ASME PCC-2–2022

(Revision of ASME PCC-2–2018)

Repair of
Pressure Equipment
and Piping
Reprinted from ASME PCC-2-2022, by permission
of The American Society of Mechanical Engineers.
All rights Reserved.

AN AMERICAN NATIONAL STANDARD

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x
 Date of Issuance: September 2, 2022

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 ASME PCC-2–2022

Article 503
Test Devices for Localized Pressure or Tightness Testing of
Welded Repairs

503-1 DESCRIPTION 503-1.2 Definitions ð22Þ

code hydrostatic leak test: a hydrostatic pressure test that
503-1.1 General meets the requirements of the applicable code, e.g., ASME
ð22Þ 503-1.1.1 Scope. This Article provides general good B31.3.
advice for the use of mechanical devices used to full system hydrostatic pressure test: a pressure test that
isolate sections of piping systems or equipment consists of the entire piping system being tested by the
nozzles and conduct a hydrostatic pressure or tightness application of pressure to the test value. This test gener-
test. Typical applications are ates stresses due to pressure, flange assembly, weight of
(a) testing the circumferential welds for the installa- piping system and test fluid, and initial flange misalign-
tion of a flange pair in a piping system ment.
(b) testing the circumferential weld for the new instal-
lation or replacement of a flange on an existing pressure local hydrostatic test: a pressure test that consists of the
vessel or tank nozzle application of pressure to the same or higher value as a full
(c) testing after the replacement or addition of new system hydrostatic pressure test at local regions around a
branches in piping systems weld in a piping system.
(d) isolating and testing piping assemblies that are weld leak test: the application of a hydrostatic test pres-
prefabricated for field installation (e.g., in modular fabri- sure to the weld location that will allow the identification
cation) of any existing through-wall leak paths in the weld.
ð22Þ 503-1.1.2 Types of Mechanical Devices for Testing
Circumferential Piping and Nozzle Welds. This Article 503-2 LIMITATIONS
describes the methods for use of four types of mechanical
503-2.1 Part 1 of This Standard
devices (see Figure 503-1.1.2-1) for isolation and testing
of piping systems or equipment nozzles in preparation for Part 1 of this Standard contains additional require-
testing. ments and limitations. This Article shall be used in
(a) Type I — internal plug with unconnected external conjunction with Part 1.
blind flange
(b) Type II — internal double-ended plug with external 503-2.2 Additional Considerations and ð22Þ
means of applying bolt load to the flange Limitations
(c) Type III — internal plug connected to an external
When using a weld test isolation device, the following
blind flange
limitations should be considered:
(d) Type IV — internal double-ended plug with no
(a) The user is cautioned to ensure that the use of any
assembly load on flange
device is done in accordance with the requirements of its
ð22Þ 503-1.1.3 Types of Mechanical Devices for Testing manufacturer, and the isolation of any system for pressure
Nozzle Neck to Shell or Head Welds, or Piping or tightness testing is verified.
Branch Connections. The following are the types of (b) There may be limitations by device manufacturers
mechanical devices (see Figure 503-1.1.3-1) for isolation regarding pressure, size, and configuration.
and testing of nozzles in pressure equipment and storage (c) Some devices may leave visible internal markings or
tanks, or branch connections in large diameter piping other damage (scoring, grooves, etc.) that may not be ac-
systems or pipelines: ceptable for certain services. For example, localized
(a) Type A — single-bolt internal device marking may result in regions of high hardness that
(b) Type B — multibolt internal device may not be acceptable in stress corrosion cracking
(c) Type C — exterior nozzle device services.

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 ASME PCC-2–2022

Figure 503-1.1.2-1
Hydrotest Device Types for Piping or Nozzles ð22Þ

(a) Type I (b) Type II

(c) Type III (d) Type IV

GENERAL NOTE: Reprinted with permission from Integrity Engineering Services, Dunsborough, Western Australia.

(d) Structural integrity of the piping system or pressure (b) Selection of device Type A, Type B, or Type C for
vessel is not being tested by this method as may be accom- nozzle neck to shell or head weld or piping branch connec-
plished by the application of a full system hydrostatic pres- tion should be made after consultation with the device
sure test. manufacturer and/or service provider. Local hydrostatic
(e) All devices will test the leak tightness of welds; testing of these joints typically does not create a state of
however, not all devices will test the integrity of the stress similar to that created by a full hydrotest or when in
weld by creating hoop and/or axial stresses that are service.
normally produced by full system hydrostatic pressure
tests. 503-3.1 Type I — Internal Plug With Unconnected
External Blind Flange
ð22Þ 503-3 DESIGN Type I devices are selected when there is a need to
(a) Table 503-3-1 should be considered for selection of conduct a pressure test that provides similar loadings
the device Type I, Type II, Type III, or Type IV for circum- as developed by a full system hydrostatic pressure test.
ferential welds. See also paras. 503-3.1 through 503-3.4.

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 ASME PCC-2–2022

Figure 503-1.1.3-1
ð22Þ Hydrotest Device Types for Nozzles or Branch Connections

GENERAL NOTE: Reprinted with permission from EST Group, Hatfield, PA, USA.

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 ASME PCC-2–2022

Table 503-3-1
Device Type Selection Guidance
Test Type I Type II Type III Type IV
Code hydrostatic leak test; all stress components Equivalent Equivalent Equivalent Equivalent
< 53 MPa (7.75 ksi)
Code hydrostatic leak test; circumferential stress Equivalent Equivalent Equivalent Equivalent
> 53 MPa (7.75 ksi), longitudinal stress [Note (1)]
< 53 MPa (7.75 ksi)
Code hydrostatic leak test; circumferential stress Equivalent Equivalent Equivalent Not equivalent
> 53 MPa (7.75 ksi), longitudinal stress [Note (2)]
> 53 MPa (7.75ksi)
Full system hydrostatic pressure test Equivalent Equivalent Not equivalent Not equivalent
[Note (3)] [Note (4)]
NOTES:
(1) Type IV hydrostatic pressure may need to be increased to compensate for the lack of flange assembly circumferential stresses.
(2) Type III may be considered equivalent if the longitudinal pressure stresses are small relative to the flange assembly stresses (< 30%).
(3) Type I may be considered equivalent if the stresses due to weight and misalignment are not considered significant.
(4) Type II may be adjusted to achieve a longitudinal stress in excess of nominal flange assembly and pressure stress, in order to compensate for
the lack of stresses due to weight and misalignment.

503-3.2 Type II — Internal Double-Ended Plug 503-3.4 Type IV — Internal Double-Ended Plug ð22Þ
With External Means of Applying Bolt With No Assembly Load on Flange
Load to the Flange (a) Type IV devices are selected when there is a need to
(a) Type II devices are selected when there is a need to conduct a leak test that does not apply any additional load-
conduct a pressure test that provides similar loadings as ings.
developed by a full system hydrostatic pressure test. (b) Tests using a Type IV device may be considered
(b) Type II devices are the only devices within the scope equivalent to full system hydrostatic pressure test
of this Article that are capable of developing a stress field when the test pressure is defined as follows:
at the weld that may be equal to or more severe than the ÄÅ ÉÑ
PHe = minÅÅÅÅ0.95 * 2Sy t/D ; PH + CAPC ÑÑÑÑ (1)
full system hydrotest (including self-weight-generated Ç Ö
external loads).
(c) A calculation to determine the appropriate bolt load where
to be applied by the external loading mechanism shall be CA = 3.0 for class 150 systems and 2.25 for class 300
developed. This calculation should determine whether the systems
developed longitudinal stresses at the weld meet or D = pipe outside diameter
exceed the full system hydrotest stress field. PC = flange class ceiling pressure according to ASME
(d) When using this method, the flange strength shall B16.5, Table A-1
be considered to ensure permanent deformation of the PH = hydrotest pressure
flange does not occur. See WRC 538 for further informa- PHe = hydrotest pressure to create an equivalent stress
tion. field
(e) Application of the external loads should be accu- Sy = the lowest specified minimum yield stress of the
rately measured so as to not be greater than the yield pipe system’s components
stress of the piping material. t = pipe wall thickness

ð22Þ 503-3.3 Type III — Internal Plug Connected to an Consultation with the device manufacturer should be
External Blind Flange considered for using Type IV devices in services above
Class 300 systems.
(a) Type III devices are selected when there is a need to (c) Type IV devices do not apply any axial stresses.
conduct a pressure test that provides similar loadings due
only to pressure as developed by a full system hydrostatic 503-4 FABRICATION ð22Þ
pressure test.
(b) Stresses applied by a Type III device include hoop This section covers the requirements for device instal-
and a reduced axial due to assembly of the device and lation.
pressure. (a) The minimum distance between the centerline of
(c) No external loadings are applied by this device. the circumferential weld to be tested and the seal location
for any of the methods described in this Article should be

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 ASME PCC-2–2022

Figure 503-4-1 (2) Fill with a pressure test medium and complete
Hydrotest Device Seal Location the test.

503-4.2 Type II – Internal Double-Ended Plug With ð22Þ

External Means of Applying Bolt Load to
the Flange
(a) A Type II device is a combination of a Type IV device
with the means to apply a bolt load to the weld. This may be
accomplished with a split ring flange that is capable of
eliminating any linear movement along the O.D. of the
pipe or nozzle (see Figure 503-4.2-1).
(b) Insert the Type IV device and secure to the I.D. of the
piping or nozzle.
(c) Install the split ring flange not less than 1.5(dt)0.5
from the end of the hydrotest device (see
Figure 503-4.2-1).
(d) Install a minimum of four bolts with nuts on the
GENERAL NOTE: Reprinted with permission from EST Group, inside of each flange to apply a force to the weld to be
Hatfield, PA, USA. tested. Apply torque to the bolt such that the resulting
stress is equal to or greater than what would be
applied by a full system hydrostatic pressure test.
(1) Determination of stress applied during test
greater than 1.5(dt)0.5(see Figure 503-4-1), where d is the should be in accordance with the construction code.
inner diameter of the pipe and T is the nominal pipe wall (2) Applied bolt stress should not exceed 380 MPa
thickness. (55 ksi), unless a higher stress is justified and calculation is
A distance less than 1.5(dt)0.5 may be used with the in accordance with ASME PCC-1, Nonmandatory Appendix
appropriate engineering analysis provided, and with O.
the acceptance of the owner. (3) Bolt torque to achieve the target bolt stress
(b) Ensure the interior of the piping system or pressure should be calculated in accordance with ASME PCC-1.
vessel is clean and free of any debris that may hinder the (e) Fill and pressurize the hydrotest device to the
sealing and/or clamping action of the device. desired pressure.
(c) Additional pipe length may be required for installa-
tion of the device to account for potential damage caused 503-4.3 Type III – Internal Plug Connected to an
by the device due to scoring, grooves, etc., as well as to External Blind Flange
allow all welds to be tested. In most cases, an additional
220 mm (9 in.) will suffice to allow for any potential (a) Install the device and assemble the flange joint.
damage to be removed and for all permanent piping to Apply torque such that the desired bolt stress is achieved;
be tested. After testing, remove the additional length of see ASME PCC-1.
pipe. (b) Fill with pressure test medium and complete the
test.
ð22Þ 503-4.1 Type I – Internal Plug With Unconnected
External Blind Flange 503-4.4 Type IV – Internal Double-Ended Plug
With No Assembly Load on Flange
(a) Type I may be installed with or without a lanyard to
prohibit movement into the pipe or pipeline (see (a) Engage the seals in accordance with the manufac-
Figures 503-4.1-1 and 503-4.1-2). turer’s instructions.
(b) For cases where a lanyard is used, a special blind (b) Fill with pressure test medium and complete the
flange from the device manufacturer may be required. test.
(c) The blind flange or piping section being tested shall See Figure 503-4.4-1.
contain openings such as threaded ports for filling and
venting and for release of pressure. It is advisable to 503-4.5 Types A, B, and C – Hydrotest Device Types ð22Þ
use a valve for pressure release. for Nozzle Welds or Piping Branch
(d) Operation (see Figure 503-4.1-3) Connections
(1) Installation of a Type I device shall be in accor-
(a) Installation of Type A, Type B, or Type C devices
dance with the manufacturer’s and/or service provider’s
shall be in accordance with the manufacturer's and/or
recommendations.
service provider's recommendations.

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 ASME PCC-2–2022

Figure 503-4.1-1
Type I Hydrotest Device With Lanyard

GENERAL NOTE: Reprinted with permission from EST Group, Hatfield, PA, USA.

Figure 503-4.1-2
Type I Hydrotest Device Without Lanyard

GENERAL NOTE: Reprinted with permission from EST Group, Hatfield, PA, USA.

(b) Fill with pressure test medium, and complete the to not less than the design pressure of the system being
test. tested while performing this examination. Acceptance
criteria shall be in accordance with the construction
503-5 EXAMINATION code or applicable in-service inspection code.

503-5.1 Examination Prior to Initiation of the 503-5.3 Examination Following Completion of the ð22Þ
Hydrotest Hydrotest
(a) Any required volumetric examination should be The interior and/or exterior of the pipe or pressure
completed prior to installation of the hydrotest device. vessel should be examined for surface damage where
(b) The weld to be tested should be examined by PT or the device clamps engaged with the interior and/or ex-
MT method. terior wall. Any damage found may be analyzed for accep-
tance using engineering methods or applicable in-service
ð22Þ 503-5.2 Examination During the Hydrotest inspection code.
(a) The minimum pressure of the hydrotest shall be
503-6 TESTING
monitored and shown to be stable for a minimum of 5
min or the time required by the construction code, which- In the context of this Article, this section is not appli-
ever is greater, indicating there are no leaks from the weld cable.
being tested.
(b) After the test pressure has been maintained for the
required duration, Visual Testing shall be performed on all
welds during the test. The test pressure should be reduced

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 ASME PCC-2–2022

Figure 503-4.1-3
Type I Typical Installations

GENERAL NOTE: Reprinted with permission from EST Group, Hatfield, PA, USA.

ð22Þ 503-7 REFERENCES (http://proceedings.asmedigitalcollection.asme.org/

proceeding.aspx?articleid=1815372&resultClick=3)
The following is a list of publications referenced in this Publisher: The American Society of Mechanical Engineers
Article. Unless otherwise specified, the latest edition shall (ASME). Two Park Avenue, New York, NY 10016-5990
apply. (www.asme.org)
ASME 16.5, Pipe Flanges and Flanged Fittings: NPS 1∕2 Brown, Warren. “Determination of Pressure Boundary
through NPS 24 Metric/Inch Standard Joint Assembly Bolt Loads.” Welding Research
ASME B31.3, Process Piping Council Bulletin 538 (February 2014).
ASME PCC-1, Pressure Boundary Bolted Flange Joint (https://www.forengineers.org/wrc-538.html)
Assembly Publisher: Welding Research Council (WRC), P.O. Box
Brown, Warren. “Comparison Between Full System 201547, Shaker Heights, OH 44120
Hydrotest and Local Hydrotest Methods for Pipe (www.forengineers.org/welding-research-council)
Butt Welds.” Paper presented at the 47th ASME Pres-
sure Vessels and Piping Conference, Paris, France, July
2013. doi:10.1115/PVP2013-97182.

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 ASME PCC-2–2022

Figure 503-4.2-1 Figure 503-4.4-1

Location of Split Ring Flange Type IV Device

1.5(dt)0.5

GENERAL NOTE: Reprinted with permission from EST Group,

Hatfield, PA, USA.

GENERAL NOTE: Reprinted with permission from Integrity Engi-

neering Services, Dunsborough, Western Australia.

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 ASME PCC-2–2022

INTENTIONALLY LEFT BLANK

300
ASME PCC-2–2022

Reprinted from ASME PCC-2-2022, by permission

of The American Society of Mechanical Engineers.
All rights Reserved.