Pneumatic Test Checklist in Plants and Refinery Projects

This article is about Checklist for Pneumatic Test, Pressure Testing Safely, pneumatic test procedure pdf as per International standards and osha standards. You can use this checklist for hydro test safety checklist also. You can find some topics points for pressure testing toolbox talk. For risk assessment for pressure testing pipework please check out here.

Pneumatic Test Checklist in Plants and Refinery Projects

1. A pressure test diagram must be with you during Pneumatic testing.
2. A test manifold arrangement with proof of Hydrotest and NDT of welds. (Test manifolds require revalidation of 36 months for each new project and for existing facilities).
3. The location of blind flanges and isolation valves, if any. (These locations should be clearly indicated in the Pressure Test diagram.).
4. The location of check valves (flappers should be removed, if necessary, prior to testing).
5. The location of the lowest rated component that determines the test pressure.
6. Relief valve size and set pressure along with the size calculation certificate and approval. A plant process or instrument engineer shall approve the relief valve set pressure and adequate relieving capacity. If neither is available consult with personnel in the Consulting Services Department or Process & Control Systems Department, if necessary, to assure that the relief valve has the proper set pressure and adequate capacity.
7. The test medium (Air or Nitrogen).
8. The test pressures and holding times.
   (Minimum 10 min holding times for steps and 30 minutes for final).
9. The minimum temperature allowed, if appropriate.
10. Inspection requirements and bubble test pressure Areas to be kept free of people during the test and the location of barricades, if appropriate The location of warning signs and markings for the test areas.
11. Work permits required, if any Additional or special personal safety equipment required.
12. Safety Instruction Sheets if available and emergency communication required, and the methods.
13. Vacuum valve size and set pressure, if any.
14. The location of the filling point.
15. Listing of correct sequence and necessary torque of all blind flange bolts and a requirement to verify proper torque when bolting
16. The verification of compliance with the manufacturer’s rating specifications ( e.g., quality, service use, pressure rating for all gaskets.
17. Tested relief valve(s) (within one month) with a tag stamped with the word “TEST”, the set pressure and date. The relief valve shall have adequate capacity to prevent overpressure during the test and shall have been tested in accordance with SAEP-319.
18. Two or more accurate and reliable pressure gauges with block and bleed valves to permit safe replacement of the gauges, if necessary. The gauges shall have been calibrated within  30 days prior to the test and their range shall be such that the maximum test pressure is within 30 to 80 percent of the full range. One gauge shall be located in the test piping such that it can be read by the pump operator. The other gauge(s) shall be located in the system under test. The pressure gauge calibration stickers should be affixed on the back of the pressure gauge.
19. A blowdown valve for depressurizing the test piping and a valve to isolate the test piping from the system under test shall be provided.
20. Do not exceed the following pressures until weaknesses have been repaired and leaks have been stopped: Any tests using air or other gas as a test medium: 173 kPa (25 psig) or 50% of the strength test pressure, whichever is the lower value.
21. After preliminary checks for leaks at the above pressures, the pressure shall be increased in steps with at least 10 minute holds at each step to permit inspection for leaks and weaknesses. In strength tests using air or other gas as the test
    medium, the pressure shall be increased in steps no greater than one-tenth of the strength test pressure after reaching 50% of the test pressure, as required in Section VIII of the ASME Pressure Vessel Code. The procedure shall have a table showing each pressure increase and minimum holding time.
22. Safe distance calculations shall be performed per ASME PCC-2-2008, Article 5.1, Mandatory Appendix lll, “Safe Distance Calculations for Pneumatic Pressure Test” and attached to the procedure.

For more information Pneumatic Pressure Testing please check out this article: PNEUMATIC TESTING PROCEDURE FOR MECHANICAL EQUIPMENT (CONVECTION, CROSS-OVER & RADIANT COIL)