STD.

4507
Engineering Standards and Specifications Pipeline

Pipeline Hydrostatic Testing

STD.4507

Scope
This standard defines requirements for pressure testing of new and existing pipelines, pump
stations, terminals, and other related pipeline facilities to substantiate the Maximum Allowable
Operating Pressure (MAOP) or the Maximum Operating Pressure (MOP), and to assist in
verifying the integrity of steel pipelines.

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TABLE OF CONTENTS

1.0 REFERENCES ..................................................................................................... 3

2.0 DEFINITIONS AND ABBREVIATIONS ............................................................... 4
3.0 APPLICABILITY AND FREQUENCY .................................................................. 5
4.0 SAFETY ............................................................................................................... 5
5.0 WRITTEN PLAN .................................................................................................. 6
6.0 PRESSURE TEST EQUIPMENT ......................................................................... 7
7.0 PERMITS ........................................................................................................... 10
8.0 HYDROSTATIC TEST FIELD ACTIVITIES........................................................ 10
9.0 STROKE-PRESSURE PLOT ............................................................................. 13
10.0 PRESSURE-TEMPERATURE-VOLUME RELATIONSHIPS ............................. 15
11.0 STATIONS AND TERMINALS ........................................................................... 16
12.0 PRETEST AND ABOVEGROUND TEST .......................................................... 17
13.0 ACCEPTABLE TEST REQUIREMENTS ........................................................... 18
14.0 PNEUMATIC TESTING ...................................................................................... 18
15.0 RECORD KEEPING ........................................................................................... 18
APPENDIX A
APPENDIX B

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1.0 REFERENCES
1.1. Pipeline and Hazardous Materials Safety Administration (PHMSA)
49 CFR 192 Transportation of Natural and Other Gas by Pipeline
49 CFR 195 Transportation of Hazardous Liquids by Pipeline

1.2. American Society of Mechanical Engineers (ASME)

ASME B16.5-2009 Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24 Metric/Inch
Standard
ASME B31.4-2006 Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids
ASME B31.8-2007 Gas Transmission and Distribution Piping Systems

1.3. American Petroleum Institute (API)

API 6D Specification for Pipeline Valves, 23rd Edition
API RP 1110 Pressure Testing of Steel Pipelines for the Transportation of Gas, Petroleum
Gas, Hazardous Liquids, Highly Volatile Liquids or Carbon Dioxide, Fifth
Edition

1.4. Enterprise Standards, Specifications, and Procedures

STD.0002 Administration of Engineering Standards and Specifications, Section 9.0
Specification Waivers
STD.0250 Project Records Management
STD.9006 Pipeline Defect Evaluation and Repair Procedure
ENG-LAB-01 Metallurgical Laboratory Protocol for Analysis of Failures, Flaws, and
Fractures
PRA-WW-5a Hydrostatic Test Discharge Permitting – Pipelines
Enterprise Safety Preparation of Pipeline Equipment and Systems for Repair and Maintenance
Policies Manual
Section 6.3
EPOLLC Gas Purging
Operations and
Maintenance (O&M)
Manual Section 1501

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1.5. Other References

AS/NZS 2885.5:2002 Australian/New Zealand Standard: Pipelines – Gas and Liquid Petroleum,
Part 5: Field Pressure Testing

2.0 DEFINITIONS AND ABBREVIATIONS

Company Enterprise Products Company
Contractor Any entity contracted by Enterprise Products Company to perform a
pressure test or pressure test activities
Enterprise Enterprise Products Company
ERW Electric Resistance Weld (pipe)
o
F degree Fahrenheit (temperature)
MAOP Maximum Allowable Operating Pressure
MOP Maximum Operating Pressure
NDE Non-destructive Examination
NIST National Institute of Standards and Technology
PSIG Pounds Per Square Inch Gauge
Shall Indicates provisions that are mandatory.
Should Indicates provisions that are recommended but not mandatory.
SMYS Specified Minimum Yield Strength
Stabilization A period of time after the pipeline is completely filled but before the
pressure is increased to test pressure to allow the pressure and temperature in
the test section to achieve steady-state. This is generally the time after the
fill pumps are shut down and while the pressure pumps are readied for
service and/or immediately after reaching test pressure.
Double Deviation Yield for unidentified or used pipe is determined by using the pressure at the
highest elevation within a test section, at which the number of pump strokes
(measured volume) per increment of pressure rise becomes twice the number
of pump strokes (measured volume) per increment of pressure rise that was
required during the straight-line part of the pressure-volume plot before any
deviation occurs.
Company The Company Representative is assigned by the Company, usually the
Representative Project Manager or Project Manager’s designee.
Test Director The Test Director is assigned by the Company, usually the project engineer.

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3.0 APPLICABILITY AND FREQUENCY

(1) This standard is not intended to apply retroactively. Hydrostatic testing to be performed after the date
on which this standard was adopted shall meet the requirements of this standard.

(2) No Enterprise facility may be placed in pressure service without first having been tested in
accordance with this procedure except that pressure testing is not required for a single component
(new) other than pipe that is added or replaced if the manufacturer certified either:

a. The component was hydrostatically tested to at least the minimum test pressure required
below; or
b. The component was manufactured using a quality control system ensuring each item
manufactured is at least equal in strength to a prototype that was tested to at least the
minimum test pressure required below.

(3) Pressure testing shall be performed:

a. Before placing in operation any new pipeline(s), pipeline facilities, replacement pipe, or
fabrications used in pressurized service.
b. When qualifying a pipeline and associated facilities for a new or higher MAOP/MOP, and the
pipeline’s ability to withstand this pressure has not been verified or integrity verification is
required.
c. As part of a conversion of service, prior to reinstating to service pipelines or facilities
previously abandoned.
d. Prior to reinstating to service pipelines or facilities previously decommissioned, and the
period of time decommissioned exceeds the recommended integrity reassessment date.
e. When the MAOP is to be requalified because of increases in class location in a gas pipeline
and previous hydrotests were not sufficiently high for the new class location.

4.0 SAFETY
(1) Personnel safety and environmental concerns shall be considered during the planning and during all
phases of a pressure test.
(2) No personnel shall be in the ditch during pressuring or within the testing area if the pressure is above
50 percent of SMYS.
(3) There shall be no public/contractor personnel or equipment working over a test section after the test
pressure has exceeded the operating pressure.
(4) Test equipment and personnel shall be positioned to minimize potential hazards. Typical positioning
should include a barrier between the test equipment and test manifold and/or placement of test
equipment a minimum distance of 50 feet from the test manifold. Personnel performing the test
should approach the pressured line only in the performance of their duties.
(5) Local authorities, governmental agencies, potential emergency response personnel, and landowners
along the right-of-way should be notified as applicable prior to the test.

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(6) Provide and maintain reliable communication equipment during pressure testing so that all personnel
directly involved may communicate.
(7) All pressure must be reduced to static pressure prior to tightening of flanges or screwed fittings.
(8) When filling, if high pressure hose is not used, adequate support and bracing shall be provided for the
rigid piping used in connecting to the facility to be tested to avoid whipping.
(9) After the test is complete, adequate support and bracing shall be provided for the dewatering line and
extreme caution shall be taken when deflectors such as ells are used.
(10) When required, an enclosed, lighted, heated, and/or air-conditioned shelter sized to house test
recording equipment and test personnel at the data procurement site of each test section shall be
provided. Adequate lighting shall be available for testing operations performed at night.

5.0 WRITTEN PLAN

Before any Enterprise facilities are pressure tested, a written hydrostatic testing plan shall be developed
and approved by Enterprise. The plan will, at minimum, cover the following topics as applicable:
5.1 Materials and Strengths
(1) List the materials to be tested and their rated strengths
(2) Provide a sketch of the facility to be tested (unless straight pipe).
5.2 Test Pressure and Duration
(1) Determine the maximum and minimum test pressure and the duration.
(2) Consider elevation changes – create a profile if elevations change more than 100 ft.
(3) Refer to Appendix A for test pressure ranges and duration
5.3 Test Medium, Source, and Disposal Methods
(1) Describe the test medium to be used.
(2) Describe the source of the test medium.
(3) Describe line cleaning requirements.
(4) Describe how the test medium will be disposed after testing is completed.
5.4 Safety
Describe the safety procedures to be used during filling, testing, and dewatering. Consider company
employees, contractors, and the general public as applicable.
5.5 Test Equipment
Describe the equipment required to acquire the data (fill volume, pressure, temperature, etc.)

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5.6 Filling and Pressurizing

(1) Describe how the facility to be tested will be filled and how the pressure will be increased from
atmospheric to final test pressure.
(2) Determine if a stroke-pressure plot is necessary.
5.7 Test Procedure
Describe how the test will be performed, including the necessity to perform stroke pressure graphs,
the rate of pressure increases, stops for leak checks, etc.
5.8 Dewatering, Drying and Cleaning
Describe how the facility will be dewatered, dried, and cleaned after testing and what will be done to
minimize contamination or corrosion if it will not be placed in service within one week of testing.
5.9 Permits
Describe any permits necessary to obtain fill water and dispose of the test water or medium

6.0 PRESSURE TEST EQUIPMENT

The following is a comprehensive list of equipment and materials needed for a pressure test utilizing
water as the test medium. Not all items will be required for each test.
6.1 Deadweight Pressure Gauges
The deadweight gauges shall be the prime source of monitoring pressure throughout the hydrostatic test.
Accurate dead weight(s) shall be used to measure test pressures. Dead weights must have been certified
for accuracy within the past 12 months by an independent testing laboratory. The accuracy of the
deadweight gauges at the time of certification shall be at a minimum ±0.1 percent of the indicated
pressure, traceable to NIST Standards. The serial number shall be clearly indicated on the deadweight
gauges. The Contractor shall present certification documents to the Company Representative prior to
testing.
6.2 Fill Pumps
Contractor shall provide fill pumps, when required, that shall be of sufficient size and capacity to fill the
test section in an efficient and timely manner that prevents the inclusion of air into the test section.
6.3 Flow Meter
Contractor should provide a flow meter of type and capacity capable of measuring the maximum water
fill rate.
6.4 Water Filter
(1) The fill pumps shall be equipped with a filter system, if required by the Company, rated at sufficient
capacity to accommodate the output of the fill pump and capable of removing 99 percent of all
particles 100 microns in diameter or larger in size.

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(2) The filter system shall be equipped with valves, gauges, and fittings sufficient to allow any necessary
backwashing and to monitor the differential pressure across the filter and positive pressure on the
discharge side of the filter.
(3) Water suction lines shall also be equipped with a filter screen to ensure no solids or debris is
introduced into the test section.

6.5 Pressure Pump and Stroke Counter

(1) Pressure pumps shall be capable of attaining the desired test pressure and shall be capable of
maintaining a pressure rise equivalent to 10 psig/minute or less. The pump unit driver shall have an
efficient clutch, transmission, and throttle system capable of maintaining a constant volumetric
injection.
(2) Once the volumetric injection rate has been established, the pump shall be capable of maintaining this
rate with only minor adjustments of the throttle.
(3) The pressure pump shall be equipped with a suitable stroke counter with a manual reset switch and a
tachometer. The stroke counter shall be located at the deadweight gauge location during the testing
operation.
(4) The pressure pump's serial number and capacity in terms of gallons/stroke shall be made provided to
the Test Director prior to testing.

6.6 Pressure Recorder

(1) At least one 24 hour pressure recorder with a ten inch (minimum) circular chart or digital strip chart
shall be used to maintain a continuous record of the pressure versus time during testing and must have
been certified for accuracy within the past six months by an independent testing laboratory. When a
possibility exists that the pressure recorder may malfunction during the test, while unattended, a
second recorder should be used in order to enhance the likelihood that at least one recorded pressure
chart is available for documentation.
(2) Certification documents shall be provided to the Company Representative by the Contractor prior to
testing.
(3) The serial number shall be clearly indicated on the pressure recorder.
(4) Compare the pressure recorder reading with the pressure obtained from the deadweight gauge before
recording test pressures.
(5) The recorder shall not be used as the prime source of the pressure readings.
(6) The range of the chart must be compatible to the spring range of the instrument on which it is used.

6.7 Temperature Recorder

(1) At least one temperature recorder shall be used to maintain a continuous record of the pipe
temperature versus time during testing and must have been certified for accuracy within the past six
months by an independent testing laboratory.

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(2) Certification documents shall be provided to the Company Representative by the Contractor prior to
testing.
(3) The temperature recorder(s) shall be located so that they will not be affected by the injection of water
used to pressure the segment to be tested.
(4) The temperature probe shall be taped to the pipe and connected to the temperature recorder. For
below ground tests, the temperature probes shall be buried. For aboveground tests, appropriate
measures shall be taken to ensure the temperature probe is insulated and shielded from ambient
conditions to better reflect the temperature of the water in the pipe and not ambient temperatures.
(5) When test water temperature is significantly different from ground temperature, consideration should
be given to locating one recorder at each end of the segment being tested, and the bulbs insulated
from the surrounding soil with a suitable insulation.
(6) Compare the temperature readings against a certified thermometer immediately before beginning the
test.
(7) The serial number shall be clearly indicated on the temperature recorder.
(8) Ambient temperature can be monitored using a test thermometer as long as it is of laboratory grade
with a range from 0°F to 120°F, and have 1°F divisions. Keep the thermometer shaded.

6.8 Test Headers

Test manifolds used to pressure test Company pipeline facilities shall be fabricated in accordance to the
following requirements:
(1) Except as specified immediately below, the minimum wall thickness and yield strength of pipe and
components used to fabricate test headers shall be designed such that the maximum test pressure
experienced during facility testing does not exceed 80 percent of SMYS.
(2) In instances where the proposed test pressure will exceed 80 percent of SMYS of the test headers, an
initial pre-test shall be conducted on the entire test header to 100 percent of the test header’s specified
minimum yield strength (SMYS) for 30 minutes. Subsequent testing shall be at the discretion of the
Company Representative, dependent upon the condition of the test manifold and verification of
qualification documentation (Test, NDE, Welding, and Material Records).
(3) A qualified welder using a qualified welding procedure shall weld all pressure piping related to the
pressure test.
(4) All butt and fillet welds shall be nondestructively tested in accordance to all applicable Enterprise
NDE standards and procedures.
(5) Test headers may also serve as fill and launching assemblies and must be designed to accommodate
the size and number of pigs or squeegees specified in the test plan.
6.9 Test Water
The Company Representative will approve the source and disposal means of the test water with required
permits (see section 7.0 of this standard).

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6.10 Tracer
Consider adding fluorescent dye or sulfur hexafluoride (SF6) – a colorless, odorless, non-toxic and non-
flammable greenhouse gas to the fill water to aid with locating of leaks.

7.0 PERMITS
Permits shall be acquired for the use and/or discharge of hydrostatic test water per Enterprise
Environmental Practice PRA-WW-5a Hydrostatic Test Discharge Permitting – Pipelines and all
applicable Company procedures referenced therein.

8.0 HYDROSTATIC TEST FIELD ACTIVITIES

8.1 General
(1) Test information generally required includes the number of test sections, test section numbering,
appropriate test pressure, tolerances, test duration, required acceptance criteria, outside diameter, wall
thickness, grade, footage, engineering station numbers and/or mileposts for the entire pipe being
tested and the written test plan.
(2) Prior to pressure testing, ensure that the test section has been isolated from all other piping
components, that all valves in the test section are open (half or full as applicable) and that check
valves are pinned open or the clapper is removed; all flanged and screwed connections have been
tightened; pressure and temperature recorders, deadweight gauge, and pressure pump are in proper
working condition and functioning properly; the deadweight gauge is level, free spinning, and
properly oiled; the spring range in each recorder is compatible with its chart; the pressure recorder is
calibrated to the deadweight gauge and the temperature recorders are calibrated to the test
thermometer.
(3) For existing liquids facilities, purging shall be performed per applicable Company procedures in
Enterprise O&M Manual and/or Enterprise Safety Policies Manual.

8.2 Filling
(1) Prior to filling the test section, ensure that valves, flanges, closures or bull plugs at the high point are
set to an appropriate position (open, closed, or partially open) to bleed all air out during filling, and
that all instrument tubing has been disconnected.
(2) Fill water shall be obtained only from approved sources.
(3) As per environmental permit requirements, arrange with an approved contract laboratory to collect a
sample of the fill water prior to filling the test section. Requested analysis will be dependent on the
state the test is being conducted in and if the section is new or used as well as the final discharge
water quality limitations.
(4) Fill the pipeline section with water at a continuous rate. Should the fill stop at any time due to
uncontrollable circumstances, the fill line shall be purged of air. Care shall be taken to ensure that no
excess air is entrapped in the pipeline.

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(5) The pipeline and components shall be completely filled with clean water from a source approved by
the Company, free of silt, trash or any substance that might be injurious to the system.
(6) All fill pump filter apparatus back flushing operations and test media shall be properly disposed of
without damage to land or contamination to the water source. Monitor the gauges on the filter for any
differential pressure across the filter and positive pressure on the discharge side of the filter.
(7) Measure the quantity of fill water pumped into the pipeline. Consider monitoring the pressure and
temperature of the test medium during the filling operation.
(8) During the filling process, construct dewatering piping (but do not connect) and water and sediment
containment/filtration facilities as provided in the water discharge permit.

8.3 Pressuring
(1) Prior to pressuring, ensure that the public, environment and Company personnel are secured. The test
area should be secured with visible tape or fence materials and with visible signs indicating hazardous
area.
(2) The stabilization period shall begin after the fill operation is complete. Sufficient time shall be
allowed for the temperature of the pipe, test medium and backfill (if any) to become relatively stable.
Verify stabilization by comparing temperature readings taken from the temperature probes at the pipe
and in the ground. Verify that all valves and components are in the proper orientation prior to
pressurization.
(3) After the stabilization period, the test section shall be pressurized to the test pressure with caution,
recognizing the possibility of failure of the piping or equipment or the potential over-pressurization of
the pipe. Meter and record the volume of water pumped into the test section during pressurization.
(4) For pipeline test sections which are not 100 percent visible for tests pressures above 90% SMYS, the
Company Representative will make a plot of the pressure versus volume of water being injected into
the test section. Refer to section 9.0 of this standard, Stroke – Pressure Plot.
(5) Pressurize the pipeline at a uniform rate, which can be maintained until test pressure is reached, and at
a reasonable rate which allows accurate pressure readings and proper collection of data. Any abrupt
changes or breaks on the charts should be labeled as to the cause, at that point on the face of the chart.
Pressure charts should have the dead weight pressures noted at the beginning and end of the test.

8.4 Pressure Test

(1) Pressure shall be increased or decreased as necessary during the hold period in order to maintain the
test pressure within the desired range as specified within the hydrostatic test plan. The pressure range
specified by the Test Director shall be in accordance to the specified range provided in Appendix A.
Pressure, time, and volume of water shall be recorded for any "bleeding-off" or re-pressuring along
with applicable comments.
(2) The test period begins when stabilization to the required target test pressure has been reached.
(3) Determine the quantity (gallons or strokes) of water used for each re-pressure. The volumes of water
added or removed to control test pressures shall be metered and recorded.

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(4) Test pressures and ambient temperatures should be recorded at approximately 15 minute intervals for
the entire test period. All information shall be recorded in ink in a neat and legible manner on the
Form 4507. The form shall incorporate all pertinent information relating to the particular test.
During all phases of pressuring, repressuring, and bleeding, an accurate log of time, pressures,
strokes, and temperatures shall also be recorded in a similar manner.
(5) The pressure and temperature recorders shall be operated throughout the test period including the
pressuring, the test duration, and the bleed down.

8.5 Hydrostatic Test Failures

(1) The failure location shall be secured by Company Representative. No one shall be allowed into the
immediate leak/rupture location until Company Representative determines that it is safe to do so.
Contact Test Director in all instances.

(2) An initial evaluation shall be conducted. The initial evaluation may consist of the following:
a. Visual inspection of the failure location to note general ROW condition, geographic
characteristics of the location, and any unusual or possibly contributing factors such as water
accumulation, other pipelines/utilities in the area, highway crossings, indications of land
movement, third-party equipment/activity in the area, and obstacles to excavation safety.
b. Visual and NDE inspection of the pipe/component at the failure location to note steel
condition (corrosion attack, gouges, dents, discoloration, etc.), external coating condition
(disbonded, damaged, missing, etc.), appearance of the leak/rupture (small hole, longitudinal
crack, circumferential crack, etc.), orientation of the leak/rupture (o’clock position), location
of the leak/rupture (pipe body, longitudinal weld, girth weld, component body, etc.), any
solids/liquids located around the pipe/component, and any solids/liquids inside the
pipe/component.
c. Photographic evidence should be collected to document the failure site and other pertinent
details regarding the failure. This should be made in place before the sample has been
removed from the ditch. Mark each photograph with the Line Name, Line ID No. and the
Asmt No., as well as the date and time the photograph was taken.

(3) Subsequent to the initial location evaluation, activities can begin to repair or replace the failed
pipe/component. All repair activities should follow STD.9006 Pipeline Defect Evaluation and Repair
Procedure.

(4) For pre-in service hydrostatic tests, all pipe failures must undergo a root cause failure analysis to
include a metallurgical examination of the failed pipe.

(5) For in-service systems, metallurgical examination is required for hydrostatic test failures unless a
waiver has been obtained and approved per Enterprise STD.0002 section 9.0 Specification Waivers.

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(6) Metallurgical examinations of hydrostatic test failures must be performed at Enterprise-approved

laboratories in accordance with Enterprise Pipeline Integrity Procedure ENG-LAB-01 Metallurgical
Laboratory Protocol for Analysis of Failures, Flaws, and Fractures.
(7) All repair activities shall be documented utilizing the Enterprise Form 140 Maintenance Report form.
(See Enterprise O&M Manual).
(8) All hydrostatic test failures shall be documented on Form 4507 (see Appendix B of this standard).

8.6 Depressurizing and Dewatering

(1) The test section shall be bled down slowly and carefully after successful completion of the test period
and acceptance of the test.
(2) After completion and acceptance of tests, completely dewater the pipeline by:
a. Connecting the discharge/dewatering pipe to the mainline and securing it to prevent whipping
after the test pressure has been bled off
b. Where feasible, running a sufficient number of appropriate pipeline pigs;
c. Filtering the test water as required by permits and/or Right of Way special requirements;
d. Sampling the discharged water as required;
e. Draining all valves, sections of non piggable pipe, and other places where water may be
trapped.
8.7 Cleaning and Drying
(1) Air dry the pipeline by repeated passages of squeegees, running a train of drying pigs with
dehumidified air from an air compressor, or as otherwise indicated in the scope of work. This process
shall continue until there is no evidence of free water exiting from the test section and the exhausted
air inside the pipeline should achieve a specified dew point of -38°F or at a humidity level as
otherwise indicated in the scope of work.
(2) The pipeline will be considered “clean and dry” when the required dew point has been achieved and
dust penetration of 1/4 in. or less is visible in a foam pig.
(3) Consider removing the air from the test section with a nitrogen purge. The air should be displaced
with squeegees or pigs followed by the nitrogen with the nitrogen left in the system having a pressure
of 50 psig or less. The nitrogen injected into the system should be at a temperature greater than 40°F
but less than 90°F and a pressure less than the MOP or MAOP of the system.
(4) After cleaning and drying, pipeline should be tied-in, purged, and loaded per the Company’s
commissioning plan, as soon as practical.

9.0 STROKE-PRESSURE PLOT

(1) The starting test pressure for preparing the stroke-pressure plot (if required per ASME B31.8
Appendix N) is at the discretion of the Testing Director; however, the starting test pressure for the
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plot shall begin prior or equal to 200 psig below the anticipated ending test pressure or after reaching
80% of the anticipated final test pressure. The test section is to be pressured with the pump operated
continuously at the determined stroke rate. It is most important that full attention be given to
maintaining a constant pump rate. Observation of a tachometer or counting strokes versus time and
small throttle adjustments may be needed to achieve a constant rate. The constant rate shall be
maintained throughout preparation of the stroke-pressure plot.
(2) A continuous plot shall be made of pump stroke versus pressure during at least the last 200 psig of
pressuring to the anticipated ending test pressure, after reaching 80% of the anticipated final test
pressure, or if the pipe properties are unknown. The yield level is defined as that point along the
stroke pressure plot at which the number of strokes per pound of pressure rise is equal to twice the
number of strokes per pound of pressure rise experienced prior to initial deviation and the yield is
determined by using the pressure at the highest elevation within the test section. (See Figure 1) Pump
strokes in excess of that determined for a constant pressure rise could be indicative of a leak. Pump
strokes versus pressure shall be indicated as a plot point at 10 psig intervals in whole multiples of 10.
Stroke readings shall be indicated at each plot point. Time in hours, minutes, and seconds shall be
indicated at the beginning and ending points as well as intermediate points at 50 psig intervals.
(3) Gear ratios and throttle setting for the pressure pump should be set so that speed changes will not be
necessary during the plot. The recommended rate of pressure increase during pressuring is 10
psig/minute or less.
(4) The pressure pump should be stopped when double stroking occurs or if a specified maximum test
pressure is reached. If double stroking (yielding) occurs before the specified minimum test pressure
is reached, the Company Representative and the Test Director shall determine whether to proceed
with increasing the pressure, revising the specified minimum test pressure to the double stroke
pressure, or other alternatives such as running a post-test deformation smart pig to detect pipe that has
been expanded.

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FIGURE 1: STRESS-STRAIN CURVE SHOWING YIELDING

10.0 PRESSURE-TEMPERATURE-VOLUME RELATIONSHIPS

Deviations in pressure, especially during the leak test phase of the pressure test, can sometimes be
explained as a result of changes in the temperature of the environment. Refer to AS/NZS 2885.5:2002
Australian/New Zealand Standard “Pipelines – Gas and Liquid Petroleum, Part 5: Field Pressure
Testing” for a method to determine the impact on pressure and volume due to variations in temperature.

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11.0 STATIONS AND TERMINALS

(1) The methods for filling station or terminal piping could be as numerous as the different configurations
encountered. When filling station or terminal piping or pig traps piping, the best rule to follow is to
use the lowest connection as the point of fill. A high point vent must also be identified to provide for
complete venting of all entrapped air prior to starting the hydrostatic test.
(2) The Test Director shall establish the maximum and minimum test pressure which shall be based on:
a. A test pressure calculated for an established pipe MOP or MAOP, or
b. As allowed by the ratings of components in the test sections such as valves, fittings, etc.
c. All test pressures are based on calculations using Barlow's Equation using the outside diameter,
the nominal wall thickness, and the SMYS of the pipe. The maximum test pressure shall not
exceed 90 percent of SMYS or component test ratings of valves, flanges, etc., whichever is less.
11.1 During the Test
(1) Before pressurizing station or terminal piping, the Test Director or Company Representative shall
ensure that the test section is securely isolated with blinds, skillets, or plugs. Precautions shall be
taken to ensure that the test will be conducted in a safe and workmanlike manner.
(2) During initial pressurizing, determine and set a pump stroke rate which will pressure the test section
at a constant stroke rate without lowering pump speed, change of pump speed, or changing gears
during the pressuring operation. The rate of pressure rise should be less than 10 psig per minute. The
final pump stroke rate and resulting rate of pressure rise shall have been finalized prior to and shall be
used during the final pressuring in the region of 200 psig below the required test pressure.
(3) When the pressurization of the test section has reached 60 to 80 percent of the test pressure, stop and
hold the pressure for 15 minutes to allow for pressure equalization, to check for leaks, and to recheck
instruments. During this leak test, the Test Director or Company Representative shall ensure that no
leaks exist in the test section. The tight line leak test shall continue until all leaks have been stopped
and no loss of pressure occurs for 15 consecutive minutes.
(4) A Stroke-Pressure Plot will be created for all testing under this section whenever a yield test is
required. Refer to section 9.0 of this standard for details.
(5) After the test pressure is reached, the time and pressure shall be recorded and these are the beginning
time and pressure of the hold period. The minimum hold period shall be as indicated in Appendix A
of this standard. The pressure during the hold period shall be the specified test pressure. During the
hold period, the pressure shall be held between -0 and +15 psig of the specified test pressure, unless
approval has otherwise been received from the Test Director. During the initial two hour period, the
number of strokes to maintain the specified test pressure after 10 minutes, 30 minutes, 60 minutes,
and 120 minutes shall be recorded. Ambient temperatures shall be recorded each half hour, beginning
with initial pressuring and continuing for the duration of the hold period, i.e., the end of the test.
(6) All data shall be recorded on Form 4507. Pressures, temperatures, stroke counts, time, and all other
data on the test section shall be clearly recorded, legible, and understandable. Each time the pressure
is increased or decreased, the time and pressure shall be recorded before and after the change of

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pressure. The volume of water added or removed shall be either measured or calculated and
recorded.

12.0 PRETEST AND ABOVEGROUND TEST

(1) Some sections of the pipeline may require testing prior to installation. The pre-testing of such a
section is necessary as it will be costly to gain access to this section to make repairs once it is
permanently installed. Roadway, waterway, and railroad crossings are examples of pipeline sections
that normally require pre-testing. The term pretest is used because the pipe segment, once installed,
will be tested again with the connecting mainline or facility piping. An aboveground test has the same
purpose of a pretest but differs in that it shall not be tested again with the interconnecting mainline or
facility piping once installed. This type of test is used for pipe segments which will be installed in an
existing pipeline or connection to an existing facility where the performance of a post installation
hydrostatic test is not practical.
(2) The Test Director shall determine the sections for pretest and aboveground test.
(3) The pretest and aboveground test shall begin by filling the section of pipeline with water and, in
doing so, making sure provision is made for the elimination of entrapped air by venting at the high
elevation of the test section. Additionally, bleeding entrapped air out of hoses leading to instruments;
i.e., deadweight gauge, recorders, prior to connecting hoses to said instruments shall be required.
(4) The procedure for a pretest and the aboveground test, which follows, differs somewhat from that of a
pipeline relocation or station and terminal test. However, the same care and precautions shall be
exercised
(5) The pretest or the aboveground test shall begin by pressurizing the pipeline section with water to a
pressure equal to 60 to 80 percent of the final test pressure, allowing 15 minutes for pressure
equalization, then checking for leaks. If the leaks cannot be stopped, bleed off pressure to
atmospheric or a safe pressure and change out or repair the source of the leak. Once any leaks have
been eliminated, continue pressurizing a pretest section to the required test pressure per Appendix A.
Valves, fittings, etc., may be limiting components of the test. Form 4507 shall be used in monitoring
the pretest and aboveground test. Test pressures and ambient temperatures should be recorded at
approximately 15 minute intervals for the entire test period. A record of bleeding off or pressuring
up shall also be taken.
(6) The minimum hold time shall be per applicable regulations (see Appendix A of this standard). The
pressure variance shall be as specified in the hydrotest plan. If the Test Director is satisfied that no
leaks exist, and can equate pressure rise or fall to temperature, the test may be accepted.
(7) Dewatering shall be done by first bleeding the pressure off at either manifold. Environmental
protection and safety is important in releasing the pressure and draining the water. Written
permission or permits, as required, from state environmental agencies will be secured by the
Company per section 7.0 of this standard. In the event that the test medium must be discharged into
vacuum trucks, provision must be maintained not to allow any of the test medium to flow into any
watercourses, including ditches, or into environmentally sensitive areas. Provision must also be
maintained to prevent erosion in the area of the discharge.

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(8) The test section shall be pigged, if required, during the dewatering stage to assure that all test water is
removed. Especially in the case of the aboveground test, the test section shall be completely
dewatered as this section will be tied into an existing facility or pipeline and will not be tested again
as would a pre-tested section

13.0 ACCEPTABLE TEST REQUIREMENTS

(1) An acceptable test will have been performed when the following conditions have been met:
a. The section has been maintained at the desired test pressure (in accordance with the hydrotest
plan) for the required hold period.
b. No visible leakage occurs where the entire test section has been visually monitored during the
required test period and no unaccountable pressure loss when the test section is not under visual
observation.
(2) Once the test is complete, the Company Representative shall ensure that the test pressure and
temperature log is reviewed by the Test Director for test approval. Depressurizing shall not begin
prior to acceptance of the test by the Test Director.

(3) For in-service pipelines, the Company Representative shall also ensure the hydrotest is reviewed and
certified by a Professional Engineer (PE) unless a waiver has been obtained and approved per
Enterprise STD.0002 section 9.0 Specification Waivers. This requirement does not apply to pre-
testing of pipe or testing of newly fabricated segments.

a. The PE review will be performed as a project Quality Assurance/Quality Control and will most
likely occur after the project field work has been completed. The PE review is not required prior
to dewatering and placing the line back into service.
b. Upon completion of the PE review, the Company Representative and Test Director shall also
perform a quality control review of the entire test package and any documents provided by the
PE. Refer to section 15.1 of this standard for a list of items to be reviewed.
(4) An approved specification waiver per Enterprise STD.0002 Section 9.0 is required for exceptions to
the above requirements for an acceptable pressure test.

14.0 PNEUMATIC TESTING

Pneumatic testing is not covered under this procedure and specification. See Enterprise STD.4403
Pneumatic Testing of Piping for pneumatic testing applicability and requirements.

15.0 RECORD KEEPING

A record of each pressure test performed, including records of unsuccessful attempts, shall be created and
maintained for the useful life of the facility per Enterprise Standard STD.0250 Project Records
Management. Only Enterprise approved forms shall be used. Forms shall be completely filled in and
have the pressure and temperature recording charts attached. All forms must be properly signed and

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approved by the Test Director. The Project Name, Project Number, and Line Identification are to be
included on ALL documentation. At minimum, the following reports shall be provided:
15.1 Final Test Report
(1) A final test report shall be prepared and filed per Enterprise Standard STD.0250 Project Records
Management. The test report shall be retained for the useful life of the pipeline and shall include the
originals of all test forms, recorder charts, etc. The Company’s Test Director shall be responsible for
documenting and filing the test reports and records.
(2) The following information shall be included and clearly labeled with the test report:
a. Recorder serial number.
b. The original pressure chart shall be signed after successful completion of the test by the Company
Representative present during the test.
c. AFE number and name of job.
d. Test reports on plants shall include a piping drawing showing what piping is included in each test.
e. Where elevation differences in the section under test exceed 100 ft, a profile of the pipeline that
shows the elevation and test sites over the entire length of the test station.
f. Calibration data and independent party certification of test equipment.
g. Start time and date of “on” test with initial pressure.
h. End time and date of “off” test with final pressure.
i. Description of test section, to include pipe data and test section number.
j. Pressuring, leak test, start of plot (if applicable), and bleed down.
k. Test Site Location and Stations.
l. Pressure of any anomalies on chart with comment.
m. The name of the operator, the name of the person responsible for making the test and the name of
the test company used (contractor – where applicable).
n. An explanation of any pressure discontinuities, including test failures.
o. In the case of a test failure, location, description, time and date of the failure, failure pressure,
cause (if known), method of repair, any metallurgical analysis report and disposition of failed
pipe.
p. Description of the test medium, source of the test medium and any additives used with it.
q. Other records as determined by the operator or required by regulation or law.

(3) The following records should also be maintained with the test report following any pressure test:
a. Sketch and/or profile drawing of the pipe or pipeline being tested including equipment location
and stationing.

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b. ANSI rating for applicable pipeline components in the test segment.

c. Copies of pipe and fitting purchase orders, mill test records, or results of laboratory testing to
confirm material composition
d. Straight-line plot of pump strokes per increment of pressure rise during pressurization.
e. Minimum and maximum test pressure and the locations of both in the test segment.
f. Physical description and location of the pressure-limiting component in the test segment.
g. Temperature log and continuous temperature chart showing pipe or test medium temperature
versus time.
h. Temperature log and continuous temperature chart showing ambient temperature versus time.
i. Description of the weather during the test (including any changes).
15.2 Field Pressure Log
Company Form 4507 shall be signed after successful completion of the test by the Company
Representative present during the test, thereby certifying that the hydrostatic test was conducted in
accordance with this standard. The report must be filled out completely and shall include the disposition
of any leaks or failures.
15.3 Fill Log
Record of water volume added to the pipeline during the filling process shall be maintained if required by
the permitting process.
15.4 Analytical Reports
All analytical laboratory reports and waste disposal records shall be maintained per Enterprise Standard
STD.0250 Project Records Management, Enterprise Environmental Practice PRA-WW-5a Hydrostatic
Test Discharge Permitting – Pipelines and all applicable Company procedures referenced therein.

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APPENDIX A

TEST PRESSURES AND DURATIONS

PRESSURE TEST SPECIFICATIONS FOR FACILITIES SUBJECT TO 49 CFR PART 192 REGULATIONS

NEW CONSTRUCTION
PRESSURES
FACILITY DURATION* MINIMUM MAXIMUM
Pipelines 8 hours 1.5 X MAOP The lesser of 110% SMYS or
double deviation
Compressor station piping, metering 8 hours 1.5 X MAOP The lesser of 110% SMYS or
facilities, offshore risers and storage double deviation
field facilities

Above Ground and Pretest 8 hours 1.5 X MAOP The lesser of 110% SMYS or
double deviation
Stations and Terminals As Determined by the Test Director
Pipelines Operating with an MAOP 1 hour 1.5 X MAOP The lesser of 110% SMYS or
<30% of SMYS, at or above 100 psig double deviation
Fabrications and short sections of 4 hours or 8 1.5 X MAOP The lesser of 110% SMYS or
pipe per 192.505(e)** hours double deviation
EXISTING FACILITIES
PRESSURES
FACILITY DURATION* MINIMUM MAXIMUM
Pipelines Class 1 or 2 locations 8 hours 1.25 X MAOP The lesser of 110% SMYS or
double deviation
Pipelines in Class 3 or 4 locations, 8 hours 1.5 X MAOP The lesser of 110% SMYS or
storage fields, facilities † double deviation
Compressor station yard piping , 8 hours 1.5 X MAOP The lesser of 110% SMYS or
metering facilities, and offshore risers double deviation
Pipelines Operating with an MAOP 1 hour 1.5 X MAOP The lesser of 110% SMYS or
<30% of SMYS, at or above 100 psig double deviation

* Test duration is a continuous hold period of the time interval indicated.

** Test durations of less than 8 hours must be approved by the Enterprise Project Manager
†
For class upgrade testing to class 4 location, contact Enterprise Transportation Compliance department for test
pressures

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PRESSURE TEST SPECIFICATIONS FOR FACILITIES SUBJECT TO 49 CFR PART 195 REGULATIONS

NEW CONSTRUCTION and EXISTING FACILITIES

PRESSURES
FACILITY DURATION* MINIMUM MAXIMUM
Pipelines, Meter Stations, and 8 hours 1.25 X MOP The lesser of 110% SMYS or
Fabrications†† double deviation
Above Ground and Pretest 4 hours 1.25 X MOP The lesser of 110% SMYS or
double deviation

††
A component other than pipe does not need to be hydrotested if it is the only item being replaced or added to the
pipeline system and complete records have been provided to confirm that the component was hydrostatically tested at
the mill.

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APPENDIX B

Form 4507

STD.4507 Appendix
B.xls

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Attachment Revision Log/Record

Revision 0.0 Publish Date: 07 Sep 11
Location of Type of
Reason for Change
Change Change
N/A N/A
Revision 1.0 Publish Date: 21 Sep 11
Location of Type of
Reason for Change
Change Change
Section 8.6(2) Revision Clarification regarding density of foam pig
Sections 9.0(1) Deletion Deleted language regarding Form 4507-B
and 9.0(2)
Section 10.0 Revision Replaced reference to Appendix B with title of referenced publication
Section 12.0(6) Revision Clarification of test duration for pretests and aboveground tests
Appendix B Addition Inserted Form 4507 as an embedded MS Word file
Sections Revision Revised “Form 4507-A” to “Form 4507”
11.1(6),
11.2(2),
12.0(5),
and 14.2
Revision 2.0 Publish Date: 16 Nov 11
Location of Type of
Reason for Change
Change Change
Section 1.3 Addition Added Enterprise standards and procedures to reference list
Section 2.0 Revision Edited definitions
Section 3.0 Revision Re-titled section “Applicability and Frequency;” Reworded several
subsections to clarify requirements
Section 3.0(1) Addition Added this section
Section 4.0 Revision Reworded several subsections to clarify requirements
Section 5.3 Addition Added “Describe line cleaning requirements”
Section 6.0 Revision Reworded several subsections to clarify requirements

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Section 7.0 Revision Reworded section to reference Enterprise Environmental Practice

PRA-WW-5a
Section 8.0 Revision Reworded several subsections to clarify requirements
Section 8.0(3) Addition Added “For existing facilities, system should be purged prior to
filling”
Section 9.0 Revision Reworded several subsections to clarify requirements
Section 10.0 Revision Added reference to AS/NZS 2885.5:2002
Section 11.0 Revision Reworded several subsections to clarify requirements
Section 12.0 Revision Reworded several subsections to clarify requirements
Section 13.0 Revision Reworded several subsections to clarify requirements
Section 14.0 Revision Added reference to Enterprise Standard STD.4403
Section 15.0 Revision Reworded several subsections to clarify requirements
Throughout Converted bullet points to outline numbering/lettering
Revision
document
Appendix A Revision Edited facilities, duration, and pressure requirements
Appendix B Revision Inserted updated Form 4507 as an embedded MS Excel file
Revision 3.0 Publish Date: 05 Jun 12
Location of Type of
Reason for Change
Change Change
Appendix B Revision Inserted updated Form 4507 as an embedded MS Excel file. Refer to
Form 4507 revision log for specific changes.
Revision 3.1 Publish Date: 06 Aug 12
Location of Type of
Reason for Change
Change Change
Section 6.7(3) Addition Added statement regarding steps to be taken when temperature probe
cannot be buried.
Revision 4.0 Publish Date: 30 Nov 12
Location of Type of
Reason for Change
Change Change
Section 1.4 Addition Added reference to Pipeline Integrity protocol for metallurgical
testing

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Section 3.0(1) Correction Grammatical correction

Section 4.0(4) Revision Revised distance between test equipment and manifold
Section 6.1 Revision Revised to require deadweight pressure gauges
Section 6.3 Revision Reworded to clarify requirements
Section 6.6(1) Addition Added option of using second pressure recorder
Section 6.6(4) Revision Reworded to clarify requirements
and (5)
Section 6.7(1) Addition Added option of using second temperature recorder
Section 6.7(3) Addition Added requirement regarding position of temperature recorder
Section 6.7(4) Revision Revised to require temperature probes to be buried for below ground
tests
Section 6.7(5) Addition Added requirement for situations where test water temperature is
significantly different from ground temperature
Section 8.4(4) Revision Reworded for clarity
Section 8.5 Revision Revised to incorporate metallurgical testing requirements
Section 8.6 Revision Reworded to clarify requirements
Section 12.0(5) Revision Reworded for clarity
Section 13.0 Revision Revised to incorporate approval process
Section 15.0 Revision Revised to explicitly state that forms must be signed and approved by
Test Director
Appendix B Revision Updated Form 4507
Revision 4.1 Publish Date: 18 Jun 13
Location of Type of
Reason for Change
Change Change
Appendix B Revision Updated Form 4507

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