Hydro Test Safety # Pneumatic Test Safety

Dear Viewers,
Our Today’s topic is Hydro Test Safety, Pneumatic Test safety.

DEFINITIONS:-
Hydro Test: A pressure or tightness test where liquid, typical water, is the test medium.
Pneumatic Test: A pressure or tightness test where a gas, generally nitrogen or air, is the test medium.

PRESSURE TESTING: GENERAL HAZARDS:-
The release of stored energy can be due to:
(a) rupture of pressure equipment due to brittle fracture;
(b) rupture of pressure equipment due to ductile fracture;
(c) detachment or removal of blanking plates and their clamps/attachment bolts, screwed plugs, isolation valves, etc;
(d) a detachment of temporary welds on plugs, at pipe ends and nozzles.
(e) failure of gaskets.
PREPARING FOR PRESSURE TEST

This section deals with the precautions to be taken before testing. These precautions apply to both hydros and pneumatic testing.
1)The area where the test is being performed shall be roped off to prevent access to unwanted persons with signs (in Arabic & English) posted on the ropes warning about the test. Minimum essential persons should only be allowed near the test area.
2)Personnel engaged in the test shall be briefed before the test, safety talks shall be conducted explaining the procedure and the hazards involved.
3)The individual system documentation shall be available before any testing and shall include information such as test limits, test pressure, test medium, duration, test blinds, blind flanges, vents, and drains.
4)Before testing, the Executor shall inspect the system to assure it conforms to the system layout drawing and that all appropriate safety precautions as per Risk Assessment have been taken.
5)P&IDs and blind lists should be utilized to identify the locations of blinds, valves, vents, and drains. KNPC Blinding &Tagging procedure shall be followed.
6) Testing equipment such as pumps, manifold, pressure and temperature recorders, pressure gauges shall be of valid calibration (as per company procedures).
7)Pressure gauges shall be fitted at both low and high point when testing large volume systems.
8)All necessary measures shall be taken to remove air from the line during filling. This includes back-pressure control, a steady controlled filling rate, use of a break tank, etc. It shall be ensured that the pump suction will not draw in the air with the water.
9)Each member of the test team shall wear goggles, and ear protection whenever pressure is applied to the system being tested. This is in addition to the mandatory PPE required.
10)Pressurize equipment shall not be approache for close examination until a reasonable period of time has elapsed.
11)Joints in the system which may fail and flexible tubing shall be restrained during the test to prevent personnel injury.
12)Equipment such as pumps, compressors, blowers, turbines, other rotating machinery and vessels, heat exchangers, towers, etc, shall be isolated from the pressure test while testing a pipeline.
13)For high-pressure systems the test pressure shall be reached in stages, each stage allowed to stabilize then visually checked for leaks. The rate of pressure increase shall be mentioned in the approved procedure.
14)The pressure gauge(s) shall be connected directly to the vessel or system and shall be visible to the operator throughout the duration of the test. They shall have valid calibration certificates.
15)All gaskets used for hydro testing/pneumatic testing shall be of an approve type meeting the actual pipe specifications.
16) Clamps and bolts: Clamps or bolts on bolted flanges must not be loosened or tightened while the pressure equipment is under pressure. The pressure equipment shall be isolated from pressure sources, de-pressurized and vented before clamps or bolts are adjusted or removed.
17) Protection against blast waves and missiles: Protection against blast waves and rocketing fragments can be provided wherever practically possible by placing the pressure equipment behind a suitable barrier or in a properly designed pit.

IMPORTANT LINKS:-
Compressed Gas Cylinder Safety #Storage & Handling.
   • Compressed Gas Cylinder Safety #Stora...  
Personal Protective Equipment.
   • Personal Protective Equipment - व्यक्...  

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