Pipeline Pressure Testing

5.1 Introduction
This chapter describes the pressure testing of land and subsea carbon steel
pipelines. Chapter 11 addresses pressure testing pipeline bundles and stainless
steel and flexible pipelines. Procedures for pressure testing with nitrogen are also
discussed in Chapter 11.

This chapter is divided into three main parts:

• The Overview introduces pipeline pressure testing for personnel with no

. .
prevIOUS expenence.
• The General Preparation for a Pipeline Pressure Test, Detailed Prepara-
tion for a Pipeline Pressure Test, and Stages of a Pipeline Pressure Test
sections describe and explain in detail the engineering and operational
procedures required to pressure test a pipeline.
• Final Reporting contains details of information typically required for the
final report submitted to the client.

5.2 Overview
5.2.1 Reasons to Pressure Test a Pipeline
The reasons to pressure test a pipeline after construction are listed below:

• Detect inherent defects in the pipeline's components

• Detect damage caused during construction
• Relieve residual stresses resulting from construction operations
• Verify that the line is strong enough to transport the product safely
• Verify that the pipeline is free from leaks

January 1997 Pipeline Pressure Testing 5-1

 5.2.2Types of Pipeline PressureTests
Three types of pressure tests used on pipelines or pipeline component parts are
listed below.

• Hydrostatic pressure-strength test

• Hydrostatic pressure-leak test
• Air or nitrogen pressure-leak test

For safety reasons, the most common tests used in the pipeline industry are the
hydrostatic pressure-strength test and the leak test. These tests can be combined
but are more often performed separately to fit into construction schedules.

An air pressure leak test is sometimes used as a pre-lay test on short pipeline
sections, such as small river or road crossings. The test pressure is not normally
more than 7 bar (100 psi).

Pipeline bundle carrier-pipe leak testing uses nitrogen at pressures exceeding 7

bar (100 psi); however, stringent safety precautions are required. For further
details on air and nitrogen leak testing, see Chapter 11.

5.2.3 Definition of a Pipeline forTest Purposes

A pipeline is usually defined, for test purposes, as the pipe that extends from pig
trap to pig trap, including all connecting lines, up to and including the first valve.

5.2.4 Test Requirements

For the strength test to be considered successful, all component parts of the
pipeline must be tested at the strength test pressure for a minimum of 24 hours
without the pipeline rupturing. This pressure must be maintained for the 24-hr
period. If the pressure rises or falls during the 24-hr test-hold period, adjustments
for the pressure change must be made.

During a pressure decay, continue to correct the calculations to determine

whether the decay is caused by temperature changes or a leak. If the temperature
changes do not correlate with the change in pressure, use calculations to deter-
mine the rate of the leak. A pressure decay that can be attributed by calculation to
external factors, such as temperature, is acceptable. If a pressure rise in observed,
make correlations to the temperature changes. If the calculations do not match the
rise in pressure caused by temperature, some external interference is altering
"system" pressure.

5.2.5 General Preparation for a Pipeline PressureTest

The five steps listed below are the standard steps in preparing for a pipeline
pressure test:

• Planning
• Engineering
• Preparing procedures
• Selecting equipment and instrumentation *

5-2 Pipeline Commissioning Manual January1997

 • Inspecting equipment (Selecting Equipment and Instrumentation and
Inspecting equipment are explained in are explained in Section 5.2.7.)

These general preparatory steps required for pressure testing are described in
detail below.

5.2.6 Stages of a Pressure Test

Planning
Planning involves the preparation of a detailed schedule to allow for the timely
completion of each activity and to ensure that relevant equipment and personnel
are available at the location on time.

Engineering
The steps in Table 5.1 comprise the engineering work involved in preparing for
pressure testing.

Table 5.1-Engineering Work

Involved in Preparing for Pressure Testing
Task Specifics
Calculating Pipeline volumes
Volume to pressurize per unit of pressure
Chemical injection rates
Pressure drop per unit of temperature
Sizing Pumps
Filters
Tanks
Suction and delivery hose or piping
Flowmeters or stroke counters
Pressure and temperature instrumentation
Discharge pipework
Drawing Equipment layouts
Test limit sketches

Preparing Procedures
Detailed, step-by-step operations procedures and contingency procedures are
normally required for pressure testing operations. The operations procedures are
described in further detail later in this section.

Contingency procedures typically contain the details of locating pipeline leaks.

The structure of contingency procedures is similar to the structure for the opera-
tions procedure.

5.2.7 Recording and Reporting Data

Selecting Equipment and Instrumentation
Equipment and instrumentation selection is made on the basis of the calculations
performed during the engineering phase.

January 1997 Pipeline Pressure Testing 5-3

 The following list of pressure test equipment and instrumentation is intended as a
guide, and should not be considered complete:

• Test cabin
• Equipment container
• Workshop container
• Personnel messing, changing, and toilet facilities (land only)
• Water supply pumps
• Pressurizing pumps
• Breaktank
• Hose reel and hoses (offshore only)
• Various hoses and piping
• Air compressor (if necessary)
• Generator (if necessary)
• Lighting towers (land only)
• Filters
• Flowmeters
• Temporary test heads
• Chemical injection pumps
• Chemical tanks
• Stroke counters
• Subsea temperature recorders (offshore only)
• Ground temperature recorders (land only)
• Ambient temperature recorders
• Pipewall temperature recorders
• Pressure recorders
• Pressure gauges
• Deadweighttester
• Data loggers (offshore only)
• Barometric recorders (offshore only)
• Hand tools
• Small fittings, such as hex nipples

Inspecting Equipment
Before mobilization, the client's representative will visit the Halliburton base to
make the following inspections:

• Inspect the proposed equipment and instruments.

• Verify that the proposed equipment can supply the required flow rates.

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 • Witness the testing of pressure hoses and manifolds.
• Inspect equipment certification.

The inspection is repeated at the site.

5.3 Detailed Preparation for the Pipeline

Pressure Testing
Detailed preparation for testing a pipeline involves the steps listed below. These
steps expand on the general steps listed above and apply to pressure testing both
subsea and on land, unless otherwise noted.

• Prepare an overall schedule

• Begin engineering
• Produce a test limit drawing
• Log other instrument locations
• Prepare a preliminary equipment list and layout drawing
• Size the equipment and instrumentation
• Produce a detailed equipment and instrumentation list
• Produce a detailed equipment layout drawing
• Prepare test procedures

NOTE Read the contract.

Make sure all equipment is on site.
Carefully study the scope of the work and the specifications.

5.3.1 Prepare an Overall Schedule

The overall schedule should describe the amount of time required for the follow-
ingtasks:

• Engineering
• Producing procedures, including quality plans and safety procedures
• Assembling equipment and instrumentation
• Mobilizing
• Doing the work
• Demobilizing
• Producing the final documentation

The dates for submitting key documents and for completing the work are agreed
upon with the client and are available in the contract. An example of an overall
schedule is shown in Appendix B.

January 1997 Pipeline Pressure Testing 5-5

 5.3.2 Begin Engineering
To begin the engineering, calculate the following parameters: (do we need units
of measurement for these calculations?)

• Pipeline volume
• Volume to pressurize
• Chemical injection rates
• Pressure drop per °C

Formulas and examples for these calculations are found in Chapter 13.

5.3.3 Produce aTest Limit Drawing

A test limit drawing can be your markings on a copy of the piping and instrumen-
tation drawing (P&ID) supplied by the client, or it can be a previously marked-up
copy provided by the client for your information. If the client does supply a
drawing indicating the test limits, use it. Request a P&ID if one is not supplied.

This test limit drawing should show the connection points for the Halliburton
pressure pumps and instrumentation.

If the test is performed from a land site or from a platform, connection points will
be available on the temporary test head or permanent pig trap (Figure 5.1).

If the pipeline has not been tied in to the platform on a subsea pipeline, connec-
tion points will be available on the temporary subsea head. Figure 5.2 shows an
example of a subsea valve arrangement for a hydrotest.

5.3.4 Measuring PipelineTemperature

Subsea temperature is usually measured by suspending a temperature probe over
the side of the platform, boat, or rig. Ground temperature is usually measured at
several points along a pipeline by burying the temperature probe to the same
depth as the pipeline.

Pipewall temperature is sometimes measured by taping an insulated temperature

probe to the pipewall at a convenient point. However, it is also sometimes
measured by inserting a thermal well into the test head or pig trap. The specifica-
tion indicates if a thermal well is required. For more information on this subject,
see J. C. Gray's article, "How Temperature Affects Pipeline Hydrostatic Test-
ing.'"

5.3.5 Prepare a Preliminary Equipment List and

Layout Drawing
Create a preliminary equipment list based on the information discussed earlier in
this chapter. Then produce a preliminary layout drawing based on this list. Figure
5.3, Page 5-8, shows a sample equipment layout drawing. Include hand tools,
small fittings, and valves in the preliminary equipment list and the layout draw-
ing.

5-6 Pipeline Commissioning Manual January1997

 Vent Purge

PG PS

Drain to
Chemical
Tanks
Drain

Fluid/Gas PG = Pressure Gauge

Delivery PS = Pig Signaller
Figure 5.1-Typical Pig Launcher for Dewatering Purposes

1/4-in. Instrument Line 3/4-in. Pressurising Hose

to Surface to Surface

ROV Hot Stabs

206

205

TIM
PLR

217 218

219 220

Transducer
208

Figure 5.2-Pipeline Hydrotesting Subsea Valve Arrangement

January 1997 Pipeline Pressure Testing 5-7

91
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and Dead Weights

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Figure 5.3-Hydrotest Equipment Setup
Size the Equipment and Instrumentation
The design of the equipment requirements is determined based on the calcula-
tions performed to fulfill the requirements of the contract. filling and dewatering
the line require a different set of calculations than the hydrotest. The rates and
pressure for filling the line must be known, as well as the factors listed below:

a. How much pressure will be used to test the line?

This information determines which pump will be used when the pipeline
is tested.
b. At what rate is the line pressured?
This information also aids in determining the type and size of pump(s)
needed. If the pressure and rate are large, then multiple HT-400 or HQ
pumps are needed to meet the requirements. The horsepower calculated
determines the pumping equipment requirements.
Example: ifthe final pressure is 2,000 psi (140 bar) and the rate of pressuring is
50 gal/min (200 Llmin), a 50-horsepower pump is all that is neeed. If the rate is
2,500 gal/min (10,000 Llmin), a 3,000-horsepower pump is needed on location.

Knowing the parameters and performing the calculations helps determine the
equipment requirements for the job.

CAUTION Do not oversize or undersize equipment or instrumentation.

Produce a Detailed Equipment and Instrumentation List

To produce a detailed equipment and instrumentation list, compare the prelimi-
nary list and the sizing information with the equipment and instrumentation
Halliburton has available.

The client's specification contains a section on equipment and instrumentation. In

this section, the pressure and flow rate ranges for the main pieces of equipment
are specified. If it is not possible to locate equipment that is within the specified
range, tell the client what is available and the cost of the available equipment.

It is permissible to list two or more pieces of equipment for a single purpose if

you are not sure which piece will be available at the time of mobilization.

Obtain full data sheets for all pieces of equipment, and include them with the
procedure.

Produce a Detailed Equipment Layout Drawing

A detailed equipment layout drawing is similar to the preliminary drawing, but it
contains specific items of equipment.

When designing the piping or hose connections between the pressure pumps and
the connection to the pipeline, include a check valve to ensure that the full
pressure in the pipeline cannot back up into the pumps. Chemical valves should
also include a check valve.

January 1997 Pipeline Pressure Testing 5-9

 Include a double block-and-bleed system of valves between the pressure pumps
and the connection to the pipeline. Chemical pumps should also have a double
block-and-bleed system.

Include a pressure safety valve in the system, located as near to the pipeline as
possible.

5.3.6 Prepare Test Procedures

NOTE Keep the language as simple as possible.
Short statements are best.

A pressure-test operation procedure typically contains the following elements:

• An introduction
• A section listing all relevant National Codes and Standards and the
client's specifications
• A detailed schedule of operations
• A list of the pipeline parameters, including length, diameter, wall thick-
ness, and test pressure
• A list of pumping rates, chemical injection rates, and volumes
• A sketch or drawing of the test limits that also shows the connection
points for Halliburton's pumps and instrumentation
• An equipment layout drawing
• A detailed list of equipment and instrumentation
• A detailed, step-by-step procedure
• Test acceptance criteria
• A quality plan showing witness and hold points
• A section containing relevant safety regulations
• An appendix containing equipment and instrumentation data sheets
• An appendix containing calculations
• An appendix containing sample report sheets
• An appendix containing chemical data sheets

NOTE The approved procedure taken to the site will also contain
equipment and instrument calibration certificates.

Follow the steps listed below to begin preparing the procedures:

1. Write a simple introduction stating the project title and the scope of
Halliburton work and describing the project.
2. Copy the section listing the relevant national codes and standards and the
client's specifications directly from the contract document.
3. Prepare a detailed schedule of operations, including an employee schedule.

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 4. List the pipeline parameters, including length, diameter, wall thickness,
and test pressure to be applied. These parameters are located in the
specification. If the pipeline is sectioned because of length or elevations,
list the sections and show the test pressure and elevations for the test
point and the high and low points.
5. Refer to the formulas and calculations in Chapter 13, and list the pump-
ing rates for pressurizing, the chemical injection rates, and the estimated
total volumes.
6. Include the limits of test and equipment drawings.
7. Include the detailed lists of equipment and instrumentation.
8. Include a list of items the client should supply. For example, water,
electricity, light, and compressed air are often supplied by the client.
Information on what the client should supply is available in the contract.
9. Include valve checklists. These lists should show the position of all
valves both before the test and after the pipeline has been depressurized.
10. The Halliburton test engineer and the client's representative should tour
the test area immediately before startup and verify that the valve posi-
tions are correct.
11. Both parties should sign the checklists.

Write The Method Statement

A detailed outline of the stages of a pressure test is available later in this section.
Each client, however, has individual requirements that are stated in the specifica-
tion. Some clients give an outline method statement in the specification. Make
sure all the points mentioned in the specification are included in the method
statement.

Write the method statement using command statements, similar to the following
statements:

• Open valve No. 123.

• Start the pumps.
• Stop the pumps at 35 bar (500 psi).

Always try to use temporary valves; however, if it is necessary to operate a

permanent valve or other piece of permanent equipment, include the statement
below in the procedure:

"Permanent valves or other equipment, such as pig trap closure doors, are
operated only under the supervision and control ofthe prime client's operations
staff. Halliburton provides labor assistance."

NOTE Pressurization cannot begin until the client gives permission.

Copy the test-acceptance criteria directly from the specification. Remember that a
quality plan showing witness and hold points is not always required. However, if
one is necessary, an example is given in Table 4.2 in Chapter 4 (Page 4-15).

January 1997 Pipeline Pressure Testing 5-11

 Safety
Include the following points in the safety section of the procedures:

• Erect safety barriers and warning signs forbidding entry to personnel

other than the test team. Be vigilant; some people ignore the warning
signs and attempt to enter and work inside the restricted area.
• Involve the site safety personnel.
• Announce over the public address system that pressure testing is in
progress to warn other personnel.
• Prohibit flexible pressure hoses inside test cabins.
• Protect hoses passing over walkways (offshore) or roads (onshore).
• Tie down all hoses at regular intervals to prevent whip in case of hose
rupture.
• Reduce pressure to a safe level before any attempt is made to repair
leaking flanges. Use a double block-and-bleed system if necessary.

5.3.7 Stages of the Pressure Test

After engineering, the pressure test can be conducted, based on a test procedures
previously described.

A pressure test consists of the stages listed below. These stages apply to both
subsea and land pressure tests, except where noted.

• Pressurizing
• Stabilizing
• Test-hold period
• Accepting the test
• Depressurizing
• Disposing of test water
• Recording and reporting data (This process is described in Section 5.3.8.)

Theses stages are described in further detail below.

Pressurizing
Pressurizing is performed at a controlled rate. During pressurizing, the pumps are
stopped at predetermined pressures to allow for the stabilizing of pressure surges
and to check the following items:

• Air content of the pipeline fill water

• Leaks in the exposed pipework
• Gross pressure losses

When pressurizing, ensure that all pressure and temperature chart recorders are
working, and replace charts where necessary before pressurizing. All parties

5-12 Pipeline Commissioning Manual January1997

involved in pressurizing should sign the charts.

Follow the steps below to complete pressurizing:

1. Pressurize to 35 bar (500 psi) at a rate of 1 bar/min (15 psi/min). A rate

of up to 3 bar/min (45 psi/min) can be used.
2. During pressurizing, log the pumped volume at I-bar (15 psi) intervals.
3. Stop pumping.
4. Check the air content.
5. Pressurize to 70 bar (1,000 psi) at a rate of 1 bar/min (15 psi/min). A rate
of up to 3 bar/min (45 psi/min) can be used.
6. During pressurizing, log the pumped volume at I-bar (15 psi) intervals.
7. Stop pumping.
8. Check visible flanges for leaks.
9. Hold pressure for at least 1 hour.
10. Pressurize to 80% of test pressure (120 bar [1,750 psi]) at a rate of 1 barf
min (15 psi/min).
11. During pressurizing, log the pumped volume at I-bar (15 psi) intervals.
12. Stop pumping.
13. Hold pressure for at least 1 hour to allow for stabilizing. More time may
be required for longer pipelines.
14. Pressurize to 95% of test pressure (142.5 bar [2,100 psi]) at a rate of 1
bar/min (15 psi/min).
15. During pressurizing, log the pumped volume at I-bar (15 psi) intervals.
16. Stop pumping.
17. Hold pressure for at least 30 minutes to allow for stabilizing. More time
may be required for longer pipelines.
18. Pressurize to test pressure (150 bar [2,200 psi]) at a rate of 0.5 bar/min (7
psi/min).
19. During pressurizing, log the pumped volume at 0.5 bar (7 psi) intervals.
20. Stop pumping.

NOTE Maintain a pressure-versus-volume plot during the pressurizing

phase.

21. Close in the pipeline to begin the stabilizing period.

22. Change the charts and have them signed.

Stabilizing
The stabilizing period allows pressure surges to settle and allows the fill water
and pipeline temperatures to adjust to the surrounding conditions. The stabilizing
period is normally at least 24 hours, but it can be longer, depending on the length
and diameter of the pipeline.

January 1997 Pipeline Pressure Testing 5-13

 During stabilizing, keep the following records:

• Log pressure at IS-minute intervals for the first 4 hours of the stabilizing
period.
• After 4 hours, log the pressure at 30-min intervals.
• Maintain a pressure-versus-time plot during the stabilizing period.

During the stabilizing period, the pressure usually decays quickly over the first 2
to 4 hours. After that time, the decay slows. When the pressure appears to have
stabilized, restart the pump and bring the pressure back to the test pressure level.
Log both the volume of water required to repressurize the pipeline and the
pressure rise in the pipeline.

Land pipeline pressure tests are very sensitive to temperature changes. There may
be a requirement to maintain the pressure between two specified figures. This
requirement could result in water being added to the test piece or being bled from
the test piece.

NOTE This process may need to be repeated.

Log both the volume of water removed or injected and the change in pressure.

Test-Hold Period
The test-hold period monitors the ability of the pipeline to hold pressure. The
test-hold period for a strength test is the 24-hour period during which the pressure
is maintained within specified plus-and-minus limits. Repressurizing and depres-
surizing are allowed during the 24-hour period; however, volumes extracted and
added and the subsequent pressure changes must be recorded and logged.

The test-hold period for a leak test is the 24-hour period during which no pres-
sure decay is allowed except for that which can be attributed by calculation to
external factors, such as temperature.

Use the following procedures for the test-hold period:

1. Close in the pipeline to begin the test-hold period.

2. Change and sign pressure charts.
3. Log the pressure at IS-min intervals for the first 2 hours or until any
decay is slight or nonexistent.
4. After this period, log the pressure at 30-min intervals.
5. Maintain a pressure-versus-time plot during the test-hold period.

Accepting the Test

The Halliburton specialist test engineer is responsible for demonstrating to the
client's representative, by calculation if necessary, that the test-hold period is
acceptable. When the engineer is satisfied that the test is acceptable, it should be
presented to the client's representative. The client's representative accepts the
pressure test. The Halliburton test engineer must sign all documentation, logs,

5-14 Pipeline Commissioning Manual January1997

charts, and test acceptance certificates on behalf of Halliburton as the indepen-
dent test company.

Depressurizing
Refer to Chapter 6 on Disposal of Treated Water.

Disposing of Test Water

Dispose of treated test water carefully. At offshore locations, close down water
makers on the installation and on adjacent installations before dumping, and do
not tum on again until at least 24 hours after dumping is complete.

NOTE Platforms, boats, and rigs need advance warning that fresh water
makers are closing down to allow time to fill potable water
tanks.

At onshore locations it may be necessary to pipe the test water to a designated

disposal area.

5.3.8 Recording and Reporting Data

Recording and reporting data during pressure testing is important because the
final report is the only record the client has of the results. The specific contents
of a Final Report are discussed later in this chapter.

The data shown in Table 5.2 are collected during pressure testing:

Table 5.2-Charts and Logs for Pressure Testing

Charts Pipeline pressure
Subsea temperature (offshore only)
Ground temperature (land only)
Ambient temperature
Pipewall temperature
Barometric pressure (offshore only)
Logs Events
Volume to pressurize
Volume of chemical injected
Pressure and time during stabilization
Pressure and time during the hold period
Pressure and time during depressurization

Examples of record sheets are included in Appendix A.

The original copy of all records becomes the property of the client.

January 1997 Pipeline Pressure Testing 5-15

 5.4 Final Reporting
Compile the Final Report and present the original and the specified number of
copies to the client. The Final Report is the only record the client has of the test
results. Include the following information in the report.

• Summary of the operations

• Copies of all charts
• Copies of all manual records
• Equipment and instrumentation calibration certificates
• Pressure-versus-volume air content plot
• Calculations of air content
• Pressure-versus-volume plot
• Calculations of pressure changes caused by temperature
• Marked-up drawings showing the limits of the test
• Test-acceptance certificate

5.5 References
1. Gray, J. c.: "How Temperature Affects Pipeline Hydrostatic Testing,"
Pipeline and Gas Journal (December 1976).

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