Pn e u m a t ic Te st in g

Presented by: Djordje Srnic, Manager of Design Survey Code Update Seminar Edmonton, October 05, 2010 Calgary, October 07, 2010

AS BA

the pressure equipment safety authority

Obj e ct ive s
Un de r st a n d Pu r pose of Pr e ssur e Te st in g Re gu la t ion Re qu ir e m e n t s H ydr ost a t ic vs. Pn e u m a t ic Te st Risk Pn e u m a t ic Te st in g Spe cific Re quir e m e n t s Re gist r a t ion Re quir e m e n t s

W h a t is t h e Pu r pose of Pr e ssu r e Te st in g?
To ve r ify system integrity leak tightness

W h y Pr e ssu r e t e st in g is r e qu ir e d?
Th e la st ph ysica l qu a lit y t e st in t h e fa br ica t ion pr oce ss Pe r for m e d pr ior t o pla cin g t h e syst e m in t o se r vice D on e in con t r olle d e n vir on m e n t Pr e fe r r e d m a in ly du e t o sa fe t y con side r a t ion s

Re gu la t ion Re qu ir e m e n t s
Se ct ion 3 0 of PESR 4 9 / 2 0 0 6 (1) All pressure piping leak tests must be conducted using the hydrostatic method. (2) Despite subsection (1), the Administrator may accept, for a specific pressure piping system, alternative test methods that are allowed in a code or standard that is declared in force. (3) A pressure piping system shall not be tested at a temperature that is colder than its minimum design temperature. (4) When conducting pressure tests, the ductile-to-brittle transition temperature and the possibility of brittle fracture must be considered by the contractor.

Alt e r n a t ive t e st M e t h ods

Pn e u m a t ic t e st H ydr ost a t ic- Pn e u m a t ic Te st I n it ia l Se r vice Le a k Te st Se n sit ive Le a k Te st Alt e r n a t ive Te st M e t h ods in Lie u of H ydr ost a t ic Le a k Te st in g for a Closu r e or Tie - I n W e lds

W h y Pn e u m a t ic Te st in g is Alt e r n a t ive t o H ydr ost a t ic Te st ?

D ifficu lt ie s w it h h ydr ost a t ic t e st in g
Supply & disposal of water, disposal of fluid additives Water leak can cause equipment damage Freeze susceptibility Structural support limitations Contamination Operational impacts - process contaminant Affect dry-out of internal refractory linings

Ava ila bilit y cle a n

a ir is r e a dily a va ila ble ,

H ydr ost a t ic vs. Pn e u m a t ic Te st Qu a lit a t ive D iffe r e n ce s

W a t e r is n ot com pr e ssible Energy storage is minimal Pressure changes finite amount by infinitesimal change in volume Water filled balloon does not pop no compressive energy Air is com pr e ssible Energy storage is large Pressure change proportional to volume change Air filled balloon pops large, instantaneous energy release

Risk

D a n ge r s Associa t e d W it h Pn e u m a t ic Te st in g

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Pr im a r y con ce r n s
Pr e ssur e w a ve Flyin g de br is

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D a m a ge cor r e la t ion
0.04 psi 0.10 0.15 0.30 0.50 0.70 1.0 2.0 2.4 2.5 3.0 Very loud noise [143 dB], sonic boom glass failure Breakage of small windows under strain Typical glass pressure induced failure 10% of windows broken Windows shattered, minor damage to house structures Upper limit for reversible effects on humans Partial demolition of houses Partial collapse of walls and roofs of houses Eardrum rupture Threshold for significant human lethality Steel frame building distorted and pulled away from foundation

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Flyin g D e br is
Fr a gm e n t a t ion Cr it e r ia Primary fragments Secondary fragments

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Pn e u m a t ic Te st Pr oce du r e ( PTP) Re gist r a t ion is Re qu ir e d

D e sign Su r ve y w ill r e vie w a n d r e gist e r PTP if p>315 psi or V>0.5m3 or Company does not have Standard PTP included in their quality program and piping system p=<315 psi and V=<0.5m3 St a nda r d PTP m a y be in clu de d in t he qua lit y syst e m a n d r e vie w e d by ABSA p=< 315 psi and V=<0.5m3

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Pn e u m a t ic Te st Pr oce du r e M u st
Pr ovide t e ch nica l j ust ifica t ion for not com ple t ing t h e h ydr ost a t ic pr e ssu r e t e st . Pr ovide a w r it t e n t e st pr oce dur e t h a t w ill fu lly a ddr e ss t h e t e ch nica l a n d sa fe t y conside r a t ions for t h e t e st . Be a cce pt a ble t o t h e ow ne r . Th e ow n e r of t h e piping syst e m m ust r e vie w t h e cir cum st a n ce s a n d de cide t o a cce pt t h e r isk of n ot h ydr ost a t ica lly t e st ing t h e piping syst e m Be r e vie w e d a n d a cce pt e d by ABSA.

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Te ch n ica l a n d Sa fe t y Con side r a t ion s

D e fin e t e st bou nda r ie s ( List of pipin g & Pr e ssur e ve sse ls in clu de d in t he t e st ) D e fin e syst e m volu m e a n d t e st flu id Ca lcu la t e t e st pr e ssur e Pr e ssur e r e lie f de vice s ( m a x se t pr e ssur e a t 1 1 0 % of t h e t e st pr e ssur e ) Sa fe t y pr e ca u t ions ( sa fe dist a n ce , ba r r ica de s, m a r k in g t h e t e st a r e a , h our s w he n t e st m a y be con du ct e d, w or k in g & e va cu a t ion pr oce dur e s, e t c.)

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Te ch n ica l a n d Sa fe t y Con side r a t ion s ( con t d)

St e ps t o m in im ize t h e ch a n ce of br it t le fa ilu r e dur in g a pne um a t ic t e st List of a ll pe r son ne l a llow e d w it h in t e st in g a r e a , r e quir e d t r a inin g a n d com pe t e nce s Pr e ca u t ions t a k e n t o pr e ve n t ga s e x pa nsion t e m pe r a t ur e dr op a n d t h e r m a l st r e ss du e t h e r m a l gr a die n t s M e t hod of t e st ing w it h de t a ils of pr e ssur e st e ps, h oldin g t im e , inspe ct ion m e t h ods, de pr e ssu r izin g Te st a cce pt a nce cr it e r ia a n d r e cor ds ( cr e a t in g a n d m a in t a in in g r e cor ds)
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Te st Pr e ssu r e
P t = 1 .1 x P x S at/ S dt Pt = test pressure P = Maximum allowable working pressure Sat = Allowable stress at the test temperature Sdt = Allowable stress at the design Temperature

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M e t h odologie s for D e fin in g Sa fe D ist a n ce

EPC com pa n ie s ha ve t h e ir ow n st a n da r ds & m e t h ods En d u se r s ha ve t h e ir ow n st a n da r ds N ASA m e t h od US D OD m e t h od ASM E PCC- 2 Ar t icle 5 .1 m e t h od

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Com m on Sa fe D ist a n ce An a lysis for Pn e u m a t ic Te st

D e fin e syst e m volu m e a n d t e st flu id Ca lcu la t e t e st pr e ssu r e Ca lcu la t e st or e d e n e r gy D e fin e e quiva le n t a m ou n t of TN T Ca lcu la t e t h e sa fe dist a n ce

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Ex a m ple :
Air ; p= 3 1 5 psi; V= 0 .5 m 3 St or e d e n e r gy = 1 ,6 7 7 k J TN T e qu iva le n t = 0 .3 9 3 k g Sa fe dist a n ce a ccor din g t o:
US DOD method R = 18.1 [m] NASA method R = 19.8 [m] ASME PCC-2 method R = 14.7 [m] * * R = 30 [m] because stored energy is E=1,677 [kJ] < 135,500 [kJ]

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ABSA is con side r in g Usin g t h e Equ iva le n t St or e d En e r gy

E= 1 ,6 7 7 [ k J] for piping syst e m w it h p= 3 1 5 [ psi] a n d V= 0 .5 [ m 3 ] Gr a ph e d st or e d e n e r gy for com bina t ion of volu m e a n d pr e ssur e w h ich w ou ld cr e a t e t h e sa m e st or e d e n e r gy a s piping syst e m w it h p= 3 1 5 [ psi] a n d V= 0 .5 [ m 3 ]

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Gr a ph

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Con clu sion

Kn ow le dge of Re gu la t ion r e qu ir e m e n t s Un de r st a n din g t h e Risk Com pe t e n cy of pe r son n e l Un de r st a n din g t e ch n ica l a n d sa fe t y con side r a t ion s D e ve lopm e n t a n d I m ple m e n t a t ion of t e st pr oce du r e ( be for e , du r in g a n d a ft e r t h e t e st )

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Qu e st ion s

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