SUMMARY:

HYDROTESTING HDPE WATER LINES

By: Camille George Rubeiz, P.E., F. ASCE, Plastics Pipe Institute, Inc. (PPI)

H
igh-density polyethylene (HDPE) The following is an overview of using of make-up water will be required to fill
pipe has been used for municipal hydrotesting and the steps to take before the expanded volume of the stretched
and industrial water applications a potable line is put into service. The pipe diameter. Neither of the above two
for some 50 years. HDPE’s heat-fused joints purposes of hydrostatic field testing observations means that a leak is present in
create a leak-free, self-restraint, monolithic of HDPE pressure pipes using water the pipeline.
pipe structure. The fused joint will also include: There are two test methods which can
eliminate infiltration into the pipe and • Assessing the installed structural be used, depending upon the objectives of
exfiltration into the environment. HDPE integrity of the pipeline for the test program. The easiest and quickest
pipe has other benefits including chemical, acceptability. method suitable for all pipe diameters is
abrasion, fatigue, seismic and corrosion • Revealing the occurrence of faults or the Modified Rebound Method originally
resistance, and is designed for water and defects in the pipe laying procedures, as developed by Lars-Eric Janson in the 1980’s.
wastewater applications meeting the latest exemplified by damaged pipe or fusion As a similar alternate, ASTM F2164 instructs
AWWA C906 and ASTM F714 standards.  joints non-conforming to the qualified to fill and then thermally stabilize the
It is advisable to begin testing early during fusion procedures. pipeline with no air entrapment, pressurize
the pipeline installation to confirm adequacy • Finding the occurrence of faults in the pipeline at test pressure for four hours,
of the fusion, laying, embedment procedures, the assembly procedures for pipeline slightly reduce the pressure, and then
and then later to progressively increase the components, as exemplified by tapping observe the pressure for one hour to remain
length of test section as experience is gained. bands or saddles, flange sets, or essentially constant (within five percent
Hydrostatic testing is universally known mechanical joint assemblies. variation) to achieve an acceptable test.
and accepted as the primary means of • Validating that the pipeline will sustain In the US and Canada, the prevailing
demonstrating the fitness for service of a an acceptable level of overpressure hydro-test method is ASTM F2164, Standard
pressurized component. HDPE pipelines slightly greater than its design pressure, Practice for Field Leak Testing of Polyethylene
as long as 3000 feet have been commonly without leakage. Pressure Pipe Systems Using Hydrostatic
tested. It is important to note that field testing Pressure. The ASTM method is essentially
is not intended to supplement or replace a hydrostatic “pressure rebound method”
product standard test requirements. and is referenced in the AWWA M55 (2020),
Polyethylene pipe is a lower modulus PE Pipe- Design and Installation and is
visco-elastic material that dilates in summarized below:
diameter (creep-strains) when subjected • Test pressure: Up to 1.5 times the working
to higher stress during hydrotest. This pressure and is taken at the lowest point in
means that for a fixed volume of clean elevation along the pipe’s test section.
fill water, the hydrostatic pressure • Leak test can be dangerous; restrain test
will decline slightly during the test section against movement
time, as the polyethylene molecular • Fill slowly to remove air
chains stretch and align under high • Maintain test pressure for 4 hours; add
stress. This pressure decline does not makeup water as needed to keep the
mean the polyethylene is leaking. It is pressure constant; water amount is not
a visco-elastic material parameter that monitored
requires adjustments to the hydrostatic • Reduce pressure by 10 psi and monitor
test procedure as compared to rigid pressure for 1 hour
elastic metallic pipes. This effect is • Pass if pressure stays within 5% of the
more noticeable in larger diameter reduced pressure
HDPE pipes, due to the large mass of In addition, the AWWA M55 (Chapter 9)
Hydrotesting can be used on runs of HDPE pipe clean fill water. Alternately, to hold describes general hydrostatic testing, based
that are hundreds of feet long constant pressure, an additional volume on ASTM F2164.

36 NASTT-NE NORTHEAST JOURNAL OF TRENCHLESS TECHNOLOGY PRACTICES SPRING 2022 | WWW.NASTT-NE.ORG

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 There are basically six steps to putting a HDPE pipe are fused together, leakage 5. Disinfection
new waterline in service: should be zero. Leak tests need to be
All new potable water pipelines
• Flushing conducted in accordance with ASTM F2164.
require disinfection in accordance with
• Filling For HDPE pipe, a pressure of 1.5 times ANSI/AWWA C651. This should take
• Testing for Leaks the design working pressure at the lowest place after the initial flushing and after
• Record Keeping point in the test section is used as the test pressure testing the line. Disinfecting
• Disinfection pressure. Acceptance is found by reducing solutions containing chlorine should
• Commissioning the test pressure by 10 psi and monitoring not exceed two percent active chlorine.
the pressure for one hour. If the pressure As soon as the normal pipe disinfection
1. Flushing remains steady – within five percent of the period is over, the disinfection solution
target value – for one hour, leakage is not should be purged and/or neutralized,
A new pipeline should be thoroughly
flushed prior to testing. This will help indicated. and the pipeline filled with fresh, clean
to prevent any damage to valves or other water. Remember, purging applies to
fitting from any foreign material left in 4. Record Keeping distribution mains as well as to each
the pipeline. This can be done by opening service line and service connection.
Test records should include:
and closing hydrants, blow-offs or drains • Name of person conducting the test,
with flow velocities sufficient to flush 6. Commissioning
including company and contact
the foreign material from the pipeline. A information The commissioning of a new or
minimum of 3ft/s is suggested. • Test medium – usually water repaired pipeline is normally carried out
• Test pressure in the following sequence:
2. Filling • Test duration and data • Cleaning and/or pigging of the pipeline
Slowly fill the pipeline to limit the flow • Pressure recording chart of pressure log • Water filling and pressure test
to low velocities that prevent surges and air • Pressure vs. makeup water added chart • Disinfection
entrapment. Also, air valves at high points • Pressure at high and low elevations • Flushing, purging, and/or
should be opened to allow air to escape as neutralization
• Elevation at the point test pressure is
the water level increases inside the pipeline. • Refilling the pipeline
measured
Temporary valves can be installed. Do not • Bacteriological sampling and testing
• A mbient temperature weather conditions
loosen flanges or connections to bleed air • Certifying and acceptance
• Pipe and valve manufacturers
from the system. The critical filling rate for • Initiating the pipeline into service
• Pipe specifications and/or standards such
pipes with air vents is usually based on five as AWWA C906-21
to fifteen percent of the pipe design flow. Additional information can be found in:
• Description of the test section length,
• ASTM F2164
location and components
3. Testing for Leaks • AWWA Manual M55,
• Description of any leaks, failures and their • PPI’s Handbook of Polyethylene Pipe
Leak testing can be done either inside repair/disposition • PPI’s newest technical document, TN-46
or outside the trench. Because joints for • Test times and dates Guidance for Field Hydrostatic Testing
of High-Density Polyethylene Pressure
Pipelines.

ABOUT PPI:
The Plastics Pipe
Institute, Inc.
(PPI) is the major
North American
trade association
representing the plastic pipe industry and is
dedicated to promoting plastic as the
materials of choice for pipe and conduit
applications. PPI is the premier technical,
engineering and industry knowledge
resource publishing data for use in the
development and design of plastic pipe and
conduit systems. Additionally, PPI
collaborates with industry organizations
When disinfecting an HDPE potable waterline, it is important that purging applies to that set standards for manufacturing
distribution mains as well as each service line and service connection. practices and installation methods.

38 NASTT-NE NORTHEAST JOURNAL OF TRENCHLESS TECHNOLOGY PRACTICES SPRING 2022 | WWW.NASTT-NE.ORG