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(Mechanical)
(OP)
20 May 09 14:45Does anyone have a hydrostatic test procedure and what type of equipment is used?
(Mechanical)
20 May 09 14:52YesQuote (kenwk):
Does anyone have a hydrostatic test procedure?
Some water, a pump, and a pressure gauge. And, of course the equipment being hydro-tested.Quote (kenwk):
What type of equipment is used?
YesSome water, a pump, and a pressure gauge. And, of course the equipment being hydro-tested.Now, if you actually have a question, and are not just looking for someone to do some free work for you, please ask a real question.
(Nuclear)
20 May 09 18:38What if he doesn't want to use water?
Can he hydrostatically test with something else if he wants to?
Or - if the something else - gets hot and blows up - does that make it become a hydrostaticaerodynamically test?
(Mechanical)
(OP)
21 May 09 07:22Do I need a special pump? Or can I fill the tank with water and connect my air compressor(or compressed gas i.e nitrogen) and apply the required pressure?
(Mechanical)
21 May 09 08:41ohhhhh geeeezzzus
please publish date and location of test
so i won't be anywhere near there.
any pump that will reach the desired pressure will do
gas in a hydrostatic test is a no-no
pnuematic test or combination hydrostatic/pnuematic is allowed if you know what you're doing.
do you have a hydrostatic test procedure in place?
pressurized gas stores a lot of energy parts can be found far away if an accident happens.
3
brandonb73(Mechanical)
21 May 09 11:12We use a portable pressure washer for field hydro's. But be very careful, they can generate up to psi. You can also get hand pumps if your vessel is small.
Your procedure should include:
1. Test medium
2. Test pressure
3. Temperature range
4. Pressure gauge range requirements and calibration
5. Hold time
6. Acceptance criteria
The ranges for these can be found in whatever code of construction or repair you are using to build or repair this item.
Double check the code of construction, but the pressure gauge range should be approximately double the intended test pressure, not more than 4 time and not less than 1.5 times.
Hope this helps.
(Chemical)
21 May 09 11:49vesselfab: I hear your frustration, but "any pump which will generate the required pressure will do" conjures up unpleasant images of huge pump connected to small, improperly vented pot...
It's possible, though not preferred, to use the "air over water" method to generate pressure for a hydrotest if you don't have a suitable pump. This does make the test less sensitive and more hazardous- a proper pump, used with a well considered procedure, is safer AND better. Keep the volume of compressed gas under test as small as humanly possible, as the hazard of the test is directly proportional to P x V of the GAS.
(Mechanical)
22 May 09 12:20Also..... no one has mentioned how much fun it is to hydro test plastic and FRP systems.For more laughs, fun and surprizes than a houseful of pipefitters - try a hydro on non-metallic systems..!!!!Tell your friends !!!Be sure to have any expendable staff stand near "things of large diameter" during the test..... :)-MJC
(Mechanical)
22 May 09 12:25Pressure testing using gas can be special fun..The Chinese found this out a couple of months ago...-MJC
(Mechanical)
22 May 09 12:52YES MOLTENMETAL
I know what you mean, one stroke of a fair size pump can over pressure a small part.
Every now and then we have to dig out the old hand pump to test a single spool.
it's a pain, the check valve leaks back and we have to shut off the gate valve quickly to maintain pressure. One of these days gonna have to fix the old antique, but, when you only use once every 2-3 years.....
(Nuclear)
22 May 09 17:00I, too, would like to be someplace else when this tank is pressurized.
Far, far someplace else.
(Mechanical)
22 May 09 17:23Pardon me, but I would like to comment on some of the condescending remarks made about this question.
Do none of you remember when you didn't know the first thing about a hydro test either? Does it make you feel smarter to embarrass the author of this post? People including myself post questions and comments on this forum to collaborate with people that have more experience or different perspectives than our own. By posting a question we are already showing vulnerability, acknowledging that there is something we don't understand. It is therefore not helpful when people make jokes and snide comments.
People should not be afraid to ask questions on this forum for fear of ridicule. People who are afraid to ask questions end up making mistakes. Sometimes those mistakes are catastrophic.
I respectfully request that if you don't have anything helpful to add to a particular thread, then please don't waste your time.
(Mechanical)
22 May 09 19:06It's not the lack of knowledge or "elementary" questions that draw ridicule. It's the lack of doing ANY work prior to coming to ask for help that gets the condescension.
For example if the OP would have done a little bit of homework, such as a Google search, particularly of this site, then they would have found the answer to their question, or at the very least, been able to frame their question in a much better manner.
We all started out knowing very little. However, through a little bit of self-directed research, many of us have become the engineer that we are today. Eng-tips is not a forum for spoon-feeding any one. Show a little bit of initiative, an indication that you have thoroughly researched a problem, and if are still stumped, you are very welcome to ask a good, thought-provoking question.
Clueless questions, or "I don't want to do the research, please tell me what I need to know" questions will continue to receive healthy doses of ridicule and condescension.
(Petroleum)
22 May 09 22:38Some of us enjoy teaching others humility. Others move on to more productive threads.
(Aeronautics)
23 May 09 01:20I would sooner see a poster ask a stupid question on here than do a stupid act.
As an apprentice I got blown 20 feet across a shop by an air over hydro test that failed, resulting in a welded seam opening in a tank.
At that time( ) there was no Internet to post a question like the one the original poster asked, you relied on the common sense of the engineers and journeymen who were your mentors.
None the less it would not hurt the OP to at least hit Google first before asking here.
B.E.
(Industrial)
26 May 09 07:56I was always taught, and in turn dictatate to all my people, there are no stupid questions, only stupid answers.
I understood this to be a professional forum.
(Mechanical)
26 May 09 10:48Amen TGS4.....
(Mechanical)
26 May 09 12:53grantak - This wasn't a stupid question, just a completely poorly thought-out question that really needed to be researched and a very small amount of thought put into it before posted.It's the lecherous nature of these poorly thought-out and very poorly researched questions that prompt the above-noted ridicule.I have tonnes of time for folks who need assistance (e.g. "Where would be the best place to start researching about hydrostatic tests?"), and then if they are confused by a reference, asking here for clarification questions (e.g. "In XXX, it discussed using a YYY pump for pressurization of the system for hydrostatic test. I've search the internet for information on this pump, but can't find our why it's preferred. Why is this pump preferred, and what are people's experience with other types of pumps?).Perhaps it's worthwhile re-posting the "Rules" for posting on an internet discussion forum, again...
(Mining)
26 May 09 13:16See ASME PCC-2&#;, PART 5, EXAMINATION AND TESTING, Article 5.1, Pressure and Tightness Testing of Piping and Equipment.This Article provides general good practice for determining the type of test, the test pressure, and the procedure for pressure and tightness testing of pressure equipment, including tubular heat exchangers, pressure vessels, and piping systems.Note that this is a general guideline. Follow the appropriate Code requirements applicable to the system you are testing and do whatever research to further your understanding of the dangers involved.
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Hydrostatic tests of a sprinkler or standpipe system are designed to spot leaks in a closed piping system and ensure that a set-up will function under pressure during a fire. A test pump is used to send pressurized water into the network at a specific pounds per square inch (PSI) rating for two hours. Assuming no visible leakage is spotted&#;or a drop in pressure indicates a hidden leak somewhere&#;the system integrity is verified and it&#;s good to go.
But when should a test be conducted on different systems? And which hydrostatic test pump should a professional fire safety contractor use to get the job done? In this QRFS blog, we explore the basics of hydrostatic testing of fire sprinklers and standpipes, plus provide some guidance on choosing a test pump that fits the bill.
Are you looking to purchase a hydrostatic test pump? QRFS carries the best pumps in the business, including the highly-portable and versatile Triple R Tru-Test and the more robust HT-90 and HT-89A.
If you know all there is to know about NFPA requirements for hydrostatic testing, you can skip to the section of this blog about choosing a pump.
Commercial fire sprinkler systems must be hydrostatically tested prior to system acceptance and whenever a subsequent revision to a system is made that involves more than 20 sprinkler heads. The test pressure defaults to 200 psi, 50 PSI higher than the normal working pressure of a system when that is more than 150 PSI, or the shutoff pressure of any onsite fire pump (if present).
System acceptance testing:
From the Edition of NFPA 13
29.2.1.1 Unless permitted by 29.2.1.3 through 29.2.1.6, all piping and attached appurtenances subjected to system working pressure shall be hydrostatically tested at 200 psi (14 bar) and shall maintain that pressure without loss for 2 hours.
29.2.1.2 Loss shall be determined by a drop in gauge pressure or visual leakage.
29.2.1.3 Portions of systems normally subjected to system working pressures in excess of 150 psi (10 bar) shall be tested as described in 29.2.1.1, at a pressure of 50 psi (3.4 bar) in excess of system working pressure.
29.2.1.4 Where a fire pump is used for a system, the test pressure shall be determined using the shutoff pressure of the pump.
29.2.1.6* The test pressure shall be read from a gauge located at the low elevation point of the system or portion being tested. The pressures in piping at higher elevations shall be permitted to be less than 200 psi (14 bar) when accounting for elevation losses. Systems or portions of systems that can be isolated shall be permitted to be tested separately.
System modification testing:
From the Edition of NFPA 13
30.8.1 Modifications to existing piping systems shall require testing at system working pressure.
30.8.1.1 Where modification is made to an existing system affecting more than 20 sprinklers, the new portion shall be isolated and tested at not less than 200 psi (14 bar) for 2 hours.
30.8.1.2 Modifications that cannot be isolated, such as relocated drops, shall require testing at system working pressure.
Testing is done at the lowest access point in the system, which is often a fire department connection (FDC) in a commercial system or another access point near the system riser. Once the air is removed via the inspector&#;s test valve (where applicable) and the pressurized water is introduced, contractors should look for any leaks in visible portions of the system (pipes, joints, and fittings) while ensuring that gauges read within about +/- 5 PSI of the specified test pressure. A significant drop in pressure either indicates a faulty gauge, a faulty pump, or a problem with system integrity somewhere.
Residential fire sprinkler systems must only be hydrostatically tested prior to acceptance at the system&#;s working pressure, according to NFPA 13D&#;unless a system has a fire department pumper connection, which means the test will have to follow the guidelines for commercial systems.
Of the above image, Fire Protection Deficiencies (which you should seriously bookmark, as it&#;s an awesome site) asks the key questions: &#;One question to ask is how this assembly passed the NFPA 13(R)* required hydrostatic pressure test. Another question to ask is was the required hydrostatic test conducted?&#;
For a more in-depth look at hydrostatically testing fire sprinklers, including special considerations such as cold-weather and pre-completion construction testing, read our previous blog: &#;What is a Hydrostatic Test of a Building&#;s Fire Protection System?&#;
The hydrostatic testing requirements on standpipe systems are a bit more stringent. Testing must be done prior to system acceptance for all types of standpipes&#;manual wet, automatic wet, automatic dry, manual dry, and semi-automatic dry, including acceptance testing of underground pipe&#;and certain systems must be fully hydrostatically tested every five years. These include:
From the Edition of NFPA 25
6.3.2.1* Hydrostatic tests of not less than 200 psi (13.8 bar) pressure for 2 hours, or at 50 psi (3.4 bar) in excess of the maximum pressure, where maximum pressure is in excess of 150 psi (10.3 bar), shall be conducted every 5 years on manual standpipe systems and semiautomatic dry standpipe systems, including piping in the fire department connection.
6.3.2.1.1 Manual wet standpipes that are part of a combined sprinkler/standpipe system shall not be required to be tested in accordance with 6.3.2.1.
The other types of standpipe systems don&#;t need to be five-year tested because it&#;s assumed that leaks would be apparent since they always have pressurized water or gases in the pipe. But there is some confusion over whether NFPA 25 requires the unpressurized pipe that leads to the fire department connection to be tested in all systems. SprinklerAge examined this issue years ago and determined that a literal interpretation of the code means only testing the three types specified:
Is it the intent to not test that portion of the piping on those three standpipes that are otherwise excluded in the standard? Apparently, the answer is yes; it is specific to just those three identified. That clause of the sentence in the code reference is not meant to be a global requirement for all systems, but is a reminder that the portion of pipe between the check valve and the FDC must also be checked. It is, however, a good question as to why we aren&#;t required to test this portion of piping in all system types.
Again, the test is done from the low point in the system, usually the fire department connection, and the inspector(s) alternately watches pressure gauges for a significant drop and examines the pipe and fittings for leaks.
There are a number of test pumps at different specifications that can get the job done when it comes to hydrostatic testing. But the two most basic requirements are how much pump you need&#; in terms of PSI and gallons per minute (GPM)&#;as well as the power source of the pump (gas, electric, drill-powered, or hand pump).
Most standard hydrostatic test pumps are electric, though gas-powered pumps are often used in applications where you require more horsepower to move more water, faster. As long as a pump can hit the 200 PSI or +50 PSI in excess of systems with a maximum working pressure above 150 PSI, it can get the job done. Triple R puts it this way:
Even though pressure is important, in reality the (GPM) will determine how long it will take to get the job done. Since most tests are done at 200 psi or less, having a higher GPM will save time and money. A pump that is rated for 2.0 GPM @ max pressure of 500 PSI will take more than twice the time to do the job of a pump rated for 4.5 GPM @ max pressure of 400 PSI.
Other factors that determine how long a job will take and how much pump you need include:
Most test pumps specifically designed for fire safety hydrostatic testing can get the job done. Once you&#;ve selected a PSI and GPM combo that works for how quickly you&#;d like to achieve test pressure, the choice then comes down to a pump&#;s specific features.
Again, gas pumps are typically used for bigger jobs with bigger pipes&#;say, a couple thousand feet of pipe that is six inches in diameter&#; such as a standpipe test in a larger building.
Electric pumps are incredibly popular because it&#;s more convenient to simply plug them in vs. dealing with fuel, and there are no fumes if they are used in indoor or otherwise enclosed settings. One of the most popular pumps sold by QRFS is the Triple R Tru-Test, a small-yet-powerful pump that can be purchased with either 120 Volt or 12 Volt power hook-ups, meaning you can either plug one into a standard electrical socket or run it off of a car battery.
The latter power source can be extremely handy for an installer or ITM contractor who is doing acceptance testing on a sprinkler system in an unfinished home without a working power supply, for example. Plumbers also use it for the hydrostatic acceptance testing of plumbing set-ups required by some local governments.
Another popular pump is the HT-90E, which is a bit bigger and moves more water (3.0 GPM vs. 2.2) yet remains light enough (32 lbs.) to easily move around on any job site. Some professionals choose the HT-89A, which is nearly identical to the 90E, except it has a pressure regulator. Pumps without these devices must be closely monitored to make sure they don&#;t go over the intended test pressure. But you can pre-set the desired PSI on an HT-89A and a bypass acts as a fail-safe to make sure the pressure doesn&#;t build beyond that setting.
Other desirable features include having quick-disconnect hoses; lighter, corrosion-resistant brass vs. cast iron or galvanized steel piping; a liquid-filled gauge; and one of the key benefits of Triple R pumps: they use lightweight aluminum and the pump is actually attached directly to the face of the motor. This means they don&#;t have the shaft that is seen in many older pumps&#;which means fewer moving parts, less maintenance, and lighter weight.
Basically, any pump that tips the scales at over 40 lbs. such as &#;
&#; is going to be a beast to carry around.
For more information on the features of our hydrostatic test pumps, stay tuned for our pending blog that goes into even greater detail.
In the meantime, check out the specs of all of our in-stock fire pumps, including the Tru-Test, HT-89A, and HT-90E.
For any other Triple R pump you may be interested in, or to find out more information about pumps or hydrostatic testing, give us a call at 888.392., , or fill out our contact form.
This blog was originally posted at QRFS.com/blog. If this article helped you, check us out at Facebook.com/QuickResponseFireSupply or Twitter @QuickResponseFS.
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