Method statement of Hydraulic Pressure Testing
--- For DMA - J1 & J1A
Before commencement of service connection in each DMA, the Hydraulic Pressure
Testing for whole DMA has to be done in order to check and make sure the whole DMA no
leakage occurred in pipeline system. This method statement describes how to do the
hydraulic pressure testing for DMA - J1 & J1A only. The details of pipeline system for DMA -
J1 & J1A are as follow:
Qty’s of
Sl. No. Pipe Type Pipe Dia. (mm) Approx. Length (m) Qty’s of WO Qty’s of Valve Remarks
End Cap
1 HDPE dn90 (DN75) 12,135.22 104 7 3
2 HDPE dn125 (DN100) 5,740.22 - - 2
3 HDPE dn180 (DN150) 3,247.80 - - 2
4 HDPE dn250 (DN200) 384.50 - - 4
5 HDPE dn315 (DN250) 66.00 - - -
Total: 21,573.74 104 7 11
Note: the Sketch of Gate Valve & Washout etc. (J1 & J1A) is attached as per attachment.
1. Material
The major materials used for the Hydraulic Testing, but are not limited to the
following:
1) HDPE Tee 03 Nos.
2) HDPE E/F Coupler 05 Nos.
3) HDPE Flange Adaptor 03 Nos.
4) Gate Valve 01 No
5) Saddle Clamp As required
6) Ferrule As required
7) Service Connection Pipes As required
8) Ball Valve As required
9) Service Connection Fittings As required
10) Flange Gaskets As required
11) Bolts, Nuts and Flat Washers As required
Pressure Test Method statement of Hydraulic Pressure Testing for DMA‐J1 & J1A – Rev. 02.09.2020
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12) Fabricated G.I pipes As required
13) G.I Bends, Tees, Reducers and Sockets etc. As required
14) Cock Valves As required
15) Pressure Gauge As required
16) Sealing Tapes As required
17) Water As required
2. Machinery / Equipment and Tools
1) Pressure Pump (Hand / Electrical Type) with High Pressure Hose
2) Water Tank with Water Hose and Filling Pump
3) Pipe Wrench
4) Spanner
5) Wrench
6) Plier
7) Screw Driver (Minus & Plus)
8) Hand Saw
3. Manpower
1) Unskilled Labor 08
2) Skilled Labor 03
3) Driver / Operator 03
4) Site In-Charge 01
4. Procedure
As the pressure testing for whole DMA, firstly, how to get the water is the most
important for this test. Basically, the water can be temporarily obtained from the
existing HDPE water pipeline after getting approval from the CWASA, otherwise, the
water bowser or deep well has to be arranged for filling water. Secondly, how to fill
water into the pipeline system and discharge, releasing the air and water from the
pipeline system are also important for this test. For this consideration, some of
house service connections shall be arranged on the suitable location within the
pipeline system due to no any washout and gate valve has been installed up to end
point in the pipeline system. The details of procedure are following:
A) Preparation
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The Temporarily Connecting Diagram for Obtaining Water from the Existing HDPE
Water Pipeline
Disconnect the sections of pipeline that isolated from the other pipeline
system if applicable.
Selecting the suitable location for connecting the existing HDPE water
pipeline and new laid HDPE pipeline in order to obtain the water from the
existing HDPE water pipeline.
Exposing the existing HDPE water pipeline and new laid HDPE pipeline by
using machinery or manual.
Closing the gate valve installed on the existing HDPE water pipeline and
cutting the existing HDPE pipeline.
Fixing the HDPE Tee and E/F Coupler on the existing HDPE water pipeline,
and connecting to the new laid HDPE pipeline, one gate valve has to be
installed between the existing HDPE water pipeline and the new laid HDPE
pipeline.
Fixing the tee, flange adaptor, filling water G.I pipe, cock valve, air release
pipe with cock valve, pressure raising pipe with cock valve, pressure gauge
pipe with cock valve etc. between the gate valve and the new laid distribution
pipe net.
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Fixing the saddle clamp, ferrule, service connection fittings, service
connection pipe with ball valve at the end point of new laid HDPE pipeline
within DMA.
The Connecting Diagram for discharging, releasing Air and Water at the end point
of HDPE pipeline
B) Filling Water
Before obtaining the water from the existing HDPE water pipeline to the new
laid HDPE pipeline by opening the gate valve installed between the existing
HDPE pipeline and new laid HDPE pipeline, the air release cock valves and
pressure raising cock valve shall be kept open position, the pressure gauge
cock valve also can be kept open position and the pressure gauge will not be
fixed right now, and also the all ball valve installed at the end point of new
laid HDPE pipeline within DMA shall be kept open position.
Filling water by opening gate valve installed between the existing HDPE
pipeline and new laid HDPE pipeline through the existing HDPE water
pipeline with pressure into the new laid HDPE pipeline.
The filling shall be carefully done by controlling the open of gate valve, the
water slowly go into new laid HDPE pipeline and the air in the pipeline will be
released through air release pipe with opened cock valve and ball valve. At
the filling time, all roads where HDPE pipelines have been installed with-in
the DMA being tested shall be checked and investigated, no water comes out
from underground or no seepage on the road surface is seen. Otherwise,
stop filling water and repair all leaks.
If the water obtained from the existing HDPE water pipeline can not be
sufficient to fill the new laid pipeline system within DMA, then close the gate
valve installed between the existing HDPE pipeline and new laid HDPE
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pipeline and starting the filling pump to fill the water into the new laid pipeline
system through the water tank.
When the filling water come out from the air release pipe or pressure gauge
pipe or ball valves, it is necessary to continue filling water without closing the
air release / pressure gauge cock valve and ball valves few minutes.
After that, the air release cock valve and the pressure gauge cock valve
could be closed, and the ball valves also could be closed one by one. When
all ball valves have been closed, then, the filling pump shall be stopped and
ready to raising pressure of new laid HDPE pipeline.
In order to make sure that the entire system is pressurized, additional
pressure gauges shall be installed at various locations within the DMA as per
attachment – Proposed Location for Installation of Pressure Gauges.
C) Raising Pressure
Before start to raising pressure of pipeline, the pressure pump (Electrical
Type) shall be checked and tested without connecting to the pressure raising
pipe.
Connecting the pressure pump (Electrical Type) to pressure raising pipe
through pressure hose. Before starting the pressure pump, continuing to fill
water to new laid HDPE pipeline through the water tank by filling pump, after
that, opening the pressure raising pipe cock valve and monitoring the
indicator of pressure gauge.
Note: Before fixing the pressure gauge, the pressure gauge pipe cock valve
cold be slowly opened and closed, make sure the air in the pressure gauge
pipe has been released, and then fixed the pressure gauge to the pressure
gauge pipe and open the pressure gauge pipe cock valve.
When the pressure shown pressure gauge fixed at pressure raising pipe is
going up, the air release pipe cock valve and all ball valves installed at end
points of pipeline within DMA could be slowly opened and closed to release
the air in the pipeline.
Stop the filling pump and start the pressure pump to continue raising the
pressure. When pressure of pipeline is rising, care shall be taken to checking
all the roads, road surface which have been laid the pipelines etc. no
leakages or no damages etc. could be found in those positions. Otherwise, it
shall be removed, re-fixed and refilled as per above steps.
Check the pressures in other gauges to make sure that the entire system is
being pressurized.
Monitoring the pressure gauges, if the pressure shown in the pressure gauge
is going down slowly, open the air release pipe cock valve and ball valves to
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release air again and re-raising the pressure as per above steps. If the
pressure shown in the pressure gauge is going down quickly, the leakages
may happen in the pipeline, the pipeline should be repaired before starting
the Hydraulic Pressure Test. If the pressure shown in the pressure gauge is
unchangeable, then stop the pressure pump, the pipeline is ready to do
Hydraulic Pressure Test. Pressure in the pipeline shall then be raised steadily
up to, and maintained at the working pressure for a period of not less than 24
hours.
D) Hydraulic pressure testing and Recording
As per design models of W-3-2, the Working Pressure of pipeline for W-3-2 is
less than 40m water head, therefore, 60m water head (0.6Mpa) pressure shall be
considered as Testing Pressure unless otherwise noted.
After the Employer and Consultant’s Representative reached to Hydraulic
Testing location, open the air release pipe cock valve to release the water of
pipeline, the pressure of pipeline shown in the pressure gauge will be gone
down.
Close the air release pipe cock valve under the instruction of Employer and
Consultant’s Representative, re-rise the pressure of pipeline by using
pressure pump to reach the Testing Pressure and stop the pressure pump.
Monitoring all pressure gauges at interval of 1/2 hrs, recording the readings
of pressure gauge and filling the water by using pressure pump to keep the
pressure as the testing pressure, the added volume of water also have to be
recorded for each time. The monitoring is going to 2 hrs. At the end of 2 hrs.,
calculate the total added water volume and compare with the allowed
leakage volume calculated according to the specifications. If the total added
water volume is less than the calculated figure, the Hydraulic Pressure Test
shall be considered as PASSED, otherwise, the Hydraulic Pressure Test
shall be considered as FAILED.
If the Hydraulic Pressure Test was failed, the leakage of pipeline has to be
found and repaired. After that, the re-pressure testing has to be done as per
above step.
When pressure test completed, Hydraulic Test Record as Appendix-A has to
be signed by the Employer, Consultant and Contractor’s Representatives.
E) Discharging Water and Backfilling
After completion of Hydraulic Pressure Test, the pressure of pipeline has to be
released and the water in the pipeline has to be discharged.
Remove the water tank and pressure pump from Hydraulic Pressure Test
location.
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Close the pressure gauge pipe cock valve and remove the pressure gauge
from the pressure gauge pipe.
Open the air release pipe cock valve and all ball valves carefully and slowly,
release the water in pipeline to water tank or sufficient drainage system.
Dismantle the fixed Hydraulic Testing system step by step. And keep the
saddle clamp, ferrule and etc. at end point of pipeline as permanent house
service connection.
The disinfection and flushing of pipeline (refer to Method Statement of
disinfection and flushing for DMA - J1 & J1A) shall be done accordingly.
Removing the Gate Valve installed between the existing HDPE pipeline and new
laid HDPE pipeline and blocking the water from the existing HDPE pipeline by
using HDPE end cap.
Backfilling the working pits which have been excavated for pressure testing,
disinfection and flushing of pipeline.
5. Safety Management and Control
Expose of location for hydraulic pressure testing would be selected for
convenience of traffic.
Necessary warning arrangements prior to hydraulic pressure testing. Warning
sign Boards, Traffic Cones and Barricading tapes would be used for the traffic
diversion, works & separating working Area if necessary.
During the night time, expose of location will be properly barricaded.
Unnecessary earth, debris and obstructions will be removed from the road as
soon as possible to allow the road users to use the road without any
inconvenience.
Follow Health & Safety Plan.
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KARNAPHULI WATER SUPPLY PROJECT-Phase 2
FIELD HYDRAULIC PRESSURE TEST OF DMA NETWORK RECORD SHEET
Contract No KWSP2/W-3-…. Primary / Secondary / Tertiary Date:
Location DMA – …….
Working pressure: 4 bars (0.4 Mpa) Test Pressure: 6 bars (0.6 MPa)
Size/Type Length (m) Location /Remarks
Pipeline Details
All permanent thrust blocks complete : ☐ Yes ☐ NO
All permanent valves installed: ☐ Yes ☐ NO
Temporary air release points provided : ☐ Yes ☐ NO
Preparation
Water Source: …………………………………………………………………………..
Start time of filling: ………………………………………………….
Start time of working pressure reached: ………………(maintain 24 hrs min)
Start time of test pressure reached: …………………………
Pressure (bars)
Time (Clock) Tim (hr: min) Volume Added (L)
Before filling After filling
0:00 Start N/A
Pressure Testing 0:30
Record at P0 1:00
(Feeding Point) 1:30
2:00
2:30
3:00
3:30
4:00 End Total
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Pressure (bars) at other Pressure Gauges before and after filling
Pressure (bars)
Time Time
(Clock) (hr: min) P1 P2 P3 P4 P5
Before After Before After Before After Before After Before After
0:00 Start Start Start Start Start
0:30
1:00
1:30
2:00
2:30
3:00
3:30
4:00 End End End End End
Note: If the end of 2 hours, the pressure of pipe line does no drop, then the testing has to be stopped.
Maximum allowable volume [0.001389 Litre x dia (mm) x Length (km)
………..(Litres)
x Duration (hr) x Pressure (bars)]
Recorded maximum % pressure drop during last 30 min ……….
Results Analysis
Is volume added less than allowable? ☐ Yes ☐ NO
Is maximum pressure drop during last 30 min less than 10%? ☐ Yes ☐ NO
TEST ☐ PASSED ☐ FAILED
Comments
…………………………………… .……………………………………
CGC (Name, Signature and Date) NJS (Name, Signature and Date)
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