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.