ISO 10802:2020

INTERNATIONAL ISO
STANDARD 10802
Second edition
2020-08
Ductile iron pipelines — Hydrostatic
testing after installation
Canalisations en fonte ductile — Essais hydrostatiques après pose
Reference number
ISO 10802:2020(E)
©
ISO 2020

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ISO 10802:2020(E)

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© ISO 2020
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Published in Switzerland
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ISO 10802:2020(E)

Contents Page
Foreword .iv
Introduction .v
1 Scope . 1
2 Normative references . 1
3 Terms and Definitions . 1
4 Safety . 3
5 Preparation of the test sections . 4
5.1 General conditions . 4
5.2 Pressure pipelines . 4
5.2.1 General. 4
5.2.2 Anchoring and closures . 4
5.2.3 Partial backfilling before testing . 6
5.2.4 Filling with water and air venting . 6
5.3 Non-pressure pipelines . 9
6 Pressure testing procedure . 9
6.1 General . 9
6.2 Preliminary operations for pressure pipelines .10
6.3 Preliminary test for pressure pipelines .11
6.4 Main pressure test .12
6.4.1 General.12
6.4.2 Water loss test .12
6.4.3 Pressure drop test — Direct reading (PDDR) .13
6.5 Determination of acceptance .13
6.6 Testing of the complete pipeline .13
6.7 Non-pressure pipelines .13
7 Acceptance criteria .14
7.1 Pressure pipelines .14
7.1.1 Water loss test — Falling pressure and water loss test — Constant pressure .14
7.1.2 Pressure drop test — Direct reading .14
7.2 Non-pressure pipelines .14
Annex A (informative) Test methods description and comparison .15
Annex B (informative) Example of hydrostatic testing report .17
Annex C (informative) Pressure pairing of component pressures and pipeline pressures .19
Bibiliography .20
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ISO 10802:2020(E)

Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). The work of preparing International Standards is normally carried out
through ISO technical committees. Each member body interested in a subject for which a technical
committee has been established has the right to be represented on that committee. International
organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.
ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
electrotechnical standardization.
The procedures used to develop this document and those intended for its further maintenance are
described in the ISO/IEC Directives, Part 1. In particular, the different approval criteria needed for the
different types of ISO documents should be noted. This document was drafted in accordance with the
editorial rules of the ISO/IEC Directives, Part 2 (see www .iso .org/ directives).
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of
any patent rights identified during the development of the document will be in the Introduction and/or
on the ISO list of patent declarations received (see www .iso .org/ patents).
Any trade name used in this document is information given for the convenience of users and does not
constitute an endorsement.
For an explanation of the voluntary nature of standards, the meaning of ISO specific terms and
expressions related to conformity assessment, as well as information about ISO's adherence to the
World Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT), see www .iso .org/
iso/ foreword .html.
This document was prepared by Technical Committee ISO/TC 5, Ferrous metal pipes and metallic fittings,
Subcommittee SC 2, Cast iron pipes, fittings and their joints.
This second edition cancels and replaces the first edition (ISO 10802:1992), which has been technically
revised.
The main changes compared to the previous edition are as follows:
— add the safety instructions for hydrostatic testing operation;
— add hydrostatic test flow chart;
— add several diagrams for comprehensiveness;
— add pressure drop test method, as alternative of constant pressure test.
Any feedback or questions on this document should be directed to the user’s national standards body. A
complete listing of these bodies can be found at www .iso .org/ members .html.
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ISO 10802:2020(E)

Introduction
Ductile pipelines include many components and jointing solutions to offer a reliable service under the
worst situations (high pressure variations, earthquakes, etc.) hence the need of a secure hydrostatic
pressure test after having taken into account possible movements of the components.
Every pipeline which has been constructed undergo a water pressure test to ensure the integrity of
pipes, joints, fittings and other components such as anchor blocks.
Normally it is made as the assembly of the pipeline progresses, according to the proposed methodology
consisting of 3 phases:
— preliminary operations to prepare the test;
— preliminary test to stabilize the pipeline and to evacuate air in the pipeline;
— main pressure test to assess the water tightness of a pipeline at test pressure; it can be done
either by a:
— water loss test: Falling pressure - WLFP or constant pressure – WLCP methods, or
— pressure drop test - Direct reading – PDDR method.
Figure 1 summarizes the sequence to follow during the test.
Figure 1 — Testing procedure flow chart
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INTERNATIONAL STANDARD ISO 10802:2020(E)
Ductile iron pipelines — Hydrostatic testing after
installation
1 Scope
This document specifies site hydrostatic acceptance tests for installed pressure and non-pressure
ductile iron pipelines used for conveying water and other liquids.
It does not cover testing of pipelines for gas.
NOTE In this document, all pressures are relative pressures expressed in bars, where 1 bar = 0,1 MPa.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edition cited applies. For
undated references, the latest edition of the referenced document (including any amendments) applies.
ISO 2531, Ductile iron pipes, fittings, accessories and their joints for water applications
ISO 6708, Pipework components — Definition and selection of DN (nominal size)
ISO 7186, Ductile iron products for sewerage applications
ISO 7268, Pipe components — Definition of nominal pressure
ISO 10804, Restrained joint systems for ductile iron pipelines — Design rules and type testing
ISO 16631, Ductile iron pipes, fittings, accessories and their joints compatible with plastic (PVC or PE)
piping systems, for water applications and for plastic pipeline connections, repair and replacement
1)
ISO 21051 , Construction and installation of ductile iron pipeline system
3 Terms and Definitions
For the purposes of this document, the terms and definitions given in ISO 6708, ISO 7268 and the
following apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https:// www .iso .org/ obp
— IEC Electropedia: available at http:// www .electropedia .org/
3.1
allowable operating pressure
PFA
P
FA
maximum internal pressure, excluding surge, that a component can safely withstand in permanent service
[SOURCE: ISO 2531:2009, 3.2, modified — The symbol has been added.]
1) Under preparation. Stage at the time of publication: ISO/FDIS 21051:2020.
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ISO 10802:2020(E)

3.2
allowable maximum operating pressure
PMA
P
MA
maximum internal pressure, including surge, that a component can safely withstand in service
Note 1 to entry: P = 1,2 × P
MA FA
[SOURCE: ISO 2531:2009, 3.17, modified — The term has been changed from "maximum allowable
operating pressure" to "allowable maximum operating pressure"; the symbol and note 1 to entry have
been added.]
3.3
allowable site test pressure
PEA
P
EA
maximum hydrostatic pressure that a newly installed component can withstand for a relatively short
duration, when either fixed above ground level or laid and backfilled underground, in order to measure
the integrity and tightness of the pipeline
Note 1 to entry: This test pressure is different from the system test pressure (3.7) which is related to the design
pressure of the pipeline.
Note 2 to entry: P = 1,2 × P + 5.
EA FA
[SOURCE: ISO 2531:2009, 3.3, modified — Note 2 to entry has been added.]
3.4
working pressure
WP
P
W
highest pressure that occurs at a time and a point in the pipeline when operating continuously under
stable conditions, without surge
3.5
maximum working pressure
MWP
P
MW
maximum pressure to which a pipeline is subjected under surge conditions
3.6
maximum design pressure
MDP
P
MD
maximum operating pressure of the system or of the pressure zone fixed by the designer considering
future developments and including surge
Note 1 to entry: It is the maximum pressure considering the design pressure and surge together, where:
— MDP is designated MDPa, P , fixed allowance for surge (secondary distribution networks);
MDa
— MDP is designated MDPc, P , surge is calculated (pumping & water mains).
MDc
3.7
system test pressure
STP
P
ST
pressure to which a pipeline or a pipeline section is subjected for testing purposes
Note 1 to entry: to entry:
— P = 1,5 × P (when P ≤ 10 bar), or
ST D MD
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ISO 10802:2020(E)

— P = P + 5 (when P > 10 bar)
ST D MD
where P is the design pressure.
D
Note 2 to entry: Annex C provides information on pressure pairing of component pressures and pipeline
pressures.
4 Safety
If not covered by a national regulation, the following specifications shall be implemented.
Related to personnel:
— At all stages of testing, the planned sequence and any variation of operations shall be controlled to
avoid danger to personnel.
— All personnel shall be clearly informed of the intensity of the loading on temporary fittings and
supports and the consequences if failure occurs.
— Prior to the commencement of operations, a check shall be made so that the appropriate safety
equipment is available and that personnel have the correct protective clothing.
Related to works:
— Permanent abutments or anchorages shall be constructed to withstand thrust at the test pressure.
Concrete anchor blocks shall be allowed to develop adequate strength before testing begins.
— Care shall be taken to ensure that caps or other temporary blanking fittings are adequately
anchored, with the load distributed according to the strength of the supporting ground. Gate valves,
fire hydrants, water hammer release equipment nor safety valves should / shall not be used as
blanking fittings.
— Any temporary supports or anchorage at the ends of the test section shall not be removed until the
pipeline is depressurized.
— After installation and until completion of reinstatement, all excavations shall remain adequately
guarded. Work not related to pressure tests shall not be permitted in pipe trenches during
pressure tests.
— When performing test, the pipe trench and its surrounding shall be guarded with safety distance.
Only inspectors can enter the area to perform their work.
Related to equipment:
— Prior to carrying out a pressure test a check shall be made to ensure that the test equipment is
calibrated, is in good working order and correctly fitted to the pipelines.
During the test:
— Air shall be exhausted from the pipeline as fully as reasonably possible. Filling shall take place slowly
from, if possible, the lowest point in the pipeline and in such a way as to prevent back siphonage and
so that air escapes at adequately sized facilities for venting.
— Care shall be taken to fill pipelines with water slowly whilst all facilities for venting are open and
the pipelines adequately vented.
— Water used for test shall be able to be drained without flooding or polluting the work site.
WARNING — The test methods described in Clauses 5 and 6 are applicable only for water-
pressure testing. They shall in no case be applied for air pressure testing because of the serious
safety hazards involved in doing so.
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ISO 10802:2020(E)

5 Preparation of the test sections
5.1 General conditions
The ductile iron pipelines shall be made of ductile iron pipes, fittings and accessories in accordance
with ISO 2531, ISO 7186 or ISO 16631, and installed in accordance with ISO 21051.
If materials other than ductile iron are included in the water network, they shall be tested separately.
The ductile iron pipeline shall be tested as a whole or, when necessary, subdivided into several test
sections selected so that:
— the test pressure can be achieved at the lowest point of each test section;
— a pressure of at least MDP can be achieved at the highest point of each test section unless otherwise
specified by the designer;
— the necessary water for testing can be provided and removed without difficulty.
The length of pipeline test sections should be determined on the basis of the following considerations:
— the local conditions;
— the availability of suitable water;
— the number of fittings and accessories (e.g. valves, hydrants, etc.) constituting the pipeline;
— the difference in elevation between different parts of the pipeline.
— the existence of locking joints:
In the event of partial locking of fittings with pipes to ensure self-anchoring, locked areas can be tested
together with unlocked areas.
In case of a completely locked section, provision shall be made to allow the pipe to pull under pressure.
The ends of these sections shall not be stopped.
5.2 Pressure pipelines
5.2.1 General
For pressure pipelines, the length of the test sections shall not exceed 1 500 m unless otherwise
specified.
5.2.2 Anchoring and closures
It is required to evaluate the hydraulic loads exerted on the ends of the pipeline and set up a properly sized
system of anchors, so as to absorb the loads in the timbers buried across the trench or in sheet piling.
Table 2 provides indicative values of a thrust force on a pipeline closure (such as, flanged blank)
generated by hydraulic pressure of 1 bar, and a calculation example of the thrust exerted by pressure.
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ISO 10802:2020(E)

Table 1 — Example of thrust calculation exerted by pressure
DN F (1 bar) DN F (1 bar) DN F (1 bar) DN F (1 bar)
daN daN daN daN
60 47 250 590 600 3 167 1 200 12 370
80 75 300 835 700 4 278 1 400 16 787
100 109 350 1 122 800 5 568 1 500 19 236
125 163 400 1 445 900 7 014 1 600 21 851
150 227 450 1 809 1 000 8 626 1 800 27 612
200 387 500 2 223 1 100 10 405 2 000 34 045
2 200 41 115 2 400 48 891 2 600 57 340
EXAMPLE  For DN150 and 10 bar, it results in a thrust force of 2 270 daN.
NOTE 1  Since the inner diameter is greater than the nominal one and it depends on the pipe pressure
class, the outer diameter has been used for the calculation for safety reasons.
2
     FP=×π×()D /4
I
where P is the hydraulic pressure, D is the internal diameter.
I
NOTE 2  1 bar = 100 kPa, 1 daN = 1,019 7 kilogram-force [kgf].
All changes in direction and/or cross-section of the pipeline, such as bends, tees, tapers (reducers) and
blank flanges, shall be adequately restrained (or anchored) before testing by means of thrust blocks or
restraining (self-anchoring) joints.
The design of the restraining (anchoring) devices shall take due consideration of the test pressure to be
applied and be in accordance with ISO 10804.
Isolation of the test sections shall be achieved by using blank flanges or other types of closures.
Other components such as gate valves, fire hydrants, water hammer release equipment or safety valves
should not be used to replace the blank flange, but if for practical reasons, valves are used as closure
pieces, the test pressure shall not exceed the rated pressure of the valves. When evaluating the overall
leakage allowance for a test section, due consideration shall be taken of the allowable leakage rate(s) of
the valve(s).
The already laid and hydraulically tested ends shall not be put under load.
In order to compensate possible subsidence, it may be needed to provide screw jacks (see Figure 2).
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ISO 10802:2020(E)

Key
1 screw jacks
2 thrust block
3 thrust F
Figure 2 — Anchoring example
5.2.3 Partial backfilling before testing
Pipelines are normally tested partially backfilled leaving the pipe joints accessible for inspection.
Sufficient backfill material shall be placed over the pipe barrel between the joints to prevent movement,
and due consideration shall be given to restraining thrust forces during the test (see Figure 3).
ln particular, restrained-joint systems which derive their stability from the interaction of the pipe and
soil should be backfilled prior to testing.
Key
1 backfill
L standardized length of the pipe
Figure 3 — Partial backfilling before testing
5.2.4 Filling with water and air venting
After having divided the pipeline into practicable test sections, the pipeline shall be completely filled
with water and air-vented. The pressure shall be raised up to at least the operating pressure, without
exceeding the system test pressure.
The pipeline shall have air-venting facilities at all high points. The ends of the relevant section shall be
blocked with blank flanges fitted with venting valves.
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ISO 10802:2020(E)

For potable water pipelines, potable water shall be used for the pressure test, unless otherwise specified
by the designer.
The presence of air in the test section of the pipeline will result in erroneous data, especially in the case
of discontinuous height profiles, which could indicate apparent leakage or could, in some cases, mark a
small leak.
The air present in the pipeline water will, over a period of time, leave the solution. The volume previously
occupied by the air will be replaced by water and, in doing so, the pipeline pressure will decrease. The
kinetics of dissolution of air in water is a function of many parameters:
— the initial saturation level of the pumped water;
— the water temperature: the amount of dissolved air decreases with an increase in temperature;
— water pressure: the amount of dissolved air increases with an increase of the water pressure;
— the location of the air pockets;
— the dimension of the interface zones between air and water;
— etc.
The pipeline shall be filled slowly, when the ventilation devices are open, from the lowest point, so
that no backflow occurs and the air can escape through ventilation devices. Too fast filling may cause
trapped air cushions.
In the case of an inconsistent height profile, venting through "pigs" is recommended, since in some cases
the line cannot be completely vented despite high flushing speeds.
As a guide, the flow-rate during filling should not exceed 10 % of the design working flow-rate.
Experience has shown that the filling speed should not exceed the values given in Figure 4.
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ISO 10802:2020(E)

DN Flow rate (l/s)
100 0,39
200 1,57
300 3,53
400 6,28
500 9,81
600 14,13
700 19,23
800 25,12
900 31,79
1 000 39,25
1 200 56,52
1 400 76,93
1 600 100,48
1 800 127,17
2 000 157,00
2 200 190,06
2 400 226,19
2 600 265,45
Key
X DN
Y filling speed
Figure 4 — Recommended filling speed
The pressure test shall be the system test pressure, calculated for the lowest point of the test section,
minus the difference in altitude. Any debris and foreign matter shall be removed from the pipeline
before testing. A calibrated pressure meter with the adequate range and precision should be installed
at the lowest point of the test section (see Figure 5).
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ISO 10802:2020(E)

Key
1 higher end
2 air vent
3 test pump and pressure meter
4 pressure to be applied STP
5 lower end
Figure 5 — Filling with water & pressure to be applied
Cement mortar lined pipelines require a period of time after filling (depending on site hygrometry
conditions) for absorption by the lining to take place.
5.3 Non-pressure pipelines
For non-pressure pipelines, the test section is usually the total length between consecutive manholes
or inspection points.
If special arrangements are made to enable testing over only part of the length between manholes
and inspection points, then the length of the test section shall not exceed 1 000 m unless otherwise
specified.
NOTE This is normally between two manholes, whose distance is normally less than 1 km.
For non-pressure pipelines, anchoring calculation is required owing to the pressure test requirement of
5 bar as per 6.7.
6 Pressure testing procedure
6.1 General
The procedure of the pressure testing of a pipeline with cement mortar is explained in the Figure 6,
with the three steps:
— the preliminary operation at working pressure,
— the preliminary test at system test pressure, for stabilizing and venting the pipeline,
— the main pressure test (falling pressure or constant pressure test, or pressure drop) to assess the
water tightness of the installed pipelines.
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ISO 10802:2020(E)

Key
X time (hours)
Y pressure (bars)
1 preliminary operation 1 h to 24 h
2 preliminary test 1 h or a longer period if specified by the designer
3 main test 1 h to 6 h per DN, call repeat if fail
Figure 6 — Pressure testing procedure
The components of the pressure testing of a pipeline is shown in Figure 7. The test methods comparison
for the three steps of the pressure testing procedure is given in Annex A.
6.2 Preliminary operations for pressure pipelines
After filling and before application of the test pressure, maintain the test section at the working pressure
(WP) for a sufficient period (up to 24 h) of time for it to stabilize with respect to line movement under
pressure and water absorption by the lining, etc.
The duration of the preliminary operations shall be specified by the designer, with respect to local
conditions, such as temperature change, humidity, length and DN of pipelines, etc.
Inspect visually all exposed joints, fittings, anchorages and closures and repair all defects, after
draining the test section if necessary.
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ISO 10802:2020(E)

Key
1 test pump
2 pressure gauge
3 pump connection
4 air vented
5 pile of soil
6 thrust force
7 anchor system
Figure 7 — Components of the pressure test
6.3 Preliminary test for pressure pipelines
When the visual inspection is satisfactory, raise the pressure steadily until the system test pressures
(STP) specified below are attained, in order to stabilize the pipeline and eliminate the air before
performing the main pressure test.
The test pressure at the lowest point of the test section shall be not less than the limit specified in a) or
b), whichever is greater.
a) For P ≤ 10 bar: P = 1,5 × P b) The maximum P : P = P
W ST W W ST MDc
For P > 10 bar: P = P + 5
W ST W
The test pressure shall not exceed the maximum test pressure (PEA) of the component (pipes, fittings,
flanges and accessories), nor the design pressure of the restraining devices, installed in the pipeline.
The test pressure at the highest point of the test section shall not be less than the
...