Hydrostatic Pressure Testing Procedure:

Document Control: Hydro.Test.

Revision: 2
Date: 20th/07/2004.

Prior to tools leaving for the job:

Certification:
1. All 3 Hoses,
2. Pressure Relief Valve,
3. Instrumentation, (such as dead-weight testers, pressure gauges on the Hydrostatic test
pump, and the other gage on the Pressure test manifold, pressure and temperature
recorders),
4. as well as the Pressure Test Manifold
used in testing shall carry current calibration certificates verifying that they meet the requirements
of accuracy and sensitivity.

Dead-weight testers shall have an accuracy of ±0.1% of the pressure being read and a sensitivity
of + 0.05% of the test pressure.

Start the equipment and insure that the oiler is dripping 3 drops per minute check for
hydraulic leaks, cracks air etc.

HOSE AND FITTING ASSEMBLY

Visual Inspection Hose/Fitting: Any of the following conditions require immediate shut down
and replacement of the Hose Assembly:
• Fitting slippage on Hose,
• Damaged, cracked, cut or abraded cover (any reinforcement exposed);
• Hard, stiff, heat cracked, or charred Hose;
• Cracked, damaged, or badly corroded Fittings;
• Leaks at Fitting or in Hose;
• Kinked, crushed, flattened or twisted Hose; and
• Blistered, soft, degraded, or loose cover.
Visual Inspection All Other: The following items must be tightened, repaired, corrected or
replaced as required:
• Leaking port conditions;
• Excess dirt buildup;
• Worn clamps, guards or shields; and
• System fluid level, fluid type, and any air entrapment.
Portable Works Limited/hydro.test…..continued

Functional Test: Operate the system at maximum operating pressure and check for possible
malfunctions and leaks. Personnel must avoid potential hazardous areas while testing and using
the system.

The equipment will be tested at the shop. The equipment will be tagged for
“Readiness” and a Delivery Note/Packing List Completed. The equipment will be
shipped in an approved storage box with certificates on load test and slings.

PROCEDURE FOR Offshore

a. On arriving from helicopter please insure that you use the hand rails read and follow all
instruction.

b. Report to the HLO office and wait for instruction. Give your name and company you will be
assigned to a lifeboat and sleeping quarters insure that you understand all the procedures if not
ask. If this is the first time on platform, inform the person in authority.

c. Ensure that all ppe requirements are in hand, hardhat, clear lens safety glasses, nomex, steel
tip boots, earplugs if needed and gloves.

d. Check with Client supervisor and visually inspect the job site before any paper work has to be
filled out. Insure that you get a clear vision on the job task if in doubt ask. Try and identify all the
hazards around the job.

e. A JSA will be filled out based on your site visit insure that all the technicians are in involved in
this JSA. There will be a tool box meeting.

REMEMER THAT THE JSA MUST REFLECT ON THE JOB THAT WILL BE IN PROGRESS OF
WHICH YOU WILL BE CONDUCTING. IF THERE IS AN APPLICATION THAT DOES REFECT
ON THE JSA WHILE THE WORK IS PROCESS STOP WORK AND REVIEW JSA. A JSA WILL
BE REVIEWED EVERY SHIFT.

f.
Insure that all procedures and all supplementary certificates are attached to the JSA.

g.
There will be two (2) permit to work trained personnel (one (1) for each shift).

h. There will be a test pack which will be developed prior to the commencement of
Hydrostatic testing, and this will outline all the parameters for conducting the tests.

Documentation:
==========
Baseline Paperwork Requirements
Standard operating procedure is required for the pressure test. The documentation will
include:
- Date of Test, Drawing number for the vessel, Location of the test, Test pressure/temperature
- Test fluid, Design temperature, Test Personnel, Reference to the vessel design documentation
- Test description and procedure, Procedure to be followed if leaks develop during the test
- Safety controls (Barricades, Warning signs, Evacuation area)

Portable Works Limited/hydro.test….continued

At the completion of the test a pressure test label must be affixed to the pressure
vessel.

Information on the label must include:

• Drawing #, Working pressure/temperature, Working fluid, Test technician, Date.

Procedure for Pressure Testing:

Locating Toolboxes, Testing and Spotting Equipment:
 Insure that toolboxes are in a proper location and that it will not be a hazard to
personnel’s and/or SIMOPS, minimize tripping hazard and tight application.
 When taking equipment out of toolboxes insure that proper lifting procedures are
followed.
 On the Hydrostatic test pump, ensure that the air regulator is in the “OFF”
position.
 Air Supply: Locate air supply before connecting air hose and inspect air hose for
cracks or any other damages that may cause damage to personnel and
equipment. TAG this end of the line “Used by Portable Works”.
 Water Supply: Locate the water outlet and inspect the hoses for damages and
suitability. Tag this end of the line “Used by Portable Works”.
 Warning Signs: Install signs indicating “Pressure testing in Progress”;
A caution sign will be put up to indicate the hazards, company, and activity,
contact and phone number.
 Caution Tape: Where the test equipment is set up, caution off area where work
station is being set up ensure that caution tape is wrapped around ALL hoses so
as to minimize the chances of causing a tripping hazard.
 When spotting equipment, verify with on-site supervisor, the lines or systems to
be worked on.
 Scaffolding: Before locating the test equipment insure that scaffolding is
inspected and is tagged of. If the job is above 6 ft a life harness must be worn.
Inspect life harness before putting on; again use proper lifting technique when
moving equipment. Use rope to get equipment on scaffolding and inspect rope
before using, when all equipment is lifted and put on scaffolding.
 The Manifold: This will be tested and certified.
The Safety Relief Valve with cert. will be set to 10% over the test pressure. There
will be 8 x 10000 psi needle valves on each port (3 will be used for instrument
hook isolation (2 for Chart Recorder which will also have the Gage) for and 3 will
be for “bleed offs” and one of these will be used for the installation of the
Pressure Relief Valve). (Note: This connection must have a shutoff valve so that
the system being tested can be isolated from the pressure source). There will be a
calibrated Gage attached to the manifold to monitor the test pressure. ALL
VALVES WILL BE CLOSED.
 Portable Works Limited/hydro.test……..continued

 Location of each joint or connection which needs to be inspected during the

hydrostatic test is to be noted. (Note: each connection must be readily visible; i.e.,
no paint on welds, no insulation etc).
 Location of high and low point drains for the test (Required only for hydrostatic
tests - high point drain is required to assure that all compressible gas is removed
from the system prior to testing. Depending on the system, more than one high
point drain may be required. Low point drain(s) are required to assure that the test
medium is removed from the system).
 Hooking up the Hydrostatic Test Equipment:
Run and connect air-hose to air supply and water-hose to water-hose intake and
secure using whip checks and safety pins.
 Hooking up the Test Hoses:
1st: Using one test hose, hook one end off of the test pump and run the other end
to the Pressure testing manifold.
2nd: Using another Test Hose line connect from the manifold to the Chart
Recorder.
3rd: Using the last Test Hose, run from the manifold discharge to the Vessel being
hydrotested.
4th: The temperature probe coming off of the chart recorder will be connected to
another port on the manifold.
 Hooking up the Pressure Relief Valve:
 5th: Install the Pressure relief Valve to another “Bleed off”.
 Use thread seal on all mechanical fittings or where applicable.
 Before you get confirmation to go ahead and pressurerize system, ensure that all
loose tools are properly placed in a tool pan after machine in set up and ready to
run.
 Double check everything before you get the “ok” to go ahead, when you get the
thumbs up to go ahead start the pressuring system make an announcement on
PA System (see procedure attached).
 Escape Route: Before pressurizing a test section, the Contractor shall ensure
that all safety precautions have been met, and that sufficient personnel are
available to meet contingencies.
 Certification: Verify equipment certification and “Fit for use”.
 TEST PACK; Verify that the “Test Pack” documents are on site.
 Test Pressures: Verify values to be used as test pressures.
Portable Works Limited/hydro.test……..continued

APPLICATION OF TEST PRESSURE


 1st: Open the Water fill inlet valve supplying water to the Hydrostatic test pump.
 All VALVES on Manifold ARE still IN THE CLOSED position.
 2nd: Open the “HIGH POINT” Drain Valve.
 3rd: OPEN the Inlet Valve (leading into the Manifold), and
 4th: OPEN the Discharge Valve (Leading from the Manifold into the vessel to be
pressure tested).
 5th: Open the block valve leading to the “Relief Valve”.
 The vessel will begin filling under normal water pressure.
 6th: When the water fills the vessel, the “HIGH POINT” drain will overflow
indicating that the vessel is full and that the all compressible gas has been
removed from the system. CLOSE the “HIGH POINT” bleed valve .
 7th: Chart Recorder: Install pen and the recorder chart in the chart recorder and ser
pen to zero.
 8th: Open valves leading to the chart recorder and temp. probe so as to fill this test
line so that when the chart recorder is put in operation there will not be a pressure
drop.
 9th: Open the Air supply valve supplying air to the Hydrostatic Test pump.
 10th: Starting Hydrostatic Pump: Open the regulator at which time the system will
begin pressurizing. The pump will operate and pump water under pressure, and
the test pressure shall be gradually increased in the system to not more 25% of the
final test pressure
 11th: Thereafter, the pressure shall be increased in steps of approximately 25% of
the test pressure and hold for 5 minutes at each interval until the required pressure
has been reached.
 12th: Once the pressure has been achieved and stabilizes (at least ten minutes) the
system must be isolated from the pressure source by CLOSING the Valve leading
from the Pump into the manifold.
 13th: Close the air supply valve supply air to the Pump.
 14th:The other valve on the Discharge end will remain OPEN.
 The chart recorder will be recording the charge in pressure since the valve
leading into the chart recorder has been opened.
 When required Chart time has been lapsed and test pressure period is
accomplished begin “BLEED DOWN” process/depressurization.
 Portable Works Limited/hydro.test…..continued.

DEPRESSURISATION
 On interruption of testing for repairs, or on completion of TEST the pressure in
the test section shall be reduced at a moderate rate.
 1st: Open the “High Point Drain” valve. This will discharge water to the drain. This
is left open until test pressure in the system reads “zero”.
 2nd: Then open bleed valves on the manifold to remove any further trapped
pressures in the system.
 3rd: Remove Chart paper from chart recorder.
 4th: Close off water fill line from the inlet to Hydrostatic test pump. The air supply
line will have been already closed.
 5th: Bleed off valve from Pump discharge to manifold to remove pressure in this
segment of pump.
 6th: Remove pump.
 7th: Disconnect the discharge hose and all pressure hoses from/on manifold.
 Before any work is carried out to remedy leaks on valves or fittings the pressure
shall be reduced to a value such that the highest point of the test section is just
above atmospheric pressure, to prevent ingress of air. Before welding or cutting,
water shall be removed by draining back.
 The test pressure shall not be retained for transfer to another section.
 Test plots and record charts shall be signed before and after each test by the
Contractor and the Engineer.
 On completion of test, return all instruments to respective storage and ensure
proper house keeping before leaving workstation.
 Prepare all documentation and handover test package to customer.

Great care must be taken when disconnecting pressurized equipment. The pressure
gauge on the pressure side must never, under any circumstances be disconnected
before depressurization is completed.