HYDROTEST

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
 HYDROTEST
• FOR STRUCTURAL INTEGRITY &
LEAK CHECK
 HYDROTEST
• SELECTION OF PUMP
• VENTING ARRANGEMENT
• BOLT TIGHTENING
• WATER QUALITY
• WATER TEMPARATURE
• Hydrotest -Heat exchanger
• Hydrotest- Vessels
 Hydrostatic Test
Types
Vertical hydro test.( At site )
Horizontal hydro test.( In shop).
REQUIREMENTS OF MATERIALS ,
TOOLS & EQUIPMENTS
Water is generally used for Hydro test with
different requirements specified by customer.
• Chloride content in PPM ( Parts Per Million).
CHLORINE PARTICLES AFFECT THE
ANTICORROSIVE PROPERTIES OF
VESSEL
• Cold water.
• Hot water.
 REQUIREMENTS OF MATERIALS ,
TOOLS & EQUIPMENTS-(CONTD.)
THERMOCOL SHEETS
• 20--30 mm thickness
• Used as a soft packing between vessel and
saddle
COVER FLANGES
• Nozzles which have original blind flanges to
be blanked by those flanges
• Other nozzles to be blanked as per specified
drawing
 SEQUENCE OF OPERATIONS

SADDLE ARRANGEMENT
• Required no. of saddles as mentioned in the
drawing are to be placed.
• Put the thermocol sheets on saddles before
keeping the vessel.
 SEQUENCE OF OPERATIONS
(CONTD.)
ORIENTATION
• Long seam, circ seam remain exposed for
visual inspection & not covered by saddle.
• Inlet nozzle for water is at the top and
drain is at the bottom.
SEQUENCE OF OPERATIONS
(CONTD.)

AIR LOCK REMOVAL

• Adequate arrangement to be made for
venting the air, trapped inside the
equipment.
REQUIREMENTS OF MATERIALS ,
TOOLS & EQUIPMENTS-(CONT.)

PRESSURE GAUGES
• Use minimum two calibrated pressure gauges
• RANGE--- MIN. 1.5 times the test pressure
MAX. 4 times the test pressure

WOODEN SADDLES (SOFT WOOD)

• To support the vessel & avoid any
deformation at contact surfaces
• GENERALLY CONTACT ANGLE---120
DEGREES
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