BECHTEL CORPORATION POWER GLOBAL BUSINESS UNIT — PLANT DESIGN ENGINEERING ey ENGINEERING DESIGN GUIDE HIGH DENSITY POLYETHYLENE (HDPE) PIPE 3DG-P33G-00001, Rev. 2, September 3, 2003 Reason for Issue: Reformatted, Revised Content and Reissued for Use Prepared by: Jim Abel SDA Checked by: Mohinder L. Nayyar m.t rarer Approved by: Ronald C. Fox 4& INTRODUCTION HDPE pipe is being used increasingly on power plant projects. Its favorable characteristics include low cost, light weight, and corrosion resistance. On the negative side, low strength, low pressure capability, low temperature capability and limitations and difficulties associated with field joining methods must be considered. When correctly specified and properly installed, HDPE pipe provides a reliable and economical piping system. This design guide will provide guidance for designing, specifying and installation of HDPE piping for power plant applications. Manufacturers of HDPE piping and sources for additional information are contained in Appendix A. Electronic documens, once eter to the electron ‘are uncontioled and may become outdated. iments in Becweb fr current revisions. Bechtel Confidential ©Bechte! Corporation 2003, 2002. Contains confidential andlor proprietary information to Bechtel and is atfitated ‘companies which shal not be uted, discosed, of reproduced in ary format by any non-Bechtelpaty without Bechiel's Prior wren permission, All rights reserved 306-P33G.00001, Rev. 2 PAGE 1 0F 19TABLE OF CONTENTS 4.0 PURPOSE 2.0 APPLICABILITY 3.0 HDPE PIPING ENGINEERING FUNDAMENTALS 4.0 APPLICATION DESIGN CONSIDERATIONS 5.0 SELECTION OF SUITABLE STANDARD PIPE CLASSE 6.0 FABRICATION AND INSTALLATION CONSIDERATIONS 7.0 PRESSURE TESTING OF HDPE PIPING 8.0 REFERENCES APPENDIX A ADDITIONAL INFORMATION Electronic documents, once printed, are uncontrolled and may become outdated. Refer to the electronic documents in BecWeb for curent revisions. Bechtel Confidential CBecttel Corporation 2003, 2002. All rights reserved 306-P336-00001, Rev. 2 10 15 15 7 19 PAGE 20F 194 PURPOSE The purpose of this engineering design guide is to provide guidance for application, design, specification and construction of HDPE piping systems. Also, this engineering design guide addresses specific issues associated with utilizing high density polyethylene (HDPE) pipe and fittings. Topics include derating factors, lack of industry standardization, joining techniques, gasketing, use of HDPE with air systems, wall thickness and backup rings for flanged joints. This engineering design guide is not intended to be used as a complete design and fabrication document, as there are differences among manufacturers. Manufacturer's data must be consulted prior to formalization of any design. 2 APPLICABILITY This design guide is recommended to be used for new plants, upgrades to existing plants, and modifications to existing plants. 3 HDPE PIPING ENGINEERING FUNDAMENTALS 3.1 GENERAL HDPE pipe can be shown to offer total installed cost advantages as compared to ductile iron in pipe sizes NPS 12 and less, and comparable cost figures in pipe sizes from NPS 14 through NPS 24. Above NPS 24 size ductile iron can be shown to have a cost advantage. The cost advantage is attained from: * Agreater number of joints that can be made with HDPE pipe (especially with two fusion machines operating in parallel) as compared to ductile iron in an equivalent time period + The pipe flexibility * Less stringent support and backfill requirements in the dimension ratio (OR) ratings typically used in power projects. HDPE pipe also offers cost advantages in comparison to cement-lined carbon steel piping in large sizes. However, the availabilty of HDPE pipe in large sizes is, limited; the largest diameter of HDPE pipe available in a DR rating that would likely be suitable for circulating water design conditions is approximately NPS 60. Because of issues with material handling and time required for butt fusion joints, Bechtel construction prefers to limit HDPE pipe size to NPS 18 and smaller unless the pipe design does not involve many fittings. Electronic documents, once printed, are uncontrolled and may become outdated Refer to the electroni¢ documents in BecwWeb forcurtent revisions. Bechtel Confidential @Bechte! Corporation 2003, 2002, All rights reserved 30G-P336.00001, Rev. 2 PAGE 3 OF 193.2 CODES AND STANDARDS For HDPE pipe within the power block, ASME 831.1 will have jurisdiction, with the exception of potable water and sanitary service piping, where the local plumbing codes will apply, and fire protection piping, which is subject to NFPA. In rare situations for transportation and distribution of natural gas, ASME B31.8, Gas Transmission and Distribution Piping Systems, might apply. 3.3 HDPE PIPE AND FITTING SPECIFICATIONS ASTM D3035 (reference 8.4) and ASTM F714 (reference 8.7) are the primary standards used for HDPE pipe. These standards govern dimensions, tolerances, and materials. There is no standard that provides dimensions and ratings for flange adapters and metallic backup rings. These are made and rated to manufacturers standards. Industry standard specifications applicable to HDPE pipe are summarized in the following table. HDPE PIPE AND FITTING SPECIFICATIONS Organization and | Title Scope | Number ASTM 02104 Polyethylene (PE) Plastic Pipe, | NPS %through | Schedule 40 NPS6 | ‘ASTM 02239 Polyethylene (PE) Plastic Pipe NPS % through (SIDR-PR) Based on Controlled | NPS 6 Inside Diameter ‘ASTM 02447 Polyethylene (PE) Plastic Pipe, | NPS % through Schedules 40 and 80 Based on | NPS 12 Outside Diameter ‘ASTM 02513 | Thermoplastic Gas Pressure Pipe, | NPS % through Tubing and Fittings NPS 12 ‘ASTM 02683, ‘Socket-Type Polyethylene Fittings | NPS % through for Outside Diameter-Controlled | NPS 4 Polyethylene Pipe and Tubing | ASTM D3035 Polyethylene (PE) Plastic Pipe NPS % through | (OR-PR) Based on Controlled NPS 24 Outside Diameter Electronic documents, once printed, are uncontrolled and may become outdated. Reler to the electron documents in BecWeb fer currant revision. Bechtel Confidential ©Bechte! Corporation 2003, 2002. Al rights reserved. ‘30G-P33G-00001, Rev. 2 PAGE 4 OF 19HDPE PIPE AND FITTING SPECIFICATIONS Organization and | Title Scope Number ‘ASTM 03261 Butt Heat Fusion Polyethylene NPS % through (PE) Plastic Fittings for NPS 48 Polyethylene (PE) Plastic Pipe and Tubing ‘ASTM D3350 Polyethylene Plastics Pipe and —_| All sizes. Fittings Materials ‘ASTM F714 Polyethylene (PE) Plastic Pipe NPS 3 through (SDR-PR) Based on Outside NPS 54 Diameter ‘ASTM F905 Qualifications of Polyethylene All sizes Saddle Fusion Joints ‘ASTM F1055 Electrofusion Type Polyethylene | All sizes Fittings for Outside Diameter Controlled Polyethylene Pipe and Tubing ‘ASTM F1056 Socket Fusion Tools for Use in | NPS % through Socket Fusion Joining NPS 4 Polyethylene Pipe or Tubing and Fittings ‘ASTM F1290 Electrofusion Joining Polyolefin | All sizes, Pipe and Fittings 3.4 RATINGS OF HDPE PIPE AND FITTINGS The thermoplastic pipe dimension ratio (DR) is defined as the ratio of piping nominal outside diameter to wall thickness. Based on the pressure design rules used for plastic pipe, different HDPE pipe sizes with the same DR will have the same pressure rating. A similar term, the inside dimension ratio (IDR), is the ratio of piping nominal inside diameter to wall thickness, used for pipe that is sized by inside diameter. Standard DRs (SDRs) and standard IDRs (SIDRs) are established by the ASTM standards governing HDPE pipe. For example, ASTM. 3035 (reference 8.4), includes SDRs 7, 9, 9.3, 11, 13.5, 15.5, 17, 21, 26 and 32.5. The pressure rating of HDPE pipe is determined by several different methods, based on the applicable design code. For ASME B31.1 applications, pressure Etectronic documents, once printed, are uncontroded and may become outdsted. Refer othe electrone documents in BecWeb for current revisions Bechtel Confidential Bechtel Corporation 2003, 2002. Alrights reserved, 306-P336-00001, Rev. 2 PAGE 5 OF 19rating is determined by calculation in accordance with Appendix Ill, Rules for Nonmetallic Piping. For plumbing code applications, either the rating in the applicable ASTM standard, or the manufacturer's rating, can be used. For NFPA applications the pipe is rated based on testing performed by the manufacturer to establish the UL listing and/or FM approval. Pressure rating of pipe in various ASTM specifications is specified at 73.4° F (23° C). HDPE pipe must be derated when operated at elevated design temperatures. Derating factors for temperatures other than the base temperature, are shown in the table below, from Reference 8.9. Pressure Capability Design Factors for HDPE Pipe at Elevated Temperatures Design Pressure Design | Design Pressure Design Temperature Derating Factor | Temperature DeratingFactor SF CC) SF CC) 73.4 (23) 10 110 (44) 0.75 80 (27) 0.95 120 (49) 0.70 ‘90 (32) 0.90 130-(55) 0.50 100 (38) 0.80 140 (60) 0.50 3.5 TYPES OF JOINTS There are no suitable solvents or adhesives for HDPE pipe that would enable solvent joints as are used for other plastic pipe materials. Rather, HDPE pipe is joined by fusion, similar to the welding of steel pipe, or by mechanical joints such as flange adapters or proprietary couplings. ASTM Standard D2687, Heat Fusion Joining of Polyolefin Pipe and Fittings, describes general procedures for making joints with HDP Pipe by means of heat fusion joining techniques. As with any piping material, incorrectly made joints are subject to failure. Compliance with joining procedures and manufacturer's recommendations is as important for HOPE as for other commonly used materials. 3.5.1 Butt Fusion Joints ‘The most common HDPE pipe joint is the butt fusion joint. It is used between two pieces of pipe, or between a pipe and a plain end fitting. All sizes of HDPE pipe can be joined by butt fusion. A special butt fusion machine, suitable for the pipe size being joined, is required. The two pieces to be joined are clamped in the butt fusion machine and the mating surfaces are machined parallel. A heated plate (400 — 500 °F) is placed between and in contact with the two surfaces, heating both to the appropriate temperature. The plate is removed, and the two Electronic documents, once printed, are uncontrolled and may become outdated. ‘Refer to the electronic documents in BecWeb for current revisions. Bechtel Confidential Bechtel Corporation 2003, 2002. Al ights reserved 306-P336-00001, Rev. 2 PAGE 6 OF 19pieces are brought together under controlled pressure and allowed to cool When correctly done, this results in a joint that is stronger than the base pipe. The butt fusion machines required to make these joints range from picnic-basket- sized hand-carried machines for pipe up to NPS 2, to truck-sized wheel-mounted machines for pipe up to NPS 60. As pipe size increases, the amount of time required for a joint to cool so that it can be removed from the machine increases dramatically. Butt Fusion Joint (courtesy of Plastics Pipe Institute) ‘A.common problem relating to the butt fusion technique includes the formation of cold joints. A cold joint is formed when excessive pressure is applied in making the joint, causing extra material to be forced out from the fusion joint. Therefore, the material that is intended to flow together never has an opportunity to mix properly, and a low strength joint forms. The excess material squeezed from the joint forms a larger-than-normal bead on the exterior of the pipe, and is an indication of a poor joint. Operator training and the proper use of fusion machines help to ensure that cold joint formation is minimized. 3.5.2 Socket Fusion Joints ‘Socket fusion is similar to butt fusion, but requires special socket fittings. HDPE pipe sizes up to NPS 4 can be joined by socket fusion. The heating element is equipped with male and female parts, to heat the outside of the pipe and the inside of the socket. Socket fusion is not cost-effective for the type of HDPE pipe work on a typical power project, and is not used. Socket Fusion Joint (courtesy of Plastics Pipe Institute) Electronic documents, once printed, are uncontoled and may become outdated Rete to he electron documents in BecWeb for curren revisions Bechtel Confcential GBechte! Corporation 2003, 2002. Al ights reserved, '306-P336-00001, Rev. 2 PAGE 7 OF 193.5.3. Electrofusion Joints Electrofusion couplings are similar to socket fusion couplings, except that the heat required to melt the pipe and fitting is generated inside the fitting itself. Heating element wires are embedded in the surface of the wall of the socket, connected to external electrical leads. The pipe is cleaned and sized, and put into the socket cold. Electric power as specified by the fitting manufacturer Fitting. Wire Colts ‘ Ta —— | Electrofusion Joint (courtesy of Plastics Pipe Institute) is applied to the external leads, heating the fitting and pipe to fusion temperature. The power is turned off and the joint is allowed to cool. Electrofusion fittings are relatively expensive. Their primary application is for repairs or for making joints in congested areas where space for a butt fusion machine is unavailable. Electrofusion joints are limited in size only to the size of the available electrofusion fittings, commonly up to NPS 24. 3.5.4 Saddle Fusion Joints Special fittings can be fabricated by saddle fusion, fusing a fitting directly to the. side of a piece of pipe. This is a specialized type of joint that should only be performed by qualified manufacturers of fittings. Saddle fusion joints are limited in size only to the size of the available fittings, commonly up to NPS 24. Saddle Fusion Joi (courtesy of Plastics Pipe Institute) Etectronic documents, once printed, are uncontilled and may become outdated. Refer tothe electronic documents in BecWeb for curren revisions. Bechtel Confidential @Bechte! Corporation 2003, 2002, All ights reserved, 306-P336-00005, Rev. 2 PAGE 8 OF 193.5.5 Flanged Joints Flanged joints are accomplished using an HDPE flange adapter and a metallic backup ring. The flange adapter is made of HDPE material and is butt fused to the mating pipe. Backup rings are similar to flanges in that bolts are passed through them to other components such as valves, ASME B16.5 flanges, other backup rings, etc. There is no standard that provides dimensions and ratings for backup rings. Backup rings are rated by the manufacturer. All sizes of HDPE pipe can be joined by flanges. Two basic types of backup rings are commonly used: flat plate designs and convoluted designs. As the name suggests, flat plate designs are cut from plate steel and are uniform in thickness throughout their cross-section. Convoluted designs, however, are cast and are not uniform in thickness. Flat plate designs are simpler and offer lead-time advantages. However, larger sizes have a tendency to deflect under higher pressure, which could lead to joint leakage. Flat plate designs do not have as high a pressure rating as convoluted designs. Convoluted designs are stiffer than plate material and are less susceptible to joint leakage. Standard pipe classes specify convoluted designs only, due to the pressure limitations of flat plate designs. Backup rings are listed in the current revision of the Factory Mutual Approval Research Guide, and backup rings continue to meet the requirements of FM Butt Fusion Joint Polyethylene Pipe Steel Pipe Polyethylene Flange Adaptor (or stub end) Bolt, Nut, and Washer Metal Back Up Ring Steel Flange Flanged Joint (courtesy of Plastics Pipe Institute) Election documents, once printed, are uncontrolled and may become outdated. eter to the electronic documents in BecWeb for curtent revisions ‘Bechtel Confentia! Bechtel Corporation 2003, 2002. All rights reserve. 306-P336-00001, Rev. 2 PAGE 9 OF 193.5.6 Proprietary Clamp-Type Joints Clamp-type systems, which join HDPE pipe without fusion, are commercially available. However, they are not recommended to be used for power plant applications. 3.6 HDPE PIPE STANDARD PIPE CLASSES Bechtel's Standard Piping Classes for HDPE pipe include four classes. The pipe classes and their ratings are as follows: EGD (150 psi at 110 °F, SDR 9), EGF (200 psi at 73.4 °F, FM rated), ESD (150 psi at 82 °F, SDR 11), and ESQ (110 psi at 73.4 °F, SDR 15.5). Because EGF is specified as an FM approved system, pressure rated by the supplier, no SDR is specified for EGF. In fact, different suppliers provide slightly different DRs to meet the FM 200 rating, All standard pipe classes specify HDPE material PE3408. Physical and chemical properties of PE3408 are controlled in accordance with the applicable ASTM standard D3035 (reference 8.4). Experience has shown that the HDPE pipe PE3408 material specifications used in the United States are typically not available locally overseas. More commonly the available materials are high performance polyethylene (HPPE) complying with BS, DIN, ISO, or other international standards. HPPE materials are different in many regards from PE3408. The HPPE resins are “bimodal”, a reference to the distribution of molecular weights in the mix. Testing is done to different criteria in terms of hours, stress, and elevated temperature. Rated pressures are determined differently. if'a project elects to utilize HPPE, rather than HDPE, substantial evaluation will be required to ensure Code or the applicable project design criteria compliance and satisfactory design. 4 APPLICATION DESIGN CONSIDERATIONS 4.4 TYPE OF FLUID HDPE pipe is typically used on water systems in a power plant. Service water, circulating water, raw water, fire water and waste water systems make extensive use of HDPE pipe for buried lines. Bechtel does not recommend the use of HDPE pipe for air systems. Electronic documents, once printed, are uncortioled and may become outdated. Ree o the electron documents in BecWeb for current revisions Bechtel Confidential @Bechte! Corporation 2003, 2002, All ights reserved, ‘30G-P39G-00001, Rev. 2 PAGE 100F 19Natural gas piping inside a power plant is under the jurisdiction of ASME B31.1 (reference 8.1) which does permit the use of ASME B31.8 (reference 8.10). As such, HDPE pipe for gas service within a power plant may comply with ASME 31.1 or ASME B31.8. Because design temperature and pressure of natural gas typically exceed HDPE pipe limits, HDPE pipe is not typically used for natural gas inside a power plant. For natural gas piping outside the jurisdiction of ASME B31.1 (reference 8.1), the Department of Transportation (DOT) has regulations that may apply. These regulations include 49CFR192.273, qualifying joining procedures for HDPE gas pipe, 49CFR192.283 and 49CFR192.285, qualifying persons who make joints in HDPE gas pipe and 49CFR192.121, which limits maximum allowable operating pressure for HDPE gas pipe 4.2. FLOWRATE AND VELOCITY HDPE pipe has excellent flow characteristics. It can carry a greater volume of fluid than steel, cast steel, or concrete pipe of the same size because it has less drag and turbulence at higher flows. HDPE pipe is corrosion resistant and less susceptible to deposits and bacteriological growth. This material is expected to retain its flow characteristics for the duration of its service life. The excellent flow characteristics may be offset by the fact that HDPE pipe is thicker than comparably-rated pipe of other materials (except concrete pipe) so the inside diameter is smaller. 4.3 DESIGN PRESSURE Design pressure for an HDPE pipe system is selected as for other materials, in accordance with the design code. ASME B31.1 paragraph 105.3(A) limits the design pressure to 150 psig 4.4 DESIGN TEMPERATURE Design temperature for an HDPE pipe system is selected as for other materials, in accordance with the design code. ASME B31.1 paragraph 105.3(A) limits the design temperature to 140 °F. Plastics Piping Institute (PP!) Report dated 9/99 defines the HDPE pipe hydrostatic design basis (HDB) as the categorized, long-term hydrostatic strength in the circumferential, or hoop, direction for a given set of end-use conditions. The HDB is established per ASTM D2837 (reference 8.3). Standard HDBs are based on a sustained pressure test at a temperature of 73.4 °F. Electronic documents, once printed, are uncontrolled and may become outdated. eter tothe elecrone documents in Beceb for current revisions Bechtel Confidential €Bechte! Corporation 2003, 2002. Alrights reserved. 306-P33G-00005, Rev. 2 PAGE 11 OF 19As the temperature increases above 73.4 °F, the pressure-retaining capabilities of HDPE pipe decrease. The applicable temperature derate factors are reflected in the standard piping class sheets for design temperatures other than 73.4 °F. 4.5 VARIATIONS IN PRESSURE AND TEMPERATURE Note that ASME B31.1, Appendix I!!, paragraph Ill-2.1.2(C) does not permit an allowance for variations of pressure or temperature or both above design conditions. HOPE pipe is relatively “forgiving” of brief periods of operation at temperature and/or pressure in excess of the design conditions. Any operating scenario in which operating conditions could exceed design conditions should be carefully evaluated to determine acceptability 4.6 THERMAL EXPANSION HDPE expands and contracts with temperature changes. However, the linear expansion coefficient (LEC) for HDPE is much higher than that of most other piping materials. The LEC for HDPE is 1.2 x 10* in./in./"F. By comparison, the LEC for carbon steel is 0.063 x 10 inJjin/°F. This can be a factor in designing HDPE piping systems. Most HDPE pipe is buried, and soil forces restrain the movement of the pipe. If the temperature of the fiuid in the pipe is high, additional measures may be required to restrain the pipe. Thermal expansion can also be a factor during installation, when the pipe is not yet buried and is subject to varying ambient temperature. 4,7 PIPE ROUTINGS AND LAYOUT ASTM D3035 (reference 8.4) provides dimensions for HDPE pipe, and ASTM 03261 (reference 8.5) provides dimensions for some fittings. ASTM D3261 (reference 8.5) does not provide dimensions for laying length or end-to-end dimensions; major suppliers of HDPE pipe often provide fittings with differing dimensions. In general HDPE pipe is field fabricated, and the expected variations in fitting dimensions are not significant. In situations where variation in fitting dimensions could result in interference with adjacent items, the designer should ensure that actual or conservative dimensions are included in the model. Pipe and components are most readily butt fused with the joint in the horizontal position. Consideration should be given to the space required for a butt fusion machine when designing HDPE pipe. Risers at the ends of buried pipe runs have to be carefully designed in such a way that they can be fabricated aboveground and then joined to the main horizontal pipe run in the trench Electronic documents, once printed, are uncontrolled and may become outdated. Ree to the electronic documents in BecWeb for current revisions. Bechtel Confidential @Bechte! Corporation 2003, 2002, Al rights reserved. 306-P326-00001, Rev. 2 PAGE 120F 19‘Above a certain size most fittings are fabricated rather than molded. Manufacturers are not consistent in the size range; but molded fittings are generally not available larger than NPS 12. Molded fittings above NPS 8 pipe size tend to be more expensive than fabricated fittings. Fittings are fabricated by butt fusion of segments of piping which are miter cut, rather than square cut. When completed, the fabricated fitting is pressure rated lower than the pipe. Accordingly, fabricated fittings are made from thicker material than the pipe they are to be used with, so as to have the same pressure rating as the pipe Fabricated fittings also tend to occupy a larger space envelope than an equivalently sized molded fitting, Standard pipe classes follow these rules for fittings: + Fittings NPS 8 and smaller are molded. «Fittings NPS 10 and larger are fabricated. * The description for fabricated fittings includes requirements for taper boring the ends to match the adjacent piping. This facilitates good fusion joints during installation. Careful coordination should be accomplished among Civil, Plant Design, and Construction when routing HDPE pipe, to reduce the risk of damage to HDPE pipe during construction. The buried pipe is susceptible to damage from puncture by rebar, or from gouging with a backhoe, etc. Some specific tecommendations include the following: * If possible, do not route HDPE pipe under building slabs or footers. Damage to the pipe during work on the slab is a risk. «If HDPE pipe is routed near concrete foundations, clearance (approximately 3-4 ft) should be maintained between concrete foundations and HDPE pipe to allow room for construction access overlap of the discipline interface (example, room for formwork braces or room for the fusion machine), Never locate flanged or mechanical joints under building slabs or footers. Spread footers should not be located below HDPE pipe after the pipe is installed, ‘+ Room should be left in the Construction schedule to allow sequencing and delay of certain underground activities. Electron documents, once printed, are uncontrolled and may become outdated Refer tothe electronic documents in BecWeb for curtentrevsions Bechtel Confidential Bechtel Corporation 2003, 2002. Alrights reserved. ‘306-P336-00001, Rev. 2 PAGE 19 0F 19HDPE pipe is flexible. It can be bent to go over, under, or around obstacles, to change elevation or to change direction. This property can be utilized to reduce the need for fittings and thereby reduce installation costs. The minimum bend radius allowable is a function of the HDPE pipe nominal pipe size and DR. Manufacturer's literature should be consulted to determine minimum bend radius in specific applications. Bending to too small a radius results in buckling. Thicker HDPE pipe (lower DR) can be bent to a smaller radius than thinner HDPE pipe. ‘Some manufacturers can provide HDPE pipe in coils in sizes up to NPS 6. HDPE pipe in coils may reduce the number of required field joints. Available coiled lengths will depend on the manufacturer, nominal pipe size, and DR of the HDPE pipe. Use of HDPE pipe in coils should be decided based on Construction preference and availabilty. HDPE pipe in all sizes is available in straight lengths. Typical available lengths are 40 ft for pipe sizes NPS 12 and less and 50 ft for pipe sizes NPS 14 and greater. 4.8 PIPING SUPPORTS HDPE pipe is used underground on power projects. Underground HDPE pipelines do not typically require thrust blocks. Good soil compaction around fittings such as tees and elbows is generally sufficient to provide adequate support. If thrust blocks are used, adequately sized concrete encasement or concrete bearing blocks set in undisturbed soil will provide sufficient support. The concrete encasement or thrust block should be made of reinforced concrete and should act as an anchor between the pipe or fitting and the solid trench wall NFPA allows butt fused HDPE pipe to be treated as a fully restrained system, so does not require thrust blocks. However, local authorities may require thrust blocks as a prerequisite to approval of a fire system Any application which utilizes HDPE pipe above ground would require that supports be spaced close together to avoid excessive spans. 4.9 ABOVEGROUND AND UNDERGROUND APPLICATIONS HDPE pipe is used underground on power projects. Use of HDPE pipe above ground is limited to short sections of pipe required to make the transition to a pipe class suitable for use above ground. HDPE pipe could also be used in a temporary application where the pipe would be allowed to run across the ground. HDPE PE3408 pipe material is a mixture of plastic resins and carbon black. Although the carbon black material is a relatively small percentage of the total Electronic documents, once printed, are uncontrlied and may become outdated. eter to the electron Gocurrets in BecWeb for curfentrevsions Bechtel Confidential BBechte! Corporation 2003, 2002. Al ights reserved. 906-P336-00001, Rev. 2 PAGE 14 0F 19composition, the carbon black gives the HDPE pipe its black color and also makes HDPE pipe resistant to damage by ultraviolet (UV) light. When exposed to sunlight the pipe will discolor, but strength is not affected. 5 SELECTION OF SUITABLE STANDARD PIPE CLASSES The use of HDPE pipe in ASME B31.1 (reference 8.1) Power Piping applications is limited to 150 psig and 140 F by paragraph 105.3(A) of ASME B31.1 (reference 8.1). ASME B31.1 paragraph 105.3 limits the use of HDPE pipe above ground to water and nonflammable liquids. When buried, ASME B31.1 (reference 8,1), 105.3(E) permits HDPE pipe to be used for flammable and combustible liquid and gas service. Common applications in power plant service include wastewater, circulating water, and raw water systems. Bechtel designs this pipe in accordance with the rules of ASME B31.1 (reference 8.1). Standard pipe classes for HDPE pipe in ASME B31.1 (reference 8.1) applications are EGD, 3DS-P72G-01033 and ESD, 3DS-P72G-01034. HDPE pipe is commonly used for fire protection lines underground. Its use in this application is typically governed by project commitment to compliance with National Fire Protection Association (NFPA) standards. This pipe is designed by the manufacturer or supplier, in accordance with NFPA rules. Components, rating, and installation must comply with the specifics of the UL listing or FM rating. The standard pipe class for HDPE in NFPA applications is EGF, 3DS-P72G-01036 HDPE pipe is also used in plumbing code applications. These include potable water service and waste water. The standard pipe class for HDPE pipe in plumbing code applications is ESQ, 3DS-P72G-01035. 6 FABRICATION AND INSTALLATION CONSIDERATIONS 6.1 SHOP FABRICATED SPOOLS HDPE pipe is typically field fabricated. However, the benefits of shop fabrication which dictate shop fabrication of most steel pipe can also apply to HDPE pipe. These benefits include lower fabrication cost and reduced time and manhours for field installation. Consideration should be given to shop fabrication of HDPE pipe, especially where pipe routing is complex or involves a large number of fittings. 6.2 FIELD FABRICATION AND INSTALLATION Specification 3S-NWP0-00022 (reference 8.8) contains specific information for installation personnel relative to all nonmetallic pipe, including HDPE pipe. This specification contains documentation requirements and technical information Electronic documents, once printed, are uncontrolled and may become outdated. Refer tothe elacronic documents in BecWeb for curent revisions. Bechtel Confidential Bechtel Corporation 2003, 2002, Al ights reserved 306-P336-00001, Rev. 2 PAGE 15 0F 19relative to forming nonmetallic joints. Forms for documenting specific pipe sizes, manufacturer, welding machines, etc. are also discussed in this specification. These forms all make up a detailed butt fusion procedure, which must be prepared based on a guide specification obtained from Bechtel Construction Engineering and Technology (CE&T) and reviewed by the same group. The pressure-retaining capability of fabricated fittings is less than straight pipe. Therefore, in order to meet the system pressure requirements, fabricated fittings have a thicker wall than the mating pipe. Fabricated fittings are specified with taper bore to match the pipe, to facilitate butt fusion. As an alternate to taper bored fittings, butt fusing thicker wall fittings to thinner wall pipe with one change of SDR rating (ie., SDR 9 to SDR 11) is commonly done up to and including NPS 18, The procedure for butt fusing thicker wall to thinner wall is very similar to butt fusing components of the same SDR rating. The fusion gauge pressure should be calculated on the basis of the thinner of the two walls and the heat soak time should be based on the thicker of the two walls (monitor the melt bead width on the side of the heater plate in contact with the thicker wall). ‘An HDPE pipe-to-HDPE pipe lap joint does not require a gasket. Installing a gasket in this application may lead to leakage. Gaskets should be used when transitioning from an HDPE flange adapter to other materials, such as steel, ductile iron, etc. Sufficient torque should be applied eventy to the backup ring bolts to prevent leakage. Retightening the bolts is recommended after the joint has been set for a period of time (usually a few hours). Butt fusion equipment is available for piping systems that range from NPS 1/2 to NPS 60. The fusion procedure remains the same, regardless of pipe diameter. Butt fusion machines are widely available in the United States for sale or rental. ‘Some distributors will buy a machine back after the job is complete. Proper servicing is critical to ensuring that a machine operates correctly; refer to manufacturer's data for recommended service intervals. Cutting to length in the field can be accomplished using a circular saw, a reciprocating saw, or a chain saw. Bar lubricant must not be used with a chain saw; the HDPE material itself provides sufficient lubrication for cutting. Chain oils will contaminate the pipe, resulting in the need to cut out the contaminated sections. Also, the exhaust from two cycle chain saw engines must not impinge on the pipe, as this will also result in pipe contamination. After cutting, the pipe is faced and joined as normal. The following table lists fusion machine sizes that are generally applicable. Note that there is overlap between machine sizes. Also note that there is a range where performance has typically been better. Etectronic sccuments, once printed, are uncontrolled and may become outdated. Refer to the electron documents in BecWeb for current revision, Bechtel Confidential ©Bechte! Corporation 2003, 2002. Al rights reserved. '30G-P336.00001, Rev. 2 PAGE 16 0F 19BUTT FUSION MACHINES ‘Machine Size, | Pipe Size Range, | Pipe Sizes Where Performance in. NPS Has Typically Been Better, NPS 4 14 24 8 28 48 12 412 a2 18 [6-18 12-18 36 [12-36 20-36 Lighter wall thickness HDPE pipe (SDR 17 and higher with thinner walls) can be susceptible to damage during backfill. However, the SDR 9, SDR 11 and SDR 15.5 ratings typically used on Bechtel projects are generally of sufficient wall thickness that damage during backfill does not occur. Most manufacturers have recommended practices for trenching and backfill in their catalogs. Installers should pay careful attention to the manufacturers’ recommendations to ensure that the pipe is not deformed due to the weight of backfill or damaged due to gouging from improper materials 6.3 REPAIRING DAMAGED COMPONENTS ‘The method for repairing damaged pipe is to cut out the damaged section and replace it with a new pipe segment. Butt fusion is the preferred joining method, but access for butt fusion equipment may be difficult or impossible. In some cases flange adapters can be butt fused to the undamaged pipe and a flanged spool piece can be installed to replace the damaged section. Electrofusion couplings may be used to good advantage for repairs. Their high cost is offset by ease and speed of installation. Electrofusion couplings are not addressed in the standard HDPE pipe class sheets, so repairs using Electrofusion coupling should be referred by the installer to Engineering for approval. Repairs using hot air or extrusion welding are not acceptable. 7 PRESSURE TESTING OF HDPE PIPING Pressure testing of HDPE pipe may be performed using air, natural gas, water, or other fluid as allowed by the applicable design code. Pressure testing using compressed air or natural gas involves some risk, because of the large amount of stored energy and the flexible nature of HDPE. Pressure testing procedures should include precautions to minimize risk and keep it within acceptable limits. Precautions can include restraining the pipe and excluding personnel from the area of the test. Etectronic éocuments, once printed, are uncontroled and may become outdated. Reler othe electronic documents in BecWeb for current revision. Bechtel Confidential Bechtel Corporation 2003, 2002. All ights reserved, '306-P336-00001, Rev. 2 PAGE 17 OF 197.1 PIPING EXEMPT FROM PRESSURE TESTING HDPE pipe systems may be exempt from pressure testing, based on the applicable design code. ASME B31.1 paragraph 137.7.1, for example, requires that completed systems be hydrotested, but allows an initial service leak test under certain circumstances when specified by the owner. However, considering that most HDPE pipe systems will be buried, and inaccessible for examination during initial service, as well as difficult to identify location and repair leaks, pressure testing prior to burial is required. 7.2 FIRE PROTECTION SYSTEM PIPING HDPE pipe in fire protection service should be pressure tested in accordance with NFPA requirements. For example, NPA 13 (reference 8.11), Chapter 10, requires that a hydrotest be conducted at 200 psi, or 50 psi in excess of the system working pressure, whichever is greater. The acceptance criterion is no loss of pressure for a period of 2 hours. 7.3 NATURAL GAS PIPING HDPE pipe in natural gas service should be pressure tested in accordance with the requirements of the design code, or DOT regulations 49CFR192 as appropriate. For example, ASME B31.8 requires that pipe in Location Class 1, Division 1, be hydrotested with water to a pressure of 1.25 times the maximum operating pressure. No leakage is acceptable during this test 7.4 PIPING CARRYING WATER AND OTHER LIQUIDS HDPE pipe carrying water and other liquids should be pressure tested in accordance with the requirements of the design code. For example, ASME B31.1 requires that the completed system be subjected to a hydrostatic test at 1.5 times the design pressure of the system. No leakage is acceptable during this test. Electronic documents, once printed, are uncontrolled and may become outdated. eter tothe electronie documents in BecWeb for curtent revisions. ‘Bechtel Confidential Bechet Corporation 2003, 2002, Al ight reserved, 306-P336-00001, Rev. 2 PAGE 18 0F 198 REFERENCES 8.1 ASME B31.1, “POWER PIPING,” 2001 EDITION 8.2 ASTM D2321, “STANDARD PRACTICE FOR UNDERGROUND INSTALLATION OF THERMOPLASTIC PIPE FOR SEWERS AND OTHER GRAVITY-FLOW APPLICATIONS,” 2000 EDITION 8.3 ASTM D2837, “STANDARD TEST METHOD FOR OBTAINING HYDROSTATIC DESIGN BASIS FOR THERMOPLASTIC PIPE MATERIALS,” 1998 EDITION 8.4 ASTM D3035, “STANDARD SPECIFICATION FOR POLYETHYLENE (PE) PLASTIC PIPE (DR-PR) BASED ON CONTROLLED OUTSIDE DIAMETER,” 1995 EDITION 8.5 ASTM D3261, “STANDARD SPECIFICATION FOR BUTT HEAT FUSION POLYETHYLENE (PE) PLASTIC FITTINGS FOR POLYETHYLENE (PE) PLASTIC PIPE AND TUBING,” 1997 EDITION 8.6 ASTM D3350, “STANDARD SPECIFICATION FOR POLYETHYLENE PLASTICS PIPE AND FITTINGS MATERIALS,” 1996 EDITION 8.7 ASTM F714, “STANDARD SPECIFICATION FOR POLYETHYLENE (PE) PLASTIC PIPE (DR-PR) BASED ON OUTSIDE DIAMETER,” 1997 EDITION 8.8 MATERIALS ENGINEERING TECHNOLOGY 3SS-NWPO0-00022, “SPECIFICATION FOR BONDING AND INSPECTION REQUIREMENTS FOR NONMETALLIC PIPING,” REV. 1, DATED NOVEMBER 27, 2002 8.9 “ABOVE GROUND APPLICATIONS FOR POLYETHYLENE PIPE”, PUBLISHED BY THE PLASTICS PIPE INSTITUTE 8.10 ASME B31.8, “GAS TRANSMISSION AND DISTRIBUTION PIPING SYSTEMS,” 1999 EDITION WITH 2000 ADDENDA 8.11 NFPA 13, “STANDARDS FOR THE INSTALLATION OF SPRINKLER SYSTEMS,” 2002 EDITION Electronic documents, once printed, are uncontrolled and may become outdates. Reler tothe elecronic documents in BecWieb for curtent revisions. ‘Bechtel Confidential CBechte! Corportion 2003, 2002, Al rights reserved '306-P336-00001, Rev. 2 PAGE 19 OF 19APPENDIX A, ADDITIONAL INFORMATION 1 Manufacturers of HDPE pipe and fittings 4.1 PIPE In North America, the major manufacturer of HDPE pipe is CPChem Performance Pipe, a division of Chevron Phillips Chemical Company. The trade name for Performance Pipe's HDPE pipe is Driscoplex. Other North American manufacturers include CSR PolyPipe and KWH Sclairpipe. 41.2. FITTINGS The pipe manufacturers identified above also manufacture molded and fabricated fittings. Several other companies also make fittings, including ISCO, Improved Piping Products, (IPP) and Central Plastics Company. Central Plastics Company and Frialen manufacture Electrofusion fittings. 2 Sources of Additional Information 2.1. PLASTICS PIPE INSTITUTE The Plastics Pipe Institute, a division of the Society of the Plastics Industry, Inc., publishes many useful documents on its Internet website. These include “Engineering Properties of Polyethylene”, “Polyethylene Joining Procedures” and many more. The Internet uniform resource locator (URL) for the Plastics Pipe Institute is http /Awww.plasticpipe.oray. 2.2 CPCHEM PERFORMANCE PIPE CPChem Performance Pipe has extensive information available on its Internet website. Among these is “The Performance Pipe Engineering Manual.” This document addresses all aspects of HDPE pipe, including, materials, specifications, design and installation. The information is specific to CPChem Performance Pipe products, but is generally applicable to other manufacturers as. well. Bulletin PP 750, “Heat Fusion Joining Procedures and Qualification Guide” is another useful guide available from CPChem Performance Pipe. The Internet URL for CPChem Performance Pipe is http:/iwww.cpchem.com/performancepipe/index.asp. Electronic documents, once printed, are uncontoled and may become outdated Refer tothe electronic documents in Becieb fo curent revisions, Bechtel Confidential Bechtel Corporation 2003, 2002, Al ights reserved. 306-P336-00001, Rev. 2 PAGE At OF At