Prepared By: Yoganandhan Loganathan
[email protected]
Notes on Pressure Testing in Piping Systems
Pressure testing is a crucial step in verifying the integrity and safety of piping systems before they
are put into operation. It involves subjecting the pipes to a specified pressure to detect leaks,
weaknesses, or defects in welds, joints, and fittings.
1. Objectives of Pressure Testing
Pressure testing serves multiple functions, including:
• Verification of structural integrity: Ensuring that the piping system can withstand
operating pressures.
• Leak detection: Identifying leaks or weak points before commissioning.
• Compliance with industry standards: Confirming that the system meets ASME B31.3,
ASME PCC-2, and other applicable codes.
• Quality control: Ensuring proper fabrication, welding, and assembly before plant start-
up.
2. Types of Pressure Tests
Different types of pressure tests are used depending on the piping system, fluid type, and
operational requirements.
2.1 Hydrostatic Test (H)
Definition: Uses water or another incompressible liquid to pressurize the system.
Purpose: Tests the pipe’s mechanical strength and checks for leaks.
Test Pressure:
o Typically, 1.5 times the design pressure for ASME B31.3 systems.
o Stress in components during the test is limited to 90% of the yield strength.
Process:
o System is filled with water.
o Air is vented from high points to avoid pressure surges.
o Pressure is increased gradually and held for a defined period.
o Leaks and pressure drops are monitored.
Advantages:
o Safer than pneumatic testing.
o Water is incompressible, reducing the risk of explosion.
Disadvantages:
o Cannot be used in piping for sensitive service.
o Requires thorough drying for systems that handle gases.
Prepared By: Yoganandhan Loganathan
[email protected]2.2 Pneumatic Test (P)
Definition: Uses compressed gas (air, nitrogen, or helium) to check for leaks.
Purpose: Used when water cannot be used (e.g., systems handling dry gases or steam).
Test Pressure:
o 1.1 times the design pressure per ASME B31.3.
o Stored energy calculations must be performed per ASME PCC-2.
Process:
o System is gradually pressurized in steps.
o Pressure is held for a set duration.
o Leak detection is performed using soap bubble tests or ultrasonic sensors.
Safety Precautions:
o Requires strict risk assessment due to the high stored energy.
o Minimum safe distance must be calculated using ASME PCC-2 formulas.
o Pneumatic Testing should not be permitted for the following piping material:
▪ Brittle material (e.g., cast iron)
▪ Plastic not specified for compressed gas service.
Advantages:
o Suitable for systems that cannot tolerate liquid testing.
o Detects small leaks effectively.
Disadvantages:
o High risk of rupture and explosion.
o Requires detailed hazard analysis.
2.3 Service Leak Test (F)
Definition: Conducted using the actual process fluid under normal operating conditions.
Purpose: Used for Category D fluids (low-pressure, non-hazardous services).
Test Pressure: Normal operating pressure.
Process:
o The system is put into operation.
o Leaks are visually inspected.
Prepared By: Yoganandhan Loganathan
[email protected] Advantages:
o Simple and cost-effective.
o No additional test medium required.
Disadvantages:
o Cannot detect potential weaknesses under higher pressures.
2.4 Sensitive Leak Test (B)
Definition: Uses specialized gas detection techniques to locate very small leaks.
Purpose: Applied in Category M fluid service (toxic, hazardous, or highly reactive
chemicals).
Process:
o A tracer gas (helium, hydrogen, or halogen) is introduced.
o Gas detectors identify leaks.
Advantages:
o Can detect minute leaks that hydrostatic and pneumatic tests may miss.
Disadvantages:
o Requires specialized equipment.
o High cost.
2.5 Alternative Leak Test (A)
Definition: Used when standard hydrostatic or pneumatic tests are impractical.
Includes:
o Vacuum box testing: Detects leaks in welds using soap solutions.
o Pressure decay testing: Measures pressure drop over time.
o Acoustic emission testing: Identifies leaks through sound waves.
2.6 Special Hydrostatic Tests (H1, H2, etc.)
Used for:
o Stainless steel pipes requiring deionized water (low chloride content).
o High-pressure systems requiring customized testing conditions.
Prepared By: Yoganandhan Loganathan
[email protected]3. Preparation for Pressure Testing
3.1 Documentation & Planning
• Define test loops and boundaries.
• Identify test pressure, medium, and duration.
• Confirm system cleanliness and readiness.
• Secure client/owner approval for testing plans.
3.2 Pre-Test Inspection
• Verify that fabrication, welding, and assembly are complete.
• Ensure that:
o All valves and fittings are properly installed.
o Pressure-relief valves and instruments are removed or isolated.
o Flange bolts are tightened to correct torque values.
3.3 System Cleaning & Flushing
• Remove debris, welding slag, and contaminants.
• Use filtered water (<50 ppm chloride for stainless steel piping).
3.4 Safety Precautions
• Temporary supports must be installed for hydrostatic testing.
• Pressure gauges & recorders:
o Calibrated within 2% of the full-scale reading.
o At least one gauge per test section.
• Personnel Safety Measures:
o Define exclusion zones for pneumatic tests based on ASME PCC-2.
o Ensure emergency depressurization methods are available.
4. Pressure Testing Procedure
4.1 Hydrostatic Testing
1. Filling the System:
o Fill from the lowest point to remove air.
o Open high-point vents to purge trapped air.
2. Pressurization:
o Increase to 50% of test pressure and check for leaks.
o Gradually raise to 100% test pressure and hold.
Prepared By: Yoganandhan Loganathan
[email protected] 3. Leak Inspection:
o Inspect welds, flanges, and fittings visually.
o Acceptable if no pressure drop occurs.
4. Depressurization & Draining:
o Release pressure slowly to prevent water hammer.
o Drain system completely and dry if required.
4.2 Pneumatic Testing
1. Gradual pressurization in steps (25%, 50%, 75%, and full pressure).
2. Hold pressure and inspect for leaks (soap bubble, ultrasonic methods).
3. Controlled depressurization to avoid sudden energy release.
5. Post-Test Requirements
• Document test results including any defects or repairs.
• Remove test blinds and restore system configuration.
• Ensure system is completely drained and dried if required.
6. Special Considerations for Pneumatic Testing
• Stored Energy Calculation (ASME PCC-2):
o E = 360 × P × V × (1 - (Pa/P)^0.286) (for air/nitrogen tests).
• Safe Distance Requirements:
o Minimum 30 m for energy ≤ 135,500,000 J.
• Risk Evaluation:
o Use ultrasonic or radiographic testing before pneumatic testing to ensure weld
integrity.
7. Conclusion
Pressure testing is a mandatory quality control step in piping systems. Adhering to ASME B31.3
and PCC-2 ensures that the system is safe, leak-free, and ready for operation.
8. Reference
– ASME B16.5 – Pipe Flanges and Flanged Fittings
– ASME B31.3 – Process Piping (Code)
– ASME PCC-2 – Repair of Pressure Equipment and Piping
– PIP PNE00012 - Piping Examination and Leak Test Guide
– PIP PNSC0021 – Leak Testing of Piping Systems
