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Non Destructive Testing - Pressure Testing is a non-destructive test performed to ensure the integrity of the pressure shell on new pressure equipment.
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Piping Codes
There are a great many codes and standards relating to piping systems. Two codes of major importance for pressure and leak
testing are the ASME B31 Pressure Piping Code and the ASME Boiler and Pressure Vessel Code. While these two codes are
applicable to many piping systems, other codes or standards may have to be met as required by the authorities, insurance
companies, or the owner of the system. Examples might be AWWA standards for water transmission and distribution system piping.
The ASME B31 Pressure Piping Code has several sections. They are:
ASME B31.1 for Power Piping
ASME B31.2 for Fuel Gas Piping
ASME B31.3 for Process Piping
ASME B31.4 for Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia, and Alcohols
ASME B31.5 for Refrigeration Piping
ASME B31.8 for Gas Transmission and Distribution Piping Systems
ASME B31.9 for Building Services Piping
ASME B31.11 for Slurry Transportation Piping Systems
The ASME Boiler and Pressure Vessel Code also has several sections which contain pressure and leak testing requirements for piping
systems, pressure vessels, and other pressure retaining items. These are:
Section I for Power Boilers
Section III for Nuclear Power Plant Components
Section V for Non Destructive Examination
Section VIII for Pressure Vessels
Section X for Fiberglass Reinforced Plastic Pressure Vessels
Section XI for In Service Inspection of Nuclear Power Plant Components
There is great similarity with respect to the requirements and procedures for testing among the many codes. Various leak-testing
methods, planning, preparation, execution, documentation, and acceptance standards for pressure testing will be discussed in this
chapter. Equipment, useful for pressure testing, will also be included in the discussion. The material that follows should not be
considered a substitute for a complete knowledge or careful study of the particular code requirement that must be used to test a
particular piping system.
Leak-Testing Methods
There are many different methods for pressure and leak testing in the field. Seven of these are:
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Non Destructive Testing - Pressure Testing is a non-destructive test performed to ensure the integrity of the pressure shell on new pressure equipment.
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Non Destructive Testing - Pressure Testing is a non-destructive test performed to ensure the integrity of the pressure shell on new pressure equipment.
This test method is sometimes called a drop test because a drop in the water level in the open standpipe, added to the system to
create the required pressure, is an indication of a leak. Once the system and standpipe is filled with water, the standpipe level is
measured and noted. After a required hold period, the height is rechecked and any decrease in level and the hold period are
recorded. Any leak location is determined by visual inspection.
Test Pressures
The selected test method and fluid test medium, together with the applicable code, will also establish the rules to be followed in
calculating the required test pressure. In most cases a pressure greater than the design pressure rating is applied for a short
duration, say at least 10 minutes. The magnitude of this initial test pressure is often at least 1.5 times the design pressure rating for
a hydrostatic test. However, it may be different, depending upon which code is applicable and whether the test is hydrostatic or
pneumatic. Furthermore, the test pressure must never exceed a pressure that would cause yielding, or the maximum allowable test
pressure of some component exposed to the test. In the case of ASME B31, section 137.1.4, and the Boiler and Pressure Vessel
Codes, the maximum test pressure must not exceed 90 percent of yield for any component exposed to the test. The test pressure is
needed to demonstrate that the system can safely withstand the rated pressure. Following this period of greater than design
pressure, it is often permissible to reduce the pressure to a lower value for examination of leaks. The examination pressure is
maintained for the length of time necessary to conduct a thorough
Test type
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Test pressure
Test pressure
Test
Examination
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Non Destructive Testing - Pressure Testing is a non-destructive test performed to ensure the integrity of the pressure shell on new pressure equipment.
Code
ASME B31.1
Hydrostatic (1 )
ASME B31.1
Pneumatic
ASME B31.1
minimum
maximum
pressure
hold time
pressure
10 minutes
Design pressure
10 minutes
Initial service
Normal operating
or design
componenet
pressure
pressure
10 minutes or
Normal operating
time to complete
pressure
leak examination
ASME B31.3
Hydrostatic
Time to complete
leak examination
but at least 10
minutes
ASME B31.3
Pneumatic
10 minutes
Design pressure
Time to complete
Design pressure
ASME B31.3
ASME I
Hydrostatic
ASME III
leak examination
Hydrostatic
pressure (5 )
Pneumatic
Division 1
Max allowable
working pressure
10 minutes
Greater of design
pressure or 0,75
times test
system componenet (5 )
pressure
Not specified,
typically 1 hr
(4)
Division 1
Subsection NB
ASME III
Design pressure
10 minutes
Greater of design
pressure or 0,75
times test
system componenet
pressure
Subsection NB
ASME III
Hydrostatic
10 or 15 minutes
per inch of design
minimum wall
thickness for
pumps and Valves
Greater of design
pressure or 0,75
times test
pressure
Pneumatic
10 minutes
Greater of design
pressure or 0,75
times test
pressure
Hydrostatic
10 minutes
Greater of design
pressure or 0,75
times test
pressure
Pneumatic
10 minutes
Greater of design
pressure or 0,75
times test
pressure
Division 1
Subsection NC
ASME III
Division 1
Subsection NC
ASME III
Division 1
Subsection ND
ASME III
Division 1
Subsection ND
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Non Destructive Testing - Pressure Testing is a non-destructive test performed to ensure the integrity of the pressure shell on new pressure equipment.
Notes:
1. Boiler external piping must be hydrostatic tested in accordance with PG-99 of ASME Code Section I.
2. ASME B31.3 hydrostatic pressure must be raised above 1.5 times design pressure in proportion to yield strength at test
temperature divided by strength at design temperature but not to exceed yield strength at test temperature. Where a vessel is
involved whose design pressure is less than the piping and where vessel cannot be isolated, the piping and vessel can be tested
together at vessel test pressure provided vessel test pressure is not less than 77 percent of piping test pressure.
3. ASME B31.3 initial service testing permitted only for piping in category D service.
4. ASME Code Section I hydrostatic test pressure at temperature of at least 70F (21C) and examination pressure
at temperature
less than 120F (49C). For a forced-flow steam generator with pressure parts designed for different pressure levels, the test
pressure should be at least 1.5 times the maximum allowable working pressure at the superheater outlet but not less than 1.25
times the maximum allowable working pressure of any part of the boiler.
5. ASME Code
Section III, Division 1, subsection NB, test pressure limits defined in section NB3226; also components containing
brazed joints and Valves to be tested at 1.5 times system-design pressure prior to installation.
6. ASME Code
Section III, Division 1, subsection NB, pneumatic test pressure for components partially filled with water shall not be
All pressure vessels have their own peculiar hazards, including great stored potential force, points of wear and corrosion, and
possible failure of overpressure and temperature control safety devices.
Government and industry have responded to the need for improved pressure systems testing by producing standards and
regulations specifying general pressure safety requirements (ASME Boiler and Pressure Vessel Code, DOE Pressure Safety Guidelines
and others).
These regulations outline requirements for implementation of a pressure testing safety program. It is critical that design and
operating personnel use these standards as benchmark criteria for writing and implementing a pressure testing safety program.
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Non Destructive Testing - Pressure Testing is a non-destructive test performed to ensure the integrity of the pressure shell on new pressure equipment.
Launch of a newly manufactured tank during a pneumatic pressure test with air
in any component that has design implications which affect the pressure
containing capability of a pressure vessel beyond the scope of the items described in existing data reports.
extra thickness of material added by design to allow for material loss from corrosive or erosive
attack.
system service that, because of chemical or other interaction with the container's materials of
construction, contents, or external environment, causes the pressure container to crack, to become embrittled, to lose more than
0.01 in. of thickness per year of operation, or to eteriorate in any way.
pressure used in the design of a pressure component together with the coincident design metal
temperature, for the purpose of determining the minimum permissible thickness or physical characteristics of the pressure
boundary. Design pressure for vessels is shown on the fabrication drawings and for piping, the maximum operating pressure is
indicated on the line list. The design pressure for piping is the larger of 110% of the maximum operating pressure or 25 psi over
the maximum operating pressure.
High Pressure - Gas Pressure greater than 20 MPa gauge (3000 psig) and liquid pressure greater than 35 MPa gauge (5000).
Intermediate Pressure - Gas Pressure from 1 to 20 MPa gauge (150 to 3000 psig) and liquid pressure from 10 to 35 MPa
gauge (1500 to 5000 psig).
Leak Test - A pressure or vacuum test to determine the existence, rate, and/or location of a leak.
Low Pressure-Gas Pressure less than 1 MPa gauge (150 psig) or liquid pressure less than 10 MPa (1500 psig).
Manned-area operation - A pressure operation, that may be conducted (within specified limits) with personnel present.
Maximum Allowable Working Pressure (MAWP) - maximum pressure permissible at the top of a vessel in its normal
operating position at the operating temperature specified for the pressure. It is the least of the values found for maximum
allowable working pressure for any of the essential parts of the vessel by the principles established in ASME Section VIII. The
MAWP is shown on the vessel nameplate. The MAWP may be taken same as the design pressure, but for the most part the MAWP
is based on the fabricated thickness minus the corrosion allowance. MAWP applies to pressure vessels only.
maximum temperature used in the design and shall not be less than the maximum
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Non Destructive Testing - Pressure Testing is a non-destructive test performed to ensure the integrity of the pressure shell on new pressure equipment.
operating temperature.
highest pressure expected during operation. This is usually 10-20% below the
MAWP.
or operating conditions with a low risk of brittle fracture. The MAMT is determined by an evaluation for pressure vessels built prior
to 1987. This term is used in API RP 579 for the brittle fracture evaluation of existing equipment. It may be a single temperature,
or an envelope of acceptable operating temperatures as a function of pressure.
The MDMT is an ASME Code term and normally shown on the vessel nameplate or U-1 Form for vessels designed per ASME
Section VIII, Division 1, 1987 edition or later.
Mpa - Absolute pressure in SI units. 1 atmosphere (14.7 psig) is equal to 0.1 MPa.
Operational Safety Procedure (OSP) - The Document used to describe the controls necessary to ensure
associated with a potentially hazardous research project or unique activity are at an acceptable level.
Pressure Equipment - Any equipment, e.g., vessels, manifolds, piping, or other components, that operates above
or below (in
operation, that may not be conducted with personnel present. The equipment must be installed
ratio of the ultimate (i.e., burst or failure) pressure (measured or calculated) to the MAWP. A Safety
Factor related to something other than the failure pressure should be identified with an appropriate subscript.
Robert B. Adams
President and CEO EST Group, Inc. Harleysville, Pennsylvania
Pressure Vessel
Pressure Vessel
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Non Destructive Testing - Pressure Testing is a non-destructive test performed to ensure the integrity of the pressure shell on new pressure equipment.
ASME B31.3 requires "leak testing" of the piping system. This is not a structural test, it is only a test to determine if there
are points within the system that are leaking.* On the other hand, there are codes which may require a structural test such
as is done by the boiler and pressure vessel code. In that case, the hydrostatic test is performed to verify that the vessel
and attached piping is structurally sound, not just leak tight.
So to conclude:
1. If the specification you've been given is to perform a hydro test at 16 bar, then that should be 1.5 times the design
pressure of 10.67 bar. Per B31.3, a pneumatic test should therefore be performed not at 16 bar, but at 1.1 times the
design pressure or 11.7 bar. Run the pneumatic pressure only as high as 11.7 bar.
2. The possibility of brittle failure should be reviewed by the appropriate engineer. In the case of temperature below 0 C,
the material used should be examined to verify it is not below the minimum useable temperature for that steel.
3. A cognizant engineer needs to produce a set of pressure test procedures. Those procedures need to indicate what
sections of pipe are being tested, what positions valves should be placed in, what relief devices need to be removed (or
installed), etc.
4. The pneumatic test needs to start at 25 psig and a preliminary examination for leaks performed prior to increasing
pressure.
5. Most important, the cognizant engineer must also examine the piping design specification for all requirements pertaining
to leak or pressure testing.
Although B31.3 describes this as a "leak test", when performed hydrostatically at 1.5 times design, it is in affect, a
structural test.
OSHA
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Werner Slken 2008 - 2013. All rights reserved.
Do not worry about your difficulties in Mathematics. I can assure you mine are still greater. Albert Einstein
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