Chrysler LLC Construction Standards

12/17/04

SECTION 15951 - TESTING OF PIPING SYSTEMS

PART 1 - GENERAL

1.1  SUMMARY

  1. This Section specifies requirements and procedures for leak testing all piping systems.
  2. This Section does not include:
  3. Testing boilers and pressure vessels for compliance with safety codes.
  4. Specifications for materials for patching mechanical systems.

1.2  SUBMITTALS

  1. 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

  1. Manufacturers: Unless otherwise directed by the Owner, provide products by one of the following:
  2. American Gas & Chemical, Inc. (Leak Tek).
  3. Industrial Colloids and Chemicals, Inc.
  4. Nupro Co. (Snoop).
  5. Approved equal.
  6. Testing shall be accomplished with a soapless lather leak detector solution.

2.2  TEST MATERIALS

  1. All test materials shall be provided by Contractor as approved by Chrysler.
  2. Contractor may substitute an alternate test fluid with Architect/Engineer’s approval where there is a possibility of system damage due to freezing.
  3. Flammable test fluids with a flash point less than 120 deg F shall not be used.
  4. Contractor shall provide necessary test equipment including pumps, plugs, gages, etc.

2.3  WATER

  1. Provided by Owner for hydrostatic testing.
  2. Use potable water for testing potable water systems.

PART 3 - EXECUTION

3.1  TYPES OF TESTS

  1. Hydrostatic test
  2. Pneumatic test
  3. Pneumatic/"soap" test
  4. Drainage systems

3.2  TESTING PROCEDURES

  1. 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.
  2. Inspect all parts of the system for leaks, especially at valves, flanges, welds, thread connections, and packed joints. Leaks shall be repaired and retested.
  3. 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.
  4. 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.
  5. Test fiberglass reinforced plastic piping to 110 percent of the design pressure hydraulically.
  6. The Architect/Engineer shall be notified in sufficient time before the test to provide a representative as a witness.
  7. 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

  1. 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.
  2. Below ground piping to existing site connection shall be tested prior to making the connection.
  3. Contractor shall provide all required valves, caps, flanges etc. to perform test.
  4. 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.
  5. Expansion joints shall be provided with restraints.
  6. 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.
  7. 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.
  8. 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.
  9. Testing of Piping with Vessel as a System
  10. 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.
  11. 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 77percent of the temperature adjusted piping design pressure as defined in ANSI B31.3.

3.4  TESTS

  1. Hydrostatic
  2. 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.
  3. 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.
  4. A pressure recorder shall monitor the testing of piping systems to verify test results.
  5. 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.
  6. 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

  1. Piping system to be tested shall be pneumatically charged with the test gas to the test pressure specified.
  2. 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.
  3. A pressure recorder shall monitor testing of piping systems to verify test results. Provide copies of test data to Chrysler.
  4. 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

  1. Charge piping system in accordance with the pneumatic test above.
  2. Examine joints for leaks with a leak detector ("soap") solution.

3.7  DRAINAGE SYSTEMS

  1. 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.
  2. 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.
  3. 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 10inches in height or a pressure of 5 psig.

3.8  PRESSURE TESTING

  1. Coolant, and metallic process piping lines shall be tested in accordance with Hydronic Systems Pressure Testing requirements specified in Article 3.8 – Pressure Testing.
  2. Industrial waste and coolant transfer piping shall be tested in accordance with Hydronic System Pressure Testing requirements

Service / 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 Division15 / -- / -- / Water / --
Pressurized Utility Drains in accordance with Division15 / 100 / 150 / Hydro/Water / 24

END OF SECTION

TESTING OF PIPING SYSTEMS 15951 - 1 of 4