O.

APPENDIX O: PRESSURE TESTING REFERENCES

O.1. HYDROSTATIC TEST PROCEDURE
This sample procedure outlines hydrostatic testing of piping and/or pressure vessels. This procedure is to be used only as a
guide to proven industry practice. All testing must be conducted using guidelines set forth in the appropriate codes. A list is
provided to aid test personnel in locating the applicable codes. The information provided must be checked to ensure it is
current and correct.

Preparation and Precautions

1. A piping and instrument drawing (P&ID) must be provided with the boundary "highlighted" for easy reference.

2. Access area around vents should be roped off during testing.

3. Safety and relief valves must be blanked off for testing.

4. All boundary valves must be danger tagged.

5. The first drain outside a boundary valve must be left open to ensure hydro pressure is limited to the test boundary.

6. Pressure vessel outer metal and water temperature must be greater than the nil-ductility temperature specified by the
manufacturer and in no case below 70°F.

7. Water chemistry must be of the same quality as the process requirements if the system and/or vessel is not to be cleaned
following hydrostatic testing.

General Procedure

1. Fill the system using the system in-line pumps, venting all high points.

2. Provide a recently calibrated (within 2 weeks) gauge with a range twice the test pressure.

3. Provide low-volume, high-head hydrostatic test pump and reservoir.

4. Pump the system or vessel pressure to test level while thoroughly examining for leaks.

5. Check drains outside the test boundary for leakage. If leakage occurs, record leakage rate of the boundary valve by timing
the flow, with a stop watch, into a 5-gal bucket.

6. Check valves for packing leakage and tighten glands as necessary, using caution not to overtighten and render the valve
inoperable.

Note

Leakage in valves is not cause for failing a hydrostatic test, but cause for initiation action to repair the valve in question. Valves may be
repaired after the test. Also, test personnel may find it necessary to obtain a high-volume hydrostatic test pump if a number of valves are
leaking beyond the capacity of the low-volume pump.

Caution

Do not use "cheaters" or otherwise overtighten valves to stop leakage. Isolation valves with leakage and control valves with excessive leakage
must be disassembled and lapped or otherwise repaired.

7. Check weld joints and bolted flanges for leakage.

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 8. After system and/or vessel is determined "tight," ready the test for inspection and witness.

9. Bring the system to test pressure. If portions of the system cannot be inspected, test must be a decay test. All buried or
insulated pipe or vessels must be decay rate tested.

10. Decay tests must be conducted during periods of constant ambient temperature to assure test pressure is not effected by
temperature changes.

11. Record test data on installation record, and have inspector(s) witness and sign the record. Attach a P&ID indicating the test
boundary.

Test duration should be as follows:

Decay test—30 min—Zero decay

Visual test—10 min—Zero leakage

Test pressure should be as follows:

Hydro 1.5 times design pressure

Pneumatic 1.5 times design piping pressure and no more than 100 psig for inspection

Pneumatic 1.25 times design vessel pressure and no more than 100 psig for inspection

Note

A system exposed to the sun may show a decay in pressure if the system or portion of the system becomes shaded during the test period.

Caution

A system may become overpressurized if shaded and, during the test period, becomes exposed to the sun.

Pressure Testing Reference Log

Code Reference Hydrostati Pneumatic Visual Gauges AI Witness Record Water Notes
c Test Test Examinati Required Forms to Temp.
Pressure Pressure on Be Signed Controls
and Test (If Pressure by AI
Sequence Permitted) (After Test
Pressure)

ASME PG-99 The tests Hydrostati Maximum An Yes P-2- All Ambient, At no time
Section I shall be c test is allowable indicating boilers but in no during
"Power made in only test working gauge, except case less hydrostati
Boilers" two method pressure visible to water and than 70°F. c test shall
stages in stated. is the electric. The metal any part of
this minimum operator temperatu the boiler
sequence: pressure controlling P-2A- re shall be
during the Electric not subjected
1. examinati pressure Boilers. exceed to a stress
Hydrostati on. applied, 120°F greater
c pressure shall be P-3- Water during than 90%
tests shall connected tube close of its yield
be applied to the Boilers, examinati strength
by raising pressure Superheat on. (0.2%
the parts. ers, offset) at
pressure Hydrostati Waterwall test
to 1.5 c head on s and temperatu
times the the gauge Economiz re.
maximum shall be ers.
allowable considere
working d P-3A-
pressure depending Engineerin

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 shown on on the g
the Data Pressure Testing Reference
location ofLog Contractor
Report to the gauge. Data for a
Code Reference Hydrostati
be Pneumatic Visual Gauges AI Witness Record
completed Water Notes
c Test
stamped Test Examinati Indicating Required Boiler to
Forms Temp.
Pressure
on the Pressure on pressure Be Signed
Unit. Controls
and Test
boiler, but (If Pressure gauges by AI
Sequence
no less Permitted) (After Test used in P-4-
then 1.25 Pressure) testing Partial
times the shall Data
maximum preferably Report.
allowable have dials
working graduated P-4A-
pressure over their Process
of any part entire Steam
of the range of Generator
boiler. The about s.
pressure double the
shall be intended P-6-
under maximum Suppleme
proper test ntal
control at pressure, Sheets.
all times but in no
so that the case shall
required the range
test be less
pressure than 1.5
is never times the
exceeded pressure.
by more The
than 6%. spacing
Close between
visual shall be
inspection such that
for the
leakage is inspector
not and the
required at operator
this stage. controlling
the test
2. The shall be
hydrostati able to
c test determine
pressure when the
may then required
be pressure
reduced has been
to the applied.
maximum
allowable
working
pressure,
as shown
on the
Data
Report, to
be
stamped
on the
boiler and
maintaine
d at this
pressure
while the
boiler is
carefully
examined.

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 Pressure Testing Reference Log

Code Reference Hydrostati Pneumatic Visual Gauges AI Witness Record Water Notes
c Test Test Examinati Required Forms to Temp.
Pressure Pressure on Be Signed Controls
and Test (If Pressure by AI
Sequence Permitted) (After Test
Pressure)

PW-54 Except as
modified
above, all
welded
drums and
other
welded
pressure
parts shall
be
subjected
to a
hydrostati
c test
pressure
of not less
than 1.5
times the
maximum
allowable
working
pressure.
The
hydrostati
c test may
be made
either in
the
Manufact
urer's
Shop or in
the field.

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 Pressure Testing Reference Log

Code Reference Hydrostati Pneumatic Visual Gauges AI Witness Record Water Notes
c Test Test Examinati Required Forms to Temp.
Pressure Pressure on Be Signed Controls
and Test (If Pressure by AI
Sequence Permitted) (After Test
Pressure)

ASME UG-99 and 1.5 times When 2/3 test Connect Yes U-1- Proof
Section UG-100 max. using pressure indicating Pressure tests may
VIII allowable pneumatic for gauge Vessels be used to
"Pressure working pressure, hydromati directly to establish
Vessels" pressure 1.25 times c test of vessel. If U-2-1 maximum
times maximum 4/5 test visibility of Partial working
lowest allowable pressure gauge is Data pressure.
ration of working for limited, Pneumatic
material pressure, pneumatic supply U-3- testing at
stress times test. additional Miniature 1.25
value at lowest gauge. Vessels working
design ratio of Recording pressure
temp. material gauge U-4- may be
stress recomme Suppleme used if
1.5 (S at value at nded for ntary water is
design test temp. large Sheets not
temp.)/S to stress vessels. feasible.
at test value at Pneumatic
temp. design Range: testing is
temp. Double the advised
test against
1.25P (S pressure, because
at design but never of hazards
temp.)/S less than of
at test 1.5 times. compress
temp. ed air in
large
Raise volume.
pressure
gradually
to 1/2 test
pressure,
then
increase in
increment
s of 1/10
the test
pressure
not
exceeding
1.25 times
the basis
for the
calculated
test
pressure,
defined in
UA-60(e).

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 Pressure Testing Reference Log

Code Reference Hydrostati Pneumatic Visual Gauges AI Witness Record Water Notes
c Test Test Examinati Required Forms to Temp.
Pressure Pressure on Be Signed Controls
and Test (If Pressure by AI
Sequence Permitted) (After Test
Pressure)

ANS1 137.1 to 1.5 times Not less than 1.20 nor Hydro and Connect Yes. P4A "Data Temperatu
B31.1 137.7 the design more than 1.50 times Pneumatic gauge Report re not
"Power pressure design pressure for a : Examine where it is Form for stated.
Piping" for a minimum of 10 minutes. at design visible. Fabricated
minimum Increase pressure to not pressure Dial shall Piping,"
of 10 over 1/2 test pressure; following be ASME
minutes. then increase in 1/10 test holding graduated Section 1,
pressure until test for to Appendix
pressure is reached. required approxima X.
Keep personnel at safe time at tely
distance from pipe while test double the
at test pressure. It shall pressure. test
then be reduced to the pressure
lesser of the design but not
pressure or 100 psig and less than
held for such time as 1.5 times
may be necessary to this
conduct the examination pressure.
for leverage.

ANS1 8.1 to 8.5 1.5 times 110% of Minimum Examine Not As Rating Not
B16.5 and Table the 100°F of 80 psig at test stated. required marked on stated.
"Steel Pipe 3. pressure pressure on valves pressure. for the valve per
Flanges, rating, rating for 4 in to 8 in system in MSS SP-
Flanged minus all valves under which the 25.
Valves, nothing, over 10 in pressure componen
and but and valves rating t or part is
Fittings" rounded 4 in to 8 in class 600 used.
off to with and
next- pressure smaller
higher 25 rating valves of
psi class 600 all
increment. and pressure
Hold higher. ratings.
minimum
of 15
seconds
for valves
2 in and
smaller, 1
minute for
valves 2.5
in through
8 in, and 3
minutes
for valves
10 in and
larger.

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 Pressure Testing Reference Log

Code Reference Hydrostati Pneumatic Visual Gauges AI Witness Record Water Notes
c Test Test Examinati Required Forms to Temp.
Pressure Pressure on Be Signed Controls
and Test (If Pressure by AI
Sequence Permitted) (After Test
Pressure)

API 650 5.3.2 to 1st - Test 3rd - No The tank Air Inspection API 650 Temperatu
"Welded 5.3.9 tank Vacuum pneumatic shall be pressure required "Storage re not
Steel bottom test tank test other observed or vacuum by Tank stated.
Tanks for welds with roof welds than from a gauges Owner's Specificati
Oil soapsuds, as in 1st vacuum safe shall have Inspector. on Data
Storage" linseed oil, step. box leak distance connectio AI is not Sheet,"
or other testing, while ns directly specified. Appendix
suitable except filling. to the The AI L.
material where Thorough space to may act
for leak water is inspection which the as
detection, not of all pressure Owner's
using available. welds or vacuum Inspector,
vacuum In that shall be is applied. however.
box at event, 2 done
minimum psi air starting 1
of 2 psi pressure hour after
vacuum is put in completio
(see the tank n of filling.
5.3.9). and all
welds are
2nd - Fill soapsuds
tank with inspected
water. externally.
Tanks This test
with tight or the
roofs are vacuum
to be filled box test
2 in above are
the top leg acceptabl
of the top e for roof
angle. weld
inspection
.

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 Pressure Testing Reference Log

Code Reference Hydrostati Pneumatic Visual Gauges AI Witness Record Water Notes
c Test Test Examinati Required Forms to Temp.
Pressure Pressure on Be Signed Controls
and Test (If Pressure by AI
Sequence Permitted) (After Test
Pressure)

API 620 5.23.1 to 1st - Following all foregoing The Inspector Manufact Temperatu
"Large 5.23.10. Magnetic tests, and after release of manomet to be urer's re not
Welded Particle - pressure, thorough visual er for qualified Certificate stated. Fill
Low- examine inspection shall be made measuring per API (see rate shall
Pressure all of the entire tank with vacuum 620, 5.02. Appendix not
Storage attachmen special attention to must be Owner M). exceed 3
Tanks" t welds attachments to the shell. attached also shall feet per
(0–15 psi) around Additional tests may be to the provide Summary hour.
openings made where it is vapor his own Report per
and advisable. Do not permit space. Air inspection 5.27.2
reinforce personnel near the tank pressure .
ments. while pressure is being gauges Weld
applied for the first time. are also Procedure
2nd - connected s and
Pressurize to the Welder
space vapor Qualificati
between space. ons per
wall and Water 5.27.3
reinforce pressure
ments gauges at Tanks
with 80 to any point shall be
100 psi air must take stamped
through into with API
telltale account Standard
holes. the 620
Apply vertical official
soapsuds hydrostati symbol.
to welds. c head of
.433 psi
3rd - Apply per
soapsuds vertical
to tank foot. A
bottom record of
welds and all
pull partial pressures
vacuum of shall be
at least 3 kept. All
psig. gauges
shall be
calibrated
on
deadweig
ht tester
before
starting
tests.

Pressure Testing Reference Log

Code Reference Hydrostati

c Test
Pressure
and Test
Sequence

API 620 5.23.1 to 4th - Alter

"Large 5.23.10 any
Welded repairs,
Low- pressurize
Pressure tank with
Storage 2 psig air

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 Tanks" of 1/2 the
(0–15 psi) design Pressure Testing Reference Log
pressure
Code Reference Hydrostati
of the Pneumatic Visual Gauges AI Witness Record Water Notes
c Test
vapor Test Examinati Required Forms to Temp.
Pressure
space. Pressure on Be Signed Controls
and Test
Apply (If Pressure by AI
Sequence
soapsuds Permitted) (After Test
to all Pressure)
welds
above
highliquid
design
level.

Combinati
on Hydro-
Pneumatic
Test of
Tanks Not
Designed
to Hold
Liquid
Above the
Specified
Capacity
Level

After
Mandator
y
Preliminari
es:

1st - Blind
off
pressure
relief
valves and
vent top
of tank.
Fill with
water to
capacity
design
level.

2nd -
Close
vents.
Pressurize
with air to
1/2 the
vapor
space
design
pressure.
Increase
pressure
gradually
to 1.25
times the
vapor
space
design
pressure
and hold
for one
hour,
observing
from a
safe
distance

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 for any
sign of Pressure Testing Reference Log
distress.
Code Reference Hydrostati Pneumatic Visual Gauges AI Witness Record Water Notes
3rdc -Test Test Examinati Required Forms to Temp.
Pressure
Release Pressure on Be Signed Controls
and Test
pressure (If Pressure by AI
Sequence
slowly and Permitted) (After Test
remove Pressure)
pressure
valve
blinds.
Inject air
until
pressure
equals
vapor
space
design
pressure
at which
relief
valves
shall
release
air. Hold
this
pressure
while all
welds are
inspected
visually
for leaks.
Examine
all welds
above
liquid level
with
soapsuds
at this
pressure.

Completel
y
Hydrostati
c Tests of
Tanks
Designed
for Liquid
to Roof
Top

After
Mandator
y
Preliminari
es:

1st - Blind
off relief
valves. Fill
with water
to roof top
with top
vented to
atmosphe
re. Close
vent.
Increase
water
pressure
slowly
until

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 topmost
point of Pressure Testing Reference Log
roof
Code Reference Hydrostati
equals Pneumatic Visual Gauges AI Witness Record Water Notes
c Test
1.25 times Test Examinati Required Forms to Temp.
Pressure
vapor Pressure on Be Signed Controls
and Test
space (If Pressure by AI
Sequence
design Permitted) (After Test
pressure. Pressure)
Hold for
one hour
minimum.

2nd -
Reduce
pressure
to vapor
space
design
pressure
and hold
until all
welds
have been
examined
for
leakage.

3rd - Vent
tank to
atmosphe
re. Lower
water to
below
relief valve
inlets.
Remove
blinds.
Inject air
until
pressure
reaches
vapor
space
design
pressure
at which
relief
valves
shall
release
air.

Pressure Testing Reference Log

Code Reference Hydrostati Pneumatic Visual Gauges AI Witness Record Water Notes
c Test Test Examinati Required Forms to Temp.
Pressure Pressure on Be Signed Controls
and Test (If Pressure by AI
Sequence Permitted) (After Test
Pressure)

API 620 Partial

"Large Vacuum
Welded Test
Low- (Required
Pressure after
Tanks" Either of
(0–15 psi) the
(Conclude Preceding
d) Two
Tests)

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 On tanks
that are Pressure Testing Reference Log
not
Code Reference Hydrostati
vertical or Pneumatic Visual Gauges AI Witness Record Water Notes
docnot
Test Test Examinati Required Forms to Temp.
Pressure
have Pressure on Be Signed Controls
and Test
cylindrical (If Pressure by AI
Sequence
sidewalls, Permitted) (After Test
release Pressure)
vapor
space air
pressure.
Connect
manomet
er to this
space.
Withdraw
water,
with vents
closed,
until the
design
partial
vacuum
relief
valve(s)
shall
operate.
With vents
closed,
continue
to
withdraw
maximum
partial
vacuum
until the
liquid level
reaches
1/2 the
high liquid
(capacity)
level for
which the
pressure
equals
vapor
space
design
pressure.
Observe
shape of
tank for
any
appreciabl
e change.

On tanks
which are
vertical
and do
have
cylindrical
sidewalls,
water is
withdrawn
from the
tank until
it is
substantia
lly empty.
When the
manomet

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 er
indicates Pressure Testing Reference Log
the design
Code Reference Hydrostati
partial Pneumatic Visual Gauges AI Witness Record Water Notes
c Test
vacuum Test Examinati Required Forms to Temp.
Pressure
pressure, Pressure on Be Signed Controls
and Test
the (If Pressure by AI
Sequence
vacuum Permitted) (After Test
relief Pressure)
valves
shall
operate.
Then
inject air
until the
pressure
reaches
the vapor
space
design
pressure.
Tank shall
be
carefully
observed
under
both
conditions
for
appreciabl
e changes
in shape.

NFPA Volume 2, All piping, Hydrostati Examine Not Not Not Not
"Foam- 1977, including c test is at test stated. stated. stated. stated.
Water Chapter 5 yard only test pressure.
Sprinkler piping and method
Systems" system stated.
piping,
200 psi
for 2
hours, or
50 psi in
excess of
maximum
static
pressure if
this
pressure
exceeds
150 psi.

AWWA Section Before Flat During Vacuum Owner's Certificate Temperatu

D100-73 12.0 painting, bottoms and after gauge inspector of re not
"Welded fill tank shall be filling. directly on AI is not Complianc stated.
Steel with water vacuum vacuum specified. e, Page
Elevated to box box. 56.
Tanks, maximum inspected
Land working at 2 psi
Pipes, and water minimum
Reservoirs level. vacuum
for Water Inspect with
Storage" for soapsuds
leakage. solution or
linseed oil.

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