GERMAN ATV RULES AND STANDARDS W A S T E W A T E R - W A S T E ADVISORY LEAFLET ATV-M 143E Inspection, Repair, Rehabilitation and Replacement of Sewers and Drains Part 6: Leak Testing of Existing, Earth Covered Sewers and Drains and Shafts Using Water, Air Overpressure and Vacuum June 1998 ISBN 3-934984-43-6 Marketing: Gesellschaft zur Förderung der Abwassertechnik e.V. (GFA) Theodor-Heuß-Allee 17 D-53773 Hennef Postfach 11 65, 53758 Hennef
Transcript
GERMAN ATV RULES AND STANDARDS
W A S T E W A T E R - W A S T E
ADVISORY LEAFLET ATV-M 143E
Inspection, Repair, Rehabilitation and Replacement of Sewers and Drains Part 6: Leak Testing of Existing, Earth Covered Sewers and Drains and
Shafts Using Water, Air Overpressure and Vacuum June 1998
ISBN 3-934984-43-6
Marketing: Gesellschaft zur Förderung der Abwassertechnik e.V. (GFA) Theodor-Heuß-Allee 17 D-53773 Hennef Postfach 11 65, 53758 Hennef
ATV-M 143E, Part 6
June 1998 2
The ATV Working Group 1.5.4 "Rehabilitation and Renewal of Drains and Sewers", which has prepared this Advisory Leaflet, has the following members:
Univ.-Prof. Dr.-Ing. D. Stein, Bochum (Chairman) Dipl.-Ing. H. Adler, Köln Dr.-Ing. H. Beyert, Aachen Dipl.-Ing. D. Blome, Bielefeld Dipl.-Ing. H. Brochier, München Dipl.-Ing. B. Chwastek, Witten Dr.-Ing. P. Drewniok, Leipzig Dipl.-Ing. W. Dürbeck, Ludwigshafen Dipl.-Ing. Fischer, Bonn Dipl.-Ing. K.-H. Flick, Köln Dipl.-Ing. V. Holzhausen, Frankfurt/Main Dipl.-Ing. F. Hoppe, Hamburg Dipl.-Ing. H.-J. John, Hamburg Dipl.-Ing. G. Koch, Stuttgart Dipl.-Ing. U. Kusche, Vreden Dipl.-Kfm. H. Müller, Schieder-Schwalenberg Dipl.-Ing. G. Niedrée, Bonn Dipl.-Ing. W. Reinhard, Darmstadt Dipl.-Ing. U. Schulz, Brüggen Dipl.-Ing. R. Siebert, Oststeinbek Prof. Dr.-Ing. V. Wagner, Neubrandenburg
Collaborated as guests: Dr.-Ing. O. Kaufmann, Bochum Dipl.-Ing. (FH) H. Loy, München
All rights, in particular those of translation into other languages, are reserved. No part of this Advisory Leaflet may be reproduced in any form by photocopy, microfilm or any other process or transferred or translated into a language usable in machines, in particular data processing machines, without the written approval of the publisher.
Gesellschaft zur Förderung der Abwassertechnik e.V. (GFA), Hennef 1998
Produced by: J. F. CARTHAUS, Bonn
Contents
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Notes for users 4 1. Preamble 4 2. Area of application 4 3. Preparatory measures 5 3.1 Planning documents 5 3.2 Accessibility 5 3.3 Cleaning 5 3.4 Verification of the tightness of the test facility 5 3.5 Safety of the receiving water 5 3.6 Protective measures 5 3.7 Traffic regulation 5 3.8 TV surveillance 5 4. Requirements on the equipment to be employed 6 4.1 Equipment 6 4.2 Air overpressure and vacuum testing 6 4.2.1 Shut-off elements 6 4.2.2 Compressor or vacuum pump 7 4.2.3 Charging device 7 4.2.4 Pressure measurement device 7 4.3 Water pressure test 7 4.3.1 Shut-off elements 7 4.3.2 Gravity tank 7 5. Execution of leak testing 7 5.1 Installation of shut-off elements 8 5.2 Leak testing using air 8 5.2.1 Testing using overpressure 8 5.2.2 Testing using vacuum 9 5.3 Leak testing using water 9 5.4 Removal of the shut-off elements 9 6. Requirements on the personnel employed 9 7. Documentation 9 7.1 General 9 7.2 Test record 10 8. Tightness criteria 10 8.1 Tightness criteria for the leak test by reach or section 10 8.1.1 Water pressure testing 10 8.1.2 Air overpressure testing 11 8.1.3 Vacuum pressure testing 11 8.1.4 Requisite test times for air overpressure and vacuum testing 11 8.2 Tightness criteria with the testing of pipe connections (sleeve testing) using air overpressure 11 8.3 Shaft/chamber testing 12 Appendix 1: Model record of leak testing by reach 13 Appendix 2: Sample record of sleeve testing 14 Appendix 3: Illustrative determination of the requisite test times with sleeve testing 15 Literature 16
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Notes for Users This ATV Standard is the result of honorary, technical-scientific/economic collaboration which has been achieved in accordance with the principles applicable for this (statutes, rules of procedure of the ATV and ATV Standard ATV-A 400). For this, according to precedents, there exists an actual presumption that it is textually and technically correct and also generally recognised. The application of this Standard is open to everyone. However, an obligation for application can arise from legal or administrative regulations, a contract or other legal reason. This Standard is an important, however, not the sole source of information for correct solutions. With its application no one avoids responsibility for his own action or for the correct application in specific cases; this applies in particular for the correct handling of the margins described in the Standard.
1. Preamble The assessment of the condition of drains and sewers, and of possible hazard potential due to damage, also demands the verification of tightness. Optical inspection (for this see ATV Advisory Leaflet M-143, Part 2 [1] can provide such information to a limited degree only. Thus visible damage does not always imply unsatisfactory tightness. On the other hand, leakage points, in particular in the area of pipe connections, are barely identifiable visibly.
For the leak testing of newly produced or rehabilitated drains and sewers there are standardised regulations available (e.g. DIN 1986, Part 1 (06/88) [2], DIN EN 752, Part 5 [3] or DIN EN 1610 [4]).
Nevertheless, leak tests on existing drains and sewers, beyond optical inspection, are required both in water laws and wastewater self monitoring regulations of individual German Federal States as well as in the ATV Standard A-142 [5].
This Advisory Leaflet lays down requirements for leak tests as repeat testing on existing earth covered drains and sewers and shafts using water and air as test medium.
2. Area of Application This Advisory Leaflet, together with the Advisory Leaflets ATV M-143, Part 1 [6] and Part 2 [1], applies for the leak testing of existing drains and sewers, including shafts, operated as gravity pipelines.
Leak tests must be carried out on drains and sewers in water catchment areas and on such on which appropriate requirements in laws or surveillance regulations of the German Federal Republic, German Federal States and communities are placed.
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3. Preparatory Measures 3.1 Planning Documents
Sufficient planning documents are to be made available for the execution of leak testing. From these the following must be particularly visible:
• site of application, • position, type, scope and regulatory characteristics (e.g. reach and/or shaft numbers)
of the object to be tested, • possibilities for entry and escape.
Attention is to be drawn to particular hazards, e.g. danger of collapse, sewer atmosphere, wastewater composition, pump surges.
3.2 Accessibility
The accessibility of the entrances is to be checked and secured for the duration of the testing.
3.3 Cleaning
The test object must be cleaned in order to facilitate the secure positioning of the shut-off elements and the problem-free execution of the leak testing. With this the cleaning of the contact surfaces between the shut-off element and the sewer wall is particularly significant.
3.4 Verification of the Tightness of the Test Facility
Before carrying out the leak test the tightness of the test facility must be verified and recorded.
3.5 Security of the Receiving Waters
The test object must be free of wastewater for the duration of the leak test. This can, for example, be achieved by diversion, temporary backing-up or by pump over. Wit pint tests (sleeve tests) the employment of equipment with a passage of a limited wastewater flow can be permitted.
3.6 Protective Measures
Appropriate measures are to be taken for the determination and avoidance of a potentially explosive atmosphere in the test object.
3.7 Traffic Regulation
Suitable measures are to be taken, in agreement with the road traffic authorities, for the regulation, safeguarding and stoppage of traffic.
3.8 TV Surveillance
With sleeve testing and leak tests by section (e.g. between two connections) in non-man-accessible drains and sewers the exact positioning of the shut-off elements must take place under TV surveillance.
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4. Requirements on the Equipment to be Employed 4.1 Equipment
The following equipment is required for the execution of leak tests using air overpressure or vacuum:
All items of equipment must conform with regulations in accordance with VDE and DIN as well as with the (German) Accident Prevention Regulations (UVV).
4.2 Air Overpressure and Vacuum Testing 4.2.1 Shut-off Elements
Shut-off elements must be robust and employed in accordance with the area of application. They are to be marked by the manufacturer with a permanent type plate on which the following details must be clearly legible:
• manufacturer, type, year of manufacture, • closable pipe diameter or pipe diameter range, • maximum operating pressure (charging pressure), • maximum permitted test pressure dependent on the test medium employed, • permitted test medium.
The equipment is to be stored carefully, protected from damage and maintained regularly. A record is to be kept of the maintenance tasks carried out. The monitoring of the equipment for its employment in accordance with its intended use must be possible by the construction management. The shut-off elements are to be provided with a clear operating instruction which must be visible on the site. Shut-off elements with test marks (e.g. ET for Eurotest) are to be checked by an independent test centre for work safety.
The sealing function in the contact area between the pipe walls and the shut-off elements must remain safely maintained for every test pressure and with every test medium used (water, air overpressure or vacuum).
Special sleeve testing equipment is to be used for sleeve tests. With the employment of combined test and injection packers, which, for example, are applied to correct locally limited leakages, the requirements of sleeve test equipment must suffice for the leak testing. The suitability of the combined test and injection packer as well as the tightness criteria (see Sect. 8.2) are to be verified.
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4.2.2 Compressor or Vacuum pump The necessary test pressure can be produced by a commercial, sufficiently dimensioned compressor or an appropriate vacuum pump.
4.2.3 Charging Device The charging device must consist of a safety valve, manometer to monitor the pressure, pressure regulator and charging hose. On achieving the test pressure the connection of the test space to the pressure tank or to the pump is to be disconnected. Pressure reduction valves and pressure controls are to be integrated into the charger together with a safety switch (e.g. a dead man's switch), in order to prevent exceeding the test pressure.
4.2.4 Pressure Measurement Device A high-resolution, electronic precision manometer (e.g. absolute pressure manometer) with a maximum measurement deviation of ± 2 mbar is to be used. Each piece of equipment is to be checked metrologically each year. The result of this test is to be documented on the equipment.
4.3 Water Pressure Test 4.3.1 Shut-off Elements
With regard to the shut-off elements the details of Sect. 4.2.1. apply analogously.
With the water pressure test the test object is to be filled from the lowest point of the pipeline. A ventilation opening, which has at least the same cross-section as the charging pipeline, is to be located on the shut-off element at the high point of the pipeline.
4.3.2 Gravity Tank With a water pressure test the test object may have no connection to a pipeline or pump subjected to overpressure. The filling with water and the achievement of the required test pressure are to take place via a gravity tank.
5 Execution of the Leak Test The leak test can be carried out by reach, i.e. from shaft to shaft, by section (e.g. between two laterals) or at a point on individual pipe connections. A test counts as successful if the test criteria in Sect. 8 are met.
He leak test can be carried alternatively using water or air. As the test using air is significantly quicker to carry out, this is preferably to be used. If doubt exists about the result of the air test then a water pressure test is to be carried out whose result is then relevant.
With regard to the security measures which are fundamentally to be carried out, attention is drawn to the relevant security directives of the Trade Association and of the Federation of German Communal Accident Insurers (BAGUV), inter alia to:
(GUV 7.4) [9] • German Safety Regulations for Pipe Construction (ZH 1/559) [10] • German Safety Regulations for Work in Enclosed Spaces of Technical Wastewater
Systems (ZH 1/177) [11]
Special instructions for the execution of leak testing using air as the test medium are in preparation. Once in force these also are to be observed.
5.1 Installation of Shut-off Elements
Operating instructions are to be observed with the installation of shut-off elements.
The insertion of the shut-off elements into the pipe may, in the first place, take place only in so far as they fit securely fullface. The firm seating is prerequisite for the subsequent positive security against accidental change of position within the pipeline to be tested.
After ensuring security the site of the installation is to be evacuated and the charging of the shut-off elements with the predetermined filling pressure from outside the shaft or pipeline is to be carried out. Charging may be with compressed air only.
5.2. Leak Testing Using Air
Leak testing using air is to be classified as hazardous work based on § 36 (1) of the UVV "General Regulations" (VBG 1). With this the following minimum requirements apply:
• the leak testing may not be carried out by only one person • suitable persons are to be tasked who are familiar with the hazards associated with
the test and • a supervisor is to be appointed.
5.2.1 Testing Using Overpressure The pressurisation of the reach to be tested, of the section or of the pipe connection with non-man-accessible drains and sewers as well as the monitoring and release of the test pressure must take place from the ground surface without hazard. An exceeding of the test pressure is to be excluded in that this
• is monitored via a manometer and • is limited to the predetermined value by a mechanically operated safety valve or
electronic pressure switch.
From the start of the pressurisation in the test space with leak testing by reach or section, work is not permitted in the pipeline or shaft for the duration of the test. During this time no one may remain in front of the shut-off elements and their hazardous zone.
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5.2.2 Test Using Vacuum
The determinations from Sect 5.2.1 apply analogously to the same extent with testing using vacuum.
5.3 Leak Testing Using Water
The pipeline to be tested is to be so filled with water that the enclosed air can escape at the shut-off element installed at the high point and thus a hazarding or erroneous measurement due to compressed trapped air is avoided. From the start of the pressurisation in the test space with leak testing by reach or section, work is not permitted in the pipeline or shaft for the duration of the test.
5.4 Removal of the Shut-off Elements
Removal of the shut-off elements may only begin after the overpressure or vacuum in the test space has been completely removed or the test water has been completely drained off.
Both the pressure balancing in the test space or the draining off of the test water and the release of pressure from the shut-off elements are to take place from a secure location outside the shaft or reach.
6 Requirements on the Personnel Employed Leak tests are to be carried out only by specialists who have proved their ability and the suitability of the equipment used. The responsible personnel employed for the leak test are to possess constructional, operational and material expertise for drains and sewers and at least one year's practical experience. A certificate of competence is to be furnished.
7 Documentation 7.1 General
The result of the leak test is to be documented on site, precisely and comprehensively in a test record. Documentation includes:
• details on the test object, • test specifications and • measurement values and measurement diagrams with a clear test note.
The employment of electronic data processing in addition to the test record to be produced on site offers itself in order to ensure an optimum and economic further processing of the data.
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7.2 Test Record
The test record is to be produced separately for each test. In detail it must contain:
• customer, contractor, if required project leader, equipment operator, test location, date and time, road name, reach number and/or the designations of the shafts delimiting the reach;
• status data on the object to be tested, such as, for example, the type of object (leak testing by reach or section, or sleeve test). Nominal width, cross-sectional dimensions, test length, material, type of sewer, year of construction, zero point of longitudinal measurement, groundwater level;
• details on test specifications, test pressure, test time, settling time, permitted pressure difference or permitted water charging;
• details on the measurement result: measured pressure difference or water charging;
• measurement diagrams with an air overpressure or vacuum test: graphical representation of the pressure run over the test time with details of the required test pressure, the permitted pressure difference, the start and end of the necessary settling time as well as the start and end of the test time;
• test note on the result of the leak test with the signature of the parties involved.
The test records are to be given a serial number and are to be archived systematically.
Examples of the layout of the test record are contained in Appendices 1 and 2.
8 Tightness Criteria With groundwater present the test pressure per meter groundwater above the pipe sole is to be increased by 100 mbar to a maximum of 200 mbar. If, during the test, the groundwater level lies above the pipe crown an infiltration test which, however, is not part of this Advisory Leaflet, can be carried out.
8.1 Tightness Criteria of the Leak Test by Reach or Section 8.1.1 Water Pressure Test Test pressure: 50 mbar (50 cm) above the pipe crown at the highest point of the
test object Water charging generally 0.2 l/m2 wetted pipe surface Test time: 15 minutes.
With regular operational water levels of more than 50 cm above the pipe crown the water level is relevant. The maximum permitted test pressure at the lowest point of the object to be tested is 0.5 bar.
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8.1.2 Air Overpressure Test
Test pressure. P = 100 mbar Permitted pressure difference ∆p = 15 mbar Necessary test time. t according to Table 1 Settling time: tS = 10 di in [min], with
di = diameter in [m]
8.1.3 Vacuum Test
Test pressure. P = 100 mbar Permitted pressure difference ∆p = 12 mbar Necessary test time. t according to Table 1 Settling time: tS = 10 di in [min], with
di = diameter in [m]
8.1.4 Required Test Times for Air overpressure and Vacuum Testing
The necessary test times of the air overpressure (see Sect. 8.1.2) and the vacuum tests for nominal widths ≤ DN 1200, presented in Table 1, result from the following relationship:
10 di [m] = test time in [min].
Intermediate values can be interpolated. The necessary test times [min] for larger nominal widths (> DN 1200) or other cross-sectional shapes, which are not presented in Table 1, can be calculated according to Equation 1:
t d di i= ⋅ ⋅ +5 61 2 3 2. [min] (1)
whereby the diameter di in [m] is to be applied. For special profiles, e.g. oval sections, an alternative diameter dE according to Equation 2 can be calculated:
d Cross tional areaCircumference
mE = ⋅−4 sec [ ] (2)
Table 1: Necessary test times (min) with the tightness testing by sewer section and/or sections of sewer using air overpressure or vacuum.
8.2 Tightness Criteria with the Testing of Pipe Connections (Sleeve Test) Using Air Overpressure
Sleeve tests in non-man-accessible drains and sewers must be carried out under camera observation.
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As almost all sleeve testing equipments have different test volumes, which are limited by the pipe walls, and possibly by the core piece and the shut-off elements of the sleeve test equipment, it is not possible to define generally valid tightness criteria for the testing of individual pipe connections.
To determine the necessary test times, the test volume of the sleeve test equipment used, including the feed hoses, in the case that these have a connection with the test space during the test, as well as the volume of the pipe connection1) must be determined. Furthermore, the area of the pipe wall between the shut-off elements must be known.
Sleeve test equipments whose air feed hoses have no connection with the test space during the teats are to be preferred.
Test pressure. P = 100 mbar Permitted pressure difference ∆p = 15 mbar Necessary test time. t according to Eqn. 3 Settling time: tS = 15 s.
t dVA
siTest volume
Pipe wall= ⋅ + ⋅1800 0 5. [ ] (3)
A sample calculation of the test times can be found in Appx. 3.
8.3 Shaft/Chamber Testing
The leak testing of shafts/chambers is preferably to be carried out as a water pressure test. The test object is filled with water to 0.5 m above the pipe crown of the connecting drains and sewers. Within the test time of 15 minutes the required water input to maintain the test pressure may not exceed 0.4 l/m2 of the wetted shaft/chamber wall (incl. the bottom of the shaft/chamber).
_________________ 1) In general, with non-man-accessible drains and sewers, the determination of the volume of the pipe connection can be dispensed with.
Appendix 1: Model record of leak testing by reach
Test Record Serial No._____________ Leak testing by reach or section using air
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Customer.____________________________
Project management:___________________
Customer:____________________________
Equipment operator:____________________
Date: ________________________________
Location: _____________________________
Street: _______________________________
Reach No.: ___________________________
Shaft designation: Shaft 1:_______________
Shaft 2:_______________
Details on test object Test details Measurement results
Diameter:______________[m]
Cross-section: Height: ____[m]
Width: ____[m]
Groundwater level: ______[m]
Test length: ____________[m]
Material:_________________
Type of sewer:____________
Test specifications:_________
Test pressure:________[mbar]
Test time: ___________[min]
Settling time:_________[min]
Perm. pres. diff.:______[mbar]
Measured pressure difference:
___________________[mbar]
Year of construction:_______
Origin of linear measurement: __________________________
Length/position of test space: __________________________
Test note:______________________________ Equipment operator:
________________________
Project management:
________________________
Customer:
________________________
Appendix 2: Model record for sleeve testing
Test Record Serial No._____________ Sleeve test using air overpressure
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Customer.____________________________
Project management:___________________
Customer:____________________________
Equipment operator:____________________
Date: ________________________________
Location: _____________________________
Street: _______________________________
Reach No.: ___________________________
Shaft designation: Shaft 1:_______________
Shaft 2:_______________
Details on test object Test details Length details
Diameter:______________[m]
Cross-section: Height: ____[m]
Width: ____[m]
Groundwater level: ______[m]
Material:_________________
Type of sewer:____________
Year of construction:_______
Test specifications:_________
Test pressure:________[mbar]
Test time: ___________[min]
Settling time:_________[min]
Perm. pres. diff.:______[mbar]
Origin of linear measurement:
________________________
Sleeve No.:_______________
Position of sleeve:_______[m]
Equipment parameters
Equipment type:___________
Equipment No.:____________
Test volume:___________[m3]
Pipe wall area: _________[m2]
Test note:______________________________ Equipment operator:
________________________
Project management:
________________________
Customer:
________________________
Appendix 3: Illustrative determination of the requisite test times with sleeve testing
The test volumes and test times calculated as an example, which are presented in Table 2, result under the following assumptions:
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• A special packer is used for each nominal width. • The diameter of the core of the packer is always 10 cm smaller than the nominal width
of the tested sewer (DN/1000-0.1 [m]). • The test length, i.e. the separation between the shut-off elements , is 20 cm. • The length of the hose carrying the air, with a diameter of 1 cm, is 150 m. • The volume of the pipe connections and the volume of the shut-off elements are
ignored in this example.
Fig. 1: Schematic representation of the test space (marked by cross hatching) - the sketch is not to scale
t dVA
sTest volume
Pipe wall= ⋅ + ⋅1800 0 5. [ ].
Table 2: Tests volumes [m3] of sleeve test equipments and the therefrom resultant test times calculated as an example
Nominal width DN 200 300 400 500 600 700 800
Volume, test space [m3] 0.005 0.008 0.011 0.014 0.017 0.020 0.024
Literature [1] ATV-M 143E: Inspection, Maintenance, Rehabilitation and Replacement of
Drains and Sewers; Part 2: Optical Inspection (06.91)
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[2] DIN 1986: Entwässerungsanlagen für Gebäude und Grundstücke; Teil 30: Instandhaltung [Drainage Systems for Buildings and Property, Part 30: Repair] (01.95)
[3] DIN EN 752: Drain and Sewer Systems Outside Buildings
[4] DIN EN 1610: Verlegung und Prüfung von Abwasserleitungen und -kanälen [Laying and Testing of Drains and Sewers] (10.97)
[5] ATV-A 142E: Sewers and Drains in Water Catchment Areas (10.92)
[6] ATV-M 143E Inspection, Maintenance, Rehabilitation and Replacement of Drains and Sewers; Part 1: Optical Inspection, Maintenance, Rehabilitation and Replacement of Drains and Sewers; Part 2: Principles (12.89)
[10] Sicherheitsregeln für Rohrleitungsbauarbeiten [Safety Rules for Pipe Construction] (ZH 1/559) (04.86)
[11] Sicherheitsregeln für Arbeiten in umschlossenen Räumen von Abwassertechnischen Anlagen [Safety Rules for Work in Enclosed Spaces of Technical Wastewater Systems] (ZH 1/177) (04.88)
