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Safety in Pressure Testing

The document provides an overview of safety measures and types of pressure testing, including hydraulic and pneumatic methods. It outlines hazards, precautions, and general safety requirements to ensure safe pressure testing procedures. Additionally, it emphasizes the importance of competent personnel and proper equipment preparation to prevent accidents during testing.

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Vikram
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39 views19 pages

Safety in Pressure Testing

The document provides an overview of safety measures and types of pressure testing, including hydraulic and pneumatic methods. It outlines hazards, precautions, and general safety requirements to ensure safe pressure testing procedures. Additionally, it emphasizes the importance of competent personnel and proper equipment preparation to prevent accidents during testing.

Uploaded by

Vikram
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Safety in pressure Testing

Presentation by :HSE-HCP
Pressure Testing: An Over view

 Categories of Pressure Testing


• Hydraulic or Hydrotesting
• Pneumatic
 Hazards during Pressure Testing
• Stored Pressure Energy
• Release of stored Energy
 Precautions to ensure safe Testing
• Blinding, Area Evacuation
• Safe procedures to be followed while Pressure Testing
Types of Pressure Testing
 TYPE 1: PROOF TEST

• When the required thickness of pressure parts has not been

accurately calculated

• Objective is to demonstrate integrity of the pressure Equipment

• Should be done Hydraulically and gradually until the specified

test pressure is reached or any significant yielding of any part of

pressure equipment occurs


Types of Pressure Testing
 TYPE 2: STANDARD PRESSURE TEST

• When the required thickness of pressure parts has been

accurately calculated

• Objective is to prove quality of material used and construction of

the pressure Equipment

• This test is done when the test pressure is typically 1.25 to 1.5

times the design


Types of Pressure Testing
 TYPE 3: LEAK TEST

• This test shall be carried out not exceeding 10% of design

pressure on pressure equipment which has not been subjected to

standard pressure test

• It may also be performed at a higher pressure , not exceeding

110% of design pressure on pressure equipment which has

passed the standard pressure test


HYDRAULIC AND PNEUMATIC TESTING

 Although pressure testing using a liquid as the pressurizing medium


(usually referred as Hydraulic testing) is not without risk, it is by far the
safest method and should be used wherever practicable>.
Pressurizing using Gas, Steam or air as the pressurizing medium
(usually referred as Pneumatic testing) is potentially dangerous
because of the Higher energy levels. In Instance , the energy released
during a total failure of a pneumatic testing at a pressure frequently
used in a pressure testing is usually 200 times the energy released by
the same volume of water compressed to the same pressure
 Pneumatic testing should only be carried out when hydraulic testing is
not practically applicable, for instance if the interior of the pressure
equipment will be contaminated by the hydraulic testing medium, or
when pressure equipment supports and/ or foundations are not
capable of supporting the weight of the equipment filled with the
medium.
Low Pressure and Vacuum hazards

 Many people say It is a very low pressure


only?

 Is Low pressure Harm less?


Pressure and Force

 Force = Pressure X Area


 This is like many small weight sitting on an area
 The larger the area greater the force
 The weight may be small , but if the area is large,
they will add up to a big force
 If 10 psi pressure is on a 12” x 12” square surface
area it produces 1,440 pounds of force which is
equivalent to 1440 lbs!
Low pressure is also harmful

ABSOLUTELY… and be especially careful with


large surfaces like man ways. 1 psi may not
even register on a gauge but it is enough for
a greatest fly and hit injury if all the bolts are
removed and the gasket is stuck
PRESSURE TESTING ACCIDENT
PRESSURE TESTING ACCIDENT
PRESSURE TESTING ACCIDENT
Accident due to vacuum formation
General Safety requirement for pressure
testing

 Competent and experienced person shall only perform the


pressure testing
 Before filling the test medium pressure test coordinator shall
ensure mechanical clearance (Installation of blind, vents at
higher elevation, Vents at the higher elevation and calibrated
pressure gauge)
 The temporary blind specification chart is given at the end
 Always fill the liquid medium from the lower elevation to vent
the air/ gases from the higher elevation
 Barricade the Area and evacuate personnel working at
pressure testing area ,Display boards may also be used
 Check integrity of the test equipment and connections that are
not subjected to test pressure must be Isolated/ Dis connected
General Safety requirement for pressure
testing

 Dial indicating pressure gauge shall be graduated over a range


of double the intended pressure but in no case shall be less
than 1.5 or more than 4 times test pressure
 When pressure is nearing the yield strength or when test
pressure of over 500 psi are being applied the pressure should
be lowered to 10% before inspecting the leaks
 Rate of pressure shall not be greater than 100 psi
 Only calibrated test gauge and safety valve is to be used with
set pressure above the 5% test pressure are to be used and
should be mounted only in the up- right position. Pump
discharge gauge should be visible to the pump operator
 In order to avoid vacuum formation , it is necessary to open the
top vents and drain the liquid from the lowest point
General Safety requirement for pressure
testing

 Lines shall be drained and dried


mechanically when the test liquid is corrosive
 Oxygen lines must be flushed out for all
hydrocarbon traces before introducing
oxygen
Preparation of piping system/ Equipment

 SUPPORT
Piping and vessels designed must be adequately
•
supported for the extra weight
 VENTS & DRAINS
• Vents of adequate capacity must be installed at high
points.Drains fitted to lines to drain test fluid must be of
adequate rating for the pressure to be encountered. The
low pressure of all such valves must be vented
 VALVES
• Valves of adequate rating for the pressure testings are to
be used
Preparation of piping system/ Equipment

 BLINDS
• Standard type of blind/end cap with appropriate pressure
withstanding capacity shall be provided.
 VACUUMS
• Vessels or tanks, which would collapse if subjected to
vacuum . Sufficient vents shall be provided while draining
the test fluid in order to prevent vacuum formation
 PUMPS
• Pumps used for pressurization of system shall be
validated and fitted with safety valve for required pressure.
Pneumatic testing area Barrication limit

 For Test pressure below 21 bar (300 psi)


No personnel shall be allowed within 15 mtr of radius .
At least three inspection phase intervals of 50,100,200 psi

 For Test pressure above 21 bar (300 psi)


No personnel shall be allowed within 25 mtr of radius .
The pressure in the vessel shall gradually be increased to not
more than ½ of the test pressure and shall be increased in the
incremental steps of 1/10 of test pressure until test pressure
has been reached

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