Technical, Operational, Practical, and Safety Considerations of Hydrostatic Pressure Testing Existing Pipelines

Technical, Operational, Practical, and Safety
Considerations of Hydrostatic Pressure Testing

Existing Pipelines
Prepared for The INGAA Foundation, Inc.
By: Jacobs Consultancy Inc. and

Gas Transmission Systems Inc.
December 5, 2013
INGAA Foundation Final

Report No. 2013.03
Disclaimer
This document, and the opinions, analysis, evaluations or recommendations contained herein
are for the sole use and benefit of the contracting parties. There are no intended third party
beneficiaries, and Jacobs Consultancy Inc. (and Jacobs Engineering affiliates), and Gas
Transmission Systems Inc. shall have no liability whatsoever to third parties for any defect,
deficiency, error, omission in any statement contained in or in any way related to this document
or the services provided.
Neither the Work Product nor any information contained therein or otherwise supplied by in
connection with the Study nor the Services released by The INGAA Foundation shall be used in
connection with any proxy, proxy statement, and proxy soliciting materials, prospectus,
Securities Registration Statement, or similar document without the express written consent of
Jacobs Consultancy Inc.
i
Foreword
On January 3, 2012, President Obama signed the Pipeline Safety, Regulatory Certainty, and
Job Creations Act of 2011, which reauthorized the Natural Gas Pipeline Safety Act of 1968. The
legislation amended many sections of the Act, including the addition of § 60139 - Maximum
Allowable Operating Pressure, stipulating “…the Secretary shall issue regulations for conducting
tests to confirm the material strength of previously untested natural gas transmission pipelines
located in high-consequence areas and operating at a pressure greater than 30 percent of
specified minimum yield strength….”
While the pipeline industry has significant experience in hydrostatic pressure testing pipelines,
the testing of existing pipelines in suburban and urban areas can present many public and
worker safety, environmental, technical and logistical challenges.
The INGAA Foundation, Inc. was formed in 1990 by the Interstate Natural Gas Association of
America (INGAA) to advance the use of natural gas for the benefit of the environment and the
consuming public. The Foundation works to facilitate the efficient construction and safe, reliable
operation of the North American natural gas pipeline system, and promotes natural gas
infrastructure development worldwide. In support of these aims, the INGAA Foundation
commissioned a study directed at the use of hydrostatic pressure testing of existing natural gas
transmission pipelines, the information necessary to conduct a pipeline hydrostatic test safely
on an existing pipeline, and whether, with the test results, the operator would have the
information necessary to assess the integrity or fitness-for-service of the pipeline.
Jacobs Consultancy Inc. and Gas Transmission Systems Inc. volunteered to develop a “White
Paper” to address the technical, operational, practical and safety considerations of hydrostatic
pressure testing existing natural gas transmission pipelines, and providing guidance to pipeline
operators to determine applicability of hydrostatic pressure testing. While commissioned by the
INGAA Foundation, this paper is an independent study, and its conclusions are based on the
expertise of the authors.
ii
We wish to acknowledge and express our appreciation to the members of the INGAA
Foundation, INGAA, and the Steering Committee for their participation and feedback in the
development of this White Paper, with special thanks to following individuals:
 Terry Boss, INGAA

 Mark Cabral, Gas Transmission Systems, Inc.
 Scott Clapp, Gas Transmission Systems, Inc.
 Terry Cole, Jacobs Consultancy Inc.
 Scott Currier, INGAA
 Narinder Grewal, Jacobs Consultancy Inc.
 Mark L. Hereth, Process Performance Improvement Consultants, LLC
 Larry Hoelscher, Williams Gas Pipeline
 Richard R. Hoffmann, INGAA Foundation
 David L. Johnson, Energy Transfer Partners, LP
 Cathy Landry, INGAA
 Raymond Lewis, Rosen USA
 Salvatore Marano, Jacobs Consultancy Inc.
 Christopher Pioli, Jacobs Consultancy Inc.
 Edward Wiegele, Willbros Group, Inc.
iii
WHITE PAPER FINAL
TECHNICAL, OPERATIONAL, PRACTICAL AND SAFETY CONSIDERATIONS
OF HYDROSTATIC PRESSURE TESTING EXISTING PIPELINES
Table of Contents
Disclaimer .................................................................................................................................... i
1 Introduction ......................................................................................................................... 1
1.1 Objective ....................................................................................................................................... 1

1.2 Purpose and Need For Hydrostatic Testing .................................................................................. 2
2 Background......................................................................................................................... 4
2.1 Hydrostatic Pressure Testing History,,,,6 ........................................................................................ 4

2.2 Impact and Magnitude of Testing Requirements ......................................................................... 8
3 Planning the Hydrostatic Pressure Test .............................................................................10
3.1 Determination of Scope .............................................................................................................. 10

3.2 Risks Associated with Testing Existing Pipelines ......................................................................... 10
3.3 Planning the Test ........................................................................................................................ 11
3.3.1 Corrosion and Damage History ........................................................................................... 11
3.3.2 Equipment and Construction Issues ................................................................................... 12
3.3.3 Logistical Issues ................................................................................................................... 12
3.4 Environmental Permitting Issues ................................................................................................ 12
3.5 Outage Management .................................................................................................................. 13
3.6 Communications ......................................................................................................................... 13
3.6.1 External Communications ................................................................................................... 14
3.6.2 Internal Communications.................................................................................................... 16
4 Pressure Test Engineering, Design and Risk Mitigation Considerations ............................17
4.1 Gather Existing Pipeline Feature Data ........................................................................................ 17

4.1.1 Historical Operation & Maintenance Data.......................................................................... 17
4.1.2 Pre-test Inspections ............................................................................................................ 18
4.2 Validate Pipeline Feature Characteristics ................................................................................... 18
4.2.1 Guide to Conservative Assumptions ................................................................................... 19
4.2.2 Resolving Unknown Feature Characteristics....................................................................... 19
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WHITE PAPER FINAL
4.3 Assess and Address Features ...................................................................................................... 20

4.4 Establishing Minimum Test Pressure and Control Point............................................................. 21
4.5 Determine Maximum Test Pressure and Control Point .............................................................. 22
4.5.1 Spike Testing ....................................................................................................................... 23
4.6 Test Duration and Timing............................................................................................................ 24
4.7 Engineering Factors for Consideration ....................................................................................... 25
4.8 Possible Components of Engineered Drawings .......................................................................... 26
4.8.1 Plan...................................................................................................................................... 26
4.8.2 Profile .................................................................................................................................. 27
4.8.3 Location Sketches................................................................................................................ 27
4.8.4 Bills of Material ................................................................................................................... 27
4.8.5 Material of Record .............................................................................................................. 27
4.8.6 Construction Details ............................................................................................................ 27
4.8.7 As-built Drawings ................................................................................................................ 27
5 Hydrostatic Test Execution ................................................................................................29
5.1 Site Specific Plans ........................................................................................................................ 29

5.1.1 Test Data ............................................................................................................................. 29
5.1.2 Authorization and Distribution ........................................................................................... 29
5.1.3 Notifications ........................................................................................................................ 29
5.1.4 Roles and Responsibilities ................................................................................................... 29
5.1.5 Spill Response ..................................................................................................................... 29
5.1.6 Equipment Required on Site ............................................................................................... 30
5.1.7 Test Equipment and Calibrations ........................................................................................ 30
5.1.8 Establish Safety Zones ......................................................................................................... 30
5.1.9 Pre-fill Sequence ................................................................................................................. 30
5.1.10 Fill Sequence ....................................................................................................................... 30
5.1.11 Test Sequence ..................................................................................................................... 31
5.1.12 Depressurization ................................................................................................................. 31
5.1.13 Dewater and Dry ................................................................................................................. 31
5.2 Testing Location and Equipment ................................................................................................ 31
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WHITE PAPER FINAL
5.2.1 Test Station Location........................................................................................................... 31

5.2.2 Charts and Dead Weight Testers Test Instruments ............................................................ 31
5.2.3 Temperature Probes ........................................................................................................... 32
5.2.4 Use of Electronics ................................................................................................................ 32
5.2.5 Calibrations and Certifications ............................................................................................ 32
5.2.6 Correlating Test Site Elevation to Maximum and Minimum Control Points ....................... 32
5.3 Pipeline Clearing/Cleaning .......................................................................................................... 32
5.4 Pre-assessment ........................................................................................................................... 33
5.5 Pipeline Fill .................................................................................................................................. 33
5.6 Leak Detection and Pressure Stabilization.................................................................................. 33
5.7 Temperature Stabilization and Effects on Pressure Readings .................................................... 34
5.8 Pressurization.............................................................................................................................. 34
5.9 Discharge Rates and Safety Considerations ................................................................................ 34
5.10 Locating Failures and Leaks......................................................................................................... 34
5.10.1 Locating Failures ................................................................................................................. 34
5.10.2 Locating Leaks ..................................................................................................................... 35
5.11 Repairing Failures........................................................................................................................ 35
5.12 Post Test Leak Monitoring .......................................................................................................... 36
5.13 Successful Test Documentation and Determination .................................................................. 36
5.13.1 Successful Test Documentation .......................................................................................... 36
5.13.2 Successful Test Determination............................................................................................ 37
6 New Technologies .............................................................................................................39
References ..............................................................................................................................40
Appendix A – Abbreviations ......................................................................................................42
Appendix B – Glossary..............................................................................................................44
Appendix C – Understanding Hydrostatic Pressure Testing (Communication Brochure) ...........48
Appendix D – Hydrostatic/Pneumatic Safety Guidelines ...........................................................50
vi
1 Introduction
1.1 Objective
Hydrostatic pressure testing of existing pipelines presents unique safety, operating,
environmental and community liaison challenges beyond those encountered in commissioning
new pipelines. In addition, outside the pipeline industry there is limited understanding regarding
technical and practical considerations of conducting hydrostatic pressure testing of existing
pipelines.
This White Paper addresses these matters by providing technical, operational, practical and
safety guidance in the planning, design and execution of hydrostatic pressure tests of existing
pipelines. This paper is directed toward natural gas transmission pipeline operators and other
industry stakeholders interested in understanding the challenges and means of successfully
conducting hydrostatic pressure tests of existing pipelines in densely populated areas. This
paper will:
 Define and explain the mechanics of the hydrostatic pressure test process.
 Identify the risks associated with hydrostatic pressure testing of existing facilities in high
consequence areas (HCAs).
 Describe the data and information about the pipeline and area along the pipeline that is
necessary to prepare for a hydrostatic pressure test.
 Identify the data and information necessary to protect the public, workers and
environment when conducting a hydrostatic pressure test.
 Present the communication and coordination efforts with state, local/public leaders and
regulatory agencies.
 Address ways to mitigate public inconvenience during pre-test planning, site
preparation, test execution and post-test restoration activities.
 Compare and contrast a successful test to an unsuccessful one and explain the
respective results and consequences of each.
 Identify new technologies and research and development (R&D) in the works that might
potentially supplement hydrostatic pressure testing.
The practice of hydrostatic pressure testing of new pipelines and of existing pipelines to assess
pipeline threats as part of the Integrity Management Programs (Code of Federal Regulation, title
49, sec. 192, Subpart O) is well developed. This White Paper is not intended to duplicate the
effort, but rather to specifically extend guidance on specific considerations to take into account
during hydrostatic pressure testing of existing pipelines. It is noted, however, that many of the
steps in this paper are applicable to any hydrostatic pressure test, regardless of why it is being
conducted.
In addition to testing previously untested pipelines, there are segments of pipeline systems
where records, surveys and other documents are not traceable, verifiable and complete, which
1
may raise concerns about the safe maximum operating pressure of the pipeline system. There
are other reasons why a gas pipeline operator might consider a hydrostatic pressure test of
existing pipeline, but they will not be addressed in detail in this White Paper (Table 1).
Table 1 – Reasons for Performing a Hydrostatic

Pressure Test of Existing Pipelines
 Assess the stability of pipeline defects controlled by hoop stress (i.e.
internal pressure).
 Establish/Validate/Increase the maximum allowable operating pressure
(Code of Federal Regulation, title 49, sec. 192.619 and associated code
sections).
 Re-qualify the pipeline after a class location change.
 Establish re-assessment intervals (Code of Federal Regulation, title 49,
sec. 192.939).
 Verify pipeline integrity after a pressure excursion above the pipelines
MAOP.
 Other operator specific assessment and safety programs.
1.2 Purpose and Need For Hydrostatic Testing

Hydrostatic pressure testing is a method used to perform strength and leak tests of a pipeline.
The test involves taking the pipeline out of service, filling it with water, raising the internal
pressure of the pipe to a designated pressure or stress level (hoop stress) and holding the pipe
at, or above, the designated pressure for a prescribed period of time.
Hydrostatic pressure testing has long been used to commission new pipeline systems or
facilities. Pipeline companies installing new pipelines perform a hydrostatic pressure test to
identify flaws in manufacturing of the materials, injurious damages incurred during transporting
the materials and defects caused in the course of constructing the facilities. A successful
pressure test establishes a safety margin for pipeline operation and the maximum allowable
operating pressure (MAOP). The safety margin is defined as the pressure difference between
the successful test pressure and MAOP.
Gas transmission companies and local distribution companies operate over 299,614 miles of
onshore interstate and intrastate gas transmission pipe (Figure 1). There are segments of the
pipeline transmission systems in operation today that were installed in the early 1900s. It is
important to note, as discussed in a study conducted by Kiefner and Associates for the INGAA
Foundation, a “well-maintained and periodically assessed pipeline can transport natural gas
indefinitely.”1
1
Kiefner, J.F. and Rosenfeld, M.J., “The Role of Pipeline Age in Pipeline Safety”, INGAA Foundation,
Final Report No. 2012.04, November 8, 2012
2
Figure 1 – U.S. Natural Gas Pipeline Network
There also are segments of pipeline systems that were installed prior to state or federal
regulations that may require a hydrostatic pressure test to be performed before operating the
pipeline or establishing an MAOP. Still, many of these pipeline systems, constructed before
regulations were enacted, were built to company standards and industry codes that required
pressure testing.
3
2 Background
2.1 Hydrostatic Pressure Testing History2,3,4,5,6
The origins of hydrostatic pressure testing can be traced back to the vessel industry prior to
1900. The natural gas pipeline industry adopted the hydrostatic pressure testing practice
decades later. Hydrostatic pressure testing of cross-country transmission pipelines, that were
several hundreds of miles in length, was a much more difficult task. Prior to 1955, the
hydrostatic pressure testing, if performed, was usually performed utilizing the commodity being
transported as the test fluid. To limit the loss of commodity in case of a failure, the testing
pressures ranged between 5 psig to 50 psig, or 10 percent higher than the operating pressure of
the pipeline. One of the first documented pressure tests using water occurred on the “Big Inch”
and “Little Big Inch” product pipelines, known as “Inch Lines.” The lines were acquired on May
1, 1947, and the operator began the process of rehabilitating the product pipelines to transport
natural gas.6 During the conversion process, the operator experienced numerous failures due
to pipe manufacturing defects and pipe corrosion. In 1950, hydrostatic pressure testing of the
pipelines was completed well above the MAOP, sometimes to 100 percent Specified Minimum
Yield Strength (SMYS) or higher. As a result of this experience, the natural gas industry
performed scientific studies between 1953 and 1968 to better understand the benefits,
limitations and workings of hydrostatic pressure testing. Over time, operators began to adopt
the practice of hydrostatic pressure testing with water to higher stress levels than had previously
been customary.
In 1928, API published Standard 5L for Line Pipe, which recommended a hydrostatic test to a
maximum of 60 percent of SMYS for pipes at the mill (“Mill Test”). In 1942, in the Fourth
Edition of API 5L recommended hydrostatic testing of pipe to a minimum of 60 percent of
SMYS and a maximum of 80 percent SMYS. In 1948, API Standard 5LX was introduced, where
designation ‘X’ denoted stronger grade pipe, which recommended an 85 percent SMYS mill
test. API 5L retained the 80 percent SMYS recommendation. In 1956 mill hydrostatic testing to
90 percent of SMYS was introduced. In 1983, API 5L and 5LX were combined in API 5L.7
The (American Standards Association) ASA B31.1 Code, prior to 1942, did not specifically
recommend testing to establish the maximum operating pressures after the installation of the
pipe. It alsot did not specify the duration of the pressure test.
2
“The Benefits and Limitations of Hydrostatic Testing” Pipeline Rules of Thumb Handbook
3
Rosenfeld, M. J. and Gailing, “Pressure testing and recordkeeping: reconciling historic pipeline practices
with new requirements”, Pipeline Pigging and Integrity Management Conference, February 13-14, 2013
4
www.kiefner.com
5
“U.S. Oil Pipe Lines”, George S. Wolbert, Jr., API, 1979
6
“The Big Inch and Little Big Inch Pipelines” Texas Eastern Transmission Corporation, May 2000
7
Kiefner, J.F. and Trench, C.J., “Oil Pipeline Characteristics and Risk Factors: Illustrations from the
Decade of Construction”, American Petroleum Institute, December, 2001
4
A new period of hydrostatic pressure testing for natural gas pipelines emerged after 1955. This
time period incorporated major technical advancements in hydrostatic pressure testing. The
American Standards Committee B31 was reorganized as ASME Code for Pressure Piping,
under procedures developed by ASME and accredited by ANSI. The ASME B31.8 Code
included pressure tests of new pipelines operating at 30 percent SMYS or greater to establish
the MAOP. However, the code did not specify the duration of the pressure test. Four classes
(Class 1, 2, 3 and 4) were defined based on the location of the pipeline and the density of
dwelling units along it. MAOP was established by testing new pipelines to a higher pressure
than the maximum operating pressure based on the pipeline’s class location. In Class 1
location, the installed pipe was tested to 1.1 times the maximum operating pressure with water,
gas, or air; in Class 2 location, the installed pipe was tested to 1.25 times the maximum
operating pressure with water, gas or air; and in Class 3 and 4 locations, the installed pipe was
tested to 1.4 times the maximum operating pressure with water. The pressure testing
requirements from 1950s to present are summarized in Table 2 “Onshore Natural Gas
Transmission Pipeline Pressure Testing Requirements of Vintage ASA/ASME B31.8 Editions.”
The Natural Gas Pipeline Safety Act, which required the Secretary of Transportation to adopt
interim rules on pressure testing, became effective August 12, 1968.. The safety standard for
gas pipelines and mains, in the majority of the states, was the ASME Code for Pressure Piping,
Gas Transmission and Distribution Piping Systems, B31.8; thus, the interim minimum safety
standards were essentially B31.8 Code requirements. Between August 12, 1968 and August 12,
1970, the Office of Pipeline Safety (OPS) of the United States Department of Transportation
(DOT) developed safety standards that would be applicable to gas facilities, with the exception
of rural gas gathering systems. This eventually became the Code of Federal Regulation (CFR),
title 49, sec. 192 "Transportation of Natural and Other Gas by Pipelines: Minimum Federal
Safety Standards," which became effective November 12, 1970.
Unlike B31.8, Code of Federal Regulation, title 49, sec. 192 specified a duration of the
hydrostatic pressure test – a minimum of eight hours for pipelines operating at a hoop stress of
30 percent or more of SMYS. The federal code also included a clause for pressure test ratios
for Classes 3 and 4. For pipelines installed and tested prior to November 12, 1970, the test
ratio was 1.4, and for the pipelines installed after November 11, 1970, the test pressure ratio
was 1.5. For Classes 1 and 2, the test pressure ratios were 1.1 and 1.25, respectively (Table
2). These requirements for testing of the installed pipelines have remained unchanged to
present-day.
5
Table 2 – Onshore Natural Gas Transmission Pipeline Pressure Testing
Requirements of Vintage ASA/ASME B31.8 Editions
Description of Pressure
Pressure Test Description operating over Present Pressure
population density at Test
30% SMYS Test Description
time of construction Description
ASA B31.1
Pipeline -1951 Subpart J [192.505];
was built Pressure ASA ASA ASA ASA [192.619 (2) (i)];
Present under ASA Test B31.1.1.8- B31.8- B31.8- B31.8- [192.611]
Day B31.1 -1942 Description 1955 1958 1963 1968
1.1 times Installed before Nov

MOP with 12, 1970 and after Nov
1.1 times MOP with
Class 1 water, gas or 11, 1970 test pressure
water, gas or air
air except tie- is 1.1 * MAOP for 8
1.1 times ins hours
MOP
Maximum with
Service water,
Division 2  Installed before Nov
Pressure gas or
plus 50psi air 12, 1970 and after
except 1.25 times Nov 11, 1970 test
1.25 times MOP tie-ins MOP with pressure is 1.25 *
Class 2
with water or air water or air MAOP for 8 hours
except tie-ins  Upgraded pipeline
is previously tested
pressure of MAOP
/.8 for 8 hours.
A 1.40 times MOP with B Installed before Nov

water except tie-ins. 12, 1970 test
1.1 times MOP with pressure is 1.4 *
air, if below 32 deg F MAOP for 8 hours;
at pipe depth or no Installed after Nov.
Class 3 water available 11, 1970 test
 1.2 times MOP with pressure is 1.5 *
air if MOP<50% MAOP for 8 hours.
1.5 times SMYS and  Upgraded pipeline
Maximum 1.40 times MOP longitudinal joint is previously tested
Division 1
Service with water factor is 1. pressure of MAOP
Pressure /.667 for 8 hours.
 A plus 1.2
times MOP  B plus Upgraded
with air, if pipeline is
Class 4 MOP<40% previously tested
SMYS and pressure of MAOP
longitudinal /.5555 for 8 hours.
joint factor
is 1.
present-day.
6
present-day.
Code of Federal Regulation, title 49, sec. 192 includes a “grandfather” clause that allows for
continued operation of pipelines at the highest operating pressure experienced during the five
years preceding July 1, 1970. A “grandfathered pipeline” refers to a line whose MAOP was
established based on the maximum operating pressure history of the pipeline rather than a
hydrostatic pressure test.
In January 2012, The “Pipeline Safety, Regulatory Certainty, and Job Creation Act of 2011”
reauthorized the Natural Gas Pipeline Safety Act. The timeline of hydrostatic pressure testing
history and regulations is summarized in Figure 2. The “Pipeline Safety, Regulatory Certainty,
and Job Creation Act of 2011” requires operators to reconfirm MAOP of interstate and intrastate
gas transmission lines in Class 3 and 4 locations and Class 1 and 2 HCAs with insufficient
MAOP records.
Section 23, of the “Pipeline Safety, Regulatory Certainty, and Job Creation Act of 2011” states:
“(c) DETERMINATION OF MAXIMUM ALLOWABLE OPERATING PRESSURE –
“(1) IN GENERAL – In the case of a transmission line of an owner or operator of a pipeline

facility identified under subsection (b)(1), the Secretary shall -
“(A) require the owner or operator to reconfirm a maximum allowable operating pressure
as expeditiously as economically feasible: and
“(B) determine what actions are appropriate for the pipeline owner or operator to take to
maintain safety until a maximum allowable operating pressure is confirmed.
Also, the “Pipeline Safety, Regulatory Certainty, and Job Creation Act of 2011” requires DOT to
issue regulations requiring operators to conduct tests to confirm the material strength of
previously untested gas transmission lines in HCAs that operate at a pressure greater than 30
percent SMYS. Operators must consider safety testing methodologies, including hydrostatic
pressure testing, and other alternative methods, including in-line inspection (ILI), determined by
DOT to be of equal or greater effectiveness.
7
Figure 2 – Key Dates and Time Periods in
Hydrostatic Pressure Testing History and Regulation8
Post construction pressure test required

Test duration not specified
1955
ASA B31.8
November 1970
1935
Title 49 CFR Part 192
ASA B31.1 Tentative Standard January 2012
1951 Subpart J [192.505]; [192.619 (2) (i)];
Post-installation pressure test not required The “2011 Act"
ASA B31.1 [192.611]
reauthorized the
1950 NGPSA
1926 1968
HPT of the NGPSA
American Standards Institute
1900 “Inch Lines” Post construction pressure test required
initiated Project B31
Hydrostatic Testing completed Test duration – 8 hours
“Grandfather Clause”
in Vessel Industry
1952 - 1968
Natural gas industry
performed scientific
studies to better
understand HPT
under ASA B31.1 thru
B31.8 code
1942
Pipeline Built 1969 - 1970
1942 - 1955
Under ASA B31.1 OPS & DOT developed
ASA B31.1
Safety Standards
Legend:
HPT = Hydrostatic Pressure Testing

ASA B31.1 = American Standard Association, Code for Pressure Piping
ASA B31.8 = American Standard Association, Code for Gas Transmission and Distribution Piping Systems
ASME = American Society of Mechanical Engineers
2011 Act = Pipeline Safety, Regulator Certainty and Job Creation Act of 2011
NGPSA = Natural Gas Pipeline Safety Act
2.2 Impact and Magnitude of Testing Requirements

Of the 299,614 miles of onshore pipelines in the United States,9 almost half of U.S. transmission
mileage was installed between 1950 and 1970, a time period during which the industry was still
studying benefits and limitations of hydrostatic pressure testing. The cumulative percentage of
transmission pipelines, by decade installed,10 is as follows:
 12 percent of the pipeline infrastructure was installed prior to 1950.

 37 percent was installed prior to 1960.
 60 percent was installed prior to 1970.
Approximately 180,000 miles of pipelines were installed before 1970. Of these, according to
DOT reports, 50,000 to 90,000 miles are either not hydrostatically tested, may not have been
8
For details refer to Table 2 - Natural gas transmission pipeline pressure testing requirements of Vintage
ASA/ASME B31.8 Editions
9
PHMSA, 2011 Annual Report Mileage for Natural Gas Transmission & Gathering Systems, Forms
F7100.2-1.
10
Kiefner, J.F. and Rosenfeld, M.J. “The Role of Pipeline Age in Pipeline Safety”. The INGAA
Foundation, Inc., November 8, 2012.
8
tested to the current Code of Federal Regulation, title 49, sec. 192 requirements in regard to
duration and pressure test ratio, or do not have sufficient records of the test. PHMSA is in the
process of developing a process to address such mileage, but the number of miles that will be
affected, the specific requirements and timelines are yet to be defined.
Testing existing pipelines presents unique challenges not experienced when testing new
pipelines.
 The line must be taken out of service for extended periods of time, requiring alternative
supply, advanced planning to re-route the flow of gas or interruption of customers.
Large water storage systems may be required to reduce outage times during fill and
discharge.
 The line may have multiple diameters, wall thicknesses and grades that complicate
pipeline cleaning and/or the design parameters of the test.
 The line may have internal contaminates. Consequently, water released during a failure
could contaminate the environment if the pipeline were not cleaned in advance of the
test. The cleaning process may generate hazardous waste streams that require
permitted handling, transportation and disposal. Test waters may not be allowed to be
discharged to ground and must be handled in accordance with environmental
regulations.
 Existing pipeline may be in close proximity to the public. Notifications and/or
evacuations may be required. Leaks and ruptures can be hazardous to the public if
appropriate precautions are not taken since a large volume of water can be released.
Testing may heighten public interest and concern rather than abate it if it is not communicated
properly. Venting and purging of natural gas from the line to prepare for the test may be
confused with damaged and leaking pipelines, which can alarm the public.
9
3 Planning the Hydrostatic Pressure Test
3.1 Determination of Scope
Operators benefit from developing protocols to achieve desired objectives. The objective of the
test must be understood so that minimum test pressure can be established. The benefit of
testing to higher pressures to maximize MAOP, or to achieve larger test pressure to operating
pressure ratios to extend Integrity Management (IM) reassessment intervals, must be balanced
with the potential for added test failures.
For instance, it may be desirable to establish the highest possible operating pressure and/or to
rule out as many defects as possible. However, the consequence of testing to pressures in
excess of multipliers in Code of Federal Regulations, title 49, sec. 192.619 could result in
failures without achieving desired benefits.
Many federal and state jurisdictional regulations come into play in the planning, design and
execution of a hydrostatic pressure test. Pipeline operators need to investigate and incorporate
specific jurisdictional requirements into their hydrostatic pressure testing plans.
3.2 Risks Associated with Testing Existing Pipelines

This paper focuses on the risks unique to hydrostatic pressure testing of existing pipelines.
Fundamentally, hydrostatic pressure testing involves the same construction risks associated
with installing pipelines such as trenching, shoring and working near other infrastructure. In
addition, when testing existing pipelines the following risks should be considered:
1.) Pipeline Failures – The risk associated with pipeline test failures can be categorized into
buried and exposed.
 Buried Pipeline – Failure on a buried pipeline may result in water breaking the
surface of the ground or paving. Subsequent erosion may occur in steep areas
and/or loose soils. Pipeline contaminants could also be released into the
environment, if not planned for and mitigated.
 Exposed Pipeline – In addition to the risks associated with a buried pipeline, a failure
on an exposed pipeline subjects people and equipment to the initial release of
energy. The pipeline and associated equipment may move or jump as a result of the
water blast if not planned for and mitigated.
2.) Public Safety – Strength testing in populated areas exposes the public to the failure
mechanisms mentioned above. Patrolling standards should be considered for the
pipeline while under test, and safety zones should be established to prevent public
access within a set distances from buried and exposed piping. (The test pressures,
percent SMYS and test media should be considered in the development of the policies).
10
The use of barricades, barriers and blast mats as mitigation measures should be
explored when safety zones cannot be enforced.
3.) Worker Safety – The INGAA Construction Safety Consensus Guideline, “Pressure
Testing (Hydrostatic/Pneumatic) Safety Guidelines,” is a good source for identifying and
mitigating these risks; a copy of the document is included in Appendix C.
In particular, when hydrostatically testing existing pipelines, access to exposed and

pressurized piping and testing equipment should be limited to only those employees
necessary to perform the work. Training programs should be reviewed and revised
accordingly. Safety practices should include the design and review of test manifolds, pig
traps, temporary manifolds, etc. Special attention should be given to worker and public
safety during the depressurization and dewatering steps, due to the temporary nature of the
equipment and the possibility of unsecured piping jumping during discharge. Training,
qualifications, and design safety requirements and policies should be extended to
contractors performing the work.
3.3 Planning the Test

Once the objective and scope has been determined, the operator must consider the physical
aspects of the line (pipeline attributes) and plan the logistics required to complete the test.
Likewise, environmental attributes such as location, proximity to water sources, elevation
changes, customer impacts, outage duration, spill prevention and safety must be considered
and planned for in the design and execution of the test. As a result, preparing to test a clean
1960 vintage pipeline, in an agricultural field, may require a far different approach than a
contaminated 1940 vintage pipeline in an urban or environmentally sensitive area.
3.3.1 Corrosion and Damage History

The history of corrosion-related leaks and/or damage should be evaluated and considered
during the planning phase. Review of maintenance records and ILI data (if available), and
discussion with operating personnel should be conducted and considered in development of the
plan. If the leak/damage history is significant, it must be addressed with preventative measures,
such as performing ILI runs, to locate and repair anomalies prior to the test, or increasing spill-
response measures employed to react to the higher probability of a failure.
Leak history related to third-party damage should also be carefully assessed, especially when a
pipeline traverses active agricultural areas or urban areas in which the pipeline occupies rights-
of-way or franchise areas with other underground utilities. Again, available ILI data should be
assessed. Based upon the results of these assessments, performing an ILI run prior to testing
should be considered.
11
3.3.2 Equipment and Construction Issues
Operators should review records, purchasing, construction and maintenance practices to
identify any facility issues that may affect test success. Examples would be:
 Dresser® Couplings may not be rated for the maximum test pressure and could result
in a leak, failure or damage under test.
 Abandoned taps might affect the test if they are not mapped, or if the tap involves a
buried valve that is not rated for the maximum test pressure.
 Miter and wrinkle bends are a concern if they are located in close proximity to the test-
head location. These bends do not experience axial loads during operation, but will
under test if they are located close to exposed ends.
 Field constructed fittings, such as fish mouth tees and mitered elbows pose a concern
because of the lack of manufacturing quality control and rating.
Section 4.0 of this report provides further information on assessing and addressing these issues
during engineering and design
3.3.3 Logistical Issues

Several logistical issues also affect the duration of the service outage, construction impacts and
cost to achieve a successful test. Consideration must be given to the following:
 Proximity to each of the identified sections of pipeline requiring testing.

 Proximity to water source/discharge location.
 Proximity to sufficient laydown/staging to support construction and water storage tanks
(e.g. work sites of up to two or more acres can be required).
 Elevation changes within identified segment and commensurate static head.
 Piggability; multi-outside diameters (ODs) within identified test section, valves and
fittings, large degree miters or mechanical fittings.
 Customer supply impacts within test section and within pipeline outage limits.
 Operational considerations due to having pipeline out of service for one to three weeks
or more and impact to other planned outages and work (i.e. transmission and
distribution planning issues).
 Incorporation of other operations and maintenance (O&M), capacity, ILI, or other
operator work.
 Temporary gas requirements; including CNG, LNG, by-pass, backfeed requirement,
back-ties, etc.
3.4 Environmental Permitting Issues

Testing existing pipelines offers the possibility of avoiding direct impacts to the environment if
the test can be lengthened to place testing equipment in environmentally innocuous locations.
This avoidance strategy may marginally increase costs but promote environmental stewardship.
12
When testing existing pipelines, the potential of releasing contaminated water can be substantial
and must be considered. The cost of cleaning lines to remove contaminants prior to filling with
test water should be balanced against generating waste streams from the cleaning effort as well
as the consequence of an environmental spill, should a failure occur.
To ensure that discharge water meets environmental permit requirements, it is important to

establish a sequence of water sampling protocols to rule out sources of contamination.
Hydrotest water can be contaminated via a number of sources. Water sampling is further
discussed in the Section 5 of this paper.
3.5 Outage Management

Operators should consider establishing policies defining what customer types may be impacted
and for how long. If applicable, customer contracts, rates and tariffs should be reviewed and a
determination made if the appropriate clauses can and will be exercised. Methods to manage
outages include:
 Scheduling work with customer planned outages.

 Coordinating with other Work Through Gas System Operators.
 Use of LNG/CNG.
 Temporary bypasses and backfeeds.
 Compression from distribution or lower-pressure lines.
3.6 Communications
A Communication Plan is needed to keep the public, jurisdictional authorities and appropriate
company personnel informed about the hydrostatic pressure testing. It is important to provide
essential information and set expectations for the pressure test to all stakeholders.
Communications should be conducted periodically as required, and when requested, to ensure
that the stakeholders have current information about the pressure test.
The Communication Plan should establish key contacts and protocols that can be employed to
defuse situations before and during the design, permitting and execution of the hydrostatic
pressure test. A good Communication Plan and outreach strategy can improve interaction with
the community and local agencies, thus avoiding time-consuming and costly complications.
A Communication Plan for hydrostatic pressure testing should address:
 External communications to landowners and tenants along pipeline, state and federal
authorities, public officials, local and regional emergency responders, and the general
public.
13
 Internal communications to employees and contractor personnel involved with various
aspects of hydrostatic pressure testing.
The operators should provide the following basic information to all stakeholders, and answer
the following questions:
 Why is a hydrostatic pressure test required?

 What is a hydrostatic pressure test?
 How does the test ensure safety and integrity of the natural gas system?
 What happens during a test and what should be expected?
 How long will the hydrostatic pressure test last?
A Communication Outreach sample is include in the Appendix B and can be found on the
INGAA Foundation website www.ingaa.org/hydrotest.
3.6.1 External Communications

In addition to basic information, specific messages for the various target audience groups
should be included:
Landowners and Tenants Along the Pipeline

Communicating with landowners and tenants is of particular importance, especially in densely
populated urban and suburban areas. Impacts to landowner operations may affect the project
schedule. Additional workspace beyond existing pipeline easements may be required.
Involving land owners early can prevent complications, delays and claims.
The operators should provide the following information to this group:
 Company name, test location and contact information.

 Contact phone numbers, both routine and emergency.
 General location information and more specific location information, or where maps can
be obtained.
 Temporary traffic detour, landlord access to property, ingress and egress for operator
and contractors’ personnel.
 The materials in use, machinery and support equipment to expect, temporary noise
level, and occasional odor of natural gas.
It is expected that some dialogue may be necessary between operator and the public in order to
convey the operator’s confidence in the integrity of the pipeline, as well as to convey the
operator’s expectations of the public during the test. Operators should take such opportunities
to talk with the public as they provide an forum to help protect assets, people and the
14
environment. Informing the community and neighborhoods is an important step in building
support. Operators may use the following to reach an affected community:
 Town hall meetings.

 Door hangers and targeted mailings.
 The use of social media, such as commercials, web sites and informational videos.
Governmental Agencies and Public Officials Other Than Emergency Responders

Various federal, state and local agencies may be involved in the approval and permitting
process associated with hydrostatic pressure testing. Identifying the agencies with jurisdiction,
and then discussing plans and objectives often streamlines the permitting process and creates a
spirit of cooperation. Contacts can be established to deal with policy-level issues that are
difficult to address at a working level.
Information that should be provided to this group includes:
 Company name, test location and contact information.

 Summary of emergency preparedness.
 Environmental issues and risk-mitigation plan.
Local and Regional Emergency Responders

Identifying the emergency responders assigned to various jurisdictions is important in
developing response plans. The operator should name a liason officer to maintain contact with
all emergency responders, including local emergency planning commissions, regional and area
planning committees, jurisdictional emergency planning offices and others. Informing these
groups of the work methods to be employed, the potential hazards and failure mechanisms
allows them to prepare for an efficient response. Notification policies, key contacts and status
reporting should be included in these plans.
Other information that should be communicated to this group includes:

 Company name and contact numbers, both routine and emergency.
 Local facility maps.
 Facility description and that the commodity transported is natural gas.
 General information about operator’s preventative measures.
 Summary of operator’s emergency capabilities.
 Coordination of operator’s emergency preparedness with local officials.
 Training on the potential environment responders will encounter should a response be
needed.
 Discussion on what happens when a release occurs during a test
15
General Public
The operators should provide the following messages to this group:
 Information regarding operator’s efforts to support pressure-test notification and other

preventative initiatives.
 Company name, contact and emergency reporting information, including general
business contact.
 Note that they may smell a natural gas odor or hear loud noise.
3.6.2 Internal Communications

The Internal Communications Plan helps keep management and other appropriate company
personnel abreast of the status of hydrostatic pressure testing activities and changes. This
communications plan should include personnel in the following internal departments:
Operations, Engineering and System Planning, Gas Control, Integrity Management, Community
Relations, Government Liaison, Corporate Media, Call Centers, and Health & Safety. The
Communication Plan should also include appropriate external contractor personnel.
Company employees can serve as excellent ambassadors to the community. They are credible
community members and neighbors. Consideration should be given to training workers who
may be questioned regarding the objective and need for the hydrostatic pressure testing.
Training and orientation for workers should include what questions can be answered and how to
direct the public to more appropriate resources. The use of an information card is a good tool in
this regard. The card can answer frequently asked questions and direct the public for additional
information.
16
4 Pressure Test Engineering, Design and Risk Mitigation
Considerations
4.1 Gather Existing Pipeline Feature Data
Prior to beginning the engineering and design of a pressure test on an existing pipeline section,
irrespective of the of purpose of the test determined in Section 3, Determination of Scope, in this
document, pipeline operators must gather available data on the pipeline section and
appurtenances that will be subjected to the proposed hydrostatic pressure test. This data
generally can be grouped into data related to the physical characteristics of the pipeline
features, down to the component level, historical operations and maintenance data and pre-test
evaluations.
Primary sources of pipeline characteristic data are:
 Pipeline feature studies utilized in MAOP validation.

 Operator’s Geographic Information Systems (GIS).
 Alignment sheets and/or transmission plat sheets.
 As-built documentation.
 Prior hydrostatic pressure test reports.
 Mill Test reports for pipe and manufacturer test reports for fittings.
 Material purchase records; contracts, purchase orders, requisitions, etc.
 Industry vintage pipe reports
4.1.1 Historical Operation & Maintenance Data

Historical operations and maintenance data on the test section provides useful information in
support of engineering and design of the test. This information provides the pipeline operator
with an indication of the condition of the pipeline and the feasibility of a successful test, the
potential for having a test failure and can detect areas of concern that should be assessed prior
to hydrostatic pressure testing, or that may limit maximum and spike test pressures. Pipeline
operators should carefully review and analyze:
 Pipeline leak history.

 Prior hydrostatic pressure test failures.
 Cathodic protection surveys.
 Valve maintenance history.
 In-line inspection data.
 Pipeline survey and patrol data (for indications of potential third party or right-of-way
encroachment damage).
17
4.1.2 Pre-test Inspections
Pipeline operators have identified the use of the following pre-test inspections/evaluations to
identify potential pigging impediments and potential failure points:
 Cleaning pigs - brush or squeegee to remove debris and scale from pipeline.
 Geometry pigs – gauge, caliper, or high-resolution deformation to ensure the passage of
fill and dewatering pigs and identify pipeline damage that may require removal.
 Metal loss pigs – axial or transverse Magnetic Flux Leakage (MFL) tools to identify
corrosion and third party damage that may not survive test pressures.
 Crack detection pigs – EMAT or ultrasonic to identify potential failure points in
longitudinal seam and welds.
4.2 Validate Pipeline Feature Characteristics

Once the pipeline operator gathers the existing pipeline feature characteristics, O&M and pre-
test data deemed appropriate for the planned test section, the data must be organized in such a
manner that it is useful and available to engineering and design personnel to validate all pipeline
features and their location within the proposed test section. This cataloguing of pipeline
features and characteristics typically would take the form of a pipeline features list or study.
Some of this information is the same information that pipeline operators must obtain for their
MAOP verification to confirm their established MAOP for pipelines operating in Class 3 and
Class 4 locations, and Class 1 and Class 2 locations in HCAs, as imposed by the Pipeline
Safety, Regulatory Certainty and Job Creation Act of 2011.
Validation of pipeline features encompasses reviewing feature data to confirm, as appropriate

for each feature, the outside diameter (OD), wall thickness (WT), grade, seam type, rating,
manufacturing information, its location within the test section, identification of any unpiggable
features, features that limit test pressure, and features or fabrication and construction threats
that may be more susceptible to failure. The location, characteristics, specifications and ratings
of each of the following should be identified, to the extent possible, prior to engineering and
designing of a hydrostatic pressure test on an existing pipeline (see section 4.3 below):
 Line pipe
 Elbows, tees, flanges, and other fittings
 Valves
 Taps
 Casings
 Spans and other exposed piping
 Sleeves and patches or other repairs
 Mechanical couplings
 Wrinkle or greater than 3 degree miter bends
 Expansion joints
18
 Non-standard fittings (i.e. fabricated elbows, reducers, etc.)
4.2.1 Guide to Conservative Assumptions

At the outset of any data validation effort, consideration should be given to the development of a
guide to conservative assumptions that the pipeline operator may need to use, if there is
insufficient data to definitively determine all characteristics of a pipeline feature. This guide is
necessarily specific to the pipeline operator based upon the operator’s historical purchasing
policies and records, design and engineering standards, specifications and standard practices.
For example, if a pipeline operator has adequate documentation that it purchased no less than
Grade B pipe and fittings (35,000 SMYS), per its historical design standards and specifications
since 1950, and all other attributes, such as OD, WT and seam type are known, it may have
sufficient documentation to confirm that the most conservative SMYS of the feature is 35,000
and not 24,000,11 as required by code, for use when SMYS is unknown. Consultation with the
operator’s legal and regulatory compliance personnel, and perhaps its regulator, must be
performed prior to implementing such a guide, but for those with sufficient documentation, such
a guide can prove valuable when validating pipeline features for hydrostatic pressure testing.
4.2.2 Resolving Unknown Feature Characteristics

When a pipeline’s feature characteristics cannot be confirmed via data validation or the use of a
guide to conservative assumptions, to a degree that the test pressure will be limited to less than
that required to meet the hydrostatic pressure-testing objective, excavation and assessment of
the feature may be a viable alternative to consider.
Various testing methodologies are available to determine the characteristics of an unknown

feature, including:
 OD and WT can be readily determined via physical measurement and ultrasonic

thickness gauging.
 The presence or type of seam may be readily evident via visual examination or may
require more in depth investigation, such as radiography, etching or other NDE
techniques.
 Confirmation of yield strength is difficult to confirm without destructive testing.
However, non-destructive technologies for confirming yield strength that show promise
are available, and may become acceptable means for confirming, if not determining,
yield strength.
11
Code of Federal Regulations, Transportation, title 49, sec. 192.107
19
The Gas Technology Institute has recently completed a study to develop a procedure to
determine yield strength without the need for a shutdown.12 While this process is not yet
approved or incorporated into regulations by PHMSA, it has been used as the basis for a
special permit request to determine yield strength. In many cases, confirming only two or three
attributes, and using minimum assumptions (per code or operator standard) for yield strength
and/or joint efficiency, provides sufficient information to satisfy the operator that the feature no
longer limits the hydrostatic pressure testing of the proposed test section.
During data validation, every effort should be made to identify pipeline sections with potential
fabrication and construction threats, such as Oxy-Acetylene welds, bell-bell chill ring (BBCR)
joints, bell and spigot joints, early vintage arc welds, etc. Depending on operator standard
practice, these threats may warrant consideration of replacement in lieu of hydrostatic pressure
testing or invoke additional constraints on the hydrostatic pressure test procedure.
4.3 Assess and Address Features

The first step in designing a hydrostatic pressure test for an existing pipeline is assessing
features to ensure that the pipeline is piggable. All unpiggable features should be removed or
replaced that might impede the passage of fill and dewatering pigs. When operators encounter
unpiggable features that are otherwise fit for service, they may find it economical to remove the
unpiggable feature, install a spool, or short section of new pipe, to facilitate testing, test the
unpiggable feature separately from the planned test, and reinstall it upon completion of the
hydrostatic test during tie-in. The operational disadvantage of this methodology is that upon
completion of the hydrostatic test, the pipeline remains unpiggable for future ILI inspections.
The method of removing and spooling, a feature for hydrostatic pressure testing, also can be
employed at features, such as valve sets and taps where dewatering and drying of the valve set
or tap piping may be difficult and result in free water remaining in the test section. Additionally,
valve shell test pressures may be below desired test pressures for the existing pipeline being
tested, or operator specifications for new installations may prescribe higher test pressures for
those assemblies, and require them to be tested separately. After all unpiggable features have
been identified, the operator’s engineers can employ appropriate design to mitigate these
features in accordance with the operator’s design, construction and operating standards.
The pipeline features list or study, which contains all of the validated features included in the
test section, must be reviewed in detail by the operator’s engineers to determine if the feature is
appropriately designed to operate at the MAOP to be established, limits the maximum test
pressure or poses an unacceptable risk of failure during the hydrostatic test. Even though a
feature may have met the code in force when it was constructed, the operator should consider
whether the feature poses a risk to the continued safe operation of the pipeline or unacceptable
risk to the pipeline, environment, workers and public in the event of failure during the hydrostatic
12
FINAL REPORT: Establishment of Yield Strength Using Sub-size Samples without Gas Line Shutdown
(Mini, Full-Wall Longitudinal Specimens), Operations Technology Development (OTD), NFP, Project No.
4.7.g / GTI Project No. 20568; Report Issued: March 4, 2011.
20
pressure test. Where the feature is non-commensurate with the MAOP to be established limits
the test pressures below the operator acceptance criteria established for the test purpose or
poses unacceptable risk, the feature should be removed or replaced.
4.4 Establishing Minimum Test Pressure and Control Point

The minimum test pressure for a hydrostatic pressure test is controlled by Code of Federal
Regulation, title 49, sec. 192 for establishing or reconfirming the MAOP of a pipeline. The table
in §192.619(a)(2)(ii) provides the minimum test pressure to MAOP ratio required depending on
class location and year installed, or converted from service other than natural gas, and class
location. Some operators may be regulated by state jurisdictions that require more stringent
test pressure to MAOP ratios. However, when an operator plans to incur the expense of testing
an existing pipeline, there are additional considerations.
The National Transportation Safety Board (NTSB) in its Safety Recommendation P-11-15 of
September 26, 2011, recommended that PHMSA “amend Code of Federal Regulation, title 49,
sec. 192 of the Federal pipeline safety regulations so that manufacturing- and construction-
related defects only can be considered stable if a gas pipeline has been subjected to a post-
construction hydrostatic pressure test of at least 1.25 times the MAOP.” Consequently, pipeline
operators should consider testing to no less than 1.25 times MAOP whenever possible in Class
1 locations, where elevation differences within the test section do not cause the test section to
be broken into uneconomic test sections to account for hydrostatic head.
Determination of minimum test pressure should also consider, but not limited to, the following:
 Current MAOP.
 MAOP of connected pipelines.
 Potential for changes in pipeline demand or delivery pressures.
 Potential for future class location change.
 Presence of HCAs.
 Any specific threats or anomalies whose elimination or absence thereof is being
confirmed by the test.
Prior to establishing minimum test pressure for the hydrostatic pressure test of an existing
pipeline in HCA, the pipeline operator should consult its integrity management (IM) department
to determine if it is appropriate and beneficial for the test to serve as an IM re-assessment. It
may be beneficial for the operator to test to higher than the minimum requirements of
§192.619(a)(2)(ii) in order to satisfy any additional IM program assessment or reassessment
requirements arising from Code of Federal Regulation, title 49, sec. 192, Subpart O.
Regardless of whether the pipeline operator wishes to establish an IM re-assessment interval,

per Code of Federal Regulation, title 49, sec. 192, the operator may want to consider testing to
as high a minimum test pressure as can be achieved, without exceeding the operator’s
21
protocols for maximum test pressure and providing an achievable range between minimum and
maximum test pressures. Higher test pressures result in smaller sub-critical anomalies
surviving the test and more effectively stabilizes them from pressure-driven growth,13 thus
providing a greater factor of safety. Flaws that survive test pressures in excess of minimum
requirements will take a longer time to reach critical size than those that survive a test
performed to minimum requirements.
4.5 Determine Maximum Test Pressure and Control Point

When establishing the maximum hydrostatic test pressure for an existing pipeline section,
operators must consider that the maximum pressure control point is not always at the lowest
elevation as is typical of post-construction strength tests. Existing pipeline tests can contain
sections designed and installed to meet prior code requirements, and the potential exists for the
test section to include multiple installations due to main extensions, relocations, repairs, etc.,
that heighten the importance of the validation of the pipeline component characteristics, as
discussed in the Validate Pipeline Feature Characteristics section of this paper. The maximum
pressure control point for an existing hydrostatic pressure test is the point within the test section,
taking static head into consideration, where the test pressure produces stresses commensurate
with the established test criterion. The maximum test pressure must not be set so high as to
potentially damage the pipe or any component being tested. If operators choose or are required
to include a spike test, the spike test pressure will be the maximum test pressure.
When testing existing pipelines, the operator must consider the benefits of testing to the highest
possible pressure, and resulting benefit of smaller remaining sub-critical anomalies surviving the
test, versus the risk of failure. API Recommended Practice 1110,14 Section 5.1.10, contains a
comprehensive list of considerations for determining maximum test pressure. When
establishing maximum test pressure on existing pipelines, operators should pay particular
attention to the following considerations:
 Elevation difference within test and resultant static head,
 Mill Test pressure, if known, or probable Mill Test pressure of all pipe segments,
 Available ILI data,
 Maximum pressure of any prior test(s),
 Pressure ratings and manufacturer test pressure of rated fittings,
 Leak history – frequency and characterization,
 Repairs – type and location,
 Proximity of test section to public, structures and environmentally sensitive areas,
13
Kiefner, J.F., “Evaluating the Stability of Manufacturing and Construction Defects in Natural Gas
Pipelines”, U.S. DOT, Final Report No. 05-12R, April 26, 2007.
14
API RECOMMENDED PRACTICE 1110, SIXTH EDITION, FEBRUARY 2013, Pressure Testing of
Steel Pipelines for the Transportation of Gas, Petroleum Gas, Hazardous Liquids, Highly Volatile Liquids
or Carbon Dioxide.
22
 Engineering evaluation of suitability of non-standard components to withstand the test
pressure, wrinkle bends, greater than 3 degree miters, mechanical couplings, expansion
joints, etc, and
 Mill Test records (if available).
Prior to engineering a pressure test on an existing pipeline, operators should consider

developing a protocol to establish the maximum test pressure that addresses the considerations
above appropriate for their pipeline systems and engineering and operating philosophies.
Establishment of a protocol promotes engineering and design consistency, streamlined
approvals and it helps ensure engineering, IM and operational considerations are appropriately
weighed and addressed by the test and provide justification and clarity to regulators.
The range between minimum and maximum test pressures, or post-spike test pressures
(discussed later in this section) at the test station, taking elevation differences into account, can
be very narrow, and in practice ranges in the 25 psig to 35 psig can be achieved without
excessive bleeding or addition of test water. This is important for operators who desire, or are
required, to include a spike test on their existing pipeline tests. A narrow test pressure range
facilitates achieving the desired spike pressure and provides for sufficient decrease in pressure
to maximum post-spike pressure to attain the maximum benefit of the spike test.
The test pressure range can be minimized by following a comprehensive test plan and carefully
monitoring test pressure and temperature during the test period. Ensuring sufficient
temperature stabilization time between completion of fill and initial pressurization can facilitate
test pressure ranges as narrow as 20 – 30 psig.
4.5.1 Spike Testing

The spike test is a variant of the hydrostatic test in which the pressure is initially raised to a
prescribed level above the minimum test pressure, or stress level, for a short period then
reduced for the remaining duration of the test. A spike test’s purpose is two-fold: the spike
portion will induce failure in the pipe where significant defects may be present, while the
subsequent reduction of pressure allows any surviving cracks to stabilize and avoids subcritical
crack growth during the hold period to detect leaks.15
Employing a minimum spike pressure of at least 5 percent, and preferably 10 percent16 or

higher over the minimum test pressure as described in Section 4.4 above, and holding for a
period of up to 30 minutes (ASME B31.8S recommends minimum 10 minutes)17 is sufficient
15
Rosenfeld, M.J.,”Hydrostatic Pressure Spike Testing of Pipelines – Why and When?”, Presentation to
American Gas Association, Operations Conference, Orlando, May 22, 2013.
16
Rosenfeld, M.J., Ibid.
17
Paragraph A-3.4.2(b), “Managing System Integrity of Gas Pipelines”, Supplement to B31.8, ASME,
B31.8S-2012.
23
when testing existing pipelines to eliminate manufacturing-related, construction-related and
corrosion defects that might otherwise grow to failure during the test period.
In order to achieve the desired result, the spike test pressure should be lowered at least 5
percent, but a reduction of 10 percent18 is preferred to prevent subcritical crack growth during
the remainder of the prescribed test period.
Incorporating a spike test may be advisable when testing existing pipelines with a test pressure
to MAOP ratio less than 1.4, and for pipelines that have experienced seam weld failures or
contain seam weld types that have exhibited susceptibility to seam cracks or failures.19
Including a spike test also provides operational benefits. Stand-by construction crews, and
other leaks/ruptures response teams can be released after completion of the spike period. The
impact and inconvenience to the public may be reduced as the threat of failure is essentially
eliminated because, if properly executed, there should be limited if any sub-critical crack growth
during the post-spike hold period.
Spike testing originated as a means to increase the time to failure after hydrostatic pressure
testing of pipelines affected by SCC. Spike testing as high as possible, within the range of 100
percent to 110 percent of SMYS, is typically recommended for assessing SCC to maximize the
retest interval and not result in significant deformation.20
4.6 Test Duration and Timing

Test duration is governed by the requirements of Code of Federal Regulation, title 49, sec. 192,
Subpart J when establishing MAOP of an existing pipeline via hydrostatic testing.
The timing of the hydrostatic test can be an important consideration. Most operators surveyed
for this paper indicated that they seek to conduct tests during daylight hours. Testing during the
day can make patrols more effective and limit the inconvenience to residents around the test
section. However, circumstances may dictate that testing be done at night to limit the impact on
traffic, businesses or the public. Testing pipelines in areas with very high daytime temperatures
also may lead an operator to conduct tests at night when the thermal effects can be minimized.
The best time for any test will depend upon the specific circumstances of the test under
consideration and impacted by permitting, safety, and the potential effects on businesses,
residents and the public.
18
19
20
Fessler, R, Batte, D, and Hereth, M, “Integrity Management of Stress Corrosion Cracking in Gas
Pipeline High Consequence Areas,” ASME STP-PT-011, 2008, ASME, New York.
24
4.7 Engineering Factors for Consideration
Testing existing pipelines requires the operator to address engineering considerations that may
not be typical for testing new pipeline installations. These can be summarized as follows:
 Selection of practical, safe and cost-efficient test sections.

 The location, accessibility and impact of the test manifolds on landowners, businesses
and the public.
 Trade-off between accessibility and constructability of aboveground test manifold
installations and additional safety and reduced impact of belowground installations.
 Test station location and safety.
 Availability of safety exclusion areas around pressurized piping and test stations and
potential for evacuations.
 Selecting the longest practical test section versus the number of isolation points (taps,
cross-ties, etc.) and their impacts to service and temporary gas requirements.
 By-pass, temporary crossties, backfeeds, cross-compression or other means to provide
continued service to meet contracts requirements.
 Test manifold and pig launcher/receiver designs.
 Number of unpiggable components and/or their limitations on desired test pressures.
 Limitations posed by valve assemblies on piggability and test pressures.
 Test section isolation from the pipeline and returning to service of the pipeline either side
of the test while test is performed.
 Isolation cap design.
 Pigging challenges associated with cleaning, fill, and dewatering due to pipeline features
that cannot be removed prior to testing.
 Assessment and possible removal of anomalies identified by any pre-test ILI runs.
Engineering evaluation and considerations of specific pipeline features.
 Spanned sections must be analyzed to ensure that the combined stresses do not
exceed (American Society of Mechanical Engineers) ASME B-31.8 requirements.
 Assessing waterway crossings and potentially limiting stress limits during testing.
Identification of impacts of test failure in waterway crossing to environment, commerce,
etc. Contingency measures in the event of failure of waterway crossing, material
availability, crossing design, emergency permitting, and contractor availability.
 Review of casings within test section, confirmation of casing isolation from pipeline, and
contingency measures in event of failure within cased section.
 Removal of any drips from the test section and potential for long lead-time permitting to
access and remove drip legs/piping.
25
Removal or limitations posed by fabrication and construction threats.
 Mitered welds or wrinkle bends.

 Mechanical fittings and couplings.
 Excessive pups or joiners.
 BBCR and bell and spigot joints.
 Oxy-Acetylene or early vintage arc welded joints.
 Other non-standard fittings.
Design of temporary test piping to locate test manifolds where desired, for by-pass piping or
isolation of laterals.
 Design with sufficient factor of safety over most restrictive design factor of existing pipe
within test section to ensure against failure.
 X-ray of all temporary welds is suggested.
 Determine limitations, if any, on reuse of temporary test piping (i.e. limit number of times
tested over prescribed percent SMYS).
 Design piping to limit number and orientation of angles considering water hammer,
surging, and impact of pigs coming into test manifolds, launchers and receivers during
cleaning, filling and dewatering.
 Proper anchoring of unrestrained piping.
4.8 Possible Components of Engineered Drawings

In addition to the operator’s standard title page, general notes, work summary, sequence of
operations, specific notes and details, legends and symbols, and other sheets included in their
standard drawing template, when preparing drawing sets for hydrostatic pressure testing,
consideration should be given to include the plan, profile, location sketches, bill of material,
material of record, construction details and as-built information. Ensuring that this information is
contained within the drawing package generally provides sufficient information for the drawings
to be used for permitting, construction, temporary and permanent easements, and provides a
basis to ensure that the as-built documentation is traceable, verifiable and complete.
4.8.1 Plan
Plan view with horizontal stationing and detail call-outs for test ends, isolation points, locations
requiring removal/replacement of unpiggable features, or to draw attention to locations of
interest during testing. The pipeline location and cadastral information is typically obtained from
operators’ GIS system. Cadastral information is readily available to operators via the internet if
needed.
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4.8.2 Profile
Profile view containing pipeline stationing and identifying all pipe specifications, lengths, and
their location within the test section, as well as the type, specifications, location and number of
components, original installation job number, year installed, current class location and limits of
HCA within the test section. This information generally is pulled from pipeline features studies
and verified by engineering during the design of the hydrostatic pressure test. Profile
information can be obtained via as-built information, GIS, or other sources and does not
necessarily require a centerline survey. However, sub-meter accuracy may be required when
testing to pressures close to 100 percent SMYS, or when elevations, within the test section, limit
the test pressure range and pose risk to over pressurization due to static head and thermal
effects. When these risks are present, the operator should consider requiring a surveyed profile.
4.8.3 Location Sketches

Location sketches of all work areas provide for operators’ engineers to identify temporary
construction easements, locate and identify bell-hole size, spoils storage, laydown and staging
areas, access roads, construction parking, environmental exclusion areas, and areas of impact
to be used to obtain encroachment, environmental and other jurisdictional permits, temporary
and permanent land rights, and for construction.
4.8.4 Bills of Material

Bills of Material, as typical with any typical construction drawing, include any temporary
hydrostatic pressure test piping that may be reused.
4.8.5 Material of Record

A Material of Record, or summary, of all materials to be included in the hydrostatic pressure test
and depicted in the Profile in tabular format is recommended. The table would typically include
the feature specifications, length or number included in the test, and identifiers that relate to the
features location within the test section and depicted in the Profile.
4.8.6 Construction Details

Construction details, sections, and elevations as required to detail the installation of test
manifolds, depict any pipe installed to remove unpiggable features, detail test isolation from
laterals, taps, services, etc., show new or replacement installations (valves, regulation stations,
ETS stations, line markers, etc.), typical trench and bell-hole details, and any other installations
the operator wishes to include.
4.8.7 As-built Drawings

Operator requirements of the as-built package is an important consideration when developing
drawings for testing existing pipelines. Having as-built documentation of hydrostatic pressure
tests on pipelines, existing and new, that are traceable, verifiable and complete is essential.
Accuracy of the as-built documentation is important and can be easier and accelerated if the
27
requirements are given proper consideration during the design process. Ensuring that test
locations are correctly tied into the operators’ GIS and coordinate systems utilized will help
ensure easy correlation to tie test documentation to the operator’s pipeline documents of record.
Exact footages of tie-in piping, their location within the test section, whether included in test
piping or tested separate, the tie-in weld locations within the pipeline, as well as weld and X-ray
mapping can be accommodated by having a sound set of design drawings.
Operators are required by Code of Federal Regulation, title 49, sec. 192.517 to retain for the life
of the pipeline a record of each test performed that contains the following:
 The operator’s name, the name of the operator’s employee responsible for making the
test, and the name of any test company used.
 Test medium used.
 Test pressure.
 Test duration.
 Pressure recording charts or other record of pressure readings.
 Elevation variations, whenever significant for the particular test.
 Leaks and failures noted and their disposition.
Operators should have clear standards on the type and calibration requirements of pressure
and temperature recording devices to be utilized for documenting the hydrostatic pressure test.
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5 Hydrostatic Test Execution
5.1 Site Specific Plans
The use of detailed procedures is an effective way to ensure that the required elements of a test
are completed in the proper sequence. Operators also can incorporate hold points to ensure
that critical actions are completed prior to moving to the next step. Furthermore, application of
procedures can ensure that a test is completed and documented sufficiently to meet company
and regulatory requirements before the test is completed. This reduces the potential for re-
work.
Every test is unique and therefore site-specific plans should be developed. Operators should
consider including the following sections in their site-specific test plans:
5.1.1 Test Data

A description of the pipeline facility involved in the test with beginning and ending points
described by (Global Positioning System) GPS locations, accurate mile points, field stations or
other means should be included.
5.1.2 Authorization and Distribution

Inclusion of a review and authorization section is encouraged. The plan should be routed to key
operating departments and support organizations to ensure department specific elements are
included and the working group is authorized to proceed. A distribution list will ensure that all
affected departments receive a copy and are aware of the upcoming test.
5.1.3 Notifications
A list of all agencies requiring notifications, and contact information, should be included. Space
should be provided to record when the notifications were made and by whom.
5.1.4 Roles and Responsibilities

Designation of key personnel and a definition of their responsibilities. This ensures roles are
understood and reduces the potential for miscommunication. Examples include Test
Supervisor, Patrol Leader, Spill Response Leader, Safety Lead, Test Technician, etc.
5.1.5 Spill Response

A section of the procedure should be dedicated to planning for the containment of a spill should
a failure occur. Required equipment such as vacuum trucks, waddles, booms, etc. should be
identified and staged at strategic locations.
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5.1.6 Equipment Required on Site
It is recommended that the equipment required to complete the test be identified and confirmed
to be onsite prior to initiating the test. For example, specialty pigs to clean or fill the line should
be confirmed prior to cutting the line.
5.1.7 Test Equipment and Calibrations

A listing of the testing equipment utilized, make model, range, serial number, accuracies and
calibrations should be included. A review and audit of this equipment by a company
representative is advisable.
5.1.8 Establish Safety Zones

Consider the consequences of a failure and establish appropriate safety zones. Access to the
safety zone should be limited to only those persons who are necessary to perform the work.
Safety zones may vary depending on exposure to risk and the operation taking place at the
time. For instance, exposure to a failure of a buried line poses less consequence than that from
exposed piping. Exposures are greater during the testing and dewatering process, and safety
zones may need to be increased during those periods.
5.1.9 Pre-fill Sequence

This section will include the steps required by the operator prior to filling the pipeline with test
water. The source water should be sampled to ensure it does not contain constituents injurious
to the pipeline or that exceed local discharge requirements. The sequence should include
procedures for clearing the pipeline and proving fill pigs will pass. It is also applicable to running
any pre-assessment tools, such as geometry pigs. This is a valuable and critical section for
pipelines that have internal contamination. If the operator suspects that its pipeline may contain
contaminants, development of appropriate chemical cleaning protocols should be developed.
The operator can then perform a cost-benefit analysis of performing chemical cleaning versus
handling potentially large volumes of contaminated test water.
Pressurizing equipment, hoses and other associated equipment must be visually inspected and
determined to be in good working condition before the test. Make sure the equipment is properly
sized and rated.
5.1.10 Fill Sequence

This section describes the step-by-step procedure to ensure the pipeline is completely filled and
pig speed is controlled. Operators may wish to be prescriptive in this section the type of pig to
be used (foam, cup, poly, bi-directional, etc.), which end to launch from, minimum and maximum
fill rates, whether contingency measures are necessary, such as holding back a pig in the fill
manifold (sleeper pig), etc. A leak characterization water sample should be obtained at this step
to be used for reporting in the event of a test failure.
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5.1.11 Test Sequence
Topics included in this section are a review of equipment to confirm pressure ratings,
procedures to reach temperature and pressure stabilization and leak detection prior to
pressurization. Test equipment locations and relationship to elevations along the test section.
Spike pressure and hold points are also described in this section. Procedures for gathering
documentation and confirming the test is successful are also included in this section.
5.1.12 Depressurization
When preparing this section, consideration should be given to the following: outlet pressure,
elevation difference, water hammer, pig velocity, discharge rate, force on elbows, etc. Be sure
that adequate valves are planned to safely throttle-down the pressure. Make sure the equipment
is properly rated and safety precautions are included. Establish effective anchoring systems
based on expected forces and to prevent whipping of discharge piping.
5.1.13 Dewater and Dry

This section should include procedures for dewatering the line, as applicable, dewatering speed,
running swab pigs, including number of pig runs or company standard for acceptable moisture
penetration, requirements for dehydrated or compressed air, use of drying chemicals, minimum
dew point requirements, and any other operator pipeline drying standards.
5.2 Testing Location and Equipment

5.2.1 Test Station Location
The test station typically is located at the end of the test where the water source and fill pumps
are positioned. This provides for efficient and immediate communication between test
supervision and construction personnel, control of water addition or removal, and reaction to a
pressure-loss situation, should one arise.
Operators surveyed for this paper reported that safety zones of minimum 50 feet are typically
employed around pressurized piping. The test station should be located outside of the safety
zone. Care must be given to protect instrumentation hoses and connections and they may need
to be covered or otherwise shaded so they are not affected by thermal effects, as appropriate.
This is particularly true if larger safety zones are required by site conditions or operator standard
practice.
5.2.2 Charts and Dead Weight Testers Test Instruments

A pressure record should be maintained and documented during the entire testing period. A
chart or digital printout with appropriate intervals and pressure range is required. When testing
over 90 percent SMYS, an electronic pressure recorder or dead weight tester is advisable.
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Pressure gauges and or a reference chart should be installed at the remote end of the test
section or at maximum or minimum elevations of the test section. These gauges are for
information purposes only. However, the reference chart could be used as a substitute for the
official test chart if necessary.
5.2.3 Temperature Probes

Temperature probes provide data for relating variations in pressure with respect to temperature
changes. It is important that probes adequately represent the temperature of water in the test
section and that the probes are not affected by changes in ambient temperature. Installing the
probe(s) away from exposed pipe and as near as possible to the pipeline is advisable. Installing
the probe 100 feet or more away from exposed piping in a post-hole sized excavation filled with
sand is a good method. The probe should be installed prior to the test to allow sufficient time
(typically eight hours) for temperature stabilization.
5.2.4 Use of Electronics

Electronic pressure and temperature recorders should record at a minimum of every 15 seconds
and print out the recordings a minimum of every 15 minutes.
5.2.5 Calibrations and Certifications

Pressure recording devices should be accurate within +/- 0.5-1.0 percent (depending on
device), checked every six months, and calibrated yearly. Dead weight testers should be
calibrated within 12 months of each use. Calibration certifications should be gathered and
included in the documentation package.
5.2.6 Correlating Test Site Elevation to Maximum and Minimum Control Points
Once the test location is determined, the minimum pressure at the maximum elevation and the
maximum pressure control point values must be correlated to the test elevation considering
hydrostatic head. Head pressures are subtracted when the test locations is lower than a control
point and added when it is higher. For water, the head pressure is calculated by multiplying the
elevation change by 0.433psi/ft.
5.3 Pipeline Clearing/Cleaning

Prior to filling, the pipeline should be cleared of any debris and obstructions that may adversely
affect the effectiveness of the fill pigs. Pipeline contaminants obtained from the clearing run
should be sampled and tested to determine their effects on fill water and the environment
should a release occur. There are numerous pigs and cleaning methods available for this
purpose and a comprehensive description is beyond the scope of this report. In extreme cases,
multiple runs with solvents or detergents may be required. Local jurisdictional ordinances
should be reviewed to determine these values.
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Requiring the use of internal tracking devices in pipeline pigs is recommended. Tracking
devices will assist in locating a stuck pig and can be used to monitor fill and discharge rates.
Understanding the travel speed of pigs is extremely valuable during cleaning operations. The
pigs must travel at a speed that will provide for sufficient contact time of the cleaning batch and
keep solids in suspension. Gelled solvents should be considered in extreme cases.
5.4 Pre-assessment
If the pipeline history is uncertain, and/or the consequence of a failure is unacceptable, it may
be prudent to perform a pre-assessment of the pipeline. The pre-assessment method should be
selected based upon the specifics of the line and the flaws/threats to be detected. Methods
range from identifying simple protrusions and obstructions by the use of gauge pigs to running
in-line inspection (ILI) tools. A description of these methods is beyond the scope of this report.
5.5 Pipeline Fill

The test section must be completely filled with water to limit stored energy being released
should a failure occur, facilitate the efficient pressurization of the test, and ensure that an
acceptable pressure volume plot of the test can be achieved. A pig must be run ahead of the
water to force as much air as possible out of the test section. For test sections where a pig
cannot be used, the air must be vented at the high points. Fill the test section from one
direction, preferably from the low end. When testing existing pipelines, it may be desirable to fill
and dewater in the same direction to jump water to an adjacent test section, due to space
constraints for water containment or availability of a suitable discharge location at the low end.
During the fill, open and close valves slowly to prevent pressure surges resulting from rapid
changes in velocity.
Size the fill pumps considering static head, due to elevation difference in the test section and
the fill time desired. Maintain backpressure on the fill pig by controlling a valve at the discharge
end. This is particularly important when the test section has downslope elevation changes
because the head pressure may propel the pig faster than the rate of the fill pump and cause
water by-pass.
5.6 Leak Detection and Pressure Stabilization

Prior to pressurization, all connections should be inspected for leaks. A practical method for
determining leaks is to record the pressure in the line upon completion of the fill. Fill pumps
typically produce pressures in the 125 to 150-psig range. Trap the pressure in the line by
closing valves and installing caps or plugs. Record the pressure again after the temperature
stabilization period is over. Any unexplainable pressure reduction should be investigated prior
to pressurization. If accessible, bleed-off any air that has migrated to high points in the test
during pressure stabilization prior to pressurization.
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5.7 Temperature Stabilization and Effects on Pressure Readings
Variations in water temperature produce changes in pressure readings. The resulting pressure
variations may be interpreted as a leak if the pressure is decreasing. Changes in pressure
increase the difficulty of controlling spike and post-spike maximum and minimum control
pressures. Use of an analytical program to identify leaks is dependent on accurate temperature
measurement. Allowing the water to reach equilibrium will greatly reduce these impacts.
Temperature stabilization time varies with the difference in water and ground temperatures.
The greater the difference, the longer the stabilization time required. Pipeline diameter is also a
major contributor. Monitor temperature and begin pressurization after temperatures become
consistent. Eight hours is generally sufficient to reach stabilization.
5.8 Pressurization
Pressurize the test section slowly while continuously monitoring the test section pressure and
then maintain the test pressure within the upper and lower bounds of the test as specified by the
procedure. Consider a hold period at 75 percent of the minimum test pressure for one hour.
The hold period will allow for final leak identification prior to going on test.
Pressurize short test sections slowly and cautiously as the pressure can build-up quickly. If
necessary, nitrogen can be used to pressurize the test sections once the test section has been
filled with water and pressure and temperature stabilization are achieved.
5.9 Discharge Rates and Safety Considerations

Ensure the written Dewatering Plan is followed on the jobsite. Install the temporary dewatering
piping per the written plan. The field supervisor should inspect the dewatering piping and the
anchoring system before dewatering. Clear the safety zone, except for those persons who are
necessary to perform the dewatering work. When removing the water from long test sections
with a pig, control the pig speed between two to five miles per hour by controlling the discharge
valve and monitoring the discharge flow rate. Ensure that the discharge rate complies with the
written Dewatering Plan and discharge permit (if applicable). It may be necessary to validate
water treatment processes by sampling treated water prior to discharge to comply with water
disposal regulations or permits.
5.10 Locating Failures and Leaks

5.10.1 Locating Failures
Most failures can be identified via standard patrolling methods because the released water will
manifest itself on the surface. However, failures may not be obvious in wet areas. Test water
dye additives are available for this purpose. However, communication with the public and
agency personnel is important because the colored water may be confused with pipeline
contaminants. In some cases, discharge permits may restrict the use of dye additives.
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5.10.2 Locating Leaks
There are various techniques for locating leaks and difficult-to-find failures. For example:
 Tracer gases can be added to the test water in anticipation of leaks or the line can be
dewatered and tracer gas included, if an unanticipated leak is discovered. The tracer gas
is detected with aboveground sampling equipment.
 Helium can be an effective solution in locating leaks. The small, light molecule readily
migrates to the surface and can be detected with instruments. However, unlike tracer
gasses, helium is mixed with air, thereby requiring the line to be dewatered and re-
pressurized with an air helium mixture.
 Freeze plugs are used to create a frozen plug in the pipeline to isolate the leaking
section. The frozen plug is created by installing a clamp on the line that circulates low-
temperature fluids. Typically, the technique is employed on long sections of line. The
line is sectioned in half and water pressure monitored on both sides. Once it is
determined which half is experiencing the leak, the section is halved again until the
section is short enough that other techniques can be used with precision.
 Geophones, or other acoustics devises, have proven effective for finding and pinpointing
leaks. Listening for a leak with such a device may not be efficient in finding leaks in a
stand-alone application, but when used to investigate an area of concern, such as where
prior leak repair has been performed, or section of pipe with suspect seam, they can be
effective in finding or ruling out leaks. Used in conjunction with tracer gas or helium,
which identify an area where the leak is located, the acoustic devices can be very
effective in definitively locating leak.
5.11 Repairing Failures

Conventional cutting and welding techniques require the line to be free of water at the repair
point. This can be accomplished by either pigging the line free of liquids or isolating water from
the failure point.
 Isolating water from the failure point requires an obstruction be installed in the line.
Freeze plugs may be used for this purpose at a point where the line is still completely full
of water. Foreman’s plugs may also serve this purpose if the failure is large enough to
accept them. In most all cases, the water will have to be pigged from the line in order to
facilitate a repair.
 Pigging the line free of liquids can be problematic because test water will escape at the
failed section. In addition, compressed air used to propel the pig will escape at the
failure point once the pig has passed. The first step is to excavate the failed location
and pump out the water. Water must be captured and handled per the discharge permit.
A patch is typically installed over the failure to limit water discharge. A repair sleeve
jacked onto the line is a good method. However, it may be necessary to reshape the
failed pipe such that a sleeve can be installed. This could adversely affect failure
forensics. Consult with engineering prior to reshaping the failed area.
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 Pressure test failures should be compiled and recorded. It is important to categorize the
cause of the failure utilizing the same cause categories as in-service failures, and
documenting whether the failure was a leak or a rupture. This information is important
for calibrating and validating the success of the operator’s integrity management
program.
5.12 Post Test Leak Monitoring

Operators should consider including procedures for checking for gas leaks shortly after the
pressure test when the pipeline is back in service. Even though most small water leaks can be
found during the hold period, there is a possibility that very small leaks may not be identified,
and may only be found after the pipeline is put in service utilizing standard gas leak surveys.
5.13 Successful Test Documentation and Determination

When testing vintage existing pipelines, operators should consider requiring the test to be
certified via use of a third-party consultant or utilization of available programs that calculate the
theoretical stress and strain of the pipeline due to internal pressure and thermal effects on
unrestrained piping during pressurization and throughout the test duration. This is typically
depicted by a pressure versus volume graph. These programs typically plot the actual test
values in real time and generate theoretical water gain/loss depending on the change in
temperature. Utilizing a program to plot the pressure-volume graph, as the test is proceeding,
has the advantage of immediately identifying when pressure gain is not commensurate with the
volume of water contained, which is indicative of a potential leak or material yielding.
Additionally, if the program indicates that the pressure and volume values adjusted for
temperature are within tolerances, the operator can have confidence that there is no leakage or
yielding. The key advantage of using a program versus manually calculating via a spreadsheet
is that minor deviations away from theoretical that are not leak related, but typically
temperature-stabilization related, can be explained and confirmed as the parameters stabilize.
An additional benefit of using a program as described above is that some tests may not stabilize
during the specified minimum test duration. By increasing the duration of the test and allowing
more time for temperature stabilization, a test that would otherwise fail can be certified.
5.13.1 Successful Test Documentation

To confirm a successful test, an operator’s technical or engineering personnel should ensure
the following documentation have been performed/completed prior to releasing the test
pressure:
 Test pressure logs and pressure and temperature charts are verified and quality
checked.
 Test report is complete and, at minimum, the information required in Code of Federal
Regulation, title 49, sec. 192.517 is included.
36
 Confirm that no leaks were observed or any leaks identified during the test were
satisfactorily repaired.
 Minimum test pressure at the control point, considering static head, was maintained for
the specified test duration.
 Spike test pressure, as applicable, was reached at the minimum test pressure control
point, considering static head and maintained for the specified duration.
 Maximum pressure at the control point, when no spike test was specified and
considering static head was not exceeded during the duration of the test.
 For tests, including a Spike Test, the Maximum Post-Spike pressure at the minimum test
pressure control point, considering static head, was not exceeded for the remaining
period of the test after the spike test period.
 Pressure versus volume plot confirming that the test did not contain any leaks nor yield
the pipeline.
Test failure analysis should be performed for any leaks or ruptures experienced. The analysis
should utilize design and material information, if available, “as found” material and construction
information, and characterize the failure cause utilizing PHMSA incident causes and type of test
failure (e.g. leak or rupture). As applicable, the Test Certification Report from third-party
contractor confirming all of the above.
5.13.2 Successful Test Determination

Success in hydrostatic pressure testing existing pipelines is defined a bit differently than in
many other kinds of tests. Of course, a test is successful if the target test parameters are
achieved and the test is satisfactorily documented. However, hydrostatic pressure tests may be
interrupted by leaks or ruptures, commonly called test “failures.” This does not necessarily
constitute a failed test. In such cases, the required repairs or replacements are made, and the
test is restarted. This process is repeated until the test is concluded with the target test
parameters achieved. This scenario also represents a successful test – the strength and
pressure-containing capability of the segment have been demonstrated and any impediments to
that capability have been removed. Thus, a hydrostatic pressure test that is ultimately
completed is successful, regardless of interruptions due to leaks or ruptures.
The operator may encounter a test as described above where the number of test “failures” is of
sufficient quantity that the prudent economic decision is to stop the retest cycle and replace the
pipeline. This situation would constitute a failed test.
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6 New Technologies
As stated in the “Pipeline Safety, Regulatory Certainty, and Job Creation Act of 2011,” under
section 23: Maximum Allowable Operating Pressure – part (d) Testing Regulations, the Act
requires the Secretary of the Department of Transportation to consider “safety testing
methodologies, including, at a minimum….other alternative methods, including in-line
inspections, determined by the Secretary to be of equal or greater effectiveness.” These “safety
testing methodologies” are intended to provide a method to “confirm the material strength” of
natural gas transmission pipelines without having to introduce water into a pipe segment and
perform a hydrostatic pressure test.
With the intention of the Pipeline Safety Act language in mind, many R&D consortiums in
coordination with trade associations, such as INGAA, have spearheaded efforts to develop
alternative technologies that can “confirm the material strength.” One such initiative is INGAA’s
Integrity Technology Development (ITD) effort. Through ITD, INGAA has identified the need for
in-line inspection technology that can identify material and construction anomalies that would fail
a 1.25 times the MAOP pressure test. Different variations of the identified technology are
required for various seam-types; however, in working with ILI technology providers, INGAA has
determined that the technologies can make it to market within a reasonable timeframe with
adequate funding.
INGAA’s ITD effort is also in the early stages of working with ILI vendors, GIS specialists, and
metallurgists to develop what has been referred to as an “as-built” tool. Such a tool would be
useful in identifying unknown properties of a pipeline for use in risk assessments or in the
planning of pressure tests. The “as-built” inspection device would work by inspecting known
areas where records are presently incomplete, taking a snapshot of the pipe, and then
referencing those snapshots against signatures of known pipe with known
properties/characteristics.
39
References
1. Kiefner, J.F. and Rosenfeld, M.J., “The Role of Pipeline Age in Pipeline Safety”,
INGAA Foundation, Final Report No. 2012.04, November 8, 2012
2. “The Benefits and Limitations of Hydrostatic Testing” Pipeline Rules of Thumb
Handbook
3. Rosenfeld, M. J. and Gailing, “Pressure testing and recordkeeping: reconciling historic
pipeline practices with new requirements”, Pipeline Pigging and Integrity Management
Conference, February 13-14, 2013
4. www.kiefner.com
5. “U.S. Oil Pipe Lines”, George S. Wolbert, Jr., API, 1979
6. “The Big Inch and Little Big Inch Pipelines” Texas Eastern Transmission Corporation,
May 2000
7. Kiefner, J.F. and Trench, C.J., “Oil Pipeline Characteristics and Risk Factors:
Illustrations from the Decade of Construction”, American Petroleum Institute,
December, 2001
8. For details refer to Table 2 - Natural gas transmission pipeline pressure testing
requirements of Vintage ASA/ASME B31.8 Editions
9. PHMSA, 2011 Annual Report Mileage for Natural Gas Transmission & Gathering
Systems, Forms F7100.2-1.
10. Kiefner, J.F. and Rosenfeld, M.J. “The Role of Pipeline Age in Pipeline Safety”. The
INGAA Foundation, Inc., November 8, 2012.
11. Code of Federal Regulations, Transportation, title 49, sec. 192.107
12. FINAL REPORT: Establishment of Yield Strength Using Sub-size Samples without
Gas Line Shutdown (Mini, Full-Wall Longitudinal Specimens), Operations Technology
Development (OTD), NFP, Project No. 4.7.g / GTI Project No. 20568; Report Issued:
March 4, 2011.Gas Technology Institute, Report on Use of Small Size Samples for
Determining Yield Strength.
13. Kiefner, J.F., “Evaluating the Stability of Manufacturing and Construction Defects in
Natural Gas Pipelines”, U.S. DOT, Final Report No. 05-12R, April 26, 2007.
14. API RECOMMENDED PRACTICE 1110, SIXTHFIFTH EDITION, FEBRUARYJUNE
201307, Pressure Testing of Steel Pipelines for the Transportation of Gas, Petroleum
Gas, Hazardous Liquids, Highly Volatile Liquids or Carbon Dioxide.
40
15. Rosenfeld, M.J.,”Hydrostatic Pressure Spike Testing of Pipelines – Why and When?”,
Presentation to American Gas Association, Operations Conference, Orlando, May 22,
2013.
16. Rosenfeld, M.J., Ibid.
17. Paragraph A-3.4.2(b), “Managing System Integrity of Gas Pipelines”, Supplement to
B31.8, ASME, B31.8S-2012.
20. Fessler, R, Batte, D, and Hereth, M, “Integrity Management of Stress Corrosion
Cracking in Gas Pipeline High Consequence Areas,” ASME STP-PT-011, 2008,
ASME, New York.
41
Appendix A – Abbreviations
ANSI American National Standards Institute
API American Petroleum Institute
ASA American Standards Association
ASME American Society of Mechanical Engineers
BBCR Bell-Bell Chill Ring
CFR Code of Federal Regulations
CNG Compressed Natural Gas
DOT United States Department of Transportation
EMAT Electro Magnetic Acoustic Transducers
ERW Electric Resistance Welded
ETS Electrolysis Test Station
FFS Fitness-for-Service
GIS Geographic Information Systems
GPS Global Positioning System
GPTC Gas Piping Technology Committee
GTS Gas Transmission Systems, Inc.
HCA High Consequence Area
ILI In-line Inspection, commonly referred to as “Smart Pig”
IM Integrity Management
INGAA Interstate Natural Gas Association of America
ITD Integrity Technology Development
LNG Liquefied Natural Gas
MFL Magnetic Flux Leakage
42
MOP Maximum Operating Pressure experienced by the pipeline based on historical
experience or lowest MAOP on a pipeline system. The MOP may be equivalent
to the MAOP, but not greater.
MAOP Maximum Allowable Operating Pressure, as established by Code of Federal

Regulations, title 49, sec. 192.619
NDE Non-Destructive Evaluation
NTSB National Transportation Safety Board
O&M Operations & Maintenance
OA Oxy Acetylene
OD Outside Diameter
OPS Office of Pipeline Safety
PHMSA Pipeline and Hazardous Materials Safety Administration
R&D Research & Development
SAW Submerged Arc Weld
SCC Stress Corrosion Cracking
SMYS Specified Minimum Yield Strength
US United States
WT Wall Thickness
43
Appendix B – Glossary
A
Alignment Sheets - Pipeline alignment sheets or maps provide a bird's eye view of the line itself
and all of its components. The purpose of this sheet is to display engineering data in relation to
the pipeline location and land base features. It shows the route of the pipeline and virtually all
the knowledge for that pipeline. Alignment sheet typically contains a landowner's name and a
space designating his ownership. It may indicate whether the land is forest or in cultivation.
Other typographical features might be listed as well such as type of soil, hilly, rolling hills,
wetlands, right-of-way, temporary work easements, etc.
B
Bell & Spigot Joints - A mechanical connection between two sections of pipe, the straight spigot
end of one section is inserted in the flared-out end (bell) of the adjoining section; the joint is
sealed by a fillet weld, a caulking compound or with a compressible ring depending on
operating pressure.
Bell-Bell-Chill Ring – Bell to bell joints welded together with the use of an internal chill ring
(also called backup ring or spacer) that is machined to conform to the inside diameter of the
pipeline and dimensions of the joint design used.
C
Casing – A length of pipe used for encasing a smaller diameter carrier pipe for installation under
a road, waterway, rail, or other foreign crossing.
Containment Boom – A temporary barrier used to contain a hazardous liquid spill.
Cross compression – Compressing gas from one isolated segment of pipeline to another to
minimize the release of methane to atmosphere during pipeline shutdowns. Or, boosting
pressure from lower pressure supply to high pressure discharge to maintain service to
customers during a pipeline shutdown.
44
D
Dresser Couplings – A coupling comprised of one cylindrical middle ring, two follower rings,
two resilient gaskets of special Dresser compound, and a set of steel trackhead bolts. The
middle ring has a conical flare at each end to receive the wedge portion of the gaskets. The
follower rings confine the outer ends of the gaskets. As the nuts are tightened, the bolts draw
the follower rings toward each other, compressing the gaskets in the spaces formed by follower
rings, middle ring flares and pipe surface thus producing a flexible, leak-proof seal on the pipe
joint.
E
Etching – Controlled preferential attack on a metal surface for the purpose of revealing
structural details. (ASTM Standard E-7 Standard Terminology Relating to Metallography)
ETS – An electrolysis test station terminal support/site is used in connection with measurement
of voltage difference and/or current flow between an underground pipe and ground potential.
F
Fish Mouth Tees – Fabricated tee constructed by splicing two pipe segments to form a tee. The
end of the branch segment is cut to fit perpendicularly into the header segment which is cut to
receive the branch laterally. The two pieces are then arc welded together to create a pressure
carrying fitting.
Foreman’s Plugs - Temporary mechanical closure not designed to retain line pressure.
Freeze Plug – Mechanical device that utilizes flow of liquid nitrogen through an external
pipeline sleeve, thereby freezing the water contained within the pipe at a fixed location.
G
Geometry Pigs - A geometry pig (pipeline inspection gauge) is a configuration pig designed to
measure inside geometry of the pipeline, such as dents, wrinkles, ovality, bend radius and
angle, and occasionally indications of significant internal corrosion.
45
I
In-line inspection (ILI) – In-line inspection is internal pipeline inspections by use of
computerized inspection tools, known as smart pigs, to verify the integrity of its pipelines. The
smart pigs inspect the pipelines for corrosion, dents, and other conditions or restrictions in the
pipeline that may affect safe pipeline operation.
M
Mill Test – Short duration hydrostatic test performed at the manufacturer’s facility in
accordance with the requirements of API Specification 5L.
Miter Bends/Elbows – Two or more straight sections of pipe matched and joined on a line
bisecting the angle of junction so as to produce a change in direction.
O
Oxy-Acetylene Welds - A welding process that uses fuel gas (acetylene) and oxygen to heat two
pieces of metal, the base metal and welding rod, to a temperature that produces a shared pool
of molten metal. Oxy-Acetylene welds are characterized by susceptibility to brittle failure and
sensitive to longitudinal strain. Oxy-Acetylene Welds were used on high pressure pipeline
systems prior to the advent of arc welding.
P
Pig Traps/Launcher/Receiver - An ancillary item of pipeline equipment with associated
pipework and valves for introducing a pig into a pipeline or removing a pig from a pipeline.
Pressure Reversal – Occurs when a defect survives a given pressure level only to fail at a lower
pressure level upon subsequent pressurization from 0 pressure.
Pup – A short length of pipe required between two pipe joints, two fittings, a pipe joint and
fitting, a fitting and a flange, or between two flanges to make up a required dimensional
distance (also called a can).
Purging - The act of replacing the atmosphere within a container by an inert substance in such a
manner as to prevent the formation of explosive mixtures.
46
S
Static Head (Hydrostatic Head) – The height in feet of a column of water at rest that would
produce a given pressure head.
Surging – See water hammer
T
Test Manifold/Head – Temporary piping installed at the test end points designed to provide
connection points for pigging operations, test medium fill and discharge, and test instruments
sample ports and designed to withstand the hydrostatic test pressure.
Tracer Gas – Chemical gas added directly to the test water as it is introduced into the pipeline
during line fill. Trained field technicians collect and analyze samples along the pipeline right-of-
way in the event of a test failure. The detection of tracer chemicals indicate the location of
leakage.
Transmission Plat Sheets – See Alignment Sheet
V
Venting/Blowdown – Controlled release of gas from a pipeline to atmosphere leaving 100%
natural gas at atmospheric pressure in the pipeline. For subsequent removal of residual gas see
Purging.
W
Water Hammer – In fluid flow, the result of a rapid increase in pressure which occurs in a
closed piping system when the liquid velocity is suddenly changed by sudden starting, stopping,
or change in speed of a pump; or sudden opening or closing of a valve which may cause a
pressure surge in the system.
Wattles – An environmental control measure consisting of permeable barriers of woven mesh

netting filled with straw or hay used to detain surface runoff and trap sediments.
Wrinkle Bends – An obsolete practice of bending generally used prior to the advent of smooth
bending techniques. The bends consist of circumferentially oriented “wrinkles” produced by a
field machine or controlled process that result in localized plastic deformation and prominent
contour discontinuities on the inner radius which shortens the intrados and changes the
pipeline direction without use of a manufactured elbow.
47
Appendix C – Understanding Hydrostatic Pressure Testing
(Communication Brochure)
[outside]
48
[inside]
49
Appendix D – Hydrostatic/Pneumatic Safety Guidelines
50
51
52
53
54
55
56

Technical, Operational, Practical, and Safety Considerations of Hydrostatic Pressure Testing Existing Pipelines

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Technical, Operational, Practical, and Safety

Considerations of Hydrostatic Pressure Testing

Prepared for The INGAA Foundation, Inc.

By: Jacobs Consultancy Inc. and

INGAA Foundation Final

 Terry Boss, INGAA

1.1 Objective ....................................................................................................................................... 1

2.1 Hydrostatic Pressure Testing History,,,,6 ........................................................................................ 4

3.1 Determination of Scope .............................................................................................................. 10

4.1 Gather Existing Pipeline Feature Data ........................................................................................ 17

4.3 Assess and Address Features ...................................................................................................... 20

5.1 Site Specific Plans ........................................................................................................................ 29

5.2.1 Test Station Location........................................................................................................... 31

Appendix A – Abbreviations ......................................................................................................42

Appendix C – Understanding Hydrostatic Pressure Testing (Communication Brochure) ...........48

Appendix D – Hydrostatic/Pneumatic Safety Guidelines ...........................................................50

Table 1 – Reasons for Performing a Hydrostatic

1.2 Purpose and Need For Hydrostatic Testing

1.1 times Installed before Nov

A 1.40 times MOP with B Installed before Nov

“(c) DETERMINATION OF MAXIMUM ALLOWABLE OPERATING PRESSURE –

“(1) IN GENERAL – In the case of a transmission line of an owner or operator of a pipeline

Post construction pressure test required

HPT = Hydrostatic Pressure Testing

2.2 Impact and Magnitude of Testing Requirements

 12 percent of the pipeline infrastructure was installed prior to 1950.

3.2 Risks Associated with Testing Existing Pipelines

In particular, when hydrostatically testing existing pipelines, access to exposed and

3.3 Planning the Test

3.3.1 Corrosion and Damage History

3.3.3 Logistical Issues

 Proximity to each of the identified sections of pipeline requiring testing.

3.4 Environmental Permitting Issues

To ensure that discharge water meets environmental permit requirements, it is important to

3.5 Outage Management

 Scheduling work with customer planned outages.

A Communication Plan for hydrostatic pressure testing should address:

 Why is a hydrostatic pressure test required?

3.6.1 External Communications

Landowners and Tenants Along the Pipeline

The operators should provide the following information to this group:

 Company name, test location and contact information.

 Town hall meetings.

Governmental Agencies and Public Officials Other Than Emergency Responders

Information that should be provided to this group includes:

 Company name, test location and contact information.

Local and Regional Emergency Responders

Other information that should be communicated to this group includes:

 Information regarding operator’s efforts to support pressure-test notification and other

3.6.2 Internal Communications

Primary sources of pipeline characteristic data are:

 Pipeline feature studies utilized in MAOP validation.

4.1.1 Historical Operation & Maintenance Data

 Pipeline leak history.

4.2 Validate Pipeline Feature Characteristics

Validation of pipeline features encompasses reviewing feature data to confirm, as appropriate

4.2.1 Guide to Conservative Assumptions

4.2.2 Resolving Unknown Feature Characteristics

Various testing methodologies are available to determine the characteristics of an unknown