HYDROTEST

SDP-1 V.P.SHUKLA
 TESTS
DESTRUCTIVE TESTS
Tensile, Impact, Bend etc
NON-DESTRUCTIVE TESTS
Radiography
Ultrasonic
Dye Penetration
Magnetic Particle
Leak tests like Air test,Ammonia test etc.
Hydrostatic test
 WHY HYDROSTATIC TEST
To ensure the integrity of the equipment
To ensure the strength of the weld joints &
material
To ensure the strength of the nozzle flange
joints
To relieve the stresses
Ensures safe and reliable performance
during the operational life
 HYDRO TEST
Good planning is essential for completion
of hydrotest in minimum possible time
Gauges, transducer/ recorder , Sq. Bar,
Hose pipes, Pump
Location, weight distribution, draining
Saddles, slope, venting
Water- quantity,quality & temperature
Torque tightening / tensioning units
Flanges, bolts / studs
 HYDRO TEST
The hydro test saddles shall be located on
shell in such a way that all circumferential
seams are free from saddle location. Long
seams if any covered by the saddle; the
corresponding location of saddle material
shall be grooved to facilitate the inspection
of weld joint under test
Sketch for Hydro test
Arrangement for Outlet Pressure Gauge

Towards Venting pipe

Valves

Pressure Gauge

Square Bar
Coupling
Arrangement for Inlet Pressure Gauge

Pressure Gauge

Valves

Coupling
From Hydrotest
Pump

Square Bar

Towards Drain
 HYDRO TEST
Carry out tightening of Nozzle / Man
way covers as per the required
torque
Use proper tightening unit to meet the
requirement of PSI / Torque and follow
the tightening sequence as per
approved procedure for bolts / studs
Start filling water after confirmation of
all requirements ( like venting, PPM of
water, Clearance of Job for fill up)
TIGHTENING SEQUENCE
(with torque tightening unit)

1
8 5

4 3

6 7
2
TIGHTENING SEQUENCE
(with tensioning unit)

1
8 3
6 5
4 7

2 2

7 4
5 6
3 8
1
 HYDRO TEST

Ensure that the nozzles (top) are

open for air removal
Let the water flow out of the top
nozzles so that the air is removed
Close the nozzle & allow the water to
flow from top and confirm absence of
air bubbles
 AIR LOCK REMOVAL

1 VESSEL IN HORIZONTAL, INCLINED AT 5 DEG.

Packing
 AIR LOCK REMOVAL
2 WHEN INTERNALS LIKE TSRs PROVIDED INSIDE THE VESSEL
 AIR LOCK REMOVAL

3 NOZZLES ON DISHEND
 HYDRO TEST

Start the pump for pressurizing the

water inside the equipment. (Selection
of pump depends on the pressure and
discharge of water from pump. Set the
output pressure of pump such that it
should not exceed hydro test pressure
for safer operation)
 HYDRO TEST
Ensure that minimum two pressure
gauges are attached
The pressure gauges shall have an upper
range of 2 times the test pressure but in
no case less than 1.5 times or more than
4 times the test pressure. The transducer
shall have minimum upper range of 1.25
times the test pressure. Only calibrated
pressure gauge and transducer shall be
used. Validity of calibration shall be
verified on the calibration sticker pasted
on the pressure indicators
 HYDRO TEST
Increase the pressure as per the
requirement given in drawing or the
approved procedure
During pressurizing from design
pressure to test pressure, no one
shall remain on the vessel or very
near to bolted connections on the
vessel
 HYDRO TEST
Hold the test pressure for minimum
30 minutes or as specified by the
drawing / specification. The test
pressure shall not get dropped
during the holding time. The vessel
connections shall not be inspected
closely for any leakage at this stage
 HYDRO TEST
Reduce the pressure to Design
pressure
Check for any leakage in weld joints
and bolted joints
If no leakage is observed,
depressurizing can be started
 HYDRO TEST
Depressurizing :
If cycle is specified , follow the same
If not specified, reduce pressure
slowly by opening the square bars (at
top) such that pressure drops to zero
Never open bottom noz./ Sq. bar
While draining the vessel, the top vent
valve shall be kept open before
opening any nozzle at the bottom. This
is for eliminating the possible collapse
of thin shells due to vacuum created
within the test vessel
 HYDRO TEST
Pressure gauges once used for a
pressure test shall be recalibrated. For
this purpose, the pressure gauges
once used shall be crossed on the
calibration sticker and send to QA