This article needs additional citations for verification .(September 2009) |
A hydrostatic test is a way in which pressure vessels such as pipelines, plumbing, gas cylinders, boilers and fuel tanks can be tested for strength and leaks. The test involves filling the vessel or pipe system with a liquid, usually water, which may be dyed to aid in visual leak detection, and pressurization of the vessel to the specified test pressure. Pressure tightness can be tested by shutting off the supply valve and observing whether there is a pressure loss. The location of a leak can be visually identified more easily if the water contains a colorant. Strength is usually tested by measuring permanent deformation of the container.
Hydrostatic testing is the most common method employed for testing pipes and pressure vessels. Using this test helps maintain safety standards and durability of a vessel over time. Newly manufactured pieces are initially qualified using the hydrostatic test. They are then revalidated at regular intervals according to the relevant standard. In some cases where a hydrostatic test is not practicable a pneumatic pressure test may be an acceptable alternative. [1]
Testing of pressure vessels for transport and storage of gases is very important because such containers can explode if they fail under pressure.
Hydrostatic tests are conducted under the constraints of either the industry's or the customer's specifications, or may be required by law. The vessel is filled with a nearly incompressible liquid – usually water or oil – pressurised to test pressure, and examined for leaks or permanent changes in shape. Red or fluorescent dyes may be added to the water to make leaks easier to see. The test pressure is always considerably higher than the operating pressure to give a factor of safety. This factor of safety is typically 166.66%, 143% or 150% of the designed working pressure, depending on the regulations that apply. For example, if a cylinder was rated to DOT-2015 PSI (approximately 139 bar), it would be tested at around 3360 PSI (approximately 232 bar).
Water is commonly used because it is cheap and easily available, and is usually harmless to the system to be tested. Hydraulic fluids and oils may be specified where contamination with water could cause problems. These fluids are nearly incompressible, therefore requiring relatively little work to develop a high pressure, and is therefore also only able to release a small amount of energy in case of a failure - only a small volume will escape under high pressure if the container fails. If high pressure gas were used, then the gas would expand to V=(nRT)/p with its compressed volume resulting in an explosion, with the attendant risk of damage or injury.
Small pressure vessels are normally tested using a water jacket test. The vessel is visually examined for defects and then placed in a container filled with water, and in which the change in volume of the vessel can be measured, usually by monitoring the water level in a calibrated tube. The vessel is then pressurised for a specified period, usually 30 or more seconds, and if specified, the expansion will be measured by reading off the amount of liquid that has been forced into the measuring tube by the volume increase of the pressurised vessel. The vessel is then depressurised, and the permanent volume increase due to plastic deformation while under pressure (permanent set) is measured by comparing the final volume in the measuring tube with the volume before pressurisation.
A leak will give a similar result to permanent set, but will be detectable by holding the volume in the pressurised vessel by closing the inlet valve for a period before depressurising, as the pressure will drop steadily during this period if there is a leak. In most cases a permanent set that exceeds the specified maximum will indicate failure. A leak may also be a failure criterion, but it may be that the leak is due to poor sealing of the test equipment. If the vessel fails, it will normally go through a condemning process marking the cylinder as unsafe.[ citation needed ]
The information needed to specify the test is stamped onto the cylinder. This includes the design standard, serial number, manufacturer, and manufacture date. After testing, the vessel or its nameplate will usually be stamp marked with the date of the successful test, and the test facility's identification mark.[ citation needed ]
A simpler test, that is also considered a hydrostatic test but can be performed by anyone who has a garden hose, is to pressurise the vessel by filling it with water and to physically examine the outside for leaks. This type of test is suitable for containers such as boat fuel tanks, which are not pressure vessels but must work under the hydrostatic pressure of the contents. A hydrostatic test head is usually specified as a height above the tank top. The tank is pressurised by filling water to the specified height through a temporary standpipe if necessary. It may be necessary to seal vents and other outlets during the test.[ citation needed ]
Portable fire extinguishers are safety tools that are required in most public buildings. Fire extinguishers are also recommended in homes. Over time the conditions in which they are housed, and the manner in which they are handled affect the structural integrity of the extinguisher. A structurally weakened fire extinguisher can malfunction or even burst when it is needed the most. To maintain the quality and safety of this product, hydrostatic testing is utilized. All critical components of the fire extinguisher should be tested to ensure proper function.
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 ]
Most countries have legislation or pressure vessel codes which requires 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. [2] [ 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. [3]
These common US standard gas cylinders have the following requirements: [4]
Typically organizations such as DOT PHMSA, ISO, ASTM and ASME specify the guidelines for the different types of pressure vessels.
Hydraulic testing is a hazardous process and should 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.
Equipment:
Pressure is the force applied perpendicular to the surface of an object per unit area over which that force is distributed. Gauge pressure is the pressure relative to the ambient pressure.
Relative density, or specific gravity, is the ratio of the density of a substance to the density of a given reference material. Specific gravity for liquids is nearly always measured with respect to water at its densest ; for gases, the reference is air at room temperature. The term "relative density" is often preferred in scientific usage, whereas the term "specific gravity" is deprecated.
A boiler is a closed vessel in which fluid is heated. The fluid does not necessarily boil. The heated or vaporized fluid exits the boiler for use in various processes or heating applications, including water heating, central heating, boiler-based power generation, cooking, and sanitation.
A diving cylinder or diving gas cylinder is a gas cylinder used to store and transport high pressure gas used in diving operations. This may be breathing gas used with a scuba set, in which case the cylinder may also be referred to as a scuba cylinder, scuba tank or diving tank. When used for an emergency gas supply for surface supplied diving or scuba, it may be referred to as a bailout cylinder or bailout bottle. It may also be used for surface-supplied diving or as decompression gas. A diving cylinder may also be used to supply inflation gas for a dry suit or buoyancy compensator. Cylinders provide gas to the diver through the demand valve of a diving regulator or the breathing loop of a diving rebreather.
Fluid statics or hydrostatics is the branch of fluid mechanics that studies the condition of the equilibrium of a floating body and submerged body "fluids at hydrostatic equilibrium and the pressure in a fluid, or exerted by a fluid, on an immersed body".
A pressure vessel is a container designed to hold gases or liquids at a pressure substantially different from the ambient pressure.
Within industry, piping is a system of pipes used to convey fluids from one location to another. The engineering discipline of piping design studies the efficient transport of fluid.
A gas cylinder is a pressure vessel for storage and containment of gases at above atmospheric pressure. High-pressure gas cylinders are also called bottles. Inside the cylinder the stored contents may be in a state of compressed gas, vapor over liquid, supercritical fluid, or dissolved in a substrate material, depending on the physical characteristics of the contents. A typical gas cylinder design is elongated, standing upright on a flattened bottom end, with the valve and fitting at the top for connecting to the receiving apparatus.
A shell-and-tube heat exchanger is a class of heat exchanger designs. It is the most common type of heat exchanger in oil refineries and other large chemical processes, and is suited for higher-pressure applications. As its name implies, this type of heat exchanger consists of a shell with a bundle of tubes inside it. One fluid runs through the tubes, and another fluid flows over the tubes to transfer heat between the two fluids. The set of tubes is called a tube bundle, and may be composed of several types of tubes: plain, longitudinally finned, etc.
A leak is a way for fluid to escape a container or fluid-containing system, such as a tank or a ship's hull, through which the contents of the container can escape or outside matter can enter the container. Leaks are usually unintended and therefore undesired. The word leak usually refers to a gradual loss; a sudden loss is usually called a spill.
Storage tanks are containers that hold liquids, compressed gases or mediums used for the short- or long-term storage of heat or cold. The term can be used for reservoirs, and for manufactured containers. The usage of the word tank for reservoirs is uncommon in American English but is moderately common in British English. In other countries, the term tends to refer only to artificial containers.
Oxy-fuel welding and oxy-fuel cutting are processes that use fuel gases and oxygen to weld or cut metals. French engineers Edmond Fouché and Charles Picard became the first to develop oxygen-acetylene welding in 1903. Pure oxygen, instead of air, is used to increase the flame temperature to allow localised melting of the workpiece material in a room environment. A common propane/air flame burns at about 2,250 K, a propane/oxygen flame burns at about 2,526 K, an oxyhydrogen flame burns at 3,073 K and an acetylene/oxygen flame burns at about 3,773 K.
Thermowells are cylindrical fittings used to protect temperature sensors installed to monitor industrial processes. A thermowell consists of a tube closed at one end and mounted on the wall of the piping or vessel within which the fluid of interest flows. A temperature sensor, such as a thermometer, thermocouple, or resistance temperature detector, is inserted in the open end of the tube, which is usually in the open air outside the piping or vessel and any thermal insulation.
A fire extinguisher is a handheld active fire protection device usually filled with a dry or wet chemical used to extinguish or control small fires, often in emergencies. It is not intended for use on an out-of-control fire, such as one which has reached the ceiling, endangers the user, or otherwise requires the equipment, personnel, resources, and/or expertise of a fire brigade. Typically, a fire extinguisher consists of a hand-held cylindrical pressure vessel containing an agent that can be discharged to extinguish a fire. Fire extinguishers manufactured with non-cylindrical pressure vessels also exist but are less common.
Pipeline leak detection is used to determine if and in some cases where a leak has occurred in systems which contain liquids and gases. Methods of detection include hydrostatic testing, infrared, and laser technology after pipeline erection and leak detection during service.
A composite overwrapped pressure vessel (COPV) is a vessel consisting of a thin, non-structural liner wrapped with a structural fiber composite, designed to hold a fluid under pressure. The liner provides a barrier between the fluid and the composite, preventing leaks and chemical degradation of the structure. In general, a protective shell is applied for protective shielding against impact damage. The most commonly used composites are fiber reinforced polymers (FRP), using carbon and kevlar fibers. The primary advantage of a COPV as compared to a similar sized metallic pressure vessel is lower weight; COPVs, however, carry an increased cost of manufacturing and certification.
FRP is a modern composite material of construction for chemical plant, pulp and paper mill, and food and pharmaceutical equipment like tanks and vessels. Chemical equipment that range in size from less than a metre to 20 metres are fabricated using FRP as material of construction.
A booster pump is a machine which will increase the pressure of a fluid. They may be used with liquids or gases, but the construction details will vary depending on the fluid. A gas booster is similar to a gas compressor, but generally a simpler mechanism which often has only a single stage of compression, and is used to increase pressure of a gas already above ambient pressure. Two-stage boosters are also made. Boosters may be used for increasing gas pressure, transferring high pressure gas, charging gas cylinders and scavenging.
Transportable pressure vessels for high-pressure gases are routinely inspected and tested as part of the manufacturing process. They are generally marked as evidence of passing the tests, either individually or as part of a batch, and certified as meeting the standard of manufacture by the authorised testing agency, making them legal for import and sale. When a cylinder is manufactured, its specification, including manufacturer, working pressure, test pressure, date of manufacture, capacity and weight are stamped on the cylinder.