Testing of Pipelines

Anomalies that are of concern for pipelines:

 Mechanical damage
 Corrosion
 Joint Crack
 Wrinkle bends
 Outside forces (landslide, river washouts etc.)

Three types of tests are carried out on Pipelines in Chemical industries:

 Inline inspection for corrosion

 Pressure testing
 Direct assessment

Inline inspection testing:

Inspecting of pipeline from the inside. They are used to detect the crack, pipe wall thickness, position,
metal loss corrosion.

 Magnetic Flux Leakage test: it is done for the areas of metal loss that have a circumferential
extent

 Thermographic Methods: the presence of flaws alter the thermal properties and consequent
heat transfer behavior. Thermograms are produced and flaws are indicated by changes in
temperature as result in modification of heat flow.

 Electromagnetic Acoustic Transducers: it used to detect the flaws and measure the thickness.
Ultrasonic acoustic sound waves generated by electromagnetic interaction with an electrical
conductor. It provide tolerance to the rough surfaces and ability to conduct high speed scans.
  Ultrasonics: there are two types of ultrasonic detecting tools used for detecting the metal loss
and axial cracks. ASTM E 1961
 It detects metal loss by sending an ultrasound wave perpendicular to the inside wall
thickness and measuring the time for the signal to be reflected from the inside and
outside surfaces. Metal loss on the inside or outside surface is detected by a change in
time of flight of the signal.
 For detecting axial cracks the ultrasound waves are oriented at approximately 45˚ to the
pipe surface. The ultrasound is then introduced to the pipe wall and then reflects from
cracks to designate their presence and depth.

Pressure testing
It involves removing the pipeline from the service, inserting water and pressurizing the water to a high-
pressure level. As per ASME B31.4.2002

Leak test A 1 hr hydrostatic or pneumatic leak test may be used for piping systems to be operated at a
hoop stress of 20% or less of the specified minimum yield strength of the pipe. The hydrostatic test
pressure shall be not less than 1.25 times the internal design pressure. The pneumatic test gage
pressure shall be 100 psi (7 bar) or that pressure which would produce a nominal hoop stress of 25% of
the specified minimum yield strength of the pipe, whichever is less.

Weldability test: The pipe shall be considered weldable if the requirements set forth in para. 434.8.5 are
met. At least one such test weld shall be made for each number of lengths to be used as listed below

Leak testing as per ASME B31.3 for all category metal and non-metals
Direct assessment:
It is an indirect integrity assessment method utilizing a structured process through which anoperator is
is able to integrate knowledge of the physical characteristic of the pipeline (changing diameter along the
length of the pipeline.) and operating history with the results of inspections, examination and evaluation
in order to assess the integrity.

Presently this method has only been developed for metal loss corrosion anomalies and therefore has
somewhat limited applicability.

Advantages and Disadvantages

- Advantages
Pressure testing  A high pressure test loads
the steel pipe to a higher
level than in service and
leaves the steel in a
condition that is more
resistant to SCC formation.
Disadvantages
 Requires taking the line out
of service for an extended
tie. Time required to remove
the pipe, fill, test, repair
ruptures or leaks, dewater
and return to service.

In-line Inspection Testing
 It does not require taking
the pipeline out of the
service.
 The cost of ILI testing could
be higher as compared to
pressure testing but these
cost can be offset because
the line can remain in
service continuing to
generate revenue.
 Small to large flaws or
developing conditions can
be detected which could
lead to service incident.
 The test cannot find the
flaws or developing
conditions
 Several types of tools has to
be run in order to inspect
the pipeline for all potential
types of defects.
 The types of defects
expected in pipeline must be
known or suspected so that
the proper In-Line Inspection
tool can be selected.

Testing of other items: as per ASME B.31.4.2002

Testing of Fabricated items:

Fabricated items such as scraper traps, manifolds, volume chambers, etc., shall be hydrostatically tested
to limits equal to or greater than those required of the completed system. This test may be conducted
separately or as a part of the completed system.

Testing of systems or parts of Systems:

 All liquid transportation piping systems within the scope of ASME B.31.4 Code, regardless of
stress, shall be tested after construction.
 Carbon dioxide systems shall be hydrostatically tested.
 Systems to be operated at a hoop stress of more than 20% of the specified minimum yield
strength of the pipe shall be hydrostatically tested in accordance with para. 437.4.1.
(Hydrostatic Testing of Internal Pressure Piping) of ASME B.31.4
 Systems to be operated at a hoop stress of 20% or less of specified minimum yield strength of
the pipe may be subjected to a leak test in accordance with para. 437.4.3 in lieu of the
hydrostatic test specified in para. 437.4.1.

Testing Controls and Protective Equipment:

All controls and protective equipment, including pressure limiting devices. regulators, controllers, relief
valves. and other safety devices, shall be tested to determine that they are in good mechanical
condition; of adequate capacity, effectiveness, and reliability of operation for the service in which they
are employed; functioning at the correct pressure; and properly installed and protected from foreign
materials or other conditions that might prevent proper operation.