Hydrotester Operator

Core Responsibilities

• High-Pressure Testing: Operate the hydraulic hydrotester to fill, vent, and pressurize LSAW pipes to the specific test pressure required by the project (often 90% to 100% of specified minimum yield strength).
• Pressure Chart Management: Monitor and record Pressure vs. Time charts. Ensure the Hold Time (typically 10–30 seconds) is strictly maintained as per specified requirements.
• Leak Detection: Conduct visual inspections during the hold period to detect any sweating, pinhole leaks in the weld seam, or seal failures at the pipe ends.
• Machine Calibration: Perform daily checks and periodic calibration of pressure transducers and master gauges to ensure 100% accuracy in pressure readings.
• Tooling & Seal Management: Select and maintain the correct Seals based on pipe diameter and wall thickness to prevent end-leaks during testing.
• Water Chemistry Control: Monitor the quality of the test water (including pH levels and corrosion inhibitors) to prevent internal oxidation or contamination of the pipe.

Technical Skill Set

• HMI/PLC Operation: Proficiency in operating automated control panels from manufacturers like Haussler, SMS Group.
• Hydraulics & Pneumatics: Understanding of high-pressure pumps, intensifiers, and rapid-fill valves.
• Mathematical Calculation: Ability to calculate test pressures based on pipe grade, diameter, and wall thickness using API formulas.
• Data Logging: Experience with digital chart recorders and integrating test data into SAP or Manufacturing Execution Systems (MES).

Key Qualifications

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  Education: ITI (Fitter/Mechanical) or a Diploma in Mechanical Engineering.
• Experience: 3-8 years of hands-on experience in high-pressure hydro-testing within a large-diameter pipe mill (LSAW/HSAW/SMLS).
• Industry Background: Candidates from similar industries are preferred for their familiarity with rigorous client-witnessed testing.

Preferred Attributes

• Extreme focus on high-pressure safety.
• Absolute honesty in chart recording; understanding that a hydrotest failure is a critical safety indicator for the end-user.

Employer Specific Expectations

• For Saudi Aramco / East Pipes: Strict adherence to specification requirement
• Focus on minimizing Cycle Time (filling/emptying speed) to maintain high-tonnage throughput without compromising safety.