INSPECTION AND TESTING REQUIREMENTS

IT-6 WASTEWATER

TABLE OF CONTENTS

IT-6.1 Inspection 1

IT-6.2 Testing 2
IT-6.1 Inspection

Please refer to IT-1 General Provisions for the procedure for initiating inspection by Council
Representatives.

IT-6.1.1 Formal Inspections

The following inspections shall be advised to and undertaken with Council’s Representatives:

a) Manhole structures shall be inspected to satisfy the requirements noted under inspection sheet IS-
6.1 – Wastewater Manhole and Pipeline <50m.

b) Pipelines as shown in Table 1: Pipe Inspection Table.

Table 1: Pipe Inspection Table:

Reticulation Visual CCTV Comment
Layout Inspection Inspection
All Lines are 50m or less Only applies where all lines are less
(MH to MH) ü than 50m in length (manhole to
manhole).
Lines greater than 50m
(MH to MH) ü

Explanatory Note:
If any part of the new reticulation requires CCTV, then all pipes on the development shall require CCTV.

c) Wastewater pump station commissioning which includes testing the operation of the pumps,
electrical and telemetry systems.

d) Should inspection of other wastewater features be required, Council shall advise in writing what
inspection/s are required.

e) Final inspection as specified in IT-1 General Provisions.

IT-6.1.2 Random Inspections

Council shall undertake random inspections of all site features throughout the construction period to
ensure good industry practice and compliance with all requirements for the infrastructure development
are being followed.

IT-6.1.3 CCTV Inspections

CCTV inspections and deliverables shall be in accordance with IT-1 Appendix C - Closed Circuit Television
(CCTV) Inspections.

All Wastewater network components shall be completed before commencement of CCTV.

Slope corrections shall be carried out where the pipe alignment is out of tolerance.

1
IT-6.2 Testing

Please refer to IT-1 General Provisions for the procedure for initiating testing attendance by Council
Representatives.

IT-6.2.1 Pre-Testing

All wastewater mains, branch pipelines and extended connections shall be pre-tested during
construction. The Contractor and Engineer must be satisfied that the final test will pass (by undertaking
pre-testing), before initiating the final test with Council.

IT-6.2.2 Gravity Reticulation

The following applies to testing of gravity reticulation:

a) All testing shall be carried out when backfilling is complete and prior to final surface sealing and/or
pavement works being completed if within the carriageway.

b) All manholes and pipes shall be flushed before testing.

c) No infiltration of water either via a manhole or pipe is permitted.

IT-6.2.2.1 Low Pressure Air Test

Drawing Ref: TS 6.1

a) Unless pipes are installed under natural groundwater, this test shall be undertaken on all pipes
unless another test method is agreed to by Council.

b) The pipeline to be tested shall be effectively plugged by fixing suitably strutted plugs at both ends
and into side connections with particular care being taken to fix plugs against movement. Air shall
be introduced by suitable means (such as hand pumps) until either:
i) A pressure of 300mm of water is indicated by a suitable manometer (such as a U-tube)
connected to the system.
ii) As noted on test sheet TS-6.1 Low Pressure Air Test.

c) After the air has attained a uniform temperature, as indicated by the pressure becoming steady, the
source of air supply shall be physically disconnected and the pressure drop measured after a test
period of 15 minutes.

d) The acceptance limit shall be no pressure loss after 15 minutes.

e) All results and comments shall be recorded on test sheet TS-6.1 Low Pressure Air Test.

f) If the test is passed, the test sheet shall be signed by:

i) The Contractor who completed the test.
ii) The Certifying Engineer or their Representative to certify that the test has passed all
requirements.
iii) Council's Representative as a witness to ensure that the test was undertaken correctly.

2
g) If the test does not pass the Engineer and Contractor shall investigate the reason/s for the test
failure, fix the problem/s and rearrange a new test.

IT-6.2.3 High Pressure Air Test

Drawing Ref: TS 6.2

a) Where pipes are installed under natural groundwater, this test shall be undertaken on all pipes
unless another test method is agreed to by Council.

b) The pipeline being tested shall be plugged as for the Low Pressure Air Test, care being taken to
secure the plugs against movement and pressurised by a compressor or other appropriate means to
a pressure of 25kPa.

c) A period of at least 2 minutes shall be allowed to ensure temperature stabilisation. The source of air
supply shall be physically disconnected and the time for the test pressure to drop from 25kPa to
17kPa noted.

d) The acceptance limit shall be as follows:

Pipe diameter Time for permissible pressure drop

(mm) (minutes)

100 3.0
150 4.0
200 6.0
230 6.5
250 7.5
300 9.0

e) If the test is passed the Test Sheet shall be signed by:

i) The Contractor who completed the test.
ii) The Certifying Engineer or their Representative to certify that the test has passed all
requirements.
iii) Council's Representative as a witness to ensure that the test was undertaken correctly.

f) If the test does not pass the Engineer and Contractor shall investigate the reason/s for the test
failure, fix the problem/s and rearrange a new test.

IT-6.2.4 Rising Main Pressure Test

Drawing Ref: TS 6.3

a) Pressure testing shall be undertaken in accordance with the procedure on test sheet TS 6.3 -
Wastewater Rising Main Pressure Test.

b) All results and comments shall be recorded on test sheet. TS 6.3 - Wastewater Rising Main Pressure
Test.

c) If the test is passed the Test Sheet shall be signed by:

3
 i) The Contractor who completed the test.
ii) The Certifying Engineer or their Representative to certify that the test has passed all
requirements.
iii) Council's Representative as a witness to ensure that the test was undertaken correctly.

d) If the test does not pass the Engineer and Contractor shall investigate the reason/s for the test
failure, fix the problem/s and rearrange a new test.

IT-6.2.5 Manhole Testing

Where required by Council, manholes shall be water tested. The test shall satisfy the requirements
noted under testing sheet TS-6.4 Manhole Infiltration Test.

IT-6.2.6 Wastewater Pump Station Commissioning

Commissioning of pump stations shall comply with:

a) IT-6.2.6.1 Pumps.

b) IT-6.2.6.2 Electronic Equipment.

c) IT-6.2.6.3 Control Systems.

IT-6.2.6.1 Pumps

This involves but is not limited to the following:

a) Ensuring all chambers and pumps are clear of all debris and tools.

b) Operation of each pump separately and in their possible combinations to confirm system and
component performance.

c) Check for excess vibration and noise.

d) Check pump polarity/rotation.

e) Receipt of factory test certificate for the pumps.

f) Pumps shall be set to work in the normal automatic operation mode after the tests have been
completed.

IT-6.2.6.2 Electronic Equipment

This involves but is not limited to the following:

a) All tests and checks required for provision of an electrical compliance by a registered electrician.

b) Receipt of factory test and calibration certificates.

c) Tests as per manufacturers installation requirements.

4
d) Calibration check against a standard.

e) Confirmation of protection against out of specification power impulses.

f) Ensuring that all overload systems are functioning.

g) Checking signals to and from the control system.

h) Checking signals to and from remote sensors.

i) Checking signals from all level control equipment to ensure safe operation and to ensure machines
will not run dry.

j) Setting to work in the normal automatic operational mode after the tests have been completed.

IT-6.2.6.3 Control Systems

This involves, but is not limited to, the following:

a) Ensure all mechanical, electrical and electronic systems are set to work and are “on-line” to operate.

b) Simulate all level induced control functions.

c) Operate all control modes.

d) Check all remote control and monitoring functions.

e) Where any of the above fail to satisfy the requirements of the specification or the Engineer, correct
the defect/s and retest.

f) Oversee operation and carry out adjustments as necessary throughout the defects liability period.

IT-6.2.7 Testing of Butt Welds in Polyethylene Pipes

Please refer to IT-5.2.1 Testing of Butt Welds in Polyethylene Pipes.

IT-6.2.8 Testing of Electrofusion Welds in Polyethylene Pipes

Please refer to IT-5.2.2 Testing of Electrofusion Welds in Polyethylene Pipes.

5
 WASTEWATER TS 6.1

Date:………………….. RC Number:………………….

Development Name and Stage:………………………

(P)ass/(F)ail
Line ID Comments
after 15mins

………………………………....(contractor) ……….………………………(certifying engineer)

…………………………..………..(council representative – witness)

WASTEWATER LOW PRESSURE AIR TEST TS 6.1

VERSION 1
JUL 2011 1
Waste water low pressure air test procedure

Testing Apparatus:
• Enough blank plugs for all non capped laterals and the open end of pipe to be
tested.
• A test plug with sufficient length of clear hose to reach 1 meter above the
manhole lid.
• A clear vessel containing 300mm depth of clean water.
• Spray bottle of soapy water.

Procedure:
1. Install blank plugs into all open ends of pipes to be tested.
2. Install test plug into the end of the main pipe and bring the hose to the top of
the manhole.
3. Blow into the test pipe until there is sufficient pressure then put the end of the
pipe into the bottom of the vessel.
4. Once the pressure has stabilised a bubble will sit at the base of the pipe.
5. If this bubble moves up the pipe there is a leak in the system, spray soapy
water around the plugs to make sure there are no leaks.
6. If after fifteen minutes the bubble has not risen in the pipe then the test has
passed.
 WASTEWATER TS 6.2

Date:………………….. RC Number:………………….

Development Name and Stage:………………………

Mins for (P)ass/(F)ail

Line ID Comments
pressure drop.

………………………………....(contractor) ……….………………………(certifying engineer)

…………………………..………..(council representative – witness)

WASTEWATER HIGH PRESSURE AIR TEST TS 6.2

VERSION 1
JUKL 2011 1
Waste water high pressure air test procedure

Testing Apparatus:
• Enough high pressure blank plugs for all non capped laterals and the open end
of pipe to be tested.
• A high pressure test plug with sufficient length of hose, with an attached
pressure gauge and shut off valve, to reach to a compressor above the manhole
lid.
• A compressor capable of attaining 25 KPa.
• Spray bottle of soapy water.

Procedure:
1. Install and inflate blank plugs into all open ends of pipes to be tested.
2. Install and inflate test plug into the end of the main pipe and bring the hose to
the top of the manhole.
3. Connect the test plug hose to the compressor and raise pressure to 25KPa
then close the valve.
4. After period of at least two minutes to allow the pressure to stabilise, top up the
pressure to 25KPa if necessary then disconnect the compressor.
5. Time how long it takes for the pressure to drop to 17KPa.
The acceptance limit shall be as follows:
Pipe diameter mm Time in minutes for permissible
pressure drop
100 3
150 4
200 6
230 6.5
250 7.5
300 9
6. If the time of pressure drop is above the acceptable limits, spray soapy water
around the plugs to make sure there are no leaks then test again if necessary.
 WASTEWATER TS 6.3

Date:………………….. RC Number:………………….

Development Name and Stage:………………………

Mins for (P)ass/(F)ail

Line ID Comments
pressure drop.

………………………………....(contractor) ……….………………………(certifying engineer)

…………………………..………..(council representative – witness)

WASTEWATER RISING MAIN PRESSURE TEST TS 6.3

VERSION 1
JUL 2011 1
Waste water rising main pressure test

Testing Apparatus:
• A pipe, that can be connected to the main, with a pressure gauge capable of
reading 1400KPa and a water meter. This should contain a valve to isolate the
system and the pressure gauge from the water blaster (see example below).
• A waterblaster capable of attaining 900 KPa.

Procedure:
1. The testing apparatus shall be connected to the lowest point of the reticulation
system to be tested.
2. Open all valves and turn the waterblaster on until the pressure on the gauge
reaches 900KPa then shut the isolation valve and disconnect the waterblaster
3. Take a reading on the meter and write this down on the sheet with the time.
4. After period of 15 minutes turn the waterblaster back on and open the isolation
valve until the pressure reaches 900KPa again then shut the isolation valve.
5. Take another reading on the meter and write this down on the sheet with the
time.
6. If the volume of water added after 15minutes is less than the calculated
allowable loss, shown on the test sheet, then the test has passed. If the volume
is more then there is a leak in the system.
The acceptance loss shall be calculated as follows:
One litre/ten mm pipe diameter/km length of pipeline/Hr
 WASTEWATER TS 6.4

Date:………………….. RC Number:………………….

Development Name and Stage:………………………

Volume of (P)ass/(F)ail
Manhole ID Comments
makeup water

Comments:

………………………………....(contractor) ……….………………………(certifying engineer)

…………………………..………..(council representative – witness)

MANHOLE INFILTRATION TEST TS 6.4

VERSION 1
JUL 2011 1
Manhole Infiltration test procedure

Testing Apparatus:
• Enough high pressure blank plugs for all pipes into and out of the manhole to
be tested.
• A means of inflating the test plugs, such as a compressor.
• Measuring vessel.

Procedure:
1. Install blank plugs into all pipes coming into the man hole.
2. Fill the manhole with water and mark the water level in the throat.
3. After 30mins measure how much water it takes to fill the manhole back up to
the mark.
4. The allowable loss shall not exceed 1 litre per meter depth in a 1050mm
manhole.