Hydrostatic testing is the primary method used to test for leaks and assess the structural integrity of meter skids, compressed gas cylinders, boilers, tubing, pipelines and other pressurized vessels. It&#;s performed by filling the system with water, pressurizing it up to a level greater than Maximum Allowable Working Pressure (MAWP), and monitoring for visible and/or measurable leaks during a specified amount of time.
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The Importance of Hydrostatic Testing
By measuring the rate of expansion of the unit, hydrostatic testing can determine whether a vessel can safely hold the amount of pressure it&#;s rated for. It ensures that the weld joints and flanges are fitted properly, and confirms that the material used has the required strength to sustain the pressure. This is especially important in industrial applications involving the storage and transportation of fuel, chemicals, and other hazardous materials that can explode if they fail under pressure, and in pipelines, where a weakness in the structural integrity of a pipe could dramatically impact both the environment and our economy.
The Hydrostatic Testing Procedure
A hydrostatic test should only be performed by skilled personnel to avoid safety incidents. The procedure will differ slightly depending on the type of vessel being tested, but the goal of all hydrostatic testing is to examine the strength of the unit under test and identify leaks or weak spots. Once the air is removed from the vessel and it has been brought to test pressure (typically 1.5X its designed pressure limit but different standards have different pressure requirements), the techs must carefully monitor and record pressure regularly over the course of the test. Pressure, media and ambient temperature readings are taken digitally or with a chart recorder at specific set frequencies determined by industry codes and standards. The tests can take anywhere from 2 to 12 hours, depending on the application.
Hydrostatic Testing Frequency
Hydrostatic testing is a mandatory prerequisite in pipeline, meter skid and wellhead commissioning and it is also used to qualify smaller pressure vessels for service. The frequency of re-qualification testing depends on the age of the unit, the substance it contains, the material construction and its rating by the original equipment manufacturer (OEM). US Department of Transportation (DOT), Transport Canada (TC) and the European Union Pressure Equipment Directive (PED) all have different requirements that typically range between 3-5 years.
A Digital Solution for Monitoring Hydrostatic Tests
Chart recorders have been used to monitor and record hydrostatic test data for decades, but advances in digital technology have introduced a more streamlined data collection process that includes the ability to download data using wireless or USB. Our Ralston Hydrostatic Test Kits allow you to collect pressure and temperature data at selected intervals, add custom fields, and create detailed reports with graphs - all with an accuracy level 10x greater than a typical chart recorder.
Learn more about our Hydrostatic Test Kits and range of quick-connects for high pressure connections on most standard test points.
A more secure pressure testing method &#; right out of thin air
Throughout most of Europe, pipelines are traditionally pressure-tested using water. However, according to some experts, air pressure testing can be a more secure pressure testing method, reducing the risk of both Legionella and water damage, especially for large commercial new builds.
Don Elworthy is a Senior Contracts Manager at Panks Engineers Ltd in the UK. Panks engages in a wide range of projects from large commercial new builds to residential one-off remodels and repairs. They specialize in building hospitals and schools where hygiene and cleanliness reign supreme.
When specifying pressure testing methods, Don always requires air-pressure testing during construction
&#;We section off about 50 metres of pipe at a time and test as construction progresses,&#; Don explains. &#;We do it this way for two main reasons. Firstly, we can avoid frozen or burst pipes in winter. And secondly, but most importantly, because it eliminates the risk of Legionella bacteria in the pipes.&#;
Reducing the risk of Legionella
In the UK, Legionella is governed by seven water companies who require Legionella risk assessment reports for every new build in the country. Don takes full responsibility for these reports and Legionella is always top of mind. If pipes are not dried properly after water-pressure testing, Legionella bacteria can grow.
&#;When you pressure test with air, you can skip the time-consuming drying phase, but also be 100% assured that no Legionella bacteria have been introduced to the pipes during construction. This is particularly important in the hospitals and schools that we build.&#;
Some contractors and installers in the UK will assume the risk of a leak if it means they can save time on the construction process. That is not a risk that Don is willing to take.
&#;I insist we pressure-test religiously. Not only does this reduce our damage liability, but it&#;s also one of our most important selling points to new clients. They benefit from this extra level of security as they can be sure they will not experience a leak that can cause further damage to their asset.&#;
Reducing liability and damage costs
Over in the Netherlands, leakage is an important topic for insurance companies. Each year, 60,000 insurance claims are filed due to water damage &#; that&#;s a value of approximately 200 million euros. Twenty-five per cent of these damages caused by drinking water installations.
Eric van der Blom, Sanitary Specialist at Techniek Nederland, the Dutch business association of technical service providers, installation companies and the technical retail trade. He is closely involved in drafting standards, practical guidelines and quality assuring systems for sanitary installations, including the pressure testing of drinking water installations.
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&#;We&#;ve recently rewritten practical guidelines for pressure-testing drinking water installations. With large buildings, water-testing puts you at a big disadvantage because you have to flush the water through the pipelines every week of the build. This costs a lot of time and money.&#;
Because air pressure testing is done incrementally it saves time on the whole. Each air pressure test takes minimum of 130 minutes, compared to only 20 minutes for each water test. However, when you add the preparation time of a water test (the time it takes to get all air out of the system) and the fact that the whole installation needs to be flushed once per week, water testing is more cumbersome and takes much longer.
&#;Our view is that pressure testing should be as convenient as possible so that installers and contractors will prioritize it With the sound of a leak fitting it is easier to find the spot to be repaired. That&#;s why we recommend air-pressure testing for larger installations,&#; says Eric. &#;In that way, we hope to reduce the annual insurance claims due to leaks.&#;
By removing a water source, installers can also remove risk from the job site. Water damage is the second most frequent cause of loss during building projects and represents a large percentage of Construction All Risk (CAR) claims. Pressure testing with air means you can be 100% sure that leaks won&#;t destroy electrical installations, new flooring or fresh drywall. The work environment becomes safer as well.
Wavin Tigris K5 Press-fit System
Wavin Tigris K5 press-fit system is a multilayer composite pipe (MLCP) for commercial projects. It is designed for ease of installation, performance and reliability and features an innovative Acoustic Leak Alarm, which detects leaks quickly and easily, as any non-pressed fitting will produce a loud whistling sound for easy localisation.
It also has a range of performance and installation features including:
Optiflow, making it best in class in flow performance with up to 50% increased inner bore.
Multi-jaw press connection - fittings can now also be pressed with common pressing profiles like U and Up, TH, H and B
Easy pipe insertion without calibration
In4Sure&#; for proper pipe position that is visible 360°
Pipe grip - pipe stays in position before pressing
Clear visual leaking when the pipe is not pressed
Reliable O-ring sealing, tested beyond market standards
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