REASONS FOR FAILURE....

If you don’t know the rules you don’t have to go by them;

This is kinda silly on this old stuff;
Under was authority;
We didn’t do this last time;
Can't find the pump;
No hose for the pump;
Hose too short;
Can’t find the right gasket;
Wrong flange on hose;
What do you mean hard pipe it;
Pump don't work;
Pump will not hold pressure;
Pump will not get to test pressure;
The check valves will not hold;
Can’t find the repair kit;
Stores is out of everything;
The stores clerks have gone home;
Can't get the air out;
Vent valve frozen;
How are we going vent;
The pump is in use;
The pump is loaned out;
Can't find the proper blanks;
Why do I have to change out the blanks;
Don't you think its too cold;
How are we going to blank a 18" line;
The whole vessel is wet;
I didn’t know we were looking for leaks;
It's gonna rain before we are through;
Its too dark to see a leak;
Can't find the gauges;
Can't find the correct range gauge;
This gage is calibrated and still want work.
Calibration sticker on gauge is out of date;
It will be too late if we have the gage calibrated;
The instrument shop doesn't like to work overtime;
The gauge isn't at 0;
What! use a hand pump;
Where is the air;
Why do we have to use DI water;
Who will sign-off on the test;
Operations is on my case;
Operation is going to startup at shift break;
The foreman is going to pull blanks in 10 min;
Why can't I use a Fire Water connection;
Who’s going to pull the blanks after shift break, I’m going home;
Why do I have to hold it for x minutes;
Why pull a vacuum and then pressure test;
The block valve leaks through;

Why can’t I pressure test using the instrument valve;

Why change out the gaskets;
What is the point of this as we have never had a leak;
These are Class 2500 flanges why are you testing at 3500 PSIG;
Why put a standpipe on the tank;
Can’t we open the manway;
Show me that on SPI’s;
What’s this going to prove;
Why start over if we have a leaking flange;
I’ll have to leave the water in overnight;
Why can’t I use the process material;
Why can’t I use air, we used it other areas;
Why can’t I use N2 it want explode;

the duration of a hydrostatic test depends upon the internal volume of the pipeline or
vessel undergoing the test.

The larger the volume, the longer the test.

I have seen hydrostatic tests run for 30 minutes, as well as for 24 hours.

Hydrostatic Tests during winter time at low ambient temperatures

Do you have any procedure on how to hydrotest piping during winter time with an
ambient temperature from 5 till -40 degrees Celsius?

Is it only by adding some antifreeze in the water test, or I have to sort out a different
system?

A)ASME code recommends (in these cases) to proceed a pneumatic test in lieu of
hydrostatic to avoid freezing of liquid inside your piping system.

Per ASME B31.3,

Par. 345 Testing

(b) Where the owner considers a hydrostatic leak test impracticable, either a
pneumatic test in accordance with para. 345.5 or a combined hydrostatic-
pneumatic test in accordance with para. 345.6 may be substituted, recognizing
the hazard of energy stored in compressed gas.

(c) Where the owner considers both hydrostatic and pneumatic leak testing
impracticable, the alternative specified in para. 345.9 may be used if both of the
following conditions apply:
(1) a hydrostatic test would damage linings or internal insulation, or contaminate a
process which would be hazardous, corrosive, or inoperative in the presence of moisture,
or would present the danger of brittle fracture due to low metal temperature during the
test

(2) a pneumatic test would present an undue hazard of possible release of energy stored
in the system, or would present the danger of brittle fracture due to low metal
temperature during the test

345.5 Pneumatic Leak Test

345.5.1 Precautions. Pneumatic testing involves the hazard of released energy stored
in compressed gas. Particular care must therefore be taken to minimize the chance of
brittle failure during a pneumatic leak test. Test temperature is important in this regard
and must be considered when the designer chooses the material of construction. See
para. 345.2.2(c) and Appendix F, para. F323.4.

345.6 Hydrostatic-Pneumatic Leak Test

If a combination hydrostatic-pneumatic leak test is used, the requirements of para.

345.5 shall be met, and the pressure in the liquid filled part of the piping shall not
exceed the limits stated in para. 345.4.2.

Only we like to avoid sudden stressing of the pipe material, so we like to raise up the
pressure step by step. But there is no a problem related to pressure drop, where
during hydrotest you have to inject a liquid to raise up the pressure. Drop in pressure is
a problem related to flowing of the fluid (dynamic), where our case is static.

The main reason that I do not believe hydrotesting provides a

benefit for in-service components is that it had been done once
during commissioning and you have proven the design.
a)The latest version of some ASME codes has increased the allowable stress for low temp ( ie below
800F) steel components, and likewise had to lower the hydro test to 1.3 times design
pressure. DO NOT HYDROTEST those components at 1.5 times design pressure- these components (
if later retrofit onto an older system) will define the max hydrotest pressure of the system

b) Newer boilers and power piping systems are using "advanced" alloys such as P91, P92, P122 etc-
these components have very low fracture toughenss at room temperature, and there are major QC
issues related to ensuring correct room temp properties vis a vis PWHT procedures. Bottom line: do
not hydrotest these components until you are absolutley sure (a) adequate room temp toughness
exists and (b) the metal temp of these parts during hydrotest is above 70 F

SEC VIII UG-99 STANDARD HYDROSTATIC TEST

Take a look at UG-99(c) and Appendix 3-2 under "calculated test pressure." Basically, this is saying
that you may test based on 1.3*MAP where MAP is the Maximum Allowable Pressure, new and cold.
Since you probably have some corrosion allowance, this will effectively raise your hydrotest pressure
without worrying about overstressing the top head.
The hydrotest multiplier was simply changed by the ultimate tensile ratio change from UTS/4 to
UTS/3.5: (3.5/4)*1.5 = 1.313.

There is an other point, before reach the 100% of test pressure you must gradually
increase the pressure into a determined time, this because if you set 100% in 1 step,
this will cause the pipe yield (or expand) a little producing a pressure drop

Only we like to avoid sudden stressing of the pipe material, so we like to raise up the
pressure step by step. But there is no a problem related to pressure drop, where
during hydrotest you have to inject a liquid to raise up the pressure. Drop in pressure is
a problem related to flowing of the fluid (dynamic), where our case is static.

please take a review for the following.

1. it is not only how to perform the hydrotest but the method of doing the test

2. think about why there is a requirements of hydrotesting?

3. you have to learn the properties and technical data of the materials so that you will
understand the limitation of hydrotesting.

4. bear in mind that all fabrications/manufactured devices or vessel/tanks has its

reference code of standards. from that standards, you will find the requirements for
testing such as ex-ray test of welds, hydrotesting or even air test, verification of
materials, etc., etc....

from that info, you will learn nearly to complete understanding why there is hydrotesting
requirements.

those people above who voluntary comments on your questions, are highly professional
to guide you....

At first, you have to define the code used in design and construction of your piping
system, I mean, did you used ASME Process Piping Code, B31.3 or Gas Transmission and
Distribution Piping System, B31.8.

I think that the 3rd party inspector is afraid of doing the hydrotest at ambient
temperature which may cause the pipe skin temperature to be lower than the MDMT of
the whole piping system. If that is the problem, I like to declare that no way to allow for
your piping system to operate or tested at temperatures lower than its MDMT.

So, the 3rd party inspector have the right to verify if the system subjected to that case
or not. And the Form of Hydrostatic Test Procedure must contain a record for these
temperatures.

Notes:

1. If there there is no statement in the contract of the project to proceed a hydrostatic

test (by water or another liquid), the ASME codes states that gas pipelines can be
pneumatically tested (by air or gas) in lieu of hydrostatic test by the conditions and
details specified by the code.
2. The relation between design pressure Pd and hydrostatic test pressure Ph for a piping
system designed and constructed as per ASME B31.3 is: Ph = 1.5 Pd (Sat ambient temp. / Sat
design temp.). But if your piping system is designed and constructed in accordance with
ASME B31.8, the relation between test pressure and design pressure is as indicated in
Table 841.322(f).

3. For more understanding to MDMT, see the following CR4 Threads: Minimum Design
Metal Temperature (MDMT) & Impact Test.

4. Relation between Stresses and holding time: The following article is extracted
from Pressure Piping code B31.8, Gas Transmission and Distribution Piping System,
Para. 841.32 (Edition 1995):

Quoted

Para. 841.321 All pipelines and mains to be operated at a hoop stress of 30% or more
of the SMYS of the pipe shall be given a test for at least 2 hours to prove strength after
construction and before being placed in operation.

Para. 841.322

(a) Pipelines located in Location Class 1 Division 1 shall be tested hydrostatically

to 1.25 times design pressure if the max. operating pressure is greater
than 72% SMYS.

(b) Pipelines located in Location Class 1 Division 2 shall be tested either with air or
gas to 1.1 times the max. operating pressure or hydrostatically to at least 1.1 times the
max. operating pressure if the max. operating pressure is 72% SMYS or less.

(c) Pipelines and mains in Location Class 2 shall be tested either with air to 1.25 times
the max. operating pressure or hydrostatically to at least 1.25 times the max. operating
pressure.

(d) Pipelines and mains in Location Class 3 and 4 shall be tested hydrostatically to a
pressure not less than 1.4 times the max. operating pressure. This requirement doesn't
apply if, at the time the pipeline or main is first ready for test, one or both of the
following conditions exist

(1) the ground temp. at pipe depth is 32 oF or less, or might fall to that temp. before the
hydrostatic test could be completed, or

(2) water of satisfactory quality is not available in sufficient quantity.

In such cases an air test to 1.1 times the max. operating pressure shall be made, and
the limitations on operating pressure imposed by Table 841.322(f) do not apply.

(e) The test requirements given in Para. 841.322(a), (b), (c), and (d) are summarized
in Table 841.322(f).

(f) In selecting the test level, the designer or operating company should be aware of the
provisions of Para. 854 and the relationship between test pressure and operating
pressure when the pipeline experiences a future increase in the number of dwellings
intended for human occupancy.

Table 841.322(f)-Edition 1999

Test Requirements for Pipelines and Mains to be Operated at Hoop Stresses of
30% or more of the SMYS of the pipe

1 2 3 4 5
Pressure Test
. .
Prescribed Max. Allowable Operating Pressure,
Location Permissible Test the Lesser of
Min. Max.
Class Fluid
1
1.25 x
Water None t.p / 1.25
m.o.p.
Division 1
1.1 x
Water None
m.o.p.
1 t.p / 1.1
1.1 x
Air 1.1 x d.p.
m.o.p.
Division 2 or d.p.
1.1 x
Gas 1.1 x d.p.
m.o.p.
1.25 x
Water None t.p / 1.25
m.o.p.
2
1.25 x 1.25 x
Air or d.p.
m.o.p. d.p.
3&4 t.p / 1.4
1.4 x None or
Water
m.o.p. d.p.
(Note 1)* or d.p.

* Note 1. For exceptions, see Para. 841.322(d).

m.o.p. = max. operating pressure (not necessarily the max. allowable operating
pressure)

d.p. = design pressure

t.p. = test pressure