PNEUMATIC TEST PROCEDURE

PURPOSE

Pneumatic test prescribed may be used in lieu of the standard hydrostatic test for vessels and pipelines:-

1. That are so designed and/or supported that they cannot safely be filled with water.
2. Not readily dried, that is to be used in services where traces of the testing liquid cannot be
tolerated.
SCOPE

This work instruction is applicable for pneumatic testing of towers, air receivers, pipelines, heat
exchangers and storage tanks.
REFERENCE DOCUMENTS
1. Applicable Drawings & Quality Assurance Plan.
2. ASME B 31.1, As Applicable.
3. ASME Section VIII Div-1.

RESPONSIBILITY
1. The Head Production shall be responsible for conducting pneumatic Test.
2. The Head Quality shall be responsible for approval of the test and get the same witnessed
by purchaser.

ACCEPTANCE CRITERIA

Except for leakage that might occur at temporary test closures for those openings intended for welded
connections, leakage is not allowed at the time of the required visual inspection.

CHECK LIST

1. Leakage from temporary seals shall be directed away so as to avoid masking leaks from other joints
2. All welded seams which will be hidden by assembly are given a visual examination for workmanship
prior to pressure test.
3. The vessel/ pipelines shall not contain “lethal” substance.
4. Put high pressure valve just after the source of pressure media and in testing equipment of testing
pipeline, to allow media to pressurize pipelines slowly and steadily.
5. Tighten two calibrated pressure gauges (pressure range of gauge should be 2 to 4 times of pneumatic
test pressure of vessel) anywhere between the testing areas as per standard engineering practice.
6. Finally mechanical clearance from the Engineer-In-Charge shall be taken before Pneumatic test in
approved format.

TEST MEDIA

Test media shall be nitrogen.

PROCESS SPECIFICATION

1. Visual Examination, Dimension verification, NDE, PWHT (if applicable) shall be completed
along with verification of internal QC records as per approved drawing and QAP to ensure that
the job is ready for the pneumatic testing.
2. Job shall also be cleared by quality head for visual, dimensional, NDE and PWHT (if applicable)
before pneumatic testing.
3. Dial indicating pressure gauge used in testing for Pressure Vessel / pipelines as per ASME
Section VIII Div 1 shall be graduated over a range of about double the intended maximum test
pressure, but in no case shall the range be less than 1 ½ nor more than 4 times that pressure.
4. The spacing between graduations in pressure gauge shall be such that the inspector and the
operator controlling the test shall be able to determine when the required test pressure has been
applied.
5. All pressure gages shall have valid calibration.
6. Before applying pressure, the test equipment shall be examined to see that it is tight and that all
low-pressure filling lines and other appurtenances that should not be subjected to the test pressure
have been disconnected.
7. Keep both temporary valves closed that have been fitted on start and end connection of source.
8. Start giving pneumatic pressure slowly by opening valve just after the source of pressure media.
9. Let the pressure increase till 0.5 X design pressure, and close source valve. Check all welded and
permanent bolted joints by soap solution.
10. If all mentioned areas of checking found OK, then open the source valve to increase the pressure
till 0.75 X design pressure, now close the source valve and check all welded and permanent
bolted joints by soap solution.
11. If all mentioned areas of checking found OK, then open the source valve to increase the pressure
till 1.1 X design pressure, and now close the source valve and check all welded and permanent
bolted joints by soap solution.
12. If all mentioned areas of checking found OK, then reduce the pressure by slightly opening the
valve fitted in testing equipment till design pressure and close the particular valve.
13. Now close the valve just after the source of pressure media and hold the pressure for 15 minutes.
14. If pressure drop is not found on both pressure gauges then the tested equipment can be certified as
found satisfactory with respect to pneumatic testing.

VENTING

1. Disconnect the testing media source.

2. Now, slowly and steadily open the valve of testing pipeline and allow releasing the pressure
gradually.

RECORDS
Records shall be prepared by Engineer in-charge and send it to inspection authority for approval.

SAFETY
1. Empower all personnel with the authority to “Stop Work” whenever hazardous conditions or

potentially hazardous conditions are identified.

2. Keep unauthorized personnel out of the test area.

3. Provide technical support for interpretation of pressure testing safety guidelines. Immediately

stop and correct any safety related non-compliant activities.

4. Adequate lighting shall be available throughout testing operations.

5. Personnel performing the test should approach the pressurized equipment/ pipelines only in the

performance of their duties.

 NOTE:- ALL THESE PROCESS SHOULD BE DONE BY QUALIFIED PROFFESIONAL
ONLY

CLIENT REPORT NO.

PROJECT NO. EQUIPMENT
DRG. NO. PROCEDURE NO.
INSPECTED BY DATE

PNEUMATIC TEST REPORT

DESCRIPTION
DESIGN CODE
DESIGN PRESSURE
DESIGN TEMPERATURE
TEST PRESSURE
DURATION OF TESTING
TESTING MEDIUM
DATE OF TEST
QUANTITY
OBSERVATION

TEST RESULT :

PRESSURE GAUGE DETAILS :

SL.NO. RANGE CALIBRATED ON CALIBRATION DUE ON
Shop in-charge Quality in-charge Approved By