DIFFERENT FORMS

OF
TESTING:
 WHAT ARE THE DIFFERENT FORMS
OF TESTING??
Testing of structural
components are classified into two
(2) namely, DESTRUCTIVE TESTING
(DT) & NON DESTRUCTIVE TESTING
Destructive testing, as the
(NDT).
name implies destroys a certain
weak portion/ whole portion of the
structural
Though component.
it may sound like
expensive as the whole component
could be destroyed, it actually is
 Testing involving the
destructive method are much
easier to be carried-out by using a
much cheaper and less
complicated device/ equipment.
As well as its results are much
easier to interpret as compared to
NDT.
That it is desirable for test
specimens that are mass produced
(like pipes) and undesirable to
those that are not mass produced
(like ships, planes, etc.)
 NDT which stands for NON-
DESTRUCTIVE TESTING gives
analysis to evaluate the properties
of a material, component, or
system, WITHOUT CAUSING
DAMAGE onto the specimen.
It uses a wide range of
analysis techniques and at the
same time certain equipments/
instrumentations to give
diagnostics.
TYPICAL METHODS
OF
TESTING:
 The field of industry employs a
wide array of testing procedures
and these include the following:
1. Hydrostatic Pressure Testing
2. Pneumatic Testing
3. Flow/ Service Testing
4. Head Pressure Testing
5. Visual Inspection
6. Holiday Testing
7. Equipment Testing
1. Hydrostatic Pressure Testing

THE PIPING
SYSTEM
2. Pneumatic Testing

INSTRUMENTAT
ION LINES
LIQUIGAZ PLANT PREMISES
PBR PLANT PREMISES
PTT DEPOT PREMISES
 A PIPING SYSTEM is an
indispensable mechanical part of
any type of industry that makes
use of fluids as part of their
A piping system allows the
processes.
convenient handling of fluids from
one location to another or from
one process into another at
precise amounts or volumes made
1. Pipes/
possible by thepipelines
use of:
2. Various fittings
3.
Instrumentations
WHY IS IT
NECESSARY
TO TEST THE
PIPING SYSTEM??
CHINESE INDUSTRIAL
PLANT
BRAZILIAN INDUSTRIAL
PLANT
 Testing the PIPING SYSTEM is
necessary so that the ERECTED
PIPELINE will:
1. Have uninterrupted fluid flow/
operation.
2. Save on costs, re: maintenance
& leaked fluid.
3. Ensure the safetiness of working
personnels/ operators of such
system from any catastrophic
breakdown/ leakage of hazardous
substances..
 Testing actually starts from its
individuals components/ materials,
namely the pipe itself & piping
components such as valves and
fittings Such testing
is more on the
flaw* on how
such components
were made.

* flaw -- material defect

-- manufacture
defect
 After the individual testing
(usually from the manufacturer),
testing is now done on the
SPOOL. SPOOL is a
span of an
assembly of pipe
and its
components
Such testing
is more on the
manner on how
the components
were assembled
together..
 Last stage of testing would be
on the pipeline itself. Whereas the
two previous testing are done
pipeline testing
outside the plant itself,
is done on the
actual plant to
where such
pipeline is to be
Afterwhich, a
erected.
test package
would then be
given to prove
its efficiency.
DIFFERENT FORMS
OF
TESTING:
 WHAT ARE THE DIFFERENT FORMS
OF TESTING??
Testing of structural
components are classified into two
(2) namely, DESTRUCTIVE TESTING
(DT) & NON DESTRUCTIVE TESTING
Destructive testing, as the
(NDT).
name implies destroys a certain
weak portion/ whole portion of the
structural
Though component.
it may sound like
expensive as the whole component
could be destroyed, it actually is
 Testing involving the
destructive method are much
easier to be carried-out by using a
much cheaper device/ equipment.
As well as its results are much
easier to interpret as compared to
NDT.
That it is desirable for test
specimens that are mass produced
(like pipes) and undesirable to
those that are not mass produced
(like ships, planes, etc.)
 NDT which stands for NON-
DESTRUCTIVE TESTING gives
analysis to evaluate the properties
of a material, component, or
system, WITHOUT CAUSING
DAMAGE onto the specimen.
It uses a wide range of
analysis techniques and at the
same time certain equipments/
instrumentations to give
diagnostics.
TYPICAL METHODS
OF
TESTING:
1. HYDROSTATIC
TESTING:
 WHAT IS HYDROSTATIC TESTING???
Hydrostatic testing is a
destructive testing performed by
filling a piping system (or vessel)
with INCOMPRESSIBLE LIQUID (water
or oil), and applying pressure to
the system (or vessel) to check for
leaks/ defects that have missed prior
Such test is the most common
detection.
method employed for testing pipes
and other pressure vessels (gas) to
maintain safety standards and the
vessels durability over a period of
 Water normally is used because
it is less viscuous & almost
incompressible that it will only
expand a very small amount should
the vessel to which it was applied
If high pressure
for testing SPLIT gas were used
instead, and the vessel was to SPLIT,
it would expand to nearly a hundred
times its actual compressed volume,
thus EXPLODING causing risk/
damage to the attendant
 In cases that water is to be used,
red/ fluorescent dyes are mixed so
as to make leaks easier to see.

Pressure applied to such tests

are according to specifications/
limitations set by the industry/
customers specifications.
The test pressure is considerably
higher that the operating pressure
to give a margin for safety
HYDROSTATIC
TESTING
PROCEDURE:
 1. PIPE OR VESSEL IS INITIALLY PREPARED...

PRESSURE
GAUGE JOINT
ZERO READING

BLOW UP SECTION OF JOINT

Showing JOINT DEFECT
 2. PRESSURE IS ADDED/ INTRODUCED..

PRESSURE
GAUGE
REGISTER PRESSURE
JOINT

FLUID ENTRY = PRESSSURE

BLOW UP OF JOINT
Showing JOINT DEFECT
 3. LEAKING TRANSPIRES DUE TO PRESSURE.

PRESSURE
GAUGE
PRESSURE DROPS,
DUE TO LEAK LEAK

FLUID PRESSURE

Blow-up Section
Showing leak due to weld joint failure
 NO LEAK PIPING SYSTEM/ VESSEL..

PRESSURE GAUGE
NEEDLE IS STEADY OR
STATIC

TEST
PRESSURE WATER PRESSURE.
 SET-UP FOR HYDROSTATIC PRESSURE TEST
A:Test Equipment

1. Water Supply

2. Test Pump

3. Manifold
Gate Valve
Check Valve
Relief Valve (see note)
Connector for inlet/outlet
Pressure Gauge (calibrated)
Wye Strainer/ Drain
RELIEF/ VENT VALVES
WYE STRAINER/ DRAIN
SET-UP FOR HYDROSTATIC PRESSURE TEST
B. Piping System to be tested

4. Low point inlet / drain.

5. High point vent.

6. Test blinds or stopper

7. Pressure Gauge
(calibrated)
Hydrostatic testing at high pressures is very
dangerous. If a portion of the system fails during
hydrostatic testing, serious injury and even
death can result; therefore, the test must be
performed only under close supervision by
qualified personnel.

DO NOT ATTEMPT TO MAKE REPAIRS TO THE

SYSTEM WHILE IT IS UNDER PRESSURE.

If repairs are necessary, stop the test, release

the pressure, and drain the system.
 PROCEDURES/
NECESSITIES IN
MAKING
HYDROSTATIC
TESTING:
1. NEED FOR THE CORRECT
TYPE/ SIZE OF PRESSURE
GAUGE:
1A. RANGE > 1.5-2x the test
1B. RELIANCE > the
pressure.
pressure gauge should
be calibrated (every 6
months)
2. PROPER SEALING OF THE
SYSTEM TO BE TESTED...
2A. Need to install BLEEDER
VALVES (high point vent
valves) at the highest
point in the piping system.
-- this is
done to prevent
formation of
bubbles/ air
pockets which
could give false
pressure
 2B. After such valve
installation, the portion of
the piping system to be tested
should be properly be sealed.
-- this could be
done by using :

A. mechanical test
plugs B. welded
caps
C. blind flanges
-- bolt
connected -- slip
 Mechanical test plugs:
used when test
pressure to be used in the
piping system to be tested is not
extremely high.
Rubber which as a
SEALANT that
expands/ contracts
depending upon
the bolt/ nut
movement
 Welded Caps:
Used when test
pressure to be used in the
piping system to be tested is
Emphasis
extremely high. should be given
to the welding procedure
where it is tested (preheated
and thenDisassembling the cap
stress relieved.. )
from the weld is done by torching
or by mechanically cutting
(grinding) through it
 Blind Flange:
Normally used as the
sealant and is either slipped
through a pair of open flanges or
is paired with a single open
flange while withstanding
extremely high
Much pressures.
easier to
disassemble unlike
the other
sealants though
the disassembly of
its connecting
bolts.
 Emphasis is given to the
proper tightening of bolts to
ensure that no leakage would
occur as well avoiding the
warping of the flange face..
Use of
torque
wrench
along with
an open-end
socket
wrench
ensures the
proper
 OPEN-END SOCKET
WRENCH

TORQUE WRENCH
RATCHET WRENCH
 Torque wrench is primarily
for tightening, using an open end
socket wrench/ ratchetwrench will
do for loosening.

Torque
wrench is
applied at
the NUT and
not on the
BOLT.
 TYPICAL BOLT BLIND FLANGE
TYPE:
 A SLIP TYPE BLIND FLANGE
could be purchased from
retailers/ it could also be
FABRICATED.
Known as PANCAKE
FLANGE, it should be of the
correct thickness and correct
material so that it could offset
the TEST PRESSURE of the
system.This to prevent it from
bending/ buckling so that it
could be removed after testing..
 A SLIP TYPE
BLIND FLANGE has a
T-handle that is
usually cut along
with the blind flange
itself. If not, such
handle could be
welded with the blind
flange itself.
WAYS OF
PERFORMING A
HYDROSTATIC
PRESSURE TEST:
PERFORMING HYDROSTATIC
PRESSURE TEST:
1. PREPARATION
2. TESTING:
2A. Water Filling
2B. Pressurizing
2C. Observation
2D. Confirmation/
approval
2E. Draining
2F. System Restoration
 PERFORMING HYDROSTATIC
PRESSURE TEST:
1. PREPARATION
-- seeking approval
(permits) from the proper
authorities of such testing.
-- complying with the set
of SAFETY REQUIREMENTS:
Barricading the test area
Putting signages on the
adjacent areas the use of PPEs
Requiring
to test personnel/ even the
non-test personnel
 PERFORMING HYDROSTATIC
PRESSURE TEST:
2. TESTING:
2A. Water Filling:
-- Open the HIGH POINT VENT
VALVES/ BLEEDER VALVES

** To prevent air pocket/ bubble

formation which is detrimental to
the system
 PERFORMING HYDROSTATIC
PRESSURE TEST:
2. TESTING:
2A. Water Filling:
-- Connect the TEST MANIFOLD
with its INLET to the WATER SUPLY
and its OUTLET with the LOW
POINT INLET VALVE of PIPING
SYSTEM to be tested
 PERFORMING HYDROSTATIC
PRESSURE TEST:
2. TESTING
2A. Water Filling:
-- Fill the piping system with
slowly
-- The with water
flow of water will in turn
cause the movement of certain
portion of trapped air/ air pockets
from flowing
-- Solid outside..
streams of water would
then follow
PERFORMING HYDROSTATIC
PRESSURE TEST:
AIR AND WATER BROKEN
STREAM

AIR

WATER
 PERFORMING HYDROSTATIC
PRESSURE TEST:
2. TESTING:
2A. Pressurizing:
-- Slowly build-up the test
pressure up to 50% of its test
capacity
-- Operator should at least be
wary of the pressure given-off by
the pump
** Rate of pressurization should
not exceed 29 psi/ min (2 bars/
min).
-- Operator should also be aware
of possible leaks even at this
minimal pressure..
 PERFORMING HYDROSTATIC
PRESSURE TEST:
2. TESTING:
2A. Pressurizing:
-- Give pressure increments of
10%, 60%, 70%, 80%, 90%, until
100% (final
** At eachtesting pressure)
increment wait for the
system to stabilized before adding
on additional pressure
-- Observe again for any
possibilities of leaks with each
possible increments
-- Upon reaching the desired test
pressure, you may now close the
valve between the test pump and
 PERFORMING HYDROSTATIC
PRESSURE TEST:
FURTHER LEAKING

LEAK

50% 60%
70% 80% 90% 100%

SYSTEM IS THEN ISOLATED.

PRESSURIZING A SYSTEM.
 PERFORMING HYDROSTATIC
PRESSURE TEST:
3. OBSERVATION:
-- After the piping system had
been ISOLATED, the full maximum
testing pressure is then
maintained for 15 minutes or
-- Observation then made for any
above
possible leaks
** Such observation is done at a
certain distance far-off the
test specimen
 PERFORMING HYDROSTATIC
PRESSURE TEST: A SYSTEM.
OBSERVING

15 mins/ more

Report:
with leak
 PERFORMING HYDROSTATIC
PRESSURE TEST:
3. OBSERVATION:
-- Following the application of the
FULL HYDROSTATIC TEST
PRESSURE, test pressure is then
reduced at AT A VALUE NOT LESS
THAN THE WORKING PRESSURE OF
THE
-- AsPIPING WSYSTEMcould now
such observation
be made at a much nearer
distance giving emphasis on joint
connections (flanged/ threaded
** In certain instances such JOINTS are
joints)
actually painted to make
observations much easier
 PERFORMING HYDROSTATIC
PRESSURE TEST:
MAXIMUM Report:
TEST NO leak
PRESSURE

NOT LESS
THAN
MAXIMUM
WORKING
PRESSURE
OF THE
PIPING FURTHER OBSERVING A
 PERFORMING HYDROSTATIC
PRESSUREAPPROVAL:
4. CONFIRMATION/ TEST:
-- If there is a LEAK, a report
would be made indicating WHERE
(specific portion) the leak took
place
** At at the
such test pressure
REPAIRS/ it
ALTERATIONS
happened
would be made before the whole piping
system/ specimen is again retested
-- If there is NO LEAK, a report
would also be made fully
CERTIFIED by the contracted
firms designated
** At such tester.
the whole piping system/
specimen is ready for use
 PERFORMING HYDROSTATIC
PRESSURE TEST:

Report:
with leak
(for repairs)

CONFIRMATION/
APPROVAL.
 PERFORMING HYDROSTATIC
5. DRAINING:
PRESSURE TEST:
-- SLOWLY open (crack) the drain
valve at the test manifold to relieve
pressure from the tested system..
-- OPEN the high point vent valve
to allow air to seep into the
system.. FAILURE TO OPEN THE HIGH POINT VENT VALVE WHILE DRAINING CAN
WARNING CREATE VACUUM IN THE PIPING SYSTEM WHICH CAN CAUSE
COLLAPSE OF THE PIPING COMPONENTS!!!

-- FULLY OPEN the drain valve at

the test manifold to DRAIN THE
SYSTEM..
Stand to the backside of the valve when releasing pressure from
CAUTION
the system
PERFORMING HYDROSTATIC
PRESSURE DRAINING
TEST: A
SYSTEM.

AIR-IN
VIBRATION IS
MINIMIZED

WATER CASCADES BACK

PIPING ASSEMBLY IS
PREVENTED FROM
WATER-OUT COLLAPSING
 PERFORMING HYDROSTATIC
6. RESTORATION:
PRESSURE TEST:
-- Remove temporary items such as
TEST BLINDS, SPOOLS, ETC..
-- Re-install permanent items such
as LINE CHECK VALVE, RELIEF
VALVES, CONTROL VALVES, GASKETS,
ETC to bring back the original
designed piping system..
-- Seek approval from the
authorized personnel of the
contracting/ testing firm that such
piping assembly is FIT to be used..
PERFORMING HYDROSTATIC
PRESSURE TEST:

RESTORATION OF THE
IMPORTANT
REMINDERS/
NOTES IN
HYDROSTATIC
PRESSURE
IMPORTANT REMINDERS/ NOTES
IN HYDROSTATIC PRESSURE
TESTING:
-- The correct test pressure for a
particular piping system..
-- Scope/ limitation of such testing
on a given assembly to be tested (at
what part/ portion)..
-- Location of instruments & if such
could be included in such testing. If
not a DUMMY should be created
-- Proper usage of piping supports..

IMPORTANT REMINDERS/ NOTES

IN HYDROSTATIC PRESSURE
TESTING:
-- Welded joints should not be HOT/
COLD INSULATED until the
completion of such testing..
-- If repairs/ alterations were made
on the test assembly after the
detection of leaks, the said
assembly is again subjected to
testing. If minor repairs/ alterations
were made, such tests could be
waived ..
IMPORTANT REMINDERS/ NOTES
IN HYDROSTATIC PRESSURE
TESTING:
-- Such testing could not used if it
would cause harm to the piping
assembly such as in
INSTRUMENTATION PIPING LINES..
-- Such testing could not used if it
the weight of the FILLING WATER is
too large to be offsetted by the
piping supports..
IMPORTANT REMINDERS/ NOTES
IN HYDROSTATIC PRESSURE
TESTING:
-- Operation of the TEST PUMP
should only be done by well versed
individuals. That as soon as the full
testing pressure has been reached,
its disassembly from the tested
piping system should be made. Or if
its operator were not in its
-- PRESSURIZATION
proximate vicinity should be done
slowly at the prescribed rate of not
exceeding 29 psi/ min...
IMPORTANT REMINDERS/ NOTES
IN HYDROSTATIC PRESSURE
TESTING:
-- Water for such testing should be
CLEAN and FRESH. If with Chlorine
content, it should not exceed 10
ppm...
-- For vessels/ pipeworks requiring
heat treatment, such testing could
only commence after such heat
treatment/ stress relieving
procedure...
2. PNEUMATIC
TESTING:
 WHAT IS PNEUMATIC TESTING???
Performing a hydrostatic test
is not at all times practical, when
bursting pressure of the piping is
minimal, such testing is not
possible. Instead
Pneumatic another
testing way of
is another
testing is done.
destructive testing procedure, this
time using COMPRESSED AIR/
PRESSURIZED GAS (nitrogen) in a
piping system (or vessel) and the
leak This
eventually tested
is the very with
same the aid
method
of soap
that bubbles.
is used by auto mechanics in
detecting leaks in a tire.
 LEAKING THEN BUBBLING TRANSPIRES
DUE TO PRESSURE.
PRESSURE
GAUGE
PRESSURE DROPS,
DUE TO LEAK

LEAK
GAS PRESSURE

Blow-up Section
Showing leak due to weld joint failure
 CONDITIONS NECESSITATING
PNEUMATIC TESTING:

1. When such piping system/ vessel is

supported in a manner in which they cannot
be safely be filled with water due to the
weight of the water in the pipe

2. When the test items cannot come in

contact with the water.
3. When the preliminary test requires a
system pressure of 100 psi below)

4. When a system has been previously

hydrostatically tested and a retest of a
part of a system is necessary.

5. When it is required by the job

specifications.