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S T D A P I I P E T R O R P
L L L O E N G L
L777 m 0732270 0 5 b l l b l l b L L L
m
Pressure Testing
f
Liquid
Petroleum Pipelines
PI RECOMMENDED PRACTICE 1110
FOURTH EDITION, MARCH 1997
Strategiesf i r Today s
Environm ental Partnership
American
Petroleum
Institute
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Pressure Testingof Liquid Petroleum Pipelines
1 Scope
This recomm ended practice covers the pressure testing of
new and existing liquid petroleum pipelines. It recommen ds
minimum procedures to be followed, sugg ests equipment to
be used, and points out factors to be con sidered during the
pressure esting of liquid petroleum pipelines. Th is reco m-
mendedpractice does notaddress owpressurepneumatic
testing.
This recommen ded practice suggests procedures hat are
based on sound eng inee ring udg men t, but certain govern-
mental requirements may differ from the procedures et forth
in this recomme nded practice. Suc h requirements should
be
fulfilled because this recommended practices not intended to
supersede
or
override them.
Please be advised hat hisdocument does notpreclude
requalifying a line for liquid service under the provisions of
ASME 31.8, Appendix N (as provided for
49
Code
of
Fed-
eral Regulations
195.5
(a) 1)
(I.)).
2 ReferencedPublications
Unless otherw ise specified, the m ost recent ed itions of
the following standa rds, code s, and specifications shall,
to the extent specified herein, form a part of this stan-
dard.
ASME'
B 3 1.4 LiquidTransportationSystems fo r Hydrocar-
bons Liquid Petroleum G as Anhydrous Ammo-
nia and Alcohols
D O T
Research and Special Programs Adm inistration
(Title 49 Code o FederalRegulations Part
195)
3 PressureTesting of iquid Petroleum
Pipelines
3 1EFINITION
In pressure testing, internal pressure above the normal or
maximumoperatingpressure is applied
to
asegment of
pipeline, under no-flow conditions, for a fixed period of
time. A liquid test medium is used to apply the internal pres-
sure.
American Society of Mechanical Engineers, 45
East
47th Street, New
York
New
York
O017 .
US. Department of Transportation. The Code
of
Federal Regularions is
availableromhe U S . GovernmentPrinting Office, Washington, D.C .
20402
3 2 CODE REQUIREMENTS FOR PRESSURE
TESTING
3 2 1 New Construction and the Replacement of
Existing Pipelines
Th e pressure testing of newlyconstructedpipelinesand
replaced segments of existing pipelines should be performed
in
accordan ce with ASME B3
1.4,49
Code of Federal Regu-
lations Part
195
and any other applicable governmental regu-
lations.
3 2 2 Qualification of Existing Pipelines For a
Higher Operating Pressure
The qualification of existing piping systems or an operat-
ing pressure higher than the previously established operat-
ing pressure shouldbe performed in accordance with ASM E
B31.4, 49 Code of Federal Regulations Part 195 and any
applicable governmental egulations.
3 2 3 Requalification of Existing Pipelines for
Continued Operation at the Current
Operating Pressure
The requalification of existing pipin g system s for con-
tinuedoperation at the previouslyestablishedoperating
pressure should be performed in accordance with ASME
B 3 1.4, 49 Code o Federal Regulations Part 195 and any
applicable governmental regulations.
3 3TESTMEDIUM
A p ressure test should be con duc ted with water; however,
liquid petroleum having a Reid vapor pressure' less than 7
pounds per square nchabsolute may
be
used as the est
medium
if
all of the followingconditions are met:
a. The pipeline
or
piping segm ent to be tested is not part of
an offshore pipeline or offshore piping facility.
b. Th e pipeline or piping segment to be tested is not located
where a release could adversely impact any environmentally
sensitive areas.
c. The pipeline or piping segment tobe ested (rated for
operation above
275
psig) is o utside of cities and/or other
highly populated areas.
d. Every building located outside
f
the owner's piping facility,
but within
300
feet 92 meters) of the pipeline or piping seg-
ment o
be
tested, sunoccupiedwhile he estpressure s
greater than
or
equal to a pressure that produc es a hoop stress
of 50 percent of the pecifiedminimum ield trength
(SMYS).
?Reid vapor pressure is defined
as
a liquid s true vapor pressure at 100°F.
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2
API RECOMMENDED
RACTICE
110
e. The pipeline or piping segment to be tested is kept under
regular surveillance by pipeline personnel equipped with por-
table radios
or
similar equipment to provide continuous com-
mu nicatio n with the person in charge.
f. Suitable contingency response equipment andpersonnel
for spill cleanup are strategically placed near the pipeline or
piping segment to be tested.
g. Test procedures meet all applicable local, state, or federal
government regulations.
3 4 EQUIPMENT AND MATERIALS FOR A
PRESSURE
TEST
Equipm ent for a pressure test should b e properly selected
and be
in
working order.The mea surement equipment should
be appropriate for the pressures expected du ring the pressure
test. The following equipment may be required for a pressure
test:
a. A high-volum e pump that fills the line, ensures adequate
pressure to overcome head, maintains sufficient velocity o
move debris, minimizes interfaces, ensures turbulent flow,
and keeps any pigs moving.
b. A test medium supply line filter that ensu res a clean test
medium.
c .
An injectionpump hat introduces corrosion inhibitors,
leak detection dyes or gases, or other che mica ls into the test
segment if their use is desired.
d. A meter for measuring line fill or a comparable mean s of
measuring it.
e. A variable spe ed, positive d isplace men t pum p that pres-
surizes the line to a suitable or appropriate level that exc eeds
the specified test pressure. The pump should have a known
volumeper stroke and should be equipped with a stroke
counter.
(A
constant-speed pump with a variable flow rate
control may be used in lieu of he abov e if he liquid test
medium injected into the pipeline is measured d uring pressur-
ization.)
f. A relief valve. Th is may be included to prevent overpres-
sure of the test segment during both the pressurizing activities
and the test.
g.
A
portable tank r transport into which excess test
medium can be discharged and from which m ake-up volumes
can be drawn.
h.
A
pressure sensing and d isplay device that has the pressure
range and increment divisions necessary to indicate antici-
pated test pressures.
i A deadweight teste^ or an equivalent pressure sensing
device that is capable of m easuring in increm ents of less than
or equal to one
(1)
pound per square inch 6.7 kilopascals).
The
device should have a certificate of calibration that is not
4All
references to “deadweight tester” in this document includ e m y equiva-
lent pressure sensing device.
more than one year old at the start of testing or calibrated
in
accordance with the manufacturer’s recomm endations.
j. A continuous-recording pressure measurement device
(such as achart recorder) that provides a permanent record
of
pressure versus time. This device should be calibrated imme-
diately before each use (using the dea dweight tester) or cali-
brated in accordance withhe manufacturer’s recom-
mendations.
k. A test medium temperature sensing and display instrument
that is properly calibrated to a range suitab le for anticipated
test temp erature s and can be read in increm ents of no ess
than O
1
OF (0.05”C ).
1 A continuous-recording emperature measurement device
that provides a pe rmanent record of pipeline temperature ver-
sus time.
m. Facilities that protect all instrumentation from weather
extremes.
n.
Equipm ent that indicates ambient temperature.
o. Electronic pressurehemperature monitoring and recording
systems that ssist in the ana lysis of test da ta. Such sy stems can
be used in lieu of the comp onents listed above provided that
the individual pressure sensors included in the systems have a
level of sensitivity and can be field calibratedn
a
manner simi-
lar to those instruments listedn Items a through m above.
p. Pigs, scrapers, spheres, and similar devices that clean the
test segm ent and facilitate the removal of air from the line.
q. Temporary manifolds and connections, as needed.
r. Equ ipme nt, mate rials, and fluids that are needed to intro-
duce and displace the test medium from the est segments.
s . Comm unication equipment that
is
adequate for coordinat-
ing test activities.
t. Equipment that isolates line segments for leak de tem ina -
tion and facilitate s repair.
u. Replacem ent pipe, valves, gaskets, and so forth, to replace
those that fail dur ing pressure test.
CAUTION: If freeze plugs are used to isolate line segments,
special handling techniques should be used to ensure person-
nel safety. Con sideratio n should be given to nonde structive
examination for flaws, toughness, and he ductile-to-brittle
transition temperature when selecting the joint for the freeze.
3 5 TESTPLAN
When planning a pressure test, the following factors should
be considered:
a. The maximu m operating pressure anticipated for the life
of the facility. Tests should normally be planned
so
that any-
where in the test segment the pressure level does not produc e
hoop stress near
or
above the SMYS. If lines are tested at
pressures that develop a hoop stress, based on nominal wall
thickness, near the SMYS of the pipe, special care shall be
taken to prevent the pipe from overstraining. Close examina-
tion of engineering documentation, such
as
mill test reports
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S T D = A P I / P E T R O R P L L L O E N G L L777 m 0732270 0 5 b 4 b 5 4
2 7 8
PRESSURE
TESTINGF LIQUID
ETROLEUM
PIPELINES
and field maintenance reports, can nsu re the minimu m grade
and wall thickne ss of pipe i n the seg me nt. If internal inspec-
tion tools surveys were cond ucte d, the data should be care-
fully reviewed. For tests at pressure levels near the SM YS ,
consideration should be given to keeping a pressure-volume
(P-V ) plot during pressurization o prevent yielding of the
pipe. The effects of transporting water through the pipeline
upon the oper ating and sta tic pressure profiles sho uld be con-
sidered.
b. C ompo sitions of the pipe and piping comp onents in the
test segment. Pipe and piping com pon ents should be located
by their size, wall thickness, grade type, internal design pres-
sure, and elevation profile.The comp onent hat controls max-
imum test pressure should be identified.
c. The shell pressure and flange rating and the location of all
pipeline valves, equipm ent, air vents, and other connection s
to the segment that will be exposed to the test pressure. Test
pressure shall not exceed the manu facturer’s recommended
maximum allowable test pressure.
d. The anticipated emperature of the est me dium , atmo-
sph ere, and ground and the temperature stabilization period
of the test medium. Particular care shou ld be taken to prevent
freezing of exposed iping uring oldweather.Large
am oun ts of exposed piping can result
in
large temperature-
related pressure chan ges, making a stable test difficult.
e. The est medium’s primary and makeup sources and any
inhibited or other treating requirements. State and local codes
should be reviewed to determinef regulatory requirements for
obtaining source water and for disposing of test water exist.
f. Sam pling provisions to ensure (and to docu ment) water
quality before the line is filled and again before ultimate dis-
posal occurs.
g. Location s and requireme nts for test medium disposal.
h. Profile and alignme nt drawing m aps.
i
Safety precautions and procedures for personnel who per-
form the test.
j .
A
delineation of the respo nsibilities of various personnel
in
the testing organization, especially those who prepare doc-
umentation.
k. Precaution s and proced ures to minim ize risk to the public
and he environm ent, especially when a test medium other
than water is to be used.
1
Notification of p roper au thorities, agen cies, and potential
emergency response personn el, as well
as
landowners along
the right-of-way.
m. A plan for dealing with failures, including equ ipm ent, per-
sonnel, materials, and inspection.
n. Methods for preserving the fractured surfaces on the failed
specim ens of pipe.
o.
Pressureproof test andpressure eak test acceptanc e
criteria.
p. Procedures and materials used for assisting in leak detec-
tion and locating, such as dyes or gases.
q.
Potential bleed location.
3 6
TEST
PROCEDURE
Before testing begins, a pressureest rocedure with
explanatory notes and data should be prepared. This detailed
procedure should provide the following:
a.
A
diagram indicating the length s, elevation s, and locations
of the test seg me nts, including any tested piping ma nifold s,
and set-up of test equipm ent. Locate the taps for the pressure
recording devic es on the pipeline. Do not locate the taps on r
near the high pressure
f i l l
piping. The taps sho uld be located
several feet from the high pressure pum p injection point in
order for the readings to be accurate during the pressurization
process.
b. Th e test medium to be used, fill rates, and the line f i l l vol-
umes for filling and at test pressure.
c. Methods for cleaning, decom mission ing, filling,nd
recommissioning est segments.
d. Meth ods for pressurizing the test segm ents. These meth-
ods shou ld indicate the locations of
the
injection points with
respect to reco rding locations and sho uld provide the speci-
fied minimum and maximum test pressures.
e. Methodsfor isolating the est segm ents. These metho ds
should indicate which blinds and plugs o install, valves o
remove, and cathodic rectifier systems to be de-energized.
f . The minimum test duration for test segments.
g. Methods for removing and disposingof the test medium.
h. Safety precautions and procedures.
i
An identification of and a specification or heweakest
link or
controlling component
in
the test section.
The specified est pressure s he minimum est pressure
that should be applied to the most elevated point in the test
segm ent. This elevation is not necessa rily that of the dead-
weight tester; therefore,
i t
should be corrected
for
eleva-
tion differe nce betw een the pipeline and deadw eight tester.
The minimum test pressure should be in accordance with
ASME B 3 1 4 and 49 Code
o Federal Regulations
Part 195.
A detailed an alysis of the profile to determine what the
pressures will be during the test should be performed so
that the pipeline will not be overpressu red at points that
are at ow eleva tions. Sinc e the test pump and recording
equipment are not necessarily at the highest elevation, test
personnel should be provided with precise target pressures
for the elevation at the pum p and recorders.
3 7 LINE FILL AND CLEANING
The line fill operation shouldperform wo unctions-
clean the line and introduce the necessary test me dium into
the test seg me nt. It should be noted that pigging oper ation s
will not normally remove all hydrocarbon s from the piping
segm ent. B efore the actual line filling operation, it is advis-
able to run a sizing pig, caliper or deformation
tool
inan
effort to identify any geometric abno rma lities that may exist
in
the line prior o the test. In addition to running a sizing pig,
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S T D = A P I / P E T R O RP 1 1 1 0 E N G L L777 m 0732270 0 5 b r l b 5 5 124 m
4
API
RECOMMENDEDRACTICE110
consid eration should also be given to runnin g a batchltrain of
cleaning pigs to remove sedime nts, paraffins, and so forth,
from those pipeline segments that are not under a normal pig-
ging program.
The filling operationnormally utilizes several differen t
pieces of equipm ent, including the following:
a Large volume (relative to line size) f i l l pump.
b. Filter screens, if a nonmun icipal water sup ply is used o
filter out sedim entkon tamina nts.
c. Flowmeter.
d. Filling pig(s).
e. Portable tank.
The large volume fill pump should be sized such that the
fill pigs w ill travel at a speed that will m aintain a tight fit
of the pig and, depending on the terrain, reduce the risk of
the ntroduc tion of air or anothe rcompressiblemixture
behind the
fill
pigs, thus making a quality test difficult. A
minimum of 2 to 3 mph is asuggestedstartingpoint.
Unless the line
fill
is occurring with som e form of back-
pressure, as pigs ravel down the line and down a slope, the
weight of the column of fluid could cause the pig to travel
faster than the filling o peration would allow, thus introduc-
ing air
or
gas behind the pig.
If w ater is used as the test me dium , tsquality and
sourceshould be determ ined. Water that is not free of sed-
iment and acid may injure the pipe, valves, nd equipment,
and should not be used unless it is filtered and inhibited.
The possible deleterious effect f additives or inhibitorson
the processing of liquid petroleum tobe transported should
be investigated.
A flow meter should be placed
in
the line so that one can
mo nitor and maintain the design rate of
fill.
The meter will
allow the test personnel to make adjustm ents as necessary as
pressure builds and
fill
rates drop. It also assists in matching
the actua l fill volume with the calcu lated
fill
volume.
Record the fill medium temperature prior to introduction
into the line. This w ill aid in the determination of line stabil-
ity.
Pigs or spheres may be inserted to sepa rate the test medium
from the estofhe pipeline content. Locators maybe
inserted
in
the pigs to track them during the filling process
and to ensu re hat the pigs are where they need to be.
A
portable tank is used to make up the d ifference between
the actual w ater supply and the high volume fill pumps. This
may not be necessary if the fill pum ps have a direct supply,
such as a river.
Excavated segm ents should be backfilled insofar as practi-
cable before pressurization. The sensor of the recording tem-
perature device(s) should be installed so that it is in contact
with the pipeline at apoint where it has normal cover and at a
distance far enough back from the injection point
so
that the
effect of the exposed piping and make-up injection on tem-
perature is minima l. The backfill around the reco rding tem-
perature device sensor should be tamped. Insulate, if
appropriate, the capillary lines to the temperature recorder,
and install the recorder
in
an insulated box. Large centrifugal
pumps and storage tanks will affect the emperatu re of the test
medium. The temperature ofhe uriedine should be
recorded
until
the
pressure test is completed.
3 8 CONDUCTING THE PRESSURE TEST
3 8 1ressurization
Gen erally, the filling process is o mple ted using a high vol-
ume pum p. Pressuriz ation above this point is the scope of this
section.
Note: Personnel conducting the test should m aintain continuous surveillance
over the operation to ensure that it is carefully controlled.
The pressurization of the section of pipe to be tested begins
once the segment is
full
of fluid and the appropriate measures
have been taken to bleed any and all air or gas out of that sec-
tion;
in
other words, he section ispacked. Pressurization
involves bringin g the se ction of pipe to be tested up from the
static pressure after the
fill
proce ss to the desired test pres-
sure. The following equipme nt may be necessary to comp lete
this process:
a. High pressure positive displacem ent pumps.
b. F low meter and volume accum ulator.
c. Deadw eight pressure tester.
d. Tempe rature recorder.
e. Pressure recorder.
f. Portable tank.
Pressurization of the section should occur at a controlled
rate oavoid surging the ine. Pipe connections should be
periodically checked for leaks during pressurization. The flow
rate sh ould be m onitore d and ogged orpreparationof a
pressure-volume P-V plot, if applicable. Calculations indicat-
ing the amo unt of s quee ze fluid require d to go from the fill
pressure to the test pressure should be made prior to the test
and given to test personnel. This information aids
in
deter-
mining the tightness of the segment and assists
in
determin-
ing, along with the
P-V
plot, if leaks have occurred or if the
pipe has yielded.
Once
80
to
90
percent of the test pressure is reach ed, the
rate of pressurization should be reduced, especially when the
test is at or near 1 0 0 percent SMYS. Once the desired test
pressure is reached, the equipment should be stopped and iso-
lated from th e sectio n. At th is point, prior to the start of the
test, it m ay be desirable to have a stabilization period, which
would allow both the temperature and pressure to settle.
Note that pressure charts, sensors, and displays only show
an appro xima tion of the actual pressu re. The ch arts provide
proof of the continuity of the test. The d eadweight tester or
electronic equipment provides the actual pressureo e
recorded.
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PRESSURE TESTINGF LIOUID ETROLEUMIPELINES
5
Keep safety
in
mind at ll times Pipe maintained at
high pressure is dangerous. Test personnel should stand at a
safe distance from the test section or stand so that there is
something substan tial between them and the section being
tested.
3 8 2 TheTest
Period
When he estpressure sreached,pumpingshouldstop
and
all
valves and connections to the line should be inspected
for leakage. After inspecting for leakage, test personnel
should take the time to verify that the specified test pres-
sure is being maintained and temperatures have stabilized.
Wh en this verification procedure ha s been comp leted , the
injection p um p should be isolated from the test section. Th e
test period should begin after the injection pump has been
stopped, and the system has stabilized. The duration of the
test period should be in accordance with ASME
B3 1.4
and
49
Code
o
Federal Regulations Part
195.
Pressureand emperatureshouldbecontinuouslymoni-
tored dur ing the test, and all of the pressure readings should
be ecorded.Deadweight estercomparisonswithpressure
recorder readings should be made at the beginning f the test,
periodically during the est, and at he end of he est. The
results of the deadweight tester checks and temperature read-
ings should be recorded on the pressure and temperature logs
within at least 30-minute intervals. Weather chang es, such
as
the development of rain or clouds, that could affect the pres-
sure and temperature recording charts should be documented
on
the deadweight log. The volume or pressure
of
any added
or subtracted test medium should be documented on theead-
weight log,
as
well as the emperature and pressure at hat
time and be acco unted f or in the assessment of the results of
the pressure test.
Minor or gradual pressure changes during the test can be
a
result of residual air in the segm ent, temperature effects, or
leakshrough malldefects
or
loose lange connections.
Extending the test duration can demonstrate thatair and tem-
perature effects have been accounted for.
3 8 3
Pressure
Test Records
Personnel conducting a pressure test should keep a com-
plete rec ord of the test, including de tails of the test operation
andevents such as weathervariations, est ailures,bleed-
Offs, repressurizations, and so forth. Any failures that occu r
during the test shou ld be described in this record. The record
should indicate theexact location
of
each failure, describe the
type of failureand tscause,anddescribe hemethod of
repair.Pipe, ittings, or valveshat ail nd re eplaced
should be marked with their pipeline station location and the
pressure at which they failed. When appropriate, such materi-
als should be preserved by the operator for failure analysis.
Records of pressure ests are to be maintained by the
operatoro omply with theequirements of ASME
B31.4, 49 Code of FederalRegulationsPart 195, and
all
otherapplicablegovernm ental egulations. Test records
may includ e, but are not necessarily limited to, the follow-
ing (Appendix
A
contains sample forms.):
a. Continuous pressure versus ime record with appropriate
information listed
on
it (see Figure
A-I) .
b. Continuous temperature versus time record with appropri-
ate information listed on
it
(see Figure A-2).
c. Deadw eight calibration certificate.
d. Test plan (se e
3.5).
e. Pressure test record and certification (see Figure
A-3)
that
includes the following:
1
Qualification calculations (see Figure
A-4).
2. Pressure and temperature log (see Figure A-5).
3. Record of th e failures that occu rred during the test and
the reason for the ailures (see Figure A-6).
3
Profile of the pipeline that shows the elevation and test
sites over the entir e length of the test section, if elevation
differences in the est section exceed 1 0 0 feet (30 meters).
5. A drawing of any facility piping tested and the limits of
the test. The se test records should be signed y the respon-
sible parties and retained for the ife
of
the facility
or
until
new test records supersed e them.
3 9DISPLACEMENTOFTESTMEDIUM
A carrier may choo se to displace est water with iquid
petroleum, air, or inert gas. If air or inert gas is to be used,
careful consideration must be given to the amount
of
energy
stored in the compressed gas.
Test medium may be displaced with spheres, squeegees, r
other pigging devices. When water is displaced,
it
should be
disposed of naccordancewith all applicablegovernment
environmental regulations. It should be noted, though, thatll
of the estwater may have
to
bestoreduntilpermitsare
received for ultimate d isposal. Product qualityor internal cor-
rosion con trol requirements may dictate that pipeline drying
regimen be conducted after the water
s
displaced.
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S T D I A P I P E T R O R P LLLO ENGL L 7 7 77 3 2 2 7 0 0 5 b q b 5 9 87T
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1
APIECOMMENDEDRACTICE 1110
S MPLE PRESSURE TEST
RECORD ND CERTIFIC TION
Test section
Date
~~~~ ~~ ~
2ompany System
Description rom to
New construction
Requalification Replacement or relocation
O
Pipeline O Station O
rest medium: water Other Inhibitor
Design data code:
O
831.4 B31.8 Appendix N Other
Pipe design data
Specification
Design
all
esign
eld joint
and grade
Comments
ressure
MYS
hickness
D
actoractor
~~~ ~~ ~ ~
Pressure test:
~ ~ ~~ ~~ ~
Test pressure should be as follows:
Minimum atigh point SMY Maximum at low point
o SM\
Elevations: pointigh point DWT
Qualifications:
Date of test: Duration of test
Testing and recording witnessed by Date
Company
Title
Company representative
Title
Testing pressure:
Maximum at low point for SMYS
Minimum at high point for SMYS
Qualified to operate at for SMYS
Report checked by Date
Approved by Time
Testing company
4ttached documents:
Pressure record Pressure and temperature lo
Temperature record
Test instrument calibration data Sketch or diagram
Qualification calculations
Profile Failure records
Zomments:
Notes:
OD = outside diameter,SMYS = specified minimum yield strength,MY = specified minimum yield, WT =deadweight tester.
For test sections containing more than one
ype
of pipe, the maximum test
ressure
at low point and minimum test pressure at high point and
resultingSMYS need tobe calculated for eachype of pipe.
Figure A- Sample Pressure Test Record and Certification
YRIGHT American Petroleum Institute