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)