HYDROTEST PROCEDURE AS PER ASME B 31.

1 (POWER PIPING)

PRESSURE TESTS General Requ re!en"# Su$a##e!$l e#. When conducted in accordance with the requirements of this Code, the pressure testing of piping systems to ensure leak tightness shall be acceptable for the determination of any leaks in piping subassemblies.

Te!%era"ure &' Te#" Me( u!. The temperature of the test medium shall be that of the available source unless otherwise specified by the Owner. The test pressure shall not be applied until the system and the pressurizing medium are appro imately at the same temperature. When conducting pressure tests at low metal temperatures, the possibility of brittle fracture shall be considered.

Per#&nnel Pr&"e)" &n. !uitable precautions in the event of piping system rupture shall be taken to eliminate hazards to personnel in the pro imity of lines being tested.

Ma* !u! S"re## (ur n+ Te#". "t no time during the pressure test shall any part of the piping system be sub#ected to a stress greater than that permitted.

Te#" n+ S),e(ule. $ressure testing shall be performed following the completion of postweld heat treatment, required, nondestructive e aminations required and all

other fabrication, assembly and erection activities required to provide the system or portions thereof sub#ected to the pressure test with pressure retaining capability.

Pre%ara" &n '&r Te#" n+ E*%&#ure &' -& n"#. "ll #oints including welds not previously pressure tested shall be left uninsulated and e posed for e amination during the test. %y prior agreement the complete system or portions thereof sub#ect to test may be insulated prior to the test period provided an e tended holding time pressurization of the system is performed to check for possible leakage through the insulation barrier.

A(( " &n &' Te!%&rar. Su%%&r"#. $iping systems designed for vapor or gas shall be provided with additional temporary supports if necessary to support the weight of the test liquid. !uch supports shall meet the requirements for testing and system cleanup procedures described.

Re#"ra n" &r I#&la" &n &' E*%an# &n -& n"#. & pansion #oints shall be provided with temporary restraint if required for the additional pressure load under test, or they shall be isolated during the system test.

I#&la" &n &' Equ %!en" an( P % n+ N&" Su$/e)"e( "& Pre##ure Te#". &quipment that is not to be sub#ected to the pressure test shall be either disconnected from the system or isolated by a blank or similar means. 'alves may be used for this purpose provided that valve closure is suitable for the proposed test pressure. Owner shall be aware of the limitations of pressure and temperature for each valve sub#ect to test conditions and as further described. (solated equipment and piping must be vented.

Trea"!en" &' 0lan+e( -& n"# C&n"a n n+ Blan1#. )langed #oints at which blanks are inserted to blank off other equipment during the test need not be tested after removal of the blank provided the requirements are subsequently performed.

Pre)au" &n# a+a n#" Te#" Me( u! E*%an# &n. (f a pressure test is to be maintained for a period of time during which the test medium in the system is sub#ect to thermal e pansion, precautions shall be taken to avoid e cessive pressure. " pressure relief device set at **+, times the test pressure is recommended during the pressure test provided the requirements are not e ceeded.

H.(r&#"a" ) Te#" n+ Ma"er al. When permitted by the -aterial !pecification, a system hydrostatic test may be performed in lieu of the hydrostatic test required by the material specifications for material used in the piping subassembly or system provided the minimum test pressure required for the piping system is met.

Pr&2 # &n &' A r 3en"# a" H +, P& n"#. 'ents shall be provided at all high points of the piping system in the position in which the test is to be conducted to purge air pockets while the component or system is filling. 'enting during the filling of the system may be provided by the loosening of flanges having a minimum of four bolts or by the use of equipment vents.

Te#" Me( u!. Water shall normally be used as the test medium unless otherwise specified by the Owner. Test water shall be clean and shall be of such quality as to minimize corrosion of the materials in the piping system. )urther recommended precautions on the quality of test water used for hydrotesting of austenitic .,// series0 and ferritic .1// series0 stainless steels are contained in "ppendi ('.

C,e)1 &' Te#" Equ %!en" $e'&re A%%l. n+ Pre##ure. The test equipment shall be e amined before pressure is applied to ensure that it is tightly connected. "ll low2pressure filling lines and all other items not sub#ect to the test pressure shall be disconnected or isolated by valves or other suitable means.

Requ re( H.(r&#"a" ) Te#" Pre##ure. The hydrostatic test pressure at any point in the piping system shall not be less than *.3 times the design pressure, but shall not e ceed the ma imum allowable test pressure of any nonisolated components, such as vessels, pumps, or valves, nor shall it e ceed the limits imposed. The pressure shall be continuously maintained for a minimum time of */ minutes and may then be reduced to the design pressure and held for such time as may be necessary to conduct the e aminations for leakage. & aminations for leakage shall be made of all #oints and connections. The piping system, e clusive of possible localized instances at pump or valve packing, shall show no visual evidence of weeping or leaking.

Pneu!a" ) Te#" n+ General. & cept for preliminary testing in accordance, pneumatic testing shall not be used unless the Owner specifies pneumatic testing or permits its use as an alternative. (t is recommended that pneumatic testing be used only when one of the following conditions e ists4

."0 When piping systems are so designed that they cannot be filled with water. .%0 When piping systems are to be used in services where traces of the testing medium cannot be tolerated Test -edium. The gas used as the test medium shall be nonflammable and nonto ic. !ince compressed gas may be hazardous when used as a testing medium, it is recommended that special precautions for protection of personnel be observed when a gas under pressure is used as the test medium. Check of Test &quipment %efore "pplying $ressure. The test equipment shall be e amined before pressure is applied to ensure that it is tightly connected. "ll items not sub#ected to the test pressure shall be disconnected or isolated by valves or other suitable means.

Prel ! nar. Te#". " preliminary pneumatic test not to e ceed 53 psig 6*73 k$a .gage08 may be applied, prior to other methods of leak testing, as a means of locating ma#or leaks. (f used, the preliminary pneumatic test shall be performed in accordance with the requirements.

Requ re( Pneu!a" ) Te#" Pre##ure. The pneumatic test pressure shall be not less than *.5 nor more than *.3 times the design pressure of the piping system. The test pressure shall not e ceed the ma imum allowable test pressure of any nonisolated component, such as vessels, pumps, or valves, in the system. The pressure in the system shall gradually be increased to not more than one2half of the test pressure,

after which the pressure shall be increased in steps of appro imately one tenth of the test pressure until the required test pressure has been reached. The pressure shall be continuously maintained for a minimum time of */ minutes. (t shall then be reduced to the lesser of design pressure or *// psig 67// k$a .gage08 and held for such time as may be necessary to conduct the e amination for leakage. & amination for leakage detected by soap bubble or equivalent method shall be made of all #oints and connections. The piping system, e clusive of possible localized instances at pump or valve packing, shall show no evidence of leaking.

Ma##4S%e)"r&!e"er an( Hal (e Te#" n+ When specified by the Owner, systems with conditions of operation and design that require testing methods having a greater degree of sensitivity than can be obtained by a hydrostatic or pneumatic test shall be tested by a method, such as helium mass2spectrometer test or halide test, which has the required sensitivity. When a mass2spectrometer or halide test is performed, it shall be conducted in accordance with the instructions of the manufacturer of the test equipment. (n all cases a calibrated reference leak, with a leak rate not greater than the ma imum permissible leakage from the system, shall be used. The equipment shall be calibrated against the reference leak in such a way that the system leakage measured by the equipment can be determined to be not greater than the leak rate of the reference leak.

In " al Ser2 )e Te#" n+ When specified by the owner, an initial service test and e amination is acceptable when other types of tests are not practical or when leak tightness is demonstrable due to the nature of the service. One e ample is piping where shut2off valves are not available for isolating a line and where temporary closures are impractical. Others may be systems where during the course of checking out of pumps, compressors, or other equipment, ample opportunity is afforded for e amination for leakage prior to full scale operation. "n initial service test is not applicable to boiler e ternal piping. When performing an initial service test, the piping system shall be gradually brought up to normal operating pressure and continuously held for a minimum time of */ minutes. & amination for leakage shall be made of all #oints and connections. The piping system e clusive of possible localized instances at pump or valve packing shall show no visual evidence of weeping or leaking. Re"e#" n+ A'"er Re%a r &r A(( " &n# 9epairs may be made to the pressure parts of boiler e ternal piping after the hydrostatic test required, provided the requirements of $W231.5 of !ection ( of the "!-& %oiler and $ressure 'essel Code are met. :onpressure parts may be welded to the pressure parts of boiler e ternal piping after the hydrostatic test required, provided the requirements of $W231., of !ection ( of the "!-& %oiler and $ressure 'essel Code are met. (n the event repairs or additions to nonboiler e ternal piping are made following a test, the affected piping shall be retested in accordance with the provisions. ;owever, a

system need not be retested after seal welding or after attachments of lugs, brackets, insulation supports, nameplates, or other nonpressure retaining attachments provided. ."0 The attachment fillet weld does not e ceed ,+< in. .*/./ mm0 thickness or, if a full penetration weld is used, the material attached does not e ceed the nominal thickness of the pressure retaining member or *+5 in. .*5./mm0, whichever is less. .%0 Welds shall be preheated as required. .C0 Welds shall be e amined as required. .=0 !eal welds shall be e amined for leakage after system startup. "ll weld defect repairs shall be made in "ccordance.