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.
