Hydrostatic and Pneumatic pressure testing Procedures
Safety
Chemical plant equipment such as pressure vessels, heat
exchangers, columns. Pipelines, etc., need to be inspected, such as after
completion of manufacture or install at regular intervals before commissioning
and during plant operations, such as ensuring legal regulations and safe
operation.
Testing methods are usually hydrostatic and pneumatic tests.
In addition to the rare test "helium test", pneumatic tests are also
widely used to minimize down time and economy and to facilitate testing.
Compared to which there are hydrostatic tests. It is also useful in detecting
very fine juice pathways that cannot be found in hydrostatic tests. However, it
is not as safe as hydrostatic for the reasons which are listed at the las of
this article.
Hydrostatic pressure test is a common non-destructive test
method used for testing after piping and pressure vessel construction. This
method is often preferred by the owner due to product consideration.
Hydrostatic pressure test example is hydrogen peroxide testing
for a pipe line or tank. Since hydrogen peroxide is very sensitive to
pollutants, it is best to use this method.
Hazards & Safety concerns during hydrostatic testing
However, in the safety frame, there is a potential risk in
the hydrostatic pressure test. It can cause injury and death as well as damage
to property if not handled properly.
Hydrostatic pressure test uses water at high pressure. The applied pressure is 1.5 times
the design pressure.If the design pressure is 8 times.
Therefore, the applied pressure for hydrostatic test will be
12 times!
In such stressful situations, the potential energy inside
the pipeline or equipment is ready to damage anything else.
Therefore, it is important to maintain the safety of the
hydrostatic pressure test.
Hydrostatic
Pressure Test Safety guidelines or best practices
Read the following hydrostatic pressure test safety tips to
keep yourself safe while dealing with on-site hydrostatic test work activity.
It would be great if you could compile the following safety
tips in the form of a hydrostatic test safety checklist.
Therefore, anyone can easily use it as a guide.
Always follow the applicable standards and best practices
for hydrostatic testing.
Analyze job safety to check for stress first before starting.
Make sure all valves, piping, flanges and containers that
will be inspected have known details. Cross check between the document and the
marking of this content.
You can reuse some materials for hydrostatic testing. But,
make sure you check their condition before using it again.
All piping and equipment facing the test pipe will have
adequate support.
Pressure escaping valve to avoid pressure l Hydro hydro
testing l. Prepare. Check the details and make sure it is in good condition.
Make sure all workers involved in the hydrostatic pressure
test are trained and have appropriate skills.
Carefully check the design pressure. Next, calculate the
hydrostatic pressure test value. Get approval from competent authorities for
testing pressure.
Inspect all equipment used for testing, such as hoses,
pressure gauges, piping, and temporary shut-offs.
Only use content in good condition. Never use sensitive,
easily broken, or stress-relieving materials.
Piping and air remaining inside the equipment is not
allowed. This is very dangerous. Therefore, make sure that you have released
air before starting the hydrostatic test.
Install safety barriers around the pressure test area. Also
install a safety line if necessary.
Use appropriate safety signs to inform people about the
hydrostatic pressure test. Install them in a suitable place that is visible.
Wear appropriate personal protective equipment (PPE) during
testing.
Only authorized workers can be allowed in the test area.
Use only calibration pressure gauge with coverage pressure
measurement of 1.5 to 2.0 times test pressure. Make sure the calibration
record.
Obtain a safety work permit before starting the hydrostatic
pressure test.
Announce a pressure test plan in the affected area.
You must stop the hydrostatic test when you notice an unsafe
condition during the test. Do not ignore any unsafe situation as it may cause
an accident.
It is very dangerous to stand in front of a pressure gauge
during a test. Avoid doing so.
Prepare enough lighting before the test even though you test
in the open.
Always first relief pressure after the end of the
hydrostatic pressure test before draining water from the tested piping or
equipment.
Always Keep a safe distance during the pressure test to
minimize the risk of any incident. Refer to a standard for calculating safe
distance.
Hazards & Safety concerns during pneumatic testing
Risks involved in pneumatic testing
Pneumatic test pressure is always lower than hydrostatic
test pressure.
Pneumatic test pressure design occurs at times of pressure
where the hydrostatic test pressure is 1.3 times the benign pressure)
Leakage is identified by the application of soapy water to
the weld joints, not by looking at the pressure gauge
What are the risks with pneumatic tests?
Aras / Gas is used for pneumatic tests.
A small leak suddenly explodes without releasing total
energy and can cause an explosion.
The time lag between
leakage and failure detection is so short that it is almost impossible to take
action.
The disadvantages of this radical proposal are small
Why is hydrostatic
test safer than pneumatic test?
The stored energy is very low.
A small leak will reduce the pressure of the gauge
immediately which is not the case when air test is medium.
It has low potential energy so losses are mostly limited to
nearby areas.
It is possible that once a minor leak is detected before you
have a complete failure
The integration of the hydrostatic test is easy to detect
leakage.
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