Water Main Leakage Test - Calculate theoretically?
I recently witnessed a pressure test followed by the leakage 
test.  Pressure dropped from 161psi to 159psi for 5,710 ft of 8-inch DI 
pipe.  Is there a way for me to verify the leakage (7.5 gal) 
theoretically?  
I'm suspicious of the leakage number because 
they pulled the suction line out of the water tank used to pump the line
 up....and I suspect air got in the suction line and messed with the 
test. Thanks for any help you can provide!  
The pressure test criteria does allow you an allowable which can be calculated in the above formula. At the end of the test you are allowed to pump an additional 4.34 gallons back into the line to bring it back to the test pressure. Typically in the northeastern U.S. I have been required to hold between 150 psi - 200 psi anywhere from 1 hour to 2 hours and everwhere in between. Once completed, if I have dropped below the test pressure, I am allowed to pump in the allowable leakage, calculated above, back into the line to get back to the test pressure. If it does not pump back up, you fail. If you pumped in an additional 7.5 gal then it appears to me that you failed. Keep in mind everywhere I have done a pressure test the rules and regulations have been different! Same basic idea but everyone seems to have there own take.
Additionally be suspicious if the contractor sees an instantaneous jump on the gauge and sucked air as you describe as the system can become air locked and is pointless after that. Contractors try everything from a "secret" buried valve or curbstop to pass if a line has become troublesome. Pay careful attention to the setup and make sure you understand the location of every valve, hydrant, and blowoff.
I fear a reader to this thread might come out of it with some 
misunderstanding of the specific test it appears was performed, as well 
as the complexity in general of hydrostatic testing issues.  To begin 
with my reading of the formula as well as tables of C600 tells me that 
when make-up water must be pumped back into an 8" ductile iron pipeline 
5,710 feet long tested at say 160 psi, the ALLOWABLE "testing allowance"
 for a two hour test per this standard should not exceed:
L=(2 
hrs) (5,710)(8)160^.5/148,000 or 7.81 gallons.  [It appears the 
contractor in this case for whatever reason pumped only 7.5 gallons back
 in, that would appear to be a "pass" at least per the AWWA standard .] 
With
 all due respect also to some of the verbiage and terminology in 
references in this thread, as well as in some of the responses, I feel 
compelled to make the following additional comments related to the 
further, original question in general of "calculating leakage".  In my 
opinion, while it is possible to do all manner of calculations e.g. with
 "bulk modulus of compressibility" of water and elastic stretching of 
pipes etc. it is generally not really practical to "calculate leakage" 
in buried pipeline tests (except maybe in some very HIGHLY controlled 
test conditions of vessels and limited pipelines).  This is due to the 
following realities, some that may really be common to installation of 
pipelines of all materials: 
1.  Despite best intentions/design, 
most rigorous or expensive installation/construction, and inspections 
etc., pipelines are not necessarily laid precisely with regard to either
 the horizontal or e.g. vertical lines on plans etc. 
2.  Similar to 
the realities/imperfections of "1.", air valves(Needle Valves) and/or other air release
 mechanisms etc. are not necessarily always installed precisely at the 
top or apex of all local, vertical crests that may happen by design, or 
inadvertently in the installation of pipelines. 
3.  Due to the combination of "1." and "2.", some air inevitably becomes trapped in pipelines. 
4.  As
 most venerable standards and specifications also require that pipelines
 be filled, e.g. in preparation for hydrostatic testing "slowly" 
[defined in some as at velocities <1 fps (0.3mps)], it is also a 
reality (at least when high velocity flushing is not accomplished prior 
to hydrostatic testing) that that any unintentionally trapped and 
unvented air will simply not be removed (or "scavenged by sufficiently 
high flow velocity) at the time the (in effect combination air and water
 containing) pipeline is pressurized in hydrostatic testing. 
5.  While
 trapped air may or admittedly may not cause any sort of noticeable 
problems in subsequent hydrostatic text results, it is well known that 
it CAN wreak literal havoc in others.  In other words, pipelines that 
contain trapped air can appear in various fashions to sometimes fail 
hydrostatic testing criteria (incidentally either raising or falling in 
pressure, or requiring excessive make-up water!), even though they 
really have no leakage!  
6.  For this reason, it is also stated in 
many long-standing specifications that the installer should remove most 
or all air (a requirement that appears, at least in many circumstances, 
sometimes easier said than done and some incongruous with the realities 
of 1-4!) 
7.  Unlike water, that as you note is relatively 
"incompressible", air is instead highly compressible, and air is also 
highly volume or pressure (if contained as in a closed hydrostatic test)
 responsive to changes in temperature in accordance with "Boyle's", 
"Charles'" and "Gay Lussacs'" et al laws/principles.  Thus if (indeed 
probably instead "when", in the case of much testing that is of rather 
long duration) there are any temperature changes this will be 
accompanied by inevitable changes in pressure etc. and/or 
disproportionate requirements for make-up water etc., that do not have 
anything to do with "leakage". 
8.  It may be tempting to just assume
 that pressurized air is just like pressurized water (the old "pressure 
is pressure" argument), and therefore will not meaningful affect test 
results.  However, this argument appears to neglect yet another 
phenomena associated with air/water mixes, that being that when there is
 no separating membrane air is also somewhat free also go into and out 
of "solution", and this in turn is probably also influenced by various 
drivers/variables of pressure and changing temperature etc. (not to 
mention the locations of at least any large columns of air e.g. from the
 pressurizing end etc.).   While much at least surface source water is 
already "saturated" with air, this may not be true of all filling water 
sources, and also other conditions.  In this regard I saw a writing many
 years ago (I think from a manufacturer of air valves), "A typical 1-mi 
(2-km) long pipeline of any diameter that has been supposedly vented of 
air will, in most instances, still contain enough dissolved air to 
completely fill over 100 ft (30 m) of the pipe."  Likewise, some water 
can soak into cement mortar linings of some types of pipe, also over 
time/pressure. 
9.  Lastly, it is also possible that there can be 
slight movement, settlement, or some extension of pipelines due to 
installation and/or Bourdon effects etc., again that has nothing 
necessarily to do with leakage but that would change the test volume and
 manifest itself in at least some loss of pressure during a long-term 
test. 
I think many of these practical realities were not lost on
 at least the formulators of venerable standards that have existed for 
decades, e.g. ANSI/AWWA C600 for the installation and testing of iron 
pipelines.  In this regard, if after more than 2 hours a particular 
closed off small diameter pipeline still holds basically a 160 psi level
 of pressure, while only losing a pound or two of water pressure, I 
suspect many Owners or installers of pipelines of many materials would 
probably be pretty happy with such an apparently tight line.  As psnyder
 notes/quotes above, the C600 standard indeed states, "Testing allowance
 shall be defined as the maximum quantity of makeup water that is added 
into a pipeline undergoing hydrostatic pressure testing... IN ORDER TO 
MAINTAIN PRESSURE within 





