Main Line Hydrostatic Test Procedure: MP4121, Revision 2, July 1999

TERASEN PIPELINES (TRANS MOUNTAIN) INC.
ENGINEERING STANDARDS AND PRACTICES
MAIN LINE HYDROSTATIC TEST PROCEDURE
MP4121, Revision 2, July 1999

MP4121 Revision 2 July 16, 1999 Page 1 of 23
Title: MAIN LINE HYDROSTATIC TEST PROCEDURE
TABLE OF CONTENTS
1.0 SCOPE...............................................................................................................................4
2.0 REFERENCE PUBLICATIONS .....................................................................................4
3.0 DEFINITIONS ...................................................................................................................4
3.1 Fabricated Assemblies ........................................................................................4
3.2 Hydrostatic Testing ..............................................................................................4
3.3 km ...........................................................................................................................4
3.4 Main Line Piping ...................................................................................................5
3.5 MOP........................................................................................................................5
3.6 NPS ........................................................................................................................5
3.7 PN...........................................................................................................................5
3.8 Station Piping ........................................................................................................5
3.9 SMYS .....................................................................................................................5
4.0 TEST REQUIREMENTS .................................................................................................5
4.1 General ..................................................................................................................5
4.1.1 Test Supervision......................................................................................... 5
4.1.2 Application .................................................................................................. 6
4.1.3 Safety .......................................................................................................... 6
4.2 Test Medium .........................................................................................................6
4.2.1 General ....................................................................................................... 6
4.2.2 Additives ..................................................................................................... 7
4.2.3 Hydrocarbons.............................................................................................. 7
4.2.4 Volatile Liquids ............................................................................................ 7
4.3 Test Duration.........................................................................................................7
4.3.1 Buried Piping During Testing...................................................................... 7
4.3.2 Piping Exposed During Testing .................................................................. 7
4.3.3 Pre-Testing Main Line Piping ..................................................................... 7
4.3.4 Fabricated Assemblies ............................................................................... 7
4.4 Test Pressure........................................................................................................7
4.4.1 Strength Test Pressure, Piping .................................................................. 7
4.4.2 Strength Test Pressure, Fabricated Assemblies........................................ 8
4.4.3 Strength Test Pressure, Maximum............................................................. 8
4.4.4 Strength Test Pressure, Minimum.............................................................. 8
4.4.5 Leak Test Pressure..................................................................................... 8
4.5 Test Equipment.....................................................................................................9
4.5.1 Equipment Required ................................................................................... 9
4.5.2 Equipment Calibration ................................................................................ 9
4.5.3 Certification ................................................................................................. 9

4.5.4 Instrumentation Arrangements ................................................................... 9
4.5.5 Test Head Assemblies................................................................................ 9
5.0 TEST PREPARATION...................................................................................................12
5.1 Test Plan..............................................................................................................12
5.1.1 Test Organization ..................................................................................... 12
5.1.2 Test Medium ............................................................................................. 12
5.1.3 Test Temperature ..................................................................................... 12
5.1.4 Test Pressure, New Construction............................................................. 13
5.1.5 Test Pressure, Existing Pipeline Systems................................................ 13
5.1.6 Drawings ................................................................................................... 13
5.1.7 Safety ........................................................................................................ 14
5.1.8 Public and Environment............................................................................ 14
5.1.9 Notification ................................................................................................ 14
5.1.10 Failures...................................................................................................... 14
5.2 Cleaning ...............................................................................................................15
5.2.1 New Construction ..................................................................................... 15
5.2.2 Retesting Main Line .................................................................................. 15
5.3 Pre-Test Logistics...............................................................................................15
5.3.1 Insulation................................................................................................... 15
5.3.2 Shelters..................................................................................................... 15
5.3.3 Temperature Recorders ........................................................................... 15
5.3.4 Fill Connections (Injection of Test Medium)............................................. 16
5.3.5 Pre-Test Organization .............................................................................. 16
5.3.6 Valve Integrity ........................................................................................... 16
6.0 TEST PROCEDURES ...................................................................................................17
6.1 General ................................................................................................................17
6.2 Filling ....................................................................................................................17
6.2.1 Fill Pigging ................................................................................................ 17
6.2.2 Fill Suction ................................................................................................ 18
6.3 Temperature Stabilization .................................................................................18
6.4 Pressurization .....................................................................................................18
6.4.1 Pressure-Volume Plots............................................................................. 18
6.4.2 Pressurizing .............................................................................................. 19
6.4.3 Leaks......................................................................................................... 19
6.5 Strength Test.......................................................................................................19
6.5.1 Relief of Test Medium............................................................................... 19
6.6 Leak Test .............................................................................................................19
6.6.1 Piping Buried During Testing.................................................................... 19
6.6.2 Piping Exposed During Testing ................................................................ 19

6.7 Depressurizing and De-Watering .....................................................................20
6.7.1 Depressurizing.......................................................................................... 20
6.7.2 De-watering............................................................................................... 20
6.7.3 Freezing Protection................................................................................... 20
7.0 ACCEPTANCE CRITERIA ...........................................................................................21
7.1 Maximum Test Pressure ...................................................................................21
7.2 Minimum Test Pressure ....................................................................................21
7.3 Reconciliations ....................................................................................................21
7.4 Leaks....................................................................................................................21
8.0 RECORDING AND DOCUMENTATION ....................................................................22
8.1 Test Data logging ...............................................................................................22
8.2 Hydrostatic Test Record....................................................................................22
8.3 Hydrostatic Test File ..........................................................................................23
1.0 SCOPE
This standard covers the mandatory hydrostatic test requirements for main line
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 Main Line piping systems. This standard excludes pneumatic
testing and hydrostatic testing of valves or station piping systems.
2.0 REFERENCE PUBLICATIONS

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 Z662-99 Oil & Gas Pipeline Systems
National Energy Board Act SOR/99-294 Onshore Pipeline Regulations, 1999
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 number GS1000.
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 Trans
Mountain or an appointed agent. The agent shall be independent of
any contractor who carries out the pressure testing and any
contractor who constructed the pipeline or any component intended
for use in the pipeline. 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 exceeds 115% of MOP (Note: visual
inspection shall take place during the leak test. These
inspections shall be conducted in accordance with subsection
6.6).
4.2 Test Medium
4.2.1 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 are valid for pure water only)
4.2.2 Additives
All necessary disposal arrangements and/or permits must be in place
prior to introduction of glycol or methanol additives to hydrotest
water.
4.2.3 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.
4.2.4 Volatile Liquids

Volatile liquids such as gasoline or crude oil shall not be used as a
test medium.
4.3 Test Duration
4.3.1 Buried Piping During Testing

Buried piping shall undergo a sequential strength and leak test. The
strength test shall be at least four (4) hours in duration, immediately
followed by a leak test of at least four (4) hours duration.
4.3.2 Piping Exposed During Testing

A leak test is not required for fully exposed piping where a complete
visual inspection to detect leaks is conducted. The test duration in
this case shall be at least one (1) hour.
4.3.3 Pre-Testing Main Line Piping

As in 4.3.2, a leak test is not required for the pre-testing of main line
pipe, provided that a visual inspection is conducted to detect leaks.
The test duration in this case shall be at least one (1) hour.
4.3.4 Fabricated Assemblies

As in 4.3.2, a leak test is not required for the testing of fabricated
assemblies provided that a visual inspection is conducted to detect
leaks. The test duration in this case shall be at least one (1) hour.
4.4 Test Pressure
4.4.1 Strength Test Pressure, Piping

The strength test pressure for buried or exposed piping shall be that
pressure at the point of maximum stress which normally produces a
hoop stress corresponding to 100% of the SMYS of the pipe. The

maximum test pressure shall be computed as shown in Appendix A.
(Note: retesting of existing pipelines may require a lower test
pressure)
4.4.2 Strength Test Pressure, Fabricated Assemblies

The minimum strength test pressure for fabricated assemblies,
whose MOP is governed by component pressure class, shall be as
indicated in Table 4.4.A.
4.4.3 Strength Test Pressure, Maximum

Notwithstanding the requirements of 4.4.1 and 4.4.2, the strength test
pressure shall not exceed 15,275 kPa (102.5% of PN 100 flange
rating).
4.4.4 Strength Test Pressure, Minimum

The minimum test pressure for piping shall not be less than 97.5%
of the required test pressure.
4.4.5 Leak Test Pressure

The leak test pressure shall be at least 110% of the MOP.
Note: The point of maximum stress generally occurs at the point of lowest
elevation, but this can vary depending on variations in pipe wall thickness
within the test section.
TABLE 4.4.A TEST REQUIREMENTS FOR MAIN LINE PIPING
Test Configuration Test Test Pressure (kPa)

Duration (hr)
Buried Strength Test 4 97.5% of PStrength ≤ P ≤ 102.5% of PStrength

Piping Leak Test 4 110% of MOP ≤ P < 115% of MOP
Exposed Piping 1 97.5% of PStrength ≤ P ≤ 102.5% of PStrength
Fabricated PN 50 (300 ANSI) 1 P ≥ 6,210

Assemblies PN 100 (600 ANSI) 1 P ≥ 12,415
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 4.5.1.A is the minimum required for either a
main line test or a test of prefabricated piping in a shop or yard.
TABLE 4.5.1.A -- MINIMUM EQUIPMENT REQUIREMENTS

Equipment Mainline Shop/Yard
Plunger type squeeze pump with or without 1
2
revolution counter as required (pump only)
Pressure recorder 4 1
Temperature recorder to record pipe, ground, and per test
2*
ambient temperatures schematic
Dead weight tester 2 1
Pressure gauge 1 1
Thermometer 1 1
Calibrated liquid measure to ± 10 ml 1 1
* pipe and ambient temperatures only
4.5.2 Equipment Calibration

All recorders and gauges shall be calibrated in accordance with EI
Procedure VII.A.1, Main Line Testing.
4.5.3 Certification
Dead weight testers and calibrated thermometers shall be certified to
a government standard every three years.
4.5.4 Instrumentation Arrangements

Refer to Figures 4.5.A and 4.5.B for typical instrumentation
arrangements.
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 ancillary piping shall
not be pressurized to a stress exceeding 50% of the SMYS of the
piping.
FIGURE 4.5.A -- HYDROSTATIC TEST SET -UP, BURIED PIPING
TEST SECTION
PIPE PIPE PIPE SOIL PIPE PIPE PIPE AMB SOIL PIPE PIPE PIPE
TR TR TR TR TR TR TR TR TR TR TR TR
M/L BLOCK GEL M/L BLOCK M/L BLOCK

10m GEL
VALVE PLUG VALVE VALVE
(TYP) PLUG
PR PR
DWT
DWT
PR NPS 2
PR
SPECTACLE
PI BLINDS
NPS 4
TEST TRAILER
PI
VENT
NPS 2
NPS 4
NPS 4
WATER
NPS 2
TANK NPS 1
TURB. METER
NPS 2 NPS 2 NPS 2 NPS 2

TURB. METER Y-STRAINER
NPS 4 NPS 4 (TYP.2)
HYDROTEST SKID
D S D S
LEGEND:
SPARE MAIN
PUMP PUMP
PI PRESSURE INDICATOR (GASO) (GASO)
TR TEMPERATURE RECORDER
NOTE:
PR PRESSURE RECORDER FLANGED AND THREADED CONNECTIONS
ARE NOT IDENTIFIED ON THIS DRAWING
ALL CONNECTIONS TO THE HYDROTEST
DWT DEAD WEIGHT TESTER
SKID ARE PN100 (ANSI Class 600) FLANGED
FIGURE 4.5.B -- HYDROSTATIC TEST SET -UP, FULLY EXPOSED PIPING
Squeeze Pump
Vent
TEST SECTION
Pipe
TR
DWT
TR Ambient
PR
PI
LEGEND:
TR Temperature Recorder
PR Pressure Recorder
PI Pressure Gauge
DWT Dead Weight Tester
* Locate in shade
5.0 TEST PREPARATION
5.1 Test Plan

Prior to the commencement of main line test, a written test plan shall be
developed. The following information shall be included in the test plan:
5.1.1 Test Organization

The test plan shall clearly delineate the responsibilities of various
personnel involved in the test, especially those who prepare the
documentation.
5.1.2 Test Medium

The source and volume of the test medium shall be identified in the
test plan. The fill volume should be sufficient to fill and pressurize
the test section (including allowance for retesting in case of line
rupture). In addition to this requirement, the following information
should also be included:
a) Identification of any permits for use and/or disposal of the test
water; (Note: These permits should be obtained well in advance
of the test date as they can take in excess of 4 weeks to
process)
b) Listing of any terms or restrictions on the water use/disposal
permit covering water quality requirements, total quantity of
water allowed to be taken, the rate of taking and discharge, and
discharge location.
5.1.3 Test Temperature

The anticipated test temperatures and any freezing precautions (if
required) shall be listed in the test plan. These temperatures should
include that of the test medium, atmosphere and ground. The test
plan should indicate how these values might affect the anticipated
temperature stabilization period of the test medium. Because of the
problems associated with reconciliation calculations, hydrotests with
pure water should be avoided at test temperatures below 5oC (Note:
as water starts to drop below 4 oC it starts to expand prior to freezing).
5.1.4 Test Pressure, New Construction

The proposed test pressure and governing point of maximum stress
shall be identified in the test plan (strength and leak test pressures).
The test pressure is the pressure measured at the location of the
dead weight tester used to monitor the test. As indicated in 4.4.1, the
strength test pressure is that pressure at the point of maximum
stress which normally produces a hoop stress corresponding to
100% of the SMYS of the pipe. The test pressure may be below that
corresponding to 100% of the SMYS because the location of the
point of maximum stress and the point where the test pressure is
monitored may not coincide. In determining the test pressure, the
following should be reviewed to locate the point of maximum stress:
a) Location of the pipe and pipe components in the test segment.
Pipe and piping components should be identified by their size,
wall thickness, grade and elevation.
b) The shell pressure and flange rating and location of all pipeline
valves, equipment and other connections to the segment that
will be exposed to the test pressure (Note: the maximum
pressure differential that a mainline valve is certified for is 10920
kPa).
5.1.5 Test Pressure, Existing Pipeline Systems

When testing existing pipeline systems, determination of the
maximum strength test pressure must take into account the
metallurgical history of the pipe. In particular the following shall be
considered:
a) prior test history (and potential for pressure reversals);
b) pipe type and method of manufacture;
c) pipe manufacturer;
d) mill test and inspection records; and
e) field inspection and test records.
5.1.6 Drawings
The test plan should include copies of the test section profile and
associated alignment drawings. The profile drawing should indicate
the fill and discharge locations, point of maximum stress, and the test
pressure monitoring station.
5.1.7 Safety
The test plan shall list the safety precautions and procedures for
personnel who perform the test. These safety precautions shall also
apply to the fill lines, instrument lines and compression equipment.
These precautions should include the appropriate provisions of
subsection 4.1.3 of this standard.
5.1.8 Public and Environment

The test plan shall list the precautions and procedures to minimize
risk to the public and the environment. When retesting sections of
the main line, there exists the potential for the loss of contaminated
water or hydrocarbons at a main line rupture. To minimize this
potential, main line block valves shall be utilized to segregate the test
section from the other contents of the main line and limit the resultant
static head at the potential leak site. Finally, plans sho uld be made
to position spill containment equipment at the appropriate locations.
5.1.9 Notification
In addition to the National Energy Board, the following provincial
authorities and individuals (as applicable) should be kept informed of
any testing of main line piping outside of Terasen Pipelines (Trans
Mountain) Inc.'s terminals and pump stations:
a) Ministry of Environment;
b) Ministry of Highways;
c) Fish and Wildlife Branch;
d) R.C.M.P. and municipal police forces;
e) affected landowners.
5.1.10 Failures
The test plan should inc lude all procedures and provisions for dealing
with a failure. This procedure should include methods for preserving
failed specimens for analysis.
5.2 Cleaning
5.2.1 New Construction

Welding slag, sand and construction debris shall be removed from
the test section prior to commencement of the test. New pipelines
shall be cleared with a construction cleaning pig. The cleaning pig
shall be run during daylight hours and shall 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.
5.2.2 Retesting Main Line

When retesting sections of the main line, flush required sectionalizing
valves prior to the movement of the test batch into place. 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. (Note: the maximum pressure differential that a
mainline valve is certified for is 10,920 kPa).
5.3 Pre-Test Logistics

After all necessary permits are in place, the appropriate notifications have
been made and the line has been cleared of any debris, the final step is
installation of test equipment and pre-test organization.
5.3.1 Insulation
For new construction, the length of bare pipe shall be minimized prior
to the commencement of main line testing operations. Any bare
piping should be backfilled, insulated and/or covered and heated
such that ambient conditions (eg. wind, rain, sunlight) will not have
adverse effects on the test results.
5.3.2 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.
5.3.3 Temperature Recorders

All test equipment shall be installed prior to filling the line with water.
For main line testing, pipe wall temperature recorders shall be
installed with the temperature bulb attached to the pipe, insulated
from the surrounding soil and backfilled. Soil temperature recorders

shall be installed to record the ground temperature 15 m from the
pipe and at the same depth as the pipe. As indicated on Figure
4.5.A, a typical test section will have five (5) pipe wall temperature
recorders (two end point and three intermediate) and two (2) soil
temperature recorders (note: ground temperature recorders are not
required for the testing of exposed piping).
5.3.4 Fill Connections (Injection of Test Medium)

The temporary fill piping shall include a meter and a recording
pressure gauge. These shall be installed in the fill line to enable the
rate of fill and 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 at the point where the fill piping is tied into the
pipeline.
5.3.5 Pre-Test Organization

The communication system and equipment used to monitor the test
section shall be thoroughly checked out prior to test. Adequate
numbers of personnel to identify leak locations shall be deployed
prior to the start of the test. Any necessary safety barricades and
warning signs should be posted on the right-of-way. All affected
sectionalizing valves should be closed and check valves should be
blocked open.
5.3.6 Valve Integrity

Where valve sealing ability of a mainline block valve is in question,
consideration should be given to installing a blind flange or using a
gel plug to ensure a tight seal.
6.0 TEST PROCEDURES
6.1 General
The test procedure covers six distinct phases. These phases include: filling,
temperature stabilization, pressurization, strength test, leak test and
depressurization. These phases are illustrated in Figure 6.1.A.
FIGURE 6.1.A -- HYDROSTATIC TEST PHASES
Strength Test Leak Test

Pressurization Depressurization
Filling Temperature Stabilization
100%
110% of MOP
60% 0f Test Pressure
Nominal
Pressure Profile
Daylight Daylight
6.2 Filling
6.2.1 Fill Pigging

New lines should be filled with water using a new urethane
unidirectional pig ahead of the fill water. When filling with a pig,
consideration shall be given to maintaining some back pressure to
prevent the pig from running away from the water when the pig is
travelling down hill. This can be achieved by controlling the rate at
which air leaves the opposite end of the test section. The rate of fill
shall not exceed that stated in the water permit. If water is moved
into test section through the pipeline, urethane pigs on either side of
the water batch are required to separate oil and water.
6.2.2 Fill Suction

If test water is taken from lakes, ponds, or streams, the water intake
shall be screened and located to eliminate entrained air. The intake
shall be such that the fill water is free of organic or particulate matter.
6.3 Temperature Stabilization

After the majority of free air as has been removed using high point vents
and/or pigs, the test section shall be pressurized to 60% of the final test
pressure and held until the temperature stabilizes (above ground test
sections should be sloped so that air will migrate to high points). The
temperature stabilization period shall last until the pipe time-temperature plot
is sufficiently asymptotic to the ground temperature. Pressures shall be
recorded on an hourly basis for buried piping and the stabilization period
should last a minimum of twelve (12) hours. Pressurization shall not proceed
until the temperature remains stable for at least two (2) hours.
6.4 Pressurization
Pressurizing to test pressure and associated pressure-volume plotting shall
be conducted during daylight hours. Pressurization shall start early enough to
allow sufficient time prior to nightfall to discover a any leaks. All hydrostatic
tests shall commence on the hour or the 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.
6.4.1 Pressure-Volume Plots

If the pressure at any location in the test section will result in a stress
greater than 100% of SMYS, a pressure-volume (PV) plot is required.
The PV plot must be maintained for the duration of the pressurization
phase and points should be plotted at every 50 kPa increment in
pressure so that any deviation from the straight-line portion of the
plot can be detected. The PV plot shall start at 60% of the final test
pressure. (Note: If two or more pumps are used in parallel to
pressure up the line to 60% of test pressure, only one pump should
be used for pressurization while PV plotting. This is recommended to
facilitate recording of volumes pumped as required by the PV plot.)
6.4.2 Pressurizing
On main line tests, upon completion of the temperature stabilization
period, the pressure shall be raised at a rate not to exceed 50 kPa
per minute (this restriction does not apply to tests that do not require
PV Plotting). Pumping shall be conducted in such a manner to
prevent surges and vibrations that could damage the pipeline.
Pumping shall continue until the pressure-volume plot reaches the
0.2% offset line, or the maximum test pressure is reached.
6.4.3 Leaks
Prior to attempting any repairs to leaks, the pressure shall be
reduced to the lower of 80% of the maximum pressure achieved at
the location of the leak, or a pressure that produces a hoop stress
equivalent to 60% of SMYS at the point of maximum stress.
6.5 Strength Test

Upon reaching the specified test pressure, the test section shall be isolated.
This may include disconnecting of the pump. After transient pressure
conditions in the test section have dissipated, the four (4) hour strength test
shall begin. (Note: Positive isolation using plugs, blind flanges or a double
block and bleed isolating arrangement is recommended to confirm no
leakage occurs through fill pipe fittings.)
6.5.1 Relief of Test Medium

Test medium shall be withdrawn prior to the pressure exceeding
102.5% of the strength 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.
6.6 Leak Test
6.6.1 Piping Buried During Testing

Upon successful completion of the strength test, the pressure shall
be bled down to a maximum of 115% of the MOP. After transient
pressure conditions in the pipe have dissipated, the leak test shall
start. The pressure shall not fall below 110% of the MOP for the
balance of the test.
6.6.2 Piping Exposed During Testing

Where the test section consists entirely of exposed piping, the leak
test is not required, provided that a complete visual inspection has
confirmed the absence of leaks. This inspection shall be completed
immediately after the strength test at the pressures specified in 6.6.1

above. No visual inspection shall be conducted while the test
pressure exceeds 115% of MOP.
6.7 Depressurizing and De-Watering
6.7.1 Depressurizing
After successful completion of the strength test (and leak test if
required) the pressure shall be bled down only to the hydrostatic
head at the bleed off point. The rate of depressurization shall not
exceed 150 kPa per minute. The bleed off point should be the
highest of the two ends in the test section to bleed excess pressure
while preventing air from entering the pipeline. Depressurizing
should be carried out slowly to prevent hydraulic surges and avoid
excessive pipe vibration. All test media must be disposed of in the
manner specified in permits.
6.7.2 De-watering
If water is moved into the test section through the pipeline, the test
water shall be retained for disposal at the appropriate location. For
new construction in excess of 300 m, de-watering shall be carried out
by propelling with compressed air, two (2) spheres or a bi-directional
pig (normally in the reverse travel to that used during filling). The air
pressure should be reduced, as the run nears completion, to
minimize stored energy in the system. De-watering lines shall be of
sufficient strength and be securely supported and tied down at the
discharge end to prevent whipping during this operation. The area at
the outlet for disposal of test water should be protected from erosion
or scouring by means of an energy absorbing diffuser or armouring of
the outlet area.
6.7.3 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 102.5% of the
strength test pressure (note: to minimize the potential for pressure reversals,
the pressure should be kept to a maximum of 115% of MOP during the leak
test).
7.2 Minimum Test Pressure

The hydrostatic pressure in the test section does not fall below:
a) 97.5% of the strength test pressure during the strength test; and
b) 110% of MOP during the leak test.
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 6.4.2).
Note: A copy of the reconciliation computations are required for leave to open
applications.
8.0 RECORDING AND DOCUMENTATION
8.1 Test Data logging

The following data shall be recorded every fifteen (15) minutes during the
first hour of the streng th test, and every thirty (30) minutes there after for the
balance of the strength and leak tests (remote data can be recorded hourly).
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 temperatures indicated by the two recorders;
e) the soil temperatures indicated by the two recorders;
f) the test pressure indicated by the deadweight tester;
g) the test pressure indicated by the recorder;
h) 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 main line 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 and test points;
d) the test medium used;
e) the test duration;
f) record of the test equipment used;
g) 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:
a) the test data logs;
b) the hydrostatic test record;
c) the elevation profile;
d) the pressure and temperature recording logs; and
e) the pressure-volume plot (if required).
HYDROSTATIC TEST PRESSURE-UP Page:
DATA SHEET
Test Section:
Test Trailer Location:
Pump #1: Unit #: Maximum Pressure Increase Rate: 50 kPa/min.
Pump #2: Unit #:
Meter #1: Unit #: Range: K Factor:
Meter #2: Unit #: Range: K Factor:

Dead Weight
Tester: Serial #:
(Optional) (Optional)
AVERAGE AVERAGE
READING INTERVAL TIME PRESSURE * TOTAL PUMP TOTAL VOLUME
STROKE RATE VOLUME RATE REMARKS
NUMBER (sec.) (kPa) STROKES (I)
(str./min.) (l/min.)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
* Note: See Master Sheet for Test Equipment Information
Recorded By: Signature: Date:

Terasen Supervisor/Technician (Print Name)
Recorded By: Signature: Date:

Terasen Supervisor/Technician (Print Name)

Main Line Hydrostatic Test Procedure: MP4121, Revision 2, July 1999

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Main Line Hydrostatic Test Procedure: MP4121, Revision 2, July 1999

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TERASEN PIPELINES (TRANS MOUNTAIN) INC.

ENGINEERING STANDARDS AND PRACTICES

MAIN LINE HYDROSTATIC TEST PROCEDURE

MP4121, Revision 2, July 1999

4.5.3 Certification ................................................................................................. 9

6.6.2 Piping Exposed During Testing ................................................................ 19

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 Test Medium

4.2.4 Volatile Liquids

4.3 Test Duration

4.3.1 Buried Piping During Testing

4.3.2 Piping Exposed During Testing

4.3.3 Pre-Testing Main Line Piping

4.3.4 Fabricated Assemblies

4.4 Test Pressure

4.4.1 Strength Test Pressure, Piping

hoop stress corresponding to 100% of the SMYS of the pipe. The

4.4.2 Strength Test Pressure, Fabricated Assemblies

4.4.3 Strength Test Pressure, Maximum

4.4.4 Strength Test Pressure, Minimum

4.4.5 Leak Test Pressure

TABLE 4.4.A TEST REQUIREMENTS FOR MAIN LINE PIPING

Test Configuration Test Test Pressure (kPa)

Buried Strength Test 4 97.5% of PStrength ≤ P ≤ 102.5% of PStrength

Exposed Piping 1 97.5% of PStrength ≤ P ≤ 102.5% of PStrength

Fabricated PN 50 (300 ANSI) 1 P ≥ 6,210

4.5 Test Equipment

4.5.1 Equipment Required

TABLE 4.5.1.A -- MINIMUM EQUIPMENT REQUIREMENTS

* pipe and ambient temperatures only

4.5.2 Equipment Calibration

4.5.4 Instrumentation Arrangements

4.5.5 Test Head Assemblies

FIGURE 4.5.A -- HYDROSTATIC TEST SET -UP, BURIED PIPING

M/L BLOCK GEL M/L BLOCK M/L BLOCK

NPS 2 NPS 2 NPS 2 NPS 2

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

5.0 TEST PREPARATION

5.1 Test Plan

5.1.1 Test Organization

5.1.2 Test Medium

5.1.3 Test Temperature

5.1.4 Test Pressure, New Construction

5.1.5 Test Pressure, Existing Pipeline Systems

5.1.8 Public and Environment

5.2.1 New Construction

5.2.2 Retesting Main Line

5.3 Pre-Test Logistics

5.3.3 Temperature Recorders

from the surrounding soil and backfilled. Soil temperature recorders

5.3.4 Fill Connections (Injection of Test Medium)

5.3.5 Pre-Test Organization

5.3.6 Valve Integrity

6.0 TEST PROCEDURES

FIGURE 6.1.A -- HYDROSTATIC TEST PHASES

Strength Test Leak Test

60% 0f Test Pressure