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Safety
Reliability of operation
Nomally two methods for pressure testing: hydrostatic and pneumatic, are widely used in
process industry.
A hydrostatic test is performed by using water as the test medium, whereas a pneumatic test
uses air, nitrogen, or any non-flammable and nontoxic gas. Pressure tests (both hydrostatic
and pneumatic) must always be performed under controlled conditions, following an
approved test plan, and documented in a test record. A single approved test plan could be
used for several similar tests, but for each test a separate test record is required.
When to perform a Pressure Test:
As per the governing code, pressure test has to be performed on piping system after all hot
works have been completed on a certain piping system. Here the term hot work means
everything related to welding or the post weld heat treatment (PWHT). PWHT also has a
potential of degrading the mechanical properties of piping, in case not addressed properly.
And this is the reason why code calls for NDT after PWHT operation. In case after carrying
out pressure testing, some modification has to be made requiring hot work, it calls for a retest
as per code. Here code specifies that the minor repairs / modifications may be waived off
provided adequate measures have been taken to ensure sound construction. Now taking this
decision as to which repairs or modifications may be waived off should be taken very
carefully. Normally, the maximum extent of repairs not requiring retesting shall be the tack
welding of any piping support or pad. Anything else shall be done following a retest.
Pressure testing and conducting 100% radiography or ultrasonic inspection shall not be
interchanged. In case carrying out of hydrostatic or pneumatic test stands impractical then
100% radiography or ultrasonic testing may be performed but in addition to this it is
advisable to check that the whole piping and its components have been supplied against
acceptable ASTM standards and required test certificates are available. Conducting 100%
radiography of all the weld joints assure that your weld joints are defect free but can never
provide you with the assurance of mechanical integrity of a system. This is also to be noted
that radiography / ultrasonic inspection shall also not to be waived off if the pipeline is to be
hydrostatically tested. This may pose an additional safety risk during the test. Moreover,
some defects in the weld zones may prove to be detrimental way after taken in service due to
severe extended service conditions.
Pneumatic Testing
Skilled and semi skilled personnel can carry out the test
Freeze susceptibility
Contamination
Difficulties
with
Pneumatic
testing:
Pneumatic tests are potentially more dangerous than hydrostatic tests because of the higher
level of potential energy stored during compressing the gas. Care must be exercised to
minimize the chance of brittle failure during testing by initially assuring the system is suitable
for pneumatic testing. Pneumatic tests could be performed only when at least one of the
following conditions exists:
When the systems are designed in such a way thet it cannot be filled with water.
When the systems are such that it is to be used in services where traces of the testing
medium cannot be tolerated.
Using a pneumatic test instead of hydrostatic requires approval from proper authority or
body.
Test Pressure:
ASME Code B 31.3 provides the basis for test pressure. The minimum hydrostatic test
pressure for metallic piping shall be as per the following equation:
Pt=1.5*Pd*(St/Sd)
Here,
Pt=minimum
test
gauge
pressure
Pd=internal
design
gauge
pressure
St=allowable
stress
value
at
test
temperature
Sd=allowable
stress
value
at
design
temperature.
The maximum allowable value of St/Sd is 6.5The pneumatic test pressure shall be as per the
following equation: Pt=1.1*PdNormal Basis for Test Method Selection:
Normally the following basis is followed in process piping industry for selection of hydro or pneumatic
tests.
1. If the fluid handled by piping system is liquid then the pipe must be hydrotested.
2. If the fluid handled is vapour or gas then the internal design pressure dictates the testing
method. For pipe design pressure 10 bar and above the pipe is hydrotested. For pipe design
pressure below 10 bar pipe is pneumatically tested.
3. If fluid handled is stream then hydrotesting is suggested.
4. If fluid handles is two-phase flow then hydrotesting is suggested. However for big size flare
headers pneumatic testing is performed.
Test Duration:
Normally every EPC company have their own standard for duration of tests. However the
recommended practice is that a QC inspector have to walk through the whole piping system and
check for leaks. Every single length of piping, welds, bolted connections shall be visually examined for
any leakage. Duration of this activity varies with the span of piping system. For larger piping system
time taken for this activity is enough to clear the pressure test. In case of piping system having smaller
span, 1 hour time may be made as standard practice for hydrostatic testing. For Pneumatic test the
test time is far lesser.Few important points to consider while hydrotesting:
The tower overhead lines which are normally hydro tested shall be decided by stress
engineer group whether to hydro test after erection or at grade, based on the capacity of
standard clip available as per engineering specification for pipe supports.
During hydrotest in case of big bore it should be decided first that line is to be hydrotested on
rack or grade if hydrotest is done on rack , hydrotest load should be considered in case of
vapour lines while providing structure / rack loading information.