S104-PPT - Hydrostatic and Pneumatic Tests

Health, Safety and Environmental Training Course
S104 - Hydrostatic and Pneumatic

tests
“People, our most important asset”
8/29/20
Contents
Purpose of the course
Introduction to pressure tests
 hydraulic tests
 pneumatic tests
Hazard related to pressure tests
Saipem Procedures
 COR-CR-HSE-125-E
 COR-CR-HSE-123-E
Safety Feedback
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Hydrostatic & Pneumatic Test
Purpose of the course
The purpose of this course is to describe
the safety precautions to establish to
ensure that PRESSURE TESTS are
undertaken in a manner that both
personnel carrying out the works and
personnel working in surrounded area will
not be exposed to hazards which may
derive from this specific activity
 as such tests can be dangerous, the potential for hazard engendered by

such tests is also defined, covering the application, preparation and
procedure for pressure testing in the field
 the aim is to ensure that potential hazards to personnel and assets are
properly managed during such operations
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Introduction to pressure tests
WHY PRESSURE TESTING

Statutory requirements:
pressure testing is universally known and accepted as a means of demonstrating

the fitness of a pressurized component for service; usually the requirements for
pressure testing of ground systems come from international Codes and
Standards:
 Code ASME B31.3 2008: “Process Piping” (applicable to piping and piping
systems)
 Code ASME B16.5a (applicable to pipe flanges and flanged fittings)
 ASME VIII: “Rules for construction of pressure vessels”

 BS EN 837: “Pressure gauges”
 BS EN 1473-2007: “Installation and equipment for liquefied natural gas, design

for onshore installation”
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Objectives of pressure testing
These tests are performed in order to ensure tightness and mechanical
strength of piping, vessels and pressure systems prior to commissioning by
detecting and locating potential leaks
The objectives of pressure testing are to:

 eliminate weak materials, defects and leaks before service
 eliminate construction defects before service

 gouges and scrapes in pipe
 incomplete welds
 wrong pipes
 wrong fittings
 loose flanges
 damaged fittings
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Warning…
EXPECT FAILURES!!!
 purpose of pressure test is to

find and eliminate problems
 to find and eliminate defects
and failures is Doing Your Job!
 work carefully assuming that
failures can happen
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Pressure Test: Hydraulic vs. Pneumatic
2 MAIN DIFFERENT TYPOLOGY OF PRESSURE TEST EXIST:
HYDRAULIC TEST
PNEUMATIC TEST
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Hydraulic Tests
Hydraulic Tests are used for confirming mechanical integrity of installed
pressure vessels and pipe lines before put it in use
main features of Hydro test:

 ’fill with water using
dedicated pumps
 ’raising pressure with pumps
in different steps, (e. g. 25%
+hold period, 50%+hold
period, 75%+hold period)
 dewater using pigs
according to “ASME Section VIII Division I”, hydraulic tests are conducted at
the pressure of 1.5 times design pressure
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Pneumatic Tests
Pneumatic Tests have the same purpose of Hydraulic Test
Main features of Pneumatic Test:

 pressure test with gas (air, inert
gases)
 no filling or dewatering
Pneumatic test shall be executed according to the following contractual

standard:
 ASME B.31.3, Ed. 2008: “Process piping, ASME Code for pressure piping
B.31”, Chapter VI – Inspection, Examination and Testing
 BS EN 1473-2007, Par. 9.4: “Pressure tests”
 NFPA 59A, Ed. 2009, Par. 9.7: “Inspection and testing of piping”
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Hydro or Pneumatic tests???
Pneumatic tests are inherently more dangerous than Hydro Tests!
HIGHER ENERGY CONTENT!!!
Pneumatic testing shall only be performed when hydrostatic testing is

impractical or undesirable, such as:
 pressure system designed or supported in a manner that unquestionably
cannot be safely filled with liquid (low pressure piping with large diameter)
 pressure system with a configuration such as it cannot be properly dried,
and traces of the test medium cannot be tolerated (e.g. cryogenic lines)
 small diameter piping systems such as instrument and air or nitrogen
distribution
 pressure system which could be damaged (linings, internal insulation or
other equipment) by hydrostatic tests
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Potential hazard for Pressure testing
Several kinds of incidents or accidents

are likely to occur during pressure
testing activities on field
DO NOT FORGET that:
PRESSURIZATION IS ENERGY STORAGE
its instantaneous release works as a bomb and may cause severe damage to
persons and equipment
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Main HAZARDS are:
MISSILES
rupture of an equipment part under test can result in fragments projection
potentially leading to personnel injuries and equipment/structure damage
Fittings can become

projectiles – big bullets
 bullet speed typically 300 to 1000 m/s (1100 to 3600 km/h)
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BLAST OVER PRESSURE
rupture of a line and/or capacity can generate a shock wave (a pressure wave
which moves at supersonic speeds) which can be hazardous for personnel
working around and surrounding equipment and structures
Due to the blast pressure, people can be reached

by flying glass and debris or can also be thrown
violently into objects
The following direct effects of the blast pressure

on human bodies have been experienced:
 eardrums rupture
 lung damage until fatality
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GAS JET
effects of blast wave and fragments are obvious and well known; the effect of
the gas jet is less common; it results from the emptying of the equipment and
the release of the pressurised gas; a thrust effect is also generated by the
release of the gas; this could lead to the displacement of the equipment being
tested:
 translation/lifting of the vessel
 whipping effect of a pipe
 the jet can still have a high velocity (>100

m/s) tens of meters away from the leak
 as consequence such a jet could generate a
significant force on the impacted surface
(equipment or personnel)
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Be aware!
Can we get hurt with low pressure?
ABSOLUTELY YES!
Be especially careful with large surfaces like manways:

1/2 psi (0.034atm) may not even register on the gauge but it’s enough to
send a hatch flying if all the bolts are removed and the gasket is stuck
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Vacuum
Can we get hurt with negative gauge pressure? ABSOLUTELY YES!
This tank collapsed while being

pumped out!
Painters had covered the vent with

plastic sheeting; the steel tank
collapsed before the plastic sucked
through
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Safety precaution for pressure testing
To prevent accidents such as those discussed

above we have to make good preparation
before starting, during execution and in
depressurizing operation
These jobs should be made in the form

standard operating procedure according to:
 COR-CR-HSE-125-E
 COR-CR-HSE-123-E
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Corporate Criteria: Hydro Testing
HSE procedures developed by Saipem
their purpose is to define the safety and environmental precautions to be

established to ensure that hydrotesting is undertaken in a manner that both
personnel carrying out the works and personnel working in surrounded area will
not be exposed to hazards which may derive from this specific activity; moreover
in the full respect of the local Environmental legislation through the proper waste
collection and storage defined in the Waste Management Plan (WMP).
Indiscriminate discharge is not allowed at all!
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Hydro Testing: Roles and Responsibilities
Hydro Testing procedure considers the following roles and responsibilities

(before and during the tests) at construction sites
 SUBCONTRACTOR
 shall develop comprehensive Testing Procedures that address the safety
of all personnel and include the provision of specific Work Instructions
and related Training and/or induction for all personnel involved in
testing operations
 the Training and Induction log shall be maintained and an identification
mark for the helmet shall be provided only to qualified personnel for the
execution of hydraulic tests
 SAIPEM CONSTRUCTION MANAGER
 responsible for ensuring the project safety requirements and specific
safety issues related to the activity considered
 SAIPEM CONSTRUCTION MECHANICAL SUPERVISOR
 responsible for ensuring the compliance with the established schedule,
project and safety requirements
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Subcontractor has to carry out at least the following preparatory work:
 Prior to writing and issuing test procedures:

review of the historical documentation for the
equipment to be tested (i.e. Design Data Sheets,
Inspection reports and Safety Instruction
Sheets)
 Before to starting the testing activities: provide the written, approved

procedures to all concerned personnel, and be available at the job sites for
pressure tests with a high potential hazard such as those on cross country
pipelines of all kinds, plant piping, pressure vessels, and power boilers
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All test Procedures, developed by Subcontractor, require Contractor approval
–each test will require prior Contractor approval

and subsequent concurrence by Company
all Subcontractors involved with hydraulic testing shall appoint Subcontractor Test Supervisor
(SCTS) to be responsible for all test activities
Contractor shall appoint Contractor Test Supervisor (CTS) to be responsible for ensuring that all
test activities are executed in compliance with the applicable specification
SCTS shall coordinate with CTS for tests execution priority

CTS will co-ordinate all other responsibilities such as Permits and any
possible interface or logistics that need expediting by Company
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Preparation for Testing, notification and documentation
 the SCTS and the CTS shall submit to the Contractor Site Manager (SM) and
to the Field HSE Manager (FHSEM) on site a written detailed “Hydraulic
Testing Report” which fully describes the methods, equipment and
precautions to be used
 this procedure shall incorporate Job Safety Analysis (JSA), applicable local
safety regulations and include personnel training and certification, test
equipment and specifications
 Hydraulic Testing Operations shall not start until approval of the
procedure document has been given by SM / FHSEM on site
 before starting the hydraulic test activity Construction personnel have to
prepare dedicated P&ID in which the pipes to be pressure tested have to be
highlighted
 this P&ID must be attached to the Work Permit together with the JSA.
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Hydro Testing: test execution
NEVER TIGHT BOLTS, FLANGES, ECT. WHEN LINES ARE UNDER

PRESSURE!!!
 Check the test pressure on the
calibrated pressure gauges both
before and after inspection of the
joints
 Check tightness of valves
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Hydro Testing: SAFETY BULLETTIN
PIPE FITTER SEVERELY INJURED TO HEAD BY A HIGH PRESSURE WATER JET
 the incident happened while the Subcontractor Hydro

testing crew was performing hydro tests on a 36”
Carbon steel line with pressure of 1915 Psi
 during the test, one pipe fitter noticed drops of water
leaking from flange joints
 he went closer to the flange for finding out the exact
location of the water leakage
 suddenly a high pressured water jet came out from pipe through the flange joint
 as confirmed by the inspection of the temporary gaskets, after dismantling of the
pipe spool, the temporary gasket broke and through the crack a high pressure
(1500 Psi) water came out
 the high pressure water with a piece of gasket hit the victim‘s face & fore head
causing severe injury to the victim’s head
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Hydro Testing: Safety instruction
GENERAL INSTRUCTION
 dedicated Work Permit must be obtained

following specific procedure
 specific Risk Assessment or JSA must be

always issued
 an Emergency Procedure has to be

issued considering unwanted events
coming from hydrotest activity
 all Personnel working at site must be

Informed in advance when hydrotest is
going to be carried out
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NOTIFICATION
Before starting any operation, the Construction
personnel responsible of hydrotest has to give
notification to all people present at site
 a communication has to be sent to Vendors, Sub-

contractors and Company which work at site
 due to the risks of the activity, the responsible of the

hydrotest shall give a notification at least 24 hours
prior to starting the operation
 the notification can be sent early due to the high

complexity of the activity or area in which the
activity has to be done
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The communication has to contain, at

least, the following information:
 area involved in the activity; it is better

to annex a plot plan with highlighting the
area
 the extension of the area to be fenced off
 time and data of starting the activity
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SAFETY REQUIREMENTS
Personnel involved in the hydraulic testing
shall have identification mark on their helmets
so that the testing crew personnel can easily
be identified in the area.
During raising of pressure nobody has to stay
inside the barricaded area, only authorized
personnel during static periods
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CTS has to guarantee, through sub-contractors, that at site the following

actions are put in place:
 fence off at safe distance from the tested circuit
 post signs around the barricaded area showing:
 “danger: no entry to unauthorized personnel”
 “use proper personal protective equipment”
 “hydrotest in operation”
 isolate any electrical connections and ensure

that cannot be energized
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SAFETY ACTIVITIES
CTS for the hydrotest has to carry out the following activities:
a) suspend all activities inside the barricaded area when the activity is being
executed
b) verify, prior to filling columns/drums/vessels or overhead piping systems
with water, if those items and their foundations/supports to withstand full
water weight
c) verify that all people involved in the activity wear appropriate Personal
Protective Equipments (PPE)
d) in addition to PPE required to the normal activity inside the plant it is
mandatory use the following personal protections
e) the persons directly involved at the discharge point shall use proper goggles
and gloves
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f) if the hydrotest is used the operator must use an overall rubber protection,
face shield, gloves and rubber boots
g) carry out a tool box meeting before start the activity

h) activate the emergency procedure in case an unwanted situation happens
i) make sure that the water to be discharged has the quality parameters
complied with standard fixed by Client
j) an HSE Officer has to assist the Construction team to prevent non

authorized personnel or vehicles from entering the barricaded area
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Hydro Testing: check list
SCTS and CTS has to S.No CHECKLIST

Specification sheet of the equipments and or pipe line, which mentions
YES NO
fill out the following

1. pressure and temperature designs are available and complete.
Check List:
Hydrostatic test pressure and temperature standard are already clearly
2. defined in the related document. Supported documents such as P&ID and
isometric drawing are available and conform to as built facilities at the field.
Pressure test planning has to be distributed to all relevant sections in the
3. site at least 24 Hrs before the execution date.
All test equipments and tools shall be inspected for wear and damage.
4. Pressure gauges used in the test have enough capacity and properly
calibrated.
Pressure gauges must be installed at a proper location so that it can be
5. easily read and do not create additional hazards to the hydrostatic test or
expose personnel to the vessel being tested.
All the temporary tools (such as valve, fitting, hoses, flanges, blind plate,
6. etc) have to be rated more than the maximum hydrostatic pressure
Isolate other equipments and pipe lines that do not include in the
7. hydrostatic test
Vents are available and installed the high points to vent air Check the vent
8. line before testing and make sure it is not blocked.
Choose drain valve at the lowest point in order to completely empty the
9. vessel and pipe
Safety relief valve is already installed. Safety relief valve setting is 1.5
10. times maximum allowable working pressure
Isolate the test area and surround it with safety line. Put appropriate safety
11. sign at that area
Make sure that all pipe and vessel supports are in good condition and have
12. been inspected.
13. Wear proper personal protective equipments
Do not start the test if a problem is identified

14.
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Hydro Testing: check list
Safety relief valve is already installed. Safety relief valve setting is 1.5 times
10. maximum allowable working pressure
Isolate the test area and surround it with safety line. Put appropriate safety
11. sign at that area
Make sure that all pipe and vessel supports are in good condition and have
12. been inspected.
13. Wear proper personal protective equipments
Do not start the test if a problem is identified

14.
Issue a work safety permit by authorized personnel

15.
Remove all air from the vessel and pipe line by water through vent line
16.
Pressurization is conducted gradually/slowly

17.
After completing the test ,open the lowest drain point to completely remove
18. water from the vessel / pipeline.
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Requirements for pneumatic & high-pressure hydrostatic
tests
the requirements above described are not applicable to pneumatic tests and
high-pressure hydraulic tests
these tests require to prepare a dedicated procedure for the project that
includes all of the special safety requirements and ASME B31.1 or ASME
B31.3 rules (as applicable)
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Corporate Criteria: Pneumatic test
safety procedure developed by SAIPEM

this Specification is to define the safety measures to be applied by
Subcontractors during the execution of Pneumatic Tests
this philosophy defines the requirements for pneumatic pressure testing (or
pneumatic leak testing) of above ground systems (applicable to piping and
piping systems within the scope of ASME B31.3, “Process Piping”)
this document covers the application, preparation and procedure for
pneumatic testing in the field
Considering the high risks for pneumatic test execution following instruction
must be strictly respected!
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Pneumatic Testing: Roles and Responsibilities
Pneumatic testing procedure considers the following roles and responsibilities
(before and during the tests) at construction sites:
 subcontractor execution responsible/contractor discipline superintendent
 shall develop a written detailed pneumatic testing report which fully
describes the methods, equipment and precautions to be used
 construction mechanical supervisor
 responsible for ensuring the compliance with the established schedule,
project and safety requirements
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Pneumatic Testing: Documentation
 the “Subcontractor execution responsible/Contractor Discipline SPT” shall

submit to the Project/Construction Manager (PM-C) and to the Field HSE
Manager (FHSEM) on site the “Pneumatic Testing Report”
 this procedure shall incorporate Job Safety Analysis (JSA), applicable local
safety regulations and include personnel training and certification, test
equipment and specifications
 the procedure document shall include the proposed format for the
authorization form and the pneumatic test certificate
 pneumatic Testing Operations shall not start until approval of the
procedure document has been given by SM / FHSEM on site
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 for each Test Assembly, the “Subcontractor execution responsible/Contractor

Discipline SPT” shall prepare an “Authorization Form” which identifies all pipe
lengths and joints
 prior to initial operations and after completion of the applicable non
destructive examinations (NDE) each piping system shall be tested to ensure
tightness
 the NDE shall be executed according to the following Contractual Standard:
 ASME B.31.3 Ed 2008 “Process piping, ASME Code for pressure piping
B.31” Chapter VI – Inspection, Examination and Testing
 BS EN 1473-2007 Par. 9.4 “Pressure Tests”
 NFPA 59A, 2009 Edition Par 9.7 “Inspection and Testing of Piping”
 the appropriate test certificates and NDE reports shall be cross-referenced on
the authorization form
 the “Subcontractor execution responsible/Contractor Discipline SPT” shall
sign the latter form to confirm that the check has been made
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Minimum documentation which shall be present on site before starting

Pneumatic Testing
 the completed authorization form shall be submitted to PM-C/FHSEM for
review and approval
 the pneumatic test on any test assembly may not proceed until the
“Subcontractor execution responsible /Contractor Discipline SPT” is in
possession of the authorization form for that assembly, signed by PM-C and
FHSEM
 this format must be attached to the work permit form
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Pneumatic Testing: Equipment and materials
The “Subcontractor execution responsible/Contractor Discipline SPT” shall provide all:
– pressure gauges
– temperature measuring devices
– recording instruments
– valves
– pipe work
– hoses
for each test
All the above items must be properly tested, calibrated and certified!
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Pneumatic Testing: Safety Concern/Exclusion Zone
Contractor shall:
–verify that Method statement and relevant JSA is prepared

–verify that PTW is in place
–verify that all the PI&D are available along with the PTW
–verify that an exclusion zone around the test assembly has
been implemented
–ensure that all unauthorized personnel are excluded from
that area, before starting the test
Safety Plan shall include a drawing indicating the the Exclusion Zones.
The test should preferably be carried out at a time when a minimum number of construction personnel are
present (i.e. during weekly day off and/or during lunch time)
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Exclusion zones shall be considered here as the minimum distance beyond which:
–there is no risk of significant injuries to personnel as a direct

consequence of the pneumatic test failure
–there is no risk of building collapse that could significantly
injure personnel;
–damage to equipment and installations is not significant
enough to cause their failure
–subsequent domino effects are excluded
safety distances may be determined by analysis of potential failure scenarios that may occur during a test
–in the absence of such an analysis, the following guidelines (by

EN 1473:2007), as shown in the table, may be used
Pressure (barg) Distances (m)
≤ 10 30
> 10 to 22 60
> 22 to 36 60
> 36 to 52 120
> 52 to 69 150
> 69 to 80 170
> 80 Not recommended
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Outside the exclusion zones, minor injuries can still occur to personnel
–buildings and equipment outside the Exclusion Zone can still

be damaged, but not enough to present a direct hazard for
personnel
Where the safety distances found are not practicable (insufficient free area around the system to be tested), a
written demand shall be issued and addressed to PM-C/FHSEM
 a risk-based assessment of the tests shall be performed

 the pressure test shall not be performed without written
authorization from SM/ FHSEM
The Exclusion Zone shall be:
 flagged (e.g. delimited by red and white barrier tapes) or barricaded;
 signed;
to prevent unauthorized personnel from entering the area
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Pneumatic Testing: Mitigation/Protection Measures
The following measures must be taken to avoid injuries or fatalities:
–test operators must wear appropriate PPE (eye and ear protection)
–test operators must attend a Toolbox Talk

 it shall be highlighted that good coordination is essential to avoid
performing the pneumatic test at the same time as other operations
if the presence of personnel involved in the test operation in the exclusion zone is essential, adequate measures shall be
taken to protect them:
–resistant shelter
–protective shield
 “Subcontractor execution responsible/Contractor Discipline SPT”

shall make sure of the efficiency of the protective measures
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Pneumatic Testing: Mitigation/Protection Measures
If equipment, pipes, buildings or any kind of structures cannot be removed

from the exclusion zone, the following measures are possible:
–evacuation of personnel inside buildings
–removal of the hazardous contents from pipes and equipment
–application of Protective shield
 a written authorization from PM-C/FHSEM is needed before applying any
protection measures
mitigation to be implemented is also housekeeping
–left material could be the source for flying object in case of
leakage/rupture during pneumatic testing
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Pneumatic Testing: Test Procedure
Testing shall not be undertaken when the weather conditions may give rise to large temperature fluctuation in a short
time; temperature of metal shall be taken to ensure that it is warmer that the minimum temperature allowed; after
evacuation of all personnel from the test area, air shall be slowly admitted to the test assembly until the pressure
attains the lesser of one-half of the required test pressure or 1.5 bar
–this phase is mentioned in literature as low pressure gas

leak testing
–its purpose is to indicate possible failure sites in the system

before high-pressure testing is undertaken
 it will indicate cracks and gross porosity in welds,

leakage through threaded components, and improper
sealing of gaskets and other joints
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all joints, flanges and welds shall therefore be tested by applying the soapy water
 flanged joints and any weld areas which may be difficult to

inspect may be tested by wrapping with a suitable adhesive
tape and applying the soap solution to a pin-hole in the tape
 potential leaks are indicated by the bubbles formed by the
leaking gas
the test assembly shall be held at this preliminary pressure for sufficient time to permit a thorough inspection of all joints,
flanges and welds to determine the location of any leaks
 if any leak is found, the test shall be aborted and the leaks
repaired before recommencing the test
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personnel performing tightening operations (if required) shall remain clear of the gasket plane
projection
 the test assembly shall not be subjected to any

shock loading, such as a hammer testing
if no leaks are found at this stage, the pressure shall be slowly increased in increments of
approximately 1 bar
 the pressure shall be held for sufficient time at

each stage to permit piping strains to equalize
when the required test pressure is attained, the test assembly shall be isolated from the air source
(but not from the relief valve) and the pressure shall be held for at least 10 minutes before
inspection to observe any fall in pressure indicative of a major leak
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this visual inspection shall be witnessed by the owner’s inspection or his delegated inspector
 during this time, the system test pressure gauge shall be

observed from a safe distance for indication of leakage
consideration shall be given to the effects of ambient/metal temperature changes during this period
 personnel shall not approach the test assembly at this

stage or during pressurization
 monitoring of pressure and temperature shall be made
from a remote location
if no leaks are indicated at the test pressure, the pressure within the test assembly shall be slowly released, down to
the atmospheric pressure
 Pressure shall be released by means of a suitable valve
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care shall be taken to avoid metal temperatures falling below minimum metal temperature (or 0°C), particularly near
the vent connection during depressurizing
the metal temperature during testing shall be at least 17°C (30°F);
 above the minimum design metal temperature (Ref.
ASME VIII Div 1) in order to minimize the risk of brittle
fracture
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Pneumatic Testing: Repairs
if any leaks are found in a welded joint, they shall be repaired (after
depressurization) using an approved weld repair procedure and proved acceptable
by radiographic testing prior to repeating the pneumatic test
any leaks at flanged joints shall be investigated prior to remedial action

care shall be taken not to apply excessive torque to bolting to achieve a leak-tight
seal
following repair of any leaks, the full pneumatic test procedure be followed in
repeating the test
As in hydro tests NEVER ATTEMPT TO

TIGHT BOLTS UNDER PRESSURE!
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Pneumatic Testing: Certification
Following successful test, the “Subcontractor execution responsible/Contractor Discipline SPT”
shall provide a test certificate for each test assembly
 the appropriate authorization form and the

permanent pressure/temperature recordings shall
be attached to each test certificate
 any previous leaks and their causes shall be noted
upon the final test certificate
the “Subcontractor execution responsible/Contractor Discipline SPT” shall report any undue
flexing, distortion or banging which may have occurred during testing
completed test certificates shall be incorporated into the final documentation for submission to
the PM-C / FHSEM
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Pneumatic Testing: Training and Communication
A dedicated training for pneumatic test will be held to all personnel involved
communication during the test shall be guaranteed

using radio on agreed channel.
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Pneumatic Testing: Check list
S.No CHECKLIST YES NO
Subcontractor Responsible
1. Is there a method statement, risk assessment carried and permit to work system
carried out for the task?
and Contractor Discipline

SPT have to fill out the 2. All the area is properly barricaded at the correct distance as for work permit/test
authorization.
following Check List
3. Pressure and temperature recorder and pressure gauges are fitted at appropriate
locations, where they can be seen and read easily, remote from the test assembly.
Metal temperature shall be monitored at each pressure gauge location and also at
the vent connection.
Around the barricaded area the following signs are posted:

4.
“PNEUMATIC TEST IN PROGRESS” “NOT ENTRY”
5. All necessary piping and valves are correctly fitted between the air source and the
test assembly, and that depressurizing and relief facilities are in place.
6. All personnel not involved in the pneumatic test must leave the restricted area.
7.
All involved personnel must wear PPE
Are pneumatic and hydraulic hoses on power operated tools checked regularly for
8. deterioration or damage?
9. Pneumatic test planning has to be distributed to all relevant sections in the site at
least 24 Hrs before the execution date.
10. Make sure that all pipe supports are in good condition and have been inspected to
carry out the test
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Safety feedback
SOMETIMES SOMETHING CAN GO WRONG!
EACH ACCIDENT PROVIDES US
safety feedback
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Safety feedback 1: Filling of a vertical tank with water
What happened? Relief valve
the top of tank blew off

Why?
because the relief valve could not displace
the air fast enough for the volume of
water that was being pumped in and,
creating overpressure inside the tank
Fault analysis
filling of the tanks was made by taking
water from fire fighting system, with flow
rates and pressures above the tank test
specification
Causes
human error / failure to comply with
procedures Top of the tank
Image appear by courtesy of TotalFinaElf
56
8/29/20 56
Safety feedback 2: Piping Pneumatic test
What happened
the tank “lifted off”
Why
leakage of air from the pipe to the
tank through the valve block
Fault analysis
a blind flange was NOT installed to
isolate the tank
Causes
lack of knowledge, Procedure and
check list outdated (do not meet
the design changes)
Image appear by courtesy of Exxon Company
57
8/29/20 57
Safety feedback 3: Emptying of a vertical tank
What happened
tank collapse during emptying
depressurizing operation
Why?
a plastic was trapped in the vent; a
vacuum was created.
Fault analysis
after setting up the pipeline operators
have started the pumps by remote
control located approximately 500
meters away from the tanks
Causes
lack of knowledge, lack of surveillance,
failure to comply procedure, poor
housekeeping Image appear by courtesy of
TotalFinaElf
58
8/29/20 58
Safety feedback 4: Pressure test incident
What happened
technician struck by a thermowell ejected from
a ¾’’ NPT female tapping in a 5K choke
manifold during a pressure test.
Why?
when the NPT thread failed the stored energy
was released and propelled the thermowell at
a velocity of 42 metres/sec (94 MPH).
Fault analysis
the technician was in front of the thermowell
tapping during the test .
Causes
lack of knowledge, failure to comply procedure,
incorrect position of the technician.
59
8/29/20 59
Conclusions and clarifications
Any question?
60
8/29/20 60

S104-PPT - Hydrostatic and Pneumatic Tests

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S104-PPT - Hydrostatic and Pneumatic Tests

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Health, Safety and Environmental Training Course

S104 - Hydrostatic and Pneumatic

“People, our most important asset”

Purpose of the course

Introduction to pressure tests

Hazard related to pressure tests

 as such tests can be dangerous, the potential for hazard engendered by

WHY PRESSURE TESTING

pressure testing is universally known and accepted as a means of demonstrating

 ASME VIII: “Rules for construction of pressure vessels”

 BS EN 1473-2007: “Installation and equipment for liquefied natural gas, design

The objectives of pressure testing are to:

 eliminate construction defects before service

 purpose of pressure test is to

main features of Hydro test:

Main features of Pneumatic Test:

Pneumatic test shall be executed according to the following contractual

HIGHER ENERGY CONTENT!!!

Pneumatic testing shall only be performed when hydrostatic testing is

Several kinds of incidents or accidents

DO NOT FORGET that:

PRESSURIZATION IS ENERGY STORAGE

Fittings can become

 bullet speed typically 300 to 1000 m/s (1100 to 3600 km/h)

Due to the blast pressure, people can be reached

The following direct effects of the blast pressure

 the jet can still have a high velocity (>100

Can we get hurt with low pressure?

Be especially careful with large surfaces like manways:

Can we get hurt with negative gauge pressure? ABSOLUTELY YES!

This tank collapsed while being

Painters had covered the vent with

To prevent accidents such as those discussed

These jobs should be made in the form

HSE procedures developed by Saipem

their purpose is to define the safety and environmental precautions to be

Hydro Testing procedure considers the following roles and responsibilities

Subcontractor has to carry out at least the following preparatory work:

 Prior to writing and issuing test procedures:

 Before to starting the testing activities: provide the written, approved

All test Procedures, developed by Subcontractor, require Contractor approval

–each test will require prior Contractor approval

SCTS shall coordinate with CTS for tests execution priority

NEVER TIGHT BOLTS, FLANGES, ECT. WHEN LINES ARE UNDER

 Check the test pressure on the

calibrated pressure gauges both

before and after inspection of the

 Check tightness of valves

 the incident happened while the Subcontractor Hydro

 dedicated Work Permit must be obtained

 specific Risk Assessment or JSA must be

 an Emergency Procedure has to be

 all Personnel working at site must be

 a communication has to be sent to Vendors, Sub-

 due to the risks of the activity, the responsible of the

 the notification can be sent early due to the high

The communication has to contain, at