WILLBROS A Good Job On Time Hydrostatic Testing Practices Establishing Verifiable, Traceable, and Accurate Documentation August 20, 2013 Hal Ozanne Willbros Engineers

WILLBROS 2 Hydrostatic Testing Practices Verifiable, Traceable, Accurate Documentation  Hydrostatic Testing Calculations  Hydrostatic Test Plans  Hydrostatic Test Reports  Data Collection and Final Verification Pipeline and Hazardous Materials Safety Administration (PHMSA)  Audits  Record Keeping  Approvals/Signatures

WILLBROS 3 Hydrostatic Testing Practices Hydrostatic Testing Calculations  Detailed calculations based on pipe characteristics and specifications –OD, wt, grade, weld/seam type, length of segment –Flange or no flanges (ANSI rating could be limiting factor for pressure) –Based on 100% SMYS or 125% MAOP –Surveyed pipe elevations –Test medium, volume, and temperature constraints  Segment lengths based on elevations and SMYS requirements  Project Management Review and Approval –Engineering Project Manager –Client Project Manager

WILLBROS 4 Hydrostatic Testing Practices Hydrostatic Testing Calculations  MAOP Verification calculated and determined by final hydro test results

WILLBROS 5 Hydrostatic Testing Practices Hydrostatic Test Plan  Set it up right and make it fully complete with Environmental Input –To comply with permits, environmental needs to be involved to ensure compliance (BLM, Corps of Engineers, FERC, NEPA, etc) –Advise on supply sources and discharge areas  Fabrication Test (4hr) or Mainline Test (8 hr) –Fabrication Test for HDDs and long bores prior to installation –Mainline Test for mainline (including HDDs) once in ground

WILLBROS 6 Hydrostatic Testing Practices Hydrostatic Test Plan  Environmental Requirements and Stipulations –Water Source –Discharge Location –Water Quality  Detailed to describe all parts of Hydro Test –Filling and pressuring up –Performing Test –Gathering Data –Completion of test –Dewatering of segment –Move water from one segment to the next or new water each segment –Drying and Cleaning –Final Verification and sign off

WILLBROS 7 Hydrostatic Testing Practices Hydrostatic Test Plan  Max and min test pressures for each Segment –Provide location of expected occurrence in plan –Provide expected test site location pressure  DOT/PHMSA Requirements (also use API RP1110) –Depends on type of test (spike test, strength test, leak test) –Pressure test medium, equipment, and materials –Qualifications of contractor and personnel performing test –Test period, failures, leaks –Test records and drawings kept for useful life of pipeline –Approval Signatures (operator of test, witness of test, personnel certifying the test)

WILLBROS 8 Hydrostatic Testing Practices Hydrostatic Test Plan  Acceptance Criteria established prior to conducting test  Proper Approvals and Signatures –Project Engineer –Project Manager –Construction Manager –Client Project Manager

WILLBROS 9 Hydrostatic Testing Practices Hydrostatic Test Report  Set it up in the beginning so that all data required to be gathered is understood by test operators  Based on Operating Company Standards and DOT/PHMSA Requirements (also API RP 1110)  Attention to Detail

WILLBROS 10 Hydrostatic Testing Practices Hydrostatic Test Report  Proper Recording of Measurements –Pipe Diameter and wall thicknesses –Pipe Grade and SMYS and/or ANSI rating –Location and elevation –Test Medium description, source, and volumes –Any additives description and volumes –Date and time of start and stops –Pressure vs. Time log –Temperature (ambient and pipe or test medium) –Weather conditions –Segment length

WILLBROS 11 Hydrostatic Testing Practices Hydrostatic Test Report  Completeness of Forms and Records  Proper Approvals and Signatures –Test Operator –Operator Supervisor –Construction Manager –Project Engineer –Client Authorized Representative (can be construction manager or project engineer in many cases)

WILLBROS 12 Hydrostatic Testing Practices Hydrostatic Test Data Collection  Planning and Preparation  Understanding Test Report and Forms –Anyone involved in the test or reviewing/approving of the test data –Allows those involved to know exactly what is required to be gathered and what is required to be approved based on what is provided  Maintain and Include Raw Data Gathered into Final Test Report Book

WILLBROS 13 Hydrostatic Testing Practices Hydrostatic Test Data Collection  Calibration of Instruments and Equipment –High volume pump and associated piping and meter for line fill –Injection pump for corrosion inhibitors, leak detection dyes or gases, or other chemicals –Variable speed PD pump for pressurization with known volume per stroke and a stroke counter –Pressure sensing device and deadweight tester –Continuous pressure recording device –Test medium temperature sensing device and display –Ambient temperature sensing device and display –Continuous temperature recording device for test medium and ambient –Test medium sampling equipment –Gas/oxygen detecting equipment

WILLBROS 14 Hydrostatic Testing Practices Hydrostatic Test Data Collection  Collecting/Recording All Details and Information Required on Reports and Forms –Test medium volumes, pressures, temperatures, times –Ambient pressures, temperatures, weather conditions –Pipe conditions and specifications (OD, wt, grade, high/low point, etc) –Instrument/Equipment calibration information –Failures, leaks, condition changes –Approvals  Maintain and Clean up All Field Notes on Drawings and Books –Incorporate into overall Test Report  Maintain All Failure Record Data for Final Book

WILLBROS 15 Hydrostatic Testing Practices Hydrostatic Test Data Collection  Temperature Recorders –Weather condition changes can affect volume of test medium to maintain constant pressure on pipeline –Secure temperature bulb directly to bare pipe, insulate, and backfill to ground level 12 hr prior to test –12 hr allows for fill medium, pipe, and ground temps to stabilize –Locate temperature bulbs on pipe a minimum of 500’ from exposed pipe

WILLBROS 16 Hydrostatic Testing Practices Hydrostatic Test Data Collection  Temperature Changes –As temp increases, pressure increases –As temp decreased, pressure decreases –Temp changes can affect volume of medium in pipe –Important to not conduct test during periods of day when temperature change is significant (frost levels play important role in test temperature as well)

WILLBROS 17 Hydrostatic Testing Practices Hydrostatic Test Data Collection  Small Leak or Change in Temperature? –Compare change in pipe temp to change in weather conditions –Change in pipe temp should correlate to change in ambient temp (changes show up on temperature plot for test) –Corrected volume equations at beginning and end of test account for change in pressure and temperature which correlates to change in volume –Spreadsheet set up to determine corrected volumes - part of test plan/report

WILLBROS 18 Hydrostatic Testing Practices Final Verification  Verify that final book is complete and contains all information in one location –Hydro Test Plan and Calcs –Test specifications –Survey data –Calibration certificates –Hydro test reports –Original test charts

WILLBROS 19 Hydrostatic Testing Practices Final Verification  If all required data is in one place, then it is easier to gather, maintain, and deliver to auditors  Ensure that the following people have signed off on the Test Report and Data Collected –Field Person Responsible for Gathering Data –Field Supervisor Over Hydro Test –Construction Manager –Project Engineer –Project Manager –Client Project Manager

WILLBROS 20 Hydrostatic Testing Practices PHMSA  Audits –Checks during construction to verify proper records being kept –Documentation is the first thing to be checked during a field audit –First impression set the tone for the audit  Record Keeping –Records should have proper approvals and signatures on them –Should be same throughout duration of project –Fabrication testing (HDDs) and Mainline testing (main pipeline)  Documentation Approvals/Signatures –Checks for field personnel, engineering personnel, and Company personnel signatures and approvals of test records and reports

WILLBROS A Good Job On Time