Polyolefins Technical Information TN005 V4

Notes on Hydrostatic Field Pressure Testing of PE

Pipes
By Bob LeHunt and PIPA Technical Committee
August 2020

It has long been recognised that for field pressure testing of polyethylene (PE) pipelines it may be
necessary to provide allowance for the fact that PE pipes are subject to creep under constant loading and
will expand due to the action of internal test pressure. Recommendations such as found in Oy Wiik &
Hoglund published literature1 (1980), were developed in Scandinavia to account for the recorded pressure
variations induced by volume expansion, especially with pipes up to DN1000.

In Australia, large diameter (e.g. DN500) pressure pipelines were being field pressure tested as long ago
as the 1960’s. AS 2033i, Installation of Polyethylene Pipe Systems, first published in 1977, acknowledged
this volume expansion phenomenon, but did not provide specific guidance for making allowances. The
main emphasis was on visual inspection of joints for leakage. This is still the most effective method if
practicable for any particular installation.

In the period since, various National and industry specifications and guidelines for PE pipe pressure testing
have been developed, including IGN 4-01-03ii (U.K.), ASTM F2164iii (U.SA.), PPI TN46iv (U.S.A.), VAV
P78 (Sweden)v, EN 805vi.

The latest revision of AS/NZS 4130 vii – ‘Polyethylene (PE) pipes for pressure applications’ has extended
the nominal pipe diameter (DN) range to include DN16 to DN2000. The absolute expansion volumes in the
larger diameter pipes has necessitated a more detailed consideration of the pressure test procedures.

Where pipe volume expansion is a consideration, the hydrostatic pressure test method should either
account for effects such as soil support or be independent of them.

Two methods that are independent of soil support influences are the modified rebound method, based on
work within CEN, and the Swedish Water Works Association VAV P78 method, originally developed by
Prof. Lars-Eric Janson. This latter method has been successfully used in Sweden since 1989 in a range of
pipe diameters up to DN800 and lengths up to 3,000 m. The method has been applied widely in Australia
and is described in various technical publications.

The modified rebound method was originally developed within CEN and has been subject to field trials in
Australia and New Zealand as part of the AS/NZS 2033 considerations (LeHunt, Stahmer and Black 2001).
It has the advantage that it is a quick test, but it cannot quantify the absolute volume of a leak in the event
of failure. This method is however suitable for all pipe diameters. For this method, it is necessary to have
a suitable diameter valve to allow the rate of pressure reduction required. Where it may be necessary to
quantify a leak, or for referee purposes (e.g. to resolve an inconclusive test result), the method of Prof.
Lars-Eric Janson (VAV P78) should be used.

Regarding other methods, ASTM F2164 is essentially a rebound method relying also on visual inspection
to detect leaks. PPI (USA) TN-46 recommendations are similar to the modified rebound method and
reference and quote AS/NZS 2566-2viii. The UK Water Industry IGN 4-01-03 (pressure decay) method is
complex, requires an estimate of the uniformity of support given by the soil and does not provide data
support for the curve slope coefficients to determine whether the result is a pass or fail.

AS/NZS 4130 applies to pipes for water, wastewater, irrigation, and other aqueous fluid applications.
Where installed pipes are of small diameter (DN250)/short length and/or for a less critical application, a

1 Wiik & Hoglund, Finnish company, now KWH Pipe.

1
Polyolefins Technical Information TN005 V4

simplified method may be adopted. Similarly, for coiled pipes without joints, apart from end connections or
pipes up to 100 m in length.

For pipelines where visual inspection of joints is not practicable, for long pipelines, or for larger diameters
(i.e. DN280), the following are the recommended procedures for field pressure testing.

The Swedish VAV P78 method has been adopted by Standards Australia in AS/NZS 2566.2 Buried flexible
pipelines Part 2: Installation, AS/NZS 2033-Installation of PE pipelines, and by the Water Services
Association of Australia (WSAA) in their Polyethylene Pipeline Code WSA 01 - 2004.

It is noted that the removal of both entrapped and dissolved air is critical to successful pressure testing.
The presence of air can distort the test results and mask the presence of a leak. Entrapped air can be
minimised by the use of firm foam pigs and limiting the input flowrate of the test water to 0.05 m/s.

Care also needs to be taken with the increases in pipe volume due to thermal expansion resulting from
increased material temperature, for example, where pipes are exposed during the test period.

These Notes relate to hydraulic pressure testing only (i.e. with water). Pneumatic testing (i.e. with
compressed air) should be avoided due to OH&S concerns arising from the substantial energy stored in a
compressed gas. AS/NZS 4130 covers PE pipes for use in fuel gas applications but testing for these
applications is covered by various State Regulations and may involve exclusion zones and/or limited
access areas. If required, information on both primary and secondary exclusion zones for both hydraulic
and pneumatic pressure testing can be found in the APGAix Code of Practice for Upstream Polyethylene
Gathering Networks – CSG Industry.

These Notes do not address the necessary procedures in preparing anchor blocks, restraints etc. or OH&S
requirements. It is assumed an acceptable Safe Work Method Statement (SWMS) is in place before any
testing is undertaken.

1. SMALL DIAMETER /SHORT LENGTH PRESSURE TESTING -

SUMMARY

• Water entry to be at the lowest point in the pipeline.

• Fill pipeline. Restrict the rate of water entry to 0.05 m/s to avoid air entrapment in downward
sloping pipe lengths.

• Flush/swab/vent all air from the pipeline.

• The Maximum System Test Pressure (STP) is 1.25 time the maximum working pressure of the
pipeline or 1.25 times the PN rating of the pipe, but is not to exceed 1.25 times the maximum
allowable operation pressure (MAOP) of the lowest pressure rated pipe or fitting in the line.

• Apply the STP to the pipeline and allow to stand without makeup pressure.

• Where the pipe and fittings joints are accessible for inspection, and there is no evidence of leaks
of the test water after at least 15 minutes, the section may be deemed to have passed the test.

• Where the joints are not accessible for inspection and the apparent loss of water after a
minimum test period of 2 h is less than that calculated from the following equation, the section
may be deemed to have passed the test.

Q < 0.14 L.D.H

Where

Q = allowable make-up water, l/h

D = pipe internal diameter, m
L = length of pipeline under test, km
H = average test head over the length of the pipeline under test, m
2
Polyolefins Technical Information TN005 V4

2. REBOUND TEST METHOD – SUMMARY

• Water entry to be at the lowest point in the pipeline.

• Fill pipeline. Restrict the rate of water entry to 0.05 m/s to avoid air entrapment in downward
sloping pipe lengths.

• Flush/swab/vent all air from the pipeline.

• MAXIMUM SYSTEM TEST PRESSURE (STP) at least 1.25 times maximum working pressure of
pipeline or 1.25 times the PN rating of the pipe, but is not to exceed 1.25 times the maximum
allowable operation pressure (MAOP) of the lowest pressure rated pipe or fitting in the line.

PRELIMINARY TEST PHASE

• Reduce pressure in the pipeline to atmospheric and let stand for 60 minutes.

• Raise the pressure to STP in less than 10 minutes and hold for 30 minutes, pumping as needed.

• Inspect for leaks, shut off pressure, let stand for 60 minutes.

• Measure pressure reading P60 > 70% STP.

MAIN TEST PHASE

• Quickly (<5 minutes) reduce pressure by ∆P, being in the range 10 -15% of STP.

• Measure and record the water volume bled out - ∆ V

• Calculate ∆ Vmax allowable if not already done.

∆ Vmax allowable = 1.2V ∆ P {1/EW + D/t e ER}

where: -

1.2 = air allowance

V = pipe volume in litres

∆ P = pressure drop, kPa

D = pipe internal diameter, m

te = pipe wall thickness, m

ER = pipe material modulus, kPa (see Table 1)

EW = Bulk modulus of water, kPa (see Table 2)

• Observe and record the pressure rise for 30 minutes.

The pipeline is deemed to pass the pressure test if:

• There are no leaks

• No components break
3
Polyolefins Technical Information TN005 V4

• The internal pressure rises or remains static over 30 minutes. If in doubt, leave for 90
minutes. The maximum allowable pressure drop in 90 minutes is 20 kPa.

If the pipeline fails:

• Locate and repair the leaks and re-test.

• If failure is marginal or doubtful, or if it is necessary to determine the leakage rate, use the
Reference Test Method.

Table 1 PE MATERIAL MODULUS ER

PE 80B - E Modulus (kPax10-3) PE 100 - E Modulus (kPax10-3)

TEMP. ° C

1 hour 2 hours 3 hours 1 hour 2 hours 3 hours

5 740 700 680 990 930 900

10 670 630 610 900 850 820

15 600 570 550 820 780 750

20 550 520 510 750 710 680

25 510 490 470 690 650 630

30 470 450 430 640 610 600

Note: Table 1 assumes MDPE characteristics for PE 80B and HDPE for PE 100.

Table 2 BULK MODULUS EW – WATER

TEMPERATURE BULK MODULUS
(kPax10-3)
°
C
5 2080

10 2110

15 2140

20 2170

25 2210

30 2230

4
Polyolefins Technical Information TN005 V4

3. REFERENCE TEST METHOD SUMMARY

• Water entry to be at the lowest point in the pipeline.

• Fill pipeline. Restrict the rate of water entry to 0.05 m/s to avoid air entrapment in
downward sloping pipe lengths.

• Flush/swab/vent all air from the pipeline.

• MAXIMUM SYSTEM TEST PRESSURE (STP) at least 1.25 times maximum working
pressure of pipeline or 1.25 times the PN rating of the pipe, but is not to exceed 1.25
times the maximum allowable operation pressure (MAOP) of the lowest pressure rated
pipe or fitting in the line.

PRELIMINARY TEST PHASE

• Raise the pressure in the pipeline to STP, close off main.

• Allow the pipeline to settle for at least 12 hours. The pressure gauge will show a drop.

• Inspect for leaks.

MAIN TEST PHASE

• Raise pressure to STP and maintain for 5 hours.

• Measure and record the water volume to keep constant pressure between 2 hours and 3
hours after test start.

5
Polyolefins Technical Information TN005 V4

• Measure and record the water volume to keep constant pressure between 4 hours and 5
hours after test start.

The pipeline is deemed to pass the pressure test if:

• ∆ V ( 5 h - 4 h ) ≤ 0.55 ∆ V ( 3 h - 2 h ) + V l e a k 1h

where: -

Vleak 1h = 0.14 L.D.H

D = Pipe internal diameter, m

L = Test pipe length, km

H = Average test head, m

• There are no visible leaks

• No components break

If the pipeline fails the pressure test:

• Repair and reinstate pipeline

• Re-test

6
 Polyolefins Technical Information TN005 V4

REFERENCES

iAS/NZS 2033 Installation of Polyethylene Pipe Systems, Standards Australia/ Standards New
Zealand.

ii
UK Water Industry Information & Guidance Note IGN 4-01-03. Pressure testing of pressure
pipes and fittings for use by public water suppliers.

iii
ASTM F2164 Standard Practice for Field Leak Testing of Polyethylene (PE) and Crosslinked
Polyethylene (PEX) Pressure Piping Systems Using Hydrostatic Pressure, American Society for
Testing and Materials.

ivTN046 Guidance for Field Hydrostatic Testing Of High Density Polyethylene Pressure
Pipelines: Owner’s Considerations, Planning, Procedures, and Checklists, Plastics Pipes
Institute, USA.

v VAV P78, Svenskt Vattens Vattenbokhandel “Anvisningar för täthetsprovning av tryckledningar

tillverkade av polyolefiner (PE, PP och PB)”, Sweden.

vi
EN 805:2000: Water Supply: Requirements for Systems and Components Outside Buildings,
Comite Europeen de Normalisation.

vii
AS/NZS 4130 Polyethylene (PE) pipes for pressure applications, Standards
Australia/Standards New Zealand.

viii
AS/NZS 2566.2 Buried Flexible Pipelines Part 2: Installation, Standards Australia/Standards
New Zealand.

Code of Practice, Upstream Polyethylene Gathering Networks – CSG Industry,Australian

ix

Pipeline and Gas Association (APGA).

For Further information please contact

Plastics Industry Pipe Association of Australia Ltd
email [email protected]