(a) Steel pipelines to operate at 30 percent or more of SMYS.
(1) Except for service lines, each segment of a steel pipeline that is to operate at a hoop stress of 30 percent or more SMYS must be strength tested in accordance with this subsection to substantiate the proposed maximum operating pressure. In addition, if there is a building intended for human occupancy within 300 feet of a pipeline, a segment of pipeline not less than 600 feet long must be hydrostatic tested to a test pressure of at least 125 percent of maximum operating pressure.
(2) Except as provided in subsection (a)(3) of this section, the strength test must be conducted by maintaining the pressure at or above the test pressure for at least 6 hours.
(3) For fabricated units, components, and short sections of pipe for which a post installation test is impractical, a pre-installation strength test must be conducted by maintaining the pressure at or above the test pressure for at least 4 hours.
(b) Pipelines to operate at hoop stress less than 30 percent of SMYS and at or above 100 psi.
(1) The pipeline operator shall use a test procedure that will ensure discovery of all potentially hazardous leaks in the segment being tested.
(2) If, during the test, the segment is to stressed to 20 percent or more of SMYS and natural gas, inert gas, or air is the test medium—
(A) A leak test must be made at a pressure between 100 p.s.i. (689 kpa) gage and the pressure required to produce a hoop stress of 20 percent of SMYS; or
(B) The line must be walked to check for leaks while the hoop stress is held at approximately 20 percent of SMYS.
(4) During testing the pressure must be maintained at or above the test pressure for at least 1 hour.
(c) Pipelines to operate below 100 p.s.i. (689 kpa) gage.
(1) Except for service lines and plastic pipelines, each segment of a pipeline to be operated below 100 p.s.i (689 kpa) gage must be leak tested in accordance with the following:
(A) The test procedure used must ensure discovery of all potentially hazardous leaks in the segment being tested.
(B) Each main that is to be operated at less than 1 p.s.i. (6.9 kpa) gage must be tested to at least 10 p.s.i. (69kpa) gage and each main to be operated at or above 1 p.s.i. (6.9 kpa) gage must be tested to at least 90 p.s.i (621 kpa) gage.
(d) Plastic pipelines.
(1) Each segment of a plastic pipeline must be tested in accordance with this subsection.
(2) The test procedure must insure discovery of all potentially hazardous leaks in the segment being tested.
(3) The test pressure must be at least 150 percent of the maximum operating pressure or 50 p.s.i. (345 kPa) gage, whichever is greater. However, the maximum test pressure may not be more than three times the pressure determined under 49 CFR 192.121, which is hereby incorporated by reference, and at a temperature not less than the pipe temperature during the test.
(4) During the test, the temperature of thermoplastic material may not be more than 100 deg. F (38 deg. C), or the temperature at which the material’s long term hydrostatic strength has been determined under the listed specification, whichever is greater.
(e) Service lines.
(1) Each segment of a service line (other than plastic) must be leak tested in accordance with this section before being placed in service. If feasible, the service line connection to the main must be included in the test; if not feasible, it must be given a leakage test at the operating pressure when placed in service.
(2) Each segment of a service line (other than plastic) intended to be operated at a pressure of at least 1 p.s.i (276 kPa) gage but not more than 40 p.s.i (276 kPa) gage must be given a leak test at a pressure of not less than 50 p.s.i (345 kPa) gage.
(3) Each segment of a service line (other than plastic) intended to be operated at pressures of more than 40 p.s.i (276 kPa) gage must be tested to at least 90 p.s.i (621 kPa) gage, except that each segment of a steel service line stressed to 20 percent or more of SMYS must be tested in accordance with paragraph (b) of this section.
(f) Records. Each operator shall make, and retain for the useful life of the pipeline, a record of each test performed under paragraphs (a) and (b) of this section. The record must contain at least the following information:
(1) The operator’s name, the name of the operator’s employee responsible for making the test record, and the name of any test company used.
(2) Test medium used.
(3) Test pressure.
(4) Test duration.
(5) Pressure recording charts, or other record of pressure readings.
(6) Elevation variations, whenever significant for the particular test.
(7) Leaks and failures noted and their disposition.History: Rule 02-01, eff 30 Aug 01.