U. S.

Coast Guard Pipeline Testing Guide

August 1994
 
 
I.          JURISDICTION FOR MARINE TRANSPORTATION RELATED PIPELINE AT
FACILITIES HANDLING OIL AND HAZARDOUS MATERIAL IN BULK
 
Under a 1971 Memorandum of Understanding (MOU) between the Department of
Transportation (DOT) and the Environmental Protection Agency (EPA), implementing
Section 311(j) (1) (c) of the Federal Water Pollution Control Act, responsibility for marine
transportation related facilities (MTR) was delegated to the Coast Guard.  The Coast
Guard is required to ensure testing is conducted by the facility along the entire marine
transfer pipe system.  These test can either be conducted by facility personnel or a third
party entity.  The goal of our pipeline testing policy is to identify and eliminate pollution
risks from transfer piping.  Coast Guard’s policy on the extent of pipeline testing is as
follows.
 
A.        For MTR co-located with non-transportation related facilities protected by Spill    
Prevention Control and Countermeasure (SPCC) Plans required by the EPA:
 
Oil transfer piping systems will be tested from the dock loading arm or manifold
of the Coast Guard inspected MTR up to the first valve encountered after the
pipe enters the SPCC area required under 40 CFR 112.7(c).
 
If the EPA expands a facility’s SPCC containment area, then the extent of pipeline
testing monitored by the Coast Guard should be adjusted accordingly.
 
NOTE:  The areas controlled by SPCC Plans provide pollution prevention for transfer
piping located inside those areas.  The EPA has not yet established a similar pollution
prevention program for hazardous liquid storage facilities.  Currently, many bulk liquid
facilities handling both oil and hazardous materials are already afforded adequate
protection form hazardous material pollution by virtue of an existing SPCC Plan. 
However, some bulk hazardous liquid MTR may not be protected by an SPCC Plan, or
the SPCC Plan may not prevent pollution from certain types of bulk liquid hazardous
materials transferred at the facility.
 
B.        For MTR co-located with non-transportation related facilities not protected by
SPCC Plans required by the US EPA:
 
Piping systems will be tested from the dock loading  arm or manifold of the
Coast Guard inspected marine transportation related facility up to the first
valve encountered after the pipe enters the secondary containment
around the bulk storage tank required in 40 CFR 112.7 (e) (2).
 
 
If conformance with this policy is not economically or physically practical for a facility
without SPCC containment, the facility can submit an application for alternative testing
to Commandant (G-MEP-1), via the COTP, per 33 CFR 154.108.
 
II.         STATIC LIQUID TESTING REQUIREMENTS FOR MARINE
TRANSPORTATION RELATED PIPELINE HANDLING OIL AND HAZARDOUS
MATERIAL IN BULK
 
The static liquid pressure test is required for marine transportation related pipelines
handling oil and hazardous material in bulk to ensure their integrity and safety.  It is a
gross test that provides general information of the pipelines susceptibility to leakage and
its overall strength.  The following guidelines contain minimum requirements for
conducting the static liquid test.  Refer to 33 CFR 156.170 for other testing
requirements.
 
The static liquid test is normally performed using water.  However, other test mediums
can be used without requesting an alternative from the COTP.
 
 
REQUIREMENTS FOR THE STATIC LIQUID TEST
 
(1)       Test pressure and frequency
 
A.        33 CFR 156.170 requires that transfer pipeline be tested annually by the
facility at 1½ times the Maximum Allowable Working Pressure (MAWP). 
The MAWP is the designed working pressure of the pipe.  Unlike
transfer hoses there is no established minimum MAWP for transfer
pipeline.  The operating pressure (i.e. the upper pressure at which the
facility decides to limit their operations) may be substituted for the MAWP
if the facility operator can demonstrate to the COTP’s satisfaction that
mechanical safeguards, such as relief valves or pump controls, are in
place to limit pump pressure to a value below the MAWP.
 
B.        At no time during the static liquid test may any part of the piping system
be subjected to a stress greater that 90 percent of its yield strength at test
temperature.
 
C.        The test pressure must not exceed the maximum rated pressure of any
component in the system.
 
(2)       Test medium
 
A.        If the liquid is flammable, its flash point shall be at least 49°c (120°F).
 
B.        The test medium must be compatible with the cargo handled and the
piping material.
 
 C.        The temperature of the test medium must be compatible with the normal
temperatures of the products transferred under the given ambient
conditions.
 
D.        Consideration should be given to the toxicity of the liquid, its potential for
pollution if spilled, and the safety of personnel in the vicinity.
 
(3)       Test criteria
 
A.        For pipe that can be visually examined, the test pressure shall be
maintained for a minimum of 10 minutes and held for such additional time
as may be necessary to conduct the examination for leakage.
 
B.        For pipe that is buried or insulated and cannot be visually examined, the
pressure shall be maintained for 1 hour.
 
C.        Insure all items (i.e. valves, pumps, etc.) that should not be subjected to
the test pressure have been disconnected or isolated by blanking or other
suitable means.
 
D.        If the testing medium in the system is subject to thermal expansion during
the test, provisions shall be made for immediate safe relief of excess
pressure.  Effects of temperature changes shall be taken into account
when interpretations are made of recorded test pressures.
 
E.        Immediately after completion of the static liquid test, it is important in cold
weather that the lines, valves, and fittings be drained completely of liquid
prone to freezing to avoid damage to the pipeline.
 
(4)       Acceptance criteria
 
A.        The pipe and all joint sections must maintain the test pressure for the
duration of the test without damage or permanent distortion.
 
B.        No leakage is allowed during the static leak test.  For pipe that can be
visually examined, leakage should be physically checked.
 
C.        Should a leak occur during the test, the line section or component part
shall be repaired or replaced to the satisfaction of the COTP and re-
tested.
 
ALTERNATIVE TESTING FOR MTR RELATED PIPELINE AT FACILITIES
HANDLING OIL AND HAZARDOUS MATERIAL IN BULK
 
The COTP may consider and approve alternative procedures, methods, or equipment
standards to be used by the facility operator under 33 CFR 156.107.  All testing
methods, other than a static liquid test, shall be considered an alternative.  Criteria have
been established for evaluating the need for an alternative testing method.  If it is
determined that a testing alternative is appropriate then it may be approved by the
COTP, without further review, if the plan for using that method is consistent with this
policy.  All other requests should be forwarded the Commandant (G-MEP) for review
with a recommendation from the COTP.
 
All alternatives for pipeline testing must offer an equivalent level of safety and protection
from pollution to substitute to the required static liquid test.  Alternatives should not be
approved if testing is for initial installation or following major alterations to the system.
 
Alternatives should only be approved when compliance with static liquid test
requirements would be economically or physically impractical.  Alternatives have been
approved when:
 
        the length of transfer system makes the costs of conducting the test and/or
disposing of contaminated liquid excessive;
 
        the product medium is reactive with water and testing would risk harm to
personnel and property; or
 
        exclusive lines used to transfer hazardous materials would be contaminated
by the test medium. 
 
Once it has been determined that an alternative testing procedure may be warranted,
the following information should be considered in evaluating the request.
 
1.         The age of the piping and dimensions of the system.
 
2.         The commodities transferred and the system’s operations.
 
3.         The history of the system including the system’s compliance performance and
past discharges and releases.
 
4.         Access to transfer system:  whether system is buried, elevated, insulted, etc.
 
5.         The presence of any relief valves in the system and their routine maintenance
schedule.
 
6.         Proximity to environmentally or economically sensitive or hazardous areas.
 
7.         The date of the last static liquid test.
 
8.         The system Maximum Allowable Working Pressure (MAWP), system operating
pressure, and relief valve settings.
 
NOTE:  Specific procedures should be included in the Facility Operations Manual. 
Alternatives can be withdrawn at any time if the COTP believes that safety and pollution
prevention requirements are not adequately met.
 
PNEUMATIC PRESSURE TESTING ALTERNATIVE FOR TRANSFER PIPELINES
 
Procedures for conducting an alternative testing method for pneumatic pressure testing
have been established and should be referenced by the COTP in evaluating such
requests.
 
Unlike the static liquid pressure test, pneumatic pressure testing involves the
compression of a gas.  This compressed gas may constitute an enormous amount of
stored energy which, in the event of a failure, releases suddenly with tremendous force. 
Special precautions to ensure the safety of personnel and property must be taken
whenever a pneumatic pressure test is conducted.
 
The pneumatic test can be an acceptable alternative for testing pipeline facilities
provided the following minimum safety precautions are taken:
 
(1)       Test pressure and duration
 
A.        IF OPERATING PRESSURE > 25% MAWP (DESIGN PRESSURE OF
PIPE)
 
For pipe that can be visually examined, the pneumatic test pressure must
be maintained at 1.25 times the MAWP for a minimum of 10 minutes and
then reduced to 700 kpa (100 psi) or the operating pressure (ex. relief
valve setting), whichever is less for such additional time as may be
necessary to conduct the examination for leaks.
 
For pipe that cannot be visually examined, the pneumatic test pressure
must be maintained at 1.25 times the MAWP for 10 minutes then followed
by a reduced pressure leak test equivalent to not less than 1.1 times the
MAWP for not less that 1 hour.
 
B.        IF OPERATING PRESSURE < 25% MAWP (DESIGN PRESSURE OF
PIPE)
 
For pipe that can be visually examined, the pneumatic test pressure must
be maintained at 700 kpa (100psi) or .25 times the MAWP, whichever is
less for a minimum of 10 minutes and for such additional time as may be
necessary to conduct the examination for leakage.
 
For pipe that cannot be visually examined, the pneumatic test pressure
must be maintained at 700 kpa (100 psi) for .25 times the MAWP,
whichever is less, for a minimum of 1 hour.
 
(2)       Test medium
 
The gas used as test fluid, if not dry air, shall be non-flammable, non-toxic and
compatible with any cargo residue in the pipe material.  The temperature of the gas
must be compatible with the pipe material.
 
(3)       Other considerations
 
A.        For pipe that can be visually examined, the test equipment must be
examined before pressure is applied to ensure that it is tight and that all
items that should not be subjected to the test pressure have been
disconnected or isolated by valves or other suitable means.
 
B.        The pressure in the system must gradually be increased to not more than
one-half of the test pressure after which the pressure is increased in steps
of approximately one tenth of the test pressure until the required test
pressure has been reached.
 
C.        A safety zone, in accordance with local code, should be established
around the pipe and should allow only essential personnel to enter  the
zone for purposes of conducting the test or examining the pipe for leaks.
 
D.        If the testing medium in the system is subject to thermal expansion during
the test, provisions shall be made for the immediate safe relief of excess
pressure.  Effects of temperature changes shall be taken into account
when interpretations are made of recorded test pressures.
 
(4)       Acceptance criteria
 
A.        The pipe must maintain the test pressure for the duration of the test
without damage or permanent distortion. 
 
B.        No leakage is allowed during the leak test.  For pipe that can be visually
examined, leakage should be checked by the use of a reliable method
such as with a liquid soap solution.
 
C.        Should a leak occur during the test, the line section or component part
shall be repaired or replaced and re-tested.
 
HAZARDOUS MATERIALS:  Pipelines must be purged of hazardous material products
before testing to the extent that a material failure or leakage during the test will not
create a hazard.
 
NOTE:  A professional engineer may certify the results of tests that meets Coast Guard
pneumatic testing requirements.
 
III.        TESTING REQUIREMENTS FOR TRANSFER HOSES
 
The hose that runs between the facility’s manifold and the vessel’s deck manifold is
separate and distinct from the transfer pipe system.   The following guidelines contain
minimum requirements for testing transfer hoses.  These tests are to be done annually
by the facility.  Refer to 33 CFR 156.170 for other testing requirements.
 
Alternative testing methods are not normally necessary since the hose can be removed
for testing.  Any alternative, other than that pre-established by this policy for testing
transfer hoses should be referred to G-MEP with a recommendation from the COTP.
 
The static liquid test is normally performed using water.  However, other test mediums
can be used without requesting an alternative from the COTP.
 
REQUIREMENTS FOR TESTING HOSES USED UNDER PRESSURE
 
(1)       Test pressure
 
Hoses used under pressure must be inspected annually at 1½ the Maximum Allowable
Working Pressure (MAWP), but not less than 1550 kPa (@225 psi).   This figure
represents 1½ times the minimum MAWP of 1040 kPa (@150 psi), required for facility
hose assemblies under 33 CFR 154.500.
 
Note:  At no time should the hose be subjected to a stress greater than 90% the yield
strength at test temperature.
 
(2)       Test medium
 
A.        If the liquid is flammable, its flash point shall be at least 49°c (120°f).
 
B.        The test medium must be compatible with the cargoes handled and
transfer hose tube as recommended by the hose manufacturer.
 
C.        The temperature of the test medium must be compatible with the normal
temperatures of the products transferred under the given ambient
conditions.
 
D.        Consideration should be given to the toxicity of the liquid, its potential for
pollution if spilled, and the safety of personnel in the vicinity.
 
(3)       Test duration
 
Pressure shall be continuously maintained for a minimum time of 10 minutes and held
for such time as may be necessary to conduct the examination for leakage.
 
(4)       Acceptance criteria
 
A.        The hose must maintain the test pressure for the duration of the test
without damage or permanent distortion.
 
B.        No leakage is allowed during the test.
 
ALTERNATIVE TESTING METHOD FOR HOSES USED EXCLUSIVELY IN GRAVITY
TRANSFERS
 
Alternative testing methods are not normally necessary since the hose can be removed
for testing.  Any alternative, other than that established by this policy for testing transfer
hoses should be referred to G-MEP with a recommendation from the COTP.
 
Where transfers are conducted by a gravity method, an alternative testing pressure to
33 CFR 154.500 (b) can be used for the hose that runs between the facility’s manifold
and the vessel’s deck manifold if the hose is permanently attached to the facility.  For
the purpose of the test, a MAWP determined by an operating pressure less that the 150
psi Maximum Allowable Working Pressure (MAWP) is acceptable provided the following
conditions are met:
 
(1)       The hose is labeled “GRAVITY ONLY”.
 
(2)       The hose is maintained at a fixed operating pressure (ex. relief valve setting of
the piping).
 
(3)       The hose is tested annually at 1.5 times the maximum operating pressure.
 
(4)       The material condition of the hose is inspected annually.
 
(5)       The alternative is only granted for those hoses used to transfer product from a
facility to a vessel where no pumps are connected during the transfer.
 
(6)       If the components that comprise the transfer system are changed, the alternative
is rescinded and a new request must be made.
 
(7)       All other requirements for testing pressure hoses apply.