Test pack template: free hydrotest test package with checklist and calculator (Excel and PDF)
Deskely Completions team Singapore
A test pack (or test package) is the file that holds everything needed to pressure test one section of piping: the lines and isometrics inside the test boundary, the test conditions, the checks that prove the section is ready, the test record and the list of spades and blinds fitted for the test. It is assembled before the test, signed during it and closed only when the line is reinstated.
This page gives you a free test pack template in Excel and PDF, with the test pressure worked out to ASME B31.3, and explains what goes in each part.
- One pack per test boundary: every line, isometric and P&ID in it listed on the index.
- Hydrotest to ASME B31.3: at least 1.5 x design pressure x St/S. Pneumatic: at least 1.1 x design pressure.
- Gauges and recorders are calibrated, in date and sized for the test pressure.
- Every spade and blind fitted for the test is registered, so every one comes out again.
What goes in a test pack?
| Section | What it holds |
|---|---|
| Cover and index | Pack number, system and subsystem, test medium and pressure, and a checklist of every document in the pack with its status. |
| Lines covered | Each line number with its size, spec, design pressure and temperature, and the isometric sheets and revisions. |
| Marked-up P&IDs | The test boundary drawn on the P&IDs, with test points, vents, drains, spades and the gauge positions. |
| Pre-test records | Weld log with NDT and PWHT accepted, the piping inspection checklist, and punch items that must close before the test. |
| Test pressure calculation | Design pressure, stress ratio and the minimum code test pressure, plus the pressure at the low point. |
| Test record | Gauges and recorder with calibration dates, the pressure and time log, the result and the witnesses. |
| Spades and blinds register | Every temporary isolation fitted for the test, with its location and who fitted and removed it. |
| Reinstatement | The line reinstatement checklist, signed before the pack is closed. |
The weld log is usually the longest part of the pack and the one most often incomplete. See the weld map and weld log.
The template
The Excel file has a sheet for each part of the pack. The calculator takes the design pressure and the allowable stresses and gives the minimum test pressure; the test record logs pressure and temperature against time, from the first stage to depressurising.
Test pressure to ASME B31.3
| Test | Minimum test pressure (B31.3 para 345) | Notes |
|---|---|---|
| Hydrostatic | 1.5 x design pressure x St/S | St/S is the allowable stress at test temperature over that at design temperature, not more than 6.5. Reduce the pressure if it would exceed yield at test temperature. |
| Pneumatic | 1.1 x design pressure | Preliminary check at the lesser of half the test pressure or 170 kPa (25 psi), then a stepped rise. Used only where water cannot be. |
| Hold time | At least 10 minutes | And long enough to examine every joint. Many specifications ask for longer. |
- Minimum test pressure
- 30 bar g
- Stress ratio St / S used
- 1.00
- Static head of water
- 1.18 bar
- Pressure at the low point, if the high point is at the test pressure
- 31.18 bar g
ASME B31.3 hydrostatic test: at least 1.5 times the design pressure, times St / S (not more than 6.5), held for at least 10 minutes. Check that the test pressure does not overstress the pipe or any component, and use the stresses from the code tables for your material. Your project test procedure takes precedence.
Test packs built from the line list, tracked to reinstatement: Deskely Testpack
The code gives the minimum. Your project specification may set a higher factor, a longer hold or a maximum, and the weakest component in the boundary (a valve, an instrument, a vessel nozzle) can cap the pressure. More in the hydrostatic and pneumatic test guide.
Gauges and the pressure record
- Use at least two gauges, or a gauge and a chart recorder, so one bad instrument cannot pass or fail the test on its own.
- Choose a range where the test pressure sits well inside the scale; a common rule is between about one third and two thirds of full scale.
- Record each gauge's number and calibration due date on the test record. An out-of-date gauge voids the test.
- Fit a relief valve on the test rig, set to protect the system from overpressure as your procedure requires.
- Log pressure and ambient or metal temperature at each stage, at the start and end of the hold, and on depressurising.
Test packs at scale
A large project can have thousands of test packs. The test is rarely what holds them up: it is the pack, with an open weld, a missing isometric revision or a spade nobody can find.
Deskely Testpack builds test packs from the line list and the drawings, records the test in the field and tracks every spade, gasket and instrument back in before the pack is closed. A closed pack updates the subsystem in Deskely Core.
The Deskely products for this
Frequently asked questions
What is a test pack?
The set of documents for one pressure test: the lines and isometrics in the test boundary, marked-up P&IDs, pre-test records, the test pressure, the test record and the spades and blinds register.
What is the difference between a test pack and a hydrotest report?
The test pack is the whole file for the test. The hydrostatic test report is the record of the test itself, which sits inside the pack.
How is the hydrotest pressure calculated?
Under ASME B31.3, at least 1.5 times the design pressure multiplied by St/S, the ratio of allowable stress at test temperature to that at design temperature, not more than 6.5.
What is the pneumatic test pressure?
Under ASME B31.3, at least 1.1 times the design pressure, reached in steps after a preliminary check at the lesser of half the test pressure or 170 kPa (25 psi).
When is a test pack closed?
After the test is accepted and the line has been drained and reinstated: spades out, permanent gaskets in, joints tightened and instruments back in place.
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