PRESSURE TESTING

SAFETY AWARENESS
Pressure Testing

❖ Pressure tests are a non-destructive way to guarantee the integrity of equipment such as
pressure vessels, pipelines, plumbing lines, gas cylinders, and tanks.

❖ It is required by the piping codes to confirm that a tank/piping system is able to bear its rated
pressure and it has no leaks.

❖ Pressure tests may be done either

❖ with liquid, usually water (hydrostatic), or

❖ with gas, usually dry nitrogen (pneumatic).

Hydrostatic Pressure Testing

• Pressure systems being hydraulically

tested must be totally filled with the
pressure medium and properly
vented through drains.
• Combination of pressure and volume
of the pressure medium
• Whenever reasonably practicable,
water used for hydraulic testing may
be contained and re-used for other
pressure tests.
• High control high-risk activities involved and
needs to be controlled includes:
• high-velocity fluid jets (puncture wounds),
• projectiles (in case of rupture due to high
pressure),
• Flooding in areas where energized
electrical systems are present
• collapse of the system or its supporting
structure
Pneumatic Testing

• Pneumatic pressure tests

shall only be performed
when a hydrostatic test is
not practical, and the
applicable regulations
allow it.
 • High control high-risk activities involved and
needs to be controlled includes:
• Flying objects such as valves, flanges, gauges
Pneumatic and fittings
Testing • Flying shrapnel such as small pieces of pipe,
pipe fittings, and other system that shatter into
pieces due to high pressure.
• Under no circumstances shall a pneumatic test
be performed with a flammable, toxic or
greenhouse effect gas.
Hazards
• Flying objects due to breaking /
failure of line, gaskets, flanges, and
gauges.

• Flooding due to water leaks in areas

where energized electrical sources
are present.

• Air entrapment inside the pipe

• Excess Pressure / incorrect

measurements by gauges.

• Pressure Safety Valves failure.

Common causes of Pressure testing failures

• Over pressurizing a system;

• Inadequate/improper pressure testing equipment;
• Operator error;
• Inadequate repairs/modifications to a system;
• Failure to properly isolate parts being tested from
other parts of a system; and
• Failure to properly isolate equipment from the piping
system being tested.
Preparation for Pressure Testing

• Using SOP for the specific pressure testing

• Permit to work
• Pressure testing safety plan

• Checklist format

• Emergency response plan including emergency shutdown

procedures and emergency contact numbers.

• Pre-test safety briefing - TBT

• Worker Training
Preparation for Pressure Testing

• Relief valves must be incorporated into the

test system to prevent over pressurization
• Protect against personnel injury
• Prevent damage to test hardware
• Prevent damage to component being
tested
• Barricade the test area with red danger tape
to keep non-essential personnel out.
• Post warning signs.
Walk down - inspection of the system
• Verify the test pressure and the design pressure from the system engineer or
other qualified person.
• Verify that the test gauges are calibrated.
• Rating of fittings, pressure gauges, vent valves, gaskets shall be suitable for
the test pressure.
• Identify any adjacent equipment that could be affected by a failure
• Ensure that the system has been completed according to the drawings
• Ensure that the system is vented to bleed out air from the system while it is
being filled with the test medium.
• Ensure that all joints and connections are exposed for inspection/evaluation.
• Look for damaged components, misaligned segments and anything else that
is out of place.
• Ensure that all necessary lockout/tagout procedures have been completed
according to the SOP.
Pressure Testing – Safety
Measures
• Pre-test safety briefing
• Access shall be free from obstacle.
• Only essential and trained persons shall be
allowed at the Pressure test work location.
• PPEs- Ensure that all affected workers are
wearing a hardhat, safety glasses and gloves
when pressure testing any piping system.
• Supervisors shall be present at work location
during hydro testing activities are done.
Pressure Testing

• Use two test gauges, one at the pressure source and

one at the highest or furthest point from the pressure
source.
• Apply pressure gradually according the applicable SOP.
• Never exceed the maximum allowable working
pressure.
• Carefully inspect all joints and connections for signs of
leaking
• Pressure testing crew should not stay in the direction
of the blind flanges to prevent injury in case of flange
rapture.
• Whip lash arrestor shall be provided at hose
connection.
Post Testing
• Release pressure before attempting to repair any leaks.
• Never attempt to repair leaks while the system is under
pressure.
• Drain the system.
• Proper collection and disposal of the liquid test
medium.
• Repair any leaks that occur.
• Retest the piping system if necessary.