Owners and operators of liquid storage tanks are responsible for scheduling regular professional inspection services. All commercial and industrial water and chemical storage tanks must undergo thorough examinations according to industry standards, ensuring safety and integrity are maintained throughout their lifespans.
What is Hydrotesting/Hydrostatic Testing
Upon completion of a newly constructed storage tank, one of the final mechanical assessments recommended is a hydrostatic test. This test method is used to evaluate the integrity and detect leaks in pressure vessels such as pipelines, plumbing systems, gas cylinders, boilers, and fuel tanks.
The procedure involves filling the vessel or pipe system with a liquid, typically water, which may be dyed to facilitate visual leak detection, and pressurizing the vessel to the specified test pressure.
Pressure integrity is assessed by closing the supply valve and monitoring for any pressure loss. The presence of a dye in the water helps visually identify the location of any leaks. Additionally, the strength of the container is evaluated by measuring any permanent deformation.
The hydrostatic test procedure is conducted to identify leaks in shell weld joints and to observe the stabilization of the liquid level at interval heights. During the test, all instrumentation should be removed to prevent damage.
Importance of Hydrotesting in Water Tanks
The construction of new tanks and significant modifications to existing storage tanks involve several testing prerequisites aimed at ensuring the equipment’s integrity. Hydrostatic testing, as the name suggests, involves filling the tank with water to test it.
The primary and most obvious purpose of filling the tank with water is to detect any leaks. The tank is filled with water at a recommended rate and then inspected after a 24-hour period to ensure there are no cracks, pinholes, or other irregularities in the welds.
Another reason for the test is to assess the mechanical strength of the tank. Weak spots become apparent when the tank is filled with water, which poses significantly less risk to workers and the environment compared to when the tank contains toxic chemicals.
A critical observation made during a hydrostatic test is the strength of the tank’s supporting foundation. The foundation is a major contributor to tank damage.
Furthermore, the hydrostatic test serves as a stability assessment, allowing the client and builder to verify that the tank base settlement falls within an acceptable range. This is achieved using a test medium such as water, which typically has a higher specific gravity than the cargo the tank is designed to hold.
How to Know if My Tank Needs Testing?
Hydro-testing for paintball tanks is essential, with requirements varying by manufacturer. Typically, high-pressure air tanks used in paintball need to undergo hydro-testing every three to five years.
The tank’s manufacturing date is usually indicated on the label, and it is the owner’s responsibility to ensure timely re-hydro-testing once the tank’s validity period expires. During hydro-testing, the tank is pressurized to a level significantly higher than its rated capacity.
If the tank passes the pressure test without any issues, its validity is extended for another three to five years. However, if the tank fails the test, replacement is necessary.
CO2 and SCBA cylinders generally require hydro-testing every five years, although newer models may have longer intervals, often every ten years. The cost for CO2 tank hydro-testing is typically around $20.
Concluding
Understanding the importance of hydro-testing your water tank is just as critical as maintaining it. Despite not always being top of mind, regular usage of your tank can lead to typical wear and tear, potentially resulting in leaks or bursts as pressure accumulates over time.
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