Professional Documents
Culture Documents
1.0
General
The specification covers site strength and tightness pressure testing on site installed
pipework.
Prior to the tests, steps shall be taken to ensure the safety of people and to minimise risk
to property.
Where possible, previously strength tested vessels, piping and sensitive instrumentation
will be isolated from test pressures.
System safety pressure relief valves venting to atmosphere will not be fitted for the tests
and their connections will be blanked.
Termination points and other open orifices will be blanked or plugged where required.
"Soapy bubble" trace solution will be used during the tightness test.
For all pressure testing, the system under test shall be isolated from the source of
pressure after the test pressure has been reached.
A pressure test safety valve of adequate size shall be installed to prevent significant overpressure.
When pressure testing on site a pressure test manifold may be used.
For visual examination, a 350 Lux minimum light intensity is preferred.
Any reduction in pressure during the strength or tightness test holding periods, any visual
leakage or any permanent deformation shall be cause for rejection. Note that the
pressure will rise or fall approximately 0.34% for every 10K rise or fall (respectively) in
temperature during the test holding period.
Where called for, official third party inspection authority test witnessing will be conducted
by an authorised inspector.
Page 1 of 10
Standard Specification No
Some customers may have specific test requirements. Where these requirements differ
from those specified in this document, reference should be made to at Technical
Department.
There may be occasions when it is difficult to pressure test e.g. repairs to a system where
the isolating valves are suspect. Jobs like this require their own method statement, risk
assessments and consultation with the Technical Department. Decisions not to pressure
test shall only be made by the Technical Department who shall advise on alternative
procedures (e.g. 100% radiography may be required).
Refer to Appendix A for a matrix on the approved type of pressure test to conduct and
competency requirements for the operations group.
The Technical Department must be consulted before pressure testing repaired equipment
or used plant.
2.0
References
The pressure test procedures referred to in this specification take into account the
requirements of:
Method Statement OFN Strength and Tightness Testing of Site Assembled Systems
Page 2 of 10
Standard Specification No
3.0
3.1
3.2
Regulators
Single stage regulation is cheaper and suitable for most Refrigeration work. Two stage
regulators may be required for close control.
Regulators have relief valves fitted. These must never be removed or tampered with.
For all refrigerant systems, excluding CO 2 systems, a 40 Bar (G) outlet regulator will be
typical as standard. This is to ensure that the outlet pressure of the regulator can never be
significantly higher than the strength test pressure.
For the case of pressure testing on CO 2 systems a higher pressure rated regulator (say 70
Bar (G) or 100 Bar (G) outlet) will be required.
The pressure regulator outlet pressure limit ensures that the system is charged in a
controlled fashion. If the system volume is of a size where it will take a considerable length
of time to reach strength test pressure consideration should be given to charging from
multiple sources. Never tamper with a regulator to increase its outlet pressure.
BOC cylinders are available with 230 Bar (G) and 300 Bar (G) pressures.
Regulators for use on 230 Bar (G) cylinders are not suitable for 300 Bar (G) cylinders.
The pressure adjuster on the regulator shall always be unwound to its minimum position
before fitting the regulator to the cylinder (or other pressure source) shall always be
unwound and the cylinder valve shall never be opened without double checking that the
adjuster is fully unwound. This will stop gas flowing through the regulator possibly before
all is ready.
Page 3 of 10
Standard Specification No
Pressure testing of secondary refrigerant circuits which are using water, glycol or brine is
treated as a special case.
For this special case and where the pipes are long, hydraulic pressure testing of the
pipelines with water is acceptable. Oil cooler glycol circuits and underfloor heater mat
circuits fall into this category.
3.2.1
Approved Equipment
Regulators
Manufacturer
3.3
Pressure Inlet
Pressure Outlet
300 Bar
100 Bar
300 Bar
40 Bar
230 Bar
40 Bar
230 Bar
40 Bar
For Use Up To
6mm o.d./4mm i.d. stainless steel tube with M6 stainless steel EO unions both
ends
NB Hydraline FX AS, SS anti-static, black PTFE tube with 304 stainless steel
braid c/w 6mm o.d. standpipes with M6 stainless steel EO unions both ends.
Stainless steel swaged ends
NB Hydraline FX AS, SS anti-static, black PTFE tube with 304 stainless steel
braid c/w 6mm o.d. standpipes with M6 stainless steel EO unions both ends.
Stainless steel swaged ends
Page 4 of 10
Standard Specification No
3.4
Calibrated Gauge
A calibrated gauge with current calibration certificate shall be used. The pressure gauge
used during the pressure tests should be within 20% to 80% of its range at the test
pressure so the pressure is in the central part of the gauge, i.e. it shall have the dial
graduated over a range of about double the intended maximum pressure.
Pressure gauges shall be re-calibrated on a 6 monthly basis.
3.6
Page 5 of 10
Standard Specification No
Large systems can be tested in stages although forward planning is necessary to ensure
bosses are welded in appropriate places. These bosses can subsequently be plugged
(and insulated over if required).
The BiS valve is normally used on CO 2 systems. Re-calibration isnt normally carried
out. The valves should be replaced if they become damaged or after 5 years.
The equipment and arrangement described allows the pressure test gas supply pressure
in the charging line to be above the system allowable pressure so that the pressure can
be brought up to test pressure in a reasonable time using a normal size of charging line.
The outlet pressure of the pressure source regulator dictates the allowable pressure of
the
charging line and the person carrying out the pressure tests must ensure that the
charging line is fit for the purpose.
3.6.1
Approved Equipment
Relief Valves
Manufacturer
Pressure Setting
Code No.
10 Bar
S25N-10B
16.2 Bar
1775CE
20.5 Bar
1776CE
24.13 Bar
1777CE
27.58 Bar
1778CE
HRP
31.0 Bar
295988
BiS Valves
RL25-G-1.6K
BiS Valves
RL25-G-6K
Danfoss CVP-XP
25 52 Bar
027B0080
Danfoss CVP-HP
4 28 Bar
027B1161
BiS Valves
4.0
4.1
Page 6 of 10
Standard Specification No
Pressurisation shall be carried out in a controlled fashion at all times and the pressure
applied gradually Note - pipework seeing pressure for the first time is in fact being
strength pressure tested from the moment gas is first introduced.
When open to the system, the pressure source shall not be left unattended.
During initial pressurisation of the system up to strength test pressure and until the
pressure is reduced to tightness test pressure, at least two people shall be in
attendance.
The system shall never be approached if the pressure is greater than 10% of the
allowable pressure unless the pressure has been reduced by at least 10% from the
previous highest pressure.
Never attempt to tighten anything (e.g. screwed fittings) with the system under pressure.
Always isolate and blow down.
A strength test shall be held for a minimum of five minutes. Never approach the system
during this time.
OFN shall not be vented into a closed space where it could become an asphyxiation
hazard.
4.2
Test Pressures
4.2.1
Page 7 of 10
Standard Specification No
Allowable Pressure
Strength Test Pressure 1.1
Strength Test Pressure 1.43
Tightness Test Pressure
17.0
18.7
24.3
17.0
20.7
22.8
29.6
20.7
65.0
71.5
93.0
65.0
75.0
82.5
107.3
75.0
5.4
Site Pipework
5.4.1
Page 8 of 10
Standard Specification No
stage in the procedure, repairs to leaks shall not be carried out unless the pipework system
has been subjected to a pressure at least 10% higher than the pressure proposed for the
checking for leaks. Repairs must only be carried out with that section vented to atmosphere.
Thereafter the pressure will be increased in stages until the strength test pressure is reached.
After the strength test pressure is reached, the pipework shall be isolated from the pressure
source and held for a minimum of 5 minutes.
There should be no appreciable drop in pressure during this time.
5.4.2
5.4.2
5.5
Page 9 of 10
Standard Specification No
(or lower if the design pressure is lower) and the factory tightness test pressure. This is
intended to allow utilisation of pressure test gas from another part of the site installed system
and 4 Bar (G) is high enough to find all likely leaks but is complementary to the factory
tightness test. It shall not be used instead of the factory tightness test and all new pipe work
etc shall be tested to the tightness test pressure specified on the Diagram of Connections.
6.0
Documentation
The following documents give further information.
Document
Details
Risk assessment
Certification
Method Statement
Site Pipework
Page 10 of 10