Expensive Hydrotests

Sometimes performing the ASME Code required hydrotest is deemed too expensive so Owner/Operators skip it. 

One factor that may raise the cost of hydrotesting is if the hydrotest pressure is much greater than the operating pressure. The higher hydrotest pressure may require the fabrication of single-use components, supplying a special set of gaskets, and another PCC-1 Appendix O calculation.

One of the sad realities of the extreme cost-cutting associated with modern manufacturing is the loss of basic design principles. I’ve noticed that performing proof tests and leak tests instead of ASME Code required hydrotests is becoming increasingly popular in new vessel construction. 

Authorized Inspectors (AIs) often assume a shop hydrotest was performed and never check the U-Form notes that clearly states otherwise. The “what can I get away with?” mentality rewards design engineers with promotions while operator roles become increasingly dangerous.