The Vessel Pressure Testing article provides you with information about pressure

vessel hydro-static testing requirements and related item in pressure vessel

inspection.
The requirements have been described based on ASME Code Section VIII. You
need to do this test after completion of the construction process, but before the
internal parts assembly and also before painting process.
This content covers all major requirements and provides you with guidelines for
test performance.
Please note that performing the pneumatic test instead of the Hydro-Static Test is
not allowed, and it can be replaced only when it is not possible due to the design
and process.

Vessel pressure testing requirements have been addressed in UG-99 and UG100 in ASME Code Section VIII Div. 1.
These are important points, which you need to take care of in vessel pressure
testing:
Activities before pressure vessel hydro-static testing, which need to be
checked by the manufacturer quality control team and a third party
inspector:
1. Checking all welding already finished and fully accepted by the NDT
examination per the project Inspection and test plan.
2. Making sure the inner part of the vessel is clean and free of remaining slag or
other elements.

making sure the external surface is dry for the correct execution of the visual
inspection during the vessel pressure testing.
3. Checking the pressure gauges' calibration tag and certificate and the range of
the lower limit and upper limit of the gauges. It needs to be between 1.5 and 4 of
the pressure test value.
4. Controlling testing equipment such as the test pump and housing for
soundness and tightness.
5. Making sure the test temperature will not violate the following values:
Min. Test temperature= MDMT + 30F
Max. Test temperature = 120F
MDMT is the pressure vessel minimum design metal temperature, and it is stated
in the pressure vessel design document.
This reduces the risk of a brittle fracture during the test.

6. Making sure which reinforcement pads are already soap tested.

7. Controlling the testing water quality and using corrosion inhibitor if it is
necessary or when the vessel metal is sensitive material
8. Checking of vents. It is required to be placed at high points of the vessel in a
position where it is possible to purge air pockets while the vessel is filling.
Activities during the pressure vessel hydro-static testing that need to be
checked by the manufacturer quality control team and a third party
inspector:

1. Making sure the filling and pressurizing are done from the lowest point and
venting from the highest point.
2. Witnessing water overflow through the venting in order to assure that no air
bubbles remain in the vessel.
3. Controlling and witnessing which pressurizing is done in three stages as
follow:
First Stage: Raise the pressure to 40% of the final pressure, stop pressurizing,
keep it for 5 minutes, and then make a fast visual inspection of the external
surface.
Second Stage: Restart pressurizing up to 70% of final pressure, stop the
operation, keep for 5 minutes and make a fast visual inspection on external
surface.
Third Stage: Restart pressurizing up to 100% of the final pressure, stop the
operation, and keep for 45 minutes.
4. When 45 minutes elapse, making sure the de-pressurizing is started and the
pressure is dropped to the Inspection Pressure.
This inspection pressure can be calculated as following:
Inspection Pressure = Hydrostatic Test Pressure / 1.3
Making sure a detail and a comprehensive inspection is carried out over the
whole body of the vessel and in the welding joints and attachments.
5. Making sure the pressure vessel hydro-static testing pressure calculated
correctly as following:
Hydrostatic Test Pressure = 1.3 x MAWP X Stress ratio
Stress Ratio = (Allowable Stress at Test Temperature)/(Allowable Stress at
Design Temperature)
6. Making sure the vessel is immediately and carefully drained after the test and
dried by air.
Activities after the pressure vessel hydro-static testing that need to be
checked by the manufacturer quality control team and a third party
inspector:

1. The pressure vessel hydro-static testing report needs to be prepared by the

manufacturer quality control team and signed by the third party or authorized
inspector.
2. If the test failed by leaking from weld joints or any other kind of defect, it is
necessary that the vessel is drained and dried and repaired based on approved
repair procedure. pressure vessel hydro-static testing needs to be repeated.