INSPECTION AND TESTING REQUIREMENTS IT-6 WASTEWATER

TABLE OF CONTENTS

IT-6.1 Inspection ................................................................................................................ 1

IT-6.2 Testing ..................................................................................................................... 2

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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) Gravity piped reticulation where the distance between manholes is 50m or less, shall undergo visual inspection. Visual inspection includes "lamping" between manholes to ensure the pipeline is laid straight for grade and alignment, has retained its shape (i.e. roundness) and is clean.

c) Gravity piped reticulation where the distance between manholes is more than 50m shall be inspected using closed circuit television (CCTV) to satisfy the same requirements as noted under b) above.

Note: If any part of the reticulation is required to be CCTV'ed then all pipes on the development shall be CCTV'ed.

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

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

f) 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.

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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

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 5 minutes.

d) The acceptance limit shall be a pressure drop not exceeding 50mm in 5 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.

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iii) Council's Representative as a witness to ensure that the test was undertaken correctly.

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

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

(mm)

Time for permissible pressure drop

(minutes)

100 150 200 230 250 300

3.0 4.0 6.0 6.5 7.5 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

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:

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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.

d) Calibration check against a standard.

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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.