pressure - The amount of force exerted on a unit of area by a fluid.

Absolute Pressure - The pressure referenced to a perfect vacuum as zero pounds

per square inch absolute.

Atmospheric Pressure - The pressure exerted by the atmosphere. Although this

pressure varies with altitude, barometric pressure and humidity, the atmospheric
pressure can be defined in custody transfer contracts, or by state and federal
authorities. Atmospheric pressure is most often stated as 14.696 pounds per square
inch absolute.

 Back Pressure - The operating pressure level measured upstream from a

control valve.

 Gauge Pressure - That pressure measured relative to atmospheric

pressure as zero, usually designated psig.

 High Vapor Pressure - A fluid which, at the measurement or proving

temperature, has a vapor pressure that is equal to or higher than
atmospheric pressure.

 Low Vapor Pressure - A fluid which, at the measurement or proving

temperature, has a vapor pressure that is less than atmospheric pressure.

 Reid Vapor Pressure (RVP) - The vapor pressure of a fluid at 100 degrees
Fahrenheit as determined by test method ASTM D 323-58. RVP is one of
the important specifications for gasoline and solvents. It is a measure of the
vapor pressure of a sample at 100°F (38°C), in the presence of air. A test is
made in a bomb, and the results are reported in pounds per square inch
absolute.
 Page : 13 of 60

Rev: 01
KLM Technology
Group
Guidelines, Consulting and Training
Engineering Best Practices May 2023

www.klmtechgroup.com

KLM Technology Group

#033, Jalan Bayu 8/1, HYDROSTATIC PRESSURE TEST
Taman Nusa Bayu,
79200 Iskandar Puteri,
Johor, Malaysia. (ENGINEERING BEST PRACTICES)

 Static Pressure - The pressure in a fluid that is exerted normal to the

surface. In a moving fluid, the static pressure is measured at right angles to
the direction of flow.

Welded joint - A union of two or more members produced by the application of a

welding process
 Page : 14 of 60

Rev: 01
KLM Technology
Group
Guidelines, Consulting and Training
Engineering Best Practices May 2023

www.klmtechgroup.com

KLM Technology Group

#033, Jalan Bayu 8/1, HYDROSTATIC PRESSURE TEST
Taman Nusa Bayu,
79200 Iskandar Puteri,
Johor, Malaysia. (ENGINEERING BEST PRACTICES)

REFFERENCES

1. “Guidelines Hydrostatic Test Water Management”, Canadian Association of

Petroleum Producers, Canada, 1996.

2. “Process Piping”, ASME B31.3 Code, 2012

3. Karl Kolmetz. Hydrostatic Pressure Testing of Piping. Engineering Practice

Vol 3 No. 8. 2017

4. K Kolmetz et al, Kolmetz Handbook of Process Equipment Design, Safety in

Process Equipment Design, Engineering Design Guidelines, 2014

5. K Kolmetz et al, Kolmetz Handbook of Process Equipment Design, Process

Safety Management, Engineering Design Guidelines, 2015

6. K Kolmetz et al, Kolmetz Handbook of Process Equipment Design, Safety

Risk Management and Loss Prevention, Engineering Design Guidelines, 2016

7. K Kolmetz et al, Kolmetz Handbook of Process Equipment Design, Pressure

Vessel Selection, Sizing and Troubleshooting, Engineering Design
Guidelines, 2020

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