ENGINEERING SPECIFICATION

4WPI-EW44001
Pressure Testing of Piping and Equipment Rev. 3
Page 1 of 35
Uncontrolled copy if printed valid for use on date of print: Print Date: 8/1/17
Denotes Revision per EPS-01123924

1. PURPOSE

1.1 This engineering specification defines the minimum requirements for conducting pressure
testing of piping systems and in-line equipment.

2. SCOPE

2.1 This specification applies to pressure testing performed on Air Products construction sites, on
Air Products customer installations, and after modification of Air Products operating plant and
equipment.

2.1.1 Note: Pressure testing at Air Products or other equipment manufacturing locations is
excluded from these requirements because these facilities have their own pressure test
procedures relating to testing piping and equipment indoors.

2.2 Air Products Representative, as used herein, shall mean the person designated by Air
Products to be in charge of the work at the site and who through knowledge, experience, and
training will act on behalf of Air Products to ensure that all specification requirements are
adhered to when the contractor performs various pressure testing duties or tasks.

2.3 This document is to be used in conjunction with the project specific Pressure Test Guideline
that is developed by the responsible Engineering Organization as designated by Air Products.
It is intended to be used as a guide for contractors to safely and efficiently complete piping
systems and in-line equipment pressure tests. The pressure test will not be considered
complete until all required forms, as specified in the project specific Pressure Test Guideline,
have been completed and approved. Required forms may include the following:

Appendix A – Pressure Test Checklist

Appendix B – Permit to Conduct a Pressure Test
Appendix C – Pressure Test Blank Log
Appendix D – Pressure Test Component Log
Appendix E – Pressure Test Circuit Completion Log

Note: Unless specified otherwise, approval by Air Products shall mean approval in writing by
the Air Products Representative.

3. RELATED INFORMATION

Note: Unless specified otherwise, reference to related documents shall mean the latest
revision in force at the time of contract award.

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 2 of 35

3.1 Air Products Engineering Documents

4WPI-670210 Bolt-Up Procedure for Flanged Connections

4WPI-FWZC01 Specification for Welded Temporary Pipe Closures
670.890 Pipelines Pressure Testing
QC 200A Pressure Test Guideline Document
QC 200B Field Pressure Test Flowsheet Guideline
About this document (for Air Products Internal Use Only)
Version history (for Air Products Internal Use Only)

3.2 American Society of Mechanical Engineers (ASME)

B31.1 Power Piping

B31.3 Process Piping

3.3 American Society for Testing and Materials (ASTM)

A 105 Standard Specification for Carbon Steel Forgings for Piping Applications
A 106 Standard Specification for Seamless Carbon Steel Pipe for High-
Temperature Service
A 285 Standard Specification for Pressure Vessel Plates, Carbon Steel, Low-
and Intermediate-Tensile Strength
B 75 Standard Specification for Seamless Copper Tube
F2164 Standard Practice for Field Leak Testing of Polyethylene (PE) Pressure
Piping Systems Using Hydrostatic Pressure

3.4 Statutory Regulations

3.4.1 In addition to the referenced documents listed in the previous section, other statutory
regulations may govern the testing of some or all piping systems and in-line equipment.
When such regulations apply, reference will be made to them on the project specific Pressure
Test Guideline. The contractor is responsible for complying with any regulations which apply
to the work specified.

4. CLARIFICATION OF RESPONSIBILITIES

4.1 The contractor shall:

• Perform the pressure test in accordance with the project specific Pressure Test Guideline.
• Inform the Air Products Representative immediately if there appears to be errors or
discrepancies in specified requirements. The contractor shall not proceed with any such
aspects of the work until they have received clarification in writing from the Air Products
Representative.
• Provide safe access for inspection throughout the set-up and test period.

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 3 of 35

4.2 Pressure testing shall include the performance of all operations necessary for the pressure
testing of piping systems and in-line equipment, safe disposal of test medium after
completion of testing, and drying of the system where specified. All tools, equipment and
materials, including testing and flushing media, temporary pipe supports, test blanks, safety
relief valves, gaskets, and similar items shall be supplied by the contractor as required.

4.2.1 Operations necessary includes, but is not limited to; blanking; valve manipulation; removal
of process pressure relief valves; installation of testing manifold, test relief valves, and
instruments; flushing/blowout, pressurization, inspection, and restoration of piping system
and in-line equipment after testing; completion of test documentation and record submittal
as required, and verification that the piping systems and in-line equipment are ready for "on-
stream" operation.

5. SPECIFICATION - PRESSURE TEST GUIDELINE

5.1 The responsible Engineering Organization, as designated by Air Products, will provide the
project specific Pressure Test Guideline. Typically this will be one of the following documents:

• QC-200A – Pressure Test Guideline Document

• QC-200B – Pressure Test Flowsheet Guideline

5.1.1 The QC-200A - Pressure Test Guideline Document is a simplified pressure test document that
will occasionally be used in lieu of QC-200B.

5.1.2 The QC-200B - Pressure Test Flowsheet Guideline, which includes the color-coded flowsheet,
will be provided for most pressure tests. This document must be used when setting up a test
circuit. It provides the boundary and specifics of each circuit and summarizes areas within
which increased attention and caution are needed.

5.2 The project specific Pressure Test Guideline will specify the appendices required for each
circuit in the pressure test that the contractor is responsible for completing and submitting to
the Air Products Representative for approval.

6. TEST PREPARATION

6.1 Flushing/Blowout

6.1.1 Pipework to be hydrostatically tested shall be flushed thoroughly with clean and filtered,
fresh water before testing. The minimum flushing fluid velocity shall be 7 m/s (23 ft./s).

6.1.2 For systems containing stainless steel, the chloride ion content of the flushing water shall be
less than 50 ppm, unless lower limits are specified in the contract documentation. When
flushing lines of other materials, a chlorine ion content of less than 200 ppm may be used.

6.1.3 Pipework to be pneumatically tested shall be blown through with compressed air at a
minimum velocity of 35 m/s (115 ft./s) and at a maximum pressure of 2 bar g (29 psig). Dry,
oil-free compressed air is required for high purity systems or when specified in the project
specific Pressure Test Guideline document.

6.1.4 When the water or air velocities specified in this section are not practical because of large line
sizes, the contractor shall submit an alternative procedure to the Air Products Representative
for approval.

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 4 of 35

6.2 Welded and Flanged Joints

6.2.1 All field-installed joints (including structural attachment welds to pressure-containing

components) in the piping system shall be accessible during testing and shall not be insulated
or otherwise covered until satisfactory completion of the pressure test.

6.2.2 Joints may be primed and painted before leak testing unless a "sensitive leak test" per ASME
B31.3, paragraph 345.8 is required by the project specific Pressure Test Guideline.

6.3 Test Loading

6.3.1 Before testing, temporary restraints shall be installed to prevent movement in spring
supports and expansion joints. Contractor is responsible for providing these temporary
restraints as specified by the responsible Engineering Organization.

6.3.2 Temporary pins or restraints installed in spring supports and expansion joints by the
equipment manufacture shall remain in place until pressure testing has been completed.

6.4 Valves

6.4.1 All instrument isolation valves shall be closed during flushing and pressure testing. All other
valves shall be tested in the open position unless indicated otherwise on the project specific
Pressure Test Guideline flowsheet. Care shall be taken to ensure that all quarter-turn valves
are properly oriented during the test.

6.4.2 The pressure source should be located upstream of check valves and the depressurizing
connection should be located downstream. When this is not possible, check valve internals
shall be removed or fixed open. All check valves on the Pressure Test Guideline flowsheet will
be circled in red so that they can be easily recognized.

6.4.3 Valves which are required to be in the closed position during pressure testing will be depicted
on the Pressure Test Guideline flowsheet with either differing colors immediately upstream
and downstream of the valve or as a vent with only a color upstream of the valve.

6.4.4 Valves which are required to be in the open position during pressure testing will be depicted
on the Pressure Test Guideline flowsheet with the same color immediately upstream and
downstream of the valve.

Note: Individual circuits may be broken down into smaller sub-circuits by closing additional
valves as approved by the Air Products Representative.

6.5 Bellows and Hoses

6.5.1 Test blanks shall only be inserted adjacent to any flanged metallic bellows expansion joints
or flex hoses if both ends of the equipment item remain connected to and fully supported by
the adjacent piping.

6.6 Equipment

6.6.1 Pressure vessels shall not be included in the pressure test unless they are depicted as being
included on the project-specific Pressure Test Guideline.

6.6.2 Pumps, turbines, compressors, and blowers shall never be included in the pressure test.

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 5 of 35

6.7 Pressure Relief Devices

6.7.1 All normal system relief valves, burst discs, and in-line instruments must be either removed
or adequately isolated before pressure testing.

6.7.1.1 An exception to this rule may exist for in-service system testing. For example, in
the USA, established industry practice for existing in-service systems or utility
systems generally permit pressure/leak test following repairs/alterations to be
conducted at 90% of the circuit's safety device set pressure. This eliminates the
need to remove/isolate the items as listed in paragraph 6.7.1.

6.8 A test pressure relief device must be directly connected to or installed in the pressure
injection manifold of the circuit under testing and must not be isolated from the test circuit by
a block valve or blind.

6.8.1 Test relief devices for hydrostatic and pneumatic tests shall be installed with a set pressure of
no more than 10% above the test pressure. The test relief device must be positioned so as
not to cause injury during discharge, and be adequately supported to accommodate reaction
forces because of discharge. Circuits must never be pressure tested without an appropriate
pressure-relieving device installed as an integral part of the circuit or equipment.

6.8.2 The test pressure relief device shall be capable of discharging the full maximum media supply
available from the high-pressure media source used for the test. If this cannot be achieved, a
restrictive orifice shall be installed in the injection manifold to limit the source flow. The sizing
of the pressure testing relief device shall be based on the piping resistance and the wide-
open resistance of any regulator, control valve, or manual valves between the pressure
source and the test circuit.

6.8.3 Contractor shall select and supply all required restriction orifice plates using Tables 4A
through 4E based on the test media supplying pressure and the PSV set pressure as listed in
the project-specific Pressure Test Guideline. To minimize the time required to pressurize a
circuit, the restrictive orifice need only be installed when the circuit reaches 90% of the test
pressure. If the test pressures or the source pressures exceed the values referenced in Tables
4A through 4E, consult with the Air Products Representative.

6.9 Non-Metallic Piping

6.9.1 Pneumatic testing of non-metallic piping is not permitted and hydrostatic testing must be
utilized.

6.9.2 High-density polyethylene (HDPE) requires special considerations and procedures for
hydrostatic pressure testing. Procedures specified in ASTM F2164 shall be followed to ensure
proper and adequate pressure testing of HDPE pipe.

7. TEST MEDIUM

7.1 All process piping shall be hydrostatically or pneumatically tested with the fluid medium as
specified in the project-specific Pressure Test Guideline. Authorization from the Air Products
Representative must be obtained before a field change of test medium.

7.2 All test fluids must pass from the source through the appropriate pressure injection manifold
before entering the test circuit.

7.3 Hydrostatic test medium shall normally be clean and filtered fresh water of such quality as
to minimize corrosion of the materials in the piping system.

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 6 of 35

7.3.1 The chloride ion content of water used for testing stainless steel lines shall be less than 50
ppm, unless lower limits are specified in the contract documentation. When testing lines of all
other materials, a chloride ion content of less than 200 ppm may be used.

7.3.2 When a hydrostatic test is to be performed and low ambient air temperatures are
encountered, the contractor shall submit a detailed proposal to provide freeze protection to at
least 5°C (10°F) lower than the minimum expected ambient air temperature. The proposal
shall include the antifreeze mixture to be used, system rinsing and drainage procedures, and
antifreeze mixture disposal plan. The contractor's detailed proposal shall be submitted to the
Air Products Representative to obtain approval from the responsible Engineering
Organization.

7.4 Pneumatic test medium shall normally be dry compressed air for hydrocarbon processing
lines and dry, oil-free compressed air for air separation processing lines. Other test mediums
such as a nitrogen/helium mixture required to perform a "sensitive leak test" per ASME B31.3
paragraph 345.8 on a specialist flammable gas system or filtered nitrogen to perform a
pressure test on a ultra high purity (UHP) gas system shall only be used when specified in the
project-specific Pressure Test Guideline.

7.4.1 Helium, Hydrogen and Flammable gas systems shall be tested with a 10% helium/90%
Nitrogen mixture using pressure decay to determine acceptance.

7.4.2 Water and particulates shall be removed whenever compressed air is used for pressure
testing of process piping. Compressed air shall be passed through either a silica gel or
activated alumina drier and then filtered before entering the system being tested and shall
have a dew point of -40°C (-40°F) or lower. The contractor shall furnish complete data on the
drier and filter system for Air Products' review before its use.

7.4.3 Dry, oil-free air is defined as air that has first been treated by using the process indicated in
paragraph 7.4.1 and then passing it through an oil coalescer. Oil-free air shall be tested for
any "free-oil" droplets by placing a cotton gauze pad directly in the outlet of the air treatment
system and permitting the normal discharge flow to pass through the pad. After a period of
one minute, the pad shall be black-lighted (3660 angstrom wavelength) to check for
hydrocarbon fluorescence. This procedure shall be repeated on a daily basis before injecting
the test media into a pressure test circuit.

7.4.4 The substitution of nitrogen in lieu of compressed air as a pneumatic test medium is strongly
discouraged; however, when nitrogen is used extra precautions must be taken to avoid
creating an asphyxiating atmosphere. Atmospheric sensing tests shall be performed before
entering any confined area. When the circuit is severely confined and adequate ventilation is
not practical, then nitrogen cannot be substituted for compressed air.

8. TEST TEMPERATURE

8.1 Piping codes B31.1 and B31.3 require that the possibility of brittle fracture be considered
when conducting hydrostatic or pneumatic pressure tests at metal temperatures near the
ductile-brittle transition temperature. Therefore, a minimum margin of 17°C (30°F) is
required between the metal temperature during testing and the system minimum design
metal temperature as listed in the project-specific Pressure Test Guideline.

8.1.1 The full test pressure shall not be applied until the piping, in-line equipment, and the test
media are at approximately the same temperature.

8.1.2 Hydrostatic testing shall not be conducted at ambient air temperatures of 2°C (36°F) or less
or where the air temperature is 5°C (41°F) and falling unless the contractor has received
approval to use an antifreeze mixture per paragraph 7.3.2 of this specification.

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 7 of 35

8.2 Hydrostatic testing shall not be conducted during periods of rain, fog, or when ambient
temperature is approaching the dew point, as the resulting surface moisture may allow small
amounts of leaking test liquid to go undetected. If a suitable cover can be provided and
existing moisture on inspection areas can be removed, than hydrostatic testing may proceed.

8.3 Field-erected boilers and the associated external piping falling under the jurisdiction of the
ASME BPVC Section I and B31.1 Power Piping Code, respectively, shall be hydrostatically
pressure tested separately from the interconnecting nonboiler external piping that falls under
the ASME B31.3 Process Piping Code. This test shall be conducted in the presence of the
Authorized Boiler Inspector.

8.3.1 The boiler and associated external boiler piping shall be pressure tested using water at not
less than 20°C (70°F) in accordance with paragraph PG-99 of Section I of the ASME BPVC.

9. PROTECTION OF ADJACENT CIRCUITS

9.1 When test circuits tie into adjacent circuits designed for a lower pressure or when a potential
danger exists downstream to personnel or equipment, the adjacent pressure circuit must be
protected from possible overpressure. Adjacent circuit protection can be accomplished by
one or more of the following:

• Installation of the circuit's normal pressure relief device.

• Removal of the pressure relief device, thereby leaving the pressure circuit open to
atmosphere.
• Installation of test blanks to achieve complete isolation of the lower pressure circuit.
• Opening a series of drain or vent valves in the lower pressure circuit and installing
devices on those valves to ensure they are kept open during the test.

9.2 Valves opened to atmosphere to protect circuits from over-pressurization must have suitable
warning signs attached and shall be locked open for the duration of the test to prevent
accidental closure.

9.3 Manual valves used to isolate a pressure test circuit from a lower pressure circuit must have
suitable warning signs attached and shall be locked closed for the duration of the test to
prevent accidental over-pressurization of the lower pressure circuit.

9.4 Precautions shall be taken to ensure that any control valves used to isolate a pneumatic test
from a lower pressure circuit cannot be opened, either manually, remotely, or automatically
during the test. Fail-open type control valves require special attention to ensure that the fail-
open mechanism is deactivated.

9.5 The project-specific Pressure Test Guideline will indicate where adjacent circuit protection is
necessary (that is, - lower pressure adjacent circuits will be clearly identified in QC-200B –
Pressure Test Flowsheet).

10. PRETEST VERIFICATION

10.1 The contractor will notify the Air Products Representative when a circuit is ready for testing
by submitting a completed Pressure Test Checklist (Appendix A) and a Permit to Conduct a
Pressure Test (Appendix B) form.

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 8 of 35

10.2 Before pressurizing each test circuit, the contractor shall verify that the piping systems are
installed according to Air Products drawings and specifications.

• The contractor shall coordinate with the Air Products Representative to determine where
the limits of each circuit shall be located.
• If the pressure test circuits are to be broken down into smaller circuits, they need to be
lettered sequentially as a, b, c, behind the assigned circuit number.
• The boundaries of any additional broken-down circuits need to be clearly identified and
defined in the Pressure Test Guideline document.
• The addition of circuits might require the contractor to add blanks/blinds to separate the
tests. Any added blanks/blinds shall be tracked in the Pressure Test Blank Log (Appendix
C).

10.2.1 The contractor shall maintain a record of any mechanical components that are added or
removed for pressure testing purposes. Examples of these components may be temporary
supports or relief devices and can be accounted for in the Pressure Test Component Log
(Appendix D).

10.2.2 If the test circuit contains in-line equipment having a significant volume, Tables 2A or 2B
shall be consulted to determine the required pressure testing safety distances. It may be
beneficial to break a circuit down into two (2) or more smaller volume circuits to reduce
safety distance requirements.

10.2.3 Verify that all paddle blinds are made up of only one single blind.

10.2.4 Visual inspection of each joint shall indicate a structurally sound and complete connection. All
welds shall have an imprinted, qualified-welder's stamp as per Air Products fabrication and
erection specifications. All flange joints shall be checked to confirm compliance with the
specifications, bolting material, bolt torque requirements, gaskets, and makeup.

11. TEST CREW AND LOCATION OF PERSONNEL DURING TESTING

11.1 Because of the potential hazards involved in hydrostatic tests over 25 bar (365 psig) and
pneumatic tests over 2 bar (29 psig), personnel shall be kept to an absolute minimum in the
immediate area of the test circuit, the injection manifold, and the injection pipe, hose, and
tubing.

11.2 The contractor shall appoint a pressure test crew and a pressure test supervisor. The crew
shall be kept to the minimum number required to expeditiously set-up, pressurize, and
inspect the test circuits. After being trained, these same individuals shall do all the testing on
site, except for minor crew adjustments as agreed by an Air Products Representative.

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 9 of 35

11.3 Areas under pressure test shall be cordoned off with barrier tape. This area must be cleared
when testing begins. The contractor shall also furnish and erect an adequate number of
warning signs in the immediate vicinity of the test circuit. These warning signs shall be
approximately 450 x 450 mm (18 x 18 in) with a yellow background and 50 mm (2 in) high
black lettering. Signs shall be provided in both the local language and in English. The wording
shall be as follows:

11.4 All personnel, including those involved in the pressure testing, must be at a safe distance
from the test circuit while it is being pressurized.

11.5 A circuit under pressure must be continuously attended by the pressure test crew and the
Air Products Representative. Under no circumstances shall a test be left unattended.

11.6 For pneumatic tests of outdoor piping systems above 2 bar (29 psig), the cordoned-off
area shall be not less than the minimum safe distance for personnel located outdoors as
given in Table 1A from the circuit under testing. If for any reason a pneumatic pressure test
includes pressurizing equipment, the minimum safe distance for personnel located outdoors
shall be as given in Table 2A. In such cases, the minimum safe distance shall be the greater
of the distances determined in Table 1A or 2A.

11.6.1 Pipe or equipment rupturing outdoors creates an additional hazard to personnel located in
buildings which may be damaged because of the shockwave created by a pV energy release.
Therefore, personnel must be evacuated from and building located within the minimum
required safe distance as given in Table 1B for piping only tests or Table 2B for piping which
includes one or more pressure vessels. The minimum required safe distance shall be the
greater of the distances determined in Tables 1B or 2B.

11.6.2 Air Products Process Safety Engineering must be consulted for personnel protection guidance
before conducting any pneumatic pressure tests within the confines of a building. Pipe or
equipment rupturing indoors can cause building structural damage which could result in the
roof or walls collapsing on people.

11.7 For hydrostatic tests of piping systems above 25 bar (360 psig), the cordoned-off area
shall be a minimum distance of 5 m (15 ft.) from the circuit under test. If for any reason
hydrostatic pressure test includes pressurizing one or more pressure vessels, the minimum
safe distance shall be increased to 10 m (33 ft.).

11.8 When it is not practical to evacuate the test circuit area (when circuits are large and traverse
a large portion of the construction site), the test must be performed after normal working
hours or on weekends when personnel access can be limited.

11.9 Personnel must never stand in line with pipe caps, plugs, or blinds which can blow loose from
equipment maintained at pressure.

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 10 of 35

12. INJECTION MANIFOLD

12.1 Figures 1 and 2 provide illustrations of typical injection manifold setups for hydrostatic and
pneumatic tests. These setups shall be followed to ensure maximum safety and reliability.

12.2 All test pressures require an injection manifold with carbon steel piping, Schedule XXS, ASTM
A106, Grade B, at a minimum.

12.2.1 Injection manifold piping may not exceed pipe size DN25 (1" NPS) unless specifically
reviewed and approved by Air Products Mechanical Systems group.

12.3 Injection manifolds used for test pressures up to 210 bar g (3000 psig) shall use ASTM A105,
3000-pound fittings, whereas injection manifolds used for test pressures between 210 bar g
(3000 psig) and 345 bar g (5000 psig) shall use ASTM A105, 6000-pound fittings.

12.4 As an alternative to carbon steel, copper tubing may be used from the injection manifold to
the test circuit if suitably rated for the service and where it can be properly secured and
protected from damage. Refer to Tables 7M (metric) and 7US (imperial) for copper tubing
pressure ratings. All fittings must be double ferrule compression type fittings as manufacture
by Swagelok, Parker, or other Air Products approved supplier, and shall be checked with a
go/no-go gap gauge.

12.4.1 High-pressure hose may also be used if suitably rated for the service and when it can be
properly secured and protected from damage. A manufacturer's certificate shall be obtained
before its use. If the hose is not new, a hydrostatic strength test shall be performed to verify
its pressure rating.

12.5 Pressure gages shall have lower range of 0 psig. Likewise, pressure gages shall be chosen
such that midpoint of gage shall be ± 25% of test safety valve setting.

12.6 All pressure gages, test relief devices, and recorders shall have current calibration
certificates.

12.7 The test manifold shall be pressure-tested before its use and must be anchored during its
use.

12.8 All components of injection manifold must have a cleaning level that is compatible with the
piping and equipment under test.

12.9 The pressure source isolation valve must be a quick-acting valve if an emergency action is
required.

13. TEST BLANKS/BLINDS

13.1 All temporary blanks shall be numbered for traceability, and the blank numbers shall be
entered on the Pressure Test Blank Log (Appendix C).

13.2 All test blank locations which are not included as part of the piping design are identified on
the Pressure Test Guideline flowsheet with a red arrow and a red letter "B".

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 11 of 35

13.3 Blanks can be:

• Paddle blinds (see Tables 3M and 3US)

• Forged or wrought caps
• Temporary pipe closures per Air Products Specification 4WPI-FWZC01 “Specification for
Welded Temporary Pipe Closures”
• Blind flanges (per mating flange class or plate thickness equal to mating blind flange)

13.4 The contractor shall refer to Tables 3M (metric units) or 3US (imperial units) to determine
paddle blind thicknesses. Paddle blind thicknesses are given by aligning the maximum circuit
design pressure with the pipe size under test. Blinds of lesser thickness may not be stacked
together to meet a thicker blind requirement.

13.5 Unless specified otherwise, all blanks should be of carbon steel construction.

13.6 Short sections of piping which have been removed to permit the installation of test blanks
shall be pressure-tested separately.

14. SYSTEM PRESSURIZATION AND INSPECTION

14.1 The following pressure injection sequence shall be rigidly followed for Pneumatic tests.

14.1.1 During pressurization of test circuits, the injection manifold shall be constantly monitored to
provide adequate response time if an emergency action is required.

14.1.2 The test circuit, Pressure Test Guideline, and pressure test relief valve shall be reviewed
immediately before test to ensure all information is consistent.

14.1.3 A pressure regulator must always be used when pressurizing lower pressure circuits from
sources with higher pressures than the circuit or equipment being tested. The test set up
shall be generally as shown in Figure 2.

14.1.4 After all of the pretest verifications, pretest setup, visual indicators (warning tape and signs),
and personnel exposure limitation requirements have been accomplished, the contractor's
pressure test supervisor shall obtain permission from the Air Products Representative to start
pressure injection.

14.1.5 Pressure should be gradually increased to the lesser of 10% of the maximum allowable
working pressure or 2 bar g (25 psig) for initial inspection. After the pressure has equalized
for a minimum of ten minutes, personnel may enter the area to perform a preliminary soap
solution test to locate major leaks. If leaks are detected, the system must be depressurized
before repairs to the leaking connection are conducted. Any joints or flanges shall be soap-
checked to ensure that connections or isolation points are maintained in leak free condition
during the pressure test.

14.1.6 Thereafter, the pressure shall be gradually increased in increments of approximately 10% of
the full test pressure, holding the pressure at each increment for a minimum of ten minutes
to allow piping strains to equalize, until the desired full test pressure is reached. The system
must be maintained at the "full test pressure" for a minimum of ten minutes and all test
personnel must be kept clear of the system.

14.1.7 The system shall then be reduced to design pressure (or at least by 10% from the "full test
pressure") and held until all joints have been inspected for leaks. There shall be no visible
leakage (bubble formation) at the design pressure. If leaks are present, the pressure must
be dropped to below 2 bar g (25 psig) to perform any tightening of flange bolts. For all other
repairs, the circuit must be completely depressurized.

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 12 of 35

14.1.8 All joints in the test circuit shall be examined by brushing with a concentrated soap solution
and checking for bubbling. All copper-based alloys (that is, brass, bronze) must be leak
tested with an ammonia-free solution such as Omega 31. For all other materials, the leak test
solution can be Joy, Ivory, Fels-Naphtha, or other solutions that are available. Although
multiple test solutions are acceptable for differing materials, it is still highly recommended to
use an ammonia-free solution for all materials to avoid accidentally applying ammonia to a
copper-based joint.

Caution: The residue of concentrated soap solvents is combustible in atmospheres

containing more than 25% oxygen and any residue shall be adequately rinsed with water
from joints on lines that are oxygen clean. Increased attention should be given to areas in
which there is a possibility that the solution could enter the system through an opening (for
example, a vertical valve). Flanged connections that will not be opened immediately after the
test are exempt from this rinsing. The residue shall, however, be adequately rinsed from a
stainless steel pipe with low chlorine content water (preferably deionized water).

14.1.9 The leak test shall not take place by feel with any part of the body as injury might result. It is
important that the entire circuit be visually inspected for defects.

14.1.10 Valves, equipment, and in-line instruments might leak through because they are designed to
normally function with a fluid or temperature different than the test medium. Also, certain
valves might not be designed to provide a tight shut-off. If a leaking valve or instrument
cannot be sealed or shut off to achieve a leak tight seal, additional gas shall be supplied to
the circuit so that the full test pressure can be maintained for ten minutes. If this still does
not allow for a successful full pressure test, Air Products might elect to have the contractor
supply and install appropriate blanks. The affected joints shall then be retested at the original
test pressure. This procedure shall be repeated until all leaks are detected and rectified.

14.1.11 When a line has been pressure-tested and must subsequently be modified, one of the
following measures (if permitted under the applicable piping code and as specified by the
responsible Engineering Organization that created the project-specific Pressure Testing
Guideline) shall be used to check the integrity of the modification:

• Pressure test the modification.

• 100% radiography and dye penetrant check for butt welds.
• Dye penetrant check for socket welds.

14.1.12 After completion of the test, the system pressure shall not be reduced until the relevant
sections of the Pressure Test Circuit Completion Log (Appendix E) have been signed by the
Air Products representative.

14.2 The following pressure injection sequence shall be rigidly followed for Hydrostatic tests.

14.2.1 During pressurization of test circuits, the injection manifold shall be constantly monitored to
provide adequate response time if an emergency action is required.

14.2.2 The test circuit, Pressure Test Guideline, and pressure test relief valve shall be reviewed
immediately before test to ensure all information is consistent.

14.2.3 After all of the pretest verifications, pretest setup, visual indicators (warning tape and signs),
and personnel exposure limitation requirements have been accomplished, the contractor's
pressure test supervisor shall obtain permission from the Air Products representative to start
pressure injection.

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 13 of 35

14.2.4 Pressure should be gradually increased to the lesser of 10% of the maximum allowable
working pressure or 2 bar g (25 psig) for initial inspection. Care must be taken to ensure that
all air is expended from the test circuit as the system is being filled with the hydrostatic test
medium. When the pressure has equalized, personnel may enter the area to perform a
preliminary leak inspection test to locate major leaks. If leaks are detected, the system must
be depressurized before repairs to the leaking connection are conducted. Any joints or
flanges shall be visually inspected to ensure that connections or isolation points are
maintained in leak free condition during the pressure test.

14.2.4.1 A preliminary pneumatic test may be made at a pressure not exceeding 1.5 bar
(22 psig), or 10% of the test pressure, whichever is the smaller, before the
hydrostatic test to locate major leaks. If leaks are detected, the system must be
depressurized before repairs to the leaking connection are conducted. Pneumatic
pressure shall be bled off after completion of the preliminary pneumatic test
before injecting hydrostatic test media.

14.2.5 Thereafter, the pressure shall be gradually increased in increments of approximately 10% of
the full test pressure, holding the pressure at each increment for a minimum of ten minutes
to allow piping strains to equalize until the desired test pressure is reached.

14.2.6 The system shall then be maintained at full test pressure until all joints have been inspected
for leaks. There shall be no visible or recorded leakage at the full test pressure. If leaks are
present, the pressure must be dropped to below 2 bar g (25 psig) to perform any tightening
of flange bolts. For all other repairs, the circuit must be completely depressurized.

14.2.7 Valves, equipment, and in-line instruments might leak through because they are designed to
normally function with a fluid or temperature different than the test medium. Also, certain
valves might not be designed to provide a tight shut-off. If a leaking valve or instrument
cannot be sealed or shut off to achieve a leak tight seal, additional water shall be supplied to
the circuit so that the full test pressure can be maintained for the duration of the test. If this
still does not allow for a successful full pressure test, Air Products might elect to have the
contractor supply and install appropriate blanks. The affected joints shall then be retested at
the original test pressure. This procedure shall be repeated until all leaks are detected and
rectified.

14.2.8 Pressure/temperature/time recorders shall be used for all hydrostatic tests and shall be
located at the lowest point in the system. A minimum of two pressure gauges shall be used
with one located at the highest point and another located at the lowest points in the system.
The test set up shall be generally as shown in Figure 1.

14.2.9 All vents and other connections which can serve as vents shall be open during filling so that
all air is expelled before applying test pressure. The pressure source shall be connected to
the lowest point in the system.

14.2.10 When a line has been pressure tested and must subsequently be modified, one of the
following measures (if permitted under the applicable piping code and as specified by the
responsible Engineering Organization that created the Pressure Testing Guideline) shall be
used to check the integrity of the modification:

• Pressure test the modification.

• 100% radiography and dye penetrant check for butt welds.
• Dye penetrant check for socket welds.

14.2.11 After completion of the test, the system pressure shall not be reduced until the relevant
sections of the Pressure Test Circuit Completion Log (Appendix E) have been signed by the
Air Products representative.

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 14 of 35

15. SYSTEM RESTORATION

15.1 Depressurization, Draining, and Drying

15.1.1 After the system being tested has been accepted, it shall be depressurized in a controlled
manner by gradually opening a depressurizing valve(s) keeping in mind the location of check
valves within the circuit. Normally lines shall be vented in the direction of process flow.

15.1.2 Caution must be used when venting accumulated gas from the system. All personnel must be
clear of the area and all gas vent piping and lines must be anchored to prevent "whipping."
Whenever possible, gas must be vented upward, rather than horizontally outward to avoid
impingement on personnel or adjacent equipment.

15.1.3 Hearing protection should be used to protect personnel against the high noise levels created
while venting down equipment.

15.1.4 After depressurization, all vents and low point drain valves on hydrostatically-tested systems
shall be opened and the system completely drained. If necessary, piping shall be blown clear
with compressed air to ensure removal of all water.

15.1.5 When specified on the Pressure Test Guideline, hydrostatically tested lines shall be dried by
blowing through with warm, dry, oil-free compressed air.

15.2 Reinstatement

15.2.1 Temporary blinds/blanks, pressure gages, test relief valves, and other equipment installed for
testing shall be removed after completion of test, and all vents and drains used for testing
shall be closed.

15.2.2 Flanged joints broken for testing need not be tested, but shall be reinstated using new
gaskets.

15.2.3 Temporary restraints installed to prevent movement in expansion joints or spring supports
shall be removed together with temporary supports and lashings.

15.2.4 All system components removed for the system test (for example, relief valves, rupture discs,
in-line instruments) shall be reinstalled. Valve internals that have been removed for the test
shall be replaced.

15.2.5 When truncated-cone strainers have remained in place for a hydrostatic pressure test, they
shall be removed following the test, inspected for damage, cleaned, and reinstalled. When Y-
type strainers have remained in place for a hydrostatic pressure test, they shall be blown
down following the test.

15.3 Pressure Test Blank Log, Pressure Test Component Log, and Pressure Test Circuit Completion
Log

15.3.1 On completion of reinstatement, the contractor shall fill in the "removal" column of the
Pressure Test Blank Log (Appendix C) and the "after test" column of the Pressure Test
Commissioning Log (Appendix D). The test shall not be considered complete until the system
has been checked and the Pressure Test Blank Log and Pressure Test Commissioning Log are
signed off by the contractor and the Air Products Representative.

15.3.2 The Air Products Representative shall also sign the relevant section of the Pressure Test
Circuit Completion Log (Appendix E).

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 15 of 35

16. DOCUMENTATION

16.1 Test Documentation

16.1.1 The test documentation listed below shall be submitted by the contractor and shall be
included in the final Quality Control (QC) hand-over package.

16.1.2 The documentation for each test circuit shall include the following appendixes as specified in
the project-specific Pressure Test Guideline:

• Pressure Test Checklist (Appendix A)

• Permit to Conduct a Pressure Test (Appendix B)
• Pressure Test Blank Log (Appendix C)
• Pressure Test Component Log (Appendix D)
• Pressure Test Circuit Completion Log (not required for individual circuits) (Appendix E)

16.1.3 Subject to the approval of the Air Products Representative, the contractor may use substitute
forms to document the test, if the same information is included.

16.1.4 Signed copies of the Pressure Test Guideline will be retained as permanent records. Job-site,
pressure test records are stored in the quality control files that are submitted to the
Air Products home office after job completion.

Table 1A
Safe Distances for Pneumatic Pressure Tests of Piping (70 mbar overpressure)
Piping Test Pressure bar g (psig)
5 10 20 30 100 150 250 300 400 500 600 700 800 900
(7 (14 (29 (435 50 (1450 (217 (362 (435 (508 (725 (870 (1015 (1160 (1305
3) 5) 0) ) (725) ) 5) 5) 1) 2) 2) 2) 3) 3) 4)
Nomin
al Pipe Minimum Safe Distances for Personnel Located Outdoors - m (ft.)
Diame
ter
DN6
(1/8") 1 (3) 1 (3) 1 (3) 1 (3) 1 (3) 1 (3) 1(3)
DN8
(1/4") 1 (3) 1 (3) 1 (3) 1 (3) 2 (7) 2 (7) 2(7)
DN10
(3/8") 1 (3) 2 (7) 2 (7) 2 (7) 2 (7) 2 (7) 2(7)
DN15
(1/2") 2 (7) 2 (7) 2 (7) 2 (7) 2 (7) 3 (10) 3(10)
DN20 3 3 3
(3/4") 2 (7) (10) (10) (10) 3 (10) 3 (10) 3(10)
DN25 1 1 1 3 3 3 3 4
(1") (3) (3) (3) 2 (7) 2 (7) 2 (7) 2 (7) (10) (10) (10) (10) (13) 4 (13) 4 (13) 4 (13)
DN50 1 1 2 3 4 5 5
(2") (3) (3) (7) 2 (7) (10) 4 (13) (13) (16) (16)
DN80 2 2 3 3 4 5 7 7
(3") (7) (7) (10) (10) (13) 5 (16) (16) (23) (23)
DN100 2 3 3 4 5 7 8
(4") (7) (10) (10) (13) (16) 6 (20) (23) (26)
DN150 2 4 5 5 7 10 12
(6") (7) (13) (16) (16) (23) 9 (30) (33) (39)
DN6
(1/8") 1 (3) 1 (3) 1 (3) 1 (3) 1 (3) 1 (3) 1(3)
DN8
(1/4") 1 (3) 1 (3) 1 (3) 1 (3) 2 (7) 2 (7) 2(7)
DN10
(3/8") 1 (3) 2 (7) 2 (7) 2 (7) 2 (7) 2 (7) 2(7)
DN15
(1/2") 2 (7) 2 (7) 2 (7) 2 (7) 2 (7) 3 (10) 3(10)

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 16 of 35

DN20 3 3 3
(3/4") 2 (7) (10) (10) (10) 3 (10) 3 (10) 3(10)
DN25 1 1 1 3 3 3 3 4
(1") (3) (3) (3) 2 (7) 2 (7) 2 (7) 2 (7) (10) (10) (10) (10) (13) 4 (13) 4 (13) 4 (13)
DN50 1 1 2 3 4 5 5
(2") (3) (3) (7) 2 (7) (10) 4 (13) (13) (16) (16)
DN80 2 2 3 3 4 5 7 7
(3") (7) (7) (10) (10) (13) 5 (16) (16) (23) (23)
DN100 2 3 3 4 5 7 8
(4") (7) (10) (10) (13) (16) 6 (20) (23) (26)
DN150 2 4 5 5 7 10 12
(6") (7) (13) (16) (16) (23) 9 (30) (33) (39)
3
DN200 (1 5 6 7 9 12 13
(8") 0) (16) (20) (23) (30) (39) (43)
4
DN250 (1 5 7 9 11 15 16
(10") 3) (16) (23) (30) (36) (49) (52)
5
DN300 (1 6 9 10 13 18 19
(12") 6) (20) (30) (33) (43) (59) (62)
6
DN400 (2 8 11 14 17 24
(16") 0) (26) (36) (46) (56) (79)
7
DN500 (2 10 14 17 21 30
(20") 3) (33) (46) (85) (70) (98)
9
DN600 (3 12 17 20 26 35 (11
(24") 0) (39) (56) (66) (85) 5)
9
DN650 (3 13 19 22(7 28 (9
(26") 0) (43) (62) 2) 2)
10
DN700 (3 14 19 23 30
(28") 3) (46) (62) (75) (98)
11
DN750 (3 15 21 25 32
(30") 6) (49) (70) (82) (105)
11
DN800 (3 16 22 27
(32") 6) (52) (72) (89)
12
DN850 (3 17 23 28
(34") 9) (56) (75) (92)
13
DN900 (4 18 25 30
(36") 3) (59) (82) (98)
14 33
DN100 (4 20 27 (108
0 (40") 6) (66) (89) )

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is classified as Air Products internal
use only, is subject to return on demand and must not be disclosed or reproduced without prior written consent. This information may be subject to export
controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 17 of 35

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is classified as Air Products internal
use only, is subject to return on demand and must not be disclosed or reproduced without prior written consent. This information may be subject to export
controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 18 of 35

Table 1A (continued)
Safe Distances for Pneumatic Pressure Tests of Piping (70 mbar overpressure)

Piping Test Pressure bar g (psig)

100 150 250 300 400 500 600 700 800 900
5 (73) 10 (145) 20 (290) 30 (435) 50 (725) (1450) (2175) (3625) (4351) (5082) (7252) (8702) (10153) (11603) (13054)
Nominal Pipe Minimum Safe Distances for Personnel Located Outdoors - m (ft.)
Diameter
DN1050 (42") 15 (49) 21 (70) 29 (95) 35 (115)
DN1200 (48") 17 (56) 23 (75) 33 (108) 40 (131)
DN1400 (56") 19 (62) 27 (89) 38 (125) 46 (151)
DN1500 (60") 21 (70) 29 (95) 41 (135) 49 (161)
DN1800 (72") 25 (82) 35 (115) 49 (161) 59 (194)

Table 1A Notes:
1. The minimum required safe distance for personnel located outdoors for a pneumatic test of outdoor piping shall be determined from this table .
2. Only the single largest pipe diameter contained in the piping system to be pressure tested needs to be considered when determining the required safe distance.
3. Safe distances are based upon 70 mbar blast overpressure limits.

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is classified as Air Products internal
use only, is subject to return on demand and must not be disclosed or reproduced without prior written consent. This information may be subject to export
controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 19 of 35

Table 1B
Safe Distances for Pneumatic Pressure Tests of Piping (50 mbar overpressure)

Piping Test Pressure bar g (psig)

100 150 250 300 400 500 600 700 800 900
5 (73) 10 (145) 20 (290) 30 (435) 50 (725) (1450) (2175) (3625) (4351) (5082) (7252) (8702) (10153) (11603) (13054)
Nominal Pipe
Diameter Minimum Safe Distances to the Nearest Part of a Building - m (ft.)
DN6 (1/8") 1 (3) 1 (3) 1 (3) 1 (3) 2 (7) 2 (7) 2 (7)
DN8 (1/4") 1 (3) 2 (7) 2 (7) 2 (7) 2 (7) 2 (7) 2 (7)
DN10 (3/8") 2 (7) 2 (7) 2 (7) 2 (7) 2 (7) 2 (7) 2 (7)
DN15 (1/2") 2 (7) 2 (7) 3 (10) 3 (10) 3 (10) 3 (10) 3 (10)
DN20 (3/4") 3 (10) 3 (10) 3 (10) 4 (13) 4 (13) 4 (13) 4 (13)
DN25 (1") 1 (3) 1 (3) 1 (3) 2 (7) 2 (7) 3 (10) 3 (10) 3 (10) 3 (10) 4 (13) 4 (13) 5 (16) 5 (16) 5 (16) 5 (16)
DN50 (2") 1 (3) 2 (7) 2 (7) 3 (10) 3(10) 5 (16) 5 (16) 6 (20) 6 (20)
DN80 (3") 2 (7) 3 (10) 3 (10) 4 (13) 5 (16) 7 (23) 7(23) 9 (30) 10 (33)
DN100 (4") 2 (7) 3 (10) 4 (13) 6 (20) 6( 20) 9 (30) 9 (30) 11 (36)
DN150 (6") 3 (10) 4 (13) 6 (20) 7 (23) 9 (30) 13 (43) 13 (43) 16 (52)
DN200 (8") 4 (13) 6 (20) 8 (26) 10 (33) 12 (39) 17 (56) 17 (56)
DN250 (10") 5 (16) 7 (23) 10 (33) 12 (39) 15 (49) 21 (69) 22 (72)
DN300 (12") 6 (20) 8 (26) 12 (39) 14 (46) 18 (59) 25 (82) 26 (85)
DN400 (16") 8 (26) 11 (36) 15 (49) 19 (62) 24 (79) 33 (108)
DN500 (20") 10 (33) 14 (46) 19 (62) 23 (75) 30 (98) 41 (135)
DN600 (24") 12 (39) 16 (52) 23 (75) 28 (92) 35 (115) 49 (161)
DN650 (26") 13 (43) 18 (59) 25 (82) 30 (98) 38 (125)
DN700 (28") 14 (46) 19 (62) 27 (89) 32 (105) 41 (135)
DN750 (30") 15 (49) 20 (66) 28 (92) 35 (115) 44 (144)
DN800 (32") 16 (52) 22 (72) 30 (98) 37 (121)
DN850 (34") 16 (52) 23 (75) 32 (105) 39 (128)
DN900 (36") 17 (56) 24 (79) 34 (112) 41 (135)
DN1000 (40") 19 (62) 27 (89) 38 (125) 46 (151)
DN1050 (42") 20 (66) 28 (92) 40 (131) 48 (157)
DN1200 (48") 23 (75) 32 (105) 45 (148) 55 (180)
DN1400 (56") 27 (89) 38 (125) 53 (174) 64 (210)
DN1500 (60") 29 (92) 40 (131) 56 (184) 69 (226)
DN1800 (72") 34 (112) 48 (157) 68 (223) 82 (269)

Table 1B Notes:

1. The minimum required safe distance to the nearest part of a building for a pneumatic pressure test of outdoor piping shall be determined from this table.
2. Personnel must be evacuated from any building located within the minimum required safe distance as determined from this table.
3. Only the single largest pipe diameter contained in the piping system to be pressure tested needs to be considered when determining the required safe distance.
4. Safe distances are based upon a 50 mbar blast wave overpressure limit.

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is classified as Air Products internal
use only, is subject to return on demand and must not be disclosed or reproduced without prior written consent. This information may be subject to export
controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 20 of 35

Table 2A

Safe Distances for Pneumatic Pressure Tests of Equipment (70 mbar overpressure)

Equipment Test Pressure - bar g (psig)

80
3 (44) 4 (58) 5 (73) 6 (87) 7 (102) 8 (116) 9 (131) 10 (145) 12 (174) 14 (203) 16 (232) 20 (290) 25 (363) 30 (435) 40 (580) 60 (870) (1160)
Equipment
Volume Minimum Safe Distances for Personnel Located Outdoors - m (ft.)
m3 (ft.3)

0.1 (4) 6 (20) 7 (23) 7 (23) 7 (23) 8 (26) 8 (26) 8 (26) 9 (30) 9 (30) 10 (33) 10 (33) 11 (36) 12 (39) 12 (39) 14 (46) 15 (49) 17 (56)

0.2 (7) 7 (23 8 (26) 9 (30) 9 (30) 10 (33) 10 (33) 10 (33) 11 (36) 12 (39) 12 (39) 13 (43) 14 (46) 15 (49) 15 (49) 17 (56) 19 (62) 21 (70)

0.5 (18) 10 (33) 11 (36) 12 (39) 12 (39) 13 (43) 14 (46) 14 (46) 15 (49) 15 (49) 16 (52) 17 (56) 18 (59) 20 (66) 21 (70) 23 (75) 26 (85) 29 (95)

1 (35) 12 (39) 14 (46) 15 (49) 15 (49) 16 (52) 17 (56) 18 (59) 18 (59) 19 (62) 20 (66) 21 (70) 23 (75) 24 (79) 26 (85) 29 (95) 33 (108) 36 (118)

5 (177) 21 (70) 23 (75) 24 (79) 26 (85) 27 (89) 29 (95) 30 (98) 31 (102) 33 (108) 34 (112) 36 (118) 39 (128) 41 (135) 44 (144) 48 (157) 55 (180) 61 (200)

10 (353) 26 (85) 29 (95) 31 (102) 33 (108) 34 (112) 36 (118) 37 (121) 39 (128) 41 (135) 43 (141) 45 (148) 48 (157) 52 (171) 55 (180) 61 (200) 70 (230) 77 (253)

30 (1060) 37 (121) 41 (135) 44 (144) 47 (154) 49 (161) 51 (167) 53(174) 55 (180) 59 (194) 62 (203) 65 (213) 70 (230) 75 (246) 80 (262) 88 (289) 100 (328) 110 (361)

50 (1766) 44 (144) 48 (157) 52 (171) 55 (180) 58 (190) 61 (200) 63 (207) 66 (217) 70 (230) 73 (240) 77 (253) 82 (269) 89 (292) 94 (308) 104 (341) 119 (390) 131 (430)
100
(3532) 55 (180) 61 (200) 66 (217) 70 (230) 73 (240) 77 (253) 80 (262 82 (269) 88 (289) 92 (302) 96 (315) 104 (341) 112 (367) 119 (390)
125
(4414) 60 (197) 66 (217) 71 (233) 75 (246) 79 (259) 82 (269) 86 (282) 89 (292) 94 (308) 99 (325)
150
(5297) 63 (207) 70 (230) 75 (246) 80 (262) 84 (276) 88 (289) 91 (299) 94 (308) 100 (328) 106 (348)
200
(7063) 70 (230) 77 (253) 82 (269 88 (289) 92 (302) 96 (315) 100 (328) 104 (341) 110 (361)
250
(8829) 75 (246) 83 (272) 89 (292) 94 (308) 99 (325) 104 (341) 108 (354) 112 (367) 119 (390)
300
(10594) 80 (262) 88 (289) 94 (308) 100 (328) 105(345) 110 (361) 115 (377) 119 (390)
400
(14126) 88 (289) 96 (315) 104(341) 110 (361) 116 (381) 121 (397)
500
(17657) 94 (308) 104(341) 112 (367) 119 (390) 125 (410)
800
(28251) 110 (361) 121 (397) 131 (430) 139 (456)

Table 2A Notes:

1. The minimum required safe distance for personnel located outdoors for a pneumatic pressure test of outdoor piping which includes one or more pressure vessels shall be
determined from this table.
2. Only the single largest pressure vessel volume contained in the piping system to be pressure tested needs to be considered when determining the required safe
distance.
3. Safe distances are based upon a 70 mbar blast wave overpressure limit.

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is classified as Air Products internal
use only, is subject to return on demand and must not be disclosed or reproduced without prior written consent. This information may be subject to export
controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 21 of 35

Table 2B

Safe Distances for Pneumatic Pressure Tests of Equipment (50 mbar overpressure)
Equipment Test Pressure - bar g (psig)
80
3 (44) 4 (58) 5 (73) 6 (87) 7 (102) 8 (116) 9 (131) 10 (145) 12 (174) 14 (203) 16 (232) 20 (290) 25 (363) 30 (435) 40 (580) 60 (870) (1160)
Equipment
Volume m3 Minimum Safe Distances to the Nearest Part of a Building - m (ft.)
(ft.3)

0.1 (4) 8 (26) 8 (26) 9 (30) 9(30) 10 (33) 10 (33) 11 (36) 11 (36) 12 (39) 12 (39) 13 (43) 14 (46) 15 (49) 16 (52) 17 (56) 20 (66) 22 (72

0.2 (7) 9 (30) 10 (33) 11 (36) 12 (39) 12 (39) 13 (43) 13 (43) 14 (46) 15 (49) 15 (49) 16 (52) 17 (56) 18 (59) 20 (66) 22 (72) 25 (82) 27 (89)

0.5 (18) 13 (43) 14 (46) 15 (49) 16 (52) 17 (56) 17 (56) 18 (59) 19 (62) 20 (66) 21 (70) 22 (72) 23 (75) 25 (82) 27 (89) 29 (95) 33 (108) 37 (121)

1 (35) 16 (52) 17 (56) 19 (62) 20 (66) 21 (70) 22 (72) 22 (72) 23 (75) 25 (82) 26 (85) 27 (89) 29 (95) 31 (102) 33 (108) 37 (121) 42 (138) 46 (151)

5 (177) 27 (89) 29 (95) 31 (102) 33 (108) 35 (115) 37 (121) 38 (125) 39 (128) 42 (138) 44 (144) 46 (151) 49 (161) 53 (174) 57 (187) 62 (203) 71 (233) 78 (256)

10 (353) 33 (108) 37 (121) 39 (128) 42 (138) 44 (144) 46 (151) 48 (157) 49 (161) 53 (174) 55 (180) 58 (190) 62 (203) 67 (220) 71 (233) 78 (256) 89 (292) 98 (322)
102
30 (1060) 48 (157) 53 (174) 57 (187) 60 (197) 63 (207) 66 (217) 69 (226) 71 (233) 76 (249) 79 (259) 83 (272)
89 (292) 96 (315) (335) 115 (377) 129 (423) 142 (466)
106
50 (1766) 57 (187) 62 (203) 67 (220) 71 (233) 75 (246) 78 (256) 81 (266) 84 (276) 89 (292) 94 (308) 98 (322) (348) 114 (374) 121 (397) 133 (436) 153 (502) 168 (551)
155
100 (3532) 71 (233) 78 (256) 84 (276) 89 (292) 94 (308) 98 (322) 102 (335) 106 (348) 113 (371) 119 (390) 124 (407) 133 (436) 144 (472) (509)
101 106 110 114
125 (4414) 77 (253) 84 (276) 91 (299) 96 (315) (331) (348) (361) (374) 121 (397) 128 (420)
102
150 (5297) 81 (266) 89 (292)96 (315) (335) 108 (354) 113 (371) 117 (384) 121 (397) 129 (423) 136 (446)
106 113
200 (7063) 89 (292) 98 (322) (348) (371) 119 (390) 124 (407) 129 (423) 132 (433) 142 (466)
114
250 (8829) 96 (315) 106 (348) (374) 121 (397) 128 (420) 133 (436) 139 (456) 144 (472) 153 (502)

300(10595) 102 (335) 113 (371) 121 (397) 129 (423) 136 (446) 142 (466) 147 (482) 153 (502)

400(14126) 113 (371) 124 (407) 133 (436) 142 (466) 149 (449) 156 (512)

500(17658) 121 (397) 133 (436) 144 (472) 153 (502) 161 (528)

800(28252) 142 (466) 156 (512) 168 (551) 178 (584)

Table 2B Notes:

1. The minimum required safe distance to the nearest part of a building for a pneumatic pressure test of outdoor piping which includes one or more pressure vessels shall
be determined from this table.
2. Personnel must be evacuated from any building located within the minimum required safe distance as determined from this table.
3. Only the single largest pressure vessel volume contained in the piping system to be pressure tested needs to be considered when determining the required safe
distance.
4. Safe distances are based upon a 50 mbar blast wave overpressure limit.

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is classified as Air Products internal
use only, is subject to return on demand and must not be disclosed or reproduced without prior written consent. This information may be subject to export
controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 22 of 35

Table 3M
Paddle Blind Thickness – Carbon Steel ASTM A285, Grade C
(Installed between flanges)

Paddle Blind Thickness (mm)

Nominal 6.4 9.5 12.7 15.9 19.1 22.2 25.4 28.6 31.8 34.9 38.1 41.3 44.5 47.6 50.8
Pipe
Size
(mm)
Maximum Circuit Design Pressure (bar g) for Pipe Size and Paddle Blind Thickness

15 747.7 -- -- -- -- -- -- -- -- -- -- -- -- -- --
20 420.6 -- -- -- -- -- -- -- -- -- -- -- -- -- --
25 269.2 605.6 -- -- -- -- -- -- -- -- -- -- -- -- --
40 93.6 210.5 374.2 -- -- -- -- -- -- -- -- -- -- -- --
50 55.6 125.1 222.4 347.6 500.5 -- -- -- -- -- -- -- -- -- --
65 39.8 89.6 159.3 248.8 358.3 487.7 -- -- -- -- -- -- -- -- --
75 26.3 59.1 105.1 164.2 236.6 322.0 420.6 532.3 -- -- -- -- -- -- --
100 16.8 37.9 67.3 105.1 151.4 206.1 269.2 340.7 420.6 508.9 -- -- -- -- --
150 8.1 18.3 32.5 50.8 73.2 99.6 130.1 164.7 203.3 246.1 292.8 343.7 398.6 457.6 --
200 5.0 11.2 19.9 31.1 44.8 60.9 79.6 100.8 124.5 150.6 179.3 210.4 244.0 280.1 318.7
250 3.2 7.4 13.1 20.5 29.6 40.3 52.6 66.5 82.2 99.4 118.3 138.9 161.1 184.9 210.4
300 2.3 5.2 9.4 14.6 21.1 28.8 37.6 47.5 58.7 71.0 84.5 99.2 115.1 132.1 150.3
350 -- 4.4 7.8 12.3 17.7 24.1 31.4 39.8 49.1 59.4 70.7 83.0 96.3 110.5 125.7
400 -- 3.4 6.1 9.4 13.7 18.6 24.3 30.8 38.0 46.0 54.7 64.2 74.5 85.5 97.3
450 -- 2.7 4.8 7.5 10.8 14.7 19.2 24.3 30.3 36.4 43.6 51.2 59.0 67.7 77.0
500 -- -- 3.9 6.1 8.8 12.0 15.7 19.9 24.5 29.7 35.3 41.5 48.1 55.2 62.8
550 -- -- 3.2 5.0 7.3 9.9 13.0 16.4 20.3 24.5 29.2 34.3 39.8 45.6 52.0
600 -- -- 2.7 4.3 6.1 8.3 11.0 13.9 17.1 20.8 24.7 29.0 33.6 38.6 43.9
750 -- -- -- 2.8 4.1 5.5 7.2 9.1 11.2 13.7 16.3 19.1 22.1 25.4 28.9
900 -- -- -- 1.9 2.8 3.9 5.0 6.3 7.9 9.5 11.3 13.3 15.4 17.7 20.2
1050 -- -- -- -- 2.1 2.8 3.7 4.7 5.8 7.0 8.3 9.8 11.4 13.0 14.9
1200 -- -- -- -- -- 2.1 2.8 3.6 4.4 5.4 6.4 7.5 8.8 10.0 11.4

Table 3M Notes:

1. The numbers tabulated at the intersections of the rows and columns are the maximum design pressures
(bar g) to be used with the pipe size and blank thickness.
2. Blinds of lesser thickness may not be stacked together to meet a thicker blind requirement.

Equation taken from ASME B31.3, 304.5.3 (Formula 15 converted to metric units):

3P
tm = d g
160SE
where tm = minimum required thickness (no corrosion allowances for blanks in testing) (mm)
dg = diameter gasket (use 150 LB spiral-wound gasket inside diameter) (mm)
P = design pressure (bar g)
SE = allowable stress – 126.2 MPa g at 38°C for ASTM A285, Grade C

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 23 of 35

Table 3US
Paddle Blind Thickness – Carbon Steel ASTM A285, Grade C
(Installed between flanges)

Paddle Blind Thickness (in)

Nominal 0.25 0.38 0.50 0.63 0.75 0.88 1.00 1.13 1.25 1.38 1.50 1.63 1.75 1.88 2.00
Pipe
Size
(in)
Maximum Circuit Design Pressure (psig) for Pipe Size and Paddle Blind Thickness

1/2 10844 -- -- -- -- -- -- -- -- -- -- -- -- -- --
3/4 6100 -- -- -- -- -- -- -- -- -- -- -- -- -- --
1 3904 8784 -- -- -- -- -- -- -- -- -- -- -- -- --
1 1/2 1357 3053 5428 -- -- -- -- -- -- -- -- -- -- -- --
2 806 1814 3226 5041 7259 -- -- -- -- -- -- -- -- -- --
2 1/2 577 1299 2310 3609 5197 7074 -- -- -- -- -- -- -- -- --
3 381 857 1525 2382 3431 4670 6100 7720 -- -- -- -- -- -- --
4 244 549 976 1525 2196 2989 3904 4941 6100 7381 -- -- -- -- --
6 117 265 471 737 1061 1445 1887 2389 2949 3569 4247 4985 5781 6637 --
8 72 162 288 451 650 884 1155 1462 1805 2184 2600 3051 3539 4062 4622
10 47 107 190 298 429 584 763 965 1192 1442 1716 2014 2336 2682 3052
12 34 76 136 212 306 417 545 689 851 1030 1226 1439 1669 1916 2180
14 -- 64 113 178 256 349 455 577 712 862 1025 1204 1396 1603 1823
16 -- 49 88 137 198 270 352 446 551 667 794 931 1080 1240 1411
18 -- 39 69 109 157 213 279 353 439 528 632 742 855 982 1117
20 -- -- 57 89 128 174 227 288 356 431 512 602 698 801 911
22 -- -- 47 73 106 144 188 238 294 356 424 497 577 662 754
24 -- -- 39 62 89 121 159 201 248 301 358 420 487 560 637
30 -- -- -- 41 59 80 104 132 163 198 236 277 321 368 419
36 -- -- -- 28 41 56 73 92 114 138 164 193 224 257 293
42 -- -- -- -- 30 41 54 68 84 102 121 142 165 189 216
48 -- -- -- -- -- 31 41 52 64 78 93 109 127 145 165

Table 3US Notes:

1. The numbers tabulated at the intersections of the rows and columns are the maximum design pressures
(psig) to be used with the pipe size and blank thickness.
2. Blinds of lesser thickness may not be stacked together to meet a thicker blind requirement.

Equation taken from ASME B31.3, 304.5.3 (Formula 15):

3P
tm = dg
16SE

where tm = minimum required thickness (no corrosion allowances for blanks in testing) (in)
dg = diameter gasket (use 150 lb. spiral-wound gasket inside diameter) (in)
P = design pressure (psig)
SE = allowable stress – 18,300 psig at 100°F for ASTM A285, Grade C

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 24 of 35

Table 4A
Restrictive Orifice Selection – 179 bar g (2600 psig) Supply Pressure

PSV Set Pressure 110.4-141.4

0.7-4.2 4.3-10.6 10.7-17.9 18.0-44.0 44.1-110.3 >141.4
Range, bar g (1601-
(10-61) (61-154) (155-260) (181-639) (640-1600) (>2050)
(psig) 2050)
Orifice Size, 1.0 1.6 2.4 3.2 4.8 6.4 7.9
mm (in) (0.040) (0.063) (0.094) (0.125) (0.188) (0.250) (0.313)

Table 4B
Restrictive Orifice Selection – 117 bar g (1700 psig) Supply Pressure

PSV Set Pressure

0.7-2.5 2.6-6.5 6.6-12.4 12.5-28.5 28.6-53.6 53.7-77.5 >77.5
Range, bar g
(10-37) (38-95) (96-180) (181-414) (415-779) (780-1125) (>1125)
(psig)
Orifice Size, 1.2 1.6 2.4 3.2 4.8 6.4 7.9
mm (in) (0.047) (0.063) (0.094) (0.125) (0.188) (0.250) (0.313)

Table 4C
Restrictive Orifice Selection – 76 bar g (1100 psig) Supply Pressure

PSV Set Pressure

0.7-3.9 4.0-7.8 7.9-18.2 18.3-35.0 35.1-49.6 >49.6
Range, bar g N/A
(10-56) (57-114) (115-264) (265-509) (510-720) (>720)
(psig)
Orifice Size, 1.6 2.4 3.2 4.8 6.4 7.9
N/A
mm (in) (0.063) (0.094) (0.125) (0.188) (0.250) (0.313)

Table 4D
Restrictive Orifice Selection – 17.2 bar g (250 psig) Supply Pressure

Set Pressure
0.7-3.5 3.6-7.5 7.6-11.0 >11.0
Range, bar g N/A N/A N/A
(10-52) (53-109) (110-160) (>160)
(psig)
Orifice Size, 3.2 4.8 6.4 7.9
N/A N/A N/A
mm (in) (0.125) (0.188) (0.250) (0.313)

Table 4E
Restrictive Orifice Selection – 10.3 bar g (150 psig) Supply Pressure

Set Pressure
0.7-1.8 1.9-4.2 4.3-6.5 >6.5
Range, bar g N/A N/A N/A
(10-27) (28-62) (63-95) (>95)
(psig)
Orifice Size, 3.2 4.8 6.4 7.9
N/A N/A N/A
mm (in) (0.125) (0.188) (0.250) (0.313)

Tables 4A thru 4E Notes:

1. Each of these orifice sizes was calculated by using the Kd factor (discharge coefficient) of 0.878 Kunkle relief valves and
.975 for Crosby relief valves in Table 6.

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 25 of 35
Table 5
Hydrostatic Test Relief Valve Liquid Flow Capacities

Recommended Test Relief H2O Flow Recommended Test Relief H2O Flow
Test Relief Valves Valve Tag No. Capacity lpm Test Relief Valves Valve Tag No. Capacity lpm
(See Note 1) (USgpm) (See Note 1) (USgpm)
Crosby DN15 (1/2" MNPT) x Kunkle Model No. 912BDCM12-
JE0000
PSV-2600T 400 (106) DN15 PSV-300T 227 (60)
DN25 (1" FNPT) PSV-2500T 393 (104) (1/2" MNPT) x DN25 (1" FNPT) PSV-280T 215 (57)
Model No. 955100MD PSV-2400T 385 (102) PSV-260T 208 (55)
PSV-2300T 374 (99) PSV-240T 201 (53)
PSV-2200T 366 (97) PSV-220T 194 (51)
PSV-2100T 359 (95) PSV-200T 185 (49)
PSV-2000T 351 (93) PSV-190T 179 (47)
PSV-1900T 340 (90) PSV-180T 173 (46)
PSV-1800T 332 (88) PSV-170T 167 (44)
PSV-1700T 321 (85) PSV-160T 163 (43)
PSV-1600T 313 (83) PSV-150T 159 (42)
Crosby DN15 (1/2" MNPT) x PSV-1500T 302 (80) PSV-140T 152 (40)
DN25 (1" FNPT) Model No.
951100MD
Kunkle Model No. 913BDCM12-
JE0000

PSV-1400T 483 (128) PSV-130T 146 (39)

PSV-1300T 468 (124) PSV-120T 140 (37)
PSV-1200T 449 (119) PSV-110T 134 (35)
PSV-1100T 430 (114) PSV-100T 128 (34)
PSV-1000T 412 (109) PSV-95T 128 (34)
PSV-950T 400 (106) PSV-90T 124 (33)
DN15 PSV-900T 389 (103) PSV-85T 121 (32)
(1/2" MNPT) x DN25 (1" FNPT) PSV-850T 378 (100) PSV-80T 117 (31)
PSV-800T 366 (97) PSV-75T 113 (30)
PSV-750T 355 (94) PSV-70T 109 (29)
PSV-700T 343 (91) PSV-65T 106 (28)
PSV-650T 332 (88) PSV-60T 102 (27)
PSV-600T 317 (84) PSV-55T 98 (26)
PSV-550T 306 (81) PSV-50T 90 (24)
PSV-500T 291 (77) PSV-45T 86 (23)
PSV-480T 287 (76) PSV-40T 79 (21)
PSV-440T 272 (72) PSV-35T 75 (20)
PSV-400T 260 (69) PSV-30T 68 (18)
PSV-365T 249 (66) PSV-25T 64 (17)
PSV-330T 238 (63) PSV-20T 57 (15)

Table 5 Notes:
1. The value preceding the "T" in the Test Valve Tag No is the required set pressure in psig.
Example: PSV-95T has a required set pressure of 95 psig (6.6 bar g).

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is classified as Air Products
internal use only, is subject to return on demand and must not be disclosed or reproduced without prior written consent. This information may be
subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 26 of 35

Table 6
Recommended Test Relief Valves

Contractor shall furnish the recommended pressure test relief valves listed in this table or
approved equal pressure test relief valves if the recommended valves are not available.

Test Relief Valves Hydrostatic Tests Pneumatic Tests

PSV-20T through PSV-300T
Set Pressure Range: 1.4 - 20.7
bar g (20 - 300 psig)
PSV-330T through PSV-1400T
Set Pressure Range: 20.7 - 96.5
bar g (300 - 1400 psig)
PSV-1500T
Set Pressure Range: 103.4 bar g
(1500 psig)
PSV-1600T through PSV-
2600T
Set Pressure Range: 103.4 -
179.3 bar g (1500 - 2600 psig)
Kunkle Model No. 912BDCM12-
JE0000 (set pressure)
DN15 (1/2" MNPT) x DN25 (1"
FNPT) D orifice = 78 mm² (0.1213
in²)
Kunkle Model No. 913BDCM12-
JE0000 (set pressure)
DN15 (1/2" MNPT) x DN25 (1"
FNPT) D orifice = 78 mm² (0.1213
in²)
Crosby Model No. 951100MD DN15
(1/2" MNPT) x DN25 (1" FNPT)
orifice = 48 mm² (0.074 in²)
Crosby Model No. 955100MD DN15
(1/2" MNPT) x DN25 (1" FNPT)
orifice = 48 mm² (0.074 in²)
Kunkle Model No. 912BDCM12-
KE0000 (set pressure)
DN15 (1/2" MNPT) x DN25 (1"
FNPT) D orifice = 78 mm² (0.1213
in²)
Kunkle Model No. 913BDCM12-
KE0000 (set pressure)
DN15 (D orifice = 78 mm² (0.1213
in²)1/2" MNPT) x DN25 (1" FNPT)
Crosby Model No. 951100MD DN15
(1/2" MNPT) x DN25 (1" FNPT)
orifice = 48 mm² (0.074 in²)
Crosby Model No. 955100MD DN15
(1/2" MNPT) x DN25 (1" FNPT)
orifice = 48 mm² (0.074 in²)

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 27 of 35

Table 7M
Copper Tubing

Tube Tube Wall Thickness (mm) Swagelok

OD Fitting
(mm) 0.71 0.89 1.24 1.65 2.11 2.41 2.77 3.05 Series
3.2 220.5 279.7 -- -- Working Pressure -- (bar g) -- 200
4.8 140.2 180.4 259.8 -- -- -- -- -- 300
6.4 100.9 130.3 192.0 258.6 -- -- -- -- 400
7.9 -- 101.4 148.1 203.5 -- -- -- -- 500
9.5 -- 83.2 120.4 166.3 -- -- -- -- 600
12.7 -- 61.2 87.7 120.0 158.0 -- -- -- 810
15.9 -- -- 69.1 93.5 122.5 143.1 -- -- 1010
19.1 -- -- 56.7 76.9 100.1 116.2 135.7 -- 1210
22.2 -- -- 48.4 64.9 84.8 98.0 114.2 -- 1410
25.4 -- -- 41.8 56.7 73.2 84.8 98.5 109.6 1610

Table 7US
Copper Tubing

Tube Tube Wall Thickness (in) Swagelok

OD Fitting
(in) 0.028 0.035 0.049 0.065 0.083 0.095 0.109 0.120 Series
1/8 3,198 4,056 -- -- Working Pressure -- (psig) -- 200
3/16 2,034 2,616 3,768 -- -- -- -- -- 300
1/4 1,464 1,890 2,784 3,750 -- -- -- -- 400
5/16 -- 1,470 2,148 2,952 -- -- -- -- 500
3/8 -- 1,206 1,746 2,412 -- -- -- -- 600
1/2 -- 888 1,272 1,740 2,292 -- -- -- 810
5/8 -- -- 1,002 1,356 1,776 2,076 -- -- 1010
3/4 -- -- 822 1,116 1,452 1,686 1,968 -- 1210
7/8 -- -- 702 942 1,230 1,422 1,656 -- 1410
1 -- -- 606 822 1,062 1,230 1,428 1,590 1610

Table 7M and 7US Notes:

1. Tables are based on high quality, soft annealed, seamless copper tubing per ASTM B75, or equivalent.
• Based on ultimate tensile strength of 30,000 psig (2070 bar g).
• For metal temperature not to exceed -20° to 100°F (-29° to 38°C).
• Allowable working pressure loads calculated from S values as specified by ASME B31.3.

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 28 of 35

Appendix A
Pressure Test Checklist

PRESSURE TEST CHECKLIST Circuit No :

Before performing a pressure test, the contractor will complete all items on these sheets to
confirm the circuit's readiness for testing. This form must be submitted for each circuit in the
Pressure Test Guideline. (N/A = Not Applicable)

Construction Completion Yes N/A

All butt welds, fillet welds, and socket welds complete?

All support welds attached to piping complete?

All stress relieving complete?

All radiography or other NDE necessary complete and approved

including additional NDE required for pneumatic testing by the code or
local regulations (for example, PED)?

System checked against P&IDs?

Material Certification checked?

Test Preparation

Are pressure test boundaries clearly defined?

All vessels to be protected spaded-/blanked-off?

Design pressures of all vessels to be tested by checking

against test pressure?

Non-return valves have internals removed or fixed open as required?

Vents and drains provided at high/low points? (To insure no air is

trapped in hydrostatic systems.)

All other plugs fully tightened?

Correct gasket and bolting installed?

Correct test relief valves provided?

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 29 of 35

Appendix A (continued)
Pressure Test Checklist

Test Preparation - continued Yes N/A

Correct range/calibrated test gauges available?

Test rig correct distance from circuit?

Area cordoned-off as necessary and warning notices posted?

Static heads allowed for?

Blanks/blinds correctly rated, in good condition, logged, numbered,

and checked?

Are all lower pressure adjacent systems, isolated by valves only,

numbered and checked as open to atmosphere?

Is pressure pump/compressor of suitable size (l/min) for test?

Are all joints accessible during test?

Have all support structures been approved for hydrostatic loads?

If not, have temporary supports been provided?

Is correct quality of test medium being used? For example, oil-free,

dry air or low "chloride-free" water for s/s.

Has ambient temperature been considered, both in terms of brittle,

fracture, freezing, and expansion under sun during day?

Are Client witnesses available?

Is Test Supervisor familiar with Pressure Test Guideline?

Has bolt tightness been checked in accordance with 4WPI-670210

“Bolt-Up Procedure for Flanged Connections”?

Have valve stem gland nuts been checked for tightness?

Have vessel and equipment nameplates been verified to ensure that

the code design pressure will not be exceeded?

I certify that all the above points have been checked for this test circuit as defined on the attached Pressure
Test Log (see Appendix E).

Contractor:

Name: .......................................................... Signature: ….............................................

Date: ….............................................

Air Products Representative:

Name: .......................................................... Signature: ….............................................

Date: ….............................................

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 30 of 35

Appendix B
Permit to Conduct a Pressure Test

This form must be submitted to the Air Products Representative for approval before the test may
begin. This form must be submitted for each circuit in the Pressure Test Guideline.

Circuit No :

We hereby apply to conduct a pressure test as defined on the attached Pressure Test Log.

We confirm we have read and understand Air Products' specification 4WPI-EW44001 "Pressure
Testing of Piping and Equipment."

We hereby attach the following documents with all pretest requirements approved:

Pressure Test Check List (Appendix A)

Pressure Test Blank Log (Appendix C)
Pressure Test Component Log (Appendix D)

I certify that I have checked all the precautions in the attached Pressure Test Check List (see
Appendix A) and that the system is in full compliance.

Contractor: Name: ................................................................

Signature: ..........................................................

Position: .............................................................

Date: …………………………………………………

Air Products Representative: I have checked the above system and authorize the pressure test to
proceed.

Name: .................................................................... Date: .............................................

Signature: ..............................................................

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 31 of 35

Appendix C

Pressure Test Blank Log

This form must be signed by the Air Products Representative for approval before the test may
begin to ensure that all necessary blanking has been used. Likewise, this form must be signed by
the Air Products Representative after completion of the test to ensure that all temporary blanks
have been removed. This form must be submitted for each circuit in the Pressure Test Guideline.

Circuit No :

Thickness
Size Installation Removal
Blank Blank or Line
(mm
Type No. Pressure No.
or in)
Class Contractor Signature Date Contractor Signature Date

Air Products Representative: (Installation Approval)

Name: .......................................................... Signature: ….............................................

Date: ….............................................

Air Products Representative: (Removal Approval)

Name: .......................................................... Signature: ….............................................

Date: ….............................................

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 32 of 35

Appendix D

Pressure Test Component Log

This form must be signed by the Air Products Representative for approval before the test may
begin. Likewise, this form must be signed by the Air Products Representative after completion of
the test to ensure that all temporary components have been removed. This form must be
submitted for each circuit in the Pressure Test Guideline. The main purpose of this form is to
track the pretest and after test installation/removal of any components besides test blanks such as
temporary supports and relief devices.

Circuit No :

Size Pretest After Test

Component Comp. Line
(mm
Type No. No.
or in)
Contractor Signature Date Contractor Signature Date

Air Products Representative: (Pretest Approval)

Name: .......................................................... Signature:…...............................................

Date: ….............................................

Air Products Representative: (After Test Approval)

Name: .......................................................... Signature:….............................................

Date: ….............................................

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 33 of 35

Appendix E

Pressure Test Circuit Completion Log

After completion of pressure testing each circuit, both the contractor and Air Products
Representative must sign and date the following Pressure Test Log.

Note: All procedures called out in Section 15 (System Restoration) of this specification
must be completed before this log can be signed off.

Circuit Full Test Air Products

Contractor Signature Date Date
# Pressure Representative Signature

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is
classified as Air Products internal use only, is subject to return on demand and must not be disclosed or reproduced without
prior written consent. This information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 34 of 35

Figure 1
Typical Hydrostatic Test Injection Manifold Setup

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is classified as Air Products
internal use only, is subject to return on demand and must not be disclosed or reproduced without prior written consent. This information may be
subject to export controls. Disclosure contrary to U.S. law is prohibited.
 Pressure Testing of Piping and Equipment
4WPI-EW44001, Rev. 3, Page 35 of 35

Figure 2
Typical Pneumatic Test Injection Manifold Setup

All information herein is the property of ©Air Products and Chemicals, Inc., unless another source is shown. This document is classified as Air
Products internal use only, is subject to return on demand and must not be disclosed or reproduced without prior written consent. This
information may be subject to export controls. Disclosure contrary to U.S. law is prohibited.