TIME LINE

• Introduction to Hydro testing

Presentation • Purpose of Hydro test

Timeline
• Pressure Vessel

• Piping

• Tanks

• Boiler
• Valves
INTRODUCTION

Hydro static test is a type of Non-

Piping System
Destructive Test which is used to
check overall integrity of the system.
Valves
System includes: Introduction

• Piping system Parameters

• Valves Procedure
• Pressure Vessels ietc Standards Pressure
Vessels
• Boilers
• Tanks
• Others Boiler
Hydrostatic testing

Piping System
Hydrostatic testing has been used to
determine and verify pipeline integrity.
Innumerable information can be obtained
through this verification process; however, Valves
it is essential to identify the limits of the Introduction
test process and obtainable results. There Parameters
are several types of flaws that can be
detected by hydrostatic testing: Procedure
Standards Pressure
Vessels

Boiler
PURPOSE OF HYDROSTATIC TEST
External corrosion:
MIC, oxidation, under
Hydrostatic test may be used to check the Internal corrosion: deposition Hydrogen induced
Pitting or uniform cracking
following: corrosion

• Existing material flaws. Contaminants such as hydrogen sulfide,

carbon dioxide, other chemicals, or even
• Flaws in the mechanical properties of water in the flow causes internal corrosion

the pipe and stress corrosion cracking

(SSC).
• Presence of active corrosion cells.
• Presence of any hard spots that can Cracking:
Stress corrosion cracking,
Embrittlement, sulfide
cause failure in long run when they come Flow induced corrosion corrosion cracking

in contact with hydrogen.

External Corrosion
• Occurs due to environmental conditions on the
outside of the pipe.
• It is the natural interaction between
the exterior surface of the pipe and the soil, air,
or water surrounding it.
o Microbiologically influenced corrosion (MIC):
Bacterially mediated process of
forming hydrogen sulfide gas and the
subsequent conversion to sulfuric acid that
attacks concrete and steel within wastewater
environments.
o Atmospheric corrosion:
It is triggered by atmospheric humidity, which
forms a thin layer of liquid on the surface.
Hydrogen Induced Corrosion
• Hydrogen-Induced Cracking (HIC) is the stepwise internal cracks that connect adjacent
hydrogen blisters on different planes in the metal, or to the metal surface
Flow Induced Corrosion
• Flow-Accelerated Corrosion (FAC) refers to the combined actions involving the removal of
magnetite (Fe3O4) layer by fluid flow and the subsequent increased corrosion of the exposed
metal, leading to wall thinning (metal loss) to the extent of perforation.
Cracking
• Stress corrosion cracking (SCC) is
the cracking induced from the combined
influence of tensile stress and
a corrosive environment.
• Stress corrosion cracking results from the
conjoint action of three components:
o Susceptible material
o Specific chemical species (environment)
o Tensile stress
• For example, copper and its alloys are
susceptible to ammonia compounds, mild
steels are susceptible to alkalis and stainless
steels are susceptible to chlorides.
Typical Hydrotesting step

Piping System
•The proof test involves
pressurizing the vessel
The process of or pipe with water to a
proof testing stress level above the
involves the design pressure but
Valves
below the yield
following steps. strength of the material
of construction. Introduction
Parameters
Procedure
Standards
• Hold the • Monitor for Pressure
pressure to the the drop in Vessels
required time. pressure.

Boiler
Hazards

Breaking/failure of line, gasket, flanges, and gauges.

Air entrapment inside the pipe.

Usage of an engine operated pump.

Inadvertently/suddenly increase of pressure due to underrated or non calibrated

pressure gauges.

Substandard support.

PSV failure.
Safety Precaution
1. Hydro test test Area shall be barricaded and provide warning boards to prevent personnel entry.
2. Calibrated pressure gauges and Pressure safety valves only shall be used.
3. Rating of fittings, pressure gauges, vent valves, gaskets shall be suitable for the test pressure.
4. Flanges and Plates shall be as per the line class.
5. All the temporary welding shall be performed by qualified welders and approved by Client QA/QC.
6. Ensure air vent provided at the highest elevation.
7. Gradual filling of lines shall be done keeping vent to open.
8. Ensure that the line is vented to remove air pockets before pressurization.
9. Pressure should be raised gradually under control to allow time for pipes to strain and time for personnel to check for leaks.
10. There shall be at least two pressure gauges, one at lowest point and another at the highest point in the system
11. Hydro testing crew should not stay in the direction of the blind flanges to prevent injury in case of flange rapture.
12. All hoses/ piping/gaskets and connectors/clamps shall be of adequate rating to withstand pressure.
13. Whip lash arrestor shall be provided at hose connection.
14. Personnel shall not approach the system under high Pressure.
15. Only essential and trained persons shall be allowed at the Hydro test work location
16. Access shall be free from any obstacle.
17. Supervisors shall be present at work location during hydro testing activities are done.
18. Risk assessment shall be done for any hydro test job.
PRESSURE VESSELS

API – 510 : Pressure Vessel Inspection

ASME Section VIII DIV-1 : ASME Boiler and Pressure Vessel Code Section VIII Rules
for Construction of Pressure Vessels
PRESSURE VESSELS

A container designed to withstand internal or

external pressure. This pressure may be
imposed by an external source, by the
application of heat from a direct or indirect
source, or by any combination thereof.

This definition includes heat exchangers, air-

coolers, unfired steam generators and other
vapor generating vessels which use heat from
the operation of a processing system or other
indirect heat source.
PRESSURE VESSELS – Repair / alter

Pressure tests are not normally conducted as part of routine inspection. A pressure test
is normally required after an alteration or major repair. After repairs (other than major
repairs) are completed, a pressure test

PRESSURE VESSEL INSPECTION CODE: IN-SERVICE INSPECTION, RATING, REPAIR, AND

ALTERATION 31 applied if the inspector believes that one is necessary and specifies it in
the repair plan

Pressure tests are typically performed on an entire vessel. However, where practical,
pressure tests of vessel components/sections can be performed in lieu of entire vessels
(e.g. a new nozzle). An engineer should be consulted when a pressure test of vessel
component/sections is to be performed to ensure it is suitable for the intended purpose.
PRESSURE VESSELS – Test Determination

When a code hydrostatic pressure test is required, the minimum test pressure should be in
accordance with the rules of the applicable code (construction code used to determine
the MAWP). 4
For this purpose, the minimum test pressure for vessels that have been rerated using the
design allowable stress published in the 1999 addendum or later of ASME Code, Section
VIII, Division I, Code Case 2290, or Code Case 2278.
• Test Pressure in psig (MPa) = 1.5 MAWP × ( temp/ temp), prior to 1999
addendum
• Test Pressure in psig (MPa) = 1.3 MAWP × ( temp/ temp), 1999 addendum
and later
• Where,
temp is the allowable stress at test temperature in ksi (MPa);
temp is the allowable stress at design temperature in ksi (MPa).
PRESSURE VESSELS – Test Preparation

Before applying a pressure test, appropriate precautions and procedures should be taken to
assure the safety of personnel involved with the pressure test.

A close visual inspection of pressure vessel components should not be performed until the vessel
pressure is at or below the MAWP.

When a pressure test is to be conducted in which the test pressure will exceed the set pressure
of the pressure-relieving device(s), the pressure-relieving device(s) should be removed.

Other appurtenances, such as gauge glasses, pressure gauges, and rupture disks, that may be
incapable of withstanding the test pressure should be removed or blanked off.
PRESSURE VESSELS - Hydrostatic Pressure Tests

Before applying a hydrostatic test, the supporting structures and foundation design should be
reviewed to assure they are suitable for the hydrostatic test load.

All instruments and other components that might experience the full hydrostatic test pressure
should be checked to ensure that they are designed for the specified pressure test; otherwise they
must be blinded off from the test.

Hydrostatic pressure tests of equipment having components of Type 300 series stainless steel
should be conducted with potable water or steam condensate having a chloride concentration of
less than 50 ppm.

The inspector should verify the specified water quality is used and that the vessel has been
drained and dried
PRESSURE VESSELS – TEST PRESSURE
Parameter Value Boiler blowdown tank
Working temperature 148 ºC
M.A.W.P 3.5
Testing temperature 148 ºC
Material SA516

Hydrostatic test minimum pressure calculation

PRESSURE VESSELS - INSPECTION

This examination for leakage shall be made of all joints and connections and all regions of high
stress such as:
• knuckles in formed heads
• cone-to-cylinder junctions
• Regions around openings.
This visual examination may be waived if a suitable gas leak test is applied satisfying the
requirements

All other locations of leakage must be corrected and the vessel retested.

Similar to VIII-1, the Inspector has a right to reject a vessel if there are visible signs of
permanent distortion following the test ASME Sec-VIII
PRESSURE VESSELS – PNEUMATIC TEST

Pneumatic test is permissible only for two

reasons:
• Pressure vessels that are designed /
Whenever possible pneumatic test should supported in such a that they cannot safely
be avoided because expansive nature of gas be filled with water.
exert extra pressure and stress on cracks • When traces of testing liquid are intolerable
causing further growth. and vessels are needed on urgent basis, so
to save time pneumatic test can be
performed.
PRESSURE VESSELS - Test Temperature and Brittle Fracture

At ambient temperatures, carbon, low-alloy, and other ferritic steels may be susceptible to brittle failure.

A number of failures have been attributed to brittle fracture of steels that were exposed to temperatures below
their transition temperature and to pressures greater than 20 % of the required hydrostatic test pressure.

The potential for a brittle failure shall be evaluated prior to hydrostatic or especially prior to pneumatic testing
because or the higher potential energy involved.

To minimize the risk of brittle fracture during a pressure test, the metal temperature should be maintained at
least 30 °F (17 °C) above the MDMT or MAT for vessels that are more than 2 in.

When hydrotesting solid or clad austenitic stainless steel, the water temperature should not exceed 120 °F (50
°C) to prevent possible chloride stress corrosion cracking.
PRESSURE VESSELS - Alternatives

Appropriate NDE (e.g. RT, UT, PT, MT, etc.) shall be specified
and conducted when a pressure test is not performed after
a major repair or alteration.

Substituting NDE procedures for a pressure test after an

alteration or major repair may be done only after the
engineer and inspector have approved.

it is advisable to conduct a FFS assessment to identify the

critical flaw size(s) to specify the acceptance criteria for the
specified NDE technique(s).

For cases where manual UT is used to examine welds in lieu

of pressure test, the owner/user shall specify industry
qualified angle beam examiners. For use of UT in lieu of RT,
ASME Code Case 2235 or ASME Code Section VIII, Division
2, 7.5.5 shall be followed.
PIPING

PIPING
API – 570 : Piping Inspection Code
ASME B 31.1 : ASME Power Piping Code
ASME B 31.3 : ASME Process Piping Code
 PIPING - INTRODUCTION
According to ASME piping system is divided into two main types:

Transport chemicals, gases, water, and other fluids

in support of an internal manufacturing or
processing operation.

Process Piping

Piping systems and their component parts, excluding

building services piping systems, that may be installed
Power Piping within electric power generating stations, industrial
and institutional plants, utility geothermal
heating systems, and central and district heating and
cooling systems.
PIPING – INTRODUCTION
Hydrostatic testing of pressure piping is a mandatory activity before finalization of any new or modified
piping system.

It is the final check of mechanical integrity of the whole system and should be followed religiously as
after this activity the piping system has to be commissioned.

• Flow/volume demands
Test • Size and length of pipe
requirements • Total overall difference
are set by from the low to highest
considering the elevations
following: • Changes in elevation or
"high spots."
PIPING - Preparation for Testing
Exposure of Joints. Ail joints including welds not previously pressure tested shall be left uninsulated and
exposed for examination during the test.

Addition of Temporary Supports. Piping systems designed for vapor or gas shall be provided with
additional temporary supports if necessary to support the weight of the test liquid

Restraint or Isolation of Expansion Joints. Expansion joints shall be provided with temporary restraint if
required for the additional pressure load under test, or they shall be isolated during the system test.

Isolation of Equipment and Piping Not a Subjected to Pressure Test. Equipment that is not to be subjected to
the pressure test shall be either disconnected from the system or isolated by a blank or similar means.

Treatment of Flanged Joints Containing Blanks. Flanged joints at which blanks are inserted to blank off other
equipment during the test need not be tested after removal of the blank provided the requirements are
subsequently performed.

Precautions Against Test Medium Expansion. If a pressure test is to be maintained for a period of time during
which the test medium in the system is subject to thermal expansion, precautions shall be taken to avoid
excessive pressure.
PIPING - Requirements for Specific Piping Systems

BOILER • Boiler external piping shall be hydrostatically tested in accordance with

EXTERNAL PG-99 of Section I of the ASME Boiler and Pressure Vessel Code.
• The test shall be conducted in the presence of the Authorized Inspector.
PIPING:
NON-BOIIER • All non boiler external piping shall be hydrostatically tested.
EXTERNAL • Lines open to the atmosphere, such as vents or drains downstream of the
last shutoff valve, need not be tested
PIPING:
PIPING - Hydrostatic Testing

Material. When permitted by the Material Specification, a system hydrostatic test may be performed in lieu of the hydrostatic
test required by the material specifications for material used in the piping subassembly or system provided the minimum test
pressure required for the piping system is met.

Provision of Air Vents at High Points. Vents shall be provided at all high points of the piping system in the position in which
the test is to be conducted to purge air pockets while the component or system is filling.

Test Medium. Water shall normally be used as the test medium unless otherwise specified by the Owner. Test water shall be
clean and shall be of such quality as to minimize corrosion of the materials in the piping system.

Check of Test Equipment Before Applying Pressure. The test equipment shall be examined before pressure is applied to
ensure that it is tightly connected. All low-pressure filling lines and all other items not subject to the test pressure shall be
disconnected or isolated by valves or other suitable means.

Required Hydrostatic Test Pressure. The hydrostatic test pressure at any point in the piping system shall not be less than 1.5
times the design pressure, but shall not exceed the maximum allowable test pressure of any non-isolated components. The
pressure shall be continuously maintained for a minimum time of 10 minutes and may then be reduced to the design pressure.
Examinations for leakage shall be made of all joints and connections.
 PIPING – TEST PRESSURE

1) Power Piping Hydrostatic Test (137.4.5)

𝑃 = 1.5𝑃
2) Process Piping: (345.4.2.)

𝑆
𝑃 = 1.5 × 𝑃 × , 𝑊ℎ𝑒𝑛 𝑑𝑒𝑠𝑖𝑔𝑛 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑖𝑠 𝑔𝑟𝑒𝑎𝑡𝑒𝑟 𝑡ℎ𝑎𝑛 𝑡𝑒𝑠𝑡 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒
𝑆

Where;
𝑃 𝑖𝑠 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 ℎ𝑦𝑑𝑟𝑜𝑠𝑡𝑎𝑡𝑖𝑐 𝑡𝑒𝑠𝑡 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒
S is allowable stress at component design temperature for the prevalent pipe material
𝑆 is allowable stress at test temperature for the prevalent pipe material
𝑃 𝑖𝑠 𝑑𝑒𝑠𝑖𝑔𝑛 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒
PIPING - EXAMPLE
PIPING - EXAMPLE
PIPING - Pneumatic Testing

Pneumatic testing shall not be

used unless the Owner specifies • When piping systems are so designed that they cannot
pneumatic testing or permits its be filled with water;
use as an alternative. It is
recommended that pneumatic • When piping systems are to be used in services where
testing be used only when one of traces of the testing medium cannot be tolerated.
the following conditions exists:
PIPING - Pneumatic Testing

Test Medium. The gas used as the test medium shall be nonflammable and nontoxic. Since
compressed gas may be hazardous when used as a testing medium, it is recommended that
special precautions for protection of personnel be observed when a gas under pressure is used
as the test medium.

Preliminary Test. A preliminary pneumatic test not to exceed 25 psig [I75 kPa (gage)] may be applied.

Required Pneumatic Test Pressure. The pneumatic test pressure shall be not less than 1.2 nor more
than 1.5 times the design pressure of the piping system. The test pressure shall not exceed the
maximum allowable test pressure of any non-isolated component. The pressure shall be continuously
maintained for a minimum time of 10 minutes. Examination for leakage detected by soap bubble or
equivalent method shall be made of all joints and connections.
PIPING – PNEUMATIC TEST

INTRODUCTION:
• Pneumatic testing involves the hazard of released energy stored in compressed gas so it
should be performed with extreme caution

• Permitted when hydro test can’t be done such as with the case of interior insulation and
refractory lining of pipe

• A pressure relief device shall be provided, having a set pressure not higher than the test
pressure plus the lesser of 10% of the test pressure.

• The gas used as test fluid, if not air, shall be nonflammable and nontoxic.

• Test Pressure:
PIPING – PNEUMATIC TEST
PROCEDURE:
• The pressure is to gradually increase until the lesser of 50% of the test pressure or 25 psig is
obtained
• Pressure is to be held at this level and a preliminary check of the welded and bolted
connections is to be conducted
• Pressure is then gradually increased in about 5 to 10 psig pressure increments, holding the
pressure after each increment for 5 to 10 minutes to allow for piping strains to equalize
• Then continuing in this pressure increment manner until the test pressure is reached
• Hold the test pressure at 110% of design pressure for 5 to 10 minutes
• Then lower the pressure to 100% of design pressure and examine the piping system for
leaks.
PIPING - PNEUMATIC TEST

PROCEDURE:
• Pressure gauges should be fitted at both low and high point when testing large volume
systems
• The system shall be filled from the lowest available point
• All vents and high point connections shall be open during this operation to allow the air in
the system to vent off
• After the system has been completely vented all vents and drains should be plugged or
blinded
• Maintain pressure for 10 minutes and then gradually increase pressure in steps of one tenth
of the test pressure until the test pressure is attained.
• The pressure shall be continuously maintained for a minimum time of 10 min and may then
be reduced to the design pressure and held for such time as may be necessary to conduct
the examinations for leakage.
PIPING - PNEUMATIC TEST
PROCEDURE:
• Whenever a leak is found from flanged connection, don’t perform any tightening before the
system pressure is brought down to at least 70%.
• A leak from a weld joint, piping base metal or any other location which may require hot
work shall only be addressed after de-pressurizing the piping under test.
• After any leaks have been repaired the system shall again be pressurized to the test
pressure in stages.
• After testing is completed, equipment should be thoroughly drained with all high point
vents open during draining, and dried by air blowing, swabbing, or other appropriate
means. If immediate draining and drying are not possible, hydro test water should be
circulated in the piping for at least one hour daily to reduce the possibility of pitting and
microbiologically influenced corrosion.
PIPING - PRECAUTIONS

Equipment fabricated from austenitic (300 series) and ferritic (400 series) stainless
steels and requiring hydrostatic testing should be tested with deionized water high
purity steam condensate, or potable water, in decreasing order of preference.

The hoop stress caused by the test pressure should not exceed yield.

Vents shall be provided at all high points of the piping system in the position in
which the test is to be conducted to purge air pockets while the component or system
is filling.
BOILER

ASME Boiler and Pressure vessel

construction, Section:1

IBR Regulation – 286

NIBC – Part 3
BOILER - INTRODUCTION

Hydrostatic testing in the boiler is carried out to

check the following
• Leakages in the boiler pressure parts (Tubes, headers and
Pipes).
• To test the soundness of welded joints and associated
pressure parts of the boiler in order to comply the code
requirements.
• To prove the strength of the boiler pressure parts at a
pressure greater than the working pressure of the boiler at
ambient temperature.
BOILER – FREQUENCY

The hydraulic test of the boiler is

carried out at the following
conditions / situations.

On completion of the boiler

erection activities

On completion of repair work on

boiler pressure parts

On completion of annual
overhaul

At the request of statutory

authority to fulfill the statutory
requirements.
BOILER – TEST PRE-REQUISTES

All welding/NDT and heat treatment activities must be completed

Buck stays, its guides and anchors are installed as per the drawings.

Permanent supports, structural bracings are provided as per the drawings.

DM water quality & availability as per requirement. (Minimum three (3) times of the boiler
water holding capacity shall be readily available).

Temporary piping’s are adequately supported.

Ensure that minimum three (3) numbers of calibrated pressure gauges are fitted at the
identified locations (One in the steam drum, one in the steam outlet header and the other
at the outlet of the hydraulic pump).
BOILER – TEST PRE-REQUISTES

Ensure that the following valves are closed.

• Root valves of all instruments.
• Chemical dosing line valves
• CBD and IBD Valves
• All header and pipe drain valves
• Soot blowing system and sample cooler system isolation valves.
Ensure that, the following valves are opened.
• Hydro test connection valve
• Filling line valve
• Drum vent valve
• Hydro test pressure indicator isolating valves
• Super heater vent valve
BOILER – TEST PRE-REQUISTES
• Ensure that, the following DM water quality is maintained.

• Chemicals – Ammonia and Hydrazine Hydrate in quantity such that water being filled shall
have 200 ppm of hydrazine and pH of 9.5 - 10
BOILER – PROCEDURE

Once the boiler

is completely
Continue the
filled, close all If no leakage is
filling until the
the air vents, observed, start
water starts Raise the Similarly raise
when water the pressurizing
Open the filling coming out pressure the pressure to
starts coming pump. The
line valve and through all the gradually to 25% 50% and 75% of
out freely hydrostatic
start filling the air vents of of the hydro test the hydro test
without air pressure should
boiler through boiler drum and pressure and do pressure and
bubbles, and be 1.5 times
low point drains. super heater visual inspection repeat above
stop the filling maximum
headers. Ensure for leakage. procedure.
pump and working
air is released
isolate the filling pressure.
completely.
pump from the
boiler.
BOILER – PROCEDURE

If no leak is observed
When the pressure release the -boiler; for
If any leakage is identified
reaches the hydro-test further work. Reduce the
it is to be attended after
pressure, stop the Check for any leakage or boiler pressure gradually
draining the water and
pressurizing pump and sweating. by crack opening drain
repeat the hydro test as
observe the pressure valves till the boiler is 2
mentioned above.
drop for 30 minutes kg/ cm2 (g) and then
open all the vent valves.
BOILER – PRECAUTIONS

The DM water
and the metal
temperature of
Dial pressure
Minimum two the pressure Do not weld
Steam drum, Proper gauge used in parts should be The metal
set of spare any pressure
man holes lighting, the testing above the temperature
gaskets for parts or
and manifolds approach shall have ambient air dew shall not
the drum and attachments
inspection platforms and dials point to prevent exceed 120°F
boiler to the
caps are communicatio graduated condensate (50°C) during
important formation on pressure
properly n systems over the the close
gaskets must the pressure parts, with
joined and must be in entire range visual
be available parts being water inside
tightly sealed. place. of the hydro examination.
ready. tested, which tubes.
test pressure. interfaces with
the detection of
small leaks.
BOILER – PRECAUTIONS

Test pressure must never exceeds more than 6% of required pressure.

DM water with oxygen scavenger added to 300ppm and PH not more than 9.5 to be used.

Boiler shall always be filled with treated water as specified in the contract. Filling the boiler
with un-treated water will cause internal damage and corrosion of pressure parts.
REPAIRED BOILER - HYDROTEST

Test pressure should be not more than 1.5 time MAWP to verify leak tightens integrity of repair

Test pressure should be adjusted for remaining corrosion allowance

During pressure test where test pressure exceeds 90% of set pressure of the PRV, then PRV should be
removed and connection is reinstated by blinding

The metal temperature for the pressure test shall be in accordance with the original code of construction
but not less than 16C and more than 49C

Hold time for pressure test shall be minimum 10 minutes prior to examination by the inspector

The test pressure should be reduced to MAWP for close examination by the inspector.
 API -653 ; Tank Inspection
TANK
and Repair.
TANK – INTRODUCTION

There are primarily two types of tanks:

• Fixed Roof: Liquid filling and draining is controlled by pressure vacuum relief valve.
• Floating Roof: Liquid filling and draining is controlled by movement of roof itself.
TANK – WHY HYDROSTATIC TEST

Hydrostatic test is needed for the following reasons:

• Final mechanical test to check mechanical strength of new storage tank. If there
are weak spots they will be evident when the tank is full of water.

• To ensure that there are no cracks, pinholes, or other discontinuities in the welds

• Tank has no leaks

• To check integrity of foundation that supports the tank.

TANK – WHEN HYDROSTATIC TEST

A full hydrostatic test shall be performed on the following:

• A reconstructed tank.

• Any tank that has undergone major repairs or major alterations.

• A tank where an engineering evaluation indicates the need for the hydrostatic test
due to an increase in the severity of service. Examples of increased service severity
are an increase in operating pressure (such as storing a product with a higher
specific gravity), lowering the service temperature, and using tanks that have been
damaged.
TANK - Hydrostatic Test Procedure

The hydrostatic test procedure encompasses the following steps:

• A tank with a hydrostatic test required by this standard shall be filled to the level stated
in API 650, Section 7.3.6(1)(a), unless the level is limited by the tank condition as given
in section 4.3.3.2 of this standard.
• That liquid level shall be held for a minimum of 24 hours.
• The tank shall be inspected frequently during the filling operation for indications of
leaks and/or settlement. Any repaired weld joints above the liquid level shall be
examined in accordance with API 650, Section 7.3.6(1)(b).
TANK - Hydrostatic Testing Exemptions

Review/Approval/Authorization Requirements:

Shell Repair:

Bottom Repair within the Critical Zone:

Shell-to-bottom Weld Repair:

Minor Shell Jacking:

Fitness-for-Service Evaluation:

Bottom Repair or Replacement Outside the Critical Zone:

Leak Tests:
TANK -Settlement Survey During Hydrostatic Testing

• When Settlement Survey is Required:

A settlement survey shall be conducted for all existing tanks that undergo a hydrostatic
test, except for tanks that have a documented service history of acceptable settlement
values, and no settlement is anticipated to occur during the hydrotest.
• Initial Settlement Survey:
When a settlement survey is required, the tank settlement shall initially be surveyed with
the tank empty, using an even number of elevation measurement points, N, uniformly
distributed around the circumference.
The minimum number of elevation points shall be as indicated by the following equation:
N = D/10
Where,
D is the tank diameter, in feet (ft).
And
N is the minimum required number of settlement measurement points, but
no less than eight.
TANK - EXAMPLE
TANK - EXAMPLE
TANK - EXAMPLE
 VALVES - INTRODUCTION
Functions of a valve: Types of valves:

 Starting and Stopping Flow  Gate Valve

 Regulating Flow Volume (called Throttling)  Globe Valve

 Preventing Reverse Flow  Check Valve

 Changing Flow Direction  Plug Valve

 Limiting Fluid Pressure  Ball Valve

 Butterfly Valve

 Diaphragm Valve

Valves can handle Liquid, Gases and Slurries

VALVES - PARTS

Back Seat

Shell
VALVES - TESTS

• Shell Test

• Back Seat

• Low-pressure closure test

• High pressure closure test

NOTE: In API-598, it is mentioned which valve require which type of test

VALVES - TESTS
VALVES –SHELL TEST PRESSURE

b: The Shell test pressure shall be 1.5

times the minimum pressure
rating at 38⁰C rounded off to the
next higher bar.

c: For Class 800 valves, the shell test

pressure shall be 1.5 times the
minimum pressure rating at 38
rounded off to the next higher
bar.
VALVES –BACKSEAT & CLOSURE TEST PRESSURE

b: 110% of maximum allowable

pressure at 38 ⁰C.

c: 110% of design differential pressure

at 38 ⁰C .
VALVES –TEST DURATION
VALVES –SHELL TEST PROCEDURE
VALVES –CLOSURE TEST PROCEDURE
VALVES –LEAKAGE

Visually detectable leakage through the pressure boundary walls and any fixed body joint is not
permitted.

For back seat tests, visually detectable leakage is not permitted.

Stem seals:

For adjustable stem seals, leakage from stem seals during the shell test not be the cause for
rejection at pressure rating greater than 38 ⁰C

For non-adjustable stem seals (O-rings, fixed single rings, etc), visually detectable leakage during
the shell test is not permitted.

No-Visually detectable leakage definition: If test fluid is liquid, there shall be no evidence of
drops or wetting of the external surfaces of the test
VALVES –LEAKAGE
The allowable leakage rate for closure test of valves with nonmetallic (e.g. ceramic) seat material
shall be equal to that specified in table 5 for a metal seated valve of equivalent size and type.
VALVES - PRECAUTIONS

• Test fluid temperature: (5 ~ 38) ⁰C

• Water must contain either water-soluble oil and/or corrosion inhibitor.

• For stainless steel valve chlorine content in water ≤ 50 ppm

• The valve shall be essentially free from trapped air

• Paint is not applied prior to hydro test because it can mask surface defects
VALVES –PNEUMATIC TEST

• High Pressure Pneumatic Shell test: This test will be done at 110% MAWP at 38C as

specified in the purchase order. Visible leakage is not allowed.

• Low Pressure Closure Test: This test is recommended to be performed using gas (air/ inert

gas, etc)

• Low-Pressure Back seat Test: Recommended test fluid is gas (air / inert gas, etc)
TANK – HYDROSTATIC TEST HEIGHT
The tank shall not be filled above the level determined by the lesser value of 𝐻 . The hydrostatic test height, 𝐻 , is calculated as
follows:
𝑆 𝐸𝑡
𝐻 = +1
2.6 𝐷
Where;

𝐻 is the height from the bottom of the shell course under consideration to the hydrostatic test height when
evaluating an entire shell course in feet; or

is the height from the bottom of the length, L, for the most severely thinned area in each shell course to the
hydrostatic test height in feet.

𝑆 is the maximum allowable hydrostatic stress in pounds per square inch (psi)

The maximum liquid level for hydrostatic test shall be determined by using the actual thickness measured for each shell course,
the allowable stress for the material in each course, and the design method to be used.
HYDROSTATIC TEST PRESSURE
Duration
SYSTEM SUB-DIVISION TEST PRESSURE Acceptance Criteria
(minutes)

A) Power Piping 𝑃 = 1.5𝑃

PIPING 𝑆 10 No leakage
B) Process Piping 𝑃 = 1.5 × 𝑃 ×
𝑆
A) Standard 𝑃 = 1.3 𝑀𝐴𝑊𝑃 × 𝐿𝑆𝑅

𝑃 = 2 𝑀𝐴𝑊𝑃 × 𝐿𝑆𝑅 , 𝑀𝐴𝑊𝑃 ≥ 30 𝑝𝑠𝑖

PRESSURE 𝑃 = 2.5 𝑀𝐴𝑊𝑃 × 𝐿𝑆𝑅 , 𝑃 ≤ 400𝐾𝑃𝑎,
B) Cast Iron 30 ~ 60 No Distortion & leakage
VESSEL 𝑀𝐴𝑊𝑃 ≤ 30 𝑝𝑠𝑖

C) Ductile iron 𝑃 = 2 𝑀𝐴𝑊𝑃 × 𝐿𝑆𝑅

A) Shell Test Table (2) Table (4)

VALVES Table (5)
B) Backseat & Closure Test Table (3) Table (4)

BOILER - 𝑃 = 1.5 𝑀𝐴𝑊𝑃 30 No leakage

No deformation of foundation
𝑆 𝐸𝑡
TANK - 𝐻 = +1 24 x 60 No distortion of tank
2.6 𝐷 No leakage
EXAMPLE

Q#1 What is the minimum hydrostatic pressure for an existing vessel where the MAWP is 1000
psi and corrected stress / temperature ratio is 1.0?

Q#2: What is the minimum hydrostatic pressure for an existing vessel where the MAWP is 500
psi and corrected stress / temperature ratio is 0.8 ?

Q#3: Calculate hydrostatic leak test at 70 degree F, required for a piping system with NPS 6
ASTM A 106 Gr B pipe that operates at a maximum of 650 degrees F and 400 psi.cvQ#3:
Calculate hydrostatic leak test at 70 degree F, required for a piping system with NPS 6
ASTM A 106 Gr B pipe that operates at a maximum of 650 degrees F and 400 psi.
EXAMPLE

Q#4: A Grey Cast Iron gate valve of class 600 & NPS “6” has to be hydro tested for body as
well as its closure. Find out test pressure and duration for both tests.

Q#5: The working pressure of boiler is 104 kg/cm2 . What would be its test pressure?
Hydrostatic pressure other section of Section Viii Pressure vessel
2) For cast iron(UCI-99)
𝑃 = 2 𝑀𝐴𝑊𝑃 × 𝐿𝑆𝑅 𝑀𝐴𝑊𝑃 ≥ 30 𝑝𝑠𝑖
𝑃 = 2.5 𝑀𝐴𝑊𝑃 × 𝐿𝑆𝑅 𝑃 ≤ 400𝐾𝑃𝑎, 𝑀𝐴𝑊𝑃 ≤ 30 𝑝𝑠𝑖
Note: pressure vessel parts shall not be painted or otherwise coated either internally or externally prior to the hydrostatic
pressure test.

3) For Ductile Cast Iron (UCD-99)

𝑃 = 2 𝑀𝐴𝑊𝑃 × 𝐿𝑆𝑅

4) For Materials having high allowable stresses at low temperature (SS, Alloys) (ULT-99)

𝑃 = 1.4 𝑃 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 = 65℃