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Hydrotest & Purging

Cylinder Hydrotesting

Hydrotesting, also known as hydrostatic testing, is a non-destructive test procedure used to check cylinders for leaks, structural flaws, durability, and corrosion. It involves filling the cylinder with water and applying pressure to test its structural integrity. The process includes:

1. Filling the Cylinder: The cylinder is filled with water and enclosed in a test jacket also filled with water.
2. Applying Pressure: Pressure is applied internally to the cylinder, causing it to expand.
3. Measuring Expansion: The total and permanent volumetric expansions of the cylinder are determined by measuring the amount of water displaced by the expansion of the cylinder when under pressure and after the pressure has been released.
4. Visual Inspection: An external and internal visual inspection of the cylinder is performed, along with a dead-ring test for steel cylinders2.

Hydrotesting is crucial for ensuring the safety and reliability of gas cylinders. According to the guidelines of the Petroleum and Explosives Safety Organisation (PESO), high-pressure seamless cylinders must undergo hydrotesting every five years, while toxic gas and CNG gas cylinders should be tested every two years.

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Pneumatic Testing

Pneumatic testing is the process of using gas to verify a vessel’s ability to withstand normal usage pressures. It ensures that the system can withstand pressures beyond its designed pressure limit and be safely subjected to its maximum operating pressure. The process includes:

1. Using Compressed Gas: Compressed air or another gas is used to simulate the pressure that the component is expected to experience during normal use.
2. Leak-Tightness and Structural Soundness: The test confirms the leak-tightness and structural soundness of pressure vessels, pipelines, and other components designed to contain or transport fluids or gases under pressure4.
 
Pneumatic testing is commonly used in various industries, including oil and gas, chemical, and petrochemical, to verify that pressure vessels, pipelines, and other equipment are structurally sound and safe to operate before being put into service.
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