Provision of EPCC Service for Fresh Water Supply Project of

S2 Camp

Hydro-test procedure for HDPE PROJECT SCOPE DISPL DOC SEQ REV
pipeline from water intake to Page 2 of 12
water treatment EBS1 DWIS50 SEME PRTS 1001 C01

DOCUMENT REVISION HISTORY SHEET

REVISION
Rev DATE ISSUED UPDATE / AMENDMENT DETAILS
DESCRIPTION

00 IFA 02-02-2021
01 IFA 10-02-2021 Updated according to PMC team comments
 Provision of EPCC Service for Fresh Water Supply Project of
S2 Camp

Hydro-test procedure for HDPE PROJECT SCOPE DISPL DOC SEQ REV
pipeline from water intake to Page 3 of 12
water treatment EBS1 DWIS50 SEME PRTS 1001 C01

Table of Contents
1.0 Purpose
2.0 Code Standard
3.0 Flowchart
4.0 Test Proceduer
5.0 HSE Measure& Safety
 Provision of EPCC Service for Fresh Water Supply Project of
S2 Camp

Hydro-test procedure for HDPE PROJECT SCOPE DISPL DOC SEQ REV
pipeline from water intake to Page 4 of 12
water treatment EBS1 DWIS50 SEME PRTS 1001 C01

1.0 Purpose
This procedure addresses the hydro testing of the underground pipeline on the
Project. The pipe material of the pipeline size 6" manufactured from high-density
polyethylene (HDPE) with approximately length 7000 m. This pipeline will transport
water frome Diyala River by water intake to water tretment. the test will done under
Test pressure 1.5 bar (g) from working pressuer and holding for 4 hor. The test will
done under the same condition for pipeline which consist of two material, HDPE and
carbon steel (Cross only). As per the practicular issues mentioned in (PPI) reports,
when the pipeline is longer than 3000-feet, the pipeline may need to be tested in
several sections. Where long lengths are tested, radio, cell phone, or other
communication means may be required between test operators for safety, to
coordinate test activities and keep the test within desired time limits. Very long test
sections may incorporate a large number of mechanical and welding connections,
which must be checked for leakage. The longer the test section becomes, the harder
it is to locate a leak or to discriminate between a leak and other effects such as
entrapped air being dissolved into solution under pressure.

2.0 Code Standard

The procedure shall conform to the following stipulations, standards and

documents.
ASTM F2164 - 02 Standard Practice for Field Leak Testing of
Polyethylene (PE) and Crosslinked Polyethylene (PEX) Pressure Piping
Systems Using Hydrostatic Pressure
ISO 4427-2: Plastic piping systems. Polyethylene pipes & fittings for water
supply.
EN 12201-2: Plastic piping systems. Polyethylene pipes & fittings for water
supply.
AWWA C906: PE -Pressure pipe & fitting

F1055 – 16 Electrofusion Type Polyethylene Fittings for Outside Diameter

Controlled Polyethylene and Cross linked Polyethylene (PEX) Pipe and
Tubing

Report No TN-46/2013a (PPI –Plastic pipe institute) (Guidance for Field

Hydrostatic Testing Of High Density Polyethylene Pressure Pipelines:
Owner’s Considerations, Planning, Procedures, and Checklists
 Provision of EPCC Service for Fresh Water Supply Project of
S2 Camp

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3.0 Flowchart

Preparation

Set up Section for Hydrotesting Installation of Water Source

Water Filling

Water charging/Air Bleeding/Pressurization Rush Repair

Strength Test

Unqualified
Qualified

HDPE pipe Network Tightness Pressure Test

Unqualified
Qualified

Dewatering and Water Disposal

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4.0 Test Proceduer

4.1 Test Section for HDPE pipe Network

CONTRACTOR shall submit pressure testing plan pressure proposed, pressure
meter gauge class certificates and calibration certificates to Clint

4.2 Preparation for Hydrotest procedure

Pressure, temperature gauge shall be used for all hydrostatic tests. The
pressure should be shown in –bar (g), all gauges should be calibrated and
valid. Two pressure gauges should installed in both of high and lowest point
of the pipeline. Piping joints and welds shall not be insulated or physically
covered until satisfactory completion of testing in accordance with this
specification.
1- Pressure gauge manifold shall be used for all hydrostatic tests.
2- Pipeline Electrofusion joints and welds shall not be physically covered until
satisfactory completion of testing in accordance with this specification.
3- All piping shall be adequately supported before the pressure test. Spring
or other variable type supports shall be blocked to prevent movement. Unless
otherwise noted,
4- Ensure that all pressure hose are conected
5- Site preparation and cleaning Pipeline. flashing the pipe line before
starting test process to keep the Pipeline clean from any debris or dust which
come through pipe during construction
- Pressure Pump for Hydrotest
- Blind flange
- Gauge Pressure from 0-25 Bar
- Vent valve

* All devices above will calibrated and submit the certificate for testing to EBS
6- Start install and close the two ends by flange (the flange content inlet water
and ventilation and install Ventilation valve to remove the pocket air to out side
7- Start Provide water to start fill all Pipeline testing and try to fill all pipe
network section by water and discharge all air out side pipe network
8- Install Hydrotest machine.
 Provision of EPCC Service for Fresh Water Supply Project of
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4.3 TEST LIQUID

An adequate supply of a safe test liquid, such as water, is necessary. The test liquid
should be of appropriate safety and quality so that the environment, system, Test
equipment, and disposal (if necessary) are not adversely affected. To estimate the
quantity of test liquid needed to conduct the test, estimate the quantity of liquid needed
to fill the test section, then add an appropriate excess quantity To account for pipe
expansion and the possibility or leakage or retesting. Up to 40 % additional test liquid
may be needed to account for the possibility of leakage or retesting. 6.2.2 To estimate
the quantity of test liquid needed to conduct the test, estimate the quantity of liquid
needed to fill the test section, then add an appropriate excess quantity to account for
pipe expansion and the possibility or leakage or retesting. Up to 40 % additional test
liquid may be needed to account for the possibility of leakage or retesting. The quantity
of liquid needed to fill the internal volume of the pipe test section may be estimated
using: (for fast reading, check fig 1)

Vm3 = 0.785 x 10 -6 x ID2 mm x Lmm

Where:

Vgal = pipe section volume, U.S. gal,

IDin. = pipe inside diameter, in.

Lft= test section length, ft,

Vm3 = pipe section volume, m3

IDmm = pipe inside diameter, mm,

Lm = test section length, m.

4.4 Partial Backfilling during Testing

When underground connections, joints, and seals are to be exposed for observation
during the test, use sufficient backfill material Placed between the joints, and over the
pipe to prevent movement, giving due consideration to restraining thrust forces. In
particular, pipes connected to restrain Joints that derive their stability from the
interaction of the pipe and soil are to be backfilled prior to testing.
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4.5 General requirement before start with hydro test

Before carrying out the hydrostatic inspection, the following action must be Verified:-

1- All the pipeline construction been completed, inspected and signed off.

2- QA/QC should verify that the proper pipe material, diameters, DR’s, flange ratings,
fittings ratings, are in accordance with the drawings and specifications.

3- The last fusion joint been allowed to cool sufficiently to ambient temperature

4- The pipeline been cleaned of all construction debris and foreign matter

5- All facilities available for preparations for testing

6-All foreign construction materials removed from the trench in contact with the
HDPE pipe

7- Will the hydro-test be scheduled to occur in dry weather, so that leaks may be
detected (testing wet weather or in water-filled trenches is not recommended)

8- The pipeline elevation profile and filling procedure should analyzed for the fill
velocity potential against dynamic surge pressure during filling, which might over-
pressure local components especially in low elevations

9- The volumetric rate of fill, fill method, and fill procedure been finalized.

10- the test plan manual been approved, circulated to all operators, and understood
by all participants in pre-test safety and quality meeting

11- All high elevation points should identified with provisions made to properly install
adequately sized air vent valves of sufficient volume & pressure capacity .Verified
that all vent points are installed in the “open” position, for proper operation during
Filling, Blind-flanges may be used as high-point vents when they are snuggly bolted
and subjected to low filling pressure, such that trapped air is pushed out past the
snug gasket, until the fill-water reaches it and sprays out, thus indicating that all air is
Expelled, followed by the mechanic fully torqueing the flange per the approved
bolting procedure with just static head against the blind.
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4.6 Test Temperature

Polyethylene piping materials are typically pressure rated at 73°F (23°C). At

higher temperatures, reduced pressure ratings and test pressures may be
required.

4.7 TEST DURATION

When the maximum test pressure is 1.5 x the system work pressure, total testing time
including the time required to pressurize, stabilize, hold test pressure, and
depressurize should not exceed 4 h.
The required period time for active pressure test not exceed than 3 hr and 1 hr for leak
test (1.1 design pressure)

Strength Test Leak Test

Item
Test Pressure Test Pressure
Pressure 1.5 WP 1.1WP
Duration ≥3hr ≥1hr
Clean and non-corrosive
Test Medium Clean and non-corrosive water
water
No leakage, pressure decrease
Standard No leakage, no deformation not more than 1% of the test
pressure
 Provision of EPCC Service for Fresh Water Supply Project of
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water intake to water EBS1 DWIS50 SEME PRTS 1001 C01
treatment

4.8 Testing In the Trench:

BDC will sperate the pipe for 7 section for hydro test, each section wil be test individually,
the length of each section will be 1km, after testing each section pass test BDC will test all
7km pipeline, Fill the pipeline with water after it has been laid; bleed off any trapped air.
Subject the lowest element in the system to a test pressure that is 1.5 times the working
pressure, and check for any leakage . The test procedures consist of two steps: the initial
expansion and the test phase. When test pressure applied to a water-filled pipe, the pipe
expands. During the initial expansion of the pipe under test sufficient make-up water must
be added to the system at hourly intervals for three hours to maintain the test pressure.
After about four hours, initial expansion should be complete and the actual test can start.
When the test is to begin, the pipe is full of water and is subjected to a constant test
pressure of 1.5 times the system design pressure. The test phase should not exceed
three hours, after which time any water deficiency must be replaced and Measured. Add
and measure the amount of make-up water required to return to the test pressure and
compare this to the maximum allowance in Figure 1. An Alternate leakage test consists of
maintaining the test pressure (described above) over a period of four hours, and then
dropping the pressure by 10 psi
(0.069Mpa). If the pressure than remains within 5% of the target value of one hour, this
indicates there is no leakage in the system.
NOTE: Under no circumstances shall the total time under test exceed (4) hours at 1 ½
times the system pressure rating. If the test is not complete within this time limit (due to
leakage, equipment failure, etc.), the test section shall be permitted to “relax” for (4) hours
prior to the next test sequence. Air testing is not recommended. Additional safety
precautions may be required.
FIGURE.1

ALLOWANCE FOR EXPANSION UNDER TEST PRESSURE

Nominal Pipe U.S. Gals/100 feet of Pipe (2) Nominal Pipe U.S. Gals/100 feet of Pipe (2)
Size inches (1) Size Inches (1)

1-Hour 2-Hour 3-Hour 1-Hour 2-Hour 3-Hour

2 0.08 0.12 0.15 20 2.80 5.50 8.00

3 0.10 0.15 0.25 22 3.50 7.00 10.50

4 0.13 0.25 0.40 24 4.50 8.90 13.30

5 0.21 0.41 0.63 28 5.50 11.10 16.80

6 0.30 0.60 0.90 30 6.20 12.60 19.10

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8 0.50 1.00 1.50 32 7.00 14.30 21.50

10 0.75 1.30 2.10 36 9.00 18.00 27.00

12 1.10 2.30 3.40 42 12.00 24.00 36.00

14 1.40 2.80 4.20 48 15.00 27.00 43.00

16 1.70 3.30 5.00 54 18.00 30.00 50.00

18 2.20 4.30 6.50

(1) mm* 0.03937 (2) multiply by 11.53 to convert to liter/100 meters of pipe

4.9 PASS/FAIL CRITERIA

If no visual leakage is observed, and pressure during the test phase remains steady
(within 5 % of the test phase pressure) for the 1 h test phase period, a passing test is
indicated.

4.10 MAJOR EQUIPMENT & MATERIALS REQUIRED

Holding Tank 1
Filling Pump 1
Test Pressure Pump 1
High Pressure Hoses & fitting As required
Suction & delivery hoses As required
Pressure gages 2 per test
Air Compressor 1
Blind/ Test Flanges As required
Test Valves, ½”, 1”, 2” As required
Power generator 1
Water Truck 1
 Provision of EPCC Service for Fresh Water Supply Project of
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4.11 MANPOWER REQUIRED

Quality Control Inspector 1

Hydrostatic Test Coordinator 1
Foreman-Mechanical 1
Hydro test Technician 1
Pipe fitter 1
Skilled Helper / Laborer 3

5.0 HSE Measure &Safety

Safety Precaution in Hydrotesting Operation: dedicated person shall be stationed
at Pressurizing point and no person is allowed to pass or remain within 35 m
range in front of pipe section. Unimpeded communication shall be maintained
during the whole process.
 Provision of EPCC Service for Fresh Water Supply Project of
S2 Camp

HYDRO TEST for HDPE

PROJECT SCOPE DISPL DOC SEQ REV
PIPELINE Page 1 of 2
EBS1 DWIS50 MEEN DWME 1025 V00

PROJECT NAME: BARAKAT DIJLA COMPANY

SYSTEM : DATE OF TEST :

TYPE OF TEST : HYDRO TEST TEST PRESSURE bar

TEST MEDIUM / TEMP : REQUIRED TEST PRESSURE: bar

TEST STARTING TIME: TEST ENDING TIME:

PRESURE HOLDING TIME : hrs

PRESSURE GAUGE SERIAL NO.:

RESULT : ACCEPT REJECT

REMARK :

SUBMITTED BY APPROVED BY APPROVED BY

BDC EBS PMC

Signature

Name

Date
 Provision of EPCC Service for Fresh Water Supply Project of
S2 Camp

HYDRO TEST for HDPE

PROJECT SCOPE DISPL DOC SEQ REV
PIPELINE Page 2 of 2
EBS1 DWIS50 MEEN DWME 1025 V00

PROJECT NAME: BARAKAT DIJLA COMPANY

SYSTEM : DATE OF TEST :

TYPE OF TEST : HYDRO TEST TEST PRESSURE bar

TEST MEDIUM / TEMP : REQUIRED TEST PRESSURE: bar

TEST STARTING TIME: TEST ENDING TIME:

PRESURE HOLDING TIME : hrs

PRESSURE GAUGE SERIAL NO.:

RESULT : ACCEPT REJECT

REMARK :

SUBMITTED BY APPROVED BY APPROVED BY

BDC EBS PMC

Signature

Name

Date