TEST PROCEDURE

HYDROSTATIC IN STEEL PIPES

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 Index
Index...................................................................................................................................2
Hydrostatic Test Operator..............................................................................................3
Security Supervisor........................................................................................................3

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1. AIM
Describe the procedure and considerations that must be taken into account during
the performance of the Hydrostatic Tests to which the manufactured pipe and spool
systems will be subjected.

2. SCOPE
This procedure applies to all personnel who will be involved in hydrostatic testing of
piping systems made of carbon steel material of any diameter.

3. REFERENCES

▪ ASME B31.3:2010 Process Piping.

▪ API STD 1104:2010 Welding of Pipelines and Related Facilities.
▪ API-RP-1110 Recommended Practice Pressure Testing of Liquid Petroleum
Pipelines

4. RESPONSIBLE
Quality control supervisor
▪ Responsible for enforcing what is established in this procedure.
▪ Guarantee compliance with the quality requirements, codes and reference
standards applicable in this procedure.
▪ Carry out the quality inspections established in the Inspection Point Plan
and in this procedure.
▪ It will generate all the protocols and/or records established in each activity
in order to validate the work that is carried out.

Hydrostatic Test Operator

▪ Main person responsible for complying at all times with the procedure and
quality standards established in this document and applying it to all personnel
under their charge.
▪ Coordinate with the Quality Supervisor, compliance with the established
control parameters and consult with him if you have any questions.
▪ Remain alert at all times to any variation in the
working conditions and immediately report them to the supervisor in charge.
▪ Carry out the splicing, unsplicing and adaptation maneuvers
facilities for carrying out the tests.

Security Supervisor
▪ Identify potential dangers in the stages of work in order to execute the activities
with the necessary measures to prevent the risks they may cause.
▪ Inspect that collaborators have their personal protective equipment, as well as
other needs to carry out the work safely.

5. STAFF QUALIFICATION
The quality supervisor must have a Level II certification in visual welding inspection,
according to the ASNT Recommended Practice RP-SNT-TC-1 A of the American
Society for Non Destructive Testing (ASNT).
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6. TERMS AND DEFINITIONS
▪ PH: Hydrostatic Test
▪ Pressure: Force exerted by a gas, liquid or solid
 ▪ Rod: Duct made up of two or more welded tubes.
▪ Spool: Set of pipes and accessories (elbow, tee, flanges) joined by welding
or flanges and that form part of a piping system, Scraper traps or pipelines for
transporting hydrocarbon or some other fluid.
▪ Welded Joint: refers to the weld bead made as a result of a welding
process, in which two materials with similar or different characteristics intervene.
▪ Hydrostatic test head: Element used to make connections to high
pressure, measurement and fluid feeding equipment.
▪ Hydrostatic test shaft: Threaded elements used to make connections to
high pressure, measurement and fluid feeding equipment

7. EQUIPMENT AND TOOLS

▪ Manometer with current calibration.
▪ manual water pump
▪ Check Valves, Ball.
▪ Blind flanges, blind plates.
▪ Hammer, square and level
▪ Teflon tape, gaskets.
▪ Mixed keys.
8. TEST DESCRIPTION
Sequence:
a) Installing measurement accessories to test heads or shaft
b) Previous filling of the Rod and/or Spool.
c) Temperature and pressure leveling and stabilization.
d) Proof
e) Depressurization.

9. PROCEDURE
9.1 PREPARATIONS FOR THE TEST:
To carry out the hydrostatic tests of rods and spools, the manufacturing and/or
modification process must have been completed and the welded joints must
have been inspected by NDT (if required), which must have been approved by
the applicable code, having released the Rod or Spool.
All piping systems shall be cleaned prior to testing by passing water or
pressurized air to remove dirt, burrs, or loose foreign matter. All control valves
will be removed during flushing.
It must be ensured that the pipes are completely clean inside before starting the
Hydrostatic Test.
Field paint or insulation shall not be applied to flanged joints, threaded
connections, untested welds, and weep holes until the system has been
successfully tested.
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All welded, threaded or flanged joints shall be uncovered and exposed for inspection.
During the Hydrostatic Test in piping systems it must be verified that the installed valves
must be fully open and must be above the test pressure.
For the installation of threaded accessories, only Teflon tape should be used, in no case
use any other material.
Any equipment or section of pipe that should not be subjected to the test must be
disconnected and replaced with a piece of pipe (Reel), or be isolated from the pressurized
zone by means of a valve or blind flange.
All systems being tested hydrostatically shall be purged of air using high point vents prior to
applying test pressure. Pipe installed with springs or counterweights shall be temporarily
supported at points where the weight of the test fluid could overload the supports.
Keep in mind that lines open to the atmosphere, such as vents, safety valves and drains,
after the last shut-off valve, do not need to be subjected to leak tests. Gaskets will be
visually inspected for proper installation.
The final weld connecting piping systems or components which have been successfully
tested will not need to be hydrostatically tested since the weld is examined during
fabrication in accordance with and passes 100% radiographic examinations or tests. 100%
ultrasonic.

9.2 TEST FLUID.

The fluid must be fresh water with prior approval from the Client/Supervision.

9.3 TEST PRESSURE.

The required hydrostatic test pressure should not be greater than 1.5 times the design
pressure. Taking into account that the maximum design pressure is 150 PSI. The test
pressure at any point in the piping system shall be 225 PSI.

9.4 TEST MANOMETER

The pressure gauge should be graduated within a range of approximately 2 times the test
pressure and should not be greater than 4 times the test pressure. The pressure gauge
must be contrasted and verified with its respective calibration certificate issued by a
laboratory certified by the National Quality Institute (INACAL).

9.5 FILLING OF THE TEST SECTION.

The water filling of the section of pipe to be tested will be by pumping from a lower level to a
higher level. The vent valves must be open during the filling process to eliminate all air.
Once the filling of the section is complete and before starting the pressurization, the supply
system will be disconnected and all valves will be closed and, if necessary, with blind or
threaded covers.
At the same time, the stabilization test will be carried out, in order to ensure that there is no
air trapped in the pipe that prevents the execution of a correct hydraulic test.
The thermal balance in the Varillon will be controlled using an ambient thermometer to
record temperatures (Pyrometer).

9.6 PRESSURIZATION AND TEST PERIOD

▪ Once the tasks stated above have been completed and the Rod and/or Spool have
been connected to the pressure and temperature instruments, the internal pressure

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 of the Rod and/or Spool will begin to rise without causing vibrations, through the use
of a high pressure pump. , the internal pressure will be increased in stages, first to
30% of the test pressure waiting for about 2 minutes for stabilization, then the
pressure will be raised to 70% of the test pressure waiting again for 2 minutes for
stabilization and finally increasing the pressure until reaching the test pressure. The
pumping speed must be regulated to minimize pressure variations.
▪ Once the test pressure has been reached (225PSI), 20 minutes will be allowed for
pressure stabilization. After 20 minutes of parameter stabilization, pressure
recording will begin for a period of 2 hours.
▪ Pressure and temperature data will be recorded at 15-minute intervals throughout
the test, until the end of the test in the Hydrostatic Test log GCOP.FO.007.
▪ No worker should be in the line of fire of the test when the section is being
pressurized.
▪ The existence of leaks or water losses will be visually verified. Once it is confirmed
that they do not exist and the time defined in the procedure has elapsed, the test is
considered accepted.
▪ In case of failure or loss during the test, a failure report will be made as indicated.
▪ Once the loss is detected, the water will be evacuated from the Varillón to proceed
with its repair and subsequently carry out a new hydrostatic test.
▪ In the event of a loss of pressure, the point of failure or water leak will be located
(accessory base material, welded joint or flanged joint). Once the point of failure or
water leak has been located, the water will be depressurized and evacuated. section
to proceed with its repair. After the repair, the process will be repeated from item
8.4.
▪ Once the testing time has concluded, the record of hydrostatic tests will be validated
with the signatures of those responsible for the execution.
9.7 PRESSURIZATION AND TEST PERIOD.
▪ After obtaining satisfactory results in the hydrostatic test and when all the data
obtained has been duly recorded and documented, the drainage valves will be
opened to eliminate the water from the Varillón, taking the safety measures required
for this task, considering it advisable to lower the pressure in a stepwise manner (if
possible in the same way as the pressure was increased).
▪ If the topographic conditions allow emptying by gravity, you may choose to start
emptying in this way. In all cases, the water will drain through a pipe that, leaving
the purge valve, will go down to ground level, exiting horizontally until its final
discharge.
9.8 ACCEPTANCE REQUIREMENTS.
Leaks will not be allowed in any part of the pipe, so it will be checked that the tested
section is completely dry, which must be checked by the authorized inspector.
The Hydrostatic Test is satisfactory if it is leak-free at the Hydrostatic test pressure and if
the pressure does not drop to more than 5 PSI, within the established test period. If the
test pressure exceeds 5PSI in a period of 1 (one) hour, and this pressure loss cannot be
attributed to temperature variations due to any external agent, it is evident that a leak
exists, therefore the tested pipe will be rejected. . It is not necessary to monitor the
temperature during the test, since it is carried out at all times at room temperature.

10.IDENTIFICATION OF HAZARDS AND ESTABLISHED PREVENTIVE

MEASURES
Verify that during the required leak testing of components and welds, adequate protection is
provided to prevent injury to persons and damage to property from dislodged fragments,

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blast waves or other consequences that may occur due to a system failure. pressurized.

ITEM DANGERS AND/OR RISKS PREVENTIVE AND CONTROL MEASURES

1 Breakage of connectors, slips
and impacts
• Previous inspection of hydraulic hose
connectors.
• Only authorized personnel may be in the
hydrostatic test area.
• Use hoses in good condition and suitable for
the pressure to which it will be subjected.
• Check the tightness of the valves, inspect
the gaskets or if there is any water liquid,
warn the supervisor in charge before
performing the hydrostatic test.
• Non-destructive testing of the entire system
before the hydrostatic test.
• Quality test on the welded seams of the pipe
(butt and fillet seams, drainage, venting,
etc.).
• The necessary precautions should be taken
with the people involved in the test, in order
to avoid standing in front of to all
those items
removable or with moving parts (valve
stems, flanges, plugs, etc.) in the event of
the possibility that any of these elements
were expelled.
• Use of gloves, glasses, helmets, earplugs.

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2 High pressures (> 225
PSI)/ Shocks

• Install safety valves calibrated or set to the

test pressure and that are activated in case
of loss of pressurization control.
• Carry out inspection pre-use of
hoses, accessories,
couplings.
Hose must be according to test pressure.
• Chat of security to the worker
indicating specific risks, control measures
and correct and safe way of carrying out
the work.
• Locate evacuation routes and meeting
points, dissemination and compliance with
procedure specific for this
proof.
• Delimit the work area with tapes and
presence of a lookout.
• Check suitable accessories for
withstand the pressure required for the
hydrostatic test using a Hydrostatic Test
Release Checklist.
• Restrict pedestrian access, placing notices
"Caution High Pressure Pipe" and signaling
the area of influence.
• Pre-use inspection of the accessories to be
used, if they are not appropriate, change
them immediately.
• Maintain a safe distance from installation
workers, avoiding
outlet of the purge jet towards the face or
body during operation.
• To avoid incidents, depressurization must
be carried out moderately and constantly.
• The necessary precautions should be taken
with the people involved in the test, in order
to avoid standing in front of to all
those items
removable or with moving parts (valve
stems, flanges, plugs, etc.) in the event of
the possibility that any of these elements
were expelled.
• Have calibrated equipment during the test,
inspection check list and approval by
supervision before starting the tests.
• Carry out a
and
good inspection
identification of overpressures within the
hours that the work will last.
• Ensure that the valves are secured to the
pipe with a good glue.

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 • Pre-use inspection of the accessories to be
used, if they are not appropriate, change
them immediately.

3 Noise / Hearing Loss

• Hearing protector, trained personnel
knowledgeable about the operation.
4 • Carry out he
and
gathering,classification
Generation of solid waste/soil
disposal of waste generated in the work
contamination.
and dispose of it correctly.

11. FORMATS
The results of the examinations carried out will be recorded in the format called
GCOP.FO.007 Pipe tightness test.
A hydrostatic test folder will be presented for each circuit, which includes test
isometrics, Welding Book, Welding Map and P&ID diagram which must indicate the
individuality of each circuit, through the placement of flanges or blind plates.

HYDROSTATIC TESTS TO BE CARRIED OUT FOR COMPLETE SECTIONS (SPOOL)

ITEM FLAT ISOMETRIC SPOOL NO. OBSERVATIONS
1 RCS-0092-19-M-PL-105-H04 6"GOC-0101-B4 SPOOL 1 Individual hydrostatic test.
RCS-0092-19-M-PL-105-H05 6"GOC-0102-B4
2 SPOOL 2
RCS-0092-19-M-PL-105-H06 3"GOC-0107-B4 Individual hydrostatic test.
3 RCS-0092-19-M-PL-105-H07 4"GOC-0103-B4 SPOOL 3 Individual hydrostatic test.
RCS-0092-19-M-PL-105-H06 3"GOC-0107-B4
4 SPOOL 4
RCS-0092-19-M-PL-105-H08 4"GOC-0103-B4 Individual hydrostatic test.
5 RCS-0092-19-M-PL-105-H08 4"GOC-0103-B4 SPOOL 5 Individual hydrostatic test.
RCS-0092-19-M-PL-105-H09 4"GOC-0112-B4
6 SPOOL 6 Individual hydrostatic test.
RCS-0092-19-M-PL-105-H10 4"GOC-0104-B4
RCS-0092-19-M-PL-105-H10 4"GOC-0104-B4
7 SPOOL 7 Individual hydrostatic test.
RCS-0092-19-M-PL-105-H12 4"GOC-0104-B4
8 RCS-0092-19-M-PL-105-H11 4"GOC-0104-B4 SPOOL 8 Individual hydrostatic test.
9 RCS-0092-19-M-PL-105-H12 4"GOC-0104-B4 SPOOL 9 Individual hydrostatic test.
10 RCS-0092-19-M-PL-105-H13 4"GOC-0104-B4 SPOOL 10 Individual hydrostatic test.
11 RCS-0092-19-M-PL-105-H14 4"GOC-0104-B4 SPOOL 11 Individual hydrostatic test.
12 RCS-0092-19-M-PL-105-H15 4"GOC-0105-B4 SPOOL 12 Individual hydrostatic test.
13 RCS-0092-19-M-PL-105-H16 4"GOC-0104-B4 SPOOL 13 Individual hydrostatic test.

12. ANNEXES
▪ Annex N°1:GCOP.FO.007 Pipe tightness test.
▪ Annex N°2:GCOP.FO.005 Welded Joints - Welding book.
▪ Annex N°3:GCOP.FO.038 Welding Map.

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Annex N°1:GCOP.FO.007 Pipe tightness test.

PIPING AIR TIGHTNESS TEST Version: 01

CUSTOMER: DATE:
PROJECT: PLACE:
Test Location: Test Date: Test type: Hydrostatic
1. GENERAL INFORMATION Doc. reference: —L J.
Reference Plane: Pneumatic □ Others

Pipeline: Technical specification:

Trunk: —..
Secondary Branches:
Working Fluid: Work pressure:
Test Fluid: Test pressure:
2.-PARAMENTS Start Time: Final hour: TOTAL TIME:
Initial Pressure: Final Pressure: ΔP:
Temp. Amb. Of start: Temp. Amb. Final: ΔT:
Test Gauge: Pressure range:
Calibration certificate: Date of calibration:
3.- GENERAL OBSERVATIONS
4.- IMAGE/PHOTOS:

REGISTRATION RESPONSIBLE NAMES AND SURNAMES / POSITION FIRMS DATE

PRODUCED BY :
REVIEWED BY :
APPROVED BY :

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Annex N°2:GCOP.FO.005 Welded Joints - Welding book.

WELDED JOINTS (WELDING BOOK) Version: 01

CUSTOMER: PROJECT: DATE:

Code Element A Element B Report / Doc.

END (*)
Item WPS Used Welding Date Process Regarding NDT /
Applied
Observation
Welder Spool no. Board Description Ø" - e(mm) Pouring A Description Ø" - e(mm) Colada B

(*)END: Non-Destructive Tests: RX (Industrial Radiography), UT: Ultrasound Test, IV: Visual Inspection, LP: Penetrating Liquid
REGISTRATION RESPONSIBLE NAMES AND SURNAMES / POSITION SIGNATURE DATE
PRODUCED BY :
REVIEWED BY :
APPROVED BY :

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Annex N°3:GCOP.FO.038 Welding
Map. GCOP.FO.038

WELDING MAP Version: 00

PROJECT: ASSOCIATED DOCUMENT:
CUSTOMER: REGISTRATION Nº: DATE:

FINAL APPROVAL:
PRODUCED BY: REVIEWED AND APPROVED: APPROVED BY: APPROVED BY:

DATE: DATE: DATE: DATE:

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