pipe specifications & quality control
TRANSCRIPT
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
Dimension: (OD, t, L)
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)
Straightness & finish
Hydrostatic Factory Test
Permeability Test on
Coating
Mortar soundness test
Steel Cylinder Test.
Dimensions: (ID, t, L)
Straightness & finish
Hydrostatic Factory Test
Permeability Test on
Coating
Mortar soundness test
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
Dimension: (OD, t, L)
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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