The Pressure Equipment Safety Authority

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the pressure equipment safety authority

Standard Pneumatic TestProcedure Requirements

AB-522Edition 1, Rev. 1 - Issued 2011-03-28Standard Pneumatic Test Procedure RequirementsIssued 2011-03-28 AB-522 Edition 1 Revision 1

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Table of ContentsFOREWORD...................................................................................................................11.0 INTRODUCTION ..................................................................................................12.0 SCOPE .................................................................................................................13.0 DEFINITIONS .......................................................................................................24.0 GENERAL ............................................................................................................2

5.0 QUALITY SYSTEM REQUIREMENTS.................................................................36.0 STORED ENERGY LIMITATION FOR A STANDARD PNEUMATIC TESTPROCEDURE.......................................................................................................37.0 PROCEDURE.......................................................................................................4REFERENCE PUBLICATIONS.......................................................................................5APPENDIX I ....................................................................................................................6APPENDIX II ..................................................................................................................7APPENDIX III ..................................................................................................................9APPENDIX IV..................................................................................................................9REVISION LOG.............................................................................................................11Standard Pneumatic Test Procedure Requirements

Issued 2011-03-28 AB-522 Edition 1 Revision 11 of 11

FOREWORDThis AB-522 Pneumatic Test Procedure Requirements document, has been issued bythe Alberta pressure equipment safety Administrator, to specify the quality managementsystem and minimum procedure requirements for organizations seeking acceptance ofpneumatic testing of pressure piping in accordance with section 30(2) of the PressureEquipment Safety Regulation (PESR).Dr K T Lau, PhD., P. Eng.Chief Inspector and Administrator

1.0 INTRODUCTION

This document outlines the quality management system and minimum procedurerequirements for Alberta authorized organizations (an organization that holds acertificate of authorization permit to construct pressure piping) seeking acceptance ofpneumatic testing of pressure piping in accordance with section 30(2) of the PressureEquipment Safety Regulation (PESR). Acceptance of pneumatic testing of pressurepiping may be on a case-by-case basis or may be permitted when the test is conductedin accordance with a standard pneumatic test procedure in accordance with theauthorized organizations quality management system. A standard pneumatic test


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procedure must include stored energy limitations established in accordance with thisrequirements document.Owner-users (i.e., AQP-8XXX series Certificate of Authorization holder) are directed to

ABSA publication AB-519 Pressure Piping Alternative Test Methods ProcedureRequirements document.

Persons considering pneumatic testing are cautioned that pneumatic pressure testing isgenerally considered to be inherently more hazardous than a hydrostatic test of thesame conditions of volume, pressure and temperature. Appropriate safety precautionsmust be taken.

2.0 SCOPEThe requirements in this document apply to pressure testing of pressure piping in

Alberta by an organization that holds a certificate of authorization permit to constructpressure piping.Standard Pneumatic Test Procedure RequirementsIssued 2011-03-28 AB-522 Edition 1 Revision 1 Page 2 of 11

3.0 DEFINITIONSAlberta Quality Program (AQP): Quality program registered with ABSA that covers adefined scope such as piping fabrication, vessel fabrication, etc and has been reviewedand accepted by an ABSA Safety Codes Officer.Hydrostatic Test:A pressure or tightness test where liquid, typically water, is the testmedium.Design Pressure: The pressure authorized on the design registration.DMT: Design Minimum Temperature.MAWP: Maximum Allowable Working PressurePCC-2: Post Construction Committee document produced by an ASME ad hoccommittee to identify generally accepted engineering standards for the inspection andmaintenance of pressure equipment after it has been placed in service.Pneumatic Test:A pressure or tightness test where a gas, generally nitrogen or air, isthe test medium.Pressure Equipment Safety Regulation (PESR):Alberta regulation issued under theSafety Codes Act.Pressure piping system: means pipes, tubes, conduits, fittings, gaskets, bolting andother components that make up a system for the conveyance of an expansible fluidunder pressure and may also control the flow of that fluid.Pressure vessel: means a vessel used for containing, storing, distributing, processing orotherwise handling an expansible fluid under pressure.Safe Distance: The minimum distance between all personnel and the equipment beingtested.Safety Codes Officer: means a safety codes officer, designated under the Act, in the

pressure equipment discipline.

4.0 GENERALLeak testing of piping is required as part of the fabrication process. Leak testing mayalso be required following repairs.Standard Pneumatic Test Procedure RequirementsIssued 2011-03-28 AB-522 Edition 1 Revision 1 Page 3 of 11

Section 30 of the Pressure Equipment Safety Regulation states30(1) All pressure piping leak tests must be conducted using the hydrostatic method.


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30(2) Despite subsection (1), the Administrator may accept, for a specific pressurepiping system, alternative test methods that are allowed in a code or standard that isdeclared in force.30(3) A pressure piping system shall not be tested at a temperature that is colder thanits minimum design temperature.

30(4) When conducting pressure tests, the ductile-to-brittle transition temperature andthe possibility of brittle fracture must be considered by the contractor.The hydrostatic test method is the mandated and preferred method of pressure testing.Hydrostatic testing presents a much lower safety hazard associated with the storedenergy compared to pneumatic testing. If it is not possible to perform a hydrostatic test,alternative testing may be considered, and the organization responsible for the testmust justify to, and seek acceptance from, ABSA for the alternative test. Appendix I, ofthis document, contains a flow chart showing when a pressure test procedure must besubmitted to ABSA for review and acceptance.This requirements document applies to pneumatic testing of pressure piping systems. Itis acceptable to conduct a pneumatic test of a pressure piping system that includes a

pressure vessel providing: the vessel has been previously tested, the MAWP of thevessel is greater than or equal to the piping design pressure, and the volume of thevessel is included in the stored energy calculations for the pneumatic test.

5.0 QUALITY SYSTEM REQUIREMENTSRefer to ABSA publication AB-518 Pressure Piping Construction Requirementsdocument for detailed quality system requirements.If pneumatic testing is to be undertaken, the quality management system manual mustdescribe the procedures to be followed to conduct the test in a safe manner. Provisionfor pneumatic testing of piping systems up 1677 kJ of stored energy (equivalent to 500liters internal volume and 2172 kPa internal pressure) may be included as a standardtesting procedure in the quality system. ABSA s acceptance of the testing procedure

can be obtained during the quality system audit. For piping systems exceeding thepneumatic test limits specified in the quality system, procedures must be prepared foreach pneumatic test and ABSA s acceptance secured prior to conducting the test.

6.0 STORED ENERGY LIMITATION FOR A STANDARD PNEUMATICTEST PROCEDUREThe standard pneumatic test procedure is limited to stored energy of 1677 kJ. If thestored energy exceeds 1677 kJ, then a job specific pneumatic test procedure must besubmitted to ABSA for review and acceptance prior to the test.Standard Pneumatic Test Procedure RequirementsIssued 2011-03-28 AB-522 Edition 1 Revision 1 Page 4 of 11

The 1677 kJ stored energy threshold was calculated using the equation in ASMEPCC-2-2008, Part 5, Article 5.1, Mandatory Appendix II with the following pressure andvolume parameters:Test Medium: air or nitrogenTest pressure: 2172 kPa ( 315 psi);Volume: 0.5m3 ( 18 ft3);the component to be tested is comprised of P-1 or P-8 material;the testing temperature is 16.7C (30F) above MDMT;Note if MDT is not specified then low temperature limits must be considered (test


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temperature would be 16oC or 60oF).Linear interpolation of the pressure-volume values is permitted providing that the storedenergy value (1677kJ) of the standard pneumatic test is not exceeded. If the storedenergy value is not exceeded the intention of the standard pneumatic test is still met.See Appendix II of this document for example of interpolation.

7.0 PROCEDUREThe owner/manufacturer/AQP holder must establish pneumatic testing procedures thataddress all the safety considerations necessary to conduct the test safely and allrequirements specified in this AB-522 document.

A sample standard pneumatic test procedure is described in Appendix IV of thisAB-522 document.The owner/manufacturer/AQP holder is responsible to establish the minimum safedistance limit for personnel to stay away from the piping system during the pneumatictest. Safe distance based on PCC-2 Article 5.1, Mandatory Appendix III and using thestandard pneumatic test values for the stored energy is a minimum of 30 m. Theowner/AQP holder may reduce this safe distance limit by installing properly designed

barriers, or placing the test item in an engineered enclosure, or by taking othermeasures to minimize the risk of harm to personnel. The owner (or the person in chargeof the pneumatic test) is responsible for the safety of all personnel during thedesignated test.Design pressure and temperature of the pressure equipment to be tested shall beestablished based on the code of construction and the approved engineering design.The organization responsible for the test must verify that the stored energy value for thetest does not exceed the stored energy limit for the standard pneumatic test (1677 kJ).Standard Pneumatic Test Procedure RequirementsIssued 2011-03-28 AB-522 Edition 1 Revision 1 Page 5 of 11

The organization responsible for the test shall determine the stored energy value for thetest in accordance with one of the methods described in Appendix II or Appendix III of

this document. Appendix II provides two methods of determining the volume limit for apneumatic test based on stored energy value of 1677 kJ. Appendix III provides amethod of calculating the stored energy for the test.If the stored energy value does not exceed 1677 kJ and the standard procedure isaccepted by an ABSA SCO, the test may proceed providing that all safety precautionsand safe distance limits are adhered to.If the stored energy value exceeds 1677 kJ for a specific test, the procedure for thespecific test must be submitted to ABSA for review and acceptance.The test must be carried out following the requirements of the construction Code asapplicable (for example, ASME Section VIII Div. 1 UG-100, B31.3-2008, paragraph345.5) and any other relevant safety regulations such as the Occupational Health and

Safety Regulation.REFERENCE PUBLICATIONS

ASME Section VIII Div. 1PCC-2-2008 Part 5

ASME B31.3Pressure Equipment Safety Regulation (AR 49/2006)Standard Pneumatic Test Procedure RequirementsIssued 2011-03-28 AB-522 Edition 1 Revision 1 Page 6 of 11


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APPENDIX IPNEUMATIC TESTING FLOW CHARTYesNoNoYes

YesYesNoNoYesYesIs Hydrostatic TestingPossible?Conduct HydrostaticTestDoes Owner AcceptPneumatic TestMethod?Investigate AlternativeLeak Test MethodIs stored energy

> 1677 kJHas StandardPneumatic TestProcedure been

Accepted By ABSAas part of AQP?Submit SpecificPneumatic TestProcedure to ABSADesign SurveyProcedure AcceptedSubmit StandardPneumatic TestProcedure to ABSA SCO

FOLLOWING ACCEPTED PROCEDURES CONDUCT PNEUMATIC TESTProcedure

AcceptedStandard Pneumatic Test Procedure RequirementsIssued 2011-03-28 AB-522 Edition 1 Revision 1 Page 7 of 11

APPENDIX IIStandard Pneumatic Test Procedure Volume LimitsTest procedure limits are calculated using method A or method B below based on the DesignPressure and the volume of the system undergoing testing. The calculation outcome will resultin relatively higher volume for lower pressure and conversely lower volume for higher pressurewhile maintaining accumulated stored energy of 1677 kJ.Step 1

Define piping system DESIGN PRESSURE (DP) and VOLUME (V) including volume of vesselsthat will be tested with this piping system.Step 2

Use the value of DP defined in step 1 to calculate the volume limit (V1) for the test applying oneof the following two methods:Method A

If Imperial units are used, calculate V1 using DP in psi3436V1 = ------------------------------------------------------- [ft3](DP +14.7) [1- (14.7/(DP+14.7))0.286]Or, if SI units are used, calculate V1 using DP in kPa


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670838.8V1 = ------------------------------------------------------- [m3](DP +100) [1- (100/(DP+100))0.286]Method B

Calculate V1 using values from table 1 and apply the following interpolation(VA VB) x (DPB DP)

V1 = VB + ---------------------------------------- [ft3] or [m3]DPB DPAWhere:DP design pressure in psi or kPaDPA the first smaller pressure value in the table 1 than the step 1 DP valueDPB the first larger pressure value in the table 1 than the step 1 DP valueVA the corresponding table 1 volume listed in same row as DPAVB the corresponding table 1 volume listed in same row as DPBFor Volume Limit (V1), Method B is showing from 0 to 3 % lower values than Method A.Standard Pneumatic Test Procedure RequirementsIssued 2011-03-28 AB-522 Edition 1 Revision 1 Page 8 of 11

Step 3

If V=< V1 The standard pneumatic test procedure may be used without submitting to DesignSurvey for review and registration if this procedure is included in the quality system.If V> V1 or company does not have the standard pneumatic test procedure included in thequality system when V=< V1 the pneumatic test procedure needs to be submitted to DesignSurvey for review and acceptance.Table 1Imperial Units SI UnitsDesignPressure VolumeDesignPressure Volumepsi ft3 kPa m315 615.90 103 17.440

20 441.00 138 12.48825 342.92 172 9.71030 273.68 207 7.75040 194.50 276 5.50850 145.27 345 4.11475 90.11 517 2.552100 66.07 689 1.871125 50.77 862 1.438150 41.39 DPA & VA 1034 1.172175 34.21 DPB & VB 1207 0.969200 29.58 1379 0.838225 25.80 1551 0.731250 22.84 1724 0.647

275 20.47 1896 0.580300 18.52 2068 0.524315 18.0 2172 0.500325 16.90 2241 0.478350 15.52 2413 0.440375 14.35 2586 0.406400 13.33 2758 0.378450 11.66 3103 0.330500 10.35 3447 0.293600 8.43 4137 0.239


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700 7.10 4826 0.201800 6.11 5516 0.173900 5.37 6205 0.1521000 4.73 6895 0.1341500 2.97 10342 0.0842000 2.21 13790 0.063Standard Pneumatic Test Procedure RequirementsIssued 2011-03-28 AB-522 Edition 1 Revision 1 Page 9 of 11

Example how to apply interpolat ion:

Using Imperial units, we found in table 1 that:DPA = 150 [psi]DPB = 175 [psi]VA = 41.39 [ft3]VB = 34.21 [ft3]

Apply the following equation from Step 2 Method B:(VA VB) x (DPB DP)V1 = VB + ---------------------------------------- [ft3]DPB DPA(41.39 34.21) x (175 160)

V1 = 34.21 + ---------------------------------------- [ft3] V1 = 38.5 [ft3]175 150

APPENDIX IIIThe stored energy for the pneumatic test may be calculated using the method providedin PCC-2, Part 5, Article 5.1 Mandatory Appendix II:If the calculated E is > 1677 kJ, the pneumatic test procedure must be submitted toDesign Survey for review and registration prior to conducting the test.The stored energy may be calculated using the following formula providing that nitrogenor air is used as the test medium:E=2.5 x Pat x V [1 Pa/Pat)0.286 ]E = stored energy, J (ft-lbs)

Pa = absolute atmospheric pressure, 101 kPa (14.7 psia)Pat = absolute test pressure, (psia)V = total volume under test pressure, m3 (ft3)

APPENDIX IVThe test must be carried out following the requirements of the construction Code asapplicable. Reference should be made to ASME Section VIII Div. 1 UG-100, B31.3-2008, paragraph 345.5, PCC 2 Article 5 and any other relevant safety regulations suchas those issued by Workplace Health and Safety.a) Precautions- Pneumatic testing involves the hazard of released energy stored incompressed gas.

Standard Pneumatic Test Procedure RequirementsIssued 2011-03-28 AB-522 Edition 1 Revision 1 Page 10 of 11

- Care must be taken to minimize the chance of brittle failure during thepneumatic leak test. Test temperature is important in this regard and mustbe considered when the designer chooses the material for construction.b) Pressure Relief Device (PRD)- A PRD shall be provided- Set point of the PRD shall not be > Test Pressure + lesser of 345 kPa (50


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psi) or 10% of the test pressure.c) Test Fluid- If not air, the gas shall be nonflammable and nontoxicd) Test Pressure- The test pressure shall be 110% of the Design Pressure

e) Procedure:- The pressure shall be gradually increased until the pressure is the lesser of170 kPa (25 psi) or of the Test Pressure. At this time the preliminarycheck shall be made.- Thereafter, the pressure shall be gradually increased in steps until the testpressure is reached. The pressure shall be held at a each step long enoughto equalize the piping strains. The safe distance must be observed duringthis portion of the test.- The test pressure shall then be reduced to the design pressure beforeexamining for leakage.Note: the safe distance must be observed from after the preliminary test until

the system pressure is reduced to design pressure after successful attainmentof test pressure.- Depressurization must take place in a controlled manner to avoid subcoolingdue to the refrigeration effect, equalizing pipe strains, and beingcautious about the effluent.

o The procedure must address the dangers of confined space and

the possibility of asphyxiation from the test medium such asnitrogen. This danger is especially high should a leak occur or atthe time of depressurization.Standard Pneumatic Test Procedure RequirementsIssued 2011-03-28 AB-522 Edition 1 Revision 1 Page 11 of 11

REVISION LOGRev # Date Description1 2011-03-28 Corrected temperature would be 16oC or 60oFpage 41 2011-03-28 Corrected PCC-2-2008, Part 5, Article 5.1, Mandatory

Appendix II page 41 2011-03-28 Corrected PCC-2 Article 5.1, Mandatory Appendix IIIpage 41 2011-03-28 Corrected Workplace Health and Safety. page 91 2011-03-28 Corrected PCC-2, Part 5, Article 5.1 Mandatory

Appendix II page 9

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