DIN 50104 Internal Pressure Test for Hollow Bodies of Various Shapes up to a Specific Internal Pressure (Water Pressure Test)

In the "DIN 50104 Internal pressure test (water pressure test) for hollow bodies of various shapes up to a certain internal pressure" standard developed by the German Institute for Standardization (DIN), there is a system for testing hollow bodies with internal pressure and detecting leaks up to a certain pressure value. The procedure is explained.

In general, requirements for pressure testing include:

• Stress exceeding yield strength: When the stress on the material exceeds the yield strength, the test pressure should be reduced to a level that does not exceed the yield strength at the test temperature. This precaution is taken to prevent permanent deformation or damage to the material.
• Liquid expansion: If the test pressure must be maintained for a certain period of time and the liquid in the system is prone to thermal expansion, appropriate measures should be taken to prevent excessive pressure build-up. This is necessary to ensure that the system remains within safe limits during testing.
• Preliminary pneumatic test: Before performing hydrostatic or pneumatic testing, it is recommended to perform a preliminary test using air at a pressure not exceeding the gauge pressure of 170 kPa. This preliminary testing helps identify any major leaks in the system before the actual pressure test is performed.
• Inspection for leaks: During the leak test, a period of at least 10 minutes should be maintained and all joints and connections should be thoroughly inspected for signs of leaks. This inspection is crucial to identify and fix possible leaks in the system.
• Heat treatment: In cases where heat treatment is applied to the system, leakage tests should be performed after the heat treatment process is completed. This helps the system maintain its seal even after undergoing any heat-related treatment.
• Low test temperature: When performing leak tests at low temperatures, especially near the metal's ductile-brittle transition temperature, it is important to consider the possibility of brittle fracture. Appropriate precautions should be taken to prevent any safety hazards due to brittle fractures during the testing process.
• Personnel protection: To ensure the safety of personnel near the piping system under test, appropriate measures must be taken in the event of a rupture in the piping system. These measures aim to minimize risks to personnel and eliminate potential hazards during the testing procedure.
• Repairs or additions after leak testing: If repairs or additions are made to the system after the initial leak test, the affected piping should be retested to ensure that the repairs or additions do not compromise the integrity of the system.
• Test records: Throughout the testing process, detailed records should be kept for each piping system.

Hydrostatic testing is a testing method used to evaluate the leak resistance and structural strength of various pressure equipment, usually in the form of hollow bodies, such as meter skids, pressurized gas cylinders, boilers, pipes, pipelines and other vessels.

This method involves filling the system or component with water or another liquid and applying pressure to it. The pressure is gradually increased to a predetermined level and maintained for a certain period of time. During testing, the system or component is inspected for any leaks, deformations or malfunctions.

Hydrostatic testing is often used for systems that handle liquids. It helps identify potential weaknesses or defects in the structure or sealing of the system and ensures the security and integrity of the system.

The hydrostatic test pressure at any point in the piping system shall not be less than 1,5 times the design pressure, but shall not exceed the maximum allowable test pressure of any uninsulated component nor shall it exceed the limits of calculated stresses due to occasional loads.

Hydrostatic testing enables accurate detection of leaks in pressurized systems or components. This test provides a comprehensive assessment of the structural integrity and durability of the object under test. However, hydrostatic testing often requires a significant amount of time to fill, pressurize, and evacuate the system or component. Meanwhile, using water as the test medium in hydrostatic tests can potentially lead to corrosion problems.

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