Pressure test requirements

The requirements for this pressure testing is contained within paragraphs “UG-99 Hydrostatic
Pressure Test”, “UG-100 Pneumatic Test”, and “UG-101 Proof Tests to Establish Maximum
Allowable Working Pressure”. Anyone even passingly familiar with the Code knows that even
the most seemingly simplest of subjects, like Pressure Tests, can lead into a myriad of
clarifications and exceptions. For this reason we will limit our discussion to cryogenic pressure
vessels built to Division 1 and “Part UHA Requirements for Pressure Vessels Constructed of High
Alloy Steel”. Further we will assume that maximum allowable working pressure (MAWP) is
determinable by calculation and that UG-101 does not apply.

Pneumatic Testing Conditions

Per the requirements of UG-99 and UG-100 a hydrostatic test (along with a visual inspection
during test) is the default test that must be satisfactorily performed as one of the conditions for
U stamping the pressure vessel. A pneumatic test may be performed if certain conditions are
met. UG-100(a) lists these conditions being for vessels:

1. that are so designed and/or supported that they cannot safely be filled with water.
2. not readily dried, that are used in services where traces of the testing liquid cannot be
tolerated and the parts of which have, where possible, been previously tested by
hydrostatic pressure to the pressure required in UG-99.

The application requirements of cryogenic pressure vessels often meet these conditions,
especially those of (2) above, and are most often pneumatically pressure tested.

Why The Pressure Test is Performed

Not discussed in UG-99 or UG-100 are the reasons the pressure test is performed. The most
obviously of reasons is that the pressure test serves as a proof of design and workmanship
verification. Two trusted sources 1 2 state these reasons for performing the pressure test,
summarizing:

 The pressure test uncovers gross errors, due to design or workmanship, including leaks
at welded, brazed or flanged connections.
 The application of the test pressure results in a stress relief of the vessel, where local
areas of high stress, either due to design or fabrication issues, undergo local yielding at
the test pressure, resulting in a better stress pattern after release of the pressure.

Regardless of the reasons behind the pressure test, the test must always be performed after all
other fabrication steps are complete.
Hydrostatic Test
The hydrostatic test utilizes a liquid to fill and pressurize the vessel. Water is most the most
commonly used liquid. The hydrostatic pressure is raised inside the vessel until the pressure
reaches at least the minimum hydrostatic test pressure which is:

Minimum Hydrostatic Test Pressure = 1.3 X MAWP x LSR

Where LSR is the smallest ratio of the allowable stress at test temperature to the allowable
stress at design temperatures of materials used in the vessel construction. (Bolting is excluded
except when the calculated test pressure will exceed 90% of the bolt material minimum yield
strength at the test temperature.)

For the hydrostatic test the Code recommends the temperature of the vessel and its contents
are the same and between a range of 30°F above the minimum design metal temperature
(MDMT) and 120°F. After the pressure reaches the test pressure, the pressure is reduced until it
reaches a value equal to the test pressure divided by 1.3. A visual examination or gas leak test is
used to check for cracks or leaks in all connections and welded joints.

The pneumatic test, on the other hand, utilizes gases, commonly nitrogen gas is specified for
cryogenic pressure vessels, to perform a similar pressure test. The vessel must meet one or
more of the stated conditions to allow the use of the pneumatic test rather than the
hydrostatic test. There are valid safety concerns regarding pneumatic testing, as it is intrinsically
less safe than hydrostatic testing.

Pneumatic Test

All vessels that undergo a pneumatic test are first examined under the requirements of UW-50,
which requires that all openings, welds, and attachments be examined before testing. For
cryogenic vessels of the type under discussion this would require liquid dye penetrant testing
per UW-50.

The minimum required test pressure for a pneumatic test is

Minimum Pneumatic Test Pressure = 1.1 X MAWP x LSR

Where again LSR is the smallest ratio of the allowable stress at test temperature to the
allowable stress at design temperatures of materials used in the vessel construction. (Bolting is
excluded except when the calculated test pressure will exceed 90% of the bolt material
minimum yield strength at the test temperature.)

For the pneumatic test the Code requires the temperature of the vessel and its contents are the
same and between a range of 30°F above the minimum design metal temperature (MDMT) and
120°F. After the pressure reaches the test pressure, the pressure is reduced until it reaches a
value equal to the test pressure divided by 1.1. Again a visual examination or gas leak test is
used to check for cracks or leaks in all connections and welded joints.

After The Pressure Test

After these tests are performed, the vessels are finally stamped to display that they meet the
ASME Code and Meyer Tool standards, ensuring the safety of our customers and their projects.
Understanding and applying the proper ASME Code rules are key to the successful design and
fabrication of your ASME Code Stamped Cryogenic Pressure Vessel. This understanding and
application is just one way Meyer Tool Reduces Project Risk and help you achieve the lowest
cost of ownership.