THERMAX LIMITED

Chinchwad, Pune – 411019

WORK PERMIT REQUEST FOR HYDROTESTING – Revision

1.
(Required for performing Hydro Test using hydro-plugs)

Flow of process Serial Number - ░ ░ ░ ░

1) Request generation and conducting the tool box talk by shop engineer
2) Request checking by shop in-charge
3) Request approval and serial no. marking on the request display the request on hydro
station by safety engineer.
4) Trouble shooting of leaking hydro-plugs (if required ) and updating the same in this form by shop
engineer
5) Validity extension request by shop engineer if required.
6) Validity extension period review by shop in-charge.
7) Validity period extension approval by safety officer (only on confirming that „Remarks‟ are
written.) and display the request on hydro station.
8) Completion approval by QAC engineer (only on confirmation that the process is completed in
approved validity period)
9) Filing of completed request by safety officer.

Note
1) Everybody (shop engineer, safety officer, shop in-charge and QC engineer) is expected to work
seriously as per this procedure to avoid failures on account of hydro-test.

Issued to : Plant ░ ░ Job Details :░░░░░░░

░ (Exact identification of the job)
Location : Column nos. ░ ░ to ░ ░ Date of work :░░░░░░░░
Work permit start time : ░ ░ ░ ░ ░ ░ ░ ░ Work permit closing time : ░ ░ ░ ░ ░ ░
░ (New form needs to be filled after expiry of the date mentioned above)
Safety checklist for Hydro testing
1] Is the test being performed by skilled person and under the supervision? Yes /
No Name of the skilled person(s) : ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░
:░░░░░░░░░░░░░░░
░ Name of the supervisor(s) :░░░░░░░░░░░░░░░
░
2] Is the hydro plug inspected for following checks before fitting in the job? Yes /
No Visual checking of Gripper condition for any
cracks, roughness : OK / Not OK
Taper portion between mandrel and gripper is
cleaned for any rust, dirt etc and lubricated. : Yes /
No Is new rubber seal used : Yes /
No Is new “O” ring between mandrel and seal
carrier used? : Yes / No
3] Are the hydro plugs facing the wall? Yes /
No (MS wall as per point no. 4 is not required if plugs are facing wall.)
4] If not facing the wall is the MS plate structure, sand filled
bags or movable RCC walls kept in front of all hydro-
plugs.
Are all the plugs facing wall/MS structure. Yes /
No (If not then hydro-test for such stubs shall be taken by blank welding.)
5] Is the area around the hydro plug is barricaded with barricading tape? Yes / No
6] Are all controls like drain valves, pressure gauge etc located
beyond the barricading? Yes / No
7] The pipe ID measured at two places at 90° are Type / Size 1 ░ ░ ░ ░& ░ ░ ░
░ (Applicable for pipes > 4” NB and < 10 mm thick)
Type / Size 2 ░ ░ ░ ░ &░ ░ ░ ░

Type / Size 3 ░ ░ ░ ░ &░ ░ ░

░ (The hydro test using plugs shall be discontinued if the variation in pipe ID is > 2 mm)
8] The size of hydro-plug used Type 1 ░ ░ ░ ░ ░ ░ ░ ░
Type 2 ░ ░ ░ ░ ░ ░ ░ ░
Type 3 ░ ░ ░ ░ ░ ░ ░ ░
9] Are the safety gags positioned exactly above the gripper Yes / No
10] Is the safety gag tightened at two places on either side of
plug with maximum OD bolt through the holes provided
and whether
the bolt is fully engaged in the nut. Yes / No
11] Is the chain fixed to the top bolt of the gag and fixed on
the plug mandrel properly Yes / No
12] Are all the bolts and nuts of 10.8 grade? Yes / No
13] Is Safety Tool Box Talk (TBT) conducted? Yes /
No 14] Name and signature of the person delivering TBT
Name ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ Signature ░ ░ ░ ░ ░ ░
░ ░ 15] Names and signatures of the person(s) receiving TBT
Name ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ Signature ░ ░ ░ ░ ░ ░ ░ ░
Name ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ Signature ░ ░ ░ ░ ░ ░ ░ ░
Job is ready for hydro-test. The set up
checked

░░░░░░░░ ░░░░░░░░
Name and signature of Name and signature of
requesting shop engineer shop in-charge
I have ckecked all the above points except 2, 7, 8 & 13. and the job is cleared for hydro-test.

░░░░░░░░
Name and signature of safety officer
Reporting of leaking hydro-plugs.
░ ░ ░ ░ ░ nos. hydro-plugs of ░ ░ ░ ░ ░ ░ ░ ░ size found leaking and corrected for the first
time in front of me.

░░░░░░░░░░░░░░░
Name and signature of shop engineer (With date and time)
In spite of above correction the same plugs found leaking during next hydro-test, hence blank
welding done for ░ ░ ░ ░ ░ nos. stubs.

░░░░░░░░░░░░░░░
Name and signature of shop engineer (With date and time)

Extension of permit validity period

Please extend the validity period up to ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ (Date and time)

Reason for extension ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░ ░

░

░░░░░░░░░░░░░░░░ ░░░░░░░░░░░░░░░░
Name and signature of shop engineer Name and signature of shop-in-

charge Validity period extended up to ░ ░ ░ ░ ░ ░ ░ ░ (Date and time)

░░░░░░░░░░░░░░░
░ Name and signature of safety
officer

The hydro-testing is witnessed and cleared by the final approving authority.

░░░░░░░░░░░░░░░░
Name and signature of QAC engineer.

TROUBLE-SHOOTING AND OTHER INSTRUCTIONS :-

1) If the plug starts leaking during hydro-test then all the pressure part shall be de-
pressurised and the plug shall be removed. The rubber seal and “O” ring shall be
changed and then the hydro-testing shall be carried out.
2) Even after this change if the same plug starts leaking, then blank welding shall be
done for that stub(s) and hydro-testing shall be continued.
3) MED shall be reported in above case for further analysis.
4) If the plug shifts outside during pressurizing, then de-pressurise the pressure part
and re- tighten the plug.
5) If the plug shifts outside by more than 10mm then de-pressurise and remove the
plug. Continue the hydro-test by blank welding.
6) Do not tighten the hydro-plug or tamper with the plug or fittings when the job is
pressurized.
7) While removing the hydro-plug, loosen the nut and tap the mandrel on the
hexagonal connector with hammer.
8) Pressurising shall be done at a slow motor speed approximately at a rate of 4 to 5
kg/cm2 per minute.
9) Use Dowty seals for all threaded joints, which are exposed to hydro pressure.