A practical Guide on field hydrostatic pressure test of high density polyethylene pipeline, Derived

from experiences and consultation.

(Hydrostatic test/Hydro-test/Pressure test)

By

Olanrewaju Saheed Olalekan.

 General introduction

Hydrostatic field test is universally known and accepted as the primary means of demonstrating the
fitness for service of a pressurized pipeline. It is the responsibility of the owner, through its agents
(engineer, contractor, or hydro-test Company) to develop its own safe and appropriate hydro-test
plan, taking into consideration all the elements Necessary for the test, in order to access and accept
the installed pipeline from the contractor. After hydrotest, a pipeline or pressure vessel component
may usually be expected to safely contain its intended operating pressure. However, even after a
successful hydro-test, leakage or forced ruptures may occur later, for a variety of other reasons. The
pre-commissioning hydrotest is simply one tool for evaluating a pipeline.

The concept behind hydro-testing is to strain the pipe, fittings and appurtenances. Any defects from
manufacturing or flaws from construction are typically forced by stress intensification to reveal
themselves by weeping, leaking, or rupture. Any remaining defects are considered sub-critical within
a tolerable flaw size limit, and should remain stable thereafter at the lower operating pressures.
Hydro-test provides the normal level of assurance for leak integrity and the absence of flaws that
exceed an intolerable flaw size. Generally speaking, the higher the ratio of test pressure to actual
operating pressure, the more effective is the test, within material stress limits.
 Aim and objectives of hydrostatic test

The purposes of the field hydrostatic pressure test of polyethylene pipes using water are many,
including:

 To access the installed structural integrity of the pipeline for acceptability.

 To reveal the occurrence of faults or defects in the pipe laying procedures, or even the pipe
itself.
 To validate that the pipeline will sustain an acceptable level of overpressure (10 bars) slightly
greater than its design pressure without leakages.
 Tools and equipments needed for the test.

 Installed HDPE Pipelines

 Flange set (Flange 320mm, 280mm,220mm Dia. X 25mm thickness ), (galvanized pipe 2'' Dia. X
4'' one end threaded outwardly), (iron plate 8mm thick ).
 Studs 150mmx24mm
 Relief valve 2''Dia
 Control valve 1'
 Bush(reducer) 2''- 1''
 Nipples 2''x2'',2''x1', 1/2''x1/2''
 Pressure gauges 16 or 20 bars.
 Pumping machine (pressurized pump)
 Set of spanner, hacksaw
 wrench , adjustable spanner, screwdrivers
 Pressure and ordinary hose 1''
 Plastic tanks 2 no of 2000 litres each
 Thread tapes
 Wheelbarrow and shovel
 Iron puncher(16mm iron rod, one end insulated )
 Saddles of different diameters

Definition of tools and equipments

HDPE PIPE:

Piping made from polyethylene is a cost effective solution for a broad range of piping problems in
municipal, industrial, marine, mining, landfill, duct and agricultural applications since 1950. It has
been tested and proven effective for above ground, surface, buried, slip lined, floating, and sub-
surface marine applications. High-density polyethylene pipe (HDPE) can carry potable water,
wastewater, slurries, chemicals, hazardous wastes, and compressed gases. It has the lowest repair
frequency per mile of pipe per year compared with all other pressure pipe materials used for urban
gas distribution. Polyethylene is strong, extremely tough and very durable. Whether you’re looking
for long service, trouble-free installation, flexibility, resistance to chemicals or a myriad of other
features, high-density polyethylene pipe will meet all your requirements.

FEATURES OF HDPE PIPE

LEAK FREE: Polyethylene pipe is normally joined by heat fusion. Butt, socket, sidewall fusion and
electro fusion create a joint that is as strong as the pipe itself, and is virtually leak free. This unique
joining method produces significant cost reductions compared to other materials.
CORROSION, ABRASION, AND CHEMICAL RESISTANT: HDPE has excellent corrosion resistance and is
virtually inert. It does not need expensive maintenance or cathodic protection. It offers better
overall resistance to corrosive acids, bases and salts than most piping materials. In addition,
polyethylene is unaffected by bacteria, fungi and the most “aggressive” naturally occurring soils. It
has good resistance to many organic substances, such as solvents and fuels.

EXCELLENT FLOW CHARACTERISTICS: Because polyethylene is smoother than steel, cast iron, ductile
iron, or concrete, a smaller PE pipe can carry an equivalent volumetric flow rate at the same
pressure. It has less drag and a lower tendency for turbulence at high flow. Its superior chemical
resistance and “non-stick” surface combine to almost eliminate scaling and pitting and preserve the
excellent hydraulic characteristics throughout the pipe service life.

LIGHTWEIGHT AND FLEXIBLE: Polyethylene pipe is produced in straight lengths or in coils. Made
from materials about one-eighth the density of steel, it is lightweight and does not require the use of
heavy lifting equipment for installation. It reduces the need for fittings, is excellent in shifting soils
and performs well in earthquake-prone areas. HDPE resists the effects of freezing and allows
bending without the need for an excessive number of fittings. Since HDPE is not a brittle material, it
can be installed with bends over uneven terrain easily in continuous lengths without additional
welds or couplings.

DUCTILITY AND TOUGHNESS: Polyethylene pipe and fittings are inherently tough, resilient and
resistant to damage caused by external loads, vibrations, and from pressure surges such as water
hammer. Even in cold weather polyethylene pipe is tolerant to handling and bending.

MANUFACTURED UNDER AWWA, NSF, ASTM, AGA, EPA, DNR, DOT, API, FM, and CSA AND OTHER
NATIONALLY RECOGNIZED STANDARDS: Polyethylene pipe is listed and approved by the standards or
committees of the agencies listed above.

AVAILABLE IN DIAMETERS FROM ½ INCH TO 63 INCH: Polyethylene pipe is available in a wide range
of diameters and wall thickness, with flanges, elbows, tees, wyes, and valves, providing a total
system solution. HDPE pipe is also available in Iron Pipe Size (IPS), Ductile Pipe Size (DIPS) as well as
metric sizes. Plastic Pipe Institute members can provide pipe, fittings and other appurtenances.

APWA COLOR CODING BY APPLICATION: Polyethylene pipe is available with color coding by
application as developed by the utility location and coordination council of the American Public
Works Association (APWA).
ASSEMBLAGE OF THE FLANGE SET

(a) Welding work procedures

 Take a flange of required size 340mm or 280mm or 220mm Dia.

 Measure and cut the 8mm iron plate required to cover centre of the flange
 Measure and bore a hole of 2'' at the centre of the flange.
 Weld (fully) the 2'' galvanized pipe to the centre of the plate.
 Give the plate full welding (butt-weld) inwardly and outwardly to the flange as shown in
Figure a and b.

Note: full welding is paramount to prevent leakages.

(b) Tightening work procedures

 Pick and tight a 2'' relief valve to the threaded side of the welded galvanized pipe.
 Make sure it's tight with the help of a thread tape and wrench.
 Tight a bush (reducer) of 2''-3/4'' to the other end of the valve.
 Connect the 3/4'' tee to the Bush (reducer) with the use of 3/4'' nipped and tight
adequately.
 Connect a 1'' control valve to the second side of the 3/4'' tee with the help of a nipped and
tight adequately.
 Fix the Pressure Gauge to the third side of the 3/4'' tee (right angle to the others end) with
the help of 3/4''- 1'' bush and tight properly.
 The other side of the control valve will be connect to the 1'' pressure hole with the help of a
nipple, the hose connected to the pumping machine as shown in Figure c, d and e.

Note: All external thread must be fastening with thread tape adequately to prevent leakages.
 HYDROSTATIC TEST (PUMP TEST / PRESSURE TEST)
Polyethylene pipe is a lower modulus visco-elastic material that dilates in diameter (creep-strains)
when subjected to higher stress during hydrotest. This means that for a fixed volume of clean fill
water, the hydrostatic pressure will decline slightly during the test time, as the polyethylene
molecular chains stretch and align under high stress. This pressure decline does not mean the
polyethylene is leaking. It is a visco-elastic material parameter that requires adjustments to the
hydrostatic test procedure as compared to rigid elastic metallic pipes. This effect is more noticeable
in larger diameter HDPE pipes, due to the large mass of clean fill water. Alternately, to hold constant
pressure, an additional volume of make-up water will be required to fill the expanded volume of the
stretched pipe diameter. Neither of the above two observations mean that a leak is presents in the
pipeline.

FACTORS THAT DETERMINE THE ACURACY OF THE TEST

Hydrostatic pressure testing requires adopting an appropriate combination of method,

pressure, time duration and length of test section. The test parameters and test details usually
are determined with due consideration for the following:

 Pipe material

 Pipe diameter and working pressure rating

 Length of test section

 Duration of the test

 Magnitude of the test pressure and planned rate of pressurization

 Presence of air in the pipeline

 Potential movement of pipeline thrust restraints

 Accuracy of test equipment

 Ambient temperature changes during testing (stability of the temperature)

 Presence of small leaks in hydrotest equipment or connections used

 Accurate volume of water required for the test pressure. this can be calculated as:

Volume of a cylinder = pie square radius height or pie square diameter over 4 height.

E. G : calculate the quantity of water required for a pipe of 110mm diameters and 918m
height. Note: radius =diameter / 2, r2 =d2/4.

3.142 X (0.11/2)2 x 918 = 8.7251769 cubic meters.

8.7251769 x 1000 = 8725.2litres. Divide it by the litres in your tanker to get it in trip.
 e. g.: 1 tanker is 7000 litres, 8725/7000 = 1.25 trips.

Multiplying factors:

 500mm pipe =196.375

 400mm pipe =125.68

 300mm pipe =70.695

 200mm pipe = 31.42.

 160mm pipe = 20.1088.

 110mm pipe = 9.50455.To be multiply by the length of test pipe to obtain litres of
water required.

Note: It is advisable to begin testing early during the pipeline installation to confirm adequacy of
the fusion, laying, embedment procedures, and then later to progressively increase the length
of test section, as experience is gained. Polyethylene pipe lengths as long as 1000 meters, or 3000
feet, have been commonly tested.

PRE-TEST EXERCISES

 Conduct a reconnaissance survey of the pipeline section to be tested, to verify if installation

is done in conformity to the drawing.
 Locate the necessary joints, fittings, service connection, and endcap e.t.c for easy inspection
during test.
 Create a vent on the endcap to expel air and saddle should be fix and tight adequately.
 Install adequate air vent valve on the saddle via nipple of adequate size.
 Connect the flange set to the pipe flange with the use of bolts and nuts and fasten properly.

NOTE: it is advisable to divide the flange set into two parts for conveniences; remove the 2''-3/4'' tee
from the relief valve to form two different components.

 Connect the pressure hose from the outlet of the pumping machine to the control valve
located on the flange set.
 Connect the ordinary hose from the make-up water tank to the inlet of the pumping
machine with the use of galvanized clip as shown in Figure f.

THE TEST PROCEDURES

 Connect a 2'' threaded galvanized pipe to the relief valve.

 Connect the water tanker hose to the pipe and hold firmly with the aid of clips
 Open the relief valve and pump the water into the pipe until all the air are expelled and
water start gushing out of the air vent valve located on the saddle.
NOTE: One personnel with cell phone or radio should mount the saddle to notify other personnel at
the flange end when water starts gushing out of the valve.

 The air vent valve should be close, pumping stopped, relief valve closed and the remaining
water pumped into the make-up tanks.
 Connect the flange set together and on the pumping machine.

NOTE: All valves (relief and control valves) must be kept opened before you on the pump to prevent
damage of the pump.

 Survey round the test pipe section to note the occurrence of leakages, faults or rupture of
the pipe.
 Continue the make-up pumping until the gauge read 10 bars (145psi).
 Off the Pump, close the relief valve and the control valve to sustain the pressure.

Note: pumping machine must be off before you close the valves to prevent damage to the pump.

 Notify the consultants for necessary approval.

NOTE: When slight reduction is noticed in the pressure before the arrival of the consultants, push
the pressure back to the appropriate test pressure.

After the approval, disconnect all fittings connected to the fangeset before you De-pressurized.

De-pressurizing procedures

After hydro-test has been successfully completed, the elevated pressure within the test section is to
be safely reduced either from the relief valve or the air vent valve located on the saddle by:

 Open the valve slightly until there is reduction in the water pressure.
 Open the valve completely until all the drainable water drain out of the pipe.
 Loose the saddle or saddles and the flange for another section of the same diameter.
 Cover the mouth of the pipe to prevent entries of dirties or debris
 GENERAL PRECAUTIONS

(A) Pumping machine and other tools

 Always check the level of the engine oil and fuel before you on the pump.
 Don't on or off the pumping machine in any circumstances against a close valve, be it relief
or control valve or else will damage some parts of the pump.
 All bolted parts should be checked for necessary re-tightening.
 The gradient between the pump inlet and the make-up water tank should not exceed
500mm, especially when the pump head in insignificant.
 Is the pressurizing pump "right sized"? Too small of a pump will extend the test duration and
too large of a pump may inhibit adequate control of the pressure.
 All tools should be handled safely and with care, because lost or damage of a single too can
hinder successfulness of the test.
 All equipments must be reviewed for capacity to perform it's functions without fault during
the test.

(B) Pipeline and other fittings

 The pipeline section to be tested must be ready for test.

 It must be supported by back filling or otherwise restrained by sand bags to prevent lateral
movement or axial contraction under test pressure.
 Atleast two calibrated pressure gauges should be used as a cross-check for gauge accuracy.
 All trapped air must be removed from the pipe at high point preferably.
 All external thread must be fastening with thread tape adequately to prevent leakages.

(C) Personnel and the test environment

 Safety meeting should be held weekly to review the safety measures and safe practices that
are being employed.
 All test Personnel must have a radio or cell phone communication so that the test progress
at remote, non line-of-sight sections can be monitored for venting, or possible leaks or other
problems.
 Citizens within the test environment should be notified of the intent to conduct hydrostatic
test.
 During testing or dewatering, there are possible unrecognized hazards that may not have
been completely controlled, such as unexpected high pressure from internal malfunctions or
equipment. Failure, rupture of the pipe or fusion joint, un-detected flaws. Such situations
may develop forces large than the design capacities of the Anchorages. All non-essential
people should be excluded from the test zone.
 References
 Field experiences
 Guidance for Field Hydrostatic Testing of High Density Polyethylene Pressure Pipeline:
Owner’s Considerations, Planning, Procedures, and Checklists TN-46/2013a. By PPI.
 HDPE: High density polyethylene pipe system Meeting the challenges of the 21st century by
PPI (Plastic pipe Institute).
 www.plasticpipe.org.
Figure A
Figure B & C
Figure D
Figure E
Figure F