Prepared By: Yoganandhan Loganathan

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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.

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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.

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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.

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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.

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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