Home Project Overview QA/QC Systems Library Shop Online Get Technical Support Training Contact

QA/QCSYSTEMS

Piping Hydrostatic Testing (overview)

ISO9000(1994)
ISO9000(2000)
QAProcedures
ConstructionProcedures
QCCheckSheets

TestPreparation

InspectionPlan

NEWClickheretopurchaseournewpipinghydrostatictestpack!

AuditDocumentation
VendorInspection
PipingHydrotesting
NonDestructiveTesting
Calibration
WeldingProcedures
QA/QCJobDescriptions
OrganisationCharts

PHOTOS
Video&Photos

1.Pressuresourceandtestgaugeshouldbeupstreamofcheckvalve.Ifpressuresourceisdownstream,checkvalve
shouldhaveflapperremovedorjacked?up.(Pressuremustbereleaseddownstreamofcheckvalveaftertestcompletion.)
2.EnsurethattestblindsinstalledaretheCorrectthickness.Ensurethatallitemssuchascontrolvalves,reliefvalves,
rupturedisks,orificeplates,diaphragminstruments,expansionjoints,etc.,whichcouldbedamagedduringpressuretest
havebeenremovedorisolated,asindicatedonthepressuretestflowdiagram.Ensurethatequipment,suchasfilters,
whichhaveinternalsthatmaybedamagedduringpressure.
3.Ensurethatallitemssuchascontrolvalves,reliefvalves,rupturedisks,orificeplates,diaphragminstruments,
expansionjoints,etc.,whichcouldbedamagedduringpressuretesthavebeenremovedorisolated,asindicatedonthe
pressuretestflowdiagram.
4.Ensurethatequipment,suchasfilters,whichhaveinternalsthatmaybedamagedduringthepressuretestareeither
blockedfromtestorthatinternalshavebeenremoved.
5.Checkalltemporarysupportsthathavebeencalledforonthepressuretestflowdiagrams,pipingarrangement
drawingsorspooldrawingtoensurethattheyhavebeenproperlyinstalled.

Posters

6.Ensurethatequipment,suchascompressors,whichmustnotbeincludedinthefieldtestshavebeenproperlyblocked
offwiththecasingdrainopen.

Rejected/Nonconforming
Work

7.Checkopenandclosedpositionofallvalves.

ConstructionProject
Overview

8.Checkforproperinstallationofventsanddrains.

FiberGlassReinforced
Piping
StructuralSteel
PilingWork
EarthWork
CivilWork
FabricationShop
WeldingPowerPiping
WeldingPipeLines
PostWeldHeatTreatment

9.Verifychloridecontentoftestwaterwhentestingstainlesssteels.
Testing:
1.Thepressuretestgaugeshallnormallybelocatedatgradenearthetestpump.
2.Pressuretestgaugesshallbecalibratedtoensureaccuratereadings.Gaugesshouldbetaggedwiththedatethey
werelastcalibrated.
3.Caremustbeexercisednottoexceedpressuretestspecifiedonthepressuretestdata.
4.Whenconductingapneumatictest,itisessentialthatthecontractspecificationforpneumatictestingbeadheredtoin
ordertoavoidcreatingasafetyhazard.
5.Pneumatictestsystemsmustincludedoubleblockvalveswithableedervalvebetweenthemtosafelyisolatethe
pressuresource(byclosingblockvalvesandopeningbleedertoatmosphere)whenincrementalandfinaltestpressures
areattained.

NondestructiveTesting
CoatingWork

TestCompletion:

ElectricalWork

1.Careshallbeexercisedincontrollingtherateofdrainingfromvesselsinrespecttoinflowofairthroughtheventto
assurethatavacuumisnotapplied.

InstrumentationWork

2.CAUTION:Priortocommencingdrainage,ensurethatallventsareopenwithplugsandblindflangesremoved.

StaticEquipment

3.Afterdrainage,removealltemporaryblindsandblanks,temporarysupport,andtemporarytestingconnections.

Boilers

4.Reinstallallitemsthatwereremovedfortest.EnsurethatlineSpecificationgasketsandboltsarebeingusedwhen
reinstallingtheseitems.

StorageTanks
HVAC

5.Removeallshippingbarsfromexpansionjoints.
6.RemoveStopsfromspringhangersandcheckcoldsettings.

SelectLanguage
Poweredby

CONTENTSOFHYDROSTATIC
TESTPACKAGES

Translate

Coversheet
DescriptionofLineTest
SafetyCheckSheet
PipeWorkPretest
Checklist
HydrostaticTestReport

AsBuiltFile

MonitoringDuringTesting
DataSheet
WeldingTravel
CheckSheet

Pressurize

HeatTreatment
CheckSheet
HardnessTestingReport
TurnoverDossier
Blow,Flush&Chemical
CleaningCheckList
Flushing&Cleaning
CheckList
PunchListCheckSheet
NDTReports

Whythissubject
Duringhydrotestingandpressuretestingoperationsincidentssometimeshappen.ThisSafetyFeedbackNoticeprovidessometypical
exampleswhichcanbeusedananaidinhighlightingthehazardsanddangersinvolvedarewhatareoftenseenasroutineoperations.

Detailsof5incidents.
1.Hydrotestofanewverticalvessel.
Therootcauseoftheincidentisnotfullyknownbuttherewassomethoughtthathydrotestingwith"verycold"waterwasa
contributingfactor.
Fortunatelynoinjuriesoccured.
clickhere
2.Fillingofaverticaltank.
Thefillingofthetankwasmadewithwaterfromafirehydrant.
Thetopthetankblewoffbecuasethereliefvalvecouldnotdisplacetheairfastenoughforthevolumeofwaterthatwasbeing
pumpedin.
clickhere
Fortunatelynoinjuryhappened,butanoperatorwasontopofthetankafewsecondsbefore.
3.Emptyingofaverticaltank.
Thecollapseofthistankhappenedwhileitwasbeingemptied.Aplasticsheetprotectingtheroofwastrappedinthevent
henceavacuumwascaused.
clickhere
Therewasnoinjury.Itshouldbenotedthatthistypeofincidentisnotthatunusual.
4.Spherecollapse.
Theaccidenthappenedduringthefillingofabar2000mLPGsphere.Itslegscollapsed.Onepersonwaskilledandone
seriouslyinjured.
Atthetimeoftheaccident,thespherewasapproximately80%fulloffreshwater.
clickhere
Thevesselslasthydrotestwas10yearsagoandthelastinspectionofitslegswas5yearsago.
Severecorrosionofthelegsundertheconcretefireprotectionwasthemaincause.Thecorrosionoccurredduetowateringressbetween
theconcreteandthesteellegs.
Thewaterprotectivecaplocatedovertheconcretewasnotsufficienttokeepwaterout.Aftertheaccident,itwasverifiedthatthesteellegs
hadthicknessreductionsofupto8mm,withpitingholesofupto10cm.
Afteranalysisandtests,ithasbeenfoundthatthefollowingfactorscausedthecollapse:
Watercapsoverthefireproofingconcretewereofpoordesigntherebylettingwaterpenetratebetweenthesteelbeamsandthe
concrete.

Verticalcracksintheconcreteletwaterin.
Repairshadbeendonetotheconcrete,butwithpoorworkmanship.
Theconcretehadnotadheredtotheoldconcrete,againlettingwaterin.
Thedelugesystemhadbeentestedwithsaltwater,increasingthepossibilityofcorrosion.
5.Emptyingofagearbox.
Tospeeeduptheremovalof250lofoilfromagearbox,theguageholewaspluggedandthebreatherwasconnectedtothe6
barairnetwork.
Thegearboxexploded,andthrewmissilesaroundseriouslydamagingsurroundingpipingandstructure.Fortunatelythere
wasnoinjury.

clickhere

SPECIFICRECOMMENDATIONS
Foreachcasethespecificrecommendationaregenerallyobvious:
1stincident:Watertempeartureiscriticalwhenhydrotesting.TFEspecification(GSPVV211)statestahtbothmetalandwatertemperature
duringpressuretestingshallbemaintainedatleastat16Coratleast10Cabovetheimpacttesttemperatureofthemetal.
2ndand3rdincidents:Ventingsystemsshallbeinspectedandcheckedbeforefillingandemptyingoperations.
4thincident:Isamaintenanceproblem?Beforetestinganoldvessel,acompleteinspectionmustbeperformedvisuallyandwithNDT.This
inspectionshallincludethevessel,nozzles,appurtenances,andsupportingstructures.
5thincident:obviouslyagearboxisnotpressurevessel,butproductivitymayleadtoariskyattitude.

MarketleadingcompaniesinthefieldofQualityAssuarance

MarketleadingcompaniesinthefieldofQualityControlSuppliers

Allmajorcreditanddebitcards
accepted