Pipe Material Report 2 22-8-2023

Engineering Services (Design) for Strategic Reservoir Stations (Phase
1)
Types of Pipes Used in Water Supply System
August 2023
Engineering Services (Design) for Strategic Reservoir Stations (Phase 1)
Pipe Material Selection Report
Table of Content
1 Introduction 4
1.1 Types of Pipes Used in Potable Water System........................................................................4
1.2 Factors Affecting the Selection of Potable Water Pipe Types.................................................5
2 High-Density Polyethylene Pipes (HDPE) 6
2.1 General Characteristics............................................................................................................6
2.2 Advantages..............................................................................................................................6
2.3 Restrictions..............................................................................................................................6
2.4 Methods of Installation............................................................................................................7
2.5 Protection of Pipes Outer and Inner Surfaces..........................................................................7
2.6 Usages.....................................................................................................................................7
3 Un-plasticized Polyvinyl Chloride Pipes (uPVC) 8
3.1 General Characteristics............................................................................................................8
3.2 Advantages..............................................................................................................................8
3.3 Restrictions..............................................................................................................................8
3.4 Methods of Installation............................................................................................................8
3.5 Protection of Pipes Outer and Inner Surfaces..........................................................................8
3.6 Usages.....................................................................................................................................9
4 Glass Fiber Reinforced Plastic Pipes (GRP) 10
4.1 General characteristics..........................................................................................................10
4.2 Advantages............................................................................................................................10
4.3 Restrictions............................................................................................................................10
4.4 Methods of Installation..........................................................................................................11
4.5 Protection of Pipes Outer and Inner Surfaces........................................................................11
4.6 Usages...................................................................................................................................11
5 Pre-stressed Concrete Pipes 12
5.1 General Characteristics..........................................................................................................12
5.2 Advantages............................................................................................................................12
5.3 Restrictions............................................................................................................................12
5.6 Usages...................................................................................................................................13
6 Ductile Iron Pipes (DI) 14
6.2 Advantages............................................................................................................................14
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6.3 Restrictions............................................................................................................................14
6.6 Usages...................................................................................................................................15
7 Steel Pipes 16
7.2 Advantages............................................................................................................................16
7.3 Restrictions............................................................................................................................16
7.6 Usages...................................................................................................................................17
8 Standards and Criteria of Choosing Pipes 18
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List of Figures
Figure 1 |Types of pipes used in potable water supply system.....................................................................4
List of Tables
Table 1 | A summary of selecting the most appropriate pipe for installation.............................................18
Table 2 | A summary of pipes’ inner and outer surfaces that needed protection........................................18
August 2023
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1 Introduction
The Water Transmission and Technologies Company (WTTCO) is planning to construct strategic Reservoir stations
for potable water in all kingdom governorates to achieve sustainable water supply in all regions and to meet
consumer demand for the years 2030 and 2050. This program consists of approximately 314 locations, which will
serve around 452 city gates.
Due to the fact that this program is considered one of the mega initiatives, WTTCO decided to split it into bundles in
order to achieve the best outcome. The first bundle, which falls under the project and shall be covered in this project,
consists of 50 locations that must be designed based on the best local/international practices.
Due to the long lifespan of water pipes in infrastructural projects, which lasts up to 50 years, and as the value of
pipeline supply and installation costs is considered a large proportion of the budget for establishing water supply
projects, choosing the appropriate type of pipes is mandatory economically and technically to ensure that the project
is properly serviced during its lifespan.
This report aims to clarify the types of pipes used in the potable water system and the characteristics of each type to
facilitate the process of selecting the appropriate type of pipe material used in potable water projects.
2 Materials Selection Philosophy

Materials selection shall be made to ensure operational reliability and integrity throughout the design life of the
pipeline, piping system or process equipment Reviewing mechanical property requirements and corrosion resistance
is the first step in the selection process.
The main criteria for materials selection shall be:
- Health and safety of personnel and the public, and protection of the environment.
- Optimization of cost versus projected design life.
- Consideration of a fall back or repair position.
- Effect on product and process contamination.
2.1 Health, Safety, and Protection of the Environment

The safety of plant personnel, protection of the environment, conservation of resources, and
preservation of assets shall be key objectives in selecting materials of construction.
Materials of construction shall be suitable for the intended service, having predictable deterioration
rates for the process stream compositions and external environments, at design temperature and
pressure, through the design life of the component.
Materials shall be selected to prevent catastrophic failures or major environmental releases. Selected
materials shall have low risk of rapid damage mechanisms, such as brittle fracture, stress corrosion
cracking (SCC), low cycle fatigue, overload, etc., and have predictable mechanical and corrosion
performance.
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2.2 Cost versus Projected Design Life

Materials of construction shall be selected considering the balance between initial capital expenses,
operational integrity reliability, and future inspection and maintenance expenses.
Materials of construction shall be selected to provide a minimum design life of 20 years and
predictable performance on an acceptable cost basis. The selection should minimize the risk of short
design life and unexpected shutdowns; review impacts on maintenance, expense costs and repair
time; and review any potential effects on product and process contamination.
In cases where a service life that significantly exceeds design life can be justifiably foreseen, and
where materials selection options identified for the design life are cost limited and are only
marginally adequate; then the use of a service life based total cost of ownership can be made. If more
expensive materials options are proven to be the economically superior option, then these shall be
proposed as the primary choice.
Use ISO 15663 for guidance on life-cycle costing.
2.3 Repairability or Fall Back Position

Materials of construction shall be capable of being repaired with reasonable effort in an acceptable
(minimum) amount of downtime or practical means of altering or bypassing the affected equipment
shall be possible until repairs can be made.
Repairability or fallback position should consider replacement lead times and ease of maintenance,
inspection, and repair.
2.4 Product and Process Contamination

Materials selection shall consider the impact of corrosion rates, surface area, recycle stream rates,
solubility, effect of corrosion products on corrosion, and other factors on contamination of the
process stream.
For pressure containment, only approved materials that are included in recognized codes and
specifications, such as API, ASME and ASTM shall be used.
2.5 Types of Pipes Used in Potable Water System

Many types of pipes are used in the water supply system that are suitable for different operating conditions. These
pipe types can be classified according to their manufacturing material as follows:
Types of Pipes Used in Potable

Water System
Iron Pipes Concrete Pipes Plastic Pipes
Ductile Iron Pipes Reinforced Concrete High-Density Polyethylene Pipes

(DI) Pipes (HDPE)
August 2023 Steel Pipes Pre-stressed Concrete Un-plasticized PolyvinylPage 5

Pipes Chloride Pipes (uPVC)
Glass Fiber Reinforced Plastic
Pipes (GRP)
Figure 1 |Types of pipes used in potable water supply system.
2.6 Factors Affecting the Selection of Potable Water Pipe Types
The types of pipes differ from each other in terms of:
 Cost
 Lifespan
 Weight
 Durability and rigidity
 Ease of installation and maintenance
 Resistance to erosion by soil, stray currents, or the transmitted liquid.
 Resistance to internal stresses, external loads and water hammer.
 The size of pipe and its capacity to carry the required flows, as some pipes are produced in small diameters
and others with large diameters.
Accordingly, the optimal pipe type varies from project to another according to the expected operating conditions.
In order to choose the optimal pipe type, a technical and economic study and comparison must be made, considering
all these factors.
In this report, the technical indicative considerations for different pipe types are explained, the methods of protecting
both the inner surface and the outer surface of the pipe are illustrated, and a summary of the installation and the
special sizes of some pipe types is presented.
This report includes a study of the following types of pipes:
1. High-Density Polyethylene Pipes (HDPE)

2. Un-plasticized Polyvinyl Chloride Pipes (uPVC)
3. Glass Fiber Reinforced Plastic Pipes (GRP)
4. Pre-Stressed Concrete Pipes
5. Ductile Iron Pipes
6. Steel Pipe
August 2023
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3 High-Density Polyethylene Pipes (HDPE)

High-density polyethylene pipes (HDPE) are plastic pipes, and currently, they are one of the most used materials in
water systems. These pipes are made of petrochemical compounds that include polymeric materials.
They are characterized by their lightweight and smooth inner surface, which increases their hydraulic efficiency.
Noting that this type of pipe requires special precautions in storage and handling, as it must not be stored in the open
air to avoid being affected by direct sunlight and temperature factors.
3.1 General Characteristics
 Type: flexible/plastic pipes

 Diameters: The produced diameters range from 16 mm to 1600 mm
 Length: The pipe is produced with a length of 6 meters and 12 meters.
 Operating pressures: pipes are produced to withstand operating pressures up to 16 bar for diameters up to
630 mm only. As for larger diameters, their pressure rating is lower.
3.2 Advantages
 Strong and impact-resistant pipes.

 Relatively lightweight.
 Flexible, especially in small diameters.
 Ease of making connections using welding.
 Availability of fittings and accessories.
 Low coefficient factor of friction due to the smoothness of the inner pipe surfaces.
 Shock and vibration absorption.
 Costs of supply and installation are relatively economical.
3.3 Restrictions
 Its toughness and resistance to stress are negatively affected by time, which must be taken into design
consideration.
 Avoid storing the pipes in the open air to avoid being affected by direct sunlight.
 The effect of dynamic loads on pressurized pipelines must be studied in view of data from the producing
companies.
 Pipes elongation must be considered during pressure tests.
 Installing the pipes needs soft material beddings in the trenches.
 Pipe welding requires both equipments as well as trained and skilled labor.
 Metal tape is needed to easily locate them using electromagnetic devices.
 Low ability to withstand water hammer effect.
3.4 Methods of Installation
 Butt Welding:
August 2023
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In this method, the pipes are connected longitudinally by heating their two ends to be welded with a special welding
machine that works electrically. This is considered the cheapest installation method used at the installation site of
the pipeline, bearing in mind that the pipes to be connected must have the same thickness.
 Electro-fusion Welding:
Welding is done by equipping the connection with a metal heating coil, where the ends of the pipes to be connected
are placed at both ends of this joint. An electrical transmission device is then used to heat the coil to complete the
welding process of the joints of the pipes.
3.5 Protection of Pipes Outer and Inner Surfaces
HDPE pipes show good corrosion resistance to soil and groundwater effects, so there is no need for any protection
against different soil types.
The outer and inner surfaces of these pipes do not need any protection or precaution.
3.6 Usages
Due to the lightweight of HDPE pipes, the ease of installation, and the possibility of their use in all types of soil and
water transfer without the need for special protection, the following uses are considered the most appropriate for
these pipes:
 House connections
 Water supply networks
It is not recommended to use these pipes in water transmission systems with large diameters and high pressures.
4 Un-plasticized Polyvinyl Chloride Pipes (uPVC)


 Diameters: The produced diameters range from 20 mm to 1000 mm
 Length: The pipe is produced with a length of 6 meters.
 Operating pressures: pipes are produced to withstand operating pressures up to 16 bar.
August 2023
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4.2 Advantages
 Ease of connections.
 Good resistance to erosion. due to the impact of soil and groundwater.
 Easy to repair and connect.
 Costs of supply and installation are relatively economical.
4.3 Restrictions
consideration.
companies.
 Pipe elongation must be considered during pressure tests.
 Installing the pipes requires soft material bedding in the trenches.
 Not suitable to transfer liquids with temperatures higher than 60°C.
 Not suitable to transfer acids and highly concentrated solvents (there is a limit for them in related
specifications).
 Not suitable to use above the ground or under direct sunlight.
 Low ability to withstand the water hammer effect.
Several methods are used in uPVC piping work, the most common of which are the following:
 It is attached using a socket and spigot joint with a rubber gasket.

 It is connected by the head and tail using adhesive.
uPVC pipes show good corrosion resistance to soil and groundwater effects, so there is no need for any protection
against different soil types.
4.6 Usages
Due to the light weight of uPVC pipes, the ease of their installation, and the possibility of using them in all types of
soil and water transfer without the need for special protection, the following uses are considered the most
appropriate for these pipes:
 House connections
 Water supply networks
It is not recommended to use these pipes in water transmission systems with large diameters and high pressures.
August 2023
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August 2023
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5 Glass Fiber Reinforced Plastic Pipes (GRP)

These pipes are made of polymers and strengthened with fiberglass in successive layers. These pipes are
characterized by their lightweight and smooth inner surface, which increases their hydraulic efficiency. But these
pipes need special care during installation in addition to their difficulty to repair and the unavailability of fittings,
which increases the difficulty of making branches on them.
5.1 General characteristics

 Diameters: The produced diameters range from 300 mm to 2600 mm.
 Operating pressures: pipes are produced to withstand operating pressures up to 16 bar; however, it is not
recommended to use them under an operating pressure of more than 10 bar.
5.2 Advantages
 High resistance to erosion by soil and groundwater.

 Flexible pipe connections.
 It can be designed and manufactured according to special needs.
 Resistant to severe weather factors, soil salts, and chemicals.
 Can be used to transfer acidic, alkaline, and oxidizing materials.
 Has a smooth inner surface, which reduces friction losses.
5.3 Restrictions
consideration.
companies.
 Vulnerability to damage due to shocks.
 According to the specifications of the manufacturer, a high degree of compaction and a bed of sand is
needed to avoid bending or transformation of the pipes.
 It might be overstressed due to land subsidence or movement.
 Avoid digging around the pipes in order not to loosen the compactions.
 Need for metal tape to be able to locate them with electromagnetic devices.
 It needs special design and precautions, especially for the main transmission lines, as they are exposed to
the water hammer effect.
 The soil and the type of foundation affect the choice of pipe stiffness, which should not be less than 5000
Newton/m2. It is recommended to use pipes with a stiffness of 10,000 Newton/ m2.
August 2023
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 Socket and Spigot method
This is done by using a suitable rubber gasket.
 Mechanical Joint
These connections are made of carbon steel covered with PVC and follow the same specifications used in the
installation of uPVC pipes in terms of excavation, bedding, installation, and backfilling.
GRP pipes show good corrosion resistance regarding soil and groundwater and do not need protection against
different types of soil.
5.6 Usages
Due to the possibility of manufacturing GRP pipes with relatively large diameters, they can be used as water
transmission lines.
However, as a result of the issues observed in many of the constructed lines, it is preferable to use them in the
transmission lines that are operated by gravity only. Additionally, it is not preferred to use them in pressurized
transmission lines due to the problems that occurred in many of the existing projects.
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6 Pre-stressed Concrete Pipes

Concrete pipes are characterized by their high strength and durability. They are often resistant to environmental
factors and thus resistant to corrosion, bending, and high temperatures. Additionally, they have the structural
integrity necessary to withstand usage for decades. Although concrete is highly susceptible to fracture due to its
rigid nature, it is used in pipe applications where concrete pipes are reinforced with steel to add tensile properties.
 Type: Rigid pipes

 Operating pressures: pipes are produced to withstand operating pressures up to 16 bar.
6.2 Advantages
 Rigidity and high bending resistance.

 Relatively low degree of compaction around it.
 Acceptable resistance to erosion from water and soil, especially if sulfate-resistant cement and protective
layers are used for the inner and outer surfaces.
6.3 Restrictions
 Heavyweight, especially in large diameters, which leads to high costs of transportation and installation.
 Pipes cannot be cut on site.
 Joints are relatively rigid.
 Difficulty in adding connections or joints after installation.
 It usually takes longer to repair than other pipes.
 Installation and connections are made by socket and spigot fittings.
Concrete pipes are subject to corrosion in some types of soil if not properly protected. Therefore, these pipes are
usually manufactured using sulfate-resistant cement to protect the pipe in general.
The outer surface must also be protected with one of the following methods:
 Coating the outer surface with three layers of bituminous coating with a total thickness of at least 450
microns. The thickness is increased in cases of very aggressive soil.
 Coating the outer surface of the pipe with epoxy tar, then enveloping the pipe with polyethylene. The
thickness of the polyethylene layer is determined based on the aggressiveness of the soil.
As for the inner surface protection, there is no need for it as this pipe is made of sulfate-resistant cement, making the
inner surface secure.
August 2023
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6.6 Usages
Due to the possibility of manufacturing concrete pipes with relatively large diameters and the ability to withstand
high pressure, they can be used as water transmission lines.
However, as a result of the relatively large costs of transportation and installation as well as the time required for
maintenance and repair work, concrete pipes are not the appropriate choice for use at the present time in potable
water projects.
August 2023
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7 Ductile Iron Pipes (DI)

Ductile iron pipes are the most commonly used type of pipe due to their durability under pressure and their lack of
rigidity. they combine the advantages of grey cast iron and steel pipes. Moreover, they have a low coefficient of
friction due to the smoothness of their inner surface, which is lined with cement mortar, increasing their hydraulic
efficiency.
 Type: semi-rigid pipes.

 Operational pressures: pipes are produced to withstand operating pressures up to 40 bar, noting that the
most common pipes have operating pressures of 16 bar and 25 bar.
7.2 Advantages
 Strong pipes with a high bearing capacity.

 Flexible pipe connections.
 Availability of fittings and connections.
 Ease to add branches and connections after installation.
 Providing leak detection methods and piping location determinations.
7.3 Restrictions
 Need precautions to prevent erosion by soil and groundwater.

 Need to be protected against stray electrical currents.
 Need thrust block instalments when changing the direction of flow.
Installation and connections of pipes are made as follows:
 Socket and spigot connections and rubber gasket.

 Using flanges and bolts.
Ductile iron pipes are subject to corrosion in some types of soil and groundwater, especially if the inner and outer
surfaces are not protected. Therefore, the type of soil and its aggressiveness must be identified in order to determine
the necessary protection for the pipe. In general, ductile iron pipes’ outer and inner surfaces should be protected.
Protect the outer surface using one of the following methods:
 Spraying the outer surface with a layer of zinc, and then coating it with a layer of bitumen is considered the
most common method.
 Spray the outer surface with a layer of epoxy.
August 2023
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As for the protection of the inner surface, it shall be done by one of the following methods:
 The inner surface is lined with high-density impermeable cement mortar, which is the most common
method.
 Spraying the inner surface with three layers of epoxy.
7.6 Usages
Due to the availability of DI pipes in large diameters up to 2000 mm and operating pressures up to 40 bar, DI pipes
are the ideal choice for the following uses:
 Water supply networks.

 Main transmission lines.
August 2023
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8 Steel Pipes
Steel pipes are made of rolled steel sheets and welded longitudinally, spirally, or seamlessly (without welding). They
are distinguished by their impact resistance and ease of assembly and formation using electric arc welding, which
facilitates the operations of joining the pipes, making branches from them, or carrying out maintenance and repair.
The major disadvantage is that they are easily corroded while existing in aggressive soil or being exposed to stray
electrical currents due to their presence near electrical cables or electrical substations.
When using steel pipes, the outer surface must be well protected with a corrosion-resistant material such as (epoxy,
bitumen, fiberglass impregnated with bitumen-polyethylene tape).
 Type: Semi-rigid pipes

 Diameters: The produced diameters range from 150 mm to 2000 mm (Larger diameters can be produced on
request).
 Length: The pipe is produced in lengths ranging from 12 meters to 18 meters.
 Operating pressures: pipes are produced to withstand operating pressures up to 80 bar, depending on pipe
thickness.
8.2 Advantages
 Strong pipes with a high bearing capacity.

 Availability of fittings and connections.
 Ease to add branches and connections after installation.
 Can withstand relatively high operating pressure.
 They are produced in relatively large diameters.
 Providing leak detection methods and piping location determinations.
8.3 Restrictions
 Need precautions to prevent erosion by soil and groundwater.

 Need to be protected against stray electrical currents.
 Need skilled welding labour.
 Butt Welding:
The pipes are connected longitudinally, and the welding is done manually or automatically with special electrically-
operated welding equipment used at the installation site of the pipeline. The pipes to be connected must be of the
same thickness.
August 2023
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Steel pipes are subject to corrosion in some types of soil and are mainly affected by stray electrical currents, which
necessitate the installation of a cathodic protection system. Therefore, the type of soil and its aggressiveness must be
identified in order to determine the necessary protection for the pipe. In addition to cathodic protection, the inner
and outer surfaces of steel pipes should be protected.
Protect the outer surface in one of the following methods:
 Spraying the outer surface with three layers of epoxy.

 Spraying the outer surface with three layers of polyethylene.
As for the protection of the inner surface, it shall be done by one of the following methods:
 The inner surface is lined with high-density impermeable cement mortar, which is the most common
method.
 Spraying the inner surface with three layers of epoxy.
8.6 Usages
Due to the availability of steel pipes in large diameters up to 2000 mm and operating pressures up to 80 bar, steel
pipes are the ideal choice for multiple uses in the potable water system and in transmission lines.
In addition, the installation method carried out by welding reduces the problems of separating and leakage in the
pipeline compared to other pipe installation methods (such as sockets and spigots, as well as flanges).
August 2023
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9 Standards and Criteria of Choosing Pipes

According to the above sections, the choice of the optimal material for pipes for potable water transmission systems
varies from one project to another according to the expected operating conditions. The following factors must be at
least specified, which mainly affect the choice of pipe material:
 Pipe diameter
 Transmission system operating pressure
 The aggressiveness of the soil
 Knowing the route of the pipeline and determining the parts exposed to the sun and the underground.
But in general, and based on what was previously explained in this report regarding the advantages and restrictions
of each pipe type, it is possible to summarize the selection of the most appropriate pipe based on the following:
Table 1 | A summary of selecting the most appropriate pipe for installation.
Operating pressure (bar) Pipe Diameter (mm) First Choice of pipe Second Choice of pipe
material material
Less than 10 bars Less than 630 mm HDPE DI
Less than 25 bars From 600 mm and up to DI Steel
2000 mm
More than 25 bars All Diameters Steel ---
All operating pressures Larger than 2000 mm Steel ---
As for the protection required for the selected pipes, it can be summarized as follows:
Table 2 | A summary of pipes’ inner and outer surfaces that needed protection.
Pipe Material Outer Surface Protection Inner Surface Protection

HDPE No need No need
DI Sprayed with a layer of zinc, then Lining with high-density
coated with a layer of bitumen impermeable cement mortar
Steel Spray with three layers of Lining with high-density
.polyethylene impermeable cement mortar
August 2023
Page 19

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Engineering Services (Design) for Strategic Reservoir Stations (Phase

Pipe Material Selection Report

Pipe Material Selection Report

Pipe Material Selection Report

Pipe Material Selection Report

2 Materials Selection Philosophy

2.1 Health, Safety, and Protection of the Environment

Pipe Material Selection Report

2.2 Cost versus Projected Design Life

2.3 Repairability or Fall Back Position

2.4 Product and Process Contamination

2.5 Types of Pipes Used in Potable Water System

Types of Pipes Used in Potable

Iron Pipes Concrete Pipes Plastic Pipes

Ductile Iron Pipes Reinforced Concrete High-Density Polyethylene Pipes

August 2023 Steel Pipes Pre-stressed Concrete Un-plasticized PolyvinylPage 5

Engineering Services (Design) for Strategic Reservoir Stations (Phase 1)

Pipe Material Selection Report

Figure 1 |Types of pipes used in potable water supply system.

2.6 Factors Affecting the Selection of Potable Water Pipe Types

The types of pipes differ from each other in terms of:

This report includes a study of the following types of pipes:

1. High-Density Polyethylene Pipes (HDPE)

Pipe Material Selection Report

3 High-Density Polyethylene Pipes (HDPE)

3.1 General Characteristics

 Type: flexible/plastic pipes

 Strong and impact-resistant pipes.

3.4 Methods of Installation

Pipe Material Selection Report

3.5 Protection of Pipes Outer and Inner Surfaces

4 Un-plasticized Polyvinyl Chloride Pipes (uPVC)

 Type: flexible/plastic pipes

Pipe Material Selection Report

4.4 Methods of Installation

 It is attached using a socket and spigot joint with a rubber gasket.

4.5 Protection of Pipes Outer and Inner Surfaces

Pipe Material Selection Report

Pipe Material Selection Report

5 Glass Fiber Reinforced Plastic Pipes (GRP)

5.1 General characteristics

 Type: flexible/plastic pipes

 High resistance to erosion by soil and groundwater.

Pipe Material Selection Report

5.4 Methods of Installation

 Socket and Spigot method

This is done by using a suitable rubber gasket.

5.5 Protection of Pipes Outer and Inner Surfaces

Pipe Material Selection Report

6 Pre-stressed Concrete Pipes

6.1 General Characteristics

 Type: Rigid pipes

 Rigidity and high bending resistance.

6.4 Methods of Installation

 Installation and connections are made by socket and spigot fittings.

6.5 Protection of Pipes Outer and Inner Surfaces

Pipe Material Selection Report

Pipe Material Selection Report

7 Ductile Iron Pipes (DI)

7.1 General Characteristics

 Type: semi-rigid pipes.

 Strong pipes with a high bearing capacity.

 Need precautions to prevent erosion by soil and groundwater.

7.4 Methods of Installation