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HomeMy WebLinkAbout1.08 Pressure testingPressure Testing I. Introduction 2. Purpose 3. Pressure Testing Procedure 3.1 Pre-Testing Requirements 3.1.1 Permits 3.2 Pressure Test Process 3.2.1 Test Medium 3.2.2 Discharge Location 3.2.3 Pumps 3.2.4 Safety Measures 3.2.5 Cleaning the Pipeline 3.2.6 Filling the Pipeline 3.2.7 Testing the Pipeline 3.2.8 Depressurizing the Pipeline 3.3 Records 1. INTRODUCTION The Pressure Testing Plan (plan) identifies measures to be taken by the ETC Canyon Pipeline, LLC (Company) and its contractors (Contractor) to ensure that pressure testing operations are carried out in accordance with the following: • United States Department of Transportation Code of Federal Regulations (CFR), Title 49, Part 192, Subpart J, entitled "Test Requirements" • Environmental Protection Agency Measures identified in this plan apply to work within the project area defined as the right-of-way (ROW) and other areas used during pressure testing of the pipeline. 2. PURPOSE The purpose of this plan is to ensure that necessary measures are implemented during pressure testing of the pipeline to ensure the safety of all pipeline construction personnel and the general public. This plan describes safety standards and practices that will be implemented during construction of the project to minimize health, safety, and environmental concerns related to pressure testing on the project. 3. PRESSURE TESTING PROCEDURES The following procedures will be implemented by the Contractor during pressure testing operations. This section of the plan describes pre-testing requirements, the typical sequence of activities associated with pressure testing operations, and notifications required by the Contractor and Company. 3.1 PRE-TESTING REQUIREMENTS 3.1.1 Permits The Company is responsible for securing nitrogen for the pressure testing of the pipeline and associated appurtenances. The Company will also comply with the rules and regulations of the Colorado Department of Public Health and the Department of Transportation (DOT). The Company will procure nitrogen from a qualified service company. Under no circumstances will an alternate medium be used without prior authorization from the Company. There will be discharge locations on private land. Discharge test nitrogen will be vented to the atmosphere at designated blow down valve sets. 3.2 PRESSURE TEST PROCESS 3.2.1 Nitrogen Delivery • Pressure test nitrogen will be delivered to a designated load point located at the starting point of the pipeline. The Company's Environmental Inspector will be responsible for notification of nearby residences or affected governmental agencies. Source of water with pipeline station number, 3.2.2 Discharge Locations There will be discharge locations on private land. Discharge test nitrogen will be vented into the atmosphere following the successful completion of the pressure test.. 3.2.3 Pumps If pumps (trucks) for pressure testing are within 100 feet of any residence, all residents will be notified at least 24 hours in advance of beginning the pipeline loading process. 3.2.4 Safety Measures The Contractor will provide for the safety of all pipeline construction personnel and the general public during pressure test operations by: • Placing warning signs in populated areas; • Restricting access to the immediate area involving the pressure test (i.e., test shelter, manifolds, pressure pumps, instruments, etc.) to only those personnel engaged in the testing operations; • Prohibiting major pipeline work not directly associated with the test operations around the pipeline sections being tested. (While the pipeline facilities are being pressurized and during the test all personnel not required for direct operations (check for leaks, tighten gaskets, check valve status, operating pumps, recording data, etc.) will be restricted from the area where the pipeline is being tested; • Providing and maintaining a reliable transportation and communication system during the test operations whereby all personnel directly involved in the test will be able to communicate test status or problems that develop during the test; • Checking all hoses, fittings, connectors, and valves for proper pressure rating; • Restraining and securing fill and discharge lines/hoses; and • Having their radiographic inspection subcontractor nondestructively inspect all temporary welds subject to pressure test pressure. 3.2.5 Cleaning the Pipeline Upon completion of the pipe lowering and backfilling operations for each test section of the pipeline and prior to filling and pressure testing, the Contractor will clean the pipeline by running cleaning pig(s) using compressed air to propel the pig(s). The pig(s) will be run completely through the pipeline test section. The Company's representative will be present to approve the cleanliness of the line. The Contractor will run the brush pigs and squeegees continuously through the line until all solid, dust, and mill scale is removed, unless otherwise approved by the Company's representative. Company's representative will be present for the first and last brush pig run to compare their respective conditions. No red dust will be blowing out of the line when the final brush pig is run. This will assure that all rust has been removed from the interior walls of the pipeline. Foam squeegees will be run after the final brush pig run to enhance the removal of dust mill scale. 3.2.6 Filling the Pipeline Prior to filling a test section with nitrogen, the Contractor will make a final check to verify the following: • Valve body drain plugs have been removed, carefully cleaned, taped (Teflon) and replaced; • All mainline valves are in open position; • Valves have been greased, stroked, and the packing tightened; all pipe and bolt connections are tight; • Test manifolds are properly fabricated and tested; • Pumps and compressors are in good working condition; • Instruments are ready for use (proper charts installed, ink pens filled, clocks wound, correct calibration, etc.); and • Pigs are properly installed. 3.2.7 Testing the Pipeline The official test duration will be 8 hours minimum with the pressure maintained at the minimum specified at all points in the pipeline section. The test will be accepted upon proof of no leakage. In the event of break during testing, the break will be repaired as directed by the Company and the above test repeated until a satisfactory test is obtained on the section. 3.2.8 Depressurizing the Pipeline As soon as possible, after the test has been presented by the Contractor as a successful test and accepted by the Company Testing Inspector, the pipeline will be depressurized. 3.3 RECORDS The Contractor will keep and furnish complete records of all phases of the testing program including recording charts, deadweight log, pressure, temperature (both pipe and ambient) and weather conditions, and make, style number, and conditions of all pigs used in filling the pipeline.