February 1998

Process Industry Practices

Piping

PIP PNSC0021
Specification for Leak Tests of Piping
 PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES

In an effort to minimize the cost of process industry facilities, this Practice has
been prepared from the technical requirements in the existing standards of major
industrial users, contractors, or standards organizations. By harmonizing these
technical requirements into a single set of Practices, administrative, application, and
engineering costs to both the purchaser and the manufacturer should be reduced. While
this Practice is expected to incorporate the majority of requirements of most users,
individual applications may involve requirements that will be appended to and take
precedence over this Practice. Determinations concerning fitness for purpose and
particular matters or application of the Practice to particular project or engineering
situations should not be made solely on information contained in these materials. The
use of trade names from time to time should not be viewed as an expression of
preference but rather recognized as normal usage in the trade. Other brands having the
same specifications are equally correct and may be substituted for those named. All
practices or guidelines are intended to be consistent with applicable laws and
regulations including OSHA requirements. To the extent these practices or guidelines
should conflict with OSHA or other applicable laws or regulations, such laws or
regulations must be followed. Consult an appropriate professional before applying or
acting on any material contained in or suggested by the Practice.

©Process Industry Practices (PIP), Construction Industry Institute, The

University of Texas at Austin, 3200 Red River Street, Suite 340, Austin,
Texas 78705. PIP member companies may copy this practice for their
internal use.

Not printed with state funds

 February 1998

Process Industry Practices

Piping

PIP PNSC0021
Specification for Leak Tests of Piping
Table of Contents

1. Introduction ..................................2 6. Field Testing................................. 3

1.1 Purpose ...............................................2 6.1 Test Conditions....................................4
1.2 Scope...................................................2 6.2 General Requirements ........................4
6.3 Test Symbol “B” ...................................5
2. References....................................2 6.4 Test Symbol “H”...................................5
2.1 Process Industry Practices ..................2 6.5 Test Symbol “H1”.................................6
2.2 Industry Codes and Standards ............2 6.6 Test Symbol “P” ...................................6
6.7 Test Symbol “F” ...................................7
3. Definitions.....................................2
7. Preparation For Test.................... 7
4. General Requirements.................3 7.1 Define Test Loops ...............................7
4.1 Prior Work............................................3 7.2 Painting and Insulation ........................7
4.2 The Company Representative .............3 7.3 Pneumatic Testing...............................7
4.3 Acceptance Criteria .............................3 7.4 Other Preparation ................................7
4.4 Report ..................................................3
4.5 Repairs or Additions After Leak
Testing .................................................3

5. Shop Leak Test.............................3

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PIP PNSC0021
Specification for Leak Tests of Piping February 1998

1. Introduction

1.1 Purpose
The purpose of this specification is to describe leak testing requirements to those
performing leak tests of ASME B31.3 Process Piping, hereinafter referred to as the
Code.

1.2 Scope
This specification states methods, practices, and precautions to be used in testing, in
accordance with the Code, and describes requirements that are in addition to those of
the Code. Requirements are applicable to both metallic and nonmetallic piping.
Piping to be leak tested, the types of testing to be done, and the test pressure are set
forth by reference to this specification.

2. References
The following documents have been referenced in this specification and become part of its
requirements. It will be necessary to understand the applicable requirements of each of them.
Refer to the latest edition. Short titles will be used herein when appropriate.

2.1 Process Industry Practices

– PIP PNSC0001 - Fabrication and Examination Specification for ASME
B31.3 Metallic Piping
– PIP PNSC0011 - Specification for Installation of Metallic Piping

2.2 Industry Codes and Standards

American Society of Mechanical Engineers (ASME)
– ASME B31.3 - Process Piping (Code)
– ASME Boiler and Pressure Vessel Code
Section V - “Nondestructive Examination” (BPV Code Section V)

3. Definitions
Company Representative: Person designated by the Owner to act on the Owner’s behalf
Symbol “B”: Sensitive Leak Test, see Section 6.3
Symbol “F”: Service Test, see Section 6.7
Symbol “H”: Hydrostatic Test, see Section 6.4
Symbol “P”: Pneumatic Test, see Section 6.6
Test Contractor: The firm hired to do the testing

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 PIP PNSC0021
February 1998 Specification for Leak Tests of Piping

4. General Requirements

4.1 Prior Work

Fabrication and/or installation, examination, and any required cleaning, except
chemical cleaning, shall be complete and in accordance with the applicable
specification.

4.2 The Company Representative

The Company Representative shall approve preparations for and witness all leak
tests.

4.3 Acceptance Criteria

Piping which is free of leakage for the duration of specified tests shall be accepted.

4.4 Report
The Test Contractor shall provide the Company Representative with a report in
accordance with the Code, Paragraph (Para.) 345.2.7.

4.5 Repairs or Additions After Leak Testing

Repairs or additions made following the leak test shall be tested in accordance with
Para. 345.2.6 of the Code.

5. Shop Leak Test

A shop may be either a commercial shop or a shop set up in the field near a work site. Tests
shall be in accordance with PIP PNSC0001. When specified in the purchase order, leak
testing of shop-fabricated piping shall be performed before shipment or assembly.

5.1 When specified, hydrostatic testing shall be done at the test pressure specified by the
Company Representative. The test fluid shall be water unless otherwise specified.

5.2 A pneumatic test (“P”), may be made only with the Company Representative's
specific agreement, and if “P” is identified as the test. Test assemblies at the pressure
stated using air unless otherwise directed. Protect personnel and property from
possible harm of disruptive pressure release.

5.3 Where a sensitive leak test (“B”) is required, the test shall be performed prior to
priming and painting.

6. Field Testing
Leak testing of piping shall be performed after examination and repair are complete, and
before start-up.

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PIP PNSC0021
Specification for Leak Tests of Piping February 1998

6.1 Test Conditions

Before conducting any leak test, the conditions listed below shall be met:
a. Plant safety rules and personnel precautions shall be observed.
b. Temporary supports, blinds, spool pieces, and other preparatory items shall be
in place. All joints not previously tested under this specification shall be left
uninsulated. For a sensitive leak test, all joints and components other than
seamless pipe, seamless butt welding fittings, and forged fittings and valves
not previously tested under this specification shall be left uninsulated and
unpainted.
c. Items to be excluded from test shall be removed or blanked.
d. Hydrotest stops in spring hangers and supports shall remain in place during the
hydrotest.
e. If ambient temperature is not above 40° F (4 C), the Company Representative
must specifically approve the test procedure of hydrostatic (“H”), pneumatic
(“P”), or service (“F”) tests, considering the need to drain the piping before it
freezes. Testing shall not be performed at an ambient temperature below the
design minimum temperature for carbon and low alloy steel piping. See Code,
Para. 301.3.1 and Para. 323.

6.2 General Requirements

The Test Symbols listed in the following paragraphs are used to indicate the type of
leak test(s) required for each pipeline and/or test loop:
6.2.1 Preliminary Test Preparation
The following requirements apply to all leak tests.
1. A pressure gauge shall be provided at the low point of the test loop.
The gauge shall have a dial scale  4-1/2 in. (110 mm) diameter, a
range such that the test pressure is within 40-80 percent of full scale,
and accompanied by documentation showing it is calibrated within 2
percent at full scale reading.
2. Piping designed for vapor or gas operation shall have temporary
supports, if designated by the Company Representative, to support the
weight of the test liquid.
3. Expansion joints shall be tested in accordance with the Code, or as
described by the Company Representative.
4. The limits of the piping to be tested shall be described by the
Company Representative.
5. If at any time the person(s) conducting the test is not in attendance, the
pressure shall be reduced below design pressure.
6. Each joint (weld, flange, packing gland, threaded or other joints) not
previously examined for leaks according to this specification, shall be

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 PIP PNSC0021
February 1998 Specification for Leak Tests of Piping

examined. Repairs shall be in accordance with Para. 345.2.6 of the

Code.

6.3 Test Symbol “B”

A Sensitive Leak Test requires:
6.3.1 The Company Representative shall specify the sequence of tests and any
required additional cleaning or drying for each pipeline.
6.3.2 The test pressure shall be as specified by the Company Representative.
6.3.3 The Test Contractor shall provide, and the Company Representative shall
approve a written, qualified procedure, and evidence of operator
qualifications for each type of leak test, in accordance with BPV Code,
Section V, Articles 1 and 10.
6.3.4 An acceptable bubble formation solution, that produces an adherent and
persistent film shall be used.
6.3.5 The piping to be tested shall be fully in place, ready for operation. Painting,
insulation, removal of temporary supports, etc. shall be completed after the
sensitive leak test has been successfully completed.
6.3.6 Initially pressurize to 25 psig (170 kPa) or half the test pressure, whichever
is less, make a preliminary check for leaks and repair any that are found.
6.3.7 Raise the pressure in steps of 25 percent of test pressure or 25 psig (170
kPa), whichever is greater, holding for one minute at each step. Repeat the
check for leaks, repairing any found, until test pressure is reached, at which
time a final check of all joints shall be made.
6.3.8 Application of bubble solution to welds and to threaded, flanged, and other
joints by a technique which minimizes initial bubbles in the solution shall be
made. Application of tape to the perimeter of the flanges and checking leaks
through a punched hole is one method to check flanges.

6.4 Test Symbol “H”

A Hydrostatic Test requires that:
1. Water from a source approved by the Company Representative as test liquid.
See also Section 7.4.2.
2. Fill piping with vents open; close the vents after piping is air-free.
3. Drain the system after the test, with vents open, through lines or hoses leading
to a discharge or recovery point acceptable to the Company Representative.
4. Stainless steel systems may require special flush or drying procedures to avoid
chloride concentration.
5. Water used for hydrotesting testing shall be free of suspended solids and
biologically inert. Chlorination at a level of 0.2 to 1.0 ppm is recommended to
prevent biological attack.

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PIP PNSC0021
Specification for Leak Tests of Piping February 1998

6. Water for hydrostatic testing in stainless steel piping shall contain not over 50


ppm of chloride (Cl ) ion.
7. Water temperature shall not be less than 40 F (4 C) nor greater than 140 F
(60 C). The preferred water temperature range is between 60 F (16 C) and
100 F (38 C).

6.5 Test Symbol “H1”

6.5.1 Test Symbol “H1” is the same as Test “H” except that the test fluid shall be
specified by the Company Representative.
6.5.2 The liquid shall be nontoxic, noncorrosive, and otherwise noninjurious to
human tissue, the piping, and the environment, as determined by the
Company Representative. If flammable, flash point shall be 140 F (60 C);
and suitable precautions shall be taken against ignition and spread of fire.

6.6 Test Symbol “P”

A Pneumatic Test requires:
6.6.1 A written procedure shall be prepared for each test loop, approved by the
Company Representative including:

Minimum piping temperature during the test

Method of limiting access to the area in which the piping is being
tested

Stored energy in the system when at the maximum test pressure
6.6.2 Compressed air shall be dry (-40 C dew point) and free of oil, dirt, and
other foreign matter. Other nonflammable gases (e.g., dry nitrogen) may be
used with the Company Representative's approval.
Precautions shall be taken against asphyxiation if gas could be released in a
confined area.
6.6.3 Drain water and condensate before testing; pressurize with vents and drains
closed.
6.6.4 A pressure relief valve shall be provided in the test loop. The set pressure
shall be test pressure + 50 psig (345 kPa) or test pressure + 10 percent of test
pressure, whichever is the lower.
6.6.5 Initially pressurize the pipe to 25 psig (170 kPa) or one half the test pressure,
whichever is less, make a preliminary check for leaks and repair all that are
found.
6.6.6 Gradually increase pressure in steps to the test pressure. Hold at steps so that
piping strains are equalized. Reduce pressure from 110 percent of design to
design pressure, check for leaks, repair any that are found.
6.6.7 Regulated release of pressure after the test.

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 PIP PNSC0021
February 1998 Specification for Leak Tests of Piping

6.7 Test Symbol “F”

A Service test requires:
6.7.1 Fill piping with the service fluid (water or air may be substituted for liquid
or gas if necessary), as specified by the Company Representative. Vents
shall be open for liquid filling.
6.7.2 Closing the vents and pressurizing the piping using the source of pressure
normal for the service (or the same pressure using water or air).
6.7.3 Releasing any excess liquid or gas to an acceptable discharge point.
6.7.4 Test pressure shall be increased, and a preliminary check made, in steps in
accordance with the Code, Para. 345.7.2.

7. Preparation For Test

7.1 Define Test Loops

In most instances a single pipeline will be the test loop. In some cases, several
pipelines (and possibly equipment items, see Code, Para. 345.4.3) can be tested as a
unit. If there are in-line items (valves, sensors, relief valves, etc.) that cannot stand
the test pressure, decide whether to blind off (if flanged ends) and test each piping
segment separately, or replace items with a spool and test the whole pipeline.
Note: Gate, globe and check valve closures are generally capable of being tested
at a differential pressure of 110 percent of the valve body rating. Quarter turn valve
closures are frequently rated at still lower pressures. If the test pressure exceeds
the valve closure rating, the valve must be tested in the open position.

7.2 Painting and Insulation

7.2.1 For hydrostatic and pneumatic tests it is necessary to be able to examine
every threaded, bolted, and welded joint (excluding welds made by a piping
component manufacturer and any welds previously tested to this
specification by a manufacturer) for leakage. The insulation must be left off.
Joints may be painted except where a sensitive leak test is specified by the
Owner.
7.2.2 For a sensitive leak test, castings and factory welds (excluding 100 percent
radiographed welds) must be accessible for examination. Except for welds
prevously tested to this specification, both insulation and paint must be left
off.
Note: In some cases paint may have to be removed from pre-painted items.

7.3 Pneumatic Testing

Because of the high amount of stored energy, all joints must be checked for tightness
before commencing the test.

7.4 Other Preparation

7.4.1 Supports and Restraints

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PIP PNSC0021
Specification for Leak Tests of Piping February 1998

Expansion joints must be fitted with restraints designed for operation. Piping
for gas or vapor not designed to bear the weight of hydrostatic test liquid
shall be provided with added support. If additional support is not practical, a
pneumatic test may be used with the Company Representative’s consent.
7.4.2 Test Fluid Supply
a. Verify that water of adequate purity will be available in the quantities
needed for hydrostatic tests. Potable water may be acceptable even for
tests on stainless steel piping, but the chloride content shall not be
more than 50 ppm.
b. Any selected test liquid should be nontoxic and nonflammable, and an
acceptable means of recovery or disposal must be determined. A
combustible liquid with flash point
140° F (60 C) may be used, but
the potential losses from burning of the liquid must be considered.
Flammable liquids with a flash point < 140° F (60 C) are prohibited.
c. The air supply required for pneumatic test is equivalent to instrument
air.
Note: Do not assume that plant instrument air can be used unless agreement to that
effect has been reached with plant personnel. If long temporary air lines would be
needed, consider a portable compressor unit that can deliver the required air
quality and pressure. Alternatively, consider dry nitrogen in cylinders with
appropriate regulators but ensure it will not be released in a confined space where
it might cause asphyxiation.

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