IBP1039_09

SLURRY PIPELINE HYDROSTATIC TESTING,

Roy G. Betinol, P.E 1
Luis Alejandro Navarro Rojas 2

Copyright 2009, Brazilian Petroleum, Gas and Biofuels Institute - IBP

This Technical Paper was prepared for presentation at the Rio Pipeline Conference and Exposition 2009, held between
September, 22-24, 2009, in Rio de Janeiro. This Technical Paper was selected for presentation by the Technical
Committee of the event according to the information contained in the abstract submitted by the author(s). The contents of
the Technical Paper, as presented, were not reviewed by IBP. The organizers are not supposed to translate or correct the
submitted papers. The material as it is presented, does not necessarily represent Brazilian Petroleum, Gas and Biofuels
Institute’ opinion, or that of its Members or Representatives. Authors consent to the publication of this Technical Paper in
the Rio Pipeline Conference Proceedings.

Abstract

The transportation of concentrates and tailings through long distance pipeline has been proven in recent years
to be the most economic, environmentally friendly and secure means of transporting of mine products. This
success has led to an increase in the demand for long distance pipeline throughout the mining industry. In year
2007 alone, a total of over 500 km of pipeline has been installed in South America alone and over 800 km are
in the planning stages. As more pipelines are being installed, the need to ensure its operating integrity is ever
increasing. Hydrostatic testing of long distance pipeline is one of the most economical and expeditious way to
proving the operational integrity of the pipe. The intent of this paper is to show the sound reasoning behind
construction hydro testing and the economic benefit it presents. It will show how hydro test pressures are
determined based on ASME B31.11 criteria.

1. Introduction
In recent years, the international community has become more aware of the climate change that has brought
us what we are experiencing today - global warming. About 10 years ago, in 1997, the United Nations
reached an agreement with the objective of reducing greenhouse gas emissions in an effort to prevent global
warming. This agreement, commonly known as the Kyoto Protocol, has been ratified by 182 participating
countries. The Intergovernmental Panel on Climate Change (IPCC) has predicted an average global rise in
temperature of 1.4° C (2.5° F) to 5.8 °C (10.4° F) between 1990 and 2100. Current estimates indicate that
even if successfully and completely implemented, the Kyoto Protocol will reduce that increase by somewhere
between 0.02 °C and 0.28 °C by year 2050 (source: Nature, October 2003).
Slurry pipeline, as part of the mining industry, is one of the contributors to carbon emission. It is
therefore prudent and judicious for us Pipeline Engineers to contribute some effort in curtailing carbon
emissions for the future of mankind. We can contribute in the form of ensuring reducing energy use, reduction
of installation footprints, water conservation and prevention of damage to our ecosystem.
So, how can Slurry Pipeline Hydrostatic Testing contribute to global warming prevention?
Obviously, any accidental leakage due to pipeline failure would produce wastage on energy use, loss of water
and damage to the affected ecosystem. With that said, compliance to hydrostatic testing is therefore an
important consideration.

1
General Manager, BRASS Chile S.A.
2
Head and Chief Hydraulic Engineer, BRASS Chile S.A.
2. Applicable Codes
The testing of a slurry pipeline shall comply with the international code, ASME B31.11 3 . The
following discussions relate to such code.

2.1 Pressure Definition

Section 1101.2.Maximum Steady State Operating Pressure is defined as the sum of the static head
pressure, pressure to overcome friction loss and any back pressure. This does not include transient or surge
pressure.
Section 1101.2.2 Internal Design Pressure must not be less than the maximum steady state operating
pressure and not less than the static head pressure at that point in the pipeline.

tr = t + A (1104.1.1) (1)

Where:
tr = Calculated wall thickness of the straight section of pipe
t= pressure design wall thickness
A= sum of allowances for threading, corrosion, erosion, and increase in wall thickness
as protective measure.

t = (Pi x D)/2S (1104.1.2) (2)

Where:
Pi = internal design pressure
D= Nominal outside diameter of the pipe
S= 0.80 E x SMYS
tn = nominal wall thickness is selected from the standard pipe tables which should be equal or
greater than tr.

MAOP = 2xSxtn/D (3)

Where:
MAOP = is the Maximum Allowable Operating Pressure
tn = Nominal wall thickness of the straight pipe
D = Nominal outside diameter of the pipe
S= 0.80 E x SMYS

Section 1102.2.4 Allowance for Variations from Normal Operations. Surge (or transient) pressure in
a slurry pipeline shall be calculated so that the level of pressure rise due to surges and other variations from
normal operations shall not exceed by more than 10% the internal design pressure at any point in the piping
system.

Pt = 1.1 x MAOP (4)

2.1 Testing
In order to meet the requirements of the Code, it is necessary that upon completion of installation, all
system, sub-systems and components must be tested. Should leaks occur during tests, the line section or
component part shall be repaired or replaced and retested in accordance with this Code.
Section 1137.1.3 Testing of Fabricated Items. Fabricated items such as special spools, pig
launcher/receiver, manifolds, tanks, etc. shall be hydraulically tested to limits equal to or greater than the
maximum operating pressure of the completed system.

3
American Society of Mechanical Engineers, B32.11 – 2002, Slurry Transportation Piping Systems.
 Section 1137.1.4.Testing After New Construction. Systems or Parts of Systems. Systems operated at
a hoop stress of more than 20% Specified Minimum Yield Strength (SMYS) shall be hydrostatically tested.
Testing of Tie-ins. For pretested sub-systems, hydro testing is not required. However, tie-in welds
and girth welds joining lengths of pretested pipe shall be inspected by radiographic or other nondestructive
testing methods.
Testing of Controls and Protective Equipment. Hydrotest pressure should not exceed manufacturers
design rating.

Section 1137.4.1. Proof Testing. Portions of slurry piping systems to be operated at a hoop stress of
more than 20% of the SMYS of the pipe shall be subjected at any point to a hydrostatic proof test equivalent
to not less than 1.1 times the internal design pressure at that point for not less than 4 hours.
API RP 1110 may be used for guidance for the hydrostatic test.
If the testing medium in the system will be subject to thermal expansions during the test, provisions
shall be made for relief of excess pressure.
After completion of the hydrostatic test, it is important in cold weather that the lines, valves, and
fittings be drained completely of any water to prevent freezing damage.

Section 1137.4.3.Leak Testing. A 1-hour hydrostatic or pneumatic leak test may be used for piping
systems to be operated at a hoop stress of 20% or less of the SMYS of the pipe. The hydrostatic test pressure
shall be not less than 1.25 times the internal design pressure. The pneumatic test gauge pressure shall be 100
psi or that pressure which would produce a nominal hoop stress of 25% of the SMYS of the pipe, which ever
is less.

3. Hydro Test Plan and Procedure

Prior to hydro testing, a complete identification of test pressures along the entire length of the
pipeline shall be made and a subsequent Plan and Testing Procedure should be generated. The Plan shall
include the test pressures along the section of the pipeline to be tested, test equipments to be used, water
source, water filling and draining and emergency plan in case of failure.

3.1. Hydro Test Pressure

In compliance to the requirement of ASME B31.11, Section 1137.4.1, the test pressure of the slurry
pipeline should be at least 10% above maximum operating pressure but not to exceed 90% of SMYS.
Figure 1 shows a typical steady state hydraulic gradient (line colored blue) as plotted against the
ground profile (shown as area in color green). The pressure limits are also plotted as the MAOP (color green
line) and the transient pressure limit (10% above MAOP).
Figure 2 shows a typical transient pressure diagram as captured during a dynamic simulation of a
shutdown sequence. The program predicts the maximum pressure created by transient along the entire length
of the pipeline. These recorded maximum pressures are then utilized as reference limits for the hydro test
pressure.
 Figure 1. Typical Steady State Hydraulic Gradient and Profile Diagram.

Figure 2. Typical photo shot of Dynamic Transient Diagram showing pressure wave along the pipeline.

Shown in Figure 3 is the static pressure condition along the pipeline during shutdown state. As may
be noticed, the maximum pressure head column is very much different from that of the dynamic operating
condition especially noticeable at the upstream side of each valve and terminal stations. Again, this high static
pressure limit is considered during hydro testing.
 Figure 3. Typical Static Column Diagram after Pipeline Shutdown.

Figure 4. Typical Steady State Static Pressure Diagram.

Shown in Figure 4 is the overall pressure condition experienced by the pipeline during extreme
operating conditions. The resulting pressure sets the minimum and maximum boundaries for the hydro test
pressure. Figure 5 shows a sample in which hydro test pressure is defined depending upon specific sectors of
the pipeline as shown by the magenta line.
 Figure 5. Hydro Test Column (m) set between minimum and maximum pressure boundaries.

3.2. Test Plan

Prior to hydro testing, the contractor or hydro test team shall prepare a plan that should include the
following:

a. Definition of test segment and its corresponding maximum test pressure which does not produce
a hoop stress near or above 90% of SMYS.
b. Identify composition of the test segment, ie. instrumentation, piping components, equipment,
valves, etc… Ensure that test pressure shall not exceed manufacturer’s recommended maximum
allowable test pressure. Isolate instruments, relief valves, and other equipment that are not
included in the test segment. Valves within the test segment should be in open position.
c. Test medium source (water) and makeup, its temperature and containment to prevent freezing.
d. Profile and alignment drawings.
e. Disposal of test medium.
f. Emergency plan.
g. Protection and notification to public authorities.
h. Identification of test personnel and its responsibilities.

4. Conducting a Pressure Test

4.1. Test Head

A typical test head is shown in Figure 6. The test head would normally include a special flanged
spool that connects to the pipeline section to be tested complete with instrumentation such as pressure gauge,
temperature sensor, dead weight tester, chart recorder, water fill, and pressurization line.
 Deadweight Tester

Pressure/Temperature
Chart Recorder

PD Pump

FM

Filter Flow High Volume Pump

Water Source
Meter

Figure 6. Standard Test Head set.

4.2. Line Fill and Cleaning

a. The line fill operation should perform two functions:
a.1 Introduce the test medium (water)
a.2 Clean the line
b. Prior to actual line fill operation, it is necessary to run sizing or caliper pigs to determine any
geometric deformations. Pigging also removes any debris or sediments in the line.

4.3. Pressurization
a. After filling the pipeline with the test medium, appropriate steps should be taken to ensure that
air is properly bled off and the pipeline section is packed. Pressurization should then commence.
b. Pressurization should be made at a controlled rate and should stop once 80% to 90% of the test
pressure is reached to allow stabilization of temperature and pressure. Pressurization to 100%
test pressure should only resume if no leaks are observed at this point.
c. The charts and sensor are used to confirm continuity and approximation of the actual pressure.
The deadweight tester provides the actual pressure recorded.

4.4. Test Period

a. When test pressure is reached, pumping should be stopped.
b. Inspect system for leaks and verify that the test pressure is maintained.
c. Monitor pressure and temperature in 30 minutes interval.
d. Test pressure should be held for at least 4 hours for above ground installations and at least 8
hours for installations that are not visible for inspection.

4.5. Pressure Test Record

a. Complete test records should be kept including information such as details of the test operation,
weather conditions, test failures, bleed off, re-pressurization, etc…
b. Test records should include the following test results:
b.1 Pressure/temperature chart
b.2 Instrument calibration certificates
b.3 Test pressure calculations
b.4 Record of failures
b.5 Pipeline profile for the test segment.
b.6 Any facility drawings indicating equipment and instrumentation used.
4.6. Test Failures
a. When a leak is observed the following steps are recommended:
a.1 Relieve pressure from the test segment by opening drain from the test header.
a.2 Ensure that defective part is free from the test medium.
a.3 Repair defective part or parts.
a.4 Record on test report the repairs made.
a.5 Redo the hydrostatic test.
b. NOTE: Repair must never be attempted on a pressurized segment.

Figure 7. Pipe Failure under Test Pressure

Figure 8. Extent of Pipe Damage detected during Hydro Test

8. References

B31.11-2002, Slurry Transportation Piping Systems, (Revision of ASME B31.11-1989).

API RP1110, 4th Edition, March 1997, Pressure Testing of Liquid Petroleum Pipeline.