PRESSURE TESTS IN WATER INSTALLATIONS

CONSTRUCTION STANDARD FOR HYDROSTATIC PRESSURE TEST IN DRINKING WATER NETWORKS

OBJECT

The purpose of this standard is to establish the technical requirements that must be met when
carrying out the hydrostatic pressure test in EPM's drinking water pipe networks, in order to
guarantee the correct assembly between sections of pipe, valves, accessories and other
elements of the network, with the absence of leaks and possible defects.

SCOPE

This standard applies to new aqueduct networks that enter the EPM system. This standard
replaces in its entirety the general construction standard and specification NEGC-704-04
“Hydrostatic test of pipes”

REFERENCE DOCUMENTS

The regulations, national and international technical standards and other documents used as
reference in this construction standard must be considered in their most recent version.

 DOCUMENT NAME NDA EPM 2013: EPM Aqueduct System Design Standard
 AWWA C605: Underground installation of polyvinyl chloride (PVC) and molecularly
oriented polyvinyl chloride (PVCO) pressure pipe and fittings
 AWWA C600: Installation of ductile-iron mains and their appurtenances AWWA C604
Installation of buried steel water pipe – 4 in (100 mm) and larger
 AWWA C303: Concrete Pressure Pipe, Bar-Wrapped Steel-Cylinder Type Manual
 AWWA M9: Concrete Pressure Pipe Manual
 AWWA M55: PE Pipe – Design and Installation ASTM E1003 Standard Practice for
Hydrostatic Leak Testing.
 ASTM F2164: Standard Practice for field Leak Testing of Polyethylene (PE) and
Crosslinked Polyethylene (PEX) Pressure Piping Systems Using Hydrostatic Pressure.
 ISO 10802: Ductile Iron Pipes. Hydrostatic testing after installation
 NTC 2263: Metrology. Pressure indicating manometers, vacuum manometers and
pressure-vacuum manometers for general uses.
 NTC 3742: Standard practice for underground installation of thermoplastic pressure
pipes
 NTC 5184 Ductile iron pipes. Hydrostatic testing after installation

TECHNICAL REQUIREMENTS

GENERAL DESCRIPTION

Quality control procedure that is carried out once the pipe has been installed and before being put
into service. The test consists of subjecting a section of pipe to a certain pressure, in order to
determine leaks or defects in the installation, so that these can be corrected and thus be able to
accept the installed section.

GENERAL ASPECTS OF THE HYDROSTATIC PRESSURE TEST

The new network may contain in its installed length, derivation collars, incorporation keys, flanges,
sections of pipe with welds, spigot-bell type connection areas, valves, hydrants, rings, among
others. For repairs on sections of the installed network, the hydrostatic pressure test is not
required.

The test pressure must be applied with a plunger pump provided with a pressure gauge, installed
in the lower part of the pipe, said test pressure must be measured at the lowest point of the
section.

For any type and material of pipe, the following considerations must be taken into account:

 The safety of people, public and private assets or properties and existing environmental
conditions of the environment must be guaranteed. Work areas must be correctly marked
in order to reduce the risk of accidents and make user traffic and pedestrian mobility more
agile and expeditious.
 The pressure test should only be performed using water, it is not permitted to be
performed with air due to the risks involved. The span should be filled slowly, taking care
to prevent a surge or air trap. Any air trap must be released. If necessary the system must
allow an air outlet and appropriate vacuum air release valves (suction cups). Vacuum air
valves or openings should be provided at all high points in the pipeline to expel air pockets
while filling. If possible, filling should be done at the low points of the system, which can
be used to subsequently purge the pipe.
 The temperature of the test fluid should not be lower than 5ºC (40ºF), nor higher than
30ºC (90ºF). The manufacturer of the pipe and accessories should be consulted about
recommendations and protection when testing outside this range has to be performed.
 The pressure test must be carried out under the supervision and approval of the
Comptroller's Office and EPM, and if necessary, additional tests may be carried out.
 Each hydrostatic pressure test must be carried out on sections with a maximum length of
500 m of installed pipe. In primary distribution networks, the lengths for the hydrostatic
test are defined from the design, as is the sizing of the required anchors and plugs.
 In all cases, the pipe manufacturer's recommendations regarding shape, duration and
other aspects that must be taken into account during the pressure test must be taken into
account.
 The contractor must provide the necessary elements for the test, including pump, pipes,
connections and other devices required.
 Where existing pipes are used to supply water in the test, they must be protected from
return flow contamination by temporarily installing a set of check valves between the test
pipe and the main supply pipe or by other approved means. by the Audit Office and EPM.
 The pipe must have the depth specified in the design and the anchors must have adequate
strength to withstand the test loads.
 During the pipe installation process, it is recommended to identify the joints and other
points where leaks may occur. The Comptroller and EPM must determine which joints and
 couplings should remain exposed, to facilitate the inspection of the hydrostatic pressure
test.
 The test should be carried out once the pipe has been filled with water and the air has
been completely evacuated.
 If unacceptable changes in position of any part of the pipe and/or appearance of leaks
occur, the pipe must be depressurized and the faults must be located and repaired, to
repeat the hydrostatic pressure test again until satisfactory results are achieved.
 The test pressure must in no case exceed the design pressure of the pipe, valves, fittings
and anchor blocks; In addition, during the development of the test, system leak checks
must be carried out at points such as valves, hydrants and other exposed accessories.
 Any water leak when its location is detected must be repaired even if the test results have
been satisfactory in terms of maintaining the test pressure and the leak limit flow.
 You should never attempt to repair a leak while the pipe is pressurized, the system should
always be depressurized before any repair.
 In each test, personnel from the Comptroller's Office and EPM must be present to approve
the proper execution of the procedure and accept the results obtained with the
declaration of “compliant hydrostatic pressure test.”
 The record of the hydrostatic pressure test must be prepared in the relevant formats.

PRESSURE GAUGES

The pressure gauges to be used during the hydrostatic pressure test must have the following
characteristics:

 Digital display
 Class 1 to 1.6
 Maximum pressure 1000 PSI
 Resolution 1 PSI maximum
 Cover 3" minimum
 Protection IP 65
 Maximum pressure record
 1/2" NPT thread connection
 Valid calibration certificate, with a calibration period of no more than one year at the time
of performing the test.

PROCEDURE FOR HYDROSTATIC PRESSURE TEST ACCORDING TO THE PIPE MATERIAL

The pipe must be filled; for this purpose, the purge valves must be plugged with blind elements,
and their mechanism must be opened. The opening of the guard valves, air valves or vent
elements must be checked.

A minimum of two (2) pressure gauges must be installed for test readings on the abscissa agreed
upon with the Comptroller's Office and EPM. If these cannot be installed at the point of the lowest
elevation, they must be installed at another point and mathematical corrections for the difference
in hydrostatic head must be made. In addition, one (1) spare pressure gauge must be available at
the time of testing, and calibration certificates for the measuring instruments must also be
presented.
Once the pipe is filled, it must be verified that there are no leaks during filling and if they exist,
they must be corrected immediately by adjusting flanges and accessories. Additionally, the
absence of air inside the pipe must be verified, which is evidenced by the water escaping and the
automatic closing of the suction cups.

For better information management, the following terms are defined:

Pt: In pipelines, the working pressure of the system corresponds to the hydrostatic pressure to
which the pipe will be subjected, without including overpressures or water hammer. In impulses,
the working pressure of the system corresponds to the dynamic pressure to which the pipe will be
subjected without including overpressures or water hammer.

Pn: It is the nominal pressure for which the pipes or accessories of a system were manufactured.
Pp: It is the test pressure with which a section will be tested.

In accordance with resolution 0330 of 2017, article 87 Hydrostatic pressures and tightness, tests
must be carried out on pipes, valves and accessories taking as reference the methods recognized
by the NTC, AWWA (American), UNE (European) standards. . Taking the above into account, below
are the requirements for each type of pipe material according to regulatory reference.

The objective of the pressure test is to verify the correct installation of the pipe and fittings. Pipes
and fittings are factory tested.

PVC PIPE

According to AWWA C605, the hydrostatic pressure test must be performed following the
following procedure:

Test pressure (Pp): The test pressure should be not less than 1.25 times the working pressure (Pt)
of the pipe measured at the highest elevation along the test section, and not less than 1.5 times
the pressure of work at the lowest elevation of the section. However, in no case may the test
pressure (Pp) exceed the design pressure of the anchors, accessories, pipes and valves of the
tested section.

Test duration: The duration of the sustained hydrostatic pressure test should be 2 hours.

Test tolerance: During the time of the pressure test, the contractor is required to evaluate the
amount of water injected into the pipe section to maintain the test pressure (Pp) with a variation
of ±5 psi (34 kPa ). If the amount of water added is less than the value predetermined by the
equation presented below, the test is considered acceptable. The addition of water maintains the
test pressure (Pp), which can drop due to air trapped in the pipe, water absorption by the pipe
walls, and temperature variations during the test.

To maintain the test pressure at the desired value, water must be pumped with a piston pump
from a calibrated container that allows readings of the volume used to be taken or a calibrated
volumetric meter must be inserted. The meter calibration certificate must be presented at the
time of testing.
During the hydrostatic pressure test, the water leaks that occur in the tested section must be
evaluated; the leaks must not exceed the acceptable limits determined by the following
expression:

Where:

Qf= Flow rate of water added per leak to maintain the test pressure (l/h)

L = Length of the pipe section tested (m)

D = Nominal diameter of the pipe (mm)

Pp = Test pressure of the tested pipe section (kPa)

No pipe installation should be accepted if the leak rate recorded during the test exceeds the
previously established limit value, and if the variation of the test pressure is greater than the value
specified above (±5 psi).

ANSI/AWWA C605 can be consulted for typical leakage tolerances for different diameters and test
pressures.

When testing against closed, metal-seated valves, an additional tolerance per closed valve of
0.0078 gal/hour/inch (0.0012 l/h/mm) of nominal valve diameter is allowed.

When there are hydrants in the test section, the test must be carried out against the closed
hydrant protection valves.

Any leak must be repaired even though the number of leaks does not exceed the limit given by the
equation presented above.

Ductile iron pipe (HD)

In accordance with the criteria of the AWWA C600, ISO 10802 and NTC 5184 standards, the
hydrostatic pressure test must be executed following the following procedure:

Test pressure (Pp): The test pressure should be not less than 1.25 times the working pressure (Pt)
of the pipe measured at the highest elevation along the test section, and not less than 1.5 times
the pressure of work at the lowest elevation of the section. The design pressures of pipes,
accessories and anchors of the tested section must not be exceeded.

Duration of the test: The duration of the sustained hydrostatic pressure test should be 2 hours.

Test tolerance: During the time of the pressure test, the contractor is required to evaluate the
amount of water injected into the pipe section to maintain the test pressure (Pp) with a variation
of ±5 psi (34 kPa ). If the amount of water added is less than the value predetermined by the
equation presented below, the test is considered acceptable. The addition of water maintains the
test pressure (Pp), which can drop due to air trapped in the pipe, water absorption by the pipe
walls, and temperature variations during the test.
To maintain the test pressure at the desired value, water must be pumped with a piston pump
from a calibrated container that allows readings of the volume used to be taken or a calibrated
volumetric meter must be inserted. The meter calibration certificate must be presented at the
time of testing.

During the hydrostatic pressure test, the water leaks that occur in the tested section must be
evaluated; the leaks must not exceed the acceptable limits determined by the following

expression:

Where:

Qf= Flow rate of water added per leak to maintain the test pressure (l/h)

L = Length of the pipe section tested (m)

D = Nominal diameter of the pipe (mm)

Pp = Test pressure of the tested pipe section (kPa)

CONCRETE PIPE (STEEL CYLINDER WITH CCP ROD REINFORCEMENT) AND WSP STEEL PIPE

Test pressure (Pp):

• In pipelines: The test pressure (Pp) must not exceed 125% of the working pressure (Pt)
measured at the lowest point of the section. Said test pressure (Pp) must not exceed the design
pressure of the anchors, accessories, pipes and valves of the tested section.

• In impulses : The test pressure (Pp) must be the greater of 125% of the working pressure (Pt) or
100% of the system design pressure (including transients). However, the designer must validate
the hydrostatic test pressure that is defined.

Duration of the test: In the pipe with internal mortar coating, once it is full of water; and the air
has been completely expelled, an initial pressure of no more than 100 psi must be applied, which
must be maintained for a minimum of 48 hours so that the internal mortar coating of the pipe is
saturated with water, ensuring that The losses are a direct reflection of the real state of the joints
and joints of the test section.

Once the saturation procedure of the interior lining is completed, the hydrostatic pressure test
must begin, raising the pressure every 100 psi, very slowly, continuing uninterruptedly, stopping
every multiple of 100 to examine accessories, anchors, flanged joints, etc., until obtain the test
pressure (Pp).

To maintain the test pressure at the desired value, water must be pumped with a piston pump
from a calibrated container that allows readings of the volume used to be taken or a calibrated
volumetric meter must be inserted. The meter calibration certificate must be presented at the
time of testing.
Once the test pressure (Pp) is reached, it must be maintained for a maximum period of four (4)
continuous hours at the lowest point, with a variation of ±5 psi (34 kPa), and with losses (leaks)
within of the acceptability parameters indicated below.

In steel pipes that do not have an internal mortar coating, it is not required to carry out the initial
water saturation during the 48 hours. In this case, the hydrostatic pressure test is carried out
within a period of 4 hours.

Test Tolerance: During the time of the pressure test, the contractor is required to evaluate the
amount of water added to the pipe run to maintain the test pressure (Pp) with a variation of ±5 psi
(34 kPa ). During the hydrostatic pressure test, the water leaks that occur in the tested section
must be evaluated; these leaks must not exceed the acceptable limits determined by the following
expression:

Where:

Qf: Flow rate of water added per leak to maintain the test pressure (l/hour)

L = Length of the pipe section tested (m)

D = Internal diameter of the pipe (mm)

The previous equation is equivalent to the recommendation presented in the AWWA M9 manual,
which presents a limit value of 1 l/mm diameter/kilometer/24 hours.

The maximum test time must be 4 hours, during which the water loss is measured and the limit
value obtained in the previous equation must not be exceeded.

POLYETHYLENE PIPE

The following requirements for the hydrostatic pressure test on polyethylene pipes are based on
the following standards and manuals: - AWWA M55 Manual - ASTM F2164 - NTC 3742 Important:
The temperature of the test fluid must not be lower than 5ºC (40ºF) , nor higher than 30ºC (90ºF).
The manufacturer of the pipe and fittings should be consulted for recommendations and
protection when testing outside this range must be performed.

Test pressure (Pp): The maximum test pressure must be 1.5 times the working pressure of the
pipe, but must not be less than 15 psi (103 kPa), nor exceed the nominal pressure for which the
pipe was manufactured. or accessories. Pressure should be measured at the lowest elevation
possible.

Test duration: The duration of the sustained hydrostatic pressure test should be 1 hour.

Test Tolerance: Because joints for polyethylene pipes are made by thermofusion or electrofusion,
the amount of leakage must be zero. (ASTM F2164 does not specify a limit flow rate of water
leakage allowed in the hydrostatic pressure test for Polyethylene pipes).
If any test shows a leak, the installer is responsible for locating and repairing the leak, and
retesting until the result is satisfactory. Retesting should be performed after depressurizing the
pipeline and allowing the pipeline to “relax” for at least eight (8) hours.

Note: You should never attempt to repair a leak while the pipe is pressurized, the system should
always be depressurized before any repair.

If the test pressure (Pp) remains stable (with a maximum variation of 5%) for one (1) hour the test
is considered successful, otherwise the procedure must be repeated after allowing the pipe to
"relax" for at least eight (8) hours.

BIBLIOGRAPHY

https://www.epm.com.co/site/Portals/3/documentos/Aguas/
NC_AS_IL01_31_Prueba_de_presion_hidrostatica.pdf?ver=2018-06-15-083425-113

http://biblioteca.enacal.com.ni/bibliotec/Libros/pdf2/terc/apphtap.pdf

https://www.aristegui.info/probe-de-presion-de-la-tuberia-instalada-en-abastecimiento/

https://www.youtube.com/watch?v=hH6Rrw_JgP8