MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG, NEW DELHI Phone: , , Extn 8406, ; Website:

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1 MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG, NEW DELHI Phone: , , Extn 8406, ; Website: व य पक पर च लन मस द हम स दर भ : स ईड 50/ ट फ व 2019 तकन क सममतत :प ल स टटक प ईपप ग मसटटम पवषय सममतत, स ईड प र प तकत भ : 1 मसपवल इ ज तनय पवर ग पर षद क सर सदटय 2 प ल स टटक प ईपप ग मसटटम पवषय सममतत, स ईड 50, स ईड 50:1, स ईड 50:2, स ईड 50:P2 क सर सदटय 3 र चच खन व ल अन य तनक य मह दय/मह दय, न म ल ख त मस द स ग ह : प रल ख स ख य श षभक स ईड 50(13636) मलप रव ह-पद यत एव औध चगक स यन त बहह टर व क मलए प ल इ ईमलन प ईप पवमशस टट [IS क पहल प न क षण] क र त य म नक मस द (आई स एस स ख य , , ) क पय इस मस द क अव क कर और अप सम मनतय यह बत त ह ए भ ज कक यह मस द प रक ल त ह त इ पर अम कर म, आपक व यवस य अथव क र ब र म क य कठ इय आ सकत ह सम मततय र जन क अ ततम ततच : 04 म चभ 2019 सम मनत यठद क ई ह त क पय अध हस त क षर क ईम द व र य उपरल ख त पत पर, स ग फ म ट म भ ज यठद क ई सम मनत प र त ह ह त ह अथव सम मनत म क व भ ष स ब ध त र ठट ह ई त उपर क त प र क यथ वत अ नतम र प द ठदय ज एग यठद सम मनत तक क प रक नत क ह ई त ववषय सलमनत क अध यक ष क पर म श स अथव उ क इच छ पर आग क क यशव ह क ल ए ववषय सलमनत क भ ज ज क ब द प र क अ नतम र प द ठदय ज एग यह प र भ रत य म क ब य र क व बस इट पर भ उप ब ध ह धन यव द र वद य ह/- (स जय प त) तनद शक औ प रम ख (मसपवल इ ज तनयर ग) ई-म ल:ced@bis.gov.in सल ग न: उपर मलखखत द र ष :

2 MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG, NEW DELHI Phone: , , Extn 8406, ; Website: DRAFT IN WIDE CIRCULATION TECHNICAL COMMITTEE: DOCUMENT DESPATCH ADVICE Reference Date CED 50/T February 2019 PLASTIC PIPING SYSTEMS SECTIONAL COMMITTEE, CED 50 ADDRESSED TO: 1. All Interested Members of Civil Engineering Division Council, CEDC 2. All Members of Plastic Piping System Sectional Committee, CED 50 and CED 50:1, CED 50:2 & CED 50:P2 3. All others interested Dear Sir (s)/madam (s), Please find enclosed the following drafts: Doc. CED50(13636) Title Draft Indian Standard for Polyethylene pipes for sewerage and industrial chemicals and effluents Specification [first revision of IS 14333] (ICS , , ) Kindly examine the draft revision and forward your views stating any difficulties which you are likely to experience in your business or profession, if this is finally adopted as National Standards. Last Date for comments: 04 March 2019 Comments if any, may please be made in the format as given overleaf and ed at madhurima@bis.gov.in or sent at the above address. In case no comments are received or comments received are of editorial nature, you will kindly permit us to presume your approval for the above document as finalized. However, in case comments, technical in nature are received, then it may be finalized either in consultation with the Chairman, Sectional Committee or referred to the Sectional Committee for further necessary action if so desired by the Chairman, Sectional Committee. The document is also hosted on BIS website Thanking you, Yours faithfully, Sd/- (Sanjay Pant) Director & Head (Civil Engg.) ced@bis.gov.in Encl: As above Telephone:

3 FORMAT FOR SENDING COMMENTS ON BIS DOCUMENTS (Please use A4 size sheet of paper only and type within fields indicated. Comments on each clause/subclause/table/fig etc. be started on a fresh box. Information in column 5 should include reasons for the comments, and those in column 4 should include suggestions for modified wording of the clauses when the existing text is found not acceptable. Adherence to this format facilitates Secretariat s work) {Please e- mail your comments to madhurima@bis.gov.in } DOC. NO. & TITLE: DOC: CED 50 (13636) Draft Indian Standard for Polyethylene pipes for sewerage and industrial chemicals and effluents Specification [ first revision of IS 14333] (ICS , , ) LAST DATE OF COMMENTS: 04 March 2019 NAME OF THE COMMENTATOR/ORGANIZATION:... Sl. (1) Clause/Subclause/Para (2) Comments/Suggestions (3) Modified Wording of the Clause (4) Reasons/ Justifications for the Proposed Changes (5) 3

4 For BIS Use Only Doc: CED 50 (13636) February 2019 BUREAU OF INDIAN STANDARDS DRAFT FOR COMMENT ONLY (Not to be reproduced without the permission of BIS or used as a Code) Plastic Piping System Last date for Comment: Sectional Committee, CED March 2019 Draft Indian Standard for POLYETHYLENE PIPES FOR SEWERAGE AND INDUSTRIAL CHEMICALS AND EFFLUENT SPECIFICATION (first revision of IS 14333) FOREWORD (Formal clauses will be added later) This Indian Standard covers requirements and test methods for polyethylene pipes for sewerage and industrial chemicals and effluents. High density polyethylene (HDPE) pipes for sewerage and industrial effluents were earlier covered along with HDPE pipes for potable water supply in IS 4984:1984. The technical committee, in view of the following reasons, felt the need to formulate a separate specification for HDPE pipes for sewerage and industrial effluents: a) That pipes meant for sewerage and for industrial effluents are subjected to higher temperature and chemical reactions during its life. b) That the maximum specified allowable hydrostatic design stress for water supply pipes at 30 C for 50 years life used in the calculation of minimum wall thickness needs modifications in view of (a) above. c) That pipes meant for water supply and for sewerage/industrial effluents need to be identified separately. Accordingly, IS 4984 was in 1995 to cover HDPE pipes for potable water supply only and IS was first published in 1996 to cover HDPE pipes for sewerage. In view of the reasons stated at (a) and (b) above, the committee in the absence of any established data for the level of chemical reactions and the rise in temperature above 30 C, had recommended a derating factor of 0.75 over the maximum allowable hydrostatic design stress of 4.0 MPa used for PE 63 grade material for water supply. 1

5 The technical committee had also recommended that the HDPE pipes covered in IS 4984:1996 may also be used for industrial effluents provided the user shall establish suitability for the intended application based on the chemical resistivity chart given in the standard in consultation with the manufacture of the pipes. This revision of the standard has been carried out to align the standard with the revised provisions in IS 4984:2016. The requirements for raw material, diameter, ovality, wall thicknesses and various tests for the PE resin and pipe have been aligned with IS 4984:2016. Further, neither the compounded material nor testing facilities for evaluating its minimum required strength (MRS) as per ISO 9080:2012 are available in India. All the raw material manufacturers in India are producing PE pipe material in virgin natural form only and presently majority of PE pipes and fittings are being manufactured by compounding natural resin with its master batch. Therefore, the Committee has decided to retain the present practice of manufacturing PE pipes with master batch technology for black pipes, in addition to manufacture by use of pre-compounded material. In this revision of the standard following major modifications have been made: a) The scope has been extended to include polyethylene pipes for industrial chemicals. b) As polyethylene pipes are designated by their minimum required strength (MRS) and PE pipes for industrial chemicals have also been covered, the earlier nomenclature of High density polyethylene pipes for sewerage has been renamed as Polyethylene pipes for sewerage and industrial chemicals and effluents. c) Overall service design Coefficient of minimum 1.25 and operating temperature of 30 C was only covered., which has been revised to cover allowable operating pressure (working pressure) chart for temperature up to 60 C and overall service design coefficient of 1.25, 1.6 and 2.0. d) Tests such as hydrostatic strength for 100 and 1000 h, slow crack growth rate test, tensile strength for butt fusion, oxidation induction time, and elongation at break have been included for pipes based on IS 4984:2016. e) The range of nominal diameter has been increased from mm to mm. Wall thicknesses have been specified based on Standard Dimension Ratio (). f) Requirement for ring stiffness of pipes has also been added. Further, pipe stiffness properties for different MRS and pipes have been added for guidance for ascertaining pipe external load bearing capability. g) Tests for oxidation induction time, volatile matter content and water content for resin have been included. 2

6 h) Chemical resistance of polyethylene and its compatibility with various fluids and its performance in different general uses has been recommended based on ISO TR 10358/IS In this revision of the standard, considerable assistance has been derived from the following international standards: DIN 8074: Polyethylene (PE) - Pipes PE 80, PE 100 Dimensions BS EN ISO : 2015 Plastic Piping Systems for Industrial Applications Polybutene (PB), polyethylene (PE), polyethylene of raised temperature resistance (PERT), crosslinked polyethylene (PE-X), polypropylene (PP) Metric series of specifications for components and the system For guidance on laying and jointing of polyethylene pipes, including storage and handling, reference may be made to IS 7634 (Part 1 and 2). For the purpose of deciding whether a particular requirement of this standard is complied with the final value, observed or calculated, expressing the result of a test or analysis shall be rounded off in accordance with IS 2 :1960 Rules for rounding off numerical values (revised). The number of significant places retained in the rounded off value should be the same as that of the specified value in this standard. 3

7 For BIS Use Only Doc: CED 50 (13636) February 2019 BUREAU OF INDIAN STANDARDS DRAFT FOR COMMENT ONLY (Not to be reproduced without the permission of BIS or used as a Code) Plastic Piping System Last date for Comment: Sectional Committee, CED March 2019 Draft Indian Standard for POLYETHYLENE PIPES FOR SEWERAGE AND INDUSTRIAL CHEMICALS AND EFFLUENT SPECIFICATION (first revision of IS 14333) 1 SCOPE 1.1 This standard specifies the characteristics and requirements for polyethylene pipes intended to be used for following applications above or below ground. a) Sewerage (pressure or non-pressure); b) Industrial effluent; and c) Industrial chemicals. 1.2 This standard covers polyethylene pipes from 63 mm to mm nominal diameter of pressure rating from 0.20 MPa (2.0 bar) to 2.5 MPa (25.0 bar). 1.3 The operating temperatures of 10 C, 20 C, 27 C, 40 C, 50 C and 60 C for different service life are covered. 1.4 The reference temperature of 20 C for 50 years of continuous stress is considered for the minimum required strength (MRS) of polyethylene base resin. The design stress at 20 C is derived by dividing MRS by the overall service (design) coefficient, C which is 1.25 (Min) for all polyethylene pipes. This standard specifies overall service design coefficient of 1.25, 1.6 and 2.0 which shall be appropriately selected by the user/design engineer keeping in view the application to which the pipes are subjected to (see also Note 1). NOTES 1 In IS 4984, which covers PE pipes for water supply for human consumption and raw water, the C value taken is Further, the maximum allowable operating pressure at 27 C has been obtained by applying a pressure reduction coefficient of

8 2 In this standard, the allowable operating pressure of IS 4984 at 27 C (for 50 years life) with service design coefficient 1.25 has been taken as reference. The maximum allowable operating pressure for an operating fluid temperature other than 27 C and service life other than 50 years, the equation as given in has been used. The maximum allowable operating pressure and life expectancy given in Tables 3 to 11 are for guidance only. 1.5 For chemical resistance of polyethylene and its compatibility with various fluids and its performance in different general uses, reference shall be made to IS16268/ISO TR For pipes for non-pressure applications, PE pipes of stiffness (SN) value of 8 and above shall be used. 1.7 This Standard does not purport to give guidelines for designing and dimensioning of pipe lines. 2 REFERENCES The following standards contain provisions, which through reference in this text, constitute provisions of this standard. At the time of publication the editions indicated are valid. All standards are subject to revision and parties to agreement based on this standard are encouraged to investigate the possibility of applying the most recent editions of the standards indicated below: IS Title IS 2530: 1963 Methods of test for polyethylene molding materials and polyethylene compounds IS 4905:2015 Random sampling and randomization procedures (first revision) IS 4984:2016 Polyethylene pipes for water supply Specification (fifth revision) IS 7328:1992 High density polyethylene materials for moulding and extrusion Specification (first revision) IS (Part 18):2004 Thermoplastic pipes and fittings Method of tests (first revision) IS (Part 1):2013 Structured-wall plastics piping systems for non-pressure drainage and sewerage Specification: Part 1 Pipes and fittings with smooth IS 16268:2017 /ISO TR TERMINOLOGY external surface, Type A Plastic Pipes and Fittings Combined chemical-resistance classification table For the purpose of this specification the following definitions shall apply: 3.1 Nominal Size (DN) Numerical designation of the size of a component, other than a component designated by a thread size, which is a convenient round number approximately equal to the manufacturing dimension in millimeters (mm). 3.2 Nominal Size (DN/OD) Nominal size related to the outside diameter. 5

9 3.3 Nominal Outside Diameter (d n ) Specified outside diameter, in millimeters, assigned to a nominal size DN/OD. 3.4 Outside Diameter at any Point (d e ) Value of the measurement of the outside diameter through its cross-section at any point of the pipe rounded to the next greater 0.1 mm. 3.5 Mean Outside Diameter (d em ) Value of the measurement of the outer circumference of the pipe or spigot end of a fitting in any cross-section divided by π (= 3.142), rounded to the next greater 0.1 mm. 3.6 Minimum Mean Outside Diameter (d em, Min ) Minimum value of the outside diameter as specified for a given nominal size. 3.7 Maximum Mean Outside Diameter (d em, Max ) Maximum value of the outside diameter as specified for a given nominal size. 3.8 Out-of-roundness (Ovality) Ovality shall be measured as the difference between maximum outside diameter and minimum outside diameter measured at the same cross-section of the pipe, at 300 mm away from the cut end, for the pipe to be coiled. 3.9 Nominal Wall Thickness (e n ) Numerical designation of the wall thickness of a pipe, which is a convenient round number approximately equal to the manufacturing dimension in millimeters Standard Dimension Ratio () The value is the ratio of the nominal outside diameter, d n, of a pipe to its nominal wall thickness. = d n /e n 3.11 Wall Thickness at any Point (e) Wall thickness at any point of the body of the pipe, around its circumference Minimum Wall thickness at any Point (e Min ) Minimum value of the wall thickness at any point of the body of the pipe, around its circumference as specified Maximum Wall Thickness at any Point (e Max ) Maximum value of the wall thickness at any point of the body of the pipe, around its circumference as specified Mean Wall Thickness (e m ) The arithmetic mean of a number of measurements regularly spaced around the circumference of the pipe in the same cross-section of the pipe, including the measured minimum and the measured maximum values of the wall thickness Tolerance Permissible variation of the specified value of a quantity expressed as the difference between the permissible maximum and permissible minimum values. 6

10 3.14 Minimum Required Strength (MRS) Minimum value in megapascals (MPa), for longterm hydrostatic strength (LTHS) of the polyethylene resin which represents the 97.5 percent confidence limits of the predicted hydrostatic strength at 20 o C for 50 years. This is considered the property of the material Overall Service Design Coefficient (C) An overall design co-efficient with a value greater than 1, which takes into consideration service conditions as well as properties of the components of a piping system other than those represented in the lower confidence limit Design Stress (σ) The maximum allowable design stress expressed in megapascals (MPa), for a given application derived by dividing MRS by the overall service design coefficient. NOTE The maximum allowable design stress obtained as above is at an operating temperature of 20 C Nominal Pressure (PN) Numerical designation used for reference purposes related to the mechanical characteristics of the component of the piping system. NOTE The relationship between MRS, PN and is given in Annex A of IS Maximum Allowable Operating Pressure (MAOP) The highest allowable continuous pressure expressed in MPa. It is given by the following equations: P(bar) = 20(MRS) C [ 1] or (2 σ) P(MPa) = C [ 1] 3.19 Melt Flow Rate (MFR) Value relating to the viscosity of the molten thermoplastic material at a specified temperature and rate of shear Virgin Material Thermoplastics material in a form such as granules which has not been previously processed other than for compounding and to which no reprocessed or recycled materials have been added Rework Material Material prepared from rejected unused pipes, including trimmings from the production of pipes, that will be reprocessed in a manufacturer's plant by a process such as extrusion and for which the complete formulation is known. 4 GRADE OF RESIN Pipes shall be classified according to the grade of the raw material (resin) as given in Table 1. The resin supplier shall give the raw material grade. 7

11 Sl Material Classification (Grade) Table 1 Classification of Materials (Clause 4) MRS (Minimum Required Strength) of PE Resin in at 20 C for 50 Years Life MPa Design Stress at 20 C MPa (1) (2) (3) (4) i) PE ii) PE iii) PE NOTES 1 The pipes are recommended for maximum liquid temperature of 60 C (see Tables 3 to 11). 2 The pipes may also be used up to the ambient temperature of - 40 C without any correction factor as long as the fluid temperatures inside the pipe do not exceed the design temperatures for which the pipes are designed for. Intermittent increase in the ambient or fluid temperatures because of weather changes would not have any deleterious effect on the pipe s long-term performance. 3 For pipes to be used for non-pressure application, resistance to external loading is an important characteristic for the pipes. The chart for stiffness values for various material grades is given in Minimum SN 8 stiffness class shall be used for such applications. 5 MATERIAL 5.1 General The material used for the manufacture of pipes should not constitute toxic hazard, should not support microbial growth and should not give rise to unpleasant taste or odour, cloudiness or discoloration of water. Pipe manufacturers shall obtain a certificate to this effect from the manufacturer of raw material. The various constituents used to make the material for extrusion shall meet the requirements specified in 5.2 to Polyethylene Resin PE resin used for the manufacture of pipes shall conform to parameters mentioned in Table 2. In addition, the resin shall conform to the requirements of of IS The material classification and conformity to Table 2 and of IS 7328 shall be provided by raw material (resin) manufacturer with documentation duly certified by the resin manufacturer. 8

12 In case of pre-compounded black material, the PE resin shall meet the requirements in The certificate for conformity in such a case shall additionally include the results of compound density, carbon black content, toluene extract, maximum volatile matter, carbon black particle size and carbon black dispersion to establish conformity to the requirements specified in Sl (i) of Table 2, 5.3(c), Sl (2), (3) and (4) of 5.3 (e) and 8.3, respectively. However the base density should meet the requirement of Table 2, when calculated as per clause of IS Table 2 Characteristics of PE Resin as Granules (Clause 5.2) Sl Characteristics Units Requirements Test Parameters Test Method (1) (2) (3) (4) (5) (6) i) Base density kg/m C IS 7328 ii) Melt flow rate 1) g / to C using a 5 kg mass IS 2530 min (both inclusive) iii) Thermal stability (oxidation induction time) min > C, isothermal Annex B of IS 4984 iv) Volatile matter mg/kg 350 Number of tests pieces 01 Annex C of IS 4984 v) Water content 2) mg/kg 300 Number of tests pieces 01 Annex D of IS ) In case of materials with 0.15 < MFR < 0.20, attention is drawn to the fusion compatibility which has to be established by the raw material supplier. The lowest MFR value resulting from the maximum lower deviation of the nominated value should be not less than For 0.15 < MFR < 0.20 compounds, fusion compatibility of larger diameter thicker walled pipes should be investigated to confirm compatibility. If electrofusion jointing is to be adopted, appropriate testing should be carried out to verify the fusion capability of such pipes. 2) The requirement is 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 (If the water content exceeds the limit, drying to be done prior to use). 5.3 Carbon black master batch Carbon black master batch shall be manufactured from a mixture of the following: a) Polyethylene, which may include co-polymers of ethylene and higher olefin, in which the higher olefin constituent does not exceed 10 percent (mass/mass) and density of kg/m 3. b) Loading of carbon black should not exceed 50 percent (m/m). c) Ash content < 0.1 percent. 9

13 d) Carbon black used in carbon black master batch shall comply with the following requirements: 1) Density: 1.5 to 2.0 g/ml; 2) Toluene extract not more than 0.1 percent (mass/mass); 3) Maximum volatile matter 0.9 percent (m/m) (see Annex C of IS 4984); and 4) Carbon black particle size should be less than μ. NOTE A test report or confirmative certificate may be obtained from the carbon black master batch manufacturer. 5.4 Anti-Oxidant The percentage of anti-oxidant used shall not be more than 0.5 percent by mass of finished resin. 5.5 Rework Material The addition of not more than 5 percent of the manufacturer s own rework material conforming to this standard is permissible. No other rework material shall be used. 6 PIPE DESCRIPTION 6.1 Pipes shall be designated according to the grade of material (see 6.1.1) followed by pressure rating (PN) (see 6.1.4), nominal outside diameter (DN) (see 6.1.3) and standard dimension ratio () (see 6.1.2). For example PE 80, PN 5, DN 200, SN 8, 26 indicates pipe pertaining to material grade PE 80 and pressure rating 5, nominal outside diameter 200 mm, stiffness class 8 with wall thickness corresponding to The grade of material shall be as given in Table The standard dimension ratio of pipes covered in this standard are: 41, 33, 26, 21, 17, 13.6, 11, 9, 7.4 and The nominal outside diameter of pipes covered in this standard are: 63, 75, 90, 110, 125, 140, 160, 180, 200, 225, 250, 280, 315, 355, 400, 450, 500, 560, 630, 710, 800, 900, 1 000, 1 200, 1 400, 1 600, 1 800, 2 000, and mm The pipes shall be classified by pressure rating (PN) corresponding to the maximum allowable operating pressure at a given temperature, as follows: 10

14 Sl Pressure Rating Maximum Allowable of Pipe Operating Pressure at 27 C (1) (2) (3) i) PN MPa ii) PN MPa iii) PN MPa iv) PN MPa v) PN MPa vi) PN MPa vii) PN MPa viii) PN MPa ix) PN MPa x) PN MPa xi) PN MPa Calculation of maximum allowable operating pressure Maximum allowable operating pressures have been derived for different temperatures and different life expectancy (see Tables 3 to 11) based on time to failure curves established using the following equation: where, log (t) = A + C T + D (log σ) σ = induced hydrostatic stress, in MPa; A, C and D = coefficients for determining time to failure curve, as given in 6.4.1; T = temperature, in K; and t = time to failure, in h. NOTE The maximum allowable operating pressure and life expectancy given in Tables 3 to 11 are for guidance only. The coefficients for determining time to failure curve for various material grades should be as given below: 11

15 Sl Material Coefficients A C D (1) (2) (3) (4) (5) i) PE ii) PE iii) PE If any material does not obey the curves with these coefficients, it is the responsibility of the user and the design engineer to get the values of maximum allowable operating pressure from raw material manufacturer with coefficients obtained for their material for various temperatures and years of life. 12

16 Table 3 Maximum Allowable Operating Pressure for Pipes of Material Grade PE 63, and Overall Service (Design) Coefficient 1.25 (Clause 6.1.4) Sl Temperature in C Years of Service Maximum Allowable Operating Pressure (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) 1) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) )

17 20) ) ) Table 4 Maximum Allowable Operating Pressure for Pipes of Material Grade PE 63, and Overall Service (Design) Coefficient 1.6 (Clause 6.1.4) Sl Temperature in C Years of Service Maximum Allowable Operating Pressure (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) 1) ) ) ) ) ) ) ) ) ) ) ) ) ) )

18 16) ) ) ) ) ) ) Table 5 Maximum Allowable Operating Pressure for Pipes of Material Grade PE 63, and Overall Service (Design) Coefficient 2.0 (Clause 6.1.4) Sl Temperature in C Years of Service Maximum Allowable Operating Pressure (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) 1) ) ) ) ) ) ) ) ) ) )

19 12) ) ) ) ) ) ) ) ) ) ) Table 6 Maximum Allowable Operating Pressure for Pipes of Material Grade PE 80, and Overall Service (Design) Coefficient 1.25 (Clause 6.1.4) Sl Temperature in C Years of Service Maximum Allowable Operating Pressure (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) 1) ) ) ) ) ) )

20 8) ) ) ) ) ) ) ) ) ) ) ) ) ) ) Maximum Allowable Operating Pressure for Pipes of Material Grade PE 80, and Overall Service (Design) Coefficient 1.6 (Clause 6.1.4) Sl Temperature in C Years of Service Maximum Allowable Operating Pressure (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) 1) ) )

21 4) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) Table 8 Maximum Allowable Operating Pressure for Pipes of Material Grade PE 80, and Overall Service (Design) Coefficient 2.0 (Clause 6.1.4) Sl Temperature in C Years of Service Maximum Allowable Operating Pressure (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) 18

22 1) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) )

23 Table 9 Maximum Allowable Operating Pressure for Pipes of Material Grade PE 100, and Overall Service (Design) Coefficient 1.25 (Clause 6.1.4) Sl Temperature in C Years of Service Maximum Allowable Operating Pressure (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) 1) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) )

24 19) ) ) ) Table 10 Allowable Working Pressure for Pipes made from PE 100, Conveying Fluid, with a Factor of Safety 1.6 (Clause 6.1.4) Sl Temperature in C Years of Service Maximum Allowable Operating Pressure (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) 1) ) ) ) ) ) ) ) ) ) ) ) ) ) )

25 16) ) ) ) ) ) ) Table 11 Allowable Working Pressure for Pipes made from PE 100, Conveying Fluid, with a Factor of Safety 2 (Clause 6.1.4) Sl Temperat ure in C Years of Service Maximum Allowable Operating Pressure (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) 1) ) ) ) ) ) ) ) ) ) ) )

26 13) ) ) ) ) ) ) ) ) )

27 6.1.5 Stiffness The stiffness properties of different pipes for various and grade of material are given below for guidance only: Sl Grade of Material, Pipe Standard Dimension Ratio () and Corresponding Stiffness Grade Stiffness (SN), in kn/m 2 (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) 12 i) PE ii) PE iii) PE Stiffness is calculated using the following formula: 10 6 SN = E 12 ( 1) 3 where, SN = ring stiffness in kn/m²; E = Young's modulus in MPa, (800 MPa for PE 63, 850 MPa for PE 80 and MPa for PE 100); and = standard dimension ratio. 24

28 6.2 Colour The colour of the pipe shall be black. 7 GEOMETRIC CHARACTERISTICS OF PIPE 7.1 Visual Appearance The internal and external surface of the pipe shall be smooth, clean and free from grooving and other defects. The ends of the pipes shall be cleanly cut square with the axis of the pipe to within the tolerances given below and free from deformity. Slight shallow longitudinal grooves or irregularities in the wall thickness shall be permissible, provided that the wall thickness remains within permissible limits. 7.2 Length Sl Table 12 Maximum Out of Roundness (Clause 7.1) Nominal Diameter, DN mm Maximum Out of Square of Pipe End mm (1) (2) (3) i) 16 to 75 2 ii) 90 to iii) 140 to iv) 200 to v) 280 to vi) 500 to vii) Above The length of straight pipe shall be 5 m to 20 m as agreed to between the manufacturer and purchaser. Short lengths of 3 m (minimum) up to the maximum of 10 percent of the total supply may be permitted. 7.3 Coiling The pipes shall be coiled such that localized deformation, for example, buckling and kinking is prevented. The minimum internal diameter of the coil shall not be less than 18 d n. The length of the coiled pipes shall be as agreed between the manufacturer and purchaser. 25

29 7.4 Dimensions The mean outside diameter,d em, and the out-of-roundness (ovality) of the pipes for different nominal diameters covered in the standard when measured in accordance with and of IS 4984 respectively, shall meet the requirements specified in Table 3 of IS The minimum and maximum wall thickness of pipes when measured in accordance with of IS 4984, shall meet the requirements specified in Table 4 of IS PERFORMANCE REQUIREMENTS 8.1 Hydraulic Characteristics Internal Pressure Creep Rupture Test When subjected to internal pressure creep rupture test in accordance with procedure given in Annex E of IS 4984 and test parameters as specified in Table 13, the pipes under test shall show no signs of localized swelling, leakage or weeping and shall not burst during the prescribed test period. Sl Table 13 Hydraulic Characteristic Requirements of Pipes (Clause and 8.1.2) Test Temperature, C Test Duration, h Induced Hoop Stress, MPa PE 63 PE 80 PE 100 (1) (2) (3) (4) (5) (6) i) ii) iii) iv) Internal Pressure Creep Rupture Test of Pipe Joints The pipe joints shall also be tested for hydraulic characteristics requirement by subjecting the butt fusion joint or electro fusion joints of a pipe to internal pressure creep rupture test at 80 C for 48 h as per Table 13 and in accordance with the method given in Annex E of IS The pipe joints under test shall show no signs of localized swelling, leakage or weeping and shall not burst during the prescribed test period. 8.2 Longitudinal Reversion Test When tested in accordance with the method given in Annex F of IS 4984, the value of the longitudinal reversion shall not be greater than 3 percent. 26

30 8.3 Carbon Black Content and Dispersion When tested from a composite sample of minimum three pipes, in accordance with IS 2530, the carbon black content shall be within 2.5 ± 0.5 percent. When tested from a composite sample of minimum three pipes, in accordance with Annex E of IS 14885, the grading shall be Melt Flow rate When tested from a composite sample of minimum three pipes as per IS 2530 at 190 C with nominal load of 5 kgf, MFR shall not deviate from the MFR of the resin by more than 30 percent. 8.5 Oxidation Induction Time The minimum oxidation induction time of the pipe when tested in accordance with the method given in Annex B of IS 4984 shall be not less than 20 min. 8.6 Density When tested from a composite sample of minimum of three pipes as per IS 7328, the base density of the pipe shall be between 940 to 960 kg/m Tensile Strength for Butt-fusion When tested according to Annex G of IS 4984, the test specimens prepared by punching/machining from pipe butt fusion sample preferably 110 mm Dia/ 11 shall show ductile failure. If the sample shows brittle fail the test may be considered as a failure. NOTE If 110 mm/ 11 pipes are not being manufactured, test shall be carried out on the nearest, preferably higher size/ ratio being manufactured. If pipe sizes only below 90 mm are manufactured, the test is not required, however, in such cases, a test certificate from the raw material (resin) supplier for establishing conformity to the above requirement for 110 mm/ 11 pipe shall be provided. 8.8 Elongation at Break When tested according to Annex H of IS 4984, the test specimens punched/machined from pipe samples, shall meet the requirements given in Table

31 Table 14 Elongation at Break Requirements of Pipes (Clause 8.8) Sl Characteristics Requirements Test Parameters Test Method Refer to Parameter Value (1) (2) (3) (4) (5) (6) i) Elongation at break for e 5 mm 350 percent Test piece shape Type 2 Annex H of Test speed 100 IS 4984 mm/min ii) Elongation at break for 5 mm <e 12mm iii) Elongation at break for e> 12mm 350 percent Test piece shape Type 1 1) Annex H of Test speed 50 mm/min IS percent Test piece shape Type 1 1) Annex H of Test speed 25 mm/min IS 4984 or Test piece shape Type 3 1) Test speed 10 mm/min 1) 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. 8.9 Slow Crack Growth Rate When subjected to test parameters as given below and tested in accordance with the procedure given in Annex E of IS 4984, the notched test specimens prepared from pipe size of preferably 110 mm and 11 in accordance of Annex J of IS 4984 shall show no signs of localized swelling, leakage or weeping and shall not burst during the prescribed test period. Sl Test Temperature C Test Duration h Internal Test Pressure, MPa PE 63 PE 80 PE 100 (1) (2) (3) (4) (5) (6) i) 80 ± h NOTE If 110 mm/ 11 pipes are not being manufactured, test shall be carried out on the nearest, preferably higher size/ ratio being manufactured. If pipe sizes only below 63 mm are manufactured, the test is not required, however, in such cases, a test certificate from the raw material (resin) supplier for establishing conformity to the above requirement for 110 mm/ 11 pipe shall be provided. 28

32 8.10 Ring Stiffness When tested according to the method described in IS (Part 18), the ring stiffness of the pipe shall be as specified in SAMPLING, FREQUENCY OF TESTS AND CRITERIA FOR CONFORMITY 9.1 Type Tests Type tests are intended to prove the suitability and performance of a new composition, a new technique or a new size of a pipe. Such tests, therefore, need be applied only when a change is made in polymer composition or method of manufacturer, or when a new size of pipe is to be introduced. Even if no change is envisaged, type test shall be done at least once during the validity period as mentioned in For each of the type test, three samples of pipes of same grade, same size, same and same pressure rating shall be selected at random from the regular production lot and shall be tested for compliance with the requirements of the type test as given in Table 15. Table 15 Type Tests (Clause 9.1.2) Sl Description Of Test Sample Size Requirement Test type Clause (1) (2) (3) (4) (5) i) Tensile strength for butt fusion ii) Fusion compatibility test: Internal pressure creep rupture test (hydrostatic resistance test) for joints at 80 C for 48 h iii) Internal pressure creep rupture Type 1 test (hydrostatic resistance test) at 27 C for 100 h iv) Internal pressure creep rupture test (hydrostatic resistance test) at 80 C for 165 h v) Internal pressure creep rupture test (hydrostatic resistance test) at 80 C for h Type 2 vi) Slow crack growth rate test If all the samples pass the requirements of the type test, the type of the pipe under consideration shall be considered eligible for type approval. 29

33 9.1.4 In case of any of the samples fails in the type test, the testing authority, at its discretion, may call for fresh samples not exceeding the original number and subject them to the type test again. If in repeat test, no single failure occurs, the type of pipe under consideration shall be considered eligible for type approval. If any of the samples fails in the repeat tests, the type of pipe shall not be approved. The manufacturer or the supplier may be asked to improve the design and resubmit the product for type approval At the end of the validity period [normally one year for internal pressure creep rupture test at 27 C for 100 h and internal pressure creep rupture test (hydrostatic resistance test) for joints at 80 C for 48 h, five years for internal pressure creep rupture test (hydrostatic resistance test) at 80 C for h, and two years for all other type tests] or earlier as may be necessary, the testing authority may call for fresh samples for type test for the purpose of type approval. 9.2 Acceptance Test Acceptance tests are carried out on sample selected from a lot for the purpose of acceptance of the lot Lot All pipes of the same size, same and same grade and also manufactured essentially under similar conditions of manufacture shall constitute a lot. For ascertaining conformity of the lot to the requirements of this standard, samples for acceptance test (see Table 16) shall be selected and prepared after conditioning at 27± 2 C and tested for compliance as per Table 16. Table 16 Acceptance Tests (Clause 9.2.2) Sl Description of Test Sample Requirement Size Clause (1) (2) (3) (4) i) Visual appearance and dimensions Table and 7.4 ii) Melt flow rate Table iii) Density Table iv) Reversion test Table v) Elongation at break Table vi) Carbon black content Table vii) Carbon black dispersion Table viii) Oxidation induction Table ix) Internal pressure creep rupture test Table (hydrostatic resistance test at 80 C for 48 h) x) Ring stiffness Table

34 9.2.3 Conformity to Dimensional and Visual Characteristics The number of test samples shall be in accordance with Table These pipes shall be selected at random from the lot and in order to ensure the randomness of selection, a random number table shall be used. For guidance and use of random number tables, IS 4905 may be referred. For the above purpose, each length of the coil of a given size, grade and shall be considered as one pipe. In the absence of a random number table, the following procedure may be adopted. Starting from any pipe in the lot, count them as 1, 2, 3, 4, etc, up to r and so on where r is the integral part of N/n, N being the number of pipes in the lot and n is the number of pipes in the samples. Every rth pipe so counted shall be drawn so as to constitute the required sample size The number of pipes given for the first sample in col 4 of Table 17 shall be examined for visual and dimensional requirements given in 7.1 and 7.4. A pipe failing to satisfy any of these requirements shall be considered as defective. The lot shall be deemed to have satisfied these requirements, if the number of detectives found in the first sample are less than or equal to the corresponding acceptance number given in col 6 of Table 17. The lot shall be deemed not to have met these requirements if the number of detectives found in the first sample is greater than or equal to the corresponding rejection numbers given in col 7 of Table 17. If, however, the number of detectives found in the first sample lies between the corresponding acceptance and rejection numbers given in col 6 and 7 of Table 17, the second sample of the size given in col 4 of Table 17 shall be taken and examined for these requirements. The lot shall be considered to have satisfied these, requirements, if the number of detectives found in the cumulative sample is less than or equal to the corresponding acceptance number given in col 6 of Table 17 otherwise not. In case, the sample size is equal or less than, lot size, 100 percent inspection shall be done for these tests and all the samples from the lot which pass these tests shall be tested for other acceptance tests. Sl Table 17 Scale of sampling for Visual and Dimensional Requirements (Clause and ) of Pipes in the Lot Sample Sample Size Cumulative Sample Size Acceptance Rejection (1) (2) (3) (4) (5) (6) (7) i) Up to First Second ii) to First Second iii) to First Second iv) and above First Second