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7 Pressure Testing Code Requirements and Best Practices

Hydrostatic testing Pneumatic testing

Pressure Testing
Pressure testing is used to determine the integrity of pressure equipment and piping systems. It is based on g the ability y of a piping p p g system y to withstand a determining hydrostatic pressure that equals or exceeds the design pressure (test pressure depends on the type of test). The tests criteria are pressure history and leak detection. A test is conducted by isolating and pressurizing the vessel/piping, and then measuring the change in pressure over a specified time. At the same time, visual inspection f l for leaks k is i conducted d t d. The test pressure shall, unless otherwise specified, be in accordance with applicable code (e.g., ASME BPVC, ASME B31.3, ASME B31.4, API 1110, etc.).

N. Al-Khirdaji, AZTech Sr. Consultant

Some Pressure Testing Requirements

Accurate and precise temperature data are essential to mathematically reconcile temperature and pressure changes observed during testing of buried pipelines and to certify absence of leakage. The API recommended practice applied by the project specifications explicitly requires temperature p measurements to be made in increments of 0.1F (0.05C) and that a continuous-recording temperature measurement device be employed to provide a permanent record of pipeline temperature versus time.

Some Pressure Testing Requirements

During a typical pipeline hydrostatic test, pressure measurements are taken and recorded at 15 or 30minute intervals using a dead weight test gauge capable of precision of 0.5 psi, or better. Each set of measurements is reconciled and the calculated net test volume is plotted on a time scale for each interval. Trends on the volume-time plot can indicate small leaks after a short monitoring period. After the elapse of the required test holding time, typically specified as 8 to 24 hours, the presence or absence of leaks is indicated with a high degree of certainty.

N. Al-Khirdaji, AZTech Sr. Consultant

Pressure Testing of Buried Pipe

Economic and construction considerations for pipeline projects typically require installation of pipe and back filling of the pipe trench before pressure testing. Since visual leak inspection of the buried pipe is not possible during testing, it is necessary to reconcile observed changes in test pressure with changes in temperature to verify the absence of leaks. leaks A mathematical calculation is necessary to make the reconciliation, and the temperature of the pipe and its contents are the most critical of several elements to be considered.

Pressure Testing of Buried Pipe

For example example, an 8-inch 8 inch, high high-pressure pressure, steel pipeline 15,000 feet long, tested with water starting at 50F, will lose about 9 pounds per square inch (psi) of pressure due to a 1F cooling. The same pipeline tested at a starting temperature of 70F will lose about 23 psi for each 1F of cooling. cooling Even more dramatically, this same pipeline, if leak tested with diesel fuel or jet fuel, would lose about 80 psi for each 1F of cooling during a typical test

N. Al-Khirdaji, AZTech Sr. Consultant

Pressure Test Planning - 1

To achieve an accurate and representative test, adequate planning is required. Some necessary information needs to be gathered prior to the test. The following information should be gathered days or weeks before the actual test:
presence of pressure relief devices, test medium information, delineation of individual pipeline test segments, and required i d test t t instrument i t t accuracy.

Just prior to test start-up, pre-test calculations should be performed to detect the presence of entrained air.

Pressure Test Planning - 2

The presence of pressure relief devices must b d be determined t i d prior i to t the th test. t t Usually these devices have a set pressure at or 5 10 % above the maximum allowable operating pressure. Such pressure relief devices must be isolated prior to conducting the test.

N. Al-Khirdaji, AZTech Sr. Consultant

Pressure Test Planning - 3

The presence of a significant amount of trapped d air i within ithi the th tested t t d pipeline i li can be b problematic to test accuracy. When testing a pipeline with water, trapped air can be eliminated by filling the tested line at a rapid enough rate, thereby creating a completely turbulent interface between the incoming water and the displaced fluid.

Pressure Test Preparation

Pressure, temperature and time recorders should be used for all hydrostatic tests tests. Pressure gauges and recorders used to indicate and record test pressure shall be dead weight tested for accuracy according to a procedure, dependent of type of equipment. All piping should be adequately supported before the pressure test. test Spring or other variable type supports should be blocked to prevent movement.

N. Al-Khirdaji, AZTech Sr. Consultant

Pressure Test Preparation

If there is a deviation of more than 2% between gauge and recorder during test, test the test shall be stopped and the equipment recalibrated. Piping joints and welds shall not be insulated or physically covered until satisfactory completion of testing in accordance with this specification, except for painting of prefabricated welds. All piping i i shall h ll be b adequately d l supported d before b f the h pressure test. Spring or other variable type supports shall be blocked to prevent movement.

Pressure Test Preparation

Unless otherwise noted, noted all valves are to be through body tested. First block valve for pressure instruments shall be included in the test. Piping containing check valves shall have the source of test pressure on the upstream side. If this is not possible, the check valve disc shall be removed or jacked open. open Where the test pressure > the maximum allowable test pressure for valves, the valves shall be blinded off on the side to be tested, or removed and replaced by dummy spools

N. Al-Khirdaji, AZTech Sr. Consultant

Pressure Test Preparation

Turbines, pumps, compressors and vessels shall be blinded off prior to pressure testing testing. A list shall be prepared for sensitive equipment that shall be removed, blocked off or isolated during testing, such as relief valves, inline instruments, turbines, pumps, compressors and vessels. vessels This list shall be a part of the test procedure

Pressure Test Preparation

Piping joints and welds should not be insulated or physically covered until satisfactory completion of testing in accordance with this specification, except for painting of prefabricated welds. Minimum of one gauge shall be positioned at the highest point and one recorder to be positioned at the lowest point. Accuracy A of f pressure gauge shall h ll be b at least l 1-2% 1 2% at full scale and 1-2% for the recorder. The test pressure shall be within 60% of the gauge range.

N. Al-Khirdaji, AZTech Sr. Consultant

Test Media
For hydrostatic testing the test medium shall in general be fresh water, water except that other suitable liquid may be used if:
The piping or inline equipment would be adversely affected by water. If the liquid is flammable, its flash point shall be at least 49 49C C and consideration shall be given to the environment. The liquid is approved by the Owner

Test Media
The chloride ion content of the water used for pressure testing stainless steel lines shall be less than 100 ppm and the line shall be properly drained soon after testing. The pH of the water shall be between 6.5 and 7.5. For pneumatic testing, the test media shall be oil free, dry air or any inert gas. The extent of pneumatic testing shall be approved approved. Specific safety precautions and requirements generally apply.

N. Al-Khirdaji, AZTech Sr. Consultant

Duration of Test Pressure

The test pressure shall be maintained for a sufficient length of time to permit visual examination to be made of all surfaces, welds and connections, but not less than thirty minutes. A one hour test duration shall apply for piping systems with pressure rating class 600# and above. Care C shall h ll be b taken k to ensure that h over-pressuring i due to static head does not take place. The piping systems shall not show any sign of plastic deformation or leakage.

After Completion of Test

The tested systems shall be depressurized by opening the depressurizing valve in the test rig. rig After depressurization, all vents and low point drain valves shall be opened and the system shall be thoroughly drained where the test medium is water. Where required, blowing by dry air or Pressurized Air Shock Blowing to remove any trapped water to be performed.

N. Al-Khirdaji, AZTech Sr. Consultant

Pneumatic Testing
Pneumatic testing is normally used in cases where water contamination of the service fluid is not tolerated or when water of suitable quality is not available. Typically, Owner approval is required before pneumatic testing is to be performed. Additionally, because of the potential energy of the compressed air (gas) in the system under pneumatic testing testing, special safety precautions and procedures have to be implemented.

Stored Energy In Pressurized Gas Vessel or Piping

When a gas is compressed, energy is stored in it. If the energy is i released l d in i an unfavorable f bl way, it will ill cause damage. Stored energies in excess of 100 kJ are considered high hazard. Sometimes it is helpful to think of stored energy in terms of f grams of f TNT (trinitrotoluene). ( i i l ) One gram of TNT contains 4.62 kJ of energy 0.01 lb TNT = 14,240 ft-lb of stored energy

N. Al-Khirdaji, AZTech Sr. Consultant

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Stored Energy In Pressurized Gas Vessel or Piping

U= Ph Vh -1

{ 1 (P1/Ph)

-1 1

Vh = The volume of the vessel. Ph = The absolute pressure of the vessel. Pl = The absolute pressure to which the vessel would drop if it burst, generally one atmosphere (14.696 psi or 101,300 Pascal). A Pascal is a Newton per square meter. = The adiabatic exponent or ratio of specific heats, Cp/Cv. (= 1.67 for monatomic gases; 1.4 for diatomic gases; 1.3 polyatomic gases)

Example: Consequences of Leakage or Rupture of Pressure Vessel and Piping

The gas is air ( = 1.4) 1 4) 3 Vh = 1.0 m (35.3 ft3) Ph = 10 atm (150 psi) gage or 11 atm absolute or 1.1 MPa Pl = 1 atmosphere or 100 kPa or 14.7 psi U ={(1*105N/m2)(1.0 m3)/(1.4-1)}{1-[1*105N/m2/ (1*105N/m2)] 1.4 } U = 1.4* 106 N-m The stored energy is 1.4 MJ (N-m is a joule), which is equivalent to 0.3 kg of TNT (1 kg TNT = 4.62 MJ)
1.4 -1

N. Al-Khirdaji, AZTech Sr. Consultant

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Potential Energy
Stored Volumes of Ideal Gas at 20 C PRESSURE, psig 10 100 1000 10000 TNT EQUIV., lbs. per ft3 0.001 0.02 1.42 6.53

TNT equiv. = 5 x 105 Calories/lb

Preparation for Pneumatic Testing

1 All major equipment items, 1. items including pumps w/mechanical seals, heat exchangers, etc. that are incapable of withstanding the test pressure shall be blanked off before pressure testing. Inline components such as filters and strainers may remain. 2 Instruments that are incapable of withstanding 2. the Test Pressure, or that are otherwise susceptible to damage, shall be removed or blanked from the Pipeline being tested, or shall be replaced with a pipeline spool.

N. Al-Khirdaji, AZTech Sr. Consultant

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Preparation for Pneumatic Testing

3. Suitable warning signs, barricades or other safety methods must be used to prevent injury to personnel during testing in the event of sudden release of pressure. Pneumatic pressure testing should be performed during off-shift hours, where possible, to reduce the potential for personnel injury. 4. Visual Examination of the piping systems shall be successfully completed before performing all pressure tests.

Preparation for Pneumatic Testing

5. All joints and welds must be uninsulated, before they are pressure tested tested. 6. If the air supply used is moist, no testing will be permitted unless ambient temperatures are expected to be above 32 F during the full duration of the test. 7. This pressure test method is restricted to 12" NPS and smaller pipelines, pipelines unless specifically approved by the owner.

N. Al-Khirdaji, AZTech Sr. Consultant

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Preparation for Pneumatic Testing

Test Fluid: Plant air, air nitrogen, nitrogen or air or nitrogen provided by a compressor, which is free from dirt, oil, weld slag, construction debris, and other foreign matter, shall be used for the pneumatic test. Test Apparatus: All gauges used for field testing shall have a suitable range and a dial scale not less than 4 1/2" diameter diameter. Gauge ranges shall be selected so that the test pressure of the system falls between 40% and 80% of the gauge scale range. Gauges shall be out of "new" quality and in first class working condition.

Preparation for Pneumatic Testing

A pressure relief device shall be installed in th test the t t loop l and d shall h ll be b set t to t relieve li at t the th greater of 25 psig or 10% above the defined Test Pressure Test Pressure: The Test Pressure shall be equal to 110% of either the design pressure of the piping system, or its weakest component.

N. Al-Khirdaji, AZTech Sr. Consultant

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Test Procedure
Test Procedure: The pressure source shall be attended constantly during the test. test Should it be necessary for the operator to leave the pressure source, he should first relieve the pressure in the test loop. A preliminary check shall be made by pressurizing the test loop to not more than 25 psig. At each increment of 25 psig, psig the pressure shall be held steady for one minute before processing to a higher pressure

Test Procedure
The following typical procedure shall be used:
1. Cl 1 Close all ll valves l in i the th line li and/or d/ blank bl k off ff all ll flanges. fl 2. Open the valve supplying the test fluid to the pipe system slowly until the pressure gauge indicates 25 psig. 3. Close the valve supplying pressure. 4. Observe the pressure gauge. If the pressure holds steady for one minute, proceed to Step 5. 5. Open the valve supplying pressure.

N. Al-Khirdaji, AZTech Sr. Consultant

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Test Procedure
6. Increase the test pressure in the line by 25 psi. 7. Close the valve supplying pressure. 8. Repeat Steps 4, 5, 6 and 7 until the Test Pressure is achieved. 9. Hold the Test Pressure for a period of time sufficient to permit a thorough inspection of all joints for leakage, but not less than 10 minutes. The pneumatic pressure test results are acceptable when there is no evidence of l k leakage or seepage and d no decrease d in i pressure shown h on the test gauge during the test. 10. Relieve the pressure in the test loop.

Test Procedure
Repair any leaks found in the test loop. After repairs, i retest t t the th test t t loop l per Steps St 1 thru th 10 above at the Test Pressure. Retesting also requires a stepwise pressure increased in 25 psig increments.

N. Al-Khirdaji, AZTech Sr. Consultant

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Test Record
Test Record: The test shall be witnessed by the designated Engineer (and other individuals as required by regulations). Records of the pressure test shall be maintained by the per company policies as identified on the Pressure Test Record Form. Records should include the test date, identification of the h pipeline i li tested d and d the h type of f pressure test used d with reference to the appropriate project and maintenance files.

Pressure Tests Pressure Vessels

130 Hydrostatic test pressure for pressure vessels

Perc cent of MAWP

110 100 90 80

Pneumatic test pressure for pressure vessels Maximum Allowable working Pressure, MAWP Maximum relief device setting Retest pressure for all vessels and systems Maximum operating pressure, MOP*

* Recommended range is 10 to 20% below the MAWP

N. Al-Khirdaji, AZTech Sr. Consultant

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Pressure Testing of Liquid Petroleum Pipelines

A pressure test is performed to test for pipeline strength t th and d leakage, l k and d to t satisfy ti f statutory t t t regulations. A pressure test includes: site preparation, temperature measurement and monitoring, time of events, pipeline packing and pressurization, strength testing, leak testing, and pipeline test documentation.

Hydrostatic Testing of Internal Pressure Piping (ASME B31.4)

API RP 1110 covers the hydrostatic of new and existing liquid petroleum pipelines. It recommends minimum procedures to be followed, suggest equipment to be used, and points out factors to be considered during hydrostatic testing of liquid petroleum pipelines. This Thi RP suggests procedures d that h are based b d on sound engineering judgments, but certain governmental requirements may differ from this procedure set forth in this RP. Such requirements supersede the RP.

N. Al-Khirdaji, AZTech Sr. Consultant

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Hydrostatic Testing of Internal Pressure Piping (ASME B31.4)

Portions of p piping p g systems y to be operated p at a hoop p stress of more than 20% of the specified minimum yield strength of the pipe shall be subjected at any point to a hydrostatic proof test equivalent to not less than 1.25 times the internal design pressure at that point (see para. 401.2.2) for not less than 4 hours. When lines are tested at pressures which develop a hoop stress, based on nominal wall thickness, in excess of 90% of the specified minimum yield strength of the pipe, special care shall be used to prevent overstrain of the pipe:

Hydrostatic Testing of Internal Pressure Piping (ASME B31.4)

Those portions of piping systems where all of the pressured components are visually inspected during the proof test to determine that there is no leakage require no further test. This can include lengths of pipe which are pre-tested for use as replacement sections. On those portions of piping systems not visually inspected while under test, the proof test shall be followed by a reduced pressure leak test equivalent to not less than 1.1 times the internal design pressure for not less than 4 hours.

N. Al-Khirdaji, AZTech Sr. Consultant

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Hydrostatic Testing of Internal Pressure Piping (ASME B31.4)

The hydrostatic test shall be conducted with water water, except liquid petroleum that does not vaporize rapidly may be used provided:
The pipeline section under test is not offshore and is outside of cities and other populated areas, and each building within 300 feet of the test section is unoccupied while the test pressure is equal to or greater than a pressure which produced a hoop stress of 50% of the specific minimum yield strength of the pipe. The test section is kept under surveillance by regular patrols during test; and Communication is maintained along the test section.

Hydrostatic Testing of Internal Pressure Piping (ASME B31.4)

If the testing medium in the system will be subject to thermal expansion during the test, test provisions shall be made for relief of excess pressure. Effects of temperature change shall be taken into account when interpretations are made of recorded test pressures. After completion of the hydrostatic test, it is important in cold weather that the lines, valves, and fittings be drained completely of any water to avoid damage due to freezing.

N. Al-Khirdaji, AZTech Sr. Consultant

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Hydrostatic Testing - 1
Hydrostatic testing is used to conduct strength tests on:
new pipes while in the manufacturing process, as well as at the completion of pipeline installation in the field prior to being placed in service.

Hydrostatic testing is also used, at times, for integrity assurance after a pipeline is in operation. Hydrostatic tests are generally the preferred integrity assessment method when the pipeline is not capable of being internally inspected or if defects are suspected that may not be detectable by internal inspection smart pigs.

Hydrostatic Testing - 2
Hydrostatic test establishes the pressure carrying capacity of a pipeline and may identify defects that could affect integrity during operation. Testing is done to a pressure that is greater than the normal operating pressure of the pipeline. This provides a margin of safety. The Th test stresses the h pipeline i li to a predetermined d i d percentage of its specified minimum yield strength (SMYS). Typically pressures range from 93% to 100% of SMYS, and the test is generally held for eight hours.

N. Al-Khirdaji, AZTech Sr. Consultant

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Hydrostatic Testing - 3
If stress corrosion cracking (SCC) is suspected, the test pressure may be increased to 100% to 105% of SMYS or higher for 30 minutes to an hour. Axial flaws such as stress corrosion cracking, longitudinal seam cracking, selective seam corrosion, long narrow axial (channel) corrosion and axial gouges are difficult to detect with Magnetic Flux Leakage (MFL) pigs and are better detected with a hydrostatic test.

Hydrostatic Testing - 4
Hydrostatic testing requires the ability to acquire large quantities of test water, which in some areas may be difficult. Once used, the test water may contain trace quantities of petroleum products, which may require treatment of the water prior to discharging or disposal. Hydrostatic H d i testing i requires i the h pipeline i li to be b out of f service for a period of time thus potentially curtailing the availability of gasoline, jet fuel, diesel fuel, crude oil, and/or home heating oil at the delivery point.

N. Al-Khirdaji, AZTech Sr. Consultant

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Leak Testing
Leak testing may be used to find leaks in a newly constructed or newly modified piping system system, or in an established system where an apparent loss of integrity has been experienced. If they exist, leaks typically occur at joints (or from through wall defects). Typically, Typically the pressure does not exceed the maximum operating pressure.

Leak Testing
Leak testing does not verify pressure rating or potential long long-term term performance. performance The system design and the pressure ratings of the installed components are the sole determinants of system pressure rating and long-term performance. Safety is of paramount importance. Leak tests can apply high stress to untried joints and parts in the system Failure can occur by leaking or by system. catastrophic rupture. In some cases, leakage may immediately precede catastrophic rupture.

N. Al-Khirdaji, AZTech Sr. Consultant

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Some US Regulations
192.507 Test requirements for pipelines to operate at a hoop stress less than 30 percent of SMYS and at or above 100 psi. (689 kPa). Except for service lines and plastic pipelines, each segment of a pipeline that is to be operated at a hoop stress less than 30 percent of SMYS and at or above 100 p psi ( (689 kPa) ) must be tested in accordance with the following: (a) The pipeline operator must use a test procedure that will ensure discovery of all potentially hazardous leaks in the segment being tested

Some US Regulations
(b) If If, during the test test, the segment is to be stressed to 20 % or more of SMYS and natural gas, inert gas, or air is the test medium:
(1) A leak test must be made at a pressure between 100 psi. (689 kPa) gage and the pressure required to produce a hoop stress of 20 % of SMYS; or (2) The line must be walked to check for leaks while the hoop stress is held at approximately 20 % of SMYS.

(c) The pressure must be maintained at or above the test pressure for at least 1 hour.

N. Al-Khirdaji, AZTech Sr. Consultant

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Pressure Test Preparation

Each test loop should be provided with a low point piping p p g connection for hydrotest y water supply. pp y High point vents shall be provided to permit the venting of air from the test loop--to ensure that the pipeline is completely filled with water. Test Pressure: The Test Pressure shall be equal to
150% of either the design pressure of the piping system or its weakest component system, component. 130% of either the design pressure of the pressure vessel, or its weakest component.

(adjusted to new and cold conditions)

Service Tests
Service tests are usually applied to non-critical service such as utility and other low pressure nonnon hazardous services. Illustrative examples: (1) Non-flammable and non-toxic fluids (2) Design pressures less than 150 psig (3) Operating temperatures range: -20 to 366o F. The criteria for application of service tests should be clearly established in the owner specifications.

N. Al-Khirdaji, AZTech Sr. Consultant

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Pneumatic Tests
Pneumatic testing is normally used in cases where water contamination of the service fluid is not tolerated or when water of suitable quality is not available. Typically, Owner approval is required before pneumatic testing is to be performed. Additionally, because of the potential energy of the h compressed d air i (gas) ( ) in i the h system under d pneumatic testing, special safety precautions and procedures have to be implemented. Test pressure for pressure vessels = 110% X DP

Leak Detection
Technology is available to detect leaks from gas pipelines. pipelines One approach involves the use of sensitive sensors on board low- flying surveillance airplanes that fly along he pipe route. Another approach entails the use of methods based on analysis of time series of pressure and/or flow i b l imbalance because b these h present some well ll known k reaction to leaks. A software-based system is typically used for such application.

N. Al-Khirdaji, AZTech Sr. Consultant

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