Hydrotest Procedure & Records

Applicable to All QCS Products

Hydrostatic Pressure Test Procedure

for

Full-Body and Annulus Testing

of

Quality Connector Systems, LLC Products

1. Purpose
Quality Connector System, LLC (QCS) Products designed with internal sealing systems
may be subject to hydrostatic pressure testing as part of their manufacturing
qualification program. Further, any QCS product that requires strength or seal
performance testing as part of their manufacturing program or installation qualification
regiment may also be subject to hydrostatic pressure testing. The purpose of this
procedure is to define the equipment, setup, and personnel required to perform a
hydrostatic pressure test acceptable to Quality Connector Systems, LLC.
2. Scope
This procedure is applicable to internal pressure testing of all QCS products with
potable water or other incompressible liquid. This procedure may only be incorporated
following a proper engineering review of the proposed test configuration, inclusive of
pressure pump, hoses, connections, closures, and pressure-sensing instrumentation.
This procedure shall NOT be used for any compressible testing media.
3. Definitions and Directives
The following definitions are applicable to this procedure:
QCS: Quality Connector Systems, LLC as a company or as a duly-authorized
individual representing the interest of Quality Connector Systems, LLC.
Customer: The purchaser of QCS components; as a company or as an
authorized individual representing the interest of the purchaser.
Test Sample: Any QCS product being hydrostatically tested, either by the
application of annulus pressure or by internal bore pressure.
Test Parameter: At a minimum, the test parameter shall be internal pressure.
Other reference parameters may be required such as temperature, displacement,
or frequency (counters). When required, the reference parameters shall be
specified on the Hydrostatic Test Requirements form; all information for each
parameter shall be properly specified and reviewed prior to test initiation.
Hold Time or Period: The time required at or above target pressure. During the
hold time, pressure may be vented to prevent damage to the test sample and test
instruments, but pressure may not be increased by pumping without restarting
the hold period.
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Recording Time or Period: The time during which all specified test parameters
shall be recorded. As a minimum, the recoding period shall begin just prior to
pressurization of the test sample and shall continue until just following complete
depressurization of the test sample.
Instrument Certification: All Instruments shall be certified in accordance with
the latest revision of QCS Calibration and Certification Policy, 0210-CCP.
Pressurizing Equipment or Device: Any liquid pump or other pressureproducing device capable of supplying sufficient pressure to achieve the required
minimum test pressure. This pump may be hand-, electric-, or pneumaticoperated. Certification is not required.

4. Test Setup and Safety Requirements

As general rules, the following requirements shall apply to all test arrangements unless
otherwise specified by QCS Engineering and noted on the Hydrostatic Test
Requirements and Records form:
Test instruments and recorders used to indicate or record test parameters shall
be plumbed or otherwise connected directly to the test sample. No valves (or
switches for electrical instruments) shall be installed between the sample and the
sensing instrument.
A block valve should be installed in the pressure hose between the test sample
and the pressurization device to allow for removal of the pumping device during
the hold period if required by Customer or equipment demands for other projects.
A vent valve shall be provided that is plumbed directly to the test sample
exclusive of any venting feature provided as part of the pressurization device.
The venting line shall be connected to the test sample in such a manner as to
allow for complete liquid filling of the sample to eliminate contained air.
Quick disconnect fittings should be avoided in any pressurized plumbing between
the block valve at the pressure source and the test sample to avoid possible leak
paths.
Pressure test hoses shall be rated at least 50% higher than any anticipated test
pressure. The hoses shall be inspected prior to every test and shall be free of
abrasions, kinks, and other injurious defects that could reduce their capacity.
Damaged hoses, fittings, valves and other items that are exposed to testing
pressure shall be rendered unusable and discarded or tagged for repair.
Hoses and other plumbing shall be of sufficient length to allow personnel to
operate and monitor test equipment a safe distance from the test sample (the
safe zone).
The Hydrostatic Test Requirements and Records form shall illustrate the test
setup inclusive of safe zone. Potential safety risks shall be listed, reviewed,
remarked, and approved prior to test initiation.
The following block diagrams illustrate acceptable test plumbing arrangements. Other
arrangements may be suitable, but must be reviewed by QCS Engineering prior to test
initiation.
NOTE: Although outside of the scope of this procedure, the test arrangement should provide for a
suitable drain valve and outlet, low on the samples body, to allow for complete drainage of the test media
after test completion without creating a hazardous condition. Further, if the media is anything other than
potable water, responsibility must be taken for proper recovery and disposal or processing of the
media.
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Recorder

Indicator

Media Source

Pressurization
Device
Test
Sample
Isolation
Valve

Vent
Valve

Typical field testing arrangement test sample remotely located from testing equipment.
Indicator
Vent
Valve

Media Source

Pressurization
Device

Recorder

Test
Sample
Isolation
Valve

Typical shop testing arrangement all components in relative close proximity.

5. Hydrostatic Pressure Test Sequence

5.1. Complete and review the Hydrostatic Test Requirements and Records form for
the particulars of the test.
5.2. Select appropriate instrument(s) and recorder(s) and verify certification
validity, range, and accuracy. Select appropriate valves, hoses, and fittings
and inspect for proper rating and absence of defects.
5.3. Plumb the test arrangement in a manner sufficient to achieve the directives of
this procedure. Insure that all connections are sufficiently tight to contain the
anticipated pressure, but not so tight as to damage the fittings.
5.4. Fill the sample by any suitable means avoiding excessive spillage of test
media that might impede leak detection.

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Note: Potable water shall be the preferred test media provided the test sample is
disassembled, cleaned, dried, and reassembled following the hydrostatic
pressure test with all post-hydrotest activities monitored by Companys inspector.
If the test sample is not to be disassembled and processed as above, the test
media shall be water with added corrosion inhibitor to prevent surface and pitting
corrosion.
5.5. After filling, finalize plumbing arrangement and purge the test arrangement of
all air by operating the pump (pressurization device) with the vent valve open.
When all air has been purged, stop the pump and close the vent valve.
5.6. Initiate recording of pressure and other test parameters. Note initial time,
pressure, and other parameters on the Hydrostatic Test Requirements and
Records form.
5.7. Verify that the test area is secure from casual entry and that all personnel not
involved in the test are a safe distance from the test arrangement.
5.8. Begin pressurization of the test sample at a safe and appropriate rate that
allows for legible scribing of the pressure or other test parameter on the
recorder and monitoring and reacting by the test technicians.
5.9. Once the pressure target is reached, cease pumping, close the isolation valve,
and record the time and all test parameters.
5.10. Monitor the test pressure for sufficient time to verify that the pressure has
stabilized. If pressure must be increased due to pressure settling:
5.10.1. record the pressure and other test parameters on the Hydrostatic Test
Requirements and Records form before opening any valve,
5.10.2. open isolation valve and apply additional pressure, and
5.10.3. record the pressure and other test parameters on the Hydrostatic Test
Requirements and Records form after closing all valves.
5.10.4. Once stabilization of the test sample has been achieved, record the time
and all test parameters on the Hydrostatic Test Requirements and
Records form and note TEST START in the comments beside that line
entry.

NOTE: Determination of a stabilized condition is to be at the discretion of the

hydrotest technician. However, if pressure drops below the minimum test pressure for
any reason after a TEST START condition has been declared, the sample must be
repressurized and the test hold period restarted in accordance with step 5.10, above.

5.11. Monitor and report the tests progress at periodic intervals throughout the hold
period. If the hold period is less than one hour, record the time and test
parameters at least three (3) times between the start and end of the hold
period. For longer hold periods, record the time and test parameters at
uniform, periodic intervals throughout the hold period at least seven (7) times
between the start and end of the hold period.
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5.12. If pressure decrease below the minimum target pressure at any time during
the hold period, the test shall be terminated, adjustments to test sample or
arrangement shall be performed, and the entire test sequence repeated. If
pressure increases above the upper test pressure limit, pressure may be
vented from the sample without restarting the hold period provided that the
minimum target pressure is not compromised.
5.13. At the completion of the hold period, record the time and all test parameters
prior to opening any valve.
5.14. Open the vent valve slowly and establish a safe and appropriate pressure
reduction rate that allows for legible scribing of the pressure or other test
parameter on the recorder.
5.15. Once the pressure has achieved an ambient state, record the time and all test
parameters.
5.16. Complete the test sequence by applying signatures of test technician and all
witnesses on the Hydrostatic Test Requirements and Records form and on the
recorder chart (if applicable). In addition, note test start and end information at
their proper position on the recording chart.
5.17. Drain the test sample of all test media and completely derig the test
arrangement and properly store all equipment.

6. Test Documentation
The test shall be properly documented by compiling a dossier containing the following
items:
Duly completed and signed test recording (chart, strip, or graph),
Duly completed and signed Hydrostatic Test Requirements and Records form,
Calibration documents for test indicators and recorders used throughout the test,
Calibration documents for any transfer calibration standards used to certify test
indicators and recorders, if applicable, and
Copies of release notes or other documents produced by customer or third-party
witnesses, if applicable.

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