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Station Hydrostatic Test Procedure: MP4111, Revision 1, June 1996
Station Hydrostatic Test Procedure: MP4111, Revision 1, June 1996
TABLE OF CONTENTS
1.0 SCOPE...............................................................................................................................3
2.0 REFERENCE PUBLICATIONS .....................................................................................3
3.0 DEFINITIONS ...................................................................................................................3
3.1 Fabricated Assemblies ........................................................................................3
3.2 Hydrostatic Testing ..............................................................................................3
3.3 km ...........................................................................................................................4
3.4 Main Line Piping ...................................................................................................4
3.5 MOP........................................................................................................................4
3.6 NPS ........................................................................................................................4
3.7 PN...........................................................................................................................4
3.8 Station Piping ........................................................................................................4
3.9 SMYS .....................................................................................................................4
4.0 TEST REQUIREMENTS .................................................................................................5
4.1 General ..................................................................................................................5
4.1.1 Test Supervision......................................................................................... 5
4.1.2 Application .................................................................................................. 5
4.1.3 Safety .......................................................................................................... 5
4.2 Stresses at Test and Operating Pressures ......................................................6
4.3 Test Medium .........................................................................................................7
4.3.1 General ....................................................................................................... 7
4.3.2 Additives ..................................................................................................... 7
4.3.3 Hydrocarbons.............................................................................................. 7
4.3.4 Volatile Liquids ............................................................................................ 7
4.4 Test Pressures and Duration..............................................................................7
4.4.1 Piping Exposed During Testing .................................................................. 7
4.4.2 Piping Buried During Testing...................................................................... 7
4.4.3 Atmospheric Drain Systems ....................................................................... 7
4.5 Test Equipment.....................................................................................................8
4.5.1 Equipment Required ................................................................................... 8
4.5.2 Equipment Calibration ................................................................................ 8
4.5.3 Certification ................................................................................................. 8
4.5.4 Instrumentation Arrangement..................................................................... 9
4.5.5 Test Head Assemblies................................................................................ 9
5.0 TEST PREPARATION...................................................................................................11
5.1 Cleaning ...............................................................................................................11
5.2 Bolting, vents and Drains ..................................................................................11
TERASEN PIPELINES (TRANS MOUNTAIN) INC.
ENGINEERING STANDARDS AND PRACTICES
MP4111 Revision 1 June 24, 1996 Page 2 of 15
Title: STATION HYDROSTATIC TEST PROCEDURE
1.0 SCOPE
This standard covers the mandatory hydrostatic test requirements for exposed
station piping systems. This standard shall be limited to systems transporting
liquid hydrocarbons including: crude oil, condensate and liquid petroleum
products. This standard shall be further limited to the testing of Low Vapour
Pressure (LVP) systems intended for Category I service.
The scope of this standard includes all pressure pipe, fittings and fabricated
assemblies used in Station piping systems. This standard excludes pneumatic
testing and hydrostatic testing of valves, main line piping systems or buried station
piping.
3.0 DEFINITIONS
3.3 km
km, the abbreviation for kilometers, denotes location according to Terasen
Pipelines (Trans Mountain) Inc. (TMPL) Profile, Drawing No. RA-98 metric.
The station piping will be referred to by station name.
3.5 MOP
MOP means Maximum Operating Pressure expressed in kPa. The MOP
shall be the lesser of the design pressure and 80% of the strength test
pressure.
3.6 NPS
NPS means Nominal Pipe Size , and the NPS system of nominal size
designation is contained in standards prepared by the American Society of
Mechanical Engineers.
3.7 PN
PN means Pressure Nominal and the PN system of nominal pressure class
designation is contained in standards prepared by the International
Organization for Standardization (ISO). The numerical part of the
designation approximates the maximum cold working pressure rating in bars
(100 kPa).
3.9 SMYS
SMYS means Specified Minimum Yield Strength. This is the minimum
yield strength prescribed by the specification or standard under which the
material is purchased.
TERASEN PIPELINES (TRANS MOUNTAIN) INC.
ENGINEERING STANDARDS AND PRACTICES
MP4111 Revision 1 June 24, 1996 Page 5 of 15
Title: STATION HYDROSTATIC TEST PROCEDURE
4.1 General
4.1.2 Application
The following information shall be filed with the National Energy
Board, or other regulating authority, prior to hydrostatic testing:
a) diagram of test section showing physical parameters of piping
and components and test conditions;
b) proposed date of test;
c) confirmation that all water use and disposal permits are in place.
4.1.3 Safety
Piping under hydrostatic test contains considerable stored energy. If
the piping ruptures in a ductile manner, it releases this energy
rapidly. The resulting jet of water can cause serious injury to
personnel in the immediate area. If the piping fails in a brittle
manner, which may occur at cooler temperatures, pieces of steel
may become projectiles. Therefore, the following safety precautions
shall be adhered to during hydrostatic testing.
a) Only personnel directly involved in the test shall be allowed in
the test area, all other personnel shall remain outside the test
area;
b) All equipment which must be attended by personnel during the
test shall be located behind a protective structure such as an
earthen berm or be located a minimum of 15 m away from the
test section during the strength test;
c) Visual inspection of the test section shall not be conducted while
the test pressure is producing a hoop stress of 100% or more of
the SMYS of the pipe (see Table 4.2.A).
TERASEN PIPELINES (TRANS MOUNTAIN) INC.
ENGINEERING STANDARDS AND PRACTICES
MP4111 Revision 1 June 24, 1996 Page 6 of 15
Title: STATION HYDROSTATIC TEST PROCEDURE
Piping Class A (PN 20) Piping Class B (PN 50) Piping Class C (PN 100)
Press. % SMYS @ Press. % SMYS @ Press. % SMYS @
@ @ @
Pipe 100% Test 100% 100% Test MOP
Size SMYS 2375 MOP19 SMYS Test621 MOP49 SMYS 12415 9930
(NPS) (kPa) kPa 00 kPa (kPa) 0 kPa 60 kPa (kPa) kPa kPa
¾ 70,585 3.4 2.7 70,585 8.8 7.0 70,585 17.6 14.1
1 65,662 4.3 2.9 65,662 9.5 7.6 65,662 18.9 15.1
1½ 50,695 4.7 3.7 50,695 12.2 9.8 50,695 24.5 19.6
2 44,283 5.4 4.3 44,283 14.0 11.2 44,283 28.0 22.4
3 29,283 8.0 6.4 29,283 20.9 16.7 29,283 41.7 33.4
4 25,386 9.4 7.5 25,386 24.5 19.5 25,386 48.9 39.1
6 20,363 11.7 9.3 20,363 30.5 24.4 20,363 61.0 48.8
8 17,995 13.2 10.6 17,995 34.5 27.6 17,995 69.0 55.2
10 16,361 14.5 11.6 16,361 38.0 30.3 16,361 75.9 60.7
12 14,182 16.7 13.4 14,182 43.8 35.0 18,899 65.7 52.5
14 12,917 18.4 14.7 12,917 48.1 38.4 17,214 72.1 57.7
16 11,303 21.0 16.8 11,303 54.9 43.9 18,125 82.4 65.9
20 9,042 26.3 21.0 9,042 68.7 54.9 17,950 85.6 68.5
24 7,530 31.5 25.2 7,530 82.5 65.9 14,949 83.1 66.4
30 6,028 39.4 31.5 8,033 77.3 61.7 11,667 106.4 85.1
TERASEN PIPELINES (TRANS MOUNTAIN) INC.
ENGINEERING STANDARDS AND PRACTICES
MP4111 Revision 1 June 24, 1996 Page 7 of 15
Title: STATION HYDROSTATIC TEST PROCEDURE
4.3.1 General
The preferred test medium is water without additives. All practical
steps shall be taken to use water as a test medium before
considering other test media. (note: the reconciliation computations
included in Appendix A of MP4121 are valid for pure water only)
4.3.2 Additives
All necessary disposal arrangements and permits must be in place
prior to introduction of glycol or methanol additives to hydrotest
water.
4.3.3 Hydrocarbons
Use of hydrocarbons such as diesel or kerosene will be considered
as a last resort. All necessary environmental precautions must be
used and in place prior to start of test.
Test Test
Test Configuration Duration Pressure MOP
(hr) (kPa) (kPa)
Equipment Quantity
Plunger type squeeze pump with or without revolution counter
1
as required
Pressure recorder scaled for 1.5 x test pressure 1
Temperature recorder to record pipe and ambient temperatures 2
Dead weight tester accurate to 5 kPa 1
Pressure gauge scaled for 1.5 x test pressure 1
Thermometer accurate to ± 0.1°C 1
Calibrated liquid measure to ± 10 ml 1
4.5.3 Certification
Dead weight testers and calibrated thermometers shall be certified to
a government standard every three years.
TERASEN PIPELINES (TRANS MOUNTAIN) INC.
ENGINEERING STANDARDS AND PRACTICES
MP4111 Revision 1 June 24, 1996 Page 9 of 15
Title: STATION HYDROSTATIC TEST PROCEDURE
LEGEND:
TR Temperature Recorder
PR Pressure Recorder
PI Pressure Gauge
DWT Dead Weight Tester
* Locate in shade
TERASEN PIPELINES (TRANS MOUNTAIN) INC.
ENGINEERING STANDARDS AND PRACTICES
MP4111 Revision 1 June 24, 1996 Page 11 of 15
Title: STATION HYDROSTATIC TEST PROCEDURE
5.1 Cleaning
Welding slag, sand and construction debris shall be removed from the test
section prior to commencement of the test. Long lines should be cleared
with a construction cleaning pig. The cleaning pig may be driven by
compressed air. If the pig becomes lodged in the line, attempts shall be
made to move it by increasing pressure. The pressure shall not normally be
increased beyond 150 kPa.
5.3 Insulation
Any bare piping should be insulated and/or covered and heated such that
ambient conditions (eg. wind, rain, sunlight) will not have adverse effects on
the test results.
5.4 Shelters
Adequate facilities to protect test personnel and instruments from inclement
weather conditions should be provided. The shelter should include adequate
lighting and heating and shall be located in accordance with the requirements
of section 4.1.3 of this standard.
6.1 General
The test procedure covers five distinct phases. These phases include: filling,
temperature stabilization, pressurization, strength test and depressurization.
These phases are illustrated in Figure 6.1.A.
FIGURE 6.1.A -- HYDROSTATIC TEST PHASES
6.2 Filling
Long lines, such as tank lines, sho uld be filled with water using a new
urethane pig ahead of the fill water. If filling with a pig, a back pressure
should be maintained ahead of the pig to prevent the pig from running away
from the water when it is travelling down hill. This can be achieved by
controlling the rate at which air leaves the opposite end of the test section.
6.4 Pressurization
Upon completion of the temperature stabilization period, the pressure shall
be raised to the test pressure at a rate not to exceed 50 kPa per minute.
Pressurizing shall be conducted in such a manner to prevent surges and
vibrations. All hydrostatic tests shall commence on the hour or half hour. All
personnel should be located in accordance with the requirements of
subsection 4.1.3 of this standard until completion of the strength test.
6.8 Depressurizing
After successful completion of the strength test the pressure shall be bled
down. Depressurizing should be carried out slowly to prevent hydraulic
surges and avoid excessive pipe vibration.
7.3 Reconciliations
The following circumstances shall be reconciled with the test data within the
accuracy limits of the instrumentation.
a) the recorded pressure losses with the recorded temperature changes;
b) the additions and withdrawals of test medium that are required to
maintain the test pressure.
7.4 Leaks
Leaks which appear during the test shall be cause for the test to be restarted
after repair of the leakage source (see subsection 6.6).
TERASEN PIPELINES (TRANS MOUNTAIN) INC.
ENGINEERING STANDARDS AND PRACTICES
MP4111 Revision 1 June 24, 1996 Page 15 of 15
Title: STATION HYDROSTATIC TEST PROCEDURE
Comments:
1) This data is only required for long test sections, such as tank lines.
HYDROSTATIC TEST DATA LOG DATE
Station Piping
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