Webinar on PDN

Pipe Specifications & Quality

Control

Presented by
Shri. R. R. Shah
(Mobile No. 9850571279)
Chief Engineer (Civil) HP & QC, Pune.
Date- 8th May 2020
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Bodwad LIS
 PDN Need

 To increase water use efficiency by 20% (Central Government

mandate)
 MWRRA ordinance, 2015 mandates irrigation of perennial
crops by micro-irrigation methods.
 Maharashtra : CCA-225 lakh Ha.
: Area that can be brought under irrigation by
available water (Surface + Ground) is
126 lakh Ha (85+41) (56% of CCA)
 To bring more area under irrigation with available water
 To avoid exorbitant cost of land acquisition.

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Various types of pipes commonly used in PDN

HDPE PVC, PVC-O

SWSRP

GRP
PCCP
PSC

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BWSC
MS DI
 Pipe description
Pipe type Description
HDPE pipe is a flexible plastic pipe made up of HDPE material i.e. polyethylene
HDPE thermoplastic made from petroleum. HDPE has high level of impermeability,
strong molecular bond, toughness and resistant to corrosion and chemicals.
The Spirally Wound Steel Reinforced Pipes (SWSRP) are structured wall pipes
SWSRP comprising of an HDPE inner smooth layer, spiral steel skeleton and outer
corrugated profile of HDPE.
Polyvinyl Chloride (PVC) pipes are made by a continuous extrusion process.
These pipes are supplied with plain or with socket-ends.
PVC,
Manufacturing of PVC-O involves process of controlled circumferential & axial
PVC-O
orientation of molecular structure resulting in formation of laminar structure of
the material used in the pipe construction.
Glass fibre reinforced Plastic (GRP) pipe is a machine made tubular pipe
GRP containing glass fibre reinforcements embedded in or surrounded by cured
thermosetting resin.
Mild steel (MS) Pipes can be manufactured from mild steel produced by the
MS open hearth or electric furnace or one of the basic oxygen processes.

Ductile iron (DI) pipes are manufactured from ductile iron. Ductile iron is a type of
DI iron in which graphite is present primarily in spherical or nodular form.
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 Pipe description (contd)
Pipe
Description
type
Prestressed Concrete Non-Cylinder Pipe (PSC) is suitably compacted concrete core
longitudinally prestressed with pretensioned high tensile steel wire embedded in
PSC
the concrete, circumferentially prestressed and coated with cement mortar or
concrete.
Prestressed Concrete Cylinder Pipe (PCCP) comprises of a welded sheet steel
PCCP cylinder with steel socket and spigot rings welded to its ends, lined with concrete
suitably compacted and circumferentially prestressed.
Bar/Wire wrapped steel cylinder (BWSC) pipe comprises of a welded steel sheet
BWSC cylinder with steel socket & spigot rings welded to its ends, lined with centrifugally
applied cement mortar within the steel cylinder.

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 Selection of pipe type for PDN
 Depends on :-
 Design Discharge.
 Pipe diameter.
 Internal Pressure.
 External Loads.
 Life of pipe.
 Cost of pipe.
 Ease in handling, transportation & storage
 Ease in laying & jointing
 Ease in maintenance & repairs.
 Durability.
 Life Cycle Analysis
 C.E. is competent authority to finalize pipe type
(As per GR dated 02/02/2017)
 Pipe thickness needs to be designed based on internal hydrostatic pressure
and external overburden, based on actual site conditions. 7

 Specials to be manufactured & supplied by pipe manufacturer.

 Basis for pipe specifications
 PDN Policy GR dated 13/01/2017
 PDN Guidelines Circular dated 02/02/2017
 Guidelines for planning & design of piped irrigation network,
July- 2017 (Published by CWC)
 Pipe distribution System for irrigation, Sept.-1998 (Published by
Indian National Committee on Irrigation & Drainage, INCID)
 Various Indian Standard Codes (About 70)
 Inputs gathered by QC team during visit to PDN works in Gujarat
during May-2018 (Arranged by WALMI, Gujarat)

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Main aspects covered in Pipe specification
 Applicable IS Codes
 Raw Materials
 Sampling Criteria for Selection of Pipes for Testing
 Pre Delivery Testing of Pipes in factory
 Marking on Pipes
 Transportation & Stacking at site of Pipes
 Laying & Jointing of Pipes
 Field Hydraulic Testing of Pipeline System
 Backfilling of Pipe Trenches
 Operation, Maintenance and Handing over of PDN system to WUA

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 Applicable codes
Pipe type Applicable Codes
IS 4984, ISO 4427, IS 8360, IS 8008, IS 7634 (Part-II), IS 7328, IS 2530, IS 10141, IS 9845 &
HDPE IS 10146

SWSRP IS 2530, IS 7328, IS 12235 (Part-6), IS 12235 (Part-9), IS 16098 (Part-1), IS 16098 (Part-2)

PVC, PVC-O IS 4985,IS 4669, IS 10151, IS 12235, IS 7634 (Part-3) , IS 5382, IS 16462, IS 16647

PCCP IS 784, IS 783, IS 3597, IS 1785 (Part 1&2), IS 383, IS 1566, IS 2062 & IS 7322

PSC IS 784, IS 783, IS 3597, IS 1785 (Part1&2), IS 383, IS 1566, IS 2062 & IS 5382

BWSC IS 15155, IS 7322, IS 783, IS 3597, IS 1566, IS 2062, IS 383 & IS 432 (Part 1&2)

GRP IS 12709, IS 13916, IS 14402, IS 11273, IS 11320, IS 11551 & IS 5382

IS 3589, IS 5822, IS 4711, IS 2062, IS 814, IS 3613, IS 456, IS 800, IS 816, IS 4353, IS 1182,
MS IS 2595 & IS 4853
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DI IS 8329, IS 9523, IS 12288, IS 11606, IS 5382, IS 638, IS 1608 & IS 1500
 Pipe classification

Pipe type Pipe classification

Based on material: PE63, PE80, PE100
HDPE
Based on pressure: PN2.5, PN4, PN6, PN10, PN12.5, PN16
PVC Based on pressure: Class1, Class2, Class3, Class4, Class5, Class6
Based on pressure: PN3, PN6, PN9, PN12, PN15
GRP
Based on stiffness: A, B, C, D
Based on manufacturing method: S, ERW, SAW
MS
Based on steel grade: Fe330, Fe410, Fe450

DI Based on service condition: K7, K8, K9, K10, K11, K12

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 Raw materials
Pipe type Raw Materials
HDPE Polyethylene.(PE63,PE80 & PE100 Grade)

SWSRP Polyethylene, Steel plate.

PVC, PVC-O Polyvinyl chloride resin.

PCCP Cement, Aggregate, Water, Admixtures, Steel Reinforcement & Steel Plates.

PSC Cement, Aggregate, Water, Admixtures, Steel wires & Steel for Specials.

BWSC Cement, Aggregate, Water, Admixtures, Steel Reinforcement & Steel Plates.

GRP Resin, Glass fibre reinforcement, Aggregate, Filler & Additives.

MS Steel Plates, Welding consumables, Cement, Aggregate, Water & Admixtures.

DI Ductile Iron

• Test certificate of raw materials used for pipe manufacturing shall be obtained.
• Manufacturer’s own rework material (generally upto 10%) is permissible. No other reworked or
recycled material shall be used in pipe manufacturing. 12
Sampling criteria for selection of pipe for testing purpose

 Different for each pipe type

 Different for various tests
 Sample size depends on lot size
 Lot: All pipes of - Same size,
- Same pressure rating,
- Same grade,
- Manufactured under similar
conditions of manufacture.
 Test samples shall be selected at random from the lot.
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Scale of sampling for visual and dimensional requirement of HDPE Pipe
(As per IS 4984: 1995)

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 Pre-delivery testing of pipes in factory
HDPE
 Dimension: (OD, t, L)
 Visual appearance
 Internal pressure creep
rupture test
 Reversion test
 Overall migration test
 Density
 Melt flow rate (MFR)
 Carbon black content and
dispersion
SWSRP
 Dimension: (OD, t, L)
 Visual appearance
 Colour of finished pipe
 Resistance to heating
 Mechanical characteristics
 Ring stiffness
 Impact strength
 Ring flexibility
 Creep ratio
PVC, PVC-O
 Dimensions : (OD, t, L)
 Visual appearance
 Opacity, Colour
 Effect on water
 Reversion test
 Vicat’s Softening Test
 Density
 Sulphated ash content test
 Resistant to external
blows at 0°C
 Internal hydrostatic
pressure test
 Ring Stiffness
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Pre-delivery testing of pipes in factory (contd.)
PSC
 Dimensions : (ID, t, L)
 Straightness & finish
 Hydrostatic Factory Test
 Permeability Test on
Coating
 Mortar soundness test
PCCP
 Dimensions: (ID, t, L)
 Straightness & finish
 Hydrostatic Factory Test
 Permeability Test on
Coating
 Mortar soundness test
 Steel Cylinder Test.
BWSC
 Dimensions: (ID, t, L)
 Straightness & finish
 Hydrostatic Factory Test
 Permeability Test on
Coating
 Mortar soundness test
 Steel cylinder test
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Pre-delivery testing of pipes in factory (contd.)
GRP DI MS

 Dimension: (ID, OD, t, L)  Dimension: (OD, t, L)  Dimensions: (OD, t)

 Workmanship
 Pipe Stiffness
 Hydraulic test
 Longitudinal Strength Test
 Hoop Tensile Strength Test
 Tests to establish potability
of water
 Ovality, deviation from
straight line.
 Tensile test
 Brinell hardness test
 Hydraulic test
 Ovality & straightness.
 Tensile strength
 Flattening test
 Guided bend test
 Hydraulic pressure test

 These tests shall be carried out in factory in the presence of Engineer’s

representative and third party agency. Some tests be carried out in presence
of QC Engineer.
 After delivery of pipes to site, some of these tests can again be carried out on
any pipe selected randomly as confirmation.
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 Test results shall always be maintained at site.
 Third party inspection agencies
 Engineers India Limited, Mumbai
 RITES (Rail India Technical Economics Services) Mumbai
 SGS, Mumbai
 VJTI, Mumbai
 VNIT (Visvesvaraya National Institute of Technology), Nagpur
 CWPRS (Central Water & Power Research Station), Pune
 CIPET (Central Institute of Plastics Engineering & Technology)

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Sample of third party inspection certificate

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Sample of third party inspection certificate (contd.)

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 Marking on pipes

 Manufacturer’s name, trademark.

 Details of raw material (e.g. Grade)
 Pressure rating.
 Nominal diameter.
 Lot No / Batch No.
 Month of manufacture.
 BIS certification mark.
 Third party certification mark.
 Name of the project.
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 Any other details (desired by Engineer)
 Transportation of pipes

 Use flat bedded vehicle.

 The pipes shall rest uniformly in the vehicle.
 One type of pipes in one vehicle.
 Pipes shall be secured effectively during transportation.
 Loading/Unloading shall be done by mechanical means.
 Padding shall be provided between coated pipes.
 In case of coated pipes, extra care shall be taken to
preserve the coating while transportation.

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 Stacking of pipes
 Stacking area shall be reasonably flat, free from sharp objects,
stones or projections likely to deform or damage the pipe.
 Pipes shall be supported evenly over entire length.
 Pipes of different diameters & different pressure classes should
preferably be stacked separately.
 While stacking in layers, proper precaution for supporting the
pipes needs to be taken.
 Rolling down of stacked pipes must be avoided.
 Dragging pipes over rough ground should be avoided.
 If pipes have been telescoped for transportation (eg.PVC), the
inner pipes should be removed first & stacked separately.
 Rubber rings, Gaskets and other jointing/fitting items shall be
stored in a cool, dry and dark place to avoid any damage.
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 Pipe laying
 Murum bedding of 150 mm under the pipe (with watering &
compaction) is preferable to provide firm, stable and uniform support
for full length of pipeline
 For rocky area, sand bedding is preferable
 Trench bottom finished levels (after bedding) shall be as per design
 For murum bedding, OK Card by field dy engr shall be issued
 Laying shall preferably be done by mechanical means
 Each pipe shall be thoroughly checked for any damage before laying
 Various appurtences as per design shall be provided while laying
(eg. Thrust block, anchor block, sluice valve, scour valve, air valve etc)

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 Pipe laying (contd.)
 Depending on pipe type, treatment for corrosion prevention
to inside and outside of pipe needs to be carried out before
laying
 For gunited pipes, continuous curing shall be done,
preferably by sprinkler method. Pipes shall be rolled over
during curing so that entire perimeter of pipe gets cured.
Alternatively, curing can be done by covering gunited pipes
by gunny bags and keeping them continuously moist.
 In case of coated pipes, extra care shall be taken to preserve
the coating while laying
 Trench shall be kept free from water till laying and jointing
has been properly done
 Metal marker tapes can be used on laid pipeline to enable
electronic location of pipeline in future
 Geotagged maps showing latitude & longitude value of each
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apex of laid pipeline shall be preserved for future reference
 Pipe laying

Shirapur LIS
Bodwad LIS

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Prakasha Burai LIS Tembhu LIS

Corrosion prevention treatment (Inside/Outside)

Prakasha Burai LIS Prakasha Burai LIS

Prakasha Burai LIS Bodwad LIS Dongargaon 27

Thanegaon LIS
 Pipe Jointing
Purpose : To withstand maximum design pressure without causing leakage)

HDPE SWSRP PVC

A. Fusion welding :  Electro Fusion Process  Solvent welded joints

 Butt fusion welding  Integral elastomeric sealing ring joints
 Socket fusion welding  Mechanical compression joints
 Electro fusion welding  Flanged joints
B. Insert type joints  Screwed or threaded joints
C. Compression fittings/push  Union coupled joints
fit joints
D. Flanged joints
E. Spigot and socket joints

To obtain good welding effect, it is necessary to do welding work by experienced welders.

Welder’s efficiency shall be tested on site before start of work and intermittently thereafter (say
after every 6 months)
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 Pipe Jointing (contd.)
PVC-O GRP

 Lubricate the chamfer of the spigot and A. Unrestrained Pipe Joint :

the seal with joint lubricant.
 Line up the pipe horizontally and
vertically.
 Insert only the chamfer edge of the
socket, just to support the pipe but
leaving the socket lip free.
 Introduce lip of the socket into pipe until
the mark is hidden into the socket.
 Spigot and Socket Joint with Single Rubber Ring Gasket
 Spigot and Socket Joint with Double Rubber Ring Gasket
 Double Socket Coupling Joint with Rubber Ring Gasket
B. Restrained Pipe Joint :
 Spigot and Socket Joint with Gluing
 Spigot and Socket Joint with Glue and Overlay
 Butt Joint
 Flanged Joint
 Steel Collar on GRP Pipe for Flanged Connection

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 Pipe Jointing (contd.)
PSC PCCP BWSC
A) Rigid joints  Aligning of pipes at joint  Aligning of pipes at joint
 Socket and Spigot locations locations.
 Collar Joint  Field welding of socket ring at  Field welding of socket ring at
 Flush Joint joint externally. joint externally.
B ) Flexible Joints  Fixing of diaper with steel strap  Fixing of diaper with steel strap
 Roll on Joint at joint location. at joint location.
 Confined Gasket  Pouring of cement mortar  Pouring of cement mortar
through diaper at joint location. through diaper at joint location.
 Filling inside of joints by cement  Filling inside of joints by
mortar. cement mortar.

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 31
Tembhu LIS
Pipe Jointing (contd.)
MS

DI

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 Pipe jointing

Shirapur LIS

Tembhu LIS
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 Field testing of laid pipeline
 After filling the pipeline with water, it should be allowed to
stabilize for sometime (eg.1 hour) in order to achieve conditions
as stable as possible for testing.
 Design test pressure as per pipe type shall be applied (eg. 1.5
times rated pressure) and maintained for given time ( e.g. 24
hours) based on pipe type
 Generally no leakage or pressure drop is expected (eg. for MS
pipe, acceptable leakage limit is 0.1 lit/mm of pipe dia/Km of
pipe line / day for each 30m pressure head)
 If test is not satisfactory, retest after corrective measure
 For longer pipelines, tests on individual sections (say 1 km
length each) as well as complete length of pipeline needs to
carried out
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 Hydraulic testing of pipes

Bodwad LIS

Bodwad LIS

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Tembhu LIS
 Backfilling of Trenches
 Backfilling shall be carried out in uniform layers of not more than 15 cm
thickness, each layer to be watered & compacted by stamping or by
mechanical means.
 For refilling of trenches upto 300 mm above top of pipeline, soft earth
or gravel of good quality free from boulders, roots, vegetable matter etc.
shall be used.
 Remaining trench can be filled with available material
 Backfilling shall be carried out as uniformly as practicable on both sides
of pipe simultaneously to avoid unequal loading

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 Payment schedule
80% of the payment will be released after supplying, lowering, laying
and jointing of pipes in one WUA area
10% of the payment will be released after satisfactory hydraulic
testing of pipeline and backfilling of trenches in one WUA area
Remaining 10% amount will be released after successful
maintenance and operation of PDN system for a period of 5 years after
commissioning in respective WUA area (2% every year).

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 Operation, Maintenance and Handing over of the
PDN System to WUA

Contractor shall perform hydraulic test of PDN system, once every year
Contractor shall flush entire pipeline on completion of every irrigation season.
Contractor shall give training to the members of WUA about O&M of PDN work and its
efficient use and protection of the system from any damages.
The contractor shall operate and maintain the PDN system for the period of 5 (five) years
after commissioning. Out of this period, during last two years the operation of the schemes
shall be done by the contractor jointly along with WUA.
On completion of O&M period, the PDN system shall be handed over to WUA alongwith
operation manual.
Detail map of the permanent marking along the alignment of pipe (geotagged map of laid
pipeline) shall be handed over to WUA.

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