345 TESTING

345.1 Required Leak Test

Prior to initial operation, and after completion of the applicable examinations required by
para. 341, each piping system shall be tested to ensure tightness. The test shall be a
hydrostatic leak test in accordance with para. 345.4 except as provided herein.

(a) At the owner’s option, a piping system in Category D fluid service may be subjected to an
initial service leak test in accordance with para. 345.7, in lieu of the hydrostatic leak test.

(b) Where the owner considers a hydrostatic leak test impracticable, either a pneumatic test in
accordance with para. 345.5 or a combined hydrostatic-pneumatic test in accordance with
para. 345.6 may be substituted, recognizing the hazard of energy stored in compressed gas.

(c) Where the owner considers both hydrostatic and pneumatic leak testing impracticable, the
alternative specified in para. 345.9 may be used if both of the following conditions apply:

(1) a hydrostatic test would damage linings or internal insulation, or contaminate a process
which would be hazardous, corrosive, or inoperative in the presence of moisture, or would
present the danger of brittle fracture due to low metal temperature during the test

(2) a pneumatic test would present an undue hazard of possible release of energy stored in the
system, or would present the danger of brittle fracture due to low metal temperature during
the test

345.2 General Requirements for Leak Tests

Requirements in para. 345.2 apply to more than one type of leak test.

345.2.1 Limitations on Pressure

(a) Stress Exceeding Yield Strength. If the test pressure would produce a nominal pressure
stress or longitudinal stress in excess of yield strength at test temperature, the test pressure
may be reduced to the maximum pressure that will not exceed the yield strength at test
temperature. [See paras. 302.3.2(e) and (f).]

(b) Test Fluid Expansion. If a pressure test is to be maintained for a period of time and the test
fluid in the system is subject to thermal expansion, precautions shall be taken to avoid
excessive pressure.

(c) Preliminary Pneumatic Test. A preliminary test using air at no more than 170 kPa (25 psi)
gage pressure may be made prior to hydrostatic testing to locate major leaks.

345.2.2 Other Test Requirements

(a) Examination for Leaks. A leak test shall be maintained for at least 10 min, and all joints and
connections shall be examined for leaks.

(b) Heat Treatment. Leak tests shall be conducted after any heat treatment has been
completed.

(c) Low Test Temperature. The possibility of brittle fracture shall be considered when
conducting leak tests at metal temperatures near the ductile-brittle transition temperature.

345.2.3 Special Provisions for Testing

(b) Flanged Joints. Flanged joints used to connect piping components and subassemblies that
have previously been tested, and flanged joints at which a blank or blind is used to isolate
equipment or other piping during a test, need not be leak tested in accordance with para.
345.1.

(c) Closure Welds. The final weld connecting piping systems or components which have been
successfully tested in accordance with para. 345 need not be leak tested provided the weld is
examined in-process in accordance with para. 344.7 and passes with 100% radiographic
examination in accordance with para. 344.5 or 100% ultrasonic examination in accordance
with para. 344.6.

345.2.4 Externally Pressured Piping. Piping subject to external pressure shall be tested at an
internal gage pressure 1.5 times the external differential pressure, but not less than 105 kPa
(15 psi).

345.2.5 Jacketed Piping

(a) The internal line shall be leak tested on the basis of the internal or external design pressure,
whichever is critical. This test must be performed before the jacket is completed if it is
necessary to provide visual access to joints of the internal line as required by para. 345.3.1.

(b) The jacket shall be leak tested in accordance with para. 345.1 on the basis of the jacket
design pressure unless otherwise specified in the engineering design.

345.2.6 Repairs or Additions After Leak Testing. If repairs or additions are made following the
leak test, the affected piping shall be retested, except that for minor repairs or additions the
owner may waive retest requirements when precautionary measures are taken to assure
sound construction.

345.2.7 Test Records. Records shall be made of each piping system during the testing,
including

(a) date of test

(b) identification of piping system tested

(c) test fluid

(d) test pressure

(e) certification of results by examiner These records need not be retained after completion of
the test if a certification by the Inspector that the piping has satisfactorily passed pressure
testing as required by this Code is retained.

345.3 Preparation for Leak Test

345.3.1 Joints 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, except that joints previously tested in accordance with this Code may be
insulated or covered. All joints may be primed and painted prior to leak testing unless a
sensitive leak test (para. 345.8) is required.
345.3.2 Temporary Supports. Piping designed for vapor or gas shall be provided with additional
temporary supports, if necessary, to support the weight of test liquid.

345.3.3 Piping With Expansion Joints

(a) Unrestrained expansion joints depend on external main anchors to resist pressure thrust
forces. Except as limited in para. 345.3.3(c), a piping system containing unrestrained expansion
joints shall be leak tested without any temporary restraints in accordance with para. 345 up to
150% of the expansion joint design pressure. If the required test pressure exceeds 150% of the
expansion joint design pressure and the main anchors are not designed to resist the pressure
thrust forces at the required test pressure, for that portion of the test when the pressure
exceeds 150% of the expansion joint design pressure, the expansion joint shall either be
temporarily removed or temporary restraints shall be added to resist the pressure thrust
forces.

(b) Self-restrained metallic bellows expansion joints (i.e., tied, hinged, pressure balanced, etc.)
have restraint hardware designed to resist the pressure thrust forces. Except as limited in para.
345.3.3(c), a piping system containing self-restrained expansion joints shall be leak tested in
accordance with para. 345. A self-restrained expansion joint previously shop tested by the
manufacturer in accordance with Appendix X may be excluded from the system to be leak
tested, except when a sensitive leak test in accordance with para. 345.8 is required. Restraint
hardware for all types of expansion joints shall be designed for the pressure thrust forces at
the test pressure.

(c) When a metallic bellows expansion joint is installed in the piping system subject to a leak
test and the leak test pressure determined in accordance with para. 345 exceeds the pressure
of the test performed by the manufacturer in accordance with Appendix X, the required leak
test pressure shall be reduced to the manufacturer’s test pressure.

345.3.4 Limits of Tested Piping. Equipment which is not to be tested shall be either
disconnected from the piping or isolated by blinds or other means during the test. A valve may
be used provided the valve (including its closure mechanism) is suitable for the test pressure.

345.4 Hydrostatic Leak Test

345.4.1 Test Fluid. The fluid shall be water unless there is the possibility of damage due to
freezing or to adverse effects of water on the piping or the process (see para. F345.4.1). In that
case another suitable nontoxic liquid may be used. If the liquid is flammable, its flash point
shall be at least 49°C (120°F), and consideration shall be given to the test environment.

345.4.2 Test Pressure. Except as provided in para. 345.4.3, the hydrostatic test pressure at any
point in a metallic piping system shall be as follows:

(a) not less than 1.5 times the design pressure.

(b) when the design temperature is greater than the test temperature, the minimum test
pressure, at the point under consideration, shall be calculated by eq. (24). When the piping
system contains more than one material or more than one design temperature, eq. (24) shall
be used for every combination, excluding pipe supporting elements and bolting, and the
maximum calculated value of PT is the minimum test gage pressure.

PT p 1.5 PRr (24)

P = internal design gage pressure

PT = minimum test gage pressure

Rr = ratio of ST/S for pipe or components without established ratings, but shall not exceed 6.5

= ratio of the component pressure rating at the test temperature to the component pressure
rating at the component design temperature for components with established ratings, but
shall not exceed 6.5

S = allowable stress value at component design temperature (see Table A-1) ST p allowable
stress value at test temperature Alternatively, for carbon steel piping with a minimum
specified yield strength not greater than 42 ksi (290 MPa), the test pressure for the assembly
of components, excluding pipe supporting elements and bolting (e.g., pipe, fittings, valves,
flanges), may be based on Rr for any of the components in the assembly.

(c) if the test pressure as defined above would produce a nominal pressure stress or
longitudinal stress in excess of the yield strength at test temperature or a pressure more than
1.5 times the component rating at test temperature, the test pressure may be reduced to the
maximum pressure that will not exceed the lesser of the yield strength or 1.5 times the
component ratings at test temperature. [See paras. 302.3.2(e) and (f).] For metallic bellows
expansion joints, see Appendix X, para. X302.2.3(a).

345.4.3 Hydrostatic Test of Piping With Vessels as a System 4

(a) Where the test pressure of piping attached to a vessel is the same as or less than the test
pressure for the vessel, the piping may be tested with the vessel at the piping test pressure.

(b) Where the test pressure of the piping exceeds the vessel test pressure, and it is not
considered practicable to isolate the piping from the vessel, the piping and the vessel may be
tested together at the vessel test pressure, provided the owner approves and the vessel test
pressure is not less than 77% of the piping test pressure calculated in accordance with para.
345.4.2(b).

345.5 Pneumatic Leak Test

345.5.1 Precautions. Pneumatic testing involves the hazard of released energy stored in
compressed gas. Particular care must therefore be taken to minimize the chance of brittle
failure during a pneumatic leak test. Test temperature is important in this regard and must be
considered when the designer chooses the material of construction. See para. 345.2.2(c) and
Appendix F, para. F323.4.

345.5.2 Pressure Relief Device. A pressure relief device shall be provided, having a set pressure
not higher than the test pressure plus the lesser of 345 kPa (50 psi) or 10% of the test
pressure.

345.5.3 Test Fluid. The gas used as test fluid, if not air, shall be nonflammable and nontoxic.
345.5.4 Test Pressure. The test pressure shall be 110% of design pressure.

345.5.5 Procedure. The pressure shall be gradually increased until a gage pressure which is the
lesser of one-half the test pressure or 170 kPa (25 psi) is attained, at which time a preliminary
check shall be made, including examination of joints in accordance with para. 341.4.1(a).
Thereafter, the pressure shall be gradually increased in steps until the test pressure is reached,
holding the pressure at each step long enough to equalize piping strains. The pressure shall
then be reduced to the design pressure before examining for leakage in accordance with para.
345.2.2(a).

345.6 Hydrostatic-Pneumatic Leak Test

If a combination hydrostatic-pneumatic leak test is used, the requirements of para. 345.5 shall
be met, and the pressure in the liquid filled part of the piping shall not exceed the limits stated
in para. 345.4.2.

345.7 Initial Service Leak Test

This test is applicable only to piping in Category D Fluid Service, at the owner’s option. See
para. 345.1(a).

345.7.1 Test Fluid. The test fluid is the service fluid.

345.7.2 Procedure. During or prior to initial operation, the pressure shall be gradually
increased in steps until the operating pressure is reached, holding the pressure at each step
long enough to equalize piping strains. A preliminary check shall be made as described in para.
345.5.5 if the service fluid is a gas or vapor.

345.7.3 Examination for Leaks. In lieu of para. 345.2.2(a), it is permissible to omit examination
for leakage of any joints and connections previously tested in accordance with this Code.

345.8 Sensitive Leak Test

The test shall be in accordance with the Gas and Bubble Test method specified in the BPV
Code, Section V, 83 Article 10, or by another method demonstrated to have equal sensitivity.
Sensitivity of the test shall be not less than 10−3 atm·ml/sec under test conditions.

(a) The test pressure shall be at least the lesser of 105 kPa (15 psi) gage or 25% of the design
pressure.

(b) The pressure shall be gradually increased until a gage pressure the lesser of one-half the
test pressure or 170 kPa (25 psi) is attained, at which time a preliminary check shall be made.
Then the pressure shall be gradually increased in steps until the test pressure is reached, the
pressure being held long enough at each step to equalize piping strains.

345.9 Alternative Leak Test

The following procedures and leak test method may be used only under the conditions stated
in para. 345.1(c).

345.9.1 Examination of Welds. Welds, including those used in the manufacture of welded pipe
and fittings, which have not been subjected to hydrostatic or pneumatic leak tests in
accordance with this Code, shall be examined as follows:

(a) Circumferential, longitudinal, and spiral groove welds shall be 100% radiographed in
accordance with para. 344.5 or 100% ultrasonically examined in accordance with para. 344.6.
(b) All welds, including structural attachment welds, not covered in (a) above, shall be
examined using the liquid penetrant method (para. 344.4) or, for magnetic materials, the
magnetic particle method (para. 344.3).
345.9.2 Flexibility Analysis. A flexibility analysis of the piping system shall have been made in
accordance with the requirements of para. 319.4.2 (b), if applicable, or (c) and (d).

345.9.3 Test Method. The system shall be subjected to a sensitive leak test in accordance with
para. 345.8.

346 RECORDS

346.2 Responsibility

It is the responsibility of the piping designer, the manufacturer, the fabricator, and the erector,
as applicable, to prepare the records required by this Code and by the engineering design.
346.3 Retention of Records

Unless otherwise specified by the engineering design, the following records shall be retained
for at least 5 y after the record is generated for the project:

(a) examination procedures

(b) examination personnel qualifications