Hydrostatic Strength of HDPE Pipes Test Procedure

NEXOR Pipes 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 Length of Test Piece from end cap to end cap(mm) 250 250 250 250 250 250 250 270 330 375 420 480

PIPE OD (mm)

20 25 32 40 50 63 75 90 110 125 140 160

180 200 225 250 280 315 355 400 450 500 560 630 710 800 900 1000 Conditioning

540 600 675 750 840 945 710 800 900 1000 1120 1260 1420 1600 1800 2000

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) <3 >3 and <8 >8 and <16 >16 and <32 >32 Conditioning Period (h) 1 3 6 10 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 = 10(2)/(SDR-1)..1 P = test pressure in bar = 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. 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 9 11 13.6 17 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 Material Test Stress (MPa) of Condition 1 (100 h, 0 20 C) 12.4 Test Stress (MPa) of Condition 2 (165 h, 0 80 C) 5.5 Test Stress (MPa) of Condition 3 (1000 h, 0 80 C) 5.0 Test Pressure (psi) 228 +/- 1 183 +/- 1 145 +/- 1 114 +/- 1

PE 100

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 Pipe Material Test Pressure (psi) of Condition 1 (100 h, 0 20 C) 450 326 Test Pressure (psi) of Condition 2 (165 h, 0 80 C) 199 167 Test Stress (psi) of Condition 3 (1000 h, 0 80 C)

PE 100 PE 80

181 145

Table 6 Test Pressures for SDR 11 Pipe Material Test Pressure (psi) of Condition 1 (100 h, 0 20 C) 360 261 Test Pressure (psi) of Condition 2 (165 h, 0 80 C) 159 133 Test Stress (psi) of Condition 3 (1000 h, 0 80 C)

PE 100 PE 80

145 116

Table 7 Test Pressures for SDR 13.6 Pipe Material Test Pressure (psi) of Condition 1 (100 h, 0 20 C) 285 207 Test Pressure (psi) of Condition 2 (165 h, 0 80 C) 126 105 Test Stress (psi) of Condition 3 (1000 h, 0 80 C)

PE 100 PE 80

115 92

Table 8 Test Pressures for SDR 17 Pipe Material Test Pressure (psi) of Condition 1 (100 h, 0 20 C) 225 Test Pressure (psi) of Condition 2 (165 h, 0 80 C) 99 Test Stress (psi) of Condition 3 (1000 h, 0 80 C)

PE 100

90

PE 80 Pipe Failure

163

83

72

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. 2
nd

Ed. Industrial Press Inc. USA. 1988

Willoughby, David et al. Plastic Piping Handbook. Mcgraw-Hill Handbooks. USA. 2002