GENERAL LEAK TEST PROCEDURE

PROJECT :

EQUIPMENT NAME : N/A

EQUIPMENT NO. : N/A

PMT NO. : N/A

APPROVALS
NAME SIGNATURE DATE
Prepared by;

Reviewed by:

Approved by;

REVISION RECORDS
REV DATE ISSUE REVISION DESCRIPTION

00 27 AUGUST 2009 For Review & Approval

01 30 NOVEMBER 2009 For Review & Approval

02 7 DECEMBER 2009 For Review & Approval

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TABLE OF CONTENTS

ITEM DESCRIPTION PAGE

1.0 PURPOSE 2

2.0 SCOPE 2

3.0 REFERENCE CODES & STANDARDS 2

4.0 PROCEDURE 2

5.0 ATTACHMENTS / WORK FLOW 4

6.0 TESTING EQUIPMENT 6

7.0 STANDARD OPERATING PROCEDURE 6

8.0 ATTACHMENT 7

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1.0 PURPOSE

The purpose of this procedure is to ensure there is no leak at any equipment and to
perform pressure testing rarely and in accordance with technical standard and meet
the requirement.

2.0 SCOPE
This procedure covers the minimum requirement for Leak Test on equipment Heat
Exchanger, Air Fin Cooler and Piping as part of work completion acceptance criteria.

3.0 REFERENCES CODES & STANDARDS

3.1 ASME VIII Div. 1

3.1.1 UG-100, “Pneumatic Test”
3.1.2 UG-99, “Standard Hydrostatic Test”

3.2 ASME B31.3

3.2.1 Chapter VI, “Inspection, Examination, and Testing – Clause
345”

4.0 PROCEDURE

The minimum hydrostatic test pressure for pressurized piping systems should not less
than 1.5 times the design pressure unless otherwise state and for the equipment
pressure is no less than 1.3 times of the design pressure. For pneumatic test, the
minimum test pressure for pressurized piping system and equipment should not less
than 1.1 times the design pressure.

4.1 When the equipment is prepared and found ready for the test, it should
be thoroughly checked and approved by the Client.

4.2 Barricade the equipment area with signage of Hydrotest in Progress,

before any application of pressure.

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4.3 Vents shall be provided at all high points of the equipment in the
position in which it is to be tested to purge possible air pockets while
the equipment is being filled.

4.4 A pump shall be connected to the equipment to be tested and shall be

controlled by a valve with a sufficient pressure rating.

4.5 Two pressure gauges with range 1.5 to 4 times of Test Pressure shall
be installed on the lower and high points of the equipment (location to
be verified at site). The indicating gauges shall be visible to the
foremen to controlling the pressure applied. All pressure gauges shall
posses a valid calibration certificates.

4.6 Fill up the equipment with potable water with Chloride contents shall
not exceed 30 PPM for testing Carbon Steel equipment. For Austenitic
Stainless Steel/300 Series Material, Chloride contents shall not exceed
50PPM. Immediately flushing will carry out with demin water for
Austenitic / 300 Series Material to avoid from corrosion.

4.7 Let the water flow out for a while to ensure there should be no air
pocket left in the equipment. Wipe out all the remaining at the
checking point. This will help for easier leak detection.

4.8 Pressure-up the equipment slowly until it reached 10% of test pressure
value, hold for 5 minutes. Check equipment for any sign of leak during
the process.

4.9 Pressure-up the equipment slowly until it reached 70% of test pressure
value. Hold for 5 minutes. Check equipment for any sign of leak
during the process.

4.10 Pressure-up the equipment slowly until it reached 100% of test

pressure value. Hold for 30 minutes. Check equipment for any sign of
leak during the process.

4.11 Liaise Client personnel to inspect and witness the Hydrotest activities.
If any leak found or fail the test, equipment shall be repair and to do
the test again until a successful test is attained satisfactory.

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 4.12 If the test was found successfully and the result is satisfied by Client
release the pressure upon permitted by him.

4.13 Gradually release the pressure at least 2/3 from test pressure value.
Hold for 5 minutes. Call Client personnel to visually check.

4.14 Gradually release the pressure until zero prior to remove all temporary
blinds and valves.

4.15 All data shall be recorded in Hydrostatic Test Record inclusive but not
limited:

a) Equipment Tag No

b) Equipment Name

c) Design Pressure

d) Test Pressure

e) Test Medium (Water/Air)

5.0 ATTACHMENTS / WORK FLOW

Pressure

Test Pressure 100 %

2/3

Design Pressure 70%

10%

0 5min 5min 30min 5 min HoldingTime

Pressure Test Chart

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 Vent
Pressure
Gauge

Pressure
Gauge

Water Inlet

Equipment Hydrotest Diagram

Pressure
Gauge

Concerning point
- Air trap/air bubble
suspected at this point

Pressure
Pressure Gauge
Gauge

Piping Hydrotest Diagram

6.0 TESTING EQUIPMENT

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 6.1 Pressure Gauge
6.2 Pressure Pump
6.3 Recorder

7.0 STANDARD OPERATING PROCEDURE (S.O.P)

7.1 Before commencing any work, supervisor shall ensure PTW has been
applied, approved and validated for the activities.

7.2 All workers shall wear a proper PPE as stated or comply with JSA or
PTW before commencing any activities.

7.3 Ensure that trained/ competent worker is put on standby together with
calibrated pressure gauge, test blind, chart recorder( if required ), water
pump at working area.

7.4 QA/QC Supervisors ensure that all calibrated pressure gauge are not
expired and have a valid calibration certificate.

7.5 All electrical hand tools, cables, hoses and equipment must be in good
condition, safe for use and shall be inspected & approved by Client
prior to use.

7.6 All electrical cables and hoses must be secured properly to prevent
tripping hazard.

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