WILLBROS

A Good Job On Time

Hydrostatic Testing Practices

Establishing Verifiable, Traceable,
and Accurate Documentation

August 20, 2013

Hal Ozanne
Willbros Engineers
 Hydrostatic Testing Practices

Verifiable, Traceable, Accurate Documentation

Hydrostatic Testing Calculations
Hydrostatic Test Plans
Hydrostatic Test Reports
Data Collection and Final Verification

Pipeline and Hazardous Materials

Safety Administration (PHMSA)
Audits
Record Keeping
Approvals/Signatures

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 Hydrostatic Testing Practices

Hydrostatic Testing Calculations

Detailed calculations based on pipe characteristics and specifications
OD, wt, grade, weld/seam type, length of segment
Flange or no flanges (ANSI rating could be limiting factor for pressure)
Based on 100% SMYS or 125% MAOP
Surveyed pipe elevations
Test medium, volume, and temperature constraints

Segment lengths based on elevations and SMYS requirements

Project Management Review and Approval
Engineering Project Manager
Client Project Manager

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 Hydrostatic Testing Practices

Hydrostatic Testing Calculations

MAOP Verification calculated and determined by final hydro test results
TEST SEGMENT 1 PIPE UNITS
Pipe OD (in) 12.75 IN
Pipe WT (in) 0.25 IN
Pipe Grade 60,000 PSI
MAOP (psig) 1,440 PSIG
Segment Legnth (ft) 100,000 FT
Design Factor 0.72 Determined by Class Location
Required Testing Factor 1.25 Based on design factor for the Class Location
SMYS Pressure 2,353 PSIG
DETERMINE WHICH MINIMUM TEST PRESSURE BELOW WILL BE USED AT HIGH POINT OF TEST SEGMENT
Minimum Test Pressure 1,800 Per code based on required testing factor and MAOP
Minimum Test Pressure 2,118 = 90% SMYS
Selected Min Test Pres. 2,118 PSIG
DETERMINE WHICH MAXIMUM TEST PRESSURE BELOW WILL BE USED AT LOW POINT OF TEST SEGMENT
Maximum Test Pressure 2,160 Test Factor of 1.5 based on 1.25 min test pressure above
Maximum Test Pressure 2,353 = 100% SMYS
Selected Max Test Pres. 2,353 PSIG
612,211 GAL
Test Segment Volume
14,576 BBL
CHECK NOTES BELOW REGARDING DEAD WEIGHT PRESSURES COMPARED TO TEST PRESSURES
Dead Weight Pres. Min 2,118 PSIG
Dead Weight Pres. Max 2,353 PSIG
Dead Weight Elevation 5,902 FT
STATION # TEST PSIG % SMYS CALCULATED MAOP
Begin Point Elevation, FT 5,902 0+00 Calculated Min Test Pressure 2,247 95.5% Test pressure is within range of minimum and maximum test pressure 1,618
Begin Point Elevation, FT 5,902 0+00 Calculated Max Test Pressure 2,219 94.3% Test pressure is within range of minimum and maximum test pressure N/A
Low Point Elevation, FT 5,594 1107+35 Calculated Min Test Pressure 2,381 101.2% TEST PRESSURE OUT OF ACCEPTABLE RANGE - CHECK SEGMENT 1,714
Low Point Elevation, FT 5,594 1107+35 Calculated Max Test Pressure 2,353 100.0% Test pressure is within range of minimum and maximum test pressure N/A
High Point Elevation, FT 6,201 590+86 Calculated Min Test Pressure 2,118 90.0% Test pressure is within range of minimum and maximum test pressure 1,525
High Point Elevation, FT 6,201 590+86 Calculated Max Test Pressure 2,090 88.8% TEST PRESSURE OUT OF ACCEPTABLE RANGE - CHECK SEGMENT N/A
End Point Elevation, FT 5,650 1278+29 Calculated Min Test Pressure 2,357 100.2% Test pressure is within range of minimum and maximum test pressure 1,697
End Point Elevation, FT 5,650 1278+29 Calculated Max Test Pressure 2,329 99.0% Test pressure is within range of minimum and maximum test pressure N/A
Elevation Change 607 FT
If the test pressure calcualted at any point along the test segment is less than the minimum test pressure, then the minimum dead weight pressure required will need to be increased,
Note 1:
provided it does not exceed the maximum test pressure.
If the test pressure calculated at any point along the test segment is greater that the maximum test pressure, then the maximum dead weight pressure required will need to be lowered
Note 2:
provided that the new lower maximum test pressure is not below the minimum required test pressure.
If the minimum and maximum dead weight test pressure range cannot be adjsuted within the test segment to keep the test pressure within the range of the minimum and maxiumum test
Note 3:
pressure, the the test segment will need to be broken into smaller segments. 4

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 Hydrostatic Testing Practices

Hydrostatic Test Plan

Set it up right and make it fully complete with Environmental Input
To comply with permits, environmental needs to be involved to ensure
compliance (BLM, Corps of Engineers, FERC, NEPA, etc)
Advise on supply sources and discharge areas

Fabrication Test (4hr) or Mainline Test (8 hr)

Fabrication Test for HDDs and long bores prior to installation
Mainline Test for mainline (including HDDs) once in ground

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 Hydrostatic Testing Practices

Hydrostatic Test Plan

Environmental Requirements and Stipulations
Water Source
Discharge Location
Water Quality

Detailed to describe all parts of Hydro Test

Filling and pressuring up
Performing Test
Gathering Data
Completion of test
Dewatering of segment
Move water from one segment to the next or new water each segment
Drying and Cleaning
Final Verification and sign off
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 Hydrostatic Testing Practices

Hydrostatic Test Plan

Max and min test pressures for each Segment
Provide location of expected occurrence in plan
Provide expected test site location pressure

DOT/PHMSA Requirements (also use API RP1110)

Depends on type of test (spike test, strength test, leak
test)
Pressure test medium, equipment, and materials
Qualifications of contractor and personnel performing
test
Test period, failures, leaks
Test records and drawings kept for useful life of pipeline
Approval Signatures (operator of test, witness of test,
personnel certifying the test)

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 Hydrostatic Testing Practices

Hydrostatic Test Plan

Acceptance Criteria established prior to conducting test
Proper Approvals and Signatures
Project Engineer
Project Manager
Construction Manager
Client Project Manager

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 Hydrostatic Testing Practices

Hydrostatic Test Report

Set it up in the beginning so that all data required to be gathered is
understood by test operators
Based on Operating Company Standards and DOT/PHMSA
Requirements (also API RP 1110)
Attention to Detail

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 Hydrostatic Testing Practices

Hydrostatic Test Report

Proper Recording of Measurements
Pipe Diameter and wall thicknesses
Pipe Grade and SMYS and/or ANSI rating
Location and elevation
Test Medium description, source, and volumes
Any additives description and volumes
Date and time of start and stops
Pressure vs. Time log
Temperature (ambient and pipe or test medium)
Weather conditions
Segment length

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 Hydrostatic Testing Practices

Hydrostatic Test Report

Completeness of Forms and Records
Proper Approvals and Signatures
Test Operator
Operator Supervisor
Construction Manager
Project Engineer
Client Authorized Representative (can be construction manager or project
engineer in many cases)

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 Hydrostatic Testing Practices

Hydrostatic Test Data Collection

Planning and Preparation
Understanding Test Report and Forms
Anyone involved in the test or reviewing/approving of the test data
Allows those involved to know exactly what is required to be gathered and
what is required to be approved based on what is provided

Maintain and Include Raw Data Gathered into Final Test Report Book

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 Hydrostatic Testing Practices

Hydrostatic Test Data Collection

Calibration of Instruments and Equipment
High volume pump and associated piping and meter for
line fill
Injection pump for corrosion inhibitors, leak detection dyes
or gases, or other chemicals
Variable speed PD pump for pressurization with known
volume per stroke and a stroke counter
Pressure sensing device and deadweight tester
Continuous pressure recording device
Test medium temperature sensing device and display
Ambient temperature sensing device and display
Continuous temperature recording device for test medium
and ambient
Test medium sampling equipment
Gas/oxygen detecting equipment
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 Hydrostatic Testing Practices

Hydrostatic Test Data Collection

Collecting/Recording All Details and Information Required on Reports
and Forms
Test medium volumes, pressures, temperatures, times
Ambient pressures, temperatures, weather conditions
Pipe conditions and specifications (OD, wt, grade, high/low point, etc)
Instrument/Equipment calibration information
Failures, leaks, condition changes
Approvals

Maintain and Clean up All Field Notes on Drawings and Books

Incorporate into overall Test Report

Maintain All Failure Record Data for Final Book

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 Hydrostatic Testing Practices

Hydrostatic Test Data Collection

Temperature Recorders
Weather condition changes can affect volume of test medium to maintain
constant pressure on pipeline
Secure temperature bulb directly to bare pipe, insulate, and backfill to ground
level 12 hr prior to test
12 hr allows for fill medium, pipe, and ground temps to stabilize
Locate temperature bulbs on pipe a minimum of 500 from exposed pipe

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 Hydrostatic Testing Practices

Hydrostatic Test Data Collection

Temperature Changes
As temp increases, pressure increases
As temp decreased, pressure decreases
Temp changes can affect volume of medium in pipe
Important to not conduct test during periods of day when temperature change
is significant (frost levels play important role in test temperature as well)

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 Hydrostatic Testing Practices

Hydrostatic Test Data Collection Test Start Date: Month Day, Year Test End Date: Month Day, Year Readings should be taken every 15 minutes for test
R E M A R KS : (No te any additio ns/withdrawals o f test medium, start
TIME

O B S . P R E S S UR E T EM P . T EM P . T EM P . T EM P .

Small Leak or Change in Temperature?

and sto p o f test, pressure reductio ns, weather changes, o r anything
(24 Hr. Clock) (Deadweight Reading) Ambient Exposed Pipe Buried Pipe, 1 Buried Pipe, 2 else that may affect the test.

Compare change in pipe temp to change in

weather conditions
Change in pipe temp should correlate to
change in ambient temp (changes show up
on temperature plot for test)
Corrected volume equations at beginning
and end of test account for change in
pressure and temperature which correlates
to change in volume
Spreadsheet set up to determine corrected Test Supervisor Signature

volumes - part of test plan/report Test Operator Signature

* Contractor shall provide means of volumetric changes to line prior to test.

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 Hydrostatic Testing Practices

Final Verification
Verify that final book is complete and contains all information in one
location
Hydro Test Plan and Calcs
Test specifications
Survey data
Calibration certificates
Hydro test reports
Original test charts

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 Hydrostatic Testing Practices

Final Verification
If all required data is in one place, then it is easier to gather, maintain,
and deliver to auditors
Ensure that the following people have signed off on the Test Report and
Data Collected
Field Person Responsible for Gathering Data
Field Supervisor Over Hydro Test
Construction Manager
Project Engineer
Project Manager
Client Project Manager

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 Hydrostatic Testing Practices

PHMSA
Audits
Checks during construction to verify proper records being kept
Documentation is the first thing to be checked during a field audit
First impression set the tone for the audit

Record Keeping
Records should have proper approvals and signatures on them
Should be same throughout duration of project
Fabrication testing (HDDs) and Mainline testing (main pipeline)

Documentation Approvals/Signatures
Checks for field personnel, engineering personnel, and Company personnel
signatures and approvals of test records and reports

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A Good Job On Time

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