SECTION : PIPING Part IV-Vol IV

FUNCTIONAL SPECIFICATION FOR Spec.No: 04-SP-05

PRESSURE TESTING OF ERECTED PIPING Rev. No: 0
SYSTEM Sheet No: 1 of 9

Functional Specification
For
Pressure Testing of Erected Piping System
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FUNCTIONAL SPECIFICATION FOR Spec.No: 04-SP-05
PRESSURE TESTING OF ERECTED PIPING Rev. No: 0
SYSTEM Sheet No: 2 of 9

1. SCOPE

These guidelines cover the requirements for pressure testing of piping systems. Part A
covers the methods to determine test pressure useful for process engineers. Part B intends
to provide guidelines for construction engineers.

2. PART A: DESIGN REQUIREMENTS

2.1 EXTRACTS OF ASME CODE FOR PRESSURE PIPING ANSI /

ASME B.31.3 – 1984

337.4 TEST PRESSURE

337.4.1 Hydrostatic Testing of Internally Pressured Piping.
The hydrostatic test pressure at any point in the system shall be as
follows except as provided in 337.4.2(b):
a) not less than 1- ½ times the design pressure;
b) for a design temperature above the test temperature, the minimum test
pressure shall be calculated by Eq.(24). If ST/S is greater than 6.5, 6.5
shall be used for the value of ST/S when calculating the minimum test
pressure.
c) PT = 1.5 P ST --------------- (24)
S
Where
PT = minimum hydrostatic gauge pressure
P = internal design gauge pressure
ST = allowable stress at test temperature
S = allowable stress at design temperature. (See SE
Values in Table A-1, or S values in Table B-1, B-2, and B-3).
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FUNCTIONAL SPECIFICATION FOR Spec.No: 04-SP-05
PRESSURE TESTING OF ERECTED PIPING Rev. No: 0
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c) If the test pressure as defined above would produce a stress in excess of the
yield strength at test temperature, the test pressure may be reduced to the
maximum pressure that will not exceed the yield strength at test temperature.
(See 302.3.2, Notes (2) and (3)).

337.4.2 Hydrostatic Testing of Piping with Vessels as a System

a) Where the test pressure of piping attached to a vessel is the same as or less
than the test pressure for the vessel, the piping may be tested with the
vessel at the test pressure of the piping.
b) Where the test pressure of the piping exceeds the vessel test pressure, and it
is not considered practicable to isolate the piping from the vessel, the piping
and the vessel may be tested together at the test pressure of the vessel, when
approved by the Company and provided the vessel test pressure is not less
than 115% of the piping design pressure adjusted for temperature as
required by 337.4.1 (b).

337.4.3 Hydrostatic Testing of Externally Pressured Piping

a) Lines in external pressure services shall be subjected to an internal test

pressure of 1-½ times the external differential design pressure but not less
than gauge pressure of 15 psi (103 kPa).

b) In jacketed lines, the internal line shall be pressure tested on the basis of the
internal or external design pressure whichever is critical. This test must be
performed before completion of the jacket if necessary to provide visual
access to the joints of the internal line as required by 337.3.

c) In jacketed lines, the jacket shall be pressure tested in accordance with

337.4.1 on the basis of the jacket design pressure unless otherwise limited by
the engineering design.
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FUNCTIONAL SPECIFICATION FOR Spec.No: 04-SP-05
PRESSURE TESTING OF ERECTED PIPING Rev. No: 0
SYSTEM Sheet No: 4 of 9

337.4.4 Pneumatic Testing

If the piping is tested pneumatically, the test pressure shall be 110% of the
design pressure. Pneumatic testing involves the hazard due to possible release
of energy stored in compressed gas. Therefore, particular care must be taken to
minimize the chance of brittle failure during testing. The test temperature is
important in this regard and must be considered when the choice of material is
made in the original design. Any pneumatic test shall include a preliminary
check at not more than 25 psi (170 kPa) gauge pressure. The pressure shall be
increased gradually in steps providing sufficient time to allow the piping to
equalise strains during test and to check for leaks.

337.5 SPECIAL ALTERNATIVE TESTS

337.5.1 Metallic Piping in Other Than Category D” Fluid Service

a) In circumstances where neither hydrostatic nor pneumatic tests in 337.4.1 and

337.4.4 are considered practical by the Company, an alternative test as
permitted by 337.5.1(b) may be employed, if both of the following conditions
apply.

1) A hydrostatic test would be damaging to linings or internal insulation;

would contaminate a process which would be hazardous, corrosive, or
inoperative in the presence of moisture; or would present a danger of brittle
fracture from low metal temperature during test.
2) A pneumatic test would introduce considerable hazard due to possible
release of stored energy in the system or would present a danger of brittle
fracture from low metal temperature during test.
b) Under the above conditions, the following shall be applied.
1) Welds, including those used in the manufacture of welded pipe and
fittings, which have not been subjected to pressure tests in accordance
with 337.4.1 or 337.4.4 shall be nondestructively examined as follows.
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FUNCTIONAL SPECIFICATION FOR Spec.No: 04-SP-05
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a) Butt welds shall be 100% radiographed in accordance with

336.4.5.
b) All welds, including structural attachment welds, shall be liquid penetrant
examined in accordance with 336.4.If the material is magnetic, magnetic
particle examination in accordance with 336.4.3 may be used in lieu of
liquid penetrant examination.
c) When heat treatment is required, the above examinations shall be
performed after heat treatment.
2) The system or joints to be tested shall be subjected to a sensitive leak test
in accordance with 337.b. All joints which have not been tested in
accordance with 337.4.1 or 337.4.4 shall be examined for leakage.
3) A flexibility analysis of the system shall be made in accordance with
319.4.2 (c) and (d).
375.5.2 Alternative Test for Category D4 Fluid Service Only:

At the Company’s option, a piping system used only for Category D fluid
service (as defined in 300.2) may be tested at the operating conditions of
the system during or prior to initial operation by examining for leaks at
every joint not previously pressure tested in accordance with this code. A
preliminary check shall be made at not more than 25 psi (170 kPa) gauge
pressure when the contained fluid is a gas or vapour. The pressure shall be
increased gradually in steps providing sufficient time to allow the piping to
equalize strains during test and to check for leaks.

2.2 EXAMINATION AND ADDITIONAL SUGGESTIONS ON PART A:

2.2.1 If ST/S ratio is high, there is a possibility that stresses induced due to
hydrostatic test pressure may exceed yield strength. This will lead to
underisable plastic deformation. This can be checked by the following :
Where
RS = PT D
2t
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FUNCTIONAL SPECIFICATION FOR Spec.No: 04-SP-05
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RS < YS
RS = Resultant Stresses due to hydrotest
PT = Hydrostatic Test Pressure.
t = Min. pipe wall thickness (i.e. excluding manufacturing
tolerances of 12.5%).
YS = Yield strength at test temperature.
(See Table A-1).
2.2.2 The provision of 337.4.2 do not replace or otherwise alter the pressure
testing requirements of the applicable vessel code.
2.2.3 Even for lines to be externally pressurised during operation, hydrostatic
pressure testing can be done by pressurising internally as the primary and
sole objective of this test is to establish leakproof joints.
2.2.4 Category D fluid Service – A fluid service in which all the following apply:

a. The fluid handled is non flammable, non-toxic, and not damaging to human
tissues;
b. The design pressure does not exceed 150 psi (1030 kPa); and
c. The design temperature is from -200F (-290C) through 3360F (1860C).

3. PART B: CONSTRUCTION REQUIREMENTS

3.1 EXTRACTS OF ANSI/ASME B31.3 – 1984
337 PRESSURE TESTS
337.1 Tests, General
Prior to initial operation, each piping system shall be pressure tested to
ensure tightness except as permitted for Category D fluid service in
337.5.2. The pressure test shall be maintained for a sufficient time, not
less than 10 min, to determine if there are any leaks.

In the event of repairs or additions are made following the pressure

tests, the affected piping shall be retested, except that, in the case of
minor repairs or additions, the Company may waive retest
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FUNCTIONAL SPECIFICATION FOR Spec.No: 04-SP-05
PRESSURE TESTING OF ERECTED PIPING Rev. No: 0
SYSTEM Sheet No: 7 of 9

requirements when precautionary measures are taken to assure sound

construction.

When conducting pressure tests at metal temperature near the ductile-to-

brittle transition temperature of the material, the possibility of brittle
fracture shall be considered.

Tests alternative to those required by 337.2, 337.3, and 337.4 may be

applied under the conditions described in 337.5.

337.2 Test Fluid

The test shall be hydrostatic using water, except as follows.
a) If there is a possibility of damage due to freezing, or if the operating fluid
or piping material would be adversely affected by water, any other suitable
liquid may be used. If a flammable liquid is used, its flash point shall not
be less than 1200 F (500C), and consideration shall be given to the test
environment.
b) If hydrostatic testing is not considered practicable by the Company, a
pneumatic test in accordance with 337.4.4 may be substituted, using air or
another non-flammable gas.
c) A preliminary air test at not more than 25 psi (170 kPa) gauge pressure may
be made prior to hydrostatic test in order to locate major leaks.
d) A combination of hydrostatic-pneumatic test is permissible. The pressure
in the liquid-filled portion of the piping shall not exceed that given in
337.4.1.

337.3 Test Preparation:

All joints, including welds and bonds, are to be left un-insulated and
exposed for examination during the test, except that joints previously tested
in accordance with this code may be insulated or covered. If a sensitive
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leak test (337.6) is required all joints mentioned above shall also be left
unprimed and unpainted.

Piping designed for vapour or gas shall be provided with additional

temporary supports, if necessary, to support the weight of the test liquid.

Expansion joints shall be provided with temporary restraint if required for

additional pressure load under test, or shall be isolated from the test.

Equipment which is not to be subjected to the pressure test shall be either

disconnected from the piping or isolated by blinds or other means during
the tests. Valves may be used provided the valve (including the closure
mechanism) is suitable for the proposed test pressure.

A flanged joint at which a blank is inserted to blank off other equipment

during the test need not be tested.

If a pressure test is to be maintained for a period of time and the test liquid
in the system is subject to thermal expansion, precautions shall be taken to
avoid excessive pressure.

337.6 Test Records

Records shall be made of each piping system during the testing. These
records shall include:
1) date of test;
2) identification of piping tested;
3) test fluid;
4) test pressure;
5) certification by examiner.
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These records need not be retained after completion of the test if a

certification by the Inspector, that the piping has been pressure tested as
required by this code, is retained.

3.2 EXPLANATION AND ADDITIONAL SUGGESTIONS ON PART B

3.2.1 Deleted

3.2.2 In services like Dry Air, Ethylene etc., small traces of water can cause
problem. Such lines should either be pneumatically tested or Hot Air
drying is to be done after Hydro-test.
3.2.3 If operating fluid in the line is much lighter than testing fluid, the additional
weight of testing fluid may render piping supports (As designed)
inadequate. This will call for additional temporary supports. The typical
examples are FLARE and vapour lines. It is preferable that hydrostatic
testing is avoided in such systems and instead pneumatic testing may be
specified.
3.2.4 Lines carrying highly hazardous/poisionous fluids must have a sensitive
leak test as per the following:

“EXTRACTS”
337.6 Sensitive Leak Test
Piping required to have a sensitive leak test shall be tested by the Gas
and Bubble Formation Testing method specified in Article 10, Section V
of the BPV code, or by another method demonstrated to have equal or
greater sensitivity. Sensitivity of the test shall be at least 10-3 atm-ml/sec
(100 Pa-ml/sec) under test conditions. If a hydrostatic pressure test is
used, it shall be done after the sensitive leak test.