Process, Safety, and Cost of Isolations and Hydrotesting

The importance of isolations and hydrotesting has been discussed by petrochemical Industries. The company has a vast network of engineering, manufacturing, and distribution locations, and distribution partners that can assist you with your project. In this article, we'll discuss the importance of isolation gaskets, including why they're so important for hydrotesting.

Process

Before you perform isolations and hydrotesting, you should determine the scope of the tests. Before starting any tests, you must have a proper plan to ensure that all equipment is ready. Hydrostatic pressure is an application of internal pressure above the normal or maximum operating pressure under no-flow conditions. It is important to note that pure water should not be used for hydrotests as it expands before freezing. The size and wall thickness of the pipes should be identified.

If a piping system contains a crack, the next step is to perform a hydrotest. A hydrotest consists of filling the system with a suitable liquid and then applying pressure to it. This fluid should be at a temperature that is equivalent to the lowest operating temperature of the vessel. It may take up to two hours for a component to fail under hydrostatic pressure. The entire process should be repeated until no leaks are detected. A variety of equipment is available for pipe connection isolations and hydrotesting. These devices are portable and easy to position. 

Locations

Isolations and hydrotesting require specific equipment and procedures. Hydrotesting involves filling a pipeline with water and pressing it to a pre-determined pressure level to check for leaks. To ensure that there are no leaks, the pipeline must be isolated before hydrotesting can begin. Ensure that access to the area is secure and that the site has proper signage in both English and local languages.

Hydrotesting and isolation operations may require an additional platform, utility boat, or dive boat spread. In general, shallow-water hydrotest locations are well-accepted. However, deep-water pipeline hydrotest locations are more complex and difficult. As a result, the equipment and procedures must be specialized and highly trained to ensure proper isolation. For these reasons, the equipment used must be certified and within the calibration range.

Safety

There is no single method to ensure the safety of isolations and hydrotesting procedures. Many factors can contribute to incidents during hydrotesting and pressure testing. For example, an incident occurred when a tank was filled with "very cold" water and the relief valve was unable to displace the air in the tank in a timely manner. The operator was on top of the tank when it blew off. This case highlights the importance of proper training.

The safety engineer should perform a walk-down procedure before pressure testing to ensure that all equipment and personnel are in place and functioning properly. The safety engineer should also cross-check important equipment systems and ensure that the system is isolated during the hydrostatic pressure test.

Cost

Isolation and testing are common methods to identify leaks in a plumbing drain system. Each section of a plumbing drain system is isolated, and the water pressure in each is tested. In a hydrostatic test, a technician places an inflatable test ball into a plumbing drain system branch, which they monitor for a certain period of time. If the water level drops, it indicates that a leak is present, and leak isolation testing is required.

When performed properly, pressure testing can effectively verify weld integrity. Its dual-port design creates a positive pressure barrier between the hot work and upstream gases. Hydrotesting equipment is designed to simulate full radial, hoop, and axial stresses. To achieve reliable and repeatable results, hydrotesting and isolations require the proper tooling, as well as the proper training.