Station Hydrostatic Test Procedure: MP4111, Revision 1, June 1996

TERASEN PIPELINES (TRANS MOUNTAIN) INC.
ENGINEERING STANDARDS AND PRACTICES
STATION HYDROSTATIC TEST PROCEDURE
MP4111, Revision 1, June 1996

MP4111 Revision 1 June 24, 1996 Page 1 of 15
Title: STATION HYDROSTATIC TEST PROCEDURE
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
5.3 Insulation .............................................................................................................11

5.4 Shelters ................................................................................................................11
5.5 Fill Connections ..................................................................................................11
5.6 Temperature Recorders ....................................................................................11
6.0 TEST PROCEDURES ...................................................................................................12
6.1 General ................................................................................................................12
6.2 Filling ....................................................................................................................12
6.3 Temperature Stabilization .................................................................................12
6.4 Pressuri zation .....................................................................................................13
6.5 Strength Test.......................................................................................................13
6.6 Relief of Test Medium........................................................................................13
6.7 Visual Inspection ................................................................................................13
6.8 Depressurizing ....................................................................................................13
6.9 Freezing Protection............................................................................................13
7.0 ACCEPTANCE CRITERIA ...........................................................................................14
7.1 Maximum Test Pressure ...................................................................................14
7.2 Minimum Test Pressure ....................................................................................14
7.3 Reconciliations ....................................................................................................14
7.4 Leaks....................................................................................................................14
8.0 RECORDING AND DOCUMENTATION ....................................................................15
8.1 Test Data Logging ..............................................................................................15
8.2 Hydrostatic Test Record....................................................................................15
8.3 Hydrostatic Test File ..........................................................................................15
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.
2.0 REFERENCE PUBLICATIONS

Where reference is made to other publications, such references shall be
considered to refer to the latest edition and any revisions thereto approved by the
organization issuing that publication. Some reference publications are
supplemented or qualified, or both, by specific requirements in this standard;
reference publications should therefore be applied only in the context of this
standard.
CSA Z662 Oil and Gas Pipeline Systems
National Energy Board Act Onshore Pipeline Regulations
3.0 DEFINITIONS
3.1 Fabricated Assemblies

The term fabricated assemblies, as used in this specification, shall include
prefabricated components such as: piping spools; scraper traps; and main
line block valves with end extensions and associated by-pass piping. The
term excludes such manufactured components as: valves; strainers; and
pump casings.
3.2 Hydrostatic Testing

Hydrostatic testing is defined as the application of internal pressure above
the normal or maximum operating pressure to a segment of piping or
pressure containing component. This pressure is applied under no flow
conditions (in the case of a pipeline) for a fixed period of time, utilizing a
liquid test medium.
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.
3.4 Main Line Piping

Main line piping includes those items through which oil industry fluids are
conveyed, which includes pipe, components, and any appurtenances
attached thereto, up to and including the isolating valves used at pump
stations and other facilities.
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).
3.8 Station Piping

Station piping includes all pipe, components and any appurtenances at Pump
Stations, Tank Farms and Terminals downstream from the first station
isolating valve or sectionalizing valve within the station.
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.
4.0 TEST REQUIREMENTS
4.1 General
4.1.1 Test Supervision

All testing shall be performed under the direct supervision of Terasen
Pipelines (Trans Mountain) Inc. or an appointed agent. The agent
shall be independent of any contractor who carries out the pressure
testing and any contractor who constructed the piping or any
component intended for use in the piping system. This agent shall
date and sign all test records.
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).
4.2 Stresses at Test and Operating Pressures

The pressures and hoop stresses (listed as a percent of SMYS) in Table
4.2.A are based on the material grades and pipe wall thicknesses specified
by Terasen Pipelines (Trans Mountain) Inc.'s standard piping classes. The
test pressure can produce a hoop stress exceeding 100% of the SMYS
of the piping for NPS 30 piping in the PN 100 pressure class. Therefore
visual inspections to detect leaks shall be conducted in accordance
with subsection 6.6.
TABLE 4.2.A -- THE RELATIONSHIP OF TEST AND DESIGN PRESSURES

TO HOOP STRESS
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
4.3 Test Medium
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.
4.3.4 Volatile Liquids

Volatile liquids such as gasoline or crude oil shall not be used for
hydrostatic testing.
4.4 Test Pressures and Duration
4.4.1 Piping Exposed During Testing

Where a complete visual inspection is conducted to detect leaks, the
test duration and pressure shall be at least one (1) hour at a
minimum test pressure of 1.25 times MOP (4 hour test durations are
required on systems regulated by the United States Federal
Department of Transportation).
4.4.2 Piping Buried During Testing

Buried piping shall be tested in accordance with Teraesn Pipelines
(Trans Mountain) Inc. Standard Main Line Hydrostatic Test
Procedure MP4121.
4.4.3 Atmospheric Drain Systems

Where a complete visual inspection is conducted to detect leaks, the
test duration shall be at least one (1) hour at a minimum test
pressure of 700 kPa.
TABLE 4.4.A MINIMUM TEST PRESSURES AND DURATION FOR EXPOSED

STATION PIPING
Test Test
Test Configuration Duration Pressure MOP
(hr) (kPa) (kPa)
Exposed Class A, PN 20 (150 ANSI) 1 2375 1900

Piping Class B, PN 50 (300 ANSI) 1 6210 4960
(1.25 x MOP)
Class C, PN 100 (600 ANSI) 1 12415 9930
Atmospheric Drain Systems 1 700 <700
4.5 Test Equipment
4.5.1 Equipment Required

The numbers of recorders, gauges, pumps, and other necessary
equipment are a function of the scope of a hydrostatic test. The
equipment listed in Table 4.4.1.A is the minimum required for a test
of prefabricated piping in a shop or yard.
TABLE 4.5.1.A -- MINIMUM EQUIPMENT REQUIREMENTS
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
4.5.2 Equipment Calibration

All recorders and gauges shall be calibrated to ±1% of full scale as
checked by dead weight tester and certified thermometers and/or ice
bath.
4.5.3 Certification
Dead weight testers and calibrated thermometers shall be certified to
a government standard every three years.
4.5.4 Instrumentation Arrangement

Refer to Figures 4.4.A for a typical instrumentation arrangement.
4.5.5 Test Head Assemblies

Test head assemblies shall not be pressurized to a stress exceeding
75% of the SMYS of the test head material. The anciliary piping shall
not be pressurized to a stress exceeding 50% of the SMYS of the
piping.
FIGURE 4.5.A -- HYDROSTATIC TEST SET -UP, FULLY EXPOSED PIPING
LEGEND:
TR Temperature Recorder
PR Pressure Recorder
PI Pressure Gauge
DWT Dead Weight Tester
* Locate in shade
5.0 TEST PREPARATION
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.
5.2 Bolting, vents and Drains

Check and tighten bonnet flange bolts, valve flange bolts, and packing of all
valves in test section. Remove and plug any bonnet relief valves which may
be vented to atmosphere. Check all plugged connections.
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.
5.5 Fill Connections

The temporary fill piping shall include a meter and a recording pressure
gauge. These shall be installed in the fill line to enable the total volume of
water which enters the test section to be determined and recorded. This
piping shall also include a filter which will remove all solids exceeding 6.4
mm in diameter. A check valve shall be installed a the point where the fill
piping is tied into the test section.
5.6 Temperature Recorders

All test equipment shall be installed prior to filling the section with water. One
recorder is installed with the temperature bulb attached to the pipe and
insulated. A second recorder shall be used to record the ambient air
temperature.
6.0 TEST PROCEDURES
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.
6.3 Temperature Stabilization

After the majority of free air as has been removed using high point vents, the
test section shall be pressurized to 60% of the final test pressure and held
until the temperature stabilizes. The temperature stabilization period shall
not be less than two (2) hours, and large bore piping systems may require
longer periods (test sections should be sloped so that air will migrate to high
points).
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.
6.5 Strength Test

Upon reaching the specified test pressure, the test section shall be isolated.
This may include disconnecting the pump. After transient pressure
conditions in the test section have dissipated, the strength test shall begin.
6.6 Relief of Test Medium

Test medium shall be withdrawn prior to the pressure exceeding 102.5% of
the design test pressure. If relief of the test medium is required, this volume
may be re-injected later should the pressure decrease. All interim
withdrawals shall be logged and reconciled. Leaks which appear at flanged
or threaded connections must be immediately repaired as they appear. The
pressure should be reduced to at least 60% of the test pressure before
leaking connections are tightened.
6.7 Visual Inspection

Where the test pressure can result in a hoop stress of 100% or more of
SMYS of the piping, no visual inspection shall take place during the strength
test. Upon completion of the strength test, the pressure shall be reduced to a
maximum of 115% of MOP and a minimum of 110% of MOP. When a
complete visual inspection has confirmed the absence of leaks, the test
section can be depressurized. No visual inspection shall be conducted
while the test pressure exceeds 115% of MOP.
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.
6.9 Freezing Protection

Dead legs, low points, and drain connections shall be emptied of water or
alternately displaced of water by methanol if freezing temperatures may
occur prior to placing the test section in service.
7.0 ACCEPTANCE CRITERIA

The hydrostatic test will be considered acceptable if the conditions listed in
subsections 7.1 through 7.4 are maintained during the test period.
7.1 Maximum Test Pressure

The hydrostatic pressure in the test section does not exceed the lesser of the
pressures that result in:
a) 102.5% of the design test pressure;
b) a stress of 100% SMYS.
7.2 Minimum Test Pressure

The hydrostatic pressure in the test section does not fall below 97.5% of the
design test pressure.
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).
8.0 RECORDING AND DOCUMENTATION
8.1 Test Data Logging

During the first hour of the test, the data listed below shall be recorded every
fifteen (15) minutes and every thirty (30) minutes there after for the balance
of test.
a) time that the reading is taken;
b) the ambient temperature indicated by the recorder;
c) the ambient temperature indicated by a mercury thermometer;
d) the pipe temperature indicated by the recorder;
e) the test pressure indicated by the deadweight tester;
f) the test pressure indicated by the recorder;
g) any remarks, such as weather conditions, phase of testing and volume
additions and withdrawals.
8.2 Hydrostatic Test Record

In addition to the test data log, all station hydrostatic tests shall be
documented with a Test Record certificate. This test record shall include:
a) the time and date of the test;
b) pipe standards or specification for the section tested;
c) location of the test section;
d) the test medium used;
e) the test duration;
f) location and cause of leaks or failures and the description of the repair
action taken.
8.3 Hydrostatic Test File

The following information shall be compiled and filed with engineering on the
completion of the test program:
a) the test data logs;
b) the hydrostatic test record;
c) the pressure and temperature recording logs;
DATE
TERASEN PIPELINE
HYDROSTATIC TEST RECORD START OF TEST
Station Piping END OF TEST
TEST LOCATION TEST MEDIUM
PIPE DESIGN DATA

Specification Wall Thickness Design
Design Factor OD (mm) SMYS (MPa)
and Grade (mm) Pressure (kPa)
CRITICAL TEST POINTS

Location Elevation Minimum Maximum
(m)
Point km kPa %SMYS KPa %SMYS
Test Point
1
High Point
1
Low Point
TEST EQUIPMENT RECORD

Function Type of Equipment Serial Number
Comments:
TERASEN REPRESENTATIVE SIGNATURE DATE

(PLEASE PRINT)
1) This data is only required for long test sections, such as tank lines.
HYDROSTATIC TEST DATA LOG DATE
Station Piping
PAGE OF
MINIMUM TEST PRESSURE kPa TEST LOCATION

MAXIMUM TEST PRESSURE kPa TEST MEDIUM
AMBIENT TEMPERATURE (°C) PIPE DEAD PRESSURE

TIME TEMPERATURE WEIGHT RECORDER REMARKS
(°C) TESTER (kPa)
RECORDER THERMOMETER (kPa)
TERASEN REPRESENTATIVE (PLEASE PRINT) SIGNATURE DATE

Station Hydrostatic Test Procedure: MP4111, Revision 1, June 1996

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TERASEN PIPELINES (TRANS MOUNTAIN) INC.

ENGINEERING STANDARDS AND PRACTICES

STATION HYDROSTATIC TEST PROCEDURE

MP4111, Revision 1, June 1996

5.3 Insulation .............................................................................................................11

2.0 REFERENCE PUBLICATIONS

3.1 Fabricated Assemblies

3.2 Hydrostatic Testing

3.4 Main Line Piping

3.8 Station Piping

4.0 TEST REQUIREMENTS

4.1.1 Test Supervision

4.2 Stresses at Test and Operating Pressures

TABLE 4.2.A -- THE RELATIONSHIP OF TEST AND DESIGN PRESSURES

4.3 Test Medium

4.3.4 Volatile Liquids

4.4 Test Pressures and Duration

4.4.1 Piping Exposed During Testing

4.4.2 Piping Buried During Testing

4.4.3 Atmospheric Drain Systems

TABLE 4.4.A MINIMUM TEST PRESSURES AND DURATION FOR EXPOSED

Exposed Class A, PN 20 (150 ANSI) 1 2375 1900

Atmospheric Drain Systems 1 700 <700

4.5 Test Equipment

4.5.1 Equipment Required

TABLE 4.5.1.A -- MINIMUM EQUIPMENT REQUIREMENTS

4.5.2 Equipment Calibration

4.5.4 Instrumentation Arrangement

4.5.5 Test Head Assemblies

FIGURE 4.5.A -- HYDROSTATIC TEST SET -UP, FULLY EXPOSED PIPING

5.0 TEST PREPARATION

5.2 Bolting, vents and Drains

5.5 Fill Connections

5.6 Temperature Recorders

6.0 TEST PROCEDURES

6.3 Temperature Stabilization

6.5 Strength Test

6.6 Relief of Test Medium

6.7 Visual Inspection

6.9 Freezing Protection

7.0 ACCEPTANCE CRITERIA

7.1 Maximum Test Pressure

7.2 Minimum Test Pressure

8.0 RECORDING AND DOCUMENTATION

8.1 Test Data Logging

8.2 Hydrostatic Test Record

8.3 Hydrostatic Test File

TEST LOCATION TEST MEDIUM

PIPE DESIGN DATA

CRITICAL TEST POINTS

TEST EQUIPMENT RECORD

TERASEN REPRESENTATIVE SIGNATURE DATE

MINIMUM TEST PRESSURE kPa TEST LOCATION

AMBIENT TEMPERATURE (°C) PIPE DEAD PRESSURE

TERASEN REPRESENTATIVE (PLEASE PRINT) SIGNATURE DATE

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