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H.M. Warmerdam
EST Group, The Netherlands
D. Kobziar,
EST Group, USA
P ressure testing the fabrication and repair removed from the hot work area during both the
of welded flange connections under welding and pressure testing phases.
ASME code traditionally requires several
steps: Over the last three decades, pipe flange isolation
1. Isolating the weld area and hydrostatic testing plugs are available to
2. Welding the flange/pipe assist maintenance staff and contractors perform
3. Blinding the pipe ends flange change outs onsite. Typical markets for
4. Filling the piping system with test media these products include refineries, chemical and
5. Pressurizing the pipe to piping system petrochemical plants, fertilizer plants, power
6. Draining and properly disposing of the test plants and other industrial applications.
medium
In addition to replacing or adding flange
Testing flange to weld connections in this way connections on site, concerns over verifying
is tried and true but can be time consuming and adequate joint strength, when pressure testing
expensive when factors such as disposal of the welded flange connections, have been brought
potentially contaminated test medium, system to light in the marketplace.
downtime, and labour hours required to perform
the work, are included with the cost of EST Group, a business unit of Curtiss-Wright
materials. In situations where the welded flange Flow Control Company, is a global
connection is attached to piping that contains manufacturer and designer of pipe and tube
potentially explosive vapors, the safety of pressure testing and plugging equipment,
With an increasing focus on safety worldwide, The plug is positioned upstream of the hot work
the need for new innovations that ensure safer area and utilizes a double-seal design to create a
working environments has increased. cavity between the seals. One of the ported
Specifically, customers required a product that connections on the plug is used to fill the cavity
would verify that hot work areas were free from with an inert medium while the other provides
explosive vapors and gases. venting of any explosive vapors or back
pressure that may exist upstream. The inert
The Double Block & Bleed Test Plug (DBB) medium is placed under pressure in the cavity
shown in Figure 3, addressed this requirement and as long as the pressure is greater than the
and revolutionized isolation and testing of pipe potential upstream pressure, no explosive vapors
connections. can propagate into the hot work area. After
welding is completed, the plug is repositioned to
allow for hydrostatic testing (Figure 4).