Technical Manual Hdpe Pipes PDF

GODAVARI POLYMERS
GODAVARI POLYMERS PVT LTD
TECHNICAL DETAILS OF POLYETHYLENE PIPE
SIVA PHANI
[Type the company name]
Contents
Page
3
Polyethylene (PE - HDPE/MDPE) Pipe
Polyethylene (PE) Pipe: Benefits
GPPLS PE Pipe: Properties
BIS Standards
11
Design Considerations
12
5.1
Advantages by Using PE100 Grade Pipe
15
Polyethylene Pressure Pipes: Designing
17
Hydraulic Perspective: Design
21
7.1
Surge Design: Water Hammer Calculation
24
Laying And Jointing Of Polyethylene (PE) Pipes
26
Maintenance In PE Pipes
30
9.1
10
Testing Of The Pipe
32
Above Ground Installation
34
10.1
Distribution Or Service Connection
36
10.2
Electro Fusion
37
11
Frequent Queries
38
12
Contact Details
42
13
PE100 wall thickness sheet
43
14
Design Analysis
44
15
Project Execution pictures
49

Head Office, #315, Minerva Complex, S. D. Road, Secunderabad 500 003
Tel: +91 (40) 27842092, 27897733 Fax: +91 (40) 27819467 Email:homail@godavaripipe.com
GODAVARI PE PIPING SYSTEM
PAGE 2
Profile: Company Details
PROFILE
Godavari Polymers Pvt Ltd is one of the largest manufacturers of
Polyethylene (PE - HDPE/MDPE) pipes and fittings to suit the customer
requirements which are part of Water Management techniques by
same thus adding value to end users and business associates.
Godavari Polymers Pvt ltd is one of the manufacturers of pressure rated
Polyethylene (HDPE/MDPE) pipes was incorporated in August, 1990 as a private
limited company with Register of companies, Andhra Pradesh with an objective
to manufacture High Density Polyethylene (HDPE) pipes and the unit is located at
Cherlapally, IDA , Secunderabad, Ranga Reddy Dist.
Godavari Polymers Pvt Limited having started operations and has a capacity of
10000 tonnes per annum with pipe sizes from 20MM to 500 mm (as per BIS
Standards), today it is one on the largest manufacturers of PE( HDPE/MDPE) pipes,
Sprinkler and Drip Irrigation Systems in Indian sub-continent.
Godavari Polymers Pvt Ltd not only into manufacturing of PE piping and also
aimed to strengthen the operations and provide customers trouble free solutions
on piping undertakes projects on turnkey basis from designing to commissioning.
The products are also serviced in many critical applications of industrial slurry and
effluents spread over various segments.
Certifications:
Our manufacturing facility is accredited for Quality Management Systems as per
DIN EN ISO 9001:2000.
GPPL products are approved by Bureau of Indian Standards and also produced in
line with other international standards Viz., BS/DIN/ISO etc.
Quality Assurance:
Godavari Polymers Pvt Ltd well established Quality Assurance system supports and
ensures highest quality in the industry for the products manufactured with timely
supply to our customers which meet the requirement completely. Godavari
products are stringently checked at each stage of the production as well as post
production process.
PAGE 3
constantly redefining our quality standards and focusing on surpassing of the
Infrastructure:
Our infrastructure plays an important role in enabling us to meet the exact
requirements and standards of the industry. We are empowered by a
sophisticated infrastructure, supported by highly experienced professionals.
us to maintain our competitive edge in the market.
Godavari Polymers has skilled and trained manpower for execution of the works
with equipment imported for meeting best installation practises.
Godavari Polymers believes and promotes on updating the clients and users on
various developments of the product and its applications. The company
continuously organizes seminars and workshops to update on various subjects at
frequent intervals. Also organizes training programs on installation techniques for
benefit of users for best installation and maintenance practises.
Customer Satisfaction:
We satisfy the requirements of our clients by foreseeing their future demands, by
maintaining a constant relationship with our customers & understanding their
exact requirements and the client satisfaction is the at most motto of the
company.
Clients:
We cater to a wide and expanding network of clients, spread all across the
Indian sub-continent.
We executed many prestigious water development projects/schemes in Govt.,
public and private sectors which not only working efficiently and also serving the
important needs of the beneficiary.
PAGE 4
All our equipment and machinery incorporate the latest technologies that enable
PART -1
POLYETHYLENE (PE - HDPE/MDPE) PIPE
Godavari Polymers Pvt Ltd (GPPL) is a proven performer in the industrial,

municipal, agricultural/irrigation, mining pipe markets. Engineered for
gravity flow systems and also pumping mains a wide range of PE (HDPE/MDPE)
Characteristics and properties of PE pipes include the following:
Strength
The inherent flexibility of the PE pipe provides this product with its inherent minimum
pipe stiffness of 320 kPa or 210 kPa. The smooth inner wall provides longitudinal
stiffness which enables alignment and grade to be maintained in the trench during
installation.
Impact Resistance
PE pipes take the knocks and bumps of handling, moving in installation with ease.
As the Combination of non-brittleness of PE and its unique Properties makes PE pipe
capable of sustaining impact in both warm weather usage and cold weather
installations.
UV Resistance
PE pipe contains a minimum of 2% carbon black additive to protect the product

from ultraviolet light. This gives PE pipe maximum weather resistance in applications
where continuous exposure to the elements is expected.
Chemical Resistance
PE has the highest level of chemical resistance of all traditional sewer products. PE
pipe brings the gravity flow sewer market the same exceptional performance
remaining tough and resistant under conditions that could seriously damage pipe
made of other conventional materials.
Recommended pH Range
PE material provides excellent resistance to both acidic and alkaline environments

with strong acids through all bases, ranging pH 1.25 to 14.
Abrasion Resistance
Tests indicate that PE pipe is highly resistant to abrasion, giving it a significant

advantage over other pipe materials in both acidic and abrasive environments.
PAGE 5
pipe designs are available to meet specific standard and project requirements.
PART-II
Polyethylene (PE) pipe: Benefits
Piping made from polyethylene is a cost effective solution for a broad range of
piping problems in municipal, industrial, marine, mining, landfill, duct and
agricultural applications. It has been tested and proven effective for above
Excellent flow characteristics
Leak free & High Joint Integrity
Corrosion, Abrasion and Chemical resistance
Excellent flow characteristics
Lightweight and Flexible
Ductility and Toughness
Advantages by using PE pipe

The design and construction of PE product offer a distinct weight advantage over
conventional pipe. They provide ease of handling, positioning, installing and
connecting those conventional pipes cannot match. PE pipe affords these
important benefits to the user:
1. Savings on Installation
Due to its light weight, less manpower and lighter machinery is needed to transport,
handle and connect PE pipe compared to most of the other pipes. That's real
savings and real value added by using PE Pipe.
2. Fittings and Accessories
Godavari piping systems comes complete with a full range of fittings. Both
moulded fittings and adapters are available, as well as an extensive selection of
Made-to-order fabricated fittings to suit special project needs.
3. Faster Installation
The Continuous coils up to 500 meters can be achieved for the pipes with
diameters from minimal to 110 mm dia pipes. For more than 110 diameter pipe
standard length s up to 12 meter is produced and these 12 meter standard lengths
are easily handled and installed using minimal equipment.
PAGE 6
ground, surface, buried, slip lined, floating, and sub-surface marine applications.
4. Impact Toughness
PE pipe is highly resistant to the rigors of installation handling in tough
environment prevailing at the site location. PE pipe can be installed with
confidence in the hottest of summer or the coldest of winter conditions.
At less than 10% the weight per meter of concrete pipe, PE pipe gives the handler
and installer a big safety advantage. For example a 2.4 m length of 900 mm
diameter concrete pipe weighs more than 2,400 kg, while an equal length of 500
mm diameter PE pipe weighs less than 100 kg.
PAGE 7
5. Safer Handling
PART-III:
About GODAVARI PE PIPE
Godavari PE (HDPE) pipe can carry potable water, wastewater, slurries,

chemicals, hazardous wastes, and compressed gases. In fact, polyethylene
pipe has a long and distinguished history of service to the gas, oil, mining and
Godavari PE pipe has the lowest repair frequency per meter of pipe per year
compared with all other pressure pipe materials used for distribution.
Polyethylene is strong, extremely tough and very durable. If the project is for long
service, trouble-free installation, flexibility, resistance to chemicals or a myriad of
other features, high-density polyethylene pipe will meet all your requirements.
Lower life cycle costs

o
Corrosion resistance. Does not rust or corrode.
Leak tight. Heat-fused joints create a homogenous, monolithic system.

The fusion joint is stronger than the pipe.
Maintains optimum flow rates. Does not support tuberculation and has a
high resistance to scale or biological build-up.
Excellent water hammer characteristics. Designed to withstand high

surge events.
High strain allowance. Virtually eliminates breakage due to freezing

pipes.
Additional cost savings are achieved by lower instance of repairs.
With no infiltration, potable water losses and groundwater treatment

costs encountered in traditional piping systems are eliminated.
Reduced installation costs

o
Material of choice for trench less technology. Used in directional boring,

ploughing, river crossings, pipe bursting and slip lining.
Fewer fittings due to pipe flexibility. Allowable bending radius of 20 to 25

times outside diameter of pipe.
Lighter equipment required for handling and installation than with

metallic materials.
Eliminates the need for thrust blocking. Heat fused joints are fully
restrained.
Lightweight and longer lengths allow for significant savings in labour and
equipment.
PAGE 8
other industries.
LEAK FREE.
o
Polyethylene pipe is normally joined by heat fusion. Butt, socket,

sidewall fusion and electro fusion create a joint that is as strong as
the pipe itself, and is virtually leak free. This unique joining method
produces significant cost reductions compared to other materials.
CORROSION, ABRASION AND CHEMICAL RESISTANT.

o
Polyethylene pipings performance in mining, dredging and similar

applications proves it will outwear many more costly piping materials
when conveying a variety of abrasive slurries.
PE has excellent corrosion resistance and is virtually inert. It does not need
expensive maintenance or cathode protection. It offers better overall
resistance to corrosive acids, bases and salts than most piping materials.
In addition, polyethylene is unaffected by bacteria, fungi and the most

aggressive naturally occurring soils. It has good resistance to many
organic substances, such as solvents and fuels.
EXCELLENT FLOW CHARACTERISTICS.

o
Because polyethylene is smoother than steel, cast iron, ductile iron, or

concrete, a smaller PE pipe can carry an equivalent volumetric flow rate
at the same pressure. It has less drag and a lower tendency for
turbulence at high flow.
Its superior chemical resistance and non-stick surface combine to

almost eliminate scaling and pitting and preserve the excellent hydraulic
characteristics throughout the pipe service life.
LIGHTWEIGHT AND FLEXIBLE

o
Polyethylene pipe is produced in straight lengths or in coils. Made from

materials about one-eighth the density of steel, it is lightweight and does
not require the use of heavy lifting equipment for installation.
It reduces the need for fittings, is excellent in shifting soils and performs
well in earthquake-prone areas. PE resists the effects of freezing and
allows bending without the need for an excessive number of fittings.
Since PE is not a brittle material, it can be installed with bends over
uneven terrain easily in continuous lengths without additional welds or
couplings.
DUCTILITY AND TOUGHNESS.

o
Polyethylene pipe and fittings are inherently tough, resilient and resistant
to damage caused by external loads, vibrations, and from pressure
surges such as water hammer. Even in cold weather polyethylene pipe is
tolerant to handling and bending.
PAGE 9
MANUFACTURED UNDER RECOGNIZED STANDARDS.

o
Polyethylene pipe is listed and approved by the standards or

committees of the agencies like BIS, EEI etc.
AVAILABLE IN DIAMETERS FROM 12mm TO 500mm

o
Polyethylene pipe is available in a wide range of diameters and wall

system solution. PE pipe is also available in Iron Pipe Size (IPS), Ductile Pipe
Size (DIPS) as well as metric sizes. Plastic Pipe Institute members can
provide pipe, fittings and other appurtenances.
PAGE 10
thickness, with flanges, elbows, tees, wyes, and valves, providing a total
PART-IV
BIS Standards
Godavari Polymers Pvt Ltd well established Quality Assurance system

supports and ensures highest quality in the industry for the products
manufactured with timely supply to our customers which meet the
stage of the production as well as post production process.
Godavari Polymers Pvt Ltd manufacturing facility is accredited for Quality
Management Systems as per DIN EN ISO 9001:2000
IS No.
IS 4984:1995
Title
Specification for High Density Polyethylene pipes for
potable water supplies (fourth revision)
IS 8008(Part 6-8):2003
Specification for injection moulded PE fittings for potable

water supplies: Part 6 Specific requirements for pipe
ends, Part 7 Specific requirements for sandwich flanges,
Part 8 Specific requirements for reducing tests
IS 8008(Part 9):2003
Injection moulded/machined high density polyethylene

(PE) fittings for potable water supplies - Specification
Part 9 Specific requirements for ends caps (first revision)
IS 8360(Part 1 - 3):1977
Specification for fabricated high density polyethylene

(PE) fittings for potable water supplies:
Part 1 General requirements
Part 2 Specific requirements for 90 tees
Part 3 Specific requirements for 90 bends
IS 14333:1996
High
density
polyethylene
pipes
for
sewerage
Specification
IS 7328:1992
Specification for PE material Moulding and Extrusion
IS 7634:1975
Specification for Laying & Jointing of PE Pipes: Part 2
PAGE 11
requirement completely. Godavari PE Products are stringently checked at each
PART-V
Design Considerations
Designing a pressure pipe line:

The primary elements in determining the minimum acceptable diameter of
any pipe network are system design flow rates and pressure drops. The design flow
design phase of a project.
Before the determination of the minimum inside diameter can be made, service
conditions must be reviewed to determine operational requirements such as
recommended fluid velocity for the application and liquid characteristics such as
viscosity, temperature, suspended solids concentration, solids density and settling
velocity, abrasiveness and corrosivity. This information is then used to determine the
minimum inside diameter of the pipe for the piping system.
PIPE SPECIFICATIONS
1. Velocity:
The maximum allowable fluid velocity in a PE Piping system is a function of the
design of a specific system and its operational conditions. For normal liquid service
applications, the acceptable velocity in pipes is 1.0 m/sec to 2.1 m/sec (3.83 ft/sec
to 7 ft/sec) with a maximum velocity limited to 2.1 m/s (7 ft/s) at piping discharge
points including pump suction lines.
Recommended liquid velocities:
Recommended Velocity
Water and similar liquids
Pipe size
Gravity system
Pumping system
High viscous liquids

Gravity system
Pumping system
75-250 mm
1 - 1.5 m /sec
1 - 2.1 m/sec
1 - 1.5 m /sec
1 - 2.1 m/sec
250- 500 mm
1 - 1.5 m /sec
1.2 - 2.1 m/sec
1 - 1.5 m /sec
1 - 1.82 m/sec
2. Pressure :
The pressure rating of a piping system is determined by identifying the maximum
steady state pressure, and determining and allowing for pressure transients. The
determination of maximum steady state design pressure and temperature is based
on an evaluation of specific operating conditions
PAGE 12
rates are based on system demands that are normally established in the process
The evaluation of conditions must consider all modes of operation. Piping

components shall be designed for an internal to hydraulic conditions based
on operating pressures, potential back pressures, surges in pressures or
temperature fluctuations, control system performance variations and
Pressure drops throughout the piping network are designed to provide an optimum
balance between the installed cost of the piping system and operating costs of the
system pumps.
Pressure drop, or head loss, is caused by friction between the pipe wall and the
fluid, and by minor losses such as flow obstructions, changes in direction, changes
in flow area, etc. Fluid head loss is added to elevation changes to determine pump
requirements.
PE Pipes are classified by the pressure rating corresponding to the maximum
permissible working pressure at the required temperature. Depending upon the
material strength the grades of the pipe is differentiated.
3. Material classification:
Proper raw materials with specified grades (PE63, PE80, and PE100) are selected for
production and these polyethylenes are polymerized in controlled environment
thus producing PE pipes of high quality products, superiority on nature.
Polyethylene (PE100) pipes can carry potable water, waste water, slurries,
chemicals, hazardous wastes and compressed gases. In fact, PE100 is strong,
extremely tough and very durable when compared to it preceding material like PE
80 grade and PE63 grade. PE100 pipe has superior qualities in terms of mechanical
and all also other properties when compared to PE80, PE63.
The Polyethylene material used for the manufacture of pipeline systems are
classified and dimensioned by long term performance under hydrostatic pressure in
accordance with IS 4984:1995.
The design basis used in IS4984:1995 for Pressure rating (PN rating) of PE pipes in
order to determine the minimum wall thickness for each diameter and PN rating
provides for the steady and continuous application of the maximum allowable
working pressure over an arbitrary period of 50 years.
The selection of the long term hydrostatic design stress value (HDS) is dependent on
the specific grade of PE and the pipe material service temperature. For the grades
of PE materials contained in IS4984:1995, the specific values of the different grades
PAGE 13
process upsets must be considered.
are shown in Table. As these values are polymer dependent, individual grades may
exhibit different characteristics and materials can be provided with
enhanced properties for crack resistance or elevated temperature
performance.
Strength (MRS), which is the hydraulic stress that would cause failure after 50 years.
PE Pipe material is evaluated by the minimum required strength (MRS)
o
When PE80 pipes are hydrostatically tested at 20 C, a minimum required

strength at 50 years of 8 Mpa MRS will be 8 Mpa
When PE100 pipes are hydrostatically tested at 20 C, a minimum required

strength at 50 years of 10 Mpa MRS Will be 10Mpa
Typical Stress Regression Curves:

The relationship between the curves in the regression curves as shown in fig.01 for
different test temperatures enables prediction of the position of the curve at 20C,
based on a known position at elevated temperature see Figure .This in turn
enables prediction of life at 20C. The value of the predicted hoop stress (97.5%
lower confidence limit) at the 50 year point is used to determine the MRS of the
material, i.e. 6.3, 8.0 or 10.0 MPa.
FIG: Stress Regression Curves
The enhanced performance of PE100 allows the pipes to be produced with thinner
pipe walls compared to PE80 pipes of equivalent SDR rating and In addition to the
PAGE 14
This classification of PE piping grade material is based on the Minimum Required
superior qualities, PE100 also has the greater resistance to rapid crack propagation
compared to PE80.
PE 80 piping system can be advantageously replaced by PE100 material,
ensuring safety, reliability and economic benefits under similar operating
the
proceeded benefits derived from
the
Polyethylene (PE) piping system.

Prime Advantages derived by using PE100 material for Polyethylene piping system:
o
Durability and sustainability of the Pipe can be achieved by using the piping
material PE100.
Due to higher superiority and durability of PE100 piping system, the overall
efficiency of the piping system can be maximized.
Excellent hydraulic properties with low friction resistance throughout life of PE

100 thus long service life is achieved and it can able to withstand higher water
hammer when compared to PE80 Pipe., As thickness of the PE100 pipe is less as
compared to PE80 pipe, Volumetric flow (Discharge of the material) from the
pipe of PE100 pipe is comparatively higher than PE80.
Due to its low weight of PE100 for same SDR of PE80, Material handling of PE100
Pipe is lot simplified.
As butt welding is directly dependent on thickness of the pipe, Time required for
Installation and jointing of PE100 pipe is less when compared to PE80 pipe.
Due to higher discharge and inner diameter of the PE100 pipe , the loading
factors on the pump assembled with the piping system can be minimized thus
saving the not only the pumping costs and maintenance costs
but also
maximizing the life and efficiency of the pump, thus the overall efficiency of the
piping system can be maximized.
Representation of PE100 Pipe & PE80 of same Nominal (Outer) diameter and
Pressure Rating

Representation of PE100 Pipe
Representation of PE80 Pipe
PAGE 15
conditions with out affecting
S. no
Polymer data
Unit
PE80
PE100
Density at 23 c
gram/cm
0.947
0.956
Viscosity number
cm/gram
360
360
Melt Flow Rate at 190 C / 5 kg
gram/ 10 min
0.3-0.5
0.2-0.5
Mechanical properties
4
Yield stress(tensile)
Mpa
21
23
Elongation at yield
Tensile modulus(Short Term)
Mpa
750
900
Notched impact strength

At 23C
Kj/m
24
26
At 20C
Kj/m
11
13
Other Properties
8
Oxidation - induction time at 210

Min
c
Carbon black content
2.3 0.2
2.3 0.2
10
Dispersion
-----
<3
11
Minimum required strength
Mpa
10
12
Resistance to S.C.P(slow crack

Propagation ) at 4.6 mpa 80 C H
notched
<3000
>3000
13
Resistance to R.C.P (rapid crack

Propagation-s4 test 110/10mm ) Bar
C
25
>25
14
Elongation at break
>600
>600
15
Linear thermal expansion
1.8
2.4
20
Electrical properties
16
Electric strength
kv/mm
53
53
17
Volume resistively
>10 ^13
>10 ^13
PAGE 16
Tabular Representation of Properties of PE100 & PE80:
Part VI
POLYETHYLENE PRESSURE PIPES

Design Aspects
Pressure Determinations:
Barlow's Formula is commonly used to determine the pressure with is the main
factor in determining the pressure rating of the piping system:
1. Internal Pressure at Minimum Yield
2. Ultimate Bursting Pressure
3. Maximum Allowable Working Pressure
Hoop Stress, Internal Pressure & Wall Thickness
Tensile Creep Curves
Polyethylene has no true elastic constants, such as elastic modulus or

proportional limit, nor do they have sharply defined yield points.
Hydrostatic Pressure
The hydrostatic pressure capacity of plastic pipe is related to a number of

variables:
o
Standard Dimension Ratio (SDR): The ratio between the outside

diameter and the wall thickness
The hydrostatic design stress of the polymer
Operating temperature
The duration and variability of the stress applied by the internal

hydrostatic pressure
Although plastic pipes can withstand short-term hydrostatic pressures at levels

substantially higher than the pressure rating, the duty is always based on the
long-term strength at 20C to ensure a design life of at least 50 years.
PAGE 17
The parameters of the Polyethylene (PE) pipe for the application are
depended on various factors which are discussed as below:
The relationship between the internal pressure, diameter, wall thickness

and the hoop stress in the pipe wall, is given by the Barlow formula,
Where
P = Maximum Allowable Operated Pressure; dm = mean outside diameter
(mm); Wt = wall thickness (mm)
s = hoop stress (Mpa)
This formula has been standardized for use in design, testing and research and is
applicable at all levels of pressure and stress. For design purposes, p is taken as the
maximum allowable working pressure and s the maximum allowable hoop stress
at 20C.
Minimum required strength (MRS)
Polyethylene (PE) Pipe and fittings material are evaluated by their
minimum required strength (MRS)
o
When PE80 pipes are hydrostatically tested at 20 C, a minimum

required strength at 50 years of 8 Mpa
=>
MRS will be 80
kg/cm2
o
When PE100 pipes are hydrostatically tested at 20 c, a minimum

required strength at 50 years of 10 Mpa
=> MRS Will be 100 kg/cm2
Design stress
o
The design stress for Polyethylene (PE) -PE80 grade pipes is 8 Mpa. The
following table shows the comparison between the 50 years MRS values
for PE (PE80) and PE (PE100) pipes.
The enhanced performance allows Polyethylene (PE) pipes to be

produced with thinner pipe walls.
PAGE 18
which can be expressed as follows:
PE100
Grade
PE80
Grade
PE63
Grade
Minimum Required
Strength ( MRS in
Mpa)
Design Stress in
Mpa
Pressure Rating as
per IS4984
Specification
At 20 oC & 50
YEARS
At 20
oC
At 30
oC
16-500
10
6.3
8.0
6,8,10,12.5,16
IS 4984:1995
16-500
6.3
2.5,4,6,8,10,12.5,16
IS 4984:1995
16-315
6.3
2.5,4,6,8,10,12.5,16
IS 4984:1995
In mm
In bar
Standard dimension ratio (SDR)

For Polyethylene (PE)
Pipe of 25 mm nominal size and above, the pipe wall
thickness bears a constant ratio to the outside diameter, for a given pressure rating.
This is known as the standard dimension ratio (SDR), which can be defined as the
ratio of nominal diameter to the wall thickness which is calculated as follows:
SDR = Nominal outside Diameter / Minimum wall thickness
Carbon Black content
Another important factor of the specification is the Carbon Black content. The
carbon black content and dispersion are so specified that the pipe, when exposed
to sun light has no damaging effects. This is particularly important as the
Polyethylene (PE) pipe can be laid over ground and stored openly, as the carbon
black content in the resin takes care of the effect of UV light.
Pressure rating
The pressure rating of Polyethylene (PE) Pipe is generally referred to in 'bar', where 1
bar equals 10.2m head (approx).
Table gives the pressure rating and SDR of both PE 80 and PE100 pipes.
Design stress calculation:
The design stress is obtained by considering the design factors, safety factors etc.
Where
S= Design Stress
; MRS=Minimum Required Strength;
F=Design Factors
PAGE 19
Pipe
Material
Grade
Nominal
Diameter
Design Factors(F):
The value of the design factors or safety factors depends not only the pipe
material but also on the numerous factors like application of the piping
systems transporting material nature & properties
and operation risks
applications of 1.25 valve times is the minimal applicable value and in vast the
design factor.
Maximum Allowable Operated Pressure(MAOP)
Considering the design factors, IS4984 standard specifies the design stress values of
6.3 Mpa, 8 Mpa & 10 Mpa are designated as PE63, PE80 & PE100 respectively.
Maximum Allowable Operated pressure (MAOP) is important criteria considered for
prescribing the pressure rating of the Polyethylene.
Where
MAOP
Max.
Allowable
Operated
Pressure
PN = Pressure Rating;
F= design factors;
F = Fd X Ft
Fd = design factors nature of the fluid;
Ft = temperature factors
PAGE 20
involved in the application . In general, Design /Safety factors for water
Part VII
HYDRAULIC PERSPECTIVE: Design
Design formulae which are used for determining the required diameter of a
pipeline are often interpreted with a great deal of precision, but it is often
overlooked
the starting point for such computations is the design flow - a
calculations based on methods.

Pipe Flow Formulae
When designing a pipeline or conduit carrying liquid, an engineer faces ambiguous
in the choosing an appropriate flow formula on which to base the calculation, so
proper selection of the design formula has to be taken in selecting the proper
formula among numerous formulae. Some of the commonly used formulae are:
Hazen-Williams equation
Mannings equation
Darcy-Weisbach equation,
incorporating
the
Colebrook-White
equation for the determination of friction factor.

The Hazen-Williams and the Mannings equations are both empirical and contain
dimensional coefficients which take account of the roughness of the pipe.
Selection of Pipe dimensions
Considering the frictional flow co-efficient factor:
It is important to realize that, whilst the inherent surface roughness of a pipe is an
important characteristic property which could be expected to be a constant for a
specific pipe, the roughness coefficient used in energy loss computations is a
parameter which is dependent on both the pipe surface and the service
conditions.
Firstly, Coefficients may need to be varied/selected depending upon the following
reasons:
Biological growths and other obstructions.
Slime deposits, encrustation, detritus and other debris.
Irregularities at joints such as:
PAGE 21
parameter which is derived from often less accurate hydrological data using
Abrupt decrease/increase in diameter
Protrusions of jointing materials
Amount and size of material to be transported
Disturbance of flow due to branches

The C factor in the Hazen and Williams formula is 155 for plastics and
less for metallic pipes. Also, because of its corrosion resistance this factor
does not change with time as there will be no deposits or incrustations
unlike metallic pipes.
A combination of Hazen-William formula and Darcy-Weisbach
formula is frequently employed for calculating head losses,
particularly in computerized calculations:
The variables a, b are Coefficients which are dimension less. .Design

based on flow velocities exceeding 3 meters /sec are not
recommended.
Flow velocities in the range of 1.0-2.5 meters/sec are considered

hydraulically and economically optimal.
Because of high surface elasticity coefficient, Polyethylene (PE) pipes

effected from water impact will be very minimal when compared to the
other pipe types, as this the main reason that in pipe lining ,smaller
dimension PE100 pipe can be used for the same work of the alternative
pipes.
Depending upon the flow coefficients as discussed, Hazen Williams formula can be
derived as below:
The Hazen-Williams formula
Q= 1002 X C X d2.65 X S0.54
= Pressure loss due to friction, in mtr / mtr
Q =Volumetric flow rate, in meter3/Hour
= Inside diameter, in meter
=Flow
Factor
Coefficient
=150
for
Polyethylene (PE)
PAGE 22
Gravity Mains
For buried gravity flow lines such as sewers and OHSR feeder water lines, the
requisite wall thickness must be established in accordance with external
stress conditions caused by earth pressure and traffic.
increasing crushing load it deform but no stress cracks form. Basically, it must be
noted that even with sewer pipes of conventional materials, the soil in the vicinity of
pipe must be compacted in accordance with the laid down specifications. If
compacted soils are not locally available they must be obtained. Polyethylene (PE)
pipes are no exception to this rule.
The minimum cover depth for road traffic loads should be 0.8m; for pipes of D>
0.8m it should be equal to the pipe diameter and for rail and road traffic, minimum
cover depths of >1.5D >1.2m should be provided.
Polyethylene (PE) pipe are dimensioned so that the long-term deformation after 50
years does not exceed 6%. It is observed that pipe equal to or less than SDR ratio of
PN6 class pipe is best suited for such deformation criteria.
Pumping Mains
A water supply distribution system consists of a complex network of interconnected
pipes, service reservoirs and pumps which deliver water from the source to the
consumer. Water demand is highly variable, both by day and season. Supply, by
contrast is normally constant. Consequently, the distribution system must include
storage elements, and must be capable of flexible operation.
Water pressures within the system are normally kept between a maximum (70m
head) and a minimum (20m head) value. This ensures that the consumer demand
is met, and that undue leakage due to excess pressure does not occur.
DESIGN FOR DYNAMIC STRESSES:
Polyethylene pressure pipes are designed on the basis of a burst regression line for
pipes subjected to constant internal pressure. From this long term testing and
analysis, nominal working pressure classes are allocated to pipes as a first indication
of the duty for which they are suitable. However, there are many other factors
which must be considered, including the effects of dynamic loading. Whilst most
gravity pressure lines operate substantially under constant pressure, pumped lines
frequently do not and it is essential that the effects of this type of loading be
considered in the pipeline design phase to avoid premature failure. This note is
PAGE 23
In the Crown Loading Test, Polyethylene (PE) pipe does not fracture. Under
intended to assist in the selection of pipe class for polyethylene pipes in

applications involving transient and cyclic operating pressures.
Pressure fluctuations in pumped mains result from events such as pump
start-up and shutdown or valves opening and closing. The approach
depends on the anticipated frequency of the pressure fluctuation as follows:
For random, isolated surge events, for example, those which result from
emergency shutdowns, the designer must ensure that the maximum and
minimum pressures experienced by the system are within acceptable limits;
and
For frequent, repetitive pressure variations, the designer must consider the
potential for fatigue and design accordingly.
Surge events are characterized by high pressure rise rates with no time
spent at the peak pressure. The maximum duration of a surge event is
about 5 minutes.
The key factors to consider are the size and frequency of the repeated
event. For large pressure cycles, a lower number of events can be
tolerated in the pipe lifetime.
For smaller pressure changes, a greater number of events are acceptable.

The only design consideration required for this type of pressure fluctuation is
that the maximum pressure should not exceed the pressure rating of the
pipe.
Surge design
It has long been recognized that polyethylene pipes are capable of handling shortterm stresses far greater than the long-term loads upon which they are designed.
Field tests of installed pipelines are conducted to verify the pipeline design and
construction. These tests are generally carried out at a pressure of 1.25 times the
maximum system operating pressure. Since the test pressure is generally the highest
pressure a pipeline will experience, the field test serves to demonstrate that all
system components, including items such as anchor blocks which are formed insitu, will be satisfactory for the operating conditions.
The demonstrated ability of polyethylene pipes to accommodate short-term surge
pressures can be utilized to advantage by allowing some over-pressurization.
However, it is recommended that the peak design pressure is limited to the field test
pressure of that pipeline in order to ensure that the pipeline as a whole is capable
of performing under these conditions. Where the generation of negative pressures
PAGE 24
adopted for pipe design and class selection when considering these events
is anticipated, the possibility of transverse buckling should be considered. This topic

is well covered in other technical literature.
Water Hammer:
Water hammer is an increase in pressure in the pipe caused by a sudden change
starting the pump etc;
The maximum surge pressure encountered is a function of the wave velocity as
follows:
Where,
C = Wave velocity (in m/sec)
d =Pipe I.D. (in mm);
t = wall thickness (in mm)

k= Fluid bulk modulus of elasticity= (2.08 X 108 for water in Kg/m2)
E = Modulus of elasticity of the pipe;
for PVC pipe in Kg/m2: 3 X 108
&
For polyethylene in Kg/m2 : 9X
107
The maximum surge pressure, P,
Where
C = Wave velocity (m/sec), as defined above
V = Maximum change in velocity ( in m/sec)
g = Acceleration due to gravity (9.81 m/sec2)
To determine the maximum change in velocity, a worst-case scenario should be

considered. This would occur when all the pumps are running at minimum static
head condition (this is the maximum velocity the pumps will produce), and are
suddenly shut down. The minimum static head would occur when the system has
the maximum water level present.
PAGE 25
in the velocity. The velocity change usually results from the closing of a valve,
Part VII
LAYING AND JOINTING OF POLYETHYLENE (PE) PIPES
The jointing of Polyethylene is confined to IS7634 (Part 2) standard which

gives guidance for the proper methods of laying and jointing of
polyethylene (PE) pipe work for the potable water supplies.
jointing process called BUTT WELDING procedure which is an most efficient type
of HEAT FUSION process.
BUTT WELDING:
The principle of heat fusion is to heat two surfaces to a designated temperature,
and then fuse them together by application of force. This pressure causes flow of
the melted materials, which causes mixing and thus fusion. When the polyethylene
material is heated, the molecular structure is transformed from a crystalline state
into an amorphous condition. When fusion pressure is applied, the molecules from
each polyethylene part mix. As the joint cools, the molecules return to their
crystalline form, the original interfaces are gone, and the two pipes become one
homogeneous unit.
Butt Fusion Machine Procedure
The principle operations include:
Clamping
The pipe pieces held axially to allow all subsequent
operations to take place.

Facing -
The pipe ends must be faced to establish clean, parallel mating
surfaces perpendicular to the centreline of the pipes.

Alignment
The pipe ends must be aligned with each other to
minimize mismatch or high-low of the pipe wall.

Heating -
A melt pattern that penetrates into the pipe must be formed
around both pipe ends.

Joining -
The melt patterns must be joined with a specified force. The
force must be constant around the interface area.

Holding -
The molten joint must be held immobile with a specified force
until adequately cooled.
PAGE 26
Jointing of PE PIPE with a PE pipe or with PE special can be jointed by making use of
The key features in attaining the required quality Butt Weld are:
1. Identifying materials being used in the installation as compatible for
welding
2. calculating appropriate welding parameters to be used
3. Maintaining and calibrating welding equipment
4. Performing welding
5. Assessing quality of welded joints made.
Polyethylene (PE) Pipes fusion procedures require specific tools and equipment for
the fusion type and for the sizes of pipe and fittings to be joined. The process can be
detailed as below:
1.
Identify materials as being compatible for welding.

1.1.
Identify materials as polyethylene (PE) from specifications and work site

instructions
1.2.
Identify PE materials and pipes supplied as being compatible for

welding from specifications.
2.
Calculate appropriate pipe welding parameters.

2.1.
Identify welding machine type and operating data
2.2.
Check whether the welding machine is automatic or semi-automatic or

manual.
2.3.
2.2 Identify pipe materials and dimensions
2.4.
Check for the Diameter with in OVALITY are same
PAGE 27
WELD PERFORMANCE CRITERIA IN DETAIL:
2.5.
Perform
welding
parameter
calculations
for
individual
welding
machines and pipe details

Maintain and calibrate welding equipment.
3.1.
Set up welding equipment and work area

3.1.1.
Welding equipment consists of Heating Plate(mirror ), trimmer,

pressure jack or hydraulic jack
3.2.
Ensure safety equipment is available and operational
3.3.
Check operation and calibrate where required, heating, trimming, and

pressure systems.
4.
Perform welding.
4.1.
Assemble pipeline components in welding machine
4.2.
Clean, align and trim pipe ends

4.2.1.
Perform heating, welding, and cooling phases using calculated

welding parameters
4.3.
Monitor and record achieved weld parameters for each joint as per
enterprise requirement
4.4.
Clean up equipment when completed as per enterprise procedures
4.5.
Clean up work site, dispose of scrap materials as per enterprise

procedures
4.6.
Use personal protective equipment as per enterprise requirements.
5. Assess quality of completed joints.

5.1.
Identify quality requirements for joints
5.2.
Assess joints against specification requirements, and report results
5.3.
Identify and report non-conformances as per enterprise requirements
6. Identify materials as being compatible for welding.

6.1.
Identify materials as polyethylene (PE) from specifications and work site

instructions
6.2.
Identify PE materials and pipes supplied as being compatible for

welding from specifications.
7.
Calculate appropriate pipe welding parameters.

7.1.
Identify welding machine type and operating data
7.2.
Check whether the welding machine is automatic or semi-automatic or

manual.
7.3.
2.2 Identify pipe materials and dimensions
7.4.
Check for the Diameter with in OVALITY are same
7.5.
Perform
welding
parameter
calculations
for
individual
welding
machines and pipe details
PAGE 28
3.
8.
Maintain and calibrate welding equipment.

8.1.
Set up welding equipment and work area

8.1.1.
Welding equipment consists of Heating Plate(mirror ),
8.2.
Ensure safety equipment is available and operational
8.3.
Check operation and calibrate where required, heating, trimming, and

pressure systems.
9.
Perform welding.
9.1.
Assemble pipeline components in welding machine
9.2.
Clean, align and trim pipe ends

9.2.1.
Perform heating, welding, and cooling phases using calculated

welding parameters
9.3.
Monitor and record achieved weld parameters for each joint as per
enterprise requirement
9.4.
Clean up equipment when completed as per enterprise procedures
9.5.
Clean up work site, dispose of scrap materials as per enterprise

procedures
9.6.
10.
Use personal protective equipment as per enterprise requirements.
Assess quality of completed joints.

10.1.
Identify quality requirements for joints
10.2.
Assess joints against specification requirements, and report results
10.3.
Identify and report non-conformances as per enterprise requirements
PAGE 29
trimmer, pressure jack or hydraulic jack
Part IX
MAINTANENCE IN PE PIPES
1. Puncher in PE line.
2. Replacements in PE pipe line.
3. Replacement of specials in PE pipe line.
5. Different options in joining of PE pipe lines.
6. Training of Department personal.
1
Puncher in PE pipe line:
PE material is a viscous-elastic material and because of which it has high elastic

expansion limit. Punchers are not usually a part of such material. Such things can
only happen when a sharp object is pierced with a considerable force. Also it
happens if it comes in contact with a hot object (+200C) for some time. At sites this
can happen while excavating with sharp shovel and its sharp teeth punchers the
pipe. It can rectified immediately by wrapping a rubber sheet over the puncher
portion of pipe and clamping it with a suitable PVC / MS saddle pieces.
The other option for this is using compression fittings by cutting the damaged
portion and joining the pipeline with compression fitting up to a size limit of 110mm.
2. Replacing in PE pipe line:
If the above case is with a greater damage where a bigger portion of pipe has to
be removed, then that piece of pipe has to be completely replaced with a new
piece by arranging a piece of same size and connecting them with flanges at both
ends of pipe.
If there is a requirement of replacing PE pipe with other type of pipe material for a
specific application, than PE pipe can undoubtedly be attached through the
flanges.
3. Replacing of specials in PE pipelines:
It is difficult that a fitting getting failed in the process of functioning. A new spare PE
fitting is simply replaced with at least joining one end by welding and the other by
flange.
If the PE fittings are not available in the department stores section then the
immediate solution is to replace with any existing fitting of same size in the
department stores made from MS /CI which are flanged at both ends. Hence it is
PAGE 30
4. Re-routing in PE pipeline.
recommended to keep in hand some spare fittings in the stores after any PE
pipeline is completed.
4. Re-routing of PE pipeline:
In any case if sudden modification of pipeline has to be done and the proposed
required position. A suitable reducer is welded in that Tee and the other end is
blind flanged.
Repair and Maintenance of the Piping system:
Pipe Laying:
For laying down the PE pipes, it is enough to make a trench which has a place at
each side of the pipe for the operation of the compaction machine .There is no
need to bring sand for bedding and It is enough to prepare the trench bottom
surface with an angle of 120 degree. The earth derived from the excavation can
be used as filling sand after eliminating the big size stones and sharp object that
may damage the pipe .In rocky place, the sharp sides of the rocks are covered by
sand in order not to allow it to damage the pipe.
All road, railway and canal crossings should be done by laying pipe within larger
diameter sleeve pipes having a minimum of once and half times the diameter of
the main. The sleeve provides an access for repairs and servicing, without the need
to disturb traffic.
The advantage of less need of brining special filling sand out of the site, less
excavation and less filling sand need.
PAGE 31
line has to be diverted to some other locations, then a Tee/Bend is placed in the
Advantages
1. Since there is no need to bring special filling sand from out of the
excavated area, filling sand cost is minimum.
2. Since less excavation is done, excavation and filling costs are minimum
Testing of the pipe and joint integrity:

Pipes before completely buried in the trenches are to be tested for withstanding
the designed water pressure. The pressure rating given in IS 4984:1995 is for the pipe
to withstand continuous rated pressure for 50 years at 300C.
As explained in earlier, Polyethylene (PE) pipes have the ability to withstand much
higher loads for short term. Testing of the welded pipe is necessary to ensure the
joint strength.
Prior to testing, the entire PE pipeline should be checked to ensure all debris and
construction materials are removed from contact with the pipes and fittings. Where
concrete anchor or thrust blocks are used no pressure testing should take place
within 7 days of casting the blocks. All mechanical ring seal joints must be
restrained either by sand bags, or by partial backfilling of the line leaving the joints
open for visual inspection. Where thermal fusion jointing has been used, no testing
should take place until the joints have completely cooled to ambient temperature.
In order to test the effectiveness of PE piping system, PE Pipeline should be checked
to ensure the leak free system. The line should be tested in smaller sections of not
more than 1000mtrs. All air the valve should be serviced and both ends should be
plugged. At the higher end an air vent pipe with a valve should be provided. The
Pipe line is to be pressurized with the help of a hydraulic test pump (Manual or
motorized)
The test pressure of 1.5 times the maximum working pressure should be maintained
for a maximum period of 8 hours or for the time necessary to visually inspect all
joints in the line.
A smaller drop in pressure may be observed due to thermal expansion or
circumferential expansion of the pipe diameter. However, this does not indicate
leakage in the pipeline. Where the installation consists of small additions to existing
pipelines the test pressure period may be 15 minutes.
PAGE 32
compared to the other pipe types.
The following procedure is recommended for PE pipe Testing.

1. When PE pipes are tested by pressurizing, there will be reduction in
pressure over time (or pressure decay) even in a leak free system,
as a result of the creep characteristics of the material. The PE pipe
2. Polyethylene pipelines must not be pressure tested unless the wall
temperature is kept below 300C. Pipe exposed to hot summer weather
should not be tested unless the ambient temperature comes to 300 C. After
filling, the pipe line shall be left to stabilize at its temperature for a minimum
period of 1 hour.
3. Fusion joints may be covered during testing. Flanged or other threaded
type joints shall be kept open for visual inspection. The pipe line shall be
filled and pressure tested from the lowest point.
4. During the test period, make-up water is continuously added to maintain
the pressure. Under no circumstance, air is to be used instead of water for
testing.
5. The test pressure shall be 1.5 times the rated pressure of pipes or of the
proposed maximum design pressure of the section. Apply the pressure by
continuously pumping at a constant rate.
6. Tests should be performed on reasonable lengths of pipelines. Long lengths
more than 2000mtrs may make leak detection more difficult.
7. Acceptance Criteria: If the pressure remains steady (within 5% of the target
value) for one and half hour, leakage is not indicated. Flanged and other
threaded connections shall be visually inspected.
8. If the test is not complete because of leakage or equipment failures, the
test section shall be depressurized and allowed to relax for at least eight
hours, before starting the next testing sequence.
9. Testing outside the trench is to be avoided, as pipe rupture may involve
safety issues.
10. Hydraulic test proves duly signed by the inspection authorities are to be
maintained by the contractor, manufacturer and consumer.
PAGE 33
expands during pressurization.
Part X
ABOVE GROUND INSTALLATION
Polyethylene pipe provides unique joint integrity, toughness, flexibility and

low weight. These factors combine to make its use practical for many
above-ground applications. Basically the pipe may be installed over the
response to temperature change. Or the pipe may be anchored by some means
that will control any change of physical dimensions; anchoring can take
advantage of polyethylenes unique stress relaxation properties to control
movement and deflection mechanically.
For
exposed
supported
above
ground pipe work, proper anchorage

is
essential.
The
anchorages
structure
and
resist
or
must
accommodate thermal stresses or

movement
over
the
ambient
temperature range to which the pipe

system
will
be
subjected.
It
is
preferable that a polyethylene pipe is

installed at or near the maximum
operating temperature such that pipes are thermally expanded whereby at that
point clamps or supports can be bolted into position thus restraining the pipe from
further movement. As the pipeline cools, tensile stresses are developed and the
pipeline will remain straight between supports. If the pipeline then warms to its
original installation temperature, it returns to its installation condition and sag
between pipe supports is minimized.
Support spacing:
Support spacing is based on pipe material
and
dimensions,
nature
of
the
flow
medium, operating temperature and the

specials & appurtenances.
Pipe clips used for anchorage and support
should have flat, non-abrasive contact
faces, or be-lined with rubber sheeting and
should not be over-tightened. The width of support brackets and hangers should
normally be either 100mm or half the nominal pipe bore diameter, whichever is the
greater.
PAGE 34
ground in an unrestrained manner, thus allowing the pipe to move freely in
If the supports are to resist the temperature controlled or thermal movement, then
the stress induced in pipes, fittings and supports should be assessed and span
distance should be specified.
Thrust Block Anchoring:
bearing joint system do not normally require anchorage to withstand loads arising
from internal pressure and flow. Thrust blocks are required for the piping
applications where the pressures are high in which the joints cannot resist the
longitudinal loading on the piping.
For joint types which do not resist end loads, plus fabricated fittings which
incorporate welded PE pipe segments, anchorage support must be provided in
order to prevent joint or fitting failure. In addition, appurtenances such as valves
should be independently supported in order to prevent excessive shear loads being
transferred to the PE pipe.
Thrust block sizing is selected based on the following:
1. Depending upon the soil type, loads arising from internal pressure, flow of the
fluid, temperature of the medium, proper fitting and specials are selected and
the block should be designed after considering this factors.
2. Sizing of the thrust block is mainly dependent on the size of the pipe and pressure
exerted by the pipe on the surrounding soil, so in order to build a block the
maximum pressure should be considered.
Mostly Thrust blocks are made from concrete and the blocks should be adequately
cured for specified period in order to allow the bonding of the concrete in order to
develop the strength before the pressure is introduced in to the piping system. The
contact point between the pipe and thrust block must be protected in order to
prevent the abrasion of the pipe.
PAGE 35
PE pipes and fittings joined by butt welding, electro fusion, or other end load
Distribution or service connection considerations

Tapping Saddles
Service connections may be provided in PE pipe systems using tapping
saddles which are either electro fusion or mechanically connected. Tapping
capacity in the pipeline. Tapping saddles may be used for tappings up to 30% of
the size of the main pipe or a maximum diameter of 50mm. Where larger off take
sizes are required, then a reducing tee section should be used.
Tapping saddles of the mechanical strap type should not be used on curved pipes.
Tapping saddles of the saddle fusion, or electro fusion type should only be used on
the top of curved lines, and not be closer to the end of the pipe than 500mm.
Connection may then be made without loss of the operating service. Alternatively,
tapping may be performed on new main lines prior to pressurization, and entry into
service using the same techniques.
Direct Tapping
The tapping of services directly into the pipe wall by drilling and tapping a thread in
the wall material is not recommended in PE pipes. This practice may lead to
premature failure of the system.
PAGE 36
saddles should not be installed closer than 100mm to prevent reduction in pressure
New development in Polyethylene (PE) pipes:

Electro Fusion:
Electro fusion is the technique of heat fusion joining is somewhat different
from the conventional fusion joining thus far described. The main difference
heat is applied. In conventional heat fusion joining, a heating tool is used to heat
the pipe and fittings surfaces. The electro fusion joint is heated internally, either by a
y coil at the interface of the joint or, as in one design, by a conductive polymer.
Heat is created as an electric current is applied to the conductive material in the
fitting.
General steps to be followed while performing electro fusion joining are:
1. Prepare the pipe
2. Clamp the fitting and pipe (S)
3. Apply the electric current
4. Cool and remove the clamps
1. Prepare the pipe:
First clean the pipe surface in the joint area. Cut the end of the pipe square (omit
this operation for saddle-type electro fusion or joints). Mark on the pipe. Surface the
proper positioning of the fitting to be installed. Scrape the surface of the pipe area
to be joined, removing all surface degradation and contamination. Exercise
caution to avoid contamination of the scraped pipe surfaces. There are tools
available to a system operator in this procedure.
2. Clamp the fitting and pipe :
Place the pipes and fitting in the clamping fixture to prevent movement of the pipe
or fitting. Give special attention to the proper positioning of the fittings on the
prepared pipe surfaces.
3. Apply electric current:
Connect the electro fusion control box to the fitting and to the power source.
Apply electric current to the fitting as specified in the manufacturers instructions. If
the control does not do so automatically, turn of the current when the proper time
has elapsed to heat the joint properly.
Allow the joint to cool for the clamping fixtures. Premature removal from the clamps
and any strain on a joint that has not fully cool can be detrimental to joint
performance.
PAGE 37
between conventional heat fusion and electro fusion is the method by which the
Part XI
F.A.Qs:
Q. What fittings are available for PE pipe?

A. Godavari Polymers Pvt Ltd (GPPL) offers PE fittings in standard
configurations, including: straight and reducing tees, elbows, crosses,
branch-saddles, etc. These can be fused directly to the PE pipe. Custom fittings are
also available upon request.
Q. In what lengths is PE pipe available?
A. GPPLS PE Pipes are available either in coils or straight lengths.
Coils are normally available for small diameter pipe (110mm and smaller).
For diameters 140 inch and larger,
Pipe is normally available in straight lengths up to 18mtr in length.
Q. How long has PE been used in sewer and water applications?

A. Polyethylene has been used in various parts like in USA, European countries and
also in Asia for sewer force mains, gravity flow sewers, and pressure water main
applications for approximately 50 years. After many years of field proven
performance, it became a standardized material and product.
Q. Is GPPL PE PIPE certified for potable water use?
A. Yes. GPPL PE PIPE piping or fittings can be used for potable water.
Q. What is the life expectancy of PE pipe?
A. THE US EPA expects 100-year service life from PE pipes. Buried solid wall or profile
wall PE pipe should last at least as long. PE pressure pipe was first used in water
service over 50 years ago. Current accelerated testing methods predict that
todays PE pressure pipes will last much longer than 50 years. Everything points to a
service life of at least 100 years in a properly designed and installed PE pipe system.
Q. Is polyethylene pipe affected by chemicals?
A. NO. Plastics are not subject to galvanic corrosion, as are metals, since they are
not conductors.
Q. Will sunlight adversely affect PE pipe?
A. NO. PE pipe can sustain the higher temperatures like sunlight etc. Black PE pipe
has been stabilized with carbon black, which is the most effective ultraviolet
PAGE 38
concentric and eccentric reducers, flanges, mechanical-joint adaptors, outlet
stabilizer. PE pipe with carbon black UV stabilization (the normal black PE pipe),
may be used indefinitely outdoors.
Q. What is the temperature range across which PE pipe may be used?
A. The upper limit temperature for pressure service is 50oC. The low
affect PE in static applications.
Q. Will PE pipe wear less than other materials in a slurry application?
A. Yes. In general terms, with adequate particulate suspension, PE pipe has an
extremely high resistance to abrasion from slurries. In some applications, PE pipe has
outlasted steel pipe by as much as 4 to 1 for a given situation.
Q. Can PE pipe be used in permanent above ground installations?
A. Yes. In many mining and industrial applications, PE pipe has been installed
above ground and has provided and continues to provide excellent service after
15 to 25 years, with the potential to remain in service for many more years.
Q. How are PE solid wall pipe and components joined and connected?
A. PE pipe is normally joined by heat fusion. Butt fusion, socket fusion, sidewall fusion
and electro-fusion are all heat fusion methods that create a leak free joint stronger
than the pipe itself. The butt-fusion procedure is most frequently used joining
procedure.
Q. How long does it take to make a butt fusion joint?
A. The time required to make a butt fusion joint is dependent upon the pipe wall
thickness and diameter, and the field weather conditions. Typically the thicker the
pipe being joined the longer it takes to make a butt fusion joint, due to heating and
cooling time requirements.
Q. What inspection criteria are used to provide assurance about the quality of heatfusion joints?
A. The fusion joint has to be made following the pipe manufacturers
recommended fusion procedures, which include the procedures described in
standards. The time-proven method used for field inspection of fusion joints is visual
examination of the melt bead.
Q. Are gaskets required between the faces of PE flanges/ joints?
A. Gaskets are not required between PE to PE connections. Elastomeric gaskets are
normally used for flanges between PE flange adapters and metal flanges.
PAGE 39
temperature limit is usually regarded as -40oC. Cold temperatures do not adversely
Q. How can PE pipe be connected to pipe made from other materials (PVC,
Ductile, Iron, and Corrugated)?
A. For non-pressure drainage applications, flexible rubber couplings are
used. These flexible couplings are made for joining all types of gravity flow
For pressure applications and low-pressure sewer applications, PE transition fittings,

PE flanges, and standard metal couplings are recommended.
Q. Will mechanical joint valves and fittings work with PE pipe?
A. Yes. Mechanical joint /flange joints which are fused to PE pipe are available as
standard products. These joints are fully restrained.
Q. Will PE pipe of the same OD size as DI pipe deliver the same flow?
A. The inside surface of PE is extremely smooth and has a very low long-term design
coefficient of friction. The smooth bore of PE pipe is maintained throughout its
service life. It is often possible to use a polyethylene pipe with a smaller inside
diameter than the comparably sized ductile iron pipe, and still achieve an equal or
greater flow. The roughness co-efficient to use with Ductile Iron pipe recognizes the
likelihood that the ID roughness will degrade over time.
Q. To avoid kinking the pipe, what is the allowable bending radius of PE pipe?
A. For Godavari PE PIPE the rule of thumb is to use a minimum bending radius of 50
times the nominal diameter of the pipe.
Q. Is expansion and contraction of PE pipe a problem?
A. No. All objects expand and contract. As with all materials, expansion and
contraction must be taken into consideration when designing a PE piping system.
The resistance to movement provided by friction between the pipe and its
embedment is usually sufficient to prevent thermal expansion and contraction.
Q. Are thrust blocks required with PE pipelines?
A. No. PE pipe and fittings joined by heat fusion are self-restrained and do not
require thrust blocks. It is only at the transition to unrestrained bell and gasketed
pipe that provision must be made to limit the transmission of axial forces to the
other piping system.
Q. Is PE pipe suitable for use under railroads?
A. Yes, PE pipe is suitable for direct burial under railroads with just 4-5 feet of cover.
An engineering burial analysis is recommended.
PAGE 40
drainage pipe, including transitions from one type or size of pipe to another.
Q. How are service connections made on PE pipe mains?

A. PE pipe can be cold or hot (under pressure) tapped using saddle fusion
tapping tees which are readily available in the industry. There are bolt-on
mechanical connections qualified for use with PE pipelines as well.
pipeline?
A. GPPL PE PIPE is pressure tested in a procedure similar to that used to test other
pipes. Normally 1.5 times of working pressure is recommended for testing the pipe.
Q. Can PE pipe be threaded using the same tapping tools commonly used for
tapping PVC or ductile iron pipe?
A. No. Tapping of PVC or ductile iron pipe relies on cutting threads into the pipe
wall. Un-reinforced PE threads loose compression of the taper threads by creepstrain, leading to drip leaks over time.
Q. How are PE pipelines located?
A. A tracer wire can be buried above the PE pipe at the time of installation to
facilitate future locates. If no metal wire was installed above the plastic pipe,
ground-penetrating radar or acoustic resonance may be used.
Q. Is it possible to repair a damaged PE pipe?
A. Yes, a full saddle clamp can be used as a temporary repair. The damaged zone
should be replaced within a scheduled maintenance period using a PE section
either heat-fused or flanged into place.
Q. How will using PE save money?
A. Using PE pipe you create a leak-free system with an exceptionally long
service life, that will save money annually on reduced leakage losses,
improved water conservation, a reduction in the need for new water
treatment plants, reduced warehousing requirements, a reduction in
maintenance
crews,
reduced
seasonal
water-main
breaks,
less
maintenance, and less rehabilitation and restoration. Savings will accrue for
many years to come.
PAGE 41
Q. What are the recommended procedures to pressure test a polyethylene
Ten good reasons why PE water pipe systems provide a

superior solution:
1.
PE pipes are flexible and tough, ensuring highest
2.
PE pipes are corrosion-free, with the lowest rate of water

leakage of any material
3.
Leak-tight fusion welded joints can even resist soil movement

like the shocks due to earthquakes
4.
Wide product range offering pressure ratings up to 16 bars

and pipe diameters from 20 to 500 mm
5.
Well adapted to cost-saving modern trench less installation

techniques, and to renovation of old pipe networks
6.
PE, as a material, is neutral towards water;
7.
The light weight of PE pipes makes them easy to transport

and install, reducing the overall installation cost
8.
Environmentally friendly: low energy consumptions and low

CO2 emissions over their life-cycle. PE is easy to recycle and
can be converted into energy at the end of its service life
9.
Successful track record of almost 50 years
10.
Innovative mindset has allowed constant improvement of

the PE materials and pipe solutions
For further details regarding the PE piping, please do contact:

Head Office, #315, Minerva Complex, S. D. Road, Secunderabad 500 003
Tel: +91 (40) 27842092, 27897733 Fax: +91 (40) 27819467 Email:homail@godavaripipe.com
PAGE 42
durability and a long service life at low maintenance costs
GODAVARI POLYMERS PRIVATE LIMITED

WALL THICKNESS PE 100 Grade PIPES :(IS 4984)
( MM )
( MM )
ONLY + 'VE
PN 6.0
PN 8.0
PN 10.0
PN 12.5
PN 16
MIN
MAX MIN MAX MIN
MAX MIN MAX MIN
mm
mm
mm
20
0.3
1.2
25
0.3
1.2
32
0.3
1.3
40
0.4
1.4
50
0.5
1.4
2.3
63
0.6
1.5
75
0.7
90
mm
mm
mm
mm
mm
mm
2.3
2.3
2.8
2.9
2.4
2.9
2.9
3.4
3.7
MAX
NOMINAL TOLERENCE OVALITY

DIAMETER
ON O.D
mm
2.8
3.4
4.3
2.4
2.9
3.5
3.7
4.3
4.6
2.8
3.5
3.7
4.3
4.6
5.3
5.7
2.9
3.4
3.8
4.4
4.7
5.4
5.7
6.5
7.1
1.6
3.5
4.1
4.5
5.2
5.6
6.4
6.8
7.7
8.5
0.9
1.8
4.1
4.8
5.4
6.2
6.7
7.6
8.2
9.3
10.2
11.5
110
2.2
5.7
6.6
7.5
8.1
9.2
10
11.2
12.4
13.9
125
1.2
2.5
5.7
6.5
7.5
8.5
9.2
10.4
11.3
12.7
14.1
15.8
140
1.3
2.8
6.4
7.3
8.4
9.5
10.3
11.6
12.7
14.2
15.8
17.6
160
1.5
3.2
7.3
8.3
9.6
10.8
11.8
13.2
14.5
16.2
18.1
20.2
180
1.7
3.6
8.2
9.3
10.8
12.1
13.3
14.9
16.3
18.2
20.3
22.6
200
1.8
9.1
10.3
12
13.4
14.8
16.5
18.1
20.2
22.6
25.1
225
2.1
4.5
10.3
11.6
13.5
15.1
16.6
18.5
20.4
22.7
25.4
28.2
250
2.3
11.4
12.8
15
16.7
18.4
20.5
22.6
25.1
28.2
31.3
280
2.6
9.8
12.8
14.3
16.8
18.7
20.6
22.9
25.3
28.1
31.6
35
315
2.9
11.1
14.4
16.1
18.9
21
23.2
25.8
28.5
31.6
35.5
39.3
355
3.2
12.5
16.2
18.1
21.2
23.6
26.2
29.1
32.1
35.6
40
44.2
400
3.6
14
18.2
21.2
23.9
27.7
29.5
34.2
36.2
41.9
45.1
52.1
450
4.1
15.6
20.4
23.8
26.9
31.2
33.1
38.3
40.7
47.1
50.8
58.7
500
4.5
17.5
22.8
26.5
29.9
34.6
36.8
42.6
45.2
52.2
56.4
65.1
PAGE 43
5.3
6.5
8.1
9.6
Designing Of The
Polyethylene Piping System In The
Project
FOR THE REFERENCE
PAGE 44
DESIGN ANALYSIS:
1
2
3
4
Presuming the following details for the calculations :

Discharge Volumetric flow)
300
m3/hour
Length of the pipe system
5000
mtr
Static Head
10
mtr
Velocity of the flow
1.4
m/sec
By calculation, the pipe suggested for above details is PE100PN08DN315
II>
Summary of Data:
1
2
(For Reference)
Pipe OD
SDR
3
4
5
6
Inside Diameter
Length of Pipe
Upstream Elevation
Downstream Elevation
Slope
8
9
10
11
15
16
17
Pumping or Gravity
inform
Weight of water inside Pipe
Kg/mtr
Stiffness Factor
KPa
Volumetric Flow Rate required under pressure
in LPS
55.56
Velocity - under pressure
Mtrs/Sec
1.39
Head loss under above conditions
Mtrs/100mts
0.49
Suction Head
Mtrs
5
TOTAL Pumping Head
Required
Mtrs
59
Rating as per IS 4984
Kg/Cm2
8
Maximum Allowable Pressure
Kg/Cm2
5
III
>
Calculation of Water Hammer
12
13
14
units
mm
dimless
mm
Mtrs
Mtrs
Mtrs
Mtrs/Mtr
Design analysis for PE piping system:
I>
Value
315
17
276.5
5
5000
0
30
0.025
pumping
main
0.064
14
(For Reference)
C
Speed of the water
m/sec
water elastic Modulus
Mpa
142
5
203
0
PAGE 45
Di
e
E
a
v
g
IV
>
120
PE Elastic Modulus
Mpa
0
276.
Inside Diameter of Pipe
mm
55
19.2
min wall thickness of Pipe
mm
25
120
Elastic Modulus of water
Mpa
0
Wave Propagation Speed
m/sec
283
velocity in the pipe line
m/sec 1.39
Acceleration due to gravity m/sec2 9.81
Surge Pressure=40 mtr or 4 bar or Kg/cm2
Calculation of Pressure rating

(For Reference)
MAOP for the media, temp and site conditions
Maximum likely Pressure Raise in the system
Pipe Rating as per IS
Ratio of pressure raise to MAOP
Max Allowable for recurring surge
Max Allowable for occasional surge
Kg/c
8 m2
Kg/c
12 m2
Kg/c
8 m2
1.5
2
4
Graph Representing the Head loss against various discharge
PAGE 46
V> Calculation of HEAD LOSS
Optimum Velocity of the flow

Pipe Length
Di
Q
=
=
V
L
Head Loss
=
=
=
TOTAL Head Loss

Elevation Diff
Suction Head
Net Head
loss
VI
>
276.5
5 mm
83.33 LPS
mtrs/s
1.4 ec
5000
0.49 mtrs/100mtr
=
=
=
59 Mtrs
30 Mtrs
5 Mtrs
35 Mtrs
(For Reference)
Internal Diameter of the pipe
(OD=315)
Volumetric Discharge
SPECIFICATION OF GRADE OF HDPE:

(For Reference)
Factors considered while designing the piping system
For potable water
Media Factor(f0)
For temp <30 oC)
Temp Factor(f1)
Country Side without
Compacted top layer
Location Factor(f2)
Resin Grade
1
1
1
PE100
SDR
1
6.3
Dim
less
Dim
less
MPa
3.75
MPa
17
Factor
P=
Max. Allowable operating pressure
Selected Pressure
as per IS 4984
with above
factors
6.3
Kg/c
m2
Kg/c
m2
MAOP
Rating
as per
IS
PAGE 47
VI
>
Soil Load and Deflections:

(For Reference)
Load calculations :
PE100
1.4
YES
NO
17
13.56944162
78
4.260141958
Mtrs
2.260141958
5
%
%
dimless
kN/m2
%
Part- II
The calculations specified above are the part of the design analysis of the buried pipe. Be informed that
the depth of the trench will calculated depending upon the diameter of the pipe, Pipe Grade , nature of
the ground/soil and also the compacting the soil above the pipe after the installation. Find below the
different conditions considered for making the trench.
Location Based on Minimum depth

on Underground Pressure Pipe
Installation
Nature of compaction of top layer

Open field
Country Side with Compacted top layers
Country Side without Compacted top layer
Urban Layouts with Compacted top layer
Urban Layouts without Compacted top layer
Submarine or under water Installations
For the calculations submitted the trench details are as follows:

Resin Grade
Height of Fill/Depth of the trench
Truck Traffic
PE100
1-1.4 DEPENDING ON PIPE
DIMENSIONS
YES
Mtr
PAGE 48
Resin Grade
Height of Fill
Truck Traffic
Compacted
SDR
Stiffness Factor
Load acting on the pipe
Maximum Deflection
Maximum Deflection without
Traffic
Allowable deflection
PIPE EXECUTION PICTURES: EXECUTED BY

PAGE 49
PROJECT DETAILS: SATYA SAI WATER PROJECT SCHEME, EAST

GODAVARI ,ANDHRA PRADESH
SITE LOCATION
OFFICIALS OF AP-Ph Dept & GODAVARI POLYMERS PERFORMING SITE SURVEY FOR
INITIATION OF WORK
PAGE 50
STEP 2: SITE CLEARING
JUNGLE CLEARENCE:
PAGE 51
STEP 3: MAKING TRENCH
BY MACHINE
BY MANUAL TRENCHING
PAGE 52
STEP 4: TRENCHING LEVELING AND MEASURING THE DEPTH OF TRENCH
BUTT FUSION/WELDING MACHNIE: AUTOMATIC MACHINE
PAGE 53
STEP 5: PIPE JOINTING
MANUAL JOINTING
MACHINE JOINTING FULLY AUTOMATIC JOINITING
PAGE 54
STEP 6: PIPE JOINTING & LAYING -UNDER THE CULVERT
STEP 6: PIPE JOINTING-IN JUNGLE
PAGE 55
STEP 7: PIPE LAYING INTO TRENCH-BY MANUAL
STEP 7: PIPE LAID UNDER THE CULVERT
PAGE 56
STEP 8 : PIPE LAID WITHOUT DISTRUBING OTHER PIPE LINE
STEP 9: PIPE LAYING UNDER THE AC PIPE
PAGE 57
STEP 10 : PE PIPE LAYING ACROSS THE WATER STREAM
STEP 10 : PE PIPE LAYING ACROSS THE WATER STREAM BY USING MACHINE
PAGE 58
STEP 10 : PE PIPE LAYING ALONG THE WATER STREAM
STEP 11: PIPE ENCASING
PAGE 59
STEP 12: PIPE TESTING
PIPE PRESSURE TEST:
PAGE 60
STEP13: PROVISION FOR TAIL PIECE-FOR WATER DISTRIBUTION
PAGE 61
STEP14: PROVISION FOR SADDLE-FOR WATER DISTRIBUTION
PAGE 62
PAGE 63
STEP15: PIPE JOB FINISHING
SITE VIEW AFTER THE COMPLETION OF TASK
PAGE 64

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GODAVARI POLYMERS

GODAVARI POLYMERS PVT LTD

TECHNICAL DETAILS OF POLYETHYLENE PIPE

Polyethylene (PE - HDPE/MDPE) Pipe

Polyethylene (PE) Pipe: Benefits

GPPLS PE Pipe: Properties

Advantages by Using PE100 Grade Pipe

Polyethylene Pressure Pipes: Designing

Hydraulic Perspective: Design

Surge Design: Water Hammer Calculation

Laying And Jointing Of Polyethylene (PE) Pipes

Testing Of The Pipe

Above Ground Installation

Distribution Or Service Connection

PE100 wall thickness sheet

Project Execution pictures

GODAVARI POLYMERS PVT LTD

GODAVARI PE PIPING SYSTEM

TECHNICAL DETAILS OF POLYETHYLENE PIPE

Profile: Company Details

GODAVARI PE PIPING SYSTEM

TECHNICAL DETAILS OF POLYETHYLENE PIPE

constantly redefining our quality standards and focusing on surpassing of the

GODAVARI PE PIPING SYSTEM

TECHNICAL DETAILS OF POLYETHYLENE PIPE

POLYETHYLENE (PE - HDPE/MDPE) PIPE

Godavari Polymers Pvt Ltd (GPPL) is a proven performer in the industrial,

PE pipe contains a minimum of 2% carbon black additive to protect the product

PE material provides excellent resistance to both acidic and alkaline environments

Tests indicate that PE pipe is highly resistant to abrasion, giving it a significant

GODAVARI PE PIPING SYSTEM

TECHNICAL DETAILS OF POLYETHYLENE PIPE

Polyethylene (PE) pipe: Benefits

Excellent flow characteristics

Leak free & High Joint Integrity

Corrosion, Abrasion and Chemical resistance

Excellent flow characteristics

Lightweight and Flexible

Ductility and Toughness

Advantages by using PE pipe

GODAVARI PE PIPING SYSTEM

TECHNICAL DETAILS OF POLYETHYLENE PIPE

GODAVARI PE PIPING SYSTEM

TECHNICAL DETAILS OF POLYETHYLENE PIPE

About GODAVARI PE PIPE

Godavari PE (HDPE) pipe can carry potable water, wastewater, slurries,

Lower life cycle costs

Corrosion resistance. Does not rust or corrode.

Leak tight. Heat-fused joints create a homogenous, monolithic system.

Excellent water hammer characteristics. Designed to withstand high

High strain allowance. Virtually eliminates breakage due to freezing

Additional cost savings are achieved by lower instance of repairs.

With no infiltration, potable water losses and groundwater treatment

Reduced installation costs

Material of choice for trench less technology. Used in directional boring,

Fewer fittings due to pipe flexibility. Allowable bending radius of 20 to 25

Lighter equipment required for handling and installation than with

GODAVARI PE PIPING SYSTEM

TECHNICAL DETAILS OF POLYETHYLENE PIPE

Polyethylene pipe is normally joined by heat fusion. Butt, socket,

CORROSION, ABRASION AND CHEMICAL RESISTANT.

Polyethylene pipings performance in mining, dredging and similar