for R&R, normally the vessels are refractory lined.

You do not want to test using water as it will damage the refractory lining.In this instance, pneumatic test should be specified.Be aware that during the pneumetic test the stored energy due to the compressability of the air used for the test is much higher and thus more damgerous than with water. For this reason, I have seen R&R specified with 100%RT, and the closing weld is done under more stringent conditions and nde tested thoroughly ("golden weld") in order to eliminate the need for further testing. I would NOT use air or any compressible fluid. What if it fails? There is a lot of energy that must be bled off (explode out) in compressed air. Water, on the other hand, is non-compressible, so as soon as the failure occurs and a little water drains out, the water pressure immediately drops very low. One mistake during a pneumatic test can cost someone their life. Not only "during" the test, but before or after the test (when applying and backing off the pressure)

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The concern with pneumatic testing is the amount of energy stored in the vessel as it is pressured up. Since water is almost incompressible, there is little pressure stored and should the vessel fail it is quickly and safely released. With pneumatic testing a failure can result in a significant release of energy and may in fact be described as an explosion. ------------------------------------------------------------------------------------------------------Question why the pneumatic test pressure for vessels is low at 1.1 times the design pressure against the 1.3 times for hydrotest. why pneumatic test is not at 1.3 times design pressure as was with hydrotest pressure or the otherwise(both at 1.1 times). What makes the difference in different pressure testing with hydro and pneumatic test answer In contrast to water, air is a highly compressible fluid. Any failure of the part to be tested can have catastrophic consequences with possible loss of life. (imagine an improperly closed end cap taking off) Whereas in the case of a hydro test, a little movement of the part releases the pressure, as the fluid is not compressible. (The energy stored in a vessel filled with compressed air is much more than the energy in the water filled vessel) That is why the pneumatic test is generally not done unless there are specific reasons to do the same. (Like shortage of water on a particular day delaying the schedule, or when water in the vessel is difficult to clean out - some processes may require bone dry vessel after the test) However I feel the pressure for hydraulic test is generally 150% of the design pressure, if

I remember right, in cases which I have come across. Where do they recommend 130% ? Is this a recent amendment? For pneumatic test the pressure may be even lower than 1.1 times the design pressure if the working temperature is higher than the testing temperature. Another answer Shop fabricated piping sections or short (as well as straight lengths) of piping are hydrotested by the piping contractor before installation on the pipe rack. However in many petrochemical plants after the piping contractor has installed the piping and you want to do a complete leak integrity check of a system which includes piping and equipment the most convenient way is to do a pneumatic test. Pneumatic test pressures should be as low as possible. As Rama described of the dangers of the stored energy of air at higher pressures there are other reasons also. For example if youa re doing a soap suds test, the best results for checking leaks are obtained when the air pressure is as low as possible. Pneuamtic testing has some peculiar characteristics. For example if you are doing a pneumatic hold test in a place where the 24 hour ambient temperature shows an extreme variance you can easily be misled. Let us take an example: The system was pressurized at, say, 10:00 P.M. in the night when ambient temperatures were say 15C to 30 psig. It has been found that if you checked the pressure at 2.00 P.M. afternoon the next day the reading on the pressure gauge may be showing 30.5 or 31 psig if there is no tangible leak from the system. How did the pressure increase? It is not such a mystery. The ambient temperature at 2:00 P.M was probably 45 or 47C which caused an expansion of the air in the system. This can cause total confusion. But the explanation is simple. The best way to avoid this kind of confusion is to take a pressure hold test reading at the same time 24 hours later i.e. at 10:00 P.M. when the ambient temperature is around the same as was when the test was started. Pneumatic test are extremely effective when done properly and are routinely done before commissioning and start-up of the plant. They can combine large sections of the plant. Also, certain pipes and lines which cannot tolerate water (process requires zero moisture) are pneumatically tested. So, good luck with your pneumatic testing
Hydrostatic Test The fluid used for the hydrostatic test is typically water. Another suitable non-toxic liquid can be substituted if there is the risk of damage due to the adverse effects of having water in the system. The system should be tested at a pressure not less than 1.5 times the design pressure. If the design temperature is above the test temperature then the required test pressure is calculated by the following equation: Pt= (1.5 PSt) S where Pt = minimum hydrostatic test gauge pressure

P = internal design gauge pressure St = stress value at test temperature S = stress value at design temperature Typically, for the pressures and temperatures in which plastic-lined pipe is used, the above calculation reduces to: Pt = 1.5 P We recommend that the system be retorqued after the first thermocycle. If the hydrostatic test is performed at the expected operating temperature (a "hot hydrotest") then the hydrotest can constitute the first thermocycle and the recommended retorquing can occur after the pressure test. Pneumatic Leak Test This pressure test is performed in some situations where the presence of any water in the system is forbidden. The test is very dangerous due to the stored energy of the compressed gas. ASME B31.3 refers to the dangers of performing this test and provides safety considerations in the standard. For a pneumatic pressure test, a pressure relief device must be in the system. This relief device should be set at the test pressure plus either 50 psi or 10% of the test pressure, whichever is lower. The gas used for the pneumatic test, if not air, can be any nonflammable and non-toxic gas. The test pressure required for this test is 110% of the design pressure. To perform the pneumatic leak test, begin by increasing the pressure until a gauge pressure of 25 psi is attained. At this point, a preliminary check for leaks must be made. After the initial check, the pressure should be incrementally increased, holding the pressure at each increment long enough to equalize the piping strains. Once the test pressure is reached, the pressure is then reduced to the design pressure before examining for leakage.

DiegoMartinez (Petroleum) 9 Jul 07 4:10 Hi All, Does anyone know if there is a safety B31.3. Any feedback is appreciated. Rgds, Brighton eliebl (Mechanical) 9 Jul 07 9:01 Search for Stored Energy Calculation. I know that NASA has a two page document that is easy to calculate a restricted distance from. It is one that is commonly used. EJL

zone when performing pneumatic testing? I couldn't find anything in Asme

Quote:
My personal practice for an air test is to be at least one zip-code away from the site. LMAO @ joe :) I don't know of any specific distance requirements, though I'd be interested in seeing that NASA document eliebel mentions. Regardless, there will always have to be someone within that area to do the test. Note that the piping code requires a leak test, not a proof test. If you're looking to do a proof test (ie: 1.5 times MAWP), then what is typically done is to disassemble the piping system and do a hydrostatic pressure test, and then reinstall the system and do the leak test. The proof test isn't required by code. 4 ASME B31.3 requires a "leak test" at 1.1 times design pressure. They also require a relief valve set at 10% above that

pressure. We always put this relief device at the source of the test pressure, and ensure by calculation that the relief device is large enough to handle the flow from the test source. When pressurizing the piping system, you should also verify you are only pressurizing those portions of the piping system that are rated for the pressure. Creating a test plan is imperative. Color code a P&ID or something along those lines. Make sure you know what lines you're pressurizing, and make sure the test plan incorporates valve open/close requirements, blanked off piping sections, etc... I'd also suggest bringing up pressure slowly - in 10% increments. Hold for 5 minutes at each level, and do a soap bubble leak test at each level. Leak testing requires someone to do the test, so they will always be near the piping during the test. One primary reason for keeping others back isn't just to keep them safe from potentially dangerous pressure, it is to maintain some control over piping and valve configuration. You need to keep people away from valves or other controls that need to be kept in a specific position during test, especially because you're generally in a construction mode and people may be less aware of lockout/tagout procedures. 9

Australia's pressure vessel code includes an appendix to calculate the pneumatic stored energy and the the recommended exclusion zone required for a pneumatic test. If you post up the dimensions, I'll run the numbers. For kicks I sometimes work out the equivalent kg of TNT that a pneumatic test represents - it helps put things in perspective. Team Members: ASME PCC-22006, page 139 -141 Article 5.1, Appendix II Stored Energy Calculations for Pneumatic Pressure Test Article 5.1, Appendix III Safe Distance Calculations for Pneumatic Pressure Test Article 5.1, Appendix IV Risk Evaluation Considerations for Pneumatic Pressure Test Article 5.2 Repairs and Alterations Without Pressure Testing

Re: Safe Distance for Pneumatic Leak Test. ASME PCC-2-2006 contains Article 5.1 Appendix III Safe Distance Calculations for Pneumatic Pressure Test. Article 5.1 of the same document is titled "Risk Evaluation Considerations for Pneumatic Pressure Test." The Article 5.1 calculation is a simple approach used widely for overpressure protection. Damage due to flying debris should be evaluated separately. The Dutch "Methods for the Calculation of Physical Effects" Part 2 CPR 14E has been used to establish exclusion zones around some large pipe systems to protect against major debris. As stated earlier, separated pieces can travel considerable distances.

Regards, Tony Paulin

Refer to the related thread, Equivalent Energy thread794-26767 I don't want to reply the dead thread. Therefore, I ask this question in new thread. I got the proposal for pneumatic test with safety protection (barricade the area) around minimum distance of :+100 ft. for stored energy 27,134 kJ. +150 ft. for stored energy over 27,134 kJ. I cannot find the source of reference for above proposal. It's seem the safe practice from the contractor's experience. Should we accept this idea? Please share your experience.

I have a spec here that states: E = {P.V/k-1} [1-{Patm/P}^k-1/k] where E = Energy Joules P = Absolute pressure Pascals V = Test Volume m^3 Patm = Atmospheric pressure pascals k = Ratio of specific heat of air TNTlb = E 4.8 x 10^-7 where TNTlb = Equivalent TNT in pounds SD = 15 (TNTlb)^0.5 where SD = Safe distance meters This compares reasonable well with your numbers. Not sure of the original source.