11 steps to prepare a hydrotest package

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🧪 Hydrostatic Test Package Preparation Guide

Inspection Point in ITP – QA/QC Controlled Document

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🔧 General Requirements

Hydrostatic testing is an essential inspection activity listed in the Inspection and Test Plan (ITP). Before performing a hydrotest, the following conditions must be fulfilled:

• The hydrotest procedure has been approved by the client and/or consultant.

• All welding activities within the test boundary must be completed and inspected by all parties.

• Non-Destructive Testing (NDT) must be performed according to the project specification, with acceptable results.

• All relevant documentation must be collected for inclusion in the test package.

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📦 11 Steps to Prepare a Hydrotest Package

1. Cover Page

• Include project name, client, contractor, system name, line class, and test type.

• A sample form can be customized to suit your project format.

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2. Content Sheet

• Provides a summary index of documents included.

• Pre-fill standard information (e.g., project name, test type) in templates to save time.

• Forms may be typed or handwritten at the site, depending on project practice.

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3. Pre-Test Checklist

• Conduct this jointly with the client before pressurization.

• Items include valve positions, flange bolt checks, blinds installed, supports in place, etc.

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4. Line List

• Include spool numbers, line numbers, service description, test pressure, and length.

• Inspector must check and sign each spool on the drawing.

• Use only approved drawings to prepare the test list.

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5. Line Check

• Verify all piping spools are installed per the approved drawings.

• Mark or highlight test spools on isometric drawings and P&IDs.

• Confirm valve direction, check valve orientation, and isolate components not to be tested.

• Submit flagged drawings for client verification and signature.

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6. Welding Data

• Include welding summary logs (WPS/PQR/WPQ) and NDT reports (RT, MT, PT, etc.).

• All visual and dimensional inspections should be satisfactory before pressure testing.

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7. Material Traceability

• Ensure all materials and spools are traceable.

• Maintain MTCs and spool traceability records as part of the QA requirement.

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8. Pressure Test Certificate

• Record actual test pressure, date/time, duration, and hold period.

• Use calibrated pressure gauges (within 6 months).

• Install two gauges: one at the highest point and one at a visible point for monitoring.

• Gauge range must be 1.5 to 4.0 times the test pressure per applicable code.

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9. Pressure Chart Recorder (if required)

• Attach the pressure chart to the package for test record verification.

• Record should reflect start/hold/end time and pressure trend.

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10. Temperature Record (Optional)

• Record ambient temperature or water temperature during testing.

• Useful for justifying pressure drops due to temperature changes.

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11. Punch List

• Include any outstanding work or comments found during pre-test or testing.

• If no issues are found, create a "no comment" punch list endorsed by the client.

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📤 Test Package Submission

Submit the complete hydrotest dossier to the client or third party for review and approval. The typical contents include:

• ✅ Cover page

• ✅ Hydrotest instruction or method statement

• ✅ Pre-test checklist / Line check record

• ✅ Line list

• ✅ Marked P&ID and Isometric drawings (highlight test area)

• ✅ Material traceability records

• ✅ Welding summary and NDT reports

• ✅ Pressure test certificate

• ✅ Calibration certificates (pressure gauge, chart recorder, thermometer, etc.)

• ✅ Photos of gauge reading at start/end of test (if required)

• ✅ Final punch list (with or without comments)

💡 All documents should be scanned and compiled into a single PDF file for submission.

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