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Hydro Test for New Bulk Cylinders by SUPERGAS- Ensuring Maximum Safety and Efficiency


We might have often heard of the Hydrostatic tests being conducted periodically for the new cylinders and even old ones. Let us know in detail what this process is all about and why it is crucial for our safety.

So, what is the Hydrostatic test? 

Hydrostatic Testing or Hydro-Testing is a process in which a cylinder is externally and internally inspected to confirm the cylinder is safe to be filled and transported. The Hydrostatic cylinder tests assess a cylinder for flaws or leaks. This process is vital because cylinders can explode if they cannot contain compressed gas.

The cylinders are made of a material with the flexibility of expansion and contraction during pressurization. The flexibility of expansion and contraction depends on numerous factors and scenarios. On account of other conditions such as filling, handling, transportation, floor conditions, there are chances of LPG leakage, rendering the cylinder unsafe for use. So, Hydrotesting is done to ensure that the cylinder can handle the typical pressure it is designed for during the filling procedure. 

As per the Petroleum & Explosives Safety Organisation (PESO) guidelines, every new cylinder must undergo Hydrostatic Test. 

Want to know the process of Hydrotesting? So, here it goes- 

Depending upon the manufacturing standard of the cylinder and its MOC, a cylinder is hydraulically tested at a pressure called Test pressure which is 1.5 times or 1.66 times of working pressure. Periodic Hydro testing is carried out to check the elasticity of the cylinder material. Every cylinder material undergoes elastic stress/expansion during each gas filling process. This elasticity deteriorates with time and repetition, which is undesirable for safety reasons. Therefore, we need to check the cylinder for its elasticity, i.e., to confirm that after releasing the test pressure, the material of the cylinder gets back to its original position within the specified tolerance limits. 

Let us look at the way how the cylinder Hydrotesting process is carried on & about: 

The hydrostatic test includes filling the cylinder/bullet with a practically incompressible liquid like water and examining it for leaks or changes in shape. The test pressure is considerably higher than the operating pressure- generally, 150% of the working pressure is applied.  

Hydrostatic testing involves filling the cylinder with water, placing it inside a water-filled test chamber called the test jacket. The cylinder is then pressurized, measuring the volume of water displaced from the test jacket by the cylinders expansion. The process is carried out both when under pressure and after being depressurized. Cylinders that demonstrate a high percentage of expansion and/or a significant difference between permanent and under-pressure expansion are unfit for use and discarded. 

The thickness of the cylinder shell/body also gets measured to ascertain that the thickness of the cylinder body metal has not been reduced due to normal wear and tear during repeated use and is well within the specified limits. 

Because hydrostatic testing involves pressurizing the cylinder above standard operating pressure, it has the benefit of yielding a high margin of confidence in the serviceability of the cylinder. Cylinder Hydrostatic testing is well suitable for detecting material discontinuities such as shrinkage/thinning, localized hard spots, gas pinholes, gas porosity, cracks, and ductile tears. 

Do You Know What to Look for When Opting for The Perfect Industrial Hydrostatic Testing Services? 

  1. i) Being aware of and using testing methods that comply with the standards set by industry-specific and governmental regulatory agencies. 

  1. ii) Recommending alternative testing failure prevention practices, in-line inspection and the application of alternative pressure testing methods along with hydrostatic testing for high-risk scenarios.  

  1. iii) Hydrostatic testing capability to 60,000 PSI with flexible/adjustable pressure settings and sufficient knowledge of equipment. 

Along with the supply of LPG, SUPERGAS believes that it is important to keep on upgrading our products, our infrastructure, and ourselves to cater to the ever-growing needs of the market. That is why our Hydrotesting unit and procedures are Avante-Garde!

The SUPERGAS Advantages: 

  • i) Enhanced Safety: Our Hydrostatic test procedure ensures no leakage, thus enhancing better safety and productivity. 

  • ii) Maximum Efficiency: LPG is filled to the right quantity without any leakage, meaning maximum efficiency. 

  • iii) Improved Quality: The end product is of superior quality, sustainable, and safer to use. 

  • Periodic Testing 

Our periodic testing of cylinders and bullets ensure that only the best goes out for sale in the market. 

We do not just serve you. We serve you well! 

That is why SUPERGAS has numerous checks and measures lined up like the Hydrostatic testing to ensure the utmost safety of our customers.