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Specification of HDPE Pipeline

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M Alim Ur Rahman
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12 views

Specification of HDPE Pipeline

Uploaded by

M Alim Ur Rahman
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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SPECIFICATIONS

FOR

HDPE PIPING SYSTEM FOR POTABLE


WATER AND OTHER
APPLICATIONS

WITH COVER THE FOLLOWING HEADS:

• HDPE PIPES HANDLING


• UNLOADING OF MATERIALS
• STORAGE & STACKING AT SITE
• INSTALLATIONS OF HDPE PIPES
• TRENCHING
• LAYING OF PIPELINE
• JOINTING (BUTT FUSION & COMPRESSION TYPE)
• BACKFILLING (INITIAL & FINAL)
• HYDRO TESTING
• COMMISSIONING OF PIPELINE
1. POLYETHYLENE PIPE

1.1 Polyethylene Pipes for Potable water application are manufactured according to
latest International Standard ISO – 4427 : 1996 DIN 8074 / 8075 for Gas ISO 4437.

1.2 IIL HDPE Pipe are produced to stringent quality control tests and inspection M/s IIL
is an ISO: 9002 certified company for producing plastic pipe systems.

2. TECHNICAL INFORMATION

2.1 Product Detail as mentioned in the attached Technical Literature in Section “D”

3. HANDLING

Storage
• Pipe, whether bundles, coils or loose pipe must be stored in a manner which is both
safe and which keeps the product free from damage. Pipe ends in particular should be
protected, as distortion or damage may cause difficulties in jointing.

• Pipe and fittings should be stored away from risk of damage from exhausts and other
heat sources.

• Pipe and large fittings can be stored externally for up to a year. However for longer term
storage cover should be provided to avoid UV damage. Compression fittings should be
stored under cover and kept dry. Fittings packaging must be kept intact up to the point
of use.

Stacking
• Individual pipes should be stacked on level ground, free of stones and sharp objects,
with timber batten supports at 1 m centers. Stack height should not exceed 1 mater for
bundle pack and 1.5 mater for loose Pipes

4. INSTALLATION PROCEDURE

Pipe Trench
• The Depth of Trench should be 0.9 Meter over the Pipe Crown in normal conditions. In
case of rocky ground then the depth of trench should be increased by at least 0.15
Meter and the excavated earth replaced by a stone free layer.

Trench Width
• The Width of Trench should be out side Pipe dia plus 300mm

Trench Bed
• In case of rocky ground then the fine sand of 0.15m thick should be used as bedding
underneath the pipe and a cover of sand on the sides and over the crown up to the
height of around 0.3m from top of the crown should be provided.
5. LAYING OF PIPES

• Small diameter pipes could easily be handle with out use of auxiliary tools & Machinery

• When jointing of bigger diameter pipes 90mm to 630mm diameter, should be using Butt
Fusion Machine.

• Whenever possible, a minimum distance of 300 mm from 'obstructions and other


services should be maintained. This distance is often possible when laying parallel to
other services but not always practicable when crossing other services. A separation
distance of 75 mm may be allowed for a square crossing but suitable protection should
be provided from possible point loading, interference, damage or contamination.

• The bending of polyethylene is permissible and the properties of fusion jointed systems
enable changes of direction without recourse to the provision of special bends or anchor
blocks. However, the pipe should not normally be cold bent to a radius smaller than 25
times the outside diameter of the pipe. For push-fit or mechanical non end-load resistant
jointing systems, anchor blocks to withstand the resultant thrusts must be provided in
the traditional manner.

• The installation of flanged fittings such as sluice valves, hydrant tees, end caps etc.
usually requires the use of polyethylene stub flanges complete with backing rings and
gaskets. Care should be taken when tightening these flanges to provide even and
balanced torque. Provision should be made where heavy fittings are installed, for
concrete support both for the weight and to resist the turning moments associated with
valves and hydrants.

7. PE JOINTING SYSTEM

General Information
• Polyethylene pipes systems are relatively simple to joint and install. Two jointing method
are available to cater for the components that are used to build an operational system.

Fusion Welding Joints


• Butt Fusion

Mechanical Fittings Joints


• Compression Fittings
• Mechanical Fittings
Fusion Welding Joints

Butt Fusion
• Butt Fusion jointing involves the Fusion of two pipe ends in a special machine which
prepares the pipe ends, heats them and brings them together under pressure to form a
homogeneous weld. The joint is fully end load resistant and is at least as strong as the
parent pipe.

With Butt Fusion Jointing it is essential that only similar


grades of PE are welded, i.e.
PE100 - PE 100 .
PE 80 - PE80
and similar SDR's are used, i.e.
SDR 11 - SDR 11 .
SDR 17 - SDR 17
Equipment Required
• Butt Fusion machine, inclusive of trimmer/planner, heater plate and hydraulic
pump.
• 220 Volts (7KVA) Generator, fuel
• Welding Tent/Base board , Pipe support rollers
• Clean water, lint free cloths ,
• Pipe end covers
• Indelible marker pen
• Pipe cutting tools

7. BACK FILLING

Initial Back Filling


• After laying the Pipeline similar filling of the trench is to be done in layers of 0.15 m
except joint by utilizing stone free soil. Similar compaction of the next layer must be
continued until a cover of at least 0.3 m above the crown of the pipes is achieved.

8. PRESSURE TESTING

It is recommended to test the pipeline in accordance with prescribed code of practice.


Normally, the leakages may occur at the butt fusion / compression joints. As such, the
backfilling of joints should only be done after testing the pipeline.

Preparation for Testing


• The Pipeline buried / anchored at specified places prior to pressure testing
• Air relief Valves should be provided at higher points
• Start filling the pipeline from the lowest point
• Open the air-relief Valves during filling of water
Testing Procedure :
• The testing pressure is raised to the nominal or working pressure either by manually
operated pump or a power-driven pump.
• This pressure is maintained for 1/2 hour, during which any loss of water is
supplemented.
• Within 30 minutes thereafter, the pressure is increased to 1.5 times of the designed
working pressure of the system. This pressure is maintained for 2 hour.
• On completion of the test sequence, the remaining pressure should be released slowly
until the pipeline, returns to its pre test condition.

• If there is leakage in the line then it must be investigated and rectified

Final Back Filling

• After pressure testing, filling of they trench is to be done in layers of 0.15m over the
pipe, utilizing stone free soil. The soil layer immediately over the pipe is to be
compacted by the tamping bars.

• The material used for upper layers can be coarser than that used for the initial backfill.
These layers should be carefully rammed down one on top of the other until the backfill
is completed.

9. COMMISSIONING PROCEDURE

• Upon the successful completion of a test, the remaining pressure in the pipeline should
be released slowly.

Fallowing successful pressure testing all new mains, lined or re-furbished, should be
commissioned in the following manner and in accordance with any local requirements:

• Cleaning of the main


• Flushing
• Refilling the main
• Disinfection
• Acceptance certification

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