Learning Objectives

Upon successful completion of this course, participants will be able to:

1. Fundamentals of Pressure Testing

• Understand the importance of pressure testing in industrial applications.
• Identify different types of pressure testing and their purposes.
• Learn about industry standards and regulatory requirements (ASME, API, ASTM, OSHA, ISO, PED, DOT).

2. Types of Pressure Testing and Their Applications

• Hydrostatic Testing – Water-based pressure testing for pipelines, pressure vessels, and heat exchangers.
• Pneumatic Testing – Air or gas-based testing for low-pressure and leak detection applications.
• Leak Testing – Helium, nitrogen, and soap bubble methods for identifying micro-leaks.
• Proof Testing – Load-bearing and material strength validation.
• Burst Testing – Determining the failure threshold of pressurized equipment.

3. Pressure Testing Equipment and Instrumentation

• Understand pressure pumps, gauges, transducers, and data loggers.
• Select the appropriate test fluid or gas for specific applications.
• Learn how to calibrate and verify pressure testing instruments.

4. Step-by-Step Pressure Testing Procedures

• Pre-test planning and site preparation.
• Equipment inspection and setup.
• Gradual pressurization and monitoring of pressure levels.
• Stabilization, hold time, and depressurization techniques.
• Data recording and test report documentation.

5. Safety Hazards and Risk Management in Pressure Testing

• Recognize common pressure testing hazards (overpressure, fluid injection, component failure, impact risks).
• Apply Personal Protective Equipment (PPE) and safety barriers.
• Implement lockout/tagout (LOTO) and isolation procedures.
• Develop contingency plans and emergency response protocols.

6. Regulatory Compliance and Documentation

• Ensure pressure testing compliance with ASME Section VIII, API 510, API 570, and OSHA requirements.
• Maintain proper pressure test records, permits, and inspection reports.
• Conduct post-test equipment inspections and certification procedures.

7. Troubleshooting and Corrective Actions

• Identify causes of pressure loss and test failures.
• Develop corrective action plans for leaks, pressure drops, and material weaknesses.
• Use non-destructive testing (NDT) techniques for deeper inspection.

8. Practical Hands-On Training and Case Studies

• Conduct live pressure testing exercises with hydrostatic and pneumatic methods.
• Analyze real-world case studies of pressure testing failures and best practices.
• Develop a customized pressure testing safety and quality control plan.

Target Audience

• Engineers and maintenance personnel
• Pipeline and pressure vessel inspectors
• Safety officers and risk management professionals
• Quality control and compliance managers
• Process plant operators and mechanical technicians