LEAK TESTING PROCEDURE

Document No: WG-LT- PROC-01

WG – QC
0 28-02-2024 FIRST ISSUE
Ahmed Alaa
Approve
Re Prepared Reviewed
Date Details d
v By By
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LEAK TESTING PROCEDURE

Table Of Contents:

1.General requirements of pressure .

2.Preparation for testing .
3.Initial Service Leak Test.
4.Pneumatic test.
5.Hydrostatic test .
This Procedure complies with ASME B31.9 as per project requirements.

General requirements of pressure test

1. Stress exceeding yield strength: the test pressure may be reduced to the
maximum pressure that will not exceed the yield strength at test
temperature.
2. Test fluid expansion: If the test pressure is to be maintained for a period of
time and the fluid in the system is subject to thermal expansion, precautions
shall be taken to avoid excessive pressure.
3. Preliminary pneumatic test: a preliminary test using air at no more than
170 kPa (25 psi) gage pressure may be made prior to hydrostatic or
pneumatic testing to locate major leaks.
4. Examination for leaks: a leak test shall be maintained for at least 10
minutes, and all joints and connections shall be examined for leaks.
5. Heat treatment: Leak tests shall be conducted after any heat treatment has
been completed.
6. Low-test temperature: The possibility of brittle fracture shall be considered
when conducting leak tests at metal temperatures near the ductile-brittle
transition temperature.
7. Personnel protection: Suitable precautions in the event of piping system
rupture shall be taken to eliminate hazards to personnel in the proximity of
lines being tested.
8. Repairs or additions after leak testing: If repairs or additions are made
after the leak test, the affected piping shall be retested.
9. Test records: Records shall be made of each piping system during the
testing, including:
o Date of test
o Identification of piping system tested
o Test fluid
o Test pressure
o Certification of results by examiner
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LEAK TESTING PROCEDURE

Preparation for testing:

1. Exposure of joints: all joints including welds not previously pressure tested
shall be left uninsulated and exposed for examination during the test.
2. Addition of temporary supports: piping systems designed for vapor or gas
shall be provided with additional temporary supports if necessary to support
the weight of the test liquid.
3. Restraint or isolation of expansion joints: expansion joints shall be
provided with temporary restraint if required for the additional pressure
load under test.

Isolation of equipment and piping not subjected to pressure test: Equipment

that is not to be subjected to the pressure test shall be either disconnected from
the system or isolated by a blank or similar means.

Initial Service Leak Test

General. For gases and steam and condensate service not over 15 psig (103 kPa
gage), and for nontoxic, non-combustible, non-flammable liquids at pressures not
over 100 psi (689 kPa gage) and temperatures not over 200°F (93°C), it is
permissible to conduct the system testing with the service fluid as outlined in next
paragragh

Service Testing. A preliminary test with air at low pressure ( 1) may be used In any
event, the piping system shall be brought up to operating pressure gradually with
visual examination at a pressure between one-half and two-thirds of operating
pressure. A final examination shall be made at operating pressure. If the piping
system is free of leaks, it will have met the requirements of this paragraph.

Pneumatic Testing

General. Compressed gas poses the risk of sudden release of stored energy. For
that reason, pneumatic testing shall be used only within the following limitations:
(a) The piping system does not contain cast iron pipe or plastic pipe subject to
brittle failure.
(b) The system does not contain soldered or solvent cement joints over NPS 2 (DN
50).
(c) The test pressure does not exceed 150 psig (1034 kPa gage).
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(d) The system will be used in gas service, or for other reasons cannot be filled
with water.
(e) Traces of a test liquid would be detrimental to the intended use of the piping.

Test Medium. The gas shall be non-flammable and nontoxic.

Preliminary Test (1).

Prior to application of full pneumatic test pressure, a preliminary test of not more
than 10 psig (69 kPa gage) shall be applied to reveal possible major leaks. (This
preliminary test may be used in conjunction with hydrostatic testing or initial
service testing.)

Pneumatic Test Pressure:

(a) Except as limited in (b), the test pressure shall not exceed 1.25 times the design
pressure. Pressure shall be applied in several stages, allowing time for the system
to reach equilibrium at each stage.
(b) The test pressure shall not exceed the maximum allowable pneumatic test
pressure for any vessel, pump, valve, or other component in the system under test.

Examination for Leakage.

After the preliminary test, pressure shall be raised in stages of not more than
25% up to full pneumatic test pressure, allowing time for equalization of strains
and detection of major leaks at each stage. Following the application of test
pressure for at least 10 min, the pressure may be reduced to design pressure and
examination shall be made for leakage of the piping. Leaks may be detected by soap
bubble, halogen gas, scented gas, test gage monitoring, ultrasonic, or other suitable
means. If leaks are found, pressure shall be vented, appropriate repair or
replacement shall be made, and the pneumatic test repeated until no
leakage is found.

Hydrostatic Testing

Test Medium:
Water at ambient temperature shall be used as the test medium except where there
is risk of damage due to freezing. Another liquid may be used if it is safe for
workmen and compatible with the piping.
Vents and Drains. Vents shall be provided at high points in the system to release
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LEAK TESTING PROCEDURE

trapped air while filling the system. Drains shall be provided at low points for
complete removal of the test liquid.

Preliminary Check. The system shall be examined to see that all equipment and
parts that cannot withstand the test pressure are properly isolated. Test equipment
shall be examined to ensure that it is tight and that low-pressure filling lines are
disconnected.

Hydrostatic Test Pressure:

(a) Minimum Pressure. Except as limited in (b), a piping system shall be subjected
to a hydrostatic test pressure that at every point in the system is not less than 1.5
times the design pressure.

(b) Maximum Pressure. The test pressure shall not exceed the maximum test
pressure for any vessel, pump, valve, or other component in the system under
test. A check shall be made to verify that the stress due to pressure at the bottom of
vertical runs does not exceed either of the following:
(1) 90% of specified minimum yield strength
(2) 1.7 times the SE value in Mandatory Appendix I, ASME B31.9 (for brittle
materials).

Examination for Leakage. Following the application of hydrostatic test pressure

for at least 10 min, examination shall be made for leakage of the piping and at all
joints and connections. If leaks are found, they shall be eliminated by tightening,
repair, or replacement, as appropriate, and the hydrostatic test repeated until no
leakage is found.