Section VIII INSTALLATION OF PLASTIC MAINS & SERVICES GENERAL ‘Since the beginning of age sal use in the mid-1960"s, plastic pipe has become te major constuction materia ‘or gs distribution use in the United Stats. AS happend with sie! pipe, operating practices with plastic ‘developed ae arent of wily experiences and infomation that was avalabie fom te vaio gs associations land ASN codes A the iaallton experince base broadened, and as new inforation onthe behavior of ‘thermoplastic materials hes evolved, and with the advent ofthe Federal Ppline Safty Standards, practies have ‘peso bter defined. “Today, plastic pipe manuteturngandinstallaonpretces are very wel ound by the flowing sources of snormation: ‘The OPS Regulations (ASTM D2513 and ASTM D2817 Incorporate) “The Guide to Federal Regulations ‘The AGA Plastic Pipe Manual for Gas Service Manutacre's Recommendations Each paste ping manufacturer mus manuf the product in accordance with existing sandards sich 5 ASTI, D213 "Standard Specification for Thesmoplasic Gas Pressure Pipe, Tubing, and Fitings”, and ASTM ‘D2517 “Standard Spasfcaton fr Reinforced Epoky Resin Gas Presure Pipe and Fitings". Adonai, ery manufacturer of plc piping stems also provides is owa use: reoramendations, Most manufacturers provide ‘rated materials ong joining practices and general insolation recommendations and some provide extensive {ining materls in adtion fo onthe jo echnical assistance and waining. Bocas import diftenes exist among the various plastic materials currently acetal fru, tis important foreach lspestor oe faa withthe characteristics ofthe paral materia chosen by hiss company, Foe this reason the Ispetor shouldbe toll faiiar with the manfctarr’s joining and inllation Tecommenations Some Companies qh hair Ispetrs tbe gualifed o join plastic ws ouined in piping ‘fey reglations section §192.28S, Others may choos to have Inspectors qualified ony to inspec plastic joins, ‘under sein 192.287 ‘Over 95% of al pls pipe curently being used for gs shun in tbe US is plyetilene. For this reason, ‘is seron will ea generally wat poletblene plastic pipe, All polytiyen pipe wed in gas distribution has the strength to provide a high margin of ust when operated at Gssgn proses, The toughness, esi, and light weight of paste pipe provide installation conveniences snd cones unsurpassed by metal piping en iibution systems. However popetivlene bas, as dos any piping ‘System eran desig, material, and procedural Limitations which can be exceeded io result in system fuse, 1s the inspectors responsibility tose at hase item imitations are not exesded daring insalason. TI, HANDLING & STORAGE OF PLASTIC PIPE Since plastis ae relatively sof, poor handing tchniqus may result in gouges, sotces, us oF punctures, Plast pipe and ting must be carefully inspected fer ets, gouges, dep seuss, and ober imperfections before the. Defective pipe must be rejected or the damaged secions must be removed A. ACCEPTABLE PIPE CONDITION: Minar exterior scratches which result fom normal handing of th pipe ‘rc accrpable. Mos sodas recommend maximum serach depth of 10% ofthe nominal wall hicks of | the pipe Impact damage can ocour parca in cold weather an ppe shouldbe inspected fer evidence of sich damage viet |LOADING & UNLOADING: When unloading or loading, ake creo not damage the pipe. For it pears shouldbe cutoned against damaging the pipe withthe forks or tines of te i trek, Cols of pipe [fe srapped or plleized for easy unloading or ling, When ualoaing or lading aight sick of pips, ‘How for some bending inthe middle of the il. Postion foc in tines fr apart as posible to reduce te ‘amount of bending, Tis wl enable operators toi the load without ising the forks to excessive eights ‘which ss dropping the lod. ‘When breaking down balk pcs o in-band, ke care to kep clear of the pipe while sopping is being ft, is recommended that pipe to be unloaded from a ruck bed nt be dropped othe ground. Rolling tie pipe dowa inclined planks wil ep damage toa minimum. Neve op the pipe oto hard pavements or Foeky train from tock bed, Ths parla import whea unloading pipe in cold weather condtons [Ac lowe temperatures, he pipe afer and more suscep to damage from impact. silo packs are motto be trans shipped and yu wll be using invidual cols itis advisable ext he large sicel bands which tite slo pack othe pallet as Soon as possible after unloading. I'here i any deformation ‘ot pipe cased by the pallet sapping, tis zeleasng of teasion wil allow any deformed ares to recover to ‘pomal shape. Any secon of pipe which are severely damaged shouldbe eut out before instalation. Aways inspect the pipe as it is being uncied and during instalation be sre no damage othe pipe has ‘omured daring shipment and subsoquent handing at he jobsite, ‘TRANSPORTING PLASTIC PIPE: During transport, the plastic ip sould be continuous supported in ‘uch a mange sto minimize movement berween the pipe and is suppor. Do nt allow the practice of ‘arng supplies or equipment ontop of plas pipe because of dame fom sharp edges and other rejections, ‘STRINGING: Reel tle can be estremety nepal when seingng colle pipe out or ies bur loa, pli or iseron renewal. Iti helpful when banding coed pipe io string the pipe out onthe ground 5 on a you aie atthe ob st. This allows the coll set wo ela, which wl simp handing and ‘emplacement ofthe pie. Larger sizes of cold pipe” and up) require we of peal sraghtning and founding machines, When uncolling pipe by ha, cu only thse saps onthe oil which are mcesay to ‘tool over rolls, cut iateraal bands whea you gett them athe eas wroled. ‘STRAIGHTENING: Whenever making socket or saddle fasion’ on freshly uncle pipe, lvays make an ‘ffor to tighten the pipe in the area in which the fasion wil e made. DRAGGING: Occasionally, when long strings of pps are joined ogee, ts necessary to drag the pipe © ‘wher it wil be installed. When the pipe must be dragged over rocky tea or hard povement, tke ‘Preeuton to protect the pie from abrasion, Sand bags used irs, or sort logs may be used o keep the pipe ‘Up a away ffm sharp rocks or hard pavemeat CUTTING: Plastic pipe and tabing should be cut wih cuters signed for se wih plastic. Many ‘manufacces provide ctr With spcial cater whetls for use With plastic. Thess tools esl produce the Square cat ends which are necesezy to provide ststctry fsion joints, Larger sizeof pipe can be it easly ‘uth plloine-ype caters, I carpenter or back swear wsed 1 cut the pipe, special care mst be taken to sue square cit eds and to clean the relat sawdust from inside he pp. Use a ol ring to aid in ‘malinga square cut when using asa STORAGE OF PLASTIC PIPE: Plate pipe and tubing shold be stored 50a 0 minimize the posi of the materia being damaged by crushing plerein, or extended exposure to direct sunlight. wnaPlastics are afc by extended exposure to sunlight though mos pls pipe manufctrers have Fncorporated UV sit in tet products fo protect agains such damage. The manafotre sould be onslted fr hisherpaicular recommendations, ‘The maximum height o which plastic canbe sacked depends on many factor uch 36 materia, siz, wall, thickness, and ambien! temperatures AL 0 time should the loading cause the pipe scion tobe forced out of ‘ound, Tis always prudent fo obtain the manufacturer's recommendations for ths purpose Il, BENDING & EARTH LOADING {madi o proper procedures for handing and joining plastic, close attention mst be given othe instalation ofall plas ppg system in the manne require oad files fom “exeraal sess". Excessive bending in lass pping syste, particularly tons, must be voided. Poo ip laying and backfiling procedures ean Fest in bending sesees which exced the maceral rent and incense the potential or fare There are some ‘uilines which can minimize te chance of damaging the pie by bending A. MINIMUMBENDING RADIUS: While plastic pipe canbe bent temporarily for instalation convenience, ‘mom manufctrers provide pemanent mitra bending dius lnsts (ach as 20 times pipe damete) ‘which should not be excveded. Beading shoud be parcuarly avoided in the are of ont or fitings (mito ot ss han 90 fo 125 times the pipe diameter), BURIAL STRESSES: 1. Pipe should e lad tv to line and grade and backfilled careflly to prevent ifereial seemeat, and thus excess bending 2 Protective sleeves and prope backfilling and compaction tehniqus for sevice branches and wasn ‘Stings combine to alleviate shearing esses, 2 Ring detection damage plats pipe camd by sith loading eno snealy 2 problems inthe sie ‘anges poneraly ied in gis dstibution tay. In the cace of iret Dui lage diameter chin wal pipes, however, manufactrers shold be cone for beklling recommendations. 4. ASTM(D2774, “Standard Recommended Practice for Underground Installation of Thermoplastic Pressure Piping”, provides goed general installation and backiling recommendations. 1, DIRECT BURIAL OF PLASTIC PIPE BY OPEN TRENCHING |A. TRENCHING: For drct ura of plas pps, teach booms shouldbe relatively smooth, continuous, and fies frocks and other deri. When edge rock, hardpan or boulders a encountered he boom of the {tench mos be ped with sand or other fine grained ll materials. Ths wench sould be wide enough to Sil fsion in the ditch ifrquire, snaking ofthe pipe slong the botom ofthe trench i ade and ling ‘and compaction of sides for ager diameter pipes. Minimim wench widths can be wilze in most nsanoes by joining the pie before lowering it ino the tench. ‘Minimum burial depth is regulated by Federal, state and local codes. Generally sufient cover nist be ‘maintained provide reasonable protection agaist anticipated external stress lads, Service lines must have “tinmmu cover of 1 inches in pve propery and I nees insects and reads, while ais in Clas 1 {Locations mst be insalle ata minim depth of 30 inches in normal sil and 24 inches in consolidated, ek 1B. PIPE PLACEMENT IN TRENCHES: Plastic pipe can be joined either above grade oro the itches as the Situation dcates, Though mos joining canbe accomplisied aboveground, joing Which must be de inthe ‘4c sald be well planed io easure that enough space i availabe and tht proper lignmeat is achieved, (Cae should be tkeao avoid bucking, gouging, aud ther mechanical éaage when lowering plastic pipe Into the dich ‘The pipe shouldbe lai so that there are no beds ina radius less han misram rmanufietures recommendation. Alighll pipe and fting joins te oie ad rae ‘lsi ‘Plat pipe must be brid far enough away fom stam line, hot wate lines, powerlines, and oer sures fof heat waved emperaares in exes of 100 Footer temperatures as euired by Federal Standards Because plastic pipe contracts a8 it coos I" pr 100" for each 10°F of temperature change) itis desirable in svar neater t stake the pie inthe boom of the trench. This provide for "sak" inthe pie to be taken {pas the pipe cools and contacts tes inthe dich port backing ‘BACKFILLING & COMPACTION: Backfling end compaction of emplaced plas pipe must be fascomplishod soa to aoid induced bending, sear snd tense esses oh, ares ofthe baking iself ‘nd from ferential seling of mateals subsequent tothe takfiling operation. Adina, care ‘Should be take o avid mechanical damage othe pe fom he Hl meri self tention tocar ‘cnplecenent, taking, and compacton procodres will vad such indced stresses and mechanical amage. : 1. Plastic mains and services should be coutiauously supported beneath their entize lengths by firm bec ‘atenal Blocking should ot be wed to intermittently suppor pipe or tubing across excavated setons, 2. Reaively sompactle an clean fill material shoud be used io inal bed newly emplaced mais nd ‘Services wih portclar enon tiling vols benexth uanstions and sence coaectons. Sie Compaction shouldbe ulized when teches ae wide enoagh ano develop lata passive soil fores ‘when backing large ameter tin wall pipes. The ist aer of material arom and abou inches ‘ove he pipe should be Sree from rocks o roan chunks which cold damage the pie. This layer should ‘erell compacted by hand or chanical tmper. Successive aers sould be spread evenly a in ‘Rlatvelywaform layreofil the tench completly without voids around or beneath rocks or humps of (ath, Large rocks, fren eit, and decomposable debris exch as wood shoud ot be ince in he ‘eck. “Hovey slr an large mechanical tempers soch as hyératammers should ony te used to consolidate ‘the ial bckfl and even then there sould De anim of 2 inches of ayered and previously ‘compacted ever, ‘VALVE INSTALLATION Each valve installed in plat pipe mst be designed so aso protect the plastic [natrial against excessive torsional or shearing lds When the ale or shuts operate, and Som ay ‘ther secondary sess that might be exerted though the valve or its enclosure. (49 CER 192.199) “The Ge material pblihe for Gas Piping Systoms sugges several metbods which can be used to prevent scessve ssc in plastic pipe at metalicvalveinalatons, Among these ae 1, Uselow rq aes 2. Anchor the valve ress turning and rotation, ‘When using metal valves, maketh transition frm metal to plat t sme distance fom te valve The tration shouldbe wel supported in undisturbed orwell compacted si. 4. Usea mete pipe sleeve rigidly connected othe valve and encasng the plastic parculaly or service tubing at x vals. 5 Cub boxes or oter enclosures shuld not be suppsted by he pas pipe, or nay way pose soondarysreset om te plac 6. Usecur boxes designe fr plasc valves. These feature a support base an devise o prevent valve body roation. vas1E, TRACER WIRES: tn order to locate plastic pipe an electrical conductor or acer wire must be installed with The ten procedure mas inire discovery ofall ptetally hazardous leks in the segment being ested {The tet pressure mast be alas 150% ofthe maximum operating presur or $0 psig, whichever is Boater but not more than thre tines the desi pres ofthe pipe vile‘+The ampere of thermoplastic material must not be more than 100° F during the test Pressure test ration i ofen dicta by state and focal odes as well as uiity standards. Generally, test duration ‘Should be detrnnod ty consideration of the volumetric content of the test section and iastrumenttion se 10 frou discovery ofall leaks, Air or inert gas are standard test mediums. |A. WHEN'TO TEST: Pressure testing of plastic shoul not be insted un it is certain hat ints are ‘lien cole abet wihsand rough Handing). Some operators pressure est new installations prior 0 bckiling so that soap bubble cocks of ois can be used oleate any leas. Ia very ho, sua conditions, the pipe may have tobe tekfilled a art patil wo avoid cooing temperature mits. int tec, the tet ection shoud be ed down or secured at intervals to prevent whipping of the pipeline shoud suse Dresuteteleascorur Ths is patculaty important when pressure tesing sections of pipe ontop of tie round prior insertion 1B. CAPPINGFOR TEST: When wing expandable cps or compression coupling type tes beads, adequate pll- fut resistance ofthe mechanical connesor must be demonstrated. Additional resaning mtods suchas nchoving saudbnazing. staking, rapping or oter meas of resuaint shouldbe used for sey. Many ‘lies us anstion tings with welded om closure aps a test heads, (C. USE OF AIR COMPRESSORS ON PLASTIC: Whes using ar compressors to pressre est scons of ‘last, er sould be taken to einlmie contamination ofthe pipe with excessive amounts of ia other ‘gents, Ol has he effet of plasticizing on polytilene which results in smal dacreaseinstengthwbere {bncstrations of ae sbsrbed ty the plat Paeumati tool les shold be by-passed or aps ries ted onthe discharge side of the compressor t minimize the amount of contamination preset i he i. "as, the temperature of tear fom the compressor must below enough so ht the est eneratare doesnot ‘cco the maximum allowable 1000 F for theroplastc materials. D, READING TEST RESULTS: When timesestng angeohune sections of plastic pip, te operator shoal be ‘gears of the creep characeriss of plastic pipe and eee ot temperate change. Ar nia ‘pressurization, pobetylene pipe may conine to expand slg causing ntceable opin zaze reading (hich wl hea sabe aera few mimes. long tem reading shouldbe nated atthe subizaton Din. Of cours the heating and cooling of the et medium asin an overnight est wl also have an eft on Dresue eadings, which coud mask ofall indicate slow eas. No specific idles can be eve, a8 {hey would vay greatly depending on volume and temperature characteristics, Vill, JOINING OF PLASTIC PIPE Polytiyene pipe and Stings may be joined by ot plat ea fision, lection, or mechanic fitings. Plastics shay be Jind to cts ty compression coupling, ang, o otbergulfedypes of proprietary tansion {Balags, The OPS Standards fo he ning of place pipe aterals ae contained in Sections 192.273 (ois must ‘be pulout resistance, follow ween procedures and be inspected) and 192.281 (methods of ening solvent (easnt,hestfsionadhese and mechanical). Manafctrer’ recommendations ae intended o enable plastic ‘ie urs to make laste ppe joints which meet OPS regulations. |A. JOINT REQUIREMENTS: (192.273) “The pipsline must be designcd and installed so that each ot wil ‘asain the lonltdnal pulbt or thr frees ease by contraction or expansion ofthe piping or by ‘iuciputedcxtoral er iteraal loading, Each joint mast be made in accordance with writen procedures that Tvs been proven by test or experince to prodoce song gasight joins, Each joint mst be inspected to insure compliance with this spar.” (192.281, General)“ plastic pip join that iota by sven emt, adhesive or heat sion may nt be ‘disturbed unl thas propery see. Plastic pipe may not be joined bya threaded ot or miter jin.” vt1. HEAT FUSION JOINTS. (192 2810]. Each beat-fsion jin on plas pipe mast comply with he folowing: 4 “A butt eatfsion joint must be joined bya device that ols the heater element square tthe ends ‘ofthe piping compresses tbe heated ends together, and olds the pipe in alignment whl te paste hardens 1b. "A tocket hea-fasion joint must te joinel bya device tat heats the mating surfaces of the ist ‘uniformly andsiataneosty to esses the same temperate” “Hert may nt be applied Wit a trch or other open ame” Sade joints, which rent spectcallyadressed in Part 192, re ypically made using a sideval fusion ‘sist ol that hls the iting im alignment wih the pipe and applies correct pressure while heating and joining pipe and fing 2. MECHANICAL JOINTS (5192281) “Each compression type mechanical joint on pls pipe must comply wit the following 44 The gasetmatrilin the coupling mst be compatible withthe plastic. ‘Aig ineroal ular ener, ata split rubolr seer, mus be used in conjunction with the coupling 1B, HOTPLATE HEAT-FUSION JOINING PROCEDURES: 1 Beat fasion joints are made by eatog mating surfaces thst ison terperae, stall with an ‘lestrialy-heated ina ple acver open Nam), and then bringing the srfces ino contact with ne another ASTM D2637 isa recommended practic for bex jing ef thermoplastic pipe and ings 2. The fision temperature rouired to produce a ssong bond depends on the parcel plastic being joined (Ovethetting, omages the ateniak and inoutieen being cos ot adequately woe Ke wat, ‘esuling in esac joints Again, refrence shouldbe made to the pipe manufacture or eis {joining resommendatons. 13. Saperised taining of consiraston personne is required priors intl installation of plasiss, Although the writen insractons ay be rather triehforward and simple, practice and ateson to details ied to proven poor quai joins wich may result fom not ally understanding those ening procedures 44. Hang equipment for larger iow of pipe may be required inorder io consistently produce a propels nade jun ‘Ths equipment id in alignment at supplies a more wiferm force required fo sion or {or inetion ofthe pipe it te fll dep oa socks joint. |. There are tre types of hotplate ea ison joins uso in the pogetipene piping sates curently avait Socket Fusion - Consisof imaltanemasly heating the eternal suriace of the pipe end andthe internal surface ofthe socket witha malelealeMeating plat wnt he material reaches fasion temperature (determined by ime), specting the melt ptr, inserting the pie end into the socket, Sf holding joni ligament whe the join cols. spect teoit afte thas been made. Ihe fision appears to contain void ran excesve amount of etwas left on the to, et out ad ‘make another fsion ‘Buti Fusion - Consists of beating the square ens ofthe pie end by Baling thm aainst a at ‘eating pat wt fasion temperetre ie reached (eterno by tine or width of met bad, pressing tbe ova cds opstie, and baling in alignment wile the ot cools. Tn But Fsin, visual es are ‘sd both daring and after the making of the joint o ull ispecdon requirements. inal cass, the ‘manufctre ofthe pipe material you are using shoul be consulted for specie recommendation. ‘vase_ Sade Fusion - Consists of simultaneously heating the sie ofthe pipe and the undesie fte Saddle Fie ns comoured esting pst wl he material eachsfosion egestas saa ney tne r wiih of melt bad, inspecting tbe et pternpresing the sade om Geer plag in lignment wile the asl ook. The usin sally sepeced ia tone property pestoned and that proper amount of mel was squecred ct around all ars of the ing. _ ELECTROFUSION HEAT-FUSION JOINING PROCEDURES: 1 These systems ar typically designed to simplify Joining of poyetintene pie, bing and Sings TRS Jo aca ining cima paleiyincs while maitining singe insallation profane Seite speed ambient enpertr rege, Cleanliness of scree iors in etoison Folio the nanufacse's instructions for al its. ‘a Fitings must Leptin their orginal packaging unt ime of instalation # RSet mst be scraped clean and kept fe of any enact other hans the iting Fin se since the iting mot specially match with he contol box. Newer systems a is market ae misable with identification provided by means of barcoding 1. Power soare requirement fr electoision mast sly observed, Tae following mst be vest ‘before connecting a ting corectvlage and ype of surent (AC oF DC) Correct power cups (Cones erreat cytes (.e: 60 Hz nomi. (Generator set on "manual mode, not “autora ‘Extension oor of adoqut wire size and not excessive Ins. Tepe 9. Pige ends mt be cut tema as posse achieve uniform gap between ends be joined in scket ‘ing “4 Scrping of pipetahing mst be thorough nd corres distance rom nds, bt mas abe done area ‘he dandonum number of mes recommended by mamofictrt 4 atgnment clap muse propery placed te assure mo movement cn osc and piping ar ety ‘ligne. 6 Very hat the Sing name displayed bythe conta bos comet denis he ing conned, DS Fe ATION I CONTROL BOX INCORRECTLY IDENTIFIES THE FITTING. A POOR JOINT WILL RESULT. +. Denot permit the fiting or pipe do be dsubed forthe pei minim Hine Foveach ofthe sbve meted manufrs Have pee eomimendatons fr espa, is kos Une For ing peace ec. Falanty wih and adherence o these ecommendsons a wty Standard i sen 1D. MECHANICAL JOINTS: ‘Mechanic its shoul be designed to taively ssn the foes cans ty contaton of hs ae aoc provision snot mode i th design ofthe ots etait sch 25 eNO, ‘ical ning ot pod ine nsaliaon, The bear ines wet with compen P= rue i ed ofthe pg and sal xed att be eof he iting, he Sn inns So ough or sharp edges and sould ste a forced tin he plas ips Tons wing Sa has Onings as pressure sealing vices on, maybe usd provided ter sable casas e used prevent longtialpullout reer mechanical falas ‘vasE. TOOLING REQUIREMENTS: et fusion joining equipment, inclodng beating tools, tot ison oer, and sae fasion assist oo snailble from several manuficuers. na few cases, the pipe manufictarrs themselves provie fusion {pining equlpment nal cass the pipe and Sting manufartrr shouldbe consulted regarding tol wage 1 Too! Maintenance: Heat fon joining tol are designed for optimum performance provided they are propery maintained, Cleanliness and good repair are essential for consistently good joints 2.‘ Heaing Tool Temperature: Heating (ols have temperature indicating thermometers and are controlled ‘by thermostatic wiches. Iti essential thatthe thermometers be checked periodically fr acurey 50 that any newded adjustment canbe made Wo entre tht als ae ested wo proper temperatures. FF. INSPECTOR'S RESPONSIBILITY: Te Inspector must ensure tat ach joints made by propel rained and qualified personnel in accordance with eablished writen procdares which are shown e saisictry {ar the particular pipe and Stings system bing joint. The fusion tols and equipment sould be inspected regulary and frequently o acu thy are clea, proplymalntined and beating plate surface costing is Intact This includes ensuring tha appropeat sal or non-esroctive requremats have Ben met IX, PLASTIC PIPE INSTALLATION REFERENCE MATERIALS “This information summarizes generally aceptodinsalaton and use practices invelving pas pipe. lf this information hasbeen prevoaslydscused in the Vaous cde an guidetine publications which wee refered 10 ‘hrouhout the toc. Below is a summary Hit of thos ec avaable references with which cach use of plastic ining stems shouldbe fui. ‘+ Tile 49, Coe of Federal Regulation, Par 192 “Transportation of Netra and Othe Gas by Pipelines: ‘Minimo Federal Sefer Standaris™ 4 Grids fo Ge Transmission nd Disnbaton Piping Stems + -AGA Plastic Pipe Manual fr Gas Service vurw