HydroProof v3.0 - Hydrotest & Pressure Test Calculator

Minimum and maximum test pressure

Code

Test type

Design pressure / MAWP

Custom factor x design

Allowable stress at test temp, S_T ?

Allowable stress at design temp, S

Stress-ratio cap ?

Lowest non-isolated component test rating ?

Pipe stress check (governing line)

Outside diameter

Nominal wall

Mill tolerance %

Yield strength at test temp, S_y ?

Elevation and equipment in the loop

High point to low point

Gauge depth below high point

Vessel test pressure in loop ?

Fluid service

Test pressure result

Test-pack volume and fill water

Line list (ASME B36.10M / B36.19M)add every line in the test pack

NPS	Schedule	Length	OD x wall	Volume

Vessels / equipment volume

Water temperature

Reserve and losses %

Tanker capacity

Water quantities

Test water quality

Material

Chloride ppm

pH

Water quality screening

Chloride screening limits are common project values, not code values. Austenitic stainless is usually tested with water of 50 ppm chloride or less and drained and dried promptly. Always follow the project specification.

Temperature effect, gauges and relief

Water temperature change in hold

Young's modulus GPa

Pipe expansion coeff. 1e-6/°C

Gauge accuracy % of span

Gauge full scale ?

Thermal pressure change (restrained, liquid-full)

dP/dT = (β − 2α) / (κ + D(1−ν²)/(E·t))

Gauge selection

Test relief device

Liquid-full systems respond strongly to temperature: sunshine on an exposed line can add several bar in minutes. Fill with water near ambient, allow it to stabilise before the hold, and log water and metal temperature with the pressure.

Pneumatic stored energy and safe distance

Safety-critical. Results are screening values. The exclusion zone for a pneumatic test must be set by a site-specific risk assessment and approved procedure (ASME PCC-2 Article 501, Energy Institute guidance, owner rules). Use a hydrostatic test wherever possible.

Test gas

Gas volume source

Gas volume

Pressure for energy ?

TNT equivalence MJ/kg

Scaled distance R_s m/kg^1/3?

Procedure minimum distance

Stored energy and indicative distance

E = [P_absV/(k−1)] · [1 − (P_atm/P_abs)^(k−1)/k] | W_TNT = E / 4.184 MJ/kg | R = R_s · W^1/3

Hydrostatic vs pneumatic at the same pressure

Pneumatic pressurising stepsB31.3 345.5.5 style

Step	Pressure	% of P_T	Action

Pump sizing, duration and cost

Fill time min

Fill pump head

Pump efficiency %

Pressurising time min

Stabilise + hold min

Inspection min

Depressurise + drain min

Crew size

Currency

Labour rate /h

Equipment hire /day

Days

Water cost /m³

Treatment / disposal /m³

Other (gas, blinds, NDE)

Contingency %

Fill pump and test pump

Q_fill = V/t_fill | P_shaft = ρgQH/η | ΔV_press = V·P_T·[κ + D(1−ν²)/(E·t)]

Duration and cost

Test-pack report

Test pack no.

System / line

Prepared by

Project / client

Reports are generated in your browser. Nothing is uploaded. Inputs are remembered on this device only.

Test-package register

Pack	System	Type	Test P	Volume	Status

Method and references

ASME B31.3 Chapter VI (345.4 hydrostatic, 345.5 pneumatic, 345.4.3 vessel in loop) · ASME B31.1 Chapter VI (137) · ASME BPVC VIII-1 UG-99, UG-100, UG-102 · ASME PCC-2 Article 501 (stored energy and safe distance) · ASME B36.10M / B36.19M pipe dimensions · IAPWS water properties. Check the edition named in your contract.