I. General Safety Specifications
RISK TYPE
PROTECTIVE MEASURES
High-pressure fluid injection
✅ Verify all pressure-bearing components (flanges/joints) have pressure ratings ≥ 1.5 times test pressure before testing<br>✅ Install explosion-resistant transparent barriers (≥8mm polycarbonate)
Mechanical pinching
✅ Equip moving parts (hydraulic cylinders/fixtures) with light curtains; implement Lockout-Tagout (LOTO) during maintenance
Electrical shock
✅ Grounding resistance ≤ 4Ω; hydraulic station motors rated ≥ IP55; cables protected by metal conduits
II. Pre-Operation Checklist
Medium Compatibility
Confirm test fluid (water/oil/gas) compatibility with valve materials (e.g., chloride ions ≤25ppm for stainless steel corrosion prevention)
For gas tests: Mandatory use of safety valve + rupture disc redundancy (ASME Section VIII requirement)
Sealing System Verification
Install test valve
Calibrate bolt pre-tightening torque
Pressurize to 10% test pressure for leak check
Soap solution bubble test at connections
Environmental Safety
Operation area floor slip resistance ≥ R10; explosive environments require ventilation (CH₄ concentration ＜1% LEL)
Flammables prohibited within 3m; ABC-class fire extinguishers accessible within 5 seconds
III. Critical Control Points During Testing
PHASE
SAFETY REQUIREMENTS
Pressure rise
⚠️ Pressure increase rate ≤ 10% of rated pressure per second; operators retreat behind blast walls above 15MPa
Pressure holding
🔒 Personnel evacuate test zone; observe via cameras (minimum safe distance = pipe diameter × 3 and ≥2m)
Depressurization
❗ First release pressure via bypass valve to ≤5% before disconnecting<br>❗ Prevent cryogenic burns with liquid media (-50℃ cryogenic valves)
IV. Mandatory Personal Protective Equipment (PPE)
Basic protection : Safety-toe boots (ANSI Z41), puncture-resistant gloves (EN 388:2016), impact goggles (3mm)
Special scenarios :
Gas testing → Add positive-pressure respirator (NFPA 1981)
High/low-temperature testing → Thermal/cryogenic suits (ISO 11612 Level B2)
Noise >85dB → Ear muffs (SNR ≥ 30dB)
V. Emergency Response
Leakage/rupture :
Immediately trigger emergency stop (red mushroom button)
Evacuate upwind; contain fluid spread using absorbent pads/dikes
Personnel injury :
High-pressure injection injury → DO NOT remove embedded objects ; apply clean cloth compression
Chemical burns → 15-minute flush followed by neutralizer (5% NaHCO₃ for acids, boric acid for bases)
Technical Basis :
Pressure vessel rupture energy formula E = (P₁·V₁)/(γ-1)·[1-(P₂/P₁)^((γ-1)/γ)] (γ = gas adiabatic index)
Example: 10L vessel at 50MPa nitrogen (γ=1.4) rupture ≈ 43kg TNT equivalent → Underscores blast barrier necessity
VI. Maintenance & Training
Daily checks : Hydraulic oil level, pressure gauge calibration validity, manual testing of safety valves
Quarterly verifications : Pressure sensor accuracy (±0.5% FS), hardness change of hydraulic seals (Shore A ±5°)
Mandatory training :
8-hour annual hands-on operator refresher (including emergency drills)
Prohibit solo operation; require certified spotter (with first-aid certification)
FINAL WARNING : Industry data shows 70% of valve testing accidents stem from un-depressurized disassembly or overpressure operation . STRICTLY ADHERE TO PSI (Pounds per Square Inch) LIMITS – LIFE ALLOWS NO SECOND CHANCES!
Key Translation Notes:
Technical Accuracy :
防爆透明挡板 → “Explosion-resistant transparent barriers” (industry standard term)
光栅防护 → “Light curtains” (specific safety device name)
邵氏A型 → “Shore A” (international hardness scale)
Safety Emphasis Retention :
“严禁/立即” converted to “STRICTLY PROHIBITED/IMMEDIATELY”
Warning symbols (⚠️/🔒/❗) preserved for visual hazard recognition
Standards Compliance :
All referenced standards (ASME/ISO/ANSI) retain original designations
Technical formulas presented verbatim with variables explained
Critical Data Preservation :
All numerical thresholds (pressures/distances/concentrations) unchanged
PPE certification levels precisely translated (e.g., ISO 11612 Level B2
