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Hydro Testing Safety 25-8-2020

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Hydro Testing Safety

 Introduction
 Purpose of Hydro Test
 Hazards
 Precautions
 Incident during Hydro Test Choke Manifold
Hydro Testing Safety
Introduction
• The hydro test is the is the technique in
which pipes, pressure vessels, gas
cylinders, tanks are tested at required
design pressure of the system or pipes or
vessel to check the leak and strength.
• It is carried out by using water. Water is
pressure by means of hand/engine pump
to a certain pressure and has to put the
system on hold for some time to observe
any leak or failure. After achieving the
require pressure, if it falls means having
some problem in the system.
Hydro Testing Safety
Purpose of Hydro Test:

• Identify the leaks.


• To check the strength
of the welded joint.
• To check the capacity
of the system.
Hydro Testing Safety
Hazards:

• Breaking/failure of line, gasket, flanges, and • Incompetency of workers.


gauges.
• Lack of supervision.
• Air entrapment inside the pipe.
• Improper Barrication and sign
• Usage of an engine operated pump. board.
• suddenly increase of pressure due • Pipe blast.
to underrated or non calibrated pressure gauges. • Pressure exceed.
• Unauthorized entry. • Poor quality of pipes.
• PSV failure.
Hydro Testing Safety
Safety Precautions of Hydro Test:
• PTW (Permit to Work) should be prepared.
• Hydro test Area shall be barricaded and provide warning
boards to prevent personnel entry.
• Calibrated pressure gauges and Pressure safety valves only
shall be used.
• Rating of fittings, pressure gauges, vent valves, gaskets shall
be suitable for the test pressure.
• All the temporary welding shall be performed by qualified
welders and approved by Client QA/QC.
• Pressure should be raised gradually under control to allow
time for pipes to strain and time for personnel to check for
leaks.
Hydro Testing Safety
Safety Precautions of Hydro Test:
• There shall be at least two pressure gauges, one at lowest
point and another at the highest point in the system.
• Hydro testing crew should not stay in the direction of the
blind flanges to prevent injury in case of flange rapture.
• Hydro testing crew should not stay in the direction of the
blind flanges to prevent injury in case of flange rapture.
• All hoses/ piping/gaskets and connectors/clamps shall be of
adequate rating to withstand pressure.
• Whip lash arrestor shall be provided at hose connection.
• Personnel shall not approach the system under high Pressure.
Hydro Testing Safety
Safety Precautions of Hydro Test:
• Only essential and trained persons shall be allowed at the
Hydro test work location.
• Access shall be free from any obstacle.
• Supervisors shall be present at work location during hydro
testing activities are done.
• Risk assessment shall be done for any hydro test job.
• Safe Distance should be maintained.
• Proper PPE should be used.
• Close supervision need to be done during job.
Hydro Testing Safety
Incident during Hydro Test Choke Manifold:
Hydro Testing Safety
Incident during Hydro Test Choke Manifold:
Hydro Testing Safety
Incident during Hydro Test Choke Manifold:
Hydro Testing Safety

THANK YOU

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