Flange and Internal Weld Testers for Hydrostatic Testing

iNPIPE PRODUCTS flange weld testers provide accurate localized pressure testing of new flange welds. This is of particular benefit when pipeline modifications and old pipe work repairs are conducted as they purely test the new weld and not the whole system. Pressure testing of an old line can lead to confusing results given the potential for other leak paths particularly on lots of other fittings. Special angled testers are also available for flanges fitted on bends.

A full range of standard flange weld testers are available up to 36” and compatible with common pipe schedules and flange configurations up to class 2500. Additional proven variations available include angled flange weld testers and increased expansion seal characteristics through patented composite Posi-seal™ technology. The design of such seals incorporates differing material hardness characteristics to withstand the continuous rigors of compression within the flange weld tester hub and expander but with the necessary reduction at the point of contact between the composite Posi-seal™ and the internal pipe wall which can be corroded or subject to hard deposition products.

Flange and internal weld tester operational benefits

• Products developed at client request, specified, and approved by all UKOOA operators and contractors
• Reduced plant operation downtime and consequent revenue stream constraints
• Reduced modification labor time
• Accurate modification time scale as the overall scope of work is minimized
• No requirement to flood and subsequently dewater the whole pipework system minimising time and consequent potential freeze damage
• No requirement for full system hydro-testing of ‘mature’ pipework which can result in additional leakage problems
• Fully certified client training on-site or factory training programs
• All flange weld testers supplied complete with current hydro-test certificate and operational instructions
• On-site technicians available for training, technical support, or tool installation and operation dependent upon client requirement
• Note: Site based Risk Assessments should always be conducted and remain the responsibility of the hiring client together with the responsibility to ensure that operators are trained in the operation of the tools
• Simple installation and operation simply explained within the Operation Manual
• Easily installed and activated in a few minutes even in the larger sizes, designed with simple handling lugs for safe and easy handling
• Designed with sensible radial clearance to cope with potential insertion clearance operational problems such as excessive weld penetration, ovality, or mineral deposits (please note: porous deposits will affect annulus pressurisation and may necessitate cleaning back to the steel substrate)
• Specialized tools can accommodate elbow, tee, or extended actuation. Solid or inflatable Posi-seal™ options dependent upon rating and application
• Suitable for most test mediums of gas or liquid depending upon the application
• High-performance composite Posi-seal™ polyurethane seals ensure optimum expansion or relaxation. Additional ultra-low temperature composite Posi seal™ polyurethane grades are available upon technical specification
• Robust design and construction ensure many years of trouble-free operation in the most difficult operational environments
• Years of continuous product development have ensured trouble-free chimney venting designs to ensure operation in any required pipe work orientation including vertical, horizontal, or inclined

Orientation and location of the weld tester must be taken into consideration to ensure that all air is effectively bled from the cavity area. Venting chimneys are available to cover any test orientation required.

All weld testing equipment and plugs are available in mechanical and hydraulic options for tethered remote operation depending upon size, location and actuation requirements. All products are supplied complete with full factory acceptance pressure test certificates which can be third party witnessed (TPI) if required. Internal weld testers can be used in a number of options and orientations for testing butt welds to line pipe. Mechanical and hydraulic options provide for local or remote actuation through extended hoses.

Internal weld testers can also be used to test the effective sealing of flange mounted ball valves. Dependent upon application, testers can be purpose manufactured to provide a specific length between the Posi-seals™. Flange weld testing can be achieved by either using the bespoke flange weld tester or by using an internal weld tester as illustrated. The weld is again located between the two Posi-seals and the weld tested by pressure testing the cavity between the two energized seals.