9 SAFETY ASPECTS OF

LEAK TESTING
9.1. SAFETY PROCEDURE
There are three important safety considerations for leak testing personnel:
(1) The inherent risks of the test side;
(2) The potential dangers from an interaction between the test system and the testing
environment;
(3) The hazard possible from a leak testing system itself. Leak tests are conducted in a
variety of potentially dangerous.
Leak testing personnel must be made aware of job hazards and be receptive to proper
training in order to protect themselves and others working close by. On many jobs,
testing must be performed at odd hours and under awkward conditions. Night shift
work, weekend work, and work in unheated areas in winter and uncooled areas in
summer are common assurance. Climbing through manholes, climbing ladders and
scaffolds, balancing on structural members, or other awkward maneuvres may all be in
a day’s work.
In addition to technical abilities and training in test procedures, the competent
technician must have other attributes. He must be determined to do a safe job under any
circumstances. He must be willing to listen and to cooperate with the many types of
personnel encountered in the field, but he must not compromise the safety aspects of his
work for the convenience of himself, his crew, or someone else.
9.2. NEED FOR SAFETY TRAINING OF TESTING PERSONNEL
Leak testing personnel can acquire a proper attitude and point of view toward safety
only through training coupled with experience. The training programme should include
first aid and life saving techniques.
In situation where irritating, toxic or corrosive dusts, gases, vapours, or fluids are
present, the testing technician should be given special training to make sure that he is
familiar with the properties of these substances and with the methods of controlling the
hazards.
The leak testing technician should have more thorough training in accident prevention
than the regular plant or construction works. The safety program must be designed with
an understanding of motivation of people.
9.3. HAZARDS IN LEAK TESTING
Pre-cleaning of test surfaces is required for leak testing where surface contamination
might prevent entry of fluid tracers. Many cleaning processes involve the use of liquid

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 solvents and vapours, some of which present possible hazards of flammability or
toxicity. Liquid leak tracers often have similar hazards, if vapours accumulate in
working areas.
Ventilation must be provided to prevent hazardous vapour concentrations. Electrical
systems must be enclosed or protected to prevent ignition of flammable vapours in air.
Access to test surfaces, particularly in large structures, can be hazardous if scaffolding
is inadequate, lighting is insufficient, or bad housekeeping creates hazards such as oily
work surfaces or obstructions in passageways.
9.4. SPECIAL SAFETY CONSIDERATIONS IN TESTING SYSTEMS UNDER
PRESSURE
When a pressure or vacuum vessel is fabricated, it will be tested to predict its safe
performance. It is sometimes necessary to exceed the designed operating conditions
during initial pressure testing. This pressurization requires many safety considerations
to ensure proper protection of personnel. Greater respect for high pressure has led to
increased safety emphasis, with the result that overall safety experience has been good.
9.5. PRECAUTIONS WITH AMMONIA
Ammonia is used as a tracer gas for many chemical indicator leak tests. At room
temperature and atmospheric pressure, NH3 is colourless, alkaline gas having a pungent
odour, which provides the signal of its presence.
Ammonia gas is irritating to the eyes and to moist skin. However, concentrations of
ammonia gas in air, in the concentration below 50 L/L (ppm), although not harmful,
are a considerable nuisance, so that people tend to avoid them.
9.6. PRECAUTIONS WITH ARGON GAS (Ar)
Sometimes, argon is used as a leak tracer gas. It is the most abundant member of the
rare gas family which consists of helium, neon, argon, krypton, and xenon.
All of these gases are monatomic and are characterized by their extreme chemical
inactivity.
Argon, a colourless, odourless, and tasteless gas is nontoxic. However, argon can act as
a simple asphyxiant by displacing the amount of air necessary to support life.
9.7. PRECAUTIONS WITH HELIUM GAS (He)
Helium is widely used as a tracer gas in leak testing with the mass spectrometer leak
detector. It is the lightest member of the rare gas family and is chemically inert,
colourless, odourless and tasteless gas. Helium is monatomic, but it can act as
asphyxiant by displacing the air necessary to support life.
Because of its low density, helium tends to rise to the top region of the closed vessels
or enclosure, where it could lead to asphyxiation of workers at these elevations.
9.8. HAZARDS ASSOCIATED WITH BUBBLE TESTS IN IMMERSION BATHS
Safety problems must be carefully considered when leak tests involve handling
hazardous gases such as hydrogen, ammonia, acetylene, oxygen, and natural (fuel) gas.
Similarly, care is required when using immersion baths of volatile, flammable, or toxic
liquids. Solvents such as ether, alcohols, acetone, and mineral oils constitute hazards,
especially when they have low flash points and vapours collect over exposed immersion
baths. Safer tracer gases and immersion bath liquids should be used whenever possible.

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9.9. RADIATION SAFETY PROCEDURES FOR LEAK TESTING WITH
KRYPTON-85 GAS
Working with penetrating radiation sources such as Krypton-85 can be as safe or
safer than many other types of work, but operating personnel must:
1. Understand that penetrating radiation is a hazard.
2. Know the limits of allowable exposure for trained personnel and for the
uninformed public (non-film-badge wearers).
3. Know how to use instrumentation for measuring radiation.
4. Know how to determine requirements and use proper radiation shielding
materials and arrangements to keep radiation levels within safe limits.
5. Know the applicable rules and regulations for control and use of materials that
produce ionizing radiations.
6. Follow the radiation safety rules and regulations and ensure proper compliance
by all personnel entering controlled radiation areas.
7. Know proper procedures for emergency control of equipment and personnel in
case of release of radioactive material into the working atmosphere, including
authorities to be notified.
8. Maintain good, permanent records in prescribed forms for transport and
installation of radioactive materials in equipment, their use during leak testing
operations, abnormal events or loss of radioactive materials, monitoring
instrumentation and equipment, and on all possible exposures of personnel to
ionizing radiations.
9.10. PROBLEMS OF INDUSTRIAL SAFETY IN THE USE OF CHEMICAL AND
INFLAMMABLE PRODUCTS
9.10.1. APPLICABLE SAFETY STANDARDS
Materials used in leak testing may be radioactive or reactive. Where such
materials are used, the appropriate safety standards and plant practices shall
apply.
9.10.2. DRAFTING OF SAFETY INSTRUCTIONS FOR THE PERSONNEL INVOLVED
Safety is the concern of every worker, with the supervisor bearing special responsibility
to ensure that the worker has been properly instructed or trained.
The role of safety instructions is to communicate those precautions which are common
sense, those which are passed down by the manufacturer, and those which might arise
with the specific application, to the worker.
9.10.3. SAFETY FACTORS APPLICABLE TO THE TEST
Aside from any hazards which might arise from the materials being used in the test, the
technician must be constantly aware of the function of the object under test. The
consequences of a failure in service emphasize the importance of the test. For pressure
tests, particularly pneumatic tests, the requirement to overpressure creates a hazard in
itself.
Investigating leaks in an operating system can be hazardous. If the system is known to
be leaking, there is a possibility that the leak is growing, and full failure could result. If

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 the working contents are explosive, combustible or toxic, leaks must be approached
with a great deal of caution.
9.11. CONTROL OF HAZARDS FROM TOXIC AND RADIOACTIVE LIQUIDS,
VAPOURS AND PARTICLES OF FLAMMABLE LIQUIDS AND VAPOURS
Hazards can be associated with the working fluids in the systems being tested or with
the testing fluids. Some specific precautions for handling chemicals are listed below.
9.11.1. CHEMICAL HANDLING
Use bottle carriers to transport chemicals. Close caps securely. Pour all chemicals
carefully. Add acid to water, not water to acid.
9.11.2. LABELS
Be sure all labels are securely attached and legible. Keep chemicals in their original
containers if possible. Label all secondary containers to avoid unknown chemicals
and/or inadvertent reaction. Date all chemicals, which may become unstable over time
or are peroxidizable.
9.11.3. SHELVES
Do not store chemicals on hard-to-reach shelves. Labels on stored chemicals should be
able to be read easily. Shelves should be made of a chemically resistant material and
should have a 2-inch lip or side rails.
9.11.4. INCOMPATIBLE CHEMICALS
Incompatible chemicals should not be stored together. For each chemical, the hazardous
nature must be considered individually and in relation to other chemicals in the area.
9.11.5. EXCESSIVE STORAGE
Avoid stockpiling chemicals. Purchase only what is needed. Use older stock first.
Discard chemicals that are no longer needed or that have expired.
9.11.6. FUME HOODS
In general, fume hoods should not be used for storage of chemicals, unless the
chemicals are part of the experiment being conducted in the fume hood at that time. The
exception is storage in a fume hood, which is specifically designed for that storage, and
where experimental procedures are not carried out.
9.11.7. HAZARDOUS WASTE STORAGE AND DISPOSAL
Regulations require that hazardous wastes be accumulated and stored in properly
managed containers on sufficiently impervious surfaces (free of cracks, gaps, etc.).
9.11.8. STORAGE
Hazardous waste in laboratories must be stored in satellite accumulation areas.
9.11.9. DISPOSAL
Once a satellite accumulation area container is filled, it must be dated and transferred to
a main accumulation area or shipped off-site. Disposal of hazardous wastes and
chemicals in laboratory sinks is prohibited by regulation.
9.11.10 LABELING
Containers that accumulate and store hazardous waste must be labeled with the
following information:

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  The words "Hazardous Waste"
 The waste type in words (Spent non-halogenated solvents, waste oil, etc.);
 The associated hazard in words (i.e. ignitable, toxic, etc.); and
 The date upon which the container became filled. Containers must be labeled and
situated so that labels are clearly visible.
9.11.11. CLOSURE
Containers must be closed at all times, unless waste is being added or removed. Open-
top funnels may not be left in open containers.
9.11.12. CONDITION
Containers must be in good condition. There may not be severe rusting, dents or other
conditions that could cause leaks, etc.
9.11.13. COMPATIBILITY
Containers must be compatible with hazardous waste stored within them. When in
doubt, use the original shipping container.
9.11.14. INSPECTIONS
Containers must be inspected weekly by laboratory personnel to ensure that they are
properly labeled, in good condition and meet the criteria described above.
9.11.15. HAZARDOUS WASTE MINIMIZATION
Laws may require generators of hazardous waste to implement measures to limit and
reduce the volume and toxicity of hazardous waste. Laboratory waste minimization
techniques include:
 Process/equipment adjustment or modification;
 Toxic material substitution;
 Waste segregation and separation; and
 Recycling
Where possible, microchemistry will reduce waste volume and has the added benefit of
minimizing health and safety concerns. The exercise of prudence in ordering new
chemicals will also ensure that excess chemical does not become subject to disposal has
hazardous waste.
9.12 SAFETY PRECAUTIONS WITH COMPRESSED GAS CYLINDERS
Use and storage of any compressed gas under high pressure can be extremely dangerous
if proper gas handling procedures are not observed. Moreover, chemical characteristics
of specialty gases themselves can pose serious health hazards if containment is not
tightly controlled. Paying close attention to a compressed gas product’s technical and
safety information is invaluable for maintaining a safe, productive working
environment and for ensuring reliable, efficient use of compressed specialty gases for
any application.
All cylinders containing gases must be labelled, packaged and shipped according to
local and national requirements as well as industry standards. Transportation label
diamonds, regardless of colour, indicate hazardous materials. Personnel handling any

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 compressed gas should be familiar with the potential hazards before using the gas. In
addition to the chemical hazards of compressed gases, hazards accompanying high
pressure or low temperature may also be present due to the physical state of the gas (i.e.
liquefied or non-liquefied).
It is also recommended that personnel who handle compressed gases engage in pre-job
discussion with their supervisor or another knowledgeable co-worker before beginning
any task. The job should be outlined job step by step. Potential emergencies and the
safe and proper measures necessary to avoid these emergencies should be discussed.
Some categories of industrial gases are described in the following paragraphs; however
it is strongly cautioned to refer to the MSDS sheets provided with the product being
used.
9.12.1. CORROSIVE
Gases that corrode material or tissue with which they come in contact, or do so in the
presence of water, are classified as corrosive. They can also be reactive and toxic and/or
flammable or an oxidizer. Most are hazardous in low concentrations over long periods
of time. It is essential that equipment used for handling corrosive gases be constructed
of proper materials. Use check valves and traps in a system where there is a possibility
that water or other inorganic materials can be sucked back into the cylinder.
Due to the probability of irritation and damage to the lungs, mucus membranes and eye
tissues from contact, the threshold limit values of the gas should be rigidly observed.
Proper protective clothing and equipment must be used to minimize exposure to
corrosive materials. A full body shower and eye wash station should be in the area.
Personnel must be familiar with the work area. Aisles should always be clear and
unobstructed in the event that the gas makes contact with the eyes and vision is
disrupted.
9.12.2. FLAMMABLE
Gases that, when mixed with air at atmospheric temperature and pressure, form a
flammable mixture at 13% or less by volume, or have a flammable range in air of
greater than 12% by volume regardless of the lower flammable limit, are classified as
flammable. They can be high-pressure, toxic, reactive and displace oxygen in air.
A change in temperature, pressure or oxidant concentration may vary the flammability
range considerably. All possible sources of ignition must be eliminated through proper
design of facilities and the restriction of smoking and open flames.
Use a vent line made of stainless steel, purge with an inert gas and use a flash arrester.
It is important to have (and know how to use) a fire extinguisher in the area where
flammable gases are used and stored, as well as a hand-held flammable gas detector to
determine if flammable gases are building up.
This gas detector can also be used as a leak detector on the lines of the equipment being
used. Always remember that the source of flammable gas must be closed or shut-off
before attempting to put out a fire involving flammable gases.
9.12.3. INERT
Gases that do not react with other materials at ordinary temperature and pressure are
classified as inert. They are colourless and odourless, as well as non-flammable and
nontoxic. The primary hazard of these gases is pressure. These gases are often stored at
pressures exceeding 2,000 psi (138 bar).

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 Also, they can displace the amount of oxygen necessary to support life when released in
a confined place. Use of adequate ventilation and monitoring of the oxygen content in
confined places will minimize the danger of asphyxiation. Always wear safety glasses
and safety gloves when working with the lines to avoid absorption of the gas through
the skin.
9.12.4. OXIDANT
Gases that do not burn but will support combustion are classified as oxidants. They can
be high-pressure, toxic and reactive, and can displace breathing oxygen from air (except
O2 itself). All possible sources of ignition must be eliminated when handling oxygen
and other oxidants as they react rapidly and violently. Do not store combustible
materials with oxidants.
Do not allow oil, grease or other readily combustible materials to come in contact with
the cylinder or equipment used for oxidant services. Use only equipment that is
intended for this type of service. Use only a regulator that has been clearly prepared for
use with this type of service - this regulator should be labelled "Cleaned for O 2
services”.
9.12.5. CRYOGENIC
Gases with a boiling point below -130°F (-90°C) at atmospheric temperature are
considered cryogenic gases. They are extremely cold and can produce intense burns
(similar to heat burns) and tissue necrosis may be even more severe. They can be non-
flammable, flammable or oxidizing. Cryogenic liquids can build up intense pressures.
At cryogenic temperatures, system components may become brittle and crack.
Never block a line filled with cryogenic liquid as a slight increase in temperature can
cause tremendous and dangerous build-up of pressure and cause the line to burst. The
system should also be designed with a safety relief valve and, depending upon the gas, a
vent line. To protect from injury, always wear gauntlet gloves to cover hands and arms,
and a cryogenic apron to protect the front of the body.
Wear pants over the shoes to prevent liquids from getting trapped inside your shoes.
Wear safety glasses and a face shield as cryogenic liquids tend to bounce upward when
spilled.
9.12.6. TOXIC OR POISON
Gases that may produce lethal or other harmful effects on humans are classified as toxic
or poison. They can be high pressure, reactive, non-flammable or flammable, and/or
oxidizing in addition to their toxicity. The degree of toxicity and the effects will vary
depending on the gas; however, death will occur when breathed in sufficient quantities.
The permissible exposure levels must be strictly adhered to.
Never work alone with toxic gases - a backup safety person is essential! Inspect the
entire assembly or system that will contain the gas and thoroughly test it for leaks with
an inert gas before use. Purge all lines with an inert gas before opening the cylinder
valve or breaking connections.
Use toxic gases in a well-ventilated area. For safety purposes and to minimize exposure,
it is important to have gas detectors. It is preferable that the breathing apparatus be
stored in a safe area immediately adjacent to the work area, so that in the event of an
emergency, a person can go directly into the area and close the door and safely put on
the apparatus.

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 Full body showers, eye washes, fire alarms and fire fighting equipment should be in the
area of use and readily accessible. Refer to your local building code for storage and use
requirements for toxic gases. Keep your inventory of toxic or poison gases to a
minimum. When a project is completed, return leftover cylinders to your gas supplier.
Some useful definitions related to industrial gases follow:
9.12.7. COMPRESSED
Non-flammable material or mixture that is contained under pressure exceeding 41 psia
(3 bar) at 70°F (21°C) or any flammable or poisonous material that is a gas at 70°F
(21°C) and 14.7 psia (1 bar) or greater.
Most compressed gases will not exceed 2,000 to 2,640 psig (138 to 182 bar) though
some go up to 6,000 psig (414 bar).
9.12.8. NON-LIQUEFIED COMPRESSED
Chemical or material other than gas in solution that under the charged pressure is
entirely gaseous at a temperature of 70°F (21°C).
9.12.9. LIQUEFIED COMPRESSED
Chemical or material that under the charged pressure is partially liquid at a temperature
of 70°F (21°C).
9.12.10. COMPRESSED GAS IN SOLUTION
Non-liquefied compressed gas that is dissolved in a solvent.
9.13 SAFETY PRECAUTIONS IN PRESSURE AND VACUUM TESTING
The testing of systems using extreme vacuums can result in collapse of the pressure
envelope. If this is a tank or vessel, then there could be damage to the test object.
Where the test system is testing using pressurization above its normal working level, it
follows that the tester should be prepared for the consequences of failure. This means
that there may need to be protective barriers or screens, but all such precautions will be
specifically dedicated to the risk involved in the test.
9.14 INDUSTRIAL SAFETY STANDARDS, HYDROTESTING OF PIPE,
PIPELINES AND VESSELS
Hydrostatic testing of pipe, pipelines and vessels is done to ensure safe operation at
design pressures, to expose possible leaks and to serve as a final validation of structural
integrity. ASME B31.3 section 345 (2010) requires hydrostatic testing to ensure
tightness and strength.
For buried high pressure pipelines, testing for strength is done by pressurizing them to
125% of their maximum operating pressure, in other words, 80% of specified minimum
yield stress or hoop stress. During the testing, it is essential to ensure that excessive
plastic deformation does not occur. On the other hand, BS PD 8010-3 (2004) requires
testing to 150% of the design pressure.
This should not be less than the maximum operating pressure plus surge and other
incidental effects that might occur during normal operation. Most countries have strict
legislation that requires pipelines and pressure vessels to be periodically tested,
typically every two years using visual inspection for high pressure gas cylinders and
five or ten years for low pressure systems.

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9.15 DANGER IN PRESENCE OF HYDROGEN
Hydrogen poses unique challenges due to its ease of leaking, low-energy ignition, wide
range of combustible fuel-air mixtures, buoyancy, and its ability to embrittle metals that
must be addressed to ensure safe operation. Hydrogen can be explosive under specific
concentration, temperature and pressure conditions. Special precautions are needed for
testing, handling and plant personnel safety. Liquid hydrogen poses additional
challenges due to its increased density and extremely low temperatures. Hydrogen-air
mixtures can ignite with very low energy input, for reference, an invisible spark can
cause ignition. The minimum energy required for spark ignition at atmospheric pressure
is approximately 0.02 millijoules.
The flammability limits based on the volume percent of hydrogen in air at 1 atm (101
kPa) are 4.0 and 75.0 while they are 4.0 and 94.0 for hydrogen in oxygen. The
explosive limits (upper and lower limits of percentage composition of a gas mixture
explodes when ignited) of hydrogen in air are 18.3 to 59 percent by volume. Hydrogen
collects under roofs and overhangs, where it forms an explosion hazard and this calls
for good ventilation. Hydrogen pipes should be located above other pipes to prevent
explosion hazards. Hydrogen leaks can support combustion at very low flow rates, as
low as 4 micrograms/s.
Flames in and around pipes or structures can create turbulence that causes a
deflagration or detonation. Further, hydrogen diffuses extensively and is particularly
subject to leakage with high leak rate because of its low viscosity and low molecular
weight (leakage is inversely proportional to viscosity).
The leak rate is 50 times that of water, and 10 times that of liquid nitrogen. Hydrogen
sensors allow for rapid detection of hydrogen leaks. As in natural gas, an odorant can be
added to hydrogen sources to enable leaks to be detected by smell. It is difficult to see
hydrogen flames with the naked eye. However, they are readily seen by UV or infrared
detectors.
9.15.1. LEAKAGE, DIFFUSION, AND BUOYANCY
These hazards result from the difficulty in containing hydrogen. Hydrogen diffuses
extensively, and when a liquid spill or large gas release occurs, a combustible mixture
can form over a considerable distance from the spill location.
Hydrogen, in both the liquid and gaseous states, is particularly subject to leakage
because of its low viscosity and low molecular weight (leakage is inversely proportional
to viscosity). Because of its low viscosity alone, the leakage rate of liquid hydrogen is
roughly 100 times that of JP-4 fuel, 50 times that of water, and 10 times that of liquid
nitrogen.
Hydrogen leaks can support combustion at very low flow rates, as low as 4
micrograms/s. Condensed and solidified atmospheric air, or trace air accumulated in
manufacturing, contaminates liquid hydrogen, thereby forming an unstable mixture.
This mixture may detonate with effects similar to those produced by trinitrotoluene
(TNT) and other highly explosive materials.
Liquid Hydrogen requires complex storage technology such as the special thermally
insulated containers and requires special handling common to all cryogenic substances.
This is similar to, but more severe than liquid oxygen. Even with thermally insulated
containers it is difficult to keep such a low temperature, and the hydrogen will gradually
leak away (typically it will evaporate at a rate of 1% per day).

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 Hydrogen collects under roofs and overhangs, where it forms an explosion hazard; any
building that contains a potential source of hydrogen should have good ventilation,
strong ignition suppression systems for all electric devices, and preferably be designed
to have a roof that can be safely blown away from the rest of the structure in an
explosion. It also enters pipes and can follow them to their destinations.
Hydrogen pipes should be located above other pipes to prevent this occurrence.
Hydrogen sensors allow for rapid detection of hydrogen leaks to ensure that the
hydrogen can be vented and the source of the leak tracked down. As in natural gas, an
odorant can be added to hydrogen sources to enable leaks to be detected by smell.
While hydrogen flames can be hard to see with the naked eye, they show up readily on
UV/IR flame detectors.
9.16 SPARKING AND COMBUSTION
Working with fuel gases including hydrogen in potential low concentrations requires
especial prudence in the use of hand tools and electrical equipment. The worker should
always be conscious of the potential for ignition and combustion. The clash of steel
tools could result in a spark, electrical equipment could short and cause an arc, and dry
clothing could result in static electricity which could also be an ignitor for the right
mixture of fuel and oxidant.
In bubble testing, simple soap or detergent solutions in water are effective and
economical indicators. If working on a line or vessel that contains, did contain or could
contain oxygen, the worker needs to be aware that some detergents contain
hydrocarbons and hence the danger of providing a fuel in the presence of pure oxygen
could have disastrous results.
9.17 EQUIPMENT SAFETY PRECAUTIONS
9.17.1 GENERAL SAFETY
1. For safety it is essential that all products are installed, operated and maintained
in accordance with the instructions supplied with them.
2. Unless specifically supplied for such use, most products are not suitable for use
outdoors or in the presence of flammable atmosphere, or in any location for
which special safety regulations apply or special precautions are necessary.
3. Vacuum systems do not provide protection against toxic, biologically or
chemically hazardous materials that may be processed therein or be evolved as a
result of processes that may be carried out under vacuum. It is necessary for the
user to provide appropriate safeguards.
9.17.2. IONIZATION GAUGES
The heads of these gauges operate at a high voltage. Connection and disconnection of
the gauge head from the supply should only be done with the gauge supply
disconnected from the mains.
The external surfaces of the gauge heads can reach high temperatures and suitable
shrouding should be provided if accidental contact is likely.
9.17.3. PUMP OILS
1. Mineral-oil-based products are only slightly to moderately irritating to the skin
and eyes. Prolonged exposure of the skin to mineral oils may give rise to
dermatitis.

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 2. Care should, however, be taken to avoid inhalation of vapours or mists arising
from undue heating or excessive mist generation. In the case of fluorinated
compounds (e.g. Fomblin) avoid contact with excessive heat ( 280 C), e.g.
lighted cigarettes, heater elements, etc.
3. Where oxygen or aggressive materials have to be pumped, an inert and
chemically resistant lubricant must be considered. Suitable members of fully
fluorinated oils can be used.
9.17.4. MOTOR DRIVEN PUMP
When a motor driven pressurizing pump is used, following actions should be
considered to avoid exceeding the pressure test:
- To install a safety valve, of such a capacity as to blow off the maximum pump
flow.
- To install a control pressure gauge near the pressurizing pump.
- To install an emergency off-switch near the pressure gauge.
- To designate personnel for full time pressure checking and to switch off the
pressurizing pump.
9.17.5. TURBOMOLECULAR PUMPS
The pumps are not normally designed to run at or near atmospheric pressure and
certainly should not be run or rotated with the inlet exposed at atmospheric pressure
without a shield on the inlet.
9.17.6. VACUUM SYSTEMS AND PROCESS PLANT
9.17.6.1 Hoists
Hydraulically operated hoists can become hazardous due to incorrect maintenance or
damage. They should have periodic checks for loss of hydraulic fluid and for jerky
operation, which is an indication of air leakage into the hydraulic system.
9.17.6.2 Exposure of human body to vacuum
1. No part of the human body should be exposed to vacuum.
2. Evacuation of the whole body will result in death and the exposure of small
areas of the body surface to the suction of the pumping system can result in
tissue damage.
3. Where large vacuum chambers have to be entered by personnel for loading,
cleaning or maintenance reasons, procedures must be designed to prevent
accidental evacuation of the work chamber with personnel inside.
9.17.7. LEAK DETECTION EQUIPMENT
High-frequency sparks testers:
These units generate a high-frequency, high-voltage spark from an accessible
unshielded probe.
2. They can ignite flammable material and should not therefore be used where
flammable material is present.
3. Bodily contact with the spark should be avoided at all times and the spark
testers should only be used by responsible trained personnel.

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 4. A serious electric shock is unlikely to be received if the probe is accidentally
touched while operating, but injury could occur if the spark reached sensitive
parts of the body (e.g. eyes). There could be a risk to persons suffering from
heart weakness.
5. Spark testers are used to test evacuated glass systems. Suitable eye protection
must be worn during testing.
9.18 USE OF MATERIAL SAFETY DATA SHEET
In the past, it was often difficult to know the hazards involved in the use of a chemical
product. If the product was highly flammable or toxic, a label was required to carry
certain warnings. However, as product liability cases began to award large settlements
to users injured by products carrying insufficient warnings, some suppliers began to
provide relatively detailed hazard information about their products.
In November 1985, it became easier to assess the hazards of chemical products to
determine their safest use. At that time, a ruling by the Occupation Safety and Health
Administration, OSHA Hazard Communication Rule became compulsory and
mandated the use of material safety data sheets (MSDS) for all chemicals that are
hazardous or contain hazardous ingredients. The MSDS must be supplied to a customer
with the initial shipment of any applicable chemical and must be updated whenever
significant new information is discovered. Material safety data sheets must be available
to the user of the product in the work area.
The format for the MSDS may be taken from the US Department of Labour’s
nonmandatory form or it may be a supplier’s individualized form.
The different sections of the (MSDS) form are as under:
(i) Section I
Section I of the form identifies the product and the party responsible for the product.
This section includes the product name as found on the container label and the name,
address and telephone number of the manufacturer, importer or distributor.
(ii) Section II
Section II lists all the hazardous materials in the product as well as an indication of their
breathing hazards. The permissible exposure limit mandated by OSHA (PEL) is the
maximum concentration that an inspector is permitted to breathe during eight hours in
twenty-four.
(iii) Section III
Section III lists relevant physical properties such as volatility, vapour pressure,
flammability, etc. of the product. These are important because they can aggravate or
sometimes diminish the effects of the hazards, listed in Section II. The need for
knowing them is very essential.
(iv) Section IV
More detailed fire and exposure hazards are listed in MSDS Section IV.
(v) Section V
Section V lists materials that may be dangerously reactive. The intent of this listing is to
provide warnings about material compatibilities, as a guide for storage or use of the
substances in mutual contact.

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 (vi) Section VI
Section VI specifies the types of exposure to guard against (rout of entry) and the acute
and chronic health conditions that can accompany over exposure to hazardous
materials.
(vii) Section VII & VIII
Earlier sections of the MSDS point out safety hazards and discuss how to deal with
them when they arise. Section VII and VIII discuss preventive measures - the means of
avoiding hazards in the first place.
Handling and storage precautions are generally based on simple good housekeeping.
Flammable, combustible or pressurized products should not be stored near heat sources.
9.19 PSYCHOLOGICAL FACTORS AND SAFETY PROGRAMME
No worker should endanger his health or his physical well-being in the course of his
duties. It follows that any industrial activity should be conducted safely and with due
respect to the environment. Generally there are laws and rules of good practice that
govern every workplace. Inspectors often are only temporary visitors to the workplace.
Although most service sites now provide site specific safety training as a condition of
working on that site, the inspector still finds the occasional site where he has to apply
his own common sense and the rules of his employer.
Every employee (and supervisor and manager) must be aware of their individual
responsibility for their own safety. Safe work practices are documented for all activities
including testing, and the worker must be aware of these practices.

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 REVISION EXERCISE NO. 9

1. What are the important safety considerations for leak testing personnel?

2. Why leak testing personnel be aware of job hazards and be properly trained?

3. Enlist awkward maneuvers while performing leak testing?

4. Why the test surface is precleaned for leak testing?

5. What are the hazards of liquid leak tracers?

6. What are the preventive measures which should be adopted to prevent the hazards of
liquid leak tracers?

7. Why the access to test surface in large structures is hazardous?

8. Which tracer gas or gases are used for many chemical indicator leak tests?

9. Which tracer gas is most widely used in leak testing with mass spectrometer?

10. Which are the characteristics, the Helium gas possess?

11. Which gases act as asphyxiant by displacing the amount of air necessary to support
life?

12. What safety mesures must be adopted by the operating personnel when working with
penetrating radiation sources such as Krypton-85?

13. What are the necessary General Safety precautions of the usage of leak testing
equipments?

14. What hazardous effects are caused by mineral-oil-based products?

15. What type of lubricant must be used when oxygen and aggressive materials have to be
pumped?

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16. What care should be taken while operating turbomolecular pumps?

17. What care should be taken when hydraulic hoists are operated?

18. What are high frequency spark testers and what are its hazards?

19. Which section of Material Safety Data Sheet (MSDS) deals with, the Name of the
product as found on the container label, the name, address and telephone number of
the manufacturer, importer or distributor?

20. Which section of (MSDS) deals with relevant physical properties of the product e.g.
volatility vapour pressure, flammability etc.?

21. Which section of MSDS deals with Safety Hazards and discuss how to deal with them
when they arise?

22. The permissible exposure limit mandated by OSHA (PEL) is?

23. How many sections Material Safety Data Sheet (MSDS) have?

24. What are the disadvantages of exposure of human body to vacuum?

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 MULTIPLE CHOICE QUESTIONS

1. Leak testing is performed on many jobs at:

a. Odd hours and under awkward conditions.
b. Night shift work and week-end work.
c. Work in unheated areas in summer and uncooled areas in winter.
d. All of the above.
e. Both a & b.
2. When a pressure or vacuum vessel is fabricated it is tested at a pressure
a. Which sometimes exceeds the designed initial pressure.
b. Which is less than the designed initial pressure.
c. Both a & b.
d. All of the above.
3. Sometimes, Argon gas is used as a leak tracer gas due to:
a. Its abundant presence in the a gas family rare
b. Mon atomic and extreme chemically inactive.
c. Colourless odourless and Non-toxicity.
d. All of the above.
e. Both a & b.
4. Connection and disconnection of the gauge head (Ionization Gauges) from the supply
should only be done with the gauge supply disconnected from the mains because:
a. Heads of gauges operate at a high voltage.
b. Heads of gauges operate at a low voltage.
c. Both a & b.
d. All of the above.
e. None of the above.
5. In case of pump oils, care should be taken to:
a. Avoid inhalation of vapours or mists arising from undue heating or excessive
mist generation.
b. Avoid contact with excessive heat (≥280°C) in case of fluorinated compounds.
c. Inhalation and contact with excessive heat do not have any effect on operating
personnel.
d. Both a & b.
e. None of the above.

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