Pressure Testing (Hydrostatic & Pneumatic) Exclusion Zone Safety Guidelines
Discussing pressure testing is a broad and detailed topic that encompasses many aspects. The primary task is to work safely. Pre-planning and risk mitigation are the core principles. Today’s safety topic does not drill into all aspects of the pressure testing process but will focus mainly on the Exclusion Zones or Safety Zones while performing the pressure test.
Most of you have been around and or have performed pressure testing for a project. And the exclusion zones are paramount to making sure people remain away from the testing area while a test is being performed.
These guidelines are to assist with the planning and execution of a pressure test event and manage the risk to life, property, and the environment.
Remember that all personnel have and should use “Stop Work Authority” whenever there is a concern during the pressure testing operation.
Remember that all personnel have and should use “Stop Work Authority” whenever there is a concern during the pressure testing operation.
Hazard Assessment and Control
Development of a Test Procedure will highlight the detailed parameters of performing the pressure test. An engineer will provide the plan which identifies the test pressure, how quickly to “Step Up” pressure, holding times at each pressure, duration of test, use of pressure specific valves and other devices, etc. The pressure testing plan shall details all aspects of the setup.
There are many safety touch-points when it comes to pressure testing and here are just a few:
The Hierarchy of Controls chart from NIOSH is a great example of how risk mitigation works.
Visit Centers for Disease Control and Prevention website for details.
General Worksite Safety
Incorporate general worksite safety precautions and procedures, as applicable.
The following are examples of general worksite safety precautions and procedures which may be incorporated into the SSSP.
Install mats or utilize secured ladders for access to test header valves. If using mat bridges across the excavation, handrails must be installed if elevated 6' above a lower level.
Provide for and require the installation of devices that mark the limits of the exclusion zone.
Keep unauthorized personnel out of the test area.
Inform all affected site and community personnel of the planned test.
Provide for and require that equipment and materials are arranged to give unobstructed access/egress during testing and in the event of an emergency.
Establish lines of communication between the Owner/Facility, Contractor, and local authorities.
Provide for and require the use of reliable transportation and communication systems during all aspects of the testing event.
Exclusion Zone
Precautions should be taken to see that people not directly engaged in the testing operations remain out of the test area during the test period.
Provide for and require that signs, barricades or other protective barriers are placed in a manner and at a distance sufficient to demarcate a safe zone to protect personnel and the public from unanticipated pressure release or equipment failure.
Exclusion Safety Zones are also important for pigging operations. Below is a quick clip of foam pig ejection. What safety exclusion zone do we have here?
Take time to do it right! Go home safe!
CONGRATULATIONS!!!
John Harleaux has been selected as our Safety Employee of the Month. We wanted to thank John for always putting safety first and dedication to making Cleveland Integrity and Eagle Infrastructure #1. His Supervisor remarks “each day onsite, out in the field, at the gym doing Crossfit or at home in LA on the farm, you won’t find a more diligent inspector who doesn’t just talk about safety, he walks it and makes it a priority in his life.
Interview Questions:
Why is Safety so important to you?
John: "When taking on a new project I always put safety first and foremost, everyone out here on the road is making a living while providing for their families and loved ones back home. By putting safety first each and every day, we are able to wake up again the next day to do it all over again.When taking on a new project I always put safety first and foremost, everyone out here on the road is making a living while providing for their families and loved ones back home. By putting safety first each and every day, we are able to wake up again the next day to do it all over again."
Why do you think submitting Near Miss reports is important?
John: "Reporting and being able to talk about near misses to fellow inspection staff as well as the contractor is very important when it comes to safety. We are all human and make mistakes, people become complacent at times and things can happen at the blink of an eye. Near misses along with good communication provides valuable information that may be implemented into a safety program and near misses should always be discussed in the field with the crew(s) on site."
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