Speeding up Hydrotesting of Pipeline HDD Sections utilising GripTight Max® Test Plugs
Discover how GripTight® Test Plugs eliminated welded end caps, reduced hydrotest time by up to 95%, and improved safety on a Gold Fields pipeline project.
Prior to installing fabricated pipeline sections beneath a road crossing, the client required hydrostatic testing to 14,295 kPa. Traditionally this would involve welding temporary end caps onto each spool before testing and then cutting them off afterwards. This approach introduced: Hot work permits Welding and cutting activities Additional labour Longer schedules Rework to prepare the pipe after testing Because the pipe had already been fabricated to its final dimensions with no green allowance, a faster, non-destructive testing solution was required
Our Solution
PipeServ supplied EST Group GripTight® Test Plugs to perform pressure testing directly from the open pipe ends. Grip Tight Test Plugs create a mechanical seal inside the pipe, allowing rapid hydrotesting without welding temporary end caps. This enabled the client to perfrom the hydrotestign ahead of schedule as well as freeing up their welders to focus on the permanent field welds
Results
The project demonstrated substantial productivity improvements over welded end caps. Key outcomes included: Up to 95% reduction in testing time Elimination of welded end caps No post-test cutting or pipe preparation Increased daily testing capacity Reusable equipment that paid for itself after approximately eight tests Significant labour savings with some applications saving more than 50 labour hours per pipe end Reduced project schedules by over seven days on larger testing programs.
Frequently Asked Questions
What are GripTight Max® Test Plugs used for?
GripTight® Test Plugs provide a fast, safe and reusable solution for hydrotesting pipelines, process piping, pressure vessels and fabricated spools. By sealing from the inside of the pipe, they eliminate the need to weld temporary end caps, significantly reducing labour, project schedules and hot work requirements
Can GripTight Max® Test Plugs be used on Horizontal Directional Drilling (HDD) pipeline sections?
Yes. GripTight Max® Test Plugs are ideal for hydrotesting HDD pipeline sections before pullback beneath roads, railways, rivers and other crossings. Pre-testing the pipeline provides confidence that the welds and fabrication are leak-free before the pipeline is installed, avoiding costly excavation or rework once the crossing has been completed.
How can GripTight Max® Test Plugs help keep pipeline construction projects on schedule?
GripTight Max® Test Plugs allow pipeline construction and project managers to complete hydrotesting without welding temporary end caps onto every spool or pipeline section. By eliminating hot work, valuable welding resources can remain focused on critical construction activities rather than temporary testing preparations. This can significantly reduce project schedules, increase the number of test packages completed each day, and help bring commissioning dates forward. GripTight® Test Plugs are particularly beneficial for: Horizontal Directional Drilling (HDD) pipeline sections prior to pullback. Valve assemblies with temporary pup pieces for factory or site acceptance testing. Emergency pipeline repairs where replacement pipe sections require rapid hydrotesting before returning the asset to service. Pipeline fabrication yards looking to maximise productivity and reduce labour costs. By freeing up skilled welders for permanent construction work, contractors can improve resource utilisation while reducing the overall cost and duration of hydrotesting operations.
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