Draft; Rev. F; 01-18-2004 For Committee Use Only AS ! "ost Constr#$tion S#%$ommittee Re&air an' (estin) Steven C.

. Ro%erts *yon'ell C+emi$al Com&any "O ,o- .0 C+annelvie/0 (1 223.0 281-842-3418 steven.ro%erts5lyon'ell.$om

ARTICLE PCC 2-2.X XX PRESSURE AND TIGHTNESS TESTING OF PIPING AND EQUIPMENT 1. 2. 3. 4. 5. 6. 7. #. $. 1&. 11. Description Limitations Definitions Planning Selection Pressure Test General !"rostatic Test Pneumatic Test Tig%tness Test Proce"ures Documentation Guide for Se e!"io# of Re$%ir Te!&#i'ue

Local 'all t%inning

Pitting

crac*s)ircumferential

Gouges

(listers

Laminations

Pressure Testing

General 'all t%inning

Longitu"inal crac*s

,omenclature/ 0 1 Generall! appropriate S 1 2lt%oug% ma! 3e accepta3le4 is not generall! use" for t%is con"ition 5 1 6a! 3e use"4 3ut re7uires special cautions , 1 ,ot generall! appropriate

Page 1

+t%er -1.

,otes/ -1. T%is met%o" ma! appl! to most met%o"s of repair.

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Draft; Rev F; 01-18-2004 For Committee Use Only

PRESSURE AND TIGHTNESS TESTING OF PIPING AND EQUIPMENT (.

1.1

De)!ri$"io#
T%e purpose of t%is gui"eline is to pro8i"e an eas! reference to t%e user in "etermining t%e t!pe of test4 t%e test pressure4 an" t%e proce"ure for pressure an" tig%tness testing of pressure e7uipment4 inclu"ing tu3ular %eat e9c%angers4 pressure 8essels4 furnace:3oiler tu3es4 an" process an" utilit! piping.

2.
2.1 2.2 2.3

Li*i"%"io#)
Section ; of Re&air of "ress#re !6#i&ment an' "i&in) contains a""itional re7uirements an" limitations. T%is article s%all 3e use" in con<unction 'it% Section ;. T%is article is "e8elope" for fiel" pressure or tig%tness testing of t%e e9isting e7uipment an" piping using eit%er of t%e t'o flui" me"iums4 li7ui" or gas. T%is article "oes not co8er 8acuum testing of e7uipment or piping.

+.
3.1 3.2

Defi#i"io#)
!"rostatic test/ 2 pressure or tig%tness test '%ere li7ui"4 t!picall! 'ater4 is t%e test me"ium. Pneumatic Test/ 2 pressure or tig%tness test '%ere a gas4 generall! nitrogen or air4 is t%e test me"ium. P#eu*%"i! "e)"i#, i) $o"e#"i% - &%.%rdou) 4 t%erefore all reasona3le alternati8es s%all 3e consi"ere" 3efore t%is option is selecte". Pressure Test/ 2 non"estructi8e test performe" to ensure t%e gross integrit! of t%e pressure component on ne' pressure e7uipment4 or on pre8iousl! manufacture" pressure an" piping e7uipment t%at %as or is in ser8ice an" t%at %as un"ergone an alteration or repair to its pressure 3oun"ar!-s. to ensure t%e gross integrit! of t%e pressure component to t%e original )o"e of )onstruction. Tig%tness Test/ 2 non"estructi8e test t%at is performe" to ensure o8erall lea* tig%tness of t%e s!stem or its connections 3efore t%e process me"ium is intro"uce".

3.3

3.4

/
4.1 4.1.1

Pre))ure Te)" P %##i#, Co#)ider%"io#)

H-dro)"%"i! $re))ure "e)" of $re))ure 0e))e ) or $i$i#, )-)"e*) T%e inspection recor"s s%oul" 3e re8ie'e" prior to testing to "etermine if t%e pressure component : s!stem %as e9perience" a cre"i3le "eterioration mec%anism. )onsi"eration s%oul" 3e gi8en to %o' eac% mec%anism coul" manifest itself. T%e inspection recor"s s%oul" 3e re8ie'e" for t%inning 3e!on" t%e specifie" limit. ;f t%inning %as occurre" 3e!on" t%e specifie" corrosion allo'ance4 an engineering e8aluation s%oul" 3e performe" using current inspection "ata. T%e material use" for t%e piping s!stem ma! %a8e 3een su3<ecte" to "eterioration "ue to temperature or process e9posure. =323.4 of 2S6> (31.3 pro8i"es consi"erations for potential "amage mec%anisms to consi"er. ;f e8i"ence of "amage

4.1.1.1

4.1.1.2

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Draft; Rev F; 01-18-2004 For Committee Use Only

is foun" 3! inspection4 an engineering e8aluation s%oul" 3e performe" using current inspection "ata. 4.1.1.3 T%e component : s!stem ma! %a8e 3een "amage" 3! mec%anical means suc% as %ig% 8i3ration. )onsi"eration s%oul" 3e gi8en to inspecting t%e entire s!stem prior to testing to loo* for e8i"ence of "amage. T%e temperature of t%e metal "uring t%e pressure test of pressure 8essels s%oul" 3e maintaine" at a minimum of 16.7? ) -3&? =. a3o8e t%e minimum "esign metal temperature -6D6T. as s%o'n on t%e 6anufacturer@s Data 5eport to re"uce t%e ris* of 3rittle fracture "uring t%e test. ;f t%e 6D6T is un*no'n4 t%e minimum allo'a3le metal temperature -626T. s%oul" 3e "etermine" using a fitnessAforAser8ice e8aluation. ;f t%e 8essel %as 3een su3<ecte" to temper em3rittlement "ue to postA'el" %eat treatment or ser8ice temperatures o8er 37&B ) -7&&B =.4 t%e pressure use" for t%e pressure test ma! nee" to 3e "etermine" 3! a fitnessAforAser8ice e8aluation. C%en pressure testing piping s!stems4 t%e am3ient temperature s%oul" 3e greater t%an 1.7? ) -35? =. an" t%e metal temperature s%oul" 3e *ept a3o8e t%e "uctileA 3rittle transition temperature. =or pressure testing "uring col"er temperatures4 consi"er t%e use of an antifreeDe solution as t%e test me"ium. T%e 8essel an" its supports an" t%e foun"ation an":or t%e piping s!stem an" its supports an" support structures s%oul" 3e e8aluate" to "etermine if t%e! 'ill a"e7uatel! support t%e 'eig%t of t%e test me"ium. Pressure gauges use" for recor"ing test pressures s%oul" 3e cali3rate" an" locate" at t%e %ig%est point on t%e 8essel or at all %ig% points on t%e piping s!stem. T%e gauges s%oul" meet t%e re7uirements of 2S6> PT) 1$.2 or similar gauge performance stan"ar". Eents s%all 3e pro8i"e" at t%e %ig% point of t%e 8essel an":or piping s!stem to purge air from t%e teste" component '%ile it is 3eing fille". T%e 8essel or piping s!stem s%all 3e e8aluate" for components t%at 'ill not 'it%stan" or 'ill interfere 'it% a pressure test. >9amples of t%ese components inclu"e orifice plates4 flo' noDDles4 control 8al8es4 etc. 2n e8aluation for t%e nee" of o8erpressure relief "e8ices s%all 3e performe". )onsi"eration s%all 3e gi8en to "isposal of t%e test 'ater as t%ere ma! 3e resi"ual contamination of process c%emicals.

4.1.2

4.1.2.1 4.1.2.2

4.1.3

4.1.4

4.1.5

4.1.6 4.1.7

4.1.# 4.1.$

4.1.1& Pressure testing s%oul" 3e complete" prior to insulating. Cel"s or ot%er <oints t%at %a8e pre8iousl! 3een pressure teste" ma! 3e insulate" or ot%er'ise co8ere" '%en permitte" 3! t%e original )o"e of )onstruction an" agree" to 3! all parties in8ol8e". 4.1.11 ;t is not re7uire" for t%e inspector to 3e certifie" per S,TAT)A12 for Lea* Testing or Eisual >9aminationF %o'e8er4 t%e inspector s%oul" %a8e t%e aut%orit! to stop a pressure test '%en "eeme" necessar! to "o so. De"icate" lines of communication

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Draft; Rev F; 01-18-2004 For Committee Use Only

s%oul" 3e in place 3et'een t%e inspector %a8ing o8ersig%t aut%orit! an" all ot%er personnel performing t%e pressure test. 4.2 4.2.1 P#eu*%"i! $re))ure "e)" of $re))ure 0e))e ) or $i$i#, ,itrogen is t%e preferre" test me"ium. 2lternati8el!4 clean4 "r!4 oilAfree air meeting t%e re7uirements of )lass 14 2 or 3 air per ;S+ #573A1/2&&14 )ompresse" 2ir Part 1/ )ontaminants an" Purit! )lasses4 s%oul" 3e use" 'it% a "e' point ranging from A2&B) to A7&B) -A4B= to A$4B=.. 2ir s%oul" not 3e use" in an! s!stem t%at cannot 3e 8erifie" as 3eing free of %!"rocar3ons since t%is coul" result in t%e formation of an e9plosi8e mi9ture. T%e inspection recor"s s%oul" 3e re8ie'e" prior to testing to "etermine if t%e pressure component : s!stem %as e9perience" a cre"i3le "eterioration mec%anism. )onsi"eration s%oul" 3e gi8en to %o' eac% mec%anism coul" manifest itself. T%e inspection recor"s s%oul" 3e re8ie'e" for t%inning 3e!on" t%e specifie" limit. ;f t%inning %as occurre" 3e!on" t%e specifie" corrosion allo'ance4 an engineering e8aluation s%oul" 3e performe". T%e component : s!stem ma! %a8e 3een "amage" 3! mec%anical means suc% as %ig% 8i3ration. )onsi"eration s%oul" 3e gi8en to inspecting t%e entire s!stem prior to testing to loo* for e8i"ence of "amage. )omponents fa3ricate" from materials suc% as cast iron an" "uctile iron s%oul" not 3e pneumaticall! pressure teste". T%e ma9imum calculate" store" energ! of an! 8essel or piping s!stem 3eing pneumaticall! pressure teste" s%oul" not 3e greater t%an 2714&&&4&&& G -2&&4&&&4&&& ftAl3s.. ;f t%e 8alue as calculate" 3! t%e e7uations of 2ppen"i9 2 is greater t%an t%is4 t%en a "etaile" %aDar" anal!sis s%oul" 3e performe" to e8aluate t%e ris* associate" 'it% t%e store" energ!. =actors to consi"er in t%is anal!sis s%oul" inclu"e/ Pressure 'a8e from potential 3last. SiDe of fragments resulting from failure of s!stem an" "istance of tra8el. 2n! "eterioration mec%anisms i"entifie". T%e 6D6T of t%e s!stem4 an" its relati8e comparison to t%e test temperature. T%e stress le8el of t%e s!stem '%ile un"ergoing a test. T%e amount of nonA"estructi8e testing performe" on 'el"s '%ic% %a8e not pre8iousl! 3een su3<ecte" to a %!"rostatic or pneumatic pressure test.

4.2.2

4.2.2.1

4.2.2.2

4.2.3 4.2.4

4.2.4.1 4.2.4.2 4.2.4.3 4.2.4.4 4.2.4.5 4.2.4.6

4.2.4.7 +t%er simultaneous inspection met%o"s 3eing performe" "uring t%e pressure test suc% as 2coustic >mission -2>. testing. 4.2.4.# See 2ppen"i9 4 for consi"erations relati8e to ris* e8aluation.

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Draft; Rev F; 01-18-2004 For Committee Use Only

4.2.5

=or pressure tests '%ere t%e ris* is "etermine" to 3e unaccepta3le4 a limite" access area an" pressure control point s%oul" 3e esta3lis%e". T%is is to pre8ent in<ur! from potential missile fragments4 s%oc* 'a8es or ot%er conse7uences of an! pressuriDe" s!stem failure. T%e minimum "istance from t%e 3oun"ar! of t%is area to t%e pressuriDe" component s%oul" 3e calculate" accor"ing to t%e follo'ing proce"ure/ =or s!stems 'it% a store" energ! of 13545&&4&&& G -1&&4&&&4&&& ftAl3s. or less4 t%e minimum "istance from all points of t%e s!stem un"er pressure s%oul" 3e 3& m -1&& ft.. =or s!stems 'it% a store" energ! of greater t%an 13545&&4&&& G -1&&4&&&4&&& ftAl3s.4 t%e minimum "istance from all points un"er pressure s%oul" 3e 6& m -2&& ft.. C%en t%e spacing re7uirements of 4.2.5.1 or 4.2.5.2 are not a8aila3le4 2ppen"i9 3 ma! 3e reference" for alternati8e spacing. C%en t%e spacing re7uirements of 4.2.5.14 4.2.5.2 or 4.2.5.3 are not a8aila3le4 consi"eration s%oul" 3e gi8en to t%e "esign4 fa3rication an" installation of an alternati8e 3arrica"e capa3le of 'it%stan"ing t%e 3last of store" energ! 'it%in t%e s!stem. +8erpressure relief protection s%all 3e pro8i"e". T%e set pressure of a pressure relief "e8ice s%oul" 3e no more t%an t%e greater of/ T%e test pressure plus 7& *Pa -1& psi.4 or 11&H of t%e test pressure.

4.2.5.1

4.2.5.2 4.2.5.3 4.2.5.4

4.2.6 4.2.6.1 4.2.6.2

1
5.1

Te)" T-$e Se e!"io#

T%e re7uirement for pressure testing ma! 3e foun" in t%e applica3le post construction stan"ar"s or gui"elines4 or in applica3le )o"e of )onstruction. C%en not specificall! reference"4 refer to =igure 1 to "etermine t%e t!pe of test to 3e performe".

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Draft; Rev F; 01-18-2004 For Committee Use Only

S ta rt

D e f in e t % e s c o p e o f e 7 u ip m e n t : p ip in g to 3 e te s te "

P e rfo rm T ig % t n e s s T e s t

, o

; s , D > in lie u o f ! " r o s t a t ic P r e s s u r e T e s t a p p lic a 3 le I

, o

; s a T ig % t n e s s T e s t p e r m it t e " 3 ! + r ig in a l ) o " e o f ) o n s tr u c t io n I

0 es

a s a n 2 lt e r a t io n o r 5 e p a ir o c c u r e " to t% e p re s s u re 3 o u n " a r! I

, o

;s t% e p u rp o s e o f t% e t e s t t o c e r t if ! in t e g r it ! I

) a lc u la t e s t o r e " e n e rg ! a n " c o n s i" e r p n e u m a t ic p re s s u re te s t p e r S e c t io n 3 . 5

0 es 0 es

, o

, o

) a n t % e s ! s t e m s a f e l! s u p p o r t % ! " r o s ta tic te s t lo a " s I

, o

;s t% e s to r e " e n e rg ! p e r > 7 . -5 . g re a te r t% a n 2 7 1 4& & & 4& & & G - 2 & & 4& & & 4& & & f tA l3 s . I

0 es

0 es

C ill a % ! " r o s t a t ic t e s t r e s u lt in p r o c e s s c o n t a m in a t io n I

0 es

D e 8 e lo p s u 3 s t it u t io n f o r p re s s u re t e s t in g

0 es

, o ) a n t % e s ! s t e m 3 e s a f e l! te s te " a f te r c o n s i" e r a tio n o f a ll r is * s I

, o P e rfo rm ! " r o s ta t ic P re s s u re T e s t + 3 t a in <u r is " ic t io n a l a p p r o 8 a l if n e c e s s a r!

0 es

Fi,ure (

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Draft; Rev F; 01-18-2004 For Committee Use Only

2
6.1

Pre))ure Te)" Ge#er%

2 pressure test of e7uipment or a piping s!stem s%oul" 3e consi"ere" if an alteration or repair %as 3een performe"4 if t%e e7uipment %as 3een rerate"4 or it nee"s to 3e reAcertifie" to "etermine integrit!. 2 pressure test ma! not 3e re7uire" for rerating e7uipment using a %ig%er allo'a3le stress since t%e original pressure test coul" 3e %ig%er t%an t%e test pressure re7uire" for rerating. T%is ma! re7uire t%e appro8al of an 2ut%oriDe" ;nspector an":or t%e local <uris"iction. ;t is recommen"e" t%at t%e s%ellsi"e of tu3ular %eat e9c%angers 3e pressure teste" "uring routine inspections an" cleaning operations to 8erif! t%e integrit! of tu3eAtoA tu3es%eet <oints. =ollo'ing t%e completion of t%e pressure test4 t%e tu3es s%oul" 3e inspecte" for 3uc*ling '%ic% ma! %a8e occurre". See also Section $.1. Pressure testing s%oul" al'a!s 3e performe" %!"rostaticall! unless one of t%e follo'ing con"itions appl!/ T%e e7uipment4 piping an":or supports4 inclu"ing foun"ations4 cannot a"e7uatel! support t%e li7ui" 'eig%t. T%e e7uipment or piping cannot 3e "rie" for ser8ices '%ere traces of t%e test li7ui" are not tolerate". T%ere is an unaccepta3le ris* of 3rittle fracture occurring. T%e test 'oul" cause unaccepta3le "amage to an! internal linings. ;f a %!"rostatic test cannot 3e performe" per Section 6.44 t%en a pneumatic pressure test s%oul" 3e consi"ere". ;f a pneumatic pressure test 'oul" present unaccepta3le %aDar"s suc% as "anger of 3rittle fracture at t%e metal test temperature4 t%en a su3stitution for pressure testing s%oul" 3e "e8elope". T%e alternati8e test ma! re7uire t%e appro8al of an 2ut%oriDe" ;nspector an":or t%e local <uris"iction.

6.2

6.3

6.4 6.4.1 6.4.2 6.4.3 6.4.4 6.5 6.5.1

3
7.1

H-dro)"%"i! Te)"
T%e test pressure of a %!"rostatic pressure test of pressure 8essels or %eat e9c%angers s%all 3e accor"ing to t%e original )o"e of )onstruction consi"ering also an! su3se7uent engineering anal!sis as "eeme" necessar!. C%en t%e re7uirements of t%e original )o"e of )onstruction are not a8aila3le4 t%e test pressure for a %!"rostatic pressure test for pressure 8essels or %eat e9c%angers s%all 3e t%e lesser of 7.2.1 or 7.2.2/ Pt 1 1.3 9 P 9 Sat S"t -1.

7.2

7.2.1 '%ere

Pt is t%e test pressure to 3e use"4 measure" at t%e top of t%e 8essel in its normal operating position

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Draft; Rev F; 01-18-2004 For Committee Use Only

P is t%e ma9imum allo'a3le 'or*ing pressure from t%e 6anufacturer@s Data 5eport4 or t%e 8alue to '%ic% t%e 8essel is 3eing rerate" to Sat is t%e allo'a3le stress at test temperature from t%e applica3le )o"e of )onstruction S"t is t%e allo'a3le stress at "esign temperature from t%e applica3le )o"e of )onstruction 1.3 is t%e test factor 7.2.2 2 pressure e7ual to t%at '%ic% results in an applie" stress e7ual to $&H t%e specifie" minimum !iel" stress at test temperature of t%e material. 0iel" strengt%s '%ic% are not foun" in t%e applica3le )o"e of )onstruction ma! 3e foun" in 2S6> Section ;;4 Part D. T%e test pressure for a %!"rostatic pressure test for piping s!stems s%oul" 3e specifie" 3! t%e o'ner an" s%all 3e accor"ing to t%e original )o"e of )onstruction. C%en t%e re7uirements of t%e original )o"e of )onstruction are not a8aila3le4 t%e test pressure for a %!"rostatic pressure test for piping s!stems s%oul" 3e specifie" 3! t%e o'ner an" s%oul" 3e at least Pt 1 1.5 9 P 9 Sat S"t -2.

7.3 7.3.1

7.3.1.1 '%ere

Pt is t%e test pressure to 3e use"4 measure" at t%e top of t%e piping s!stem in its normal operating position P is t%e internal "esign pressure of t%e piping s!stem Sat is t%e allo'a3le stress at test temperature from t%e applica3le )o"e of )onstruction S"t is t%e allo'a3le stress at "esign temperature from t%e applica3le )o"e of )onstruction 1.5 is t%e test factor ;f t%e "esign pressure of t%e piping s!stem cannot 3e 8erifie"4 t%e 8alue for P in e7uation -2. ma! 3e t%e lesser of t%e follo'ing T%e ma9imum allo'a3le pressure at "esign temperature for flanges in t%e piping s!stem from 2S6> (16.5 or ot%er applica3le stan"ar". T%e ma9imum allo'a3le pressure calculate" for t%e limiting component of t%e piping s!stem. T%e test pressure s%oul" not e9cee" t%at '%ic% results in an applie" stress greater t%an 1&&H t%e specifie" minimum !iel" stress at test temperature of t%e material. 0iel" strengt%s at am3ient temperature ma! 3e foun" in 2S6> (31.3 or ot%er applica3le )o"e of )onstruction. 0iel" strengt%s at %ig%er temperatures ma! 3e foun" in 2S6> (JPE )o"e Section ;;4 Part D. Pressure testing of a piping s!stem t%roug% e7uipment is not recommen"e". Piping ma! 3e teste" 'it% a pressure 8essel if it is impractical to isolate t%e piping from t%e 8essel4 t%e test pressure of t%e piping is e7ual to or less t%an t%e test pressure of t%e 8essel an" t%e 8essel an" its supports 'ill a"e7uatel! support t%e 'eig%t of t%e test li7ui".

7.3.1.2 7.3.1.2.1 7.3.1.2.2 7.3.1.2.3

7.4

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Draft; Rev F; 01-18-2004 For Committee Use Only

7.4.1

;f t%e test pressure of t%e piping e9cee"s t%e test pressure of t%e 8essel4 t%e 8essel test pressure ma! 3e use" pro8i"e" it is at least 77H of t%e piping test pressureF ot%er'ise t%e piping s%oul" 3e isolate" from t%e pressure 8essel an" pressure teste" in"epen"entl!. Piping s!stems t%at operate at atmosp%eric pressure ma! 3e lea* teste" 3! filling 'it% test li7ui" onl!.

7.5

4
#.1

P#eu*%"i! Te)"
C%en a %!"rostatic pressure test cannot 3e performe" per Section 7 -see Section 6.4.4 a pneumatic pressure test ma! 3e performe". T%is ma! re7uire t%e appro8al of an 2ut%oriDe" ;nspector an":or 3! t%e local <uris"iction. T%e test pressure for a pneumatic pressure test for pressure 8essels or %eat e9c%angers s%all 3e accor"ing to t%e original )o"e of )onstruction. ;f t%e re7uirements of t%e original )o"e of )onstruction are not a8aila3le4 t%e test pressure for a pneumatic pressure test for pressure 8essels s%all 3e Pt 1 1.1 9 P 9 Sat S"t -3.

#.2 #.3 #.3.1 '%ere

Pt is t%e test pressure to 3e use" P is t%e ma9imum allo'a3le 'or*ing pressure from t%e 6anufacturer@s Data 5eport. ;f un*no'n4 use t%e 8essel@s "esign or rate" pressure. Sat is t%e allo'a3le stress at test temperature from t%e applica3le )o"e of )onstruction. S"t is t%e allo'a3le stress at "esign temperature from t%e applica3le )o"e of )onstruction 1.1 is t%e test factor T%e test pressure for a pneumatic pressure test for piping s!stems s%all 3e Pt 1 1.1 9 P Pt is t%e test pressure to 3e use" P is t%e internal "esign pressure of t%e piping s!stem 1.1 is t%e test factor T%e store" energ! of t%e e7uipment or piping s!stem un"er pneumatic pressure s%oul" 3e calculate" an" con8erte" to e7ui8alent poun" s of T,T -Trinitrotoluene. using t%e e7uations s%o'n in 2ppen"i9 2. T%e store" energ! 8alue of 2714&&&4&&& G -2&&4&&&4&&& ftAl3s. is e7ui8alent to an e9plosi8e energ! of 127 poun"s of T,T. -4.

#.4 #.4.1 '%ere

#.5

#.5.1

5
$.1

Ti,&"#e)) Te)"
2 tig%tness test is performe" to "etect lea*s at 8arious locations 'it%in a pressure s!stem. ;t ma! 3e performe" on s!stems t%at %a8e pre8iousl! 3een pressure teste"4

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Draft; Rev F; 01-18-2004 For Committee Use Only

for closure 'el"s of piping s!stems4 on tu3eAtoAtu3es%eet <oints an" on s!stems e9empte" from %!"rostatic or pneumatic testing. 2S6> Section E4 2rticle 1& pro8i"es information on a 8ariet! of lea* testing met%o"ologies. $.2 $.3 2 sensiti8e lea* test per (31.34 latest e"ition is t%e preferre" met%o" for con"ucting a tig%tness test. ;t is recommen"e" t%at t%e applie" test pressure for 8essels an" piping not e9cee" 4&H of t%e "esign pressure. o'e8er4 lea*age at flange" <oints ma! 3e e8i"ent at muc% lo'er pressures '%en using sensiti8e lea* "etection met%o"sF t%erefore4 it is recommen"e" t%at t%e minimum test pressure 3e specifie" '%ic% ena3les t%e test sensiti8it! re7uirements to 3e met.

(6
1&.1 1&.1.1 1&.1.2 1&.1.3 1&.1.4

Pro!edure)
T%e follo'ing items s%oul" 3e consi"ere" '%en "e8eloping %!"rostatic pressure test proce"ures for 8essels or piping s!stems/ 2ll e7uipment an":or piping to 3e teste" s%oul" 3e 8erifie" as 3eing clean of all "irt4 'el" slag4 construction "e3ris or ot%er unaccepta3le foreign matter. 5emo8e items i"entifie" in Section 4.1.7. 2ll spring supports in 8apor ser8ice lines s%oul" 3e protecte" 'it% a"e7uate tra8el stops to pre8ent o8erloa"ing "uring t%e pressure test. Temporar! supports s%oul" 3e pro8i"e" for piping an":or piping supports t%at %a8e not 3een "esigne" to support t%e 'eig%t of t%e test li7ui" use" for %!"rostatic pressure test. T%e use of salt or 3rac*is% 'ater s%oul" 3e a8oi"e". Test 'ater s%oul" 3e free from se"iment an" corrosi8e su3stances. T%e test 'ater s%oul" 3e 8erifie" to 3e free of micro3es. ;f an unaccepta3le le8el of micro3es is in t%e 'ater4 it s%oul" 3e "isinfecte". Test 'ater use" for austenitic steel 8essels or piping s!stems4 or for components cla" or o8erlai" 'it% austenitic stainless steel4 s%oul" 3e con"ensate4 "emineraliDe" or pota3le 7ualit! 'ater 'it% a 8erifie" c%lori"e content of less t%an 5& ppm. =ollo'ing a %ol"Atime of a minimum of 1& minutes4 t%e component-s. 3eing teste" s%oul" 3e 8isuall! e9amine" for e8i"ence of lea*s at locations suc% as flanges4 'el" <oints an" t%rea"e" connections. ;t is recommen"e" t%e pressure 3e re"uce" 3! 3&H for t%is e9amination. Test li7ui" s%oul" 3e "raine" imme"iatel! after completion of t%e %!"rostatic test. )are s%oul" 3e e9ercise" to pre8ent t%e creation of internal negati8e pressure -8acuum. "uring "raining. Pressure 8essels an":or piping s!stems t%at 'ill %ol" t%e test 'ater for more t%an ten -1&. "a!s4 '%et%er or not t%e test li7ui" is pressuriDe"4 s%oul" 3e treate" 'it% a corrosion in%i3itor an" 3ioci"e. 2 corrosion engineer s%oul" 3e consulte".

1&.1.5 1&.1.6 1&.1.7

1&.1.#

1&.1.$

1&.1.$.1

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Draft; Rev F; 01-18-2004 For Committee Use Only

1&.1.$.2 1&.1.$.3

;f furt%er "r!ing is necessar!4 t%e use of %ot air s%oul" 3e consi"ere". ;f complete "rainage of austenitic stainless steel 8essels an":or piping s!stems is not possi3le4 t%e components s%oul" 3e flus%e" 'it% lo' c%lori"e -less t%an 5 ppm. 'ater. 2fter completion of t%e test4 t%e 8essel an":or piping s!stem s%all 3e restore" to its operating con"ition. T%is inclu"es4 3ut is not limite" to4 t%e follo'ing/

1&.1.1&

1&.1.1&.1 2ll flange" <oints 3lin"e" for pressure testing s%all 3e reassem3le" 'it% ne' gas*ets an" tig%tene" per applica3le specifications. )onsi"eration s%oul" 3e gi8en to 2S6> P))A1 Gui"elines for Pressure (oun"ar! (olte" =lange Goint 2ssem3l!. 1&.1.1&.2 2ll strainers containe" in t%e piping s!stem s%oul" 3e remo8e"4 cleane" an" reinstalle". 1&.1.1&.3 Temporar! tra8el stops installe" in spring supports s%oul" 3e remo8e". 1&.1.1&.4 Eent an" 3lee" connections t%at 'ere installe" for testing purposes onl! s%oul" 3e plugge" using materials an" met%o"s per t%e applica3le specification. )onsi"eration s%all 3e gi8en to seal 'el"ing '%en necessar!. 1&.2 1&.2.1 1&.2.1.1 1&.2.1.2 1&.2.1.3 1&.2.1.4 1&.2.1.5 1&.2.2 1&.2.2.1 T%e follo'ing items s%oul" 3e consi"ere" '%en "e8eloping pneumatic pressure test proce"ures for 8essels or piping s!stems/ Step 1 5aise pressure to t%e lesser of 17& *Pa -25 psi. or 25H of test pressure. (loc* in suppl! an" %ol" for ten -1&. minutes. ;nspect s!stem for lea*s. ;f lea*s are "isco8ere"4 release pressure4 repair an" return to Step 1. ;f no lea*s are "isco8ere"4 procee" to Step 2. Step 2 Gra"uall! increase s!stem pressure to 5&H of t%e test pressure as follo's

1&.2.2.1.1 ;ncrease from pressure in Step 1 3! 35& *Pa -5& psi. or to 35H test pressure. ol" for minimum t%ree -3. minutes to allo' strains to e7ualiDe. )ontinue to increase 3! 35& *Pa -5& psi. increments until t%e s!stem pressure is at 5&H test pressure. 1&.2.2.1.2 ol" at 5&H test pressure for a minimum of ten -1&. minutes. +3ser8e pressure gage for loss of s!stem pressure. ;f pressure loss e9cee"s 1&H of test pressure4 t%e s!stem pressure s%oul" 3e re"uce" to t%at specifie" 3! Section 1&.2.2.1.1 an" c%ec* for lea*s.

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Draft; Rev F; 01-18-2004 For Committee Use Only

1&.2.2.1.3 ;f no loss of pressure is "etecte"4 su3<ect to appro8al of t%e inspector4 procee" to Step 3. 1&.2.3 1&.2.3.1 Step 3 Gra"uall! increase s!stem pressure in increments of 1&H of test pressure. 2t eac% increment4 3loc* suppl! an" o3ser8e pressure gage for fi8e -5. minutes.

1&.2.3.1.1 ;f pressure loss is o3ser8e"4 release pressure an" perform necessar! repairs. 5eturn to Step 1. 1&.2.3.2 1&.2.3.3 +nce full test pressure is reac%e"4 3loc* suppl! an" o3ser8e pressure gage for a minimum of one -1. minute. 5e"uce s!stem pressure to t%e follo'ing applica3le pressure

1&.2.3.3.1 T%e test pressure "i8i"e" 3! t%e test factor for 8essels4 -see >7uation 3.. ;f t%ere is no test factor a8aila3le4 use 4:5 test pressure4 or 1&.2.3.3.2 Design pressure for piping. 1&.2.4 1&.2.4.1 Step 4 )on"uct a complete inspection for lea*age of t%e 8essel an":or piping s!stem at locations suc% as flanges4 'el" <oints an" t%rea"e" connections. ,ote/ ;t is assume" t%at t%e integrit! of t%e pressuriDe" s!stem %as 3een pro8en 3! Section 1&.2.3.2 an" t%e 3arrica"es re7uire" 3! Section 4.2.5.4 can 3e safel! passe". ;f no lea*age is "isco8ere"4 release s!stem pressure. ;f lea*age t%at is not accepta3le is "isco8ere"4 relie8e all s!stem pressure an" repair. 5epeat Steps 2 an" 3. Step 5 2fter completion of t%e test4 t%e 8essel an":or piping s!stem s%all 3e restore" to its "esign con"ition. T%is inclu"es4 3ut is not limite" to4 t%e follo'ing/

1&.2.4.2 1&.2.4.3 1&.2.5 1&.2.5.1

1&.2.5.1.1 2ll flange" <oints 3lin"e" for pressure testing s%all 3e reassem3le" 'it% ne' gas*ets an" tig%tene" per applica3le specifications. )onsi"eration s%oul" 3e gi8e to 2S6> P))A1 gui"elines. 1&.2.5.1.2 Eent an" 3lee" connections t%at 'ere installe" for testing purposes onl! s%oul" 3e plugge" using materials an" met%o"s per t%e applica3le specification. )onsi"eration s%all 3e gi8en to seal 'el"ing '%en necessar!. 1&.3 1&.3.1 T%e follo'ing items s%oul" 3e consi"ere" '%en "e8eloping pneumatic tig%tness test proce"ures for 8essels or piping s!stems/ )lean4 "r!4 oil free air s%oul" 3e use" as t%e test me"ium4 e9cept in s!stems '%ic% cannot 3e 8erifie" as free from %!"rocar3ons. =or t%is situation4 nitrogen s%oul" 3e use" as t%e test me"ium4 -see 4.2.1..

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Draft; Rev F; 01-18-2004 For Committee Use Only

1&.3.2

To minimiDe t%e store" energ! of a s!stem4 t%e ma9imum test pressure s%oul" 3e no more t%an 4&H of t%e "esign pressure of t%e 8essel or piping s!stem. T%e test pressure s%oul" 3e no less t%an t%e lesser of 1&5 *Pa -15 psi. or 25H of t%e s!stem "esign pressure. T%e s!stem pressure s%oul" 3e gra"uall! increase" until t%e s!stem pressure is t%e lesser of 17& *Pa -25 psi. or 25H of t%e test pressure. ol" at t%is pressure long enoug% to con"uct a preliminar! inspection for lea*s. Gra"uall! increase s!stem pressure in increments of 1&H of test pressure4 %ol"ing for K to 1 minute at eac% increment. ol" at final test pressure an" complete a t%oroug% inspection for lea*age using t%e Gas an" (u33le test met%o" specifie" in 2S6> Section E4 2rticle 1&4 or ot%er met%o" of e7ual or 3etter sensiti8it!. ;f lea*age is "isco8ere" an" a <oint must 3e tig%tene"4 re"uce s!stem pressure to t%e lesser of 5&H of test pressure or 17& *Pa -25 psi. an" tig%ten. 2fter completion of t%e test4 t%e 8essel an":or piping s!stem must 3e restore" to its operating con"ition.

1&.3.3

1&.3.4

1&.3.4.1 1&.3.5

((
11.1

Do!u*e#"%"io#
2 pressure test recor" s%oul" 3e prepare" prior to t%e pressure test an" complete" upon acceptance of t%e test 3! t%e o'ner or t%e o'ner@s "esignate" representati8e. 2 sample recor" form is pro8i"e" in 2ppen"i9 1.

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Draft; Rev F; 01-18-2004 For Committee Use Only

2ppen"i9 1
PRESSURE 7 LEA8 TESTING
TEST RECORD Location: System / Test Number: Equipment Identification App icab e Code: !ydrostatic "neumatic Combination !ydro#"neumatic Test Type: Initia Ser$ice Lea% Ot&er 'specify( Test )edia: D+, / Re$- NoItem ID / Equip No- / Line NoReq*d Test "ressure: Standard / Specification Test .oundaries '"artia /rom:
Test On y(

Sensiti$e Lea%

To:

"re#Test Inspection C&ec% ist 'to be comp eted by Inspection Representati$e(

1 2 7 : 4 < = ? 15 11 Appro$ed test media source's( identified / ocated C& oride content of +ater $erified 3 45 ppm 'Stain ess 6 !i,& A oy Stee s( Items not to be sub8ected to test pressure &a$e been iso ated from test 'e-,-9 contro $a $es9 instruments9 be o+s9 etc-( Equipment / pipin, is proper y supported9 stops insta ed in sprin, supports . inds are proper si;e / t&ic%ness for pressure and correct y ocated / insta ed A de$iations to test procedures / codes / standards &a$e been appro$ed 6 copies of appro$a s attac&ed "ressure ,au,e / recorder ran,es are > 1-4 and 3 : times t&e req*d test pressure Required o$er#pressuri;ation protection de$ices &a$e been insta ed A required +e din, and NDE &as been comp eted Temperature of equipment 6 test media stabi i;ed 6 min- test temp- $erified

N/A

Satisfactory 'Initia /Date(

0nsatisfactory 'Initia /Date(

Date Tested: Ambient Temp: @au,e / Recorder Nos- 6 Ca ibration Due Dates: Actua Test "ressure: Test Accepted:

)eta Temp: Test Duration '!o d Time(:

AC Representati$e / Company Test System Drained / / us&ed 0pon Comp etion of Testin,:

O+ner Representati$e Not App icab e

/abricator Representati$e / Company Remar%s:

O+ner Representati$e

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Draft; Rev F; 01-18-2004 For Committee Use Only

2ppen"i9 2
Store' !ner)y Cal$#lations for "ne#mati$ "ress#re (est
T%e store" energ! of t%e e7uipment or piping s!stem s%oul" 3e calculate" an" con8erte" to e7ui8alent poun"s of T,T -Trinitrotoluene. using t%e follo'ing e7uations/ > 1 1:-*A1. 9 Pat 9 E 1 -Pa:Pat.L-*A1.:*M C%ere

-2A1.

> is t%e store" energ!4 Goules -ftAl3s. Pat is t%e a3solute test pressure Pa -psia. Pa is a3solute atmosp%eric pressure4 1&1 *Pa -14.7 psia. E is t%e total 8olume un"er test pressure4 63 -ft3. * is t%e ratio of specific %eat for t%e test flui"

C%en using air or nitrogen as t%e test me"ium -* 1 1.4.4 t%is e7uation 3ecomes > 1 2.5 9 Pat 9 E 1 -Pa:Pat.&.2#6 an" T,T 1 '%ere

-2A2.

> -*g. 45&&&&& > is t%e store" energ!4 Goules Pat is t%e a3solute test pressure Pa Pa is a3solute atmosp%eric pressure4 1&1&&& Pa E is t%e total 8olume un"er test pressure4 63

-2A3.

=or NS customar! units using air or nitrogen as t%e test me"ium -* 1 1.4.4 t%is e7uation 3ecomes > 1 36& 9 Pat 9 E 1 -Pa:Pat.&.2#6 an" T,T 1 C%ere > 156$$32 -l3s. -2A5.

-2A4.

> is t%e store" energ!4 ftAl3s Pat is t%e a3solute test pressure psia Pa is a3solute atmosp%eric pressure4 14.7 psia E is t%e total 8olume un"er test pressure4 ft3

See also Section 4.2.4 an" 4.2.5.

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Draft; Rev F; 01-18-2004 For Committee Use Only

2ppen"i9 3
Alternative Safe Distan$e Cal$#lations for "ne#mati$ "ress#re (est
To "etermine t%e potential effect of t%e actual "istance an o3<ect -or person. is from t%e e7uipment 3eing teste"4 a scale" "istance is calculate" using t%e follo'ing e7uation/ 5S)2L>D 1 C%ere 5 T,T 5S)2L>D 5 -T,T.1:3 1 actual "istance from e7uipment4 6 -ft. 1 >nerg! measure" in T,T4 *g -l3s.4 "etermine" from e7uations -2A3. or -2A5. 1 scale" factor to "etermine if "istance is safe

Nse Ta3le 3A1 to "etermine if actual "istance is enoug% to pro8i"e for safet!.
5S)2L>D -m:*g1:3. 5S)2L>D -ft:l31:3. (iological >ffect 2& 12 6 2 5& 3& 15 5 A Lung "amage 6ortalit! Structural =ailure Glass 'in"o's (ric* 'alls A

>ar"rum rupture )oncrete 3loc* panels

Ta3le 3A1 =or e9ample4 to pre8ent lung "amage4 t%e "istance a person is from t%e e7uipment s%oul" result in an 5S)2L>D 8alue of more t%an 6 m:*g1:3 -15 ft:l31:3.. ,ote t%e structural "amage t%at can occur4 '%ic% s%all 3e accounte" for.

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Draft; Rev F; 01-18-2004 For Committee Use Only

2ppen"i9 4
Ris7 !val#ation Consi'erations for "ne#mati$ "ress#re (est
C%en consi"ering t%e ris* anal!sis factors liste" in Section 4.2.44 it s%oul" 3e remem3ere" t%at ris* is a t'o "imensional com3ination of pro3a3ilit! -or li*eli%oo". an" conse7uence. 5is* is t%e measure of t%e potential for %arm or loss -i.e.4 %aDar". t%at reflects t%e li*eli%oo" -or fre7uenc!. an" se8erit! of an a"8erse effect to %ealt%4 propert!4 or t%e en8ironment. ;f pro3a3ilit! an" conse7uence are "efine" 7uantitati8el! -i.e. numerical 8alues are assigne".4 ris* is t%e pro"uct. 5is* 1 Pro3a3ilit! 9 )onse7uence -4A1.

;n a 7ualitati8e assessment4 a matri9 is t!picall! use" to com3ine pro3a3ilit! an" conse7uence. T%e "efinition of ris* can 3e 3ot% general an" insuranceArelate"/ 1. T%e c%ance of in<ur!4 "amage4 or lossF a "angerous c%anceF a %aDar" 2. ;n insurance -a. t%e c%ance of lossF -3. t%e "egree of pro3a3ilit! of lossF -c. t%e amount of possi3le loss of t%e insuring compan!F in full4 amo#nt at ris7F -". a person or t%ing 'it% reference to t%e ris* in8ol8e" in insuring %im or itF -e. t%e t!pe of loss t%at a polic! co8ers4 as life4 fire4 etc. to r#n 8or ta7e9 a ris7F to e9pose oneself to t%e c%ance of in<ur! or lossF to en"anger oneselfF to ta*e a c%ance. ;n re8ie'ing e7uation -4A1.4 it is clear t%at e8en t%oug% t%e conse7uence ma! 3e significant4 a 8er! lo' pro3a3ilit! e9ists4 t%us t%e ris* 3ecomes accepta3le. =or e9ample4 t%e conse7uence of an airliner cras%ing is significant in t%at it 'ill most li*el! result in serious in<ur! or "eat% to t%e passengers along 'it% ma<or "amage or total loss of t%e aircraft. o'e8er4 t%e pro3a3ilit! of t%e airliner cras%ing is 8er! lo'4 t%us4 t%e pu3lic accepts t%e ris* associate" 'it% airline tra8el. 5is* ma! 3e applie" to pneumatic testing also. >9amples ma! inclu"e/ 2 ne' austenitic stainless steel piping s!stem t%at %as 3een %!"rostaticall! teste" "uring s%op fa3rication 'it% t%e e9ception of four -4. final fiel" assem3l! circumferential 3utt 'el"s. T%e piping s!stem %as a total 8olume '%ic% results in an energ! le8el greater t%an 2714&&&4&&& G -2&&4&&&4&&& ftAl3s.F %o'e8er4 it is not feasi3le to separate t%e piping s!stem into smaller sections for testing4 nor is it feasi3le to install 3last 3arriers. (! performing 8olumetric e9amination suc% as NT or 5T an" "etermining t%e 'el"s are free of re<ecta3le in"ications4 t%e ris* associate" 'it% a full pneumatic pressure test of t%is s!stem ma! 3e "eeme" accepta3le. 2n e9isting car3on steel 8essel 'it% an 6D6T rating of A45B ) -A5&B =. into '%ic% a ne' noDDle %a" 3een installe" follo'ing all re7uirements of t%e original )o"e of )onstruction. T%e 8essel %as a total 8olume '%ic% results in an energ! le8el greater t%an 2714&&&4&&& G -2&&4&&&4&&& ftAl3s.F %o'e8er4 it is still "esire" to perform a pressure test to c%ec* t%e integrit! of t%e 'el" an" o3tain t%e ot%er 3enefits of pressure testing. ;t is not feasi3le to install 3last 3arriers. (! performing 8olumetric e9amination suc% as NT on t%e noDDle attac%ment 'el" an" "etermining t%e 'el" is free of re<ecta3le in"ications4 along 'it% 8erification 3! inspection t%at t%e 8essel is in a li*eAne' con"ition4 t%e ris* associate" 'it% a full pneumatic pressure test of t%is 8essel ma! 3e "eeme" accepta3le.

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