APPENDIX G
HYDROSTATIC TEST PLAN
PACIFIC TRAIL PIPELINES
KSL PROJECT
025040-1100-0038
HYDROSTATIC TEST PLAN
O25040-1100-0038-R0 Hydrostatic Test Plan
Page 1 of 7
PACIFIC TRAIL PIPELINES
KSL PROJECT
025040-1100-0038
HYDROSTATIC TEST PLAN
Table of Contents
1.0
INTRODUCTION ................................................................................................................ 3
2.0
SELECTION OF TEST SECTIONS ......................................................................................... 3
3.0
TYPICAL HYDROSTATIC TEST DESCRIPTION ...................................................................... 4
4.0
SCOURCING OF TEST WATER............................................................................................. 4
5.0
DISPOSAL OF TEST WATER................................................................................................ 5
6.0
HYDROSTATIC TEST GUIDELINES ...................................................................................... 5
7.0
REFERENCES ..................................................................................................................... 7
O25040-1100-0038-R0 Hydrostatic Test Plan
Page 2 of 7
PACIFIC TRAIL PIPELINES
KSL PROJECT
025040-1100-0038
HYDROSTATIC TEST PLAN
1.0
INTRODUCTION
As per CSA Z662 requirements, the constructed pipeline and all pressure bearing appurtenances must
be subjected to a strength and leak test. The most common method is to fill a completed pipe section
with water and “squeeze” the pressure to predetermined limits. As water itself has mass, it adds to
the pressure at the low point, hence elevation differences play an important role in the selection of
test points. Therefore were elevation differences are excessive, a test may be completed using air as
medium. Air test sections must be designed for such a test and adequate measures need to be taken
to protect the safety of personnel executing the test and the general public. For the purposes of this
Hydrostatic Test Plan it is anticipated that approximately 25 km out of the 467 km line will be tested
by using air. The total volume of water required roughly equates to the volume of the pipe line that is
to be tested.
The purpose of this Hydrostatic Test Plan is to outline a general approach as to how testing will be
conducted, recognizing that detailed arrangements only can be made after detailed engineering has
been completed and the contractor has been consulted.
2.0
SELECTION OF TEST SECTIONS
Because of the length of the KSL project (467 km), the pipeline will be sub-divided in five Spreads.
Currently, the following Spreads have been identified:
Spread 1
from kp 0 to kp 80
(80 km)
Spread 2
from kp 80 to kp 162
(82 km)
Spread 3
from kp 162 to kp 243 (81 km)
Spread 4
from kp 243 to kp 354 (111 km)
Spread 5
from kp 354 to kp 467 (113 km)
In turn, the Spreads will contain a number of valve sections, usually not longer than 30 km in length.
As it is the purpose of the test to include as many field welds as practicable, it is preferred to arrange
the test sections in such way that the number of tie-in (or Golden) welds is kept to a minimum.
Another factor that determines the length of test is the fluctuation of elevation in the terrain. With the
grade and various pipe wall thicknesses selected, elevation differences of only a few hundred metres
would push the test out of limits. This means that if the maximum pressure limit at low elevation point
is maintained, the high point won’t meet the minimum pressure, or if the minimum pressure at high
elevation is maintained, the low elevation section maximum pressure would be exceeded. Pipe
sections containing excessive elevations differences are candidates for air testing.
Final considerations for the selection of test sections are the availability of water sources and dewatering sites. Ideally, one end of the section is located near a large water body while the other end
O25040-1100-0038-R0 Hydrostatic Test Plan
Page 3 of 7
PACIFIC TRAIL PIPELINES
KSL PROJECT
025040-1100-0038
HYDROSTATIC TEST PLAN
is located near a gentle sloped meadow where water can be drained in a controlled manner. Where
water sources are not readily available, it may have to be pumped or trucked in. Similarly, if suitable
de-watering sites cannot be found, the water may need to be trucked to a specific site or pumped into
the next section.
In summary, optimum selection of test sections can be made when environmental, engineering, and
constructional constraints have been identified and adequately addressed.
3.0
TYPICAL HYDROSTATIC TEST DESCRIPTION
Upon completion of a section that satisfies the above described criteria, the pipe is sealed off by
welding test heads on both ends. These test heads contain valves that allow the filling and
pressurizing of the pipe with water. The tests heads will also have the appropriate valves for hooking
up calibrated instruments and chart recorders.
For the filling of the pipe a large pump is required to ensure “steady” filling of the pipeline and
minimizing the risk or trapping air. Once the line is filled a squeeze pump is used to put the line under
a slight positive pressure while time is allowed for temperature equalization between the water and
the pipe/soil. Once the temperature has been stabilized, the pressure can be raised by means of the
squeeze pump to the predetermined values for the strength and leak tests. The temperatures of the
pipe and the pressures are monitored and documented through special equipment such as gauges,
dead-weights and recorders. As pressure is a function of temperature, care will be taken that the two
are correlated.
Upon successful completion of the test, the instruments are disconnected and the water drained by
opening appropriate valves. Initially the water will drain due to the pressure in the pipe but when the
pressure has reached that of the atmosphere a pig is used to push the remaining water out. If the
test fails, an investigation is conducted as to the reason, repairs are made, and the line is re-tested.
This sequence is repeated until the test is successful.
4.0
SCOURCING OF TEST WATER
Water will be drawn from suitable sources and returned to the appropriate watersheds in accordance
with the Hydrostatic Test Water Management Guidelines as prepared for the Canadian Association of
Petroleum Producers (CAPP). To ensure protection of anadromous and resident fish, the Freshwater
Intake End-of-Pipe Fish Screen Guideline as prepared by the Department of Fisheries and Oceans will
be followed.
During filling of the pipeline test section, the water withdrawal rate will be limited to no more than
10% of stream flow at the time of withdrawal or as stipulated in the EPP and/or the water withdrawal
permit. The water will be used for testing as found, without addition of any chemicals or conditioners.
The Contractor will have to specify which water bodies will be utilized, when the withdrawal will take
O25040-1100-0038-R0 Hydrostatic Test Plan
Page 4 of 7
PACIFIC TRAIL PIPELINES
KSL PROJECT
025040-1100-0038
HYDROSTATIC TEST PLAN
place, and the location and description of in-water withdrawal equipment, so that permit conditions
can be met.
In the event that suitable, natural water bodies are too remote for practical use, the Contractor may
opt to source water from a municipality (e.g. from a fire main). In such case the water will be
transported by truck and loaded into a large storage tank before filling of the line takes place. Special
permits may be needed to use and dispose of the water.
5.0
DISPOSAL OF TEST WATER
After hydrostatic test completion of the pipe, the test water will be returned to its source watershed
unless permit conditions state otherwise. The test water is expected to contain a minor amount of rust
particles and dirt picked up from inside the pipe, otherwise, the pipe and appurtenances which have
never been in service will not contain petroleum products or other contaminants.
Water will typically be released onto a non-erodible surface (e.g., a sheet of plastic fabric), and
directed to filter through established vegetation before returning to a watercourse. It is expected that
the initial release and the final release of test water will contain higher concentration of rust particles
than the volume in the middle. Although rust particles are non toxic, test water will be sampled near
the beginning, during the middle and near the end of the release for laboratory testing for the project
record.
In some circumstances, test water may be moved from a tested section directly into an untested
section. This option would reduce the overall use of water, but is only recommended to be applied if
the length of the second section is shorter than the first, and when the second section has a
dewatering site as least as favourable as the first.
6.0
HYDROSTATIC TEST GUIDELINES
Obtain Approvals
1. Obtain the applicable government agency approvals for water withdrawal
and discharge to allow for hydrostatic testing of the pipeline.
Approval / Code of
Practice Conditions
2. Conduct all hydrostatic testing activities in accordance with federal and
provincial government agency approvals.
3. Adhere to approved water sources and withdrawal rates. Potential water
sources include:
•
Rivers
•
Lakes
•
Wells
•
Municipal Supplies
O25040-1100-0038-R0 Hydrostatic Test Plan
Page 5 of 7
PACIFIC TRAIL PIPELINES
KSL PROJECT
025040-1100-0038
HYDROSTATIC TEST PLAN
4. Restrict water withdrawal for hydrostatic testing not to exceed 10% of the
stream flow of the watercourse at the time of withdrawal or as required by
permit / approval conditions.
Equipment and
Workers
5. Ensure that sufficient workers and equipment are available onsite to
repair any rupture, leak or erosion problem that may arise during testing.
Water Trucks
6. Ensure that water trucks, if used to transport test water to the fill site, are
clean.
Sump Excavation
7. Obtain any federal approvals required for in stream work and abide by
approval conditions. Excavate sump, if necessary, in the substrate of the
water source. Employ sediment reduction methods (e.g., sediment mats,
silt fence, sand bag, coffer dam, etc.), if warranted, to protect downstream
fish, fish habitat and water users from increased sedimentation or
reduced water quality.
Isolate Pumps
8. Isolate test pumps and storage tanks with an impermeable lined dyke or
depression to capture any spills of fuels or lubricants.
Screen Intake
9. Pump intakes must minimize disturbance to the streambed and must be
screened with a maximum mesh size of 2.54 mm and approach velocity
of 0.038 m/s.
Chemical Additives
10. No chemicals, biocides or conditioners will be added to the pipeline test
water unless otherwise approved by the appropriate authority. If an
antifreeze / water mix is to be used as the test medium for specific pipe
segments, the test medium will be rented and returned to the supplier
upon completion of the test.
Dewatering
11. Depending on test section configurations, test water from one test section
may be pushed to the next test section. In such case water may need to
be added or discharged, depending on volume differences between the
sections.
12. Use a diffuser to dissipate and reduce the rate of water as it is released
and monitor dewater points for potential erosion problems. Use riprap,
sheeting, tarpaulins or other comparable measures to protect the ground
and vegetation from erosion at dewatering sites.
13. Monitor discharge locations to ensure that no erosion, flooding or
detrimental ice build-up occurs.
14. Dewater into a bar ditch if feasible, or onto other well-drained, level to
very gently sloping land. Do not dewater directly back into a watercourse
or water body unless otherwise approved by the appropriate authority.
15. Return the test water to its source watershed to prevent the inter-basin
transfer of aquatic organisms unless otherwise approved by the
appropriate authority.
Sample Collection
16. Collect samples of source water, hydrostatic test water and soil of the
receiving environment and analyze to demonstrate regulatory
compliance. For this purpose, samples will be collected of hydrostatic test
water at the beginning, middle and end of the release for laboratory
testing for the project record.
O25040-1100-0038-R0 Hydrostatic Test Plan
Page 6 of 7
PACIFIC TRAIL PIPELINES
KSL PROJECT
025040-1100-0038
HYDROSTATIC TEST PLAN
7.0
REFERENCES
CSA Standard Z662-03 Oil and Gas Pipeline Systems
CAPP Hydrostatic Test Water Management Guidelines (September 1996)
Freshwater Intake End-of-Pipe Fish Screen Guideline DFO
O25040-1100-0038-R0 Hydrostatic Test Plan
Page 7 of 7