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Pressure Leak Testing Guide PDF
Pressure Leak Testing Guide PDF
This best practice guideline was produced with the assistance of BCAS members
and the Society is grateful to those who contributed.
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1.0 Introduction
The testing of compressed air pipe systems is essential for two reasons:
a. To establish the system leak rate – for energy efficiency and reliability purposes
This leads to two distinct tests a) the leakage test and b) the pressure (integrity)
test. They have different objectives but are often confused. The confusion may arise
from that fact that the two tests are carried out one after the other, during the same
commissioning visit to site.
2.0 Scope
This guide concerns the pressure testing of piping and its associated components.
The scope does not extend to air receivers.
This guide should be used in conjunction with the BCAS Installation Guide.
All testing described in this guide refers to the pneumatic testing method only,
i.e. the system is pressurised with air or gas. Hydraulic/hydrostatic testing
(i.e. pressurising the system with water) is no longer a recommended test method.
Significant problems arise in removing the water after the test, and there are potential
safety aspects of any residual water left in the system being ejected under force when
compressed air is reintroduced. Contact BCAS if details of the hydraulic method
are required.
In the same way that air receivers are a source of stored energy, so is pipework.
The Pressure Systems Safety Regulations 2000 Approved Code of Practice states that
the owner/user of the system must ensure that those doing the installation have the
required training, skills and experience.
If there are one or two extremely small inaudible leaks in a large system
(new or extended), the cost to locate and repair them, will significantly outweigh
the annual cost of the leaks. If a client requires a guaranteed leak-free system,
as would be necessary for distributing a hazardous gas such as acetylene, then the
recommendation would be to specify that all joints are welded professionally for
health and safety reasons.
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3.3 Agreeing the Conditions for the Pressure (Integrity) Test
The pressure at which the integrity test is conducted and its duration should be
agreed at the contract stage such that the test can be costed correctly.
The term ‘PS’ has been in use since the introduction of the Pressure Equipment
Directive. Most compressed air equipment subject to the Pressure Equipment
Directive (PED) will show the ‘PS’ value on the equipment.
When agreeing the test conditions, the test pressure chosen should be related to one
of these reference pressure values. The test pressure value used has traditionally
been 1.5 times the design pressure of the system. However, this does not take into
account the actual operating pressure nor the age of the system being tested.
For general industrial activities with pressures up to 40 bar 1.5 is an acceptable factor.
If required, then the test pressure values stated in the Pressure Equipment Directive
may be chosen as either 1.25 or 1.43 times ‘PS’.
For applications where the operating pressure of the system is in excess of 40 bar or
that a test pressure cannot be achieved using a factor of 1.5 then a lower test pressure
value may be agreed. Across different industries acceptable test pressure values
range from actual system pressure, i.e. 1:1, or a small increase to 10% above system
pressure.
The duration is also variable, and the longer the duration required the higher the cost
of conducting the test. See Section 4.2.
a) 1.1
b) 1.25
c) 1.43
d) 1.5
e) Any other factor agreed between the supplier and customer
The value chosen is then multiplied by the reference pressure value identified from
3.3.1 to determine the actual test pressure value
The leakage and integrity tests are usually carried out sequentially and should be
undertaken in the presence of /witnessed by the client.
A pneumatic test of a compressed air system for leakage should be the first step.
The following procedure should be strictly adhered to and carried out at pressures
not exceeding 6 bar:
c. Any valve intended to isolate part of the compressed air pipe system should be
in the open position. Ball valves are recommended since they allow immediate
isolation of the ring main system from the compressor.
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4.1 Leakage Test
The purpose of the leakage test is to establish the performance of the system from an
energy efficiency perspective.
b. Using a compressor or medium suitable for this purpose (the system compressor
may be suitable if it is installed and functional), pressure should be applied at a
maximum incremental rate of 1 bar per minute.
Note: If the system being tested is oil free then the use of a test compressor
could introduce contamination. In this case it is recommended to use an inert gas
(nitrogen or argon) from a suitably regulated bottle.
c. During this pressurisation investigate any signs of possible failure, e.g. obvious
audible leaks, movements in the piping and fittings or noises from the piping and
fittings not consistent with the functional operation of valves, which may form part
of the system under test.
e. The pressure shall be maintained for 15 minutes to allow the system to stabilise.
Then the pressure shall be sustained for a period long enough to allow for an
examination to discover any leaks.
f. Check for leaks using the pressure decay method and locate leaks using a leak
detection agent or an ultrasonic leak detector. Monitor the system pressure using
a calibrated pressure gauge which will also indicate leakage.
h. Repeats stages b. to g. until it has been established that the agreed leakage rate
has not been exceeded.
The staged testing of the piping system in this way reduces the probability of
potentially difficult dismantling procedures to rectify a subsequent fault.
This test usually follows on from the leakage test in Section 4.1.
a. Continue raising the pressure incrementally until the agreed test pressure value
is reached, which should not exceed the reference pressure value agreed in
section 3.3.
b. The test pressure should be held for long enough to examine all of the joints and
where relevant surfaces for leakage or plastic deformation. It is recommended to
hold the test pressure for a minimum of 15 minutes or any longer period agreed
and/or necessary to establish the integrity of the system.
c. Where the test pressure was above the normal working pressure then reduce the
test pressure until the normal working pressure is reached, taking care to ensure
that the air is being discharged safely. Hold the working pressure for at least one
hour and monitor for signs of leakage.
e. After pressure testing to confirm the integrity of the pipe system, connect all
equipment included in the operational system. The joints made to all operational
equipment should be tested for leakage using a leak detection agent or an
ultrasonic leak detector.
f. Issue a dated test certificate witnessed and signed by the client or the client’s
representative to the effect that they have witnessed the pressure test and
accepted the leakage results.
Refer to the BCAS Pipe Joint Guide for details on threading and assembly of pipe joints
for compressed air using metallic tubes and fittings where the pressure tight joints are
made on threads.
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4.3 Follow Up Check
After the first 48-96 hours of operation, all joints should be visually/audibly checked to
ensure that none have loosened due to settling of the components.
Important note: only the new part of the system is pressure tested. The existing
system should not be pressure tested, and should be isolated before pressure
testing commences.
Conduct the leakage test per Section 4.1, steps a – f , ensuring that the client signs as
witnessing the test and agreeing to the results.
In the situation where a new system has been installed and a few months later,
additional single line drops are added separately the latter qualify as single line drops
with no requirement for pressure tests on the whole system to be repeated.
All jointing shall be carried out employing the process described by the manufacturer
of the system or the relevant British Standard.
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6.4 ‘Press-fit’ Joints
This is a mechanical pressed joint using an O-ring to make it fluid tight. The joint can
be made by either hand force crimping tools or powered hand tools. It should be
noted that the joint cannot be disassembled without destroying the connection and
the need to remake the joint completely with new fittings. Therefore, where flexibility
is required, other systems may be more suitable.
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Annex A. Measurement of Leakage
If it is required to measure the actual leakage rate, two methods are available.
8 ¼ 0.5
10 ⅜ 0.8
15 ½ 1.8
20 ¾ 3
25 1 5
32 1¼ 8
40 1½ 13
50 2 20
65 2½ 33
80 3 50
100 4 78
125 5 123
150 6 177
Q = V * ∆P Where:
V = D2 Where:
V = volume of 10m length of pipe
100
D = the manufacturer’s stated internal bore in mm.
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Annex A.3. Method 2 Direct Measurement of Pressure Decay
1. Main compressor used to pressurise the system (this may be the system’s own
compressor or a portable compressor, or other suitable medium brought in
especially for the purpose).
7. Non-return valve.
8. Length of tubing, DN8 or larger for connection to test point in system (should be
straight tubing and not coiled type).
6
1
5 4 2
The items in Figure 1 shown inside the chain dot line will form a portable and
complete test unit.
d. Close ball valve (6) with flow control valve (5) initially in the fully open position.
e. If the supply from the test compressor (2) is insufficient to supply the leakage from
the system under test then the pressure gauge reading (3) will fall. If the supply
from the test compressor exceeds the leakage then the pressure gauge reading (3)
will rise.
f. Adjust the flow control valve (5) until the pressure gauge reading remains steady
for at least 5 minutes. Read the flow-meter (4) and record this value as the
leakage flow.
g. Locate and cure the leak points and repeat the tests until the recorded flow is
equal to or less than the agreed maximum leakage.
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Annex B.
Installation Guide
Compressed Air Condensate Guide
Pipe Joint Guide
H&SE Publications
SKILLcard
The Pressure Equipment Regulations (S.I. 1999 No. 2001) may be viewed on the UK
Government website, www.hmso.gov.uk/stat.html
BS EN ISO 10255: Non Alloy steel tubes for welding and threading.
(Superseding BS EN 1387)
BS EN ISO 15614: Welding procedure tests for the arc welding of steels.
(Superseding BS EN 288)
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