Hydrotest Pressure

UG-99
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 Pressure Testing
Standard Hydrotest Pressure as per UG -99

Hydrotest
Maximum
Pressure
Allowable
Working
Pressure

Design
Pressure

Operating
Pressure
Hydrotest Pressure
• Hydrotest is an opportunity to check the leak
tightness of mechanical joints such as:
A. Flanged Joints
B. Threaded connection
C. Fittings in instrument tubing

• Actual pressure the vessel is tested at.

• Hydro test pressure is 1.3 times the design
pressure (ASME requirement).
Test me
for
Leakage
 Pressure Vessel under Hydro testing

• Example: If the design pressure is - 100 KPa(g),

then the hydro test pressure is - 130 KPa(g).
Therefore, the rule is called the 10/13 rule.
• The hydro test pressure is set by code:
• ASME III and ASME B 31.1.

• It is 130 % more than the design pressure.

• It is the maximum pressure that a vessel
undergoes throughout its lifetime.
vent
Hydrotest Pressure
• ASME Section VIII, Div. 1 (ASME Code) sets out the general requirements for the
inspection and testing of pressure vessels.
• One of the requirements is that either a hydrostatic test or pneumatic test must be
performed, and the vessel must be inspected during the test.
• The test is done after all fabrication has been completed and all examinations have been
performed.
• For most pressure vessels, a hydrostatic test in accordance with UG-99 is done with
water.
• For pressure vessels that cannot be safely filled with water, or where even traces of the
testing liquid cannot be tolerated, a pneumatic test may be done in accordance with
UG-100.
Hydrostatic Test Procedure

1 Designed Pressure Vessel: Internal Pressure

UG-99 Endnotes 36: The maximum allowable

Subjected to Hydrostatic Pressure test: working pressure may be assumed to be the

2
A. 1.3 x DP x LSR (Most of the time) same as the design pressure when calculations
are not made to determine the maximum
B. 1.3 x MAWP x LSR (ASME & API) allowable working pressure.

C. 1.3 x MAP x LSR (PTS 12.20.01) NOTE: LSR =

Material Stress at Test temperature
Material Stress at Design Temperature

3
Hydrostatic test pressure reading.
Adjusted for any static head conditions. Which depends on:
Elevation of the Chamber – Elevation of the Pressure Gauge
 Ug-99(b)

Hydrotest Pressure Calculation (at site and shop corroded condition)

This stress ratio is the ratio of pressure components such as shell,

Ph = 1.3 x MAWP x Lowest Stress Ratio dish ends, nozzles, their flanges & to be precise also of nozzle
bolting.

material stress at its operating(test) temperature

R=
material stress at its design temperature
Hydrostatic
Pressure If the end client or the equipment owner does not specify the MAWP (Maximum Allowable
Working Pressure) as the design criteria then we may select the UG-99 (b) (36) – Endnote
(36).
The MAWP (Maximum Allowable Working Pressure) may be assumed to be the same as the
design pressure when calculations are not made to determine the MAWP (Maximum
Allowable Working Pressure).

Visual Inspection Shall be made at a pressure not less than – the Test pressure divided by 1.3
Ph
Pinspection =
1.3
• LSR stands for Lowest Stress Ratio.

• Though the pressure vessels are designed for high-temperature applications, they will
be hydro-tested at room temperature.

• Since the induced stress in pressure vessels due to hydrostatic test is a function of
temperature.

• A conversion factor called LSR is used to convert the allowable stress value at test
temperature to the stress value at the designed temperature.

• For example, if the pressure vessel is designed to handle the fluid at room temperature,
then LSR=1.

• Note: Test pressure will be higher than the maximum allowable working pressure.
 Test Pressure Ph = 1.3 x MAWP x Lowest Stress Ratio

Ph
Inspection Pressure Pinspection ≥
1.3
Test Pressure Holding
Time
ASME does not specify
anything about the test
pressure holding time.
As a practice, 30 to 60
minutes is followed.
Example
• Material – SS 316 L

• Design Temperature – 400° F

• Design pressure – 3000 Psi Gauge

Maximum Allowable Stress of SS 316 L – 20000 Psi Gauge @ 100° F and

@ 400° F – 190000 Psi Gauge.

20,000
Ph = 1.3 x 3000 x ( ) Ph
19300 Pinspection =
1.3
Ph = 4041.450 4041.450
Pinspection =
1.3
Pinspection = 3108.807
Process of Hydro Static Testing:

1
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.

2
STAGE
Restart pressurizing up to 70% of final pressure, stop the operation,
keep it for 5 minutes and make a fast visual inspection on the external
surface.

3
STAGE
Restart pressurizing up to 100% of the final pressure, stop the operation,
and keep for 45 minutes.
 Activities Before Hydro Testing:
1. Checking all welding already finished and fully accepted by the 6. MDMT is the pressure vessel minimum design metal
NDT examination per the project Inspection and test plan. temperature, and it is stated in the pressure vessel design
document. This reduces the risk of a brittle fracture during the
2. Make sure the inner part of the vessel is clean and free of
test.
remaining slag, and the external surface is dry for the correct
execution of the visual inspection during the vessel pressure 7. Make sure which reinforcement pads are already soap tested.
testing.
8. Controlling the testing water quality and using corrosion
3. Checking the pressure gauges’ calibration tag and certificate inhibitor if it is necessary or when the vessel metal is sensitive
and the range of the lower limit and upper limit of the gauges. It material.
needs to be between 1.5 and 4 of the pressure test value.
9. Checking of vents. It is required to be placed at high points of
4. Controlling testing equipment such as the test pump and the vessel in a position where it is possible to purge air pockets
housing for soundness and tightness. while the vessel is filling.

5. Making sure the test temperature will not violate the following
values: Min. Test temperature= MDMT + 30°F, Max. Test
temperature = 120°F.
 This stress ratio is the ratio of pressure components such as shell,
𝐏𝐡 = 𝟏. 𝟑 𝐱 𝐌𝐀𝐖𝐏 𝐱 𝐋𝐨𝐰𝐞𝐬𝐭 𝐒𝐭𝐫𝐞𝐬𝐬 𝐑𝐚𝐭𝐢𝐨 dish ends, nozzles, their flanges & to be precise also of nozzle
bolting.

material stress at its operating(test) temperature

𝐑=
material stress at its design temperature
Hydrostatic
Pressure If the end client or the equipment owner does not specify the MAWP (Maximum Allowable
Working Pressure) as the design criteria then we may select the UG-99 (b) (36) – Endnote (36).

Hydrotest Pressure Calculation ??

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