18. Hydrotest

Hydrotest is a way of checking the integrity of pressure vessels, pipelines, cylinders, boilers, storage tanks as well as fuel tanks. With the help of this test, pressure tightness, strength and any leakages are checked.

Hydrotest involves a test which is performed with the help of water (which is why this test is called hydro) passed through the pipelines or tanks or any fuel carrying vessels in order to inspect any leakages in the material assembly.

Hydrotest is one of the most common methods used for testing the pressure vessels, pipelines, tanks, for any leakages and pressurization integrity of the system.

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Hazard Category	Hazards	Controls
Water Freeze	1. Can occur when tempertatures drop below 0 ℃. Water freezing can also put additional stress on pipe work and plant, as well as the testing equipment.	1. Supervisors shall ensure that hydrotesting is not carried out where there is a risk of water freeze. 2. The temperature shall be monitored to ensure that it does not fall below freezing point.
Hose Breakage During Testing	1. Although hydrotesting is normally associated with relatively low pressures, accidents can still occur by the falure of hoses and/or connectors.	1. Supervisors shall ensure that all equipment being used complies with all relevant ACOP(Approved Code of Practice)’s and safety standards and are certified for use. 2. Hoses shall be inspected on a routine basis to check for defects which may have occurred through wear and tear or abuse.
Inadequate Testing Procedures	1. Accidents can occur if a “safe system of work” has not been implemented prior to testing.	1. Only tarined personnel shall be involved in testing procedures. 2. A safe system of work shall be implemented for the testing operation and personnel advice of the system prior to work commencement, i.e. at “TBT” stage. 3. Personnel shall ensure that there are no conflicting activities going on during hydrotesting stage, Which could have a direct impact on the testing operation. 4. The test area shall be barriered off and signs erected to warn and prevent access to other personnel.
Tripping Hazards from Hoses	1. Can occur when hose, etc. are trailed across access/egress routes.	1. Personnel shall ensure that all hoses have been routed in a safe menner and are suitable protected against whiplash should connections fail. 2. Any hoses routed across access/egress ways shall be protected using a scaffold board either side of the hose. 3. A sign or barrier tape shall be used to highlight the hazard.