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11 steps to prepare a hydrotest package


🧪 Hydrostatic Test Package Preparation Guide

Inspection Point in ITP – QA/QC Controlled Document

🔧 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.

📦 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.

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.

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.

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.

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.

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.

7. Material Traceability

  • Ensure all materials and spools are traceable.

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

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.

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.

10. Temperature Record (Optional)

  • Record ambient temperature or water temperature during testing.

  • Useful for justifying pressure drops due to temperature changes.

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.

📤 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.