Hydrostatic Test

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Hydrostatic Strength of NEXOR HDPE Pipes – Test

Procedure

June 6, 2006

ABSTRACT

The procedural standard of hydrostatic HDPE pipe test

performed at NEXOR PIPES is detailed below.

Introduction

Hydrostatic pipe test measures the resistance of pipes to

internal pressure. It is one of the easiest ways to assess long
term performance if piping materials. The methodology
performed at NEXOR PIPES, which closely follows ISO 1167,
is detailed below.   

Procedure

Preparation of Test Pieces

Three test pieces are required. The length of the pipe

between the end caps must be at least the length listed on
table 1.

Table 1 Length of Test Pipe

PIPE OD Length of Test Piece from end cap to end

(mm) cap(mm)

20 250

25 250

32 250

40 250

50 250

63 250

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75 250

90 270

110 330

125 375

140 420

160 480

180 540

200 600

225 675

250 750

280 840

315 945

355 710

400 800

450 900

500 1000

560 1120

630 1260

710 1420

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 800 1600

900 1800

1000 2000

Conditioning

A pipe after being extruded must be allowed to sit for a

minimum period of 24 hours before performing a hydrostatic
test. A conditioning period must also be followed to ensure
that the pipe walls achieve thermal equilibrium. Conditioning
is done by placing the pipe inside the test bath at the
specified test temperature for a period indicated on table 2.

Table 2 Conditioning Period

Thickness (mm) Conditioning Period (h)

<3 1

>3 and <8 3

>8 and <16 6

>16 and <32 10

>32 16

Calculation of Test Pressure

The test pressure is calculated based on the design stress of

the pipe material and using the following formula.

P = 10σ(2)/(SDR-1)…………………………..1

P = test pressure in bar

σ = is the stress to be induced by the applied pressure, in

MPa.

SDR = standard dimension ratio of the pipe

The design stress is based on the Minimum Required

Strength (MRS) at 50 years and 20 0C and the design
coefficient.

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PE 80 has an MRS of 8 MPa and the minimum design
coefficient is 1.25; both of these lead to a maximum design
stress of 6.3 MPa.

Using a design stress of 6.3 MPa and formula 1, table 3 lists

some of the test pressures at various SDRs.

Table 3 Sample test pressures for PE 80 with a Design

Stress of 6.3 MPa

SDR Test Pressure (psi)

9 228 +/- 1

11 183 +/- 1

13.6 145 +/- 1

17 114 +/- 1

Application of Test Pressure

Pressure is applied in a steady incremental manner at the

rate of 30 psi per minute.

Measuring Hydrostatic Strength according to ISO

Following ISO 4427 and ISO 1167, the three test pieces are
to be subjected to different test conditions. Each are listed on
table 4 for PE100 and PE 80.

Table 4 Three different Test Conditions - Test Stress,

Temperature, and Time

Pipe Test Stress Test Stress Test Stress

Material (MPa) of (MPa) of (MPa) of
Condition 1 Condition 2 Condition 3
(100 h, 200C) (165 h, 800C) (1000 h, 800C)

PE 100 12.4 5.5 5.0

PE 80 9.0 4.6 4.0

Based on the test stresses, the following test pressures are

to be applied for a given SDR. The values given in tables 5 to
8 have a tolerance of +/- 1 psi.

Table 5 Test Pressures for SDR 9

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 Pipe Test Pressure Test Pressure Test Stress
Material (psi) of (psi) of (psi) of
Condition 1 Condition 2 Condition 3
(100 h, 200C) (165 h, 800C) (1000 h,
800C)

PE 100 450 199 181

PE 80 326 167 145

Table 6 Test Pressures for SDR 11

Pipe Test Pressure Test Pressure Test Stress

Material (psi) of (psi) of (psi) of
Condition 1 Condition 2 Condition 3
(100 h, 200C) (165 h, 800C) (1000 h,
800C)

PE 100 360 159 145

PE 80 261 133 116

Table 7 Test Pressures for SDR 13.6

Pipe Test Pressure Test Pressure Test Stress

Material (psi) of (psi) of (psi) of
Condition 1 Condition 2 Condition 3
(100 h, 200C) (165 h, 800C) (1000 h,
800C)

PE 100 285 126 115

PE 80 207 105 92

Table 8 Test Pressures for SDR 17

Pipe Test Pressure Test Pressure Test Stress

Material (psi) of (psi) of (psi) of
Condition 1 Condition 2 Condition 3
(100 h, 200C) (165 h, 800C) (1000 h,
800C)

PE 100 225 99 90

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 PE 80 163 83 72

Pipe Failure

In case of pipe failure, the mode of failure is recorded and a

picture of the pipe is taken.

A failure is brittle if there is no visible yield deformation.

If a break occurs ain the test piece at a distance of less than

10 % of the length of the test piece from the end cap, the
results must be disregarded.

Test Reporting

Please see attached sample report.

References

ISO 1167 -1 Thermoplastics pipes, fittings, and assemblies

for the conveyance of fluids – Determination of the resistance
to internal pressure. Part 1 : General Method.

ISO 1167 -2 Thermoplastics pipes, fittings, and assemblies

for the conveyance of fluids – Determination of the resistance
to internal pressure. Part 2 : Preparation of Pipe Test Pieces.

ISO 4427 Polyethylene Pipes for water supply -

Specifications

Chasis, David. Plastic Piping Systems. 2nd Ed. Industrial

Press Inc. USA. 1988

Willoughby, David et al. Plastic Piping Handbook. Mcgraw-

Hill Handbooks. USA. 2002

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