A pressure test is always required for a new pressure system before use or an existing

pressure system after repair or alteration to ensure the following:

Safety

Reliability of operation

and leak tightness of pressure systems

Also The last physical quality test in the fabrication process

Nomally two methods for pressure testing: hydrostatic and pneumatic, are widely used in
process industry.
A hydrostatic test is performed by using water as the test medium, whereas a pneumatic test
uses air, nitrogen, or any non-flammable and nontoxic gas. Pressure tests (both hydrostatic
and pneumatic) must always be performed under controlled conditions, following an
approved test plan, and documented in a test record. A single approved test plan could be
used for several similar tests, but for each test a separate test record is required.
When to perform a Pressure Test:
As per the governing code, pressure test has to be performed on piping system after all hot
works have been completed on a certain piping system. Here the term hot work means
everything related to welding or the post weld heat treatment (PWHT). PWHT also has a
potential of degrading the mechanical properties of piping, in case not addressed properly.
And this is the reason why code calls for NDT after PWHT operation. In case after carrying
out pressure testing, some modification has to be made requiring hot work, it calls for a retest
as per code. Here code specifies that the minor repairs / modifications may be waived off
provided adequate measures have been taken to ensure sound construction. Now taking this
decision as to which repairs or modifications may be waived off should be taken very
carefully. Normally, the maximum extent of repairs not requiring retesting shall be the tack
welding of any piping support or pad. Anything else shall be done following a retest.
Pressure testing and conducting 100% radiography or ultrasonic inspection shall not be
interchanged. In case carrying out of hydrostatic or pneumatic test stands impractical then
100% radiography or ultrasonic testing may be performed but in addition to this it is
advisable to check that the whole piping and its components have been supplied against
acceptable ASTM standards and required test certificates are available. Conducting 100%
radiography of all the weld joints assure that your weld joints are defect free but can never
provide you with the assurance of mechanical integrity of a system. This is also to be noted
that radiography / ultrasonic inspection shall also not to be waived off if the pipeline is to be
hydrostatically tested. This may pose an additional safety risk during the test. Moreover,
some defects in the weld zones may prove to be detrimental way after taken in service due to
severe extended service conditions.

Comparison of Hydrostatic and Pneumatic Testing:

Hydrostatic Testing

Pneumatic Testing

Test pressure is normally 30% higher than the design pressure

Test pressure is normally 10% higher than t

Recommended for high pressure applications

Recommended only for low pressure applic

Test media (Water) used is not compressible by pressure

application

Test media (Air) used is compressible by pr

Energy stored per unit volume of water under test pressure is

very negligible

Energy stored per unit volume of compresse

pressure is very high

Needs thorough cleaning after test to

eliminate moisture especially for service which are reactive to
moisture / fluids

Easy to clean after testing

Pressure Relief devices are recommended to control sudden

increase in pressure during testing

Pressure relief devices are must during test

pressurisation

Chances of equipment/ Pipe / test apparatus

failures are very low

Chances of equipment/ Pipe / test apparatus

failures are high

Weight of equipment along with test medium as

water is high hence special attention should be given to floor
and supporting arrangements

Weight of equipment with test medium

as air is comparatively less

Needs verification and examination of joints and connections

before testing

Needs very careful checking of weld joints

testing

Test media can be reused or transferred to other place after

testing

Test media can not be reused or transferred

testing

Skilled and semi skilled personnel can carry out the test

Needs involvement of senior experienced st

test.

Recommended where large volumes are to be tested at same

time (example pipe lines )

If pipe lines are tested should be done with

lengths at a time.

Damages made by failures are less compared to failures in

pneumatic testing

Damages made by failures in testing are ver

extensive

Hydrotest is a regular day to day practice and safe procedure

and it can be followed in any work site

Needs special attention and safety precautio

Pressure changes finite amount by infinitesimal change in

volume

Pressure change proportional to volume ch

Difficulties with hydrostatic testing:

Supply & disposal of water, disposal of fluid additives

Water leak can cause equipment damage

Freeze susceptibility

Structural support limitations

Contamination

Operational impacts process contaminant

Affect dry-out of internal refractory linings

Difficulties

with

Pneumatic

testing:

Pneumatic tests are potentially more dangerous than hydrostatic tests because of the higher
level of potential energy stored during compressing the gas. Care must be exercised to
minimize the chance of brittle failure during testing by initially assuring the system is suitable
for pneumatic testing. Pneumatic tests could be performed only when at least one of the
following conditions exists:

When the systems are designed in such a way thet it cannot be filled with water.

When the systems are such that it is to be used in services where traces of the testing
medium cannot be tolerated.

Using a pneumatic test instead of hydrostatic requires approval from proper authority or
body.
Test Pressure:
ASME Code B 31.3 provides the basis for test pressure. The minimum hydrostatic test
pressure for metallic piping shall be as per the following equation:
Pt=1.5*Pd*(St/Sd)
Here,
Pt=minimum
test
gauge
pressure
Pd=internal
design
gauge
pressure
St=allowable
stress
value
at
test
temperature
Sd=allowable
stress
value
at
design
temperature.
The maximum allowable value of St/Sd is 6.5The pneumatic test pressure shall be as per the
following equation: Pt=1.1*PdNormal Basis for Test Method Selection:
Normally the following basis is followed in process piping industry for selection of hydro or pneumatic
tests.
1. If the fluid handled by piping system is liquid then the pipe must be hydrotested.
2. If the fluid handled is vapour or gas then the internal design pressure dictates the testing
method. For pipe design pressure 10 bar and above the pipe is hydrotested. For pipe design
pressure below 10 bar pipe is pneumatically tested.
3. If fluid handled is stream then hydrotesting is suggested.

4. If fluid handles is two-phase flow then hydrotesting is suggested. However for big size flare
headers pneumatic testing is performed.
Test Duration:
Normally every EPC company have their own standard for duration of tests. However the
recommended practice is that a QC inspector have to walk through the whole piping system and
check for leaks. Every single length of piping, welds, bolted connections shall be visually examined for
any leakage. Duration of this activity varies with the span of piping system. For larger piping system
time taken for this activity is enough to clear the pressure test. In case of piping system having smaller
span, 1 hour time may be made as standard practice for hydrostatic testing. For Pneumatic test the
test time is far lesser.Few important points to consider while hydrotesting:

The tower overhead lines which are normally hydro tested shall be decided by stress
engineer group whether to hydro test after erection or at grade, based on the capacity of
standard clip available as per engineering specification for pipe supports.

During hydrotest in case of big bore it should be decided first that line is to be hydrotested on
rack or grade if hydrotest is done on rack , hydrotest load should be considered in case of
vapour lines while providing structure / rack loading information.