BRITISH STANDARD BS EN

12162:2001
+A1:2009

Liquid pumps Safety

requirements
Procedure for
hydrostatic testing

ICS 23.080

NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW

BS EN 12162:2001+A1:2009

National foreword

This British Standard is the UK implementation of EN 12162:2001+A1:2009.

It supersedes BS EN 12162:2001 which is withdrawn.
The start and finish of text introduced or altered by amendment is indicated
in the text by tags. Tags indicating changes to CEN text carry the number of
the CEN amendment. For example, text altered by CEN amendment A1 is
indicated by !".
The UK participation in its preparation was entrusted to Technical
Committee MCE/6, Pumps and pump testing.
A list of organizations represented on this committee can be obtained on
request to its secretary.
This publication does not purport to include all the necessary provisions of a
contract. Users are responsible for its correct application.
Compliance with a British Standard cannot confer immunity from
legal obligations.

This British Standard was

published under the authority
of the Standards Committee
and comes into effect on 15
May 2001 Amendments/corrigenda issued since publication

Date Comments
BSI 2009
31 July 2009 Implementation of CEN amendment A1:2009

ISBN 978 0 580 62246 5

EUROPEAN STANDARD EN 12162:2001+A1
NORME EUROPENNE
EUROPISCHE NORM May 2009

ICS 23.080 Supersedes EN 12162:2001

English Version

Liquid pumps - Safety requirements - Procedure for hydrostatic

testing

Pompes pour liquides - Exigences de scurit - Procdure Flssigkeitspumpen - Sicherheitstechnische Anforderungen

d'essai hydrostatique - Prozessverfahren fr hydrostatische Druckprfung

This European Standard was approved by CEN on 18 January 2001 and includes Amendment 1 approved by CEN on 19 April 2009.

CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European
Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national
standards may be obtained on application to the CEN Management Centre or to any CEN member.

This European Standard exists in three official versions (English, French, German). A version in any other language made by translation
under the respons bility of a CEN member into its own language and notified to the CEN Management Centre has the same status as the
official versions.

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland,
France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal,
Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.

EUROPEAN COMMITTEE FOR STANDARDIZATION

COMIT EUROPEN DE NORMALISATION
EUROPISCHES KOMITEE FR NORMUNG

Management Centre: Avenue Marnix 17, B-1000 Brussels

2009 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 12162:2001+A1:2009: E
worldwide for CEN national Members.
BS EN 12162:2001+A1:2009
EN 12162:2001+A1:2009 (E)

Contents

Foreword ...................................................................................................................................................................... 3
Introduction ................................................................................................................................................................. 4
1 Scope .............................................................................................................................................................. 5
2 Normative references .................................................................................................................................... 5
3 Terms and definitions ................................................................................................................................... 6
4 General ............................................................................................................................................................ 6
5 Timing of the test ........................................................................................................................................... 6
6 Preparation for testing .................................................................................................................................. 7
7 Test equipment .............................................................................................................................................. 7
8 Test liquid ....................................................................................................................................................... 7
9 Test pressure ................................................................................................................................................. 7
10 Test procedure ............................................................................................................................................... 8
11 Acceptance criteria ........................................................................................................................................ 9
12 Repairs ............................................................................................................................................................ 9
13 Test Records .................................................................................................................................................. 9
Annex A (informative) Random sample schedule .................................................................................................. 11
Annex ZA (informative) !Relationship between this European Standard and the Essential
Requirements of EU Directive 98/37/CE"
" ............................................................................................... 13
Annex ZB (informative) !Relationship between this European Standard and the Essential
Requirements of EU Directive 2006/42/EC"
" ........................................................................................... 14
Bibliography .............................................................................................................................................................. 15

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 BS EN 12162:2001+A1:2009
EN 12162:2001+A1:2009 (E)

Foreword
This document (EN 12162:2001+A1:2009) has been prepared by Technical Committee CEN /TC 197, "Pumps", the
secretariat of which is held by AFNOR.

This European Standard shall be given the status of a national standard, either by publication of an identical text or
by endorsement, at the latest by November 2009, and conflicting national standards shall be withdrawn at the latest
by December 2009.

This document includes Amendment 1, approved by CEN on 2009-04-19.

This document supersedes EN 12162:2001.

The start and finish of text introduced or altered by amendment is indicated in the text by tags
!".

This European Standard has been prepared under a mandate given to CEN by the European Commission and the
European Free Trade Association, and supports essential requirements of EU Directive(s).

!For relationship with EU Directive(s), see informative Annexes ZA and ZB, which are integral parts of this
document."

Annex A is informative.

According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Cyprus, Czech Republic,
Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania,
Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden,
Switzerland and United Kingdom.

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BS EN 12162:2001+A1:2009
EN 12162:2001+A1:2009 (E)

Introduction
CEN have prepared a series of related machinery safety standards, some of which are to be harmonised European
Standards, in order to implement the essential requirements for health and safety set down in the Supply of
Machinery (Safety) Directive. This European Standard is one of this series and provides the procedure to be used
for a specific verification requirement of EN 809.

The subject of this European Standard is the proving of the integrity of pump parts intended to withstand internal
pressure. It refers, therefore, to the in-process testing of pump parts so that each item may be considered to have
been examined.

This European standard is a type C standard as stated in EN 1070.

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 BS EN 12162:2001+A1:2009
EN 12162:2001+A1:2009 (E)

1 Scope
This standard specifies the hydrostatic test procedure to be applied to pressure containing parts of all types of
liquid pumps including any auxiliary equipment making up a pump unit as described in the scope of EN 809:1998,
except :

domestic water pumps within the scope of EN 60335-2-41:1996 or EN 60335-2-51:1997 ;

domestic circulation pumps within the scope of EN 1151:1999 ;

!deleted text"

!fire-fighting pumps with primers within the scope of EN 1028-1:2002+A1:2008 and EN 1028-
2:2002+A1:2008;"

pump parts with a maximum allowable working pressure below 0.1 bar.

Requirements are included for applying a hydrostatic test at different pressures to separate zones within a pump
which are subject to different allowable maximum working pressures.

This standard is for pumps and pump units which are placed upon the market after the publication date of the
standard.

2 Normative references
This European Standard incorporates by dated or undated reference, provisions from other publications. These
normative references are cited at the appropriate places in the text and the publications are listed hereafter. For
dated references, subsequent amendments to or revisions of any of these publications apply to this European
Standard only when incorporated in it by amendment or revision. For undated references the latest edition of the
publication referred to applies (including amendments).

EN 809:1998, Pumps and pump units for liquids - Common safety requirements.

!EN 1028-1:2002+A1:2008, Fire fighting pumps - Fire fighting centrifugal pumps with primer - Part 1 :
Classification - General and safety requirements"

!EN 1028-2:2002+A1:2008, Fire fighting pumps - Fire fighting centrifugal pumps with primer - Part 2 : -
Verification of general and safety requirements"

EN 1151:1999, Rotodynamic pumps - Circulation pumps having an electrical effect not exceeding 200 W for
heating installations and domestic hot water installations - Requirements, testing, marking.

EN 12723:2000, Liquid pumps - General terms for pumps and installations - Definitions, quantities, letter symbols
and units.

!deleted text"

EN 60335-2-41:1996, Safety of household and similar electrical appliances - Part 2: Particular requirements for
electric pumps for liquids having a temperature not exceeding 35 C.

EN 60335-2-51: 1997, Safety of household and similar electrical appliances - Part 2: Particular requirements for
stationary circulation pumps of heating and service water installations.

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BS EN 12162:2001+A1:2009
EN 12162:2001+A1:2009 (E)

3 Terms and definitions

For the purposes of this standard, EN 12723:2000 and the following definition apply:

"Item" or "items to be tested"

any part, component, sub-assembly, pump or pump units which is to be the subject of hydrostatic pressure test1)

4 General
4.1 All pressure containing items shall be hydrostatically pressure tested. The purpose of this hydrostatic test is
to demonstrate the absence of leakage through pressure containing walls of any item under test and from the joints
formed by an assembly of items under test, by imposing a defined pressure in excess of the allowable working
pressure for which the item is supplied.

4.2 This test procedure shall be applied to a sampling programme only where the manufacturer can show the
validity of the sampling programme and that it is appropriate for the application.

An example of a sampling programme is given in annex A.

4.3 Pumps with double volutes, multiple stages, and otherwise with internal separating walls and to be tested
segmentally shall have a hydrostatic pressure applied to each segment related to the operating conditions in the
segment when the pump is working at its allowable working pressure.

4.4 Pressure containing chambers which function independently shall be tested separately without pressure
being applied to any adjacent chamber.

4.5 To avoid excessive loads on crank-shafts in multiplex reciprocating pump assemblies those elements in the
suction stage of the cycle shall be supported or disconnected from the crank-shaft.

5 Timing of the test

The manufacturer shall allow sufficient time during manufacture for the test and examination of all items within the
scope of this standard. The test may be carried out on an individual item or on a sub-assembly as a group of items.
Normally, the hydrostatic test is carried out :

after completion of machining ;

prior to the application of coatings, insulation, and overlays, (protection of raw parts against rust shall not be
considered as a coating) ;

following non-destructive testing, or after special leak tests below a gauge pressure of 0,5 bar

on reciprocating positive displacement pumps, at the start of the performance test of the fully assembled
pump.

1) A rotating mechanical seal assembled into a pump or into a separate sub-assembly, together with an end plate to connect the
stationary elements of the seal to the stationary parts of the pump, will not be considered as an item to be tested but may be
subjected to the test pressure.
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 BS EN 12162:2001+A1:2009
EN 12162:2001+A1:2009 (E)

6 Preparation for testing

6.1 Items to be subjected to test shall be free from grease, oil and other contaminants, and any cleaner used
shall be compatible with the materials of manufacture of the pump, its auxiliaries, and its intended use.

6.2 The items to be tested are to be assembled for the test and all openings are to be blanked-off by appropriate
means which may include blind flanges, plugs, closures and tension rings. Care shall be taken in selecting the
closure arrangements not to impose forces capable of distorting the items under test nor of otherwise obscuring
any leak. Through bolting shall not be used unless it is part of the construction of the item being tested.

6.3 The item to be tested and the gauge lines are to be vented and filled completely with the test liquid.

6.4 Wherever feasible the mating parts and fasteners used in any assembly shall be those to be used in the
delivered pump, otherwise reasons for deviating from this requirement shall be recorded.

7 Test equipment
7.1 The test equipment shall comprise a device for generating the test pressure using a test liquid defined in
clause 8.1, the item to be tested prepared in accordance with clause 6, and a pressure indicating device.

NOTE The device generating the test pressure may be the pump under test.

7.2 The hydrostatic test shall be carried out with calibrated pressure gauges. The pressure indicating device
selected shall be accurate to within 1,5 % of the reading at the test pressure. The reference point for the pressure
shall be the lowest point of the item to be tested. The applied test pressure shall be uniformly distributed within the
item being tested.

8 Test liquid
8.1 The hydrostatic test is normally to be carried out using clean water at ambient temperature, with the addition
of corrosion preventative and organic growth inhibitors where necessary. If the properties of the material imposes a
limit on the test temperature which affects the test procedure this is to be noted on the test record.

8.2 An alternative liquid shall be used where clean water is not appropriate for the application. The liquid used
and the reason for its selection shall be recorded.

Where residual chloride deposition is not acceptable for the application, the chloride content of the test liquid shall
not exceed 50 ppm (0,005 %).

9 Test pressure
9.1 The hydrostatic test pressure relates to the allowable working pressure at ambient temperature of the items
to be tested. Where the items to be tested are to be offered for general application the test pressure shall relate to
their maximum allowable working pressure.

9.2 The hydrostatic test pressure shall be calculated from the formula:

Ptest = K 1 K 2 Pallw

where

p test is the hydrostatic test pressure ;

p allw is the allowable working pressure at operating temperature ;

K1 is a factor whose value shall be determined by the pump specification, but shall not be less than 1,3 ;
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BS EN 12162:2001+A1:2009
EN 12162:2001+A1:2009 (E)

K2 is a factor whose value shall be determined by the material strength

allowable stress at ambient temperature

=
allowable stress at operating temperature

10 Test procedure
10.1 At the start of the hydrostatic pressure test the external walls of the item to be tested shall be dry.

10.2 Prior to applying the test pressure the arrangements used to seal the chambers to be pressurised shall be
inspected for proper bolting and enclosure.

10.3 The hydrostatic pressure shall be steadily increased in a controlled manner until the test pressure is
achieved. The test pressure shall be held essentially constant for the full duration of the test period. Throughout this
procedure continuous observation shall be maintained to detect any leakage.

10.4 The test pressure shall be maintained for a sufficient time to allow the item being tested to be completely
inspected. This will normally be not less than 60 s.

Longer periods will be necessary for large, heavy castings, and for those made from forgings or welded
construction. These longer periods shall be determined by the pump specification or as otherwise set out in table 1
below.

Table 1 - Longer test periods

Items to be tested Test duration

in min.
Rotodynamic pumps
pumps rated above 25 bar 30

pumps rated above 10 bar and not above 25 bar 10

pumps rated up to 10 bar 5

Rotary positive displacement pumps 10

Reciprocating positive displacement pumps 10
Cooling passages 10
Cooling jackets for bearings, shaft seals, pedestals oil
coolers, shaft seal coolers and cooling coils

Heating jackets

10.5 If the item to be tested is a completely assembled pump or pump unit, checks shall be made to ensure that
excessive stresses are not created on the shaft seal or on the rod seal and the results of the checks recorded.

10.6 At the end of the test duration the sudden release of the test liquid shall be avoided.

10.7 If necessary, the tested item shall be completely drained of test liquid and thoroughly washed and carefully
dried. When using oil as the test liquid, drying is not usually required.

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 BS EN 12162:2001+A1:2009
EN 12162:2001+A1:2009 (E)

When residual chloride deposition is not acceptable, washing shall be by de-ionised or distilled water and
evaporative drying should be avoided. Any other special cleaning requirements applied to the item being tested
shall be examined for additional hazards and appropriate measures taken to reduce them. The results of the
examination shall be recorded.

11 Acceptance criteria
11.1 The integrity of the item under test is to be regarded as satisfactory if during the test period there are no
visible signs of leakage.

11.2 Leakage through shaft or rod packing, through temporary gaskets or through internal test partitions required
for segmental hydrostatic testing, is acceptable.

12 Repairs
If the acceptance criteria stated in clause 11 are not met the cause shall be identified and the manufacturer shall
either safely dispose of the item tested or apply suitable corrections. After correction, the hydrostatic test shall be
repeated. The methods of correction and any changes to the design shall be recorded.

13 Test Records

13.1 The manufacturer shall keep a record of the test and its results. The record shall contain:

identification of the item tested ;

details of the test including the liquid used, the test pressure, and the test result ;

any corrective actions applied including changes to the design ;

other information required by this standard to be recorded.

13.2 Test certificate

If required by the purchaser a test certificate may be made available. The test certificate shall certify that the
hydrostatic test was carried out in accordance with this Standard, and that the test item met the acceptance criteria.
Where a sampling programme is used the certificate shall include a reference to the quality grade of the test lot.

Annex A gives an example of random sample schedule.

13.3 Test report

If required by the purchaser, the manufacturer/supplier may supply a report of the hydrostatic test, which shall
indicate at least the following information:

identification of the pump ;

type and characterising data (eg. dimensions) of the item tested ;

list of any modifications made to the design ;

applicable test-, quality-, supply-standard ;

type of test liquid ;

test pressure ;

test duration ;
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BS EN 12162:2001+A1:2009
EN 12162:2001+A1:2009 (E)

result of the test ;

date when the test was carried out ;

signature of the inspector or test controller.

Each item subject to a test report shall be marked uniquely for identification.

In the case of a witnessed test, the acceptance of an item or its release for further manufacturing steps shall be
confirmed by the signature of the purchaser's representative.

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 BS EN 12162:2001+A1:2009
EN 12162:2001+A1:2009 (E)

Annex A
(informative)

Random sample schedule

This annex provides an example of a statistically based sampling programme for the selection and assessment of
test items for series or mass-produced pumps, as allowed in clause 3. It is based upon ISO 2859-1. The
programme relates the size of the test lot to the size of the production lot or batch being considered and relates the
permitted incidence of defects to a quality grade.

Defects are defined as deviations from permitted tolerances but not sufficiently so as to permit the delivery of
unsafe products.

A.1 Selection of quality grade

The selection of the appropriate quality grade is made on the basis of the assessed risks of hazards to safety which
relate to the integrity of the pressure retaining walls and joints. Quality Grade 1 may be considered adequate for
pumps handling noxious but non-toxic or flammable liquids and is likely to be selected for pumps supplied for most
industrial uses. Similarly, Quality Grade 3 may be considered adequate for a pump which is intended for decorative
water display.

The Acceptable Quality Limit is defined as the average incidence of defects in a batch. The sampling numbers in
Table A.1 give a 95 % probability that the sample represents the entire batch. But it is not certainty, and there
remains a calculable possibility that the batch may have a higher defect rate than the AQL. Values of these
probabilities against actual defect rates can be found from ISO 2859-1.

A.2 Formation of a test-lot

A production lot or batch from which the samples are to be chosen for testing shall comprise only such items which
have been manufactured under the same processes and to the same state of manufacture. A sample of one or
more items must be taken at random from the lot, without regard to their quality. The random sample must be
representative of the entire lot. It must be selected in such a way that each item or unit is given the same probability
of being chosen.

The number chosen shall conform to Table A.1 below, and will form the test lot.

A.3 Acceptance and rejection

The acceptance or rejection of a production lot or batch shall be made on the basis of the number of defective
items found in the test lot as set out in Table A.1 below.

Each defective item recognised in the test shall be discarded. This is independent of the decision regarding
whether the lot is or is not accepted. Discarded items can be repaired or otherwise corrected and then shall be
retested prior to being accepted.

A.4 Symbols
N the number of units making up the production lot, batch or group which are to be assessed for acceptance ;

n the number of units selected from the production lot or batch which make up the test lot and are tested ;

c the maximum number of defective units permitted in a test lot to permit acceptance of the production lot or
batch.

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BS EN 12162:2001+A1:2009
EN 12162:2001+A1:2009 (E)

Table A.1 - Quality grade

Quality Grade 1 2 3
Acceptable Quality Limit 0,1 % 1,0 % 2,5 %
N n c n c n c
2 to 8 N 0 N 0 5*) 0
9 to 15 N 0 N 0 5 0
16 to 25 N 0 13 0 5 0
26 to 50 N 0 13 0 5 0
51 to 90 N 0 13 0 20 1
91 to 150 125a 0 13 0 20 1
151 to 280 125 0 50 1 32 2
281 to 500 125 0 50 1 50 3
501 to 1200 125 0 80 2 80 5
1200 to 10000 125 0 150 5 150 10
a Test lot is the number shown or N whichever is the lesser.

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 BS EN 12162:2001+A1:2009
EN 12162:2001+A1:2009 (E)

Annex ZA
(informative)

!Relationship between this European Standard and the Essential

Requirements of EU Directive 98/37/CE

This European Standard has been prepared under a mandate given to CEN by the European Commission and the
European Free Trade Association to provide a means of conforming to Essential Requirements of the New
Approach Directive Machinery 98/37/EC, amended by 98/79/EC

Once this standard is cited in the Official Journal of the European Communities under that Directive and has been
implemented as a national standard in at least one Member State, compliance with the normative clauses of this
standard, except clauses 13.2 and 13.3, confers, within the limits of the scope of this standard, a presumption of
conformity with the Essential Requirements 1.3.2 and 1.5.13 of that Directive and associated EFTA regulations.

WARNING Other requirements and other EU Directives may be applicable to the product(s) falling within the
scope of this standard."

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BS EN 12162:2001+A1:2009
EN 12162:2001+A1:2009 (E)

Annex ZB
(informative)

!Relationship between this European Standard and the Essential

Requirements of EU Directive 2006/42/EC

This European Standard has been prepared under a mandate given to CEN by the European Commission and the
European Free Trade Association to provide a means of conforming to Essential Requirements of the New
Approach Directive 2006/42/EC on machinery

Once this standard is cited in the Official Journal of the European Communities under that Directive and has been
implemented as a national standard in at least one Member State, compliance with the normative clauses of this
standard, except clauses 13.2 and 13.3, confers, within the limits of the scope of this standard, a presumption of
conformity with the Essential Requirements 1.3.2 and 1.5.13 of that Directive and associated EFTA regulations.

WARNING Other requirements and other EU Directives may be applicable to the product(s) falling within the
scope of this standard."

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 BS EN 12162:2001+A1:2009
EN 12162:2001+A1:2009 (E)

Bibliography

[1] ISO 2859-1:1989, Sampling procedures and tables for inspection by attributes Part 1: Sampling plans
indexed by acceptable quality level (AQL) for lot-by-lot inspection.

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BS EN
12162:2001
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