Boia BECHTEL LIMITED STANDARD DESIGN GUIDE 306 ZO1E 022 ONSHORE PIPELINES SECTION 22 HYDROSTATIC TESTING x NS-VL-Sy5] ISSUED FOR USE Wile Ts ut 93_| ISSUED FOR REVIEW R.K. | P.A. REV DATE REVISION BY HKD APPR SEC22 306 ZO1E 022 00 Page 1 of 2722. 22.3 22. 22. 22.! 22. 22. 22. 22. 22. 22. 22. SEC22 ea Name eR wR CONTENTS: INTRODUCTION CODES TEST MEDIUM INHIBITORS EQUIPMENT PLANNING PROCEDURE LINE FILL TESTING DISPLACEMENT/DISPOSAL TEST RECORDS SAFETY APPENDICES Residual Air Determination Temperature Compensation - Water Pressure - Volume Relationship Test Record Forms/Reports 306 ZOLE 022 00 Page 2 of 2722.0 22.1 SEC22 HYDROSTATIC TESTING INTRODUCTION The purpose of hydrostatic testing pipelines is two-fold; to ensure that the pipe has the mechanical strength to withstand operating pressures and that it does not have any discontinuities which leak. This is accomplished by subjecting the pipeline test sections to the following: IA strength test A tightness test 22.141 22.1.2 Strength Test ‘The minimum duration of the strength test is normally four hours. The amount of pressure to be applied at the low point of each test section involved is specified, or must fall within a range specified by the applicable code to which the pipeline is designed. During the strength test, pressure is maintained by additional pumping if necessary. Normally, the hydrostatic test pressures for sections of cross country pipelines are calculated to develop a hoop stress of 90% of the minimum specified yield strength at the lowest point of the test section. When lines are tested at pressures which develop a hoop stress in excess of 90% of the specified minimum yield strength of the pipe, special care must be exercised to ensure the combined stress in the pipe (hoop stress, temperature stress, plus longitudinal bending stress) does not exceed the minimum yield strength. Tightness Test The tightness test is usually maintained for not less than 24 hours without pumping. 306 ZO1E 022 00 Page 3 of 2722.2 22.3 SEC22 At the end of the test period, the pressure of the test section must equal the pressure recorded at the beginning of the test. Any difference in pressure upon completion of the tightness test must be attributable to temperature change alone. If temperature variation cannot account for the difference in pressure, a retest is required. CODES The hydrostatic testing of newly constructed pipelines and replaced segments of existing pipeline facilities must be performed in accordance with the requirements set forth in local national codes and applicable governmental regulations. Some of the better known codes are: ANSI 8.31.4 ANSI 8.31.8 BS 8010 1P6 Institute of Petroleum 1GE/TD/1 Institution of Gas Engineers Some codes are more severe than others, especially where leak testing is concerned. The particular requirements of the applicable code must be well known prior to the development of hydrostatic test programs. TEST MEDIUM The test medium for a hydrostatic test is not necessarily limited to fresh water. Brackish or sea water may be used provided suitable chemical treatment is applied. Needless to say, local codes and regulations will govern in the choice of the test medium as well as the environmental impact of the test medium should there be a leak. 3D ZO1E 022 00 Page 4 of 2722.4 22.5 SEC22 INHIBITORS Two basic problems can be expected in using water or seawater to hydrotest; oxygen corrosion and bacteria. Oxygen in the water reacts with the steel until the oxygen is depleted. The problem can be significant and chemical inhibition is usually recommended if the water is to remain in the line for a month or longer. For shorter periods, oxygen may be removed by the use of an oxygen scavenger, a chemical which reacts with oxygen in the water. Bacteria growth (sulphate reducers), may not be a significant problem during the hydrotest period but are capable of setting up corrosion cells which will continue to exist during the operation of the pipeline. Bactericides are available which will control sulphate reducing bacteria in water. Before specifying the use of any inhibitor, specialist guidance must be obtained. EQUIPMENT 22.5.1 Equipment Used For Hydrotest Equipment for hydrotest must be properly selected and in good working order. Equipment affecting the accuracy of the measurements used to validate the specified test pressure must be designed to measure the pressures to be encountered during the hydrotest. Equipment will normally include the following: a) A high volume pump capable of filling the line at a minimum velocity of 0.9m/s. (Note, on large lines, this can prove difficult and a smaller pump may have to be selected, this will not however help to sweep air fram the line). 3DG ZOIE 022 00 Page 5 of 27SEC22 b) 4) f) 9) A test medium supply line filter capable of ensuring a clean test medium. Chemical inhibitors and injection units. A flow meter for measuring line fill, the accuracy of which should be a least equal to 0.2% of the added volume needed to produce a hoop stress equal to the SMYS, A variable speed, positive displacement pump capable of pressurising the line at least 700 kPa (approximately 100 psi) in excess of the specified test pressure. The pump should have a known volume per stroke and should be equipped with a stroke counter. (A constant speed pump having a variable flow rate contro} may be used in liew of the above if the liquid test medium injected into the pipeline is measured during pressurisation). A calibration tank to measure displaced volume of the pump should be piped into the circuit to provide spot checks of the volume rating during pressurisation. A portable tank, if required, capable of providing a source of liquid test medium for topping up etc. (10 minutes supply). A large diameter bourdon tube type pressure gauge with a pressure range and increnent divisions necessary to indicate anticipated test pressures. Pressure measuring equipment should have an accuracy and repeatability of 20.1%. A 24 hour recording pressure gauge with charts and ink. This gauge should be deadweight tested immediately prior to and after use. 306 Z01E 022 00 Page 6 of 27SEC22 22.5.2 5) Two glass laboratory thermometers, with a 75mm (approximately 3 inches) immersion capability, capable of measuring temperatures from 0°C (32°F), to 50°C (122°F). The accuracy of the equipment should be +0.1°C (0.18°F) . k) A 24 hour recording thermometer capable of recording temperatures from 0°C (32°F), to 50°C (122°F). The accuracy of the equipment should be +0.1°C (0.18°F). 1) Pigs, scrapers, spheres and similar devices to be used to clean and swab the test segment and remove air from the line. All such devices should be equipped with location devices. mn) Temporary manifolds and connections as required (see Figure 1). Notes On Equipment Arrangement The deadweight pressure gauge, pressure recorder and dial pressure gauge are on a common manifold connected to the pipeline by a high pressure hose. This enables the test station to be situated a safe distance from the line, at least 30 metres. To ascertain when thermal equilibrium has been reached between the pipeline and the surrounding environment, thermometers (or thermocouples) should be placed both on the pipe to measure the temperature of the test fluid and in the surrounding soil at a depth equal to the pipeline centre line, as shown in Figure 2. 3DG ZO1E 022 00 Page 7 of 27“4 avosiwen 4524 21,¥150H04N 1 3unald as orl pineam e@ 3yHNOIS G@ }22.6 PLANNING The following factors must be considered in developing a hydrostatic test programme: a) The maximum operating pressure anticipated through the life of the pipeline. On liquid lines which usually have a pronounced hydraulic gradient due to friction losses, the operating pressure reduces considerably with distance from the upstream pump station. This may allow the application of lower test pressures and thus permit longer and fewer test sections; provided, of course, that the pipeline is not being designed for full shut-in pressure equivalent to the maximum discharge pressure of the upstream station. b) Location of pipe and other piping components in the test segment by size, wall thickness, grade type and internal design pressure(s). All or any one of these items will affect the test pressure to be applied and the length and number of test sections into which the total pipeline is to be segmented. 5) Shel} pressure rating and location of all pipeline valves, air vents, and connections to the test section. Particular care must be given to the pressure ratings of valves and other fittings and/or appurtenances which will be tested as a part of the pipeline test section. Situations have occurred where the maximum permissible test pressure for these items has been less than the planned test pressure for the pipe. d) Anticipated temperature of test medium, atmosphere and ground. SEC2Z 306 ZO1E 022 00 Page 8 of 2722.7 SEC22 Pressure varies with temperature and over pressuring of the pipe during the test is a possibility which must be planned for. In cold climates, freezing of the test medium and its consequences must be considered. e) Source(s) of test medium and necessary chemical treatment, if required. f) Locations and requirements for test medium disposal. Environmental impact, possible damage, and the requirements of local regulatory agencies must be considered in determining the locations and method of test medium disposal upon completion of the hydrostatic test. 9) Profile and alignment drawings and maps. h) Safety precautions and procedures. PROCEDURES Prior to hydrostatic testing, a detailed test procedure must be prepared and approved. Such a procedure must as a minimum include the following: a) A detailed hydrostatic test diagram showing the lengths and locations of the test segments with their respective minimum and maximum specified test pressures (see Figure 3); b) The source(s) and the test medium to be used, including the points of injection; <) Chemical inhibitors, if required, and dosage to be used. d) A detailed list of equipment required. e) A procedure for cleaning and filling the line. 306 Z01£ 022 00 Page 9 of 27© gungrd Bit tg pay bid22.8 SEC22 f) 9) h) i) ALINE FILL 22.8.1 A procedure for determining the volume of residual air in the filled test section. A procedure for pressurising the test section including minimum hold times for each of the two types of tests, strength and tightness. A procedure for locating and repairing leaks. A procedure for the displacement and disposal of the test medium, Applicable safety precautions and associated procedures. Cleaning Anew pipeline will initially contain a quantity of millscale, dross, welding rods, silica and sand, and other miscellaneous items. These must be removed prior to running the gauging pig through the test section, otherwise there is a good possibility that the pig will become stuck. Where the quantity of debris is expected to be high, the construction specifications should require the contractor to run swabbing pigs by compressed air through his tie-in sections prior to tying in. The bulk of the debris can be removed in this way by running the pigs as often as necessary. Then, before filling the test section, a column of the test liquid of the order of 500 metres long, should be pumped into the line ahead of any pigs to act as a wash, 306 ZO1E 022 00 Page 10 of 27SEC22 22.8.2 22.8.3 Gauging A gauging pig is used to ensure that the line is free of dents, buckles, or other obstacles. The gauging pig consists of a conventional cup pig with a thin circular plate mounted on the front end. The plate may be steel (Sm thick) or aluminium (10mm thick) with a diameter usually 95% of the smallest internal pipe diameter to be encountered in the test section. The gauging pig is normally run behind the cleaning pigs during line filling. while running the pigs, a plot of the driving pressure should be maintained and monitored for any unexplainable increases in pressure which may indicate that pipe damage has temporarily or totally blocked the pig. On completion of the gauging run and ahead of pressurising the test section, the plates should be inspected to determine if any pipe damage exists. If the plate is deformed, the damaged pipe must be located and repaired or replaced. As an alternative to or in conjunction with the gauging pig, an electronic "caliper" pig may be run. Filling The line fi11 operation usually occurs concurrently with the cleaning and gauging of the test section. Care must be taken to minimise the intrusion of air into the test section. Under normal circumstances, sufficient air is swept out of the line by the cleaning and gauging pigs to enable an accurate test to be made. However, in mountainous terrain, air may bypass the cups of the pig if column (test medium) separation occurs on downhil1 sections. 306 ZO1E 022 00 Page 11 of 2722.9 SEC22 TESTING 22.9.1 vents, if necessary, for cross country pipelines should be limited to those locations where severe entrapment of air is expected. Unrestricted use of vents tends to compromise the “tightness” of the pipeline as the vents present an additional possible source of leaks. Pumping for line fill should continue until all the pigs have been received at the receiving scraper trap. At this point, the gauging plates should be inspected for damage. Pressurisation should not begin until the temperature of the filled pipeline has stabilised. The temperatures of the test medium and the ground are plotted against time until the temperature plot of the test medium becomes asymptotic to that of the ground temperature or no temperature change occurs for a period of twelve hours. The quantity of residual air in the test section is then checked using the method described in Appendix A. Strength Test The test segment should be pressurised at a slow constant rate to approximately 70% of test pressure. At this point, the pumping rate should be regulated to minimise pressure variations and to ensure that increments no greater than 10 psi may be accurately read and recorded. The dead weight tester should be used periodically to check the calibration of the pressure recorder and all pipe connections should be periodically checked for leakage. Upon reaching the required test pressure, pumping is stopped. The pressure recorder can then be set to real time and the hold period commenced. 30G ZO1E 022 00 Page 12 of 27SEC22 22.9.2 If adding or subtracting of the test medium is required to maintain the test pressure between the pre-determined minimum and maximum values, the quantity of added or subtracted medium should be measured as accurately as possible so that a balance can be made. When testing at minimum specified yield or at actual yield, a plot of pressure versus volume is commenced at some stage within the elastic limit {normally 80% SMYS) to provide sufficient time for the speed of the test to be adjusted to approximately 10 psi/min. During the first stages of the p/v plot, the volume of water required to increase the pressure by 10 psi should be noted and as pressurisation continues this figure should be checked regularly to observe any deviation. With this method an accurate determination of yield point can be made, i.e., when yielding occurs, the volume of water required to increase the pressure by 10 psi will increase. If a leak is suspected, the pressure should be reduced for safety reasons to not more than 50% of the required test pressure before visual inspection is carried out. No work should be carried out until the pressure has been further reduced to static head plus one bar (15 psi). Tightness Test The tightness test should be maintained for not less than 24 hours without pumping. Shortly before the water in the line reaches the highest temperature of the day, the line is brought to the tightness test pressure specified. 3DG Z01E 022 00 Page 13 of 2722.10 SEC22 No further pumping is permitted for the duration of the tightness test. If the water temperature increases, the tightness test pressure is maintained by bleeding. When it is certain that the highest temperature of the day has been reached, a 24 hour chart is started. If the pipeline is completely filled with test medium (no air pockets), any temperature difference in the medium will cause variations in the pressure according to the formula in Appendix 8. If at the end of the 24 hour test period the chart does not close perfectly, the decision must be made whether this is due to leakage, or test medium temperature change, or air in the line. If there is doubt, the tightness test should be continued for anather 24 hours. With a perfect test, the chart should close at the same pressure when the starting temperature is reached approximately 24 hours later. Any leaks must be located, repaired and the tightness test repeated. DISPLACEMENT/DISPOSAI Upon successful completion of the tightness test, the test fluid should be drained from that section of the line or displaced into the next section. Displacement may be done using spheres, foam pigs, batch pigs, or similar devices using dry, oil free air or product as the propelling medium. Dependent on the test medium and the propelling medium care must be exercised to avoid any possibility of an explosive mixture forming. The disposal of the test medium must be done in an approved manner in accordance with all relevant safety and environmental protection precautions. 30G ZO1E 022 00 Page 14 of 2722.0 22.12 SEC22 ‘TEST RECORDS The records following as a) b) f) SAFETY to be prepared for each test section should include the a minimum: Log of hourly dead weight pressure readings and ambient temperatures during pressurising, strength test, leak test and stabilisation periods. Pressure recording charts for pressurising period, strength test, leak test, and stabilisation periods. Temperature recording charts for pipe test fluid and ground. Pressure volume plots, and pressurising and bleed volumes. Equipment details. The hydrostatic test forms given in Appendix D. The safety of all persons directly involved in the tests must be ensured and all necessary precautions must be taken to prevent any injury to the public and/or damage to property as a result of the test. Prior to the start of any hydrostatic test, a detailed safety procedure must be prepared and approved, and must include as a minimum, the following: a) b) The manning of any venting points for the release of air or test medium for the duration of any such venting operation. The permanent manning of each test end throughout the duration of the test. 30G ZO1E 022 00 Page 15 of 27SEC22 °) qd) e) f) The manning and patrolling of the test length commensurate with the location of the test section. The provisions of warning notices at both sides of every road and railway crossing. The permanent manning of every major crossing. The adequate notice of the intended tests to all relevant authorities, landowners, and tenants. ‘30G ZO1E 022 00 Page 16 of 27SEC22 APPENDICES Residual Air Determination Temperature Compensation - Water Pressure - Volume Relationship Test Record Forms/Reports 3DG ZOLE 022 00 Page 17 of 27APPENDIX A RESIDUAL AIR DETERMINATION To enable an accurate pressure test to be made, the air in the pipe must be removed. The cleaning and gauging operation normally sweeps out sufficient air to enable an accurate test to be made. However, the quantity of residual air should be checked. This may be done by following the procedure outlined below: a SEC22 Temperature Stabilisation The fill water and ground temperatures are plotted against time until the fill water plot becomes asymptotic to the ground temperature or shows no temperature change for twelve hours. Initial Pressurisation The test section is pressurised to approximately 50% of the final test pressure and a pressure versus pressurisation volume plot observed until the plot becomes a straight line, see Figure A-1. Measurement of Residual Air The residual air is measured by extrapolating the straight portion of the line backwards to the volume axis. The intercept indicates the air volume. If the air volume indicated is less than 0.2% of the pipeline test section, then the test may proceed. Should the residual quantity of air be too large, the line should be pigged again and the test remade. 3DG ZO1E 022 00 Page 18 of 27T-¥ nota AOTd ASSL UVLBOWOAH wosww3ane guia aang eri 1. ‘eawee wouvoy "uN ene a, ours: “2A uo) ant een ans waar ‘on oot to Qaru-sinesaua DanmonaineeauiB: soso, | an ———_ SS3udAPPENDIX B TEMPERATURE COMPENSATION - WATER VOLUME CHANGES AND POISSON'S RATIO The length of buried and above ground restrained pipelines cannot change. this effects a change in diameter due to Poisson's ratio of 0.3 for steel. As a result, the increase in pipe diameter due to internal pressure P is reduced by 9% and the increase in pipe diameter due to thermal expansion is increased by 30%. The following notations are used: pe Hydrostatic test pressure, psi Pressure increment, psi ap 29 x 10° psi (Youngs Modulus) aT = Temperature increase, °F D- Outside diameter of pipe, inch te Wall thickness of pipe, inch do = Change in pipe diameter, inch Linear thermal expansion of steel = oc, = 6.5 x 10°°/F Thermal expansion of water coef = oc, = 115 x 10°/°F Bulk modulus of water k = 0.335 x 10° psi The volume change due to change in pipe diameter equals 1/4n [(D + d0)* - 0°] equals about 1/2 DdO, assuming the term d0® is negligible. SEC22 ‘306 ZO1E 022 00 Page 19 of 27TIGHTNESS TEST The tightness test is normally carried out on buried pipelines at a pressure slightly below the strength test pressure. If temperature and pressure would be constant during 24 hours without pumping it would prove that there are no leaks in the line. However, the temperature is not exactly constant so that there will be pressure variations, which can be predicted as follows: nD? Jo.91 dPD a (pipe) = — |——— + 1.3 ocar 2 2teE nD? joc,dT - dp dV (water) = — _ 4 k Since water volume and pipe volume must be the same (no air pockets) dv (pipe) = dV (water) 0.910 1 dP = dt (oc, - 2.6 0c.) + oS Gc 4 For Example 0.91 D 1 dP = dT (115 - 2.6 x 6.5) 4 + 29 t 0.335, 3126 dP = dT (D/ t + 98) 3126 dP = dT — = 13.7 dT (dT in °F) for large diameter pipeline with 229° D/t = 134 For each °F temperature drop, the test pressure would drop 13.7 psi. SEC22 306 ZO1E 022 00 Page 20 of 27APPENDIX C PRESSURE ~ VOLUME RELATIONSHIP If the line is completely filled with water (no air pockets) the volume increase due to pumping, at constant temperature equals: 07 0.91 dPD on 0 4 L avs [— 6 eo 2teE 4 k 2 ba nL . (0.0314 (D/t + 95) dP) 4x 10 no is the volume of the pipeline section under test Where 4 SEC22 3DG ZO1E 022 00 Page 21 of 27APPENDIX D TEST RECORD FORMS/REPORTS SEC22 30G ZO1E 022 00 Page 22 of 27HYDROSTATIC TEST RECORD Contractor Testing Subcontractor . To... Section From .. Wall Thickness . Cleaning and Gauging Date Started & Completed . + Type Pigs .. Gauging Plate Diameter «mm No. Gauging Runs No. Cleaning Runs . Thickness Filling Source of Water ... tees Water Analysis issued by «22.22... co pH value corrected to 6.75 by introduction of of . -maintained Number and type of filling pigs used Time and Date filling completed Testing Elevation at: highest point .. recording point Pressure required at recording point .. ee Baaaso5c6600 Pressure pump started at ... «+ Required pressure reached at ........... Note: Subsequent repressuring and depressing to be noted on Log. Recorder, gauges and deadweight tester calibrated at .......... 24 hours test started at + (Per Log) finished at .. + (per Log) , at lowest point ... Test Approved -+Contractor .. «+ Engineer SEC22 3DG ZO1E 022 00 Page 23 of 27TEST FAILURE REPORT Schedule To Station .... To Station Station ... Station ... Test Section .... Failure No. . Date of Failure . Pressure Failure . Pressure at Pump .. ce Ambient Air Temperature - Start Pressuring . Anbient Air Temperature - Time of Failure Failure Location Straight Joint or Bend Position of Longitudinal Seam Distance End of Failure to End Joint Length of Failure . Pipe Manufacturer . Package No. «+. Replacement Pipe Manufacturer Replacement Total Length ... Property Damage Joint No. Number of Welds Remarks . Signed . Testing Contractor Engineer Signed Distribution : Yellow to Contractor Blue to Contract Manager Green te Project Manager White to Inspector SEC22 3DG ZO1E 022 00 Page 24 of 27HYDROSTATIC TEST DATA RECORD Schedule + To Station Type and Size of Pipe Test Section .... Test Started Station +1961 Test Finished . Punp Used oo 7 Elevation High Point « Elevation Low Point Location Dead Weight Recorder: Station .... . Elevation DEAD WEIGHT RECORDED READINGS Time Pressure Time Pressure Time Pressure (PSIG) (PSIG) (PSIG) Testing Contractor Engineer Yellow to Contractor Blue to Contractor Manager Green to Project Engineer White to Inspector Distribution: SEC22 30G Z01E 022 00 Page 25 of 27HOURLY TEMPERATURE AND PRESSURE RECORD Schedule vee Station . To Station Test Section Gauge Location - Station Date HOUR TEMP PRESS -—-HOUR TEMP PRESS HOUR TEMP PRESS 8.00 AM 4.00 PM 12.00 MID 9.00 5.00 1.00 AM 10.00 6.00 2.00 11.00 7.00 3,00 12.00 NOON 8.00 4,00 1.00 PM 9.00 5.00 2.00 10.00 6.00 3.00 11.00 7.00 Gauge No. - Type Gauge Used Remarks. Testing Contractor Engineer Distribution: Yellow to Contractor Blue to Contractor Manager Green to Project Engineer White to Inspector SEC22 3DG ZO1E 022 00 Page 26 of 27‘COMPLETED TEST SECTION REPORT Schedule ... ses Station . ++ To Station . soso Time Started ....... Pressure . . Time completed ....... Pressure .... . Location . see. Location sees Minimum. Test Section .....4. Time of test Date Started .. Date completed .. Elevations - Maximum . Minimum .... Test Pressure - Maximum . Failure in Section No. .....+.++++++. Noted in Failure Reports.......ssseee0s Remarks sete seeeeee sesesesessees Signed Testing Contractor Engineer Signed .. Distribution: Yellow to Contractor Blue to Contract Manager Green to Project Engineer White to Inspector SEC22 30G ZO1E 022 00 Page 27 of 27