Hydrostatic Test Page 1 of 16

Hydrostatic Test Pressure Test

(Integrity)
(Medium) ,
4

(compressed air), Nitrogen Helium

compressed air
7 bar
Workshop Air Compressor 7 bar


5

15 (psi)
(Pressure Vessel) ASME Code VIII Div.1
, Casing Pump Compressor Heat Exchanger
Code
ASME Code British Standard BS 5500 Code

(Wall thickness) (Corrosion Allowance,
CA)



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(Medium)

(Medium) , (Compressed Air), Nitrogen

Nitrogen (Compressible
12

Fluids) (Stored energy)

Compressible Fluids
13

0.01 barg (Head 10 1 bar
30 cm. 0.03 bar )

2-2.5 bar

14

(Incompressible Fluid)
(Stored energy)
Diesel
(Flash point) 50oC

15
(Refractory) (Cryogenic
System) Nitrogen

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(Test Pressure)

(Design Pressure)
(Operating Pressure)
(Test pressure) Yield Strength Safety Factor

ASME Code, VIII Div.1
18

Vessel :-
PR
t = + CA (1)
SE - 0.6P

22 t = Vessel, in.
P = Design Pressure, psi.
R = Vessel CA, in.
E = Joint Efficiency

26

CA
27 = , in.
S = Allowable Tensile stress, psi.

Allowable Tensile Stress (S) ASME Code

29

Tensile test Tensile Strength Yield Strength Allowable Stress

2

Ultimate tensile Strength ( u )

Su = (2)
4.0

Yield Strength ( y )
Sy = (3)
1.5

Ultimate Tensile Strength ( u ) Yield Strength ( y )

35

(Specified Minimum Tensile Strength, SMTS) (Specified Minimum Yield

Strength, SMYS) ASME Standards
Safety Factor Tensile Strength Yield
Strength .
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(3)
36

1.5 Stress
SMYS ( Allowable stress 3)
Yield

37

1.5
Code ASME VIII Div.1
1.5
38

ASME VIII Div.1

2001 ASME Code Yield Strength Safety Factor 1.3
British Standard BS 5500 Safety Factor

(Design Pressure)
39

(Static head)

(Catalyst)
(Bulk density)
(Fluid Mechanics)
Hydrotest
40

Pressure gauge
Pressure gauge Test Pressure Static head
Pressure gauge
( 10 1 bar.)

1
42

30-35C

St
Pt = 1.5 P d (4)
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46 Pt = test
Pd =
St
48 =
S
49 =

16,000
Fig. 1
14,000 Comparison of the m aximum
allow able stresses for various steels
12,000 plates at different temperatures (From
ASME VIII Div. 1)
10,000
Allowable stress, psi

8000

A 285 Gr. C
6000 A 515, A516 Gr. 60
A 387 5 Cl. 2 (5% C./ Mo)
4000

2000

300 350 400 450 500 550 600 650

o
Maximum Metal Temperature, C

A285 Gr.c ASME Code

Pressure Vessel
18 barg. 400 C 1 400 C
Allowable Stress 12,400 psi 30 C Allowable
Stress 13,800 psi. Hydrostatic test

13800
Pt = 1.5 x 18
12400

= 30.0 barg.

Test Stress

Hydrotest pressure
Stress Test (Test stress)
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Test Stress Code

58

Hydrotest 12.55
15.5
Material : ASTM A516 Gr.70
Design Pressure : 18.00 barg.
Design temperature : 48 C
Test Pressure : 27.00 barg.
Corrosion Allowance : 1.5 mm.
Top wall thickness : 50.00 mm.
Bottom wall thickness : 53.00 mm.
Joint Efficiency : 1.0

Inlet, 6
PI

Thickness 50. 00 mm

ID = 12,55 0 mm
15. 5 m

Thickness 53.00 mm

Outlet, 8

Drain, 1

Hydro test
52.80 mm. Test stress :-

Test Pressure at bottom = (27 + 1.55) x 14.5

Pt = 413.97 psi.

ASME Code Spherical Vessel :-

P Ri
t = (5)
2SE - 0.2P
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Design pressure Test pressure Test Stress :-

P t (R i + 0.2t)
R

St =
2t

12550
Ri R = = 247.04 in.
2 x 25.4

52.80
t = = 2.079 in.
25.40

413.97 [247.04 + (0.2 x 2.079)]

Test stress, S t =
2 x 2.079

= 24,636.6 psi

ASME Code, SMYS A 516 Gr.70 38,000

89 psi.
Hydrotest

Hydrotest Austenitic Stainless Steels

Stainless Steel Austenite

Austenitic Stainless Steel Stainless 3
Type 304, 316, 317 (Series 300) 201 202

(Crack) Tensile Stress (Chloride)
Stress Corrosion Cracking (SCC)
Tensile Stress

Hydrotest
92

50 ppm. Stress Corrosion Cracking

25-150 ppm

Hydrotest
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Hydrotest
4 C
(Brittleness)
R-453 CHANNEL FAILURE

3
Failed in the longitudinal
direction of maximum
stress and perpendicular
to the forc e

3 hydrostatic test

Hydrotest

Hydrotest
test

Hydrotest
98

Test Pump, Flexible hose,

Pressure gauge 2 gauge Calibrate
test Spade (
99

) Test Pressure
(Instrument)
Test pressure Safety valve
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100

Hydro test ASME Code

30
101

ASME Pressure Vessel Code

ASME/ANSI B31.3 Chemical Plant and
Petroleum Refinery Piping 10 ASME/ANSI 31.8 Piping for
Gas Transmission 2

102

(Strength test)
(Design Pressure)

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Strength test
30 min .

Hydro static test pressure

Pressure at the vessel top, barg

Leak t est Design pressur e

Time

3 4

(Vent) (Drain)

Hydrostatic Test

Hydrostatic test
test
Support (Foundation)
Thermowell Blind


106

10 bar
1.2
10 bar 113 Tons
(Bolts) 5
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Vent
Hydrostatic end force,
Cover
Hydro static F = PxA
end force, F

10 x (120) 2
F =
4
= 113, 097 kg
D = 1.2 m

Pt = 10 b arg

Test pump
Tank

Drain

4
5

(Mechanical Explosion)

Pneumatic Test

Pneumatic test Test Compressible Fluid Compressed

air, Nitrogen, Helium
Pneumatic test , (Refractory)
( Hydrotest
)


110

Mechanical Explosion ,
.



111

(Sonic velocity) (Shock wave)

Hydrostatic Test Page 12 of 16

6 7
TNT

Fig. 6 Equivalent TNT burst energy for water-filled vessel s

2 4 68 2 4 68 2 4 68 2 4 68 2 4 68 2 4 68
105

Water temperature = 68o F

Ambient pressure = 1 atm
Burst pressure, psig

104

103

102
10-5 10-4 10-3 10-2 10-1 1 10

Burst energy (W/V = lbs TNT/ft 3) for Water

Fig. 7 Equivalent TNT burst energy for ga s-filled vessel s

2 4 6 8 2 4 6 8 2 4 6 8 2 4 6 8
105

Gas temperature = 70o F

Ambient pressure = 1 atm
Burst pressure, psig

104

103

102
10-2 10-1 1 10 102

Burst energy (W/V = lbs TNT/ft 3) for Gases

6
TNT 7
TNT
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Table 1 Overpressure from 1 lb Hemispherical

Charge of TNT-Surface Explosion in Open Air

Distance, ft Overpressure, psi t 1, m/s t2, m/s

2 320.0 0.2 0.8
4 70.0 0.8 1.6
6 28.0 1.8 2.4
8 15.0 3.0 3.0
10 9.6 4.3 3.2
20 3.0 12.0 --
40 1.2 29.0 --
100 0.35 82.0 --
200 0.13 169.0 --
400 0.05 346.0 --

t1 = blast wave arrival time, t2 = time required for the overpressure to decay back to zero

Table 2 Structural and Biological Response to

Overpressure and Shrapnel

Blast overpressure Structural or biological response to blast effects

or shrapnel momentum

0.5-1 psig Glass windows shatter

1-2 psig Corrugated asbestos siding shatter; corrugated steel
or alum inum paneling buckles
2-3 psig Nonreinforced concrete or cinderblock wall (8-12 in.
thick) shatter
5 psig Eardrums rupture
7-8 psig Nonreinforced brick w alls (8-12 in. thick) shear and fall
15 psig Lung dam age occurs
115 ft/s for a 0.35 oz glass Projectile penetrates abdomen
projectile
10 ft/s for a 10 lb m asonry Projectile penetrates abdomen
projectile
10 ft/s for a 160 lb m an Skull fractures from impact

1 TNT 1
2

15
Hydrostatic Test Page 14 of 16

TNT Equivalent, Distance Overpressure,

lb , ft psig
10, 000 10,000

0.1

1,000 1,000
Fig. 8
1
Nomograph for
100
100 estimating
10 overpressure s
resulting from open-
10 10 air surface explosion
100
of s hemispherical
TNT charge
1 1 1000

0.1

Nomograph 8 TNT

5 m3
117

( 1.2 )
10 barg. ( )
:-
118

Burst Pressure = 10 x 14.5 = 145 psi.

6 Burst energy
120 2 x 10-2 lb TNT/ft3

Burst Energy = 2 x 10-2 x 5 x (3.28)3

= 3.52 lb TNT

8 10
18 psig

Burst Energy
125 = 8 x 10-5 x 5 x (3.28)3

= 0.014 Ib TNT.
Hydrostatic Test Page 15 of 16

Hydrotest
127

Pneumatic test
128

Hydrotest

Pneumatic Test

Pneumatic test 1.25

(1.25 Design pressure) Pressure vessels 1.10
Piping system
1. 25 psi (170 kPa)

2.
3. 10%

4. (Design pressure)

7 (Safety distance)

0.1

1) ASME/ANSI B31.3; Chemical Plant and Petroleum Refinery Piping, 1987
2) ASME/ANSI B31.8; Gas Transmission and Distribution Piping Systems, 1999
3) ;
, Pressure Vessels 2545
4) T.M. Flynn; Cryogenic Engineering, Mercel Dekker Inc., 1997
5) ASME VIII Div 1; Pressure Vessel, 1995
Hydrostatic Test Page 16 of 16

6) J. R. Farr and M. H. Jawad; Guidebook for the Design of ASME Section VIII
Pressure Vessels, 2nd. Edition, ASME Press, 2001

.. (), .., .507

American Society of Mechanical Engineers