Pipeline testing

Hydrotesting of pipes, pipelines and vessels is performed to expose defective materials that
have missed prior detection, ensure that any remaining defects are insignificant enough to
allow operation at design pressures, expose possible leaks and serve as a final validation of
the integrity of the constructed system. ASME B31.3 requires this testing to ensure tightness
and strength.

Buried high pressure oil and gas pipelines are tested for strength by pressurising them to at
least 125% of their maximum allowable working pressure (MAWP) at any point along their
length. Since many long distance transmission pipelines are designed to have a steel hoop
stress of 80% of specified minimum yield strength (SMYS) at Maximum allowable operating
pressure MAOP, this means that the steel is stressed to SMYS and above during the testing,
and test sections must be selected to ensure that excessive plastic deformation does not
occur.[citation needed]

For piping built to ASME B31.3, if the design temperature is greater than the test
temperature, then the test pressure must be adjusted for the related allowable stress at the
design temperature. This is done by multiplying 1.5 MAWP by the ratio of the allowable
stress at the test temperature to allowable stress at the design temperature per ASME B31.3
Section 345.4.2 Equation 24. Test pressures need not exceed a value that would produce a
stress higher than yield stress at test temperature. ASME B31.3 section 345.4.2 (c)

Other codes require a more onerous approach. BS PD 8010-2 requires testing to 150% of the
design pressure - which should not be less than the MAOP plus surge and other incidental
effects that will occur during normal operation.[citation needed]

Leak testing is performed by balancing changes in the measured pressure in the test section
against the theoretical pressure changes calculated from changes in the measured temperature
of the test section.

Australian standard AS2885.5 "Pipelines—Gas and liquid petroleum: Part 5: Field pressure
testing" gives an excellent explanation of the factors involved.[clarification needed]

In the aerospace industry, depending on the airline, company or customer, certain codes will
need to be followed. For example, Bell Helicopter has a certain specification that will have to
be followed for any parts that will be used in their helicopters.[citation needed]

Testing frequency
Most countries have legislation or building code that requires pressure vessels to be regularly
tested, for example every two years (with a visual inspection annually) for high pressure gas
cylinders and every five or ten years for lower pressure ones such as used in fire
extinguishers.[citation needed][clarification needed] Gas cylinders which fail are normally destroyed as
part of the testing protocol to avoid the dangers inherent in them being subsequently
used.[citation needed][clarification needed]

These common gas cylinders have the following requirements:[citation needed]

  DOT-3AL gas cylinders must be tested every 5 years and have an unlimited life.
 DOT-3HT gas cylinders must be tested every 3 years and have a 24-year life.
 DOT-3AA gas cylinders must be tested every 5 years and have an unlimited life.
(Unless stamped with a star (*) in which case the cylinder meets certain specifications
and can have a 10-year hydrostatic test life).

Typically organizations such as ISO, ASTM and ASME specify the guidelines for the
different types of pressure vessels.

Safety
Hydraulic testing is a hazardous process and needs to be performed with caution by
competent personnel. Adhering to prescribed procedures defined in relevant technical
standards appropriate to the specific application and jurisdiction will usually reduce these
risks to an acceptable level.

 A leak of high pressure liquid can cut or penetrate the skin and inject itself into body
tissues. This can cause serious direct injury to the operator, and if the fluid is toxic or
contaminated there will be additional adverse effects.
 A pressurised hose that is not securely attached or which fails under pressure may
whip around spraying water or oil and could hit someone and cause injuries. A whip
check can be used to restrain such hoses.
 Enclosing the components to be tested, hazard signage, use of appropriate personal
protective equipment and providing barriers to access for non-essential personnel are
common precautions.

Equipment. 1.Pressure gauges[1.5 to 4.0 times of test pressure] 2.Water tanks 3.Potable tanks
4.Pumbs for water filling and pressure 5.pressure gauges and temperature recorder.