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.

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

21. Any questions?
Ain't nothing finer, than being a pipeliner!