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SAFETY NEWS

POWER & GAS

Nr ??-
Nr 03- May October 2013
2011

s suc NEVER UNDERESTIMATE THE HAZARDS OF PRESSURE TESTS


During the phases of construction and commissioning, pressure
tests are carried out. The accident history demonstrates, if still
necessary, how much these operations are hazardous.

The two main hazards which one must contend with during
pressure testing are the formation of missiles and the generation
of a shock wave. The failure can be of the item being tested,
clamping equipment holding it in place or the source of pressurising
fluid. Experimental evidence indicates that shock waves are not
formed when the pressurising medium is a compressed liquid. Thus
shock waves can largely be discounted when pressure testing
using water at ambient temperature. On the other hand, shock
waves are the norm when pressuring with a gas or a saturated
volatile liquid. In contrast, missiles can be generated whatever the
pressurising medium. The prevailing safety rule is to give priority to
hydrotests. However, although less dangerous they are still
hazardous and should not be underestimated as demonstrated by
a fatal accident occurred on March 2013 in a Power Plant in
construction.

A GRP pipe (Glass Reinforced Plastic) of larger diameter must be


hydraulically tested at 1.5 times its working pressure, which was
fixed at 9.0 bars. A method statement and job safety analysis were
written. The section of the pipe to be tested was equipped with an
end flange of 4 Tons. 2 vents located at highest points of access
manholes were used to purge the air during the filling. A pump was
used to fill and pressurize the whole assembly. To be noted that the
end of the pipe equipped with the blind flange was forming a slight
slope without vent at his highest point. The test pressure was
almost reached when the 4 tons flange and the lamination pipe
thrown away violently. The mass hit violently a supervisor killing
him instantly.
The analysis of the accident revealed the following:
- Hydrotests are dangerous operations and people responsible for
carrying them did not really have consciousness of it;
- The strength of the projection was accentuated by the fact that
most probably some air had been accumulated in the upper end
portion of the pipe (missing vent);
- People were entering the safety perimeter defined around the
pipe.

A method for the calculation of the safety perimeter and procedure


for pressure test are available at the Risk Management & Safety
Dpt.

Want to know more? Requiring specific information?


Contact:
Frdric Kolen Projet Manager Tel. 9523
Claude Vancraeynest Principal Engineer - Tel. 8009
Ermenegildo Aromatario Risk Mgt & Safety Tel. 8187

CONTACT: leme.comunication@tractebel.com

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