TSC Pes 0003 QC BM VPCR 009 A

Interconnecting Utilities and Offsite of MOKRAN
Petrochemical Complex - Stage 1
Hydrostatic procedure for HDPE Material
Purch. Vendor. PO No. Dis. Tag No. Doc. Seq. Rev.

Document No.:
TSC PES 0003 QC BM VPCR 009 00
TSC PES 0003 QC BM VPCR 009 A Page 1 of 16
Hydrostatic procedure For HDPE Material
Approved: Vendor shall issue “AFC/ AFD/AFP/AFT/AFI” status.

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Approved as noted: Vendor to amend and submit the “Issued for
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Commented: Vendor to amend and submit the “Issued for Approval”
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status.
Rejected: (vendor to resubmit with same revision
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The above checking result by Purchaser shall in no way relieve Vendor of any liability,
obligation and responsibility out of the purchase order and the mutual agreement in writing
Date: Dept.: Signature:
Only for internal review

CV PI EL IN ME MA
ST MC PR SF HV TC
A 07-Jan-2023 ISSUE FOR COMMENT A.Amini A.Amini A.Amini

Rev. DATE PURPOSE OF ISSUE PREPARED CHECKED APPROVED

Document No.:
Revision Index
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TABLE OF CONTENT
1. Hydrostatic pressure test in the Lab. ................................................................................................................5

1.1. Goal .........................................................................................................................................................5
1.2. Scope of Application ............................................................................................................................... 5
1.3. Project Specification ................................................................................................................................ 5
1.4. Reference Standards ................................................................................................................................ 5
1.5. Test Specimen Preparation ......................................................................................................................5
1.6. Method .....................................................................................................................................................6
1.7. Service & Maintenance ............................................................................................................................7
2. Hydrostatic pressure test at site ........................................................................................................................9
2.1. Overview..................................................................................................................................................9
2.2. Safety considerations ............................................................................................................................... 9
2.3. Preparation ...............................................................................................................................................9
2.4. Temperature effect ...................................................................................................................................9
2.5. Filling the pipeline ...................................................................................................................................9
2.6. Pipeline testing under 20 °C (pipe's exterior surface temperature) ........................................................ 10
2.6.1. Methodology................................................................................................................................................... 10
2.6.2. Test equipment ............................................................................................................................................... 10
2.6.3. Initial test ........................................................................................................................................................ 11
2.6.4. The calculated pressure for the pipeline (MDP) ............................................................................................. 11
2.6.5. Final test ......................................................................................................................................................... 11
2.6.6. End of testing .................................................................................................................................................. 12
2.7. Pipeline test for temperature above 20 °C (pipe's outer surface temperature) ....................................... 12
2.7.1. Initial test ........................................................................................................................................................ 12
2.7.2. Final test ......................................................................................................................................................... 13
2.7.3. Short-term test ................................................................................................................................................ 13
2.7.4. Applying the test pressure .............................................................................................................................. 13
2.7.5. Equipment required for testing and related methodology ............................................................................... 14
2.8. Measurement instruments ...................................................................................................................... 14
2.8.1. Internal pressure measurement ....................................................................................................................... 14
2.8.2. Thermometer .................................................................................................................................................. 14
2.8.3. Calculating the volume of test water .............................................................................................................. 14

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2.8.4. Calculating the volume of water discharged ................................................................................................... 14

2.8.5. Test and its results .......................................................................................................................................... 14
2.8.6. Pressure reduction........................................................................................................................................... 14
2.8.7. Repeat the initial test ...................................................................................................................................... 15
2.8.8. Repeating the final test ................................................................................................................................... 15
2.8.9. Test Report ..................................................................................................................................................... 16

Document No.:
1. Hydrostatic pressure test in the Lab.

1.1. GOAL
The purpose of this instruction is to investigate the plastic behavior of polyethylene pipes at internal pressures.
1.2. SCOPE OF APPLICATION
Hydrostatic pressure test is performed for all manufactured pipes sizes from 16 to 400 mm.
1.3. PROJECT SPECIFICATION
• Negin Mokran Development Petrochemical Co. (NMPC) has decided to develop a third hub of
Petrochemical Industries in Chabahar Free Trade-Industrial Zone.
• Based on detailed investigation, 1,200 hectares of Chabahar Free Trade- Industrial Zone with
dimensions of 2.7 × 4.4 Km has been allocated for petrochemical zone.
• Mokran Abniroo "MAN" is a company organized and exists under the laws of the Islamic Republic of
Iran and is a sub-company of NMPC, desires to establish "Interconnecting Utilities and Offsite of
MOKRAN Petrochemical Complex - Stage 1".
1.4. REFERENCE STANDARDS

• ISIRI 12181-1(2, 3, 4) Plastics. Pipes, fittings and assemblies for the conveyance of fluids Determination
of the resistance to internal pressure. Part 1: General method and
• ISO 9080 Plastics piping and ducting systems — Determination of the long-term hydrostatic strength of
thermoplastics materials in pipe form by extrapolation and
• ISO 1167 Thermoplastics pipes, fittings and assemblies for the conveyance of fluids Determination of
the resistance to internal pressure — Part 1: General method
1.5. TEST SPECIMEN PREPARATION

The free length of the pipe between the end caps shall be at least three times the nominal outer diameter (dn)
and at least 250 mm, but if the minimum free length specified for pipes with dn greater than 315 mm cannot be
attained, the shorter free length at least twice the dn can be selected. Cut the sample so that the cut ends of the
pipes are perfectly flat and perpendicular to the pipe axis. After closing the A-type gaps, fill the pipe with clean
and preferably treated water and put the test specimen, according to Table 1, in the water tank so that the
specimen temperature reaches to the water tank temperature (20 or 80 degrees C). (Water temperature
tolerance is ± 1 ° C)
Since the new standard 12181 does not specify the minimum length of the specimens and there is no reference
to the exact length of the specimen, the following formula is used in the preparation of the specimen that covers
the minimum length according to the standard. (250+3D+2L) mm
It should be noted that metal gaps are used for pipes up to 160 mm in size and polyethylene flanges are used
for pipes with 180 to 400 mm in size to block the samples.

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Time intervals for stabilizing isothermal conditions (Table 1)
Time intervals for stabilizing environmental Pipe Thickness (e min)

conditions (hours) )mm(
1 e min<3
3 3≤ e min<8
6 8≤ e min<16
10 16≤ e min<32
16 32≤
1.6. METHOD
Calculate the pressure based on the measured dimensions of the specimen from the following equation:
2e min
P =10 δ or P = 2×10 S/ (SDR-1) SDR= DO/emin
𝑑e m − e min
P = Hydrostatic pressure (Bar)
δ = environmental stress (design) created by the applied pressure (MPa)
SDR = Standard Dimension Ratio (mm)
emin = minimum wall thickness (mm)
The value of δ is calculated from the following table according to the type of test and the raw materials:
Temperature Test time δ

Raw materials
(°C) (H) (MPa)
PE-63 20 100 8
PE-63 80 165 3.5
PE-80 20 100 10
PE-80 80 165 4.5
PE-80 80 1000 4
PE-100 20 100 12.4
PE-100 80 165 5.4
PE-100 80 1000 5
Table2
Complete the information requested in the relevant software and start the test after airing the pipe.
Any localized swelling, fractures and hair cracks leading to pressure drop in the pipe or preventing uniform
pressure rise will be considered a defect and the test will stop automatically.
Any leakage at the gaps or bursting of the specimen near them indicates an invalid test and causes the test to
be repeated with the new specimen.
All test parameters and Pressure change-vs. - Time diagrams are recorded for each sample and sent to the
customer upon request. (See related standards for more information).

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1.7. SERVICE & MAINTENANCE

- After the test, remove the specimen from the pond and remove the gaps, dry it completely and place it in
place.
-Check the pressure of the treated water in the pressure vessel so that it is not less than 3 bar.
- Open the inlet water filter in the pressure generating device in case of clogged sediment and rinse with water.
Before performing any test, check the outlet water of the respective terminal and clean any rust or foreign mass
in the outlet.

Document No.:

Document No.:
2. Hydrostatic pressure test at site

2.1. OVERVIEW
Any newly constructed or newly modified piping system should be leak tested before starting the operation to
determine if leaks exist in the system. DVGW W400-2 instruction is used to test the internal pressure of the pipe
under a temperature of 20 °C. This instruction is an alternative index for the DIN 4279 standard. DVS 2210-1
instruction is used when the pipe wall temperature is over 20 °C.
Internal pressure testing should be done by skilled experts. The person conducting this test must have full
information about the piping system, the pipe pressure testing, measurements, and safety considerations.
2.2. SAFETY CONSIDERATIONS

Entering the trench of the pipe under testing is prohibited. Before testing, ensure calibration of all barometers
and assure if they are connected under the supervision of skilled persons and according to instructions.
The pipeline under test must be fully controlled throughout the test to avoid injury to persons.
2.3. PREPARATION
Safety equipment coverage: If necessary, cover the surface of the pipe to avoid temperature alterations during
the test. Leave the joint parts (such as welding or fitting area) uncovered, but these parts should also be
protected from direct sunlight.
2.4. TEMPERATURE EFFECT

Minimize the effect of temperature by taking measures mentioned earlier. Ensure that the pipe's surface
temperature does not exceed 20 °C during testing (Test Method A), where the temperature is determined to be
up to 20 °C. In the final test, the pipe wall temperature should be roughly equal at the start and end of the test.
2.5. FILLING THE PIPELINE

Put the pipeline fully or in the parts under the pressure test. The test steps should be split so that the test
pressure is achieved in the lowest part of the pipe. At the highest point of the line, the pressure should be
reached at least 1.1 times the pressure calculated for the MDP (Maximum Design Pressure) system.
The test line length can be up to 3 km, given the diameter of the pipe and the location of piping. Some features
to consider are preparing the water required for the test and determining the place to drain it after the test.
Before testing, make sure that there are no foreign particles inside the pipe.

Document No.:
Ensure that there is no air trapped in the test section. For this, fill the pipe slowly from the lowest level, use
equipment vents at high points to remove air.
The speed of water filling should not be extremely high and normally is recommended at 1 m/s.
Pipeline filling operation can be done shortly (or even a day) before the start of the test. At this step, there is no
pressure on the pipe. If pipe filling is done before starting the test, wait an hour after pipe filling and start the
test again.
Pipeline filling starts from the lowest area of the pipe. Calculate the volume of water input at a given time to
allow enough time for drainage at the highest point of the pipeline. Table 2 presents the values of the volume
of inlet water.
Diameter (DN; mm) Speed V 1/s Diameter (DN; mm) Speed V 1/s
Less than 80 0.15 250 2.0
100 0.3 300 3.0
150 0.7 400 6.0
200 1.5 500 9.0
When filling the pipeline and conducting the test, allocate sufficient time to allow air to leave the pipeline. Given
the diameter of the pipe, the recommended water filling time is 6 to 12 hours.
2.6. PIPELINE TESTING UNDER 20 °C (PIPE'S EXTERIOR SURFACE TEMPERATURE)

2.6.1. Methodology
• The test is done in three steps:
• Initial test or saturation step
• Pressure drops test step
• The final step
2.6.2. Test equipment

Use a barometer with an accuracy of ≤ 0.1 bar. The type of barometer is an important factor to consider. For
example, for a pressure test of 15 bar, a barometer measuring range should be between 0 and 20 bar. To
measure the surface temperature of the pipe, use measuring instruments with an accuracy of ≤ 0.1 k.

Document No.:
2.6.3. Initial test

The initial test can be done at least an hour after the pipeline was filled. After filling, both ends of the part under
testing must be closed. Within 10 minutes, we should reach the pressure level of the STP (System Test Pressure)
test. The pressure limit of the STP test is equal to
STP = MDP × 1.5 or
STP = MDP + 5 bar
The lower value applies
The exception to this guideline is for PE100 pipes with SDR17.
According to the DVGW W400-2 instruction (section 16.4), for testing PE100 pipes with SDR17, the maximum
test pressure must be 12 bar.
2.6.4. The calculated pressure for the pipeline (MDP)

Use lower values when choosing the test pressure from the above equations. After reaching the test pressure
limit, keep the pressure constant for the next half an hour with the help of a pump if the pressure drops. Then
allow an hour for the viscoelastic changes in the pipeline to balance. During this period, the maximum pressure
drop can be up to 20%. Higher pressure drops indicate the possibility of water leakage or unauthorized changes
in water temperature.
2.6.5. Final test

Despite the constant pressure during an hour, the expansion in the pipe is not finished yet. To create the balance
and stop the pipe from expanding in a short time (less than two minutes), we reduce the pressure.
For this, the pipe pressure in pipes with the pressure of up to 10 bar is reduced up to 2 bar, and the pipe pressure
in pipes with the pressure of up to 16 bar is reduced up to 3 bar, both during less than 2 minutes. This pressure
reduction causes contraction (return to the previous state) in the pipe. In the next half an hour, sealing or
leakage of the pipe can be ensured.
After the pressure was decreased and the final test was started for half an hour, the pressure in the pipeline
increases slowly or at least remains constant. When there is uncertainty about the test result, you can continue
the test for another hour and a half.

Document No.:
2.6.6. End of testing

When there is a reduction in pressure in the pipeline, detect the leakage source and fix it. The test should be
repeated several times to ensure that the pipeline is sealed. If a pipeline is pressurized at periodic intervals and
all tests are positive, then after starting the whole pipeline, we put it under nominal pressure for 2 hours.
Repeat this after any on-line repairs.
Documentation: After the test, all test steps must be carefully recorded and reported in the report form.
Pressure variations in pressurized polyethylene pipes by Contraction test to determine sealing or leakage
2.7. PIPELINE TEST FOR TEMPERATURE ABOVE 20 °C (PIPE'S OUTER SURFACE TEMPERATURE)
2.7.1. Initial test
The initial test is to prepare the pipe for the final test. During the initial test, a balance of tension and expansion
happens in the pipe, which must be developed by adding water (pumping water) up to the calculated rate.

Document No.:
2.7.2. Final test

After the initial test was ended, the final test starts. During the final test, less pressure drop is observed,
considering that the water temperature remains constant. In the final test, it is normally not required to add
water to keep the pressure constant. We monitor the line sealing test.
2.7.3. Short-term test

This test is for special cases. Note that during this test, the stress-expansion balance in the pipe does not happen,
therefore, we cannot be sure for 100% that the pipeline is sealed.
Explanation Initial test Final test Short-run test
Calculating test For pipe’s wall temperature and Less than and/or equal
pressure by the 85% of the test pressure 1.1 than the test pressure
curve pipe design pressure to the test pressure
Pipe with or without branch with
3h 3h 1h
maximal length of 100 m
Pipe with or without branch
Test duration 6h 6h 3h
100m<total length≤500m
Pipe with or without branch with The pipeline should be tested in the length of maximally 500 m.
maximum length of over 500 m 6h 6h 6h
At least three controls
Control results include the test At least two controls during At least one control with
Control during during the test by
pressure and temperature should be the test without increasing the constant pressure during the
the test establishing the test
included in the report. test pressure test
pressure
For this test, no numbers and
Maximally 1 bar during an Maximally 0.5 bar during an
Pressure drops Considering E-Module figures have been recorded for
hour PE≤1.0 bar/h hour PE≤0.5 bar/h
pressure drop
2.7.4. Applying the test pressure

Pumps equipped with a motor must be used to apply pressure in the line test. For pipes with a diameter of up
to DN 50, we can use hand pumps. To apply the test pressure to reach the maximum rate, ensure the
proportional increase in the pressure (Figure 1).

Document No.:
2.7.5. Equipment required for testing and related methodology

Pumps equipped with a motor are used to generate pressure. Other required tools include the following:
- Water tank
- One-way valve to avoid water return
- Water meter
- Pressure gauge
- Thermometer
- De-aeration equipment
2.8. MEASUREMENT INSTRUMENTS

2.8.1. Internal pressure measurement
The location of the pressure gauge is in the lowest area of the pipeline. The 0.1 bar gage is recommended to
be scaled.
2.8.2. Thermometer
To consider the effect of temperature, the water and ambient temperature should be measured during the
test. The temperature of the area that is in direct contact with sunlight should also be measured.
2.8.3. Calculating the volume of test water

The volume of water inside the pipeline should be measured, as it is necessary to calculate the total volume of
water when adding water to establish the test pressure.
2.8.4. Calculating the volume of water discharged

After the final test was started, the volume of water should be drained and its value recorded,
by decreasing the test pressure.
2.8.5. Test and its results

During the initial and final tests, the pressure drop should be according to Table 1. The pressure drop should
be included in the test report. The maximum pressure should be gained up to 2 hours after the start of the test.
If the drop is more than what is mentioned in Table 1, joints such as welding and flange should be controlled.
Changes in ambient temperature must also be considered in the case of pressure drop.
2.8.6. Pressure reduction

If during the initial pressure test, the drop in pressure is according to table 1, then the pressure should be
diminished after the end of the initial test and the final test should be started. Such a reduction in the pressure
should be done within a maximum of 2 minutes. The internal pressure reaction should also be monitored. The
final test can be maintained if the internal pressure remains constant for 30 minutes and even slightly increases.

Document No.:
2.8.7. Repeat the initial test

If the pressure drop does not stop after the end of the initial test and is related to the change in ambient
temperature, then we can conclude that the pipeline has a drop leakage. Therefore, it should be stopped and
the pipeline inspected. Then, the internal pressure should be reached to the test pressure by a certain volume
of water. After an hour, increase the pressure drop by adding water to the test pressure. If the pressure is not
fixed after this time, the water should be discharged, the pressure reduced to zero, and the initial test repeated.
2.8.8. Repeating the final test

If during the final test the pressure drop is higher than the values given in Table 1, this indicates a leakage in
the pipeline. The leakage point should be detected during the visit and repaired and the final test repeated.

Document No.:
2.8.9. Test Report

This form is Report of Hydrostatic Pressure test at site according to German water and gas association standard
(DVGW) W400-2

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Interconnecting Utilities and Offsite of MOKRAN

Petrochemical Complex - Stage 1

Hydrostatic procedure for HDPE Material

Purch. Vendor. PO No. Dis. Tag No. Doc. Seq. Rev.

Hydrostatic procedure For HDPE Material

Approved: Vendor shall issue “AFC/ AFD/AFP/AFT/AFI” status.

Date: Dept.: Signature:

Only for internal review

A 07-Jan-2023 ISSUE FOR COMMENT A.Amini A.Amini A.Amini

Hydrostatic procedure for HDPE Material

Purch. Vendor. PO No. Dis. Tag No. Doc. Seq. Rev.

Hydrostatic procedure for HDPE Material

Purch. Vendor. PO No. Dis. Tag No. Doc. Seq. Rev.

1. Hydrostatic pressure test in the Lab. ................................................................................................................5

Hydrostatic procedure for HDPE Material

Purch. Vendor. PO No. Dis. Tag No. Doc. Seq. Rev.

2.8.4. Calculating the volume of water discharged ................................................................................................... 14

Hydrostatic procedure for HDPE Material

Purch. Vendor. PO No. Dis. Tag No. Doc. Seq. Rev.

1. Hydrostatic pressure test in the Lab.

1.4. REFERENCE STANDARDS

1.5. TEST SPECIMEN PREPARATION

Hydrostatic procedure for HDPE Material

Purch. Vendor. PO No. Dis. Tag No. Doc. Seq. Rev.

Time intervals for stabilizing isothermal conditions (Table 1)

Time intervals for stabilizing environmental Pipe Thickness (e min)

Temperature Test time δ

Hydrostatic procedure for HDPE Material

Purch. Vendor. PO No. Dis. Tag No. Doc. Seq. Rev.

1.7. SERVICE & MAINTENANCE

Hydrostatic procedure for HDPE Material

Purch. Vendor. PO No. Dis. Tag No. Doc. Seq. Rev.

Hydrostatic procedure for HDPE Material

Purch. Vendor. PO No. Dis. Tag No. Doc. Seq. Rev.

2. Hydrostatic pressure test at site

2.2. SAFETY CONSIDERATIONS

2.4. TEMPERATURE EFFECT

2.5. FILLING THE PIPELINE

Hydrostatic procedure for HDPE Material

Purch. Vendor. PO No. Dis. Tag No. Doc. Seq. Rev.

2.6. PIPELINE TESTING UNDER 20 °C (PIPE'S EXTERIOR SURFACE TEMPERATURE)

2.6.2. Test equipment

Hydrostatic procedure for HDPE Material

Purch. Vendor. PO No. Dis. Tag No. Doc. Seq. Rev.

2.6.3. Initial test

2.6.4. The calculated pressure for the pipeline (MDP)

2.6.5. Final test

Hydrostatic procedure for HDPE Material

Purch. Vendor. PO No. Dis. Tag No. Doc. Seq. Rev.

2.6.6. End of testing

Hydrostatic procedure for HDPE Material

Purch. Vendor. PO No. Dis. Tag No. Doc. Seq. Rev.

2.7.2. Final test

2.7.3. Short-term test

2.7.4. Applying the test pressure

Hydrostatic procedure for HDPE Material

Purch. Vendor. PO No. Dis. Tag No. Doc. Seq. Rev.

2.7.5. Equipment required for testing and related methodology

2.8. MEASUREMENT INSTRUMENTS

2.8.3. Calculating the volume of test water

2.8.4. Calculating the volume of water discharged

2.8.5. Test and its results