Pressure testing procedure for the pressure testing of the HDPE pipe

1.

Program objective

The purpose of this procedure is to ensure that the new HDPE pipe is leak free and that all client requirements regarding the integrity of the welds are met.

2.

Scope

This procedure is applicable to all employees and subcontractors employed to perform the hydraulic pressure test on the HDPE sludge line on Duvha Power Station.

3.
3.1

Definitions
Risk assessment The process/program to determine as far as reasonably possible, what the dangers/hazards to the health and safety of persons attached to any activity or work are and what precautionary measures should be taken to mitigate the risks

4.
4.1

Responsibilities
Management Shall ensure that all employees and subcontractors employed to perform the hydraulic pressure test complies with the requirements as set out in this procedure Ensure that the risk assessment is in place prior to commencement of the hydraulic pressure test Ensure that all safety measures as depicted in the risk assessment are in place and monitored during the duration of the work.

4.2

Supervisor Will be responsible for initiating and controlling this procedure Will discuss the procedure and risk assessment in detail with all employees and subcontractors prior to the commencement of work Monitor conditions to ascertain whether there are any leaks on the pipeline

Pressure testing procedure for the pressure testing of the HDPE pipe

Ensure that safety precautions as set out in the risk assessment are adhered to during the duration of the test

4.3

Employees and contractors performing the pressure test Use all personal protective equipment as required to perform the work Communicate with the supervisor regarding any hazards noticed

5.
5.1

General Information
Communication Communication will be by means of a radio between the employees or subcontractor at either end of the pipe line

5.2

Water supply The client will provide an ample water supply for the pressure testing of the HDPE pipeline.

5.3

Equipment A Rothenberger RP 50 S testing pump will be used for this procedure. The equipment is equipped with a calibrated pressure gauge.

6.
6.1

Procedure
Preparation of pipeline The pressure test will be performed after backfilling and compaction as per SABS 1200 LB 1983 Bedding (pipes) is completed for the entire length of trench A flange with a 2 and 1 valve and pressure gauge should be fastened to the bottom end of the pipe, nearest to the tie in point, from where the pipe will be filled with water Provision will be made for a half inch adaptor to connect the pipe to the Rothenberger testing pump

Pressure testing procedure for the pressure testing of the HDPE pipe

6.2 Test

On the other end of the pipe a flange with a 2 valve will be connected

The valve at the top end of the pipe should be open at the onset of the pressure test. This will ensure that the air escapes as the pipe is filled with water

As soon as water comes out of the valve at the top end of the pipe, the valve should be closed

The equipment as described in section 5.3 of this procedure will be used to increase the pressure in the pipe

The pressure should be brought up to at least 1.25 times the normal operating pressure The normal operating pressure of this system is 475 kPa. The pressure in the pipe should therefore be brought up to 600 kPa

The supply valve should be closed after the specified pressure has been reached The pressure should be maintained at 1.25 times the normal operating pressure for a minimum of 3 hours

If the pressure shows any deviation from the testing pressure after 3 hours under pressure the pipe is leaking

If the pipe is leaking the leak must be located and repaired after which this procedure should be repeated

If the pressure is maintained for the required 3 hour period it is accepted that the pipe is not leaking

6.4

Completion of pressure test Upon completion of the hydraulic pressure test al valves should be opened and the pipe should be allowed to drain

Pressure testing procedure for the pressure testing of the HDPE pipe

A document stating that a pressure test was performed and witnessed and should be signed by the Eskom representative that witnessed the test, the subcontractor that performed the test and an AquaPlan representative