🧪 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.

ASM Handbook Set (33 Volumes + Index)

Volume 1: Properties and Selection: Irons, Steels, and High-Performance Alloys

Volume 2: Properties and Selection: Nonferrous Alloys and Special-Purpose Materials

Volume 3: Alloy Phase Diagrams

Volume 4: Heat Treating

Volume 4A: Steel Heat Treating Fundamentals and Processes

Volume 4B: Heat Treating Technologies (shipping October 2014)

Volume 4C: Induction Heating and Heat Treating

Volume 4D: Heat Treating Irons & Steels (shipping October 2014)

Volume 5: Surface Engineering

Volume 5A: Thermal Spray Technology

Volume 6: Welding, Brazing and Soldering

Volume 6A: Welding Fundamentals and Processes

Volume 7: Powder Metal Technologies and Applications

Volume 8: Mechanical Testing and Evaluation

Volume 9: Metallography and Microstructures

Volume 10: Materials Characterization

Volume 11: Failure Analysis and Prevention

Volume 12: Fractography

Volume 13A: Corrosion: Fundamentals, Testing, and Protection

Volume 13B: Corrosion: Materials

Volume 13C: Corrosion: Environments and Industries

Volume 14A: Metalworking: Bulk Forming

Volume 14B: Metalworking: Sheet Forming

Volume 15: Casting

Volume 16: Machining

Volume 17: Nondestructive Evaluation and Quality Control

Volume 18: Friction, Lubrication, and Wear Technology

Volume 19: Fatigue and Fracture

Volume 20: Materials Selection and Design

Volume 21: Composites

Volume 22A: Fundamentals of Modeling for Metals Processing

Volume 22B: Metals Process Simulation

Volume 23: Materials for Medical Devices

Comprehensive Index to ASM Handbooks, Third Edition

Format: Hardbound, 33 Volume Set + Index

Publisher: ASM International

Published: 2014

Order at https://www.asminternational.org/books-handbooks/

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