Pipe Specifications & Quality Control

Webinar on PDN

Pipe Specifications & Quality Control

Presented byShri. R. R. Shah

(Mobile No. 9850571279)

Chief Engineer (Civil) HP & QC, Pune.Date- 8th May 2020

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Bodwad LIS

PDN Need

To increase water use efficiency by 20% (Central Governmentmandate)

MWRRA ordinance, 2015 mandates irrigation of perennialcrops by micro-irrigation methods.

Maharashtra : CCA-225 lakh Ha.

: Area that can be brought under irrigation byavailable water (Surface + Ground) is

126 lakh Ha (85+41) (56% of CCA)

To bring more area under irrigation with available water

To avoid exorbitant cost of land acquisition.

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Various types of pipes commonly used in PDN

HDPE PVC, PVC-O

GRP

PSCPCCP

MSBWSC

DI

SWSRP

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Pipe description

Pipe type Description

HDPE HDPE pipe is a flexible plastic pipe made up of HDPE material i.e. polyethylenethermoplastic made from petroleum. HDPE has high level of impermeability,strong molecular bond, toughness and resistant to corrosion and chemicals.

SWSRPThe Spirally Wound Steel Reinforced Pipes (SWSRP) are structured wall pipescomprising of an HDPE inner smooth layer, spiral steel skeleton and outercorrugated profile of HDPE.

PVC, PVC-O

Polyvinyl Chloride (PVC) pipes are made by a continuous extrusion process.These pipes are supplied with plain or with socket-ends.Manufacturing of PVC-O involves process of controlled circumferential & axialorientation of molecular structure resulting in formation of laminar structure ofthe material used in the pipe construction.

GRP Glass fibre reinforced Plastic (GRP) pipe is a machine made tubular pipecontaining glass fibre reinforcements embedded in or surrounded by curedthermosetting resin.

MS Mild steel (MS) Pipes can be manufactured from mild steel produced by theopen hearth or electric furnace or one of the basic oxygen processes.

DI Ductile iron (DI) pipes are manufactured from ductile iron. Ductile iron is a type ofiron in which graphite is present primarily in spherical or nodular form.

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Pipe description (contd) Pipe

type Description

PSC

Prestressed Concrete Non-Cylinder Pipe (PSC) is suitably compacted concrete corelongitudinally prestressed with pretensioned high tensile steel wire embedded inthe concrete, circumferentially prestressed and coated with cement mortar orconcrete.

PCCP Prestressed Concrete Cylinder Pipe (PCCP) comprises of a welded sheet steelcylinder with steel socket and spigot rings welded to its ends, lined with concretesuitably compacted and circumferentially prestressed.

BWSC Bar/Wire wrapped steel cylinder (BWSC) pipe comprises of a welded steel sheetcylinder with steel socket & spigot rings welded to its ends, lined with centrifugallyapplied cement mortar within the steel cylinder.

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Depends on :-

Design Discharge.

Pipe diameter.

Internal Pressure.

External Loads.

Life of pipe.

Cost of pipe.

Ease in handling, transportation & storage

Ease in laying & jointing

Ease in maintenance & repairs.

Durability.

Life Cycle Analysis

C.E. is competent authority to finalize pipe type

(As per GR dated 02/02/2017)

Pipe thickness needs to be designed based on internal hydrostatic pressure

and external overburden, based on actual site conditions.

Specials to be manufactured & supplied by pipe manufacturer.

Selection of pipe type for PDN

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PDN Policy GR dated 13/01/2017

PDN Guidelines Circular dated 02/02/2017

Guidelines for planning & design of piped irrigation network,

July- 2017 (Published by CWC)

Pipe distribution System for irrigation, Sept.-1998 (Published by

Indian National Committee on Irrigation & Drainage, INCID)

Various Indian Standard Codes (About 70)

Inputs gathered by QC team during visit to PDN works in Gujarat

during May-2018 (Arranged by WALMI, Gujarat)

Basis for pipe specifications

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Main aspects covered in Pipe specification Applicable IS Codes

Raw Materials

Sampling Criteria for Selection of Pipes for Testing

Pre Delivery Testing of Pipes in factory

Marking on Pipes

Transportation & Stacking at site of Pipes

Laying & Jointing of Pipes

Field Hydraulic Testing of Pipeline System

Backfilling of Pipe Trenches

Operation, Maintenance and Handing over of PDN system to WUA

Pipe type Applicable Codes

HDPEIS 4984, ISO 4427, IS 8360, IS 8008, IS 7634 (Part-II), IS 7328, IS 2530, IS 10141, IS 9845 &

IS 10146

SWSRP IS 2530, IS 7328, IS 12235 (Part-6), IS 12235 (Part-9), IS 16098 (Part-1), IS 16098 (Part-2)

PVC, PVC-O IS 4985,IS 4669, IS 10151, IS 12235, IS 7634 (Part-3) , IS 5382, IS 16462, IS 16647

PCCP IS 784, IS 783, IS 3597, IS 1785 (Part 1&2), IS 383, IS 1566, IS 2062 & IS 7322

PSC IS 784, IS 783, IS 3597, IS 1785 (Part1&2), IS 383, IS 1566, IS 2062 & IS 5382

BWSC IS 15155, IS 7322, IS 783, IS 3597, IS 1566, IS 2062, IS 383 & IS 432 (Part 1&2)

GRP IS 12709, IS 13916, IS 14402, IS 11273, IS 11320, IS 11551 & IS 5382

M SIS 3589, IS 5822, IS 4711, IS 2062, IS 814, IS 3613, IS 456, IS 800, IS 816, IS 4353, IS 1182, IS 2595 & IS 4853

DI IS 8329, IS 9523, IS 12288, IS 11606, IS 5382, IS 638, IS 1608 & IS 1500

Applicable codes

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Pipe classification

Pipe type Pipe classification

HDPE Based on material: PE63, PE80, PE100Based on pressure: PN2.5, PN4, PN6, PN10, PN12.5, PN16

PVC Based on pressure: Class1, Class2, Class3, Class4, Class5, Class6

GRP Based on pressure: PN3, PN6, PN9, PN12, PN15Based on stiffness: A, B, C, D

MS Based on manufacturing method: S, ERW, SAWBased on steel grade: Fe330, Fe410, Fe450

DI Based on service condition: K7, K8, K9, K10, K11, K12

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Raw materials

Pipe type Raw Materials

HDPE Polyethylene.(PE63,PE80 & PE100 Grade)

SWSRP Polyethylene, Steel plate.

PVC, PVC-O Polyvinyl chloride resin.

PCCP Cement, Aggregate, Water, Admixtures, Steel Reinforcement & Steel Plates.

PSC Cement, Aggregate, Water, Admixtures, Steel wires & Steel for Specials.

BWSC Cement, Aggregate, Water, Admixtures, Steel Reinforcement & Steel Plates.

GRP Resin, Glass fibre reinforcement, Aggregate, Filler & Additives.

MS Steel Plates, Welding consumables, Cement, Aggregate, Water & Admixtures.

DI Ductile Iron

• Test certificate of raw materials used for pipe manufacturing shall be obtained. • Manufacturer’s own rework material (generally upto 10%) is permissible. No other reworked or

recycled material shall be used in pipe manufacturing.

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Different for each pipe type

Different for various tests

Sample size depends on lot size

Lot: All pipes of - Same size,

- Same pressure rating,

- Same grade,

- Manufactured under similar

conditions of manufacture.

Test samples shall be selected at random from the lot.

Sampling criteria for selection of pipe for testing purpose

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Scale of sampling for visual and dimensional requirement of HDPE Pipe (As per IS 4984: 1995)

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Pre-delivery testing of pipes in factory

HDPE SWSRP PVC, PVC-O

Dimension: (OD, t, L)

Visual appearance

Internal pressure creep

rupture test

Reversion test

Overall migration test

Density

Melt flow rate (MFR)

Carbon black content and

dispersion


Visual appearance

Colour of finished pipe

Resistance to heating

Mechanical characteristics

Ring stiffness

Impact strength

Ring flexibility

Creep ratio

Dimensions : (OD, t, L)

Visual appearance

Opacity, Colour

Effect on water

Reversion test

Vicat’s Softening Test

Density

Sulphated ash content test

Resistant to external

blows at 0°C

Internal hydrostatic

pressure test

Ring Stiffness

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Pre-delivery testing of pipes in factory (contd.)

PSC PCCP BWSC

Dimensions : (ID, t, L)

Straightness & finish

Hydrostatic Factory Test

Permeability Test on

Coating

Mortar soundness test

Dimensions: (ID, t, L)




Coating


Steel Cylinder Test.

Dimensions: (ID, t, L)




Coating


Steel cylinder test

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These tests shall be carried out in factory in the presence of Engineer’srepresentative and third party agency. Some tests be carried out in presenceof QC Engineer.

After delivery of pipes to site, some of these tests can again be carried out onany pipe selected randomly as confirmation.

Test results shall always be maintained at site.

GRPDI MS

Dimension: (ID, OD, t, L)

Workmanship

Pipe Stiffness

Hydraulic test

Longitudinal Strength Test

Hoop Tensile Strength Test

Tests to establish potability

of water


Ovality, deviation from

straight line.

Tensile test

Brinell hardness test

Hydraulic test

Dimensions: (OD, t)

Ovality & straightness.

Tensile strength

Flattening test

Guided bend test

Hydraulic pressure test

Pre-delivery testing of pipes in factory (contd.)

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Engineers India Limited, Mumbai

RITES (Rail India Technical Economics Services) Mumbai

SGS, Mumbai

VJTI, Mumbai

VNIT (Visvesvaraya National Institute of Technology), Nagpur

CWPRS (Central Water & Power Research Station), Pune

CIPET (Central Institute of Plastics Engineering & Technology)

Third party inspection agencies

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Sample of third party inspection certificate

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Sample of third party inspection certificate (contd.)

Marking on pipes

Manufacturer’s name, trademark.

Details of raw material (e.g. Grade)

Pressure rating.

Nominal diameter.

Lot No / Batch No.

Month of manufacture.

BIS certification mark.

Third party certification mark.

Name of the project.

Any other details (desired by Engineer)21

Transportation of pipes

Use flat bedded vehicle.

The pipes shall rest uniformly in the vehicle.

One type of pipes in one vehicle.

Pipes shall be secured effectively during transportation.

Loading/Unloading shall be done by mechanical means.

Padding shall be provided between coated pipes.

In case of coated pipes, extra care shall be taken topreserve the coating while transportation.

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Stacking of pipes Stacking area shall be reasonably flat, free from sharp objects,

stones or projections likely to deform or damage the pipe.

Pipes shall be supported evenly over entire length.

Pipes of different diameters & different pressure classes shouldpreferably be stacked separately.

While stacking in layers, proper precaution for supporting thepipes needs to be taken.

Rolling down of stacked pipes must be avoided.

Dragging pipes over rough ground should be avoided.

If pipes have been telescoped for transportation (eg.PVC), theinner pipes should be removed first & stacked separately.

Rubber rings, Gaskets and other jointing/fitting items shall bestored in a cool, dry and dark place to avoid any damage.

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Murum bedding of 150 mm under the pipe (with watering &compaction) is preferable to provide firm, stable and uniform supportfor full length of pipeline

For rocky area, sand bedding is preferable

Trench bottom finished levels (after bedding) shall be as per design

For murum bedding, OK Card by field dy engr shall be issued

Laying shall preferably be done by mechanical means

Each pipe shall be thoroughly checked for any damage before laying

Various appurtences as per design shall be provided while laying

(eg. Thrust block, anchor block, sluice valve, scour valve, air valve etc)

Pipe laying

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Depending on pipe type, treatment for corrosion preventionto inside and outside of pipe needs to be carried out beforelaying

For gunited pipes, continuous curing shall be done,preferably by sprinkler method. Pipes shall be rolled overduring curing so that entire perimeter of pipe gets cured.Alternatively, curing can be done by covering gunited pipesby gunny bags and keeping them continuously moist.

In case of coated pipes, extra care shall be taken to preservethe coating while laying

Trench shall be kept free from water till laying and jointinghas been properly done

Metal marker tapes can be used on laid pipeline to enableelectronic location of pipeline in future

Geotagged maps showing latitude & longitude value of eachapex of laid pipeline shall be preserved for future reference

Pipe laying (contd.)

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Pipe laying

Shirapur LIS

Bodwad LIS

Prakasha Burai LIS Tembhu LIS

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Corrosion prevention treatment (Inside/Outside)

Prakasha Burai LIS

Prakasha Burai LIS Prakasha Burai LIS

Bodwad LIS Dongargaon

Thanegaon LIS

Pipe Jointing

HDPE SWSRP PVC

A. Fusion welding :

Butt fusion welding

Socket fusion welding

Electro fusion welding

B. Insert type joints

C. Compression fittings/push

fit joints

D. Flanged joints

E. Spigot and socket joints

Electro Fusion Process Solvent welded joints

Integral elastomeric sealing ring joints

Mechanical compression joints

Flanged joints

Screwed or threaded joints

Union coupled joints

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Purpose : To withstand maximum design pressure without causing leakage)

To obtain good welding effect, it is necessary to do welding work by experienced welders.Welder’s efficiency shall be tested on site before start of work and intermittently thereafter (sayafter every 6 months)

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PVC-O GRP

Lubricate the chamfer of the spigot and

the seal with joint lubricant.

Line up the pipe horizontally and

vertically.

Insert only the chamfer edge of the

socket, just to support the pipe but

leaving the socket lip free.

Introduce lip of the socket into pipe until

the mark is hidden into the socket.

A. Unrestrained Pipe Joint :

Spigot and Socket Joint with Single Rubber Ring Gasket

Spigot and Socket Joint with Double Rubber Ring Gasket

Double Socket Coupling Joint with Rubber Ring Gasket

B. Restrained Pipe Joint :

Spigot and Socket Joint with Gluing

Spigot and Socket Joint with Glue and Overlay

Butt Joint

Flanged Joint

Steel Collar on GRP Pipe for Flanged Connection

Pipe Jointing (contd.)

Pipe Jointing (contd.)PSC PCCP BWSC

A) Rigid joints

Socket and Spigot

Collar Joint

Flush Joint

B ) Flexible Joints

Roll on Joint

Confined Gasket

Aligning of pipes at joint

locations

Field welding of socket ring at

joint externally.

Fixing of diaper with steel strap

at joint location.

Pouring of cement mortar

through diaper at joint location.

Filling inside of joints by cement

mortar.

Aligning of pipes at joint

locations.

Field welding of socket ring at

joint externally.

Fixing of diaper with steel strap

at joint location.

Pouring of cement mortar

through diaper at joint location.

Filling inside of joints by

cement mortar.

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31Tembhu LIS

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Pipe Jointing (contd.)MS

DI

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Pipe jointing

Shirapur LIS

Tembhu LIS

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After filling the pipeline with water, it should be allowed tostabilize for sometime (eg.1 hour) in order to achieve conditionsas stable as possible for testing.

Design test pressure as per pipe type shall be applied (eg. 1.5times rated pressure) and maintained for given time ( e.g. 24hours) based on pipe type

Generally no leakage or pressure drop is expected (eg. for MSpipe, acceptable leakage limit is 0.1 lit/mm of pipe dia/Km ofpipe line / day for each 30m pressure head)

If test is not satisfactory, retest after corrective measure

For longer pipelines, tests on individual sections (say 1 kmlength each) as well as complete length of pipeline needs tocarried out

Field testing of laid pipeline

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Hydraulic testing of pipes

Bodwad LIS

Tembhu LIS

Bodwad LIS

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Backfilling shall be carried out in uniform layers of not more than 15 cmthickness, each layer to be watered & compacted by stamping or bymechanical means.

For refilling of trenches upto 300 mm above top of pipeline, soft earthor gravel of good quality free from boulders, roots, vegetable matter etc.shall be used.

Remaining trench can be filled with available material

Backfilling shall be carried out as uniformly as practicable on both sidesof pipe simultaneously to avoid unequal loading

Backfilling of Trenches

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80% of the payment will be released after supplying, lowering, layingand jointing of pipes in one WUA area

10% of the payment will be released after satisfactory hydraulictesting of pipeline and backfilling of trenches in one WUA area

Remaining 10% amount will be released after successfulmaintenance and operation of PDN system for a period of 5 years aftercommissioning in respective WUA area (2% every year).

Payment schedule

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Contractor shall perform hydraulic test of PDN system, once every year

Contractor shall flush entire pipeline on completion of every irrigation season.

Contractor shall give training to the members of WUA about O&M of PDN work and itsefficient use and protection of the system from any damages.

The contractor shall operate and maintain the PDN system for the period of 5 (five) yearsafter commissioning. Out of this period, during last two years the operation of the schemesshall be done by the contractor jointly along with WUA.

On completion of O&M period, the PDN system shall be handed over to WUA alongwithoperation manual.

Detail map of the permanent marking along the alignment of pipe (geotagged map of laidpipeline) shall be handed over to WUA.

Operation, Maintenance and Handing over of the PDN System to WUA

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Documents

Pipe Specifications & Quality Control