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

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.