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    Hydro Vs Pneumatic

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    Anonymous rYZyQQot55
    A pressure test is required for new or repaired pressure systems to ensure safety, reliability, and leak tightness. The two main methods are hydrostatic testing using water or pneumatic testing using air/gas. Hydrostatic testing is recommended for high pressure systems and uses 30% higher pressure than design. Pneumatic testing is for low pressure systems using 10% higher pressure than design. Key factors in selecting the method include the type of fluid handled and design pressure. Hydrostatic testing allows visual inspection for leaks but requires cleaning, while pneumatic testing is easier to clean up but more dangerous if failures occur. Duration is typically 1 hour for hydrostatic and less for pneumatic tests.

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    Hydro Vs Pneumatic

    Uploaded by

    Anonymous rYZyQQot55
    269 views4 pages
    A pressure test is required for new or repaired pressure systems to ensure safety, reliability, and leak tightness. The two main methods are hydrostatic testing using water or pneumatic testing using air/gas. Hydrostatic testing is recommended for high pressure systems and uses 30% higher pressure than design. Pneumatic testing is for low pressure systems using 10% higher pressure than design. Key factors in selecting the method include the type of fluid handled and design pressure. Hydrostatic testing allows visual inspection for leaks but requires cleaning, while pneumatic testing is easier to clean up but more dangerous if failures occur. Duration is typically 1 hour for hydrostatic and less for pneumatic tests.

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    Hydro vs Pneumatic

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    A pressure test is required for new or repaired pressure systems to ensure safety, reliability, and leak tightness. The two main methods are hydrostatic testing using water or pneumatic testing using air/gas. Hydrostatic testing is recommended for high pressure systems and uses 30% higher pressure than design. Pneumatic testing is for low pressure systems using 10% higher pressure than design. Key factors in selecting the method include the type of fluid handled and design pressure. Hydrostatic testing allows visual inspection for leaks but requires cleaning, while pneumatic testing is easier to clean up but more dangerous if failures occur. Duration is typically 1 hour for hydrostatic and less for pneumatic tests.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    269 views4 pages

    Hydro Vs Pneumatic

    Uploaded by

    Anonymous rYZyQQot55
    A pressure test is required for new or repaired pressure systems to ensure safety, reliability, and leak tightness. The two main methods are hydrostatic testing using water or pneumatic testing using air/gas. Hydrostatic testing is recommended for high pressure systems and uses 30% higher pressure than design. Pneumatic testing is for low pressure systems using 10% higher pressure than design. Key factors in selecting the method include the type of fluid handled and design pressure. Hydrostatic testing allows visual inspection for leaks but requires cleaning, while pneumatic testing is easier to clean up but more dangerous if failures occur. Duration is typically 1 hour for hydrostatic and less for pneumatic tests.

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    The document discusses pressure testing of piping systems, comparing hydrostatic and pneumatic testing methods. Key factors in determining the appropriate test method include the design pressure, material being transported, and size of the system.

    The two main methods for pressure testing piping systems are hydrostatic testing, which uses water, and pneumatic testing, which uses air, nitrogen, or another non-flammable, nontoxic gas.

    Factors that determine whether a system should be hydrostatically or pneumatically tested include the internal design pressure, nature of the material being transported (liquid, gas, vapor), and size of the system. Hydrostatic testing is generally recommended for higher pressure systems or those transporting liquids.

    Pressure Tests of Piping systems -Hydrotest Vs Pneumatic Test :

    A pressure test is always required for a new pressure system before use or an existing pressure system after repair or
    alteration to ensure the following:

    Safety

    Reliability of operation

    and leak tightness of pressure systems

    Also The last physical quality test in the fabrication process

    Normally two methods for pressure testing: hydrostatic and pneumatic, are widely used in process industry.
    A hydrostatic test is performed by using water as the test medium, whereas a pneumatic test uses air, nitrogen, or any
    non-flammable and nontoxic gas. Pressure tests (both hydrostatic and pneumatic) must always be performed under
    controlled conditions, following an approved test plan, and documented in a test record. A single approved test plan could
    be used for several similar tests, but for each test a separate test record is required.

    When to perform a Pressure Test:


    As per the governing code, pressure test has to be performed on piping system after all hot works have been completed on
    a certain piping system. Here the term hot work means everything related to welding or the post weld heat treatment
    (PWHT). PWHT also has a potential of degrading the mechanical properties of piping, in case not addressed properly. And
    this is the reason why code calls for NDT after PWHT operation. In case after carrying out pressure testing, some
    modification has to be made requiring hot work, it calls for a retest as per code. Here code specifies that the minor repairs
    / modifications may be waived off provided adequate measures have been taken to ensure sound construction. Now taking
    this decision as to which repairs or modifications may be waived off should be taken very carefully. Normally, the maximum
    extent of repairs not requiring retesting shall be the tack welding of any piping support or pad. Anything else shall be done
    following a retest.
    Pressure testing and conducting 100% radiography or ultrasonic inspection shall not be interchanged. In case carrying out
    of hydrostatic or pneumatic test stands impractical then 100% radiography or ultrasonic testing may be performed but in
    addition to this it is advisable to check that the whole piping and its components have been supplied against acceptable
    ASTM standards and required test certificates are available. Conducting 100% radiography of all the weld joints assure that
    your weld joints are defect free but can never provide you with the assurance of mechanical integrity of a system. This is
    also to be noted that radiography / ultrasonic inspection shall also not to be waived off if the pipeline is to be
    hydrostatically tested. This may pose an additional safety risk during the test. Moreover, some defects in the weld zones
    may prove to be detrimental way after taken in service due to severe extended service conditions.

    Comparison of Hydrostatic and Pneumatic Testing:


    Hydrostatic Testing

    Pneumatic Testing

    Test pressure is normally 30% higher than the design pressure Test pressure is normally 10% higher than the design
    pressure
    Recommended for high pressure applications

    Recommended only for low pressure applications

    Test media (Water) used is not compressible by pressure


    application

    Test media (Air) used is compressible by pressure


    application

    Energy stored per unit volume of water under test pressure is


    very negligible

    Energy stored per unit volume of compressed air under


    test pressure is very high

    Needs thorough cleaning after test to eliminate moisture


    especially for service which are reactive to moisture / fluids

    Easy to clean after testing

    Pressure Relief devices are recommended to control sudden


    increase in pressure during testing

    Pressure relief devices are must during test to ensure


    no over pressurization

    Chances of equipment/ Pipe / test apparatus


    failures are very low

    Chances of equipment/ Pipe / test apparatus


    failures are high

    Weight of equipment along with test medium as


    water is high hence special attention should be given to floor
    and supporting arrangements

    Weight of equipment with test medium


    as air is comparatively less

    Needs verification and examination of joints and connections


    before testing

    Needs very careful checking of weld joints thoroughly


    before testing

    Test media can be reused or transferred to other place after


    testing

    Test media cannot be reused or transferred to other


    place after testing

    Skilled and semi-skilled personnel can carry out the test

    Needs involvement of senior experienced staff to


    monitor the test.

    Recommended where large volumes are to be tested at same


    time (example pipe lines )

    If pipe lines are tested should be done with small


    segmental lengths at a time.

    Damages made by failures are less compared to failures in


    pneumatic testing

    Damages made by failures in testing are very huge and


    extensive

    Hydrotest is a regular day to day practice and safe procedure


    and it can be followed in any work site

    Needs special attention and safety precautions

    Pressure changes finite amount by infinitesimal change in


    volume

    Pressure change proportional to volume change

    Difficulties with Hydrostatic Testing:

    Supply & disposal of water, disposal of fluid additives

    Water leak can cause equipment damage

    Freeze susceptibility

    Structural support limitations

    Contamination

    Operational impacts process contaminant

    Affect dry-out of internal refractory linings

    Difficulties with Pneumatic Testing:


    Pneumatic tests are potentially more dangerous than hydrostatic tests because of the higher level of potential energy
    stored during compressing the gas. Care must be exercised to minimize the chance of brittle failure during testing by
    initially assuring the system is suitable for pneumatic testing. Pneumatic tests could be performed only when at least one
    of the following conditions exists:

    When the systems are designed in such a way thet it cannot be filled with water.

    When the systems are such that it is to be used in services where traces of the testing medium cannot be
    tolerated.
    Using a pneumatic test instead of hydrostatic requires approval from proper authority or body.

    Test Pressure:
    ASME Code B 31.3 provides the basis for test pressure. The minimum hydrostatic test pressure for metallic piping shall be
    as per the following equation:
    Pt=1.5*Pd*(St/Sd)
    Here,
    Pt=minimum test gauge pressure
    Pd=internal design gauge pressure
    St=allowable stress value at test temperature
    Sd=allowable stress value at design temperature.
    The maximum allowable value of St/Sd is 6.5
    The pneumatic test pressure shall be as per the following equation: Pt=1.1*Pd
    Normal Basis for Test Method Selection:
    Normally the following basis is followed in process piping industry for selection of hydro or pneumatic tests.
    1. If the fluid handled by piping system is liquid then the pipe must be hydro tested.
    2. If the fluid handled is vapour or gas then the internal design pressure dictates the testing method. For pipe design
    pressure 10 bar and above the pipe is hydrotested. For pipe design pressure below 10 bar pipe is pneumatically
    tested.
    3. If fluid handled is stream then hydrotesting is suggested.
    4. If fluid handles is two-phase flow then hydrotesting is suggested. However for big size flare headers pneumatic
    testing is performed.
    Test Duration:
    Normally every EPC company have their own standard for duration of tests. However the recommended practice is that a
    QC inspector have to walk through the whole piping system and check for leaks. Every single length of piping, welds, bolted
    connections shall be visually examined for any leakage. Duration of this activity varies with the span of piping system. For
    larger piping system time taken for this activity is enough to clear the pressure test. In case of piping system having
    smaller span, 1 hour time may be made as standard practice for hydrostatic testing. For Pneumatic test the test time is far
    lesser.
    Few important points to consider while hydrotesting:
    The tower overhead lines which are normally hydro tested shall be decided by stress engineer group whether to hydro test
    after erection or at grade, based on the capacity of standard clip available as per engineering specification for pipe
    supports.

    During hydrotest in case of big bore it should be decided first that line is to be hydrotested on rack or grade if
    hydrotest is done on rack , hydrotest load should be considered in case of vapour lines while providing structure /
    rack loading information.

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