1、Designation: E 1003 05Standard Test Method forHydrostatic Leak Testing1This standard is issued under the fixed designation E 1003; the number immediately following the designation indicates the year oforiginal adoption or, in the case of revision, the year of last revision. A number in parentheses i
2、ndicates the year of last reapproval. Asuperscript epsilon (e) indicates an editorial change since the last revision or reapproval.1. Scope1.1 This test method covers the testing of components forleaks by pressurizing them inside with a liquid.1.2 This test method can be used on piping, valves, andc
3、ontainers with welded or fitted sections which can be sealed attheir ends and which are designed for internal pressure.1.3 Basic procedures are described based on the type ofinspection used. These procedures should be limited to findingleakage indications of 4.5 3 109mol/s (1 3 104Std cm3/s)2or larg
4、er.1.4 The values stated in SI units are to be regarded asstandard.1.5 This standard does not purport to address the safetyconcerns, if any, associated with its use. It is the responsibilityof the user of this standard to establish appropriate safety andhealth practices and determine the applicabili
5、ty of regulatorylimitations prior to use.2. Referenced Documents2.1 ASTM Standards:3E 543 Practice for Agencies Performing NondestructiveTestingE 1316 Terminology for Nondestructive Testing2.2 ASNT Documents:4SNT-TC-1A Recommended Practice for Personal Qualifica-tion and Certification in Nondestruct
6、ive TestingANSI/ASNT CP-189 ASNT Standard for Qualification andCertification of Nondestructive Testing Personnel42.3 AIA Standard:5NAS-410 Certification and Qualification of NondestructiveTest Personnel3. Terminology3.1 DefinitionsFor definitions of terms used in this stan-dard, see Terminology E 13
7、16 Section E.4. Summary of Test Method4.1 Hydrostatic testing requires that a component be com-pletely filled with a liquid, such as water. Pressure is slowlyapplied to the liquid until the required pressure is reached. Thispressure is held for the required time at which point thecomponent is inspec
8、ted visually to locate leaks or the pressureon the gauge is recorded to determine the components totalleakage.4.2 The two basic procedures are described together withmethods for improving their sensitivity.4.2.1 Pressure Drop IndicationThis procedure is usedprimarily to measure total system leakage.
9、4.2.2 Visual Inspection for Leakage This procedure isintended primarily to locate leaks.4.3 Ultrasonic pretesting for gross leaks is described.5. Basis of Application5.1 The following items are subject to contractual agree-ment between the parties using or referencing this test method:5.2 Personnel
10、Qualification5.2.1 If specified in the contractual agreement. Personnelperforming examinations to this test method shall be qualifiedin accordance with a nationally or internationally recognizedNDT personnel qualification practice or standard such asANSI/ASNT CP-189, SNT-TC-1A, NAS-410, or similar d
11、ocu-ment and certified by the employer or certifying agency, asapplicable. The practice or standard used and its applicablerevision shall be identified in the contractual agreement.5.3 Qualification of Nondestructive AgenciesIf specifiedin the contractual agreement, NDT agencies shall be qualifiedan
12、d evaluated as described in Practice E 543. The applicableedition of Practice E 543 shall be specified in the contractualagreement.1This test method is under the jurisdiction of ASTM Committee E07 onNondestructive Testing and is the direct responsibility of Subcommittee E07.08 onLeak Testing.Current
13、 edition approved Dec. 1, 2005. Published December 2005. Originallyapproved in 1984. Last previous edition approved in 2000 as E 1003 - 95(2000).2The gas temperature is referenced to 0C. To convert to another gas referencetemperature, Tref, multiply the leak rate by (Tref+ 273)/273.3For referenced A
14、STM standards, visit the ASTM website, www.astm.org, orcontact ASTM Customer Service at serviceastm.org. For Annual Book of ASTMStandards volume information, refer to the standards Document Summary page onthe ASTM website.4Available from American Society for Nondestructive Testing, 1711 ArlingatePla
15、za, P.O. Box 28518, Columbus, OH 43228-0518.5Available from Aerospace Industries Association of America, Inc. (AIA), 1250Eye St., NW, Washington, DC 20005.1Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.5.4 Re-examination of Repaired
16、/Reworked ItemsRe-examination of repaired/reworked items is not addressed in thistest method, they shall be specified in the contractual agree-ment.6. Significance and Use6.1 This test method is useful for quality control testing andfield inspection of piping systems, pipelines, valves, andcontainer
17、s that are expected to retain liquids. It is not sensitiveenough for leak testing when toxic or explosive gas is expectedto be retained under pressure.7. Interferences7.1 The interior and exterior welds and joints where leaksare often found must be free of oil, grease, flux, slag, or othercontaminan
18、ts that might temporarily block or mask leakage.New systems should be tested prior to painting, where practi-cal.7.2 Hydrostatic testing should not be performed before aleak test using air or a tracer gas. The liquid test media mayclog small leaks causing later tests to be inaccurate.7.3 Test liquid
19、 must be equal or above atmosphere tempera-ture or droplets will form on the outside. The minimumtemperature of the liquid should be 16C 61F.7.4 If the container to be tested has parts made of stainlesssteel, nickel, or chromium alloys, the liquid or any additivesused must have a sulfur and halogen
20、content of less than 50ppm of each. If water is used as a test fluid it should bedeionized.7.5 To avoid brittle fracture, the test pressure must not beapplied until the metal and the test fluid are approximately thesame temperature. The metal should be a minimum of 16C61F prior to the application of
21、 pressure.7.6 If a test liquid other than water is used, the liquids flashpoint should be 93C 200F or above.7.7 If plastic parts are used in the test container, the fluidshould not promote stress cracking or softening on the plastic.7.8 When the test container has carbon steel components, arust inhi
22、bitor should be used.8. Apparatus8.1 Pressure GaugeThe gauge must be able to withstandnormal test pressures and be accurate enough to record smallpressure drops. Pressure gauges should be calibrated beforeeach test. The gauge must be accurate to within 1 % of fullscale. The gauge must read at least
23、1.5 3 but not more than4 3 the maximum test pressure to be used. (See TerminologyE 1316 for a description of terms.)8.2 Pressure Relief Valve.8.3 Pressure Alarm.8.4 Emergency Pressure Shut-Off Valve.8.5 Trapped Air Vent.8.6 Pressure Pump.8.7 Liquid Test Media.8.8 Pressure Hoses and Fittings.8.9 Prot
24、ection Chamber for High-Pressure Tests.9. General Procedures9.1 Openings:9.1.1 Seal all openings using plugs or covers that canwithstand the test pressure and can be completely removedafter the test.9.1.2 The test fluid inlet should be located on the bottom ofthe test object with the trapped air ven
25、t at the highest point.9.1.3 Components rated at pressures below the test pressuremust be isolated.9.2 GaugesOne or more test gauges must be connected tothe system. If more than one gauge is used, one may be arecording gauge. At least one gauge which is used for accep-tance of the test shall be cali
26、brated within 30 days prior to use.One indicating gauge must be easily visible to the operatorcontrolling the pressure throughout the pressurizing and testingcycle.9.3 Pre-Test Inspection:9.3.1 Before pressurizing is begun, inspect the outside of thetest object to verify that it is dry and all welds
27、 and connectorsare exposed if a visual inspection is to be conducted.9.3.2 Securely brace critical areas that may not be able towithstand the weight.9.4 PressurizingGradually increase the pressure in thesystem to 50 % of test pressure and make an initial check forleakage. Thereafter slowly increase
28、the pressure to the final testpressure. The test pressure usually is between 75 % and 150 %of the operating design pressure.9.5 Leak Test:9.5.1 At the completion of test pressure holding time,examine the system for leakage. Examination for leakage shallbe made of all accessible joints and connection
29、s, attachmentwelds where practical, and weep holes for paddings andattachments. Also inspect the area around inaccessible leakagesites.9.5.2 The inspector shall circle all accessible leaks found onthe equipment using a nondeleterious marker. The magnitudeof leak shall be described in terms of: damp
30、or moist area,drops per minute or steady stream.9.6 DepressurizingAfter inspection release the pressureslowly. The air vents need to be opened during draining toadmit air and prevent collapsing of the test system.10. Pressure Drop Method10.1 Pressurize the system in accordance with Section 8.10.2 Af
31、ter reaching full pressure check the system to makesure all trapped air has been removed.10.3 Disconnect the pressure pump and allow the pressurein the system to stabilize for a period of 10 min or 5 % of thetest time whichever is longer.10.4 After stabilization, record the exact pressure and moni-t
32、or during the test period.10.5 Sensitivity:10.5.1 Sensitivity for this type of test using water as the testfluid is normally 4.5 3 107mol/s (1 3 102Std cm3/s)2.10.5.2 By lengthening the test period, results can often beimproved to 4.5 3 108mol/s (1 3 103Std cm3/s)2.10.5.3 Sensitivity increases to 4.
33、5 3 108mol/s (1 3 103Std cm3/s)2can be achieved when the test fluids resistance toflow is decreased by use of a water additive and an alternativetest fluid, such as a penetrant.E100305211. Visual Inspection Method11.1 Pressurize the system in accordance with the proce-dures in Section 8.11.2 After r
34、eaching test pressure, inspect the outside sur-faces for leakage.11.2.1 Test pressure should be held for a minimum of 6min/cm 1.5 min/in. of wall thickness. As a minimum the testpressure should be held for 10 min and the maximum timeshould be limited to 2 h.11.2.2 If the system is not intended to op
35、erate under steadypressure, pulse the pressure in the system one or more timesafter each complete inspection cycle by dropping the pressureto 50 % of final test pressure and bringing it back to testpressure.11.2.3 If the outside of the system is covered by insulationwhich is not removed, increase th
36、e test time by a factor of 10,to a maximum of 4 h.11.3 Sensitivity:11.3.1 Normal sensitivity for visual inspection using deion-ized or distilled water as the test fluid is 4.5 3 107mol/s(1 3 102Std cm3/s)2.11.3.2 Sensitivity can be improved to 4.5 3 108mol/s(1 3 103Std cm3/s)2by using products to en
37、hance leakagevisibility as follows:11.3.2.1 Water developer applied to outside which changescolor in contact with moisture.11.3.2.2 Visible dye tracer added to the test water.11.3.2.3 Fluorescent dye tracer added to the test water.11.3.3 Sensitivity can be improved to 4.5 3 108mol/s(1 3 103Std cm3/s
38、)2by lowering the resistance to test liquidflow at the interface between the fluid and the leak by using awater additive and an alternate test fluid, such as a penetrant.11.3.4 By combining a visibility enhancer and low resis-tance to flow, sensitivity of the test can be improved to4.5 3 109mol/s (1
39、 3 104Std cm3/s)2.12. Pretest to Locate Gross Leaks12.1 This test can be applied to the system prior to hydro-static testing to locate leaks larger than 4.5 3 107mol/s(1 3 102Std cm3/s)2and as a precautionary procedure to savetime.12.2 Ultrasonic Test:12.2.1 Use air, nitrogen, or other nonflammable
40、gas as a testmedium.12.2.2 Pressurize the system with the gas gradually to 50 %of design pressure.Aminimum pressure is 170 kPa 25 psi forthis test.12.2.3 Inspect all joints and connections and welds with anacoustic leak detector capable of hearing airborne audiofrequencies in the range of 45 000 Hz.
41、13. Report13.1 The following information should be recorded at thetime of the measurements and included in the report:13.1.1 Date tested.13.1.2 Test conditions (temperature, pressure, test time).13.1.3 Leak locations.13.1.4 Leakage rate.13.1.5 Test fluid.13.1.6 Signature of tester.14. Precision and
42、Bias14.1 This procedure is believed to represent the best avail-able method. No round-robin tests have been made to deter-mine the precision and reliability of this method. The bias ofthe test is dependent on the operational procedure used and thetraining and qualification of the operators. No state
43、ment ismade about the precision or bias of the procedure since theresult merely states whether there is conformance to the criteriafor success specified in the test method.15. Keywords15.1 hydrostatic leak testing; leak testing; pressure leaktestingASTM International takes no position respecting the
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46、dquarters. Your comments will receive careful consideration at a meeting of theresponsible technical committee, which you may attend. If you feel that your comments have not received a fair hearing you shouldmake your views known to the ASTM Committee on Standards, at the address shown below.This st
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