Submitted By: Pauline L Lally

Approved By: Jason Taylor

Effective Date: February 10, 2015

Pressure Test Performance for HVAC, Process,

Plumbing and Gas Piping
PURPOSE:
To be considered a High Performance company, we must strive for 0 error or NO leaks on piping
and/or components that we install. The following describes how to test pressure on piping systems in
order to avoid any failures due to improper or inadequate joining of piping and/or fittings and to
provide written documentation that said testing has been performed and witnessed by the client’s
representative.

PROCEDURE:
1. HVAC/Process Piping:
1.1. Close off any open ends in piping.
1.1.1. In the cases where components are not available during the preliminary installation
and/or are not piped off, blanks or valves are to be used to completely close the
piping loop.
1.2. Using air, pump the system up to the appropriate psi as follows:
1.2.1. Piping should be slowly pressurized to 60 psi; let stand for 10 to 15 minutes or as
suggested by manufacturers’ representatives. Proceed to pressurize system to 125
psi.
1.3. While filling the system with city pressure water, air shall be disbursed from the system high
points while filling with city pressure. Once the system is flooded and air is removed, a
hydro pump of adequate capacity shall be used to increase the pressure to 125 psi.
1.4. For HVAC systems, once the buildings mains have been tested, individual coils installed after
the initial hydro test shall be pressurized with air at 125 psi. Separate test forms with unit
numbers shall be completed by PSI and signed by the client’s representative.
2. Gas Piping
2.1. Gas piping less than or equal to ½ psi or 14” of water column, extending from the outlet of
the meter set assembly to the closed shutoff valve of each appliances shall withstand a
pressure of at least 6” mercury or 3# gauge for a period of not less than 10 minutes.
2.2. The remainder of the piping system previously installed may be tested to not more than 3”
of mercury or 1-1/2 psi for a period of not less than 10 minutes without showing any drop in
pressure.
3. Gas Piping systems for industrial and other large installations
3.1. Shall be tested at a pressure of least 10 times (maximum 100 psi) the proposed maximum
working pressure. Test duration shall be long enough to determine if there are any leaks

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 but not less than one hour for each 100 linear feet of pipe or fraction thereof. The duration
of the test need not exceed 24 hours irrespective of system design.
4. Plumbing – Inspection of rough plumbing
4.1. Water Test
4.1.1. A water test shall be applied to the drainage system either in its entirety or in
sections. If applied to the entire system, all openings in the piping shall be tightly
closed, except the highest opening and the system filled with water to point of
overflow. If the system is tested in sections, each opening shall be tightly plugged,
except the highest opening of the section under test, and each section shall be
filled with water. When testing successive sections, at least the upper ten feet of
the next preceding section shall be tested, so that no joint or pipe in the building
(except the uppermost ten feet of the system) shall have been submitted to a test
that utilizes less than a 10 ft. head of water. The water shall be kept in the system
or in the portion under test for at least 15 minutes before the inspection starts:
The system shall then be tight at all points.
4.2. Air test
4.2.1. An air test shall be performed by attaching an air compressor testing apparatus to
any suitable opening, and, after closing all other inlets and outlets to the system,
forcing air into the system, until there is a uniform gauge pressure of 5 psi. This
pressure shall be held without introduction of additional air for a period of at least
15 minutes. The gauge used for this test shall be calibrated in increments no
greater than 1/10 of a pound.
5. Plumbing – Testing the Water Distribution and Supply System
5.1. Upon completion of a section or of the entire water supply system when roughed, it shall be
tested and proved tight under a pressure not less than 125 psi. Air or other inert gases may
be used for testing.
6. Once the test has been completed, complete the form named WITNESS OF PRESSURE TEST
PERFORMANCE in its entirety. (See Sample). Have the client representative sign the form where
indicated. Send a copy of the signed form to the office.
7. Hydro test shall take place only after air test is witnessed and signed by the client representative
and after the signed test is on file at the office.
8. All completed and signed test forms will be uploaded by PSI’s drop box by the end of the day.
9. No form will be given to the client’s representative without first uploading the form to Drop Box.
10. Once weekly, or more often if required, the PM will download and save on the completed form(s)
in the folder named and located: F:\Shared\Pressure Test Forms
11. A blank copy of the Pressure Test Form is located in F:\Shared\Pressure Test Forms.

SAMPLE FOLLOWS

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 WITNESS OF PRESSURE TEST PERFORMANCE1

This is to acknowledge that the following pressure test was performed and witnessed.
Name of Piping Systems’ Team Member performing test_____________________________________________________

Date test was performed:_________________ Job #___________ Job Name: _________________________________

Duration of testing time: _________________ Job Location: _______________________________________________

TEST MEDIUM AND PRESSURE

SYSTEM TYPE COMPONENT DURATION
RATING
HVAC, process piping All piping Air @ 125 psi  One hour minimum
Hydro (water) @ 125 psi  Two hours minimum
Gas, low pressure All piping 3 psi  10 minutes minimum
Gas, high pressure All Piping Determined by Inspector: Determined by pressure
Recorded on: (check off) available on job-site:
Gauge  ____ hours (not less than
Graph  one hour for each 100 ft.
of pipe)
Tested at _________psi
Plumbing Underground 10 feet head pressure  15 minute minimum
In wall rough 10 feet head pressure  15 minute minimum
FINISH PLUMBING:
Water piping, hot Air @ 125 psi  15 minute minimum
Water piping, cold Air@ 125 psi  15 minute minimum

Description of piping and/or components tested including location:

__________________________________________________________________________________________________
__________________________________________________________________________________________________
__________________________________________________________________________________________________

PRINT CLIENT/INSPECTOR NAME: _______________________________________________________________________

Sign Name and Date of client’s representative who witnessed test:
__________________________________________________________________________________________________

If system was tested in sections, what is the status of any blanks or valves used?

Installed Removed Closed Opened

Pan Blanks Valves
Location: Location:

TESTING CRITERIA (see reverse side of this sheet) (unless otherwise specified by the client)

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Air testing shall be conducted prior to hydrostatic testing. Per ASME 31.1: preliminary test pressurized piping at 60 psi.,
to identify major leaks, for a duration of thirty (30) minutes. Test pressure shall then be slowly increased to 125 psi. for a
duration of one (1) hour minimum.
Hydrostatic leak testing shall be done in accordance with ASME B31.1 Power Piping Code. Testing medium shall be water
at ambient temperature. Test pressurized piping to 150% of design operating pressure, not less than 125 psi, for a
duration of two (2) hours. Traps, equipment and sundries shall be isolated during the test.
Gas Piping shall be done in accordance with NFPA-54 Chapter 7
Plumbing test shall be done in accordance with 248 CMR. All individual inspections shall have test form completed and
signed by the Inspector. Picture of copy of signature on building permit shall be forwarded to the office on the date of
the inspection.
1
NOTE: Do Not use this form for the testing of P.V.C., Sprinkler piping or gas.

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