Hydrostatic Testing

Pressure test system to

demonstrate
Integrity

By
Anil Kumar Saxena
Pressure testing is required by most piping codes to verify that a
new, modified or repaired piping system is capable of safely
withstanding its rated pressure and is leak tight.
Compliance to piping codes may be mandated by regulatory and
enforcement agencies , insurance carriers ,or the terms of the
contract for the construction of the system. Pressure testing
whether or not legally required serves the useful purpose of
protecting workers and the public.
Pressure testing may also be used to establish a pressure rating
for a component or special system for which it is not possible to
establish a safe rating by calculation. A prototype of the
component or system is subjected to a gradually increasing
pressure until measurable yielding first occurs or alternatively ,to
the point of rupture. then by using derating factors specified in the
code or the standard appropriate to the component or system. it
is possible to establish a design pressure rating from the
experimental data
 Leak Testing Methods

There are many different methods for pressure and leak

testing in the field, seven of these are,
1.) Hydrostatic testing, which uses water or another liquid
under pressure.
2), Pneumatics or gaseous fluid testing, which uses air or
another gas under pressure.
3). A combination of pneumatics and hydrostatic testing,
where low pressure air is first used to detect defect.
4). Initial service testing ,which involves a leakage
inspection when the system is put in to inspection.
5). Vacuum testing which uses negative pressure to
check for the existence of a leak.
6). Static head testing which is normally done for drain
piping with water left in a standpipe for a set period of time.
7). Halogen and helium leak detection
 Sensitivities of Leak Testing Methods and Acceptance Standards
The order in which the various leak testing methods
indicate leak tightness, from least sensitive to most
sensitive , are
1).Hydrostatic leak testing with visual observation.
2).Pneumatic testing with visual observation of bubbles
in soapy mixture.
3). Gas leak testing
4. Helium –mass spectrometer sniffer
5). Halogen-diode sniffer
6). Helium-mass-spectrometer tracer technique
7). Helium-mass-spectrometer hood method.
The ASME B31 Pressure piping Code has several
sections. They are,

ASME B 31.1 For Power Piping

ASME B 31.2 For Fuel Gas Piping
ASME B 31.3 For Process Piping
ASME B 31.4 For liquid transportation system for
hydrocarbons, LPG, Anhydrous
Ammonia & Alcohols.
ASME B 31.5 For Refrigeration Piping
ASME B 31.8 Gas Transmission and Distribution
Piping system.
ASME B 31.9 For Building Services Piping
ASME B 31.11 For Slurry Transportation Piping
System
 The ASME Boiler and Pressure Vessel Code also has
several sections which contain pressure and leak testing
requirements for piping systems pressure vessels and other
pressure retaining items. These are.
Section I For Power Boilers
Section III For Nuclear Power Plant Components
Section V For Non Destructive Examination
Section VIII For Pressure Vessels
Section X For Fiberglass, Reinforced Plastic Pressure
Vessels.
Section XI For in service inspection of Nuclear Power Plant
Components.
 •Hydrostatic testing is most often preferred over
pneumatic testing because of safety considerations.
Water is the preferred fluid medium for hydrostatic
testing. In addition to its relatively incompressible
nature , it is also the safest fluid because of its nontoxic
and non-flammable and it remains in liquid form down to
atmospheric pressure unless heated above the boiling
point. Water is readily & economically available ASME B
31.3 section 137.43 specifies water as the test fluid for
hydrostatic test unless otherwise specified. If hydro
testing is being considered for a system that was
designed for use of gaseous medium as the process
fluid. It must first be determined that the piping system
will support the weight of the test liquid or that the piping
can be safely supported during the hydrostatic test.
There are some cases where water cannot be
employed as a fluid test medium. Traces of
water left in the piping may react adversely with
the process/ For example in piping for liquid
sodium or a cryogenic process. If the test is to
be run at temperature condition which would
make freezing likely, antifreeze may be added to
the water as long as the antifreeze is not harmful
to the piping or process. And the disposal of
large amounts of antifreeze is not
environmentally unacceptable. If water cannot
be employed as the test fluid medium & another
liquid is not practical pneumatics test may be the
next best choice.
Test Pressure

Hydrostatic test pressure at any point in a

metallic piping system shall be as follows:

(a) Not less than 1.5 times the design

pressure;

(b) For design temperature above the test

temperature, the minimum test pressure
shall be calculated by following eq.except
that the value of St/S shall not exceed 6.5
9
For design temperature > test temperature

Pt = 1.5 PST / S

ST/S must be ≤ 6.5

PT = Minimum hydrostatic test pressure, psig

P = Internal design pressure, psig
ST = Allowable stress at test temperature, psi
S = Allowable stress at design temperature, psi
 Pressure Gauges
Calibrated pressure gauges with range of 1.5 to 4
times test pressure should be used for pressure
test. For the ASME Section 1 work the pressure
gauge used shall be graduated over the entire
range of about double the intended maximum test
pressure but in no case less then 1.5 times that
pressure. Pressure gauges shall be calibrated
within a period not exceeding three months prior
to testing. Two gauges should be used for
pressure test. One gauge must be located at the
highest vent of the equipment & other gauge can
be located in a lower place.
RECORDS

This as a minimum should cover the following for the hydro

testing.

1). Any special treatment imparted to the test liquid.

2). Calibration reference of the pressure indicating gauge.
3). Calibration references of the pressure & temperature records.
4). Date and time of the test.
5). MAWP (Maximum Allowable Working Pressure)
6). MDMT
7). Test Pressure
8). Test temperature of the fluid.

Test plugging records to be maintained in the drawing after

completion of the test of schematics sketch to be drawn and
maintained.
Hydro-Test Pressure and Procedures

Except where it is necessary to meet design

codes or statutory requirements, the
hydrostatic test pressure should be limited to
150 % of design pressure. Pressure shall be
applied in small increments. The following
points shall be considered while carrying out
hydrostatic testing.

1). All floats shall be removed before filling

the system with water.
2) All air present in the system shall be
vented while admitting the test fluid.
3) Piping designed for vapour and gas shall
be provided with additional temporary
supports, if necessary. All spring support shall
be kept in locked position during hydro-test.
4).Line containing check valves shall have
source of test pressure on the upstream side.
5).Valves shall not be subjected to a test
pressure in excess of manufacturer's
allowable test rating. When permitted, the
installed valves shall be kept open.
6). Control and relief valves shall be excluded
from the test irrespective of their pressure
rating.

7). Instrument take-off piping up to the first

block valve shall be tested along with piping to
which it is connected. Testing of remaining
line leading up to the instrument can also be
done at the same time provided instruments
are blocked off from the source of pressure
and vented to atmosphere.

.
8). Open ends of piping where blanks cannot
be used e.g. pumps, compressors, etc. shall
be blinded off by using standard blind flanges
of same rating as the piping system being
tested.
9) Indicating pressure gauges mounted locally
may be tested with the line, provided the test
pressure is not in excess of their scale
ratings.

10) Orifice plates in horizontal lines shall not

be installed till completion of test.
 11) The test shall be carried out at ambient
temperature and it should be less than 50 deg. C.

12) All vent valves during filling up and draining

shall be kept fully open.

13) Hydrostatic testing of ferritic material shall

be carried out using suitably inhibited water,
which permits an extended period between the
start of testing and drying of components.

14) Hydrostatic testing of austenitic material

shall be carried out using water chloride content
less than 50 PPM
Draining The System
After the leakage test is completed the system may be
drained. The piping may be drained and left to air dry or
have hot air blown through it to dry it. Alternatively it may
be left filled to prevent rust from forming until the system is
put in to operations. If the system is left filled after testing
there should be warning tags on the valves to advise
anyone of the wet layup condition .In draining the system,
the following precautions should be observed.
1)First make sure all system vents are open.
2).Vents on tank-vessels should be open and functional to
avoid damage during draining.
3).The rate of drainage should not exceed the allowable
rate of the building or temporary drainage system.
4).disposal of test liquid contains surface preservatives or
other water additives must meet local and project
environmental requirements.
Hydrostatic test for pressure vessels
a). hydrostatic test shall be conducted on all vessels after
1). All fabrication has been completed, except for operations
which could not be performed prior to the test such as weld end
preparation cosmetic grinding on the base material which does
not affect the required thickness.
2). All examinations have been performed , except those
required after the test.
b). Vessels designated for internal pressure shall be subjected
to a hydrostatic test pressure which at every point in the vessel
is at least equal to 1.3 times the maximum allowable working
pressure to be marked on the vessel multiplied by the lowest
ratio (for the materials of which the vessel is constructed) of the
stress value S for the test temperature on the vessel to the
stress value S for the design temperature. All loadings that may
exist during this test shall be given consideration.
c).Following the application of the hydrostatic
test pressure, an inspection shall be made of all
joints and connections. This inspection shall be
made at a pressure not less than the test
pressure divided by 1.3 except for leakage that
might occur at temporary test closures for those
openings intended for welded connections.
Leakage is not allowed at the time of the
required visual inspection.
d). Vent shall be provided at all high points of
the vessels in the position in which it is to be
tested to purge possible air pockets while the
vessel is filling.
e). Any nonhazardous liquid at any temperature may be
used for the hydrostatic test if below its boiling point.
Combustible liquids having a flash point less than 110
deg F(43 deg.c) such as petroleum distillates may be
used only for near atmospheric temperature test. It is
recommended that the metal temperature during
hydrostatic test be maintained at least 30 deg F (17
deg.c)above the minimum design metal ,but not exceed
120 deg F(48 deg c)to minimize the risk of brittle
fracture. The test pressure shall not be applied until the
vessel & its contents are at about the same
temperature. If the test temperature exceeds 120 deg F
(48 deg. C) it is recommended that inspection of the
vessel required be delayed until the temperature is
reduced to 120 deg F(48 deg.c).
Hydraulic Test of Piping With Vessels as a
system

a). Where the test pressure of piping attached to a

vessel is the same as or less than the test pressure
for the vessel , the piping may be tested with the
vessel at the piping pressure.
b). Where the test pressure of the piping exceed the
vessel test pressure and it is not considered
practicable to isolate the piping from the vessel. The
piping and vessel may be tested together at the
vessel test pressure, provided the owner approves
and the vessel test pressure is not less than 77% of
the piping test pressure calculated in accordance
with.
 Pneumatic Test Pressure and Procedure

Pneumatic testing shall be considered where

hydro-testing is not possible due to design or
service requirements. The consequences of
failure during a pneumatic test can be
devastating and such testing requires special
precaution. Pneumatic testing shall be carried
out in line with proven standards/ codes. The
pneumatic test procedure shall be duly
approved. Some of the precautions to be taken
are as follows
The fluid normally used for a pneumatic test is
compressed air, or nitrogen. Nitrogen should
not be used in a closed area if the possibility
exists that the escaping nitrogen could
displace the air in the confined space. Persons
have been known to become unconscious
under such circumstances before realizing they
were short of oxygen Because of the greater
damage or injury with a gaseous test medium,
the pressure that may be used for visual
examination for leak is lower for some piping
codes than in the case for a Hydrostatic test.
For example, for pneumatic test .ASME B
31.3 permits the pressure to be reduced to
the lower of 100 psig (690 kpa) of the
design pressure during the examination for
leakage. If the pressure required by the code
is quite high, persons may be barred from
the test area and some listening device used
to search for leaks. However ,normally
inspection for a leak is done with a soapy
water mixture that applied to the joints and
which produces bubbles when air is
escaping.
Testing of piping pressures

The test fluid should be water unless

there is the possibility of damage due
to freezing or other adverse effects of
water on the piping system or the
process or unless the test water will
become contaminated and its disposal
will present environmental problems.
 •In either case, another suitable nontoxic
liquid may be used. If the liquid is flammable,
its flash point shall be at least 120°F (49°C)
or greater, and consideration shall be given
to the effect of the test environment on the
test fluid.
•The piping shall be subjected to thorough
testing including NDT as considered
necessary to ensure that there are no
inherent defects / operating deterioration
which may cause failure of piping during
testing.
 •Except where it is necessary to meet design
codes or statutory requirements, the test
pressure should be limited to 110% of design
pressure. Pressure shall be applied in small
increments/as per the spec.

•Close visual examination of piping shall not be

resorted to at a pressure higher than the
design pressure
 Shell & Tube Heat Exchanger
Testing & Inspection

1. Pressure-containing parts and assemblies,

including auxiliaries, shall be hydrostatically
tested at a minimum test pressure of one and
a half times the maximum allowable working
pressure in the new and cold condition of the
exchanger.
2. Except where specifically allowed or
specified elsewhere in this standard, a
pneumatic testing using air or nitrogen in lieu
of hydrotest with water shall not be performed
unless allowed by design engineers
acceptable, the test pressure shall be in
accordance with ASME Section VIII, Div 1,
Paragraph UG-100
3. If parts shown on exchanger drawings
cause test pressure to be lower than
required, the parts shall be removed or
isolated as appropriate
 4. Testing shall take place after original or
remedial post-weld heat treatment, except that
all welded attachments equipped with telltale
holes shall be pneumatically tested at 50 kPa
prior to heat treatment and hydrotest of the
exchanger.

5. Telltale holes shall not be obstructed during

the hydrotest of the exchanger. Examination
shall be conducted on each split reinforcing
pads, when used.
6. The use of gasket adhesives, except
graphite and oil or grease, shall be prohibited.
7. Where applicable, test shall be in accordance with
the ASME Code. In the event that a discrepancy
exists between the ASME Code test pressure and
the test pressure in this standard, design engineer
shall be consulted.

8 Following the application of test pressure, a visual

inspection for leaks shall be performed at a pressure
not less than the design pressure or two thirds of the
test pressure, whichever is greater. This pressure
shall be held for one hour per 25 mm of maximum
shell or formed head thickness, with a one hour
minimum and five hours maximum.
 9. Vertical exchangers shall be designed for
field hydrotest in vertical position.
10. Metal temperature of the pressure-
containing parts during the hydrotest shell be
maintained at the following, whichever is
warmer
a. 17 °C
b. 19 °C above the minimum design metal
temperature at minimum allowable working
pressure (MAWP)
c. 17 °C above the ductile-to-brittle transition
temperature of the steel
11. Water used to test 12 and 17 Cr stainless steels
(types 405, 410, and 430), austenitic stainless steels
and Monel shells, internals, cladding, weld overlay,
tubes or lining shall not have chlorides more than
allowed by design engineer’s specification. Fabricator
shall provide a test certificate or other documentation
as a proof of chloride content.

12. Exchanger shall be examined for complete

drain after hydrostatic test. If complete drainage is
not possible, exchanger shall be flushed with
chloride-free water, alcohol, petroleum distillate, or
suitable flushing solution. Exchanger shall not be
dried with hot air. Cold (unheated) air may be used
to blow water out of pockets.
13. The interconnecting flanged joints of stacked
exchangers shall be checked for leaks by air-and-
soap test at pressure given by design engineer.
When interconnection piping between stacked
exchangers are of butt-weld type, welding
procedure and performance qualification shall be
reviewed prior to welding the connection. All
nondestructive examination shall be conducted in
accordance with previous sections on butt welded
attachments.

14.New gaskets shall be used on all flanges and

nozzle joints after the testing is completed.
Hydro test of Tanks

When the entire tank is completed, it shall be filled

with water to the top angle or the design liquid level
and the design internal air pressure shall be applied
to the enclosed space above the water level and
held for 15 minutes. The air pressure shall then be
reduced to one half the design pressure and all
weld joints above the liquid level shall be checked
for leak by means of a soap film.Linsed oil or
another suitable material. Tank vents shall be
tested during or after the test.After the test water
has been emptied from the tank (and the tank is at
atmospheric pressure)
Hydrostatic Testing Requirements

This hydrostatic test of the tank shall be conducted before

permanent external piping is connected to the tank. After
complition of the hydro test only non structural small
attachments may be welded to the tank in accordence with the
procedure.Any welded joints above the test water level shall
be examined for leakage by one of the following method.

1). Coating all of the joints on the inside with a highly

penerating oil, such as automobile spring oil and carefully
examining the outside of the joints for leakage.
2). Applying vacuum to either side of the joints or applying
internal air pressure as specified for the roof test and carefully
examining the joints for leakage .
3). Using any combination of the methods stipulated in
subitems 1 & 2.
The minimum fill and discharge rate , if any. Shall be
specified by the purchaser on the data sheet when
settlement measurements are specified by the
purchaser. the maximum filling rates shall be as
follows, unless otherwise restricted by the
requirements.

Bottom Tank Portion Maximum

course Filling Rates
Thickness
Less than 22 mm (7/8 -Top Course 300 mm ( 12 inch) / hr
inch) - Below Top Course 460 mm (18 inch) / hr.

22 mm(7/8 inch) & thicker -Top third of tank 230 mm (9in. )/hr.
- Middle third of tank 300 mm (12 in.) / hr
--Bottom third of tank 460 (18 in. ) / hr.
Filling may continue which elevation measurements are
being made as long as the change in water elevation for
a set of readings does not exceed 300 mm(12in.)
Unless waived on the data sheet, the manufacturer shall
make shell elevation measurements in accordance with
the following.
1). Shell elevation measurements shall be made at
equally-spaced intervals around the tank circumference
not exceeding 0.8 m(32 ft)The minimum number of shell
measurement points shall be eight.
2). Observed elevations shall be referred to a
permanent bench mark. The level instrument shall be
set up at least 1.5 times tank diameter away from the
tank when tank elevation readings are taken. six sets of
settlement readings are required.
a. Before start of the hydro test
b. With tank filled to ¼ test height (+/- 600mm[12ft])
c. With tank filled to ½ test height (+/- 600 mm[12 ft])
d. With tank filled to ¾ test height (+/- 600 mm[12 ft])
e. At least 24 hours after the tank has been filled to the
maximum test height. This 24 hrs period may be
increased to duration specified on the data sheet if the
purchaser so requires for condition such as;
1) The tank is he first one in the area.
2) The tank has a larger capacity then any other existing
tank in the area.
3) The tank has a higher unit bearing load than any other
existing tank in the area.
4) There is a question regarding the rate or magnitude of
settlement that will take place.
f. After tank has been emptied of test water.