General requirements.

(a)No person may operate a new segment of pipeline, or return to service a segment of pipeline that has been relocated or replaced, until—#

(1)It has been tested in accordance with this subpart and § 192.619 to substantiate the maximum allowable operating pressure; and#

(2)Each potentially hazardous leak has been located and eliminated.#

(b)The test medium must be liquid, air, natural gas, or inert gas that is—#

(1)Compatible with the material of which the pipeline is constructed;#

(2)Relatively free of sedimentary materials; and#

(3)Except for natural gas, nonflammable.#

(c)Except as provided in § 192.505(a), if air, natural gas, or inert gas is used as the test medium, the following maximum hoop stress limitations apply:#

Class location Maximum hoop stress allowed as percentage of SMYS Natural gas Air or inert gas 1 80 80 2 30 75 3 30 50 4 30 40#

(d)Each joint used to tie in a test segment of pipeline is excepted from the specific test requirements of this subpart, but each non-welded joint must be leak tested at not less than its operating pressure.#

(e)If a component other than pipe is the only item being replaced or added to a pipeline, a strength test after installation is not required, if the manufacturer of the component certifies that:#

(1)The component was tested to at least the pressure required for the pipeline to which it is being added;#

(2)The component was manufactured under a quality control system that ensures that each item manufactured is at least equal in strength to a prototype and that the prototype was tested to at least the pressure required for the pipeline to which it is being added; or#

(3)The component carries a pressure rating established through applicable ASME/ANSI, Manufacturers Standardization Society of the Valve and Fittings Industry, Inc. (MSS) specifications, or by unit strength calculations as described in § 192.143.#