PNEUMATIC TESTING PROCEDURE

2.0 Introduction
Prior to acceptance and issuance of Permit to Operate by Jabatan Kesihatan dan
Keselamatan Pekerjaan ( JKKP ), the completed piping installation ( system ) shall be
subjected to various testing(s) in order to ensure that all the elements of the system i.e.
design, material, fabrication and installation are according to sound engineering practice
and acceptable by the authorities and client.

1.1

Basically there are 4 type(s) of test(s) need to be carried out for the system , i.e.

Pressure Test

Leak Test

Non-Destructive Test

Holiday Test ( For underground pipe wrapping testing )

In this procedure, only item I & ii shall be presented.

2.0 Concerned Party

All the concern parties shall be notified for the time and date for the test to be carried out
especially JKKP State representatives/inspector

JKKP Officer

Clients representative

Contractors representative
It is best to confirm with the States JKKP representative before informing
the other parties since JKKP is the most important party in this procedure.

2.0 Test Preparation

Before the testing, the contractor must ensure that all the

necessary material, tool and

equipment to carry out the test shall be adequately prepared and checked to ensure in
working order. Among the important things are :

Adequate amount of Nitrogen ( Oxygen-free )

Leakage detector ( soap water or device )

Pressure recorder chart paper

Pressure gauge

Pressure recorder ( Calibration certificate shall be presented prior to testing )

Fire extinguishers

Purging hose

Hand Tools ( wrench ,standby pressure gauge, etc )

Testing form

Testing notification signage

The client / owner must adequately notify all the internal workers of the testing exercise to
ensure that safety precaution and measures can be taken to restrict the movement of the
non-relevant parties into the testing site.
Signage(s) must be strategically located to inform the by-passers of the exercise.

2.0 Test Parameter

The testing will only be carried out on the high pressure section of the system. This
means that only the pipes between clients service station and the valve (normally located
at the furthest point of the system before the valve train) are subjected to the test.

Equipment which is not to be included in the test shall be either disconnected from the
piping or isolated by blanks, blind flanges or caps.

The testing pressure is 1.5 times greater of the operating pressure using Oxygen-Free
Nitrogen. The test must be carried out by the period of 2 hours or as directed by JKKP.

If the pressure is monitored by a mechanical pressure recorder, the chart produced shall
be considered as a test record. However, for the purpose of counter-checking, a pressure
reading shall also be taken and recorded at an interval of 15 minutes.

2.0 Test Method

Firstly, the followings must be determined:

Equipment or components designed for the operating pressure less than the
testing pressure shall be disconnected from the piping and capping the outlet.

Equipment or components designed for the operating pressure equal or greater

than the testing pressure, that equipment shall be isolated from the piping by way
of closing ( shut-off ) their valve.

Ensure that all the valves before entering the low pressure section must be at
close position. Double check to ensure that there should be no openings,
uncapped or open valves within the intended test section.

Install the pressure recorder or / and pressure gauge as the designated

monitoring point. Pressure must be monitored and recorded at an interval of 15
minutes for a period of two (2) hours or so as directed by the authority.

Insert the Nitrogen into the system at a pressure 1.5 times than the intended
supply / operating pressure. Immediately after inserting the gas into the system, it
shall be checked to ascertain that there is no leakage by mean of an approved
combustible gas detector or non-corrosive soap and water solution.

Any reduction of pressure shall be deemed to indicate the presence of a leak

unless such reduction can be readily attributed to some other causes.

If leakage or other defects are identified and located, immediate corrective

actions shall be taken. After the corrective action, if directed by the authority,
retesting of the pipe must be at a pressure and period determine by the authority.

Upon completion of the testing, the test report must be verified and endorsed for
test acceptance by the Authority ( JKKP ), Gas Supplier, Client and the
Contractor ( Alam Gas )

ANY DOUBT OR DISCREPANCIES FOUND ON THIS PROCEDURE CAN BE REFFERED TO

SECTION 4 OF MS 930.