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#What is Hydrostatic Testing and Why is it Important?
**Hydrostatic testing** is an important process used to verify the structural integrity and safety of many types of pressurized equipment and containers. This article will provide an overview of hydrostatic testing, explain why it is critical, and outline the key steps involved.
##What is Hydrostatic Testing?
**Hydrostatic testing**, also sometimes referred to as a pressure test, involves filling a container or system with a liquid, usually water, and pressurizing it to levels beyond its normal operating pressure. The goal is to ensure that the unit can withstand the increased internal stresses without any leaks, deformations, or other failures.
Hydrostatic testing puts tremendously more force on the walls of a vessel or pipe system than it would see in typical use. This enables inspectors to identify any weaknesses or flaws that could lead to future ruptures or accidents. Catching these problems ahead of time allows the equipment to be repaired or replaced before an actual failure occurs.
##When is Hydrostatic Testing Required?
There are many types of equipment, pipes, and storage vessels that require periodic hydrostatic testing for recertification and safety, including:
- Fuel and gas cylinders - Tested every 5 or 10 years depending on the cylinder type
- Fire extinguishers - Tested every 5 or 12 years depending on the extinguisher type
- Gas and chemical pipelines - Tested when installed and at regular intervals afterwards
- Boilers and pressure vessels - Tested upon installation and at regular intervals
- SCUBA tanks - Tested every 1-5 years depending on use
- Home gas lines - Tested when a house changes owners
Mandated test intervals vary by location and application, but are always aimed at preventing catastrophic failures.
##The Hydrostatic Testing Process Step-by-Step
Performing a proper hydrostatic test involves several key stages:
1. Clean and Inspect
The item must be cleaned and examined to ensure no pre-existing damage is present. Any necessary repairs are completed at this time.
2. Seal
All inlets, outlets, and openings are sealed to make the system water tight. Temporary seals or caps may be required.
3. Fill
The vessel is filled completely with a test fluid, typically water. All air must be bled out to leave a fully pressurized system.
4. Pressurize
The system is then pressurized to the specified test pressure. This is usually 1.5 times the equipment's maximum allowable working pressure.
5. Hold
Once pressurized, the test pressure must be held steady for a set period of time, generally between 5 and 60 minutes.
6. Examine
All surfaces and seal points are carefully examined for any leaks, bulges, deformations, or other anomalies while at full test pressure.
7. Depressurize
The system is gradually depressurized and drained once the examination is complete.
8. Verify
Final verification, documentation, and potential certification of a successful test takes place. Failed tests require repairs and retesting.
9. Return to Service
The equipment can then be returned to normal operation once it passes testing.
##Hydrostatic Testing Services
Since hydrostatic testing requires specialized equipment, certified technicians, and strict adherence to safety and quality protocols, most organizations rely on third-party testers.
There are hydrostatic testing companies that provide mobile on-site testing services across many industries including:
- Fire and safety equipment annual certifications
- Scheduled test certifications for pipelines and chemical vessels
- One-off testing needs during new equipment installations or housing purchases
Finding an experienced tester simplifies maintaining compliance and safety.
##Hydrostatic Testing for Safety
Performing periodic **hydrostatic testing** provides tremendous value in preventing loss of life and property from equipment failures under pressure. While the process does take equipment out of service temporarily, that small sacrifice enhances public safety for years to come.
Proper testing also reduces expenses from accidental leakage, unplanned downtime, and major repairs after failures occur. Although no inspection regimen can catch every potential issue, responsible **hydrostatic testing** goes a long way towards effective risk management.
#In Summary
- Hydrostatic testing involves pressurizing vessels and equipment with water to test safety and integrity.
- Periodic hydrostatic testing is mandated for many types of pressurized systems to prevent failures.
- Certified technicians follow a careful multi-step process to conduct testing properly.
- Outsourcing to a qualified hydrostatic testing company ensures compliance.
- Hydrostatic testing provides substantial safety benefits by identifying flaws before catastrophic failures can occur.
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