Pneumatic testing: pressure integrity for critical systems

Pneumatic testing validates the structural integrity and leak-tightness of piping systems, pressure vessels, and process equipment before they are introduced to process media. Using compressed air or nitrogen as the test medium, our teams verify that every joint, weld, flange, and connection meets design pressure specifications.

FARAMED deploys mobile pneumatic testing units with high-precision instrumentation for rapid, safe, and fully documented pressure testing on industrial construction sites.

Types of pneumatic tests

Strength test (pressure test)

The system is pressurized to a specified multiple of the design pressure (typically 1.1x for pneumatic per ASME B31.3) and held for a defined period. Pressure decay is monitored with calibrated instruments to confirm structural integrity.

Leak test

After the strength test, pressure is reduced to design pressure and held. Sensitive leak detection methods (soap bubble, ultrasonic, or helium tracer) are applied to every joint and connection. Any detectable leak is classified, repaired, and retested.

Service test

For instrument air systems and pneumatic actuator supply lines, the test verifies not only integrity but also functional performance: flow capacity, pressure regulation, and dew point compliance.

Our equipment

• Mobile air compressors rated for test pressures up to 350 bar
• Nitrogen supply systems for oxygen-free testing environments
• Calibrated digital pressure recorders with continuous data logging
• Ultrasonic leak detectors for high-sensitivity detection
• Calibrated pressure gauges and dead-weight testers
• Certified pressure relief devices for test safety
• Barricading and exclusion zone equipment per HSE requirements

Safety management

Pneumatic testing carries inherently higher risk than hydrostatic testing due to the stored energy in compressed gas. Our safety approach includes:

• Risk assessment before every test — documented HAZOP-style review of test boundaries, exclusion zones, and energy release scenarios
• Barricading and exclusion zones — physical barriers and signage per client and regulatory requirements
• Pressure build-up in steps — incremental pressurization (25%, 50%, 75%, 100%) with hold periods and inspection at each step
• Trained personnel — all technicians hold valid pressure testing certifications and site-specific HSE inductions
• Emergency procedures — documented and communicated to all personnel in the test area

Documentation and compliance

Every pneumatic test generates a complete documentation package:

• Test procedure approved by client engineering
• Pressure-time chart with continuous digital recording
• Leak test inspection report with joint-by-joint results
• Deficiency log and repair records
• Completion certificate signed by FARAMED and client representative

Applicable standards

• ASME B31.3 — Process piping pressure testing
• ASME VIII — Pressure vessel testing
• EN 13480 — Metallic industrial piping
• PED 2014/68/EU — Pressure Equipment Directive
• Client-specific specifications — adapted to each EPC and Owner requirement

Where we deploy

• FPSO topsides and module yards
• Offshore platforms (North Sea, GoM, SE Asia)
• Onshore refineries and petrochemical plants
• LNG terminals and regasification units
• Power plants and industrial utilities

Ready to plan your pneumatic testing program?

Contact our engineering team to discuss your piping scope, test pressures, and schedule. We will provide a mobilization plan and testing protocol tailored to your project specifications.