Hydrostatic Test Schedule

11/9/2019 Piping Hydrostatic Testing (overview) | QA/QC Construction
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PIPING HYDROSTATIC TESTING (OVERVIEW)
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(OVERVIEW)
1. Pressure source and test gauge should be upstream of check valve. If pressure
source is downstream, check valve should have apper removed or jacked?up.
(Pressure must be released downstream of check valve after test completion.)
2. Ensure that test blinds installed are the Correct thickness. Ensure that all items
such as control valves, relief valves, rupture disks, ori ce plates, diaphragm
instruments, expansion joints, etc., which could be damaged during pressure test
have been removed or isolated, as indicated on the pressure test ow diagram.
Ensure that equipment, such as lters, which have internals that may be damaged
during pressure.
3. Ensure that all items such as control valves, relief valves, rupture disks, ori ce
plates, diaphragm instruments, expansion joints, etc., which could be damaged
during pressure test have been removed or isolated, as indicated on the pressure
test ow diagram.
4. Ensure that equipment, such as lters, which have internals that may be damaged
during the pressure test are either blocked from test or that internals have been
removed.
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5. Check all temporary supports that have been called for on the pressure test ow
diagrams, piping arrangement drawings or spool drawing to ensure that they have
been properly installed.
6. Ensure that equipment, such as compressors, which must not be included in the
eld tests have been properly blocked off with the casing drain open.
7. Check open and closed position of all valves.
8. Check for proper installation of vents and drains.
9. Verify chloride content of test water when testing stainless steels.
Testing
1. The pressure test gauge shall normally be located at grade near the test pump.
2. Pressure test gauges shall be calibrated to ensure accurate readings. Gauges

should be tagged with the date they were last calibrated.
3. Care must be exercised not to exceed pressure test speci ed on the pressure test
data.
4. When conducting a pneumatic test, it is essential that the contract speci cation
for pneumatic testing be adhered to in order to avoid creating a safety hazard.
5. Pneumatic test systems must include double block valves with a bleeder valve
between them to safely isolate the pressure source (by closing block valves and
opening bleeder to atmosphere) when incremental and nal test pressures are
attained.
Test Completion
1. Care shall be exercised in controlling the rate of draining from vessels in respect to
in ow of air through the vent to assure that a vacuum is not applied.
2. CAUTION: Prior to commencing drainage, ensure that all vents are open with
plugs and blind anges removed.
3. After drainage, remove all temporary blinds and blanks, temporary support, and
temporary testing connections.
4. Reinstall all items that were removed for test. Ensure that line Speci cation
gaskets and bolts are being used when reinstalling these items.
5. Remove all shipping bars from expansion joints.
6. Remove Stops from spring hangers and check cold settings.
Why this subject

During hydrotesting and pressure testing operations incidents sometimes happen.
This Safety Feedback Notice provides some typical examples which can be used an an
aid in highlighting the hazards and dangers involved are what are often seen as
routine operations.
Details of 5 incidents
1: Hydro-test of a new vertical vessel

The root cause of the incident is not fully known but there was some thought
that hydrotesting with “very cold” water was a contributing factor. Fortunately
no injuries occured.
Hydro-test of a new vertical vessel
2: Filling of a vertical tank

The lling of the tank was made with water from a re hydrant. The top the tank
blew off becuase the relief valve could not displace the air fast enough for the
volume of water that was being pumped in. Fortunately no injury happened, but
an operator was on top of the tank a few seconds before.
Filling of a vertical tank
3: Emptying of a vertical tank

The collapse of this tank happened while it was being emptied. A plastic sheet
protecting the roof was trapped in the vent; hence a vacuum was caused. There
was no injury. It should be noted that this type of incident is not that unusual.
Emptying of a vertical tank
4: Sphere collapse
The accident happened during the lling of a bar 2000 m LPG sphere. Its legs
collapsed. One person was killed and one seriously injured.
At the time of the accident, the sphere was approximately 80% full of fresh
water.
The vessel’s last hydro-test was 10 years ago and the last inspection of its legs
was 5 years ago.
Severe corrosion of the legs under the concrete re protection was the main
cause. The corrosion occurred due to water ingress between the concrete and
the steel legs.
The water protective cap located over the concrete was not suf cient to keep
water out. After the accident, it was veri ed that the steel legs had thickness
reductions of up to 8mm, with piting holes of up to 10cm .
After analysis and tests, it has been found that the following factors caused the
collapse:
Water caps over the re-proo ng concrete were of poor design thereby
letting water penetrate between the steel beams and the concrete.
Vertical cracks in the concrete let water in.
Repairs had been done to the concrete, but with poor workmanship.
The concrete had not adhered to the old concrete, again letting water in.
The deluge system had been tested with salt water, increasing the possibility
of corrosion.
Sphere collapse
5: Emptying of a gear box

To speeed up the removal of 250l of oil from a gear-box, the guage hole was
plugged and the breather was connected to the 6 bar air network.
The gear box exploded, and threw missiles around seriously damaging
surrounding piping and structure. Fortunately there was no injury.
Emptying of a gear box
SPECIFIC RECOMMENDATIONS
For each case the speci c recommendation are generally obvious:
1st incident : Water tempearture is critical when hydro testing. TFE speci cation (GS
PVV 211) states taht both metal and water temperature during pressure testing shall
be maintained at least at 16ºC or at least 10ºC above the impact test temperature of
the metal.
2nd and 3rd incidents : Venting systems shall be inspected and checked before lling
and emptying operations.
4th incident : Is a maintenance problem? Before testing an old vessel, a complete

inspection must be performed visually and with NDT. This inspection shall include the
vessel, nozzles, appurtenances, and supporting structures.
5th incident : obviously a gear-box is not pressure vessel, but productivity may lead to
a risky attitude.

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11/9/2019 Piping Hydrostatic Testing (overview) | QA/QC Construction

PIPING HYDROSTATIC TESTING (OVERVIEW)

HOME / QA/QC SYSTEMS / PIPING HYDROSTATIC TESTING

7. Check open and closed position of all valves.

8. Check for proper installation of vents and drains.

9. Verify chloride content of test water when testing stainless steels.

2. Pressure test gauges shall be calibrated to ensure accurate readings. Gauges

5. Remove all shipping bars from expansion joints.

6. Remove Stops from spring hangers and check cold settings.

Why this subject

1: Hydro-test of a new vertical vessel

Hydro-test of a new vertical vessel

2: Filling of a vertical tank

Filling of a vertical tank

3: Emptying of a vertical tank

Emptying of a vertical tank

Vertical cracks in the concrete let water in.

5: Emptying of a gear box

Emptying of a gear box

4th incident : Is a maintenance problem? Before testing an old vessel, a complete

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