Hydrotest and Pneumatic Test of Piping Systems-Hydrotest Vs Pneumatic Test

Written by Anup Kumar Dey in Construction ,Engineering Materials ,Inspection and

Testing ,Maintenance ,Mechanical ,Pipeline ,Piping Design Basics ,Piping Interface ,Piping Stress
Analysis ,Piping Stress Basics ,Process

Table of Contents
 Types of Pressure Testing
 What is Hydro-Test or Hydrostatic Test?
 What is the Pneumatic Test?
 When to perform a Pressure Test
 Comparison of Hydrostatic and Pneumatic Testing
 Difficulties with hydrostatic testing
 Difficulties with Pneumatic testing
 The basis for Pressure Test Method Selection
 Pressure Test Duration
 Hydrotest Fluid
 Hydrotest system preparation
 Hydrotesting Documentation
 Hydrostatic Testing Problems
 Hydrotest Checklist
 Video Tutorial on Differences between Hydrostatic test and Pneumatic test

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
Subsequent to repairs and heat treatment and prior to initial operation or commissioning of any plant
it has to be ensured that there is no evidence of leakage by Pressure Testing.

Types of Pressure Testing

In the process Industry, two methods are widely used for pressure testing of piping or equipment. They are

 hydro-static test or Hydrotest and

 pneumatic test
What is Hydro-Test or Hydrostatic Test?
Hydro test or Hydrostatic test is a type of pressure test performed on piping and pressure vessels to
check system integrity under pressure condition. A hydrostatic test is performed by using water as
the test medium.

What is the Pneumatic Test?

The pneumatic test is a type of pressure test for checking system integrity under the pressurized
condition and applied to systems where the hydro-static test is difficult to apply. A pneumatic test
uses air, nitrogen, or any non-flammable and non-toxic 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 the 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 the 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 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 a detrimental way after taken in service due to severe extended service
conditions.  
Comparison of Hydrostatic and Pneumatic Testing
The following table lists down the major differences between hydrostatic and pneumatic testing.

Hydrostatic Testing Pneumatic Testing

Test pressure is normally 50% higher than the design pressure Test pressure is normally 10% higher than
the design pressure
Recommended for high-pressure applications Recommended only for low-pressure
applications
Test media (Water) used is not compressible by pressure application Test media (Air) used is compressible by
pressure application
Energy stored per unit volume of water under test pressure is very Energy stored per unit volume of
negligible compressed air under test pressure is very
high
Needs thorough cleaning after the test to eliminate moisture especially Easy to clean after testing
for service which are reactive to moisture/fluids
Pressure Relief devices are recommended to control a sudden increase Pressure relief devices are must during the
in pressure during testing test to ensure no over-pressurization
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 Weight of equipment with the test medium
special attention should be given to floor and supporting arrangements as air is comparatively less
Needs verification and examination of joints and connections before Needs very careful checking of weld joints
testing thoroughly before testing
Test media can be reused or transferred to other places after testing Test media can not be reused or transferred
to other places after testing
Skilled and semi-skilled personnel can carry out the test Needs involvement of senior experienced
staff to monitor the test.
Recommended where large volumes are to be tested at the same time If pipelines are tested should be done with
(example pipelines ) small segmental lengths at a time.
Damages made by failures are less compared to failures in pneumatic Damages made by failures in testing are very
testing huge and extensive
Hydrotest is a regular day to day practice and safe procedure and it can Needs special attention and safety
be followed in any worksite precautions
 Pressure changes finite amount by an infinitesimal change in volume  Pressure change proportional to volume
change
Table: Hydro Test vs Pneumatic Test
Difficulties with hydrostatic testing
 Supply & disposal of water, disposal of fluid additives
 A 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 that 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.

How to calculate Hydrotest 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:

P t =1.5*P d *(S t /S d )
Here,
Pt=minimum test gauge pressure
Pd=internal design gauge pressure
St=allowable stress value at the test temperature
Sd=allowable stress value at design temperature.
The maximum allowable value of St/Sd is 6.5

How to Calculate Pneumatic Test Pressure?

The pneumatic test pressure shall be as per the following equation:

 P t =1.1*P d
The basis for Pressure Test Method Selection
Normally the following basis is followed in the process piping industry for the selection of hydro or
pneumatic tests.

1. If the fluid handled by the piping system is liquid then the pipe must be hydro tested.
2. If the fluid handled is vapor or gas then the internal design pressure dictates the testing
method. For pipe design pressure 10 bar and above the pipe is hydro tested. For pipe design
pressure below 10 bar pipe is pneumatically tested.
3. If fluid handled is steam then hydro testing is suggested.
4. If the fluid handled is two-phase flow then hydro testing is suggested. However, for big size
flare headers, pneumatic testing is performed.

Pressure Test Duration
Normally every EPC company has its own standard for the duration of tests. However, the recommended
practice is that a QC inspector has 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. The duration of this
activity varies with the span of the piping system. For larger piping system time taken for this activity is
enough to clear the pressure test. In the case of a piping system having a smaller span, 1 hour time may be
made as standard practice for hydrostatic testing. For the Pneumatic test, the test time is far lesser.

Few important points to consider while hydro-testing:

 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 the hydro test in case of big-bore, it should be decided first that line is to be hydro tested on
rack or grade if the hydro test is done on the rack, the hydro test load should be considered in case of
vapor lines while providing structure/rack loading information.

Hydrotest Fluid
As the name signifies, the test has to be performed using clean potable water free from suspended solids.
However different codes specify different requirements for water quality. Hence, hydro tests need to be
performed following those instructions.

Hydrotest system preparation

The piping network and the connected equipment must be prepared thoroughly before proceeding for
pressure tests like hydro or pneumatic testing. Codes like ASME B31.3/ ASME B 31.1 and local company
instructions normally provide guidelines for such preparation.
Piping systems that are normally open to the atmosphere, such as drains, vents, discharge piping from
pressure-relieving devices, sewers, and stack downstream of the seal drum, need not be subjected to the
piping test pressure.
For some countries, The provincial local inspector shall be notified at least 48 hours in advance of pressure
testing of piping under the jurisdiction of the provincial safety code for witnessing at his/her option.

The following equipment shall be excluded from all piping pressure tests:

 Vessels and tanks

 Heat exchangers
 Rotating machinery, such as pumps, compressors, and turbines
 Equipment and Supplier furnished piping specifically recommended by the manufacturer not to be
tested
Underground portions of piping systems may be tested and covered before testing aboveground portions.

Roughly, The following steps should be followed for preparing the piping system for leakage testing.

Comparison of P&ID/PEFS and Isometric Drawing

The first step is to compare the piping isometrics with the P&ID drawings to check if any discrepancy exists.
All valve types, flow directions, branch tie-ins, and any material changes, etc are reviewed thoroughly. In-line
components are verified and ensured that they are able to withstand the test pressure.

Thorough Inspection before testing

All sorts of ultrasonic and radiographic inspections or checks must be carried out before the actual pressure
test is started. 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 be waived off if the pipeline is to be hydrostatically
tested.

Joints shall be exposed

All joints, welds (including structural attachment welds to pressure-containing components), and bonds shall
be left uninsulated and exposed for examination during leak testing as per Section 345.3.1 of ASME B31.3,
except that joints previously tested in accordance with this Code may be insulated or covered.

Provision of Temporary Supports

If required Pipings designed for vapor or gas services shall be provided with additional temporary supports, to
support the weight of test liquid as the test liquid is heavier than service fluid.

Spring Supports in Piping System

All Spring supports shall be kept in the locked condition during hydrostatic testing. Holding pins shall not be
removed from spring supports until testing is completed and the system is drained. Care shall be taken to
avoid overloading any parts of the supporting structures during hydrostatic testing.
Instruments

 All in-line Instruments shall be either removed or blocked prior to hydro testing to prevent damage
during hydro testing (e.g. meters).
 Instrument take-off piping and sampling system piping, up to the first block valve, shall be tested with
the piping to which it is connected.
 Instrument lead lines, between the first block valve and the instruments to which they are connected,
shall be pressure tested to the test pressure of the associated piping. Testing may be performed
separately or at the same time as the piping is tested, but the instruments shall be disconnected.

Hydrotest for Piping with Expansion Joints

If there is an expansion joint in the piping system under the leakage test, the following criteria shall be
applied.

1. An expansion joint that depends on external main anchors to restrain pressure end load shall be
tested in place in the piping system.
2. A self-restrained expansion joint previously shop-tested by the manufacturer
3. A piping system containing expansion joints shall be leak tested without temporary joint or anchor
restraint at the lesser of
4. 150 % of design pressure for a bellows-type expansion joint, or
5. the system test pressure determined in accordance with para. 345

In no case shall a bellows-type expansion joint be subjected to a test pressure greater

than the manufacturer’s test pressure.

 When a system leak test at a pressure greater than the minimum test pressure specified in (c), or
greater than 150% of the design pressure within the limitations of para. 345.2.1(a) is required, bellows-
type expansion joints shall be removed from the piping system or temporary restraints shall be added to
limit main anchor loads if necessary.

Limits of Tested Piping

Equipment that is not to be tested must be either disconnected from the piping or isolated by blinds or other
means during the test. A valve may be used provided the valve is suitable for the test pressure.

Rotating Machinery
For rotary machinery, such as pumps, compressors, or steam turbines,  have lube and seal oil systems that
could be impaired by the presence of water. These systems shall not be subjected to the piping test
pressure.

Test Water
Clean water that will not corrode and/or damage the test system shall be used for hydrostatic tests. If
municipal water is not available, supply water may be obtained from a native water supply. Water containing
silt or suspended material shall not be used, and a suitable filter with 40 mesh should be provided in the filling
line. A mixture of glycol-water shall be used where the ambient temperature may reach less than 0°C (32°F)
during testing or prior to dry-out

Temporary Spades and Blanks

If Temporary spades and blanks are installed for testing purposes, those must be designed to withstand the
test pressure without distortion. The presence of spades shall be clearly visible during testing. The
recommended practice is to use standard blind flanges as per ASME B16.5 or B16.47 and spades acc. to
ASME B16.48.

Check Valves
Check Valves shall have the piston or flap removed for testing,  where pressure can not be located on the
upstream side of the valve. The locking device of the flap pivot pin shall be reinstated together with the flap
and a new cover gasket shall be installed after completion of the test.

Completion of Hot Work

Wherever applicable All hot works, related to welding or the post-weld heat treatment have to be completed
before the Hydrostatic test.

Installation of Barriers
It is necessary to install safety barriers around the piping system under test prior to starting pressurization
related to testing. Public Address announcements and access restriction procedures such as permit to work
shall be implemented. Under no circumstances should anyone other than an authorized person be allowed
within the safety barriers.

Control Valves
Prior to the leakage test, Control Valves and soft-seal block Valves shall be removed from the piping and
replaced with pipe spools. However, All welded Valves need to be tested along with pipings otherwise
Radiographic Testing of golden joints (welded) will be required.

Physical Inspection
Prior to test following should be checked :

 All gravity supports installed.

 Proper pipe routing.
 Vents or other high point connections shall be opened to eliminate air from and plugged during the
test.
 lines that are to receive a hydrostatic test.
 Completed and torqued flanges with no missing bolts or gaskets.
 Proper material type verified using color codes or markings, and heat numbers recorded if required by
the codes.
 Correct valve type and orientation.
 Vents and drains installed to allow proper filling and draining
 When a pressure test is required to be maintained for a period of time during which the testing medium
in the system would be subject to thermal expansion, the provision shall be made for the relief of any
pressure greater than the maximum test pressure.
 All required piping stress relief, weld examinations, and welding documentation completed and
acceptable. A relief valve to be added such that the test pressure is not exceeded beyond a safe amount.
 When conducting tests at freezing temperatures, the test shall not take more than 4 hours, and special
precautions, such as using glycol/water mixture, shall be observed to avoid freezing damage

Hydrotesting Documentation
The individual system documentation i.e. test pack shall be available prior to any testing and shall include
information such as test limits, test pressure, test medium, duration, test blinds, blind flanges, vents, and
drains.

The use of marked up P&IDs coupled with isolation registers should be utilised to identify the locations of
blinds, Valves, vents and drains.

Records shall be made of each piping system test. In general, these records shall include the following
information:

 Date of test
 Identification of piping system
 Test medium
 Test pressure
 Minimum ambient temperature
 Test medium temperature
 Certification by examiner
 Test duration
 Pipe standards or specifications for the test
 Pressure and temperature recording charts and logs
 Location and cause of leaks/failures
 Repair procedures used in the event that the pipe leaked of failed
 Test results
 Name of test operator
 Minimum metal temperature (if applicable)
 Test gauge calibration date
Forms, when completed, shall be retained in the Construction Contractor’s QC file as a permanent record.

Hydrostatic Testing Equipment

Testing equipment such as pumps, manifold, pressure, and temperature recorders, pressure gauges should
be within calibration/certification (as per company procedures) and connected to the lowest convenient
connection within the system to ensure the best results.

Hydrostatic Testing Problems

Even though proper industry-approved methods are followed for pressure testing, still due to some
negligence hazards do happen. Some of the most common reasons for failures during hydro test and
pneumatic tests are:

 Over pressurization
 Operator error
 Inadequate equipment
 Poor component design
 Improper isolation of the tested system from equipment or remaining parts of the system.
 Inadequate repairs
So it is always a good idea to follow safe work practices for Hydro testing. The below-mentioned steps can be
followed to avoid hazards of Pressure Testing:

 Prepare a standard operating procedure (SOP) for the hydro test or pneumatic test following the latest
applicable code
 Developing a checklist using the sop and sticking to it.
 Train the involved personnel indicating the potential hazards and safety measures.
 Develop a Pre-test safety plan and conduct a pre-test safety briefing just prior to hydro testing.
 Perform a Walk down inspection following the checklist to ensure all hydro test checkpoints are taken
care of.
 After the hydrostatic test, gradually release the pressure and drain the system.
Hydrotest Checklist
The following section provides a sample of hydrotest checklist to inform the major points that must be
considered.

  Hydrotesting Checklist      
  Pre HydroTest Checklist      
Sr Description Complie Not Remarks
No d Complied
1 All Affected person like Owner, Managers, Workers, Suppliers, informed      
2 Test pressure and duration received or estimated      
3 Standard Operating Procedure identified      
4 Pre-test safety plan completed      
5 Required workers properly trained      
6 Test Equipment inspected, calibrated and certified      
7 Test Temperature verified      
8 Test area barricated and warning signs posted to keep non-essential members outside the hydrotest      
zone
9 Walk down inspection performed      
10 Hydrotest system preparation proper      
11 Vent Valve, Block Valve closed      
12 All joints exposed, No insulation      
13 System parts properly aligned      
14 Torque on bolted connections as per manufacturer guidelines      
15 Lockout tagout finished as per guidelines      
16 Emergency contact information collected      
17 proper isolation from equipment and non-test parts following SOP performed      
18 Pressure relief valve installed      
  Checklist during Hydrotest      
19 Hydrotest equipment properly installed      
20 Working professional with all PPE equipment      
21 Pressure applied gradually following work procedure/standards      
22 Pressure maintained for the pre-decided time duration      
23 All exposed joints thoroghly checked for leakage potential.      
  Post Hydrotest Checklist      
24 Repairs started aifter the release of Hydrotest Pressure.      
25 Pressure is released gradually.      
26 Water disposed of as per procedure      
27 Repairs performed following procedures