Let'sFab Trending Posts for Fabriction Industry Learn, Guide and Digitize Fabrication Techniques Tue, 06 Jan 2026 05:21:17 +0000 en hourly 1 https://wordpress.org/?v=6.9.1 https://letsfab.in/wp-content/uploads/2022/07/cropped-Logo512x512-32x32.png Let'sFab Trending Posts for Fabriction Industry 32 32 What is a Flat Pattern or Fabrication Layout? How to make Flat Pattern or Fabrication Layout for Sheet Metal Works or Fabrication Shapes https://letsfab.in/flat-pattern/ Sun, 26 Jul 2020 14:33:45 +0000 https://letsfab.in/?p=3077 Flat Pattern is nothing but unfolded shape of any sheet metal shapes or fabrication shapes before forming processes such as Bending, Rolling, etc. We can also say that Flat pattern is a pre or raw flat surface before forming activity in sheet metal or fabrication Industry. In most of the fabrication Industries, the Flat Pattern is also called as Fabrication Layout.

The post What is a Flat Pattern or Fabrication Layout? How to make Flat Pattern or Fabrication Layout for Sheet Metal Works or Fabrication Shapes appeared first on Let'sFab.

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What is a Flat Pattern or Fabrication Layout?

Flat Pattern is nothing but unfolded shape of any sheet metal shapes or fabrication shapes before forming processes such as Bending, Rolling, etc. We can also say that Flat pattern is a pre or raw flat surface before forming activity in sheet metal or fabrication Industry. In most of the fabrication Industries, the Flat Pattern is also called a Fabrication Layout.

Flat Pattern Making or Flat Surface Development process is very useful while working in the sheet metal Industry and Equipment fabrication Industry. In Sheet Metal or Fabrication Industry Flat Pattern making is useful for forming various shapes such as Conical Shapes, Box Shapes, Pipe Shapes, Transition Shapes such as Square to Round or Round to Square, or any complex shapes used for various applications in various Industry.

In Flat Pattern Marking we are calculating dimensions of shapes such as when we do compete forming process or fabrication process it will formed in to our required size Final shapes as per our manufacturing requirements.

Methods for Flat Pattern or Fabrication Layout Generating

Flat Pattern Marking can be generated by using following methods.

  1. Geometrical Method or Marking Method.
  2. Numerical Method or Calculation Method.

These above two methods are the basis of generating flat pattern marking of any fabrication shapes or sheet metal shapes. we can generate flat pattern marking of any shapes by using any one of the above methods.

How to Generate Flat Pattern or Fabrication Layout Marking of Fabrication Shapes or Sheet Metal Shapes.

Fabrication Layout or Flat Pattern marking can be generated by using various ways that we are going to lean ahead. Use of Fabrication Layout Generating Method depends upon various factors or applications of shapes or accuracy of shapes. As we are providing education is in the fabrication of process equipment so we see various ways of generating fabrication layout or flat pattern of various fabrication shapes on the aspect of the Fabrication Industry.

Now, we see various ways of generating fabrication layout or flat pattern these are listed below :

  1. Marking Method.
  2. Calculation Method.
  3. By using 2D Drafting Software.
  4. By using 3D CAD Software.
  5. By Using Flat Pattern Software.
  6. By Using Mobile Application.

We will now discussed all above ways of fabrication layout or flat pattern layout generating way on aspects of fabrication.

1. Marking Method or Geometrical Method

Marking Method is very old method of generating fabrication Layout or Flat Pattern method. In this Method, Fabrication Layout Markings are generated using geometrical concepts of surface development. In this method, geometrical dimensions of shapes are measured, and using some geometrical process or steps fabrication layout is generated. It is very widely used and popular method but it has various disadvantageous of this method and the major disadvantageous of this method is it required too much time and space for layout generating flat pattern fabrication layout. it also has one more big disadvantage is that lack of accuracy or we can not control accuracy because it depends upon manual works. So due to its time consumption and space requirements and lack of accuracy, now days this method is not preferred. But it this method is very important to learn because it is base of other method because now days this method is used by combination some modern software to reduce time and space requirement.

if you are working in the fabrication field this method is still used because most of the small fabricators can not afford modern tools or they do not have skilled manpower to use modern tools. This method is very helpful when you are working on a remote area where you don’t have any access to the software or modern tools of fabrication layout or flat pattern. As per our Point of view, it is very important to learn this method because it is still used in day to day fabrication activity of many industries. if you want to learn this method then you can join our 70 Days Video Course on Fabrication Layout were all commonly used shapes explained in a very simple way or if you don’t want to join this course you can also learn by yourself by reading our book “Master in Fabrication Layout Development”.

2. Calculation Method or Numerical Method

Calculation method or numerical method is also a widely used for generating fabrication layout or flat pattern layout. It is very popular method because you can used this method anywhere, required less time, no space requirement and accuracy is also better than marking method so most of the fabricator used this method while working in fabrication layouting. In this method you have to use some numerical calculation formulas to derive your flat pattern layout markings of required fabrication shapes or sheet metal shapes. You have to use different formulas for different shapes and you can calculate in very simple ways.

It is a very useful method and a time-saving method for fabrication layout. Its accuracy is very good but its accuracy mainly depends upon the user due to manual calculations. Nowadays this method is used with some modification by using computerized or numerical tools so that manual calculations should get avoided and get accurate results such as by using Microsoft Excel or any mathematical calculation tool for calculations. This method required no skilled manpower but should capable f doing mathematical calculations. if you want to learn this numerical calculation method then you can join our 70 Days Video Course on Fabrication Layout were all commonly used shapes explained in a very simple way with practical example solution or if you don’t want to join this course you can also learn by yourself by reading our book “Master in Fabrication Layout Development”

3. By using 2D Drafting Software

Fabrication Layout or Flat Pattern layout can also be generated by using 2D drafting software such as AutoCad or any similar drafting software. In this method, You have to developed fabrication layout or flat pattern layout by drafting 2D drawing of required fabrication shapes but for generating flat pattern you have to use marking method because this method is similar to marking method but the only difference is that you are doing this marking by drawing on 2D drawing software. This method is a modification method of marking method this method is used to avoid space requirement and reduce the time of marking and get higher accuracy than the normal marking method. It is modified method of the Marking Method. In most of the fabrication Industry, this method is very commonly used and AutoCad is very common 2D Drafting software is used in this method. The major disadvantage of this method is that it required skilled manpower and if you have to make some changes to shapes you have to repeat the same process again and it consumes time and cost. so for nowadays, other methods are used in day to day fabrication activity to faster results and accuracy.

4. By using 3D CAD Software

Fabrication Layout or Flat pattern layout is also generated by using 3D CAD Software. it is a very accurate, time-saving, and faster method. you can generate fabrication layout marking of any complex shapes by using this method. Normally SolidWorks or any other similar CAD software that having unfold or flat pattern generating options available in software can be used in this method. In this method, you have to make a 3D model of your required shape and just apply to unfold command or flat pattern option to generate a flat pattern or fabrication layout marking of these shapes and that can be used in fabrication works. This method is the most accurate, easy, and faster method for the flat pattern. This method has also some disadvantages such as it required very skilled manpower to use this software and it also required cost for buying these Softwares and skilled manpower so it is a very costly method so it is economical for those having already this software and manpower for some other works.

5. By using Flat Pattern Software

In today modern world lots of specializes software are available for some specific application similarly for generating Flat Pattern or Fabrication Layout some Flat Pattern generating software is also available in market such as Plate and Sheet Professional and any other similar software that specially made for flat pattern generation. You can use this software for you fabrication works and this software are very customized and can be available as per user requirements. This method is very simple to used and time saving method. it also has very accurate results so you can go for this method for your day to day fabrication or flat pattern activity. This software has only one disadvantages is that it required higher cost for buying this software.

6. By Using Mobile Application

It is a very modern and very popular method of generating flat pattern or fabrication layout because it is very handy and convenient to use. It has eliminated all disadvantages of all above methods discussed, so this method is become very popular nowadays. It generate very accurate results. It is very faster and does not consumes time of user it required only time required for inputting the values and it generate results in within seconds. It does not involves any cost of using this tool because this available at almost free of cost. It increase you efficiency and productivity by saving your time and material cost. It is very hand and portable you can use this tool to any where at any time. In this method you have to just download App in you mobile device and you can use it you have to select your required shape gives the input of this shapes and just click on calculate button then it will give you your results and using this results you can use this in your day to day fabrication activity.

Now you are thinking that how you will get will this tool at free of cost. By analyzing this problems of fabricator Let’sFab Educational Services has developed this tool for you at free of cost. if you want to download this tool in your device just click here or visit our website our apps page and download the Fabrication Flat Pattern Tool and use this in your fabrication works.

This is all about the fabrication layout. I hope you will get enough ideas about what is fabrication layout, what are the methods of fabrication layout, and ways of generating a flat pattern.

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What is WPS PQR WPQ and ASME Section IX Overview https://letsfab.in/wps-pqr-wpq-as-per-asme-section-ix/ Sat, 25 Apr 2020 16:08:02 +0000 http://letsfab.in/?p=2567 Welding Procedure Specification is written procedure prepare to Provide direction for Making Sound Production Weld as per Code Requirements.

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What is Mean By WPS/PQR/WPQ

Welding Procedure Specification (WPS) : Welding Procedure Specification is written procedure prepare to Provide direction for Making Sound Production Weld as per Code Requirements.

WPS Consist of Welding Variables Such as Essential Welding Variable, Supplementary Variables and Non Essential variables.

  1. Essential Welding Variables : This Variables are related to Mechanical Properties of Weld Joints. Any Changes in this variables affect Mechanical properties of Weld Joints so if you want to change any variables it needs to re-qualify Welding Procedure Specification (WPS)
  2. Supplementary Variables : This Variables are related to Toughness Properties of Weld Properties of Weld Joints. Any Changes in this variables affect Toughness properties of Weld Joints so if you want to change any variables it needs to re-qualify Welding Procedure Specification (WPS). But this variables are applicable only if material required toughness properties.
  3. Non Essential Variables : This Variables Does not affect any Mechanical Properties So any Changes in this variables does not required to re-qualify Welding Procedure Specification.

Procedure Qualification Record (PQR) : Procedure Qualification Record is a compiled document of Recorded Values of All Variables during Welding and It also includes Test Result of Tested Specimen or Weld Coupon welded by Welder.

PQR Consist of Real time values of welding variables and test result documents of weld coupon. All PQR data should be recorded during welding process in witness of Inspection Authority of this Procedure Qualification.

Welder Performance Qualification (WPQ) : Welder Performance Qualification is written Document that Certify that welder or Welding Operator is capable of Producing Sound weld joints as per code requirements.

WPQ Consist of all variables related to welder performance and range of qualified values of Welder Performance. this Performance Qualification Test should also conducted with witness of Inspection Authority of Performance Qualification.

This is documents proves the ability of Welder or Welding Operator as per job requirement.

If you want to learn all concept of WPS PQR WPQ in details in Hindi then you can learn with us by enrolling in our 28 Days Video Course on ” WPS PQR WPQ Pro”. To Know more Course Details Click here…

wps pqr wpq

Overview of ASME Section IX Code

ASME Section IX Code : It is reference code of Welding, Brazing and Fusing Qualification.

ASME Section IX Code is four Sub Parts :

  1. Part QG – General Requirement of Welding, Brazing and Fusing.
  2. Part QW – Welding
  3. Prat QB – Brazing
  4. Part QF – Fusing

Part QG – General Requirement for Welding, Brazing and Fusing

  1. Procedure Specification (QG-101)
  2. Procedure Qualification Record (QG-102)
  3. Performance Qualification (QG-103)
  4. Performance Qualification Record (QG-104)
  5. Variables (QG-105)
  6. Organisational Responsibility (QG-106)
  7. Ownership Tranfer (QG-107)
  8. Qualification Made to Previous Editions (QG-108)
  9. Defintions (QG-109)

Part QW – Welding

  1. Article I – Welding General Requirements.
  2. Article II – Welding Procedure Qualification.
  3. Article III – Welding Performance Qualification
  4. Article IV – Welding Data
  5. Article V – Standard Procedure Specification.

This is overview of ASME Section IX on the point of Welding aspect as this Post is only Related to WPS PQR WPQ so we had considered only part related to Welding Qualifications.

If you want to learn all concept of WPS PQR WPQ in details in Hindi then you can learn with us by enrolling in our 28 Days Video Course on ” WPS PQR WPQ Pro”. To Know more Course Details Click here…

If you want to increase you knowledge in fabrication Pressure Vessels, Heat Ex-changer, Storage Tank, Piping and other Process Equipment then you can join our various video course know more Click here…

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Pressure Vessels Heads App by Let’sFab https://letsfab.in/pressure-vessels-heads-calculator/ Fri, 14 Feb 2020 16:54:56 +0000 http://letsfab.in/?p=1473 Pressure Vessels Heads app is very helpful for Calculation of Blank Diameter, Weight,Crown Radius, Knuckle Radius,Height etc.

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Pressure Vessels Heads App by Let’sFab

Pressure Vessels Heads app is very helpful for Calculation of Blank Diameter, Weight, Crown Radius, Knuckle Radius, and Height of pressure Vessel heads such as Torispherical Head, ellipsoidal head and Hemispherical head.

This Tool is also Used to Calculate Template Layout Marking for 2:1 Ellipsoidal Dish ends. It is also applicable for Pressure Vessel End Caps, Dish Ends, Formed Heads and End Closure etc.

Click here to Download App for Android Device.

Click here to Download App for iOS Apple Device.

Click here to Download for Windows PC or Desktop.

Click here to Download for MacOS Apple Devices.

Pressure Vessels Heads App Having Following Types of Calculators:

  1. Flat Dish End Blank Diameter Calculator.
  2. Toripherical Dish Ends Blank Diameter Calculator.
  3. Ellipsoidal Dish Ends Blank Diameter Calculator.
  4. Hemispherical Dish Blank Diameter Calculator.
  5. Ellipsoidal Head Template Layout Marking Calculator.

Pressure Vessels Heads app is designed for following Heads.

  1. 10% Torispherical head or Torispherical dish Ends.
  2. 2: 1 Ellipsoidal head or Ellipsoidal Dish Ends.
  3. Hemispherical heads or Hemispherical Dish Ends.

All dimensional Input Should be required in this application is in MM or Metric System.

How To Use Pressure Vessels Heads App :

1. Flat Heads Blank Calculator :

This Tool is used to Calculates All Terms of Flat Dish End such as Dish End Height, Dish End Blank Diameter and Dish End Weight.

In this Application you have to provide required inputs data of Flat Dish ends such as Dish end Inside Diameter in mm, Dish End Knuckle radius in mm, Dish End Straight Face in mm, Dish End Thickness in mm and Dish end Specific Gravity. Alternately, If you don’t know it then Select Material From List. After that you have to Click on Calculate Button. After that you will get result output.

This app gives output as Flat Dish End Height in mm, Flat Dish end Blank Diameter Required in mm and Flat Dish End Weight in Kg. If Your Material is not available in Material Selection List. Then Please enter Specific Gravity of Material Manually in Specific Gravity Input Field.

2. Ellipsoidal Heads Blank Calculator :

This Tool is used to Calculates All Terms of Ellipsoidal Dish End such as Dish end Crown Radius, Knuckle radius, Dish End Height without Straight Face, Dish End Height with Straight face, Dish End Blank Diameter and Dish End Weight.

In this Application you have to provide required inputs data of Ellipsoidal Dish ends is Dish End Inside Diameter in mm, Dish End Straight Face in mm, Dish End Thickness in mm and Dish end Specific Gravity. If you don’t have this then Select Material From List then Click on Calculate Button. After that you will get result output. This app gives output as Dish End Crown radius in mm, Knuckle Radius in mm, Height without Straight Face in mm, Height With Straight Face in mm, Blank Diameter Required in mm and Dish End Weight in Kg.

If Your Material is not available in Material Selection List then please enter Specific Gravity of Material Manually in Specific Gravity Input Field.

3. Torispherical Heads Blank Calculator :

It is used for Calculating Torispherical Dish End Crown Radius, Knuckle Radius, Heights, Blank Diameter and Weights. To use this calculator Follow me Process as Ellipsoidal Heads Calculator.

4. Hemispherical Heads Blank Calculator :

It is used for Calculating Hemi Dish End Radius, Dish End Heights, Blank Diameter and Dish End Weights. To use this calculator Follow me Process as Ellipsoidal Heads Calculator.

5. Ellipsoidal Head Template Layout Marker:

It Used to Generate Elliptical Head Template Layout Marking Coordinates for faster Layout.

It is useful for Fabrication Engineer for Getting All Term related to Pressure Vessels End Caps, Pressure Vessel Heads or Pressure Vessels Dish Ends.

In this App use can also Calculates Weight of Dish Ends for Different Types of Materials. Some of the materials are Carbon steel, Stainless Steel, Aluminium, brass , bronze, Copper, Lead etc. materials.

Blank Diameter calculated by This Tool is useful for Estimation and costing purpose. So that while Cutting Blank size of the above Dish End please consult with your head manufacture for desired Accuracy.

Click here to Download App for Android Device

Click here to Download App for iOS Apple Device

Click here to Download for Windows PC or Desktop.

Click here to Download for MacOS Apple Devices.

If you want other fabrication apps for your daily fabrication activity then Click here…

If you want sharpen your knowledge in Pressure Vessels Heads then learn from Our 21 Days Video Course for Becoming Expert in Pressure Vessels Heads or Dish Ends or Formed Heads or End Closure or End Cap. To Get in Discounted Price Click here…

YouTube Video
Watch this video on YouTube.

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Pressure Vessels Heads https://letsfab.in/pressure-vessels-heads/ Thu, 13 Feb 2020 13:39:49 +0000 http://letsfab.in/?p=1348 What is Mean By Pressure Vessels Heads : It is Part of Pressure Vessel which closes ends of the cylindrical section or shell of the pressure vessel is called as Pressure Vessels Heads.

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What is Mean By Pressure Vessels Heads :

It is major Part of Pressure Vessel which closes ends of the cylindrical section or shell of the pressure vessel is called as Pressure Vessels Heads. There are various common names are used for Pressure Vessels Heads which are Dish Ends, Formed Heads, End Closure, End Caps, Vessel Ends, Vessel Caps etc. but most Common name is Dish ends.

Types of Pressure Vessels Heads :

There are four basic types of pressure vessels heads or Dish ends is most widely used in fabrication of Pressure Vessels.

  1. Flat Heads
  2. Ellipsoidal Heads
  3. Toripherical Heads or Flange and Dished Heads
  4. Hemipherical Heads

Flat Heads :

It is the simplest form of the pressure vessels heads but it has less usefulness in pressure vessels heads. So it is not preferred as much as of others because it has less pressure withstanding capacity than the other types of heads due to lower radial section is available for pressure distribution. So maximum exposure is comes on flat section so it is not economical.

Flat Heads

Commonly Used terms in the Flat Head is Flat Head Inside Diameter (ID), Knuckle Radius (R), Dish End Total Height (H) and Straight Face (SF). Flat Heads General Drawing Representation is shown in above Drawing.

Ellipsoidal Heads :

It is a most widely used Pressure Vessel Heads. It has wider Radial section is available for pressure distribution.it withstand maximum pressure as compared to other heads. So it is most preferred pressure vessels heads. for same design condition, Dish end Thickness of ellipsoidal heads is approximately equals to shell thickness so it is most economical heads. Generally most used Ellipsoidal Heads Configuration is as per 2:1 Ellipsoidal Section.

2:1 Ellipsoidal Heads

Commonly Used Terms in 2:1 Ellipsoidal Heads is Inside Diameter (ID), Crown Radius (C.R), Knuckle Radius (K.R), Dish End Total Height (H) and Straight Face (SF). 2:1 Ellipsoidal Head General Drawing Representation is shown in above Drawing. Ellipsoidal Heads required more time of forming as compared to Flat Heads and Torispherical Heads. It is Most Economical Pressure Vessels Heads.

Torispherical Heads or Flange and Dished Heads :

It is also most widely used heads. It also has more radial section for pressure distribution so it also withstand maximum pressure but lower than ellipsoidal Heads. So that it is less economical than ellipsoidal heads but it also widely use due to lower time required for forming than the ellipsoidal heads.

So that for same design condition, Torispherical Heads Thickness is nearly 1.77 times the Shell Thickness for same Design Pressure and Temperature.

Torispherical Heads

Commonly Used Terms in Torispherical Heads is Inside Diameter (ID), Crown Radius (C.R), Knuckle Radius (K.R), Dish End Total Height (H) and Straight Face (SF). Torispherical Head General Drawing Representation is shown in above Drawing.

It required less time of forming that ellipsoidal heads so it also more preferred heads due to simplicity of this heads. This Heads is also Called as Flange and Dished Heads.

Hemispherical Heads:

This Head or Dish end is also used in pressure vessels fabrication. It has Maximum Radial Section is available than the other types of heads. Due to this it has maximum pressure distribution area is available.So that, for Same Design Condition Hemi Heads Thickness is approximately half of the shell Thickness for same pressure and Temperature.

So it is most economical Heads than the other types of Heads but it required maximum time of forming.

Hemispherical Heads

Commonly used terms in Hemi Heads is Inside Diameter (ID), Crown Radius (R), Dish end Total Height (H) and Straight Face (SF). Choice of Dish Ends is Depends upon Design Conditions and Their Applicability of Pressure Vessels Heads.

This are the four Basic Types of Dish ends are used in Pressure Vessels Fabrication. Most of the Dish end terms are calculated by using standard relationships with their inside diameter. On the Part of fabrication Point of View We have to Calculate various terms. This terms includes Dish End Terms, Blank Diameter, Weight, Surface Area, Volume Calculations are required in fabrication of Dish Ends.

Letsfab is continuously working to digitize fabrication techniques, so we had developed many tools for fabrication that save time and cost. To get this tools visit our app page from menu-bar or click here

If you want sharpen your knowledge in Pressure Vessels Heads then learn from Our 21 Days Video Course for Becoming Expert in Pressure Vessels Heads or Dish Ends or Formed Heads or End Closure or End Cap. To Get in Discounted Price Click here…

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Procedure for Pressure Test or Hydrotest https://letsfab.in/hydrotest-procedure/ Fri, 27 Apr 2018 06:01:28 +0000 http://letsfab.in/?p=457 Hydrotest Procedure Scope : This Procedure is applicable to Boiler External piping and Pressure vessels constructed to ASME Code B31.1 & sec VII Div 1. Respectively. It also applies to pressure retaining items repair or altered in accordance & the National Code (NBIC)

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Procedure for Pressure Test or Hydrotest

SCOPE

This Procedure is applicable to Boiler External piping and Pressure vessels constructed to ASME Code B31.1 & sec VII Div 1. Respectively. It also applies to pressure retaining items repair or altered in accordance & the National Code (NBIC)

REFERENCES

  1. ASME Sec . I Edition 2007 Addenda 2009.
  2. ASME B 3.1.1 Edition – 2004..         
  3. ASME Code Sec. VIII. Div 1 Edition 2007 Addenda 2009.

PROCEDURE

Responsibilities.

The Concerned Procedure Engineer is responsible for preparation of the test item for Pressure Testing.

  1. The designated QA/QC Engineer / Inspector is responsible for witnessing the item being tested. He is responsible for arranging for notifying the TPI. Sufficiently in advance for witnessing pressure test.
  2. The designed Production Engineer is responsible for ensuring that during the test only essential personnel are present in the work area. The work area shall be suitable cordoned off otherwise isolated such hat unrelated personnel do not stray into it.
  3. The designated QA/QC Engineer / Inspector is responsible to verify that the NDE and all fabrication works are completed and accepted before releasing the item for pressure testing.

Equipment

  • The test equipment shall be in accordance with the applicable client’s specification if any and shall be adequate to provide necessary test pressure at a safe rate of increases.
  • All components of the test system shall be rated to with stand test pressure.
  • Pressure and temperature recording devices may be used to record medium temperature and pressure on a continuous basis during the test duration.
  • A temperature measuring device shall be used to record the metal temperature during the test.

Preparation for Pressure test.

  1. Vent shall be provided at all high points of the vessel in the position in which it is to be tested to purge possible air pockets while vessel is filling.
  2. The QA/ QC Engineer / Inspector shall verify that coating is not applied prior to test at weld joints.
  3. Test pressure shall be according to table 1 of this procedure.
  4. All lines and appurtenances which do not form part of the test system shall be removed or otherwise isolated from the test system before the test.
  5. Blind flanges and gaskets shall be installed as necessary. All fitting shall be tightened expect the vent points.
  6. The test medium is portable water for carbon and low alloy steel items for high alloy steel such as stainless steel  de-mineralized water shall be used.
  7. The temperature of the test fluid shall be checked. It is recommended, that the metal temperature during test be maintained as per the table no. 2 of this procedure.
  8. It is also described that the steel temperature should not be too close atmospheric dew point so that the results may not be hampered by condensation of moisture from the atmosphere. Wherever possible; steps should be taken to ensure that the items are provided with an adequate cover such that the metal temperature does not rise significantly.
  9. The test pressure for Hydro-test shall be specified in the applicable fabrication drawing

Pressure Gauges

  • At least once calibrated pressure gauge shall be directly connected to the code item being tested at the highest point, and shall be visible to the operated controlled the test.
  • The pressure gauge shall have a range of about double the test pressure, but shall not be less tan 1 ½ nor more than 4 times the test pressure. For boilers external piping dial pressure used in testing shall preferably have dials graduated over the range of about double the intended maximum test pressure. But no case the arrange shall be less than 1 ½ times the pressure.
  • An additional calibrated pressure gauge may be fitted at a suitable location visible to the operator controlling the pressure at all time. If not fitted at the highest point. Then the pressure shall be accordingly corrected for the static head difference.

Filling with test fluid

  • The test fluid is usually filled from the lower end of the item. Progressing towards the vents on completion. The rate of flow should be such that it does not cause excessive bubbles which may be entrapped in recesses.
  • The vent shall be closed after filling the vessel completely and ensuring that no air is left entrapped within the test system.

Testing

  1. After filling the test system with fluid, the pressure is gradually increased. He test pressure is determined from the drawing (approved fpr construction issue). In cases where this is not available the test pressure shall be obtained from desing engineer by the QA / QC engineer and communicated to the production engineer. He pressure is increased to around 25 50 % of the test pressure. The connections are then checked for leak tightness.
  2. If leaks are observed, the system is De – pressurized and the leaking points are attended suitably (by tightening or by replacing gaskets if necessary).
  3. After checking that, there is no leak, the pressure is gradually increased to the test pressure. The QA/QC Engineer / Inspector shall record the start time of the test after reaching the test pressure.
  4. The test pressure shall be held for specified minimum holding time. If holding period is not specified, the pressure shall be maintained for 60 minute minimum.
  5. After the holding time is elapsed, he pressure is reduced ( by bleeding the test system) to he inspection test pressure. At this point, the QA/QC Engineer / Inspector shall visually inspect the vessel to detect leaks. All weld joint and connections shall be checked visually.
  6. If leaks are detected at flange joints the pressure shall be reduced to zero, the concerned flanges tightened and retested.
  7. If leaks are detected at weld, the test item is considered to have failed in the test NCR shall be raise & disposition shall be undertaken.
  8. If the test is satisfactory, the QA/QC Engineer / Inspector shall approved it by endorsing the test report with attachments like chart, calibration certificates of pressure gauge etc.
  9. After completing the test, the test fluid shall be drained off from the test system and the system shall be cleaned and isolated. While draining, care shall be exercised to ensure that adequate venting is incorporated yo prevent damage item.

Table – 1: Test Pressure

Applicable Code SectionMinimum test PressureVisual Examination Pressure
ASME Code Sec VIII Div 1MAWP multiplied by 1.3Test pressure Divided by 1.3
ASME B 31.11.5 times of the design pressureDesign pressure
ASME Code Sec IMAWP multiplied by 1.5Test pressure Divided by 1.5

Table – 2: Recommended Maximum & Minimum Temperature During Hydro static Test.

Applicable Code SectionMinimum Metal temperatureMax Metal Temperature during close Eamination
ASME Code Sec VIII Div 130 Deg F (17 Dec C) above MDMT120 Deg F ( 48 Deg C)
ASME B 31.1 & Sec I 20 Deg C (Water Temperature)120 Deg F ( 48 Deg C)

This all about Hydro test procedure.

If you are working in the field of fabrication then we have simplified your day to day fabrication activity by developing various calculators so that you can minimize your time and cost of fabrication also increase the accuracy of your fabrication works and improve your workmanships, so let’s try our free apps, Click here for more details…

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