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Testing requirements for piping systems are covered in para. 345 of ASME B31.3
code. As per ASME B31.3, prior to initial operation and after completion of
applicable examinations as per para. 341, each piping system shall be tested to
ensure tightness. The recommended test is a hydrostatic leak test.
If a hydrostatic leak test is deemed impracticable by the owner, then either a
pneumatic test or a combined hydrostatic-pneumatic test may be substituted,
recognizing the hazards associated with stored energy in compressed gas. This
article will discuss the hydrotest procedure for piping. The requirements related
to pneumatic test will be covered in a separate article.
Hydrotest Fluid
The default hydrotest fluid in most cases is water. Water used for hydrostatic
testing of piping shall be fresh, clean and free from suspended solids and other
foreign matter. Water may not be used as a hydrostatic test medium under the
following circumstances:
the presence of water in the piping system may have adverse effects during
plant start-up and operation.
the piping material or its lining may deteriorate in the presence of hydrotest
fluid.
there is a likelihood of test water to be contaminated during testing and its
disposal may pose environmental hazards.
drop in ambient temperature may cause water to freeze during the test.
Flushing
Prior to the hydrotest, the system shall be flushed with the dedicated test
medium to remove all dirt and foreign matter. Recommended methods of flushing
are:
for lines up to 6” diameter, liquid volume flushing. For this method the
minimum velocity in the largest pipe diameter to be not less than 3
meters/second.
for lines over 6” diameter, hydroblast by means of self climbing high
pressure water jet nozzles (Dynorod method) or approved equivalent.
for air, halon and hydraulic lines, air blast cleaning ensuring a minimum
velocity of 10 meters/second at the outlet end is achieved.
All necessary precautions shall be taken to avoid debris being pushed into
associated equipment or “dead ends”.
Flushing shall proceed in an intermittent manner allowing time between flushes
for debris to be cleared from line. Flushing shall continue for sufficient time to
ensure that line is cleaned to the satisfaction of Company.
Manifold provided with end caps suitable for the system pressure testing. It
is recommended that all joints in a test manifold are of welded type and should
be subject to 100% non-destructive examination by MPI and Radiography.
Pressure relief valve of adequate capacity to relieve the system of any
overpressure.
A manual bleed valve for emergency bleeding and depressurisation of the
piping system, should the relief valve fail.
A pressure gauge, pressure recorder and temperature recorder connection.
The pressure gauge should be calibrated preferably within 4 weeks of the test
being carried out. The hydrotest pressure should preferably fall within 35-75%
of the full range of pressure gauge.
A connection to connect the hydrotest or pneumatic pump to the manifold.
A connection to connect the test manifold to the low point of the piping
system for filling and pressurisation.
Hoses that connect the pumps to the test manifold and the test manifold to
the piping system shall be rated for the test pressure and fitted with safety
chains of sufficient strength that will prevent whipping of the hose, should the
coupling get disconnected.
All valves and fittings on the manifold shall be of the next higher rating.
The strength of the test manifold should be validated by testing the manifold
between 1.2 to 1.4 times of its rated system test pressure. Note that ASME
B31.3 code does not provide any guidance on the recommended test pressure.
These are based on construction industry practices.
PRESSURE TEST MANIFOLD
Piping required to have a sensitive leak test as per line list will be tested by the
Gas and Bubble Formation Testing Method specified in Article 10, Section V of
the ASME Boiler Pressure Vessel Code. Sensitivity of the test shall not be less
than 10-3 atm-ml/sec (100 Pa-ml/s) under test conditions.
The test pressure shall be at least the lesser of 1.00 bar (100 kPa) gage, or 25%
of the design pressure.
The pressure shall be gradually increased until a gauge pressure the lesser of
one-half the test pressure or 1.70 bar (170 kPa) is attained, at which time a
preliminary check shall be made. Then the pressure shall be gradually increased
in steps until the test pressure is reached, the pressure being held long enough at
each step to equalize piping strains.
If a Sensitive Leak test is required, joints will also be left unprimed and
unpainted.