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SECTION 6

INSPECTION AND TESTING OF PIPELINES AND STRUCTURES

6.1 CLEANING AND INSPECTION OF PIPELINES


The Contractor shall ensure during and after construction that the pipes remain
clean and free of all silt, mortar, debris and other obstructions, and if required
by the Engineer, the pipelines shall be cleaned out using approved methods and
equipment which do not damage the internal lining of the pipes and manholes.
When work is not in progress the open ends of the pipeline shall be securely
plugged with an approved watertight plug or stopper to prevent the ingress of
deleterious matter into pipelines.
After backfilling pipe trenches and completing chambers, hatch boxes, etc.,
and before the trench surfaces are reinstated, the interior of pipelines shall be
cleaned of silt and debris by approved methods for inspection by the Engineer's
Representative as follows:-

All newly constructed pipelines of 600 mm (nom.) internal diameter and


smaller shall have a loose plug passed through them to show that they are clear
of obstruction and free from deflection. The loose plug shall be dimensioned to
suit the permissible minimum deflected diameter of the pipe. Alternately, a
deflectometer capable of measuring diametric dimensions both vertically and
horizontally may be used as specified in Clause 4.4.8.
All newly constructed pipelines greater than 600 mm (nom.) internal diameter
will after cleaning be inspected from the inside and the Contractor shall
provide a suitable trolley for this purpose.
All renovated or replaced pipeline shall after cleaning, be inspected from the
inside using CCTV inspection as specified in Section 13.
In addition gravity pipelines or sewers shown as straight lines between
manholes on the drawings shall be subjected to a light sighting test as detailed
in the pipelaying specification Clause 4.4.3.

Pipelines, manholes, chambers/structures will be inspected again before being


put in service or taking over (whichever is sooner) and if required by the
Engineer's Representative shall be cleaned again in whole or in part by suitable
means which may include, if directed, flushing with clean water.

6.2 TESTING OF PIPELINES


6.2.1 General
The Contractor shall make his own arrangements for the supply of water used
for testing and cleaning of pipelines which shall be obtained from a source
approved by the Engineer. All water required for testing and cleaning shall be
provided by the Contractor at his cost.

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Prior to commencement of flushing or testing, approval shall be obtained to the


methods and programme for testing and to the method of disposal of all fluids
used for flushing or testing purposes. Under no circumstances will permission
be given for the discharge of such fluids into the existing sewerage system.
If permission is given to use new or existing pipelines or culverts which are not
part of a live system, they shall be thoroughly cleaned of all silt and any
resulting damage made good after use.
If lagoons for the storage of such fluids are permitted, they must be suitably
protected with fencing and attended by day and night to prevent access by the
general public and will not be sited adjacent to buildings. Approved means of
preventing the formation of mosquito larvae on the surface of the lagoons will
be employed.

Testing of pipelines shall in all cases be applied in the presence of the


Engineer's Representative. The Contractor shall notify the Engineer at least 48
hours before hand of his intention to test a section of pipeline. The Contractor,
at his own expense, shall provide complete plant and all struts, thrust blocks,
etc., as may be necessary for effectively testing the pipelines to the specified
pressures.
Pipelines shall be properly completed and supported before being put under
test. No testing will be permitted until seven days after thrust blocks and other
holding down works have been completed.

For both gravity and pressure pipelines only testing of new, renovated, or
replaced sections of pipelines and fittings will be required under the Contract,
in accordance with this Specification, unless detailed otherwise. Such testing
will be carried out before making final connections to the existing network.
However where tees or other fittings are inserted into existing pipelines and
where lengths of pipeline are replaced no backfilling will be allowed at the tees
or fittings or at the joints between new and existing pipework until the pipeline
has been returned to service and a visual inspection of all such fittings and
joints made at the network pressure.

Should any inspection be unsatisfactory or any test fail the Contractor shall
replace defective pipes, leaking joints or otherwise re-execute defective work
as instructed following which cleaning and testing will be repeated until the
Engineer's Representative certifies the pipeline to be satisfactory.

6.2.2 Testing of Non-Pressure Pipelines


All non-pressure pipelines of 600 mm nominal diameter or smaller shall be
given a preliminary air test when the pipeline is bedded and jointed before
backfilling and a final water test after backfilling in the presence and to the
satisfaction of the Engineer.
Unless otherwise instructed non-pressure pipelines shall be tested in sections
between manholes.

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INSPECTION AND TESTING OF PIPELINES AND STRUCTURES

Preliminary and final air and water tests will not normally be applied to
pipelines greater than 600 mm (nom.) internal diameter and acceptance of
these pipelines will be dependent on satisfactory visual inspection of the pipes
and joints.
Air Test (Preliminary Test)

After a length of pipeline is bedded and jointed, and before backfilling, it shall
be given a preliminary test as detailed below:
1. The Contractor shall plug all pipe outlets with suitable plugs, and brace
each plug securely where needed.
2. Air shall be pumped in slowly to the pipe until a pressure of 100 mm head
of water is indicated on a manometer connected to the system.
3. After the internal pressure of 100 mm is obtained, two minutes shall be
allowed for the air temperature to stabilize within the pipe.
4. Air may be added to restore the pressure to 100 mm.
5. During a further period of 5 minutes (without further pumping of air) the
pressure should not fall below 75 mm.
6. Release of the air pressure shall be carried out by removal of the stopper at
the end of the pipeline away from the manometer which will remain
connected. Failure to carry out the air pressure release in this manner shall
render the test invalid.
7. The Contractor will not be permitted to commence testing later than 4
hours after sunrise or earlier than 4 hours before sunset during the summer
period unless otherwise directed by the Engineer.

Water Test (Final Test)


After backfilling the length of pipeline under test, it shall be given the
following final test:
1. All branches and open ends shall be closed with suitable stoppers, secured
with longitudinal braces before testing commences.
2. Water shall be filled from the lowest point and air allowed to escape. No
entrapped air shall remain in the pipeline while testing.
3. An internal pressure equivalent to a head of water of depth to invert of the
pipeline plus 1.25 m, or 4 m head whichever is greater shall be maintained
for 30 minutes to allow for initial absorption of water.
4. After that, the test pressure shall be maintained for 60 minutes and water
added shall be measured.
5. Pipeline shall be treated as passed if water consumption in 60 minutes does
not exceed 7.5 litres per metre of diameter per 30 m of length of pipeline
under test.
Where in the opinion of the Engineer's Representative the above test is not
sufficiently indicative of water tightness by reason of high ground water levels
the test will not be applied. Acceptance of the pipelines will then depend on
satisfactory inspection or testing for infiltration as referred to below, and air
test of the pipeline in manhole lengths.

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INSPECTION AND TESTING OF PIPELINES AND STRUCTURES

The Engineer may require any length of pipe suspected of being damaged to be
retested by the water test at any time during the contract period.

Infiltration Test

After completion of backfilling and restoration of normal subsoil conditions,


all gravity pipelines and manholes shall be examined for infiltration as follows:
1. All inlets to the system shall be closed to prevent the entrance of water.
2. Pumping of groundwater shall be discontinued for at least 3 days prior to
the test for infiltration.
3. The section of the pipeline under test, including manholes, shall be
accepted as satisfactory if the infiltration does not exceed 1.00 litre per
hour per metre of pipe line per metre of nominal internal diameter.
Notwithstanding the satisfactory completion of the infiltration test, if there is
any discernible flow of water entering the pipeline at a point which can be
located either by visual or closed circuit television inspection, appropriate
measures shall be taken to stop such infiltration.
6.2.3 Testing of Pressure Pipelines
All pressure pipelines of 675 mm or more internal diameter shall have each
joint individually tested by means of an approved joint testing apparatus.

Pipelines of less than 675mm shall be subjected to a preliminary air test as


soon as a length of pipe has been laid and before backfilling. Pressure pipelines
shall then be given a final test using water after they have been backfilled,
cleaned and inspected.

Preliminary pressure testing of pipelines may be carried out if so required by


the Engineer with partial backfill only and exposed joints, but the stability and
safety of the Works must be ensured at all times.

Each test shall be restricted to pipes of one class. Pipelines shall be tested in
sections not exceeding 500m or between valve positions. In addition the whole
pipeline shall be tested upon completion. Particular care must be taken to
isolate air valves, etc., not to apply higher pressure than specified at any point
on the pipelines and to ensure that the pipelines are adequately anchored before
any test is carried out.
Gauges used for testing pressure pipelines shall be capable of reading
increments of 0.1m head. Before any pressure gauge is used, the Contractor
shall arrange for it to be checked independently and a dated certificate of its
accuracy shall be provided to the Engineer. Calibration of pressure gauges
shall be carried out at regular intervals as required by the Engineer

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INSPECTION AND TESTING OF PIPELINES AND STRUCTURES

Air Test (Preliminary Test)

As soon as a length of pressure pipe has been laid and before backfilling, when
applicable and when ordered it shall be subjected to the following preliminary
test:
1. The Contractor shall plug all pipe outlets with suitable plugs, and brace
each plug securely where needed.
2. Air shall be pumped in slowly to the pipe until a pressure of 300 mm head
of water is indicated on a manometer connected to the system.
3. After the internal pressure of 300 mm is obtained, two minutes shall be
allowed for the air temperature to stabilize within the pipe.
4. Air may be added to restore the pressure to 300 mm.
5. The test will not be satisfactory if the air pressure falls to less than 275 mm
during a period of 5 minutes without further pumping of air.

Water Test (Final Test)


Pressure pipelines shall be given the following final test using water after they
have been backfilled, cleaned and inspected:
1. All the joints of the pipeline shall be left open for the purpose of inspection
for leakage if any, where practicable or instructed by the Engineer.
2. Pipe ends shall be closed with suitable stoppers, secured with longitudinal
braces/thrust block, before testing commences.
3. Water shall be filled slowly (to prevent possible water hammer) from the
lowest points and air allowed to escape through an air vent fixed for the
purpose at the highest points of the pipeline section under test. No
entrapped air shall remain in the pipeline while testing.
4. Pressure in the pipeline shall then be raised steadily upto and maintained at
the rated pressure for a period of 30 minutes to allow for absorption and
achieve conditions as stable as possible for testing.
5. If no leakage has been observed, pumping shall then be resumed and the
pressure slowly raised to the specified test pressure.
6. Unless specified elsewhere or directed otherwise by the Engineer, the test
pressure shall be 900 KN per square metre (91.8 m head of water).
7. Test pressure shall be continuously maintained by the use of the pump for a
period of 60 minutes and the amount of makeup water required to maintain
the pressure shall be accurately measured (to the nearest 1/8 litre).
8. Pipeline shall be deemed to have passed the test if all the following
conditions are satisfied:
i. No water is visible coming out of the pipe or joints at any point;
ii. Amount of make-up water required does not exceed 1 litre per hour
per 100 mm diameter per kilometer of pipeline under test;
iii. The loss of the pressure during the test period does not exceed 70KN
per square metre.

6.3 TESTING OF VALVES


Valves and all pipelines appurtenances shall be hydraulically tested together
with the pipeline in which they are installed. Valves shall be tested for
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SECTION 6

INSPECTION AND TESTING OF PIPELINES AND STRUCTURES

operation under working pressure and shall be adjusted so that they operate
smoothly, seat properly and are installed to tolerances recommended by the
manufacturer.

6.4 TESTING OF RENOVATED AND REPLACED PIPELINES


All non-pressure pipelines renovated or replaced by slip lining, soft lining, or
pipe bursting methods shall be given an air test or water test per Clause 6.2.2 in
the presence and to the satisfaction of the Engineer.

6.5 TESTING OF WATER RETAINING STRUCTURES


All water retaining structures shall be visually inspected to confirm that there
is no infiltration. Where it is required by the Engineer, water retaining
structures shall be tested for watertightness. The structure shall be filled with
water and shall stand for a period of three days, to allow for absorption. The
structure shall be considered satisfactory if, subsequent to this period, there
shall be no fall in level over a period of 24 hours (after making the allowance
for rainfall and evaporation) and there shall be no visible leaks, or damp
surface areas.

This shall be carried out before any backfilling and before the application of
any external concrete protection has taken place. Any damages revealed as a
result of such tests shall be made good to the satisfaction of the Engineer.

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