B.
663
PRESSURE AND LEAK TESTING
TABLE B14.1 Test and Examination Pressures
Code
Test type
Test pressure
minimum
Test pressure
maximum
Test pressure
hold time
Examination
pressure
ASME B31.1
Hydrostatic1
1.5 times design
Max allowable test
pressure any component or 90 percent
of yield
10 minutes
Design
pressure
ASME B31.1
Pneumatic
1.2 times design
1.5 times design or
max allowable test
pressure any component
10 minutes
Lower of 100
psig or
design
pressure
ASME B31.1
Initial
service
Normal operating
pressure
Normal operating
pressure
10 minutes or
time to complete leak examination
Normal operating
pressure
ASME B31.3
Hydrostatic
1.5 times
design2
Not to exceed yield
stress
Time to complete leak examination
but at least
10 minutes
1.5 times
design
ASME B31.3
Pneumatic
1.1 times design
1.1 times design plus
the lesser of 50 psi
or 10 percent of test
pressure
10 minutes
Design
pressure
ASME B31.3
Initial
service3
Design pressure
Design pressure
Time to complete leak examination
Design
pressure
ASME I
Hydrostatic
1.5 times max
allowable
working
pressure4
Not to exceed 90 percent yield stress
Not specied,
typically 1 hr
Max allowable working
pressure4
ASME III
Division 1
Subsection NB
Hydrostatic
1.25 times system design
pressure5
Not to exceed stress
limits of design section NB-3226 or
maximum test pressure of any system
component5
10 minutes
Greater of
design pressure or .75
times test
pressure
ASME III
Division 1
Subsection NB
Pneumatic
1.2 times system
design
pressure6
Not to exceed stress
limits of design section NB-3226 or
maximum test pressure of any system
component
10 minutes
Greater of
design pressure or .75
times test
pressure
B.664
GENERIC DESIGN CONSIDERATIONS
TABLE B14.1 Test and Examination Pressures (Continued )
Test pressure
minimum
Test pressure
maximum
Test pressure
hold time
Examination
pressure
Hydrostatic
1.5 times system
design
pressure
If minimum test pressure exceeded by 6
percent establish
limit by the lower of
analysis of all test
loadings or maximum test pressure
of any component
10 minutes or
15 minutes
per inch of
design minimum wall
thickness for
pumps and
valves
Greater of
design pressure or .75
times test
pressure
ASME III
Division 1
Subsection NC
Pneumatic
1.25 times system design
pressure
If minimum test pressure exceeded by 6
percent establish
limit by the lower of
analysis of all test
loadings or maximum test pressure
of any component
10 minutes
Greater of
design pressure or .75
times test
pressure
ASME III
Division 1
Subsection ND
Hydrostatic
1.5 times system
design pressure for completed components, 1.25
times system
design pressure for piping systems
If minimum test pressure exceeded by 6
percent establish
limit by the lower of
analysis of all test
loadings or maximum test pressure
of any component
10 minutes
Greater of
design pressure or .75
times test
pressure
ASME III
Division 1
Subsection ND
Pneumatic
1.25 times system design
pressure
If minimum test pressure exceeded by 6
percent establish
limit by the lower of
analysis of all test
loadings or maximum test pressure
of any component
10 minutes
Greater of
design pressure or .75
times test
pressure
Code
Test type
ASME III
Division 1
Subsection NC
Notes:
1. Boiler external piping must be hydrostatic tested in accordance with PG-99 of ASME Code Section I.
2. ASME B31.3 hydrostatic pressure must be raised above 1.5 times design pressure in proportion to yield
strength at test temperature divided by strength at design temperature but not to exceed yield strength at test
temperature. Where a vessel is involved whose design pressure is less than the piping and where vessel cannot be
isolated, the piping and vessel can be tested together at vessel test pressure provided vessel test pressure is not
less than 77 percent of piping test pressure.
3. ASME B31.3 initial service testing permitted only for piping in category D service.
4. ASME Code Section I hydrostatic test pressure at temperature of at least 70F (21C) and examination
pressure at temperature less than 120F (49C). For a forced-ow steam generator with pressure parts designed
for different pressure levels, the test pressure should be at least 1.5 times the maximum allowable working pressure
at the superheater outlet but not less than 1.25 times the maximum allowable working pressure of any part of
the boiler.
5. ASME Code Section III, Division 1, subsection NB, test pressure limits dened in section NB3226; also
components containing brazed joints and valves to be tested at 1.5 times system-design pressure prior to installation.
6. ASME Code Section III, Division 1, subsection NB, pneumatic test pressure for components partially lled
with water shall not be less than 1.25 times system-design pressure.
PRESSURE AND LEAK TESTING
B.665
inspection for leakage. Again the examination pressure depends upon the particular
code and the selected method of testing. Table B14.1 gives test and examination
pressures for some of the ASME B31 and Boiler and Pressure Vessel codes.
The test pressure for each test is calculated by multiplying the code requirements
for the leak-test method by the design pressure of the weakest component or line
within the test boundary. An exception to this occurs when the design rating is
given for a higher temperature than the temperature at which the pressure and
leak test will be conducted. In this case the test pressure must be increased by an
amount reecting the decrease in strength of the material between the test temperature and the operating temperature unless that would exceed code limitations
regarding the maximum test pressure. Another exception occurs in ASME B31.3,
where a vessel cannot be isolated from the system, and the allowable vessel pressure
is less than calculated test pressure for the piping. In such a case it is acceptable
to hydrostatic test the piping at the maximum allowable vesseltest pressure provided the owner approves and the reduced test pressure is at least 77 percent of
the calculated test pressure per ASME B31.3, section 345.4.3.
PRESSURE TESTING PROCEDURES
The eld engineer, responsible for the implementation of the eld test program,
must rst be familiar with the testing provisions of the code or standards that are
part of the contract. This person must assure coordination between the test supervisor, QA/QC, the contractor, and owner. The person responsible for the testing
should begin preparation for the testing phase far enough ahead of piping system
completion so that all the equipment needed to conduct the test is ready to be used
and all preparations are completed before testing is scheduled to begin.
Preparation of Test-Package Documentation
A P&ID (piping and instrumentation diagram) marked with information concerning
the pressure test, the piping isometrics, a valve line-up sheet, a test cover sheet,
and a test data sheet make up the package of test documentation.
The P&ID should be marked with the scope of the leak test, showing boundary
valves and test blind locations to isolate connections of the piping to the parts of
the system which do not need to be pressure tested. If hydrostatic test plugs are
required to seal any pipe or vessel openings, that requirement should be noted.
The valve line-up sheet shown in Fig. B14.5 should be completed, showing the
valve positions required for the test. Also identify any valves which must have the
internals removed or must be blocked in position. Test blinds may be fabricated
in accordance with the data given in Table B14.2. The ASME B31 codes do not
require retesting of a anged joint once the blinds are removed.
Determine the required test pressure by reviewing the P&ID drawings to obtain
the lowest line index and lowest design pressure rating within the boundary of the
test. Two checks are required for proper test pressure.
First, review the design documents and vendor information to ensure that the
test pressure will not overpressurize any equipment or piping component within
the pressure test boundary. In addition, verify that there will be no possibility of
brittle fracture at the test pressure and temperature.
Second, determine the head loss between the lowest part of the piping and the
gauge location. The head loss in psig is equal to the difference in elevation in feet
B.668
GENERIC DESIGN CONSIDERATIONS
FIGURE B14.6 Pressure test data sheet.
this checklist. A comparison of the P&ID drawings and the piping isometrics must
be made to determine if there are any discrepancies. Review all valve types, ow
directions, branch tie-ins, and any material changes. Recheck all in-line components
to verify they can withstand the required test pressure.
After the crosscheck is complete conduct a physical inspection of the piping
system using the P&IDs and piping isometrics. Typically systems are inspected for
Completed and torqued anges with no missing bolts or gaskets
All gravity supports installed
Proper pipe routing
Correct valve type and orientation
Vents and drains installed to allow proper lling and draining
