HYDROSTATIC PRESSURE TEST OF DRINKING WATER PIPES

AIM
In the hydrostatic pressure test of drinking water pipes, a review of the different
pressure specifications and duration of the hydrostatic pressure tests that the drinking
water pipes are subjected to will be carried out, once their buried installation has been
completed. The basis of the test is to pressurize the system for a certain time to verify
that there are no leaks. If the pressure remains constant during the test it means there
are no leaks.

APPLICATION OF THE HYDROSTATIC TEST

This procedure applies to pipeline systems for the transportation, handling and
distribution of liquid and gaseous hydrocarbons, made of carbon steel, of any
diameter, whether new, out of operation or intended to operate under conditions
different from those for which they were designed. and pipes that are used for repair.
This procedure is of general application and mandatory observance in hydrostatic
testing work on pipes and accessories.

Hydrostatic test:
It is the pressure test that pipes must undergo to certify their tightness, maintaining
the pressure for an established time, using water as the test fluid.
PREVIOUS ACTIVITIES
Before performing the hydrostatic test, the following activities must be carried out:
Prepare hydrostatic test program.

Recognize the areas where the hydrostatic test will be carried out. Inform the
agencies involved and hold a meeting prior to the hydrostatic test.

Obtain access permits to the DDV of the pipeline and surface facilities, if
required.

Obtain permission to carry out risky work from the industrial safety
department.

Process authorization to vent or burn gas (if required) with PROFEPA and/or
SEMARNAT.

Process authorization for final disposal of the water used in the test before the
National Water Commission (CNA) or corresponding authority (if required).
 Request the intervention of the Secretary of Energy and/or CRE Verification
Units for the certification of the hydrostatic test.

Have materials and equipment required for the hydrostatic test. Establish good
communication with mobile equipment, if required.

Designate the personnel responsible for each area, who must give clear and
precise instructions to the personnel involved.

Ensure the availability, quantity and quality of the required water. Have the
technical characteristics sheet of the manufacturer of the pipe to be tested.

Carry out a sampling of the thickness measurement of the pipe to be tested, as

determined and if required.

Determine the pressure of the hydrostatic test and its duration.

Lay and join the sections of pipe to be tested with butt welding, using the
necessary equipment, if required.

Ensure that the pipe or segment is clean internally before starting the
hydrostatic test.

Ensure tightness at the ends of the pipe to be hydrostatically tested, by

installing blind flanges, plugs or blind joints.

Calibrate and install pressure gauges, manographs and thermographs in the

places required.

Install vents in the upper parts to bleed the air, if required. Install nipple of the
required diameter for water injection.

SPECIFIC PROCEDURES
The minimum specified measurement stress: It is the resistance at the minimum
flow rate indicated by the pipe manufacturer's specifications. It is usually expressed
in lb/in² (psi) or N/mm2.
 Manograph: It is a pressure gauge with graphic recording.

Manometer: It is a pressure gauge.

Pressure: It is the force exerted perpendicularly on a surface, based on the

atmospheric pressure by measurement. It is usually expressed in lb/in² (psi) or
kg/cm².

Design Pressure: It is the pressure with which a pipeline is designed and its value
must be greater than or equal to the maximum operating pressure.

Operating Pressure: It is the actual pressure at which a system operates, under

normal conditions.

Hydrostatic Test Pressure: It is the maximum internal pressure allowed to carry out
the hydrostatic test.

Maximum Operating Pressure: It is the maximum pressure to which a pipeline is

subjected during its operation.

Pressurize: Apply pressure to the inside of a tube or container.

Hydrostatic Test: It is the pressure test to which the pipes must be subjected to
certify their tightness, maintaining the pressure for an established time, using
water as the test fluid.

Temperature: It is the heat content in the matter. It can be expressed in ºC or ºF.

Ambient Temperature: It is the temperature of the air in the environment

surrounding the place where the installation is located.

Thermograph: It is a temperature meter with graphic recording.

MATERIALS NEEDED FOR THE HYDROSTATIC PRESSURE TEST

Hydrostatic test equipment (pump and connection elements between it and
the pipe)
Calibrated volume water tank
 Calibrated flow meter.
Calibrated pressure gauges, capable of measuring the test pressure, and with
the indicated resolution.
Chronometer
HYDROSTATIC TEST PROCEDURE
Once the activities have been carried out, the pipe must be filled, the purge
valves must be plugged with blind elements, and their mechanism must be
opened. The opening of the guard valves, air valves or vent elements must be
checked.

The maintenance personnel and/or contracting company must inject the water
into the pipe until it is packed, completely eliminating the air (bleeding)
through the vent valves, placed in the highest parts of the system. If required, a
gasket may be used to fill the duct.

A minimum of two pressure gauges must be installed for test readings on the
abscissa agreed upon with the Comptroller's Office and EPM. In addition, a
spare pressure gauge must be available at the time of testing, and calibration
certificates for the measuring instruments must also be presented.

Operation personnel must test and install the pressure and temperature
recorders, test and install the pressure pump with sufficient capacity to achieve
the specified pressure. The pressurization of the pipe begins, injecting water to
increase the pressure until the specified test pressure is reached.

The operating personnel must start recording in the graph when the test
pressure is obtained, which must bear, at a minimum, the signature of the
maintenance, operation, industrial safety and environmental protection
personnel at the beginning of the test. An effort will be made to obtain the
signature of the representative of the Ministry of Energy or verification Unit
duly registered with the Energy Regulatory Commission.

Maintenance and operation personnel must maintain the hydrostatic test

pressure for one hour without significant pressure variations. In addition, the
hydrostatic test pressure must be lowered to 50%. To do this, the hydrostatic
test pressure must be increased again to 100%; this must be maintained at the
hydrostatic test pressure at 100% for the specified time.

If pressure losses occur due to leaks in the pipe, accessories or connections, the
maintenance or operation personnel must correct and repeat the test until
acceptance. At the end of the test, the graph will be removed and signed by at
least maintenance, operation, industrial safety and environmental protection
personnel. An effort will be made to obtain the signature of the representative
 of the energy ministry or verification unit duly registered with the energy
regulatory commission.

Maintenance, operation and industrial safety personnel must slowly press the
tested pipe until reaching zero pressure. To do this, the personnel in charge
must completely empty the tested pipe by appropriate means (drain,
maneuvers, etc.). Maintenance personnel must confine the water in
appropriate places that do not affect the environment, complying with the
requirements of the national water commission and the corresponding official
standards, where applicable.

The maintenance, operation, security and contracting company personnel must

verify that all equipment, tools, materials and accessories used in the
development of the hydrostatic test (blind flanges, plugs or blind joints,
pressure gauges, mammographs, thermographs, nipples, etc.) are removed.
couplings, etc.). Carrying out the respective cleaning of the areas as
appropriate.

CONCLUSION
The main potential dangers are external corrosion, internal corrosion, stress
corrosion cracking, manufacturing defects, construction defects, equipment
failures, incorrect operations.

The risk assessment method consists, starting from the identification of

potential hazards, in having reliable data, estimating the probability of failure,
estimating the consequence of failure and if all hazards have been evaluated,
estimating the total risk in operation, evaluating integrity and propose the
response to the integrity assessment.

All equipment that works pressurized goes through hydrostatic pressure tests,
the pressure and time will depend on the conditions of the system and/or the
existing standard.