Cairo Inspection Company
Eng. Ibrahim Eldesoky
ASNT –NDT-LEVEL III
ASME AUTHORIZED INSPECTOR
UG-99(b)
Standard hydrostatic tests are conducted at a pressure
which at every point is at least equal to:
1.3 x MAWP x lowest ratio of Stest / Sdesign
permitted stress value for the materials of which the
vessel is constructed.
Example Applying The Rules of UG-99(b)
MAWP = 375PSI @ 800° F
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■ A hydrostatic test based on calculated Test pressure (3-2) may
be used under the following conditions:
Highest permissible internal pressure is determined using
nominal thickness (including corrosion allowance) of each
element of the vessel and using the allowable stress @ test
temperature;
The hydro test pressure at the top of the vessel shall be the
minimum of the calculated test pressures; multiplied by 1.3 and
reducing this value by the hydrostatic head
■ these provisions are by agreement between the user and the
Manufacturer;
■ the Inspector shall reserve the right to require the
Manufacturer or designer to provide calculations used in
determining the hydrostatic test pressure of any part of the
vessel.
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■ UG-99(b) are minimum requirements, while UG-99(c) is a
special test based on calculations. Any intermediate value may
be used.
■ This Division does not specify an upper limit for hydrostatic
test pressure. However, if the hydrostatic test pressure is
allowed to exceed, either intentionally or accidentally, the value
determined as prescribed in (c) above to the degree that the
vessel is subjected to visible permanent distortion, the
Inspector shall reserve the right to reject the vessel.
■ 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.
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■ Except for leakage at temporary test closures for those
openings intended for welded connections, leakage is not
allowed.
■ Leakage from temporary seals shall be directed away so as
to avoid masking leaks from other joints.
■ It is recommended that the metal temperature during the
hydrostatic test be maintained at least 30° F (17° C) above
the minimum design metal temperature, but need not exceed
120° F (48° C), to minimize the risk of brittle fracture.
■ The test pressure shall not be applied until the vessel and
it's contents are at about the same temperature.
CAUTION: a small liquid relief valve set to 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.
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■ Vents shall be provided at all high points of the vessel in the test
position to purge possible air pockets while the vessel is filling.
■ 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 that should not be subject to the test
pressure have been disconnected.
■ Vessels, except for those in lethal service [(UW-2(a)], may be
painted or otherwise coated either internally or externally, and
may be lined internally, prior to the pressure test.
■ The user is cautioned that such painting or coating may mask
leaks that would otherwise have been detected during the
pressure test.
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UG-100, Pneumatic test
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:
that are so designed and/or supported that they cannot
safely be filled with water;
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.
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Except for enameled vessels, the pneumatic test
pressure shall be at least equal to:
1.1 x MAWP x lowest ratio of Stest/ Sdesign
S = permitted stress value for the materials of which
the vessel is constructed.
In no case shall the pneumatic test pressure exceed 1.1
times the basis for calculated test pressure (3-2).
The metal temperature during the pneumatic test shall
be maintained at least 30 ° F (17° C) above the MDMT to
minimize the risk of brittle fracture.
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The pressure in the vessel shall be gradually
increased to not more than one-half of the test
pressure;
thereafter, the test pressure shall be increased in
steps of approximately 1/10 of the test pressure
until the required pressure is reached.
After the test pressure is reached, the pressure
shall be reduced to the value equal to the test
pressure divided by 1.1 and held for a sufficient
time to permit inspection of the vessel
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An indicating gage shall be connected directly to the vessel.
If the indicating gage is not readily visible to the operator
controlling the pressure, an additional gage shall be provided
where it is visible to the operator.
Dial indicating pressure gauges shall be graduated over a
range of about double the intended maximum test pressure,
but in no case shall the range be the test pressure.
less than 1 1/2 times, nor
more than 4 times the test pressure.
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Digital reading pressure gages having a wider range
of pressure may be used provided the readings give
the same degree of accuracy as obtained with dial
pressure gages.
All gages shall be calibrated against a:
- standard dead weight tester, or
- calibrated master gage.
Gages shall be calibrated any time there is reason to
believe they are in error.
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