Pressure and Leak Testing Training

Section 1: Introduction to Pressure and Leak Testing (5 minutes)
This module will introduce the learner to the course and will emphasise the importance of leak testing of disturbed joints on hydrocarbon systems prior to returning to service.

• Recognise what leak testing is used for
• Recognise what pressure testing is used for
• Identify systems that require to be pressure or leak tested
• Identify the risk mitigation measures which should be taken while carrying our pressure or leak testing
• Recognise the risk of working in oxygen deficient atmospheres

Section 2: Leak Testing and Pressure Testing Methods and Associated Hazards (10 minutes)
This module will discuss the various methods of leak testing, and pressure testing of vessels and pipework, and will also consider the hazards associated with hydrostatic and pneumatic testing.

• Identify various methods of pressure / leak testing
• Recognise what is meant by the terms ‘proof testing’ and ‘strength testing’ in relation to pressure vessels and pipework
• Recognise the differences between, and the risks of, using water as a test medium compared to pressurised inert gas

Section 3: Preparing a Leak Test (15 Minutes)
This module will provide information on planning a leak test, the use of P&IDs, valve line-up checklists and task risk assessment

• Recall why valve checklists should be used when planning a leak test
• Identify the requirement for task risk assessments prior to leak testing
• Identify the main hazards during leak testing
• Recall the information required when planning a leak test
• Recognise the documentation that can be used to identify test boundaries

Section 4: Carrying out a Leak Test (15 minutes)
This module will discuss the practicalities of leak testing on site, the safety precautions required, and how pressure is applied incrementally.

• Identify the pre-use checks that should be carried out on equipment used for leak testing
• Identify the equipment required for leak testing
• Recognise when a nitrogen intensifier pump can be used
• Recall why Helium is used as a trace gas
• Recall when a HeliTest leak detection device should be used

Section 5: Test Pressure and Test Documentation (15 minutes)
This module will consider test pressures and how these are controlled below design pressure, in addition to discussing the compilation of test documentation prior to handover to Operations

• Identify why associated systems should be considered during leak testing
• Identify PSV ratings
• Identify how tests should be recorded and the information that should be included in test certificates
• Identify the specifications that can be consulted to identify design pressures

Section 6: Accumulator Charging
• Recall the functions of a hydraulic accumulator
• Recall the charging procedures for hydraulic accumulators
• Recall who is responsible for charging and maintaining hydraulic accumulators
• Recall the checks required to maintain the safety of hydraulic accumulators

Exam in the e-learning course

• Internet access - users will need a device with a web browser and internet connection
• System - runs on computers, tablets and mobile devices using Windows 7 and above and MAC OS devices running IOS 11 and above
• Browsers - Edge, Chrome, Firefox and Safari
• Minimum browser size – none
• Audio – requires device speaker or headphones