PNEUMATIC TESTING PROCEDURE FOR

MECHANICAL EQUIPMENT (CONVECTION, CROSS-

OVER & RADIANT COIL)
1.0 PURPOSE.
2.0 SCOPE.
3.0 APPLICABLE DOCUMENTS.
4.0 RESPONSIBILITY.
5.0 MANPOWER.
6.0 TOOLS & EQUIPMENT.
7.0 METHODS/PROCEDURE.
8.0 QUALITY CONTROL.
9.0 SAFETY PRECAUTION.
10. ATTACHMENTS.

PNEUMATIC TESTING PROCEDURE FOR MECHANICAL EQUIPMENT (CONVECTION,

CROSS-OVER & RADIANT COIL)

1.0 PURPOSE

This method statement shall provide minimum guidelines to carry out pneumatic testing works in
plants and refinery projects.

2.0 SCOPE

This Method Statement covers the procedure of pneumatic testing of mechanical equipments,
pipelines (Convection, Cross-over & Radiant Coil) for plants and refinery projects.

3.0 APPLICABLE DOCUMENTS

3.1 Project Specifications and Standards

3.1.1 ASME 31.3 Process Piping.

3.1.2 ASME Section V, Article 10 and Article 10 Appendix I (Reference SAES-A-004 Para
5.6.3).
3.1.3 S-000-3160-004 Piping Pressure Test Procedure.
3.1.4 S-000-3160-007 Piping Internal Cleaning Procedure.
3.1.5 SAEP-302 Instruction for Obtaining a Waiver of a Mandatory Saudi ARAMCO
Engineering Requirements.
3.1.6 SAES-A-004 General Requirements for Pressure Testing.
3.1.7 SAES-A-104 Wastewater Treatment, Reuse and Disposal.
3.1.8 SAES-L-150 Pressure Test of Plant Piping and Pipelines.
3.1.9 SATIP-A-004-01 Pneumatic Pressure Testing.
3.1.10 SAIC-A-2001 Review Procedure – Pressure Testing (All Applications).
 3.1.11 Construction Safety Manual.
3.1.12 Schedule “Q” Quality Requirement.

4.0 RESPONSIBILITY

4.1 Construction Manager is responsible for implementing HSE and shall study, analyze and
schedule all construction activities with his department to include manpower and equipment line
up as well as other possible resources required for the successful implementation of the
construction work activities. Study all aspects of work procedure as per JV Technical Scope of
Work.
4.2 Hydrotest Supervisor shall assist Construction Manager in the overall construction activities.
Receives and carries out directives and strategies of Construction Manager in various phases of
duties assigned by this immediate Supervisor.

4.3 Hydrotest Foreman shall be responsible for the direct work supervision at site and ensure that
the work is performed in accordance with JV Technical Scope of Work and specification.
4.4 QC Engineer/Inspector shall be responsible to verify the work and ensure that the work is
being performed in accordance with the water disposal procedure.
4.5 QC Group shall prepare all required documents for water disposal and will lead in
coordinating with proponent and client to witness and accept the work.
4.6 Safety Supervisor/Officer shall monitor and ensure that the work is done in accordance with
JV Safety Standard Procedure and in accordance with Saudi ARAMCO Safety Standard
Procedure.

5.0 MANPOWER

5.1 The Hydrotest Supervisor shall control the overall activity of testing works and he shall be
directly reporting to the Construction Manager. The basic manpower under him shall consist but
not limited to the following:
5.1.1 Piping Foreman.
5.1.2 Pipefitters.
5.1.3 Welder.
5.1 .4 Rigger.
5.1.5 Crane Operator.
5.1.6 Helper.
5.1.7 Scaffolder (by others).
5.2 QC Inspector.

5.3 Safety Supervisor/Officer.

6.0 TOOLS AND EQUIPMENT

6.1 Tools and equipment needed should be in good condition and must be checked by Hydrotest
Supervisor & Safety Officer prior to use. These includes but not limited to:

1. Sets of wrenches
2. Hand Tools
3. Air compressor
4. High Pressure hose
5. Test Manifold
6. Pressure Gauge
7. Pressure Relief Valve
8. Temporary Spool
9. Test Blind
10. Test Blind
11. Temporary support
12. Temporary material
13. Crane
14. Welding machine

6.2 Test Manifold

6.2.1 Before employing the pressure testing manifold in the actual system pressure test, it shall
be separately pressure tested to at least 1.2 times the system test pressure but not less than the
discharge pressure of the pump used for the pressure testing.
6.2.2 The test manifold shall be designed and constructed to meet the minimum system
requirements and approved by the Engineering Division Head in operating facilities or
responsible Project Inspection Division Head in new construction
6.2.3 Test manifold shall have 100% NOT of all welds.
6.2.4 Test manifolds for new construction shall be revalidated for each new project and every 60
months for operating facilities.

7.0 METHODS/ PROCEDURE:

7.1 Preparatory Works

7.1.1 Secure work permit from DEC/JGC concerned personnel prior to start of work/activity
7.1.2 Prepare all materials needed for the job.

7.2 General Requirements

7.2.1 General Instruction Gl-0002.102 “Pressure Testing Safely” shall be followed during
pressure Testing

7.2.2 Pneumatic Testing

7.2.2.1 Pneumatic testing is not permitted without written approval of the manager, Inspection
Department, unless specifically allowed by this standard or the referenced Saudi Aramco SAESs
or SAMSSs. This test, when conducted, shall be in accordance with Gl-0002.102 for additional
safety requirements.
7.2.2.2 Pneumatic testing with air of piping systems or equipment which has been in flammable
service shall be concurred by the Manager, Loss Prevention Department.
7.2.3 Test Package preparation and handling shall be in accordance with approved procedure.

7.2.4 Approved Test Package shall be made available for reference in setting up the pressure test
of line or system.
7.2.5 Prior to test, weld lines shall be thoroughly dry, cleaned of rust, grease, paint, or other
contaminants.
7.2.6 It shall be confirmed that NDE records (MT, PT, RT, UT) showing extend, sequence on
NDE selection meeting project specification, line check, line internal cleanliness check as
required have been completed and approved and all “A” punch items are completed prior to the
release of line for pressure testing.

7.2.7 Flange joints shall be checked for tightness or other possible sign of leaks. All flanges shall
be securely taped and pinhole provided in the tape for leak detection.
7.2.8 Pipes shall be sufficiently supported. All anchors, supports, guides and hangers shall be
checked for correct installation. Expansion joints with tie rods and retaining nuts shall be
installed in the test position in accordance with manufacture recommendation and spring hangers
or springs supports shall be provided with temporary restraints where needed to prevent
excessive travel or deformation under test loads.
7.2.9 Test shall not be done with the instrument connected. Test shall be carried out for the
piping up to the first valve of instrument pressure piping. In this case, if flange or union is
installed at instrument side of the first valve, such flange or union shall be kept disconnected
during the test. Test lines shall be sealed to prevent dust or egress induced to the instrument
pressure piping.
7.2.10 All valves in the test system shall be fully open.

7.3 Test Preparation

7.3.1 Preparation of pressure test shall be in accordance with SAES-A-004

7.3.2 Temporary blind flanges and test blinds shall be installed at locations shown on the mark
P&ID and isometric drawing included in the test package. Test blind shall be in adequate
thickness to withstand the test pressure; test blind should be lifted and installed by using flange
jack which is the special jig for safety and easy installation.
7.3.3 Temporary gasket shall be installed at test limit and shall be equivalent to permanent gasket
for 600# and higher rating and all RTJ lines.

7.3.4 Equipment such as drums, heat exchangers, pumps, tanks, etc. that is not to be tested shall
be either disconnected from the piping or isolated by blinds or means during pneumatic testing.
7.3.5 For piping system with check valves, the pressure shall be from the upstream of the check
 valves or the internal of the check valves can be removed under Company supervision. Check
valve shall not be used for isolation.

7.3.6 Stopper of spring supports shall not be removed before pneumatic test.
7.3.7 Instrument connections shall be closed with proper gasket and blind flange and tubing from
instrument root valve is to be disconnected.

7.3.8 Blind Flanges, paddle blinds or spectacle blinds shall be used to isolate the test sections.
They shall be the same class rating of the system or may be fabricated from verifiable
identification of base material and approval of calculations by the supervisor, CSD Piping Unit
when this is not practical  closed block valves (gate, globe, plug and ball may be used to isolate
the piping sections (providing the valves are not passing, otherwise the spectacle plate/blind shall
be installed in the closed position. If block valve are used in lieu of blinds, provisions shall be
made to ensure no overpressure can occur in the system that is not being tested, due to possible
leak through the valves.

7.3.9 The following components shall removed or isolate by inserting blinds and or temporary
spools:

7.3.9.1 Control valves, thermo wells, orifice plates, restriction orifice, strainer elements, filter
elements, rupture discs, flow nozzles, displacement and turbine meters, self contained regulators,
rota meters, pressure gauges, level gauges, level instruments, Conical Strainers, flow glasses,
sample probes, safety showers and eye washers, non-slam check valves, dual plate check valves,
pressure relief valves, steam traps, auto drains, sample coolers and chemical injections.
7.3.10 The piping systems shall be cleaned in accordance with SAIC-L-2017 and SATR-A-2008.
7.3.11 Pressure gauges shall be calibrated prior to its use. Calibration interval shall not exceed
one (1) month as mentioned in Section 8 Para.8.1.5 of SAES-A-004 “General Requirements for
Pressure Testing. Calibration certificates shall be included in the Test Package.
7.3.12Calibrated pressure gauges shall be installed at appropriate locations. All gauges shall have
a range such that the test pressure is within 30-80% of the full range. A minimum of two
pressure gauges shall be installed on the system, one on the pressure control point and the other
on the test system.

The accuracy of the gauges shall be within 5% tolerable accuracy. Sketch showing location of
the gauges vis-~-vis highest and lowest point are included in the test.
7.3.13Pressure relief valve shall be calibrated within one week prior to test date and shall have
adequate capacity set to relief at 5% above the test pressure. It can be set 10% above the test
pressure if the test pressure is less than 85% SMYS. Refer to ASME B31.3-2008 Table A-1 for
values. Calibration report shall be inserted into the Test Package.
7.3.14The following shall be excluded from the pneumatic test. Refer to SAES-A-004 Para. 8.2.
Also, other unlisted sensitive equipment or as designated by Saudi Aramco Piping Standards
Committee or other equipment specific Saudi Aramco Standards Committees can be added.

1. Rotating machinery, such as pumps, turbines and compressors.

2. Strainers and filter elements.
3. Pressure relieving devices, such as rupture disks and pressure relief valves.
4. Locally mounted indicated pressure gauges, where the test pressure will exceed their scale range.
5. Equipment that cannot be drained.
6. Instrument devices.
7. The piping system shall be accessible for visual inspection during leak testing and to ensure that
all weld joints, threaded joints, flange joints shall be left exposed no cover up of masking tape,
unprimed and unpainted for examination during leak testing.

7.4 Pneumatic Test

7.4.1 Identify the test limit shown on the Test Package. (Test package to be reviewed separately)
7.4.2 Prepare test equipment and test manifolds to the designated location.
Pressure gauge shall be installed at the highest point of the line injection of pressure through a
test manifold. Test manifold shall be at the lowest point of the line.
7.4.3 Review each test package and assure pre-test checklist has been completed and accepted by
QC and permitted to test.

7.4.4 Close all the open ends of the piping system to be tested, valves to install plug, cap, or
blind flange, and equipment terminals. Provide temporary spool piece for those excluded pieces,
etc.
7.4.5 The area around the system to be tested shall be cleared of unauthorized personnel and
warning notices shall be posted during the time that piping system is pressurized for the test. No
one shall approach the test area for a minimum of 10 minutes after the test pressure is reached
and before commencement of inspection of the system, the isolation valve between the
temporary test manifold/piping and the piping/equipment under pressure test shall be closed and
the test pump disconnected. The isolation valve
downstream of the manifold shall be opened after the pump is disconnected.
7.4.6 Two (2) personnel shall be at the pressure control point monitoring the gauge whenever the
system contains pressure.

7.4.7 Take a temperature reading of metal to assure that it is warmer than the coldest temperature
allowed.
7.4.8 Test medium will be introduced to the system using air compressor. The test medium “dry
air” shall be introduced into the piping system gradually until the pressure is lesser than half of
the test pressure. At this ‘point, the pressure shall be maintained for 10 minutes.
7.4.9 First leak detection shall be made for all welding and flange joints.
7.4.1 0The pressure rise during a pressure test shall be gradual and under control to allow time
for material to strain, and time for personnel to check for leaks.
7.4.11 The pressure shall be gradually increased to the test pressure.
7.4.12For table shown on Figure-1 weaknesses are repaired and leaks are stopped before
proceeding to any higher pressure.

7.4.13After attaining test pressure and before commencing line inspection of the system, the
isolation valve between test manifold and piping under pressure test shall be closed and the
compressor’s hose disconnected.
7.4.14Conduct visual inspection of the line to detect evidence of leakage.
7.4.15ARCC and DEC/JGC authorized personnel shall check the line for leaks.
7.4.16Cover joints and welds with Chloride-free leak detection fluid using a chemist’s wash
bottle or other suitable means. Ordinary household soaps or detergents are not permitted. Also,
the bubble forming solution shall be compatible with the temperature of the test conditions.
Refer to ASME V Art. 10 Appendix I “Bubble Test- Direct Pressure Technique”.
7.4.17If leaks are found, marked the location of leaks and depressurized the line to pressure
gauge dial indicating zero before any repair works or tightening of
bolts. After the repair, re-test the line as per above sequence.

7.4.18Maintain test pressure for sufficient length of time but no less than 30 minutes to permit
thorough visual inspection of all joints and weld. Test pressure will be maintained not greater
than two (2) hours after notification of client’s inspector. Pressure shall be reduced gradually
when depressurizing. The depressurizing valve and piping shall be arranged for safe discharge of
the test media upon completion of the test. Do not depressurize a system by loosening bolts in a
flange or by unscrewing fittings. Authorized personnel shall open the vent’s valve gradually to
prevent vacuum forming.

7.4.19Approved test forms shall be completed and signed by appropriate inspection personnel of
Saudi Aramco.

7.5 Restoration
7.5.1 After completion of pressure test, permanent gasket and temporary gasket installed where
to be reinstated shall be replaced to a new permanent gasket except for PIKOTEK gasket, ring
joint gasket and rubber sheet gasket as mentioned in S-000-3160-004 Para. 6.8.
7.5.2 Remove all temporary materials used for the test. Reinstall all items temporarily removed
during testing.

7.5.3 Inspect restoration of piping system, verify reassembly and flow arrow direction of valves
and other miscellaneous components where applicable.

7.5.4 All plugged shall be installed and seal welded.

7.5.5 Endorse to DEC/JGC for inspection of reinstatement / restoration. If approved, sign Test
Package Flow Sheet (Front Sheet) and Reinstatement / Final Checklist Test Package. Punched
items by DEC/JGC shall be filled-up using Construction Punch list Form SATR-A-2007 and
return for clearing.

7.5.6 Upon acceptance. Punched items shall be filled-up and returns to ARCC for clearing. If
approved, Contractor shall sign checking Item on Test Package Flow Sheet (Front Sheet) and
Reinstatement I Final Checklist of Test Package.

8.0 QUALITY CONTROL

8.1 QC Inspector shall be responsible to conduct all required inspection/documentation and to

assure that all applicable requirements, codes and standards are complied with.
8.2 QC to monitor testing activities and sign documents as per SATIP-A-004-01

9.0 SAFETY PRECAUTION

Safety Requirement, arrangement of equipment and system to carryout safe pressure testing shall
be in full compliance to the Saudi Aramco G.I 0002-102 “Pressure Testing Safely”

9.1 Construction Manager/Supt./Supv./FM shall be responsible for the implementation of this

procedure and the required orientation necessary for the work force.
9.2 Safety Supervisor/Officer shall monitor compliance of the entire working crew regarding
safety procedures until the work is fully completed.

9.3 In plant areas and shops the test area shall be barricaded and warning signs shall be posted to
alert approaching personnel, where practical.

9.4 Personnel shall be posted at plant sites to keep the test area clear of all people not connected
with the test, if necessary.

9.6 No work shall be carried out on system while system is under pressure.
9. 7 A test system under pressure shall never be left un-attended until test is de pressurized.
9.8 When testing at high elevation, strong and safe scaffold shall be prepared. Also ladder or
mobile access lift can be used. No going out from the man basket into an elevated working
platform.
9.9 The pressure rise during a pressure test shall be gradual and under control to allow time for
material to strain, and time for personnel to check for leaks. Do not exceed the following
pressures until weaknesses have been repaired and leak has been stooped.
9.10 Working on a system while it is under pressure is very hazardous because a failure could be
initiated at the work due to the addition of stresses in material. Therefore, a system shall be
depressurized (with the exception of pressure due to a head of liquid) before any work is done to
stop leaks or repair weaknesses, including the tightening of bolts.
9.11 Upon completion of the test system should be emptied in such a way as not to cause
vacuum and collapse. The depressurizing valve and piping shall be arranged for
safe discharge of the test medium upon completion of the test. Do not depressurize a system by
loosening bolts in a flange or unscrewing fittings because this could lead to injury. Temporary
gaskets shall not exceed the specified rating indicated by manufacturer’s data sheet or spiral
wound permanent gaskets must be used for those ratings where temporary gaskets are not
available.
9.12 Good housekeeping must be maintained for the duration of work.
9.13 Job Hazard and Risk Assessment (JHRA) of this method statement shall be disseminated
and explained to workers for safety awareness.

10. ATTACHMENT:

Job Hazard and Risk Assessment

Test Package

Pneumatic Test Checklist in Plants and Refinery Projects

This article is about Checklist for Pneumatic Test, Pressure Testing Safely, pneumatic test
procedure pdf as per International standards and osha standards. You can use this checklist for
hydro test safety checklist also. You can find some topics points for pressure testing toolbox talk.
For risk assessment for pressure testing pipework please check out here.
 Pneumatic Test Checklist in Plants and Refinery Projects

1. A pressure test diagram must be with you during Pneumatic testing.

2. A test manifold arrangement with proof of Hydrotest and NDT of welds. (Test manifolds require
revalidation of 36 months for each new project and for existing facilities).
3. The location of blind flanges and isolation valves, if any. (These locations should be clearly
indicated in the Pressure Test diagram.).
4. The location of check valves (flappers should be removed, if necessary, prior to testing).
5. The location of the lowest rated component that determines the test pressure.
6. Relief valve size and set pressure along with the size calculation certificate and approval. A plant
process or instrument engineer shall approve the relief valve set pressure and adequate relieving
capacity. If neither is available consult with personnel in the Consulting Services Department or
Process & Control Systems Department, if necessary, to assure that the relief valve has the
proper set pressure and adequate capacity.
7. The test medium (Air or Nitrogen).
8. The test pressures and holding times.
(Minimum 10 min holding times for steps and 30 minutes for final).
9. The minimum temperature allowed, if appropriate.
10. Inspection requirements and bubble test pressure Areas to be kept free of people during the test
and the location of barricades, if appropriate The location of warning signs and markings for the
test areas.
11. Work permits required, if any Additional or special personal safety equipment required.
12. Safety Instruction Sheets if available and emergency communication required, and the methods.
13. Vacuum valve size and set pressure, if any.
14. The location of the filling point.
15. Listing of correct sequence and necessary torque of all blind flange bolts and a requirement to
verify proper torque when bolting
16. The verification of compliance with the manufacturer’s rating specifications ( e.g., quality,
service use, pressure rating for all gaskets.
17. Tested relief valve(s) (within one month) with a tag stamped with the word “TEST”, the set
pressure and date. The relief valve shall have adequate capacity to prevent overpressure during
the test and shall have been tested in accordance with SAEP-319.
18. Two or more accurate and reliable pressure gauges with block and bleed valves to permit safe
replacement of the gauges, if necessary. The gauges shall have been calibrated within  30 days
prior to the test and their range shall be such that the maximum test pressure is within 30 to 80
percent of the full range. One gauge shall be located in the test piping such that it can be read by
the pump operator. The other gauge(s) shall be located in the system under test. The pressure
gauge calibration stickers should be affixed on the back of the pressure gauge.
19. A blowdown valve for depressurizing the test piping and a valve to isolate the test piping from
the system under test shall be provided.
20. Do not exceed the following pressures until weaknesses have been repaired and leaks have been
stopped: Any tests using air or other gas as a test medium: 173 kPa (25 psig) or 50% of the
strength test pressure, whichever is the lower value.
21. After preliminary checks for leaks at the above pressures, the pressure shall be increased in steps
with at least 10 minute holds at each step to permit inspection for leaks and weaknesses. In
strength tests using air or other gas as the test
medium, the pressure shall be increased in steps no greater than one-tenth of the strength test
pressure after reaching 50% of the test pressure, as required in Section VIII of the ASME
Pressure Vessel Code. The procedure shall have a table showing each pressure increase and
minimum holding time.
22. Safe distance calculations shall be performed per ASME PCC-2-2008, Article 5.1, Mandatory
Appendix lll, “Safe Distance Calculations for Pneumatic Pressure Test” and attached to the
procedure.
For more information Pneumatic Pressure Testing please check out this article: PNEUMATIC
TESTING PROCEDURE FOR MECHANICAL EQUIPMENT (CONVECTION, CROSS-
OVER & RADIANT COIL)

Many industrial components undergo stringent pressure testing to determine their structural
integrity before use. Conduits such as pipelines and storage vessels undergo various pressure-
mediated checks to ensure they meet all relevant industrial safety standards. Depending on
manufacturer or operator preferences, pressure testing can be done either hydrostatically or
pneumatically.
Contact NiGen today if you’re in the market for pressure testing services from a reputable and
experienced company!

Pressure Testing for Pipelines and Pressure Vessels

The purpose of pneumatic and hydrostatic testing is to ensure a pipeline or vessel is free from
leaks and can withstand the pressure of normal usage. Before being put into service or returned
to service after repairs, many different types of industrial equipment and facilities require this
testing. In many situations, government regulations clearly specify what testing is required. In
addition, many companies have their own additional internal testing guidelines and policies.

The most commonly used set of specifications for pressure and leak testing is the ASME B31
Pressure Pipeline Code. This code details testing steps and requirements for different types of
piping. Hydrostatic testing is performed with a liquid like water and pneumatic tests use a gas
like nitrogen.

When Should You Perform a Pressure Test?

Pressure testing is a vital part of the completion process for industrial equipment and systems.
These checks ensure the inspected components function properly under operational conditions
without posing an industrial safety hazard to the personnel who operate them.

There are various points in the operational lifespan of industrial systems where pressure testing is
mandatory. Newly fabricated pipelines, containment vessels, and fittings must be subjected to a
suitable pressure testing method. Further, pressure testing is indicated following equipment
maintenance, component replacement, or repair.

In both newly assembled systems and component maintenance scenarios, the purpose of testing
remains the same: safety of operation and maximal efficiency.

NiGen Pressure Testing Services

No matter your application or industry, our pressure testing company has the knowledge and
expertise required to protect the integrity of your processes. We offer two methods for pressure
tests: hydrostatic and pneumatic.
Pneumatic Testing in Houston, Texas

Pneumatic pipe testing is conducted using air as the test media to ascertain the structural integrity
of a pipeline or other industrial containment or transport vessels. Pneumatic testing can be done
using air, nitrogen, or other inert, non-toxic gases. Pneumatic testing requires the incorporation
of pressure monitoring and release devices to allow for maximum operator safety.

What Is Pneumatic Testing?

Pneumatic testing is the process of using a gas to determine if a vessel can safely withstand the
pressures required under normal usage. To do this, a gas is inserted and the pressure is increased
above the normal pressure the vessel is designed to withstand once put in service. The pneumatic
testing will help to identify any leaks, faulty joints, or other operational issues.

Pneumatic Pipe Testing Procedure

 As earlier mentioned, pneumatic pipeline/vessel testing is conducted at a pressure that exceeds
the maximum value specified by the manufacturer by at least 10%. The test procedure involves
shutting off all equipment valves except the delivery port for the test medium.

The test gas is used to gradually build the pressure within the pipeline until the required test
value is met. This pressure is maintained while the system is analyzed for defects. Breaches can
then be identified using a bubble-forming substance applied to the exterior of the component
being tested.

Pneumatic Test Procedure for Pressure Vessels

Pneumatic Test Procedure for Pipelines

Hydrostatic Testing in Houston, Texas

Hydrotesting is another pressure testing option where a liquid (usually water) is injected into a
pipe system to check for structural flaws permitting leakage. Hydrostatic testing allows the
detection of leaks that only become obvious at elevated operating pressures.

What Is Hydrostatic Pressure Testing?

In hydrostatic pressure testing a liquid is used to check for leaks before putting a pressure vessel
or pipeline into service. The liquid is pressurized within the pipeline or vessel to make sure that it
can withstand the pressures of normal usage.

Hydrostatic Pressure Test Procedure

In hydrostatic pressure testing, a liquid is used to check for leaks before putting a pressure vessel
or pipeline into service. The liquid is pressurized within the pipeline or vessel to make sure that it
can withstand the pressures of normal usage.

In order to test, the pipe or pressure vessel must be filled with a liquid. The liquid used is
typically water unless water will damage the pipe or vessel. To meet ASME hydrostatic test
requirements, before the test begins, the high points of the pipe or vessel must have vents to
allow any air to escape as water is added. All air must be cleared before the test can be
completed.

What Is Pneumatic Testing and Why Is It Required

 May 17, 2021
 
 1:27 pm
What Is Pneumatic Testing and Why Is It Required 
 Ensuring that all equipment is functional and ready to go can save you the hassle in the long run
— plus lots of money and stress. Your pressure systems are no exception. For your piping
systems, you will need to rely on a pressure test to test its functionality. 

Pneumatic testing is a key pressure test that can help you assess your systems. Continue reading
to learn what pneumatic testing is and why it may need to be performed on your pressure
systems. 

The Basics of Pneumatic Testing 

At the core of pneumatic testing is the use of air — or another inert gas medium like nitrogen or
helium — to pressurize a piping system. The air or nitrogen is confined throughout the piping
system to mimic a high-pressure environment at 100% of the system’s design.  

Air and nitrogen are the most commonly used mediums since they are affordable. Helium is
more expensive but can be used as the most accurate tracer gas if deemed necessary. 

Why Pneumatic Tests Are Necessary 

Pneumatic tests and all pressure tests are necessary to ensure your pressure system’s safety,
reliability, and leak tightness.  

This is required before utilizing newly installed pressure systems and ones that have been
recently repaired. Pressure tests are performed to help understand the limits and capabilities of a
pressure system. These components are crucial to know before putting the pipeline into
service. Of course, they also help to prove that your equipment meets industry
qualifications and requirements. 

What is learned through a pressure test? 

 Safety capabilities 
 Detecting leaks 
 Understand maximum capacity 
 Testing Joint fittings 
It’s important to note that pressure tests are not a matter of you should do it, but rather it’s
a mandatory test to comply with industry safety standards. 

Pneumatic and Hydrostatic Testing 

While pressure tests are mandatory, pneumatic testing is not the first option. Before considering
pneumatic testing, most services will attempt performing a standard hydrostatic test. Both
are viable options, but pneumatic testing is potentially more dangerous. 

Hydrostatic testing indicates similar things as pneumatic testing but uses water instead of gas as
the pressure testing medium. Compressed air or nitrogen can contain 200 times more stored
energy for the same free volume and pressure conditions compared to water. With much higher
amounts of stored energy, it is more likely to cause damage if mishandled. 
 Pneumatic testing is convenient and more accurate than hydrostatic testing, but the
industry requires hydrostatic testing to be considered beforehand. 

When Pneumatic Testing Is Utilized 

In certain scenarios — pneumatic testing becomes the only option available. While potentially
dangerous, an experienced service will follow all guidelines and ensure that your equipment is
not harmed.  

Pneumatic testing is utilized when: 

 Pressure systems are designed so that they cannot be filled with water. 
 Traces of water cannot be tolerated when the system is in service. 
For piping systems that transport primarily gas, like natural gas pipelines, pneumatic testing
would be used. Water or any other liquid would be too heavy and potentially damage the
pipelines from their weight. 

How Often Do You Need to Perform a Pneumatic Test? 

The industry regulations require that you test your pressure system once when it is first installed
and then every time after repair or alteration. If these don’t apply, then you don’t
necessarily have to get them retested. 

But, as mentioned before — a leak or sudden collapse of your pressure systems can cause
tremendous financial damage. That’s why you should get a pneumatic test done at least once
a year. If applicable, keep in mind that you only have to get a pneumatic test or hydrostatic test
— not both.  

Benefits of Pneumatic Testing 

Even if pneumatic testing is the less used test, certain benefits should be brought to attention.  

 More accurate at detecting leaks – The small atomic structure of gases — particularly helium —
allow them to pass through leaks that liquid cannot. Paired with mass spectrometry, it’s easy to
tell if gases have leaked out of the pressure system. 
 No water damage – There’s no need to worry about the weight of water collapsing the structure
of the pressure system. 
 Easy to clean
The accuracy is especially important if your piping or other pressure systems are sensitive to
leaks. Pinpointing the location of leaks can prevent catastrophic damage before they occur. 

Limitations of Pneumatic Testing 

Working with gases ends up being the main cause of limitations when it comes to pneumatic
testing. There would be hundreds more stored energy in compressed gases than liquid and
 volatile if anything were to go wrong. If an old piping system ends up collapsing during the
pneumatic test, the energy is released — causing fatal damage. 

Because of this intensity, some limitations are put on pneumatic testing: 

 Recommended only for low-pressure applications. 

 Chances of equipment or pipe failure are high. 
 Only small segments of the piping can be tested at a time. 
 The damage tends to be extensive if handled improperly. 
 Must be conducted by an experienced service or personnel — this is not a suggestion.  
 Needs special attention and safety regulations — barriers must be installed, and people cannot be
working during the entirety of testing. 
Before a pneumatic test can be carried out, the service will need a written justification for the
pneumatic testing along with a piping schematic. While service will handle the schematic and
other documentation for you, it may delay the speed at which your pressure systems can be
tested. 

The Precision Fabricating & Cleaning team are experts when it comes to pneumatic testing. Let
us handle all of your cleaning and testing needs! Click here and contact us today!  

Hydrostatic Pressure Testing for Pipes and Pressure Vessels

For testing, the pressure vessel or pipeline must be filled with a liquid. The liquid is typically
water unless it will damage the container. To meet ASME hydrostatic test requirements, before
the test begins, the high points of the pipe or vessel must have vents to allow any air to escape as
water is added. All air must be cleared before the test can be completed.

ASME B31.1 Hydrostatic Test

ASME B31.3 Hydrostatic Test

ASME B31.5 Hydrostatic Test

Which Pressure Test Method is Right for You?

While both hydrostatic and pressure testing methods can be used to objectively assess equipment
integrity, operators must choose the test best suited to their unique systems. For high-pressure
operations that are not moisture sensitive, hydrostatic pressure testing is recommended. For low-
pressure applications where moisture might damage sensitive components or alter delicate
chemical balances, pneumatic testing is the smarter choice.

Learn more about the difference between hydrostatic and pneumatic testing.

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NiGen Offers Hydrostatic and Pneumatic Pressure Testing Services

At NiGen, we offer cutting-edge hydrostatic and pneumatic pressure testing solutions in

Houston, Texas. Our team specializes in applications that leverage our on-site nitrogen
generators for the pressure vessel and pipeline industry. We have provided services for thousands
of miles of pipeline using the latest nitrogen membrane equipment available. We provide
services for purging, pigging, inerting, drying/dehydrating, pneumatic testing, commissioning
and decommissioning, chemical cleaning, and leak detection.

To learn more about how we can help meet your unique testing requirements, please contact
us today!
 How to Ask About Precision Cleaning: Various Methods and Their Applications
 April 19, 2021
 
 7:15 am
How to Ask About Precision Cleaning: Various Methods and Their Applications
More than a simple dusting or the occasional wiping down of vital equipment, precision cleaning
is extensive cleaning. Not extensive in the fretty or overbearing way, but extensive in a necessary
way. Precision cleaning is more than just a touch-up on appearance, as it can improve human
health, machine health, and productivity.

But, any knowledgeable precision cleaning company will be well versed in what procedures they
offer. With so many options, it could make for an overwhelming experience — especially for
newcomers. Asking for the perfect method can be a challenge, but we’re here to help. We’ll keep
it simple, and you’ll have a more comprehensive idea of precision cleaning.

Various Precision Cleaning Methods

Though no two precision cleaning companies are fully alike, the biggest ones will offer the same
services. These include (but are not limited to):

● Mechanical Cleaning/Descaling

● Passivation

● Degreasing

● Ultrasonic Cleaning

We’ll examine how the procedure works and why it may be necessary for your machines for
each method.

Mechanical Cleaning/Descaling

Scaling refers to the build-up of mineral deposits within equipment; they are formed when water
and equipment’s internal components interact. Mechanical cleaning, or “descaling”, is the
process of removing the excess mineral deposits contained within.

The first step of descaling is to loosen the mineral deposits. A service will perform:

● Brushing

● Shot preening

● Grit blasting

● Tumbling
● Grinding

Once the mineral deposits become loose, valves and other components will need to be cleaned of
loose dirt, debris, and scales. This is achieved by using several methods:

● Vacuum cleaning

● Brushing

● Air Blowing

● Flushing with solvent or clean water

The Purpose of Descaling

The scales that build up within equipment can cause numerous problems. Equipment health,
human health, and heating safety are jeopardized when scales are present. The longer they
continue to build up, the more potent their effects will be.

● Equipment health – Scale build-up will clog filters, pipes, and valves. When these components
are clogged, they will not perform effectively while constantly working in overdrive for minimal
results.

● Human health – Equipment used in colder environments or serves the purpose of cooling is
susceptible to hosting Legionella bacteria — culprit to a common type of pneumonia. When
scales, dirt, and slime are present in air filters and valves, Legionella breed even faster.

● Heating safety – While metal equipment is conductive of electricity, scales formed from
magnesium and calcium create insulation. These scales will make equipment more susceptible to
overheating and can be especially dangerous for boilers and pipework.

Passivation

Without all the chemistry jargon, passivation is a treatment for stainless steel equipment; it
involves the removal of external contaminants by using a chemical solution. These contaminants
exist in the form of free irons that form rust when exposed to oxygen and rainfall.

To remove free irons before rust settles in or remove rust in general, an acidic solution is applied
to the surface or flushed through filters and valves for internal precision cleaning. Solutions such
as nitric acid will be used to clean equipment without affecting the components themselves in
any harmful manner.

The solution is used on the surface of the equipment and can be flushed through valves and
filters. Checking valves and filters beforehand could give you a better idea of what you need for
your cleaning.

The Purpose of Passivating

Passivating removes rust and the potential for rust, which can be detrimental to machine health.
By regularly passivating, machines will be less susceptible to rust. This promotes equipment
durability, safety, and conductivity.

● Equipment durability – Rust weakens the typically sturdy metal structure by replacing it with a
brittle powder substance. As a result, equipment becomes dented more easily and will need to be
replaced more often.

● Safety – While rust does not cause biological concerns, for the most part, it can become a
safety concern. Like bridges and roads that collapse because of unchecked rusting, the equipment
can be ravaged by rust. Because equipment structure is altered and damaged, the equipment may
fail to function properly, causing harm.

● Conductivity – Similar to scaling, rust makes conductive material more inductive. This will
push equipment to push harder for the same results and increases the likeliness to overheat.

Degreasing

Degreasing is a process that utilizes low concentrations of alkaline cleaners to remove lubricants
and oils. While it possesses certain uses on its own, it is often used to increase the effect of
passivation.

The Purpose of Degreasing

Whether the grease is naturally occurring or something that your machine requires, degreasing
on a routine interval may be beneficial. Degreasing promotes accuracy, compatibility and
improves passivation.

● Accuracy – Layers of oil and lubricant may interfere with an equipment’s ability to read
intricate data. Routinely scheduled meter and gauge cleanings will remove grease and make them
more accurate.

● Compatibility – When equipment is greasy, certain materials will not be compatible with one
another. These material incompatibles will cause malfunction or stop equipment from
functioning altogether.

● Improving passivation – When lubricants and oils are removed, the acid solution used in
passivation will directly contact the metal surface. Without the grease to act as a barrier,
passivation will be more thorough and form a protective film around the surface. This protective
film has anti-erosion properties.

Ultrasonic Cleaning

Ultrasonic cleaning utilizes high frequencies (20-40 kHz) that form cavitation bubbles that move
the cleaning solution to every nook and cranny of the equipment. The ultrasonic frequency
pressure then causes the solution to bubble rapidly at these sites, dislodging contaminants like
dust, dirt, and grime.

The Purpose of Ultrasonic Cleaning

As machine parts become more compact, intricate, and delicate, abrasive precision cleaning
methods can ruin machinery completely. But, ultrasonic cleaning is gentle, effective, and
versatile. Utilizing high frequencies in precision cleaning ensures that our components remain
safe, promotes human health, and ensures flexible cleaning.

● Component safety – With frequency waves and a mild solution, even the most intricate parts
will be safe. That’s because there are no demanding steps like scrubbing, pressure spraying, or
flooding. Gauge and transducer cleaning can be done effectively despite their delicateness and
size.

● Human health – Not only are contaminants removed by this process but so are mold and
bacteria.

● Flexibility – Even the smallest of equipment can be cleaned with this process. The high
frequencies allow the solution to penetrate and enter crevices, cracks, and tight spaces that other
procedures cannot manage.

Precision Fabricating & Cleaning provides precision cleaning services to the following
specifications:

0-73579, 1P00070, 1P00071, 24555-GEN-0001, 24555-SPEC-0003, 5-75014, 5-75059, 5-75192,

ARP1176, ARP598, ARP599, AS4059, AS598, ASTM D1193, ASTM F312, ASTM F331,
ASTM G93, CGA 4.1, IEST-STD-CC1246, ISO 14644 .ISO 14952, JSC-SPEC-C-20C, KSC-C-
123 ,MA0110-301, MA0110-301, MAP211025 VC, MIL-PRF-27401, MIL-SPEC-164D, MIL-
STD-1246, MIL-STD-1246, MSFC-SPEC-164, NAVY OXYGEN CLEANER NOC, PWA 80-
81, RA0110-018, RA0110-046, RA0110-047, RA0110-24, RA1110-022, RA1110-025,
RA1610-065, RA1610-075, RA321270, RAPWA80, RAPWASP80, RPTSTD-8070-0001, SAE
ARP 598, SAE ARP1176, SN-C-0005, STP0565, STP0637 ,STP1012, RL10012, D-
0656395 ,MC072214, B185020, STP 50408, MP 50063, AS 611

Let Precision Fabrication & Cleaning help you with our top-notch precision cleaning
services. Click HERE to start a conversation with PFC.

References:

Top 10 Benefits of Using Ultrasonic Cleaners, Part 1

Precision Cleaning: What Exactly Does This Mean?

Why Do We Need To Descale: 5 Important Reasons

Passivation and it’s benefits

What is the Passivation Process?

 
What is the Passivation Process?
As defined in MIL-STD-753C, the passivation process is the final treatment/cleaning process
used to remove iron from the surface of corrosion resistant steel parts such that a more uniform
formation of a passive surface is obtained thus enhancing corrosion resistance.
Stainless steel is different from other metals in that as you get closer to the surface the
composition of the metal actually changes.  In the passivation process, free iron is removed from
the surface into solution, leaving behind a higher chromium level.  A good chrome to iron ratio is
usually considered to be 1.5 to 1 or higher.

What is Passivation?
Passivation is a chemical treatment for stainless steel and other alloys that enhances the ability
of the treated surfaces to resist corrosion.
There are many benefits of passivated equipment and systems:
 Passivation removes surface contamination
 Passivation increases corrosion resistance
 Passivation reduces the risk of product contamination
 Passivation allows you to extend system maintenance intervals

Composition of Stainless Steel

To understand passivation of stainless steel, it is critical to look at stainless steel itself.  All
stainless steels are alloys of iron, nickel, and chromium. Chromium makes up at least 10% of the
metal.  It is this element that gives stainless steel its resistance to corrosion.  Often steel-makers
add molybdenum to enhance chromium’s protective characteristics for highly corrosive or high-
temperature applications.
Beyond the chemical makeup of the metal, the composition varies in the different layers that
make up stainless steel.  At the surface is the passive layer, sometimes referred to as the passive
film, is responsible for providing corrosion resistance.  It is a very thin layer of highly stable
metal atoms that do not easily corrode or rust.  It is only a few atomic layers in thickness where
the ratio of chromium to iron (Cr/Fe) is at least 1.5-to-1.  The chromium binds with oxygen to
create a chemically inert, “passive” surface.
The illustration below shows the very thin passive layer at the outer surface of the metal:

Below the passive layer is the transition area where nickel is in higher concentrations.  Like the
passive film, it is only 3 to 4 atomic layers in thickness.  The nickel in this section protects the
passive film by preventing chemical reactions with the iron in the layer below.  It also acts as a
protective barrier to the base metal which makes up the majority of the stainless steel. The
percentages of chromium, nickel and iron vary by the intended use of the item.
 Why Do You Need to Passivate?
Although passivation occurs naturally in corrosion resistant and chromium-rich alloys, given the
proper conditions, a new stainless steel vessel or part needs to be passivated prior to being placed
into service.  Fabrication, machining and welding leave behind contaminants such as metal
oxides, inclusions, fabrication debris, and tramp iron, thereby compromising the metal’s natural
ability to resist corrosion.

How Does Passivation Work?

Chemical passivation enhances the chemistry of the passive layer by increasing the ratio of very
stable chromium atoms to the more reactive iron atoms in the upper three to five atomic layers of
the metal’s surface.  This enrichment can be quantitatively measured using a variety of methods,
including Auger Electro Spectroscopy (AES), Electron Spectroscopy for Chemical Analysis
(ESCA), and Energy Dispersive X-ray Analysis (EDX).  The most commonly used data
generated from these techniques to evaluate the passive layer is the chromium to iron ratio and
the depth of enhancement.

Current Passivation Methodologies

Astro Pak employs many different methods of passivation, including:
 Tank Immersion – Usually done at an Astro Pak site and is advantageous for treating all
the fabrication surfaces at the same time for uniformity of finish and optimum corrosion
resistance.
 Circulation – Chemical solution is circulated through a system of pipework and is
particularly recommended for piping that will carry corrosive liquids.
 Spray Application – Can be done at Astro Pak or at a customer site and advantageous for
on-site treatment but proper acid disposal and safety procedures are essential.
 Gel Application – Manual treatment can be accomplished by brushing on pastes or gels to
the surface. It is useful for spot treatment of welds and other intricate areas that require
manual detail.
Hydrostatic Testing: What is it, how does it work, and what are the benefits?
 June 18, 2021
 
 10:51 am
Hydrostatic Testing: What is it, how does it work, and what are the benefits?

Hydrostatic testing can be defined as the process of subjecting a material to a controlled pressure
and observing how it reacts to the pressure. The test is used for many reasons: determining if an
object will withstand various loads or stresses, detecting leaks in hydraulic systems or pipes,
ensuring that equipment functions properly before use, etc. Hydrostatic tests are conducted by
filling an object with water and pressurizing it to test for strength and leaks. The ability to detect
leaks in an object is one of the most important reasons why this type of testing should be
performed regularly.
This article will discuss what hydrostatic testing entails, how it works, and the benefits
associated with it.

What is hydrostatic testing?

 Hydrostatic testing is an integral part of quality control. Hydrostatic tests are performed to
determine the structural integrity and fitness for use of a variety of objects including gas
cylinders, storage tanks, and chemical pipelines. The test works by filling the object with water
until it’s completely full and then pressurized–ensuring that it can hold up under pressure without
bursting open at any seams nor allowing leaks from within its structure.

The name comes from when engineers used compressed air as their hydraulic fluid instead of
water; the term “hydro” meaning water in Greek) and “statikos,” which means solid (as in static).

Hydrostatic testing also provides a level of confidence that the object will hold up under pressure
and withstand exposure to corrosive environments without bursting open at any seams nor
allowing leaks from within its structure.

What is hydrostatic testing used for?

Hydrostatic testing is a pressure-based technique used to test the integrity of piping systems, gas
cylinders, boiler components, and all other kinds of pressure vessels. Hydro-tests are commonly
done after repairs and downtime to determine if items will operate properly when put back into
use.

Hydrostatic testing is a common tool used by engineers to ensure that equipment has been rebuilt
or repaired properly. It’s most commonly employed for DOT-required containers with the aim to
work out any potential leaks and verify it is fully safe for use. This is important because if you
have a DOT-required container and it’s not been properly tested, what is inside the canister could
be contaminated.

A hydrostatic test will bring up any potential leaks in equipment and also show if there are any
structural problems with the exterior or interior of the tank that might lead to leaks later on.

How does hydrostatic testing work?

Hydrostatic testing is done by filling containers with water at high pressure until they reach their
designated capacity; this allows engineers to see where leaks appear (signifying small holes) as
well as find out how strong each welded seam really is. This type of inspection provides much
more information than just visually inspecting your stainless-steel containers because you’re
looking for inconsistencies and then repairing them before something goes wrong during use.

Hydrostatic testing is an effective method for detecting a leak before it becomes costly.

The process works because water will breach any gap between two pieces of imperfectly sealed
pipe if there’s enough pressure applied to force its way through; this means every time we turn
on our faucet and allow water into the pipes below ground, those leaks are being detected
without us ever knowing about them.
 Meeting DOT Specifications for hydrostatic testing

Hydrostatic testing is also mandated by the Department of Transportation (DOT) as part of the
certification process to show that a cargo tank and its fittings are able to maintain an airtight seal
under pressure when being filled or emptied. This ensures that they do not leak any flammable
fluids during their use. The DOT’s rules mandate this test at present intervals in order to prevent
catastrophic damage in case there was a puncture somewhere along the way.

How do I avoid disasters with hydrostatic testing?

The best way to avoid disaster is to have an experienced technician perform your hydrostatic
testing. There are two main types of tests:

 Type I, which is conducted at the completion of construction and includes a tank test for pressure
integrity as well as confirmation that all welds are intact
 Type II, which evaluates specific components like tanks or pumps used in underground storage
systems
Just because you’ve done this type of testing before doesn’t mean it’s time to stop! Hydrostatic
testing should be performed every year after installation or sooner if there has been any change
in environmental conditions.

What are the benefits with outsourcing hydrostatic testing?

Working with a company that offers hydrostatic testing services can be more beneficial than
purchasing and operating the equipment because of cost, time, and resources. Additional benefits
include a faster turnaround time, increased safety for your staff and customers resulting in
improved product quality assurance; decreased repair costs; minimizing risk exposure and
liability claims.

A team of highly trained hydro-testers can help chemical, industrial or other companies to stay
compliant with hydrostat specifications.

Conclusion

Hydrostatic testing provides many benefits for a business by ensuring the quality of their
product. For example, this process can be used to ensure that equipment is functioning properly
before use and also detect leaks in hydraulic systems or pipes. If you are interested in learning
more about hydrostatic testing and other methods we offer, or if you need help meeting DOT or
CGA specifications, it may be time to outsource the process with an experienced partner like us
here at Precision Fabricating & Cleaning. Contact PFC today!
Why Passivation is Necessary and How Can It Benefit Your Company
 July 16, 2021
 
 12:11 pm


Why Passivation is Necessary and How Can It Benefit Your Company 

Simply put, the passivation process assists in removing corrosion contaminants such as free iron
from the surface of stainless steel. At first glance, the procedure may appear to be purely
cosmetic, but there are internal benefits as well.  

Whether you’re aiming to precision clean valves, filters, or any other metallic component,
passivation is needed to keep processing smooth and long-lasting. What exactly is passivation,
and how can it benefit as a precision cleaning method? Let’s find out. 

The Science Behind Passivation 

Without all the chemistry jargon and complexities, at its core, Passivation is the process of
treating or coating a metal in order to reduce the chemical reactivity of its surface. In stainless
steel, passivation means removing the free iron from the surface of the metal using an acid
solution to prevent rust.  

Free irons and/or iron compounds are stripped off the surface through an acid solution. If free
irons are not removed, a rust build-up can occur due to repeated exposure to oxygen and rainfall. 

When the surface iron is removed, the other components of the alloy (primarily chromium, often
nickel as well) are left behind as a surface layer over the underlying steel.  

Upon exposure to air, these elements react with oxygen to form an oxide layer that protects the
rest of the steel from corrosion.  

An acidic solution is a chemical agent that is able to passivate — with nitric acid being the most
commonly used. It serves to remove free irons without jeopardizing internal components or
structures. 

The structure of stainless steel must be considered as well. Chromium makes up at least 10% of
stainless steel and has anti-erosion properties. When Chromium is combined with iron at a 1.5 to
1 ratio or greater, a thin yet effective corrosion resistance film is naturally formed on the surface.
The more compatible the ratio, the stronger the film becomes. This film may also be referred to
as a “passive” layer. But, this film can be damaged in two common ways:  

 Too much free iron will remove or weaken the protective film. 
 Welding, fabrication, and machining leave behind metallic oxides and debris that disrupt the
ratio. 
When precision cleaning is done through passivation, contaminants are removed from the
surface of the stainless steel, thus reestablishing the optimal ratio between the stable chromium
and the reactive iron. When the ratio is optimal, the “passive” layer will be stronger and thicker. 

Why is Passivation Necessary 

 If passivation were just a cosmetic feature, then it would be completely fine to
ignore. But, rusting machinery is a different story and needs to be actively managed. To
emphasize how much of a problem rust actually is, it costs U.S. companies over $300 billion per
year. 

That’s exactly why passivation is necessary. Rather than letting rust create dents and damages,
performance issues, and eventually lead to complete machine failure, snip the problem before it
gets out of hand. 

If you wait too long, you may have to replace entire sets of equipment that are multiple fold
more expensive than precision cleaning. 

Passivation processes are controlled by industry standards, the most prevalent among them being
ASTM A380, ASTM A967 and AMS 2700. These industry standards list several passivation
processes that can be used, with the choice of specific method left to the customer and vendor.
The “method” is either a nitric acid-based passivating bath, or a citric acid-based bath, these
acids remove surface iron and rust, while sparing the chromium. 

Benefits of Passivation 

Now that we know what passivation is and why it’s necessary, let’s examine the benefits that it
can provide. 

Enforced “Passive” Protective Layer 

As mentioned before, passivation helps to maintain the natural outer film that protects stainless
steel from rusting. In its natural state, the film is effective but very thin. But with passivation, we
manipulate the ratio between Chromium and Iron to be the most compatible and create a thicker
“passive” layer. This helps to protect your components. 

When working with precision cleaning experts, they’ll utilize tests to determine how much free
iron there is and how close they are from that optimal ratio. These include: 

 High-humidity test 
 Copper Sulfate 
 Water wetting and drying 
 Ferroxyl test 
Appearance Improvement 

This one is a pretty obvious benefit. When passivation is completed, the yellowing and bumps of
rusting metal will return back to a newer look. 

Maintains Strong Stainless Metal Structure 

Rust weakens the very structure of stainless steel. The typical strong iron is replaced by flaky
powder; that’s why rusted metal is easier to dent and damage valuable components. Even more,
rusting accelerates with time. It’ll begin to spread and start concentrating rust on certain parts of
the surface. 
 Keeps Electricity Conducting Properties 

Rust is an insulator of electricity, meaning that electricity flow will decrease when there’s rust
present. Companies choose to use stainless steel (or similar metals) because electricity does a
great job at transporting electrical flow from one spot to another. 

This is a problem for equipment such as transducers which use electric signals to communicate
measurements. If transducer cleaning is not maintained regularly and begins to rust, it may
interfere with accurate measuring. 

For high-powered machinery, this efficiency and speed are often necessary for things to even
function optimally. When you precision clean and utilize the passivation process, there’s no need
to worry about your machinery’s conducting capabilities. 

Allows for Extended Maintenance Intervals 

With regularly scheduled passivation precision cleanings, total system maintenance will not be
required as often as before. With unrusted stainless steel, your equipment will last longer and
require less monitoring. 

Promotes Safety 

Because rust itself is made up of iron and oxygen, it poses no biological threat to
humans. But, rust can jeopardize overall safety. Like you see with bridges and roads that
collapse, rust can compromise structure and security. If you want to avoid malfunction or
machine failure-related injuries, passivation can help. 

Passivation is Versatile 

Many methods of passivation can be employed for a variety of machine parts. 

 Submersion – Metals are submerged in a tank of acidic solution. This is typical for smaller
equipment and parts that can be dismantled easily. Submersion offers quick and uniform
passivation. Submersion is the most common approach and works well with gauge and
transducer cleaning. 
 Circulation – An acidic liquid can be circulated through values and filters to de-rust your
machinery’s internal components. Even if these parts are not visible to us, it’s still important to
passivate the inside of your systems as well. If you check valves afterward, they’ll look brand
new no matter how many years they’ve been at work. 
 Spray Application – This method is for any parts that cannot fit into the tanks. The method
involves manually spraying acidic solution in order to remove free iron and rust.
How do you verify passivation solution strengths? 

Titration: 

Titration is the slow addition of one solution of a known concentration (called a titrant) to a
known volume of another solution of unknown concentration until the reaction reaches
neutralization, which is often indicated by a color change. 
The solution called the titrant must satisfy the necessary requirements to be a primary or
secondary standard. In a broad sense, titration is a technique to determine the concentration of an
unknown solution. 

Discoloration after passivation 

Heating stainless steel to temperatures in excess 800°F can cause metallurgical changes and

reduce corrosion resistance in a manner that is not corrected by surface cleaning or chemical
passivation. Typically, stainless steels contain less than 30% chromium and more than 50%
iron. While stainless steels are resistant to rusting at room temperatures, they’re prone
to discoloration by oxidation at elevated temperatures due to the presence of chromium and other
alloying elements such as titanium and molybdenum.

Proper handling of parts that have been passivated 

Once a part is passivated, proper handling procedures must be followed to prevent the surface
from being damaged and allowing iron to be introduced back onto the surface. 

Many people would think that the stainless-steel parts of a machine should be able to withstand
normal handling procedures. During normal handling, a passivation layer can be removed in two
ways. Parts can come into contact with corrosive agents that chemically damage the chromium
oxide or parts are not handled properly and mechanically remove the oxide layer. 

After the surface is protected, it’s important not to expose it to any chemicals that can damage
the oxide or strip away a section of the native surface. This means protecting parts from exposure
to acids during passivation, as well as exposure to organic acids, such as vinegars and lemons
which may be present in the workplace.  

Storage of the passivated parts should be done in such a manner to not allow damage to
occur. This can be accomplished by using a container that will not allow contact from foreign
objects. 

Precision Fabrication & Cleaning is Here to Help 

Are the benefits of passivation appealing to you and your company? PFC is here to help! With
knowledgeable and experienced staff, class 7 cleanroom and class 5 workstations, and time-
sensitive turnarounds, we’re here to say. Passivation is much more than a cosmetic procedure.
There are many real-world benefits to passivation-based precision cleaning, and we would even
consider it necessary. Act sooner than later, and it could save you thousands of dollars. 
Pneumatic test vs. Hydrostatic Test: Differences and Safety Protocols
Apr 7, 2022 | Pressure Testing

Pressure testing procedures are key to ensuring the integrity of a wide variety of industrial
components and equipment – including pipes, tanks, pressure vessels, fittings, and more. These
tests are vital in both new component manufacturing, during routine maintenance, and quality
verification of a component. 
Pressure testing can be done using two different methodologies:: hydrostatic and pneumatic.
Hydrostatic tests utilize water as a medium, while the latter uses gas. There are important
differences between both, most notably the level of energy released at failure. Let’s explore those
differences and how we can keep your staff safe under both scenarios.
When to use pneumatic testing and hydrostatic testing
Hydrotest or hydrostatic testing is typically used for higher pressure components. Although
water is most commonly used, other fluids such as oil or hydraulic fluid are sometimes used
based on the materials under test and corrosion considerations.
On the other hand, pneumatic testing is regularly used for lower pressure components. Air is
commonly used as the test medium, although another gas such as nitrogen can also be used in
particular circumstances where low chemical reactivity is desired.
It is important to understand that water or oil are considered to be incompressible under the most
reasonable pressures used in pressure testing. This is beneficial in that the test requires less
energy to exert the required pressure than if a compressible medium is used. Less energy in
means less energy out in the case of a failure. 
Why is pneumatic test more dangerous than hydrotest?
Because pneumatic tests use a compressible gas, more energy is required to reach the required
pressure. This energy is stored in the compressed gas and can be released explosively on failure.
For this reason, pneumatic testing represents a significant hazard above and beyond
hydrostatic testing. How much of a hazard?
An explosion of 200 ft. of 36 in. pipe containing 500 psi of pressure can create a blast wave
nearly equivalent to 80 lb of TNT.
Pneumatic testing is much more dangerous than hydrostatic testing. Pneumatic testing
requires higher levels of training, a pressure relief device is mandatory, and a higher safety rating
of an enclosure such as TotalShield’s Shielding Rooms or Machine Enclosure is needed.
Based on the higher risk associated with pneumatic pressure testing, should hydrostatic testing
always be used? Well, not necessarily. Let’s look at some of the considerations.
Pneumatic Testing Advantages and Disadvantages

Hydrostatic Advantages and Disadvantages

 No matter which pressure testing process is used, the safety of your staff should be a top priority.
Let’s discuss now how to ensure safety during both pressure testing processes. 
Guide to Pressure Testing Safety
Hydrostatic Testing Safety Procedures
In the case of hydrostatic pressure testing, there is a risk of injury from a high-pressure stream of
liquid hitting the operator or the possible expulsion of a subcomponent such as a bolt or flange at
high velocity. To prevent injury, all test components should be secured to avoid movement
under pressure.
These are some hydrotest pressure safety protocols you should follow:
 All fittings and connectors are installed and tensioned properly 
 The test operator should wear proper safety equipment, including eye protection
 When liquids other than water are used, additional safety and environmental factors must be
observed
 Unauthorized personnel should not be allowed in the testing area
TotalShield manufactures a range of pressure testing blast containment products to add a final
level of protection for hydrostatic testing. We can provide blast and impact-resistant Shielding
Rooms for testing on larger items or smaller benchtop mounted enclosures for small
components. 
In either case, we work with the operator of the hydrostatic test to determine likely modes of
failure and then calculate the energy associated with the ballistic impact of an ejected
subcomponent. 
It is critical to analyze the size and mass of every component that might be ejected and then
design an enclosure with a margin of safety to contain those ballistic objects. Our engineers can
also work with your team to create inlet and outlet ports in the enclosure for test fittings such as
fluid hoses and drains.

Pneumatic Testing Safety Procedures

As we’ve mentioned before, the risks associated with pneumatic testing are much greater
than in a hydrostatic scenario. Like hydrostatic testing, there is the threat that an object will be
ejected ballistically. There is also a risk of explosive blast. Put simply, an object under pneumatic
pressure becomes a bomb, and at higher pressures, the explosive energies associated with a
failure can be catastrophic. 
Remember, we are adding significant amounts of energy to the system to compress the gas
enough to reach the desired pressure. Upon rupture, that energy is released. This can result in
an explosive event that releases a pressure wave and shrapnel and can result in grievous
injury or death.

All of the safety precautions mentioned above for hydrostatic testing also apply to pneumatic
testing. In addition, a pressure relief device should be considered to any pneumatic testing. These
devices can take many forms:  a simple plug designed to be ejected above a certain pressure,
safety valves, or relief valves can be used.
The training of personnel is also vitally important in pneumatic testing. Only employees who
have the required training and experience should be allowed to conduct pneumatic testing.
TotalShield’s shield pneumatic pressure testing enclosures are designed with a margin of safety
for both ballistic failure and stored energy release in the pneumatic testing scenario. We work
with your team to determine the total pressurized volume and total mass of the Unit Under Test
(UUT) to ensure that you receive an enclosure certified to keep your staff safe in the event of
failure.
Pneumatic and hydrostatic pressure test safety
Both pneumatic and hydrostatic testing play a vital role in manufacturing and maintenance.
When done properly, these are safe activities. 
Our engineers can help you design a shielding room, shield pressure testing enclosure, or
ballistic shielding blanket that will keep your people safe while doing pneumatic and hydrostatic
testing

Pressure test programs are critical for verifying pressure ratings and evaluating the integrity of
vessels, components, and systems. Element offers hydraulic and pneumatics static and dynamic
pressure testing. The fluids can be conditioned to extreme high and low temperatures.  

Hydrostatic pressure testing

A hydrostatic pressure test uses liquid as the medium for applying pressure. During testing,
vessels such as pipes, tubing, fuel assemblies, boiler components or fuel tanks are filled with
water (or another specified liquid). The component is pressurized to a certain level for a specific
amount of time, based on customer or industry requirements. Acceptance of the test is based on
the ability of the material under test to hold the specified pressure without deformation of the
material or leakage. 

 
Depth testing and submerge testing

These methods are performed to determine how a product will react underwater, or while under
external pressure.

 Pneumatic pressure testing

Unlike the hydrostatic pressure test, pneumatic pressure testing is performed using air pressure,
and is often used to find leaks in sealing systems, ductworks, or ventilation pipes. Using a
pressure gauge, pneumatic testing assesses individual components and complete systems to
isolate failures and determine pressure rating. 

 Proof pressure testing 

Also known as the modified hydrostatic test, proof pressure testing uses liquid to apply a force
above a product’s intended operating pressure. The results of the test determine whether the
product can withstand the stress without permanent damage. 

 Ultimate pressure testing

Ultimate pressure testing is performed to determine the maximum pressure level that a
component can withstand before failure.  Our experts can help you determine safe operating
levels for your equipment, helping to prevent catastrophic issues in the field.

 Burst pressure test

This test increases the pressure applied to the test item until a physical failure occurs.

 Cyclic pressure testing

Cyclic pressure testing evaluates how products handle pressure and fatigue over their service
lifespan. The testing applies liquid or air pressure at a cyclical rate, which is typically a specified
amount of time on and time off. Cyclic pressure tests help to determine a product’s susceptibility
to fatigue failure when in use. We can reach pressure ramp rates of up to 200,000 PSI per
second.

Mechanical and structural pressure testing  

Our building products experts offer specialized pressure testing to evaluate the environmental
forces on structures and materials.Mostly used for building products, load tests apply force to a
product to determine its ability to withstand various environmental factors. Element offers a
number of load tests, including Racking Shear, Axial Load, Transverse Load, Diaphragmatic and
Long-Term Transverse Load. 
  

The Element advantage 

Element provides pressure test methods to a variety of industry standard methods, as well as
custom projects designed by our experts. We offer a wide range of hydrostatic and pneumatic
pressure methods for evaluating virtually any product.

For more information about our pressure test services, or to request a quote, contact us today.

Pneumatic Testing Steps of Pressure Vessel per ASME Section VIII;

Pressure testing using the Pneumatic Test according to ASME Section VIII has the

following steps:

1. Step 1 to increase the pressure to 50% of required pressure test ( Test, Pressure ).
2. Gradually increase the pressure in steps, stepby 10% of Test pressure until equal to Test
pressure.
3. Test the pressure by keeping the pressure at Test pressure fora period of time.
4. Reduce the pressure to Test pressure divided by 1.1 in order to inspect the leak of the Pressure
vessel using Visual method.
5. If no leakage is found, reduce the pressure.Complete thePneumatic test
a) Subject to the provisions of UG-99 (a) (1) and UG-99 (a) (2), a pneumatic test prescribed in
this paragraph may be used in lieu of the standard hydrostatic test prescribed in UG-99 for
vessels:

1. that are so designed and/or supported that they cannot safely be filled with water
2. not readily dried, that are to be used in services where traces of the testing liquid cannot
be tolerated and the parts of which have, where possible, been previously tested by
hydrostatic pressure to the pressure required in UG-99.
(b) Except for enameled vessels, for which the pneumatic test shall be at least equal to but not
exceed, the maximum allowable working pressure to be marked on the vessel, the pneumatic test
pressure at every point in the vessel shall be at least equal to 1.1 times the maxi-mum allowable
working pressure 36 multiplied by the lowest stress ratio (LSR) for the pressure-boundary
materials of which the vessel is constructed. The stress ratio for each pressure-boundary material
is the ratio of the stress value Sat its test temperature to the stress value Sat its design
temperature (refer UG-21).

Bolting shall not be included in the determination of the LSR, except when 1.1 times the LSR
multiplied by the allowable stress of the bolt at its design temperature exceeds 90% of the bolt
material specified minimum yield strength at the test temperature. All loadings that may exist
during this test shall be given consideration. In no case shall the pneumatic test pressure exceed
1.1 times the basis for the calculated test pressure as defined in 3-2.

(c) The metal temperature during pneumatic test shall be maintained at least 30°F (17°C) above
the minimum design metal temperature to minimize the risk of brittle fracture. [refer UG-20 and
Figure UCS-66.2, Note (6)]

(d) The pressure in the vessel shall be gradually increased to not more than one‐half of the test
pressure.Thereafter, the test pressure shall be increased in steps of approximately one‐tenth of
the test pressure until the required test pressure has been reached. Then the pres-sure shall be
reduced to a value equal to the test pressure divided by 1.1 and held for a sufficient time to
permit inspection of the vessel.

Any leaks that are present, except for leakage that might occur at temporary test closures for
those openings intended for welded connections, shall be corrected, and the vessel shall be
retested.

The visual inspection of the vessel at the required test pressure divided by 1.1 may be waived,
provided:

 a suitable gas leak test is applied;

 substitution of the gas leak test is by agreement reached between Manufacturer and
Inspector;
 all welded seams that will be hidden by assembly are given a visual examination for
workmanship prior to assembly;
 the vessel will not contain a“lethal”substance.
(e) Painting and Coating:

 Unless permitted by the user or his designated agent, pressure-retaining welds of vessels
shall not be painted or otherwise coated either internally or externally prior to the
pneumatic pressure test.
 When painting or coating prior to the pneumatic test is permitted, or when internal linings
are to be applied, the pressure-retaining welds shall first be leak tested in accordance
with Section V, Article 10. Such a test may be waived with the approval of the user or
his designated agent.
 Vessels for lethal service [refer UW-2(a)] shall not be painted or otherwise coated or
lined either internally or externally prior to the pneumatic pressure test