Hydrotest Pressure
Minimum test pressure per applicable codeMaximum allowable working pressure of the system
Please enter a value
ALLOWABLE STRESS AT DESIGN TEMP (OPTIONAL)
Material allowable stress at max operating temperature (for stress ratio)
ALLOWABLE STRESS AT TEST TEMP (OPTIONAL)
Material allowable stress at ambient (test) temperature
+ Add Elevation Difference (Hydrostatic Head)
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HIGH POINT ELEVATION
LOW POINT ELEVATION
WATER TEMPERATURE
+ Add System Volume (for Personnel Safe Distance)
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SYSTEM VOLUME CALCULATOR (OPTIONAL)
SYSTEM VOLUME
Optional — used to calculate a test-specific personnel safe distance below, based on the elastic energy stored in the compressed water. Leave blank to skip.
SCALED-DISTANCE CONSEQUENCE LEVEL (Rscaled)
Only affects the VERY HIGH tier (above 2,500 kJ), where distance is calculated rather than fixed. Adapted from PCC-2 Table 501-III-1-1 for internal consistency — not a PCC-2 requirement for hydrotest.
MINIMUM TEST PRESSURE
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TEST PRESSURE FACTOR
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STRESS RATIO
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Code reference:
🛡️ Personnel Safe Distance
📋 Recommendations
Water Volume
Total fill volume for pipe segments, manifolds and equipmentExtra volume for inline valves, vessels, manifold bodies, etc.
Bolts & Gaskets
Stud bolt count, size and gasket dimensions per ASME B16.5Pneumatic Test Pressure
Minimum test pressure, preliminary pressure and step procedure🛑Pneumatic testing requires written engineering approval and a formal safety plan before execution.
UNITS
Total internal volume of all piping, vessels and equipment in test boundary
SCALED-DISTANCE CONSEQUENCE LEVEL (Rscaled)
Per ASME PCC-2 Table 501-III-1-1. Only affects cases above the fixed-distance table range (>200M ft·lb / ≈271 MJ), where distance is calculated rather than fixed. 20 (code default) is the least restrictive; 2 is the fatality threshold, not a "safe" distance.
AMBIENT / SITE TEMPERATURE
Used to accurately estimate gas mass in the system — actual site temperature (e.g. summer in KSA) can differ significantly from a fixed 20°C/68°F assumption.
GAS CYLINDER SPEC (FOR CYLINDER COUNT ESTIMATE)
Default is a typical 50 L / 200 bar industrial nitrogen cylinder — replace both values with your actual supplier's cylinder water capacity and charge pressure for an accurate cylinder count.
Blind Flange
Required thickness per ASME VIII-1 UG-34Spade / Vent & Drain
Spectacle blind thickness and vent/drain sizing
UNITS
BORE DIAMETER (PIPE ID)
DESIGN PRESSURE
MATERIAL
Stored Energy Check
Isothermal expansion energy for pneumatic test safety assessmentℹ️ Stored energy and safe distance are calculated per ASME PCC-2 Mandatory Appendix 501-II/501-III: E = 2.5·Pt·V·[1−(Pa/Pt)^0.286] (isentropic expansion), with safe distance from the 501-III fixed-minimum table below ~271 MJ and an uncapped scaled-distance formula (R = Rscaled × W^⅓) above it.
UNITS
bar
Enter gauge pressure (barg). Absolute pressure calculated automatically.
TOTAL SYSTEM VOLUME
Include all piping, vessels, and in-scope equipment within test boundary
SCALED-DISTANCE CONSEQUENCE LEVEL (Rscaled)
Per ASME PCC-2 Table 501-III-1-1. Only affects cases above the fixed-distance table range (>200M ft·lb / ≈271 MJ). 20 (code default) is the least restrictive; 2 is the fatality threshold, not a "safe" distance.
Water Specifications
Physical properties and quality requirements for hydrotest water20°C
Manifold Design
Hydrotest manifold volume, sizing and pressure classHeader length
BRANCH CONNECTIONS
Branch length · Number of branches
PRESSURE & RATING