Hydro testing safety.

By(Manoj Kumar,HSE Professional,hseguru@yahoo.in,+91-8252771261,Aadhaar

Number:584186777088).

Lets talk about hydro-testing safety.Hydrostatic testing, is a type of test

that is performed on pressure vessels to check for leaks. Hydro testing
involves completely filling up a pressure vessel with water and then
pressurizing it. Once pressurized, leaks can be detected. Hydro testing
can be used to determine if a pressure vessel has the correct
mechanical properties.

PURPOSE OF HYDRO TEST:

1. Identify the leaks.

2. To check the strength of the welded joint.

3. To check the capacity of the system.

HAZARDS OF HYDRO TEST:

1. Breaking/failure of line, gasket, flanges, and gauges.

2. Air entrapment inside the pipe.

3. Usage of an engine operated pump.

4. Inadvertently/suddenly increase of pressure due to underrated or

non calibrated pressure gauges.

5. Substandard support.

6. PSV failure.

SAFETY PRECAUTIONS OF HYDRO TEST:

1. Hydro test test Area shall be barricaded and provide warning boards
to prevent personnel entry.

2. Calibrated pressure gauges and Pressure safety valves only shall be

used.

3. Rating of fittings, pressure gauges, vent valves, gaskets shall be

suitable for the test pressure.
4. Flanges and Plates shall be as per the line class.

5. All the temporary welding shall be performed by qualified welders

and approved by Client QA/QC.

6. Ensure air vent provided at the highest elevation.

7. Gradual filling of lines shall be done keeping vent to open.

8. Ensure that the line is vented to remove air pockets before

pressurization.

9. Pressure should be raised gradually under control to allow time for

pipes to strain and time for personnel to check for leaks.

10. There shall be at least two pressure gauges, one at lowest point and
another at the highest point in the system

11. Hydro testing crew should not stay in the direction of the blind
flanges to prevent injury in case of flange rapture.

12. All hoses/ piping/gaskets and connectors/clamps shall be of

adequate rating to withstand pressure.

13. Whip lash arrestor shall be provided at hose connection.

14. Personnel shall not approach the system under high Pressure.
15. Only essential and trained persons shall be allowed at the Hydro
test work location

16. Access shall be free from any obstacle.

17. Supervisors shall be present at work location during hydro testing

activities are done.

18. Risk assessment shall be done for any hydro test job.