Pressure testing

Pressure testing is a way to provide quality

assurance of any pipeline or pressure vessel,
and helps identify damaged or defective pipe
fittings, joints, valves, hydrants and thrust
restraint systems.
There are many advantages of pressure
testing such as decreasing expense risks and
decreasing health and safety risk.
We can divide pressure testing into 2 methods:
1. Hydrostatic Pressure Test.
2. Pneumatic Pressure Test.

Hydrostatic testing
This is a nondestructive test used to check the quality of
welds on closed containers such as pressure vessels and
tanks. The test usually consists of filling the vessel with
water and applying a pressure greater than the working
pressure of the vessel. Sometimes, large tanks are filled
with water which is not under pressure to detect possible
leakage through defective welds. Another method is to test
with oil and then steam out the vessel. Back seepage of oil
from behind the liner shows up visibly. Hydrostatic testing is
the most common procedure used to qualify newly
manufactured cylinders, spheres and tubes used for the
transportation of dangerous goods. Hydrostatic testing is
also required periodically to re-qualify these pressure
vessels for continued service.

Hydrostatic Pressure Testing:is a way in which leaks can

be found in pressure vessels, pipelines and plumbing .Using
this test helps maintain safety standards and durability of a
vessel over time. Newly manufactured pieces are initially
qualified using the hydrostatic test, they are then continually
re qualified at regular intervals using the proof pressure test
which is also called the modified hydrostatic test. Hydrostatic
testing is also a way in which a gas pressure vessel, such as a
gas cylinder or a boiler, is checked for leaks or flaws. Testing is
very important because such containers can explode if they
fail when containing compressed gas.

During a hydrostatic test, a pressure vessel is placed

inside a closed system, usually a test jacket filled with
water, and a specified internal water pressure is
applied to the container inside this closed system. The
applied internal pressure causes an expansion of the
container being tested, and the total and permanent
expansion that the container undergoes are measured.
These volumetric expansion measurements, in
conjunction with an internal and external visual
inspection of the container, are used to determine if a
pressure vessel is safe for continued use, or has
suffered from a degradation in its structural integrity
and must be condemned.

Some pressure vessels may be re-qualified by

means of a proof-pressure test. This method, also
known as a modified hydrostatic test, consists of
subjecting a pressure vessel to a specified
internal pressure and inspecting the pressurized
container for leaks, bulges or other defects. This
method is permitted only when the applicable
regulations do not require the determination of
volumetric expansion measurements (e.g. for
certain types of low pressure cylinders such as
those used on many portable fire extinguishers).

HYDROSTATIC TEST
MARKINGS
Pressure vessels that have been hydrostatically
tested and re-qualified must be marked by the
retest facility with the facility retester identification
number (RIN), and the retest date. Depending on
the age of the container, it may contain none or
many sets of retest markings. The oldest date
marked on the container is the date of the original
hydrostatic test carried out by the manufacturer,
and is considered the manufacturing date. Any
subsequent dates marked on the container are a
record of the hydrostatic tests that the container
has undergone.

HYDROSTATIC TEST
INTERVALS
The hydrostatic test interval and
service life of various pressure
vessels are generally determined by
the specification or exemption to
which the pressure vessel was
manufactured.

Precautions after Hydro testing Drying

Equipment left wet after testing is at risk because the
chloride levels of pools of water will rise as the water
evaporates: PCC may initiate at these high chloride levels.
To prevent chloride concentration after hydrotesting, the
equipment should be thoroughly dried and sealed if it is to
be left for more than a day or two before being put into
service. This can be achieved by draining the water out
(properly designed equipment will allow for complete
drainage), then blowing dry air through the wet spaces.
When the humidity of the air is high, this process should be
completed when the work is at its coolest (i.e. at night), to
prevent condensation when the work cools.
Drying the equipment also stifles any microbiological
infections, which will not progress on a dry surface.

 see ASME VIII div 1 UG-99 STANDARD HYDROSTATIC TEST(a) A hydrostatic test shall be conducted on all vesselsafter:(1) all fabrication has been completed, except foroperations which
could not be performed prior to the testsuch as weld end preparation [see U-1(e)(1)(a)], cosmeticgrinding on the base material which does not affect therequired thickness; and(2) all
examinations have been performed, exceptthose required after the test.The completed vessels, except those tested in accordancewith the requirements of UG-100 and UG-101, shall
havesatisfactorily passed the hydrostatic test prescribed in thisparagraph.(b) Except as otherwise permitted in (a) above and 27-4, vessels designed for internal pressure shall be
subjectedto a hydrostatic test pressure which at every point in thevessel is at least equal to 1.3 times the maximum allowableworking pressure34 to be marked on the vessel
multipliedby the lowest ratio (for the materials of which the vesselis constructed) of the stress value S for the test temperatureon the vessel to the stress value S for the design
temperature(see UG-21). All loadings that may exist during this testshall be given consideration.(c) A hydrostatic test based on a calculated pressuremay be used by agreement
between the user and the Manufacturer.The hydrostatic test pressure at the top of thevessel shall be the minimum of the test pressures calculatedby multiplying the basis for calculated
test pressure asdefined in 3-2 for each pressure element by 1.3 and reducingthis value by the hydrostatic head on that element.When this pressure is used, the Inspector shall reserve
theright to require the Manufacturer or the designer to furnishthe calculations used for determining the hydrostatic testpressure for any part of the vessel.(d) The requirements of (b)
above represent the minimumstandard hydrostatic test pressure required by thisDivision. The requirements of (c) above represent a specialtest based on calculations. Any intermediate
value of pressuremay be used. This Division does not specify an upperlimit for hydrostatic test pressure. However, if the hydrostatictest pressure is allowed to exceed, either
intentionallyor accidentally, the value determined as prescribed in (c)above to the degree that the vessel is subjected to visiblepermanent distortion, the Inspector shall reserve the
rightto reject the vessel.(e) Combination units [see UG-19(a) and UG-21] shallbe tested by one of the following methods.(1) Pressure chambers of combination units that havebeen
designed to operate independently shall be hydrostaticallytested as separate vessels, that is, each chamber shallbe tested without pressure in the adjacent chamber. If thecommon
elements of a combination unit are designed fora larger differential pressure than the higher maximumallowable working pressure to be marked on the adjacentchambers, the
hydrostatic test shall subject the commonelements to at least their design differential pressure, correctedfor temperature as in (b) above, as well as meet therequirements of (b) or (c)
above for each independentchamber.(2) When pressure chambers of combination unitshave their common elements designed for the maximumdifferential pressure that can possibly
occur during startup,operation, and shutdown, and the differential pressure isless than the higher pressure in the adjacent chambers, thecommon elements shall be subjected to a
hydrostatic testpressure of at least 1.3 times the differential pressure Tobe marked on the unit, corrected for temperature as inUG-99(b).Following the test of the common elements and
theirinspection as required by (g) below, the adjacent chambersshall be hydrostatically tested simultaneously [see (b) or(c) above]. Care must be taken to limit the differentialpressure
between the chambers to the pressure used whentesting the common elements.The vessel stamping and the vessel Data Report mustdescribe the common elements and their limiting
differentialpressure. See UG-116(j) and UG-120(b).(f) Single-wall vessels designed for a vacuum or partialvacuum only, and chambers of multichamber vesselsdesigned for a vacuum or
partial vacuum only, shall besubjected to an internal hydrostatic test or when a hydrostatictest is not practicable, to a pneumatic test in accordancewith the provisions of UG-100. Either
type of testshall be made at a pressure not less than 1.3 times thedifference between normal atmospheric pressure and theminimum design internal absolute pressure.(g) Following the
application of the hydrostatic testpressure, an inspection shall be made of all joints andconnections. This inspection shall be made at a pressurenot less than the test pressure divided
by 1.3. Except forleakage that might occur at temporary test closures forthose openings intended for welded connections, leakageis not allowed at the time of the required visual
inspection.Leakage from temporary seals shall be directed away soas to avoid masking leaks from other joints.The visual inspection of joints and connections for leaksat the test
pressure divided by 1.3 may be waived provided:(1) a suitable gas leak test is applied;(2) substitution of the gas leak test is by agreementreached between Manufacturer and Inspector;
(3) all welded seams which will be hidden by assemblybe given a visual examination for workmanship priorto assembly;(4) the vessel will not contain a "lethal" substance.(h) Any
nonhazardous liquid at any temperature maybe used for the hydrostatic test if below its boiling point.Combustible liquids having a flash point less than 110F(43C), such as petroleum
distillates, may be used onlyfor near atmospheric temperature tests. It is recommendedthat the metal temperature during hydrostatic test be maintainedat least 30F (17C) above the
minimum designmetal temperature, but need not exceed 120F (48C), tominimize the risk of brittle fracture. [See UG-20 and GeneralNote (6) to Fig. UCS-66.2.] The test pressure
shallnot be applied until the vessel and its contents are at aboutthe same temperature. If the test temperature exceeds 120F(48C), it is recommended that inspection of the
vesselrequired by (g) above be delayed until the temperature isreduced to 120F (48C) or less.CAUTION: A small liquid relief valve set to 113 times the test pressureis recommended
for the pressure test system, in case a vessel, while undertest, is likely to be warmed up materially with personnel absent.(i) Vents shall be provided at all high points of thevessel in the
position in which it is to be tested to purgepossible air pockets while the vessel is filling.(j) Before applying pressure, the test equipment shallbe examined to see that it is tight and that
all low-pressurefilling lines and other appurtenances that should not besubjected to the test pressure have been disconnected.(k) Vessels, except for those in lethal service, may
bepainted or otherwise coated either internally or externally,and may be lined internally, prior to the pressure test.However, the user is cautioned that such painting /coating /lining may
mask leaks that would otherwise havebeen detected during the pressure test.

 The Vessel Pressure Testing article provides you with information about
pressure vessel hydro-static testing requirements and related item in
pressure vessel inspection.
The requirements have been described based on ASME Code Section
VIII. You need to do this test after completion of the construction
process, but before the internal parts assembly and also before painting
process.
This content covers all major requirements and provides you with
guidelines for test performance.
Please note that performing the pneumatic test instead of the HydroStatic Test is not allowed, and it can be replaced only when it is not
possible due to the design and process.
Vessel pressure testing requirements have been addressed in UG-99
and UG-100 in ASME Code Section VIII Div. 1.
These are important points, which you need to take care of in vessel
pressure testing:

 Activities before pressure vessel hydro-static testing, which need to be checked by the manufacturer quality control
team and a third party inspector:
1. Checking all welding already finished and fully accepted by the NDT examination per the project Inspection and test plan.
2. Making sure the inner part of the vessel is clean and free of remaining slag or other elements.
making sure the external surface is dry for the correct execution of the visual inspection during the vessel pressure testing.
3. Checking the pressure gauges' calibration tag and certificate and the range of the lower limit and upper limit of the gauges. It
needs to be between 1.5 and 4 of the pressure test value.
4. Controlling testing equipment such as the test pump and housing for soundness and tightness.
5. Making sure the test temperature will not violate the following values:
Min. Test temperature= MDMT + 30F
Max. Test temperature = 120F
MDMT is the pressure vessel minimum design metal temperature, and it is stated in the pressure vessel design document.
This reduces the risk of a brittle fracture during the test.
6. Making sure which reinforcement pads are already soap tested.
7. Controlling the testing water quality and using corrosion inhibitor if it is necessary or when the vessel metal is sensitive material
8. Checking of vents. It is required to be placed at high points of the vessel in a position where it is possible to purge air pockets
while the vessel is filling.
Activities during the pressure vessel hydro-static testing that need to be checked by the manufacturer quality
control team and a third party inspector:
1. Making sure the filling and pressurizing are done from the lowest point and venting from the highest point.
2. Witnessing water overflow through the venting in order to assure that no air bubbles remain in the vessel.
3. Controlling and witnessing which pressurizing is done in three stages as follow:
First Stage:Raise the pressure to 40% of the final pressure, stop pressurizing, keep it for 5 minutes, and then make a fast visual
inspection of the external surface.
Second Stage:Restart pressurizing up to 70% of final pressure, stop the operation, keep for 5 minutes and make a fast visual
inspection on external surface.
Third Stage:Restart pressurizing up to 100% of the final pressure, stop the operation, and keep for 45 minutes.

 4. When 45 minutes elapse, making sure the de-pressurizing is started and the pressure is
dropped to the Inspection Pressure.
This inspection pressure can be calculated as following:
Inspection Pressure = Hydrostatic Test Pressure / 1.3
Making sure a detail and a comprehensive inspection is carried out over the whole body of the
vessel and in the welding joints and attachments.
5. Making sure the pressure vessel hydro-static testing pressure calculated correctly as
following:
Hydrostatic Test Pressure = 1.3 x MAWP X Stress ratio
Stress Ratio = (Allowable Stress at Test Temperature)/(AllowableStress at Design Temperature)
6. Making sure the vessel is immediately and carefully drained after the test and dried by air.
Activities after the pressure vessel hydro-static testing that need to be checked by
the manufacturer quality control team and a third party inspector:
1. The pressure vessel hydro-static testing report needs to be prepared by the manufacturer
quality control team and signed by the third party or authorized inspector.
2. If the test failed by leaking from weld joints or any other kind of defect, it is necessary that
the vessel is drained and dried and repaired based on approved repair procedure. pressure
vessel hydro-static testing needs to be repeated.
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