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Pullman Kel1dgg Page 1 of 5
Proce4ure Specification July 28, 1976

Field Pneumatic Leak Testing

of Cryogenic Piping
WAS

A. SCOPE

1. This specification together with th~ PEtID's, nomenclature,data

sheets, and drawings covers the requirements for the pneumatic field
pressure testing of cryogenic pipipg to assure the tightness of welds,
connections anll joints. The data sheets, PEtID's, nomenclature and
standards that define the systems to be tested and the testing pressures,
order of testing and testing media will be listEld on the procedure data
sheet.

2. All pneumatic testing of cryogenic piping shall meet the requirements of

A.."iSI :831. 3-1973, "Petroleum Refinery Piping".

3. All pressure vElssels, exchangeJ;'s, storage vessels, etc., which are subject
to the pneumatic test pressure as part of a piping system shall have pre-
viously passed the code required pressure test and shall have design pres-
sures equal to or greater than 80% of the test press~re of the piping system.

B. GENERAL

1. Leak testing shall be made preferably on completed systems which include

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'" 2.

3.
connected piping and equipm~ntwith the limitations imposed herein .

When mandatory governmental rules or regulations are applicable, the

requirements thereof shall be followed.

All shop fabricated piping and piping components shall be hydrostatically

tested in the shop eJtcept as otherwise stated herein.

4. All welds made on piping in the field shall be pneumatically tested.

5. Each test system shall be kept as small as practicable.

C. TEST FLUID

1. Pressure testing shall be with dry and oil free air or dry nitrogen.

2. Air may be used in the initial phase of the test procedure to check for
large leaks in the systems. Nitrogen will be the pneumatic test fluid
in all remaining stages of the test procedure as specified in Section H
Paragraph I and may be cascaded from one test pressure level to another
in order to conserve the nitrogen.

D. PREPARATION FOR TESTING

1. Piping, vessels, etc. specified herein or on the nomenclature, PEtID's,

drawings or data sheets as requiring different test pressures or media
shall be isolated from the tested systems.
 Spec. 8-1P5300
Page 2 of 5
July 28~ 1976

.' 2.

3.
Test and examination requirements for reinforcing pads, and restrictions
on painting, insulating, and covering or burying welds listed in the following
paragraphs shall apply only to those items which have not previously been suc-
cessfully pressure tested in either the shop or the field.

Each field attached reinforcing pad, or each segment thereof, and similar
attachments shall be tested at a pressure of 3.45 bar (eff) (50 psig) with
nitrogen. Test and vent holes shall be left open upon completion of the test.

(a) Reinforcing pads for pipe connections with diameters 24 inches and above,
and pressures under 6.89 bar (eff) (100 psig) shall be tested at 0.69
bar (ef£) (10 psig).

4. When piping joints not previously tested are required to be painted, insulated
or buried, the paint or insulation shall not be applied to the pipe j~ints
and they shall be left exposed until the tests are completed unless specific
approval is given on the drawings or by the Engineering Department.

5. A calibrated pressure recorder shall be used on each piping system. One

or more calibrated indicating test gages shall be connected directly to the
piping system as necessary to coordinate the pressurizing opera.tion. The
indicating gages used shall be visible to the operator controlling the pres-
sure. Pressure gages used shall have dials graduated over a range of approxi-
mately two times the intended maximum test pressure.

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6. Before applying pressure all lines or systems shall be inspected to insure
that all parts not included in the test are isolated and properly protected
against over pressure.

7. The point of introduction of the test medium shall be located upstream of

check valves and the point of release downstream.

8. Piping that connects to lines installed by others may be isolated from such
lines by valves or test blanks located at or near the juncti.on. When neces-
sary to include parts of such lines in the test, the owner's representative
shall be given prior notice so that test conditions may be mutually agreed
upon.

9. Valves shall be in the open pbsition but not back seated for the test unless
otherwise specified. Automatic control valves shall normally be in the open
position.

10. When control valves are used for the purpose of isolating systems having
different test pressures they shall be single seated valves with manual
bperators, they shall be designed to take the full test pressure differential
and they shall be locked closed with the motor power disconnected from· the
valves.

11. When block valves are used for the purpose of isolating systems having dif-
ferent test pressures they shall be locked in the closed position •

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 Spec.8-lP5300
Page 3 of 5
July 28, 1976

E. EQU!PMENT.NOT SUBJECT TO·TEST!NG

• 1. The following equipment shall not be subjected to testing pressures:

(a) Centrifugal and reciprocating compressors.

(b) Explosion discs and flame arrestors.

(c) Relief valves unless specifically used for over pressure protection.

(d) Any equipment which does not have a specific test pressure.

Ce) Expansion joints unless adequate for the test pressure.

2. Lines which are normally open directly to the atmosphere such as vents, drains,
and safety relief valve discharge lines (except closed relief valve discharge
systems) shall not be pressure tested. All joints in such lines shall be vis-
ually examined for proper installation. A low pressure leak test shall be made
on closed relief valve discharge systems.

3. Instrument piping beyond the primary block valve, except the p1p1ng for locally
mounted indicating pressure gages and for pressure gages used in the test, shall
be separately tested. Pressure gages shall not be subjected to pressure in
excess of their scale range.

F. PRECAUTIONS DURING PNEUMATIC TESTING

e1. During pneumatic tests all personnel not directly involved shall be cleared
from the immediate area. The pressure control point shall be located at a
minimum distance of 30.5 m (100 ft) from any equipment or pipe under test.
Personnel shall not approach the equipment under test until the pressure
has been maintained for at least ten minutes.

2. Any enclosed area shall be continually purged with air while personnel are
inside the area.

G. EXAMINATION PRIOR TO PNEUMATIC TESTING

1. All field buttwelds shall be examined by a 100% radiographic examination prior

to pneumatic testing.

2. All ~elds including structural attachment welds to p1p1ng in magnetic materials

shall be magnetic particle examined prior to pneumatic testing.

3. All welds including structural attachment welds to piping in non-magnetic

materials shall be dye penetrant examined prior to pneumatic testing.

4. All post weld heat treatment if r~quired shall be performed prior to

pneumatic testing.

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5. All radiographic, magnetic particle and dye penetrant examinations shall be
in accordance with paragraph 336.4 of ANSI B3l.3 and limitations on defects
shall be in accordance with paragraph 327.4 of ANSI B3l.3.
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Spec. 8-lP5300
Page 4 of 5
July 28, 1976

•• PNEUMATIC TESTING
1. The procedure for the pneumatic testing of piping systems shall be as follows:

(a) A preliminary pneumatic test using air as the test medium shall be made
on each piping system in order to locate major leaks. The pressure in
the system shall be gradually raised to approximately 1.72 bar (eff)
(25 psig) or 25% of the design pressure whichever is lower and held at
this level for a minimum of 10 minutes to allow the piping to equalize
strains during the test before the leak check is started.

(b) Using nitrogen as the test medium the above procedure shall be repeated
except that the pressure shall be gradually increased to 60% of the design
pressure, held for a minimum of 10 minutes and then reduced to 50% of the
design pressure and the system then checked for leaks.

(c) This procedure shall be repeated raising the pressure gradually to 85%
of the design pressure holding the pressure for 10 minutes then reduc-
ing it to 75% of the design pressure before checking for leaks.

(d) The procedure is again repeated raising the pressure gradually to 110%
of the design pressure and holding it for a minimum of 10 minutes at
this pressure before reducing it to 100% of the design pressure. Follow-
ing this the system is to be checked for leaks.

(e) When increasing the test pressure above the 50% level, the test pressure
shall be increased in steps of approximately 10% of the design pressure
and holding at each. increment for approximately 10 minutes until the re-
quired stopping points are reached.

2. All welded, threaded, flanged,and packed joints shall be leak tested at every
test level using a proprietary flu·id mixture such as "Sherlock 5 Second Leak
Test Fluid", "Seamtest" or equivalent, predetermined to have a sensitivity
of approximately 10- 2 atm cc per second. As each joint, weld, connection,
etc. is examined it shall be color coded with a dab of pa.int approximately
1" wide by 3" long per paragraph 4 by the Clients' inspector to visua.lly in-
dicate that it was tested and that it did not leak at the indicated test
pressure. Close control and vigilance shall be maintained after each test
and the paint returned to a central control point.

3. Prior to pneumatic testing, the pipe shall be coated with Carboline 4674 mod-
ified silicone paint for a distance of approximately 304.8 mm (12 in.) adjacent
to all joints being tested. Care shall be taken to insure that the joints
will not be coated with the paint. Any temporary protective coating on the
area of the pipe to be painted shall be removed with a cleaning solvent prior
to application of the paint. Care will also be taken to insure that the calor
coding paint used during pneumatic testing will be applied only on the pipe
surfaces coated with Carboline 4674 modified silicone paint.

4. The following calor identification shall be used on each joint at each stage of

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the testing procedure •
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• Spec. 8-lP5300
Page 5 of 5
July 28, 1976

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4. (Continued)

(a) 1. 72 bar (eff) (25 psig) or 25% of design pressure - red

(b) 50% of design pressure - green

(c) 75% of design pressure - blue

(d) at 100% of the design pressure - yellow

5. In no case shall the pneumatic test pressure of the piping systems exceed
1.10 times the design pressure of the piping system being tested.

I. REPAIRS

1. Except when specifically prohibited, changes or additions as permitted by the

code may be made without retesting. Repairs made to stop leakS shall be re-
tested.

J. RECORDS

1. Records of the testing operations shall be filed with the job inspection records.
The records shall include the following:

(a) Date of test

(b) Identification of system tested

(c) Test fluid

(d) Test pressure

(e) Test temperature

(f) Pullman Kellogg InSpector's signature and Owner's approval

K. COMPLETION

1. All test blanks, temporary p1p1.ng , supports, etc • shall be removed. The ap-
plication of paint and insulation to vessels and piping and the installation
of internals, etc. shall be completed.

2. Materials such as gaskets, bolting, etc. damaged during the test shall be
replaced •