PROCEDURE NO.

PAGE OF
PTD-DGS-117 1 8

PREPARED BY DATE
PROCESS TECHNOLOGY PROCEDURES Edited from existing April 30, 2000
doc by J.R. Barnhart
APPROVED BY
DEPARTMENT: PROCESS ENGINEERING JRB
SUBJECT: MINIMUM TEST PRESSURE CALCULATION DESIGN REVISION DATE REV.
GUIDE 11/01/02 1

1.0 SCOPE

This design guide1 presents the procedures for calculating minimum test pressure for
piping subjected to internal or external pressures.

2.0 RESPONSIBILITIES

The process engineer is responsible for calculating the minimum test pressure for lines
shown on the piping and instrumentation diagrams (P&IDs) and in the line summary.

The line summary will print the minimum test pressures based on the information provided
for each line. The basis for calculations are standard piping material specifications and
the codes and standards identified in Section 3.0 of this document. The test pressures in
the line summary should be the calculated test pressures rounded to the nearest highest 5
pounds per square inch gage (psig).

3.0 CODES AND STANDARDS

The latest issue of the following codes and standards are referenced in this design guide.

1. ASME/American National Standards Institute (ANSI)

B31.1 Power Piping
B31.2 Fuel Gas Piping
B31.3 Chemical Plant and Petroleum Refinery Piping
B31.4 Liquid Transportation Systems for Hydrocarbons, Liquid
Petroleum Gas, Anhydrous Ammonia, and Alcohols
B31.5 Refrigeration Piping
B31.8 Gas Transmission and Distribution Piping Systems
B31.9 Building Services Piping
B31.11 Slurry Transportation Piping Systems

Table 1 cross references the pipe classification standards with nine different services.

1
Rev. 0 of the Design Guide was adapted with minimal changes from a Pasadena document, DSG-MP13, 11/92
 Table 1 - Pipe Classification Cross References

Service Pipe Classification

Building services piping ASME/ANSI B31.9

Chemical plant and petroleum refinery piping ASME/ANSI B31.1

Fuel gas piping ASME/ANSI B31.2

Gas transmission and distribution piping system ASME/ANSI B31.8

Liquid transportation systems for hydrogen, liquid ASME/ANSI B31.4

petroleum gas, anhydrous ammonia, and alcohols

Power piping ASME/ANSI B31.1

Refrigeration piping ASME/ANSI B31.5

Slurry transportation piping systems ASME/ANSI B31.11

4.0 TEST PRESSURE

In accordance with ASME/ANSI B31 (.1, .2, .3, .4, .5, .6, .8, .9, and .11), the test pressure
setting falls into two main categories:

1. Internal Pressure
Internal pressure includes hydrostatic testing and pneumatic testing.
2. External Pressure
External pressure includes hydrostatic testing and pneumatic testing.

4.1 Internal Pressure Test Procedure

The following guideline shall be used to calculate the minimum test pressure subject to
internal and/or external pressure.
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4.1.1 Power Piping

In accordance with ASME/ANSI B31.1, the following requirements of hydrostatic testing

apply to power piping:

1. The hydrostatic test pressure at any time shall not be less than 1.5 times the design
pressure for design temperature at or below the test temperature.
2. For design temperature above the test temperature, the minimum test pressure
shall be calculated by Equation 5-4, except that the value of S  /S shall not exceed
6.5 (for the value of S  , see ASME/ANSI B31.1, Stress Table A-1).
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4.1.2 Pneumatic Testing

Pneumatic testing shall not be used unless the Purchaser specifies pneumatic testing or
permits its use as an alternative. Pneumatic testing is recommended for use only when
one of the following conditions exists:

1. When piping systems are designed so that they cannot be filled with water
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2. When piping systems are to be used in services where traces of the testing
medium cannot be tolerated

The pneumatic test pressure shall not be less than 1.2 times the design pressure. The
test pressure shall not exceed the maximum allowed test pressure of any nonisolated
component in the system (see Equation 5-2).

Test temperature must be considered when the designer chooses the construction
material.
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4.1.3 Fuel Gas Piping

In accordance with ASME/ANSI B31.2, hydrostatic test pressure and pneumatic testing for
fuel gas piping shall meet the following requirements:

1. For hydrostatic test pressure, see Paragraph 4.1.1. However, the test pressure
value shall not be less than 3 psig.

2 For pneumatic testing and test pressure, see Paragraph 4.1.2. The test pressure
shall not be less than 3 psig.
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4.1.4 Chemical Plant and Petroleum Refinery Piping

In accordance with ASME/ANSI B31.3, hydrostatic test pressure and pneumatic testing for
chemical plant and petroleum refinery piping shall meet the following requirements:
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1. For hydrostatic test pressure, see Paragraph 4.1.1. However, if the test pressure as
defined in that paragraph would produce a stress in excess of the yield strength at
test temperature, the pressure may be reduced to the maximum pressure that will
not exceed the yield strength at test temperature (see ASME/ANSI B31.3 and
Equation 5-4).

For pneumatic testing, see Paragraph 4.1.2. The test pressure value shall be 110
percent of the design pressure (see Equation 5-1).
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4.1.5 Liquid Transportation Systems for Hydrocarbon, Liquid Petroleum Gas, Anhydrous
Ammonia, and Alcohols

In accordance with ASME/ANSI B31.4, the hydrostatic testing (for liquid only) and the
proof test for liquid transportation systems for hydrocarbons, liquid petroleum gas,
anhydrous ammonia, and alcohols shall meet the following requirements:

1. The portion of piping to be operated at a hoop stress of more than 20 percent of the
specified minimum yield strength of the pipe shall be subjected at any point to a
hydrostatic proof test not less than 1.25 times the internal design pressure
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multiplied by the lowest ratio of the permissible stress intensity value (see Equation
5-3). This requirement pertains to those piping systems that are visually inspected.
2. For piping systems that are not visually inspected, the proof test shall be followed
by a reduced pressure leak test of no less than 1.1 times the internal design
pressure for not less than 4 hours (see Equation 5-1).

4.1.6 Refrigeration Piping

In accordance with ASME/ANSI B31.5, the hydrostatic test pressure and the pneumatic
testing for refrigeration piping shall meet the following requirements:
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1. For hydrostatic test pressure, see paragraph 4.1.1. However, if the test pressure
defined in that paragraph would produce a stress in excess of the yield strength at
test temperature, the pressure may be reduced to the maximum pressure that will
not exceed the yield strength at test temperature (see ASME/ANSI B31.3).
2. For pneumatic testing, see Paragraph 4.1.2. The test pressure value shall be 110
percent of the design pressure (see Equation 5-1).

4.1.7 Nuclear Power Piping

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In accordance with ASME B31.7, the hydrostatic test pressure and pneumatic testing for
nuclear power piping shall meet the following requirements:
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1. Except as otherwise permitted in ASME B31.1, Paragraphs 1-737.1 and 1-737.4.7,

piping systems shall be subject to a hydrostatic test pressure at every point in the
system that is not less than 1.25 times the internal design pressure multiplied by
the lowest ratio of the permissible stress-intensity value (see Equation 5-3).
2. For pneumatic testing and test pressure, see Paragraph 4.1.2.

4.1.8 Gas Transmission and Distribution Piping System

In accordance with ASME/ANSI B31.8 and Table 2, the testing of gas transmission and
distribution piping systems shall meet the following requirements:
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1. Hydrostatic testing is required for piping systems operating at hoop stress of 30

percent or more of the specified minimum yield strength of the piping material.
2. Pipeline and mains located in Class 1 locations shall be tested either with gas or air
or hydrostatically tested at 1.1 times the maximum operating pressure.
3. Pipeline and mains located in Class 2 locations shall be tested either with gas or air
or hydrostatically tested at 1.25 times the maximum operating pressure.
4. Pipeline and mains located in Class 3 and 4 locations shall be tested hydrostatically
at 1.4 times the maximum operating pressure.
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5. Offshore platform piping and prefabricated portions of offshore platform risers shall
be tested hydrostatically at 1.4 times the maximum operating pressure.

4.1.9 Building Services Piping

In accordance with ASME/ANSI B31.9, hydrostatic testing and test pressure and
pneumatic testing and test pressure for building services piping shall meet the following
requirements:

1. For hydrostatic testing and test pressure, see Paragraph 4.1.1.

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2. For pneumatic testing and test pressure, see Paragraph 4.1.2. The following
exceptions to Paragraph 4.1.2 apply:
a. The piping system should not contain cast iron piping.
b. The piping system should not contain soldered joints over 2 inches in diameter.
c. The test pressure should not exceed 150 psig.
d. If the piping system is nonmetallic, it should not be larger than 2 inches National
Pipe Threads (NPT).

4.1.10 Slurry Transportation Piping Systems

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In accordance with ASME/ANSI B31.11, hydrostatic and leak testing for slurry
transportation piping systems shall meet the following requirements:
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1. The portion of piping to be operated at a hoop stress of more than 20 percent of the
specified minimum yield strength of the pipe shall be subjected at any point to a
hydrostatic proof test not less than 1.1 times the internal design pressure multiplied
by the lowest ratio of the permissible stress intensity value (see Equation 5-1).
2. When lines are tested at a pressure that develops a hoop stress based on nominal
wall thickness (in excess of 90 percent of the specified minimum yield strength of
the pipe), special care shall be used to prevent overstrain of the pipe.
3. For piping systems that are visually inspected, no further test is needed.
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4. For piping systems that are not visually inspected, the proof test shall be followed
by a reduced pressure leak test of no less than 1.1 times the internal design
pressure for not less than 4 hours.
5. A 1-hour hydrostatic or pneumatic leak test may be used for piping systems that will
be operated at a hoop stress of 20 percent or less of the specified minimum yield
strength of the pipe. The hydrostatic test pressure shall not be less than 1.25 times
the internal design pressure. The pneumatic test pressure shall be 100 psig or a
pressure that would produce a normal hoop stress of 25 percent of the specified
minimum yield strength of the pipe, whichever is less.
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4.2 Hydrostatic Testing of External Pressure Piping

Lines in full or partial vacuum service shall be tested at a minimum internal pressure of
+15 psig, unless limited to a lower pressure by design. Jacketed lines shall be tested on
the basis of the jacket pressure in accordance with Paragraph 4.1. The internal line shall
be tested on the basis of the internal or external pressure, whichever is critical, unless
limited by design. Lines in external pressure service shall be subjected to an internal
pressure test at not less than the external design pressure.

5.0 EQUATIONS
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The following equations are used in minimum test pressure calculation:

1. Pneumatic Testing

PS
PT  1.1 x (Eq. 5-1)
S

2. Pneumatic Test Pressure

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PS
PT  1.2 x (Eq. 5-2)
S
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Table 2 - Test Requirements for Pipelines and Mains To

Operate at Hoop Stresses of 30 Percent or More of the
Specified Minimum Yield Strength of the Pipe

Pressure Test Prescribed

Maximum Allowable
Class Location Permissible Test Operating Pressure, the
Fluid Lesser or
Minimum Maximum
(x mop)
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1 Water 1.10 None tp – 1.10

Air 1.10 1.1 x dp or
Gas 1.10 1.1 x dp dp

2 Water 1.25 None tp – 1.25

Air 1.25 1.25 x dp or
dp

3 Water 1.40 None tp – 1.40

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or
dp

4 Water 1.40 None tp – 1.40

or
dp

Source: ASME/ANSI B31.8, 841.3225

mop = maximum operating pressure (not necessarily the maximum allowable operating pressure)
dp = design pressure
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tp = test pressure

This table brings out the relationship between test pressures and maximum allowable operating pressures
subsequent to the test. If an operating company decides that the maximum operating pressure will be less
than the design pressure, a corresponding reduction prescribed test pressure may be made as indicated in
the Pressure Test Prescribed, Minimum, column. However, if this reduced test pressure is used, the
maximum operating pressure cannot later be raised to the design pressure without retesting the line to the
test pressure prescribed in the Pressure Test Prescribed column.

3. Hydrostatic Testing
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PS
PT  1.25 x (Eq. 5-3)
S

4. Hydrostatic Test Pressure

PS
PT  1.5 x (Eq. 5-4)
S
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where:

PT = minimum hydrostatic gage pressure

P = internal design pressure
S = allowable stress at test temperature
S = allowable stress at design temperature; ANSI B31.3, Table A-1. For high
pressure (above 2,500-pound flange rating), use ANSI B31.8, Table K-1.

5. Hoop Stress
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PD
 (Eq. 5-5)
2t

where:

P = design pressure
D = internal diameter
t = wall thickness
 = yield stress
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