Friday, June 19, 2020

Safe Hydro/Pneumatic Testing

HSE Precautions 

Hydro testing is always a high risk activity which involves many hazards, and some of leading hazards are as given below:

  • Abnormal increase of pressure 
  • Significant reduction in pressure
  • Flooding
  • Asphyxiation
  • Loss of load
  • Air hose Eject
  • Explosions
  • Rupture of vessel/container
  • Manual handling
  • Access & egress
  • Slip & trips
  • Pressurized vessels

To avert or avoid any unpleasant and unwanted incident while carrying out Hydro Testing, proper Safety initiatives as outlined below must be followed:
  • The Hydro/Pneumatic testing team must review method statement and task risk assessment (MS & TRA) related to Hydro / Pneumatic testing. 
  • Valid Permit to Work (PTW) for Hydro test/ Pneumatic test must be available.
  • Use Checklist for Hydro Testing Activities.
  • Prior the testing activity proceedings, all technical team members must attend proper toolbox talks (TBT).
  • Safe working distance to be calculated and maintained.
  • Hydro test Area shall be barricaded and provide warning boards to prevent unauthorized personnel entry.
  • Standardized Calibrated pressure gauges and Pressure safety valves only shall be utilized.
  • Rating of fittings, pressure gauges, vent valves, gaskets shall be appropriate for the test the pressure.
  • Flanges and Plates shall be according to line class.
  • Pressure should be raised gradually under control to allow time for pipes to strain and time for personnel to check for any possible leaks.
  • Hydro testing team should not stay in the direction of the blind flanges to avoid any serious physical injury in case of flange rapture.
  • All hoses, gaskets, connectors and clamps shall be of suitable and quality rated to bear and hold pressure.
  • Whip lash arrestor shall be maintained at hose connection.
  • Any technical team member shall not approach the system under high Pressure.
  • Only authorized, competent and well trained technician shall be permitted at the Hydro test work area.
  •  Access and egress shall be free from any obstacle.
  • Competent and accountable Supervisory staff shall be present at work location during hydro testing activities are done.
  • Proper communication and Coordination with nearby working teams/companies regarding Hydro /Pneumatic Testing and formal notification to be circulated.
  • At the end of the task, make sure that good housekeeping is maintained and proper disposal of Hydro test waste water is done.

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