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WILLBROS

WILLBROS A Good Job On Time Hydrostatic Testing Practices Establishing Verifiable, Traceable, and Accurate Documentation August

A Good Job On Time

Hydrostatic Testing Practices

Establishing Verifiable, Traceable,

and Accurate Documentation

August 20, 2013

Hal Ozanne

Willbros Engineers

Hydrostatic Testing Practices

Hydrostatic Testing Practices • • Verifiable, Traceable, Accurate Documentation  Hydrostatic Testing Calculations  Hydrostatic Test

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

Hydrostatic Testing Practices • • Verifiable, Traceable, Accurate Documentation  Hydrostatic Testing Calculations  Hydrostatic Test

Hydrostatic Testing Practices

Hydrostatic Testing Practices • Hydrostatic Testing Calculations  Detailed calculations based on pipe characteristics and specifications

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

Hydrostatic Testing Practices

Hydrostatic Testing Practices • Hydrostatic Testing Calculations  MAOP Verification calculated and determined by final hydro

Hydrostatic Testing Calculations

  • MAOP Verification calculated and determined by final hydro test results

TEST SEGMENT 1 PIPE UNITS
TEST SEGMENT 1 PIPE UNITS
TEST SEGMENT 1 PIPE UNITS
TEST SEGMENT 1 PIPE UNITS

TEST SEGMENT 1

PIPE

UNITS

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

Test Segment Volume

612,211

GAL

14,576

BBL

CHECK NOTES BELOW REGARDING DEAD WEIGHT PRESSURES COMPARED TO TEST PRESSURES

Selected Min Test Pres.

2,118

PSIG

DETERMINE WHICH MAXIMUM TEST PRESSURE BELOW WILL BE USED AT LOW POINT OF TEST SEGMENT

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

Test pressure is within range of minimum and maximum test pressure

Calculated Min Test Pressure

Calculated Min Test Pressure

Calculated Max Test Pressure

Test pressure is within range of minimum and maximum test pressure

N/A

1,618

N/A

Calculated Max Test Pressure

Test pressure is within range of minimum and maximum test pressure

1,714

TEST PRESSURE OUT OF ACCEPTABLE RANGE - CHECK SEGMENT

TEST PRESSURE OUT OF ACCEPTABLE RANGE - CHECK SEGMENT

N/A

Calculated Max Test Pressure

Calculated Min Test Pressure

Test pressure is within range of minimum and maximum test pressure

1,697

Calculated Max Test Pressure

Calculated Min Test Pressure

Test pressure is within range of minimum and maximum test pressure

1,525

N/A

Test pressure is within range of minimum and maximum test pressure

5,594 1107+35 6,201 590+86 5,902 0+00 5,594 1107+35 6,201 590+86 5,650 5,650 1278+29 1278+29 5,902 0+00
5,594
1107+35
6,201
590+86
5,902
0+00
5,594
1107+35
6,201
590+86
5,650
5,650
1278+29
1278+29
5,902
0+00
Low Point Elevation, FT Low Point Elevation, FT Begin Point Elevation, FT High Point Elevation, FT
Low Point Elevation, FT
Low Point Elevation, FT
Begin Point Elevation, FT
High Point Elevation, FT
High Point Elevation, FT
Begin Point Elevation, FT
End Point Elevation, FT
End Point Elevation, FT
  • Test Factor of 1.5 based on 1.25 min test pressure above

Based on design factor for the Class Location

2,353 100.0% 2,118 90.0% 2,219 94.3% 2,381 101.2% 2,329 99.0% 2,090 88.8% 2,357 100.2% 2,247 95.5%
2,353
100.0%
2,118
90.0%
2,219
94.3%
2,381
101.2%
2,329
99.0%
2,090
88.8%
2,357
100.2%
2,247
95.5%

Determined by Class Location

Required Testing Factor

Maximum Test Pressure

Maximum Test Pressure

Selected Max Test Pres.

Segment Legnth (ft)

SMYS Pressure

  • FT

Design Factor

MAOP (psig)

Pipe WT (in)

Pipe OD (in)

Pipe Grade

PSIG

PSIG

PSI

IN

IN

If the minimum and maximum dead weight test pressure range cannot be adjsuted within the test
If the minimum and maximum dead weight test pressure range cannot be adjsuted within the test
If the minimum and maximum dead weight test pressure range cannot be adjsuted within the test
If the minimum and maximum dead weight test pressure range cannot be adjsuted within the test

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

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

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 that the new lower maximum test pressure is not below the minimum required test pressure.

pressure, the the test segment will need to be broken into smaller segments.

provided it does not exceed the maximum test pressure.

Elevation Change

Note 2:

Note 1:

Note 3:

607

FT

If the minimum and maximum dead weight test pressure range cannot be adjsuted within the test

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Hydrostatic Testing Practices

Hydrostatic Testing Practices • Hydrostatic Test Plan  Set it up right and make it fully

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

Hydrostatic Testing Practices • Hydrostatic Test Plan  Set it up right and make it fully
Hydrostatic Testing Practices • Hydrostatic Test Plan  Set it up right and make it fully

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Hydrostatic Testing Practices

Hydrostatic Testing Practices • Hydrostatic Test Plan  Environmental Requirements and Stipulations – Water Source –

Hydrostatic Test Plan

  • Environmental Requirements and Stipulations

Water Source Discharge Location Water Quality

  • Detailed to describe all parts of Hydro Test

Hydrostatic Testing Practices • Hydrostatic Test Plan  Environmental Requirements and Stipulations – Water Source –

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

Hydrostatic Testing Practices

Hydrostatic Testing Practices • Hydrostatic Test Plan  Max and min test pressures for each Segment

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)

Hydrostatic Testing Practices • Hydrostatic Test Plan  Max and min test pressures for each Segment

Hydrostatic Testing Practices

Hydrostatic Testing Practices • Hydrostatic Test Plan  Acceptance Criteria established prior to conducting test 

Hydrostatic Test Plan

  • Acceptance Criteria established prior to conducting test

  • Proper Approvals and Signatures

Project Engineer Project Manager Construction Manager Client Project Manager

Hydrostatic Testing Practices • Hydrostatic Test Plan  Acceptance Criteria established prior to conducting test 

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Hydrostatic Testing Practices

Hydrostatic Testing Practices • Hydrostatic Test Report  Set it up in the beginning so that

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

Hydrostatic Testing Practices • Hydrostatic Test Report  Set it up in the beginning so that

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Hydrostatic Testing Practices

Hydrostatic Testing Practices • Hydrostatic Test Report  Proper Recording of Measurements – Pipe Diameter and

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

Hydrostatic Testing Practices • Hydrostatic Test Report  Proper Recording of Measurements – Pipe Diameter and
Hydrostatic Testing Practices • Hydrostatic Test Report  Proper Recording of Measurements – Pipe Diameter and

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Hydrostatic Testing Practices

Hydrostatic Testing Practices • Hydrostatic Test Report  Completeness of Forms and Records  Proper Approvals

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)

Hydrostatic Testing Practices

Hydrostatic Testing Practices • Hydrostatic Test Data Collection  Planning and Preparation  Understanding Test Report

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

Hydrostatic Testing Practices • Hydrostatic Test Data Collection  Planning and Preparation  Understanding Test Report
Hydrostatic Testing Practices • Hydrostatic Test Data Collection  Planning and Preparation  Understanding Test Report

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Hydrostatic Testing Practices

Hydrostatic Testing Practices • Hydrostatic Test Data Collection  Calibration of Instruments and Equipment – High

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

Hydrostatic Testing Practices • Hydrostatic Test Data Collection  Calibration of Instruments and Equipment – High

Continuous temperature recording device for test medium and ambient

Test medium sampling equipment Gas/oxygen detecting equipment

Hydrostatic Testing Practices

Hydrostatic Testing Practices • Hydrostatic Test Data Collection  Collecting/Recording All Details and Information Required on

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

Hydrostatic Testing Practices

Hydrostatic Testing Practices • Hydrostatic Test Data Collection  Temperature Recorders – Weather condition changes can

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

Hydrostatic Testing Practices • Hydrostatic Test Data Collection  Temperature Recorders – Weather condition changes can

Hydrostatic Testing Practices

Hydrostatic Testing Practices • Hydrostatic Test Data Collection  Temperature Changes – As temp increases, pressure

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)

Hydrostatic Testing Practices • Hydrostatic Test Data Collection  Temperature Changes – As temp increases, pressure

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Hydrostatic Testing Practices

Hydrostatic Testing Practices • Hydrostatic Test Data Collection  Small Leak or Change in Temperature? –

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

Test Supervisor Signature Test Operator Signature
Test Supervisor Signature
Test Operator Signature

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

Test Supervisor Signature Test Operator Signature * Contractor shall provide means of volumetric changes to line
Test Supervisor Signature Test Operator Signature * Contractor shall provide means of volumetric changes to line
Test Supervisor Signature Test Operator Signature * Contractor shall provide means of volumetric changes to line
Test Supervisor Signature Test Operator Signature * Contractor shall provide means of volumetric changes to line
Test Supervisor Signature Test Operator Signature * Contractor shall provide means of volumetric changes to line
Test Supervisor Signature Test Operator Signature * Contractor shall provide means of volumetric changes to line
else that may affect the test. (24 Hr. Clock) Test Start Date: Test End Date: Month
else that may affect the test.
(24 Hr. Clock)
Test Start Date:
Test End Date:
Month Day, Year
Month Day, Year
Readings should be taken every 15 minutes for test
T EM P.
T EM P.
and stop of test, pressure reductions, weather changes, or anything
R EM AR KS: (Note any additions/withdrawals of test medium, start
Buried Pipe, 1
Buried Pipe, 2
TIME
OB S. PRESSUR E
T EM P.
T EM P.
(Deadweight Reading)
Ambient
Exposed Pipe

Hydrostatic Testing Practices

Hydrostatic Testing Practices • Final Verification  Verify that final book is complete and contains all

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

Hydrostatic Testing Practices • Final Verification  Verify that final book is complete and contains all

Hydrostatic Testing Practices

Hydrostatic Testing Practices • Final Verification  If all required data is in one place, then

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

Hydrostatic Testing Practices • Final Verification  If all required data is in one place, then

Hydrostatic Testing Practices

Hydrostatic Testing Practices • PHMSA  Audits – Checks during construction to verify proper records being

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

WILLBROS

WILLBROS A Good Job On Time www.willbros.com

A Good Job On Time

WILLBROS A Good Job On Time www.willbros.com

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