Introduction To Hydro Testing-Process Piping

INTRODUCTION TO HYDRO TESTING- PROCESS PIPING
Debasish Sarma- MIEAust, Msc. BEngg

Introduction
A Hydrostatic (HYDRO) test is a type of pressure test in which process components such as
pipelines, piping, pressure vessels and fuel tanks can be tested for their strength and leaks.
The procedure involves filling the test system with a liquid (Water) and pressurising it to a
specified test pressure.Where equipment is shop or field assembled into, pressure tests may
also be completed to prove the mechanical strength and integrity of the whole assembled
system including piping flanged/coupled joints and equipment connections. It is a standard
industry practice for most pressure retaining systems and is used to demonstrate the integrity
and fit for use of the system under test prior to start up. Although methods of calculations and
procedures of testing vary according to design codes and materials under test, the concepts of
hydro test remains the same. This article is limited to metallic process piping systems tested
according to ASME B31.3 and BPV Section VIII.
Basic Steps of a Hydro testing
1) Pre-test Activities and site set up
Any item/part/component with a maximum allowable hydrostatic test pressure less than the
piping system test pressure or not part of the pressure test is removed or positively isolated.
All test battery limits are fitted with fully rated blind flanges, spade blinds or closed position
spectacle blinds. The perimeter of the hydrostatic testing is barricaded and signs set up to
inform personnel that a hydrostatic test is in progress.In-line Ball valves are kept half open
and globe and gate valves fully open, any other valves are generally being as advised in the
manufacturer’s manual.
2) Test medium and Temperature
Test water is usually neutral pH water Nontoxic, potable or demineralised water. The
temperature of the material of construction and the testing mediums is kept the same as far as
is practical. The temperature for the test is usually kept between 5 to 48 C so that a factor
o
like pressure deration does not come into play.

3) Test Pressure Calculations
Usually, process piping is tested to 1.5 times the design pressure (ASME B31.3 para 345),
except as provided in the paragraph below. Before proceeding with any hydro test, test
calculations are required to be made and approved by the Principal and signed off.For a
design temperature above the test temperature, the minimum test pressure shall be calculated
by the following equation, except that the ratio of ST/S should not exceed 6.5.
P = 1.5PS /S
T T
Where:
P = Minimum Hydrostatic Gauge Pressure
T
P = Internal Design Gauge Pressure

S = Allowable Stress at Test Temperature
T
S = Allowable Stress at Design Temperature

(Refer Table I, Appendix A of ASME B31.3 for values of S and S ) T
Where the test pressure as defined above would produce a stress in excess of 95 percent of
the yield strength at test temperature, the test pressure will be reduced to the maximum
pressure at which the stress will not exceed 95 percent of the yield strength at the test
temperature. The maximum test pressure at which the stress produced will not exceed 95
percent of the yield strength will be calculated by equation for internal pressure in para.
304.1.2 of ASME B31.3.
When determining the test pressure, consideration should be given to the applicable static
head in the system subjected to the test. The required test pressure should be achieved at the
lowest point in the system. If it is achieved at the highest point, the test pressure at the lowest
point will exceed the stipulated test pressure. Test pressures may be taken at any point on the
system being tested provided a correction for static head is agreed with the owner’s site
representative. Where static head is significant, the datum elevation should be the lowest
point being tested.
4) Test Arrangement
Once the test procedure is approved, the test arrangement is set up. This includes test
equipment like manifolds, gauges, chart recorders and temperature recorders, as well as
temporary vent valves etc as needed. A typical test set up and manifold arrangement is shown
below:
Photo: Typical Manifold and filling arrangement- Shop Hydro test.
4) Filling and Venting
Systems to be hydrostatically tested are filled gradually from a water source or tanker
ensuring the fill rate is according to test procedure. System is also vented during filling to
ensure elimination of air pockets. Before application of hydrostatic test pressure, the
temperatures of the test fluid and the material of the piping are allowed to equalise to within
+/- 5°C.
5) Pressurisation
Pressurisation starts after the entire system has been filled and isolated. Pressure is gradually
increased to 50% of test pressure and then the system is allowed to stabilise for a period of
time. This is also the time when we inspect for any leaks of buckling. With no leaks evident,
pressure is increased to 75% of test pressure and the same process is repeated until 100% of
test pressure is achieved. Some tests allow pressure to be topped up during test with make-up
water. Any leaks, deformations/distortions, drop in pressure or other issues identified are then
corrected and retested as per the approved design requirements and governing code.
6) Post Test
After testing, the equipment and piping system are safely and gradually depressurised,
completely drained/flushed and dried to prevent corrosion. During draining vent valves are
usually kept open at the highest point of the system to prevent vacuum. If a piping system is
to be dried by blowing, drains or vents are opened in order to avoid pressuring the system.
Piping that is hydrostatically tested, is dried by either hot air blowing, or with nitrogen.
Unless the design/operation requires otherwise, piping systems are dried to the point where
air exiting the system is measured to be at a maximum dew point of 0 C. Hydro test records
o
and test reports are then generated and signed off signalling the successful conclusion of the
test and system proceeds to the next stage of completion.

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INTRODUCTION TO HYDRO TESTING- PROCESS PIPING

Debasish Sarma- MIEAust, Msc. BEngg

like pressure deration does not come into play.

P = Internal Design Gauge Pressure

S = Allowable Stress at Design Temperature

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