GERMAN ATV RULES AND STANDARDS

W A S T E W A T E R W A S T E

ADVISORY LEAFLET ATV-M 143E Inspection, Repair, Rehabilitation and Replacement of Sewers and Drains
Part 6: Leak Testing of Existing, Earth Covered Sewers and Drains and Shafts Using Water, Air Overpressure and Vacuum June 1998 ISBN 3-934984-43-6

Marketing: Gesellschaft zur Frderung der Abwassertechnik e.V. (GFA) Theodor-Heu-Allee 17 D-53773 Hennef Postfach 11 65, 53758 Hennef

ATV-M 143E, Part 6

The ATV Working Group 1.5.4 "Rehabilitation and Renewal of Drains and Sewers", which has prepared this Advisory Leaflet, has the following members: Univ.-Prof. Dr.-Ing. D. Stein, Bochum (Chairman) Dipl.-Ing. H. Adler, Kln Dr.-Ing. H. Beyert, Aachen Dipl.-Ing. D. Blome, Bielefeld Dipl.-Ing. H. Brochier, Mnchen Dipl.-Ing. B. Chwastek, Witten Dr.-Ing. P. Drewniok, Leipzig Dipl.-Ing. W. Drbeck, Ludwigshafen Dipl.-Ing. Fischer, Bonn Dipl.-Ing. K.-H. Flick, Kln Dipl.-Ing. V. Holzhausen, Frankfurt/Main Dipl.-Ing. F. Hoppe, Hamburg Dipl.-Ing. H.-J. John, Hamburg Dipl.-Ing. G. Koch, Stuttgart Dipl.-Ing. U. Kusche, Vreden Dipl.-Kfm. H. Mller, Schieder-Schwalenberg Dipl.-Ing. G. Niedre, Bonn Dipl.-Ing. W. Reinhard, Darmstadt Dipl.-Ing. U. Schulz, Brggen Dipl.-Ing. R. Siebert, Oststeinbek Prof. Dr.-Ing. V. Wagner, Neubrandenburg Collaborated as guests: Dr.-Ing. O. Kaufmann, Bochum Dipl.-Ing. (FH) H. Loy, Mnchen

All rights, in particular those of translation into other languages, are reserved. No part of this Advisory Leaflet may be reproduced in any form by photocopy, microfilm or any other process or transferred or translated into a language usable in machines, in particular data processing machines, without the written approval of the publisher. Gesellschaft zur Frderung der Abwassertechnik e.V. (GFA), Hennef 1998 Produced by: J. F. CARTHAUS, Bonn

Contents June 1998

ATV-M 143E, Part 6

Notes for users 1. 2. 3. 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 4. 4.1 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.3 4.3.1 4.3.2 5. 5.1 5.2 5.2.1 5.2.2 5.3 5.4 6. 7. 7.1 7.2 8. 8.1 8.1.1 8.1.2 8.1.3 8.1.4 8.2 8.3 Preamble Area of application Preparatory measures Planning documents Accessibility Cleaning Verification of the tightness of the test facility Safety of the receiving water Protective measures Traffic regulation TV surveillance Requirements on the equipment to be employed Equipment Air overpressure and vacuum testing Shut-off elements Compressor or vacuum pump Charging device Pressure measurement device Water pressure test Shut-off elements Gravity tank Execution of leak testing Installation of shut-off elements Leak testing using air Testing using overpressure Testing using vacuum Leak testing using water Removal of the shut-off elements Requirements on the personnel employed Documentation General Test record Tightness criteria Tightness criteria for the leak test by reach or section Water pressure testing Air overpressure testing Vacuum pressure testing Requisite test times for air overpressure and vacuum testing Tightness criteria with the testing of pipe connections (sleeve testing) using air overpressure Shaft/chamber testing 4 4 4 5 5 5 5 5 5 5 5 5 6 6 6 6 7 7 7 7 7 7 7 8 8 8 9 9 9 9 9 9 10 10 10 10 11 11 11 11 12 13 14 15 16

Appendix 1: Model record of leak testing by reach Appendix 2: Sample record of sleeve testing Appendix 3: Illustrative determination of the requisite test times with sleeve testing Literature

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Notes for Users

This ATV Standard is the result of honorary, technical-scientific/economic collaboration which has been achieved in accordance with the principles applicable for this (statutes, rules of procedure of the ATV and ATV Standard ATV-A 400). For this, according to precedents, there exists an actual presumption that it is textually and technically correct and also generally recognised. The application of this Standard is open to everyone. However, an obligation for application can arise from legal or administrative regulations, a contract or other legal reason. This Standard is an important, however, not the sole source of information for correct solutions. With its application no one avoids responsibility for his own action or for the correct application in specific cases; this applies in particular for the correct handling of the margins described in the Standard.

1.

Preamble

The assessment of the condition of drains and sewers, and of possible hazard potential due to damage, also demands the verification of tightness. Optical inspection (for this see ATV Advisory Leaflet M-143, Part 2 [1] can provide such information to a limited degree only. Thus visible damage does not always imply unsatisfactory tightness. On the other hand, leakage points, in particular in the area of pipe connections, are barely identifiable visibly. For the leak testing of newly produced or rehabilitated drains and sewers there are standardised regulations available (e.g. DIN 1986, Part 1 (06/88) [2], DIN EN 752, Part 5 [3] or DIN EN 1610 [4]). Nevertheless, leak tests on existing drains and sewers, beyond optical inspection, are required both in water laws and wastewater self monitoring regulations of individual German Federal States as well as in the ATV Standard A-142 [5]. This Advisory Leaflet lays down requirements for leak tests as repeat testing on existing earth covered drains and sewers and shafts using water and air as test medium.

2.

Area of Application

This Advisory Leaflet, together with the Advisory Leaflets ATV M-143, Part 1 [6] and Part 2 [1], applies for the leak testing of existing drains and sewers, including shafts, operated as gravity pipelines. Leak tests must be carried out on drains and sewers in water catchment areas and on such on which appropriate requirements in laws or surveillance regulations of the German Federal Republic, German Federal States and communities are placed.

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3.
3.1

Preparatory Measures
Planning Documents

Sufficient planning documents are to be made available for the execution of leak testing. From these the following must be particularly visible: site of application, position, type, scope and regulatory characteristics (e.g. reach and/or shaft numbers) of the object to be tested, possibilities for entry and escape. Attention is to be drawn to particular hazards, e.g. danger of collapse, sewer atmosphere, wastewater composition, pump surges. 3.2 Accessibility

The accessibility of the entrances is to be checked and secured for the duration of the testing. 3.3 Cleaning

The test object must be cleaned in order to facilitate the secure positioning of the shut-off elements and the problem-free execution of the leak testing. With this the cleaning of the contact surfaces between the shut-off element and the sewer wall is particularly significant. 3.4 Verification of the Tightness of the Test Facility

Before carrying out the leak test the tightness of the test facility must be verified and recorded. 3.5 Security of the Receiving Waters

The test object must be free of wastewater for the duration of the leak test. This can, for example, be achieved by diversion, temporary backing-up or by pump over. Wit pint tests (sleeve tests) the employment of equipment with a passage of a limited wastewater flow can be permitted. 3.6 Protective Measures

Appropriate measures are to be taken for the determination and avoidance of a potentially explosive atmosphere in the test object. 3.7 Traffic Regulation

Suitable measures are to be taken, in agreement with the road traffic authorities, for the regulation, safeguarding and stoppage of traffic. 3.8 TV Surveillance

With sleeve testing and leak tests by section (e.g. between two connections) in non-manaccessible drains and sewers the exact positioning of the shut-off elements must take place under TV surveillance.

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4.
4.1

Requirements on the Equipment to be Employed

Equipment

The following equipment is required for the execution of leak tests using air overpressure or vacuum: shut-off elements, compressor, condenser or vacuum pump, charging device incl. pressure reduction valve and/or electronic pressure cut-off, pressure measurement device, facility for recording and archiving measurement data.

To carry out water pressure testing a gravity tank is necessary. All items of equipment must conform with regulations in accordance with VDE and DIN as well as with the (German) Accident Prevention Regulations (UVV). 4.2 4.2.1 Air Overpressure and Vacuum Testing Shut-off Elements

Shut-off elements must be robust and employed in accordance with the area of application. They are to be marked by the manufacturer with a permanent type plate on which the following details must be clearly legible: manufacturer, type, year of manufacture, closable pipe diameter or pipe diameter range, maximum operating pressure (charging pressure), maximum permitted test pressure dependent on the test medium employed, permitted test medium.

The equipment is to be stored carefully, protected from damage and maintained regularly. A record is to be kept of the maintenance tasks carried out. The monitoring of the equipment for its employment in accordance with its intended use must be possible by the construction management. The shut-off elements are to be provided with a clear operating instruction which must be visible on the site. Shut-off elements with test marks (e.g. ET for Eurotest) are to be checked by an independent test centre for work safety. The sealing function in the contact area between the pipe walls and the shut-off elements must remain safely maintained for every test pressure and with every test medium used (water, air overpressure or vacuum). Special sleeve testing equipment is to be used for sleeve tests. With the employment of combined test and injection packers, which, for example, are applied to correct locally limited leakages, the requirements of sleeve test equipment must suffice for the leak testing. The suitability of the combined test and injection packer as well as the tightness criteria (see Sect. 8.2) are to be verified. June 1998

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4.2.2 Compressor or Vacuum pump The necessary test pressure can be produced by a commercial, sufficiently dimensioned compressor or an appropriate vacuum pump. 4.2.3 Charging Device

The charging device must consist of a safety valve, manometer to monitor the pressure, pressure regulator and charging hose. On achieving the test pressure the connection of the test space to the pressure tank or to the pump is to be disconnected. Pressure reduction valves and pressure controls are to be integrated into the charger together with a safety switch (e.g. a dead man's switch), in order to prevent exceeding the test pressure. 4.2.4 Pressure Measurement Device

A high-resolution, electronic precision manometer (e.g. absolute pressure manometer) with a maximum measurement deviation of 2 mbar is to be used. Each piece of equipment is to be checked metrologically each year. The result of this test is to be documented on the equipment. 4.3 4.3.1 Water Pressure Test Shut-off Elements

With regard to the shut-off elements the details of Sect. 4.2.1. apply analogously. With the water pressure test the test object is to be filled from the lowest point of the pipeline. A ventilation opening, which has at least the same cross-section as the charging pipeline, is to be located on the shut-off element at the high point of the pipeline. 4.3.2 Gravity Tank

With a water pressure test the test object may have no connection to a pipeline or pump subjected to overpressure. The filling with water and the achievement of the required test pressure are to take place via a gravity tank.

Execution of the Leak Test

The leak test can be carried out by reach, i.e. from shaft to shaft, by section (e.g. between two laterals) or at a point on individual pipe connections. A test counts as successful if the test criteria in Sect. 8 are met. He leak test can be carried alternatively using water or air. As the test using air is significantly quicker to carry out, this is preferably to be used. If doubt exists about the result of the air test then a water pressure test is to be carried out whose result is then relevant. With regard to the security measures which are fundamentally to be carried out, attention is drawn to the relevant security directives of the Trade Association and of the Federation of German Communal Accident Insurers (BAGUV), inter alia to:

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German Accident Prevention Regulations (UVV) "General Regulations" (VBG 1) [7] German Accident Prevention Regulations (UVV) "Construction Work" (VBG 37 [8] German Accident Prevention Regulations (UVV) "Technical Wastewater Systems" (GUV 7.4) [9] German Safety Regulations for Pipe Construction (ZH 1/559) [10] German Safety Regulations for Work in Enclosed Spaces of Technical Wastewater Systems (ZH 1/177) [11] Special instructions for the execution of leak testing using air as the test medium are in preparation. Once in force these also are to be observed. 5.1 Installation of Shut-off Elements

Operating instructions are to be observed with the installation of shut-off elements. The insertion of the shut-off elements into the pipe may, in the first place, take place only in so far as they fit securely fullface. The firm seating is prerequisite for the subsequent positive security against accidental change of position within the pipeline to be tested. After ensuring security the site of the installation is to be evacuated and the charging of the shut-off elements with the predetermined filling pressure from outside the shaft or pipeline is to be carried out. Charging may be with compressed air only. 5.2. Leak Testing Using Air

Leak testing using air is to be classified as hazardous work based on 36 (1) of the UVV "General Regulations" (VBG 1). With this the following minimum requirements apply: the leak testing may not be carried out by only one person suitable persons are to be tasked who are familiar with the hazards associated with the test and a supervisor is to be appointed. 5.2.1 Testing Using Overpressure

The pressurisation of the reach to be tested, of the section or of the pipe connection with non-man-accessible drains and sewers as well as the monitoring and release of the test pressure must take place from the ground surface without hazard. An exceeding of the test pressure is to be excluded in that this is monitored via a manometer and is limited to the predetermined value by a mechanically operated safety valve or electronic pressure switch. From the start of the pressurisation in the test space with leak testing by reach or section, work is not permitted in the pipeline or shaft for the duration of the test. During this time no one may remain in front of the shut-off elements and their hazardous zone.

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5.2.2 Test Using Vacuum

The determinations from Sect 5.2.1 apply analogously to the same extent with testing using vacuum. 5.3 Leak Testing Using Water

The pipeline to be tested is to be so filled with water that the enclosed air can escape at the shut-off element installed at the high point and thus a hazarding or erroneous measurement due to compressed trapped air is avoided. From the start of the pressurisation in the test space with leak testing by reach or section, work is not permitted in the pipeline or shaft for the duration of the test. 5.4 Removal of the Shut-off Elements

Removal of the shut-off elements may only begin after the overpressure or vacuum in the test space has been completely removed or the test water has been completely drained off. Both the pressure balancing in the test space or the draining off of the test water and the release of pressure from the shut-off elements are to take place from a secure location outside the shaft or reach.

Requirements on the Personnel Employed

Leak tests are to be carried out only by specialists who have proved their ability and the suitability of the equipment used. The responsible personnel employed for the leak test are to possess constructional, operational and material expertise for drains and sewers and at least one year's practical experience. A certificate of competence is to be furnished.

7
7.1

Documentation
General

The result of the leak test is to be documented on site, precisely and comprehensively in a test record. Documentation includes: details on the test object, test specifications and measurement values and measurement diagrams with a clear test note. The employment of electronic data processing in addition to the test record to be produced on site offers itself in order to ensure an optimum and economic further processing of the data.

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7.2 Test Record

The test record is to be produced separately for each test. In detail it must contain: customer, contractor, if required project leader, equipment operator, test location, date and time, road name, reach number and/or the designations of the shafts delimiting the reach; status data on the object to be tested, such as, for example, the type of object (leak testing by reach or section, or sleeve test). Nominal width, cross-sectional dimensions, test length, material, type of sewer, year of construction, zero point of longitudinal measurement, groundwater level; details on test specifications, test pressure, test time, settling time, permitted pressure difference or permitted water charging; details on the measurement result: measured pressure difference or water charging; measurement diagrams with an air overpressure or vacuum test: graphical representation of the pressure run over the test time with details of the required test pressure, the permitted pressure difference, the start and end of the necessary settling time as well as the start and end of the test time; test note on the result of the leak test with the signature of the parties involved. The test records are to be given a serial number and are to be archived systematically. Examples of the layout of the test record are contained in Appendices 1 and 2.

Tightness Criteria

With groundwater present the test pressure per meter groundwater above the pipe sole is to be increased by 100 mbar to a maximum of 200 mbar. If, during the test, the groundwater level lies above the pipe crown an infiltration test which, however, is not part of this Advisory Leaflet, can be carried out.

8.1
8.1.1

Tightness Criteria of the Leak Test by Reach or Section

Water Pressure Test 50 mbar (50 cm) above the pipe crown at the highest point of the test object generally 0.2 l/m2 wetted pipe surface 15 minutes.

Test pressure: Water charging Test time:

With regular operational water levels of more than 50 cm above the pipe crown the water level is relevant. The maximum permitted test pressure at the lowest point of the object to be tested is 0.5 bar.

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ATV-M 143E, Part 6

8.1.2 Air Overpressure Test P = 100 mbar p = 15 mbar t according to Table 1 tS = 10 di in [min], with di = diameter in [m]

Test pressure. Permitted pressure difference Necessary test time. Settling time: 8.1.3 Vacuum Test

Test pressure. Permitted pressure difference Necessary test time. Settling time: 8.1.4

P = 100 mbar p = 12 mbar t according to Table 1 tS = 10 di in [min], with di = diameter in [m]

Required Test Times for Air overpressure and Vacuum Testing

The necessary test times of the air overpressure (see Sect. 8.1.2) and the vacuum tests for nominal widths DN 1200, presented in Table 1, result from the following relationship: 10 di [m] = test time in [min]. Intermediate values can be interpolated. The necessary test times [min] for larger nominal widths (> DN 1200) or other cross-sectional shapes, which are not presented in Table 1, can be calculated according to Equation 1:
t = 5.61 2 di 3 + di 2 [min]

(1)

whereby the diameter di in [m] is to be applied. For special profiles, e.g. oval sections, an alternative diameter dE according to Equation 2 can be calculated:
dE = 4 Cross sec tional area [m] Circumference

(2)

Table 1:

Necessary test times (min) with the tightness testing by sewer section and/or sections of sewer using air overpressure or vacuum.
100 1 200 2 300 3 400 4 500 5 600 6 700 7 800 8 900 9 1000 10 1100 11 1200 12

Nominal width DN Test time [min]

8.2

Tightness Criteria with the Testing of Pipe Connections (Sleeve Test) Using Air Overpressure

Sleeve tests in non-man-accessible drains and sewers must be carried out under camera observation. June 1998

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ATV-M 143E, Part 6

As almost all sleeve testing equipments have different test volumes, which are limited by the pipe walls, and possibly by the core piece and the shut-off elements of the sleeve test equipment, it is not possible to define generally valid tightness criteria for the testing of individual pipe connections. To determine the necessary test times, the test volume of the sleeve test equipment used, including the feed hoses, in the case that these have a connection with the test space during the test, as well as the volume of the pipe connection1) must be determined. Furthermore, the area of the pipe wall between the shut-off elements must be known. Sleeve test equipments whose air feed hoses have no connection with the test space during the teats are to be preferred. Test pressure. Permitted pressure difference Necessary test time. Settling time:
t = 1800 di + 0.5 VTest volume APipe wall [ s]

P = 100 mbar p = 15 mbar t according to Eqn. 3 tS = 15 s. (3)

A sample calculation of the test times can be found in Appx. 3. 8.3 Shaft/Chamber Testing

The leak testing of shafts/chambers is preferably to be carried out as a water pressure test. The test object is filled with water to 0.5 m above the pipe crown of the connecting drains and sewers. Within the test time of 15 minutes the required water input to maintain the test pressure may not exceed 0.4 l/m2 of the wetted shaft/chamber wall (incl. the bottom of the shaft/chamber).

_________________
1)

In general, with non-man-accessible drains and sewers, the determination of the volume of the pipe connection can be dispensed with.

Appendix 1: Model record of leak testing by reach

Test Record
Leak testing by reach or section using air

Serial No._____________

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ATV-M 143E, Part 6

Customer.____________________________ Project management:___________________ Customer:____________________________ Equipment operator:____________________ Date: ________________________________ Location: _____________________________ Street: _______________________________ Reach No.: ___________________________ Shaft designation: Shaft 1:_______________ Shaft 2:_______________ Details on test object Diameter:______________[m] Test details Test specifications:_________ Measurement results Measured pressure difference:

Cross-section: Height: ____[m] Test pressure:________[mbar] ___________________[mbar] Width: ____[m] Groundwater level: ______[m] Test length: ____________[m] Material:_________________ Type of sewer:____________ Year of construction:_______ Origin of linear measurement: __________________________ Length/position of test space: __________________________ Test time: ___________[min] Settling time:_________[min] Perm. pres. diff.:______[mbar]

Test note:______________________________
Equipment operator: ________________________ Project management: ________________________ Customer: ________________________

Appendix 2: Model record for sleeve testing

Test Record
Sleeve test using air overpressure

Serial No._____________

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ATV-M 143E, Part 6

Customer.____________________________ Project management:___________________ Customer:____________________________ Equipment operator:____________________ Date: ________________________________ Location: _____________________________ Street: _______________________________ Reach No.: ___________________________ Shaft designation: Shaft 1:_______________ Shaft 2:_______________ Details on test object Test details Length details Origin of linear measurement:

Diameter:______________[m] Test specifications:_________

Cross-section: Height: ____[m] Test pressure:________[mbar] ________________________ Width: ____[m] Test time: ___________[min] Sleeve No.:_______________ Position of sleeve:_______[m]

Groundwater level: ______[m] Settling time:_________[min] Material:_________________ Type of sewer:____________ Year of construction:_______ Perm. pres. diff.:______[mbar]

Equipment parameters Equipment type:___________ Equipment No.:____________ Test volume:___________[m3] Pipe wall area: _________[m2]

Test note:______________________________
Equipment operator: ________________________ Project management: ________________________ Customer: ________________________

Appendix 3: Illustrative determination of the requisite test times with sleeve testing The test volumes and test times calculated as an example, which are presented in Table 2, result under the following assumptions: June 1998

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ATV-M 143E, Part 6

A special packer is used for each nominal width. The diameter of the core of the packer is always 10 cm smaller than the nominal width of the tested sewer (DN/1000-0.1 [m]). The test length, i.e. the separation between the shut-off elements , is 20 cm. The length of the hose carrying the air, with a diameter of 1 cm, is 150 m. The volume of the pipe connections and the volume of the shut-off elements are ignored in this example.

Fig. 1:

Schematic representation of the test space (marked by cross hatching) the sketch is not to scale
t = 1800 d + 0.5 VTest volume APipe wall [s].

Table 2: Tests volumes [m3] of sleeve test equipments and the therefrom resultant test times calculated as an example Nominal width Volume, test space Volume, hose Test volume Pipe wall area Test time DN [m3] [m3] [m3] [m2] [s] 200 0.005 0.012 0.017 0.126 203 300 0.008 0.012 0.020 0.188 171 400 0.011 0.012 0.023 0.251 156 500 0.014 0.012 0.026 0.314 149 600 0.017 0.012 0.029 0.377 145 700 0.020 0.012 0.032 0.440 143 800 0.024 0.012 0.036 0.503 147

Literature
[1] ATV-M 143E: Inspection, Maintenance, Rehabilitation and Replacement of Drains and Sewers; Part 2: Optical Inspection (06.91) June 1998

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[2] DIN 1986: Entwsserungsanlagen fr Gebude und Grundstcke; Teil 30: Instandhaltung [Drainage Systems for Buildings and Property, Part 30: Repair] (01.95) Drain and Sewer Systems Outside Buildings Verlegung und Prfung von Abwasserleitungen und -kanlen [Laying and Testing of Drains and Sewers] (10.97) Sewers and Drains in Water Catchment Areas (10.92) Inspection, Maintenance, Rehabilitation and Replacement of Drains and Sewers; Part 1: Optical Inspection, Maintenance, Rehabilitation and Replacement of Drains and Sewers; Part 2: Principles (12.89)

[3] [4] [5] [6]

DIN EN 752: DIN EN 1610: ATV-A 142E: ATV-M 143E

[7] [8] [9] [10] [11]

UVV Allgemeine Vorschriften ["General Regulations"] (VBG 1) (10.91) UVV Bauarbeiten ["Construction Tasks"] (VBG 37) (04.77) UVV Abwassertechnischeanlagen (GUV 7.4) ["Technical Wastewater [Safety Rules Systems"] for Pipe

Sicherheitsregeln fr Rohrleitungsbauarbeiten Construction] (ZH 1/559) (04.86)

Sicherheitsregeln fr Arbeiten in umschlossenen Rumen von Abwassertechnischen Anlagen [Safety Rules for Work in Enclosed Spaces of Technical Wastewater Systems] (ZH 1/177) (04.88)

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