Hydrostatic test - Wikipedia https://en.wikipedia.

org/wiki/Hydrostatic_test

A hydrostatic test is a way in which pressure vessels such as

pipelines, plumbing, gas cylinders, boilers and fuel tanks can
be tested for strength and leaks. The test involves filling the
vessel or pipe system with a liquid, usually water, which may
be dyed to aid in visual leak detection, and pressurization of
the vessel to the specified test pressure. Pressure tightness can
be tested by shutting off the supply valve and observing
whether there is a pressure loss. The location of a leak can be
visually identified more easily if the water contains a colorant.
Hydrostatic tester
Strength is usually tested by measuring permanent
deformation of the container. Hydrostatic testing is the most
common method employed for testing pipes and pressure vessels. 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 re-qualified at regular intervals using the proof
pressure test which is also called the modified hydrostatic test. Testing of pressure vessels for
transport and storage of gases is very important because such containers can explode if they fail
under pressure.

Testing procedures
Examples
Pipeline testing
Testing frequency
Safety
References
External links

Hydrostatic tests are conducted under the constraints of either the industry's or the customer's
specifications, or may be required by law. The vessel is filled with a nearly incompressible liquid –
usually water or oil – pressurised to test pressure, and examined for leaks or permanent changes in
shape. Red or fluorescent dyes may be added to the water to make leaks easier to see. The test
pressure is always considerably higher than the operating pressure to give a factor of safety. This
factor of safety is typically 166.66%, 143% or 150% of the designed working pressure, depending on
the regulations that apply. For example, if a cylinder was rated to DOT-2015 PSI (approximately
139 bar), it would be tested at around 3360 PSI (approximately 232 bar). Water is commonly used
because it is cheap and easily available, and is usually harmless to the system to be tested.

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Hydraulic fluids and oils may be specified where contamination with water could cause problems.
These fluids are nearly incompressible, therefore requiring relatively little work to develop a high
pressure, and is therefore also only able to release a small amount of energy in case of a failure -
only a small volume will escape under high pressure if the container fails. If high pressure gas were
used, then the gas would expand to V=(nRT)/p with its compressed volume resulting in an
explosion, with the attendant risk of damage or injury.

Small pressure vessels are normally tested using a water jacket

test. The vessel is visually examined for defects and then
placed in a container filled with water, and in which the change
in volume of the vessel can be measured, usually by
monitoring the water level in a calibrated tube. The vessel is
then pressurised for a specified period, usually 30 or more
seconds, and if specified, the expansion will be measured by
reading off the amount of liquid that has been forced into the
measuring tube by the volume increase of the pressurised
vessel. The vessel is then depressurised, and the permanent
volume increase due to plastic deformation while under
pressure is measured by comparing the final volume in the Water jacket test
measuring tube with the volume before pressurisation. A leak
will give a similar result to permanent set, but will be
detectable by holding the volume in the pressurised vessel by closing the inlet valve for a period
before depressurising, as the pressure will drop steadily during this period if there is a leak. In
most cases a permanent set that exceeds the specified maximum will indicate failure. A leak may
also be a failure criterion, but it may be that the leak is due to poor sealing of the test equipment. If
the vessel fails, it will normally go through a condemning process marking the cylinder as unsafe.

The information needed to specify the test is stamped onto the cylinder. This includes the design
standard, serial number, manufacturer, and manufacture date. After testing, the vessel or its
nameplate will usually be stamp marked with the date of the successful test, and the test facility's
identification mark.

A simpler test, that is also considered a hydrostatic test but can be performed by anyone who has a
garden hose, is to pressurise the vessel by filling it with water and to physically examine the outside
for leaks. This type of test is suitable for containers such as boat fuel tanks, which are not pressure
vessels but must work under the hydrostatic pressure of the contents. A hydrostatic test head is
usually specified as a height above the tank top. The tank is pressurised by filling water to the
specified height through a temporary standpipe if necessary. It may be necessary to seal vents and
other outlets during the test.

Portable fire extinguishers are safety tools that are required in most public buildings. Fire
extinguishers are also recommended in homes. Over time the conditions in which they are housed,
and the manner in which they are handled affect the structural integrity of the extinguisher. A

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structurally weakened fire extinguisher can malfunction or even burst when it is needed the most.
To maintain the quality and safety of this product, hydrostatic testing is utilized. All critical
components of the fire extinguisher should be tested to ensure proper function.

Hydrotesting of pipes, pipelines and vessels is performed to expose defective materials that have
missed prior detection, ensure that any remaining defects are insignificant enough to allow
operation at design pressures, expose possible leaks and serve as a final validation of the integrity
of the constructed system. ASME B31.3 requires this testing to ensure tightness and strength.

Buried high pressure oil and gas pipelines are tested for strength by pressurising them to at least
125% of their maximum allowable working pressure (MAWP) at any point along their length. Since
many long distance transmission pipelines are designed to have a steel hoop stress of 80% of
specified minimum yield strength (SMYS) at Maximum allowable operating pressure MAOP, this
means that the steel is stressed to SMYS and above during the testing, and test sections must be
selected to ensure that excessive plastic deformation does not occur.

For piping built to ASME B31.3, if the design temperature is greater than the test temperature,
then the test pressure must be adjusted for the related allowable stress at the design temperature.
This is done by multiplying 1.5 MAWP by the ratio of the allowable stress at the test temperature to
allowable stress at the design temperature per ASME B31.3 Section 345.4.2 Equation 24. Test
pressures need not exceed a value that would produce a stress higher than yield stress at test
temperature. ASME B31.3 section 345.4.2 (c)

Other codes require a more onerous approach. BS PD 8010-2 requires testing to 150% of the
design pressure – which should not be less than the MAOP plus surge and other incidental effects
that will occur during normal operation.

Leak testing is performed by balancing changes in the measured pressure in the test section against
the theoretical pressure changes calculated from changes in the measured temperature of the test
section.

Australian standard AS2885.5 "Pipelines – Gas and liquid petroleum: Part 5: Field pressure
testing" gives an excellent explanation of the factors involved.

In the aerospace industry, depending on the airline, company or customer, certain codes will need
to be followed. For example, Bell Helicopter has a certain specification that will have to be followed
for any parts that will be used in their helicopters.

Most countries have legislation or building code that requires pressure vessels to be regularly
tested, for example every two years (with a visual inspection annually) for high pressure gas
cylinders and every five or ten years for lower pressure ones such as used in fire extinguishers. Gas
cylinders which fail are normally destroyed as part of the testing protocol to avoid the dangers

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inherent in them being subsequently used.

These common gas cylinders have the following requirements:

DOT-3AL gas cylinders must be tested every 5 years and have an unlimited life.
DOT-3HT gas cylinders must be tested every 3 years and have a 24-year life.
DOT-3AA gas cylinders must be tested every 5 years and have an unlimited life. (Unless
stamped with a star (*) in which case the cylinder meets certain specifications and can have a
10-year hydrostatic test life).
Typically organizations such as ISO, ASTM and ASME specify the guidelines for the different types
of pressure vessels.

Hydraulic testing is a hazardous process and needs to be performed with caution by competent
personnel. Adhering to prescribed procedures defined in relevant technical standards appropriate
to the specific application and jurisdiction will usually reduce these risks to an acceptable level.

A leak of high pressure liquid can cut or penetrate the skin and inject itself into body tissues.
This can cause serious direct injury to the operator, and if the fluid is toxic or contaminated
there will be additional adverse effects.
A pressurised hose that is not securely attached or which fails under pressure may whip
around spraying water or oil and could hit someone and cause injuries. A whip latch arrestor
can be used to restrain such hoses.
Enclosing the components to be tested, hazard signage, use of appropriate personal protective
equipment and providing barriers to access for non-essential personnel are common
precautions.
Equipment:

1. Pressure gauges [1.5 to 4.0 times of test pressure]

2. Water tanks
3. Potable tanks
4. Pumps for water filling and pressure
5. Pressure gauges and temperature recorder

"OSHA" (http://www.osha.gov/SLTC/etools/evacuation/portable_hydro.html). Retrieved

2006-10-05.

Retrieved from "https://en.wikipedia.org/w/index.php?title=Hydrostatic_test&oldid=917589818"

This page was last edited on 24 September 2019, at 14:46 (UTC).

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