Section T

TESTING

Section 2
Water Reticulation Testing

2.1

Water Reticulation Testing

Testing Pipelines

2.1.1 General
After a length of the pipeline has been completed it shall be tested as a whole
against stop ends. The stop ends shall be supplied and fixed by the Contractor
and shall be properly strutted to ensure that no movement can take place and they
shall be of sufficient strength to withstand the full test pressure which is to be
applied.
Testing shall be carried out over lengths of approximately (2) two kilometre
where possible or the full replacement length between washout or overcrossings
but not against adjacent valves. Testing shall not be carried out until the
backfilling of the pipe trenches except at the joints, have been completed.
Backfilling at flexible joints shall be left uncompleted to facilitate inspection of
these joints during testing.
Temporary marker posts shall be installed immediately after testing at all
junctions between tested lengths.
Before any length of pipeline is subjected to test pressure, care shall be taken to
ensure that all weight, thrust and anchor blocks intended to prevent vertical and
lateral displacement of pipes or specials have been properly completed. All
valves shall be checked before the test to ensure that they are in working order.
Prior to filling the line with clean water for water testing, the line shall be
thoroughly inspected jointly with the S.O. to ensure that the line is cleaned from
stones, dirt, debris, plastic paper or any other matter that may have entered after
laying of pipework.
The water for filling and testing the pipeline shall be obtained from an approved
source. It shall be free from silt, contamination and pollution. The Contractor
shall make all arrangements necessary for conveying the water to the point of
filling. The test ends shall be tapped for suitable size test connection. When
using high pressure pumps for water feeding, regulate the feed slowly to allow
minimum or bubbles into the pipeline.
The fill and test position shall be located at the lowest point of the pipeline
profile to encourage the expulsion of air as the pipe is being filled. All air-valve
positions and the end of the test section shall be vented during the filling of water
to bleed out all trapped air which may affect the test.
The Contractor shall supply all necessary apparatus including pipework, pumps,
flowmeters and pressure charts/recorders and carry out all work necessary to test
the pipeline. Pressure gauges are to have a dial at least 200 mm in diameter and
shall have unit graduations on the gauges of not more than 0.1 bar. The pressure
recorders shall have the ability to record pressures down to 0.1 bar. The gauges
and recorders are to be checked against a guaranteed standard unit before use
and at other times as the S.O. may direct. The flowmeter to measure the quantity

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of flow pumped shall be suitable for the flowrate of the pumps supplied by the
Contractor. The flowmeter shall have an accuracy of not more than 2% at
transition flowrate of the meter as specified in BS5728. The flowmeter shall have
an integral totaliser display built-in.

The S.O. will attend all tests and all apparatus and methods shall be to his
approval. No length of pipeline shall be deemed to have passed its pressure test
until the S.O. has issued a certificate to the Contractor to this effect.
Substantial completion will not be certified before the mains have been
successfully water tested.
The Contractor shall take all necessary steps to locate any leakage, supply
necessary materials and make necessary repairs or remake any joints, and restore
the ground at no extra cost to the Contract until, on retest, the requirements of
permissible loss are complied with.
A pressure test on washout pipework shall not be required. The performance of
washout pipework shall, however, be observed during flushing of the pipelines
after testing. Each scour valve in turn shall be opened fully under the normal
working head in the pipeline for sufficient time to allow proper flushing of the
pipeline and to check the watertightness of the washout pipework. All water used
for testing purposes shall be recorded. The Contractor shall carry out any
necessary remedial work to pipework as directed by the S.O.
2.2

Testing DI Pipelines

2.2.1 Test Pressure

The test pressure to be applied shall be 15 bar at the lowest point.
2.2.2 Leakage Testing
In testing, the main shall be filled with clean water and properly vented to
remove trapped air. After a period of 24 hours, the pressure shall be raised by
pumping to the specified test pressure. Pumping shall then cease at 10 bar and
after a period of 24 hours, pumping shall be resumed and the quantity required to
be pumped, in order to restore the test pressure, divided by the time, shall be the
measure of the rate of loss.
The length of main under test shall be deemed to have passed the test if the
leakage does not exceed 0.1 litre per mm of internal diameter per 24 hour per
kilometre of pipeline per 30m of water pressure.

Water Reticulation Testing

2.2.3 Marking of Pipes and Fittings

The following cast on or cold stamped marks shall appear on the socket end of
each pipe:(a) The indicator that the pipe is of ductile iron DI.
(b) The year manufacture (the last two digits)
(c) The manufacturer's identification mark
(d) The nominal diameter (ND)
(e) The class designation ( 40, K9 or K12)
(f) The serial number
(g) Standard reference
(h) Initial SAJH in capital letter
In the case of fittings, these marks shall be placed on the body of each fitting
along with its main characteristics (ie. the angle of bend in degrees, the pressure
rating of the flange etc.). For pipes and fittings having a spigot end for use with a
`push-on' type joint, socket penetration lines (two white painted lines) shall be
painted on the spigot end of the pipes and fittings.

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