हिन्दुस्तान पेट्रोलियम कार्पोरेशन लिमिटेड Doc No.

SP – 12
Hindustan Petroleum Corporation Limited
Issue No.
परियोजना एवं पाइपलाइन 01 Issue Date
Projects & Pipelines
Safety Procedure for Hydrotesting Rev No. 0 Page 1 of 8

Issue By Approved By

Management Representative DGM-Projects

Revision and Amendment sheet

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can be revised up to maximum 5 revisions and after 5 th
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 हिन्दुस्तान पेट्रोलियम कार्पोरेशन लिमिटेड Doc No. SP – 12
Hindustan Petroleum Corporation Limited
Issue No.
परियोजना एवं पाइपलाइन 01 Issue Date
Projects & Pipelines
Safety Procedure for Hydrotesting Rev No. 0 Page 2 of 8

SAFETY PROCEDURE FOR HYDROTESTING

1.0 Purpose

To encourage and educate personnel on the HPCL sites to

regard Safety First as its prime objective and to be aware of
their commitment, responsibility and statutory obligation.
This procedure will provide information and guidance while
Hydrotesting. To identity tendency of unsafe activities and
condition and provide safe work environment.

2.0 Scope

Applicable to all Pipeline Project locations and greenfield

project sites.

3.0 Reference

OISD GDN -192

OISD-141
OISD-105
HSE procedures in practice

4.0 Responsibility

4.1 ROU In-charge / Officer In-charge / Project consultant’s

Safety Officer

4.2 Officer In-Charge / Project consultant’s Safety Officer shall

ensure that all the work is done with proper work permit &
use of proper PPEs.

5.1 Procedure

5.2 Prerequisite before starting work

 हिन्दुस्तान पेट्रोलियम कार्पोरेशन लिमिटेड Doc No. SP – 12
Hindustan Petroleum Corporation Limited
Issue No.
परियोजना एवं पाइपलाइन 01 Issue Date
Projects & Pipelines
Safety Procedure for Hydrotesting Rev No. 0 Page 3 of 8

1. All stakeholders should be informed in advance and take

prior approval as advised and required.
2. Do Job Safety Analysis (JSA) with stakeholders involved in
activities and make JSA as mentioned in OISD-105 and get
signatures of designated person of Client, EPMC, Contractor
and Stackholders for mentioned activities.
3. Job to be supervised by a competent person. Designated
safety person should be present always at site.
4. All person should wear required PPEs.
5. Conduct Tool Box Talk daily and maintain record. Approved
format of Tool Box Talk by Client/EPMC should be used.
6. Sufficient Number of dry chemical type/CO2 type fire
extinguisher, Sand Buckets, DCP Powder etc. shall be made
available by contractor before starting work. Hose-Pipe
connected to Hydrant line, Fire Tender etc. may be made
available while working in the vicinity of existing HPCL
installation.
7. First Aid Box should always be available at site. Regular
inspection should be done by EPMC/Client to ensure that all
medicines are available and expired medicine should be
replaced before expiry date.
8. Only trained personnel to be deployed for this activity.
9. All Measuring & Test Equipment’s used must be well
maintained.
10. All lifting devices & Tools used shall be well maintained
and approved by a competent authority.
11. All heavy equipment shall be equipped with an
operational back up alarm.
12. Proper Warning Boards and Safety Boards should be
provided at working site.

5.3 PPEs

Persons working at site shall always wear the appropriate

personal protective equipment which can include the following;
 हिन्दुस्तान पेट्रोलियम कार्पोरेशन लिमिटेड Doc No. SP – 12
Hindustan Petroleum Corporation Limited
Issue No.
परियोजना एवं पाइपलाइन 01 Issue Date
Projects & Pipelines
Safety Procedure for Hydrotesting Rev No. 0 Page 4 of 8

1. Safety Helmets
2. Safety footwear
3. Leather glovers
4. Goggles
5. Face and eye protection with correct grade of shield;

Above mentioned PPEs are minimum required which may include

more PPEs as per work and site conditions.

5.4 Detail of activities

1. Crew safety
2. Equipment suitability and fitness
3. Hydrotesting
4. Water handling before and after hydrotesting

5.5 Hazards involved

1. Crew safety
i. Injury/Accident due to collapsing of
trench/Machinery failure
ii. Noise, eye hazards
iii. Electrical hazards

2. Equipment suitability and fitness

i. Failure of Equipment may cause
injury/accident/damage to facilities
ii. moving equipment
3. Hydrotesting
i. Hit by object
ii. Burst of Pressurized parts
iii. Fire and burn while welding hydrotesting header
iv. Failure of Pressuring Pumps
4. Water handling before and after hydrotesting
 हिन्दुस्तान पेट्रोलियम कार्पोरेशन लिमिटेड Doc No. SP – 12
Hindustan Petroleum Corporation Limited
Issue No.
परियोजना एवं पाइपलाइन 01 Issue Date
Projects & Pipelines
Safety Procedure for Hydrotesting Rev No. 0 Page 5 of 8

i. Damage to nearby crop/building due to water

flooding
ii. Environment damage due to releasing water
without testing/treating
iii. Hindrance in movement of machinery/people due
to water flooding.

5.6 Precaution

1. Crew safety
i. All working person should be healthy and mentally sound.
ii. All the testing equipment shall have valid calibration test
certificates.
iii. Crew should wear proper PPEs asper job and site
requirement.
iv. Don’t touch any open/cut electric wire which may cause
electric shock.
v. Proper Warning board should be provided and area should
be corned off to avoid entry of any unauthorised person.
vi. During pressurization warning sign boards shall be displayed
as “KEEP AWAY – SYSTEM UNDER PRESSURE” in English,
Hindi and Local language.
vii. Conduct “Safety Awareness Program” from time to time.
viii. Conduct “Safety Induction Training “of every new person jo

2. Equipment suitability and fitness

 हिन्दुस्तान पेट्रोलियम कार्पोरेशन लिमिटेड Doc No. SP – 12
Hindustan Petroleum Corporation Limited
Issue No.
परियोजना एवं पाइपलाइन 01 Issue Date
Projects & Pipelines
Safety Procedure for Hydrotesting Rev No. 0 Page 6 of 8

i. Calibrated and operative pressure gauges to be used with

recording of readings at intervals. All measuring & test
equipments must be well maintained.
ii. Header fitting being used should be approved by EPMC.
iii. Leakage should be checked with Visual inspection on regular
basis and inform to supervisor immediately if any leakage
found.
iv. Valid RC Book with Insurance of Machinery/Vehicle being
used should be available with operator. Operator should
have valid Driving License of Heavy Machinery. Vehicle
Fitness certificate should be available with driver.
v. All equipment shall be inspected daily and maintained in
good working condition. An inspection report shall be given
to the supervisor immediately upon completion.

3. Hydrotesting

i. Review test procedure before allowing testing with water or

air or any other fluid. Testing should be done only after
proper Job Safety Analysis (JSA) and its approval.
ii. While welding hydrotesting header, Ensure that welding is
done properly and all precaution are being taken to avoid
any fire/burn while doing header welding.
iii. Provide relief valves of adequate size while testing with air
or other gases.
iv. Ensure compliance of necessary precautions, step wise
loading, tightening of fasteners, grouting etc. before and
during testing. Inform all concerned in advance of the
testing.
v. Keep the vents open before opening any valve for
filling/draining of liquid used for hydrotesting.
vi. The filling/draining should not exceed the designed rate for
pressure testing.
vii. Provide separate gauges of suitable range for pressurising
pump and the equipment to be tested.
 हिन्दुस्तान पेट्रोलियम कार्पोरेशन लिमिटेड Doc No. SP – 12
Hindustan Petroleum Corporation Limited
Issue No.
परियोजना एवं पाइपलाइन 01 Issue Date
Projects & Pipelines
Safety Procedure for Hydrotesting Rev No. 0 Page 7 of 8

viii. Provide gauges at designated locations for monitoring of

pressures.
ix. Check the calibration of all pressurising equipment and
accessories and maintain records.
x. Take readings at pre-defined intervals.
xi. After stipulated test pressure has been achieved the test
pressure shall be retained in the pipeline section for period
of 6 hours and recorded by MANOTHERMOGRAPH. A constant
observation of the ambient temperature and pressure shall
be maintained by reading of pressure gauge at regular
interval of 30 minute in the temperature / pressure recording
log format.
xii. Arrangement to be made to ensure that the pressurizing
system i.e. motor-pump set is out of circuit so that the
system under hydro testing is not re-pressurized by the
contractor due to pressure drop before a pre-defined time
xiii. Non return valve at the pressurising inlet to hold the water
pressure

4. Water handling before and after hydrotesting

i) Water shall be drained by opening the drain valve and
blowing compressed air at the vent connection.
ii) For testing of pipe section clean construction potable water
shall be used.
iii)During filling of water proper venting shall be done at the
highest point to remove all the entrapped air.
iv)Pipeline section shall be gradually pressurized to the test
pressure and intermediate checks shall be done for any
possible leakages.
v) During pressurization warning sign boards shall be displayed
as “KEEP AWAY – SYSTEM UNDER PRESSURE”
vi)Test pressure shall be retained in the section for the 6 hours
and the section shall be visually examined for leakage and
defects. During holding period if the pressure exceeds the
maximum allowable test pressure, then necessary bleeding
 हिन्दुस्तान पेट्रोलियम कार्पोरेशन लिमिटेड Doc No. SP – 12
Hindustan Petroleum Corporation Limited
Issue No.
परियोजना एवं पाइपलाइन 01 Issue Date
Projects & Pipelines
Safety Procedure for Hydrotesting Rev No. 0 Page 8 of 8

off shall be done to bring the pressure down to the specified

pressure.
vii)All necessary pressure, temp records will be maintained and
will be recorded on log Book.
viii) The cleaning operations shall be performed by
propelling air driven pigs provided with spring loaded brushes
and chisels to remove all mill scale, rust / sand from the
internal of the pipe sections.
ix)Necessary arrangement shall be made for safe disposal of
hydro test water by making suitable drains and pits.
x) Dewatering shall start after getting clearance from
HPCL/EPMC and the water shall be transferred to the next
test section wherever required. Before releasing the water for
draining the section, Contractor shall neutralise the test
water and procedure for treatment of inhibited water to
prevent pollution shall be submitted to HPCL

6.0 RECORDS

a. Permit as per OISD-105

b. JSA and Tool Box Talk records as per OISD-105
c. Safety Checklists
d. Accident Reports as per OISD-107
e. Safety Training Record
f. Induction Reports