Hydrotest and Pneumatic Test of Piping Systems-

Hydrotest Vs Pneumatic Test (With PDF)

whatispiping.com/hydrotest-vs-pneumatic-test/

Anup Kumar Dey December 1, 2019

A pressure test is always required for a new pressure system before use or an
existing pressure system after repair or alteration  to ensure the following:  

Safety
Reliability of operation
and leak tightness of pressure systems
Also The last physical quality test in the fabrication process

Subsequent to repairs and heat treatment and prior to initial operation or

commissioning of any plant it has to be ensured that there is no evidence of
leakage by Pressure Testing.

Types of Pressure Testing

In the process Industry, two methods are widely used for pressure testing of piping or
equipment. They are

hydro-static test or Hydrotest and

pneumatic test

What is Hydro-Test or Hydrostatic Test?

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Hydro test or Hydrostatic test is a type of pressure test performed on piping and
pressure vessels to check system integrity under pressure conditions. A
hydrostatic test is performed by using water as the test medium.

What is the Pneumatic Test?

The pneumatic test is a type of pressure test for checking system integrity under
the pressurized condition and applied to systems where the hydro-static test is
difficult to apply. A pneumatic test uses air, nitrogen, or any non-flammable and
non-toxic gas.

Pressure tests (both hydrostatic and pneumatic) must always be performed under
controlled conditions, following an approved test plan, and documented in a test record. A
single approved test plan could be used for several similar tests, but for each test a
separate test record is required.

When to perform a Pressure Test

As per the governing code, a pressure test has to be performed on the piping system
after all hot works have been completed on a certain piping system. Here the term hot
work means everything related to welding or the post-weld heat treatment (PWHT).
PWHT also has the potential of degrading the mechanical properties of piping, in case not
addressed properly. And this is the reason why code calls for NDT after PWHT operation.

In case after carrying out pressure testing, some modification has to be made requiring
hot work, it calls for a retest as per code. Here code specifies that the minor
repairs/modifications may be waived off provided adequate measures have been taken to
ensure sound construction. Now taking this decision as to which repairs or modifications
may be waived off should be taken very carefully. Normally, the maximum extent of
repairs not requiring retesting shall be the tack welding of any piping support or pad.
Anything else shall be done following a retest.  

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Pressure testing and conducting 100% radiography or ultrasonic inspection shall not be
interchanged. In case carrying out of hydrostatic or pneumatic test stands impractical
then 100% radiography or ultrasonic testing may be performed but in addition to this it is
advisable to check that the whole piping and its components have been supplied against
acceptable ASTM standards and required test certificates are available.

Conducting 100% radiography of all the weld joints assure that your weld
joints are defect-free but can never provide you with the assurance of
mechanical integrity of a system.

This is also to be noted that radiography / ultrasonic inspection shall also not be waived
off if the pipeline is to be hydrostatically tested. This may pose an additional safety risk
during the test. Moreover, some defects in the weld zones may prove to be detrimental
way after being taken in service due to severe extended service conditions.  

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Comparison of Hydrostatic and Pneumatic Testing
The following table lists down the major differences between hydrostatic and pneumatic
testing.

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Hydrostatic Testing Pneumatic Testing

Hydrostatic test pressure is normally 50% Pneumatic test pressure is normally

higher than the design pressure. 10% higher than the design
pressure

Hydrotest is recommended for high-pressure A Pneumatic test is recommended

applications. only for low-pressure applications.

In a hydro test, the test media (Water) used In a pneumatic test, the test media,
is not compressible by pressure application. Air is compressible by pressure
application.

In hydrostatic testing, the energy stored per The energy stored per unit volume
unit volume of water under test pressure is of compressed air under test
negligible. pressure in the case of a pneumatic
test is very high.

Needs thorough cleaning after the Easy to clean after pneumatic

hydrostatic test to eliminate moisture testing.
especially for services that are reactive to
moisture/fluids.

Pressure Relief devices are usually Pressure relief devices are a must
recommended to control a sudden increase during the pneumatic test to ensure
in pressure during hydro testing. no over-pressurization.

Chances of equipment/ Pipe/test apparatus Chances of equipment/ Pipe/test

failures are very low during hydro testing. apparatus failures are high during
pneumatic testing.

Weight of equipment along with hydro test Weight of equipment with the
medium as water is high hence special pneumatic test medium as air is
attention should be given to floor and comparatively less.
supporting arrangements.

Needs verification and examination of joints Needs very careful checking of

and connections before testing. weld joints thoroughly before
testing.

In hydrostatic testing, the test media can be In pneumatic testing, the test media
reused or transferred to other places after can not be reused or transferred to
testing. other places after testing.

Skilled and semi-skilled personnel can carry Needs involvement of senior

out the test. experienced staff to monitor the
test.

Recommended where large volumes are to If pipelines are tested should be

be tested at the same time (example done with small segmental lengths
pipelines). at a time.

Damages made by failures are less Damages made by failures in

compared to failures in pneumatic testing. testing are very huge and extensive
as compared to hydrostatic testing.

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 Hydrotest is a regular day-to-day practice Needs special attention and safety
and safe procedure and it can be followed in precautions for performing a
any worksite. pneumatic test.

Pressure changes finite amount by an The pressure change is

infinitesimal change in volume. proportional to volume change.

Table: Hydro Test vs Pneumatic Test

Difficulties with hydrostatic testing

Supply & disposal of water, disposal of fluid additives
A water leak can cause equipment damage
Freeze susceptibility
Structural support limitations
Contamination
Operational impacts – process contaminant
Affect dry-out of internal refractory linings

Difficulties with Pneumatic testing

Pneumatic tests are potentially more dangerous than hydrostatic tests because of
the higher level of potential energy stored during compressing the gas. Care must
be exercised to minimize the chance of brittle failure during testing by initially assuring the
system is suitable for pneumatic testing.

Pneumatic tests could be performed only when at least one of the following conditions
exists:

When the systems are designed in such a way that it cannot be filled with water.
When the systems are such that it is to be used in services where traces of the
testing medium cannot be tolerated.

Using a pneumatic test instead of hydrostatic requires approval from proper

authority or body.

How to calculate Hydrotest Pressure? | Hydrostatic Test Pressure

Calculation
ASME Code B 31.3 provides the basis for test pressure. The minimum hydrostatic test
pressure for metallic piping shall be as per the following equation:

Pt=1.5*Pd*(St/Sd)

Here,

Pt=minimum test gauge pressure

Pd=internal design gauge pressure

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St=allowable stress value at the test temperature
Sd=allowable stress value at design temperature.

The maximum allowable value of St/Sd is 6.5

How to Calculate Pneumatic Test Pressure? | Pneumatic Test Pressure

The pneumatic test pressure shall be as per the following equation:

 Pt=1.1*Pd

The Basis for Pressure Test Method Selection

Normally the following basis is followed in the process piping industry for the selection of
hydro or pneumatic tests.

1. If the fluid handled by the piping system is liquid then the pipe must be hydro
tested.
2. If the fluid handled is vapor or gas then the internal design pressure dictates
the testing method. For pipe design pressure 10 bar and above the pipe is
hydro tested. For pipe design pressure below 10 bar pipe is pneumatically
tested.
3. If fluid handled is steam then hydro testing is suggested.
4. If the fluid handled is two-phase flow then hydro testing is suggested.
However, for big size flare headers, pneumatic testing is performed.

Hydrostatic Test Duration

Normally every EPC company has its own standard for the duration of tests. However, the
recommended practice is that a QC inspector has to walk through the whole piping
system and check for leaks. Every single length of piping, welds, bolted connections shall
be visually examined for any leakage. The duration of this activity varies with the span of
the piping system. For a larger piping system time taken for this activity is enough to clear
the pressure test. In the case of a piping system having a smaller span, 1 hour time may
be made as standard practice for hydrostatic testing. For the Pneumatic test, the test time
is far lesser.

Few important points to consider while hydro-testing:

The tower overhead lines which are normally hydro tested shall be decided by
stress engineer group whether to hydro test after erection or at grade, based on the
capacity of standard clip available as per engineering specification for pipe
supports.
During the hydro test in case of big-bore, it should be decided first that line is to be
hydro tested on rack or grade if the hydro test is done on the rack, the hydro test
load should be considered in case of vapor lines while providing structure/rack
loading information.

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Hydrotest Fluid
As the name signifies, the test has to be performed using clean potable water free from
suspended solids. However different codes specify different requirements for water
quality. Hence, hydro tests need to be performed following those instructions.

Hydrotest System Preparation

The piping network and the connected equipment must be prepared thoroughly before
proceeding for pressure tests like hydro or pneumatic testing. Codes like ASME B31.3/
ASME B 31.1 and local company instructions normally provide guidelines for such
preparation.

Piping systems that are normally open to the atmosphere, such as drains, vents,
discharge piping from pressure-relieving devices, sewers, and stack downstream of the
seal drum, need not be subjected to the piping test pressure.

For some
countries, The provincial local inspector shall be notified at least 48 hours
in
advance of pressure testing of piping under the jurisdiction of the
provincial safety code
for witnessing at his/her option.

The following equipment shall be excluded from all piping pressure tests:
Vessels and tanks
Heat exchangers
Rotating machinery, such as pumps, compressors, and turbines
Equipment and Supplier furnished piping specifically recommended by the
manufacturer not to be tested

Underground
portions of piping systems may be tested and covered before testing
aboveground
portions.

Roughly, The
following steps should be followed for preparing the piping system for
leakage
testing.

Comparison of P&ID/PEFS and Isometric Drawing

The first step is to compare the piping isometrics with the P&ID drawings to check if any
discrepancy exists. All valve types, flow directions, branch tie-ins, and any material
changes, etc are reviewed thoroughly. In-line components are verified and ensured that
they are able to withstand the test pressure.

Thorough Inspection before testing

All sorts of ultrasonic and radiographic inspections or checks must be carried out before
the actual pressure test is started. Conducting 100% radiography of all the weld joints
assure that your weld joints are defect-free but can never provide you with the assurance

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of mechanical integrity of a system. This is also to be noted that radiography / ultrasonic
inspection shall also not be waived off if the pipeline is to be hydrostatically tested.

Joints shall be exposed

All joints, welds (including structural attachment welds to pressure-containing
components), and bonds shall be left uninsulated and exposed for examination during
leak testing as per Section 345.3.1 of ASME B31.3, except that joints previously tested in
accordance with this Code may be insulated or covered.

Provision of Temporary Supports

If required Pipings designed for vapor or gas services shall be provided with additional
temporary supports, to support the weight of test liquid as the test liquid is heavier than
service fluid.

Spring Supports in Piping System

All Spring supports shall be kept in locked condition during hydrostatic testing. Holding
pins shall not be removed from spring supports until testing is completed and the system
is drained. Care shall be taken to avoid overloading any parts of the supporting structures
during hydrostatic testing.

Instruments
All in-line Instruments shall be either removed or blocked prior to hydro testing to
prevent damage during hydro testing (e.g. meters).
Instrument take-off piping and sampling system piping, up to the first block valve,
shall be tested with the piping to which it is connected.
Instrument lead lines, between the first block valve and the instruments to which
they are connected, shall be pressure tested to the test pressure of the associated
piping. Testing may be performed separately or at the same time as the piping is
tested, but the instruments shall be disconnected.

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 A sample figure showing hydro-testing scheme

Hydrotest for Piping with Expansion Joints

If there is an expansion joint in the piping system under the leakage test, the following
criteria shall be applied.

1. An expansion joint that depends on external main anchors to restrain pressure end
load shall be tested in place in the piping system.
2. A self-restrained expansion joint previously shop-tested by the manufacturer
3. A piping system containing expansion joints shall be leak tested without temporary
joint or anchor restraint at the lesser of
4. 150 % of design pressure for a bellows-type expansion joint, or
5. the system test pressure determined in accordance with para. 345

In no case shall a bellows-type expansion joint be subjected to a test pressure

greater than the manufacturer’s test pressure.

When a system leak test at a pressure greater than the minimum test pressure
specified in (c), or greater than 150% of the design pressure within the limitations of
para. 345.2.1(a) is required, bellows-type expansion joints shall be removed from
the piping system or temporary restraints shall be added to limit main anchor loads
if necessary.

Limits of Tested Piping

Equipment that is not to be tested must be either disconnected from the piping or isolated
by blinds or other means during the test. A valve may be used provided the valve is
suitable for the test pressure.

Rotating Machinery

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For rotary machinery, such as pumps, compressors, or steam turbines,  have lube and
seal oil systems that could be impaired by the presence of water. These systems shall not
be subjected to the piping test pressure.

Test Water
Clean water that will not corrode and/or damage the test system shall be used for
hydrostatic tests. If municipal water is not available, supply water may be obtained from a
native water supply. Water containing silt or suspended material shall not be used, and a
suitable filter with 40 mesh should be provided in the filling line. A mixture of glycol-water
shall be used where the ambient temperature may reach less than 0°C (32°F) during
testing or prior to dry-out

Temporary Spades and Blanks

If Temporary spades and blanks are installed for testing purposes, those must be
designed to withstand the test pressure without distortion. The presence of spades shall
be clearly visible during testing. The recommended practice is to use standard blind
flanges as per ASME B16.5 or B16.47 and spades acc. to ASME B16.48.

Check Valves

Check Valves shall have the piston or flap removed for testing,  where pressure can not
be located on the upstream side of the valve. The locking device of the flap pivot pin shall
be reinstated together with the flap and a new cover gasket shall be installed after
completion of the test.

Completion of Hot Work

Wherever applicable All hot works, related to welding or the post-weld heat treatment
have to be completed before the Hydrostatic test.

Installation of Barriers
It is necessary to install safety barriers around the piping system under test prior to
starting pressurization related to testing. Public Address announcements and access
restriction procedures such as permits to work shall be implemented. Under no
circumstances should anyone other than an authorized person be allowed within the
safety barriers.

Control Valves

Prior to the leakage test, Control Valves and soft-seal block Valves shall be removed from
the piping and replaced with pipe spools. However, All welded Valves need to be tested
along with pipings otherwise Radiographic Testing of golden joints (welded) will be
required.

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Physical Inspection

Prior to the pressure test following should be checked :

All gravity supports installed.

Proper pipe routing.
Vents or other high point connections shall be opened to eliminate air from and
plugged during the test.
lines that are to receive a hydrostatic test.
Completed and torqued flanges with no missing bolts or gaskets.
Proper material type verified using color codes or markings, and heat numbers
recorded if required by the codes.
Correct valve type and orientation.
Vents and drains installed to allow proper filling and draining
When a pressure test is required to be maintained for a period of time during which
the testing medium in the system would be subject to thermal expansion, the
provision shall be made for the relief of any pressure greater than the maximum test
pressure.
All required piping stress relief, weld examinations, and welding documentation
completed and acceptable. A relief valve to be added such that the test pressure is
not exceeded beyond a safe amount.
When conducting tests at freezing temperatures, the test shall not take more than 4
hours, and special precautions, such as using glycol/water mixture, shall be
observed to avoid freezing damage

Hydrotesting Documentation
The individual system documentation i.e. test pack shall be available prior to any testing
and shall include information such as test limits, test pressure, test medium, duration, test
blinds, blind flanges, vents, and drains.

The use of marked-up P&IDs coupled with isolation registers should be utilized to identify
the locations of blinds, Valves, vents, and drains.

Records shall be
made of each piping system test. In general, these records shall include
the
following information:

Date of test
Identification of piping system
Test medium
Test pressure
Minimum ambient temperature
Test medium temperature
Certification by examiner
Test duration
Pipe standards or
specifications for the test

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 Pressure and temperature
recording charts and logs
Location and cause of
leaks/failures
Repair procedures used in the
event that the pipe leaked of failed
Test results
Name of test operator
Minimum metal temperature (if
applicable)
Test gauge calibration date

Forms, when
completed, shall be retained in the Construction Contractor’s QC file as a
permanent record.

Hydrostatic Testing Equipment

Testing equipment such as pumps, manifold, pressure, and temperature recorders,

pressure gauges should be within calibration/certification (as per company procedures)
and connected to the lowest convenient connection within the system to ensure the best
results.

Hydrostatic Testing Problems

Even though proper industry-approved methods are followed for pressure testing, still due
to some negligence hazards do happen. Some of the most common reasons for failures
during hydro tests and pneumatic tests are:

Over pressurization
Operator error
Inadequate equipment
Poor component design
Improper isolation of the tested system from equipment or remaining parts of the
system.
Inadequate repairs

So it is always a good idea to follow safe work practices for Hydro testing. The below-
mentioned steps can be followed to avoid hazards of Pressure Testing:

Prepare a standard operating procedure (SOP) for the hydro test or pneumatic test
following the latest applicable code
Developing a checklist using the sop and sticking to it.
Train the involved personnel indicating the potential hazards and safety measures.
Develop a Pre-test safety plan and conduct a pre-test safety briefing just prior to
hydro testing.
Perform a Walk down inspection following the checklist to ensure all hydro test
checkpoints are taken care of.
After the hydrostatic test, gradually release the pressure and drain the system.

Hydrotest Checklist

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The following section provides a sample of the hydro test checklist to inform the major
points that must be considered.

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  Hydrotesting Checklist      

  Pre HydroTest Checklist      

Sr Description Complied Not Remarks

No Complied

1 All Affected people like Owner,      

Managers, Workers, Suppliers, informed

2 Test pressure and duration received or      

estimated

3 Standard Operating Procedure identified      

4 Pre-test safety plan completed      

5 Required workers properly trained      

6 Test Equipment inspected, calibrated,      

and certified

7 Test Temperature verified      

8 Test area barricaded and warning signs      

posted to keep non-essential members
outside the hydro-test zone

9 Walk down inspection performed      

10 Hydrotest system preparation proper      

11 Vent Valve, Block Valve closed      

12 All joints exposed, No insulation      

13 System parts properly aligned      

14 Torque on bolted connections as per      

manufacturer guidelines

15 Lockout tag-out finished as per      

guidelines

16 Emergency contact information      

collected

17 proper isolation from equipment and      

non-test parts following SOP performed

18 Pressure relief valve installed      

  Checklist during Hydrotest      

19 Hydrotest equipment properly installed      

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 20 Working professional with all PPE      
equipment

21 Pressure applied gradually following      

work procedure/standards

22 Pressure maintained for the pre-decided      

time duration

23 All exposed joints are thoroughly      

checked for leakage potential.

  Post-Hydrotest Checklist      

24 Repairs started after the release of      

Hydrotest Pressure.

25 Pressure is released gradually.      

26 Water disposed of as per procedure      

27 Repairs performed following procedures      

Table: Hydrotest Checklist

Frequently Asked Questions | Hydrotest FAQs

What is the difference between the Hydro test and the Hydrostatic test?

Both hydro test and hydrostatic test refers to the same pressure test method. Hence, both
are the same and there is no difference between Hydrotest and Hydrostatic test.

What is the Hydrotest pressure for Pipeline?

The hydrostatic test pressure considered for pipeline systems is 1.25 times the design
pressure.

How is the Hydrostatic test done?

A Hydrostatic test is done by filling the system with water and then pressurizing it to hydro
test pressure (usually 1.5 times of design pressure). The pressurized system is kept for a
predecided time and then visually all joints are checked for any leakage.

Can a Hydrostatic test cause damage?

Yes, a hydrostatic test can cause damage. Some examples of hydro test hazards are
provided here.

What is the safest type of Pressure Testing?

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Hydrostatic testing is the safest type of pressure testing as it generated considerably less
stored energy which in turn involves less risk to workers.

Is a Hydrostatic test mandatory?

Most of the codes and standards prefer to use hydro testing as the best method for
pressure integrity checks. However, in some situations, the hydrostatic test may be
avoided. An example is a golded joint.

A golden joint is usually the final joint to weld the new pipe with the existing pipe.
As the Hydrostatic test is usually not feasible, NDE (ultrasonic or radiographic test)
is performed in place of pressure testing.

How long should a pressure test last?

It depends on various factors like the governing codes, standards, and local procedures;
length of the system, number of joints to check, etc. Usually, the system should be
pressurized for a least 10 minutes.

Video Tutorial on Differences between Hydrostatic test and

Pneumatic test
The following video tutorial explains the major differences between the Hydrostatic test
and the Pneumatic test.

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