Hydrostatic Pressure Test

A hydrostatic test is a way in which leaks can be found in pressure vessels such as pipelines and
plumbing. The test involves placing water, which is often dyed for visibility, in the pipe or vessel
at the required pressure to ensure that it will not leak or be damaged. It is the most common
method employed for testing pipes and 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 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.

Testing procedures
Hydrostatic tests are conducted under the constraints of either the industry's or the customer's
specifications. The vessel is filled with a nearly incompressible liquid - usually water or oil - and
examined for leaks or permanent changes in shape. Red or fluorescent dyes are usually added to
the water to make leaks easier to see. The test pressure is always considerably higher than the
operating pressure to give a margin for safety. This margin of safety is typically 150% or 5/3 of
the design 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 almost incompressible (compressible only by
weight, not air pressure), so will only expand by a very small amount should the vessel split. If
high pressure gas were used, then the gas would expand to perhaps several hundred times its
compressed volume in an explosion, with the attendant risk of damage or injury. This is the risk
which the testing is intended to mitigate.

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 by monitoring the water level. For best accuracy, a digital
scale is used to measure the smallest amounts of change. The vessel is then pressurized for a
specified period, usually 30 or more seconds, and then depressurized again. The water level in
the jacket is then examined. The level will be greater if the vessel being tested has been distorted
by the pressure change and did not return to its original volume, or some of the pressurized water
inside has leaked out. In both cases, this will normally signify that the vessel has failed the test.
If the Rejection Elastic Expansion is more than 10%, or not up to DOT or customer standards,
the cylinder fails, and then goes through a condemning process marking the cylinder as unsafe.
This measures the overall leakage of a system instead of locating the leaks and additives can be
added to the water to reduce resistivity and increase the sensitivity of the test. The hydrostatic
test fluid can also clog small holes (1x10^-6 std cm^3/s or smaller) as a result of the increase in
pressure. This is another reason why water is commonly used.

All the information the tester needs is stamped onto the cylinder. This includes the DOT
information, serial number, manufacturer, and manufacture date. Other information is stamped as
needed such as the REE or how much the manufacturer specifies the cylinder should expand
before it is considered unsafe. All this information is usually taken down and stored on a
computer prior to the testing process. All this information is necessary for keeping track of when
the cylinder has been or needs to be hydrotested.

Water jacket test

A simpler test, that is still considered a hydrostatic test but can be performed by anyone who has
a garden hose, is to pressurize the vessel by filling it with water and to physically examine the
outside for leaks. The pressure level achieved in this sort of test does not come close to the
pressure level that would be used in a professional testing facility.

Examples
Portable fire extinguishers are safety tools that are required to be on hand in almost every public
building. Fire extinguishers are also highly recommended in every home. Over time the
conditions in which they are housed, and the manner in which they are handled have an impact
on the structural integrity of the extinguisher. A 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 must be utilized. All critical components of the fire extinguisher
must be tested to ensure proper function. The cylinder would be tested by using the water jacket
test.

As previously mentioned, the water pressure inside the tank will usually be 150% of the normal
operating pressure. The change in volume of the cylinder is calculated by measuring the change
in the water levels outside the cylinder. This can be done with a digital scale, as well to detect the
slightest changes most always in grams. The cylinder can also be visually checked for leaks or
the pressure drop method can be utilized to measure the overall efficiency of the cylinder.
Pipeline testing
Hydrotesting of pipe, pipelines and vessels is done 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. ASME B31.3 section 345

Buried high pressure oil and gas pipelines are tested for strength by pressurizing them to at least
125% of their maximum operating pressure (MAOP) 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 (SMYS) at 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.

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.

Testing frequency
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 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.
 SP-Cylinders Special Permit #
 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)
In the U S and Canada, organizations such as ASTM, and ASME specify the guidelines for the
different types of pressure vessels.

According to ASME Section VIII Division I, hydrostatic pressure is conducted at the pressure of
1.5 times design pressure. If a vessel is design for holding 1.0 kg/cm2.g pressure, the hydrostatic
pressure test has to be done at 1.5 kg/cm2.g.

Hydrostatic test is also applied to existing equipments and pipe lines to check for leakage after
being repaired or maintained. Hydrostatic job number increases during plant Turn Around
period. Because at that time, most of equipments are opened for checking, inspection, clean-up,
repairing, replacing certain parts or performing internal modification.

The use of high pressure is the main source of hazards associated with hydrostatic pressure test.
Hydrostatic test stores energy. High pressure could damage the facilities and endanger worker's
safety. You should have included this into your own hazard identification.

Safety Checklist:

In order to prevent accident from hydrostatic test operation, we have to make good preparation
prior to do the test, during the pressurization process and depressurizing operation. These jobs
should be made in the form standard operating procedure. And here are the safety checklists for
each stage.

Hydrostatic test preparation:

Specification sheet of the equipments and or pipe line, which mentions pressure and temperature
designs are available and complete.

* Hydrostatic test pressure and temperature standard are already clearly defined in the related
document.
* Supported documents such as P&ID and isometric drawing are available and conform to as
built facilities at the field.
* Pressure test planning has to be distributed to all relevant sections in the plant site at least two
days before the execution date.
* Make good coordination among related sections that involve in the test.
* All test equipments and tools shall be inspected for wear and damage.
* Pressure measurement tools are calibrated and their statuses of calibration are still valid.
* Pressure gauges used in the test have enough capacity. The gauges are recommended to have
150% of the maximum allowable working pressure.
* The pressure gauge is safety type, with blowout back.
* Pressure gauges must be installed at a proper location so that it can be easily read and do not
create additional hazards to the hydrostatic test or expose personnels to the vessel being tested.
* All the temporary tools (such as valve, fitting, hoses, flanges, blind plate, etc) have to be rated
more than the maximum hydrostatic pressure.
* Isolate other equipments and pipe lines that do not include in the hydrostatic test.
* Vents are available and installed the high points to vent air. Check the vent line before testing
and make sure it is not blocked.
* Choose drain valve at the lowest point in order to completely empty the vessel and pipe.
* Safety relief valve is already installed. Safety relief valve setting is 1.5 times maximum
allowable working pressure.
* Safety relief valve is calibrated.
* Isolate the test area and surround it with safety line. Put appropriate safety sign at that area.
* Do not allow person who does not have any relation with the hydrostatic test, to enter the test
area.
* If possible perform the test from a remote area.
* Make sure that all pipe and vessel supports are in good condition and have been inspected.
* All hoses must be tied down.
* Water temperature must be more than 16oC (60 F).
* The hydrostatic-pressurizing pump is completed with safety relief valve.
* Wear proper personal protective equipments.
* Do not start the test if a problem is identified.
* Issue a work safety permit by authorized personnel.

Pressurization process:

* Remove all air from the vessel and pipe line by water through vent line.
* Pressurization is conducted gradually/slowly.
* Mark all leak points and repair them before preceding the test.
* Do not monitor during pressurization step directly from the front of sight glass or level glass.

De-pressurization process:

* Start de-pressurization by opening gradually the vent valve. Do it slowly.

The above hydrostatic pressure test safety checklist will ensure worker's safety and the facility of
the plant. Thus, do not try to ignore them.