3 Best Practices for 100% Regulatory Compliant Testing
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This document outlines best practices for hydrostatic testing pipeline assets to verify documentation, trace records, and ensure regulatory compliance. It discusses computing test parameters, developing a test plan addressing environmental permits and safety, gathering test data, and confirming results in a final report. The process aims to precisely record all pipeline details, test pressures, temperatures, and outcomes to demonstrate asset integrity and allow auditing at any time.
3 Best Practices for 100% Regulatory Compliant Testing
- 1. The Hydrostatic Testing Best Practices Plan to Verify, Trace, & Precisely Record Documentation Jared Head
- 2. Hydrostatic Testing BestPractices Verify, Trace, & Record PHMSA Best Practice CTA Test Computations Test Plan Test Report Data Gathering Final Confirmation Asset Audits File Documents Approvals/Sigs Reg. Compliance Lead Time to Plan Operating Capacity Asset longevity Protocol
- 3. Hydrostatic test computations Precise estimations of pipeline features & descriptions -Diameter, wall thickness, length, pipe grade, age, etc. -API vs ASME/ANSI Rating on operation pressure -SMYS: 90%-100% & MOP: 125% for 4 hours -Accurate elevations of pipeline -Test medium (water), volume of medium, & temperature stabilization Line sections based on elevations and SMYS Project Manager Verification of job scope -Project Managing Engineer -Customer Asset Manager
- 4. H y d r o s t a t i c t e s t c o m p u t a t i o n s MOP validated by hydro test outcome
- 5. Hydrostatic test plan Follow the PHMSA standard IMP with environmental compliance -Environmental questions need to be solved to obtain permits for compliance: EPA, NEPA, BLM, SPE, FERC, DOT, OSHA, etc. -Locate areas that supply water sources, consult with operators/contractors to solve these issues, and find discharge areas that are compliant. Fabricated test = 4 hours | Mainline test = 8 hours -Long bore hours before pipe install and fabricated test for HDDs -Test for mainline once installed to test for HDDs
- 6. Hydrostatic test plan Environment Rules & Regulations -Water source -Discharge area -Quality of water Order of test plan steps -Line fill and applying pressure -Testing -Data gathering -Finishing test -Dewatering the section -Push slug of water to next section or use new water -Drying to dewpoint & cleaning -Final Confirmation with approvals
- 7. Hydrostatic test plan Minimum, Target, & MOP for each section for pressure DOT/PHMSA Rules -Test type: spike, strength, leak -Test medium, equipment, instruments -OQ certs of personnel doing test -Test failures, leaks, blowouts -Test duration -Test data & drawings -Proper approvals from project personnel -These will be all required to be maintained as part of the test plan
- 8. Hydrostatic test plan Items needed for approval before starting test -This should be communicated between asset owner and contractors/subcontractors before performing the work so there isn't any delay in the project schedule. -Emails, drawings, Gantt charts, and conference calls are a great way to communicate job expectations, area of concerns, strategies, etc.
- 9. Hydrostatic test report Meeting between job managers to understand the data found is stored before job kick-off According to operating company's procedures while following DOT/PHMSA compliance Thorough, step-by-step program
- 10. Hydrostatic test report Accurate measurements -Pipe diameter & WT -Pipe grade & SMYS/ANSI rating -Line location & elevation -Test medium: source & volume -Chemicals: used & volume -Test schedule (ex: Gantt chart) -Test pressure: time recorded -Temperature of pipe & medium -Weather -Test lengths per segment
- 11. Hydrostatic test report Accuracy of Recorded data -All written data must be transported to digital format for storage -Written information can be lost or misread -Written information has a shelf life
- 12. Hydrostatic test data gathering Researching & implementing Knowing the test reports & records -Personnel verifying the test data -Shows those collaborating with the reports what is mandatory to be gathered and what steps are needed to be approved Make sure all written data is stored in Final Confirmation Book
- 13. Hydrostatic test data gathering Equipment & measuring devices are calibrated -High horse-powered pump with hoses and gauges to fill the line -Injection pump for chemicals, dyes, & gases -Speed pump with volume per stroke & stroke counter -Pressure sensory instrument or deadweights testing & recording sheet -Test medium temperature tracker instrument & recording sheet -Your surrounding environment temperature gauge & recording sheet -Test medium sampling instrument -Gas/O2 sensing instrument
- 14. Hydrostatic test data gathering Record all info on the mandatory reports -Test medium: pressures, time-length, volume, temperatures -Environment temperatures & weather -Pipe quality and pipe specs (wt, OD, high/low) -Calibration certs & info -Blow-outs, leaks, failed test, etc. -Project leaders signing approvals Keep records of all engineering designs, drawings, blue prints, etc. -Have it in the correct place in the Final Book Keep all the failed data gathered
- 15. Hydrostatic test data gathering Temperature gauges -Weather can effect the test medium with constant pressure on pipeline -Place temperature bulb against pipe, insulate, & backfill to surface level 12 hours before test -12 hours let test medium, line, surface temps to stabilize -Find temp bulbs on pipeline at least 500 feet from exposed pipe
- 16. Hydrostatic test data gathering Temperature gauges -Temp increases = pressure increases -Temp decreases = pressure decreases -Temp change creates volatility in volume of test medium in the line -Avoid testing times with high temperature gain/loss in the day
- 17. Hydrostatic test data gathering Is it a leak or change in temperature? -Pipe temp change vs. Weather temp change -Pipe temp change should run parallel with environment temp change -Volume estimations at start & end of test are taken into play with: pressure change + temperature change = volume change -Verified volumes will be recorded on spreadsheet
- 18. Final Confirmation Get confirmation that the Final Book is complete and contains the right details in 1 location -Test plans & correct recordings -Test specs & descriptions -Survey info -Copies of calibrated certs -Test reports -Test charts (Gantt, temp. plot, etc.)
- 19. Final Confirmation Since the entire report will be structured in 1 place, it will be easy to gather the proper documents to give to auditors Make sure the following personnel have signed off on the report & data: -Anyone who recorded the data -Supervisor of the test -Constr. Supervisor -Engineer -PM -Customer project rep.
- 20. DOT/PHMSA Asset audits -Reviews while constructing to confirm correct records obtained -Job docs are the first requirement verified during a field audit All records are maintained -Stored in an area where it easily reachable for any company personnel to review the file to give indications of pipeline details