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Technical Service Department Version: 6.

0, October 30, 2015


ESS2.21 Hydrostatic Testing Standard for Facilities Piping

Revision History

Version Date Summary of Changes Author Reviewer Approver

1.0 10-11-11 New Specification. LS


2.0 10-11-17 Revised as per Pembina’s mark-ups. LS
3.0 11-01-04 Revised as per Pembina’s mark-ups. LS
4.0 11-01-05 Revised as per Pembina’s mark-ups. LS
Issued as Final.
5.0 11-06-14 Updated Owner User Manual LS
References.
6.0 15-10-30 Renamed as a Recommended R Baron B Watts J Huber
Practice, update template, structure,
references and various sections.

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ESS2.21 Hydrostatic Testing Standard for Facilities Piping

Table of Contents
1.0 SCOPE .......................................................................................................................... 5
2.0 LEGISLATION, REGULATIONS, CODES, STANDARDS, AND SPECIFICATIONS ..................... 5
2.1 Pembina Standards and Specifications ............................................................................. 5
2.2 Industry Codes and Standards ........................................................................................... 6
2.3 Legislation and Provincial Regulations .............................................................................. 6
2.4 Application ......................................................................................................................... 6
2.5 Quality Assurance (QA) and Quality Control (QC) ............................................................. 7
2.6 Conflict Between Specifications, Codes, and Standards ................................................... 9
3.0 TERMS AND DEFINITIONS ........................................................................................... 10
3.1 Overview .......................................................................................................................... 10
3.2 Language Use ................................................................................................................... 10
3.3 Definitions and Acronyms ............................................................................................... 10
4.0 STANDARD PRACTICE FOR PRESSURE TEST PLAN/TEST PACKS ..................................... 15
4.1 Corporation Responsibilities ........................................................................................... 15
4.2 Contractor/Test Operator Responsibilities ..................................................................... 16
4.3 Test Pressure and Duration ............................................................................................. 18
4.4 Test Medium and Test Temperature ............................................................................... 18
4.5 Site Preparation and Contingency Plan ........................................................................... 18
4.6 Hazard Mitigation, Safety Precautions, and Environmental Issues ................................ 18
4.7 Special Alternate Test, Tie-in Welds, Closure Welds, and Hydrotest Waiver ................. 18
4.8 Pressure/Volume (PV) Plot .............................................................................................. 19
4.9 Pressure Test Equipment and Components .................................................................... 19
5.0 TEST GUIDELINES........................................................................................................ 20
5.1 General ............................................................................................................................ 20
5.2 Test Water ....................................................................................................................... 20
5.3 Test Preparation – Field Guidelines................................................................................. 21
5.4 Hydrostatic Test Guidelines ............................................................................................. 22
5.5 Test Records .................................................................................................................... 22

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ESS2.21 Hydrostatic Testing Standard for Facilities Piping

5.6 Test Completion............................................................................................................... 23


Appendix A – Industry Standards Pressure Testing Requirements ........................................ 24
Appendix B – Regulations in Canada .................................................................................... 25
Appendix B.1 National .............................................................................................................. 25
Appendix B.2 Province of British Columbia .............................................................................. 25
Appendix B.3 Province of Alberta............................................................................................. 26
Appendix B.4 Province of Saskatchewan.................................................................................. 27
Appendix B.5 Province of Manitoba ......................................................................................... 27
Appendix B.6 Province of Ontario ............................................................................................ 27
Appendix B.7 Field Closure Welds ............................................................................................ 28
Appendix C – Regulations in USA ......................................................................................... 29
Appendix C.1 General ............................................................................................................... 29
Appendix C.2 State of Oregon .................................................................................................. 29
Appendix C.3 State of North Dakota ........................................................................................ 29
Appendix D – Maximum Hydrostatic Test Pressure for Valves .............................................. 30
Appendix E – Closure Checklist ............................................................................................ 31
Appendix F – Pressure Test Record ...................................................................................... 32

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Engineering Standards and Specifications
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ESS2.21 Hydrostatic Testing Standard for Facilities Piping

1.0 SCOPE

This document provides technical support and guidelines for hydrostatic testing of equipment and
piping defined as pressure-retaining components by the relevant ASME Codes of construction and
legislative regulations. The codes and regulations listed below further define the required scope and
limitations of testing of those components constructed to these codes which are contained within the
defined scope of construction.
This Recommended Practice shall be mainly applied on facilities piping systems designed and
constructed in accordance with the latest editions of ASME B31.1, ASME B31.3 and CSA Z662, which are
regulated under the various local jurisdictions.
When the need to apply the requirements of CSA Z662 pipelines under a Pipeline Act or other B31
pressure piping system such as B31.1, B31.4, and B31.8, etc. in regions where there may or not be
jurisdictional controls, the Pembina Technical Services Group shall be informed immediately and a
request for any required direction shall be formally submitted by the Designated Engineer or the
equivalent level of management.
Detailed reference to the project-specific requirements shall be made when the Request for Quote is
provided to Bidders. Bidders shall verify receipt/review of those requirements and any exceptions taken
shall be clarified with written acceptance prior to contract award.

2.0 LEGISLATION, REGULATIONS, CODES, STANDARDS, AND


SPECIFICATIONS

The following specific standards and codes listed as part of any jurisdictional regulations shall apply.
Work shall be in accordance with the latest revision/edition of all applicable codes, standards,
specifications, legislation and regulations listed below. The term “latest edition” shall be interpreted as
the revision including addenda/amendments of the publication in effect on the date of purchase order
or contract award. As regularly occurs, various industry standards cite a specific revision of another
code. Common usage is that this be regarded as mandatory and that the latest revision including any
amendments would otherwise apply where the reference is undated. Some standards permit the use of
newer or amended editions at the discretion of the user. Overall, it is intended that the more stringent
requirement shall be met and any conflict brought about by a subsequent revision of a referenced code
shall be referred to the Corporation for resolution. Except as modified by the requirements specified
herein or the details of any drawings, all work shall comply with the applicable provisions of the
referenced publications.
Where design/fabrication criteria or code and standards requirements are affected by city, provincial,
state or federal stipulations, this document shall be used as a recommended practice and project-
specific amendments shall be added as necessary to ensure compliance.

2.1 Pembina Standards and Specifications


The following Pembina standards and specifications apply to this practice:
• Pembina Pipeline Corporation - Corporate Supply Chain Policy

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ESS2.21 Hydrostatic Testing Standard for Facilities Piping

• Pembina Pipeline Corporation - Pressure Equipment Integrity Management Program


Manual, TS-FAC-MAN-0001;
• Pembina Pipeline Corporation - Closure Weld procedure , TS-FAC-PROC-0003;
• EG 3.6, Pressure Control and Overpressure Protection; and
• ESS 3.42, Facility Piping Specifications.

2.2 Industry Codes and Standards


The following industry codes and standards apply to this practice:
• CSA B51, Boiler, Pressure Vessel, and Pressure Piping Code;
• CSA Z662, Oil and Gas Pipeline Systems;
• ASME, Boiler and Pressure Vessel Code, All Sections;
• ASME B31.1, Power Piping;
• ASME B31.3, Process Piping;
• ASME B31.4, Pipeline Transportation Systems for Liquids and Slurries;
• ASME B31.8, Gas Transmission and Distribution Piping Systems;
• ASME B16.47, Large Diameter Steel Flanges;
• ASME B16.48, Line Blanks; and
• ASME B36.10M, Welded and Seamless Wrought Steel Pipe.

2.3 Legislation and Provincial Regulations


Legislation of the various jurisdictions applies to this practice as follows:
• Appendix A – Industry Standards Pressure Testing Requirements;
• Appendix B – Regulations in Canada
o Appendix B.1 National;
o Appendix B.2 Province of British Columbia;
o Appendix B.3 Province of Alberta;

1 Closure weld procedure TS-FAC-PROC-003 is a procedure accepted by the jurisdiction, allowing
the Owner to accept additional responsibility that is usually restricted to the Regulator.
o Appendix B.4 Province of Saskatchewan;
o Appendix B.5 Province of Manitoba;
o Appendix B.6 Province of Ontario;
o Appendix B.7 Field Closure Welds
• Appendix C – Regulations in USA
o Appendix C.1 General
o Appendix C.2 State of Oregon; and
o Appendix C.3 State of North Dakota.

2.4 Application
For Pembina Canadian Operations (within all Canadian jurisdictions) the provisions of CSA B51,
jurisdictional requirements, and the applicable Code(s) of construction shall apply including any
exemptions current to the time of construction.

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ESS2.21 Hydrostatic Testing Standard for Facilities Piping

For Pembina International Operations there may or may not be a jurisdiction to support regulatory
requirements for a specific region. Notification shall be given to any existing jurisdiction for the verification
of the compliance level required by Pembina. This shall be the responsibility of the Pembina Designated
Engineer or the equivalent level of management and shall be subject to the review and endorsement of
the Pembina Technical Services Group.The applicable Code(s) of construction shall apply including any
exemptions current to the time of construction.
Where a jurisdiction does not exist, notification shall be given to the Pembina Technical Services Group to
evaluate/verify the compliance level required by the Corporation. This notification shall be the
responsibility of the Pembina Designated Engineer or the equivalent level of management. It is intended
that a team effort will produce the level of compliance required to ensure, as a minimum, that the
applicable Code(s) of construction applies including any exemptions current to the time of construction.
All applications for jurisdictional approval are subject to review by the Pembina Technical Services Group
and a request for any required direction shall be formally submitted by the Designated Engineer or the
equivalent level of management.

2.5 Quality Assurance (QA) and Quality Control (QC)

2.5.1 Responsibilities for Pembina Canadian Operations are defined as follows:


CONTRACTOR RESPONSIBILITIES - Canada
Contractors performing fabrication, examinations, and/or pressure testing shall maintain a quality
program meeting the intent of CSA Q9002 and acceptable to the Pembina Technical Services Group. In
addition, Contractors performing fabrication of facility piping systems shall maintain valid quality
program registration with the local jurisdiction.
Contractors shall be familiar with, and experienced in, the Code(s) of construction specific to the project
as follows:
As applicable, Contractors performing fabrication, examinations, and/or pressure testing shall meet the
minimum requirements of ASME B31.1, Chapter I, Scope and Definitions, Chapter V, Fabrication,
Assembly, and Erection, Chapter VI, Inspection, Examination, and Testing, and all other applicable
sections and paragraphs.
As applicable, Contractors performing fabrication, examinations, and/or pressure testing shall meet the
minimum requirements of ASME B31.3 Chapter I, Scope and Definitions (specifically Manufacturer,
Fabricator, and Erector), Chapter V, Fabrication, Assembly, and Erection, Chapter VI, Inspection,
Examination, and Testing, and all other applicable sections and paragraphs.
• Various responsibilities exist to ensure that QA and QC in Pembina Standards, for products
and services, will be met as required by Pembina Pipeline Corporation Pressure Equipment
Integrity Management Program Manual, TS-FAC-MAN-0001.
• The Designated Engineer or the equivalent level of management shall be responsible for
distribution of project requirements with direct reference to the applicable jurisdictional
requirements, specifications, Codes of construction and Recommended Practices.
• Contractors shall be subject to a Pembina Technical Services audit/review determined by
the Pembina Technical Services Group on an as-needed basis.
PEMBINA (or RESPRESENTATIVE) RESPONSIBILITIES - Canada

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ESS2.21 Hydrostatic Testing Standard for Facilities Piping

Pembina representatives performing inspections shall meet the minimum requirements of the Code(s)
of construction specific to the project as follows:
• ASME B31.1, Chapter I, Scope and Definitions, and Chapter VI, Inspection, Examination, and
Testing (Qualifications of the Owner’s Inspector); and
• ASME B31.3, Chapter I, Scope and Definitions, and Chapter VI, Inspection, Examination, and
Testing (Qualifications of the Owner’s Inspector).
When not defined in the Code of construction, other supporting qualifications and /or experience may
or not be required. The required qualifications of individuals and/or companies shall be determined by
project complexity on a project-by-project basis. The Designated Engineer shall be responsible for the
appointment of Pembina’s representative to the project, with the recommendation/approval of the
Technical Services Group.
Pembina representatives performing inspections shall verify compliance as follows:
• Evaluate technical data as a minimum, perform inspections and witness tests, etc.
• The Designated Engineer will establish and coordinate inspection hold points with the
Vendor. Accessibility to all Vendors’ fabrication shops, manufacturing and test facilities, etc.
is MANDATORY.
• The acceptance of the results or its option not to carry out this examination does not relieve
the Vendors from their responsibilities and liabilities with respect to defective materials and
workmanship.
2.5.2 Responsibilities for Pembina International Operations are defined as follows:
CONTRACTOR RESPONSIBILITIES - International
Contractors performing fabrication, examinations, and/or pressure testing shall maintain a quality
program meeting the intent of ASQC Q9002 or equivalent and acceptable to the Pembina Technical
Services Group. In addition, Contractors performing fabrication of facility piping systems shall maintain
valid quality program registration with the local jurisdiction when applicable.
Contractors shall be familiar with, and experienced in, the Code(s) of construction specific to the project
as follows:
Contractors performing fabrication, examinations, and/or pressure testing shall meet the minimum
requirements of ASME B31.1. Chapter I Scope and Definitions, Chapter V, Fabrication, Assembly, and
Erection, Chapter VI, Inspection, and Testing, and all other applicable sections and paragraphs.
Contractors performing fabrication, examinations, and/or pressure testing shall meet the minimum
requirements of ASME B31.3, Chapter I Scope and Definitions (specifically Manufacturer, Fabricator, and
Erector), Chapter V, Fabrication, Assembly, and Erection, Chapter VI, Inspection, Examination, and
Testing, and all other applicable sections and paragraphs.
Contractors performing fabrication, examinations, and/or pressure testing shall meet the minimum
requirements of ASME B31.4, Chapter I, Scope and Definitions, Chapter V, Construction, Welding, and
Assembly, Chapter VI, Inspection and Testing, and all other applicable sections and paragraphs.
Contractors performing fabrication, examinations and / or pressure testing shall meet the minimum
requirements of ASME B31.8, General Provisions and Definitions, Scope and Intent and all other
applicable sections and paragraphs including Chapter I, Materials and Equipment, Chapter II, Welding,

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ESS2.21 Hydrostatic Testing Standard for Facilities Piping

Chapter III, Piping System Components and Fabrication Details, and Chapter IV, Design, Installation, and
Testing, and all other applicable sections and paragraphs.
Various responsibilities exist to ensure that QA and QC in Pembina Standards, for products and services,
will be met as required by Pembina Pipeline Corporation Pressure Equipment Integrity Management
Program Manual, TS-FAC-MAN-0001.
The Designated Engineer or the equivalent level of management shall be responsible for distribution of
project requirements with direct reference to the applicable jurisdictional requirements, Specifications,
Codes of construction and Recommended Practices.
Contractors shall be subject to a Pembina Technical Services audit/review determined by the Pembina
Technical Services Group on an as-needed basis.
PEMBINA (or RESPRESENTATIVE) RESPONSIBILITIES - International
Pembina representatives performing inspections shall meet the minimum requirements of the Code (s)
of construction specific to the project as follows:
• ASME B31.1, Chapter I, Scope and Definitions and Chapter VI, Inspection, Examination, and
Testing ( Qualifications of the Owner’s Inspector);
• ASME B31.3, Chapter I, Scope and Definitions and Chapter VI, Inspection, Examination, and
Testing (Qualifications of the Owner’s Inspector);
• ASME B31.4, Chapter I, Scope and Definitions and Chapter VI, Inspection and Testing
(Qualification of Inspector); and
• ASME B31.8, General Provisions and Definitions, Scope and Intent, and all other applicable
sections and paragraphs including 841.22, Inspection Provisions.
When not defined in the Code of construction, other supporting qualifications and /or experience may
or not be required. The required qualifications of individuals and/or companies shall be determined by
project complexity on a project-by-project basis. The Designated Engineer shall be responsible for the
appointment of Pembina’s representative to the project, with the recommendation/approval of the
Technical Services Group.
Pembina representatives performing inspections shall verify compliance as follows:
• Evaluate technical data as a minimum, perform inspections and witness tests, etc.
• The Designated Engineer will establish and coordinate inspection hold points with the
Vendor. Accessibility to all Vendors’ fabrication shops, manufacturing, and test facilities, etc.
is MANDATORY.
• The acceptance of the results or its option not to carry out this examination does not relieve
the Vendors from their responsibilities and liabilities with respect to defective materials and
workmanship.

2.6 Conflict Between Specifications, Codes, and Standards

2.6.1 General
Where a conflict occurs between this Recommended Practice and any specification, regulation, code, or
standard that has been specified for a particular service or item of equipment, the Owners Technical
Services Group shall be consulted and a written ruling shall be obtained before any work is started.

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Where a Code of construction or Standard is not represented in this Recommended Practice, the
Designated Engineer and Technical Services Group shall determine the best course of action through the
Management of Change (MOC) process and a directive shall be given to the Project as to the best course
of action to be undertaken which shall satisfy all safety, quality, cost, and delivery issues.
Where regulatory codes or regulations conflict with the specification, it is intended that the more
stringent specification shall govern (to be referred to the Corporation for resolution).

3.0 TERMS AND DEFINITIONS

3.1 Overview
The Corporation has defined certain terms to ensure correct interpretation, where such terms (or their
derivatives) appear throughout this practice.

3.2 Language Use


Must is a mandatory requirement which is required to meet legislated requirements.
Shall is an absolute requirement which is to be followed strictly in order to conform to the standard.
Should is a recommendation. Alternative solutions having the same functionality and quality are
acceptable.
May indicates a course of action that is permissible within the limits of the standard (a permission).
Can is conditional and indicates a possibility open to the user of the standard.

3.3 Definitions and Acronyms


Act or ASCA or SCA - The Alberta Safety Codes Act and the Regulations.
ABSA - The pressure equipment safety authority delegated to act as the Alberta jurisdiction for
administering the delivery of all safety programs under the Safety Codes Act as it applies to pressure
equipment (A.I.A. Quality Manual, Section 2, Definitions, 2.0).
Acceptance or Approval - It shall be indicated by signature or initial or stamp and the date.
Access to Codes - Availability for use on the same day.
Administrator - The Administrator in the pressure equipment discipline appointed under the Act [SCA,
1(1) (b)].
A.I. - Authorized Inspector which is regulatory employed by the ASME accredited A.I.A., who is qualified
by written examination in accordance with the ASME QAI-1 standard. The ABSA A.I. is also a Safety
Codes Officer (Boilers and Pressure Vessels appointed to administer the Alberta Safety Codes Act).
A.I.A. Authorized Inspection Agency - An inspection agency authorized by a regulatory authority to
perform inspections required under the Act including Inspection bodies such as A.I.A. accredited by
ASME. [CSA B51, clause 3, AB-518, Edition 5, Page 5 of 49].
Authorized Inspector and/or Inspector - An Employee of an agency authorized by a regulatory authority
and who is qualified and certified to perform API 570 (piping) & API 510 (pressure vessel) inspections.

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ASQC Q9002 - American Society for Quality Control: Quality Systems-Model for Quality Assurance in
Production, Installation, and Servicing.
Alteration - A change in the item described on the original Manufacturer's Data Report which affects the
pressure-containing capability of the pressure-retaining item. Non-physical changes such as an increase
in the maximum allowable working pressure (internal or external), increase in design temperature, or a
reduction in minimum temperature shall be considered alterations.
AQP - Alberta Quality Program number issued by ABSA. A company holding a valid AQP number from
ABSA is qualified to undertake activities that are authorized by the Certificate of Authorization Permit.
ASME - American Society of Mechanical Engineers.
ASNT – The American Society for Nondestructive Testing.
Boiler External Piping and Joint (BEP) - Piping which is subject to mandatory inspection by the
Authorized Inspector, as defined in ASME BPVC Section I and ASME B31.1.
Buyer - Any Engineering company working on behalf of Pembina.
CAP - Certificate of Authorization Permit issued by ABSA.
CGSB - Canadian General Specifications Board. This body provides acceptance criteria for inspection
levels of personnel performing nondestructive testing.
Competent, in relation to a person – Possessing the appropriate qualifications, knowledge, skills, and
experience to perform the work safely and in accordance with the Act [PESR, Section I Interpretation].
CRN - Canadian Registration Number issued by a pressure equipment jurisdiction in Canada as per the
requirements of CSA B51. A CRN is a design registration number and in the case of pressure equipment
for use in Alberta, a number issued by ABSA.
CSA - Canadian Standards Association.
CSA B51 - Boiler, Pressure Vessel, and Pressure Piping Code.
Certified Individual (CI) - An individual who is qualified and certified in accordance with the Alberta
requirements that coincide with ASME requirements, to perform the duties of a CI as specified by the
ASME Code. The CI is responsible for Safety Codes Act compliance when the A.I. is not involved.
Closure Welds - (ASME B31.3) – “The final weld connecting piping systems or components which have
been successfully tested in accordance with Para. 345 need not be leak tested provided the weld is
examined in-process in accordance with Para. 344.7 and passes 100% radiographic examination in
accordance with Para. 344.5 or 100% ultrasonic examination in accordance with Para. 344.6”.
ASME Code - American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code or
Pressure Piping Code declared in force [PESR Section I, Interpretation].
Contractor - Shall include all contractors engaged in the construction, reconstruction, improvement, or
dismantling of any physical structure that is part of Pembina’s facilities.
Construction Drawings - Are any drawings which are not sent to the Jurisdictional Authority Design
Survey.
Corporation - Pembina Pipeline Corporation.
Designated Engineer - Qualified engineer designated by Pembina.
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Design Basis Memorandum (DBM) - A document or series of documents prepared by a competent


engineering resource to identify the design, operating conditions, service requirements, and other
information needed to execute a safe design, construction, and inspection of the pressure piping
system.
DN - A dimensionless designator used in the SI (metric) system to describe pipe size [PESR, Partial
Exemption].
Expansible Fluid - A vapour or gaseous fluid or a liquid under pressure and at a temperature at which
the liquid changes to a gas or vapour when the pressure is reduced to atmospheric pressure or when the
temperature is increased to ambient temperature [PESR, Section I: Interpretation].
Examination - Quality control functions performed by the manufacturer, fabricator, or erector.
Fittings or Pressure Fitting - A valve, gauge, regulating or controlling device, flange, pipe fitting or any
other appurtenance that is attached to, or forms part of, a boiler, pressure vessel, fired-heater pressure
coil, thermal liquid heating system or pressure piping system. [PESR, Section I: Interpretation].
AER – The Alberta Energy Regulator (formerly ERCB).
He (or His or Him) - Within this written quality control system and its implementation “He” refers to the
position within the organization and not necessarily the gender of the individual in the position.
ISO - International Organization for Standardization.
Inspection - Functions performed for the Owner by the Owner’s Inspector or Inspector’s delegate.
Inspector - Owner’s Inspector as defined in ASME B31.3.
ITP - An Inspection Test Plan.
Job File - A file which contains all of the records documenting quality control for the item constructed.
This file shall be assigned a unique number to identify the job.
Joint – A point at where the connection between two components occurs.
Jurisdiction - As applicable to this quality system a jurisdiction is a governmental entity with the power,
right, or authority (or an organization delegated this authority by government) to interpret and enforce
law, rules, or ordinances pertaining to boilers, pressure vessels, pipelines, or other pressure-retaining
items.
LDT - Line Designation Table.
LVP - Low Vapour Pressure Covering:
• Hydrocarbons with a vapour pressure of 110 KPa absolute or less at 38°C (Reid method as
per ASTM D323);
• Multiphase liquids; and
• Oilfield water.
Lot - Defines the piping sizes/scope which are agreed to between the contracting parties before start of
work.
MOC - Management of change. It is a best practice used to ensure that safety, health, and environmental
risks are controlled when a company makes changes in their facilities, documentation, personnel, or
operations.

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Manufacturer - Pressure piping system fabricator or contractor holding a valid Certificate of


Authorization Permit (AQP number) for pressure piping fabrication in Alberta. Manufacturers located
outside of Alberta, but within Canada, who want to fabricate pressure piping systems at their locations
and ship them to Alberta for installation must be registered with the local pressure equipment
jurisdiction.
Manufacturing Data Book (MDB) - Is the exhibit which, with its table of contents, illustrates the relative
documents required in the “Turn-Over Package” forwarded to the Owner or Owner’s agent.
Material Test Report (MTR) - A document on which are recorded the results of tests, examinations,
repairs, or treatments reported as required by the basic material specification.
Maximum Test Pressure - The highest allowable test pressure gauge reading. (The pressure test rating
of the weakest component in the test system as determined under the applicable Code of construction –
e.g. ASME B31.3 Para. 345.4).
Minimum Design Metal Temperature (MDMT) - Design Minimum Temperature for which the material is
normally suitable without impact testing other than that required by the governing material
specification.
Minimum Test Pressure - The lowest allowable test pressure gauge reading. (The calculated test
pressure including any design temperature factor but excluding the additional pressure resulting from
the static head of the test fluid as determined under the applicable Code of construction – e.g. ASME
B31.3 Para. 345.4).
NDE - Nondestructive Examination conducted in accordance with the requirements of the ASME Section
V Code and AB-518, Edition 5 Page 6 of 49.
NEB - National Energy Board.
NPS - Nominal Pipe Size.
Organization - A structured social arrangement which pursues collective goals and controls its own
performance through a permanent arrangement of elements. These elements and their actions are
determined by rules so that certain tasks can be fulfilled through a system of the coordinated division of
competent skills.
Owner - The ultimate Owner who placed the order for the engineering, procurement, construction, and
installation of pressure piping system(s) at his site.
P&ID’s - Piping and Instrumentation Diagrams.
Permit - A Certificate of Authorization Permit issued by ABSA pursuant to Section 44 of the SCA.
PESR - Pressure Equipment Safety Regulation, Alberta Regulation 49/2006.
Pembina - Pembina Pipeline Corporation.
P.Eng. - A professional engineer who is experienced in the design of pressure piping and is registered in
any province of Canada or a state of the United States of America [AB-518, Edition 5, page 5 of 49,].
Pressure Equipment - A thermal liquid heating system and any containment for an expansible fluid
under pressure, including, but not limited to, fittings, boilers, pressure vessels, and pressure piping
systems, as defined in the regulations [SCA-1(1)(y)].

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Procedure Qualification Record (PQR) - A document that records what occurred during the welding of a
test coupon and the results of testing of the coupon. A Procedure Qualification Record is used to
support one or more Welding Procedure Specifications. With the exception of that allowed by ASME
Code Section IX paragraph QW-200.2, revisions to Procedure Qualification Records are not permitted
without dated recertification of the PQR.
Pressure Piping System - Pipes, tubes, conduits, fittings, gaskets, bolting, and other components that
make up a system for the conveyance of an expansible fluid under pressure and may also control the
flow of that fluid [PESR].
Pressure Plant - A pressure vessel or a system or arrangement of pressure vessels and the pressure
piping system used in connection with the pressure vessel or the system or arrangement of pressure
vessels [PESR].
Power Plant - A boiler in which steam or other vapour is generated at a pressure exceeding 103 kPa or a
temperature exceeding 121°C, a boiler in which liquid can be heated to a pressure 1100 kPa or a
temperature exceeding 121°C or both, or a system or arrangement of boilers described in the two
foregoing sentences and the pressure vessels, pressure piping systems, and fittings used in connection
with one or more of the boilers [PESR].
PRD - A Pressure Relief Device.
PV - Pressure/Volume.
QA - Quality Assurance is a way of preventing mistakes or defects in manufactured products and
avoiding problems when delivering solutions or services to customers which ISO 9000 defines as "part
of quality management focused on providing confidence that quality requirements will be fulfilled".
QC - Quality Control (part of a QMS focused on fulfilling quality requirements).
Quality Control Manager (QCM) - An employee of Pembina designated by the President to have the
responsibility and authority to maintain this Quality Control System, and the organizational freedom to
recognize quality control problems and provide solutions to those problems.
Quality Control Inspector (QCI) - An employee of Pembina designated by the Quality Control Manager
to perform the quality control duties as specified in this Quality Control Manual. The Quality Control
Inspector reports directly to the Quality Control Manager on any quality related matter.
QMS - Quality Management System for the purpose of directing and controlling an organization with
regard to quality.
Repair (In-Service Equipment) The work necessary to restore a pressure-retaining item to a safe and
satisfactory condition where there is no deviation from the original design.
SCA - Safety Codes Act enacted by the Legislative Assembly of Alberta.
SCO - A Safety Codes Officer employed by ABSA.
SNT-TC-1A – The American Society for Nondestructive Testing, Inc. Recommended Practice No.SNT-TC-
1A, Personnel Qualification and Certification in Nondestructive Testing (Accepted as an ANSI Code of
construction).
Subcontractor - A company/individual who is qualified and proven capable in performing duties in
compliance with the Alberta Safety Codes Act and customer specifications.

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System Test - A test that includes multiple sections of piping, having the same or different design
pressures, but which are tested together at one time using a single test procedure and pressure.
Sub-Vendor - Any party engaged by the Vendor with the approval of Pembina to undertake a specific
part of the work.
Test Temperature - The minimum system temperature occurring during the test period.
Tubing - A component in a pressure piping system.
Turn-over Package - The compilation of the pertinent manufacturing documents as referenced in the
Table of Contents of the Manufacturing Data Book as requested by the Client and forwarded at time of
shipping (also variously known as “Shipping Dossier” or “Mud Book”).
Vendor - The successful bidder.
Vessel Designer - The qualified and competent individual assigned the responsibility of developing,
reviewing, and controlling the code calculations of the vessel design.
Visual Testing (VT) - Is the required, on-going examination and inspection of pressure equipment, where
the Examiner and the Inspector participate in a visual review of the construction or assembly. Particular
attention is paid to the required testing at which time the entire assembly is visually examined and
inspected for Code compliance and leaks.
Welder - Within this practice (unless specifically differentiated as Welding Operator(s)) Welder(s) shall
be understood to include an individual who performs manual or semiautomatic welding as well as an
individual who operates machine or automatic welding equipment.
Welding Examiner - A qualified contractor to Pembina. The Welding Examiner must hold a Welding
Examiner Certificate of Competency issued pursuant to the Alberta Pressure Welders Regulation and/or
have qualifications that have been accepted by ABSA as a Welding Examiner.
WPS - A Welding Procedure Specification meeting the requirements of ASME Section IX Code.

4.0 STANDARD PRACTICE FOR PRESSURE TEST PLAN/TEST PACKS

4.1 Corporation Responsibilities


The purpose of this section is to define Corporate responsibilities for the testing performed and
documentation representing the verification of compliance for Contractor and the Owner’s Inspector.
The Owner is responsible for the piping system and shall ensure that compliance is enforced.
The Designated Engineer shall be responsible for the following:
Piping system pressure test activities shall be performed as referenced in the Purchase Order to
the Contractor (Vendor) and shall be defined by any jurisdictional requirements and, as a
minimum, the Code of construction specific to the project.
Piping system pressure test activities shall be performed under the direct continuous supervision of the
Pembina site representative who shall ensure that the following occurs as a minimum:
• All the basic information/documentation required for Test Pack preparation is available as
follows:
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o Verification of compliance to the jurisdictional requirement and Code(s) of construction


specific to the project.
o System Piping and Instrumentation Diagrams (P&ID’s) schematically reflecting
equipment items and their design conditions, interconnecting piping with
numbered/sized lines and their respective class, incorporated tagged instruments,
associated process notes, and any required mechanical execution requirements, etc.
o P&ID (Vendor Package) is supplied to define interconnection details/package limits in
order to ensure package is properly isolated and not retested where not
required/desired.
o Line Designation Table (LDT) by line number including design, operating, upset, and test
conditions; mechanical features such as paint, insulation, heat tracing, pipe schedule,
and postweld heat treatment; and NDE, etc. Note that the listed test pressure is
determined using the ratio of component allowable stress at test temperature to that at
design temperature. Note that all piping systems/lines are carried on the LDT including
those lines exempt from testing.
o Piping Line Class/Specifications reflecting various governing standards, design
requirements, postweld heat treatment, materials and valve selection, and connectivity,
etc.
o Piping Isometrics with the complete fabrication details, design conditions,
interconnections, and supports, etc. Note that items such as break flange pairs or vents
and drains at system high and low points may not be carried on the P&ID’s until design
development of piping isometrics which would define the requirements.
o Information/documents related to system fabrication which may be relevant and could
include weld detail/procedures/history/mapping, postweld heat treatment, and NDE
reports of radiography, ultrasonics, toughness, and hardness, etc.
o Reinforcing Pad Pressure Test Certificate.

4.2 Contractor/Test Operator Responsibilities


The purpose of this section is to define the Contractor and Test Operator responsibilities for the testing
performed and documentation representing the verification of Contractor compliance as verified by the
Owner’s Inspector.
The following describes, but is not limited to:
• Ensuring that compliance with any jurisdictional requirements and Code(s) of construction
specific to the project has been completed.
• All welded joints are tested in the unpainted condition to allow 100% visual examination.
• Sourcing and assembly of the basic information/documentation required for test procedure
preparation as addressed in the foregoing.
• Preparation of the Pressure Test Plan.
• Preparation of individual Pressure Test Packs as follows:
o Review and mark P&ID’s to determine extent of each Test Pack and define the total
number of Packs. Individual Packs include as large a piping system as practical limited to
design pressure difference not exceeding 15% of the lowest design pressure.
o Where piping systems are of welded connectivity, a cascade test may be used on the
higher pressure portion prior to closure welding and followed by a complete test repeat

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of the combined systems at the lowest pressure. Note, FOR EXAMPLE, that while B31.3
permits hydrotest to material specified minimum yield strength (SMYS) at test
temperature as per Para. 345.2.1, this Recommended Practice imposes test pressure
not exceeding 90% SMYS as per Para. 345.5.4 (providing the same margin to avoid
yielding as for pneumatic testing).
o Although there will be exceptions based on welded connectivity etc., this
Recommended Practice imposes that the following be excluded from piping pressure
tests/Test Pack configuration as reflected on the Test Pack Diagram:
Pressure vessels, filters, and storage tanks.
Heat exchangers and fired heaters.
Rotating equipment - pumps, compressors, and turbines.
Where equipment item “test-through” cannot be avoided, confirm that
structure/foundation is designed to support water - filled equipment and supported
piping.
Safety valves, rupture disks, flame arrestors, expansion joints, steam traps, control
valves, locally – mounted pressure/level gauges and flow meters, in-line process
valves (particularly those soft – seated), and check valves (alternately,
flapper/piston removed/blocked open).
Packaged equipment/piping systems otherwise tested.
Plumbing systems otherwise tested.
Lines and systems open to atmosphere including drains, vents, open discharge of
relief valve, and atmospheric sewers/building drains.
Instrument lead/impulse lines from first process block valve to instrument shall be
otherwise tested to associated process piping standards but shall exclude the
instrument. Instrument take-offs, process lead lines, sample lines, etc. shall be
tested to first block valve with the associated process piping.
• Rationalizing test pressures as a result of maximizing test limits to 90% SMYS is permitted in
the interest of test efficiency improvement gained by reducing the number of Test Packs.
• Line blinds/blanks shall conform to ASME B16.48 as applicable or may otherwise be
calculated by the rules of B31.3 Para. 304.5.3.
• Note that the requirements for temporary pipe supports and spring support blocks/chocks
shall be clearly identified on piping ISO’s with the facility blaze-ribbon tagged to high-light
their post – test removal requirement.
• Preparation of detailed Test Pack Diagram schematically depicting:
o Marked P&ID’s and piping ISO’s reflecting extent/limit of test.
o Fill/vent/drain locations. Specific reference shall be made to the provision made to
prevent system vacuum build upon draining of the test medium post-test.
o Test head/manifold arrangement and hook-up/temporary piping.
o Water supply pumps hook-up.
o Pressure pump hook-up.
o Blowdown compressor hook-up (as required).
o Location and range of pressure gauges. A minimum of two calibrated devices are
required - one located at an accessible low point and the other on the high point of the
test configuration.

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4.3 Test Pressure and Duration


Test pressure is determined as per the applicable Code of construction and shall be clearly stated on the
LDT (on P&ID’s and piping ISO’s only as required).
As a minimum, the Designated Engineer shall approve the P&ID’s and LDT. The Contractor shall verify
that the piping ISO’s clearly reflect the required information from the applicable P&ID’s and LDT.
The Owner’s Inspector shall verify Contractor compliance with the Code of construction and the review
of the approved P&ID’s and LDT at the time of test.
The Owner’s Inspector is required to and shall perform a 100% visual inspection of all joints subject to
test pressure.
The Contractor shall perform a 100% visual inspection of all joints subject to test pressure.
While a 10 minute hold may suffice for simple/individual spools, this standard recommends a 60 minute
minimum hold for piping systems to permit the required examination. Test duration will be confirmed at
the discretion of Owner’s Inspector.
Deviation from this recommendation shall only be allowed under approval of Owner’s Inspector.

4.4 Test Medium and Test Temperature


Test medium is determined as per the applicable Code of construction, and shall be clearly stated on the
LDT (on P&ID’s and piping ISO’s only as required), and is subject to the approval of Pembina’s Technical
Services Manager.
Test medium should be water at metal temperatures not less than 2°C. Other media are permitted at
metal temperatures no less than -20°C. For materials with unknown MDMT, consult Pembina’s
Designated Engineer.

4.5 Site Preparation and Contingency Plan


Pressure testing must be conducted with due regard for the safety of life and property and the planning
and implementation must therefore mitigate unnecessary exposure to procedural hazards. This shall be
reviewed and approved by the Designated Engineer as well as the Owner’s Inspector.

4.6 Hazard Mitigation, Safety Precautions, and Environmental Issues


All involved personnel have “Stop Work” authority whenever there is a concern for safety. Hazard
assessment is to be performed and an appropriate personnel exclusion zone identified and
signed/barricaded. Test team members only are permitted within the exclusion zone.
Equipment/materials are so arranged as to provide unobstructed access/egress during testing and in the
event of an emergency.

4.7 Special Alternate Test, Tie-in Welds, Closure Welds, and Hydrotest Waiver
When required by the Designated Engineer, the following guidelines may apply:
Alternates to the mandated hydrostatic test required by ASME B31.3 Para. 345.1 are listed as follows:

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a) Alternative Leak Test for the extenuating circumstances defined in Para 345.1 (c) is
permitted in accordance with Para 345.9 and although onerous, includes:
• Para 345.9.1 Examination of Welds.
• Para 345.9.2 Flexibility Analysis.
• Para 345.9.3 Test Method is the Sensitive Leak Test mandated under Para 345.8.
b) Tie-in welds as discussed under c) closure welds following.
c) Closure welds when allowed, are for example as per ASME B31.3 Para. 345.2.3 (c), the final
weld connecting piping systems or components otherwise successfully tested need not be
leak tested provided the weld is examined in process as per Para. 344.7 and passes 100%
visual with 100% radiography or 100% ultrasonic examination.
d) Hydrotest Waiver-lines open to atmosphere such as vents or drains downstream of last
shutoff valve need not be leak-tested.
NOTE: Refer to Appendix B for specific requirements based on jurisdiction and company.

4.8 Pressure/Volume (PV) Plot


When required by the Designated Engineer, the following guidelines may apply:
Development of a pressure/volume plot may be required for those systems where the otherwise
determined hydrotest pressure would result in a pipe stress of 90% SMYS at test temperature.

4.9 Pressure Test Equipment and Components


Verification for Contractor compliance with the following is to be performed by the Owner’s Inspector:
The Contractor’s responsibilities include compliance with the Code(s) of construction, all applicable
requirements, as well as the following (compliance to be verified by Owner’s Inspector):
The required test equipment including, such as Master gauges, gauges, and time/temperature recorders
(digital or analog) shall be as per the contractors Quality Manual or, as a minimum, be calibrated to a
traceable/known National Standard.
Test gauges and recorders shall be verified at test pressure against a properly ranged Master Pressure
Gauge prior to each use. A Test Gauge Verification Log shall be used to document this verification by
recording date, test pressure, Test Gauge number, Master Pressure Gauge number and the initials of the
person accepting the verification of the Test Gauge.
The maximum interval between pressure measuring device calibrations shall be twelve months. All
other equipment used for Code-required measurement or inspection shall be calibrated at intervals as
recommended by the manufacturer or as established by the Owner’s Inspector.
Miscellaneous Components:
Special length bolting and test gaskets may be required during testing, and shall be removed after test
completion and replaced with standard line class bolts and new service gaskets.
A field procedure must be established and care taken to ensure the installation and removal of material
which is specified for testing only.

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Spectacle blinds/blinds and spacers as per Piping Line Class, extra length bolting, and gaskets for testing
shall be otherwise furnished as part of the installation contract.

5.0 TEST GUIDELINES

5.1 General
The following information is provided for guidance and shall be applied in conjunction with the
Contractor’s Quality Program. When a Contractor is not required to have a Quality Program, the
Designated Engineer, with the support of Pembina Technical Services, shall determine the extent and
application of this Recommended Practice to the specific project.
Subsequent to repairs, heat treatment, NDE, and examination, the Contractor must inspect the pressure
piping system to ensure materials, construction, and installation comply with the regulations. Prior to
initial operation, all installed piping shall be pressure tested except as otherwise noted.
When required, the jurisdictional local inspector shall be notified at least 48 hours in advance of
pressure testing of piping under its jurisdiction for witnessing at his/her option.
The test shall be hydrostatic using water unless there is a possibility of damage due to freezing; or, if the
operating fluid or piping material would be adversely affected by water. Any other suitable liquid or
additives may be used on approval by the Pembina Designated Engineer. Testing of ferritic piping,
however, is limited to the temperature restrictions otherwise noted.
If a flammable liquid is used, its flash point shall be no less than 49°C (120°F) and consideration shall be
given to the test environment.
If testing with glycol-water mixture to prevent freezing, the safety, leakage, and disposal considerations
of the test fluid shall be considered.

5.2 Test Water


Clean water that will not corrode and/or damage the test system shall be used for hydrostatic tests. If
municipal water is not available, supply water may be obtained from native water supply (e.g. dugout).
Water containing silt or suspended material shall not be used, and a suitable 40 mesh filter should be
provided in the filling line. Pembina’s Designated Engineer shall approve the proposed source of test
water.
If water source is not potable, Pembina’s Designated Engineer shall consider adding inhibitor to reduce
risk of pitting corrosion or introduction of Microbiologically Induced Corruption (MIC). Pembina’s
Designated Engineer should also consider biodegradable inhibitor to allow test fluid disposal to the
environment.
Chlorides content exceeding 25ppm is not permitted.
A mixture of glycol/water shall be used where the ambient temperature may reach less than 0°C (32°F)
during testing or prior to dry-out.

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5.3 Test Preparation – Field Guidelines


Joints, including welds, shall be left uninsulated and exposed for examination during the test, except
that joints previously treated may be insulated or covered. All joints that require a leak test shall not be
primed/painted prior to leak testing.
Underground portions of piping systems may be tested and covered before testing aboveground
portions.
Piping designed for vapour or gas shall be provided with additional temporary supports, if necessary to
support the weight of the test liquid. Where required, temporary supports shall be used as specified in
the pressure test documents.
Lines that are counterweight-supported shall be temporarily blocked during testing in order to sustain
the weight of the test fluid. Spring hangers that have been provided with stops for carrying the test load
normally do not require additional temporary supports.
Before testing, the following procedures shall be carried out:
• Verify that any required heat treatment has been performed and that all NDE requirements
are complete.
• Piping systems shall have been thoroughly checked for completeness.
• Piping systems shall be checked to ensure that the entire system can be completely drained
after testing.
• Vents or other high point connections shall be opened to eliminate air from lines, and
system shall be purged of air before hydrostatic test pressure is applied.
• Short pieces of piping that must be removed to permit installation of a blind or blank shall
be tested separately.
• Flanged joints at which a blank is inserted to isolate other equipment during a test need not
be tested after blank is removed.
• Lines containing check valves shall have the source of pressure located in the piping
upstream of the check valve so that the pressure is applied under the seat. If this is not
possible, remove or jack up the check valve closure mechanism or remove check valve
completely, and provide necessary filler piece or blinds. Removed internals shall be bagged
and placed nearby in order that inspectors may verify that the internals have been removed
for the test.
• When conducting tests at freezing temperatures, the test shall not take more than 4 hours,
and special precautions, such as using glycol/water mixture, shall be used to avoid freezing
damage. Follow precautions to minimize the risk of brittle fracture as otherwise noted.
• Systems that include expansion joints, which have been removed for pressure testing, shall
be investigated to see that any required temporary restraints, anchors, or guides are
installed or removed prior to test.
• When a pressure test is required to be maintained for a period of time during which the
testing medium in the system would be subject to thermal expansion, provision shall be
made for relief of any pressure greater than the maximum test pressure.
• With prior authorization from Pembina’s Designated Engineer, piping or sections of piping to
be tested may be isolated by closed valves provided the valve closure is suitable for the test
pressure as defined in Appendix D.
• Drain and vent valves are to be in open position and plugged during test to permit testing of

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valve packing.
• Bypass valves on gate valves provided with centre cavity pressure equalizing bypass shall be
open during the test.

5.4 Hydrostatic Test Guidelines


Piping systems shall be pressurized slowly and evenly to prevent vibrations. When the pressure has been
raised to 1000 kPa, a leak check shall be done to check all valves and fittings. If leaks are found, system
must be depressurized prior to repairs.
In order to hydrostatic test as much piping as possible at one time, a systems test may be employed.
The minimum test pressure for a system test shall be such that each line in the system is subjected to its
required minimum test pressure.
The maximum system test pressure shall not exceed the pressure test rating of any piping component.
Maximum test pressures for valves conforming to ASME B16.34 are as specified in Appendix D.
Where a suitable valve is not available for closed valve isolation, vessels, equipment, or other piping not
included in the system pressure test shall be either disconnected from the system or isolated by blinds
or other means during the test.
The normal location for the pressure test gauge is at grade near the pressure test pump. Readings may
be made at higher points providing the gauge pressure reading and the static head [9.79 kPa/m (0.433
psi/ft.) for water] between grade and the point of measurement do not exceed the maximum test
pressure. Gauges shall be tagged with the date last calibrated, and this activity shall be recorded.
Gauges shall be a minimum 100 mm (4”) diameter face and shall be graduated over a range of
approximately double the intended test pressure but in no case shall the range be less than 1.5 times
nor greater than 4 times that pressure.
At least two gauges shall be used per test. One gauge shall be located on the test head and one on the
system being tested. Gauges must read within 5% of each other.
The use of NDE in lieu of the hydrotest for the final closure weld requires a hydrotest waiver as
described in Section 4.7.
Test Plan procedures, and schedules shall be reviewed by Pembina prior to commencement.
All tests shall be witnessed and accepted by the Inspector. The test results shall be recorded and a copy
shall be provided to Pembina.

5.5 Test Records


Records shall be made of each piping system test and shall include the information tabulated in the form
provided (Refer Appendix F).
The completed forms shall be retained in the Construction Contractor’s QC file as a permanent record. A
copy of each piping pressure test system record form shall be given to Pembina’s Authorized Inspector
for verification of compliance.
Pembina’s record retention policy shall be consulted for the requirements on the submission and
retention of piping pressure test records within each local jurisdiction.

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5.6 Test Completion


All tests are to be witnessed by a Pembina-qualified inspector.
If leaks are found, their location shall be marked, the pressure shall be gradually released, and the piping
shall be drained or vented. Appropriate repair or replacement shall be made in accordance with
approved procedures. The affected piping shall be retested at the pressures originally specified for the
test.
All tests where potential freezing of the test medium may occur shall be evaluated by the Contractor
and a plan shall be submitted in writing to the Design Engineer and the Owner’s Inspector for review
and approval prior to testing.
After lines have been drained, temporary supports shall be removed, and insulation and painting
completed. Spring hangers provided with stops to carry the test load shall have these stops removed
except those identified to be removed after system is charged.
Instruments which were removed or blocked out for test shall be reinstalled and blocks placed in the
normal operating position.
Temporary bolting and gaskets used for pressure testing shall be removed and replaced with line class
bolts and gaskets.
Check valves that were jacked open or had the internals removed for pressure testing shall be returned
to their proper operating position.
Instruments and process lead lines that were subjected to the hydrostatic pressure test shall be blown
out with dry air (dew point -60°C) or nitrogen.
Vent and drain connections that were added solely for pressure testing shall be closed and seal welded
as required. Drains shall have either the valve closed and plugged or, if the valve is removed, the
connection plugged and seal welded as required.
Painting and insulation shall be completed after inspection of seal welded vents and drains. Strainer
screens shall be removed, cleaned, and reinstalled.

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Appendix A – Industry Standards Pressure Testing Requirements

It is the Owner’s responsibility to ensure that the piping system is compliant with the applicable
Regulations, Codes, Standards, and Specifications. The designated Engineer is responsible for ensuring
that all required pressure tests are compliant.
Industry Standards Pressure Testing Requirements are defined by the applicable Code(s) of construction.
For example, ASME B31.3 (including its special provision for Closure Weld Examination) also covers
applicable pressure equipment/pressure piping associated with pipelines under CSA Z662).

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Appendix B – Regulations in Canada

Appendix B.1 National


National Energy Board (NEB) - Its scope generally includes interprovincial and international oil and gas
pipelines. Pipelines which lie completely within the borders of a single province are regulated by the
regulatory body of that jurisdiction. The designated Engineer is responsible for ensuring that all required
pressure tests are compliant.

Appendix B.2 Province of British Columbia


The designated Engineer is responsible for ensuring that all required pressure tests are compliant as
follows:
1 Oil and Gas Activities Act, (under BC Oil and Gas Commission) Regulation, B.C. Reg. 282/2010 –
Facility permit holders must:
• Section 76b - Provide 2 day notice before conducting a pressure test on process piping.
• Section 78 (2) - Design and construct a piping system at a gas processing plant in accordance
with ASME B31.3.
• Section 78 (3) - Design and construct, for a facility other than a gas processing plant, every
portion of the piping system in accordance with either:
a) ASME B31.3
b) CSA Z662
• Section 78 (5) - Indicate on the facility as - built drawings and on the piping of the facility the
interface between the foregoing two standards where applicable.
2 Safety Standards Act (under BC Safety Authority) SBC 2003 Chapter 39. This Act applies to:
• Section 2 (1) (b) (vi) gas systems and equipment.
• Section 2 (1) (b) (vii) pressure vessels.
• Section 2 (1) (b) (viii) pressure piping.
This Act does not apply to:
• Section 3 (2) those facilities, other than boilers, pressure vessels, and pressure piping listed
above which are attached to, used in the operation of, or in association with, a pipeline
defined in Section 1 (2) of the Oil and Gas Activities Act.
3 Safety Standards Act, Power Engineers, Boiler, Pressure Vessel and Refrigeration (B.C. Reg.
104/2004). Section 1 Definitions for the Act defines pressure piping as a system for the
conveyance of:
a) An expansible fluid.
b) A non-expansible or thermal fluid with an operating temperature exceeding 121°C or a
working pressure exceeding 1100 kPa.
Section 2 (1) Definitions and interpretations for the regulation defines expansible fluid as:
a) Vapour.
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b) Gaseous substances.
c) Liquid under pressure and temperature at which the liquid changes to a gas or vapour
when the pressure is reduced to atmospheric pressure or when the temperature
increases to ambient temperature.
“Pressure” is defined as gauge pressure of 103 kPa (equivalent to 15 psi).
Section 3 (1) Application of this regulation includes every piping system.
Section 3 (2) Application of this regulation does not include:
a) A pressure piping system operating at and with a relief valve set at 103 kPa or less.

Appendix B.3 Province of Alberta


2 ABSA Safety Codes Act (RSA 2000 Chapter S-1) – Application of Act, Section 2 (1) (d) gas systems
and (f) pressure equipment.
3 ABSA Pressure Equipment Safety Regulations (AR 44/2006) and its companion User Guide AB-
516 Section 1 (1) (aa) pressure piping defined as that for the conveyance of an expansible fluid.
Piping that does not contain an expansible fluid at maximum design temperature is not a
“pressure piping” system under the regulation. Refer also to Section 3: Exemptions, Section 4:
Partial Exemption, and its Variance No: VA12-006 (under IB12-010).
4 ABSA Pressure Equipment Exemption Order AR 56/2006, Exemptions Section 2 (1) (e) pipeline
and (f) related installations.
5 AER Pipeline Act (RSA 2000 Chapter P-15), Interpretation Section 1 (1) (t) pipeline and (u)
processing plant, Application of Act Section 2 (d) boiler, pressure vessel, or pressure piping
system.
6 AER Pipeline Rules (AR 91/2005), Interpretation Section 1 (4) and (5) pipeline definitions. Note
that Part 3 addresses pipeline pressure testing.
7 AER Directive 077: Pipelines – Requirements and Reference Tools, Part B provides an
interpretation of jurisdictional relationships for pipeline, pressure equipment, and pressure
piping and provides Figures 1 through 11 graphically illustrating the complexities.
8 AER Oil and Gas Conservation Rules (AR 151/1971), Part 7, Production Operations, and Part 9,
Processing Plants.
9 AER Oil Sands Conservation Rules (AR 76/1988) Part 2, 3 (1) Regulatory approvals required, and
Part 5, Processing Plant.
10 ABSA Pressure Piping Construction Requirements AB-518 defines Alberta requirements for
pressure piping fabrication contractors and their required Quality Management Systems (QMS)
as well as those pressure piping construction activities preformed under a valid Certificate of
Authorization and specifying the completion of those activities as a prerequisite to the pressure
test. The pressure test for all pressure piping is required to be a hydrotest as per PESR Section
30: but other tests are permitted under ASME B31.3 as listed following where a hydrotest
cannot be performed.

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11 In - process examination of closure weld on previously tested systems and successful 100% RT or
100% UT examination (B31.3 Para. 345.2.3).
12 Pneumatic Leak Test (B31.3 Para. 345.5).
13 Hydrostatic - Pneumatic Leak Test (B31.3 Para. 345.6).
14 Initial Service Leak Test (B31.3 Para. 345.7) - applicable to Category D fluids. This procedure of
testing to only operating pressure is not permitted under the superseding PESR Section 30 (1)
for hydrostatic testing of all piping. The use of alternative test methods is otherwise permitted.
15 Sensitive Leak Test (B31.3 Para. 345.8).
16 Alternative Leak Test (B31.3 Para. 345.9).
17 ABSA Pressure Piping Alternative Test Methods Procedure Requirements AB-519 references the
testing alternatives and defining the Owner – User Integrity Management System for Closure
Welds, Tie-in Welds, etc.
18 ABSA Standard Pneumatic Test Procedure Requirements for Piping Systems AB-522 addressing
and quantifying the hazards involved and referencing ASME PCC-2, Repair of Pressure
Equipment and Piping, Part 5, Examination and Testing including:
• Article 5.1, Pressure and Tightness Testing of Piping and Equipment.
• Article 5.1, Mandatory Appendix I Pressure/Leak Testing.
• Article 5.1, Mandatory Appendix II Stored Energy Calculations for Pneumatic Pressure Test.
• Article 5.1, Mandatory Appendix III Safe Distance Calculations for Pneumatic Pressure Test.
• Article 5.1, Mandatory Appendix IV Risk Evaluation Considerations for Pneumatic Pressure
Test.
19 Closure weld procedure TS-FAC-PROC-003 is a procedure accepted by the jurisdiction, allowing
the Owner to accept additional responsibility that is usually restricted to the Regulator.

Appendix B.4 Province of Saskatchewan


The Boiler and Pressure Vessel Regulations (Chapter B-5.1 REG 1) of the Boiler and Pressure Vessel Act,
1999 Para. 3(1) lists classes of pressure equipment exemptions. Para. 20(1) stipulates that all piping
other than power and refrigeration be constructed, inspected, and tested in accordance with the
requirements of CSA B51 and ASME B31.3.

Appendix B.5 Province of Manitoba


The Steam and Pressure Plants Act (C.C.S.M.C. 210) Para. 1) lists pressure plant exemptions and appears
to carry no industry standards/codes conformance stipulations nor design, construction, inspection, and
test requirements for pressure equipment.

Appendix B.6 Province of Ontario


Province of Ontario regulations under the Technical Standards and Safety Act define the required
compliance with the various CSA Standards and ASME Codes. Approval submissions include a Piping
Systems Installation and Test Data Report.

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Appendix B.7 Field Closure Welds


Field closure welds shall be examined in accordance with ASME B31.3 Para. 345.2.3 (c) in lieu of pressure
testing. A hydrotest waiver form shall be completed for all cases. For registered piping systems,
examination of closure welds in lieu of pressure testing requires approval of the local jurisdiction in
accordance with Pembina’s Owner User manual.
As an example, in Alberta, ABSA AB-518 permits and AB-519 defines the alternative testing procedure
which includes the closure weld option. In addition to specific case by case approval submissions, AB-519
provides minimum requirements for an Owner-user integrity management system for those organizations
holding a Certificate of Authorization and employing an in-house Chief Inspector which would avoid ABSA
acceptance of each occurrence.
The regulations in other Provinces may be similar and the designated Engineer is responsible for
ensuring that all required pressure tests are compliant.

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Appendix C – Regulations in USA

Appendix C.1 General


Where a jurisdiction exists, notification shall be given to that local jurisdiction for the verification of the
compliance level required by Pembina. This shall be the responsibility of the Pembina Designated Engineer
or the equivalent level of management and shall be subject to the review and endorsement of the
Pembina Technical Services Group.The applicable Code(s) of construction shall apply including any
exemptions current to the time of construction.
Where a jurisdiction does not exist, notification shall be given to the Pembina Technical Services Group to
evaluate/verify the compliance level required by Pembina. This notification shall be the responsibility of
the Pembina Designated Engineer or the equivalent level of management. It is intended that a team
effort will produce the level of compliance required to ensure, as a minimum, that the applicable Code(s)
of construction applies including any exemptions current to the time of construction.
Where a Code of construction or Standard is not represented in this Recommended Practice, the
Designated Engineer and Technical Services Group shall determine the best course of action through the
Management of Change (MOC) process and a directive shall be given to the Project as to the best course
to be undertaken which shall satisfy all safety, quality, cost, and delivery issues.
Where design/fabrication criteria or code and standards requirements are affected by city, provincial,
state or federal stipulations, this Document shall be used as a Recommended Practice and project-
specific amendments shall be added as necessary to ensure compliance.

Appendix C.2 State of Oregon


State of Oregon regulations under the Boiler and Pressure Laws and Rules define the minimum safety
standards governing the installation and operation of pressure equipment.
The designated Engineer is responsible for ensuring that all required pressure tests are compliant.

Appendix C.3 State of North Dakota


State of North Dakota regulations under the Industrial Commission of the Oil and Gas Division define the
minimum safety standards governing the installation and operation of pressure equipment.
The Designated Engineer is responsible for ensuring that all required pressure tests are compliant.

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Appendix D – Maximum Hydrostatic Test Pressure for Valves

Table 1: Maximum Hydrostatic Test Pressure (kPag) for Valves

Carbon Steel Stainless Steel


Flange 304 (2.1)
Rating 316 (2.2)
Normal (1.1) 304L, 316L (2.3)
(Class) 321 (2.4)
347, 348 (2.5)
Shell Seat Shell Seat Shell Seat
150 3,000 1,960 2,900 1,900 2,400 1,590
300 7,700 5,110 7,500 4,960 6,300 4,140
600 15,400 10,210 14,900 9,930 12,500 8,270
900 23,000 15,320 22,400 14,890 18,700 12,410
1500 38,300 25,530 37,300 24,820 31,100 20,680
2500 63,900 42,550 62,100 41,370 51,800 34,470

Notes:
6.0 The above chart provides the maximum allowable hydrotest pressures of NPS 2 through NPS 24
flanged and standard class weld end valves (shell test, with valve open and seat test, with valve
closed). The above Shell test and Seat test pressures are based on ASME B16.34, Para. 2.5.3.
7.0 If approved by Pembina’s Designated Engineer, flanged valves manufactured according to API-
600 and API-602 may be tested in accordance with the above chart. Carbon steel, Normal (1.1),
Class 800 Threaded or Socket weld valves manufactured according to API-602 may be tested to
20500 kPag (shell test) or 13620 kPag (seat test).
8.0 For valves not conforming to the above standards, the Manufacturers' recommended test
pressure limits for both shell and seat shall be used.
9.0 Maximum test pressures for valves over NPS 24 and piping components not covered by this
chart shall be provided by the Construction Contractor as applicable to Pembina’s Designated
Engineer for approval.

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Appendix E – Closure Checklist Sample


Job No.
Weld No.
Unit No.
CWP No.
Original Repair No.
ISO or Drawing No.
Insert Required? Pipe Diameter
Nominal Joint Thickness
WPS & Rev. No.
Material & Grade to Type & Grade
REQUIREMENTS FOR FIELD USE ONLY
Purge Required Gas Type Recorded Results
Preheat Temp F Min
Welding Super.
Cleanliness, Fit-up and AWS/Date Other
Release Date
Release for welding
Interpass Temp C Max
VT-Root Pass
VT-Filler Passes
Final VT, Released for NDE
PWHT Temp C
Hold Time Hrs
NON DESTRUCTIVE EXAMINATION
Liquid Penetrate
Magnetic Particle NON DESTRUCTIVE EXAMINATION
Radiography Performed By:
Other NDE Subcontractor:
FILLER MATERIAL Accept Reject
Covered Bare Accept Reject
Accept Reject
Other Accept Reject
Area Welding Specialist Review & Holding Point(s) Actual Filler Material Used

Supplement Sheet Yes No


Completed By:
Remarks
Area Welding Specialist
Above “REQUIREMENTS” Certified Correct

Area Welding Specialist Welder’s Name & Symbol


Remarks:
Above “RESULTS” Certified Correct
(Note: This form is for general closure weld. It may be modified to suit each construction site specific use.)

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Appendix F – Pressure Test Record


Date (yyy.mm.dd): Pressure Test Record
Pressure Test Record ID:
Pressure Test Plan ID:
Pressure System (Test Pack) ID: Note: Retention of Records – 5 Year Minimum
System Service:
Facility/Plant:
TEST PARAMETERS:
Test Type: Hydrostatic Pneumatic
Required Test Pressure: Maximum Test Pressure (90% SMYS):
Test Medium: Min. Permitted Test Medium Temp:
Required Test Hold Time: Actual Ambient Temp. Range: °C High
Test Start Time: °C Low
Test Duration/Actual Hold Time: Actual Minimum Metal Temp:
Actual Test Pressure: Test Completion Time:
Actual Disposal of Test Medium: Actual Test Medium Temp. Range: °C High
Test Medium Chlorides Content: °C Low
TEST EQUIPMENT: REFERENCE INSTRUMENT TEST EQUIPMENT
Pressure Deadweight TI PR PI TR
Make:
Range:
Serial Number:
Calibration Date:
ENVIRONMENTAL CONTROLS:
Exclusion Zone (Personnel Safety):
Exclusion Zone Controls:
RESULTS:
System Inspection: Reasons/Causes:
Satisfactory: Unsatisfactory:
Pressure Test: Reasons/Causes:
Satisfactory: Unsatisfactory:
Leaks/Failures Location:
Repair Procedures:
Remarks:
Refer Attached Pressure/Temperature Records/Charts/Logs:

RESULT APPROVALS: DATE (yyyy.mm.dd) FABRICATOR/TEST OPERATOR PEMBINA PPC INSPECTOR


Release for Test
Tested/Accepted
Reinstated After Test

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