POLYETHYLENE PIPES AND FITTINGS FOR PRESSURISED WATER, GAS AND INDUSTRIAL APPLICATIONS TECHNICAL GUIDE corys “ian +GF+ Gore rscue oryIntroduction Specifications ‘Characteristics & Properties Design Considerations Handling & Storage Jointing Method Installation Testing & Commissioning Health & Safety Other Approvals Notes 22S Se = =e men coRYys Gin GF FaSsccusrere tou} coRYySs CCoryss the holding company fr Hepworth PME LLC)-Corys is brand bon from a strong heritage. For more than 35 years, the Abdul Convenienty flexible Te Resists cracking TS Good fusibilty T= Non corrode 7% Tough TR Resistant to chemical attack by aqueous media ~~ Strong Te Low fictional resistance, Strength ‘The “strength” ofa pipeline may be considered as the ability to withstand (hoop) stress inthe pipe material under intemal pressure ‘over a prolonged period of ime. The design stress considered the Is taken to bea ife expectancy in excess of $0 years. ‘The stresfife characteristics are obtained by a standard universally ‘accepted test procedure, regression curve prediction. The regression curve shows the performance ability ofthe material Under a specified load fora design life in excess of 50 years. ‘The strength of polyethylene is known tobe timed temperature dependent. Ths characteristics used to asess the future available strength ofthe pipe material by generating regression curves from varying stress/ife to fallure tests at higher temperatures than ‘that normally experienced in disbution mains. These prolonged tests, in excess of 10,000 hours, are accelerated for quality control Purposes by using elevated temperatures (typically 80%) “The method therefore identifies 2 Minimum Required Strength ‘CMRS ) value derived from the SO year extrapolated 97.5% Lower confidence limit (LCL) foilure stress. Foe tegresin Caves P80 Maint 20°C CORYS ies +GF+ A salety factors applied to the MRS to determine the Hyro- static Design Stress ( HDS ). Recent European practice has been to specify the ISO minimum safetlactor for PE of 1.25 for buried ‘water applications 2.0 for buried gas applications and 1.6 for above ground non gas applications. PE pipes are not recommended for above ground gas applications Using these anaiyses, the predicted minimum failure tess of PEBO material is 8.0 MPa ~ (based on the extrapolated 50 year 97.5% LCL stress value at 207), Figure 1 gives a regression curve (or series of data points for a material at 20%. ‘The predicted minimum failure stress of PE 100 material is 10.0 MPa. With a design co-fficent of 1.25, the design stress of this materials 80. Fare Regresion Canes or P00 Matias a 20°C GEORG FISCHER PIPING SYSTEMS (Characteristics and Properties WCharacteristics and Properti Toughness In practice itis recognised that PE isa tough, resibent material capable of withstanding the normal rigours of pipelaying conditions. “The many years of succesful installation of polyethylene pipe in the ‘925 and water industry adds confidence to this recognition. However, the definition and description of this characteristic i ificult and complex. There is no single test or measure one can apply, 2 itis a combination of many characteristics and properties. ‘Abrasion ‘Although the material has high resistance to abrasion by suspended partces being cated in the water, the extemal surface can be seratched and gouged by sharp objects. Careful handling is therefore required but provided the depth ofthe notch is no greater than 10% ofthe wall thickness ther is no sigificant loss inthe Performance ofthe pipe. Flexibility, Recovery and Creep ‘The inherent flexibility and recovery of PE enables the pipeline to absorb impact loads, vibration and stress caused by soil or ground ‘movement. This also implies that PE pipes ‘Chemical Resistance and Stability Corrosion Resistance For al practical purposes PE is chemical ner within its normal temperature range of use, It does not rot rust, pit, corrode or lose wall thickness through chemical or electrical reaction wth the _surounding sol. It does not normally support the growth of, nor it affected by algae, bacteria or fungi. ‘Chemical Effects PE has a good resistance to a wide range of chemicals. In the water “supply context the main concem the elec of cenain chemica's ‘esting in contaminated ground, some of which can have harm effect upon the pipe material or may cause minor taste problems in ‘ecreme cases. n broad terms the most common harmful ‘chemicals can be grouped into Oxises, Cracking Agents and ‘eran solvents a follows: Permeability ‘may have usell fatigue characteristics where cyclic loadings are present, (pumping mains, heavy trafic lading conditions, et). ts absorption of groundmavement is advantageous in potently Unstable areas such as recently file ground or mining areas. ‘The property of flexibility and the abiity to deform without Permanent damage (ceep/relaxation property) enabies pipelines to be contoured to dificult road layouts or rapid changes of rection. Polyethylene is subject to creep under stress but those stresses developed wil eax with time. This characteristic requires 2 diferent approach from the tractonal pressure testing procedures. Crack Resistance E's tough with brite type fale dificult to achieve even in laboratory tess uness itis at very low temperature. Failure cracks are usually ofa ductile nature and, sofa, tests inicate that rapic ‘ack propagation (RCP) in water filed SDR1 pipe is sow, ‘Gaastrophic failure, rapid crack propagation, appears unikely Under normal distribution conditions The difference between brite and duct failure is illustrated in Specification ISO 1167. Group — fet on PE ‘Oxidzers | Vary song aces | Degradation Cradkng | Deepens [No degracaton but unde igh ‘ages lenpereies ccleates cading laser ares in bile meer Sobens | Hydrocarbons such | No degradation but maybe Speros and ote” | Soeorbd nfo ppe wat causing Fedcion in hoop stenath and Dose ase probs ‘Teble 1-Harmful Chemicals ‘Where pipelines ae tobe lai in environments where concentra- tions of such chemicals may prevail (eg. garage forecourt, within ‘certain processing works, etc) the use of PEis NOT recommended unless suitably protected. For further information, Hepworth PIME Technical Services Deparment should be ‘onstited. The effect of specifi chemicals on polyethylene pipe is considered inthe ISO specification, ISO DP 10358, All grades of polyethylene can be shown to be permeable to certain gases and liquids under extreme conditions, the rate of permeation being mainly dependent upon the media involved and the wall thickness ofthe pipe concerned. ‘Weatherabilty and Temperature Changes Generally PE material has good weatherbilty properties and can readiy withstand the variations of weather without degradation but ‘certain properties require consideration. Coefficient of Expansion PE has a coeffdent of linear expeansion of approximately between (0.16-0.20mm per meter per TC which is an order of magnitude ‘greater than exists in metal pipeines and this characteristic must be considered carefully in the design ofthe pipeline and during insalation. The coefficient of circumferential expansion is approximately one half the linesr value and seldom presents CORYS Siem +GF+ problems in system design except where large diameter compression fitings ae proposed. ‘Temperature Range From the ime of manufacture tothe time that a PE pipeline is commissioned, the pipe wil normally be subject toa range of temperatures and some exposure to UV light (unlighd. Both require attention during this period, Once installed underground, the effects are usualy insignificant asthe viscoelastic properties of the material make it quite adaptable to relaxing or adjusting wth time to stresses imposed by thermal changes due to weather and soll temperature. GEORG FISCHER PIPING SYSTEMS Thee pSemer larencd ‘Temperature Stability “The exposure of PE to normal changes in temperature does not ‘cause degradation ofthe material. During manufacture and fusion pining the materia is subjected to temperatures in the range of 200% ~ 240 and to safeguard against degradation at these high ‘melt temperatures special stablisers are used. PE pipe should not bbe used under pressure at constant temperatures in excess of 200 ‘without an appropriate reduction in its design pressure rating ifthe minimum design ife of 50 years isto be achieved. Low Temperature ‘The mechanical properties of poyetiyene alow the ppe tobe ‘successfully operated in low temperature environments, Laboratory base texts inate that PE wil retain its flexi unt tempers- tures as low as 60 are reached. A the moder cold tempera tures the low thermal conduct of PE wil delay the freezing of the water contained win the pipe n acto, should the water become frazen the inherent feb ofthe mata wl accommo date the expansion due to the formation ofc without lesng to rupture ofthe pipe wal. UY Degradation PE pipe is subject to a degree of degradation when exposed to ‘excessive ultraviolet light (suiigh®, UV stabilisers (ant-onidents) are used in the manufacture to counteract this eect and such material has withstood practical exposures for periods in excess of ‘2 year without apparent deleterious effects. This surface cegrada- tion has a particular impact when using fusion jointing techniques {and leads to recommendations forthe peeling ofthe surace ofthe material prior to jointing. PE is basically intended for use in buried conditions uniess protected from prolonged sunlight exposure. This i refiected in the current recommendation to provige protection when used in above-ground situations or when stored outside for periods greater than one year. ‘Thermal and Electrical Conduction PEs @ poor conductor of heat buts lammabie, therefore @ naked flame should not be used for the thawing of frozen pipework. At all times pipes should be protected against radiant heat that could raise its surface temperature above 60. PE is also 2 poor ‘conductor of electricity and no attempt should, therefore, be made to Use pipework constructed ofthe material a @ means of earthing electrical equipment; similaty the contents of such pipes cannot be ‘thawed by elecrical techniques using the pipe as the conductor. Because ofits high electrical resistivity, caution is required in the use ‘of PE pipes where high leves of static electricty may be present. Hydraulic Properties ‘The smooth bore of PE pipes enables them to be treed 2s "hycraulically smooth” when used forthe conveyance of potable water. The smooth surface discourages the formation of scale in hard water areas but particular waters may, at certain times, give rise to slime and sit deposits associated mainyat joints or itings which may increase frictional losses. cORYS Gis +GF+ For the purpose of calculation of flaw rates in NEW pipelines the ‘Colebrook: White formula may be used in which the value ofthe hydraulic roughness factor Ks is 0.003mm for clan water. (GEORG FISCHER PIPING SYSTEMS ‘Characteristics and PropertiesOther Applications ‘Athough princpaly developed for conveying water and gas, polyethylene pipes have many other applications, some of which (Sewage pumping mains, where the materials resilience provides ‘excellent resistance tothe surge pressures generated by continuous ‘Pump starting and stopping. {@ Slurry conveyance in quarries, mines, et. In this application, PE pipes provide superb resistance to abrasion, When comparing PE pipes with conventionapipes used for slury applications, consider- able increase in lifetimes can be achieved. 1G) Fire mains FM Approved piping systems offer sae, secure and Correction free solutions for underground fire fighting mains. () Chiled Water (©) Demineralses Water (6) IndustiavCherical applications Submarine pipetines (6) Rehabilitation of existing pipelines by reining (©) Compressed Air Lines (10) Vaccum Sewage (11 Telecom Applications (12) Ship Building (13) gation (14) Sea Water Intakes (15) Aqua and Marine Parks corRys eter +GF+ Frese 4 Phe peDAR rly ‘When considering the design of polyethylene ppe systems, the appropriate international specications should be taken inte consideration, For ‘example extracts from the WRe Manual are published here with acknowledgment to the Foundation for Water Research, Review of Current Position PEBO and PE100 pressure gas and water mains are ner fexble, lightweight and have the reouired structural strength without being brite. They ae stable for use where ground movernentis expected, winere corrosive sols are present and where long ducts ad fesibil bending re required. They appear to witstand surge pressures beter than PVCU pipe ad to be even more restart to freezing because of the improved thermal insulation properis, Fusion welded PE ping systems resist axial stresses arising from thermal or pressurisation elects, except at the transition points to non end lad bearing pipe systems. Thrust bloks and anchorages need only to be considered in thse cass. ‘Beth PE8O and PE100 pipes alow the use of many modem no cig teciniques. Environment PE pipes are normally joined using fusion techniques. But fusion Fpiting is usualy cared out above ground and after cooling: long engi of pipe are snaked into the trench, Fusion jointing using the elecrofusion joining technique may be Cartied out atthe trench bottom, but care mast be taken to keep Foiming surfaces Gean and cry. ‘The sub surface material to be excavated should be assessed forts suitability as selected backil mater ie, re fom large sharp stones, heavy clay, ee the material is ureutable fr beeing and surround to the pipe then imported material shoul be utiised and the surplus spol removed from ste “The propetes of PE make such pipelines particulary sutabe for «reas subject to ground movement ue fo seismic forces, ining “subsidence, compaction of filed stes or the disturbance caused by the aces of other tities in the vc. "Where PEs o be used in environments with temperatures greater than 20€ the allowable operating pressures should be reduce in accordance with the manufacturer's recommendations. Corrosive ground (eg. ground with low pH or high sulphate ‘Caracerisic) has itt or no effect upon PE but afl metal tings, ancillary equipment, bots, ec, should be careful protected inthe normal wa. Contaminated ground, however, must be considered carefuily. PEs resistant to many ciemicals, buts wuneable to petroleum products and certain solents; where concentrations of such contaminants exist PE should NOT be used unless suitably protected. Where any doubt ‘e extwust ystems oF other Neat ‘sourees and fo avoid possible contamination from materials such as lest ol. Metal chains or sings should not be brought nto direct ‘contact wi te materia. Webbed slings of paypropyene or ryion are recommended. Straight pipes shouldbe fuly supported and bound together Pipes must not rest onthe integral socket ones incorpo- razec: When ransporting 'pupped Ming, these should nat be loaded iva way that could citort the pup end. Both vertcal and horizontal _dtvries of called pipes are permisibleathaugh Inthe case of horizontal transportation speck arrangements may be requked, Off Loading — Frame Packed Ppes When ing by cane, non metalic ‘wide band sings or ropes should be used. and for pipe lengths oreter than 6m, lad spreading bears ofa length atleast equiient to one ‘quarter of the length of the pipe or bunclepack shoud be empioyed CORYS Gi +GF+ sreppee ‘Tember Frames wl ‘gure 1 Typ ames pack of FE Pipes Figure 2 Liting Famed packs by Crane (GEORG FISCHER PIPING SYSTEMS WWW.orys.aecoRYySs Peer es ‘Chains or end hooks should not be used. Care shouldbe tan to avid > ‘equecns intelli. Herein action to effluent spose projec, polythene pombe weter dition mains ink communis and Public Utty pumping talons over sever! Klmetnes. There are ‘numerous examples where one coninuous but-nelded polyethyiene pene traverses ane and vater over many Klee. Adore Ground Indlistons ‘Where PE pips are to be used in above ground ital, they mutt be protec agaire: exposure w crea runight ite good design raaice to hele thermoplagc pes ove ground. Tis wl ep > reduce the amount of movement caused by teipertire vation. “apper for Hadtrontally ane Veetcly Sampenlad Pips ‘There are tno main factors tn be cansklered when specing supper ‘deals for spernded PE ripe spies, SEA Techical requremenes TR eshte: ‘Teehtca| Respirementa: Payernyene pbs Intaid n above ground eyes wl generaly be black Where PE pipe i specie this must be protected rom direct ‘exporure to ula let igh eunighe “The cnrec spedtion of resehs and supports lian essential part of suspended PE pipe system design. end raat lake account of exoarsion ‘and contraction a the extreme maximum and minimum sevice CORYS Gi +GF+ Angin 38 Runes ceirl oy ‘Connection to Polyethylene Mains “The preferred method of connecting polyethylene service pipes from polyethylene mains is my means of elecrofusion sefapping tees. Laying Polyetylene Services Service pipes are avai coisa hus oer an opportu ot WA. eerofson couples the number of reqedin parca ston Th, geet withthe fact joint aboveground enables narrow renches to be pence ciigisl net aieiaon ae oe NBL compression tings teal or pasion “The deal bed and surround requierents normally applied to ‘mainaying may not aways be achievable, Cae shoul be taken to ‘ensure the pipe isnot bedded on uneven o sharp projecing materi. Every effort shouldbe made to adequately compact suitable fine ‘material around the pipe to at least 100rim above the pie before oral back-iling takes place. CORYS Bie +GF+ soemceTesting & Commissioning ‘Testing and Commissioning ‘This Section deals withthe standard procedures for testing installed Pipelines prior to commisioring, These standards will nomally require, {asa minimum, the adequate fushing ofthe serie and the testing of al ppes an joints to the maximum head to which the syste i to be subjected Hydrostatic Pressure Testing ‘The normal esting procedure used for most pipelinemateris requires the application of 2 nominated hydraulic pressure to the pain, then isolating the pressure pump fora peri of 1 hour. The success ofthe testis then judged by the quantty of water recuied to restore the cotginal test pressure measured against a given formula ‘Aer being tested al sevice pipes must be subjected toa fal ¥ APPROVED — KITEMARK corRys Cit +GFt SeNSoeeue 4 Reeac ‘APPROVED “The increasing acceptance of polyethylene as an approved ‘material fr safe transportation and distribution of both gasand ‘water has led tothe fre fighting industry introducing the rmaterlalfor fire-fighting applications. Hepworth PME (LLC) and our principal Georg Fischer Piping ‘Systems (Switzerland) have successfully undertaken FM Approval Testing and Auditing which means that we are now able to offer fully Factory Mutual (FM) approved Fie Fighting Pipe Systems for buried applications with operating pressures up to and including 12bars, ‘Main pipeline sizes from 90mm to 400mm are approved for fire-fighting applications together with a wide range of tings. Please refer to our installation instructions when ‘undertaking any fire-fighting pipeline installations. Copy avallable upon request. coRYys +GFt Stingent FM Testing and Auditing guarantees customer confidence for the use of polyethylene as a material for buri firefighting applications Fusion welded joint ensure that he “subsequent pipe system is secure and safe andis able to give an ‘operational lifetime of more than 50 years, leakand corrosion free ‘with minimal maintenance. (GEORG FISCHER PING SYSTEMS,fat] HEAD OFFICE- UAE Senate) ern nt cere me POT aT cee} hepworth@eimae Pate ABU DHABI SHARJAH ALAIN OMAN BAHRAIN SUBSIDIARY COMPANY DOHA www.corys.ae