HYDROTEST

TESTSDESTRUCTIVE TESTSTensile, Impact, Bend etcNON-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 timeGauges, transducer/ recorder , Sq. Bar, Hose pipes, PumpLocation, weight distribution, draining Saddles, slope, ventingWater- quantity,quality & temperatureTorque tightening / tensioning unitsFlanges, 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

HYDRO TEST Carry out tightening of Nozzle / Man way covers as per the required torqueUse proper tightening unit to meet the requirement of PSI / Torque and follow the tightening sequence as per approved procedure for bolts / studsStart filling water after confirmation of all requirements ( like venting, PPM of water, Clearance of Job for fill up)

12345678TIGHTENING SEQUENCE (with torque tightening unit)

1122334455667788TIGHTENING SEQUENCE (with tensioning unit)

HYDRO TESTEnsure that the nozzles (top) are open for air removalLet the water flow out of the top nozzles so that the air is removedClose 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 REMOVAL2 WHEN INTERNALS LIKE TSRs PROVIDED INSIDE THE VESSEL

AIR LOCK REMOVAL3 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 TESTEnsure that minimum two pressure gauges are attachedThe 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 TESTIncrease 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 TESTHold 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 TESTReduce the pressure to Design pressureCheck for any leakage in weld joints and bolted jointsIf no leakage is observed, depressurizing can be started

HYDRO TESTDepressurizing :If cycle is specified , follow the sameIf 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 TESTPressure 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

HYDROTESTFOR STRUCTURAL INTEGRITY & LEAK CHECK

HYDROTEST SELECTION OF PUMPVENTING ARRANGEMENTBOLT TIGHTENINGWATER QUALITYWATER TEMPARATUREHydrotest -Heat exchangerHydrotest- Vessels

Hydrostatic TestTypes 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 VESSELCold water.Hot water.

REQUIREMENTS OF MATERIALS , TOOLS & EQUIPMENTS-(CONTD.)THERMOCOL SHEETS20--30 mm thicknessUsed as a soft packing between vessel and saddleCOVER FLANGESNozzles which have original blind flanges to be blanked by those flangesOther nozzles to be blanked as per specified drawing

SEQUENCE OF OPERATIONS SADDLE ARRANGEMENTRequired 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.) ORIENTATIONLong 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 REMOVALAdequate arrangement to be made for venting the air, trapped inside the equipment.

REQUIREMENTS OF MATERIALS , TOOLS & EQUIPMENTS-(CONTD.)

PRESSURE GAUGESUse minimum two calibrated pressure gaugesRANGE--- MIN. 1.5 times the test pressure MAX. 4 times the test pressureWOODEN SADDLES (SOFT WOOD)To support the vessel & avoid any deformation at contact surfacesGENERALLY CONTACT ANGLE---120 DEGREES