Hydrostatic Pressure Testing Safety Checklist

Has a written hydrostatic test plan been reviewed and approved by a qualified engineer or the Authority Having Jurisdiction (AHJ)?

Is the specified test pressure clearly documented and does it NOT exceed the maximum allowable test pressure for the piping system and components (typically 1.5 times the design pressure)?

Has material compatibility with the test fluid (typically potable water) been verified for all piping components, including gaskets and seals?

Are all isolation valves that will be subjected to test pressure rated for that pressure and in good working order?

Is the pressure gauge calibrated and certified within the last year? Verify calibration sticker is present and legible.

Is there a documented procedure for venting trapped air from the system during filling?

Is there a documented procedure for safely draining the system after the test?

Is there an emergency plan in place in case of a pipe rupture or other failure during the test?

Are all pipe supports and hangers properly installed and capable of supporting the weight of the water-filled piping system?

Are adequate thrust blocks or other restraints installed at all dead ends, tees, and bends to prevent movement due to hydrostatic pressure? Verify design calculations.

Are all test caps and plugs rated for at least the specified test pressure? Verify markings are present and legible.

Are test caps securely installed with appropriate thread sealant or gaskets to prevent leaks or blowouts?

Are all valves within the test section in the fully open or fully closed position as required by the test plan?

Has the piping system been flushed to remove debris and contaminants prior to testing?

Are temporary supports installed as needed to prevent sagging or overstressing of the piping during testing?

Are expansion joints properly restrained or isolated during the test to prevent damage?

Has a clearly marked exclusion zone been established around the piping system during the test? Minimum radius: 25 feet.

Have all non-essential personnel been evacuated from the exclusion zone?

Are warning signs posted at the perimeter of the exclusion zone indicating the presence of a hydrostatic pressure test?

Are all personnel involved in the test wearing appropriate PPE, including safety glasses, hard hats, and steel-toed boots?

Is there a reliable communication system in place to allow personnel to communicate during the test?

Is there a readily accessible emergency shutdown valve or other means of quickly depressurizing the system in case of a failure?

Verify that PNEUMATIC (air) testing is ABSOLUTELY PROHIBITED on PVC or other plastic piping systems. Only hydrostatic testing is permitted.

During pressurization, are personnel visually monitoring the piping system from a safe distance for any signs of leaks or distress?

Is the system being pressurized slowly and in a controlled manner to prevent pressure surges?

Is the pressure being continuously monitored during the test using a calibrated pressure gauge?

Is the system being visually inspected for leaks at all joints, connections, and fittings?

Is the pressure drop being monitored over the duration of the test to ensure it remains within acceptable limits (typically less than 5% of the test pressure)?

Is the system being held at the specified test pressure for the required duration (typically 2-4 hours)?

If leaks are detected, is there a procedure in place for safely depressurizing the system and repairing the leaks?

After repairs, is the system being retested to verify the integrity of the repairs?

Is the water temperature being monitored during the test to account for thermal expansion or contraction?

Is a properly sized pressure relief valve installed to prevent over-pressurization of the system?