Appendix D
PRESSURE TESTING AND INSPECTION

1. General

Whenever practical, pressure vessels and systems should be sent to the Facilities Maintenance Technician Shops (Building 76, ext. 7669) for pressure testing. When this is not practical, the vessel or system must be tested in accordance with the in-place pressure testing procedures described in Section 2, below. Pressure tests performed at Berkeley Lab must be conducted by a certified pressure installer, and must be observed (or conducted) and certified by the Engineering Division Director or his or her designee.

A summary of pressure-vessel and pressure-system testing is given in Table D-1.

The person who certifies the test must complete the Pressure Test Record form (Fig. D-1) and then attach an “LBNL Pressure Tested” label (Fig. D-2) to the vessel or system if it has passed the test.

Table D-1. Summary of Pressure-Vessel and Pressure-System Testing.

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LAWRENCE BERKELEY NATIONAL LABORATORY PRESSURE-TEST RECORD Date: _______________ Location of vessel (or system): Build. _____ Rm. _____ Description: ___________________________________ _____________________________________________ _____________________________________________ Pressure Vessel  Pressure System  (check box) "Pressure-Tested" Label attached  TEST INFORMATION: 1. Test pressure _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ____________________ Pa (______________ kpsi) 2. Testing Fluid (oil, He, etc.) _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __________________________________________ 3. Test Temperature _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ______________________°C (_______________°F) 4. Design Temperature _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _______________________°C (______________°F) 5. Safety Case _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ___________________________________________ 6. Responsible Designer _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Name: ___________________________________________ 7. Responsible User _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Name: ___________________________________________ Dept. ______________________________________ Divn: ______________________________________ 8. Diameter measurements (for pressure-vessel tests only) Location (marked) Before testing After testing Difference (+ or –) Remarks: _________________________________________________________________ Test by: ______________________________________ M&O, Mech. Shop CERTIFICATION: The vessel identified above has been pressure tested and is approved for operation within these test conditions. Certified by: ____________________________________________ Fig. D-1. Pressure Test Record.

When pressure vessels or systems are fabricated for Berkeley Lab by outside vendors, pressure testing may be performed by the vendor, but must be witnessed and documented by a Berkeley Lab responsible designer.

Pressure-test and pressure-inspection records must be maintained for the life of the vessel by the Facilities Maintenance Technician Shop, ext. 7669.

Pressure vessels must be tested in accordance with the rules in this section, using an inert fluid.

Pressure vessels for low-hazard inert systems for operation with nonflammable, nontoxic, and nonradioactive fluids

Pressure vessels for high-hazard reactive systems for operation with oxygen or flammable, toxic, and/or radioactive fluids

Inert-substance (low-hazard) pressure systems that will operate with nonhazardous liquids, inert gases, or compressed air

Reactive-substance (high-hazard) pressure systems that will operate with oxygen or with flammable, toxic, and/or radioactive fluids

Pressure vessels and systems may be leak tested at their MAWP level after successful pressure testing. Preliminary leak testing of nonpressure-tested or nondocumented pressure vessels or systems must be limited to a maximum of 20% of the test pressure (or proposed test pressure).

If a leak is detected during pressure tests of a vessel or system, and it is decided to locate the leak before completing the test, the pressure must be reduced to not over one-half the immediately preceding test pressure while the leak is being located.

A system or vessel must not be repaired while it is pressurized unless this is specifically authorized by the responsible designer.

Any modification to a pressure vessel or system, other than repair or replacement with an exact duplicate of existing components, must be approved by the responsible designer and recorded in a revision to the applicable engineering drawing, to the Safety Note, and to the AHD (if applicable). The initial pressure test must be repeated before any further use of the modified vessel or system.

If an ASME-Code vessel is modified, the Code stamping must be obliterated, and the Engineering Division Director must be so notified.

When pressure equipment has been modified for use at a pressure below the original design pressure, all modifications (e.g., use of fewer bolts in flanged joints) must be approved by the responsible designer. All safety requirements for the lower pressure must be met, and the reduced working pressure and the number of bolts or other supports required must be clearly marked on the equipment. If high-strength bolts or other special bolts are required, this must also be clearly marked on the equipment near the bolt holes.

Instructions on precautions for operation of the modified equipment must be sent to all concerned personnel, and one copy must be filed in the Safety Note file of the Engineering Division.

All high-hazard equipment that is neither a part of Facilities nor under the jurisdiction of the State of California must be as specified in the Safety Note or AHD.

Pressure reinspection is performed by a pressure inspector or by a responsible designer and is recorded on a Pressure Inspection Record form (Fig. D-3). The completed form must be signed by the responsible user and sent to the Facilities Maintenance Technician Shop, where it is kept for the life of the vessel.

The results of the retest must be certified on a Pressure Test Record Form (Fig. D-1) to be filed with the initial Pressure Test Record by the testing organization, and an LBNL Pressure Tested label (Fig. D-2) must be affixed on the vessel or system.

2. In-Place Pressure Testing

If it is impractical to pressure test a vessel or system at the Mechanical Shop, M&O Shop, or some other approved location, pressure test it in place, in accordance with the provisions of this section.

The responsible user must ensure that in-place retesting of pressure equipment is performed for which he or she is responsible. Although other individuals may be designated to observe and direct testing or retesting, responsibility for safe conduction of the test and safe functioning of tested pressure equipment cannot be delegated.

The responsible designer must prepare the required test procedure, direct the test personnel, and witness in-place pressure testing of vessels and systems for which he or she is responsible.

A written test procedure must be prepared for every high-hazard pressure test conducted in the field. When in-place pressure testing occurs, the test procedure must be included in (or appended to) the Safety Note.

Procedures for in-place testing of high-hazard vessels and systems must be approved by the Engineering Division Director or his or her designee.

The Building Manager or Area Supervisor must be advised of pressure tests planned in his or her facility, and EH&S must be notified if toxic and/or radioactive material is involved.

All pressure tests must be conducted by either the responsible designer or a person designated by the responsible designer, or by a Facilities Maintenance Technician, Facilities Mechanic, or Machinist in the Assembly Shop. Pressure tests must be observed and certified by the responsible designer or a pressure inspector.

For in-place testing with liquids, all air must be carefully removed from both the testing system and the equipment to be tested. This is because compressed air will expand violently in case of vessel failure. Spongy action of pumping equipment usually indicates the presence of trapped air.

Pressure testing with a gas is far more dangerous than testing with a liquid. Therefore, tests must be conducted with liquids, whenever practical.

Before testing, barricade the equipment being tested, shield the controls and operators, and evacuate all unauthorized personnel from the test area. Signs reading “Danger—High-Pressure Test in Progress—Keep Out” must be posted at all approaches to the test area.

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