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
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Verifiable, Traceable, Accurate Documentation
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Hydrostatic Testing Calculations
Hydrostatic Test Plans
Hydrostatic Test Reports
Data Collection and Final Verification
Pipeline and Hazardous Materials
Safety Administration (PHMSA)
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Audits
Record Keeping
Approvals/Signatures
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WILLBROS
Hydrostatic Testing Practices
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Hydrostatic Testing Calculations
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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
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Segment lengths based on elevations and SMYS requirements
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Project Management Review and Approval
– Engineering Project Manager
– Client Project Manager
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WILLBROS
Hydrostatic Testing Practices
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Hydrostatic Testing Calculations
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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
Test Segment Volume
612,211 GAL
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
TEST PSIG
% SMYS
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
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
STATION #
Elevation Change
Note 1:
Note 2:
Note 3:
WILLBROS
CALCULATED MAOP
1,618
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,
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
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
pressure, the the test segment will need to be broken into smaller segments.
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Hydrostatic Testing Practices
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Hydrostatic Test Plan
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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
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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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WILLBROS
Hydrostatic Testing Practices
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Hydrostatic Test Plan
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Environmental Requirements and Stipulations
– Water Source
– Discharge Location
– Water Quality
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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
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Hydrostatic Test Plan
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Max and min test pressures for each Segment
– Provide location of expected occurrence in plan
– Provide expected test site location pressure
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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
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Hydrostatic Test Plan
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Acceptance Criteria established prior to conducting test
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Proper Approvals and Signatures
– Project Engineer
– Project Manager
– Construction Manager
– Client Project Manager
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Hydrostatic Testing Practices
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Hydrostatic Test Report
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Set it up in the beginning so that all data required to be gathered is
understood by test operators
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Based on Operating Company Standards and DOT/PHMSA
Requirements (also API RP 1110)
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Attention to Detail
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Hydrostatic Testing Practices
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Hydrostatic Test Report
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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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WILLBROS
Hydrostatic Testing Practices
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Hydrostatic Test Report
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Completeness of Forms and Records
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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
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Hydrostatic Test Data Collection
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Planning and Preparation
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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
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Maintain and Include Raw Data Gathered into Final Test Report Book
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Hydrostatic Testing Practices
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Hydrostatic Test Data Collection
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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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WILLBROS
Hydrostatic Testing Practices
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Hydrostatic Test Data Collection
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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
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Maintain and Clean up All Field Notes on Drawings and Books
– Incorporate into overall Test Report
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Maintain All Failure Record Data for Final Book
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Hydrostatic Testing Practices
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Hydrostatic Test Data Collection
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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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WILLBROS
Hydrostatic Testing Practices
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Hydrostatic Test Data Collection
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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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WILLBROS
Hydrostatic Testing Practices
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Hydrostatic Test Data Collection
Test Start Date:
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Small Leak or Change in Temperature?
Month Day, Year
Test End Date:
TIME
O B S . P R E S S UR E
T EM P .
(24 Hr. Clock)
(Deadweight Reading)
Ambient
T EM P .
Month Day, Year
T EM P .
T EM P .
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
and sto p o f test, pressure reductio ns, weather changes, o r anything
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
volumes - part of test plan/report
Test Supervisor Signature
Test Operator Signature
* Contractor shall provide means of volumetric changes to line prior to test.
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Hydrostatic Testing Practices
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Final Verification
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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
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Final Verification
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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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WILLBROS
Hydrostatic Testing Practices
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PHMSA
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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
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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)
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Documentation Approvals/Signatures
– Checks for field personnel, engineering personnel, and Company personnel
signatures and approvals of test records and reports
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WILLBROS
A Good Job On Time
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