Hydrostatic Testing
Hydrostatic testing of in-situ pipelines to revalidate maximum allowable operating pressures (MAOPs), and to assess the integrity of pipeline systems, poses unique challenges as compared to hydrostatic testing of newly installed modern pipeline systems. Although minimum test pressures are prescribed by 49 CFR 192, Subpart J requirements for establishing and re-validating MAOP, the minimum and maximum test pressures for in-situ pipeline tests should also include consideration of Client’s Integrity Management re-inspection intervals (49 CFR 192 Subpart O) and pipeline re-assessment timelines, probable mill test pressures, leak and external/internal corrosion history, overall pipeline integrity assessment, public and personnel safety, and failure contingency.
GTS engineering teams assist their Clients in determining the appropriate scope of hydrostatic test sections factoring in pipeline feature characteristics and their location within the pipeline, operational considerations (pipeline lifecycle pressure fluctuations, pipeline piggability, continuity of service and impacts to ongoing operations), availability and disposal of hydrostatic test water, land access and availability, environmental, biological and other permitting restrictions, to name a few. GTS has developed processes for construction drawings, test procedures and as built quality assurances to confirm that the resultant hydrostatic test record is traceable, verifiable and complete. With over 40 employees dedicated to Hydrostatic Testing, and nearly 200 miles of pipelines tested, GTS has the breadth and depth of experience to deliver on your hydrostatic test design needs.
Broad Range of Service and Support Offerings:
Code compliance
- Pipeline features data review and validation
- Records research and evaluation
- Determination of minimum test pressures
- Recommendations in regard to testing requirements and parameters
Multi-disciplined team involvement
- GTS personnel integrate with Client’s Teams or can stand alone
- Test segment determination/validation; including permitting, access, public impact and safety, laydown and staging, water sourcing and disposal
- Test segment prioritization recommendations and support
- Innovative failure contingency planning and leak detection system selection
- Cross compression, temporary/permanent by-passes and other clearance/continuity of service related options
- Clearance writing and support
- Encroachment permitting
- Utilization of Specialty Consultant/Contractor SME Relationships
- Liaison with other Client Departments/Programs
- Environmentally conscientious water handling and disposal procedures
- Program reporting and performance metrics
- Data compilation for management and regulatory reporting
Engineering Analysis & Design process
- Engineering Estimates
- Structured approach to test section engineering and design
- “Material of Record” research and verification
- Alternative development and analysis/reports
- Concise, detailed hydrotest Design Drawing template
- Special consideration given to stations and other difficult/non-piggable test sections
- Assessment of probable mill test pressures and maximum test pressure recommendation
- Rural and urban considerations are understood and reflected in designs
- Piggability evaluation and resultant pipeline modifications
- Identification of alternative test mediums to meet specific test requirements
- Customizable Site-Specific Test Procedure template
- Milestone and deliverable metrics and reporting
QA/QC procedures – Engineering, Design Development, Jobsite and Records Review
- Process definition
- Design milestones checklists
- Milestone reviews
- In process inspections
- Continuous process improvement
- Program quality initiatives
- “As-Built” construction documentation review
