1 Purpose ‘The purpose of these procedures is to ensure that pressure tests are conducted safely and effectively, They cover pressure testing of new and existing pressure systems and components, They apply to mechanies, supervisors, field construction managers, inspectors, custodians, subcontractors responsible for pressure tests, and the pressure systems program manager. 2 Procedures Pressure tests are performed to ensure the safety, reliability, and leak tightness of pressure systems. A. pressure testis required for a new pressure system before use or an existing pressure system after repair or alteration, ‘There are two methods for pressure tess: hydrostatic and pneumatic, A hydrostatic testis performed by using water as the test medium, whereas a pneumatic test uses air, nitrogen, or any noa-flammable and non- toxic gas. At SLAC pressure tests must be hydrostatic unless pneumatic tests can be justified, Al pressure tests are to be conducted using a gauge that has been calibrated within the previous 12 months. ‘The pressure gauge should be sized so that the test pressure isin the middle third of the gauge's pressure range. Gauge materials and fluids are to be compatible withthe test fluid ‘When possible, the use of blind/blank flanges or eaps should be considered for test boundaries to prevent damage to valves. Pressure tests must always be performed under controlled conditions, following an approved test plan, and documented in a test record. A single approved test plan may be used for several similar tests, but a separate test record is required for each, 2.1 Hydrostatic Testing Hydrostatic is the preferred method of pressure test at SLAC. 2.2 Pneumatic Testing Pneumatic tests are potentially more dangerous than hydrostatic because of the higher level of potential ‘energy. Pneumatic tests may be performed only when at least one of the following conditions exists:SSLAC National Accelerator Laboratory Environment, Safety & Health Division Pressure Systems| Pressure Test Procedures = When pressure systems are so designed that they cannot be filled with water. ‘= When pressure systems are to be used in services where traces of the testing medium cannot be tolerated, Using a pneumatic test instead of hydrostatic requires approval by the pressure systems program manager In addition to 2 justification, a piping schematic for pneumatic pressure testis required. A recommended typical piping schematic for pneumatic testis shown in Figure 1 Important Installation of a pressure relief valve is required for a pneumatic test Figure 1. Recommended Typical Piping Schematic for Pneumatic Testing 2.3. Test Procedure Step Person Action Planning 1 Mechanic ‘Completes pressure test plan after consuling the project engineer and submis for approval 2, Supervisor ‘Approves plan FCM in charge of test Approves plan 4, Pressure systems Approves plan (not required for routine testing of existing systems) program manager PerformingSLAC National Accelerator Laboratory Environment, Sa Pressure Systems| Pressure Test Procedures Step Person Action 5. Mechanic Ensures the pressure gauges used have current calibration stickers 6 Mechanic Removes pressure relief valves or non-eclosing relief devices from the vessel or test boundary where the test pressure will exceed the set pressure af the valve or device OR Holds down each valve by means of an appropriate tet camp and pressurizes both sides of non-reclosing relief devicos Installs temporary, higher-rated devices where practical 1 Mechanic Installs the calibrated test gauge so itis visible at all imes 8 Mechanic Ensures the skit blanks, test plugs, or clamps are appropriate for use and are free of obvious defects 8 Mechanic Removes al persons not clrecly involved withthe test rom the pressure test ‘exclusion zone. Posts baricades, signage, etc. as specified in Pressure Test Plan te prevent unauthorized personnel entry 40. Inspector Reviews approved test plan; reviews test set-up; verifies test equipment is appropriate far the test 41. Inspector Witness entrety of test 12, Mechanic Verifies thatthe pressure is continually monitored to ensue that pressure never exceeds the designated test pressure ofthe system 18. Mechanic Hydrostatic testing: Fils and vents system as necessary to remove as much air as practical 14, Mechanic Pressurzes system following testing protocol specified in Pressure Test Plan. Holds pressure attest pressure for specified time noting any drop in pressure. 18. Mechanic Pneumatic tasting: reduces the pressure to the design pressure (or as specified in Pressure Test Pan) before proceeding wih the inspection; holds the pressure fora suficient period of ime to permit inspection of the system 16 Mechanic Pneumatic testing: Applies a soap solution to accessible welds, screwed pipe jsints, anges, etc. whore leakage is suspected 17. Mechanic IFthere is evidence of structural distortion, ether rejects the system or repairs as advised by the Inspector 18 Mechanic Ifthere is leakage inthe system, performs the following as appropriate: 1» Ensure repairs is performed and returns to Step 13 or 1 Rejects the system 18. Mechanic Pneumatic testing: When the testis completed, vents the test pressure to ‘approved discharge location and returns relief devices to normal configuration Hydrostatic testing: Relieves pressure and disposes of test fd as described in Pressure Test Plan and relums relief devices to normal configuration Recor 20. Inspector ‘Signs pressure test recordSLAC National Accelerator Laboratory Environment, Sa Pressure Systems| Pressure Test Procedures Step Person Action 21. Mechanic ‘Completes pressure test record and submits copy tothe pressure systoms program manager and tothe Building Inspection Office (when applicable) 22. Mechanic ‘Submits copies ofthe test plan and test record to the custodian 2.4 Test Pressure Codes and standards organizations (ASME, NFPA) and state regulations (California Code of Regulations) specify test pressures and procedures applicable to various systems. The test pressure for a piping system is based on the maximum design pressure of the system, and fora pressure vessel based on the maximum allowable working pressure (MAWP) of the vessel. Systems undergoing retesting should not be tested at, pressures higher than the original testing pressure, ‘The project engineer and the pressure system mechanie are responsible for defining the pressure test plan and documenting it on the Pressure Test Plan Form. The following table provides guidance in selecting the appropriate test pressure and in developing the test procedure. Unless otherwise noted below; there should be no pressure drop in the system for the required test duration Table 1 Test Pressures for New Pressure Vessel and Piping Systems Type of System TestMedium Test Pressure Test Procedure Code Reference Pressure Vessel Hydrostatic 1.3 times MAWP ‘ASME BPVC-VIIIUG- (Division 1) Preumatic 1.1 times MAWP 99 Pressure Vessel Hydrostatic 1.25 times ‘ASME BPVC-VIIL2 (Division 2) MAWP Preumatic 1,15 times MAWP Building Services Water 1.5 times design pressure 10 minutes ASME B31.9 6s 937.3, (Hydrostatic) (inimum) For noretoxc fuids, air, ‘vacuum, non: flammable gasses installed as par of the building (excepting laboratory anc experimental Building Services Nonsloxic, Not exceeding 1.25 times Pressure raised by not ASME B31.9 ss 997.4 (Proumatic) non design pressure, and not more than 25% per For non-toxic ids, air, lammable exceeding 150 psig step. vacuum, non: 998 Peumatictestng of plastic 10 minutes (minimum) flammable gasses pipe or britle materials not at est pressure, installed as part of the allowedSLAC National Accelerator Laboratory Environment, Safety & Health Division Pressure Systems| Pressure Test Procedures Type of System _ Test Medium Test Pressure TestProcedure Code Reference Baling except Pressure maybe laberatary anc cedcod to design experimeria) pressure before txamining freaks Process Pring Water ~—~=«.S tras design pressure 30 minutos ASME B31 93s HEA (Hydrostatic) (minimum) cM 1405, For al gases and fids Process Piping Aroranon- i.1101.39tines denn Fistleakcheck __ASMEBS1.9ee M55 (Preumatiz) tovc, non prossure performed (smaler of) yc 1405 For allgasses and flammable Not exceeding 160 psig 0.5 mes design fluids gas without approval of PSWG pressure and 25 psig Preumatic testng of plastic Ra'se pressure pine or britle materials not 9f@dually in steps. alowed 30 minutes (minimum) attest pressure. Pressure shall be reduced to design pressure before examining fr leaks. Plumbing Fixture water Water 41.5 times the maximum 15 minutos CPC 6094 supply system design pressure ASME B31.9 Pressure Sewer Water 10° head of water 18 Minutes| Pc Ti22 Ejector Systems Air 5 psi 18 minutes cPc7123 Sewer Lines within Water 10° head of water except top 15 Minutes PC 7122 building, drainage and 10 feet flo highest point ope 110724 storm drains Air 5 psi 45 minutes cPCTi23 ope 1107.22 Sewer line: Bulding to Water Fillo highest point PC 723.1 sewer Underground Fire Water 200 psior $0 psiabove 2 hours NFPA 13: 6.10.22 Protection water supply working pressure (wnichever 4. § PSI variation is greater) allowedSLAC National Accelerator Laboratory Environment, Sa Pressure Systems| Pressure Test Procedures Type of System __TestMedium Test Pressure TestProcedure Code Reference Wet Pipe Fire ator 200 psiorS0 psiabove —_2hours NFPA 13 28.2.1 Protection Systems working pressure (whichever is greater) Dry Pipo Fire ir 40PSI Hydrostaictest NFPA 1328221 Protection System requied in aditon to Pneumatic test. Pneumatic test for 24 hours wih less than 1.5 PSIG pressure los. Field Consiucted —Iner.gas Refer to Cafomia cmc 11162 Refrigerant Piping Mechanical Code section ASHRAE 16:10.1.2 11162 and table 1116.2 HycronicPiping =< Water_—=S«.S times the maximum 30 Minutes ‘OMG 1205.2 (Hydronic systems are system design pressure but bulding heating, rnotless than 100 PSI cooling, vniltion, and air conttionng systems) Fuel Gas Pressuretest 15 times the maximum ‘2hourfor each 600 OPC 12133 using ar, working pressure, utnot- cubicfeetofpipe cc 13133, nivogen, less than 10 PSI volume (or action of carbon butnotlessthan 15 NFPAS# 8.14 doxde or an minutes inert test gas never oxygen ‘Vacuum Systems Arextractor For ordinary vacuum [ASME Section VI systems; Full atmosphere aifferental For systems not intended to be pumped out to full ‘atmospheric pressure aiffrental: 110% of max allowable extemal differential pressure, but nat ‘mare than full atmospheric pressure, For vacuum systems within a pressure vessel: 110% ofSLAC National Accelerator Laboratory Environment, Sa Pressure Systems| Pressure Test Procedures ‘Type of System Test Medium Test Pressure ‘Test Procedure Code Reference Tax alowable working pressure differential 2.5 Test Plans A pressure est plan at a minimum contains the following formation: ‘= Approved Pressure Test Plan Form = Drawings of the system being tested. Identify the location of test setup, test boundaries, identify all blank/blind flange locations if applicable = Drawing showing the exclusion zone with location of signage, arvicads, or other controls "Detail of the test setup. Identify the pressure ratings of all components and pressure relief valve setting, Provide product data sheets if needed. = Pressure gauge calibration sheet Detailed test procedure 3 Forms ‘The following forms and systems are required by this procedure: Pressure Systems: Pressure Test Plan Form (SLAC-1:730-0A21J-044). A detailed pressure test plan is required for every pressure test conducted at the laboratory. An approved plan may be used for several similar tests Pressure Systems: Pressure Test Reoord Form (SLAC-I-730-0A21J-045). A separate test record is required for each pressure test ‘= Pressure Systems Database, Database of pressure systems 4 Recordkeeping ‘The following recordkeeping requirements apply for this procedure: ‘The custodian of a given pressure system must maintain copies of test plans and records for five years ‘= The pressure systems program manager maintains copies of all pressure test plans and records permanently,SLAC National Accelerator Laboratory Environment, Sa Pressure Systems| Pressure Test Procedures 5 References SLAC Environment, Safety, and Health Manual (SLAC-1-720-0A29Z-001) = Chapter 14, “Pressure Systems! Pressure Systems: Installation, Inspection, Maintenance, and Repair Reauirements (SLAC-1:730- (0A218-053) Pressure Systems Safety Program (SharePoint) = Chapter 51, “Control of Hazardous Energy” ‘Other Documents + Title 24, California Code of Regulations, California Building Standards Code” = Part 4, “California Mechanical Code”, Part 4 (24 CCR Part = Patt 5, “California Plumbing Code”, Part § (24 COR Part 8) = American Society of Mechanical Engineers (ASME). Boiler and Pressure Vessel Code (BPVC) (ASME BPVC) "ASME, Code for Pressure Piping (ASME B31) (including applicable addenda and code eases) — ASME B31.1, “Power Piping” (ASME B31. — ASME B31.3, “Process Piping” (ASME 831.3) — ASME B31.9, “Building Services Piping” (ASME B31.9) ‘= National Board of Boiler and Pressure Vessel Inspectors (NBBI) = NB 23, National Board Inspection Code (NBIC) (NBBI NB 23) ‘= National Fire Protection Association (NFPA) 13, “Standard for the Installation of Sprinkler Systems” (NFPA 13) "= Brookhaven National Laboratory. Vacuum Systems Consensus Guideline for Department of Energy’ Accelerator Laboratories (BNL-81715-2008-IR)