API 510 Preparatory Class

Lesson 5

Hydrostatic, Pneumatic Tests

UG-99 Standard Hydrostatic Test Page 80 Section VIII

(a) A hydrostatic test shall be conducted on all vessels after: (1) all fabrication has been completed, except for operations which could not be performed prior to the test such as weld end preparation. (2) all examinations have been performed, except those required after the test...

UG-99 Standard Hydrostatic Test

(b) Except as otherwise permitted in (a) above and 27-3, vessels designed for internal pressure shall be subjected to a hydrostatic test pressure which at every point in the vessel is at least equal to 1.3 times the maximum allowable working pressure to be marked on the vessel multiplied by the lowest ratio (for the materials of which the vessel is constructed) of the stress value S for the test temperature on the vessel to the stress value S for the design temperature

Stress at Test Temp Stress at Design Temp

UG-99 Standard Hydrostatic Test

(c) A hydrostatic test based on a calculated pressure may be used by agreement between the user and the manufacturer.. A New and Cold Test relates to a statement in API 510.

(d) The requirements of (b) above represent the minimum standard hydrostatic test pressure required by this Division

UG-99 Standard Hydrostatic Test

(g) Following the application of the hydrostatic test pressure, an inspection shall be made of all joints and connections. This inspection shall be made at a pressure not less than the test pressure divided by 1.3. Except for leakage that might occur at temporary test closures for those openings intended for welded connections, leakage is not allowed at the time of the required visual inspection..

UG-99 Standard Hydrostatic Test

The visual inspection of joints and connections for leaks at the test pressure divided by 1.3 may be waived provided:
(1) a suitable gas leak test is applied; (2) substitution of the gas leak test is by agreement reached between Manufacturer and Inspector; (3) all welded seams which will be hidden by assembly be given a visual examination for workmanship prior to assembly; (4) the vessel will not contain a lethal substance.

UG-99 Standard Hydrostatic Test

(h) Any non-hazardous liquid at any temperature may be used for the hydrostatic test if below its boiling point. Combustible liquids having a flash point less than 110F, such as petroleum distillates, may be used.. It is recommended that the metal temperature during hydrostatic test be maintained at least 30F above the minimum design metal temperature, but need not exceed 120F, to minimize the risk of brittle fracture. API 510 has a different rule for this, it recommends that the temperature be 10F above for 2 (50mm) thickness and under and 30F above for over 2 inches (50mm) .

UG-99 Standard Hydrostatic Test

Footnote Caution: A small liquid relief valve set to 1-1/3 times the test pressure is recommended for the pressure test system, in case a vessel, while under test, is likely to be warmed up materially with personnel absent. (i) Vents shall be provided at all high points of the vessel in the position in which it is to be tested to purge possible air pockets. (j) Before applying pressure, the test equipment shall be examined to see that it is tight and that all low pressure filling lines and other appurtenances

UG-99 Standard Hydrostatic Test

(k) Vessels, except for those in lethal service, may be painted or otherwise coated either internally or externally, and may be lined internally, prior to the pressure test. However, the user is cautioned that such painting / coating / lining may mask leaks that would otherwise have been detected during the pressure test.

API 510 Hydrostatic Test Procedure

1. If the test is required it shall be conducted after welded repairs. 2. The test pressure must at least be1.3 times the MAWP or whatever the original design Code specified i.e. 1.5. 3. The test pressure shall be adjusted for lowest ratio of stresses. 4. Any non-hazardous fluid may be used if below its boiling point. 5. It is recommended that the metal temperature during hydro test be maintained at least 10 F above MDMT for vessels 2 (51mm) and less and 30 F above for vessels over 2 (51mm) to minimize the risk of brittle fracture. 6. Following the application of hydro pressure a visual inspection shall be performed at no less than the test pressure divided by 1.3 or whatever was originally used.

UG-99 Standard Hydrostatic

Problem: Calculate the required hydro test pressure for a vessel using the following conditions: Material Carbon Steel Design Temp. 700 F Test Temp 85 F MAWP 350 psi Step 1 Determine the ratio of stresses for the test and design temperatures.

(a) From Table 1A Section II Part D. Stress allowed at 700 F = 15,500 psi Stress allowed at 85 F = 16,300 psi

UG-99 Standard Hydrostatic

(b) Per UG-99 the ratio equals
Stress at Test Temp. Stress at Design Temp.

16,300 1.05 15,500

(c) Per UG-99 the ratio equals Step 2 UG-99(b) Test pressure equals 1.3 x MAWP x ratio 1.3 x 350 psi x 1.05 = 477.75 psi at the top of the vessel.

UW-50 NDE of Welds for Pneumatically Tested Vessels

Look at the reference next to UG-100 (See UW-50)

This is what is referred to as a parenthetical reference in the ASME Codes. You must read these to see what modifiers the Code has placed on subject paragraph.
On welded pressure vessels to be pneumatically tested in accordance with UG-100, the full length of the following welds shall be examined for the purpose of detecting cracks: (a) all welds around openings; (b) all attachment welds, including welds attaching nonpressure parts to pressure parts, having a throat thickness greater than 1/4 in.

UG-100 Standard Pneumatic Page 81 Section VIII

(a) Subject to the provisions of UG-99(a)(1) and (a)(2), a pneumatic test prescribed in this paragraph may be used in lieu of the standard hydrostatic test prescribed in UG-99 for vessels: (1) that are so designed and/or supported that they cannot safely be filled with water; (2) not readily dried, that are to be used in services where traces of the testing liquid cannot be tolerated and the parts of which have, where possible, been previously tested by hydrostatic pressure to the pressure required in UG-99.

UG-100 Standard Pneumatic

(b) Except for enameled vessels, for which the pneumatic test pressure shall be at least equal to, but need not exceed, the maximum allowable working pressure to be marked on the vessel, the pneumatic test pressure shall be at least equal to 1.1 times the maximum allowable working pressure to be stamped on the vessel multiplied by the lowest ratio of the stress value S for the test temperature of the vessel to the stress value S for the design temperature. In no case shall the pneumatic test pressure exceed 1.1 times So we have: Stress at Test Stress at Design

UG-100 Standard Pneumatic

(c) The metal temperature during pneumatic test shall be maintained at least 30F (17C) above the minimum design metal temperature to minimize brittle fracture risk. [See UG20 and General Note (6) to Fig. UCS-66.2.] * API 510 states as a minimum Pneumatic tests shall meet all the safety requirements of ASME Section VIII. (d) The pressure in the vessel shall be gradually increased to not more than one-half of the test pressure. The test pressure shall be increased in steps of approximately onetenth of the test pressure until the required test pressure has been reached. Pressure shall be reduced to a value equal to the test pressure divided by 1.1 and held for a sufficient time to permit inspection of the vessel.

UG-100 Standard Pneumatic Tests

1. If the test is required it shall be conducted after welded repairs. 2. The welded repairs shall be subjected to the tests required by UW-50. 3. The test pressure must at least be 1.1 times the MAWP or whatever the original design Code specified i.e.1.25. 4. Test pressure is adjusted for lowest ratio of stresses. 5. Metal must be maintained at least 30 F over MDMT. 6. The test pressure shall be raised at a gradual rate to not more than 1/2 the test pressure and then raised by 1/10th of the test pressure until the test is reached. 7. Visual inspection must be made at test pressure divided by 1.1 or whatever was originally used.. The visual may be waived if the requirements in UG-100 are met.

UG-100 Calculating Pneumatic Test Pressure

Problem: Calculate the required pneumatic test pressure for a vessel using the following conditions. Material Carbon Steel Design Temp. 700 o F Test Temp 85 o F MAWP 350 psi Step 1: Determine the ratio of stresses for the test and design temperatures. (a) From Table 1A Section II Part D. Stress allowed at 700 o F= 15,500 psi Stress allowed at 85 o F= 16,300 psi

UG-100 Calculating Pneumatic Test Pressure

(b) Per UG-100 the ratio equals

Stress at Test Temp. Stress at Design Temp.
16,300 1.05 15,500

Step 2 Per UG-100(b) Test pressure equals

Stress at Test Temp. 1.1 x MAWP x Stress at Design Temp.

1.1 x 350 psi x 1.05 = 404.25 psi

Pneumatic Test Procedure

1. Slowly raise the pressure to approximately one-half 404.25 psi which equals 202.125. Next raise the pressure in steps of one-tenth of the test pressure. 2. 202.125 + 40.425 = 242.55 psi 3. 242.55 + 40.425= 282.975 psi 4. 282.975 + 40.425 = 323.40 psi 5. 323.40 + 40.425 = 363.825 psi 6. 363.825 + 40.425 = 404.25 psi There are a total of 6 steps when raising up to pneumatic test pressure. Finally lower to the inspection pressure of 404.25/1.1 = 367.5 psi

UG-102 Test Gauges Overview

The Code has some definite requirements for the selection and uses of gages for the tests described in UG-99 and UG100. Directions for location, number of, range of and the calibration of the indicating gage(s) is located in UG-102. The high points of UG-102 are below.

1. An indicating gage shall be connected directly to the vessel. If it is not readily visible to the operator of the test equipment an additional gage shall be used which is visible.... 2. When doing large vessel pressure tests it is recommended to have a recording gage in addition to the indicating gage.

UG-102 Test Gages Overview

3. Dial type indicating gages shall have a range of about double the maximum test pressure, but in no case shall the range of the gage be less than 1 1/2 times nor more than 4 times the maximum test pressure. 4. Digital gages having a wider range may be used as long as they provide the same or greater accuracy of the dial type. 5. All gages shall be calibrated against a standard deadweight tester or a calibrated master gage. 6. Gages must be calibrated any time their accuracy is in doubt.

Class Quizzes UG-99/UG-100/102

1. A vessel made of Stainless Steel is being hydrostatically tested after an alteration. The vessel's MAWP is 225 psi at 400 o F. The allowable stress at operating is 14,700 psi and 16,700 psi at the test temperature. Answer the following: a. What is the required test pressure? b. What is the least pressure for the inspection? c. In psi, what is the min. and max. range of the test gage?

Class Quizzes UG-99/UG-100/102

2. A pneumatic test of a vessel will be conducted to a pressure of 310 psi. Describe the steps for raising the vessel to the test pressure. At what pressure shall the visual examination take place?

Solutions
1. Hydrostatic Test a.

16,700 1.3 x 225 x 332.295 psi 14,700

332.295 255.61 psi 1 .3

b.

c. Min. gage range 1.5 x 332.295 = 498.4 ( 500 psi ) Max. gage range 4 x 332.295 = 1329.18 ( 1000 psi ) the gage pressure at the 4X range would be rounded down to closest standard range!

Solutions
2. Pneumatic Test Step 1 Raise the pressure to the test pressure, x 310 psi = 155 psi, then raise in steps of 1/10 to full test pressure. Step 2 Step 3 Step 4 Step 5 Step 6 155+31=186 psi 186+31=217 psi 217+31=248 psi 248+31=279 psi 279+31=310 psi

The inspection pressure is 310/1.1 = 281.8 psi for visual inspection.

The End