A hydrostatic test pump is a mechanical device that exposes pressure vessels, pipes, and other containers to high-pressure water to check their integrity and strength. This test identifies potential leaks or weaknesses and assures the structural soundness of the tested components for safe operation. Hydro test pump pressurizes the system to a certain level and maintains pressure for a predetermined amount of time to evaluate its performance under stress.

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What is Hydrostatic Testing?

Hydrostatic testing (also called hydro testing) is a method of verifying the structural integrity and safety of pressure vessels, pipes, hoses, and other equipment by subjecting them to high-pressure liquid, typically water. The object being tested is filled with water, and pressure is gradually applied to exceed its normal operating conditions. This helps identify any leaks, weaknesses, or defects that could compromise the equipment’s functionality or pose safety risks.

Hydrostatic tests are often necessary after equipment shutdowns, repairs, or prolonged time sitting idle to verify that it will operate properly when it returns to service. Hydrostatic testing is commonly used in industries such as construction, oil and gas, manufacturing, and firefighting to ensure compliance with safety standards and regulations.

How Does a Hydrostatic Test Pump Work?

The process of how a hydrostatic pump works involves the following steps:

1. Component Preparation: The component to be tested is filled with the test fluid, ensuring that all air is purged from the system to prevent pressure inconsistencies.
2. Pressure Buildup: The hydrostatic pump is activated, and the hydraulic pump starts pressurizing the fluid. As the pump operates, it generates hydraulic pressure that is transmitted to the component being tested.
3. Pressure Monitoring: Pressure gauges continuously monitor the pressure buildup, allowing operators to observe and record the pressure as it increases.
4. Test Pressure Attainment: The pressure is incrementally increased to the desired test level, which is often well above the component’s intended operating pressure. This elevated pressure exposes potential weaknesses in the system, such as leaks or structural deficiencies.
5. Test Duration: The component is subjected to the test pressure for a specific duration, during which inspectors carefully examine it and its surroundings for any signs of leakage, deformation, or abnormal behavior.
6. Pressure Release: Once the test duration is complete, the pressure is gradually released, and the component is depressurized in a controlled manner.
7. Inspection and Analysis: After depressurization, the component is thoroughly inspected again for any changes or damage resulting from the test. The recorded data, including pressure levels and test outcomes, can be analyzed for compliance and decision-making.

Common Applications Of Hydrostatic Testing

Theoretically, all systems that need to maintain pressure greater than ambient pressure have the potential to benefit from a hydro test. The following industries and applications are the most common examples.

• Sprinkler Frameworks

 Several sprinkler frameworks must be tested on a regular basis by code to ensure that they can withstand pressure when activated and perform properly. A siphon is linked to the main sprinkler framework line and compressed to 250 PSI, which it must maintain for 15 minutes.

• Fire Hoses

Some crucial applications like fire hoses must be checked to guarantee they do not burst or fail in service. They are usually checked before being placed in fire trucks or transported to fire stations. Inspectors will fill hoses with fluid and pressurize them to a minimum of 300 PSI in line with National Fire Protection Association (NFPA) specifications.

• Pipe Manufacturers

Hydro testing will be performed on pipes of varied lengths in commercial pipe manufacturing plants, particularly those offered to government agencies. They need to prove that each pipe fits specifications and will not fail in significant applications such as naval defense vessels.

• Chemical Industry

 Testing containers and vessels used for transporting, storing, or processing chemicals to prevent leaks and hazardous situations.

• Automotive Industry

Hydro testing plays a vital role in assessing the structural integrity and leak resistance of various components used in vehicles. These components include fuel tanks, radiators, and hydraulic systems, among others.

What Should We pay attention to When Using Hydro Test Pump?

Hydrostatic testing is a vital process for evaluating the structural integrity of pressure vessels, pipelines, and other critical components. Ensuring safety when using the hydro test machine in this procedure is of utmost importance.

Regular equipment inspections, including pumps, hoses, valves, and gauges, help detect and address potential sources of failure. Adhering to prescribed pressure limits prevents over-pressurization, while the inclusion of pressure relief mechanisms adds an extra layer of protection by dissipating excess pressure. Anchoring the test object securely and choosing a suitable testing environment contribute to minimizing risks.

A gradual pressure increase allows for close observation of potential anomalies, while a well-defined emergency plan outlines steps to handle unexpected events. After testing, a thorough inspection of the test object helps identify any stress or damage resulting from the test.

Compliance with industry regulations, meticulous record-keeping, and a comprehensive risk assessment can further enhance the safety of hydrostatic testing. By adhering to these precautions, a safe and controlled testing environment is established, mitigating potential hazards and ensuring the well-being of personnel and equipment throughout the process.

Conclusion

Hydro testing provides many benefits for a business by ensuring the quality of its product. This process can be used to ensure that equipment is functioning properly before use and also detect leaks in hydraulic systems or pipes. So a suitable hydro test pump is critical.

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Procedure for Hydrostatically Testing Pressure Vessel

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Procedure for Hydrostatically Testing Pressure Vessel

Procedure for Hydrostatically Testing Pressure Vessel

sraesttam

(Petroleum)

(OP)

29 Jan 19 20:46

I am planning to leave the vessel on the trailer horizontally, fill it all of the way up with water using a garden hose, pressure up to 30 PSI using a hydrostatic test pump, hold the pressure for 5 minutes, pressure up to 300 PSI (1.5 x MAWP) using a hydrostatic test pump, hold the pressure for 5 minutes, bleed off pressure, drain, set in place, and then put into service.

Do you have any recommendations regarding my procedure? Is there anything that I am forgetting?

I have no experience hydrostatically testing pressure vessels. I own a 10,000 psi hydrostatic test pump that I use for pressure testing oilfield equipment that I will be utilizing for this.


Vessel Nameplate

I recently purchased a 240 gallon pressure vessel that I plan to utilize as a compressed air storage receiver in my shop. The vessel was manufactured in 2002 and is rated for 200 PSI MAWP @ 400 degrees F. The vessel is designed to be installed vertically. I plan to operate this vessel at 175 psig. I would like to hydrotest this vessel to ensure that it can be operated safely. I am doing this solely for peace of mind and therefore I do not need any type of certification. A picture of the vessel nameplate is uploaded.I am planning to leave the vessel on the trailer horizontally, fill it all of the way up with water using a garden hose, pressure up to 30 PSI using a hydrostatic test pump, hold the pressure for 5 minutes, pressure up to 300 PSI (1.5 x MAWP) using a hydrostatic test pump, hold the pressure for 5 minutes, bleed off pressure, drain, set in place, and then put into service.Do you have any recommendations regarding my procedure? Is there anything that I am forgetting?I have no experience hydrostatically testing pressure vessels. I own a 10,000 psi hydrostatic test pump that I use for pressure testing oilfield equipment that I will be utilizing for this.

RE: Procedure for Hydrostatically Testing Pressure Vessel

Dhurjati Sen

(Materials)

30 Jan 19 13:32

The following is required for your peace of mind.

1. Carry out a visual inspection of the vessel internally if possible, else externally.

2. Look for physical damage, dents etc.

3. Carry out LPI of all nozzles.

4. Use potable water with a chloride content less than 250 ppm for hydro-test. Else dry the vessel completely using hot air, etc. after hydro-test and complete drain out of water.

5. Install a pressure relief valve on the discharge of the hydro-test pump. Set it at 110% of test pressure, i.e. 330 psi.

6. Use original gaskets.

7. The test presure is to be held for at least 10 minutes or as long as you need to complete the inspection.

Regards.

Dear sraesttam,The following is required for your peace of mind.1. Carry out a visual inspection of the vessel internally if possible, else externally.2. Look for physical damage, dents etc.3. Carry out LPI of all nozzles.4. Use potable water with a chloride content less than 250 ppm for hydro-test. Else dry the vessel completely using hot air, etc. after hydro-test and complete drain out of water.5. Install a pressure relief valve on the discharge of the hydro-test pump. Set it at 110% of test pressure, i.e. 330 psi.6. Use original gaskets.7. The test presure is to be held for at least 10 minutes or as long as you need to complete the inspection.Regards.

DHURJATI SEN

https://www.nace.org/people/dhurjatisen

RE: Procedure for Hydrostatically Testing Pressure Vessel

r6155

(Mechanical)

30 Jan 19 14:20

First you need
1)Documentation: drawings, calculations, material test reports, etc.
2)Check actual thickness of pressure parts
3)See API 510, pressure test may be waived

Regards
r6155

RE: Procedure for Hydrostatically Testing Pressure Vessel

EdStainless

(Materials)

30 Jan 19 14:43
If they look heavily rusted then I would clean the tank before testing.
If after cleaning they look pitted then I would look for another tank.
Your procedure is sound.

The first thing that I would do is grab a fiberscope and look at the inside , bottom welds.If they look heavily rusted then I would clean the tank before testing.If after cleaning they look pitted then I would look for another tank.Your procedure is sound.

= = = = = = = = = = = = = = = = = = = =
P.E. Metallurgy, Plymouth Tube

RE: Procedure for Hydrostatically Testing Pressure Vessel

MJCronin

(Mechanical)

30 Jan 19 17:00

Air receivers are notorious for internal corrosion as drainage of water always becomes a problem. Put your time, effort and money into assuring that you will not be operating a corroded vessel ........IMHO

If the vessel has a MAWP of 200 psig and you intend to operate it below that pressure, why are you performing this test ?Air receivers are notorious for internal corrosion as drainage of water always becomes a problem. Put your time, effort and money into assuring that you will not be operating a corroded vessel ........IMHO

MJCronin
Sr. Process Engineer

RE: Procedure for Hydrostatically Testing Pressure Vessel

LittleInch

(Petroleum)

30 Jan 19 17:14

Weight of this full of water will be a lot more than normal so the legs might need some support or re-inforcement.

Pressure tests often go up in stages 25/50/75/100%.

A 16 year old vessel eh? Agree totally with above - a very good internal check for corrosion is a primary requirement before you start.

External UT might be required in some locations.

Difficult to see without some dimensions / pictures etc, but I would be a little wary of doing this with the vessel on its side. This could concentrate stresses if not completely flat and is much better if you can lift it up. apart from anything else where are the connection points? There is often one in the top dome so it's easy to completely vent the vessel.Weight of this full of water will be a lot more than normal so the legs might need some support or re-inforcement.Pressure tests often go up in stages 25/50/75/100%.A 16 year old vessel eh? Agree totally with above - a very good internal check for corrosion is a primary requirement before you start.External UT might be required in some locations.

Remember - More details = better answers
Also: If you get a response it's polite to respond to it.

RE: Procedure for Hydrostatically Testing Pressure Vessel

sraesttam

(Petroleum)

(OP)

1 Feb 19 17:55

All, thank you for your recommendations.
Dhurjati Sen:I will carry out a visual inspection, look for damage, and will be using city treated drinking water for the testing. I will hold the max pressure for 10 minutes.

r6155: Thanks for the information.

EdStainless: I will see about using a scope to visually inspect the bottom welds and bottom part of the vessel. Maybe this is the excuse I need to buy a scope.


MJCronin: I am performing the test based on two assumptions (please let me know if they are incorrect). 1) I would rather have a vessel fail while filled with water than when filled with air. 2) If the vessel passes a hydrotest at 1.5 x MAWP, then operating at 0.875 x MAWP should be fine for a couple of years as long as the tank does not experience major corrosion. I am planning to install an autodrain on this vessel to ensure that it stays as dry as possible. I am also considering installing a refrigerated air dryer before this tank.

LittleInch: The vessel is approximately 3 feet in diameter by 8 feet tall. The vessel will be holding approximately 240 gallons / 2000 pounds of water. I do not believe that there is an opening on the top of the vessel. (I have not had a chance to actually go inspect this yet.) I think that there is one opening on the bottom and four on the shell. There are 2 x 2 inch openings on the "east" and "west" side of the tank. I am planning to lay the vessel down where it is completely flat and not rest on any tank openings, plugs, etc. If it test upright, I think that I will still have a couple of foot of air "head" at the top of the tank, hence my thought to keep it on its side so that the tank will be entirely full of water. I will stage up the test in 25/50/75/100% increments.

It will probably be a couple of months before I get around to this, but I will post the results of the test.

Thank you again.

RE: Procedure for Hydrostatically Testing Pressure Vessel

zeusfaber

(Military)

1 Feb 19 21:45

Quote (sraesttam)

1) I would rather have a vessel fail while filled with water than when filled with air.

Absolutely. We've burst vessels both ways, and it's the difference between watching a concrete megablock being tossed thirty feet into the air or wrecking the blockhouse completely and picking large cylinder fragments up off the beach three quarters of a mile away.

Absolutely. We've burst vessels both ways, and it's the difference between watching a concrete megablock being tossed thirty feet into the air or wrecking the blockhouse completely and picking large cylinder fragments up off the beach three quarters of a mile away.

RE: Procedure for Hydrostatically Testing Pressure Vessel

r6155

(Mechanical)

2 Feb 19 01:35

sraesttam, you are working in a wrong way

1)Hydrostatic pressure test for a PV made in year 2002 is 1.3 x MAWP ( not 1.5)
2)Water temperature during test shall be controlled
3)Be careful of notch toughness of pressure components before pressure test
4)Be careful: in nameplate you can see RT-NO
5)Visual inspection shall be at MAWP after pressure test 1.3 x MAWP
6)More informaion in ASME PCC-2 Repair of Pressure Equipment and Piping
7)There is an opening on the top of the PV.

Regards
r6155

RE: Procedure for Hydrostatically Testing Pressure Vessel

SnTMan

(Mechanical)

2 Feb 19 02:07 sraesttam if you will supply this number to the

Just noticed the NB #.if you will supply this number to the National Board they should, for a small fee, be able to supply you with the U-1, telling you more about what you've got.

The problem with sloppy work is that the supply FAR EXCEEDS the demand

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