AN OVERVIEW OF

PRESSURE TESTING
Presentation 2006

Index
Introduction
Definition & Purpose
Application
Types of Pressure Tests
Safety Requirements
Governing Standards
General Requirements

Determine Test Pressure

Flushing / Cleaning
Pressurizing
Leak Detection Methods
Test Duration
Depressurize & Disposal
Lay-Up

INTRODUCTION
Pressure

Testing is one of the quality control

methods that is universally known and
accepted as a means of demonstrating the
fitness of a pressurized component for
service.

DEFINITION & PURPOSE

Pressure Testing is defined as a test conducted to any
pressure component or equipment by subjecting it to an
internal pressure using liquid or gas.
Purpose

To ensure strength of the pressure component

To ensure tightness of the system
To detect and eliminate any defects
To show or prove that no defect exists

Pressure = Force per Unit Area

= pounds per sq. inch
= psi

APPLICATION

Pipe Spools

Plant Piping

Pipeline

Pressure Vessels & Tanks

Heat Exchangers

Valves

Non-Metallic Pressure Component

TYPES OF PRESSURE TESTING

A.

Hydrostatic Testing is a pressure test

using water or other approved liquid as the
test medium.

B.

Pneumatic Testing is a pressure test using

air or other approved gas as testing
medium.

Safety Failure During Test

Safety Failure During Test

SAFETY REQUIREMENTS
Follow

the requirements of G.I. 2.102

Obtain work permit from operating organization.

Cordon off the testing area.
Only qualified personnel shall be involve.
Use only proper test equipment
Avoid striking or working on equipment being tested
while under pressure.
Piping or equipment must be adequately supported.
Controlled pressure rise.

GOVERNING STANDARDS
Saudi Aramco Standards

G.I. 2.102 Pressure Testing

Safely
SAES-A-004 General
Requirements for Pressure Testing
SAES-A-007 Hydrostatic Testing
Fluids and Lay-Up Procedures
SAES-L-150 Pressure Testing of
Plant Piping and Pipelines
04-SAMSS-048 Valve Testing &
Inspection Requirements
SAEP-327 Disposal of
Wastewater from Cleaning,
Flushing, and Hydrostatic Test
Water.

Industry Standards

ASME B31.3 Process Piping

ASME B31.4 Pipeline
Transportation Systems for
Liquid Hydrocarbons & Other
Liquids
ASME B31.8 Gas
Transmission and Distribution
Piping Systems
API 598 Valves Inspection
and Testing. Or any Standard
stated in the P.O.
API 600 Valves
API 602 Valves
ASME B16.34 Valves

GENERAL REQUIREMENTS
Approved

Written Test Procedure

Test Package
Pre- Test Inspection
Test Equipment
Calibrated Instruments

Equipment
& Instruments Required
Test

Manifold tested to at least 20% above

test pressure.
Pressure Gauge calibrated within one
month of the test and the range shall be such
that test pressure shall be within 30% to 80%
of its range.
Relief Valve calibrated within 1 week of
testing. Set at 5% above test pressure.
Pressure Pump

Test Manifold For Hydrostatic Testing

Relief Valve

Vent Valve

Pressure Gauge

Block Valve

Bleeder Valve
Hand Pump

DETERMINING TEST PRESSURE

A.

The hydrostatic test shall produce a hoop stress in

the pipe of 90% of the specified minimum yield
strength or SMYS. (SAES-L-150).
P = 2 x t x 0.9S
D
Where:

P = test pressure, psig

S = SMYS, pounds per sq. in.

D= outside diameter of pipe, in.
t = wall thickness, in. (less mill tolerance)
Note: Design Temperature & Test temperature considerations are critical. When Design
Temps exceed Test Temps, see ASME B31.3, 345.4.2
Pt = 1.5 x PSt
S

Determining Test Pressures

B.
C.
D.
E.
F.
G.

By flange rating or valves in the line (from ASME

B16.5 & ASME B16.34)
By operating pressure (for service test)
By 1.5 times the design pressure (minimum
required by ASME B31.3 paragraph 345.4.2)
For Pneumatic Testing it is 110% of the design
pressure as per ASME B31.3 paragraph 345.5.4.
200 psig for firewater lines. (SAES-B-017 Par.12.6).
Refer to SAES-A-004 & SAES-L-150 for other
equipment & testing condition.

SAMPLE PRESSURE TEST

PACKAGE REVIEW (CALCS)
VERIFY LIMITING FACTOR CALCS:
1.
Piping calcs ... How to do it. Where to go.

P = 2 x t x 0.9S / D
Proposed Test Pressure = 1125 psig in your test package (limiting factor Class 300 Flange)
Material (piping spec) is ASTM A 106 Grade B (Not Grade A ... Be very careful checking)
S or SMYS is Found in ASME B31.3 Appendix A Tables (pg 430/596) = 35 KSI
D is listed on SIS Sheets as 2 , 24 & 16 ... Use outside diameters of 2.375, 16 & 24
T is listed on SIS Sheets as: 2 = Sch 80 or .218 wall, 16 & 24 = Std wall or .375
T include Mill Tolerance ... 87.5% of Nominal for seamless pipe, or .01 for rolled plate
T = .218 x .875 or .191 for 2 pipe & .375 x .875 or .328 for 16 & 24 pipe

Calcs as follows:
2 2 x .191 x .9 (35,000) / 2.375 = .382 x 31,500 = 12,033 / 2.375 = 5,066 psig
16 2 x .328 x .9(35,000) / 16 = .656 x 31,500 = 20,664 / 16 = 1292 psig
24 2 x .328 x .9(35,000) / 24 = .656 x 31,500 = 20,664 / 24 = 861psig

REVIEW RESULT: WE REJECT TEST PACKAGE & REQUIRE TEST

PRESSURES BE DROPPED TO LIMITING FACTOR or 861 psig.
SIS Sheets must be revised to show corrections.

COMMON LIMITING FACTORS

FOR PRESSURE TEST
1. Flange fitting pressure ratings (ASME B16.5, B16.47 for large diameter,
API Work ratings)
2. Valve Flange Ratings (ASME B16.34)
3. Large Diameter Piping (Check calcs quickly on all 12 +)
4. Schedule 20 or 30 piping is checked very closely
5. Special SA Considerations for Systems (Flare Headers, etc)
6. Testing against a closed valve (1.1 times pressure rating of
Valve, not 1.5 times rating as allowed in Valve body tests)
Learn to do 2-minute calcs per package and quickly review calcs.
Keep a fast check sheet available for pressure ratings. Never look
Up the same stuff on a regular basis. BE EFFICIENT!!!
CORROSION ALLOWANCE FINDINGS ... WHOSE JOB IS IT?
SPEED DRILL & CLASSROOM PRACTICE (LIMITING FACTOR)

FLUSHING

The piping system is filled up with water and at

low points of the system water is released. In
case of pipelines, scraper is used ahead of the
Hydrotest water.

In Pneumatic testing, the system is filled with air

and with all exit points open, check the
cleanliness of the system by using a clean target
paper.

FLUSHING CONCERNS
1. Low point accumulated water & debris.
2. Where is the low point? Low point drain?
3. Using gravity and air to blow dry lines.
Blow from high points (Dry Rag, debris)
4. Disagreements about adequacy of flushing.
Torch Slag controversy for set-on weld bosses
Discoloration of water, noted heavy deposits
DO NOT FORGET THE VALVES (DRAINS)
Check Valves & other locations for problems
RANDOM Valve Checks after flushing ... Youll be
surprised what you will find.

PRESSURIZING

Test fluid injected at the lowest point in the system

Gradually increase the pressure in the system to
50% of the required test pressure, or 25 psig for
pneumatic test. (QC HOLD POINT ... Equalization)
20% increment for hydrostatic test and 10%
increment for pneumatic test.
Disconnect the pressure pump and allow the
pressure in the system to stabilize for a period of 10
minutes or 5% of the test time whichever is longer.
Use Tape for pressure readings over time of test.
Press into test report as hard evidence of passing
tests. Also train your QC to be extremely efficient.

Plant Piping Isometric Drawing

LEAK DETECTION METHODS

Visual

Inspection Method: During and after

the completion of test pressure, conduct a full
visual inspection of the system. All welds,
threaded/flanged connections, and including
valves must be inspected for leaks.
Pressure Drop Method: After stabilization
record the exact pressure and monitor during
the test period. This method is particularly
used in testing pipelines or any 24 hour
recorded testing.

Pressure Chart

Pressure/Temperature Chart

Leak Detection
In

Pneumatic Testing all joints are

inspected by applying a mixture of soapwater solution or any commercial leak
detectors.

TEST DURATION
30 minutes minimum for hydrostatic test of plant
piping. (SAES-L-150 Para. 7.2)
In pipelines, 2 hours strength test plus 24 hours
recorded tightness test. (SAES-L-150 Para. 8.3)
4 hrs for firewater lines.(SAES-B-017 Para. 12.6)
As long as necessary for inspection of leaks in
pneumatic testing.
For Valves, as per applicable standard such as
API 598, MSS-SP80, or AWWA.

Depressurizing & Test Water Disposal

Upon

completion of a successful hydrostatic

test release the pressure through the vent
valves and bleed valves. The test liquid shall
be slowly drained with vents open to prevent
collapse of system. (Random Witness Point)

Test

fluid shall be disposed in accordance with

SAEP-327. The disposal procedure must first
be approved by the Environmental Protection
Department of Saudi Aramco.

LAY-UP (Refer to SAES-A-007)

Lay-up

rules (14 & 60 day ... LL)

Ambient Lay-Up
Dry Lay-Up
Wet Lay-Up
Inert Gas Lay-Up
Use of Vapor-Phase Corrosion
Inhibitors