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PART 2 MATERIALS
2.01 WATER Potable water shall be used for hydrostatic testing of potable pipeline and recycled water mains. Raw water shall be used for testing of raw water mains. 2.02 CONNECTIONS: Testing water shall be supplied through a connection equipped with a backflow prevention device at the point of connection to the potable/ Raw water source used. The Contractor shall provide any temporary piping needed to deliver potable water to the piping that is to be tested
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PART 3 EXECUTIONS ??? 3.01 GENERAL: The Contractor shall furnish all labor, materials, tools, and equipment for testing. Temporary blocking during the tests will be permitted only at temporary plugs, caps or where otherwise directed by the Consulting Engineer. All valves and appurtenances shall be operated during the test period. The test shall be conducted with valves in the open position. At the onset of testing, all valves, air vacuum assemblies, blow offs, and services shall be monitored for possible leakage and repairs made, if necessary, before the test proceeds. The appurtenances shall be monitored through the duration of the testing.
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FIELD HYDROTEST G.R.P UNDER GROUND PIPING SYSTEM with COUPLING JOINTS Required Tools & Tackles:
Come along jacks with nylon slings- for pipe joining /coupling fixing. Nylon twines for marking pipe alignment. Limestone powder. Theodolite for pipe alignment. Earth compaction Equipments. Filling pumps/ Dewatering pump for filling of pipe prior to pressure test./Required if trenches are flooded Pressurizing/Reciprocating Pumps- for Pressurizing the system under Test. Hoses with connectors and fittings. End caps/Blind Flanges as per Diameter with adequate flange connectors for filling, air vents and gauges. Nozzles/AVT for release of air. Pressures gauges/Valves and connectors. Rotary Disc cutter /Grinder- 4 & 5 discs. Knife cutters and blades. Measuring instruments-pi Tapes, Vernier calipers, Feeler Gauges etc. Electrical Extension board. Mobile crane Lifting Tackles with slings for pipe movement.
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???
locations thrust block to be casted prior testing. Additional lamination to the field is to be provided on the bend portions which will get embedded in concreting. For this approved lamination layer sequence will be provided from M/s Pacific. Make sure that the backfilling slope at the joints location is maintained with minimum pipe exposure. Internal visual inspection shall be carried out for accessible pipe diameters for any possible damage during installation/ backfilling. Vertical deflection measurements shall be taken to observe the pipe behavior after the backfill.
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DN>=300
Procedure for checking the initial diametrical deflection for installed pipes:
1. 2. 3. 4. Complete backfilling to grade (pipe zone, crown & native Backfill) Complete removal of temporary sheeting (if used) Turn of the dewatering system (if used) Measure and record the pipes vertical diameter.
OFF
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Note: For smaller diameter pipes, a deflection testing device (commonly called a pig) may be pulled through the pipes to measure the vertical diameter. 5. Calculate vertical deflection: Ensure that the pipes are backfilled to the minimum cover depth requirement before the hydro test.
Calculate as follows: Actual I.D. = Vertical I.D. + Horizontal I.D. pipe spools Single measurement for 2 would not be sufficient. So measurement
Deflection measurement procedure: The Pipe laying supervisor / inspector will enter into the pipe at a distance of about 1 to 2 m near the coupling and would check the original vertical and horizontal dimensions inside the pipe. If the Pipe or section is found to be over deflected or out of our recommended standard then the procedure is to remove topsoil to the level at which pipe comes back or regains its original shape & then to re-compact the side fill & topsoil.
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All flanges are tightened to the specified torque bolt sequence. The method is as follows 1. 2. 3. 4. 5. Thoroughly clean the flange face and the Oring groove. Ensure the sealing gasket is clean and undamaged. Position sealing gasket in groove. Align flanges to be joined Insert bolts, washers and nuts. All hardware must be clean and lubricated to avoid incorrect tightening. Washers must be used on all GRP flanges. 6. Using a torque wrench, Tighten all bolts to 35Nm torque, following standard flange bolt tightening sequences. 7. Repeat this procedure, raising the bolt torque to 70 Nm, or until the flanges touch at their inside edges. Do not exceed this torque. To do so may cause permanent damage to GRP flanges. 8. Check bolt torques one hour and adjust if necessary to 70 Nm.
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Make sure that the valves are anchored and the above ground piping, if any, is supported as specified.
IMPORTANT:
capacity of 100 m / hour are generally used for larger diameter pipes). The sign that the pipe line is completely filled with water is when the water starts coming through highest venting point on the line. Keep the venting valve open for some time to ensure that no air entrapment is left in the pipe line. Stop water pumps at this stage & check the flanges, valves and connected accessories for any seepage/ leakage while keeping the vents open. PRESSURIZING: Start pressurizing the segment/system through pump. Once the water starts coming out through vent opening, close the valve at low elevation. Later, on the high elevation end the vent. Valves shall be closed while allowing water to come out. The pressure increment shall be maintained at 0.5 Bars/10 minutes at this stage. When the pressure reaches to 2 bars, the pump shall be stopped. Keep this stoppage for 1520 minutes. During this time, following checks shall be made:
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A) Pressure at each test gauge shall be checked & recorded on inspection sheets. B) Watch the pressure at the water feed point for any decrease in pressure. C) Walk through along with the underground lines to observe any traces of wet soil and any unusual at every interval of 3045 minutes.
ANY PRESSURE DROP, VALVE LEAKAGES SHALL BE IMMEDIATELY REPORTED TO THE TEAM LEADER Unless there are no findings which prevent the test from continuing, the segment/system shall be further pressurized. Connect the hose with the pressure pump and start pressurizing the line. At this stage slightly open the vent. Valve fixed at higher elevation to ensure that no entrapped air is present. Upon confirmation of water coming out, the vent. Valve shall be closed. The system is now totally close and under pressure. Continue the pressure pump until it reaches 5.0 bar. During this operation, the pump shall be constantly attended for pressure control. Stop the pressure pump once it reaches to 5.0 bars and let it to stabilize. There could be a drop of pressure due to thermal expansion, which could either be makeup by restarting the pump or keep it as it is & record on the inspection sheet. Keep this stoppage for about 30 minutes. During this period, repeat the same sequence of inspection as described earlier. The finding and observation shall be recorded on inspection sheet.
REPEATED
ANY PRESSURE DROP, VALVE LEAKAGES SHALL BE IMMEDIATELY REPORTED TO THE TEAM LEADER. Unless there are no findings which prevent the test from continuing, the segment/ system shall be further pressurized to the required field test pressure *THIS TEST PRESSURE SHALL BE MAINTAINED FOR A PERIOD OF MAXIMUM 24hrs, AFTER PRESSURE STABILIZATION, As per IS13916.
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Thorough inspection shall be made as FINAL INSPECTION. After the test pressures is reached then check for any drop in pressure. Enter the findings in Hydro test report which shall be duly signed by the Client, Inspection agency and Contractor. The test shall be considered as PASS if no sign of leakage are observed; the inspection sheet(s) shall be signed by the authorities. POST HYDROTEST: After completion the test open all vent valves. Drain or flush out the filled water from the pipe segment/ system through drain valves. This pressure release shall be made slowly @ 2bar/ 5 minutes. Remove the end cap from the segment as per procedure and close the same with temporary cover to avoid any particles from entering inside the line. PPSPL Installation/Site engineer will advice you in this process. Prepare the pipe end to be ready for next installation. Connect the adjacent segment end with closure pipe piece. Continue the installation for the other segments & conduct the hydro test in the similar manner as described earlier, keep connecting the segments through closure spools. The clearance maintained between the two segments can be later installed as MakeUp pipe piece with double spigot calibration to facilitate the jointing on existing pipe segment. The test of this MakeUp pipe can be done during the time of commissioning. As per ease of availability of fittings for Salvaging the water or the water will be brought in by bore holes or other water bodies (lake, river, pond etc).
ANNEXURE -I
The opened ends of a line must be sealed temporarily with GRP or steel/cast iron end-caps. GRP testing end-caps can be purchased from the manufacturer with the pipes & the fittings. The end-caps should have an inlet & an out let. The inlet should be placed at the bottom of the end-cap at the low end of the test section, and the outlet at the top of the end-cap at the high end. See fig22 for a typical arrangement of a test section & apparatus. The approximate end thrust force is given below in Table.
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Bracing test-ends and set-up Due to the thrusts occurring at the testing end-caps, temporary blocks must be used to brace the pipe end-caps in order to prevent line displacement as indicated in figure below.
In the gap between the end of the pipeline & the block, jacks should be placed as shown in figure. This will keep the testing end cap at its original position if the block starts to move. The last pipe length should also be wedged on both sides, at the top & at the bottom, in order to prevent. Note: It may be possible to reduce the size of the concrete blocks by driving into the ground, several meters deep, two or more steel piles back to back. Sheet piles so positioned behind the concrete blocks will provide additional bracing
STEEL OR SHEET?
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Filling the line with water: If it is not possible to fill the line from the lowest point, an additional outlet should be added at the inlet end-cap to release air. The line should be filled slowly & evenly with water from the lowest end point. At high points, an air release valve is normally installed, as specified by the design Engineer (see Appendix II for additional details). Though these valves the entrapped air inside the pipe will get released. After filling the line with water, the test section should be left for an initial period of at least 12 hours under a static pressure of 2-3bars for stabilization. The filling rate of the line with water should be controlled such that the water velocity does not exceed 0.3m/sec. Volume of water required: Below Table indicates the approx volume of water required in order to fill PACIFIC Pipes per 100 meter of pipeline. DN(mm) 80 100 150 200 250 300 350 400 450 500 600 700 800 Water Volume (m^3)/100m of pipeline 0.5 0.8 1.8 3.1 4.9 7.1 9.6 12.6 15.9 19.6 28.3 38.5 50.3 DN(mm) 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 2000 2200 2400 Water Volume (m^3)/100m of pipeline 63.6 78.5 95.0 113.0 132.7 153.9 176.7 201.0 226.9 254.4 314.1 380.1 452.4
A. Test pressure gages shall be calibrated within 90 days of use and clearly marked on each gage the date of calibration, calibration certificates of gages shall be presented before the start of each test and copy included with hydro test report.
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B. Minimum number of 2 calibrated pressure gages shall be used for each hydro test. This is in case of gage failure or incorrect gage reading during test if only using one gage, pressure gage failure is both a safety risk to personel and over pressurizing of equipments. C. Pressure gages used shall have a range of reading where as the final test pressure will fall in the middle third of the gage range.
THIS PROCEDURE IS MADE MANDATORY TO THE INSTALLER AND DEVIATION SHALL BE CONSULTED WITH THE PACIFIC/DL FIELD SERVICE REPRESENTATIVE
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