DIS 5.11.

ENGINEERING PROCEDURES

SECTION 5 - PIPE SYSTEM CONSTRUCTION

SUB-SECTION 5.11- PIPE LINING PROCEDURES
MODULE 5.11.1 - CLOSE-FIT POLYETHYLENE
LINING OF PIPE

AUGUST 1992
J179 ( Rev 11/97 )
.
 DIS 5.11.1

CONTENTS

Page

FOREWORD iii

BRIEF HISTORY iv

1. SCOPE 1

2. REFERENCES 1

3. BRIEF DESCRIPTION OF PROCESSES 1

3.1 Cold swagelining 1

3.2 Hot swagelining 1

3.3 Rolldown 1

4. SELECTION CRITERIA 1

5. SITE INVESTIGATION 2

6. CLOSED-CIRCUIT TELEVISION SURVEY AND

MAINS CLEANING OPERATION 2

7. GAUGING PIGS, DIE SIZING AND ROLLER SETTINGS 2

8. LOCATION OF LAUNCH AND RECEPTION PITS 3

9. POSITIONING AND ANCHORING OF EQUIPMENT 3

10. TOWING HEAD TYPES 4

11. INSPECTION AND TESTING 4

12. SAFETYASPECTS 4

13. CLOSE-FIT LINING OPERATION 5

14. CONNECTION OF CLOSE-FIT LINED SECTIONS 6

15. PIPE PROTECTION REQUIREMENTS FOR SDR 26 AND

THINNER WALLED POLYETHYLENE PIPE 6

16. BUTT FUSION PROCEDURES 7

TABLES

1 Technical information for close-fit lining of mains 9

FIGURES

1 Typical gauging pig 11

2 Swagelining systems 12

3 PE towing head assembly 13

4 Mechanical spider towing head assembly 13

J179 ( Rev 11/97 ) -i-

DIS 5.11.1

Page

5 Two part mechanical towing head assembly 14

6 Solid type (machined from solid PE) 14

7 Alternative thermal contraction couplings using electrofusion couplings 15

8 Position of steel anti-shear sleeve and thermal contraction split sleeve 16

APPENDICES

A TYPICAL CLOSE-FIT LINING DATA SHEET 17

- ii - J179 ( Rev 11/97 )

 DIS 5.11.1

FOREWORD

This specification has been adopted by Transco and is an editorial revision of the former British Gas
TransCo specification GBE/DIS 5.11.1. It reflects the identity and organizational structure of Transco - a
part of BG plc.

This Transco specification has been approved for use throughout Transco.

Comments and queries regarding the technical content of this Transco specification should be directed to:

Lead Role Engineer

Transco
West Area Office
Glevum House
Bristol Road
Gloucester
GL2 6YA

Further copies of this Transco specification can be obtained from Dataform Print Management using the
print requisition form G004 quoting the Form Number of this Transco specification (not the designation)
and your cost code.

Transco specifications are revised, when necessary, by the issue of amendments or new editions. Users
should ensure that they are in possession of the latest versions by referring to the Transco Register of
Engineering Documents available on the Transco Information Library.

Contractors and other users external to Transco should direct their requests for further copies of Transco
specifications to the department or group responsible for the initial issue of their contract documentation .

Compliance with this specification does not confer immunity from prosecution for breach of statutory or
other legal obligations.

DISCLAIMER

This specification is provided for use by Transco and such of its contractors as are obliged by the terms of
their contracts to comply with this specification. Where this specification is used by any other party it is the
responsibility of that party to ensure that the specification is correctly applied.

J179 ( Rev 11/97 ) - iii -

DIS 5.11.1

BRIEF HISTORY

This Module 5.11.1 was originally designated PS/G12.

First published as GBE/DIS 5.11.1 August 1992

© BG plc 1992

This Transco specification is copyright and must not be reproduced in whole or in part by any means
without the approval in writing of BG plc.

- iv - J179 ( Rev 11/97 )

 DIS 5.11.1

ENGINEERING PROCEDURES
SECTION 5 - PIPE SYSTEM CONSTRUCTION
SUB-SECTION 5.11 - PIPE LINING PROCEDURES
MODULE 5.11.1 - CLOSE-FIT POLYETHYLENE LINING
OF PIPE

1. SCOPE
This Module 5.11.1 of the Transco Engineering Procedures* (formerly Code of Practice for Distribution)
gives guidance on the close-fit lining of existing mains using polyethylene (PE) pipe.
* Hereinafter referred to as 'this Module 5.11.1'

2. REFERENCES
This Module 5.11.1 makes reference to the document listed in below. Unless otherwise specified the latest
editions of the document, including all addenda and revisions, shall apply.

Transco specification

Code of Practice for Distribution:

Module 5.5 - Pressure testing.

3. BRIEF DESCRIPTION OF PROCESSES

3.1 Cold swagelining
Cold swagelining is the process of pulling PE pipe through a die at ambient temperature to reduce its
diameter and permit its entry into the main to be lined. On release of the winch load, the PE pipe recovers
towards its original diameter to form a close fitting lining to the bore of the main.

3.2 Hot swagelining

Hot swagelining is a process similar to cold swaging with the addition of preheating the PE pipe before
entry into the die. Hot swagelining reduces towing loads.

3.3 Rolldown
Rolldown is the process of reducing the outside diameter of the PE pipe by pushing it through sizing rollers
prior to its insertion into the main. In this case the pipe retains its new size until internal pressure, usually
hydraulic, is applied causing reversion towards its original size and forming a close-fit lining to the bore of
the mains. Detailed information on this process is not contained in this Module 5.11.1 and should be
obtained from the licensees.

4. SELECTION CRITERIA
4.1 Close-fit linings may be installed in various pipe materials (e.g. pit cast iron, spun iron, ductile
iron, steel) provided that the original pipe is reasonably circular.

4.2 Pipe sizes up to and including 24 in. may be considered for replacement using the close-fit lining
technique.

4.3 The PE liner pipe to be used should have an original diameter slightly larger than the bore of the
pipe to be lined in order to obtain a close-fit. Both standard and non-standard PE pipe sizes may be used
(see Table 1).

J179 ( Rev 11/97 ) -1-

DIS 5.11.1

4.4 The wall thickness of the PE lining should be minimized to maximize the carrying capacity of the
main. Where coiled pipe or saddle fusion joints are used, particularly in smaller pipe sizes, thicker wall pipe
may be necessary.

5. SITE INVESTIGATION
5.1 Maximum use should be made of all available records. Details of material types together with the
position of existing valves, plugs, bends, tees, condensate receivers, change and double collars, service
connections or any other obstructions in the main should be obtained.

5.2 Details of other utilities plant must be obtained and both electricity cables and telephone ducts
should be physically marked out on site.

5.3 Route inspection together with on-site marking-out of the main and any recorded features should
take place. This will assist with the validation of recorded information.

5.4 Following isolation and purging of the main, the bore should be checked at the access points and
recorded. It should be noted that the internal diameter of each cast iron pipe may vary along its length.

6. CLOSED-CIRCUIT TELEVISION SURVEY AND MAINS CLEANING OPERATION

6.1 It is essential prior to close-fit lining that the main is internally inspected by closed-circuit
television (CCTV) to confirm that there are no unrecorded features and also that all debris has been
removed.

6.2 Where appropriate, excavations which are required for the removal of obstructions should be
utilized as access points, e.g. the CCTV survey and mains cleaning operations.

6.3 From any excavation it may be possible to survey up to 600 m of isolated main (300 m in each
direction), depending on the size of the main.

6.4 Following the CCTV survey, further mains cleaning may be required together with the removal of
any obstructions which have been located during the survey.

6.5 Consideration should be given to sections of main in which gas conditioning agents may collect.

6.6 All CCTV surveys undertaken should be recorded.

6.7 Various methods of pipe cleaning may be employed. Rack-borers, scrapers and wire brushes used
in conjunction with rubber pull-throughs and a winch are usually sufficient, except where heavy
encrustations are encountered.

Consideration should also be given to the use of a vacuum unit for cleaning pipes having dry deposits.

6.8 Whatever method of cleaning is used, it is advisable that a further CCTV survey is carried out to
confirm that all debris has been removed from the pipe, and that the cleaning operation has been successful.

6.9 After cleaning, a towing line should be installed in the pipe in preparation for the gauging
operation.

6.10 All obstructions shall be removed prior to the close-fit lining operation and, in the case of bends
and condensate receivers, an additional metre of pipe on either side of the obstruction should be removed.

6.11 Any solid or liquid material found within the main shall be regarded as potentially hazardous and
shall be removed and disposed of in accordance with safe working practices and any appropriate legislation.

7. GAUGING PIGS, DIE SIZING AND ROLLER SETTINGS

7.1 Following the completion of the CCTV survey and cleaning operation, the internal bore of the
main should be sized using a suitable steel or PE gauging pig. A typical gauging pig is shown in Figure 1.
This should establish the minimum bore of the pipe to be lined and also highlight any internal obstructions
which may not be evident from the CCTV survey or from access points.

-2- J179 ( Rev 11/97 )

 DIS 5.11.1

7.2 When sizing the internal bore of the main to be lined, the gauging pig should preferably be pulled
through by hand in each direction. When pulling the gauging pig through using a winch, the pulling force
should be closely monitored and recorded.

If the gauging pig cannot be pulled through, then, depending upon the type of obstruction, the responsible
Engineer shall decide whether to resort to a smaller gauging pig or remove the obstruction.

If the smaller gauging pig cannot be pulled through and the obstruction cannot be removed, the responsible
Engineer should consider using an alternative method of replacement.

7.3 The gauging pig should be long enough (i.e. at least 3D) to prove the bore.

7.4 Upon completion of the pipe sizing operation, the required die size should be selected from the
standard range of swage die sizes provided for each nominal bore of pipe given in Table 1. Any departure
from the die size or specialist die design may have a deleterious effect on the process. Where the lower
sized gauging pig has been used, the lower die size must also be used.

In the case of reduction of liner diameter by rollers, the roller setting should be obtained from the licencee.

8. LOCATION OF LAUNCH AND RECEPTION PITS

8.1 Dependent upon the results of the initial site survey and CCTV investigation, launch and
reception pits may be constructed. Consideration should be given to re-using CCTV investigation pits as
launch/reception pits.

8.2 The size of all launch pits, reception pits and lead-in trenches should be kept to a minimum
consistent with PE pipe diameter and depth of cover.

8.3 Consideration should be given to the stringing of the PE pipe and location of pits, which may
affect access to local premises, inconvenience to the public and cost. This may ultimately affect the
maximum pulling length available unless the process can be halted to allow additional liner pipe lengths to
be fused on. A profiled pipe entry roller of appropriate size used in a horizontal position shall facilitate entry
of the PE pipe into the host main.

8.4 Every attempt should be made to maximize the pulling length consistent with site constraints. In
cases where there are a number of deflected joints, the maximum pulling length may need to be reduced.

8.5 Liner pipe may be pulled through pits where long radius bends of up to 22.5 0 have been
removed, provided a suitable length of the existing pipe is removed to allow for the increased radius
required by the PE pipe. Where bends in excess of this have been removed, separate pulling sections are
necessary and a new fitting required.

9. POSITIONING AND ANCHORING OF EQUIPMENT

9.1 Above ground, the close-fit lining rig shall be securely anchored and positioned either
horizontally or inclined. Where practicable, the die unit shall be placed below ground secured to the entry of
the existing main. The die end of the close-fit lining rig should be lined up with the main in a slit trench and
suitably strutted. In soft ground, sheet piling or concrete thrust blocks may be necessary. For further details
of the position of the close-fit lining rig, see Figure 2.

CAUTION - The following method of anchoring shall not be used on a live gas main.

In unstable ground conditions, it is possible to provide an alternative form of anchoring by exposing a

section of isolated main at the rear of the close-fit lining rig and then attaching anchor chains directly from
the exposed section of the main to the close-fit lining rig.

9.2 The cold swagelining rig, which internally reacts all resultant forces, is positioned directly on the
end of the host main to be swaged (see Figure 2 c)).

CAUTION - Where the host main is in poor condition, additional thrust restraint should be used or
may be required.

J179 ( Rev 11/97 ) -3-

DIS 5.11.1

9.3 The use of a hydraulic pushing machine enables greater lengths to be achieved and also
considerably reduces the winch force required. When a hydraulic pushing machine is used, it shall be
secured and not left free-standing.

10. TOWING HEAD TYPES

Different towing heads are required for each pipe diameter and wall thickness. All towing heads and
connecting shackles shall be clearly marked with their safe working load (SWL). Examples of towing head
designs are shown in Figures 3 to 6 inclusive. Towing heads are suitable for repeated use, but damaged or
worn towing heads should not be used.

A minimum safety factor of 2.1 should be applied for all horizontal winching operations.

11. INSPECTION AND TESTING

11.1 All external beads of the butt fusions shall be removed and inspected prior to insertion. The
internal beads of butt fusions of PE pipe sticks shall be removed prior to insertion.

11.2 PE pipe strings shall be visually inspected for damage. Any damage to the pipe wall which
reduces the wall thickness by more than 10% shall be removed.

11.3 Before use, the PE pipe string shall be tested to 100 mbar for 10 min during which time
appropriate safety precautions shall be taken and a test certificate issued on completion.

11.4 All close-fit lined sections shall be tested in accordance with Module 5.5 and a test certificate
shall be issued.

In the case of medium pressure mains being pressurized to 3 bar, a settling period of 24 h shall elapse prior
to the initial test reading being taken.

11.5 If the hot swagelining process is interrupted, the close-fit lined sections shall have their internal
bore proved using a suitable gauging or inflatable pig prior to commissioning of that lined section.

12. SAFETY ASPECTS

12.1 Close-fit lining involves the use of winching equipment. The following essential precautions shall
be taken:

a) The Engineer shall ensure that all equipment is of suitable construction for its duty and is in
good condition. Those who operate the equipment shall be adequately trained.
b) The rig, winch, lifting and towing equipment (e.g. cable, rope) shall be visually inspected for
damage and wear prior to use.
c) Shackles, chains, lifting slings and towing eyes shall be clearly stamped with SWL details,
and test certificates shall be available upon request.
d) The close-fit lining rig shall be of adequate design to withstand the forces likely to be
imposed during operation. It shall be proof tested and labelled with its SWL.
e) The winching equipment shall be fitted with a calibrated load indicator.
Only purpose-built winching equipment shall be used for any winching operation.
f) The winch unit shall be fitted with an automatic safety override to ensure that the maximum
pulling force cannot be exceeded.

12.2 Where practicable, the winch load shall be reacted against the outlet end of the existing main, and
all cables/ropes under tension shall be below ground or constrained. The length of exposed cable or rope
under tension shall be kept to a minimum and contained or constrained against breakage. Care shall be taken
when the PE is finally pulled through the die as reversion and sudden release take place.

Adequate precautions shall be taken to ensure that all personnel are protected from the length of exposed
cable or rope under tension.

-4- J179 ( Rev 11/97 )

 DIS 5.11.1

12.3 Anchorage should be provided to prevent unexpected movement whilst a pipe string is set out on
rollers.

13. CLOSE-FIT LINING OPERATION

13.1 Prior to the commencement of close-fit lining operations, the interface of the PE pipe to host
metallic main shall be treated by either of the following methods:

a) whilst observing appropriate safety precautions, rounding off all of the cut ends of the host
metallic main using a suitable rotary grinding tool, or
b) installing a 2 mm thick stainless steel shim at the metallic to PE interface at the point where
the PE pipe protrudes from the host metallic main.

13.2 The close-fit lining die shall be checked for damage and kept clean.

13.3 Close-fit lining should preferably be a continuous process. In the case of hot swagelining, if for
any reason a stoppage is necessary, the burner should be shut down, the burner door opened and the fan left
running to reduce the temperature. If these steps are not taken necking of the material may occur when the
towing winch load is re-applied.

In the case of both hot and cold swagelining, it is essential to maintain a reduced winch tension during any
significant pause in close-fit lining. This reduced winch load should be sufficient to prevent rapid reversion
but insufficient to pull more pipe through the die.

13.4 During the close-fit lining operation the towing rates, temperature (in the case of hot
swagelining), inserted pipe sizes and towing loads should be monitored. The maximum towing force on any
pipe should not exceed the values given in Table 1.

13.5 The pipe entry roller shall be adjusted once the towing head starts to enter the pipe to ensure the
inserted pipe is centralized.

13.6 Once the towing head has emerged from the end of the host main, further pipe should be pulled
through to allow for reversion of the pipe when the winch load is removed.

13.7 Each individual close-fit lining operation should be recorded on a data sheet. A typical close-fit
lining data sheet is given in Appendix A.

13.8 Precautions shall be taken to ensure that the cable or rope is not damaged by the pipe end where it
emerges from the host main.

13.9 During close-fit lining, the following precautions shall be taken:

a) Radio, or other approved types of communication shall be maintained at all times between
the close-fit lining rig and winch unit operators.
b) Pedestrians shall be excluded from the footpath area when passing the exposed cable/rope
under tension between the close-fit lining rig and the pipe entry point.
c) An 'unsafe zone' shall be indicated around the close-fit lining rig and winch unit by the use of
physical barriers and signs warning of 'NO ENTRY'.

NOTE - To avoid confusing drivers, the 'NO ENTRY' sign should not be the same
as that used for road traffic.

d) Adjustment of the pipe entry roller to allow the PE towing head to enter the pipe requires one
person to enter the launch pit adjacent to the pipe entry roller. Once this has been done,
personnel should not enter the trenches.

J179 ( Rev 11/97 ) -5-

DIS 5.11.1

e) Only the person measuring the dimensions of the inserted pipe should be allowed to stand at
the front of the close-fit lining rig. All other personnel shall stand clear of the close-fit lining
rig cable/rope and winch unit whilst close-fit lining is in progress.
f) Safety helmets, gloves and footwear should be worn by all personnel.
g) All anchor points shall be monitored whilst close-fit lining is in progress.
h) Care should be taken when removing the split die due to circumferential stress loading at this
point. The 'split die' bolts should be removed first followed by the carrier bolts.

13.10 The use of clean water to lubricate and clean the PE pipe is recommended. Additionally, two
small 'V' (vee) cuts in the end of the PE pipe assist in reducing the towing load in a controlled manner in the
final stages of the operation.

14. CONNECTION OF CLOSE-FIT LINED SECTIONS

14.1 Sufficient time should be allowed after removal of the winch load to permit natural recovery of
the close-fit lined pipe before any connections are made. A minimum of 1h should be allowed. Dependent
upon ambient temperature conditions, overnight relaxation of the close-fit lined pipe is advantageous to
avoid undue stress on the fitting.

The length of free-standing SDR 26 and thinner walled PE pipe should be not greater than 10 m, and it is
essential that a good standard of backfill and compaction of materials surrounding the PE pipe is achieved.

14.2 Where a metal bodied transition fitting is used to connect close-fit lined pipe together, the fitting
should be adequately supported prior to backfilling.

14.3 When connecting metal bodied transition fittings, the distance between flange packing faces
should be not greater than 0.1% of the exposed length of pipe.

14.4 Where connections are made to non-anchored mechanical joints, a system of anchoring the pipe
against thermal contraction should be used at intervals not greater than 600 m. The preferred method of
achieving this is by the use of an electrofusion coupling as shown in Figure 7. The pipe shall be expanded to
the original outside diameter to permit fusion to take place. Alternatively, this may be achieved by using an
anti-shear sleeve and split section of the same size PE pipe, as shown in Figure 8.

14.5 Where electrofusion couplings are used to connect lined sections, the PE pipes shall be expanded
to enable steel inserts to be fitted prior to the fusion operation.

Steel inserts shall be used when using electrofusion couplings on SDR 26 or thinner PE pipe of any
diameter, swaged or unswaged.

Additionally, steel or plastic inserts shall be used on any other close-fit lined pipe.

14.6 If electrofusion service tees are to be installed on 'free-standing' sections of SDR 26 PE pipe, the
pipe shall be mechanically supported over a length of 300 mm whilst fusion of the electrofusion service tee
takes place.

15. PIPE PROTECTION REQUIREMENTS FOR SDR 26 AND THINNER WALLED

POLYETHYLENE PIPE
All 'free-standing' sections of pipe shall be protected from the risk of interference damage. Suitable methods
of protection are:

a) Laying protective marker tape and heavy duty protective PE tiles (minimum 3.5 mm thick x
600 mm wide) 300 mm above the pipe.
b) Laying precast concrete flags, together with protective marker tape, 300 mm above the pipe.

-6- J179 ( Rev 11/97 )

 DIS 5.11.1

16. BUTT FUSION PROCEDURES

Special welding techniques are required for the jointing of thin walled PE pipe normally used for close-fit
insertion.

J179 ( Rev 11/97 ) -7-

DIS 5.11.1

-8- J179 ( Rev 11/97 )

 DIS 5.11.1

TABLE 1 - Technical information for close-fit lining of mains

J179 ( Rev 11/97 ) -9-

DIS 5.11.1

- 10 - J179 ( Rev 11/97 )

 DIS 5.11.1

FIGURE 1 - Typical gauging pig

J179 ( Rev 11/97 ) - 11 -

DIS 5.11.1

a) Hot swagelining system

b) Cold swagelining system above ground

c) Cold swagelining system below ground

d) Cold swagelining from a coil trailer

FIGURE 2 - Swagelining systems

- 12 - J179 ( Rev 11/97 )

 DIS 5.11.1

FIGURE 3 - PE towing head assembly

FIGURE 4 - Mechanical spider towing head assembly

J179 ( Rev 11/97 ) - 13 -

DIS 5.11.1

FIGURE 5 - Two part mechanical towing head assembly

FIGURE 6 - Solid type (machined from solid PE)

- 14 - J179 ( Rev 11/97 )

 DIS 5.11.1

FIGURE 7 - Alternative thermal contraction couplings using electrofusion couplings

J179 ( Rev 11/97 ) - 15 -

DIS 5.11.1

FIGURE 8 - Position of steel anti-shear sleeve and thermal contraction spilt sleeve

- 16 - J179 ( Rev 11/97 )

 DIS 5.11.1

APPENDIX A

TYPICAL CLOSE-FIT LINING DATA SHEET

J179 ( Rev 11/97 ) - 17 -