REAFFIRMATION

November 2008

Process Industry Practices

Piping

PIP PNSC0021
Leak Testing of Piping Systems
 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.

This Practice is subject to revision at any time.

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

University of Texas at Austin, 3925 West Braker Lane (R4500), Austin,
Texas 78759. PIP member companies and subscribers may copy this Practice
for their internal use. Changes, overlays, addenda, or modifications of any
kind are not permitted within any PIP Practice without the express written
authorization of PIP.

PRINTING HISTORY
February 1998 Issued November 2008 Reaffirmation
February 2004 Complete Revision

Not printed with State funds

 REAFFIRMATION
November 2008

Process Industry Practices

Piping

PIP PNSC0021
Leak Testing of Piping Systems
Table of Contents

1. Introduction................................. 2
1.1 Purpose............................................ 2
1.2 Scope ............................................... 2

2. References .................................. 2
2.1 Process Industry Practices .............. 2
2.2 Industry Codes and Standards ........ 2

3. Definitions ................................... 2

4. Requirements.............................. 2
4.1 General Requirements..................... 2
4.2. Preparation for Testing .................... 3
4.3 Leak Tests ....................................... 6
4.4 Post-Leak Test Requirements ......... 9

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PIP PNSC0021 REAFFIRMATION
Leak Testing of Piping Systems November 2008

1. Introduction

1.1 Purpose
This Practice provides leak-testing procedures for piping designed and constructed to
ASME B31.3 Process Piping, hereinafter referred to as the Code.

1.2 Scope
This Practice describes the procedures, practices, and precautions to be used in leak
testing metallic and nonmetallic piping in accordance with the Code, and describes
requirements that are in addition to those of the Code.

2. References
Applicable parts of the following Practices, industry codes and standards, and references shall
be considered an integral part of this Practice. The edition in effect on the date of contract
award shall be used, except as otherwise noted. Short titles are used herein where appropriate.

2.1 Process Industry Practices (PIP)

– PIP PNE00012 – Piping Examination and Leak Test Guide

2.2 Industry Codes and Standards

• American Society of Mechanical Engineers (ASME)

– ASME B31.3 Process Piping (the Code)
– ASME Boiler and Pressure Vessel Code
Section V Nondestructive Examination (BPV Code, Section V)

3. Definitions
owner: The party who owns the facility wherein the leak-testing services will be provided

4. Requirements

4.1 General Requirements

4.1.1 Prior Work
Fabrication and/or installation, examination, and required cleaning shall be
complete and in accordance with the applicable specification.
4.1.2 Approval
The owner shall approve preparations for and witness all leak tests.
4.1.3 Acceptance Criteria
Piping that is free of leakage for the duration of the specified tests shall be
accepted.

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REAFFIRMATION PIP PNSC0021
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4.1.4 Report
A report shall be provided to the owner in accordance with the Code,
Paragraph (Para.) 345.2.7.
4.1.5 Repairs or Additions Following Leak Testing
Repairs or additions made following the leak test shall be tested in
accordance with the Code, Para. 345.2.6.
4.1.6 Exempt Piping
Leak testing of the piping system is not required for the following cases:
4.1.6.1 If postweld heat treatment (PWHT) is not required, attachment welds
of nonpressure-containing parts to pressure-containing parts that
have been previously tested
4.1.6.2 Piping that discharges directly to the atmosphere with a maximum
internal pressure not exceeding 10 psig (69 kPag)

4.2. Preparation for Testing

4.2.1 Define Test Loops and Procedures
4.2.1.1 Test diagrams and test procedures shall be prepared. They shall
include the limits of piping and equipment included in each test, test
pressures, test temperature, test fluid, line flushing requirements, and
safety precautions.
4.2.1.2 In most cases, to facilitate including as much piping as practical in
one test circuit, more than one pipeline will be included in the test
circuit. If there are in-line items (valves, sensors, relief valves, etc.)
that are not designed for the test pressure, it shall be decided whether
to blind off (if flanged ends) and test each piping segment separately,
or replace items with a spool and test the whole pipeline.
4.2.1.3 The effect of static head of the testing liquid shall be considered in
determining the effective test pressure of any elements within a
tested system.
4.2.2 Painting and Insulation
4.2.2.1 For hydrostatic and pneumatic tests, it is necessary to be able to
examine every threaded, bolted, and welded joint for leakage
(excluding welds made by a piping component manufacturer and any
welds previously tested to this specification by a manufacturer). The
insulation shall be left off. Joints may be painted except when a
sensitive leak test is specified by the owner.

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4.2.2.2 For a sensitive leak test, castings and factory welds (excluding 100%
radiographed welds) shall be accessible for examination. Except for
welds previously tested to this Practice, both insulation and paint
shall be left off.
Comment In some cases, paint may have to be removed from
prepainted items.
4.2.3 Test Fluid Supply
4.2.3.1 The availability of water of adequate purity in the quantities needed
for hydrostatic tests shall be verified.
4.2.3.2 For stainless steel piping, the chloride content shall not be more than
50 ppm.
4.2.3.3 Any selected test liquid shall be nontoxic and nonflammable, and an
acceptable means of recovery or disposal shall be determined. A
combustible liquid with flash point >= 140°F (60°C) may be used,
but the potential losses from burning of the liquid shall be
considered. Flammable liquids with a flash point < 140°F (60°C)
shall not be used.
4.2.3.4 The air quality required for pneumatic testing shall be equivalent to
instrument air.
4.2.4 Components
4.2.4.1 Components in new piping systems that interfere with filling,
venting, draining, or flushing shall not be installed until after line
flushing and pressure testing are completed. These components
include orifice plates, flow nozzles, sight glasses, venturis, positive
displacement and turbine meters, and other in-line equipment.
4.2.4.2 Pressure Gages and Recorders
1. Pressure gages and recorders shall be calibrated before the tests.
The calibration interval shall not exceed one year. Calibration
certificates shall be made available before commencement of the
pressure test. Stickers shall be applied indicating the latest
calibration date.
2. A pressure gage shall be provided at the low point of the test
loop. The gage shall have a dial scale > = 4-1/2-inch (110-mm)
diameter, a range such that the test pressure is within 40% to
80% of the full scale and accompanied by documentation
showing that it has been calibrated within 2% at full-scale
reading.
3. If large systems are tested, the owner shall determine the need
for additional gages.
4.2.4.3 Instrument take-off piping and sampling system piping up to the first
isolation block valve shall be pressure tested together with the piping
or equipment to which it is attached.

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4.2.4.4 Vents and Drains

1. Vents shall be provided at all high points in the tested system as
needed.
2. Excluding buried piping, drains shall be provided at all low
points in the system and immediately above check valves in
vertical lines.
4.2.4.5 Temporary Connections and Supports
1. Temporary connections shall be provided for depressurizing and
draining the system to the sewer or disposal area.
2. If required, temporary supports shall be installed before
hydrostatic testing and flushing of the piping. These supports
shall not be removed until after the system has been fully
drained. The structural support system shall be verified for
hydrostatic loads before testing.
3. 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 owner’s written consent.
4. A bleed valve shall be provided to protect the piping and
equipment from overpressure. The bleed valve shall be readily
accessible if immediate depressurization is required.
5. Expansion joints, spring hangers, and spring supports shall be
provided with temporary restraints if needed to prevent excessive
travel or deformation under the weight of the hydrotest fluid
loads.
4.2.5 Equipment Excluded from Pressure Test
The following list defines the equipment that shall be excluded from the test.
Other unlisted sensitive equipment or those designated by the owner may be
added:
a. Rotating machinery, such as pumps, turbines, and compressors
b. Strainers and filter elements
c. Pressure-relieving devices, such as rupture disks and pressure-relief
valves
d. Locally mounted indicating pressure gages, if the test pressure exceeds
the scale range
e. Instrument devices
f. Skid-mounted piping systems that have been successfully shop-tested

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Leak Testing of Piping Systems November 2008

4.2.6 Isolation of Test Sections

4.2.6.1 ASTM A-36 test blanks of a thickness suitable for the test pressure
shall be used to isolate the test sections. If test blanks are not
workable, closed block valves (gate, globe, plug, ball, etc.) can be
used to isolate equipment or piping sections provided that the valves
are not leaking. Otherwise, the spectacle plate/blind shall be installed
in the closed position. If closed block valves are used in lieu of
blinds, provision shall be made to ensure that no overpressure can
occur in the system that is not being tested because of a possible leak
through the valves.
4.2.6.2 If a block valve is used for isolating test sections, the differential
pressure across the valve seat shall not exceed the rated seat pressure.
4.2.6.3 An isolation valve shall be provided between the pressure-testing
manifold and the system that is being tested. The isolation valve
shall be rated for the manifold test pressure if in the closed position.

4.3 Leak Tests

Leak testing of piping shall be performed after examination and repairs are complete
and before start-up. Refer to PIP PNE00012 for the definition of the test symbols.
4.3.1 Test Conditions
Before conducting any leak test, the following conditions shall be met:
a. Plant safety rules and personnel precautions shall be observed.
b. An approved test procedure shall be available at the site before
commencing any pressure testing activities.
c. Temporary supports, blinds, spool pieces, and other preparatory items
shall be in place.
d. Items to be excluded from testing shall be removed or blanked.
e. Hydrotest stops in spring hangers and supports shall remain in place
during the hydrotest.
f. If ambient temperature is not above 40°F (4°C), the owner shall
specifically approve the test procedure considering the need to drain the
piping before it freezes. Testing shall not be performed at an ambient
temperature lower than the design minimum temperature for carbon and
low alloy steel piping. See the Code, Para. 301.3.1 and Para. 323.
4.3.2 General Test Procedures
4.3.2.1 Filling the System
1. Filling and pressurizing shall be done on the upstream side of
check valves in the system. If this is not possible, the check
valves shall either be removed or blanked off.
2. The test fluid shall be injected at the lowest point in the system
to minimize entrapped air.

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REAFFIRMATION PIP PNSC0021
November 2008 Leak Testing of Piping Systems

3. If filling at the lowest point is not practical, the owner shall be

consulted.
4. If the test fluid is liquid, all vents shall be open during filling.
4.3.2.2 After the test pressure is reached and before commencement of
inspection of the system, the isolation valve between the temporary
test manifold/piping and the piping/equipment under pressure test
shall be closed and the test pump disconnected.
4.3.2.3 During the application of the test pressure, all in-line valves (if not
used as test isolation valves) shall be in an open position with the
provision that double block and bleed valves with cavities shall be
kept only partially open to allow the cavity to be filled and
pressurized.
4.3.3 Test Symbol “B”
A Sensitive Leak (“B”) Test requires that:
4.3.3.1 The owner shall specify the sequence of tests and any required
additional cleaning or drying for each pipeline.
4.3.3.2 A written, qualified procedure and evidence of operator
qualifications for each type of leak test shall be provided in
accordance with BPV Code, Section V, Article 1 and Article 10 and
approved by the owner.
4.3.3.3 An acceptable bubble formation solution that produces an adherent
and persistent film shall be used.
4.3.3.4 The piping shall be initially pressurized to 25 psig (170 kPag) or
one-half the test pressure, whichever is less; and then preliminarily
checked for leaks and repaired if any leaks are found.
4.3.3.5 The pressure shall be raised in steps of 25% of test pressure or 25 psi
(170 kPa), whichever is greater, and held for 1 minute at each step.
The check for leaks shall be repeated, repairing any found, until the
full test pressure is reached. Then, a final check of all joints shall be
made.
4.3.3.6 Bubble solution shall be applied to welds and to threaded, flanged,
and other joints by a technique that minimizes initial bubbles in the
solution.
Comment Application of tape to the perimeter of the flanges
and checking leaks through a punched hole is one
method to check flanges.

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4.3.4 Test Symbol “H”

A Hydrostatic (“H”) Test requires that:
4.3.4.1 Water is used as test liquid and obtained from a source approved by
the owner.
4.3.4.2 Water temperature shall not be less than 40ºF (4°C) nor greater than
140ºF (60ºC). The preferred water temperature range is between 60ºF
(16ºC) and 100ºF (38ºC).
4.3.4.3 Water used for hydrostatic testing shall be free of suspended solids
and biologically inert. Chlorination at a level of 0.2 ppm to 1.0 ppm
is recommended to prevent biological attack.
4.3.4.4 The system shall be drained after the test, with vents open, through
lines or hoses leading to a discharge or recovery point acceptable to
the owner.
Comment: Stainless steel systems may require special flush or
drying procedures to avoid chloride concentration.
4.3.5 Test Symbol “H1”
4.3.5.1 The requirements for Test Symbol “H1” are the same as for Test
Symbol “H” except that the test fluid shall be specified by the owner.
4.3.5.2 The liquid shall be nontoxic, noncorrosive, and otherwise
noninjurious to human tissue, piping, and the environment as
determined by the owner.
4.3.5.2 If flammable, the flash point shall be >140ºF (60°C) and suitable
precautions shall be taken against ignition and the spread of fire.
4.3.6 Test Symbol “P”
A Pneumatic (“P”) Test requires that:
4.3.6.1 A written procedure shall be prepared for each test loop. The
procedure shall be approved by the owner including:
a. Minimum piping temperature during the test
b. Method of limiting access to the area in which the piping is
being tested
c. Stored energy in the system when at the maximum test pressure
4.3.6.2 Pneumatic testing with air of piping systems that have been in
flammable service shall include procedures to avoid explosive
flammable air mixtures.

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4.3.6.3 Compressed air shall be dry (-40ºF [-40ºC] dew point) and free of
oil, dirt, and other foreign matter. Other nonflammable gases (e.g.,
dry nitrogen) may be used with the owner's approval.
Comment: Precautions shall be taken against asphyxiation if
gas could be released in a confined area.
4.3.6.4 The water and condensate shall be drained before testing.
4.3.6.5 The piping shall be pressurized with vents and drains closed.
4.3.6.6 A pressure-relief valve shall be provided in the test loop. The set
pressure shall be test pressure + 50 psi (345 kPa) or test pressure +
10% of test pressure, whichever is the lower.
4.3.6.7 The piping shall be initially pressurized to 25 psig (170 kPag) or
one-half the test pressure, whichever is less; and then preliminarily
checked for leaks and repaired if any leaks are found.
4.3.6.8 The pressure shall be gradually increased in steps to the test
pressure, and the pressure shall be held at each step so that piping
strains are equalized.
4.3.6.9 The pressure shall be reduced from 110% of design to design
pressure. Checks for leaks shall be made, and repaired if any are
found.
4.3.6.10 The release of pressure shall be regulated after the test.
4.3.7 Test Symbol “F”
A Service (“F”) Test requires that:
4.3.7.1 Piping shall be filled with the service fluid as specified by the
owner. Vents shall be open for liquid filling.
Comment: Water or air can be substituted for liquid or gas if
necessary.
4.3.7.2 The vents shall be closed and the piping shall be pressurized by
using the source of pressure that is normal for the service.
Comment: Use the same pressure if water or air is substituted.
4.3.7.3 Any excess liquid or gas shall be released to an acceptable
discharge point.
4.3.7.4 Test pressure shall be increased, and a preliminary check made, in
steps in accordance with the Code, Para. 345.7.2.

4.4 Post-Leak Test Requirements

After leak testing has been successfully completed and the results approved by the
owner, the following operations shall be carried out:

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PIP PNSC0021 REAFFIRMATION
Leak Testing of Piping Systems November 2008

4.4.1 Draining of Test Fluid

The pressure shall be released and the system shall be drained from the
downstream side of check valves. All vents shall be opened before draining
to facilitate drainage and to prevent the formation of a vacuum. No test fluid
shall remain in low points.
4.4.2 Disposal of Test Fluid
The test fluid shall be disposed of as directed by the owner.
4.4.3 Test Vents and Drains
Vents and drains used only for the pressure test shall be removed and the
connections permanently sealed.
4.4.4 Removal and Reconnection of Components
1. All temporary items installed for testing purposes (e.g., manifolds,
valves, blinds, spacers, and supports) shall be removed.
2. Items that were removed for testing shall be reinstalled.
3. Items, such as instrument air tubing, etc., which were disconnected
before testing shall be reconnected.
4. Isolation valves that were closed for the test and that are required to be in
the open position for process reasons shall be opened. If the valve cavity
has a drain, the cavity shall be drained.
5. Paddle blinds and spectacle blinds shall be removed.
4.4.5 Pickling
If required, piping shall be pickled after the hydrostatic test.

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