Pressure Test: Hydrostatic and Pneumatic Test Requirements Page 1 of 14

PRESSURE TEST: HYDROSTATIC AND

PNEUMATIC TEST REQUIREMENTS
By ARANER Posted 2017-11-15 In Refrigeration, Our Most Popular Post

Pressure tests are a non-destructive way to guarantee the integrity of

equipment such as pressure vessels, pipelines, plumbing lines, gas cylinders,
boilers and fuel tanks. It is required by the piping codes to confirm that a piping
system is able to bear its rated pressure and it has no leaks.

The most widely used code for pressure and leak test is the ASME B31 Pressure
Piping Code. Among its several sections, the requirements and procedures
listed in the codes below are followed by ARANER:

• ASME B31.1 Power Piping

• ASME B31.3 Process Piping

• ASME B31.5 Refrigeration Piping

Pressure tests may be done either with liquid, usually

water (hydrostatic), or with gas, usually dry nitrogen
(pneumatic).

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ASME B31.1
The hydrostatic test pressure at any point in the piping system shall not be less
than 1.5 times the design pressure, but shall not exceed the maximum allowable
test pressure of any non-isolated component, nor shall it exceed the limits of
calculated stresses due to occasional loads.

ASME B31.3
The test pressure shall be not less than 1.5 times the design pressure. When the
design temperature is greater than the test temperature, the minimum pressure
shall be calculated by eq.  PT = 1,5P ST/S , where =allowable stress at test
temperature, S=allowable stress at component design temperature, P=design
gage pressure.

The test pressure may be reduced to the maximum pressure that will not
exceed the lower of the yield strength or 1.5 times the component ratings at test
temperature.

The pressure shall be continuously maintained for a minimum time of 10

minutes and may then be reduced to the design pressure and held for such
time as may be necessary to conduct the examinations for leakage.
Examinations for leakage shall be made of all joints and connections.

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PNEUMATIC TEST
1. Precautions: Pneumatic testing involves the hazard of released energy stored in

compressed gas. Particular care must be taken. It is recommended to be used only when

piping systems are so designed that they cannot be filled with water, i.e, refrigerant

systems; or when piping systems are to be used in services where traces of the testing

medium cannot be tolerated.

2. Test fluid: The gas used as test fluid, if not air, shall be nonflammable and nontoxic, such

as nitrogen.

3. Pressure and procedure: the pressure limits and methodology is different for the codes

mentioned above.

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ASME B3.1
The pneumatic test pressure shall not be less than 1.2 nor more than 1.5
times the design pressure of the piping system. It shall not exceed the maximum
allowable test pressure of any non-isolated component.

The pressure in the system shall gradually be increased to not more than 1/2 of
the test pressure, after which the pressure shall be increased in steps of
approximately 1/10 of the test pressure until the required test pressure is
reached. The pressure shall be continuously maintained for a minimum time of
10 min.

It shall then be reduced to the lower of design pressure or 100 psig [700 kPa
(gage)] and held for such time as may be necessary to conduct the examination
for leakage. Examination for leakage by soap bubble or equivalent method shall
be made of all joints and connections.

ASME B31.3
The test pressure shall not be less than 1.1 times the design pressure and
shall not exceed the lower of 1.33 times the design pressure or the pressure
that would produce a nominal pressure stress or longitudinal stress in excess of
90 % of the yield stress of any component at the test temperature.

The pressure shall be increased until a gage pressure, which is the lower of 0.5
times the test pressure or 170 kPa (25 psi), at which time a preliminary check
shall be made. Thereafter, the pressure shall be gradually increased in steps
until the pressure is reached, holding the pressure at each step until the piping
strains are equalized.

The pressure shall then be reduced to the design pressure before

examining for leakage. During the test, a pressure relief device shall be
provided, having a set pressure not higher than the test pressure plus the lower
of 345 kPa (50 psi) or 10% of the test pressure.

ASME B31.5

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The test pressure shall be at least 1.1 and shall not exceed 1.3 times the
design pressure of any component in the system. The pressure in the system
shall be gradually increased to 0.5 times the test pressure, after which the
pressure shall be increased in steps of approximately 1/10 of the test pressure
until the required test pressure is reached.

The test pressure shall be maintained for at least 10 minutes. It may then
be reduced to the design pressure and conduct the examination for leakage.
During the test, a pressure relief device shall be provided, having a set pressure
above the test pressure, but low enough to prevent permanent deformation of
any of the system components.

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