Technical knowledge
Hydrostatic testing and non destructive examination of alloy fittings
What hydrostatic testing proves, how non destructive methods such as ultrasonic, dye penetrant and radiography apply to fittings and flanges, and how to specify an examination scope that is meaningful.
What a hydrostatic test does and does not prove
A hydrostatic test pressurises the component with water to a multiple of the design pressure and holds it. It demonstrates strength and leak tightness at the test condition. It will not reliably detect a laminar discontinuity parallel to the surface, a shallow crack or an unfused weld root that is still pressure tight. That is why the test is never a substitute for NDT.
Choosing the right examination method
| Method | Finds | Applies to |
|---|---|---|
| Ultrasonic testing | Internal discontinuities, laminations, thickness | Forgings, plate, thick sections |
| Dye penetrant | Surface breaking cracks and porosity | Machined faces, weld ends, grooves |
| Radiography | Volumetric weld defects | Weld seams on formed fittings |
| Magnetic particle | Surface and near surface discontinuities | Ferromagnetic materials only |
| Eddy current | Surface and near surface defects in tube | Seamless tube inspection |
| Visual examination | Surface condition, marking, finish | Every component |
Writing a scope that means something
- Name the method and the standard, for example ultrasonic testing to the applicable ASTM or ISO practice.
- State the extent: 100 % of components, a statistical sample, or specific areas.
- State the acceptance criteria, not just the method. A method without an acceptance level is unenforceable.
- State the qualification level of the operator and who witnesses.
- Require the results to be recorded against the heat number and the component marking.
Alloy specific notes
- Duplex and super duplex. Add impact and corrosion testing rather than relying on NDT alone.
- Titanium. Verify shielding quality because weld contamination is the dominant risk and is best controlled during welding, not found afterwards.
- Nickel alloys. Dye penetrant on all machined sealing surfaces is standard good practice.
- Chloride control. Use chloride free penetrants and low chloride test water on stainless and nickel alloys, and dry thoroughly afterwards.
Questions about this topic
Can a hydrostatic test replace NDT?
No. A hydro test demonstrates leak tightness and strength at the test pressure; it will not detect most planar defects that could grow in service. Specify both.
Why must the test water be low chloride for stainless and nickel alloys?
Chloride left on the surface after testing can initiate pitting or stress corrosion cracking, particularly in crevices and under insulation. Use low chloride water and dry the components thoroughly afterwards.
Who should witness the testing?
The purchaser, the EPC or an appointed inspector. Where independent verification is required, inspection by SGS can be arranged and the third party test report issued with the shipment.
Questions about our products
What products does Hangbo Alloy supply?
Four product families, all available in nickel-based alloys, titanium, duplex and special stainless steel: flanges, butt weld pipe fittings, elbows, and seamless tube and pipe. Flanges cover weld neck, long weld neck, slip-on, blind, socket weld, threaded and lap joint patterns. Fittings and elbows cover concentric and eccentric reducers, equal and reducing tees, caps, stub ends, and 45°, 90° and 180° returns in both long and short radius, plus 3D and 5D bends for piggable lines. Seamless tube and pipe is supplied cold drawn or hot finished from 6 mm to 630 mm outside diameter.
Which alloy grades are available for these products?
More than 90 grades are published in our grade library. The most requested are Inconel 625, 718, 600 and X-750, Hastelloy C-276, C-22 and B-2, Monel 400 and K-500, Incoloy 800H, 825 and 925, duplex 2205 and super duplex 2507, 316L, 904L and 254SMO stainless steel, and titanium Grade 2 and Grade 5. Nickel-based grades can also be supplied with VIM plus ESR double melting where cleanliness or fatigue life is critical.
What sizes, wall thicknesses and pressure classes can you supply?
Flanges run from NPS ½ to NPS 24 to ASME B16.5 and from NPS 26 to NPS 60 to ASME B16.47 Series A or B, in pressure classes 150 through 2500. Butt weld fittings and elbows run from NPS ½ to NPS 48 (DN 15 to DN 1200) in wall thickness Schedule 5S through XXS. Seamless tube and pipe covers 6 mm to 630 mm outside diameter, in random lengths of about 5 to 7 metres or fixed lengths up to 12 metres. Non-standard and intermediate sizes are quoted on request.
Which material and dimensional standards do you work to?
Forged flanges to ASTM B564, B381 and A182 with dimensions to ASME B16.5 and ASME B16.47. Butt weld fittings and elbows to ASTM B366 and A403 with dimensions to ASME B16.9 and MSS SP-43. Seamless tube and pipe to ASTM B444, B423, B622, B163, B167, B861, A312, A213 and A790. Marking follows MSS SP-25 and the applicable product standard. If your project is governed by EN, DIN, JIS or a company specification, send the document and we will confirm equivalence before quoting.
Is there a minimum order quantity?
There is no minimum for standard sizes and grades held in stock, and prototypes, spares and small trial batches are accepted. Made-to-order melts and special forgings carry a minimum weight that depends on the alloy and the route, typically from about 500 kg for special grades.
What inspection and certification is issued with the goods?
Every shipment carries an EN 10204 3.1 mill test certificate quoting the actual chemical and mechanical results for the specific heat lot, together with dimensional records and heat treatment data where applicable. Testing is carried out in house by optical emission spectrometry, tensile, impact and hardness testing, plus ultrasonic and eddy current examination, with hydrostatic pressure and intergranular corrosion testing to ASTM G28 or A262 Practice E where the specification requires it. Third party inspection by SGS or another recognised agency can be arranged, and their report is issued alongside the shipment.
What are typical lead times?
Standard stock items ship within days. Common production grades such as Inconel 625 or duplex 2205 are typically a few weeks. Special chemistries, larger forgings and items that require third party inspection take longer and are quoted individually against the requirement.
How are the products packed for export?
Flanges and fittings receive a rust preventive coating, are individually wrapped and are packed in plywood cases secured with steel banding. Tube ends are capped and bundles are strapped. Packing lists quote heat numbers so every case can be cross-checked against the mill certificate on arrival. We quote EXW, FOB, CFR, CIF and DAP, and mixed-alloy orders can be consolidated into one shipment with a single documentation package.
How do I request a quotation or a sample?
Send the grade or UNS number, the dimensions including schedule or wall thickness, the governing material and dimensional standards, quantity, any heat treatment or NDT scope and the certificate type you need; a drawing is ideal for special flanges and fittings. Email demi@nickel-alloy.com or message us on WhatsApp +86 15618279078 and we normally issue a formal quotation within 24 hours on working days. Samples and previous test reports can be arranged before the first order.
Talk to an engineer
Share your duty conditions and we will shortlist candidate alloys within one working day.