Guidance To Good Engineering Practices - Pressure Testing

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Following the guidance le not compulsory and you are tree {0 take other action. But if you do follow the guicance you vill normally be doing enough to comply with the law. Heath and eatoty inspectors seek to secure compliance with the law and may refer to this guidance as Mustrating ‘900d practice, INTRODUCTION 1 This guidance note gives advice to employers, ‘managers and supervisors of pressure testing sms/operators and self-employed persons. It provides guidance on how pressure testing can be safely carried ul by means of risk assessment, a safe system of work and suitable precautions. Its technical appendix gives advice on the design of protective barters i there ie a risk of pressure equpment rupture or detachment of a component while under test 2 The appendix to this guidance note is based upon 2 ‘esearch report commissioned by HSE and pubished as HSE Contract Research Report No CRR168 Prossure lest ‘ety. ts reference is given in Further information’ at the end ofthis note. The report was prepared by G Savile and 'S M Rlichardson, Imperial College of Science, Technology ‘and Medicine and B J Sxilerne de Bristowe, BUS Rosearch. Its 165 pages describe, in detail, a method for ‘he quantification ofthe hazards assaciatod with the Conduct of pressure tests and with the sizing of protective Darners to prevent injury. It will be particulary useful 12 Pressure testing sub-contractors and organisations. ‘Specialising in the design and construction of barriers to Contain biast and fragments, DEFINITIONS 3_Inthis document the term ‘pressure equipment means ‘a pressure vessel, pipowork, systoms comprising one or ‘ore pressure vessels and associated pipework, and any ‘ther container of pressure, that need to be pressure tested, Safety in pressure testing ST Guidance Notes are published under five subject headings: Medical Environmental Hygiene Chemical Safety Plant and Machinery General eT 4 Pressure equipment is normally pressure or leak tested after manufacture, repair or modification. Itmay also need to be periodically pressure tested as part of a routine inspection regime. 5 The term ‘pressure tes” inthis document inclidos the foloming: (a) Proof pressure test: his is caried out when the required thicknoss ofall the prossure parts hes not been accurately calculated or isin doubt. Its objective is to demonstrate the integnty of the Pressure equipment, Proof pressure testing should ‘only be carried out hydrautcally and! the pressure applied gradually untl the spectied test pressure is reached or unti signicant yielding of any part of the pressure equipment occurs. A method to determine significant yield is contained in British Standerd ‘5500: 1997, amended 1998 Specification for unfred tusion-welded pressure vessels, (©) Stanciard pressure tos: this tost ie used when the ‘oquired thickness of all pressure parts has boon calculated. Its objective Is to prove the quality of materials used and the construction of the pressure equipment belore it ontors oF re-enters service. This tests carried out at a specified pressure above the design pressure, typically 1.25 to 1.5 times the design pressure, (©) Leak test this test may be carried out at a pressure ‘ot exceeding 10 % of the design pressure on pressure equiptment which has not been subjected toa standard pressure test. It may also bo Performed at a higher pressure, not exceeding 110% Of the design pressure, cn pressure equipment which has satsfactorly passod the standard pressure tes. (0) Functional test this test is eartied out using @ suitable test medium at design pressure, or working pressure if his is lower, to check thatthe pressure ‘equipment and its components function properly ‘may inciude the actuation of moveable parts, such 5 the opening and closing of valves, Hydraulie and pneumatic testing © _Atthough pressure testing using @ liquid as the ressunising medium (usually referred to as hydraulic testing) not without risks, itis by far the safer method and shouls be used wherever practicable, Pressure testing using at, steam or gas as the pressurising ‘medium (usually referred to as pneumatic testing) is potentially more dangerous because ot the higher energy levels involved, For examplo, the energy released during a total failure of pressure equipment containing ‘compressed alr at pressures frequently used in pressure testing 's more than 200 timos the energy released by the ‘same Volume of water compressed to the same pressure. 7. Pnoumatic testing should only be carried out when hydraulic testing is not practicable, for instance where the interior ofthe pressure equipment wil be contaminated by the hydraulic test medium, or when the pressure ‘equipment supports and/or foundations are not capable of supporting the weight of ihe equipment filed with the medium 8 A pneumatic leak test within the limitations sot out in paragraph 5(c) above ean be used to find small but signifiean' leaks, especially in ecuipment which wit contain fammable gases andlor fluids RISK ASSESSMENT 9 The ist step to take before carrying out any pressure tes is 1o perform a rsk assessment of he ‘operation. Risk assessmont guides the judgement ofthe employer or the self-employed person as to the measures they need fo take to carry out their legal obligations when pressure testing. It eles on the identification of al televant hazards and dangers, and consists of an estimation ofthe risks arising from them with a view to their contro or avoidance. For further guidance on risk assessment see the relevant HSE publications listed in ‘Further information’ at the end of this document, 10 _As pressure testing is sometimes undertaken by ‘specialist sub-contractors there is @ need lor co-operation and co-ordination between ther and the pressure ‘equipment manufacturer and/or owner to ensure that all risks are taken into accourt. 11__Ansk assessment wil indicate the extent and Content ef the safe system of work that needs to be in Place before any pressure testing is carried out, A sate system of work is necessary to ensure the safety of testing personnel and other people in the vicinity, including the general pubic, 12 _ The assessment should also incicate whether or not pressure equipment ceeds to be placed behind a bamier \when its tested, bearing in mina that pressure equipment pneumatically tested will contain considerably more energy than the seme equipment subject to hydraulc testing, Hazards 13. The main hazard when pressure testing is the Unintentional reloase of stored energy. in the case of ‘pneumatic testing this can lead to a blast wave and missiles, However in tha case of hydraulic testing, bast has lite energy and itcan be assumed that al expansion ‘eneray goes into missile energy, 14 _ The hazards presented by the compressibily flammability and toxicity ofthe testing mackum should a'so be considered, Stored energy 18 Risk assessment of pressure testing activities should take account of the energy stored inthe pressure equipment neing tasted snd dangers arising when this stored energy is suddenly and unintentionally released, creating blast waves and missiles. The release of stored energy can be due to: (2) rupture of pressure equipment due to brite fracture: (©) rupture of pressure equipment due to ductile fracture, (©} detachment or removal of blanking plates and their ‘lamps/attachment botts, screwed plugs, isolation valves ete; (6) cetachment of temporary welds on plugs, at pipe ends and nozzles. 16 Calculation ofthe stored compressed energy in the Pressure equipment wil indicato the extent of possible blast anc missile formation fit ruptures or components become detached under test pressure, Formulae for Calculating stored energy in gas and liquid fled systems. {are shown in the appendix to this document. Further detailed information is available in HSE Contract Research Report No CRAI68 Pressure test safety. Biest and its effects 17 _Biast and ts effects on structures are briefly described in the appendix. The Research Report Pressure test safely reviows the physics of blast wave formation, discusses the response of structures to dynamic loads imposed by biast waves and missiles and tives some worked examples. Missile formation 18 _ The appendix describes how the mass. siz, stiane and speed of each fragment can be determined. It also ‘ives formulae for calculating the thickness of Containment walls. Fuller explanations and worked ‘examples are contained in Pressure fast safety 19. Possible modes of failure and hence fragment size should be the subject of ciscuesione between the ‘manager/supervisor ofthe pressure testing leam /operators and the pressure equipment designer. In stuabons where pressure tests are carried out by sub-contractors they Should obtain sutcient information from the designer ant ‘manufacturer fortis assessment to be made, Brittle fracture 20 The risk of rupture of the prossure equipment due to bite fracture under the test conaitions should be assessed at the design stage. This may affect the choice cof materials of construction and the temperature at which tests willbe carried cut, ‘SAFE SYSTEM OF WORK 21__Arisk assessment should indicate the extent and, Content ofthe safe system of work that needs to bein Place before ary pressure testing is carried out Permit-to-work system 22 _ An important element ofthis sate system will be the lwntten permi-to-work system. Thie should require: (a) Recorded positive vertication by a competent Person that sate working conditions are in place betore each pressure test commences. (©) Recorded authorisation by a competent person that the pressure equipment is isolated from pressure sources, fully de-pressunssed and vented (or, if {ustilied by a risk assessment, to any other sate leva) before dismanting of the pressure equipment, ts components or any remedial work takes piace. Training 23 _The sale system of work should also require that al persons involved in pressute/ieak testing are adequately and properly trained, riten testing instructions and procedures 24 Written testing instructions should be available ‘which include procedures for pressursing, de- pressursation and venting. These should ba drawn up by ‘ competent person. Any changes inthe instructions or Procedures should be agreed in writing with the ‘competent person. The instructions should define: (8) the test pressure, the test duration and testing ‘medium to be used: (©) where the testing medium supply line is to be attached to the pressure equipment: (c} the position and specication of safety valves and pressure gauges: (4) _ the position of isolation vawves; and (e} the sequence for opening vent valves when more than one venting position isto be used, 25. Wapproprate, an up-to-date piping and insitumentation drawing showing the positon of all isolation valves, safety valves, non return valves, pressure ‘gauges. testing medium supply points, vent valves and blanking plates should accompany these instructions. 26 Tables may also be needed as a checklist to show it valves are in the normally open or normaly costed Condition curing pressurisation and de-pressursalion, This should ensure that when the aressure equipment 's handed ‘back for subsequent remedial or other work thera is no residual pressure ieft in t. Any reference to the checking of valves should include remotely operated valves, 27 _ Depending upon the complexity ofthe pressure ‘equipment under test, the system af work should include the following requkrements: (2) the dimensions of the designated test are including minimum safe distances from the pressure equipment under test; (©) _ the designated test area should be isolated as a no {90 area and testing should not start uni all persons. are in a sate piace (6) only those persons essential forthe operation of the test equipment should be allowed in the vicinity of the test alter prossurisation has begun; (8) checks to ensure that all test equipment used during the testis capable of withstanding the ful test pressure; (2) the pressure should be appliad gradually or increased by steps of approximately 10% untl the required test ‘pressure is reachod. It may be necessary to record ‘est prascure at suitable intervals; (©) pressure equipment at pressure should not be approached for lose examination uni a reasonable period of me has elapsed. The pressure at which it can be approached for close ‘examination should be specified inthe testing Procedure. For the safty of testing porsonnel it ay be necessary to consider remote viewing procedures rather than ciose physical examination: () unauthorised persons should not be allowed to ‘approach the pressure equipment untlit has been de-pressurised and vented: and (9) the pressure should be recoried ater the equipment has been isolated trom its pressure source and de-pressursatior/venting has been ‘completed. This wil indicate if thare aro any Instances of re-pressurcation or failure to ce- pressurise and vent before any work on the equipment takes place. Venting 28 _ Thore should be suticient venting positions to prevent the testing macium being trapped behind nor- ‘rotum valves, in dead legs or between isolation valves. Instruction should be provides on how the pressure equipment can be safely tested and vented in discrete sections, if this isthe intended method of testing. Where the section under test terminates at a vale it should not ‘be possible for pressure to build up inside an adjacent closed section i his valve leaks. 29 _ Belore remedial or other work is 10 be carried out on the pressure equipment it should be vented and the ‘Pressure tosting medium supply ine disconnected, If itis unreasonable to cisconnec: the supply lie then the isolation valve should be focked inthe closed position, Clamps and bolts 30 Clamps or bolts on bolted flanges must not be: loosened or tightened wile the prassure equipment is under pressure. The pressure equipment should bo isolated from pressure sources, de- pressurised and vonted botore clamps or bolts are adjusted or removed. 31 Clamps should be fited and tightened in accordance with the manulacturer’s recommended Procedures, Flanged joints should be fited withthe _appropraata bos and gaskets and tightened in ‘accordance with written procedures. Test equipment 32 Pressure gauges should be fitted at or near each venting and pressurising medium supply point where they ccan easly bo seon by the operator. Further pressure {gauges should be incorporated to datect any residual Dressureif there is a isk that pressurising medium can be ‘rapped by check valves and similar equiornent. 33 All pressure gauges usod ‘or pressure testing should be compared regularly with a calibrated gauge anc records of the comparison kept. Any gauges used during the test should have a cutront cotifcata of ealbration 34 __Itmay also be nacessary to provide temperature ‘gauges to check the testng medium temperature, i this is 2 tolovant factor. GENERAL PRECAUTIONS FOR PRESSURE TEST 35 _ Care should be taken not fo over-stiess the Pressure equipment during the test. Test pressures Should be limited 1 ensure that the neakest partis not subjected to stresses greater than those specified in the appropriate standard or code. 36 Pressure equipment should not be subjected to any form of shock loading when under pressure, 37 To avoid brite fracture the temperature of the ‘meaium entering the pressure equipment should not be lower than the test temperatura statod in the testing procedure, Evaluation and inspection prior to test 38 _ To minimise the risk of failure while under test, the Pressure equipment should be evaluated and inspected before itis tasted, The evaluation should inciude Consideration of the design criteria, material specication ‘and construction methods. The inspection may need to Include visual and other non-destructive testing (NDT) ‘methods fo ensure that thore ara no significant defects whieh eculd lead to falure during the test. 39 _ Special attention should be gven tothe testing of Pressure equipment which has been refurbished or repaired alter a period of service. Such equipment may have been ‘subjected 0 cycic loacing andlor corroswe environments NOT may be necessary before the fest to ensure that metal thickness meets spectied design requirements and that there are no significant defects which may lead fo failure ‘dung the test. Repair records should also be checked 10 ‘ensure that any repairs were correctly carted cut Protection against blast waves and missiles 40 _ Protection against blast waves and rockating fragments can be provided by placing the pressure ‘equipment behind a suitable baer or ina properly designed Pit. Formulae to calculate the thickness of barriers are showe in the appendix but more detailed informations given in HSE Contract Research Report Pressure fest safety. Safety valves 41. Salety valves of adequato size and marked withthe ‘Sot pressure should be installed in or close tothe test ‘supply ine to prevent the test prassure being exceeded. It should not be possible to isolate these valves from the tosting medium pressure. ts vital that safely valves are supplied and maintained in proper working order. They Should be regulary stripped, cleaned and examined, and the set pressure checked belore re-use, Flexible pipes 42 _ Flexible pipes and their connections should be ‘regularly examined to reduce the risk af them bursting or coming apart, Safety restraints should be attached so as {o proventflexibe pipes tlaling about in the event of them coming apart. Personal protection 43 There is a risk of injury irom particles of dit anc high velocity jets ejected during a hydraulic test at high Pressure. A much greator risk exis during a pneumatic, test, Personal protection including eye protection should ' provided and used by persons working within the pressure test facility, PNEUMATIC TESTING PRECAUTIONS, 44 _ Where possibie, steps should be taken to reduce toa ‘Tinimum the intemal volume of pressure equipment 0 be pneumatically tested e.g. by means of non-compressable ‘material. This wil reduce the amount of energy stored and 50 reduce the consequorces ofa rupture. It may be possibie fo isolate sectons of the equipment and test them ‘seperately flowed by reassembly and leak testing Large pressure systems 45 tthe risk assessment of a pressure test indicates the pressure equipment should be placed behind barriers but itis too targe oF heavy todo $0, then any persons in the test danger zone, including nearby buildings, public rads or open areas, should be kept clear unt the test is over. It may be possible to carry out the fest at night ‘whon it wil cause the least disruption to the general pute and normal production, Flow regulation 46 The testing medium prossure should be controted ‘by reducing valves and flow control valves. ‘Test tomperature 47 Local ching during ilng and emprying of the ‘equipment when pneumatically testing can lead to brite fracture. This risk should be minimised by avoiding sudden changes in low rate across inlet and exhaust Control valves or nozzles. HYDRAULIC TESTING PRECAUTIONS 48 Pressure oquipmont being hydrauically tested should be totaly filed with liquid and propery vented to exclude air pockets. In some cases the equipment may be 80 constructed that it cannot be ful flooded for a hydraulic test and the stored energy ofthe trapped air or gas creates ‘ hazard. In these circumstances precautions suitable for pneumatic testing should be considered. 49 The effect on the test pressure of static head of hhysrauiie test medium should be considered and taken Into account i necessary. 50_To avoid ice damage to the pressure equipment ‘when hydraulically testing with water, the temperature ‘during the test should not be lass than 7°C. Heating may ‘eed to be provided when there is ari of the water lteezing. UNDERWATER PNEUMATIC TESTING 51 Underwator pneumatic testing is often used to combine a standard pressure tect with leak test for ‘small, batch produced pressure equipment ‘52 The test tank should be propery designed and tested to wihstanc any sudden release of pressure safely. Deep immersion of pressure equipment in water \wil not provide enough protection ifthe test tank is Incapable of withstanding the hydraulic shock of a pressure release, 53. Safeguards should be provided which ensure that (a) the equipment is completely immersed to its Specified dopth while the standard pressure testis being carried out, and (©) access into the designated danger zone is roventod, 54 Case observation of the equipment for leaks should only be permitted under the folewing conditions: (@) when the leak tost pressure is less than or equal 10 10% of the design pressure, or (6) _attor a successful standard pressur test, when the leak test pressure does not exceed the design pressure, 55__ tis recommended that the water temperature and 10 is included in Pressure test safety Examples Again, Savile etal provide examples of how fragment si0 and velocity can be assessed and of how Containment thicknesssess can be calculated for commen Containment materials. 5 Blast and its effect on structures {In comparison with the behaviour of missiles. our knowledge of biast waves is very limited. Most of the information evailabio is for miitary explosives and for chemical explosions such as gas explosions. In order to assess the damage causad by a failed pressure vassal, it is assumed thatthe blast rom a ruptured pressure vessel is the same as the blast caused by the detonation of te ‘amount of TNT which will release the same energy io kg OF TNT Is equivalent toa stored onergy of 4.5 MA ‘Although biest can largely be avoided by using liquid as the test medium rather than gas, the impact of missiles on protective wails has a biast-lke effect and consideration of bast should stil be mace. ‘Savile otal review the physics of blast formation and how ‘his has been used to develop relationships to predict biast effects from known data. For explosives and ‘chemical explosions, this has been used to estimate sale distances from explosions and distances to which debris, might be propelled. Factors whieh may neod to be taken ‘inte account inckude: (2) reflection of blast waves from unyielding surfaces; (©) energy yield magnification due to reflection of blast waves from the ground or rom internal surfaces of a blast chamber; and (6) geometric eects due to local flue of a pressure vessel or due to the position ofthe vessel being on-central within blaet chamber Test chambers For intemal bass within a test chamber, experimental work using charges of Sig TNT has been camiod oul to produce pressure-time histories which have been ‘approximated by a simple modal. Its possible to use this ‘approach to estimate the impulse load taken by the test ‘chamber from the peak pressure and impulse received by the cubicle walls during the intial shocks. For totally enclosed chambers itis necessary to add on the pressure {oad and impulse due to the roleased gas. I the chamber Is fully vented, for example with one wall completely open then the aduition ofthe pressure and impulse loads cue 10 the released gas is not necessary. Savile et al provide references for charts from which ‘shock loading on chambers can be determined and deserve a method for estimating the gas pressure loading for unvented chambers. Additionally they provide a simple method for estimating te biast-ike etfect of missile impact. An example is given of how this approach can be Used to calculate peak pressures and impulse loads. Structural response to blest Blast from an explosion damagos a structure by causing it lo Seform. Damage is most likely when the period of the biast impulse is close to tng natural visation period of the ‘stuctur. Ifthe blast impulse period is long compared to the natural period, the structure can be considered to be loaded quasi-statically. In this case the displacement of the structure is related solely to the peak force produced by the biast and the stitiness ofthe structure. Ifthe blast Impulse period is short when compared to the natural Period, the biast load will be over before the structure has ‘moved. This is known as impulsive loading, Where the blast impulse period is close to the natural period, deflection wi be betwoon the static and impulsive cases: and it wil be necessary to solve equations of motion numerically to obtain the response of the structure. tis clearly important that damage assessment is not based on the peak blast pressure slone; it loading is Impulsive rather than quasi-static then severe ove estimation of damage could result Savile 6t al show how the blast response of structures ‘made trom flat plates, including steel and concrete, can be represented as a pressure impulse diagram so that the bressure-impuise combinations which result in structural etormation can be predicted. Example calcwations are: siven for representative structures, REFERENCES 1 Savile G et al Pressure test satoty CRRI6S HSE Books 1998 ISBN 0.7176 1522 1 2 Reid A Cet al The properties of gases and liquids 4th 6 MeGraw-Hil 1987" 3. Sandler § | (Eaitor) Models for thermodynamic and phase equitbrivm calculations Dekker 190% 4 Angus S et al International thermodynamic tables of tive fui state nitrogen Pergamon 1979 REFERENCES FOR TABLE 1 IN CHRONOLOGICAL ORDER 1 Sage BH and Lacey WN AP! Research project 37 (monograph) American Petroleum Institute 1950 2 Hlilsentath J et al Circular $64 American National Bureau of Standards (ANBS) 1955 3 BonzlerH end Koch AV Chem. Ing Tech 195527 71 4 Cramer Chom. ing. Tech, 1955 27 404 5 Sage BH and Lacey WN AP! Research project 37 (onograph) American Petroleum institute 1955 6 Din F Thermodynamic functions of gases vo's 1-3 Butterworth 1958.61 7 Mann DB and Stowar RB Technical note 8 ANBS 1959 & —_Edminster W C Applied hystocarbon thermodynamics Gull Publishing Company 1961 8 Strobridge T R Technical note 129 ANBS 1962 40 Mann DB Technical note 154 ANBS 1962 11 Canjar L N etal Hydrocarbon Processing and Petroleum Reiner (a) 1962 41 (9) 291; (0) (10) 149; (6) (11) 208; (6) (12) 118; (e) 1963 42 (4) 429; (f (6) 127: (g) 1964 49 (6) 177: (m) 1965 44 (9) 215; (9 (10) 137: (00) 145: (at (11) 293; (9 (19) 287 12 Roder H Met al Monograph 94 ANAS 1963 13. Hurst JG and Stewart R B Technical note 202 ANBS 1963) '4 Harrison AH and Douslin D R. Perluorocyclobutane: the thermodynamic properties of the reai gas US Department of the Interior 1964 18 Kubin RF and Presley LL SP 3002 Nat. Aero. Space Admin. 1964 16 McCarty RD and Stewart AB Advances in thermodynamic propemtes at extreme temperatures anct pressures ASME 1965 84 17 Am. Soe. of Heating, Rettig. and Ait Cond, Engineers Thermodynamic properties of refrigerants 1969 18 GarjarL Net al Hydrocarbon Processing and Petroleum Refiner 1966 48 (a) (1) 195: (o) (1) 199; (6) (2) 188; (a) (2) 161; e) (8) 137: (9 (3) 143; (g) (4) 161; (>) (4) 165 19 Canjar LN and Manning FS Thermodynamic properties and reduced correlations for gases Gait Publishing Company 1967 20 Vukatovich MP and Altunin VV. Thermodynamic propenies of carbon dioxide Cotlets 1968 21 Gosman A Let al National standards reference data Series NBS 27 1969 22 Keenan JH et al Stoam tables - internationa! fection in Si units Wiley 1969 23 Vasserman A A and Rabinovich V A ‘Thermophysical properties of iquié air and its properties 'srael Programme for Scionilc Translations 1970 2 Zagoruchenko V A and Zhuravelev A Mt Thermophysical properties of gaseous and liquid methane US Depariment of Commerce 1970 25 Weber LA J Res. Nat. Bur. Standards 197074 93, 26 UK sieam tables in SI units Aenotd 1970 27 LinD CK otal J Chom Eng Data 1971 16.416 28 Staring KE Hydrocarbon processing 1971 50 (4) 439 29 Staring KE and Kwok ¥ C Hydrocarbon processing 1971 60 (4) 140 90 Angus $ and Armstrong 8 Intemational thermodynamic tables ofthe fud state - argon 1971 Buterworth 1972 31__Roder HM and Wober LA Oxygen technology ‘survey vol 1: ‘Thermophysical properties’ NASA 1972 32 McCarty RD Thormophysical properties of hholun-4 Technical note 622 ANBS 1972 33 _ Thermodynamic properties of benzene Item number 73009 Engineering Sciences Data Unit 1973 34 Dawson P P and MeKetta JJ J .Cham. Eng. Data 1973.18.78 35 Angus S et al Intemational thermodynamic tables fof the tui stato - ethylene 1972 Butterworth 1974 ©Crown copyright 1999 Fist pobliched 1977 Second ection 1982 Applications or reproduction shouts be made in wring to: Copyright Uni, Her Mejesty's Stationary Otic, St Cioments House, 2-18 Colegate, Norwich NRG 160 [Al ightsreseved. 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