SAFETY IN PRESSURE TESTING

Prepared by Reviewed by Approved by

Name

Designation

Date

Signature
Amendment Sheet

Revision
Date Description of Changes
No

23.12.2019 Document No. & Format No. updated

01

00 15.10.2016 Issued for Implementation

Contents
1.0 Purpose.................................................................................................................................................. 1
2.0 Scope...................................................................................................................................................... 1
3.0 Abbreviations & Definitions.................................................................................................................. 1
3.1 Abbreviations......................................................................................................................... 1
3.2 Definitions.............................................................................................................................. 1
4.0 Roles & Responsibilities........................................................................................................................ 2
5.0 Procedure............................................................................................................................................... 3
5.1 Hazards of Pressure testing.................................................................................................... 3
5.2 Risk Assessment..................................................................................................................... 4
5.3 Pre-Requisite for Pressure Testing......................................................................................... 4
6.0 Pressure Testing Training....................................................................................................................... 4
7.0 Notification............................................................................................................................................ 5
8.0 Documentation....................................................................................................................................... 5
9.0 Safety Instruction................................................................................................................................... 5
10.0 Safe Distance......................................................................................................................................... 5
11.0 Safety Clearance Notice (SCN) before Pre-Commissioning.................................................................. 6
12.0 Permit to Work System.......................................................................................................................... 6
13.0 Safety Precautions for Pressure Testing................................................................................................. 6
13.1 Prior to Pressure test............................................................................................................. 6
13.2 During Pressure test............................................................................................................... 9
13.3 After Pressure test............................................................................................................... 10
14.0 Nitrogen Handling............................................................................................................................... 10
15.0 Communication.................................................................................................................................... 11
16.0 Emergency Response Actions.............................................................................................................. 11
17.0 Records................................................................................................................................................ 12
1.0 Purpose
The purpose of this procedure is to

• Provide basic safety requirements while performing pressure testing to safeguard LTHE
employees, contractors and the assets.
• Ensure that all hazards associated with pressure testing are identified and the associated
risks are mitigated to an acceptable level.
• Define the roles and responsibilities of all parties involved in pressure testing.
• Ensure that relevant communication has been maintained.
• Define the line of communication to be established in case of an emergency during
pressure testing in order to minimize incident consequences.

2.0 Scope
This document addresses the all pressure testing activities that are carried out at LTHE
project sites, facilities and yards.

3.0 Abbreviations & Definitions

3.1 Abbreviations
COSHH Control of Substance Hazardous to Health
HSE Health, Safety and Environment
JSA Job Safety Analysis
MJ Mega Joule
MSDS European Conformity
PPE Personal Protective Equipment
PTW Permit to Work
P&ID Piping and Instrumentation Drawing
QA Quality Assurance
QC Quality Control
SCN Safety Clearance Notification
SIMOPS Simultaneous Operations

3.2 Definitions

Hydrostatic Test
Hydrostatic tests are carried out using water, or other liquids, as the test medium. This method is safer
than pneumatic testing and should always be used where practicable.
Pneumatic Test
Pneumatic Tests use air or inert gas as the test medium, and consequently are potentially much more
dangerous than hydraulic or hydrostatic testing because of the energy stored in the compressed gas.
(This means that at the test pressure normally encountered, the energy of compressed air or gas is
over 200 times the energy contained in the same volume of water at the same pressure)
Pressure Test

A test performed to equipment or piping subjecting it to an internal pressure using liquid or gas to
ensure strength and/or tightness of the system at the test pressure.

4.0 Roles & Responsibilities

Project Manager/Production In-charge/Execution In-charge/LTHE Representative

Project Manager/Production In-charge/Execution In-charge/LTHE Representative is responsible for

ensure that the safety requirements and specific safety issues related to this activity are established.

Pre Commissioning Manager/Execution Engineer

The Pre Commissioning Manager/Execution Engineer will be responsible

• To ensure safety of the Pressure testing team and the facility being pressure tested.
• Ensure PTW is obtained before commencement of activity.
• Ensure JHA is carried out
• Ensure calibrated pressure gauges are used
• Ensure blinds used are of appropriate ratings
• The pressure testing team members are briefed on hazards associated with activities and
safe work methodology to be followed;
• The pressure testing team members are briefed on availability and use of PPE;
• Co-ordinate with the project HSE department including client;
• Ensure availability of medical help and facility for the treatment in case of:
o Physical Injury
o Asphyxiation
• Before the start of pressure test, ensure that the safety audit (Check) of the plant is
completed and the checklist neutralized (corrective action completed).
• The pressure testing team members are aware of overall plot plan and familiar with the
emergency escape routes.
• A mock emergency drill is conducted and emergency procedures followed.
• Before undertaking the pressure testing that he has all emergency phone numbers with
him and the copy of the "On-site Emergency Management Plan "and conversant with its
requirements.

Responsibility of the pressure testing team members

Pressure testing team members shall

• Familiarize themselves with the HSE pressure testing procedure.

• Have access to the material safety data sheet of the hazardous chemicals being handled they
are aware and conversant with the process hazard of the plant being commissioned.
• Have the list of PPE'S and familiar with the use of these equipments.
• Understand the safety procedure of the operating plant.
• Familiar with the plant layout and knowledge of the escape routes.
• Use mandatory PPE.
• Familiar with the exposure symptoms of the hazardous chemicals being handled.
• Have access to the emergency telephone numbers.
 • Physically fit and mentally alert during the work.

HSE Manager
• Shall ensure & monitor the safety requirement are in place.
• Identifying the requirement of safety equipment and personnel protective Equipment
(PPE) ensuring its availability at site, and enforcing use of the PPE as per the job
requirement.
• Ensure functioning of the fire and safety equipments installed.
• Ensure availability of display boards at site, detailing the safety precautions, the important
telephone numbers, and the escape route in case of any emergency like fire.
• Ensure availability of first aid kit. In consultation with the Pre commissioning
Manager/execution Engineer and he will co-ordinate for the medical assistance for the
team.
• Formulation of proper evacuation plan in co-ordination with client safety department.
• Organize regular safety meetings with client safety department and the pre
commissioning team members.
• Carryout emergency mock drill
• Will carry out the safety audit before start of pressure testing activities.

5.0 Procedure

5.1 Hazards of Pressure testing

Mishaps and failures during pressure testing may result in injuries, fatalities, and property damage.
The greatest potential hazard is an uncontrolled release of the large amount of energy that can be
stored in compressed air, gas or other fluid, either in a pneumatic test or in a hydrostatic test, where
gas may be trapped in such places as unvented high points, horizontal lines, and valve bodies. Other
hazards are associated with the handling of chemical additives, entering confined spaces, brittle
fracture of materials, and disposal of test mediums.
Uncontrolled releases of stored energy from compressed air or other gas can take the form of
explosions. High velocity streams of fluid can be created or piping and equipment can move. The
degree of these hazards are determined primarily by the test pressure and the volume of air, gas or
other fluid involved.

5.2 Risk Assessment

Hazards associated with pressure testing activities are fully understood and effectively managed, risk
assessment shall be carried out prior to any pressure testing activities. Risk assessment must not be
limited to examining work equipment; equally important are the conditions in which the work is to be
carried out and other personnel that might be affected by the work. Risk assessments must be carried
out as specified in HIRA procedure.

5.3 Pre-Requisite for Pressure Testing

During pressure testing, co-ordination between construction and pre commissioning personnel is
ensured by the following:

• Total pressure testing work must be planned and written. Protocol must be issued by the pre
commissioning/Execution in charge to all concerned.
• Safety documentation system, work permit system must be established before pressure test
work is started.
• Risk Assessment shall be done.
• Addressing HSE in all planning and co-ordination meetings.
 • Having clearly defined systems and handover procedures specifying system conditions and
the necessary documentation for the transfer of care and custody systems.
• Having systems or areas under pressure testing clearly identified by signs and barrier tape
with access restricted to essential personnel holding pressure testing team identification
(Stickers or Badges)
• All instruments calibrations have been checked, instrument loop checks have been completed
and the instruments have been on line and verified.
• All valves stroke checked and actuators of actuated valves taken into operation
• HSE trainings for personnel have been carried out as given in section 6.
• Telecommunication system is in operation.
• Relevant authorities have been notified and are in attendance if required.
• All necessary personnel are present and fully briefed regarding their functions and
responsibilities.
• Pressure test shall start only after obtaining the Safety Clearance Notification from the
concerned Quality Engineer to the Pre commissioning Manager/Execution Engineer.
• No other work can be carried out in the pressure testing area.
• It shall be ensured that all relevant statutory & calibration certificates are available before
start of the pressure test activities.
• Appropriate PPEs shall be worn by the concerned employees.

6.0 Pressure Testing Training

All personnel involved in the Pressure testing shall attend training prior to being allowed on
to site. The training shall cover viz. Safety during pressure testing, Emergency response, First
aid, Treatment for electric shock, and Spill Management, Pressure testing, Risk assessment,
MSDS, COSHH.

7.0 Notification
Before starting any operation, the Pre commissioning personnel responsible of pressure test has to
give notification to all people present at site. Therefore a communication has to be sent to, all
personnel who work at site. The notification can be sent early due to the high complexity of the activity
or area in which the activity has to be done. Refer Safety Flash format.

The communication has to contain, at least, the following information:

• Area involved in the activity. It is better to annex a plot plan with highlighting the
area.
• The extension of the area to be fenced off.
• Time and data of starting the activity.

8.0 Documentation
Before starting the pressure test activity Construction Engineer / Execution Engineer have to prepare
dedicated P&ID in which the piping and vessel to be pressure tested have to be highlighted. This P&ID
must be attached to the Work Permit together with the JSA. Permit Issuer will verify, before start
activity, that the circuit has being prepared complying with all prescriptions written in the JSA and
Work permit. Construction Engineer / Execution Engineer have also to prepare a map showing:

• The location of the pressure test.

• The required barricaded area.
• Date and time of starting the activity.

Manifold, tubes, gauges, safety valves must be calibrated for the ratio of the test.
9.0 Safety Instruction
Personnel responsible (Pre-commissioning Engineer/Execution Engineer) for the pressure test have to
guarantee, that at site the following actions are put in place.
Post signs around the barricaded area showing:
• "DANGER: NO ENTRY TO UNAUTHORIZED PERSONNEL"
• "PRESSURETEST IN OPERATION"
• "USE PROPER PERSONAL PROTECTIVE EQUIPMENT"
An HSE Officer has to assist the Pressure testing team to prevent non authorized personnel or vehicles
from entering the barricaded area.

10.0 Safe Distance

Safe distance shall be calculated using the “LTHE/QHSE/HSE/F/15.3 Safe Distance for
Pressure testing”
The stored energy of any vessel / pipe pneumatically tested shall not be greater than 271 MJ.

If greater than 271 MJ than one of the following shall occur.

• The system shall be divided into smaller volumes

• Safe distance calculated shall be adhered
• If Not achievable, consideration should be given to the design, fabrication, and
installation of an alternative barricade capable of withstanding the blast of stored
energy within the system

11.0 Safety Clearance Notice (SCN) before Pre Commissioning.

SCN is issued by the authorised person (e.g. Quality Engineer) after erection of equipment
and pipelines as per the drawings and manufacturers recommendation to
• Pre commissioning Manager/Execution Engineer
• Contractor

All the other construction/fabrication staff (Civil, Mechanical, structural, general) must vacate the
safety clearance zone, control room and the areas should be cordoned and closed.
Each contractor (Civil, Electrical, and Mechanical) receives a copy of SCN and signs the
acknowledgement copy. Contractor must ensure that his personnel, tools, equipment are removed
from the area.

HSE engineer inspects the Site and counter signs the SCN before giving final clearance.

12.0 Permit to Work System

Permit to work systems will be implemented throughout the Project , to ensure that tasks involving
risks are subjected to thorough and systematic planning and preparation prior to their authorization
to proceed. Only persons who have successfully completed permit to work training shall be
permitted to receive, review and/or sign work permits. PTW coordinator and PTW Issuing Authority
to manage the PTW System.

13.0 Safety Precautions for Pressure Testing

Stored energy and joint quality has to be kept in mind, prior to pressure testing. Welded joints has to
be radiographed and bolted joints needs to be properly torqued.
13.1 Prior to Pressure test

General Precautions
• PTW shall be obtained and test pressure needs to validated by Commissioning Manager/
Execution In-charge and QA/QC personnel
• Pneumatic Test shall be conducted in the morning or lean period;
• Safe distance shall be calculated as per format LTHE/QHSE/HSE/F/15.3 Safe Distance for
Pressure testing and barrication done as per it.
• Sand bag or shields may be provided as protection projectiles in case
• Safe place shall be provided to personnel involved in testing activity to monitor & control the
testing activity;
• TBT shall be conducted prior to start of activity;
• Emergency procedure shall be in place in case of foreseen emergency situations;
• Before water filling, all temporary structures, vessels, supports are needs to be checked to
withstand the load of testing medium;
• Mandatory PPEs must be worn by all workmen involved in the testing activity;
• Use personal protective equipment for handling chemicals according to the Materials Safety
Data Sheets;
• Communication system must be in place before pressurising the system during pneumatic
testing activity;
• All anchors, guides, supports, spring hangers and spring supports are checked for correct
installation. Additional sand bagging may be provided where necessary, as mitigating steps
for the protection of adjacent equipment deemed. Anchoring method and distance to be
placed shall be decided by the site team.

Pressurizing / Testing Equipment

• Air Compressor / Pressurizing Pump shall have a valid Third Party certificate; it shall be
ensured.
• Safety Valve must be installed in air compressor / pressurizing pump;
• The compressors and the associated equipment shall be located outside the exclusion zone in
a safe location away from the test system;
• Alternatively a blast wall shall be placed made of sand bags or concrete / steel barriers to
protect from projectiles;
• The test pump, if any, shall be located such that the pump operator will not be exposed to
danger in the event of a failure

Pressure Hoses
• Connection at the lowest point of the filler pump to the network to be tested via a
high-pressure hose;
• Capacity of hoses should be at least double the test pressure;
• Chicago coupling shall be used for all hose connection;
• Whip arrester shall be used for all pressure hose connections and shall be anchored where
ever required;

Manifold
• All manifolds shall be designed & fabricated with Project specification or approved WPS;
• Manifold shall have a valid Third Party certificate;
• And it must be tested 10% greater than test pressure;

Pressure Gauges
• Calibrated Pressure gauges shall be installed in highest & lowest point of piping system;
• nd it’s maximum scale must be twice than the test pressure;
Valves (used for Pressure Testing)
• Two Safety Relief valve shall be installed for Pneumatic testing;

• Relief valve shall be 1.1 times of test pressure and shall have ejecting capacity greater than
stored energy;
• Relief valve shall been calibrated and the valve shall be located in the system under test and
near the test pump or other test medium supply;
• No block valve shall be provided in relief valve inlet & outlet;
• A readily accessible blow down valve shall be provided on the system under test for the
purpose of draining test fluid;

Blinds & Gaskets

• Test blinds, gaskets, nuts & bolts (as per Project Material Specification)
• All required isolations are done by standard blinds & gaskets;
• Install temporary blind, flanges (including temporary gaskets) and/or
plugs in all the battery limits / tie-in locations;

Venting Arrangements
• Adequate vents shall be provided for removing trapped air;
• Vents shall be free from obstructions and installed at higher elevation;
• Vents should be in open condition;

Piping System, Other Equipment & Valves

• Piping System are constructed as per drawing;
• Appurtenances (Accessories / Items) not part of the pressure test shall be blinded;
• Lines involved in testing must be free from any foreign particles; If considered necessary
washing / cleaning with water and/or air blowing shall be permitted;
• Provisions shall be made to ensure that no pressure build-up in equipment that is not being
tested;
• Pipe thickness, material, weld quality shall be assured by QC dept.;
• Temporary locking of expansion joints to avoid lateral movements;
• All supports & anchorages must be in place & additional supports shall be provided
considering the weight of filled lines;
• Ball valves located at battery limits shall be isolated from piping system if it is in opposite
direction. Otherwise it must be in “fully open configuration”;
• Spring supports shall be temporarily locked to withstand line weight during testing;
• Tightening of bolts on all flanged and/or threaded connections;
• Valve seats/supports must not subjected to pressure in excess of maximum valve operating
pressure / as specified by supplier;

Temporary Isolation :
• All valves & in-line equipment must be removed / excluded from the test; (If necessary, the
pre-fabrication & installation of mock-ups);
• Control valve, spectacle blinds and orifice plates must be removed.
13.2 During Pressure test
The rate of pressurization should not be > 0.5 Bar per Minute
Step 1

• Raise pressure to the lesser of 0.71 Bar or 10% of test pressure;

• Block in supply and hold for recommended period;
• Visually inspect system for leaks;
• If leaks are discovered, release pressure, repair, and return to Step 1;
• If no leaks are discovered, proceed to Step 2;

Step 2
Gradually increase system pressure to 50% of the test pressure as follows,

• Continue to increase by 3.5 bar increments until pressure is 50% test pressure and hold for 3
minutes for very increments; this is to allow strains to equalize.
• Increase pressure at the rate of 0.5 Bar per Minute or less
• Hold at 50% test pressure for the recommended period;
• If pressure loss exceeds 10% of test pressure, depressurize to 25% test pressure and check for
leaks;
• If leaks are discovered, release pressure, repair, and return to Step 1;
• If no loss of pressure is detected, subject to approval of the inspector, proceed to Step 3;

Step 3
Gradually increase system pressure to the test pressure as follows,

• This operation shall be done only in the presence of HSE engineer;

• HSE staff shall also monitor the gauge pressure not exceeding test pressure;
• Gradually increase pressure in increments of 10% of test pressure at the rate of 0.5 Bar per
Minute or less, till the Test Pressure is attained.
• At each increment, block supply and observe pressure gauge for 5 minutes minimum to allow
piping to equalize strains.
• If pressure loss observed, reduce pressure to 25% test pressure and check for leaks;

Step 4
Final Inspection,

• Reduce pressure to the design pressure;

• Conduct a complete inspection for leakage;
• If leaks are discovered, release pressure, repair, and return to Step 1;
• If no leakage is discovered, release system pressure;

Step 5
System restoring
• Do not depressurize by loosening bolts or by unscrewing fittings;
• Any flange, blind, bolts, apparatus shall be loosened/removed only after depressurizing is fully
complete;
• Ensure the pressure gauge is zero and no trapped air inside;
• Only after approval from supervisor any dismantling job shall be commenced;
CAUTION: No personnel entry will be allowed for system inspection during pressurization, stabilization
and hold periods. Personnel are only permitted entry for the initial system integrity check at 0.71 Bar,
25% test pressure & at design pressure for inspection. The pre commissioning manager/Execution
Engineer shall solely control entry of personnel.
13.3 After Pressure test
• Do not depressurize a system by loosening bolts in a flange or by unscrewing fittings because
this could lead to injury.
• Drain liquid from a system slowly and with the vents open to prevent a possible vacuum.
• Keep the test relief valve installed until the test liquid has been drained to prevent possible
overpressure due to thermal expansion.
• Make sure that the water to be discharged has the quality parameters complied with standard
fixed by client.

14.0 Nitrogen Handling

• An over - Pressure Protection Panel will be used when nitrogen pump is used (to shut down
nitrogen pressurised pump in case of over pressurisation)
• Handlings of Nitrogen Hazards are simple asphyxiant, extreme cold.
• Use certified Nitrogen carrying trucks
• Deploy competent Supervisor & HSE officer for close supervise for Nitrogen handling
operations.
• Position Nitrogen truck in proper places and provide wheel choke
• Nitrogen handling hoses shall be SS Flexible materials.
• Control Valves shall be temperature controlled (suitable extreme cold condition)

Effects associated with oxygen depletion due to nitrogen ingestion

OXYGEN LEVEL EFFECTS

12% to 16% Breathing, pulse rate increased,

Muscular coordination slightly disturbed

11% to 14% Emotional upset, Abnormal fatigue, Disturbed Respiration

6% to 10% Nausea and Vomiting, Collapse or loss of consciousness

Below 6% Convulsive movements, possible respiratory collapse

and death
15.0 Communication
HSE Coordination Meeting
HSE Coordination Meeting shall be held at least once in the project prior to pressure testing
activity
Attendees will include:
• Pre commissioning Manager/Execution Engineer
• HSE Manager
• Site Managers (Subcontractors) shall be invited
• Safety Representatives (Subcontractors) shall be Invited.
Toolbox Talk
Tool Box Talks shall be conducted daily.
Announcement before pressure testing
Before the pressure testing, all employees shall be notified through megaphone/by raising
sounds etc.
16.0 Emergency Response Actions
Emergency

The emergencies possible during pressure testing activities are the following:
• Water/ gas leak
• Burst due to pneumatic pressure
• Personal injury
All Emergencies are responded in accordance to the emergency plan prepared.

Pressure testing team shall be acquainted with the emergency procedures prevailing in the premises
of the owner. A detail of the procedures shall be made available and communicated properly to all the
personnel under direct or indirect purview of the commissioning team and emergency drills shall be
carried out periodically.

Emergency contact numbers shall be displayed at all conspicuous location. Adequate First aid boxes,
First aiders, Firefighting equipments and Ambulance shall be arranged. Assembly Points shall be
located, sign board placed and notified to all concerned.
Alarms
Audible and/or visual alarm in case of emergency shall be provided. All personnel shall be familiar with and
trained to recognize alarm tones, ensuring they know what the required action will be in the event of an
alarm tone sounding.

17.0 Records

Records Format No.

Safety Clearance Notification LTHE/HSE/PR12/F09

Safety Flash LTHE/ HSE/PR15/F01

Safety Check for Hydro test Operation / Pneumatic Test/

LTHE/HSE/PR15/F02
Card Board Blasting Operation

Safe Distance for Pressure testing LTHE/HSE/PR15/F03