LOGO PROCEDURE N°001

HYDRAULIC TESTS FOR

POLYETHYLENE PIPES
Construction site:

ELABORATED REVIEWED APPROVED

REVISION HISTORY
REV. DATE REASON FOR REVIEW
 INDEX

1. Aim.

2. Documentation Reference.

3. Scope and Aspects Generals.

4. Flowchart.

5. Development.
a) Previous requirements.
b) Hydraulic Testing Phase.
c) Open Trench Hydraulic Test.
d) Covered Trench Hydraulic Test.

6. Equipment and media.

7. Security.

8. Controls.

9. Additional comments.

10. Documentation Archive.

11. Responsibilities.
 1. Aim.

The objective of this procedure is to present the general guidelines to follow to

carry out the hydraulic testing test in the Installation of HDPE pipes for Drinking Water

Networks.

The purpose of the hydraulic test is to verify that before providing service, all

components of the drinking water networks have been correctly installed and do not

present leaks. In order to guarantee the minimum useful life of 50 years.

2. Reference documentation.

• Approved plans for construction.

• Technical Specifications of the project.

• Descriptive memory.

• National Building Regulations of Peru.

• Technical Specifications for Execution of Sedapal or EPS Works.

• Technical sheets of the manufacturers of the tube to be used.

• ASTM-2164

• AWWA M-155

• Equipment calibration certificates

• Activity procedure.
3. Scope and General Aspects.

The hydraulic test for HDPE pipes in the installation of water networks is

applied in the execution of pipe and accessory installation works basically in the

drinking water lines and networks of the different Sanitation projects in our country.
 4. Flowchart.

Figure No. 1. Hydraulic test graph. Source: (Own 2020)

5. Development:

5.1 Previous requirements:

Before the start of the hydraulic test, the following requirements must be met,

under the responsibility of the Engineer:

• General:

a) Prior to testing, heat fusion joints must be completely cooled and

mechanical joints must be fully assembled with all necessary seals and

all fasteners installed and tightened.

b) Flushing may be necessary to remove system dirt and debris that could

damage valves, regulators, etc.

c) Allow the test section concrete anchors to cure until they have developed

sufficient strength to withstand the test pressure thrust forces.

d) Verify that the plugs and clamps have been correctly installed at the

beginning and end of the section to be tested.

e) Install the hydraulic test bucket at the beginning of the section and at the

bottom of the section.

f) Check the parts mentioned in Annex 33 .

g) Verify that the pressure gauges are correctly calibrated.

V Test section:

a) Testing can be performed on the entire system or on sections of the

system. The size of the test section is determined by the capacity of the

filling and pressurization equipment. The section must be filled,

pressurized, and tested within the total time allotted for testing. Teams

that have inadequate capacity may not be able to complete the test

within the allowed testing time frames. If so, use higher capacity test

equipment or test a smaller (shorter) section of the system.

V Test temperature:

a) Polyethylene piping materials are typically pressure rated at (23 C°). At

higher temperatures, reduced pressure ratings and modified test

pressures may be required. Pipe manufacturers propose in their

installation recommendations, fittings or components to assist with

elevated temperature pressure ratings.

b) It is recommended to use the following table according to the

temperature status. Preferably try to avoid high temperatures.

Table 1. Test Pressure Conversion.

 Test section ≤80(≤27)+ ≤90(≤32) ≤100(≤38) ≤110(≤43) ≤120(≤49) ≤130(≤54) ≤140(≤60)+
temperature
°F(°C)
Multiply 1.0 0.9 0.8 0.8 0.7 0.7 0.6

The maximum service temperature for performance tubing PE pressure pipes is 140°F
(60°C).
Source: (Performance Pipe 2018)

V Maximum test pressure:

a) The maximum test pressure for pressure-rated polyethylene pipe shall

not exceed 1.5 x (PD) the system design pressure when lower pressure

components or devices are not present, or have been removed or

isolated from the section. of testing. According to ASTM-2164 standard.

b) The maximum test pressure shall not exceed the pressure rating of the

lowest pressure rated component in the test section, where lower

pressure components or devices cannot be removed or isolated from the

section. The fatigue pressure of the tube and its changing dimensions

must also be avoided.

V Duration of the test:

a) The time required to pressurize, stabilize, maintain test pressure and

depressurize should not exceed 8 h.

b) If retesting is necessary, the test section should be depressurized for 8 h

before retesting.

c) Before applying pressure, examine the test equipment and all

connections to and in the test section to ensure that all are in proper
 working condition and tightly connected.

d) Before pressure is applied, insulated components or devices must be

vented to the atmosphere.

5.2 Phases of Hydraulic Tests.

a) PHASE-I

Visual Inspection: The first step is to verify the joints of the installed line

and perform a visual examination of the pipe placement in the trench.

Filling: Allows you to slowly fill in the test section. Purge all air. Take all

appropriate precautions to ensure that no air is trapped in the test section. (

Warning : Trapped air can lead to explosive, violent, and dangerous catastrophic

failure because both the pressure stress in the pipes and the energy used to

compress the trapped air are released.)

To allow air to escape from the test section, flow rates during filling should

not exceed the capacities of air release devices or other openings used to release

trapped air and consideration should be given to placing bleed valves at points.

heights of the section. To avoid or limit transient pressure surges, the filling flow

rate should not exceed the design velocity of the piping system.

Temperature equalization: Allow the test section and the test liquid to

equalize to a temperature.

b) PHASE-II

Initial expansion phase: The filling of the section must always be carried

out from the lowest point.

When the test section is completely filled and purged of air, gradually
increase the pressure in the test section to the pressure

of testing required.

If the test pressure cannot be reached, or if it takes an excessively long time

to reach the test pressure, there may be failures such as excessive leaks, tied air or

open valves, or the pressurization equipment may be inadequate for the size of the

test. test section. If such faults exist, stop pressurizing and correct them before

continuing.

c) PHASE-III

Main test phase: Reduce the test pressure with the P formula. P=1.5 x PD.

(Design pressure) but this must not exceed the PN of the pipe, maintain this

pressure for 1 hour or 30 minutes depending on what the Supervising Engineer

indicates. Do not increase pressure or add makeup water.

d) PHASE-IV

Depressurization: Depressurizes the test section by reducing pressure or

releasing test liquid at a controlled rate. Sudden depressurization can cause water

hammer.

Pass/Fail Criteria: If no visual leak is observed, and the test phase pressure

remains stable (within 5% of the test phase pressure) during the 1-h test phase

period, the indicates a passing test.

Another way to consider our test satisfactory taking into account that the

pressure time is 30 minutes is by applying the following formula:

pp
AP manometer < -5
 PP: Test Pressure.

e) PHASE-V

Retest: If retesting is necessary, depressurize the test section and correct

any faults or leaks in the section. Do not attempt to correct faults or correct leaks

while the test section is under pressure.

Verify that the tested section is not fatigued, verify the diameter and

thickness, otherwise the tested section could fail again.

system design pressure, allow the test section to “relax” for at least 8 hours

before repressurizing. After the relaxation period, repeat the initial expansion and

testing phases.
5.3 After the test

Remove temporary closure and isolation devices from the test section.

Depending on the application, it may be necessary to wash, disinfect or drain.

Regulations may restrict or require specific procedures for some post-test

procedures, such as drainage and disposal of test fluids.

a) Open Trench Hydraulic Test.

Before proceeding to fill the water lines to be tested; Both its accessories

and its fire taps must previously be anchored, the same as carrying out its first

compacted filling, only all its joints must be exposed.

During the testing process, personnel will not be allowed to remain inside the

trench, with the exception of the worker who will go down to inspect the joints,

valves, accessories, etc.

b) Hydraulic Test with Compacted Fill or Covered Trench.

The test will be carried out in a covered trench with compacted fill and

disinfection, after the Supervision or Inspection has approved the open trench test.

The test procedure will be as indicated in the previous section, with the sole

exception that it will be carried out with the trench completely filled and compacted.

The pressure and duration of the covered trench test.

To perform the hydraulic test in a covered trench, all connections of the

circuit under test must have been completed.

The trench test with compacted fill will not be authorized if the water line has

not previously satisfactorily completed the open trench test.

6. Equipment and media.

• Pressure gauges.

• Valves

• Hydraulic test bucket.

• Plugs.

• Clamps with Perforation.

7. Security.

During the execution of what is indicated in this procedure, the

following risks must be taken into account:

• Cuts on the hands.

• Blows to the head and extremities.

• Landslides.

• Falls from height and at the same level.

• Overexertion.

• Thermal Stress.

• Inhalation of dust.

• Run over.
Therefore, the use of the following protections will be mandatory:

• Protective helmets.

• Impact protection glasses.

• Breathing mask.

• Uniform.
 • Protective shoes.

• Work gloves.

• Reflective colored vests.

• Double-way mask for handling additives.

• Earmuffs or earplugs.

• Studs for placing signage.

• Signaling mesh tape.

• Traffic signals.

All crew personnel must have the respective safety elements and the

necessary equipment for handling the tubes and accessories.

Areas where there are interferences with easement crossings or others that

prevent the execution of the work must be identified; these must be reported to

social intervention.

Identify the restrictions that may arise to carry out the activities, referring to:

Field Personnel, Uniforms, PPEs, Materials, Tools, Equipment, Social Problems,

Environmental Problems, etc.

All personnel must have an induction talk from the Risk Prevention area,

a talk on Archaeological remains, a talk on first aid and administration, before

entering the work.

The condition of the tools delivered to the workers will be verified.

Take necessary measures to ensure that all parts of the section under

test are restrained against movement if a failure occurs. Such measures may

include fills, anchors or other appropriate means.

 8. Controls.

In order to carry out the control of hydraulic tests for polyethylene pipes

in the installation of water networks in the field, a protocol is proposed in which

all the data obtained and carried out will be recorded, which must have the

corresponding signatures of those who perform the test. as well as those they

supervise. As can be seen in Annex 34 and Annex 35.

9. Additional comments.

For the development of the procedure described in this section,

international installation standards were considered along with the experience

of the master executors and the procedures and information obtained from the

manufacturers of this HDPE pipe.

10. Documentation Archive.

To record hydraulic tests, it is recommended to use a database

prepared in Excel to have control of all the tests carried out.

11. Responsibilities.

The people responsible for the correct execution of this Hydraulic test are the

following:

• The Resident Engineer: He is in charge of preparing, training and verifying

the correct execution of the hydraulic test.

• The Supervising Engineer: The supervising professional is in charge of

verifying the results of the hydraulic test to determine whether the installation
of the drinking water pipes meets the installation specifications and is
suitable for putting it into service.