FACTORY ACCEPTANCE TESTING
Life Support Package
LSP-005
DOCUMENT INFORMATION
Doc No:
LSP-005-FAT-2015
Srl No:
Revision
Mag file
Issued
02-02-2015.
Author
Unique
FAT
LSP-005
VK
CLIENT
16 June 2013
Page 1 of 24
Contents
1. Introduction ........................................................................................................................................................ 4
1.1 Scope ............................................................................................................................................................ 4
1.2 Objective ....................................................................................................................................................... 4
1.3 Definitions..................................................................................................................................................... 4
1.4 Responsibilities ............................................................................................................................................. 4
1.5 Reference Documents .................................................................................................................................. 4
2. GENERAL ............................................................................................................................................................. 5
2. 1 Operations manual ...................................................................................................................................... 5
2.2 Cleanliness of System ................................................................................................................................... 5
2.3 Permanent marking of equipment ............................................................................................................... 6
2.4 Calibration of essential gauges and clocks ................................................................................................... 6
2.5 Structural integrity and corrosion status of system ..................................................................................... 6
2.6 Gas distribution system ................................................................................................................................ 7
2.7
ECU-1 (ECU-C-101-010) ..................................................................................................................... 8
2.7-1 QC Checks ............................................................................................................................................. 8
2.7-2 Pipe Pressure leak Testing ................................................................................................................... 9
2.7-3 Function testing .................................................................................................................................. 10
2.7-4 Pump Electrical Testing ...................................................................................................................... 11
2.7-5 Heater Element Electrical Testing ...................................................................................................... 11
2.7-6 Electrical Function Testing .................................................................................................................. 12
2.8
ECU-2 (ECU-C-101-011) ................................................................................................................... 13
2.8-1 QC Checks ........................................................................................................................................... 13
2.8-2 Pipe Pressure leak Testing ................................................................................................................. 14
2.8-3 Function testing .................................................................................................................................. 15
2.8-4 Pump Electrical Testing ...................................................................................................................... 16
2.8-5 Heater Element Electrical Testing ...................................................................................................... 16
2.8-6 Electrical Function Testing .................................................................................................................. 17
2.9
IMCA Testing & Reports Required ....................................................................................................... 18
2.10
Main electrical supplies ....................................................................................................................... 19
2.11
FAT
Communication systems...................................................................................................................... 19
16 June 2013
Page 2 of 24
2.12. Analyzer Calibration. ............................................................................................................................... 20
2.13.
Fire Protection.................................................................................................................................. 20
2.14.
Internal Electrical .............................................................................................................................. 20
2.15.
General Safety Audit of System ........................................................................................................ 21
3. PRESSURE TESTING ........................................................................................................................................... 22
3.1 Piping pressure testing ............................................................................................................................... 22
3.2. Hose components pressure test. ............................................................................................................... 23
4. Control Measures ........................................................................................................................................... 24
FAT
16 June 2013
Page 3 of 24
1. Introduction
This FAT has been compiled to define testing requirements for maintaining the certification of the portable chamber
control (Life Support Package). It may also form the basis of the certificate that is to be issued upon successful completion
of the testing and inspection listed herein.
Only a nominated competent person may sign for the completion of a task detailed in this manual. Before doing so,
section 1.1 must be completed by the person signing.
IMPORTANT
This manual is used for each periodic survey. During each year, the equipment comprising the portable chamber control
may change. Always check that the copy being used has been revised for the year and type of survey being performed.
1.1 Scope
The scope of this Factory Acceptance Test (FAT) covers the testing of all equipment that is contained in the Life Support
System ( LSP 005) as defined by the client approved manufacturing design data provided with the FAT.
1.2 Objective
To Ensure that the LSP design & Operation meets the contractual requirements.
1.3 Definitions
The following terms and abbreviations are used throughout this manual and their meaning will be as defined below.
Classification Society
Det Norske Veritas (DNV)
ECU
Environmental Control Unit
HRV
Hyperbaric Rescue Vessel
SPP
Sound Powered Phone
SWL
Safe Working Load.
1.4 Responsibilities
Unique System shall prepare the FAT and carry out all the testing.
The Client Representative shall approve the FAT and witness all the testing.
1.5 Reference Documents
DNV-RP-E403- standard for hyperbaric evacuation system
IMO Code of Safety for Diving System
IMCA Applicable code of practice for Life support system
Client Approved design data-
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& Sign
FAT
Client name &
Sign
16 June 2013
Page 4 of 24
2. GENERAL
2. 1 Operations manual
Inspection
1.
System Operation & maintenance manual shall be reviewed by the
DNV Surveyor.
2.
Planned maintenance system shall be reviewed by the DNV surveyor
3.
Safety valves, Gauges, Alarms and piping should be registered in
planned maintenance system for record keeping
Any portable / temporarily installed equipment used as part of the
portable chamber control should also be maintained by the operator
/ owner.
4.
Accept/Reject
Reason
Accept/Reject
Reason
2.2 Cleanliness of System
Inspection
1.
2.
3.
Internal & External visual survey shall be performed by the surveyor
to assure the cleanliness and suitability of the system.
Attention should be paid to ensure the contamination , damages, or
any external defects.
All internal equipment and control panel should be free of corrosion
and any other debris.
4.
An oxygen cleaning procedure should be in place for the cleaning of
new pipe work that is used for breathing- PRO-0013 (DNV approved)
5.
Cleaning report should be reviewed by the surveyor
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name
& Sign
FAT
Client
name &
Sign
Client
name &
Sign
16 June 2013
Page 5 of 24
2.3 Permanent marking of equipment
Inspection
1.
2.
3.
Accept/Reject
Reason
Accept/Reject
Reason
Accept/Reject
Reason
Check for permanent marking of electrical cables, strips, valves and
fittings penetrators, and regulators
The marked equipment should be traceable through the Planned
Maintenance System.
.Ensure all the markings on the control panel are in place.
2.4 Calibration of essential gauges and clocks
Inspection
1.
All Gauges should be tested as per IMCA D 018
2.
Depth gauges & life support Gauges should be calibrated by a
qualified competent person on a 6 monthly basis and calibration
equipment should be traceable to IMCA
3.
Ensure the serial number and certificate numbers and test date
labels are available on the gauges
2.5 Structural integrity and corrosion status of system
Inspection
1.
The container should be made as per DNV rules DNV 2.7-1 and
review the DNV certificate of the container.
2.
Attention should be made to maintenance, possible damage and
serious corrosion
3.
Corrosion inspection shall be done internally & externally on all the
equipment inside the LSP container
4.
Perform a thorough examination the lifting slings and shackles to
ensure they meet the SWL.
Unique
name
& Sign
FAT
Client
name &
Sign
Client
name &
Sign
16 June 2013
Page 6 of 24
2.6 Gas distribution system
Inspection
1.
2.
Accept/Reject
Reason
Valves on the control panels should turn smoothly. Care must be
taken to ensure no pressure is behind the valves.
The HP oxygen control system should not be fitted with quarter turn
valves.
3.
Ensure all valves and piping is marked and connected correctly
Ensure the pressure testing of the panels are satisfactory and review
the certificate.
Unique
name
& Sign
FAT
Client
name &
Sign
Client
name &
Sign
16 June 2013
Page 7 of 24
2.7 ECU-1 (ECU-C-101-010)
ECU Testing shall include the following.
2.7-1 QC Checks
Inspection
Accept/Reject
1.
Ensure frame is Painted and in good condition
2.
Complete a visual inspection of the ECU and ensure all areas are free
of dirt, bad workmanship or scratches.
Ensure all bolts where used on vibration applications are nylock or
have spring washers.
Ensure all lifting arrangements are full safety bolts with split pin and
castle nut.
Ensure all supplied nuts are replaced with stainless steel, including
nuts, etc.
Inspect filter after use and ensure it is clean before packing.
3.
4.
5.
6.
7.
Hazard warning signs must be displayed on all potentially dangerous
areas. (Electrical boxes, Moving parts and any Hot parts)
8.
All valves to be labeled
9.
All inlet and outlet to be labeled with function
10.
A nameplate must be a fixed to the product.
11.
Ensure all valves are accessible and operate easily.
12.
Ensure all valve operate fully open and fully closed.
13.
Ensure all valves are labeled correctly for function.
14.
15.
Ensure all exhaust pipe-work such as relief valve vents, etc vent in to
an enclosed space or safe place. (Never into a person face or body)
Ensure pipe clamps are secure.
16.
Ensure all pressure gauges are filled with glycerine.
17.
Inspect insulation and ensure all areas are covered. Ensure insulation
is neat and tidy.
Unique
name
& Sign
FAT
Client
name &
Sign
Reason
N/A
Client
name &
Sign
16 June 2013
Page 8 of 24
Reason
Inspection
Accept/Reject
19.
Control switch board securely fastened to the frame.
20.
All cabling is fastened and safely conducted within the product.
21.
Drawing of the electrical wiring is inside. Record drawing no and revision.
DWG No. USD-E-14-1295 Rev B and supply USD-E-14-1271 Rev C
22.
All wires are visibly in good condition
23.
All switches relay and blocks are numbered.
24.
All panel wires are numbered
25.
With the power OFF at the main circuit breaker and disconnected,
conduct a panel wire pull test; ensure all wires are installed tightly.
26.
Ensure the electrical switches and dials do no protrude into walkways.
2.7-2 Pipe Pressure leak Testing
All leak tests are to be done at the MAWP of the piping system under test
Pipe number/description
Operating pressure (bar)
1.
HOT Supply
3 Bar
2.
HOT Return
3 Bar
3.
COLD Supply
3 Bar
4.
COLD Return
3 Bar
5.
HOT Tank
Surface
6.
COLD Tank
Surface
7.
COLD Chiller gas delivery
Leak test at WP
8.
COLD Chiller gas suction
Leak test at WP
Unique
name
& Sign
FAT
Client
name &
Sign
Pass/Fail
Client
name &
Sign
16 June 2013
Page 9 of 24
2.7-3 Function testing
Test Method
Required result
Result obtained
Accept/
Reject
1.
Check flow rate of water,
Minimum flow of both the
pumps - 25l/min
2.
Record Ambient Temperature
These values are for future
comparison
3.
Verify pt100 temperature readings.
+/-1C Difference
4.
Function test level switch while filling
tank
Functioning
5.
Turn on pumps, check direction and
pressure
6.
Function test flow switches, turn
pumps on and off 3 times
7.
Note the time taken to reach the temp
from first reading to set temperature
9.
Run Chiller on cooling, set cooling
temp at 6C (while running the
resistance heater)
Off @ 6C; On @ 6.5 C
11.
Leak test delivery gauge on chiller.
No Leaks
12.
Test Standby Heating Element check
cut out temperature.
Run system for a total test time of 4
hours without fault
Off @ 60C; On @ 59.9 C
13.
Unique
name
& Sign
FAT
Clockwise, +/-2.5bar@ 50Hz
Ambient
Temp:
HOT WATER
PUMP:
COLD WATER
PUMP:
3 successful indications
required
Cold water- 20C to 6C
Hot Water- 49.5C to 60 C
4 hours run, no faults
Client
name &
Sign
Client
name &
Sign
16 June 2013
Page 10 of 24
2.7-4 Pump Electrical Testing
Megger and Continuity testing
All megger testing is to be done at 500V for a minimum of 30 seconds per line. A minimum ohm reading of 1
Mega Ohm or more should be obtained. Remove all star point connection or links for this test.
Electrical motor testing
Cold water pump SN:0409133905
1.
U1 V1
2.
V1 W1
3.
W1 U1
Megger result
Continuity result
Hot water pump SN: 0409133913
1.
U1 V1
2.
V1 W1
3.
W1 U1
2.7-5 Heater Element Electrical Testing
Resistance element
1.
Heater element- EL1 El2
2.
Heater element- EL2 El3
3.
Heater element- EL3 El1
Unique
name
& Sign
FAT
Megger result
Client
name &
Sign
Continuity result
Client
name &
Sign
16 June 2013
Page 11 of 24
2.7-6 Electrical Function Testing
Test Method
Required result
1.
Confirm Gefran Temperature Controller parameters
are correct
Control Parameters
setting
2.
Confirm The chiller Cold Controller parameters are
correct
O/L-1
Control Parameters
setting
9. Amp
Confirm overload settings for the overloads is
set to the Amp ratings on the motors
nameplate:
O/L-2
9 Amp
O/L-3
2.3 Amp
O/L-4
2.3 Amp
3.
4.
5.
Function test Over Temp Controller to ensure that the
Heater Element will de-energize when the tank
temperature value exceeds that of the set value on
the Over-Temp Controller.
Test that when the chiller water tank level is low
Result
obtained
Accept/Reject
1C
The Tank Water level
light will be on
The Manual Heater
Element Contactor will
not energize.
6.
Cold water pump Amp reading
2 Amp @ 50Hz (0.2)
7.
Cold water chiller Amp reading
5.5 Amp @ 50Hz ( 2)
8.
HOT water pump Amp reading
2.0Amp @ 50Hz (0.5)
9.
Heater Element Amp Reading
7.5Amp @ 50Hz (0.5)
Unique
name
& Sign
FAT
Client
name &
Sign
Client
name &
Sign
16 June 2013
Page 12 of 24
2.8 ECU-2 (ECU-C-101-011)
ECU Testing shall include the following.
2.8-1 QC Checks
Inspection
Accept/Reject
1.
Ensure frame is Painted and in good condition
2.
Complete a visual inspection of the ECU and ensure all areas are free
of dirt, bad workmanship or scratches.
Ensure all bolts where used on vibration applications are nylock or
have spring washers.
Ensure all lifting arrangements are full safety bolts with split pin and
castle nut.
Ensure all supplied nuts are replaced with stainless steel, including
nuts, etc.
Inspect filter after use and ensure it is clean before packing.
3.
4.
5.
6.
7.
Hazard warning signs must be displayed on all potentially dangerous
areas. (Electrical boxes, Moving parts and any Hot parts)
8.
All valves to be labeled
9.
All inlet and outlet to be labeled with function
10.
A nameplate must be a fixed to the product.
11.
Ensure all valves are accessible and operate easily.
12.
Ensure all valve operate fully open and fully closed.
13.
Ensure all valves are labeled correctly for function.
14.
15.
Ensure all exhaust pipe-work such as relief valve vents, etc vent in to
an enclosed space or safe place. (Never into a person face or body)
Ensure pipe clamps are secure.
16.
Ensure all pressure gauges are filled with glycerine.
17.
Inspect insulation and ensure all areas are covered. Ensure insulation
is neat and tidy.
Unique
name
& Sign
FAT
Client
name &
Sign
Reason
N/A
Client
name &
Sign
16 June 2013
Page 13 of 24
Reason
Inspection
Accept/Reject
19.
Control switch board securely fastened to the frame.
20.
All cabling is fastened and safely conducted within the product.
21.
Drawing of the electrical wiring is inside. Record drawing no and revision.
DWG No. USD-E-14-1295 Rev B and supply USD-E-14-1271 Rev C
22.
All wires are visibly in good condition
23.
All switches relay and blocks are numbered.
24.
All panel wires are numbered
25.
With the power OFF at the main circuit breaker and disconnected,
conduct a panel wire pull test; ensure all wires are installed tightly.
26.
Ensure the electrical switches and dials do no protrude into walkways.
2.8-2 Pipe Pressure leak Testing
All leak tests are to be done at the MAWP of the piping system under test
Pipe number/description
Operating pressure (bar)
1.
HOT Supply
3 Bar
2.
HOT Return
3 Bar
3.
COLD Supply
3 Bar
4.
COLD Return
3 Bar
5.
HOT Tank
Surface
6.
COLD Tank
Surface
7.
COLD Chiller gas delivery
Leak test at WP
8.
COLD Chiller gas suction
Leak test at WP
Unique
name
& Sign
FAT
Client
name &
Sign
Pass/Fail
Client
name &
Sign
16 June 2013
Page 14 of 24
2.8-3 Function testing
Test Method
Required result
Result obtained
Accept/
Reject
1.
Check flow rate of cooling water,
Minimum flow of both the
pump -25l/min
2.
Record Ambient Temperature
These values are for future
comparison
3.
Verify pt100 temperature readings.
+/-1C Difference
4.
Function test level switch while filling
tank
Functioning
5.
Turn on pumps, check direction and
pressure
6.
Function test flow switches, turn
pumps on and off 3 times
7.
Note the time taken to reach the temp
from first reading to set temperature
9.
Run Chiller on cooling, set cooling
temp at 6C (while running the
resistance heater)
Off @ 6C; On @ 8 C
11.
Leak test delivery gauge on chiller,
No Leaks
12.
Test Standby Heating Element check
cut out temperature.
Run system for a total test time of 4
hours without fault
Off @ 60C; On @ 59 C
13.
Unique
name
& Sign
FAT
Clockwise, +/-2.5bar@ 50Hz
Ambient
Temp:
HOT WATER
PUMP:
COLD WATER
PUMP:
3 successful indications
required
Cold water- 18C to 6C
Hot Water- 53.5C to 64 C
4 hours run, no faults
Client
name &
Sign
Client
name &
Sign
16 June 2013
Page 15 of 24
2.8-4 Pump Electrical Testing
Megger and Continuity testing
All megger testing is to be done at 500V for a minimum of 30 seconds per line. A minimum ohm reading of 1
Mega Ohm or more should be obtained. Remove all star point connection or links for this test.
Electrical motor testing
Cold water pump SN:0409133905
1.
U1 V1
2.
V1 W1
3.
W1 U1
Megger result
Continuity result
Hot water pump SN: 0409133913
1.
U1 V1
2.
V1 W1
3.
W1 U1
2.8-5 Heater Element Electrical Testing
Resistance element
1.
Heater element- EL1 El2
2.
Heater element- EL2 El3
3.
Heater element- EL3 El1
Unique
name
& Sign
FAT
Megger result
Client
name &
Sign
Continuity result
Client
name &
Sign
16 June 2013
Page 16 of 24
2.8-6 Electrical Function Testing
Test Method
Required result
1.
Confirm Gefran Temperature Controller parameters
are correct
Control Parameters
setting
2.
Confirm The chiller Cold Controller parameters are
correct
O/L-1
Control Parameters
setting
9. Amp
Confirm overload settings for the overloads is
set to the Amp ratings on the motors
nameplate:
O/L-2
9 Amp
O/L-3
2.3 Amp
O/L-4
2.3 Amp
3.
4.
Function test Over Temp Controller to ensure that the
Heater Element will de-energize when the tank
temperature value exceeds that of the set value on
the Over-Temp Controller.
1C
5.
Measure Amps drawn on resistance heater- 6kW
7.5 AMPS(0.5)
6.
Test that when the chiller water tank level is low
Result
obtained
Accept/Reject
The Tank Water level
light will be on
The Manual Heater
Element Contactor will
not energize.
7.
Cold water pump Amp reading
2 Amp @ 50Hz (0.2)
8.
Cold water chiller Amp reading
5.5 Amp @ 50Hz ( 2)
10.
HOT water pump Amp reading
2.0Amp @ 50Hz (0.5)
11.
Heater Element Amp Reading
7.5Amp @ 50Hz (0.5)
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Client
name &
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16 June 2013
Page 17 of 24
2.9 IMCA Testing & Reports Required
DESCRIPTION
IMCA SECTION
PARAGRAPH
IMCA D024, Section 16
6.8
Electrical Protection
UDp-14-64184,64185,64186
IMCA D024, Section 16
6.9
Electrical testing
UDp-14-64184,64185,64186
IMCA D024, Section 16
6.10
Emergency Electrical testing
UDp-14-64184,64185,64186
IMCA D024, Section 16
8.5
BA Testing function test
UDP-14-64473
IMCA D024, Section 16
8.6
BA Cylinder gas leak test
UDP-14-64474
IMCA D024, Section 16
8.7
BA Cylinder Over pressure test
12-36753-1
IMCA D024, Section 16
8.10
Communication testing
UDP-14-64187,64188
IMCA D024, Section 16
8.22
Communication testing
UDP-14-64187,64188
IMCA D024, Section 16
8.31
Pipe work over pressure test
UDP-14-64216,64217,64218
IMCA D024, Section 16
8.32
Pipe work Visual Inspection
UDP-14-64467,64468,64469
IMCA D024, Section 16
8.33
Pipe work gas leak test
UDP-14-64467,64468,64469
IMCA D024, Section 16
8.35
Relief valve visual examination
IMCA D024, Section 16
8.36
Relief valve Function & gas leak test
UDP-14-64191,64192,64193,64194, 64195
UDP-14-64191,64192,64193,64194, 64195
IMCA D024, Section 16
8.38
UDp-14-64184,64185,64186
IMCA D024, Section 16
8.48
Electrical Equipment Function ,
Continuity & resistance check
Analyzer function test
IMCA D024, Section 16
8.49
Alarm function test
UDP-14-64182, 64183
IMCA D024, Section 16
9.3
ECU Function test
UDP-14-64210, 64214
IMCA D024, Section 16
11.5
Hose component Over pressure test
UDP-14-64170,171,173,175
IMCA D024, Section 16
11.5
UDP-14-64170,171,173,175
IMCA D024, Section 16
11.5
Hose component Visual examination
check
Hose component Gas leak test
IMCA D024, Section 16
12.6
IMCA D024, Section 16
12.7
Electrical Cable continuity and
resistance
check Over pressure test
Hose component
IMCA D024, Section 16
12.8
Hose component Visual inspection
IMCA D024, Section 16
12.8
Hose component gas leak test
IMCA D024, Section 16
12.2
Fire fighting testing
Unique
name
& Sign
FAT
Client
name &
Sign
Report Number(s)
UDP-14-64182, 64183
UDP-14-64170,171,173,175
UDP-14-64169,172,174,176,
177,178,179, 180,181,182,183
UDP-14-64169,172,174,176,
177,178,179, 180,181,182,183
UDP-14-64169,172,174,176,
177,178,179, 180,181,182,183
158561/1 , 158561/2
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name &
Sign
16 June 2013
Page 18 of 24
2.10
Main electrical supplies
Inspection
2.
Main power supplies for the following are to be inspected and
tested:
Megger
Internal power outlets
MEGGER
CONTINUITY
3.
Monitoring devices
4.
Control Panel
5.
SPHL Cable- Comms-1
6.
SPHL Cable- Comms-2
7.
SPHL Cable- Power-1
8.
SPHL Cable- Power-2
1.
9.
Accept/Reject
Reason
Accept/Reject
Reason
Monitor coaxial cable- Core
Monitor coaxial cable- Coax
2.11
Communication systems
Inspection
1.
Test the main communications 3 Diver Rack mound
communication. It should include,
Channel -1 communication testing with test speaker
Channel -2 communication testing with test speaker
Channel -3 communication testing with test speaker
Accept
2.
The test should include the use of the sound powered phone and
headsets.
Accept
3.
Video Monitor shall be tested with a test camera in order to function
test
Accept
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16 June 2013
Page 19 of 24
2.12. Analyzer Calibration.
Inspection
Accept/Reject
1.
All the analyzer should be function tested in order to ensure the
functioning of the device
2.
Analyzers should be calibrated for their required gas sensor with
calibrated gas.
3.
DNV Surveyor shall review the certificate for the analyzers
Reason
2.13. Fire Protection
Inspection
Accept/Reject
1.
Suitable portable fire extinguisher should be placed inside the
system for the fire protection.
2.
Fill level of the fire extinguisher need to be checked and confirmed.
3.
The cylinder need to be checked for any leaks
Ensure the testing of the fire extinguisher is in date and review the
certificate.
Reason
2.14. Internal Electrical
Test internal lighting system with normal power
SYSTEM
POWER
Internal Lighting
Normal Electrical power
OPERATIONAL
Comments
Emergency Electrical Power
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Client
name &
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Client
name &
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16 June 2013
Page 20 of 24
2.15. General Safety Audit of System
Equipment/System
Requirement
Walkways
Clear
Non Slip
Sea fastenings
General equipment verified as sea fastened adequately
Electrical supply
Correctly connected to board,
adequate rating of board,
cables protected from damage
Gas supply
Hoses protected from damage
Hoses out of the direct sun or covered
Unique
name
& Sign
FAT
Findings
Client
name &
Sign
Client
name &
Sign
16 June 2013
Page 21 of 24
3. PRESSURE TESTING
3.1 Piping pressure testing
Pressure testing is to be carried out on all relevant components the following Table gives indicative test pressures for
typical components of the control panel & system.
ITEM
Hydro Testing
(Review)
Gas Leak Testing
(Witnessed )
Duration- 1 hour
Pass/ Fail
Mix-1 In
Mix-1 Out
Mix-2 in
Mix-2 out
O2 Injection in
O2 Injection Out
Bibs in
Bibs out
Depth in
Sample in
Panel Exhaust
Flow test need to carried out with full working pressure of the system along with the whips and hoses
Visual Examination: E External; I Internal.
All above to be witnessed by DNV surveyor.
Hydro-test covers thorough visual inspection, internally.
Leak test with minimum 100% Nitrogen. Note fire risk with air at high pressure.
When testing gauges ensure the gauge is not pressurized above maximum pressure.
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3.2. Hose components pressure test.
Item
Hydro
Testing
Length
Working
Pressure
Gas Leak
Testing
(Witnessed)
1 hour
Hydro test
(Witnessed)
Pass/ Fail
Depth
Sample
O2 Make-up
In
Out
BIBS Supply
In
Out
Mix-1
In
Out
Mix-2
In
Out
Exhaust
Hot Water Supply
In
Hot Water Return
Out
Cold Water Supply
In
Cold Water Return
Out
Flow test from the panel through the interconnecting hoses with 200 bar on line.
Hot and cold water flow test through hoses
Pressure and leak test of the hoses
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4. Control Measures
The following are typical controls which may be required from the task risk assessment
Inspection
1.
Accept/Reject
Reason
Access restrictions and barriers
2.
Hearing protection for gas testing
3.
4.
5.
6.
7.
8.
9.
Eye protection
Hose and whip securing
Permit to work to be raised for the test
Provision of suitable ventilation in the area of the pressure test
Provision of suitable escape routes for test personnel
Provision of oil contamination cleanup materials if the test medium
is oil
Ensuring that a failure during the pressure test will not cause
damage to the surrounding area (water leakage causing damage to
surrounding area due to poor drainage or gas escape causing
localized
overpressure)
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Page 24 of 24
