what's the min &max range of pressure gauge for hydro test

How to check hytrotest in heat exchanger

30 and 80 Percentage
Non Destructive Testing - Hydrostatic testing

Hydrostatic testing of pressure piping is a mandatory activity before finalization of any new or
modified piping system.
It is the final check of mechanical integrity of the whole system and should be followed
religiously as after this activity the piping system has to be commissioned.
This test is carried out at a pressure 1.5 times higher than the design pressure of a system
regardless of the service conditions of a piping system.
This article discuss some of the major requirements of hydrostatic testing of pressure piping as
per ASME B31.3 for process piping and specifically provides guidelines on some issues not
directly addressed in the code.

Some guidlines

 All joints in a test section shall be accessible during tests and shall not be painted,
insulated, backfilled or otherwise covered until satisfactory completion of testing in
accordance with the requirements in the specification.
 All equipment and piping to be pressure tested shall be thoroughly cleaned of all dirt,
welding slag, construction debris, or other foreign matter.
 All vents and other connections which can serve as vents shall be open during filling so
that all air is vented prior to applying test pressure to the system.
 Test vents shall be installed at high points. Drain points for fluid disposal after testing,
shall be provided.
 Equipment which is not to be subjected to pressure test shall be either disconnected from
the piping or blocked off during the test.
 Temporary spades and blanks installed for testing purposes shall be designed to withstand
the test pressure without distortion.
 Presence of spades shall be clearly visible during testing.
 The recommended practice is to use standard blind flanges as per ASME B16.5 or B16.47
and spades acc. to ASME B16.48.
 Spring supports shall be restrained or removed and expansion bellows removed during
hydrostatic testing.
Piping which is spring or counterweight supported shall be blocked up temporarily to a
degree sufficient to sustain the weight of the test medium.
 Holding pins shall not be removed from spring supports until testing is completed and the
system is drained.
Care shall be taken to avoid overloading any parts of the supporting structures during
hydrostatic testing.

Barriers shall be erected and where practical, Public Address announcements made and
access restriction procedures such as permit to work implemented prior to any
pressurisation commencing. Under no circumstances should anyone other than an
authorised person be allowed within the safety barriers.

An important aspect is, that materials used in pressure systems comply with all the required
tests, all materials are certified and that the engineer has made the right choice of materials.
 (see main Menu "Societies" numerous ASTM material standards)

Hydrostatic test has to be performed after all hot works have been completed on a certain piping
system.
Hot work includes everything related to welding or the post weld heat treatment (PWHT).
All radiographic and ultrasonic inspections should be carried out before the pressure test is
started.
Conducting 100% radiography of all the weld joints assure that your weld joints are defect free
but can never provide you with the assurance of mechanical integrity of a system.
This is also to be noted that radiography / ultrasonic inspection shall also not to be waived off if
the pipeline is to be hydrostatically tested.

The individual system documentation i.e. Test Pack shall be available prior to any testing and
shall include information such as test limits, test pressure, test medium, duration, test blinds,
blind flanges, vents and drains.

The use of marked up P&Ids coupled with isolation registers should be utilised to identify the
locations of blinds, Valves, vents and drains.

Testing equipment such as pumps, manifold, pressure and temperature recorders,

pressure gauges should be within calibration/certification (as per company procedures) and
connected to the lowest convenient connection within the system to ensure best results.

Control Valves and soft-seal block Valves shall be removed from the piping prior to the test and
replaced with pipe spools.

Check Valves shall have the flap or piston removed for testing, where pressure can not be
located on the upstream side of the Valve. The locking device of the flap pivot pin shall be
reinstated together with the flap and a new cover gasket shall be installed after completion of
the test.
Piping which is normally open to the atmosphere, such as drains, vents, discharge piping from
pressure relieving devices, sewers, and stack downstream of the seal drum, shall not be
subjected to the piping test pressure

Rotating machinery, such as pumps, turbines, and compressors. Machinery lube and seal oil
systems which could be impaired by the presence of water, shall not be subjected to the piping
test pressure.
Strainer elements, filter elements, expansion joints, and pressure relieving devices, such as
rupture discs and pressure Relief Valves. All locally mounted indicating pressure gauges.
Preparation and Testing

Pressure gauges should be fitted at both low and high point when testing large volume
systems.
The system shall be filled from the lowest available point; all vents and high point
connections shall be open during this operation to allow the air in the system to vent off.
After the system has been completely vented all vents and drains should be plugged or
blinded. Verify that Valves are in place and open/closed as required.

Maintain pressure for 10 minutes and then gradually increase pressure in steps of one
tenth of the test pressure until the test pressure is attained.
The recommended practice of a QC inspector is to
walk through the whole piping system and check for leaks.
Every single length of piping, welds, bolted connections shall be visually examined for any
leakage.
Duration of this activity varies with the span of piping system.

For larger piping system time taken for this activity is enough to clear the hydrostatic test.
In case of piping system having smaller span, 1 hour time may be made as standard practice.

Whenever a leak is found from flanged connection, it is advisable not to perform any tightening
before the system pressure is brought down to at least 70%.
A leak from a weld joint, piping base metal or any other location which may require hot work
shall only be addressed after de-pressurizing the piping under test.

After any leaks have been repaired the system shall again be pressurised to the test pressure in
stages.
The test should be witnessed and accepted by a third party, client representative or a
responsible person within the company and signed as accepted.
Pressure and ambient temperatures should be recorded throughout the complete test cycle.
These charts should form part of the Hydrostatic Test Documentation.
On completion of the test, the system shall be depressurised by controlled means and all vents
opened prior to draining of the system to avoid any vacuum within the system.

Where in the code book does it state that the Hydrostatic Gauge should be
between 1.5-4 times the hydrostatic test pressure? I've seen it but cannot find
it... B31.3.

B31.3 sets no rules for this. Haven't read this section of B31.1 but suspect it's
no different.

The 1.5x to 4x is the requirement for the range of the gauge relative to the
calculated hydrotest pressure per ASME VIII.

Calibration is mandatory; see ASME B31.1 Appendix J-1.2.10.

The 1.5X to 4X limits only applies to analog gauges, and that's because they
reach their best accuracy (as a percentage of full scale) within this range.
That's a feature of the Bourdon tube. The code does have different rules for
digital gauges, or at least Section III does: "Digital type pressure gages may
be used without range restriction provided the combined error due to
calibration and readability does not exceed 1% of the test pressure."
Sec V (Article 10) T-1031
I'm confused over the requirements for pressure gauges that are to be used for hydrotesting pressure piping
manufactured to either B31.1 or B31.3.

Neither B31.1 or B31.3 state any requirements for gauge calibration or gauge ranges (at least that I can find,
maybe I'm wrong). Nor can I find references to other ASME codes. However Sec V Article 10 Leak Testing,
does state a min range of 1.5 times test pressure to a max of 4 times the test pressure. It also states that the
gauges must be calibrated annually and provide accuracy equal to the manufacturers stated accuracy.

Besides being a good idea is annual calibration mandatory?

Are the pressure ranges mandatory? I plan on buying a digital gauge which is very accurate over its entire
range and would like to limit the number of gauges I buy.

Hydrostatic test requirements.

The following minimum requirements apply to a pipeline company when it conducts a hydrostatic test of a new or
existing pipeline:

(1) If a pipeline company uses a manifold for hydrostatic testing, the company must provide an isolation valve
between the pressure testing manifold and the pipeline being tested. The isolation valve must be rated for the
manifold test pressure when in the closed position. The pipeline company must separately pressure test the manifold
used in the actual pressure test to at least 1.2 times the pipeline test pressure, but not less than the discharge
pressure of the pump used for the pressure testing.

(2) If a pipeline company uses a pressure relief valve to protect the pipe, each such valve must be of adequate
capacity and set to relieve at ten percent above the hydrostatic test pressure. The pipeline company must calibrate
the relief valve within one month prior to the hydrostatic test.

(3) The pipeline company may use a bleed valve to protect the pipeline from overpressure. When a pipeline
company uses a bleed valve, the valve must be readily accessible in case immediate depressurization is required.

(4) All equipment such as hoses, piping, and other equipment used to hydrostatically test the pipe must be
rated for at least the target pressure.

(5) The pipeline company must maintain documents identifying how each hydrostatic test was conducted. Each
document must be signed by a person with sufficient knowledge, certifying that the document contains accurate
information about the test. The documents must contain the following information:

(a) The date of the test;

(b) A test chart or other record that shows that the pressure was maintained at the minimum test pressure
throughout the entire test;

(c) Beginning and ending times of the test;

(d) Beginning and ending temperatures; and

(e) Highest and lowest pressure achieved.

 (6) The pipeline company must conspicuously post precautions such as warning signs indicating that a
hazardous liquid pipeline is under test conditions.

(7) The pipeline company must notify the local government and fire department with jurisdiction in the area
affected by the hydrostatic test.

(8) The pipeline company shall not add any water to the pipeline after the hydrostatic test has started.
Because pressure varies significantly with changing test water temperatures, each pipeline company must take into
consideration temperature variations in the test water before accepting the test results.

(9) The pipeline company must comply with applicable rules of the Washington state department of ecology
addressing disposal of testing water.

Engineering Specification for Pressure Test of Piping System

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This content provides you with a example specification for pressure test of piping system. This
content is useful for field inspectors.

1. GENERAL - Pressure Test of Piping System

1.1. SCOPE

This specification covers the minimum requirements for pressure testing, draining and
reinstatement of the piping system (A/G & U/G) in the construction works for use in industrial
plants. Pressure test shall be a hydrostatic leak test, only where a hydrostatic leak test is
impractical, pneumatic leak test may be substitute but it shall be subject to Owner’s prior
approval. Lines and systems which are open to the atmosphere, such as drains, vents and open
safety valve discharges, do not require pressure testing. These lines shall be visually examined to
determine that all joints are properly made up.

This specification covers non-metallic piping. This specification does not cover the testing of
pressure vessels, exchangers, piping in fired heater and other equipment (including packages)
which are tested in accordance with codes and standards under which they have been built.

All required equipment, devices, tools, materials and labors for any construction work, test and
inspection shall be provided by Construction Contractor.

Sound engineering practices shall be followed in the absence of specified standards or

specifications subject to Owner’s prior approval.
1.2. CODES AND STANDARDS - Pressure Test of Piping System

ASME B31.3: Process Piping

ASME Sec. V: Non-Destructive Examination

1.3. RELATED ENGINEERING & CONSTRUCTION SPECIFICATION

The following related Engineering Specifications are applied as supplement of this

specifications.

Cleaning for Pipe lines

Inspection and test of piping construction

1.4. RETEST - Pressure Test of Piping System

In the event repairs of additions are made following the pressure tests, the affected piping shall be re-
tested, except that, in the case of minor repairs or additions the Owner may waive retest requirements
when precautionary measure are taken to assure sound construction.

1.5. UNIT - Pressure Test of Piping System

SI units shall be applied except nominal size of pipe and nozzle shall be in inches and flange rating shall
be in pounds. “BEDD shall also be considered”.

2. SAFETY

2.1. Full care and precaution shall be given by the field management for the safety of the workmen to
prevents accidents during the execution of the works.

2.2. Especially the pneumatic testing involves the hazard due to possible release of energy stored in
compressed gas. Therefore, particular care must be taken to minimize the chance of brittle failure of
metals and thermoplastics.

2.3. Pressure testing shall be performed in presence of the Owner’s inspector.

2.4. Pressure testing shall be performed when the weather condition is suitable for inspection.

3. TEST FLUID - Pressure Test of Piping System

3.1. HYDROSTATIC TEST

3.1.1. As a rule, test shall be hydrostatic, using fresh water or industrial water. The water shall have a
suitable corrosion inhibitor which meets Owner approval. Where the use of sea water is unavoidable,
agreement between Owner and Construction Contractor shall be made, before proceeding with the work.
When sea water is used, quick draining and sufficient cleaning by fresh water shall be performed after
completion of the testing.

3.1.2. Where atmospheric temperature is 0 ºC or below water shall not be used unless water is
heated by steam or other heat source, and maintained at temperature of 4ºC or above during the testing.

3.1.3. If there is a possibility of damage due to freezing, or if the operating fluid or piping material
would be adversely affected by the water, any other suitable liquid such as oil or kerosene may be used
with agreement between Owner and Construction Contractor.

3.1.4. For testing of system containing stainless steel piping system, the chloride ion content of water
refer to para. 8.5.7 of Spec. 0000-S1830-002

3.2. PNEUMATIC TEST - Pressure Test of Piping System

As a rule, test shall be pneumatic, using air. The use of other test fluid shall be subject to agreement
between Owner. Pneumatic testing shall be made with oil free air.

4. TEST PREPARATION - Pressure Test of Piping System

4.1. CLEANING

4.1.1.Testing shall be performed by qualified personnel of Construction Contractor who are thoroughly
familiar with all equipment and test.

Prior to test, any piping system to be tested shall be cleaned. And all joints, including welds, are to be left
un-insulated and exposed for examination during the test, except that joints previously tested in
accordance with this specification may be insulated or covered.

Construction Contractor shall consider temporary gaskets (free asbestos) for testing.

4.1.2. Piping shall be inspected for completeness and conformity to piping drawings and specifications.

4.1.3. All required non-destructive testing (NDT) and soap tests of reinforcing rings shall be completed
with results satisfactory to Owner.
4.1.4. Owner will release all piping system for flushing and testing after he has satisfied himself that the
system is complete and ready for testing. Piping shall be divided into test system by using blinds caps or
plugs suitably.

4.1.5. All instruments in the test system shall be excluded from flushing / testing by isolation or
removal.

4.1.6. Instrument piping shall be tested up to the first block valve.

4.1.7. All other valves in the piping system shall be kept in open position.

4.1.8. All tests executed with day temperature or fluid temperature of 5°C and lower or when frost is
expected during night and system may stay filled over night shall have anti-freeze. (Glycol)

4.1.9. Trash and construction debris shall be removed from the piping system by flushing with water or
by blowing with air or nitrogen in line with the pressure test medium. All lines shall be completely free of
weld slag and other foreign material and shall be reasonably clean.

4.1.10.

Flushing through equipment or machinery is not allowed. Flushing shall be performed against open pipe
ends.

4.1.11. All flushing operations shall be carried out in the presence of Owner’s inspector.

4.1.12.Flushing water shall be drained through hoses locations as indicated by Owner.

4.1.13. Before commencing pressure test, the Contractor, shall prepare and submit for the Owner
approval a detailed flushing test procedure.

4.1.14. The area shall be continuously monitored by test personnel while testing is being performed that-
any change in test procedures or conditions will be noted immediately and corrective-action taken as
required.

4.1.15. Plugs shall be removed from tell-tale holes in compensating rings and reinforcement pads around
branches (nozzle) and the holes left open hydrostatic testing to observed any leakage.

4.1.16. Pressure test flow diagram shall be prepared by Construction Contractor. These diagrams shall
show the system to be tested, the valves to be opened, and the equipment to be blanked with blind flanges
and necessary instrumentation.
4.2. BLIND FLANGES AND BLANKS - Pressure Test of Piping System

4.2.1. Where the piping system is required to be disconnected from equipment in the test, disconnected
end of the piping shall be isolated by blind flange having the same rating with the piping system to be
tested.

4.2.2. Where the piping system to be tested is isolated at a pair of companion flanges, blank shall be
inserted between the companion flanges. Minimum thickness of blanks shall be as listed in Table 1. And
a record should be kept showing the location of all test blinds to assure their removal. These blanks shall
be supplied by Construction Contractor.

4.2.3. A grip shall be fixed to outside of the blank (blind flange) to be used for the test, and shall be
painted in red to distinguish from other blanks. The blank shall be indicated on the pressure test flow
diagram.

4.2.4. No testing shall be down against closed valves, blind flange or blanks. Instrument block valves
shall be exempted from this rule.

4.2.5. For flanged control valves with block valves and a by-pass, if the test pressure upstream and down
stream is the same, the block and by-pass valve shall be left open, with the control valve removed and
blinds.

4.2.6. In case the test pressure upstream and down stream of the control valve is different, the test on the
upstream position shall be made with the by-pass valve open and blanked-off, upstream block valve open
and blanked off and control valve removed.

4.3. PIPE SUPPORTING ELEMENT - Pressure Test of Piping System

4.3.1. Piping designed for vapor or gas shall be provided with additional temporary supported, if
necessary, to support the weight of the test liquid.

4.3.2. Prior to the liquid fill for test of the piping system, it shall be checked that springs with "down
travel stop" have the "stop" inserted. The "stop" in the spring shall be removed after draining of test fluid
from the piping system.

4.4. VENT - Pressure Test of Piping System

During water-filling, the air is to be removed from the line by leaving the vent valves open until water
spurts from them.

4.5. PRESSURE TEST GAUGES - Pressure Test of Piping System

4.5.1. Two calibrated dial indicating pressure gauges, at least, shall be provided at the pump discharge
and other suitable locations.
4.5.2. All gauges used shall be checked for accuracy. All test pressure gauges shall be calibrated at
regular intervals at least every two weeks. Calibration certificate shall be available at the work
site and all gauges shall be properly identified to enable tractability to the calibration
certifications.

4.5.3. The test pressure shall be checked by means of a gauge having a range from zero up to 1.5 to 2
times the intended maximum test pressure.

4.5.4. Pressure gauge shall be connected at point as near as possible in highest and lowest point of the
piping system to be tested. Where practical, the static head of the water column shall be taken
into account in the test pressure.

4.5.5. Calibration of gauges shall be repeated whenever requested by Owner.

4.6. MISCELLANEOUS - Pressure Test of Piping System

4.6.1. Subject to permission lines which are to be tested with their service fluid (category D fluid) may be
subjected to an initial service leak test in accordance with para. 345.7 of ASME B31.3 in lieu of the
hydrostatic leak test. It shall be subject to Owner prior approval.

4.6.2. Pressure-relief valve which is calibrated shall be provided in order that excess test pressure can
be escaped.

4.6.3. Lines containing check valve shall have the source of pressure located in the piping upstream of
check valve so that pressure is applied under the seat. If this is not possible, check valve disk shall be
removed or located open.

4.6.4. Expansion joints of the sliding sleeve or bellows type shall be provided with temporary restraint
if required for additional load under-test, or shall be isolated from the test.

4.6.5. Prior to start test, the piping system shall be checked that all the valve discs are located suitable
open and closed position, and the vents and drains are installed properly for the test.

4.6.6.The following items shall be isolated or block them out of the test. Field tests of these items, when
required, are covered by their respective specifications; equipment, machinery, Relief valves, Rupture
discs, Flame arrestor, Displacement meters, Rotameters, Pressure gauges, Gage glasses, Filter and strainer
elements and Control valves with close tolerances. Steam traps, internals and any items not designed to
with stand the pressure.

- All instrument control piping down stream of first piping block valve

- All orifice plates which interfere with filling, venting and draining shall be removed from the test.
5. TEST PRESSURE

5.1. HYDROSTATIC TEST - Pressure Test of Piping System

The hydrostatic test pressure at any point in the system shall be as follows.

5.1.1. Test pressure shall not be less than 1-1/2 times the minimum design pressure,but shall not
exceed the maximum allowable test pressure for flanges, according to ASME B16.5 OR ASME
B16.47.

5.1.2. The test pressure shall be corrected to take into account the line temperature as per clause
345.4.2 of ASME B31.3.

5.1.3. As a rule, the test pressure shall be as shown in "the line Designation Table".

5.1.4. The following points shall be taken into account to determine the test pressure.

A. The weakest component in the piping system to be tested.

B. In case that the piping system is tested together with equipment having lower test pressure than the
system.

5.2. PNEUMATIC TEST - Pressure Test of Piping System

5.2.1. If the piping is tested pneumatically, the test pressure shall be 110% of the design pressure of the
system. If the test pressure exceeds 6 bars written approval of the Owner shall be obtained.
Welds of piping subject to pneumatic strength test above 6 bars shall be %100 radio graphed.

5.2.2.The test temperature is important in pneumatic test and must be considered when the choice of
material is made in the original design.

6. TESTING PROCEDURES - Pressure Test of Piping System

6.1. HYDROSTATIC TEST

6.1.1. Hydrostatic test pressure shall be applied by means of a suitable test pump or other pressure
source, which shall be positively isolated from the system until ready to test. Test equipment (hydrostatic,
pneumatic, etc.) shall be approved by Owner.

The pump shall be attended constantly during the test by an authorized operator. Whenever the pump is
left un attended, it shall be positively disconnected from the system, while the pressure gauge remains
connected to the test system.

6.1.2. Procedures for hydrostatic pressure test shall be as specified below:

A. After filling the water and purging the air in the piping system to be tested, the pressure shall be
increased gradually in the steps as shown in Table 2, maintaining for at least 3 minutes in each step to
allow the equalization of strain during test and to check for leaks.

B. The test pressure shall be maintained for at least one hour prior to starting inspection and long enough
to enable inspection of the complete test system by Owner.

6.1.3.

On water filling for the test in chilly district, or leaving the piping system liquid filling, the piping
system shall be taken into account for variation of atmospheric temperature and due care shall be given
for freezing or thermal expansion.

6.1.4. The Construction Contractor shall be responsible for the supply of suitable pumps for the
testing. As a minimum a high volume centrifugal pump for filling and a variable speed positive
displacement, reciprocating pump, with sufficient discharge head and capacity for the
pressurization shall be provided. The Construction Contractor shall provide chemical injection
pump and means necessary for measuring of the inhibitor to be added to test water.

6.2. PNEUMATIC TEST - Pressure Test of Piping System

6.2. Procedure for pneumatic test shall be as specified below:

The sequence of test pressurizing

A. After evacuating all personnel from the test area The system shall be pressurized to 1.7 Bar G.
and held for sufficient time to allow the piping to equalize strains (ten minutes minimum). All
joints (threaded, socket welded, butt welded and flanged) shall be preliminary tested for leakage using the
test solution.

B. Pressurize the system gradually to 60% of the indicated test pressure, and hold at that
pressure for a sufficient length of time to allow the piping to equalize strains (ten minutes
minimum).
C. Reduce the pressure to 50% of the indicated test pressure and retest all joint for leakage.

D. Pressurize in steps of not more than 10%, until the indicated test pressure has been reached. The
pressure shall be held at each step during pressurizing sequence (to allow the piping to equalize strains)
for a period of not less than ten minutes. The indicated test pressure shall be held for a sufficient length of
time to permit the testing of all joints, the pressure shall then be reduced to the design pressure before
examining for leakage.

E. Each reinforcing pad (or each segment thereof) and similar attachments shall be tested at a
designated test pressure with air, a soap solution shall be used to detect air leaks. Test and vent
holes shall be left open upon completion of the test.

6.2.2. A soap solution shall be applied to all screwed, weld and flanged joints undergoing pneumatic
test.

6.2.3. Where line list or line designation table indicate pneumatic testing, no hydro testing shall
be performed.

6.2.4. As pneumatic testing presents special risk due to possible release of energy stored in the
compressed gas almost care shall be taken during pressurization and inspection of the system to
prevent any danger to personnel or equipment and the chances of a brittle failure of piping.

During testing precaution and procedure shall be as laid down on paragraph 345.5 of the ASME B31.3

6.3. The Construction Contractor shall make sure that prefabricated piping which are not
included in the pressure test are certified by an authorized inspector.

6.4. Welds or portion of welds that leak during hydrostatic test shall be repaired, cutout,
rewelded, radiographed (if needed) and line shall be hydrostatically tested again.

6.5. All costs incurred in repairing defective or rejected work and all consequential heat
treatment and additional examination costs are to be borne by the Construction Contractor.

7. PRESSURE RELEASING - Pressure Test of Piping System

After completion of the test, the pressure shall be released so as not to endanger personnel or damage
equipment. As a rule, releasing rate shall be 300 Kg/Sq.cmhr, but lining pipe, tower filled with catalyst,
etc., shall be less than 25 Kg/Sq.cmhr.

8. DRAINING

8.1. After completion of the test, the piping system including equipment to be tested shall be drained as
completely as possible.
8.2. All vents shall be opened before the piping system is drained and shall be remain open during
draining to prevent pulling a vacuum on the piping system.

8.3. After drainage, remove all temporary blinds and blanks, temporary supports, and temporary testing
connections, as per drawings and specifications and reinstall all items such as control valves, relief valves,
rupture discs, orifice plates etc., which were removed for test. Ensure that line specification of gaskets
and bolts are being used when reinstalling these items. All flange joints for the test shall be made up with
new temporary gaskets provided by the Construction Contractor.

8.4. All drained lines shall be dried after testing by blowing through with dry oil free air. Special care
shall be taken that no freezing can occur in winter.

8.5. Owner will confirm when a line is considered dried by Construction Contractor.

After approval by Owner and reinstallation, the system shall be released for activities like, tracing,
painting, insulation, etc.

9. EXTERNALLY PRESSURED PIPING - Pressure Test of Piping System

Piping subject to external pressure shall be tested an internal gage pressure 1.5 times the external
differential pressure, but net less than 105kpa(15 PSi)

10. TEST RECORDS - Pressure Test of Piping System

Records shall be made for each piping system during the testing and these records shall include
the following items.

A. Extent of testing and specification

B. Identification of piping tested

C. Pressurizing apparatus

D. Test pressure and test duration

E. Test fluid

F. Date of test

G. Approval signature of witness (Owner's and Construction Contractor's representative)

H. Signature of person in charge of testing

I. Applicable remarks concerning defects

J. Water temperature and chloride content

K. Design temperature and pressure

All tests satisfactory or not shall be record on the test form and complete set will be made part of
the permanent job records.

Return from Pressure Test of Piping System to Industrial Inspection

Return from Pressure Test of Piping System to Inspection for Industry Home

why pressure gauges are filled with liquid?

Liquid-filled gauges are generally preferred over dry gauges for 2 reasons: Performance And ROI.
Liquid-filled gauges are filled with a liquid, usually glycerin or silicone oil and are designed to perform
optimally in less-than-ideal conditions.

While WIKA’s liquid-filled gauges are engineered to function in difficult environments, they’re also more
economical from a long-term perspective: High heat, pulsation, or vibration lead to instrument breakdown.

Liquid Filled vs. Traditional Gauges

The primary reason for gauge failure is vibration.

In traditional dry gauges, delicate links, pivots, and pinions are prone to damage from vibration, leading to
inconsistent performance.

In a liquid-filled gauge, the fluid fill effectively dampens system pulsation, making the gauge pointer easier
to read.

Likewise, humidity and moisture pose problems for dry gauges. Condensation can make a gauge
difficult to read or, in some cases, can cause failure due to icing.

Liquid-filled gauges, though, are sealed to prevent internal condensation, and by keeping moisture out of
the system, gauge movement is protected during icing conditions.

The choice of fill fluid is based on the application, but Glycerin is typically used for room-temperature
applications and

Silicone Oil is commonly used for extreme temperature applications, especially when icing is a
problem.

An oil with insulating properties is ideal if the system has exposed electrical contacts.
 Why Liquid Filled?
Liquid-filled pressure gauges offer a number of advantages over traditional, dry case pressure gauges:

 Liquid-filled gauges have longer lives than traditional (non-hermetically-sealed) gauges because of their
viscous fluid filling. Over time, this design advantage results in costs savings due to lowered
instrumentation costs as well as lessened unscheduled downtime.
 Internal liquids protect against severe temperature fluctuations and vibrations—major factors in the
breakdown of regular gauges. Because they dampen temperature spikes and vibrations, WIKA’s liquid-
filled gauges are easier to read, allowing for greater accuracy and process control.
 In traditional gauges, condensation build-up results in visibility issues. This can be a crucial (and costly)
flaw in high-humidity environments—an unreadable gauge is a worthless gauge. A solution to the impact
of high humidity situations, WIKA’s liquid-filled gauges are designed to prevent moisture from entering not
only the body casing but also the inside of the case lens.
 Because they are sealed and constructed to meet rugged specifications, liquid-filled gauges are
commonly used in highly corrosive chemical processes or in manufacturing or refining processes, and
where products must be transported, stored, or handled in extreme temperature conditions.

Liquid-filled Gauges from WIKA

While some customers are concerned about the cost of liquid filling for a pressure gauge, the long-term
payoff is clear: Better protection against vibration, pulsation, corrosion, and moisture makes for a long-
lasting, reliable instrument. WIKA’s liquid-filled gauges are highly durable, meaning less cost and better
accuracy over time, and our line includes a number of customizable process gauges, including gauges
built for the demanding conditions of the oil and gas industry.