Hydrostatic Testing Practices Establishing Verifiable, Traceable, and Accurate Documentation

1. Hydrostatic Testing PracticesEstablishing Verifiable, Traceable, and Accurate Documentation August 20, 2013 Hal Ozanne Willbros Engineers

2. 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

3. 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

4. Hydrostatic Testing Practices • Hydrostatic Testing Calculations • MAOP Verification calculated and determined by final hydro test results

5. 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

6. 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

7. 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)

8. 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

9. 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

10. 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

11. 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)

12. 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

13. 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

14. 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

15. 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

16. 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)

17. Hydrostatic Testing Practices • Hydrostatic Test Data Collection • Small Leak or Change in Temperature? • 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

18. 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

19. 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

20. 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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