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

Pressure Test Method statement of Hydraulic Pressure Testing for DMA-J1 & J1A – Rev. 05.11.2020
Page 1 of 12
 11) Bolts, Nuts and Flat Washers As required

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,

Pressure Test Method statement of Hydraulic Pressure Testing for DMA-J1 & J1A – Rev. 05.11.2020
Page 2 of 12
 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

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.
Pressure Test Method statement of Hydraulic Pressure Testing for DMA-J1 & J1A – Rev. 05.11.2020
Page 3 of 12
  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.

 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.

Pressure Test Method statement of Hydraulic Pressure Testing for DMA-J1 & J1A – Rev. 05.11.2020
Page 4 of 12
  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 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.

Pressure Test Method statement of Hydraulic Pressure Testing for DMA-J1 & J1A – Rev. 05.11.2020
Page 5 of 12
 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 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.

Pressure Test Method statement of Hydraulic Pressure Testing for DMA-J1 & J1A – Rev. 05.11.2020
Page 6 of 12
  Monitoring all pressure gauges at interval of 1/2 hrs, recording the
readings of pressure gauge. The monitoring shall be continuously
observed for 2 hour. At the end of 2 hrs., then calculate the pressure drop
percentage. If within any 30 mins. the percentage of pressure drop is less
than 10% of test pressure, 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.

 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

Pressure Test Method statement of Hydraulic Pressure Testing for DMA-J1 & J1A – Rev. 05.11.2020
Page 7 of 12
  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.

Pressure Test Method statement of Hydraulic Pressure Testing for DMA-J1 & J1A – Rev. 05.11.2020
Page 8 of 12
Pressure Test Method statement of Hydraulic Pressure Testing for DMA-J1 & J1A – Rev. 05.11.2020
Page 9 of 12
Pressure Test Method statement of Hydraulic Pressure Testing for DMA-J1 & J1A – Rev. 05.11.2020
Page 10 of 12
Pressure Test Method statement of Hydraulic Pressure Testing for DMA-J1 & J1A – Rev. 05.11.2020
Page 11 of 12
Pressure Test Method statement of Hydraulic Pressure Testing for DMA-J1 & J1A – Rev. 05.11.2020
Page 12 of 12