DaimlerChrysler
Construction Standards
12/17/04
SECTION 15951 - TESTING OF PIPING SYSTEMS
PART 1 - GENERAL
1.1
SUMMARY
This Section specifies requirements and procedures for leak testing all piping systems.
This Section does not include:
Testing boilers and pressure vessels for compliance with safety codes.
Specifications for materials for patching mechanical systems.
1.2
SUBMITTALS
Test Reports: Prepare test report for each system being tested indicating system description, date of
test, type of test, test pressure, ambient temperature, and witness signature.
PART 2 - PRODUCTS
2.1
LEAK DETECTOR ("SOAP") SOLUTION
Manufacturers: Unless otherwise directed by the Owner, provide products by one of the following:
American Gas & Chemical, Inc. (Leak Tek).
Industrial Colloids and Chemicals, Inc.
Nupro Co. (Snoop).
Approved equal.
Testing shall be accomplished with a soapless lather leak detector solution.
2.2
TEST MATERIALS
All test materials shall be provided by Contractor as approved by DaimlerChrysler.
Contractor may substitute an alternate test fluid with Architect/Engineer’s approval where there is a
possibility of system damage due to freezing.
Flammable test fluids with a flash point less than 120 deg F shall not be used.
Contractor shall provide necessary test equipment including pumps, plugs, gages, etc.
2.3
WATER
Provided by Owner for hydrostatic testing.
Use potable water for testing potable water systems.
PART 3 - EXECUTION
3.1
TYPES OF TESTS
Hydrostatic test
Pneumatic test
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Pneumatic/"soap" test
Drainage systems
3.2
TESTING PROCEDURES
Blank off or replace with spool pieces items of equipment such as vessels, pumps, instruments,
controls, safety and relief valves, and alike rated for pressure less than the test pressure. All
equipment shall be reconnected after testing.
Inspect all parts of the system for leaks, especially at valves, flanges, welds, thread connections, and
packed joints. Leaks shall be repaired and retested.
Contractor shall use precautions during pneumatic pressure testing to safeguard personnel. Clear
installation area of personnel not engaged in the testing operations. Visually inspect the system
for compliance with design drawings and specifications prior to test.
Pneumatic testing of nonmetallic piping is not permitted except with written approval of the
Architect/Engineer. If nonmetallic piping is tested pneumatically, the test pressure shall be 110
percent of the design pressure.
Test fiberglass reinforced plastic piping to 110 percent of the design pressure hydraulically.
The Architect/Engineer shall be notified in sufficient time before the test to provide a representative as
a witness.
Contractor is not permitted to test the piping without a representative of the Owner being present
or without signed permission. If permitted, the test record form shall read that the test
was run without a witness and must be signed by the Architect/Engineer.
3.3
TESTING PREPARATION
Aboveground piping joints, including welds and bonds, shall be left uninsulated and exposed for
examination during the test, except that joints previously tested in accordance with this
specification may be insulated or covered. If pneumatic/"soap" test is required, all joints also
shall be left unprimed and unpainted.
Below ground piping to existing site connection shall be tested prior to making the connection.
Contractor shall provide all required valves, caps, flanges etc. to perform test.
Piping designed to convey vapor or gas shall be provided with additional temporary supports, as
required to support the weight of the test fluid where hydrostatic testing is specified.
Expansion joints shall be provided with restraints.
Equipment which is not to be subjected to pressure test shall be either disconnected from the piping or
isolated by blinds or other means during the tests. Valves may be used provided the valve
(including the closure mechanism) is suitable for proposed test pressure. After test is complete,
instruments, valves, etc. shall be reconnected and leak tested to the operating pressure of the
system.
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A flanged joint at which a blank is inserted to blank-off other equipment during the test is not required
to be tested. A "blank list" shall be prepared listing where blanks have been installed for testing,
and shall be provided to the Architect/Engineer after testing is complete to verify that all blanks
have been removed.
Precautions shall be taken to avoid excessive pressure during the pressure test due to thermal
expansion of the test fluid during the course of the test.
Testing of Piping with Vessel as a System
When the test pressure of piping attached to a vessel is the same or less than the test pressure
of the vessel, the piping may be tested with the vessel at the test pressure of the piping.
When the test pressure of the piping exceeds the vessel test pressure and it is not considered
practical to isolate the piping from the vessel, the piping and vessel may be tested
together at the test pressure of the vessel when approved by the Architect/Engineer and
when the vessel test pressure is not less than 77 percent of the temperature adjusted
piping design pressure as defined in ANSI B31.3.
3.4
TESTS
Hydrostatic
Piping system to be tested shall be charged with test liquid to the test pressure specified. The
pressure test shall be maintained as indicated in 3.8 to determine if there are any leaks.
Exterior surface of pipe and fittings shall show no cracks or other forms of leaks and be
completely drop dry. Test liquid shall be warm enough to preclude atmospheric moisture
on system surfaces; use supplemental heat if necessary.
Piping system shall be filled slowly from the lowest point in the system such that all air is purged
through a valved vent at a high point in the pipe. All piping being tested shall be in contact
with all hangers and supports before filling. Upon completion of filling and air purging, the
vent valve shall be closed slowly and the system slowly pressurized to prevent water
hammer. Quick-closing valves and booster pumps without suitable controls shall not be
used.
A pressure recorder shall monitor the testing of piping systems to verify test results.
If hydrostatic testing is not considered practical by the Owner, a pneumatic test may be
substituted using oil-free compressed air or another nonflammable gas. If piping is tested
pneumatically, test pressure shall be 110 percent of the design pressure.
Hydrostatic testing shall not be performed in cases where a freeze potential exists. Test piping
with non-freezing medium or on days when it is not going to freeze.
3.5
PNEUMATIC TESTING
Piping system to be tested shall be pneumatically charged with the test gas to the test pressure
specified.
Piping system shall be maintained at the test pressure for not less than two hours, unless otherwise
noted, to determine if there are any leaks. Test shall be made when ambient air temperature is
approximately constant. Corrections for pressure differences due to temperature changes shall
be made.
A pressure recorder shall monitor testing of piping systems to verify test results. Provide copies of test
data to DaimlerChrysler.
Pneumatic tests shall include a preliminary check at not more than 25 psig to examine for major leaks.
Pressure shall be increased gradually in steps. Provide time to allow piping to equalize strains
during test and to check for leaks.
3.6
PNEUMATIC/"SOAP" TEST
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Charge piping system in accordance with the pneumatic test above.
Examine joints for leaks with a leak detector ("soap") solution.
3.7
DRAINAGE SYSTEMS
Underground process drainage piping shall be tested hydraulically at a static head of 10 feet. Leakage
at any point in the system will be sufficient cause for rejection and renewal as required.
Aboveground process drainage lines shall be tested hydraulically by closing all openings in the system,
except opening above the roof, and by filling the system to the point of overflowing. In no case
shall pressure exerted on the system be less than 10 feet of head. Leakage at any joint in the
system will be sufficient cause for rejection and renewal of joint unless joint can be taken up
sufficiently to stop leakage.
Alternate Test: Air tests may be substituted for hydraulic tests by forcing air into the closed system at a
uniform pressure sufficient to support a column of mercury 10 inches in height or a pressure of 5
psig.
3.8
PRESSURE TESTING
Coolant, and metallic process piping lines shall be tested in accordance with Hydronic Systems
Pressure Testing requirements specified in Article 3.8 – Pressure Testing.
Industrial waste and coolant transfer piping shall be tested in accordance with Hydronic System
Pressure Testing requirements
Design
Pressure (psig)
Test Pressure
(psig)
Test Type/Test
Medium
Min. Test
Duration Hours
Hydronic Systems in
accordance with Division 15
100
150
Hydro/Water
24
Compressed Air Systems in
accordance with Division 15
125
190
Pneu/Nitro or
Dry Air
1
Natural Gas Systems
Aboveground in accordance
with Division 15
10
15
Pneu/Nitro
24
Atmospheric Utility Drains in
accordance with Division 15
--
--
Water
--
Pressurized Utility Drains in
accordance with Division 15
100
150
Hydro/Water
24
Service
END OF SECTION
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