Everything You Need to Know About Hydrostatic Test Pumps and How to Use Them

You want to know that a pressurised system can do the job. A hydrostatic test pump does just that.

Hydrostatic test pumps perform water pressure testing, ensuring that a hydraulic system is working efficiently, that the component parts of a pressurised system are structurally sound and that there are no leaks even under excess pressure.

A hydrostatic test is a vital safety measure when storing or transporting any pressurised liquids or gases. It is especially important when the substances are potentially volatile or otherwise hazardous such as chemicals, gas or fuel when leaks could pose serious safety hazards.

But ALL pressurised systems must be tested regularly and/or after a period of disuse to ensure their efficient and safe operation.

Understanding Hydrostatic Test Pumps

Hydrostatic test pumps are usually made up of the following components; a pump, reservoir, and pressure gauge together with hoses and valves which connect the components of the test pump and the system that it is testing.

The test fluid is forced into the system from the test pump reservoir until it reaches the test pressure recommended by the manufacturer and/or in accordance with regulations.

Preparation Before Using Hydrostatic Test Pump

Proper preparation is of the utmost importance before performing a hydrostatic test.

Firstly the system that is going to be tested needs to be disconnected from any other equipment and systems it is connected to.

Once it has been isolated the hydrostatic test can focus on that system alone and ensure accurate results as well as not putting unexpected and unwanted pressure on other systems and or equipment.

Then the system being tested must be completely drained and vented to ensure that there are no air pockets that may cause problems with the accuracy of the hydrostatic test and that the high pressure test fluid can be added.

Finally, the pressure release valves must be disabled; these are designed to ensure the release pressure when it goes over a specific limit. As the test will be deliberately exceeding that limit they must be disabled for the test to work.

Step-by-Step Guide on How to Use Hydrostatic Test Pump

The following steps are useful guidance on how to use a hydrostatic test pump.

1. Check the correct hydrostatic test parameters for the system being tested. These will be dependent on the operating pressure and are usually set within the design phase. Test pressure is usually 1.25 times the working pressure.
2. Set up the pump and connect the hoses ensuring fittings are secure and leak free so that the test is accurate.
3. Turn on the pump to begin pumping water (or other test fluid) into the system.
4. Pressurise the system gradually to avoid any damage that can be caused by pressure surges.
5. Monitor the pressure until it reaches the required test parameters.
6. Once the desired level of pressure is reached, it needs to be held at that pressure for the amount of time specified in the test parameters. This is usually between 15 and 30 minutes.
7. While the system is being held at those specific pressures a thorough visual inspection must be completed this is to check for any signs of system weakness such as weak materials, deteriorated components, leaks or bulges.
8. Following the test, the system should be depressurised and vented in a controlled way to avoid potentially damaging and dangerous sudden drops in pressure.
9. Undertake any repairs required.
10. Reset the system.

Tips for Effective Use of Hydrostatic Test Pump

• Ensure proper calibration of the pump.
• Work with the pressure ratings and limitations of the system being tested.
• Follow the proper testing methods.
• Undertake regular maintenance and inspection of the hydrostatic test pump and associated equipment.
• Ensure the person responsible for carrying out the hydrostatic testing has an understanding of testing factors.
• Ensure that the test fluid is disposed of or recycled properly and in accordance with regulations following the hydrostatic test.

Common Mistakes to Avoid When Using Hydrostatic Test Pump

• Over-pressurising the system.
• Neglecting safety precautions.
• Using incorrect test medium or equipment.
• Not holding the system at the maximum pressure specified for long enough.
• Skipping proper preparation such as venting and depressurisation procedures.

Conclusion

A hydrostatic test is an important part of the safe and efficient operation of any pressurised system. It should be undertaken in accordance with regulations and the manufacturers recommendations and it should also be done by a qualified and trained engineer.

To find out about our testing services get in touch with us at MCH Hydraulics today.