En Standard Specification

SPECIFICATIONS FOR POLYETHYLENE (PE)
PIPES & FITTINGS FOR WATER SUPPLY

APPLICATIONS

SPECIFICATIONS FOR POLYETHYLENE (PE) PIPES, FITTINGS, SPECIALS,
ACCESSORIES FOR WATER SUPPLY APPLICATIONS

TABLE OF CONTENTS

PAGE NUMBER

1.0 GENERAL 6j-3

1.1 Ambient Conditions 6j-3

1.2 Suitability for Potable Water 6j-3

1.3 Definitions 6j-3

1.4 Materials 6j-3

1.5 Inspection and Testing 6j-3

1.6 Marking of Pipes, Fittings valves and Specials 6j-4

1.7 Protection during Delivery 6j-7

1.8 Storing handling and hauling of Pipes, Fittings and Specials 6j-7

1.9 Packing of bolts, joint rings and gaskets 6j-12

1.10 Manufacturer's Certificate 6j-12

1.11 Quality and workmanship 6j-12

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2.0 TECHNICAL REQUIREMENTS FOR POLYETHYLENE PIPES
AND FITTINGS FOR WATER SUPPLY APPLICATIONS 6j-14

2.1 Scope 6j-14

2.2 Reference Standards 6j-14

2.3 Definitions 6j-15

2.4 Classification 6j-15

2.5 Materials 6j-16

2.6 Dimensions of Pipes and Fittings 6j-21

2.7 Method of Manufacture of Pipes and Fittings 6j-22

2.8 Tolerances 6j-24

2.9 Final Acceptance at Site 6j-24

2.10 Specification for Butt Fusion Welding Machine 6j-25

Annex A - Characteristics of the PE compound as granules 6j-26

Annex B - Physical Characteristics of PE pipes 6j-27 6j-30

Annex C - Sling Arrangement for Lifting 63mm dia. coils 6j-31


1.0 GENERAL

1.1 Ambient Conditions

All items of materials and equipment shall be in every respect suitable for storage,
installation, use and operation in the conditions of temperature and humidity
appertaining in Sri Lanka.

The annual average temperature is 35
0
C while the relative humidity varies generally
from 70% during the day to 90% at night. The pH

of water to be conveyed ranges
from 6.5 7.9.

The climate of Sri Lanka is at times, hot and the sunlight is intense. Ambient
temperature of up to 40
0
C is possible and surfaces exposed to the sunlight may rise
to even higher temperatures.

1.2 Suitability for Potable Water

Pipes and pipeline components, including their protective coatings and joint
materials, that will or may come into contact with potable water shall not constitute a
toxic hazard; shall not support microbial growth; shall not cause taste or odour,
cloudiness or discolouration of the water and shall be approved by recognized
certifying authority listed below, as being suitable for using portable water supply
schemes.

NSF International, World Headquarters, 789 N. Dixboro Road, Ann Arbor, MI
48105 USA

Water Regulations Advisory Scheme, Fern Close, Pen-Y-Fan Industrial Estate,
Oakdale, Gwent, UK, NP11 3EH

IAPMO Research & Testing, 5001 E, Philadelphia St., Ontario, CA 91761-USA

1.3 Definitions

The definitions given in the relevant standards which are referred to in the
specification shall apply for the terms used in this specification.

1.4 Materials

All pipes & fittings shall be of blue colour and shall comply to the Clause 5 of the
Technical Specification hereof.

1.5 Inspection and Testing

The Contractor shall supply, furnish and prepare the necessary test pieces and
samples of all materials and supply the labour facilities and appliances for such
testing as may be required to be carried out on his premises according to this
specification. If there are no facilities at his own works for making the prescribed
tests the Contractor shall bear the cost of carrying out the tests elsewhere.


The Engineer or his representative or nominated inspection authority shall have full
access to all parts of the plant that are concerned with the testing, furnishing or
preparation of materials for the performance and testing of work under this
Specification.

The Contractor shall furnish the Engineer or his representative or nominal inspection
authority with reasonable facilities and space (without charge) for the inspection,
testing and obtaining of such information, as he desires regarding the character of
material in use and the progress and manner of the work.

The manufacturer shall provide results of tests conducted, in accordance with the
BSEN or ISO standards given in the Specification.

1.6 Marking of Pipes, Fittings and Specials

All markings described below shall be legible and indelible unless otherwise
specified.

All pipes and fittings shall be marked as specified in clause 8 of ISO 4427 : 1996 (E)
or BSEN 12201-2:2003 and as specified in the Table 1 hereof. The manufacturers
name Identification mark and the PN rating shall be marked legibly and indelibly on
the pipes together with the information shown below.

Markings should be in such a way that it does not initiate cracks or other types of
failures and that normal storage, weathering, handling, installation and use shall not
affect the legibility of the markings.

During the manufacturing process, the pipe should be marked with pertinent product
and process information at approximately 1m intervals along the pipe.

Specifications require at least the following information to be included.

Manufacturer's identification or logo,

Standard number (Specification number)

The designation of the pipe material (PE 80 or PE 100 etc.)

The dimensions (Nominal outside diameter, nominal wall thickness)

The outside diameter tolerance (A or B)

Third party certification mark by the inspection agency approved by the
Engineer.

The Production Period (date and code)

The Nominal Pressure (PN)


Standard Dimension Ratio (SDR)

The marking should be printed in the following colours:

PE 100 SDR 11 Black
SDR 17.6 Red
SDR 26 Yellow
SDR 33 Orange

In addition to the information given in clause 7 of General Specifications following
information to be marked on the fittings:

In case of a bend, bending angle and incase of unequal tee branch line
size and main line size.

Pressure rating at relevant temperature

Standard Dimension Ratio (SDR)

Fusion time (Seconds)

Cooling time (minutes)

System voltage

Moulded-in identification and appropriate product information

Terminal pin size of electro fusion fittings


Table 1 Marking

Item Diameter (mm) Details required Lettering Heights
Details (mm)
Pipes &
Fittings

above 160

"NWSDB"; "WATER", Third
Party Certificate Mark
(at 3 m intervals)

50

SDR Production Date, PN
outside diameter and other
(at 3 m intervals)

25
Manufacturing standard
(at 3 m intervals)

15
Pipes &
Fittings
below 160 "NWSDB", WATER
(at 3 m intervals)

25
Third Party Certificate Mark
(at 3 m intervals)

40
SDR, Manufacturing standard,
outside diameter, production
date, PN and other
(at 3 m intervals)

15


All fittings must be packed in such a way to allow instant use on site without
additional cleaning. All electro-fusion fittings must be packed in transparent
protective bags. The electro-fusion fittings must then be packed in carton boxes.
The Contractor shall label and clearly mark all crates and boxes legibly and indelibly
as specified in the notes forming a part of this Specification.

All fittings shall be marked with the corresponding item number in the Bills of
Quantities or any other number specified by the Engineer. An individual data carrier
card in compliance with ISO 7810 and ISO 7811 containing a magnetic strip and
appropriate bar codes as well as manual setting information for data transfer
purposes must be supplied with each item as appropriately.

1.7 Protection during Delivery

The Contractor shall provide methodology of protection of pipes and fittings, to the
approval of the Engineer and obtain written approval prior to the pipes and fittings
leaving the place of manufacture and shall maintain such protection until the items
reach their destination in order to guard effectively against damage during handling,
transit and storage and ingress of foreign matter inside the pipes & fittings.

All fittings shall be securely packed in crates and boxes to prevent damage during
delivery. The cost of packing shall be deemed to be included in the Contract Rates
and crates will not be returned.

The Supplier shall provide necessary details to the shipping line on precautions to be
taken during loading/unloading, handling & transport of the pipes & fittings and
other components, in the sea. Supplier shall provide to the purchaser a set of
recommendations of manufacturer for handling, loading, unloading, transporting and
storing of polyethylene pipes and fittings.

1.8 Storing, Handling and Hauling of Pipes, Fittings and Specials

All materials shall be stored in an approved location and in such a manner as to
preserve their quality and condition as recommended by the manufacturer.

All materials should be carefully inspected at the time of delivery and any defective
material set aside before accepting the delivery into stores. Any such defects should
be notified to the supplier immediately.

Materials and components shall be handled in such a manner as to avoid any damage
or contamination and in accordance with all applicable manufacturers
recommendations.


1.8.1 General Principles

The recommendations for handling and storage of PE pipes shall have greater care in
the handling of PE 100 pipe coils too shall have greater care as of pipes of similar
wall thickness.

Polyethylene is a tough resilient material which is relatively light and easy to handle
although it is prone to damage through scoring by sharp objects. Therefore careful
handling is always required and the dragging of straight pipe and coils should be
avoided.

The maximum allowable depth of scoring of the external surface of the pipe is 5% of
the wall thickness. Pipes and fittings showing obvious defects or excessive scoring
should be withdrawn, clearly identified as unsuitable and, where appropriate,
returned to the source of supply.

The general properties of polyethylene are unaffected by low ambient temperatures
but, having very smooth surfaces, the pipes and fittings become slippery in wet or
frosty weather. Particular attention should be given to effective securing and storage
under such conditions. Extra care should also be taken when handling large diameter
prefabricated fittings during very cold weather.

The packaging of pipes by the manufacturer is normally consistent with the
requirement to prevent damage and to comply with safety considerations. Usually
pipes are delivered strapped into convenient bundles or banded coils. Fittings are
normally supplied in separate cartons together with any associated small items, such
as bolts and gaskets.

As far as practicable the protective packaging (pallets, strapping, bags etc.) should be
kept intact until the material is required for use. The temporary capping or plugging
of pipe ends is recommended.

Pipes and fittings likely to be stored outside for periods longer than 12 months
should be covered by a tarpaulin or black polyethylene sheeting to prevent ultra
violet degradation from sunlight. Electro fusion fittings should be stored under cover
and in their protective packaging.

For hygiene purposes, the pipe ends must be protected from the ingress of dirt/water
etc. This protection should be carefully disposed of following use.

1.8.2 Transport and Delivery

For transporting bulk loads, vehicles should be provided with a clean flat bed, free
from nails or other projections, which may cause damage. If high sided lorries are
used, special care must be taken to prevent slippage or excessive bowing of the pipes
and extra protection given at all sharp edges.


Care should be taken to avoid positioning pipes and fittings near or adjacent to
exhaust systems or other heat sources and to avoid possible contamination from
materials such as lubricating or hydraulic oils, gaseous, solvent and other aggressive
chemicals.

Metal chains or slings should not be brought into direct contact with the material.
Webbed slings of polypropylene or nylon are recommended. Straight pipes should
be fully supported and bound together. Pipes must not rest on the integral socket, if
one is incorporated.

When transporting 'pupped' fittings, these should not be loaded in a way that it could
distort the pupped end.

Both vertical and horizontal deliveries of coiled pipes are permissible, although in
the case of horizontal transportation special notification may be required for highway
authorities in respect of wide load regulations.

Following the quality control inspection and testing, caps or plugs are to be provided
to protect the jointing surfaces during transportation and storage. The finished and
protected pipes are then carefully packed into manageable units (bundles or coils)
prepared for shipments.

1.8.3 Off Loading

1.8.3.1 Bundled Pipes

When lifting by crane, non metallic wide band slings or ropes should be used, and
for pipe lengths greater than 6m, load spreading beams of a length at least equivalent
to one quarter of the length of the pipe or bundle pack should be employed.

Chains or end hooks should not be used. Care should be taken to avoid damage to
pipes and pipe ends during lifting, particularly those pipes with couplers.

Some bending should be allowed for in the middle of the lift when loading and
unloading pipes and, because of this, lifting points should always be well spread and
evenly spaced.

Standard bundle packs, 6m long, may be handled by fork lift trucks but due
allowance should be made for the flexible nature of the pipes in the positioning of
the forks and the raising of the load.

Bundle packs greater than 6m long should be handled either by a side loader with a
minimum of four supporting forks, or by a crane using a spreader beam and suitable
slings. Individual pipes may be and led in the same way. Off-loading on site may be
made easier by using skid timbers and rope slings.


1.8.3.2 Coiled Pipes

Pipe coils shall be transported inside containers from place of manufacture.
Manufacturer/Tenderer (Contractor) shall ensure that coils of pipes are not exposed
to direct sunlight at any place, during transit. Tenderer (Contractor) shall deliver the
pipe containers in closed condition to purchaser's stores as directed and only inside
the purchaser's warehouse, the containers shall be opened for inspection. Tenderer in
coordination with the purchaser shall make arrangements for customs clearance,
when the containers are brought to storage warehouse.

Reinforced adhesive tape at least 50 mm wide should be used for banding. Complete
coils are secured by outer and intermediate bands and individual layers are also
independently secured. These should not be removed until the pipe is required for
actual use.

Pipe less than 63 mm in diameter should be moved and uncoiled using an approved
dispensing trailer.

Before unstrapping pipe form the coil or drum, both pipe ends must be firmly
mechanically restrained. The band securing the outer end of the pipe should be
removed first and the movement of the free end carefully controlled. This removal
should be followed with those securing successive layers. No more bands should be
removed than necessary to release the length of pipe immediately required. After
sufficient pipe has been cut from the coil the protective end cap must be replaced on
the remainder. The outer end of the pipe should be suitably re-marked as such.

When removed form the coil or drum, the pipe will be oval and curved. The extent
of ovality and curvature will depend upon the temperature, SDR rating, pipe
diameter, coil diameter and material type. Although both ovality and curvature will
reduce naturally with time, special hardware is available to facilitate handling and
jointing.
(See the fig. 1 in Annex - C hereof, showing the proper handling methods for coils)

1.8.3.3 Fittings

Hooks should not be used to lift fittings which are generally supplied in cardboard
boxes or polyethylene bags.

1.8.3.4 Storage at Depot

Materials of different polymer manufacture should be kept separately and clearly
identified.

Blue polyethylene pipe should preferably be stored under cover and protected from
direct sunlight until required for use. Where storage facilities necessitate the
material to be exposed externally, suitable good protective sheeting should be used.

All pipe stacks should be made on sufficiently firm, leveled ground and free from
stone to support the weight of the pipes and any necessary lifting equipment.

N NW WS SD DB B/ / S Sp pe ec ci if fi ic ca at ti io on n f fo or r P PE E P Pi ip pe es s & & F Fi it tt ti in ng gs s 6 6j j - - 1 10 0

Stacking heights should be kept to a minimum and without exceeding the
manufacturers recommendation and adequate space allocated for lifting machinery
to manoeuvre (more carefully and often with difficulty) without causing accidental
damage.

For safety and the convenience of handling, the stacking height for bundles should
not be more than 3 metres. To prevent possible deformation of the pipes, bundles
must be stored timber to timber.

The Bidder shall make arrangements to stack wrapped/bagged coils neatly on robust
pallets (free from projections), in Central Stores, conforming to the following
maximum stack heights.

7 coils for 20 mm diameter pipe

Forklift trucks shall not be used to load and unload pipes except where coils are
neatly stacked on pallets or coils and are provided with slings.

For similar reasons, pipe coils should be stored flat and the number of coils per stack
should be limited to;

Where individual pipe lengths are stacked in pyramidal fashion, deformation may
occur in the lower layers, particularly in warm weather. Such stacks should therefore
be no more than 1 metre high. Socketed pipes should be stacked with the sockets at
alternate ends and with the sockets protruding to avoid uneven stacking which may
permanently distort the pipes.

Polyethylene fittings should be stored under cover, preferably on racking and in the
manufacturers protective wrapping or cartons which should be kept intact until the
fitting is required for use.

At all times pipes and fittings should be stored away from exhaust outlets and all
other high temperature sources. Care should also be taken to avoid contact with
lubricating or hydraulic oils, gasoline, solvents and other aggressive chemicals.


All special tools and equipment associated with the jointing of PE pipes and fittings
should be stored separately and securely until they are required for use. The heating
faces of fusion tools should be kept in a position where the surfaces are protected
from scratching or other damage. Tools incorporating cutting edges should likewise
be protected from damage that could cause poor joint preparation.

1.9 Packing of Bolts, Joint Rings and Gaskets

Bolts of the same length and size (and their accompanying nuts and washers) shall be
packed together in boxes not exceeding 100 kg. gross weight.

J oint rings and gaskets shall be packed in boxes and separate packages shall be
provided for each size and description of ring or gasket.

Each box and package therein shall be clearly labeled stating the number, size and
description of the contents.

1.10 Manufacturer's Certificate

The Contractor shall supply to the Engineer a certificate stating that each item
supplied has been subjected to the tests laid down herein and conforms in all respects
to this Specification or such other Specification which has been submitted to and
approved by the Engineer.

1.11 Quality and Workmanship

All pipes, fittings and accessories shall be manufactured in compliance with the ISO
9001:2008 quality management system standards for the manufacturing factory. In
addition to product quality control tests the manufacturers also must perform and
satisfy long term type tests to demonstrate long term performance of pipe as detailed
in relevant standards. Quality Management System Certification should be from an
organization accredited to issue such certification and the manufacturer shall have
this certification valid during the supply and delivery of the materials. Documentary
evidence regarding accreditation together with the scope of certification should be
provided.


1.11.1 Quality Assurance (Q/A) at Manufacturers Works

The manufacturer shall operate a quality assurance scheme to (BS 5750 part 2), and
on award of order shall submit a copy of his quality assurance guidelines, as issued
to his production works sections. This shall include the following items, detailing the
frequency of quality assurance checking.

a. Raw Materials
i. Vetting and recording of certificates provided by the raw
material manufacturer (S).

ii. Chemical testing of raw material and frequency of tests.

b. Pipe Manufacture (for each pipe diameter)

i. Checking of extrusion compound temperature at the
extruder (state the temperature) and state its
consequence on quality.

ii. Temperature of water bath/sprayed water cooling
system on extruded pipe.

iii. Maintenance of pull force on extruded pipe.

i. Procedure for resumption of production after an
interruption on the production line (e.g. power
failures, change of pipe production batches, etc.)

ii. Hourly production records.

iii. Frequency of calibration of testing equipments

iv. Inspection of stock yards (visually) and packing
methods.


2.0 TECHNICAL REQUIREMENTS FOR POLYETHYLENE (PE) PIPES,
FITTINGS, SPECIALS AND ACCESSORIES FOR WATER SUPPLY
APPLICATIONS

2.1 Scope

This specification covers polyethylene pipes and associated fittings for the use of
cold drinking water.

2.2 Reference Standards

ISO 4427:2007 Polyethylene (PE) pipes for water supply
specifications.

EN12201-1:2003 Plastic piping System for Water Supply Polyethylene
(PE) Part 1- General
EN12201-2:2003 Part 2- Pipes
EN12201-3:2003 Part 3- Fittings
EN12201-4:2003 Part 4- Valves
EN12201-5:2003 Part 5- Fitness for purpose of the system

BSEN ISO 1167-1:2006 Thermoplastics pipes for the conveyance of fluids.
Determination of the resistance to internal pressures.
General Method.

BSEN ISO 1167-2:2006 Thermoplastic pipes for the conveyance of fluids.
Determination of the resistance to internal pressures.
Preparation of pipe pieces.

BS ISO 4065:1996 Thermoplastic pipes universal wall thickness table.

BS ISO 11922-1:1997 Thermoplastics pipes for the conveyance of fluids.
Dimensions and tolerances.

BSEN 1092-1-3 Flanges & their joints, circular flanges for pipes,
BSEN 1092-2-4 valves, fittings & accessories
PN designated
Part 1 : Steel flanges
Part 2 : Cast iron flanges
Part 3 : Copper alloy flanges
Part 4 : Aluminium alloy flanges

BSEN 1515:2000 Flanges & their joints, bolting, selection of bolting


BSEN 1092-1:2007 Flanges & their joints circular flanges for pipes,
valves, fittings & accessories PN designated steel
flanges

BSEN ISO 12162:1996 Thermoplastics material for pipes and fittings for
pressure applications clarifications clarification and
designation overall service (design-co-efficient).
ISO 161-1 Thermo Plastic pipes for the transport of fluids
nominal out side diameter and nominal pressure

DIN 8074 Polyethylene pipes dimensions
August 1999

DIN 16963 1-15 series Pipes joints and elements for high Density
Polyethylene (PE) pressure pipe lines.

BS 7874:1998 Method of test for microbiological deterioration of
elastomeric seals for joints in pipe work and pipes.

BSEN 681-1:1996 Elastomeric seals, material requirements for pipe joint
seals used in water and drainage applications.
Vulcanized rubber.

BSEN 681-2:2000 Elastomeric seals, material requirements for pipe joint
seals used in water and drainage applications.
Thermoplastic elastomers.

BS 6920 Specification for suitability of non-metallic products
for use in contact with water intended for human
consumption w.r.t to their effect on the quality of the
water.

2.3 Definitions

The definitions given in the relevant standards which are referred to in the
specification, shall apply for the terms used in this specification.

2.4 Classification

2.4.1 The terms PE 100 are a classification developed in line with a decision taken at
CEN/TC 155, the European Technical Committee drafting plastics piping system
standards for polyethylene products for water supply.

2.4.2 According to this classification, as detailed in ISO/DIN 12162
,
material has a
Minimum Required Strength (MRS) value of 8 Mpa and PE 100 has a MRS value of
10 Mpa. The international Standards Organization (ISO) technical procedure
ISO/TR 9080:1992 identifies these MRS values derived from the 50 year
extrapolated 97.5% Lower Confidence Limit (LCL) failure stress.


2.5 Materials

Pipes and fittings shall be manufactured by using polyethylene as main raw material.
The raw material used in manufacturing process shall be of reputed suppliers and
comply with the following characteristics tabulated in Table 2 in Annex A.

2.5.1 Non-metallic Materials

All non-metallic materials supplied shall be in conformity with the BS 6920 Part
1 to 3:2000, BS 6920 Part 4:2001; suitability of non metallic products for use in
contact with water intended for human consumption with regard to their effect on the
quality of water or approved equivalent publication, as a recognized certifying
authority having passed full tests of effect on water quality under the requirements
for the testing of non-metallic materials for use in contact with potable water.

2.5.2 Pipes

Polyethylene pipes shall be flexible and in pipe form or coil form complying with
standards given in the reference standards in the document. Pipe jointing
methods shall be as follows.

Jointing Methods

1. Electro-fusion Temperature, time, alignment
2. Butt-fusion Temperature, time, alignment
3. compression Rubber rings

2.5.3 Fittings

Polyethylene fittings shall be manufactured by injection moulding, factory welding
or formed in the factory complying with the standards referred in the document.

Fittings shall be suitable either for electro fusion or but welding as specified in the
Bill of quantities. All dimensions of electro fusion fittings must be fusible with one
fusion machine.

2.5.3.1 Types of pipe fittings

The following types of fittings shall comply to EN 12201-3/ ISO 4427
a) Spigot fittings
b) Electro-fusion fittings and
c) Mechanical fittings and joints


2.5.3.1.1 Spigot Fittings

Spigot fittings fall under two clauses as shown below.

Class Description
Moulded Injection moulded fittings

Fabricated Fitting which are assembled using
butt-fusion joints

2.5.3.1.2 Electro-fusion Fittings

Electro-fusion fittings shall be injection moulded fittings made of PE but
incorporating integral heating element(s) to enable fusion jointing with PE pipes.

2.5.3.1.3 Mechanical J oints and Fittings

i. General

Metal and plastic fittings available for use with PE pipe are:

Polymeric coated Flanged and other adaptors
Mechanical type couplers c/w restrainer

The materials and constituent elements used in making the fitting (including
elastomers, greases and any metal parts) shall be as resistant to the external and
internal environments as the other elements of the piping system and shall have a life
expectancy under the following conditions as least equal to that of the PE pipe
confirming to EN 12201-3 or ISO 4427 with which they are intended to be used:

a) During storage :
b) Under the effect of the fluids being conveyed :
c) Taking account of the service environment and operating conditions.
The requirements for the level of material performance for non-polyethylene parts
shall be at least as stringent as that of the PE pipe systems.

All mechanical joints and fittings shall be of approved types designed specifically for
PE pipe system. They shall be supplied with all necessary coupling, rings, nuts,
bolts, washers, rubber rings/sealing gaskets and restrainers/stiffeners.

All mechanical joints, fittings and systems shall confirm to the requirements
specified in BS EN 12201-5/ISO 4427 of Table below as applicable.


Characteristics for fitness for purpose of the joint, fitting of system

Characteristics Test Method
Hydrostatic strength at room temperature BSEN 921:1995

Cohesive resistance for Electro-fusion
socket fittings for electro fusion
saddle fittings

ISO 13954
ISO 13955
ISO 13956
Resistance to tensile force

ISO 13953
Mechanical Joints

Leak tightness under internal pressure

BSEN 715
Leak tightness under internal pressure when
subjected to bending (up to and including 63
mm)

BSEN 713
Plastics piping systems, Elastomeric sealing
rings type joints

BSEN 911
External pressure text

Resistance to pull out under constant
longitudinal force

BSEN 712 /ISO 3501

2.5.3.2 Compression Fittings, Nuts for PE Pipes

Couplings, flange adaptors etc shall be compatible with the pipes specified in item
4.1 hereof; together with following;

All bodies shall be injection moulded from recognized top quality
poly propylene.
Bodies shall be coloured black
Bodies must have moulded in manufacturer identification, material
and series information and dimension of the outside pipe diameter.
All male and female threads shall be injection moulded to the ISO 7/1
standards.
Nuts must have UV resistance of grade 8 of ASTM D2585.

2.5.3.3 Joint Rings

The physical properties of elastomeric joint rings shall comply with Table 2 of
EN 681-1:1996. The joint rings shall also comply with the relevant provisions in


BS 7874:1 1998 for effects on water quality and resistance to microbiological
deterioration.

J oint rings shall be supplied by the pipe manufacturer.

Each joint ring shall be marked clearly and durably in accordance with the following
information in a manner that does not interfere with the sealing function of the ring,
in complying with clause 10 of EN 681-1:1996.

a). The nominal size

b). Manufacturers identification

c). The number of the BS or BSEN with seal type designation

d). Abbreviation for the elastomer

2.5.3.5 Flanges

All flanges dimensionally shall be in accordance with BSEN 1092: 1 to 4:Flanges
and their joints and BSEN 1515:2000 1 to 2 Flanges and their joints Bolting. The
screw threads in the pipes and fittings shall be complying with ISO Metric Screw
Threads (ISO 7-1 and 2).

2.5.3.6 Flange Joints for Pipes and Pipeline Fittings

Flanges for pipes and pipeline fittings shall unless otherwise stated comply with BS
4504: section 3.1: 1989 and BSEN 1092: Part 2: 1997. Flanges shall be of PN16
nominal pressure rating and shall be raised faced, unless otherwise stated.

Flanges in accordance with BSEN 545 and ISO 2531 are dimensionally compatible
with BS 4504: Section 3.1.

Flanged joints shall be complete with all nuts, bolts, gaskets and two washers per
bolt.

The flanges of all fittings shall be integrally cast. The flanges of flanged pipes shall
either be integrally cast or screwed or factory welded unless otherwise stated.
Factory welded means that the flanges are welded to the pipes at the point of
manufacture under factory conditions with inspection agency certification.

The Contractor shall be responsible for checking and ensuring that mating flanges
are compatible in all cases, including where connections are required to pipe work
and valves associated with pumping plant and inlet/outlet pipe work at service
reservoirs or other structures.


2.5.3.7 Steel Flange Converter

Steel Flange Converter shall be made out of polyethylene and shall conform to the
EN 12201-3:2003 & EN 12201-5:2003 specification for mechanical fittings and
joints including flanges for polyethylene pipes for conveyance of cold potable water
for the size range 90-1000 inclusive made of metal or plastics or a combination of
both.

2.5.3.8 Gaskets for Flanged Joints

Gaskets for flanged pipe joints shall be of the inside bolt circle type and the
dimensions shall comply with BSEN 1514-2:2005 Flanges and their joints.
Dimensions of gaskets for PN-designated flanges. Spiral wound gaskets for use with
steel flanges.

The physical properties of gaskets shall comply with BS 7874:1998 (Method of test
for microbiological deterioration of elastomeric seals for joints in pipework and
pipelines for effects on water quality and resistance to microbiological deterioration).

The Gaskets shall also comply with the relevant provisions in BS 7874:1998 for
effects on water quality and resistance to microbiological deterioration.

The Gasket material shall be EPDM and shall be of average hardness of 65-75.

The Gaskets shall be supplied by the manufacturer and shall suit for PN 16 flanges
unless otherwise stated.

Each gasket shall be marked clearly and durably in accordance with the following
information in a manner that does not interfere with the sealing function of the
gasket, in complying with clause 10 of EN 681-1:1996.

a). The nominal size

b). Manufacturers identification
c). The number of the BS or BSEN with seal type designation.

d). Abbreviation for the elastomer


2.5.3.9 Nuts, Bolts and Washers

The nuts, bolts and washers for flanged joints shall be of high tensile steel and shall
comply with BS4395: Part 1 and 2: 1969.

The bolting shall comply with the relevant provisions of BS 4504: Section 3.1:1989.

The Bolt lengths shall be sufficient to ensure that nuts are full threaded when
tightened in their final position with two threads showing.

Two washers per each bolt shall be supplied for providing under the head of the bolt
and under the nut.

The bolts and nuts shall be hexagonal and shall be in accordance with BS 4190:2001
ISO metric black hexagon bolts, screws and nuts, Specification, the bolts, studs, nuts
and washers used shall be made of stainless steel or hot-dipped galvanized carbon
steel coated with fusion bonded epoxy powder or polyamide 11 to the finished
thickness of coating between 75 m and 125 m according to WIS 4-52-03-1994. Cold
applied high solid epoxy shall be used to repair the damaged coatings on the bolts
and nuts after fastening.

2.5.4 Testing

Testing shall be carried out fully in accordance with the requirements of ISO 4427
and DIN 8075-1999 or equivalent standard acceptable to the purchaser.

Test parameters of physical and mechanical characteristics for pipes & fittings shall
be as indicated in Table 3, 4, 5, 6 in Annex B.

2.6 Dimensions of Pipes and Fittings

Dimension of standard pipes shall conform to the following standards.

ISO 4427 PE pipes for water supply specifications

BSEN ISO 1167-1:2006 & for outside diameter & nominal pressures
BSEN ISO 1167-2:2006

ISO 161-1 Thermo Plastic pipes for the transport of fluids
nominal out side diameter and nominal
pressure

BS ISO 4065 1996 Thermoplastic pipes universal wall thickness
table

ISO 11922 1:1997 Thermoplastic pipes for the conveyance of
fluid -


Dimensions & tolerances Part I metric series

DIN 8074 Polyethylene pipes dimensions
August 1999

Standard lengths of a straight pipe shall be 12 m.

Dimensions of fittings shall conform to the following standards.

EN 12201-3:2003 Plastic piping System for Water Supply
Polyethylene (PE) 3 - Fittings

DIN 16963 1-15 series Pipes joints and elements for high Density
Polyethylene (PE) pressure pipe lines.

2.7 Method of Manufacturing of Pipes & Fittings

2.7.1 Manufacturing of PE Pipes and Fittings

2.7.1.1 Polyethylene are manufactured by various processes and are blended with anti-
oxidants, pigments and UV stabilizers to ensure the material is suitable for use in the
water industry. Amongst other factors, the range and quantities of co-monomers
used can result in substantially different basic properties, e.g. melt flow rate, density,
creep resistance etc.

The resulting compound is normally delivered to the manufacture in the form of
granules and the PE pipes are produced by an extrusion process.

The bidder shall submit full details of manufacturing process that he intended to
use with the bid.

2.7.2 Production Quality Control

2.7.2.1 The manufacture of PE pipe is a continuous processing which necessitates strict and
accurate control of both materials and plant to achieve the required quality. A range
of quality control tests pressures in the relevant standards should be applied within
the scope of a quality assurance in accordance with BS EN ISO 9001: 2008.

2.7.2.2 These control procedures shall include:

quality testing of raw materials, i.e. base compound.


Checks on the uniformity and consistency of the granules

control of processing parameters in terms of temperature, pressure, flow
rates, haul off speed and energy input

visual inspection of the pipes to check general appearance, dimensional
compliance and any indication of inclusions or processing flaws in pipe
barrels and jointing ends,

production short term tests, to identify any variations in the plant function.

2.7.2.3 Essential short-term quality control tests and procedures are described in the relevant
Water Industry Specifications include the following

appearance and surface condition

dimensions

thermal stability

elongation at break

hydrostatic pressure test at 80
0
C

short term pressure test

2.7.3 Product Type Tests

2.7.3.1 In addition to 'production quality control' tests, there are a number of important
longer-term "Type Tests that must be undertaken to demonstrate the long-term
performance of the pipe. These tests are also required whenever there is any change
in such parameters as formulation, size, classification or processing technique.

2.7.3.2These Type Tests are again detailed in the relevant specifications and include the
following:

effect on water quality

resistance to weathering

long term hydrostatic pressure testing

resistance to fracture on impact tensile strength,


elongation and weld test

2.7.3.3 Perhaps the most fundamental Type Test is the long term hydrostatic test which is a
standard means of predicting the long-term performance of the pipe. In this test,
samples are subjected different circumferential (hoop) stresses by pressurization and
the subsequent time to pressure is recorded. The individual results are plotted as a
log stress versus log time graph. They are then subjected to regression analysis to
obtain an extrapolated 50 year stress level.

2.7.3.4 It is worth bearing in mind that the above requirements for long-term performance
levels are minimum values and manufacturers usually ensure that their products can
comfortably meet these standards, i.e. the pipes have an additional factor of safety
built into them to cover any manufacturing variables.

2.8 Tolerances

Tolerances on wall thickness & weight, and length shall be in accordance with BS
ISO 11922 - 1: 1997 or DIN 8074 1999 or ISO 4427

The tolerances on flange thickness and flange diameter shall be in accordance with
BS4504: section 3.1:1989.

The tolerances on flange thickness, flange diameter and bolt holes in polyethylene
Steel flange converters to be used of connecting different type of material shall
conform to BS 4504:1989.

2.9 Final Acceptance at site

All pipes, fittings, valves and accessories shall conform to the specification at site.
Engineer shall carryout necessary inspections at site prior to final acceptance.


2.10 Specification for Butt Fusion Welding Machine

i. Machine shall be hydraulically operated and suitable for welding of PE pipes .

ii. Machine shall consist of self aligning frame and compact dimensions, to be
suitable for working on narrow roads.

iii. Machine shall comprised of four clamps in lightweight alloy of which the third
one is easily adjustable in order to weld special pieces, and the automatic
disconnecting devices to detach the pipes the heating mirror at the end of heating
time.

iv. Heating mirror shall be silver stone coated with electronic thermostat and
separate thermometer in order to continuously check the temperature of the
heating mirror. Operating electricity requirement of the heating mirror shall be
230V 50Hz.

Also it shall include removable electric facing tool complete with reducing gear, double
cutting edged blades, safety micro switch all which allow the engine to start only in
operating position.

i. An electrically operated mechanical block device avoiding dislocation during
the facing operation. Operating electricity requirement shall be 230V, 50Hz.

ii. A support for facing tool and heating mirror suitable to carry the two part and to
hold them when it is not in use.

iii. Hydraulic double throw pump with precision pressure gauge (class 1.0-100 bar
scale and 100mm face to easy reading) incorporates a device which maintains
pre-set line pressure even when motor is not running. Allows continuous pressure
adjustments and features flexible hoses with quick disconnect dry-lock
couplings. Mounted in a tough protective frame, with two transport handles.
Operating electricity requirement is 230V 50Hz.

iv. Light weight aluminium reducing inserts (8 inserts per set including 6 inserts for
pipes and 2 inserts for fittings) sizes 200,225,250,280,315,355,400,450mm.

v. Upper fitting clamp 500mm for short fittings.

vi. Stub end device with size range 200 to 500 mm.

vii. A Generator of adequate capacity.

viii. A 2 year warranty to cover all the equipments offered.


ANNEX A

Table 2 Characteristics of the PE compound as granules

Characteristics

Requirements
a
Test parameters Test method
Compound density

>930 kg/m
b
Test temperature
Number of Samples

23
0
C
shall conform to ISO
1183:1987

ISO
1183:1987
Carbon black
content (black
compound)

(2 to 2, 5)% by
mass
Shall conform to ISO 6964:1986 ISO
6964:1986
Carbon black
dispersion (black
compound)

<grade 3 Shall conform to ISO 18553:2002
c
ISO
18553:2002
Pigment dispersion
(blue compound)

<grade 3 Shall conform to ISO 18553:2002
c
ISO
18553:2002
Water content
b

<300 mg/kg Number of test pieces
d
1 EN 12118
Volatile content

<350 mg/kg Number of test pieces
d
1 EN 12099
Oxidation induction
time

<20 min Test temperature
Number of test pieces
d

200
0
C
e
3
EN 728
Melt mass-flow rate
(MFR) for PE 40

0, 2 to 1,4 g/10
min Maximum
deviation of +
20% of the
nominated value

Load
Test temperature
Time
d

2,16 kg
190
0
C
10 min
shall confirm to
EN ISO 1133:1999

EN ISO
1133:1999,
Condition D
Melt mass-flow rate
(MFR) for PE 63,
PE 80 and PE 100

0, 2 to 1,4 g/10
min Maximum
deviation of +
20% of the
nominated value

Load
Test temperature
Time
d

5 kg
190
0
C
10 min
shall confirm to
EN ISO 1133:1999

EN ISO
1133:1999,
Condition T
a
Conformity to these requirements shall be proved by the compound manufacture.

b
Only applicable if the measured volatile content is not in conformity with its specified requirement. In case of
dispute the requirement for water content shall apply. An alternative test method ISO 760:1978 [2] [7] may be used.

c
In case of dispute the test pieces for carbon black dispersion and pigment dispersion shall be prepared by the
compression method.

d
The number of test pieces given indicate the quantity required to establish a value for the characteristic described in
the table. The number of test pieces required for factory production control and process control should be listed in the
manufacturers quality plan (for guidance see prCEN/TS 12201-7[7]).

N NW WS SD DB B/ /S SB BD D/ /S SU UP P/ /P PE E/ /L LC C : : S Sp pe ec ci if fi ic ca at ti io on ns s 6 6j j - - 2 26 6
C CA AP PC C : : M MP PC C : : D DP PC C : :- - D De ec ce em mb be er r 2 20 01 10 0 V Ve er rs si io on n 1 1

ANNEX B

Table 3 - Physical Characteristics of PE Pipes

Characteristics
requirements

Requirements Test parameters Test method
Elongation at break for
e <mm
>350% Test piece shape speed of
test number of test pieces
a

Type 2
100 mm/min
shall confirm to EN
ISO 6259-1:2001

EN ISO 6259-
1:2001 and ISO
6259-3:1997
5 mm <e <12 mm
a

Type 1
b

50 mm/min
shall confirm to EN
ISO 6259-1:2001

EN ISO 6259-
1:2001 and ISO
6259-3:1997
e >12 mm
a

Type 1
b

25 mm/min
shall confirm to EN
ISO 6259-1:2001

EN ISO 6259-
1:2001 and ISO
6259-3:1997
OR
Test piece shape
Speed of test
a

Type 3
b

10 mm/min
shall confirm to EN
ISO 6259-1:2001

Melt mass-flow rate
MFR for PE 40
Change of
MFR by
processing +
20%
c

Load
Test temperature
Time
a

2,16 kg
190
0
C
10 min
shall confirm to
EN ISO 1133:1999

EN ISO
1133:1999,
Condition D
Melt mass-flow rate
MFR for PE 63, PE 80
and PE 100
Change of
MFR by
processing +
20%
c

Load
Test temperature
Time
a

5 kg
190
0
C
10 min
shall confirm to
EN ISO 1133:1999

EN ISO
1133:1999,
Condition T
Oxidation induction
time
>20 min Test temperature
a, d

200
0
C
e

3

EN 728
Effect on water
quality
f

National regulations apply

a
the table. The number of test pieces required for factory production control and process control should be listed in
the manufacturers quality plan (for guidance see preCEN/TS 12201-7[3]).

b
Where practical machined type 2 test pieces may be used for pipe wall thickness <25 mm. The test may be
terminated when the requirement is met, without continuing until the rupture of the test piece.
c
Value as measured on the pipe relative to the value measured on the compound used.

d
Samples to be taken from the inner wall surface.

e
Test may be carried out as an indirect test at 210
0
C providing that there is clear correlation of the results to those at
200
0
C : in cases of dispute the reference temperature shall be 200
0
C.


ANNEX B
Table 4 - Mechanical Characteristics of PE Pipes

Characteristics
requirements

Requirements Test parameters Test
method Parameters Value
Hydrostatic strength
at 20
0
C
No failure during
test period of any
test pieces
End caps
Conditioning period
b

Type of test
Test temperature
Test period
Circumferential (hoop)
stress for :
PE 40
PE 63
PE 80
PE 100
Type a)
a

Shall confirm to EN921:1994
3
Water-in-water
20
0
C
100 h

7,0 MPa
8,0 MPa
10,0 MPa
12,4 MPa

EN921:1994
at 80
0
C
No failure during
test period of any
test pieces
End caps
Conditioning period
b

Type of test
Test temperature
Test period
stress for :
PE 40
PE 63
PE 80
PE 100
Type a)
a

3
Water-in-water
80
0
C
165 h

2,5 MPa
3,5 MPa
4,5 MPa
5,4 MPa

EN921:1994
at 80
0
C
No failure during
test period of any
test pieces
End caps
Conditioning period
b

Type of test
Test temperature
Test period
stress for :
PE 40
PE 63
PE 80
PE 100
Type a)
a

3
Water-in-water
80
0
C
1000 h

2,0 MPa
3,2 MPa
4,0 MPa
5,0 MPa

EN921:1994
a
Type b) end caps may be used for batch release tests for diameters >500 mm.

b

c
Premature ductile failures are not taken into account. For retest procedure see Clause 7.3 of BSEN 12201-2:2003


ANNEX B
Table 5 - Physical Characteristics of PE Fittings

Characteristics
requirements

Melt mass-flow rate
(MFR) for PE 40
Change of MFR
by processing +
20%
b)

Load
Test temperature
Test period
a

2,16 kg
190
0
C
10 min
shall confirm to EN ISO
1133:1999
EN ISO
1133:1999,
condition D
Melt mass-flow rate
(MFR) for PE 463,
PE 80 and PE 100
Change of MFR
by processing +
20%
b

Load
Test temperature
Test period
a

5 kg
190
0
C
10 min
shall confirm to EN ISO
1133:1999

EN ISO
1133:1999,
condition T
Oxidation induction
time

>20 min Test temperature
a

200
0
C
c

3
EN 728
Cohesive resistance
for electro fusion
socket fittings
Length of
initiation rupture
<L
2
/3 in brittle
failure
Test temperature
a

23
0
C
shall confirm to ISO
13954:1997
ISO
13954:1997
OR
Cohesive resistance
for electro fusion
socket fittings

Surface rupture:
>25%, brittle
failure
Test temperature
a

23
0
C
as specified in ISO/DIS
13956:1996
ISO/DIS
13956:1996
Tensile strength for
butt fusion fittings
spigoted fittings
Test to failure :
Ductile :pass
Brittle :fail
Test temperature
a)

23
0
C
as specified in ISO/DIS
13953:2001

ISO
13953:2001
Impact resistance of
tapping tees
No failure, no
leaks
Test temperature
Mass of striker
Height
Conditioning period:
in air
in liquid

(0 +2)
0
C
(2500 +20) g
(2000 +10) mm

4 h
2 h

EN 1716
Effect on water
quality

National regulations apply
a
manufacturers quality plan for guidance see preCEN/TS 12201-7[7].

b
Value as measured on the fitting relative to the value measured on the compound used.

c
Test may be carried out as an indirect test at 210
0
C providing that there is clear correlation of the results to those at
200
0
C : in cases of dispute the reference temperature shall be 200
0
C.


ANNEX B
Table 6 - Mechanical Characteristics of PE Fittings

Characteristics
requirements

at 20
0
C
No failure during
test period of any
test pieces
End caps
Conditioning period
b

Type of test
Test temperature
Test period
stress
c
for :
PE 40
PE 63
PE 80
PE 100
Type a)
a

3
Water-in-water
20
0
C
100 h

7,0 MPa
8,0 MPa
10,0 MPa
12,4 MPa

EN921:1994
at 80
0
C
No failure during
test period of any
test pieces
End caps
Conditioning period
b

Type of test
Test temperature
Test period
stress
c
for :
PE 40
PE 63
PE 80
PE 100
Type a)
a

3
Water-in-water
80
0
C
165 h
d

2,5 MPa
3,5 MPa
4,5 MPa
5,4 MPa

EN921:1994
at 80
0
C
No failure during
test period of any
test pieces
End caps
Conditioning period
b

Type of test
Test temperature
Test period
stress
c
for :
for : PE 40
PE 63
PE 80
PE 100
Type a)
a

3
Water-in-water
80
0
C
1000 h

2,0 MPa
3,2 MPa
4,0 MPa
5,0 MPa

EN921:1994
a
Type b) end caps may be used for batch release tests for diameters >500 mm.

b

c
The stress shall be calculated using the dimensions of the pipe used in the test assembly.

d
Premature ductile failures are not taken into account. For retest procedure see Clause 7.4 of BSEN 12201-3:2003


ANNEX C

Note : Loop of sling should be adequately long and strong for lifting the coil

Fig. 1 -


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SPECIFICATIONS FOR POLYETHYLENE (PE)

PIPES & FITTINGS FOR WATER SUPPLY

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