PEW 104

Pressure Testing

Purpose of Pressure Testing

Pressure testing is a method that the inspector uses to determine that the equipment is safe for operation.
Pressure testing checks the ability of piping and equipment to withstand operating design pressures.

Types of pressure test

Two types of pressure test are performed at Saudi Aramco

Strength test Tightness test

Conversion Chart
Pounds per square inch (psi) x 6.89 x 103 = Pascal's Bar x 14.5 = psi Pascal's x 1.45 x 104 = psi Bar x 105 = Pascal's Kg / cm2 x 14.2 = psi

Pneumatic Tests

Tests that use a gas medium are called?

Pneumatic Tests

GI 2. 102 Pressure testing Safely GI 2.102... specifies the necessary safety requirements for pneumatic testing.

SAES A 004

SAES A 004 General Requirements For Pressure Testing

SAES - A -004 Continued

SAES A 004 provides specific guidance about pressure testing

Scope Definitions General Requirements Test Preparation

SAES - A -004 Continued

SAES A 004 provides specific guidance about pressure testing

Test Procedure Test Pressure Temperature Duration

GI 2. 102 Pressure testing Safely

GI 2.102 Specifies Safety Information

Assign Responsibility Issue Written,Approved Procedures

Use Proper Test Medium

GI 2. 102 Pressure testing Safely

GI 2.102 Specifies Safety Information
Use Appropriate Test Equipment Obtain Work Permits

Isolate Equipment Not Adequate for Test

Pressure

GI 2. 102 Pressure testing Safely

GI 2.102 Specifies Safety Information Control Access to the Test Site Advise Government Affairs of None Saudi Aramco Exposures Remove Air Pressure Before Pressurizing

GI 2. 102 Pressure testing Safely

GI 2.102 Specifies Safety Information

Control Pressure Rise Depressurize Before Stopping Leaks or Repairing Restrict Approach to System

GI 2. 102 Pressure testing Safely Pressure Test Safely!!!

Hydrostatic Test Diagram The hydrostatic diagram is used for both hydrostatic and pneumatic pressure tests

Verify Test Pressure The limiting factor for any pressure test is the pressure rating of the weakest component in the system under test

Plant Piping The minimum hydrostatic test pressure for plant piping as stated in SAES - L-004 shall produce a hoop stress of 90% of the specified yield strength

Test Pressure Calculation

Pt = 2(.9YT) D Pt = Minimum Test Pressure Y = Specified Minimum Yield Strength of the Pipe T = Nominal Pipe Thickness x .875 D = Outside Diameter

Test Pressure Calculation ASME B31 . 3

Pd = 2SEt D Pt = Minimum Test Pressure Pd = Maximum Allowable Operating Pressure S = Maximum Allowable Stress for a Given Temperature

Test Pressure Calculation ASME B31 . 3 ....Cont Pd = 2SEt D

E = Longitudinal Joint Efficiency t = Nominal Pipe Thickness D = Outside Diameter of Pipe

Piping Components The correct test pressure for flanges and valves are calculated according to ASME 16.5

ASME 16.5
Paragraph 8.3... The hydrostatic shell test for flanged fittings shall be no less than 1.5 times the 100 0 F rating rounded off to the next higher 25 psi increment.

ASME 16.5
Paragraph 8.3.1... The test shall be made with water,which may contain a corrosion inhibitor, with kerosene, or with another suitable fluid provided its viscosity is no greater than That of water, at a test temperature of not above 125o F.

ASME 16.5
Paragraph 8.3.2... The test duration shall be a minimum of one minute for fittings NPS 2 and Smaller, two minutes for fittings NPS 2 - NPS 8 and three minutes For fittings NPS 10 and larger.

ASME 16.5 Paragraph 8.3.3... No visible leakage is permitted the through pressure boundary wall

Variables That Effect Pressure Elevation Where the pipeline transverses hilly

terrain test pressures will differ from

one level to another

Temperature Pressure changes when you have a change in test water temperature.

Pneumatic Test Hazards

Do not approach any piping or

equipment during pneumatic pressure

testing

Pneumatic Test Hazards Never hammer test piping or that is undergoing pneumatic pressure test

Pneumatic Test Hazards Air is not approved for use as a test medium unless the system has been

thoroughly cleaned

Pneumatic Test Hazards In no case will oxygen or any toxic gas be used as a test medium.These gases present extreme hazards to personnel and equipment

Chief Inspection Engineer The Chief Inspection Engineer reviews the pneumatic pressure test procedure

PEW 104

Pressure Testing (Part Two)

Vacuum Box Test Vacuum box bubble emission leak testing provides for the detection of through thickness discontinuities in welds

Visual Inspection in the field The inspector performs visual inspection of the test preparations in the field

Drains and Vents

SAES - A - 004 specifies that vents and drains must be properly located throughout the system under test

Temporary Piping Temporary piping must be pre tested at pressure twenty percent higher than the test pressure specified for the system under test

Protection of System Components There are usually components in a system that must be isolated during the test

Protection of System Components The inspector must verify that correct test medium will be used

Protection of System Components The inspector must verify that correct Chemical treatment will be provided

Protection of System Components

The inspector must verify correct safety equipment for all hot work carried out if the test medium is above (120 F) or below (150 F)

Protection of System Components

The inspector must verify that all the components are rated for a pressure that meets or exceeds the pressure specified for the test

Protection of System Components The inspector must verify that all Pipe flanges,bolts and gaskets are Are in serviceable condition

Protection of System Components The inspector must verify that all new welded joints are properly completed and left exposed for the test

Test Pressure Gauges SAES-A-004 specifies that two or More pressure gauges must be installed to monitor the pressure during all stages of the test

Test Pressure Gauges The gauges must have a range such that the pressure specified for the test is between 30% and 80% of the full range

Test Pressure Gauges The gauges must indicate within 5% of each other for any given pressure

Test Pressure Gauges The gauges must have a calibration stickers that indicate calibration within the past month

Test Pressure Gauges The gauges must have a calibration certificates available to document calibration accuracy

Calibration OK

Test Pressure Gauges Test Pressure Gauges gauges must have a block valve and a bleed valve that allows the pressure gauge to be replaced while the system is pressurized

Test Pressure Relief Valves The pressure relief setting must be 5% above the specified test pressure

Test Pressure Relief Valves The pressure relief valve must have been tested within the past week

Tested

Test Pressure Relief Valves The date of the relieving test must be clearly indicated on the test
Tested 03/03/00

PEW 104

Pressure Testing (Part Three)

Witnessing System Pressurization Remove Air Before Pressurizing as this reduces potential for damage

Witnessing System Pressurization Control Pressure Rise

Witnessing System Pressurization Depressurize before stopping leaks or repairing

Witnessing System Pressurization Restrict approach to the system

Witness Strength & Tightness Tests The inspector witnesses the strength test by observing from a safe distance

Strength Tests

Strength tests are only given to new equipment

Tightness Tests

The strength test must be followed by a tightness test for cross country pipelines

Witnessing System Depressurization Depressurize Safely The system should be depressurized through appropriate drain piping

Witnessing System Depressurization Depressurize Safely The test media must be disposed according to the procedure