TESTING AND DISINFECTING REQUIREMENTS FOR NEW WATER MAINS

Scope
This section describes the requirements for pressure/leak testing, and disinfecting of water mains and
appurtenances, including but not limited to, air release valve assemblies, blow off valve assemblies, fire
hydrant assemblies, service assemblies, pressure reducing and pump stations, altitude valve stations, and
all other appurtenances.

This section does not include disinfecting procedures for water storage tanks.

Description of Work and Materials

This work shall consist of filling the water main and appurtenances with water and bleeding off all
entrapped air, allowing the pipe line to soak, making all connections to the water main for expelling air
and for testing equipment, running the test, visually inspecting exposed appurtenances, locating and
repairing all leaks, retesting, application of disinfectant, and flushing operations.

Materials furnished for this work shall include, but not be limited to, pipe and fittings for connections to
the main, pumps, pressure regulator, a calibrated water storage tank, disinfectant, and all other
materials, fittings and pipelines required to perform the tests and make the necessary repairs.

Required Work Sequence

The pressure test and the test for allowable leakage shall be performed simultaneously. Testing shall not
commence until the water main and all appurtenances have been completely installed. The Contractor
may, at any time, perform his own pressure and leak test; however, these tests will in no way offset the
requirement for a final pressure and leak test.

After successfully testing the water main and appurtenances, they may then be re-flushed and
disinfected.

System Operations
Only City personnel shall oversee the operation of valves and appurtenances that are a part of the treated
water system in active service.

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 Hydrostatic Testing

General
This section shall consist of testing the water main and appurtenances for both pressure and leakage
requirements. These tests will be run simultaneously. Guidance for both testing standards can be found in
the AWWA C600-17 (ductile iron mains) and AWWA C605-17 (PVC/PVCO mains).

Prior to testing, the water main shall be slowly and carefully filled with potable water to eliminate air
pockets and flushed to clean the pipe of surface dirt and other debris in the pipe. The water main shall be
filled at the recommended maximum filling velocity of 1 foot/sec while venting air. Precautions shall be
taken to prevent air from being trapped in the pipe. All air shall be expelled slowly from the pipe and
appurtenances in a manner so as not to create excessive surge pressures. All appurtenances shall be left
on during the testing procedure.

If an existing valve is suspected of leaking, the Contractor may repair or replace the valve at his own
expense, or disconnect the water main from the valve, install a bulkhead, and retest.

Test Section Length

The length of water main being tested at any one time shall not exceed 2,000 feet unless otherwise
approved by the City Engineer, or allowed in the Special Conditions of the Contract.

Testing Equipment
The Contractor shall be responsible for supplying, maintaining, and operating all testing equipment. In
general, the testing equipment configuration shall consist of a pump receiving water from a calibrated
storage tank. The pump discharge shall enter the water main through a tap or appurtenance. A pressure
sustaining valve capable of being adjusted within the required pressure ranges shall be placed on a tee
located in the pump discharge line. Discharge from the pressure sustaining valve shall return to the
calibrated storage tank. Other types or configurations of testing equipment shall be subject to the City
Engineer's approval. The pressure pump and pressure sustaining valve shall remain in operation
continuously throughout the test period.

Test Pressure
The test pressure shall be 75 psi over working pressure, or 160 psi, whichever is greater. The pressure
maintained at the pump shall be adjusted for the difference in elevation between the lowest elevation of
the test section and the pump location.

Test Duration
The test duration shall be 2 hours. Pressure in the water main shall be maintained as near the calculated
test pressure as possible for the full 2 hour duration. The pressure pump and pressure sustaining valve
shall remain in operation continuously throughout the duration of the test. A loss of more than 5 psi
during the test shall result in a test failure and the test must be restarted.

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Allowable Leakage
The allowable leakage per test section shall be calculated from the formula contained in this subsection.
Different sized water mains that might be contained within the same test section shall be calculated
separately and their allowable leakage added together. This formula represents the allowable leakage
regardless of the number of joints, couplings, fittings, valves, pressure reducing or pump station or any
other appurtenances on the water main. The length of pipe contained in these appurtenances shall not
be counted as adding to the length of water main being tested.

𝑳𝑫 𝟏
𝑽= (𝑷𝟐 )
𝟏𝟒𝟖, 𝟎𝟎𝟎

Where:

V = Allowable leakage in gallons per hour

L = Length of water main in feet

D = Nominal diameter in inches

P = Average test pressure in psi**

** The average test pressure shall be calculated as the test pressure for the lowest elevation of the test
section less one-half the elevation change to the highest point on the test section.

Repairs
During the pressure and leakage test, all accessible appurtenances shall be inspected for visual signs of
leakage. All visual leaks shall be corrected immediately, regardless of the amount of leakage and the test
shall be run again for its full duration. If the pressure and leakage test fails, the Contractor shall begin to
investigate all areas of suspected leakage and shall make all repairs necessary in order to affect a
successful test. All repair methods shall be subject to the City Engineer approval. All leaks detected shall
be repaired to a water tight condition. All repairs made shall be retested in accordance with these
specifications. All repairs shall be made and a successful test accomplished prior to taking bacteriological
samples.

Preliminary Flushing

After satisfactory completion of the pressure/leakage testing, the water shall receive a preliminary flush.
Flushing of the water main shall be conducted under the supervision of the City of Aurora’s Engineering
Department or its designee, in accordance with the flushing plan. The flushing shall include 100% of the
newly installed water main as well as every fire hydrant installed. Flushing shall take place between
7:30am and 4:00pm Monday through Friday, excluding Holidays. The Engineering Department must be
notified at least 48 hours in advance of flushing operations.

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The flushing velocity in the main shall be a minimum of 3.0 feet/second and shall be tested with a pitot
gauge at each flowing hydrant nozzle. All filling and preliminary flushing of water mains shall follow the
AWWA C600-17 (ductile iron mains) or AWWA C605-13 (PVC/PVCO mains) standards. The following table
may be used for recommended flows to properly flush piping.

Required Flow and Openings to Flush Pipelines*

Size of Tap
Pipe Flow Required to Produce Number of 2-1/2
Diameter 3.0ft/s Velocity in Main 1 - inch 1-1/2 inch 2-inch inch Hydrant
(Inch) (gpm) Number of Taps on Pipe** Outlets
4 120 1 - - 1
6 260 - 1 - 1
8 470 - 2 - 1
12 1,060 - - 3 2
16 1,880 - 5 2
* Assuming 40 psi residual pressure in existing water main a 2 ½” hydrant nozzle will discharge
approximate 1000 gpm and 4 ½” will discharge 2,500 gpm.

** Number of taps on pipe based on discharge through 5 ft. of galvanized iron (GI) pipe with one 90
degree elbow.

NOTE: Flushing is no substitute for preventive measures during construction. Certain contaminants, such
as caked deposits, resist flushing at any feasible velocity.

Disinfecting

General
The interior of all water mains and appurtenances shall be disinfected in accordance with AWWA C651-14
(or newer) and these specifications. Disinfection requirements shall include preventive and corrective
measures during construction, forms of chlorine and methods of application, final flushing, and
bacteriological tests.

The method and technique described in these specifications are minimum requirements only. The
Contractor shall be solely responsible for the methods and techniques used to successfully disinfect the
water mains and appurtenances and for disposing of the highly chlorinated water during flushing
operations.

Preventive and Corrective Measures During Construction

Precautions shall be taken to protect the interior of water mains and appurtenances against
contamination. The open ends of all water main laid in the trench shall be closed with water tight plugs
when pipe laying has stopped. Stockpiled pipe and appurtenances shall also be protected from
contamination.

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If dirt or other contaminants enter the water main or appurtenances and, in the opinion of the City of
Aurora Engineer or Engineering Department Representative, the contaminant will not be removed by the
flushing operation, the interior surfaces shall be cleaned by mechanical means.

Water mains and appurtenances flooded during construction shall be cleared of flood water, flushed with
potable water, isolated, and filled with chlorinated water so that at the end of a 24-hour holding period,
the free chlorine residual is not less than 25 mg/L. The chlorinated water shall be flushed as described
under Final Flush of these specifications.

Methods of Chlorination
The City of Aurora will only accept the continuous feed method of chlorination using liquid sodium
hypochlorite (NaOCl). The City of Aurora Engineering Representative or designee shall witness the
chlorination of the water main. Chlorination of the water main shall not be permitted until the main has
passed the pressure/leakage test and a preliminary flushing has been performed.

Under supervision of the City’s Engineering Representative, water from the existing distribution system
shall be made to flow at a constant rate into the newly installed water main. At a point not more than 10
feet downstream from the beginning of the new main, water entering the new main shall receive a dose
of chlorine fed at a constant rate such that the water will receive not less than 25 mg/L free chlorine
(table 4 in the AWWA 651-14 gives the amount of chlorine required per 100 feet of pipe).

Once the entire main has been chlorinated, all valves (main line and hydrant) not used to isolate the new
main from the old, shall be fully operated and all hydrants operated to expose the surfaces to the super
chlorinated water. After a 24-hour holding period in the mains, there shall be a free chlorine residual of
not less than 10 mg/L of free chlorine.

Chlorine required to produce an initial 25-mg/L concentration in 100 ft of pipe by diameter

100% 1% Chlorine
Pipe Diameter Chlorine Solution
inches lb gal
4 0.013 0.16
6 0.03 0.36
8 0.054 0.65
12 0.12 1.44
16 0.217 2.6

The application of chlorine shall not cease until the entire main is filled with chlorinated water. The
chlorinated water shall be retained in the main for at least 24 hours.

The methods and techniques used for preliminary flushing and chlorinating the mains shall be as
described in Section 4.7 of AWWA C651-14 (or newer).

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Final Flushing
The heavily chlorinated water shall be flushed from the mains and appurtenances after the minimum 24-
hour holding and shall not remain in the mains more than 32 hours. The heavily chlorinated water shall
be flushed from the mains and appurtenances until chlorine measurements show that the concentration
in the water leaving the main is no higher than 2.0 mg/L of free chlorine.

There are two options available to dispose of the heavily chlorinated water:

1) Discharge to sanitary sewer is the preferred option. The discharge must be coordinated with
the City of Aurora Wastewater Treatment Plants. Care must be taken to prevent any potential
cross-connection during discharge into the sanitary sewer. To achieve this an appropriate air gap
must be employed between the hose and sewer opening.

2) Chemical dechlorinating utilizing a neutralizing agent. The environment to which the

chlorinated water is to be discharged shall be inspected. The Contractor shall be solely
responsible for any damage caused by the discharge of heavily chlorinated water. If there is any
question that the chlorinated discharge will cause damage to the environment, then a reducing
agent shall be applied to the water to be wasted to neutralize thoroughly the chlorine residual
remaining in the water. Reducing agents and their use shall comply with AWWA C655-18,
Appendix A. Where necessary, federal, state, and local regulatory agencies shall be contacted to
determine special provisions for the disposal of heavily chlorinated water.

Bacteriological Samples
Upon completion of the disinfection process, water samples shall be tested for bacteriological quality in
accordance with AWWA “Standard Methods for the Examination of Water and Wastewater” and shall
show the absence of coliform organisms. The contractor shall contact the City of Aurora Water
Department at (330) 995-9019 at least 24 hours in advance to schedule bacteria sampling. The water
shall sit for a minimum of 24 hours undisturbed for the first set of samples to be collected. The main will
be resampled again after a minimum of 16 hours during which the water is to remain undisturbed. Both
sets of samples must pass for the main to be approved for release.

Bacteriological samples shall be collected by the City of Aurora Water Department and tested at the
Portage County Water Resources (PCWR) laboratory. Samples are only collected on Monday, Tuesday,
Wednesday and Thursday mornings (between 7:30am – 12pm), excluding Holidays. Samples will NOT be
collected on Fridays, Saturdays, Sundays, Holidays or the day preceding a Holiday (if such holiday falls
during the week).

All of the water main that is covered by one OEPA permit must be tested and sampled as a complete
project. Bacteriological sampling will not begin until the entire length of the water main being permitted
by the OEPA for that particular project has been installed, pressure tested and chlorinated. Modifications
of this requirement must be discussed with the City of Aurora Engineering and Water Departments 7 days
prior to disinfection procedures.

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The number and location of sample assemblies shall be determined by the City of Aurora. Samples shall
be collected every 1,200 feet of the new water main, plus one set from the end of the line and at least
one from each branch greater than one pipe length (generally 20 feet). If trench water has entered the
new main, or if in the opinion of the City Representative, excessive dirt or debris has entered the pipe,
samples will be required every 200 feet.

Sampling assemblies shall be installed at a minimum every 1,200 feet of water main or as directed by the
City. A corporation cock will be installed in the main with a bacteria sampling assembly at each sampling
location. A curb stop or ball valve can be used in the portion of the assembly that is above ground to
facilitate the sampling procedure. At least 18 inches of smooth copper tube must extend beyond the
valve (located above ground) and be bent in a downward arc. Additional length shall be provided to
prevent flooding, to go into storm conveyance system, etc. Contractor shall be responsible for controlling
direction of flow to proper drainage location to prevent flooding. Once installed, Contractor shall not be
permitted to operate or otherwise tamper with bacteria sampling assemblies without approval from the
City. The bacteria sampling assembly shall not be removed until the Contractor has received written
notice that the main has passed all bacteriological tests per AWWA C651-92 Ohio EPA requirements.

Materials for bacteria sampling assemblies shall be as specified for service connection, with the exception
that a ball valve may be substituted for the curb stop. The ball valve shall be bronze, two piece body,
chrome plated, brass ball, Teflon seats and stuffing box ring, with lever handle and balancing stops, solder
or threaded ends with union; and shall be Model #S-587-70 or T-587-70 as manufactured by Nibco.

If bacteriological tests show the water to be safe, the main may be placed in service, only after receiving a
written confirmation from the City of Aurora. Upon receipt of written confirmation that the main has
been placed in service, the Contractor shall immediately remove all "bacteria sampling assemblies."

Re-Disinfection
If the initial disinfection fails to produce satisfactory bacteriological samples, the main may be re-flushed
and shall be resampled. If these second check samples continue to show the presence of coliform
organisms, then the main shall be re-chlorinated by the continuous-feed method of chlorination until
satisfactory results are obtained.

Final Connection to Existing Water Main

Upon final written approval from the City of Aurora that all bacteria testing requirements have been
completed with negative results, the new water main may be put into service. The valve connecting the
new water main to the existing main may be operated by City personnel or designated representatives.
Upon approval the tapping and installation of service connections may commence.