Pipeline Commissioning: From First Weld to Final Certificate
The trench is dug, the pipe is laid, and your groundwork is complete. What comes next? Before any new pipeline—whether it’s a 600m rising main or a 25m local connection—can be put into service, it must be professionally commissioned. This is a crucial, multi-stage process involving a specific sequence of services to prove the pipeline is strong, clean, and fully compliant with UK water authority standards.
At Pipe Testing Services (PTS), we manage the entire pipeline commissioning process for contractors and developers across the country. This guide explains the three core phases required to get your new pipeline signed off without delays.
The Purpose of a Formal Commissioning Process
A formal commissioning process provides documented proof that a new asset is fit for purpose. It is a regulatory gateway that protects the integrity of the wider water network and ensures public health is safeguarded. Each step builds upon the last, providing a complete quality assurance record for the final handover.
Phase 1: The Build – Creating a Structurally Sound Pipeline
The integrity of any modern PE pipeline begins with the quality of its joints. The first phase of commissioning is the physical construction, where sections of pipe are expertly joined to create a continuous, monolithic line.
- The Service: Pipe Fusion Welding Services are essential at this stage. Our certified technicians use butt fusion for joining long, straight sections of pipe and versatile electrofusion for installing fittings, valves, and making connections in tight spaces.
- The Goal: To create a pipeline that is structurally sound from the outset, with joints that are as strong as the pipe itself. A well-executed welding phase is the foundation for a successful pressure test.
Phase 2: The Proof – Verifying Pipeline Integrity
Once the pipeline is fully constructed, its structural integrity and leak-tightness must be proven. You cannot disinfect a pipeline if you are not certain it is completely sealed.
- The Service: Rising Mains Pressure Testing is the definitive method of verification.
- The Goal: The new pipe is filled with water and pressurised to 1.5 times its normal working pressure. Using digital data loggers, we hold this pressure for a set period. A stable pressure reading provides a clear pass, proving to clients and groundworks contractors that their 90mm or 180mm PE mains are 100% leak-free.
Phase 3: The Polish – Ensuring Water Safety and Compliance
After the pipeline has been proven to be strong, it must be proven to be clean. This is the final and most critical hurdle for any pipeline intended to carry potable (drinking) water.
- The Service: Chlorination Services and subsequent water sampling.
- The Goal: We disinfect the internal surfaces of the pipe to eradicate any contaminants introduced during the installation phase. Afterwards, we take a water sample and send it to an independent, UKAS-accredited laboratory for analysis. A passing lab result is the final piece of scientific proof needed for the water authority.
A Real-World Example
Many of our projects involve managing the complete commissioning sequence from start to finish. Our work on a significant new rising main installation in Leicester is a perfect example of this integrated process.
The project involved installing over 1.6 kilometres of new polyethylene (PE) pipe, which required a meticulous, phased approach to ensure a successful handover.
- Many of our projects involve managing the complete commissioning sequence from start to finish. Our work on a significant new rising main installation in Leicester is a perfect example of this integrated process. The project involved installing over 1.6 kilometres of new polyethylene (PE) pipe, which required a meticulous, phased approach to ensure a successful handover.
This project showcases how each phase of the commissioning process builds upon the last—from the initial weld to the final certificate—to deliver a robust, reliable, and fully compliant piece of infrastructure. You can learn more about this specific project by reading our full Leicester Rising Main case study.
The Advantage of an Integrated Commissioning Partner
Coordinating separate contractors for welding, testing, and chlorination can be inefficient and risks creating gaps in compliance documentation, leading to project delays. By partnering with a single specialist contractor like Pipe Testing Services, you get:
- A Seamless Workflow: Our teams handle the entire sequence, ensuring a smooth and logical transition between each critical phase.
- One Point of Contact: You get clear communication and straightforward project management from start to finish.
- Guaranteed Compliance: We understand the end-to-end process and ensure the final compliance pack is complete and has everything the water authority requires for sign-off.
If you are a contractor or developer planning a new pipeline installation and need an expert partner to manage the full commissioning process, contact Pipe Testing Services today.
Get in Touch with PTS
To discuss your requirements, schedule a consultation, or request a quote, please contact us at:
- Phone:01922 451646
- Email:enquiries@pipetestingservices.co.uk.
- Address:Unit 27 Birchbrook Industrial Estate, Shenstone, Lichfield, Staffs, WS14 0DJ
FAQs for the Pipeline Commissioning Process
How long does the entire commissioning process take?
The on-site work for welding and pressure testing can vary depending on the pipe length and complexity. The final step, water sampling, is the main time constraint. While the sample can be taken on the same day as the chlorination, the UKAS laboratory results typically take 3-5 working days to come back. It is vital to schedule your commissioning with this in mind.
Do I need all three phases for a foul or storm drain?
Not always. Foul and storm rising mains, like the one in the groundworks tender we recently quoted for, require a pressure test to prove they are leak-proof and will not pollute the environment. However, they do not carry drinking water, so they do not typically require the full chlorination and sampling phase.
What paperwork do I receive at the end?
Upon successful completion, PTS provides a full compliance pack. This includes the Pipe Fusion Welding logs (if applicable), the Hydrostatic Pressure Test Certificate with its data graph, and the Chlorination Certificate accompanied by the official UKAS Laboratory results. This pack contains everything you need for project handover.