Safe Work Procedure: Pipeline Hydrotest

Document Number: [SWP-NUMBER] Revision Date: [DATE] Next Review Date: [NEXT REVIEW DATE] Department: [DEPARTMENT NAME]

1. Scope

This procedure covers the safe execution of hydrostatic testing on pipelines to ensure their integrity and safety before being put into service. It applies to all pipeline systems that require pressure testing as part of their commissioning or maintenance processes.

This procedure is applicable in environments where pipelines are installed, including aboveground and underground settings. It should be used in conjunction with other relevant procedures and safety standards, such as the Canada Occupational Health and Safety Regulations and the Safety Standards for General Safety and Health Standards.

2. Definitions

Pipeline A system of pipes used to transport fluids, as defined in section 2 of the Canadian Energy Regulator Act.

Hydrostatic Test A method of testing pipelines by filling them with water and pressurizing them to check for leaks and structural integrity.

Pressure Piping System An assembly of pipes and related components that contain a gas, vapor, or liquid and are connected to a boiler or pressure vessel.

3. Responsibilities

3.1 Supervisors

Ensure all personnel are trained and competent in hydrostatic testing procedures.
Verify that all equipment and PPE are available and in good condition.
Oversee the testing process to ensure compliance with safety standards.

3.2 Workers

Follow the hydrostatic testing procedure as outlined.
Use the required PPE and equipment correctly.
Report any safety concerns or equipment malfunctions immediately.

3.3 Health and Safety Representative

Conduct regular safety audits of the hydrostatic testing process.
Provide feedback and recommendations for improving safety measures.

4. Potential Hazards and Risks

Hazard	Risk	Control Measures
High pressure	Pipe rupture or explosion	Use pressure relief devices and maintain pressure within safe limits [1]
Water leakage	Slips and falls	Ensure proper drainage and use non-slip mats
Equipment failure	Injury from flying debris	Regular maintenance and inspection of equipment [1]

5. Personal Protective Equipment (PPE)

Proper PPE is essential to protect workers from potential hazards during hydrostatic testing.

Hard hat - Protects against head injuries from falling objects.
Safety goggles - Protects eyes from water spray and debris.
Gloves - Provides hand protection from sharp edges and chemicals.
Steel-toed boots - Protects feet from heavy objects and slips.
Hearing protection - Required if noise levels exceed safe limits.

Inspect PPE before use and replace any damaged items immediately.

6. Equipment and Tools

Using the correct equipment and tools is crucial for a safe hydrostatic test.

Pressure pump - Used to pressurize the pipeline.
Pressure gauges - Monitors the pressure within the pipeline.
Relief valves - Prevents over-pressurization.
Hoses and fittings - Connects the pump to the pipeline securely.
Water source - Provides the necessary volume for testing.

Inspect all equipment before use and ensure it is calibrated and in good working condition.

7. Pre-Job Requirements

7.1 Training and Competency

Personnel must be trained in hydrostatic testing procedures and emergency response.

7.2 Pre-Job Briefing

Conduct a briefing to discuss the testing procedure, potential hazards, and emergency protocols.

7.3 Work Area Preparation

Ensure the area is clear of non-essential personnel and that all safety barriers and signs are in place.

8. Safe Work Procedure Steps

Step 1: Preparation

Verify that all equipment is available and in good condition.
Ensure all personnel are wearing the required PPE.
Conduct a pre-test inspection of the pipeline.

Step 2: Filling the Pipeline

Connect the water source to the pipeline using secure fittings.
Fill the pipeline with water, ensuring no air pockets remain.
Monitor the filling process to prevent overfilling.

Step 3: Pressurization

Gradually increase the pressure using the pump.
Monitor pressure gauges closely to maintain within safe limits.
Inspect for leaks and structural integrity during the test.

9. Precautions and Safety Measures

Ensure all personnel are clear of the pipeline during pressurization.
Use remote monitoring where possible to reduce exposure.
Have emergency shut-off procedures in place.

10. Emergency Procedures

10.1 General Emergency Response

Evacuate the area immediately if a rupture occurs.
Shut down the pressure pump and relieve pressure safely.

10.2 Specific Emergency Scenarios

Pipeline Rupture - Evacuate and follow emergency shutdown procedures.
Equipment Failure - Cease operations and inspect equipment.

10.3 Emergency Contact Information

List of emergency contacts and their phone numbers.

11. Incident Reporting and Investigation

Report any incidents or near-misses immediately. Conduct a thorough investigation to determine the cause and implement corrective actions.

12. References and Related Documents

Canada Occupational Health and Safety Regulations
Safety Standards for General Safety and Health Standards

Approved by: [NAME AND POSITION] Date: [APPROVAL DATE]