5.2.3.1equipment For High Voltage Spark Testing

T E C H N I C A L I N F O R M A T I O N
5.2.3 High Voltage Spark Testing

(for determination of penetrations or leakages in the lining system)
High Voltage Spark testing shall be performed in accordance with the guidelines DVS 2225-2
This test method is based on the principle of gas discharge when an electrical high voltage is
applied to a discharge path.
The test set-up consists of a voltage source and a brush or punctual electrode. The method
requires that there is a counter-electrode of conducting material on the back of the weld.
e.g:AGRU installation profiles with coextruded electroconductive layer or HDPEel-Tear Off
profiles.
Wwhen applying alu-tape on the backside of the CPL this needs to be considered before
installationof the Sure Grip on the studded side in the area of the designated welding zone.
Tack-welding thin copper wire in the joint area prior to extrusion welding is also commonly used.
Field of application: In principle, all weld structures can be tested continuously for
imperviousness using this method.
The test is preferably applied to extrusion seams for installed Sure Grip lining systems
5.2.3.1Equipment for High Voltage Spark Testing (see page 9)

Commonly used spark testing equipment for plastic liners
5.2.3.2 Execution
The weld area must be dry and free from contamination. Particles of dirt can form an
insulating layer and thus affect the test. The test voltage must be matched to the material and
the thickness of the membrane and to the weld width. Information about the breakdown
voltages in air and in Test voltage as a function of the membrane thickness and the sparking
distance during the high voltage test (Source: STUVA Report 12179, Page 93). 0.Z
(see page 8)
For HDPE liners with a thickness of 2.0 mm and above for example, the permissible
test voltage is approximately 40 kV. With a test voltage of 40 kV, in dry air a sparking
distance of approximately 15 mm results. Thus surface seams approximately 30 mm wide can
for example be tested if the counter-electrode lies in the centre of the weld, the lack of
imperviousness is continuous and runs virtually perpendicularly to the weld. The sparking
distances increase with higher air humidity. The brush electrode is passed over the weld at a
speed of approximately 2-3 m/min. Care must be taken to ensure that the field strength
necessary for the flash-over can build-up.
AGRUSAFE Sure Grip  D&I

file:vol3/vas/des1_maintenance.p65
L/Ni/Wb-05-2001-Rev.00
7
The test method is based on the principle of gas discharge with the installation of electric high voltage to a discharge space.
The test equipment consists of a high voltage source (alternating voltage of 60 kV) and an electrode. In practice, sparking
balls turned out to be more meaningful than brush electrodes. This method requires a counter electrode out of conductive
material on the backside of the joint.
In general, all joint forms can be tested with this method regarding tightness.
The joint area must be dry and free of pollutions. The test is impossible with a closed film of moisture. Particles of dirt
could build a lagging and could influence the test.
Before the begin of the test, the sparking distance between the unit electrode and the counter electrode (copper wire, metal
foil, conductive PE...) in air and on a dry sheet surface with testing voltage has to be determined. The sparking distance
is the distance of the maximum allowed un tightness so that it can be recognized. Higher air humidity’s and moist surfaces
enlarge the sparking distance.
The sparking ball is carried through the joint with a speed of 2 - 3 m/min. Un tightness will cause a visible and audible
spark over.
If no spark over appears the joint is tight. The limits of the method are that only un tightness can be proven which is within
the sparking distance.
An evaluation of the quality of the weld itself can not bederived . Therefore it is necessary to make a test weld prior field
seaming and destructive seam tests for the qualtiy of the weld.
Test Voltage for Spark Testing

acc. DVS 2225 part4
100
60 Material Thickness in
40
conjunction to the dielectric
strength (Voltage in KV)
20
Voltage [kV]
test range
10
8
6
4
Voltage as function of spark

2
length in dry air [mm]
1
0,1 0,2 0,4 0,6 0,8 1 2 4 6 8 10 20
mm
L/Ni/Wb-05-2001-Rev.00
8

Standard Spark test equipment
Picture shows a failure in the extrusion welding Picture shows a failure in the extrusion welding
seam (spark) seam
5.2.3.3 Test results

When continuous lack of imperviousness exists over the test length (half the weld width) a
flash-over takes place between the electrode, which is visible and audible
5.2.3.4 Evaluation of theTest Results

The weld is regarded as impervious if no spark discharge occurs.
If a spark discharge is indicated the seam has to be properly repaired.
5.2.3.5 Limits of the method

Only leakages which are continuous and which run virtually perpendicularly to the weld can
be detected. The test length must be matched to the sparking distance in air.
The method is not applicable for electroconductive HDPEel-Sure Grip Lining.
The method does not indicate if the seam bonding quality is sufficient.
L/Ni/Wb-05-2001-Rev.00
9
Counter Electrode is required for spark testing:

a) counter electrode using AGRU installation profiles:
HDPEel Tear Off Profile

extrusion welding
b) counter electrode using electroconductive wire

electroconductive wire extrusion welding
b) counter electrode using electroconductive tape
electroconductive tape extrusion welding

L/Ni/Wb-05-2001-Rev.00
10
5.3 Documentation
All records from inspections shall be documented in a report with the installation sketch or drawing
where all seams are numbered.
The results of the site tests must be recorded in test reports as an additional note to the test reports
for executed inspections after finishing the installation work prior to filling of the basins .
It is also recommended to take pictures for record.
5.3.1 Vacuum and Spark Testing Documentation

-Vacuum and Spark testing crew will use Mean Streak permanent markers to write on liner
indicating tester‘s ID number, date and pass/fail designation on all areas tested.
-Records of testing will be maintained by the CQC (certyfied quality control)

Coordinator or testing crew.
5.3.2 Failure and Repair Documentation
If any damages will be identified during inspection adequate repair must be performed.
Repair shall be in accordance to the Sure Grip installation guidelines.
The properly repaired sections have to be tested for tightness with spark or vacuum test method.
All repair work will be documented and a note to the test report is added including type of failure,
repair method, seam test.
In case of necessary consultations are requested AGRU or the local agency of AGRU shall be contacted.

L/Ni/Wb-05-2001-Rev.00
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5.2.3.1equipment For High Voltage Spark Testing

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T E C H N I C A L I N F O R M A T I O N

5.2.3 High Voltage Spark Testing

5.2.3.1Equipment for High Voltage Spark Testing (see page 9)

AGRUSAFE Sure Grip  D&I

5.2.3 High Voltage Spark Testing

Test Voltage for Spark Testing

Voltage as function of spark

5.2.3 High Voltage Spark Testing

5.2.3.3 Test results

5.2.3.4 Evaluation of theTest Results

5.2.3.5 Limits of the method

Counter Electrode is required for spark testing:

HDPEel Tear Off Profile

b) counter electrode using electroconductive wire

b) counter electrode using electroconductive tape

electroconductive tape extrusion welding

AGRUSAFE Sure Grip  D&I

5.3.1 Vacuum and Spark Testing Documentation

-Records of testing will be maintained by the CQC (certyfied quality control)

5.3.2 Failure and Repair Documentation

AGRUSAFE Sure Grip  D&I

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