Valve Pressure Testing Safety Operation Procedures
Valves Pressure testing is an essential part of assessing the integrity and performance of valves. This procedure determines whether the valves can ensure the expected service pressure. In order to perform a valvePpressure test correctly and safely, the following procedure is required.
I. Pre-test Procedure:
1. Before the actual test pressure is applied, all personnel should be instructed to read the applicable safety rules and procedures.
2. The valve must be fitted with a safety valve conforming to the design standard, pressure testing standard, casing size, the maximum allowable working pressure, and the test pressure.
3. Ensure that the area is kept clear of debris and other tools and equipment during the pressure testing period.
4. Close all blind flanges and make sure that the pipeline is completely blocked.
II. Pressure Testing Procedure:
1. The valve is connected to the test medium (oil, water, steam, or air).
2. Install an appropriate safety valve or safety valve with a backflow prevention device in between the valve and the testing medium source.
3. Open the rapid release valve or air-tight quick opening valve on the test medium source, then check and adjust the performance of the valve.
4. Increase the test pressure in steps.
5. Move the valve and the safety valve up to the rated test pressure.
6. Monitor the valve and the safety valve while they are under pressure.
7. After the test pressure is fully achieved, record the test pressure, safety valve opening pressure, test duration, and the valve character’s opening and closing times, etc.
8. After the testing is complete, reduce the test pressure and close the valve.
9. Monitor the test pressure for a further 30 minutes and check for any possible leaks.
III. Test medium:
1. Test water should be clean and without suspended particles, such as from rivers, lakes, and wells and filtered upon use.
2. Air – is used for certain types of actuators and should be dry and clean and free from dust particles and dirt.
IV. Test Pressure:
1. Test pressure must not exceed the rated test pressure of the valve.
2. Test pressure must not exceed the maximum allowable working pressure of the valve.
3. Test pressure must not be lower than the design standard rated test pressure specified in the relevant standard.
4. Increase the test pressure gradually and monitor the valve and safety valve for any signs of an increase in leakage over time.
V. Test frequency:
1. Test every valve when installing it for the first time.
2. Test the valve after each maintenance and repair.
3. Test the valve at predetermined intervals as specified in the program of maintenance.
VI. Post-test Procedure
1. After the test is complete, close the valve.
2. Drain the test medium.
3. Remove any debris or material caused by the pressure test.
4. Record the test results.
5. Report any incidents or safety issues.
These procedures are to be strictly observed during the pressure testing of valves to ensure the safety of all personnel and the successful completion of the task. Safety is everyones responsibility and all personnel involved in the pressure testing of valves must adhere to these procedures to ensure the safe and successful completion of the pressure testing.
