33 05 05.31 - Hydrostatic Testing.pdf
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This is a technical specification document for hydrostatic testing procedures applicable to the North Earl Street Low Pressure Sanitary Sewer Extension Project (Project No. 011361.0461) being procured by the Weaverland Valley Authority in Lancaster County, Pennsylvania. The specification details requirements for hydrostatic testing of pressure piping systems, including ductile iron, PVC, and polyethylene (PE) piping. For ductile iron or PVC piping, contractors must conduct hydrostatic tests at 1.5 times the working pressure for a minimum of two hours, with allowable leakage calculated using a specified formula based on pipe length, diameter, and test pressure; the specification requires pressure maintenance within plus or minus 5.0 psi of test pressure and mandates correction and retesting of any visible leaks regardless of quantity. For polyethylene piping, testing must comply with ASTM F 2164 standards, requiring a 150 psi hydrostatic test for two hours, followed by a pressure reduction phase where pressure must remain within 5 percent of target pressure for one hour with no additional makeup water added; piping showing visual leakage must be depressurized for a minimum of eight hours before retesting.
Submittals required prior to testing initiation include detailed testing procedures, equipment lists, testing sequence schedules, provisions for disposal of flushing and test water, and certification of test gage calibration. All testing equipment must be calibrated and include pressure pumps, pressure hoses, water meters, test connections, pressure relief valves, and pressure gages calibrated to 0.1 psi accuracy. The specification references AWWA C600 standards for ductile iron installations and requires verification that trenches are backfilled and pressure piping thrust restraints are installed before testing commences. No pricing information, set-asides, incumbent vendors, or contract award details are contained within this technical specification document.
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33 05 05.31 - HYDROSTATIC TESTING
Herbert, Rowland & Grubic, Inc. 33 05 05.31 - 1 011361.0461
SECTION 33 05 05.31 - HYDROSTATIC TESTING
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes: Hydrostatic testing of pressure piping.
B. Related Requirements:
1. Section 33 31 26 - Sanitary Pressure Sewer Piping: Pipe materials and accessories normally encountered with municipal sanitary sewage force mains.
1.2 REFERENCE STANDARDS
A. American Water Works Association:
1. AWWA C600 - Installation of Ductile-Iron Water Mains and Their Appurtenances.
B. American Standard Testing Methods
1. ASTM F 2164 - Standard Practice for Field Leak Testing of Polyethylene (PE) and
Crosslinked Polyethylene (PEX) Pressure Piping Systems Using Hydrostatic Pressure
1.3 SUBMITTALS
A. Section 01 33 00 - Submittal Procedures: Requirements for submittals.
B. Submit following items prior to start of testing:
1. Testing procedures.
2. List of test equipment.
3. Testing sequence schedule.
4. Provisions for disposal of flushing and test water.
5. Certification of test gage calibration.
C. Test and Evaluation Reports: Indicate results of piping tests.
PART 2 - PRODUCTS
2.1 HYDROSTATIC TESTING
A. Equipment:
1. Pressure pump.
2. Pressure hose.
3. Water meter.
4. Test connections.
5. Pressure relief valve.
6. Pressure Gage: Calibrated to 0.1 psi.
Herbert, Rowland & Grubic, Inc. 33 05 05.31 - 2 011361.0461
PART 3 - EXECUTION
3.1 EXAMINATION
A. Section 01 73 00 - Execution and Closeout Requirements: Requirements for installation examination.
B. Verify that piping is ready for testing.
C. Verify that trenches are backfilled.
D. Verify that pressure piping thrust restraints have been installed.
3.2 FIELD QUALITY CONTROL
A. Section 01 40 00 - Quality Requirements: Requirements for inspecting and testing.
B. Testing of Pressure Ductile Iron or PVC Piping:
1. Test system according to AWWA C600 and following:
a. Hydrostatically test each portion of pressure piping, including valved section, at 1.5 times working pressure of piping, based on elevation of lowest point in piping corrected to elevation of test gage.
b. Conduct hydrostatic testing for at least two hours.
c. Slowly fill with water portion of piping to be tested, expelling air from piping at high points.
d. Install corporation cocks at high points.
e. Close air vents and corporation cocks after air is expelled.
f. Raise pressure to specified test pressure.
g. Observe joints, fittings, and valves undergoing testing.
h. Remove and renew cracked pipes, joints, fittings, and valves that show visible leakage.
i. Retest.
j. Correct visible deficiencies and continue testing at same test pressure for additional two hours to determine leakage rate.
k. Maintain pressure within plus or minus 5.0 psi of test pressure.
l. Leakage is defined as quantity of water supplied to piping necessary to maintain test pressure during period of testing.
m. Compute maximum allowable leakage using following formula:
1) L = [SD x sqrt(P)]/C.
2) L = testing allowance, gph.
3) S = length of pipe tested, feet.
4) D = nominal diameter of pipe, inches.
5) P = average test pressure during hydrostatic testing, psig.
6) C = 148,000.
7) If pipe undergoing testing contains sections of various diameters, calculate allowable leakage from sum of computed leakage for each pipe size.
2. If testing of piping indicates leakage greater than that allowed, locate source of leakage, make corrections, and retest until leakage is within acceptable limits.
Herbert, Rowland & Grubic, Inc. 33 05 05.31 - 3 011361.0461
3. Correct visible leaks regardless of quantity of leakage.
C. Testing of Pressure PE Piping:
1. Test system according to ASTM F 2164 and following:
a. Hydrostatically test each portion of pressure piping, including valved section, at 150 psi for 2 hours.
b. Initial expansion phase
1) Slowly fill with water portion of piping to be tested, expelling air from piping at high points.
2) Install corporation cocks at high points.
3) Close air vents and corporation cocks after air is expelled.
4) Raise pressure to specified test pressure.
5) Observe joints, fittings, and valves undergoing testing.
6) Add make-up water as necessary to maintain maximum test pressure for 2 hours.
c. Test Phase:
1) Immediately after expansion phase, reduce test pressure by 10 psi and stop adding makeup water.
2) Monitor pressure for 1 hour.
d. Remove and renew cracked pipes, joints, fittings, and valves that show visible leakage.
e. Retest after section is depressurized for 8 hours, minimum.
f. If no visual leakage is observed and test pressure remains within 5% of the target pressure, no leakage is indicated.
2. If testing of piping indicates leakage, locate source of leakage, make corrections, and retest until leakage is within acceptable limits.
3. Correct visible leaks regardless of quantity of leakage.
END OF SECTION
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