LINDE STANDARD

Pressure testing

LS 133-02

Piping and equipment at construction sites

Page 1 of 9

Contents
1
2
3
4
5
5.1
5.2
6
7
8

Scope ................................................................2
Scheduling of the pressure test.........................2
Test method ......................................................2
Requirements ....................................................2
Performance ......................................................3
Hydrostatic test .................................................3
Pneumatic test ..................................................4
Water quality .....................................................4
Exceptional cases .............................................5
Test results and test report ...............................5

Annex A
Annex B
Annex C

(normative) Performance of
pneumatic testing ....................................6
(normative) Safety areas for
pneumatic testing ....................................7
(normative) Temporary blinds for
pressure testing ......................................8

Remarks on the current issue:

Revision: Blind thicknesses in annex C changed; editorially revised.
Previous issues: 05.2006, 07.2006, 07.2008
Responsible department(s) for the technical content: GCQ
Confidentiality class 1 in accordance with LS 104-03: Unrestricted publication

06

01.2013

GCQ / Henn

GCQ / Helmreich

05

07.2008

TM-Q / Henn

TAW / Rahofer

LEHQ-ENM1S /
Schmitt
TAW-N / Schmitt

Status

Issue

Date

Prepared

Checked

Approved

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File name:

LS 133-02 (EN)

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Issue 06/01.2013

LS 133-02

Page 2 of 9

Scope

This standard applies to the performance of pressure tests, i. e. hydrostatic or pneumatic tests of piping and
equipment on construction sites or pre-fabrication sites.
During pressure testing the leak tightness, the form/shape stability and the strength integrity of the test system
will be determined.
Project specific or component specific requirements from codes, regulations or specifications have preference
over the requirements of this standard.

Scheduling of the pressure test

Pressure testing shall be performed after completion of construction activities on the pressure-retaining wall and
after inspection and release by the inspection agency, but prior to applying painting, insulation, rubber coating,
brick-lining, metallic liners and similar coating to the inside and outside wall.
For piping a single-layer outside primer is admissible, provided that the consents of the purchaser, authority
resp. inspection agency exists.
For underground piping the area of the welding seams shall be accessible for inspection.
During the pressure test the number of personnel in the direct neighborhood shall be limited to a minimum
(e.g. testing after working hours).

Test method

The standard test method is hydrostatic testing, by using water as test fluid. The additional static load due to the
water weight of the systems to be tested, to supports, foundations, etc. shall be considered by taking
appropriate measures.
If in exceptional cases e.g. due to process reasons, the hydrostatic test is not suitable the pressure test may be
performed as pneumatic test, after consultation with the purchaser. Due to the risk potential occurring with
compressed gases precautions shall be taken for personnel protection. If applicable, the test shall be previously
agreed upon with the relevant industrial safety authorities and the inspection agency.
Generally, pressure testing shall be performed at room / ambient temperature. At low ambient temperature
(< 5 C), additional measures shall be agreed upon with the purchaser and the inspection agency.
If pressure vessels are subject to pressure testing on site, the instructions of the vessel manufacturer shall be
observed.
NOTE: Heat exchangers can be designed for differential pressure. This shall be considered during pressure
testing. Corresponding data are shown on the vessel nameplate.

Requirements

For pressure testing the following minimum requirements shall apply:

If components with longitudinal welds are installed, these welds shall be prior pressure-tested or 100%
nondestructively tested (shall apply to pneumatic test only)

Parts which are to be excluded from the pressure test (e.g. rupture discs, sensitive measuring
instruments, special components subject to a lower test pressure) shall be dismantled or isolated from the
system.

Documents specifying test method (test fluid), pressure test limits and test pressure shall be prior
approved by purchaser. (e.g. drawings with welding and testing plan or line/isometric list, isometric
drawing with defined pressure test circuits, etc.)

The static pressure of the water column shall be considered at large differences in height

Advance notice for inspection to the parties involved shall be given.

Pre-condition for pressure testing are the accepted final inspection and compliance with specified scope
of examinations

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LS 133-02

Page 3 of 9

For pneumatic testing, radiographic examination of at least 10 % of all circumferential-welds and nozzle
welds > DN 100 (4 inches) shall be required. Nozzle welds which cannot be radiographed shall where
appropriate be ultrasonically tested resp. tested for surface cracks

Calibrated measuring instruments (pressure gauge, pressure transmitter) with measuring range
< 1.5 x test pressure shall be used; for pneumatic testing 2 independent measuring instruments with
remote reading or with reading from a protected area will be required, preferably with pressure recorder

Safety measures shall be observed against unintentional pressure increase due to heating of the test fluid
at rising ambient temperature. The pump shall be separated from the test system during testing

Sufficiently dimensioned parts for isolating the pressure chamber, such as blind flanges, line blinds, caps,
pressure devices (for temporary blinds refer to Annex C) shall be used

For hydrostatic testing the installation of vents and drains at high and low points will be required

Safety distances for test personnel and other involved persons according to Annex B for pneumatic
testing shall be observed

Pneumatic testing systems shall be kept small and large-size vessels shall be isolated, if possible.
Demarcation of a separate protection area and marking with "no access permitted" will be required

A responsible for supervision of the defined safety precautions and performance of the pressure testing
shall be nominated

Approval for the pneumatic testing by the authority and the purchaser shall be obtained

Performance

Test pressures and performance shall be acc. to the specified codes and standards.
NOTE: The factor for the calculation of the test pressure is not always constant. Calculated stress factors for the
design temperature (temperature correction factor) as specified in design and construction codes may have to
be considered.

5.1

Hydrostatic test

The test fluid shall be water according to Paragraph 6; the test pressure shall be applied at the
highest point

Securing of a dry outside surface (e.g. protection against rainy weather); in case of condensate, waiting
for temperature balance between test fluid and wall

Piping spring hangers shall be locked.

Safety distance for pressure vessels shall be at least 1 x vessel length

Pressure chamber shall be completely vented during filling

Temperature control; pressurization only after reaching of the specified test temperature (= metal
temperature)

The pressure shall be increased slowly and continuously till reaching test pressure.

Minimum holding period at test pressure shall be observed.

Visual examination of the walls after 15 min at the earliest and for piping with covered welds (under
reinforcing pads, etc.) after at least 30 min holding time at test pressure

Visual examination for leaks of the welds and detachable connections

Prior to draining: open vents, otherwise danger of bulging due to forming vacuum

After pressure testing immediate draining of water, removal of water residues, if any (e.g. by blowing) and
venting of the walls, otherwise danger of corrosion

Removal of deposits (rust, mud); flushing of the piping, if required

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5.2

Issue 06/01.2013

LS 133-02

Page 4 of 9

Pneumatic test

The test fluid shall be an oil-free and dry gas, air or nitrogen

Observation of safety precautions

Pressurization and pressure verification from a safe distance see Annex A and B

First leak test at 0.5 to 1.0 bar by visual examination of the welds and detachable connections after
application of foam-frothing agent

Increase pressure slowly and step-by-step till reaching test pressure; after a holding period of 10 min
each, visual examination and noise control from a safe distance

At test pressure (acc. Code) a holding time of at least 30 min (no access permitted during holding time
above max. allowable working pressure!)

If a safety valve is installed for protection against unintentional pressure increase (e.g. acc. to
ASME B31.3), the cross-section of the safety valve shall consider the required blow off volume

Access to the safety area only after decrease of the test pressure to the maximum allowable working
pressure. At this pressure inspect the piping for deformations and cracks. In the welding seam zone and
on all detachable connections a second leak test with frothing agents (bubble test) shall be performed
additionally

Exemption for Cold Boxes: Due to safety precautions the leak test on welds at maximum allowable
working pressure, with foam-frothing agents, shall be omitted. This leak test shall be carried out after
pressure release to 0.5 1.0 bar

Continuous decrease of pressure;

venting the pressure chamber of vessels and piping, which had been tested with nitrogen, otherwise risk
of suffocation during access

Washing off of the residues of the foam-frothing agent to prevent corrosion

Water quality

For the pressure test with liquid, clean (free from suspended substances) water of drinking water quality shall be
used. The admissible chloride content (including bromides, iodides) is specified in Table 1. The material data
given in Table 1 shall apply to all surfaces being in contact with water, i.e. also to metallic internals and
claddings. For constructions involving material combinations, the more stringent requirements each shall apply.
Table 1: Admissible chloride content of the water for pressure testing
Material group
1

Ferritic steels, unalloyed/low-alloyed steels 9% Cr,

welded with ferritic filler material

Ferritic-austenitic steels, Mo-alloyed (duplex steels)

Stainless 18/9-CrNi-steels, Mo-alloyed

Aluminium materials

Stainless 18/9-CrNi-steels without Mo

Stainless, ferritic Cr-steels

Ferritic steels, welded with austenitic filler material

Heat-resistant, austenitic steels (CrNi, NiCr) and Ni-base alloys

Copper materials including brass

10

Plastic materials

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Chloride content
ppm = mg/l
< 250

< 150

< 50

no
limitation

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Page 5 of 9

Exceptional cases

If, in exceptional cases, water is to be used with a chloride content exceeding the values of Table 1, namely

up to max. 500 ppm for the material groups 1 to 3

up to max. 150 ppm for the material groups 4 to 8

it shall be inhibited, e.g. with 1.5 % by weight of sodium carbonate or 0.5 % by weight of sodium nitrate.
Inhibition with lime solution or organic inhibitors needs the consent of the purchaser. For inhibition and additions
to water for obtaining a freezing point depression the local applicable regulations for water shall be observed.
At unknown or considerably variable water quality, the determination of the halides (chloride, bromide, iodide) is
required prior to each pressure testing, e.g. by means of "Aquaquant Chlorid" from Merck, Darmstadt.
If the proceeding acc. to this standard is not useful for an individual case, the details shall be agreed upon with
the purchaser and the inspection agency, e.g. for

ambient temperatures below 5 C,

using another liquid instead of water,

using another gas instead of air or nitrogen,

plastic components, e.g. GRP.

Test results and test report

The requirements are fulfilled, if

no inadmissible pressure drop is recorded and

no inadmissible deformations are found and

no liquid penetrates to the surface during the hydrostatic test or

no formation of foam is detected during the pneumatic test

The accepted pressure test shall be confirmed in a test report by the parties involved, by observing the specified
regulations, and by indicating the equipment tested, test method, test pressure, test period, test fluid, test results
and date and, where applicable, test temperature, pressure gauge No. with calibration certificate and pressure
recorder report.
At a not accepted pressure test, the purchaser shall be informed immediately. The further proceeding shall then
be agreed upon with the purchaser and the parties involved.

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LS 133-02

Page 6 of 9

Annex A
(normative)
Performance of pneumatic testing

SG

Pt
SG

1.0p
SG

0.9p

SG

0.8p

SG

0.7p

Pressure

SG

0.6p
SG

0.5p

th

D*)

0.5-1.0 bar

Start

End

Time

Figure A.1: Performance of a pneumatic test

Pt
t
th
D
SG

Test pressure (acc. Code)

Holding time 10 min
Holding time 30 min
Leak test with foam-frothing agent according Paragraph 5.2
Visual examination and noise control

*) applies for cold boxes in lieu of leak testing at 1.0 p

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LS 133-02

Page 7 of 9

Annex B
(normative)
Safety areas for pneumatic testing
For pressure vessels the safety distance shall be according Table B.1.
For piping the safety distance shall be in accordance with Table B.1 and upon consultation with the parties
involved.
Table B.1: Safety distances for vessels

Volume
m3
1
2
3
4
5
7
10
15
20
30
40
50
60
70
80
90
100
150
200
300
400
500

Pt=5
bar

Pt=10
bar

Pt=15
bar

2.1
2.9
3.6
4.1
4.6
5.4
6.5
7.9
9.2
11.2
13.0
14.5
15.9
17.2
18.3
19.5
20.5
25.1
29.0
35.5
41.0
45.9

3,3
4.7
5.7
6.6
7.4
8.8
10.5
12.8
14.8
18.2
21.0
23.5
25.7
27.7
29.7
31.5
33.2
40.6
46.9
57.4
66.3
74.2

4.3
6.1
7.4
8.6
9.6
11.4
13.6
16.6
19.2
23.5
27.2
30.4
33.3
35.9
38.4
40.7
42.9
52.6
60.7
74.4
85.9
96.0

Safety Distance
m
Pt=20
Pt=25
bar
bar

Pt=30
bar

Pt=35
bar

Pt=40
bar

5.1
7.2
8.9
10.2
11.5
13.6
16.2
19.8
22.9
28.1
32.4
36.2
39.7
42.9
45.8
48.6
51.2
62.7
72.4
88.7
102.5
114.5

6.5
9.2
11.3
13.0
14.6
17.3
20.6
25.3
29.2
35.7
41.3
46.1
50.5
54.6
58.3
61.9
65.2
79.9
92.2
113.0
130.5
145.8

7.1
10.1
12.4
14.3
16.0
18.9
22.6
27.6
31.9
39.1
45.1
50.5
55.3
59.7
63.8
67.7
71.4
87.4
100.9
123.6
142.7
159.6

7.7
10.9
13.4
15.4
17.2
20.4
24.4
29.9
34.5
42.2
48.8
54.5
59.7
64.5
69.0
73.1
77.1
94.4
109.0
133.5
154.2
172.4

5.9
8.3
10.1
11.7
13.1
15.5
18.5
22.7
26.2
32.1
37.0
41.4
45.4
49.0
52.4
55.6
58.6
71.7
82.8
101.4
117.1
131.0

Note:
The values shown in the table are based on the following formula acc. to Regels voor toestellen
onder druk "Rules for pressure vessels" T 0240:

l 1.51 V pt pt0.714

in which: l = safety distance

V = volume
pt = test pressure
Intermediate values can be interpolated.

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Page 8 of 9

Annex C
(normative)
Temporary blinds for pressure testing

C.1

General requirements

Temporary blinds shall always be installed between a pair of flanges.

Table C.1 defines the minimum thickness of temporary blinds to be used for the purpose of pressure testing
only. These thicknesses are calculated considering a minimum yield strength of 235 MPa of the material at
room / ambient temperature. In case materials are used with deviating applicable calculation strength values, a
calculation for the thickness shall be provided to the purchaser prior to pressure testing.
Temporary blinds shall not be used as blind flanges resp. line blinds for permanent installation.

C.2

Marking of temporary blinds

Materials used shall be identifiable by marking.

For the purpose of identification and proper handling, temporary blinds shall be provided with a welded-on lifting
lug which shall be marked with red paint and hard stamped with the nominal diameter (DN/NPS) and the
maximum allowable test pressure.

C.3

Handling and assembly instructions

Temporary blinds shall be mounted centred and as a minimum cover the entire flange sealing surface. The
temporary blind shall not touch flange bolts after installation. Sealing surface of temporary blinds shall be flat,
smooth and free of scale and/or other irregularities.
Unless otherwise instructed by purchaser in writing, temporary blinds shall be removed directly after pressure
testing, after test systems were cleaned and dried.

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File name:

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LS 133-02

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Table C.1: Thickness of temporary blinds for flanges considering minimum yield strength of 235 MPa
DN NPS
15
20
25
40
50
65
80
100
150
200
250
300
350
400
450
500
600
700
750
800
900
1000
1100
1200
1300
1400
1500
1600
1800
2000

0.5
0.75
1
1.5
2
2.5
3
4
6
8
10
12
14
16
18
20
24
28
30
32
36
40
44
48
52
56
60
64
72
80

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5
1
1
1
2
2
2
3
3
4
5
6
7
8
9
11
12
14
16
16
18
20
22
24
26
28
30
32
35
39
43

10
1
2
2
2
3
3
3
4
6
7
9
10
12
13
15
16
19
22
23
25
28
31
34
37
40
43
46
49
55
61

15
2
2
2
3
3
4
4
5
7
8
10
12
14
16
18
20
23
27
28
30
34
38
41
45
48
52
56
59
67
74

20
2
2
2
3
4
4
5
6
8
10
12
14
16
18
21
23
27
31
32
35
39
43
47
52
56
60
64
69
77
86

25
2
2
3
3
4
5
5
6
9
11
13
16
18
20
23
25
30
34
36
39
44
48
53
58
62
67
72
77
86
96

30
2
3
3
4
4
5
6
7
10
12
15
17
20
22
25
28
33
37
40
43
48
53
58
63
68
73
79
84
94
105

35
2
3
3
4
5
6
6
7
10
13
16
18
21
24
27
30
35
40
43
46
51
57
62
68
74
79
85
91
102
113

40
2
3
3
4
5
6
7
8
11
14
17
20
23
26
29
32
38
43
46
49
55
61
67
73
79
85
91
97
109
121

45
2
3
3
4
5
6
7
8
11
14
18
21
24
27
31
34
40
46
48
52
58
65
71
77
84
90
96
103
115
128

50
3
3
4
5
5
6
7
9
12
15
19
22
24
29
32
36
42
48
51
55
61
68
75
81
88
95
101
108
122
135

55
3
3
4
5
6
7
8
9
12
16
19
23
27
30
34
37
44
51
53
57
64
71
78
85
92
99
106
113
128
142

60
3
3
4
5
6
7
8
10
13
17
20
24
28
31
35
39
46
53
56
60
67
75
82
89
96
104
111
118
133
148

65
3
3
4
5
6
7
8
10
14
18
21
25
29
33
37
41
48
55
58
62
70
78
85
93
100
108
116
123
139

70
3
4
4
5
6
8
9
10
14
18
22
26
30
34
38
42
50
57
60
65
73
80
88
96
104
112
120
128
144

75
3
4
4
6
6
8
9
11
15
19
23
27
31
35
39
44
52
59
62
67
75
83
91
99
108
116
124
132
149

80
3
4
4
6
7
8
9
11
15
19
23
28
32
36
41
45
53
61
64
69
78
86
94
103
111
120
128
137

Maximum test pressure Pt [bar]

85 90 95 100 105 110 115 120 125
3 3 3 3 3 4 4 4 4
4 4 4 4 4 4 4 5 5
5 5 5 5 5 5 5 5 5
6 6 6 6 7 7 7 7 7
7 7 7 8 8 8 8 8 8
8 9 9 9 9 10 10 10 10
10 10 10 10 11 11 11 11 11
11 12 12 12 13 13 13 13 13
16 16 17 17 17 18 18 18 19
20 21 21 21 22 23 23 23 24
24 25 26 26 27 27 28 29 29
28 29 30 31 32 32 33 34 34
33 34 35 36 37 38 38 39 40
37 38 39 40 41 42 43 44 45
42 43 44 45 47 48 49 50 51
46 48 49 50 51 53 54 55 56
55 56 58 60 61 62 64 65 66
63 64 66 68 70 71 73 74 76
66 68 70 72 74 75 77 79 80
71 73 75 77 79 81 83 85 86
80 82 85 87 89 91 93 95 97
89 91 94 96 98 101 103 105 107
97 100 103 105 108 110 113 115 118
106 109 112 115 118 120 123 126 128
115 118 121 124 127 130 133 136 139
123 127 130 134 137 140 143 146 149
132 136 140 143 147 150
141 145 149

130
4
5
6
7
9
10
11
14
19
24
30
35
41
46
52
57
68
77
82
88
99
109
120
131
142

135
4
5
6
7
9
11
12
14
20
25
30
36
42
47
53
58
69
79
83
90
101
112
122
133
144

140
4
5
6
8
9
11
12
14
20
26
31
36
42
48
54
59
70
80
85
91
102
114
124
136
147

145
4
5
6
8
9
11
12
14
20
26
31
37
43
49
55
60
72
82
86
93
104
116
127
138
150

150
4
5
6
8
9
11
13
15
21
26
32
38
44
49
56
61
73
83
88
95
106
118
129
140

155
4
5
6
8
9
11
13
15
21
27
32
38
44
50
56
62
74
84
89
96
108
119
131
143

160
4
5
6
8
9
11
13
15
21
27
33
39
45
51
57
63
75
86
91
98
110
121
133
145

165
4
5
6
8
9
11
13
15
21
27
33
39
46
52
58
64
76
87
92
99
111
123
135
147

170
4
5
6
8
9
11
13
16
22
27
34
40
47
53
59
65
77
88
94
101
113
125
137
150

175
4
5
6
8
10
12
14
16
22
28
34
41
47
53
60
66
79
90
95
102
115
127
139

File name:

180
4
5
6
8
10
12
14
16
23
28
35
41
48
54
61
67
80
91
96
104
116
129
141

185
4
6
7
9
10
12
14
17
23
29
35
42
49
55
62
68
81
92
98
105
118
130
143

190
5
6
7
9
10
12
14
17
23
30
36
42
49
56
62
69
82
93
99
106
119
132
145

195
5
6
7
9
10
13
14
17
24
30
36
43
50
56
63
70
83
95
100
108
121
134
147

200
5
6
7
9
10
13
14
17
24
30
37
43
50
57
64
71
84
96
101
109
122
136
149

LS 133-02 (EN)