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    PE Design Guide

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    Design Guide for Polyethylene (PE) Pipelines for Water Supply Purpose Design Division Water Supplies Department August 2006 CONTENTS INTRODUCTION CHARACTERISTICS AND PROPERTIES 2.1 Material, Strength and Pressure Rating of Pipe 2.2 Temperature Effect on Pipeline 2.3 Chemical Resistance and Permeability 2.4 Potential Problems PIPE SIZE 3.1 Size Designation 3.2 Selection of Pipe Size PIPE ROUTE SELECTION OF JOINT TYPE 5.1 Types of Joint 5.2 Joint Type Selection for Various Sizes 5.3 Flange Joint FITTINGS INSTALLATION 6.1 General Arrangement 6.2 Installation Details PIPELINE DESIGN 7.1 Cover to Pipe 7.2 Trial Pits and Inspection Pits 7.3 Public Utilities 7.4 Trenching, Backfilling, Bedding, Haunching and Surround 7.5 Pipes Protruding from Structures 7.6 Thrust Blocks 7.7 Waste Detection Meter and Flowmeter Installation 7.8 Swabbing 7.9 Squeeze-off Closure CONTRACTOR'S PROPOSAL 8.1 Supply and Lay Arrangement 8.2 Jointing Details PRESSURE TESTING AND COMMISSIONING 9.1 Pressure testing 9.2 Commissioning of PE Pipeline Page 10 10 - 11 - 12 - 13 13 - 16 16 le - 1s - 20 - 21 a1 22 22 23 23 ere a 12 13 15 17 18 20 2. 22 10.0 DESIGN CONSULTATION 10.1 Operational Region 10.2 Training 11.0 FEEDBACK AND REVIEW REFERENCES FIGURES Figure 1 Regression curve for PE 80 at 20°C Figure 2 Regression curve for PE 100 at 20°C Figure 3 Definition for leakage, leaching and permeation Figure 4 Pipelines protruding from structures TABLES Table 1 Expansion/Contraction of PE 80 pipeline Table 2 Expansion/Contraction of PE 100 pipeline Table 3 Harmful chemicals to PE pipe Table 4 Dimensions for sizes 20 to 315 Table 5 Equivalent pipe sizes Table 6 Typical bolt torques Table 7 Sizes of sectional and isolation valve and stopcock Table 8 Trench widths for PE pipe Page 24 24 25 - 18 - 12 14 17 24 27 1g APPENDICES Appendix A Appendix B Appendix ¢ Appendix D Classification of Joint Types VJ Flange Adaptor for PE Pipe Typical Details of Fittings Installation Examples of Methods of Connect ion using Proprietary Products (for Illustration only’ Design Guide for Polyethylene (PE) Pipelines for Water Supply Purpose (august 2006) INTRODUCTION Polyethylene (PE) pipe is a relatively new material. In 1994, Water Supplies Department introduced the Medium Density Polyethylene (MDPE) pipes and published the “Interim Design Guide for Medium Density Polyethylene (MDPE) Pipelines for Water Supply Purpose” in conjunct ion with the use of such pipe material. Since then, high quality materials have been developed and High Performance Polyethylene (HPPE) pipes are available for use for water supply. ‘The MDPE and HPPE pipes are now collectively referred to as PE pipes. In the market, the commonly available PE pipes are blue, black and yellow in colour. It is, however, the practice of Water Supplies Department (WSD) to use blue coloured PE pipes to facilitate identification of buried water pipelines in Hong Kong. This design guide is a document for blue PE pipes for water supply purpose. PE pipes are classified either as PE 80 or PE 100 pipes which are equivalent to the former MDPE pipes and HPPE pipes respectively. PE 100 is higher in density than PE 80. In general, PE 100 permits thinner pipe walls than PE 80 for the same operating pressure. It therefore provides for a larger bore and increased flow capacity for a given nominal pipe size which in practice refer to the outer diameter of the pipe. This design guide takes into account the above changes and serves to unify a vast number of design parameters to suit local environment and the need of Hong Kong's water supply systems. It supplements WSD Civil Engineering Design Manual Vol II Chapter 1 which does not cover the design of PE pipe although the use of polyethylene pipe is briefly mentioned. For general technical aspects relating to the design of pipelines, which is not covered in this context, the Design Manual should be followed. CHARACTERISTICS AND PROPERTIES Material, Strength and Pressure Rating of Pipe (a) Polyethylene is a synthetic thermoplastic material produced fromthe polymerisat ion of ethylene ina closed loop reactor. The conditions under which polymerisation takes place and the specific catalyst used control the properties of the polymer. A wider range of materials may be produced which can be broadly characterised by their molecular weight, crystallinity and density. (b) The molecular weight distribution influences both the melt flow characteristics and the toughness of the material. The absolute value of the molecular weight also controls toughness. (c) The density of the material is closely related to its crystallinity or structural regularity which in turn influences a wide range of physical properties. For example, the increase in the density of the material would improve its short term strength but would trade off its ductility The lower the ductility of the material the more difficult it becomes in the redistribution of stresses around defects and cracks thus reducing the effective toughness of the material. (a) The "Strength" of a PE pipe is taken as the ability to withstand (hoop) stress in the pipe material under internal hydraulic pressure over a prolonged period of time. It isbothtimeandtemperaturedependent. Theminimumrequired strength (MRS) of PE pipe is based on the 50 year lower confidence limit of the failure stress at 20°C which is obtained by long term extrapolation in accordance with ISO TR 9080. The MRS of PE 80 and PE 100 materials are 8.0 MPa and 10.0 MPa respectively. The regression curve for PE 80 and PE 100 at 20°C are shown in the following figures: Stree MPs PES REORESSION 1 ore Shee 3 woeiae ae a rr ee ‘Tne hear og sont) Figure 1 : Regression Curve for PE 80 at 20% (e) (£) 15} PE o0 REGRESSION comer a wie am re "| a mo" 3 4] Wert 1 ota ot aor SE ‘Time owe lg sealed Figure 2 : Regression Curve for PE 100 at 20°C Pressure rating of PE pipe is normally referred to in "bars" and at 20°C. Given the adoption of the design stresses, pipes of the same pressure rating will have a constant ratio between the outside diameter and the wall thickness. Such ratio is termed as Standard Dimension Ratio(SDR) . Nominal Outside Diameter SDR = ‘Nominal Wall Thickness For normal water supply purposes, the design stress of PE80 (for nominal size from 20 to 63 mm inclusive) and PE100 pipes at 200C are set to be 6.3 MPa and 8.0 MPa respectively. With SDR of 11, Maximum Operating Pressure (MOP) of 12.5 bars and 16 bars will be yielded for PE80 and PE100 respectively. Pipes of a higher SDR, such as SDR = 17.6, 26 and 33, are available in the market. In view of the limited applications of low pressure rating pipes in Hong Kong’s distribution systems, pipes of SDR of 11 should be used. Similar to other thermoplastic pipes, strength of PE is rather temperature dependent. In general, the higher the temperature, the lower will be the strength. The MOP of PE pipe will decrease by 2% for every 1°C increase in temperature above 20°C. Thus, a reduction factor should be adopted for the design of PE pipe to cater for temperature effect. (g) (h) iat The maximum diurnal temperature of buried pipelines for cold fresh water supply in hot summer months is expected not to be higher than 27°C. Given the temperature at 27°C, the pressure rating will decrease by 14%. In this regard, a reduction factor of 0.86 is recommended for the design of fresh water PE pipe. Salt water is directly extracted from the sea and some salt water service reservoirs are currently without roof. The maximum temperature of salt water is between 25°C and 31°C for most of the time in summer. For the design of the salt water PE pipe, it is reasonable and prudent to assume a design working temperature of 30°C. Hence, the corresponding pressure reduction factor of 0.8 is recommended. For instance, given that a 16 bar pipe operating at 30°C for salt water, the reduction factor is 0.8. The maximum design working pressures of PE pipes will be equal to 16 x 0.8 = 12.8 bars. 2.2 Temperature Effect on Pipeline {a) Exclusion of temperature effect on pipe strength does not preclude its effect being considered for pipeline expansion and contraction. PE80 and PE100 pipes have respectively coefficients of linear expansion of 1.5 x 10 ‘ per °C and 1.3 x 10% per °C which are about 10 times greater than that of metal pipe. For the purpose of estimating temperature effect , temperature variation in degree Celsius for water inside pipelines can be taken as 24 (a range corresponding to a 31°C maximum and a 7°C minimum). Expansion/Contract.ion for various lengths of PE80 and PE100 pipelines are shown in Table 1 and 2 below. Table 1 Expansion/Contraction of PE80 pipeline Length Temperature Variation of (metres) 24 Degree Celsius (approx. in millimetres) 1 4 2 7 4 14 6 22 8 23 10 36 12 43 20 72 50 180 (b) ~5- Table 2 Expansion/Contraction of PE100 pipeline Length Temperature Variation of (metres) 24 Degree Celsius (approx. in millimetres) 1 3 2 é 4 12 6 19 8 25 10 31 12 37 20 62 50 156 Internal stresses due to linear expansion and contraction can be taken up by pipe continuity through fusion joints or end-load-resistant mechanical joints. Experience in the UK shows that most failures in PE pipelines are in the mechanical joints in the form of pull-out and leakage. To avoid contraction afterwards, pipe closings should not be made under direct sunray and with more than 10 metres of pipe length without soil cover. When a contract involves laying of other pipe materials, consideration should be given to divide the Works into Sections so that laying of PE pipes need not be carried out in hot summer months. 2.3 Chemical Resistance and Permeability (a) For all practical purposes, PE is chemically inert except to the group of chemicals as listed in Table 3. Moreover, it does not support the growth of bacteria or fungi. Table 3. Harmful chemicals to PE pipe Group Generalised | Bffect on PE Possible Examples Problems Oxidisers | Strong acids | Degradation Bursting Cracking | Detergents No degradation but | Burst ing agents accelerates cracking under stress in brittle manner. Solvents | Hydro-carbons | No degradation but | Burst ing such as|may be absorbed | and taste petrols and|into pipe wall | problems oils causing reduction in hoop strength. (b) {c) (a) fe) (£) Chemicals, in particular organic chemicals, may attack plastic pipes in three ways as illustrated in Figure 3. omen = ~@© (1) Leakage (2} Leaching ©... (3) Permeation Figure 3 Definition for leakage, leaching and permeation While leakage and leaching can largely be controlled by using PE pipe which complies with an acceptable standard, attack by harmful chemicals particularly permeation by hydrocarbons is a major source leading to contaminated water supply. Researches in the Netherlands reported that for the common plastic materials used in water supply pipeworks, polyethylene is most sensitive to permeation. Pending on the emergence of satisfactory materials, PE pipelines should not be designed to be laid in areas of known or suspected contamination, or inside or adjacent to petrol stations, laundries, dry cleaners and industrial areas having chemical plants. Similarly, PE pipelines should not be designed to run parallel with any existing or proposed oil-filled electric cables which are at the same level or above the proposed pipelines. Likewise, planning proposal for any of the aforesaid installations adjacent to existing or proposed PE pipelines should be objected if no protective measures to the pipelines are provided. As a protective measure, a minimum horizontal separation of 5 metres between the centreline of the pipeline and the nearest facet/boundary of the installation concerned shall be provided/maintained. Oil-filled electric cables running below the proposed PE pipelines are permitted. The use of petrolatum anticorrosion tape, such as "Denso Tape", for protect ionof flanged connections isnot permitted. (9) ony Ss See further discussions on protection of PE flange joints in Section 5.3. Project engineers should solicit/collect information, during circulations and site inspections, with regard to the presence of these installations and observe the criteria of separation in (e) above. 2.4 Potential Problems (a) (b) {e) Fire resistance PE is flammable. Unlike uPvC, which is flame-retardant, PE once reaches the ignition point will keep burning. Therefore if naked flame has to be used in the trench, for example for welding of steel pipe joints, precautionary measures have to be taken to shield the PE pipe or complete all the flame-generating operations before laying the PE pipe. Termite attack Another potential problem is termite attack which however has not been discussed in literature originated in the UK so far. Termite damage is widespread in sub-tropical and tropical areas. Although cellulose is the staple diet of termites, theyare reported tonibbleat anything including synthetic polymers that present in their way. Researches inJapanon various synthet icpolymers suggested that termite resistance is proportional to the hardness of the material; the harder the material, the higher will be the termite resistance. The resistance for common synthetic materials in descending order is nylon, High Density Polyethylene, Low Density Polyethylene and then PVC (plasticized). Currently there is no major trend that can be identified for the precautionary measures taken by Hong Kong's utility undertakings. Hongkong Electric has anti-termite treatment to their plastic cable sheath while Hong Kong and China Gas who started to lay yellow PE 80 pipe in 1987 has hitherto no reports on termite attack to their pipes. There appears to be no concluding evidence at this stage regarding the extent of termite attack on buried PE 80 pipe in Hong Kong. It would be prudent to keep this aspect in view in particular when investigating any failure of PE 80 pipe where the cause of failure is not that apparent. Fast Fracture Fast fracture is a phenomenon in PE pipeline failure whereby a substantial section of pipeline is suddenly cracked along its entire length during service conditions such that repair would be extremely difficult, time-consuming and costly. An analogy of fast fracture would be the bursting of an 3.0 PIPE 3.1 Size (a) (b) oe inflated balloon when punctured by a needle. This type of failure happens in temperate regions and has caused considerable concern in the UK water industry. The real cause of failure isnot yet fully understood. Nevertheless, fast fracture has been simulated under laboratory conditions where the pipe is submerged in iced water and with the presence of air together with pressurised water inside the pipe. Though there are limited evidence from laboratory tests, it is believed that fast fracture would not be a major problem for PE pipelines in tropical areas. SIZE Designation PE pipes are designated by a nominal size equivalent to the mean outside diameter. Principal dimensions for pipes of nominal sizes up to 315 and SDR = 11 are shown in Table 4 below. Table 4 Dimensions for sizes 20 to 315 Mean Outside | Wall Thickness for Nominal Diameter SDR = 11 Size (mm) Min. Max. Min. Max. 20 20.0 | 20.3 2.0 2.3 25 25.0 | 25.3 Bi 2.7 32 32.0 32.3 Sa 314 50 50.0 50.4 4.6 512 63 63.0 63.4 5.8 6.5 90 90.0 90.6 8.2 9.2 125 125.0 | 125.8 11.4 12.7 180 1go.o | 181.2 16.4 18.2 250 250.0 | 251.5 22.7 25.1 315 315.0 | 316.9 28.6 31.6 Since the wall of PE pipe is thicker when compared with pipes of other materials, the internal bore of PE pipe is smaller. Table 5 shows the equivalent sizes of theG.I., uPVC and DI pipe compared with PE pipe. 3.2 Table 5 Equivalent pipe sizes PE (mm) GI_{wm) upvc (inch) 20 15 % 32 25 1 50 40 1% 63 50 2 PE_ (mm) DI_ (mm) uPVC (inch) 90 80 3 125 100 4 180 150 6 250 200 - 315 250 - Selection of Pipe Size (a) (b) Care should be taken when interpreting the size of distribution and service mains from a Planning Report. Distribution networks are based on pipes of standard materials adopted by the Department, which for the same nominal sizes will have similar internal bores. Therefore, if PE pipes are to be used, the equivalent size of PE pipe should be selected from Table 5. It should be noted that the equivalent size of PE pipe in Table 5 are based on the SDR of 11. If PE pipes with other SDR values are to beused for some particular projects, calculation is required to find out the internal bores and hence obtain the equivalent sizeof theconnectingpipe. For instance, PEpipeof nominal size of 315 mm with SDR of 33 is equivalent to DN 300 DI pipe instead of DN 250 DI pipe. PE pipe has a very smooth internal bore. The hydraulic frictional coefficients normally used in design flow charts for new continuous straight PE pipelines working under pressure can be taken as Colebrook - White Ks = 0.003 mm Hazen Williams c = 150 However, frictional resistance of a PE pipeline is complicated by the presence of valves and fittings, the uneven alignment resulting from the flexible pipe material and internal beads in butt welded joints (see discussions in Section 5.1(a)). For the sake of simplifying design, frictional resistance of PE pipelines may be arbitrarily down-rated to have an overall Hazen Williams C = 120 to allow for secondary and minor losses. App A 4.0 PIPE ROUTE (a) (b) {e) All PE pipelines should be designed to be laid buried Pipe routes should avoid stream-crossings, laying above ground or supporting on structures. If these are unavoidable, a localised conversion to other pipe materials should be considered. Research on the fatigue response of PE pipes and fittings has indicated that generally PE pipes will not fail in a fatigue mode (unless damaged). The dynamic loads normally considered during operation are: + Internal cyclic loading e.g. surge associated with pumping regimes or the rapid closure of valves; « External cyclic loadings due to traffic conditions In general terms and for normal use, PE pipelines which are correctly laid, bedded and supported are capable of withstanding such imposed loadings. As pipe bedding is crucial for the PE pipel ines towithstandthecyclic loadings, the laying of PE pipeline in carriageway should follow the practice as stipulated in Section 7.4. Constraint in chemical resistance as stated in Section 2.3 (d) of this design guide should also be observed in selection of the routes for PE pipelines. 5.0 SELECTION OF JOINT TYPE 5.1 Types of Joint (a) (b) A general classification and sketches for types of joint used in polyethylene pipelines are in Appendix A. Joints are broadly classified into 3 main categories : fusion joints, mechanical joints and saddles. Experience from the UK shows that fusion joints, if properly made, give a much more trouble-free joint type than the mechanical joints and therefore should be adopted whenever possible. However, the internal beads resulting from butt fusion joint will seriously impede the flow inside pipes of sizes 63 and below and hence butt fusion joint is mainly for sizes 90 and above. For pipe sizes < 63, the most common joint type is mechanical joint. In addition, metal mechanical joint is more widely used than plastic mechanical joint. Only electro-fusion and socket fusion joints which do not create internal beads are employed. For sizes > 63, butt fusion welded joint (ec) (a) fe) -.- is the most common type and electro-fusion joint, though more expensive in the cost of the fittings, is gaining a large share of all the joints being made. Heat fusion joints are more reliable than mechanical joints The success of heat fusion joints, whether they are butt fusion or electro-fusion, depend on operator technique and if the joints are properly made, they will be more veliable than mechanical joints. As discussed in Section 2.2 (a) above, non-end-load-resistant mechanical jointswill easilyresult in leakage and pull-out under the thermal movement of polyethylene pipelines. For this reason, they should not be adopted normally. Mechanical jointing systems should be used for emergency repairs under a wet condition. Further uses of mechanical joints are given in Section 7.5(b). 5.2 Joint Type Selection for Various Sizes {a} The permitted jointing systems for PE pipelines shall be as follows For sizes < 63 1. End-load-resistant, mechanical (i) metal flanged joint and flange adaptor (44) collar type with a metal body and metal or rubber compression rings 2. Heat fusion (i) socket fusion (ii) electro-fusion 3. Heat fusion saddle For sizes > 63 1. End-load-resistant, mechanical (i). metal flanged joint and flange adaptor (i) collar type with a metal body and metal or rubber compression rings 2. Heat fusion App. B (b) -12- (i) butt fusion (with external debeading) (ii) electro-fusion 3. Heat fusion saddle Since joints for polyethylene pipelines are highly specialised (such as electro-fusion couplers) and are dependent on the manufacturers! design, the exact jointing details for all works contracts should be proposed by the Contractor for the agreement of the Engineer. Uponapproval, the Contractor shall procure all the necessary fittings (including quantities requested by the relevant Region for the maintenance of the pipeline in new works contracts) as set out in the BQ of the Contract. See consultation with the Operational Regions in Section 10.1. 5.3 Flange Joint (a) (b) (eo) For transition of PE pipe to metal flanges (say CI gate valve installation), the use of polyethylene stub/full faced flanges with metal backing ring is necessary. The transition can also be made by Viking Johnson flange adaptor for PEpipes (using theAqualock or Aquagripseries fittings) . Details of WJ flange adaptor are shown in Appendix B. For the former type of transition, the transition fitting is usually fusion welded onto the pipe and a metal mating flange (the backing ring) allows bolted connection to the metal flange. Both types of transition fittings are end-load resistant. When tightening bolts for polyethylene stub flanges, care should be taken to provide the torque loading evenly to the limits recommended by the manufacturer. Typical bolt torques are shown in Table 6. The table is extracted from the Manual for PE Pipe Systems for Water Supply Applications by the Water Research Centre. Table 6 Typical bolt torques Nominal PE | Equivalent Size of | No. of Torque Size (mm) | Metal Flange (mm) | Bolts Required (Nm) 63 50 4 35 90 80 8 35 125 100 8 35 180 150 8 60 250 250 12 100 ‘The fittings to be procured shall be specified to have one of the following protection coatings including: 6.0 6.2 App. ¢ App. D 6.2 (i) galvanising (ii) fusion bonded epoxy (444) Rilsan Nylon 11 Bolts and nuts shall be supplied with a coating compatible with the coating of the fitting. Options include galvanising to BS EN ISO 1461 or coated with fusion bonded epoxy or Rilsan Nylon 11. Ordinary black bolts protected by site applied zinc rich paint are not acceptable. As hydrocarbons will attack PE pipe, the use of petrolatum tape for corrosion protection will not be permitted. Given the small sizes of the pipe, protection by bituminous tape is not appropriate. FITTINGS INSTALLATION General Arrangement (a) (b) Typical installation details for various fittings for inclusion in a works contract are given in Appendix C. Common fittings shown in the appendix include isolation valves, air valves, hydrants, washout tees and service tees. Inthe industry, there are some proprietary products that can be used to provide alternatives to simplify the method of connect ion to suit some particular site conditions. Some examples are given in Appendix D for illustration. Connection details of other fittings such as bends, tapers (reducers), elbows, caps, collars (couplers) and the like shall be proposed by the Contractor as per the standard Part icular Specification given in later part of this design guide. For installation of waste detection meters and flowmeters, please refer to Section 7.7. Installation Details fa) Sectional and isolation valve Sizes of sectional and isolation valves and stopcocks for PE distribution and service mains shall be as shown in Table 7. (b) Table 7 Sizes of sectional and isolation valve and stopcock Equivalent Size of Valve Size of | Size of Pipe PE Pipe | (GI or DI) Brass Copper CI Gate Stopcock | Alloy Gate | Valve valve 20 15 15* - - 32 25 25 25* - 50 40 40 40* - 63 50 50 50* - 80 80 - 80 - 125 100 - 100 100* 180 150 - - 150 250 200 - - 200 315 250 - - 250 * Preferred options Brass stopcocks and copper alloy gate valves can be installed by means of a pair of mechanical couplers (with locking nuts, compressible rings and metal inserts) suitable for connection to Rp internal threads to BS 21. Replacement of valves will be similar to that for uPVC pipelines. CI gate valves should be installed by means of PE pupped flange adaptors (i.e. spigot of the fitting is of the same Das the connecting pipe) on the upstream side and VJ Aquagrip series flange adaptors on the downstream side. The pupped flange adaptor is for butt or electro-fusion jointed with the pipe or with a pupped branch of a tee. Details can be found in Appendix Cc. All sectional and isolation valves shall be firmly secured in position to prevent over-stressing of the connecting pipe during valve operation. Air valve For size < 90, double air valves (DAV) are not normally installed. When installing DAV for PE pipe > 90, due to the overall size and weight of the DAV, consideration should be given to convert the pipe to other pipe materials such as DI before branching out for DAV connection. (c) (a) fe) Cae When installing single air valve (SAV) for pipe sizes > 90, a PE branch flanged tee with metal backing ring drilled to’ PN16 should be positioned upright for connection to a PN16 DI blank flange onto which the extension piece of the SAV is fixed. Standard size for the flanged tee and blank flange shall be DN 80 and drilling to BS 4504 PN 16. For pipe size < 63, a special 90° tee with threaded male offtake can be used for direct connection with the SAV extension piece. Hydrants Given the size of PE pipe under trial, pedestal hydrant should rarely be needed. If GI swan neck hydrants are required, the section of pipe downstream of the control copper alloy gate valve should be converted back to conventional pipe material and adopt the installation details as shown in the Manual of Mainlaying Practice. Similar practice should be adopted for pedestal hydrant if required in large sizes PE pipelines. Washout, Since the quantity of water to be discharged will be small under normal drain-down of pipe or emergency repair, washout, pipes should be direct ly discharged to natural stream course (if arrangement agreed by relevant authorities) or to pump pits for subsequent discharge. In view of the lack of local experience on the reliability of PE pipelines, direct connection to public storm drain isnot recommended because with such a connect ion any leakage as a consequence of joints or fittings failure may not. be easily noticeable. Service tee Service tees are normally tapped from the distribution mains by heat fusion saddles. The soil surrounding the pipe and the saddle shall be fully hand compacted soil backfill which shall provide sufficient anchorage for the thrust acted on the saddle. An isolation valve shall be installed in a short distance about 1 to 1.5 metres away from the saddle. 7.0 Ta PIPELINE DESIGN Cover to Pipe (a) (b) Although PE pipe is flexible, it is sufficiently sturdy to withstand normal backfill loads and any ordinary live load that may be present on top of the soil cover. Research in the UK has been conducted to explore the possibility of laying PE pipe at a depth of 600 mmto pipe crown. Such depth is, however, not supported in the UK in consideration of freezing in winter times, deep ploughing, and byelaws for water supply. As these considerations are not applicable to Hong Kong, recommendations in Section 1.9.4 in Vol II of the Design Manual regarding cover to pipe should be followed. I£ pipe cover in carriageway (see note below) is less than 600 mm, the pipe (including fittings) should be protected by concrete surround. Before concreting, the pipe and fittings should be wrapped with a layer of heavy duty polythene sheet to avoid possible damage during pouring and compact ion and to prevent high localised stresses during concrete hardening. The pipe should also be securely fixed onto the pipe trench toprevent floatation during concreting. Trial Pits and Inspection Pits Besides the recommendations in Section 1.9.2 of Vol II of the Design Manual, inspection pits should also be used to confirm the absence of peat or other contaminated soils which should be removed if present and be replaced by clean backfill. If the level of ground water table is high, granular bedding should be used. Public Utilities (a) (b) (c) Colour of PE pipelines shall be of the standard blue colour to distinguish them from the yellow PE gas pipes which have been installed in Hong Kong commencing from 1987. The colour of blue PE pipe is very similar to that of street lighting cable which is about 30 mm in size and laid in a depth of 450mm to 600mm from the pavement surface. Therefore, small size PE pipelines in footpath at shallow depth must be laid with identification tapes. All other utility undertakings should be advised that prior = 47 = approval must be obtained from WSD before encasing WSD's PE water main with concrete and that if approval is given, the water main should be wrapped with a layer of heavy duty polythene sheet before concreting. 7.4 Trenching, Backfilling, Bedding, Haunching and Surround (a) (b) (c) (d) (e) As PE pipes can be jointed on ground surface and lowered into the trench bottom afterwards, width of trench can be as narrow as practicable. Narrow trenching techniques using specialist equipment are being developed and assessed in the UK. A figure of 250 mm plus the outside diameter of the pipe has been recommended in the UK to be the minimum trench width for straight pipe section. However, the trench width must be such so as to allow proper compaction of the backfill. Recommended trench widths for PE pipe in this design guide are shown in Table 8 below : Table 8 Trench widths for PE pipe Pipe size Depth to pipe invert in mm 63 or below| 90 - 125 | 180 or above Not exceeding 350 450 OD plus 350 $00 Exceeding 500 600 OD plus 500 900 Non-cohesive soils, such as CDG or CDV, which are free from sharp stone and the like are suitable materials for backfilling. If material excavated from the trench is unsuitable, import fills including 10 mm single-sized aggregate and coarse sand are acceptable. PE pipes can be laid directly on trimmed trench bottom. Bricks or other hard materials should not be placed under the pipe as temporary support. In wet or soft ground, or where the trench bottom is hard and irregular, a minimum 100 mm thick granular bedding should be used. Granular bedding will be easier to be laid together with the light-weight PE pipe than concrete bedding and therefore should be adopted wherever possible. Top 300 mm thick of the backfill material should be compacted in accordance with the GS. (£) Concrete surround should be provided in accordance with Section 7.1 (b) and at crossings with other utilities whose settlement may induce unduly high stresses in the PE pipe. 7.5 Pipes Protruding from Structures (a) Special precautions should be taken where the PE pipe passes through structures. The details of pipe through wall vary according to the various design considerations: (i) need for watertightness (ii) load transfer from pipe to structure (144) effect of RIGID connect ion between pipe and structure (such as cast-in construction) on stresses of the pipe. (iv) differential settlement. (b) Typical designs to cope with the above situations are shown in Figure 4a to Figure 4c below. WALL EXPANDING GROUT SPECIAL FABRICATED PIPE SECTION W/OD. GROOVES. DRISCOPIPE Figure 4a Grouted in Wall MOLDED ‘STUB END DRISCOPIPE HDPE SPOOL ~OR- METAL SPOOL ‘GROOVED INTOWALL. METAL FLANGE BOLTED TOASA FLANGE ON SPOOL, Figure 4b Puddle Connection Figure 4c Rigid Connection Pipelines Protruding From structures Figure 4a is suitable for simple "wall passing" where none of the considerations in Sub-section (a) above are needed to be taken into account. To tackle with factor (i), or (ii) or a combination of both factors, details in Figure 4bmaybe adopted. Ifwatertightness is required, the puddle unit should be made of metal since thermal movement of (e) = Ot PE is comparat ively large andwatert ightnessmay be impaired. Where undue stresses on the pipe at a rigid connection is envisaged, details as shown on Figure 4c can be adopted. The coupling to be used can be Viking Johnson Aqualock series (for sizes 63 to 180) and Aquagrip series (for sizes 180 and above) which is specifically for PE pipes and for connection between PE pipes and other pipe materials. Where differential settlement may occur, the pipe flexibility should NOT be relied upon to withstand the bending and shear stresses that have been resulted. A pair of Viking Johnson couplings should be included to absorb the anticipated differential settlement . 7.6 Thrust Blocks (a) (b) {c) (a) The design guidelines in Section 1.9.9 of Vol II of the Design Manual and Guidance Note on the Design of Thrust Blocks for Buried Pipelines should generally be followed except the points raised in (b) to (d) below. As PE pipes shall be heat fusion jointed or mechanically jointed with end-load resistance, the design of thrust block should follow the procedures similar to those for steel pipelines where joint continuity is assumed to take half of the thrust. For buried PE pipe size 90 and under which is subject to a working pressure of 8 bars or less, thrust blocks for all bends which are less than 45° are not required. This recommendation is in line with mainlaying practice in the UK where thrust blocks for pipelines having continuity is not normally required. one-sixth of the passive resistance at the back of thrust blocks is permitted to be mobilised to resist thrust at the working condition. The rationale is that under normal circumstances when the pipe is exposed by a second-comer, the blocks should have been adequately supported/strutted. If a block and the connecting pipe are exposed without any support/strutting, the flexible pipe itself will highly be susceptible to bulging out. Failure would rarely be due to movement of the block alone. There is not much literature on the behaviour of PE pipelines under surgecondition, Transient rapid increase in internal pressure of a pipeline will occur as a result of sudden Change in the flow due to closure of a valve or pump shutdown. As water is incompressible, the change in momentum of the water inside a pipeline will directly be absorbed by the pipeline including of course any pressure relieving devices. PE iteelf is flexible and it is believed that a major portion of the change in momentum would be absorbed by a slight circumferential dilation of the pipe and/or elongation of the pipeline. As a result, the rise in pressure under = ait 4 surge should not be great. For checking thrust block stability under testing condition, surge pressure can be neglected. An FOS of 1.1 against sliding at 1.5 times the maximum working pressure would be the sufficient condition at testing. (e) Heavy duty polythene sheeting shall be used for PE pipes being encased in concrete thrust blocks to relieve stress concentration due to expansion or irregular concrete surfaces. A minimum overall membrane thickness of 3 mm is recommended. In order to avoid possible damage during pouring or compaction and to minimize local stress, the membrane should extend by a minimum of 100 mm from the edge of the concrete encasing. Waste Detection Meter and Flowmeter Installation (a) Where waste detection meters are required ina PE pipeline, consideration should be given to convert the pipeline to other appropriate pipe materials before entering and leaving the waste detection meter chambers. (b) Exact requirements on waste detection and waste detection meter installation should be discussed with and agreed by the Leakage Management Section of the Development (1) Division. (c) Similarly when flowmeter are required, the pipe should be converted to other appropriate pipe materials before entering and leaving the flowmeter chambers. Swabbing Like other plastic pipe materials, the internal surface of PE pipe is smooth and collection or accumulation of dirt inside the pipe is not likely. Therefore, swabbing should normally not be required for new PE pipelines. In the case where swabbing is considered necessary for larger size mains of 125 and above, swabs inthe formof soft "pigs" shouldbeemployed. Hard"bullets" swabs may scrape the internal surface and damage the internal beads of the butt fusion joints and so they must not be used. Squeeze-off Closure (a) The ductility and toughness of PE enable the flow in a pipe to be stopped by "squeezing of £" using special equipment ina way that can be applied to a rubber hose. On releasing the pressure, the PE pipe will eventually return to its - 22 - original condition and, as stated in published literature, the subsequent pressure rating of the pipe is unaffected. However, more researches are required toassess the potential damage to the pipe by the squeeze-off operation. (b) For the time being, the squeeze-off operation should not be allowed in both construction stage (probably proposed by the Contractor to facilitate hydraulic testing) and during maintenance by the Region for emergency closure or isolation for tapping tees. CONTRACTOR'S PROPOSAL Supply and Lay Arrangement PE pipes and fittings are based on advanced plastics technology and there has been a lot of different designs in the market. With the introduction of BS EN 12201 and relevant Water Industry specifications, manufacture of PE pipes is largely unified though there are considerable differences in the design of fittings in particular the mechanical joints and saddles. Fittings and pipes from different manufacturers may not be suitable for direct jointing by heat fusion. Moreover, the making of a fusion joint requires special expensive equipment. Nevertheless, these problems can be alleviated by the supply and lay arrangement. Jointing Details (a) As mainlaying contracts for PE pipelines will be in the supply and lay form, the alignment plan and longitudinal profile of the proposed mains should only provide the general information in respect of level, bedding type, location of fittings and broad type of fittings used as given in Section5.2(a). For VJ type couplings and flange adaptors, the phrase such as "Viking Johnson Aqualock (or Aquagrip as appropriate) coupling/flange adaptor or equivalent" should be used. (b) To facilitate maintenance, standard pipes and fittings, and mechanical joints should be maintained by the Regions for emergency use. 9.2 10.0 10.1 Ea: PRESSURE TESTING AND COMMISSIONING Pressure testing Pressure testing procedure for general pipelines is specified in Clause 11.3.3 of BS EN 805:2000 except those pipelines with visco-elastic (creep) behaviour. Since polyethylene pipeline is one of this kind, it is treated as a special case. The special pressure testing procedure for polyethylene pipeline as given in Appendix A.27 of BS EN 805:2000 should be adopted. Commissioning of PE Pipeline (a) The commissioning of anewor repaired PEpipeline isnormally carried out in the following sequence: (i) cleaning or swabbing if necessary (ii) sterilisation (iii) refilling the main (iv) bacteriological sampling (v) introduction to service {b) It should be noted that PE is not resistant to attack by liguid chlorine as chlorine and its free ions are strong oxidisers. Therefore, caution should be taken when sterilising the pipe to avoid leaving too long the solid chloride of lime in the wet pipe before refilling. A satisfactory way of introducing the sterilising chemical is to dose the water in the pipeline with a homogeneous solution having free chlorine strictly in accordance with Gs Clause 22.73(2). The Contractor shall be required to propose the way of introducing the chemical into the pipeline for the approval of the Engineer. Such method shall meet the above requirements and at the same time causing no health hazard to the labour. DESIGN CONSULTATION Apart from the liaison work as stated in Section 11 of vol I of the Design Manual, all in-house circulations and consultations should highlight to the addressees! attention that the proposed pipework is of PE. In addition, Sub-sections 10.1 and 10.2 below should be observed. Operational Regions (a) Operational Region's view should be sought with respect to any specific requirement relating to the maintenance of the pipeline. (b) a= Moreover, as PE pipe will be used in secondary distribution mains and service mains for connection to consumers, the relevant Region should be requested to provide details of the required tees and connections such as locations, levels of connecting service mains (to be confirmed by inspection pits), material and proposed joint type and pipe material for connection. 10.2 Training 11.0 Training Unit of the Department should be informed of the programme of the contract so that prior training to relevant staff, in particular the supervisory staff, may be provided if necessary. In addition, training opportunities arising from the mainlaying works, such as site visits and hands-on demonstrations can be identified and can be arranged for other staff of the Department. FEEDBACK AND REVIEW fa) (b) This document should be reviewed and updated regularly where necessary in the light of experience gained in Hong Kong and technological development of PE pipe in the world. To facilitate the review, all feedback on the use of this design guide should be addressed to Chief Engineer/Design, Water Supplies Department for collation and evaluation. Information on all but not limited to the following aspects will be most useful «@ cost (ii) trenching, compacting, bedding and haunching (441) jointing system (iv) hydraulic testing w) training and supervision (vi) chemical attack (vii) temperature effect (viii) termite attack (ix) operation and maintenance (x) failure and its cause (xi) time requirement for the supply and lay of PE pipes 10. REFERENCES: BS 4504 - Circular flanges for pipes, valves and fittings (PN designated) BS EN 805:2000 - Water supply - Requirements for systems and components outside buildings BS EN ISO 1461:1999 - Hot dip galvanized coatings on fabricated iron and steel articles. Specifications and test methods BS _EN 12201-1:2003 - Plastics piping systems for water supply - Polyethylene (PE) Part 1: General BS EN 12201-2:2003 - Plastics piping systems for water supply - Polyethylene (PE) Part 2: Pipes BS EN 12201-3:2003 ~ Plastics piping systems for water supply - Polyethylene (PE) - Part 3: Fittings BS EN 12201-4:2003 - Plastics piping systems for water supply - Polyethylene (PE) Part 4: Valves BS EN 12201-5:2003 - Plastics piping systems for water supply - Polyethylene (PE) - Part 5: Fitness for purpose of the system ISO TR 9080 - Plastics piping and ducting systems ~ Determination of the long-termhydrostatic strength of thermoplastics materials in pipe form by extrapolation Water Industry Specification No. 4-32-02, Specification for polyethylene pressure pipe for cold potable water (underground) , Issue 3, Aug 88, WRc publication. ql 12. 13. 14 1s. 16 17. 18. 19. 26 - Water Industry Specification No. 4-32-03, Specification for blue polyethylene (PE) pressure pipe for cold potable water (nominal sizes 90-1000 underground or protected) , Plus Amendment , Jul 89, Issue 3, May 87, WRc publication. Water Industry Specification No. 4-32-04, Specification for polyethylene socket & spigot fittings, saddles and drawn bends for _use with cold potable water PE pressure pipes, Issue 2, Dec 88, WRc Publication. Water Industry Specification No. 4-32-06, Specification for PE electrofusion couplers & fittings for cold water supply for nominal sizes up to and including 180, Issue 1, Sept 89, WRe Publication. Water Industry Specification No. 4-32-08, Specification for site fusion jointing of MDPE pipe and fittings, Plus Amendment, Nov 88, Issue 1, Aug 88, WRc publication. Water Industry Specification No. 4-24-01, Specification for mechanical fittings and joints including flange for PE pipes for the conveyance of cold potable water for the size range 90 = 1000 made of metal or plastics or a combination of both, Issue 1, Apr 91, WRe publication. General information on the use of different types of corrosion resistant pipe materials as inside service in building, WSD, June 2000. Study on the use of polyethylene (PE) pipes for conveying salt water, Research & Development Section, Regional Administration Division, WSD, December 2000. Technical paper 1 - Application of larger size PH pipe, Agreement No. CE 6/2001 : Replacement and Rehabilitation of Water Mains Stage 1 Phase 18 Package 1 - Hong Kong and Islands - Design and Construction, Maunsell-Scott Wilson Joint Venture. Report on Concrete Encasement of Polyethylene Pipework, Contract No. 24/WSD/02 - Replacement and Rehabilitation of Water Mains Stage 1 Phase 1 - Mains in Kowloon City, San Po Kong and Wong Tai Sin, MWH-Atkins China Joint Venture 20 21. 22. 27 - Report on Concrete Encasement of Polyethylene Pipework, Contract No. 24/wSD/02 - Replacement and Rehabilitation of Water Mains Stage 1 Phase 1 - Mains in Kowloon City, San Po Kong and Wong Tai Sin, MWH-Atkins China Joint Venture. R. Hopman and T.J.J. vanden Hoven (1992), Permeation of organic chemicals through plastic water pipes, AQUA Vol. 41, No. 3, pp. 158 - 162. T. Nakamura, et al. (1985), Practical applications of nylon-jacketedtermite-resistant power cables, Sumitomo Electric Technical Review, No 24, Jan 85, pp. 91 - 99. Appendix A Classification of Joint Types Compression Ring Appendix A Appendix a Page 2 of 5 Socket fusion tee Butt fusion tee Ul Socket fusion coupler Ez i | Electro-fusion socket and spigot tee Spigot tee with electro-fusion coupler ato Appendix A Page 3 of 5 Completion sleeve Mechanical flange fi —, Socket fusion flange Butt fusion flange =e Electro-fusion flange Appendix A page 4 of 5 Cone Reducing Bush . Nut Fitting End Washer [\;— RE. Tube Detail of joint using a metal compression cone and liner Elastomeric compression ring Seer Detail of joint using an elastomeric compression ring and liner Insert 'O' ring SFAB Ting Body Detail of joint using grab ring and liner Appendix A Page 5 of 5 A iia Plastics saddle for electro-fusion with self-tapping ferrule ‘Anchor for antishear Plastics saddle for saddle fusion with self-tapping ferrule Appendix B Wo Flange Adaptor for PE Pipe Overview Mar ar Seeds ae Te for a simple, high performance’ ‘mechanical method of jointing Ce eat een ee eee and grip PE pipe to prevent pipe collapse and pullout Or See es Cor eatey Eee teas ee tae Skeeter eens] eee kets Sea} tent ei Ce LE Seed Sor ties feet are ‘even under wate Pome ee eet Saeed rs er ements eed SCs eo eet ete pee eat Sector ee eee pressure capabilities of MDPE (PEBO) and HPPE (PELOO} pipe. Roca) ~ Rilsars Nyion coated flange bady and clamp bands (other coatings Pers ts aA ea nae) ieee cad ee Sr a Rete ects rece ea eee aes Padediete eae eas Derr - AquaGrip™ sizes up to and including ance ‘oseToR 800 Lightweight, compact design + Easter handing, quicker installation, Slip-on coupling “Without centra stop or obstruction making it easier to effect repairs to existing pipelines. + No need to dismantle products to install them, ‘Same size bolt throughout range (up to 180mm) * Cary just one spannerfwrench forall pe sizes, End load bearing (up to 180mm) + Flange adaptors and straight couplings designed to the full Type 1 pertormance requirements of WIS 4-24-01, Axial pipe adjustment Substantial axial pipe adjustment up to ‘50mm - ideal for making pipe insertions, vate insertions, etc, into existing lines. No need for precise cutting of the pipes ‘or machined pipe ends. exo rN cnureer tes casner AquaGrip™ Flange Adaptor 80mm cruPPce uns casner Approvals. Approved by the UK Water Regulations "Advisory Scheme. Versatile range available st + Stalgnt couplings for simple, convene» repairs, or new lay connections. + Flange adaptors to introduce valves and flanged fitings or connect to existing fianged pipowork + Transton joints to connect PE pipe to ther pipe materials + Supplied complete v liners for PE pipes. centre SLEBE ours, us, AND WASHERS r AquaGrip Flange Adaptor (Ops can enable downsizing of ‘expensive valves and fitings Connect to other types of pipe via flange connection or replace damaged pipe lengths with new pipe + Introduce flanged ftings, such as metal valves, into a polyethylene pipeline. Tackle problems of misshapen polyethylene pine ends, For structural lining use in conjunction with mains refurbishment techniques such as Swage-Line* RollDawn® and Die Draw, Positive gripping mechanism * Uniquely designed clamp bands lock onto the anchoring shoulder, providing maximum end restraint. (ype 1 performance to WIS 4-24-01 Up to and inciuding 450mm SDR 11). Reduce valve and fitting costs + AquaGrip Is available with reduced bore flanges which can help you reduce valve fitting costs eg: 315mm pipe OD x 250mm flange, ‘500mm pipe OD x 450mm flange. Generous cutting tolerance + Can compensate for cutting inaccurecy (4omm minimum tolerance). Performance criteria + UK Water Regulations Advisory Scheme approved and designed to meet the performance requirements of Wis 4-24-01. (Type 1 up to 450mm SOR 11, other sizes minimum Type 2). AquaGrip sver 225mm al larger TOLERANE — anewoa avcHoRING Ws ance ADAeToR 800% INcosPoRarins PRPEUNER For non-structural lining ask for details of Viking Johnson LinerGrip, designed to offer a flanged termination to PE lined metal pipe. Bespoke items can be produced for special applications eg. underwater installations. Ask our Technical Support Department for information. Appendix ¢ Typical Details of Fittings Installation COPPER ALLOY CATE VALVE FE PIPE PE pipe Ee = JUNO MALE a OR EQUIVALENT FOR PIPE SIZE 90 AND BELOW MATING FLANGE (BACKING RING ) ELECTRO-FUSION CU GATE\ VALVE COUPLER PE PIPE PE FLANGE tug PRE AQUALOCK FLANGE ADAPTOR OR EQUIVALENT (BUTT FUSION or ‘DAPTOR OR EQUIVALE! ELECTRO-FUSION JOINTED TO” PE PIPE ) FOR PIPE SIZE 125 TUR PIPE SIZE 125 PE FLANGE ‘STUB PIPE FLANGE |” ADAPTOR OR EQUIVALENT FOR PIPE SIZE 180 AND ABOVE TYPICAL INSTALLATION DETAILS FOR GATE VALVES NBO COPPER ALLOY GATE VALVE J PE PIPE, GJ. LONGSCREW — eed : Cc BUTE INSTALLATION OF SWAN NECK HYDRANTS DN25 SAY. + STOPCOCK VARIES 4, To sur ON 80 DJ, BLANK FLANGE nae DRILLED AND TAPPED AT CENTRE WITH Rp1, 8821 THREADS PE PIPE a eo TYPICAL 1 10 15m HEAT FUSION’ SADOLE FULLY COUPACTED SO. BACKALL Z PE DISTRIBUTION MAIN’ INSTALLATION DETAILS FOR S.A.V. COPPER ALLOY GATE VALVE TYPICAL DETAILS OF TAPPING SERVICE TEE — SN TO CONSUMER CONNECTION Appendix D Examples of Methods of Connection using Proprietary Products (for Illustration only) * Howle Flange Adaptor KLEYA. Telescopic Sistem 2000 r . We ise Blsnantie Flange @estran) ye = 7 ¢ I tt ) DETAIL 1 — - 1a PE-Dl Pipe Connection C c= ' 14 al) 7 PE Main Pipe DI Main Pipe — * Hane €2-Elyps0 Gate Valve Flanged Enals x Hayle Flange Adaptor Gate Valve Systen 2000 Nr 0400 Ne. 4000¢2/4700c2 Restraint) AL. Hawle-A Valves No. 40008 1 nq a perat_2 PE-Gate Valve a Conne=tion| Q ry ia ae eee: ee PE Main Pipe: ry PE Main Pipe Howie Flange Adaptor Systen 2000 Nr. 0400 Gestraind ml Os PE Main Pipe “PE End Cap xHowle Flange Adaptor Systen 2000 Nr. 0400 (Restraint) Notes 1. All DI pipework shown has sane DN as the adjacent PE pizework. 2. All DI fittings shall be in strict accordance with PS Appensix 18

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