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1.Pressuresourceandtestgaugeshouldbeupstreamofcheckvalve.Ifpressuresourceisdownstream,checkvalve
shouldhaveflapperremovedorjacked?up.(Pressuremustbereleaseddownstreamofcheckvalveaftertestcompletion.)
2.EnsurethattestblindsinstalledaretheCorrectthickness.Ensurethatallitemssuchascontrolvalves,reliefvalves,
rupturedisks,orificeplates,diaphragminstruments,expansionjoints,etc.,whichcouldbedamagedduringpressuretest
havebeenremovedorisolated,asindicatedonthepressuretestflowdiagram.Ensurethatequipment,suchasfilters,
whichhaveinternalsthatmaybedamagedduringpressure.
3.Ensurethatallitemssuchascontrolvalves,reliefvalves,rupturedisks,orificeplates,diaphragminstruments,
expansionjoints,etc.,whichcouldbedamagedduringpressuretesthavebeenremovedorisolated,asindicatedonthe
pressuretestflowdiagram.
4.Ensurethatequipment,suchasfilters,whichhaveinternalsthatmaybedamagedduringthepressuretestareeither
blockedfromtestorthatinternalshavebeenremoved.
5.Checkalltemporarysupportsthathavebeencalledforonthepressuretestflowdiagrams,pipingarrangement
drawingsorspooldrawingtoensurethattheyhavebeenproperlyinstalled.
Posters
6.Ensurethatequipment,suchascompressors,whichmustnotbeincludedinthefieldtestshavebeenproperlyblocked
offwiththecasingdrainopen.
Rejected/Nonconforming
Work
7.Checkopenandclosedpositionofallvalves.
ConstructionProject
Overview
8.Checkforproperinstallationofventsanddrains.
FiberGlassReinforced
Piping
StructuralSteel
PilingWork
EarthWork
CivilWork
FabricationShop
WeldingPowerPiping
WeldingPipeLines
PostWeldHeatTreatment
9.Verifychloridecontentoftestwaterwhentestingstainlesssteels.
Testing:
1.Thepressuretestgaugeshallnormallybelocatedatgradenearthetestpump.
2.Pressuretestgaugesshallbecalibratedtoensureaccuratereadings.Gaugesshouldbetaggedwiththedatethey
werelastcalibrated.
3.Caremustbeexercisednottoexceedpressuretestspecifiedonthepressuretestdata.
4.Whenconductingapneumatictest,itisessentialthatthecontractspecificationforpneumatictestingbeadheredtoin
ordertoavoidcreatingasafetyhazard.
5.Pneumatictestsystemsmustincludedoubleblockvalveswithableedervalvebetweenthemtosafelyisolatethe
pressuresource(byclosingblockvalvesandopeningbleedertoatmosphere)whenincrementalandfinaltestpressures
areattained.
NondestructiveTesting
CoatingWork
TestCompletion:
ElectricalWork
1.Careshallbeexercisedincontrollingtherateofdrainingfromvesselsinrespecttoinflowofairthroughtheventto
assurethatavacuumisnotapplied.
InstrumentationWork
2.CAUTION:Priortocommencingdrainage,ensurethatallventsareopenwithplugsandblindflangesremoved.
StaticEquipment
3.Afterdrainage,removealltemporaryblindsandblanks,temporarysupport,andtemporarytestingconnections.
Boilers
4.Reinstallallitemsthatwereremovedfortest.EnsurethatlineSpecificationgasketsandboltsarebeingusedwhen
reinstallingtheseitems.
StorageTanks
HVAC
5.Removeallshippingbarsfromexpansionjoints.
6.RemoveStopsfromspringhangersandcheckcoldsettings.
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CONTENTSOFHYDROSTATIC
TESTPACKAGES
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Coversheet
DescriptionofLineTest
SafetyCheckSheet
PipeWorkPretest
Checklist
HydrostaticTestReport
AsBuiltFile
MonitoringDuringTesting
DataSheet
WeldingTravel
CheckSheet
Pressurize
HeatTreatment
CheckSheet
HardnessTestingReport
TurnoverDossier
Blow,Flush&Chemical
CleaningCheckList
Flushing&Cleaning
CheckList
PunchListCheckSheet
NDTReports
Whythissubject
Duringhydrotestingandpressuretestingoperationsincidentssometimeshappen.ThisSafetyFeedbackNoticeprovidessometypical
exampleswhichcanbeusedananaidinhighlightingthehazardsanddangersinvolvedarewhatareoftenseenasroutineoperations.
Detailsof5incidents.
1.Hydrotestofanewverticalvessel.
Therootcauseoftheincidentisnotfullyknownbuttherewassomethoughtthathydrotestingwith"verycold"waterwasa
contributingfactor.
Fortunatelynoinjuriesoccured.
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2.Fillingofaverticaltank.
Thefillingofthetankwasmadewithwaterfromafirehydrant.
Thetopthetankblewoffbecuasethereliefvalvecouldnotdisplacetheairfastenoughforthevolumeofwaterthatwasbeing
pumpedin.
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Fortunatelynoinjuryhappened,butanoperatorwasontopofthetankafewsecondsbefore.
3.Emptyingofaverticaltank.
Thecollapseofthistankhappenedwhileitwasbeingemptied.Aplasticsheetprotectingtheroofwastrappedinthevent
henceavacuumwascaused.
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Therewasnoinjury.Itshouldbenotedthatthistypeofincidentisnotthatunusual.
4.Spherecollapse.
Theaccidenthappenedduringthefillingofabar2000mLPGsphere.Itslegscollapsed.Onepersonwaskilledandone
seriouslyinjured.
Atthetimeoftheaccident,thespherewasapproximately80%fulloffreshwater.
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Thevesselslasthydrotestwas10yearsagoandthelastinspectionofitslegswas5yearsago.
Severecorrosionofthelegsundertheconcretefireprotectionwasthemaincause.Thecorrosionoccurredduetowateringressbetween
theconcreteandthesteellegs.
Thewaterprotectivecaplocatedovertheconcretewasnotsufficienttokeepwaterout.Aftertheaccident,itwasverifiedthatthesteellegs
hadthicknessreductionsofupto8mm,withpitingholesofupto10cm.
Afteranalysisandtests,ithasbeenfoundthatthefollowingfactorscausedthecollapse:
Watercapsoverthefireproofingconcretewereofpoordesigntherebylettingwaterpenetratebetweenthesteelbeamsandthe
concrete.
Verticalcracksintheconcreteletwaterin.
Repairshadbeendonetotheconcrete,butwithpoorworkmanship.
Theconcretehadnotadheredtotheoldconcrete,againlettingwaterin.
Thedelugesystemhadbeentestedwithsaltwater,increasingthepossibilityofcorrosion.
5.Emptyingofagearbox.
Tospeeeduptheremovalof250lofoilfromagearbox,theguageholewaspluggedandthebreatherwasconnectedtothe6
barairnetwork.
Thegearboxexploded,andthrewmissilesaroundseriouslydamagingsurroundingpipingandstructure.Fortunatelythere
wasnoinjury.
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SPECIFICRECOMMENDATIONS
Foreachcasethespecificrecommendationaregenerallyobvious:
1stincident:Watertempeartureiscriticalwhenhydrotesting.TFEspecification(GSPVV211)statestahtbothmetalandwatertemperature
duringpressuretestingshallbemaintainedatleastat16Coratleast10Cabovetheimpacttesttemperatureofthemetal.
2ndand3rdincidents:Ventingsystemsshallbeinspectedandcheckedbeforefillingandemptyingoperations.
4thincident:Isamaintenanceproblem?Beforetestinganoldvessel,acompleteinspectionmustbeperformedvisuallyandwithNDT.This
inspectionshallincludethevessel,nozzles,appurtenances,andsupportingstructures.
5thincident:obviouslyagearboxisnotpressurevessel,butproductivitymayleadtoariskyattitude.
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