pipe. After blanking off all openings of the pipe,
over-pressure protection and their inlet and discharge
completely fill it with water through the nipple fitted to
piping, shall be greater than the capacity of the source
the one blank flange.
being used to pressurize the system. Relief valves are
classified as either the primary or secondary relief
valve.
SETUP.--System setup is similar to the hydrostatic
testing done in the shop. You will use a portable pump
with the required gauges and relief valves incorporated
must be of the manual type that can be operated from
into the pump control panel or on a separate manifold.
the control station. Usually the primary relief valve is
You should also take the following precautions when
a manually operated valve with a drain to a sump or
hydrostatically testing shipboard systems:
other suitable drainage system. The person controlling
the source of pressure (pump operator) cannot also be a
relief valve operator.
When setting up a component for testing, each
outlet of the component must be blanked off
Secondary Relief--The secondary relief valve
with blank flanges or other suitable blank
may be either manually or automatically operated. The
fittings. One fitting should be drilled and
secondary relief valve is usually located next to the
tapped, and fitted with a nipple of suitable size
primary relief valve on a hydrostatic testing unit but
for connecting the hose from the hydrostatic
may also be remotely located. If the secondary relief
pump.
valve is of the manual type, another operator must be
stationed to operate this valve.
Protect equipment, tanks, gauges, and
If the secondary relief is of the automatic type, test
machinery that would be subjected to a test
the set point of the relief valves to be used. If necessary,
pressure higher than their specified test
adjust the set point no more than 30 days before the
pressure by disconnecting from the system, or
relief valves ae to be used for the hydrostatic test. In
isolating from the test.
conducting a 135 percent test, the set point of the relief
2
valve shall be no greater than 100 lb/in or 10 percent
Provide expansion joints with temporary
above the test pressure, whichever is less.
restraints, if required, or isolate them from the
test.
Eliminate air pockets before any system is
After assembling all required testing equipment and
pressurized for a hydrostatic test to prevent the
checking calibration dates, you are ready to set up the
equipment for your test. Whether testing in the shop or
a ship's system, the setup of the equipment is similar.
Verify that all valves and equipment in or
Both shop and system testing will be discussed in this
connected to the portion of the piping system
chapter.
to be pressurized are in the required position or
SHOP HYDROSTATIC TEST SETUP.--Most
condition.
shop testing is done in areas that are specifically
designed and built for hydrostatic testing. These areas
Testing Procedures
have installed pumps, gauges, and relief valves
permanently mounted in the area. The operating station
is isolated from the testing area to provide protection to
After obtaining and setting up the equipment, you
the operator in case of failure of the component being
are ready to begin testing of the component. Generally,
tested.
the sequence for testing is as follows:
When setting up a component for testing, each
1. Establish required prerequisites and initial
outlet of the component must be blanked off with blank
conditions.
flanges or other suitable blank fittings. One fitting
2. Align the system for testing.
should be drilled and tapped, and fitted with a nipple of
3. Station the operator, manual relief valve
suitable size for connecting the hose from the
operator, and inspector. Two manual relief
hydrostatic pump. Use appropriate bolts to secure the
valve operators may be required if a manual
flanges or fittings with gaskets to all openings of the
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