Pipeline Pre-Commissioning
Before a newly constructed pipeline can be commissioned and brought into service, it must undergo a series of checks to ensure it is structurally sound, leak-free, and suitable for transporting product. This crucial step, known as pipeline pre-commissioning, verifies the pipeline’s integrity, cleanliness, and readiness for operation.
Pre-commissioning is not only a best practice but also a requirement under safety regulations such as those set by the Pipeline & Hazardous Materials Safety Administration (PHMSA) in the United States, as well as international standards (API, ASME, and ISO).
What is Pipeline Pre-Commissioning?
Pipeline pre-commissioning is the process of proving that a pipeline system can safely contain and transport its intended product—whether liquid, gaseous, or multiphase hydrocarbons, water, steam, CO₂, nitrogen, or other industrial fluids.
It is the bridge between construction and commissioning (or start-up). While commissioning involves introducing the product and bringing the pipeline “live,” pre-commissioning ensures the system is clean, pressurized, and verified to operate without leaks.
Typical pre-commissioning steps include:
Cleaning – removing debris, mill scale, or corrosion using pigs, gels, or chemical cleaning.
Gauging – verifying the internal diameter and detecting restrictions.
Filling (Flooding) – introducing water or other fluids to displace air.
Hydrostatic Testing – pressurizing the pipeline above its design operating pressure to confirm strength and leak-tightness.
Dewatering & Drying – removing test water and lowering the dew point to prevent internal corrosion.
Specialized Testing – nitrogen testing, helium leak detection, vacuum drying, or pneumatic testing, depending on pipeline type.
Keep reading to learn about American Pipeline Solutions’ pre-commissioning process, when this process should occur and the types of pipes that are tested.
American Pipeline Solutions’ Pipeline Pre-Commissioning Process
At APS, we provide a full spectrum of pipeline pre-commissioning services to ensure your assets are safe and compliant before handover. Our process typically involves:
Pipeline Cleaning (Pigging)
We start by running pigs through the pipeline to remove construction debris and contaminants. This step ensures the internal bore is free from obstructions that could compromise performance.Pipeline Gauging (Caliper Pigging)
APS uses advanced caliper tools equipped with mechanical fingers or sensors to measure the internal structure and diameter, detecting dents or restrictions that may affect flow.Pipeline Integrity Testing
Hydrostatic testing is carried out to confirm the pipeline can hold pressure over a specified duration. The pipeline is filled using a fill pig propelled by water, eliminating air pockets before pressurization.Stabilization
The pipeline is pressurized (typically around 200 psi or per project specifications) and monitored until temperature and pressure equalize, preparing it for testing.Dewatering and Drying
Once testing is complete, we dewater the pipeline using compressed air and monitor pig returns. For drying, we deploy foam swabs, cleaning pigs, and desiccant dryers until the line reaches a -40° dew point.
Specialized Services
APS also offers nitrogen testing, filtration, pneumatic testing, and other custom solutions to meet project-specific requirements.
An example of an integrity test that is used on newly constructed pipelines is hydrostatic testing. Hydrostatic testing is used to determine if your pipeline’s pressure level is maintained over a specified amount of time.
Next, APS will fill and stabilize your pipeline in preparation for testing. APS’ team uses a fill pig tool propelled by a column of test water when filling your pipeline. This eliminates any air within the pipeline.
What Pipelines Need Pre-Commissioning?
Pipeline pre-commissioning is a process that is commonly used for new pipelines constructed by a utility provider. One example of a type of utility provider that utilizes pipeline pre-commissioning is a gas utility provider. When taking over ownership of a pipeline from a contractor, the utility provider must perform pre-commissioning testing before bringing the pipeline live.
APS has experience in providing all pre-commissioning services for various types of pipeline systems, including:
Newly built or constructed pipelines
New gas pipeline systems
New water and wastewater pipeline systems
Natural gas pipeline systems
Newly installed pipelines for academic campuses
This is by no means an exhaustive list of the types of pipeline systems that can receive pre-commissioning testing. Customers are welcome to contact the APS team to determine the best pre-commissioning testing process for your needs.
When is Pre-Commissioning Required?
Pre-commissioning is essential for:
Newly constructed pipelines before handover from contractor to operator.
Gas utility pipelines before initial use.
Water and wastewater systems to verify safe handling of public infrastructure.
Natural gas and hydrocarbon pipelines to prevent leaks and environmental risks.
Campus and industrial pipelines where safety and compliance are critical.
Any new or majorly modified pipeline must undergo pre-commissioning before being considered safe for operation.
Why Pipeline Pre-Commissioning Matters
The importance of pre-commissioning goes beyond regulatory compliance. A thorough process protects public safety by preventing leaks and failures, safeguards the operator’s investment by reducing corrosion risks, and ensures that the pipeline will operate at peak efficiency from day one. By addressing potential weaknesses before a line is put into service, operators minimize costly downtime and environmental risk.
Pipeline Pre-Commissioning Services at APS
American Pipeline Solutions offers a full suite of services to prepare pipelines for safe and reliable operation. These include pigging and cleaning, caliper pigging, hydrostatic testing, filling and filtration, dewatering and drying, nitrogen testing, and pneumatic or leak testing. Each service is delivered with attention to safety, precision, and cost-effectiveness, so your project is ready for seamless commissioning.
Partner with APS for Expert Pipeline Pre-Commissioning
Whether you are commissioning a natural gas line, a municipal water system, or an industrial network, APS has the knowledge, equipment, and experience to deliver results. Our team works with utility providers, contractors, and operators to ensure every pipeline is safe, compliant, and ready for service.
Does your project require pipeline pre-commissioning? Contact American Pipeline Solutions today for a reliable and cost-effective solution.
FAQs:
What is pipeline pre-commissioning?
Pipeline pre-commissioning is the process of proving that a new or modified pipeline can safely contain and transport its intended product before it’s brought into service. It bridges construction and commissioning. During pre-commissioning, the pipeline is cleaned, gauged, filled, pressure-tested, dewatered, and dried so operators can verify integrity, cleanliness, and leak-tightness in line with PHMSA and industry standards.
How is pre-commissioning different from commissioning?
Pre-commissioning prepares the pipeline for service; commissioning actually introduces the product and brings the system “live.” In pre-commissioning, APS focuses on cleaning, gauging, hydrostatic testing, dewatering, and drying to confirm the line is structurally sound and leak-free. Commissioning then follows with controlled product introduction, operational checks, and handover to normal operations.
What are the main steps in APS’s pre-commissioning process?
APS typically starts with pipeline cleaning using pigs to remove construction debris and contaminants. We then perform gauging or caliper pigging to detect restrictions, followed by hydrostatic testing with a fill pig to eliminate trapped air. After stabilization at the specified test pressure, we dewater and dry the line—often to around a -40° dew point—and apply any specialized tests such as nitrogen or pneumatic testing as required.
Which types of pipelines need pre-commissioning?
Pre-commissioning is essential for newly built or significantly modified pipelines across many sectors. This includes gas utility lines, natural gas transmission, water and wastewater systems, campus and district energy networks, and industrial or municipal infrastructure. Any pipeline that will handle hydrocarbons, water, steam, CO₂, nitrogen, or other industrial fluids should be pre-commissioned before it is considered safe for operation.
Why is pipeline pre-commissioning required by regulations?
Regulators such as PHMSA, along with standards bodies like API, ASME, and ISO, require that new pipelines be proven safe and leak-free before entering service. Pre-commissioning demonstrates that the system can withstand the specified test pressure, hold that pressure over time, and operate without leaks. This protects public safety, reduces environmental risk, and provides documented evidence of compliance for operators and utility providers.
What test pressures and dew points are typical in APS projects?
Test pressures and dew-point targets are set per project specifications, design codes, and operator requirements. APS often performs hydrostatic testing at pressures above normal operating levels to prove strength and leak-tightness. After testing, we dewater and dry the line using foam swabs, cleaning pigs, and desiccant dryers until it reaches the agreed dew point—commonly around -40°—to minimize the risk of internal corrosion.
Can APS provide specialized pre-commissioning tests like nitrogen or pneumatic testing?
Yes. In addition to standard cleaning, gauging, hydrostatic testing, dewatering, and drying, APS provides specialized services such as nitrogen testing, filtration, pneumatic testing, and other custom procedures. These methods are selected based on pipeline design, product, location, and safety requirements, allowing us to tailor the pre-commissioning program to each project’s needs.
Who typically hires APS for pipeline pre-commissioning services?
APS works with utility providers, contractors, and asset operators responsible for bringing new pipelines into service. Gas utilities, municipalities, industrial facility owners, and campus infrastructure managers rely on APS to deliver pre-commissioning programs that are safe, compliant, and well-documented, so they can accept ownership of the line with confidence.
How does pre-commissioning help reduce future downtime and costs?
A thorough pre-commissioning program identifies leaks, restrictions, and weaknesses before the pipeline is placed into service. By cleaning the line, confirming wall strength, and achieving a low dew point, operators reduce corrosion risk, improve initial flow performance, and avoid early failures. That upfront rigor helps minimize unplanned outages, emergency repairs, and environmental incidents over the life of the asset.
Does your newly constructed pipeline need pipeline pre-commissioning testing?
Contact American Pipeline Solutions’ expert team to receive a timely and cost-effective solution today.
