Part G — Equipment & Plant

Pressure testing and stored energy

Workbook section 69

Owner

HSE Manager / Document Controller

Review / trigger

Annual review; update immediately if legal, authority, project, client, or scope requirements change.

Primary references

Plans TOC - Part G; G - Stored Energy Matrix; G - Pressure Testing Approval; Plan G69 Pressure Testing Pneum

Checkpoints

Open live checklist

#	Area	Checkpoint / Requirement	Evidence / Acceptance Criteria	Responsible	Frequency
1	Pressure Test Planning & Authorisation	Written pressure test procedure/method statement approved by Engineer prior to any hydrostatic/pneumatic test.	Approved method statement with sign-off.	Site Engineer	Before test
2	Pressure Test Planning & Authorisation	Permit to Work (Pressure Test Permit) issued and authorised by competent authority before commencing test.	Signed pressure test permit on file.	HSE Officer/Permit Issuer	Before each test
3	Pressure Test Planning & Authorisation	Test pressure, hold duration and acceptance criteria defined per design code (ASME B31.3/API/project spec).	Test parameters documented in test pack.	Project Engineer	Before test
4	Pressure Test Planning & Authorisation	Pneumatic testing avoided in favour of hydrostatic testing wherever feasible due to higher stored energy risk.	Justification recorded where pneumatic method selected.	Project Engineer	Before test
5	Pressure Test Planning & Authorisation	Exclusion/barricaded zone with minimum safe distance established and signed for duration of pressure test.	Exclusion zone diagram and barrier inspection record.	Site Supervisor	During test
6	Pressure Test Planning & Authorisation	Test team briefed on procedure, roles, emergency response and communication protocol before test start.	Toolbox talk/briefing attendance sheet.	HSE Officer	Before each test
7	Pressure Test Planning & Authorisation	Weather and environmental conditions checked suitable for outdoor pressure testing (no lightning risk, etc.).	Weather log entry prior to test start.	Site Supervisor	Before test
8	Equipment Verification & Calibration	Pressure gauges used for test calibrated with valid certificate traceable to accredited laboratory (ESMA/DAC-accredited).	Calibration certificate with validity date checked.	QA/QC Engineer	Before test / per calibration cycle
9	Equipment Verification & Calibration	Dual pressure gauges (primary and check gauge) installed at test point to cross-verify readings.	Photo/verification of two gauges at test manifold.	Test Engineer	Before test
10	Equipment Verification & Calibration	Pressure relief/safety valve installed on test system set below maximum allowable test pressure.	PRV set-point certificate and physical verification.	Test Engineer	Before test
11	Equipment Verification & Calibration	Test pump, hoses and fittings inspected and rated for required test pressure with safety margin.	Equipment inspection checklist with pressure ratings.	Test Engineer	Before test
12	Equipment Verification & Calibration	Test medium (water/nitrogen/air) confirmed appropriate for system and compatible with materials.	Test medium approval recorded in test pack.	Project Engineer	Before test
13	Equipment Verification & Calibration	Recording chart/data logger calibrated and functioning to capture pressure-time profile of test.	Data logger calibration certificate and test printout.	QA/QC Engineer	Before/during test
14	Pre-Test Inspection of System	Piping/vessel supports, anchors and thrust blocks inspected and confirmed adequate before pressurising.	Support inspection checklist signed off.	QA/QC Inspector	Before test
15	Pre-Test Inspection of System	All welds/joints in test section visually inspected and NDT completed with acceptable results prior to test.	NDT reports and weld inspection records.	QA/QC Inspector	Before test
16	Pre-Test Inspection of System	Temporary blinds, test plates and end caps rated for test pressure and correctly installed with witness marks.	Blind list/register with pressure rating verified.	Test Engineer	Before test
17	Pre-Test Inspection of System	All valves, vents and drains in test circuit identified, tagged and positioned per test line-up diagram.	Line-up diagram with valve position checklist.	Test Engineer	Before test
18	Pre-Test Inspection of System	Instrumentation and equipment not rated for test pressure isolated or removed from test circuit.	Isolation checklist confirming excluded items.	Test Engineer	Before test
19	Pressurisation & Hold Monitoring	Pressure increased gradually in defined steps/increments with hold and inspection at each stage.	Step pressurisation log with time/pressure readings.	Test Engineer	During test
20	Pressurisation & Hold Monitoring	Continuous visual and audible monitoring maintained during pressure build-up; no personnel in exclusion zone except essential.	Personnel log confirming zone clearance during pressurisation.	HSE Officer	During test
21	Pressurisation & Hold Monitoring	Test pressure and hold time recorded at defined intervals until acceptance duration completed.	Pressure log sheet/chart with start/end times.	Test Engineer	During test
22	Pressurisation & Hold Monitoring	Pressure drop, if any, investigated immediately and test halted pending root cause identification.	Deviation report and corrective action record.	Site Engineer	Upon deviation
23	Pressurisation & Hold Monitoring	Communication (radio/hand signals) maintained between control point and exclusion zone monitors throughout test.	Communication protocol log/checklist.	HSE Officer	During test
24	Depressurisation & Post-Test	System depressurised gradually and safely following controlled venting procedure after successful hold.	Depressurisation log with time and method.	Test Engineer	After test
25	Depressurisation & Post-Test	Vented gas/fluid directed to safe location away from personnel and ignition sources, per environmental permit.	Vent location diagram and environmental compliance record.	HSE Officer	During depressurisation
26	Depressurisation & Post-Test	Test results (pass/fail) documented, signed by all witnessing parties and included in test pack/dossier.	Signed pressure test certificate/report.	QA/QC Engineer	After test
27	Depressurisation & Post-Test	Temporary test fittings, blinds and gauges removed and system restored to operational configuration.	Restoration checklist with sign-off.	Site Engineer	After test
28	Depressurisation & Post-Test	Non-conformances or failures during test logged, investigated and re-test scheduled with corrective actions.	NCR record and re-test authorisation.	QA/QC Engineer	Upon failure
29	Stored Energy Identification & Isolation	Hazard identification/risk assessment conducted to identify all stored energy sources (pressure, hydraulic, pneumatic, spring, electrical, gravitational) before work.	Risk assessment/JHA documenting energy sources.	HSE Officer	Before task
30	Stored Energy Identification & Isolation	Lockout-Tagout (LOTO) procedure applied to isolate stored energy sources prior to equipment intervention.	LOTO permit/isolation certificate with lock/tag numbers.	Isolation Authority	Before intervention
31	Stored Energy Identification & Isolation	Zero-energy verification performed (bleed down, gauge check, try-out) after isolation and before work commences.	Zero-energy verification checklist signed by competent person.	Competent Person	Before work commences
32	Stored Energy Identification & Isolation	Accumulators, springs and hydraulic cylinders confirmed de-pressurised/blocked before disassembly.	De-energisation checklist for mechanical stored energy.	Maintenance Engineer	Before disassembly
33	Stored Energy Identification & Isolation	Group/multiple lockout arrangements used where several workers/crafts are exposed to same energy source.	Group lockout log with names of all workers involved.	Site Supervisor	During multi-crew work
34	Emergency Preparedness for Pressure/Stored Energy Work	Emergency response plan specific to pressure test/stored energy release established and communicated to team.	Emergency plan document with briefing record.	HSE Manager	Before task
35	Emergency Preparedness for Pressure/Stored Energy Work	First aid and firefighting equipment available and accessible at pressure test location.	Equipment inspection checklist at test site.	HSE Officer	Before test
36	Emergency Preparedness for Pressure/Stored Energy Work	Rescue/muster arrangements defined and practiced for personnel in vicinity of high-pressure test area.	Muster point map and drill record.	HSE Officer	Before test / periodically
37	Emergency Preparedness for Pressure/Stored Energy Work	Incident reporting procedure for pressure test failures aligned with ADOSH-SF/Civil Defence notification requirements.	Incident reporting flowchart with authority contacts.	HSE Manager	Ongoing
38	Records, Competency & Compliance	Test engineers/technicians hold documented competency/training for pressure testing activities.	Training certificates on file, verified against personnel on site.	HSE Manager	Prior to assignment
39	Records, Competency & Compliance	Pressure test dossier compiled including procedure, permit, calibration certs, charts and sign-offs retained for project record.	Complete test dossier filed and indexed.	QA/QC Engineer	After test
40	Records, Competency & Compliance	Pressure testing activities comply with applicable UAE codes and Civil Defence/Municipality requirements for site safety.	Compliance checklist referencing applicable code/authority.	HSE Manager	Before test / audit
41	Records, Competency & Compliance	Audit of pressure testing and stored energy control practices conducted periodically with findings closed out.	Audit report with corrective action tracking.	HSE Manager	Quarterly
42	Pressure Test Planning & Authorisation	Pressure test schedule reviewed and approved by client/third-party inspection agency where required by contract.	Approved test schedule with client sign-off.	Project Engineer	Before test
43	Pressure Test Planning & Authorisation	Simultaneous operations (SIMOPS) review conducted to ensure no conflicting activities near pressure test area.	SIMOPS assessment/register entry.	Site Engineer	Before test
44	Pressure Test Planning & Authorisation	Test water source and disposal method identified and approved, considering volume and quality.	Water source/disposal approval document.	Site Engineer	Before test
45	Pressure Test Planning & Authorisation	Emergency shutdown/stop procedure for pressure test defined and understood by all test personnel.	Briefing record referencing shutdown steps.	HSE Officer	Before test
46	Pressure Test Planning & Authorisation	Third-party or client witness notified and scheduled to attend test as per contract requirement.	Witness notification record/attendance confirmation.	QA/QC Engineer	Before test
47	Pressure Test Planning & Authorisation	Test area cordoned with physical barriers, warning signage and flashing lights where required.	Barricade and signage inspection photo record.	Site Supervisor	Before test
48	Pressure Test Planning & Authorisation	Test package reviewed to confirm system boundary/limits of test correctly defined on P&ID.	Marked-up P&ID matching test boundary.	QA/QC Engineer	Before test
49	Equipment Verification & Calibration	Test hoses/fittings visually inspected for cuts, bulges or corrosion before connecting to pressurised system.	Hose inspection checklist with condition rating.	Test Engineer	Before test
50	Equipment Verification & Calibration	Pressure test pump discharge fitted with non-return valve to prevent backflow/uncontrolled release.	Valve verification recorded in equipment checklist.	Test Engineer	Before test
51	Equipment Verification & Calibration	Nitrogen/gas cylinders used for pneumatic testing secured upright, capped, and stored away from heat sources.	Cylinder storage inspection checklist.	Store Keeper	Before/after use
52	Equipment Verification & Calibration	Test manifold and gauge assembly leak-checked at low pressure before full pressurisation.	Low-pressure leak test record.	Test Engineer	Before test
53	Equipment Verification & Calibration	Backup/spare calibrated gauge available on site in case of primary gauge failure during test.	Spare gauge inventory with calibration certificate.	QA/QC Engineer	Before test
54	Pre-Test Inspection of System	Pipe supports and guides checked for freedom of movement to accommodate test pressure expansion.	Support movement inspection checklist.	QA/QC Inspector	Before test
55	Pre-Test Inspection of System	Flange bolting fully torqued to specification and verified by QA/QC prior to test.	Bolt torque record/checklist per flange.	QA/QC Inspector	Before test
56	Pre-Test Inspection of System	Test section isolated from live/energised systems using confirmed positive isolation (spades/blinds), not valves alone.	Positive isolation certificate with blind list.	Test Engineer	Before test
57	Pre-Test Inspection of System	Vent and drain points confirmed open/closed correctly per test line-up before pressurisation begins.	Valve line-up verification checklist signed off.	Test Engineer	Before test
58	Pre-Test Inspection of System	Ambient temperature and test fluid temperature recorded to allow for pressure correction calculations.	Temperature log recorded in test pack.	Test Engineer	Before test
59	Pressurisation & Hold Monitoring	Personnel not directly involved in test kept outside exclusion zone; access controlled by dedicated zone marshal.	Zone marshal log with access control record.	HSE Officer	During test
60	Pressurisation & Hold Monitoring	Rate of pressure increase controlled per procedure to avoid shock loading of system components.	Pressurisation rate log compared to procedure limit.	Test Engineer	During test
61	Pressurisation & Hold Monitoring	Visual inspection for leaks, weeps or deformation conducted at each hold stage before proceeding.	Stage inspection checklist with findings.	QA/QC Inspector	During test
62	Pressurisation & Hold Monitoring	Temperature compensation applied to pressure readings if ambient conditions change significantly during hold.	Corrected pressure calculation recorded in log.	Test Engineer	During test
63	Pressurisation & Hold Monitoring	Test halted and system isolated immediately if unexpected noise, movement or leak detected.	Incident stop record with time and action taken.	Site Engineer	Upon abnormal observation
64	Depressurisation & Post-Test	Personnel kept clear of exclusion zone until system confirmed fully depressurised and vented to atmosphere.	Zone clearance confirmation log.	HSE Officer	After depressurisation
65	Depressurisation & Post-Test	Test water disposed of in accordance with environmental permit/local authority requirements (e.g., Municipality trade effluent rules).	Waste water disposal manifest/permit reference.	HSE Officer	After test
66	Depressurisation & Post-Test	Test equipment (pumps, hoses, gauges) decontaminated/inspected and returned to store in serviceable condition.	Equipment return inspection checklist.	Store Keeper	After test
67	Depressurisation & Post-Test	Lessons learned/observations from test captured and shared with project team for future tests.	Lessons learned log/meeting minutes.	Project Engineer	After test
68	Stored Energy Identification & Isolation	Energy isolation points labelled and mapped on isolation diagram accessible to all affected workers.	Isolation diagram posted at work area.	Isolation Authority	Before task
69	Stored Energy Identification & Isolation	Individual employee locks used for personal LOTO in addition to group lockout box where applicable.	Personal lock register cross-checked with LOTO log.	Site Supervisor	During work
70	Stored Energy Identification & Isolation	Isolation devices (locks, tags, chains) inspected periodically for damage or unauthorised removal.	Isolation device inspection checklist.	HSE Officer	Monthly
71	Stored Energy Identification & Isolation	Re-energisation procedure requires sign-off from all workers before locks removed and system restored.	Re-energisation authorisation sign-off sheet.	Isolation Authority	Upon work completion
72	Stored Energy Identification & Isolation	Training on hazardous energy control (LOTO) provided to all personnel involved in isolation activities.	Training records/certificates on file.	HSE Manager	Prior to assignment / periodic refresher
73	Emergency Preparedness for Pressure/Stored Energy Work	Nearest hospital/Civil Defence contact numbers displayed at pressure test control point.	Emergency contact signage verified on site.	HSE Officer	Before test
74	Emergency Preparedness for Pressure/Stored Energy Work	Mock drill for pressure release/failure scenario conducted periodically to test emergency response readiness.	Drill report with attendance and lessons learned.	HSE Manager	Semi-annually
75	Emergency Preparedness for Pressure/Stored Energy Work	PPE for pressure test personnel (face shield, hearing protection) provided and worn during pressurisation/depressurisation.	PPE compliance observation record.	HSE Officer	During test
76	Records, Competency & Compliance	Pressure test certificates cross-referenced with equipment/piping tag numbers in project quality records.	QA traceability matrix linking certificates to tags.	QA/QC Engineer	After test
77	Records, Competency & Compliance	Stored energy control (LOTO) audit findings tracked to closure with assigned responsible person and due date.	Audit tracker with closure evidence.	HSE Manager	Quarterly
78	Records, Competency & Compliance	Subcontractor pressure testing activities verified for compliance with main contractor HSE requirements before approval.	Subcontractor HSE approval checklist.	HSE Manager	Before subcontractor mobilisation
79	Pressure Test Planning & Authorisation	Test procedure includes maximum allowable working pressure (MAWP) reference to prevent over-pressurisation.	MAWP value cross-checked in test procedure.	Project Engineer	Before test
80	Equipment Verification & Calibration	Test pump relief valve function tested by manual lift prior to test commencement.	Manual lift test record.	Test Engineer	Before test
81	Pre-Test Inspection of System	Piping cleanliness (flushing/debris removal) confirmed complete before hydrostatic test to avoid gauge/valve damage.	Flushing completion certificate.	QA/QC Inspector	Before test
82	Pressurisation & Hold Monitoring	Test log co-signed by client/third-party witness confirming agreement with recorded pressure and time values.	Co-signed test log sheet.	QA/QC Engineer	During test
83	Depressurisation & Post-Test	Residual trapped pressure in dead-leg sections verified released before disconnecting test equipment.	Dead-leg bleed-down verification checklist.	Test Engineer	After test
84	Stored Energy Identification & Isolation	Hydraulic system accumulators depressurised and mechanically blocked before maintenance intervention.	Accumulator isolation checklist.	Maintenance Engineer	Before intervention
85	Stored Energy Identification & Isolation	Isolation certificate reviewed and re-validated if work extends beyond originally authorised shift/duration.	Revalidated isolation certificate.	Isolation Authority	Upon shift change/extension
86	Emergency Preparedness for Pressure/Stored Energy Work	Wind sock/direction indicator available at test site to assist safe evacuation planning for gas release scenario.	Windsock inspection/presence check.	HSE Officer	Before test
87	Records, Competency & Compliance	Pressure testing procedures reviewed and updated periodically to reflect lessons learned and code changes.	Document control record showing revision history.	HSE Manager	Annually
88	Records, Competency & Compliance	Statutory/Third-party inspection body certification obtained for pressure vessels/piping where mandated before test.	Third-party certification on file.	QA/QC Engineer	Before test / per statutory requirement

Each checkpoint records Status (Yes / No / N/A), Comments, Corrective Action and Sign-off. Switch to Complete in-app to fill it here, or download the blank version to complete on site.

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