COURSE OVERVIEW:

Pressure testing is a critical quality control process used to verify the mechanical integrity of piping, vessels, and equipment before they are commissioned or returned to service. This course provides a comprehensive guide to the methodologies of hydrostatic and pneumatic testing, focusing on the rigorous standards required to ensure the system can safely contain its design pressure. Participants will explore the technical requirements of ASME B31.3 and ASME Section VIII, learning how to calculate test pressures and manage the stresses imposed during the test.

Safety is the paramount concern during pressure testing due to the immense stored energy within the system. This training focuses on the development of a "Test Pack" and the implementation of safety exclusion zones to protect personnel and property. The scope includes the selection of calibrated instrumentation, the management of test media, and the procedures for safe venting and draining. Participants will analyze the risks associated with pneumatic testing compared to hydrostatic methods and the specific precautions required for each.

The coverage of the course extends to the practical execution of the test, including the detection of leaks and the interpretation of pressure-time charts. Attendants will learn how to identify "false" pressure drops caused by temperature fluctuations and how to document the results for regulatory compliance. By the end of this program, participants will be able to plan and oversee pressure tests that are technically sound, accurately documented, and executed with the highest regard for operational safety.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1.  Explain the technical purpose and legal requirements of pressure testing.

2.  Differentiate between Hydrostatic, Pneumatic, and Hydro-Pneumatic tests.

3.  Calculate the required test pressure based on design and allowable stress.

4.  Prepare a comprehensive Pressure Test Pack including P&IDs and checklists.

5.  Select and verify the calibration of pressure gauges and chart recorders.

6.  Identify the risks of brittle fracture and the importance of test temperature.

7.  Execute safe filling, air venting, and pressurization sequences.

8.  Establish and manage safety exclusion zones and "Line of Fire" protocols.

9.  Diagnose the causes of pressure loss during the hold period.

10.  Manage the safe disposal of test media and chemical additives.

11.  Apply the specific safety guidelines for high-pressure pneumatic testing.

12.  Document test results accurately for final system certification.

13.  Troubleshoot equipment failures such as temporary blind or flange leaks.

TARGET AUDIENCE:

Project Engineers, Quality Control Inspectors, Maintenance Supervisors, Commissioning Technicians, and Safety Officers.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.