PRESSURE TEST PROCEDURE

  1. Purpose
    1.1 To establish a procedure which defines the methods and requirements for pressure testing of burner products.
  2. Scope
    2.1 To meet project testing requirements, whilst proving component integrity, in a safe and controlled manner. Testing to be carried out in accordance with ASME B31.3 wherever possible.
    2.2 SAFETY – The following safety precautions shall be observed during pressure testing.
    2.2.1 Air under pressure is extremely dangerous. The pressure test inspector shall ensure all operators understand and take precautions to prevent the entrapment of air in any component, which is subject to a hydraulic pressure test.
    2.2.2 The test pressure stated within the project specific documents must not be exceeded under any circumstances.
    2.2.3 Test area have to identification mark and access to be restricted to authorised personnel only. All equipment to be used in testing to be suitable for the test pressure and in good condition.
  3. Test Requirements
    3.1 The test shall only be performed after 48 hours have elapsed from the last welding or PWHT on
    pressure parts and equipment supporting parts (parts that require a pressure test).
    3.2 No welding shall be done on the equipment and on any part in electric contact with the equipment while the equipment is holding water.
    3.3 Pressure gauges shall be calibrated before the beginning of the test with a minimum a validity of 3 months for calibration.
    3.4 The maximum scale value shall always be within 1.5 times and 4 times the test pressure and be
    preferably twice the test pressure.
    3.5 The smallest scale division shall not exceed 5 % of the maximum scale indication.
    3.6 The test pressure shall be that stated in on the detailed drawing of the component being tested with a minimum of 3.0 Barg.
  4. Hydraulic Test Procedure (For carbon steel pressure containing burner component assemblies)
    4.1 Blank off all openings except the fill point and incorporate calibrated pressure gauge. Gauge calibration to be traceable to national standard.
    4.2 It is recommended that a relief valve is incorporated within the system which is set at a pressure
    approximately 10% above the required test pressure.
    4.3 Fill burner component assembly with water (test water to verify that chloride content is below 50 PPM) until all internal air has been allowed to escape. Test medium to be fresh, clean potable water with the addition of a corrosion inhibitor to inhibit rust and corrosion. Fill to be from low point in system where ever possible and vent at highest point. Filling and Testing should not commence if
    ambient and /or system surface temperature is below 10°C or above 40°C.
    4.4 Close vessel and remove spilled water from the vessel surface.
    4.5 Upon reaching the test pressure the system under test is to be isolated and the test pump
    disconnected. Test pressure to be noted.
    4.6 Test period should be at least 30 minutes. Carry out a new equipment inspection. Note : No item shall be physically inspected at full pressure. Once the unit has been held at the correct pressure for the required duration the pressure should be dropped to the design operating pressure for visual
    examination. ③
    4.7 Any leaks found are to be marked and reported to the Project Manager and/or customer witness.
    4.8 On completion of satisfactory test, release pressure gradually to atmospheric pressure.
    4.9 The equipment shall be fully drained, dried and cleaned.
    4.10 Vessel to be hard stamped in accordance with project requirements.
    4.11 A Test Certificate shall be raised and signed by the Pressure Test Inspector.
    The Test Certificate is to be offered to any witnessing Inspectors for their endorsement.
    The Certificate should note the following as a minimum:
    Date of test
    Identification of Component Assembly being tested
    Test Pressure
    Test Medium
    Test Duration
    Certification of results by examiner
    Pressure Test Inspector’s name
    Test gauge ID No’s and calibration due date
    A Pressure Gauge Calibration Certificate shall be provided by the Pressure Test Inspector.
  5. Corrective Actions
    5.1 Any leaks /pressure drop found shall be reported to Project Manager.
    5.2 Project Manager to determine corrective action.
    5.3 Following corrective action pressure test to be repeated in accordance with this procedure. Project Manager to witness as a minimum.

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