TESTING & COMMISSIONING

MEC –P09
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1.0 TESTING OF DOMESTIC WATER PIPING

The entire water supply system in this contract shall be thoroughly pressure-tested
and balanced by the Contractor. All water, hydraulic pumps, flow gauges, pressure
gauges, temporary connections, fuel and labour required for this purpose shall be
provided.

(a) Pressure test

Reticulation and main distribution pipes shall be slowly and carefully charged
with water in order that all air is expelled from the system. The system shall be
allowed to stand for full for 24 hours.

(i) A test pressure of 1.5 times the maximum working pressure measured
at the lowest point or 100 psig measured at the lowest point,
whichever imposes the higher pressure on the system, shall be
applied for 24 hours. After correction for ambient temperature the
pressure drop shall not exceed 5% of the test pressure.

(ii) Should any signs of leakage occur in the tanks or pipework, their
positions shall be marked and the Contractor shall carry out remedial
measures. The pressure tests procedure shall be repeated until the
whole water system passes.

(iii) No pipework shall be covered or concealed until it has been tested to

the satisfaction of the Architect. Where arrangement of work makes
necessary, the piping system shall be tested by sections but final
overall test shall be carried out to prove joints between sections.

(iv) All equipment not designed to withstand test pressure shall be

disconnected during test, but shall be reconnected and tested under
actual working pressure.

(b) Flow test

Upon completion of pressure tests on all risers, all pumps shall be run with all
valves fully open. During test running, the following data shall be recorded:

(i) Flow at outlet into tank to which water is pumped.

(ii) Head at pump discharge outlet

(iii) Current consumed

(iv) Voltage

The permanently installed pumps shall not be used for pressure testing of the water
system.

The Contractor shall submit a testing schedule as required.

The contractor shall ensure the safety of all persons employed in or about the
conduct of all tests and to take all necessary and proper precautions to prevent
damage or injury to any person arising out or any test.

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The testing through permanently installed equipment shall not be included in the test
procedure.

All pipe supports, anchors and thrust blocks shall be fitted to underground pipework
services prior to pressure testing. Additional temporary supports shall be provided
where required due to the weight of the test water.

When conditions require a test pressure to be maintained for a period of time, during
which the testing medium in the system might be subject to thermal expansion,
provision shall be made for the relief of excess pressure.

2.0 FLUSHING/STERILIZATION OF COLD WATER SYSTEM

Upon completion of the pressure tests to the satisfaction of the Architect and the
Local Authority, the whole system shall be thoroughly flushed with clean mains water
to remove any dirt or debris within the system. All terminal outlets shall be opened to
ensure that uninterrupted water passage is possible.

(a) The system should then be filled with water for a second time, but as the
storage tank/break tank is filling a sterilizing chemical containing chlorine
should be added to ensure thorough mixing of the chemical and water. The
dose should be such as to give 50 parts of chlorine to one million parts of
water.

(b) After filling the system, the incoming water supply should be shut-off and each
tap on the distribution pipes opened successively, starting with the nearest
cistern. As the water which issues from each tap begin to smell of chlorine,
the tap should be closed.

(c) The whole system should then be allowed to stand charge with treated water
for a period of at least 3 hours, after which a test should be made by smell for
residual chlorine. If none is found, the sterilization should be repeated.

(d) Before any water is used for domestic purposed, the whole system must be
emptied and thoroughly flushed out with clean water.

3.0 BALANCING

Upon completion of flushing/sterilization and connection of sanitary fittings, the water

supply system shall be balanced.

Prior to balancing, all isolation valves shall be checked to be in the fully open position.

The balancing shall be carried out on a floor-by-floor basis. All water appliances on
the floor to be balanced shall be fully turned on.

Commissioning and performance tests shall be carried out using trained,

experienced, commissioning engineers/Technicians.

A detailed list of the equipment proposed for use during commissioning and
performance testing shall be submitted prior to commencement of commissioning.

The hydraulic systems shall be balanced to within the tolerances detailed in the
specification on the drawings, commissioning coded and guides.
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4.0 RECORDS

All pressure, flow and balancing tests shall be recorded and certified by the
Contractor and the Architect.

The pressure, time and date of tests shall be included in the records. The Architect
reserves the right to order a re-test should the Contractor fails to produce authentic
test records.

5.0 GALVANISING

All items noted on the drawings as galvanised shall be hot-dipped galvanised in

accordance with ASTM A123 and shall have a minimum of 2.5 ounces of zinc per
square foot.

All items to be galvanised shall be complete and finished including all drilling, cutting
and shaping prior to galvanising.

Before being delivered to the galvanised shop, every article shall be cleaned of paint,
oil, grease, welding spatters, welding slag, and any foreign substance not readily
removed by the normal cleaning methods used in the galvanising trade. Removal of
these substances may require degreasing, grinding, buffing, chipping and abrasive
blast cleaning.

After galvanising, the zinc-coated articles shall be free from uncoated spots. The
coating shall be free from blisters, flux, black spots, or other defects not consistent
with good galvanizing practice.

Galvanised members are not allowed to be welded or subject to any form of heat
treatment unless otherwise stated in the specifications or drawings in which case, the
galvanised members that are to be permanently fixed to the structure by welding shall
be attached after the supporting members are primed but before topcoats are added.
The heat-affected area shall be cleaned by blasting and the surface coated to the
same standard as the supporting members.

6.0 SAMPLING

The sampling point shall comprise all necessary stainless steel pipework and fittings
from the point of tapped-off. It shall be complete with all valves, gauges and swan
neck as detailed on the drawing.

Where installed indoor, the point shall be complete with drain gully, with cover and
pipework to the nearest and most suitable floor gully.

The sampling point shall be housed in a galvanised mild steel housing, painted as
detailed in this specification, complete with padlock, generally in accordance with
Local Water Authority requirements.

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7.0 TESTING OF SANITARY PIPING

The Architect reserves the right to request for water or air or smoke tests as well as
for hydraulic performance to be performed by this Contractor at his expense including
the furnishing of the necessary equipment.

7.1 TYPES OF TEST

Followings are the types of test and its requirements.

(a) Water Test

Water test shall be performed before the appliances are connected and may
be carried out in sections so as to limit the static head to 4.6m.

All openings affected by the test shall be hermetically sealed and the system
shall be filled with water.

The water level shall be maintained by the system at its filled height for a
period of thirty minutes by the addition of water.

The quantity of water added to maintain the original water level must not
exceed 13.6 litres for every fifty joints in the section tested of equivalent
proportion.

Every joint shall be carefully examined for leaks while the system is filled with
water.

The soil, waste and ventilation pipe work is designed for a gravity system and
the maximum test pressure applied shall not exceed 4.6m.

Once a section of pipe work to be tested is filled with water, it shall stand for
30 minutes to absorb any pockets of air. Top up with water, if necessary, and
add no further water for thirty minutes.

Permissible water loss shall be as tabulated:

_____________________________________________________________

Nominal Pipe Size (mm) Loss (volume)

_____________________________________________________________

100 0.5 litres/metre

150 0.8 litres/metre

200 1.2 litres/metre

_____________________________________________________________

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(b) Air Test

Air test may be performed by inserting expanding rubber testing plugs in the
lower and upper ends of the main soil pipe and main ventilating pipes and
sealing the plugs with water necessary. The water seals of all sanitary
appliances shall be fully charged.

The testing plug at the upper end of the ventilation pipe should be fitted with a
tee-piece with a cock on each branch. A flexible tube manometer should be
fixed to one branch while air pressure is being introduced into the system
through the other branch until the desired pressure is indicated on the
manometer scale.

The air test applied shall be 38mm water gauge for three (3) minutes without
loss.

(c) Smoke Detection

Smoke can be introduced into the system by a small machine under the
source pressure as for the air test.

The whole system shall be filled with smoke before the openings are sealed
with plugs.

The pressure on the smoke shall be maintained for three (3) minutes after the
last opening has been sealed.

Smoke test is not recommended if UPVC pipe material is adopted.

Smoke testing shall normally only be used instead of air test when an
undetectable leak in the system occurs.

(d) Leak Detection Using Soap Solution

Should the system or section of the system fail the air test or the smoke
machine test, as described, soap solution shall be applied to the pipes and
joints to detect leakage by the formation of bubbles.

(e) Hydraulic Performance

Hydraulic performance discharge tests shall be made from all appliances

singly and collectively. Obstruction in any of the pipelines shall be traced and
the whole system examined for proper hydraulic performance including the
retention of an adequate water seal in each trap.

END OF SECTION

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